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

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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 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 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 m2 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

φ Opening 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 φ Smoke exhaust throat mm 225 φ Connector heat carrying media mm 80

Boiler Mass Kg 505 585 665 745 825 905 985 1065 1145 1225

*) Requesting different φ opening – 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 Třebíč APH-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 Třebíč AOH – 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 ledges 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

boi

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in. 5

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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 φ 10 - Burner plate with supplied insulation is to be mounted on hinges, and φ 12 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 φ 10 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 φ 150 (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 φ 10 of length 1,550 mm

- Burner plate with supplied insulation is to be mounted on hinges, and φ 12 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 plate insul. 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 φ 10 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 φ 225 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 Ca2+ 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 Topená řská technika VIADRUS