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Installation instructions
Condensing gas boiler
Logamax plus
GB142-24
GB142-30
GB142-45
GB142-60
6720649345-02.0N
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 in this manual with the owner/operator and make sure that he or she is familiar with all the necessary operating instructions.
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.
Read carefully before carrying out installation and maintenance.
About these instructions
About these instructions
These Installation Instructions contain important information for the safe and professional installation, start-up and maintenance of the boiler with boiler capacities 24, 30, 45 and 60 kW.
These Installation Instructions are intended for professional installers, who have the necessary training and experience for working on heating and gas systems.
Subject to technical changes
Slight changes may be made to the illustrations, process steps and technical data as a result of our policy of continuous improvement.
Updating of documentation
Please contact us if you have any suggestions for improvements or corrections.
Table of contents
1 Safety and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
Hazard definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3
1.4
The following instructions must be observed . . . . . . . . . 3
Observe these instructions for space heating water . . . . 4
1.5
Tools, materials and additional equipment . . . . . . . . . . . 4
1.6
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Packaging and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1
Requirements for the installation room . . . . . . . . . . . . . . 9
6.2
Fitting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3
6.4
Making the gas connection . . . . . . . . . . . . . . . . . . . . . . 10
Fitting the heating circuit supply and return pipes . . . 10
6.5
6.6
Combustion Air and Ventilation Openings . . . . . . . . . . 13
Installation of the flue gas adapter (included in the
6.7
scope of delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation of the Exhaust and Air Intake system . . . . 14
6.8
Conversion to Propane . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1
External connection board connections . . . . . . . . . . . 18
8 Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1
8.2
8.3
8.4
8.5
8.6
8.7
Testing for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Filling the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Filling the condensate trap . . . . . . . . . . . . . . . . . . . . . . 22
Bleeding the gas supply valve . . . . . . . . . . . . . . . . . . . . 22
Checking the combustion air/flue gas connection . . . 22
Checking the orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inlet gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.8
Checking and adjusting the gas/air ratio . . . . . . . . . . . 23
8.9
Carrying out a leak test in operating conditions . . . . . 24
8.10
Measuring the carbon monoxide content (CO) . . . . . . 24
8.11
Function testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.12
Measuring the ionization current . . . . . . . . . . . . . . . . . . 24
8.13
Testing the Ignition Safety shut off device . . . . . . . . . . 25
8.14
Installing the casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.15
Informing the owner, handing over the technical documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 BC10 basic controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1
Operating the BC10 basic controller . . . . . . . . . . . . . . . 25
9.1.1
Switching the heating system on and off . . . . . . . . . . . . 26
9.1.2
Displaying the operating conditions of the burner and resetting the burner or resetting burner faults . . . 26
9.1.3
Displaying the heating system status and/or faults . . . 26
9.2
Carrying out additional tasks . . . . . . . . . . . . . . . . . . . . . 27
9.2.1
Carrying out a flue gas test . . . . . . . . . . . . . . . . . . . . . . . 27
9.2.2
Selecting partial load operation (e. g. during flue gas testing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.2.3
Switching the heating system to manual mode . . . . . . . 27
9.3
Configuring the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3.1
Adjusting the heating capacity . . . . . . . . . . . . . . . . . . . . 27
9.3.2
Setting the DHW temperature value . . . . . . . . . . . . . . . 28
9.3.3
Entering the space heating water temperature . . . . . . . 28
9.3.4
Setting the pump post-purge period . . . . . . . . . . . . . . . 28
10 Shutting down the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.1
Shut down the heating system using the control unit . . 28
10.2
Shutting down the heating system in the event of an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.1
Preparing the boiler for inspection . . . . . . . . . . . . . . . . 29
11.2
Visual inspection for general signs of corrosion . . . . . . 29
11.3
Internal leak testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.4
Measuring the ionization current . . . . . . . . . . . . . . . . . . 29
11.5
Measuring the inlet gas pressure . . . . . . . . . . . . . . . . . . 29
11.6
Checking and adjusting the gas/air ratio . . . . . . . . . . . . 29
11.7
Carrying out a gas leak test in operating conditions . . . 29
11.8
Measuring the carbon monoxide content (CO) . . . . . . . 29
11.9
Carrying out a pressure test of the heating system . . . . 29
11.10 Checking the functioning and the safety of the air intake and flue gas conduit . . . . . . . . . . . . . . . . . . . . 29
11.11 Checking venting systems . . . . . . . . . . . . . . . . . . . . . . . 29
12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.1
Cleaning the heat exchanger, burner and condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.2
Checking and adjusting the gas/air-ratio . . . . . . . . . . . . 31
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13.1
Operating messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13.2
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
13.3
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.1
Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.2
Inspection report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
14.3
Maintenance report . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
1 Safety and general instructions
Please observe these instructions in the interest of your own safety.
1.1
Designated use
The boiler was designed for heating water for a central heating system and generating domestic hot water.
The boiler is delivered with a BC10 basic controller and the “Universal
Automatic Burner Control Unit 3” (UBA 3) pre-installed.
The boiler can be fitted with a modulating outdoor reset control AM10
(scope of delivery), a room controller RC10 (optional), or an On/Off thermostat or relay panel end switch (accessories).
1.2
Hazard definitions
The following defined terms are used throughout the documentation to bring attention to the presence of hazards of various risk levels. Notices give important information concerning the operation of the product.
DANGER:
Indicates the presence of hazards that will cause severe personal injury, death or substantial property damage.
WARNING:
Indicates the presence of hazards that can cause severe personal injury, death or substantial property damage.
CAUTION:
Indicates presence of hazards that will or cause minor personal injury or property damage.
CAUTION: Risk of electrical shock
Indicates presence of hazards due to electric shock.
NOTICE:
▶ Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.
1.3
The following instructions must be observed
• The boiler must only be used for its designated purpose, observing the Installation Instructions.
• Only use the boiler in the combinations and with the accessories and spares listed.
• Other combinations, accessories and consumables must only be used if they are specifically designed for the intended application and do not affect the system performance and the safety requirements.
Safety and general instructions
1
• Maintenance and repairs must only be carried out by trained professionals.
• You must report the installation of a condensing gas boiler to the relevant gas utility company and have it approved.
• You are only allowed to operate the condensing gas boiler with the combustion air/flue gas system that has been specifically designed and approved for this type of boiler.
• Please note that local permission for the flue system and the condensate water connection to the public sewer system may be required.
You must also observe:
• the local building regulations stipulating the installation rules.
• the local building regulations concerning the air intake and outlet systems and the chimney connection.
• the regulations for the power supply connection.
• the technical rules laid down by the gas utility company concerning the connection of the gas burner fitting to the local gas main.
• the instructions and standards concerning the safety equipment for the water/space heating system.
• the Installation Instructions for building heating systems.
• The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the boiler. The pan must not restrict combustion air flow.
• The boiler must be installed such that the gas ignition system components are protected from water (dripping, spraying, rain etc.) during boiler operation and service.
• The boiler must not be installed on carpeting.
• Do not restrict or seal any air intake or outlet openings.
• If you find any defects, you must inform the owner of the system of the defect and the associated hazard in writing.
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 3
2
Regulations and guidelines
DANGER: if flammable gas explodes.
Beware if you smell gas: there may be an explosion hazard!
Warning: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
▶ Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler.
What to do if you smell gas:
▶ Do not try to light any boiler.
▶ Do not touch any electrical switch; do not use any phone in your building.
▶ Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
▶ If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
1.4
Observe these instructions for space heating water
Unsuitable heating system water can promote the formation of scale or sludge, which affects system efficiency. It can also cause corrosion and reduce life of the heat exchanger.
• You must follow Buderus guidelines for boiler water quality.
• Thoroughly flush the system prior to filling.
• Use of a Buderus approved boiler cleaner is recommended.
• Never use salt bedding exchangers to soften the water.
• Do not use inhibitors or other additives unless approved by Buderus for that purpose!
• When frost protection of the heating system is desired, only use Buderus-approved Aluminumsafe antifreeze.
•
• When using oxygen-permeable pipes, e. g. for floor heating systems, you must separate the system using heat exchangers.
The maximum permissible flow rate of the GB142-
24/30 this is 11 GPM (gal./min.)(= 42 l/min.), for the GB142-45 is 15 GPM (= 57 l/min.) and for the
GB142-60 is 20 GPM (= 76 l/min.).
1.5
Tools, materials and additional equipment
For the installation and maintenance of the boiler you will need the standard tools for space heating, gas and water fitting.
In addition, a handtruck with a fastening belt is useful.
1.6
Disposal
• Dispose of the boiler packaging in an environmentally sound manner.
• Dispose of components of the heating system (e. g. boiler or control device), that must be replaced in an environmentally responsible manner.
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 latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada, installation must be in accordance with the requirements of CAN/CSA
B149.1, Natural Gas and Propane Installation Code.
Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
Install CO detectors per local regulations. Boiler requires yearly
maintenance, see maintenance section see chapter 12 “Maintenance”, page 29.
Operating Limits of the boiler
Max. boiler temperature: 230 °F (110 °C)
Max. operating pressure: 44 psi (3 bar)
The hot water distribution system must comply with all applicable codes and regulations. When replacing an existing boiler, it is important to check the condition of the entire hot water distribution system to ensure safe operation.
Massachusetts Installations Only
(a) For all side wall side horizontally vented gas fueled 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 seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
• I
NSTALLATION 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 thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
4 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
• A
PPROVED 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.
• S
IGNAGE
. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight
(8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. the sign shall read, in print size no less than one-half (½) inch in size,
“G
AS VENT DIRECTLY BELOW
. K
EEP CLEAR OF ALL OBSTRUCTIONS
”.
• I
NSPECTION
. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspections, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CRM 5.08(2)(a)1 through 4.
(b) E
XEMPTIONS
: The following equipment is exempt from 248 CRM
5.08(2)(a)1 through 4:
• 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
• 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.
(c) M
ANUFACTURES REQUIREMENTS
- G
AS EQUIPMENT VENTING SYTEM REQUIRED
.
Product description
3
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:
• Detailed instructions for the installation of the venting system or the venting system components: and
• A complete parts list for the venting system design or venting system.
(d) M
ANUFACTURES REQUIREMENTS
- G
AS EQUIPMENT VENTING SYTEM 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:
• The referenced “special venting systems” shall be included with the appliance or equipment installation instructions: and
• 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.
3 Product description
6
5
4
3
2
1
14 15 16
Fig. 1 Logamax plus GB142-24/30 (left) and GB142-45/60 (right)
[1] Drawer with control unit
[2] Universal Burner Automat (UBA3)
[3] Control unit BC10
[4] Gas valve
[5] Cover
[6] Flue measuring points
[7] Parallel flue
[8] Burner
7
8
9
10
11
12
13
9
5
2
1
4
3
6
14 15 16
72150200-1.1TD
[9] Latches of which two have locks
[10] Sighting glass
[11] Heat exchanger
[12] Back cover
[13] Air intake for the fan
[14] Fan
[15] Condensate trap and internal condensate drain flue gas pipe
[16] External Connection Board (under the cover)
[17] Pressure sensor
7
8
9
10
11
12
13
9
17
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 5
3
Product description
2 3 4
90
100
110
120
130
140
5
90
110 130
150
170
190
6
1 12 11 10 9
Fig. 2 Basic Controller Logamatic BC10
[1] Main switch
[2] DHW temperature knob
1)
[3] LED “DHW status”
[4] Display
[5] Space heating water temperature knob
[6] LED “Heating system status”
[7] Under the cover a RC system controller can be installed
[8] LED “Burner Operation”
[9] Service Tool connector
[10] “Service” e button
[11] “Chimney sweep” d button
[12] “Reset” c button
[13] Air intake for the fan
8
7
72150200-2.1TD
1)
ECO mode means that the temperature inside the hot water tank is 140 °F
(60 °C), with a hysteresis (
ΔT) of 18 °F (10 °C) instead of 9 °F (5 °C)
6 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
4 Dimensions and connections
6.2"
(158 mm)
20" (500 mm)
12" (300 mm)
0.25"
(6 mm)
Dimensions and connections
4
22" (560 mm)
13.2" (335 mm) 4.3" (110 mm)
5.5" (239 mm)
A
3" (75 mm)
C
16" (420 mm)
B
D E F G
1.8" (46 mm)
18.7" (475 mm)
> 6"
(150 mm)
> 4"
(100 mm)
72150200-3.1TD
Fig. 3 Dimensions and connections for boiler GB142-24/30 (dimensions in inches)
[A] (AA) Flue gas connection (inside diameter 3")
[B] (LA) Air intake (inside diameter 3")
[C] (WB) Wall bracket
[D] (GAS) diameter Gas connection, ¾" NPT
[E] (AKO) Condensate water outlet, Ø 1.3" (Ø 32 mm) outside
[F] (VK) Supply, Ø 1.0"
1)
(Ø 25.4 mm)
[G]
(Ø 25.4 mm)
Observe the lateral minimum distances of the boiler
(12" = 300 mm) and the necessary distances (24" =
600 mm) at the front and 4" (100 mm) at the top for removing the casing and for servicing. Closet clearances are: 4" (100 mm) to the right, 4" (100 mm) at the top and 6" (150 mm) to the left.
1)
One Ø 1.0" (Ø 25.4 mm) inside x 1" NPT threaded compression fitting is delivered enclosed with boiler packaging
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 7
4
Dimensions and connections
20" (500 mm)
12" (300 mm)
6.2"
(158 mm)
0.25"
(6 mm)
5.5" (239 mm)
13.2" (335 mm)
35.4" (900 mm)
4.3" (110 mm)
A B
9.7" (246 mm)
C
16" (420 mm)
D E F G
1.8" (46 mm)
18.7" (475 mm)
20.7" (526 mm)
> 6"
(150 mm)
> 4"
(100 mm)
72150200-4.1TD
Fig. 4 Dimensions and connections for boiler GB142-45/60 (dimensions in inches)
[A] (AA) Combustion air
[B] (LA) Air intake
[C] (WB) Wall bracket
[D] (GAS) Gas connection, ¾" NPT
[E] (AKO) Condensate water outlet, Ø 1.3" (Ø 32 mm)
[F] (VK) Supply, Ø 1.0"
1)
(Ø 25.4 mm)
[G]
(Ø 25.4 mm)
Observe the lateral minimum distances of the boiler
(12" = 300 mm) and the necessary distances (24" =
600 mm) at the front and 4" (100 mm) at the top) for removing the casing and for servicing. Closet clearances are: 4" (100 mm) to the right, 4" (100 mm) at the top and 6" (150 mm) to the left.
1)
One Ø 1.0'' (Ø 25.4 mm) inside x 1'' NPT threaded compression fitting is delivered enclosed with boiler packaging
8 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Packaging and transportation
5
5 Packaging and transportation
5.1
Scope of delivery
The boiler is delivered fully assembled.
▶ When receiving the delivery, check if the packaging is intact.
▶ Check that all the items listed in fig. 5 are included in the delivery.
8
5
1
2
3
6
7
4
6
6.1
Installation
Requirements for the installation room
DANGER:
▶ Install the heating system in a frost-free room.
▶ Do not store any flammable materials or liquids in the immediate vicinity of the boiler.
▶ Never use any chlorinated detergents or halogenated hydrocarbons (e. g. in spray cans, solvents and detergents, paints, adhesives).
▶ Do not allow too much dust to collect on the boiler.
6.2
Fitting the boiler
Observe the installation clearances of the combustion air/flue gas system.
NOTICE:
▶ To protect the connection orifice you must not remove the styrofoam bottom panel.
▶ Do not lift the boiler by the drawer.
▶ Do not remove the transport safety clamps (
from the drawer at this time.
▶ Protect the boiler and the combustion air/flue gas orifice against pollution during installation.
▶ Remove the packaging materials and dispose of them.
▶ Use the mounting template to mark the drill holes.
▶ Install the wall bracket taking into account the necessary service clearances.
▶ Remove the transport safety clamps (
9
72150200-5.1TD
Fig. 5 Items supplied with unit (1 box)
[1] Boiler with casing
[2] Wall bracket
[3] Technical documents including: User's Instructions
1)
, Installation
Instructions, wall mounting template and Servicing Instructions
[4] Compression fittings (2x)
[5] GB142 Boiler manifold including: low loss header, pressure relief valve, tridicator, DHW connections, Grundfos 15-58 3-speed boiler circulator, supply and return shutoff ball valves
[6] AM10 with outdoor sensor
[7] Propane conversion kit
[8] Flue gas adapter
[9] Boiler connection kit, including the DHW sensor
72150200-6.1TD
Fig. 6 Removing the transport safety clamps
▶ Use the radiator key to unlock the two latches a quarter turn
(
▶ Open the latches (
▶ Remove the casing by lifting it upwards and then pulling it forwards
(
fig. 7, [3]); do not hold the casing by the latches.
3.
2.
2.
1.
2.
2.
72150200-7.1TD
1)
The user’s instructions (in a special format) is located in the boiler drawer
Fig. 7
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Removing the casing
9
6
Installation
▶ Hold the boiler by the rear boiler casing and place it on the wall bracket.
▶ Level out the boiler.
6.3
Making the gas connection
DANGER:
Only carry out work on gas lines if you are licensed for such work.
▶ Determine proper size gas pipe for the installation using table 1 and
table 2. Do not forget the pipe fitting losses and observe proper size
of the fittings.
Length of pipe (feet)
10
20
30
40
50
75
100
150
¼ "
278
190
152
130
115
93
79
64
Gas Volume Capacity (ft3 / hr)
1)
1"
520
350
285
245
215
175
160
120
1 ¼ "
1,060
730
590
500
440
360
305
250
1 ½ "
1,600
1,100
890
760
670
545
480
380
Table 1 Gas Pipe Capacity for different pipe sizes
1)
Maximum pipe capacity in ft3/hr, based on a specific gravity of .60 (42 mbar) and a inlet gas pressure of 14 inches W.C. (35 mbar) or less and a pressure drop of 3 inches W.C. (20 mbar)
Steel pipe diameter in inches
¾
1
1 ¼
1 ½
Equivalent length for Pipe Fittings in feet
90°-Elbow
Type of pipe fitting
Tee (flow thru branch)
Gate valve
Equivalent length in feet
Gas cocks
2.1
2.6
3.5
4.0
4.1
5.2
6.9
8.0
0.5
0.6
0.8
0.9
Table 2 Equivalent length for pipe fittings in feet
1.25
1.60
2.15
2.50
▶ Install the ¾" gas cock on the gas connection.
▶ Connect the gas pipe to the gas cock (
fig. 8, [1]) so that it is free
from any strain
NOTICE:
▶ When installing the gas supply connection, it must comply with local regulations or, if such regulations do not exist, with the National Fuel Gas Code,
ANSI Z 223.1. In Canada, the gas supply connection must comply with local regulations or, if such regulations do not exist, with CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
A sediment trap must be provided upstream of the gas controls.
6.4
Fitting the heating circuit supply and return pipes
NOTICE:
▶ To protect the entire heating system we require installing a WYE strainer in the return circuit. When retrofitting the boiler to an existing heating system this filter is required.
▶ Install shut-off valves immediately before and after the dirt particle filter to allow the filter to be cleaned.
▶ Fit a filling and drain cock in the heating system supply pipe if required.
▶ Also fit an adequately sized safety valve in the system that meets all applicable codes and regulations.
NOTICE:
▶ When using oxygen-permeable pipes, e. g. for radiant floor heating systems, you must separate the system using heat exchangers. Buderus recommends hydraulically isolating snowmelt systems using heat exchangers.
▶ Thoroughly flush all pipes and radiators. Use of a Buderus approved boiler cleaner is recommended.
▶ Refer to the installation template for the pipe connection dimensions.
▶ Fit the compression fittings (
fig. 9, [1] and [2]) first to the
Hydronic set (
fig. 10, 11 and 12) and then to the boiler.
1
3
2
3
4
11
1
Fig. 8 Making the gas connection
10
72150200-8.1TD
10
5
6
9
8
Fig. 9 Pump manifold installation
[1] Compression fitting (heating system supply pipe)
[2] Compression fitting (heating system return pipe)
7
72150200-9.1TD
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Installation
6
[3] Di electric union
[4] DHW return 1" FPT
[5] Low loss header
[6] Tridicator
[7] System return 1½ MPT
[8] System supply 1½ MPT
[9] Drain valve
[10] DHW supply 1" FPT
[11] Relief valve
▶ Connect the expansion tank to the system.
▶ Connect the pipes so that they are free from strain.
Connecting boiler with DHW tank
▶ Connect the external hot-water tank according to the Installation instructions of the hot-water tank and fittings concerned.
Piping examples
▶ The following illustrations are two Installation examples.
NOTICE:
▶ The following illustrations are simplified conceptual illustrations only.
Piping and field components must be field verified.
Fig. 10 is a schematic representation of fig. 9.
1
2
DANGER:
If this boiler is installed in a closed water supply system with an external indirect DHW tank, such as one having a backflow preventer in the cold water supply line, means shall be provided to control thermal expansion.
▶ Contact the water supplier or local plumbing inspector on how to control this situation.
Relief valve
The indirect DHW tank must have a temperature and pressure relief valve installed. The relief valve shall comply with the Standard for Relief
Valves and Automatic Gas Shutoff Devices for Hot Water Supply
Systems, ANSI Z21.22-CSA 4.4.
▶ Install the relief valve according fig. 10. The relief valve must comply
with following specifications:
– dimensions: height 2¼ inch (57.15 mm), width 2 inch
(50.8 mm);
– 30 Psi (2 bar) discharge pressure;
– discharge is ¾ inch (19.1 mm) female in diameter.
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.
NOTICE:
▶ For the maximum permissible flow rate of the DHW
1
2
11
10
9
8
PT
3
4
5
6
7
72150200-10.1TD
Fig. 10 Schematic representation of the boiler with the hydronic set
[1] Flue gas
[2] Air intake
[3] Pump manifold
[4] DHW return 1" FPT
[5] Low loss header
[6] PT gauge (pressure and temperature gauge)
[7] System return 1½ MPT
[8] System supply 1½ MPT
[9] Drain valve
[10] Pump manifold shut-off valve
[11] DHW supply 1" FPT
3
16
15
14
13
12
11
10
PT
Additional
DHW
Tank
4
5
6
7
8
9
72150200-11.1TD
Fig. 11 Schematic representation of the boiler with the hydraulic set connected to an optional hot water tank with one or multiple zones including one pump and zone valves
[1] Flue gas
[2] Air intake
[3] Optional DHW tank
[4] Primary pump
[5] Shut-off valve
[6] PT gauge (pressure and temperature gauge)
[7] Zone valve
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 11
6
Installation
[8] Radiant
[9] Additional zones
[10] Shut-off valve
[11] Zones
[12] Secondary pump
[13] Drain valve
[14] Low loss header
[15] DHW pump
[16] Pressure relief valve
NOTICE:
▶ Primary boiler pump must have an internal check valve.
1 2
• Refer to the manufacturer’s instructions when installing LWCO and
Manual Reset High Limit.
• LWCO is installed external to the boiler and must be located above the highest point of the boiler heat exchanger.
• Manual Reset High Limit remote sensing bulb must be located in the boiler supply.
• In a cascade each boiler must be equipped with its own LWCO and
Manual Reset High Limit.
▶ Remove the 1” plug and connect a 1" Tee at the back of the boiler manifold.
▶ Connect a 1" well for the Manual Rest High Limit probe [6] at the horizontal end.
▶ Install a 1" stand pipe that reaches above the highest point of the boiler heat exchanger at the vertical connector of the Tee.
▶ Install a second Tee with an automatic air vent [1] at the top and a
LWCO [2] just below.
▶ Wire the LWCO [NC1] and the Manual Reset High Limit [NC2] normally closed dry contacts in series with EV pins 1 and 2 on the boiler, which will shut off the burner when the connection is interrupted.
1
2
NC1
GRY RED LT. BLU
FW EV DWV
1 2 1 2 1 2 1
NC2
3
15
14
13
12
11
Additional
DHW
Tank
10
PT
4
5
6
7
8
9
72150200-12.1TD
Fig. 12 Schematic representation of the boiler with the Hydronic set connected to an optional hot water tank with one or multiple zones and zone pumps
[1] Flue gas
[2] Air intake
[3] Optional DHW tank
[4] Primary pump
[5] Shut-off valve
[6] PT gauge (pressure and temperature gauge)
[7] Zone pump
[8] Radiant
[9] Additional zones
[10] Shut-off valve
[11] Zones
[12] Drain valve
[13] Low loss header
[14] DHW pump
[15] Pressure relief valve
Low Water Cut-Off (LWCO) and External Manual Reset High Limit
A hot water boiler installed above radiation level or as required by the
Authority having jurisdiction, must be provided with an external Low
Water Cut-Off (LWCO) and/or an External Manual Reset High Limit device, either as a part of the boiler or at the time of boiler installation.
• Contractor to furnish and install LWCO and Manual Reset High Limit devices as required by local codes.
• Do not install any type of value or check valve in between boiler and
LWCO or Manual Reset High Limit.
6
5
3
4
72150200-53.1TD
Fig. 13 Low Water Cut-Off views
(Note: Power supply to LWCO and external high limit not shown for clarity.)
[1] Automatic air vent
[2] Low Water Cut-Off
[3] Manual Reset High Limit
[4] DHW Return
[5] DHW Supply
[6] Manual Reset High Limit probe
12 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
6.5
Combustion Air and Ventilation Openings
Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Ventilation, of the
National Flue Gas Code, ANSI Z223.1, or Sections 7.2, 7.3 or 7.4 of
CAN/CGA B149, Installation Codes, or applicable provisions of the local building codes.
CAUTION: BOILER DAMAGE AND OPERATIONAL
FAILURES !
Due to insufficient or lacking openings for combustion air and/or ventilation of the boiler room. Provisions for combustion air and ventilation are always required, regardless whether the combustion air is taken from the outside (sealed combustion) or inside (non sealed combustion for combustion). Insufficient ventilation of the boiler room can lead to high air temperatures. This can result in boiler damage.
▶ Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of openings takes place.
▶ When the problem is not resolved, do not operate the boiler.
▶ Please note these restrictions and its dangers to the operator of the boiler.
CAUTION: BOILER DAMAGE !
Due to contaminated air.
▶ Boiler must be clear and free from combustible materials, gasoline and other flammable vapors and liquids, and corrosive liquids and vapors. Never use chlorine and hydrocarbon containing chemicals
(such as spray chemicals, solution and cleaning agents, paints, glues etc) in the vicinity of the boiler.
▶ Do not store and use these chemicals in the boiler room.
▶ Avoid excessive dust formation and build-up.
NOTICE:
▶ When one expects contaminated combustion air
(near swimming pools, chemical cleaning operations and hair salons), sealed combustion operation is recommended.
DANGER: FIRE DANGER !
Due to flammable materials or liquids.
▶ Do not store flammable materials and liquids in the immediate vicinity of the boiler.
All Air from Inside the Building (non sealed combustion)
The closet shall be provided with two permanent openings communicating directly with an additional room(s). The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 Btu per hour of total input rating of all gas utilization equipment in the confined space, but no less than 100 square inches. One opening shall commence within 12 inches
(305 mm) of the top, and one opening shall commence within 12 inches
(305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 inches (75 mm).
• 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.
Installation
6
• Where communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per
4,000 Btu/hr of total input rating of all equipment in the enclosure.
• Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per
2,000 Btu/hr of total input rating of all equipment in the enclosure.
• Where ducts are used, they shall be of the same cross-sectional area as the free area of the opening to which they connect.
6.6
Installation of the flue gas adapter (included in the scope of delivery)
Before installing the exhaust and air intake system, it is necessary to remove the transport safety device and to install the flue gas adapter.
NOTICE:
▶ Before installing the exhaust and air intake system, it is necessary to remove the transport safety device and to install the flue gas adapter.
▶ Remove the transport safety device with the two screws (
72150200-13.1TD
Fig. 14 Removing the transport safety device
▶ Remove the protective cap from the internal condensate bypass pipe. Place the flue gas adapter and connect the internal condensate bypass pipe (
Fig. 15 Placing the flue gas adapter
72150200-14.1TD
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 13
6
Installation
▶ Screw on the flue gas adapter using 6 screws (
[3] 12" (300 mm) over maximum snow level or 24" (600 mm) whichever is greater
[4] Intake 3" (80 mm)
[5] 3" × 1.5" (80 × 38.1 mm)
2
3
1
4
Fig. 16 Connecting the flue gas adapter
6.7
Installation of the Exhaust and Air Intake system
NOTICE:
▶ Consult local and state codes pertaining to special building code and fire department requirements.
Adhere to national code requirements.
NOTICE:
▶ Observe the listed maximum lengths of vent system, which are boiler model dependent. The maximum
permissible lengths are listed in table 4, page 18.
An optional concentric vent/air intake body (
used for the installation of a vertical venting system as well as for a horizontal venting system. The concentric vent/air intake body can be ordered by Buderus Hydronic Systems, part no. BRYKGAVTO601CV.
Other optional vent kits are:
383-500-397 Plastic Vent Kit
2
72150200-27.1TD
Fig. 18 Horizontal venting system (sealed combustion)
[1] Exhaust 3" (80 mm)
[2] Intake 3" (80 mm)
[3] 24" max. (610 mm max.)
[4] 3" × 1.5" (80 × 38.1 mm)
The boiler can also be operated with separate air intake and exhaust piping (
2
1 3
3
4
1
5
Fig. 17 Vertical venting system (sealed combustion)
[1] Exhaust 3" (80 mm)
[2] 10"- 0" min. (250 mm - 0 mm min.)
72150200-19.1TD
14
72150200-20.1TD
Fig. 19 Horizontal venting system (non sealed combustion only) -
Situation 1
[1] Exhaust 3" (80 mm)
[2] Intake 3" (80 mm)
[3] 3" × 1.5" (80 × 38.1 mm)
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 gauge, service regulator or the like (for non sealed combustion applications only).
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
The termination shall terminate at least 4 ft (1,220 mm) below, 4 ft
(1,220 mm) horizontally from, or 1 ft (305 mm) above any door, window, or gravity air inlet into any building.
Vent must be at least 12 inches (305 mm) above grade, anticipated snow line or roof surface (Canada 18'' (457 mm) minimum) (
Installation
6
Vent termination must be at least 7 ft (2,135 mm) above a public walkway (
Vent must be 3 ft (915 mm) above any forced air intake within 10 ft
(3,050 mm) (
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 outside walls, inside corners and 5 ft (1525 mm) below roof overhang
(
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.
2
2
2
4
2
1
2
3
72150200-17.1TD
Fig. 20 Vent and air pipe position (1) of a sealed combustion system
[1] Intake
[2] 12" (300 mm) minimum
[3] 24" (610 mm) minimum
[4] Exhaust
5'
(1525 mm)
1'
1'
3'
(915 mm)
7'
4'
(1220 mm)
4'
4'
(1220 mm)
(1220 mm)
3'
(1220 mm)
3
1 2
Fig. 21 Vent position of a system with combustion air supply from the room (non-room sealed)
[1] At least 1 ft (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 (3050 mm)
[3] Forced air inlet
[4] Gravity air Inlet
3'
(915 mm)
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
1'
4
72150200-18.1TD
15
6
Installation
All vent pipes must be glued, except for the flue gas adapter (
[1]) which is screwed into place and the first connection to the flue gas adapter (
fig. 22, [2]). Installed you can slide the pipe onto the
adapter, properly supported and the exhaust pipe must be pitched a minimum of a ¼ inch per foot back to the boiler. This allows the condensate to drain away. Fix the screws (
fig. 22, [3]), this is obliged
for Canada.
2
NOTICE:
▶ Use materials approved by the authority having jurisdiction. In the absence of such authority, PVC and CPVC pipe must comply with ASTM D1785,
F441 or D2665. Cement and primer must comply with ASTM D2564 or F493. For Canada, use CSA or
ULC certified PVC or CPVC pipe, fittings and cement.
Below are approved examples of vertical and horizontal venting installation
NOTICE:
▶ Place pipe supports every 5 feet (1525 mm) of horizontal run, beginning with support near boiler.
NOTICE:
▶ Periodic cleaning of the vent terminal and air-intake screens is mandatory.
3
1
3
2
72150200-16.1TD
Fig. 22 Vent pipes
All combustion air and vent pipe materials and fittings must comply with the following:
Item
Vent or air pipe and fitting
Pipe cement/ primer
Material United States Canada
PVC schedule 40 ANSI/ASTM D1785 CSA or BH Gas
PVC-DWV ANSI/ASTM D2665 venting
CPVC schedule 40 ANSI/ASTM F441 systems,
ULC S636
1)
ABS-DWV ANSI/ASTM D2661 certified only schedule 40
PVC ANSI/ASTM D2564
CPVC
ABS
ANSI/ASTM F493
ANSI/ASTM D2235
Table 3
1)
Components of the certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings Plastic components, and specified primers and glues of the certified vent system must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts.
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.
NOTICE:
▶ A minimum clearance of 4 feet horizontally from and in no case above and below, unless a 4-foot horizontal distance is maintained, from electric gauges, gas gauges, regulators and relief equipment.
1
5
4
72150200-21.1TD
Fig. 23 Vertical parallel venting system (sealed combustion) -
Situation 1
[1] Exhaust 3" (80 mm)
[2] 10"- 0" min. (250 mm - 0 mm min.)
[3] 24" min. (610 mm min.)
[4] 12" (300 mm) over maximum snow level or 24" (600 mm) whichever is greater
[5] Intake 3" (80 mm)
16 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
1
2
3
2
3
1
Installation
6
4
72150200-22.1TD
Fig. 24 Horizontal venting system (sealed combustion) - Situation 2
[1] Exhaust 3" (80 mm)
[2] 3" × 1.5" (80 × 38.1 mm)
[3] Intake 3" (80 mm)
3
72150200-24.1TD
Fig. 26 Horizontal parallel venting system (sealed combustion)
[1] Exhaust 3" (80 mm)
[2] 12" minimum
[3] Intake 3" (80 mm)
[4] 12" (300 mm) minimum
3
2
4
2
1
5
4
5
1
72150200-23.1TD
Fig. 25 Vertical parallel venting system (sealed combustion) -
Situation 2
[1] Exhaust 3" (80 mm)
[2] 12" (300 mm) over maximum snow level or 24" (600 mm) whichever is greater
[3] 24" min. (610 mm min.)
[4] Intake 3" (80 mm)
[5] 3" × 1.5" (80 × 38.1 mm)
72150200-25.1TD
Fig. 27 Vertical venting system (non sealed combustion only)
[1] 3" × 1.5" (80 × 38.1 mm)
[2] Exhaust 3" (80 mm)
[3] 10"- 0" min. (250 mm - 0 mm min.)
[4] 12" (300 mm) over maximum snow level or 24" (600 mm) whichever is greater
[5] Intake
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 17
7
Electrical connections
3
2
1
4
5
CAUTION:
Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.
NOTICE:
▶ For Direct venting properly reassemble and reseal the vent and air-intake systems.
6.8
Conversion to Propane
To convert the boiler to propane, following the instructions in the
“Propane, Conversion Kit” Instruction manual. Available kits
72150200-26.1TD
Fig. 28 Vertical exhaust and horizontal intake venting system (sealed combustion)
[1] 3" × 1.5" (80 × 38.1 mm)
[2] Exhaust 3" (80 mm)
[3] 10"- 0" min. (250 mm - 0 mm min.)
[4] 12" (300 mm) over maximum snow level or 24" (600 mm) whichever is greater
[5] Intake 3" (80 mm)
Do not exceed the total equivalent venting length of 100 feet
(30,480 mm) (GB142-24/30/45) and 60 feet (18,288 mm) (GB142-
60) maximum requirement each for the intake and exhaust piping.
See table 4 for the Friction Loss Equivalent in piping and fittings.
Fittings or Piping Equivalent
45 degree elbow
90 degree elbow plastic pipe per foot concentric vent kit feet
3
5
1
3
Table 4 Friction Loss Equivalent in piping and fittings
m
0.91
1.52
0.30
0.91
Example:
When you end up using 3 x 45°-elbows and the concentric vent kit, then the total venting length may not exceed 88 feet (26.84 m) (GB142-24/
30/45) or 48 feet (14.65 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 (3.64 m)
Total venting length for this example is:
GB142-24/30/45 = 100 ft (30.48 m) - 12 ft (3.64 m) = 88 feet
(26.84 m)
GB142-60 = 60 ft (18.29 m) - 12 ft (3.64 m) = 48 feet (14.65 m).
NOTICE:
The minimum covering wall thickness is 1" (25 mm).
The maximum covering wall thickness is 16" (406 mm).
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.
Installations should also conform with CSA C22. 1 Canadian Electrical
Code Part 1 if installed in Canada.
7.1
External connection board connections
Make all electrical connections inside the external connection box.
▶ Remove the cover of the external connection box (
72150200-28.1TD
Fig. 29 Removing the cover from the external connection box
DANGER: Connecting incoming power
The boiler must be electrically grounded in accordance with local codes, or in absence of local codes, with the
National Electrical Code, ANSI/INFPA 70 and/or the CSA
C22.1, Electrical Code.
18 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
▶ Install a 120V cable to the boiler (
▶ Lead the cable through the cable guide (
2.
1.
72150200-29.1TD
Fig. 30 External connection board
Terminals 1 – 6 (
fig. 31) are low-voltage connections and terminals
7 – 10 (
fig. 31) are 120 Volt connections.
2
4 6
1 3 5 7 8 9
10
72150200-30.1TD
Fig. 31 Connections to external connection board
[Pos] Abbr. Color
[1] RC orange
[2]
[3]
[4]
[5]
[6]
FA
WA
FW
EV
DWV
[10] Netz blue green gray red green
[7] PK green
[8] PS gray
[9] PZ lilac white
Component
RC room controller connection or for an
AM10 or other module
Outdoor-temperature sensor
Potential-free On/Off thermostat
DHW temperature sensor
External switching contact, potential-free for floor heating safety etc.
Connection for external 3-way valve
Primary loop pump 120 V 60 Hz
DHW tank pump 120 V 60 Hz
DHW recirculating pump 120 V 60 Hz
Main power connection 120 V 60 Hz
CAUTION: RISK OF ELECTRIC SHOCK.
Once the main power supply is on then there is 120V on terminals 7 – 10 (can only be used with the correct configuration of the control unit and specific system hydraulics), if the main switch of the BC10 basic controller is switched on.
RC terminal
Connector for installation of an RC controller for indoor reset operation or a module like the AM10.
FA terminal
This is the terminal where you connect the outdoor temperature sensor.
Only necessary for outdoor weather responsive operation.
WA terminal
For connection of a potential free thermostat or relay panel end switch.
FW
Connection for an external DHW tank sensor.
Electrical connections
7
EV terminal (external switching contact)
This terminal can be used for example for the safety switch of floor heating. This protects the floor heating against too high boiler water temperatures (external manual reset high limit). The boiler is shut down when the external switching contact is opened.
The normally closed contacts of a LWCO will shut down burner operation but allow the pump to continue to operate in case of a low water condition.
DWV
Terminal for connection of an external 3-way valve (not used).
PK
Connector for the primary loop pump 120 V 60 Hz.
PS
Connector for the DHW tank pump 120 V 60 Hz.
PZ
Connector for the DHW recirculating pump 120 V 60 Hz.
NETZ
Main power connector 120 V 60 Hz (-15% +10%).
120-volt connections
CAUTION:
Make sure that the power consumption of each of the terminals 7 – 9 (
circuit diagram) does not exceed
250 W or 5 Amp.
CAUTION:
Label all wires prior to disconnection when servicing.
Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 19
7
Electrical connections
High Voltage
L
L white
N PE
N
Grid lilac
14
L N PE
13
PZ
25
L grey
N PE
24
PS
63
L green
N PE
61
PK white
3 2
DWV
1 red
2
EV
1
External connection for specialist servicing company grey
2
FW
1 green
2
WA
1 blue orange
2
FA
1 2
RC
1
8 7 6 5 4 3 2 1
6
6
5
5
4 3 2 1
4 3 2 1
6
5
L
N
3
7
4
120 VAC
120 VAC
120 VAC
L
PE
N
10
11
9
PE
N
L
14
12
13
Fig. 32 Electric circuit diagram
120 VAC
Supply sensor
Safety-temperature sensor
Return sensor
Ionization
230 VAC
230 VAC
10 VAC
10 VAC
24 VAC
0 VAC
24 VRAC
24 VRAC
76
49
16
44
17
45
55
1
28
90
81
25
52
27
23
79
53
69
68
67
24
22
14
13
39
38
12
11
70
61
62
2
72150200-31.1TD
20 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Start-up procedure
8
8 Start-up procedure
There are several steps involved in starting up the boiler.
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
A.
B.
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
C.
•
•
•
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
D.
Do not use this appliance if any parts have been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
OPERATING INSTRUCTION
STOP! read the safety information above on this label.
Set the thermostat or other operating control to lowest setting.
This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
Close main gas shut off valve.
Wait (5) minutes to clear out any gas. Then smell for gas. Including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.
Open main shut off valve.
Set the thermostat or other operation control to desired setting.
Turn on all electric power to the appliance.
If the appliance will not operate, follow the instruction "To Turn Off Gas To
Appliance" and call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1.
2.
3.
Set the thermostat or other operating control to lowest setting.
Close main gas shut off valve.
708.375A - 2172B
72150200-32.1TD
Fig. 33
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 21
8
Start-up procedure
8.1
Testing for gas leaks
Prior to start-up of the boiler you must check the external tightness of the gas supply valve and confirm this in the start-up report.
WARNING:
▶ Cover endangered positions before leak testing.
▶ Do not spray the leak testing agent onto cables, plugs or electrical connection lines. Do not allow it to drip onto them either.
DANGER:
Leaks may be caused to pipes and screw connections during commissioning and maintenance activities.
▶ Carry out a proper leak test.
▶ Only use approved leak detection agents for leak detection.
▶ Disconnect the heating system from the power supply.
▶ Check the exterior tightness of new conduit sections up to and including the direct sealing point on the gas burner fitting. The maximum test pressure allowed on the input of the gas burner fitting is 14 inch W.C. (35 mbar).
8.2
Filling the boiler
Set the main switch to “1” a
.
[p/0.0| appears in the display of the
BC10 telling you that there is no system pressure.
▶ Fill the heating system to a pressure of around 20 psi (1.5 bar).
NOTICE:
▶ Observe the space heating water requirements as
described in paragraph 1.4 on page 4.
▶ Observe the pressure on the BC10 or the P/T gauge in the pump manifold for the heating circuit. The fill pressure of the system should be at least the required inlet pressure for the expansion tank plus
7.2 psi (0.5 bar). The minimum pressure is 15 psi (1.0 bar) (on a cold system). The maximum pressure is 44 psi (3.0 bar) (if the heating medium temperature is at its highest possible level). If this pressure is exceeded, the pressure relief valve will open.
NOTICE:
If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system.
▶ Contact the water supplier or local plumbing inspector on how to correct the situation. Never plug the relief valve.
For first time start up it is necessary to set the DHW temperature knob h and the space heating water temperature knob i to the desired setting
(
9.3.2 and 9.3.3). Factory setting is “0”.
WARNING:
There is a hot water scald potential if the BC10 is set too high.
8.3
Filling the condensate trap
▶ Make sure that you fill the condensate trap with water. This is to prevent exhaust gases from entering the room.
▶ Remove the condensate trap (
fig. 34) by disconnecting the
connection to the heat exchanger and the connection to the condensate bypass pipe.
72150200-33.1TD
Fig. 34 Filling water into the condensate trap
▶ Fill with water and refit the condensate trap in reverse order.
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.
8.4
Bleeding the gas supply valve
▶ Loosen the screw plug on the testing nipple for the gas connection and venting (
fig. 35, [1]) by two turns and fit a hose.
1
72150200-34.1TD
Fig. 35 Bleeding the gas supply conduit
▶ Slowly open the gas shut-off valve.
▶ Run the gas that is discharged through a water bath.
▶ Close the gas shut-off valve when no more air is released.
▶ Remove the hose and tighten the screw plug again.
8.5
Checking the combustion air/flue gas connection
Check the following points:
▶ Is the prescribed combustion air/flue system used?
▶ Have the instructions for configuring the flue system as specified in the relevant Installation instruction for the flue gas system been observed?
8.6
Checking the orifices
CAUTION:
The burner must only be commissioned if the correct orifices are fitted (
▶ Convert the burner fitting to another gas type if required (
chapter 6.8 “Conversion to Propane”, page 18).
22 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Boiler capacity
Type of gas supply inch
24 kW Natural gas 0.175
LPG P 0.132
30 kW Natural gas 0.175
LPG P 0.132
45 kW Natural gas 0.213
LPG P 0.163
60 kW Natural gas 0.295
LPG P 0.213
Table 5 Gas orifice diameter
Gas orifice diameter
No CO
2
Altitude 0-10,200 ft
-correction Altitude
4,001-10,200 ft mm
4.45
3.35
4.45
3.35
5.40
4.15
7.50
5.40
with CO
2
-correction inch mm
0.179
0.134
4.55
3.40
0.177
0.134
0.219
0.163
0.301
0.215
4.50
3.40
5.55
4.15
7.65
5.45
8.7
Inlet gas pressure
▶ Connect the pressure gauge connection hose (
testing nipple (
1
Start-up procedure
8
▶ Switch on the heating system by setting the main switch to position
“1” a
(
chapter 9 “BC10 basic controller”, page 25).
▶ Press the “Chimney Sweep” d
button and hold it (for approx.
2 seconds) until the display shows a decimal point.
▶ Measure the gas connection pressure as soon as the “Burner” LED g
lights and enter this value in the start-up report.
The inlet gas pressure must be:
• for natural gas - min. 3.5 to 10.5 inch W.C (8.7 to 26.1 mbar), nominal supply pressure 7.0 inch W.C. (17,4 mbar)
• for LPG - min. 8.0 to 13.0 inch W.C. (19.9 to 32.3 mbar), nominal supply pressure 11.0 inch W.C. (27.4 mbar).
▶ Repeatedly press the “Service” e
button until the temperature indication is displayed.
▶ Press the “Chimney Sweep” d
button to end the measurement procedure.
▶ Close the gas shut-off valve.
▶ Remove the connection hose again and tighten the screw plug on the testing nipple.
▶ Open the gas shut-off valve again.
CAUTION:
▶ Contact the relevant gas utility company if the required inlet gas pressure is not available.
▶ Install a gas pressure regulator before the gas burner fitting if the supply pressure is too high.
8.8
Checking and adjusting the gas/air ratio
▶ Switch off the heating system using the main switch b.
▶ Loosen the screw plug on the measuring nipple for the burner pressure by 2 rotations (
1
2
72150200-35.1TD
Fig. 36 Measuring the inlet gas pressure
[1] Testing nipple
[2] Pressure gauge connection hose
▶ Slowly open the gas shut-off valve.
The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5 kPa).
The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi
(3.5 kPa).
▶ Briefly press on the control panel cover to open it.
2
Fig. 37 Opening the control panel
72150200-36.1TD
72150200-51.1TD
Fig. 38 Checking the gas/air ratio
[1] Burner pressure measuring nipple
[2] Pressure gauge connection hose
▶ Set the pressure gauge to zero.
▶ Use a hose to connect the plus terminal of the pressure gauge to the burner pressure measuring nipple (
▶ Switch on the heating system using the main switch a
.
▶ Press the “Chimney Sweep” d button and hold it (for approx. two seconds) until the display shows the decimal point.
▶ Press and hold the “Chimney Sweep” d and “Service” e
buttons
(for approx. five seconds) until the display shows “Lxx” (e. g. L80).
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 23
8
Start-up procedure
▶ Set the boiler to partial load “L30” by pressing the “Chimney
Sweep” d
button (higher values) or the “Reset” c
button (lower values).
▶ Read out the differential pressure. The differential pressure (p
Gas
– p
Air
) must be -0.02 inch W.C. (- 5 Pa) (±0.02 inch W.C. = ± 5 Pa)
(read-out on pressure gauge: -0.04 – 0 inch W.C. = -10 – 0 Pa).
▶ Enter the value measured in the start-up report.
▶ If the gas/air ratio is not correct it can be adjusted using the adjustment screw (
fig. 39, [1]). The adjustment screw is located
behind the cover screw.
8.10
Measuring the carbon monoxide content (CO)
▶ Measure the carbon monoxide content on the flue gas sampling point
(
1
72150200-37.1TD
Fig. 39 Setting the gas/air ratio
▶ Repeatedly press the “Service” e
button until the temperature indication is displayed.
▶ Press the “Chimney Sweep” d
button until the decimal point is cleared from the display.
▶ Switch off the heating system using the main switch.
▶ Remove the measurement set-up, tighten the screw in the burner pressure measuring nipple.
▶ Switch on the heating system using the main switch a.
8.9
Carrying out a leak test in operating conditions
▶ Check all gaskets and joints in the burner gas circuit for leaks while the burner is operational, using a foaming agent.
DANGER:
Leaks may be caused to pipes and screw connections during start-up activities if flammable gas explodes.
▶ Only use approved leak detection agents for leak detection such as a soapy water solution.
CAUTION:
due to a short circuit.
▶ Cover damageable parts before leak testing.
▶ Do not spray the leak testing agent onto cables, plugs or electrical connection lines. Do not allow it to drip onto them either.
72150200-38.1TD
Fig. 40 Flue gas sampling point
The CO values in an air-free condition must be below 400 ppm or
0.04 vol. %. Values of 400 ppm and up indicate that the burner adjustment may be wrong, the gas burner fitting or the heat exchanger are dirty or that there may be burner faults.
▶ You must establish and resolve the cause. The boiler must be operational when you do this.
8.11
Function testing
▶ 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.
▶ You must also test the gas and water lines for leaks.
8.12
Measuring the ionization current
▶ Switch off the heating system using the main switch b.
▶ Disconnect the plug and socket connection of the monitoring cable and connect the measuring device in series (
μA direct current range on the measuring device. The measuring device must have a resolution of at least 1 μA.
24
Fig. 41 Measuring the ionization current
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
72150200-39.1TD
▶ Switch on the heating system using the main switch a
.
▶ Press the “Chimney Sweep” d
button and hold it (for approx. two seconds), until the display shows the decimal point.
▶ Press and hold the “Chimney Sweep” d
and “Service” e
buttons, until the display shows “Lxx” (e. g. L80).
▶ Set the boiler to partial load “L30” by pressing the “Chimney Sweep” d
button (higher values) or the “Reset” c
button (lower values).
▶ Measure the ionization current. When the boiler is in partial load mode the ionization current must be > 5 μA DC.
▶ Enter the value measured in the start-up report.
▶ Repeatedly press the “Service” e
button, until the temperature indication is displayed.
▶ Press the “Chimney Sweep” d
button to end the measurement procedure.
▶ Switch off the heating system using the main switch b
.
▶ Remove the measuring device and restore the plug and socket connection.
▶ Switch on the heating system again using the main switch a
.
▶ Push against the drawer (
fig. 42) to close the control panel.
BC10 basic controller
9
8.14
Installing the casing
▶ Install the casing and close the latches (
casing by the latches.
▶ Lock the latches using the radiator key.
72150200-41.1TD
Fig. 43 Installing the casing
8.15
Informing the owner, handing over the technical documents
▶ Show the owner how the heating system works and how the boiler can be operated. Hand over the technical documents.
9
9.1
BC10 basic controller
Operating the BC10 basic controller
2 3 4 5 6
72150200-40.1TD
Fig. 42 Closing the control panel
8.13
Testing the Ignition Safety shut off device
▶ Switch off the heating system using the main switch b.
▶ Disconnect the plug and socket connection of the monitoring cable.
▶ Switch on the heating system using the main switch a
.
▶ 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 one start-up attempt and three restart attempts.
After each start-up attempt the boiler will signal a start-up failure. A “6A”
(=
[6/a//|) code can be seen in the display.
After the last start-up attempt, the boiler will lock out. The “6A”
(=
[6/a//|) 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” button return to normal operating conditions.
90
100
110
120
130
140
90
110 130
150
170
190
1 12 11 10 9 8
7
72150200-52.1TD
Fig. 44 BC10 basic controller – Controls
[1] Main switch
[2] DHW temperature knob
[3] LED “DHW status”
[4] Display
[5] Space heating water temperature knob
[6] LED “Heating system status”
[7] Under the cover a RC system controller can be installed (not available).
[8] LED “Burner Operation”
[9] Service Tool connector
[10] “Service” e
button
[11] “Chimney sweep” d button
[12] “Reset” c button
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 25
9
BC10 basic controller
9.1.1
Switching the heating system on and off
Switching on the heating system
▶ Set the main switch a
on the BC10 basic controller to position “1”
(On).
Switching off the heating system
▶ Set the main switch b
on the BC10 basic controller to position “0”
(Off).
Resetting the boiler or resetting faults
If the boiler is down due to a fault, you can reset the boiler by pressing the “Reset” c
button. This is only possible for so-called lock-out faults.
There is another type of fault, so-called blocking faults, that reset themselves when the cause has been remedied.
▶ Press the “Reset” c
button to reset the boiler.
The display shows “rE”
[\/r/e| while resetting. It is only possible to reset the boiler when a lock-out code (blinking fault code) is visible in the display.
9.1.2
Displaying the operating conditions of the burner and resetting the burner or resetting burner faults
Displaying the operating conditions of the burner
The LED g indicates the operating condition of the burner.
NOTICE:
▶ If the burner returns to fault mode after resetting the boiler, you must resolve the fault using the servicing section in this document. Contact your supplier if necessary.
LED
On
Off
Condition Explanation
Burner operational The water in the boiler is being heated.
Burner off The water in the boiler has reached the required temperature or there is no heat request.
9.1.3
Displaying the heating system status and/or faults
The display of the BC10 basic controller shows the status of the heating system.
Table 6 LED indication
In the event of a fault the display immediately shows the fault or the warning in the form of an error code (
display will flash if the fault is a lock-out fault.
▶ Press the “Service” e
button to switch between status displays or to read out the service and error codes.
▶ Resolve the fault
The following status displays can be seen depending on the operating conditions: p q
Displays (examples) Values
[1/4/0| p
1) number 0 … 199
2)
[p/2/1|
> P15 q
[p/1/2|
[-/h/\|
P3 … P12
[h/\/7| p p q
Meaning
Current boiler water temperature (in °F)
Current system pressure (in psi)
Warning:
(changing)
System pressure is too low (between 3 and
12 psi = 0.2 and 0.8 bar)
[-/h/\|
[1/4/0| number 0 … 199
Current boiler water temperature (in °F)
[p/1/2|
P3 … P12 Current system pressure (in psi)
[p/3/\| p
(flashing)
< P3
[2/0/7| number > 200
[1/4/0|
[p/3/\| number 0 … 199
< P3
Operating condition/Remedy
Normal operating conditions
Warning
Heating system remains operational between 12 psi and 3 psi (0.8 and 0.2 bar).
▶ Fill the heating system and restore the minimum filling pressure (≥ 14.5 psi = ≥ 1.0 bar).
The system pressure is shown for 10 minutes after which the standard display returns.
Fault: system pressure is far too low (< 3 psi =
< 0.2 bar)
Fault
Error code
Remedy the error see servicing section
Burner and boiler circuit pump are not operational.
Frost protection is active up to 2 psi (0.1 bar).
Current boiler water temperature (in °F)
The heating system will only become operational again if the pressure is back to 14.5 psi (1.0 bar).
Current system pressure (in psi)
▶ Fill the heating system and restore the minimum filling pressure (≥ 14.5 psi = ≥ 1.0 bar).
The system pressure is shown for 10 minutes after which the standard display returns.
Fault
[3/a/\|
(partially flashing) p
Combination of letters and digits
[2/0/7| number > 199 p q
Service code
Error code
Remedy the error using the servicing section in this manual
[1/4/0| number 0 … 199
Current boiler water temperature (in °F)
[p/2/1|
> P15 Current system pressure (in psi)
Lock-out faults (flashing display) must be reset by pressing the “Reset” c
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.
Table 7 Possible status displays
26 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
BC10 basic controller
9
Displays (examples) Values
[a/1/2| p
A00 … A99
[8/1/6| number > 800
Meaning
Service code
Error code
Remedy the error using the service section in this manual
Operating condition/Remedy
System faults
System faults are faults in the heating system that do not affect the burner number > 800 operation.
p
[-/h/\| p q
[1/4/0| number 0 … 199
[p/2/1|
[\/-/\|
(flashing)
> P15
Current boiler water temperature (in °F)
Current system pressure (in psi)
Fault
No communication between BC10 and automatic gas burner.
Table 7 Possible status displays
1)
2)
Standard display for this operating condition. This display appears after 5 minutes if no button is pressed.
The temperature is higher as 199° when 199 is blinking in the display
Fault
Remedy the error using the service section in this manual.
▶ Check the connections to both devices.
▶ Check the communication lines.
9.2
Carrying out additional tasks
9.2.1
Carrying out a flue gas test
The “Chimney Sweep” d
button is used for the flue gas test.
The heating control system works at the maximum flow temperature for
30 minutes. This is set on the BC10 basic controller using the “maximum heater temperature” knob. During flue gas testing the decimal point lights up in the display.
▶ Press and hold the “Chimney Sweep” d
button (< 5 seconds) until the decimal point is displayed.
▶ Carry out the flue gas test.
▶ Press the “Chimney Sweep” d
button to interrupt the flue gas test.
9.2.2
Selecting partial load operation (e. g. during flue gas testing)
You can operate the boiler at a reduced boiler capacity during flue gas testing. This reduction is only effective for the duration of the flue gas test.
▶ Press the “Chimney Sweep” d
button (max. 2 seconds) until the decimal point shows in the status display. This will switch on the flue gas test.
▶ Press and hold the “Chimney Sweep” d
and “Service” e
buttons
(for approx. 5 seconds) to enter the partial load mode.
▶ Press the “Reset” c button to reduce the boiler capacity percentage.
Example: boiler capacity reduced to 50 % (=
[l/5/0]) of the rated boiler capacity.
▶ Press the “Chimney Sweep” d
button to increase the boiler capacity percentage.
▶ When test is completed, press the “Service” e
button until the temperature indication is displayed.
▶ Press the “Chimney Sweep” d
button until the decimal point is cleared from the display.
9.2.3
Switching the heating system to manual mode
In manual mode the heating system can be operated independently of an external control unit. The boiler is operated with the heating system temperature set on the right knob serving as the target value.
A blinking decimal point is displayed while manual mode is active.
▶ Press the “Chimney Sweep” d
button (for more than 5 seconds) until the decimal point in the status display flashes.
▶ Turn the knob i to set the maximum space heating system temperature.
▶ Press the “Chimney Sweep” d
button to exit manual mode.
WARNING:
▶ Turn the “space heating system temperature” i knob to limit the heating system temperature to the permissible flow temperature for the floor heating circuit (e. g. 86 – 104 °F = 30 – 40 °C), so pipes will not overheat.
DANGER:
The heating system can freeze up if a power failure occurs or after switching off the power supply, because manual operation then is no longer active.
▶ You must re-activate manual operation after switching on the system to keep the heating system operational (especially if there is a risk of frost).
9.3
Configuring the boiler
9.3.1
Adjusting the heating capacity
Setting the heating capacity depending on the maximum heat requirement (
Regulator settin g in % boiler cap.
24 kW
Heating capacity (±5 %, sea level boiler cap.
30 kW boiler cap.
45 kW
1)
) boiler cap.
60 kW kW btu kW btu kW btu kW btu
L30
7.2 24,566 8.7 29,684 13.5 46,062 18.0 61,542
L40
9.6 32,755 11.7 39,920 18.0 61,416 24.0 82,080
L50
12.0 40,944 14.8 50,498 24.5 83,619 30.0 102,630
L60
14.4 49,133 17.8 60,734 27.0 92,178 36.0 123,192
L70
16.8 57,322 20.9 71,311 31.5 107,573 42.0 143,766
L80
19.2 65,510 23.9 81,547 36.0 122,976 48.0 164,352
L90
21.6 73,699 27.0 92,124 40.5 138,389 54.0 184,950
L--
24.0 81,888 30.0 102,360 45.0 153,810 60.0 205,560
Table 8 Heating capacity
1)
For use at high altitude the capacity decreases with 3% for every 1000 feet.
▶ Press and hold the “Chimney Sweep” d
and “Service” e
buttons until an “L” with a double-digit value (e. g. L80) or an “L” followed by two dashes (L - -) is displayed. Factory setting “L- -”(=
[l/-/-|).
▶ Set the heating capacity by pressing the “Chimney Sweep” d button (higher values) or the “Reset” c
button (lower values).
▶ Press the “Service” e
button to confirm the setting.
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 27
10
Shutting down the system
9.3.2
Setting the DHW temperature value
▶ Turn the “DHW temperature” h
rotary knob to set the desired temperature of the hot water in the hot-water tank.
0
Eco
Aut
1)
Condition
Off
Economy mode,
Hot water temperature
2)
140 °F (60 °C)
86 – 140 Direct setting on
BC10
Entry via thermostat
(presetting)
Explanation
No hot water supply (only heating mode).
LED
Off
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.
On
3)
The temperature set on the BC10 is a temperature that cannot be changed using a RC thermostat.
The temperature is set on the thermostat (e. g. RC30). If no thermostat is connected, the maximum DHW temperature is
140 °F (60 °C).
Table 9 Settings of “DHW temperature” knob
1)
2)
3)
This function has been optimized for boilers with combined DHW heating (combiunits).
The heating program (timer) of the room control unit remains active, as a result of which no hot water is heated during night-time operation.
The heating program (timer) of the room control unit remains active, as a result of which no hot water is heated during night-time operation.
9.3.3
Entering the space heating water temperature
▶ Turn the “space heating water temperature” i
knob to set the upper limit value of the heater water for the heating operation.
This limitation does not apply to DHW preparation.
0
Condition
Off
86 – 190 Direct setting on
Aut
BC10 in °F (86 –
190 °F = 30 –
90 °C)
Entry via thermostat
(presetting)
Explanation
No supply to heating system (only
DHW heating operation).
The temperature set on the BC10 is a temperature that cannot be changed using a RC thermostat.
Supply temperature does not rise above the set temperature.
On
1)
The temperature is automatically determined on the basis of the heating characteristic. If no thermostat is connected, the maximum heater temperature is
190 °F (90 °C).
LED
Off
Table 10 Settings of “space heating water temperature” rotary knob
1)
The LED under the rotary knob lights up when the heating system is switched on and heat is requested. In summer mode the heating system is switched off (LED off).
9.3.4
Setting the pump post-purge period
A pump must be connected to PK (
fig. 31, [7]) of the external
connection board in order to be able to set the pump run over time.
CAUTION:
▶ Set the boiler primary pump post-purge period to
24 hours if the heating system is controlled by room temperature sensor and there is a risk of parts of the heating system that are outside the coverage of the room thermostat freezing (e. g. radiators in a garage; constant circulation).
▶ Press and hold the “Chimney Sweep” d
and “Service” until the display shows “L- -”(=
[l/-/-|).
e
buttons
▶ Press the “Service” e
button. The display shows “F05”. The heating system has been factory-set to a pump post-purge period of
5 minutes.
▶ Press the “Chimney Sweep” d
or “Reset” c
buttons to set the pump post-purge period. The pump post-purge period can be set from 5 – 60 minutes (F 5 – F60) or to 24 hours (F1d).
▶ Press the “Service” e
button to confirm the setting.
NOTICE:
▶ On thermostat only systems a 5 to 10 minute postpurge setting is recommended to purge heat from the boiler.
10 Shutting down the system
DANGER:
The heating system may freeze if it is not operational in times of frost. Protect the heating system against freezing if there is a danger of frost affecting the system.
Drain the heating system water from the lowest point of the heating system. The vent screw at the highest point of the heating system must then be open.
DANGER:
Should overheating occur or gas supply fail to shut off, turn off the manual gas control valve to the boiler.
10.1
Shut down the heating system using the control unit
Shut down your heating system using the BC10 basic controller. When the BC10 basic controller is shut down, the burner is also switched off automatically. Further information on how to operate the BC10 basic
controller can be found in chapter 9 “BC10 basic controller”, page 25.
▶ Switch off the heating system using the main switch b.
▶ Close the main shut-off valve or the gas shut-off valve.
10.2
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.
▶ Close the main shut-off valve.
28 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
11 Inspection
We advise you to offer your customer an annual inspection and maintenance contract (for the contents of this contract,
If inspection reveals that maintenance work is necessary you can carry this out as required (
chapter 12 “Maintenance”, page 29).
CAUTION:
▶ Check and clean the heating system once a year.
▶ Carry out a maintenance overhaul if necessary.
Immediately repair defects to avoid damage to the heating system!
WARNING:
Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.
CAUTION: Risk of electric shock.
▶ Before opening the system: disconnect the heating system from the power supply using the heating system emergency OFF button or disconnect the relevant circuit breaker of the house from the power grid.
▶ Secure the heating system against accidental restarting.
▶ 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
Preparing the boiler for inspection
▶ Switch off the heating system using the main switch b
.
▶ Remove the cover from the boiler (
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.
11.2
Visual inspection for general signs of corrosion
▶ Check all gas and water pipes for signs of corrosion.
▶ Replace any pipes that are corroded.
11.3
Internal leak testing
▶ Switch off the heating system using the main switch b
.
▶ Test for internal leaks of the gas burner fitting on the inlet side, applying a test pressure of 7.0 inch W.C. (17.4 mbar) in case of natural gas and 11.0 mbar (27.4 mbar) in case of LPG.
After one minute the pressure must not have dropped by more than
3.8 inch W.C. (10 mbar).
▶ If the pressure has dropped more, you must check all gaskets and joints upstream of the gas burner fitting for leaks using a foaming agent. Repeat the pressure test if no leaks are found. If the pressure has again dropped by more than 3.8 inch W.C. (10 mbar) per minute you will have to replace the gas burner fitting.
11.4
Measuring the ionization current
See section 8.12“Measuring the ionization current” page 24.
11.5
Measuring the inlet gas pressure
See section 8.7“Inlet gas pressure”, page 23.
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Inspection
11
11.6
Checking and adjusting the gas/air ratio
See section 8.8“Checking and adjusting the gas/air ratio”, page 23.
11.7
Carrying out a gas leak test in operating conditions
See section 8.9“Carrying out a leak test in operating conditions”, page 24.
11.8
Measuring the carbon monoxide content (CO)
See section 8.10“Measuring the carbon monoxide content (CO)”, page 24.
11.9
Carrying out a pressure test of the heating system
See chapter 8“Start-up procedure”, page 21.
11.10 Checking the functioning and the safety of the air intake and flue gas conduit
See section 8.5“Checking the combustion air/flue gas connection”, page 22.
11.11 Checking venting systems
Check air intake and flue gas for obstruction or damage.
12 Maintenance
CAUTION:
There is no need to lubricate the combustion motor as it is permanently lubricated.
▶ Switch off the heating system using the main switch b
.
▶ Close the gas shut-off valve.
▶ Remove the casing.
12.1
Cleaning the heat exchanger, burner and condensate trap
CAUTION:
To avoid a short circuit.
▶ Do not spray the cleaning agent onto the burner, the hot surface ignitor, the ionization electrode or other electric components.
▶ Dismantle the hot surface ignitor and the ionization electrode.
▶ Loosen the fastening nuts (
▶ Remove the earth cable (
▶ Remove the retaining plate.
▶ Pull the hot surface ignitor (
fig 45, [3]) and the ionization
electrode (
fig 45, [4]) out of the heat exchanger.
4
1
1
3
2
72150200-42.1TD
Fig. 45 Removing the hot surface ignitor and the ionization electrode
[1] Fastening nut
[2] Earth cable
[3] Hot surface ignitor
[4] Ionization electrode
29
12
Maintenance
▶ Loosen the threaded connection to the gas control valve (
[1]) and pull the plug (
fig 46, [2]) from the gas valve terminal
block.
▶ Pull the plug from the fan unit (
▶ Loosen both sets of retaining clips (
burner cover and remove the burner cover with the fan unit and the gas burner fitting (
▶ Remove the baffle plate and clean it using compressed air
(
5
5
4
1
4
3
2
Fig. 48 Baffle plate
▶ Flush the heat exchanger with water (
72150200-45.1TD
72150200-43.1TD
Fig. 46 Removing the connections
[1] Gas control valve
[2] Plug
[3] Fan unit
[4] Retaining clip heat exchanger
[5] Retaining clip burner
▶ Remove the gas/air distributor plate (
fig 47, [2]), the orifice plate
(GB142-24, GB142-30 and GB142-60 only,
burner (
fig 47, [4]). Note that the orifice plate of the GB142-60
has a different shape.
▶ Clean the gas/air distributor plate, the orifice plate (GB142-24,
GB142-30 and GB142-60 only) and the burner using compressed air.
1
72150200-44.1TD
Fig. 47 Cleaning the burner cover, gas/air distributor plate, orifice plate and burner
[1] Gas burner fitting
[2] Gas/air distributor plate
[3] Orifice plate
[4] Burner
2
3
4
Fig. 49 Cleaning the heat exchanger
▶ Re-assemble all parts in reverse order of disassembly.
72150200-46.1TD
NOTICE:
▶ It is important to inspect and properly replace the rubber gaskets.
▶ Switch on the heating system using the main switch a
.
▶ Press the “Chimney Sweep” d
button until the decimal point is displayed. Leave the boiler on for approx. 10 minutes.
▶ Switch off the heating system using the main switch b
.
▶ Dismantle the boiler again and flush the heat exchanger with water.
▶ Pull the condensate trap from the condensate plate (
▶ Pull the internal condensate bypass pipe from the condensate trap
(
30 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Appendix
13
▶ Loosen the condensate trap from the connection (
remove it.
3.
1.
2.
72150200-47.1TD
Fig. 50 Condensate trap
▶ Use a bristle brush to clean the condensate trap.
▶ Flush the condensate trap.
▶ Fill the condensate trap with water before re-installing it.
▶ Check the condensate trap gasket for damage and replace it if necessary.
▶ Re-assemble all parts in reverse order of disassembly.
12.2
Checking and adjusting the gas/air-ratio
See section 8.8“Checking and adjusting the gas/air ratio”, page 23.
13 Appendix
13.1
Operating messages
▶ Press the “Service” e
button a number of times to switch between the various status displays.
Display
Normal mode =/-
[-/h//|
[=/h//|
Normal mode 0
[0/a//|
Meaning
Boiler in space heating mode
Boiler in DHW heating mode
1)
[0/c//|
[0/e//|
[0/h//|
[0/l//|
[0/u//|
[0/y//|
Test mode -
[-/a./| Dot displayed in right hand bottom corner
Burner interval circuit, burner will start automatically after 10 minutes
Burner is started
More capacity was delivered than required
Standby
Gas burner fitting is opened
Initializing/ pre purge
Flow temperature higher than set
Boiler in flue gas test
Manual mode -
[-/h.}Blinking dot in right hand bottom corner
Reset
[r/e//|
Boiler in manual mode
Reset (after holding the “Reset” c for 5 seconds, the heating system is returned to its switch-on condition)
button
Table 11 Normal operating messages
1)
“- H” May also appear when the boiler is in frost protection mode. There has been a continuous DHW demand and CH request for more then one hour. The boiler then switches to CH mode. The operating code flashing in the display after the service button is pressed is A01/ 818. To enable the DHW, restart the boiler.
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 31
13
Appendix
13.2
Error messages
▶ Press the “Service” e
button to display the service code (e. g.
“3A”).
▶ Press the “Service” e
button to display the error code (e. g. “207”).
The error message is a combination of the service code (e. g. “3A”) and the error code (e. g. “207”). You can only resolve the error message using the Service chapter in this manual.
INSTRUCTION FOR INSTALLERS
▶ The display may also show system faults (e. g. “A11”).
In principle, they are identified by the initial letter “A” and they refer to faults between the boiler and the additionally available electronic components.
Display
2
Meaning
Water flow / water pressure
E 207 System pressure too low < 3 psi (0.2 bar).
F 271 Temperature difference between safety and supply sensors too much or no temperature increase after starting the burner.
L 266 Test of pump operation via a pressure increase in the heating system (during pump start).
P
Temperature increase of safety sensor or supply sensor too high.
U
Temperature difference between supply and return sensor too much.
Y
Pump feedback fault.
3
Fan speed
A 264 Fan unit failed during operation.
C 217 Fan unit is running too fast.
F 273 Continuous 24 hour operation.
4
L 214 Fan shut down during security test.
P 216 Fan unit is running too slowly.
Y 215 Fan unit is running too fast.
Temperatures
A 218 Supply sensor over 220 °F (105 °C).
E 278 Sensor test failed
F 219 The safety temperature sensor has detected a flow temperature of over 266 °F (130 °C)
L 220 Safety sensor affected by short circuit or higher than
266 °F (130 °C).
6
P 221 Loose contact or defective safety sensor.
U 222 Supply sensor affected by short circuit.
Y 223 Loose contact or faulty supply sensor.
Flame monitoring
A 227 No ionization message after ignition.
C 228 Ionization measured before burner start.
L 306 The flame went out during the heating phase.
P 229 Hot-surface ignitor on for too long.
7
Grid voltage
C 261 The grid power was interrupted after an error.
L 261
280
UBA fault.
8
Y
External switching contact
External switching contact, e. g. temperature safety switch for floor heating, has taken place.
Table 12
Display
9
Meaning
System faults
A 235 Communication fault between UBA and KIM.
H 237
267
272
UBA fault.
P 239 UBA fault.
L 234
238
239
Faulty gas burner fitting cable connection.
U 233 KIM out of order.
Y
Communication fault between BC10 basic controller and UBA.
E
System faults
1, A, C,
F, H, L,
Y
Internal UBA fault.
Table 12
32 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Appendix
13
13.3
Technical specifications
General specifications
Gas category
Rated thermal load for Natural gas
Rated heating capacity for heating curve
176/140 °F (80/60 °C)
Rated heating capacity for heating curve
122/86 °F (50/30 °C)
Boiler efficiency rating max. capacity for
heating curve 176/140 °F (80/60 °C)
1)
Boiler efficiency rating max. capacity for
heating curve 122/86 °F (50/30 °C)
CSA Output
Heating
Max. flow temperature
Heater water temperature
unit
btu/hr btu/hr btu/hr
%
% btu/hr
boiler cap. 24 kW
Natural gas boiler cap. 30 kW
Natural gas boiler cap. 45 kW
Natural gas boiler cap. 60 kW
Natural gas
25,700 – 84,800 31,800 – 106,000 46,000 – 160,900 66,000 – 214,800
22,700 – 75,200 28,100 – 91,500 40,600 – 142,200 58,200 – 189,800
25,300 – 83,300 30,700 – 102,400 45,100 – 158,500 64,800 – 211,600
88
97
76,300
88
97
95,400
88
97
144,800
88
97
178,900
Maximum operating overpressure of boiler
Heating exchanger heating circuit volume
Pipe connections
Gas connection
Heating system water connection
Condensate water connection
Flue gas values
Condensate water quantity for natural gas
G20, 104/86 °F (40/30 °C) pH value condensate water
Flue gas mass flow rate at full load
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
CO
2
content, full load, natural gas G20
CO
2
content, full load, LPG G31, propane
Standard emission factor CO
Standard emissions factor NO x
Free fan feed pressure
°F (°C)
°F(°C) psi (bar) gallons (l) inch inch (mm) inch (mm) gallons per hour pH g/s
°F(°C)
°F(°C)
°F(°C)
°F(°C)
194 (90)
86 –190 (30–90), can be set on BC10 basic controller
43.5 (3)
0.7 (2.5)
¾ '' NPT
1.0'' NPT (25.4)
Ø 1.3'' (Ø 32)
2.6
approx. 4.1
10.0
150 (66)
135 (57)
113 (45)
91 (33)
%
%
mg/kWh mg/kWh
inch w.c. (Pa)
9.2
10.0
≤ 15
≤ 20 up to 0.023
(up to 60)
Flue gas connection
Ø Flue system, dependent on the air in the room
Ø Flue gas system, independent of the air in the room
Electric data
Mains voltage (-15%, +10%)
Fuses inch (mm) inch (mm)
3 (80)
3/3 (80/80) parallel
Electrical protection rating
Electrical power consumption, at full load
Electrical power consumption, at partial load
Boiler dimensions and weight
Height × Width × Depth
V, Hz amps
W
W
120, 60
5 amps 120 V slow blow
IP X4D
96
22
Weight inch (mm) lbs (kg)
28 x 22 x 18.7
(712 x 560 x 475)
110 (50)
Table 13 Technical specifications
1)
2)
The performance information shown is based on 'European performance standards'.
If the heating capacity is limited to max. 80 % (L80).
194 (90)
86 –190 (30–90), can be set on BC10 basic controller
43.5 (3)
0.7 (2.5)
¾ '' NPT
1.0'' NPT (25.4)
Ø 1.3'' (Ø 32)
3.3
approx. 4.1
12.6
167 (75)
137 (58)
118 (48)
91 (33)
9.2
10.0
≤ 15
2)
up to 0.039
(up to 100)
3 (80)
3/3 (80/80) parallel
120, 60
5 amps 120 V slow blow
IP X4D
117
22
28 x 22 x 18.7
(712 x 560 x 475)
110 (50)
194 (90)
86 –190 (30–90), can be set on BC10 basic controller
58 (4)
1.0 (3.6)
¾ '' NPT
1.0'' NPT (25.4)
Ø 1.3'' (Ø 32)
4.7
approx. 4.1
19.4
150 (66)
135 (57)
96 (36)
91 (33)
9.3
10.0
≤ 15
≤ 20 up to 0.054
(up to 140)
3 (80)
3/3 (80/80) parallel
120, 60
5 amps 120 V slow blow
IP X4D
64
20
28 x 35.4 x 18.7
(712 x 900 x 475)
143 (65)
194 (90)
86 –190 (30–90), can be set on BC10 basic controller
58 (4)
1.3 (4.7)
¾ '' NPT
1.0'' NPT (25.4)
Ø 1.3'' (Ø 32)
7.1
approx. 4.1
25.9
150 (66)
135 (57)
96 (36)
91 (33)
9.3
10.0
≤ 15
≤ 20 up to 0.054
(up to 140)
3 (80)
3/3 (80/80) parallel
120, 60
5 amps 120 V slow blow
IP X4D
82
22
28 x 35.4 x 18.7
(712 x 900 x 475)
158 (72)
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 33
14
Reports
Type of gas supply
Natural gas
LPG P
Factory pre-setting of the gas control valve
Delivered factory-set: Natural Gas
Suitable for propane after conversion
(
chapter “Conversion to Propane”).
Information on gas type instruction plate:
Set to gas category: Propane.
Table 14 Factory setting of the gas control valve
▶ The gas orifice diameter is marked on the gas orifice (in mm).
▶ The venturi article number is marked on both clips of the venturi
(
1
Boiler capacity
Type of gas supply
Venturi article number
Gas orifice diameter
Altitude 0 - 10,200 ft
No CO
2 correction
Altitude 4,001
- 10,200 ft with CO
2 correction
[inch] [mm] [inch] [mm]
24 kW Natural gas H 423.072A 0.175
4.45
0.179
4.55
LPG P 423.072A 0.132
3.35
0.134
3.40
30 kW Natural gas H 423.072A 0.175
4.45
0.177
4.50
LPG P 423.072A 0.132
3.35
0.134
3.40
45 kW Natural gas H 423.170A 0.213
5.40
0.219
5.55
LPG P 423.170A 0.163
4.15
0.163
4.15
60 kW Natural gas H 423.173A 0.295
7.50
0.301
7.65
LPG P 423.173A 0.213
5.40
0.215
5.45
Table 15 Gas orifice diameter
1
Fig. 51 Venturi article number
72150200-48.1TD
14 Reports
14.1
Start-up report
Put your signature and the date at the bottom of the start-up report.
Start-up activities
1.
Fill the heating system and check that all connections are tight
• Inlet pressure of expansion tank (observe the Installation Instructions for the expansion tank)
• Pressurize the system
• Fill the condensate trap
Page
2.
Carry out a gas tightness test
3.
Note down the gas characteristics: Wobbe index
4.
Convert the boiler to another type of gas supply (only if allowed)
5.
Vent the gas supply conduit
6.
Check the combustion air/flue gas connection
7.
Measure the gas connection pressure (flow pressure)
8.
Check and adjust the gas/air ratio
9.
Measure the carbon monoxide content (CO)
10. Check and if necessary adjust the carbon monoxide content (CO
2
)
11. Measuring the ionization current
12. Make the necessary settings on the thermostat
13. Carry out function testing
14. Fitting the casing
15. Inform the owner; hand over the technical documents
Confirm proper start-up
Operating heat value
Measured values
_____________ psi
_____________ psi
_____________ kWh/m
3
_____________ kWh/m
3
____________ inch W.C.
____________ inch W.C.
_____________ ppm
_____________ %
_____________ mA
Remarks
Company stamp/signature/date
Table 16
34 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Reports
14
14.2
Inspection report
▶ Please indicate the inspection activities that you have carried out and enter the values measured.
Inspection activities
1.
Test the general condition of the heating system
2.
Carry out a visual inspection and test the functions of the heating system
3.
Test all gas and water conduits and fittings for:
• their tightness during operation
• visible corrosion
• signs of aging
• fill the condensate trap
Page Date: __________ Date: __________ Date: __________
4.
Check the burner, the heat exchanger and the condensate trap for pollution.
First shut down the heating system
5.
Check the burner and the ignition and ionization electrodes.
First shut down the heating system
6.
Measure the ionization current
7.
Measure the gas connection pressure (flow pressure)
8.
Check the gas/air ratio
9.
Carry out a gas tightness test in operating conditions
10. Measure the carbon monoxide content (CO)
11. Check the water pressure of the heating system
• Inlet pressure of expansion tank (also see the Installation Instructions for the expansion tank)
• Filling pressure.
12. Check the operation and safety of the air intake and flue pipe
13. Check that the thermostat is set in line with the needs (see documents with thermostat)
14. Final check of inspection activities, note down the measurement and test results
15. Confirm proper inspection
____________ mA ____________ mA ____________ mA
____________ psi ____________ psi ____________ psi
______ inch W.C. ______ inch W.C. ______ inch W.C.
____________ % ____________ % ____________ %
____________ psi
____________ psi
____________ psi
____________ psi
____________ psi
____________ psi
Company stamp/ signature
Company stamp/ signature
Company stamp/ signature
Table 17
14.3
Maintenance report
▶ Sign for the maintenance activities that you have carried out and enter the date.
Needs-dependent maintenance activities
1.
Clean the burner, the heat exchanger and the condensate trap. First shut down the heating system
2.
Check and adjust the gas/air ratio
CO
2
content with full load
CO
2
content with partial load
Confirm proper maintenance
Page Date: __________
_____________ inch W.C.
_____________ %
_____________ %
Date: __________
_____________ inch W.C.
_____________ %
_____________ %
Table 18
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Company stamp/ signature
Company stamp/ signature
35
15
Spare parts
15 Spare parts
Below is a list of the spare parts for this boiler. Look up the position number in the exploded view drawing on the next 2 pages for the illustration. Spare parts may be ordered from Buderus.
Pos.
Description
1 Casing 24/30 kW
2
Casing 45/60 kW
Casing latches left (2 pc)
4
5
3
3
6
Casing latches right (2 pc)
Casing seal 24/30 kW
Casing seal 45/60 kW
Wall mounting bracket
7
9
Back panel 24/30 kW
Back panel 45/60 kW
Cap air vent
Seal ring Ø 3''
10 Seal ring Ø 80 mm
11 Flue gas collector
12 Oval seal
13 Heat exchanger 24/30 kW
Heat exchanger 45 kW
Heat exchanger 60 kW
14 Heat exchanger baffle 24/30 kW
15 Seal condensate collector 24/30 kW
Seal condensate collector 45 kW
Seal condensate collector 60 kW
16 Condensate collector + sealing 24/30 kW
Condensate collector + sealing 45 kW
Condensate collector + sealing 60 kW
17 Clamp
18 Sensor NTC
19 Revision set air vent
1)
20 Sight glass
21 Burner box 24/30 kW
Burner box 45 kW
Burner box 60 kW
22 Safety sensor
23 Seal burner 24/30 kW
Seal burner 45 kW
Seal burner 60 kW
24 Gas/air distribution plate 24/30 kW
Gas/air distribution plate 45 kW
Gas/air distribution plate 60 kW
25 Orifice plate 24/30 kW
Orifice plate 45 kW
Orifice plate 60 kW
26 Burner 24/30 kW
Burner 45 kW
Burner 60 kW
27 Gas-air inlet
28 Seal fan
29 Ionization electrode
30 Hot surface ignitor
31 Shield hot surface ignitor
Table 19
7746900160
7746900161
7098828
7098834
7098838
67900522
7098840
7098844
67900521
7098848
7100136
7098822
7098575
7099057
7098875
67900525
Product No.
7099988
7099901
7099039
7099038
7098752
7098798
7098364
7099001
7099903
7100250
8718600719
7096475
7098857
7098858
7746900159
78194
7098916
7098920
67900526
7100922
7098926
67900527
7100920
7098832
67900523
7099003
7098932
67900528
7099004
7099023
78195
7099006
7100229
Pos.
Description
32 Mounting plate
33 Seal mounting plate (5 pc)
34 Air inlet pipe; 24/30 kW
Air inlet pipe; 45/60 kW
35 Seal Ø50 mm (5 pc)
36 Venturi 24/30 kW
Venturi 45 kW
Venturi 60 kW
37 Seal set (4 pc)
38 Fan
39 Gas control valve 24/30/45 kW
Gas control valve 60 kW
40 Gas supply pipe GB142 USA
41 Spring (5 pc)
42 Seal 2x16x22 (5 pc)
43 L.P. Orifice Ø 3.35 - 24/30 kW 0-10,200 ft
L.P. Orifice Ø 3.40 - 24/30 kW
4,001-10,200 ft
7098778
76687
7746901353
L.P. Orifice Ø 4.15 - 45 kW 0-10,200 ft
N.G. Orifice Ø 4.45 - 24/30 kW 0-10,200 ft
7746901355
7099016
N.G. Orifice Ø 4.50 - 30 kW 4,001-10,200 ft 7746901421
N.G. Orifice Ø 4.55 - 24 kW 4,001-10,200 ft 7746901354
N.G. Orifice Ø 5.40 - 45 kW 0-10,200 ft
L.P. Orifice Ø 5.40 - 60 kW 0-10,200 ft
76690
76690
L.P. Orifice Ø 5.45 - 60 kW 4,001-10,200 ft 7746901357
N.G. Orifice Ø 5.55 - 45 kW 4,001-10,200 ft 7746901356
N.G. Orifice Ø 7.50 - 60 kW 0-10,200 ft 76686
N.G. Orifice Ø 7.65 - 60 kW 4,001-10,200 ft 7746901358
44 Condensate trap, part of pos. 88
45 Seal condensate trap (5 pc)
8718600689
7100742
46 Supply pipe CH; 24/30/45 kW
47 Supply pipe CH; 60 kW
48 Return pipe 24/30/45 kW
Return pipe 60 kW
49
50 Bottom plate
75990
75991
7099965
709945
8718600019
7099049
78191
7099050
51 Transformer 120V
52 Grommet
53 External connection board
54 External connection board cover
55 Fuse 5 AF slow blow
56 UBA cover
57 UBA3 - 120V
58 Drawer
73814
7099046
73904s
7099047
8718600083
7099043
7099037
78186
59 Drawer front
60 Controller connection plate
61 On/off switch
62 Controller cover
63 Boiler ident. module 24 kW
Boiler ident. module 30 kW
Boiler ident. module 45 kW
Boiler ident. module 60 kW
64 Cable harness low voltage
65 Cable harness high voltage
7099041
73698
78223
78224
78225
7736700204
78193
7099957
Product No.
7098852
7098850
7099024
7099923
7099058
7099020
7099925
7099931
7099021
78184
7746900891
7736700203
76685
7100549
Table 19
36 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Pos.
Description
66 O-ring (10 pc)
67 Sealing bush (set)
68 Cable harness of on/off switch
69 Cable harness BX holder
70 Fuse holder
71 Seal Ø60 mm (5 pc)
72 O-ring set orifice
73 Seal (5 pc)
74 Set screw M5x20 (5 pc)
75 Cap 24/30 kW
76 Double nipple THR x COMPR
77 Cable saddle (10 pc)
78 Bolt M6x16 (2 pc)
79 Clip pressure sensor
80 Drain plug
81 Cap connection piece
82 Clip (5 pc)
83 Centering ring (5 pc)
84 Coupling nut pump
85 Seal pump (10 pc)
86 Coupling nut pump
87 Conversion set pump
88 Flue gas adaptor drain set, incl. pos. 44
89 Flue gas silencer 24/30/45 kW
Table 19
1) not shown in exploded views
Product No.
38434s
7099002
7099072
7099070
38345
7098878
7099018
8718600045
7099065
79105
75977
7098810
7099078
7101370
7099364
38498
73651s
73480s
73481s
15022s
15020
73149
8718600686
7099056
Spare parts
15
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 37
15
Spare parts
Exploded view Logamax plus GB142-24/30
27
28
71
74
74
40
41
42
34
35
36
74
72
73
37
21
10
17
23
24
25
26
29
32
33
22
31
30
14
19
66
66
18
83
11
13
89
12
17
16
15
84
85
87
43
39
45
44
38
85
86
48
47
76
49
88
81
79
82
80
4
76
20
75
77
7
67
2
64
3
65
54
69
62
57
63
70
55
56
1
61
68
60
53
9
88
78
5
6
52
51
50
59
58
72150200-49.1TD
Fig. 52
38 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)
Spare parts
15
Exploded view Logamax plus GB142-45/60
27
28
34
71
74
74
40
41
42
35
36
74
72
73
43
39
37
21
26
23
24
25
17
29
32
33
22
31
30
14
17
16
15
19
66
18
66
83
10
11
13
89
12
84
85
87
45
44
38
88
81
49
79
82
80
20
85
86
48
47
77
4
2
67
7
9
88
5
78
67
6
Fig. 53
59
1
62
61
60
68
3
57
54
63
70
55
56
53
64
65
52
51
69
50
58
72150200-50.1TD
Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05) 39
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Table of contents
- 11 Connecting boiler with DHW tank
- 11 Piping examples
- 11 Relief valve
- 12 Low Water Cut-Off (LWCO) and External Manual Reset High Limit
- 13 All Air from Inside the Building (non sealed combustion)
- 16 Below are approved examples of vertical and horizontal venting installation
- 19 RC terminal
- 19 FA terminal
- 19 WA terminal
- 19 FW
- 19 EV terminal (external switching contact)
- 19 DWV
- 19 PK
- 19 PS
- 19 PZ
- 19 NETZ
- 19 120-volt connections
- 26 Switching on the heating system
- 26 Switching off the heating system
- 26 Displaying the operating conditions of the burner
- 26 Resetting the boiler or resetting faults