Buderus Logamax plus GB162-L.B. 80 kW, Logamax plus GB162-L.B. 100 kW, Logamax plus GB162-80 kW, Logamax plus GB162-100 kW Installation Instructions Manual

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Page 1

Condensing gas boiler

6720645916-00.1N

CAUTION!

Before putting the boiler into operation read this manual carefully.

DANGER!

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

CAUTION!

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

NOTICE!

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

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

• 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.

Notice!

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

• This manual must be retained for future reference.

Installation instructions

Logamax plus

GB162-L.B. 80 kW GB162-L.B. 100 kW

6720645916 (2014/10) US

Read carefully before carrying out installation and maintenance.

Page 2

6720645916-01.TD

34 2

3738

3639

Fig. 1 Logamax plus GB162-L.B. with pump group

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)2

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[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 gas sensor [17] Flue measuring point [18] Measuring point for air intake [19] Flue gas connection [20] Air intake connection [21] Fan [22] Gas valve [23] Venturi [24] Burner cover [25] Flow temperature sensor [26] Ionization electrode [27] Sighting glass [28] Glow igniter [29] Safety temperature sensor [30] Heat exchanger [31] Pressure sensor [32] Return temperature sensor [33] Universal Burner Automatic Version 3 (UBA 3) [34] Draw with function module integration options [35] Cover shield [36] Condensate trap

Pump group (scope of delivery) [37] Isolating valve, blue (CH boiler return) with pump, drain cock, check valve and thermometer [38] Manual gas shut off valve, yellow (GAS) [39] Isolating valve, red (CH boiler flow) with drain cock, pressure gauge and thermometer [40] Pressure gauge [41] Isolating valve [42] Thermometer (optional accessory) [43] Drain valve [44] Safety valve 30 psi (2 bar) (or 50 psi [3.45 bar] = optional)

The pump group also includes an insulation cover (see also pump group installation instructions). Low loss header (single appliance only): [45] Low loss header (not illustrated)

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Contents

1 Explanation of symbols and safety information . . . . . . . . . . . 5

1.1 Guideline to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Massachusetts Installations Only . . . . . . . . . . . . . . . . . . 6

3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Heating system water quality . . . . . . . . . . . . . . . . . . . . . . 8

3.3 Pump test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.4 Freeze protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.5 Tools, materials and further equipment . . . . . . . . . . . . . 8

3.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

4.1 Without pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.2 With pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

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

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

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

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

6.2 Requirements for the heating system . . . . . . . . . . . . . . 12

6.3 Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.4 Water and Gas connection . . . . . . . . . . . . . . . . . . . . . . . 13

6.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6.4.2 Connecting the pressure relief valve (PRV) . . . . . . . . . 14

6.4.3 Making the gas connection . . . . . . . . . . . . . . . . . . . . . . 14

6.4.4 Installing the heating supply and return pipe . . . . . . . . 14

6.4.5 Installing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.4.6 Installing the condensate trap . . . . . . . . . . . . . . . . . . . . 15

6.5 Connecting the condensate drain pipe . . . . . . . . . . . . . 16

6.5.1 Connecting the expansion vessel in a

single-boiler system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.6 Combustion Air and Ventilation Openings . . . . . . . . . . 16

6.7 Flue gas adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.8 Installation of the Exhaust and Air Intake system . . . . . 18

6.9 Multiple boiler vent terminal clearance . . . . . . . . . . . . . 23

7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.1 External connection board connections . . . . . . . . . . . . 24

7.1.1 Routing the cable through the boiler . . . . . . . . . . . . . . . 24

7.1.2 Low voltage connections . . . . . . . . . . . . . . . . . . . . . . . . 25

7.1.3 120 VAC connections . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.1.4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.2 Installing function modules (accessories) . . . . . . . . . . 26

7.2.1 Installing function modules in the boiler . . . . . . . . . . . . 26

7.2.2 Installing function modules outside the boiler . . . . . . . 28

7.3 Electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 29

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

8.1 BC10 basic controller . . . . . . . . . . . . . . . . . . . . . . . . . . 30

8.2 BC10 operating instructions . . . . . . . . . . . . . . . . . . . . . 31

9 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9.1 Check for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.2 Fill the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9.3 Fill the condensate trap with water . . . . . . . . . . . . . . . . 35

9.4 Bleed the gas supply valve . . . . . . . . . . . . . . . . . . . . . . . 35

9.5 Check the air/flue gas connection . . . . . . . . . . . . . . . . . 36

9.6 Checking the appliance configuration . . . . . . . . . . . . . 36

9.7 Measure the gas inlet pressure (working pressure) . . . 36

9.8 Carry out a leakage test in operating conditions . . . . . 38

9.9 Check and adjust the flue gases CO

emissions . . . . . 38

9.10 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.11 Measure the ionization current . . . . . . . . . . . . . . . . . . . 39

9.12 Test the Ignition Safety shut off device . . . . . . . . . . . . . 40

9.13 Boiler settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.13.1 Set the heating capacity . . . . . . . . . . . . . . . . . . . . . . . . 40

9.13.2 Set the space heating water temperature . . . . . . . . . . 40

9.13.3 Set the pump run-over time . . . . . . . . . . . . . . . . . . . . . . 40

9.13.4 Switch DHW mode ON/OFF . . . . . . . . . . . . . . . . . . . . . . 40

9.13.5 Set the DHW temperature . . . . . . . . . . . . . . . . . . . . . . . 40

9.14 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

9.14.1 Close the boiler door and the control panel . . . . . . . . . 41

9.14.2 Hand over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10 Shutting down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10.1 Shut down the appliance using the basic controller . . 41

10.2 Shutting down the heating system if there is a

risk of freezing (interruption of use) . . . . . . . . . . . . . . 41

10.3 Shutting down the heating system in the event

of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

11.1 Prepare the appliance for inspection . . . . . . . . . . . . . . 42

11.2 Carry out a visual check for general signs of corrosion 42

11.3 Gas valve leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . 42

11.4 Measure the ionization current . . . . . . . . . . . . . . . . . . . 43

11.5 Measure the gas inlet pressure (working pressure) . . . 43

11.6 Check and adjust the flue gas CO

emissions . . . . . . . 43

11.7 Carry out a leakage test in operating conditions . . . . . 43

11.8 Measure the flue gases CO

emissions . . . . . . . . . . . . . 43

11.9 Fill the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . 43

11.10 Check the air/flue gas connection . . . . . . . . . . . . . . . . . 43

12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

12.1 Prepare the heating system for maintenance . . . . . . . . 43

12.2 Remove the boiler door . . . . . . . . . . . . . . . . . . . . . . . . . 43

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)4

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12.3 Clean the heat exchanger, burner and

condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

12.3.1 Remove the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

12.3.2 Remove the burner cover with the fan and the

gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

12.3.3 Remove the burner and the burner seal . . . . . . . . . . . . 45

12.3.4 Checking ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . 45

12.3.5 Disconnect the condensate trap . . . . . . . . . . . . . . . . . . 46

12.3.6 Remove the condensate collector . . . . . . . . . . . . . . . . . 46

12.3.7 Clean the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . 47

12.4 Check and adjust the flue gases CO

12.5 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

emissions . . . . . 47

Explanation of symbols and safety information

1 Explanation of symbols and safety information

1.1 Guideline to symbols

Warnings

Warnings are indicated in the text by a warning triangle and a gray background.

In case of danger from electric shock, the exclamation point on the warning triangle is replaced with a flash.

13 Display information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

13.1 Removing the control panel . . . . . . . . . . . . . . . . . . . . . . 48

13.2 Replacing the control panel . . . . . . . . . . . . . . . . . . . . . . 48

13.3 BC10 Display readings . . . . . . . . . . . . . . . . . . . . . . . . . 48

13.4 BC10 Display settings . . . . . . . . . . . . . . . . . . . . . . . . . . 48

13.5 BC10 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

14 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

14.1 Technical specifications of GB162-boilers at

low BTU (4,000-10,200 ft.) . . . . . . . . . . . . . . . . . . . . 54

15 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

15.1 Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

15.2 Inspection report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

15.3 Service report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

16 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing damage are not taken.

• NOTE indicates that damage to property may occur.

• CAUTION indicates possible minor to medium personal injury.

• WARNING indicates possible severe personal injury.

• DANGER indicates a potential for loss of life.

Important Information

Important information neither indicating personal injury nor damage to property are marked with this symbol. They are separated by lines above and below the text.

Additional symbols

Symbol Explanation

▶ Sequence of steps  Cross-reference to other points in this document or to

other documents

• Listing/list entry – Listing/list entry (2nd level)

Table 1

1.2 Safety instructions

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

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 5

WARNING:

A fire or explosion may result causing pr operty damage, personal injury or death.

▶ If the information in these instructions is not followed

exactly,

DANGER:

if flammable gas explodes.

▶ Beware if you smell gas: there may be an explosion

hazard!

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

the vicinity of this or any other boiler.

Page 6

Regulations and guidelines

WARNING:

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

▶ Make sure that air vents are not reduced in size or

obstructed.

▶ The boiler may only be operated after the defect has

been remedied.

▶ Warn the user of the system of the defect verbally

and in writing.

WARNING:

Danger of fatal accident from explosive fumes.

▶ Only carry out work on gas pipes and fittings if you

are properly registered.

General warnings

The following instructions must be observed

• The boiler must only be used for its designated purpose, observing the Installation Instructions.

• Only use the boiler in the combinations and with the accessories and spares listed.

• Maintenance and repairs must only be carried out by trained professionals.

• You are only permitted to operate the condensing gas boiler with the combustion air/flue gas system that has been specifically designed and approved for this type of boiler.

• Please note that local approval of the flue system and the condensate connection to the public sewer system may be required.

• If boiler installation is provided as replacement heater, do not connect new boiler venting to an existing vent system, if it is shared with other appliances.

• 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 concerning the connection of the gas burner fitting to the local gas main.

• The instructions and standards concerning the safety equipment for the water/space heating system.

• The Installation Instructions for building heating systems.

• The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lo wer flo ors of t he stru cture. When su ch 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.

• Do not restrict or seal any air intake or outlet openings.

• If you find any defects, you must inform the owner of the system of the defect and the associated hazard in writing.

• The boiler must not be installed on carpeting.

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.

2 Regulations and guidelines

• The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

• Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

▶ Install CO detectors per local regulations. Boiler requires yearly

maintenance  chap. 12 "Maintenance", page 43.

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 applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot wate r distribution system to ensure safe operation.

2.1 Massachusetts Installations Only

(a) For all side wall side horizontally vented gas fuelled equipment

installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than 7 feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

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

– 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.

– 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 30 day period, a battery operated carbon monoxide detector with an alarm shall be installed. alarm and battery back-up may be installed on the next adjacent floor level.

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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 8 ft. above grade directly in line with the exhaust vent terminal for the horizontally vented gas fuelled heating appliance or equipment. The sign shall read, in print size no less than 1-½" in size, GAS VENT DIRECTLY BELOW. “KEEP CLEAR OF ALL OBSTRUCTIONS”.

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

(b) EXEMPTIONS: The following equipment is exempt from 248 CRM

5.08(2)(a)1 through 4:

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

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

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

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.

General information

3 General information

About these instructions

These Installation Instructions contain important information for the safe and professional installation, start-up and maintenance of the boiler with boiler input rating of 80 kW and 100 kW.

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

Cascade installation

Special cascade units (accessories) have been developed to enable this boiler to be installed 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-L.B. 80 kW/100 kW:

• Installation instructions,

• User’s manual,

• Service manual.

Subject to technical modifications

Slight changes may be made without prior notice to the illustrations, process steps and technical data as a result of our policy of continuous improvement

GB162-L.B. Natural Gas Propane Gas

80 kW 290,000 btu/hr 270,000 btu/hr 100 kW 333,000 btu/hr 315,000 btu/hr

Table 2 max. input rate

3.1 Designated use

The boiler was designed to heat water in a central heating system and generating domestic hot water. It is suitable for connection to fully pumped, sealed water systems only, with a maximum supply temperature set point off 180 °F (82 °C). The boiler can be installed either as a single system or as part of a multiple system (cascade system).

This boiler may not be installed in places below 4,001 ft.

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 7

Page 8

General information

3.2 Heating system water quality

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

CAUTION:

Risk of system damage due to unsuitable heating system water.

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

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

3.3 Pump test

If the boiler has not been operational for approx. 2 days, the pump will automatically run for 10 seconds every 24 hours. This pump test is first carried out 24 hours after the main power has been connected to the boiler.

3.4 Freeze protection

The boiler has integrated freeze protection that switches the boiler ON at a space heating (CH) water temperature of 45 °F (7 °C) and switches it OFF at a CH flow 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 ( § 13.4. page 48)

3.5 Tools, materials and further equipment

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

3.6 Disposal

▶ Dispose of the boiler packaging in an environmentally sound manner. ▶ Dispose of components of the heating system (e. g. boiler or control

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

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Page 9

4 Dimensions and connections

DFE

4.1” (103.5 mm)

38.58” (980 mm)

5.3” (135 mm)

1.4” (35 mm)

5.4” (138 mm)

6.4” (162 mm)

1.54” (39 mm)

5.1” (130 mm)

5.5” (140 mm)

5.1” (130 mm)

0 020.5” (520 mm)

39.5” (1003 mm) 40,55” (1030 mm)

51.6” (1310 mm)

16” (406 mm)

D/F

A/B

6” (152 mm)

18.3” (465 mm)

0.25” (6 mm)

16.5" (420 mm)

1.2” (30 mm)

24.8” (630 mm)

20.5" (520 mm)

6720645916-02.1TD

4.1 Without pump group

Dimensions and connections

Fig. 2 Dimensions and connections without pump group

[A] (LA) = Flue gas connection; inside diameter 4" (100 mm) [B] (AA) = Air intake connection; inside diameter 4"(100 mm) [C] (WB) = Wall Bracket (not shown) [D] (VK) = Supply; G1½" union nut with female thread [E] (GAS) = Gas connection to boiler; Rp1" female thread [F] (RK) = Return; G1½" union nut with female thread [G] (AKO) = Condensate outlet; Ø 32 mm (1¼")O/D

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 9

The required permanent clearances (closet) are: in front: 1" (25 mm) right side: 0 left side: 0 above: 6" (152 mm). The position selected for installation MUST allow adequate space for servicing in front of the boiler of at least 16.5" + 20.5" = 37" (940 mm). Maintain an installation clearance from combustible construction from hot water piping of at least 1" (25 mm).

Page 10

DFE

4.1” (103.5 mm)

38.58” (980 mm)

5.3” (135 mm)

1.4” (35 mm)

5.4” (138 mm)

6.4” (162 mm)

1.54” (39 mm)

5.1” (130 mm)

5.5” (140 mm)

5.1” (130 mm)

0 020.5” (520 mm)

39.5” (1003 mm) 40,55” (1030 mm)

51.6” (1310 mm)

16” (406 mm)

D/F

A/B

6” (152 mm)

18.3” (465 mm) 0.25” (6 mm)

H/J

1.2” (30 mm)

50.4” (1280 mm)

24.8” (630 mm)

16.5" (420 mm)

20.5" (520 mm)

6720645916-03.1TD

Dimensions and connections

4.2 With pump group

Fig. 3 Dimensions and connections with pump group

[A] (LA) = Flue gas connection; inside diameter 4" (100 mm) [B] (AA) = Air intake with pompadour; inside diameter 4" (100 mm) [C] (WB) = Wall Bracket (not shown) [D] (VK) = Supply; G1½" union nut with female thread [E] (GAS) = Gas connection to boiler; Rp1" female thread [F] (RK) = Return; G1½" union nut with female thread [G] (AKO) = Condensate outlet; Ø 32 mm (1¼")O/D [H] (PF) = Pump group supply; G1½" male thread, flat seal [I] = Gas connection to pump group; 1" NPT female thread [J] (PR) = Pump group return; G1½" male thread, flat seal

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Page 11

Packaging and transportation

6 720 646157-05.1TD

5 Packaging and transportation

5.1 Scope of delivery

The boiler is delivered factory-assembled.

▶ When receiving the delivery, check if the packaging is intact. ▶ Check that all items are included in the delivery.

2 1

Fig. 4 Items supplied with unit

Nr. Parts Qty. Packaging

1 Boiler with casing 1 1 box 2Wall bracket 1 3 Condensate trap with hose 1 4 Technical documents set 1 5 Supply and return union nuts with sealing

rings 6 Screws and plugs for wall bracket 2 7 Union nut for gas connection 1 8 DHW sensor 1 9 Pump group 1 1 box

Table 3 Items supplied with GB162-L.B. 80 kW/100 kW

7746800103-01.1TD

1 2

7746800103-02.1TD

Fig. 5 Additional accessories

[1] Low loss header (single installation only) [2] AM10 modulating outdoor reset control

5.2 Transporting the boiler

CAUTION: The boiler may be damaged when it is

improperly secured. ▶ Only transport the boiler using the right

transportation equipment, such as a hand truck with a fastening belt or special equipment for maneuvering steps.

▶ During transportation the boiler must be secured on

the transportation equipment to prevent it from falling off.

▶ Protect all parts against impacts if they are to be

transported.

▶ Observe the transportation markings on the

packaging.

CAUTION: The unpacked boiler may be damaged when not protected against contamination.

▶ Leave the protective covers on the connections. ▶ Cover the flue gas connections at the top of the boiler

with plastic film.

▶ Always lift and carry the boiler with 2 people as shown in fig. 6, or use

a hand truck or special equipment.

Additional required accessories (not in delivery content)

A single boiler must be installed with the Buderus low loss header (LLH) to regulate the flow. The low loss header must be ordered separately. The low loss header delivery comes also with the AM10 modulating outdoor reset control.

Multiple boiler cascade installations can use the Buderus cascade frame accessories. Please contact Buderus for further informations.

▶ When receiving the delivery, check if the packaging is intact. ▶ Check that all items are included in the delivery ( fig. 5).

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Fig. 6 Lift and carry the boiler correctly

Page 12

6 720 646157-06.1TD

Installation

CAUTION: Damage to the unit by lifting or carrying

incorrectly. ▶ Do not hold the boiler by the door covering the

control panel ( fig. 7).

Fig. 7 Incorrect way of lifting and carrying the boiler

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

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

6.3 Installing the boiler

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

▶ Before starting installation check that the carrying capacity of the

wall is sufficient for the boiler weight.

NOTICE

▶ To protect the connection orifice you must not

remove the styrofoam bottom panel.

▶ Do not lift the boiler by the door covering the control

panel ( chap. 5.2 "Transporting the boiler", page 11).

▶ Protect the boiler and the combustion

air/flue gas orifice against pollution during installation.

▶ Remove the packaging and dispose of it in an environmentally

manner.

▶ Measure the installation height ( chap. 4 "Dimensions and

connections", page 9). ▶ Mark both holes with the wall bracket ( fig. 8) using a spirit level. ▶ Install the wall bracket with 2 screws ( fig. 8).

6 Installation

6.1 Requirements for the installation room

DANGER:

▶ Install the heating system in a frost-free room. ▶ If the boiler is operated dependent on room air, the

installation room must have the required air vents. Do not obstruct these vents. The air vents must always be free.

▶ When installed in a room with thin walls or a thin

floor, resonating noise may occur. Install noise reducing parts if required.

▶ Do not store any flammable materials or liquids in the

immediate vicinity of the boiler.

▶ Never use any chlorinated detergents or halogenated

hydrocarbons (e. g. in spray cans, solvents and detergents, paints, adhesives).

▶ Do not allow too much dust to collect on the boiler.

6.2 Requirements for the heating system

▶ 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).

6 720 646157-07.1TD

Fig. 8 Installing the wall bracket

▶ With 2 people, lift the boiler by holding it by its back and by the

transport rail at its bottom and install it on the wall bracket ( fig. 6, page 11).

▶ The boiler can be moved sideways to get the correct position.

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Page 13

▶ Level the boiler with the set screw and a spirit level ( fig. 9).

6 720 646157-08.1T

6 720 646157-09.1TD

6 720 646157-10.1TD

6 720 646157-11.1TD

Fig. 9 Aligning the boiler with the set screw

▶ Remove the protective covers from the bottom of the boiler

( fig. 10).

Fig. 11 Pump group

[1] pressure relief valve [2] supply water valve [3] manual gas shutoff valve [4] circulation pump [5] gas inlet [6] return water valve [7] pump group cover

Installation

NOTICE

▶ If you do not use the included pump group, you have to

install a separate circulation pump under the boiler. This pump must be selected so that the volume flow through the boiler is sufficient to handle the maximum boiler input rating ( § 6.4.5, page 15).

▶ Install the pump group on the boiler in accordance with the pump

group installation instructions.

A single boiler must be installed with the low loss header to regulate the flow.

Fig. 10 Removing the covers - boiler bottom

▶ Install the low loss header [1].

NOTICE

▶ Some residual water from final testing may leak

away.

6.4 Water and Gas connection

6.4.1 General

The water and gas connections to the boiler are made using the pump group ( fig. 4, page 11). This pump group includes the circulation pump and a pressure relief valve.

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Fig. 12 Low loss header

Page 14

7746800103-03.1TD

894

Installation

NOTICE

▶ Avoid installing the boiler above radiation levels.

If the boiler is installed above radiation sections, a low water cutoff shall be installed and wired to the boiler. Follow local code or in case of use of a low water cutoff, be aware to use an air vent, in order to prevent the boiler from shutting down unnecessarily

6.4.2 Connecting the pressure relief valve (PRV)

The pressure relief valve is a part of the supplied pump group ( fig. 11, [1]). A listed ASME pressure relief valve supplied with the boiler must be installed at the time of installation. No valve is to be placed between the PRV and the boiler.

No reducing coupling or other restriction may be installed in the discharge line. The discharge line must be within 12" (305 mm) with a minimum of 4" (100 mm) above a drain and installed such that it allows complete drainage of both the PRV and the line. The location of the PRV must be readily accessible for servicing or replacement and be mounted as close to the boiler as possible. To install the PRV, a suitable fitting connected to an extension on a “T” fitting can be sweated to the hot water line. Support all piping.

Maintain an installation clearance from combustible construction of at least 1" (25 mm) from the hot water piping.

6.4.3 Making the gas connection

DANGER:

▶ Only carry out work on gas lines if you are a qualified

gas fitter

Equivalent length for Pipe Fittings in feet (m)

Type of pipe fitting

Steel pipe diameter in inches (mm)

¾ (19) 2.1 (0.64) 4.1 (1.25) 0.5 (0.15) 1.25 (0.38) 1 (25) 2.6 (0.79) 5.2 (1.59) 0.6 (0.18) 1.60 (0.49) 1¼ (32) 3.5 (1.07) 6.9 (2.11) 0.8 (0.24) 2.15 (0.66) 1½ (38) 4.0 (1.22) 8.0 (2.44) 0.9 (0.27) 2.50 (0.76)

Table 5 Equivalent length for pipe fittings in feet

6.4.4 Installing the heating supply and return pipe

90º-Elbow

Tee flow th ru

branch

Equivalent length in feet (m)

Gate valve Gas cocks

▶ The manual gas shutoff valve is part of the pump group, and is

installed in accordance with the pump group installation

instructions. ▶ Determine proper size gas pipe for the installation using table 4 and

table 5. Do not forget the pipe fitting losses and observe proper size

of the fittings. ▶ Connect the gas supply pipe to the manual gas shutoff valve, so that

it is free from any strain.

Length of pipe in feet (m)

10 (3.05) 278 520 1,060 1,600 20 (6.1) 190 350 730 1,100 30 (9.15) 152 285 590 890 40 (12.2) 130 245 500 760 50 (15.25) 115 215 440 670 75 (22.88) 93 175 360 545 100 (30.5) 79 160 305 480 150 (47.25) 64 120 250 380

Table 4 Gas pipe capacity for different pipe sizes

1) Maximum pipe capacity in ft.3/hr, based on a specific gravity of 60 (42 mbar)

and a inlet gas pressure of 14" W.C. (35 mbar) or less and a pressure drop of 3"

W.C. (20 mbar)

Gas volume Capacity in ft.3/hr

¾" 1" 1¼" 1½"

Fig. 13 Connecting the boiler supply and return

[1] Supply [2] Return [3] Isolating valves [4] Drain cock [5] Gas valve [6] Pressure relief valve [7] Condensate trap [8] Pump [9] Non-return valve [10] Dirt filter (for example scale cartridge or y-strainer) [11] Gas supply [12] Air gap > 1" (25.4 mm) [13] Low loss header (single boiler installation)

NOTICE

▶ When using plastic pipes, observe the supplier’s

instructions - especially those referring to recommended jointing techniques and the notes relating to the heating system water on page 8.

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Page 15

Installation

6 720 646157-014.1TD

6 720 646157-15.1TD

NOTICE

▶ To prevent contamination in the heating system we

recommend you integrate a dirt filter ( fig. 13, [10]) in the return pipe, near the boiler. In an old system it is a requirement to install a dirt filter. Also install shutoff valves to enable filter cleaning immediately upstream and downstream of the dirt filter (scale cartridge or y-strainer)

▶ Connect the supply pipe with a flat rubber seal installed to the Supply

connection ( fig. 13, [1]) making sure it is not under stress. Use a supply pipe with a minimum diameter of 1½" (38 mm).

▶ Connect the return pipe with a flat rubber seal installed to the Return

connection ( fig. 13, [2]) making sure it is not under stress. Use a return pipe with a minimum diameter of 1½" (38 mm).

6.4.5 Installing the pump

Always use the supplied Buderus pump group and the low loss header when installing a single boiler so correct flows are guaranteed. It is not necessary to install a low loss header for cascade systems.

▶ Install the pump ( fig. 13, [8]) in the return circuit ( fig. 13,

[2]).

6.4.6 Installing the condensate trap

WARNING:

Danger of fatal accident due to poisoning

▶ If the condensate trap is not filled with water, flue gas

can escape and put people's lives at risk.

▶ Connect the condensate trap [1] to the condensate outlet.

The condensate trap has a bayonet connector, insert and turn ¼ rotation clockwise to click into position.

Fig. 15 Installing the condensate trap

▶ Connect the condensate trap hose [3] and the rubber sleeve [2] to

the condensate trap [1].

▶ Fill the condensate trap (supplied with the boiler) with water

( fig. 14).

6 720 646157-13.1TD

Fig. 14 Filling the condensate trap with water

Fig. 16 Installing the condensate trap hose

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Page 16

7746800103-62.1TD

> 1” (25.4 mm)

6 720 645916-017

7746800103-04.1TD

Installation

6.5 Connecting the condensate drain pipe

NOTICE

▶ The condensate must be drained from the boiler in

accordance with local, state or federal rules and regulations.

NOTICE

▶ Use materials approved by the authority having

jurisdiction. In the absence of such authority, PVC and CPVC pipe must comply with ASTM D1785, F441 or D2665. Cement and primer must comply with ASTM D2564 or F493. For Canada, use ULC certified PVC or CPVC pipe, fittings and cement.

6.5.1 Connecting the expansion vessel in a single-boiler system

CAUTION:

Damage to the installation due to faulty pressure relief valve.

▶ The expansion vessel must be of sufficient capacity.

▶ Connect the expansion tank to the boiler return. If a check valve is

available: connect the expansion vessel to the CH-side of the check valve in the return circuit [1].

Fig. 19 Connecting the expansion vessel in a single-boiler system

[1] Expansion vessel [2] Gas supply [3] Air gap < 1" (25.4 mm)

Fig. 17 Connecting the condensate trap

[1] Condensate trap [2] Air gap > 1" (25.4 mm)

6.6 Combustion Air and Ventilation Openings

Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Ventilation, of the National Flue Gas Code, ANSI Z223.1/NFPA 54, or Sections 7.2, 7.3 or

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

DANGER:

Fire danger due to flammable materials or liquids.

▶ Do not store flammable materials and liquids in the

immediate vicinity of the boiler.

WARNING:

Boiler Damage.

Fig. 18 Condensate drainage pipe

▶ Install the condensate drain pipe taking the following into account:

– An air gap of at least 1" (25.4 mm) must be maintained between

the boiler condensate trap hose and the condensate pipe work ( fig. 17 and fig. 18).

– If the condensate outlet of the boiler is lower than the drain, a

condensate pump must be used.

– The condensate produced by the boiler has a pH value between

3 and 4.

▶ Install a neutralization unit if required by the local code.

▶ Boiler must be clear and free from combustible

materials, gasoline and other flammable vapors and liquids, and corrosive liquids and vapors. Never use chlorine and hydrocarbon containing chemicals (such as spray chemicals, solution and cleaning agents, paints, glues etc.) in the vicinity of the boiler

▶ Do not store and use these chemicals in the boiler

room.

▶ Avoid excessive dust formation and build-up.

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Page 17

Installation

6 720 645916-19.1N

7 746 800 103-09.1D

CAUTION:

Boiler damage and operational failures! Due to insufficient or improper ope nings for combustion air and/or ventilation of the boiler room. Provisions for combustion air and ventilation are always required, regardless whether the combustion air is taken from the outside (sealed combustion) or inside (room air for combustion). Insufficient ventilation of the boiler room can lead to high air temperatures. This can result in boiler damage.

▶ Make sure that intake and exhaust openings are

6.7 Flue gas adapter

CAUTION:

Risk of boiler damage due to excessive dust and airborne debris levels.

▶ Do not operate the boiler when there is a lot of dust in

the boiler room, e.g. due to building work.

▶ An air filter must be fitted if the supply of combustion

air contains large quantities of dust (e.g. from unpaved roads and tracks or dusty workplaces such as quarries, mines, etc.) or airborne seeds from plants.

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

▶ When the problem is not resolved, do not operate the

boiler.

CAUTION:

▶ Do not use lubricants to avoid degradation of the lip

rings.

▶ Please note these restrictions and its dangers to the

operator of the boiler.

▶ When installing PVC vent pipes remove the upper lip ring and insert

[1].

NOTICE

▶ When one expects contaminated combustion air

(near swimming pools, chemical cleaning operations and hair salons), sealed combustion operation is

▶ In case of open venting, use basket [2] on the air intake. ▶ When installing parallel PP venting material remove upper lip ring and

insert [1] and use PVC/PP PolyPro adapter offered by your local vent supplier.

recommended.

All Air form inside the Building (non sealed combustion)

The closet shall be provided with 2 permanent openings communicatin g directly with an additional room(s). The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each ope ning shall have a minimum free area of 12" per 1,000 btu/h of total input rating of all gas utilization equipment in the confined space, but no less than 1.002". One opening shall commence within 12" (305 mm) of the top, and one opening shall commence within 12" (305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 4" (101.6 mm).

1. Where directly communicating with the outdoors, each opening shall have a minimum free area of 12" per 4,000 Btu/hr of total input rating of all equipment in the enclosure.

2. Where communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 12" per 4,000 Btu/hr of total input rating of all equipment in the enclosure.

Fig. 20 Connecting the flue gas adapter (parallel)

▶ When installing concentric PP venting material remove upper lip ring

and insert ( fig. 20, [1]) and place air intake cap [1].

3. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 12" per 2,000 Btu/hr of total input rating of all equipment in the enclosure.

4. Where ducts are used, they shall be of the same cross-sectional area as the free area of the opening to which they connect.

All Air from Outdoor (sealed combustion)

The closet shall be provided with two permanent openings, one commencing within 12" (305 mm) from the top, and one commencing within 12" (305 mm) from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. The minimum dimension of air openings shall be no less than 4" (101.6 mm).

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 17

Fig. 21 Placing air intake cap

Page 18

6 720 645916-20.1N

12" (305 mm)

minimum

12" (305 mm)

minimum

12" (305 mm)

minimum

INTAKE

EXHAUST

12" (305 mm)

minimum

12" (305 mm)

minimum

6 720 646916-21.1N

Installation

6.8 Installation of the Exhaust and Air Intake system

NOTICE

▶ Consult local and state codes pertaining to special

building code and fire department requirements. Adhere to national code requirements.

▶ Observe the listed maximum lengths of vent system,

which are boiler model dependent. The maximum permissible lengths are listed in table 8, page 22.

Optional vent kits are:

1. Parallel or concentric, horizontal (with approved wall terminal) or vertical

Fig. 22 Vent pipes

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

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

Vent must be at least 12" (305 mm) above grade, anticipated snow line or roof surface (Canada 18" (457 mm) minimum) ( fig. 23). Vent termination must be at least 7 ft. (2,135 mm) above a public walkway ( fig. 24).

Vent must be 3 ft. (915 mm) above any forced air intake within 10 ft. (3,050 mm) ( fig. 24). Do not extend exposed vent pipe outside the building beyond recommended distance. Condensate could freeze and block vent pipe.Vent should terminate at least 3 ft. (915 mm) away from adjacent walls, inside corners and 5 ft. (1,525 mm) below roof overhang ( fig. 24). It is not recommended to terminate vent above any door or window, condensate can freeze causing ice formations. Do not use chimney as a raceway if another boiler or fireplace is vented into or through chimney.

All PVC and CPVC vent pipes must be glued, except for the flue gas adapter. Installed you can slide the pipe onto the adapter, properly supported and the exhaust pipe must be pitched a minimum of a ¼" (6.35 mm) per foot back to the boiler. This allows the condensate to drain away. All non-steel combustion air and vent pipe materials and fittings must comply with the following and must be UL approved venting material:

Item Material United States Canada

4" (100 mm) Intake/combustion air pipe and fitting

PVC schedule

ANSI/ASTM D1785 BH gas

40, 80 PVC-DWV ANSI/ASTM D2665 CPVC schedule

ANSI/ASTM F441

40, 80 PP

M&G Duravent PolyPro and

ANSI Cat IV, approved

Polypropylene Centrotherm InnoFlue SW

PP-Flex M&G Duravent PolyPro Flex and

ANSI Cat IV,

approved

Polypropylene

venting

systems,

ULC

S636

Class IIA -

PVC,

Class IIB -

CPVC,

Class IIC -

Polypro-

pylene

Centrotherm InnoFlue SW Flex

4"/6" (100/150 mm) concentric Intake/combustion

PP Bosch Concentric

ANSI Cat IV,

approved

Polypropylene

air pipe and fitting Pipe cement /

primer

PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493

Table 6 Approved venting air pipe material

1) For installations in Canada, field supplied plastic vent piping must comply with CAN/CGA B149.1 (latest edition) and be certified to the Standard for Type BH Gas Venting systems. ULC S636 Components of this listed system shall not be interchanged with other vent systems or unlisted pipe/fittings. All plastic components and specified primers and glues of certified vent systems must be from a single manufacturer and not mixed with other system manufacturer's vent system parts. The supplied vent connector and separate available wall termination kits are certified as part of the GB162 Boiler.

Fig. 23 Vent and air pipe position (1) of a sealed combustion system

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Page 19

Installation

(2135 mm)

(305 mm)

(1220 mm)

(1525 mm)

(1220 mm)

(915 mm)

(305 mm)

(1220 mm)

6 720 645916-22.1N

Approved vent terminations and flue material:

Roof terminals

4"/6" (100/150 mm)

4"/6" (100/150 mm) (PP)

Flue System (trade name)

Concentric PVC IPEX System 636 no.

M&G Duravent PolyPro concentric and Centrotherm Innoflue SW

Vent / air intake terminal(s)

CVK M&G Duravent Order

No. 4PPS-VK (-TC) or Centrotherm ICRT4679

concentric

4" (100 mm) (PP)

M&G Duravent - PolyPro Flex Chimney Cap Centrotherm - Innoflue

M&G Duravent order No. 4PPS FCT or Centrotherm ISCP04

SW Flex Chimney Cap

Wall terminals Flue System

(trade name)

4" (100 mm) PVC/parallel stainless

steel

4" (100 mm) PolyPro Twin pipe

termination (PP)

4" (100 mm) Parallel PVC to

Vent / air intake terminal(s)

ANSI/ASTM D1785 or Field Controls

M&G Duravent Order No. 4PPS-HTP

IPEX no. CVK

ANSI/ASTM D1785

Table 7 Approved vent terminations and flue material

Roof terminals

4"/6" (100/150 mm)

Flue System (trade name)

Concentric PP M&G Duravent PolyPro

Vent / air intake terminal(s)

Bosch Order No. 7738004825

concentric

90°-elbow with inlet screen

PVC/stainless steel ANSI/ASTM D1785 or

Z-Flex/Heat Fab

PP M&G Duravent PolyPro

or Centrotherm Innoflue SW

Table 7 Approved vent terminations and flue material

NOTICE

▶ Use of cellular core PVC (ASTM F891), cellular core

CPVC, or Radel® (polyphenolsulfone) in venting systems shall be prohibited.

▶ Covering non-metallic vent pipe and fittings with

thermal insulation shall be prohibited.

▶ A minimum clearance of 4 ft. (1,220 mm)

horizontally from and in no case above and below, unless a 4 ft. (1,220 mm) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment

Fig. 24 Vent and air pipe position (2) of a system with combustion air supply from the room (non-sealed)

[1] Height at Least 1ft (305 mm) above grade and snow line [2] Exhaust terminal must be at least 3 ft. (915 mm) above forced air

inlet within 10 ft. (3,050 mm) [3] Forced Air Inlet [4] Gravity Air Inlet

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Installation

Below are approved examples of vertical and horizontal venting installation

NOTICE

▶ Place pipe supports every 5 ft. (1,525 mm) of

horizontal and vertical run, beginning with support near boiler.

▶ The condensate must be drained in accordance with

the applicable rules ( § 6.5, page 16).

▶ Periodic cleaning of the vent terminal and air-intake

screens is mandatory.

▶ Avoid locating vent terminals near equipment or

construction which can be subject to degradation from exhaust gases.

Fig. 25 Horizontal venting system (sealed combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm)

Fig. 26 Concentric horizontal venting system (sealed combustion)

[1] concentric adaptor 4" (100 mm) / 6" (150 mm) [2] exhaust 4" (100 mm) / intake 6" (150 mm) [3] place the air intake cap

Fig. 27 Horizontal venting system (sealed combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm)

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Installation

7746800103-07.1TD

6 720 645916-27.1N

Fig. 28 Vertical parallel venting system (sealed combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm) [3] 10"- 0" MIN (250 mm - 0 mm MIN) [4] 12" (300 mm) over max. snow level or 24" (600 mm) whichever

is greater

Fig. 30 Vertical venting system (non sealed combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm) [3] 12" (300 mm) over max. snow level or 24" (600 mm) whichever

is greater

[4] 10"- 0" MIN (250 mm - 0 mm MIN)

Fig. 29 Vertical venting system (sealed combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm) [3] 12" (300 mm) over maximum snow level or 24" (600 mm)

whichever is greater

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Fig. 31 Flex Chimney Cap (PP) vertical venting system (sealed

combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm)

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Installation

Fig. 32 Vertical concentric venting system (sealed combustion)

[1] exhaust 4" (100 mm) [2] intake 4" (100 mm) [3] 12" (300 mm) over max. snow level or 24" (600 mm) whichever

is greater

[4] 10"- 0" MIN (250 mm - 0 mm MIN)

Do not exceed the total equivalent venting length of 100 feet (30,480 mm) maximum requirement each for the intake and exhaust piping.

NOTICE

▶ Appliance input rates are based on minimum vent

length operation. Longer vent lengths (up to maximum) will reduce the input proportionally.

Equivalent

Friction losses

feet m

45° elbow 4", PVC, CPVC 4 1.22 90° elbow 4", PVC, CPVC 7 2.13 4" plastic pipe per foot, PVC, CPVC 1 0.30 parallel vent kit 2 0.61 concentric PVC terminal 4"/6" (100/150 mm) 20 6.1 45° elbow 4" (100 mm), PolyPro Elbow 7.2 2.2 45° elbow 4"/6" (100/150 mm), PolyPro Elbow 3.7 1.14 90° elbow 4" (100 mm), PolyPro Elbow 11.8 3.6 90° elbow 4"/6" (100/150 mm), PolyPro Elbow 5.6 1.72 4" (100 mm) PolyPro Pipe per foot 3.3 1.0 concentric 4"/6" (100/150 mm), PolyPro Pipe per foot 3.3 1.0 4" (100 mm) PolyPro Flex pipe per foot 6.9 2.1 parallel PolyPro Wall terminal 4" (100 mm) 13.8 4.2 concentric PolyPro Wall terminal 4"/6" (100/150 mm) 20.3 6.2 concentric PolyPro Roof terminal 4"/6" (100/150 mm) 26.0 7.9 PolyPro Roof terminal Flex Chimney Cap 3.3 1.0

Table 8 Friction Loss Equivalent in piping and fittings

See table 8 for the Friction Loss Equivalent in piping and fittings.

Example:

When you end up using 3 x 45 ° -elbows and the concentric roof terminal, then the total venting length may not exceed 68 ft. (20.72 m). 3 × 45°-elbow = 3 x 4 ft. (1.22 m) = 12 ft. (3.66 m) concentric roof terminal 4"/6" = 20 ft. (6.10 m).

Total friction loss equivalent =32 ft. (9.76 m)

Total venting length for this example is: GB162-L.B. 80 kW/100kW = 100 ft. (30.48 m) - 32 ft. (9.76 m) = 68 ft. (20.72 m) each for the intake and exhaust piping.

NOTICE

▶ The minimum covering wall thickness is 1"

(25.4 mm). The maximum covering wall thickness is 16" (406 mm).

▶ For direct venting properly reassemble and reseal

the vent and air-intake systems.

CAUTION:

▶ Vent connectors serving appliances vented by

natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

a) Seal any unused openings in the common venting system.

b) Visually inspect the venting system for proper size and horizontal

pitch and determine there is no restriction, leaka ge, corrosion and other deficiencies which could cause unsafe condition.

c) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

d) Test for spillage at the draft hood relief opening after 5 minutes of burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

e) Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

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WARNING:

6720645916-030.1N

▶ Improper venting of the GB162 boiler can result in

excessive levels of carbon monoxide which can result in severe personal injury or death. The boiler must be vented in accordance with the 'Venting of Equipment' section of the latest edition of ANSI Z

223.1 / NFPA 54 Natural Fuel Gas Code and/or the 'Venting systems and air supply for appliances' section of the latest version of CAN/CGA B149.1 Natural Gas and Propane Installation Code in Canada and in accordance with all applicable local building codes.

NOTICE

▶ To avoid moisture and frost build-up and to maintain

clearances to openings on adjacent homes, 45° and 90° elbows or tees may be attached to the end of the vent termination pipe to direct exhaust plumes away from the adjacent structure. The total allowable vent length, maximum number of elbows and distance to air intake restrictions must be adhered to.

Installation

6.9 Multiple boiler vent terminal clearance

Vertical terminations: The combustion air inlet pipe must terminate in a downward position using 2 × 90 ° elbows. The combustion air inlet pipe shall terminate at least 3 ft (914 mm). horizontally from the center line of the exhaust vent, this is to prevent cross contamination of flue gases into the combustion air stream.

Terminate all exhaust vents at the same height and all combustion air inlets at the same height, while maintaining the minimum 36" (914 mm) height clearance from the exhaust to the down turned 90° elbow and combustion air inlet.

Exhaust vent termination edge shall be at least 24" (610 mm) from the edge of the air inlet pipe of an adjacent heater. Exhaust vent terminations shall be placed at a minimum of 12" (305 mm) center to center ( fig. 33 and fig. 34).

Air intake terminations may be placed adjacent to each other. The combustion air inlet is part of the direct vent system and not classified as a forced air inlet.

Fig. 33 Vertical terminations

[1] minimum 12" (305 mm) [2] minimum 36" (914 mm) [3] minimum 36" (914 mm) [4] minimum 12" (305 mm) [5] minimum 36" (915 mm) [6] minimum 24" (610 mm)

Horizontal terminations: Combustion air inlet elbow must terminate at least 12"(305 mm) below exhaust elbow or outlet, but not exceed 15" (381 mm) maximum separation ( fig. 34).

Horizontal termination shall not extend beyond 18" from the building (based on minimum 12" (305 mm) required separation between intake and exhaust). Exhaust vent vertical rise shall not extend beyond 39" (991 mm) from building penetration to termination elbow ( fig. 34). Condensate could freeze and block vent pipe.

Terminate all exhaust vents at the same height and all combustion air inlets at the same height, while maintaining the minimum 12" (305 mm) vertical height clearance from between exhaust and combustion air inlet. Exhaust vent termination edge shall be at least 12" (305 mm) laterally from the edge of the air inlet pipe of an adjacent heater. The combustion air inlet is part of the direct vent system and not classified as a forced air inlet.

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Electrical connections

7 Electrical connections

Devices such as pumps, outdoor sensor and 3-way valve are all connected to the external connection board.

The electrical connections to the boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI/NFPA-70.

If installed in Canada, electrical connections should conform with CSA C22.1 Code part 1.

7.1 External connection board connections

WARNING:

Danger of fatal accident due to electric shock.

▶ 120 VAC-connections may be present on the

external connection board when power is supplied to the boiler.

▶ Open the boiler door. ▶ Remove the screw to release the cover over the electrical

connections and pull the cover upwards ( fig. 35).

Fig. 34 Horizontal terminations

[1] minimum 12" (305 mm) [2] maximum 15" (381 mm) [3] maximum 18" (457 mm) [4] minimum 12" (305 mm) [5] minimum 12" (305 mm) [6] maximum 39" (991 mm)

Fig. 35 Removing the cover

7.1.1 Routing the cable through the boiler

▶ Route the cable for the low-voltage connections through the opening

on the left [1].

▶ Route the cable for the 120 VAC connections through the opening on

the left [2].

▶ Route and attach the cable for the 120 VAC connections using the

strain relief clamps [3].

▶ Only the 120 V electrical connections require a 14 gauge wire.

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Electrical connections

6 720 646157-33.1N

2 3

1234 5 6 7 8 9 10

6 720 646157-34.1N

RC FA WA FW EV DWV RC FA WA FW

▶ Connect all components to the relevant terminals:

RC Terminal - Room Controller

▶ Connect a Room- or Cascade controller to the orange RC terminal

( fig. 37) ( § 7.1.4, page 26).

FA Terminal - Outdoor temperature sensor

If outdoor temperature-dependant control operation is used, an outdoor temperature sensor must be connected.

▶ Connect the outdoor temperature sensor to the blue FA terminal

( fig. 37).

WA Terminal - Potential-free heat demand

With this connection the room temperature-based modulating function of the boiler is not used. This has a negative effect on comfort and energy consumption. The boiler will now only modulate up to the preset space heating water temperature.

▶ Connect the potential-free heat demand contact (On/Off

thermostat) or relay panel end switch to the green WA terminal ( fig. 37). The maximum allowed resistance of this circuit is 100 Ω.

NOTICE

▶ The RC and WA terminals cannot be used

simultaneously.

Fig. 36 Routing the cable

7.1.2 Low voltage connections

WARNING:

due to electric shock.

▶ Make sure no power is supplied to the boiler when

making connections

Fig. 37 External connection board connections

no. abbr. color component

1 RC orange Room controller RC and EMS bus 2 FA blue Outdoor-temperature sensor 3 WA green Potential free On/off thermostat 4 FW grey DHW temperature sensor 5 EV red External switch contact, potential free,

e. g. for floor heating safety 6 DWV green Connection for external 3-way valve 7 PK green External heating pump 120 VAC (for use

with non Buderus pump group) 8 PS grey DHW tank pump 120 VAC 9 PZ lilac DHW recirculation pump 120 VAC 10 Netz white Main power connection 120 VAC

Table 9 External connection board connections

FW Terminal - DHW temperature sensor

▶ Connect the external DHW temperature sensor to the grey FW

terminal, using the harness enclosed with the DHW temperature sensor.

NOTICE

▶ It is not possible to connect more than 1 DHW

temperature sensor in the boiler.

▶ Connect a DHW temperature sensor suitable for this

particular boiler.

EV Terminal - External switching contact

An external switch contact can be used, i.e. to safeguard a floor heating system so that the heating water temperature will not become too high etc.

When the external switch contact is opened, the boiler will be switched off for heating operation and for domestic hot water operation. The pump continues to run for the run-over time set on the boiler.

▶ Remove the cable from the EV terminal ( fig. 37). ▶ Connect the external switch contact to the red EV terminal

( fig. 37).

DWV Terminal - 3-way valve

▶ Do not use this connection.

7.1.3 120 VAC connections

NOTICE

▶ Use the 120 VAC connections for specific hydraulic

configurations and a corresponding controller.

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6 720 646157-36.1N

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Electrical connections

Fig. 38 120 VAC Connections

[1] PK [2] PS [3] PZ [4] 120 VAC

PK Terminal - External pump

▶ Connect the external heating or system pump (for situations where

the pump of the Buderus pump group is not used) to the green PK terminal ( fig. 38). The maximum allowed connected load of the pump = 100 Watts.

PS Terminal - DHW pump

▶ Connect the DHW pump to the grey PS terminal ( fig. 38).

The maximum allowed connected load of the pump = 100 Watts.

PZ Terminal - DHW circulation pump

▶ Connect the DHW circulation pump to the lilac PZ terminal

( fig. 38). The maximum allowed connected load of the pump = 100 Watts.

Mains connector

WARNING:

Connecting incoming power

▶ Ground the boiler electrically in accordance with

local codes, or in absence of local codes, with the National Electrical Code, ANSI/INFPA 70 and/or the CSA C22.1, Electrical Code.

Fig. 39 Installing the room controller

7.2 Installing function modules (accessories)

NOTICE

▶ Refer to the installation instructions of the relevant

function modules for information about installation and combination possibilities.

The following function modules (accessories) can be connected to the boiler:

• Heat demand 0-10 V module EM10,

• Error reporting module EM10,

• Switch module WM10,

• Mixing module MM10.

The function modules (accessories) can be installed in 2 ways:

• in the boiler (max. 2), see § 7.2.1.

• outside the boiler, see § 7.2.2.

7.2.1 Installing function modules in the boiler

▶ Loosen the screw (step 1). ▶ Pull open the drawer (step 2).

▶ Install a 120 VAC cable to the boiler mains connection.

7.1.4 Controller

NOTICE

▶ It is not possible to connect more than 1 room

controller.

The following controls can be connected to the boiler:

• Logamatic RC35 room controller,

• Logamatic 4323 controls,

• Control with contact for potential free heat demand

• Error reporting module EM10, 0 – 10 V input (can be used to conver t a 0 – 10 V signal to a modulating signal),

• MCM boiler cascade module up to 16 boilers.

To install additional modules in the boiler, see § 7.2 "Installing function modules (accessories)", page 26.

Installing an RC35 controller as an outdoor reset control in the boiler

▶ Open the control panel cover. ▶ Remove the cover [1]. ▶ Install the RC35 in the slot [2].

Fig. 40 Opening the drawer

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Electrical connections

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6 720 646157-40.1N

6 720 646157-42.1N

▶ Install the wall bracket in the relevant slots in the drawer ( fig. 41).

Fig. 41 Installing the wall bracket

▶ Click the function module(s) into position in the wall bracket

( fig. 42).

▶ Slide the drawer back into the boiler. ▶ Connect the free 120 VAC mains cable ( fig. 43) to the module

[1]. If more modules are used, the 120 VAC supply for the second module can be taken from the first module using the cable enclosed with the module.

6 720 646157-41.1N

Fig. 44 Interconnecting modules

NOTICE

▶ The module may have the letters RC or EMS above

the connection ( fig. 45, [1]).

Fig. 42 Clicking the function module into position

▶ Remove the drawer. ▶ Remove the covers of both free connectors on the function module

connection cables ( fig. 43).

▶ Connect the free connector of the EMS bus connecting cable

( fig. 44) to the first module ( fig. 45).

▶ If more modules are used, the EMS bus connection for the second

module may be branched off from the first module using the cable enclosed with the module ( fig. 44 and fig. 45).

Fig. 45 Connecting several modules

NOTICE

Pay attention to the polarity when using an EMS bus connection cable

▶ Connect the wire from terminal 1 to terminal 1 and

from terminal 2 to terminal 2 ( fig. 44 and fig. 45).

Fig. 43 Removing the covers

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RC FA WA FW EV DWV

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7.2.2 Installing function modules outside the boiler

▶ Install the module on the wall according to the installation

instructions of the module.

▶ Make an EMS bus connection cable using a 2-core cable and the

connector enclosed with the module ( fig. 46). Important: Use the connector of the same color as the connections on the module.

Fig. 46 EMS bus polarity

NOTICE

Pay attention to the polarity when using an EMS bus connection cable. ▶ Connect the wire from terminal 1 to terminal 1 and

from terminal 2 to terminal 2 ( fig. 44 and fig. 45).

▶ Connect the EMS bus connection cable to the orange RC connection

of the external connection board [1].

Fig. 47 External connection board - Room controller RC and EMS bus

(connection color orange)

▶ To connect other modules, see § 7.2.1.

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Electrical connections

7.3 Electrical wiring diagram

CAUTION:

Wiring errors can cause improper and dangerous operation.

▶ Label all wires prior to disconnection when servicing. ▶ Verify proper operation after servicing.

Logamax plus GB162-80 kW/-100 kW

orange/white

white

blue grey

orange

white

white/black

orange/white

black blue

red

white

brown

black

red

orange

white/black

red

orange/white

brown

grey

blue

orange

red

grey

white

black

127856

12347856

orange naranja orange

22 24

50 78

red

black

red

white

blue azul bleu

red

blue

brown

External connection for professional use / Conexión para expertos técnicos /

Connexion externe pour l’enterprise d’entretien spécialiste

turqoise

red

grey

green verde vert

turquesa

rojo

gris

turquoise

rouge

gris

16 17 18 19 20 21 22 23 24 25

Fig. 48 Electrical wiring diagram

[1] 81-pole connector (AC 0, 10, 24 and 230 V) [2] 16-pole connector (AC 120 V) [3] Connection for pump in connection kit (accessory) [4] Fan [5] Gas valve [6] Transformer [7] Glow ignitor [8] Earth

Pin Patilla Broche

1 2

Switch contact

grey

blue

grey

black

white

orange

green verde vert

Pin Patilla Broche

[9] Ionization [10] Pressure sensor [11] Return sensor [12] Safety-temperature sensor [13] Supply sensor [14] Flue gas sensor [15] Fuse (5 amp. FAST, sand filled) [16] BUS function modules [17] Connector for BC10 Basic

brown

blue

green/yellow

blue

green/yellow

brown

120 VAC

Controller [18] Room controller RC and EMS bus [19] Outdoor temperature sensor [20] On/off temperature controller

(potential free) [21] DHW sensor [22] External switch contact

(potential free, e.g. floor

heating)

blue

black

brown

120 VAC 120 VAC

[23] External 3-way valve [24] Boiler pump (120 VAC, max.

100 W) [25] DHW pump (pump 120 VAC,

brown

blue

120 VAC

max. 100 W) [26] DHW re-circulation pump (pump

120 VAC, max. 100 W)

black blue brown green grey orange red white yellow

negro azul marrón verde gris naranja rojo blanco amarillo

noir blue brun vert gris orange rouge blanc jaune

[27] Main power connection 120 V/

60 Hz, max. permissible 5 A [28] Mains switch [29] 120 VAC function module [30] Ground

IMPORTANT

The wires in this mains lead are colored in accordance with the following code:

GREEN AND YELLOW - EARTH; BLUE NEUTRAL; BROWN - LIVE

As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings identifying the terminals in your connector proceed as follows: The wire colored green and yellow must be connected to the terminal on the

blue

black

brown

green/yellow

blue

brown

green/yellow

connector marked with the letter E or by the earth symbol or colored

green/yellow

green or green-and-yellow. The wire colored brown must be connected to the terminal marked with the letter L or

grey gris gris

blanco

lila

blanc

lilas

27 28 29

6 720 646157-45.1N

white

lilac

colored red. The wire colored blue must be connected to the terminal marked with the letter N or colored black.

WARNING

THIS APPLIANCE MUST BE EARTHED Ensure that your appliance is connected correctly - if you are in any doubt consult a qualified electrician. For location of individual components, see service section and the exploded views in this manual.

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110

140

130

120

100

130

170

150

110

190

6720645916-47.1N

Operation

8Operation

8.1 BC10 basic controller

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

▶ Push on the control panel ( fig. 49) to get access to the BC10 basic

controller ( fig. 50).

Fig. 49 Opening the control panel

CAUTION:

▶ Limit the space heating water temperature to the

maximum flow temperature of the floor heating circuit.

▶ A power interruption discontinues manual

operation. Frost damage may occur.

“Chimney sweep” button ( fig. 50, [3])

The “Chimney sweep” button is used to put the boiler into flue gas test, service or manual operation mode. The BC10 maximum heating water temperature setting applies.

• The flue gas test enables the boiler to be run in full-load operation manually for a short period ( table 12, page 31).

• The service mode enables the boiler to be run in part-load operation manually for a short period. Measurements and settings can be carried out on the boiler ( table 13, page 31).

• The manual operation mode enables the boiler to be operated manually for a longer period. Use this mode when the control system has not been installed yet or is out of order ( table 14, page 32).

“Service” button ( fig. 50, [4])

The “Service” button is used to display the current space heating water temperature, the current system pressure etc.

Service Tool connection ( fig. 50, [5])

For further information please contact Buderus.

LED “Burner operation” ( fig. 50, [6])

The LED “Burner operation” lights when the burner of the boiler is active and is extinguished when the burner is switched OFF.

The LED “Burner operation” indicates the burner status.

Fig. 50 BC10 basic controller

[1] Main power switch [2] “Reset” button [3] “Chimney sweep” button [4] “Service” button [5] Service Tool Connector [6] LED “Burner operation” [7] LED “Central heat demand” [8] Space heating water temperature knob [9] Display [10] DHW temperature knob [11] LED “DHW demand ”

The BC10 basic controller has the following components:

“Main power switch” ( fig. 50, [1])

The main power switch is used to switch the boiler ON and OFF.

“Reset” button ( fig. 50, [2])

If a fault has occurred you may have to restart the boiler by pressing the “Reset” button.

This is only required in the event of a “locking” fault. “Blocking” faults are reset automatically as soon as their cause has been corrected. The display shows [\/r/e| during the reset operation.

LED Status Explanation

ON Burner

Boiler water is being heated.

operational

OFF Burner off The space heating water temperature has reached

the target value and there is no heat demand.

Table 10 Meanings of LED “Burner operation” indications

LED “Central heat demand” ( fig. 50, [7])

The LED “Central heat demand” lights when there is a heat demand and is extinguished when the heat demand is no longer present.

Space heating water temperature knob ( fig. 50, [8])

The Space heating water temperature knob is used to set the upper space heating water temperature limit. The unit is °F.

Display ( fig. 50, [9])

The appliance display values, display settings and display codes can be read out from the display. If a fault occurs the display will immediately show the accompanying fault code. The fault code flashes if a locking fault has occurred.

DHW temperature knob ( fig. 50, [10])

The DHW temperature knob is used to select the required temperature of the hot water in the hot water cylinder. The unit is °F ( table 20, page 40).

LED “DHW demand” ( fig. 50, [11])

The LED “DHW status” lights when there is a DHW request and is extinguished when the DHW demand is no longer present.

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Operation

8.2 BC10 operating instructions

You can navigate through the menu structure of the boiler on the BC10 using the “Reset” button, the “Chimney sweep” button, the “Service button” ( fig. 50, [ 2, 3 and 4]) and the display ( fig. 50, [ 9]).

Normal Operation menu

Step 1 [\/7/5| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 2 Press the e button. Step 3 [p/2/2|| Shows currently measured system pressure in psi ( § 13.3, page 48). Step 4 Press the e button. Step 5 [-/h/\] Current display code. In this case: Operating phase: Boiler in heating mode ( § 13.5, page 49). Step 6 After 5 seconds the display returns to step 1, or Step 7 Press the e button.

Table 11 Normal operation

Flue Gas Test menu

Step 1 [1/2/0| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 2 To activate the flue gas test:

Press and hold the d button for more than 2 but not longer than 5 seconds.

Step 3 [1/2/0| The non-flashing dot in the right-hand bottom corner of the display shows the flue gas test has been activated:

• the boiler is in heating mode at a capacity of 100% for a maximum of 30 minutes,

• space heating water temperature is as set on the BC10 basic controller,

• DHW mode is not possible.

Step 4 Press the e button. Step 5 [p/2/2| Shows currently measured system pressure in psi ( § 13.3, page 48). Step 6 Press the e button. Step 7 [-/a/\] Display code. Operating phase: The boiler is in flue gas test mode ( § 13.5, page 49). Step 8 Press the e button. Step 9 [1/2/0| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 10 After 30 minutes or after a power interruption the flue gas test ends automatically.

To end manually press and hold the d button for more than 2 seconds until the dot disappears.

Table 12 Flue gas test

The menu structure consists of 5 menus:

• Normal Operation menu,  table 11

• Flue Gas Test menu,  table 12

• Service Mode menu,  table 13

• Manual Operation menu,  table 14

• Settings menu,  table 15.

Service Mode menu

Step 1 [1/2/0| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 2 To activate service mode 1st step:

Press and hold the d button for more than 2 but not longer than 5 seconds.

Step 3 [1/2/0| The non-flashing dot is shown in the right-hand bottom corner of the display shows the boiler is now in Flue gas test mode. Step 4 To activate service mode 2nd step:

Simultaneously press and hold the d+ e buttons for more than 2 seconds.

Step 5 [l/-/-] Display shows the maximum capacity setting during heating mode in % ( § 13.4, page 48).

In this case: [l/-/-] = 100%. Service mode has been activated. You can now adjust the boiler performance to partial load, i.e. to check the gas/air ratio or the ionization current.

Step 6 Press and hold the c button until the display shows [l/3/6]. Display setting: with a 80-kW boiler and [l/3/0] with a 100-kW boiler.

Minimum capacity setting during heating mode in % ( § 13.4, page 48). The boiler will reduce its performance to 36% or 30% respectively within a couple of seconds. The space heating water temperature set on the BC10 basic controller (control panel) applies now. Check the gas/air ratio or the ionization current and if necessary set the gas/air ratio according to § 9.9 or § 9.11.

Step 7 Press the e button. Step 8 [f/\/5] This parameter shows the pump run-over time in minutes that starts when the heating mode has ended ( § 13.4, page 48).

Table 13 Service mode

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Operation

Service Mode menu

Step 9 Press the e button. Step 10 [c/\/1] This parameter indicates the DHW mode status setting ( § 13.4, page 48). Step 11 Press the e button. Step 12 [1/2/0| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 13 Press the e button. Step 14 [p/2/2] Shows currently measured system pressure in psi ( § 13.3, page 48). Step 15 Press the e button. Step 16 [-/a/\] Display code: Operating phase: The boiler is in service mode ( § 13.5, page 49). Step 17 After 30 minutes or after a power interruption the flue gas test ends automatically. To end manually press and hold the d button for more

than 2 seconds until the dot disappears.

Step 18 The boiler input rating drops to the preset capacity ( table 15, page 32).

Table 13 Service mode

Manual Operation menu

Step 1 [1/2/0| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 2 To activate manual operation: Press and hold the d button for more than 5 seconds. Step 3 [\/7/5} A flashing dot in the right-hand bottom corner of the display shows manual operation is active. This means that the boiler is

permanently in heating mode: Space heating water temperature is as set on the BC10 basic controller. The LED “Heating system status” lights. DHW mode is possible during manual operation.

Step 4 Press the e button. Step 5 [p/2/2} Shows currently measured system pressure in psi ( § 13.3, page 48). Step 6 Press the e button. Step 7 [-/h/\} Display code. Operating phase ( § 13.5, page 49). The boiler is in manual operation mode.

During manual operation the “Settings” menu (table 15 from step 2) can be used to temporarily change the target boiler performance. NOTE: If the boiler output has been changed temporarily, this must be set again after ending manual operation, according to the “Settings” menu ( table 15, page 32).

Step 8 Press the e button. Step 9 [1/2/0} Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 10 After a power interruption manual operation ends automatically.

To end manually press and hold the d button for more than 2 seconds until the dot disappears.

Table 14 Manual operation

Settings menu

Step 1 [1/2/0| Shows currently measured space heating water temperature in °F ( § 13.3, page 48). Step 2 To open the “Settings” menu: Press and hold the d+ e buttons for more than 2 seconds. Step 3 [l/-/-| This shows the “Settings” menu is open. You can adjust the setting of this parameter. Step 4 [l/-/-| Target output. Adjust as follows, or go to step 5.

Lower: Decrease the modulation rate with the c button. The minimum setting for boilers with low BTU is [l/3/6| = 36% with an 80 kW boiler and [l/3/0| = 30% with a 100 kW boiler. Higher: Increase the modulation rate with the d button. The maximum setting is [l/-/-| = 100%. This is equal to the factory setting.

Step 5 Press the e button. Step 6 [f/\/5| Pump run-over time in minutes (starts when the heating mode has ended). Adjust as follows or go to step 7.

Lower: Decrease the time with the c button. The minimum setting is [f/\/0|= 0 minutes. The factory default setting is 5 minutes. CAUTION! Do not set the post purge time to less than 5 minutes. Higher: Increase the time with the d button. The maximum setting is [f/6/0||= 60 minutes or [f/1/d|= 24 hours.

Step 7 Press the e button. Step 8 [c/\/1| DHW mode status setting. Adjust as follows or go to step 9.

DHW mode can be switched OFF or ON. This setting has priority over other DHW mode settings, such as those made on the room thermostat. Set the DHW mode with the cor d buttons. [c/\/1| means “ON”, [c/\/0| means “OFF”. NOTE: Setting [c/\/0| also switches OFF the hot water cylinder frost protection.

Step 9 After 5 seconds or after a power interruption the settings menu ends automatically. To end manually press the ebutton.

Any adjustments that you have made have been confirmed.

Table 15 Settings

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Start-up procedure

9 Start-up procedure

There are several steps involved in starting up the boiler. Complete the commissioning record log book after carrying out all activities described in this chapter ( § 15.1, page 56).

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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

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

BEFORE OPERATING smell all around the appliance area for gas. Be sure to

smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

•

Do not try to light any appliance.

•

Do not touch any electric switch; do not use any phone in your building.

•

Immediately call your gas supplier from a neighbor's phone. Follow the gas

supplier's instruction.

•

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

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

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

Do not use this appliance if any parts have been under water. Immediately call a

qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

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

2. Turn off all electric power to the appliance.

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

4. This appliance is equipped with an ignition device which

5. Close main gas shut off valve.

6. Wait (5) minutes to clear out any gas. Then smell for gas. Including near the

7. Open main shut off valve.

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

9. Turn on all electric power to the appliance.

10. If the appliance will not operate, follow the instruction "To Turn Off Gas To

1. Turn off all electric power to the appliance if service is to be performed.

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

3. Close main gas shut off valve.

Fig. 51 Safety sticker

OPERATING INSTRUCTIONS

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

floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

Appliance" and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

708.375A - 2172B

6720645916-48.1N

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Start-up procedure

9.1 Check for gas leaks

Prior to the initial start-up check that the gas flow pipe work is gas-tight; this must be confirmed in the start-up report.

WARNING:

▶ The boiler and its manual gas shutoff valve must be

isolated from the gas supply piping system during any pressure testing of that system, exceeding

0.5 psi (34.5 mbar). The maximum test pressure allowed at the manual gas shutoff valve inlet is 0.5

psi (34.5 mbar). ▶ Cover endangered positions before leak testing. ▶ Do not spray the leak testing agent onto cables, plugs

or electrical connection lines. Do not allow it to drip

onto them either.

DANGER:

Leaks may be caused to pipes and screw connections during commissioning and maintenance activities.

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

detection.

▶ If 0.5 psi (34.45 mbar) or less, slowly open the gas valve by pushing

on the gas valve and turning it ¼ rotation in a counter-clockwise direction ( fig. 52). The gas valve is open when it is in the vertical

position. ▶ Shut off the appliance from the power supply. ▶ Check the new conduit section up to and including its connection (i.e.

direct sealing location) to the gas fitting for leaks, using a foaming

product.The maximum test pressure allowed at the manual gas

shutoff valve inlet is 0.5 mbar (0.2" W.C.).

9.2 Fill the heating system

To ensure a trouble-free operation of the boiler, read the accompanying instructions about water quality, before filling the heating system.

NOTICE

▶ At initial start up, the boiler will start as soon as the

system pressure exceeds 15 psi (1.0 bar).

▶ If the system pressure falls below 3 psi (0.2 bar) the

boiler will stop and generate a fault code.

▶ Push and open the control panel cover. ▶ Turn the Space heating water temperature knob [8] and DHW

temperature knob [10] counterclockwise to the “0” position.

Fig. 53 BC10 basic controller

▶ Turn the vent key a quarter rotation to undo the boiler door lock

( fig. 54, detailed picture).Push the fastener down ( fig. 54, step 2) and open the boiler door.

▶ Remove the insulation cover of the pump group ( fig. 54, step 4).

Fig. 52 Open the gas valve

[1] pressure relief valve [2] supply water valve [3] pump [4] manual gas shutoff valve [5] return water valve

6720645916-49.1N

Fig. 54 Opening the boiler door

To purge the boiler, every radiator in the heating system must have a purge facility. In some situations it may even be necessary to provide extra purging facilities at certain locations. The boiler itself has an automatic air vent.

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Start-up procedure

6720645916-52.1N

6720645916-53.1N

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6720645916-54.1N

6720645916-55.1N

6720645916-56.1N

▶ Loosen the cap of the automatic air vent ( fig. 55) by turning

¼ rotation counterclockwise.

Fig. 55 Opening the automatic air vent

▶ Open the heating supply and return isolating valves on the pump

group ( fig. 56). The open position is parallel to the pipe.

▶ Fill the heating system to a pressure of about 20 psi (1.5 bar)

The pressure in the heating system, which is measured directly at the boiler, must be at least equal to the required pre-pressure of the expansion vessel plus 7 psi (0.5 bar). This minimum pressure must not be less than 12 psi (0.8 bar) (if the heating system is cold). The maximum pressure in the heating system, measured directly at the boiler, must not exceed 30 psi (2.6 bar) or 50 psi (3.5 bar) when the optional 50 psi (3.5 bar) pressure relief valve is used.

▶ Purge the heating system via the air vents on the heating bodies.

Start at the lowest floor of the premises and then work your way up from floor to floor.

9.3 Fill the condensate trap with water

▶ Fill the condensate trap with water ( fig. 58). For disconnecting

the condensate trap ( § 12.3.5, page 46).

Fig. 58 Filling the condensate trap with water

WARNING:

Danger of fatal accident due to poisoning.

▶ If the condensate trap is not filled with water, flue gas

can escape and put people's lives at risk.

9.4 Bleed the gas supply valve

Fig. 56 Opening the isolating valves (here: open position)

▶ Read the pressure (PSI) from the pressure gauge on the pump group

or on the control panel of the BC10 ( fig. 57).

Fig. 57 Reading the pressure gauge

▶ Close the gas valve ( fig. 59).

Fig. 59 Closing the gas valve

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6720645916-58.1N

6720645916-59.1N

Start-up procedure

▶ Open the screw plug on the testing nipple of the gas supply pressure

and for purging [1] by 2 turns and install a hose.

Fig. 60 Bleeding the gas flow pipe

▶ Slowly open the gas valve by pushing on the gas valve and turning it

counterclockwise through ¼ rotation ( fig. 61). The gas valve is

open when it is in the vertical position.

9.6 Checking the appliance configuration

NOTICE

The burner must only be put into use with the correct orifice ( table 16).

▶ Consult the relevant gas utility company for the type

of gas supply.

▶ Check that the actual gas supply is in accordance

with the type of gas supply specified on the gas classification label ( fig. 62).

Fig. 62 Checking the gas classification label

Fig. 61 Opening the gas valve

▶ Purge the gas supply into a well ventilated area. ▶ Close the gas shutoff valve when no more air is present ( fig. 59). ▶ Remove the hose and tighten the screw plug on the testing nipple

again.

NOTICE

▶ Test the tightness of the measuring nipple(s) used.

9.5 Check the air/flue gas connection

Check the following points:

• Is the prescribed flue gas system used ( § 6.8, page 18)?

• Have the configuration instructions from the relevant flue gas system

installation instructions been observed?

Gas orifice

Boiler

GB162-L.B. 80kW/ 100kW

Type of gas

supply

Altitude in ft. (m)

Natural gas 4,001-10,200

(1,220-3,111)

LPG 4,001-8,000

(1,220-2,625)

LPG 8,001-10,200

(2,625-3,111)

diameter in

inch (mm)

0.370 (9.40)

0.185 (4.70)

0.197 (5.00)

Table 16 Gas orifice diameter

9.7 Measure the gas inlet pressure (working pressure)

▶ Open at least 2 radiator valves, if present. Do not switch ON the

boiler. ▶ Push on the control panel to open it. ▶ Switch OFF the power supply to the appliance. ▶ Close the gas valve in a clockwise direction ( fig. 63).

6720645916-60.1N

Fig. 63 Closing the gas valve

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Start-up procedure

6720645916-61.1N

▶ Turn the vent key through a quarter rotation to undo the boiler door

lock ( fig. 54, page 34). ▶ Push the fastener down and open the boiler door. ▶ Open the screw plug on the testing nipple for the gas inlet pressure

▶ Press the “Chimney sweep” dbutton ( fig. 65, [3]) to clear the

reading ( table 12, page 31).

10 9 8

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Fig. 65 BC10 basic controller

[1] Main switch [2] “Reset” button [3] “Chimney sweep” button [4] “Service” button

Fig. 64 Measuring the gas supply pressure

▶ Reset the digital pressure gauge to “0”.

[5] Connection possibility for the diagnosis connector [6] LED “Burner operation” [7] LED “Central heat demand” [8] Space heating water temperature knob

NOTICE

▶ Throughout the measuring operation, keep the digital

pressure gauge in the same position (horizontal or

[9] Display [10] DHW temperature knob [11] LED “DHW demand”

vertical) in which it was reset to “0”.

WARNING:

▶ Connect the pressure gauge connection tube to the positive port of

the testing nipple ( fig. 64, [2]). ▶ Slowly open the gas valve by pushing on the gas valve and turning it

¼ rotation in an counterclockwise direction ( fig. 61, page 36).

The gas valve is open when it is in the vertical position.

A leaking testing nipple causes explosive fumes.

▶ Check the testing nipples used for leaks. ▶ Only use approved detection products to locate

leaks.

▶ Switch ON the appliance by pressing the main switch of the BC10

basic controller ( fig. 65, [1]). ▶ Press and hold the “Chimney sweep” button ( fig. 65, [3) (approx.

2 seconds), until the dot in the right-hand bottom corner of the

display ( fig. 65, [9]) appears ( table 12, page 31). ▶ After the LED “Burner operation” ( fig. 65, [6]) has lit up wait for

1 minute until the boiler is burning at full load. ▶ Statically measure the gas supply pressure and enter it in the start-up

NOTICE

▶ If the supply pressure is too low, check the gas supply

pipe or contact the relevant gas utility company if the required supply pressure is not available.

▶ If the supply pressure is too high, a gas pressure

regulator must be integrated upstream of the gas fitting. Contact the gas utility company.

report ( § 15.1, page 56).

To obtain the best performance of the appliance, the gas supply pressure must be:

▶ Close the gas valve. ▶ Remove the gauge-connection tube and tighten the screw plug on the

testing nipple again.

Statically measured1) gas supply pressure

Natural gas inch W.C.

(mbar)

LPG inch W.C.

(mbar)

▶ Open the gas valve again by pushing on the gas valve and turning it

¼ rotation in a counterclockwise direction.

Min. 5 (12.4) 8 (19.9) Nom. 8 (19.9) 11 (27.4) Max. 10,5 (26.1) 13 (32.3)

Table 17 Gas supply pressure

1) Measured statically perpendicular to flow at full load.

▶ Press the “Service”

e button ( fig. 65, [4]) repeatedly until the

temperature reading is shown in the display.

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Start-up procedure

9.8 Carry out a leakage test in operating conditions

WARNING:

Leaks may be caused to pipes and screw connections during commissioning and maintenance activities.

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

detection.

▶ Press and hold the “Chimney sweep” d button ( fig. 65, [3])

(approx. 2 seconds), until the dot in the right-hand bottom corner of the display ( fig. 65, [9]) appears ( table 12, page 31).

▶ After the LED “Burner operation” ( fig. 65, [6]) has lit up wait for

1 minute until the boiler is burning at full load.

▶ Use a foaming product to check all sealing locations in the total gas

circuit of the burner while the burner is active.

▶ Press the “Chimney sweep”

d button ( fig. 65, [3]) to clear the

reading ( table 12, page 31).

9.9 Check and adjust the flue gases CO2 emissions

CAUTION:

Take adequate time to properly measure the CO

▶ Changes will only be measurable after about

1 minute.

▶ Let the CO

value stabilize for about 30 seconds

before reading and/or readjusting.

values.

▶ Press and hold the d button ( fig. 69, [3]) (approx. 2 seconds),

until the dot in the right-hand bottom corner of the display ( fig. 69, [9]) appears ( table 12, page 31).

▶ After the “LED Burner operation” ( fig. 69, [6]) has lit wait for

1 minute until the boiler is burning at full load.

▶ Measure in the flue gas measuring port, with closed boiler door, the

percentage. The value has to be 9.3% ± 0.2%.

▶ If necessary: open the boiler door and adjust the CO

percentage to

9.3% by means of the adjustment screw on the gas valve with the red sleeve ( fig. 67) and close boiler door again. Note the set value in table 27 on page 56.

If the CO2 percentage is not adjustable above 9% the problem can be:

• The gas pressure is to low ( § 9.7, page 36).

•CO

analyzer set incorrectly. Set CO2 analyzer on natural gas.

• Very low calorific gas. No solution, accept lower CO

percentage.

▶ Open at least 2 radiator valves, if present. Do not switch ON the

boiler. ▶ Push on the control panel to open it. ▶ Switch OFF the appliance by pressing the main switch of the BC10

basic controller ( fig. 65, [1]). ▶ Remove the cover from the flue gas measuring point ( fig. 66, [1]). ▶ Connect the flue gas analyzer to the left-hand measuring point, insert

it roughly 2" ( fig. 66).

Fig. 66 Measuring the flue gases CO emissions

▶ Switch ON the appliance by pressing the main switch of the BC10

basic controller.

6720645916-64.1N

Fig. 67 Adjusting flue gases CO2 emissions (at full load)

NOTICE

▶ The adjustment screw has no limit stop, there for it is

not defined, in advance, that turning left or right will give a higher or lower value.

▶ Simultaneously press and hold the

d+ e buttons for more than

2 seconds, to activate service mode for partial load setting.

▶Press and hold the

c button until the display shows:

– [l/3/6| with a 80 kW boiler or – [l/3/0| with a 100 kW boiler.

▶ After the load is adjusted to partial load, wait for 1 minute until the

boiler burns at partial load.

▶ Measure in the flue gas measuring port the CO

percentage. The

value has to be 1 to 1.5% lower than the measured value at full load.

E.g. full load measured value = 9.3:

9.3 - 1 = 8.3 and 9.3 - 1.5 = 7.8

So when the CO

percentage at full load is 9.3%, the partial load CO2

percentage value has to be between 8.3% and 7.8%.

If necessary:

▶ Adjust the CO

percentage to the calculated value, by means of the

air/gas ratio adjustment screw [1]. The adjustment screw is located

behind the screw plug. ▶ Open the screw plug. ▶ Turn adjustment screw to the left for a lower CO

percentage.

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Start-up procedure

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▶ Turn adjustment screw to the right for a higher CO2 percentage. ▶ After adjusting close the screw plug.

Fig. 68 Adjusting gas/air ratio at minimum load

▶ Note the set value in table 27 on page 56. ▶ Switch OFF the heating system by pressing the main switch of the

BC10 basic controller ( fig. 69, [1]).

▶ Remove the flue gas analyzer and fit the cover back onto the flue gas

measuring point ( fig. 69, [1]).

▶ Switch ON the heating system by pressing the main switch of the

BC10 basic controller ( fig. 69, [1]).

▶ Press on the control panel to close it.

9.10 Function test

▶ During initial start-up and annual inspection and/or needs-oriented

servicing, make sure that all control, regulating and safety devices are in full working order and, if applicable, check them for correct adjustment.

▶ The gas and water circuits must be tested for leaks ( §9.1,

page 34), ( § 9.9, page 38).

▶ Push the fastener down (fig. 54, step 2) and open the boiler door. ▶ Undo the plug and socket connection of the monitoring cable

( fig. 70).

6720645916-67.1N

Fig. 70 Removing the ionization electrode plug and socket connection

▶ Connect the multi meter in series ( fig. 71). Select the μA DC range

on the multi meter. The multi meter must have a resolution of at least 1μA.

9.11 Measure the ionization current

▶ Press on the control panel to open it. ▶ Open at least 2 radiator valves, if present. Do not switch ON the

boiler.

▶ Switch OFF the appliance by pressing the main switch of the BC10

basic controller ( fig. 69, [1]).

Fig. 69 BC10 basic controller

▶ Turn the vent key through a quarter turn to undo the boiler door lock

( fig. 54, step 1).

6720645916-68.1N

Fig. 71 Measuring the ionization current

▶ Switch ON the appliance by pressing the main switch of the BC10

basic controller ( fig. 69, [1]).

▶ Activate the Service mode in accordance with the “Service mode”

menu ( table 13, page 31).

▶ Set the capacity to minimum (part load) according to the “Service

mode” menu ( table 13, page 31).

▶ After the LED Burner “operation” ( fig. 69, [6]) has lit wait for

1 minute until the boiler is burning at part load.

▶ Measure the ionization current. The ionization c urrent must be > 5 μA

DC at part load operation.

▶ Enter the result in the start-up report ( § 15.1, page 56).

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Start-up procedure

▶ If the result is not as it should be ( § 9.9, page 38) or check the

ionization electrode ( § 12.3.4, page 45).

▶ Press and hold the “Chimney sweep”

d button ( fig. 69, [3])

(approx. 2 seconds), until the dot in the right-hand bottom corner of the display ( fig. 69, [9]) appears ( table 12, page 31).

▶ Switch OFF the appliance by pressing the main switch of the BC10

basic controller ( fig. 69, [1]). ▶ Remove the multi meter and reconnect the monitoring cable. ▶ Switch ON the appliance by pressing the main switch of the BC10

basic controller ( fig. 69, [1]). ▶ Check that the boiler performance is still at the required value

( table 13, page 31).

9.12 Test the Ignition Safety shut off device

▶ Switch OFF the appliance by pressing the main switch of the BC10

basic controller ( fig. 69, [1]). ▶ Disconnect the plug and socket connection of the monitoring cable. ▶ Switch ON the appliance by pressing the main switch of the BC10

basic controller ( fig. 69, [1]). ▶ Press the “Chimney Sweep”

d button and hold it (for approx.

2 seconds), until the display shows the decimal point. ▶ Check if the boiler does 1 start-up attempt and 3 restart attempts.

After each start-up attempt the boiler will signal a start-up failure. A “6A” code can be seen in the display.

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

▶ Connect the plug and socket connection of the monitoring cable. ▶ Press the “Reset” button. ▶ Check if the boiler starts-up. ▶ Press the “Chimney Sweep”

d button return to normal operating

conditions.

9.13 Boiler settings

9.13.1 Set the heating capacity

▶ Set the required heating capacity on the BC10 according to the

“Settings” menu. See table 18, when making these settings.

Rated heating capacity (±5%), based on natural gas

Display indication [%]

GB162-L.B. 80 kW GB162-L.B. 100 kW

kW btu/h kW btu/h

L30 29.9 97,900 L40 32.9 104,400 39.9 130,500 L50 41.5 130,500 49.8 163,200 L60 50.1 156,600 59.8 195,800 L70 58.7 182,700 69.7 228,400 L80 67.3 208,800 79.6 261,000 L90 75.9 234,900 89.6 293,700 L-- 84.5 261,000 99.5 326,300

Table 18 Heating capacity (as a percentage) low BTU (4,001-

10,200 ft.)

9.13.2 Set the space heating water temperature

▶ Set the upper space heating water temperature limit for heating

mode with the “space heating water temperature” knob ( fig. 72,

[8]) ( table 19). This limitation does not apply to DHW

preparation.

(sea level)

Knob position Explanation

0 No supply to appliance (e.g. only DHW mode) 86-190 The temperature (in °F) set on the BC10 cannot be

changed with a room controller. The supply temperature does not rise above this set temperature. (maximum supply temperature set point 180 °F (82 °C)).

Aut The temperature is determined automatically on the basis

of the heating curve. If no room controller is connected, the maximum supply temperature is 180 °F (82 °C).

Table 19 Setting of the “space heating water temperature”

10 9 8

110

100

120

130

140

130

110

150

170

190

123456

Fig. 72 BC10 basic controller

9.13.3 Set the pump run-over time

▶ Set the pump run-over time according to the “Settings” menu

( table 15, page 32).

If the heating system is room temperature controlled, and not controlled parts of the heating system risk freeze damage (e.g. radiators in the garage), set the pump run-over time to 24 hours.

9.13.4 Switch DHW mode ON/OFF

▶ Set the DHW mode according to the “Settings” menu ( table 15,

page 32).

When DHW-mode is switched OFF ([c/\/0|), the freeze protection for the hot water cylinder (if present) is switched OFF.

9.13.5 Set the DHW temperature

▶ Set the DHW temperature knob ( fig. 72, [10]) to the required

temperature of the hot water in the hot water cylinder ( table 20).

Knob position Explanation

0 DHW mode is OFF (only heating mode) ECO Economy mode. The DHW will only be reheated to 140 °F

(60 °C), if the temperature has significantly fallen. This reduces the number of burner starts and saves energy. As a result the water may be a bit colder initially.

86-140 The temperature set on the BC10 is a temperature that

cannot be changed using a RC thermostat.

Aut The temperature is set on the thermostat (e. g. RC35).

If no thermostat is connected, the maximum DHW temperature is 140 °F (60 °C).

Table 20 Setting of the “DHW temperature”

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Shutting down the system

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9.14 Final activities

9.14.1 Close the boiler door and the control panel

▶ Close the boiler door ( fig. 73) and lock the fastener by turning the

vent screw through ¼ rotation in a clockwise direction.

▶ Push on the control panel to close it.

Fig. 73 Closing the boiler door

9.14.2 Hand over

▶ Hand over all relevant documentation to the end user and explain

his/her responsibilities under the relevant national and regional regulations.

▶ Explain and demonstrate the start-up and shut down procedures.

▶ Close the main gas supply or the gas valve ( fig. 74).

Fig. 74 Closing the gas valve

10.2 Shutting down the heating system if there is a risk of freezing (interruption of use)

If conditions are such that the heating system has to be shut down for a long period while there is a risk of freezing, the water must be drained from the heating system.

▶ Push on the control panel to open it. ▶ Switch off OFF appliance by pressing the main switch of the BC10

( fig. 72, [1]). ▶ Close the main gas supply or the gas valve ( fig. 74). ▶ Drain the heating water at the lowest point of the heating system,

using the drain cock or the heating body ( fig. 75). The (automatic)

air vent at the highest point of the heating system/radiator must be

open.

10 Shutting down the system

CAUTION:

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

▶ Protect the heating system against freezing if there is

a danger of frost affecting the system. Drain the heating system water from the lowest point of the heating system. The vent screw at the highest point of the heating system must then be open.

10.1 Shut down the appliance using the basic controller

Shut down your appliance by means of the Logamatic BC10 basic controller. When the system is shut down, the burner is automatically switched off.

Further information about the use of the BC10 basic controller is provided in chap. 8 "Operation", page 30.

▶ Push on the control panel to open it. ▶ Switch OFF the appliance by pressing the main switch of the BC10

( fig. 72, [1]).

Fig. 75 Draining the heating system (example)

10.3 Shutting down the heating system in the event of an

emergency

You must immediately close the main shutoff valve or gas shutoff valve and disconnect the power from the appliance.

▶ Close the main shutoff valve.

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Inspection

11 Inspection

Offer your customer an annual inspection and maintenance contract. The activities to be included in an annual inspection and maintenance contract can be found in the inspec tion ( § 15.2, page 57) and service reports ( § 15.3, page 57).

WARNING:

Do not use this boiler if any part has been under water.

▶ Immediately call a qualified service technician to

inspect the boiler and to replace any part of the control system and any gas control which has been under water.

CAUTION:

Insufficient or improper cleaning and maintenance can cause damage to the installation.

▶ Inspect and clean the appliance once a year. ▶ Carry out maintenance as required. Immediately

remedy faults. This will avoid further damage to the system!

▶ Close the isolating valves [2].

Fig. 76 Closing the valves (here: in closed position)

▶ Open the boiler door:

– Turn the vent key through a quarter rotation to undo the boiler

door lock ( fig. 77, step 1).

– Push the fastener down ( fig. 77, step 2) and open the boiler

door.

NOTICE

▶ If the boiler door cannot be opened completely,

remove it ( § 12.2, page 43).

CAUTION:

Risk of electric shock.

▶ Before opening the appliance: ▶ disconnect the appliance from the power supply

using the appliance emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid.

▶ Secure the appliance against accidental restarting.

▶ Periodically examine the venting systems and cleaning of the screens

in the vent terminal.

▶ Also periodically inspect the low water cutoffs, including flushing of

float types and clean the condensate collections and disposal system.

11.1 Prepare the appliance for inspection

INSTRUCTION FOR THE INSTALLER

▶ If gas pipes have to be disconnected from the gas

burner fitting, the burner cover must only be opened by a specialized professional.

▶ Switch OFF the appliance by pressing the main switch of the BC10. ▶ Close the gas valve [1].

Fig. 77 Opening the boiler door

11.2 Carry out a visual check for general signs of corrosion

▶ Check all gas and water-bearing pipes for signs of corrosion and for

leaks. ▶ Replace any pipes that are corroded. ▶ Carry out a visual inspection of the burner, heat exchanger,

condensate trap, automatic air vent and all fittings in the boiler.

11.3 Gas valve leakage test

▶ Check the internal tightness of the gas fitting on the input side (with

the boiler switched OFF) at a test pressure of 7.0" W.C. (17.4 mbar)

for natural gas and 8.0" W.C. (19.9 mbar) for LPG. ▶ Check that the appliance is switched OFF. ▶ Open the screw plug on the testing nipple for the gas connection by

2turns ( fig. 78, [1]).

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▶ Connect the pressure gauge tube to the testing nipple ( fig. 78,

6720645916-77.1N

6720645916-75.1N

[2]). The pressure drop allowed after 1 minute is max. 3.8" W.C. (10 mbar).

▶ If the pressure drop is higher, check all sealing locations of the gas

fitting for leaks using a foaming product. Repeat the pressure test if no leaks are found. Replace the gas fitting if the pressure drop is higher than 3.8" W.C. (10 mbar) per minute again. See § 12.3.2 "Remove the burner cover with the fan and the gas valve", page 44 for instructions on how to remove.

Fig. 78 Checking the gas fitting for internal tightness

11.4 Measure the ionization current

( § 9.11, page 39).

Maintenance

12 Maintenance

CAUTION:

Risk of electric shock.

▶ Before opening the appliance: disconnect the

appliance from the power supply using the appliance emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid.

▶ Secure the appliance against accidental restarting.

INSTRUCTION FOR THE INSTALLER

▶ Record the activities in the service report ( § 15.3,

page 57).

NOTICE

▶ There is no need to lubricate the combustion motor

as it is permanently lubricated.

12.1 Prepare the heating system for maintenance

INSTRUCTION FOR THE INSTALLER

▶ If gas pipes have to be disconnected from the gas

burner fitting, the burner cover must only be opened by a specialized professional.

▶ Switch OFF the appliance by pressing the main switch of the BC10. ▶ Close the gas valve [1]. ▶ Close the isolating valves [2].

11.5 Measure the gas inlet pressure (working pressure)

( § 9.7, page 36).

11.6 Check and adjust the flue gas CO2 emissions

( § 9.9, page 38).

11.7 Carry out a leakage test in operating conditions

( § 9.8, page 38).

11.8 Measure the flue gases CO2 emissions

( § 9.9, page 38).

11.9 Fill the heating system

To ensure a trouble free operation of your boiler check the pH-value every year and correct it, if necessary. See accompanying manual about water quality for more information ( § 9.2, page 34).

11.10 Check the air/flue gas connection

( § 9.5, page 36).

Fig. 79 Closing the valves (here: in closed position)

12.2 Remove the boiler door

▶ Unscrew the control panel from the boiler door and hang it on the

boiler frame ( § 13.1, page 48).

▶ Unscrew the bolt from left-hand top hinge of the boiler door and

remove it together with the washer( fig. 80). ▶ Slightly lift the door and pull it from the hinge. ▶ Put the door upright in a safe position.

NOTICE

▶ The cover over the electrical connections does not

have to be removed from the boiler.

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1 2

6720645916-81.1

Maintenance

Fig. 80 Removing the boiler door

12.3 Clean the heat exchanger, burner and condensate trap

The boiler heat exchanger has a self-cleaning coating.

CAUTION:

To avoid a short circuit.

▶ Do not spray the cleaning agent onto the burner, the

hot surface ignitor, the ionization electrode or other electric components.

12.3.2 Remove the burner cover with the fan and the gas valve

▶ Pull the mains connector [1] from the fan. ▶ Pull the connector of the harness [2] from the fan while pushing on

the connector lock to loosen it.

Fig. 82 Removing the connectors from the fan

▶ Pull the air suction tube from the fan ( fig. 83).

12.3.1 Remove the gas valve

▶ Undo the gas fitting screw connection [1] and pull the 4 connectors

[2] from the gas valve.

Fig. 81 Undoing the connections to the gas fitting

6720645916-82.1N

Fig. 83 Pulling the air suction tube from the fan

▶ Carefully open the 4 snap retaining clips on the burner cover

( fig. 84). The retaining clips may be under tension.

▶ Remove the retaining clips.

6720645916-83.1N

Fig. 84 Opening the retaining clips

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Maintenance

6720645916-84.1N

6720645916-85.1N

6720615405-035.1TD

▶ Remove the burner cover with the gas/air unit ( fig. 85).

Fig. 85 Removing the burner cover with the gas/air unit

12.3.3 Remove the burner and the burner seal

▶ Remove the burner seal [1] and replace it if necessary. ▶ Remove the burner plate [2] and clean it on all sides using

compressed air or a soft brush.

When re-installing the burner plate make sure that the notch is on the right-hand side ( fig. 86, detailed picture).

NOTICE

If the seat of the cover plate leaks, the seal can burn away.

▶ Check the cover plate for tightness.

NOTICE

Since the effectiveness of the seals in the ignition unit is reduced, the gas condensing boiler may become damaged. ▶ The rubber seal ( fig. 88, [3]) and the cover plate

with seal ( fig. 88, [4]) need to be replaced every 4years.

▶ Check the individual components of the ignition unit ( fig. 88) for

wear or contamination ( fig. 87). ▶ If required, replace the ionization electrode and/or glow ignitor. ▶ After checking or replacing the ionization electrode and/or the glow

ignitor fit a new cover plate and rubber seal.

Fig. 86 Removing the burner plate and the burner seal

12.3.4 Checking ignition unit

DANGER:

▶ Close the gas valve prior to working on components

in contact with gas.

▶ Check for gas tightness after carrying out work on

components in contact with gas.

NOTICE

The glow ignitor is fragile. ▶ Handle with care.

7 746 800 040-128.2TD

Fig. 87 Checking the ionization electrode

Fig. 88 Replacing the ignition unit

[1] glow ignitor [2] Ionization electrode [3] Rubber seal [4] Cover plate with seal [5] Nut

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6720645916-89.1N

6720645916-91.

Maintenance

12.3.5 Disconnect the condensate trap

▶ Disconnect the condensate trap hose [3] and the rubber sleeve [2]

from the condensate trap [1].

▶ Turn the condensate trap a quarter rotation counterclockwise

( fig. 89).

6720645916-88.1N

Fig. 89 Disconnecting the condensate trap hose

[1] Condensate trap [2] Rubber sleeve [3] Condensate trap hose

▶ Disconnect the condensate trap from the coupling and remove it [1].

12.3.6 Remove the condensate collector

▶ Disconnect the flexible condensate drain hose and bend it

backwards ( fig. 91).

6720645916-90.1N

Fig. 91 Removing the condensate trap hose

▶ Open the 2 clamps on the right and left at the bottom of the

condensate collector [1].

▶ Pull the condensate collector down [step 1] and remove it by pulling

it towards you [step 2].

Fig. 90 Disconnecting the condensate trap

▶ Rinse the condensate trap to clean it. ▶ Fill the condensate trap with water and reinstall it.

NOTICE

▶ The condensate trap has a bayonet connector.

After inserting it, the condensate trap must be turned ¼ rotation clockwise to click into position.

Fig. 92 Removing the condensate collector

▶ Check the condensate collector for damage and replace it if required.

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Maintenance

6720645916-92.1N

6720645916-93.1N

▶ Clean the condensate collector mechanically (using compressed air

or a soft brush) and rinse it with clean water ( fig. 93).

Fig. 93 Cleaning the condensate collector

12.3.7 Clean the heat exchanger

CAUTION:

Incorrect handling can damage the boiler.

▶ Do not use metal brushes or similar hard cleaning

tools.

▶ Handle the glow ignitor with care, it is made from

fragile ceramic material.

▶ Cover the boiler interior using a blanket or a cover to

prevent dirt entering the boiler.

▶ Refit the condensate collector and make sure that the 2 retaining

clips close smoothly. If this is not the case, the seal between the

condensate collector and the flue pipe at the rear side of the heat

exchanger may be leaking. ▶ Connect the flexible condensate drain hose to the condensate

collector. ▶ Re-install the condensate trap. ▶ Rinse the heat exchanger with clean water. ▶ Reassemble all boiler components in reverse order:

– Burner with burner seal,

– Burner cover with fan and gas valve,

– Gas valve,

– Glow ignitor and ionization electrode. ▶ Start up the boiler ( chap. 9 "Start-up procedure", page 33).

12.4 Check and adjust the flue gases CO2 emissions

( § 9.9, page 38)

12.5 Function check

▶ Slowly open the gas valve by pushing on the gas valve and turning it

¼ rotation in an counterclockwise direction. ▶ Switch ON the appliance by pressing the main switch on the BC10

basic controller [1]). ▶ Set the space heating water temperature knob [8] and the DHW

temperature knob [10] to the maximum temperatures. ▶ Enter a heat demand via the control unit and check that the boiler

starts the heating mode. ▶ Open a hot water tap and check that the boiler starts the DHW mode. ▶ Set the space heating water temperature knob [8] and the DHW

temperature knob [10] to the required temperatures.

10 9 8

WARNING:

If the condensate collector is installed incorrectly.

▶ Flue gas or condensate may leak

▶ Clean the heat exchanger with compressed air or a soft brush

( fig. 94).

Fig. 94 Cleaning the heat exchanger

110

100

120

130

140

123456

Fig. 95 BC10 basic controller

110

130

150

170

190

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Display information

13 Display information

13.1 Removing the control panel

To make it easier to use the buttons on the control panel when the boiler door is open and to make it easier to read the values in the display, you can disassemble the control panel from the boiler door and hang it from the boiler frame.

▶ Open the boiler door. ▶ Loosen the 2 screws of the control panel at the rear side of the boiler

door [1].

Fig. 96 Loosening the screws

▶ Loosen the cable tie [1]. ▶ Remove the control panel( fig. 97).

▶ Use the 2 hooks to hang the control panel from the boiler

( fig. 98).

Fig. 98 Hanging the control panel from the boiler frame

13.2 Replacing the control panel

▶ Take the control panel from the boiler frame. ▶ Install the control panel in the boiler door by following the procedure

in § 13.1 "Removing the control panel", page 48 in reverse order.

13.3 BC10 Display readings

Display readings

Display reading Key to display reading Unit Range

[\/7/5| Current space heating water

°F [\/\/0| - [1/9/0|

temperature

[p/2/2| Current system pressure psi [p/0/0| - [p/5/8|

Table 21 BC10 Display readings

Fig. 97 Removing the control panel

13.4 BC10 Display settings

Display readings

Display setting Meaning of display setting Unit Range Factory-adjusted setting

[l/9/9| Low BTU (4,001-10,200 ft.):

configured target load (GB162-L.B. 80 kW) Low BTU (4,001-10,200 ft.):

configured target load (GB162-L.B. 100 kW)

[f/\/5| Configured target value of the pump run-over time.

NOTE: Do not set the pump run-over time to less than [f/\/5| (= 5 minutes).

[c/\/1| DHW flow operating condition setting.

NOTE: If the setting [c/\/0| is displayed, the frost protection of the DHW flow has also been switched off.

Table 22 BC10 Display settings

% [l/3/6| - [l/9/9| / [l/-/-| 100% [l/-/-|

% [l/3/0| - [l/9/9| / [l/-/-| 100% [l/-/-|

min. [f/0/0| - [f/6/0| / [f/1/d| 100% [f/\/5|

- [c/\/0| “Off” / [c/\/1| “On” [c/\/1|

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Display information

13.5 BC10 Display codes

The following table contains all codes that can show on the BC10 display. To show the current display code and/or sub code, press the “Service”

There are 3 main code groups:

• Operating codes - this code gives the status of the boiler. No action is

Main display

Table 23 Display codes

e button repeatedly.

necessary.

Sub display

code

[\/-/\|

[-/a/\| [2/0/8|

[-/h/\| [2/0/0|

[-/h/} [2/0/0|

[=/h/\| [2/0/1|

[0/a/\| [2/0/2|

[0/a/\| [3/0/5|

[0/c/\| [2/8/3|

[0/e/\| [2/6/5|

[0/h/\| [2/0/3|

[0/l/\| [2/8/4|

[0/u/\| [2/7/0|

[0/y/\| [2/0/4|

code Key to display code Other effects

Display codes

Operating phase: Communication test while starting up. This display code flashes 5 times within 5 seconds while starting up to indicate that the communication between the UBA 3 and the BC10 basic controller is being tested. If a new UBA 3 or a new KIM was fitted, this code will flash for max. 10 seconds.

Blocking fault: If this code continues to flash on the display, there is a fault in the communication between the UBA 3 and the BC10 basic controller.

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

Operating phase: The boiler is in heating mode

Operating phase: The boiler is in manual operation mode.

Operating phase: The boiler is in DHW mode.

Operating phase: Pump run-over time via the external hot water cylinder 130 seconds at minimum speed. The LED “Burner operation” is off.

Operating phase: The switch optimization program is activated. This program is activated if there has been a DHW request from an RC regulator more frequently than once every 10 minutes. This means that the boiler cannot be restarted until at least 10 minutes have elapsed since initial burner start-up.

Operating phase: The boiler cannot start up temporarily after a DHW request has ended.

Pre-operative phase: The boiler prepares for a burner start-up whenever a heat demand or a DHW request arises.

Readiness for operation: The boiler is in standby mode. There is a current heat demand, but too much energy has been supplied.

Readiness for operation: The boiler is in standby mode. There is no current heat demand.

Ignition phase: The gas valve is activated.

Start-up phase: The boiler starts up after activation of the mains power supply or completion of a system reset. This code is displayed for a maximum of 4 minutes.

Operating phase: The flow temperature sensor has detected that the current flow temperature is higher than the flow temperature setting on the BC10, or that it is higher than the flow temperature calculated according to the heating curve, or that it is higher than the flow temperature calculated for the DHW mode.

• Locking faults - the boiler resumes normal operation when the fault

has cleared.

• Blocking faults - the boiler is locked and will only restart after a

manual reset. The pump will operate continuously for frost

protection.

If a blinking code is displayed together with other codes, all displayed codes will blink. A locking code will always show on the first screen of the BC10.

No heating operation and no DHW.

The room temperature is too high.

The room temperature is not possibly reached.

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Display information

Main display

code

Sub display

code

[0/y/\| [2/7/6|

[0/y/\| [2/7/7|

[0/y/\| [2/8/5|

[1/a/\| [3/1/6|

[1/l/\| [2/1/1|

[1/u/\| [3/1/7|

[1/y/\| [3/1/8|

[2/e/\| [2/0/7|

[2/f/\| [2/6/0|

[2/p/\| [2/7/1|

[2/p/\| [2/1/2|

[2/u/\| [2/1/3|

[2/y/\| [2/8/1|

[2/y/\| [2/8/2|

[3/a/\| [2/6/4|

[3/c/\| [2/1/7|

[3/f/\| [2/7/3|

[3/l/\| [2/1/4|

[3/p/\| [2/1/6|

[3/y/\| [2/1/5|

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

Table 23 Display codes

Display codes

Key to display code Other effects

Locking fault: The flow temperature sensor has measured a current flow temperature

The room temperature is not possibly reached.

higher than 203 °F (95 °C). Locking fault:

The safety temperature sensor has measured a current flow temperature

The room temperature is not possibly reached.

higher than 203 °F (95 °C). Locking fault:

The return temperature sensor has measured a current return temperature

The room temperature is not possibly reached.

higher than 203 °F (95 °C). Blocking fault:

No heating operation and no DHW.

The flue gas sensor temperature is too high. Locking fault:

No heating operation and no DHW. There is no connection between contacts 78 and 50 of the UBA 3 installation base.

Blocking fault:

No heating operation and no DHW. The flue gas sensor contacts have shorted.

Blocking fault:

No heating operation and no DHW. The flue gas sensor contacts are open.

Locking fault:

No heating operation and no DHW. The system pressure is too low (less than 3 psi [0.2 bar]).

Locking fault: The flow temperature sensor has not, after burner start-up, detected any temperature increase in the heating systems water.

Locking fault: The heating water temperature difference, measured between the flow temperature sensor and the safety temperature sensor, is too high.

Locking fault: The flow temperature sensor has measured a heating water temperature increase of over 40 °F/s (5 °C/s).

Locking fault: The temperature difference measured between the flow temperature sensor and the return temperature sensor, is more than 122 °F (50 °C).

Locking fault: The pump has stopped or is running without water.

Locking fault: No feedback from the pump.

Locking fault: The tacho signal from the fan has failed during the operating phase.

Blocking fault:

No heating operation and no DHW. No current of air after a certain time.

Operating phase: The appliance has been switched off for a couple of seconds, because it had been running without any interruption for 24 hours. This is a safety check.

Blocking fault:

No heating operation and no DHW. The tacho signal from the fan is not present during the pre-operative or operating phase.

Blocking fault:

No heating operation and no DHW. The fan is running too slowly.

Blocking fault:

No heating operation and no DHW. The fan is running too fast.

Blocking fault:

No heating operation and no DHW. The flow temperature sensor has detected a flow temperature of over 221 °F (105 °C)

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Main display

code

Sub display

code

[4/c/\| [2/2/4|

[4/e/\| [2/7/8|

[4/f/\| [2/1/9|

[4/l/\| [2/2/0|

[4/p/\| [2/2/1|

[4/u/\| [2/2/2|

[4/y/\| [2/1/3|

[5/h/\| [2/6/8|

[6/a/\| [2/2/7|

[6/c/\| [2/2/8|

[6/c/\| [3/0/6|

[6/l/\| [2/2/9|

[6/p/\| [2/6/9|

[6/y/\| [2/0/3|

[7/c/\| [2/3/1|

[7/h/\| [3/2/8|

[7/l/\| [2/6/1|

[7/l/\| [2/8/0|

[8/y/\| [2/3/2|

[8/8/8|

Table 23 Display codes

Display codes

Key to display code Other effects

Blocking fault:

No heating operation and no DHW. There is no bridging cable between contacts 22 and 24 of the UBA 3 contact strip.

Blocking fault:

No heating operation and no DHW. The sensor test has failed.

Blocking fault:

No heating operation and no DHW. The safety temperature sensor has detected a flow temperature of over 266 °F (130 °C).

Blocking fault:

No heating operation and no DHW. The contacts for the safety temperature sensor have shorted or the safety temperature sensor has detected a flow temperature of over 266 °F (130 °C).

Blocking fault:

No heating operation and no DHW. The contacts for the safety temperature sensor have been interrupted.

Blocking fault:

No heating operation and no DHW. The contacts for the safety temperature sensor have shorted.

Blocking fault:

No heating operation and no DHW. The contacts for the safety temperature sensor have been interrupted.

Operating phase: Component test phase.

Locking fault: The system has detected an insufficient ionization current during the ignition phase.

Blocking fault:

No heating operation and no DHW. The system has detected an insufficient ionization current after 4 start-up attempts.

Blocking fault:

No heating operation and no DHW. The system has detected an ionization current before burner start-up.

Blocking fault:

No heating operation and no DHW. An ionization current has been measured after the burner shut down.

Blocking fault: The system has detected an insufficient ionization current during the operating phase.

Blocking fault:

No heating operation and no DHW. The system has detected an insufficient ionization current during the operating phase.

Blocking fault:

No heating operation and no DHW. The ionization current is too high.

Blocking fault:

No heating operation and no DHW. The power supply was interrupted during a locking fault

[4/a/\| [4/c/\| [4/e/\| [4/f/\| [4/l/\| [4/p/\| [4/u/\| [4/y/\|

Blocking fault:

No heating operation and no DHW. There was a momentary interruption of power.

Blocking fault:

No heating operation and no DHW. The UBA 3 is defect.

Blocking fault: The UBA 3 is defect.

Operating phase:

No heating operation. The external switch contact is open.

Start-up phase: The boiler starts up after activation of the mains power supply or completion of a system reset. This code is displayed for a maximum of 4minutes.

Display information

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 51

Page 52

Display information

Main display

code

Sub display

code

[9/a/\| [2/3/5|

[9/h/\| [2/3/7|

[9/h/\| [2/7/2|

[9/l/\| [2/3/4|

[9/l/\| [2/3/8|

[9/p/\| [2/3/9|

[9/u/\| [2/3/3|

[a/0/1| [8/0/0|

[a/0/1| [8/0/8|

[a/0/1| [8/0/9|

[a/0/1| [8/1/0|

[a/0/1| [8/1/1|

[a/0/1| [8/1/6|

[a/0/1| [8/2/8|

[a/0/2| [8/1/6|

[a/1/2| [8/1/5|

[a/1/2| [8/1/6|

[a/1/8| [8/2/5|

Table 23 Display codes

Display codes

Key to display code Other effects

Blocking fault:

No heating operation and no DHW.

The UBA 3 or the KIM is defective. Blocking fault:

No heating operation and no DHW.

The UBA 3 or the KIM is defective. Blocking fault:

No heating operation and no DHW.

The UBA 3 or the KIM is defective. Blocking fault:

No heating operation and no DHW.

The contacts for the gas valve have been broken. Blocking fault:

The UBA 3 or the KIM is defective. Blocking fault:

No heating operation and no DHW.

The UBA 3 or the KIM is defective. Blocking fault:

No heating operation and no DHW.

The UBA 3 or the KIM is defective. Locking fault:

Minimum outdoor temperature is assumed. The contacts to the outdoor-temperature sensor have shorted or are interrupted, the sensor has been connected incorrectly or is defective.

Locking fault:

No DHW is heated any more. The contacts to the DHW temperature sensor have shorted or are interrupted, the sensor has been connected incorrectly or is defective.

Locking fault:

No DHW is heated any more. The contacts to DHW temperature sensor to have shorted or are interrupted, the sensor has been connected incorrectly or is defective.

Locking fault: The boiler water does not warm up. Sensor lead broken or shorted, sensor connected incorrectly or defective, filling pump connected incorrectly or defective, permanent tapping or leak.

Locking fault:

No DHW available, but there is heating

operation. The DHW priority is cancelled

when the fault message appears. Switch

the boiler off and on to reset the boiler.

Thermal disinfection was interrupted. Thermal disinfection has failed. Outlet flow during disinfection period too high, sensor lead broken or shorted, sensor connected incorrectly or defective, filling pump defective.

Locking fault: No connection to EMS. EMS bus system is overloaded, UBA 3/MC10 is defective.

Locking fault:

The boiler no longer receives a heat

demand. The heating system does not heat

any longer.

No heating operation and no DHW. Water pressure sensor generates a fault code. The digital water pressure sensor is defective.

Locking fault: No communication with BC10. Contact problem at BC10 or BC10 is

BC10 settings are no longer taken over by

RCxx devices. defective.

Locking fault: The contacts to the switch sensor have shorted or are interrupted, the sensor has been connected incorrectly or is defective.

The water flow to the downstream heating

circuits may be faulty now they can no

longer be provided with the required heat

capacity. Locking fault:

WM10 not available or no communication. WM10 or bus circuit connected

Heating circuit pump 1 is activated

continuously. incorrectly or defective, WM10 is not recognized by the RC-thermostat.

Locking fault: Conflicting addresses. Both RC20 and RC35 are registered as Master.

Both RC35 and RC20 activate heating

circuit 1 and DHW. Depending on the

heating programs set and the required

room temperatures, the heating system

can no longer work correctly. DHW mode

does not work well.

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)52

Page 53

Main display

Sub display

code

[a/2/1| [8/0/6|

[a/2/1| [8/1/6|

[a/3/2| [8/0/7|

[a/3/2| [8/1/6|

[c/a/\| [2/8/6|

[c/0/\| [2/8/8|

[c/0/\| [2/8/9|

[c/u/\| [2/4/0|

[c/y/\| [2/4/1|

[e/l/\| [2/9/0|

[e/\/\|

[2/4/2|

[2/8/7|

code

thru

Display information

Display codes

Key to display code Other effects

Locking fault: RC20-HK1 temperature sensor. The integrated temperature sensor of the remote control (control unit) of heating circuit 1 is defective.

Locking fault: The contacts to the heating circuit flow sensor have shorted or are interrupted, the sensor has been connected incorrectly or is defective.

Locking fault: MM10 not available or no communication. The heating circuit addresses on the MM10 and the RC35 do not match up, the MM10 or the bus circuit is connected incorrectly or is defective, MM10 is not recognized by the RC35.

Blocking fault: The return temperature sensor has measured a return temperature higher than 221 °F (105 °C)

Blocking fault: The contacts for the pressure sensor have been interrupted or have shorted.

Blocking fault: The contacts for the pressure sensor have shorted.

Blocking fault: The contacts for the return temperature sensor have shorted.

Blocking fault: The contacts for the return temperature sensor have been interrupted.

Locking fault: The UBA 3 or the KIM is defective.

Blocking fault: The UBA 3 or the KIM is defective.

Since there is no actual room temperature information, room influence and optimization of the switch times do not work. The EMS works on the basis of the values last set on the remote control.

Since there is no actual room temperature information, room influence and optimization of the switch times do not work.

Heating circuit pump 2 is activated depending on the preset value. The power to the mixer is switched off and the mixer stays in the state it was last put in (can be adjusted manually).

Heating circuit 2 cannot be operated correctly. MM10 and the mixer automatically goes into emergency operation. Heating circuit pump 2 is activated continuously. Monitor data in the RC35 is invalid.

No heating operation and no DHW.

[h/\/7|

Operating phase: The system pressure is too low (less than 12 psi [0.8 bar]).

[p/-.-|

Operating phase: The system pressure is too high (higher than 58 psi [4.0 bar]).

[\/r/e|

Locking fault: Reset is carried out. This code appears after the “Reset” button on the display was pressed for 5 seconds.

Table 23 Display codes

1) Any display code with a dot in bottom right hand corner.

2) Any display code with a blinking dot in bottom right hand corner.

3) Any display code starting with the letter E (except EL).

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 53

No heating operation and no DHW.

Page 54

Technical specifications

14 Technical specifications

14.1 Technical specifications of GB162-boilers at low BTU (4,000-10,200 ft.)

GB162-L.B. 80

General specifications unit

Gas category Natural gas Propane Natural gas Propane Rated thermal load btu/h 100,000-290,000 90,000-270,000 100,000-333,000 90,000-315,000 Rated heating capacity,

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

heating curve 122/86 °F (50/30 °C) Boiler efficiency at max. capacity,

heating curve 176/140 °F (80/60 °C) Boiler efficiency at max. capacity,

heating curve 122/86 °F (50/30 °C) CSA Output btu/h 261,000 243,000 295,000 279,000 De-ration altitudes 4,001 - 6,000 ft. % / 1,000 ft. 2.3 2.3 1.4 2.0 De-ration altitudes 6,000 - 8,000 ft. % / 1,000 ft. 2.3 2.1 1.5 1.9 De-ration altitudes 8,000 - 10,200 ft. % / 1,000 ft. 2.2 1.5 1.9 1.3 AFUE at 80/180 °F (27/82 °C) 93.8 93.9 n/a n/a BTS 2000 at 80/180 °F (27/82 °C), partial load n/a n/a 96.1 96.1 BTS 2000 at 80/180 °F (27/82 °C), full load n/a n/a 90.8 90.8 Heating Maximum flow temperature °F (°C) 180 (82) Maximum working pressure (boiler) psi (bar) 50 (3.6) Minimum water circulation volume Gal/h (l/h) 0 Flow temperature °F(°C) 86-180 (30-82), can be set on the BC10 basic controller Resistance at ΔT = 20 K psi (bar) 3.26 (225) 4.57 (315) Heating circuit volume of heat exchanger Gal l 1.3 (5.0) Pipe connections boiler, without pump group Gas connection in Rp 1" Heating water connection in G 1½" union nut with female thread enclosed Condensate connection in (mm) Ø 1¼" (32) Flue gas values Condensate quantity at 104/86 °F (40/30 °C) Gal/h (L/h) 2.4 (9.0) 2.85 (10.8) pH value of condensate pH approx. 4.1 Flue gas mass flow rate, full load g/s 35.3 44.9 Flue gas temperature 176/140 °F (80/60 °C),

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

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

full load Flue gas temperature 122/86 °F (50/30 °C),

partial load CO2 content at full load % 9.3 ± 0,2% 9.6 9.4 ± 0,2% 9.7 Free fan feed pressure " w.c. (Pa) 0.602 (150) 0.883 (220) Flue gas connection Ø Flue gas system, room-air dependent in (mm) Ø 4" (100) Ø Flue gas system, room-air independent in (mm) Ø 4" (100)/ 4" (100) parallel

Table 24 Technical specifications of GB162-boilers at low BTU

btu/h 89,000-255,200 76,700-237,600 89,000-293,000 76,700-277,200

btu/h 99,000-281,300 85,300-261,900 99,000-326,300 85,300-308,700

% 88 88

% 97 98

°F(°C) 153 (67) 149 (65) 169 (76) 165 (63)

°F(°C) 142 (61) 136 (58) 142 (61) 136 (58)

°F(°C) 118 (48) 114 (46) 124 (51) 120 (49)

°F(°C) 93 (34) 88 (31) 96 (34) 88 (31)

(NG)

GB162-L.B. 80

(LP)

GB162-L.B.100

(NG)

GB162-L.B. 100

(LP)

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)54

Page 55

Technical specifications

7.25

6.53

5.80

5.08

4.35

3.63

2.90

2.18

1.45

0.73

2.2 4.4 6.6 8.8 11.0 13.2 15.4 17.6 19.8 22.0

500 1000 1500 2000 2500 3000 3500 4000 4500 5000

500

450

400

350

300

250

200

150

100

psi mbar

L/h

GPM

100 kW

80 kW

6720645916-98.1N

General specifications unit

GB162-L.B. 80

(NG)

GB162-L.B. 80

(LP)

GB162-L.B.100

(NG)

Electrical data Mains connection voltage VAC, Hz 120, 60 Electrical protection rating IPX4D Fuses Amp 5 Electrical power consumption,

W 104 156

full load (without a pump group) Electrical power consumption,

W 29 29

partial load (without a pump group) Boiler dimensions and weight Height × width × depth (with pump group) in (mm) 50.4 x 20.5 x 18.3 (1280 x 520 x 465) Weight (without a pump group) lb (kg) 154 (70) Other specifications Pump group pump UP 26-99

Table 24 Technical specifications of GB162-boilers at low BTU

Thermal power gas boiler

GB162L.B. 80 kW/ 100 kW

Type of

gas

supply

Natural

gas

Altitude

in kwh (m)

4,001 - 10,200

(1,220 - 3,048)

LPG 4,001 - 8,000

(1,220 - 2,408)

LPG 8,000 - 10,200

(2,408 - 3,048)

Gas orifice

diameter

in mm (inch)

9.40

(0.370)

4.70

(0.185)

5.00

(0.197)

Set number

with orifice

8718600323

7746900499

Type of gas supply Factory pre-setting of the gas control valve

Natural gas Delivered factory-set: Natural Gas LP-gas Suitable for propane after conversion (also see

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

Table 26 Factory setting of the gas control valve

• The gas orifice diameter is marked on the gas orifice (in mm).

Table 25 Gas orifice diameter

Hydraulic resistance of the boiler

GB162-L.B. 100

(LP)

Fig. 99 Boiler resistance curve

[1] Volume flow [2] Pressure drop

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 55

Page 56

Reports

15 Reports

15.1 Start-up report

▶ Enter your signature and the date after completing the start-up activities.

Start-up activities Page Measurement results Remarks

1. Check for gas leaks page 34

2. Fill the heating system page 34

- Pre-pressure expansion vessel (refer to the installation instructions for the expansion - vessel)

- Heating system filling pressure _____________ psi

3. Fill the condensate trap with water page 35

4. Write down the gas characteristics Heat input _____________ btu/ft.

Heat output _____________ btu/PM

5. Bleed the gas supply valve page 35

6. Check the air/flue gas connection page 36

7. Checking the appliance configuration page 36

8. Measure the gas inlet pressure (working pressure) page 36 _____________ "W.C.

9. Carry out a leakage test in operating conditions page 38

10. Check and adjust the flue gases CO2 emissions page 38 _____________ ppm

11. Carry out a function test page 39

- Measure the ionization current page 39 _____________ μA

12. Measure the pH-value Fill in the record book

 

_____________ psi



  



13. Boiler settings page 40

14. Final activities page 41

- Close the boiler door and the control panel

- Hand over

Confirming proper start-up

Company stamp/signature/date

Table 27 Start-up report

 

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)56

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Reports

15.2 Inspection report

▶ Indicate the inspection activities that have been carried out, enter the values measured and enter your signature and the date.

Date: Date: Date: Date: Date: Date: Date:

Inspection activities See paragraph

1. Check the general condition of the heating system

2. Carry out a visual in spection and function test of the heating system

3. Checking the gas and water-bearing system components for:

- Operational tightness § 9.8, page 38

- Visible corrosion § 11.2, page 42

-Signs of wear

- Fill the condensate trap § 9.3, page 35

4. Measure the ionization current §9.11, page39

5. Measure the gas inlet pressure (working pressure)

6. Check and adjust the flue gases CO2 emissions §9.9, page 38 _______ _______ _______ _______ _______ _______ _______

7. Carry out a leakage test in operating conditions § 9.8, page 38

8. Check and adjust the flue gases CO2 emissions § 9.9, page 38 _____ppm _____ppm _____ppm _____ppm _____ppm _____ppm _____ppm

9. Fill the heating system

- Pre-pressure of expansion vessel (also see

installation instructions for expansion vessel)

- Filling pressure § 9.2, page 34 _______psi _______psi _______psi _______psi _______psi _______psi _______psi

10. Check the air/flue gas connection § 9.5, page 36

11. Checking the boiler settings of the control device (in accordance with requirements)

12. Final check of the inspection activities, documenting the measurement and test results

13. Confirming proper inspection

§ 9.7, page 36 _______ _______ _______ _______ _______ _______ _______

documents for the

control device.

___________ ___________ ___________ ___________ ___________ ___________ ___________



      



_______ μA _______ μA _______ μA _______ μA _______ μA _______ μA _______ μA

" W.C. " W.C " W.C " W.C " W.C " W.C " W.C

"W.C. "W.C "W.C "W.C "W.C "W.C "W.C



_______psi _______psi _______psi _______psi _______psi _______psi _______psi

       

      

Company stamp/ signature

Table 28 Inspection report

15.3 Service report

▶ Indicate the maintenance activities that have been carried out, enter the values measured and enter your signature and the date.

Page Date: Date: Date: Date: Date: Date: Date:

Needs-dependant maintenance activities

1. Clean the heat exchanger, burner and condensate trap page 44

2. Check and adjust the flue gases CO2 emissions page 38 _______ _______ _______ _______ _______ _______ _______

- CO2 content at full load ______% ______% ______% ______% ______% ______% ______%

- CO2 content at part load ______% ______% ______% ______% ______% ______% ______%

3. Function check page 47

4. Confirming proper inspection

Table 29 Service report

___________ ___________ ___________ ___________ ___________ ___________ ___________



"W.C. "W.C. "W.C. "W.C. "W.C. "W.C. "W.C.



Company stamp/ signature

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 57

Page 58

Spare parts

16 Spare parts

The following are parts commonly required due to damage or replacements. Their failure will affect safety or performance of this appliance. For a pictorial representation of the part see the respective position number on the exploded view pictures on page 60 and page 61.

Description Product No.

1 Door USA L.B. 8718600326 2 Sealing door 7101382 3 Door lock 7101384 4 Hinge door 7101520 5 Wall mounting bracket 7101386 6 Bracket left 7101388 7 Bracket right 7101390 8 Adjusting foot 7101394 9 Transport slide (L+R) 7101392 10 Drawer modules 7101496 11 Screw 4.2x8.5 (10 pc) 7100748 12 Condensate collector 7101396 13 Seal condensate collector 7746900152 14 Seal Ø 3.2" (80 mm) 7101400 15 Upper side condensate collectors 7101402 16 Mounting flue-gas pipe 7101398 17 Exhaust pipe 7101404 20 Condensate collector 8718600611 21 Seal condensate collector 73463 22 Drain pipe 7101410 23 Sealing bush (white) 73449 24 Condensate drain pipe 7101535 25 Fan 7746900382 26 Seal fan 7101450 27 O-ring 70x3 (2 pc) 7101416 28 Venturi 7746901751 29 Seal Ø 2.4" (60 mm) 73563 30 Gas valve, natural gas 8718600291 30 Gas valve, LP-gas 8718600323 31 Seal 33 x 24 x 3.5 (10 pc) 7098962 32 Gas pipe 7746900397 33 Flange gas valve 8718600286 34 O-ring (10 pc) 7101504 36 Screw M5 x 20 (10 pc) 7099650 37 Screw M5 x 16 (10 pc) 7101484 38 Screw M6 x 20 (10 pc) 7101486 39 Air inlet pipe 7101462 40 Sealing (10 pc) 7101482 41 Air vent revision set 7101428 42 Clip 7101430 43 Sensor NTC 7746900391 44 Clip (4 x 2 pc) 7746700063 45 O-ring 9.19 x 2.62 (10 pc) 78175s

Table 30 Spare parts

Description Product No.

46 Pressure sensor 8718600019 47 O-ring 14 x 1.78 (10 pc) 7101646 48 Return/supply pipe 7101438 49 Connection nipple CH 73080 50 Clip 7746700069 51 O-ring (10 pc) 7101488 52 Flue gas sensor 7746700420 56 Mounting set with sight glass 8718600172

with glow ignitor

with ionization electrode 60 Heat exchanger 7746900383 61 Cover controller BC10 73698 62 Burner 7101444 63 Seal Burner 7101446 65 Burner box 7101448 66 Front connection board 7101490 67 BC10 USA 78186 68 On/off switch 7099041 69 Knob BC10 38724 70 Draw connection board 7101480 71 Cover control box 7101498 73 Transformer 78191 74 UBA 3 8718600083 75 Fuse 5AF (10 pc) 8718601966 76 Connection board 7099042 77 Electronic connection red 73776 78 Electronic connection grey 73774 79 Electronic connection grey 73773 80 Electronic connection blue 73775 81 Electronic connection orange 73777 83 Flue gas adapter 73936 84 Measure nipple cap 7101424 86 Cable harness low voltage 7746900392 87 Cable harness high voltage 7746900393 88 Cable harness on/off switch 7101476 89 Cable harness earth 7101474 91 Union nut 1½" (5 pc) 73481s 92 Sealing (5 pc) 7746700417 93 Nut 1" 7099416 95 Gas valve 7746900401 96 Pump UP26-99U 7746900402 98 Level ball valve blue 7746700421 99 Level ball valve red 7746700422 100 Casing 7101514 101 Thermometer 7746900404 102 Manometer 7101506 105 Valve housing return 74549 106 Air release tap 7746900403

Table 30 Spare parts

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)58

Page 59

Description Product No.

107 Connection pressure gauge 73081 108 Drain pipe 7101410 109 Valve housing supply 7746900406 110 Adapter parallel 4" 7746900384 111 Adapter insert 4" 7746900385 112 Open venting insert 7746900386 113 Lip ring 114 7746900387 114 Lip ring 103 7746900388 117 Strain relief bracket 7746900398 118 Safety valve ASME 7746900405 119 Low loss header 7746901646 120 plug protector 73948

- AM10 7746900020

- HCM 1231 – 100 kW (4,001-10,200 ft.) 8718600324

- HCM 1232 – 80 kW (4,001-10,200 ft.) 8718600325

- Screw 6.3 x 19 (10 pc) 73986

Table 30 Spare parts

Spare parts

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 59

Page 60

6720645916-99.2TD

112

114

111

113

110

114

111

113

119

117

31 40

Spare parts

Fig. 100 Exploded view Logamax plus GB162-L.B. 80 kW/100 kW

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)60

Page 61

6720645916-100.2TD

120

118

105

106

109

107

102

101

100

Spare parts

Fig. 101 Exploded view pump group GB162-L.B. 80 kW/100 kW

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 61

Page 62

Index

Appliance configuration............................................. 36

BC10 basic controller............................................... 30

Burner .............................................................. 45

Carbon monoxide content .......................................... 39

CO values

Condensate collector ............................................... 47

Condensate trap ........................................... 35, 45–46

Connections

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

................................................ 9, 13, 24

DHW circulation pump .............................................. 26

DHW pump.......................................................... 26

Dimensions ...................................................... 9–10

.............................................................. 30

Display

Display codes ....................................................... 50

Drain ................................................................ 42

Emergency.......................................................... 42

Leakage test ............................................... 34, 39, 43

Log book............................................................. 33

Main power switch................................................... 30

Manual operation Menu structure

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

...................................................... 31

Normal operation .................................................... 31

Pump run-over time ............................................. 8, 41

Pump test ............................................................ 8

Room controller ..................................................... 26

Safety ............................................................... 33

Service mode

Service Tool ......................................................... 30

Settings ............................................................. 32

Shutting down

Signs of corrosion ................................................... 43

Space heating ....................................................... 30

........................................................ 31

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

Fault ........................................................... 49–50

Flow temperature

Flue gas connection ............................................. 36, 55

Flue gas test ........................................................ 31

Freeze damage

Freeze protection ..................................................... 8

Function module Function test

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

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

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

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

Gas connection ..................................................... 14

Gas supply valve .................................................... 35

Gas tightness Gas/air ratio

....................................................... 35

........................................................ 38

Heat exchanger ................................................. 45, 48

Heating capacity Heating system water Hydraulic resistance

.................................................... 41

................................................. 7

................................................ 56

Ignition unit ......................................................... 46

Inspection report ................................................... 58

Installation room Ionization current

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

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

Technical specifications ............................................. 55

Transportation

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

Working pressure............................................... 36, 55

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10)62

Page 63

Notes

Logamax plus GB162-L.B. 80 kW / 100 kW – 6720645916 (2014/10) 63

Page 64

Buderus Logamax plus GB162-L.B. 80 kW, Logamax plus GB162-L.B. 100 kW, Logamax plus GB162-80 kW, Logamax plus GB162-100 kW Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual