Lochinvar CPM Series Cascade Header Kits Installation Guide

This product is designed for the installation, commissioning,
and maintenance of CPM and CPMSP Cascade header kits. It is
essential to read this manual in conjunction with the installation
manual for the specific boiler model.

2. Main Dimensions

Refer to the following dimensions for installation:

L1 (frame)
L2 (standards)

L3 (total)
L4 (open header)

H1 (gas)
H2 (open header)

H3 (open header)
D1 (Connection)

D2 (Connection)
D3 (gas)

A (gas)
B (headers)

Product Usage Instructions

3. Explanation of Parts and Groups

Understand the different parts and groups involved in the
cascade system. Note the variations for CPM and CPMSP boilers.

4. Frame Groups

Learn about the cascade frame groups for 1, 2, 3, and 4 boilers.
Familiarize yourself with the frame group parts for
installation.

5. Mounting the Boilers on the Frame

Follow detailed instructions on how to mount the boilers
securely on the frame.

6. Mounting the Connecting Sets

Instructions on how to properly mount and connect the connecting
sets.

8. Low Velocity Headers

Information on low velocity headers and their importance in the
system.

9. Plate Separators

Details on plate separators and their role in the installation
process.

11. Installation

Step-by-step guidance on the installation process.

12. Cascade Control

Understand output control and boiler sequence for effective
cascade control.

13. Options

Explore additional options available for customization.

FAQ

Q: Where can I download the ICM manual?

A: The ICM manual can be downloaded at www.lochinvar.ltd.uk

“`

View Fullscreen

CPM, CPMSP Cascade header kits Installation, Commissioning and Maintenance Instructions
CPM58 CPM77 CPM96 CPM116 CPMSP116 CPM144 CPM175
Installation manual_CPM-CPM-SP Cascade header kits_January 2019

INDEX
1. INTRODUCTION …………………………………………………………………………………………………………………….. 3
2. MAIN DIMENSIONS………………………………………………………………………………………………………………… 4 2.1 Cascade dimensions. The picture shows connecting sets for CPM boilers for CPM SP boilers the connecting sets are different. ……………………………………………………………………………………………….. 4 2.2 Cascade Dimensions (use in conjunction with 2.1) ……………………………………………………………. 5
3. EXPLANATION OF PARTS AND GROUPS ………………………………………………………………………………. 6 3.1 Cascade parts and groups. For the CPM/ CPM SP boilers, the return connecting sets for the CPM are different to the CPM SP range……………………………………………………………………………………… 6
4. FRAME GROUPS …………………………………………………………………………………………………………………… 7 4.1 Cascade frame groups for 1, 2, 3,and 4 boilers. ……………………………………………………………….. 7 4.2 Frame group parts (use in conjunction with 4.1) ……………………………………………………………….. 8
5. MOUNTING THE BOILERS ON THE FRAME ……………………………………………………………………………. 9 5.1 Mounting details……………………………………………………………………………………………………………. 9
6. MOUNTING THE CONNECTING SETS …………………………………………………………………………………… 10 6.1 Connecting sets. …………………………………………………………………………………………………………. 10
7. MOUNTING THE HYDRAULIC GROUP ………………………………………………………………………………….. 12 7.1 Hydraulic group for 2 boilers CPM 58116 and/or CPM SP ……………………………………………… 13 7.2 Hydraulic groups for 3 and 4 boilers CPM 58116 and/or CPM SP …………………………………… 14 7.3 Hydraulic groups for 2 and 3 boilers CPM 144175…………………………………………………………. 15 7.4 Hydraulic group for 4 boilers CPM 144175……………………………………………………………………. 16
8. LOW VELOCITY HEADERS ………………………………………………………………………………………………….. 17
9. PLATE SEPARATORS………………………………………………………………………………………………………….. 18
10. FLUE GAS AND AIR SUPPLY……………………………………………………………………………………………….. 19 10.1 Individual or common flue systems ……………………………………………………………………………….. 19 10.2 Individual flue systems…………………………………………………………………………………………………. 19 10.3 Common flue systems …………………………………………………………………………………………………. 19
11. INSTALLATION ……………………………………………………………………………………………………………………. 20
12. CASCADE CONTROL …………………………………………………………………………………………………………… 20 12.1 Output control …………………………………………………………………………………………………………….. 20 12.2 Boiler sequence ………………………………………………………………………………………………………….. 20
13. OPTIONS …………………………………………………………………………………………………………………………….. 21

1. Introduction
This Installation manual should be read in conjunction with the installation (ICM) manual for either the CPM gascondensing boiler or the CPM SP cascade system boiler. If you do not have a copy of the ICM, it can be downloaded at www.lochinvar.ltd.uk
Figure 1. Typical cascade configuration. This Cascade manual is for use with the CPM and CPM SP wall-hung high efficiency condensing boilers manufactured by Lochinvar Limited These boilers are available, in order of ascending output, as CPM 58, CPM 77, CPM 96, CPM 116, CPM 144, CPM 175 and CPM SP Range The CPM 58-116 boilers can be supplied in one cascade set, as can the CPM 144-175 boilers; due to their size difference, they cannot be mixed. Lochinvar Limited can supply standard cascade systems with mounting frame, piping and low loss headers for up to four boilers. All CPM boilers are equipped as standard with an internal cascade manager for up to twelve boilers. No extra controllers are necessary; you only connect a 2-wire cable between all boilers. The low-loss header can be fitted on the right-hand side as well as on the left-hand side without altering the pipework. The gas connection can be fitted on one of both sides, independently from the side chosen for the low loss header.To commission the cascade installation, it is necessary to set a number of parameters on the boilers, see boiler ICM.

2. Main dimensions
Page | 4

2.1 Cascade dimensions. The picture shows connecting sets for CPM boilers for CPM SP boilers the connecting sets are different.

2.2 Cascade Dimensions (use in conjunction with 2.1)

CPM 58 -116 and CPMSP
L1 (frame) L2 (standards) L3 (total) L4 (open header) H1 (gas) H2 (open header) H3 (open header) D1 (Connection) D2 (Connection) D3 (gas) A (gas) B (headers)
CPM 144 -175
L1 (frame) L2 (standards) L3 (total) L4 (open header) H1 (gas) H2 (open header) H3 (open header) D1 (Connection) D2 (Connection) D3 (gas) A (gas) B (headers)

2 boilers
1015 1140 1358 190 787 766 436 RP 1½” R 1½” R 1¼” 271 283 2 boilers
1015 1125 1408 265 766 144 487 DN 65 PN6 (2½”) DN 65 PN6 (2½”) R 2″ 338 283

3 boilers
1520 1630 1914 265 789 766 487 DN 65 PN6 (2½”) DN 65 PN6 (2½”) R 1½” 283 283 3 boilers
1520 1630 1940 290 766 165 440 DN 80 PN6 (3″) DN 80 PN6 (3″) R 2″ 338 283

4 boilers
1980 2084 2393 290 791 768 440 DN 80 PN6 (3″) DN 80 PN6 (3″) R 2″ 283 283 4 boilers
1980 2090 2465 355 768 168 440 DN 96 PN6 (4″) DN 96 PN6 (4″) DN 80 (3″) 338 283

3. Explanation of parts and groups
Each cascade set exists of the following parts and groups:
1. Two to four CPM/CPM SP boilers. 2. The frame group (with locking plates) as determined by the number of boilers. 3. Connecting groups to connect the boilers to the hydraulic groups (one group for each boiler, each group
consists of one gas, one flow and one return connecting set). 4. Hydraulic group, of one gas, one flow and one return header with all fixing and connecting parts. 5. Low-loss header or hydraulic separation plate heat exchanger.(plate would be supplied loose)
Frame group

CPM boilers

CPM SP boilers

Hydraulic group

Low velocity header

Connecting sets CPM

Connecting sets CPM SP

3.1 Cascade parts and groups. For the CPM/ CPM SP boilers, the return connecting sets for
the CPM are different to the CPM SP range.
Page | 6

4. Frame groups
4.1 Cascade frame groups for 1, 2, 3,and 4 boilers.

Item Number
1 2 3 4 5 6
7
8

Description standard upper beam mid/lower beam locking plate lock bolt M8 x 35 seal plug 70mm x 50mm seal plug 50mm x 50mm bolt M8 x 70 nut M8 washer M8 adjusting bolt standard M16 x 80

2 Boiler mounting
frame Quantity
2 1 2 2 2 2 4 12 12 14 4

4.2 Frame group parts (use in conjunction with 4.1)

3 Boiler mounting
frame Quantity
2 1 2 3 3 2 4 12 12 15 4

4 Boiler mounting
frame Quantity
3 2 4 4 4 3 6 18 18 22 6

Page | 8

5. Mounting the boilers on the frame
All lines/piping must be mounted free of tension. The weight of all the components must be supported separately from the boiler so there is no force on the connections. This might influence the mounting position of the boiler. Before mounting the boiler on the frame, ensure that the frame is level in both directions. If necessary adjust with the adjusting bolts on the lower side of the frame (see drawing). After mounting the boiler on the frame, ensure that the boiler is level. If necessary, adjust with the adjusting bolts on the lower rear side of the back panel. (See drawing). When the adjusting bolts are not sufficient, it may be necessary to fill behind the bolts to get the boiler level. The levelling margin is between boiler hanging level, and hanging backwards a little.
The boiler should not lean forward in the mounted position.
Lock the suspension bracket with the locking strip to prevent the boiler from falling off the bracket (See drawing).
Locking
Levelling boiler
Levelling frame 5.1 Mounting details.

6. Mounting the connecting sets
First, connect the connecting sets hand-tight to the boiler connections. In a cascade set-up, do NOT use the T-pieces delivered with the boilers. The shortest connecting set should be connected to the gas connection on the boiler. Make sure to connect the flow connecting set (middle length) to the boiler flow connection (left-side connection) and the return connecting set (longest) to the boiler return connection (right-side connection). The open connection in the flow connecting set is meant for a pressure relief valve, and the one in the return connecting set is to be used for an 8litre expansion vessel as per BS6644. A kit is available as an ancillary option.
For the CPM SP116 boiler the return connecting set differs, due to the external pump.

Flow connecting set

Return connecting set

connection to boiler
connection for pressure relief valve

connection to boiler
Expansion vessel connection

ball valve

check valve

Gas connecting set connection to boiler gas valve
coupling to gas header

coupling to flow header

CPM CPM SP boiler with external pump:

ball valve
coupling to return header
connection to boiler
pump location

6.1 Connecting sets.
Page | 10

Expansion vessel connection
check valve
ball valve and coupling to return header

Connecting pipework sets for boilers CPM58-CPM116 and CPM SP

Description Connecting set gas ¾” Flow connecting set 1″ Return connecting set CPM 1″ Return connecting set CPM SP 1″ Connection size relief valve and bleed valve: both Rp 1″

2 boilers Quantity Required
2
2
2
2

3 boilers Quantity Required
3
3
3
3

Connecting sets for boilers CPM144-CPM175
Description Connecting set gas 1″ Flow connecting set 11/4″ Return connecting set 11/4″ Connection size relief valve and bleed valve: both Rp 1″

2 boilers Quantity Required
2
2
2

3 boilers Quantity Required
3
3
3

4 boilers Quantity Required
4 4 4 4
4 boilers Quantity Required
4 4 4

7. Mounting the hydraulic group
Connect the gas header to the gas connecting sets. Connect the flow header to the flow connecting sets. Connect the return header to the return connecting sets. Mount all headers with the clamps to the frame. All lines/piping must be mounted free of tension. The weight of all the components must be supported separately from the boiler so there is no force on the connections. This might influence the mounting position of the boiler. When all parts are mounted in the right place, and are free of tension, fasten all couplings and fasten the clamps.
Page | 12

7.1 Hydraulic group for 2 boilers CPM 58116 and/or CPM SP

4 6

1 2

4 5
98

Connecting sets in the picture are CPM versions.

Item Number
1 2 3 4 5 6 7 8 9 10

Description gas header flow header return header clamp gas header clamp flow/return header seal cap gas header seal cap flow/return header coupling (2-parts) gasket for coupling bolt + nut + washer

Hydraulic group for 2 Boilers Quantity 1 1 1 2 4 1 2 2 2 24

7.2 Hydraulic groups for 3 and 4 boilers CPM 58116 and/or CPM SP
4 6 7 9 9
1

4 3

Connecting sets in the picture are CPM versions.

Item Number
1 2 3 4 5 6 7 8 9 10
Page | 14

Description gas header flow header return header clamp gas header clamp flow/return header seal cap gas header seal cap flow/return header coupling (2-parts) gasket for coupling bolt + nut + washer

9 8

5 10

Hydraulic group for

3 Boilers

4 Boilers

Quantity

7.3 Hydraulic groups for 2 and 3 boilers CPM 144175
4
6 7 9 5 9
1

7 5
8

2
9
3
9 8 10 5

4 5

Item Number
1 2 3 4 5 6 7 8 9 10

Description gas header flow header return header clamp gas header clamp flow/return header seal cap gas header seal cap flow/return header coupling (2-parts) gasket for coupling bolt + nut + washer

Hydraulic group for

2 Boilers

3 Boilers

Quantity

7.4 Hydraulic group for 4 boilers CPM 144175

4 5

7
6 10

5
10 8 9

11 3

Item Number
1 2 3 4 5 6 7 8 9 10
Page | 16

Description gas header flow header return header clamp gas header clamp flow/return header seal cap gas header seal cap flow/return header coupling (2-parts) gasket for coupling bolt + nut + washer

4
1
4 2
9 5
10 9 5 11
Hydraulic group for 4 Boilers Quantity 1 1 1 2 4 1 2 4 16 24

8. Low velocity headers
The low velocity header can be mounted on the right-hand or the left-hand side of the flow and return headers, whatever is the best place to connect the headers to the heating installation. The supplied caps or flanges must block the opposite end of the flow and return headers.

L Fig. 8.2

L Fig. 8.1 Figure 2. Low velocity headers.

9. Plate separators
For systems were the water quality cannot be guaranteed it may be better to install a plate separator instead of a low velocity header. This will isolate the boilers hydraulically from the dirty system. A suitable plate is available as an option from Lochinvar; these are sized based on the number of boilers required.
See section 6.15 in CPM/CPM-SP Installation Manual for important information regarding the use of a plate separator.
Page | 18

Low velocity headers for boilers 58 116

Low velocity group

2 boilers: E00.000.164

Drawing

Fig. 8.1

Venting valve ½” 1

E04.015.066

Drain valve ½”

E04.008.025

R 1½”

H1 (boiler-side)

330

H2 (installation-side)

436

190

3 boilers: E00.000.165
Fig. 8.2 E04.015.066 E04.008.025 DN 65 PN6 (2½”)
330 487 265

4 boilers: E00.000.166
Fig. 8.2 E04.015.066 E04.008.025 DN 80 PN6 (3″)
330 440 290

Low velocity group Drawing Venting valve ½” 1 Drain valve ½” D H1 (boiler side) H2 (installation side) L

2 boilers E00.000.165 Fig. 8.2
E04.015.066 E04.008.025 DN 65 PN6 (2½”)
330 487 265

3 boilers E00.000.166 4 boilers E00.000.167

Fig. 8.2

E04.015.066

E04.008.025

DN 80 PN6 (3″)

DN 96 PN6 (4″)

330

440

439

290

355

1 : We standard supply a manual venting valve that can be mounted on top of the low loss header to manually bleed the air from the low loss header. Instead of the ½” manual bleed valve, an automatic air vent can be installed, up to 1″ max.

10. Flue gas and air supply
10.1 Individual or common flue systems
Lochinvar Limited CPM/CPM SP cascade-sets can be equipped with individual or common flue systems. Using separate venting material is always preferred above common venting. Only when separate venting cannot be used, should a common vent system be used.
When chosen for an individual flue system each boiler has its individual flue gas outlet and air supply lines to the outside of the building. This may be executed in parallel or concentric flue gas and air supply pipes. When chosen for a common flue system this must be executed in parallel flue gas and air supply pipes.
10.2 Individual flue systems
Individual flue systems can be chosen as mentioned in the CPM instruction manual. The flue system should comply with the chapter “Flue gas and air supply system” of the CPM/CPM SP manual. For each boiler, the combined resistance of the individual flue gas and air inlet pipe can be calculated and checked with the maximum for the gas-side resistance. Resistance table and example calculations are given in the same aforementioned chapter of the CPM manual.
10.3 Common flue systems
Common flue systems must be designed according to: EN 13384-2 “Chimney Thermal and fluid dynamic calculation methods Part 2: Chimneys serving more than one heating appliance.” For common flue gas systems, the parameter P5DB has to be adjusted to prevent recirculation of flue gases.
Lochinvar can supply a common flue cascade system for up to 4no CPM58-116 boilers, see CPM ICM manual for details available at www.lochinvar.ltd.uk

11. Installation
Follow the instruction given within the ICM manual for either the CPM or CPM SP, these are available from Lochinvar Limited at www.lochinvar.ltd.uk

12. Cascade control
12.1 Output control
The total cascade set-up will act as one single big boiler, switching on- and off boilers, depending on the total load necessary to adjust and keep the flow temperature at the calculated value. When the heat demand rises, more boilers are switched on, and when heat demand falls, one or more boilers will be switched off. The boiler that was switched on last, will be switched off first (see table below).

12.2 Boiler sequence
To distribute operating hours equally over all boilers, the working sequence of the boilers will change every two hours.

Hour X

Switching ON sequence

Switching OFF sequence

Master Slave 1 Slave 2 Slave 3 Slave 4 Slave 7 Slave 6 Slave 5 Slave 4 Slave 3

Slave 5 Slave 6 Slave 7

Slave 2 Slave 1 Master

X+1

Slave 7 Master Slave 1 Slave 2 Slave 3 Slave 6 Slave 5 Slave 4 Slave 3 Slave 2

Slave 4 Slave 5 Slave 6

Slave 1 Master Slave 7

X+2

Slave 6 Slave 7 Master Slave 1 Slave 2 Slave 5 Slave 4 Slave 3 Slave 2 Slave 1

Slave 3 Slave 4 Slave 5

Master Slave 7 Slave 6

X+3 ………..

Slave 5 Slave 6 Slave 7 Master Slave 1 Slave 4 Slave 3 Slave 2 Slave 1

Slave 2 Slave 3 Slave 4

Master Slave 7 Slave 6 Slave 5

…………………………………………………

Table 1. Boiler sequence example of an eight boiler cascade.

In this table a total of eight boilers (one master, seven slaves) is mentioned as an example, in practice the maximum number in a cascade, without extra (external) control, is twelve boilers.

Page | 20

13. Options

To complete your cascade set-up / heating installation you can choose for next options:

Room Temperature Controllers

RC OpenTherm with ambient sensor

RC OpenTherm with remote ambient sensor

Clock thermostat

RCH E-bus with ambient sensor (for EBC)

RCH E-bus with remote ambient sensor (for EBC)

Plate Separators

Plate separator for CPM SP232 Package

Plate separator for CPM SP348 Package

Plate separator for CPM SP464 Package

Sensors

Outside air temperature sensor

10 External flow temperature sensor low velocity header

11 External ambient sensor for RC and RCH

12 External flow temperature sensor heating circuit (zone)

Heating circuit controller

13 EBC 2-zone E-bus controller

14 Wall-mounted case with terminal board for EBC

15 IF OpenTherm / E-bus interface

Parameter programming

16 Interface cable and software to programme the boiler

Modulating Modulating On / Off Modulating Modulating
12kOhm@25°C 10kOhm@25°C 5kOhm@25°C 5kOhm@25°C

Table 2. Accessories and parts.

S04.016.355 S04.016.358 E04.016.308 S04.016.357 S04.016.361
LOKG-250L LOKG-400L LOKG-450L
E04.016.306 E04.016.304 E04.016.359 E04.016.363
E04.016.319 E04.000.103 E04.016.362
S04.016.586

RC OpenTherm room temperature controller (1 and 2) RCH E-bus room temperature controller for EBC (4 and 5)
EBC 2-zone E-bus controller (10) mounted in wall-mounted case with terminal board (11)

Wall-mounted case with terminal board for EBC (11) Figure 3. A few examples of accessories.

– notes –
Page | 22

– notes –

Page | 24

Documents / Resources

Lochinvar CPM Series Cascade Header Kits [pdf] Installation Guide
CPM58, CPM77, CPM96, CPM116, CPMSP116, CPM144, CPM175, CPM Series Cascade Header Kits, CPM Series, Cascade Header Kits, Header Kits

References

User Manual

Lochinvar CPM Series Cascade Header Kits Installation Guide

CPM Series Cascade Header Kits

Specifications

Product Information

1. Introduction

2. Main Dimensions

Product Usage Instructions

3. Explanation of Parts and Groups

4. Frame Groups

5. Mounting the Boilers on the Frame

6. Mounting the Connecting Sets

8. Low Velocity Headers

9. Plate Separators

11. Installation

12. Cascade Control

13. Options

FAQ

Q: Where can I download the ICM manual?

Documents / Resources

References

Leave a comment

Cancel reply