Buderus Logamax plus GB142-30 Installation Instructions Manual

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Buderus Logamax plus GB142-30 Installation Instructions Manual | Manualzz

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]

(RK) Return, Ø 1.0"

1)

(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]

(RK) Return, Ø 1.0"

1)

(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 (

 fig. 6)

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 (

 fig. 6).

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

(

 fig. 7, [1]).

▶ Open the latches (

 fig. 7, [2]).

▶ 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

pump see section 1.4, page 4.

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 (

 fig. 14).

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).

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 (

 fig. 16).

[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 (

 fig. 17 and 18) can be

used for the installation of a vertical venting system as well as for a horizontal venting system. The concentric vent/air intake body can be ordered by Buderus Hydronic Systems, part no. BRYKGAVTO601CV.

Other optional vent kits are:

383-500-397 Plastic Vent Kit

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 (

 fig. 18 and fig. 19).

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) (

 fig. 20).

Installation

6

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

 fig. 21).

Vent must be 3 ft (915 mm) above any forced air intake within 10 ft

(3,050 mm) (

 fig. 21).

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

(

 fig. 21).

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 (

 fig. 22,

[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

 page 36

“Spare parts”, [43].

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 (

 fig. 29).

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 (

 fig. 30, [1]).

▶ Lead the cable through the cable guide (

 fig. 30, [2]).

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 (

 table 5).

▶ 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 (

 fig. 36, [2]) to the

testing nipple (

 fig. 36, [1]).

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 (

 fig. 38, [1]).

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 (

 fig. 38, [1]).

▶ 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

(

 fig. 40).

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 (

 fig. 41). Select the

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 (

 fig. 43). Do not lift the

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 (

 section 13.2). The status

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

 section 13.3.

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/\|

1)

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

2)

Current boiler water temperature (in °F)

[p/1/2|

P3 … P12 Current system pressure (in psi)

[p/3/\| p

1)

(flashing)

< P3

[2/0/7| number > 200

[1/4/0|

[p/3/\| number 0 … 199

< P3

2)

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/\|

1)

(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

2)

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 (

 table 8).

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

2)

in °F

Entry via thermostat

2)

(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.

On

3)

On

3)

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)

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,

 page 35 and page 35).

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 (

 fig. 7, page 9).

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 (

 fig 45, [1]).

▶ Remove the earth cable (

 fig 45, [2]).

▶ 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 (

 fig 46,

[1]) and pull the plug (

 fig 46, [2]) from the gas valve terminal

block.

▶ Pull the plug from the fan unit (

 fig 46, [3]).

▶ Loosen both sets of retaining clips (

 fig 46, [4] and [5]) of the

burner cover and remove the burner cover with the fan unit and the gas burner fitting (

 fig 47, [1]).

▶ Remove the baffle plate and clean it using compressed air

(

 fig 48).

5

5

4

1

4

3

2

Fig. 48 Baffle plate

▶ Flush the heat exchanger with water (

 fig. 49).

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,

 fig 47, [3]) and the

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 (

 fig 50, [1]).

▶ Pull the internal condensate bypass pipe from the condensate trap

(

 fig 50, [2]).

30 Logamax plus GB142-24/30/45/60 – 6720820104 (2017/05)

Appendix

13

▶ Loosen the condensate trap from the connection (

 fig 50, [3]) and

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)

1)

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)

≤ 20

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

(

 fig. 51, [1]).

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

21

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

24

25

24

25

25

21

_____________ psi

21

21

21

_____________ kWh/m

3

_____________ kWh/m

3

22

22

23

____________ inch W.C.

23

____________ inch W.C.

24

_____________ 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: __________

29

29

22

29

  

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

29

24

23

23

29

29

22

25

____________ 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: __________

29

23

_____________ 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

Pressure sensor

1)

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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