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