Table Of Contents - Worcester GB162-65 Installation And Servicing Instruction

CONTENTS
CONTENTS
1 Key to symbols and safety instructions . . . . . . . 6
1.1 Explanation of symbols . . . . . . . . . . . . . . . 6
1.2 Safety instructions . . . . . . . . . . . . . . . . . . 7
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Regulations and directives . . . . . . . . . . . . . . . . 12
3.1 Designated use . . . . . . . . . . . . . . . . . . . . 12
3.2 Boiler room . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Combustion air flue gas connection . . . . 12
3.4 Quality of the heating system water . . . . 12
3.5 Quality of the pipework . . . . . . . . . . . . . . 13
3.6 Maintenance schedule . . . . . . . . . . . . . . 13
3.7 Applicability of regulations . . . . . . . . . . . 13
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Please observe these instructions . . . . . 14
4.2 Tools, materials and further equipment . 14
4.3 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Lifting and carrying the boiler . . . . . . . . . 15
5.2 Transporting the boiler with a trolley . . . 15
6 Items supplied with boiler . . . . . . . . . . . . . . . . 16
7 Dimensions of boiler . . . . . . . . . . . . . . . . . . . . . 17
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.1 Installing the boiler . . . . . . . . . . . . . . . . . 19
8.2 General connection of mains water
and gas components
8.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2.2 Install the water and gas connections
to the boiler using a pump group
(accessory) . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2.3 Install the water and gas connections
to the boiler without a pump group . . . . . 20
8.2.4 Installing the differential pressure
controller . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2.5 Installing the isolating valves . . . . . . . . . 22
8.2.6 Installing the drain cock . . . . . . . . . . . . . 22
8.2.7 Installing a pressure relief valve . . . . . . . 22
8.2.8 Selecting and installing the pump . . . . . . 22
8.2.9 Installing the condensate trap . . . . . . . . 23
8.2.10 Condensate removal . . . . . . . . . . . . . . . . 23
8.2.11 Connecting the condensate drain pipe . . 25
8.2.12 Connecting the expansion vessel
in a single-boiler system . . . . . . . . . . . . . . 25
8.3 Flue Installation . . . . . . . . . . . . . . . . . . . . 26
8.3.1 Siting the flue terminal . . . . . . . . . . . . . . 26
4
. . . . . . . . . . . . . . . . 20
8.3.2 Air supply and flue gas exhaust in
a room sealed installation . . . . . . . . . . . . .27
8.3.3 Maximum Flue length (L) . . . . . . . . . . . . . 28
8.3.4 Additional flue parts . . . . . . . . . . . . . . . . 28
8.3.5 Standard 100 mm flue systems . . . . . . . . 28
8.3.6 Installation of the horizontal flue . . . . . . . 29
8.3.7 Flue pipe preparation and assembly . . . . 29
8.4 Flue gas connection . . . . . . . . . . . . . . . . . 30
8.4.1 Open flue operation . . . . . . . . . . . . . . . . . 30
8.4.2 Room sealed operation . . . . . . . . . . . . . . 30
8.4.3 Flue material . . . . . . . . . . . . . . . . . . . . . . 30
8.4.4 Calculating the air intake and flue
gas pipe dimensions . . . . . . . . . . . . . . . . .30
8.5 Electrical connections . . . . . . . . . . . . . . . 30
8.5.1 Electrical wiring diagram . . . . . . . . . . . . . 31
8.5.2 Terminal strip connections . . . . . . . . . . . 32
8.5.3 Routing the cable through the boiler . . . . 32
8.5.4 Description of the terminal strip
connections . . . . . . . . . . . . . . . . . . . . . . .33
8.5.5 230 V connections (only for GB162-65) . . 36
8.5.6 Installing function modules (accessories) 37
9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1 General items . . . . . . . . . . . . . . . . . . . . . 40
9.2 BC10 control operating instructions . . . . 41
10 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1 Filling the heating system . . . . . . . . . . . . 47
10.1.1 Filling the heating system . . . . . . . . . . . . 47
10.1.2 Filling the condensate trap with water . . 49
10.2 Testing and measuring . . . . . . . . . . . . . . . 49
10.2.1 Checking for gas leaks . . . . . . . . . . . . . . . 49
10.2.2 Bleeding the gas flow pipe . . . . . . . . . . . 50
10.2.3 Gas consumption test . . . . . . . . . . . . . . . 50
10.2.4 Checking the flue gas connection . . . . . . 51
10.2.5 Checking the appliance configuration . . . 51
10.2.6 Measuring the gas inlet pressure
(working pressure) . . . . . . . . . . . . . . . . . .51
10.2.7 Checking and adjusting the gas/air-ratio . 52
10.2.8 Carrying out a leakage test in
operating conditions . . . . . . . . . . . . . . . . .54
10.2.9 Measuring the flue gases CO
10.2.10 Carrying out a function test . . . . . . . . . 55
10.2.11 Measuring the ionisation current . . . . . 55
10.3 Boiler settings . . . . . . . . . . . . . . . . . . . . . 56
10.3.1 Setting the heating capacity . . . . . . . . . . 56
10.3.2 Setting the maximum CH flow
temperature . . . . . . . . . . . . . . . . . . . . . . .57
10.3.3 Setting the pump run-over time . . . . . . . . 57
10.3.4 Switching DHW mode on/off . . . . . . . . . . 57
10.3.5 Setting the DHW temperature . . . . . . . . . 57
10.4 Final activities . . . . . . . . . . . . . . . . . . . . . 58
10.4.1 Closing the boiler door and the
control panel . . . . . . . . . . . . . . . . . . . . . . .58
10.4.2 Handing over . . . . . . . . . . . . . . . . . . . . . . 58
10.5 Commissioning record log book . . . . . . . 59
6 720 648 726 (2011/07)
emissions . 55
2