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Service manual - Logamax plus GB142 (USA/CA) - en - Buderus

Service manual - Logamax plus GB142 (USA/CA) - en - Buderus

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Servicing instructionsCond<strong>en</strong>sing gas boilerWARNING!Improper installation, adjustm<strong>en</strong>t, alteration, service or maint<strong>en</strong>ance cancause injury, loss of life or property damage. Refer to this <strong>manual</strong>. Forassistance or additional information consult a qualified installer, serviceag<strong>en</strong>cy or the gas supplier.NOTICE!In the Commonwealth of Massachusetts this boiler must be installed by alic<strong>en</strong>sed Plumber or Gas Fitter.Warning: If the information in these instructions isnot followed exactly, a fire or explosion may resultcausing property damage, personal injury or death.– Do not store or use gasoline or other flammable vapors and liquids inthe 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 yourbuilding.• Immediately call your gas supplier from a neighbor’s phone. Followthe gas supplier’s instructions.• If you cannot reach your gas supplier, call the fire departm<strong>en</strong>t.– Installation and service must be performed by a qualifiedinstaller, service ag<strong>en</strong>cy or the gas supplier.Notice:This <strong>manual</strong> must be retained for future refer<strong>en</strong>ce.7214 9400 (11/2011) US/<strong>CA</strong><strong>Logamax</strong> <strong>plus</strong><strong>GB142</strong>-24/30/45/60For installersPlease read thoroughlybefore servicing


PrefaceAbout these instructionsThese Servicing Instructions contain important information todiagnose and resolve issues concerning the <strong>GB142</strong> boiler withcapacities 24, 30, 45 and 60 kW.These Servicing Instructions are int<strong>en</strong>ded for specialist installers,who have the necessary training and experi<strong>en</strong>ce for workingon heating and gas systems.Subject to technical changes!Slight changes may be made to the illustrations, process stepsand technical data as a result of our policy of continuousimprovem<strong>en</strong>t.Updating of docum<strong>en</strong>tationPlease contact us if you have any suggestions for improvem<strong>en</strong>tsor corrections.2<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


1Safety and g<strong>en</strong>eral instructions1.8 AbbreviationsAM10 = Outdoor reset moduleAS = System fault codeAV = Air V<strong>en</strong>tBC = Operating codeBC10 = Control panel (on the boiler)BCT = Boulter <strong>Buderus</strong> cylinder thermostatBDV = Boulter <strong>Buderus</strong> diverter valveBKS = Blocking boiler fault codeCB = Connection BlockCH = C<strong>en</strong>tral HeatingCHF = C<strong>en</strong>tral Heating SupplyCHR = C<strong>en</strong>tral Heating ReturnCM10 = Cascade moduleCT = Cylinder ThermostatCWDO = Cond<strong>en</strong>sate water drainage outletCM10 = Cascade moduleDHW = Domestic Hot WaterDV = Diverter ValveE = EarthEM10 = External control moduleEMS = Energy managem<strong>en</strong>t systemFA = Outdoor s<strong>en</strong>sorHK1 or HK2 = C<strong>en</strong>tral Heating lineKIM = Boiler id<strong>en</strong>tification moduleL = Live LineLED = Light Emitting DiodeLSV = Lock Shield ValveMCW = Mains Cold WaterMM10 = Controler for HK2, second C<strong>en</strong>tral Heating line module.N = NeutalPE = GroundPL = Perman<strong>en</strong>t hot lineProg = ProgrammerRT or RC = Room ThermostatSC = <strong>Service</strong> codeT = TimerTRV = Thermostatic Radiator ValveÜC = Other display codesUBA 3 = Universal automatic burner control unit 3VKS = Locking boiler fault codeWC = Wiring C<strong>en</strong>treWM10 = Controler for HK1, first C<strong>en</strong>tral Heating lineZV = Two Port Zone Valve6<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


3Product description3 Product description6786 79101185412135491011123329291 14 15 16fig. 1 <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30 (left) and <strong>GB142</strong>-45/60 (right)pos. 1: Drawer with control unitpos. 2: Universal Burner Automat (UBA 3)pos. 3: Control unit BC10pos. 4: Gas valvepos. 5: Coverpos. 6: Flue measuring pointspos. 7: Parallel fluepos. 8: Burnerpos. 9: Latches of which two have locks11415 13 16 17pos. 10: Sighting glasspos. 11: Heat exchangerpos. 12: Back coverpos. 13: Air intake for the fanpos. 14: Fanpos. 15: Cond<strong>en</strong>sate trap and internal cond<strong>en</strong>sate drain fluegas pipepos. 16: External Connection Board (under the cover)pos. 17: Pressure s<strong>en</strong>sor23 45 61009011012013014090110130150170190112 11 10fig. 2 Basic Controller Logamatic BC10pos. 1: Main switchpos. 2: DHW temperature knob 1)pos. 3: LED "DHW status"pos. 4: Displaypos. 5: Space heating water temperature knobpos. 6: LED "Heating system status"98pos. 7:pos. 8:pos. 9:Under the cover a RC system controller can be installed.LED "Burner Operation"<strong>Service</strong> Tool connectorpos. 10: "<strong>Service</strong>" e buttonpos. 11: "Chimney sweep" d buttonpos. 12: "Reset" c button71) ECO mode means that the temperature inside the hot water tank is 140 °F (60 °C), with a hysteresis (ΔT) of 18 °F instead of 9 °F8<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Operation 44 Operation4.1 Operating the BC10 basic controller4.1.1 G<strong>en</strong>eralThe boiler is equipped with an control unit, the basic controllerBC10. The BC10 allows you to operate the boiler.• Briefly press on the control panel cover to op<strong>en</strong> it(see fig. 3).The basic controller BC10 (see fig. 2) is located on the left side inthe drawer.On the right side of the drawer there’s space for a RC control unit.4.1.2 Switching the heating system on and offSwitching on the heating system• Set the main switch on the BC10 basic controller to position "1"(On).Switching off the heating system• Set the main switch on the BC10 basic controller to position "0"(Off).fig. 3Op<strong>en</strong>ing the control panel4.2 M<strong>en</strong>u structure of the BC10 basic controllerThe m<strong>en</strong>u structure of the boiler can be viewed on the BC10 usingthe "Reset" c, "Chimney sweep d" and "<strong>Service</strong> e" (seefig. 2, pos. 9, 10 and 11) buttons and the display indication (seefig. 2, pos. 4).The m<strong>en</strong>u structure consists of 4 m<strong>en</strong>us, schematicallyrepres<strong>en</strong>ted on the following pages using structure diagrams:– "Flue gas test" m<strong>en</strong>u (page 10)– "<strong>Service</strong> Mode" m<strong>en</strong>u (page 11)– "Manual Operation" m<strong>en</strong>u (page 12)– "Settings" m<strong>en</strong>u (page 12).<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 9


4Operation4.2.1 "Flue gas test" m<strong>en</strong>u"FLUE GAS TEST" MENU72Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.Activateflue gas test?noyesActivate flue gas test:Press and hold the chimney sweep button2 to 5 seconds.72.The flue gas test is activated as soon as a dot isvisible in the lower right hand corner of thedisplay. This means that the boiler runs inheating mode at 100 % for 30 minutes. Themaximum boiler water temperature as set onthe BC10 basic controller applies here.Press the service button.P2 9.psiCurr<strong>en</strong>t heating system pressure. See page 20.Press the service button.A .Operating code. See page 21.Press the service button.72.Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 .. 93 °C). See page 20.Have30 min. passed orwas the powerinterrupted?yesnonoDeactivateflue gas test?yesDeactivate flue gas test:Press and hold the chimney sweep button formore than 2 seconds, until the decimal pointhas disappeared.10<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Operation 44.2.2 "<strong>Service</strong> Mode" m<strong>en</strong>u"SERVICE MODE" MENU72Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.Activateservice mode?noyesBoiler load in line with "Settings" m<strong>en</strong>u.Activate service mode 1st step:Press and hold the "Chimney sweep" buttonfor 2 to 5 seconds.72.As soon as a non-flashing dot is shown in theright-hand bottom corner of the display, theboiler will run in heating mode at 100 % load for30 minutes. The maximum boiler watertemperature set on the BC10 basic controllerapplies.+Activate service mode 2nd step:Simultaneously press and hold the "Chimneysweep" and "<strong>Service</strong>" buttons for more than2 seconds.L .Curr<strong>en</strong>t boiler load. See page 20.<strong>Service</strong> mode activated.You can now temporarily lower the boiler loadto partial load to check, and if relevant set thegas/air ratio or the ionization curr<strong>en</strong>t.-Press and hold the "Reset" button until thedisplay shows "L30."P2 9.psiCurr<strong>en</strong>t heating system pressure. See page 20.Press the "<strong>Service</strong>" button.AOperating code. See page 46..L 30.Curr<strong>en</strong>t boiler load. See page 20.The boiler will reduce its load to 30 % within acouple of seconds. The maximum boiler watertemperature as set on the BC10 basic controllerapplies. Check the gas/air ratio (see page 108)or the ionization curr<strong>en</strong>t (see page 95) andadjust the gas/air ratio if necessary.Press the "<strong>Service</strong>" button.72.Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.Have 30 min.passed or was thepower interrupted?yesPress the "<strong>Service</strong>" button.72.Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.Press the "<strong>Service</strong>" button.noDeactivateservice mode?yesDeactivate service mode:Press and hold the "Chimney sweep" button formore than 2 seconds until the decimal pointhas disappeared.no<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 11


4Operation4.2.3 "Manual Operation" m<strong>en</strong>u"MANUAL OPERATION" MENU72Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.Activate <strong>manual</strong>operation?noyesTo activate <strong>manual</strong> operation:Press and hold the "Chimney sweep" button formore than 5 seconds.72.As soon as a flashing dot is shown in the righthandbottom corner of the display, <strong>manual</strong>operation is active. The means that the boiler isperman<strong>en</strong>tly in heating mode. The maximumboiler water temperature as set on the BC10basic controller now applies. The "Heatrequest" LED is lit.Press the "<strong>Service</strong>" button.P2 9.psiCurr<strong>en</strong>t heating system pressure. See page 20.Press the "<strong>Service</strong>" button.H .Operating code. See page 20.During <strong>manual</strong> operation the "Adjustm<strong>en</strong>ts"m<strong>en</strong>u on page 12 can be used to temporarilychange the required boiler load in case of anemerg<strong>en</strong>cy.Press the "<strong>Service</strong>" button.72.Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.noPowerinterrupted?noDeactivate <strong>manual</strong>operation?yesyesDeactivate <strong>manual</strong> operation:Press and hold the "Chimney sweep" button formore than 2 seconds until the flashing decimalpoint has disappeared.4.2.4 "Adjustm<strong>en</strong>ts" m<strong>en</strong>u12<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Operation 4"ADJUSTMENTS" MENU72Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.Op<strong>en</strong> the“Adjustm<strong>en</strong>ts” m<strong>en</strong>u?+yesOp<strong>en</strong> programming mode: Simultaneouslypress and hold the "Chimney sweep" and"<strong>Service</strong>" buttons for more than 2 seconds.noBoiler load and pump post purgetime settings confirmed.LAs soon as the display shows "L--", theprogramming mode is op<strong>en</strong>. The firstparameter shown on the display is used to setthe boiler load for heating operation.yes, lower-Adjust the boiler load withthe "Reset" button.Adjust boiler load?noyes, higher+Adjust the boiler load withthe "Chimney sweep" button.L30The setting "L30" means that theheating load is lowered to 30 %.L„L__“ is the maximumheating load setting of 100 %.Factory default setting: "L " = 100 %.Press the "<strong>Service</strong>" button.F5As soon as the display shows "F ", the secondparameter can be set. This parameterindicates the pump post purge time.yes, lower-Adjust the pump post purge time withthe "Reset" button.Adjust pump postpurge time?noyes, higher+Adjust the pump post purge time with the"Chimney sweep" button.F00"F00" is the minimum pump post purge timesetting in minutes. "F60" is the maximumpump post purge time setting in minutes.F 1d"F1d" is the maximumpump post purge time setting for one day.Factory default setting "F 5" = 5 minutes.Have at least5 min. passed without a button beingpressed or was the power supplyinterrupted ?yesnoPress the "<strong>Service</strong>" button.<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 13


5Function5 Function5.1 G<strong>en</strong>eralTo clarify the operation of the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60thermal power gas boilers under normal operating conditions, thework steps are schematically repres<strong>en</strong>ted in the structure diagramson the following pages of this chapter.14<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Function 55.2 Structure diagram "Function"1Start upConnect the heating system to the power gridby turning the circuit breaker ON.Turn the main switch on the BC10 toposition “1” (ON), see page 8, fig. 2.The LED of the UBA 3 lights for 1 second.This means that the UBA 3 is reading theKIM. If a new KIM or UBA 3 has be<strong>en</strong>installed, the LED will flash at a highfrequ<strong>en</strong>cy for max. 10 sec. while data is beingexchanged.8 . 88 . .A display check is carried out(for max. 1 second).Flashes twice for 2 seconds untilcommunication betwe<strong>en</strong> the UBA 3 and theBC10 has be<strong>en</strong> established.72Curr<strong>en</strong>t supply temperature 0 ... 199 °F(-18 ... 93 °C). See page 20.0UOperating code.The heating boiler is started.Press the "<strong>Service</strong>" button.Start of air-side pre-flushing phase.The blower runs for < 20 seconds atapprox. 60 % of the maximum speed.P 2 9psiCurr<strong>en</strong>t heating system pressure.See page 20.Is theair purging phaseokay?noUnit will show an error code.Fault must be fixed beforeproceeding.See chapter 6, 7 and 7.2.Press the "<strong>Service</strong>" button.2yespage 16<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 15


5Functionpage 1520HOperating code.The boiler is in ready mode,there is no heat request.Start of pump post purge time via the heatingsystem. Pump post purge time in line with"Settings" m<strong>en</strong>u.See page 12 and page 20.Factory default setting: 5 minutes.Has the pump postpurge time expired?yesnoIsthetemperaturein the hot watertank at least no9 °F (5 K)lower than thetemperature seton the BC10or RC?Isthere a heatrequest from theroom or outdoortemperaturedep<strong>en</strong>d<strong>en</strong>tregulator?noThe primary circulation pump stops.3yes6yes5page 18page 17page 19Has the primarycirculation pump be<strong>en</strong> off formore than 24 hours?noIsthetemperaturein the hot watertank at least9 °F (5 K) lower thanthe temperature seton the BC10or RC?noIsthere a heatrequest from theroom or outdoortemperaturedep<strong>en</strong>d<strong>en</strong>tregulator?noyesyesyesThe primary circulation pump is run for10 seconds to prev<strong>en</strong>t it from seizing up.36page 17page 19Have t<strong>en</strong> secondspassed or was the power supplyinterrupted?yesnoIsthetemperaturein the hot watertank at least9 °F (5 K) lower thanthe temperature seton the BC10or RC?noIsthere a heatrequest from theroom or outdoortemperaturedep<strong>en</strong>d<strong>en</strong>tregulator?noyesyes36page 17page 1916<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Function 5page 163The "Hot water mode" LED on theBC10 is lit.0CThe blower is started up.The tank filling pumpis activated.The hot surface ignitor is activatedfor sev<strong>en</strong> seconds.The primary circulation pumpis started.0LIgnition phase:The gas valve is op<strong>en</strong>ed.7page 19noH<strong>GB142</strong> is in the hot water mode.The "Burner" LED is lit.Isthe supplytemperature 82.8 Khigher than the hot watertemperature settingor higher than200 °F (93 °C)?Is the temperaturein the hot water tank higherthan the hot water temperature settingin the BC10 or RC controldevice?yesno0YyesThe gas valve is closed,the burner is shut down.The "Hot water mode" LEDgoes off.The "Burner" LED goes off.4The blower stops.page 18noIsthe supplytemperature lowerthan the presethot water temperature<strong>plus</strong> 63 °F (35 K)?yes<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 17


5Functionpage 1840AThe gas valve is closed,the burner is shut down.The "Burner" LED goes off.Start the pump over-run time through the hotwater tank at least 30 seconds,max. 1 minute, if there is a heat request.Air-side after-purging by blowerfor 30 seconds.The blower stops.0HThe primary circulation pump stops.The tank filling pumpis stopped.Is there aheat request from the room oroutdoor temperature-dep<strong>en</strong>d<strong>en</strong>tregulator?6yesno5page 16page 1918<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Function 5page 16, page 186The "Heat request" LED is lit.0CThe blower is started up.The hot surface ignitor is activated forsev<strong>en</strong> seconds.The circulation pump is started up.0LIgnition phase:The gas valve is op<strong>en</strong>ed.HThe <strong>GB142</strong> <strong>en</strong>ters heating mode.The "Burner" LED is lit.Is thetemperature in the hot waterat least 9 °F (5 K) lower than the temperatureset on the BC10 or RC?noIs theroom or outdoor temperaturedep<strong>en</strong>d<strong>en</strong>tregulator in the requestposition?noyesyes7page 17noIsthe supplytemperature11 °F (6 K) higher thanthe target value? (The target valueis calculated by the outdoortemperature-dep<strong>en</strong>d<strong>en</strong>t regulatoror is set - in the ev<strong>en</strong>t of roomtemperature-dep<strong>en</strong>d<strong>en</strong>tregulation- on theBC10)The "Heat request" LED goes off.Yes0HThe gas valve is closed,the burner is shut down.0YThe gas valve is closed,the burner is shut down.The "Burner" LED goes off.The "Burner" LED goes off.Start of pump post purge time via the heatingsystem. Pump post purge time in line with"Settings" m<strong>en</strong>u. See page 12 and page 20.Factory default setting: 5 minutes.Air-side after-purging by blower for30 seconds.The primary circulation pump stops.noThe blower stops.Isthe supplytemperature 11 °F (6 K)lower than thetarget value?yesThe blower stops.5page 16<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 19


6Symptoms6 Symptoms6.1 Display indication on the BC10 basic controller6.1.1 G<strong>en</strong>eralA display value or code is shown on the display of the BC 10 basic controller (see page 8, fig. 2).6.1.2 Display values on the display of the BC10 basic controllerThe display value is shown automatically or can be called up by pressing the "Chimney sweep d" or "<strong>Service</strong> e" button (seepage 10 and 12.The following display values can be shown on the display of the BC10 basic controller:DisplayvalueType of display value Unit Range[\/7/2| Curr<strong>en</strong>t supply temperature °F [\/\/0| – [l/9/9| 1) /Factorydefaultsetting°C [-/1/8| – [\/9/3|[p/2/9| Curr<strong>en</strong>t heating system pressure psi [p/0/0| – [p/2/9| /[l/9/9| Configured target load % [l/3/0| – [l/9/9| / [l/?/?| [l/?/?|[f/\/5| Configured target pump post purge time min [f/0/0| – [f/6/0| / [f/1/d| [f/\/5|table 1Display values on the BC10 basic controller6.1.3 Display codes on the display of the BC10 basiccontrollerA display code shows the curr<strong>en</strong>t status of the <strong>Logamax</strong> <strong>plus</strong><strong>GB142</strong>.The display value is shown automatically or can be called up bypressing the "<strong>Service</strong> e" button.Two display codes (see table 2 level 3 and level 4) are shown.After the first display code (level 3) is displayed, the second one(level 4) can be called up by pushing the “<strong>Service</strong> e“ button. Onthe BC10 basic controller level 4 can only be called up in the ev<strong>en</strong>tof a fault code.Under normal operating conditions it is only possible to call up level4 using the RC control device or a service tool.If the display code is a fault code, this fault code either flashes(locked fault code) in the display or it is shown perman<strong>en</strong>tly(blocking fault code). A boiler reset is only necessary with alocking fault code (flashing) (see 8, fig. 2). The cause of thefault must be remedied first. The cause has to be remediedand the boiler resumes regular operation.In the ev<strong>en</strong>t of a locking boiler fault code both the displayvalue and the display code flash.If there are more than once display codes at the same time,the display codes will be shown in turn. And if one of thesedisplay codes is a locking display code, the blocking displaycodes shown will also flash.20<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Symptoms 6The following display values can be shown on the display ofthe BC10 basic controller:Abbreviations used in table 2:Type of display code:BC - Operating codeSC – <strong>Service</strong> codeBKS – Blocking boiler fault codeVKS – Locking boiler fault code (flashing)AS – System fault codeÜC – Other display codeszMaindisplaycodeDisplay codez SubdisplaycodezSymptomsKey to display codeType ofdisplaycodeResetrequired?Othersymptoms[\/\/\| [\/\/\|No indication indisplay.[\/-/\|Communication test while starting up.This code flashes 2 x 2 seconds whilestarting up to indicate that thecommunication betwe<strong>en</strong> the UBA 3 andthe BC10 basic controller is being tested.If a new UBA 3 or a new KIM was fitted,this code will flash formax. 10 seconds. If this code continuesto flash on the display, there is a fault inthe communication betwe<strong>en</strong> the UBA 3and the BC10 basic controller.See page 46.This fault code will also appear wh<strong>en</strong>connecting a thermostat to the RCterminals.e [-/a/\]or any otherindicationwith aperman<strong>en</strong>tdot in thebottomright-handcorner.[2/0/8|1)The boiler is in the flue gas test mode orin service mode.ÜCBCNo heatingoperation and nohot water.DiagnosisRemedypage 28 page 28page 10 orpage 11page 10 or page 11e [-/h/\| e [2/0/0|1)The boiler is in heating mode.BCe [-/h/}any otherindicationwith aflashing dotin thebottomright-handcorner.e [=/h/\| e [2/0/1|1)e [2/0/0|1)The boiler is in <strong>manual</strong> operation mode. BC The roomtemperature is toohigh.page 12 page 12The boiler is in hot water mode.BCe [0/a/\| e [3/0/5|1)table 2The boiler has switched off. Start thepump over-run time via the tank for atleast 30 seconds and maximum1 minute.Display indications on the BC10 basic controller1) only visible using the service tool2)is being carried outBC<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 21


6SymptomsSymptomszMaindisplaycodeDisplay codez SubdisplaycodezKey to display codeType ofdisplaycodeResetrequired?OthersymptomsDiagnosisRemedye [0/a/\| e [2/0/2|1)Operating phase:The switch optimization program isactivated.This program is activated if there is morethan one burner firing requests from anRC or ON/OFF regulator within 10minutes.This means that the boiler cannot berestarted until at least t<strong>en</strong> minutes haveelapsed since initial startup of the burner.BCPossibly noheating operation.e [0/c/\| e [2/8/3|1)The burner is started.BCe [0/e/\| e [2/6/5|1)Readiness for operation:The boiler is in ready mode.The time-proportional program isactivated.The time-proportional program isactivated as soon the load requested bythe modulating room controller is lowerthan the lower limit of the boiler load.During the time-proportional program theburner is switched on and off repeatedly.The period in which the burner isswitched on dep<strong>en</strong>ds on the differ<strong>en</strong>cebetwe<strong>en</strong> the load required by themodulating room controller and the lowerlimit of the boiler load. As soon as theburner is switched on, the device isoperating at minimum load. As soon asthe burner is switched off, the displaycode [0/e/\| e [2/6/5| is indicated in thedisplay of the BC10.The time-proportional program isdeactivated automatically as soon as theload required by the modulating roomcontroller is higher than the lower limit ofthe boiler load.BCe [0/h/\| e [2/0/3|1)The boiler is in ready mode, there is noheat request.BCe [0/l/\| e [2/8/4|1)The gas valve is op<strong>en</strong>ed.BCe [0/u/\| e [2/7/0|1)Power Up.Boiler is starting up after a reset or afterthe main power is switched on.This display code will be displayed for 4minutes maximum.BCe [0/y/\| e [2/0/4|e [0/y/\| e [2/7/6| ee [0/y/\| e [2/7/7| ee [0/y/\| e [2/8/5| e1)The boiler switches off, the temperatureis higher than the target temperature.The supply s<strong>en</strong>sor has measureda temperature higher than 203 °F(95 °C).The safety s<strong>en</strong>sor has measureda temperature higher than203 °F (95 °C).The return s<strong>en</strong>sor has measureda temperature higher than203 °F (95 °C).BCBKSBKSBKSnononotable 2Display indications on the BC10 basic controller1)only visible using the service tool2) is being carried out22<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Symptoms 6zMaine [1/c/\| e [2/1/0| ee [1/l/\| e [2/1/1| eFlue gas s<strong>en</strong>sor is activated(not available).The UBA 3 does not register anyconnections to the unused contacts 78and 50.BKS no Flue gas s<strong>en</strong>sorhas measured aflue gas temperaturehigher than221 °F (105 °C)BKS no No heatingoperation and nohot water.e [2/e/\| e [2/0/7| e The system pressure is too low. BKS no No heatingoperation and nohot water.e [2/f/\| e [2/6/0|e [2/f/\| e [2/7/1| ee [2/l/\| e [2/6/6| e1)e [2/p/\| e [2/1/2|1)e [2/u/\| e [2/1/3|e [3/a/\| e [2/6/4| ee [3/f/\| e [2/7/3| ee [3/l/\| e [2/1/4| e1)No temperature increase after burnerstart or the temperature differ<strong>en</strong>cebetwe<strong>en</strong> the supply and safety s<strong>en</strong>sors ismore than 27 °F (15 K).The temperature differ<strong>en</strong>ce betwe<strong>en</strong> thesupply and safety s<strong>en</strong>sors is more than27 °F (15 K).The primary circulation pump does notg<strong>en</strong>erate a pressure differ<strong>en</strong>ce.Temperature increase of supply s<strong>en</strong>soror safety s<strong>en</strong>sor is more than 9 °F/sec(5 K/sec).The temperature differ<strong>en</strong>ce betwe<strong>en</strong> thesupply and return s<strong>en</strong>sors is more than90 °F (50 K).The air flow by the blower has failedduring the operating phase.The blower is switched off during thesafety test.The blower is switched off during thesafety test.page 48 page 48page 48 page 48BC page 49 page 49BKS no page 49 page 49VKS yes No heatingoperation andno hot water.page 50 page 50BC page 52 page 52BC page 53 page 53BKS no page 54 page 54BKS no page 55 page 55VKS yes No heatingoperation andno hot water.e [3/p/\| e [2/1/6| e The blower is running too slowly. VKS yes No heatingoperation andno hot water.e [3/y/\| e [2/1/5| e The blower is running too fast. VKS yes No heatingoperation andno hot water.e [4/a/\| e [2/1/8| ee [4/c/\| e [2/2/4| eThe supply s<strong>en</strong>sor has measured atemperature higher than 221 °F (105 °C).The UBA 3 does not register the short cutbestwe<strong>en</strong> the unused contacts 22 and24.VKS yes No heatingoperation andno hot water.VKS yes No heatingoperation andno hot water.e [4/e/\| e [2/7/8| e The s<strong>en</strong>sor test has failed. VKS yes No heatingoperation andno hot water.e [4/l/\| e [2/2/0| ee [4/p/\| e [2/2/1| eThe safety s<strong>en</strong>sor is shorted ormeasures temperatures higher than 266°F (130 °C).The safety s<strong>en</strong>sor contactis interrupted.VKS yes No heatingoperation andno hot water.VKS yes No heatingoperation andno hot water.e [4/u/\| e [2/2/2| e The supply s<strong>en</strong>sor is shorted. VKS yes No heatingoperation and nohot water.table 2displaycodeDisplay codez SubdisplaycodezSymptomsKey to display codeDisplay indications on the BC10 basic controller1)only visible using the service tool2) is being carried outType ofdisplaycodeResetrequired?OthersymptomsDiagnosisRemedypage 56 page 56page 57 page 57page 58 page 58page 59 page 59page 60 page 60page 60 page 60page 61 page 61page 62 page 62page 63 page 63<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 23


6SymptomszMaine [4/y/\| e [2/2/3| e The supply s<strong>en</strong>sor contact is interrupted. VKS yes No heatingoperation andno hot water.e [6/a/\| e [2/2/7| ee [6/a/\| e [2/2/7| ee [6/c/\| e [2/2/8| ee [6/c/\| e [3/0/6| ee [6/l/\| e [2/2/9| eNo ionization after ignition.After four startup attempts, a lockingboiler fault follows [6/a/\|.page 64 page 64BKS no page 65 page 65No ionization after four startup attempts. VKS yes No heatingoperation andno hot water.An ionization curr<strong>en</strong>t was measuredbefore the burner start.An ionization curr<strong>en</strong>t was measured afterthe burner switch-off.Ionization fails during the operatingphase.VKS yes No heatingoperation andno hot water.VKS yes No heatingoperation andno hot water.page 65 page 65page 72 page 72page 72 page 72BKS no page 73 page 73e [6/p/\| e [2/6/9| e The hot surface ignitor activates too long. VKS yes No heatingoperation andno hot water.e [7/c/\| e [2/3/1| eThe power supply was interrupted andswitched on again after a fault message.VKS yes No heatingoperation andno hot water.e [7/l/\| e [2/6/1| e The UBA 3 is defective. VKS yes No heatingoperation andno hot water.e [7/l/\| e [2/8/0| e The UBA 3 is defective. VKS yese [8/y/\| e [2/3/2|1)page 78 page 78page 78 page 78page 78 page 78The external switch contact is activated. BC page 79 page 79[8.8.8]Display test while starting up. This codeis displayed for a maximum of 1 second.e [9/a/\| e [2/3/5| ee [9/h/\| e [2/3/7| ee [9/h/\| e [2/6/7| ee [9/h/\| e [2/7/2| ee [9/l/\| e [2/3/4| eKIM or UBA 3 is defective. VKS yes No heatingoperation andno hot water.KIM or UBA 3 is defective. VKS yes No heatingoperation andno hot water.The UBA 3 is defective. VKS yes No heatingoperation andno hot water.The UBA 3 is defective. VKS yes No heatingoperation andno hot water.The gas valve coil or the wiring to the gasvalve is defective.ÜCVKS yes No heatingoperation andno hot water.e [9/l/\| e [2/3/8| eThe UBA 3 is defective. VKS yese [9/p/\| e [2/3/9| e KIM or UBA 3 is defective. VKS yes No heatingoperation andno hot water.e [9/u/\| e [2/3/3| e KIM or UBA 3 is defective. VKS yes No heatingoperation andno hot water.table 2displaycodeDisplay codez SubdisplaycodezSymptomsKey to display codeDisplay indications on the BC10 basic controller1) only visible using the service tool2)is being carried outType ofdisplaycodeResetrequired?OthersymptomsDiagnosisRemedypage 80 page 80page 80 page 80page 81 page 81page 80 page 80page 80 page 8024<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Symptoms 6zMaine [a/0/1| e [8/0/0| e Outdoor s<strong>en</strong>sor AS The minimumoutdoortemperature isassumed.S<strong>en</strong>sorconnected orfitted incorrectly.S<strong>en</strong>sor wirebrok<strong>en</strong> orshorted.The s<strong>en</strong>sor isdefective.e [a/0/1| e [8/0/8| eHot water temperature s<strong>en</strong>sor AS No water isheated any more.e [a/0/1| e [8/0/9| e Hot water temperature s<strong>en</strong>sor 2 S<strong>en</strong>sor wirebrok<strong>en</strong> orshorted.e [a/0/1| e [8/1/0| ee [a/0/1| e [8/1/1| etable 2displaycodeDisplay codez SubdisplaycodezSymptomsKey to display codeDisplay indications on the BC10 basic controller1) only visible using the service tool2)is being carried outType ofdisplaycodeResetrequired?OthersymptomsHot water remains cold. AS The systemconstantly tries toheat the hot watertank to the hotwater target valuesetting.The hot waterpriority iscancelled wh<strong>en</strong>the fault messageappears.Thermal disinfection. AS Thermaldisinfection wasinterrupted.DiagnosisS<strong>en</strong>sorconnected orfitted incorrectly.The s<strong>en</strong>sor isdefective.Perman<strong>en</strong>ttapping or leak.S<strong>en</strong>sorconnected orfitted incorrectly.S<strong>en</strong>sor wirebrok<strong>en</strong> orshorted.The s<strong>en</strong>sor isdefective.Fill pumpconnectedincorrectly ordefective.Tap flow rate toogreat duringdisinfectionperiod.Boiler load toolow forsimultaneousheat use byother connectedloads (e. g. 2ndheating circuit).S<strong>en</strong>sorconnected orfitted incorrectly.S<strong>en</strong>sor wirebrok<strong>en</strong> orshorted.The s<strong>en</strong>sor isdefective.Fill pumpdefectiveRemedyCheck the s<strong>en</strong>sorconnection and thes<strong>en</strong>sor wire.Check the s<strong>en</strong>sorinstallation.Compare theresistance value tothe s<strong>en</strong>sor graph.Check the s<strong>en</strong>sorconnection and thes<strong>en</strong>sor wire.Check the s<strong>en</strong>sorinstallation on thehot water tank.Compare theresistance value tothe s<strong>en</strong>sor graph.Remedy the leak ifrelevant.Check the s<strong>en</strong>sorconnection and thes<strong>en</strong>sor wire.Check the s<strong>en</strong>sorinstallation on thehot water tank.Compare theresistance value tothe s<strong>en</strong>sor graph.Test the fill pumpoperation e. g.using a relay test.Choose the time forthermal disinfectionso that noadditional heatrequest occurs atthis time.Check the s<strong>en</strong>sorconnection and thes<strong>en</strong>sor wire.Check the s<strong>en</strong>sorinstallation on thehot water tank.Compare theresistance value tothe s<strong>en</strong>sor graph.Test the fill pumpoperation e. g.using a relay test.<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 25


6SymptomszMaine [a/0/1| e [8/1/6| e No communication with EMS. AS The boiler nolonger gets heatrequests; theheating system nolonger heats.EMS bus systemis overloaded.UBA 3/MC10 isdefective.e [a/0/1| e [8/2/8| e Water pressure s<strong>en</strong>sor. AS The digital waterpressure s<strong>en</strong>soris defective.e [a/0/2| e [8/1/6| e No communication with BC10. AS BC10 settings ar<strong>en</strong>o longer tak<strong>en</strong>over by RCxxdevices.e [c/0/\| e [2/8/8| ee [c/0/\| e [2/8/9| ee [c/a/\| e [2/8/6| eThe UBA 3 has no connection to thepressure s<strong>en</strong>sor or there is a short circuit.Short circuit in connection to pressures<strong>en</strong>sor.The return s<strong>en</strong>sor has measured atemperature higher than 221 °F (105 °C).VKS yes No heatingoperation and nohot water.e [c/u/\| e [2/4/0| eThe return s<strong>en</strong>sor is shorted. VKS yese [c/y/\| e [2/4/1| e The return s<strong>en</strong>sor contact is interrupted. VKS yese [e/\/\| e [2/9/0| e The UBA 3 is defective. BKS no No heatingoperation andno hot water.+ any digitor lettere [e/\/\|+ any digitor lettere [2/4/2|to[2/8/7|VKSe KIM or UBA 3 is defective. VKS yes No heatingoperation andno hot water.yesContact problemat BC10 or BC10is defective.page 82 page 82page 80 page 80page 80 page 80[h/\/7|The heating system pressure is too low. SC page 78 page 80e [h/\/7| eThe heating system pressure is too low. SC page 78 page 80table 2displaycode[r/e/\|Display codez SubdisplaycodezSymptomsKey to display codeReset is carried out. After pressing the"Reset" button this code is displayed for5 seconds.Display indications on the BC10 basic controller1) only visible using the service tool2)is being carried outType ofdisplaycodeÜCResetrequired?2)OthersymptomsDiagnosisRemedyReset by switchingthe heating systemon and off.Inform theBUDERUScustomer servicedepartm<strong>en</strong>t ifnecessary.Replace the digitalwater pressures<strong>en</strong>sor.Check the BC10connection.Replace the BC10if necessary.6.2 LED on the UBA 3In addition to the display indication on the BC10 basic controller, there is a red LED on the UBA 3.The meaning of this LED is explained in see table 3.LEDOffFlashing slowly (1 Hz)MeaningNormal operationThere is a boiler fault (locking fault).Flashing fast (10 seconds) During startup after replacing the KIM or the UBA 3.Ontable 3 LED on the UBA 3During a fault in the UBA 3 or if the KIM is not recognized.26<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 77 Diagnosis7.1 Faults without a fault codeHot water requestAlthough the UBA 3 indicates that the system is ready foroperation, it is possible that in the ev<strong>en</strong>t of a hot water request nohot water is made available, or it is only made available for a shorttime.Structure diagram for troubleshooting, see page 33.Heating modeAlthough the UBA 3 shows that the system is ready for operationand the room temperature has not reached the preset value, the<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong> does not <strong>en</strong>ter the heating mode.Structure diagram for troubleshooting: page 44.<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 27


7DiagnosisNo displayNo indication in display.Do the otherfunctions of the device worknormally?NoCheck that the mains power switchis ON.yes19page 29Is the mains powerswitch ON?yesCheck that the operating switch is inposition “1” (ON). See page 9.noSwitch on the mains power switch.Is theoperating switch on the BC 10 inposition “1” (ON)?yesCheck that there is a 120V AC powersupply at the mains power switch.noTurn the operating switch on the BC 10 toposition “1” (ON). See page 9 (fig. 2).Is there a voltage at themains power switch?yesMeasure the resistance of the 120V ACsupply cord.noDeal with any problem in the electricalsystem.Is the 120V AC cord okay?yesCheck the fuse on the rear of the UBA 3using a volt-ohm-multimeter.See page 84.noReplace the cable loom (or the affectedpart thereof.yesIs the fuse okay?44noReplace the fuse.See page 84.page 83Is there any indication on theBC10 display?noTurn the operating switch on the BC10 toposition “0” (OFF). See page 9, par. 4.2.yes7page 308page 3128<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7page 2819Check that there is betwe<strong>en</strong> 7.8 and 15.2VDC on both contacts 1 and 2 of the BC10.See page 126.Is there a voltage?NoMeasure the relevant part of the cable loom.See page 126.YesReplace the BC10.See the fitting instructions ofthe BC10.Is the cable loom okay?NoReplace the cable loom or theaffected part thereof.Yes44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 29


7DiagnosisNo display, part 2page 287Disconnect the following boiler compon<strong>en</strong>tsfrom the electrical power supply:- the blower, see page 86,- the primary circulation pump,see page 126.Check the fuse on the rear of the UBA 3again using a volt-ohm-multimeter.See page 84.Is the fuse okay?YesNoReplace the fuse again.See page 84.Turn the operating switch on the BC10 toposition “1” (ON). See page 9, par. 4.2.Is there any indication on theBC10 display?YesTurn the operating switchto “0” (OFF).No9page 32Connect the external primarycirculation pump.Turn the operating switch on the BC 10 toposition “1” (ON). See page 9, par. 4.2.Is there any indication on theBC10 display?NoReplace the external primarycirculation pump.10Yespage 31Replace the fuse again.See page 84.30<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7No display, part 3page 3010Turn the operating switch on the BC10 toposition “0” (OFF). See page 9, par. 4.2.Connect the blower. See page 86.Turn the operating switch on the BC10 toposition “1” (ON). See page 9, par. 4.2.Is there any indication on theBC10 display?YesNoReplace the blower.See page 88.Replace the fuse again.See page 84.8page 318Fit the casing.Turn the operating switch on the BC10 toposition “0” (OFF). See page 9, par. 4.2.Make the heating system readyfor operation.Turn the operating switch on the BC10 toposition “1” (ON). See page 9, par. 4.2.<strong>Logamax</strong> <strong>plus</strong><strong>GB142</strong>-15/24/30/45/60 okay.<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 31


7DiagnosisNo display, part 4No display, part 5page 309Use a volt-ohm-multimeter to check thesupply wires of the primary circulation pump,the blower and the hot surface ignitor for signsof short circuiting.See page 87 and page 93.Are the wires okay?YesUse a volt-ohm-multimeter to measurecontacts L and N of the transformer forresistance.NoReplace the cable loom or the affected partthereof and the fuse again.See page 84.Is the resistance approx. 50 Ohms?YesNoReplace the transformer,see page 109.And replace the fuse again.See page 84.Measure the supply cord of the transformer tomake sure it is not brok<strong>en</strong> or shorted.Is the supply cord okay?NoReplace the supply cord of the transformerand replace the fuse again.See page 84.Yes44page 838page 3132<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Hot water mode not operational; heating mode is operationalNo hot water but heating is operational,possibly radiators become hot withoutthere being a heat request.On devices withexternal hot water tanks.Turn the operating switch on the BC10 toposition “0” (OFF) and turn the operatingswitch to "1" (ON).Op<strong>en</strong> hot water tap.Check that the hot water outlet conduitimmediately under the hot water tankbecomes hot and that the settings on theRC device are correct.Does this conduit warm upto approx. 140 °F (60 °C)?Yes11Check:Nopage 34- that the hot water supply has be<strong>en</strong> registered withthe control device. See the Operating instructionsof the BC10 and the RC control device.- that the hot water target value setting is high<strong>en</strong>ough (140 °F = 60 °C). See page 8, fig 2.- that the hot water supply is not switched off by thetimer program of the RC control device. See theOperating Instructions of the RC control device.Are the settings okay?YesCheck that the "Hot water mode" LEDon the BC10 is lit.See page 8, fig 2.NoAdjust the settings.Is the LED lit?No1213Yespage 34page 358page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 33


7DiagnosisNot hot water, branch 001page 3311The cause of the fault is to be found outsidethe device and the hot water tank.Check that the cold water inlet and hot wateroutlet conduit connections on the hot watertank are not reversed.Are the water-sideconduits connected properly?YesClose the shut-off valve in the cold-water inletand op<strong>en</strong> a hot water tap at random to see ifwater comes out of it.NoConnect the conduits correctly.Is this the case?NoCheck to see if any other external part of theheating circuit is a possible cause.YesThe cause is th<strong>en</strong> a defective mixer tap, athermostat-controlled mixer valve or a shortcircuit betwe<strong>en</strong> the hot- and cold-waterconduit circuits.Are such items detected?YesPlace the affected compon<strong>en</strong>ts out of service.No44page 838page 31Not hot water, branch 002Not hot water, branch 00334<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Repl. AApage 3312Check the hot water temperature s<strong>en</strong>sor.See page 89.Is the hot watertemperature s<strong>en</strong>sor okay?YesCheck the wire of the hot water temperatures<strong>en</strong>sor betwe<strong>en</strong> the terminal strip and theUBA 3 mounting base using a continuitychecking device. See page 92.NoReplace the hot water temperature s<strong>en</strong>sor.See page 91.Is the wire okay?YesNoReplace the cable loom or the affected partthereof.44page 838page 31page 3313Check that the burner in the boiler activatesas specified in the structural diagram,page 17.Does the burner in theboiler activate?YesIs a tank filling pump fitted?YesNoNoRemedy the fault using the structure diagramthat corresponds with the fault code.21page 3615page 398page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 35


7DiagnosisRepl. BBpage 3421Check that the tank filling pumpis running.Is the tank fillingpump running?NoCheck that during hot water mode there is a120V AC voltage on the tank filling pump.Yes45page 37Is the tank filling pumpbeing activated?NoCheck the connection board to make sure thatthere is 120V AC on both contacts L and N ofconnection PS (gray) during hot water mode.Yes46page 37Doesthe connection boardhave on both contacts L and N ofconnection PS 120V AC during hotwater operation?YesReplace the supplycord of the tank-fillingpump.NoCheck the fuse on the connection board.Value: 5A. See page 84.Is the fuseon the connection boardokay?YesCheck the cable loom of the device.NoReplace the fuse onthe connection board.See page 84.Is the cable loom okay?YesReplace the circuit board.NoReplace the cableloom.Is the tank filling pumprunning?NoYes44page 838page 3136<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7page 3645Check the tank-filling pump for soiling or fora defective pump impeller wheel.Is thetank-filling pump soiled or is the pumpimpeller wheel defective?NoYesReplace or clean the tank fillingpump.The external hot water tank is furred up.Decalcify the tank.8page 31page 3646Check that the pump impeller wheel of thetank filling pump is not blocked.Is thepump impeller wheel of the tank fillingpump blocked?NoYesAs described for the primary circulationpump, the tank filling pump must be turned inthe direction of rotation of the pump using ascrewdriver.8page 3147page 37<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 37


7Diagnosispage 3647Check that the capacitor of thetank filling pump is okay.Is thecapacitor of the tank filling pumpokay?NoYesReplace the tank fillingpump.Replace thecapacitor.8page 3138<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7page 3415Check the primary circulation pump forcorrosion or scale.Is therecorrosion or scale inside the primarycirculation pump?NoCheck the following elem<strong>en</strong>ts for soiling and/or damage:- the combustion-air inlet conduit- the air suction tube,- the gas orifice, see page 101- the blower, see page 86- the connection betwe<strong>en</strong> the blower and theburner- the burner- the heat exchanger, see page 117- the flue gas conduit.YesClean the primarycirculation pump (inside).Are the abovem<strong>en</strong>tionedcompon<strong>en</strong>ts clean andfree from damage?NoClean and/or replace the correspondingcompon<strong>en</strong>ts.YesMeasure the inlet gas pressure (flowpressure). See page 107.Is the inlet gas pressureokay?YesNoIf the required inlet gas pressure is notavailable, you should consult the relevantgas utility company.16page 408page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 39


7DiagnosisRepl. CCpage 3916Check the gas/air ratio.See page 108.Is the gas/air ratiookay?YesNoAdjust the gas/air ratio.See page 108.Check the hot water tankfor scale build-up.Is the hot water tankscaled up?NoCheck to see if any other external partof the heating circuit is a possible cause ofthe fault.YesDecalcify the tank.Are such items detected?YesPlace the affected compon<strong>en</strong>ts out of service.No44page 838page 3140<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7hot water but no c<strong>en</strong>tral heatinghot water available,no heating operation.On devices withexternal hot water tanks.Check that the RC control device settings arecorrect. See the Operating Instructions of theRC control device.Are the RC controldevice settings correct?YesCheck that the "Heating request" LED on theBC10 is lit. See fig. 2, page 8.NoIncrease the temperature setting on the RCcontrol device. See the Operating Instructionsof the RC control device.Is the "Heating request"LED lit?YesNoCheck the control device. See page 104.Check that the boiler water temperaturesetting on the BC10 (see page 9) or theRC control device is high <strong>en</strong>ough.Is the boiler water temperature settinghigh <strong>en</strong>ough?YesCheck that the boiler load setting is correct.See "Adjustm<strong>en</strong>ts" m<strong>en</strong>u on page 12.NoIncrease the boiler water temperature settingon the BC10 (see page 9) or on theRC control device.Is the boiler load setting high<strong>en</strong>ough?YesNoIncrease the boiler load setting.See "Adjustm<strong>en</strong>ts" m<strong>en</strong>u on page 12.Is aNohot water tank connected? 44Yespage 838page 31Is aNotank pump fitted? 20Yespage 4244page 83<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 41


7DiagnosisHot water but no c<strong>en</strong>tral heating continued -2page 4120Check that the DHW circulation pump isrunning, as described for the primarycirculation pump.Is theDHW circulation pump running?NoCheck that during heating mode there is a120V AC voltage on the DHW circulationpump.Yes48page 43Is there avoltage?NoYes49page 43Check the connection board to make sure thatthere is 120V AC on both contacts L and Nof connection PS (gre<strong>en</strong>) during heatingmode.Isthere a voltage?YesReplace the supply cord ofthe tank-filling pump.NoCheck the cable loom ofthe device.Is the cable loomokay?YesNoReplace thecable loom.Replace the connection board.Is the DHW circulationpump running?NoYes44page 838page 3142<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7page 3648Check the DHW circulation pump for soiling orfor a defective pump impeller wheel.Is theDHW circulation pump soiled or isthe pump impeller wheeldefective?YesClean or replace or the DHW circulationpump.NoThe fault is caused by thesystem and not by theboiler.8page 31page 3649Check that the pump impeller wheel isnot blocked.Is thepump impeller wheelblocked?NoYesAs described for the primary circulationpump, the DHW circulation pump must beturned in the direction of rotation of thepump using a screwdriver.8page 3150page 43<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 43


7Diagnosispage 3650Check that the capacitor of the DHWcirculation pump is okay.Is thecapacitor of the DHW circulationpump okay?NoReplace the capacitor.YesReplace the DHW circulation pump.8page 31Hot water but no c<strong>en</strong>tral heating continued -3no c<strong>en</strong>tral heating44<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7No digital pressure displayNo digital system water pressure indication onthe display of the BC10 basic controller.Check that the cable plug from the pressures<strong>en</strong>sor is connected.See page 8, fig. 1, pos. 17.Is the plug-and-socketconnection okay?YesCheck the wires betwe<strong>en</strong> the pressure s<strong>en</strong>sorplug and the UBA 3 mounting base, by usinga proper measuring device.See page 126, fig 110.NoReconnect the plug-and-socket connection ofthe pressure s<strong>en</strong>sor.See page 8, fig. 1, pos. 17.Is the wiringokay?YesReplace the pressure s<strong>en</strong>sor to test whetherthe fault can be traced back to the s<strong>en</strong>sor.See page 116, paragraph 8.1.33.NoReplace the cable loom or the affectedpart thereof.Can a pressureindication be read out on thedisplay?YesNo44page 838page 29<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 45


7Diagnosis7.2 Faults with a fault codeThe following structural diagrams can be used for the systematictroubleshooting of faults with fault codes.While trying to establishes the fault causes, you should always alsocheck the contacts of all electrical plug-and-socket connectionsand the connection plugs in the UBA 3.WARNING!Danger to life due to electric shock.• Switch off the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong> wh<strong>en</strong>testing the connections!Wh<strong>en</strong>ever a fault has be<strong>en</strong> remedied, you must press the "Reset"button (for at least 5 seconds) to reset the UBA 3 to its settingstatus (release).NOTE!Resetting is not possible by switching off theoperating switch!If a fault is displayed again, you should follow the relevant structuraldiagram to carry out further troubleshooting.Certain trouble-shooting activities have to be carried out in theheating mode of the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>. The flue gas test or theservice mode must be activated th<strong>en</strong>, see chapter „4 Operation“ onpage 9, "Flue gas test" m<strong>en</strong>u on page 10 and "<strong>Service</strong> Mode"m<strong>en</strong>u on page 11.Locking boiler-fault code - (dash)No communication betwe<strong>en</strong> UBA 3 andBC10.Other display code.Press the "Reset" button.Newfault message?NoYes44page 838page 31Operating code -A46<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


iiliDiagnosis 7Lo0 Y 276The supply s<strong>en</strong>sor has measured atemperature higher than 203 °F (95 °C).ckngboLocking boiler-fault code.il0 Y 277The safety s<strong>en</strong>sor has measured atemperature higher than 203 °F (95 °C).er-faultcLocking boiler-fault code.0 Y 285The return s<strong>en</strong>sor has measured atemperature higher than 203 °F (95 °C).ode1L(flLocking boiler-fault code.ashng)BockngWait approx. 60 seconds until the boilerautomatically becomes operational again.boiler-faultcofault message 0 Y ?NoYesAre all servicing cocksop<strong>en</strong>?YesNoOp<strong>en</strong> the servicing cocks.Is thesystem pressure (measured on the boiler)in the heating system at least14.5 psi (1 bar)?YesNoFill and bleed the heating system.Is at leastone thermostatic valve op<strong>en</strong>?NoOp<strong>en</strong> a thermostatic valve.YesCheck the supply, safety and return s<strong>en</strong>sors(page 89).Are the supply and safetys<strong>en</strong>sors okay?YesCheck the primarycirculation pump.NoReplace the supply, safety and/or returns<strong>en</strong>sors (page 91).Is the primary circulationpump okay?YesNoReplace the primarycirculation pump.44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 47


7Diagnosisde 2E1L 21 1The UBA 3 does not register any connectionsto the unused contacts 78 and 50.Locking boiler-fault code.Check the contact betwe<strong>en</strong> the UBA 3and the UBA 3 mounting base.See page 125, fig 109.Is the contactokay?YesTry to remedy the fault by replacing the <strong>en</strong>tirecable loom.NoRestore the contact betwe<strong>en</strong> the UBA 3 andthe UBA 3 mounting base.See page 125, fig 109.Has the malfunction be<strong>en</strong> repaired?YesNo44page 838page 312E 207The system pressure is too low.Locking boiler-fault code.Is the pressurein the heating system at least14.5 psi (1 bar)?YesReplace the pressure s<strong>en</strong>sor to test whetherthe fault can be traced back to the s<strong>en</strong>sor.See page 116.NoFill and bleed the heating system.Is theblocking boiler-fault codecleared from the display?YesNo44page 838page 31Operating code 2F48<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Blocking boiler-fault code 2F2F 2602F 271No temperature increase after burner start orthe temperature differ<strong>en</strong>ce betwe<strong>en</strong> the supplyand safety s<strong>en</strong>sors is more than 27 °F (15 K).The temperature differ<strong>en</strong>ce betwe<strong>en</strong> the supplyand safety s<strong>en</strong>sors is more than 27 °F (15 K).Operating codeLocking boiler-fault code.Wait approx. 60 seconds until the boilerautomatically becomes operational again.fault message 2F ?NoYesAre all servicing cocksop<strong>en</strong>?YesNoOp<strong>en</strong> the servicing cocks.Is thesystem pressure (measured on the boiler)in the heating system at least14.5 psi (1 bar)?YesNoFill and bleed the heating system.Is at leastone thermostatic valve op<strong>en</strong>?NoOp<strong>en</strong> a thermostatic valve.YesCheck the supply and safety s<strong>en</strong>sors(page 89).Are the supply and safetys<strong>en</strong>sors okay?YesCheck the primarycirculation pump.NoReplace the supply and/or safety s<strong>en</strong>sors(page 91).Is the primary circulationpump okay?YesNoReplace the primarycirculation pump.44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 49


7DiagnosisLocking boiler fault code 2L2 L 2 66The primary circulation pump does notg<strong>en</strong>erate a pressure differ<strong>en</strong>ce.Locking boiler-fault code.Check the primary circulation pump formechanical jamming.Is the primary circulation pumpjammed?NoDoes the primary circulationpump run during ? 2LNoCheck the primary circulation pumpactivation.YesYesTry to undo the jam or replace the primarycirculation pump.22page 51Is the activation okay?YesReplace the primary circulation pump.NoCheck the primary circulation pump; checkthat the supply cord is not brok<strong>en</strong>.Is the supply cord okay?NoReplace the supply cord.Yes44page 838page 3150<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 2L TTpage 5022Check the primary circulation pump forsoiling.Is the primary circulation pumpsoiled?NoYesClean the circulation pump (inside).Is the expansiontank correctly connected tothe supply conduit?NoCheck whether the pressure s<strong>en</strong>sor is soiled.See page 116.YesConnect the expansion tank to the returnconduit.Is the pressure s<strong>en</strong>sorsoiled?NoReplace the pressure s<strong>en</strong>sor.See page 116.YesClean the pressure s<strong>en</strong>sor.Has the malfunction be<strong>en</strong>repaired?NoYes44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 51


7DiagnosisOperating code 2P2P 21 2Temperature increase of supply s<strong>en</strong>sor or safetys<strong>en</strong>sor is more than 7.5 °F/sec (5 K/sec).Operating codeWait approx. 30 seconds until the boilerautomatically becomes operational again.fault message 2P ?NoYesAre all servicing cocksop<strong>en</strong>?YesIs the pressurein the heating system (measured onthe boiler) at least14.5 psi (1 bar)?YesIs at leastone thermostatic valve op<strong>en</strong>?YesCheck the supply and safety s<strong>en</strong>sors(page 89).NoNoNoOp<strong>en</strong> the servicing cocks.Fill and bleed the heating system.Op<strong>en</strong> a thermostatic valve.Are the supply and safetys<strong>en</strong>sors okay?YesCheck the primarycirculation pump.NoReplace the supply and/or safety s<strong>en</strong>sors(page 91).Is the primary circulationpump okay?YesNoReplace the primarycirculation pump.44page 838page 3152<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Operating code 2U2U 21 3The temperature differ<strong>en</strong>ce betwe<strong>en</strong> the supplyand return s<strong>en</strong>sors is more than 90 °F (50 K).Operating codeWait approx. 30 seconds until the boilerautomatically becomes operational again.fault message 2U ?NoYesAre all servicing cocksop<strong>en</strong>?YesIs at leastone thermostatic valve op<strong>en</strong>?YesCheck the supply and return s<strong>en</strong>sors(page 89).NoNoOp<strong>en</strong> the servicing cocks.Op<strong>en</strong> a thermostatic valve.Are the supply and returns<strong>en</strong>sors okay?YesCheck the primarycirculation pump.NoReplace the supply and return s<strong>en</strong>sors(page 91).Is the primary circulationpump okay?NoReplace the primarycirculation pump.44Yes8page 31page 83<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 53


7DiagnosisBlocking boiler-fault code 3A3A 264The air fan has failed during the operatingphase.Locking boiler-fault code.Check that both the plug-and-socketconnections of the blower are correctly fitted.See page 88, fig 12.Are the plug-and-socketconnections fitted correctly?YesCheck blower – activation 120V ACSee page 86.NoReconnect the plug-and-socket connection ofthe blower. See page 88, fig 12.Is the activation okay?YesCheck the tacho wire of the blower.See page 88.No23page 55Tacho wire okay?NoReplace the tacho wire (page 88).YesCheck whether you can remedy the fault bytemporarily fitting a new blower.See page 88, paragraph 8.1.6.Has the malfunction be<strong>en</strong> repaired?NoCheck that the mains voltage is120V AC.YesSuffici<strong>en</strong>t mains voltage?NoHave the electrical system tested.Yes44page 838page 3154<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Blocking boiler fault code 3A-2Blocking boiler fault code 3Fpage 5423Check the supply cord of the blower(120V AC). See page 87.Is the supply cord okay?NoReplace the supply cord.Yes44page 838page 313F 273The blower is switched off during the safetytest.Locking boiler-fault code.Fully switch off the heat request and checkthat the blower is still operational after1 minute.Is the blowerstill operational?NoYes44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 55


7DiagnosisLocking boiler fault code 3L3 L 2 14The blower is switched off during the safetytest.Locking boiler-fault code.Check that both the plug-and-socketconnections of the blower are correctly fitted.See page 88, fig 12.Are theplug-and-socket connections fittedcorrectly?YesCheck blower – activation 120V AC.See page 86.NoReconnect the plug-and-socket connection ofthe blower. See page 88, fig 12.Is the activation okay?YesCheck the tacho wire of the blower.See page 88.No24page 57Tacho wire okay?NoReplace the tacho wire. See page 88.YesAttempt to rectify the fault by temporarilyreplacing the blower.See page 88.Has the malfunction be<strong>en</strong> repaired?NoYes44page 838page 3156<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 3L-2page 5624Check the supply cord of the blower(120V AC). See page 87.Is the supply cord okay?NoReplace the supply cord.Yes44page 838page 313 P 2 16The blower is running too slowly.Locking boiler-fault code.Check to see if the bloweris soiled or wet.Is the blower dry andclean?YesCheck that the mains voltage is120V AC.NoClean or replace the blower.See page 88.Suffici<strong>en</strong>t mains voltage?NoHave the electrical system tested.YesTry to remedy the fault by integrating anotherprovisional blower. See page 88.Has the malfunction be<strong>en</strong> repaired?NoYes44page 838page 31Locking boiler-fault code 3P (flashing)<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 57


7DiagnosisLocking boiler-fault code 3Y (flashing)3 Y 2 15The blower is running too fast.Locking boiler-fault code.Check the plug-and socket connection of thetacho wire to the blower. This is the thin plug.See page 88, fig 12.Is the plug-and-socketconnection okay?YesCheck the tacho wire by measuring theresistance (is the wire brok<strong>en</strong>?).See page 88.NoRestore the plug-and-socket connection.Tacho wire okay?YesCheck that the mains voltage is120V AC.NoReplace the tacho wire.Suffici<strong>en</strong>t mains voltage?YesCheck that there is no blockage in the bloweror the heat exchanger and that the flue-gassystem is connected.NoHave the electrical system tested.Did you find ablockage?NoCheck to see if there is a second blower in theflue gas outlet conduit or air inlet system.YesDeal with blockage.Is a secondblower fitted?NoCheck to see if the blower wheel has comeloose at the motor spindle.YesTake the second blower out of service.Replace the blower.See page 88, par. 8.1.6.Blower wheel loose?NoAttempt to rectify the fault by temporarilyfitting another blower. See page 88.YesHas the malfunction be<strong>en</strong> repaired?Yes44Nopage 838page 3158<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 4A4A2 18C A 2 86The supply s<strong>en</strong>sor has measured atemperature higher than 221 °F (105 °C).The return s<strong>en</strong>sor has measured atemperature higher than 221 °F (105 °C).Locking boiler-fault code.Locking boiler-fault code.Press the "Reset" button.New fault message?<strong>CA</strong>4AYesAre all servicing cocksop<strong>en</strong>?YesNoNoOp<strong>en</strong> the servicing cocks.Is thesystem pressure (measured on theboiler) in the heating system at least14.5 psi (1 bar)?YesIs at leastone thermostatic valveop<strong>en</strong>?YesCheck the primarycirculation pump.NoNoFill and bleed the heating system.Op<strong>en</strong> a thermostatic valve.Is the primary circulationpump okay?YesCheck the supply or return s<strong>en</strong>sor (page 89).NoReplace the primarycirculation pump.Are the supply andreturn s<strong>en</strong>sors okay?NoReplace the supply and return s<strong>en</strong>sor(page 91).Yes44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 59


7DiagnosisLocking boiler-fault code 4C (flashing)Locking boiler-fault code 4E (flashing)4C2 24The UBA 3 does not register the short cutbestwe<strong>en</strong> the unused contacts 22 and 24.Locking boiler-fault code.Check the contact betwe<strong>en</strong> the UBA 3and the UBA 3 mounting base.See page 126, fig 110.Is the contact okay?YesTry to remedy the fault by replacing the <strong>en</strong>tirecable loom.NoRestore the contact betwe<strong>en</strong> the UBA 3 andthe UBA 3 mounting base.See page 125, fig 109.Has the malfunction be<strong>en</strong> repaired?YesNo44page 838page 314E2 78The s<strong>en</strong>sor test has failed.Locking boiler-fault code.Measure the voltage to check for a possibleshort circuit in the supply or safety s<strong>en</strong>sorwiring. See page 126.Is the wiringokay?YesNoReplace the cable loom or the affected partthereof.44page 838page 31Locking boiler-fault code 4E (flashing)60<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 4L4L2 20The safety s<strong>en</strong>sor is shorted or measurestemperatures higher than 266 °F (130 °C).Locking boiler-fault code.Press the "Reset" button.New fault message 4L ?NoYesAre all servicing cocksop<strong>en</strong>?YesNoOp<strong>en</strong> the servicing cocks.Is the pressure in theheating system at least14.5 psi (1 bar)?YesNoFill and bleed the heating system.Is at leastone thermostatic valveop<strong>en</strong>?YesCheck the primarycirculation pump.NoOp<strong>en</strong> a thermostatic valve.Is the primary circulationpump okay?YesCheck the wire to the safety s<strong>en</strong>sor for signsof short circuiting (page 92).NoReplace the primarycirculation pump.Is the wire okay?YesNoReplace the cable loom or the affected partthereof.25page 6226page 62<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 61


7DiagnosisLocking boiler fault code 4L-2page 61page 612526Check the safety s<strong>en</strong>sor (page 89).NoIs the safety s<strong>en</strong>sor okay? Replace the safety s<strong>en</strong>sor (page 91).Yes44page 838page 314P2 21The safety s<strong>en</strong>sor contact is interrupted.Locking boiler-fault code.Press the "Reset" button.New fault message 4P?NoYesCheck the wire to the safety s<strong>en</strong>sor for thecorrect contact (page 92).Is the wire okay?YesCheck the safety s<strong>en</strong>sor (page 89).NoReplace the cable loom or the affected partthereof.NoIs the safety s<strong>en</strong>sor okay? Replace the safety s<strong>en</strong>sor (page 91).Yes44page 838page 31Locking boiler fault code 4P62<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 4U4U2 22C U 2 40The supply s<strong>en</strong>sor contact is shorted.The return s<strong>en</strong>sor contact is shorted.Locking boiler-fault code.Locking boiler-fault code.Press the "Reset" button.New fault messageU or C ?4 UYesCheck the wire to the supply or return s<strong>en</strong>sorfor signs of short circuiting (page 92).NoIs the wire okay?YesCheck the supply and return s<strong>en</strong>sor(page 89).NoReplace the cable loom or the affected partthereof.Are the supply and returns<strong>en</strong>sors okay?NoReplace the supply and return s<strong>en</strong>sor(page 91).Yes44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 63


7DiagnosisLocking boiler fault code 4Y4 Y 2 23C Y 2 41The supply s<strong>en</strong>sor contact is interrupted.The return s<strong>en</strong>sor contact is interrupted.Locking boiler-fault code.Locking boiler-fault code.Press the "Reset" button.New fault messageor ?4YCYYesCheck the wire to the supply or return s<strong>en</strong>sorfor the proper contact (page 92).NoIs the wire okay?YesCheck the supply and return s<strong>en</strong>sor(page 89).NoReplace the cable loom or the affected partthereof.Are the supplyand return s<strong>en</strong>sors okay?YesNoReplace the supply and return s<strong>en</strong>sor(page 91).44page 838page 3164<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 6A6 A 2 27No ionization after four startup attempts.Locking boiler-fault code.27 page 71Press the "Reset" button.New fault message 6A ?YesIs theheating system propanegas-fired?NoMeasure the static inlet gas pressure.See page 107.NoYesContact the gas utility company to <strong>en</strong>sure thatno nitrog<strong>en</strong> remains in the gas tank or gassupply pipes.Is theinlet gas pressureokay?YesBleed the gas supply pipe. See page 106.No28 page 68Has the gas supply pipebe<strong>en</strong> bled of air?YesCheck the hot surface ignitor is activatedduring the operating code 0C .See page 92.NoBleed the gas supply pipe. See page 106.Is thehot surface ignitor activatedduring the operatingcode . 0CYesCheck the resistance of the hot surfaceignitor. See page 93.No29 page 68Is the resistance of thehot surface ignitorokay?YesNoReplace the hot surface ignitor.See page 94.30page 6631page 71<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 65


7DiagnosisLocking boiler fault code 6A -2page 6530Check the hot surface ignitor glowsduring the operating code 0C .See page 92.Does thehot surface ignitor activatedglow during the operatingcode ? 0CYesCheck the gas valve is op<strong>en</strong>ed during theoperating code 0L .See page 98.NoReplace the hot surface ignitor.See page 94.Is the gas valveop<strong>en</strong>?YesMeasure the dynamic inlet gas pressure.See page 107.No32 page 69Is thedynamic inlet gas pressureokay?YesMeasure the gas/air ratio during the startupphase. See page 108.No33 page 70Is the gas/air ratio correctlyadjusted?YesCheck that the correct gas orifice was fitted.See page 127, table 5.NoAdjust the gas/air ratio.See page 108.Was thecorrect gas orificefitted?YesNoFit the correct gas orifice.See page 127, table 5.34page 6731page 7166<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 6A -3page 6634Check the following elem<strong>en</strong>ts for soiling,damage and correct assembly:- the combustion-air inlet conduit- the air suction tube- the seal betwe<strong>en</strong> the V<strong>en</strong>turi and the blower- the gas orifice, see page 101 andpage 127, table 5- the blower, see page 86- the connection betwe<strong>en</strong> the blower and theburner- the burner- the heat exchanger, see page 117- the flue gas conduit.Are the abovem<strong>en</strong>tionedcompon<strong>en</strong>ts clean andfree from damage?NoClean and/or replace the correspondingcompon<strong>en</strong>ts.YesMeasure the ionization curr<strong>en</strong>t.See page 95.Is the ionization curr<strong>en</strong>tokay?YesNo35 page 7131page 71<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 67


7Diagnosisvorh6A Branch 036A Branch 04page 6528Check whether the gas stop tap is op<strong>en</strong>.See page 101.Is the gas stop tap op<strong>en</strong>?YesCheck to see if there is a blockage in theconduit betwe<strong>en</strong> the gas stop tap and gasvalve.NoOp<strong>en</strong> the gas stop tap. See page 101.Did youfind a blockage?NoCheck for blockages in the remaining sectionof the gas supply pipe.YesDeal with blockage.Did youfind a blockage?NoIf the required inlet gas pressure is notavailable, you should consult your gas utilitycompany.YesDeal with blockage.31page 71page 6529Measure the resistance in the wires betwe<strong>en</strong>the switch of the hot surface ignitor and theUBA 3. See page 99.Is the wiring okay?NoReplace the cable loom or the affected partthereof.Yes44page 8331page 7168<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 76A Branch 05 v1 v8page 6632Check the plug-and-socket connection of thegas valve. See page 99.Is the plug-and-socketconnection okay?YesCheck the gas valve during theoperating code 0L to make sure it receivespower th<strong>en</strong>. See page 98.NoReconnect the plug-and-socket connection atthe gas valve. See page 99.Does the gas valve receive power?NoMeasure the resistance in the wires betwe<strong>en</strong>the gas valve plug andthe UBA 3 mounting base.YesReplace the gas valve.See page 101.Is the wiring okay?YesNoReplace the cable loom or the affected partthereof.44page 8331page 71<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 69


7Diagnosis6A Branch 06page 6633Check whether the gas stop tap is op<strong>en</strong>.See page 101.Is the gas stop tap op<strong>en</strong>?YesCheck for blockages in the remaining sectionof the gas supply pipe.NoOp<strong>en</strong> the gas stop tap. See page 101.Did you find a blockage?NoCheck for blockages in the remaining sectionof the gas supply pipe.YesDeal with blockage.Did you find a blockage?NoCheck whether the overall gas-conduitnetwork is of suffici<strong>en</strong>t capacity.YesDeal with blockage.Is the overall gas-conduitnetwork of suffici<strong>en</strong>t capacity?NoReinforce the gas-conduit network.YesConsult the utilitycompany.31page 7170<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 76A Branch 07page 6735Check the plug-and-socket connectionbetwe<strong>en</strong> the ionization electrode and cableloom. See page 95.Is the plug-and-socketconnection okay?YesMeasure the resistance in the wires betwe<strong>en</strong>the ionization electrode plug and the UBA 3mounting base. See page 95.NoCorrectly insert the plug into its socket.Is the wiring okay?YesNoReplace the cable loom or the affected partthereof.Check the ionization electrode and replace itif necessary. See page 9731page 71pages 65 to 7131Press the "Reset" button.Has a new fault codeoccurred?NoYesHas a new locking boiler faultcode occurred?6ANoRemedy the fault using the structure diagramthat corresponds with the fault code.YesDid yougo through all structure diagramsthru 35 ?YesNo27page 6544page 838page 316A Branch 08<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 71


7DiagnosisLocking boiler fault code 6C6 C 2 28An ionization curr<strong>en</strong>t was measured beforethe burner start.Locking boiler-fault code.Press the "Reset" button.New fault message 6C ?NoYesCheck the ionization electrode for soiling.Damage see page 95.Is the ionization electrodeokay?YesNoReplace the ionization electrode.See page 97.44page 728page 316 C 3 06An ionization curr<strong>en</strong>t was measured after theburner switch-off.Locking boiler-fault code.Check that the burner is still under pressureafter the heat request has <strong>en</strong>ded.See page 108, par. 8.1.26.Is the burner still underpressure?YesReplace the gas valve.See page 101.No44page 778page 31Locking boiler fault code 6C-272<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Blocking boiler-fault code 6L6L 229Ionization fails during the operating phase.Locking boiler-fault code.Is theheating system propanegas-fired?NoMeasure the static inlet gas pressure.See page 107.YesEnsure that no nitrog<strong>en</strong> remains in the gastank or gas supply pipes, in close consultationwith the gas utility company.Is the static inlet gas pressureokay?YesBleed the gas supply pipe. See page 106.No38 page 75Has the gas supply pipebe<strong>en</strong> bled of air?YesMeasure the dynamic inlet gas pressure.See page 107.NoBleed the gas supply pipe. See page 106Is thedynamic inlet gas pressureokay?YesMeasure the gas/air ratio during the startupphase. See page 108.No39 page 76Is the gas/air ratio correctlyadjusted?YesNoAdjust the gas/air ratio.See page 108.40page 7441page 77<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 73


7DiagnosisBlocking boiler-fault code 6L - 2page 7340Check that the correct gas orifice was fitted.See page 127, table 5.Was thecorrect gas orificefitted?YesCheck the following elem<strong>en</strong>ts for soiling,damage and correct assembly:- the combustion-air inlet conduit- the air suction tube- the seal betwe<strong>en</strong> the V<strong>en</strong>turi and the blower- the gas orifice, see page 101 andpage 127, table 5- the blower, see page 86- the connection betwe<strong>en</strong> the blower and theburner- the burner- the heat exchanger, see page 117- the flue gas conduitNoFit the correct gas orifice.See page 127, table 5.Are the abovem<strong>en</strong>tionedcompon<strong>en</strong>ts clean andfree from damage?NoClean and/or replace the correspondingcompon<strong>en</strong>ts.YesMeasure the ionization curr<strong>en</strong>t.See page 95.Is the ionization curr<strong>en</strong>tokay?YesNo42 page 7741page 7774<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Blocking boiler-fault code 6L - br12page 7338Check whether the gas stop tap is op<strong>en</strong>.See page 101.Is the gas stop tapop<strong>en</strong>?YesCheck to see if there is a blockage in the gasconduit section betwe<strong>en</strong> the gas stop tap andgas valve.NoOp<strong>en</strong> the gas stop tap. See page 101.Did you find a blockage?YesDeal with blockage.NoCheck for blockages in the remaining sectionof the gas supply pipe.Did you find a blockage?YesDeal with blockage.NoIf the required inlet gas pressure is notavailable, you should consult the relevantgas utility company.41page 77<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 75


7DiagnosisBlocking boiler-fault code 6L branch 13page 7339Check whether the gas stop tap is fully op<strong>en</strong>.See page 101.Is the gas stop tapfully op<strong>en</strong>?YesCheck to see if there is a blockage in the gasconduit section betwe<strong>en</strong> the gas stop tap andgas valve.NoOp<strong>en</strong> the gas stop tap. See page 101.Did you find a blockage?NoCheck for blockages in the remaining sectionof the gas supply pipe.YesDeal with blockage.Did you find a blockage?NoCheck whether the overall gas-conduitnetwork is of suffici<strong>en</strong>t capacity.YesDeal with blockage.Is the overall gas-conduitnetwork of suffici<strong>en</strong>t capacity?NoReinforce the gas-conduit network.YesConsult the gas utility company.41page 7776<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Blocking boiler-fault code 6L branch 14page 7442Check the plug-and-socketconnection betwe<strong>en</strong> the ionization electrodeand cable loom. See page 95.Is the plug-and-socketconnection okay?YesMeasure the resistance in the wires betwe<strong>en</strong>the ionization electrode plug and the UBA 3mounting base. See page 99.NoCorrectly insert the plug into its socket.Is the wiring okay?YesReplace the ionization electrode.See page 97NoReplace the cable loom or the affected partthereof.41page 77page 73 – page 7741Press the "Reset" button.Has a new fault codeoccurred?NoYesHas a new locking boiler faultcode occurred?6LNoRemedy the fault using the structure diagramthat corresponds with the fault code.YesDid yougo through all structure diagramsthru 14?YesNo44page 2944page 838page 31locking boiler fault code 6L Zijtak 1e 5<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 77


7DiagnosisLocking boiler-fault code 6P (flashing)6 P 2 69The hot surface ignitor activates too long.Locking boiler-fault code.Press the "Reset" button.Has the malfunction be<strong>en</strong> repaired?YesNoKIM defective, contact the <strong>Buderus</strong> customerservice departm<strong>en</strong>t. See on the back side ofthis docum<strong>en</strong>t.8page 317 C 2 31The power supply was interruptedafter a fault message.Locking boiler-fault code.Press the "Reset" button.Has a new fault codeoccurred?NoYesRemedy the fault using the structure diagramthat corresponds with the fault code.8page 31Locking boiler-fault code 7C Locking boiler-fault code 7L (flashing)78<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Operating code 8Y7 L 2 617 L 2 80The UBA 3 is defective.The UBA 3 is defective.Locking boiler-fault code.Locking boiler-fault code.44page 838 Y 232The external switch contact is activated.Locking boiler-fault code.Check that the switch contact isconnected to the boiler.See page 106, fig. 54, pos. 5 "EV".Is an external switchcontact connected?YesCheck to see if an external switch contactis op<strong>en</strong>, by measuring its resistance using avolt-ohm-multimeterNo43page 80Is the external switchcontact op<strong>en</strong>?NoMeasure the cable loom betwe<strong>en</strong> the UBA 3and the terminal strip.See page 126, fig 110.YesExternal switch contact has <strong>en</strong>ergized.Is the cable loom okay?YesCheck the contact betwe<strong>en</strong> the UBA 3and the UBA 3 mounting base.NoReplace the cable loom or the affected partthereof.Is the contact okay?YesNoRestore the contact.44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 79


7DiagnosisOperating code 8Y dl 2page 7943Check to see if a bridge wire is pres<strong>en</strong>t.See page 106, fig. 54, pos. 5 "EV".Is there a bridge wire?YesMeasure the cable loom betwe<strong>en</strong> the UBA 3and the terminal strip.See page 126, fig 110.NoRestore the bridge on the terminal strip again(see page 106, fig. 54).Is the cable loom okay?YesCheck the contact betwe<strong>en</strong> the UBA 3 andthe UBA 3 mounting base.Is the contact okay?YesNoNoReplace the cable loom or the affected partthereof.Restore the contact.44page 838page 319 A2 359 H2 379 P2 399 U2 33+ any digit or letter toE 2 42 2 87KIM or UBA 3 is defective.KIM or UBA 3 is defective.KIM or UBA 3 is defective.KIM or UBA 3 is defective.KIM or UBA 3 is defective.Locking boiler-fault code.Locking boiler-fault code.Locking boiler-fault code.Locking boiler-fault code.Locking boiler-fault code.+ any digit or letter The UBA 3 is defective. Locking boiler-fault code.E 290Press the "Reset" button.Newfault message 9A or9H9P9UEor or or ?NoYes44page 838page 31Locking boiler fault codes 9A, 9H, 9P, 9U, E80<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Locking boiler fault code 9L9 L 2 349 L 2 38The gas valve coil or the wiring to the gasvalve is defective.The UBA 3 is defective.Locking boiler-fault code.Locking boiler-fault code.Press the "Reset" button.New fault message 9L ?NoYesCheck the plug-and-socket connection of thegas valve. See page 98, par. 8.1.18.Is the plug-and-socketconnection okay?YesMeasure the wire betwe<strong>en</strong> the gas valveand the UBA 3.See page 99, fig 8.1.20.NoRestore the plug-and-socket connection.See page 98, par. 8.1.18.Is the wire okay?YesMeasure the resistance of the two gas valvecoils. See page 101, par. 8.1.22.NoReplace the cable loom or the affected partthereof.Is the resistance correct?YesNoReplace the gas valve.See page 101.44page 838page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 81


7DiagnosisLocking boiler fault code H 7/P--C 0 2 88C 0 2 89The UBA 3 has no connection to the pressures<strong>en</strong>sor or there is a short circuit.Short circuit in connection to pressure s<strong>en</strong>sor.Locking boiler-fault code.Locking boiler-fault code.Check the plug-and socket connection of thepressure s<strong>en</strong>sor. See page 8, fig. 1, pos. 17.Is the plug-and-socketconnection okay?YesCheck the wiring betwe<strong>en</strong> the pressures<strong>en</strong>sor and the UBA 3 mounting base bymeasuring the resistance (fracture).See page 126, fig 110.NoRestore the plug-and-socket connection.Is the wiring okay?YesTry to remedy the fault by integratinganother provisional pressure s<strong>en</strong>sor.See page 116.NoReplace the cable loom or the affected partthereof.Has the malfunction be<strong>en</strong> repaired?YesNo44 8page 83page 3182<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Diagnosis 7Replace the UBA44Check the contacts betwe<strong>en</strong> the UBA 3 andthe UBA 3 mounting base, betwe<strong>en</strong> the BC10and the base plate and all other plug-andsocketconnections.See from page 92.Remedy contact faults.See from page 92.Press the "Reset" button and hold it for2 seconds. See page 9.Replace the UBA 3. See page 125.NoIs the same fault messagedisplayed?NoYesHas the UBA 3 alreadybe<strong>en</strong> replaced?YesCall the <strong>Buderus</strong> customer service departm<strong>en</strong>t.See on the back side of this docum<strong>en</strong>t.Has a new fault occurred?NoYesRemedy the fault using the structure diagramfrom this docum<strong>en</strong>t that corresponds with thefault code.8page 31<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 83


8Actions8 Actions8.1 Testing, measuring, adjusting and replacingvarious compon<strong>en</strong>ts8.1.1 Checking the UBA 3 fuse; replace if necessary• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 by turning it counterclockwise(see fig. 4, pos. 1).2WARNING!Do not pull or move side to side the UBA 3during loos<strong>en</strong>ing or tight<strong>en</strong>ing of UBA 3 fast<strong>en</strong>ingscrew.• Remove the UBA 3 once the fast<strong>en</strong>ing screw is fully loos<strong>en</strong>edby pulling it forward carefully as indicated by the arrow (seefig. 4, pos. 2).• Dismantle the fuse holder by loos<strong>en</strong>ing the bayonet connector(see fig. 5, pos. 1).• Remove the fuse from the fuse holder.• Check the circuit continuity through the fuse using the volt-ohmmultimeter.If brok<strong>en</strong>, replace it by (a new) spare ceramic fuse5 amps, 250V fast blow (F5AH, 250V) (fig. 5, pos. 2).• Re-assemble the UBA 3 in reverse order of disassembly.• Fast<strong>en</strong> the UBA 3 by only turning the fast<strong>en</strong>ing screw clockwise.WARNING!Do not push or force the UBA 3 in place by hand.1fig. 4 Dismantling the UBA 312• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 5Checking the fuses84<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.2 External connection board fuse• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Remove the cover from the connection box (fig. 6).fig. 6Removing the cover from the connection box• Dismantle the fuse holder (fig. 7, pos. 10).• Remove the fuse from the fuse holder.• Check the circuit continuity through the fuse using the volt-ohmmultimeter.If brok<strong>en</strong>, replace it with a (new) ceramic fuse5 amps, 250V fast blow (F5AH, 250V).• Re-install the cover on the connection box.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).11RC FA WA FW EVPK PS PZ Grid1 2 3 4 5 6 7 8 9 10fig. 7 External connection boardpos. 1: RC Room thermostat (connection color orange)pos. 2: Outdoor-temperature s<strong>en</strong>sor (connection colorblue)pos. 3: Pot<strong>en</strong>tial-free On/Off thermostat (connection colorgre<strong>en</strong>)pos. 4: DHW temperature s<strong>en</strong>sor (connection color grey)pos. 5: External switching contact, pot<strong>en</strong>tial-free for floorheating safety etc. (connection color red)pos. 6: DO NOT USEpos. 7: Primary loop pump 120V 60Hz (connection colorgre<strong>en</strong>)pos. 8: DHW tank pump 120V 60Hz (connection color grey)pos. 9: DHW recirculating pump 120V 60Hz (connectioncolor lilac)pos. 10: main connection 120V 60Hz (connection colorwhite)pos. 11: Fuse holder<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 85


8Actions8.1.3 Checking the fan unit; 120 VAC controlNOTEThe fan unit can be controlled using the RC controldevice relay test function. Further instructions forthe RC control device are in the Installation andMaint<strong>en</strong>ance Instructions.WARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.• Remove the casing.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Disconnect the 120V AC plug of the fan unit.• Test the voltage with the volt-ohm-multimeter; set it to VAC.Minimum value 250V AC.• Connect the volt-ohm-multimeter to the outer two plug contacts(blue and brown) (see fig. 8).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Start up the boiler in accordance with the "Flue gas test" m<strong>en</strong>u.See page 10 "Flue gas test" m<strong>en</strong>u.• Check that while the operating code [0/l/\| is displayed,120V AC is available on the outer two contacts (blue andbrown) of the plug (see fig. 8).• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Reconnect the plug to the fan unit.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 8Checking for 120V AC voltage86<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.4 Checking the fan unit; supply cord (120V AC)WARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.2• Remove the casing.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Disconnect the 120V AC plug of the fan unit.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 9, pos. 1).• Remove the UBA 3 by pulling it forward as indicated by thearrow (see fig. 9, pos. 2).• Set the volt-ohm-multimeter to "Resistance testing".• Test the fan unit supply cord to make sure that there is no shortcircuit in it and that it is not brok<strong>en</strong> anywhere (see fig. 10 andfig. 110 on page 126).• Reconnect the plug to the fan unit.• Re-assemble the UBA 3 in reverse order of disassembly.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Fit the casing.1fig. 9 Dismantling the UBA 381-pole connectorPin 12855Pin 16Pin 8116-pole connectorPin 1KIMfig. 10UBA 3 installation base<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 87


8Actions8.1.5 Checking the fan unit; tacho cableWARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.• Remove the casing.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Dismantle the tacho cable plug.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 9, pos. 1).• Remove the UBA 3 by pulling it forward as indicated by thearrow (see fig. 9, pos. 2).• Test the tacho cable to make sure that there is no short circuitin it and that it is not brok<strong>en</strong> (see fig. 11).• Assemble the tacho cable plug.• Re-assemble the UBA 3 in reverse order of disassembly.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 1181-pole connectorPin 12855Pin 81KIMUBA 3 installation basePin 16Pin 116-pole connector8.1.6 Replacing the fan unitNOTEFollow the installation instructions for 120V fanunits!• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Remove both cable plugs from the fan unit(see fig. 12, pos. 1).1fig. 12Disconnect the cable plug from the fan unit88<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Remove the air suction tube (see fig. 13, pos. 1).• Remove the fan unit fast<strong>en</strong>ing screw (see fig. 13, pos. 2).• Remove the fan unit by swinging it to the right(see fig. 13, pos. 3).• Install the new fan unit.• Install the fast<strong>en</strong>ing screw, air suction tube and both plugs.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).321fig. 13Dismantling the fan unit8.1.7 Checking the supply/return/safety/hot-water temperatures<strong>en</strong>sorsNOTICEThe curr<strong>en</strong>t temperature measured by the supply,return and safety s<strong>en</strong>sors, can be read out from theRC control device.For further instructions, see installation and maint<strong>en</strong>anceinstructions of the RC control device.12WARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.V• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.fig. 14Checking the supply/return s<strong>en</strong>sors<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 89


8Actions• Disconnect the plug and socket connection of the cable for thes<strong>en</strong>sor concerned.• Test the resistance of the s<strong>en</strong>sor concerned.Supply s<strong>en</strong>sor see fig. 14, pos. 1.Return s<strong>en</strong>sor see fig. 14, pos. 2.Safety s<strong>en</strong>sor see fig. 15, pos. 1.• Measure the temperature near the s<strong>en</strong>sor using a secondsthermometer.• Compare the values measured to the values in table 4 on th<strong>en</strong>ext page. If the values differ, the s<strong>en</strong>sor is brok<strong>en</strong>.• Reconnect the plug and socket connection if the s<strong>en</strong>sor is OK.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).1fig. 15Checking the safety s<strong>en</strong>sorTemperature inResistance in°F °C Ω32 0 29,49041 5 23,46250 10 18,78759 15 15,13668 20 12,26877 25 10,00086 30 8,19795 35 6,754104 40 5,594113 45 4,656122 50 3,893131 55 3,271140 60 2,760149 65 2,339158 70 1,990167 75 1,700176 80 1,458185 85 1,255194 90 1,084203 95 940212 100 817table 4S<strong>en</strong>sor resistance values (target values)90<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.8 Replacing the supply/return/safety s<strong>en</strong>sors• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the maint<strong>en</strong>ance shut-off valves.• Drain the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>.• Disconnect the plug and socket connection.• Unscrew the s<strong>en</strong>sor concerned and replace it by a new one.Supply s<strong>en</strong>sor see fig. 16, pos. 1.Return s<strong>en</strong>sor see fig. 16, pos. 2.Safety s<strong>en</strong>sor see fig. 17, pos. 1.• Restore the plug and socket connection.• Op<strong>en</strong> the maint<strong>en</strong>ance shut-off valves.• Purge air from the boiler.12fig. 16 Replacing the supply/return s<strong>en</strong>sorsNOTICEFill and purge the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong> asrequired. See installation and maint<strong>en</strong>ance instructions<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).18.1.9 Checking the hot-water temperature s<strong>en</strong>sor• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Disconnect the plug and socket connection of the cable for thehot-water temperature s<strong>en</strong>sor.• Pull out the s<strong>en</strong>sor and replace it by a new one.• Restore the plug and socket connection.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 17Replacing the safety s<strong>en</strong>sor<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 91


8Actions8.1.10 Checking the supply/return/safety s<strong>en</strong>sors cableWARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.2• Check all plug and socket connections of the s<strong>en</strong>sors and theUBA 3. A plug that has not be<strong>en</strong> inserted correctly may be thecause for a fault message. Th<strong>en</strong> start the boiler by pressing"Reset" c.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 18, pos. 1).• Remove the UBA 3 by pulling it forward as indicated by thearrow (see fig. 18, pos. 2).• Disconnect the plug and socket connection of the cable for thes<strong>en</strong>sor.1fig. 18 Dismantling the UBA 3• Check the cable betwe<strong>en</strong> the plug and socket connection andthe 81-pole plug in the UBA 3 installation base (see fig. 19)using a circuit continuity testing device.See the electric circuit diagram, fig. 110 on page 126.Pin 12855Pin 16• Test this in a straight line twice and test it diagonally twice.• Restore the plug and socket connection if the cables are OK.• Install the UBA 3.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).81-pole connectorKIM16-pole connector8.1.11 Checking the hot surface ignitor; controlNOTICEThe hot surface ignitor can be controlled using theRC control device relay test function. Furtherinstructions for the RC control device are in theinstallation and maint<strong>en</strong>ance instructions.fig. 19Pin 81UBA 3 installation basePin 1• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Disconnect the plug and socket connection of the hot surfaceignitor.• Set the measuring device to 120V AC.• Connect the measuring device to the plug on the cableharness.• Connect the heating system to the power supply, insert themain fuse or switch on the circuit breaker.92<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Set the main switch on the BC10 to "1" (On).• Start up the boiler in accordance with the "Flue gas test" m<strong>en</strong>u.See page 10 "Flue gas test" m<strong>en</strong>u.• Test that during the ignition phase, while the operating code[0/l/\| is being displayed, 120V AC is measured.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the measuring device.• Assemble the plug and socket connection of the hot surfaceignitor.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).8.1.12 Checking the hot surface ignitor; resistance• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Disconnect the plug and socket connection of the cable of thehot surface ignitor.• Test the resistance of the hot surface ignitor on the plug.A resistance value betwe<strong>en</strong> 50 – 300 Ω means that the hotsurface ignitor is OK (see fig. 20).• Remove the measuring device.• Reconnect the cable plug if the hot surface ignitor is OK.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).8.1.13 Checking the hot surface ignitor; supply cordWARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.fig. 20Checking the hot surface ignitor2• Remove the casing.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Pull the plug of the hot surface ignitor.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 21, pos. 1).• Remove the UBA 3 by pulling it forward as indicated by thearrow (see fig. 21, pos. 2).• Set the volt-ohm-multimeter to "Resistance testing".1fig. 21 Dismantling the UBA 3<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 93


8Actions• Test the supply cord of the hot surface ignitor to make sure thatthere is no short circuit in it and that it is not brok<strong>en</strong> (fig. 23,fig. 22 and fig. 110 on page 126).Pin 81Pin 12855Pin 1Pin 16KIM81-pole connector16-pole connectorfig. 22UBA 3 installation base• Fit the plug to the hot surface ignitor.• Re-assemble the UBA 3 in reverse order of disassembly.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Fit the casing.fig. 23Testing the supply cord of the hot surface ignitor8.1.14 Replacing the hot surface ignitor• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Disconnect the plug and socket connection of the cable of thehot surface ignitor.• Loos<strong>en</strong> the fast<strong>en</strong>ing screws (fig. 24, pos. 1).• Remove the earth cable (fig. 24, pos. 2).• Remove the mounting plate (fig. 24, pos. 3).• Remove the hot surface ignitor (fig. 24, pos. 4).• Install the new hot surface ignitor with a new gasket and attachthe mounting plate with fast<strong>en</strong>ing screws (see fig. 24, pos. 1).• Restore the plug and socket connection of the hot surfaceignitor.• Fit the casing.fig. 24Replacing the hot surface ignitor94<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).8.1.15 Testing the ionization curr<strong>en</strong>tWARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Disconnect the plug and socket connection of the monitoringcable.• Connect the measuring device in series (see fig. 25).• Set the multi-meter to DC µA.• Connect the heating system to the power supply, insert themain fuse or switch on the circuit breaker.• Set the main switch on the BC10 to "1" (On).• Start up the boiler in accordance with the "<strong>Service</strong> Mode" m<strong>en</strong>u.See page 11 "<strong>Service</strong> Mode" m<strong>en</strong>u.• Test the ionization curr<strong>en</strong>t at partial load. The boiler is in partloadoperation as soon as, in the "<strong>Service</strong> Mode" m<strong>en</strong>u, [l/3/0|is selected. The ionization curr<strong>en</strong>t must be > 1.4 DC µA.• Remove the measuring device.• Reconnect the plug and socket connection of the monitoringcable if the ionization curr<strong>en</strong>t is OK.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 25Testing the ionization curr<strong>en</strong>t8.1.16 Checking the ionization electrode; cable• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Dismantle the plug and socket connection of theionization electrode.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 26, pos. 1).• Remove the UBA 3 by pulling it forward as indicated by thearrow (see fig. 26, pos. 2).21fig. 26 Dismantling the UBA 3<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 95


8Actions• Test the ionization cable betwe<strong>en</strong> the plug and socket connectionand the UBA 3 installation base to make sure that it has noshort circuit to earth (see fig. 27 and fig. 110 on page 126) andthat it is not brok<strong>en</strong> anywhere (see fig. 28).• Assemble the plug and socket connection of the ionization electrode.• Re-assemble the UBA 3 in reverse order of disassembly.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 27Testing the earth connection circuit of the ionizationelectrode (1)Pin 12855UBA3Pin 81Pin 1KIM81-pole connector16-pole connectorPin 16fig. 28Testing the earth connection circuit of the ionizationelectrode (2)96<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.17 Checking the ionization electrode; replace ifnecessary• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Disconnect the plug and socket connection of the cable.• Set the volt-ohm-multimeter to "Resistance testing".• Test the earth connection circuit of the ionization electrode (seefig. 27). The height of the resistance value must be infinite.• Loos<strong>en</strong> the fast<strong>en</strong>ing screws (see fig. 29, pos. 1).• Remove the earth cable (see fig. 29, pos. 2).• Remove the mounting plate (see fig. 29, pos. 3).• Dismantle the ionization electrode (see fig. 29, pos. 4).• Set the volt-ohm-multimeter to "Resistance measurem<strong>en</strong>t".• Test the resistance of the ionization electrode (see fig. 30).The resistance must be 0 Ω.fig. 29Replacing the ionization electrode• Check the ionization electrode for contamination, wear ordamage (see fig. 31).• Replace the ionization electrode if required.• Install a new ionization electrode with a new gasket and securethe mounting plate with the fast<strong>en</strong>ing screws.• Fit the earth cable (see fig. 29, pos. 2).• Restore the plug and socket connection.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 30Testing the resistance of the ionization electrodefig. 31Checking the ionization electrode<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 97


8Actions8.1.18 Checking the gas control valve; cable connections• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Check that the plug of the gas control valve has be<strong>en</strong> installedcorrectly (see fig. 32, pos. 1).• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).1fig. 32Checking the cable connections to the gas controlvalve (e.g. HONEYWELL gas control valve)8.1.19 Checking the gas control valve; ControlNOTICEYou can drive the burner (the gas valve) using therelay test in combination with the RC controldevice. See installation and maint<strong>en</strong>ance instructionsof the RC control device.WARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.• Remove the casing.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Start up the boiler in accordance with the “Flue gas test” m<strong>en</strong>u.See page 10 "Flue gas test" m<strong>en</strong>u.• Use a volt-ohm-multimeter to check that, while operating code[0/l/\| is displayed, there is a voltage on the plug of the gascontrol valve. The test must indicate a voltage of 20 – 24 VDCboth wh<strong>en</strong> testing on the c<strong>en</strong>tral and left contacts and wh<strong>en</strong>testing on the c<strong>en</strong>tral and right contacts (see fig. 33).• Fit the casing.fig. 33Voltage testing on the gas control valve98<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.20 Checking the gas control valve; cable connectionbetwe<strong>en</strong> gas control valve and UBA 3 installationbaseWARNING!Avoid damage: do not push the measuring pin ofthe volt-ohm-multimeter too deeply into the socket.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Remove the plug of the gas control valve (see fig. 34).fig. 34Removing the gas control valve plug• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 35, pos. 1).• Pull the UBA 3 forward in the direction indicated by the arrow(see fig. 35, pos. 2).21fig. 35 Dismantling the UBA 3• Test the resistance of the cable betwe<strong>en</strong> the plug of the gascontrol valve and the UBA 3 installation base (see fig. 36,fig. 37 and circuit diagram, fig. 110 on page 126).• Reconnect the plug to the gas control valve (see fig. 34).• Re-install the UBA 3 (see fig. 35).• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 36Testing the cable betwe<strong>en</strong> the gas control valve andthe UBA 3 installation base<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 99


8ActionsPin 81Pin 1KIM81-pole connector16-pole connectorPin 12855Pin 16fig. 37UBA 3 installation base8.1.21 Ohming out the gas control valve• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Remove the plug of the gas control valve (see fig. 38).• Set the volt-ohm-multimeter to "Resistance testing".Use a scale of 200 Ω or greater.fig. 38Removing the gas control valve plug• Test the resistance of both coils of the gas control valve usingthe volt-ohm-multimeter. The resistance measured betwe<strong>en</strong>the left and c<strong>en</strong>tral contacts (see fig. 39) must be approx. 75 Ωand betwe<strong>en</strong> the right and c<strong>en</strong>tral contacts (see fig. 40) thismust be approx. 185 Ω (+/- 10 Ω). If this is not the case, the gascontrol valve will probably be defective. It must th<strong>en</strong> bereplaced.• Attach the plug to the gas control valve.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 39 Testing the resistance on the gas burner ass’y (1)100<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8fig. 40 Testing the resistance on the gas burner ass’y (2)8.1.22 Replacing the gas control valveDANGERWork on gas pipes and fittings must only be carriedout by a registered service provider.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the gas shut-off valve (see fig. 41, pos. 1).fig. 41Gas shut-off valve closed (1), gas shut-off valveop<strong>en</strong> (2)• Remove the cable plug from the gas control valve (see fig. 42,pos. 1).fig. 42Removing the gas control valve plug<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 101


8Actions• Remove both cable plugs from the fan unit (see fig. 43, pos. 1).1fig. 43Disconnect the cable plug from the fan unit• Loos<strong>en</strong> the union nut of the gas control valve (see fig. 44,pos. 1).1 2fig. 44Loos<strong>en</strong>ing the union nut• Loos<strong>en</strong> both sets of retaining clips (fig. 44, pos. 2 and fig. 45,pos. 1) of the burner cover and remove the burner cover withthe fan unit and the gas burner fitting.1 1fig. 45Loos<strong>en</strong>ing the retaining clips102<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Loos<strong>en</strong> three screws on the gas control valve (see fig. 46,pos. 1).111fig. 46Loos<strong>en</strong>ing the screws• Remove the gas control valve (see fig. 47).• Remove the gas orifice from the gas control valve (see fig. 48,pos. 1).• Install the gas orifice in the new gas control valve.• Mount the new gas control valve on the fan unit.• Assemble the burner cover with the fan unit and the gas controlvalve.• Close both retaining clips.• Tight<strong>en</strong> the union nut of the gas pipe on the gas control valve.Make sure that you have inserted the gasket!• Connect both cable plugs to the fan unit.• Connect the cable plug to the gas control valve.• Op<strong>en</strong> the gas shut-off valve (see fig. 49, pos. 2).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 47fig. 481Dismantling the gas control valveDismantling the gas orifice<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 103


8ActionsNOTICE!Carry out all start-up activities according to theInstallation and Servicing Instructions andcomplete the start-up report.You must also check all gaskets and seals affected by the replacem<strong>en</strong>tactivities during the tightness test carried out in operatingconditions!• Fit the casing.fig. 49Gas shut-off valve closed (1), gas shut-off valveop<strong>en</strong> (2)8.1.23 Checking the control unit; connections to the boilerIf an On/Off thermostat is used and the boiler does not react toa heat request:• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Remove the cover from the connection box (see fig. 50).• Use a jumper wire to create a bridging circuit betwe<strong>en</strong> the two"WA" contacts (see fig. 53, pos. 3).• Connect the heating system to the power supply, insert themain fuse or switch on the circuit breaker.• Set the main switch on the BC10 to "1" (On).• If the boiler switches to heating mode (operating code [-/h/\| )after some time, the cause of the fault must be outside theboiler.• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off). See page 9 „M<strong>en</strong>ustructure of the BC10 basic controller“.• Remove the bridge betwe<strong>en</strong> the two "WA" contacts (see fig. 53,pos. 3).• Connect the On/Off thermostat directly to the two "WA"contacts of the boiler using a short cable (see fig. 53, pos. 3).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Set the On/Off thermostat to the request position.• If the boiler switches to heating operation (operating code[-/h/\| ) after some time, the fault is caused by the cablebetwe<strong>en</strong> the On/Off thermostat and the boiler.fig. 50fig. 51Removing the cover from the connection boxInstalling the cover of the connection box104<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• If the boiler does not switch to heating mode after some time,the fault is caused by the On/Off thermostat.• Correct the cause of the fault.• Fit the cover on the connection box (see fig. 51).• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).If a modulating control unit is used and the boiler does notreact to a heat request:• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Remove the cover from the connection box (see fig. 52).• Connect the modulating control directly to the two "RCxx"contacts of the boiler using a short cable (see fig. 53, pos. 1).• Connect the heating system to the power supply, insert themain fuse or switch on the circuit breaker.• Set the main switch on the BC10 to "1" (On).• Set the modulating control to the request position.• If the boiler switches to heating mode (operating code [-/h/\| )after some time, the fault is caused by the cable betwe<strong>en</strong> themodulating control and the boiler.fig. 52Removing the cover from the connection box• If the boiler does not switch to heating mode after some time,the fault is caused by the modulating control.• Correct the cause of the fault.RC FA WA FW EV11PK PS PZ Grid1 2 3 4 5 6 7 8 9 10fig. 53 External connection boardpos. 1: RC Room thermostat (connection color orange)pos. 2: Outdoor-temperature s<strong>en</strong>sor (connection colorblue)pos. 3: Pot<strong>en</strong>tial-free On/Off thermostat (connection colorgre<strong>en</strong>)pos. 4: DHW temperature s<strong>en</strong>sor (connection color grey)pos. 5: External switching contact, pot<strong>en</strong>tial-free for floorheating safety etc. (connection color red)pos. 6: DO NOT USEpos. 7: Primary loop pump 120V 60Hz (connection colorgre<strong>en</strong>)pos. 8: DHW tank pump 120V 60Hz (connection color grey)pos. 9: DHW recirculating pump 120V 60Hz (connectioncolor lilac)pos. 10: Main connection 120V 60Hz (connection colorwhite)pos. 11: Fuse holder<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 105


8Actions• Fit the cover on the external connection box (see fig. 54).• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 54Installing the cover of the connection box8.1.24 Bleed the gas supply pipe• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the gas shut-off valve (see fig. 56, pos. 1).• Op<strong>en</strong> the screw plug on the testing nipple for the inlet gas pressureand for purging (fig. 55) by two turns and install a hose.• Op<strong>en</strong> slowly the gas shut-off valve.• Run the gas that flows out through a water bath.• Close the gas shut-off valve wh<strong>en</strong> no more air escapes.• Remove the hose and tight<strong>en</strong> the screw plug again.• Carefully op<strong>en</strong> the gas shut-off valve (see fig. 56, pos. 2).• Check the testing nipple for leaks.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 55Bleeding the gas supply pipe106<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.25 Measuring the inlet gas pressure (flow pressure)• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Op<strong>en</strong> at least one thermostatic radiator valve.• Close the gas shut-off valve (see fig. 56, pos. 1).• Op<strong>en</strong> the screw plug on the testing nipple for the inlet gas pressure(see fig. 57, pos. 1) by two turns.• Set the pressure gauge to zero.• Connect the measuring hose of the pressure gauge to thetesting nipple (see fig. 57, pos. 2).• Carefully op<strong>en</strong> the gas shut-off valve (see fig. 56, pos. 2).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Put the heating boiler into operation, see "Flue gas test" m<strong>en</strong>uon page 10.• Measure the inlet gas pressure wh<strong>en</strong> the "Burner" (On/Off) LEDon the BC10 basic controller lights.• The inlet gas pressure must be:– for natural gas – min. 3.5 to 10.5 inch W.C (8.7 to 26.1mbar), 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).• Set the main switch on the BC10 to "0" (Off).• Close the gas shut-off valve (see fig. 56, pos.1).• Remove the hose and tight<strong>en</strong> the screw plug on the testingnipple again.• Op<strong>en</strong> again the gas shut-off valve (see fig. 56, pos. 2).• Check the testing nipple for leaks.• Fit the casing.• Set the main switch on the BC10 to "1" (On).NOTE!If the required inlet gas pressure is not available,you should consult your gas utility company. If theinlet gas pressure is too high, a gas pressure regulatoris to be integrated upstream of the gas valve.fig. 56fig. 57Gas shut-off valve closed (1), gas shut-off valveop<strong>en</strong> (2)Measure the inlet gas pressure<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 107


8Actions8.1.26 Measure and adjust the gas/air ratio• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the gas shut-off valve (see fig. 56, pos. 1).• Op<strong>en</strong> at least one thermostatic radiator valve.• Op<strong>en</strong> the screw plug on the testing nipple for the burner pressure(fig. 58, pos. 1) by two turns.• Set the pressure gauge to zero.• Use a hose to connect the + connection of the pressure gaugeto the burner pressure measuring nipple (fig. 58, pos. 2).• Op<strong>en</strong> the gas shut-off valve (see fig. 56, pos. 2).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 58Checking the gas/air ratio• Put the heating boiler into operation, see "<strong>Service</strong> Mode" m<strong>en</strong>uon page 11.• Read out the gas/air ratio from the pressure gauge wh<strong>en</strong> theboiler is in part-load operation.The boiler is running in part-load operation wh<strong>en</strong>, in the"<strong>Service</strong> mode" m<strong>en</strong>u L30 has be<strong>en</strong> set.• The differ<strong>en</strong>tial 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 Pa – 0 Pa). See fig. 59.incorrectcorrectincorrect-0.06 -0.04 -0.02 0 0.02(inch W.C.)turn counterclockwiseturn clockwisefig. 59Differ<strong>en</strong>tial pressure gas/air ratio part-load• If the gas/air ratio is incorrect, it can be adjusted on the setscrew (fig. 60, pos. 1).NOTE!The set screw is located behind the screw-oncover. This must be removed first.• Set the main switch on the BC10 to "0" (Off).• Close the gas shut-off valve (see fig. 56, pos. 1).• Remove the hose and tight<strong>en</strong> the screw plug on the testingnipple again.• Op<strong>en</strong> the gas shut-off valve (see fig. 56, pos. 2).• Check the testing nipple for leaks.• Fit the casing.• Set the main switch on the BC10 to "1" (On).fig. 60Adjusting the gas/air ratio108<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.27 Measuring the carbon monoxide cont<strong>en</strong>t (CO)• Measure the carbon monoxide cont<strong>en</strong>t on the flue gas samplingpoint (see fig. 61).• The CO values in an air-free condition must be below 400 ppmor 0.04 vol. %.• Values of 400 ppm and up indicate that the burner adjustm<strong>en</strong>tmay be wrong, the gas burner fitting or the heat exchanger aredirty or that there may be burner faults.• You must establish and resolve the cause. The boiler must beoperational wh<strong>en</strong> you do this.fig. 61Flue gas sampling point8.1.28 Transformer; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Dismantle the cover of the external connection board(see fig. 62).fig. 62Removing the cover from the connection box• Pull the 4 plugs from the external connection board(see fig. 63, pos. 1, 2, 3 and 4).1432fig. 63Pulling the external connection board plug<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 109


8Actions• Loos<strong>en</strong> the 2 external connection board fast<strong>en</strong>ing screws (seefig. 64, pos. 1).1fig. 64Loos<strong>en</strong>ing the fast<strong>en</strong>ing screws• Remove the external connection board (see fig. 65).fig. 65Removing the external connection board• Remove the transformer shield (see fig. 66).fig. 66Removing the transformer shield110<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Pull both plugs on the rear of the transformer (see fig. 67).• Check to see if you measure any resistance on the two cableplugs. If you do th<strong>en</strong> the transformer is not the problem. If youdon't measure any resistance th<strong>en</strong> replace the transformer asdescribed in the following steps.fig. 67Pulling the plugs from the transformer• Remove the transformer by pulling it in the direction indicatedby the arrow (see fig. 68).• Install the new transformer.• Re-assemble all parts and plugs in reverse order of disassembly.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 68Removing the transformer8.1.29 Automatic air purging system; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the maint<strong>en</strong>ance shut-off valves and drain the <strong>Logamax</strong><strong>plus</strong> <strong>GB142</strong>. (see fig. 69).fig. 69Draining the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong><strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 111


8Actions• Remove the plastic cover from the top of the boiler (see fig. 70).fig. 70Removing the plastic cover of the automatic airpurging system• Remove the float cap (see fig. 71).fig. 71Removing the float cap• Dismantle the valve case by pulling it upwards through theop<strong>en</strong>ing in the housing (see fig. 72).• Assemble the new valve case and all other parts in reverseorder of disassembly.NOTICEFill and purge the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong> asrequired.See installation and maint<strong>en</strong>ance instructions<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 72Dismantling the valve case for the automatic airpurging system112<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.30 Burner; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the gas shut-off valve (see fig. 73, pos. 1).fig. 73Gas shut-off valve closed (1), gas shut-off valveop<strong>en</strong> (2)• Remove the cable plug from the gas control valve(see fig. 74, pos. 1).1fig. 74Replacing the gas control valve(e.g. HONEYWELL gas control valve)• Remove both cable plugs from the fan unit (see fig. 75, pos. 1).fig. 751Disconnecting the cable plug from the fan unit<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 113


8Actions• Loos<strong>en</strong> the union nut of the gas control valve (see fig. 76,pos. 1).1 2fig. 76Loos<strong>en</strong>ing the gas control valve• Loos<strong>en</strong> both sets of retaining clips (fig. 76, pos. 2 and fig. 77,pos. 1) of the burner cover and remove the burner cover withthe fan unit and the gas burner fitting.fig. 771 1Loos<strong>en</strong>ing the retaining clips• Remove the burner gasket (see fig. 78, pos. 1).• Remove the gas/air distributor plate (see fig. 78, pos. 2).• Remove the orifice plate (only applies to <strong>Logamax</strong> <strong>plus</strong><strong>GB142</strong>-24/30 and <strong>GB142</strong>-60) (see fig. 78, pos. 3). Note thatthe orifice plate of the <strong>GB142</strong>-60 has a differ<strong>en</strong>t shape.• Remove the burner (see fig. 78, pos. 4).1234fig. 78Removing the burner114<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Install the new burner (see fig. 79).WARNING!Fit the burner so that the scale mark is located onthe left-hand side (see fig. 79).• Re-assemble all other parts in reverse order of disassembly.fig. 79Installing the burner• Op<strong>en</strong> the gas shut-off valve (see fig. 80, pos. 2).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Also check all joints and gaskets affected by the replacem<strong>en</strong>tactivities while carrying out the tightness test in operatingconditions.• Set the gas/air ratio again. See paragraph 8.1.26.fig. 80Gas shut-off valve closed (1), gas shut-off valveop<strong>en</strong> (2)8.1.31 Sight glass; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Loos<strong>en</strong> both screws of the sight glass (see fig. 81, pos. 1).• Remove the sight glass mounting plate.• Disassemble the sight glass inclusive of both gaskets.• Assemble the new sight glass and all further parts in reverseorder of disassembly; remember to fit new gaskets.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 81Loos<strong>en</strong>ing the screws of the sight glass1<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 115


8Actions8.1.32 Cond<strong>en</strong>sate trap; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Pull the cond<strong>en</strong>sate trap from the cond<strong>en</strong>sate plate(see fig. 82, pos. 1).• Pull the internal cond<strong>en</strong>s bypass pipe from the cond<strong>en</strong>sate trap(see fig. 82, pos. 2).• Loos<strong>en</strong> the cond<strong>en</strong>sate trap from the connection (see fig. 82,pos. 3) and remove it.• Fill the new cond<strong>en</strong>sate trap with water.• Re-assemble the new cond<strong>en</strong>sate trap in reverse order ofdisassembly.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).8.1.33 Pressure s<strong>en</strong>sor; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the maint<strong>en</strong>ance shut-off valves and drain the <strong>Logamax</strong><strong>plus</strong> <strong>GB142</strong>.• Remove the cable plug from the pressure s<strong>en</strong>sor.fig. 8231 2Disconnecting the cond<strong>en</strong>sate trap connection• Loos<strong>en</strong> the pressure s<strong>en</strong>sor by removing the securing clip (seefig. 84).• Assemble the new pressure s<strong>en</strong>sor and the plug in reverseorder of disassembly.NOTICEFill and purge the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong> asrequired.See installation and maint<strong>en</strong>ance instructions<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).fig. 83Draining the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>fig. 84Loos<strong>en</strong>ing the pressure s<strong>en</strong>sor116<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.34 Heat exchanger; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Close the maint<strong>en</strong>ance shut-off valves and drain the <strong>Logamax</strong><strong>plus</strong> <strong>GB142</strong>, see 116, fig. 83.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Close the gas shut-off valve(see fig. 85, pos. 1).fig. 85Gas shut-off valve closed (1), gas shut-off valveop<strong>en</strong> (2)• Remove the cable plug from the gas control valve(see fig. 86, pos. 1).1fig. 86Replacing the gas control valve(e.g. HONEYWELL gas control valve)• Remove both cable plugs from the fan unit (see fig. 87, pos. 1).fig. 871Disconnecting the cable plug from the fan unit<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 117


8Actions• Loos<strong>en</strong> the union nut of the gas control valve (see fig. 88,pos. 1).1fig. 88Loos<strong>en</strong>ing the gas control valve• Pull both retaining clips (see fig. 89, pos. 1) on the burner coverto op<strong>en</strong> them and remove the burner cover with the fan unit andthe gas control valve.fig. 891 1Loos<strong>en</strong>ing the retaining clips• Remove the burner gasket (see fig. 90, pos. 1).• Remove the gas/air distributor plate (see fig. 90, pos. 2).• Remove the orifice plate (only applies to <strong>Logamax</strong> <strong>plus</strong><strong>GB142</strong>-24/30 and <strong>GB142</strong>-60) (see fig. 90, pos. 3). Note thatthe orifice plate of the <strong>GB142</strong>-60 has a differ<strong>en</strong>t shape.• Remove the burner (see fig. 90, pos. 4).1234fig. 90Removing the burner118<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Disconnect the plug and socket connections of the supply,return and safety s<strong>en</strong>sors (see fig. 91, 92 and 93).fig. 91Loos<strong>en</strong>ing the plug and socket connections of thesupply s<strong>en</strong>sorfig. 92Disconnect the plug and socket connection of thereturn s<strong>en</strong>sorfig. 93Disconnect the plug and socket connection of thesafety s<strong>en</strong>sor<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 119


8Actions• Disassemble the supply and return s<strong>en</strong>sors (see fig. 94, pos. 1and 2).1WARNINGTo prev<strong>en</strong>t mix-ups, the supply s<strong>en</strong>sor is markedby a red sleeve on the side of the cable harness.2fig. 94Replacing the supply/return s<strong>en</strong>sors• Dismantle the safety s<strong>en</strong>sor (see fig. 95, pos. 1).1fig. 95Dismantling the safety s<strong>en</strong>sor• Disconnect the hot surface ignitor and ionization electrodeplugs.• Loos<strong>en</strong> the fast<strong>en</strong>ing screws (see fig. 96, pos. 1).• Pull the earth cable from the hot surface ignitor (see fig. 96,pos. 2).• Dismantle the mounting plate (see fig. 96, pos. 3).fig. 96Replacing the hot surface ignitor120<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Remove both the hot surface ignitor and the ionization electrodeby pulling them loose (see fig. 97, pos. 1).1fig. 97Removing the hot surface ignitor and the ionizationelectrode• Dismantle the cond<strong>en</strong>sate trap connection to the cond<strong>en</strong>satecollector (see fig. 98, pos. 1).12fig. 98Dismantling the cond<strong>en</strong>sate trap connection to thecond<strong>en</strong>sate collector• Op<strong>en</strong> the four latches of the cond<strong>en</strong>sate collector(see fig. 99, pos. 1).1fig. 99Op<strong>en</strong>ing the latches of the cond<strong>en</strong>sate collector<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 121


8Actions• Remove the cond<strong>en</strong>sate collector (see fig. 100, pos. 1).1fig. 100Removing the cond<strong>en</strong>sate collector• Loos<strong>en</strong>ing the backflow connection betwe<strong>en</strong> the primary pumpand heat exchanger (see fig. 101, pos. 1).• Dismantle the t<strong>en</strong>sion spring betwe<strong>en</strong> the supply pipe and theheat exchanger (see fig. 101, pos. 2).12fig. 101Loos<strong>en</strong>ing the backflow connection and dismantlingthe t<strong>en</strong>sion spring• Loos<strong>en</strong>ing with one turn the nut betwe<strong>en</strong> the supply connectionand three way valve connection AB(see fig. 102, pos. 2).• Pull the supply pipe out of the heat exchanger (see fig. 102,pos. 1).1WARNING!Water will be released.2fig. 102Removing the supply pipe122<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 8• Loos<strong>en</strong> the fast<strong>en</strong>ing screws of the combustion air supply andflue gas exhaust connections (see fig. 103, pos. 1).1fig. 103Loos<strong>en</strong>ing the fast<strong>en</strong>ing screws of the combustion airsupply and flue gas exhaust connections• Pull the combustion air supply (see fig. 104, pos. 2) and fluegas exhaust (see fig. 104, pos. 1) connections on top of theboiler upwards to remove them.12fig. 104Loos<strong>en</strong>ing the combustion air supply and flue gasexhaust connections• Loos<strong>en</strong> the 6 fast<strong>en</strong>ing screws of the flue gas adapter(see fig. 105, pos. 1).1fig. 105Loos<strong>en</strong>ing the fast<strong>en</strong>ing screws<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 123


8Actions• Remove the flue gas adapter (see fig. 105, pos. 1) from the topof the boiler.1fig. 106Removing the flue gas adapter• Remove the heat exchanger by grabbing its bottom <strong>en</strong>d andpulling forward and th<strong>en</strong> pushing it upwards (see fig. 107,pos. 1).• Assemble the new heat exchanger and all other parts in reverseorder of disassembly.1NOTICE!Fill and purge the <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong> asrequired. See installation and maint<strong>en</strong>ance instructions<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60.Remove the flue gas collector from the old heatexchanger, including the oval seal. Put silicon kiton both sides of the oval seal, the flue gas collectorand the heat exchanger. Reassemble the flue gascollector with the oval seal to the heat exchanger.Check if the oval seal is placed correctly byop<strong>en</strong>ing the cond<strong>en</strong>sate collector (see page 122,fig. 100).• Op<strong>en</strong> the gas shut-off valve (see fig. 108, pos. 2).• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).• Also check all joints and gaskets affected by the replacem<strong>en</strong>tactivities while carrying out the tightness test in operatingconditions.• Set the gas/air ratio again. See paragraph 8.1.26, page 108.fig. 107Dismantling the heat exchangerfig. 108Gas shut-off valve closed (1), gas shut-off valve op<strong>en</strong>(2)124<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Actions 88.1.35 UBA 3; replacing• Switch off the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "0" (Off).• Remove the casing.• Loos<strong>en</strong> the fast<strong>en</strong>ing screw of the UBA 3 (see fig. 109, pos. 1).• Pull the UBA 3 forward in the direction indicated by the arrow(see fig. 109, pos. 2).• Install the new UBA 3.• Tight<strong>en</strong> the fast<strong>en</strong>ing screw again.• Fit the casing.• Switch on the power supply of the heating system on the circuitbreaker.• Set the main switch on the BC10 to "1" (On).12fig. 109 Dismantling the UBA 3<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 125


1459App<strong>en</strong>dix9 App<strong>en</strong>dixWARNINGLabel all wires prior to disconnection wh<strong>en</strong> servicing.Wiring errors can cause improper and dangerous operation.Earth120 VACFunction moduleOperating switchMains supply120 VAC 60 HzLLwhiteNNGridHigh VoltagePECirculating pump120 VAC, max. 250 VAlilacL N PE14 13PZDHW circulator120 VAC, max. 250 VALgreyNPEBoiler circulator120 VAC, max. 250 VAgre<strong>en</strong>25 24 63 61PSPKLNPEExternal 3-way valveExternal switch contactPot<strong>en</strong>tial-free e.g.for floor heatingDHW s<strong>en</strong>sorOn/Off temperaturecontrol, pot<strong>en</strong>tial-freeOutdoor-temperatures<strong>en</strong>sorModulating room controllergre<strong>en</strong>white red grey blue orange2 2 1 2 1 2 1 2 11 3 2 1DWV EV FW WA FA RCBC10 connectorBusFunction moduleExternal connection for specialist servicing company8 7 6 5 4 3 2 18321123443215432117161514131211109816-pole connector(120 VAC)16151Connection box UBA 3.01516131545146192379537726636475743637585733603584334585776543216 54321126 54321120 VACFunction moduleLNLPEN6537410119120 VAC120 VAC120 VAC120 VAC16-pole connectorPin 16 Pin 12 31 2 31 2N PE LN 120 LVACKIMM55 Pin 8128Pin 1HotsurfaceignitorGas burnerfitting TransformerFan unit6 75 1 2 3 41 2 3 4 5181-pole connectorEarthSupply s<strong>en</strong>sorSafety-temperature s<strong>en</strong>sorReturn s<strong>en</strong>sorPPressures<strong>en</strong>sorIonization3 2 1230 VAC230 VAC10 VAC10 VAC24 VAC0 VAC24 VRAC24 VRAC2422141339381211706162255128908125522723795376491644174581-pole connector(AC 0, 10, 24 and 120 V)PENL141213696867fig. 110Electric circuit diagram126<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


App<strong>en</strong>dix 9Gas orifice diameter Altitude 0 - 10,200 ftBoiler capacityType of gas supplyV<strong>en</strong>turi articl<strong>en</strong>umberNo CO 2 correctionAltitude 4,001 - 10,200 ftwith CO 2 correction[inch] [mm] [inch] [mm]24 kW30 kW45 kWNatural gas H 423.072A 0.175 4.45 0.179 4.55LPG P 423.072A 0.132 3.35 0.134 3.40Natural gas H 423.072A 0.175 4.45 0.177 4.50LPG P 423.072A 0.132 3.35 0.134 3.40Natural gas H 423.170A 0.213 5.40 0.219 5.55LPG P 423.170A 0.163 4.15 0.163 4.15Natural gas H 423.173A 0.295 7.50 0.301 7.6560 kWLPG P 423.173A 0.213 5.40 0.215 5.45table 5 Gas orifice diameterType of gassupplyNatural gas HLPG PFactory setting of gas burner fittingDelivered factory-set to Wobbe index14.1 kWh/m 3 (based on 59 °F (=15°C),14.7 psi (=1,013 mbar)), suitable forWobbe index range 11.3 – 15.2 kWh/m 3 .Information on gas type instruction plate:Set to gas category: G 20 – 2E.Previous indications: set to Wobbe index15.0 kWh/m 3 (based on 32 °F (=0°C), 14.7 psi(=1,013 mbar)), suitable forWobbe index range 12.0 – 15.7 kWh/m 3 .Suitable for propane after conversion (also seethe chapter "Conversion to another type of gassupply").Information on gas type instruction plate:Set to gas category: G 31 – 3P.Table 6Factory setting of gas burner fitting• The diameter of the gas orifice islocated on the gas orifice.• The article number of the V<strong>en</strong>turi is located on both clamps ofthe V<strong>en</strong>turi (see fig. 111, pos. 1 and 2).12fig. 111V<strong>en</strong>turi article number<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 127


10Spare parts10 Spare partsBelow is a list of the spare parts for this boiler. Look up the position number in the exploded view drawing on the next two pages for theillustration. Spare parts may be ordered from <strong>Buderus</strong>.Pos. Description Product No.1Casing 24/30 kW 7099988Casing 45/60 kW 70999012 Casing latches left (2 pc) 70990393 Casing latches right (2 pc) 70990384Casing seal 24/30 kW 7098752Casing seal 45/60 kW 70987985 Wall mounting bracket 70983646Back panel 24/30 kW 7099001Back panel 45/60 kW 70999037 Cap air v<strong>en</strong>t 71002509 Seal ring Ø 3” 77470s10 Seal ring Ø 80 mm 709647511 Flue gas collector 709885712 Oval seal 7098858Heat exchanger 24/30 kW 774690015913 Heat exchanger 45 kW 7746900160Heat exchanger 60 kW 774690016114 Heat exchanger baffle 24/30 kW 7098828Seal cond<strong>en</strong>sate collector 24/30 kW 709883415 Seal cond<strong>en</strong>sate collector 45 kW 7098838Seal cond<strong>en</strong>sate collector 60 kW 67900522Cond<strong>en</strong>sate collector + sealing 24/30 kW 709884016 Cond<strong>en</strong>sate collector + sealing 45 kW 7098844Cond<strong>en</strong>sate collector + sealing 60 kW 6790052117 Clamp 709884818 S<strong>en</strong>sor NTC 710013619 Revision set air v<strong>en</strong>t ** 709882220 Sight glass 7098575Burner box 24/30 kW 709905721 Burner box 45 kW 7098875Burner box 60 kW 6790052522 Safety s<strong>en</strong>sor 78194Seal burner 24/30 kW 709891623 Seal burner 45 kW 7098920Seal burner 60 kW 67900526Gas/air distribution plate 24/30 kW 710092224 Gas/air distribution plate 45 kW 7098926Gas/air distribution plate 60 kW 6790052725Orifice plate 24/30 kW 7100920Orifice plate 60 kW 7746900120Burner 24/30 kW 709900326 Burner 45 kW 7098932Burner 60 kW 6790052827 Gas-air inlet 709900428 Seal fan 709902329 Ionization electrode 7819530 Hot surface ignitor 709900631 Shield hot surface ignitor 710022932 Mounting plate 709885233 Seal mounting plate (5 pc) 7098850Pos. Description Product No.34Air inlet pipe; 24/30 kW 7099024Air inlet pipe; 45/60 kW 709902335 Seal Ø50 mm (5 pc) 7099058V<strong>en</strong>turi 24/30 kW 709902036 V<strong>en</strong>turi 45 kW 7099925V<strong>en</strong>turi 60 kW 709993137 Seal set (4 pc) 709902138 Fan 7818439 Gas control valve 709902540 Gas supply pipe <strong>GB142</strong> <strong>USA</strong> 7668541 Spring (5 pc) 710054942 Seal 2x16x22 (5 pc) 7098778L.P. Orifice Ø 3.35 - 24/30 kW0-10,200 ft76687L.P. Orifice Ø 3.40 - 24/30 kW4,001-10,200 ft7746901353L.P. Orifice Ø 4.15 - 45 kW0-10,200 ft7746901355N.G. Orifice Ø 4.45 - 24/30 kW0-10,200 ft7099016N.G. Orifice Ø 4.50 - 30 kW4,001-10,200 ft774690142143N.G. Orifice Ø 4.55 - 24 kW4,001-10,200 ft7746901354N.G. Orifice Ø 5.40 - 45 kW0-10,200 ft76690L.P. Orifice Ø 5.40 - 60 kW0-10,200 ft76690L.P. Orifice Ø 5.45 - 60 kW4,001-10,200 ft7746901357N.G. Orifice Ø 5.55 - 45 kW4,001-10,200 ft7746901356N.G. Orifice Ø 7.50 - 60 kW0-10,200 ft76686N.G. Orifice Ø 7.65 - 60 kW4,001-10,200 ft774690135844 Cond<strong>en</strong>sate trap, part of pos. 88 871860068945 Seal cond<strong>en</strong>sate trap (5 pc) 710074247Supply pipe CH; 24/30/45 kW 75990Supply pipe CH; 60 kW 7599148Return pipe 24/30/45 kW 709965Return pipe 60 kW 70994549 Pressure s<strong>en</strong>sor ** 871860001950 Bottom plate 709904951 Transformer 120V 7819152 Grommet 709905053 External connection board 709904254 External connection board cover 709904655 Fuse 5 AF slow blow 73904s56 UBA cover 709904757 UBA 3 - 120V 7099707** not shown in exploded views128<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Spare parts 10Pos. Description Product No.58 Drawer 709904359 Drawer front 709903760 Controller connection plate 7818661 On/off switch 709904162 Controller cover 73698Boiler id<strong>en</strong>t. module 24 kW 7822363Boiler id<strong>en</strong>t. module 30 kW 78224Boiler id<strong>en</strong>t. module 45 kW 78225Boiler id<strong>en</strong>t. module 60 kW 7822664 Cable harness low voltage 7819365 Cable harness high voltage 709995766 O-ring (10 pc) 38434s67 Sealing bush (set) 709900268 Cable harness of on/off switch 709907269 Cable harness BX holder 709907070 Fuse holder 3834571 Seal Ø60 mm (5 pc) 709887872 O-ring set orifice 709901873 Seal (5 pc) 709905974 Set screw M5x20 (5 pc) 709906575 Cap 24/30 kW 7910576 Double nipple THR x COMPR 7597777 Cabel saddle (10 pc) 709881078 Bolt M6x16 (2 pc) 709907879 Clip pressure s<strong>en</strong>sor 710137080 Drainplug 709936481 Cap connection piece 3849882 Clip (5 pc) 73651s83 C<strong>en</strong>tering ring (5 pc) 73480s84 Coupling nut pump 73481s85 Seal pump (10 pc) 15022s86 Coupling nut pump 1502087 Conversion set pump 7314988 Cond<strong>en</strong>sate drain set, incl. pos. 44 8718600686<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 129


10Spare partsExploded view <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/307121291910741732331123272231242825 30742615146613661220988344041423536 377472 4339731738454416888179188387808284858586474876767564497675772786436554691616062576370555653525168595058130<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications!


Spare parts 10Exploded view <strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-45/60712129191027287474172324252632333122301466111312209881566734171618838485587404142353674727343393745443848881794980828586474877676762783645465161625763705556535269605168595058<strong>Logamax</strong> <strong>plus</strong> <strong>GB142</strong>-24/30/45/60 - We reserve the right to make any changes due to technical modifications! 131


Unites States and CanadaBosch Thermotechnology Corp.50 W<strong>en</strong>tworth Av<strong>en</strong>ueLondonderry, NH 03053Tel. 603-552-1100Fax 603-584-1681www.buderus.usU.S.A.Products manufactured byBosch Thermotechnik GmbHSophi<strong>en</strong>strasse 30-32D-35576 Wetzlarwww.buderus.com721.494A 0007Bosch Thermotechnology Corp. reserves the rightto make changes without notice due to continuing<strong>en</strong>gineering and technological advances.

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