TopGas Cascade Condensing Gas Boilers Technical Information and Assembly Manual Output range 60 to 720 kw Subject to modification
Contents 1. Important Information 4 1.1. Documentation 4 1.2. Guarantee 4 1.3. Other instructions 4 1.4. Safety instructions 4 1.5. Related Installation Documents 5 1.6. Transport and Storage 5 1.7. Installation. Location requirements 5 Page No. 2. Technical Description 6 2.1. Technical Description 6 2.2. Cascade Product Codes 6 3. Technical Data 7 3.1. Technical data, TopGas Cascade 60 7 3.2. Technical data, TopGas Cascade 80 8 3.3. Technical data, TopGas Cascade 100 9 3.4 Technical data, TopGas Cascade 120 10 3.5. Technical Drawings, cascade in-line frame mounted 11 3.6. Technical Drawings, cascade back to back frame mounted 17 3.7. Technical Drawings, optional single and two boiler low loss headers 22 3.8. Technical Drawings, optional cascade low loss headers 23 3.9. Technical Drawings, optional cascade air and dirt separators 24 4. Installation requirements 25 4.1. Hydraulic Installation 25 4.2. Recommendations 25 4.3. Water Quality 25 4.4. Gas Connection 25 4.5. Flue Gas Connection, Chimney 26 4.6. Electrical Connections 26 4.7. Ventilation 26 4.8. Automatic Air Vent 26 4.9. Condensate Drainage 26 5. TopGas Cascade Assembly 27 5.1. Step 1: Build the frame (2-4 boiler inline, 3-4 boiler back to back) 27 5.1.1. Step 1: Build the frame (1 boiler inline, 2 boiler back to back) 29 5.2. Step 2: Mount the boilers 31 5.3. Step 3: Pipe the gas from the header to the boilers 32 5.4 Step 4: Connect the nipples to the flow and return headers 34 5.5. Step 5: Connect the boiler to the flow and return header (TopGas 60 and 80) 35 5.5.1 Step 5: Connect the boiler to the flow and return header (TopGas 100 and 120) 36 5.6. Step 6: Connect the blanking flanges 37 5.7. Step 7: Fit the pre-formed insulation wrap 38 5.8. Step 8: Fitting the back boiler connections 38 6. Accessories - Hydraulics and Gas 40 6.1. Low loss header 40 6.2. Air and dirt separator 41 2
6.3. TopGas 60 single boiler low loss header 41 6.4. TopGas 80 single or two boiler low loss header 41 6.5. TopGas 100,120 single boiler low loss header 41 6.6. Boiler circulating pump, TopGas (60,80) 41 6.7. Pump insulation cover, TopGas (60,80) 41 6.8 Boiler circulating pump, TopGas (100,120) 41 6.9. Boiler flow and return connection valve set, TopGas (60,80) 42 6.10 Boiler flow and return connection valve set, TopGas (100,120) 42 6.11 Gas Filter 42 6.12 Liquid gas conversion kit 42 7. Accessories Controls 43 8. Accessories - Flues (Cascade) 47 8.1. Cascade in-line connection kit 47 8.2. Cascade back to back connection kit 48 8.3. Additional kit for use with a back to back cascade flue system having an odd number of boilers 49 8.4. Cascade flue end cap 49 8.5. 1000mm extension piece (Ø200mm) 49 8.6. 1900mm extension piece (Ø200mm) 49 8.7. 45 flue elbow (Ø200mm) 50 8.8. 90 flue elbow (Ø200mm) 50 8.9. Flat roof flashing (Ø200mm) 50 8.10. Pitched roof flashing (Ø200mm) 50 8.11. 1600mm long roof terminal (Ø200mm) 50 8.12. Additional wall bracket (Ø200mm) 50 9. Accessories - Flues (Individual - concentric) 9.1. Flue spigot transition piece 51 9.2. Connection C100/150 to 2xE100PP 51 9.3. 1000mm extension (including support bracket) 51 9.4. 500mm extension (including support bracket) 51 9.5. Vertical terminal (black) with cap 51 9.6. Vertical adapter with 2 sample points 51 9.7. Vertical adapter with condensing drain connection, siphon kit & 2 sample points 51 9.8. 45 elbow 51 9.9. 90 elbow 51 9.10. Support bracket 51 9.11. Lead pitched roof flashing 52 9.12. Aluminium flat roof flashing 52 9.13. Wall terminal kit (for horizontal discharge) 52 9.14. Air inlet non-return damper for TopGas (60-120) only 52 10. Accessories - Flues (Individual - Plume kit) 53 10.1. Plume management kit 53 10.2. Plume 90 elbow 53 10.3. Plume 45 elbow 53 10.4. Plume extension 53 10.5. Plume nose piece 53 11. Typical Hydraulic Schematic 54 Hoval Service and Spares Contact details 55 3
1. Important Information 1.1. Documentation Hoval gas boilers are only to be installed and placed in operation by suitably qualified technicians; these instructions are therefore intended to give a brief description of the Hoval TopGas Cascade for the specialist covering the installation, commissioning, and subsequent maintenance of these units. Other documents apply in addition to these instructions. We accept no liability for any damage caused by failure to observe these instructions. There is a risk of injury or death to the user or others, or of damage to the product and other property, in the event of improper use or use for which it is not intended. The product is intended as a heat generator for closed hot water/central heating installations and for hot water generation. The system may only be placed in operation when all relevant standards and safety regulations have been complied with. The following conditions must be satisfied: The installation of boilers and their ancillary equipment is normally carried out by the Heating Engineer, and for the purpose of this manual he / she is regarded as the installer, and, as such, it is his / her responsibility to ensure that he / she has read and understood the contents of this manual before installing the boiler. 1.2. Guarantee Important Note: Proper functionality is only guaranteed if the installation and operating instructions are observed and the boiler is regularly maintained. The installation should be in accordance with current I.E.E. Regulations, relevant British & European Standards and Codes of Practice, Building Regulations and Local Authority Bylaws. Troubleshooting and damage repair caused by contaminated operating media (gas, water, combustion air), unsuitable chemical additives to the heating water, incorrect handling, faulty installation, inadmissible modifications and damage due to the exercising of force are not covered by our warranty; the same applies to corrosion through halogen compounds, e.g. from spray cans, paints, adhesives, solvents and cleaning agents. Hoval gas boilers are only to be installed by competent and qualified persons. No modifications are to be made to the boilers. 1.3. Other instructions Depending on the model, any further instructions are enclosed with the individually packed components. For any adjustments and additional accessories please refer to the relevant Technical Information Installation Instructions for the individual Hoval TopGas boilers and any relevant installation Standards and Regulations. 1.4. Safety instructions Installation and maintenance of the boiler must only be performed by a competent person with valid accreditation from the Health and Safety Executive in accordance with the Gas Safety (Installation and Use) Regulations 1998. The existing regulations, rules and guidelines must be observed when doing so. The competent person is also responsible for inspection, maintenance and repairs to the boiler, and alterations to the gas volume setting. Safety valve installed (closed system) Power supplies connected and tested Controls system commissioned System filled with water and suitably treated Expansion vessel connected and charged Boilers connected to an appropriate flue or chimney Burner parameters are set correctly When maintaining working on individual appliances or the TopGas cascade assembly; Allow the gas boilers to cool Switch off the boilers and isolate from the electrical supply Shut off the gas isolating valve to either the individual appliance or the cascade gas header Close the isolation valves of the appliance (heating flow and return) Replace all removed covers and cladding on completion of the repair / maintenance work Do not exceed the maximum operating pressure and temperature of the gas boiler (see identification plate) What to do in an emergency if you smell gas Installation errors, damage, tampering, unauthorised installation sites or similar can cause gas to escape and result in a risk of poisoning and explosion. If there is a smell of gas in the building, proceed as follows: Avoid rooms that smell of gas If possible, open doors and windows fully and ensure adequate ventilation Do not use naked flames (e.g. lighters, matches) Do not smoke Do not use any electrical switches, mains plugs, doorbells, telephones Close the gas meter isolator device or the main isolator If possible, close the gas isolator cock in the gas supply Leave the building If you can actually hear gas leaking, leave the building immediately and ensure that others do not enter the building Alert the fire brigade and police when you are outside the building Notify the gas supply company or National Grid Transco 0800 111 999 by telephone from outside the building! 4
1.5. Related Installation Documents To ensure the safe installation and continued satisfactory operation of your appliance, all works shall be carried out by a competent installer fully conversant with the required current and up to date, acts, standards, laws and regulations relevant for this range of equipment at the time of installation. Installers shall carry out a full site risk assessment and put into place all necessary steps and procedures to comply with the Health and Safety at Work Act and ensure safety of themselves and others with regard to manual handling and working at height requirements. Attention shall be paid to (but not restricted to) the following: Gas Safety (Installation and Use) regulations Non Domestic Heating, Cooling and Ventilation Compliance Guide All current Building Regulations for England and Wales (Includes Approved Codes of Practice and Approved Documents for building regulations e.g. L1, L2A, L2B, L8) The Building Standards, Scotland, and any requirements determined by the local authorities within BS 7671 Requirements for electrical installations. IEE Wiring Regulations The Electricity at Work Regulations The Clean Air Act 1993, 1968 1993 and the 3rd Edition of the Chimney Height memorandum 1981. (installations exceeding 150 kw) The Water supply (water fittings) regulations 1999 BS 5440-1 Flueing and ventilation for gas appliances BS 5854 Code of practice for flues and flue structures in buildings BS EN 12828 Design of water-based heating systems BS 6644 Specification for the installation of gas fired hot water boilers with rated inputs between 70 kw (net) and 1.8 MW (net) (2nd and 3rd family gases) BS 6700 Specification for the design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages BS 6880 Code of practice for low temperature heating systems with outputs greater than 45 kw: Part 1 Fundamental and design considerations Part 2 Selection of equipment Part 3 Installation, commissioning and maintenance BS 6981 Installation of low pressure gas pipework of up to 35mm in domestic premises BS 4814 Specification for: Expansion vessels using an internal diaphragm, for sealed hot water and heating systems BS 7074 Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems Part 1 Code of practice for domestic heating and hot water Part 2 Code of practice for low and medium temperature hot water systems BS 7593 Code of practice for treatment of water in domestic hot water central heating systems BS EN 13831 Closed expansion vessels with built in diaphragm BS EN 14336 Heating systems in buildings. Installation and commissioning of water based heating systems Directive VDI 2035 Prevention of damage in water heating systems due to scale formation Institute of Gas Engineers Publications: IGE/UP/1 (Edition 2) Strength testing, tightness testing and direct purging of industrial and commercial gas installations IGE/UP/1A (Edition 2) Strength testing, tightness testing and direct purging of small, low pressure industrial and commercial natural gas installations IGE/UP/1B (Edition 2) Tightness testing and direct purging of small natural gas installations IGE/UP/2 (Edition 2) Installation pipework on industrial and commercial premises IGE/UP/7 (Edition 2) Gas in timber and light steel framed buildings IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1 Flued appliances 1.6. Transport and Storage Please remove the packing materials and examine the consignment for correctness, completeness and possible transport damage. The equipment is to be transported and stored only in its original packing. Interim storage of Hoval gas boilers should only to take place in weather protected rooms and only in the original packing. The ambient conditions for storage must be within the following limits: Air temperature: -10 C - 50 C Air humidity: 50-85% relative humidity No condensation 1.7. Installation. Location requirements The installation site of the boiler cascade should allow proper connection of the flue duct work to all the boilers in the cascade. In addition, there should be adequate room for maintenance and air circulation around the cascade of boilers. The boiler cascade must be set up in a separate installation room. A floor standing boiler cascade must be installed on a flat, or level fire proof floor. All boilers must have a minimum clearance of 500mm at the front for preventative maintenance and commissioning work to be carried out. 5
2. Technical Description 2.1. Technical Description The Hoval TopGas Cascade allows a number of individual Hoval TopGas boilers to be mounted into a common arrangement. A cascade of one to six TopGas (60), (80), (100) or (120) boilers can be arranged in-line on a free standing frame. As an alternative a cascade of two to six boilers can be arranged back to back on a free standing frame. Each individual Hoval TopGas boiler is a gas fired appliance suitable and approved as a heat producer for hot water heating systems with a maximum flow temperature of 85 C and a maximum operating pressure of 2.5 bar. TopGas boilers are suitable for operation with either Natural Gas or LPG. Each boiler has an Aluminium Alloy integrated heat exchanger complete with integral down firing pre-mix burner and is capable of full condensing operation. The combustion air is drawn into the boiler via the burner fan through openings in the top casing of each boiler. This is directly from the plant room or via an air/flue gas concentric chimney arrangement allowing the boiler to be operated in a room sealed (or room air independent) manner. The combustion air is mixed with an incoming gas supply to match the individual boiler output and combustion is completed across a high temperature stainless steel mesh adjacent to the heat exchanger. The hot gases are forced through the heat exchanger to cool and deliver their energy to the heating system and then discharged via the flue. If the gases are cooled below their dew point condensation will occur on the boiler surfaces. Each TopGas boiler within the cascade is supplied with flexible flow and return hydraulic connections including fittings; a valve set incorporating isolation valves, safety valve, non return valve, and a drain valve; an A-rated circulating pump; and a gas connection kit including an isolation valve, 28mm TracPipe and necessary fittings. A condensate trap is supplied with each boiler to be fitted and piped to drain by the installer. A pipework header set is supplied with each cascade to allow all the individual TopGas boilers to be connected together to create the cascade. The LTHW and gas header size will vary depending on the cascade type. An insulation wrap is fitted to the LTHW header pipework. When assembled the TopGas cascade boilers can be individually controlled via an external building management system or can be sequenced by the optional heating controller set TopTronic E ZE1 into the master boiler with an additional TopTronic E ZE3 module fitted into all the other boilers in the cascade. A wired connection must be fitted between each boiler and a common flow sensor fitted into the pipework to allow control via the boiler(s). The cascade of boilers are connected to LTHW and gas headers forming a primary circuit via an optional low loss header or air/dirt separator. Each cascade is designed to operate with a T of 20 C on the primary circuit. When the optional low loss header or air/dirt separator the secondary sized can operate with either an 11 or 20 C T. Each boiler in the cascade requires a suitable flue connection to discharge products of combustion. Note that the boilers require a minimum working pressure of 1 bar and therefore the system pressure must be in line with this and must encompass the required volume of expansion. Each cascade is made up of individual boilers each of the same size. It is NOT possible to arrange a cascade with different size TopGas boilers. Please see the cascade options listed below. For further information on the TopGas boiler please refer to the Technical Information and Installation Instructions, document No. 4214783. 2.2. Cascade Product Codes In-line frame mounted (not including optional low loss header or air/dirt separator) Boiler Model No of boilers: One Two Three Four Five Six TopGas 60 7015818 7015839 7015840 7015841 7015842 7015843 TopGas 80 7015865 7015864 7015863 7015862 7015861 7015860 TopGas 100 7015799 7015773 7015812 7015813 7015814 7015815 TopGas 120 7015871 7015870 7015869 7015868 7015867 7015866 Back to back frame mounted (not including low loss header or air/dirt separator) Boiler Model No of boilers: One Two Three Four Five Six TopGas 60-7015844 7015845 7015846 7015847 7015848 TopGas 80-7015824 7015823 7015822 7015821 7015820 TopGas 100-7015801 7015800 7015802 7015816 7015817 TopGas 120-7015859 7015828 7015827 7015826 7015825 6
3. Technical data 3.1. Technical data, TopGas Cascade 60 Number of TopGas Boilers in Cascade Two Three Four Five Six Nominal output at 80/60 C with Natural Gas kw 113.2 169.8 226.4 283.0 339.6 Nominal output at 40/30 C with Natural Gas kw 124.0 186.0 248.0 310.0 372.0 Nominal output at 80/60 C with LPG kw 113.2 169.8 226.4 283.0 339.6 Nominal output at 40/30 C with LPG kw 122.2 183.3 244.4 305.5 366.6 Nominal load with Natural Gas kw 115.4 173.1 230.8 288.5 346.2 Nominal load with Propane kw 115.4 173.1 230.8 288.5 346.2 Operating pressure, minimum/maximum bar 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 Operating temperature, maximum C 85 85 85 85 85 Boiler water content litres 10.8 16.2 21.6 27.0 32.4 Boiler weight (dry, excluding frame and headers) kg 198 297 396 495 594 Frame, header and fixings weight (inline) kg 259 459 518 718 777 Frame, header and fixings weight (back to back) kg 248 301 317 517 565 Boiler full load efficiency @ 80/60 C (ncv basis/ gcv basis) % 99.4/89.6 99.4/89.6 99.4/89.6 99.4/89.6 99.4/89.6 Boiler part load efficiency @ 40/30 C (ncv basis/ gcv basis) % 110.4/99.5 110.4/99.5 110.4/99.5 110.4/99.5 110.4/99.5 UK Part L Seasonal efficiency % 97.6 97.6 97.6 97.6 97.6 Standing losses at 70 C W 210 315 420 525 630 NO X emissions (dry and stoichoimetric) mg/kwh 27 27 27 27 27 Natural Gas pressure, minimum/maximum mbar 17.4-50 17.4-50 17.4-50 17.4-50 17.4-50 LPG pressure, minimum/maximum mbar 37-50 37-50 37-50 37-50 37-50 Gas consumption (corrected 0 C, 1013mbar) Natural Gas E (H U 9.97kWh/m 3 ) m 3 /h 13.6 20.19 26.92 33.65 40.38 Propane (H U 25.9 kwh/m 3 ) m 3 /h 4.4 6.6 8.8 11 13.2 Operating voltage (1) V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Type of protection IP 20 20 20 20 20 Condensate quantity (40/30 C Natural Gas) l/h 10.8 16.2 21.6 27.0 32.4 Condensate ph value 4-6 4-6 4-6 4-6 4-6 Flue gas mass flow kg/h 190.2 285.3 380.4 475.5 570.6 Flue gas temperature 80/60 C C 65.6 65.6 65.6 65.6 65.6 Flue gas temperature 50/30 C C 44.8 44.8 44.8 44.8 44.8 (1) Each boiler in the cascade requires a 230Vac, 10amp power supply 7
3.2. Technical data, TopGas Cascade 80 Number of TopGas Boilers in Cascade Two Three Four Five Six Nominal output at 80/60 C with Natural Gas kw 147.4 221.1 294.8 368.5 442.2 Nominal output at 40/30 C with Natural Gas kw 162.0 243.0 324.0 405.0 486.0 Nominal output at 80/60 C with LPG kw 147.4 221.1 294.8 368.5 442.2 Nominal output at 40/30 C with LPG kw 159.8 239.7 319.6 399.5 479.4 Nominal load with Natural Gas kw 150.8 226.2 301.6 377.0 452.4 Nominal load with Propane kw 148.8 223.2 297.6 372.0 446.4 Operating pressure, minimum/maximum bar 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 Operating temperature, maximum C 85 85 85 85 85 Boiler water content litres 10.8 16.2 21.6 27.0 32.4 Boiler weight (dry, excluding frame and headers) kg 198 297 396 495 594 Frame, header and fixings weight (inline) kg 259 459 518 718 777 Frame, header and fixings weight (back to back) kg 248 301 317 517 565 Boiler full load efficiency @ 80/60 C (ncv basis/ gcv basis) % 98.8/89.0 98.8/89.0 98.8/89.0 98.8/89.0 98.8/89.0 Boiler part load efficiency @ 40/30 C (ncv basis/ gcv basis) % 110.8/99.9 110.8/99.9 110.8/99.9 110.8/99.9 110.8/99.9 UK Part L Seasonal efficiency % 97.8 97.8 97.8 97.8 97.8 Standing losses at 70 C W 210 315 420 525 630 NO X emissions (dry and stoichoimetric) mg/kwh 28 28 28 28 28 Natural Gas pressure, minimum/maximum mbar 17.4-50 17.4-50 17.4-50 17.4-50 17.4-50 LPG pressure, minimum/maximum mbar 37-50 37-50 37-50 37-50 37-50 Gas consumption (corrected 0 C, 1013mbar) Natural Gas E (H U 9.97kWh/m 3 ) m 3 /h 15 22.5 30 37.5 45 Propane (H U 25.9 kwh/m 3 ) m 3 /h 5.76 8.64 11.52 14.4 17.28 Operating voltage (1) V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Type of protection IP 20 20 20 20 20 Condensate quantity (40/30 C Natural Gas) l/h 14.2 21.3 28.4 35.5 42.6 Condensate ph value 4-6 4-6 4-6 4-6 4-6 Flue gas mass flow kg/h 249 373.3 498 622.5 747 Flue gas temperature 80/60 C C 74.4 74.4 74.4 74.4 74.4 Flue gas temperature 40/30 C C 52 52 52 52 52 (1) Each boiler in the cascade requires a 230Vac, 10amp power supply 8
3.3. Technical data, TopGas Cascade 100 Number of TopGas Boilers in Cascade Two Three Four Five Six Nominal output at 80/60 C with Natural Gas kw 180.8 271.2 361.6 452 542.4 Nominal output at 40/30 C with Natural Gas kw 200 300 400 500 600 Nominal output at 80/60 C with LPG kw 180.8 271.2 361.6 452 542.4 Nominal output at 40/30 C with LPG kw 200 300 400 500 600 Nominal load with Natural Gas kw 186 279 372 465 558 Nominal load with Propane kw 186 279 372 465 558 Operating pressure, minimum/maximum bar 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 Operating temperature, maximum C 85 85 85 85 85 Boiler water content litres 14 21 28 35 42 Boiler weight (dry, excluding frame and headers) kg 232 348 464 580 696 Frame, header and fixings weight (inline) kg 293 505 586 798 879 Frame, header and fixings weight (back to back) kg 272 347 367 579 639 Boiler full load efficiency @ 80/60 C (ncv basis/ gcv basis) % 98.3/88.6 98.3/88.6 98.3/88.6 98.3/88.6 98.3/88.6 Boiler part load efficiency @ 40/30 C (ncv basis/ gcv basis) % 110.9/99.9 110.9/99.9 110.9/99.9 110.9/99.9 110.9/99.9 UK Part L Seasonal efficiency % 97.8 97.8 97.8 97.8 97.8 Standing losses at 70 C W 230 345 460 575 690 NO X emissions (dry and stoichoimetric) mg/kwh 26 26 26 26 26 Natural Gas pressure, minimum/maximum mbar 17.4-50 17.4-50 17.4-50 17.4-50 17.4-50 LPG pressure, minimum/maximum mbar 37-50 37-50 37-50 37-50 37-50 Gas consumption (corrected 0 C, 1013mbar) Natural Gas E (H U 9.97kWh/m 3 ) m 3 /h 18.64 27.96 37.28 46.6 55.92 Propane (H U 25.9 kwh/m 3 ) m 3 /h 7.18 10.77 14.36 17.95 21.54 Operating voltage (1) V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Type of protection IP 20 20 20 20 20 Condensate quantity (40/30 C Natural Gas) l/h 17.8 26.7 35.6 44.5 53.4 Condensate ph value 4-6 4-6 4-6 4-6 4-6 Flue gas mass flow kg/h 310 465 620 775 930 Flue gas temperature 80/60 C C 69 69 69 69 69 Flue gas temperature 40/30 C C 48 48 48 48 48 (1) Each boiler in the cascade requires a 230Vac, 10amp power supply 9
3.4. Technical data, TopGas Cascade 120 Number of TopGas Boilers in Cascade Two Three Four Five Six Nominal output at 80/60 C with Natural Gas kw 215.2 322.8 430.4 538 645.6 Nominal output at 40/30 C with Natural Gas kw 240 360 480 600 720 Nominal output at 80/60 C with LPG kw 215.2 322.8 430.4 538 645.6 Nominal output at 40/30 C with LPG kw 240 360 480 600 720 Nominal load with Natural Gas kw 223 334.5 446 557.5 669 Nominal load with Propane kw 223 334.5 446 557.5 669 Operating pressure, minimum/maximum bar 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 Operating temperature, maximum C 85 85 85 85 85 Boiler water content litres 14 21 28 35 42 Boiler weight (dry, excluding frame and headers) kg 232 348 464 580 696 Frame, header and fixings weight (inline) kg 293 505 586 798 879 Frame, header and fixings weight (back to back) kg 272 347 367 579 639 Boiler full load efficiency @ 80/60 C (ncv basis/ gcv basis) % 97.7/88.0 97.7/88.0 97.7/88.0 97.7/88.0 97.7/88.0 Boiler part load efficiency @ 40/30 C (ncv basis/ gcv basis) % 109.0/98.2 109.0/98.2 109.0/98.2 109.0/98.2 109.0/98.2 UK Part L Seasonal efficiency % 96.3 96.3 96.3 96.3 96.3 Standing losses at 70 C W 230 345 460 575 690 NO X emissions (dry and stoichoimetric) mg/kwh 27 27 27 27 27 Natural Gas pressure, minimum/maximum mbar 17.4-50 17.4-50 17.4-50 17.4-50 17.4-50 LPG pressure, minimum/maximum mbar 37-50 37-50 37-50 37-50 37-50 Gas consumption (corrected 0 C, 1013mbar) Natural Gas E (H U 9.97kWh/m 3 ) m 3 /h 21.4 32.1 42.8 53.5 64.2 Propane (H U 25.9 kwh/m 3 ) m 3 /h 8.34 12.51 16.68 20.85 25.02 Operating voltage (1) V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Type of protection IP 20 20 20 20 20 Condensate quantity (40/30 C Natural Gas) l/h 20.6 30.9 41.2 51.5 61.8 Condensate ph value 4-6 4-6 4-6 4-6 4-6 Flue gas mass flow kg/h 372 558 744 930 1116 Flue gas temperature 80/60 C C 74.9 74.9 74.9 74.9 74.9 Flue gas temperature 40/30 C C 52.7 52.7 52.7 52.7 52.7 (1) Each boiler in the cascade requires a 230Vac, 10amp power supply 10
3.5. Technical Drawings, cascade in-line frame mounted One boiler, in-line frame mounted - 1 x TopGas 60 (7015818), 1 x TopGas 80 (7015865) ONE BOILER 1* TopGas 45-80 One boilers, in-line frame mounted - 1 x TopGas 100 (7015799), 1 x TopGas 120 (7015871) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 ONE BOILER 1* TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 11
3.5. Technical Drawings, cascade in-line frame mounted Two boilers, in-line frame mounted - 2 x TopGas 60 (7015839), 2 x TopGas 80 (7015864) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 TWO BOILER 1* 2 TopGas 45-80 Two boilers, in-line frame mounted - 2 x TopGas 100 (7015773), 2 x TopGas 120 (7015870) Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 12
3.5. Technical Drawings, cascade in-line frame mounted Three boilers, in-line frame mounted - 3 x TopGas 60 (7015840), 3 x TopGas 80 (7015863) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 THREE BOILER 1* 2 & 1*1 TopGas 45-80 Three boilers, in-line frame mounted - 3 x TopGas 100 (7015812), 3 x TopGas 120 (7015869) Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 13
3.5. Technical Drawings, cascade in-line frame mounted Four boilers, in-line frame mounted - 4 x TopGas 60 (7015841), 4 x TopGas 80 (7015862) FOUR BOILER 2* 2 TopGas 45-80 Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 Four boilers, in-line frame mounted - 4 x TopGas 100 (7015813), 4 x TopGas 120 (7015868) ONE BOILER 4 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 14
3.5. Technical Drawings, cascade in-line frame mounted Five boilers, in-line frame mounted - 5 x TopGas 60 (7015842), 5 x TopGas80 (7015861) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 FIVE BOILER 2 * 2 & 1*1 TopGas 45-80 Five boilers, in-line frame mounted - 5 x TopGas 100 (7015814), 5 x TopGas 120 (7015867) ONE BOILER 5 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 15
3.5. Technical Drawings, cascade in-line frame mounted Six boilers, in-line frame mounted - 6 x TopGas 60 (7015843), 6 x TopGas 80 (7015860) SIX BOILER 3* 2 TopGas 45-80 Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 Six boilers, in-line frame mounted - 6 x TopGas 100 (7015815), 6 x TopGas 120 (7015866) ONE BOILER 6 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 16
3.6. Technical Drawings, cascade back to back frame mounted Two boilers, back to back frame mounted - 2 x TopGas 60 (7015844), 2 x TopGas 80 (7015824) TWO BOILERS 1*2 TopGas 45-80 Two boilers, back to back frame mounted - 2 x TopGas 100 (7015801), 2 x TopGas 120 (7015859) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 TWO BOILER 1*2 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 17
3.6. Technical Drawings, cascade back to back frame mounted Three boilers, back to back frame mounted - 3 x TopGas 60 (7015845), 3 x TopGas 80 (7015823) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 FOUR BOILERS 2*2 TopGas 45-80 Three boilers, back to back frame mounted - 3 x TopGas 100 (7015800), 3 x TopGas 120 (7015828) THREE BOILERS 2+1 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 18
3.6. Technical Drawings, cascade back to back frame mounted Four boilers, back to back frame mounted - 4 x TopGas 60 (7015846), 4 x TopGas 80 (7015822) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 FOUR BOILERS 2*2 TopGas 45-80 Four boilers, back to back frame mounted - 4 x TopGas 100 (7015802), 4 x TopGas 120 (7015827) Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ FOUR BOILERS 2*2 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 19
3.6. Technical Drawings, cascade back to back frame mounted Five boilers, back to back frame mounted - 5 x TopGas 60 (7015847), 5 x TopGas 80 (7015821) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 FIVE BOILERS 3*2 TopGas 45-80 Five boilers, back to back frame mounted - 5 x TopGas 100 (7015816), 5 x TopGas 120 (7015826) FIVE BOILERS 3*2 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 20
3.6. Technical Drawings, cascade back to back frame mounted Six boilers, back to back frame mounted - 6 x TopGas 60 (7015848), 6 x TopGas 80 (7015820) Connections 1. Gas DN65 PN6 2. Heating Flow DN80 PN6 3. Heating Return DN80 PN6 4. Condensate Drain trap DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G1 SIX BOILERS 3*2 TopGas 45-80 Six boilers, back to back frame mounted - 6 x TopGas 100 (7015817), 6 x TopGas 120 (7015825) SIX BOILERS 3*3 TopGas 100/120 Connections 1. Gas DN65 PN6 2. Heating Flow DN100 PN6 3. Heating Return DN100 PN6 4. Condensate Drain DN40 5. Flue Concentric 100/150mm 6. Safety Valve R1 7. Boiler Drain G¾ Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements Optional low loss header or air/dirt seperator not shown 21
3.7. Technical Drawings, optional single and two boiler low loss headers Single TopGas 60 boiler low loss header (2057320) 90 1" BSP Boiler Flow 171 1 1/2" BSP System Flow 83 35 400 234 330 Please see Accessories section for further information 1" BSP Boiler Return 90 1 1/2" BSP System Return Single or two TopGas 80 boiler low loss header (2057322) 150 2 1/2" Boiler Flow 270 2 1/2" System Flow 75 80 650 450 500 Please see Accessories section for further information Single TopGas 100,120 boiler low loss header (6043445) 2 1/2" BSP Boiler Return 150 2 1/2" BSP System Return Please see Accessories section for further information Connections 1. Primary Flow DN100 PN6 2. Primary Return DN100 PN6 3. Secondary Flow DN100 PN6 4. Secondary Return DN100 PN6 22
3.8. Technical Drawings, optional cascade low loss headers Low loss header for all TopGas 60,80 cascades (6034283) Please see Accessories section for further information Connections 1. Primary Flow DN80 PN6 2. Primary Return DN80 PN6 3. Secondary Flow DN125 PN6 4. Secondary Return DN125 PN6 5. Automatic Air Vent Connection 1/2 BSP 6. Pocket Connection 1/2 BSP (plugged) 7. Drain Point 1/2 BSP (plugged) Low loss header for all TopGas 100,120 cascades (6042824) Please see Accessories section for further information Connections 1. Primary Flow DN100 PN6 2. Primary Return DN100 PN6 3. Secondary Flow DN150 PN6 4. Secondary Return DN150 PN6 5. Automatic Air Vent Connection 1/2 BSP 6. Pocket Connection 1/2 BSP (plugged) 7. Drain Point 1/2 BSP (plugged) 23
3.9. Technical Drawings, optional cascade air and dirt separators Air and dirt separator for all TopGas 60 and TopGas 80 cascades (2067549) Air Dirt Seperator for TopGas 60 & 80 Cascades Please see Accessories section for further information Connections 1. Primary Flow DN80 PN6 2. Primary Return DN80 PN6 3. Secondary Flow DN125 PN6 4. Secondary Return DN125 PN16 5. Automatic Air Vent 6. Pocket Connection 1/2 BSP (plugged) 7. Drain Valve 1/2 BSP (plugged) Air and dirt separator for all TopGas 100 and TopGas 120 cascades (2066122) Please see Accessories section for further information Connections 1. Primary Flow DN100 PN6 2. Primary Return DN100 PN6 3. Secondary Flow DN150 PN6 4. Secondary Return DN150 PN6 5. Automatic Air Vent 6. Pocket Connection 1/2 BSP (plugged) 7. Drain Valve 1/2 BSP (plugged) 24
4. Installation Requirements 4.1. Hydraulic Installation 4.3. Water Quality Water from each safety valve discharge can cause severe burns. Install the safety valve to ensure that there is no danger to other persons. Route the safety valve discharge pipe to a tundish and pipe to drain (not supplied by Hoval). The heating water must be treated in the TopGas Cascade to the correct standard. Specific information can be found in the TopGas Technical information Installation instructions document: TopGas 35-120, document: 4214 783 Flush the heating installation thoroughly prior to installation as any foregin bodies or contaminants in the pipework may damage the boiler. If oxygen ingress is possible ensure that de-aeration equipment is installed. If the plant is topped up with raw water ensure the overall water quality still meets the required specification. The total amount of filling and replacement heating system water which is used throughout the total service life of the boiler must not exceed three times the service capacity of the plant. 4.2. Recommendations It is recommended that each system should be filled and refilled with treated water and specialist companies will be able to advise in this respect. Before filling check the following: The system heating water must be tested anually as a minimum but Hoval recommend this to be done twice a year or after every drain down and re-fill. If the water treatment specialist recommends that this needs to be done more frequently please follow their advice. On account of the danger of spot corrosion the chloride, nitrate and sulphate contents of the heating water must not exceed 200mg/l in total. The ph value of the heating water should lie between 8,0 and 8,5 after 6-12 weeks of heating operation. The boilers have aluminium heat exchangers which are in contact with the heating water: Any inhibitors used must take account of this and specialist advice should be sought prior to filling the system based on local water quality conditions. All connections are made and tightened Sensor and instrument pockets are fitted and water tight Spare sockets are fitted with plugs and are water tight All valves in the heating circuit are open The installation is completely vented if a pressurisation unit is installed reference should be made to the manufacturers filling instructions and applied The installation is fully flushed A suitable strainer and air/dirt separator are fitted to protect the equipment supplied. For connection to the system a hydraulic header has to be used. Hoval offer an optional low loss header kit or an air and dirt separator that can act as a hydraulic header between the boiler cascade and the heating system. These options should be installed adjacent to the boiler cascade and advice should be sought from Hoval technical if an alternative method is to be adopted. 4.4. Gas Connection The gas installation must fully conform with IGE/UP/2 and all related regulations. The incoming natural gas supply to the TopGas Cascade must be between 18-50 mbar with all connected appliances at full output. For LPG this must be between 37-50 mbar. All gas pipework must be tested and purged in accordance with IGE/UP/1 or IGE/UP/1A. Any gas work performed must be done by competent persons holding a valid qualification. The pump set supplied with each boiler in the cascade is sized to provide a ΔT of 20 K across each boiler flow and return. An electrical flying lead is provided for the installer to connect each pump to it s respective TopGas boiler. A minimum flow must be maintained through a boiler that is firing or being called to fire. As standard the TopGas boilers have a pump over-run feature that maintains water flow through the boilers for five minutes after it has completed its firing sequence. To allow the boiler to operate correctly it must have a minimum water pressure of 1 bar. If this is not present an error code P27 will be displayed on each individual boiler control panel and the boiler will not operate. IMPORTANT NOTE: Following assembly of the TopGas Cascade arrangement it is the installer s responsibility to carry out suitable water-side and gas-side pressure tests and a flue system tightness test. These tests are to be carried out by suitably qualified personnel. 25
4.5. Flue Gas Connection, Chimney Each boiler in the TopGas cascade must be fitted with a flue to safely exhaust the products of combustion from the plant room. Each boiler can be configured such that it takes it air directly from the boiler plant room (room air dependent) or via closed concentric flue/air supply system (room sealed or room air independent). Ideally the vertical adapter piece (Part No 2042406), which includes the sampling points, must be fitted to the transition piece to ensure that flue gas sampling can be carried out close to the boiler. If the headroom immediately above the boiler is limited then it would be acceptable to fit this part in the horizontal directly after the bend provided that it is positioned in such a way that condensate is not able to leak from the sample points in the flue. Care should therefore be exercised when fitting this flue part. In the case of room sealed operation each of the boilers within the cascade must be fitted with individual concentric (100/150mm) flue. The maximum length of the concentric flue allowable will depend on the TopGas model and the proposed layout or route of the flue. Where the boiler cascade takes its air supply directly from the plant room, It is possible to combine one or more TopGas boilers into a common flue duct, where each boiler within the cascade is connected to a common duct or ducts via an individual flue connection piece. In this case all boilers in the cascade should be provided with the optional air inlet non-return flap (available as an accessory for the TopGas 60-120) boilers or with an external non-return flap (not Hoval supply). 4.6. Electrical Connections The electrical installation must fully conform with BS7671 and all other regulations. Each boiler requires its own 230Vac, 10A power supply with an isolator mounted locally to the boiler (not by Hoval). When a TopGas Cascade is purchased with the TopTronic E cascade control system each boiler will need to be connected together with a three core communications cable (not by Hoval). Please refer to the electrical wiring diagram supplied with the cascade package. This will detail other optional electrical items that have been purchased. See the Accessories section in this document for futher details. In all cases the flue terminal positions should comply with the requirements of BS 5440-1 in the case of cascades with a total heat input <70 kw net CV basis, or the requirements of BS 6644 when the aggregate heat input of the cascade >135 kw on a net CV basis (note that this may limit the number of low level horizontal flue discharge options available). Owing to the water vapour content and the relatively low temperature of the flue gases then further condensation can be expected within the flue system and therefore provision must be made to remove this from the flue with appropriate trapped drains. There must be a fall on horizontal sections of the flue to prevent standing condensate, and the flue must be able to withstand the mildly acidic nature of the condensate. The flue system must be pressure tight and able to operate under a positive pressure without products of combustion escaping into the plant room or other parts of the building that the flue passes through. Where appliance is to be room sealed (LAS) then a Hoval flue adaptor piece with sample points (part no. 2042406) must be fitted on the boiler to allow the boilers to be commissioned and serviced. 4.7. Ventilation Sufficient air must be supplied to each boiler to ensure that the requirements of combustion and cooling are met and to afford a general level of ventilation in the plant room. In ALL cases the necessary ventilation to the Hoval TopGas cascade must be in line with the requirements set out in BS 6644, IGE/UP/10 and any local requirements. Cooling air around the boilers must be sufficient such that the temperatures in the installation location do not exceed those listed in BS 6644. 4.8. Automatic Air Vent All TopGas boilers are fitted with automatic air vents. These must be left open and operative at ALL times! If the cap is closed then damage will occur to the boilers. 4.9. Condensate Drainage Only flue gas systems or components tested and approved should be connected to the Hoval TopGas boiler or the Hoval TopGas boiler cascade. It is important that a flue sample point is fitted on both sides of the concentric flue system or on the flue side of a conventional flue. IMPORTANT NOTE: Where the Hoval UK 150/100 concentric flue system is to be used with a TopGas boiler then the flue spigot transition piece (Part No 2069894) must be fitted to the boiler and clamped into position. The remaining flue parts to the terminal piece are then push fit. Each TopGas boiler is supplied with a condensate trap which must be fitted. This must then be piped to the drain but with a suitable air gap between the discharge point and the drain or galley so this pipe cannot pressurise (not by Hoval). No isolating or non-return valves should be fitted in the condensate discharge pipework and the pipework material should be suitable for use with condensate. 26
5.TopGas Cascade Assembly, 2 boilers in-line and 3 or 4 boilers back to back Find a suitable space and prepare the frame for assembly. Each frame will come with: 4 x 80mm M12 bolts (2056546) 2 x side plates 4 x M12 nuts (2042599) 1 x vertical centre support 8 x M12 washers (2042608) 2 x horizontal support arms 1 x 1/8 Gas test nipple (2056819) 1 x horizontal cross bar 1 x 1/4 to 1/8 reducing bush (2068414) 12 x 60mm M16 bolts (2042557) 12 x M16 nuts (2044783) 24 x M16 washers (2042610) Flow, return and gas connection gaskets 8 x M10 adjustable feet (2067454) 2 x DN80 Unions (TG60, 80) 2067951 2 x DN100 Unions (TG100,120) 2043066 Insulation wrap on LTHW pipework (not shown) Fit the adjustable feet to both the center support and both side plates. Set to the correct length and tighten using a 22mm spanner. Lay out the frame work on the floor and ensure you have all correct components. You will see M10 holes to the outside ends on both support arms. Ensure these are at the bottom so they line up with the side plates. Support arms will have: 2 x 130mm M12 bolts (2056533) 2 x M10 nuts (2042599) 4 x M10 washers (2042608) Screw the M12 bolts (2056533) through both support arms and centre support with a washer (2042608) either side and tighten to 45Nm and stand the frame up. 27
Hold up the center piece and support arms and align with the side piece. Place the M12 bolt (2056546) through the support arm and through the side piece with a washer either side (if holes do not align then adjust the feet as appropriate) and add the M10 nut (2042599). Repeat this process for the other side and tighten bolts to 45Nm. Once you have bolted the center piece and side pieces together you should have the stand as shown to the right. To ensure that the frame is stable check with a spirit level. The cross bar has an alignment hole in the middle of the underside as shown in the picture to the right. This slots onto the top of the centre support so that the holes at either end align with the holes on the side pieces. Thread both the M12 bolt (2056546) through the crossbar and side pieces with a washer either side, add the M12 nut, then tighten both to 45Nm. The frame should now look like the image to the right. Please ensure that all of the bolts have washers either side of the frame work and are all tightened to 45Nm. 28
If the cascade arrangment purchased is a three or four boiler back to back model, you will receive rear support legs as shown opposite. These are to be fitted onto the rear of the side plates as shown. You will also recieve extension pipes that will connect the flex connections to the header. Each rear support will come with the fixings: 2 x 80mm M12 bolts (2056546) 2 x M12 nuts (2042599) 4 x M12 washers (2042608) 3 x M10 adjustable feet (2067454) Build as shown and tighten to 45Nm. 5.1.1 Step 1: Build the frame (1 boiler inline 2 boiler back to back) 6 x 80mm M12 bolts (2056546) 2 x side plates 6 x M12 nuts (2042599) 2 x horizontal support beam 12 x M12 washers (2042608) 1 x horizontal cross bar 1 x 1/8 Gas test nipple (2056819) 1 x 1/4 to 1/8 reducing bush (2068414) 12 x 50mm M16 bolts (2053287) 12 x M16 nuts (2044783) 24 x M16 washers (2042610) Flow, return and gas connection gaskets 6 x M10 adjustable feet (2067454) 2 x DN80 Unions (TG60, 80) (2067951) 2 x DN100 Unions (TG100,120) (2043066) Insulation wrap on LTHW pipework (not shown) Fit the adjustable feet to both of the side plates. Set to the correct length and tighten using a 22mm spanner. 29
Hold the two side pieces in line and align the holes at the bottom with the holes in the bottom support beam using the M12 bolts (2056546). Tighten the nuts after both bolts are through the holes to make the alignment easier. Build as shown and tighten to 45Nm. Hold the middle support beam in place and thread the M12 bolts (2056546) through the beam and the aligned hole in the framework. Ensure that the holes are to the bottom of the beam for boiler alignment. Tighten the nuts after both bolts are through the holes to make the alignment easier. Build as shown and tighten to 45Nm. Hold the crossbar in place and thread the M12 bolts (2056546) through the crossbar and the aligned hole in the framework. Tighten the nuts after both bolts are through the holes to make the alignment easier. Build as shown and tighten to 45Nm. Once you have bolted the crossbar piece to the frame then screw in the engineering studs by hand into the installed inserts. Place the gas pipe into the respective hole and the flow pipe (top slot) and the return pipe (bottom slot) and ensure they are securely in place with the alignment slots, this will ensure that the connections are correctly aligned. 30
If the cascade arrangment purchased is a two boiler back to back model, you will receive rear support legs as shown opposite. These are to be fitted onto the rear of the side plates as shown. You will also receive extension pipes that will connect the flex connections to the header. Each rear support will come with the fixings: 1 x 80mm M12 bolts (2056546) 1x 35mm M12 bolts (2042537) 2 x M12 nuts (2042599) 4 x M12 washers (2042608) 2 x M10 adjustable feet (2067454) If there are multiple sets of headers in your installation please connect them and tighten to 180Nm ensuring they have the correct gaskets between them: 65mm NB - 110mm OD, 78mm ID (2056845) 80mm NB - 132mm OD, 90mm ID (2043206) 100mm NB - 165mm OD, 115mm ID (2043208) 5.2. Step 2: Mount the boilers Connect each TopGas boiler to the frame using: 2 x M10 engineering studs (2067745) 2 x M10 nuts (2042608) Tighten to a maximum of 60Nm. Ensure that the boiler is safely lifted into position using appropriate lifting equipment. 31
TopGas Cascade Assembly 5.3. Step 3: Pipe the gas from the header to the boilers Using PTFE tape (or other suitable thread sealing media), wrap both sides of the 1 nipple (2043076) before screwing into the header. Ensure sealing media used is suitable for natural gas. Fit the nipple into the header and tighten ensuring a good seal is made. Fit the 1 gas isolation valve (2067892) to the nipple. On the outlet of the gas isolation valve, fit the TracPipe connector (2067994). Before fitting apply PTFE tape (or other suitable thread sealing media). Ensure sealing media used is suitable for natural gas. Screw into the top of the valve and tighten ensuring a good seal is made. Note, ensure that the valve is in the correct orientation, when the valve is open the handle must point upwards. Attach the 3/4 to 1 concentric reducer (2068561) to the gas connection on the boiler and then fit the TracPipe connector (2067994). Before fitting apply PTFE tape (or other suitable thread sealing media). Ensure sealing media used is suitable for natural gas. Screw into both sides of the boss and tighten ensuring a good seal is made. 32
TopGas Cascade Assembly Measure the gap between the two TracPipe connectors and cut the 28mm TracPipe to length using a rotary tube cutter. Cut between corrugations. Take care not to tighten the pipe cutter too tightly as it may cause deformations. You will have been supplied a 500mm length of TracPipe per boiler TopGas 60,80,100,120 (2067839). Measure carefully - do not cut this too short. Ensure the cut has a good smooth edge. Using a knife, cut back the insulation on the TracPipe approximately 25mm to allow the fitting to slide onto the pipe. Slide on the brass union and fit the sealing washer to the next available full corrugation. Pull the brass union back over the sealing washer once complete. Do this to both ends of the pipe. Once the pipe is complete, fit it to both connector ends to the fittings now attached to the boiler and the header. Tighten these to a value of 61Nm. Once complete apply tape to the exposed stainless steel pipework as this will reduce the risk of any external damage. Fit the loose 1/4 to 1/8 reducing bush into the 1/4 socket fitted on top of the horizontal gas header, then fit the 1/8 gas nipple into the bush using suitable sealing media. 33
TopGas Cascade Assembly 5.4. Step 4: Connect the nipples to the flow and return headers Prepare all flexible pipework nipples as below using PTFE tape (or other suitable thread sealing media). There will be 4 off per boiler. Please be aware that you do not apply PTFE tape to the side with the flat face suitable for a gasket. Screw these nipples into the headers and also into the valve sets. Tighten to ensure a good seal is made. When installing a back to back arrangement you will be supplied extention pieces for the flow, return and gas pipe that screw into the connection on the header. TopGas 100,120 Flow and Return Extension pipe (5041198) TopGas 60,80 Flow and Return Extension pipe (5041200) TopGas 60-120 Gas Extension pipe (5041199) 34
TopGas Cascade Assembly 5.5. Step 5: Connect the boiler to the flow and return headers (TopGas 60 and 80) Arrange the pump (2056729) and valve set (6012948) ready to be connected to the boiler. Please be aware that all of the gaskets must be fitted in the correct positions as shown in the picture on the right. Note: the pump may be different to the one shown in the photograph. Fit the flow pipe valve set to the boiler complete with supplied gasket and union (2067951) and tighten. Ensure all valves are correctly aligned as per the picture. Fit the supplied circulation pump to the return connection of the boiler with a gasket joint. Be aware of the flow direction, this should be pointing up towards the boiler. When satisfied that all is correct tighten the union (2067951). Fit the remaining return pipe valve set to the underside of the pump using the supplied gasket and tighten. Ensure all valves are correctly aligned as per the picture below. When complete fit the two piece pump insulation housing (2056817). The pump will be supplied with a 2m long MOLEX connector lead (2056730) that wires into terminals 25, N, E. 35
5.5.1. Step 5: Connect the boiler to the flow and return headers (TopGas 100 and 120) Arrange the pump (2064823) and valve set (6042514) ready to be connected to the boiler. Please be aware that all of the gaskets must be fitted in the correct positions as shown in the picture on the right. Note: the pump may be different to the one shown in the photograph. Fit the flow pipe valve set to the boiler complete with supplied gasket and union (2043066) and tighten. Ensure all valves are correctly aligned as per the picture. Fit the supplied circulation pump (2064823) to the return connection of the boiler with a gasket joint. Be aware of the flow direction, this should be pointing up towards the boiler. When satisfied that all is correct tighten the union (2043066). Fit the remaining return pipe valve set to the underside of the pump using the supplied gasket and tighten. Ensure all valves are correctly aligned as per the picture to the right. When complete fit the two piece pump insulation housing supplied with the pump. The pump will be supplied with a 2m long MOLEX connector lead (2068178) that wires into terminals 25, N, E. 36
TopGas Cascade Assembly Fit one side of the flexible pipe to the nipple on the header and the other side to the respective valve. A gasket must be used at either end to ensure a water tight seal. Tighten accordingly. 5.6. Step 6: Connect the blanking flanges When assembled decide which end of the headers you would like to connect the system pipework to. At the opposing end you need to fit blanking flanges with their associated gaskets. The heating system flow and return pipework should both connect to the same end of the headers. Tighten the M16 nuts and bolts to 180Nm. 37
5.7. Step 7: Fit the pre-formed insulation wrap Fit the supplied pre-formed insulation wrap to the flow and return headers, align the pre cut holes with the connections on the headers and push the insulation wrap together ensuring the the teeth on the insulation wrap interlock. Important Note: If you have a back to back version you will need to fit the preformed insulation wrap before connecting the rear extension pipes and connection sets. 5.8. Step 8: Fitting the back boiler connections Fit the 1 gas isolation valve (2067892) to the extension pipe. On the outlet of the gas isolation valve, fit the TracPipe connector (2067994). Before fitting apply PTFE tape (or other suitable thread sealing media). Ensure sealing media used is suitable for natural gas. Connect the ¾ connection to the 1 concentric reducer (see page 32) then follow all steps on page 33. Finally connect the 1 union on the gas TracPipe onto the 1 nipple.. 38
For the flow and return connections fit the 1¼ union (TopGas 60,80) or 1½ union (TopGas 100,120) on the flexible pipe to the extension pipe. Before fitting apply PTFE tape (or other suitable thread sealing media). Tighten to ensure a good seal is made. See page 35 for the TopGas 60,80 or page 36 for TopGas 100,120 for pump and valve set connection instructions. Fit the remaining side of the flexible pipe to the respective valve. A gasket must be used at either end to ensure a water tight seal. Tighten accordingly. 39
6. Accessories - Hydraulics and Gas 6.1. Low loss header Used to allow secondary system flow flexibility. Designed for a primary T of 20 C. Allows for the secondary side to work with a T as low as 11 C. Supplied with a 1/2 automatic air vent, plugged 1/2 drain points and a plugged 1/2 BSP socket to accept an optional cascade control flow temperature sensor (with pocket) where required. Flanged on the primary side to connect directly to the TopGas Cascade LTHW headers. Two models avaiable: DN80 PN6 inlet, DN125 PN6 outlet For 2-6 x TopGas 60 and 2-6 x TopGas 80 6034 283 DN100 PN6 inlet, DN150 PN6 outlet For 2-6 x TopGas 100 and 2-6 x TopGas 120 6042 824 6.2. Air and dirt separator Effectively removes any dirt from the system whilst dispersing any air present. Used to allow secondary system flow flexibility. Designed for a primary T of 20 C. Allows for the secondary side to work with a T as low as 11 C. Supplied with a 1/2 automatic air vent, an 1/2 drain valve and a plugged 1/2 BSP socket to accept an optional cascade control flow temperature sensor (with pocket) where required. Flanged on the primary side to connect directly to the TopGas Cascade LTHW headers. Two models avaiable: DN80 PN6 inlet, DN125 PN6 outlet For 1-6 x TopGas 60 and 1-6 x TopGas 80 2067 549 DN100 PN6 inlet, DN150 PN6 outlet For 1-6 x TopGas 100 and 1-6 x TopGas 120 2066 122 ABOVE A STATIC HEAD OF 15 METRES A VACUUM DEGASSER SHOULD BE FITTED AS WELL AS THE AIR AND DIRT SEPARATOR. PLEASE CONSULT HOVAL TECHNICAL FOR FURTHER INFORMATION (the static height is taken from the installed location of the air and dirt separator to the highest point in the system). 40
THIS DRAWING IS COPYRIGHT OF HOVAL AND SHALL NOT BE REPRODUCED WITHOUT PRIOR WRITTEN PERMISSION Drawing Status Project Name TEL: 44( 0 ) 1636 672711 FAX: 44( 0 ) 1636 673532 Drawn By Drawn Date Checked by Checked Date ukrani 16/12/2013 Approved By Approved Date Scale: Client / Description DWG No. pump master ORDER NO. THIS DRAWING IS COPYRIGHT OF HOVAL AND SHALL NOT BE REPRODUCED WITHOUT PRIOR WRITTEN PERMISSION Drawing Status Project Name Client / Description TopGas Cascade 60-720 kw 6.3. TopGas 60 single boiler low loss header 2057 320 Single TopGas 60 boiler low loss header Complete with 1 BSP connections on the inlet and 1½ BSP on the outlet. 90 1" BSP Boiler Flow 6.4. TopGas 80 single or two boiler low loss header 83 171 1 1/2" BSP System Flow 35 Single or two TopGas 80 boiler low loss header Complete 400 234with 2½ BSP 330 connections on both the inlet and the outlet. 2057 322 4 3 2 1 D C 1" BSP Boiler Return 90 1 1/2" BSP D System Return 6.5. TopGas 100,120 single boiler low loss header Northgate Newark Nottinghamshire TEL: 44( 0 ) 1636 672711 FAX: 44( 0 ) 1636 673532 www.hoval.co.uk NG24 1JN Single TopGas 100 or TopGas120 boiler low loss header WorkInProgress Complete with DN100 PN6 flanged connections on both the 2057320 single header 1 & half inch assembly.idw Drawn By Drawn Date Checked by Checked Date C ukrani 18/12/2013 Approved By Approved Date Scale: inlet and the outlet. 6043 445 DWG No. 2057320 ORDER NO. 6.6. Boiler Circulating pump, TopGas (60,80) B B Seperate individual boiler A-rated circulating pump for TopGas 60,80. A 4 3 Grundfos UPML 32-95 180 AUTO single phase pump with G2 DRAWN connections. ukrani 20/06/2016 CHECKED TITLE QA A A 2m long electrical lead (with Molex connector) is available to MFG APPROVED SIZE DWG NO REV connect the pump to the boiler. 2 C as SCALE SHEET 1 OF 1 1 Northgate Newark UPML www.hoval.co.uk 32-95 180 AUTO pump Nottinghamshire NG24 1JN 2056 729 WorkInProgress pump master.idw Electrical connection lead 2056 730 6.7. Pump insulation cover, TopGas (60,80) Two piece insulation cover for Grundfos UPML 32-95 180 AUTO pump 2056 817 6.8. Boiler circulating pump, TopGas (100,120) Seperate individual boiler A-rated circulating pump for TopGas 100,120. Grundfos MAGNA 1 25-80 180 AUTO single phase pump with G1½ connections. A 2m long electrical lead is available to connect the pump to the boiler. Includes a two piece insulation cover MAGNA 1 25-80 180 AUTO pump 2064 823 Electrical connection lead 2068 178 41
6.9. Boiler flow and return connection valve set, TopGas (60,80) Connection set for TopGas (60,80) For use with circulation pump mounted on the return connection. 6012 948 consisting of: 4 3 2 Return: Isolating valve R 1 ¼ with gland nut 2. Side outlet branch with drain cock and G ¾ connection for expansion vessel. (Allows above Grundfos pump to be connected directly) Flow: Extension G 2 x L=180mm with integrated non-return valve. Isolating valve R 1 ¼ with gland nut 2. Side outlet branch with safety valve (3 bar) and drain cock. 1 D 4 3 6.10. Boiler flow and return connection valve set, TopGas (100,120) D 2 1 Connection set for TopGas (100,120) For circulation pump mounted on the return connection consisting of: C D 6042 514 C Return: C 1½ x 1½ DN40 combined isolating ball valve, non-return valve, safety valve (3bar) and drain cock. B B Flow: 1½ x 1½ isolating ball valve. B DRAWN ukrani 20/06/2016 CHECKED TITLE QA MFG APPROVED A Includes a pair of 1½ Female unions. 4 3 2 SIZE C SCALE DWG NO SHEET 1 OF 1 1 REV DRAWN ukrani 20/06/2016 CHECKED A QA TITLE A MFG APPROVED 4 3 2 SIZE C SCALE DWG NO SHEET 1 OF 1 1 REV 6.11 Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 µm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar Type Connection 70612/6B Rp ¾ 2007 995 70602/6B Rp 1 2007 996 6.12 Liquid gas conversion kit 619 568 42
Boiler controller with heating controller set RS-OT Heating controller set RS-OT (Not for mixing operation!) For 1 heating circuit without mixing operation Flow temperature control controlled by atmospheric conditions with outdoor sensor, immersion sensor (calorifier sensor) and overridable room temperature sensor. Can be implemented as a room temperature control without outdoor sensor. TopGas classic (60-120) For integration into boiler control panel: Mounting set RS-OT must be ordered. TopGas classic (60-120) Only wall mounting possible! 6020 566 Mounting set RS-OT Assembly set for mounting of heating controller set RS-OT into boiler 6018 218 BMS module 0-10 V/ OT - OpenTherm (building management system) no control unit TopTronic E or RS-OT necessary power supply via OT bus Temp. control external with 0-10 V 0-1.0 V no request 1.0-9.5 V...0-100 C Cannot be installed in boiler control panel: TopGas classic (60-120), 6016 725 43
Accessories - Controls Cascade controls with heating controller set TopTronic E ZE1 6037 312 Heating controller set TopTronic E ZE1 (Can be built in) as supplement for basic boiler control panel G04. -- Installation of the TopTronic E basic module heat generator in the controller When assembled the TopGas cascade boilers can be individually controlled via an external building management system or can be sequenced by the optional heating controller set TopTronic E ZE1 into the master boiler with an additional TopTronic E ZE3 module fitted into all the other boilers in the cascade. A wired connection must be fitted between each boiler and a common flow sensor fitted into the pipework to allow control via the boiler(s). Notice No additional module expansions or controller modules can be installed in the boiler control panel! This means an additional mixer circuit must be implemented using the Top- Tronic E heating circuit/hot water module in an external wall casing. -- Can be optionally networked with a total of up to 16 controller modules (incl. solar module) Consisting of: -- TopTronic E control module -- TopTronic E basic module heat generator -- Rast-5 basic plug set -- fitting accessories -- 1 pce. outdoor sensor AF/2P/K -- 1 pce. immersion sensor TF/2P/5/6T/S1, L = 5.0 m with plug -- 1 pce. contact sensor ALF/2P/4/T/S1, L = 4.0 m with plug -- cable set ZE1 Heating controller set TopTronic E ZE3 Heating controller set TopTronic E ZE3 is fitted in optional boilers 2-6. One TopTronic E ZE3 module should be ordered for each boiler. For example: 4 x TopGas boilers part number includes: 1 x TopTronic E touchscreen display 1 x TopTronic E control module 4 x TopTronic E ZE1 control 4 x TopTronic E ZE3 module Number of boilers Package part number 2 Boiler cascade 6043 453 3 Boiler cascade 6043 454 4 Boiler cascade 6043 455 5 Boiler cascade 6043 456 6 Boiler cascade 6043 457 Flow temperature guard for underfloor heating (per heating circuit 1 guard) 15-95 C, differential gap 6 K, capillary tube max. 700 mm, setting (visible from the outside) inside the housing cover Clamp-on thermostat RAK-TW1000.S Thermostat with strap, without cable and plug 242 902 44
TopTronic E module expansions for TopTronic E basic module heat generator TopTronic E module expansion heating circuit TTE-FE HK Expansion to the inputs and outputs of the basic module heat generator or the heating circuit/domestic hot water module for implementing the following functions: -- 1 heating circuit without mixer or -- 1 heating circuit with mixer 6034 576 + OR ODER incl. fitting accessories 1x contact sensor ALF/2P/4/T L = 4.0 m Can be installed in: Wall housing Note The supplementary plug set may have to be ordered to implement functions differing from the standard! Consult Hoval Technical for site specific requirements. TopTronic E module expansion heat accounting TTE-FE WMZ/EBZ Expansion to the inputs and outputs for the basic module heat generator for implementing the following functions: -- Calculating total energy consumption -- Calculating the heat generator energy for heating -- Calculating the heat generator energy for hot water 6037 062 incl. fitting accessories 3x contact sensor ALF/2P/4/T L = 4.0 m Can be installed in: Wall housing Note The flow rate sensor set must be ordered as well. Flow rate sensor sets Size Connection Flow rate l/min DN 8 G ¾ 0.9-15 DN 10 G ¾ 1.8-32 DN 15 G 1 3.5-50 DN 20 G 1¼ 5-85 DN 25 G 1½ 9-150 6038 526 6038 507 6038 508 6038 509 6038 510 TopTronic E module expansion Universal TTE-FE UNI Expansion to the inputs and outputs of a controller module (basic module heat generator, heating circuit/domestic hot water module, solar module, buffer module) for implementing various functions 6034 575 incl. fitting accessories Can be installed in: Wall housing, control panel 45
Accessories for TopTronic E Supplementary plug set for basic module heat generator (TTE-WEZ) for controller modules and module expansion TTE-FE HK 6034 499 6034 503 TopTronic E controller modules TTE-HK/WW TopTronic E heating circuit/ hot water module TTE-SOL TopTronic E solar module TTE-PS TopTronic E buffer module TTE-MWA TopTronic E measuring module TopTronic E room control modules TTE-RBM TopTronic E room control modules easy white comfort white comfort black Enhanced language package TopTronic E one SD card required per control module Consisting of the following languages: HU, CS, SK, RO, PL, TR, ES, HR, SR, PT, NL, DA TopTronic E remote Gateway connection TTE-GW TopTronic E online LAN TTE-GW TopTronic E online WLAN SMS remote control unit System component SMS remote control unit TopTronic E interface modules GLT module 0-10 V Gateway module ModBus TCP/ RS485 Gateway module KNX TopTronic E wall casing WG-190 Wall casing small WG-360 Wall casing medium WG-360 BM Wall casing medium with control module cut-out WG-510 Wall casing large WG-510 BM Wall casing large with control module cut-out TopTronic E sensors AF/2P/K Outdoor sensor TF/2P/5/6T Immersion sensor, L = 5.0 m ALF/2P/4/T Contact sensor, L = 4.0 m TF/1.1P/2.5S/6T Collector sensor, L = 2.5 m System housing System housing 182 mm System housing 254 mm 6034 571 6037 058 6037 057 6034 574 6037 071 6037 069 6037 070 6039 253 6037 079 6037 078 6018 867 6022 797 6034 578 6034 579 6034 581 6035 563 6035 564 6035 565 6035 566 6038 533 2055 889 2055 888 2056 775 2056 776 6038 551 6038 552 Bivalent switch 2061 826 46
Dn 200 TopGas Cascade 60-720 kw 8. Accessories - Flues (Cascade) TopGas PP single skin Cascade Flues - Please note that an End Cap is required with each package. All include high performance EPDM seals. Maximum total flue length for cascade flues is 30m (excluding the 6 x TopGas 120 arrangement that has a maximum length of 15m). This above includes for one 90 bend on the outlet of the cascade collector and a roof terminal. Each additional 90 bend will reduce the total available flue length by 3.3m Each additional 45 bend will reduce the total available flue length by 1.5m All flue systems must have a 3 fall to the Cascade flue end cap to avoid condensate collecting in the horizontal flue pieces. 5 6 8.1. Cascade in-line connection kit TopGas 60-120 Cascade in-line boiler flue piece (Ø200mm). Boiler connection 100/150mm. One required per boiler in an in-line arrangement or for the singular boiler in an odd number back to back arrangement. See table below for cutting lengths (to be done on site by the installer). 2069 096 4 2 3 1. Air intake grill 2. Vertical extension piece 3. Sample point 4. 90 elbow 5. Collector piece with single input at 45 6. Suspension kit and wall bracket 1 Important Note: A minimum clearance of 200mm is required to the rear of the in-line boiler cascade assembly to accommodate the cascade flue (as it overhangs at the rear of the assembly). L=858 P=798 400 216 730 358 CUTTING TABLE TUBE LENGTH FLUE CENTRES Dn 100 Dn.150 858 798 TOPGAS 100-120 BRIDGING LENGTHS 840 780 TOPGAS 100-120 STANDARD LENGTHS 818 758 TOPGAS 60-80 BRIDGING LENGTHS 766 686 TOPGAS 60-80 STANDARD LENGTHS L P DESCRIPTION EXT KIT LINE PP 100/150-200 P798 DATE SHEET: 02-2017 ALL RIGHTS RESULTING FROM THIS DESIGN, ARE RESERVED TO THE M&G GROUP REMARK M&G Group HOVAL TOPGAS 60-80 & 100-120 DRAWN Units in mm. J. Renkema Tolerances:(unless otherwise specified) DATE 02/02/2017 Holes: ±0.1 Angles: ±1 Other: ±1 PROJ. NR. P-15134 CHECKED - TOOL.NR. - SCALE SHEETSIZE SHEET NR. MATERIAL SPEC. NR. DRAW.NR. ART.NR. PP 47 17 00629 00g 41.008.12.58
Dn 200 TopGas Cascade 60-720 kw 6 8.2. Cascade back to back connection kit 2069 097 5 4 TopGas 60-120 Cascade back to back boiler flue piece (Ø200mm). Boiler connection 100/150mm. One required per pair of back to back boilers. See table below for cutting lengths (to be done on site by the installer). 2 3 1. Air intake grill 2. Vertical extension piece 3. Sample point 4. Transition fittings 5. Collector piece with twin inputs at 45 6. Suspension kit 1 L=858 P=798 520 216 997 Dn 100 Dn 150 CUTTING TABLE TUBE LENGTH FLUE CENTRES 858 798 TOPGAS 100-120 BRIDGING CENTRES 840 780 TOPGAS 100-120 STANDARD CENTRES 818 758 TOPGAS 60-80 BRIDGING CENTRES 746 686 TOPGAS 60-80 STANDARD CENTRES L P DESCRIPTION EXT KIT B-B PP 100/150-200 P798 REMARK HOVAL TOPGAS 60-80 & 100-120 DRAWN Units in mm. J. Renkema Tolerances:(unless otherwise specified) DATE 02/02/2017 Holes: ±0.1 Angles: ±1 Other: ±1 TOOL.NR. SCALE - MATERIAL PP SPEC. NR. DATE SHEET: 02-2017 ALL RIGHTS RESULTING FROM THIS DESIGN, ARE RESERVED TO THE M&G GROUP M&G Group PROJ. NR. CHECKED P-15134 - SHEETSIZE SHEET NR. DRAW.NR. ART.NR. 17 00630 00e 41.008.12.59 48
8.3. Additional kit for use with a back to back cascade flue system having an odd number of boilers. 2069 098 In this case please order an inline connection kit (part No 2069096) above together with one of these kits for the odd boiler. Please see example below of items required for a five boiler back to back cascade flue system. Replace with kit No 2069098 8.4. Cascade flue end cap 2069 099 1 TopGas Cascade flue end cap (Ø200mm) complete with condensate trap. 1. Flue cap with seal 2. Condensate trap - 40mm outlet (pipework to suitable drain by the installer) 2 Note, one end cap is required with all flue cascade packages. TopGas PP Cascade Flues - Other components 8.5. 1000mm extension piece (Ø200mm) 8.6. 1900mm extension piece (Ø200mm) 2059 865 2059 866 49
8.7. 45 flue elbow (Ø200mm) 2059 867 8.8. 90 flue elbow (Ø200mm) 2059 868 8.9. Flat roof flashing (Ø200mm) Made from aluminium 2059 869 8.10. Pitched roof flashing (Ø200mm) Roof pitch 28-32 Roof pitch 38-42 Roof pitch 48-52 2069 174 2069 175 2069 176 Made from aluminium with a lead base 8.11. 1600mm long roof terminal (Ø200mm) 2059 870 Black finish (RAL 9005) 8.12. Additional wall bracket (Ø200mm) 2059 871 All items finished grey RAL 7040 unless otherwise stated 50
DATE SHEET: 02-2017 ALL RIGHTS RESULTING FROM THIS DESIGN, ARE RESERVED TO THE M&G GROUP REV.NR. R EVISION DESCRIPTION BY P ROJ. NR. 1 DESCRIPTION REMARK DRAWN DATE PROJ. NR. CHECKED E. Moed 01/06/2017 P -15270 Units in mm. Tolerances:(unless otherwise specified) Holes: ±0.1 Angles: ±1 Other: ±1 TOOL.NR. SCA LE SHEETSIZE SHEET NR. MATERIAL PP S PEC. NR. DRA W.NR. ART.NR. DATE Ø152 Ø102 TopGas Cascade 60-720 kw 9. Accessories - Flues (Individual - concentric) Inside Ø 152 Ø100 Inside Ø 102 Ø100 40 ±2 (10) 115 60 ±3 130 ±2 240 155 ±2 152 102 9.1 Flue spigot transition piece complete with clamp band 110 1135 1095 Ø100 1000 / 500 / 250 990 / 490 / 240 500 490 Ø100 Ø150 Ø100 102 240 152 102 115 152 9.2 Ø150 Connection C100/150 to Ø1002xE100PP For separate routing of flue gases and combustion Recommendation: If the air inlet is near a noise sensitive place (window of bedroom, terrace etc.) we recommend the use of a sound absorber on the air inlet. 2015 244 1000 / 500 / 250 990 / 250 490 / 240 240 9.3 1000mm extension (including support bracket) 2042 409 Ø150 Ø150 Ø100 102 152 9.4 500mm extension (including support bracket) 2042 408 9.5 Vertical terminal (black) with cap (including support bracket) 2042 404 110 110 110 110 110 Ø102 Ø152 Ø102 150 100 50 150 00 100 150 100 150 100 80 124 80 Ø80 24 124 80 124 Ø80 124 10 155 155 155 10 10 155 10 10 155 95 90 95 95 90 95 90 95 90 90 45 45 45 45 Ø100 Ø150 Ø100 Ø100 Ø150 Ø150 Ø100 Ø150 Ø100100 Ø150 100 100 100 100 215 Ø102 Ø152 Ø102 Ø152 135 135 125 125 135 125 135 125 Ø152 Ø102 150 125 215 Ø102 Ø102 Ø152 Ø152 93 93 Ø152 Ø102 150 150 125 125 45 215 215 Ø102 Ø152 93 135 125 Ø152 Ø102 Ø152 Ø102 150 125 93 93 Ø152 Ø102 Ø150 150 125 This part must be fitted to all TopGas boilers requiring concentric Ø100 flue parts. Please see important Ø150 note on page 26. 2069 894 Ø100 Ø150 (15) Ø152 Ø102 Outside Ø 100 Outside Ø 148,5 215 Ø150 Ø100 Ø150 Ø150 Ø100 Ø100 AIR INLET ADAPTER M&G TO IA 2069894 Ø100 - Ø150 17 02675 00a 41.008.12.55 Ø80 Ø124 10 155 95 90 45 100 Ø102 Ø152 135 125 Ø100 102 152 150 125 93 1230 680 1180 1290 Ø150 275 195 93 degree bend 152 Ø100 102 Ø150 152 152 102 102 152 102 1220 max 152 102 Ø100 Wall terminal Ø150 Ø100 Ø100 Ø150 Ø150 Ø100 Ø152 Ø150 Wall Ø100 Ø102 Vertical plate Ø152 Ø150 adaptor Ø152 Ø102 Ø102 Ø152 215 140 Wall plate 9.6 Vertical adapter Complete with 2 sample points. Ø160 Please see important note on page 26. 9.7 Vertical adapter 40 390 160 22-45 200 165 2042406 2042 415 Complete with condensing drain connection, siphon kit and 2 sample points. 9.8 45 elbow 2042 411 9.9 90 elbow 2042 410 9.10 Support bracket 2042 414 Ø150 Ø150 Ø150 Ø150 51 160
135 125 240 TopGas Cascade 60-720 kw Ø150 Ø150 93 Ø152 Ø102 160 160 9.11 Lead pitched roof flashing 2042 412 22-45 22-45 200 200 (to suit roof angle 25-45 degrees) 40 Ø160 Ø160 40 165 1230 1180 680 1290 Ø150 Ø100 102 152 150 125 Ø1 Ø1 1 1 250 Ø150 9.12 Aluminium flat roof flashing 2042 413 160 Ø100 Ø150 165 390 390 1220 max 140 9.13 100/150 Wall terminal kit (for horizontal discharge) 22-45 200 2042 405 275 195 93 degree bend Vertical adaptor Wall terminal Wall plate Wall plate Comprises of vertical adaptor, 93 degree elbow 2 wall plates and a horizontal wall terminal. Max dimension Ø160 can be extended by use of extension pieces. 40 165 All items finished white RAL 9016-9.14 Air inlet non-return damper for TopGas (60-120) only 390 6036 265 Fitted inside the boiler casing to prevent back flow of flue gases through an off-line cascade boiler. Cannot be used with models 35 and 45. - - Where the boiler cascade takes its air supply directly from the plant room, it is possible to combine one or more TopGas boilers into a common flue duct, where each boiler within the cascade is connected to a common duct or ducts via an individual flue connection piece complete with a non-return flap or damper. In this case all boilers should be provided with an optional air inlet non-return flap (available as an accessory for the TopGas 60-120 as above) or with an external non-return flap for the TopGas 35 - and 45 (not Hoval supply). Flue design (TopGas 60-120) An adapter with sample points must be used (fitted to the boiler flue outlet connection). The flue gas is very cool and saturated with moisture so there will be very little or no buoyancy to pull the gases up the chimney. The burner fan assists with the evacuation of the flue gases so there may be slight pressurisation of the flue. It is permissible for the condensate from the flue system to drain back through the boiler. Horizontal flue sections must be inclined back to the boiler (3 minimum) to prevent condensate remaining in the flue. Flues must be designed to meet all current regulations / standards. See Technical data section for flue gas mass flow rates, temperatures, usable 33 fan overpressure and ventilation requirements. 25 32 The tables below are for guidance only. 100/150 PP TopGas concentric 45 flue (in chimney stack) Maximum flue lengths 32 (TopGas 35-60) Max flue height (m) 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 16 TopGas 45 14 0 1 2 3 4 Horizontal 12 flue gas pipe length (m) The above figures 10 include for one 93 degree bend. Additional 93 degree bends will have the effect of 8 reducing the length by 2.5 metres and 45 degree bends 18 will reduce the 6length by 1.5 metres. The flue lengths stated 16 will have 4 no effect on the boiler output. TopGas 45 4215256-02 14-06/17 eight (m) 12 10 Max flue height (m) Max flue height (m) 33 31 30 29 28 27 26 25 24 23 22 21 20 19 TopGas 60 18 2 TopGas 60 TopGas 45 TopGas 45 100 PP flue (in chimney stack, provision for room air is required) 0 1 2 3 4 Horizontal flue gas pipe length (m) TopGas 60 0 0 1 2 3 4 5 6 Max flue height (m) 25 20 15 10 5 Max flue Max height flue height (m) (m) Max flue height (m) 31 25 30 29 TopGas 45 28 20 27 26 15 25 24 TopGas 60 TopGas 60 23 10 22 21 205 TopGas 45 19 0 1 2 3 0 4 Horizontal flue gas pipe length (m) 0 1 2 3 4 5 6 Horizontal flue gas pipe length (m) TopGas 60 100/150 PP concentric flue (horizontal discharge) 18 16 14 0 12 0 10 1 2 3 4 5 6 Horizontal flue gas pipe length (m) 8 TopGas 60 6 4 2 0 TopGas 45 0 1 2 3 4 5 6 Horizontal flue gas pipe length (m) Max flue height (m) 20 15 10 5 0 0 1 2 Horizonta 52 To
10. Accessories - Flues (Individual - Plume kit) TopGas aluminium plume kit. All include high performance EPDM seals. 2 10.1. Plume management kit 2060 156 5 4 Plume management kit to direct products of combustion to discharge at high level. Suitable for all models of TopGas boiler. 1 7 6 2 3 1. Concentric horizontal - C100/150 2. Plume 90 elbow - DN100 3. Plume extension, 1m - DN100 4. Plume nose piece - DN100 5. Mounting bracket - DN100 6. Wall plate - C100/150 7. Flue clamp - C100/150 Concentric horizontal and internal wall plate finished white RAL 9016 10.2. Plume 90 elbow 2060 159 90 elbow, DN100, aluminium 10.3. Plume 45 elbow 2060 158 45 elbow, DN100, aluminium 10.4. Plume extension 2060 157 1m extension, DN100, aluminium 10.5. Plume nose piece 2060 160 Nose piece, DN100, aluminium All DN100 items finished black RAL 9005 53
11. Typical Hydraulic Schematic AF RBM TTE-GW Typical heating system (not by Hoval) TTE-ZE1 TTE-ZE3 VF1 B1 VF2 B1 DHWS T T T T TopGas Dies ist ein unerlaubter Weg! Gehen Sie 1 einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit P ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas M5.1 TopGas Dies ist ein unerlaubter Weg! Gehen 2 Sie - 6 einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit P ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas M5.2 AAV LLH SVLF YK1 M M K 1 YK2 M S L P MK2 S F Dies ist ein unerlaubter Weg! T Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhova lhovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhova lhovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval h CWS ST Legend: AAV: Automatic air vent AF: Outdoor temperature sensor B1: Flow temperature limiter B2: Flow temperature limiter CWS: Cold water supply DHWS: Domestic hot water supply LLH: Optional low loss header (or air and dirt separator) M5.1: Boiler circulation pump M5.2: Boiler circulation pump MK1: Mixed circuit heating pump MK2: Mixed circuit heating pump SF: Calorifier temperature sensor SLP: Calorifier loading pump ST: Strainer SVLF: Common flow sensor TTE-GW: Gateway module TTE-RBM: Room control module TTE-ZE1: Heating controller set TTE-ZE3: Base module heat generator VF1: Mixed circuit flow sensor VF2: Mixed circuit flow sensor YK1: Mixed circuit control valve YK2: Mixed circuit control valve Notes : - This hydraulic schematic just shows the basic principle. The installation must be in accordance with local regulations. - With underfloor heating an over temperature thermostat has to be installed. - Anti thermal siphon dip has to be installed (ATS). - Safety valve (SV) position on return with optional connection set for TopGas (100,120). 54
Service All TopGas boilers can be commissioned by our dedicated service team. For annual servicing of TopGas boilers and other equipment please contact our Hoval Service department. TopGas spares kits are available from our spares department. Service: 01636 593413 or service@hoval.co.uk Spares: 01636 593412 or spares@hoval.co.uk 55
An expert partner One-stop shopping With us you can easily incorporate gas, oil, heat pump, solar, CHP, or biomass energy solutions into your heating system. Technical advice We are happy to assist you and your planning partners in developing intelligent systems, allowing you to take advantage of our expertise and the experience of our specialists. After sales For specialist commissioning and maintenance of your Hoval equipment, contact our service and spares department. Hoval Ltd Northgate Newark-on-Trent Nottinghamshire NG24 1JN United Kingdom Phone 01636 672 711 Fax 01636 673 532 email boilersales@hoval.co.uk www.hoval.co.uk 4215256 / 02-06/17 Responsibilty for energy and environment Hoval follows a policy of continued improvement and reserves the right to change specifications without notice.