Buderus Logano plus GB402 Instruction Manual

Read carefully prior to operation.
6720865368 (2019/05) GB
Operating instructions for users
Gas-fired condensing boiler
Logano plus
0010018644-002
GB402-395...620

Table of contents
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Table of contents 1 Explanation of symbols and safety instructions
1.1 Explanation of symbols
Warnings
In warnings, signal words at the beginning of a warning are used to
indicate the type and seriousness of the ensuing risk if measures for
minimising danger are not taken.
The following signal words are defined and can be used in this document:
DANGER:
DANGER indicates that severe or life-threatening personal injury will
occur.
WARNING:
WARNING indicates that severe to life-threatening personal injury may
occur.
CAUTION:
CAUTION indicates that minor to medium personal injury may occur.
NOTICE:
NOTICE indicates that material damage may occur.
Important information
The info symbol indicates important information where there is no risk to
people or property.
Additional symbols
Table 1
1 Explanation of symbols and safety instructions . . . . . . . . . . . 2
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . 3
2 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Water quality (fill and top-up water) . . . . . . . . . . . . . . . . 5
2.3 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.1 Product information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Checking the operating pressure, topping up the
heating water and venting the system. . . . . . . . . . . . . . . 7
3.1.1 Checking the operating pressure . . . . . . . . . . . . . . . . . . 7
3.1.2 Topping up the heating water and venting the
system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Switching on the heating system. . . . . . . . . . . . . . . . . . . 7
4 Shutting down the heating system . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Shutting down the heating system via the control
unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Shutting down the heating system in an
emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 What makes regular service important? . . . . . . . . . . . . . 8
5.2 Cleaning and care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Recognising the operating condition and clearing
faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 Product data for energy consumption. . . . . . . . . . . . . . . 9
7.2 Environmental protection/disposal. . . . . . . . . . . . . . . . . 9
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document
• a list entry
– a list entry (second level)

1
Explanation of symbols and safety instructions
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1.2 General safety instructions
HInstructions for the target group
These operating instructions are intended for the
heating system user.
All instructions must be observed. Failure to comply
with instructions may result in material damage and
personal injury, including possible loss of life.
▶ Read and retain the operating instructions (heat
source, heating controller, etc.) prior to operation.
▶ Observe the safety instructions and warnings.
HSafety of electrical devices for domestic use
and similar purposes
The following requirements apply in accordance with
EN 60335-1 in order to prevent hazards from
occurring when using electrical appliances:
“This appliance can be used by children of 8 years and
older, as well as by people with reduced physical,
sensory or mental capabilities or lacking in experience
and knowledge, if they are supervised and have been
given instruction in the safe use of the appliance and
understand the resulting dangers. Children shall not
play with the appliance. Cleaning and user
maintenance must not be performed by children
without supervision.”
“If the power cable is damaged, it must be replaced by
the manufacturer, its customer service department or
a similarly qualified person, so that risks are avoided.”
HDanger through failure to consider your own
safety in an emergency such as a fire
▶ Never put yourself at risk of fatal injury. Your own
safety is paramount.
HIf you smell gas
▶ Close gas isolator.
▶ Open windows and doors
▶ Never operate electrical switches, including
telephones, plugs or doorbells.
▶ Extinguish any naked flames. Do not smoke! Never
use any lighters or sources of ignition of any kind!
▶ Warn all occupants in the building, but do not ring
doorbells.
▶ If you can actually hear gas escaping, leave the
building immediately. Prevent third parties from
entering and notify police and fire brigade from
outside the building.
▶From outside the building, call your gas supplier
and licensed contractor.
HDanger if you smell flue gas
▶ Switch off the boiler.
▶ Open windows and doors.
▶ Notify an approved contractor.
HDanger to life from carbon monoxide
Carbon monoxide (CO) is a poisonous gas, which
arisesduringtheincompletecombustionoffossil fuels
such as oil, gas or solid fuels.
Dangers arise, if carbon monoxide escapes from the
heating system due to a fault or a leak and collects
unnoticed in enclosed spaces.
You can neither see, taste nor smell carbon monoxide.
To avoid danger from carbon monoxide:
▶ Have the heating system inspected and serviced
regularly by an approved contractor.
▶ Use a CO detector, which gives an alarm in good
time if CO escapes.
▶ If you suspect a CO leak:
– Warn your neighbours and leave the building
immediately.
– Call an approved contractor.
– Have any defects rectified.
HInstallation and conversion
▶ Correct and proper installation and adjustment of
the burner and the control unit are the fundamental
requirements for safe and economical operation of
the floor standing boiler.
▶ Only permit an authorised contractor to install the
boiler.
▶ Never modify any parts for flue gas routing.
▶ Electrical work must only be carried out by qualified
electricians.
▶ With open-flue mode: do not cover or reduce the
size of ventilation apertures in doors, windows or
walls. If draught-proof windows are fitted, ensure
there is an adequate supply of combustion air.
▶ Use the DHW cylinder exclusively for heating hot
water.
▶Never shut off pressure relief valves!
Water may be expelled at the pressure relief valve of
the heating circuit and DHW pipework during heat-
up.

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HInspection/maintenance
Heating systems must be regularly maintained.
In that way, you will obtain a high level of efficiency and
low fuel consumption.
You will achieve a high level of operational safety and
reliability.
And you will obtain the cleanest possible combustion.
▶Recommendation for customers: arrange a
maintenance and inspection contract with an
authorised contractor, covering an annual
inspection and demand-dependent maintenance.
▶ Maintenance and repairs may only be carried out by
an authorised contractor.
▶ Have any faults immediately rectified to prevent
damage to the system.
▶ The user is responsible for ensuring the heating
system is safe and environmentally compatible.
▶ Only use genuine spare parts! Damage caused by
the use of spare parts not supplied by Buderus is
not covered by the warranty.
HDanger posed by explosive and easily
flammable materials
▶ Any work on components that carry gas may only be
carried out by an approved contractor.
▶ Never use or store easily flammable materials
(paper, thinners, paints etc.) near the boiler.
HDanger of poisoning
Insufficient ventilation can lead to dangerous flue gas
leaks.
▶ Ensure that ventilation or extract air apertures are
not reduced or closed.
▶ Faults should be rectified without delay, otherwise
the boiler must not be operated.
▶ If flue gas enters the installation location, ventilate
and vacate the area and if necessary call the fire
brigade.
▶ Inform the system user in writing of the problem and
associated danger.
HDanger of water damage
▶ In the event of severe risk of flooding, shut down the
power and fuel supply to the device before water
enters the installation location.
▶ Never use the device if any part of it has been under
water.
▶ Immediately get in touch with a qualified service
technician to have the device inspected and have
any part of the control system and any air/gas ratio
control valves that have been under water replaced.
HCombustion air/ambient air
The air in the installation location must be free of
flammable or chemically aggressive substances.
▶ Do not store or use any corrosive substances
(solvents, adhesives, chlorinated cleaning agents,
etc.) within the vicinity of the heat source.
▶ Avoid very dusty atmospheres.
HRisk of damage from operating errors
Operator errors can result in personal injury and/or
material damage.
▶ Ensure that children never operate this appliance
unsupervised or play with it.
▶ Ensure that only personnel who can operate this
appliance correctly have access to it.
HAdditional important notes
▶ Never switch off or interrupt the power supply to
the pump in case of overheating or if the gas supply
does not shut down. Instead, interrupt the gas
supply at another point outside the heating system.
▶ The flue system must be checked annually. During
this inspection, have a contractor replace any parts
that show signs of damage through corrosion or
other causes.
▶ The boiler must be serviced annually by a qualified
service provider. The inspection must include the
main burner, the entire flue gas and air supply
system and the ventilation apertures or air inlet
openings. During this inspection, have a contractor
replace any parts that show signs of damage
through corrosion or other causes.

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Product Information
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2 Product Information
To ensure safe, economical and environmentally responsible use of the
heating system, we recommend that you read the safety instructions and
operating instructions carefully.
These instructions provide the operator of the heating system with an
overview of the use and operation of the boiler.
2.1 Declaration of Conformity
The design and operation of this product conform to European Directives
and the supplementary national requirements. Its conformity is
demonstrated by the CE designation.
You can view the Declaration of Conformity on the internet
(back cover).
2.2 Water quality (fill and top-up water)
▶ For information regarding the water quality, see the enclosed
operator's log "Water quality requirements for heat sources made
from aluminium".
2.3 Product overview
The GB402 is a floor standing condensing boiler with an aluminium heat
exchanger.
2.3.1 Product information
The main components of the Logano plus GB402 are:
• Control unit (not included in scope of delivery)
• Boiler block
• Appliance frame and casing
• Gas burner
The control unit monitors and controls all electrical components of the
floor standing boiler.
The boiler block transfers the heat generated by the burner to the
heating water. The thermal insulation reduces the radiation and standby
losses.
The control unit enables the basic operation of the heating system. It
provides the following functions, among others, for that purpose:
• Turning the heating system on/off
• Setting the DHW temperature and maximum boiler temperature in
heating mode
• Status display
The floor standing boiler can be operated with various Logamatic control
units, e.g. Logamatic 5313or 8313).
Operation of the floor standing boiler is only permitted with the control
unit also mounted on the boiler.
Many additional functions that enhance control and operating
convenience as well as providing information on the heating system
settings are described in the relevant technical documentation of the
installed control unit.

2Product Information
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Fig. 1 Logano plus GB402, 395...620 kW - main components
[1] Boiler front panel
[2] Air/gas ratio control valve
[3] Control unit
(shown for illustration purposes: Logamatic 5313or 8313)
[4] Gas burner with burner rod
[5] Boiler block with thermal insulation
[6] Boiler casing
[7] Differential pressure switch
[8] Condensation catch pan and siphon
[9] Burner control unit
0010018751-001
1
2
3
4
5
6
89 7

3
Commissioning
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3 Commissioning
3.1 Checking the operating pressure, topping up the
heating water and venting the system
3.1.1 Checking the operating pressure
Your heating contractor will have set the red needle of the pressure
gauge [1] to the required operating pressure (at least 1 bar) and will
have recorded this value in table 8, page 14.
▶ Check that the pressure gauge needle [2] is within the green band
[3}.
▶ If the pressure gauge needle drops below the green band, top up the
heating water.
Fig. 2 Pressure gauge for sealed systems
[1] Red needle
[2] Pressure gauge needle
[3] Green marking
Table 2 Operating pressure (entered by the heating contractor)
3.1.2 Topping up the heating water and venting the system
CAUTION:
Health risk through contaminated drinking water!
▶ Observe all country-specific regulations and standards regarding the
prevention of drinking water contamination.
▶ In Europe, observe standard EN 1717.
NOTICE:
Material damage due to thermal stresses!
When topping up a hot boiler with cold heating water, thermal stresses
can lead to cracking due to internal stress.
▶ Only fill the heating system when cold. Maximum flow temperature
40 °C.
NOTICE:
System damage due to frequent topping up!
If you have to top up the heating water frequently, the heating system
may suffer damage through corrosion or scaling, depending on the water
quality.
▶ Ask a certified heating contractor if the local water can be used
untreated or whether it needs to be treated.
▶ Notify your heating contractor if you frequently need to top up your
heating system.
Topping up heating water is different for individual heating systems.
Therefore, ask your approved contractor to advise you accordingly.
The refill quantities must be documented in the operator's log.
3.2 Switching on the heating system
Observe technical documentation of the installed control unit.
Before switching on (Chapter 2.3.1), ensure that:
• the operating pressure is high enough,
• the fuel supply has been turned on at the main shut-off valve, and
• the heating system emergency stop switch is switched on.
Operating pressure
Set operating pressure
(optimum value) _____________ bar
6 720 615 876-59.2T
3
2
1

4Shutting down the heating system
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4 Shutting down the heating system
4.1 Shutting down the heating system via the control unit
NOTICE:
Frost damage!
If the heating system is not standing in a frost-proof room and is not in
operation, it may freeze up when exposed to frost. In summer mode or if
heating mode is blocked, only the device frost protection remains active.
▶ Leave the heating system switched on at all times whenever possible,
and set the flow temperature to at least 30 °C,
-or-
▶ Protect the heating system against frost by having the heating and
DHW pipes drained by a contractor from the lowest point.
▶ Shutting down the heating system via the ON/OFF switch at the
control unit (Chapter 2.3.1).
4.2 Shutting down the heating system in an emergency
Only use the boiler room circuit breaker or heating system emergency
stop switch to switch off the heating system in an emergency.
▶ Never risk your own life. Your own safety is paramount.
▶ Close off the fuel supply installed on site.
▶ Isolate the heating system from the mains power supply via the
heating system emergency stop switch or the main circuit breaker.
5 Inspection and maintenance
5.1 What makes regular service important?
Heating systems should be regularly serviced for the following reasons:
• To maintain a high level of efficiency and to operate the heating
system economically (low fuel consumption)
• To achieve a high level of operational reliability
• To maintain the cleanest possible combustion
NOTICE:
Material damage due to a lack of or incorrect cleaning and service.
▶ Have the heating system inspected, maintained and cleaned once a
year by a certified heating contractor.
▶ We recommend you enter a contract covering an annual inspection
and demand-based maintenance.
5.2 Cleaning and care
To clean the boiler:
▶ Do not use abrasive or aggressive cleaning agents.
▶ Clean the casing with a damp cloth (soapy solution).
6 Troubleshooting
6.1 Recognising the operating condition and clearing
faults
NOTICE:
Frost damage!
If the heating system is not standing in a frost-proof room and is not in
operation, it may freeze up when exposed to frost. In summer mode or if
heating mode is blocked, only the device frost protection remains active.
▶ Leave the heating system switched on at all times whenever possible,
and set the flow temperature to at least 30 °C,
-or-
▶ Protect the heating system against frost by having the heating and
DHW pipes drained by a contractor from the lowest point.
If a fault has developed, the fault code flashes on the control unit display.
For more information on rectifying the problem or on possible faults,
refer to the corresponding technical documentation of the installed
control unit.
If the fault cannot be cleared:
▶ Note down the fault message and notify a heating contractor.

7
Appendix
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7 Appendix
7.1 Product data for energy consumption
The following product data satisfy the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013
supplementing Directive 2010/30/EU.
Table 3 Product data for energy consumption
7.2 Environmental protection/disposal
Environmental protection is a fundamental corporate strategy of the
Bosch Group.
The quality of our products, their economy and environmental safety are
all of equal importance to us and all environmental protection legislation
and regulations are strictly observed.
We use the best possible technology and materials for protecting the
environment taking account of economic considerations.
Packaging
Where packaging is concerned, we participate in country-specific
recycling processes that ensure optimum recycling.
Allof ourpackagingmaterialsareenvironmentallycompatible and canbe
recycled.
Used appliances
Used appliances contain valuable materials that can be recycled.
Thevarious assembliescan be easilydismantled. Synthetic materialsare
marked accordingly. Assemblies can therefore be sorted by composition
and passed on for recycling or disposal.
Used electrical and electronic appliances
Electrical or electronic devices that are no longer
serviceable must be collected separately and sent for
environmentallycompatible recycling(in accordance with
the European Waste Electrical and Electronic Equipment
Directive).
To dispose of old electrical or electronic devices, you
should use the return and collection systems put in place in the country
concerned.
Batteries must not be disposed together with your household waste.
Used batteries must be disposed of in local collection systems.
Gas type G20 8732923571
Gas type G25 8732923664
Product data Symbol Unit
Product type – – GB402-395
Floor standing condensing boiler – – Yes
Specified heat output Prated kW 367
Available heat output
At rated heat output and high temperature regime1)
1) High-temperature operation means a return temperature of 60 °C at the boiler inlet, and a flow temperature of 80 °C at the boiler outlet.
P4kW 367.4
At 30 % of rated output and low-temperature operation2)
2) Low-temperature operation means a return temperature (at the boiler inlet) of 30 °C for floor standing condensing boilers, of 37 °C for floor standing boilers, and 50 °C for
other boilers
P1kW 121.8
Useful efficiency
At rated heat output and high temperature regime1) 4% 88.7
At 30 % of rated output and low-temperature operation2) 1% 97.2
Auxiliary electricity consumption
At full load elmax kW 0.449
At part load elmin kW 0.045
On standby PSB kW 0.005
Other items
Standby heat loss Pstby kW 0.828
NOx emissions NOx mg/kWh 36

Buderus
Cotswold Way, Warndon, Worcester WR4 9SW
All Enquiries: 0330 123 3004
www.buderus.co.uk
In the UK and IE, Buderus is a brand name
of Bosch Thermotechnology Ltd.