Hoval TopGas Cascade 60 Technical Information And Assembly Instructions
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Hoval TopGas Cascade 60 Technical Information And Assembly Instructions

Hoval TopGas Cascade 60 Technical Information And Assembly Instructions

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TopGas Cascade
Condensing Gas Boilers
Technical Information and Assembly Manual
Output range 60 to 720 kW
4215256-00 - 11/16
Subject to modification

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Summary of Contents for Hoval TopGas Cascade 60

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

  • Page 2: Table Of Contents

    TopGas Cascade 60 - 720 kW Contents Page No. Important Information 1.1. Documentation 1.2. Guarantee 1.3. Other instructions 1.4. Safety instructions 1.5. Related Installation Documents 1.6. Transport and Storage 1.7. Installation. Location requirements Technical Description 2.1. Technical Description 2.2. Cascade Product Codes Technical Data 3.1.
  • Page 3 TopGas Cascade 60 - 720 kW 6.3. TopGas 60 single boiler low loss header 6.4. TopGas 80 single or two boiler low loss header 6.5. TopGas 100,120 single boiler low loss header 6.6. Boiler circulating pump, TopGas (60,80) 6.7. Pump insulation cover, TopGas (60,80) Boiler circulating pump, TopGas (100,120) 6.9.

  • Page 4: Important Information

    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 Hoval gas boilers are only to be installed and placed in operation improper use or use for which it is not intended. The product is by suitably qualified technicians;...

  • Page 5: Related Installation Documents

    The equipment is to be transported and stored • BS 5854 Code of practice for flues and flue structures in only in its original packing. Interim storage of Hoval gas boilers buildings should only to take place in weather protected rooms and only in •...

  • Page 6: Technical Description

    2.1. Technical Description A pipework header set is supplied with each cascade to allow all The Hoval TopGas Cascade allows a number of individual Hoval the individual TopGas boilers to be connected together to create TopGas boilers to be mounted into a common arrangement.

  • Page 7: Technical Data

    TopGas Cascade 60 - 720 kW 3. Technical data 3.1. Technical data, TopGas Cascade 60 ® Number of TopGas Boilers in Cascade Three Four Five Nominal output at 80/60°C with Natural Gas 113.2 169.8 226.4 283.0 339.6 Nominal output at 40/30°C with Natural Gas 124.0...
  • Page 8 TopGas Cascade 60 - 720 kW 3.2. Technical data, TopGas Cascade 80 ® Number of TopGas Boilers in Cascade Three Four Five Nominal output at 80/60°C with Natural Gas 147.4 221.1 294.8 368.5 442.2 Nominal output at 40/30°C with Natural Gas 162.0...

  • Page 9: Technical Data, Topgas ® Cascade 100

    TopGas Cascade 60 - 720 kW 3.3. Technical data, TopGas Cascade 100 ® Number of TopGas Boilers in Cascade Three Four Five Nominal output at 80/60°C with Natural Gas 180.8 271.2 361.6 542.4 Nominal output at 40/30°C with Natural Gas Nominal output at 80/60°C with LPG...

  • Page 10: Technical Data, Topgas ® Cascade 120

    TopGas Cascade 60 - 720 kW 3.4. Technical data, TopGas Cascade 120 ® Number of TopGas Boilers in Cascade Three Four Five Nominal output at 80/60°C with Natural Gas 215.2 322.8 430.4 645.6 Nominal output at 40/30°C with Natural Gas Nominal output at 80/60°C with LPG...

  • Page 11: Technical Drawings, Cascade In-Line Frame Mounted

    ONE BOILER 1* TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 12 ONE BOILER 2 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 13 ONE BOILER 3 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 14 7. Boiler Drain G¾” Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 15 7. Boiler Drain G¾” Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 16 ONE BOILER 6 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...

  • Page 17: Technical Drawings, Cascade Back To Back Frame Mounted

    TWO BOILER 1*2 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 18 THREE BOILERS 2+1 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 19 FOUR BOILERS 2*2 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 20 FIVE BOILERS 3*2 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...
  • Page 21 SIX BOILERS 3*3 TopGas 100/120 Note: Condensate drainage, fluing, safety valve discharge and boiler drain pipework to be supplied and fitted by the installer (not by Hoval) Blanking flanges can be fitted either side of the header assembly to suit site requirements...

  • Page 22: Technical Drawings, Optional Single And Two Boiler Low Loss Headers

    TopGas Cascade 60 - 720 kW 3.7. Technical Drawings, optional single and two boiler low loss headers Single TopGas 60 boiler low loss header (2057320) 1" BSP 1 1/2" BSP Boiler Flow System Flow 1" BSP 1 1/2" BSP Please see Accessories section for further information...

  • Page 23: Technical Drawings, Optional Cascade Low Loss Headers

    TopGas Cascade 60 - 720 kW 3.8. Technical Drawings, optional cascade low loss headers Low Loss Herader for TopGas 45,60 & 80 cascades (6042897) Low loss header for all TopGas 60,80 cascades (6034283) Connections 1. Primary Flow DN80 PN6 2. Primary Return DN80 PN6 3.

  • Page 24: Technical Drawings, Optional Cascade Air And Dirt Separators

    TopGas Cascade 60 - 720 kW 3.9. Technical Drawings, optional cascade air and dirt separators Air and dirt separator for all TopGas 60 and TopGas 80 cascades (2067549) Air Dirt Seperator for TopGas 60 & 80 Cascades Connections 1. Primary Flow DN80 PN6 Connections 2.

  • Page 25: Installation Requirements

    For connection to the system a hydraulic header has to be used. Any gas work performed must be done by competent persons Hoval offer an optional low loss header kit or an air and dirt holding a valid qualification. separator that can act as a hydraulic header between the boiler cascade and the heating system.

  • Page 26: Flue Gas Connection, Chimney

    (not by Hoval). Where appliance is to be room sealed (LAS) then a Hoval flue No isolating or non-return valves should be fitted in the adaptor piece with sample points (part no. 2042406) must be fitted condensate discharge pipework and the pipework material should on the boiler to allow the boilers to be commissioned and serviced.

  • Page 27: Topgas Cascade Assembly

    TopGas Cascade 60 - 720 kW 5.TopGas Cascade Assembly, 2 boilers in-line and 3 or 4 boilers back to back Find a suitable space and prepare the frame for assembly. Each frame will come with: 4 x 75mm M10 bolts (2056546)
  • Page 28 TopGas Cascade 60 - 720 kW Hold up the center piece and support arms and align with the side piece. Place the M10 bolt (2056546) through the support arm and through the side piece with a washer either side (if holes do not align then adjust the feet as appropriate) and add the M10 nut (2042599).

  • Page 29: Step 1: Build The Frame (1 Boiler Inline 2 Boiler Back To Back)

    TopGas Cascade 60 - 720 kW If the cascade arrangment purchased is a three or four boiler back to back model, you will receive rear support legs as shown opposite. These are to be fitted onto the rear of the side plates as shown. You will also recieve extension pipes that will connect the flex connec- tions to the header.
  • Page 30 TopGas Cascade 60 - 720 kW Hold the two side pieces in line and align the holes at the bottom with the holes in the bottom support beam using the M10 bolts (2056546). Tighten the nuts after both bolts are through the holes to make the alignment easier.

  • Page 31: Step 2: Mount The Boilers

    TopGas Cascade 60 - 720 kW If the cascade arrangment purchased is a two boiler back to back model, you will receive rear support legs as shown opposite. These are to be fitted onto the rear of the side plates as shown. You will also receive extension pipes that will connect the flex connections to the header.

  • Page 32: Step 3: Pipe The Gas From The Header To The Boilers

    TopGas Cascade 60 - 720 kW TopGas Cascade Assembly 5.3. Step 3: Pipe the gas from the header to the boilers Using PTFE tape (or other suitable thread sealing media), wrap both sides of the 1” nipple (2043076) before screwing into the header.
  • Page 33 TopGas Cascade 60 - 720 kW TopGas Cascade Assembly Measure the gap between the two TracPipe connectors and cut the 28mm TracPipe to length using a rotary tube cutter. Cut between corrugations. Take care not to tighten the pipe cutter too tightly as it may cause deformations.

  • Page 34: Step 4: Connect The Nipples To The Flow And Return Headers

    TopGas Cascade 60 - 720 kW TopGas Cascade Assembly 5.4. Step 4: Connect the nipples to the flow and return headers Prepare all flexible pipework nipples as below using PTFE tape (or other suitable thread sealing media). There will be 4 off per boiler. Please be aware that you do not apply PTFE tape to the side with the flat face suitable for a gasket.

  • Page 35: Step 5: Connect The Boiler To The Flow And Return Header (Topgas 60 And 80)

    TopGas Cascade 60 - 720 kW TopGas Cascade Assembly 5.5. Step 5: Connect the boiler to the flow and return headers (TopGas 60 and 80) Arrange the pump (2056729) and valve set (6012948) ready to be connected to the boiler. Please be aware that all of the gaskets must be fitted in the correct positions as shown in the picture on the right.

  • Page 36: Step 5: Connect The Boiler To The Flow And Return Header (Topgas 100 And 120)

    TopGas Cascade 60 - 720 kW 5.5.1. Step 5: Connect the boiler to the flow and return headers (TopGas 100 and 120) Arrange the pump (2064823) and valve set (6042514) ready to be connected to the boiler. Please be aware that all of the gaskets must be fitted in the correct positions as shown in the picture on the right.

  • Page 37: Step 6: Connect The Blanking Flanges

    TopGas Cascade 60 - 720 kW TopGas Cascade Assembly Fit one side of the flexible pipe to the nipple on the header and the other side to the respective valve. A gasket must be used at either end to ensure a water tight seal. Tighten accordingly.

  • Page 38: Step 7: Fit The Pre-Formed Insulation Wrap

    TopGas Cascade 60 - 720 kW 5.7. Step 7: Fit the pre-formed insulation wrap Fit the supplied pre-formed insulation wrap to the flow and return headers, align the pre cut holes with the connections on the head- ers and push the insulation wrap together ensuring the the teeth on the insulation wrap interlock.
  • Page 39 TopGas Cascade 60 - 720 kW For the flow and return connections fit the 1¼” union (TopGas 60,80) or 1½” union (TopGas 100,120) on the flexible pipe to the extension pipe. Before fitting apply PTFE tape (or other suitable thread sealing media). Tighten to ensure a good seal is made.

  • Page 40: Accessories - Hydraulics And Gas

    TopGas Cascade 60 - 720 kW 6. Accessories - Hydraulics and Gas 6.1. Low loss header Used to allow secondary system flow flexibility. Designed for a primary ∆T of 20°C. Allows for the secondary side to work with a ∆T as low as 11°C.

  • Page 41: Topgas 60 Single Boiler Low Loss Header

    TopGas Cascade 60 - 720 kW 1" BSP 1 1/2" BSP Boiler Flow System Flow 6.3. TopGas 60 single boiler low loss header 2057320 Single TopGas 60 boiler low loss header Complete with 1”BSP connections on the inlet and 1½” BSP on the outlet.

  • Page 42: Boiler Flow And Return Connection Valve Set, Topgas

    TopGas Cascade 60 - 720 kW 6.9. Boiler flow and return connection valve set, TopGas (60,80) Connection set for TopGas (60,80) 6012948 For use with circulation pump mounted on the return connection. consisting of: Return: Isolating valve R 1 ¼” with gland nut 2”. Side outlet branch with drain cock and G ¾”...

  • Page 43: Accessories Controls

    TopGas Cascade 60 - 720 kW Accessories - Controls Cascade controls with heating controller set TopTronic® E ZE1 Heating controller set TopTronic® E ZE1 (Can be built in) as supplement for basic boiler control panel G04. - Installation of the TopTronic E basic module ®...
  • Page 44 TopGas Cascade 60 - 720 kW TopTronic E module expansions ® for TopTronic E basic module heat generator ® TopTronic® E module expansion heating 6034 576 circuit TTE-FE HK Expansion to the inputs and outputs of the basic module heat generator or the heating circuit/do-...
  • Page 45 TopGas Cascade 60 - 720 kW Accessories for TopTronic ® Supplementary plug set for basic module heat generator (TTE-WEZ) 6034 499 for controller modules and module expansion TTE-FE 6034 503 TopTronic® E controller modules TTE-HK/WW TopTronic® heating circuit/ 6034 571...

  • Page 46: Accessories - Flues (Individual - Concentric)

    Ø100 Ø152 Ø150 Ø102 TopGas Cascade 60 - 720 kW 1135 1095 Ø100 Ø100 8. Accessories - Flues (Individual - concentric) Ø150 1000 / 500 / 250 Ø100 990 / 490 / 240 Ø150 2015 244 Connection C100/150 to 2xE100PP Ø100...

  • Page 47: Aluminium Flat Roof Flashing

    In this case all boilers should be provided with an optional air inlet non-return flap (available as an accessory for the TopGas 60-120 as above) or with an external non-return flap for the TopGas 35 and 45 (not Hoval supply).

  • Page 48: Accessories - Flues (Individual - Plume Kit)

    TopGas Cascade 60 - 720 kW 9. Accessories - Flues (Individual - Plume kit) TopGas aluminium plume kit. All include high performance EPDM seals. 9.1. Plume management kit 2060156 Plume management kit to direct products of combustion to discharge at high level. Suitable for all models of TopGas boiler.

  • Page 49: Typical Hydraulic Schematic

    TopGas Cascade 60 - 720 kW 10. Typical Hydraulic Schematic TTE-GW Typical heating system (not by Hoval) TTE-ZE1 TTE-ZE3 DHWS M K 1 TopGas TopGas Dies Dies unerlaubter Weg! unerlaubter Weg! 2 - 6 Gehen einen Gehen einen Dies Schritt zurück oder Schritt zurück oder...

  • Page 50: Hoval Service And Spares Contact Details

    TopGas Cascade 60 - 720 kW All TopGas boilers can be commissioned by our dedicated ® service team. Service For annual servicing of TopGas boilers and other equipment ® please contact our Hoval Service department. TopGas spares kits are available from our spares department.
  • Page 51 Hoval Ltd Northgate Newark-on-Trent Nottinghamshire NG24 1JN United Kingdom Phone 01636 672 711 01636 673 532 email boilersales@hoval.co.uk www.hoval.co.uk Responsibilty for energy and environment Hoval follows a policy of continued improvement and reserves the right to change specifications without notice.

This manual is also suitable for:

Topgas cascade 80Topgas cascade 100Topgas cascade 120

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