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- GB162-100
- Installation And Servicing Instructions
Worcester GB162-100 Installation And Servicing Instructions
Summary of GB162-100
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Uk/ie installation and servicing instructions wall hung gas fired condensing boiler worcester commercial boiler series gb162-50/65/80/100 6 720 648 726-000.1td for central heating systems and indirect fed domestic hot water 672 0813171 (2015/04).
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Product overview 6720813171 (2015/04) 2 product overview fig. 1 gb162-50/65/80/100 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.
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Product overview 6720813171 (2015/04) 3 [1] bc10 basic controller holder [2] installation option for room controller, e.G. Rc35 [3] bc10 basic controller, can be expanded e.G. By the rc35 room controller [4] connection box (low-voltage and 230v connections) [5] fan harness and mains lead of the pump...
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Contents 6720813171 (2015/04) 4 contents 1 key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 5 1.1 key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 gen...
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Key to symbols and safety instructions 6720813171 (2015/04) 5 12.3 carry out a visual check for general signs of corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 12.4 gas valve leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . 47 12.5 measuring the...
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Key to symbols and safety instructions 6720813171 (2015/04) 6 1.2 safety instructions if you smell gas: ▶ call national gas emergency service on 0800 111 999. ▶ lpg boilers call the supplier‘s number on the side of the lpg tank. ▶ turn off the ecv (emergency control valve) at the meter/regulator. ▶ ...
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Key to symbols and safety instructions 6720813171 (2015/04) 7 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 pre...
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General 6720813171 (2015/04) 8 the position selected for installation must allow adequate space for servicing in front of the boiler. • in front: 550 mm • below: 350 mm • right side: 0 mm • left side: 0 mm • above: 40 mm. In addition, sufficient space may be required to allow lifting access to the w...
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Regulations and directives 6720813171 (2015/04) 9 hand over please complete the appropriate sections on completion of the installation and commissioning in the relevant log book an hand it over to the end user. 3 regulations and directives 3.1 designated use the boiler may only be used to heat up wa...
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Safety 6720813171 (2015/04) 10 4 safety please observe these instructions for your own safety. 4.1 please observe these instructions observe the following instructions when installing and operating the heating system: • the local building regulations as regards the installation conditions. • the loc...
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Items supplied with boiler 6720813171 (2015/04) 11 fig. 3 lift and carry the boiler correctly fig. 4 incorrect way of lifting and carrying the boiler 5.2 transporting the boiler with a trolley ▶ place the boiler in its packaging on the hand truck and secure it with a strap if necessary. ▶ transport ...
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Dimensions of boiler 6720813171 (2015/04) 12 7 dimensions of boiler fig. 6 dimensions and connections without pump group (dimensions in mm) [cdo] condensate drain outlet; Ø 24 mm o/d [cfo] distance from wall bracket to centre of horizontal flue elbow; 337.5 mm for Ø 80/125 flue and 339.5 mm for Ø 10...
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Dimensions of boiler 6720813171 (2015/04) 13 fig. 7 dimensions and connections with pump group (dimensions in mm) 1) the pump group is an accessory which has to be ordered separately. [cdo] condensate drain outlet; Ø 24 mm o/d [chf] ch (boiler) flow; g1½" union nut with female thread [chr] ch (boile...
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Installation 6720813171 (2015/04) 14 8 installation this section explains how to install the boiler in a professional manner. 8.1 installing the boiler observe the installation distances of the concentric flue gas system in the separate flue gas system manual. ▶ before starting installation check th...
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Installation 6720813171 (2015/04) 15 8.2 general connection of mains water and gas components 8.2.1 general the water and gas connections to the boiler can be made in either of 2ways: • using a pump group ( fig. 12) • without a pump group. Fig. 12 pump group (accessory) the circulation pump is not...
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Installation 6720813171 (2015/04) 16 ▶ install the gas valve connector 1" [1] (accessory). ▶ install the gas valve [2] onto the gas pipe. Use a gas valve with a minimum diameter of 1". Fig. 14 making the gas connection [1] gas valve connector 1" [2] gas valve 1" ▶ connect the main gas pipe to the ga...
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Installation 6720813171 (2015/04) 17 ▶ install the pump ( fig. 15, [8]) in the return circuit ( fig. 15, [2]). 8.2.9 installing the condensate trap ▶ fill the condensate trap (supplied with the boiler) with water ( fig. 16). Fig. 16 filling the condensate trap with water ▶ connect the condensat...
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Installation 6720813171 (2015/04) 18 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 chloride), bs (acrylonitrile-butadienestyrene), pp (polypropylene polyprolene) or pvc-c (cross-link...
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Installation 6720813171 (2015/04) 19 fig. 22 external termination of condensate drain pipe to absorption point [1] external length of pipe 3 m max. [2] plastic tube [3] bottom of tube sealed [4] limestone chippings [5] two rows of three 12 mm holes at 25 mm centres, 50 mm from bottom of tube and fac...
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Installation 6720813171 (2015/04) 20 8.3 flue installation 8.3.1 siting the flue terminal fig. 26 balanced flue terminal position terminal position minimum spacing [mm]: [a] directly below, above or alongside an opening window, air vent or other ventilation opening 300 [b] below guttering, drain pip...
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Installation 6720813171 (2015/04) 21 if this could occur the appliance must be turned off, and labelled as unsafe until corrective action can be taken. 8.3.2 air supply and flue gas exhaust in a room sealed installation a ventilation cover is integrated into the condensing gas system boilers. This c...
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Installation 6720813171 (2015/04) 22 8.3.3 maximum flue length (l) the maximum pipe length (l) of the air supply and flue gas exhaust pipes for the condensing gas system boilers is determined by the total pressure loss of all components in the flue system. Maximum length of horizontal or vertical ex...
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Installation 6720813171 (2015/04) 23 8.3.6 installation of the horizontal flue the standard flue is suitable for lengths up to 660 mm ( fig. 32). For longer flue runs up to 29.0 m for flue system 100/150 and 7.3 m for flue system 80/125, flue extensions are available (accessory). Fig. 32 installat...
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Installation 6720813171 (2015/04) 24 example of a flue 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 thi...
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Installation 6720813171 (2015/04) 25 8.5.1 electrical wiring diagram fig. 37 electrical wiring diagram warning: ▶ do not directly connect a 230 v thermostat to this boiler. Use the grey 230v connection box (supplied with gb162-50/65). Earth ionisation pressure sensor return sensor safety-temperature...
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Installation 6720813171 (2015/04) 26 8.5.2 terminal strip connections ▶ turn the vent key through a quarter rotation to undo the boiler door lock ( fig. 38, see detailed picture). ▶ push the fastener down ( fig. 38) and open the boiler door. Fig. 38 open the boiler door ▶ undo 1 screw to release...
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Installation 6720813171 (2015/04) 27 fig. 42 terminal strip connections [1] room controller rc and ems bus (connection colour orange) [2] outdoor-temperature sensor (connection colour blue) [3] connection terminal for potential free heat demand (connection colour green) [4] dhw temperature sensor (c...
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Installation 6720813171 (2015/04) 28 connecting the outdoor temperature sensor if outdoor temperature-dependant control operation is used, an outdoor temperature sensor must be connected. ▶ connect the outdoor temperature sensor to the blue fa terminal, using a 2-core cable of 0.75 mm². Fig. 47 term...
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Installation 6720813171 (2015/04) 29 ▶ 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. ▶ remove the grey cover of the 230 volt converter [1]. ▶ feed the 230 v switch live and neutral (from e...
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Installation 6720813171 (2015/04) 30 connection to the terminal strip of the boiler ▶ connect the external pump, if available, (not the pump of the pump group) to the green pk terminal. The maximum allowed connected load of the pump = 250 watts. Fig. 56 terminal strip - external heating pump 230 v (...
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Installation 6720813171 (2015/04) 31 ▶ install the wall bracket (accessory with function module) in the relevant slots in the draw. Fig. 61 installing the wall bracket ▶ click the function module(s) into place in the wall bracket. ▶ remove the draw. Fig. 62 clicking the function module into place in...
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Operation 6720813171 (2015/04) 32 fig. 66 ems bus polarity installing and connecting function modules outside the boiler ▶ install the module on the wall. ▶ make a sufficiently long ems bus connection cable, using a 2-core cable of 0.4 - 0.75 mm² and the connector enclosed with the module ( fig. 6...
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Operation 6720813171 (2015/04) 33 “chimney sweep” button the “chimney sweep” button ([3] is used to put the boiler into flue gas test, service or manual operation 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”, p...
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Commissioning 6720813171 (2015/04) 37 10 commissioning this section explains how to start up the boiler. ▶ complete the commissioning record log book after carrying out the activities described below ( section 10.5 “commissioning record log book”, page 45). 10.1 filling the heating system 10.1.1 f...
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Commissioning 6720813171 (2015/04) 38 ▶ 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) ▶ read the pressure from the pressure gauge on the pump group or on the control panel of the b...
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Commissioning 6720813171 (2015/04) 39 ▶ slowly open the gas valve by pushing on the gas valve and turning it ¼ rotation in an anticlockwise direction. The gas valve is open when it is in the vertical position. Fig. 79 open the gas valve ▶ switch off the power supply to the heating system. Fig. 80 sw...
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Commissioning 6720813171 (2015/04) 40 10.2.4 checking the flue gas connection check the following points: • has the prescribed flue gas system been used ( section 8.4 “flue gas connection”, page 23)? • have the configuration instructions from the relevant flue gas system installation instructions ...
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Commissioning 6720813171 (2015/04) 41 ▶ press and hold the “chimney sweep” button [3] (approximately 2 seconds), until the dot in the right-hand bottom corner of the display [9] appears. See also table 10, “flue gas test”, page 34. ▶ after the “burner” led [6] has lit up wait for one minute until th...
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Commissioning 6720813171 (2015/04) 42 ▶ set the capacity to minimum (part load) according to the “service mode” menu ( table 11, page 34). ▶ after the “burner” led ( fig. 86, [6]) has lit up wait for one minute until the boiler is burning at part load. ▶ read the differential pressure during ser...
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Commissioning 6720813171 (2015/04) 43 10.2.9 measuring the flue gases co 2 emissions ▶ open at least 2 thermostatic radiator valves. Do not switch on the boiler. ▶ push on the control panel to open it ( fig. 68, page 32). ▶ switch off the heating system by pressing the mains switch of the bc10 bas...
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Commissioning 6720813171 (2015/04) 44 ▶ measure the ionisation current. The ionisation current must be > 5 μa dc at part load operation. ▶ enter the result in the commissioning log book ( section 10.5 “commissioning record log book”, page 45). ▶ if the result is not as it should be, check the gas/...
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Commissioning 6720813171 (2015/04) 45 10.4 final activities 10.4.1 closing the boiler door and the control panel ▶ close the boiler door and lock the fastener by turning the vent screw through ¼ rotation in a clockwise direction. Fig. 94 closing the boiler door ▶ push on the control panel to close i...
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Shutting down the heating system 6720813171 (2015/04) 46 11 shutting down the heating system 11.1 shutting down the heating system using the basic controller shut down your heating system by means of the bc10 basic controller. When the system is shut down, the burner is automatically switched off. F...
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Inspection 6720813171 (2015/04) 47 ▶ close the gas valve [1]. ▶ close the isolating valves[2]. Fig. 100 closing the valves (here: in closed position) 12.2 opening the boiler door ▶ turn the vent key through a quarter rotation to undo the boiler door lock ( detailed picture). ▶ push the fastener do...
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Maintenance 6720813171 (2015/04) 48 12.12 inspection log book ▶ enter your signature and the date after completing the inspection activities. 13 maintenance ▶ prepare the system for maintenance as described in the chapter on inspection ( section 12.1, page 46). 13.1 removing the boiler door if the...
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Maintenance 6720813171 (2015/04) 49 13.2 cleaning the heat exchanger, burner and condensate trap the boiler has a self-cleaning coating. 13.2.1 removing the gas valve ▶ undo the gas fitting screw connection [1] and pull the 4 connectors [2] from the gas valve. Fig. 104 undoing the connections to the...
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Maintenance 6720813171 (2015/04) 50 ▶ carefully open the 4 snap closures on the burner cover. The snap closures may be under tension. ▶ remove the snap closures. Fig. 107 opening the snap closures ▶ remove the burner cover with the gas/air unit. Fig. 108 removing the burner cover with the gas/air un...
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Maintenance 6720813171 (2015/04) 51 13.2.5 disconnecting the condensate trap ▶ disconnect the condensate trap hose [3] and the rubber sleeve [2] from the condensate trap [1]. ▶ turn the trap clockwise a quarter turn. Fig. 112 disconnecting the condensate trap hose [1] condensate trap [2] rubber slee...
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Maintenance 6720813171 (2015/04) 52 13.2.7 cleaning the heat exchanger ▶ check the bottom and top sides of the heat exchanger for dirt. ▶ clean the heat exchanger with compressed air or a soft brush. Fig. 117 cleaning the heat exchanger ▶ refit the condensate collector. ▶ connect the flexible conden...
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Display information 6720813171 (2015/04) 53 14 display information this section describes how to read operating and fault messages from the bc10 basic controller and what they mean. 14.1 removing the control panel from the boiler to make it easier to use the buttons on the control panel when the boi...
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Technical specifications 6720813171 (2015/04) 61 15 technical specifications the technical specifications serve to provide information about the boiler performance profile. Unit gb162-50 gb162-65 gb162-80 gb162-100 rated thermal load for g20 kw 14.6 - 47.5 14.6 - 62.0 19.3 - 82.0 19.3 - 96.5 rated h...
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Technical specifications 6720813171 (2015/04) 62 pump group operating conditions for time constants fuels and configurations hydraulic resistance of the boiler fig. 122 boiler resistance curve pump group unit gb162-50/65/80/100 general pump group components casing, gas isolating valve, pressure reli...
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Technical specifications 6720813171 (2015/04) 63 15.1 spare parts list gb162-80/100 the following are parts commonly required due to damage or replacements. Their failure will affect safety or performance of this appliance. For a pictorial representation of the part see the respective position numbe...
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Technical specifications 6720813171 (2015/04) 64 exploded view gb162-80/100 6 720 648 726-124.1td 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 2...
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Technical specifications 6720813171 (2015/04) 65 exploded view pump group gb162-80/100 0 1 2 3 4 12 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.
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Technical specifications 6720813171 (2015/04) 66 15.2 spare parts list gb162-50/65 for a pictorial representation of the part see the respective position number on the exploded view pictures on page 68 and 69. Description product no. 1 door 8718689173 2 sealing door 7101382 3 door lock 7101384 4 hin...
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Technical specifications 6720813171 (2015/04) 67 126 body three way valve 20374 127 motor three way valve 20375 128 three way valve complete 20373 129 check valve 7746900606 130 repair set three way valve 1”+ 5/4” 75400 131 valve housing supply (single) 74547 valve housing supply (combi) 74548 132 v...
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Technical specifications 6720813171 (2015/04) 68 exploded view gb162-50/65 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 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...
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Technical specifications 6720813171 (2015/04) 69 exploded view pump group with dhw gb162-50/65 0 1 2 3 4 12 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.
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6720813171 (2015/04) 70 notes.
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6720813171 (2015/04) 71 notes.
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Worcester, bosch group cotswold way, warndon, worcester wr4 9sw. Tel. 0330 123 9559 worcester, bosch group is a brand name of bosch thermotechnology ltd. Worcester-bosch.Co.Uk 6720813171 worcester, bosch group: technical support: 0330 123 3366 appointments: 0330 123 9339 spares: 0330 123 9779 litera...