Worcester GB162-50 V2 Installation, Commissioning And Servicing Instructions
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Worcester GB162-50 V2 Installation, Commissioning And Servicing Instructions

Commercial wall hung gas fired condensing boilers
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Installation, commissioning and servicing instructions
Wall hung gas fired condensing boilers
Worcester Commercial Boiler Series
GB162-50/65/85/100 V2

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Summary of Contents for Worcester GB162-50 V2

  • Page 1 Installation, commissioning and servicing instructions Wall hung gas fired condensing boilers Worcester Commercial Boiler Series GB162-50/65/85/100 V2...

  • Page 2: Table Of Contents

    Flue terminal positions ......21 Measure the CO and CO2 content ....36 Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 3: Explanation Of Symbols And Safety Instructions

    Service record ....... .51 • a list entry – a list entry (second level) Table 1 Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 4: General Safety Instructions

    ▶ Turn off the gas at the meter or regulator. prosecution. ▶ Open windows and doors. • If you are in any doubt, contact the Worcester ▶ Warn your neighbours and leave the building. Technical help-line ▶ Prevent anyone from entering the building.
  • Page 5 When handing over, instruct the user how to operate the heating system and inform the user about its operating conditions. ▶ Explain how to operate the heating system and draw the user's attention to any safety relevant action Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 6: Regulations

    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 Salt based artificially softened water must not be used to fill the central heating system. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 7: Scope Of Delivery

    7 °C and will operate the [10] Strain relief (6 × ) circulating pump until a boiler temperature of 15 °C is reached. The boiler does not guarantee the protection of the entire heating system from frost. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 8: Pump Anti-Seizure

    Condensate pipe, Ø external diameter 24 mm Pump group for gas connection, R 1" female thread Pump group for flow, G 1½ '' male thread with flat gasket Heating flow, G 1½ '' screw fitting with female thread Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 9: Product Overview

    [29] Drain & fill valve (DFV) [30] Expansion vessel connection [31] Hydraulic isolation valves [32] Gas isolation valve [33] Drain cock [33] Pressure gauge [34] Pressure Relief Valve 0010025976-001 Fig. 4 GB162 V2 with pump group Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 10: Wiring Diagram

    [29] Pump group, external pump 230 V AC, max. 250 W [13] Safety temperature sensor [14] Flame sense electrode [15] Earth [16] Turquoise - no function [17] Grey - no function [18] Blue - outside temperature sensor Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 11: Specifications

    Natural gas E, H, E (G20) 5.03 6.81 8.68 10.24 The product data on energy consumption can be found in the operating Propane 3P (G31) 1.80 2.48 3.19 3.76 instructions for the user. Table 4 Gas consumption Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 12: Hydraulic Resistances

    65 kW [min.] Residual head at minimum pump speed 50 kW 1000 1500 2000 2500 3000 3500 4000 4500 5000 [l/h] 001002647-001 Fig. 6 Resistance graph per type [l/h] Flow rate [mbar]Pressure drop Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 13: Pre-Installation

    ▶ It is recommended that you fit a primary water cleanser to the If plastic pipes are used in the heating system, with an underfloor heating system. Worcester recommends a filter that will help remove both system for example, magnetite and non-magnetic debris.

  • Page 14: Condensate Pipe Work

    External rain water pipe into foul water 43mm 90° male/female bend Condensate trap of 75mm already incorporated into the boiler Table 9 0010025983-001 Fig. 11 Sealed system Expansion vessel - CH return Pressure relief discharge Drain cock Radiators Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 15: Internal Connections

    A suitable permanent connection to the foul waste pipe should be used. Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 16 Condensate trap of 75mm already incorporated into the boiler 0010025989-001 Fig. 17 External disposal Condensate discharge from boiler [13] Insulate and increase pipe size [14] Pipe work transition Condensate trap of 75mm already incorporated into the boiler Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 17: Pressure Relief Pipe Work

    • In commercial installations an internal drain in the plant room can be DO NOT fit a condensate pump when combining the PRV and condensate. used for both the pressure relief and condensate discharge. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 18: Boiler Location And Clearances

    To ensure optimal operation, the appliances should 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 19: Maximum Flue Length (L)

    100/150 flue system ( fig. 25 and fig. 26). For flue length see Flue size 100/150 and 80/125 table 10. Model Maximum flue length [m] concentric flue system 100/150mm 80/125mm 50-V2 65-V2 85-V2 100-V2 Table 10 Max. flue lengths, incl. wall/roofterminal in metres Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 20: Standard 100 Mm Flue Systems

    90° flue turret finishing kit outer wall 0010026002-001 3.8.6 Flue pipe preparation and assembly Fig. 30 Flue terminal position Measure the flue length L. Refer to figures 28 and 29. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 21: Flue Gas Connection

    If room-sealed fluing is not desired or possible due to local conditions, the boiler can be set up for operation to take air for combustion from the room in an open flue arrangement (contact Worcester Technical team for advice). Pipe = 2m The boiler is factory-fitted with a concentric connection.

  • Page 22: Transport

    ▶ Turn off gas valve before working on gas-carrying components. Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided. Active plume management is ▶ Check for leaks before working on gas-carrying components. encouraged. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 23: Unpacking The Boiler

    Fig. 34 Installing the mounting bracket on the wall • Flow and return isolation valves ▶ Hook the boiler on to the mounting bracket. • Pressure gauge • Thermometer • Pressure Relief Valve • Pump • Drain & fill valve (DFV) Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 24: Installing The Gas Isolation Valve

    Fig. 38 Mounting the pump group Hydraulic and gas connections (without pump group) NOTICE: Damage to appliance due to excessive operating pressure. ▶ Mount a pressure relief valve between the boiler and isolation valve. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 25: Gas Connection

    ▶ Select a pump that has a residual head of at least 200 mbar at the required flow rate. 0010020132-001 Fig. 41 Installation of the low loss header Low loss header Expansion vessel Pump Hydraulic isolation valve Pressure differential controller (bypass) Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 26: Installing The Siphon

    If the option to connect the expansion vessel to the pump group is used with a back-to-back cascade installation (TR), a right-angled coupling is required in the front row of the boilers. ▶ Remove the cap from the connection point [1]. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 27: Mounting The Back Panel Insulation

    Fig. 47 Control principle of room temperature-dependent control Boiler Room temperature-dependent controller Radiator valve Thermostatically controlled radiator valve (TRV) 0010010001-001 Other rooms Fig. 46 Mounting the insulated rear panel Living space Installation location Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 28: Connection Of The Control Units

    ▶ Turn the locks a quarter turn clockwise then remove the cover. Fig. 52 Cable entry ▶ Connect the wire to the corresponding connector block. ▶ Plug the connector block in at the terminal strip. 45° 0010010005-001 Fig. 50 Removing the cover Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 29: Connecting The On/Off Room Temperature-Dependent Control Unit

    230 Volt convertor, compensating controller, via the blue connector block on the terminal • On/off temperature controller, Volt free. strip [1]. ▶ Install the RTH convertor as specified in the accompanying wiring instructions. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 30: Connecting A Cylinder Temperature Sensor

    [1]. Use the power cable supplied with the function module for this. All Worcester boilers require a permanent live. A mains supply of 230 V - 50 Hz is required. External controls are suitable for volt free installation (or 230V via the relay supplied with the 50-V2 and 65-V2 boilers).

  • Page 31: Operating The Boiler

    ( Chapter 12.2 "Reset"). Chimney sweep d key The boiler can be brought into operation via the d key in order to carry out measurements. Used for servicing. Info L key Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 32: Setup Menu

    ▶ Set the required output (in %) [3] via M and N. ▶ Perform the required measurement. ▶ Hold down d to switch off the chimney sweep mode. Heating mode is switched on. Setting: On, Off. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 33: Fault History" Menu

    ▶ Press the M and N keys again simultaneously for 5 seconds to remove the key block; the word “Lock” disappears. ▶ Check whether the boiler is connected to a flue system as specified in the flue pipe documentation provided. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 34: Adjusting The Output

    ▶ Take the boiler out of operation. ▶ Remove the casing. ▶ Close gas isolation valve. ▶ Make sure the heating system can dissipate the heat generated. 0010010027-001 Fig. 67 Connecting the pressure gauge at 50-V2 and 65-V2 Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 35: Measure Gas/Air Ratio

    ▶ Close the gas isolation valve. ▶ Close the gas isolation valve. ▶ Remove the pressure gauge. ▶ Close the test nipple. ▶ Open the gas isolation valve. ▶ Bring the boiler into operation. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 36: Measure The Co And Co2 Content

    ▶ The gas valve is factory set and must not be adjusted during commissioning if found to be out of tolerance, please contact the Worcester, Bosch Group help line 0330 123 3366. 0010010034-001 Fig. 71 Removing the cap of the flue gas testing point...

  • Page 37: Measure Ionisation Current

    Measure ionisation current ▶ Take the boiler out of operation. ▶ Pull the connector plugs apart. ▶ Connect the multi-meter on both sides of the open plugs (in series). 0010010035-001 Fig. 73 Connecting the multi-meter Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 38: Testing For Gas Leaks

    13. Instruct the user, hand over 8.13 Final steps technical documentation. ▶ Fit the casing. Confirm professional commissioning: ▶ Complete the Benchmark checklist (50-V2 and 65-V2) or commissioning report (85-V2 and 100-V2). Company stamp/ signature/date Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 39: Shutdown

    Used batteries must be disposed of in local collection systems. Inspection and servicing To safeguard the efficiency of the boiler and avoid possible technical problems, the boiler must be inspected and serviced at least once a year. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 40: To Clean The Burner

    Fig. 80 Remove the gas-air unit together with the burner cover. 11.3 To clean the burner ▶ Remove the burner gasket and replace if necessary. 0010010041-001 Fig. 78 Detaching the air intake pipe (Pictured: 50/65kW) 0010010046-001 Fig. 81 Removing the burner gasket Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 41: Cleaning The Heat Exchanger

    ▶ Insert the burner [1] with the notch pointing to the right [3]. 0010010050-001 Fig. 83 Cleaning the heat exchanger 11.5 Checking the ignition system NOTICE: Damage to the glow ignitor. The glow ignitor unit is made of breakable material. ▶ Handle with care. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 42: Clean Condensate Trap/Siphon

    Fig. 89 Opening the snap fasteners of the condensate sump 0010010055-001 Fig. 87 Removing the condensate trap Threaded connector Condensate trap ▶ Flush out condensate trap. ▶ Fill the siphon completely with water. ▶ Reattach the siphon. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 43: Testing The Gas Supply Pressure

    2 revolutions. 0010010059-001 Fig. 93 Setting the gas/air ratio (50-V2 and 65-V2) Differential pressure incorrect Differential pressure correct 6 720 807 034-67.1DDC Fig. 91 Opening the burner pressure test nipple (50-V2 and 65-V2) Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 44: Measure Co/Co2 Content

    12. Check that the control is set correctly. ▶ Consult the instruction manual of the controller.       13. Final inspection check, take measurements and document measurement and test results. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 45: Display Codes

    The boiler is modulating upwards.      The boiler is preparing for a burner start. The fan and pump are activated.      The gas valve is switched. Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 46 ▶ Check whether it is possible to achieve sufficient flow in the heating system. ▶ Check the cabling to the pump and corresponding sensors. Replace the faulty component if necessary. Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 47 ▶ Check whether it is possible to achieve sufficient flow in the heating system. ▶ Check the cabling and function of the pump and boiler return temperature sensor. Replace the faulty component if necessary. Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 48 ▶ Check the plug and wiring of the burner control unit. ▶ Check the operating characteristics of the boiler by replacing the burner control unit. Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 49 DHW ▶ Refill the heating system. mode.    The boiler is reset.   The boiler is reset. Table 18 Operating and fault codes Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 50 * All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer. Worcester Commercial Boiler Series – 6720814332 (2019/04)

  • Page 51: Service Record

    * All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.  Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk Worcester Commercial Boiler Series – 6720814332 (2019/04)
  • Page 52 CONTROLS AND CONNECTIVITY TEAM: 0330 123 3641 APPOINTMENTS: 0330 123 9339 SPARES: 0330 123 9779 LITERATURE: 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Bosch Thermotechnology Ltd. Cotswold Way, Warndon Worcester WR4 9SW United Kingdom Tel. 0330 123 9559 worcester-bosch.co.uk...

This manual is also suitable for:

Gb162-65 v2Gb162-100 v2Gb162-85 v2

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