Worcester GB162-100 Installation And Servicing Instruction Download Page 4

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CONTENTS

6 720 648 726 (2011/07)

CONTENTS

Key to symbols and safety instructions . . . . . . . 6

1.1

Explanation of symbols . . . . . . . . . . . . . . . 6

1.2

Safety instructions . . . . . . . . . . . . . . . . . . 7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Regulations and directives . . . . . . . . . . . . . . . . 12

3.1

Designated use . . . . . . . . . . . . . . . . . . . . 12

3.2

Boiler room . . . . . . . . . . . . . . . . . . . . . . . 12

3.3

Combustion air flue gas connection . . . . 12

3.4

Quality of the heating system water . . . . 12

3.5

Quality of the pipework . . . . . . . . . . . . . . 13

3.6

Maintenance schedule . . . . . . . . . . . . . . 13

3.7

Applicability of regulations . . . . . . . . . . . 13

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1

Please observe these instructions . . . . . 14

4.2

Tools, materials and further equipment . 14

4.3

Recycling . . . . . . . . . . . . . . . . . . . . . . . . . 14

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.1

Lifting and carrying the boiler . . . . . . . . . 15

5.2

Transporting the boiler with a trolley . . . 15

Items supplied with boiler . . . . . . . . . . . . . . . . 16

Dimensions of boiler . . . . . . . . . . . . . . . . . . . . . 17

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8.1

Installing the boiler . . . . . . . . . . . . . . . . . 19

8.2

General connection of mains water
and gas components . . . . . . . . . . . . . . . . 20

8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2.2 Install the water and gas connections

to the boiler using a pump group
(accessory) . . . . . . . . . . . . . . . . . . . . . . . . 20

8.2.3 Install the water and gas connections

to the boiler without a pump group . . . . . 20

8.2.4 Installing the differential pressure

controller . . . . . . . . . . . . . . . . . . . . . . . . . 22

8.2.5 Installing the isolating valves  . . . . . . . . .  22
8.2.6 Installing the drain cock  . . . . . . . . . . . . .  22
8.2.7 Installing a pressure relief valve  . . . . . . .  22
8.2.8 Selecting and installing the pump . . . . . .  22
8.2.9 Installing the condensate trap  . . . . . . . .  23
8.2.10 Condensate removal . . . . . . . . . . . . . . . .  23
8.2.11 Connecting the condensate drain pipe . .  25
8.2.12 Connecting the expansion vessel

in a single-boiler system . . . . . . . . . . . . . . 25

8.3

Flue Installation . . . . . . . . . . . . . . . . . . . . 26

8.3.1 Siting the flue terminal . . . . . . . . . . . . . . 26

8.3.2 Air supply and flue gas exhaust in

a room sealed installation . . . . . . . . . . . . .27

8.3.3 Maximum Flue length (L) . . . . . . . . . . . . .  28
8.3.4 Additional flue parts  . . . . . . . . . . . . . . . .  28
8.3.5 Standard 100 mm flue systems . . . . . . . .  28
8.3.6 Installation of the horizontal flue . . . . . . .  29
8.3.7 Flue pipe preparation and assembly  . . . .  29
8.4

Flue gas connection . . . . . . . . . . . . . . . . . 30

8.4.1 Open flue operation . . . . . . . . . . . . . . . . .  30
8.4.2 Room sealed operation  . . . . . . . . . . . . . .  30
8.4.3 Flue material  . . . . . . . . . . . . . . . . . . . . . .  30
8.4.4 Calculating the air intake and flue

gas pipe dimensions . . . . . . . . . . . . . . . . .30

8.5

Electrical connections . . . . . . . . . . . . . . . 30

8.5.1 Electrical wiring diagram . . . . . . . . . . . . .  31
8.5.2 Terminal strip connections  . . . . . . . . . . .  32
8.5.3 Routing the cable through the boiler . . . .  32
8.5.4 Description of the terminal strip

connections . . . . . . . . . . . . . . . . . . . . . . .33

8.5.5 230 V connections (only for GB162-65) . . 36
8.5.6 Installing function modules (accessories) 37

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9.1

General items . . . . . . . . . . . . . . . . . . . . . 40

9.2

BC10 control operating instructions . . . . 41

10 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 47

10.1 Filling the heating system  . . . . . . . . . . . .  47
10.1.1 Filling the heating system  . . . . . . . . . . . .  47
10.1.2 Filling the condensate trap with water  . .  49
10.2 Testing and measuring . . . . . . . . . . . . . . .  49
10.2.1 Checking for gas leaks . . . . . . . . . . . . . . .  49
10.2.2 Bleeding the gas flow pipe  . . . . . . . . . . .  50
10.2.3 Gas consumption test  . . . . . . . . . . . . . . .  50
10.2.4 Checking the flue gas connection  . . . . . .  51
10.2.5 Checking the appliance configuration . . .  51
10.2.6 Measuring the gas inlet pressure

(working pressure) . . . . . . . . . . . . . . . . . .51

10.2.7 Checking and adjusting the gas/air-ratio . 52
10.2.8 Carrying out a leakage test in

operating conditions . . . . . . . . . . . . . . . . .54

10.2.9 Measuring the flue gases CO

emissions . 55

10.2.10 Carrying out a function test  . . . . . . . . .  55
10.2.11 Measuring the ionisation current  . . . . .  55
10.3 Boiler settings  . . . . . . . . . . . . . . . . . . . . .  56
10.3.1 Setting the heating capacity  . . . . . . . . . .  56
10.3.2 Setting the maximum CH flow

temperature . . . . . . . . . . . . . . . . . . . . . . .57

10.3.3 Setting the pump run-over time . . . . . . . .  57
10.3.4 Switching DHW mode on/off . . . . . . . . . .  57
10.3.5 Setting the DHW temperature . . . . . . . . .  57
10.4 Final activities  . . . . . . . . . . . . . . . . . . . . .  58
10.4.1 Closing the boiler door and the

control panel . . . . . . . . . . . . . . . . . . . . . . .58

10.4.2 Handing over . . . . . . . . . . . . . . . . . . . . . . 58
10.5 Commissioning record log book . . . . . . . 59

Summary of Contents for GB162-100

Page 1: ...SERVICING INSTRUCTIONS WALL HUNG GAS FIRED CONDENSING BOILER WORCESTER COMMERCIAL BOILER SERIES GB162 65 80 100 6 720 648 726 000 1TD FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER 6 720 648 726 2011 07 ...

Page 2: ...720 648 726 2011 07 2 PRODUCT OVERVIEW Fig 1 GB162 65 80 100 with pump group 14 13 12 11 10 8 7 6 4 5 3 2 1 6 720 648 726 001 1TD 18 17 16 15 14 19 32 33 34 36 37 38 35 39 43 42 41 40 9 20 21 22 23 24 25 26 27 28 29 30 31 ...

Page 3: ...i 23 Burner cover 24 Flow temperature sensor 25 Ionisation electrode 26 Sight glass 27 Glow ignitor 28 Safety temperature sensor 29 Heat exchanger 30 Pressure sensor 31 Return temperature sensor 32 Universal Burner Automatic Version 3 UBA 3 33 Drawer with function module integration options 34 Cover shield 35 Condensate trap Pump group optional accessory 36 Isolating valve blue CH boiler return wi...

Page 4: ... 4 Additional flue parts 28 8 3 5 Standard 100 mm flue systems 28 8 3 6 Installation of the horizontal flue 29 8 3 7 Flue pipe preparation and assembly 29 8 4 Flue gas connection 30 8 4 1 Open flue operation 30 8 4 2 Room sealed operation 30 8 4 3 Flue material 30 8 4 4 Calculating the air intake and flue gas pipe dimensions 30 8 5 Electrical connections 30 8 5 1 Electrical wiring diagram 31 8 5 2...

Page 5: ...Checking the flue gas connection 62 12 12 Inspection log book 63 13 Maintenance 64 13 1 Removing the boiler door 64 13 2 Cleaning the heat exchanger burner and condensate trap 64 13 2 1Removing the gas valve 64 13 2 2Removing the burner cover with the fan and the gas valve 65 13 2 3Removing the burner and the burner seal 66 13 2 4Checking ignition unit 66 13 2 5Disconnecting the condensate trap 66...

Page 6: ...H THE COMPLETED INSTALLATION CHECKLIST OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813 EIRE ONLY AND THE USER MANUAL WITH THE OWNER OR AT THE GAS METER AFTER INSTALLATION OR SERVICING THE INSTALLATION CHECKLIST CAN BE FOUND IN THE BACK PAGES OF THIS INSTALLATION MANUAL ABBREVIATIONS USED IN THIS MANUAL Warnings in this document are framed and identified by a warning triangle which is printed on...

Page 7: ...icinity of the appliance Chemically aggressive substances can corrode the appliance and invalidate any warranty FITTING AND MODIFICATIONS Fitting the appliance and any controls to the appliance may only be carried out by a competent engineer in accordance with the current Gas Safety Installation and Use Regulations Flue systems must not be modified in any way other than as described in the fitting...

Page 8: ... for check valves of nominal size up to and including DN 54 BS6283 4 Safety and control devices for use in hot water systems Specification for drop tight pressure reducing valves of nominal size up to and including DN 50 for supply pressures up to and including 12 bar BS6880 Code of practice for low temperature hot water heating systems for output greater than 45 kW BS6891 Installation of low pres...

Page 9: ...s open to the ground Timber framed building Where the boiler is to be fitted to a timber framed building the guidelines laid down in BS5440 Part 1 and IGE Gas Installations in Timber Frame Buildings should be adhered to Bathroom Installations This appliance is rated IP X4D The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the cu...

Page 10: ... with the correct dosage of an approved water treatment product such as Sentinel X100 to fill and top up the system For more information about Sentinel call 0151 420 9563 B When using water treatment only products suitable for use with Worcester heat exchangers are permitted e g Sentinel X100 Your warranty is at risk if an incorrect water treatment product is used in conjunction with this applianc...

Page 11: ...boiler in accordance with its designated use and the installation and maintenance instructions Installation maintenance and repair must be carried out by competent service engineers e g Gas Safe registered Only use the boiler in conjunction with the accessories and spare parts indicated in the installation and maintenance instructions Other accessories and consumables may only be used if they are ...

Page 12: ...the installation room must have the required air vents DO NOT obstruct these vents The air vents must always be free 3 4 QUALITY OF THE HEATING SYSTEM WATER Thoroughly clean and flush the system before filling it Use only unsoftened mains tap water when filling or topping up the system The use of dirty water will lead to build ups of sludge and corrosion which can in turn result in malfunctioning ...

Page 13: ... makes maintenance activities necessary these activities have to be carried out Æ chapter 13 Maintenance page 64 3 7 APPLICABILITY OF REGULATIONS Changes or amendments to the regulations also apply at the time of installation and have to be complied with CAUTION Boiler damage due to corrosion B If the boiler is used in systems with gravitation circulation or in open systems the boiler circuit must...

Page 14: ...B Dispose of the boiler s packaging material in an environmentally friendly manner B Dispose of those components of the heating installation e g boiler or controller which have to be replaced in an environmentally friendly manner by handing them in at an authorised recycling facility DANGER Danger of fatal accident from explosive fumes If you smell gas there is a danger of explosion B No naked lig...

Page 15: ...e protected against impacts B Observe the transport symbols and instructions on the packaging CAUTION Damage to the installation due to external contamination Proceed as follows if the boiler has been unpacked but is not put into operation yet B Protect the boiler connections against pollution by leaving the protective covers on the connections B Cover the flue gas injectors at the top of the boil...

Page 16: ... Check that all items have been supplied with the boiler Fig 5 Items supplied with unit 1 Boiler assembly 2 Wall bracket 3 Condensate trap with condensate trap hose 4 Technical documents set 5 Flow and return union nuts with sealing rings 2x 6 Screws and plugs for wall bracket 2x 7 Compression elbow for pressure relief valve in pump group 6 720 648 726 005 1TD 1 5 4 7 3 6 2 ...

Page 17: ... remove FGC AIC Flue gas air intake connection Ø 80 125 for GB162 65 and Ø 100 150 for GB162 80 100 GAS Gas connection to boiler G1 female thread The servicing clearances required are in front 50 mm below 0 mm 250 mm with pump group right side 0 mm left side 0 mm above 30 mm The position selected for installation MUST allow adequate space for servicing in front of the boiler in front 550 mm below ...

Page 18: ...on to boiler G1 female thread GAS P Gas connection to pump group Rp1 female thread PF Pump group flow G1 male thread flat seal PR Pump group return G1 male thread flat seal The servicing clearances required are in front 50 mm below 0 mm 250 mm with pump group right side 0 mm left side 0 mm above 30 mm The position selected for installation MUST allow adequate space for servicing in front of the bo...

Page 19: ...ket using the 2 enclosed screws step 4 Fig 8 Installing the wall bracket B With two people lift the boiler by holding it by its back and by the transport rail at its bottom and install it on the wall bracket Æ fig 3 page 15 B Slide the boiler into place Æ fig 9 Fig 9 Sliding the boiler B Level the boiler using the set screw and a spirit level Æ fig 10 Fig 10 Aligning the boiler with the set screw ...

Page 20: ...tion methods are described below B Decide whether you would like to connect the heating device with or without a pump group If you don t use our pump group you have to calculate a separate pump Make sure that the pump is large enough for the flow to overcome resistance in the heating circuit 8 2 2 INSTALL THE WATER AND GAS CONNECTIONS TO THE BOILER USING A PUMP GROUP ACCESSORY The central heating ...

Page 21: ...re systems BS 5449 or EN 12823 B Connect the flow pipe with a flat rubber seal installed to the CHF CH boiler flow connection 1 making sure it is not under stress Use a flow pipe with a minimum diameter of 1 DANGER Danger of fatal accident from explosive fumes B Make sure that the factory fitted flat rubber seal is located in the threaded connection boiler side Æ fig 13 detailed picture CAUTION Pi...

Page 22: ... INSTALLING A PRESSURE RELIEF VALVE B Install a 4 bar pressure relief valve Æ fig 15 6 with a minimum passage of 22 mm in the flow circuit Make sure that the pressure relief valve is always installed between the boiler and the isolating valve so that the boiler will always be in contact with the pressure relief valve even if the isolating valves are closed 8 2 8 SELECTING AND INSTALLING THE PUMP B...

Page 23: ...e horizontal or approximately 50 mm per metre of pipe run If this is can not be achieved consider the use of a sewage pump It should be noted that the connection of a condensate pipe to a drain may be subject to local building controls MATERIAL FOR CONDENSATE The condensate drainage pipe should be run in a standard drain pipe material e g PVC polyvinyl chloride PVC U unplasticized polyvinyl chlori...

Page 24: ...ction is only possible upstream then an air break is needed between the two traps This is normally provided by the sink waste pipe Æ fig 20 and 21 Fig 20 Internal termination of condensate drain pipe to external waste point 1 Sink 2 Boiler 3 No length restriction 4 Open end of pipe direct into drain below ground but above water level An air gap should be maintained between the boiler condensate tr...

Page 25: ...he condensate trap and the condensate drain pipe is 2 cm An air gap should be maintained between the boiler condensate trap and the condensate pipework 8 2 12 CONNECTING THE EXPANSION VESSEL IN A SINGLE BOILER SYSTEM B Connect the expansion tank to the boiler return CHR If a non return valve is available connect the expansion vessel to the CH side of the non return valve in the return circuit Æ fi...

Page 26: ...the same wall 1500 mm L Horizontally from a terminal on the wall 300 mm M Adjacent to opening 300 mm N Above intersection with roof 300 mm O From a vertical structure on the roof 500 mm The flue for installations in excess of 70 kW must be installed in accordance with the recommendations of IGE UP10 Pluming will occur at the terminal so terminal positions where this could cause a nuisance should b...

Page 27: ... be connected to a Worcester horizontal or vertical flue terminal These terminals have been developed specifically for Worcester condensing gas boilers and have been comprehensively tested for trouble free operation when correctly installed Standard horizontal flue pack Æ fig 27 for GB162 80 100 1 Flue turret 100 150 2 Horizontal flue terminal 100 150 3 Flue finishing kit Standard horizontal flue ...

Page 28: ...t roof pitched roof 8 3 5 STANDARD 100 MM FLUE SYSTEMS The standard concentric flue system provides for a max horizontal straight length Æ table 6 subsection 8 3 4 Full instructions for fitting this flue are in subsection 8 3 6 Installation of the horizontal flue on page 29 L 6 720 648 726 030 1TD A L B 6 720 648 726 031 1TD GB162 Maximum flue length m concentric flue system 100 150 80 125 65 20 7...

Page 29: ... face of the wall Refer to figure 35 Extension outer flue L 70 mm inner flue L 50 mm The measurement is from the formed end Fig 35 Flue terminal position B Assemble flue system completely Push the flue fully together The slope of the terminal outlet must face downwards see fig 35 item 1 The assembly will be made easier if a solvent free grease is lightly applied to the male end of the flue B Push ...

Page 30: ...LUE DESIGN CALCULATION FOR CONCENTRIC FLUE SYSTEM 100 150 USING LENGTH METHOD Boiler GB162 80 Flue system concentric 100 150 Maximum length 18 m Here we have 4 meter pipe 2 x 2 m 4 0 m 2 x 90 bends 2 x 2 1 m 4 2 m The total length of this flue system 8 2 m Sum of length 8 2 m maximum length 18 m Æ robust flue design Fig 36 Example 1 8 5 ELECTRICAL CONNECTIONS When connecting the electrical compone...

Page 31: ... sand filled Room controller RC and EMS bus Connector for BC10 basic controller BUS function modules b The 230 Volt converter is only applicable for Logamax plus GB162 65 a Connection to the external pump is only possible if no internal pump has been integrated in the connection kit Volt free external control device external 230V controls 2 1 b a 230 Volt converter IMPORTANT The wires in this main...

Page 32: ...The listing below shows which components must be connected to which terminals see section 7 5 4 page 36 Fig 40 Terminal strip A Low voltage connections B 230 V connections 8 5 3 ROUTING THE CABLE THROUGH THE BOILER B Route the cable for the low voltage connections through the hole on the left 1 B Route the cable for the 230 V connections through the hole on the right 2 B Attach the cable for the 2...

Page 33: ...STALLING A MODULATING CONTROL ROOM CONTROLLER Fig 43 Terminal strip RC room controller and WA potential free heat demand INSTALLING AN RC35 ROOM CONTROLLER AS AN OUTDOOR TEMPERATURE DEPENDANT CONTROL IN THE BOILER For outdoor temperature dependant control operation only it is possble to install the room controller e g RC35 in the boiler In this case the controller does not have to be connected to ...

Page 34: ...lour green Fig 49 Terminal strip WA potential free heat demand If you install the room controller e g RC35 in the boiler only outdoor temperature controlled operation is possible See the room controller user manual for further information This connection is reverse proof This means that it does not matter in which order the wires are connected This connection is non polarity sensitive This means t...

Page 35: ...0 V connected to the room control converter only for GB162 65 For connection see the electrical wiring diagram supplied with the 230 Volt converter ON OFF temperature controller volt free B Connect the black pre wired main appliance lead to a permanent live supply from the same fused isolator as all other controls on the heating system L N E B Remove the grey cover of the 230 Volt converter 1 B Fe...

Page 36: ...to be installed by a registered installer electrician CONNECTION TO THE FREE 230 VAC CONNECTION LEAD B Unwind the 230 VAC cable 1 and route it out of the boiler Æ fig 55 Fig 54 230 VAC cable of the pump B Cut the plug from the 230 VAC cable B Connect the 230 VAC cable to the pump Fig 55 Route the 230 VAC pump cable CONNECTION TO THE TERMINAL STRIP OF THE BOILER B Connect the external pump if avail...

Page 37: ...pole switch 1 The means of isolation must be accessible to the user after installation The electrical connection to the mains supply should be readily accessible and adjacent to the boiler If the supply cord is damaged it must be replaced by a registered Gas Safe installer to avoid a hazard and must be an original spare part The electrical supply for both the boiler and the system must be taken fr...

Page 38: ...e the draw Fig 62 Clicking the function module into place in the wall bracket B Remove the covers of both free connectors on the function module connection cables B Slide the draw back into the boiler Fig 63 Removing the covers B Connect the free 230V AC mains cable Æ fig 63 to the module 1 If more modules are used the 230 VAC supply for the second module can be taken from the first module using t...

Page 39: ...onnect the EMS bus connection lead of the first module to the next module Æ fig 65 B Make a sufficiently long 230 V AC mains cable using a 3 core cable of at least 0 75 mm with an earthing wire the connector enclosed with the module and a 230 V AC earthed plug B Connect the 230 V AC mains cable to the module Æ fig 65 If more modules are used the 230 V AC supply to the next module can be branched o...

Page 40: ...ration mode The flue gas test enables the boiler to be run in full load operation manually for a short period See table 10 Flue gas test page 42 The service mode enables the boiler to be run in part load operation manually for a short period Measurements and settings are carried out on the boiler during service mode See table 11 Service mode page 43 Manual operation mode enables the boiler to be o...

Page 41: ...LED The DHW mode LED Æ fig 69 10 lights up when a DHW request has occurred and it is extinguished when this DHW request is no longer required DHW TEMPERATURE DIAL Only functional when used in conjunction with Bosch controllers The DHW temperature dial Æ fig 69 11 is used to select the required temperature of the hot water in the hot water cylinder The unit is C See table 18 page 57 9 2 BC10 CONTRO...

Page 42: ...than 2 but not longer than 5 seconds Step 4 2 4 Display value As soon as a non flashing dot is shown in the right hand bottom corner of the display the flue gas test has been activated This means that the boiler is in heating mode at a capacity of 100 for a maximum of 30 minutes The maximum CH flow temperature as set on the maximum CH flow temperature dial of the BC10 basic controller now applies ...

Page 43: ...play shows l 2 5 with a 80 kW boiler or l 2 0 with a 65 and 100 kW boiler Step 8 l 2 5 Display setting with a 80 kW boiler and l 2 0 with a 65 and 100 kW boiler Minimum capacity setting during heating mode in Also see section 14 3 page 71 The boiler will reduce its performance to 25 or 20 respectively within a couple of seconds The maximum CH flow temperature set on the BC10 basic controller contr...

Page 44: ...he display manual operation is active This means that the boiler is permanently in heating mode The maximum CH flow temperature as set on the maximum CH flow temperature dial of the BC10 basic controller control panel now applies The Heat request LED lights up DHW mode is possible during manual operation Step 5 Press the e button Step 6 p 1 6 Display value Currently measured system pressure in bar...

Page 45: ...oiler and l 2 0 20 with a 65 and 100 kW boiler Higher Increase the target boiler output with the d button The maximum setting is l 100 This is equal to the factory setting Step 7 Press the e button Step 8 f 5 Display setting Set the second parameter as soon as the display shows f 5 This parameter shows the target pump run over time in minutes after heating operation has ended Also see section 14 3...

Page 46: ...14 3 page 71 Step 13 Set the DHW mode status Yes Æ step 14 No Æ step 15 Step 14 Set the DHW mode target status with the c or d buttons c 1 means On c 0 means Off Please note Setting c 0 also switches off the hot water cylinder frost protection Step 15 Have at least 5 seconds passed without a button being pressed and or has the mains voltage been interrupted Yes Æ step 17 No Æ step 16 Step 16 Press...

Page 47: ...ation 1 to undo the boiler door lock Æ detailed picture B Push the fastener down 2 and open the boiler door 3 B Remove the insulation cover of the pump group 4 Fig 71 Opening the boiler door The boiler has an automatic air vent to purge the boiler To purge the boiler every radiator in the heating system must have a purge facility In some situations it may even be necessary to provide extra purging...

Page 48: ... Water non return valve with reduced pressure Zone RPZ valve assembly incorporating a Type BA air gap Tundish Control valve stop valve on the heating system pipework Fig 74 System fill category 4 B Open the heating flow and return isolating valves on the pump group open position parallel to the pipe Fig 75 Opening the isolating valves here open position B Read the pressure from the pressure gauge ...

Page 49: ...ective expansion vessel In this case the cause of the water loss must be repaired as soon as possible 10 1 2 FILLING THE CONDENSATE TRAP WITH WATER B Fill the condensate trap with water Fig 78 Filling the condensate trap with water 10 2 TESTING AND MEASURING 10 2 1 CHECKING FOR GAS LEAKS Prior to the initial start up check that the gas supply pipework is gas tight this must be confirmed in the com...

Page 50: ...shing on the gas valve and turning it anticlockwise through rotation fig 85 page 58 The gas valve is open when it is in the vertical position B Purge the gas supply into a well ventilated area B Close the gas shut off valve when no more air is present fig 87 B Remove the hose and tighten the screw plug on the testing nipple again Fig 82 Bleeding the gas flow pipe 10 2 3 GAS CONSUMPTION TEST B Isol...

Page 51: ...gas valve in a clockwise direction Æ fig 81 page 50 B Turn the vent key through a quarter rotation to undo the boiler door lock Æ fig 71 see detailed picture page 47 B Push the fastener down and open the boiler door Æ fig 71 page 47 Boiler Type of gas supply Gas injector diameter mm GB162 65 Natural gas H Venturi 1 1 Check the gas classification label on the Venturi LPG 3P 5 3 GB162 80 Natural gas...

Page 52: ... sweep button 3 to clear the reading Also see table 10 Flue gas test page 50 Fig 86 BC10 basic controller B Close the gas valve Æ fig 81 page 50 B Remove the gauge connection tube and tighten the screw plug on the testing nipple again B Open the gas valve again by pushing on the gas valve and turning it rotation in an anticlockwise direction Æ fig 79 page 49 10 2 7 CHECKING AND ADJUSTING THE GAS A...

Page 53: ...e Service mode in accordance with the Service mode menu Æ table 11 page 43 B Set the capacity to minimum part load according to the Service mode menu Æ table 11 page 43 B After the Burner LED Æ fig 86 6 has lit up wait for one minute until the boiler is burning at part load B Read the differential pressure during service mode The differential pressure pgas pair must be 5 Pa 5 Pa indication on the ...

Page 54: ...y sweep button 3 approx 2 seconds until the dot in the right hand bottom corner of the display 9 appears See also table 10 Flue gas test page 42 B After the Burner LED 6 has lit up wait for one minute until the boiler is burning at full load B Use a foaming product to check all sealing locations in the total gas circuit of the burner while the burner is active B Press the Chimney sweep button 3 to...

Page 55: ...e 61 B Press the Chimney sweep button Æ fig 90 3 to clear the reading See also table 10 Flue gas test page 42 B Switch off the heating system by pressing the mains switch of the BC10 basic controller Æ fig 90 1 B Remove the flue gas analyser and fit the cover back onto the flue gas measuring point Æ fig 91 1 B Switch on the heating system by pressing the mains switch of the BC10 basic controller Æ...

Page 56: ...ot in the right hand bottom corner of the display Æ fig 90 9 appears See also table 10 Flue gas test page 42 B Switch off the heating system by pressing the mains switch of the BC10 basic controller Æ fig 90 1 B Remove the multimeter and reconnect the monitoring cable B Switch on the heating system by pressing the mains switch of the BC10 basic controller Æ fig 90 1 B Check that the boiler perform...

Page 57: ...he Maximum CH flow temperature dial Æ fig 94 8 B Limit the maximum CH flow temperature in the Settings menu in most cases 45 C B Observe that the underfloor heating system must be equipped with a safety limiter e g via the external switching contact Æ page 35 Dial position Explanation 0 No supply to radiators e g only DHW mode 30 90 The temperature is set permanently on the BC10 and cannot be chan...

Page 58: ...the system the installer should hand over to the end user by the following actions B Hand over all relevant documentation to the end user and explain his her responsibilities under the relevant national and regional regulations B Explain and demonstrate the starting and shutting down procedures 6 720 648 726 095 1TD 6 720 648 726 044 1TD NOTE B During initial start up and annual servicing make sur...

Page 59: ...__________kWh m _____________kWh m 3 Checking for gas leaks 49 4 Bleeding the gas flow pipe 50 5 Checking the flue gas connection 51 6 Checking the appliance configuration 51 7 Measuring the gas supply pressure working pressure 51 _____________mbar 8 Checking and adjusting the gas air ratio 51 _____________Pa mbar 9 Carrying out a leakage check in operating conditions 54 10 Measuring the carbon mo...

Page 60: ...system has to be shut down for a long period while there is a risk of freezing the water must be drained from the heating system B Push on the control panel to open it B Switch off the heating system by pressing the mains switch of the BC10 1 B Close the main gas supply or the gas valve Æ fig 81 page 50 B Drain the heating water at the lowest point of the heating system using the drain cock or the...

Page 61: ...ORROSION B Check all gas and water bearing pipes for signs of corrosion and for leaks WARNING Damage to the installation due to insufficient or improper cleaning and maintenance B Inspect and clean the heating system once a year B Carry out maintenance as required Immediately remedy faults This will avoid further damage to the system DANGER Danger of fatal accident due to electric current when the...

Page 62: ...gher than 10 mbar per minute again Æ section 13 2 1 Removing the gas valve on page 64 for instructions on how to remove Fig 103 Checking the gas fitting for internal tightness 12 5 MEASURING THE IONISATION CURRENT See section 10 2 11 Measuring the ionisation current page 55 12 6 MEASURING THE GAS INLET PRESSURE WORKING PRESSURE See section 10 2 6 Measuring the gas inlet pressure working pressure p...

Page 63: ... 10 2 7 page 51 _________ Pa _________ Pa _________ Pa 7 Carrying out a tightness check of the gas circuit in operating conditions Section 10 2 8 page 54 8 Measuring the carbon monoxide content CO air free Section 10 2 9 page 55 _________ ppm _________ ppm _________ ppm 9 Checking the system pressure Pre pressure of expansion vessel also see installation instructions for expansion vessel Filling p...

Page 64: ...ightly lift the door and pull it from the hinge Put the door upright in a safe position and make sure that it cannot fall over Fig 104 Removing the boiler door 13 2 CLEANING THE HEAT EXCHANGER BURNER AND CONDENSATE TRAP The boiler has a self cleaning coating 13 2 1 REMOVING THE GAS VALVE B Undo the gas fitting screw connection 1 and pull the 4 connectors 2 from the gas valve Fig 105 Undoing the co...

Page 65: ... gas fitting B Pull the air suction tube from the fan Fig 107 Pulling the air suction tube from the fan B Carefully open the 4 snap closures on the burner cover The snap closures may be under tension B Remove the snap closures Fig 108 Opening the snap closures B Remove the burner cover with the gas air unit Fig 109 Removing the burner cover with the gas air unit GB162 80 100 GB162 65 6 720 648 726...

Page 66: ... seal Fig 111 Checking the ionisation electrode Fig 112 Replacing the ignition unit 1 Glow ignitor 2 Ionisation electrode 3 Rubber seal 4 Cover plate with seal 5 Nut 13 2 5 DISCONNECTING THE CONDENSATE TRAP B Disconnect the condensate trap hose 3 and the rubber sleeve 2 from the condensate trap 1 B Turn the trap clockwise a quarter turn Fig 113 Disconnecting the condensate trap hose 1 Condensate t...

Page 67: ...t at the bottom of the condensate collector 1 B Pull the condensate collector down step 1 and remove it by pulling it towards you step 2 Fig 116 Removing the condensate collector B Check the condensate collector for damage and replace it if required B Clean the condensate collector mechanically using compressed air or a soft brush and rinse it with clean water Fig 117 Cleaning the condensate colle...

Page 68: ...h of the BC10 basic controller 1 B Set the maximum CH flow temperature dial 8 and the DHW temperature dial 10 to the maximum temperatures B Enter a heat demand via the control unit and check that the boiler starts the heating mode B Open a hot water tap and check that the boiler starts the DHW mode B Set the maximum CH flow temperature dial 8 and the DHW temperature dial 10 to the required tempera...

Page 69: ...eaning the burner heat exchanger and condensate trap after shutting down the heating system 64 2 Checking and adjusting the gas air ratio CO2 content at full load CO2 content at part load 52 _______ Pa _______ _______ _______ Pa _______ _______ _______ Pa _______ _______ _______ Pa _______ _______ _______ Pa _______ _______ 3 Function testing 68 4 Confirming proper maintenance Company stamp signat...

Page 70: ... Undo the 2 screws of the control panel at the back of the boiler door 1 Fig 120 Undoing the screws B Undo the cable tie 1 B Remove the control panel Fig 121 Removing the control panel 1 Cable tie B Use the 2 hooks to hang the control panel from the boiler Fig 122 Hanging the control panel from the boiler frame 14 2 DISPLAY READINGS For exact troubleshooting instructions please refer to the boiler...

Page 71: ... 0 Off On c 1 Table 23 Display settings Display codes Display code LED on UBA 3 Other effects z Main display code z Sub display code z Key to display code Reset requi red Operating phase Communication test while starting up This display code flashes 5 times within 5 seconds while starting up to indicate that the communication between the UBA 3 and the BC10 basic controller is being tested If a new...

Page 72: ...ibly reached e 0 a e 3 0 5 2 Operating phase The boiler cannot start up temporarily after a DHW request has ended Off e 0 c e 2 8 3 2 Pre operative phase The boiler prepares for a burner start up whenever a heat demand or a DHW request arises Off e 0 e e 2 6 5 2 Readiness for operation The boiler is in standby mode There is a current heat demand but too much energy has been supplied Off e 0 h e 2 ...

Page 73: ...oom temperature is not possibly reached e 0 y e 2 8 5 e Fault The return temperature sensor has measured a current return temperature higher than 95 C No 4 5 Off The room temperature is not possibly reached e 1 l e 2 1 1 e Fault There is no connection between contacts 78 and 50 of the UBA 3 installation base No Off No heating operation and no DHW e 2 e e 2 0 7 e Fault The system pressure is too lo...

Page 74: ...3 f e 2 7 3 e Operating phase The appliance has been switched off for a couple of seconds because it had been running without any interruption for 24 hours This is a safety check No 4 5 Off e 3 l e 2 1 4 e Fault The tacho signal from the fan is not present during the pre operative or operating phase Yes 5 6 7 8 flashing 1 Hz No heating operation and no DHW e 3 p e 2 1 6 e Fault The fan is running ...

Page 75: ...hing 1 Hz No heating operation and no DHW e 4 u e 2 2 2 e Fault The contacts for the safety temperature sensor have been interrupted Yes 5 6 7 8 flashing 1 Hz No heating operation and no DHW e 4 y e 2 2 3 e Fault The contacts for the safety temperature sensor have been interrupted Yes 5 6 7 8 flashing 1 Hz No heating operation and no DHW e 5 h e 2 6 8 e Operating phase Component test phase No Off ...

Page 76: ... e 7 l e 2 6 1 e Fault The UBA 3 is defect Yes 5 6 7 8 flashing 1 Hz No heating operation and no DHW e 7 l e 2 8 0 e Fault The UBA 3 is defect Yes 5 6 7 8 flashing 1 Hz e 8 y e 2 3 2 2 Operating phase The external switch contact is open Off No heating operation and no DHW 8 8 8 Start up phase The boiler starts up after activation of the mains power supply or completion of a system reset This code ...

Page 77: ... been connected incorrectly or is defective No Off Minimum outdoor temperature is assumed e a 0 1 e 8 0 8 e Fault The contacts to the DHW temperature sensor have shorted or are interrupted the sensor has been connected incorrectly or is defective No Off No DHW is heated any more e a 0 1 e 8 0 9 e Fault The contacts to DHW temperature sensor 2 have shorted or are interrupted the sensor has been con...

Page 78: ...gs are no longer taken over by RCxx devices e a 1 1 e 8 0 2 e Fault Time not set Failing time setting e g due to a long power cut No Off Limited operation of all heating programs and fault list e a 1 1 e 8 0 3 e Fault Date not set Failing date setting e g due to a long power cut No Off Limited operation of all heating programs holiday function fault list e a 1 1 e 8 2 1 e Fault RC35 HK1 remote con...

Page 79: ...re information room influence and optimization of the switch times do not work The EMS works on the basis of the values last set on the remote control e a 1 1 e 8 2 7 e Fault RC35 HK2 temperature sensor The external temperature sensor of the remote control control unit of the heating circuit is defective e a 1 2 e 8 1 5 e Fault The contacts to the switch sensor have shorted or are interrupted the ...

Page 80: ... not work The EMS works on the basis of the values last set on the remote control e a 2 1 e 8 1 6 e Fault RC25 HK1 communication RC25 addressed incorrectly wired incorrectly or defective No Off Since there is no actual room temperature information room influence and optimization of the switch times do not work e a 2 2 e 8 0 6 e Fault RC25 HK2 temperature sensor The integrated temperature sensor of...

Page 81: ...or the bus circuit is connected incorrectly or is defective MM10 is not recognized by the RC35 No Off Heating circuit 2 cannot be operated correctly MM10 and the mixer automatically goes into emergency operation Heating circuit pump 2 is activated continuously Monitor data in the RC35 is invalid e c a e 2 8 6 e Fault The return temperature sensor has measured a return temperature higher than 105 C...

Page 82: ...y indication with a permanent dot in the bottom right hand corner 2 Only visible on the Service Tool or a specific RC regulator 3 Any indication with a flashing dot in the bottom right hand corner 4 This fault code may deactivate again automatically after a specific time without reset Heating and DHW are now available once more 5 If more faults occur simultaneously the relevant fault codes are sho...

Page 83: ...sistance at ΔT20 mbar 170 225 320 Max boiler working pressure bar 4 Content of heating circuit heat exchanger l 5 Pipe connections Gas connection inch G1 Heating water connection inch G1 union nut with female thread enclosed Condensate water connection mm Ø 24 Flue gas values Condensate water quantity for natural gas G20 0 30 C l h 6 9 9 0 10 8 pH value of condensate water pH approx 4 1 Flue gas m...

Page 84: ... isolating valve pressure relief valve stop valves check valves drain cock pressure gauge pump Pump type UPER 25 80 pump group UPER 25 80 UPS 25 80 pump group UPS 25 80 Table 26 Pump group Operating conditions and time constants Unit GB162 65 80 100 Maximum ambient temperature C 40 Maximum flow temperature C 90 Maximum working pressure boiler bar 4 Current rating 230 V AC 50 Hz 10A IP X4D Table 27...

Page 85: ...cket 73965 6 Bracket left 73962 7 Bracket right 73963 8 Adjusting foot 73949 9 Transport slide L R 73951 10 Drawer modules 73964 11 Screw 4 2 x 8 5 x 10 pc 73988 12 Condensate collector 73930 13 Seal condensate collector 7746900152 14 Seal 80 mm 73931 15 Upper side condensate collectors 73934 16 Mounting flue gas pipe 73907 17 Exhaust pipe 73935 18 Adapter air inlet 73938 19 Seal 100 mm 73939 20 C...

Page 86: ...600083 75 Fuse 5AF 10 pc 73904s 76 Connection board 73814 77 Electronic connection red 73776 78 Electronic connection grey 73774 79 Electronic connection green 73773 80 Electronic connection blue 73775 Description Product No 81 Electronic connection orange 73777 82 Flue gas exhaust connection 73940 83 Flue gas adapter 73936 84 Measure nipple cap 73937 85 Seal 150 mm 73968 86 Cable harness low volt...

Page 87: ...4 1TD 5 4 84 43 50 50 51 43 44 45 42 65 36 7 6 37 34 27 29 36 40 38 16 13 44 44 47 44 45 45 46 43 71 67 69 68 72 76 81 80 73 74 66 77 78 79 75 19 26 2 85 19 14 14 32 11 84 40 31 9 10 21 48 48 51 49 49 22 23 21 9 8 14 15 39 63 14 28 33 30 18 41 17 25 1 62 24 20 12 3 52 70 83 82 35 120 121 61 60 ...

Page 88: ...IFICATIONS 6 720 648 726 2011 07 88 EXPLODED VIEW PUMP GROUP GB162 80 100 0 1 2 3 4 1 2 91 92 92 92 96 106 100 102 104 103 101 101 99 97 95 93 91 91 40 98 107 108 105 90 109 89 88 86 87 132 131 6 720 648 726 125 1TD ...

Page 89: ...0 31 Seal 33 x 24 x 3 5 10 pc 73368s 32 Gas pipe 73975 33 Flange gas valve 8718600286 34 O ring 10 pc 73982 36 Screw M5 x 20 10 pc 73572s 37 Screw M5 x 16 10 pc 73970 38 Screw M6 x 16 10 pc 73971 39 Air inlet pipe 73926 40 Seal 10 pc 73969 41 Air vent revision set 73916 42 Clip 73973 43 Sensor NTC 78159 44 Clip 3 x 2 pc 78156s 45 O ring 9 19 x 2 62 10 pc 78175s 46 Pressure sensor 73915 47 O ring 1...

Page 90: ...verter with box 78079 121 230 Volt converter 78091 122 Pipe three way valve boiler 73076 123 Pipe three way valve connection set 73077 124 Return pipe hot water tank 73078 125 Pipe straight DN 25mm L 30cm 73079 126 Body three way valve 20374 127 Motor three way valve 20375 128 Three way valve complete 20373 129 Check valve 74551 Description Product No 130 Repair set three way valve 1 5 4 75400 131...

Page 91: ... 43 44 45 42 65 36 7 6 37 34 27 29 36 40 38 16 13 44 44 47 44 45 45 46 43 71 67 69 68 72 76 81 80 73 74 66 77 78 79 75 19 26 2 85 14 14 14 32 84 40 31 9 10 21 48 48 51 49 49 22 23 21 9 8 14 15 39 63 14 28 33 30 18 41 17 25 1 62 24 20 12 3 52 70 83 54 82 120 121 60 11 61 6 720 648 726 126 1TD ...

Page 92: ...07 92 EXPLODED VIEW PUMP GROUP WITH DHW GB162 65 0 1 2 3 4 1 2 91 92 92 92 96 106 100 102 104 103 101 101 99 97 95 93 91 91 40 98 107 108 105 132 125 123 122 122 123 125 125 125 124 126 130 127 128 131 129 90 109 89 88 87 86 6 720 648 726 127 1TD ...

Page 93: ...st 55 Flue Gas Test menu 41 Flue installation 26 Frost 11 60 Fuels 84 Function test 55 G Gas category 84 Gas consumption test 50 Gas inlet pressure 51 Gas leakage teat 54 Gas pipe 49 Gas valve leakage test 62 Gas air ratio 52 Gas air unit 65 H Heat exchanger cleaning 64 I Inspection log book 63 Installation distances 19 Ionisation current 55 M Manual Operation menu 41 N Normal Operation menu 41 P ...

Page 94: ...INDEX 6 720 648 726 2011 07 94 NOTES ...

Page 95: ...INDEX 6 720 648 726 2011 07 95 NOTES ...

Page 96: ...9900 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 648 726 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0844 693 3028 APPOINTMENTS 0844 892 3000 SPARES 01905 752571 LITERATURE 0844 892 9800 TRAINING 01905 752526 SALES 01905 752640 ...

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Worcester GB162-100, Installation And Servicing Instruction

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