Viadrus G 300 Bedienungsanleitung

MANUAL

FOR ASSEMBLY OF BOILER

VIADRUS G 300

Date of revision 8/2007

Contents:

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

2. VIADRUS GLADIATOR G 300 Boiler Technical Data....................................................................................4

3. Generally..............................................................................................................................................................6

4. Boiler Installation.................................................................................................................................................6

4.1. Boiler Body Installation...............................................................................................................................6

4.1.1. List of parts needed.............................................................................................................................6

4.1.2.Installation procedure...........................................................................................................................6

4.2. Pressurizing boiler vessel.............................................................................................................................7

4.3. Boiler Armature Installation.........................................................................................................................8

4.3.1. Installation of burner plate..................................................................................................................8

4.3.2. Installation of the Closure Plate..........................................................................................................8

4.3.3. Installation of the Smoke Exit Neck....................................................................................................9

4.3.4. Installation of Heating Media Takeoffs..............................................................................................9

5. Boiler Jacketing..................................................................................................................................................10

6. Installation of the Control Box...........................................................................................................................11

6.1. Box Description.........................................................................................................................................11

Order

Order Specification Code (type designation)

G 300 X X X X

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.

Number of

links:

5: 5 links

6: 6 links

7: 7 links

8: 8 links

9: 9 links

10: 10 links

11: 11 links

12: 12 links

13: 13 links

14: 14 links

Type of regulation:

4: Electropanel – basic

design

6: Electropanel - fixed

OS 06

The way of delivery:

S : compound/ assembled state

R : decomposed/disassembled

state

In your order, it is necessary to specify parameters as per the requisite

specification Code.

Burner type:

0: no burner

1: with burner

2. VIADRUS GLADIATOR G 300 Boiler Technical Data

Table 1 Thermo – technical Parameters of the Boiler

Calorific value of fuel Natural gas 33.99 MJ/Kg Light Heating Oil (TOEL) 42.65 MJ/Kg

Boiler size (number of sections)

5 6 7 8 9 10 11 12 13 14

Nominal Heating Power

103 126 149 172 195 218 241 264 287 310

Nominal Thermal Power

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

Efficiency

% 90,5

Fuel Consumption

Natural gas

11,5 14,1 16,7 19,3 21,9 24,5 27,1 29,7 32,2 34,9

Extra light Heating Oil (TOEL)

Kg/h

As per data from burner manufacturer

Volume of boiler water space

56,4 65,4 74,4 83,4 92,4 101,4 110,4 119,4 128,4 137,4

Maximum water process

overpressure

bar

Maximum operating

temperature of heating water

°C

95 (115)

Combustion products technical

data

Required pressure

mbar

0,05

Maximum overpressure in the

burning chamber

mbar

Combustion products

temperature

°C

185

Combustion products mass

- gaseous 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

Depth of combustion chamber

475 585 698 805 915 1025 1135 1245 1355 1465

Heat transfer surface

5,48 6,75 8,02 9,29 10,56 11,83 13,10 14,37 15,64 16,91

Minimum length of burner

nozzle

125 160

Maximum length of burner

protrusion into chamber

φOpening for burner *)

150 165

Boiler width

750

Boiler height

1355

Boiler depth

737 847 957 1067 1177 1287 1397 1507 1617 1717

φSmoke exhaust throat

225

φConnector heat carrying media

Boiler Mass

505 585 665 745 825 905 985 1065 1145 1225

*) Requesting different φopening – please specify in your order (optional)

Table 2 – Recommended Types of Burners for Natural gas and Biogas

Boiler size (number

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

Nominal Heating

Power kW

103 126 149 172 195 218 241 264 287 310

Recommended burners – gaseous fuel 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

STG 146

BG 300 BG

300 2 BG

300 M

BG 300

BG 300 2

BG 300 M

BG 400

BG 400 2

BG 400 M

BG 450

BG 450 2

BG 450 M

BENTONE

BG 300 LN

BG 400 LN BG 450 LN

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 – liquid fuel 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 ST 146

B 20K

B 20K-2

B 30

B 30 – 2

B 40

B 40 – 2

B 45 – 2

PBS TřebíčAOH – M 02 PN AOH – M 04 PN

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

Unless the above recommended burners are used, the manufacturer does not guarantee achieving performance

at specified parameters

Figure 1 Boiler G 300 Assembly Scheme

3. Generally

Boiler VIADRUS G 300 is supplied in a disassembled state, i.e. individual sections on palette, boiler

armature and auxiliaries in proper packaging container, jacket and insulation also in the packaging case.

Figure 2 Placement of Boiler G 300 in Boiler Room

4. Boiler Installation

4.1. Boiler Body Installation

4.1.1. List of parts needed

−Number of sections Front, rear and 3 to 12 middle sections (as per size of the boiler)

−Number of boiler inserts 8 -26 (as per boiler size)

−Boiler binder sealant

−Oil paint for painting boiler inserts

−Anchor bolts: 4 pc, length determined by the boiler size – from 505 to 1495 mm (in 110 mm steps)

−Limiting insert

−Plugging stopper G 2”

−Plugging stopper G 2” with G ½” threading

−Thermostats well

−Thermometers well

−Manometer check valve

4.1.2. Installation procedure

−Boiler is to be built on a horizontal bedding

−Position the rear link on the bedding and using suitable brace, support it

−Drilled openings of the insert holes in rear link should be thoroughly cleaned to remove remnants of

conservation agent and impurities

−Outer edges of the said holes to be dulled by cabinet file, then paint the openings by oil paint or varnish

−Put inserts already painted by oil paint or varnish, into the appropriate openings and tap by using wooden

mallet Insert must be properly and evenly put through

−Deposit boiler glue paste on prepared cleanly grinded off surfaces of the sections joint

The following general rules apply to

the assembling operation of boiler

links:

−

Boiler is to be built on a horizontally

true bedding about 50 mm high; the

dimensions of boiler should be

exceeded also by 50 mm.

−

During the individual link bonding,

it is necessary to ensure that the

sealing ledge

s are perfectly sealed

using boiler sealant supplied

−

The same care should be taken with

respect to sealing the boiler to the

smoke exhaust neck and smoke

uptake

*) It is necessary to respect the

selected type of burner layout

requirements ( gas inlet , burner

length etc.)

L of boiler + min. 500

−Put the link over the protruding parts of the inserts in such a way that the inserts edge in easily into the link

openings for inserts, tap in place by wooden mallet and using bonding tools, bind together

CAUTION:

Ensure that the spacing between individual sections remains during the whole process of binding together

equal!

−Repeat the process to carry out binding of all remaining sections

CAUTION:

To bind at any one time more than one link is not permitted!

−Bonded boiler body should then be secured using anchor bolts

CAUTION:

Anchor bolt nuts to be tightened very lightly, to allow thermal dilation of the boiler body during operation

−Perimeter groove (dovetail) always created by binding of two sections should be thoroughly filled over the

whole perimeter by boiler sealant

4.2. Pressurizing boiler vessel

−Lower opening of the front link is to be plugged off using stopper G 2”

−upper opening of the front link is to be plugged off using stopper G 2” with threading G ½”

−Affix the thermostat well into G ½” opening in the upper stopper

−Into existing holes G ½” in the castings of the front link affix: On the right hand side the well of manometer,

and o the left, the check valve for the manometer

−All threaded joints to be sealed by hemp

−Insert the limiting insert into lower opening located on the rear link (heating water intake) for sizes of the

boiler up to 10 sections, the said limiting insert is made of cast iron. It must be positioned such as to show the

recess in the insert sideways and, the insert would be by its lug positioned into the collar of the preceding link

joint. For sizes of the boiler over 10 sections, the said limiting insert is made of steel. It must be placed into

the lower rear hole in last rear link, into the boiler body. Its position is delimited by the end-stops located on

the limiting insert.

−Affix the flange with socket for possible pressure water connection, into the rear lower opening of the rear

link.

−The upper opening in the rear link (takeoff of the heating water) should be closed by sealed flange equipped

with the de-aerating valve.

−Open the de-aeration valve and fill the boiler vessel with cold water, then close the valve.

termostat

well

capillary

thermometer

well

check valve

plug

G2“

plug G2 “with thread G ½“ front section central section anchor bolt boiler insertion rear section

restrictive insertion

11 - 14 sections

restrictive insertion

5 - 10 sections

−Perform the overpressure test using the 8 bar pressure over at least 15 minutes. During the overpressure test,

there must not appear any leaks

−Carry out visual inspection

4.3. Boiler Armature Installation

4.3.1. Installation of burner plate

-Mount into the lower holes having M 12 threading in the front link:

a) On the right – hinges (bolt M12 x 65 with an eye) such that the distance of the eye opening axis from the

edge of the link was 40 mm; on the left – stud bolts M 12 x 80 for opening the burner plate to the right

b) On the left – hinges (bolt M12 x 65 with an eye) such that the distance of the eye opening axis from the

edge of the link was 40 mm; on the right – stud bolts M 12 x 80 for opening the burner plate to the left

-Into the groove located in the burner plate, insert sealing flex-cord FS 000 φ10

-Burner plate with supplied insulation is to be mounted on hinges, and φ12 x 63 pegs positioned

-Close the burner plate, inspect it for correct seating and position, and tighten the M12 nuts with wshers

-Into the groove located in the burner plate, insert sealing flex-cord FS 000 φ10 of length 810 mm

-In accordance with the burner used, install the burner flange The latter is supplied in the standard styling

without connecting threads but, optionally as per client's wishes, after the burner type selected is announced,

a flange φ150 (φ140,φ165) mm with connecting thread could be supplied.

-Following instructions provided by the burner manufacturer (the burner installation set up is always included

in the procedure for installation form the supplier), prepare the flange for affixing the burner

4.3.2. Installation of the Closure Plate

-Mount into the lower holes having M 12 threading in the

front link:

a) On the right – hinges (bolt M12 x 65 with an eye) such

that the distance of the eye opening axis from the edge of

the link was 40 mm; on the left – stud bolts M 12 x 80

for opening the burner plate to the right

b) On the left – hinges (bolt M12 x 65 with an eye) such

that the distance of the eye opening axis from the edge of

the link was 40 mm; on the right – stud bolts M 12 x 80

for opening the burner plate to the left

-Into the groove located in the burner plate, insert sealing flex-

cord FS 000 φ10 of length 1,550 mm

-Burner plate with supplied insulation is to be mounted on

hinges, and φ12 x 63 pegs positioned

-Close the burner plate, inspect it for correct seating and

position, and tighten the M12 nuts with washers

insul. adapting

piece

burner plate

small valve

sight glass

flange for burner

150

sealing plateinsul.

adapting

piece

4.3.3. Installation of the Smoke Exit Neck

-Into the groove located in the

burner plate, insert sealing flex-

cord FS 000 φ10 of length 900

-Position the smoke exit socket

assembly (throat castings and the

explosive clack valve) over 3 pc of

studs M 8 x 30 and fasten nuts

M 8 with washers

-Connecting boiler with the vent

stack is done as per project

documentation, using the smoke

duct φ225 mm, to be

positioned over the exhaust vent

sleeve, then connected with the

chimney.

4.3.4. Installation of Heating Media Takeoffs

−On the upper flange connector of the rear link seat the flange itself with heating water takeoff and sealing,

then tighten using nuts M12 with washers

−On the lower flange joint position the flange with the sleeve 3” and another with ¾” , for filling and draining

tap furnished with the seals. So created joint tighten using M12 nuts with washers.

CAUTION: Prior to installing the lower flange, inspect whether in the lug is not missing the limiting insert.

Once the boiler is hot, re-tighten all the flange connections.

Filling of the heating system by water First, the whole heating system must be thoroughly flushed to cause

removal of all impurities that may be deposited in the distributions or heating bodies and could subsequently

become a source of pump damage. To fill the boiler and heating system, it is necessary to use clear, colorless

water, free from foreign matter in suspension, without any oil or chemically aggressive substances. Circulating

and replenishing water must correspond to:

Table 3 Highest Allowable Limits for Heating Water as per ČSN 07 7401:1992 Code.

Hardness

mmol/L

0,3

Total concentration of Fe + Mn

mg/L

*) recommended value

draw-off

orifice

sealing

explosion

shutter -

small cover

heating water and

drilled water flange

with sealing

drain valve G¾“

heating water flange

cover with sealing

In case the hardness be outside of the specifications, water must be conditioned.. Experience shows that even

multiple reheat of the hard water will not prevent deposition of salts on interior surfaces of the boiler vessel.

Deposits of about 1 mm thick (limestone) will cause a loss of heat transfer from metal to water of about 10%.

During the heating season, a stable level of water volume in the system must be ensured while being mindful

that the heating system must be periodically de-aerated. Boiler and heating system water must never be

discharged or bled from the system save for urgent and necessary situations such as maintenance, etc. Bleeding

the conditioned water from the heating system and refilling it with new water is always associated with danger of

an increased corrosion and calcite deposit formation. Should it be necessary to refill the water in the heating

system, it is permitted only when the boiler is let to cool; this will prevent a potential crack failure of cast-iron

sections.

5. Boiler Jacketing

- on the upper riser of front and rear section from inside screw on 4 screw M8 4 section consoles (2 left and 2

right)

elektropanel

electro-panel console

right section console

jacket front section

side jacket part

w. insulation

left front side

jacket part w.

insulation

upper front jacket

part w. insulation

upper rear jacket part

w. insulation

rear lower

jacket part

w. insulation

rear upper jacket

w. insulation

left section console

connecting console console of jacket right front side jacket

part

w. insulation

console of

jacket

right section

console

left section

console

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