Hoval TopGas Cascade 60 Technical Information And Assembly Instructions

Hoval
Brand
Hoval
Model
TopGas Cascade 60
Type
Technical Information And Assembly Instructions

This manual is also suitable for

Technical Information and Assembly Manual
Output range 60 to 720 kW
4215256-00 - 11/16 Subject to modification
TopGas Cascade
Condensing Gas Boilers
2
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
Contents
Page No.
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
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owandreturnheaders 34
5.5.  Step5:Connecttheboilertotheowandreturnheader(TopGas60and80) 35
5.5.1  Step5:Connecttheboilertotheowandreturnheader(TopGas100and120) 36
5.6.  Step6:Connecttheblankinganges 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
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TopGas Cascade 60 - 720 kW
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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owandreturnconnectionvalveset,TopGas(60,80) 42
6.10  Boilerow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 (Individual - concentric) 46
8.1. Connection C100/150 to 2xE100PP 46
8.2. 1000mm extension (including support bracket) 46
8.3. 500mm extension (including support bracket) 46
8.4. Vertical terminal (black) with cap 46
8.5. Vertical adapter with 2 sample points 46
8.6. Vertical adapter with condensing drain connection, siphon kit & 2 sample points 46
8.7. 45° elbow 46
8.8. 90° elbow 46
8.9. Support bracket 46
8.10.  Leadpitchedroofashing 46
8.11.  Aluminiumatroofashing 47
8.12. Wall terminal kit (for horizontal discharge) 47
8.13. Air inlet non-return damper for TopGas (60-120) only 47
9. Accessories - Flues (Individual - Plume kit) 48
9.1. Plume management kit 48
9.2. Plume 90° elbow 48
9.3. Plume 45° elbow 48
9.4. Plume extension 48
9.5. Plume nose piece 48
10. Typical Hydraulic Schematic 49
Hoval Service and Spares Contact details 50
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TopGas Cascade 60 - 720 kW
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1. Important Information
1.1. Documentation
Hoval gas boilers are only to be installed and placed in operation
by suitably qualied 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.
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 modications 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 qualied
persons. No modications 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.
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 satised:
• Safety valve installed (closed system)
• Power supplies connected and tested
• Controls system commissioned
• System lled with water and suitably treated
• Expansion vessel connected and charged
• Boilers connected to an appropriate ue 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 ow 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 identication 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 ames (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 re 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!
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TopGas Cascade 60 - 720 kW
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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 ttings) regulations 1999
• BS 5440-1 Flueing and ventilation for gas appliances
• BS 5854 Code of practice for ues and ue structures in
buildings
• BS EN 12828 Design of water-based heating systems
• BS 6644 Specication for the installation of gas red hot
water boilers with rated inputs between 70 kW (net) and
1.8 MW (net) (2nd and 3rd family gases)
• BS 6700 Specication 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 Specication 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 ue 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 oor standing boiler cascade must be installed on a at, or level
re proof oor.
All boilers must have a minimum clearance of 500mm at the front
for preventative maintenance and commissioning work to be
carried out.
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TopGas Cascade 60 - 720 kW
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2. Technical Description
2.2. Cascade Product Codes
In-line frame mounted (not including optional low loss header or air/dirt separator)
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
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 red appliance
suitable and approved as a heat producer for hot water heating
systems with a maximum ow 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 ring 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/ue gas con-
centric 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 tempera-
ture 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
ue. 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 exible
ow and return hydraulic connections including ttings; 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 t-
tings. A condensate trap is supplied with each boiler to be tted
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 depend-
ing on the cascade type. An insulation wrap is tted 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 tted into all the other boilers in the cascade. A wired con-
nection must be tted between each boiler and a common ow
sensor tted 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 sepa-
rator the secondary sized can operate with either an 11 or 20°C ∆T.
Each boiler in the cascade requires a suitable ue 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.
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
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TopGas Cascade 60 - 720 kW
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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 xings weight (inline) kg 259 459 518 718 777
Frame, header and xings weight (back to back) kg 248 301 317 517 565
Boiler full load efciency @ 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 efciency @ 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 efciency % 97.6 97.6 97.6 97.6 97.6
Standing losses at 70°C W 210 315 420 525 630
NOX 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 (HU 9.97kWh/m3) m3/h 13.6 20.19 26.92 33.65 40.38
Propane (HU 25.9 kWh/m3) m3/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 ow 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
3. Technical data
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TopGas Cascade 60 - 720 kW
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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 xings weight (inline) kg 259 459 518 718 777
Frame, header and xings weight (back to back) kg 248 301 317 517 565
Boiler full load efciency @ 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 efciency @ 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 efciency % 97.8 97.8 97.8 97.8 97.8
Standing losses at 70°C W 210 315 420 525 630
NOX 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 (HU 9.97kWh/m3) m3/h 15 22.5 30 37.5 45
Propane (HU 25.9 kWh/m3) m3/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 ow 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
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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 xings weight (inline) kg 293 505 586 798 879
Frame, header and xings weight (back to back) kg 272 347 367 579 639
Boiler full load efciency @ 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 efciency @ 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 efciency % 97.8 97.8 97.8 97.8 97.8
Standing losses at 70°C W 230 345 460 575 690
NOX 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 (HU 9.97kWh/m3) m3/h 18.64 27.96 37.28 46.6 55.92
Propane (HU 25.9 kWh/m3) m3/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 ow 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
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TopGas Cascade 60 - 720 kW
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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 xings weight (inline) kg 293 505 586 798 879
Frame, header and xings weight (back to back) kg 272 347 367 579 639
Boiler full load efciency @ 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 efciency @ 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 efciency % 96.3 96.3 96.3 96.3 96.3
Standing losses at 70°C W 230 345 460 575 690
NOX 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 (HU 9.97kWh/m3) m3/h 21.4 32.1 42.8 53.5 64.2
Propane (HU 25.9 kWh/m3) m3/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 ow 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
11
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
3.5. Technical Drawings, cascade in-line frame mounted
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”
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
One boiler, in-line frame mounted - 1 x TopGas 60 (7015818), 1 x TopGas 80 (7015865)
One boilers, in-line frame mounted - 1 x TopGas 100 (7015799) , 1 x TopGas 120 (7015871)
ONE BOILER 1* TopGas 100/120
ONE BOILER 1* TopGas 45-80
12
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
3.5. Technical Drawings, cascade in-line frame mounted
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Two boilers, in-line frame mounted - 2 x TopGas 60 (7015839) , 2 x TopGas 80 (7015864)
Two boilers, in-line frame mounted - 2 x TopGas 100 (7015773), 2 x TopGas 120 (7015870)
ONE BOILER 2 TopGas 100/120
TWO BOILER 1* 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”
13
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Three boilers, in-line frame mounted - 3 x TopGas 60 (7015840), 3 x TopGas 80 (7015863)
Three boilers, in-line frame mounted - 3 x TopGas 100 (7015812), 3 x TopGas 120 (7015869)
3.5. Technical Drawings, cascade in-line frame mounted
ONE BOILER 3 TopGas 100/120
THREE BOILER 1* 2 & 1*1 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”
14
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Four boilers, in-line frame mounted - 4 x TopGas 60 (7015841), 4 x TopGas 80 (7015862)
Four boilers, in-line frame mounted - 4 x TopGas 100 (7015813), 4 x TopGas 120 (7015868)
3.5. Technical Drawings, cascade in-line frame mounted
ONE BOILER 4 TopGas 100/120
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”
15
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Five boilers, in-line frame mounted - 5 x TopGas 60 (7015842), 5 x TopGas80 (7015861)
Five boilers, in-line frame mounted - 5 x TopGas 100 (7015814), 5 x TopGas 120 (7015867)
3.5. Technical Drawings, cascade in-line frame mounted
ONE BOILER 5 TopGas 100/120
FIVE BOILER 2 * 2 & 1*1 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”
16
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Six boilers, in-line frame mounted - 6 x TopGas 60 (7015843), 6 x TopGas 80 (7015860)
Six boilers, in-line frame mounted - 6 x TopGas 100 (7015815), 6 x TopGas 120 (7015866)
3.5. Technical Drawings, cascade in-line frame mounted
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”
17
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Two boilers, back to back frame mounted - 2 x TopGas 60 (7015844), 2 x TopGas 80 (7015824)
Two boilers, back to back frame mounted - 2 x TopGas 100 (7015801), 2 x TopGas 120 (7015859)
3.6. Technical Drawings, cascade back to back frame mounted
TWO BOILER 1*2 TopGas 100/120
TWO BOILERS 1*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”
18
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Three boilers, back to back frame mounted - 3 x TopGas 60 (7015845), 3 x TopGas 80 (7015823)
Three boilers, back to back frame mounted - 3 x TopGas 100 (7015800), 3 x TopGas 120 (7015828)
3.6. Technical Drawings, cascade back to back frame mounted
THREE BOILERS 2+1 TopGas 100/120
FOUR BOILERS 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”
19
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Four boilers, back to back frame mounted - 4 x TopGas 60 (7015846), 4 x TopGas 80 (7015822)
Four boilers, back to back frame mounted - 4 x TopGas 100 (7015802), 4 x TopGas 120 (7015827)
3.6. Technical Drawings, cascade back to back frame mounted
FOUR BOILERS 2*2 TopGas 100/120
FOUR BOILERS 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”
20
TopGas Cascade 60 - 720 kW
4215256-00 - 11/16
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, uing, safety valve discharge and boiler drain pipework to be supplied and tted by the installer (not by Hoval)
Blanking anges can be tted either side of the header assembly to suit site requirements
Optional low loss header or air/dirt seperator not shown
Five boilers, back to back frame mounted - 5 x TopGas 60 (7015847), 5 x TopGas 80 (7015821)
Five boilers, back to back frame mounted - 5 x TopGas 100 (7015816), 5 x TopGas 120 (7015826)
3.6. Technical Drawings, cascade back to back frame mounted
FIVE BOILERS 3*2 TopGas 100/120
FIVE BOILERS 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”
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Hoval TopGas Cascade 60 Technical Information And Assembly Instructions

Hoval
Brand
Hoval
Model
TopGas Cascade 60
Type
Technical Information And Assembly Instructions
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