Buderus GB162/100 Manual de usuario

Please read thoroughly before starting installation

7217 5800 – 01/2006 GB (EN) For heating engineers

Installation instructions

Logamax plus GB162-80/100

cascade unit

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Fig. 1 Overview of Logamax plus GB162 cascade frame

Item 1: Supports

Item 2: Connecting frame

Item 3: Main gas pipe

Item 4: Flow and return header

Item 5: Gas connection kit TL-inline

Item 6: Mounting bracket

Item 7: Boiler connection set TL-inline

Item 8: Boiler connection set TR-back-to-back

Item 9: Boiler assembly connection kit

Item 10: Gas connection kit TR-back-to-back

Item 11: Flange seals

Item 12: Low loss header

11 12

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

List of contents

1 General points . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Items supplied with unit . . . . . . . . . . . . . . . . 4

3 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Cascade frame installation . . . . . . . . . . . . . . 8

4.1 Boiler assembly and pump group installation . . . . . 9

4.2 Installing the insulation . . . . . . . . . . . . . . . . . . . . . 10

W• http://www.buderus-commercial.co.uk We reserve the right to make technical modifications.

Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

General points1

1 General points

The installation instructions for cascade systems with

Logamax plus GB 162 appliances are provided to enable

correct and easy installation.

The modular cascade frame consists of a number of supports

with connecting frames which are screwed together during

installation.

The compact dimensions of the individual cascade frame parts

enable simple and quick installation.

2 Items supplied with unit

Cascade frame (fig. 1):

– Supports

– Connecting frame

– Main gas pipe

– Flow and return header

– Boiler connection kit

– Flange seals

– Low loss header

– Blank flanges

– Rubber pump seals

– Fixings

– Installation instructions

Boiler (fig. 2):

(to be ordered from your supplier)

– Mounting bracket

–Boiler

– Siphon

– Installation instructions.

Pump group (fig. 3):

(to be ordered from your supplier)

– Connection kit

– Installation instructions

The connection kit consists of:

– Maintenance valves

– Drain cock

– Gas isolation valve

– Pressure relief valve

– Non-return valve

–Pump

– Pressure gauge.

Fig. 2 Items supplied with the boiler assembly

Fig. 3 Items supplied with pump group

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Items supplied with unit 2

Buderus supplies cascade systems in TL and TR

configurations:

TL: Inline installation

All boiler assemblies are in a line enabling an easy-to-monitor

installation in a narrow room.

TR: Back-to-back installation

The boiler assemblies are located on both sides of the frame

and are installed back-to-back to create a compact installation

which ideally suits rectangular rooms and which ensures the

best possible access to all boilers.

The relevant configuration can be selected on the basis of the

performance required (see table 1).

Boiler assembly connection kit

The connection kit can be used both for the Logamax plus

GB162-80 and for the 100-kW version. The connection kit

includes a pressure relief valve, a non-return valve, a pump

and isolating valves.

Bend sets with low loss header

The Logamax plus GB162 cascade system can be installed in

various configurations (fig. 4). By using the bend set the low

loss header can be installed at an angle to the boilers. The gas

pipe is reversible so that the gas connection can be at the other

side of the boilers to the flow and return connections to the

header.

Appliance

performance

[kW]

Cascade

system options

TL = inline

TR = back-to-back

Number of boilers

Logamax plus

GB162

80 100

80 Single installation 1 –

100 Single installation – 1

160 TL2 or TR2 2 –

180 TL2 or TR2 1 1

200 TL2 or TR2 – 2

240 TL3 or TR3 3 –

260 TL3 or TR3 2 1

280 TL3 or TR3 1 2

300 TL3 or TR3 – 3

340 TL4 or TR4 3 1

360 TL4 or TR4 2 2

380 TL4 or TR4 1 3

400 TL4 or TR4 – 4

440 TL5 or TR5 3 2

460 TL5 or TR5 2 3

480 TL5 or TR5 1 4

500 TL5 or TR5 – 5

520 TL6 or TR6 4 2

540 TL6 or TR6 3 3

560 TL6 or TR6 2 4

580 TL6 or TR6 1 5

600 TL6 or TR6 – 6

620 TL7 or TR7 4 3

640 TL7 or TR7 3 4

660 TL7 or TR7 2 5

680 TL7 or TR7 1 6

700 TL7 or TR7 – 7

720 TL8 or TR8 4 4

740 TL8 or TR8 3 5

760 TL8 or TR8 2 6

780 TL8 or TR8 1 7

800 TL8 or TR8 – 8

Table 1 Cascade selection

Low loss

header

TL- configuration

(inline)

TR- configuration

(back-to-back)

2½" TL2, TL3 TR2

3" TL4 TR3, TR4

4" TL5, TL6, TL7, TL8 TR5, TR6, TR7, TR8

Table 2 Low loss header configuration

Fig. 4 Cascade system configuration varieties

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Dimensions3

3Dimensions

Fig. 5 Dimensions of cascade systems 1

Item A: TL-inline configuration

Item B: TR-back-to-back installation

Item 1: Flow and return header

Item 2: Low loss header with bend set

Item 3: Low loss header, straight

Item 4: Enclosed welding flanges

497

147

525

575

1722

1 2 3 4

675

810

525

510

288

3 4

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Dimensions 3

Cascade

system

Length (mm) Width (mm)

X1 + Y1

TR2 575 + 38 = 613 992

TR3, TR4 1100 + 42 = 1142 992

TR5, TR6 1625 + 45 = 1670 992

TR7, TR8 2150 + 45 = 2195 992

Table 3 TR-back-to-back configurations

Caution!

The dimensional tolerance is ± 5%.

Cascade

system

Length (mm) Width (mm)

X1 + Y1

TL2 1100 + 38 = 1138 575

TL3 1625 + 38 = 1663 575

TL4 2150 + 42 = 2192 575

TL5 2675 + 45 = 2720 575

TL6 3200 + 45 = 3245 575

TL7 3725 + 45 = 3770 575

TL8 4250 + 45 = 4295 575

Table 4 TL-inline configurations

Cascade system Header (inch) Length

(mm)

(flange dimension in mm)

TL2, TL3, TR2 2½ " straight 488 – – – 488 Blank flange C2631 37.2 NW

65/76.1 PN6

right-angled 213 213 621 133 –

TL4, TR3, TR4 3 " straight 571 – – – 571 Blank flange C2631 37.2 NW

80/88.9 PN6

right-angled 252 252 728 157 –

TL5, TL6, TL7, TL8

TR5, TR6, TR7, TR8 4 " straight 651 – – – 651 Blank flange C2631 37,2 NW

100/114.3 PN6

right-angled 313 313 849 198 –

Table 5 Header dimensions

Fig. 6 Dimensions of cascade systems 2

180

992

1710

328

247

310

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Cascade frame installation4

4 Cascade frame installation

zFix the frame onto the first leg of the cascade unit.

Use the M8 x 70 screws for this.

zNow fix the next leg and continue fitting until the cascade

unit is compelte.

zPosition the frame into its final position.

zAdjust the frame so that it is in the right position and so that

it is level both horizontally and vertically. Fit additional

washers under the leg until level.

zSecure the frame to the floor. Ensure bolts are aligned to the

legs. Do not bend or place the leg under stress to make it fit.

zInstall the main gas pipe. Use the M8 x 70 screws for this.

Do not fully tighten the screws yet.

zInstall the header pipe. Use the M8 x 70 screws for this.

Do not fully tighten the screws yet.

zFit the boiler mounting brackets on the top of the frame.

Install the nuts at the rear of the frame. The underside of the

bracket should be level with the underside of the frame.

Use the M8 x 65 screws for this.

Caution!

– Make sure that the surface the cascade

system is to be installed on is flat.

– Use a spirit level when installing the cascade

system.

– Check that the load-bearing capacity of the

floor is sufficient for the weight of the installa-

tion (approx. 100 kg for each boiler with

accessories).

Caution!

Make sure that the slots for the boiler mounting

bracket are at the top of the frame.

Caution!

For TR-back-to-back configurations, both boiler

mounting brackets are fitted simultaneously,

using the same screws. Only use M8 x 65

screws to secure the mounting brackets.

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Cascade frame installation 4

4.1 Boiler assembly and pump group

installation

zHang the first boiler on the cascade frame as shown in fig. 7

or fig. 8.

zPut the boiler in the correct position and level it horizontally

and vertically. Use the set screws on the lower rear of the

boiler to adjust it.

zConnect the pump group (see Logamax plus GB162 Instal-

lation and service instructions).

zRemove the protective yellow caps from the main gas pipe.

zApply PTFE tape to the screw thread connections.

zConnect up the gas connection pipe between the gas valve

and the main gas pipe. Use PTFE tape to create a perfect

seal.

zRemove the protective caps from the header.

zRemove all red paint and unevenness from the flow and

return connections of the header.

zInstall the flow pipe(s) between the header and the pump

group.

zInstall the return pipe(s) between the header and the pump

group.

zRepeat the above steps to install all boilers.

zIf required, seal off any unused connections of the main gas

pipe and the header.

zInstall the condensate drain pipe. Use the pre-assembled

mounting brackets on the supports for this.

zWhen installing a cascade with an angled low loss header,

install the set of bends between the header and the low loss

header. Fit the enclosed flange seals in between. Use the

corresponding screws.

– 2½" low loss header M12 x 50

– 3" low loss header M16 x 55

zInstall the low loss header with the corresponding flange

seals. Use the corresponding screws.

– 2½" low loss header M12 x 50

– 3" low loss header M16 x 55

Fig. 7 Installation sequence for a TL-inline configuration

1 2 3

Note!

You must observe the installation sequence

indicated in fig. 7 and fig. 8 when installing the

boilers.

Fig. 8 Installation sequence for TR-back-to-back

configuration

1 3 5

2 4 6

Caution!

– Do not install the pump group cover until

pressure has been supplied to the boiler

system and the gas pipe.

– Check the cascade system for leaks.

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Installation instructions Logamax plus GB162-80/100 cascade unit • Version 01/2006

Cascade frame installation4

4.2 Installing the insulation

zInstall the rear insulation over the header (fig. 9, item 1).

zWhen an angled low loss header has been installed, fit the

insulation around the bends.

zInstall the rear insulation part over the low loss header

(fig. 9, item 2).

zIf required, trim the insulation so that it is straight

(fig. 9, item 3).

zFor 2½" and 3" low loss header: install the inserts in the

outer insulation. For a 2½" low loss header: install the redu-

cing inserts in the outer recesses (fig. 10, item 2).

For a 3" low loss header: install the reducing inserts in the

inner groves (fig. 10, item 1).

zClick the insulation together.

zInstall the front insulation of the low loss header. If required,

trim the insulation so that it is straight (fig. 9, item 3).

zInstall the end cover over the header (fig. 9, item 4).

Fig. 9 Header

Caution!

First start up the cascade system and test the

system for leaks. Then install the insulation.

Fig. 10 Inner insulation

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