Worcester GB162-50 User manual

UK/IE
Installation instructions
Pump Group
6 720 648 721-000.1TD
For wall hung gas-fired condensing boiler GB162-50/65/80/100
6720813174 (2014/09)

Contents
6720813174 (2014/09)2
Contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 2
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 About these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Items supplied with pump group . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 General installation instructions . . . . . . . . . . . . . . . . . . . 5
5.2 Making the gas connection . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3 Removing the non-return valve (if necessary) . . . . . . . . . 5
5.4 Installing the heating flow and return . . . . . . . . . . . . . . . . 6
5.5 Rotating the pressure relief valve . . . . . . . . . . . . . . . . . . . 7
5.6 Installing the syphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.7 Connecting the condensate drain pipe . . . . . . . . . . . . . . 8
5.8 Connecting the expansion vessel (accessory) . . . . . . . . 9
5.9 Making the electrical connections to the pump . . . . . . . . 9
5.10 Installing the insulation cover . . . . . . . . . . . . . . . . . . . . 10
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Key to symbols and safety instructions
1.1 Key to symbols
Warnings
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 occur.
•DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety instructions
Please observe these instructions for your own safety. You can find a
detailed explanation of the format of these instructions in the Installation
and Servicing Instructions of the GB162-50/65/80/100.
Observe the following instructions when installing and operating the
pump group:
Repairs
▶ DANGER OF FATAL ACCIDENT by unprofessional repair. Do not
repair parts with safety functions.
▶ DANGER OF FATAL ACCIDENT due to electric shock. Before opening
the boiler:
Switch off the power supply to the boiler by pulling the mains plug
from the socket.
IF YOU SMELL GAS:
▶CALL NATIONAL GAS EMERGENCY SERVICE ON
0800 111 999
▶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
▶DO NOT TURN ELECTRICAL SWITCHES ON OR OFF
▶DO NOT STRIKE MATCHES OR SMOKE
▶PUTOUTNAKEDFLAMES
▶ OPEN DOORS AND WINDOWS
▶ KEEP PEOPLE AWAY FROM THE AFFECTED AREA.
Warnings in this document are framed and identified by
a warning triangle which is printed on a grey
background.
Electrical hazards are identified by a lightning symbol
surrounded by a warning triangle.
Important information in cases where there is no risk of
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.
Symbol Meaning
▶ a step in an action sequence
a reference to a related part in the document or to other
related documents
• a list entry
–a list entry (second level)
Table 1

Regulations
6720813174 (2014/09) 3
2Regulations
2.1 About these instructions
These installation instructions contain important information about the
safe and proper installation of the GB162-50/65/80/100 pump group.
These installation instructions are for competent heating engineers (e.g.
Gas Safe registered) who, due to their professional training and
experience, are experts at dealing with heating systems and gas
installations.
2.2 Intended use
The pump group must only be installed on the GB162-50/65/80/100
heating boiler.
2.3 Regulations
Please ensure that you comply to all regulations at the time of
installation.
3 Items supplied with pump group
▶ Check that the packaging is intact upon delivery.
▶ Check that all items have been supplied with the unit.
Fig. 1 Items supplied with GB162-50/65/80/100 pump group
[1] Insulation cover
[2] Isolating valve, red (CH boiler flow) with drain cock, pressure
gauge, thermometer (for pump UPER 25-80) and 4-bar safety
valve
[3] Technical documents
[4] Gas valve, yellow (GAS)
[5] Isolating valve, blue (CH boiler return) with pump, drain cock and
non-return valve (removable)
[6] Connecting bracket
[7] Flat rubber seal 1½’’ (2x)
The country-specific standards and guidelines and the
technical documents pertaining to the boiler must be
observed for the installation and operation of the heating
system! Please contact your supplier if anything is damaged or
missing.
6 720 648 721-001.1TD
1
2
3
4
5
6
7

Dimensions
6720813174 (2014/09)4
4 Dimensions
Fig. 2 Dimensions and connections [mm]
1) DO NOT remove the cap CS (not used in UK)
2) The pump group is accessory and can be ordered separately. This figure shows a pump group, that isn’t ment for DHW supply, but ONLY for
central heating hot water supply. There is also a pump group with 3-way valve (accessory) available, which is ment for DHW supply.
[Shortcut] Descriprion
[CS] Cap (DO NOT remove; not used in UK)
[CDO] Condensate drain outlet Ø 24 mm O/D
[CHF] CH (boiler) flow; G1½" union nut with female thread
[CHR] CH (boiler) return; G1½" union nut with female thread
[FGC/AIC] Flue gas/air intake connection: Ø 80/125 for GB162-50/65 and Ø 100/150 for GB162-80/100
[Gas B] Gas connection to boiler; G1" female thread
[Gas P] Gas connection to pump group; Rp1" female thread
[PF] Pump group flow; G1½" male thread, flat seal
[PR] Pump group return; G1½" male thread, flat seal
6 720 648 721-002.1TD
AIC
FGC
AIC
FGC
CDO
CDO
Gas P
Gas P
Gas B Gas B
CHF/CHR
CHRCHF
PF/PR PF PR
CS

Installation
6720813174 (2014/09) 5
5Installation
5.1 General installation instructions
▶ Connect all pipes without forcing them into place.
▶ Make sure that the connections are tight and carry out a gas and
water tightness test after completing the connection work (boiler
installation and servicing instructions).
5.2 Making the gas connection
Fig. 3 Rubber seal
▶ Install the gas valve [1] onto the gas pipe (GAS) in the boiler.
▶ Connect the main gas supply to the gas isolating valve [2] free of
strain.
Fig. 4 Making the gas connection
[1] Gas isolating valve
[2] Gas connection
5.3 Removing the non-return valve (if necessary)
If the system pressure is not sufficient according to table 4, page 7, you
can remove the integrated non-return valve from single-boiler systems.
Selecting the correct pump group
▶ Select the correct pump group using table 4.
DANGER: Danger of fatal accident from explosive
fumes.
▶ Only carry out work on gas pipes and fittings if you
are properly certified (e.g. Gas Safe registered).
DANGER: Danger of fatal accident due to gas escaping.
▶ Make sure that the factory-fitted flat rubber seal is
located in the threaded connection (boiler side)
(fig. 3, detailed picture).
6 720 648 721-003.1TD
6 720 648 721-004.1TD
1
2
We advise you to integrate a gas filter in the gas line.
▶ Make the gas connection according to the country-
specific standards and regulations.
▶ Carry out gas leak test on gas connection using leak
detection spray
WARNING: Danger of fatal accident from explosive
fumes.
Pipes and screw connections may leak after
commissioning and maintenance activities have been
carried out.
▶ Carry out a leakage test.
▶ Only use approved detection products to locate
leaks.
GB162-
50
GB162-
65
GB162-
80
GB162-
100
Multi-boiler system
(cascade system) UPER 25-80/UPS 25-80
pump group with pump
Single-boiler
system with
diverter valve
Single-boiler
system without
diverter valve
UPER 25-80/UPS 25-
80 pump group with
pump
1)
UPER
25-80/
UPS25-80
pump
group with
pump
1) Only remove the non-return valve from the pump group (beneath the pump)
when installing single-boiler systems
2)
2) Do not use a pump group or switch, but select a separate pump using the
installation and servicing instructions with the boiler.
Table 2 Selecting the correct pump group
WARNING: Damage tot the unit in cascade systems or in
single-boiler systems with a switch due to the heating
medium flowing back.
▶ Only remove the non-return valve from the pump
group of a single-boiler system if the residual head
(table 4, page 7) is not sufficient.
GB162-
50
GB162-
65
GB162-
80
GB162-
100
Multi-boiler system
(cascade system) not allowed
Single-boiler system
with diverter valve
Single-boiler system
without diverter
valve
Check the residual head
not
effective,
use pump
Table 3 Removing the non-return valve

Installation
6720813174 (2014/09)6
Removing the non-return valve
Remove the non-return valve before installing the heating flow and
return circuits otherwise it cannot be fully removed anymore!
▶ Remove the pump [1].
▶ Remove the flat rubber seal [2].
Fig. 5 Removing the pump
▶ Remove the non-return valve [1]. This will damage the non-return
valve beyond repair.
Fig. 6 Removing the non-return valve
▶ Rotate and shake the pump group.
Fig. 7 Removing the rest of the non-return valve
▶ Then fit back the flat rubber seal [2] and the pump [1].
Fig. 8 Fitting the pump
5.4 Installing the heating flow and return
▶ Install the blue and red isolating valve [2 and 6] with the flat rubber
seals in place on the CHR and CHF (boiler return and flow)
connections.
▶ Connect the flow pipe to the red isolating valve [3] free of strain. If
necessary, use the screw fitting (accessory, [4]).
▶ Connect the return pipe to the blue isolating valve [7] free of strain.
If necessary, use the screw fitting (accessory, [4]).
▶ Calculate the flow and return pipe diameters taking into
consideration the residual head downstream of the pump group with
the minimum required volume flow (table 4, fig. 24 and fig. 25 on
page 11). The minimum diameters of the flow and return pipes are
1½’’ and Ø 35 mm.
WARNING: Damage to the unit due to reduced flow or
pipes becoming clogged up.
▶ Make sure that no fragments of the non-return valve
stay behind in the pipe.
6 720 614 027-021.1TD
1
2
6 720 614 027-022.1TD
1
To prevent pollution in the heating system we advise you
to integrate a dirt filter in the return circuit. When
connecting the heating boiler to an existing heating
system, this dirt filter must be installed.
6 720 614 027-023.1TD
6 720 614 027-024.1TD
1
2

Installation
6720813174 (2014/09) 7
Fig. 9 Installing the isolating valves
[1] Pressure relief valve
[2] Isolating valve, red
[3] Flow connection
[4] Screw fitting 1" female thread (accessory)
[5] Pump
[6] Isolating valve, blue
[7] Return connection
▶ Install a shut-off valve for filter cleaning immediately upstream and
downstream of the dirt filter.
Installing the differential pressure controller
In situations where there is no low less header, installing a by-pass valve
with a differential pressure controller would be required.
If a low less header is present, it may be required -depending on the
situation - to install a differential pressure controller to the secondary
side of the open manifold. This serves to protect the secondary pump
against overheating as a result of insufficient flow.
Installing the drain cock
Since the isolating valve for the return circuit already has an integrated
filling and drain valve, fitting a drain valve is not necessary.
Installing the non-return valve
Since the isolating valve for the return circuit (blue) already has an
integrated non-return valve, fitting a non-return valve in the return circuit
is not necessary.
5.5 Rotating the pressure relief valve
▶ Remove the retaining pin from the pressure relief valve body
(step 1).
▶ Rotate the valve body (step 2).
Fig. 10 Removing the retaining pin
boiler pump
non
return
valve
residual
head
[mbar]
with minimum
required
volume flow
[l/h]
GB162-50
UPS 25-80 with 1)
1) Switch required
2,200
without 550 2,200
UPER 25-80 with 1) 2,200
without 550 2,200
GB162-65
UPS 25-80 with 1) 3,000
without 375 3,000
UPER 25-80 with 1) 3,000
without 375 3,000
GB162-80
UPS 25-80 with 153 3,600
without 259 3,600
UPER 25-80 with 1) 3,600
without 219 3,600
GB162-100
UPS 25-80 with 1) 4,300
without 1) 4,300
UPER 25-80 with 1) 4,300
without 1) 4,300
Table 4 Residual head downstream of pump group with a single-boiler
system ( Δ T = 20 K)
When using plastic pipework in the heating system, e.g.
for underfloor heating, it has to be oxygen diffusion tight.
If this pipework does not comply with the relevant
standards, a heat exchanger must be integrated to
separate the systems.
6 720 648 721-005.1TD
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7
CDO
CHF CHR
To prevent the pressure in the heating system from
becoming excessively high, a pressure relief valve is
required.
A 4-bar pressure relief valve forms part of the pump
group [1].
6 720 648 721-006.1TD

Installation
6720813174 (2014/09)8
▶ Re-fit the retaining pin through the valve body.
Fig. 11 Re-fitting the retaining pin
▶ Fit the compression elbow [1] (supplied packed with the boiler)
using thread sealant.
▶ Fit a 22 mm metal discharge pipe [2].
Fig. 12 Fitting the compression elbow with discharge pipe
5.6 Installing the syphon
▶ Fill the syphon (supplied with the boiler) with clean water.
Fig. 13 Filling the syphon with clean water
▶ Connect the syphon [1] to the condensate drain outlet (CDO).
Fig. 14 Installing the syphon
[1] Syphon
▶ Connect the syphon hose [3] andthe rubber sleeve [2] to the syphon
[1].
Fig. 15 Installing the syphon hose
[1] Syphon
[2] Rubber sleeve
[3] Syphon hose
5.7 Connecting the condensate drain pipe
▶ Connect the condensate drain pipe to the syphon.
Observe the following regulations:
• The waste water disposal regulations.
• Plastic pipework must be used to drain the condensate, at least until
it is delivered to the sewage system.
• The condensate must be able to run into a funnel (or neutralisation
tank) without restrictions. This prevents condensate from building
up in the boiler. The syphon in the connection kit must no be
permanently connected to the condensate drain pipe. The minimum
distance between the syphon and the condensate drainage pipe is 2
cm [1].
DANGER: Danger of fatal accidentdue to poisoning.
▶ If the syphon is not filled with clean water, flue gas
can escape and put people's lives at risk.
6 720 648 721-007.1TD
1
2
6 720 648 721-008.1TD
6 720 614 027-06.1TD
The trap is fitted with a bayonet connection. After
pushing [1.] the trap upwards into place, you have to
turn it a ¼ turn anticlockwise [2.] until it locks into
position.
1.
2.
7746800108-13.1TD
1
1
2
3
7746800108-14.1TD

Installation
6720813174 (2014/09) 9
Fig. 16 Condensate drain pipe
[1] Condensate drain pipe
5.8 Connecting the expansion vessel (accessory)
Connecting the expansion vessel in a multi-boiler configuration
(cascade configuration)
In cascade systems only one expansion vessel is required for the heating
system.
▶ Connect the expansion vessel to the secondary side of the header in
the return circuit, so that every boiler is connected to the expansion
vessel.
Refer to the cascade system installation instructions for the installation
details.
Fig. 17 Connecting the expansion vessel in a multi-boiler configuration
(cascade configuration)
[1] Expansion vessel
[2] Low loss header
5.9 Making the electrical connections to the pump
▶ Turn the vent key through a quarter rotation to undo the boiler door
lock [1].
▶ Push the fastener down [2] and open the boiler door [3].
▶ Remove the cover shield of the pump group [4].
Fig. 18 Opening the boiler door
▶ Undo 1 screw to release the cover over the electrical connections
and pull the cover up.
Fig. 19 Pulling the cover over the electrical connections up
WARNING: Damage tot the unit due to faulty pressure
relief valve.
▶ The expansion vessel must be of sufficient capacity.
1
7746800108-16.1TD
6 720 648 721-009.1TD
CHF Gas Gas CHF CHR
1
2
CHR
1. 2.
3.
4.
6 720 648 721-010.1TD
7746800108-19.1TD
2. 1.

Commissioning
6720813174 (2014/09)10
▶ Lay the pump connection cable from the boiler through the hole
under the electrical connection box downwards (fig. 20, [1] and
fig. 21, [1]).
Fig. 20 Laying the pump connection cable
[1] Pump connection cable
Fig. 21 Laying the pump connection leads
[1] Pump connection cable
▶ Connect the tacho cable connector [1] to the pump.
▶ Connect the mains cable connector [2] to the pump.
Fig. 22 Connecting the pump
[1] Tacho cable connector
[2] Mains cable connector
5.10 Installing the insulation cover
▶ Feed the insulation cover with its upper edge into the groove in the
lower support.
Fig. 23 Installing the insulation cover
6 Commissioning
6 720 646 828-009.1TD
1
6 720 646 828-010.1TD
1
The door over the boiler control panel must be closed.
See the Installation and servicing instructions of the
boiler assembly for commissioning instructions.
Observe the safety instructions and take the relevant
measures.
6 720 646 828-011.1TD
2
1
6 720 648 721-012.1TD

Technical specifications
6720813174 (2014/09) 11
7 Technical specifications
Fig. 24 Residual head downstream of the pump group (UPS 25-80) - with and without a non-return valve
[l/h] Volume flow
[mbar] Residual head
[1] Residual head downstream of the pump group without a non-return valve (UPS 25-80)
[2] Residual head downstream of the pump group with a non-return valve (UPS 25-80)
Fig. 25 Residual head downstream of the pump group (UPER 25-80) - with and without a non-return valve
[l/h] Volume flow
[mbar] Residual head
[1] Residual head downstream of the pump group without a non-return valve (UPER 25-80) - full load
[2] Residual head downstream of the pump group with a non-return valve (UPER 25-80) - full load
[3] Residual head downstream of the pump group with a non-return valve (UPER 25-80) - partial load
0
100
200
300
400
500
600
700
800
900
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
[mbar]
[l/h] 6 720 615 676-015.1TD
1
2
0
100
200
300
400
500
600
700
800
900
[mbar]
[l/h] 6 720 648 721-013.1TD
1
2
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
3

Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. [phone]
Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
6720813174
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