Lochinvar EFB Series Guide

EFB
WALL HUNG GAS FIRED CONDENSING BOILERS
Cascade pipework headers
Installation manual_EFB Cascade_June 2019
MODELS
EFB85
EFB105
EFB125
EFB155
Installation, Commissioning, User and
Maintenance instructions

Table of Contents
1. INTRODUCTION........................................................................................................................................4
2. INSTALLATION PROCEDURE CASCADE CONFIGURATION ..............................................................5
3. CALCULATE DIMENSIONS AND SPACE OF CASCADE CONFIGURATION.......................................6
4. EXPLANATION OF PARTS AND GROUPS.............................................................................................9
5. CONNECTING SETS...............................................................................................................................10
6. HYDRAULIC AND GAS HEADER GROUP............................................................................................11
6.1 Headers...........................................................................................................................................11
6.2 Support beam and support brackets ...............................................................................................11
6.3 Headers and connecting sets..........................................................................................................12
7. MOUNTING THE FRAME........................................................................................................................13
7.1 Frame elements...............................................................................................................................13
7.2 Procedure for mounting the frame...................................................................................................14
8. MOUNTING THE GAS HEADER ............................................................................................................15
9. MOUNTING THE BOILERS ON THE FRAME........................................................................................16
10. MOUNTING THE HYDRAULIC GROUP AND THE CONNECTING SETS............................................17
11. MOUNTING THE LOW LOSS HEADERS...............................................................................................18
12. DETERMINE THE MANAGING AND DEPENDANT BOILERS .............................................................19
13. COMPLETE THE MECHANICAL INSTALLATION ................................................................................19
14. MOUNT THE FLUE GAS AND AIR SUPPLY SYSTEMS.......................................................................20
14.1 Individual flue systems ....................................................................................................................20
14.2 Common flue system.......................................................................................................................20
15. SET PARAMETERS................................................................................................................................21
16. COMMISSIONING THE CASCADE CONFIGURATION.........................................................................21
17. ACCESSORIES .......................................................................................................................................22
18. REFERENCES.........................................................................................................................................22
18.1 List of figures ...................................................................................................................................22
18.2 List of tables.....................................................................................................................................22
19. APPENDIX A –CASCADE PARTS........................................................................................................23

1. Introduction
This manual has been written for:
•The installer
•System design engineers
•Service engineers
READ AND UNDERSTAND THE INSTRUCTIONS
Read and fully understand all instructions before attempting to operate maintain or install the unit.
This Cascade manual is intended for the EFB boiler series as manufactured by Lochinvar Limited.
The boilers can be combined in one cascade configuration. This ensures that the power required can always be
achieved. Since several boilers are combined this allows for a large modulation range accurately matching boiler
output to system load.
Lochinvar Limited 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 EFB-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, Commissioning, User and
Maintenance instructions for the boilers available at www.lochinvar.ltd.uk .
Figure 1.1 Typical cascade configuration

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.
2. Determine the dimensions of the cascade set and the required space at the planned location.
This is described in detail in chapter 3.
3. Mount the frame.
This is described in detail in chapter 7.
4. Mount the gas header.
This is described in detail in chapter 8.
5. Mount the boilers on the frame.
This is described in detail in chapter 9.
6. Mount the hydraulic group and the connecting sets.
This is described in detail in chapter 10.
7. Mount the low loss header.
This is described in detail in chapter 11.
8. Determine which boiler is managing and which are depending.
This is described in detail in chapter 12.
9. Complete the mechanical installation of the cascade configuration.
This is discussed in chapter 13.
10. Mount the flue gas and air supply systems.
This is discussed in chapter 14.
11. Set the parameters in the software by means of the controller of each boiler.
This is discussed in chapter 15.
12. Commission the cascade installation.
This is discussed in chapter 16.

3. Calculate dimensions and space of cascade configuration
This chapter explains 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 3.1 Dimensions front view

Figure 3.2 Dimensions: side views
Height at A
Model
Twin-pipe
Concentric
EFB85
1876mm
1821mm
EFB105
1876mm
1821mm
EFB125
1876mm
1821mm
EFB155
1916mm
n/a
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 3.1 and Figure 3.2 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
A cascade configuration of 275 kW is required, which will consist of 2 boilers, refer to Table 3.1 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.
All these dimensions have to be taken into account when determining the space required for placing the cascade
configuration.
EHS.T0200.5050

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
422
422
H1 (height gas)
308
308
308
H2 (height header coupling)
248
248
248
H3 (height couplings)
350
350
350
D1 (header connection size)
DN 65 PN6 (2½ “)
DN 65 PN6 (2½ “)
DN 65 PN6 (2½ “)
D2 (header connection size)
DN 65 PN6 (2½ “)
DN 65 PN6 (2½ “)
DN 65 PN6 (2½ “)
D3 (gas connection size)
R 2”
R 2”
R 2”
A (gas)
253
253
253
B (headers)
459
459
459
Table 3.1 Dimensions EFB 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
487
H1 (height gas)
308
308
H2 (height header coupling)
257
257
H3 (height couplings)
380
380
D1 (header connection size)
DN 80 PN6 (3 “)
DN 80 PN6 (3 “)
D2 (header connection size)
DN 80 PN6 (3 “)
DN 80 PN6 (3 “)
D3 (gas connection size)
R 2”
R 2”
A (gas)
253
253
B (headers)
466
466
Table 3.2 Dimensions EFB 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
628
628
H1 (height gas)
327
327
327
H2 (height header coupling)
272
272
272
H3 (height couplings)
420
420
420
D1 (header connection size)
DN 100 PN6 (4 “)
DN 100 PN6 (4 “)
DN 100 PN6 (4 “)
D2 (header connection size)
DN 100 PN6 (4 “)
DN 100 PN6 (4 “)
DN 100 PN6 (4 “)
D3 (gas connection size)
DN 80 (3”)
DN 80 (3”)
DN 80 (3”)
A (gas)
253
253
253
B (headers)
482
482
482
Table 3.3 Dimensions EFB cascade 540 to 930 kW

4. Explanation of parts and groups
Each cascade configuration exists of the following parts and groups:
1. The number of boilers as selected.
2. The frame group (with locking plates) as determined by the number of boilers.
3. An external pump for each boiler. (either supplied by the installer or by Lochinvar at extra cost)
4. Connecting sets to connect the boilers to the hydraulic and gas header groups. Each connecting set contains
one gas, one supply and one return pipe. More details can be found in chapter 5.
5. Hydraulic and gas header group, existing of 1 gas, 1 supply and 1 return header, including all mounting and
connecting parts. More details can be found in chapter 6.
6. Low-loss header to connect the hydraulic group to the heating installation.
Figure 4.1 Cascade parts and groups
Boilers (1)
Frame
group (2)
Hydraulic and gas
header group (5)
Low loss header (6)
Connecting sets (4)
Pump (3)
EHS.T0400.5030

5. Connecting sets
Supply connecting set
Gas connecting set
connection to boiler
connection to boiler
Connection for pressure
relieve valve
ball valve
ball valve
coupling to supply header
coupling to gas header
Return connecting set with external pump
connection to boiler
pump location
connection to pump
connection for boiler bleed valve
check valve
ball valve
coupling to return header
Figure 5.1 Connecting sets
The gas connecting set should be connected to the gas connection on the boiler.
The supply connecting set must be connected to the boiler supply connection (front connection on the boiler) and
the return connecting set (longest) to the boiler return connection (back connection on the boiler).
The open connection in the supply connecting set is meant for a pressure relief valve, and the open connection in
the return connecting set is to be used for a boiler bleeding valve.
EHS.T0700.5010
EHS.T0700.5010
EHS.T0700.5010

6. Hydraulic and gas header group
6.1 Headers
1. Gas header (yellow marking)
2. Supply header (red marking)
3. Return header (blue marking)
Figure 6.1 Parts hydraulic and gas header group
6.2 Support beam and support brackets
Figure 6.2 Headers support beam and support brackets
1.
2.
3.
U-bolt
U-bolt
Support bracket
water headers
Support
bracket
gas header
Headers support beam
Seal plug

6.3 Headers and connecting sets
Figure 6.3 Headers and connecting sets
Variant sizes
Depending on the cascade configuration the headers come in the following size varieties:
Header
Varieties
Gas header
DN50 / DN80
Water header (supply and return)
DN65 / DN80 / DN100
See also Table 3.1, Table 3.2 and Table 3.3.
1
2
Red
Blue
1. Gas connection set
2. Supply connection set
3. Return connection set
E67.5020.002
3
3
3

7. Mounting the frame
7.1 Frame elements
The first part of the actual installation of the cascade configuration is assembling the frame on which the boilers
will be hung.
The basic frame exists of the following elements:
L-shaped stands
Top beam
In-between beam (middle beam)
Mounting material (bolts, washers)
1
Locking strip
2
In-between beam
3
Top-beam
4
L-stand
5
Rectangular seal plug 70x50
6
Bolt M8x25 DIN933
7
Washer M8 DIN 125-1A
B
Figure 7.1 Frame elements

The number of elements to be mounted depends on the number of boilers which have to be combined.
# Boilers
# L-
stands
# Top beams
# In-between
beams
# Frame
braces
Width
beams
1*
2
1
1
1
440 mm
2
2
1
1
1
930 mm
3
2
1
1
1
1420 mm
4
3
2
2
2
930 mm
5
consists of a
2-boiler frame
and a
3-boiler frame
3
1
1
1
930 mm
1
1
1
1420 mm
6
option 1
3
2
2
2
1420 mm
option 2
4
3
3
3
930 mm
*A frame can also be mounted for a single boiler, although a 1 boiler configuration does not fall within the cascade scope of this manual.
Table 7.1 Frame elements per cascade set
Attention!
Each set for the required cascade configuration will contain the exact amount of material required
for the cascade configuration type ordered.
7.2 Procedure for mounting the frame
See also Figure 7.1.
To mount the frame, subsequently carry out the steps in the following procedure:
1. Check after unpacking that all parts are actually present.
2. Mount the in-between beam(s) between the L-stands.
Ensure that the beam’s flange hole falls over the raised edge of the L-stand connection hole.
Mount the beam(s) loosely; do not yet tighten the bolts.
3. Mount the top beam(s) between the L-stands.
Ensure that the beam’s flange hole falls over the raised edge of the L-stand connection hole
Mount the beam(s) loosely; do not yet tighten the bolts.
4. Level the L-stands, both vertically and horizontally.
Use a level and the adjustment bolts on the bottom of the L-stands.
Attention!
The frame must be levelled tension-free.
So do not tighten bolts or mount boilers before the frame has been levelled.
Attention!
After mounting the frame, the frame must be braced or mounted to the wall or ceiling to prevent
the frame and boilers from wobbling.
Check the local building regulations for the relevant requirements

8. Mounting the gas header
Attention!
All lines/piping must be mounted free of tension. The weight of all the components should be
supported separately from the boiler so there is no force on the connections.
Attention!
During mounting of the gas header group it is very important that the position of the support beam
as well as the support brackets of the headers allow for some play (tolerance) for a neat
installation. After finishing the installation, the support beam and brackets can be tightened.
1. Mount the support beam(s) for the hydraulic and gas header group loosely between the legs of the L-stands.
2. Mount the support brackets for the gas header at nominal height. See also Figure 6.2.
3. Place the gas header(s) on the support brackets and fasten it (them) loosely with the U-bolts. Make sure that
the connections for the corresponding connecting sets are at the upper side of the header(s).
4. Next mount the boilers on the frame. See chapter 9.

9. Mounting the boilers on the frame
1. Before mounting the boiler on the frame, ensure that the frame is level both horizontally and vertically. If
necessary adjust with the adjusting bolts on the lower side of the frame (see Figure 9.1).
2. Hang the boilers on the frame.
3. Align the boilers with the L-stand in such a way that there is an exact 50 mm gap between the boilers.
4. Lock the suspension bracket with the locking strip to prevent the boiler from falling off the bracket (see
drawing).
5. Make sure that the boiler is at the right position (near level).
The boilers must hang backwards slightly (1º +/- 0.5º). If necessary, adjust with the adjusting bolts on the
lower rear side of the back panel (see Figure 9.1). When the adjusting bolts are not sufficient, the space
behind the bolts needs to be filled to achieve the correct position.
Attention!
The boiler must never lean forward in the mounted position.
6. Next mount the hydraulic group and connecting sets. See chapter 10.
Figure 9.1 Mounting details
Levelling frame
Locking
Levelling boiler

10. Mounting the hydraulic group and the connecting sets
Mount the Hydraulic kits and connecting sets after fitting the boiler first.
Attention!
All lines/piping must be mounted free of tension. The weight of all the components should be
supported separately from the boiler so there is no force on the connections.
Attention!
During mounting of the hydraulic and gas header group it is very important that the position of the
support beam as well as the support brackets of the headers allow for some play (tolerance) for a
neat installation. After finishing the installation, the support beam and brackets can be tightened.
1. Mount the support brackets for the return header at nominal height. See also Figure 6.2.
2. Place the return header(s) (bottom water header / blue) on the support brackets and fasten it (them) loosely
with the U-bolts. Make sure that the connections for the corresponding connecting sets are at the back of the
header.
3. Mount the connecting sets for the return header. See also Figure 6.3.
Attention!
An external pump (to be ordered separately) must be mounted between the return connecting set
and the boiler.
Required for this are:
- pump supplied with 2 flat-seal two-part couplings;
- 1 flat-seal coupling for connection to boiler (inside thread / female thread)
- 1 flat-seal coupling for connection to connecting set (outside thread / male thread)
a. Fit the flat-seal couplings to the boiler and to the connecting set.
b. Mount the pump to the boiler; pay attention to its orientation.
c. Mount the connecting set to the pump; pay attention to its orientation.
d. Bend the flexible part of the return connecting set into a smooth bend.
e. Fit the connecting set to the return header (conical three-part coupling). Fit the loose part to the header
and then fasten the coupling.
4. Mount the support brackets for the supply header. See also Figure 6.2.
5. Place the supply header(s) (top water header / red) on the support brackets and fasten it (them) loosely with
the U-bolts.
6. Mount the connecting sets for the supply header. See also Figure 6.3.
The connecting set has a three-part coupling for the connection to the boiler.
a. Fit the loose part of the three-part coupling to the boiler.
b. Fit the connecting set to the coupling.
c. Fit the connecting set to the supply header (conical three-part coupling). Fit the loose part to the header
and then fasten the coupling.
7. Fit the gas connecting sets to the boiler and to the gas header.
8. When all parts are mounted correctly and are free of tension, fasten all couplings, bolts and U-bolts.
9. Next mount the low loss header. See chapter 11.

11. Mounting the low loss headers
After mounting the hydraulic and gas header group and the connecting sets to the boilers, the low loss header
must be mounted to the supply and return headers.
Figure 11.1 Low loss header
Depending on the configuration of the cascade setup, one of the following low loss headers can be mounted:
Type
Size
Used for
Article number
Size
DN 65
2,5”
Cascade installation up to 360 kW
E68.0300.501
120 x 120 x 3
DN 80
3”
Cascade installation 360 up to 540 kW
E68.0300.502
140 x 140 x 4
DN 100
4”
Cascade installation 540 to 930 kW
E68.0300.503
200 x 200 x 5
Table 11.1 Low loss header connection sizes
The low-loss header can be fitted on the right-hand side as well as on the left-hand side without making any
alterations to the supplied parts. The gas connection can also be fitted on one of both sides, independent from the
side chosen for the low loss header.
1. Mount the low loss header.
It can be mounted on the right-hand or the left-hand side of the supply and return headers, whatever the best
place for connecting the headers to the heating installation.
2. Fit the supplied flanges on the opposite end of the supply and return headers in order to block those ends.
3. Fit the supplied seal cap on the opposite end of the gas header in order to block that end.

12. Determine the managing and dependant boilers
Before completing the mechanical installation it is important to decide which boiler will be the managing boiler.
Any of the boilers can be assigned as managing boiler; all the other boilers in the cascade configuration have to be
assigned as depending boilers.
When the CH supply temperature is based on an outdoor sensor, only one outdoor sensor is needed. This sensor is
connected to the managing boiler and calculates the CH setpoint for the cascade system.
A cascade system can be used with a DHW indirect tank. A DHW circulator and sensor must be connected to the
managing boiler.
All boilers in the cascade system have to be assigned a unique address. This is done in the parameters of each
boiler.
How to assign unique addresses to boilers and how to manage the parameters required for the cascade
configuration is described in detail in the chapter(s) about Cascading in the Installation & Service Manual of the
EFB boiler series.
13. Complete the mechanical installation
After the previous instructions have been completed, the cascade configuration must be connected to the heating
system and the mechanical installation of the cascade configuration must be completed with all other necessary
parts and connections.
This may include:
All valves
Non-return valves
Strainers
Air separators
Expansion vessel
Overflow
Attention!
The hydraulic piping of the Lochinvar Limited cascade systems already contains non-return valves
underneath each boiler. When other hydraulic systems are used, non-return valves must be fitted
in the return pipe of each boiler.
The Installation, Commissioning, User and Maintenance instructions of the EFB boiler series provides you with the
necessary installation schemes and requirements to complete the installation.
In addition to the instructions from Installation, Commissioning, User and Maintenance instructions, it is
imperative for the cascade configuration to:
Complete all wiring of the boilers according to the boiler manual. For the system to work for cascade the
communication busses must be parallel linked together.
Attention!
Link all connections 10 to 10 and all connections 11 to 11, do not mix these.
Link connections 10 of the dependent boilers to 20 of the managing boiler, and connections 11 of
the dependent boilers to 21 of the managing boiler.
For more information refer to the chapters on Electrical Installation and Cascade in the Installation,
Commissioning, User and Maintenance instructions of the EFB boiler series. If no expansion vessel or overflow
is fitted to the T-connection of the supply connecting set and/or return connecting set, the T-connection(s)
must be blocked by fitting a cap or stopper on the T-connection(s) in question.

14. Mount the flue gas and air supply systems
After the cascade installation has been connected to the heating installation, the flue gas and air supply systems
must be mounted in compliance with the applicable standards and regulations and in accordance with the
instructions from Installation, Commissioning, User and Maintenance instructions of the EFB boiler series.
14.1 Individual flue systems
The individual flue systems must be mounted in compliance with the applicable standard and in accordance with
the instructions from the Installation, Commissioning, User and Maintenance instructions of the EFB boiler series
(“Flue gas and air supply system”).
For each boiler, the combined resistance of the individual flue gas and air inlet pipe can be calculated and checked
with the maximum resistance allowed.
For resistance tables and example calculations we refer to the aforementioned chapter in the boiler manual.
14.2 Common flue system
A common flue system must be designed in accordance with EN 13384-2 “Chimney – Thermal and fluid dynamic
calculation methods –Part 2: Chimneys serving more than one heating appliance.”
Attention!
Each boiler is fitted with a NRV to prevent flue gas recirculation in non-firing boilers.
Attention!
Consult a suitably qualified flue specialist when designing common flue systems