Remeha Quinta Pro Technical Information

Cascade systems Quinta Pro

Great Britain

Installation and Service Manual

124823-01

Contents

1 Introduction ................................................................................................4

1.1 General ..................................................................4

2 General description of cascade systems .................................................5

2.1 The optimum number of boilers in a

cascade ..................................................................5

2.2 Compact cascade configurations .......................6

2.3 Cascade systems ..................................................6

2.4 Hydraulic isolation: low loss header ..................6

2.5 Output control .......................................................6

3 Remeha cascade systems .........................................................................7

3.1 General ..................................................................7

3.2 Structure of cascade systems .............................7

4 Cascade system components ...................................................................9

4.1 General ..................................................................9

4.2 Main pipes .............................................................9

4.3 Low loss header ..................................................10

4.4 Boiler pump .........................................................10

4.5 Boiler connection kits ........................................10

4.5.1 Connection kit with pump ......................................11

4.6 Free-standing frames .........................................11

4.7 Accessories .........................................................11

4.8 Installation area and dimensions ......................12

5 Installation drawings for cascade systems ...........................................13

5.1 General ................................................................13

5.2 Wall-mounted linear configuration - LW ...........14

5.2.1 Installation drawing with 2 boilers - LW .................14

5.2.2 Installation drawing with 3 boilers - LW .................15

5.2.3 Installation drawing with 4 boilers - LW .................16

5.2.4 Installation drawing with 5 boilers - LW ................17

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Contents

5.2.5 Installation drawing with 6 boilers - LW ................18

5.3 Free-standing linear configuration - LV ............19

5.3.1 Installation drawing with 2 boilers - LV ..................19

5.3.2 Installation drawing with 3 boilers - LV ..................20

5.3.3 Installation drawing with 4 boilers - LV ..................21

5.3.4 Installation drawing with 5 boilers - LV .................22

5.3.5 Installation drawing with 6 boilers - LV .................23

5.4 Back-to-back configuration - RG .......................24

5.4.1 Installation drawing with 3 boilers - RG .................24

5.4.2 Installation drawing with 4 boilers - RG .................25

5.4.3 Installation drawing with 5 boilers - RG .................26

5.4.4 Installation drawing with 6 boilers - RG .................27

6 Independently installed cascade systems .............................................28

6.1 General ................................................................28

6.2 Standard cascade system ..................................29

6.3 Dimensioning a standard low loss header .......30

6.4 DUO and TRIO low loss headers .......................30

6.5 Boiler and system pumps ..................................31

6.6 Non-return valve .................................................32

6.7 Overflow valve and manual seals .....................32

6.8 Expansion vessel ................................................32

6.9 Configuration and mounting .............................33

7 Gas connection ........................................................................................34

7.1 General ................................................................34

7.2 Gas pressures .....................................................34

8 Connections for the air and exhaust pipes ............................................35

8.1 General ................................................................35

8.2 Individual flue gas discharge ............................35

8.3 Joint flue gas discharge .....................................35

8.4 Material requirements ........................................36

8.5 Condensate drain ...............................................36

9 Exploded view ..........................................................................................37

9.1 Exploded view .....................................................37

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Cascade systems Quinta Pro 1. Introduction

1 Introduction

1.1 General

This technical information contains useful and important information for proper dimensioning of a cascade system with wall-mounted boilers. It describes the correct use of the complete Remeha cascade systems with the modulating wall-mounted boilers Quinta Pro 30/45/65/90/115.

Please contact us if you have any questions or for further information about cascade configurations.

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2. General description of cascade systems Cascade systems Quinta Pro

2 General description of cascade systems

2.1 The optimum number of boilers in a cascade

In many situations it is advantageous to spread the total required heat output over several boilers. This can be made possible by means of a "cascade system". In a cascade configuration, heating boilers are connected hydraulically. If the heat demand increases or decreases, boilers are switched on or off respectively. If using a Remeha multiple boiler controller or a quality building management system. 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:

4 Investment:

When boilers are split up, the investment costs (boiler cost including installation, fittings, pipe work, pumps and control equipment) can work out lower or higher. However, this depends to a large extent on the situation.

4 Reliability:

Reliability increases with the number of boilers. Research has shown that reliability is already optimum for systems with four boilers in a cascade.

4 Efficiency:

There is no appreciable difference in terms of efficiency between several small or one or two larger boilers.

4 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.

4 Configuration:

The lightweight and compact design means that you have more flexibility when siting the boilers. Very little floor space is required and there is minimum load on the floor.

4 Adjustment:

When using several boilers and modulating control, the heat output offered is virtually equal to the heat output requested.

A number of the points mentioned are dependent on the situation and so consideration as to which solution is the best will need to be given on a project-by-project basis.

The cascade kits are not supplied with the boilers they must be ordered separately.

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Cascade systems Quinta Pro

2.2 Compact cascade configurations

The boilers Quinta Pro 30/45/65/90/115 are particularly suitable for use in a cascade configuration. Their width of only 50 cm means that a high heat output level can be installed on a small wall. This big difference becomes apparent when comparing a Remeha cascade system with cascade systems using boilers from other manufacturers.

2.3 Cascade systems

For installing 2 to 6 boilers, our product range includes systems that are very comprehensive and easy to install. The hydraulic and gas system can be put together entirely without welding, using screw connections, compression connections and flanges. The individual components of the cascade systems are available for independent cascade installation.

2. General description of cascade systems

For example, using 6 times a Quinta Pro 115, only approx.

3.8 m (including low loss header) wall width is required for 642 (80/60℃) kW. The boilers therefore allow an exceptionally compact cascade configuration.

2.4 Hydraulic isolation: low loss header

Practical experience has shown that it is beneficial to create hydraulic isolation 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 influences 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 conditions for the system.

2.5 Output control

Use the iSense Pro for up to 6 boilers or the iSense in combination with the Celcia MC4 for a maximum of 4 boilers.

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3. Remeha cascade systems Cascade systems Quinta Pro

3 Remeha cascade systems

3.1 General

In order to make it as simple as possible to create a cascade configuration, our product range has included complete cascade systems for years. The compact design of the boilers, combined with the smart gas and water connection technology of the cascade system, makes it possible to install a high heat output in a small area. For example, using six Quinta Pro 115 boilers, only 3.8 m approx. (including low loss header) wall width is required for 642 kW (60/80℃). The cascade systems can be divided into 3 main groups:

4 2 to 6 boilers in a linear configuration, wall mounted.

4 2 to 6 boilers in a linear configuration, mounted on a free-standing

frame.

4 3 to 6 boilers in a back-to-back configuration, mounted on a free-

standing frame.

3.2 Structure of cascade systems

The return, flow, and gas connections of the individual boilers are connected 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 loss 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 condensed 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.

Please contact us for different configurations (specials). We also provide in-depth advice on the choice of flue gas discharge material and control engineering, including for non-standard configurations.

Any combination of boilers is possible. See the table for the corresponding heat outputs.

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Cascade systems Quinta Pro 3. Remeha cascade systems

Boiler type Useful output [kW]

50/30 °C 80/60 °C

Quinta Pro 30 31.4 29.3

Quinta Pro 45 43.0 40.0

Quinta Pro 65 65.0 61.0

Quinta Pro 90 89.5 84.2

Quinta Pro 115 114.0 107.0

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T003254-B

4. Cascade system components

4 Cascade system components

4.1 General

The cascade systems consist of the following components:

4 Main pipes.

4 Low loss header.

4 Boiler pump.

4 Boiler connection kits.

4 Free-standing frames.

4 Accessories.

4.2 Main pipes

Cascade systems Quinta Pro

The main pipes consist of: main flow, return and gas pipe with wall bracket for all boilers. The cascade systems consist of the following components. By connecting main pipes, it is possible to extend the system to a maximum of 6 boilers in a linear configuration or 2 x 3 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 flow and return pipe 65 mm:

4 Main pipes for 2 boilers with gas pipe DN 50

4 Main pipes for 3 boilers with gas pipe DN 50

4 Main pipes for 4 boilers with gas pipe DN 50

Diameter flow and return pipe 100 mm:

4 Main pipes for 2 boilers with gas pipe DN 65

4 Main pipes for 3 boilers with gas pipe DN 65

4 Main pipes for 4 boilers with gas pipe DN 65

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T003256-B

Cascade systems Quinta Pro

4.3 Low loss header

4.4 Boiler pump

4. Cascade system components

The low loss headers have the following connecting flanges:

4 Low loss header for main pipes with diameter = 65 mm up to a

heat output of 460 kW. Boiler-side connection: DN 65 (PN6, DIN 2631; 4 holes). System-side connection: DN 100 (PN6, DIN 2631; 8 holes).

4 Low loss header for main pipes with diameter = 100 mm up to a

heat output of 642 kW Boiler-side connection: DN 100 (PN6, DIN 2631; 4 holes). System-side connection: DN 125 (PN6, DIN 2631; 8 holes).

The low loss header is supplied with a manual air vent as standard.

4.5 Boiler connection kits

The cascade sets are supplied complete with pump for each Quinta Pro. Designed for a nominal flow rate based on a design condition of 20℃ on the boiler primary side of the header.

The boiler connection kits include the required glands.

The boiler connection kit consists of service shut-off valves in the flow, return 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 safety valve, non-return valve, filling and drain cock and expansion vessel connection. The return valve has a T piece for additional connections (for example an expansion vessel or calorifier).

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T003258-C

35 x 1.5 mm

11/4" bu 11/4" bu 3/4" bu

28 x 1.5 mm

T003260-A

T003261-A

315mm

4. Cascade system components

Cascade systems Quinta Pro

4.5.1. Connection kit with pump

4.6 Free-standing frames

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

Ball valve, overflow, non-return valve, expansion vessel connection (¾" male thread) and filling/drain cock in return pipe

Ball valve in flow pipe

Gas cock

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 is equipped with a fitting bracket. 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 delivery, along with installation instructions. Fastenings for fixing to the floor are not included.

4.7 Accessories

4 Elbow kit for angled connection of the low loss header in 65 and

100 mm diameters.

4 Connecting flanges for system side of the low loss header.

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.

4 Modulating weather compensator iSense Pro.

4 Modulating controller Celcia MC4 (always with a iSense

controller).

4 Frame fixing plate for iSense Pro and Celcia MC4.

4 Insulation for low loss header, low loss header elbow, connection

kits and main pipes.

4 Gas filters DN 50 and DN 65.

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Cascade systems Quinta Pro 4. Cascade system components

4 Gas filter extension piece (for fitting gas filter next to low loss

header) DN 50 and DN 65 (To be used when gas filter is fitted on the same side as the low loss header + elbows or low loss header + insulation).

4 Adjustable legs.

4.8 Installation area and dimensions

Select the desired combination of boilers on the basis of the required heat output. We recommend a clearance of 1 m (at least 60 cm) in front of the units. The distance between the boilers is 3 cm. A wall bracket is supplied for wall-mounted linear configuration. 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 40 cm above the units. This distance also depends on any installation of flue gas discharge and air supply collector pipes.

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5. Installation drawings for cascade systems Cascade systems Quinta Pro

5 Installation drawings for cascade

systems

5.1 General

The cascade systems can be divided into 3 main groups:

4 2 to 6 boilers in a linear configuration, wall mounted.

4 2 to 6 boilers in a linear configuration, mounted on a free-standing

frame.

4 3 to 6 boilers in a back-to-back configuration, mounted on a free-

standing frame.

The boiler side of the cascade systems is sized to 20∆T. The low loss header is based on 20 / 11∆T.

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