Viadrus G 300 User manual

MANUAL
FOR ASSEMBLY OF BOILER
VIADRUS G 300
Date of revision 8/2007

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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

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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

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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) 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 m
3
/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
L 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 4
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 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
Depth of combustion chamber mm 475 585 698 805 915 1025 1135 1245 1355 1465
Heat transfer surface m
2
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
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
φSmoke exhaust throat
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)
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

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Figure 1 Boiler G 300 Assembly Scheme

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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

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−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

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−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

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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
mm
-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 1
Ca
2+
mmol/L 0,3
Total concentration of Fe + Mn mg/L 3*
*) 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

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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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-Hang the side parts of the jacket cover with insulation over the upper cast lugs on the front and rear link in
such a way that the front wall with cutouts for armature bolting leans tightly against the front link.
-Side parts of the cover bolt from the front (in about a centre of the height of front wall), using M6 screws
with rosette washers
-Side parts of the cover on its front lower position, to be joined using the front portion of the cover jacket –
then the lower jacket part using the connecting gussets
-Rear cover – bottom part with insulation – to be hanged using hooks inserted into the rectangular cutouts
and, secure it by means of the sheet metal screws 2.9 x 9.5 to the side shrouds
-Rear housing – upper part with insulation – position it on the edges of the side shrouding and screw it to
them as well as to the bottom part using sheet metal screws 2.9 x 9.5
-Place upper insulation (freely laid belts of the material) over the upper surfaces of the boiler body, on the
sides
-Upper shroud – lid with insulation to be inserted by its studs into requisite gussets located on side covers
-front shroud – lid to be inserted by its studs into requisite gussets located on the side covers
6. Installation of the Control Box
6.1. Box Description
The control box 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
1 Main switch
2 Signalling of operation stage II.
3 Service thermostat stage I.
4 Safety thermostat
5 Service thermostat stage II.
6 Running hours counter stage I. and II.
7 Thermomanometer
8 Blind flanges
9 Fuse 10 A
10 Burner failure signalling
11 Heating water temperature exceeded – signalling
„ The Operation and installation manual is a part of delivery in case that a equithermal
regulation is required “.

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For size
5 – 10 sections
For size
11 – 14 sections

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1 – jacket front section
2 – front section
3 – central section
4 – rear section
5 – boiler insertion
6 – anchor bolt
7 – plug with external thread
8 – thermomanometer clack valve
9 – sealing plate
10 – insul. adapting piece
11 – burner plate
12 – insul. adapting piece
13 – draw-off orifice
14 – explosion shutter - small cover
15 – 2x reservoir
16 – sealing
17 – heating water flange cover
18 – mica little window
19 – mica small window sealing
20 – heating water and drilled water flange
21 – restrictive insertion
22 – flange for burner 150
23 – electro-panel
24 – thermomanometer
25 – blind flange large
26 – drain cock
27 – small valve
28 – rear lower jacket part
29 – rear jacket part insulation
30 – rear upper jacket
31 – upper jacket part insulation
32 – side jacket part
33 – insul. of jacket side part
34 – upper jacket part
35 – upper jacket part insulation
36 – cons. with cable trough
37 – left section console
38 – section console
39 – jacket side part
40 – side jacket part insulation
41 – front side jacket part
42 – upper front jacket part
43 – upper jacket part insulation
44 – electro-panel console
45 – running hours counter
46 – connecting console
47 – network module

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ŽDB GROUP a.s., závod Topenářská technika VIADRUS