Buderus GB162/100 User manual

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
B2
B1
A1
A1
B1
B2
A2
C2
C1
C1
C2
A2
A1
A2
B1
B2
9
7
1
5
2
3
4
11 12
10
6
8

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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

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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
12
12
12
12
12
12

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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
X1
1722
Y1
1 2 3 4
675
810
525
L1
B1
B2
510
288
1
2
3 4
4
1
2
3
4
0
B3
F1
A
B

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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)
B1
(mm)
B2
(mm)
B3
(mm)
L1
(mm)
F1
(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
92
71
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
1
3
2
4
Caution!
First start up the cascade system and test the
system for leaks. Then install the insulation.
Fig. 10 Inner insulation
1
12
2

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

Heating system specialist:
!
Cotswold Way,
Warndon,
Worcester,
WR4 9SW,
United Kingdom
Buderus Commercial Telephone: 01905 - 75 27 94
Buderus Commercial Fax: 01905 - 75 31 30
www.buderus-commercial.co.uk
In the UK, Buderus is a trading name of BBT Thermotechnology Ltd.

C & F Quadrant Ltd.
Unit L40 Cherry Orchard Industrial Estate
Cherry Orchard, Dublin 10
Telephone: [phone]
Fax: [phone]
www.c&fquadrant.ie
e-mail: sales@c&fquadrant.ie
UK
EIRE
721.758A – 7063A – 01/2006