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1. 24 262 Fault No off No feedback from the pump JA 264 Fault No Off The tacho signal from the fan has failed during the 4 5 operating phase e JE e Tat e Fault Yes flashing No heating operation and no No current of air after a certain time 5 697 1Hz DHW 8 e JF e g13 e Operating phase No Off The appliance has been switched off for a couple of 4 5 seconds because it had been running without any interruption for 24 hours This is a safety check e 3 LL e taut e Fault Yes flashing No heating operation and no The tacho signal from the fan is not present during the 5 6 7 1Hz DHW pre operative or operating phase 8 e 3 PL e Ja he e Fault Yes flashing No heating operation and no The fan is running too slowly 5 6 7 1Hz DHW 8 e 3 ng e PE st e Fault Yes flashing No heating operation and no The fan is running too fast 5 697 1Hz DHW 8 e T un L e 1 2 Bt e Fault Yes flashing No heating operation and no The flow temperature sensor has detected a flow 5 67 1Hz DHW temperature of over 105 C 8 e J E e PE aut e Fault Yes flashing No heating operation and no There is no bridging cable between contacts 22and 24o0f 5 6 7 1Hz DHW the UB
2. e JE A e yz 21 e Fault Yes flashing No heating operation and no The system has detected an insufficient ionisation current 5 6 7 1Hz DHW after four start up attempts 8 e Jr L e Isar e Fault Yes flashing No heating operation and no The system has detected an ionisation current before 5 67 1Hz DHW burner start up 8 e JEr i e I3Bng e Fault Yes flashing No heating operation and no An ionisation current has been measured after the burner 5 6 7 1Hz DHW shut down 8 e EL e 72g e Fault No Off The system has detected an insufficient ionisation current 4 5 during the operating phase e JEP f e Je Bot e Fault Yes flashing No heating operation and no The glow ignitor was activated for more than 10 minutes 5 6 7 1Hz DHW 8 e JE gt e 203t e Fault Yes flashing No heating operation and no The ionisation current is too high iHz DHW e I TE E e 23 t e Fault Yes flashing No heating operation and no The power supply was interrupted during a locking fault 5 6 7 1Hz DHW AA AC 4E 4F 4L AP AU 4Y 8 e JA L e Yag e Fault Yes flashing No heating operation and no The UBA 3 is defect 5 6 7 1Hz DHW 8 3 Art Jagnt Fault Yes flashing e The UBA 3 is defect 5 697 1Hz
3. a code a code Key to display code red UBA3 Other effects e Att e B23 S Fault No Since there is no actual room RC35 HK1 remote control No remote control assigned temperature information although frost protection type FROST has been set room influence and Alt B24 Fault optimization ofthe switch RC35 HK2 remote control No remote control assigned times do not work The EMS although frost protection type FROST has been set works on the basis of the values last set on the remote control e Ati amp HA e Fault No Off Since there is no actual room RC35 HK1 temperature sensor The external temperature temperature information sensor of the remote control control unit of heating room influence and circuit 1 is defective optimization of the switch Ri B21 Fault times do not work The EMS e e RC35 HK2 temperature sensor The external temperature works on the basis of the sensor of the remote control control unit of the heating values last set on the remote circuit is defective control e At amp B 5 Ss Fault No Off Limited operation of all The contacts to the switch sensor have shorted or are heating programs holiday interrupted the sensor has been connected incorrectly or function fault list is defective e R t2 e B 16 e Fault No Off Heating circuit pump 1 is WM10 not available or no co
4. Display settings Factory adjusted Meaning of display setting setting L495 Configured target load 50 kW Lap L39 L 100 455 Configured target load 65 kW Leo L99 L 100 NE L495 Configured target load 80 kW 96 L25 L39 L 100 L495 Configured target load 100 kW Leo L99 L 100 am FS Configured target value of the pump run over time min FGO FRU F td 24h FS Note Do not set a pump run over time of less than F 5 5 minutes E DHW supply operating condition setting Not appli Ir nl of On EL cable Please note If thesetting EL is displayed the frost protection of the DHW supply has also been switched off Table 23 Display settings 14 4 BC10 Display codes Display codes Display code Sub display A code Main display code LED on UBA3 a Key to display code Other effects y Ft Operating phase Off or Communication test while starting up This display code flashing flashes 5 times within 5 seconds while starting up to at 8 Hz indicate that the communication between the UBA 3 and the BC10 basic controller is being tested If anew UBA 3 or anew KIM was fitted this code will flash for max 10 seconds lI f Fault Off or If this code continues to flash on the dis
5. Step13 Press the button Table 11 Service mode 34 6720813171 2015 04 WORCESTER Bosch Group Operation Service Mode menu Step 14 gH Display value Currently measured CH flow temperature in C Also see section 14 3 page 54 Step15 Press the button Step16 F 6 Display value Currently measured system pressure in bar Also see section 14 3 page 54 Step17 Press the button Step18 H Display code Operating phase The boiler is in service mode Also see section 14 3 page 54 Step19 Press the button Step 20 gH Display value Currently measured CH flow temperature in C Also see section 14 3 page 54 Step21 Have 30 minutes passed or has the mains voltage been interrupted Yes gt step22 No gt step23 Step22 Service mode is deactivated gt step 25 Step23 Deactivate service mode Yes gt step 24 No stepi5 Step24 To deactivate the service mode Press and hold the button for more than 2 seconds until the dot disappears Step25 The boiler capacity drops to the preset capacity see the Settings menu table 13 gt step 1 Table 11 Service mode Manual operation menu Step 1 gH Display value Currently measured CH boiler flow temperature in C Also see section 14 2 page 53 Step2 Activate manual operation Yes gt step3 No step Step3 To activate manual
6. Step2 Continue in Normal operation menu Yes gt step3 No gt stepi Step3 Press the button Step4 F 6 Display value Currently measured system pressure in bar Also see section 14 2 page 53 Step5 Press the 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 step8 Step8 Press the button gt step 1 Table 9 Normal operation 6720813171 2015 04 33 WORCESTER Operation Bosch Group Flue Gas Test menu Step 1 gH Display value Currently measured CH flow temperature in C Also see section 14 2 page 53 Step2 Activate flue gas test Yes gt step3 No gt stepi Step3 To activate the flue gas test Press and hold the amp button for more than 2 but not longer than 5 seconds Step4 24 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 Stepb Pressthe button Step6 P L6 Display value Cur
7. 6 720 648 726 108 1TD Fig 107 Opening the snap closures gt Remove the burner cover with the gas air unit 6 720 648 726 109 1TD 13 2 4 Checking ignition unit CAUTION Damage to the glow ignitor gt The glow ignitor is fragile Handle with care NOTICE If the seat of the cover plate leaks the seal can burn away gt Check the cover plate for tightness DANGER Close the gas valve prior to working on components in contact with gas gt 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 gt Therubber seal gt fig 111 3 andthe cover plate with seal gt fig 111 4 need to be replaced every 4 years C gt eE Fig 108 Removing the burner cover with the gas air unit 13 2 3 Removing the burner and the burner seal gt Remove the burner seal 1 and replace it if necessary gt 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 gt detailed picture 6 720 648 726 110 1TD Fig 109 Removing the burner plate and the burner seal gt Chec
8. 6720813171 2015 04 Bosch Group WORCESTER Technical specifications Exploded view GB162 80 100 m n Del Dee 449 45 45 43 9 p 6 720 648 726 124 1TD 6720813171 2015 04 64 WORCESTER Technical specifications Bosch Group Exploded view pump group GB162 80 100 6 720 648 726 125 1TD 65 6720813171 2015 04 Technical specifications WORCESTER Bosch Group For a pictorial representation ofthe part see the respective position 52 Ignitor housing incl glow ignitor and 8718600172 number on the exploded view pictures on page 68 and 69 ionisation electrode Description Product No 60 Heat exchanger 8718600269 1 Door 8718689173 61 Cover controller BC10 73698 2 Sealing door 7101382 62 Burner 7101444 3 Door lock 7101384 63 Seal Burner 7101446 4 Hinge door 7101520 65 Burner box with clamps 7101448 5 Wall mounting bracket 7101386 66 Fac
9. gt Remove the packaging and dispose of it in an environmentally manner gt Measure the installation height gt chapter 7 Dimensions of boiler page 12 gt Mark out both holes using the wall bracket step 1 using a spirit level gt Drill 2 holes in the wall step 2 Insert the 2 enclosed plugs in the drilled holes step 3 gt Install the wall bracket using the 2 enclosed screws step 4 v Tar 6 720 648 726 008 1TD Fig 8 Installing the wall bracket gt With 2 people lift the boiler by holding it by its back and by the transport rail at its bottom and install iton the wall bracket gt fig 3 page 11 gt Slide the boiler into place gt fig 9 amp 6 720 648 726 009 1TD Fig 9 Sliding the boiler gt Level the boiler using the set screw and a spirit level fig 10 6 720 648 726 010 1TD Fig 10 Aligningthe boiler with the set screw gt Remove the protective covers from the bottom of the boiler 2 fig 11 il Some residual water from final testing may leak away 6 720 648 726 011 1TD Fig 11 Removing the covers 14 6720813171 2015 04 WORCESTER Bosch Group Installation 8 2 Generalconnection of mains water and gas components 8 2 1 General The water and gas connections to th
10. 6 720 648 726 004 1TD Fig 4 Incorrect way of lifting and carrying the boiler 5 2 Transporting the boiler with a trolley DANGER Danger of injury due to improperly secured boiler gt 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 Securethe boiler onthe transportation equipment to prevent it falling off Placethe boiler in its packaging on the hand truck and secure it with astrap if necessary gt Transport the boiler to the installation location 6 Items supplied with boiler The boiler is delivered factory assembled gt Check that the packaging is intact upon delivery gt Check that all items have been supplied with the boiler Fig 5 1 2 3 4 5 6 7 Items supplied with unit Boiler assembly Wall bracket Condensate trap with condensate trap hose Technical documents set Flow and return union nuts with sealing rings 2x Screws and plugs for wall bracket 2x Compression elbow for pressure relief valve in pump group 6720813171 2015 04 11 WORCESTER Dimensions of boiler Bosch Group 7 Dimensions of boiler CHF CHR 6 720 648 726 006 1TD Fig 6 Dimensions and connections WITHOUT pump group dimensions in mm CDO C
11. 6 720 648 726 073 1TD 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 Ma Stop Strainer RPZ Stop cold water cock cock m 6 720 648 726 074 1TD Fig 74 System fill category 4 6720813171 2015 04 37 Commissioning WORCESTER Bosch Group gt Open the heating flow and return isolating valves on the pump group open position parallel to the pipe LE 6 720 648 726 075 1TD Fig 75 Opening the isolating valves here open position gt 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 6 720 648 726 076 1TD Fig 76 Reading the pressure gauge gt Purge the heating system via the air vents on the radiators Start at the lowest floor of the premises and
12. CAUTION N gt Donotuse galvanised radiators or pipes 6720813171 2015 04 15 Installation WORCESTER Bosch Group gt Install the gas valve connector 1 1 accessory gt Install the gas valve 2 onto the gas pipe Use a gas valve with a minimum diameter of 1 6 720 648 726 014 1TD Fig 14 Making the gas connection 1 Gas valve connector 1 2 Gas valve 1 gt Connect the main gas pipe to the gas connection making sure it is not under stress Use a gas pipe of at least 22 mm gt 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 When using plastic pipes observe the supplier s il instructions especially those referringto 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 gt Install shut off valves to enable filter cleaning immediately upst
13. 10 2 5 Checking the appliance configuration The burner must only be put into use with the right injectors gt table 14 Boiler Type of gas supply Gas injector diameter mm GB162 50 Natural gas H Venturi LPG 3P 58 GB162 65 Naturalgas H Venturi LPG 3P 58 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 1 Check the gas classification label on the Venturi NOTICE gt Consult the relevant gas utility company for the type of gas supply gt Check that the actual gas supply is in accordance with the type of gas supply specified on the gas classification label gt fig 83 fi 6 720 648 726 083 1TD Fig G3 Checking the gas classification label Type of gas supply Natural gas H Factory presetting for the gas burner Delivered ready for operation adjusted to Wobbe index 14 1 kWh m with reference to 15 C 1013 mbar applicable to Wobbe index range 12 7 to 15 2 kWh m 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 10 2 6 Measuring the gas inlet pressure working pressure Open atleast 2thermostatic radiator
14. 6720813171 1 1TD aay jenueyod iejonuoo enjereduie yo uo Josuas e nyesedwe JoopInO snq swa pue OH J8jonuoo WOOH o o Volt free external control device 19jonuoo oiseq 0 08 10 J0PSUUOY external 2 230V controls 1 seinpoui uonounj sna 230 Volt converter gt Fig 37 Electrical wiring diagram 25 6720813171 2015 04 Installation WORCESTER Bosch Group 8 5 2 Terminalstrip connections gt Turn the vent key through a quarter rotation to undo the boiler door lock gt fig 38 see detailed picture gt Push the fastener down gt fig 38 and open the boiler door 6 720 648 726 038 1TD Fig 38 Open the boiler door gt Undo 1 screw to release the cover over the electrical connections and pull the cover upwards gt fig 39 6 720 648 726 039 1TD Fig 39 Pullup the cover over the electrical connections The terminal strip in the boiler gt 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 gt section 7 5 4 page 36 If uncertain how to connect controls to this appliance first contact the Worcester technical helpline on 0330 123 3366 or your supplier
15. rotation in an anticlockwise direction gt fig 79 page 39 Switch on the heating system by pressing the mains switch of the BC10 basic controller gt fig 90 1 gt Press and hold the Chimney sweep button gt fig 90 3 approximately 2 seconds until the dot in the right hand bottom corner of the display gt fig 90 9 appears See also table 10 Flue gas test page 34 gt After the Burner LED gt fig 90 6 has lit up wait for one minute until the boiler is burning at full load vvv v v gt 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 gt After the Burner LED 6 has lit up wait for one minute until the boiler is burning at full load gt Use a foaming product to check all sealing locations in the total gas circuit of the burner while the burner is active WARNING N Damage to the installation due to short circuits gt Cover any hazardous locations prior to locating the leaks gt Do not spray the leak detection product on cable runs plugs or electrical wiring Do not let it drip onto them either gt Press the Chimney sweep button 3 to clear the reading See also table 10 Flue gas test page 34 6 720 648 726 069 1TD Fig 90 BC10 basic controller 42 67208131
16. union nut with female thread CS Cap DO NOT remove FGC AIC Flue gas air intake connection 80 125 for GB162 50 65 and 100 150 for GB162 80 100 GASB Gas connection to boiler G1 female thread GASP Gas connection to pump group Rp1 female thread PF Pump group flow G1 male thread flat seal PR Pump group return G1 male thread flat seal The servicing clearances required are in front 50mm below 0 mm 250 mm with pump group right side 0mm leftside Omm above 30 mm The position selected for installation MUST allow adequate space for servicing in front of the boiler in front 550 mm below 350 mm rightside 0mm leftside 0 mm above 40 mm 6720813171 2015 04 13 Installation WORCESTER Bosch Group 8 Installation This section explains how to install the boiler in a professional manner 8 1 Installing the boiler Observe the installation distances of the concentric flue gas system in the separate flue gas system manual Before starting installation check that the carrying capacity of the wall is sufficient for the boiler weight CAUTION Damage to the installation gt Donotremove the polystyrene foam bottom slab otherwise the connection injectors might be damaged gt Donotlift the boiler by holding it by the door over the BC10 gt section 5 1 gt During installation work cover the boiler and the flue gas adapter to prevent site dirt from entering
17. FW DWV RC WA EV ii s ji odd TN se ELE ed A B 6 720 648 726 040 1TD Fig 40 Terminal strip A Low voltage connections B 230 V connections 8 5 3 Routing the cable through the boiler gt Route the cable for the low voltage connections through the hole on the left 1 gt Route the cable for the 230 V connections through the hole on the right 2 gt Attach the cable for the 230 V connections using the strain relief clamps 3 6 720 648 726 041 1TD Fig 41 Routing the cable 8 5 4 Description of the terminal strip connections Connectall components to the relevant terminals DANGER Danger of fatal accident due to electric shock Items 1 6 are low voltage connections and items 7 10 are 230 V connections gt fig 42 Please be aware thatthere may be a voltage on items 7 10 230 V when power is supplied to the boiler 26 6720813171 2015 04 WORCESTER Bosch Group Installation FA FW DWV Mains is i a 230 V Bi WA ev een OOOO TY 5 6 720 648 726 042 1TD gt Push the arrow on the control panel cover to open gt fig 44 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 gre
18. For more information about Sentinel call 0151 420 9563 gt 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 gt Itis most important that the correct concentration of the water treatment product is maintained in accordance with the manufacturer s instructions gt Ifthe 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 gt Inhard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is not permitted gt Under no circumstances should the boiler be fired before the system has been thoroughly flushed gt Donot use artificially softened water gt Only plastic pipework containing a polymeric barrier should be used Copper pipework must be used for the first 600 mm E 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 soften
19. 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 6720813171 2015 04 WORCESTER Contents Bosch Group 8 3 5 Standard 100 mm flue systems 22 Contents 8 3 6 Installation of the horizontal flue 23 8 3 7 Flue pipe preparation and assembly 23 8 4 Flue gas connection 0c c cece cence eee 23 1 Key to symbols and safety instructions 5 11 Key toSymbolS va oo 5 8 4 1 Open flue operation eE E ahi EHER 23 1 2 Safety instructions 0 ccc ccc eee ee ees 6 ms Room sealed N 8 4 3 Flue material 0 cece cece eee ees 23 8 4 4 Calculating the air intake and flue gas pipe 2 Generalist cc 8 dimensions sss 23 8 5 Ele
20. amp amp buttons for more than 2 seconds Step6 L Display setting Maximum capacity setting during heating mode in 96 Also see section 14 3 page 54 In this case L 10096 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 Press and hold the button until the display shows Les with a 80 kW boiler 20 with a 65 and 100 kW boiler or L 40 with a 50 kW boiler Step8 25 Display setting with a 80 kW boiler L 2 0 with a 65 or 100 kW boiler and L 30 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 96 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 Step9 Press the button Step10 FS 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 Step11 Press the button Stepi2 E Display setting This parameter indicates the DHW mode status setting Also see section 14 3 page 54
21. boiler flow temperature dial The maximum CH boiler flow temperature gt 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 gt 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 gt 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 gt fig 69 11 is used to select the required temperature of the hot water in the hot water cylinder The unit is C gt 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 gt fig 69 items 2 3 and 4 and the display gt 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 Normal operation menu Step1 24 Display value Currently measured CH flow temperature in C Also see section 14 2 page 53
22. 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 gt Ensure that the heating system is permanently operational especially if there is a risk of freezing If conditions are such that the heating system has to be shut down fora long period while there is a risk of freezing the water must be drained from the heating system Push onthe control panel to open it gt Switch off the heating system by pressing the mains switch of the BC10 1 gt Close the main gas supply or the gas valve gt fig 81 page 39 gt 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 Ber EN 6 720 648 726 099 1TD Fig 98 Draining the heating system 12 Inspection Theactivitiestobe included in an annualinspection and maintenance contract can be found in the inspection and service record log book gt pages 48 and 52 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 12 1 Preparing the heating system for inspection DANGER N Danger of fatal accident
23. 000 oo o o Q oo lt EE A eseq Bununow Q9 e van 10j2euuoo ejod 9 060 060 00 IN ad N OZ 4 3 ov E r Kiossaose ow ip uonoeuuoo 17 mop 1 ui duind 10 D Mi i Vene ne E v EHESHHEHEHHEHD i 00 00000 0000000 Lud i n OPE Bu Jo1oeuuoo 9jod 1g 1 1 1 1 Za i 1 i ME 8 5 H Sons iL pi pi ni i 2 sosuas H o gt 1 Ss lemsseiq z 2 l 1 000 3 i g 9 lo x coi 2 1 gt gt g gt 2 F a Ao g g i o Qo 1 ss i 3 8 1 AR 1 j 1 i oo OO OO oo 0000000 000000 i 58 7 Fe KR SORPTSRT 8 e See EFN 838 2x i A og2 pue pz OL 0 Ov 4012euuoo ejod g A oez Ov pue A 031 Ov so npow uonounj External connection for professional use i Be Oo PROS u9IIMS iO L oo DM a gr Q x 0 tm on bo aktn GONK ot on N D red turquoise gray blue green orange yoyms suw Hl Mose xew 8 ovnosz dund LEID Buneeu euyxa e yes OWA 083 lo vor jq ss w d Xew ic ZHOS OVA 082 uompoeuuoo sureyy o MOSZ Xeu OVA 082 S dund uoyejnowio MHA dwnd MHA a Connection to the external pump is only possible if no internal pump has been integrated in the connection kit anea Aem aa y jeulexg Buneay 1001 10 ba ee1j jenueyod JORIUOD uos eueyx3 Josues MHA b The 230 Volt converter is only applicable for Logamax plus GB162 50 65
24. 8 e HH e gig Operating phase Off No heating operation and no 2 The external switch contact is open DHW HAA Start up phase On 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 e JR e Joget e Fault Yes flashing No heating operation and no 2 The UBA 3 or the KIM is defective 1Hz DHW e Tay f e 13377 e Fault Yes flashing No heating operation and no The UBA 3 or the KIM is defective 1Hz DHW e Jak L e Je ET e Fault Yes flashing No heating operation and no The UBA 3 or the KIM is defective iHz DHW e Jf e 212 e Fault Yes flashing No heating operation and no The UBA 3 or the KIM is defective 5 6 7 1Hz DHW 8 e Tart e lTa3ut e Fault Yes flashing No heating operation and no The contacts for the gas valve have been broken 5 67 1Hz DHW 8 3 gr t la3Bt Fault Yes flashing e The UBA 3 or the KIM is defective 5 6 7 1Hz 8 e Igp L e jz qt e Fault Yes flashing No heating operation and no The UBA 3 or the KIM is defective 5 6 7 1Hz DHW 8 Table 24 Display codes 6720813171 2015 04 57 WORCESTER Display information Bosch Group Display codes Display code ET Sub Reset display display requi LEDon code Key to display code red UBA3 Other effects e
25. 91 Union nut 177 5 pc 734815 31 Seal 33x24x3 5 10 pc 73368s 92 Seal 10pc 7098266 32 Gaspipe 7101466 H LEE KERLE 33 Flange gas valve 8718600286 95 Gas valve 7101512 34 O ring 10 pc 7101504 96 Pump UPER 25 80 130 7101508 36 Screw M5 x 20 10 pc 7099650 97 Drain cock 7098666 37 ScrewM5x16 10pc 7101484 100 Casing 7101514 38 Screw M6 x 16 10 pc 7101486 101 Thermometer 73890 39 Air inlet pipe 7101462 102 Manometer 7101506 40 Seal 10 pc 7101482 103 Safety valve 7099949 41 Air vent revision set 7101428 104 Clip 5 pc 73651s 42 Clip 7101430 105 Seal 5 pc 73638s 43 SensorNTC 7101532 106 Drain cock 7101516 44 Clip 3x2 pc 774670063 107 Connection pressure gauge 73081 45 O ring 9 19 x 2 62 10 pc 78175s 108 Drain pipe 7101531 46 Pressure sensor 8718600019 109 Plug protector 73948 47 O ring 14 x 1 78 10 pc 7099069 120 230 Volt converter with box 78079 48 Return Supply pipe 7101438 121 230 Volt converter 78091 49 Connection nipple CH 73080 122 Pipe three way valve boiler 73076 50 Clip 7746700069 123 Pipe three way valve connection set 73077 51 O ring 10 pc 7101488 124 Return pipe hot water tank 73078 125 Pipe straight DN 25mm L 30cm 73079 66 6720813171 2015 04 WORCESTER Bosch Group Technical specifications Description Product No 126 Bodythree way valve 20374 127 Motor three way valve 20375 128 Three
26. HK2 communication RC25 addressed incorrectly wired incorrectly or defective temperature information room influence and optimization of the switch times do not work Table 24 Display codes 6720813171 2015 04 59 WORCESTER Display information Bosch Group Display codes Display code Main Sub Reset display display requi LEDon code code Key to display code red UBA3 Other effects e R32 e BDT Fault No off Heating circuit pump 2 is The contacts to the heating circuit flow sensor have activated depending on the shorted or are interrupted the sensor has been preset value The power to connected incorrectly or is defective the mixer is switched off and the mixer stays in the state it was last put in can be adjusted manually e Ale e B B O Fault No Off Heating circuit 2 cannot be MM10 not available or no communication The heating operated correctly MM10 circuit addresses on the MM10 and the RC35 do not and the mixer automatically match up the MM10 or the bus circuit is connected goes into emergency incorrectly or is defective MM10 is not recognized by the operation Heating circuit RC35 pump 2 is activated continuously Monitor data in the RC35 is invalid e J ER L e 1 PAB e Fault Yes flashing No heating operation and no Thereturn te
27. SS LI i 6 720 648 726 030 1TD Fig 30 Vertical flue length 6 720 648 726 031 1TD 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 gt 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 gt 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 Maximum flue length m concentric flue system 100 150 80 125 50 20 7 7 65 20 T T 80 18 100 18 gt Table6 Max flue lengths incl wall roofterminal in meters Reduced flue length m concentric flue system concentric flue system 100 150 80 125 bend extension bend extension A a 0 Fs 45 90 0 5m im 45 90 0 5m im 50 12 21 05 10 09 19 05 10 65 12 21 05 10 09 19 05 10 80 12 21 05 10 09 19 05 10 100 12 21 05 10 09 19 05 10 Table 7 Reduced flue lengths in meters 1 For every bend or extension the max flue length L has to be reduced The t
28. Slide the draw back into the boiler 6 720 648 726 063 1TD N 6 720 648 726 064 1TD Fig 64 Interconnecting modules gt Connect the 230 VAC mains cable of the first module to the next module connection 1 Module 1 Module 2 TT TST EE m BEI EN X 20 Module X il The module may have the letters RC or EMS above the 6 720 648 726 065 1TD Tothe 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 Fig 65 Connecting several modules gt Connect the free connector of the EMS bus connecting cable to the first module gt fig 64 2 gt 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 gt fig 65 and 66 Fig 63 Removing the covers NOTICE Pay attention to the polarity when using an EMS bus connection cable gt Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 gt fig 65 and 66 6720813171 2015 04 31 Operation WORCESTER Bosch Group 6 720 648 726 066 1TD Fig 66 EMS bus polarity Installing and connecting function modules outside the boiler gt Install the module on the wall gt Mak
29. This boiler must only be operated by a responsible adult who has t 4 ype A air gaps been instructed in understands and is aware of the boiler s j operating conditions and effects BS6282 1 Devices with moving parts for the prevention of contamination of water by backflow Specification for HEALTH AND SAFETY check valves of nominal size up to and includingDN 54 BS6283 4 Safety and control devices for use in hot water systems Specification for drop tight pressure 6 6720813171 2015 04 WORCESTER Bosch Group Key to symbols and safety instructions 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 R1 in domestic premises 2nd family gas BS7074 1 Code of practice for domestic and hot water supply BS7671 Requirements for Electrical Installations IEE Wiring Regulations seventeenth edition BSEN 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 Instal
30. and no There is no connection between contacts 78 and 50 of DHW the UBA 3 installation base Fault No Off No heating operation and no The system pressure is too low less than 0 2 bar DHW Fault No Off The flow temperature sensor has not after burner start up detected any temperature increase in the heating system water Fault The heating water temperature difference measured between the flow temperature sensor and the safety temperature sensor is too high Fault No Off The flow temperature sensor has measured a heating 4 5 water temperature increase of over 5 C s Fault No Off The temperature difference measured between the flow 4 5 temperature sensor and the return temperature sensor is more than 50 C e ey e 2B e Fault No off The pump has stopped or is running without water T gO 00 0 0 OS OH ecco o o OY ij ru OY ru 4 m OY ru 4 4 OY ru co uw BE BF BF EP OHO q AY 0 0 0 0 00 0 0 0 q 00 0 0 eu Table 24 Display codes 6720813171 2015 04 55 Display information WORCESTER Bosch Group display code Sub display code Display codes Display code Key to display code LED on UBA3 Other effects
31. due to electric current when the boiler is on gt 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 gt Switch off the power supply to the heating system 6 720 648 726 080 1TD Fig 99 Switch off the power supply to the heating system 46 6720813171 2015 04 WORCESTER Bosch Group Inspection DANGER N Danger of fatal accident from explosive fumes gt Only carry out work on gas pipes and fittings if you are Gas Safe ACS registered gt Close the gas valve 1 gt Close the isolating valves 2 6 720 648 726 101 1TD Fig 100 Closing the valves here in closed position 12 2 Opening the boiler door gt Turn the vent key through a quarter rotation to undo the boiler door lock gt detailed picture gt Push the fastener down and open the boiler door If the boiler door cannot be swung open completely il remove it gt section 13 1 Removing the boiler door page 48 6 720 648 726 038 1TD Fig 101 Opening the boiler door 12 3 Carry outa visual check for general signs of corrosion gt Check all gas and water bearing pipes for signs of corrosion and for leaks gt Replace any pipes that have corroded gt Carry out a v
32. glow i ignitor Burner cover with fan and gas valve The glow ignitor is made from fragile ceramic material Gas valve Glow ignitor and ionisation electrode gt Do not damage the glow ignitor i n EMEN gt Start up the boiler gt chapter 10 Commissioning page 37 gt Check the bottom and top sides of the heat exchanger for dirt CAUTION Damage to the installation due to dirt particles gt Cover up the boiler interior e g using a blanket or a cover 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 gt Slowly open the gas valve by pushing on the gas valve and turning it J rotation in an anticlockwise direction gt fig 79 page 39 gt Switch on the heating system by pressing the mains switch of the BC10 basic controller 1 gt Set the maximum CH flow temperature dial 8 and the DHW temperature dial 10 to the maximum temperatures gt Enter a heat demand via the control unit and check that the boiler starts the heating mode gt Open ahot water tap and check that the boiler starts the DHW mode gt Set the maximum CH flow temperature dial 8 and the DHW temperature dial 10 to the required temperatures gt Clean the heat exchanger with compressed air or a soft brush 6 720 648 726 118 1TD Fig 117 Cleanin
33. in the return circuit gt fig 15 4 8 2 7 Installing a pressure relief valve CAUTION Damage to the installation The pressure in the heating system can become excessively high gt Install a pressure relief valve gt Install a 4 bar pressure relief valve gt 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 gt Selecta pump according to the hydraulic boiler resistance specified intable 5 or in the curve in fig 122 on page 62 gt When using the curve take the nominal required volume flow into consideration according to table 3 gt When selecting the pump take the maximum volume flow of the boiler according to table 4 into consideration 16 6720813171 2015 04 WORCESTER Bosch Group Installation Select a pump with a residual head of at least 200 mbar il at the minimum required volume flow gt table 4 GB162 50 GB162 65 GB162 80 GB162 100 2 200 3 000 3 600 4 300 Table3 Nominal required volume flow l h at AT 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 AT 20 K GB162 50 GB162 65 GB162 80 GB162 100 90 170 225 320 Table 5 Res
34. in the right hand bottom corner of the display fig 90 9 appears See also table 10 Flue gas test page 34 gt Switch off the heating system by pressing the mains switch of the BC10 basic controller fig 90 1 gt Remove the multimeter and reconnect the monitoring cable gt Switch on the heating system by pressing the mains switch of the BC10 basic controller fig 90 1 gt Check that the boiler performance is still at the required value See the Service mode menu gt table 11 page 34 10 3 Boiler settings 10 3 1 Setting the heating capacity gt Set the required heating capacity on the BC10 according to the Settings menu gt table 13 page 36 See table 16 when making these settings Display Rated heating capacity at 40 30 C kW indication GB162 50 GB162 65 GB162 80 GB162 100 L20 15 6 21 3 L25 u 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 SIND 38 0 45 8 L50 25 4 34 2 42 2 50 5 L55 27 9 INES 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 U 50 67 6 19 9 L85 42 6 55 9 U 50 71 8 84 8 L90 45 0 59 0 U 50 76 0 89 7 L95 47 5 62 1 U 50 80 3 94 6 IE 49 9 65 2 U 50 84 5 99 5 Table 16 Heating capacity in kW as a percentage 1 Capacity at BC10 basic controller with removed jumper 10 3 2 Set
35. must be turned clockwise through rotation until it clicks into place gt fig 17 page 17 13 2 6 Removing the condensate collector gt Disconnect the flexible condensate drain hose and bend it backwards ao EOI Fig 114 Removing the condensate trap hose gt Open the 2 clamps on the right and left at the bottom of the condensate collector 1 gt Pull the condensate collector down step 1 and remove it by pulling it towards you step 2 Fig 115 Removing the condensate collector 6 720 648 726 116 1TD gt Check the condensate collector for damage and replace it if required gt Clean the condensate collector mechanically using compressed air or asoft brush and rinse it with clean water 6 720 648 726 117 1TD Fig 116 Cleaning the condensate collector 6720813171 2015 04 51 Maintenance WORCESTER Bosch Group 13 2 7 Cleaning the heat exchanger Refit the condensate collector gt Connect the flexible condensate drain hose to the condensate CAUTION Damage to the installation collector A gt Do not use metal brushes or similar hard cleaning gt Re install the condensate trap tools gt Rinse the heat exchanger with clean water gt Reassemble all boiler components in reverse order Burner with burner seal CAUTION Damage to the installation due to faulty
36. occur DANGERindicates possible risk to life Important information Important information in cases where there is no risk of il 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 Additional symbols Symbol Meaning gt a step in an action sequence gt a reference to a related part in the document or to other related documents a list entry a list entry second level Table 1 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 INSTALL
37. page 42 12 9 Measuring the flue gases CO 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 6720813171 2015 04 47 WORCESTER Maintenance Bosch Group 12 12 Inspection log book gt Enter your signature and the date after completing the inspection activities Inspection activities 1 Checking the general condition of the heating system oO oO oO 2 Carrying out a visual inspection and function test of m o o the heating system 3 Checking the gas and water bearing system Section 10 2 8 page 42 m o Lr components for Section 12 3 page 47 Operational tightness Visible corrosion Signs of wear 4 Measuringthe ionisation current Section 10 2 11 page 43 pA pA pA 5 Measuring the gas supply pressure working Section 10 2 6 page 40 mbar mbar mbar pressure 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 Section 10 2 8 page 42 m oO Oo operating conditions 8 Measuring the carbon monoxide content CO air Section 10 2 9 page 43 ppm ppm ppm free 9 Checking the system pressure Section 10 1 page 37 oO oO oO Pre pressure of expansi
38. possibilities 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 inthe 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 gt Loosen the screw 1 gt Pull open the draw 2 i i amp 6 720 648 726 060 1TD Fig 60 Opening the draw 30 6720813171 2015 04 WORCESTER Bosch Group Installation gt Install the wall bracket accessory with function module in the relevant slots in the draw 6 720 648 726 061 1TD Fig 61 Installing the wall bracket gt Click the function module s into place in the wall bracket gt Remove the draw gt Connect the free 230 VAC mains cable gt 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 6 720 648 726 062 1TD Fig 62 Clicking the function module into place in the wall bracket gt Remove the covers of both free connectors on the function module connection cables
39. 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 767 1 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 Acompartment 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 follow
40. runs plugs or electrical wiring Do not let it drip onto them either 6 720 648 726 088 1TD Fig 88 Gas air difference at low load gt Enter the result in the commissioning log book section 10 5 Commissioning record log book page 45 gt Ifthe gas air ratio is incorrect it must be adjusted on the set screw Torx 40H 1 The set screw is located behind the screw on cover gt Press the Chimney sweep button gt fig 90 3 to clear the reading See also table 10 Flue gas test page 34 gt 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 6 720 648 726 089 1TD 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 Fig 89 Gas air difference at low load gt Press the Chimney sweep button gt fig 86 3 until the dot disappears from the display gt Switch off the heating system by pressing the mains switch of the BC10 basic controller gt fig 90 1 Close the gas valve gt 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
41. the DHW temperature sensor gt Connect the DHW temperature sensor to the grey FW terminal using the harness enclosed with the DHW temperature sensor 1 NOTICE gt This connection is reverse proof This means that it does not matter in which order the wires are connected gt It is not possible to connect more than one DHW temperature sensor in the boiler Itis only possible to connect a DHW temperature sensor which is suitable for this boiler 6 720 648 726 050 1TD 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 gt Remove the cable from the EV terminal gt Connect the external switch contact to the red EV terminal This connection is reverse proof This means that it does not matter in which order the wires are connected EV cooooofggl 6 720 648 726 051 1TD Fig 51 Terminal strip external switch contact potential free e g for floor heating connection colou
42. to use this room controller for room temperature controlled operation the room controller must be installed in aliving room Fig 44 Opening the control panel gt Remove the cover 1 gt Install the RC35 in the slot 2 UC S O 668 6 720 648 726 045 1TD Fig 45 Remove the cover and install the room controller in the boiler only for outdoor temperature dependant operation If you install the room controller e g RC35 in the il boiler only outdoor temperature controlled operation is possible See the room controller user manual for further information Installing and connecting other controllers outside the boiler gt Install the controller as described in the relevant installation instructions gt Connect aRC25 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 mm This connection is reverse proof This means that it does not matter in which order the wires are connected 6 720 648 726 046 1TD Fig 46 Terminal strip Room controller RC and EMS bus connection colour orange 6720813171 2015 04 27 Installation WORCESTER Bosch Group Connecting the outdoor temperature sensor If outdoor temperature dependant control operation is used an outdoor temperature sensor must be connected gt Connect the outdoor temperature sensor to th
43. 0 G Above adjacent ground roof or balcony level 300 H From a surface facing the terminal 600 I Froma 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 0 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 UP 10 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 preventignition or damage to any pa
44. 0 mm without the use of a wall spacing frame 185 mm with the use of a wall spacing frame B 337 5 mm for 80 125 mm horizontal flue 339 5 mm for 100 150 mm horizontal flue L fluelength 6 720 648 726 034 1TD Fig 34 Flue length side il The flue must be inclined from the boiler gt 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 6 720 648 726 035 1TD Fig 35 Flue terminal position gt Assemble flue system completely Push the flue fully together The slope of the terminal outlet must face downwards gt 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 An inner flue finishing kit is provided which should be il fitted to the ducts before assembly 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 gt 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 w
45. 0c cece eee 38 5 1 Liftingand carrying the boiler 10 10 2 1 Checking for gas leaks csse 38 5 2 Transporting the boiler with a trolley 11 10 2 2 Bleeding the gas flow pipe 0000 ee 39 10 2 3 Gas consumption test 0 e cece een eee 39 p g j 10 2 4 Checking the flue gas connection 40 6 Items supplied with boiler Lsu eue 11 10 2 5 Checking the appliance configuration 40 10 2 6 Measuring the gas inlet pressure working pressure 40 7 Dimensions of boiler esee 12 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 emissions 43 8 Installation oos ease rh eR ER n reaa 14 10 2 10Carryingouta function test 008 43 8 1 Installingtheboiler eee sees 14 10 2 11Measuring the ionisation current 05 43 8 2 General connection of mains water and gas 10 3 Boiler settings 00 c ccc ce eee e eee ee 44 components cece cece eee eee tee ee 15 10 3 1 Setting the heating capacity 44 82 General eor RR erus 15 10 3 2 Setting the maximum CH flow temperature 44 8 2 2 Install the water and gas connections to the boiler 10 3 3 Setting the pump run over time 08 44 using a pump group acces
46. 3 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 WORCESTER Bosch Group
47. 44 63 Seal Burner 7101446 65 Burner box with clamps 7101448 66 Facia 8718689154 67 Controller connection plate 73692 68 On Off switch 7099041 69 KnobBC10 38724 70 Draw connection board 73909 71 Cover control box 7101498 72 Cover connection board 230 V 73815 73 Transformer 7101640 74 UBA3 8718600083 75 Fuse5AF 10 pc 8718601966 76 Connection board 7099042 77 Electronic connection red 73776 78 Electronic connection grey 73774 79 Electronic connection green 13773 80 Electronic connection blue 73775 81 Electronic connection orange 13777 82 Flue gas exhaust connection 1146901750 83 Flue gas adapter 73936 84 Measure nipple cap 71101424 85 Sealib0mm 73968 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 1 5 pc 734815 92 Seal 10 pc 7098266 93 Nut1 7099416 95 Gasvalve 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
48. 71 2015 04 WORCESTER Bosch Group Commissioning 10 2 9 Measuring the flue gases CO emissions gt Open atleast 2 thermostatic radiator valves Do not switch on the boiler gt Push on the control panel to open it gt fig 68 page 32 gt Switch off the heating system by pressing the mains switch of the BC10 basic controller fig 90 1 gt Remove the cover from the flue gas measuring point 1 gt Connect the flue gas analyser to the left hand measuring point AND S LL T 6 720 648 726 091 1TD Fig 91 Measuring the gas supply pressure gt Switch on the heating system by pressing the mains switch of the BC10 basic controller fig 90 1 gt Press and hold the Chimney sweep button gt 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 gt After the Burner LED gt fig 90 6 has lit up wait for one minute until the boiler is burning at full load gt Measure the carbon monoxide content at the flue gas measuring point gt 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 gt section 10 2 7 page 41 a dirty gas burner or heat exchanger or burner faults gt You must d
49. A 3 contact strip 8 e T 4E L e Ta At e Fault Yes flashing No heating operation and no The sensor test has failed 5 697 1Hz DHW 8 e 4 FL e 721 gt e Fault Yes flashing No heating operation and no The safety temperature sensor has detected a flow 5 67 1Hz DHW temperature of over 105 C 8 e T LL e J22 04 e Fault Yes flashing No heating operation and no The contacts for the safety temperature sensor have 5 6 7 1Hz DHW shorted or the safety temperature sensor has detected a 8 flow temperature of over 130 C e T PL e hee it e Fault Yes flashing No heating operation and no The contacts for the safety temperature sensor have 5 67 1Hz DHW shorted 8 e 4 ut e PE EE e Fault Yes flashing No heating operation and no The contacts for the safety temperature sensor have been 5 6 7 1Hz DHW interrupted 8 e J u e PE al e Fault Yes flashing No heating operation and no The contacts for the safety temperature sensorhavebeen 5 6 7 1Hz DHW interrupted 8 e GH amp 7266 e Operating phase No Off Component test phase BA e eet Fal No Off The system has detected an insufficient ionisation current 4 5 during the ignition phase Table 24 Display codes 56 6720813171 2015 04 AWWORCESTER Bosch Group Display information ET display code Sub display Display codes Display code Key to display code Other effects
50. ATION MANUAL ABBREVIATIONS USED IN THIS MANUAL 6720813171 2015 04 Key to symbols and safety instructions WORCESTER Bosch Group Diameter 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 E Earth FGC Flue gas Connection HK1 Heating circuit 1 HK2 Heating circuit 2 IP Ingress Protection BCM Boiler identification Module L Live LPG Liquid Petroleum Gas LSV Lock Shield Valve MCW Mains Cold Water N Neutral 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 T Timer TRV Thermostatic Radiator Valve WC Wiring Centre Table 2 Abbreviations 1 2 Safety instructions IF YOU SMELL GAS gt CALL NATIONAL GAS EMERGENCY SERVICE ON 0800 111 999 gt 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 v The appliance contains no asbestos and no substances have been used in the construction process that cont
51. Installation and servicing instructions Wall hung gas fired condensing boiler Worcester Commercial Boiler Series d 6 720 648 726 000 1TD WORCESTER Bosch Group st e wo e g m N m e a co e N N ce WORCESTER p Product overview Bosch Grou Product overview s l N r et z XXX S XXX CX 6 720 648 726 001 1TD Fig 1 GB162 50 65 80 100 with pump group 2 6720813171 2015 04 WORCESTER Bosch Group Product overview 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 Fanharness 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 lonisation electrode 26 Sight glass 27 Glow ignitor 28 Safety temperature sensor 29 Heat exchanger 30
52. T aute 1 FEE amp Fault Yes flashing No heating operation and no The UBA 3 or the KIM is defective 5 697 1Hz DHW 8 e RD e B e Fault No Off Minimum outdoor The contacts to the outdoor temperature sensor have temperature is assumed shorted or are interrupted the sensor has been connected incorrectly or is defective e RD e EME e Fault No Off No DHW is heated any more The contacts to the DHW temperature sensor have shorted or are interrupted the sensor has been connected incorrectly or is defective e RD e 809 e Fault No Off No DHW is heated any more The contacts to DHW temperature sensor 2 have shorted or are interrupted the sensor has been connected incorrectly or is defective e RB e B 10 e Fault No Off No DHW available but there The boiler water does not warm up Sensor lead broken or is heating operation The shorted sensor connected incorrectly or defective filling DHW priority is cancelled pump connected incorrectly or defective when the fault message appears e RB e BI e Fault No Off Thermal disinfection was Thermal disinfection has failed Outlet flow during interrupted disinfection period too high sensor lead broken or shorted sensor connected incorrectly or defective filling pump defective e RB e B IB e Fault No Off The boiler no longer receives No connect
53. 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 amp 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 gt DO NOT TURN ELECTRICAL SWITCHES ON OR OFF BS5482Code of practice for domestic butane and propane gas burning gt DONOT STRIKE MATCHES OR SMOKE installations Installations at permanent dwellings residential park gt PUT OUT NAKED FLAMES homes and commercial premises with installation pipework sizes not gt OPEN DOORS AND WINDOWS exceeding DN 25 for steel and DN 28 for corrugated stainless steel or gt KEEP PEOPLE AWAY FROM THE AFFECTED AREA copper BOILER OPERATION BS6281 1 Devices without moving parts for the prevention of GE contamination of water by backflow Specification for
54. all 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 Anair 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 gt table 7 The total reduced pipe length must be less than the maximum pipe length table 6 See also the next example 6720813171 2015 04 23 Installation WORCESTER Bosch Group Example of a flue design calculation for concentric flue system 100 150 using lengt
55. ansport slide L R 7101392 10 Drawer modules 7101496 11 Screw 4 2x8 5x 10 pc 7100748 12 Condensate collector 7101396 13 Seal condensate collector 7746900152 14 Seal 80mm 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 73939 20 Condensate trap 8718600611 21 Seal condensate trap 73463 22 Drainpipe 7101410 23 Seal bush white 73449 24 Condensate drain pipe 7101535 25 Fan 100 kW 7101454 26 Seal Fan 7101450 27 O ing70x3 2 pc 7101416 28 Venturi 8718600301 29 Seal 60mm 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 3x2 pc 774670063 45 O ring 9 19 x 2 62 10 pc 78175s 46 Pressure sensor 8718600019 47 O ing 14x 1 78 10 pc 7099069 48 Return Supply pipe 7101438 49 Connection nipple CH 73080 50 Clip 7746700069 Description Product No 51 O ring 10 pc 7101488 52 gnitor housing incl glow ignitor and 8718600172 ionisation electrode 60 Heat exchanger 8718600269 61 Covercontroller BC10 73698 62 Burner 71014
56. ards The relevant Irish standards should be followed including ECTI National rules for electrical installations IS 813 2002 for Domestic Gas Installations Health and amp Safety Document No 635 Ventilation Requirements BS5440 2 BS6644 up to a total boiler rating of 70 kW input 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 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 N working on water bearing components 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
57. cal data Mains connection voltage V 230 50Hz Electrical protection rating IP X4D B33 IP XOD Electrical power consumption full load without a pump W 45 99 97 147 group Electrical power consumption partial load without a W 20 21 30 28 pump group Boiler dimensions and weight Height x width x depth with pump group mm 1413 5 x 520 x 465 Weight without a pump group kg 70 Other specifications Gas injector diameter G20 mm u 8 4 8 4 Gas injector diameter G31 mm 53 5 3 4 7 4 7 Table 25 Technical specifications 6720813171 2015 04 61 WORCESTER Technical specifications Bosch Group Pump group 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 for time constants Operating conditions and time constants GB162 50 65 80 100 Maximum ambient temperature C 40 Maximum flow temperature C 90 Maximum working pressure boiler bar 4 Current rating 230 VAC 50 Hz 10 A IP X4D Table 27 Operating conditions and time constants Fuels and configurations Fuels and configurations GB162 50 65 80 100 GB162 65 80 100 Natural gas H G20 and LPG 3P G31 Version B23 C13 C33 C43 C53 C63 Cg3 depending on room air and inde
58. can only be used for the il GB162 50 65 appliance Fig 36 Example 1 24 6720813171 2015 04 AWWORCESTER Installation Bosch Group Electrical wiring diagram 8 5 1 WARNING gt Do not directly connect a 230 V thermostat to this boiler Use the grey 230V connection box supplied with GB162 50 65 jenuew siy ui SMAIA pepojdxoe y pue uomoes BIIAJAS 995 sjueuoduioo enpiArpur JO uomo Jo J uer2u32eje perjrpenb e 3jnsuoo 1qnop Aue ul ase noA ji A 08 1109 pejoeuuoo s aouel dde 1no zey ensu3 q3H 1L4V3 38 LSNW 3ONVIETddV SIHLONINHVM e q paJnojoo 10 N J9319 84 YIM paysewW euiulJo 94 0 pe32euuoo aq jsnui en q paJno oo 9JIM y Pad peJnojoo Jo 7 104 94 uM pexJreui euru 94 0 pej2euuoo aq jsnuu UMOJA pa4nojo9 9JIM Y MOj 9 pue u 18 10 U33138 peJnojoo 10 JOQWAS yye y Aq 10 3 49319 AY YIM pey reui 10 29uuoo y uo euruL9 au 0 pe1 euuoo eq JSN Moj o pue uaaJ8 paJnojoo 9JIM Y SMO OJ Se paa2oJd 10328uuoo JNOA ui speura 94 SurAjmuepi SBUL pejnojoo y uy puods 1109 Jou Aew e uei dde y jo pea SUIEW y ul saJiM ay Jo SINO OI au SYJAIT NMOH8 IVHLRO3N 30118 H18V3 MOTT3A ANY N3389 epoo SuiMoJ oj 3U YLM e2uepJo 2e UI peJnojo9 9Je peo sureui siu ui S9JIM AU LNV IHOdWI ze zZz 3 J019euuoo 9jod 9 peli pues Mmolq MOIS S ISNA See MO wo 000
59. ctrical connections cece eee eeee 24 8 5 1 Electrical wiring diagram Lsse 25 3 Regulations and directives se eeeeee 9 8 5 2 Terminal strip connections ssssseess 26 3 1 Designateduse 0 0 cece eee eee eee e es 9 8 5 3 Routing the cable through the boiler 26 3 2 jBollerroomi ne TER ER ERE ER nennt 9 8 5 4 Description of the terminal strip connections 26 3 3 Combustion air flue gas connection 9 8 5 5 230V connections only for GB162 50 65 29 3 4 Quality of the heating system water 9 8 5 6 Installing function modules accessories 30 3 5 Quality of the pipework 0c cece eee 9 3 6 Maintenance schedule 00ec cece eee 9 3 7 Applicability of regulations esee 9 Operation 5 ieei re rere p ehe yeh Rr reor EET 32 9 1 Generalitems cece eee cee eee eee 32 9 2 BC10 control operating instructions 33 4 Safety ann 10 4 1 Please observe these instructions 10 4 2 Tools materials and further equipment 10 10 Commissioning esee 37 AS Recycling eegene e a i 10 10 1 Filling the heating system eee eene 37 10 1 1 Filling the heating system 2222cc222 37 10 1 2 Filling the condensate trap with water 38 b Transport used 10 10 2 Testingand measuring
60. d 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 CAUTION N Boiler damage due to corrosion gt Ifthe 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 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 gt pages 48 and 52 If inspection reveals a situation which makes maintenance activities necessary these activities have to be carried out gt chapter 13 Maintenance page 48 NOTICE Damage to the installation due to insufficient or N improper cleaning and maintenance gt Inspect and clean the heating system as required once a year Carry
61. densate absorption point The condensate drain pipe should have a minimum outside diameter of 21 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 18 6720813171 2015 04 WORCESTER Bosch Group Installation When discharging condensate to an outside drain il 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 300 mm min Y 400 mm min 6 720 648 726 022 1TD 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 gt Connect the condensate drain pipe to the condensate trap gt fig 23 1 and fig 24 1 6 720 648 726 023 1TD Fig 23 Connecting the condensate trap 1 Condensate trap 6 720 648 726 024 1TD Fig 24 Condensate drainage pipe 1 Minimum distance 2 cm Observe the following regulations The local waste water
62. 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 Anairgap should be maintained between the boiler condensate trap and the condensate pipework 8 2 12 Connecting the expansion vessel in a single boiler system CAUTION Damage to the installation due to faulty N pressure relief valve gt The expansion vessel must be of sufficient capacity gt Connect the expansion tank tothe boiler return CHR If anon return valve is available connect the expansion vessel to the CH side of the non return valve in the return circuit gt fig 25 1 6 720 648 726 025 1TD Fig 25 Connecting the expansion vessel in a single boiler system 1 Expansion vessel 6720813171 2015 04 19 Installation WORCESTER Bosch Group 8 3 Flue Installation 8 3 1 Siting the flue terminal 6 720 648 726 026 1TD 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 30
63. do the plug and socket connection of the monitoring cable 6 720 648 726 092 1TD Fig 92 Removing the ionisation electrode plug and socket connection gt Connect the multimeter in series Select the uA DC range on the multimeter The multimeter must have a resolution of at least 1 pA 6 720 648 726 093 1TD Fig 93 Measuring the ionisation current gt Switch on the heating system by pressing the mains switch of the BC10 basic controller fig 90 1 gt Activate the Service mode in accordance with the Service mode menu table 11 page 34 gt Set the capacity to minimum part load according to the Service mode menu gt table 11 page 34 gt After the Burner LED gt fig 90 6 has lit up wait for one minute until the boiler is burning at part load 6720813171 2015 04 43 Commissioning WORCESTER Bosch Group gt Measure the ionisation current The ionisation current must be gt 5 uA DC at part load operation Entertheresult in the commissioning log book section 10 5 Commissioning record log book page 45 gt Ifthe result is notas it should be check the gas air ratio gt section 10 2 7 page 41 or check the ionisation electrode gt section 13 2 4 page 50 gt Press and hold the Chimney sweep button gt fig 90 3 approximately 2 seconds until the dot
64. door 48 6720813171 2015 04 WORCESTER Bosch Group Maintenance 13 2 Cleaning the heat exchanger burner and condensate trap The boiler has a self cleaning coating WARNING Damage to the installation due to short circuits gt Do not spray the detergent onto the burner the glow ignitor the ionisation electrode or other electrical components 13 2 1 Removing the gas valve gt Undo the gas fitting screw connection 1 and pull the 4 connectors 2 from the gas valve GB162 50 65 P 6720813171 3 1TD Fig 104 Undoing the connections to the gas fitting 13 2 2 Removing the burner cover with the fan and the gas valve gt Pull the mains connector 1 from the fan gt Pullthe 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 gt Pull the air suction tube from the fan 6 720 648 726 107 1TD Fig 106 Pulling the air suction tube from the fan 6720813171 2015 04 49 Maintenance WORCESTER Bosch Group gt Carefully open the 4 snap closures on the burner cover The snap closures may be under tension gt Remove the snap closures
65. e a sufficiently long EMS bus connection cable using a 2 core cable of 0 4 0 75 mm and the connector enclosed with the module gt fig 66 Important Use the connector of the same colour as the connections on the module NOTICE Pay attention to the polarity when using an EMS bus connection cable gt Connect the wire from terminal 1 to terminal 1 and from terminal 2 to terminal 2 fig 65 and 66 gt Connect the EMS bus connection cable to the orange connection of the terminal strip 1 dg 6 720 648 726 067 1TD Fig 67 Terminal strip Room controller RC and EMS bus connection colour orange gt Connect the other end of the EMS bus connection cable to the first module gt fig 65 The module may have the letters RC or EMS above the il connection gt fig 65 1 gt 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 gt Connect the EMS bus connection lead of the first module to the next module gt fig 65 gt Makeasufficiently long 230 VAC mains cable using a 3 core cable of atleast 0 75 mm with an earthing wire the connector enclosed with the module and a 230 VAC earthed plug gt Connect the 230 VAC mains cable to the module gt fig 65 If more modules are used the 230 VAC supply to the next module can be branched off from the previous module usin
66. e blue FA terminal using a 2 core cable of 0 75 mm This connection is non polarity sensitive This means that it does not matter which order the wires are connected 6 720 648 726 047 1TD Fig 47 Terminal strip Outdoor temperature sensor connection colour blue Connecting the potential free heat demand gt Connect the potential free heat demand contact to the green WA terminal gt fig 48 The maximum allowed resistance of this circuit is 100 Q Use a 2 core cable of 0 75 mm WA coooa 6 720 648 726 048 1TD Fig 48 Terminal strip potential free heat demand connection colour green NOTICE gt Itis not possible to connect a thermostat simultaneously to the RC connection and to the terminal for the potential free heat demand WA gt fig 49 gt Itis 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 gt This connection is reverse proof This means that it does not matter which order the wires are connected 6 720 648 726 048 1TD Fig 49 Terminal strip WA potential free heat demand Connecting
67. e boiler can be made in either of 2ways using a pump group 2 fig 12 without a pump group 8 2 3 Install the water and gas connections to the boiler without a pump group gt Connect all pipes making sure that they are not bent or twisted to cause any stress CAUTION N gt Donot use galvanised radiators or pipes 6 720 648 726 012 1TD 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 gt 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 pumpis large enough fort
68. e pump run over time according to the Settings menu 2 table 13 page 36 10 3 4 Switching DHW mode on off il If this setting is seen it switches off the frost protection for the hot water cylinder if present gt Set the DHW mode according to the Settings menu gt table 13 page 36 10 3 5 Setting the DHW temperature gt Set the DHW temperature dial gt fig 90 10 to the required temperature of the hot water in the hot water cylinder gt table 18 Explanation Legionella information 0 DHW mode is off if There is no risk of legionella applicable only heating contamination mode 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 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 45 60 DHW temperature in C 44 6720813171 2015 04 WORCESTER Bosch Group Commissioning 10 4 Final activities 10 4 1 Closing the boiler door and the control panel gt Close the boiler door and lock the fastener by turning the vent screw through rotation in a clockwise direction x 6 720 648 726 095 1TD Fig 94 Closing the boiler door 10 5 Commissioning record log book Enter your signature and the date after comp
69. e 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 Inthe 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 14 5 Re fitthe control panel in the boiler gt Take the control panel from the boiler frame gt Attach the control panel to the boiler door again by following the above procedure in reverse order and secure it with 2 screws 60 6720813171 2015 04 WORCESTER Bosch Group Technical specifications 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 capacit
70. ed 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 TheGB162 50 65 80 100 issuitablefor use as asingle 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 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 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 If there is a risk of radiators or pipe sections freezing up we recommend setting the pu
71. edied using the Service instructions Contact Worcester if necessary See the back of this document for contact details 32 6720813171 2015 04 WORCESTER Bosch Group Operation Chimney sweep button The Chimney sweep button 3 is used to put the boiler into flue gas test service or manual operation mode Theflue 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 gt table 12 Manual operation page 35 Amaximum 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 WARNING N Damage to the installation with underfloor heating by the floor being overheated gt 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 t
72. en 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 Thefollowing controls can be connected to the boiler Control with contact for potential free heat demand RC25 RC35 room controller 4121 4122 4323 cascade controller Errorreporting module EM10 0 10 V input can be used to convert a0 10 Vsignal to a modulating signal Connecting and installing a modulating control room controller Ja 6 720 648 726 044 1TD Itis not possible to connect more than one room controller gt fig 43 RC WA cooeg ea 6 720 648 726 043 1TD 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 itis 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
73. er 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 CAUTION Damage to the installation due to impacts The boiler contains parts which can be damaged by N 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 N contamination Proceed as follows if the boiler has been unpacked but is not put into operation yet gt Protect the boiler connections against pollution by leaving the protective covers on the connections gt Cover the flue gas injectors at the top of the boiler with plastic film 6 720 648 727 010 1TD Fig 2 Open cover panel 5 1 Lifting and carrying the boiler Toliftand carry the boiler place one hand atthe bottom ofthe boiler and the other hand on its front gt fig 3 CAUTION Damage to the unit due to it being lifted and N carried incorrectly gt Donothold the boiler by the door over the control panel gt fig 4 to lift and carry it 10 6720813171 2015 04 WORCESTER Bosch Group Items supplied with boiler 6 720 648 726 003 1TD Fig 3 Liftandcarry the boiler correctly
74. etermine and remove the cause gt chapter 12 page 46 gt Press the Chimney sweep button gt fig 90 3 to clear the reading See also table 10 Flue gas test page 34 gt Switch off the heating system by pressing the mains switch of the BC10 basic controller fig 90 1 gt Remove the flue gas analyser and fit the cover back onto the flue gas measuring point fig 91 1 gt Switch on the heating system by pressing the mains switch of the BC10 basic controller gt fig 90 1 gt Press on the control panel to close it gt fig 95 page 45 10 2 10 Carrying out a function test gt 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 gt The gas and water circuits must be tested for leaks gt sections 10 2 1 and 10 2 8 10 2 11 Measuring the ionisation current gt Push onthe control panel to open it gt fig 68 page 32 gt Open at least 2 thermostatic radiator valves Do not switch on the boiler gt Switch off the heating system by pressing the mains switch of the BC10 basic controller gt fig 90 1 gt Turn the vent key through a quarter rotation to undo the boiler door lock gt fig 71 see detailed picture page 37 gt Push the fastener down and open the boiler door gt fig 71 page 37 gt Un
75. g and maintenance activities have been carried out Carry outa correct leakage test Only use approved leak detection spray to locate leaks CAUTION Damage to the installation due to short N circuits gt Cover any hazardous locations prior to locating the leaks gt Donotspray the leak detection product on cable runs plugs or electrical wiring Do not let it drip onto them either 38 6720813171 2015 04 WORCESTER Bosch Group Commissioning Slowly open the gas valve by pushing on the gas valve and turning it Y4 rotation in an anticlockwise direction The gas valve is open when itis in the vertical position 6 720 648 726 079 1TD Fig 79 Open the gas valve Switch off the power supply to the heating system 6 720 648 726 080 1TD Fig 80 Switch off the power supply to the heating system gt 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 gt Close the gas valve LI 6 720 648 726 081 1TD Fig 81 Closing the gas valve gt Open the screw plug on the testing nipple of the gas supply pressure and for purging 1 by 2 turns and install a hose gt Slowly open the gas valve by pushing on t
76. g the connector enclosed with the module and a 3 core 0 75 mm current cable with an earthing wire gt Connect the 230 VAC supply cable of the previous module to the next module gt fig 65 9 Operation 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 gt Pushon the control panel to open it ES 6 720 648 726 044 1TD Fig 68 Opening the control panel The BC10 basic controller is located on the left behind the door 2 fig 1 4 The BC10 basic controller consists of the following components 6 720 648 726 069 1TD 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 during the reset operation If the boiler stops due to a fault again after resetting the il fault the fault can be rem
77. g the heat exchanger CAUTION Damage to the installation due to undesired flue gas or condensate leakage gt 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 6 720 648 726 069 1TD Fig 118 BC10 basic controller 13 5 Service record log book Complete the log book while carrying out needs oriented maintenance gt Enter your signature and the date after completing the maintenance activities Needs oriented maintenance activities 1 Cleaning the burner heatexchanger and condensate 49 O o m o O trap after shutting down the heating system 2 Checking and adjusting the gas air ratio 41 Pa Pa Pa Pa Pa CO content at full load CO content at part load 3 Function testing 52 DO o m LH O Confirming proper maintenance Company stamp Company stamp Company stamp Company stamp Company stamp signature date signature date signature date signature date signature date Table 21 52 6720813171 2015 04 AWWORCESTER Bosch Group Display information 14 Display information This section describes how to read operating and fault messages from the BC10 basic controller and what they mean For exact troubleshooting instructions please refer to the boiler service instructio
78. h method Boiler GB162 80 Flue system concentric 100 150 Maximum length 18 m Here we have 4 meter pipe 2 x 2 m 4 0m 2x90 bends 2x 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 Roofterminal R SS N Pipe 2m 90 bend Length 21m Pipe 2m 5 1 p bend Maximum length allowed after the Length 21m boiler GB162 80 18m 6 720 648 726 036 1TD 8 5 Electrical connections When connecting the electrical components observe the wiring diagram the installation and servicing instructions of the relevant product 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 gt Use cable of at least 0 75 mm gt Ifthe 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 gt 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
79. he 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 N gt Donotconnectatemperature controller to the 230 V connections Mains PK PS PZ 230V l 6 720 648 726 053 1TD 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 gt 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 tothe green PK terminal of the boiler To connect order a PK plug accessory Proceed as follows WARNING gt Damage to the installation by the boiler being overloaded The maximum electrical load that can be connected to the free 230 VAC connection cable of the pump gt fig 54 1 and to the green EP connector gt 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 elect
80. he 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 gt Install the pump group on the boiler in accordance with the enclosed installation instructions gt Make sure that the connections are tight and carry out a gas and water leakage test after completing the connection work DANGER Danger of fatal accident from explosive fumes gt Only carry out work on gas pipes and fittings if you are Gas Safe ACS registered Installing the gas connection 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 2 fig 13 detailed picture 6 720 648 726 013 1TD Fig 13 Rubber seal The gas installation must be installed in accordance with BS 6891 CAUTION Pipework from the meter to the boiler must be of adequate size The complete installation must be tested for gas leakage and purged as described in IGE UP 1b 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
81. he gas valve and turning it anticlockwise through rotation gt fig 85 page 58 The gas valve is open when it is in the vertical position gt Purge the gas supply into a well ventilated area gt Close the gas shut off valve when no more air is present fig 87 gt Remove the hose and tighten the screw plug on the testing nipple again NOTICE N gt Test the tightness of the measuring nipple s used GB162 50 65 6720813171 2 1TD Fig 82 Bleeding the gas flow pipe 10 2 3 Gas consumption test gt Isolate all other appliances gt Set the boiler to full load gt Ensure that there is no modulating of the fan gas valve by operating the test mode gt Carry out the gas consumption procedure as described in the latest edition of the Essential Gas Safety book 6720813171 2015 04 39 Commissioning WORCESTER Bosch Group 10 2 4 Checking the flue gas connection Check the following points Hasthe prescribed flue gas system been used gt section 8 4 Flue gas connection page 23 Havetheconfiguration instructions from the relevant flue gas system installation instructions been observed Ensure all flue system connections made correctly Has the annual CO and NO clearance to combustible materials been measured Have the permissible maximum length limit values from the flue gas system installation instructions been observed
82. he 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 gt 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 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 gt 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 LED Status Explanation On Burner Boiler water is being heated operational 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 Heat demand LED The Heat demand LED gt 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
83. ia 8718689154 6 Bracket left 7101388 67 Controller connection plate 73692 7 Bracket right 7101390 68 On Off switch 7099041 8 Adjusting foot 7101394 GU kmb ctu 38724 9 Transportslide L R 7101392 70 Draw connection board 73909 10 Drawer modules 7101496 71 Cover control box 7101498 11 Screw4 2x8 5 x 10 pc 7100748 72 Cover connection board 230 V 73815 12 Condensate collector 7101396 T3 Transformer 7101640 13 Seal condensate collector 7746900152 74 UBA3 8718600083 14 Seal80mm 7101400 75 Fuse 5AF 10 pc 8718601966 15 Upper side condensate collectors 7101402 76 Connection board 7093042 16 Mounting flue gas pipe 7101398 TT Electronic connection red 73776 17 Exhaust pipe 13927 78 Electronic connection grey 13774 18 Adapter air inlet 7101412 79 Electronic connection green 13773 19 Seal80mm 7101400 80 Electronic connection blue 73775 20 Condensate trap 8718600611 81 Electronic connection orange T3111 21 Seal condensate trap 73463 82 Flue gas exhaust connection 7746900414 22 Drainpipe 7101410 83 Fluegas adapter 73936 23 Seal bush white 73449 84 Measure nipple cap 7101424 24 Condensate drain pipe 7101535 85 Seal 125mm 7746900323 25 Fan 73924 86 Cable harness low voltage 73944 26 SealFan 7101450 87 Cable harness high voltage 7101478 27 Seal Fan 7099712 88 Cable harness on off switch 7101476 28 Venturi 8718600300 89 Cable harness earth 7101474 29 Seal 50mm 7099728 90 Mains cable 7101471 30 Gas valve 8718600298
84. ing 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 tothe 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 6720813171 2015 04 General WORCESTER Bosch Group The position selected for installation must allow adequate space for servicing in front of the boiler infront 550mm 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 CAUTION Use this device for its intended purpose only DANGER Notes relating to the heating system water gt 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
85. ion Yes gt step 13 No gt step5 Step 13 To deactivate manual operation Press and hold the button for more than 2 seconds until the dot disappears gt step 1 Table 12 Manual operation 6720813171 2015 04 35 Operation WORCESTER Bosch Group Settings Menu Step 1 gH Display value Currently measured CH flow temperature in C Also see section 14 2 page 53 Step2 Open the Settings menu Yes gt step3 No gt stepi Step3 To open the Settings menu Press and hold the amp amp buttons for more than 2 seconds Step4 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 Step5 Adjust boiler performance Yes gt step7 No step6 Step6 Lower Decrease the target boiler output with the amp 9 button The minimum setting is L g 5 25 with an 80 kW boiler L 20 2096 with a 65 or 100 kW boiler and L 40 30 with a 50 kW boiler Higher Increase the target boiler output with the button The maximum setting is l 100 96 This is equal to the factory setting Step7 Pressthe button Step8 F5 Display setting Set the second para
86. ion to EMS EMS bus system is overloaded a heat demand The heating UBA3 MC10 is defective system does not heat any longer e AG e Hed e Fault No Off No heating operation and no Water pressure sensor generates a fault code The digital DHW water pressure sensor is defective e Ade e B B e Fault No Off BC10 settings are no longer No communication with BC10 Contact problem at BC10 taken over by RCxx devices or BC10 is defective e RII e BD e Fault No off Limited operation of all Time not set Failing time setting e g due to a long power heating programs and fault cut list e Rt e 803 e Fault No Off Limited operation of all Date not set Failing date setting e g due to a long power heating programs holiday cut function fault list e Ati e He e Fault No Off Since there is no actual room RC35 HK1 remote control No remote control assigned temperature information although room temperature control has been set room influence and e AL e Br e Fault optimization ofthe switch RC35 HK2 remote control No remote control assigned times do not work The EMS although room temperature control has been set works on the basis of the values last set on the remote control Table 24 Display codes 58 6720813171 2015 04 AWWORCESTER Bosch Group Display information Display codes Display code Sub display Reset requi display LED on
87. istance over the boiler at the nominal required volume flow mbar gt Install the pump gt fig 15 8 in the return circuit gt fig 15 2 8 2 9 Installing the condensate trap DANGER Danger of fatal accident due to poisoning N gt Ifthe condensate trap is not filled with water flue gas can escape and put people s lives at risk gt Fill the condensate trap supplied with the boiler with water gt fig 16 6 720 648 726 016 1TD Fig 16 Filling the condensate trap with water gt Connect the condensate trap 1 to the condensate drain outlet CDO The trap is fitted with a bayonet connection After il pushing step 1 the trap upwards into place you have to turn ita turn anticlockwise step 2 until it locks into position 6 720 648 726 017 1TD Fig 17 Installing the condensate trap 1 Condensate trap gt Connect the condensate trap hose 3 and the rubber sleeve 2 to the condensate trap 1 rT 6 720 648 726 018 1TD 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 wate
88. isual 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 gt 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 gt Ifthe 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 gt section 13 2 1 Removing the gas valve on page 49 for instructions on how to remove 6 720 648 726 085 1TD 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 Seesection 10 2 8 Carrying out aleakage test in operating conditions
89. k the individual components of the ignition unit gt fig 111 for wear or contamination gt fig 110 gt lf 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 E Y ANS j amp 7 746 800 040 128 2TD Fig 110 Checking the ionisation electrode 6720615405 035 1TD Fig 111 Replacing the ignition unit 1 Glow ignitor 2 lonisation electrode 3 Rubber seal 4 Cover plate with seal 5 Nut 50 6720813171 2015 04 WORCESTER Bosch Group Maintenance 13 2 5 Disconnecting the condensate trap gt Disconnect the condensate trap hose 3 and the rubber sleeve 2 from the condensate trap 1 gt Turn the trap clockwise a quarter turn N 6 720 648 726 113 1TD Fig 112 Disconnecting the condensate trap hose 1 Condensate trap 2 Rubber sleeve 3 Condensate trap hose gt Disconnect the condensate trap from the coupling and remove it 1 6 720 648 726 114 1TD Fig 113 Disconnecting the condensate trap in the pump group gt Rinse the condensate trap to clean it gt Fill the condensate trap with approximately 1 01 water before refitting it The condensate trap has a bayonet connector After il inserting it the condensate trap
90. lation 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 4 and 3 4 family gases BSEN 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 BSEN 15420 Gas fired central heating boilers Type C boilers of nominal heat input exceeding 70 kW but not exceeding 1000 kW Irish Stand
91. leting the start up activities gt Push on the control panel to close it A 6 720 648 726 044 1TD 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 gt Hand overall relevant documentation to the end user and explain his her responsibilities under the relevant national and regional regulations gt Explain and demonstrate the starting and shutting down procedures NOTICE During initial start up and annual servicing make sure thatall 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 Measurement Start up activities results Remarks 1 Filling and pressure testing the heating system o Pre pressure expansion vessel refer to the installation instructions for the expansion vessel 37 bar Heating system filling pressure 37 bar 2 Write down the gas characteristics Wobbe index kWh m Operating heat value kWh m 3 Checking for gas leaks 38 LI 4 Bleedingthe gas flow pipe 39 O 5 Checkingtheflue gas connection 40 LI 6 Checkingthe appliance configuration 40 LI 7 Measuring the gas supply pressure working pressure 40 _ mbar 8 Checking and adju
92. meter as soon as the display shows F 5l 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 seta pump run over time of less than F 5 5 minutes Step9 Setthe pump run over time after heating operation has ended Yes gt step 10 No gt stepii Step10 Lower Decrease the target pump run over time after the end of heating operation with the button The minimum settingis F O 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 button The maximum setting is F E0 60 minutesor F td 24 hours Step11 Press the button Step12 E Display setting Set the third parameter as soon as the display shows E t 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 Step13 Set the DHW mode status Yes gt step 14 No step 15 Step14 Set the DHW mode target status with the or buttons means On E means Off Please note Setting L also switches off the hot water cylinder frost protection Step15 Have atleast 5 seconds passed without a button being pressed and
93. mmissioning gt 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 gt After the Burner LED 6 has lit up wait for one minute until the boiler is burning at full load gt 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 gt Press the Service button 4 repeatedly until the temperature reading is shown in the display gt Press the Chimney sweep button 3 to clear the reading Also see table 10 Flue gas test page 50 6 720 648 726 069 1TD Fig 86 BC10 basic controller DANGER Danger of fatal accident from explosive fumes N gt Check the testing nipples used for leaks gt Only use approved leak detection spray to locate leaks NOTICE N gt Check the gas supply pipe or contact the relevant gas utility company if the required supply pressure is not available gt Ifthe supply pressure is too high a gas pressure regulator must be integrated upstream of the gas fitting Contact the gas utility company gt Close the gas valve fig 81 page 39 gt Remove the gauge connection t
94. mmunication WM10 or bus activated continuously circuit connected incorrectly or defective WM10 is not recognized by the RC35 e H B e Bo5 e Fault No Off Both RC35 andRC25 activate Conflicting addresses Both RC25 and RC35 are heating circuit 1 and DHW registered as Master 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 Re e BDB O Fault No Off Since there is no actual room RC25 HK1 temperature sensor The integrated temperature information temperature sensor of the remote control control unit of room influence and heating circuit 1 is defective optimization of the switch times do not work The EMS works on the basis of the values last set on the remote control e Re e B 5 e Fault No Off Since there is no actual room RC25 HK1 communication RC25 addressed incorrectly temperature information wired incorrectly or defective room influence and optimization of the switch times do not work e Age e sis e Fault No Off Since there is no actual room RC25 HK2 temperature sensor The integrated temperature information temperature sensor of the remote control control unit of room influence and heating circuit 2 is defective optimization of the switch times do not work The EMS works on the basis of the values last set on the remote control e App e B Bl e Fault No Off Since there is no actual room RC25
95. mp over run time to 24 hours See section 14 3 page 54 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 aresult of our policy of constant development there may be small differences between illustrations functional steps and technical data 6720813171 2015 04 WORCESTER Bosch Group Regulations and directives 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 e
96. mperature sensor has measured a return 5 6 7 1Hz DHW temperature higher than 105 C 8 e T tu t e Teupt e Fault Yes flashing No heating operation and no The contacts for the return temperature sensor have 5 6 7 1Hz DHW shorted 8 e EL e gat e Fault No Off No heating operation and no The UBA 3 or the KIM is defective 4 5 DHW e T E e 1 ay at e Fault Yes flashing No heating operation and no 9 E The UBA 3 or the KIM is defective 5 6 7 1Hz DHW 8 42B1F en M T Operating phase No Off Possibly no heating operation di The system pressure is too low less than 1 0 bar or no DHW available e H 1 e Operating phase No Off Possibly no heating operation The system pressure is too low less than 1 0 bar or no DHW available pes Operating phase No Off The system pressure is too high over 4 0 bar or the pressure sensor has not detected a system pressure boiler functioning normally rE Fault Off Reset is carried out After pressing the Reset button this code is displayed for 5 seconds Table 24 Display codes 1 Anyindication 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 th
97. n a room sealed f 12 1 Preparing the heating system for inspection 46 installation 2 00 ccc cece cece nee eens 21 12 2 Openingtheboilerdoor 00e c2ccce0000e A7 8 3 3 MaximumFluelength L 22 8 3 4 Additionalflueparts 222222 22 6720813171 2015 04 WORCESTER Bosch Group Key to symbols and safety instructions 12 3 Carry outa visual check for general signs of COMOSION Ares 47 12 4 Gas valve leakage test 0 ccc cece eee 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 emissions 47 12 10 Filling the heating system 0 0 00 47 12 11 Checking the flue gas connection 47 12 12 Inspection log book 0c cece eee eee ees 48 13 Maintenance ovo seen 48 13 1 Removing the boiler door Lus 48 13 2 Cleaning the heat exchanger burner and condensate trap ssesssee sees 49 13 2 1 Removing the gas valve ccc cece eee 49 13 2 2 Removing the burner cover with the fan and the Bas Valve nee 49 13 2 3 Removing the burner and the burner seal 50 13 2 4 Checking ignition unit 0c cee ee eee 50 13 2 5 Di
98. nd the condensate drain pipe is 2 cm An air gap should be maintained between the boiler condensate trap and the condensate pipework 21 5 mm min 450 mm min 3 6 720 648 726 019 1TD 021 5 mm min 6 720 648 726 020 1TD 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 921 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 Nolength restriction 4 Open end of pipe direct into drain below ground but above water level Anairgap should be maintained between the boiler condensate trap and the condensate pipework 021 5 mm min 1 6 720 648 726 021 1TD 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 Nolength restriction 4 Open end of pipe direct into drain below ground but above water level Con
99. nd 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 amaximum of 8 boilers with a total capacity of 800 kW can be connected together ona floor surface of approximately 2 m 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 Conformity has been substantiated by the proper documents which together with the declaration of conformity are filed with the manufacturer The appliance complies with the basic requirements of C the relevant European directives 3 2 Boiler room CAUTION N Damage to the installation due to frost gt Install the heating sys
100. ns You may also contact Worcester technical support 0330 123 3366 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 gt Open the boiler door gt fig 38 Opening the boiler door page 26 gt Undo the 2 screws of the control panel at the back of the boiler door 6 720 648 726 120 1TD Fig 119 Undoing the screws gt Undo the cable tie 1 gt Remove the control panel H 6 720 648 726 121 1TD Fig 120 Removing the control panel 1 Cabletie gt Use the 2 hooks to hang the control panel from the boiler 6 720 648 726 122 1TD Fig 121 Hanging the control panel from the boiler frame 14 2 Display readings Display reading Key to display reading Unit Range gH Current CH flow temperature C 0 130 P El Current system pressure bar I Poor P4 Table 22 Display readings 6720813171 2015 04 53 Display information WORCESTER Bosch Group 14 3 BC10 Display settings
101. on vessel also see installation instructions for expansion vessel bar bar bar Filling pressure ud a a 10 Checking the operation and safety of the airintake and Section 10 2 4 page 40 oO o o flue gas pipe 11 Checking the boiler settings of the control device in See the documents for the o m m accordance with requirements control device 12 Final check of the inspection activities documenting oO oO oO the measurement and test results 13 Confirming proper inspection Company stamp Company stamp Company stamp signature date signature date signature date Table 20 13 Maintenance gt 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 gt Unscrew the control panel from the boiler door and hang it on the boiler frame gt fig 119 Undoing the screws page 53 gt Unscrew the bolt from the left hand top hinge of the boiler door and remove it together with the washer gt 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 The cover over the electrical connections does not have to be removed from the boiler 6 720 648 726 104 1TD Fig 103 Removing the boiler
102. ondensate drain outlet 24 mm O D CFO Distance from wall bracket to centre of horizontal flue elbow 337 5 mm for 80 125 flue and 339 5 mm for 100 150 flue CHF CH boiler flow G1 union nut with female thread CHR CH boiler return G1 union nut with female thread CS Cap DO NOT remove FGC AIC Flue gas air intake connection 80 125 for GB162 50 65 and 100 150 for GB162 80 100 GAS Gas connection to boiler G1 female thread The servicing clearances required are infront 50mm below 0 mm 250 mm with pump group rightside Omm leftside 0 mm above 30 mm The position selected for installation must allow adequate space for servicing in front of the boiler in front 550 mm below 350 mm right side 0mm left side 0 mm above 40 mm 12 6720813171 2015 04 WORCESTER Bosch Group Dimensions of boiler 40 1280 1003 1310 ICHF GASB CHR 7 VA L 4 4 A x VA vA vA Z A L L L 4 A A 4 Z 7 4 Zi 4 A 7 4 PA y v L FA vA 7 L 4 7 4 4 of IA B MM M CDO 7 6 720 648 726 007 1TD 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 24 mm O D CHF CH boiler flow G1 union nut with female thread CHR CH boiler return G1
103. operation Press and hold the amp button for more than 5 seconds Step4 gH 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 Step5 Pressthe button Step6 P Est Display value Currently measured system pressure in bar Also see section 14 2 page 53 Step Pressthe button Step8 H st 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 Step9 Press the button Step 10 g Us Display value Currently measured CH flow temperature in C Also see section 14 2 page 53 Step11 Has there been a power failure Yes step 1 No gt step12 Step12 Deactivate manual operat
104. or has the mains voltage been interrupted Yes gt step 17 No step 16 Step16 Press the button Step 17 gH Display value Any adjustments that you have made have been confirmed gt step 1 Table 13 Settings 36 6720813171 2015 04 WORCESTER Bosch Group Commissioning 10 Commissioning If a fault occurs then refer to the servicing manual or contact Worcester This section explains how to start up the boiler gt Complete the commissioning record log book after carrying out the activities described below gt section 10 5 Commissioning record log book page 45 10 1 Filling the heating system 10 1 1 Filling the heating system At initial start up the boiler will start up as soon as the il 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 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 gt Push on the control panel to open it gt fig 68 gt Turn the maximum CH flow temperature dial B and DHW temperature dial 10 anticlockwise to the 0 position 6 720 648 726 069 1TD Fig 70 BC10 basic controller gt Turn the vent key through a quarter rotation 1 to undo the boiler door lock gt detailed picture gt Push the fas
105. otal reduction length must never exceed the maximum flue length 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 gt 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 Important Any horizontal flue system fitted toa il 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 22 6720813171 2015 04 WORCESTER Bosch Group Installation 8 3 6 Installation of the horizontal flue The standard flue is suitable for lengths up to 660 mm gt 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 PALLAPA 6 720 648 726 032 1TD 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 gt Measure the flue length L Refer to figures 33 and 34 6 720 648 726 031 1TD Fig 33 Flue length rear A 15
106. out maintenance as required Immediately remedy faults This will avoid further damage to the system 3 7 Applicability of regulations Changes or amendments to the regulations also apply at the time of installation and have to be complied with 6720813171 2015 04 Safety WORCESTER Bosch Group 4 Safety Please observe these instructions for your own safety 4 1 Please observe these instructions Observe the following instructions when installing and operating the heating system Thelocal building regulations as regards the installation conditions Thelocal building regulations as regards fresh air supply and air exhaust facilities and flue connections Theregulations for electrical connections to the power supply Thegasutility company rules for connecting the gas burner to the local gas mains Theregulations and standards concerning the safety facilities for the DHW heating system Theinstallation instructions for producers of heating systems DANGER Danger of fatal accident from explosive fumes If you N smell gas there is a danger of explosion gt Nonaked lights No smoking Do not use lighters gt 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 f
107. pendent of room air Compliance with increased tightness requirements with operation independent of room air Gas category according to EN 437 GB IE Ilayap 20 37 mbar Table 28 Fuels and configurations Hydraulic resistance of the boiler 500 450 400 350 300 250 200 Boiler resistance mbar 150 100 50 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Volume flow l h 6720813171 5 1TD Fig 122 Boiler resistance curve 62 6720813171 2015 04 WORCESTER Bosch Group Technical specifications 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 Tr
108. play there is a flashing fault in the communication between the UBA 3 and the at8 Hz BC10 basic controller e A e 208 Operating phase Offor No heating operation and no 1 2 The boiler is in flue gas test or service mode flashing DHW at 8 Hz e H e 200 Operating phase Off 2 The boiler is in heating mode e H yl e 200 Operating phase Off The room temperature is too 3 2 The boiler is in manual operation mode high e LH e gU Operating phase Off 2 The boiler is in DHW mode e H e en Operating phase Off 2 Pump run over time via the external hot water cylinder 130 seconds at the minimum speed The Burner LED On Off is off e oA e 202 Operating phase Off The room temperature is not 2 The switch optimization program is activated This possibly reached 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 e BR e 3 Operating phase Off The boiler cannot start up temporarily after a DHW request has ended Table 24 Display codes 54 6720813171 2015 04 AWWORCESTER Bosch Group Display information Display codes Display code ET Sub Reset display f display f requi LED on code code Key to display code red UBA3 Other effects DE amp EEE Pre operative phase Off 2 The boiler prepares for a burner start up whenever a heat demand o
109. r 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 WARNING Any external run must be insulated with water proof insulation It should be noted that the connection of a condensate pipe to a drain may be subject to local building controls 6720813171 2015 04 17 Installation WORCESTER Bosch Group Material for condensate il Ensure that the condensate trap is filled with water 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 21 5 mmwith no length restriction It should incorporate a trap witha 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 gt fig 19 condensate seal The minimum distance between the condensate trap a
110. r a DHW request arises 26S Readiness for operation Off 2 The boiler is in standby mode There is a current heat demand but too much energy has been supplied Readiness for operation Off The boiler is in standby mode There is no current heat demand Ignition phase Off The gas valve is activated DE DH ru ra Lut uL Du ru 4 ra Start up phase Off 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 gu Operating phase Off The room temperature is not 2 The flow temperature sensor has detected that the possibly reached current flow temperature is higher than the flow temperature setting on the BC10 or that itis higher than the flow temperature Calculated according to heating requirements or that it is higher than the flow temperature calculated for the DHW mode Fault No Off The room temperature is not The flow temperature sensor has measured a current flow 4 5 possibly reached temperature higher than 95 C Fault No Off The room temperature is not The safety temperature sensor has measured a current 4 5 possibly reached safety temperature higher than 95 C Fault No Off The room temperature is not The return temperature sensor has measured a current 4 5 possibly reached return temperature higher than 95 C Fault No Off No heating operation
111. r 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 aroom 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 28 6720813171 2015 04 WORCESTER Bosch Group Installation WARNING N This appliance must be earthed Connectthe 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 NOTICE gt Connect the 230 Volt converter grey box via the pair of black low voltage cable to terminal WA 2 figure 48 gt Remove the grey cover of the 230 Volt converter 1 gt Feed the 230 V switch live and neutral from external controls through the cable gland gt Identify the 230 V terminal block by the hashed area and 230 VAC warning triangle gt Connect the switch live to terminal 1 and a neutral to terminal 2 2 NOTICE N gt Terminal 3 2 is not used es is 6 720 648 726 052 1TD Fig 52 Connection box 230 Volt connection 8 5 5 230V connections only for GB162 50 65 NOTICE T
112. ravene 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 amp 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
113. ream and downstream of the dirt filter gt Connect the flow pipe with a flat rubber seal installed to the CHF CH boiler flow connection 1 making sure it is not under stress Use a flow pipe with a minimum diameter of 1 gt 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 1 6 720 648 726 015 1TD Fig 15 Connecting the boiler flow and return 1 CH boiler flow 2 CH boiler return 3 Isolating valves 4 Drain cock 5 Gasvalve 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 alow 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 gt Install a isolating valve for maintenance and repair purposes in both the boiler flow and return circuits gt fig 15 3 Use isolating valves with a minimum diameter of 1 8 2 6 Installing the drain cock gt Connecta drain cock
114. rently measured system pressure in bar Also see section 14 2 page 53 Step7 Press the button Step 8 H Display code Operating phase The boiler is in flue gas test mode Also see section 14 3 page 54 Step9 Pressthe button Step 10 24 Display value Currently measured CH flow temperature in C Also see section 14 2 page 53 Step11 Have 30 minutes passed or has the mains voltage been interrupted Yes gt stepi No gt step12 Step12 Deactivate flue gas test Yes gt step 13 No gt step5 Step13 To deactivate the flue gas test Press and hold the amp button for more than 2 seconds until the dot disappears gt step 1 Table 10 Flue gas test Service Mode menu Step 1 gH Display value Currently measured CH flow temperature in C Also see section 14 2 page 53 Step2 Activate service mode Yes gt step3 No gt stepi Step3 To activate service mode 1st step Press and hold the button for more than 2 but not longer than 5 seconds Step4 24 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 96 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 Step5 To activate service mode 2nd step Simultaneously press and hold the
115. rician Connection to the free 230 VAC connection lead gt Unwind the 230 VAC cable 1 and route it out of the boiler 2 fig 55 PT TT 5 m li a 6 720 648 726 054 1TD Fig 54 230 VAC cable of the pump gt Cut the plug from the 230 VAC cable gt Connect the 230 VAC cable to the pump 6 720 648 726 055 1TD Fig 55 Route the 230 VAC pump cable 6720813171 2015 04 29 Installation WORCESTER Bosch Group Connection to the terminal strip of the boiler gt 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 e cy A 6 720 648 726 056 1TD Fig 56 Terminal strip external heating pump 230 V connection colour green Connecting the DHW pump Connectthe DHW pump to the grey PS terminal The maximum allowed connected load of the pump 250 Watts 6 720 648 726 057 1TD 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 PZ 6 720 648 726 058 1TD Fig 58 Terminal strip DHW pump 230 V connection colour grey Connecting to the mains il All Worcester boilers require a pe
116. rizontal flue pack gt 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 6 720 648 726 027 1TD Fig 27 Standard horizontal flue pack 415 mm 6 720 648 726 028 1TD Fig 28 Side flue and rear flue installation Standard vertical flue pack gt 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 6 720 648 726 029 1TD Fig 29 Standard vertical flue pack 6720813171 2015 04 21 Installation WORCESTER Bosch Group 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 gt fig 30 and fig 31 For flue length see table 6 z A I Vy SS EE L SS SSS
117. rmanent live 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 mm 24x 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 DANGER Danger of fatal accident due to electric shock N gt Disconnect the boiler from the mains power supply before working on the boiler 6 720 648 726 059 1TD Fig 59 Mains supply 8 5 6 Installing function modules accessories Refer to the installation instructions of the relevant function modules for information about installation and combination
118. rom 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 vvv v v DANGER N Danger of fatal accident from explosive fumes gt 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 N flue gas can escape if the air supply is insufficient gt Make sure that air vents are not reduced in size or obstructed gt The boiler may only be operated after the defect has been remedied gt Warn the user of the system of the defect verbally and in writing Thecondensing gas boiler may only be used with the combustion air flue gas systems designed and approved specifically for this type of boiler Note incertain 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 gt Dispose of the boiler s packaging material in an environmentally friendly manner gt Dispose of those components of the heating installation e g boiler or controll
119. rt 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 20 6720813171 2015 04 AWORCESTER Bosch Group Installation It is very important to ensure that products of il 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 If this could occur the appliance must be turned off and labelled as unsafe until corrective action can be taken DANGER gt Only use Worcester flue gas systems As other flue gas systems are not tested with this appliance 8 3 2 Air supply and flue gas exhaust ina room sealed installation Aventilation 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 toa 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 ho
120. sconnecting 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 logbook cece ee 52 14 Display information eesueeeeee eese 53 14 1 Removing the control panel from the boiler 53 14 2 Display readings 0 cece cece eee eee 53 14 3 BC10 Display settings 00 eee 54 14 4 BC10Display codes 0 cece cece eee eee 54 14 5 Re fit the control panel inthe boiler 60 15 Technical specifications ceeeeeeeeees 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 Warnings in this document are framed and identified by N a warning triangle which is printed on a grey background Electrical hazards are identified by a lightning symbol N surrounded by a warning triangle 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
121. sea connection tube to connect the positive port of the pressure gauge to the testing nipple for burner pressure gt fig 87 2 gt Slowly open the gas valve by pushing on the gas valve and turning it rotation in an anticlockwise direction gt fig 79 page 39 gt Switch on the heating system by pressing the mains switch of the BC10 basic controller fig 86 1 gt Activate the Service mode in accordance with the Service mode menu gt table 11 page 34 6720813171 2015 04 41 Commissioning WORCESTER Bosch Group gt Set the capacity to minimum part load according to the Service mode menu gt table 11 page 34 gt After the Burner LED gt fig 86 6 has lit up wait for one minute until the boiler is burning at part load gt Read the differential pressure during service mode The differential pressure pgas Pair must be 5 Pa 5 Pa indication on the pressure gauge 10 to 0 Pa DANGER Danger of fatal accident from explosive fumes gt Check the testing nipples used for gas tightness gt Only use approved leak detection products to locate leaks wrong right wrong 15 10 5 0 5 Pa 0 15 0 10 0 05 0 00 0 05 mbar turn anticlockwise turn clockwise WARNING N Damage to the installation due to short circuits gt Cover any hazardous locations prior to locating the leaks gt Donotspray the leak detection product on cable
122. sory sss 15 10 3 4 Switching DHW mode on off 008 44 8 2 3 Install the water and gas connections to the boiler 10 3 5 Setting the DHW temperature 005 44 withoutapumpgroup 2 cece cere eee eee 15 10 4 Finalactivities 0 0 cece cece eee eee eee 45 8 2 4 Installing the differential pressure controller 16 10 4 1 Closing the boiler door and the control panel 45 8 2 5 Installing the isolating valves 16 10 4 2 Handing over 00 ccc cece cece eee eee e ee 45 8 2 6 Installingthe drain cock issue 16 10 5 Commissioning record log book 45 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 11 Shutting down the heating system 46 8 2 10 Condensate removal sse 17 11 1 Shutting down the heating system using the 8 2 11 Connecting the condensate drain pipe 19 basic controller 2 eneeneneenennnnnnnenne 46 8 2 12 Connecting the expansion vessel in a single boiler 11 2 Shutting down the heating system if there is a risk SYSTEM cud E ne een 19 of freezing interruption ofuse 46 8 3 Flue Installation 0 c cece cece eee ee 20 8a siting EU A vast EEE 20 12 Inspection 2 2 un ee 46 8 3 2 Air supply and flue gas exhaust i
123. sting 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 43 o Measure the ionisation current 43 pA 12 Boiler settings 44 DO 13 Closing and locking the boiler door 45 O 14 Informing the user handing over technical documents 45 O Confirming proper commissioning Company stamp signature date Table 19 6720813171 2015 04 45 Shutting down the heating system WORCESTER Bosch Group 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 gt Push onthe control panel to open it 6 720 648 726 044 1TD Fig 96 Opening the control panel gt Switch off the heating system by pressing the mains switch of the BC10 1 6 720 648 726 069 1TD Fig 97 BC10 basic controller gt Close the main gas supply or the gas valve gt fig 81 page 39 11 2 Shutting down the heating system if there is a risk of freezing interruption of use WARNING Damage to the installation due to freezing The heating system may freeze up after some time in
124. tem in a room whichis free from frost WARNING N Fire hazard due to flammable materials or liquids gt Donotstore any flammable materials or liquids in the direct vicinity of the boiler gt Observe all statutory building regulations applying to the place of installation CAUTION Boiler damage due to contaminated combustion air or contaminated air in the boiler room gt 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 gt Insuch situations you must opt for a room sealed 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 ofthe 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 lea
125. tener down 2 and open the boiler door 3 gt Remove the insulation cover of the pump group 4 a 6 720 648 726 071 1TD 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 gt Turnthe cap of the automatic air vent through one rotation to loosen it ES 6 720 648 726 072 1TD 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 SYSTEM FILL Heating retum Non retum Non retum Hose valve valve Mains su Stop cock r TEmporay hose Test cok
126. then work your way up from floor to floor 6 720 648 726 077 1TD 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 acouple 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 Fillthe condensate trap with water 6 720 648 726 016 1TD 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 DANGER Danger of fatal accident from explosive fumes Pipes and fittings may leak after commissionin
127. ting the maximum CH flow temperature gt Set the upper CH flow temperature limit for heating mode gt table 17 using the Maximum CH flow temperature dial gt fig 97 8 heating system The setting at the BC10 cannot be adjusted viathe menu but must instead be set via the Maximum CH flow temperature dial gt fig 97 8 gt Limit the maximum CH flow temperature in the Settings menu in most cases 45 C gt Observe that the underfloor heating system must be equipped with a safety limiter e g via the external switching contact gt page 28 WARNING Damage to the installation due to N overheating the floor slab when using an underfloor This limit value does not apply to DHW mode 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 ofthe 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 10 3 3 Setting the pump run over time Setthe pump run over time to 24 hours if the heating system is controlled depending on room temperature and there is a risk of parts ofthe heating system not controlled by the room controller freezing e g radiators in the garage Setth
128. ube and tighten the screw plug on the testing nipple again gt Open the gas valve again by pushing on the gas valve and turning it rotation in an anticlockwise direction gt fig 79 page 39 10 2 7 Checking and adjusting the gas air ratio WARNING Damage to the boiler by incorrect adjustment of the gas N air ratio gt Adjust gas air ratio only with part load gt Adjust gas air ratio only based on the gas air pressure differential and never based on measured flue gas values such as CO CO NO Open atleast 2 thermostatic radiator valves Do not switch on the boiler gt Push on the control panel to open it gt fig 68 page 32 gt Switch off the heating system by pressing the mains switch of the BC10 basic controller gt fig 86 1 gt Close the gas valve gt fig 81 page 39 gt Turn the vent key through a quarter rotation to undo the boiler door lock 2 fig 71 see detailed picture page 37 gt Push the fastener down and open the boiler door gt fig 71 page 37 gt Open the screw plug on the testing nipple for the burner pressure by 2 turns 1 gt Set the pressure gauge to 0 GB162 50 65 6720813171 2 1TD Fig 87 Checking the gas air ratio Throughout the measuring operation keep the digital pressure gauge in the same position horizontal or vertical in which it was reset to 0 gt U
129. valves Do not switch on the boiler gt Push on the control panel to open it gt fig 68 page 32 gt Switch off the power supply to the heating system gt fig 90 6 720 648 726 080 1TD Fig 84 Switch off the power supply to the heating system gt Close the gas valve in a clockwise direction gt fig 81 page 39 gt Turn the vent key through a quarter rotation to undo the boiler door lock gt fig 71 see detailed picture page 37 gt Push the fastener down and open the boiler door gt fig 71 page 37 gt Open the screw plug on the testing nipple for the gas hook up pressure and for purging by 2 turns 1 gt Reset the digital pressure gauge to 0 Throughout the measuring operation keep the digital il pressure gauge in the same position horizontal or vertical in which it was reset to 0 gt Connect the pressure gauge connection tube to the positive port of the testing nipple 2 LI 6 720 648 726 085 1TD Fig 85 Measuring the gas supply pressure gt Slowly open the gas valve by pushing on the gas valve and turning it rotation in an anticlockwise direction gt fig 79 page 39 The gas valve is open when it is in the vertical position gt Switchonthe heating system by pressing the mains switch 1 of the BC10 basic controller 40 6720813171 2015 04 WORCESTER Bosch Group Co
130. way valve complete 20373 129 Check valve 7146900606 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 3x 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 7101422 following spare parts Cap flue gas adapter DN 160 80 7101418 Seal DN 110 7101492 Seal DN 160 7101494 6720813171 2015 04 67 Bosch Group WORCESTER Technical specifications Exploded view GB162 50 65 6 720 648 726 126 1TD 6720813171 2015 04 68 WORCESTER Bosch Group Technical specifications Exploded view pump group with DHW GB162 50 65 6 720 648 726 127 1TD 6720813171 2015 04 69 WORCESTER Bosch Group Notes 70 6720813171 2015 04 WORCESTER Bosch Group Notes 6720813171 2015 04 71 Worcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 0330 12
131. y 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 Wh 0 Maximum volume flow Wh 5 000 CH boiler flow temperature C 30 90 can be set on the BC10 basic controller Resistance at ATo9 mbar 90 170 225 320 Max boiler working pressure bar 4 Content of heating circuit heat exchanger 5 Pipe connections Gas connection inch G1 Heating water connection inch G1 union nut with female thread enclosed Condensate water connection mm 924 Flue gas values Condensate water quantity for natural gas G20 40 30 C Wh 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 21 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 5 57 61 57 Flue gas temperature 50 30 C fullload C 43 43 48 51 Flue gas temperature 50 30 C part load C 33 33 34 34 CO 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 lg G61 9 flue gas system room air dependent mm 100 or 2110 0100 with air intake strainer basket accessory flue gas system room air independent mm standard 080 125 standard 100 150 concentric concentric Electri

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