Buderus GB162 User manual

Please read thoroughly before operating
6 720 646 148 - 11/2010 US/CA (en) For the user
This manual is available in the English and French
language.
This manual must be retained for future use.
User’s Instructions
Condensing gas boiler
Logamax plus GB162-L.B. 80 kW/100 kW

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Warning: If the information in these instructions is not followed exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
– 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.
CAUTION !
The operating manual is part of the documentation that is delivered to the instal-
lation's operator. Go through the information in this manual with the owner/oper-
ator and make sure that he or she is familiar with all the necessary operating
instructions.

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Contents
1 For your safety . . . . . . . . . . . . . . . 5
1.1 Designated use . . . . . . . . . . . . . . . . . . 5
1.2 Safety instructions . . . . . . . . . . . . . . . . 6
1.3 Quality of the heating system water . . . 8
2 Lighting Instructions . . . . . . . . . . . 9
3 Operating the BC10 basic
controller 10
3.1 General . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Switching ON and OFF . . . . . . . . . . . 11
3.3 Setting the DHW temperature value . 12
3.4 Setting the space heating water
temperature 15
3.5 "Burner ON" LED . . . . . . . . . . . . . . . . 17
3.6 Other functions and economic
heating 17
4 Starting up the boiler . . . . . . . . . 18
4.1 Boiler settings . . . . . . . . . . . . . . . . . . .18
4.2 Check the system pressure . . . . . . . . . 19
4.3 Fill the heating system . . . . . . . . . . . .20
4.4 Frost protection . . . . . . . . . . . . . . . . . .23
5 Shutting down the boiler . . . . . . 24
6 Operating and error messages . 25
6.1 Normal operation menu . . . . . . . . . . . .25
6.2 Manual Operation menu . . . . . . . . . . .26
6.3 Settings menu . . . . . . . . . . . . . . . . . . .28
6.4 Display codes . . . . . . . . . . . . . . . . . . .31
6.5 Identifying and resetting faults . . . . . .34

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Preface
About these instructions
These user's Instructions contain important
information for the safe and proper operation
of Logamax plus GB162-L.B. 80kW/100kW
condensing gas boilers.
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of
life.
Subject to technical changes!
Changes may be made following technical
improvements!
Updating of documentation
Please contact us if you have any suggestions
for improvements or corrections.

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For your safety
1 For your safety
Logamax plus GB162 L.B. condensing gas
boilers are designed and built according to the
latest technological advances and safety
requirements.
The design is specifically focused on ease of
use. To ensure the safe, economical and envi-
ronmentally friendly use of the heating system
we urge you to read and observe the User's
Instructions.
1.1 Designated use
The boiler was designed for heating water for
a central heating system and generating
domestic hot water. The boiler can be installed
either as a single system or as part of a
multiple system (cascade system) with a
maximum of 8 boilers connected together.
Hazard definitions
ADANGER
Indicates the presence of hazards that
will cause severe personal injury, death
or substantial property damage.
AWARNING
Indicates the presence of hazards that
can cause severe personal injury, death
or substantial property damage.
ACAUTION
Indicates presence of hazards that will
or can cause minor personal injury or
property damage.
HCAUTION
Risk of electric shock.
Indicates presence of hazards due to
electric shock.

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For your safety
INOTICE
Indicates special instructions on instal-
lation, operation or maintenance that
are important but not related to
personal injury or property damage.
1.2 Safety instructions
Make sure to observe these safety instruc-
tions. Failure to do so can result in property
damage, personal injury or loss of life.
– Installation, gas and flue connection,
commissioning, electrical connection and
maintenance activities must only be carried
out by a trained service provider.
– Certain work, e.g. on gas lines, may require
a professional license. Only carry out such
work if you are licensed to do so.
– Only use the boiler for its intended purpose
and only when it is in working order.
– Have a trained service provider check,
clean and service the heating system once
a year.
Buderus recommends a contract for annual
service and maintenance.
– The condensate collection and disposal
system must be periodically cleaned by a
trained service technician.
– Have your trained service provider give you
detailed instructions about the operation of
the heating system.
– Carefully read these user's instructions.
– Immediately have all defects to the heating
system repaired.
– Ensure that air intake and outlet openings
are open and free from obstructions at all
times.

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For your safety
– Do not store any flammable material or
liquids in the immediate vicinity of the
boiler.
– Never use chlorinated detergents or
halogenated hydrocarbons (e.g. in
spraycans, solvents and detergents,
paints, adhesives) in the room where the
boiler is installed.
– When Calcium Chloride is present in
concrete floors (when poured in winter) it is
necessary to seal the floor with a suitable
paint.
– Do not allow too much dust to collect on the
device.
– Do not use the boiler if any part has been
under water. Immediately call a trained
service technician to inspect the boiler and
to replace any part of the control system
and any gas control which has been under
water.
– Should overheating occur or the gas supply
fails to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead,
shut off the gas supply at a location
external to the boiler.
– The venting system must be inspected
annually. Replace any parts which show
deterioration from corrosion or any other
sources.
– This boiler does not have a pilot. It has an
ignition device which automatically lights
the burner.
– Check for smell of gas around the boiler
area. Be sure to smell next to the floor
because propane gas is heavier than air
and will settle on the floor.
– Use only your hand to turn the gas control
knob (fig. 4 on page 18). Never use tools. If
the knob will not turn by hand, don't try to

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For your safety
repair it, call a trained service technician.
Force or attempted repair may result in a
fire or an explosion.
– When the vent system is blocked, this
boiler will shut off automatically with code
'3C'. Immediately call a trained service
technician to inspect and reset the boiler.
1.3 Quality of the heating system water
Use only untreated tap water when filling or
topping up the heating system. The use of
unsuitable heating system water will lead to
build-ups of sludge and corrosion, which can
in turn result in the malfunctioning of the boiler
and damage to the heat exchanger.
DO NOT treat the water with products such as
pH-adjusting substances (chemical additives)
and antifreeze or water softeners.

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Lighting Instructions
2 Lighting Instructions
ASTOP!
Read the chapter "For your safety" on page 5
before lighting the boiler.
Follow the instructions to start up the boiler in
“Starting up the boiler” on page 18

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Operating the BC10 basic controller
3 Operating the BC10 basic controller
Fig. 1 Logamatic BC10 basic controller – Controls
1: Main power switch
2: "Reset" button
3: "Chimney sweep" button
4: "Service" button
5: Service Tool connector
6: LED "Burner operation"
7: LED "Heating system status"
8: Space heating water temperature knob
9: Display
10: DHW temperature knob
11: LED "DHW status"
888
1
10 9 8
110
140
130
120
90
100
130
170
150
90
110
190
7
21
11 34 56

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Operating the BC10 basic controller
3.1 General
The boiler is equipped with a control unit, the BC10
basic controller (fig. 2). This controller can be used
to control the heating system.
Push on the control panel to open it (fig. 2) and
get access to the controller.
3.2 Switching ON and OFF
Set the main switch on the BC10 to position "1"
(ON) to switch ON the boiler and set it to "0" to
switch the boiler OFF.
Fig. 2 Opening the control panel
INOTICE
If your heating system consists of several
boilers (cascade system), you have to
carry out the settings on the control units of
all individual boilers.

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Operating the BC10 basic controller
HCAUTION
Risk of electric shock.
If a hazardous situation occurs, shut OFF power to the boiler using the emergency shutoff
switch or the boiler circuit breaker (see chapter 4 "Starting up the boiler", page 18). Make
yourself familiar with the location of the emergency shutoff switch and the boiler loop
circuit breaker.
3.3 Setting the DHW temperature value
Check the local code for the max. DHW temper-
ature.
Turn the "DHW temperature" rotary knob to set
the desired temperature of the hot water in the
DHW tank.
140
130
120
90
100
110

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Operating the BC10 basic controller
1This function has been optimized for boilers with combined DHW heating (combi-units).
2The LED under the rotary knob lights if the DHW temperature is below the target value (heat request for
DHW).
Condition Explanation LED
0OFF No hot water supply (only heating mode). OFF
Eco 1Economy mode,
Hot water temperature
140 °F (60 °C)
The DHW will only be reheated to 140 °F (60 °C),
if the temperature has signifcantly fallen. This
reduces the number of burner starts and saves
energy. As a result the water may be a bit cooler
initially.
ON 2
86 – 140 Direct setting on BC10
in °F
The temperature set on the BC10 is a fixed
temperature that cannot be changed using a
RC thermostat.
ON 2
Aut Entry via thermostat
(presetting)
The temperature setting defaults to the maximum
DHW temperature of 140 °F (60 °C).
ON 2
Table 1 Settings of "DHW temperature" knob

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Operating the BC10 basic controller
Anti-scald table
Temperature of
water
Minimum time for
first degree burn
Minimum time for second or third
degree burn
111 °F (44 °C) 5 hours 7 hours
116 °F (47 °C) 35 minutes 45 minutes
118 °F (48 °C) 10 minutes 14 minutes
122 °F (50 °C) 1 minute 5 minutes
131 °F (55 °C) 5 seconds 25 seconds
140 °F (60 °C) 2 seconds 5 seconds
149 °F (65 °C) 1 second 2 seconds
158 °F (70 °C) –1 second
Table 2 Temperature/Time/Burn Chart

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Operating the BC10 basic controller
3.4 Setting the space heating water
temperature
Turn the "space heating water temperature" knob
to set the upper limit value of the heater water for
the heating operation. This limitation does not
apply to DHW preparation.
190
170
150
130
90
110

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Operating the BC10 basic controller
Condition Explanation LED
0OFF No supply to heating system (only DHW heating
operation).
OFF
86 – 190 Direct setting on
BC10 in °F
The temperature set on the BC10 acts as a high limit.
With a AM10 or RC10 control, the water temperature
will be at a equal or lesser value. With a On/Off
thermostat the water temperature will always be the
set temperature. Supply temperature never rises
above the set temperature.
ON 1
Aut Entry via thermostat
(presetting)
The temperature high limit setting defaults to the
maximum boiler water temperature of 180 °F (82 °C).
ON 1
Table 3 Settings of "space heating water temperature" rotary knob
1The LED under the rotary knob lights when the heating system is switched ON and heat is requested.
In summer mode the heating system is switched OFF (LED OFF).

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Operating the BC10 basic controller
3.5 "Burner ON" LED
The LED indicates the operating condition of the
burner.
3.6 Other functions and economic heating
The functions described above are basic functions, carried out directly on the boiler using the
BC10 basic controller.
LED Condition Explanation
ON Burner active The water in the boiler is being heated.
OFF Burner OFF The water in the boiler has reached the required temperature or
there is no heat request.
Table 4 LED indication

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Starting up the boiler
4 Starting up the boiler
4.1 Boiler settings
Turn the "space heating water temperature" and
"DHW temperature" rotary knobs to "Aut" (auto-
matic mode).
The control unit will now take control.
Slowly open the gas valve by pushing on the gas
valve and turning it ¼ rotation in an counterclock-
wise direction (fig. 3, pos. 1). The gas valve is
open when it is in its vertical position.
Open the pump group isolating valves (fig. 3,
pos. 2).
190
170
150
130
90
110
140
130
120
90
100
110
+
Fig. 3 Opening gas- and isolating valves
2
1

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Starting up the boiler
Set the main switch on the basic controller to
position "1" (ON). The basic controller checks the
current system status and the burner becomes
operational as soon as there is a heat request.
This procedure takes approx. 30 seconds.
Adjust the settings on the control unit (see the
Operating Instructions for the control unit).
4.2 Check the system pressure
If the heating system has just been filled, the system
pressure must initially be checked every day, for
1 week.
The maximum pressure in the heating system,
measured directly at the boiler, must not exceed
51 psi (3.5 bar).
Press the "Service" button (fig. 1, pos. 4) until the
system pressure ("P22") is shown in the display
(pos. 9).

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Starting up the boiler
Fill the heating system if the system pressure
has dropped below 15 psi (1.0 bar) according
to paragraph “Fill the heating system” on
page 20.
4.3 Fill the heating system
Remove the lower casing from the pump group
(fig. 4).
Fig. 4 Removing the lower casing