Worcester GB162 User manual

UK/IE
INSTALLATION INSTRUCTIONS
CASCADE UNIT
6 720 648 720-000.1TD
FOR WALL HUNG GAS-FIRED CONDENSING BOILER GB162-65/80/100
6 720 648 720 (2011/07)

PRODUCT OVERVIEW
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2
Product overview
Fig. 1 Overview of cascade frame
1Supports
2Connecting frame
3Main gas pipe
4Flow and return header
5Gas connection kit TL-inline
6Mounting bracket
7Boiler connection set TL-inline
8Boiler connection set TR-back-to-back
9Boiler assembly connection kit
10 Gas connection kit TR-back-to-back
11 Flange
12 Low loss header
B1 A1
A1
B1
C2
C1 C1
A1
A2
B1
B2
B2
A2 C2
A2
B2
1
5
2
3
4
8
6
10
12
11
9
7
7214 6000-001.1TD

CONTENTS
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CONTENTS
1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Explanation of symbols . . . . . . . . . . . . . . . 4
2 General points . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Items supplied with unit . . . . . . . . . . . . . . . . . . . 6
4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Cascade frame installation . . . . . . . . . . . . . . . . 10
5.1 Boiler assembly and pump group
installation . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Installing the insulation . . . . . . . . . . . . . . 11

KEY TO SYMBOLS
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1KEYTOSYMBOLS
1.1 EXPLANATION OF SYMBOLS
WARNINGS
Keywords indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
•NOTE 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
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 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
Ba step in an action sequence
Æa reference to a related part in the
document or to other related documents
•a list entry
–a list entry (second level)
Table 1

GENERAL POINTS
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2 GENERAL POINTS
The installation instructions for cascade systems with
GB162 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.

ITEMS SUPPLIED WITH UNIT
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3ITEMS SUPPLIED WITH UNIT
CASCADE FRAME (ÆFIG. 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 (ÆFIG. 2)
(TO BE ORDERED FROM YOUR SUPPLIER)
•Mounting bracket
•Boiler
•Siphon
•Installation instructions.
Fig. 2 Items supplied with the boiler assembly
PUMP GROUP (ÆFIG. 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. 3 Items supplied with pump group
Worcester 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.
Depending on the desired output, a choice can be made
between different types.
BOILER ASSEMBLY CONNECTION KIT
The connection kit can be used for the 65-kW, 80-kW and
100-kW version. The connection kit includes a pressure
relief valve, a non-return valve, a pump and isolating
valves.
6 720 648 720-001.1TD
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
6 720 648 720-002.1TD

ITEMS SUPPLIED WITH UNIT
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BEND SETS WITH LOW LOSS HEADER
The GB162 cascade system can be installed in various
configurations (Æfig. 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.
Fig. 4 Cascade system configuration varieties
1 21 2
1 21 2
1 21 2
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DIMENSIONS
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4DIMENSIONS
Fig. 5 Dimensions of cascade systems 1
ATL-inline configuration
BTR-back-to-back installation
1Flow and return header
2Low loss header with bend set
3Low loss header, straight
4Enclosed welding flanges
497
147
525
575
X1
1722
Y1
675
810
525
L1
B1
B2
510
288
1
2
3
4
0
B3
F1
3 41
2
4
3
1
B
A
2 4
6 720 648 720-003.1TD

DIMENSIONS
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Fig. 6 Dimensions of cascade systems 2
Cascade
system
Length [mm]
X1 + Y1 Width [mm]
TR2 575 + 38 = 613 992
TR3, TR4 1100 + 42 = 1142 992
TR5, TR6 1625 + 45 = 1670 992
TL7, TR8 2150 + 45 = 2195 992
Table 3 TR-back-to-back configurations
CAUTION:
BThe dimensional tolerance is ±5%.
Cascade
System
Length [mm]
X1 + Y1 Width [mm]
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
180
992
1710
328
247
92
71
310 7214 6000-006.1TD

CASCADE FRAME INSTALLATION
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5CASCADE FRAME INSTALLATION
BFix the frame onto the first leg of the cascade unit.
Use the M8 x 70 screws for this.
BNow fix the next leg and continue fitting until the
cascade unit is compelte.
BPosition the frame into its final position.
BAdjust 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.
BSecure 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.
BInstall the main gas pipe. Use the M8 x 70 screws for
this. Do not fully tighten the screws yet.
BInstall the header pipe. Use the M8 x 70 screws for
this. Do not fully tighten the screws yet.
BFit 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.
5.1 BOILER ASSEMBLY AND PUMP
GROUP INSTALLATION
BHang the first boiler on the cascade frame as shown
in fig. 7 or fig. 8.
Fig. 7 Installation sequence for a TL-inline
configuration
Fig. 8 Installation sequence for TR-back-to-back
configuration
BPut 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.
BConnect the pump group (ÆGB162 Installation and
service instructions).
BRemove the protective yellow caps from the main gas
pipe.
BApply PTFE tape to the screw thread connections.
BConnect up the gas connection pipe between the gas
valve and the main gas pipe. Use PTFE tape to create
a perfect seal.
BRemove the protective caps from the header.
BRemove all red paint and unevenness from the flow
and return connections of the header.
BInstall the flow pipe(s) between the header and the
pump group.
BInstall the return pipe(s) between the header and the
pump group.
CAUTION:
BMake sure that the surface the cascade
system is to be installed on is flat.
BUse a spirit level when installing the cas-
cade system.
BCheck that the load-bearing capacity of
the floor is sufficient for the weight of the
installation (approx. 100 kg for each boil-
er 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.
You must observe the installation sequence
indicated in fig. 7 and fig. 8 when installing
the boilers.
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531
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CASCADE FRAME INSTALLATION
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BRepeat the above steps to install all boilers.
BIf required, seal off any unused connections of the
main gas pipe and the header.
BInstall the condensate drain pipe. Use the pre-
assembled mounting brackets on the supports for
this.
BWhen 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.
BInstall 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.
5.2 INSTALLING THE INSULATION
BInstall the rear insulation over the header [1].
BWhen an angled low loss header has been installed, fit
the insulation around the bends.
BInstall the rear insulation part over the low loss
header [2].
BIf required, trim the insulation so that it is straight [3].
Fig. 9 Sammelleitung
BFor 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 [2]. For a 3"
low loss header: install the reducing inserts in the
inner groves [1].
Fig. 10 Inner insulation
BClick the insulation together.
BInstall the front insulation of the low loss header. If
required, trim the insulation so that it is straight
(Æfig. 9, [3]).
BInstall the end cover over the header (Æfig. 9, [4]).
CAUTION:
BDo not install the pump group cover until
pressure has been supplied to the boiler
system and the gas pipe.
BCheck the cascade system for leaks.
CAUTION:
First start up the cascade system and test
the system for leaks. Then install the
insulation.
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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
6 720 648 720
WORCESTER, BOSCH GROUP:
TECHNICAL SUPPORT: 0844 693 3028
APPOINTMENTS: 0844 892 3000
SPARES: 01905 752571
LITERATURE: 0844 892 9800
TRAINING: 01905 752526
SALES: 01905 752640