Buderus Logamax plus GB162 Manual de usuario

Please read these instructions carefully before starting the operation

Installation instructions

Cascade frame for

Logamax plus

CAUTION!

Before putting the boiler into operation read this manual care-

fully.

WARNING!

Improper installation, adjustment, alteration, service or main-

tenance can cause injury, loss of life or property damage. Re-

fer to this manual. For assistance or additional information

consult a qualified installer, service agency or the gas suppli-

er.

CAUTION!

The operating manual is part of the documentation that is de-

livered to the installation's operator. Go through the informa-

tion in this manual with the owner/operator and make sure

that he or she is familiar with all the necessary operating in-

structions.

Notice:

This manual is available in the English and French

language.

This manual must be retained for future reference.

– Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other

appliance.

– What to do if you smell gas

• Do not try to light any boiler.

• Do not touch any electrical switch; do not use any

phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the fire

department.

– Installation and service must be performed by a

qualified installer, service agency or the gas

supplier.

Warning: If the information in these instructions

is not followed exactly, a fire or explosion may

result causing property damage, personal injury

or loss of life.

GB162-80 kW/100 kW

6720820106 (2017/05) US/CA

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements!2

Overview Cascade frame for Logamax plus GB162-80 kW/100 kW

Fig. 1 Overview of cascade frame for Logamax plus GB162-80 kW/100 kW

1: Supports

2: Connecting frame

3: Supply and return header

4: Manual gas shutoff valve

5: Mounting bracket

6: Cascade connection set TL-inline

7: Cascade connection set TR-back-to-back

8: Pump group

9: Flange seals - gaskets

10: Low loss header

1General information

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements! 3

Contents

1 General information . . . . . . . . . . . . . . . . . . .3

2 Items supplied with unit . . . . . . . . . . . . . . .3

2.1 Configurations . . . . . . . . . . . . . . . . . . . . . . . 4

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

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . .8

4.1 Installing the Cascade frame . . . . . . . . . . . . 8

4.2 Installing the Boiler assembly and Pump

Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3 Installing the insulation . . . . . . . . . . . . . . . . 9

1 General information

The installation instructions for cascade systems with

Logamax plus GB162 appliances are provided to

enable correct and easy installation.

For installation of cascade flue systems refer to the

Flue Cascade manual with number 6720646836

(EN/FR) at www.buderus.us.

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. 2)

See also fig. 1 on page 2:

1. Pallet with cascade frame:

– supports

– connecting frame

– supply and return header

– flange seals - gaskets

– low loss header

– blank flanges

– rubber pump seals

– fixings

– fasteners

2. Box with cascade frame connection set TL-inline;

For a TL-inline configuration then 2 cascade

connection sets for the TL-inline are included.

NOTICE

Please refer to the Logamax plus

GB162-80kW/100kW Installation Instruc-

tion Manual for details on the installation,

start-up, maintenance and troubleshooting

of the boiler(s).

Fig. 2 Items supplied with the cascade frame

2Items supplied with unit

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements!4

3. Box with cascade frame connection set TR-back-

to-back;

For a TR-back-to-back cascade connection set

then

1 TR-back-to-back cascade connection set is

included and one TL-inline cascade connection set

is included

4. Installation instructions.

Boiler (→fig. 3):

(to be ordered from your supplier)

1. Boiler with casing

2. Parallel flue adapter

3. Screws and plugs for wall bracket

4. Union nut for gas connection

5. Wall bracket

6. Condensate trap with hose

7. Supply and return union nuts with sealing rings

8. Technical documents set.

Pump group (→fig. 4):

(to be ordered from your supplier)

1. Installation instructions

2. Connection kit.

The connection kit consists of:

3. Maintenance valve(s) - fill and drain

4. Gas isolation valve

5. Flow check valve

6. Pump

7. Pressure gauge

8. Pressure relief valve.

2.1 Configurations

Buderus supplies cascade frame systems in TL and TR

configurations:

TL - Inline frame installation

All boiler assemblies are installed in one line, enabling

an easy-to-monitor installation in a narrow room.

Fig. 3 Items supplied with the boiler assembly

Fig. 4 Items supplied with pump group

System gross output Cascade frame

system options

TL = inline

TR = back-to-

back

Number

of boilers

GB162

Natural

gas LPG

k.Btu/hr k.Btu/hr 80

100

290 270 80 Single installation 1 –

333 315 100 Single installation – 1

580 540 160 TL2 or TR2 2 –

623 585 180 TL2 or TR2 1 1

666 630 200 TL2 or TR2 – 2

870 810 240 TL3 or TR3 3 –

913 855 260 TL3 or TR3 2 1

956 900 280 TL3 or TR3 1 2

999 945 300 TL3 or TR3 – 3

1,203 1,125 340 TL4 or TR4 3 1

1,246 1,170 360 TL4 or TR4 2 2

1,289 1,215 380 TL4 or TR4 1 3

1,332 1,260 400 TL4 or TR4 – 4

1,536 1,440 440 TR5 3 2

1,579 1,485 460 TR5 2 3

1,622 1,530 480 TR5 1 4

1,665 1,575 500 TR5 – 5

1,826 1,710 520 TR6 4 2

1,869 1,755 540 TR6 3 3

1,912 1,800 560 TR6 2 4

1,955 1,845 580 TR6 1 5

1,998 1,890 600 TR6 – 6

2,159 2,025 620 TR7 4 3

2,202 2,070 640 TR7 3 4

2,245 2,115 660 TR7 2 5

2,288 2,160 680 TR7 1 6

2,331 2,205 700 TR7 – 7

2,492 2,340 720 TR8 4 4

2,535 2,385 740 TR8 3 5

2,578 2,430 760 TR8 2 6

2,621 2,475 780 TR8 1 7

2,664 2,520 800 TR8 – 8

Table 1 Cascade selection

2Items supplied with unit

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements! 5

TR - Back-to-back frame installation

The boiler assemblies are installed back-to-back on

both sides of the frame, 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 (→table 1).

Boiler assembly connection kit

The connection kit can be used both for the Logamax

plus GB162-80 kW and the GB162-100 kW boilers.

The connection kit includes a pressure relief valve, a

flow check valve, a pump and isolating valves.

The Logamax plus GB162 cascade frame and

hydraulic system can be installed in 2 different configu-

rations (→fig. 5).

The gas connection can be made to either side of the

boilers, independent of the supply- and return connec-

tions.

Low loss

header

TL- configuration

(inline)

TR- configuration

(back-to-back)

2½" TL2, TL3 TR2

3" TL4 TR3, TR4

4" 5 boilers and more

Table 2 Low loss header configuration

Fig. 5 Cascade system configuration varieties

3Dimensions

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements!6

3 Dimensions

Fig. 6 Dimensions of cascade frame and hydraulic systems - 1

A: TL - Inline configuration

B: TR - Back-to-back configuration

1: Supply and return header

2: Low loss header

3: Enclosed welding flanges

X1 Y1

1 2 3

(525 mm)

20¾” (288 mm)

11¼”

32” (810 mm)

20” (510 mm)

22¾”

(575 mm)

20¾”

(525 mm)

26¾” (1722 mm)

6” (147 mm)

19½” (497 mm)

26½” (675 mm)

D1 D1

- Front view -

- Top view -

3Dimensions

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements! 7

Fig. 7 Dimensions of cascade frame systems - 2

CAUTION

The dimensional tolerance is ± 5%.

39" (992 mm)

7" (180 mm)

67¼" (1710 mm)

9¾" (247 mm)

3½" (92 mm)

12¼" (310 mm)

- Side view -

Cascade

frame

system

Length

Width

X1 +Y1

TL2 43 3/8"

1,100 mm +1 3/8"

38 mm =44¾"

1,138 mm

22¾"

575 mm

TL3 64 1/8"

1,625 mm +1 3/8"

38 mm =65½"

1,663 mm

22¾"

575 mm

TL4 84 5/8"

2,150 mm +1 5/8"

42 mm =86¼"

2,192 mm

22¾"

575 mm

Table 3 TL-inline configurations

Cascade

frame

system

Length

Width

X1 +Y1

TR2 22 7/8"

575 mm +1 3/8"

38 mm =24¼"

613 mm

39"

992 mm

TR3, TR4 43 3/8"

1,100 mm +1 5/8"

42 mm =45"

1,142 mm

39"

992 mm

TR5, TR6 64"

1,625 mm +1¾"

45 mm =

65¾"

1,670 mm

39"

992 mm

TR7, TR8 84¾"

2,150 mm +1¾"

45 mm =86½"

2,195 mm

39"

992 mm

Table 4 TR-back-to-back configurations

Cascade frame system Header diameter D1 (inch) Length L1 (inch) F1 (flange dimension in mm)

TL2, TL3 2½ " 19" (482 mm) Blank flange C2631 37.2 NW 65/76.1 PN6

TL4, TR4 3 " 22¾" (571 mm) Blank flange C2631 37.2 NW 80/89 PN6

5 boilers and more 4 " 25½" (651 mm) Blank flange C2631 37.2 NW 100/114¼ PN6

Table 5 Header dimensions

4Installation

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements!8

4 Installation

4.1 Installing the Cascade frame

Fix the supporting frame onto the first support of the

cascade unit with the M8 x 70 screws.

Fix the next support and continue the installation

until the cascade unit is complete.

Position the cascade frame in its final position.

Level the cascade frame both horizontally and verti-

cally by fitting additional washers below the support.

Secure the cascade frame to the floor. Make sure

that the bolts are aligned with the supports. Do not

bend or place the support under stress to make it fit.

Install the header pipe with the M8 x 70 screws.

Do not fully tighten the screws yet.

Fit the boiler mounting brackets on the top side of

the frame with M8 x 65 screws. Install the nuts at the

rear of the frame. The bottom side of the bracket

should be level with the bottom side of the frame.

4.2 Installing the Boiler assembly and

Pump Group

Hang the first boiler on the cascade frame as shown

in fig. 8 or fig. 9.

Put the boiler in the correct position and level it hori-

zontally and vertically. Use the set screws on the

lower rear of the boiler to adjust it.

Connect the pump group (see Pump group Installa-

tion instructions).

Remove the protective caps from the header.

Remove all red paint and unevenness from the

supply and return connections of the header.

Install the supply pipe(s) between the header and

the pump group.

Install the return pipe(s) between the header and the

pump group.

Repeat the above steps to install all boilers.

If required, seal off any unused connections of the

header.

Install the condensate drain pipe. Use the pre-

assembled mounting brackets on the supports for

this.

Install 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

– 4" low loss header M16 x 55.

Check the cascade system for leaks.

CAUTION

– Make sure that the cascade system is

installed on a flat surface.

– Make sure the cascade system is

installed level (use a spirit level).

– Check that the carpenters load-bearing

capacity of the floor is sufficient for the

weight of the installation (approx.

220 lbs [100 kg] for each boiler with

accessories).

NOTICE

Make sure that the slots for the boiler

mounting bracket are at the top side of the

frame.

NOTICE

For TR-back-to-back configurations, both

boiler mounting brackets are attached

simultaneously, using the M8 x 65 screws.

Fig. 8 Installation sequence for a TL-inline configuration

123

- Top view -

NOTICE

Observe the boiler installation sequence

indicated in fig. 8 and fig. 9.

Fig. 9 Installation sequence for TR-back-to-back

configuration

NOTICE

Pressure test all fittings prior to installing

covers.

- Top view -

4Installation

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements! 9

4.3 Installing the insulation

Install the rear insulation over the header (→fig. 10,

[1]).

Install the rear insulation part over the low loss

header

(→fig. 10, [2]).

If required, trim the insulation so that it is straight

(→fig. 10, [3]).

For 2½" and 3" low loss header:

- install the inserts in the outer insulation.

For a 2½" low loss header:

- install the reducing inserts in the outer recesses

(→fig. 11, [2]).

For a 3" low loss header:

- install the reducing inserts in the inner groves

(→fig. 11, [1]).

Click the insulation together.

Install the front insulation of the low loss header.

If required, trim the insulation so that it is straight

(→fig. 10, [3]).

Install the end cover over the header (→fig. 10, [4]).

Fig. 10 Header

NOTICE

First start up the cascade system and test

the system for leaks. Then install the insu-

lation.

Fig. 11 Inner insulation

4Notes

Logamax plus GB162-80 kW/100 kW – Subject to modifications resulting from technical improvements!10

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