Viadrus G 300 Fiche technique

BOILER OPERATION AND INSTALLATION

MANUAL

VIADRUS G 300

Date of revision 8/2007

Table of contents: page

1. Boiler use and advantages....................................................................................................................................3

2. Boiler VIADRUS G 300 technical data............................................................................................................4

3. Description..........................................................................................................................................................5

3.1. Boiler construction...................................................................................................................................... 5

3.2. Electrical diagrams....................................................................................................................................... 6

4. Positioning and installation................................................................................................................................10

4.1. Boiler standing in boiler room ................................................................................................................... 10

4.2. Directives and regulations......................................................................................................................... 11

5. Order, delivery and assembly............................................................................................................................12

5.1. Order .......................................................................................................................................................... 12

5.2. Delivery and accessories............................................................................................................................ 12

5.3. Assembly process...................................................................................................................................... 12

6. Commissioning ..................................................................................................................................................12

6.1. Checking activities before initiation ......................................................................................................... 12

6.2. Boiler conversion from „ liquid fuels“ to „ gas fuels“ and back............................................................... 13

7. Boiler operation by user....................................................................................................................................13

8. Maintenance.......................................................................................................................................................14

9. Instructions for product disposal after its service life ........................................................................................15

10. Failures and their elimination ........................................................................................................................15

Dear customer

we thank you that you decided to purchase VIADRUS G 300 boiler thus showing your confidence in

company of ŽDB GROUP a.s., VIADRUS Heating technique plant.

For you to get used to operating your new product correctly from the start please read carefully this

manual instructing you how to use the product (first of all chapter No.7 - Boiler operation by user). Please

follow the information stated in further text and also the Regulation No.91/93 Coll.. issued by Czech Labour

Safety Office for ensuring the labour safety in law-pressure boiler rooms; this will guarantee a long-time and

failure-free boiler operation to both your and our satisfaction.

Order: Order specification code (type designation)

G 300 X X X X

The way of delivery:

S : compound/ assembled state

R : decomposed/disassembled

state

Type of regulation:

4: Electropanel – basic

design

6: Electropanel - fixed

OS 06

Type of burner:

0: no burner

1: with burner

In the order it is necessary to specify the data according to the order

specification code

Number of sections :

5: 5 sections

6: 6 sections

7: 7 sections

8: 8 sections

9: 9 sections

10: 10 sections

11: 11 sections

12: 12 sections

13: 13 sections

14: 14 sections

1. Boiler use and advantages

Cast-iron sectional warm-water boiler VIADRUS G 300 is designed for heating the heat carrying substance

(water) by the thermal energy which it gets from gas or liquid fuels burning process while using the appropriate

pressure burners. These burners must correspond to :

ČSN 07 5800:1990 Burners for gas and liquid fuels

ČSN 07 5806:1986 Burners for gas fuels

ČSN 07 5853:1990 Burners for liquid fuels.

The boiler is made exclusively for law-pressure warm-water systems of central heating with maximum

working temperature of the heat-carrying substance (water) up to 115 °C, at the maximum working

overpressure of 4 bar and for burning the fuels as follows:

- gas fuels - natural gas

- liquid fuels - furnace oil extra light (TOEL)

The boiler body is tested by applying the test overpressure of 8 bar.

The boiler advantages are as follows:

1. Long service life of the cast-iron boiler body

2. A highly economical operation . The efficiency of combustion higher than 90,5 % for all kinds of fuels

and in the whole performance range.

3. At request delivery including the burner.

4. A modern design.

5. A fully automated two-stage operation at the recommended types of burners.

6. Operation signalling, possibly the signals used for transfer into a superior control system and the boiler

failures. Possibility to operate the boiler through a superior automatics or space temperature sensor.

7. At request there can be ordered the regulation elements designed for heat carrying substance(water)

temperature up to 115°C (as standard they are delivered up to the temperature of 95 °C).

8. Possibility of boilers concatenation.

9. Delivery in either an assembled or disassembled condition at customer ´s request

10. Depending on boiler room layout there can be designed opening of sealing and burner plate either to the

left or right hand side.

11. Easily accessible sight glass and the probe for overpressure measuring in the combustion chamber .

12. In combination with recommended burners (see chapter„Boiler technical parameters“) spares of

environment because the combustion results meet in the whole performance line the rigid environmental

standards and regulations.

2. Boiler VIADRUS G 300 technical data

Table No.1 Boiler thermo-technical parameters

fuel efficiency : natural gas 33,99 MJ/kg furnace oil extra light (TOEL) 42,65 MJ/kg

Boiler size - number of

sections

ks 5 6 7 8 9 10 11 12 13 14

Rated thermal output kW 103 126 149 172 195 218 241 264 287 310

Rated thermal input kW 113,2 138,5 163,7 189 214,3 239,6 264,8 290,1 315,4 340,7

Efficiency % 90,5

Fuels consumption

natural gas m3/h 11,5 14,1 16,7 19,3 21,9 24,5 27,1 29,7 32,2 34,9

furnace oil extra light (TOEL) kg/h dle výrobce burneru

Boiler water volume l 56,4 65,4 74,4 83,4 92,4 101,4 110,4 119,4 128,4 137,4

Max. working water overpressure bar 4

Max. operating temperature of

heating water

°C 95 (115)

Combustion gas technical data

Necessary draught mbar 0,05

Max. overpressure in

combustion chamber

mbar 2

Combustion gas temperature °C 185

Combustion gas mass

- gas fuel ; 9,5% CO2 kg/h 191 233 276 318 361 403 446 488 531 574

- liquid fuel ; 13%CO2 kg/h 172 210 248 287 325 363 402 440 478 517

Dimensions

combustion space volume dm381,79 100,73 119,68 138,62 157,56 176,51 195,45 214,39 233,33 252,27

Heat-delivery surface m25,48 6,75 8,02 9,29 10,56 11,83 13,10 14,37 15,64 16,91

combustion space depth mm 475 585 698 805 915 1025 1135 1245 1355 1465

min. length of burner orifice mm 125 160

max. burner orifice at the

combustion space

mm 50

orifice for burner φ*) mm 150 165

boiler width mm 752

boiler height mm 1386

boiler depth A mm 899 119 1339 1559 1779

outlet orifice φmm 225

heat carrying substance

connection φ

mm 80

Boiler mass kg 505 585 665 745 825 905 985 1065 1145 1225

*) requirement for other orificeφ– please state in order (at request )

Tab. No.2 Recommended types of burners

Boiler size - number

of sections pc 5 6 7 8 9 10 11 12 13 14

Rated thermal output kW 103 126 149 172 195 218 241 264 287 310

Recommended burners for gas fuels combustion

WEISHAUPT WG 20 N/1 - A WG 30 N/1 - C WG 40 N/1-A

INTERCAL SGN 44/2 SGN 55/2 SGN 66/2 SGN 77/2-350

BENTONE BG 300-2, M BG 400-2, M BG 450-2, M

PBS TřebíčAPH-M 02 PZN,PPN APH-M 04 PZN,PZ,PPN

RIELLO GULLIVER BS 3D GULLIVER BS 4D RS 28 TC RS 38 TC

Recommended burners for liquid fuels combustion

WEISHAUPT WL 20-A WL 30 - C WL 40 Z-A

INTERCAL SL 44/2 SL 55/2 SL 66/2 SL 77/2

BENTONE B 20K-2 B 30 - 2 B 40 - 2

PBS TřebíčAOH – M 02 PN AOH – M 04 PN

RIELLO GULLIVER RG 3D GULLIVER RG 4D RL 28 TC RL 38 TC

UNIGAS LO 140 LO 200 LO 400 LO 400

When using other than recommended burners the manufacturer doesn’t guarantee the stated parameters

achievement.

3. Description

3.1. Boiler construction

The boiler body (Fig. No.1) consists of sections assembled by means of forced-on insertions and is secured

by anchor bolts. Boiler has a three-draught construction and the sections create the combustion space and the

convection part, inside then the boiler water space. The tightness of boiler gas combustion space is guaranteed

by boiler cement applied to sections seating faces and to circumference of individual section joints.

On the front section there are fixed sealing and burner plates that either can be opened to right or left hand

side according to boiler room layout. This must correspond with screw suspensions positioning (lugs).

The openings G 2"in the front section are closed with plugs G 2". The upper plug has a boring G 1/2“ for

the basin of regulation and safety thermostat. In the left upper riser of the section there are two openings G

1/2" for thermometer and pressure gauge sensors.

The input and output of a heat carrying substance is situated at the rear part of boiler and it is carried out with

flanges and a mouthpiece DN 80. At the lower flange with a mouthpiece there is positioned the filling &

discharging cock. In the opening for heat carrying substance input (under the flange) there is positioned a

restrictive insertion (5 – 10 sections and 11 – 14 sections), which streamlines the water flow in boiler.

The combustion gases from the boiler are led/ taken away through a flue orifice with an explosion shutter

which at the same time serves as a small cleaning cover. At the flue orifice there are measuring points for

temperature and combustion gases analysis.

The boiler body is fully insulated by plates made of mineral insulation . The steel shell of boiler is surface

treated by comaxite paint. In the upper front part of boiler there is positioned the electro-panel with regulation,

safety and control elements.

Fig. No.1 Boiler assembly

3.2. Electrical diagrams

Conductor colour:

GNYE green- yellow

BK black

RD dark red

Legend:

F1 fuse 6,3 A

S1 Main switch

H1 Boiler under voltage signalling

Z1 Suppression component

BT1 Safety thermostat

PS1 Water pressure manostat

H2 Safety thermostat signalling

K1 Eternal operation relay

COVER OF ELEKTROPANEL

BT2 Service thermostat

X10 Burner connector

H3 Burner defect signalling

H4 Burner 2nd stage working signalling

MPH1 Service hours gauge for 1st burner stage

MPH2 Service hours gauge for 2nd burner stage

BT3 Thermostat for 2nd burner stage

X20 Burner connector

NOTE:

Water pressure manostat (PS1)only in design for MORA company, in case it is used reconnect

the conductor BT1:14 from terminal X1:8 to X1:9.

The outside control relay 24AVC(K1) only in design for SLANT/FIN firm; in case it isn’t used

reconnect the conductor X10: T1 from terminal X1:12 to X1:13.

Fig. No.2 Elementary wiring diagram for electro-panel connection

relay

VAC

Outside

control

X20

Burner

connector

X10

Burner

connector

NOTE:

Water pressure manostat (PS1) only in design for MORA

company, in case it is used reconnect the conductor

BT1:14 from terminal X1:8 to X1:9. – conductor nr.18.

The outside control relay 24AVC(K1) only in design for

SLANT/FIN firm; in case it isn’t used reconnect the

conductor X10: T1 from terminal X1:12 to X1:13.

PS1

Water

pressure

manostat

Suppression component

Cover of elektropanel

Fig. No.3/1 Electro-panel wiring diagram

running hours counter

MPH1

Service hours gauge for

1st burner stage

MPH2

Service hours gauge for

2nd burner stage

fuse 6,3 A

BT3

Thermostat for

2nd burner stage

Burner 2nd

stage

working

signalling

BT1

Safety thermostat

Burner

defect

signalling

Safety thermostat

signalling

Main switch

Boiler under

voltage

signalling

BT2

Service thermostat

network module

COVER

Fig. No.3/1 Electro-panel wiring diagram

Note

1) bypass pump controlled by a

thermostat

BOILER REGULATION

master control

boiler burner

failure

Boiler bypass

pump

boiler circulation

pump

protected input

1 NPE 50 Hz 230 V/16 A

boiler

main

switch

Fig. No.4 RZ 20 Regulation wiring diagram (OS 06)

4. Positioning and installation

4.1. Boiler standing in boiler room

The boiler is designed for positioning in closed

areas with aggressiveness degree between a little up

to moderately aggressive and in terms of

electrotechnic regulations in a common

environment (ČSN 33 2000 – 7

– 701:1997). It agrees with the use in rooms

separated from housing room itself (Declaration

91/93 Coll.., ČSN 07 0703:1986 Gas boilers).

Boiler noise level does not exceed the maximum

level of LA= 75 dB(A) - (the real value depends

on the type of used burner : for recommended

types it ranges between 60 – 70 dB).

The boiler must be positioned on a fireproof pad

or a sustaining wall approx. 50 mm high. In front

of boiler there must be left a free handling area

minimum for the boiler depth + 500 mm, from one

side 600 mm (access to the back).

When positioning the boiler there must be

respected the layout requirements of selected

type of burner (gas inlet and others.)

L of boiler + min. 500

*) It is necessary to respect the

selected type of burner layout

requirements ( gas inlet , burner

length etc.)

Fig. No.5 Boilers positioning in boiler room

For safety reasons at the installation there must be observed the distance of 200 mm from flammable

substances (ČSN 06 1008:1997 – Fire safety of local appliances and heat sources). For easily flammable

substances it means those that are quickly self-burning also after removing the source of inflammation (like tar

paper, cardboard, asphalt and tar paper, wood and hardboards , plastic substances, flooring) the distance gets

doubled. A safe distance must be doubled also in case that the building material flammability degree hasn’t been

proved.

In case that there is a danger of a temporary intrusion of combustible vapours or gases into the boiler room or

at the works at which there temporarily occurs the fire & explosion danger (gluing the flooring, coats with

combustible paints ) the boiler must be put out of operation in time and before the works commencement.

Warning:

No subjects made of flammable substances (see Fig. No.5) are allowed to be put on the boiler and within a

distance smaller than the safety distance.

Filling the heating system with water. The heating system must be thoroughly flushed out so that all

impurities that could be deposited in distribution system and radiators are washed out because otherwise they

could damage the pump. Water for filling the boiler and heating system must be clear and colourless , with no

suspended substances, oil or chemically aggressive substances. The circulation and filling water parameters must

correspond to:

Tab. No.3 The highest permissible values of heating water according to ČSN 07 7401:1992

hardness (mmol/l) 1

Ca2+ (mmol/l) 0,3

Total Fe + Mn concentration (mg/l) 3*

*recommended value

In case that the water hardness is unsuitable it must be adjusted. Not even heating the water with higher

hardness several times will prevent the soils precipitation on the boiler body walls. Precipitation of 1 mm calcite at

a given point will reduce the passage of heat from metal to water by 10%.

During the heating season it is necessary to keep a constant heating water volume in the heating system and be

particular about venting the heating system. Water from boiler and heating system must never be discharged or

taken for use except for inevitable cases like repairs etc. By discharging the heating water and filling the system

with new water the danger of corrosion and scaling is increased. In case that it is necessary to replenish water in

heating system, we only refill it in a cold boiler, otherwise the sections could crack.

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