Installation Instructions

List of Contents

• 1 General points
• 2 Items supplied with unit
• 3 Dimensions
• 4 Cascade frame installation
  • 4.1 Boiler assembly and pump group installation
  • 4.2 Installing the insulation

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
• Gas connection kit TL-inline
• Mounting bracket
• Boiler connection set TL-inline
• Boiler connection set TR-back-to-back
• Boiler assembly connection kit
• Gas connection kit TR-back-to-back
• Flange seals
• Low loss header
• Blank flanges
• Rubber pump seals
• Fixings
• Installation instructions

Fig. 1: Overview of Logamax plus GB162 cascade frame. This diagram shows the main structural components of the cascade unit, including supports, connecting frames, headers for flow and return, gas pipes, and connection kits for different configurations (TL-inline, TR-back-to-back).

Boiler (Fig. 2)

(to be ordered from your supplier)

• Mounting bracket
• Boiler
• Siphon
• Installation instructions.

Fig. 2: Items supplied with the boiler assembly. This illustration depicts the boiler itself, along with its mounting bracket and a siphon.

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. 3: Items supplied with pump group. This illustration shows the components of the pump group connection kit, including various valves, a pump, and a pressure gauge.

Configurations and Boiler Assembly Connection Kit

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.

Low loss header configuration

Table 2: Low loss header configuration.

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.

Table 1: Cascade selection

This table lists appliance performance in kW and the corresponding cascade system options (TL-inline, TR-back-to-back) for 80 kW and 100 kW Logamax plus GB162 boilers, indicating the number of boilers required for each configuration.

Fig. 4: Cascade system configuration varieties. This diagram illustrates different arrangements of boilers in cascade systems, showing inline (TL) and back-to-back (TR) setups with low loss headers.

3 Dimensions

Fig. 5: Dimensions of cascade systems 1. This diagram provides front and side views of cascade systems, detailing measurements for TL-inline (A) and TR-back-to-back (B) configurations, including flow and return header (1), low loss header with bend set (2), straight low loss header (3), and enclosed welding flanges (4). Key dimensions like X1, Y1, L1, B1, B2, B3, and F1 are indicated.

Fig. 6: Dimensions of cascade systems 2. This diagram shows overall dimensions of cascade systems, including width and height, with specific measurements for headers and flange dimensions.

Table 3: TR-back-to-back configurations

Table 4: TL-inline configurations

Caution!

The dimensional tolerance is ± 5%.

Table 5: Header dimensions

4 Cascade frame installation

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 installation (approx. 100 kg for each boiler with accessories).

• Fix the frame onto the first leg of the cascade unit. Use the M8 x 70 screws for this.

Caution!

• Make sure that the slots for the boiler mounting bracket are at the top of the frame.

• Now fix the next leg and continue fitting until the cascade unit is complete.
• Position the frame into its final position.
• Adjust 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.
• Secure 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.
• Install the main gas pipe. Use the M8 x 70 screws for this. Do not fully tighten the screws yet.
• Install the header pipe. Use the M8 x 70 screws for this. Do not fully tighten the screws yet.
• Fit 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!

• 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.