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Worcester-Bosch GB162-65 Manual

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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
6720813171 (2016/05)
Product overview
6720813171 (2016/05)2
Product overview
Fig. 1 GB162-50/65/80/100 with pump group
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6 720 648 726-001.1TD
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Product overview
6720813171 (2016/05) 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
[6] Condensate drain outlet
[7] Condensate collector
[8] Boiler front door
[9] Automatic air vent
[10] Quick clip fasteners
[11] Air inlet pipe
[12] Gas pipe
[13] Flue gas pipe
[14] Door lock
[15] Testing point for flue gas
[16] Testing point for air intake
[17] Air intake connection
[18] Flue gas connection
[19] Cover shield
[20] Fan
[21] Gas valve
[22] Venturi
[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) with pump, drain cock, non-return valve and thermometer
[37] Gas valve, yellow (GAS)
[38] Isolating valve, red (CH boiler flow) with drain cock, pressure gauge, thermometer and 4-bar pressure relief valve
[39] 4-bar pressure relief valve and securing pin
[40] Pressure gauge
[41] Drain valve
[42] Isolating valve
[43] Thermometer (optional accessory)
The pump group also includes an insulation cover (see also pump group installation instructions).
Contents
6720813171 (2016/05)4
Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 5
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Regulations and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Combustion air flue gas connection . . . . . . . . . . . . . . . . . 9
3.4 Quality of the heating system water . . . . . . . . . . . . . . . . . 9
3.5 Quality of the pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Applicability of regulations . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Please observe these instructions . . . . . . . . . . . . . . . . 10
4.2 Tools, materials and further equipment . . . . . . . . . . . . 10
4.3 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Lifting and carrying the boiler . . . . . . . . . . . . . . . . . . . . 10
5.2 Transporting the boiler with a trolley . . . . . . . . . . . . . . 11
6 Items supplied with boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Dimensions of boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.1 Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.2 General connection of mains water and gas
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2.2 Install the water and gas connections to the boiler
using a pump group (accessory) . . . . . . . . . . . . . . . . . . 15
8.2.3 Install the water and gas connections to the boiler
without a pump group . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2.4 Installing the differential pressure controller . . . . . . . 16
8.2.5 Installing the isolating valves . . . . . . . . . . . . . . . . . . . . 16
8.2.6 Installing the drain cock . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2.7 Installing a pressure relief valve . . . . . . . . . . . . . . . . . . 16
8.2.8 Selecting and installing the pump . . . . . . . . . . . . . . . . 16
8.2.9 Installing the condensate trap . . . . . . . . . . . . . . . . . . . 17
8.2.10 Condensate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2.11 Connecting the condensate drain pipe . . . . . . . . . . . . 19
8.2.12 Connecting the expansion vessel in a single-boiler
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Flue Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3.1 Siting the flue terminal . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3.2 Air supply and flue gas exhaust in a room sealed
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.3.3 Maximum Flue length (L) . . . . . . . . . . . . . . . . . . . . . . . 22
8.3.4 Additional flue parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3.5 Standard 100 mm flue systems . . . . . . . . . . . . . . . . . . . 22
8.3.6 Installation of the horizontal flue . . . . . . . . . . . . . . . . . . 23
8.3.7 Flue pipe preparation and assembly . . . . . . . . . . . . . . . 23
8.4 Flue gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.1 Open flue operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.2 Room sealed operation . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.3 Flue material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4.4 Calculating the air intake and flue gas pipe
dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.5.1 Electrical wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . 25
8.5.2 Terminal strip connections . . . . . . . . . . . . . . . . . . . . . . . 26
8.5.3 Routing the cable through the boiler . . . . . . . . . . . . . . . 26
8.5.4 Description of the terminal strip connections . . . . . . . . 26
8.5.5 230 V connections (only for GB162-50/65) . . . . . . . . 29
8.5.6 Installing function modules (accessories) . . . . . . . . . . . 30
9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.1 General items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.2 BC10 control operating instructions . . . . . . . . . . . . . . . 33
10 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1.1 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1.2 Filling the condensate trap with water . . . . . . . . . . . . . 38
10.2 Testing and measuring . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.1 Checking for gas leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2.2 Bleeding the gas flow pipe . . . . . . . . . . . . . . . . . . . . . . . 39
10.2.3 Gas consumption test . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.2.4 Checking the flue gas connection . . . . . . . . . . . . . . . . . 40
10.2.5 Checking the appliance configuration . . . . . . . . . . . . . . 40
10.2.6 Measuring the gas inlet pressure (working pressure) . . 40
10.2.7 Checking and adjusting the gas/air-ratio . . . . . . . . . . . . 41
10.2.8 Carrying out a leakage test in operating conditions . . . 42
10.2.9 Measuring the flue gases CO
2
emissions . . . . . . . . . . . . 43
10.2.10Carrying out a function test . . . . . . . . . . . . . . . . . . . . . . 43
10.2.11Measuring the ionisation current . . . . . . . . . . . . . . . . . . 43
10.3 Boiler settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.3.1 Setting the heating capacity . . . . . . . . . . . . . . . . . . . . . . 44
10.3.2 Setting the maximum CH flow temperature . . . . . . . . . 44
10.3.3 Setting the pump run-over time . . . . . . . . . . . . . . . . . . . 44
10.3.4 Switching DHW mode on/off . . . . . . . . . . . . . . . . . . . . . 44
10.3.5 Setting the DHW temperature . . . . . . . . . . . . . . . . . . . . 44
10.4 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.4.1 Closing the boiler door and the control panel . . . . . . . . 45
10.4.2 Handing over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.5 Commissioning record log book . . . . . . . . . . . . . . . . . . 45
11 Shutting down the heating system . . . . . . . . . . . . . . . . . . . . . . 46
11.1 Shutting down the heating system using the
basic controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.2 Shutting down the heating system if there is a risk
of freezing (interruption of use) . . . . . . . . . . . . . . . . . . 46
12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12.1 Preparing the heating system for inspection . . . . . . . . 46
12.2 Opening the boiler door . . . . . . . . . . . . . . . . . . . . . . . . . 47
Key to symbols and safety instructions
6720813171 (2016/05) 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 ionisation current . . . . . . . . . . . . . . . . . 47
12.6 Measuring the gas inlet pressure (working pressure) . 47
12.7 Checking and adjusting the gas/air-ratio . . . . . . . . . . . 47
12.8 Carrying out a leakage test in operating conditions . . . 47
12.9 Measuring the flue gases CO
2
emissions . . . . . . . . . . . 47
12.10 Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . 47
12.11 Checking the flue gas connection . . . . . . . . . . . . . . . . . 47
12.12 Inspection log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13.1 Removing the boiler door . . . . . . . . . . . . . . . . . . . . . . . 48
13.2 Cleaning the heat exchanger, burner and
condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
13.2.1 Removing the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 49
13.2.2 Removing the burner cover with the fan and the
gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
13.2.3 Removing the burner and the burner seal . . . . . . . . . . 50
13.2.4 Checking ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . 50
13.2.5 Disconnecting the condensate trap . . . . . . . . . . . . . . . 51
13.2.6 Removing the condensate collector . . . . . . . . . . . . . . . 51
13.2.7 Cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 52
13.3 Checking and adjusting the gas/air-ratio . . . . . . . . . . . 52
13.4 Function check in operating conditions . . . . . . . . . . . . 52
13.5 Service record log book . . . . . . . . . . . . . . . . . . . . . . . . 52
14 Display information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
14.1 Removing the control panel from the boiler . . . . . . . . . 53
14.2 Display readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
14.3 BC10 Display settings . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14.4 BC10 Display codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
14.5 Re-fit the control panel in the boiler . . . . . . . . . . . . . . . 60
15 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
15.1 Spare parts list GB162-80/100 . . . . . . . . . . . . . . . . . . 63
15.2 Spare parts list GB162-50/65 . . . . . . . . . . . . . . . . . . . 66
1 Key to symbols and safety instructions
1.1 Key to symbols
Warnings
Keywords indicate the seriousness of the hazard in terms of the
consequences of not following the safety instructions.
• NOTICE indicates that material damage may occur.
• CAUTION indicates that minor to medium injury may occur.
• WARNING indicates that serious injury may occur.
• DANGER indicates possible risk to life.
Important information
Additional symbols
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER
APPLIANCE MODEL(S) STATED ON THE FRONT COVER OF THIS
MANUAL ONLY AND MUST NOT BE USED WITH ANY OTHER MAKE OR
MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK AND IRELAND ONLY AND MUST
BE FOLLOWED EXCEPT FOR ANY STATUTORY OBLIGATION.THIS
APPLIANCE MUST BE INSTALLED BY A GAS SAFE REGISTERED,
COMPETENT PERSON. FAILURE TO INSTALL CORRECTLY COULD LEAD
TO PROSECUTION.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL
HELPLINE (0330 123 3366).
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM
WORCESTER.
PLEASE LEAVE THESE INSTRUCTIONS WITH 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 a grey
background.
Electrical hazards are identified by a lightning symbol
surrounded by a warning triangle.
Important information in cases where there is no risk of
personal injury or material losses is identified by the
symbol shown on the left. It is bordered by horizontal
lines above and below the text.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document or to other
related documents
• a list entry
– a list entry (second level)
Table 1
Key to symbols and safety instructions
6720813171 (2016/05)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.
▶ DO NOT TURN ELECTRICAL SWITCHES ON OR OFF.
▶ DO NOT STRIKE MATCHES OR SMOKE.
▶ PUT OUT NAKED FLAMES.
▶ OPEN DOORS AND WINDOWS.
▶ KEEP PEOPLE AWAY FROM THE AFFECTED AREA.
BOILER OPERATION:
This boiler must only be operated by a responsible adult who has
been instructed in, understands, and is aware of the boiler's
operating conditions and effects.
HEALTH AND SAFETY
The appliance contains no asbestos and no substances have been used
in the construction process that contravene the COSHH Regulations
(Control of Substances Hazardous to Health Regulations 1988).
COMBUSTION AND CORROSIVE MATERIALS
Do not store or use any combustible materials (paper, thinners, paints
etc.) inside or within the vicinity 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 instructions. Any misuse or unauthorised modifications to the
appliance, flue or associated components and systems could invalidate
the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING
Advise the user to have the system serviced annually by a competent,
qualified Gas Safe registered engineer. Approved spares must be used
to help maintain the economy, safety and reliability of the appliance.
IMPORTANT
The service engineer must complete the Service Record on the
Installation Checklist after each service.
INSTALLATION REGULATIONS
Current Gas Safety (Installation & Use) Regulations:
All gas appliances must be installed by a competent person in
accordance with the above regulations. Failure to install appliances
correctly could lead to prosecution.
The appliance must be installed in accordance with, and comply to, the
current: Gas Safety Regulations, IEE Regulations, Building Regulations,
Building Standards (Scotland) (Consolidation), Building Regulations
(Northern Ireland), local water by-laws, Health & Safety Document 635
(The Electricity at Work Regulations 1989) and any other local
requirements.
Directives:
• 2009/142/EEC gas appliance directive
• 92/42/EEC boiler efficiency directive
• 73/23/EEC low voltage directive
• 89/336/EEC EMC directive
• 97/23/EC pressure equipment directive
• any relevant requirement of the local authority.
British Standards:
Where no specific instruction is given, reference should be made to the
relevant British Standard codes of Practice.
BS4814:1Specification for expansion vessels using an internal
diaphragm, for sealed hot water heating systems.
BS5482Code of practice for domestic butane- and propane gas-burning
installations. Installations at permanent dwellings, residential park
homes and commercial premises, with installation pipework sizes not
exceeding DN 25 for steel and DN 28 for corrugated stainless steel or
copper.
BS6281:1 Devices without moving parts for the prevention of
contamination of water by backflow. Specification for
type A air gaps.
BS6282:1 Devices with moving parts for the prevention of
contamination of water by backflow. Specification 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
ØDiameter
AB Automatic Bypass
AIC Air Intake Connection
AV Air Vent (automatic)
BC10 Basic Controller
CB Connector Block
CDO Condensate drain outlet
CH Central Heating
CHF Central Heating Flow
CHR Central Heating Return
CT Cylinder Thermostat
DHW Domestic Hot Water
DV Diverter Valve
EEarth
FGC Flue gas Connection
HK1 Heating circuit 1
HK2 Heating circuit 2
IP Ingress Protection
BCM Boiler identification Module
LLive
LPG Liquid Petroleum Gas
LSV Lock Shield Valve
MCW Mains Cold Water
NNeutral
NG Natural Gas
NTC Negative Temperature Coefficient (sensor)
JB Junction Box / 230 Volt Converter
PF Pump group Flow
PL Permanent Live
PR Pump group Return
Prog Programmer
PRV Pressure Relief Valve
RT Room Thermostat
TTimer
TRV Thermostatic Radiator Valve
WC Wiring Centre
Table 2 Abbreviations
Key to symbols and safety instructions
6720813171 (2016/05) 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 pressure gas pipe work up to 35 mm
(R1¼“) in domestic premises (2
nd
family gas).
BS7074:1 Code of practice for domestic and hot water supply.
BS7671 Requirements for Electrical Installations IEE Wiring
Regulations seventeenth edition.
BS EN 303-7 Heating boilers. Gas-fired central heating boilers
equipped with a forced draught burner of nominal heat
output not exceeding 1000 kW.
CISBE Guide Reference sections B7, B11 and B13.
CP 342-2 Code of practice for centralized hot water supply.
Buildings other than individual dwellings.
IGE/UP/2 Gas installation pipework and compressors on
industrial and commercial premises.
IGE/UP/10 Installation of gas appliances in industrial and
commercial premises, part 1: flued appliances.
EN12828 Central heating for domestic premises.
Installation not exceeding 70 kW rated input
BS5440:1 Flues and ventilation for gas appliances of rated
heating not exceeding 70 kW (net): Flues.
BS5440:2 Flues and ventilation for gas appliances of rated
heating not exceeding 70 kW (net): Air Supply.
BS5449 Specification for forced circulation hot water central
heating systems for domestic premises.
BS5546 Installation of gas hot water supplies for domestic
purposes.
BS6798 Installation of gas fired boilers of rated input up to
70 kW (net).
BS7593 Treatment of water in domestic hot water central
heating systems.
BS EN 483 Gas-fired central heating boilers. Type C boilers of
nominal heat input not exceeding 70 kW.
BS EN 677 Gas-fired central heating boilers. Specific
requirements for condensing boilers with a nominal
heat input not exceeding 70 kW.
Installation of rated input greater than 70 kW
BS 6644 Specification for Installation of gas-fired hot water
boilers of rated inputs between 70 kW (net) and
1.8 MW (net) (2
nd
and 3
rd
family gases).
BS EN 15417 Gas-fired central heating boilers. Specific
requirements for condensing boilers with a nominal
heat input greater than 70 kW but not exceeding
1000 kW.
BS EN 15420 Gas-fired central heating boilers. Type C boilers of
nominal heat input exceeding 70 kW, but not
exceeding 1000 kW.
Irish Standards
The relevant Irish standards should be followed, including:
• ECTI National rules for electrical installations
• IS 813:2002 for Domestic Gas Installations.
Health and & Safety Document No. 635.
Ventilation Requirements
BS5440:2 (up to a total boiler rating of 70 kW input).
BS6644 (Total boiler rating of 70 kW to 2000 kW input).
The manufacturer's notes must not be taken, in any way, as
overriding statutory obligations.
The design and construction of the Worcester Wall hung gas fired
condensing boiler conforms to the basic specifications listed in the
European directive governing gas-fired appliances 2009/142/EEC, and
with respect to EN 625, EN 483 and EN 677.
• The boiler is designed exclusively for heating water as part of a
central heating system and/or hot-water system.
• For optimum, long-term reliable functioning of the boiler, and in
order to be able to claim under the terms of the manufacturer's
warranty. The boiler must be inspected and maintained at least once
a year (under normal operating conditions) by a Gas Safe / ACS
registered installation and service engineer.
• When instructions are not followed, warranty is invalid.
• Condensing boilers work more efficiently if the return temperature is
as low as possible.
LPG Installations
An appliance using L.P.G. must not be installed in a room or internal
space below ground level unless one side of the building is 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 current IEE
(BS 7671) Wiring Regulations. In Scotland, the electrical provisions of
the building regulations applicable in Scotland, with respect to the
installation of the boiler in a room or internal space containing a bath or
shower.
If the appliance is to be installed in a room containing a bath or shower
then, providing water jets are not going to be used for cleaning purposes
(as in communal baths/showers), the appliance can be installed in Zone
3, as detailed in BS 7671.
Compartment Installations
A compartment used to enclose the boiler should be designed and
constructed especially for this purpose. An existing cupboard or
compartment may be used, provided that it is modified for the purpose.
In both cases, details of essential features of cupboard/compartment
design, including airing cupboard installation, are to conform to the
following: BS 6798 (No cupboard ventilation is required - see 'Air
Supply' for details).
It is not necessary to have a purpose-provided air vent in the room or
internal space in which the boiler is installed. Neither is it necessary to
ventilate a cupboard or compartment in which the boiler is installed, due
to the low surface temperatures of the boiler casing during operation;
therefore the requirements of BS 6798, Clause 12, and BS 5440:2 may
be disregarded.
See for the required service clearances fig. 6 and fig. 7.
Observe the corresponding technical rules and the
building supervisory and statutory regulations when
installing and operating the system.
WARNING: Keep the control unit housing closed when
working on water-bearing components.
General
6720813171 (2016/05)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
wall mounting bracket. Wall-mounted condensing gas system boilers
must only be used with Worcester flue gas systems, which are certified
with this type of boiler.
Observe the relevant standards, regulations and legislation of the
country or region of final use.
Safe handling of substances:
No asbestos, mercury or CFCs are included in any part of the boiler and
its manufacture.
Potable water:
All seals, joints and compounds (including flux and solder) and
components used as part of the secondary domestic water system must
be approved by WRAS.
CH Water:
Artificially softened water must not be used to fill the central heating
system.
2 General
These installation and maintenance instructions apply to the following
wall-mounted condensing gas boilers:
• GB162-50
• GB162-65
• GB162-80
• GB162-100.
The name of the boiler is made up of the following components:
• GB: Condensing gas boiler
• 162: Type
• 50, 65, 80 or 100: heating range in kW.
The GB162-50/65/80/100 is suitable for use as a single boiler or as part
of a cascade system.
The following technical documentation is available for the
GB162-50/65/80/100:
• Installation and maintenance instructions
•User Manual
• Technical product guide.
If you have any suggestions for improvement or have found any
discrepancies, please do not hesitate to contact us.
CE label
Energy efficiency
Energy efficiency information is given in the User Instructions of the
appliance.
Frost protection
The boiler has integrated frost protection.
The frost protection switches the boiler on at a CH flow temperature of
7 °C and switches it off at a CH flow temperature of 15 °C.
The central heating system is not protected against frost.
Pump test
If the boiler has not received a heat demand for approximately 4 weeks,
the pump will automatically cycle for 10 seconds every 24 hours. This
pump test is first carried out for 24 hours when first switched back on.
Important general instructions for use
Only use the 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 specifically
provided for the designated use and if system performance and safety
are not affected in any way.
The boiler is suitable for connection to fully pumped, sealed water
systems only. Arrangements for draining the system by draining valves
must be provided in the installation pipework.
Subject to technical modifications
As a result of our policy of constant development, there may be small
differences between illustrations, functional steps and technical data.
CAUTION: Use this device for its intended purpose only.
DANGER:
Notes relating to the heating system water.
▶ Thoroughly clean and flush the system before it is
filled with water. Use only unsoftened mains water
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.
▶ 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 appliance. For more
information, contact Worcester Technical Product
Support Department.
▶ It is most important that the correct concentration of
the water treatment product is maintained in
accordance with the manufacturer's instructions.
▶ If the boiler is used in an existing system any
unsuitable additives must be removed by thorough
cleaning. BS 7593 details the steps necessary to
clean a central heating system.
▶ In hard water areas, treatment to prevent lime scale
may be necessary - however, the use of artificially
softened water is not permitted.
▶ Under no circumstances should the boiler be fired
before the system has been thoroughly flushed.
▶ Do not use artificially softened water.
▶ Only plastic pipework containing a polymeric barrier
should be used. Copper pipework must be used for
the first 600 mm.
The appliance complies with the basic requirements of
the relevant European directives. Conformity has been
substantiated by the proper documents which, together
with the declaration of conformity, are filed with the
manufacturer.
If there is a risk of radiators or pipe sections freezing up,
we recommend setting the pump over-run time to
24 hours. See section 14.3, page 54.
Regulations and directives
6720813171 (2016/05) 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 water for heating systems and/or
domestic hot water (DHW) systems.
The boiler can be installed either as a single system or as part of a
multiple system (cascade system). A cascade system enables several
boilers of this type to be connected together, where a maximum of
8 boilers with a total capacity of 800 kW can be connected together on a
floor surface of approximately. 2 m².
Special cascade units (accessories) have been developed to enable this
boiler to be installed in a cascade system. Every cascade unit includes an
installation frame, horizontal headers, connection pipes for the boiler,
main gas pipe and vertical low loss header.
Cascade units are available for installing the boilers in line or back-to-
back. These cascade units make installing a cascade system easier and
less labour intensive. Please contact your dealer or the manufacturer for
further information about cascade systems.
The construction and operating behaviour of the boiler are in
accordance with the requirements listed:
3.2 Boiler room
▶ Observe all statutory building regulations applying to the place of
installation.
The boiler can only be mounted to the wall or installed in a cascade
system. When installed in a room with thin walls or a thin floor,
resonating noise may occur. Install noise reducing parts if required.
3.3 Combustion air flue gas connection
If the boiler is operated dependent on room air, 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 of the boiler and damage to the heat
exchanger.
Inhibit the system with the correct dosage of an approved product.
Do not treat the water with antifreeze or water softeners.
The pH of the heating system water must be between 7 and 8.5. If this is
not the case, please contact Worcester Customer Service before
proceeding.
3.5 Quality of the pipework
When using plastic pipework in the heating system, e. g. for floor
heating, it has to be oxygen-tight according to relevant UK-Standards. If
the plastic pipes do not comply with these standards, the system parts
must be isolated using heat exchangers.
3.6 Maintenance schedule
The activities to be included in an annual inspection and maintenance
contract can be found in the service section of this manual ( pages 48
and 52).
If inspection reveals a situation which makes maintenance activities
necessary, these activities have to be carried out ( chapter 13
“Maintenance”, page 48).
3.7 Applicability of regulations
Changes or amendments to the regulations also apply at the time of
installation and have to be complied with.
The appliance complies with the basic requirements of
the relevant European directives.
Conformity has been substantiated by the proper
documents which - together with the declaration of
conformity - are filed with the manufacturer.
CAUTION:
Damage to the installation due to frost.
▶ Install the heating system in a room which is free from
frost.
WARNING:
Fire hazard due to flammable materials or liquids.
▶ Do not store any flammable materials or liquids in the
direct vicinity of the boiler.
CAUTION:
Boiler damage due to contaminated combustion air or
contaminated air in the boiler room.
▶ Never use the boiler in an environment which
contains lots of dust or aggressive chemicals. Such
as spray shops, hairdresser's shops, agricultural
enterprises (manure) or locations where
trichloroethylene or hydrogen halides (e.g.
contained in aerosols, certain adhesives, solvents or
detergents, paints) and other aggressive chemicals
are used or stored.
▶ In such situations you must opt for a room sealed
installation.
CAUTION:
Boiler damage due to corrosion.
▶ If the boiler is used in systems with gravitation
circulation or in open systems, the boiler circuit must
be isolated from the rest of the system by means of a
(plate-type) heat exchanger.
NOTICE:
Damage to the installation due to insufficient or
improper cleaning and maintenance.
▶ Inspect and clean the heating system as required
once a year.
▶ Carry out maintenance as required. Immediately
remedy faults. This will avoid further damage to the
system.
Safety
6720813171 (2016/05)10
4Safety
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 local building regulations as regards fresh air supply and air
exhaust facilities and flue connections.
• The regulations for electrical connections to the power supply.
• The gas utility company rules for connecting the gas burner to the
local gas mains.
• The regulations and standards concerning the safety facilities for the
DHW/heating system.
• The installation instructions for producers of heating systems.
• The condensing gas boiler may only be used with the combustion air/
flue gas systems designed and approved specifically for this type of
boiler.
• Note: in certain areas permits are required for the flue gas system
and for connecting the condensate water drain to the public sewage
network.
4.2 Tools, materials and further equipment
Boiler installation and maintenance requires standard tools for heating,
gas and water installation.
In addition you will need a hand truck/cart with a securing strap.
4.3 Recycling
▶ Dispose of the boiler's packaging material in an environmentally
friendly manner.
▶ 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.
5 Transport
This chapter describes how to transport the boiler safely and without
damaging it.
Fig. 2 Open cover panel
5.1 Lifting and carrying the boiler
To lift and carry the boiler, place one hand at the bottom of the boiler and
the other hand on its front ( fig. 3).
DANGER:
Danger of fatal accident from explosive fumes. If you
smell gas, there is a danger of explosion.
▶ No naked lights. No smoking. Do not use lighters.
▶ DO NOT operate any device that is likely to produce
sparks. Do not operate any electrical switches,
including telephones, plugs or doorbells.
▶ Shut off the main gas supply.
▶ Open doors and windows.
▶ Warn the residents but do not ring doorbells.
▶ Contact the gas utility company from a telephone
located outside the building.
▶ If you can hear gas leaking out, evacuate the building
immediately, prevent other persons from entering,
and notify the police and fire service immediately
(from a telephone outside the building).
DANGER:
Danger of fatal accident from explosive fumes.
▶ Only carry out work on gas pipes and fittings if you
are Gas Safe / ACS registered.
DANGER:
Danger of fatal accident due to poisoning. Dangerous
flue gas can escape if the air supply is insufficient.
▶ Make sure that air vents are not reduced in size or
obstructed.
▶ The boiler may only be operated after the defect has
been remedied.
▶ Warn the user of the system of the defect verbally
and in writing.
CAUTION: Damage to the installation due to impacts.
The boiler contains parts which can be damaged by
impacts.
▶ During further transport all parts must be protected
against impacts.
▶ 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:
▶ Protect the boiler connections against pollution by
leaving the protective covers on the connections.
▶ Cover the flue gas injectors at the top of the boiler
with plastic film.
CAUTION: Damage to the unit due to it being lifted and
carried incorrectly.
▶ Do not hold the boiler by the door over the control
panel ( fig. 4) to lift and carry it.
6 720 648 727-010.1TD
Items supplied with boiler
6720813171 (2016/05) 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 the boiler to the installation location.
6 Items supplied with boiler
The boiler is delivered factory-assembled.
▶ Check that the packaging is intact upon delivery.
▶ 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
DANGER: Danger of injury due to improperly secured
boiler.
▶ Use proper transport equipment, such as a trolley
with a securing strap, a stair-climbing hand truck or a
convertible hand truck to transport the boiler.
▶ Secure the boiler on the transportation equipment to
prevent it falling off.
6 720 648 726-003.1TD
6 720 648 726-004.1TD
Dimensions of boiler
6720813171 (2016/05)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 100/150 flue
[CHF] CH (boiler) flow; G1½" union nut with female thread
[CHR] CH (boiler) return; G1½" union nut with female thread
[CS] Cap (DO NOT remove)
[FGC/AIC] Flue gas/air intake connection: Ø 80/125 for GB162-50/65 and Ø 100/150 for GB162-80/100
[GAS] Gas connection to boiler; G1" female thread
The servicing clearances required are:
•in front: 50mm
• below: 0 mm (250 mm with pump group)
•right side: 0mm
•left side: 0mm
•above: 30mm.
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: 0mm
•left side: 0mm
•above: 40mm.
CDO
1280
980
1003
1030
1186
1310
135
103.5
520
300
140
130 130
39
35
138
162
465
6
152
CHF CHRGAS
CDO
CS
CHF/CHR
GAS
550
40
0
0 0
CFO
FGC
AIC
FGC
AIC
6 720 648 726-006.1TD
Dimensions of boiler
6720813171 (2016/05) 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 (boiler) return; G1½" union nut with female thread
[CS] Cap (DO NOT remove)
[FGC/AIC] Flue gas/air intake connection: Ø 80/125 for GB162-50/65 and Ø 100/150 for GB162-80/100
[GAS B] Gas connection to boiler; G1" female thread
[GAS P] Gas connection to pump group; Rp1" female thread
[PF] Pump group flow; G1½" male thread, flat seal
[PR] Pump group return; G1½" male thread, flat seal
The servicing clearances required are:
• in front: 50 mm
• below: 0 mm (250 mm with pump group)
•right side: 0mm
•left side: 0mm
•above: 30mm.
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: 0mm
•left side: 0mm
•above: 40mm.
CDO
1280
980
1003
1030
1186
1310
135
103.5
520
300
140
130 130
39
35
138
162
465
6
152
FGC
AIC
FGC
AIC
CHF CHRGAS B
PF PRGAS A
CDO
CS
PF/PR
550
40
0
0
0
1)
1)
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Installation
6720813171 (2016/05)14
8Installation
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 that the carrying capacity of the
wall is sufficient for the boiler weight.
▶ Remove the packaging and dispose of it in an environmentally
manner.
▶ Measure the installation height ( chapter 7 “Dimensions of boiler”,
page 12).
▶ Mark out both holes using the wall bracket (step 1) using a spirit
level.
▶ Drill 2 holes in the wall (step 2).
▶ Insert the 2 enclosed plugs in the drilled holes (step 3).
▶ Install the wall bracket, using the 2 enclosed screws (step 4).
Fig. 8 Installing the wall bracket
▶ With 2 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 ( fig. 3,
page 11).
▶ Slide the boiler into place ( fig. 9).
Fig. 9 Sliding the boiler
▶ Level the boiler using the set screw and a spirit level ( fig. 10).
Fig. 10 Aligning the boiler with the set screw
▶ Remove the protective covers from the bottom of the boiler
( fig. 11).
Fig. 11 Removing the covers
CAUTION: Damage to the installation.
▶ Do not remove the polystyrene foam bottom slab,
otherwise the connection injectors might be
damaged.
▶ Do not lift the boiler by holding it by the door over the
BC10 ( section 5.1).
▶ During installation work, cover the boiler and the flue
gas adapter to prevent site dirt from entering.
6 720 648 726-008.1TD
Some residual water from final testing may leak away.
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6 720 648 726-010.1TD
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Installation
6720813171 (2016/05) 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 factory-installed in the boiler. This pump is
included in the pump group (accessory).
If you do not make use of a pump group, you have to install a separate
circulation pump under the boiler. This pump must be selected so that
the volume flow through the boiler is sufficient to handle the maximum
boiler capacity.
Correct pump selection see chapter 8.2.8 “Selecting and installing the
pump”, page 16.
The pump group has been developed specifically for this boiler and has
already been fitted with the correct pump.
The pump group also includes various fittings, such as service fittings, a
pressure relief valve, a pressure gauge, a gas valve etc. This makes
installing the appliance easier to overcome resistance in the heating
circuit.
Both installation methods are described below.
▶ 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 system should be installed in accordance with
BS 6798 and, in addition, for small bore and micro bore systems,
BS 5449 or EN 12823.
The gas installation must be installed in accordance with BS 6891.
▶ Install the pump group on the boiler in accordance with the enclosed
installation instructions.
8.2.3 Install the water and gas connections to the boiler without
a pump group
▶ Connect all pipes making sure that they are not bent or twisted to
cause any stress.
▶ Make sure that the connections are tight and carry out a gas and
water leakage test after completing the connection work.
Installing the gas connection
Fig. 13 Rubber seal
The gas installation must be installed in accordance with BS 6891.
The complete installation must be tested for gas leakage and purged as
described in IGE/UP/1b.
CAUTION:
▶ Do not use galvanised radiators or pipes.
6 720 648 726-012.1TD
CAUTION:
▶ Do not use galvanised radiators or pipes.
DANGER: Danger of fatal accident from explosive
fumes.
▶ Only carry out work on gas pipes and fittings if you
are Gas Safe / ACS registered.
DANGER: Danger of fatal accident from explosive
fumes.
▶ Make sure that the factory-fitted flat rubber seal is
located in the threaded connection (boiler side)
( fig. 13, detailed picture).
CAUTION:
Pipework from the meter to the boiler must be of
adequate size.
NOTICE:
For the installation of the gas valve a gas valve connector
1" [1] is necessary. To order, see address on the back of
this document.
6 720 648 726-013.1TD
Installation
6720813171 (2016/05)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 gas connection making sure it is not
under stress. Use a gas pipe of at least Ø 22 mm.
▶ Make the gas connection according to the country-specific standards
and regulations.
▶ Carry out gas leak test on gas connection using leak detection spray
and purged as described in IGE/UP/1b.
Installing the heating flow and return pipe
The central heating system should be installed in accordance with
BS 6798 and, in addition, for small bore and micro bore systems,
BS 5449 or EN 12823.
▶ 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 1½".
▶ Connect the return pipe with a flat rubber seal installed to the CHR
(CH boiler return) connection [2] making sure it is not under stress.
Use a return pipe with a minimum diameter of 1½".
Fig. 15 Connecting the boiler flow and return
[1] CH boiler flow
[2] CH boiler return
[3] Isolating valves
[4] Drain cock
[5] Gas valve
[6] Pressure relief valve
[7] Condensate trap
[8] Pump
[9] Non-return valve
[10] Dirt filter
8.2.4 Installing the differential pressure controller
In situations where there is no low loss header, installing a bypass with a
differential pressure controller would not be required.
If a low loss header is present, it may be required -depending on the
situation - to install a bypass with a differential pressure controller to the
secondary side of the low loss header. This serves to protect the
secondary pump against overheating as a result of insufficient flow.
8.2.5 Installing the isolating valves
▶ Install a isolating valve for maintenance and repair purposes in both
the boiler flow and return circuits ( fig. 15, [3]). Use isolating
valves with a minimum diameter of 1½".
8.2.6 Installing the drain cock
▶ Connect a drain cock in the return circuit ( fig. 15, [4]).
8.2.7 Installing a pressure relief valve
▶ Install a 4-bar pressure relief valve ( 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
▶ Select a pump according to the hydraulic boiler resistance specified
in table 5 or in the curve in fig. 122 on page 62.
▶ When using the curve take the nominal required volume flow into
consideration according to table 3.
▶ When selecting the pump, take the maximum volume flow of the
boiler according to table 4 into consideration.
When using plastic pipes, observe the supplier’s
instructions - especially those referring to
recommended jointing techniques and the notes relating
to the heating system water on page 6
NOTICE:
To prevent contamination in the heating system we
recommend you to integrate a dirt filter [10] in the
return pipe, near the boiler. In an old system it is a
requirement to install a dirt filter.
▶ Install shut-off valves to enable filter cleaning
immediately upstream and downstream of the dirt
filter.
2
G1”
R1”
6 720 648 726-014.1TD
1
CAUTION: Damage to the installation.
The pressure in the heating system can become
excessively high.
▶ Install a pressure relief valve.
10
3 3
6 720 648 726-015.1TD
7
4
1
6
3
5
3
8
9
2
Installation
6720813171 (2016/05) 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 condensate trap [1] to the condensate drain outlet
(CDO).
Fig. 17 Installing the condensate trap
[1] Condensate trap
▶ Connect the condensate trap hose [3] and the rubber sleeve [2] to
the condensate trap [1].
Fig. 18 Installing the condensate trap hose
[1] Condensate trap
[2] Rubber sleeve
[3] Condensate trap hose
8.2.10 Condensate removal
Positioning and termination of the condensate drain pipe
The condensate pipe should run and connected to the internal sewage
pipe in the house or waste pipe. Alternatively, the condensate can be
discharged into the rainwater system if connected to a foul water
draining system, or into a purpose-made soak away (condensate
absorption point).
All connecting drainage pipework should generally have a fall of at least
2.5° to the 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.
Select a pump with a residual head of at least 200 mbar
at the minimum required volume flow ( table 4).
GB162-50 GB162-65 GB162-80 GB162-100
2,200 3,000 3,600 4,300
Table 3 Nominal required volume flow [l/h] at
Δ
T = 20 K
GB162-50 GB162-65 GB162-80 GB162-100
5,000 5,000 5,000 5,000
Table 4 Maximum volume flow [l/h] at
Δ
T = 20 K
GB162-50 GB162-65 GB162-80 GB162-100
90 170 225 320
Table 5 Resistance over the boiler at the nominal required volume flow
[mbar]
DANGER: Danger of fatal accident due to poisoning.
▶ If the condensate trap is not filled with water, flue gas
can escape and put people's lives at risk.
The trap is fitted with a bayonet connection. After
pushing [step 1] the trap upwards into place, you have
to turn it a ¼ turn anticlockwise [step 2] until it locks into
position.
6 720 648 726-016.1TD
WARNING:
Any external run must be insulated with water proof
insulation.
1.
2.
1
6 720 648 726-017.1TD
1
6 720 648 726-018.1TD
3
2
1
Installation
6720813171 (2016/05)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-linked polyvinyl chloride).
Any internal pipework should be of a diameter to match the
requirements of the condensate exit pipe on the appliance.
Termination to internal pipe
The condensate drain pipe should have a minimum outside diameter of
Ø21.5 mm with no length restriction. It should incorporate a trap with a
75 mm condensate seal and be connected to the stack at a point at least
450 mm above the invert of the stack. The trap built into the boiler will
provide this 75 mm ( fig. 19) condensate seal.
The minimum distance between the 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.
Fig. 19 Termination of condensate drain pipe to internal pipe
[1] Boiler
[2] Internal soil and vent pipe
[3] Invert
[4] No length restriction
External termination via internal branch (e.g. sink waste)
The condensate drain pipe should have a minimum outside diameter of
Ø21.5 mm with no length restriction. The connection should preferably
be made downstream of the sink waste trap. If the connection is only
possible upstream, then an air break is needed between the 2traps.
This is normally provided by the sink waste pipe ( 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 trap and
the condensate pipework.
Fig. 21 External termination of condensate drain pipe via internal
discharge branch (e.g. sink waste – proprietary fitting) and
condensate trap
[1] Sink
[2] Boiler
[3] No length restriction
[4] Open end of pipe direct into drain, below ground but above water
level
Condensate absorption point
The condensate drain pipe should have a minimum outside diameter of
Ø21.5 mm and the external pipe length should not be more than 3 m.
The condensate absorption point should be sited in a convenient
position as close as possible to the boiler but not in the vicinity of other
services. See fig. 22 for information.
Ensure that the condensate trap is filled with water.
Ø21.5 mm min.
450 mm min.
6 720 648 726-019.1TD
4
3
2
1
Ø21.5 mm min.
4
3
2
1
6 720 648 726-020.1TD
Ø21.5 mm min.
4
3
2
1
6 720 648 726-021.1TD
Installation
6720813171 (2016/05) 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 facing away from house
[6] Hole depth
[7] Ground (either/or)
8.2.11 Connecting the condensate drain pipe
▶ Connect the condensate drain pipe to the condensate trap
( fig. 23, [1] and fig. 24, [1]).
Fig. 23 Connecting the condensate trap
[1] Condensate trap
Fig. 24 Condensate drainage pipe
[1] Minimum distance > 2 cm
Observe the following regulations:
• The (local) waste water disposal regulations.
• The condensate trap in the connection kit must not be permanently
connected to the condensate drain pipe. The minimum distance
between the 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
▶ 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 ( fig. 25, [1]).
Fig. 25 Connecting the expansion vessel in a single-boiler system
[1] Expansion vessel
When discharging condensate to an outside drain
caution must be taken to ensure blockage cannot occur
during freezing conditions. If this is likely to occur, the
use of a condensate trap is recommended.
Ø100 mm min.
400 mm min.
300 mm min.
25 mm min.
1000 mm min.
Ø21.5 mm min.
6 720 648 726-022.1TD
7
6
5
4
3
2
1
1
6 720 648 726-023.1TD
CAUTION: Damage to the installation due to faulty
pressure relief valve.
▶ The expansion vessel must be of sufficient capacity.
1
6 720 648 726-024.1TD
1
6 720 648 726-025.1TD
Installation
6720813171 (2016/05)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 pipes or soil pipes 200
[C] Below eaves 200
[D] Below balconies or a car port roof Not recommended! 200
[E] From vertical drain pipes or soil pipes 150
[F] From internal or external corners 300
[G] Above adjacent ground, roof or balcony level 300
[H] From a surface facing the terminal 600
[I] From a terminal facing a terminal 1200
[J] From an opening in a car port (e.g. door or window) into dwelling. Not recommended! 1200
[K] Vertically from a terminal on the same wall 1500
[L] Horizontally from a terminal on the wall 300
[M] Adjacent to opening 300
[N] Above intersection with roof 300
[O] From a vertical structure on the roof 500
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 be avoided.
The air supply and the flue gas exhaust must meet the applicable general
regulations. Please consult the instructions provided with the flue
terminal kits prior to installation.
The boiler must be installed so that the terminal is exposed to external
air.
It is important that the position of the terminal allows the free passage of
air at all times.
Minimum acceptable spacing from the terminal to obstructions and
ventilation openings are specified in fig. 26.
If the lowest part of the terminal is less than 2 metres above the level of
the ground, balcony, flat roof or place to which any person has access,
the terminal must be protected by a guard.
Ensure that the guard is fitted centrally.
The flue assembly shall be so placed or shielded as to prevent ignition or
damage to any part of the building.
The flue outlet duct and the terminal of the boiler must not be closer
than 25 mm to combustible material. Detailed recommendations on the
protection of combustible material are given in IGE UP10.
A
F
M
G
M
B,C
F
F
B,C
K
G
K
K
G
C
L
L
A
N
N
O
E
FJ
K
G
D
H, I
6 720 648 726-026.1TD
Installation
6720813171 (2016/05) 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 cover houses a number of components, such as the burner and the
heat exchanger. Since this ventilation cover is part of the air supply
system, it is vital that it is always installed correctly.
To ensure optimal operation, the appliances must 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 ( fig. 27) for GB162-80/100:
• 1: Flue turret 100/150;
• 2: Horizontal flue terminal 100/150;
• 3: Flue finishing kit.
Standard horizontal flue pack ( fig. 27) for GB162-50/65:
• 1: Flue turret 80/125;
• 2: Horizontal flue terminal 80/125;
• 3: Flue finishing kit.
Fig. 27 Standard horizontal flue pack
Fig. 28 Side flue and rear flue installation
Standard vertical flue pack ( fig. 29) for GB162-80/100:
• Concentric vertical flue pipe 100/150;
• Wall clamp.
Standard vertical flue pack ( fig. 29) for GB162-50/65:
• Concentric vertical flue pipe 80/125;
• Wall clamp.
Fig. 29 Standard vertical flue pack
It is very important to ensure, that products of
combustion discharging from the terminal cannot re-
enter the building or any other adjacent building.
Through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation/air-
conditioning.
DANGER:
▶ Only use Worcester flue gas systems. As other flue
gas systems are not tested with this appliance.
6 720 648 726-027.1TD
415 mm
8 mm
L
6 720 648 726-028.1TD
6 720 648 726-029.1TD
Installation
6720813171 (2016/05)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 extensions for 100/150 flue
system ( fig. 30 and fig. 31). For flue length see table 6.
Fig. 30 Vertical flue length
Fig. 31 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 planning the layout of
the place of installation ( subsection 8.3.1: “Siting the flue terminal”
on page 20).
Maximum wall thickness without extensions is 415 mm. Maintain a
minimum side clearance of 8 mm ( fig. 28).
8.3.4 Additional flue parts
The additional flue parts listed can be ordered from your supplier.
Flue size 100/150 and 80/125
Weathering slates for 100/150 and 80/125
Flat roof, pitched roof.
8.3.5 Standard 100 mm flue systems
The standard concentric flue system provides for a max. horizontal
straight length ( 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 23.
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
50 20 7,7
65 20 7.7
80 18 –
100 18 –
Table 6 Max. flue lengths, incl. wall/roofterminal in meters
GB162 Reduced flue length [m]
1)
1) For every bend or extension the max. flue length (L) has to be reduced.
concentric flue system
100/150
concentric flue system
80/125
bend extension bend extension
45° 90° 0.5m 1m 45° 90° 0.5m 1m
50 1.2 2.1 0.5 1.0 0.9 1.9 0.5 1.0
65 1.2 2.1 0.5 1.0 0.9 1.9 0.5 1.0
80 1.2 2.1 0.5 1.0 0.9 1.9 0.5 1.0
100 1.2 2.1 0.5 1.0 0.9 1.9 0.5 1.0
Table 7 Reduced flue lengths in meters
The total reduction length must never exceed the
maximum flue length.
Important: Any horizontal flue system fitted to a
condensing boiler must be inclined towards the
appliance at an angle of 52 mm per metre length to
prevent condensate dripping from the flue terminal.
This means that the clearance above the appliance must
be increased to match the duct length. See fig. 6 on
page 12.
Installation
6720813171 (2016/05) 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 Installation with horizontal flue gas terminal
[1] maximum length
[2] terminal assembly
[3] 90° bend
[4] finishing kit
[5] outer wall
8.3.7 Flue pipe preparation and assembly
▶ Measure the flue length L. Refer to figures 33 and 34.
Fig. 33 Flue length - rear
[A] 150 mm without the use of a wall spacing frame
[] 185 mm with the use of a wall spacing frame
[B] 337.5 mm for Ø 80/125 mm horizontal flue
[] 339.5 mm for Ø 100/150 mm horizontal flue
[L] flue length
Fig. 34 Flue length - side
▶ Mark off the lengths shown onto the pipe and cut to length. The cuts
must be square and free from burrs. Terminal assembly outer (air)
pipe - L-70 mm, inner (flue) pipe - L-50 mm. The measurement is
made from the ridge at the terminal indicating the outer 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
▶ Assemble flue system completely. Push the flue fully together.
The slope of the terminal outlet must face downwards ( 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.
▶ Push the assembly through the wall and slide the terminal onto the
flue connector. Ensure that the terminal is fully entered into the
socket on the boiler.
▶ From the outside fix the flue finishing kit to the terminal and, after
ensuring the flue is properly inclined towards the boiler, fix the
finishing kit to the wall. If the terminal is within 2 m of the ground
where there is access then an approved terminal guard must be
fitted. The guard must give a clearance of at least 50 mm around the
terminal and be fixed with corrosion resistant screws.
8.4 Flue gas connection
8.4.1 Open flue operation
If operation independent of room air is not desired or not possible due to
local conditions, the boiler can be set up for operation to take air for
combustion from the room (contact Worcester Technical).
The boiler is factory-fitted with a concentric connection.
An air intake strainer basket can be used for operation dependent on
room air. This prevents falling dirt from entering the boiler (contact
Worcester Technical; accessory).
8.4.2 Room sealed operation
The boiler can be connected to a concentric flue gas system.
The boiler is factory-fitted with a concentric connection.
8.4.3 Flue material
When using plastic flue material, PPS is recommended.
8.4.4 Calculating the air intake and flue gas pipe dimensions
The total reduced pipe length is calculated from the sum of the reduced
length of the horizontal and vertical flue ducting and the reduced length
of every elbow ( table 7).
The total reduced pipe length must be less than the maximum pipe
length ( table 6).
See also the next example.
The flue must be inclined from the boiler.
6 720 648 726-032.1TD
5
4
3
2
1
A
L
B
6 720 648 726-031.1TD
L
6 720 648 726-034.1TD
An inner flue finishing kit is provided which should be
fitted to the ducts before assembly.
6 720 648 726-035.1TD
4
3
2
1
Installation
6720813171 (2016/05)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 this flue system =8.2 m
Sum of length (8.2 m) < maximum length (18 m) robust flue design!
Fig. 36 Example 1
8.5 Electrical connections
When connecting the electrical components, observe the wiring
diagram, the installation and servicing instructions of the relevant
product.
6 720 648 726-036.1TD
Pipe=2m
Pipe=2m
Roofterminal
90° bend
Length=21m
90° bend
Length=21m
Maximum length
allowed after the
boiler (GB162-80)
18 m
WARNING: Damage to the installation due to short
circuits.
To prevent electrical components from short-circuiting,
only use:
– original cables and wiring supplied by the
manufacturer.
– single core cable.
▶ Use cable of at least 0.75 mm².
▶ If the mains lead has to be replaced, you may only use
an original manufacturer-supplied mains lead.
DANGER: Danger of fatal accident due to electric
current when the boiler is open.
▶ Before opening the boiler: Isolate the mains supply.
▶ Secure the heating system so that it cannot be
switched on again unexpectedly, pulling the mains
plug from the wall socket.
The 230V converter can only be used for the
GB162-50/65 appliance.
Installation
6720813171 (2016/05) 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 sensor
Flow sensor
81-pole connector
Pin 81
Pin 1
Pin 1
Pin 16
16-pole connector
16-pole connector
(AC 120 V and AC 230 V)
81-pole connector
(AC 0, 10, 24 and 230 V)
Connection
for pump in
connection kit
(accessory)
Fan
Gas valve
Transformer
Glow
ignitor
UBA 3.0 mounting base
230 VAC
function modules
230 VAC
function modules
Earth
Mains switch
Mains connection
230 VAC 50Hz,
max. permissible: 10 A
Outdoor-temperature
sensor
On/Off temperature
controller,potential free
DHW sensor
External switch contact
potential free, e.g.
for floor heating
External three-way valve
Switch contact
External connection for professional use
External heating
pump 230 VAC
max. 250 W
DHW pump
230 VAC max. 250 W
DHW circulation pump
230 VAC max. 250 W
green gray lilac white
green gray red turquoiseorange blue
FUSE 5 slow blow
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 GB162-50/65
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
6720813171-1.1TD
IMPORTANT: The wires in this mains lead are coloured in accordance with the following code: GREEN AND YELLOW - EARTH; BLUE - NEUTRAL; BROWN - LIVEAs the
colours of the wires in the mains lead of the appliance may not correspond with the coloured markings identifying the terminals in your connector proceed as follows:
The wire coloured green and yellow must be connected to the terminal on the connector marked with the letter E or by the earth symbol or coloured green or green-and-
yellow. The wire coloured brown, must be connected to the terminal marked with the letter L or coloured red. The wire coloured blue must be connected to the terminal
marked with the letter N or coloured black.WARNINGTHIS APPLIANCE MUST BE EARTHED. Ensure that your appliance is connected correctly - if you are in any doubt
consult a qualified electrician.For location of individual components, see service section and the exploded views in this manual.
Installation
6720813171 (2016/05)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 the cover over the electrical connections
and pull the cover upwards ( fig. 39).
Fig. 39 Pull up the cover over the electrical connections
The terminal strip in the boiler ( fig. 40) has a number of terminals to
connect internal and external electrical components. The listing below
shows which components must be connected to which terminals
( 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
▶ Route the cable for the low-voltage connections through the hole on
the left [1].
▶ Route the cable for the 230 V-connections through the hole on the
right [2].
▶ Attach the cable for the 230 V-connections using the strain relief
clamps [3].
Fig. 41 Routing the cable
8.5.4 Description of the terminal strip connections
▶ Connect all components to the relevant terminals.
If uncertain how to connect controls to this appliance,
first contact the Worcester technical helpline on
0330 123 3366 or your supplier.
6 720 648 726-038.1TD
6 720 648 726-039.1TD
DANGER: Danger of fatal accident due to electric shock.
Items 1 – 6 are low-voltage connections and items
7 – 10 are 230 V-connections ( fig. 42).
▶ Please be aware that there may be a voltage on items
7 – 10 (230 V), when power is supplied to the boiler.
AB
PK PS PZ
Mains
230 V
RC WA EV
FA FW DWV
6 720 648 726-040.1TD
3
2
1
6 720 648 726-041.1TD
Installation
6720813171 (2016/05) 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 (connection colour grey)
[5] External switch contact, potential free, e. g. for floor heating
(connection colour red) (thermal protection)
[6] Connection for external three-way valve
[7] External heating pump 230 V (connection colour green) (for use
with non Worcester pump group)
[8] DHW pump 230 V (connection colour grey)
[9] DHW Circulation pump 230 V (connection colour lilac)
[10] Mains connection 230 V AC (connection colour white)
General control connection
The following controls can be connected to the boiler.
• Control with contact for potential free heat demand
• RC25, RC35 room controller
• 4121, 4122, 4323 cascade controller
• Error reporting module EM10, 0 – 10 V input (can be used to convert
a 0 – 10 V signal to a modulating signal).
Connecting and installing 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
possible to install the room controller (e.g. RC35) in the boiler. In this
case, the controller does not have to be connected to the terminal strip
afterwards. If you would like to use this room controller for room
temperature-controlled operation, the room controller must be installed
in a living room.
▶ Push the arrow on the control panel cover to open ( fig. 44).
Fig. 44 Opening the control panel
▶ Remove the cover [1].
▶ Install the RC35 in the slot [2].
Fig. 45 Remove the cover and install the room controller in the boiler
(only for outdoor temperature-dependant operation)
Installing and connecting other controllers outside the boiler
▶ Install the controller as described in the relevant installation
instructions.
▶ Connect a RC25 or RC35 room controller or a 4121, 4122 or 4323
cascade controller to the orange RC terminal using a 2-core cable of
0.75 mm².
Fig. 46 Terminal strip – Room controller RC and EMS bus (connection
colour orange)
It is not possible to connect more than one room
controller ( fig. 43).
PK PS PZ
Mains
230 V
RC WA EV
FA FW DWV
10
6 720 648 726-042.1TD
9876
54321
RC WA
6 720 648 726-043.1TD
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.
6 720 648 726-044.1TD
6 720 648 726-045.1TD
21
RC
6 720 648 726-046.1TD
Installation
6720813171 (2016/05)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 Terminal strip - Outdoor-temperature sensor (connection
colour blue)
Connecting the potential-free heat demand
▶ Connect the potential-free heat demand contact to the green WA
terminal ( fig. 48). The maximum allowed resistance of this circuit
is 100 Ω. Use a 2-core cable of 0.75 mm².
Fig. 48 Terminal strip - potential-free heat demand (connection colour
green)
Fig. 49 Terminal strip - WA potential-free heat demand
Connecting the DHW temperature sensor
▶ Connect the DHW temperature sensor to the grey FW terminal, using
the harness enclosed with the DHW temperature sensor [1].
Fig. 50 Terminal strip - potential-free heat demand (connection colour
green)
Connecting an external switch contact
A potential-free external switch contact can be connected. This external
switch contact can be used to safeguard a underfloor heating system so
that the heating water temperature will not become too high etc.
When the external switch contact is opened, the boiler will be switched
off for heating operation and for domestic hot water operation.
The pump continues to run for the run-over time set on the boiler.
▶ Remove the cable from the EV terminal.
▶ Connect the external switch contact to the red EV terminal.
Fig. 51 Terminal strip - external switch contact, potential-free, e. g. for
floor heating (connection colour red)
Connecting external 230 V controls with use of the 230 Volt
converter (only for GB162-50/65)
The gas wall hung boiler condensing can be fitted with the following
external controls:
• a room-temperature control device at 230 V connected to the room
control converter (only for GB162-50/65). For connection, see the
electrical wiring diagram supplied with the 230 Volt converter),
• ON/OFF temperature controller, Volt free.
This connection is non polarity sensitive. This means that
it does not matter which order the wires are connected.
NOTICE:
▶ It is not possible to connect a thermostat
simultaneously to the RC connection and to the
terminal for the potential-free heat demand (WA)
( fig. 49).
▶ It is possible to operate the boiler with an On/Off
contact for potential-free heat demand, but the room
temperature-based modulating function of the boiler
cannot then be used anymore. This has a negative
effect on comfort and energy consumption. If an On/
Off contact for potential-free heat demand is
installed, the boiler will only modulate up to the
preset CH flow temperature.
▶ This connection is reverse-proof. This means that it
does not matter which order the wires are
connected.
FA
6 720 648 726-047.1TD
WA
6 720 648 726-048.1TD
WA
6 720 648 726-048.1TD
NOTICE:
▶ This connection is reverse-proof. This means that it
does not matter in which order the wires are
connected.
▶ It is not possible to connect more than one DHW
temperature sensor in the boiler. It is only possible to
connect a DHW temperature sensor which is suitable
for this boiler.
This connection is reverse-proof. This means that it does
not matter in which order the wires are connected.
6 720 648 726-050.1TD
1
EV
6 720 648 726-051.1TD
Installation
6720813171 (2016/05) 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 external controls)
through the cable gland.
▶ Identify the 230 V terminal block by the hashed area and 230 VAC
warning triangle.
▶ Connect the switch live to terminal “1” and a neutral to terminal “2”
[2].
Fig. 52 Connection box - 230 Volt connection
8.5.5 230 V connections (only for GB162-50/65)
Fig. 53 Terminal strip - external heating pump 230 V (connection
colour green)
Connecting an external boiler pump - general
Since the boiler has not been fitted with a pump, a pump must be
connected to the boiler.
When using a pump group with an integrated pump:
▶ Read the assembly instructions of the pump group for the electrical
pump connections.
If you do not make use of a pump group, you can connect the external
pump in 2 ways:
• to the unused 230 VAC pre-wired pump cable;
• to the green PK terminal of the boiler. To connect order a PK plug
(accessory).
Proceed as follows:
The maximum electrical load that can be connected to the free 230 VAC
connection cable of the pump ( fig. 54, [1]) and to the green EP
connector ( fig. 56) is 250 Watts in total. If a load of more than
250 Watts is to be connected, this is possible by using an additional
230/230 V relay, which has to be installed by a registered installer/
electrician.
Connection to the free 230 VAC connection lead
▶ Unwind the 230 VAC cable [1] and route it out of the boiler
( fig. 55).
Fig. 54 230 VAC cable of the pump
▶ Cut the plug from the 230 VAC cable.
▶ Connect the 230 VAC cable to the pump.
Fig. 55 Route the 230 VAC pump cable
WARNING:
▶ This appliance must be earthed.
NOTICE:
▶ Connect the 230 Volt converter (grey box) via the
pair of black low voltage cable to terminal WA.
( figure 48).
NOTICE:
▶ Terminal 3 [2] is not used.
NOTICE:
The 230 V connections can only be used with a
corresponding control unit. If you use other than the
GB162 pump group, you must ensure that it correctly
connects to the terminal strip in fig. 53.
▶ Observe the layout document and the installation
instructions of the control unit.
WARNING:
▶ Do not connect a temperature controller to the 230 V
connections.
6 720 648 726-052.1TD
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PK PS PZ
Mains
230 V
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WARNING:
▶ Damage to the installation by the boiler being
overloaded.
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Installation
6720813171 (2016/05)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 (connection
colour green)
Connecting the DHW pump
▶ Connect the DHW pump to the grey PS terminal.
The maximum allowed connected load of the pump = 250 Watts.
Fig. 57 Terminal strip - DHW pump 230V (connection colour grey)
Connecting the DHW circulation pump
▶ Connect the DHW circulation pump to the lilac PZ terminal. The
maximum allowed connected load of the pump = 250 Watts.
Fig. 58 Terminal strip - DHW pump 230 V (connection colour grey)
Connecting to the mains
A mains supply of 230 V - 50 Hz is required.
External controls are suitable for volt free installation.
Wiring to the boiler must be in accordance with the current I.E.E.
(BS 7671) Wiring Regulations and any local regulations.
Wiring should be a 3 core PVC insulated cable, not less than 0.75 mm²
(24 x 0.2 mm), and to table 16 of BS 6500.
Connection must be made in a way that allows complete isolation of the
electrical supply such as a double pole switch having 3 mm contact
separation in both poles, or by a three pin connector, serving only the
boiler and system controls. This boiler is equipped with a double 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
from the same fused spur outlet.
Fig. 59 Mains supply
8.5.6 Installing function modules (accessories)
The following function modules (accessories) can be connected to the
boiler:
• Heat demand 0-10 V module EM10
• Error reporting module EM10
• Switch module WM10
• Mixing module MM10
• Solar module SM10.
Function modules (accessories) can be installed in 2 ways:
• in the boiler (max. 2)
• outside the boiler.
Both methods are described below.
▶ Determine how the modules have to be installed.
Installing and connecting function modules (accessories) in the
boiler
▶ Loosen the screw [1].
▶ Pull open the draw [2].
Fig. 60 Opening the draw
All Worcester boilers require a permanent live.
DANGER: Danger of fatal accident due to electric shock.
▶ Disconnect the boiler from the mains power supply
before working on the boiler.
PK
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PS
6 720 648 726-057.1TD
PZ
6 720 648 726-058.1TD
Refer to the installation instructions of the relevant
function modules for information about installation and
combination possibilities.
ON
OFF
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Installation
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▶ 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 the wall bracket
▶ Remove the covers of both free connectors on the function module
connection cables.
▶ Slide the draw back into the boiler.
Fig. 63 Removing the covers
▶ Connect the free 230 VAC mains cable ( 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 the cable enclosed
with the module.
Fig. 64 Interconnecting modules
▶ Connect the 230 VAC mains cable of the first module to the next
module.
Fig. 65 Connecting several modules
▶ Connect the free connector of the EMS bus connecting cable to the
first module ( fig. 64, [2]).
▶ If more modules are used, the EMS bus connection for the second
module may be branched off from the first module using the cable
enclosed with the module ( fig. 65 and 66).
6 720 648 726-061.1TD
6 720 648 726-062.1TD
6 720 648 726-063.1TD
The module may have the letters RC or EMS above the
connection [1].
NOTICE:
Pay attention to the polarity when using an EMS bus
connection cable.
▶ Connect the wire from terminal 1 to terminal 1 and
from terminal 2 to terminal 2 ( fig. 65 and 66).
2
1
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To the 230 VAC mains plug in
the earthed socket or a free
connector in the boiler.
To a free connector in the boiler or
the terminal strip. Note: This
connection is not reverse-proof.
Operation
6720813171 (2016/05)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. 66). Important: Use the connector of the same colour as the
connections on the module.
▶ Connect the EMS bus connection cable to the orange connection of
the terminal strip [1].
Fig. 67 Terminal strip - Room controller RC and EMS bus (connection
colour orange)
▶ Connect the other end of the EMS bus connection cable to the first
module ( fig. 65).
▶ If more modules are used, the EMS bus connection for the second
module may be branched off from the first module using the cable
enclosed with the module.
▶ Connect the EMS bus connection lead of the first module to the next
module ( fig. 65).
▶ Make a sufficiently long 230 VAC mains cable, using a 3-core cable of
at least 0.75 mm² with an earthing wire, the connector enclosed with
the module and a 230 VAC earthed plug.
▶ Connect the 230 VAC mains cable to the module ( fig. 65). If more
modules are used, the 230 VAC supply to the next module can be
branched off from the previous module using the connector enclosed
with the module and a 3-core 0.75-mm² current cable with an
earthing wire.
▶ Connect the 230 VAC supply cable of the previous module to the
next module ( fig. 65).
9Operation
9.1 General items
The boiler is fitted with a control unit, the BC10 basic controller.
This controller can be used to control the heating system.
▶ Push on the control panel to open it.
Fig. 68 Opening the control panel
The BC10 basic controller is located on the left, behind the door
( fig. 1, [4]).
The BC10 basic controller consists of the following components:
Fig. 69 BC10 basic controller
[1] Mains switch
[2] “Reset” button
[3] “Chimney sweep” button
[4] “Service button”
[5] Service Connector
[6] “Burner” LED (On/Off)
[7] “Heat demand” LED
[8] Maximum CH flow temperature dial
[9] Display
[10] DHW temperature dial
[11] “DHW mode” LED
Mains switch
The mains switch [1] is used to switch the boiler on and off.
“Reset” button
If a fault has occurred you may have to restart the boiler by pressing the
“Reset” button [2]. This is only required in the event of a “locking” fault.
“Blocking” faults are reset automatically as soon as their cause has been
corrected. The display shows [\/r/e| during the reset operation.
NOTICE:
Pay attention to the polarity when using an EMS bus
connection cable.
▶ Connect the wire from terminal 1 to terminal 1 and
from terminal 2 to terminal 2 ( fig. 65 and 66).
The module may have the letters RC or EMS above the
connection ( fig. 65, [1]).
6 720 648 726-066.1TD
RC
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1
If the boiler stops due to a fault again after resetting the
fault, the fault can be remedied using the Service
instructions. Contact Worcester if necessary.
See the back of this document for contact details.
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Operation
6720813171 (2016/05) 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”, page 34.
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. ( table 11, “Service mode”,
page 34).
Manual operation mode enables the boiler to be operated manually for a
long period. The boiler is switched to manual mode when the control
system has not been installed yet or is out of order ( table 12, “Manual
operation”, page 35).
A maximum heating water temperature in accordance with the setting of
the “Maximum heating water temperature” dial [8] on the BC 10 basic
controller applies during chimney sweep, service and manual operation.
“Service” button
The “Service” button [4] is used to display the current CH flow
temperature, the current system pressure etc. Also see table 22, “BC10
Display readings”, page 53, table 23, “BC10 Display settings”, page 54
and table 24, “BC10 Display codes”, page 54.
Service Tool connection
This service connection is for Worcester service engineers only.
“Burner” (On/Off) LED
The “Burner” (On/Off) LED ( fig. 69, [6]) lights up when the burner of
the boiler is active and it is extinguished when the burner is switched off.
The “Burner” (On/Off) LED indicates the burner status.
“Heat demand” LED
The “Heat demand”LED ( fig. 69, [7]) lights up when the control
system has made a heat demand and it is extinguished when this heat
demand is no longer required.
Maximum CH (boiler) flow temperature dial
The maximum CH (boiler) flow temperature ( fig. 69, [8]) is used to
set the upper CH (boiler) flow temperature limit. The unit is °C.
Display
The heating system display values, display settings and display codes
can be read out from the display ( fig. 69, [9]). If a fault occurs the
display will immediately show the accompanying fault code. The fault
code display will flash if a locking fault is detected.
“DHW mode” LED
The “DHW mode” LED ( 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 ( fig. 69, [11]) is used to select the
required temperature of the hot water in the hot water cylinder.
The unit is °C ( table 18, page 44).
9.2 BC10 control operating instructions
You can navigate through the menu structure of the boiler on the BC10
using the “Reset” button, the “Chimney sweep” button, the “Service
button” ( fig. 69, items 2, 3 and 4) and the display ( fig. 69, [9])
using table 9 to table 13.
The menu structure consists of 5 menus:
• Normal Operation menu
• Flue Gas Test menu
• Service Mode menu
• Manual Operation menu
• Settings menu.
WARNING:
Damage to the installation with underfloor heating: by
the floor being overheated.
▶ Limit the maximum CH flow temperature using the
“Maximum CH flow temperature” dial [8] to the
maximum flow temperature of the floor heating
circuit (usually maximum 40 °C).
WARNING:
Damage to the installation due to frost while manual
operation is switched on. After a power failure or after
switching off the supply voltage, the heating system may
freeze since manual operation is no longer active then.
▶ Start manual operation after switching on the heating
system, so that the system is permanently in
operation (especially if there is a risk of freezing).
LED Status Explanation
On Burner
operational
Boiler water is being heated.
Off Burner off The CH (boiler) flow temperature has
reached the set temperature or there is no
heat demanded.
Table 8 Meanings of “Burner” (On/Off) LED indications
Normal operation menu
Step 1 [\/2/4| Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 53.
Step 2 Continue in Normal operation menu? Yes: step 3
No: step 1
Step 3 Press the e button.
Step 4 [p/1.6| Display value. Currently measured system pressure in bar. Also see section 14.2, page 53.
Step 5 Press the e button.
Step 6 [-/h/\| Random display code. In this case: Operating phase: Boiler in heating mode. Also see section 14.3, page 54.
Step 7 Have at least 5 seconds passed without a button being pressed and/or has the mains voltage been interrupted? Yes: step 1
No: step 8
Step 8 Press the e button. step 1
Table 9 Normal operation
Operation
6720813171 (2016/05)34
Flue Gas Test menu
Step 1 [\/2/4| Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 53.
Step 2 Activate flue gas test? Yes: step 3
No: step 1
Step 3 To activate the flue gas test: Press and hold the d button for more 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. 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. Also see section 14.2, page 53.
Step 7 Press the e button.
Step 8 [-/h/\] Display code: Operating phase: The boiler is in flue gas test mode. Also see section 14.3, page 54.
Step 9 Press the e button.
Step 10 [\/2/4] Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 53.
Step 11 Have 30 minutes passed or has the mains voltage been interrupted? Yes: step 1
No: step 12
Step 12 Deactivate flue gas test? Yes: step 13
No: step 5
Step 13 To deactivate the flue gas test: Press and hold the d button for more than 2 seconds until the dot disappears. step 1
Table 10 Flue gas test
Service Mode menu
Step 1 [\/2/4| Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 53.
Step 2 Activate service mode? Yes: step 3
No: step 1
Step 3 To activate service mode 1st step: Press and hold the d button for more 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
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 (control panel) now applies.
Step 5 To activate service mode 2nd step: Simultaneously press and hold the d + e buttons for more than 2 seconds.
Step 6 [l/-/-] Display setting. Maximum capacity setting during heating mode in %. Also see section 14.3, page 54. In
this case: [l/-/-] = 100 %. Service mode has been activated. You can now temporarily lower the boiler
performance to partial load to check and if relevant set the gas/air ratio or the ionisation current.
Step 7 Press and hold the c button until the display shows [l/2/5] with a 80-kW boiler, [l/2/0] with a 65 and
100-kW boiler or [l/3/0] with a 50-kW boiler.
Step 8 [l/2/5] Display setting: with a 80-kW boiler, [l/2/0] with a 65 or 100-kW boiler and [l/3/0] with a 50-kW boiler.
Minimum capacity setting during heating mode in %. Also see section 14.3, page 54. 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 (control panel) applies now. Check the gas/air ratio or the
ionisation current and if necessary set the gas/air ratio according to subsection 10.2.7 or
subsection 10.2.11.
Step 9 Press the e button.
Step 10 [f/\/5| Display setting: This parameter shows the pump run-over time in minutes when heating mode has been
ended. Also see section 14.3, page 54.
Step 11 Press the e button.
Step 12 [c/\/1| Display setting: This parameter indicates the DHW mode status setting. Also see section 14.3, page 54.
Step 13 Press the e button.
Table 11 Service mode
Operation
6720813171 (2016/05) 35
Step 14 [\/2/4| Display value. Currently measured CH flow temperature in °C. Also see section 14.3, page 54.
Step 15 Press the e button.
Step 16 [p/1.6| Display value. Currently measured system pressure in bar. Also see section 14.3, page 54.
Step 17 Press the e button.
Step 18 [-/h/\| Display code: Operating phase: The boiler is in service mode. Also see section 14.3, page 54.
Step 19 Press the e button.
Step 20 [\/2/4| Display value. Currently measured CH flow temperature in °C. Also see section 14.3, page 54.
Step 21 Have 30 minutes passed or has the mains voltage been interrupted? Yes: step 22
No: step 23
Step 22 Service mode is deactivated. step 25
Step 23 Deactivate service mode? Yes: step 24
No: step 15
Step 24 To deactivate the service mode: Press and hold the d button for more than 2 seconds until the dot disappears.
Step 25 The boiler capacity drops to the preset capacity, see the “Settings” menu (table 13). step 1
Manual operation menu
Step 1 [\/2/4| Display value. Currently measured CH (boiler) flow temperature in °C. Also see section 14.2, page 53.
Step 2 Activate manual operation? Yes: step 3
No: step 1
Step 3 To activate manual operation: Press and hold the d button for more than 5 seconds.
Step 4 [//2/4} Display code: Operating phase: As soon as a flashing dot is shown in the right-hand bottom corner of the
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. Also see section 14.2, page 53.
Step 7 Press the e button.
Step 8 [-/h//} Display code: Operating phase: Also see section 14.3, page 54. The boiler is in manual operation mode.
This means that the boiler is in heating mode while there is no heat request from the controller. During
manual operation the “Settings” menu (table 13 from step 3) can be used to temporarily change the
target boiler performance.
Note: If the boiler performance has been changed temporarily, this must be set again after ending
manual operation, according to the “Settings” menu (table 13, page 36).
Step 9 Press the e button.
Step 10 [//2/4} Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 53.
Step 11 Has there been a power failure? Yes: step 1
No: step 12
Step 12 Deactivate manual operation? Yes: step 13
No: step 5
Step 13 To deactivate manual operation: Press and hold the d button for more than 2 seconds until the dot disappears. step 1
Table 12 Manual operation
Service Mode menu
Table 11 Service mode
Operation
6720813171 (2016/05)36
Settings Menu
Step 1 [\/2/4| Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 53.
Step 2 Open the “Settings” menu? Yes: step 3
No: step 1
Step 3 To open the “Settings” menu: Press and hold the d + e buttons for more than 2 seconds
Step 4 [l/-/-] Display setting. As soon as the display shows [l/-/-], the “Settings” menu is open. You can set the boiler
performance using the first parameter shown on the display. Also see section 14.3, page 54.
Step 5 Adjust boiler performance? Yes: step 7
No: step 6
Step 6 Lower: Decrease the target boiler output with the c button. The minimum setting is [l/2/5] = 25 % with an 80-kW
boiler, [l/2/0] = 20 % with a 65 or 100-kW boiler and [l/3/0] = 30 % with a 50-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 54.
Note: Do not set a pump run-over time of less than [f/\/5| (= 5 minutes).
Step 9 Set the pump run-over time after heating operation has ended? Yes: step 10
No: step 11
Step 10 Lower: Decrease the target pump run-over time after the end of heating operation with the c button.
The minimum setting is [f/\/0| = 0 minutes. The factory default setting is 5 minutes.
Caution: Do not set the target pump run-over time after the end of heating operation to less than 5 minutes.
Higher: Increase the target pump run-over time after the end of heating operation with the d button.
The maximum setting is [f/6/0| = 60 minutes or [f/1/d| = 24 hours.
Step 11 Press the e button.
Step 12 [c/\/1| Display setting. Set the third parameter as soon as the display shows [c/\/1|. This parameter indicates
the DHW mode status setting. This enables DHW mode to be switched off or on. This setting has priority
over other DHW mode settings, such as those made on the room thermostat. Also see section 14.3,
page 54.
Step 13 Set the DHW mode status? Yes: step 14
No: 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: step 17
No: step 16
Step 16 Press the e button.
Step 17 [\/2/4| Display value. Any adjustments that you have made have been confirmed. step 1
Table 13 Settings
Commissioning
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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 Filling the heating system
The pre-pressure of the expansion vessel must be at least equal to the
static pressure (system height to the centre of the expansion vessel),
however never less than 0.5 bar.
▶ Push on the control panel to open it ( fig. 68).
▶ Turn the maximum CH flow temperature dial [8] and DHW
temperature dial [10] anticlockwise to the “0” position.
Fig. 70 BC10 basic controller
▶ Turn the vent key through a quarter rotation [1] to undo the boiler
door lock ( detailed picture).
▶ Push the fastener down [2] and open the boiler door [3].
▶ 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 facilities at certain locations.
▶ Turn the cap of the automatic air vent through one rotation to loosen
it.
Fig. 72 Opening the automatic air purging unit
Filling and refilling of the heating circuit must have been carried out by a
method that has been approved by the Water Regulation Advisory
Scheme (WRAS), for the type of heating appliances, i.e. Domestic
(in-house) Fluid Category 3. Non-Domestic (other than in-house) Fluid
Category 4. Depending on the Fluid Category the approved method
should comprise of the following:
Requirements Fluid Category 3 systems
• Control valve (stop valve) including a double check valve on the
mains cold water supply pipe.
• Temporary connection to be removed after filling (filling loop).
• Control valve (stop valve) on the heating system pipework.
Fig. 73 System fill - category 3
Requirements Fluid Category 4 systems
• Control valve (stop valve) on the mains cold water supply pipe.
•Strainer.
• 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
If a fault occurs, then refer to the servicing manual or
contact Worcester.
At initial start up, the boiler will start up as soon as the
system pressure exceeds 1.0 bar. If the system pressure
falls to below 0.2 bar the boiler will stop and generate a
fault code.
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Heating return
SYSTEM FILL
Hose
return
Stop
cock
Test cock
Non return
valve
Non return
valve
Mains
supply
Temporary hose
Stop cock
Commissioning
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▶ 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 BC10.
The pressure in the heating system, which is measured directly at the
boiler, must be at least equal to the required pre-pressure of the
expansion vessel plus 0.5 bar. This minimum pressure must not be less
than 1.0 bar (if the heating system is cold). The maximum pressure in
the heating system, measured directly at the boiler, must not exceed
3.5 bar.
Fig. 76 Reading the pressure gauge
▶ Purge the heating system via the air vents on the radiators. Start at
the lowest floor of the premises and then work your way up from floor
to floor.
Fig. 77 Purging the heating system
If the boiler has been in use for approximately one week and the pressure
reading on the display is less than 1.0 bar, the system has to be topped
up.
The pressure loss in a heating system is caused by air bubbles escaping
via fittings and (automatic) air vent units. The oxygen contained in the
fresh heating water will also escape from the heating water after some
time and cause the pressure in the heating system to drop.
This explains why it is normal that the heating system must be topped up
a couple of times after commissioning it. Eventually the system will have
to be topped up on average once a year.
Should it be necessary to top up the heating system more frequently,
water is probably escaping due to a leakage in the system or a defective
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
▶ 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 commissioning log book.
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DANGER: Danger of fatal accident from explosive
fumes.
Pipes and fittings may leak after commissioning and
maintenance activities have been carried out.
▶ Carry out a correct leakage test.
▶ Only use approved leak detection spray to locate
leaks.
CAUTION: Damage to the installation due to short
circuits
▶ Cover any hazardous locations prior to locating the
leaks.
▶ Do not spray the leak detection product on cable
runs, plugs or electrical wiring. Do not let it drip onto
them either.
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▶ 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 Switch off the power supply to the heating system
▶ Check the new pipe section up to and including its connection (i.e.
direct sealing location) to the gas fitting for leaks, using a foaming
product. The maximum test pressure allowed at the gas valve inlet is
150 mbar.
10.2.2 Bleeding the gas flow pipe
▶ Close the gas valve.
Fig. 81 Closing the gas valve
▶ Open the screw plug on the testing nipple of the gas supply pressure
and for purging [1] by 2 turns and install a hose.
▶ Slowly open the gas valve by pushing on the gas valve and turning it
anticlockwise through ¼ rotation ( fig. 85, page 58). The gas valve
is open when it is in the vertical position.
▶ Purge the gas supply into a well ventilated area.
▶ Close the gas shut-off valve when no more air is present (fig. 87).
▶ 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
▶ Isolate all other appliances.
▶ Set the boiler to full load.
▶ Ensure that there is no modulating of the fan gas valve by operating
the test mode.
▶ Carry out the gas consumption procedure as described in the latest
edition of the Essential Gas Safety book.
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ON
OFF
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NOTICE:
▶ Test the tightness of the measuring nipple(s) used.
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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 been observed?
• Ensure all flue system connections made correctly. Has the annual
CO
2
and NO
x
, clearance to combustible materials been measured?
Have the permissible maximum length limit values from the flue gas
system installation instructions been observed?
10.2.5 Checking the appliance configuration
The burner must only be put into use with the right injectors
( table 14).
Fig. 83 Checking the gas classification label
10.2.6 Measuring the gas inlet pressure (working pressure)
▶ Open at least 2thermostatic radiator valves. Do not switch on the
boiler.
▶ Push on the control panel to open it ( fig. 68, page 32).
▶ Switch off the power supply to the heating system ( fig. 90).
Fig. 84 Switch off the power supply to the heating system
▶ Close the gas valve in a clockwise direction ( fig. 81, page 39).
▶ Turn the vent key through a quarter rotation to undo the boiler door
lock ( fig. 71, see detailed picture, page 37).
▶ Push the fastener down and open the boiler door ( fig. 71,
page 37).
▶ Open the screw plug on the testing nipple for the gas hook-up
pressure and for purging by 2 turns [1].
▶ Reset the digital pressure gauge to “0”.
▶ Connect the pressure gauge connection tube to the positive port of
the testing nipple [2].
Fig. 85 Measuring the gas supply pressure
▶ Slowly open the gas valve by pushing on the gas valve and turning it
¼ rotation in an anticlockwise direction ( fig. 79, page 39).
The gas valve is open when it is in the vertical position.
▶ Switch on the heating system by pressing the mains switch [1] of the
BC10 basic controller.
Boiler Type of gas supply Gas injector diameter [mm]
GB162-50 Natural gas H Venturi
1)
1) Check the gas classification label on the Venturi.
LPG 3P 5.3
GB162-65 Natural gas H Venturi
LPG 3P
5.3
GB162-80 Natural gas H 8.4
LPG 3P
4.7
GB162-100 Natural gas H 8.4
LPG 3P 4.7
Table 14 Gas injector diameter
NOTICE:
▶ Consult the relevant gas utility company for the type
of gas supply.
▶ Check that the actual gas supply is in accordance with
the type of gas supply specified on the gas
classification label ( fig. 83).
Type of gas
supply
Factory presetting for the gas burner
Natural gas H Delivered ready for operation, adjusted to Wobbe
index 14.1 kWh/m³ (with reference to 15 °C,
1013 mbar), applicable to Wobbe index range 12.7
to 15.2 kWh/m³. Markings on gas classification
label: Configured category: G 20 – 2H.
LPG 3P After adaptation by a Gas Safe registered installer,
the unit can be run on LPG.Markings on gas
classification label: Configured category: G 31 – 3P.
Table 15 Factory presetting for the gas burner
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Throughout the measuring operation, keep the digital
pressure gauge in the same position (horizontal or
vertical) in which it was reset to “0”.
ON
OFF
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▶ 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 the
boiler is burning at full load.
▶ Measure the gas supply pressure and enter it in the commissioning
log book, page 72.
The gas supply pressure must be:
• for natural gas H min. 17 mbar, max. 25 mbar, nominal supply
pressure 20 mbar.
• for LPG min. 30 mbar, max. 50 mbar, nominal supply pressure
37 mbar.
▶ Press the “Service” button [4] repeatedly until the temperature
reading is shown in the display.
▶ Press the “Chimney sweep” button [3] to clear the reading. Also see
table 10, “Flue gas test”, page 50.
Fig. 86 BC10 basic controller
▶ Close the gas valve ( fig. 81, page 39).
▶ Remove the gauge-connection tube and tighten the screw plug on the
testing nipple again.
▶ Open the gas valve again by pushing on the gas valve and turning it ¼
rotation in an anticlockwise direction ( fig. 79, page 39).
10.2.7 Checking and adjusting the gas/air-ratio
▶ 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 basic controller ( fig. 86, [1]).
▶ Close the gas valve ( fig. 81, page 39).
▶ Turn the vent key through a quarter rotation to undo the boiler door
lock ( fig. 71, see detailed picture, page 37).
▶ Push the fastener down and open the boiler door ( fig. 71,
page 37).
▶ Open the screw plug on the testing nipple for the burner pressure by
2 turns [1].
▶ Set the pressure gauge to “0”.
Fig. 87 Checking the gas/air ratio
▶ Use a connection tube to connect the positive port of the pressure
gauge to the testing nipple for burner pressure ( fig. 87, [2]).
▶ Slowly open the gas valve by pushing on the gas valve and turning it
¼ rotation in an anticlockwise direction ( fig. 79, page 39).
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 86, [1]).
▶ Activate the Service mode in accordance with the “Service mode”
menu ( table 11, page 34).
DANGER: Danger of fatal accident from explosive
fumes.
▶ Check the testing nipples used for leaks.
▶ Only use approved leak detection spray to locate
leaks.
NOTICE:
▶ Check the gas supply pipe or contact the relevant gas
utility company if the required supply pressure is not
available.
▶ If the supply pressure is too high, a gas pressure
regulator must be integrated upstream of the gas
fitting. Contact the gas utility company.
WARNING:
Damage to the boiler by incorrect adjustment of the gas/
air-ratio.
▶ Adjust gas/air-ratio only with part load.
▶ Adjust gas/air-ratio only based on the gas/air
pressure differential and never based on measured
flue gas values such as CO/CO
2
/NO
x
.
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Throughout the measuring operation, keep the digital
pressure gauge in the same position (horizontal or
vertical) in which it was reset to “0”.
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▶ 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 service mode. The differential
pressure (p
gas
- p
air
) must be –5 Pa (±5 Pa) (indication on the
pressure gauge: –10 to 0 Pa).
Fig. 88 Gas/air difference at low load
▶ Enter the result in the commissioning log book ( section 10.5
“Commissioning record log book”, page 45).
▶ If the gas/air-ratio is incorrect, it must be adjusted on the set screw
(Torx 40 H) [1]. The set screw is located behind the screw-on cover.
Fig. 89 Gas/air difference at low load
▶ Press the “Chimney sweep” button ( fig. 86, [3]) until the dot
disappears from the display.
▶ Switch off the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Close the gas valve ( fig. 81, page 39).
▶ Remove the measuring devices.
▶ Tighten the screw in the burner pressure measuring nipple.
▶ Slowly open the gas valve by pushing on the gas valve and turning it
¼ rotation in an anticlockwise direction ( fig. 79, page 39).
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Press and hold the “Chimney sweep” button ( fig. 90, [3])
(approximately 2 seconds), until the dot in the right-hand bottom
corner of the display ( fig. 90, [9]) appears. See also table 10,
“Flue gas test”, page 34.
▶ After the “Burner” LED ( fig. 90, [6]) has lit up wait for one minute
until the boiler is burning at full load.
▶ Press the “Chimney sweep” button ( fig. 90, [3]) to clear the
reading. See also table 10, “Flue gas test”, page 34.
▶ Check that the boiler performance is still at the required value. See
table 13 “Settings”, page 36.
10.2.8 Carrying out a leakage test in operating conditions
▶ 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 the
boiler is burning at full load.
▶ Use a foaming product to check all sealing locations in the total gas
circuit of the burner while the burner is active.
▶ Press the “Chimney sweep” button [3] to clear the reading. See also
table 10, “Flue gas test”, page 34.
Fig. 90 BC10 basic controller
-15 -10 -5 0 5 (Pa)
-0.15 -0.10 -0.05 0.00 0.05 (mbar)
turn anticlockwise turn clockwise
wrong right wrong
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DANGER: Danger of fatal accident from explosive
fumes.
▶ Check the testing nipples used for gas tightness.
▶ Only use approved leak detection products to locate
leaks.
WARNING:
Damage to the installation due to short circuits.
▶ Cover any hazardous locations prior to locating the
leaks.
▶ Do not spray the leak detection product on cable
runs, plugs or electrical wiring. Do not let it drip onto
them either.
DANGER: Danger of fatal accident from explosive
fumes.
Pipes and fittings may leak after commissioning
activities have been carried out.
▶ Only use approved leak detection products to locate
leaks.
WARNING:
Damage to the installation due to short circuits.
▶ Cover any hazardous locations prior to locating the
leaks.
▶ Do not spray the leak detection product on cable
runs, plugs or electrical wiring. Do not let it drip onto
them either.
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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 basic controller ( fig. 90, [1]).
▶ Remove the cover from the flue gas measuring point [1].
▶ Connect the flue gas analyser to the left-hand measuring point.
Fig. 91 Measuring the gas supply pressure
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Press and hold the “Chimney sweep” button ( fig. 90, [3])
(approximately 2 seconds), until the dot in the right-hand bottom
corner of the display ( fig. 90, [9]) appears. See also table 10,
“Flue gas test”, page 34.
▶ After the “Burner” LED ( fig. 90, [6]) has lit up wait for one minute
until the boiler is burning at full load.
▶ Measure the carbon monoxide content at the flue gas measuring
point ( fig. 91).
The CO values in air-free condition must be less than 400 ppm or
0.04 vol. %. Values of 400 ppm or more indicate an incorrect burner
adjustment ( section 10.2.7, page 41), a dirty gas burner or heat
exchanger or burner faults.
▶ You must determine and remove the cause ( chapter 12,
page 46).
▶ Press the “Chimney sweep” button ( fig. 90, [3]) to clear the
reading. See also table 10, “Flue gas test”, page 34.
▶ Switch off the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Remove the flue gas analyser and fit the cover back onto the flue gas
measuring point ( fig. 91, [1]).
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Press on the control panel to close it ( fig. 95, page 45).
10.2.10 Carrying out a function test
▶ During initial start-up and annual inspection and/or needs-oriented
servicing, make sure that all control, regulating and safety devices
are in full working order and, if applicable, check them for correct
adjustment.
▶ The gas and water circuits must be tested for leaks
( sections 10.2.1 and 10.2.8).
10.2.11 Measuring the ionisation current
▶ Push on the control panel to open it ( fig. 68, page 32).
▶ Open at least 2 thermostatic radiator valves. Do not switch on the
boiler.
▶ Switch off the heating system by pressing the mains switch of the
BC10 basic controller (
fig. 90, [1]).
▶ Turn the vent key through a quarter rotation to undo the boiler door
lock ( fig. 71, see detailed picture, page 37).
▶ Push the fastener down and open the boiler door ( fig. 71,
page 37).
▶ Undo the plug and socket connection of the monitoring cable.
Fig. 92 Removing the ionisation electrode plug and socket connection
▶ Connect the multimeter in series. Select the μA DC range on the
multimeter. The multimeter must have a resolution of at least 1 μA.
Fig. 93 Measuring the ionisation current
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Activate the Service mode in accordance with the “Service mode”
menu ( table 11, page 34).
▶ Set the capacity to minimum (part load) according to the “Service
mode” menu ( table 11, page 34).
▶ After the “Burner” LED ( fig. 90, [6]) has lit up wait for one minute
until the boiler is burning at part load.
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▶ 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/air ratio
( section 10.2.7, page 41) or check the ionisation electrode
( section 13.2.4, page 50).
▶ Press and hold the “Chimney sweep” button ( fig. 90, [3])
(approximately 2 seconds), until the dot in the right-hand bottom
corner of the display ( fig. 90, [9]) appears. See also table 10,
“Flue gas test”, page 34.
▶ Switch off the heating system by pressing the mains switch of the
BC10 basic controller fig. 90, [1]).
▶ Remove the multimeter and reconnect the monitoring cable.
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller ( fig. 90, [1]).
▶ Check that the boiler performance is still at the required value. See
the “Service mode” menu ( table 11, page 34).
10.3 Boiler settings
10.3.1 Setting the heating capacity
▶ Set the required heating capacity on the BC10 according to the
“Settings” menu ( table 13, page 36). See table 16 when making
these settings.
10.3.2 Setting the maximum CH flow temperature
▶ Set the upper CH flow temperature limit for heating mode
( table 17) using the “Maximum CH flow temperature” dial
( fig. 97, [8]).
This limit value does not apply to DHW mode.
10.3.3 Setting the pump run-over time
Set the pump run-over time to 24 hours if the heating system is
controlled depending on room temperature, and there is a risk of parts
of the heating system not controlled by the room controller freezing (e.g.
radiators in the garage).
▶ Set the pump run-over time according to the “Settings” menu
( table 13, page 36).
10.3.4 Switching DHW mode on/off
▶ Set the DHW mode according to the “Settings” menu ( table 13,
page 36).
10.3.5 Setting the DHW temperature
▶ Set the DHW temperature dial ( fig. 90, [10]) to the required
temperature of the hot water in the hot water cylinder ( table 18).
Display
indication
[%]
Rated heating capacity at 40/30 °C [kW]
GB162-50 GB162-65 GB162-80 GB162-100
L20 – 15.6 – 21.1
L25 – 18.7 21.1 26.0
L30 15.6 21.8 25.3 30.9
L35 18.1 24.9 29.6 35.8
L40 20.5 28.0 33.8 40.7
L45 23.0 31.1 38.0 45.8
L50 25.4 34.2 42.2 50.5
L55 27.9 37.3 46.5 55.4
L60 30.3 40.4 50.7 60.3
L65 32.8 43.5 54.9 65.2
L70 35.2 46.6 59.1 70.1
L75 37.7 49.7 63.4 75.0
L80 40.1 52.8 (
1)
50)
1) Capacity at BC10 basic controller with removed jumper.
67.6 79.9
L85 42.6 55.9 (
1)
50) 71.8 84.8
L90 45.0 59.0 (
1)
50) 76.0 89.7
L95 47.5 62.1 (
1)
50) 80.3 94.6
L-- 49.9 65.2 (
1)
50) 84.5 99.5
Table 16 Heating capacity in kW (as a percentage)
WARNING: Damage to the installation due to
overheating the floor slab when using an underfloor
heating system.
The setting at the BC10 cannot be adjusted via the menu
but must instead be set via the “Maximum CH flow
temperature” dial ( fig. 97, [8]).
▶ Limit the maximum CH flow temperature in the
“Settings” menu (in most cases 45 °C).
▶ Observe that the underfloor heating system must be
equipped with a safety limiter, e.g. via the external
switching contact ( page 28).
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 changed with a room controller (e. g. RC35).
Aut The temperature is determined automatically on the basis
of the heating curve. If no room controller is connected,
90 °C is the maximum CH (boiler) flow temperature.
Table 17 Setting of “Maximum CH (boiler) flow temperature” dial
If this setting [c/\/0| is seen, it switches off the frost
protection for the hot water cylinder (if present).
Dial
position
Explanation Legionella information
0 DHW mode is off (if
applicable only heating
mode)
There is no risk of legionella
contamination
ECO Do not use this setting!
30 – 45 DHW temperature in °C The risk is very low if the DHW
mode is used every day.
45 – 60 DHW temperature in °C There is no risk of legionella
contamination. This position
is recommended.
Aut DHW temperature is 60 °C There is no risk of legionella
contamination
Table 18 Settings on the DHW temperature dial
Commissioning
6720813171 (2016/05) 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 it.
Fig. 95 Closing the control panel
10.4.2 Handing over
After completing the installation and commissioning of the system the
installer should hand over to the end user by the following actions.
▶ Hand over all relevant documentation to the end user and explain his/
her responsibilities under the relevant national and regional
regulations.
▶ Explain and demonstrate the starting and shutting down procedures.
10.5 Commissioning record log book
▶ Enter your signature and the date after completing the start-up activities.
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NOTICE:
▶ During initial start-up and annual servicing, make
sure that all control, regulating and safety devices are
in full working order and, if applicable, check for
correct adjustment.
▶ Always keep the user manual and installation and
servicing instructions by the boiler.
6 720 648 726-044.1TD
Start-up activities Page
Measurement
results
Remarks
1. Filling and pressure testing the heating system.
• Pre-pressure expansion vessel (refer to the installation instructions for the expansion vessel)
• Heating system filling pressure
37
37
_________bar
_________bar
2. Write down the gas characteristics: Wobbe-index
Operating heat value
_______kWh/m³
_______kWh/m³
3. Checking for gas leaks 38
4. Bleeding the gas flow pipe 39
5. Checking the flue gas connection 40
6. Checking the appliance configuration 40
7. Measuring the gas supply pressure (working pressure) 40 _______mbar
8. Checking and adjusting the gas/air ratio 40 _______Pa/mbar
9. Carrying out a leakage check in operating conditions 42
10. Measuring the carbon monoxide content (CO), air free 43
11. Function testing
Measure the ionisation current
43
43
________μA
12. Boiler settings 44
13. Closing and locking the boiler door 45
14. Informing the user, handing over technical documents 45
Confirming proper commissioning
Company stamp/signature/date
Table 19
Shutting down the heating system
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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.
Further information about the use of the BC10 basic controller is
provided in chapter 9 “Operation”, page 32.
▶ Push on the control panel to open it.
Fig. 96 Opening the control panel
▶ Switch off the heating system by pressing the mains switch of the
BC10 [1].
Fig. 97 BC10 basic controller
▶ Close the main gas supply or the gas valve ( fig. 81, page 39).
11.2 Shutting down the heating system if there is a risk of
freezing (interruption of use)
If conditions are such that the heating 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.
▶ Push on the control panel to open it.
▶ Switch off the heating system by pressing the mains switch of the
BC10 [1].
▶ Close the main gas supply or the gas valve ( fig. 81, page 39).
▶ Drain the heating water at the lowest point of the heating system,
using the drain cock or the radiator. The (automatic) air vent at the
highest point of the heating system/radiator must be open.
Fig. 98 Draining the heating system
12 Inspection
▶ The activities to be included in an annual inspection and maintenance
contract can be found in the inspection and service record log book
( pages 48 and 52).
12.1 Preparing the heating system for inspection
▶ Switch off the power supply to the heating system.
Fig. 99 Switch off the power supply to the heating system
WARNING: Damage to the installation due to freezing.
The heating system may freeze up after some time in
certain situations, e.g. after a power failure, when the
supply voltage has been switched off, in case of faulty
gas supply, a boiler fault etc.
▶ Ensure that the heating system is permanently
operational (especially if there is a risk of freezing).
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WARNING: Damage to the installation due to
insufficient or improper cleaning and maintenance.
▶ Inspect and clean the heating system once a year.
▶ 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
boiler is on.
▶ Before opening the boiler: Switch off the power
supply to the boiler by isolating the supply and
removing the fuse.
▶ Secure the heating system so that it cannot be
switched on again unexpectedly.
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▶ 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 down and open the boiler door.
Fig. 101 Opening the boiler door
12.3 Carry out a visual check for general signs of
corrosion
▶ Check all gas and water-bearing pipes for signs of corrosion and for
leaks.
▶ Replace any pipes that have corroded.
▶ Carry out a visual inspection of the burner, heat exchanger,
condensate trap, automatic air vent and all fittings in the boiler.
12.4 Gas valve leakage test
Check the internal tightness of the gas fitting on the input side (with the
boiler switched off) at a test pressure of 20 mbar for natural gas.
▶ Open the screw plug on the testing nipple for the gas connection by
2 turns.
▶ Connect the pressure gauge tube to the testing nipple. The pressure
drop allowed after one minute is max. 10 mbar.
▶ If the pressure drop is higher, check all sealing locations of the gas
fitting for leaks using a foaming product. Repeat the pressure test if
no leaks are found. Replace the gas fitting if the pressure drop is
higher than 10 mbar per minute again ( section 13.2.1 “Removing
the gas valve” on page 49 for instructions on how to remove).
Fig. 102 Checking the gas fitting for internal tightness
12.5 Measuring the ionisation current
See section 10.2.11 “Measuring the ionisation current”, page 43.
12.6 Measuring the gas inlet pressure (working pressure)
See section 10.2.6 “Measuring the gas inlet pressure (working
pressure)”, page 40.
12.7 Checking and adjusting the gas/air-ratio
See section 10.2.7 “Checking and adjusting the gas/air-ratio”, page 41.
12.8 Carrying out a leakage test in operating conditions
See section 10.2.8 “Carrying out a leakage test in operating conditions”,
page 42.
12.9 Measuring the flue gases CO
2
emissions
See section 10.2.9 “Measuring the flue gases CO2 emissions”, page 43.
12.10 Filling the heating system
See section 10.1 “Filling the heating system”, page 37.
12.11 Checking the flue gas connection
See section 10.2.4 “Checking the flue gas connection”, page 40.
DANGER:
Danger of fatal accident from explosive fumes.
▶ Only carry out work on gas pipes and fittings if you
are Gas Safe / ACS registered.
If the boiler door cannot be swung open completely,
remove it ( section 13.1 “Removing the boiler door”,
page 48).
6 720 648 726-101.1TD
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Maintenance
6720813171 (2016/05)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 boiler door cannot be fully opened, it may be necessary to remove
the door for inspection and maintenance activities.
Proceed as follows:
▶ Unscrew the control panel from the boiler door and hang it on the
boiler frame ( fig. 119 “Undoing the screws”, page 53).
▶ Unscrew the bolt from the left-hand top hinge of the boiler door and
remove it together with the washer.
▶ Slightly 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. 103 Removing the boiler door
Inspection activities Date: ________ Date: ________ Date: ________
1. Checking the general condition of the heating system.

2. Carrying out a visual inspection and function test of
the heating system.

3. Checking the gas and water-bearing system
components for:
• Operational tightness
• Visible corrosion
• Signs of wear.
Section 10.2.8, page 42.
Section 12.3, page 47.

4. Measuring the ionisation current. Section 10.2.11, page 43.
___________ μA
___________ μA ___________ μA
5. Measuring the gas supply pressure (working
pressure).
Section 10.2.6, page 40.
________ mbar
________ mbar ________ mbar
6. Checking the gas/air-ratio. Section 10.2.7, page 40.
_________ Pa
_________ Pa _________ Pa
7. Carrying out a tightness check of the gas circuit in
operating conditions.
Section 10.2.8, page 42.

8. Measuring the carbon monoxide content (CO), air
free.
Section 10.2.9, page 43.
_________ ppm _________ ppm _________ ppm
9. Checking the system pressure.
• Pre-pressure of expansion vessel (also see
installation instructions for expansion vessel)
•Filling pressure.
Section 10.1, page 37.
_________ bar
_________ bar
_________ bar
_________ bar
_________ bar
_________ bar
10. Checking the operation and safety of the air intake and
flue gas pipe.
Section 10.2.4, page 40.

11. Checking the boiler settings of the control device (in
accordance with requirements).
See the documents for the
control device.

12. Final check of the inspection activities, documenting
the measurement and test results.

13. Confirming proper inspection.
Company stamp/
signature/date
Company stamp/
signature/date
Company stamp/
signature/date
Table 20
The cover over the electrical connections does not have
to be removed from the boiler.
6 720 648 726-104.1TD
Maintenance
6720813171 (2016/05) 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 gas fitting
13.2.2 Removing the burner cover with the fan and the gas valve
▶ Pull the mains connector [1] from the fan.
▶ Pull the connector of the harness [2] from the fan while pushing on
the connector lock to loosen it.
Fig. 105 Undoing the connections to the gas fitting
▶ Pull the air suction tube from the fan.
Fig. 106 Pulling the air suction tube from the fan
WARNING: Damage to the installation due to short
circuits.
▶ Do not spray the detergent onto the burner, the glow
ignitor, the ionisation electrode or other electrical
components.
GB162-80/100
6720813171-3.1TD
GB162-50/65
GB162-80/100
2
1
2
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GB162-50/65
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Maintenance
6720813171 (2016/05)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 unit
13.2.3 Removing the burner and the burner seal
▶ Remove the burner seal [1] and replace it if necessary.
▶ Remove the burner plate [2] and clean it on all sides using
compressed air or a soft brush.
When re-installing the burner plate make sure that the notch is on the
right-hand side ( detailed picture).
Fig. 109 Removing the burner plate and the burner seal
13.2.4 Checking ignition unit
▶Check the individual components of the ignition unit ( fig. 111) for
wear or contamination ( fig. 110).
▶ If required, replace the ionisation electrode and/or glow ignitor.
After checking or replacing the ionisation electrode and/or the glow
ignitor fit a new cover plate and rubber seal.
Fig. 110 Checking the ionisation electrode
Fig. 111 Replacing the ignition unit
[1] Glow ignitor
[2] Ionisation electrode
[3] Rubber seal
[4] Cover plate with seal
[5] Nut
6 720 648 726-108.1TD
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1
CAUTION: Damage to the glow ignitor.
▶ The glow ignitor is fragile. Handle with care.
NOTICE:
If the seat of the cover plate leaks, the seal can burn
away.
▶ Check the cover plate for tightness.
DANGER:
▶ Close the gas valve prior to working on components
in contact with gas.
▶ Check for gas tightness after carrying out work on
components in contact with gas.
NOTICE: Device damage.
Since the effectiveness of the gaskets in the ignition
device is reduced, the gas condensing boiler may
become damaged.
▶ The rubber seal ( fig. 111, [3]) and the cover plate
with seal ( fig. 111, [4]) need to be replaced every
4 years.
7 746 800 040-128.2TD
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Maintenance
6720813171 (2016/05) 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 sleeve
[3] Condensate trap hose
▶ Disconnect the condensate trap from the coupling and remove it [1].
Fig. 113 Disconnecting the condensate trap in the pump group
▶ Rinse the condensate trap to clean it.
▶ Fill the condensate trap with approximately 1.0 l. water before
refitting it.
13.2.6 Removing the condensate collector
▶ Disconnect the flexible condensate drain hose and bend it
backwards.
Fig. 114 Removing the condensate trap hose
▶ Open the 2 clamps on the right and left at the bottom of the
condensate collector [1].
▶ Pull the condensate collector down (step 1) and remove it by pulling
it towards you (step 2).
Fig. 115 Removing the condensate collector
▶ Check the condensate collector for damage and replace it if required.
▶ Clean the condensate collector mechanically (using compressed air
or a soft brush) and rinse it with clean water.
Fig. 116 Cleaning the condensate collector
The condensate trap has a bayonet connector. After
inserting it, the condensate trap must be turned
clockwise through ¼ rotation until it clicks into place
( fig. 17, page 17).
6 720 648 726-113.1TD
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6720813171 (2016/05)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 condensate drain hose to the condensate
collector.
▶ Re-install the condensate trap.
▶ Rinse the heat exchanger with clean water.
▶ Reassemble all boiler components in reverse order:
– Burner with burner seal
– Burner cover with fan and gas valve
– Gas valve
– Glow ignitor and ionisation electrode.
▶ Start up the boiler ( chapter 10 “Commissioning”, page 37).
13.3 Checking and adjusting the gas/air-ratio
See section 10.2.7 “Checking and adjusting the gas/air-ratio”, page 41.
13.4 Function check in operating conditions
▶ Slowly open the gas valve by pushing on the gas valve and turning it
¼ rotation in an anticlockwise direction ( fig. 79, page 39).
▶ Switch on the heating system by pressing the mains switch of the
BC10 basic controller [1].
▶ Set the maximum CH flow temperature dial [8] and the DHW
temperature dial [10] to the maximum temperatures.
▶ Enter a heat demand via the control unit and check that the boiler
starts the heating mode.
▶ Open a hot water tap and check that the boiler starts the DHW mode.
▶ Set the maximum CH flow temperature dial [8] and the DHW
temperature dial [10] to the required temperatures.
Fig. 118 BC10 basic controller
13.5 Service record log book
Complete the log book while carrying out needs-oriented maintenance.
▶ Enter your signature and the date after completing the maintenance
activities.
CAUTION: Damage to the installation.
▶ Do not use metal brushes or similar hard cleaning
tools.
CAUTION: Damage to the installation due to faulty glow
ignitor.
The glow ignitor is made from fragile ceramic material.
▶ Do not damage the glow ignitor.
CAUTION: Damage to the installation due to dirt
particles.
▶ Cover up the boiler interior, e. g. using a blanket or a
cover.
CAUTION: Damage to the installation due to undesired
flue gas or condensate leakage.
▶ When installing the condensate collector, make sure
that the 2 snap closures close smoothly. If this is not
the case, the seal between the condensate collector
and the flue pipe at the back of the heat exchanger
may be leak.
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Needs-oriented maintenance activities Page
Date:
_____________
Date:
_____________
Date:
_____________
Date:
________
Date:
________
1. Cleaning the burner, heat exchanger and condensate
trap after shutting down the heating system.
49

2. Checking and adjusting the gas/air ratio:
•CO
2
content at full load
•CO
2
content at part load.
41 __________ Pa
__________ %
__________ %
__________ Pa
__________ %
__________ %
__________ Pa
__________ %
__________ %
__________ Pa
__________ %
__________ %
__________ Pa
__________ %
__________ %
3. Function testing. 52

4. Confirming proper maintenance.
Company stamp/
signature/date
Company stamp/
signature/date
Company stamp/
signature/date
Company stamp/
signature/date
Company stamp/
signature/date
Table 21
Display information
6720813171 (2016/05) 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 boiler
door is open and to make it easier to read out the values in the display,
you can disassemble the control panel from the boiler door and hang it
from the boiler frame.
▶ Open the boiler door ( fig. 38 “Opening the boiler door”, page 26).
▶ Undo the 2 screws of the control panel at the back of the boiler door
[1].
Fig. 119 Undoing the screws
▶ Undo the cable tie [1].
▶ Remove the control panel.
Fig. 120 Removing the control panel
[1] Cable tie
▶ Use the 2 hooks to hang the control panel from the boiler.
Fig. 121 Hanging the control panel from the boiler frame
14.2 Display readings
For exact troubleshooting instructions please refer to
the boiler service instructions. You may also contact
Worcester technical support (0330 123 3366)
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Display
reading Key to display reading Unit Range
[\/2/4| Current CH flow temperature. °C [\/\/0| – [1/3/0|
[p/1.6| Current system pressure. bar [p/0.0| – [p/4.0|
Table 22 Display readings
6 720 648 726-122.1TD
Display information
6720813171 (2016/05)54
14.3 BC10 Display settings
14.4 BC10 Display codes
Display settings
Display
setting
Meaning of display setting Unit Range
Factory
adjusted
setting
[l/9/9| Configured target load (50 kW). % [l/3/0| – [l/9/9| / [l/-/-| 100 % [l/-/-|
[l/9/9| Configured target load (65 kW). % [l/2/0| – [l/9/9| / [l/-/-| 100 % [l/-/-|
[l/9/9| Configured target load (80 kW). % [l/2/5| – [l/9/9| / [l/-/-| 100 % [l/-/-|
[l/9/9| Configured target load (100 kW). % [l/2/0| – [l/9/9| / [l/-/-| 100 % [l/-/-|
[f/\.5| Configured target value of the pump run-over time.
Note: Do not set a pump run-over time of less than [f/\/5|
(= 5 minutes).
min. [f/0/0| – [f/6/0| / [f/1/d| 24 h [f///5|
[c/\/1| DHW supply operating condition setting.
Please note: If the setting [c/\/0| is displayed, the frost protection of
the DHW supply has also been switched off.
Not appli-
cable.
[c/\/0| Off / On [c/\/1|
Table 23 Display settings
Display codes
Display code
LED on
UBA 3 Other effectsz
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 UBA 3
or a new KIM was fitted, this code will flash for max.
10 seconds.
Off or
flashing
at 8 Hz
[\/-/\|
Fault:
If this code continues to flash on the display, there is a
fault in the communication between the UBA 3 and the
BC10 basic controller.
Off or
flashing
at 8 Hz
e
[-/a/\]
1)
e
[2/0/8|
2)
Operating phase:
The boiler is in flue gas test or service mode.
Off or
flashing
at 8 Hz
No heating operation and no
DHW.
e
[-/h/\|
e
[2/0/0|
2)
Operating phase:
The boiler is in heating mode.
Off
e
[-/h/}
3)
e
[2/0/0|
2)
Operating phase:
The boiler is in manual operation mode.
Off The room temperature is too
high.
e
[=/h/\|
e
[2/0/1|
2)
Operating phase:
The boiler is in DHW mode.
Off
e
[=/h/\|
e
[2/0/1|
2)
Operating phase:
Pump run-over time via the external hot water cylinder
130 seconds at the minimum speed. The “Burner” LED
(On/Off) is off.
Off
e
[0/a/\|
e
[2/0/2|
2)
Operating phase:
The switch optimization program is activated. This
program is activated if there has been any demand more
frequently than once every 10 minutes. This means that
the boiler cannot be restarted until at least 10 minutes
have elapsed since initial burner start-up.
Off The room temperature is not
possibly reached.
e
[0/a/\|
e
[3/0/5|
2)
Operating phase:
The boiler cannot start up temporarily after a DHW
request has ended.
Off
Table 24 Display codes
Display information
6720813171 (2016/05) 55
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
[2/0/3|
2)
Readiness for operation:
The boiler is in standby mode. There is no current heat
demand.
Off
e
[0/l/\|
e
[2/8/4|
2)
Ignition phase:
The gas valve is activated.
Off
e
[0/u/\|
e
[2/7/0|
2)
Start-up phase:
The boiler starts up after activation of the mains power
supply or completion of a system reset. This code is
displayed for a maximum of 4 minutes.
Off
e
[0/y/\|
e
[2/0/4|
2)
Operating phase:
The flow temperature sensor has detected that the
current flow temperature is higher than the flow
temperature setting on the BC10, or that it is higher than
the flow temperature. Calculated according to heating
requirements, or that it is higher than the flow
temperature calculated for the DHW mode.
Off The room temperature is not
possibly reached.
e
[0/y/\|
e
[2/7/6|
e
Fault:
The flow temperature sensor has measured a current flow
temperature higher than 95 °C.
No
4)
5)
Off The room temperature is not
possibly reached.
e
[0/y/\|
e
[2/7/7|
e
Fault:
The safety temperature sensor has measured a current
safety temperature higher than 95 °C.
No
4)
5)
Off The room 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 low (less than 0.2 bar).
No Off No heating operation and no
DHW.
e
[2/f/\|
e
[2/6/0|
e
Fault:
The flow temperature sensor has not, after burner start-
up, detected any temperature increase in the heating
system water.
No Off
e
[2/f/\|
e
[2/7/1|
e
Fault:
The heating water temperature difference, measured
between the flow temperature sensor and the safety
temperature sensor, is too high.
e
[2/p/\|
e
[2/1/2|
e
Fault:
The flow temperature sensor has measured a heating
water temperature increase of over 5 °C/s.
No
4)
5)
Off
e
[2/u/\|
e
[2/1/3|
e
Fault:
The temperature difference measured between the flow
temperature sensor and the return temperature sensor, is
more than 50 °C.
No
4)
5)
Off
e
[2/y/\|
e
[2/8/1|
e
Fault:
The pump has stopped or is running without water.
No Off
Display codes
Display code
LED on
UBA 3 Other effectsz
Main
display
code
z
Sub
display
code
z Key to display code
Reset
requi-
red?
Table 24 Display codes
Display information
6720813171 (2016/05)56
e
[2/y/\|
e
[2/8/2|
e
Fault:
No feedback from the pump.
No Off
e
[3/a/\|
e
[2/6/4|
e
Fault:
The tacho signal from the fan has failed during the
operating phase.
No
4)
5)
Off
e
[3/c/\|
e
[2/1/7|
e
Fault:
No current of air after a certain time.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[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
1Hz
No heating operation and no
DHW.
e
[3/p/\|
e
[2/1/6|
e
Fault:
The fan is running too slowly.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[3/y/\|
e
[2/1/5|
e
Fault:
The fan is running too fast.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[4/a/\|
e
[2/1/8|
e
Fault:
The flow temperature sensor has detected a flow
temperature of over 105 °C.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[4/c/\|
e
[2/2/4|
e
Fault:
There is no bridging cable between contacts 22 and 24 of
the UBA 3 contact strip.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[4/e/\|
e
[2/7/8|
e
Fault:
The sensor test has failed.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[4/f/\|
e
[2/1/9|
e
Fault:
The safety temperature sensor has detected a flow
temperature of over 105 °C.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[4/l/\|
e
[2/2/0|
e
Fault:
The contacts for the safety temperature sensor have
shorted or the safety temperature sensor has detected a
flow temperature of over 130 °C.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[4/p/\|
e
[2/2/1|
e
Fault:
The contacts for the safety temperature sensor have
shorted.
Yes
5)
6)
7)
8)
flashing
1Hz
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
1Hz
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
1Hz
No heating operation and no
DHW.
e
[5/h/\|
e
[2/6/8|
e
Operating phase:
Component test phase.
No Off
e
[6/a/\|
e
[2/2/7|
e
Fault:
The system has detected an insufficient ionisation current
during the ignition phase.
No
4)
5)
Off
Display codes
Display code
LED on
UBA 3 Other effectsz
Main
display
code
z
Sub
display
code
z Key to display code
Reset
requi-
red?
Table 24 Display codes
Display information
6720813171 (2016/05) 57
e
[6/a/\|
e
[2/2/7|
e
Fault:
The system has detected an insufficient ionisation current
after four start-up attempts.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[6/c/\|
e
[2/2/8|
e
Fault:
The system has detected an ionisation current before
burner start-up.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[6/c/\|
e
[3/0/6|
e
Fault:
An ionisation current has been measured after the burner
shut down.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[6/l/\|
e
[2/2/9|
e
Fault:
The system has detected an insufficient ionisation current
during the operating phase.
No
4)
5)
Off
e
[6/p/\|
e
[2/6/9|
e
Fault:
The glow ignitor was activated for more than 10 minutes.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[6/y/\|
e
[2/0/3|
e
Fault:
The ionisation current is too high.
Yes flashing
1Hz
No heating operation and no
DHW.
e
[7/c/\|
e
[2/3/1|
e
Fault:
The power supply was interrupted during a locking fault
4A, 4C, 4E, 4F, 4L, 4P, 4U, 4Y.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[7/l/\|
e
[2/6/1|
e
Fault:
The UBA 3 is defect.
Yes
5)
6)
7)
8)
flashing
1Hz
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
1Hz
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 is
displayed for a maximum of 4 minutes.
On
e
[9/a/\|
e
[2/3/5|
e
Fault:
The UBA 3 or the KIM is defective.
Yes flashing
1Hz
No heating operation and no
DHW.
e
[9/h/\|
e
[2/3/7|
e
Fault:
The UBA 3 or the KIM is defective.
Yes flashing
1Hz
No heating operation and no
DHW.
e
[9/h/\|
e
[2/6/7|
e
Fault:
The UBA 3 or the KIM is defective.
Yes flashing
1Hz
No heating operation and no
DHW.
e
[9/h/\|
e
[2/7/2|
e
Fault:
The UBA 3 or the KIM is defective.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[9/l/\|
e
[2/3/4|
e
Fault:
The contacts for the gas valve have been broken.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[9/l/\|
e
[2/3/8|
e
Fault:
The UBA 3 or the KIM is defective.
Yes
5)
6)
7)
8)
flashing
1Hz
e
[9/p/\|
e
[2/3/9|
e
Fault:
The UBA 3 or the KIM is defective.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
Display codes
Display code
LED on
UBA 3 Other effectsz
Main
display
code
z
Sub
display
code
z Key to display code
Reset
requi-
red?
Table 24 Display codes
Display information
6720813171 (2016/05)58
e
[9/u/\|
e
[2/3/3|
e
Fault:
The UBA 3 or the KIM is defective.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[a/0/1|
e
[8/0/0|
e
Fault:
The contacts to the outdoor-temperature sensor have
shorted or are interrupted, the sensor has 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 connected
incorrectly or is defective.
No Off No DHW is heated any more.
e
[a/0/1|
e
[8/1/0|
e
Fault:
The boiler water does not warm up. Sensor lead broken or
shorted, sensor connected incorrectly or defective, filling
pump connected incorrectly or defective.
No Off No DHW available, but there
is heating operation. The
DHW priority is cancelled
when the fault message
appears.
e
[a/0/1|
e
[8/1/1|
e
Fault:
Thermal disinfection has failed. Outlet flow during
disinfection period too high, sensor lead broken or
shorted, sensor connected incorrectly or defective, filling
pump defective.
No Off Thermal disinfection was
interrupted.
e
[a/0/1|
e
[8/1/6|
e
Fault:
No connection to EMS. EMS bus system is overloaded,
UBA3/MC10 is defective.
No Off The boiler no longer receives
a heat demand. The heating
system does not heat any
longer.
e
[a/0/1|
e
[8/2/8|
e
Fault:
Water pressure sensor generates a fault code. The digital
water pressure sensor is defective.
No Off No heating operation and no
DHW.
e
[a/0/2|
e
[8/1/6|
e
Fault:
No communication with BC10. Contact problem at BC10
or BC10 is defective.
No Off BC10 settings 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 control. No remote control assigned,
although room temperature control has been set.
No Off Since there is no actual room
temperature 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
[8/2/2|
e
Fault:
RC35-HK2 remote control. No remote control assigned,
although room temperature control has been set.
Display codes
Display code
LED on
UBA 3 Other effectsz
Main
display
code
z
Sub
display
code
z Key to display code
Reset
requi-
red?
Table 24 Display codes
Display information
6720813171 (2016/05) 59
e
[a/1/1|
e
[8/2/3|
e
Fault:
RC35-HK1 remote control. No remote control assigned,
although frost protection type “FROST” has been set.
No Off Since there is no actual room
temperature 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
[8/2/4|
e
Fault:
RC35-HK2 remote control. No remote control assigned,
although frost protection type “FROST” has been set.
e
[a/1/1|
e
[8/2/6|
e
Fault:
RC35-HK1 temperature sensor. The external temperature
sensor of the remote control (control unit) of heating
circuit 1 is defective.
No Off Since there is no actual room
temperature 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 sensor has been connected incorrectly or
is defective.
No Off Limited operation of all
heating programs, holiday
function, fault list.
e
[a/1/2|
e
[8/1/6|
e
Fault:
WM10 not available or no communication. WM10 or bus
circuit connected incorrectly or defective, WM10 is not
recognized by the RC35.
No Off Heating circuit pump 1 is
activated continuously.
e
[a/1/8|
e
[8/2/5|
e
Fault:
Conflicting addresses. Both RC25 and RC35 are
registered as Master.
No Off Both RC35 and RC25 activate
heating circuit 1 and DHW.
Depending on the heating
programs set and the
required room temperatures,
the heating system can no
longer work correctly. DHW
mode does not work well.
e
[a/2/1|
e
[8/0/6|
e
Fault:
RC25-HK1 temperature sensor. The integrated
temperature sensor of the remote control (control unit) of
heating circuit 1 is defective.
No Off Since there is no actual room
temperature 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/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 the remote control (control unit) of
heating circuit 2 is defective.
No Off Since there is no actual room
temperature 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/2/2|
e
[8/1/6|
e
Fault:
RC25-HK2 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.
Display codes
Display code
LED on
UBA 3 Other effectsz
Main
display
code
z
Sub
display
code
z Key to display code
Reset
requi-
red?
Table 24 Display codes
Display information
6720813171 (2016/05)60
14.5 Re-fit the control panel in the boiler
▶ Take the control panel from the boiler frame.
▶ Attach the control panel to the boiler door again by following the
above procedure in reverse order and secure it with 2 screws.
e
[a/3/2|
e
[8/0/7|
e
Fault:
The contacts to the heating circuit flow sensor have
shorted or are interrupted, the sensor has been
connected incorrectly or is defective.
No Off Heating circuit pump 2 is
activated depending on the
preset value. The power to
the mixer is switched off and
the mixer stays in the state it
was last put in (can be
adjusted manually).
e
[a/3/2|
e
[8/1/6|
e
Fault:
MM10 not available or no communication. The heating
circuit addresses on the MM10 and the RC35 do not
match up, the MM10 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.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[c/u/\|
e
[2/4/0|
e
Fault:
The contacts for the return temperature sensor have
shorted.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
e
[e/l/\|
e
[2/9/0|
e
Fault:
The UBA 3 or the KIM is defective.
No
4)
5)
Off No heating operation and no
DHW.
e
[e/\/\|
9)
e
[2/4/2|
–
[2/8/7|
e
Fault:
The UBA 3 or the KIM is defective.
Yes
5)
6)
7)
8)
flashing
1Hz
No heating operation and no
DHW.
[h/\/7|
Operating phase:
The system pressure is too low (less than 1.0 bar).
No Off Possibly no heating operation
or no DHW available.
e
[h/\/7|
e
Operating phase:
The system pressure is too low (less than 1.0 bar).
No Off Possibly no heating operation
or no DHW available.
[p/-.-| Operating phase:
The system pressure is too high (over 4.0 bar) or the
pressure sensor has not detected a system pressure
(boiler functioning normally).
No Off
[\/r/e| Fault:
Reset is carried out. After pressing the “Reset” button this
code is displayed for 5 seconds.
Off
1) Any 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 shown after another. If one of these fault codes is a flashing fault code, the other fault codes will also flash.
6) The cause of this fault must be corrected first.
7) The display values, e.g. the system pressure, are also shown as flashing codes.
8) In the event of this fault, the circulation pump is started up and remains in continuous operation in order to minimise the possibility of the heating system freezing up.
9) “E” + random digit or letter.
Display codes
Display code
LED on
UBA 3 Other effectsz
Main
display
code
z
Sub
display
code
z Key to display code
Reset
requi-
red?
Table 24 Display codes
Technical specifications
6720813171 (2016/05) 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 heating capacity, heating curve 80/60 °C kW 14.2 - 46.6 14.2 - 60.5 18.9 - 80.0 19.0 - 94.5
Rated heating capacity, heating curve 50/30 °C kW 15.6 - 49.9 15.6 - 65.0 20.8 - 84.5 20.5 - 99.5
Boiler efficiency at max. capacity, heating curve 80/60 °C % 98 97 97 98
Boiler efficiency at max. capacity, heating curve 50/30 °C % 105 107
Rated efficiency, heating curve 75/60 °C % 106 106 107 107
Rated efficiency, heating curve 50/30 °C % 110 108 110 110
Standby heat loss % 0.05 0.05 0.05 0.06
Hot water circuit
Minimum water circulation volume l/h 0
Maximum volume flow l/h 5,000
CH (boiler) flow temperature °C 30 – 90, can be set on the BC10 basic controller
Resistance at ΔT
20
mbar 90 170 225 320
Max. boiler working pressure bar 4
Content of heating circuit heat exchanger l5
Pipe connections
Gas connection inch G1“
Heating water connection inch G1½“ union nut with female thread enclosed
Condensate water connection mm Ø 24
Flue gas values
Condensate water quantity for natural gas G20, 40/30 °C l/h 5.2 6.9 9.0 10.8
pH value of condensate water pH approximately 4.1
Flue gas mass flow rate, full load g/s 21.6 27.2 35.3 44.9
Flue gas temperature 80/60 °C, full load °C 60 64 67 76
Flue gas temperature 80/60 °C, part load °C 57 57 61 57
Flue gas temperature 50/30 °C, full load °C 43 43 48 51
Flue gas temperature 50/30 °C, part load °C 33 33 34 34
CO
2
content at full load, natural gas G20 % 9.3/9.2 9.4/9.2 9.3 9.4
Free fan feed pressure Pa 85 120 139 220
Flue gas connection
Flue gas value group for air intake/flue gas system II
6
(G61)
Ø flue gas system, room-air dependent mm Ø100 or Ø110
(Ø100 with air intake strainer basket, accessory)
Ø flue gas system, room-air independent mm standard Ø80/125
concentric
standard Ø100/150
concentric
Electrical data
Mains connection voltage V 230, 50 Hz
Electrical protection rating IP X4D (B
23
; IP X0D)
Electrical power consumption, full load (without a pump
group)
W 45 99 97 147
Electrical power consumption, partial load (without a
pump group)
W 20 21 30 28
Boiler dimensions and weight
Height × width × depth (with pump group) mm 1413.5 × 520 × 465
Weight (without a pump group) kg 70
Other specifications
Gas injector diameter G20 mm ––8.4 8.4
Gas injector diameter G31 mm 5.3 5.3 4.7 4.7
Table 25 Technical specifications
Technical specifications
6720813171 (2016/05)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 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 GB162-50/65/80/100
Maximum ambient temperature °C 40
Maximum flow temperature °C 90
Maximum working pressure (boiler) bar 4
Current rating 230 V AC, 50 Hz, 10 A, IP X4D
Table 27 Operating conditions and time constants
Fuels and configurations GB162-50/65/80/100
GB162-65/80/100 Natural gas H (G20) and LPG 3P (G31)
Version B
23
, C
13
, C
33
, C
43
, C
53
, C
63
, C
83
depending on room air and independent of room air
(Compliance with increased tightness requirements with operation independent of room air).
Gas category according to EN 437 GB/IE II
2H3P
20; 37 mbar
Table 28 Fuels and configurations
65 kW
80 kW
100 kW
Volume flow [l/h]
Boiler resistance [mbar]
6720813171-5.1TD
50 kW
Technical specifications
6720813171 (2016/05) 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 number on the exploded view pictures on page 64 and 65.
Description Product No.
1 Door 8718689173
2 Sealing door 7101382
3 Door lock 7101384
4 Hinge door 7101520
5 Wall mounting bracket 7101386
6 Bracket left 7101388
7 Bracket right 7101390
8 Adjusting foot 7101394
9 Transport slide (L + R) 7101392
10 Drawer modules 7101496
11 Screw 4.2 x 8.5 x (10 pc) 7100748
12 Condensate collector 7101396
13 Seal condensate collector 7746900152
14 Seal 80 mm 7101400
15 Upper side condensate collectors 7101402
16 Mounting flue-gas pipe 7101398
17 Exhaust pipe 7101404
18 Adapter air inlet 7101412
19 Seal 100 mm 7736700056
20 Condensate trap 8718600611
21 Seal condensate trap 73463
22 Drain pipe 7101410
23 Seal bush (white) 73449
24 Condensate drain pipe 7101535
25 Fan – 100 kW 7101454
26 Seal Fan 7101450
27 O-ring 70 x 3 (2 pc) 7101416
28 Venturi 8718600301
29 Seal Ø 60 mm 7099686
30 Gas valve 8718601978
31 Seal 33 x 24 x 3.5 (10 pc) 73368s
32 Gas pipe – 100 kW 7101466
33 Flange gas valve 8718600286
34 O-ring (10 pc) 7101504
35 Orifice 100 kW 7746901753
36 Screw M5 x 20 (10 pc) 7099650
37 Screw M5 x 16 (10 pc) 7101484
38 Screw M6 x 16 (10 pc) 7101486
39 Air inlet pipe – 100 kW 7101462
40 Seal (10 pc) 7101482
41 Air vent revision set 7101428
42 Clip 7101430
43 Sensor NTC 7101532
44 Clip (3 x 2 pc) 774670063
45 O-ring 9.19 x 2.62 (10 pc) 78175s
46 Pressure sensor 8718600019
47 O-ring 14 x 1.78 (10 pc) 7099069
48 Return/Supply pipe 7101438
49 Connection nipple CH 73080
50 Clip 7746700069
51 O-ring (10 pc) 7101488
52 Ignitor housing (incl. glow ignitor and
ionisation electrode)
8718600172
60 Heat exchanger 8718600269
61 Cover controller BC10 73698
62 Burner 7101444
63 Seal Burner 7101446
65 Burner box with clamps 7101448
66 Facia 8718689154
67 Controller connection plate 73692
68 On/Off switch 7099041
69 Knob BC10 38724
70 Draw connection board 73909
71 Cover control box 7101498
72 Cover connection board 230 V 73815
73 Transformer 7101640
74 UBA 3 8718600083
75 Fuse 5AF (10 pc) 8718601966
76 Connection board 7099042
77 Electronic connection red 73776
78 Electronic connection grey 73774
79 Electronic connection green 73773
80 Electronic connection blue 73775
81 Electronic connection orange 73777
82 Flue gas exhaust connection 7746901750
83 Flue gas adapter 73936
84 Measure nipple cap 7101424
85 Seal 150 mm 7736700059
86 Cable harness low voltage – 100 kW 7101472
87 Cable harness high voltage 7101478
88 Cable harness on/off switch 7101476
89 Cable harness earth 7101474
90 Mains cable 7101471
91 Union nut 1½" (5 pc) 73481s
92 Seal (10 pc) 7098266
93 Nut 1" 7099416
95 Gas valve 7101512
96 Pump UPS 25-80-130 73954
97 Drain cock 7098666
100 Casing 7101514
101 Thermometer 73890
102 Manometer 7101506
103 Safety valve 4 bar 73957
104 Clip (5 pc) 73651s
105 Seal (5 pc) 73638s
106 Drain cock 7101516
107 Connection pressure gauge 73081
108 Drain pipe 7101531
109 Plug protector 73948
120 230 Volt converter with box 78079
121 230 Volt converter 78091
131 Valve housing supply (single) 74547
132 Valve housing return (single) 74549
– Screw 6.3 x 19 (10 pc) 73986
Description Product No.
Technical specifications
6720813171 (2016/05)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
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
Technical specifications
6720813171 (2016/05) 65
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
Technical specifications
6720813171 (2016/05)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 Hinge door 7101520
5 Wall mounting bracket 7101386
6 Bracket left 7101388
7 Bracket right 7101390
8 Adjusting foot 7101394
9 Transport slide (L + R) 7101392
10 Drawer modules 7101496
11 Screw 4.2 x 8.5 x (10 pc) 7100748
12 Condensate collector 7101396
13 Seal condensate collector 7746900152
14 Seal 80 mm 7101400
15 Upper side condensate collectors 7101402
16 Mounting flue-gas pipe 7101398
17 Exhaust pipe 73927
18 Adapter air inlet 7101412
19 Seal 80 mm 7101400
20 Condensate trap 8718600611
21 Seal condensate trap 73463
22 Drain pipe 7101410
23 Seal bush (white) 73449
24 Condensate drain pipe 7101535
25 Fan 73924
26 Seal Fan 7101450
27 Seal Fan 7099712
28 Venturi 8718600300
29 Seal Ø 50 mm 7099728
30 Gas valve 8718600298
31 Seal 33 x 24 x 3.5 (10 pc) 73368s
32 Gas pipe 7101466
33 Flange gas valve 8718600286
34 O-ring (10 pc) 7101504
36 Screw M5 x 20 (10 pc) 7099650
37 Screw M5 x 16 (10 pc) 7101484
38 Screw M6 x 16 (10 pc) 7101486
39 Air inlet pipe 7101462
40 Seal (10 pc) 7101482
41 Air vent revision set 7101428
42 Clip 7101430
43 Sensor NTC 7101532
44 Clip (3 x 2 pc) 774670063
45 O-ring 9.19 x 2.62 (10 pc) 78175s
46 Pressure sensor 8718600019
47 O-ring 14 x 1.78 (10 pc) 7099069
48 Return/Supply pipe 7101438
49 Connection nipple CH 73080
50 Clip 7746700069
51 O-ring (10 pc) 7101488
52 Ignitor housing (incl. glow ignitor and
ionisation electrode)
8718600172
60 Heat exchanger 8718600269
61 Cover controller BC10 73698
62 Burner 7101444
63 Seal Burner 7101446
65 Burner box with clamps 7101448
66 Facia 8718689154
67 Controller connection plate 73692
68 On/Off switch 7099041
69 Knob BC10 38724
70 Draw connection board 73909
71 Cover control box 7101498
72 Cover connection board 230 V 73815
73 Transformer 7101640
74 UBA 3 8718600083
75 Fuse 5AF (10 pc) 8718601966
76 Connection board 7099042
77 Electronic connection red 73776
78 Electronic connection grey 73774
79 Electronic connection green 73773
80 Electronic connection blue 73775
81 Electronic connection orange 73777
82 Flue gas exhaust connection 7746900414
83 Flue gas adapter 73936
84 Measure nipple cap 7101424
85 Seal 125 mm 7736700058
86 Cable harness low voltage 73944
87 Cable harness high voltage 7101478
88 Cable harness on/off switch 7101476
89 Cable harness earth 7101474
90 Mains cable 7101471
91 Union nut 1½" (5 pc) 73481s
92 Seal (10 pc) 7098266
93 Nut 1" 7099416
95 Gas valve 7101512
96 Pump UPER 25-80-130 7101508
97 Drain cock 7098666
100 Casing 7101514
101 Thermometer 73890
102 Manometer 7101506
103 Safety valve 7099949
104 Clip (5 pc) 73651s
105 Seal (5 pc) 73638s
106 Drain cock 7101516
107 Connection pressure gauge 73081
108 Drain pipe 7101531
109 Plug protector 73948
120 230 Volt converter 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
Description Product No.
Technical specifications
6720813171 (2016/05) 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 Valve housing return (single) 74549
Valve housing return (combi) 74550
– Screw 6.3 x 19 (10 pc) 73986
– Clip suction pipe 73053
Spare part boiler
– Hot water sensor 7098774
– Adapter cable boiler sensor 73754
– Adapter cable three way valve 7099585
– Wire hot water tank 74552
– Sensor locking pin 73495
– Conversion set 7746901190
– Flue gas adapter DN 160-80 with the
following spare parts
7101422
– Cap flue gas adapter DN 160-80 7101418
– Seal DN 110 7101492
– Seal DN 160 7101494
Description Product No.
Technical specifications
6720813171 (2016/05)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
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
Technical specifications
6720813171 (2016/05) 69
Exploded view pump group with DHW GB162-50/65
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
122122
123
125
125
125
124
126
130
127
128
131
129
90
109
89
88
87
86
6 720 648 726-127.1TD
6720813171 (2016/05)70
Notes
6720813171 (2016/05) 71
Notes
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
LITERATURE: 0330 123 9119
TRAINING: 0330 123 0166
SALES: 0330 123 9669
… 20 …


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