Applications Manual Gas condensing boiler WARNING! Improper installation, adjustment, alteration, service or maintenance can cause injury, loss of life or property damage. Refer to the installation and operating manuals. For assistance or additional information, consult a trained and certified installer, service agency or the gas supplier. CAUTION! The installation and operating manuals are part of the documentation that is delivered to the installation's operator.
| Technical specifications are subject to change without prior notice GB162 Applications Manual Logamax plus GB162 applications manual | 03.
|3 GB162 Applications Manual Table of Contents 1 Reference Documents 4 2 Boiler Components & Controls 5 2.1 Periphery 6 2.2 Low Loss Header (LLH) 7 2.3 Cascade Kits 9 2.4 AM10 Outdoor Reset Modulating Boiler Control 10 2.5 RC35 Room Controller and User Interface 14 2.6 0-10V BMS Interface & Common Fault Module EM10 22 2.7 MCM10 Multi Cascade Module 23 3 Sample Applications 27 Legend 28 3.
| GB162 Applications Manual 1 Reference Documents The following table references all related documentation to the GB162 series boiler. To obtain copies of these documents, please go to our website at www.buderus.us.
GB162 Applications Manual |5 2 Boiler Components & Controls This chapter outlines the various components available with the GB162 series boiler along with the following control options: • AM10 - Outdoor Reset Modulating Boiler Control • MCM10 - Multi-boiler Cascade Module • RC35 - Energy Management System (EMS) with Outdoor Reset, Room Reset, Zoning and Solar Thermal capabilities • Logamatic 4000 Control System (see Logamatic 4000 Applications Manual) This manual outlines the most common applicati
| GB162 Applications Manual 2.1 Periphery 2.1.1 Low Water Cut-off (LWCO) and External Manual Reset High Limit National or local code may require the installation of an external Low Water Cut-Off (LWCO) and/or an External Manual Reset High Limit. Notes: 1. Contractor to furnish and install LWCO and Manual Reset High Limit devices as required by local codes. 2. Do not install any type of valve or check valve in between boiler and LWCO or Manual Reset High Limit. 3.
|7 GB162 Applications Manual under flowing can result in too great a delta T, resulting in considerable heat being shed in the beginning of the loop and insufficient heat left for the remainder of the loop. 2.2 Low Loss Header (LLH) 2.2.1 General Information Installation of a LLH however requires a pump on the boiler side and one on the system side. As their flow rates are typically low, some manufacturers design a LLH to include an air eliminator and dirt separator.
| GB162 Applications Manual Possible scenarios of the LLH: V₁ V₂ R₁ R₂ Both primary and secondary flow rates are identical. V₁ R₁ V₂ R₂ The boiler flow rate is greater than the system flow rate and hot supply water is returning to the boiler. V₁ V₂ R₁ R₂ The system flow rate is greater than the boiler flow rate and cold return water is sent back out to the system. Fig.
|9 GB162 Applications Manual 2.3 Cascade Kits The Logamax plus GB162 cascade system can be installed in 2 different configurations (fig. 5). Buderus offers cascade systems in TL and TR configurations for up to 4 boilers. For cascades of 5 to 16 boilers use single boiler manifolds. The gas connection can be made to either side of the boilers, independent of the supply and return connections.
| GB162 Applications Manual 2.4 AM10 Outdoor Reset Modulating Boiler Control Product Description The AM10 is a modulating outdoor reset control for Buderus boilers equipped with the EMS bus. It sets the supply water temperature based on outdoor temperature. The boiler fires, runs and modulates based on the information received from the AM10, and the delta T between supply and return.
| 11 GB162 Applications Manual Heating curve The AM10 has a built in linear heating curve that sets the supply water temperature in relation to the outdoor temperature. Top of heating curve represents the water temperature at 14°F (-10°C) outdoor temperature. Based on type of heating system different water temperatures are recommended for bottom of heating curve. The boiler follows the heating curve in the AM10 up to the maximum supply water temperature set on the boiler dial which works as a high limit.
| GB162 Applications Manual Heating curve chart in Degrees Celsius: 100 Boiler High Limit 90 90 Radiant Floor Panel Radiators Baseboard Hydro Air Cast Iron Radiators 80 Supply Water Temperature [°C] 70 60 50 Use high limit to prevent radiant floor damage from overheating. (not in cascades) 40 30 20 Heating curve base point 10 Upper Reference point WWSD factory default 0 25 20 10 15 0 5 Outdoor Temperature [°C] -5 -10 -15 -20 Fig.
| 13 GB162 Applications Manual WWSD Single Boiler Control Warm weather shut down (WWSD) temperature is factory set for 70°F (21°C). If the outdoor temperature rises above this setting, the boiler will be turned off except for generating DHW. The value can be adjusted between 32°F (0°C) and 86°F (30°C).
| GB162 Applications Manual 2.5 RC35 Room Controller and User Interface The RC35 is an outdoor reset based heating system control with room influence and optional solar thermal DHW generation. 2.5.2 Overview 2.5.
| 15 GB162 Applications Manual 2.5.3 RC35 room control programming aspects User menu: User Menu THU 06.07. 2011 4:45pm Room 71.9 °F Standard display Modes of operation Switching program Warm weather shut down (WWSD) DHW temperature Vacation Party program Pause function Thermal desinfection Service menu: + THU 06.07. 2011 4:45pm Room 71.9 °F + Service Menu Quick operation Settings Diagnosis Servicing Reset Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual 2.5.4 RC35 wiring diagrams The RC35 user interface can be installed in a reference room to utilize the internal thermostat for room reset, or in a dedicated bracket in the boiler if room influence is not required. Mounting the RC35 in the room and utilizing its internal room sensor: Fig.11 RC35 wiring using its internal room sensor Mounting the RC35 in the room and utilizing a remote room sensor (part number: 5 993 226): Fig.
| 17 GB162 Applications Manual 2.5.5 EMS modules for RC35 Single Mixed Heating Zone Module MM10 This module is needed to operate a mixed heating zone pump and motorized mixing valve. The RC35 can control up to 3 MM10 modules per system. Features of the MM10: • Room reset, outdoor reset, outdoor reset with room influence.
| GB162 Applications Manual Solar Thermal DHW Module SM10 The SM10 Module integrates a Solar Thermal DHW system with an EMS boiler system which provides significant energy savings for DHW generation. The integrated system knows when solar energy is available and reduces boiler run time and boiler starts.
| 19 GB162 Applications Manual 2.5.6 Mixing Module MM10 Wiring Diagram 120 L Fuse 5 AT - + - + 14AWG 120 V 60Hz 14AWG, Max. 5A 14AWG, Max. 5A System Main power 18AWG 18AWG 18AWG supply 120 V 60Hz 2) Valve actuator motor run time: Notes: Polarity matters on EMS/RC bus: Connect 1 to 1 and 2 to 2. Implement the installation, fuse protection, main isolator, emergency stop switches and safety measures in accordance with local/national regulations.
| GB162 Applications Manual 2.5.7 WM10 - System or Low Loss Header Module Wiring Diagram 120 L - + - + 14AWG 120 V 60Hz 14AWG, Max.5A 18AWG Main power 120 V 60Hz 18AWG 18AWG zone low loss header Notes: Polarity matters on EMS/RC bus: Connect 1 to 1 and 2 to 2. Implement the installation, fuse protection, main isolator, emergency stop switches and safety measures in accordance with local/national regulations. Warning! Ground yel/grn must not be used as a control line.
| 21 GB162 Applications Manual 2.5.8 Solar Module SM10 Wiring Diagram 120 L - + - + 14AWG 120 V 60Hz 18AWG 14AWG, Max. 1A 18AWG 18AWG 18AWG Main power 120 V 60Hz tank Notes: Polarity matters on EMS/RC bus: Connect 1 to 1 and 2 to 2. Implement the installation, fuse protection, main isolator, emergency stop switches and safety measures in accordance with local/national regulations. Warning! Ground yel/grn must not be used as a control line. Ensure phases are connected correctly.
| GB162 Applications Manual 2.6 0-10V BMS Interface & Common Fault Module EM10 The EM10 Module allows interfacing a single boiler with a Building Management System (BMS) for temperature or output setpoint control. The EM10 also has a dry set of N/O and N/C contacts that can be used to trigger a system alarm. Features of the EM10: • Run single boiler based on BMS input 0-10V signal for temperature or output setpoint control • Input: 0-10V • Common fault dry contact output NO/NC • 120V supply Fig.
| 23 GB162 Applications Manual 2.7 MCM10 Multi Cascade Module The MCM10 - Multi Cascade Module allows running and staging multiple boilers in a cascade system. Each MCM10 controls up to 4 boilers, and with 4 modules in a system, up to 16 boilers can be controlled. The MCM10 can only be used with boilers that have the EMSBUS (UBA3, UBA3.5). Boilers of any size can be connected in the cascade system as long as they are EMS-BUS compatible. 2.7.
| GB162 Applications Manual 2.7.2 MCM10 LED Functions MCM10 Front Panel 1 2 GRN 1 GRN 5 Off: No power / internal error MCM10 Off: Pump off On: Pump on RED ! GRN 4 Off: No fault present Blinking: System fault present (example: system, switching contact activated. Off: No communication On: Communication between MCM10 and the previous MCM10. Communication between MCM10 and a Heating Controller (e.g.
| 25 GB162 Applications Manual 2.7.3 MCM10 Electrical Connection Diagram YEL YEL 120V 120V PE N L PE N L Input Mains Supply GRN RED PE N L NO C NC RED WHT GRN 2 3 4 System supply temperature sensor - use only in combination with AM10 Outdoor Temperature Sensor - use only in combination with RC35 GRY BLK 13 14 Communication between this MCM10 and previous MCM10 15 16 Communication between this MCM10 and following MCM10 120V PE N L PE N L NO C NC 0 ....
| GB162 Applications Manual 2.7.
| 27 GB162 Applications Manual 3 Sample Applications Legend 28 3.1 System 1: Single boiler with outdoor reset, multiple heating zones with zone pumps and DHW 29 3.2 System 2: Single boiler with outdoor reset, multiple heating zones with zone valves and DHW 33 3.3 System 3: Single boiler with one heating zone, outdoor reset with room feedback and DHW priority 37 3.4 System 4: Single boiler with RC35, one heating zone, & solar thermal DHW 41 3.
| GB162 Applications Manual Legend pipe pipe thermal Expansion tank and PRV for solar thermal system o T Single mixed heating zone module MM10 Unmixed heating zone and low loss header module WM10 Thermal solar DHW module SM10 MCM10 multiboiler cascade module Communication line Sensor line Low voltage line (maximum 24V) Line voltage line (120V) Fig.21 Legend NOTICE: All drawings in this manual are conceptual in nature and only depict components relevant for the systems shown.
| 29 GB162 Applications Manual 3.1 System 1: Single boiler with outdoor reset, multiple heating zones with zone pumps and DHW Summary: Additional instructions: Single boiler supplying multiple heating zones equipped with 3rd party thermostats and zone pumps. This system is recommended if pressure drops in individual zones are too great to be served by a single system pump (see system 2). See manufacturer’s installation and operating instructions for details on 3rd party components.
| GB162 Applications Manual Piping Diagram - System 1 Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
GB162 Applications Manual | 31 Wiring Diagram - System 1 Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Programming - System 1 • When powering up the AM10 the current outdoor temperature is displayed (Fig. 22). • Press the mode key to switch to the next menu item. On the screen a block will indicate the current step from 1 through 5. • The second menu item is the current supply temperature computed based on the current outdoor temperature (Fig. 23). • Press the mode key to switch to the next menu item. • Define the heating curve by entering two distinct set points.
| 33 GB162 Applications Manual 3.2 System 2: Single boiler with outdoor reset, multiple heating zones with zone valves and DHW Summary: Additional instructions: Single boiler system with a system pump supplying multiple heating zones with 3rd party thermostats and zone valves. Use this design for systems with smaller pressure drops, e.g. baseboard and panel radiators, compared to system 1 which better handles radiant floors with high pressure drops that require a separate pump for each zone.
| GB162 Applications Manual Piping Diagram - System 2 Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
GB162 Applications Manual | 35 Wiring Diagram - System 2 PH Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Programming - System 2 • When powering up the AM10 the current outdoor temperature is displayed (Fig. 28). • Press the mode key to switch to the next menu item. On the screen a block will indicate the current step from 1 through 5. • The second menu item is the current supply temperature computed based on the current outdoor temperature (Fig. 29). • Press the mode key to switch to the next menu item. • Define the heating curve by entering two distinct set points.
| 37 GB162 Applications Manual 3.3 System 3: Single boiler with one heating zone, outdoor reset with room feedback and DHW priority Summary: Required components: Ideal setup for large open floor plans, e.g. restaurants, churches, retail, shop floors, etc. • • • • • GB162 boiler RC35 controller WM10 LLH module PH system circulator PS DHW tank loading circulator • ECM pumps (low energy or constant pressure pumps) are recommended for constant flow rate and additional energy savings.
| GB162 Applications Manual Piping Diagram - System 3 FK Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
GB162 Applications Manual | 39 Wiring Diagram - System 3 Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Programming - System 3 Enter the service level in RC35 control as described in the Installation and Service instructions or in chapter 2.4.2. Important parameters: • Go to settings, press MENU/OK • Turn dial clockwise until Did you install a low loss header module? appears. Select Yes. • Turn dial clockwise until Is heating zone 1 installed (unmixed heating zone)? appears. Select Yes.
| 41 GB162 Applications Manual 3.4 System 4: Single boiler with RC35, one heating zone, & solar thermal DHW Summary: Ideal setup for large open floor plans, e.g. restaurants, churches, retail, shop floors, etc. plus a significant DHW demand daily. Single boiler system supplying one unmixed heating zone combined with solar thermal DHW with boiler backup. This is a proven system that is simple to install, almost maintenance free, and fully automated.
| GB162 Applications Manual Piping Diagram - System 4 K Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
GB162 Applications Manual | 43 Wiring Diagram - System 4 Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Programming - System 4 Enter the service level in RC35 control as described in the Installation and Service instructions or on chapter 2.4.2. Important parameters: • Go to settings, press MENU/OK • Turn dial clockwise until Did you install a low loss header module? appears. Select Yes. • Turn dial clockwise until Is heating zone #1 installed (unmixed heating zone)? appears. Select Yes.
| 45 GB162 Applications Manual 3.5 System 5: Multi boiler system with staging control and outdoor reset The GB162 was designed from the beginning as a cascadable appliance.
| GB162 Applications Manual Piping Diagram - System 5 FV NOTE: Up to 4 boilers can be cascaded using this setup; options include back to back (TR rack) or in line (TL rack), or wall mount. Only 2 boilers are shown for clarity. For larger cascades please see systems 6 and 7. Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
| 47 GB162 Applications Manual Wiring Diagram - System 5 FV NOTE: Up to 4 boilers can be cascaded using this setup. Only 2 boilers are shown for clarity. Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Programming - System 5 The MCM10 does not require any programming whatsoever. • When powering up the AM10 the current outdoor temperature is displayed (Fig. 37). • Press the mode key to switch to the next menu item. On the screen a block will indicate the current step from 1 through 5. • The second menu item is the current supply temperature computed based on the current outdoor temperature (Fig. 38). • Press the mode key to switch to the next menu item.
GB162 Applications Manual | 49 3.6 System 6: Multi-boiler Cascade I Summary: Multi-boiler system with staging control and many options for heat distribution.
| GB162 Applications Manual Piping Diagram - System 6 NOTE: Up to 16 boilers can be cascaded using this setup. Only 5 boilers are shown for clarity. Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
| 51 GB162 Applications Manual Wiring Diagram - System 6 1 4 FV FA 2 3 1 4 Legend: 1 RC35 connects to WM10 that connects to 11/12 Outdoor sensor (FA) to 3/4 2 Dry contact connects to 7/8 3 0-10V input to 9/10 4 AM10 connects to 11/12 System supply sensor (FV) connects to 1/2 NOTE: Up to 16 boilers can be cascaded using this setup. Only 5 boilers are shown for clarity. When using the RC35 and WM10 versus the AM10, note the different sensor locations for accurate operation.
| GB162 Applications Manual Programming - System 6 MCM10 multi cascade controller does not require any programming. • Set boiler dial on BC10 to AUT on each boiler. • Set DHW dial on boiler to the OFF position if not in use. Wiring detail • If using the AM10 follow the wiring and programming in chapter 2.3. Connect a system supply sensor to pins 1/2. • If using a 0-10V signal from a BMS connect to pins 9/10.
GB162 Applications Manual | 53 3.7 System 7: Multi-boiler Cascade II Summary: Multi-boiler system with staging control and many options for heat distribution.
| GB162 Applications Manual Piping Diagram - System 7 NOTE: Up to 16 boilers can be cascaded using this setup. Only 5 boilers are shown for clarity. Technical specifications are subject to change without prior notice Logamax plus GB162 applications manual | 03.
| 55 GB162 Applications Manual Wiring Diagram - System 7 3 4 1 FV FA 2 3 1 4 Legend: 1 RC35 connects to WM10 that connects to 11/12 Outdoor sensor (FA) to 3/4 2 Dry contact connects to 7/8 3 0-10V input to 9/10 System supply sensor (FV) connects to 1/2 4 AM10 connects to 11/12 System supply sensor (FV) connects to 1/2 NOTE: Up to 16 boilers can be cascaded using this setup. Only 5 boilers are shown for clarity. Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Programming - System 7 MCM10 multi cascade controller does not require any programming. • Set boiler dial on BC10 to AUT on each boiler. • Set DHW dial on boiler to the OFF position if not in use. Wiring detail • If using the AM10 follow the wiring and programming in chapter 2.3. Connect a system supply sensor to pins 1/2. • If using a 0-10V signal from a BMS connect to pins 9/10.
GB162 Applications Manual | 57 Appendix • Appendix 1 - Single boiler with 0-10V heat demand input • Appendix 2 - Multi-boiler cascade with 0-10V heat demand input • Appendix 3 - Adding DHW priority to System 1 • Appendix 4 - Adding DHW priority to a multiboiler cascade Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Appendix 1 - Single boiler with 0-10V heat demand input (1) the system supply temperature (2) power output Control based on supply temperature The EM10 uses the 0-10V signal of the building management system to compute the system supply temperature set point. This is a linear ratio (table 5). 0 Flow temperature set point (boiler) (°F) (°C) 32 0 Status of boiler 167 (75) 140 (60) 113 (45) 86 (30) 60 (15) 32 (0) Voltage Figure 42 0 -10V Diagram OFF 0.
GB162 Applications Manual | 59 Appendix 1 - Wiring diagram Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Appendix 2 - Multi-boiler cascade with 0-10V heat demand input The MCM10 accepts a quantified heat demand from a building management system, which can be used to control: (2) power output of the boilers (boiler modulation) Control of system supply water temperature The MCM10 uses the 0-10V signal of the building management system to compute the system supply water temperature set point. This is a linear ratio (table 7).
| 61 GB162 Applications Manual Appendix 2 - Wiring diagram Only with Set Point Acc Supply Temperature Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Appendix 3 - Adding DHW priority to System 1 Description To add DHW priority to a single-boiler installation with multiple zone pumps, use piping and wiring as shown here. Use a Zone Pump Relay Panel with DHW priority built in and a RIB relay and wire up as shown in the wiring diagram. In detail: When the Tank sensor FW senses a DHW demand it will trigger the relay which causes the zone circulators to shut off and the tank loading pump PS to come on.
GB162 Applications Manual | 63 Appendix 3 - Piping and wiring diagram Logamax plus GB162 applications manual | 03.
| GB162 Applications Manual Appendix 4 - Adding DHW priority to a multi-boiler cascade Description To add DHW priority to a multi-boiler cascade, use piping and wiring as shown here. Install a DHW tank aquastat in the indirect fired DHW tank. Use a zone relay to turn the tank loading pump on and communicate the heat demand to the cascade controller.
GB162 Applications Manual | 65 Appendix 4 - Piping and wiring diagram NOTE: Other components not shown for clarity. Logamax plus GB162 applications manual | 03.
| Technical specifications are subject to change without prior notice GB162 Applications Manual Logamax plus GB162 applications manual | 03.
GB162 Applications Manual Logamax plus GB162 applications manual | 03.
Products manufactured by: Bosch Thermotechnik GmbH Sophienstrasse 30-32 D-35576 Wetzlar www.buderus.de Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances. BTC 432001101 H | 6720640377 0005 Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel.: 603-552-1100 Fax: 603-965-7581 www.buderus.
