Hoval TopGas Cascade 60 Technical Information And Assembly Instructions

Technical Information and Assembly Manual

Output range 60 to 720 kW

4215256-00 - 11/16 Subject to modification

TopGas Cascade

Condensing Gas Boilers

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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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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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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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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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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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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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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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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

ONE BOILER 6 TopGas 100/120

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

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Hoval TopGas Cascade 60 Technical Information And Assembly Instructions

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