Bosch Worcester GB162-100 V2, Installation, Commissioning And Servicing Instructions

Page 1: ...water 6720814332 2018 04 UK IE If you smell gas Well away from the building In Great Britain call the National Gas Emergency Service on 0800 111 999 In Northern Ireland call 0800 002 001 and in Ireland call 1850 20 50 50 L P G boilers Call the supplier s number on the side of the gas tank These appliances are for use with Natural Gas or L P G Cat II2H3P type C13 C33 C53 Model GC Number Natural Gas...

Page 2: ...5 5 12 Mounting the back panel insulation 25 6 Electrical connection 26 6 1 Control principle 26 6 2 Connection of the control units 26 6 3 Installation of the strain relief 27 6 4 Connecting the on off room temperature dependent control unit 27 6 4 1 Connecting the RTH convertor only for 50 V2 and 65 V2 27 6 5 Connecting the modulating controller 28 6 6 Connecting an external switching contact 28...

Page 3: ...equirementsof the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot water Industry Council w...

Page 4: ...pecification for the installation and maintenance of gas fired hot water boilers of rated inputs between 70kW net and 1 8MW net 2nd and 3rd family gases BS6798 Installation of gas fired boilers of rated input up to 70kW net BS6891 Installation of low pressure gas pipe work up to 28mm R1 BS7074 1 Code of practice for domestic and hot water supply BS7593 Treatment of water in domestic hot water cent...

Page 5: ...ddress on the back cover of these instructions 2 3 Appliance types This document refers to the following appliance types GB162 50 V2 GB162 65 V2 GB162 85 V2 GB162 100 V2 The designation of the boiler comprises the following Worcester manufacturer GB162 V2 product name 50 65 85 or 100 type name 2 4 Data plate The dataplate isonthetopofthe boilertotheleftofthe fluegasadaptor figure 4 8 The data plat...

Page 6: ...tee the protection of the entire heating system from frost 2 10 Pump anti seizure The pump starts automatically for 10 seconds every 24 hours if the pump has not been operated during this time This procedure prevents the pump from seizing 2 11 Dimensions Fig 3 Dimensions mm 1 Concentric flue Ø 80 125 mm 50 V2 and 65 V2 or Ø 100 150 mm 85 V2 and 100 V2 2 Ventilation panel 3 Gas connection for boile...

Page 7: ...ir connection concentric 11 Flue gas connection concentric 12 Flue gas testing point 13 Flue gas temperature sensor 14 Incoming air testing point 15 Cap combustion air connection overpressure flue 16 Flue pipe 17 Fan 18 Burner 19 Ignition device 20 Flow temperature sensor 21 Safety temperature sensor 22 Pressure sensor 23 Heat exchanger 24 Return temperature sensor 25 Boiler ID module KIM 26 Locki...

Page 8: ...ller RTH convertor included in 50 V2 and 65 V2 delivery 22 Pump control signal PWM 23 On off switch 24 Grey no function 25 White power supply 230 V AC 50 Hz 26 Orange power supply of the 1st function module 230 V AC 27 Purple no function 28 Green pump group or external 29 Pump group external pump 230 V AC max 250 W 6720814332 7 1TD D17 D13 D16 C4 C3 C8 C7 A8 A7 A2 A1 A4 A5 G6 G5 F2 F1 0V 24V 13 12...

Page 9: ...2 6 25 102 6 25 155 Permissible ambient temperature C 0 40 Maximum flow temperature Tmax C 90 Maximum operating pressure PMS bar 4 Maximum condensate accumulation rate l h 6 0 7 6 9 3 11 0 Connections Flue gas connection concentric air supply mm 80 125 100 150 Heating flow return pipe boiler inch G 1 Gas connection boiler inch R 1 Condensate drain flexible hose external diameter mm 24 Emission lev...

Page 10: ...ed 251 37 45 Table 6 Gas supply pressures Country Gas design pressure mbar Gas category Gas family Default setting mbar GB IE 20 2H 2H G20 20 Table 7 Natural gas Unit Appliance type 50 V2 65 V2 85 V2 100 V2 Required flow rate at ΔT 20 K l h 2200 3000 3600 4300 Max flow rate at ΔT 20 K l h 5000 Resistance of boiler with required flow rate mbar 90 170 225 320 Table 8 Hydraulic resistances 6720814332...

Page 11: ...astic pipe work Any plastic pipe work must have a polymeric barrier with 600mm minimum length of copper pipe before being connected to the boiler Plastic pipe work used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approximately 50 C Primary systems connections valves All system connections taps and mixing valves ...

Page 12: ... Temporary hose Stop cock Mains cold water Stop cock Stop cock Strainer RPZ Tundish 6 720 648 726 074 1TD 3 3 1 2 4 4 4 4 6720813171 10 2TD NOTICE Whereanewor replacementboiler isbeinginstalled accesstoaninternal gravitydischarge pointshould be one of the factors considered in determining boiler location The condensate pipe must be nominally 22mm Ø plastic pipe The condensate pipe work must fall a...

Page 13: ...ate trap of 75mm already incorporated into the boiler 3 5 2 External connections Ifnootherdischargemethodispossiblethentheuseofanexternallyrun condensate drainage pipe terminating at a suitable foul water discharge point or purpose designed soak away may be considered If this method is chosen then the following measures should be adopted The external run be kept as short as possible and not exceed...

Page 14: ...with two rows of three 12mm holes on 25mm centres and 50mm from the bottom of the tube The holes must face away from the house The tube must be surrounded by at least 100mm of limestone chippings to a depth of 400mm In situations where there are likely to be extremes of temperature or exposure theuseofaproprietarytrace heatingsystemforexternalpipe work incorporating anexternal frostthermostat shou...

Page 15: ...e 2 Outside wall 3 Drain pipe 4 External drain Combined PRV and condensate The PRV and condensate discharge can be combined by the installer on the 50kW and 65kW models only according to BS 6798 However care must be taken to ensure that an air gap is present between the PRV discharge pipe and the connection to the condensate discharge pipe This is to guard against any potential blockage of the PRV...

Page 16: ...as boilers and have been comprehensively tested for trouble free operation when correctly installed These boilers are also compatible with third party flues if required Standard horizontal flue pack fig 22 for 50 V2 and 65 V2 1 Flue turret 80 125 2 Horizontal flue terminal 80 125 3 Flue finishing kit Standard horizontal flue pack fig 22 for 85 V2 and 100 V2 1 Flue turret 100 150 2 Horizontal flue ...

Page 17: ...Vertical flue length Fig 26 Horizontal flue length A Distance from centre of flue to inside rear wall B Distance from centre wall bracket to centre of flue elbow L Distance from centre of flue to outside wall Take the flue pipe clearances into account when installation the linstallation location Maximum wall thickness without extensions is 415 mm Maintain a minimum side clearance of 25 mm fig 23 3...

Page 18: ...e L minus 50mm Flue gas L minus 70mm Mark off the lengths and cut to length The cuts must be square and free from burrs Assemble flue system completely Push the flue fully together The slope of the terminal outlet 2 must face downwards The assembly will be made easier if a solvent free grease is lightly applied to the male end of the flue Fig 30 Flue terminal position Model Reduced flue length m 1...

Page 19: ...ntering the boiler contact Worcester Technical accessory 3 9 2 Room sealed operation The boiler can be connected to a concentric flue gas system The boiler is factory fitted with a concentric connection 3 9 3 Flue material When using 3rd party plastic flue material PPS is recommended 3 9 4 Calculating the air intake and flue gas pipe dimensions The total reduced pipe length is calculated from the ...

Page 20: ...fromtheground or if a person could come into contact with the flue terminal 18 600mm distance to asurface facing a terminal unless it will cause a nuisance BS 5440 Part 1 recommends that care is taken when siting terminals in relation to surfaces facing a terminal In instances where the combined output of the installation exceeds 70kW net heat input the flue solution must be installed in accordanc...

Page 21: ...g the boiler The boiler may only be hung on the wall or installed on a cascade frame Wall mounted installation Check whether the wall is strong enough to support the weight of the boiler pump group and water content Mount a fastening structure if required Determine the position of the boiler on the wall Mark holes using the mounting bracket supplied figure 34 Install the mountingbracketon the wall...

Page 22: ...l the gas connection on the boiler using an approved sealant 1 Mount the gas isolation valve G 1 in the gas line 2 Connect the gas pipe without stress to the gas isolation valve Fig 37 Installing the gas isolation valve 1 Sealing agents 2 Gas isolation valve 5 6 2 Mounting the pump group Attach the screw fitting delivered with the boiler figure 1 8 to the flow and return connection of the boiler C...

Page 23: ...alve 5 7 2 Mounting the pump Select a pump based on the technical data tab 4 page 9 Take the required flow rate into account tab 8 page 10 If a low loss header is not used Select a pump that has a residual head of at least 200 mbar at the required flow rate Install the pump 6 in the return pipe 5 Fig 40 Connection of the heating water pipework 1 Flow pipe 2 Pressure Relief Valve 3 Hydraulic isolat...

Page 24: ...ig 41 Installation of the low loss header 1 Low loss header 2 Expansion vessel 3 Pump 4 Hydraulic isolation valve 5 Pressure differential controller bypass 5 9 Installing the siphon Remove the transport protection plug Fig 42 Remove the transport protection plug Fill the condensate trap with water Install the condensate trap Fig 43 Installing the condensate trap 6720812338 2 1TD 1 2 3 4 4 5 6 720 ...

Page 25: ...thiscaseis5 m Fill the trap in the waste water pipe 5 11 Expansion vessel connection Remove the cap from the connection point 1 Connect the connection pipe of the expansion vessel to the connection point Fig 45 Expansion vessel connection 5 12 Mounting the back panel insulation Hook the insulated rear panel of the pump group into the boiler Fig 46 Mounting the insulated rear panel NOTICE Boiler da...

Page 26: ...e TRV 5 Other rooms 6 Living space 7 Installation location Fig 48 Principle of weather compensated control 1 Boiler 2 Room temperature dependent controller 3 Thermostatically controlled radiator valve TRV 4 Other rooms 5 Living space 6 Installation location 7 External 8 Outdoor temperature sensor 6 2 Connection of the control units The terminal strip is located behind the cover Unscrew the control...

Page 27: ... free on off room temperature dependent control units without heat acceleration element anticipation resistor can be connected Connecttheon offroomtemperature dependentcontrolunitviathe green plug on the terminal strip 1 The maximum permissible electrical resistance of this cable is 100 Ω Fig 54 Connecting the on off room temperature dependent control unit 6 4 1 Connecting the RTH convertor only f...

Page 28: ...e 6 9 Connecting the 3 way valve Connection to the turquoise connector block is not possible 6 10 Connecting the function module accessory Connect the BUS cable to the connection for the modulating controller chapter 6 5 Connect the power supply of the function module to the connector block 1 Usethepowercablesuppliedwiththefunctionmodulefor this Fig 58 Connecting the mains voltage 6 11 Connecting ...

Page 29: ...d adjacent to the boiler If the supply cord is damaged it must be replaced by a qualified electrician to avoid a hazard and must be an original spare part The electrical supply for both the boiler and the system must be taken from the same fused spur outlet Fig 60 Mains supply 1 Switch 7 Operating the boiler Fig 61 Control panel 1 On off switch 2 Reset key 3 Chimney sweep key 4 Help key 5 Display ...

Page 30: ... Operating pressure bar display flashes if the operating pressure is too low C Chimney sweep mode service operation B Burner in operation R Central heating ON S DHW ON I Pump running T Outside temperature display An interlocking fault has occurred or the boiler requires a service Table 13 Display indications in normal mode After a few minutes of inactivity the menu closes automatically and the hom...

Page 31: ...the M and N keys simultaneously for 5 seconds The word Lock is displayed for 5 seconds figure 64 The information menu remains readable Fig 64 Display Lock Disable Press the Land c keys again simultaneously for 5 seconds to remove the key block the word Lock disappears Heating mode is switched on Setting On Off Set the maximum boiler flow temperature based on the heating system type Adjustment rang...

Page 32: ...a the red knob on the front to medium level Ext in Adjust the pump run on time in the setup menu Chapter 7 2 8 7 Testing the gas supply pressure Measure the gas supply pressure when the burner is in operation at full load Proceed as follows Take the boiler out of operation Remove the casing Close gas isolation valve Make sure the heating system can dissipate the heat generated WARNING Gas explosio...

Page 33: ... tab 6 page 10 Take the boiler out of operation Close the gas isolation valve Remove the pressure gauge Close test nipple for gas supply pressure Open the gas isolation valve Bring the boiler into operation Check gas tightness of the boiler 8 8 Measure gas air ratio Take the boiler out of operation Close the gas isolation valve Undo the nozzle pressure test nipple 1 by turning it through 2 revolut...

Page 34: ... the test nipple Open the gas isolation valve Bring the boiler into operation 8 9 Measure the CO and CO2 content Take the boiler out of operation Remove the cap of the flue gas testing point 1 Fig 71 Removing the cap of the flue gas testing point 1 Flue gas testing point 2 Air supply testing point Connect the flue gas analyser to the test point Bring the boiler into operation Make sure that the bo...

Page 35: ...urer The installer must be competent in the use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer The gas valve is factory set and must not be adjusted during commissioning if found to be out of tolerance please contact the Worcester Bosch Group help line 0330 123 3366 Yes No Yes Yes Set boiler to minimum rate Check all seals around the burner internal flue ...

Page 36: ...cause of a possible leak Take steps to remedy the leak Exit the chimney sweep mode 8 12 Check the operating characteristics of the boiler Create a heat demand and check whether the boiler starts burning after several minutes to support the boiler operation If applicable open a DHW tap and check the DHW temperature and DHW volume 8 13 Final steps Fit the casing Complete the Benchmark checklist 50 V...

Page 37: ...oiler and avoid possible technical problems the boiler must be inspected and serviced at least once a year 11 1 Important information You will need the following measuring devices and tools Pressure gauge with a measurement accuracy of 0 01 mbar Use only original spare parts When carrying out the work check all removed gaskets for damage deformation or ageing and replace if necessary Commissioning...

Page 38: ...Pictured 50 65kW Release the 4 snap fasteners on the burner cover The snap fasteners are under tension Fig 79 Opening the snap fasteners Remove the gas air unit together with the burner cover Fig 80 Remove the gas air unit together with the burner cover 11 3 To clean the burner Remove the burner gasket and replace if necessary Fig 81 Removing the burner gasket 6 720 807 034 042 2DDC 6 720 807 034 ...

Page 39: ...r glow ignitor unit fit a new cover plate with gasket 4 and gasket 3 Fig 85 Replacing the ignition device 1 Glow ignitor 2 Flame sense electrode 3 Seal 4 Cover plate with gasket 5 Nut Insert the burner 1 with the notch pointing to the right 3 NOTICE Damage to the boiler The heat exchanger has been coated This coating must not be damaged Steel brushes abrasives or similar must therefore not be used...

Page 40: ...densate trap 2 Fig 87 Removing the condensate trap 1 Threaded connector 2 Condensate trap Flush out condensate trap Fill the siphon completely with water Reattach the siphon Hand tighten the threaded connector 11 7 Cleaning the condensate sump If the siphon is soiled check and clean the condensate sump as necessary Pull the condensate hose down and turn it towards the rear Fig 88 Remove the conden...

Page 41: ...2 revolutions Fig 91 Opening the burner pressure test nipple 50 V2 and 65 V2 Fig 92 Opening the burner pressure test nipple 85 V2 and 100 V2 Connect pressure gauge Set pressure gauge to 0 Hold the pressure gauge at the same height when the measurement is in progress Open the gas isolation valve Bring the boiler into operation Make sure that the boiler can dissipate the heat generated Start the chi...

Page 42: ... the flue gas non return valve must be checked Open the inspection aperture 1 of the flue gas turret Check the flue gas non return valve 2 for wear damage or soiling and replace if necessary Close the inspection aperture of the flue gas non return valve Fig 95 Checking the flue gas non return valve 1 Inspection aperture 2 Flue gas non return valve 11 12 Measure ionisation current See chapter 8 10 ...

Page 43: ..._ mbar 6 Measure gas air ratio _______ Pa _______ Pa _______ Pa _______ Pa _______ Pa _______ Pa 7 Carry out a tightness test during operation 8 Measure the CO content flue gas analysis _______ ppm _______ ppm _______ ppm _______ ppm _______ ppm _______ ppm 9 Measure the ionisation current _______ μA _______ μA _______ μA _______ μA _______ μA _______ μA 10 Check the charge pressure Check the char...

Page 44: ...endent control has been adjusted Increase the above if necessary Check the wiring and function of the cylinder temperature sensor Replace the component if necessary 2 1 2 The actual temperature recorded by the flow temperature sensor or the safety sensor is rising too quickly Check the water pressure of the boiler vent the heating system and the boiler Check whether it is possible to achieve suffi...

Page 45: ...ks Check the wiring and function of the pressure sensor C E 2 6 6 3 Pump test failed Check the water pressure of the boiler vent the heating system and the boiler Check whether it is possible to achieve sufficient flow in the heating system Check function of the pump Check function and cabling of the pressure sensor Check the operating characteristics of the boiler by replacing the faulty componen...

Page 46: ...e safety temperature sensor haveshortedorthesafetytemperaturesensorhas detected a temperature higher than 130 C E 9 2 2 1 3 The contacts of the safety temperature sensor have been interrupted Check the plug of the sensor Check the operating characteristics of the boiler by replacing the sensor E 9 2 2 4 3 The temperature measured by a device thermostat e g maximum or burner thermostat is too high ...

Page 47: ...it is faulty Check the plug and wiring of the burner control unit Check the operating characteristics of the boiler by replacing the burner control unit E A 2 6 9 3 The ignition device has been activated for too long Check the plug and wiring of the burner control unit Check the operating characteristics of the boiler by replacing the burner control unit F 0 2 3 7 3 The burner control unit or the ...

Page 48: ...t a wind turbine or other equipment that could cause an interruption Check the electrical installation F A 3 0 6 3 An ionisation current was measured after the burner went out Inspect the ionising part of the ignition device Replace the faulty component if necessary Check whether the gas air ratio upstream and downstream of the burner phase remains the same Check whether voltage is present at the ...

Page 49: ...6720814332 2018 04 49 Notes ...

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Page 52: ...9559 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6720814332 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0330 123 9779 LITERATURE 0330 123 9119 TRAINING 0330 123 0166 SALES 0330 123 9669 ...