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GB162-80
Worcester GB162-80 Installation And Servicing Instructions
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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 h
ot water
6720813171 (2015/04)
2
Table of Contents
Default Chapter
4
Table of Contents
4
1 Key to Symbols and Safety Instructions
5
Key to Symbols
5
Safety Instructions
6
2 General
8
3 Regulations and Directives
9
Designated Use
9
Boiler Room
9
Combustion Air Flue Gas Connection
9
Quality of the Heating System Water
9
Quality of the Pipework
9
Maintenance Schedule
9
Applicability of Regulations
9
4 Safety
10
Please Observe These Instructions
10
Tools, Materials and Further Equipment
10
Recycling
10
5 Transport
10
Lifting and Carrying the Boiler
10
Transporting the Boiler with a Trolley
11
6 Items Supplied with Boiler
11
7 Dimensions of Boiler
12
8 Installation
14
Installing the Boiler
14
General Connection of Mains Water and Gas Components
15
General
15
Install the Water and Gas Connections to the Boiler Using a Pump Group (Accessory)
15
Install the Water and Gas Connections to the Boiler Without a Pump Group
15
Installing the Differential Pressure Controller
16
Installing the Isolating Valves
16
Installing the Drain Cock
16
Installing a Pressure Relief Valve
16
Selecting and Installing the Pump
16
Installing the Condensate Trap
17
Condensate Removal
17
Connecting the Condensate Drain Pipe
19
Connecting the Expansion Vessel in a Single-Boiler System
19
Flue Installation
20
Siting the Flue Terminal
20
Air Supply and Flue Gas Exhaust in a Room Sealed Installation
21
Maximum Flue Length (L)
22
Additional Flue Parts
22
Standard 100 MM Flue Systems
22
Installation of the Horizontal Flue
23
Flue Pipe Preparation and Assembly
23
Flue Gas Connection
23
Open Flue Operation
23
Room Sealed Operation
23
Flue Material
23
Calculating the Air Intake and Flue Gas Pipe Dimensions
23
Electrical Connections
24
Electrical Wiring Diagram
25
Terminal Strip Connections
26
Routing the Cable through the Boiler
26
Description of the Terminal Strip Connections
26
Connections (Only for GB162-50/65)
29
Installing Function Modules (Accessories)
30
9 Operation
32
General Items
32
BC10 Control Operating Instructions
33
10 Commissioning
37
Filling the Heating System
37
Filling the Condensate Trap with Water
38
Testing and Measuring
38
Checking for Gas Leaks
38
Bleeding the Gas Flow Pipe
39
Gas Consumption Test
39
Checking the Flue Gas Connection
40
Checking the Appliance Configuration
40
Measuring the Gas Inlet Pressure (Working Pressure)
40
Checking and Adjusting the Gas/Air-Ratio
41
Carrying out a Leakage Test in Operating Conditions
42
Measuring the Flue Gases CO 2 Emissions
43
10Carrying out a Function Test
43
11Measuring the Ionisation Current
43
Boiler Settings
44
Setting the Heating Capacity
44
Setting the Maximum CH Flow Temperature
44
Setting the Pump Run-Over Time
44
Switching DHW Mode On/Off
44
Setting the DHW Temperature
44
Final Activities
45
Closing the Boiler Door and the Control Panel
45
Handing over
45
Commissioning Record Log Book
45
11 Shutting down the Heating System
46
Shutting down the Heating System Using the Basic Controller
46
Shutting down the Heating System if There Is a Risk of Freezing (Interruption of Use)
46
12 Inspection
46
Preparing the Heating System for Inspection
46
Opening the Boiler Door
47
Carry out a Visual Check for General Signs of Corrosion
47
Gas Valve Leakage Test
47
Measuring the Ionisation Current
47
Measuring the Gas Inlet Pressure (Working Pressure)
47
Checking and Adjusting the Gas/Air-Ratio
47
Carrying out a Leakage Test in Operating Conditions
47
Measuring the Flue Gases CO 2 Emissions
47
Filling the Heating System
47
Checking the Flue Gas Connection
47
Inspection Log Book
48
13 Maintenance
48
Removing the Boiler Door
48
Cleaning the Heat Exchanger, Burner and Condensate Trap
49
Removing the Gas Valve
49
Removing the Burner Cover with the Fan and the Gas Valve
49
Removing the Burner and the Burner Seal
50
Checking Ignition Unit
50
Disconnecting the Condensate Trap
51
Removing the Condensate Collector
51
Cleaning the Heat Exchanger
52
Checking and Adjusting the Gas/Air-Ratio
52
Function Check in Operating Conditions
52
Service Record Log Book
52
14 Display Information
53
Removing the Control Panel from the Boiler
53
Display Readings
53
BC10 Display Settings
54
BC10 Display Codes
54
Re-Fit the Control Panel in the Boiler
60
15 Technical Specifications
61
Spare Parts List GB162-80/100
63
Spare Parts List GB162-50/65
66
Other manuals for Worcester GB162-80
User Instructions
12 pages
Installation And Servicing Instruction
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Installation Instructions
12 pages
5
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Worcester GB162-80 Specifications
General
Output
80 kW
Fuel Type
Natural gas or LPG
Fuel
Natural gas or LPG
Warranty
2 years
Type
Condensing Boiler
Mounting
Wall Mounted
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