Hoval TopGas Cascade 100 Technical Information And Assembly Instructions Download Page 1

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Technical Information and Assembly Manual

Output range 60 to 720 kW

4215256-00 - 11/16

Subject to modification

TopGas Cascade

Condensing Gas Boilers

Summary of Contents for TopGas Cascade 100

Page 1: ...Technical Information and Assembly Manual Output range 60 to 720 kW 4215256 00 11 16 Subject to modification TopGas Cascade Condensing Gas Boilers ...

Page 2: ...al 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 ...

Page 3: ... 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 flashing 46 8 ...

Page 4: ...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 even...

Page 5: ...s 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 he...

Page 6: ...ow 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 fit tings 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...

Page 7: ... 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 NOX emissions dry and stoichoimetric mg kWh 27 27 27 27 27 Natural Gas pressure minimum maximum mbar 17 4 50 17 4 5...

Page 8: ...d 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 NOX emissions dry and stoichoimetric mg kWh 28 28 28 28 28 Natural Gas pressure minimum maximum m...

Page 9: ...asis 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 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 5...

Page 10: ... 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 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...

Page 11: ...n DN40 5 Flue Concentric 100 150mm 6 Safety Valve R1 7 Boiler Drain G 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 One boiler in line frame mounted 1 x TopGas ...

Page 12: ...tted 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 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 Co...

Page 13: ... fitted 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 ...

Page 14: ...n be fitted 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 ...

Page 15: ...be fitted 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...

Page 16: ...an be fitted 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 Co...

Page 17: ...ted 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...

Page 18: ...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 To...

Page 19: ...d 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 Top...

Page 20: ...d 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 Top...

Page 21: ...ted either side of the header assembly to suit site requirements Optional low loss header or air dirt seperator not shown Six boilers back to back frame mounted 6 x TopGas 60 7015848 6 x TopGas 80 7015820 Six boilers back to back frame mounted 6 x TopGas 100 7015817 6 x TopGas 120 7015825 3 6 Technical Drawings cascade back to back frame mounted SIX BOILERS 3 3 TopGas 100 120 SIX BOILERS 3 2 TopGa...

Page 22: ...wing Status Project Name Drawn By Drawn Date Checked by Ch Approved By Approved Date Scale DWGNo ORDERNO Client Description 2057322 Singleheader 2 half inch idw WorkInProgress ukrani 18 12 2013 2057322 150 650 270 450 75 80 500 2 1 2 BSP Boiler Return 2 1 2 BSP System Return 2 1 2 Boiler Flow 2 1 2 System Flow 150 Single TopGas 60 boiler low loss header 2057320 Northgate Newark Nottinghamshire NG2...

Page 23: ...2 BSP plugged 7 Drain Point 1 2 BSP plugged 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 Low Loss Herader for TopGas 100 120 cascades 6042824 Please see Accessories section for further information Please see Accessories...

Page 24: ...Secondary Return DN125 PN16 5 Automatic Air Vent 6 Pocket Connection 1 2 BSP plugged 7 Drain Valve 1 2 BSP plugged 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 Air Dirt Seperator for TopGas 100 120 Cascades Connections Please see Accessor...

Page 25: ... 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 fi...

Page 26: ...t 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 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...

Page 27: ...1 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 5 TopGas Cascade Assembly 2 boilers in line and 3 or 4 boilers back to back Lay out the frame work on the floor and ensure you have all correct components You will see M10 holes to the outs...

Page 28: ...erside 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 M10 bolt 2056546 through the crossbar and side pieces with a washer either side add the M10 nut then tighten both to 45Nm Once you have bolted the center piece and side pieces together you should have the stand as shown to...

Page 29: ... adjustable feet 2067454 Build as shown and tighten to 45Nm Fit the adjustable feet to both of the side plates Set to the correct length and tighten using a 22mm spanner 5 1 1 Step 1 Build the frame 1 boiler inline 2 boiler back to back 6 x 75mm M10 bolts 2056546 2 x side plates 6 x M10 nuts 2042599 2 x horizontal support beam 12 x M10 washers 2042608 1 x horizontal cross bar 1 x 1 8 Gas test nipp...

Page 30: ...re 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 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 connec tions are correctly aligned Hold the two side p...

Page 31: ...Tighten to a maximum of 60Nm Ensure that the boiler is safely lifted into position using appropriate lifting equipment 5 2 Step 2 Mount the boilers 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 fle...

Page 32: ...itable 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 2042714 to the gas con nection on the boiler and then fit the TracPipe connector 2067994 Before ...

Page 33: ... on the TracPipe approximate ly 25mm to allow the fitting to slide onto the pipe Slide on the brass union and fit the sealing washer to the next avail able 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...

Page 34: ...ble 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 ...

Page 35: ...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 cor rectly 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...

Page 36: ...fied 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 cor rectly 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 term...

Page 37: ...ght seal Tighten accordingly TopGas Cascade Assembly Tighten the M16 nuts and bolts to 180Nm 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 con nect to the same end of the headers 5 6 Step 6 Connect the blanking ...

Page 38: ...ill need to fit the pre formed 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...

Page 39: ...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 ...

Page 40: ...ry 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 TopG...

Page 41: ...s 80 boiler low loss header Complete with 2 BSP connections on both the inlet and the outlet 2057322 6 6 Boiler Circulating pump TopGas 60 80 Seperate individual boiler A rated circulating pump for TopGas 60 80 Grundfos UPML 32 95 180 AUTO single phase pump with G2 connections A 2m long electrical lead with Molex connector is available to connect the pump to the boiler UPML 32 95 180 AUTO pump Ele...

Page 42: ... 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 Rp Rp 1 70612 6B 2007 995 70602 6B 2007 996 1 1 2 2 3 3 4 4 A A B B C C D D SHEET 1 OF 1 DRAWN CHECKED QA MFG APPROVED ukrani 20 06 2016 DWG NO TITLE SIZE C SCALE REV 1 1 2 2 3 3 4 4 A A B B C C D D SHEET 1 OF 1 DRAWN ...

Page 43: ...c E basic module heat generator in the controller Notice No additional module expansions or cont roller 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 ...

Page 44: ... 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 incl fitting accessories 3x contact sensor ALF 2P 4 T L 4 0 m Can be installed in Wall ...

Page 45: ... 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 con trol unit TopTronic E interface modules GLT module 0 10 V Gateway module...

Page 46: ...100 Ø150 Ø102 Ø152 9 0 9 5 100 45 125 135 Ø102 Ø152 9 3 125 150 Ø150 200 160 2 2 4 5 0 Ø160 Ø102 Ø152 215 Ø100 Ø150 102 152 110 Ø100 Ø150 Ø102 Ø152 9 0 9 5 100 45 125 135 Ø102 Ø152 9 3 125 150 Ø150 200 160 2 2 4 5 40 Ø160 Ø102 Ø152 215 Ø100 Ø150 8 1 Connection C100 150 to 2xE100PP For separate routing of flue gases and combustion Recommendation If the air inlet is near a noise sensitive place wind...

Page 47: ... pipe length m Max flue height m TopGas 35 45 TopGas 60 21 22 23 24 25 26 27 28 29 30 31 32 33 0 1 2 3 4 0 5 10 15 20 25 0 1 2 3 4 5 6 20 19 0 2 4 6 8 10 12 14 16 18 0 1 2 3 4 5 6 Horizontal flue gas pipe length m Max flue height m TopGas 60 TopGas 35 TopGas 45 TopGas 60 TopGas 35 45 Horizontal flue gas pipe length m Max flue height m Horizontal flue gas pipe length m Max flue height m TopGas 35 4...

Page 48: ...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 2060156 1 9 2 Plume 90 elbow 90 elbow DN100 aluminium 2060159 9 3 Plume 45 elbow 45 elbow DN100 aluminium 2060158 9 4 Plume extension 1m extension DN100 aluminium 2060157 9 5 Plume nose piece Nose piece DN100 aluminium 2060160 7 6 2 2 4...

Page 49: ...to Attention Pour la réalisation pratique de l installation il faut utiliser le schéma détaillé 1 8 SVLF B1 VF1 T T M K 1 M YK1 Dies ist ein unerlaubter Weg Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape Sie haben die Möglichkeit ein neues Shape zu nehmen hovhovalhovalhoval hovalhovalhovalhov Gas P TopGas 1 M5 1 Gas Dies ist ein unerlaubter Weg Gehen Sie einen Schritt zurück oder lös...

Page 50: ...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 Service ...

Page 51: ... equipment contact our service and spares department Responsibilty for energy and environment One stop shopping With us you can easily incorporate gas oil heat pump solar CHP or biomass energy solutions into your heating system 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 Hoval follow...

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