Eco Heating Systems CB 85 CH Manuale utente

Installation manual

CASCADE SETUP

Wall-hung high efficiency central heating boilers

CB 85 CH

CB 105 CH

CB 125 CH

CB 155 CH

INITIAL VERSION

E93.9950EN

S67.500.004.003.03

E93.9950EN CB Cascade manual 3

Table of Contents

1. INTRODUCTION........................................................................................................................................4

2. INSTALLATION PROCEDURE CASCADE CONFIGURATION..............................................................5

3. DETERMINE POWER REQUIRED FOR THE CASCADE CONFIGURATION........................................6

4. CALCULATE DIMENSIONS AND SPACE OF CASCADE CONFIGURATION ......................................8

5. EXPLANATION OF PARTS AND GROUPS ..........................................................................................11

6. CONNECTING SETS ..............................................................................................................................12

7. HYDRAULIC AND GAS HEADER GROUP............................................................................................13

7.1 Headers...........................................................................................................................................13

7.2 Support beam and support brackets...............................................................................................13

7.3 Headers and connecting sets..........................................................................................................14

8. MOUNTING THE FRAME .......................................................................................................................15

8.1 Frame elements ..............................................................................................................................15

8.2 Procedure for mounting the frame ..................................................................................................16

9. MOUNTING THE GAS HEADER............................................................................................................17

10. MOUNTING THE BOILERS ON THE FRAME........................................................................................18

11. MOUNTING THE HYDRAULIC GROUP AND THE CONNECTING SETS............................................19

12. MOUNTING THE LOW LOSS HEADERS ..............................................................................................20

13. DETERMINE MANAGING AND DEPENDING BOILERS ......................................................................21

14. COMPLETE THE MECHANICAL INSTALLATION................................................................................21

15. MOUNT THE FLUE GAS AND AIR SUPPLY SYSTEMS.......................................................................22

15.1 Individual flue systems....................................................................................................................22

15.2 Common flue system.......................................................................................................................22

16. SET PARAMETERS................................................................................................................................23

17. COMMISSIONING THE CASCADE CONFIGURATION ........................................................................23

18. ACCESSORIES.......................................................................................................................................24

19. REFERENCES.........................................................................................................................................24

19.1 List of figures...................................................................................................................................24

19.2 List of tables ....................................................................................................................................24

20. APPENDIX A – CASCADE PARTS........................................................................................................25

4E93.9950EN CB Cascade manual

1. Introduction

This Cascade manual is intended for the wall-hung high efficiency central heating boilers from the CB boiler

series as manufactured by ECO Heating Systems.

The boilers can be combined in one cascade configuration. This ensures that the required power can always be

achieved. Since several boilers are combined this allows for a deeper modulation range and for more precisely

achieving the required level.

Furthermore the cascade configuration offers an increased reliability: should one boiler go into error, the

cascade configuration will continue to operate.

ECO Heating Systems can supply standard cascade systems with mounting frame, piping and low loss headers

for up to six boilers depending on the range. Larger amounts of boilers in a cascade combination are possible

but require a dedicated system which must be designed separately.

The software allows for combining of up to 16 CB-boilers in a single cascade installation.

This document will offer you a general procedure for the complete installation of a cascade configuration.

For specific details regarding connections, parameters, venting, etc. see the Installation & Service Manual of the

boilers.

Figure 1.1 Typical cascade configuration

S67.500.004.003.02

E93.9950EN CB Cascade manual 5

2. Installation procedure cascade configuration

In order to completely install a cascade configuration of two or more boilers, the following procedure should be

observed:

1. Calculate the total required amount of power for the cascade configuration and determine the

number of boilers necessary in the cascade configuration to achieve the required power.

This is described in detail in chapter 3.

2. Determine the dimensions of the cascade set and the required space at the planned location.

This is described in detail in chapter 4.

3. Mount the frame.

This is described in detail in chapter 8.

4. Mount the gas header.

This is described in detail in chapter 9.

5. Mount the boilers on the frame.

This is described in detail in chapter 10.

6. Mount the hydraulic group and the connecting sets.

This is described in detail in chapter 11.

7. Mount the low loss header.

This is described in detail in chapter 12.

8. Determine which boiler is managing and which are depending.

This is described in detail in chapter 13.

9. Complete the mechanical installation of the cascade configuration.

This is discussed in chapter 14.

10. Mount the flue gas and air supply systems.

This is discussed in chapter 15.

11. Set the parameters in the software by means of the controller of each boiler.

This is discussed in chapter 16.

12. Commission the cascade installation.

This is discussed in chapter 17.

6E93.9950EN CB Cascade manual

3. Determine power required for the cascade configuration

The first step in the installation procedure for the cascade configuration is to determine the total power required

for the cascade configuration. This power is calculated based on the size of the room(s) to be heated and other

relevant variables. If the required power in kW is known, consult Table 3.1 (below) in order to determine which

combination of boilers can be applied to achieve the required power.

Total

Power *

CB 85 CH CB 105 CH CB 125 CH CB 155 CH

Total number

boilers

Cascade type

170

CCB-170-2-2000

187

CCB-187-2-1100

204

CCB-204-2-0200

210

CCB-210-2-1010

227

CCB-227-2-0110

236

CCB-236-2-1001

249

CCB-249-2-0020

253

CCB-253-2-0101

255

CCB-255-3-3000

272

CCB-272-3-2100

276

CCB-276-2-0011

289

CCB-289-3-1200

295

CCB-295-3-2010

302

CCB-302-2-0002

305

CCB-305-3-0300

312

CCB-312-3-1110

321

CCB-321-3-2001

328

CCB-328-3-0210

335

CCB-335-3-1020

338

CCB-338-3-1101

340

CCB-340-4-4000

351

CCB-351-3-0120

355

CCB-355-3-0201

357

CCB-357-4-3100

361

CCB-361-3-1011

374

CCB-374-3-0030

374

CCB-374-4-2200

378

CCB-378-3-0111

380

CCB-380-4-3010

387

CCB-387-3-1002

391

CCB-391-4-1300

397

CCB-397-4-2110

400

CCB-400-3-0021

404

CCB-404-3-0102

406

CCB-406-4-3001

407

CCB-407-4-0400

413

CCB-413-4-1210

420

CCB-420-4-2020

423

CCB-423-4-2101

426

CCB-426-5-5000

427

CCB-427-3-0012

430

CCB-430-4-0310

436

CCB-436-4-1120

E93.9950EN CB Cascade manual 7

Total

Power *

CB 85 CH CB 105 CH CB 125 CH CB 155 CH

Total number

boilers

Cascade type

440

CCB-440-4-1201

446

CCB-446-4-2011

453

CCB-453-3-0003

453

CCB-453-4-0220

456

CCB-456-4-0301

459

CCB-459-4-1030

472

CCB-472-4-2002

476

CCB-476-4-0130

479

CCB-479-4-0211

486

CCB-486-4-1021

489

CCB-489-4-1102

499

CCB-499-4-0040

502

CCB-502-4-0121

506

CCB-506-4-0202

511

CCB-511-6-6000

512

CCB-512-4-1012

525

CCB-525-4-0031

529

CCB-529-4-0112

538

CCB-538-4-1003

551

CCB-551-4-0022

555

CCB-555-4-0103

578

CCB-578-4-0013

604

CCB-604-4-0004

624

CCB-624-5-0050

650

CCB-650-5-0041

676

CCB-676-5-0032

702

CCB-702-5-0023

729

CCB-729-5-0014

748

CCB-748-6-0060

755

CCB-755-5-0005

775

CCB-775-6-0051

801

CCB-801-6-0042

827

CCB-827-6-0033

853

CCB-853-6-0024

880

CCB-880-6-0015

906

CCB-906-6-0006

* Figures in this column represent the nominal output in kW at 50 °C/30 °C

Table 3.1 Cascade power calculation table based on CB boilers

EXAMPLES

1) In case the required power is calculated at 275 kW, the table will show you that the required cascade type is

CCB-276-2-0011 and that the cascade configuration should have 2 boilers: one CB 125 CH boiler and one

CB 155 CH boiler.

2) In case the required power is calculated at 440 kW, the table will show you that the required cascade type is

CCB-440-4-1201 and that the cascade configuration should have 4 boilers: one CB 85 CH boiler, two CB

105 CH boilers and one CB 155 CH boiler.

8E93.9950EN CB Cascade manual

4. Calculate dimensions and space of cascade configuration

In this chapter is explained how to determine the dimensions of the cascade configuration and how much space

is required in the room where the cascade configuration will be installed.

Figure 4.1 Dimensions front view

L2 (length incl. low loss header)

L1 (length)

EHS.T0200.5050

E93.9950EN CB Cascade manual 9

Figure 4.2 Dimensions: side views

After you have determined which cascade configuration will be applied and therefore how many boilers must be

combined in the cascade configuration, the next step is to determine the total dimensions of the cascade

configuration and the space required for the cascade configuration.

Figure 4.1 and Figure 4.2 show a schematic representation of a cascade configuration. The dimensional

references in this figure (L1-L3, H1-H3, D1-D3, A, B) correspond with the dimensional references in the tables

below.

EXAMPLES

In case a cascade configuration for 275 kW is required, which will exist of 2 boilers, refer to Table 4.1 for the

dimensions of the cascade configuration. The table shows that frame length for this configuration is 1030 mm

and the total length including the low loss header is 1428 mm.

In case a cascade configuration for 440 kW is required, which will exist of 4 boilers, refer to Table 4.2 for the

dimensions of the cascade configuration. The table shows that frame length for this configuration is 2010 mm

and the total length including the low loss header is 2408 mm.

All these dimensions have to be taken into account when determining the space required for placing the

cascade configuration.

EHS.T0200.5050

Bolts can be adjusted max. 50 mm

EHS.T0200.5050

10 E93.9950EN CB Cascade manual

Number of boilers

(up to 360 kW)

2 boilers 3 boilers 4 boilers

L1 (length frame)

1030

1520

2010

L2 (total length incl. header) 1428 1918 2408

L3 (length low loss header)

422

H1 (height gas)

308

H2 (height header coupling)

248

H3 (height couplings)

350

D1 (header connection size)

DN 65 PN6 (2½ “)

D2 (header connection size)

DN 65 PN6 (2½ “)

D3 (gas connection size) R 2” R 2” R 2”

A (gas)

253

B (headers)

459

Table 4.1 Dimensions CB cascade up to 360 kW

Number of boilers

(360 up to 540 kW)

3 boilers 4 boilers

L1 (length frame)

1520

2010

L2 (total length incl. header)

1938

2473

L3 (length low loss header)

487

H1 (height gas)

308

H2 (height header coupling)

257

H3 (height couplings) 380 380

D1 (header connection size)

DN 80 PN6 (3 “)

D2 (header connection size)

DN 80 PN6 (3 “)

D3 (gas connection size) R 2” R 2”

A (gas)

253

B (headers)

466

Table 4.2 Dimensions CB cascade 360 up to 540 kW

Number of boilers

(540 to 930 kW)

4 boilers 5 boilers 6 boilers

L1 (length frame)

2010

2500

2990

L2 (total length incl. header)

2614

3104

3594

L3 (length low loss header)

628

H1 (height gas)

327

H2 (height header coupling)

272

H3 (height couplings) 420 420 420

D1 (header connection size)

DN 100 PN6 (4 “)

D2 (header connection size)

DN 100 PN6 (4 “)

D3 (gas connection size) DN 80 (3”) DN 80 (3”) DN 80 (3”)

A (gas)

253

B (headers)

482

Table 4.3 Dimensions CB cascade 540 to 930 kW

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