Viadrus G 300 Instruction Manual

Contents: page
1. Boiler Uses and Advantages ........................................................................................................................3
2. VIADRUS G 300 Boiler Technical Data .......................................................................................................4
3. Description....................................................................................................................................................7
3.1 Boiler Construction..................................................................................................................................7
3.2 Electrical Schematics of Connections.....................................................................................................9
4. Placement and Installation ........................................................................................................................ 11
4.1 Boiler placement in a boiler room ........................................................................................................ 11
4.2 Rules and Directives............................................................................................................................ 12
5. Order, delivery and assembly.................................................................................................................... 13
5.1 Order.................................................................................................................................................... 13
5.2 Supply and Auxiliaries.......................................................................................................................... 13
5.3 Installation Procedure .......................................................................................................................... 14
6. Operational First Start-up .......................................................................................................................... 14
6.1 Control Activities Before Starting-up.................................................................................................... 14
6.2 Boiler adjusting from “liquid fuels” to “gas fuels” and vice versa ......................................................... 14
7. Boiler User Operating Procedure .............................................................................................................. 15
8. IMPORTANT CAUTIONS.......................................................................................................................... 16
9. Maintenance .............................................................................................................................................. 17
10. Failures and Remedies............................................................................................................................ 17
11. Instructions for product disposal after its service life............................................................................... 17
12. Guarantee and Liability for Defective Goods........................................................................................... 18

3
Dear Client
We appreciate your confidence in our firm ŽDB GROUP a.s., VIADRUS division and, we would like to
thank you for purchasing Gas fired Boiler VIADRUS G 300.
In order to get used to a correct handling with Your new product, please kindly read and get
acquainted with a Guide for Use (primarily with the chapter No.7 – Boiler User Operating Procedure
and the chapter No. 8 – IMPORTANT CAUTIONS ). We would appreciate if you could kindly adhere to
the following information and the Publication No. 91/93 Col. issued by the Czech High Authority on
Work Safety for ensuring the safe operation in the low pressure boiler rooms; this in turn should
ensure to you a trouble free operation of the boiler over many years, to yours and our satisfaction.
Order Order Specification Code (type designation)
G 300 X X X X
1. Boiler Uses and Advantages
Cast iron link hot water boiler VIADRUS G 300 is designed for heating a heat-transfer substance (water)
by thermal energy that is being acquired by burning gas or liquid fuels with the use of appropriate pressure
burners. These burners must be designed to conform with:
ČSN 07 5806 Burners for gas and liquid fuels
ČSN 07 5806 Burners for gas fuels
ČSN 07 5853 Burners for liquid fuels
This boiler is manufactured exclusively for low pressure hot water heating systems where, at
maximum functional pressure of 400 kPa, a maximum heating temperature of the heat carrying agent
of 115 °C is reached.
- gas fuels - Natural gas
- liquid fuels - Extra light Heating Oil (TOEL)
The boiler vessel is tested at overpressure of 800 kPa.
Advantages are:
1. High longevity of the cast-iron boiler body
2. Highly economical operation Over the whole power rating ranges, the fuel burning efficiency is higher
than 90.5 % for all kind of fuels
3. As per wishes of the client, order supplied with burner
4. Contemporary design
5. For recommended burner types fully automatic 2 step operation available.
6. Signalization during operation and failure announcement for transfer to the supervisory regulation
system.
7. Boiler could be controlled with aid of supervisory automatics or, space sensor of temperature.
8. If client wishes, the regulatory elements can be ordered for temperature of heat-transfer substance
(water) up to 115 °C (up to 95 °C supplied as standard).
9. Boilers could be inter connected to a cascade scheme.
10. Delivery disassembled or assembled as per client’s wishes.
11. Depending on the boiler room disposition, closure plate opening could be towards left or right side
12. Easily accessible viewing glass and the probe for overpressure measurement in the combustion
chamber
13. When used with burners recommended by the manufacturer (see Chapter “Boiler Technical
Parameters”), boilers of this sort are regardful of environment because the fuel combustion products
strictly conform to the demanding ecological standards and regulations.
In your order, it is necessary to specify the details according to the ordering
specification code.
Delivery Conditions:
S: Completed assembly
R: Disassembled
Type of regulation:
4: OS 04
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
Type of burner:
0: No burner
1: With burner

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2. VIADRUS 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) 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
Nominal Thermal Power kW 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 m3/h 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 L56,4 65,4 74,4 83,4 92,4 101,4 110,4 119,4 128,4 137,4
Maximum water process
overpressure kPa 400
Maximum operating
temperature of heating
water °C 95 (115)
Combustion products technical data
Required pressure Pa 5
Maximum overpressure in the
burning chamber kPa 0,2
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
Volume of combustion
chamber dm381,79 100,73 119,68 138,62 157,56 176,51 195,45 214,39 233,33 252,27
Heat transfer surface m25,48 6,75 8,02 9,29 10,56 11,83 13,10 14,37 15,64 16,91
Depth of combustion chamber mm 475 585 698 805 915 1025 1135 1245 1355 1465
Minimum length of burner
nozzle mm 125 160
Maximum length of burner
protrusion into chamber mm 50
φOpening for burner *) mm 150 165
Boiler width mm 750
Boiler height mm 1355
Boiler depth mm 737 847 957 1067 1177 1287 1397 1507 1617 1717
Diameter of smoke socket mm 225
φConnector heat carrying
media mm 80
Boiler Mass kg 505 585 665 745 825 905 985 1065 1145 1225
*) Requesting different φopening – please specify in your order (optional)

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Table no. 2 Recommended types of burners
Boiler size (number of sections)
5 6 7 8 9 10 11 12 13 14
Nominal Heating Power (kW)
103 126 149 172 195 218 241 264 287 310
BENTONE
STG 146 BG 300 BG 300 BG 300 BG 400 BG 400 BG 400 BG 400 BG 450-2 BG 450-2
BG 300 BG 300-2 BG 300-2 BG 300-2 BG 400-2 BG 400-2 BG 400-2 BG 400-2 BG 450 M BG 450 M
BG 300-2 BG 300 M BG 300 M BG 300 M BG 400 M BG 400 M BG 400 M BG 400 M
BG 300 M
CUENOD
NC.12
GX207
NC.16
GX207
NC.21
GX207
NC.21
GX207
C.24
GX207
C.30
GX207
C.30
GX207
C.43
GX207
C.43
GX207
C.43
GX207
NC.12
GX507
NC.16
GX507
NC.21
GX507
NC.21
GX507
C.24
GX507
C.30
GX207
C.30
GX207
C.43
GX207
C.43
GX207
C.43
GX207
INTERCAL
SGN 44/2 SGN 44/2 SGN 55/2 SGN 55/2 SGN 55/2 SGN 66/2 SGN 66/2 SGN
77/2-350
SGN
77/2-350
SGN
77/2-350
WEISHAUPT
for
g
aseous fuel combustion
WG
20N/1-C
WG
20N/1-C
WG
20N/1-C
WG
20N/1-C
WG
30N/1-C
WG
30N/1-C
WG
30N/1-C
WG
30N/1-C
WG
30N/1-C
WG
40N/1-A
Boiler size (number of sections)
5 6 7 8 9 10 11 12 13 14
Nominal Heating Power (kW)
103 126 149 172 195 218 241 264 287 310
BENTONE
B2 KS B 30 B 30 B 30 B 40 B 40 B 40 B 40 B 40 B 45-2H
ST 146 B 20-2 B 30-2H B 40-2H B 40-2H B 40-2H B 40-2H B 40-2H B 40-2H
B20
B 20-2
CUENOD
NC.12
H201
NC.16
H201
NC.21
H201
NC.21
H201
C.24
H201
C.30
H201
C.30
H201
C.43
H201
C.43
H201
C.43
H201
INTERCAL
SL 44/2 SL 44/2 SL 44/2 SL 55/2 SL 55/2 SL 66/2 SL 66/2 SL 66/2 SL 77/2 SL 77/2
WEISHAUPT
for li
q
uid fuel combustion
WL 20/2-
C
WL 20/2-
C
WL 20/2-
C
WL 20/2-
C WL 30Z-C WL 30Z-C WL 30Z-C WL 30Z-C WL 30Z-C WL 40Z-A
Unless the above recommended burners are used, the manufacturer does not guarantee
achieving performance at specified parameters

6
COMBUSTION PRODUCTS PRESSURE LOSS (NATURAL GAS)
0
2
4
6
8
10
12
14
16
1234
ZTRÁTA NA STRANĚSPALIN [mbar]
POČET ČLÁNKŮ
COMBUSTION PRODUCTS PRESSURE LOSS (TOEL)
0
2
4
6
8
10
12
14
16
1234
TLAKOVÁ ZTRÁTA NA STRANĚSPALIN [mbar]
POČET ČLÁNKŮ
WATER PRESSURE LOSS
0
0,05
0,1
0,15
0,2
0,25
012345678
PRŮTOK [m
3
.h
-1
]
TLAKO VÁ Z TRÁTA /kPa/
FLOW [m
3
.h-
1
]
WATER PRESSURE LOSS [kPa]
PRESSURE LOSS [mbar]
PRESSURE LOSS [mbar]
NUMBER OF LINKS NUMBER OF LINKS

7
3. Description
3.1 Boiler Construction
Boiler body (see Figure 1) is composed of sections with aid of pressed inserts that are secured by anchor
bolts. The boiler sections create the combustion space and convection part, inside is then actual water
space of the boiler. Tightness of the combustion space inside the boiler is secured by a binder applied on
touching surfaces of the sections and on the connection surfaces of the individual sections.
The front link is furnished with an insulated closure plate that could be made to open left or right
according to the boiler room disposition. This must have corresponding hinges and closures installed (ok).
Openings G 2” in the front link are covered by plugs G 2”. Top plug is with G 1/2” drill for regulation and
safety thermostat well. In the left top link lug are two openings G 1/2” for thermometer and manometer
sensors.
Intake and take off of the heating media is situated on the rear link; furnished with flanges and sleeve DN
80. The draining and filling tap is situated on the lower sleeve. In the opening for heat transfer substance
(under the flange) is located a limiting insert (5 – 10 sections and 11 – 14 sections) that directs flow of water
inside the boiler.
Combustion products are taken out of the boiler by a draught sleeve and an explosive clack valve which
serves concurrently as a cleaning lid. There are measuring positions located on the draught sleeve for
temperature measurement and combustion products analysis.
The whole boiler body is perfectly insulated by plates made of mineral wool. The steel cover jacket of the
boiler is surface treated by a (comaxite) paint. Control box is affixed t the top boiler casing, and it houses all
switching, regulatory and security elements as well as their interconnecting terminals.

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Figure 1 Boiler G 300 Assembly
capillary pressure
gauge check valve
well of capillary
thermometer
thermostats
well
anchor bolt
see-
throu
g
h
switch
box
measuring
places for
temperature
and effluent
analysis
protection
crimp
fill and drain
tap G 3/4”
insulation
flange of
heating water
with sleeve
smoke exhaust
throat
explosive
shutter –
cleaning cover
sealing cord
flange of return
water with
limiting insert
plug
flange for
burner
insulated
burner plate
insulated
closure plate
plug stopper
with drill ½”
front section
insert
rear section
middle section
leak proof
binde
r
probe for
overpressure
measurement
in the
combustion
chamber
size limiting insert for 11 – 14 links

9
3.2 Electrical Schematics of Connections
Fig. no. 2 Electrical connections of control box OS 04
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 BT2 Service thermostat
Conductor colour: GNYE green- yellow BK black RD dark red
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
CASE
COVER OF CASE
NOTE: Water pressure manostat (PS1) only in design for MORA firm. In case of use disconnect the the link of terminals X1:8 and X1:9. The relay of the external control 24VAC (K1) only in the design for SLANT/FIN firm. In case it is not used connect the conduit from X10:T1 from terminal X1:9 to X1:10.

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Fig. no. 3 Electrical connections of control box OS 04
COVER
ELEKTROPANEEL COVER
COVER
Z1
suppression component
S1+H1
Main switch +”Boiler under
voltage” signalling
H4
2nd stage burner
operation
H3
Burner
breakdown
H2
Safety
thermostat
signalling
BT3
the 2nd burner stage
thermostat
MPH2
The 2nd burner stage service
hours meter
PS1
Heating water
minimum
pressure
X10
Feeding and the
1st burner stage
connector
X20
The 2st burner
stage connector
A1
Outside
control
K1
Relay
24VAC
BT2
The 1st burner stage
thermostat
BT1
Safety
thermostat
MPH1
The 1st burner stage
service hours meter
F1
Fuse
6,3 A
ELEKTROPANEEL
Network module
ELEKTROPANEEL
Note: The water pressure manostat (PS1) only in version for MORA firm. In case of use disconnect the the link of terminals X1:8 and X1:9 – conductor no. 18. The relay of external control 24 VAC (K1) only in version for SLANT/FIN firm In case it is not used do not install the conductors no. 6 and 7 and switch over the conductor from X10:T1 from terminal X1:12 to X1:13.
COVER

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4. Placement and Installation
4.1 Boiler placement in a boiler room
The boiler is equipped with a movable mains supply and a plug. The boiler must be according to
EN 60 335 – 1 ed. 2 Art. 7.12.4 positioned in a way making sure that the plug is accessible.
Boiler is designed for placing in enclosed spaces having low up to middle aggressive environment; from
the point of view of electro-technical regulations the surroundings just ordinary (ČSN 33 2000 – 7 – 701). It is
also suitable for use in spaces separated from the actual residential environs (Notice 91/93 Col..,
ČSN 07 0703 - Boiler room with gas fuel –operated equipments).
Boiler operates at noise level not exceeding level LA= 75 dB(A) (the actual magnitude depends on
the type of burner used: For the recommended types it ranges between 60 – 70 dB).
Boiler must be build on non-flammable liner or on a bedding about 50 mm high. A non-encumbered
space must be left in front of the boiler to allow manipulations, this must be the depth of the boiler + 500 mm
minimum, from the side 600 mm (to allow access to the rear).
Above all for boiler placement it is necessary to respect the disposition requirements for selected
type of the burner (gas intake, etc.)
Figure No. 4 Placement Options in the Boiler Room
From the viewpoint of safety it is necessary to keep a distance away from flammable substances
of 200 mm (ČSN 06 1008 – Fire safety for local appliances and heat sources). For easily flamable materials
known to ignite and burn fast by itself even when the source of ignition is removed (such as paper, cartons,
ashpalt and tarboard, wood and laminated wood plates, plastic, floor covers etc.) it is necessary to double
the safety clearance, i.e. to at least 400 mm. In case of doubt, about the combustibility of the given
environment of the building material, it is necessary also to at least double the required safety clearance.
Particular attention must be paid to a danger of ingress of external flammables (vapors, gases),
especially during work involving such a temporary danger potential (fire or explosion) such as application of
floor coverings, painting with flammable paints etc., the boiler must be shut down early enough before a
beginning of such activities.
Notice:
At no time may things made of combustible materials placed on or near the boiler in proximity less
than is the safe clearance allowed (see fig. no. 4).
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
socle 50

12
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 Code.
Hardness mmol/L 1
Ca2+ mmol/L 0,3
Total concentration of Fe + Mn mg/L 3*
*) recommended value
WARNING!!! The use of anti-freeze mixture is not recommended by the manufacturer.
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.
Table 4 Combustibility Degrees of Building Materials and Products
Degree of combustibility
Of building materials and
products
Building materials and products classified as per degree of
flammability
(EN 13 501-1)
A– non combustible granite, sandstone, concretes, bricks, ceramic tiles, malts, fire-resistant
plasters, …
B– difficult to ignite and burn acumin, izumin, heraclit, lignos, slabs and basalt wool, slabs of glass
fibres,...
C1– difficult to burn hard wood such as beech, oak, hobrex slabs, werzalite, formica, sirkolite, ...
C2– medium flammable soft wood such as fir, larch, spruce, pine, chipboard, cork, rubber flooring, …
C3– easily combustible ashphalt tar paper, cardboard, chip boards, cellulose matter, polyurethane,
polystyrene, polyethylene, PVC…
4.2 Rules and Directives
Boiler could only be installed by a firm with valid license to carry out installations and maintenance
of gas fired appliances. For every installation, there must be a detailed projects plan prepared in
conformance with valid legislative.
a) to the heating system
ČSN 06 0310 Heating systems in buildings – Designing and installation
ČSN 06 0830 Heating systems in buildings – protecting device
ČSN 07 7401 Water and steam for thermal energy equipments with working pressure up to
8 MPa
EN 267 Forced draught oil burners – Definitions, requirements, testing, marking
EN 303-1 Heating boilers – Part 1: Heating boilers with forced draught burners – Terminology,
general requirements, testing and marking
EN 303-2 Heating boilers – Part 2: Heating boilers with forced draught burners – Special
requirements for boilers with atomizing oil burners
EN 676 Automatic forced draught burners for gaseous fuels
b) to the gas distribution
ČSN 07 0703 Boiler room with gas fuel –operated equipments
ČSN 38 6405 Gas equipments. Operating principles
ČSN 38 6420 Industrial gas pipelines
EN 1775 Gas supply - Gas pipework for buildings - Maximum operating pressure less than or
equal to 5 bar - Functional recommendations.
EN 12007-1 Gas supply systems – Pipelines for maximum operating pressure up to and including
16 bar – Part 1: General functional recommendations
EN 12007-2 Gas supply systems – Pipelines for maximum operating pressure up to and including
16 bar – Part 2: Specific functional recommendations for polyethylene (MOP up to
and including 10 bar)
EN 12007-3 Gas supply systems – Pipelines for maximum operating pressure up to and including
16 bar – Part 3: Specific functional recommendations for steel

13
EN 12007-4 Gas supply systems – Pipelines for maximum operating pressure up to and including
16 bar – Part 4: Specific functional recommendations for renovation
Act no. 222/94 Coll. on the conditions of enterprise and public service performance in power industry sector and
on the state energy inspection
Promulgation 91/93 Coll. of Czech work safety office regarding the work safety assurance in low-pressure
buildings
c) to liquid fuel distribution
ČSN 65 0201 Combustible liquids. Premises for production, storage and handling
Prom. MV ČR č. 35/77 on fire safety at storing and using the heating oil
PO 1410/65 of 01. 03. 1966 temporary regulations for heating with heating oil and fuel oil
d) to the electrical network
ČSN 33 0165 Electrical regulations. Marking the conductors with colours or digits. Implementing
regulations.
ČSN 33 1500 Electrical regulations. Electrical equipments revision
ČSN 33 2000-3 Electrical regulations. Electrical equipments Part 3: Setting the basic characteristics.
ČSN 33 2000-4-41 Electric equipments: part 4: Safety chap. 41: Protection against electrical accident.
ČSN 33 2000-5-51 ed. 2 Electrical regulations. Electrical equipments construction.
ČSN 33 2130 Electrical regulations. Internal wiring.
ČSN 33 2180 Electrical regulations. Connection of electrical devices and appliances.
ČSN 34 0350 Electrical regulations. Regulations for mobile connections and cord extension sets.
EN 60079-10 Electrical apparatus for explosive gas atmospheres – Part 10: Classification of
hazardous areas.
EN 60079-14 ed.2 Electrical apparatus for explosive gas atmospheres – Part 14: Electrical installations
in hazardous areas (other than mines)
EN 60 335-1 ed.2 Household and similar electrical appliances – Safety – Part 1: General requirements.
EN 60 335-2-102 Household and similar electrical appliances – Safety – Part 2-102: Particular
requirements for gas, oil and solid-fuel burning appliances having electrical
connections.
EN 60445 ed. 3 Basic and safety principles for man – machina interface, marking and identification –
Identification of equipment terminals and conductor terminations
EN 60446 Basic and safety principles for man – machina interface, marking and identification –
Identification of conductors by colours or numerals
e) to the chimney
ČSN 73 4201 Chimneys and flue gas ducting– designing, implementation and connection of fuel
consumers.
The connection must carried out only if approved by a chimney organization wand must meet all provisions of
these standards. The chimney must be resistant to combustion gases condensate, otherwise it might be
seriously damaged.
f) regarding the fire regulations
ČSN 06 1008 Fire safety of heat installations.
EN 13501-1 Fire classification of construction products and building elements – Part 1:
Classification using test data from reaction to fire tests.
g) to the system of HWS heating
ČSN 06 0320 Heating systems in buildings – Hot water preparation – Designing and planning
ČSN 06 0830 Heating systems in buildings – Safety devices.
ČSN 73 6660 House water plumbing
5. Order, delivery and assembly
5.1 Order
In your order, it is necessary to specify the following:
1. Boiler size
2. Requirements for accessories delivered according to client’s wish.
5.2 Supply and Auxiliaries
Standard:
•In disassembled condition (individual sections on a pallet, boiler armature and accessories in transport
packaging)
•Casing including insulation in carton box

14
•Blind flange for burner (necessary openings for used type of burner is performed during the actual
assembling procedure)
•Control box OS 04
•Commercial and technical documentation.
Optional Extras Desired:
•In assembled condition – boiler body with installed armature on a pallet protected by a foil, accessories
placed inside the boiler. Casing including insulation in carton box
•Delivery with recommended burner (see table no. 2)
•Burner flange Ø 150 mm (Ø 140mm, Ø 165 mm) with connection openings as per the ordered burner
•Delivery of burners possible
•Regulatory elements available in version for output temperature up to 115 °C.
Optional boiler equipment isn’t included in boiler basic price.
5.3 Installation Procedure
Instructions for installing the boiler are in “Manual for installation of boiler VIADRUS G 300”.
6. Operational First Start-up
Only licensed service organization, authorized to perform given activities with heating systems, is
permitted to commission boilers into operation, to set up the heating power, to carry out all
interventions into electrical boiler systems and to execute connections of regulatory elements.
1. Installation of the burner, setting it properly and commissioning the boiler into operation must be
entrusted to the burner supplier’s authorized service organization The service organization is obliged to
train the operating personnel in operation, pass on them the appropriate manual for manipulation with
the burners and, to secure carrying out warranty as well as post-warranty service and repairs
2. Before commissioning the boiler into operation a record into Inspection book must be performed.
6.1 Control Activities Before Starting-up
Prior to commissioning the boiler into operation, the following must be inspected first:
a) Completeness of heating system fill by water (thermomanometer control)and leaktightness of the
assembly
b) Setting up 2nd step boiler thermostat (nominal output) at 60 – 90 °C (in case of boiler’s operation over
95 °C in range of 60 – 115 °C).
c) Opening of all valves and taps between the boiler and the heating system
d) Fuel infeed open.
e) Fuel output pressure before boiler according the burner documentation.
f) Electrical supply network connection 230 V/380 V 50 Hz/TN-S
g) Chimney connection (necessary chimney draught is 5 Pa).
h) Maximum combustion space overpressure is 0,2 kPa. To measure the pressure in the combustion
chamber is used a probe located on the burner plate.
Regulation elements set up:
- Regulatory thermostat 1st step (decreased output) – set by manufacturer permanently at 95 °C
- Safety thermostat - permanently set by a manufacturer at 105 °C (in case of boiler’s operation over
95 °C- at 120 °C)
6.2 Boiler adjusting from “liquid fuels” to “gas fuels” and vice versa
Adjusting the boiler form liquid fuels to gas fuels and back does not require other actions than changing
burner and its flange. Before converting we recommend the perform a body control of the boiler, combustion
products ducts and their careful cleaning.
This conversion (burner exchange) will the customer demand only from a contract service organization –
an organization with approval to perform such an activity.

15
7. Boiler User Operating Procedure
Boiler works automatically in accordance with the regulatory elements settings; user is allowed to
carry on the following operator’s activities only. The authorized service organization that
commissions the boiler into operation is obliged to instruct the user with proper operating
procedures:
1. Switching the boiler ON and OFF using the power switch located on the control box OS 04 of the boiler.
2. Setting up desired heating water temperature on the boiler thermostat, in range of 60 to 95 °C (in case
of boiler’s operation over 95 °C – setting up at 115 °C).
3. Unblocking the Safety Thermostat Should the boiler be shut off by action of the safety thermostat, this
action will be announced on the power module by a lighted indicator “Excess Temperature”. Unblocking
(reset) of the thermostat can be performed by the user by pushing button “unblocking” located on the
back panel of the control box.
4. Heating system pressure checking
PORUCHA
V TOP. SYSTÉMU
TERMOSTAT II. STUPNĚ
II. STUPEŇ
PORUCHA
HOŘÁKU
II. STUPEŇ
HLAVNÍ
VYPÍNAČ
HAVARIJNÍ
TERMOSTAT
TERMOSTAT
I. STUPNĚ
závod topenářské techniky BOHUMÍN
VIADRUS
Fig. no. 5 Control box OS 04
The control box OS 04 (see Figure 5) is composed from the following basic parts:
−Basic box with instrument panel
−Capillary manometer
−Capillary thermometer
−Regulatory Thermostat I. step
−Regulatory Thermostat II. step
−Safety thermostat
−Operating hours I. and II. Step metering devices
−Control lights indicating operation in mode I and II of the burner
−Signal light “failure” indicating a contact actuation on safety thermostat
−Connector terminal
Capillary
thermometer
Capillary
manometer
Operating hours
I. and II. Step
metering
devices
Signal light “failure” indicating
a contact actuation on safety
thermostat
Malfunction
of burner
Main power
switch
Control lights
indicating operation
in mode II of the
burner
Combustion
products
temperature I. Step –
Mechanical unblocking of
the Safety Thermostat
Cable bushings
Combustion products
temperature II. Step –
Set Up
VIADRUS
závod Topenářská technika Bohumín

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8. IMPORTANT CAUTIONS
1. The boiler only can be used for the purpose that it is destined for.
2. Boiler operates automatically after it is turned on. It can be operated only by adult persons that
have read this manual for the operation of burner.
3. The boiler is not destined for the use by persons (incl. children) whose physical, sensual or
mental disability or lack of experience and knowledge prevent them from a safe use of the
appliance unless they are supervised or if they were not instructed on the use of appliance by a
person responsible for their safety.
4. Children should be supervised in order to ensure that they do not play with the appliance.
5. The boiler must be operated according to this manual and applicable norms.
6. Combustion air must not contain high humidity and dust contamination. If these cannot be
eliminated from the boiler surrounding it is necessary to bring the ¨combustion air into the boiler room
from outer environment.
7. The boiler room must be kept always clean and dust free. It is mandatory to eliminate from the
boiler room area all possible sources of contamination and during maintenance work (such as isolation
work, general clean up of the boiler room) that is about to cause increased dust contamination airborne
levels, the boiler must be shut down. It should be remembered that even partial contamination of burner
nozzles by impurities shall devalue the combustion process, and will endanger the economic and
reliable performance of the boiler.
8. To prevent condensation deposits on the boiler with subsequent low temperature corrosion,
where there is assumption of permanent operation at lower temperatures (transient periods, in heating
systems with large volumes of heating water, lower power mode of operation, etc.), it is necessary to
ensure that the returning water flow temperature is kept above 50 °C. This is best achieved via own
dedicated boiler recirculating circuit.
9. Calibration of the 1st step of burner (decreased power) is necessary to perform with regards to the
combustion products temperature in a way that it will not be lower than 130 °C.
10. 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.
11. If boiler malfunction condition arises, signalling lamp "Burner malfunction" will light up. It is located
on control box OS 04. In case of power failure, the burner is shut off. Pending a power restoration in the
public network, the automatic new re-ignition cycle will initiate
12. Operational malfunctions of burners are described in detail in the manual for burners’ operation,
including methods of their repair and it is mandatory to obey them.
13. When longer term shutdown of the system is planned, disconnect the boiler from el. power
distribution network.
14. particular attention must be paid to a danger of ingress of external flammables (vapors, gases),
especially during work involving such a temporary danger potential (fire or explosion) such as
application of floor coverings, painting with flammable paints etc., the boiler must be shut down early
enough before a beginning of such activities.
15. At no time may things made of combustible materials placed on or near the boiler in proximity
less than is the safe clearance allowed.
16. User is obliged to contract for installation, commissioning to operation, regular maintenance
and repairs to mitigate failures only to a professional contracted service organization that is
accredited for these services by the Boiler manufacturer “ŽDB GROUP a.s., VIADRUS division“.
Non compliance and tempering other than with these approved firms will cause invalidation of
the guarantee for proper boiler operation. “Osvědčení o jakosti a kompletnosti kotle VIADRUS G
300“ = „Certificate of Quality and Completeness of the Boiler VIADRUS G 300“ must be filled by
the contracted service firm and then it becomes a „Guarantee Certificate“.

17
17. At least once a year, a regular service maintenance must be carried out on the boiler, as per the
following chapter.
If the above stated conditions are not strictly followed, it is not possible to claim warranty repairs.
9. Maintenance
All actions may be carried out only by the contract service organizations provided these are properly
trained by the manufacturer.
1. Disconnect the boiler from the electrical power distribution network.
2. Shut off the boiler main gas infeed valve.
3. Open burner plate with the burner and closure plate.
4. Check boiler’s convection surface contamination and use a brush to remove the impurities from heat
exchange surfaces of the convection and combustion surfaces. Remains after cleaning must be
removed both from the combustion space and the draught sleeve after removal of cleaning lid –
explosive shutter. Explosive shutter and springs must not be manipulated.
5. Check for possible deposits inside the burner tubing. In case of contamination please remove it
according to process described by the manufacturer of burner.
6. Carefully close burner plate with burner, closure plate and all lids – check their tightness.
7. Install holder with an explosive shutter.
8. Open fuel infeed, connect the electrical supply and turn on the boiler.
9. Leaktightness control of the burner’s fuel infeed.
10. Set up and Adjustments to Thermal Boiler Power Output
10. Failures and Remedies
- The failures repairs may only be carried out by a fully trained contractual service organization, obligated
to make a record of such action into the guarantee list attachment.
- In case of repeated blocking of the safety thermostat or, the fuse affected by the reverse flow of
the combustion products, it is also necessary to call the service organization.
- Operational malfunctions of burners are described in detail in the manual for burners’ operation,
including methods of their repair and it is mandatory to obey them.
11. Instructions for product disposal after its service life
ŽDB GROUP a.s., is a contracting partner of the firm EKO–KOM a. s. with the client number
EK–F00060715. The packages comply with EN 13427.
We recommend to dispose the packages in the following way:
-plastic foil, cardboard cover, use a salvage point
-metal strapping tape, use a salvage point
-wooden base, is designated for a single usage and no longer can be used as a product. Its disposal is
subject to Act. 477/2001 Sb. a 185/2001 Coll.as amended.
Whereas the boiler is constructed from common metal materials, we recommend to dispose the individual
parts as follows:
- the heat exchanger (grey cast-iron), use a junk
- distribution pipes, shells, use a junk.
- other metal parts, use a junk
- insulation material ROTAFLEX, through a firm engaged in waste collection and disposal.
In case that the product has lost its serviceability, you can use the back collection service (if this is
introduced). If the originator has declared that it is the waste and it will be handled according to the
legislative provisions valid in the particular country.

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12. Guarantee and Liability for Defective Goods
ŽDB GROUP a. s., VIADRUS divisionprovides a guarantee for:
–For boilers 24 months after the boiler putting into operation, but maximum 30 months after the date it
was dispatched from the manufacturing factory.
–For boiler drum 5 years after the date its dispatch from the manufacturing factory.
To maintain the validity of the guarantee undertaking, the manufacturer requests:
–In compliance to the Act no. 222/94 Coll. on the conditions of enterprise and public service performance
in power industry sector and on the state energy inspection, and ČSN 91 93, ČSN 07 0703: “Czech
Highest Authority for the Labor Safety and for Assuring Work Safety in the Low pressure Boiler
rooms”, and ČSN 38 6405, ČSN EN 1775 to carry on regular inspections of the boiler. All controls to
be carried out exclusively by authorized service organization (contractual service), accredited by the
manufacturer ŽDB GROUP a.s., VIADRUS division and, by the manufacturer of the burning devices.
–Keep thorough records of all warranty and post-warranty repairs performed as well as a record of all
regular annual inspections of the boiler – these to be marked on the attachment to the warranty
certificate – an integral part of the revision record book of the boiler.
Guarantee will not be honoured when:
- Faults caused by improper assembly and improper attendance of the product and faults caused
by improper maintenance see chap. 9
- Faults and damage caused by failure to observe water quality in heating system see chap. no.
4.1 and 4.2 or by using the anti-freeze mixture
- Faults caused by failure to observe instructions stated in this manual
- Faults exist as a result of faulty installation and incorrect operating of the product
- Damage to the product during transport or due to other type of mechanical damage outside of
the plant
- Faults due to improper warehousing
All reports of faults must be done immediately after their occurrence and always in writing
Unless the above directives are strictly adhered to, the guarantee extended by the manufacturer shall
not be honoured.
Manufacturer reserves the rights to changes made in the context of product innovation; these might
not be included in this Manual hereto presented.

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Information for customer
Packaging edentification
PE Plastic sacks, folie, corrugaled board, iron and plastic fix
line
Assessment reference
Identification od principál materials used. Paper, Polyethylene, iron, wood
Part 1: Summary of assessment
Standard/Report Assessment requirement Claim Note
1.1 Prevention by source
reduction
YES
1.2 Heavy metals and ensure below maximum permitted
levels for components
(CR 13695-1:2000)
YES
1.3 Other
noxious/hazardous
substances
ensure in compliance with
(CR 13695-2:2002, EN 13428:2000) YES
2 Reuse ensure reusability in all terms of the
standard for the functional packaging
unit (EN 13429:2000)
NO
3.1 Recovery by material
recycling
ensure recyclability in all term sof the
standard for the functional packaging
unit (EN 13430:2000)
YES
3.2 Recovery in the form
of energy
ensure that calorific gain is achievable
for the functional packaging unit (EN
13431:2000)
YES Iron - NO
3.3 Recovery by
composting
ensure compost ability in all terms of
the standard for the functional
packaging unit (EN 13432:2000)
NO
NOTE Conformity with EN 13427 requires affirmative responses to sections 1.1; 1.2; 1.3 and to at
least one of 3.1; 3.2; 3.3. In addition, where a claim of reuse is made section 2 should also record
affirmative responses.
Part 2: Statement of conformity
In the light of the assessment results recorded in part I above, this packaging is claimed to comply
with the requirements of EN 13427:2000.

20
Date of revision 44/2010 SD – GB