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Cascade frame installation
6720813173 (2014/09) 7
5 Cascade frame installation
Fix the frame onto the first leg of the cascade unit. Use the M8 x 70
screws for this.
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.
5.1 Boiler assembly and pump group installation
Hang 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
Put 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.
Connect the pump group ( GB162 Installation and service
instructions).
Remove the protective yellow caps from the main gas pipe.
Apply PTFE tape to the screw thread connections.
Connect up the gas connection pipe between the gas valve and the
main gas pipe. Use PTFE tape to create a perfect seal.
Remove the protective caps from the header.
Remove all red paint and unevenness from the flow and return
connections of the header.
Install the flow 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 main gas pipe and
the header.
Install the condensate drain pipe. Use the pre-assembled mounting
brackets on the supports for this.
When 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.
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.
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).
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.
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.
7


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