Buderus Logamax plus GB162 Instructions for use

WARNING!
Improper installation, adjustment, alteration, service or maintenance
can cause injury, loss of life or property damage. Refer to the
installation and operating manuals. For assistance or additional
information, consult a trained and certified installer, service agency
or the gas supplier.
CAUTION!
The installation and operating manuals are 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 the appliance and its operation.
NOTICE!
In the Commonwealth of Massachusetts this boiler must be installed
by a licensed Plumber or Gas Fitter.
Applications Manual Gas condensing boiler
Logamax plus GB162

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GB162 Applications Manual | 3
Table of Contents
1 Reference Documents 4
2 Boiler Components & Controls 5
2.1 Periphery 6
2.2 Low Loss Header (LLH) 7
2.3 Cascade Kits 9
2.4 AM10 Outdoor Reset Modulating Boiler Control 10
2.5 RC35 Room Controller and User Interface 14
2.6 0-10V BMS Interface & Common Fault Module EM10 22
2.7 MCM10 Multi Cascade Module 23
3 Sample Applications 27
Legend 28
3.1 System 1: Single boiler with outdoor reset, multiple
heating zones with zone pumps and DHW 29
3.2 System 2: Single boiler with outdoor reset, multiple
heating zones with zone valves and DHW 33
3.3 System 3: Single boiler with one heating zone,
outdoor reset with room feedback and DHW priority 37
3.4 System 4: Single boiler with RC35, one heating
zone, & solar thermal DHW 41
3.5 System 5: Multi boiler system with staging control
and outdoor reset 45
3.6 System 6: Multi-boiler Cascade I 49
3.7 System 7: Multi-boiler Cascade II 53
Appendix 57
Appendix 1 - Single boiler with 0-10V heat demand input 58
Appendix 2 - Multi-boiler cascade with 0-10V heat
demand input 60
Appendix 3 - Adding DHW priority to System 1 62
Appendix 4 - Adding DHW priority to a multi-boiler
cascade 64

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1 Reference Documents
The following table references all related documentation to the
GB162 series boiler. To obtain copies of these documents,
please go to our website at www.buderus.us.
Document Name Description Of Contents
Installation Instructions • Safety and general instructions
• Product specifications
• Installation
• Electrical connections
• Operation (start-up and shut down procedure)
Maintenance and Service Instructions • Product description
• Safety and general instructions
• Operation
• Symptoms
• Diagnosis
• Inspection / Maintenance
Operating Instructions • Safety information
• Lighting instructions
• Operating the BC10 basic controller
• Boiler start-up and shut down
• Operating and error messages
Installation Instructions - Pump Group • Safety and general information
• Dimensions and connections
• Items supplied with pump group
• Installation
Installation Instructions - Cascade Frame • General information
• Items supplied with the unit
• Cascade configurations
• Dimensions
• Installation
Record Book - Water Quality Requirements • Requirements
• Operator‘s log
Gas Valve Replacement Instructions • Safety considerations
• Parts list
• Gas valve replacement
• Operating instructions
Propane Conversion Kit Instructions • Safety considerations
• Parts list
• Liquid Propane conversion
• Operating instructions
Technical Service Bulletin:
TBG-07_Boiler Water Chemistry & Freeze Prevention Guidelines • Recommended steps for commissioning boiler • Water chemistry guidelines
• Dielectric isolation
• Cleaning requirements
• Fill water and chemistry
• Eliminating system leaks
• Aluminum safe anti-freeze guidelines
• Buderus selected suppliers of water treatment products
Table 1

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This chapter outlines the various components available
with the GB162 series boiler along with the following control
options:
• AM10 - Outdoor Reset Modulating Boiler Control
• MCM10 - Multi-boiler Cascade Module
• RC35 - Energy Management System (EMS) with
Outdoor Reset, Room Reset, Zoning and Solar
Thermal capabilities
• Logamatic 4000 Control System (see Logamatic 4000
Applications Manual)
This manual outlines the most common applications available
using these components and controls. These application
sections contain diagrams of preferred piping with associated
wiring diagrams and controller programming, along with
additional important information.
2 Boiler Components & Controls

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2.1 Periphery
National or local code may require the installation of an external
Low Water Cut-Off (LWCO) and/or an External Manual Reset
High Limit.
Notes:
1. Contractor to furnish and install LWCO and Manual Reset
High Limit devices as required by local codes.
2. Do not install any type of valve or check valve in between
boiler and LWCO or Manual Reset High Limit.
3. Refer to the manufacturer’s instructions when installing
LWCO and Manual Reset High Limit.
4. LWCO is installed external to the boiler and must
be located above the highest point of the boiler heat
exchanger.
5. Manual Reset High Limit remote sensing bulb must be
located in the boiler supply.
6. In a cascade each boiler must be equipped with its own
LWCO and Manual Reset High Limit.
Fig. 1 Low Water Cutoff views
NOTE: Power supply to LWCO and external high limit not shown for
Installation instructions (Fig. 1):
At the back of the boiler manifold remove the 1” plug and
connect a 1” Tee. At the horizontal end connect a 1” well for
the Manual Reset High Limit probe. At the vertical connector
of the Tee, install a 1” stand pipe that reaches above the
highest point of the boiler heat exchanger. Install a second
Tee with an automatic air vent at the top and a LWCO just
below.
Wire the LWCO and the Manual Reset High Limit 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.
2.1.1 Low Water Cut-off (LWCO) and External Manual Reset High Limit
clarity. Follow manufacturer’s instructions.

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2.2 Low Loss Header (LLH)
2.2.1 General Information
GB162GB162
Fig. 2 Two Boiler System with Low Loss Header
Supply
Supply
Return Return
BOILER SYSTEM
Fig. 3 Low Loss Header Overview
Modern compact wall hung gas appliances are often equipped
with boiler controlled modulating pumps, some of which are
also used for making DHW. These pumps are operating in ways
that optimize boiler efficiency and longevity, but are not suitable
for supplying the system at the same time. As a result the
system must be set up with hydraulic separation between the
primary and secondary sides.
A LLH is nothing more than a large pipe, installed between the
heat sources and the system. It is used in single or multi boiler
installations of appliances with small water volumes to separate
the flow of water and heat between boiler and the system loops.
When the circulating volumes between boiler loop and system
loop differs greatly, a LLH can help avoid over flowing or under
flowing one or the other. Over flowing can lead to noise and
erosion in the piping, and can be identified by a boiler or system
not coming up to temperature, or by a narrow delta T. Under
flowing means that the heat is not being transported away from
the boiler, causing it to bounce off the high limit. In the system
under flowing can result in too great a delta T, resulting in
considerable heat being shed in the beginning of the loop and
insufficient heat left for the remainder of the loop.
Installation of a LLH however requires a pump on the boiler
side and one on the system side.
As their flow rates are typically low, some manufacturers design
a LLH to include an air eliminator and dirt separator.
A LLH is required in systems with low mass boilers and multiple
zones with zone pumps. The LLH ensures a constant flow rate
through the boiler independent of how many zones are calling
and independent of the flow rate in the system loop. It prevents
pumps from working against each other, resulting in balanced
flows, even heat distribution, and reduction of potential noise.

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Possible scenarios of the LLH:
V₂V₁
R₂R₁
V₂V₁ V₂V₁
Both primary and secondary flow rates are
identical.
The boiler flow rate is greater than the
system flow rate and hot supply water is
returning to the boiler.
The system flow rate is greater than the
boiler flow rate and cold return water is sent
back out to the system.
R₂
R₁ R₂
R₁
Fig. 4 Three possible flow patterns with a LLH
LLH are equipped with a well for a system strategy sensor to
measure supply water temperature.
A LLH is oversized to a point that it can handle the maximum
possible flow rates on either side without significant pressure
drop.
In the center of the LLH is the point of equilibrium and zero
pressure. It allows for a variety of flow rates to occur on both
sides of the system without influencing the other side.
A common case from retrofit applications: The system pumps
are too strong and remove more water from the LLH than
delivered by the boiler. With the consequence that none of
the zones gets up to temperature. Required measure: reduce
system flow rates.
For system redundancy, energy optimization, or combination
of different fuel types, different boiler types or models may be
combined in systems. Based on the load this allows turning
off complete appliances resulting in higher efficiencies of the
remaining system.
When a larger heat demand occurs additional boilers can be
enabled one by one. The changing flow rates are balanced by
the LLH and all boilers and zones in operation are continued to
be supplied with the necessary volumes.
To ensure efficiency while also providing redundancy, each
boiler must have its own boiler pump.
In particular when an existing system is retrofit with a new boiler
it is necessary to evaluate the boiler and system flow rates. A
reduction of boiler output can in many cases reach 40% and
completely change system hydraulics.
Example:
Old boiler output 480 MBH (140 kW)
New boiler output: 340 MBH (100 kW)
The new system requires a system flow rate of 19 gpm (4300
liters/hr) at 36°F (20°C) delta T.
As older systems are typically equipped with oversized pumps,
the retrofit system can be expected to use pumps that may
be half the size of the old ones. In this case only a LLH allows
balancing of the primary and secondary flow rates.
It is recommended to use multi speed or ECM pumps.
Sizing a Low Loss Header
Size the pumps and LLH by the greater of the two volumes that
is circulating: boiler circuit or system circuit.
.
Note: It is recommended to set the minimum delta T between
boiler supply and boiler return to 20 to 25°F (10 to 15°C) by
adjusting the speed of the circulator or installing flow setters.
For sizing a LLH at maximum throughput the flow rate should
not exceed 0.67 feet/second (0,2 m/s). This makes the LLH
the area of slowest velocity and allows it to be used as an air
separator and dirt separator.
Over sizing a LLH however does not have negative
consequences on the system. In fact a buffer tank can be used
instead of a LLH.

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GB162 Applications Manual | 9
Buderus offers cascade systems in TL and TR configurations for
up to 4 boilers. For cascades of 5 to 16 boilers use single boiler
manifolds.
TL - Inline installation
All boiler assemblies are installed in one line, enabling an
easy-to-monitor installation in a narrow room.
TR - Back-to-back installation
The boiler assemblies are installed back-to-back on both
sides of a free standing frame, to create a compact installation
which ideally suits rooms without available wall space and
ensures the best possible access to all boilers.
The relevant configuration can be selected on the basis of
the performance required (see table 2).
System gross output Cascade
system options
TL = inline
TR = back-to-
back
Number of
boilers
GB162
Natural
gas LPG
k.Btu/hr k.Btu/hr kW 80
kW 100 kW
290 270 80 Single installation 1 –
333 315 100 Single installation – 1
580 540 160 TL2 or TR2 2 –
623 585 180 TL2 or TR2 1 1
666 630 200 TL2 or TR2 – 2
870 810 240 TL3 or TR3 3 –
913 855 260 TL3 or TR3 2 1
956 900 280 TL3 or TR3 1 2
999 945 300 TL3 or TR3 – 3
1,160 1,080 320 TL4 or TR4 4 –
1,203 1,125 340 TL4 or TR4 3 1
1,246 1,170 360 TL4 or TR4 2 2
1,289 1,215 380 TL4 or TR4 1 3
1,332 1,260 400 TL4 or TR4 – 4
Table 2 Cascade selection
Low loss
header TL- configuration (inline) TR- configuration (back-to-back)
2½“ TL2, TL3 TR2
3“ TL4 TR3, TR4
4“ 5 boilers and more
Table 3 Low loss header configuration
The Logamax plus GB162 cascade system can be installed
in 2 different configurations (fig. 5).
The gas connection can be made to either side of the
boilers, independent of the supply and return connections.
TR conguration
TL conguration
Fig. 5 Cascade system configuration varieties
2.3 Cascade Kits

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Product Description
The AM10 is a modulating outdoor reset control for Buderus
boilers equipped with the EMS bus. It sets the supply water
temperature based on outdoor temperature. The boiler fires,
runs and modulates based on the information received from the
AM10, and the delta T between supply and return.
An ON/OFF signal from a third party room thermostat or
zone controller (not included) is used to communicate a heat
demand. TheAM10 offers warm weather shutdown (WWSD)
when the outdoor temperature rises above a custom setable
temperature (default: 70°F (21°C)).
To control and stage multiple boilers, combine the AM10 with an
MCM10 cascade module.
Outdoor reset
Outdoor reset is a way to economically control space heating
based on the outdoor temperature. It functions based on the
fact that the colder the weather the greater the heat loss of a
structure, and the higher the supply water temperature needed
to heat the house. On a warmer day with smaller heat loss a
lower water temperature will be able to heat the house. This has
several advantages:
1. Save fuel by running the boiler at lower temperatures
which reduces the heat going up the chimney.
2. Lower water temperatures allow taking advantage of the
energy trapped in the flue gases (latent heat) in a
condensing appliance.
3. Added comfort because temperature changes are not felt
with lower water temperatures running constantly.
To achieve these goals the reset curve must be properly
adjusted to match the application and the heat loss of
the structure. The reset curve tells the boiler what water
temperature is needed at a certain outdoor temperature.
Outdoor reset is the preferred control when using multiple
zones, as the boiler supply water temperature is not dictated by
a master or largest zone, but solely based on the heat loss of
the structure.
Fig. 6 AM10 Modulating Control
2.4 AM10 Outdoor Reset Modulating Boiler Control

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GB162 Applications Manual | 11
Heating curve
The AM10 has a built in linear heating curve that sets the supply
water temperature in relation to the outdoor temperature.
Top of heating curve represents the water temperature at 14°F
(-10°C) outdoor temperature. Based on type of heating system
different water temperatures are recommended for bottom of
heating curve. The boiler follows the heating curve in theAM10
up to the maximum supply water temperature set on the boiler
dial which works as a high limit. In addition the warm weather
shut down (WWSD) turns the heating system off when the
temperature outdoors rises above a certain value.
Heating curve chart in Degrees Fahrenheit:
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
-1001020304050607080
Outdoor Temperature [°F]
Supply Water Temperature [°F]
194
14
WWSD factory default
Boiler High Limit
Upper Reference point
Heating curve base point
Use high limit to prevent
radiant floor damage
from overheating.
(not in cascades)
Radiant Floor
Panel
Radiators
Baseboard
Hydro Air
Cast Iron Radiators
Fig. 7 Heating curve chart in Degrees Fahrenheit
Outdoor
Temperature Radiant Floor Panel
Radiators Cast Iron Radiators Baseboard Hydro Air
(°F)
0 120 176 162 184 190
14 120 160 150 167 182
68 86 100 100 100 150
70 85 98 98 98 148

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Heating curve chart in Degrees Celsius:
F
0
10
20
30
40
50
60
70
80
90
100
-20
-15-10-5
0
5
10
152025
Outdoor Temperature [°C]
Supply Water Temperature [°C]
WWSD factory default
Boiler High Limit
Upper Reference point
Heating curve base point
Use high limit to prevent
radiant floor damage
from overheating.
(not in cascades)
90
Radiant Floor
Panel
Radiators
Baseboard
Hydro Air
Cast Iron Radiators
ig.8 Heating curve chart in Degrees Celsius
Outdoor
Temperature Radiant Floor Panel
Radiators Cast Iron Radiators Baseboard Hydro Air
(°C)
-18 49 80 72 84 88
-10 49 71 66 75 83
20 30 38 38 38 65
21 29 37 37 37 64

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GB162 Applications Manual | 13
WWSD
Warm weather shut down (WWSD) temperature is factory set
for 70°F (21°C). If the outdoor temperature rises above this
setting, the boiler will be turned off except for generating DHW.
The value can be adjusted between 32°F (0°C) and 86°F
(30°C).
Mounting of the AM10
The recommended mounting locations are either on the wall
next to the boiler or on the boiler jacket. A mounting bracket is
included with the controller.
Positioning the outdoor sensor
For best performance the outdoor sensor is to be positioned at
a location where it is not influenced by sunlight. Mount only on a
North facing wall of the building, and at least 1 foot above snow
line. Keep the sensor away from heat sources such as a dryer,
water heater, or boiler vents, windows, etc.
Multi-Zone Relay Box
Fig. 9 Installation example with zone relay box
Single Boiler Control
To equip a single GB162 boiler with outdoor reset control, the
following items are recommended: (not included)
• ON/OFF thermostat for each heating zone
• Pump relay or zone valve panel according to the number of
zones
• Low and high voltage wiring
Wiring Details:
If there are multiple zones, wire all closed contacts to the AM10
so that each call for heat produces a heat demand.
Set the BC10 central heating dial to automatic (AUT), unless the
system consists exclusively of low temperature radiant, where
the central heating dial can be used as a high limit protection.
(not with MCM10).
Note: Do not install an RC10, EM10, or RC35 when using this
configuration as these devices do not coexist with the
AM10. For multi-boiler systems add the MCM10 cascade
module between the AM10 and the boilers.

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The RC35 is an outdoor reset based heating system
control with room influence and optional solar thermal DHW
generation.
2.5.1 Features and benefits
Control features
• Outdoor reset
• Room reset
• Setback options
- Room setback
- Night setback
- Outdoor setback
- Shut-down
• 8 pre-loaded time programs with option to create custom
program
• System Efficiency
- Microprocessor coordinates boiler operation to ensure
maximum comfort with optimized energy usage
- Adjustable warm weather shut down (WWSD)
- Room influence setting to prevent zone overheating
• Monitoring
- Monitoring of system data including operating hours and
burner starts
- Solar thermal gain monitoring in combination with SM10
module
• User friendly
- Easy to use due to LCD display with full text
- Relay testing for start-up, commissioning and
troubleshooting to verify proper wiring
• Service information
- Service and diagnostic system simplifies troubleshooting
- Maintenance reminder feature alerts the operator when
servicing is due
• Modular structure of the control system allows customizing
for many applications
- Up to 4 heating zones (3 mixed, 1 unmixed) using 3
MM10 - Mixing Modules
- Solar thermal integration for DHW generation using
SM10 - Solar Thermal Module
- Integration of a low loss header using WM10 - Low Loss
Header Module
- Cascade up to 16 boilers using up to 4 MCM10 - Multi-
Boiler Cascade Modules. Buderus offers prefabricated
cascade manifolds with LLH for 2, 3 and 4 boilers.
- DHW preparation including control of a DHW
recirculation pump
2.5.2 Overview
1
2
3
4
5
67
8
9
10
11
71.9 °F
Room
THU 06.07. 2011 4:45pm
Fig.10 Description of the RC35 room control
1: Automatic mode (switching program)
2: Continuous heating (day temperature)
3: Permanently reduced (night temperature)
4: DHW single charge button
5: Change temperature temporary
6: Back
7: Show data
8: Set day or night temperature
9: Set current date
10: Set current time
11: Open User menu
2.5 RC35 Room Controller and User Interface

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GB162 Applications Manual | 15
2.5.3 RC35 room control programming aspects
User menu:
Standard display
Modes of operation
Switching program
Warm weather shut down (WWSD)
DHW temperature
Vacation
Party program
Pause function
Thermal desinfection
71.9 °F
Room
THU 06.07. 2011 4:45pm
User Menu
Service menu:
Quick operation
Settings
Diagnosis
Servicing
Reset
++
71.9 °F
Room
THU 06.07. 2011 4:45pm
Service Menu

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2.5.4 RC35 wiring diagrams
The RC35 user interface can be installed in a reference room to
utilize the internal thermostat for room reset, or in a dedicated
bracket in the boiler if room influence is not required.
Mounting the RC35 in the room and utilizing its
internal room sensor:
Fig.11 RC35 wiring using its internal room sensor
Mounting the RC35 in the room and utilizing a remote
room sensor (part number: 5 993 226):
Fig.12 RC35 wiring using its remote room sensor

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GB162 Applications Manual | 17
2.5.5 EMS modules for RC35
Single Mixed Heating Zone Module MM10
This module is needed to operate a mixed heating zone pump
and motorized mixing valve. The RC35 can control up to 3
MM10 modules per system.
Features of the MM10:
• Room reset, outdoor reset, outdoor reset with room influence.
• Keyed and color coded connecting plugs
• Sends a quantified heat demand to the boiler
• Mounting: In the boiler or on the wall
• LED indicator for mode of operation
• Up to 3 modules per heating system
• Uses the RC35 user interface
• 120V supply
• Each module allows it’s own temperature zone and timer
program
• Selectable set back options for each individual zone
• Anti-freeze protection per zone
• Pump anti-seize function
• Input: 1 x Heating Zone Supply Sensor
• Outputs: 1 x Heating Zone Pump 120V
1 x 3-way Floating Mixing Valve 120
Unmixed Heating Zone & Low Loss Header Module
WM10
The WM10 has two functions:
1. Runs one unmixed heating zone
2. Controls the hydraulic separation between the boiler loop
and system loop in systems with a low loss header (LLH)
Features of the WM10:
• In an unmixed heating zone a separate timer program can
be selected.
• Keyed and color coded connecting plugs
• Communication with EMS boiler-data bus
• Mounting: In the boiler or on the wall
• LED indicator for mode of operation
• 1 module per heating system
• 120V supply
• Input: 1 x Heating Zone Supply Sensor or System Supply
Sensor
• Output: 1 x Heating Zone Pump 120V or System Pump 120V
Fig.13 Single Mixed Heating Zone Module MM10
Fig.14 Unmixed heating zone and Low loss header Module
WM10

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Solar Thermal DHW Module SM10
The SM10 Module integrates a Solar Thermal DHW system
with an EMS boiler system which provides significant energy
savings for DHW generation. The integrated system knows
when solar energy is available and reduces boiler run time and
boiler starts.
Features of the SM10:
• Keyed and in color coded connecting plugs
• Communication with EMS boiler-data bus
• Mounting: In the boiler or on the wall
• LED indicator for mode of operation
• 1 module in a heating system
• Solar pump modulation 20-100% to maximize solar gain
• 120V supply
• Input: 1 x Collector Sensor
1 x Solar Tank Sensor (Bottom)
• Outputs: 1 x Solar Thermal Pump 120V Fig.15 Solar Thermal DHW Module SM10

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GB162 Applications Manual | 19
2.5.6 Mixing Module MM10 Wiring Diagram
120
14AWG
L
120 V 60Hz
120 V 60Hz
14AWG,
Max. 5A
14AWG,
Max. 5A 18AWG
18AWG 18AWG
Main power supply
run time:
Valve actuator
motor
System
-+-+
2)
1) Requires 120V mixing valve with 3-point floating actuator.
Maximum current: 5A
2) Hot: increase hot water delivery to zone
Cold: decrease hot water delivery to zone
Fuse
5 AT
Notes:
Polarity matters on EMS/RC bus: Connect 1 to 1 and 2 to 2.
Implement the installation, fuse protection, main isolator,
emergency stop switches and safety measures in accordance with
local/national regulations.
Warning! Ground yel/grn must not be used as a control line.
Ensure phases are connected correctly.

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2.5.7 WM10 - System or Low Loss Header
Module Wiring Diagram
120
L
120 V 60Hz
14AWG
120 V 60Hz
Main power
14AWG,
Max.5A
18AWG 18AWG 18AWG
zone
low loss
header
-+-+
Notes:
Polarity matters on EMS/RC bus: Connect 1 to 1 and 2 to 2.
Implement the installation, fuse protection, main isolator,
emergency stop switches and safety measures in accordance with
local/national regulations.
Warning! Ground yel/grn must not be used as a control line.
Ensure phases are connected correctly.