DeDietrich INNOVENS PRO MCA 160 User manual

en
Cascade description
High-efficiency wall-hung gas boilers
MCA 160

Contents
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Liabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.1 Manufacturer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Installer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.3 User's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1 Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Description of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Cascade configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Hydraulic isolation: low-loss header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 De Dietrich cascade systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.2 Main pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.3 Low-loss header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4.4 Boiler pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4.5 Boiler connection kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.4.6 Free-standing frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.5 Accessories and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.1.1 Points to consider for boiler replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.2 Cascade system structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Choice of the location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.1 Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.2 Installation area and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Connecting diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.2 Linear, wall-mounted - LW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.3.3 Linear, free-standing - LV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.4 Back-to-back configuration - RG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.1.1 Connecting the hot tap water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2.1 Gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Air supply/flue gas outlet connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.3.1 Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.2 Individual flue gas outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.3 Joint flue gas outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.4 Dimensions for back-to-back configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.5 Dimensions for linear configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.3.6 Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.7 Additional guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.8 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1 Independently installed cascade systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
7.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1.2 Standard cascade system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.1.3 Dimensioning a standard low loss header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1.4 Boiler and system pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1.5 Non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contents
2 MCA 7680446 - v.01 - 14082017

7.1.6 Overflow valve and manual seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.1.7 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.1.8 Configuration and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Contents
7680446 - v.01 - 14082017 MCA 3

1 Safety
1.1 Liabilities
1.1.1 Manufacturer's liability
Our products are manufactured in compliance with the requirements of the
various Directives applicable. They are therefore delivered with the
marking and any documents necessary. In the interests of the quality of
our products, we strive constantly to improve them. We therefore reserve
the right to modify the specifications given in this document.
Our liability as manufacturer may not be invoked in the following cases:
Failure to abide by the instructions on installing the appliance.
Failure to abide by the instructions on using the appliance.
Faulty or insufficient maintenance of the appliance.
1.1.2 Installer's liability
The installer is responsible for the installation and initial commissioning of
the appliance. The installer must observe the following instructions:
Read and follow the instructions given in the manuals provided with the
appliance.
Install the appliance in compliance with prevailing legislation and stand
ards.
Carry out initial commissioning and any checks necessary.
Explain the installation to the user.
If maintenance is necessary, warn the user of the obligation to check the
appliance and keep it in good working order.
Give all the instruction manuals to the user.
1.1.3 User's liability
To guarantee optimum operation of the system, you must abide by the fol
lowing instructions:
Read and follow the instructions given in the manuals provided with the
appliance.
Call on a qualified professional to carry out installation and initial com
missioning.
Get your installer to explain your installation to you.
Have the required inspections and maintenance carried out by a quali
fied installer.
Keep the instruction manuals in good condition close to the appliance.
1 Safety
4 MCA 7680446 - v.01 - 14082017

2 About this manual
2.1 General
This technical information contains useful and important details for proper
dimensioning of a cascade system with wall-mounted boilers. The descrip
tion includes the correct use of the complete De Dietrich cascade system
with MCA 160 modulating wall-mounted boilers, potentially combined with
one or more MCA 45-115 boilers. Separate cascade systems are available
for a combination consisting exclusively of MCA 45-115 boilers. Refer to
separate cascade description.
Important
Please contact us if you have any questions or for further informa
tion about cascade configurations.
2.2 Symbols used
2.2.1 Symbols used in the manual
This manual uses various danger levels to draw attention to special in
structions. We do this to improve user safety, to prevent problems and to
guarantee correct operation of the appliance.
Danger
Risk of dangerous situations that may result in serious personal
injury.
Danger of electric shock
Risk of electric shock.
Warning
Risk of dangerous situations that may result in minor personal in
jury.
Caution
Risk of material damage.
Important
Please note: important information.
See
Reference to other manuals or pages in this manual.
2 About this manual
7680446 - v.01 - 14082017 MCA 5

3 Description of the product
3.1 Cascade configuration
In many situations it is advantageous to spread the total required heat out
put over several boilers. This can be made possible by means of a "cas
cade configuration". In a cascade configuration, heating boilers are con
nected hydraulically. If the heat demand increases or decreases, boilers
are switched on or off respectively. It is then important to determine the
ideal number of boilers for the cascade. The following factors need to be
taken into account when deciding on the number of boilers:
Investment:
When boilers are split up, the investment costs (boiler cost including in
stallation, fittings, pipe work, pumps and control equipment) can work
out lower or higher. However, this depends to a large extent on the sit
uation.
Reliability:
Reliability increases with the number of boilers. Research has shown
that reliability is already optimum for systems with four boilers in a cas
cade.
Efficiency:
There is no appreciable difference in terms of efficiency between several
small or one or two larger boilers.
Maintenance and faults:
There is a greater overall risk of faults in a system with several boilers. A
larger group of engineers can service and maintain smaller boilers.
Arrangement:
The compact units and therefore compact configuration means that you
have more flexibility for potential boiler locations.
Adjustment:
When using several boilers and modulating control, the heat output of
fered is virtually equal to the heat output requested.
Important
A number of the points mentioned are dependent on the situa
tion and so consideration as to which solution is the best will
need to be given on a project-by-project basis.
3.2 Hydraulic isolation: low-loss header
Practical experience has shown that it is beneficial to create hydraulic iso
lation between the boiler circuit and the system circuit using a low-loss
header. This means that a widely varying volume flow on the system side
hardly influences the volume flow on the boiler side at all. This also applies
in reverse: a widely varying volume flow on the boiler side hardly influen
ces the volume flow on the system side at all. Controlling several different
groups hydraulically is therefore significantly easier as they do not, or
barely, influence each other. This creates better overall operating condi
tions for the system.
3.3 De Dietrich cascade systems
In order to make it as simple as possible to create a cascade configura
tion, De Dietrich has included complete cascade systems in the range for
some years. The compact design of the boilers, combined with the smart
gas and water connection technology (no brazing) of the cascade system,
makes it possible to install a high heat output system in a small area.
For example, eight MCA 160 boilers can be installed in an area of 4.4 m²
(including low-loss header) to provide close to 1200 kW.
3 Description of the product
6 MCA 7680446 - v.01 - 14082017

Important
Please contact us for different configurations (specials). We also
provide in-depth advice on the choice of flue gas outlet material
and control engineering, including for non-standard configurations.
If you want to decide on the position of the boilers and the configuration
yourself, choose an independently installed cascade system. Be sure to
use De Dietrich cascade components.
For more information:
See
Appendix, page 48
3.4 Main components
3.4.1 General
The cascade systems consist of the following components:
Main pipes
Low-loss header
Boiler pump
Boiler connection kits
Free-standing frames
Accessories
3.4.2 Main pipes
The main pipes consist of: main supply, return and gas pipes.
By connecting main pipes, it is possible to extend the system to a maxi
mum of 8 boilers in a linear configuration or 2 x 4 boilers in a back-to-back
configuration.
In a linear configuration, the rear connections must be capped off using
the caps supplied. In a back-to-back configuration with an odd number of
boilers, the unused connections must also be capped off.
Diameter of supply and return pipes 100 mm:
Main pipes for 2 (4) boilers with gas pipe DN 65
Main pipes for 3 (6) boilers with gas pipe DN 65
3.4.3 Low-loss header
The low-loss headers have the following connecting flanges:
Low-loss header for main pipes with diameter = 65 mm up to a heat out
put of 350 kW
Connection DN 65/DIN 2631 (4 holes)
Low-loss header for main pipes with diameter = 65 mm up to a heat out
put of 350 - 460 kW
Connection DN 65/DIN 2631 (4 holes)
Fig.1 Main pipe
AD-0000823-01
Fig.2 Low-loss header DN65
AD-0001428-01
3 Description of the product
7680446 - v.01 - 14082017 MCA 7

Important
In the case of DN 65 low-loss headers, an adapter is supplied in
order to be able to close the DN 100 flanges of the collector pipe
kit in the MCA 160 cascade.
3.4.4 Boiler pump
An energy-saving, modulating pump is supplied with cascade systems for
each MCA 160 boiler and any MCA 45-115 45, 65, 90 or 115 boiler.
Important
The boiler connection kits include the required glands.
3.4.5 Boiler connection kits
The boiler connection kit consists of service shut-off valves in the flow, re
turn and gas pipes and also include the pipes between boiler and main
pipes. In a back-to-back configuration, the length of the pipes that go to
the rearmost row of boilers has been adjusted to the correct length. It is
assumed that, when an odd number of boilers are supplied, the larger
number of boilers is mounted on the front. The service shut-off valve in the
return includes a non-return valve, filling and drain cock and expansion
vessel connection, for example. The safety valve is included. Supply and
return T-pieces are supplied for systems with calorifier connection, so the
installer can work from there towards the calorifier. The calorifier should be
boosted by a pump (not supplied, nor the required non-return valve).
Fig.3 Low-loss header DN100
AD-0001427-01
Fig.4 Adapter DN 65 —> DN 100
AD-0000865-01
3 Description of the product
8 MCA 7680446 - v.01 - 14082017

Connection kit with pump
Connection kit with pump for the MCA 160
Flow connection: (1¼" female thread to boiler and 35 x 1.5 mm to
main pipe)
Return connection: (1¼" female thread to boiler and 35 x 1.5 mm
to main pipe)
Gas connection: (1" female thread to boiler and 28 x 1.5 mm to
main pipe)
Boiler pump
1Ball valve, non-return valve, expansion vessel connection (½" male
thread) and filling/drain cock in return pipe
2Ball valve in supply pipe as well as safety valve
3Gas valve
Connection kit with pump for the MCA 45-115
Flow connection: (1¼" female thread to boiler and 35 x 1.5 mm to
main pipe)
Return connection: (1¼" female thread to boiler and 35 x 1.5 mm
to main pipe)
Gas connection: (¾" female thread to boiler and 28 x 1.5 mm to
main pipe)
Boiler pump
1Ball valve, non-return valve, expansion vessel connection (½" male
thread) and filling/drain cock in return pipe
2Ball valve in supply pipe as well as safety valve
3Gas valve
Fig.5 Connection kit with MCA 160 pump
AD-4100096-02
11/4" bu 11/4" bu 1" bu
1 2
3
35 x 1.5 mm
28 x 1.5 mm
35 x 1.5 mm
Fig.6 Connection kit with MCA 45-115
pump
AD-4100097-01
35 x 1.5 mm
35 x 1.5 mm
11/4" bu 11/4" bu 3/4" bu
28 x 1.5 mm
1 2
3
3 Description of the product
7680446 - v.01 - 14082017 MCA 9

Connection kit for calorifier
Connection kit for calorifier with MCA 160
Flow connection: (1¼" female thread to boiler and 35 x 1.5 mm to
main pipe)
Return connection: (1¼" female thread to boiler and 35 x 1.5 mm
to main pipe)
Gas connection: (1" female thread to boiler and 28 x 1.5 mm to
main pipe)
Boiler pump
1Ball valve, non-return valve, expansion vessel connection (½" male
thread) and filling/drain cock in return pipe
2Ball valve in supply pipe as well as safety valve
3Gas valve
Connection kit for calorifier with MCA 45-115
Flow connection: (1¼" female thread to boiler and 35 x 1.5 mm to
main pipe)
Return connection: (1¼" female thread to boiler and 35 x 1.5 mm
to main pipe)
Gas connection: (¾" female thread to boiler and 28 x 1.5 mm to
main pipe)
Boiler pump
1Ball valve, non-return valve, expansion vessel connection (½" male
thread) and filling/drain cock in return pipe
2Ball valve in supply pipe as well as safety valve
3Gas valve
Fig.7 Connection kit for MCA 160 calorifi
er
AD-4100098-01
35 x 1.5 mm
35 x 1.5 mm
11/4" bu 11/4" bu 1" bu
28 x 1.5 mm
1 2
3
Fig.8 Connection kit for MCA 45-115 cal
orifier
AD-4100099-01
35 x 1.5 mm
35 x 1.5 mm
11/4" bu 11/4" bu 3/4" bu
28 x 1.5 mm
1 2
3
3 Description of the product
10 MCA 7680446 - v.01 - 14082017

3.4.6 Free-standing frames
The free-standing frames consist of a combination of I and/or L poles with
an intermediate frame. 1 intermediate frame is required per boiler. The L
poles have bolt holes for fixing to the floor. The frame has two fitting brack
ets. The top bracket should be used with a MCA 160 boiler and the bottom
bracket for a MCA 45-115 boiler L poles are only required if boilers are
mounted at the rear of the frame (for a back-to-back configuration). Only l
poles are used with linear configurations. The top of the frame can be
used as a cableway. The nuts and bolts required are included with the de
livery, along with installation instructions. Fastenings for fixing to the floor
are not included.
3.5 Accessories and options
3.5.1 Accessories
Elbow kit for angled connection of the low-loss header in 65 and 100
mm diameters
Connecting flanges DN 65 and DN 100 for system side of the low-loss
header
Important
Depending on the system resistance, it may be necessary to
switch to a larger pipe diameter after the connecting flanges of the
low-loss header.
Insulation for low-loss header, low-loss header elbow, connection kits
and main pipes.
DN 65 gas filter
Gas filter expansion piece (for mounting gas filter next to low-loss head
er) DN 65 (to be used if gas filter mounted on the same side as the low-
loss header with elbows or low-loss header with insulation).
Temperature sensor including thermostat pocket for low-loss header.
Adjustable feet
Calorifier connection
Fig.9 Frames
AD-0000830-01
Fig.10 Elbow kit
AD-0000831-01
315 mm
315 mm
3 Description of the product
7680446 - v.01 - 14082017 MCA 11

4 Before installation
4.1 Installation requirements
4.1.1 Points to consider for boiler replacement
If the boiler output is reduced, the water flow rate will need to be adjusted
accordingly. Imagine that 4 MCA 160 boilers are connected in a cascade.
The total water flow rate is then 4 x 6.38 = 25.5 m3/h (at ΔT= 20° C). If the
water is now pumped around the system at 32.7 m3/h, it flows in the low-
loss header from the return to the supply line at 7.42 m3/h. The ΔT in the
system is then 25.5/32.7 times as great as on the boiler side. If the boilers
heat to 90/70° C, the system then heats with a supply temperature of +/-
85° C. Most heat-output elements (such as radiators) have an exponential
curve. This means that a lower supply temperature results in much less
heat output. This can lead to complaints about the cold. The solution is to
match the flow rate in the system to the flow rate in the boilers. A lower
supply temperature is then worse than a lower water flow rate, especially
for the heat-output elements, where a high water temperature is required.
4.1.2 Cascade system structures
The return, flow, and gas connections of the individual boilers are connec
ted using the fittings supplied by means of horizontal connections to main
pipes for return, flow and gas. These pipes are welded onto a frame that
rests on the floor and is fixed to the wall or to a free-standing frame. The
low-loss header supplied has flange connections, which can be fitted to
the left or right of the cascade main pipe as required. The blind flanges
supplied are then fitted on the other side. The gas main pipe has a flange
to which the optional gas filter can also be connected on the left or right as
required. When a gas filter is used, a pressure drop of 3 mbar over the gas
filter must be taken into account. The minimum gas pressure after the gas
filter is 20 mbar for L gas and 17 mbar for H gas. A common PVC con
densed water discharge pipe (not supplied) can be installed in the frame.
For this purpose, holes have been made in the frame into which this pipe
can be fitted (to the left or right as required) sloping downwards.
Important
Any mix of MCA 160 and MCA 45-115 boilers is possible. This
manual focuses on the combination of MCA 160 boilers. Separate
cascade systems are available for combination consisting exclu
sively of MCA 45-115 boilers.
See table for outputs of the different boilers.
Tab.1 Boiler outputs
Boiler type Nominal output [kW]
50/30° C 80/60° C
MCA 45-115 45 43 40
MCA 45-115 65 65 61
MCA 45-115 90 89.5 84.2
MCA 45-115 115 114 107
MCA 160 157 148
4 Before installation
12 MCA 7680446 - v.01 - 14082017

4.2 Choice of the location
4.2.1 Boiler room
One or more boilers with a combined load less than 130 kW maximum
can, if required, be located in a boiler or operations room. A cascade sys
tem with a total maximum load of more than 130 kW must comply with the
regulations that apply to boiler rooms.
4.2.2 Installation area and dimensions
Fig.11 Lifting aids
AD-0000138-03
Select the desired combination of boilers on the basis of the required heat
output. We advise leaving 1 m of free space at the front of the units. The
distance between individual boilers is 3 cm. A wall bracket is supplied for
wall-mounted linear configurations. This must be mounted at a height as
specified in the installation manual supplied with the cascade system. We
recommend a clearance of at least 50 cm above the units. This distance
also depends on any installation of flue gas outlet and air supply collector
pipes. Consult the flue gas tables.
The weight of the MCA 160 boiler exceeds the maximum lift weight for one
person. We recommend the use of a lifting aid.
4.3 Connecting diagrams
4.3.1 General
The cascade systems can be divided into 3 main groups:
2 to 8 boilers in a linear configuration, wall mounted (LW)
2 to 8 boilers in a linear configuration, mounted on a free-standing frame
(LV)
3 to 8 boilers in a back-to-back configuration, mounted on a free-stand
ing frame (RG)
For each main group, the first listing is a sample configuration for two MCA
160 boilers and one MCA 45-115 boiler. Of course, many more configura
tions are possible but they would be too numerous to include in this techni
cal information.
4 Before installation
7680446 - v.01 - 14082017 MCA 13

4.3.2 Linear, wall-mounted - LW
Sample configuration drawing with 3 LW boilers; 2 x MCA 160
and 1 x MCA 45-115.
Fig.12 3 LW boilers
AD-4100020-01
C
1890
630630 630
A B 500
602
325500 305 173
80 30600
1805
226
325
125
1736
1924
1603,5
267,5
1
4
3
4
2
1System water supply; connection DN 65/DIN 2631 (4
holes)
2System return; connection DN 65/DIN 2631 (4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 330 mm up to 350 kW and
560 mm above 350 kW
BSystem return centre line = 210 mm to 350 kW and
200 mm above 350 kW
CLow-loss header; DN 65 connection with adapter to
DIN 100 = 361 mm to 350 kW and 701 mm above
350 kW
4 Before installation
14 MCA 7680446 - v.01 - 14082017

Configuration drawing for 2 boilers - LW
Fig.13 2 LW boilers
AD-4100000-01
C 630 630
602 602
325 305 173
30 600
1230
226
325
125
1736
2003,5
1924
267,5
1260
A B
1
2
4
3
1System water supply; connection DN 65/DIN 2631 (4
holes)
2System return; connection DN 65/DIN 2631 (4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 330 mm
BSystem return centre line = 210 mm
CLow-loss header; DN 65 connection with adapter
from DIN 65 to DIN 100 = 361 mm
4 Before installation
7680446 - v.01 - 14082017 MCA 15

Configuration drawing for 3 boilers - LW
Fig.14 3 LW boilers
AD-4100001-01
C
1890
630630 630
A B 602
602
325 305 173
30 600
1860
226
325
125
1736
2003,5
1924
267,5
4
3
1
2
1System water supply; connection DN 65/DIN 2631 (4
holes)
2System return; connection DN 65/DIN 2631 (4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 330 mm up to 350 kW and
560 mm above 350 kW
BSystem return centre line = 210 mm to 350 kW and
200 mm above 350 kW
CLow-loss header; DN 65 connection with adapter to
DIN 100 = 361 mm to 350 kW and 701 mm above
350 kW
4 Before installation
16 MCA 7680446 - v.01 - 14082017

Configuration drawing for 4 boilers - LW
Fig.15 4 LW boilers
AD-4100002-01
C
2520
630630630 630
A B 602
602
325 305 173
30 600
2490
226
325
125
1736
2003,5
1924
267,5
4
3
1
2
1System water supply; DN 100/DIN 2631 connection
(4 holes)
2System water supply; DN 100/DIN 2631 connection
(4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 560 mm
BSystem return centre line = 200 mm
CLow-loss header; DN 100 = 633 mm connection
4 Before installation
7680446 - v.01 - 14082017 MCA 17

Configuration drawing for 5 boilers - LW
Fig.16 5 LW boilers
AD-4100003-01
C
3150
630630630630 630
A B 602
602
30 600
3120
226
325
125
325 305 173
1736
2003,5
1924
267,5
1
2
3
4
1System water supply; DN 100/DIN 2631 connection
(4 holes)
2System water supply; DN 100/DIN 2631 connection
(4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 560 mm
BSystem return centre line = 200 mm
CLow-loss header; DN 100 = 633 mm connection
4 Before installation
18 MCA 7680446 - v.01 - 14082017

Configuration drawing for 6 boilers - LW
Fig.17 6 LW boilers
AD-4100004-01
C
3780
630630630630630 630
A B 602
602
30 600
3750
226
325
125
325 305 173
1736
2003,5
1924
267,5
4
1
2
3
1System water supply; DN 100/DIN 2631 connection
(4 holes)
2System water supply; DN 100/DIN 2631 connection
(4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 560 mm
BSystem return centre line = 200 mm
CLow-loss header; DN 100 = 633 mm connection
4 Before installation
7680446 - v.01 - 14082017 MCA 19

Configuration drawing with 7 boilers - LW
Fig.18 7 LW boilers
AD-4100005-01
C
4410
630630630630630630 630
A B 602
602
30 600
4380
226
325
125
325 305 173
1736
2003,5
1924
267,5
3
4
1
2
1System water supply; DN 100/DIN 2631 connection
(4 holes)
2System water supply; DN 100/DIN 2631 connection
(4 holes)
3Gas supply connection DN 65/DIN 2633 (4 holes)
4Suspension points
Air supply 150 mm
Flue gas outlet 150 mm
ASystem flow centre line = 560 mm
BSystem return centre line = 200 mm
CLow-loss header; DN 100 = 633 mm connection
4 Before installation
20 MCA 7680446 - v.01 - 14082017