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Installation and Servicing Instructions Logamax plus GB142-24/30/45/60 • Version 12/2004

Buderus Hydronic Systems • http://www.buderus.net

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Page 1: ...ormation in this manual with the owner operator and make sure that he or she is familiar with all the necessary operating instructions Notice This manual must be retained for future reference 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 appliance Do not touch any electrical swit...

Page 2: ...onal installation start up and maintenance of the appliance with appliance capacities 24 30 45 and 60 kW These Installation and Servicing Instructions are intended for specialist installers who have the neces sary training and experience for working on heating and gas systems Subject to technical changes Slight changes may be made to the illustrations process steps and technical data as a result o...

Page 3: ...d off 36 10 1 2 Displaying the operating conditions of the burner and resetting the burner or resetting burner faults 36 10 1 3 Displaying the heating system status and or faults 37 10 2 Carrying out additional tasks 39 10 2 1 Carrying out a flue gas test 39 10 2 2 Selecting partial load operation e g during flue gas testing 39 10 2 3 Switching the heating system to manual mode 39 10 3 Configuring...

Page 4: ...ontrol valve Cable connection between gas control valve and UBA3 installation base 62 14 20 Ohming out the gas control valve 64 14 21 Replacing the gas control valve 65 14 22 Checking the control unit connections to the appliance 68 14 23 Transformer checking and if necessary replacing 70 14 24 Automatic air purging system replacing 72 14 25 Burner replacing 73 14 26 Sight glass replacing 76 14 27...

Page 5: ...er with the combustion air flue gas system that has been specifically designed and approved for this type of appliance Please note that local permission for the flue system and the condensate water connection to the public sewer system may be required You must also observe the local building regulations stipulating the installation rules the local building regulations concerning the air intake and...

Page 6: ...rials and additional equipment For the installation and maintenance of the appliance you will need the standard tools for central heating gas and water fitting In addition a handtruck with a fastening belt is very useful 1 6 Disposal Dispose of the appliance packaging in an environmentally sound manner Dispose of components of the heating system e g appliance or control device that must be replace...

Page 7: ...CGA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment 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 Appliance requires yearly maintenance see maintenance section see chapter 13 Maintenance page 46 Operati...

Page 8: ...pos 12 Back cover pos 13 Air intake for the fan pos 14 Fan pos 15 Condensate trap pos 16 External Connection Board under the cover 1 2 3 6 9 11 13 14 9 16 15 7 5 8 1 4 10 12 13 14 2 3 5 4 6 7 9 11 9 8 10 12 16 15 Fig 2 Basic Controller Logamatic BC10 pos 1 Main switch pos 2 DHW temperature knob pos 3 LED DHW status pos 4 Display pos 5 Heating water temperature knob pos 6 LED Heating system status ...

Page 9: ...F WB C Air intake inside diameter 3 Return Ø 1 1 1 Ø 28 mm Supply Ø 1 1 1 Ø 28 mm Wall bracket 1 One Ø 1 1 Ø 28 mm inside x 1 NPT threaded compression fitting is 12 300 mm 4 100 mm 20 500 mm 6 2 158 mm 0 25 6 mm 1 8 46 mm 18 7 475 mm 6 150 mm 2 2 55 mm 3 75 mm 3 75 mm 6 150 mm 1 2 30 mm 16 420 mm 7 5 190 mm 28 712 mm 4 7 119 mm 4 3 110 mm 13 2 335 mm 22 560 mm 3 75 mm 4 100 mm 6 150 mm D E F G A B...

Page 10: ... 28 mm Supply Ø 1 1 1 Ø 28 mm Wall bracket 1 One Ø 1 1 Ø 28 mm inside x 1 NPT threaded compression fitting is delivered enclosed 20 7 526 mm 1 2 30 mm 16 420 mm 7 5 190 mm 28 712 mm 4 7 119 mm 4 3 110 mm 13 2 335 mm 35 4 900 mm 9 7 246 mm 12 300 mm 4 100 mm 20 500 mm 6 2 158 mm 0 25 6 mm 1 8 46 mm 18 7 475 mm 6 150 mm 4 100 mm 2 2 55 mm 3 75 mm 3 75 mm D E F G A B C NOTICE Observe the lateral mini...

Page 11: ...he room where it is to be installed Fig 5 Items supplied with unit Pos Parts Quantity Packaging 1 Appliance with casing 1 1 box 2 Wall bracket 1 3 Technical documents 1 including User s Instructions Installation and Servicing instructions wall mounting template 3 4 Compression fittings 2 5 Room thermostat 1 6 Flue gas adapter 1 Table 1 Items supplied with unit 1 The user s instructions in a specia...

Page 12: ... Remove the transport safety clamps fig 6 taking into account the necessary service clearances DANGER Install the heating system in a frost free room Do not store any flammable materials or liquids in the immediate vicinity of the appliance Never use any chlorinated detergents or halogenated hydrocarbons e g in spraycans solvents and detergents paints adhesives Do not allow too much dust to collec...

Page 13: ...z Connect the gas pipe to the gas cock fig 8 pos 1 so that it is free from any strain Fig 7 Removing the casing 1 2 2 2 2 3 Fig 8 Making the gas connection 1 DANGER Only carry out work on gas conduits and fittings if you are licensed for such work Length of pipe feet Gas Volume Capacity ft3 hr 1 1 1 1 10 278 520 1 060 1 600 20 190 350 730 1 100 30 152 285 590 890 40 130 245 500 760 50 115 215 440 ...

Page 14: ...n feet 2 1 4 1 0 5 1 25 1 2 6 5 2 0 6 1 60 1 3 5 6 9 0 8 2 15 1 4 0 8 0 0 9 2 50 Table 3 Equivalent length for pipe fittings in feet Fig 9 Pump manifold installation pos 1 Compression fitting heating system supply pipe pos 2 Compression fitting heating system return pipe pos 3 DHW supply pos 4 DHW return pos 5 Relief valve 2 1 3 4 5 NOTICE Piping and components connected to the water appliance for...

Page 15: ...ump manifold shut off valves pos 4 secondary supply pos 5 DHW return pos 6 secondary return GB142 GB142 FLUE GAS PT AIR INTAKE pump manifold 1 4 5 6 2 3 NOTICE The following illustrations are simplified conceptual illustrations only NOTICE If this water heater is installed in a closed water supply system such as one having a backflow preventer in the cold water supply line means shall be provided ...

Page 16: ...Aditional zones zones Radiant FLUE GAS PT AIR INTAKE 9 1 2 4 5 6 3 7 8 WARNING No valve is to be placed between the relief valve and the tank Discharge of the relief valve must be conducted to a suitable place for disposal when relief occurs and no reducing coupling or other restriction may be installed in the discharge line Fig 12 Schematic representation of the appliance with the Hydronic set co...

Page 17: ...fficiently sized and no reduction or closure of openings takes place When the problem is not resolved do not operate the appliance Please note these restrictions and its dangers to the operator of the appliance WARNING APPLIANCE DAMAGE due to contaminated air Appliance must be clear and free from combustible materials gasoline and other flammable vapors and liquids and corrosive liquids and vapors...

Page 18: ...l communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communi cate with the outdoors The minimum dimension of air openings shall be no less than 3 inches 75 mm 1 Where directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr of total input rating of all equipment in the enclosure 2 Where communicating...

Page 19: ... vent pipes must be glued except for the flue gas adapter fig 14 pos 1 which is screwed into place and the first connection to the flue gas adapter fig 14 pos 2 Installed you can slide the pipe onto the adapter properly supported and the exhaust pipe must be pitched a minimum of a inch per foot back to the appli ance This allows the condensate to drain away All combustion air and vent pipe materia...

Page 20: ...ertical venting system sealed combustion INTAKE EXHAUST 10 0 MIN 250 mm 0 mm MIN 12 300 mm OVER MAXIMUM SNOW LEVEL OR 24 600 mm WHICHEVER IS GREATER 3 80 mm 3 80 mm 1 Fig 16 Vertical venting system room air only INTAKE EXHAUST 10 0 MIN 250 mm 0 mm MIN 12 300 mm OVER MAXIMUM SNOW LEVEL OR 24 600 mm WHICHEVER IS GREATER 3 80 mm Fig 17 Vertical parallel venting system sealed combustion INTAKE EXHAUST...

Page 21: ...feet GB142 24 30 45 and 60 feet GB142 60 maximum requirement each for the intake and exhaust piping Fig 18 Horizontal venting system room air only INTAKE EXHAUST 3 80 mm NOTICE The condensate water must be drained in accordance with the applicable rules See chapter 7 Connecting the condensate water drain Fig 19 Horizontal parallel venting system sealed combustion INTAKE EXHAUST 3 3 3 80 mm 3 80 mm...

Page 22: ...88 feet 26 82 m GB142 24 30 45 or 48 feet 14 63 m GB142 60 3 x 45 elbow 3 x 3 ft 0 91 m 9 ft 2 73 m concentric vent kit 3 ft 0 91 m Total friction loss equivalent 12 ft 3 66 m Total venting length for this example is GB142 24 30 45 100 ft 30 48 m 12 ft 3 66 m 88 feet 26 82 m GB142 60 60 ft 18 29 12 ft 3 66 m 48 feet 14 63 m Fittings or Piping Equivalent feet m 45 degree elbow 3 0 91 90 degree elbo...

Page 23: ...n If the condensate outlet of the appliance is lower than the drain a condensate pump must be used The condensate produced by the appliance has a pH value between 3 and 4 Install a neutralization unit if required by the local code NOTICE The condensate water must be drained from the appliance and possibly from the flue in accordance with the applicable rules Observe the local regulations Fig 21 Co...

Page 24: ...you connect the outdoor temperature sensor Only necessary for outdoor weather responsive operation WA terminal For connection of a potential free thermostat or relay panel end switch FW Connection for an external DHW tank sensor Fig 22 Removing the cover from the external connection box Fig 23 external connection board Fig 24 Connections to external connection board 1 2 RC FA WA FW EV PK PS PZ Net...

Page 25: ... protects the floor heating against too high appliance water temperatures external manual reset high limit The appliance is shut down when the external switching contact is opened DWV Terminal for connection of an external 3 way valve PK Connector for the primary loop pump 120V 60Hz PS Connector for the DHW tank pump 120V 60Hz PZ Connector for the DHW recirculating pump 120V 60Hz Netz Main power c...

Page 26: ...L PE N L PE N L PE N L PE N L 53 79 23 PE L N PE L N Fan unit Gas burner fitting Transformer Hot surface ignitor 16 pole connector 120 VAC 81 pole connector AC 0 10 24 and 120 V 81 pole connector 16 pole connector Connection box UBA 3 0 Ionization Earth Pressure sensor Return sensor Safety temperature sensor Supply sensor Operating switch Earth 120 VAC Function module Mains supply 120 VAC 60 Hz Ci...

Page 27: ... 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 r r to repair it call a qualified serv r r ice technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any ...

Page 28: ...ure of the system should be at least the required inlet pressure for the expansion tank plus 7 2 psi 0 5 bar The minimum pressure is 15 psi 1 0 bar on a cold system The maximum pressure is 44 psi 3 0 bar if the heating medium temperature is at its highest possible level If this pressure is exceeded the pres sure relief valve will open For first time start up it is necessary to set the DHW temperat...

Page 29: ...ate trap see fig 26 z Fill with water and refit the condensate trap in reverse order 9 4 Venting the gas supply valve z Loosen the screw plug on the testing nipple for the gas connection and venting fig 27 pos 1 by two turns and fit a hose z Slowly open the gas shut off valve z Run the gas that is discharged through a water bath z Close the gas shut off valve when no more air is released z Remove ...

Page 30: ...in excess of psi 3 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than psi 3 5 kPa Type of gas supply Factory setting of gas burner fitting Natural gas H Delivered factory set to Wobbe index 14 1 kWh m3 based on 59 F 15 C 14 7 psi 1 0...

Page 31: ...e must be for natural gas min 6 5 9 6 inch W C 17 25 mbar nominal supply pressure 7 7 inch W C 20 mbar for LPG min 8 0 inch W C 19 9 mbar max 13 0 inch W C 32 3 mbar nominal supply pressure 11 0 inch W C 27 3 mbar z Repeatedly press the Service button until the temperature indication is displayed z Press the Chimney Sweep button to end the measurement procedure z Close the gas shut off valve z Rem...

Page 32: ... z Set the appliance to partial load by pressing the Chimney Sweep button higher values or the Reset button lower values z Read out the differential pressure The differential pressure pGas pAir must be 0 2 inch W C 5 Pa 0 2 inch W C 5 Pa read out on pressure gauge 0 4 0 inch W C 10 0 Pa z Enter the value measured in the start up report z If the gas air ratio is not correct it can be adjusted using...

Page 33: ...dirty or that there may be burner faults z You must establish and resolve the cause The appli ance must be operational when you do this 9 11 Function testing z You must check the functioning and if readjustment is possible the adjustment of all control regulating and safety devices when carrying out start up tests annual inspections or maintenance as required z You must also test the gas and water...

Page 34: ...isplay shows the decimal point z Press and hold the Chimney Sweep and Service buttons until the display shows e g z Set the appliance to partial load by pressing the Chimney Sweep button higher values or the Reset button lower values z Measure the ionization current When the appliance is in partial load mode the ionization current must be 5 µA DC z Enter the value measured in the start up report z...

Page 35: ... the drawer fig 34 to close the control panel 9 13 Installing the casing z Install the casing and close the latches fig 35 Do not lift the casing by the latches z Lock the latches using the radiator key 9 14 Informing the owner handing over the technical documents z Show the owner how the heating system works and how the appliance can be operated Hand over the technical documents Fig 34 Closing th...

Page 36: ...ing the burner or resetting burner faults Displaying the operating conditions of the burner The LED indicates the operating condition of the burner Fig 36 BC10 basic controller Controls pos 1 Main switch pos 2 DHW temperature knob pos 3 LED DHW status pos 4 Display pos 5 Heating water temperature knob pos 6 LED Heating system status pos 7 Under the cover a RC system controller can be installed pos...

Page 37: ...splay will flash if the fault is a lock out fault z Press the Service button to switch between status displays or to read out the service and error codes z Resolve the fault see subsection 16 3 The following status displays can be seen depending on the operating conditions U NOTICE If the burner returns to fault mode after reset ting the appliance you must resolve the fault using the servicing sec...

Page 38: ...ts flashing display must be reset by pressing the Reset button Blocking faults reset automatically as soon as the cause has been removed Remedy any blocking faults that remain active for a long time using the service section in this manual number 200 Error code Remedy the error using the servicing section in this manual number 0 199 Current heater water temperature in F P15 Current system pressure...

Page 39: ...tion is only effective for the duration of the flue gas test z Press the Chimney Sweep button max 2 seconds until the decimal point shows in the status display This will switch on the flue gas test z Press and hold the Chimney Sweep and Service buttons for approx 5 seconds to enter the partial load mode z Press the Reset button to reduce the appliance capacity percentage Example appliance capacity...

Page 40: ...alues or the Reset button lower values z Press the Service button to confirm the setting 190 170 150 130 90 110 Regulator setting in Heating capacity in kW 5 appliance cap 24 kW appliance cap 30 kW appliance cap 45 kW appliance cap 60 kW 7 2 8 7 13 5 18 0 9 6 11 7 18 0 24 0 12 0 14 8 24 5 30 0 14 4 17 8 27 0 36 0 16 8 20 9 31 5 42 0 19 2 23 9 36 0 48 0 21 6 27 0 40 5 54 0 24 0 30 0 45 0 60 0 Table...

Page 41: ...not be changed using a RC thermostat On 2 Aut Entry via thermostat presetting The temperature is set on the thermostat e g RC30 If no thermostat is connected the maximum DHW temperature is 140 F 60 C On 2 Table 11 Settings of DHW temperature knob 1 This function has been optimized for appliances with combined DHW heating combi units 2 The heating program timer of the room control unit remains acti...

Page 42: ...onic Systems http www buderus net BC10 basic controller 10 z Press the Chimney Sweep or Reset buttons to set the pump post purge period The pump post purge period can be set from 5 60 minutes or to 24 hours G z Press the Service button to confirm the setting NOTICE On thermostat only systems a 5 to 10 minute post purge setting is recommended to purge heat from the appliance ...

Page 43: ...r page 36 z Switch off the heating system using the main switch z Close the main shut off valve or the gas shut off valve 11 2 Shutting down the heating system in the event of an emergency You must immediately close the main shut off valve or gas shut off valve and disconnect the power from the heating system z Close the main shut off valve DANGER The heating system may freeze if it is not operati...

Page 44: ...s and water pipes for signs of corrosion z Replace any pipes that are corroded CAUTION Check and clean the heating system once a year Carry out a maintenance overhaul if necessary Immediately repair defects to avoid damage to the heating system WARNING Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace ...

Page 45: ... dropped by more than 3 8 inch W C 10 mbar per minute you will have to replace the gas burner fitting 12 4 Measuring the ionization current See subsection 9 12 Measuring the ionization current page 33 12 5 Measuring the inlet gas pressure See subsection 9 7 Inlet gas pressure page 30 12 6 Checking and adjusting the gas air ratio See subsection 9 8 Checking and adjusting the gas air ratio page 31 1...

Page 46: ... to the gas control valve fig 38 pos 1 and pull the plug fig 38 pos 2 from the gas valve terminal block z Pull the plug from the fan unit fig 38 pos 3 z Loosen both sets of retaining clips fig 38 pos 4 and 5 of the burner cover and remove the burner cover with the fan unit and the gas burner fitting fig 39 pos 1 Then remove the gas air distributor plate fig 39 pos 2 the orifice plate fig 39 pos 3 ...

Page 47: ...ng system using the main switch z Dismantle the appliance again and flush the heat exchanger with water z Pull the condensate trap from the condensate plate fig 42 pos 1 z Loosen the condensate trap from the connection fig 42 pos 2 and remove it z Flush the condensate trap z Fill the condensate trap with water before re installing it z Loosen the retaining clips fig 38 pos 5 page 46 on the condens...

Page 48: ...ications Installation and Servicing Instructions Logamax plus GB142 24 30 45 60 Version 12 2004 Buderus Hydronic Systems http www buderus net Maintenance 13 13 2 Checking and adjusting the gas air ratio See chapter 9 8 Checking and adjusting the gas air ratio page 31 ...

Page 49: ...3 pos 2 z Dismantle the fuse holder by loosening the bayonet connector see fig 44 pos 1 z Remove the fuse from the fuse holder z Check the circuit continuity through the fuse using the volt ohm multiammeter If broken replace it by a new spare fuse 5 amps 120 V slow blow fig 44 pos 2 z Re assemble the UBA3 in reverse order of disassembly z Fit the casing z Connect the heating system to the power su...

Page 50: ...the fan unit z Test the voltage with the volt ohm multiammeter set it to VAC Minimum value 250 VAC z Connect the volt ohm multiammeter to the outer two plug contacts blue and brown see fig 47 Fig 46 External connection board pos 1 RC Room thermostat connection color orange pos 2 Outdoor temperature sensor connection color blue pos 3 Potential free On Off thermostat connection color green pos 4 DHW...

Page 51: ...ng the fan unit Supply cord 120 VAC z Remove the casing z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Disconnect the 120 VAC plug of the fan unit z Loosen the fastening screw of the UBA3 see fig 48 pos 1 z Remove the UBA3 by pulling it forward as indicated by the arrow see fig 48 pos 2 z Set...

Page 52: ...n it and that it is not broken see fig 50 z Assemble the tacho cable plug z Re assemble the UBA3 in reverse order of disassembly z Fit the casing z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On 14 6 Replacing the fan unit z Disconnect the heating system from the power supply remove the main fuse or swi...

Page 53: ... the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Disconnect the plug and socket connection of the cable for the sensor concerned z Test the resistance of the sensor concerned Supply sensor see fig 53 pos 1 Return sensor see fig 53 pos 2 Safety sensor see fig 54 pos 1 z Measure the temperature near the sensor using a seconds thermomet...

Page 54: ...s GB142 z Disconnect the plug and socket connection z Unscrew the sensor concerned and replace it by a new one Supply sensor see fig 55 pos 1 Return sensor see fig 55 pos 2 Safety sensor see fig 56 pos 1 z Restore the plug and socket connection z Open the maintenance shut off valves z Purge air from the appliance Temperature Resistance in F C 32 0 29 490 41 5 23 462 50 10 18 787 59 15 15 136 68 20...

Page 55: ... inserted correctly may be the cause for a fault message Then start the appliance by pressing Reset z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Loosen the fastening screw of the UBA3 see fig 57 pos 1 z Remove the UBA3 by pulling it forward as indicated by the arrow see ...

Page 56: ...use or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Disconnect the plug and socket connection of the hot surface ignitor z Set the measuring device to 120 VAC z Connect the measuring device to the plug on the cable harness z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch o...

Page 57: ... the measuring device z Reconnect the cable plug if the hot surface ignitor is OK z Fit the casing z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On 14 12 Checking the hot surface ignitor Supply cord z Remove the casing z Disconnect the heating system from the power supply remove the main fuse or switch ...

Page 58: ...eplacing the hot surface ignitor z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Disconnect the plug and socket connection of the cable of the hot surface ignitor z Loosen the fastening screws fig 63 pos 1 z Remove the earth cable fig 63 pos 2 z Remove the mounting plate fi...

Page 59: ... device in series see fig 64 z Set the multi meter to DC µA z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On z Start up the appliance in accordance with the Service Mode menu z Test the ionization current at partial load The appli ance is in part load operation as soon as in the Service Mode menu D is s...

Page 60: ... indicated by the arrow see fig 65 pos 2 z Test the ionization cable between the plug and socket connection and the UBA3 installation base to make sure that it has no short circuit to earth see fig 66 and fig 25 on page 26 and that it is not broken anywhere see fig 67 z Assemble the plug and socket connection of the ionization electrode z Re assemble the UBA3 in reverse order of disassembly z Fit ...

Page 61: ...ove the earth cable see fig 68 pos 2 z Remove the mounting plate see fig 68 pos 3 z Dismantle the ionization electrode see fig 68 pos 4 z Set the volt ohm multiammeter to Resistance measurement z Test the resistance of the ionization electrode see fig 69 The resistance must be 0 z Do a visual check of the ionization electrode z Check the ionization electrode for contamination wear or damage see fi...

Page 62: ...t the main switch on the BC10 to 1 On z Start up the appliance z Use a volt ohm multiammeter to check that while operating code D is displayed there is a voltage on the plug of the gas control valve The test must indicate a voltage of 20 24 VDC both when testing on the central and left contacts and when testing on the central and right contacts see fig 72 D Gas valve energized z Fit the casing 14 ...

Page 63: ... resistance of the cable between the plug of the gas control valve and the UBA3 installation base see fig 75 fig 76 and circuit diagram fig 25 on page 26 z Reconnect the plug to the gas control valve see fig 73 z Re install the UBA3 see fig 74 z Fit the casing z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to...

Page 64: ...scale of 200 or greater z Test the resistance of both coils of the gas control valve using the volt ohm multiammeter The resis tance measured between the left and central contacts see fig 78 must be approx 75 and between the right and central contacts see fig 79 this must be approx 185 10 If this is not the case the gas control valve will probably be defective It must then be replaced z Attach the...

Page 65: ...fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Close the gas shut off valve see fig 80 pos 1 z Remove the cable plug from the gas control valve see fig 81 pos 1 z Remove both cable plugs from the fan unit see fig 82 pos 1 Fig 80 Gas shut off valve closed 1 gas shut off valve open 2 DANGER Work on gas pipes and fittings must only be carried o...

Page 66: ...s net Servicing 14 z Loosen the union nut of the gas control valve see fig 83 pos 1 z Pull both retaining clips see fig 84 pos 1 on the burner cover to open them and remove the burner cover with the fan unit and the gas control valve z Loosen three screws on the gas control valve see fig 85 pos 1 Fig 83 Loosening the union nut 1 Fig 84 Loosening the retaining clips 1 Fig 85 Loosening the screws 1 ...

Page 67: ... the gas control valve Make sure that you have inserted the gasket z Connect both cable plugs to the fan unit z Connect the cable plug to the gas control valve z Open the gas shut off valve see fig 88 pos 2 z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On You must also check all gaskets and seals affect...

Page 68: ...ance z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the bridge between the two WA contacts see fig 92 pos 3 z Connect the On Off thermostat directly to the two WA contacts of the appliance using a short cable see fig 92 pos 3 z Connect the heating system to the power supply insert the ...

Page 69: ...e appliance switches to heating mode operating code D after some time the fault is caused by the cable between the modulating control and the appliance z If the appliance does not switch to heating mode after some time the fault is caused by the modulating control z Correct the cause of the fault Fig 91 Removing the cover from the connection box Fig 92 External connection board pos 1 RC Room therm...

Page 70: ...breaker z Set the main switch on the BC10 to 1 On 14 23 Transformer checking and if necessary replacing z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Dismantle the cover of the external connection board see fig 94 z Pull the 4 plugs from the external connection board see ...

Page 71: ...60 Version 12 2004 Buderus Hydronic Systems http www buderus net z Loosen the 2 external connection board fastening screws see fig 96 pos 1 z Remove the external connection board see fig 97 z Remove the transformer shield see fig 98 Fig 96 Loosening the fastening screws 1 Fig 97 Removing the external connection board Fig 98 Removing the transformer shield ...

Page 72: ... see fig 100 z Install the new transformer z Re assemble all parts and plugs in reverse order of disassembly z Fit the casing z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On 14 24 Automatic air purging system replacing z Disconnect the heating system from the power supply remove the main fuse or switch...

Page 73: ...Fit the casing z Connect the heating system to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On 14 25 Burner replacing z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Close the gas shut off valve see fig 104 po...

Page 74: ...w buderus net Servicing 14 z Remove the cable plug from the gas control valve see fig 105 pos 1 z Remove both cable plugs from the fan unit see fig 106 pos 1 z Loosen the union nut of the gas control valve see fig 107 pos 1 Fig 105 Replacing the gas control valve e g HONEYWELL gas control valve 1 Fig 106 Disconnecting the cable plug from the fan unit 1 Fig 107 Loosening the gas control valve 1 ...

Page 75: ...n unit and the gas control valve z Remove the burner gasket see fig 109 pos 1 z Remove the gas air distributor plate see fig 109 pos 2 z Remove the orifice plate only applies to GB142 24 30 see fig 109 pos 3 z Remove the burner see fig 109 pos 4 z Install the new burner see fig 110 z Re assemble all other parts in reverse order of disassembly Fig 108 Loosening the retaining clips 1 Fig 109 Removin...

Page 76: ...r ratio again See Chapter 9 8 14 26 Sight glass replacing z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Loosen both screws of the sight glass see fig 112 pos 1 z Remove the sight glass mounting plate z Disassemble the sight glass inclusive of both gaskets z Assemble the n...

Page 77: ...to the power supply insert the main fuse or switch on the circuit breaker z Set the main switch on the BC10 to 1 On 14 28 Pressure sensor replacing z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Close the maintenance shut off valves and drain the Logamax plus GB142 z Remov...

Page 78: ...ch off the circuit breaker z Close the maintenance shut off valves and drain the Logamax plus GB142 z Set the main switch on the BC10 to 0 Off z Remove the casing z Close the gas shut off valve see fig 115 pos 1 z Remove the cable plug from the gas control valve see fig 116 pos 1 z Remove both cable plugs from the fan unit see fig 117 pos 1 Fig 115 Gas shut off valve closed 1 gas shut off valve op...

Page 79: ...s 1 z Pull both retaining clips see fig 119 pos 1 on the burner cover to open them and remove the burner cover with the fan unit and the gas control valve z Remove the burner gasket see fig 120 pos 1 z Remove the gas air distributor plate see fig 120 pos 2 z Remove the orifice plate only applies to GB142 24 30 see fig 120 pos 3 z Remove the burner see fig 120 pos 4 Fig 118 Loosening the gas contro...

Page 80: ...us Hydronic Systems http www buderus net Servicing 14 z Disconnect the plug and socket connections of the supply return and safety sensors see fig 121 122 and 123 Fig 121 Loosening the plug and socket connections of the supply sensor Fig 122 Undoing the plug and socket connection of the return sensor Fig 123 Undoing the plug and socket connection of the safety sensor ...

Page 81: ...he safety sensor see fig 125 pos 1 z Disconnect the hot surface ignitor and ionization electrode plugs z Loosen the fastening screws see fig 126 pos 1 z Pull the earth cable from the hot surface ignitor see fig 126 pos 2 z Dismantle the mounting plate see fig 126 pos 3 Fig 124 Replacing the supply return sensors 1 2 WARNING To prevent mix ups the supply sensor is marked by a red sleeve on the side...

Page 82: ...ce ignitor and the ioniza tion electrode by pulling them loose see fig 127 pos 1 z Dismantle the condensate trap connection to the condensate collector see fig 128 pos 1 z Open the four latches of the condensate collector see fig 129 pos 1 Fig 127 Removing the hot surface ignitor and the ionization electrode 1 Fig 128 Dismantling the condensate trap connection to the condensate collector 1 Fig 129...

Page 83: ...rus net z Remove the condensate collector see fig 130 pos 1 z Dismantle the tension spring between the supply pipe and the heat exchanger see fig 131 pos 1 z Pull the supply pipe out of the heat exchanger see fig 132 pos 1 Fig 130 Removing the condensate collector 1 Fig 131 Loosening the backflow connection and dismantling the tension spring 1 Fig 132 Removing the supply pipe 1 2 1 WARNING Water w...

Page 84: ... combustion air supply and flue gas exhaust connections on top of the appliance upwards to remove them see fig 133 pos 1 z Loosen the 6 fastening screws of the flue gas adapter see fig 134 pos 1 z Remove the flue gas adapter see fig 134 pos 1 from the top of the appliance Fig 133 Loosening the combustion air supply and flue gas exhaust connections 1 Fig 134 Loosening the fastening screws 1 Fig 135...

Page 85: ...activities while carrying out the tight ness test in operating conditions z Set the gas air ratio again See Chapter 9 8 page 31 14 30 UBA3 replacing z Disconnect the heating system from the power supply remove the main fuse or switch off the circuit breaker z Set the main switch on the BC10 to 0 Off z Remove the casing z Loosen the fastening screw of the UBA3 see fig 138 pos 1 z Pull the UBA3 forw...

Page 86: ...semble all parts in reverse order of disas sembly z Carry out the start up activities and complete a new start up report z Also check all joints and gaskets affected by the installation activities while carrying out the tightness test in operating conditions z Place a new sticker over the existing sticker indicating the type of gas supply installed z Fit the casing again NOTICE The appliance is fa...

Page 87: ...ating mode D Appliance in DHW mode Normal mode 4 D Burner interval circuit 10 minutes after burner start 6 D Burner is started 8 D More capacity was delivered than required D Standby D Gas burner fitting is opened A D Initializing pre purge B D Flow temperature higher than set Test mode Appliance in flue gas test Manual mode Appliance in manual mode Reset 8 D Reset after holding the Reset button f...

Page 88: ...rnal switching contact External switching contact e g temperature safety switch for floor heating has taken place System faults Communication fault between UBA and KIM UBA fault 3 UBA fault Faulty gas burner fitting cable connection 8 KIM out of order Communication fault between BC10 basic controller and UBA System faults Internal UBA fault Display Meaning Water flow water pressure System pressure...

Page 89: ...32 Ø 1 3 Ø 32 Ø 1 3 Ø 32 Ø 1 3 Ø 32 Flue gas values Condensate water quantity for natural gas G20 104 86 F 40 30 C gallons per hour 2 6 3 3 4 7 7 1 pH value condensate water pH approx 4 1 approx 4 1 approx 4 1 approx 4 1 Flue gas mass flow rate at full load g s 10 0 12 6 19 4 25 9 Flue gas temperature 176 140 F 80 60 C full load F C 150 66 167 75 150 66 150 66 Flue gas temperature 176 140 F 80 60 ...

Page 90: ...so see the chapter Conversion to another type of gas supply Information on gas type instruction plate Set to gas category Propane Table 17 Factory setting of the gas control valve Fig 140 Venturi article number 1 2 Thermal power gas appliance Typeof gas supply Gas orifice diameter in mm inch Type of orifice above 4 500 ft Venturi article number GB142 24 Natural gas 4 45 0 174 4 65 0 181 423 072A L...

Page 91: ..._ kWh m __________ kWh m 4 Vent the gas supply conduit 29 5 Check and if necessary adjust the carbon monoxide content CO2 __________ 6 Check the combustion air flue gas connection 30 7 Convert the appliance to another type of gas supply only if allowed 86 8 Measure the gas connection pressure flow pressure 30 ________ inch W C 9 Check and adjust the gas air ratio 31 ________ inch W C 10 Measure th...

Page 92: ...he burner and the ignition and ionization electrodes First shut down the heating system 46 6 Measure the ionization current 33 _______ µA _______ µA _______ µA 7 Measure the gas connection pressure flow pressure 30 _______ psi _______ psi _______ psi 8 Check the gas air ratio 31 _____ inch W C _____ inch W C _____ inch W C 9 Carry out a gas tightness test in operating conditions 45 10 Measure the ...

Page 93: ... carried out and enter the date Needs dependent maintenance activities Page Date _____________ Date _____________ 1 Clean the burner the heat exchanger and the condensate trap First shut down the heating system 46 2 Check and adjust the gas air ratio CO2 content with full load CO2 content with partial load 31 _____________ inch W C _______________ _______________ _____________ inch W C ___________...

Page 94: ...7 67 Sealing bush set 7099002 68 Cable harness of on off switch 7099072 69 Cable harness BX holder 7099070 71 Seal Ø60 mm 5 pc 7098878 72 O ring set orifice 7099018 73 Seal 5 pc 7099059 74 Setscrew M5x20 5 pc 7099065 75 Cap 24 30 kW 79105 76 Double nipple THR x COMPR 75977 Pos Description Product No 1 Casing 24 30 7099988 Casing 45 60 7099901 2 Casing latches left 2 pc 7099039 3 Casing latches rig...

Page 95: ...lus GB142 24 30 45 60 Version 12 2004 Buderus Hydronic Systems http www buderus net Exploded view Logamax plus GB142 24 30 1 2 3 4 33 32 34 27 31 30 29 28 74 74 23 17 17 19 10 11 12 9 8 7 48 20 44 45 16 14 15 47 18 5 6 67 35 36 37 72 43 39 73 40 41 42 58 50 51 53 65 64 54 52 56 62 57 63 60 61 59 13 22 38 26 25 24 21 68 74 71 69 75 76 76 49 ...

Page 96: ... 30 45 60 Version 12 2004 Buderus Hydronic Systems http www buderus net Spare parts 18 Exploded view Logamax plus GB142 45 60 1 2 3 4 33 32 34 27 31 30 29 28 74 74 23 24 25 26 17 17 19 10 11 12 9 8 7 48 20 44 45 16 14 15 47 18 5 6 67 67 35 36 37 72 43 39 73 40 41 42 58 50 57 63 60 61 59 56 54 51 64 52 53 65 13 22 38 69 62 68 74 21 71 49 ...

Page 97: ...ults 37 Flue gas test 39 Frost 12 43 Function testing 33 G Gas leak tests 28 Gas nozzle 67 Gas nozzles 30 Gas supply conduit 29 Gas supply pressure 30 Gas air distributor plate 46 Gas air ratio 31 H Heat exchanger 46 89 Heater water temperature 41 Heating mode 68 Heating system water 43 Hot water target value 41 I Inspection report 92 Installation room 12 Internal tightness testing 45 Ionisation e...

Page 98: ...reserve the right to make any changes due to technical modifications Installation and Servicing Instructions Logamax plus GB142 24 30 45 60 Version 12 2004 Buderus Hydronic Systems http www buderus net Notes ...

Page 99: ...99 We reserve the right to make any changes due to technical modifications Installation and Servicing Instructions Logamax plus GB142 24 30 45 60 Version 12 2004 Buderus Hydronic Systems http www buderus net ...

Page 100: ...1 2719 www buderus net Buderus Hydronic Systems reserves the right to make changes without notice due to continuing engineering and technological advances Contractor PRODUCTS MANUFACTURED BY Buderus Heiztechnik GmbH 35573 Wetzlar http www heiztechnik buderus de email inof heiztechnik buderus de ...

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