Buderus GB162 User manual

Installation Instructions
GB162 Concentric Horizontal Vent Kit
FOR BUDERUS GB162 SERIES BOILERS

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|Concentric Horizontal Vent Kit
Bosch Thermotechnology Corp.Data subject to change
Installation Manual

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Bosch Thermotechnology Corp. Data subject to change
Table of Contents
1 Explanation Of Symbols 4
1.1 Key To Symbols 4
1.2 Safety Instructions 4
2 Scope Of Delivery 6
3 Installation 7
3.1 Notes On Installation 7
3.2 Appliance Adapter 7
3.3 Elbow and Wall Termination 7
4 Spare Parts 10

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Bosch Thermotechnology Corp.Data subject to change
Installation Manual
1 Explanation Of Symbols
1.1 Key To Symbols
Warnings
Warnings in this document are identified by a
warning triangle printed against a grey background.
Keywords at the start of a warning indicate the type
and seriousness of the ensuing risk if measures to
prevent the risk are not taken.
The following keywords are defined and can be used in this
document:
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not
avoided, could result in minor to moderate injury.
NOTICE is used to address practices not related to personal
injury.
Important information
This symbol indicates important information where
there is no risk to people or property.
1.2 Safety Instructions
WARNING:
Read all instructions before installing. Perform the
steps in the indicated sequence. Failure to comply
with these instructions can result in severe, possibly
fatal, personal injury as well as damage to property
and equipment.
WARNING: Installation and servicing
Ensure that only a licensed contractor installs or
services the gas appliance.
On hot components use only material with
adequate temperature rating.
WARNING: Installation and commissioning
In the Commonwealth of Massachusetts, the
gas appliance must be installed by a licensed
plumber.
DANGER: If you smell flue gas
Switch off the appliance.
Open windows and doors.
Inform a trained and certified installer.
DANGER: Insufficient ventilation may cause
toxic flue gases to escape posing a risk of flue gas
poisoning.
Never close off or reduce the size of the air intake
and outlet openings.
The appliance must not be operated until any
obstructions have been removed.
Inform the system operator in writing of the
problem and the associated dangers.

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DANGER : Danger from escaping flue gases
Ensure all vent pipes and chimneys are not
damaged or blocked.
Connect only one appliance to each vent system
or chimney liner.
The venting system piping must not feed into
another air exhaust duct.
Do not route the flue system piping through or
inside another air exhaust duct.
WARNING: Combustion air
Keep the combustion air free of corrosive
substances (halogenated hydrocarbons that
contain chlorine or fluorine compounds).
WARNING: Maintenance
Customers are required to:
Sign a maintenance and inspection contract with
an authorized contractor. Inspect and maintain
the gas appliance on a yearly basis or more
frequently if required. Service as needed.
Use only genuine spare parts.
DANGER: Fatal accidents!
Carbon monoxide poisoning.
Carefully plan where you install the gas appliance.
Correct combustion air supply and flue pipe
installation are very important. If a gas appliance
is not installed correctly, fatal accidents can
result such as carbon monoxide poisoning or fire.
DANGER: Carbon monoxide poisoning.
Exhaust gas must be vented to outside using
approved vent material. (In Canada use
only ULCS636 approved material). Vent and
combustion air connector piping must be sealed
gas-tight to prevent flue gas spillage, carbon
monoxide emissions and risk of fire, resulting in
severe personal injury or death. Approved vent
terminations must be used when penetrating to
the outside.
WARNING:
Do not obstruct the flow of combustion and
ventilation air.
NOTICE:
The complete installation must comply with
national, state, and local code. The installation
instructions in both the gas appliance installation
manual and this vent system installation manual
must be followed exactly.
NOTICE:
The concentric horizontal vent terminal is
intended for installation only with the GB162
series boilers (hereafter referred to as
"appliance"):
- GB162-80 kW
- GB162-100 kW

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Installation Manual
2 Scope Of Delivery
The GB162 Concentric Vent Kit comes packaged as described
below.
5⅞"(150)
8¹¹⁄₁₆" (220)
8¹¹⁄₁₆" (220)
3
4x
5
4x
1
6
4
9⁷⁄₁₆" (240)
Ø 5⅞" (150)
2
Ø 6"(150)
30⅜"(772)
23
⁵⁄₁₆
"(592) 7
¹⁄₁₆
"(180)
Fig. 1 Scope of delivery - dimensions in inches (mm)
Fig.1 Legend:
Components:
190° elbow
2Terminal assembly
3Inner wall seal
4Outer wall seal
5Connecting/securing screws and wall anchors
6Appliance adapter
Needed Tools:
- Hole saw
- Tape measure
- Phillips screw driver
- Drinking water (as lubricant for gaskets)
- Weatherproof caulk

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Bosch Thermotechnology Corp. Data subject to change
3 Installation
3.1 Notes On Installation
NOTICE:
It is the installer's responsibility that the appliance is
installed according to the manufacturer's installation
instructions, this accessory manual, as well as
national, state, and local code.
CAUTION:
The location and orientation of the vent termination
must follow those stated in the appliance Installation
Manual. Ensure flue discharge does not create a
hazard or nuisance.
NOTICE:
The concentric vent kit is approved for zero
(0", 0 mm) clearance to combustibles.
NOTICE:
This vent system is ULC-S636 certified for Canada.
DANGER:
Ensure the termination is installed at least 12"
(300 mm) above the average snow line. If this is
not feasible, this termination can not be used.
3.2 Appliance Adapter
Discard original appliance adapter, vent flange and gasket that
was supplied with the boiler.
Set the appliance adapter down onto the pipe ensuring that the
analyzer ports are facing to the front of the appliance and the
adapter screw holes are aligning with those of the appliance.
Fig. 2 Installing adapter
Insert the 4 screws, but do not tighten all the way.
3.3 Elbow and Wall Termination
Apply a small amount of clean water as lubricant on all
gaskets.
Place elbow on top of the appliance adapter and align.
Fig. 3 Installing elbow

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Installation Manual
The appliance adapter can be swivelled around its
vertical axis.
Measure the length of the vent terminal assembly (Fig. 4,
[1]) taking into account the thickness of the outside wall [S]
and the distance from the outside wall to the end of the vent
pipe [L]). It is recommended to keep at least 4" (100mm)
clearance from the ceiling or joists for accessibility reasons.
F
L
13
³/
₁₆" -
20⅞"(335 - 530mm)
1/4" per foot
(50 mm per meter)
K
S
1
≥4"(100mm)
ig. 4 Penetration through the outside wall
Select the required diameter [K] of the hole in the wall
according to the wall thickness S.
Sizing hole penetration
Wall Thickness S Diameter K
6" - 9 ½" (150 - 240 mm) 7 1/4" (155 mm)
9 ½" - 16½" (240 - 420 mm) 7 1/2" (165 mm)
16½" - 20 ⅞" (420 - 530 mm) 8" (170 mm)
Cut the hole in the wall while allowing clearance for the
required pitch of the air/vent pipe up to a maximum of 3/8"
wider than the air supply pipe
Extending the concentric pipe length is permissible. The
maximum straight vent length allowed is dependant on
appliance type and number of elbows used. See tables
below.
Maximum straight vent pipe length allowed for Ø 4" / Ø 6"
(Ø 100/150mm) concentric pipe
# of 90° elbows
used Maximum straight vent pipe length allowed
1 22ft (6.705m)
2 20ft (6.096m)
3 19ft (5.791m)
4 17ft (5.181m)
5 15ft (4.572m)
6 13ft (3.962m)
Friction Loss Equivalent for Fittings
Fitting Equivalent
feet m
45 deg 4"/6" (100/150mm), PolyPro Elbow 3.7 1.14
90 deg 4"/6" (100/150mm), PolyPro Elbow 5.6 1.72
Example:
— Model: GB162-80
— 90° elbows used: 3
— 45° elbows used: 0
Maximum straight vent pipe allowed: 19ft (5.791m)
Slide the outer wall seal [2] onto the terminal [1] as shown.
1 2
Fig. 5

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Position terminal [1] from the outside through the vent
opening so rubber thimble [2] is flush against outside wall
(Fig. 6) .
Slide the inner wall seal [3] onto the terminal [1] as shown
(Fig. 6).
1.
2.
1
32
Fig. 6 Inserting termination from the outside
Connect the termination to the elbow or to additional
concentric pipe if extending the vent length.
Fig. 7 Completed adapter and concentric assembly
Ensure all components are properly connected and aligned,
and that the termination has the proper pitch as shown in
Fig. 4.
Using screws provided, secure inner and outer wall seals to
the wall.
Complete installing the appliance per the Boiler Installation
Instructions.

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Installation Manual
4 Spare Parts
Concentric Vent Kit Components
Description Bosch Part Number
Concentric Vent Kit PP 100/150, GB162 7738004825
Concentric Adapter GB162 PP 80-100/150 7738004826
Wall Plate pe 150 7738004835
Wall Plate Fire Stop Support alu 150 7738004836
Wall Bracket 150 7738004837
Horizontal Concentric Vent Kit Hardware 7738003237
Additional Concentric Vent Kit Accessories
Description Bosch Part Number
Extension PP 100/150 x 10 inch 7738004827
Extension PP 100/150 x 20 inch 7738004828
Extension PP 100/150 x 40 inch 7738004829
Extension PP 100/150 x 80 inch 7738004830
Elbow PP 100/150 90° 7738004831
Elbow PP 100/150 45° 7738004832
PP Inner Seal EPDM 100 7738004833
PP Outer Seal EPDM 150 7738004834
To purchase additional concentric pipe lengths and
fittings, please contact Bosch Customer Service at
1-866-642-3198.

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Bosch Thermotechnology Corp. Data subject to change
Notes:

United States and Canada
Bosch Thermotechnology Corp.
50 Wentworth Avenue
Londonderry, NH 03053
Tel: [phone]
Fax: [phone]
www.boschheatingandcooling.com
BTC 432001102 A / 05.2015