Worcester GB162 Bedienungsanleitung

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

6 720 648 720 (2011/07)

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

C1 C1

A2 C2

7214 6000-001.1TD

CONTENTS

6 720 648 720 (2011/07) 3

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

6 720 648 720 (2011/07)

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

6 720 648 720 (2011/07) 5

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

6 720 648 720 (2011/07)

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

6 720 648 720 (2011/07) 7

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

7214 6000-004.1TD

DIMENSIONS

6 720 648 720 (2011/07)

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

1722

675

810

525

510

288

3 41

2 4

6 720 648 720-003.1TD

DIMENSIONS

6 720 648 720 (2011/07) 9

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]

[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

310 7214 6000-006.1TD

CASCADE FRAME INSTALLATION

6 720 648 720 (2011/07)

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.

31 2

7214 6000-007.1TD

2 4 6

531

7214 6000-008.1TD

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