Worcester GB162-65 Installation And Servicing Instruction
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Worcester GB162-65 Installation And Servicing Instruction

Wall hung gas fired condensing boiler
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See also: Instructions for Installation and Servicing , Instructions for Using
INSTALLATION AND SERVICING INSTRUCTIONS
WALL HUNG GAS FIRED CONDENSING BOILER
WORCESTER COMMERCIAL BOILER SERIES
GB162-65/80/100
FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER

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  • Page 1 INSTALLATION AND SERVICING INSTRUCTIONS WALL HUNG GAS FIRED CONDENSING BOILER WORCESTER COMMERCIAL BOILER SERIES GB162-65/80/100 FOR CENTRAL HEATING SYSTEMS AND INDIRECT FED DOMESTIC HOT WATER...
  • Page 2 PRODUCT OVERVIEW PRODUCT OVERVIEW 6 720 648 726-001.1TD Fig. 1 GB162-65/80/100 with pump group 6 720 648 726 (2011/07)
  • Page 3 PRODUCT OVERVIEW BC10 basic controller holder Installation option for room controller, e.g. RC35 BC10 basic controller, can be expanded e.g. by the RC35 room controller Connection box (low-voltage and 230V connections) Fan harness and mains lead of the pump Condensate drain outlet Condensate collector Boiler front door Automatic air vent...

  • Page 4: Table Of Contents

    ..... . .33 Please observe these instructions ..14 8.5.5 230 V connections (only for GB162-65) . . 36 Tools, materials and further equipment . 14 8.5.6 Installing function modules (accessories) 37...
  • Page 5 15.1 Spare parts list GB162-80/100 ..85 15.2 Spare parts list GB162-65 ... . 89 Index ....... . . 93...

  • Page 6: Key To Symbols And Safety Instructions

    WARNINGS INSTALL CORRECTLY COULD LEAD TO PROSECUTION. Warnings in this document are framed and IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER identified by a warning triangle which is TECHNICAL HELPLINE (0844 892 3366). printed on a grey background.

  • Page 7: Safety Instructions

    KEY TO SYMBOLS AND SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS Mains Cold Water IF YOU SMELL GAS: Neutral B CALL NATIONAL GAS EMERGENCY SERVICE ON Natural Gas 0800 111 999 Negative Temperature Coefficient (sensor) B LPG BOILERS CALL THE SUPPLIER‘S NUMBER ON THE SIDE OF THE LPG TANK Junction Box / 230 Volt Converter B TURN OFF THE ECV (EMERGENCY CONTROL VALVE)
  • Page 8 KEY TO SYMBOLS AND SAFETY INSTRUCTIONS IMPORTANT BS6880 Code of practice for low temperature hot water heating systems for output greater The service engineer must complete the Service Record than 45 kW. on the Installation Checklist after each service. BS6891 Installation of low pressure gas pipe work up INSTALLATION REGULATIONS to 35 mm (R1¼“) in domestic premises (2nd...
  • Page 9 BS 7671. way, as overriding statutory obligations. Compartment Installations The design and construction of the Worcester Wall hung A compartment used to enclose the boiler should be gas fired condensing boiler conforms to the basic designed and constructed especially for this purpose. An...
  • Page 10 Potable water: mounted condensing gas system boilers must only be All seals, joints and compounds (including flux and used with Worcester flue gas systems, which are solder) and components used as part of the secondary certified with this type of boiler.

  • Page 11: General

    The GB162-65/80/100 is suitable for use as a single boiler or as part of a cascade system. The boiler is suitable for connection to fully pumped, sealed water systems ONLY.

  • Page 12: Regulations And Directives

    The pH of the heating system water MUST be between 7 B Do not store any flammable materials or and 8.5. If this is not the case, please contact Worcester liquids in the direct vicinity of the boiler. Customer Service before proceeding.

  • Page 13: Quality Of The Pipework

    REGULATIONS AND DIRECTIVES CAUTION: Boiler damage due to corrosion. B If the boiler is used in systems with gravitation circulation or in open systems, the boiler circuit must be isolated from the rest of the system by means of a (plate-type) heat exchanger. QUALITY OF THE PIPEWORK When using plastic pipework in the heating system, e.

  • Page 14: Safety

    SAFETY SAFETY Please observe these instructions for your own safety. DANGER: Danger of fatal accident due to poisoning. PLEASE OBSERVE THESE Dangerous flue gas can escape if the air INSTRUCTIONS supply is insufficient. Observe the following instructions when installing and B Make sure that air vents are not reduced operating the heating system: in size or obstructed.

  • Page 15: Transport

    TRANSPORT 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 impacts. B During further transport all parts must be protected against impacts.

  • Page 16: Items Supplied With Boiler

    ITEMS SUPPLIED WITH BOILER ITEMS SUPPLIED WITH BOILER The boiler is delivered factory-assembled. B Check that the packaging is intact upon delivery. B Check that all items have been supplied with the boiler. 6 720 648 726-005.1TD Fig. 5 Items supplied with unit Boiler assembly Wall bracket Condensate trap with condensate trap hose...

  • Page 17: Dimensions Of Boiler

    CH (boiler) return; G1½’’ union nut with female thread Cap (DO NOT remove) FGC/AIC Flue gas/air intake connection: Ø 80/125 for GB162-65 and Ø 100/150 for GB162-80/100 Gas connection to boiler; G1’’ female thread The servicing clearances required are: • in front: 50 mm •...
  • Page 18 CH (boiler) flow; G1½’’ union nut with female thread CH (boiler) return; G1½’’ union nut with female thread Cap (DO NOT remove) FGC/AIC Flue gas/air intake connection: Ø 80/125 for GB162-65 and Ø 100/150 for GB162-80/100 GAS B Gas connection to boiler; G1’’ female thread GAS P Gas connection to pump group;...

  • Page 19: Installation

    INSTALLATION INSTALLATION This section explains how to install the boiler in a B With two people, lift the boiler by holding it by its professional manner. back and by the transport rail at its bottom and install it on the wall bracket ( fig.

  • Page 20: General Connection Of Mains Water And Gas Components

    INSTALLATION 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.
  • Page 21 INSTALLATION INSTALLING THE GAS CONNECTION B Install the gas valve [2] onto the gas pipe. Use a gas valve with a minimum diameter of 1". DANGER: Danger of fatal accident from explosive fumes. B Make sure that the factory-fitted flat rubber seal is located in the threaded connection (boiler side) ( fig.

  • Page 22: Installing The Differential Pressure

    Select a pump with a residual head of at Drain cock least 200 mbar at the minimum required Gas valve volume flow ( table 4). Pressure relief valve Condensate trap Pump GB162-65 GB162-80 GB162-100 Non-return valve Dirt filter 3,000 3,600 4,300 Δ...

  • Page 23: Installing The Condensate Trap

    INSTALLATION 8.2.9 INSTALLING THE CONDENSATE TRAP B Connect the condensate trap hose [3] and the rubber sleeve [2] to the condensate trap [1]. DANGER: Danger of fatal accident due to poisoning. B If the condensate trap is not filled with water, flue gas can escape and put people's lives at risk.
  • Page 24 INSTALLATION TERMINATION TO INTERNAL PIPE The condensate drain pipe should have a minimum outside diameter of Ø21.5 mm with no length restriction. It should incorporate a trap with a 75 mm condensate seal and be connected to the stack at a point at least 450 mm above the invert of the stack.

  • Page 25: Connecting The Condensate Drain Pipe

    INSTALLATION When discharging condensate to an outside drain caution must be taken to ensure blockage cannot occur during freezing conditions. If this is likely to occur, the use of a condensate trap is recommended. Ø21.5 mm min. 1000 mm min. 6 720 648 726-024.1TD Fig.

  • Page 26: Flue Installation

    INSTALLATION FLUE INSTALLATION 8.3.1 SITING THE FLUE TERMINAL H, I 6 720 648 726-026.1TD Fig. 26 Balanced flue terminal position Terminal position Minimum spacing: Directly below, above or alongside an opening window, air vent or other ventilation opening 300 mm Below guttering, drain pipes or soil pipes 200 mm Below eaves...

  • Page 27: Air Supply And Flue Gas Exhaust In A Room Sealed Installation

    • Wall clamp. system, it is vital that it is always installed correctly. To ensure optimal operation, the appliances must be connected to a Worcester horizontal or vertical flue terminal. These terminals have been developed specifically for Worcester condensing gas boilers and have been comprehensively tested for trouble free operation when correctly installed.

  • Page 28: Maximum Flue Length (L)

    INSTALLATION 8.3.3 MAXIMUM FLUE LENGTH (L) 8.3.4 ADDITIONAL FLUE PARTS The maximum pipe length (L) of the air supply and flue The additional flue parts listed can be ordered from your gas exhaust pipes for the condensing gas system boilers supplier.

  • Page 29: Installation Of The Horizontal Flue

    INSTALLATION 8.3.6 INSTALLATION OF THE HORIZONTAL FLUE B Mark off the lengths shown onto the pipe and cut to length. The cuts must be square and free from burrs. The standard flue is suitable for lengths up to 660 mm Terminal assembly outer (air) pipe - L-70 mm, inner fig.

  • Page 30: Flue Gas Connection

    An air intake strainer basket can be used for operation 90° bend dependent on room air. This prevents falling dirt from Length=21m Pipe=2m entering the boiler (contact Worcester Technical; accessory). 8.4.2 ROOM SEALED OPERATION 90° bend The boiler can be connected to a concentric flue gas...

  • Page 31: Electrical Wiring Diagram

    Connection to the external pump is only possible if no internal pump external 230V controls has been integrated in the connection kit. b) The 230 Volt converter is only applicable for Logamax plus GB162-65 230 Volt converter Fig. 37 Electrical wiring diagram...

  • Page 32: Terminal Strip Connections

    Routing the cable components must be connected to which terminals (see section 7.5.4, page 36). If uncertain how to connect controls to this appliance, first contact the Worcester technical helpline on 0844 892 3366 or your supplier. 6 720 648 726 (2011/07)

  • Page 33: Description Of The Terminal Strip Connections

    (connection colour red) (thermal protection) Connection for external three-way valve External heating pump 230 V (connection colour green) (for use with non Worcester pump group) DHW pump 230 V (connection colour grey) DHW Circulation pump 230 V (connection colour lilac) Mains connection 230 V AC (connection colour white) 6 720 648 726-044.1TD...
  • Page 34 INSTALLATION CONNECTING THE POTENTIAL-FREE HEAT DEMAND If you install the room controller (e.g. RC35) B Connect the potential-free heat demand contact to in the boiler, only outdoor temperature- the green WA terminal ( fig. 48). The maximum controlled operation is possible. See the allowed resistance of this circuit is 100 ohms.
  • Page 35 DHW temperature sensor in the CONNECTING EXTERNAL 230 V CONTROLS WITH USE boiler. It is only possible to connect a OF THE 230 VOLT CONVERTER (ONLY FOR GB162-65) DHW temperature sensor which is suitable for this boiler. The gas wall hung boiler condensing can be fitted with the following external controls: •...

  • Page 36: Connections (Only For Gb162-65)

    INSTALLATION 8.5.5 230 V CONNECTIONS (only for GB162-65) CONNECTION TO THE FREE 230 VAC CONNECTION LEAD NOTE: B Unwind the 230 VAC cable [1] and route it out of the The 230V connections can only be used with boiler ( fig.

  • Page 37: Installing Function Modules (Accessories)

    6 720 648 726-058.1TD Fig. 58 Terminal strip - DHW pump 230V (connection colour grey) CONNECTING TO THE MAINS All Worcester boilers require a permanent live. 6 720 648 726-059.1TD Fig. 59 Mains supply A mains supply of 230 V - 50Hz is required.
  • Page 38 INSTALLATION INSTALLING AND CONNECTING FUNCTION MODULES B Remove the covers of both free connectors on the (ACCESSORIES) IN THE BOILER function module connection cables. B Loosen the screw (step 1). B Slide the draw back into the boiler. B Pull open the draw (step 2). 6 720 648 726-060.1TD 6 720 648 726-063.1TD Fig.
  • Page 39 INSTALLATION B Connect the 230 V AC mains cable of the first module INSTALLING AND CONNECTING FUNCTION MODULES to the next module. OUTSIDE THE BOILER B Install the module on the wall. The module may have the letters RC or EMS B Make a sufficiently long EMS bus connection cable, above the connection [1].

  • Page 40: Operation

    If the boiler stops due to a fault again after resetting the fault, the fault can be remedied using the Service instructions. Contact Worcester if necessary. See the back of this document for contact details. "CHIMNEY SWEEP" BUTTON The "Chimney sweep" button ([3] is used to put the 6 720 648 726-044.1TD...

  • Page 41: Bc10 Control Operating Instructions

    "BC10 Display codes", page 71. The menu structure consists of 5 menus: SERVICE TOOL CONNECTION • Normal Operation menu This service connection is for Worcester service • Flue Gas Test menu engineers only. • Service Mode menu • Manual Operation menu "BURNER"...
  • Page 42 OPERATION Normal operation menu [\/2/4| Step 1 Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 70. Step 2 Continue in Normal operation menu? Yes: step 3 step 1 Step 3 Press the button. [p/1.6| Step 4 Display value.
  • Page 43 OPERATION Service Mode menu [\/2/4| Step 1 Display value. Currently measured CH flow temperature in °C. Also see section 14.2, page 70. Step 2 Activate service mode? Yes: step 3 step 1 Step 3 To activate service mode 1st step: Press and hold the button for more than 2 but not longer than 5 seconds [\/2/4]...
  • Page 44 OPERATION Service Mode menu [\/2/4| Step 20 Display value. Currently measured CH flow temperature in °C. Also see section 14.3, page 71. Step 21 Have 30 minutes passed or has the mains voltage been interrupted? Yes: step 22 step 23 Step 22 Service mode is deactivated.
  • Page 45 OPERATION Manual operation menu Step 11 Has there been a power failure? Yes: step 1 step 12 Step 12 Deactivate manual operation? Yes: step 13 step 5 Step 13 To deactivate manual operation: step 1 Press and hold the button for more than 2 seconds until the dot disappears. Table 12 Manual operation Settings menu [\/2/4|...
  • Page 46 OPERATION Settings menu [c/\/1| Step 12 Display setting. Set the third parameter as soon as the display shows [c/\/1|. This parameter indicates the DHW mode status setting. This enables DHW mode to be switched off or on. This setting has priority over other DHW mode settings, such as those made on the room thermostat.

  • Page 47: Commissioning

    If a fault occurs, then refer to the servicing undo the boiler door lock ( detailed picture). manual or contact Worcester. B Push the fastener down [2] and open the boiler door [3]. This section explains how to start up the boiler.
  • Page 48 COMMISSIONING Filling and refilling of the heating circuit must have been B Open the heating flow and return isolating valves on carried out by a method that has been approved by the the pump group (open position: parallel to the pipe). Water Regulation Advisory Scheme (WRAS), for the type of heating appliances, i.e.

  • Page 49: Filling The Condensate Trap With Water

    COMMISSIONING 10.2 TESTING AND MEASURING B Purge the heating system via the air vents on the radiators. Start at the lowest floor of the premises 10.2.1 CHECKING FOR GAS LEAKS and then work your way up from floor to floor. Prior to the initial start-up check that the gas supply pipework is gas-tight;...

  • Page 50: Bleeding The Gas Flow Pipe

    B Switch off the power supply to the heating system. NOTE: B Test the tightness of the measuring nipple(s) used. GB162-65 6 720 648 726-080.1TD Fig. 80 Switch off the power supply to the heating system B Check the new pipe section up to and including its connection (i.e.

  • Page 51: Checking The Flue Gas Connection

    Boiler Type of gas supply diameter [mm] (WORKING PRESSURE) B Open at least two thermostatic radiator valves. Do not GB162-65 Natural gas H Venturi switch on the boiler. LPG 3P B Push on the control panel to open it ( fig.

  • Page 52: Checking And Adjusting The Gas/Air-Ratio

    COMMISSIONING B Open the screw plug on the testing nipple for the gas B Press the "Chimney sweep" button [3] to clear the hook-up pressure and for purging by 2 turns [1]. reading. Also see table 10, "Flue gas test", page 50. B Reset the digital pressure gauge to "0".
  • Page 53 B Set the pressure gauge to "0". the "Service mode" menu ( table 11, page 43). GB162-65 B After the "Burner" LED ( fig. 86, [6]) has lit up wait for one minute until the boiler is burning at part load.

  • Page 54: Carrying Out A Leakage Test In Operating Conditions

    COMMISSIONING B Press the "Chimney sweep" button ( fig. 86, [3]) 10.2.8 CARRYING OUT A LEAKAGE TEST IN until the dot disappears from the display. OPERATING CONDITIONS B Switch off the heating system by pressing the mains DANGER: Danger of fatal accident from switch of the BC10 basic controller ( fig.

  • Page 55: Measuring The Flue Gases Co

    COMMISSIONING 10.2.9 MEASURING THE FLUE GASES CO B Switch off the heating system by pressing the mains EMISSIONS switch of the BC10 basic controller fig. 90, [1]). B Open at least 2 thermostatic radiator valves. Do not B Remove the flue gas analyser and fit the cover back switch on the boiler.

  • Page 56: Boiler Settings

    B Set the required heating capacity on the BC10 according to the "Settings" menu ( table 13, page 45). See table 16 when making these settings. Display Rated heating capacity at 40/30 °C [kW] indication GB162-65 GB162-80 GB162-100 15.6 – 21.1 18.7 21.1...

  • Page 57: Setting The Maximum Ch Flow Temperature

    COMMISSIONING 10.3.2 SETTING THE MAXIMUM CH FLOW 10.3.5 SETTING THE DHW TEMPERATURE TEMPERATURE B Set the DHW temperature dial ( fig. 94, [10]) to the B Set the upper CH flow temperature limit for heating required temperature of the hot water in the hot mode ( table 17) using the "Maximum CH flow water cylinder (...

  • Page 58: Final Activities

    COMMISSIONING 10.4 FINAL ACTIVITIES 10.4.2 HANDING OVER After completing the installation and commissioning of 10.4.1 CLOSING THE BOILER DOOR AND THE the system the installer should hand over to the end user CONTROL PANEL by the following actions. B Close the boiler door and lock the fastener by turning B Hand over all relevant documentation to the end user the vent screw through ¼...

  • Page 59: Commissioning Record Log Book

    COMMISSIONING 10.5 COMMISSIONING RECORD LOG BOOK B Enter your signature and the date after completing the start-up activities. Measurement Start-up activities Page results Remarks Filling and pressure testing the heating system. • Pre-pressure expansion vessel (refer to the _____________bar installation instructions for the expansion vessel) _____________bar •...

  • Page 60: Shutting Down The Heating System

    SHUTTING DOWN THE HEATING SYSTEM SHUTTING DOWN THE HEATING SYSTEM 11.1 SHUTTING DOWN THE HEATING 11.2 SHUTTING DOWN THE HEATING SYSTEM USING THE BASIC SYSTEM IF THERE IS A RISK OF CONTROLLER FREEZING (INTERRUPTION OF USE) Shut down your heating system by means of the BC10 WARNING: Damage to the installation due basic controller.

  • Page 61: Of Use)

    INSPECTION INSPECTION B The activities to be included in an annual inspection DANGER: and maintenance contract can be found in the Danger of fatal accident from explosive inspection and service record log book ( pages 63 fumes. and 69). B Only carry out work on gas pipes and WARNING: Damage to the installation due fittings if you are Gas Safe / ACS to insufficient or improper cleaning and...

  • Page 62: Gas Valve Leakage Test

    INSPECTION 12.8 CARRYING OUT A LEAKAGE TEST IN B Replace any pipes that have corroded. OPERATING CONDITIONS B Carry out a visual inspection of the burner, heat exchanger, condensate trap, automatic air vent and See section 10.2.8 "Carrying out a leakage test in all fittings in the boiler.

  • Page 63: Inspection Log Book

    INSPECTION 12.12 INSPECTION LOG BOOK B Enter your signature and the date after completing the inspection activities. Inspection activities Date: ________ Date: ________ Date: ________ Checking the general condition of the heating system. Carrying out a visual inspection and function test of the heating system. Checking the gas and water-bearing Section 10.2.8, system components for:...

  • Page 64: Maintenance

    4 connectors [2] from the gas valve. boiler door and remove it together with the washer. B Slightly lift the door and pull it from the hinge. Put the GB162-65 door upright in a safe position and make sure that it cannot fall over.

  • Page 65: Removing The Burner Cover With The Fan And The Gas Valve

    B Pull the mains connector [1] from the fan. B Pull the connector of the harness [2] from the fan while pushing on the connector lock to loosen it. GB162-65 GB162-80/100 6 720 648 726-107.1TD Fig. 107 Pulling the air suction tube from the fan B Carefully open the 4 snap closures on the burner cover.

  • Page 66: Removing The Burner And The Burner Seal

    MAINTENANCE 13.2.3 REMOVING THE BURNER AND THE BURNER SEAL B Remove the burner seal [1] and replace it if necessary. B Remove the burner plate [2] and clean it on all sides using compressed air or a soft brush. When re-installing the burner plate make sure that the notch is on the right-hand side ( detailed picture).

  • Page 67: Removing The Condensate Collector

    MAINTENANCE B Disconnect the condensate trap from the coupling B Pull the condensate collector down (step 1) and and remove it [1]. remove it by pulling it towards you (step 2). 6 720 648 726-114.1TD Fig. 114 Disconnecting the condensate trap in the pump group 6 720 648 726-116.1TD Fig.

  • Page 68: Cleaning The Heat Exchanger

    MAINTENANCE 13.2.7 CLEANING THE HEAT EXCHANGER B Reassemble all boiler components in reverse order: – Burner with burner seal CAUTION: Damage to the installation. – Burner cover with fan and gas valve B Do not use metal brushes or similar hard –...

  • Page 69: Service Record Log Book

    MAINTENANCE 13.5 SERVICE RECORD LOG BOOK Complete the log book while carrying out needs-oriented maintenance. B Enter your signature and the date after completing the maintenance activities. Needs-oriented maintenance Date: Date: Date: Date: Date: activities Page ________ ________ ________ ________ ________ Cleaning the burner, heat exchanger and condensate trap...

  • Page 70: Display Information

    For exact troubleshooting instructions please refer to the boiler service instructions. You may also contact Worcester technical support (0844 693 3028) 14.1 REMOVING THE CONTROL PANEL FROM THE BOILER To make it easier to use the buttons on the control panel...

  • Page 71: Bc10 Display Settings

    DISPLAY INFORMATION 14.3 BC10 DISPLAY SETTINGS Display settings Factory Display adjusted setting Meaning of display setting Unit Range setting [l/9/9| [l/2/0| [l/9/9| [l/-/-| [l/-/-| Configured target load (65 kW). – 100 % [l/9/9| [l/2/5| [l/9/9| [l/-/-| [l/-/-| Configured target load (80 kW). –...
  • Page 72 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [-/h/} [2/0/0| Operating phase: The room temperature is too The boiler is in manual operation mode. high.
  • Page 73 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [0/y/\| [2/0/4| Operating phase: The room temperature is not The flow temperature sensor has detected possibly reached. that the current flow temperature is higher than the flow temperature setting on the BC10, or that it is higher than the flow...
  • Page 74 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [2/p/\| [2/1/2| Fault: 4) 5) The flow temperature sensor has measured a heating water temperature increase of over 5 °C/s.
  • Page 75 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [4/c/\| [2/2/4| Fault: flashing No heating operation 1 Hz and no DHW. 5) 6) There is no bridging cable between contacts 7) 8) 22 and 24 of the UBA 3 contact strip.
  • Page 76 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [6/c/\| [3/0/6| Fault: flashing No heating operation 1 Hz and no DHW. 5) 6) An ionisation current has been measured 7) 8) after the burner shut down.
  • Page 77 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [9/h/\| [2/7/2| Fault: flashing No heating operation 1 Hz and no DHW. 5) 6) The UBA 3 or the KIM is defective. 7) 8) [9/l/\| [2/3/4|...
  • Page 78 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [a/0/1| [8/1/1| Fault: Thermal disinfection was interrupted. Thermal disinfection has failed. Outlet flow during disinfection period too high, sensor lead broken or shorted, sensor connected incorrectly or defective, filling pump defective.
  • Page 79 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [a/1/1| [8/2/3| Fault: Since there is no actual room RC35-HK1 remote control. No remote temperature control assigned, although frost protection information, room type "FROST"...
  • Page 80 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [a/1/8| [8/2/5| Fault: Both RC35 and RC25 activate heating Conflicting addresses. Both RC25 and RC35 circuit 1 and DHW. are registered as Master.
  • Page 81 DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [a/2/2| [8/1/6| Fault: Since there is no actual room RC25-HK2 communication. RC25 addressed temperature incorrectly, wired incorrectly or defective. information, room influence and optimization of the...

  • Page 82: Re-Fit The Control Panel In The Boiler

    DISPLAY INFORMATION Display codes Display code LED on Other effects UBA 3 Main Reset display display Key to display code requi- code code red? [h/\/7| Operating phase: Possibly no heating operation or no DHW The system pressure is too low (less than available.

  • Page 83: Technical Specifications

    TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS The technical specifications serve to provide information about the boiler performance profile. Unit GB162-65 GB162-80 GB162-100 Rated thermal load for G20 14.6 - 62.0 19.3 - 82.0 19.3 - 96.5 Rated heating capacity, heating curve (80/60 °C) 14.2 - 60.5...
  • Page 84 TECHNICAL SPECIFICATIONS Unit GB162-65 GB162-80 GB162-100 Electrical data Mains connection voltage Electrical protection rating IP X4D (B ; IP X0D) Electrical power consumption, full load (without a pump group) Electrical power consumption, partial load (without a pump group) Boiler dimensions and weight Height ×...

  • Page 85: Spare Parts List Gb162-80/100

    TECHNICAL SPECIFICATIONS HYDRAULIC RESISTANCE OF THE BOILER 100 kW 80 kW 65 kW Volume flow [l/h] 6 720 648 726-123.1TD Fig. 123 Boiler resistance curve 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.
  • Page 86 TECHNICAL SPECIFICATIONS Description Product No. Description Product No. Screw M5 x 20 (10 pc) 73572s Electronic connection orange 73777 Screw M5 x 16 (10 pc) 73970 Flue gas exhaust connection 73940 Screw M6 x 16 (10 pc) 73971 Flue gas adapter 73936 Air inlet pipe –...
  • Page 87 TECHNICAL SPECIFICATIONS EXPLODED VIEW GB162-80/100 44 45 6 720 648 726-124.1TD 6 720 648 726 (2011/07)
  • Page 88 TECHNICAL SPECIFICATIONS EXPLODED VIEW PUMP GROUP GB162-80/100 6 720 648 726-125.1TD 6 720 648 726 (2011/07)

  • Page 89: Spare Parts List Gb162-65

    TECHNICAL SPECIFICATIONS 15.2 SPARE PARTS LIST GB162-65 For a pictorial representation of the part see the respective position number on the exploded view pictures on page 91 and 92. Description Product No. Description Product No. Screw M6 x 16 (10 pc)
  • Page 90 TECHNICAL SPECIFICATIONS Description Product No. Description Product No. Electronic connection orange 73777 Repair set three way valve 1”+ 75400 5/4” Flue gas exhaust connection 7746900414 Valve housing supply (single) 74547 Flue gas adapter 73936 Valve housing supply (combi) 74548 Measure nipple cap 73937 Valve housing return (single) 74549...
  • Page 91 TECHNICAL SPECIFICATIONS EXPLODED VIEW GB162-65 44 45 6 720 648 726-126.1TD 6 720 648 726 (2011/07)
  • Page 92 TECHNICAL SPECIFICATIONS EXPLODED VIEW PUMP GROUP WITH DHW GB162-65 6 720 648 726-127.1TD 6 720 648 726 (2011/07)

  • Page 93: Index

    INDEX INDEX Symbols ...................."DHW mode" LED Inspection log book .................."Heat demand" LED Installation distances ..........Ionisation current ......Ambient temperature, maximum ................Appliance configuration Manual Operation menu ................... BC10 basic controller Normal Operation menu ...........
  • Page 94 INDEX NOTES 6 720 648 726 (2011/07)
  • Page 95 INDEX NOTES 6 720 648 726 (2011/07)
  • Page 96 01905 752571 LITERATURE: 0844 892 9800 TRAINING: 01905 752526 SALES: 01905 752640 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0844 892 9900 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 648 726...

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