Viadrus G 90 8, G 90 15, G 90 12, G 90 10, G 90 Series Manual For Assembly
VIADRUS G 90
Manual for assembly of boiler
GB_2017_23 ND
GB_ _ND2015_26
Contents
1 Boiler technical data .................................................................................................................................................................................... 3
2 Boiler Installation ......................................................................................................................................................................................... 5
2.1 Pedestal Installation ............................................................................................................................................................................... 5
2.2 Binding of the Boiler Body ...................................................................................................................................................................... 5
2.3 Installation of tubing, fittings and a well .................................................................................................................................................. 6
2.4 Installation of a partitioned horizontal draught interrupter ....................................................................................................................... 7
2.5 Installation of burner .............................................................................................................................................................................. 7
2.6 Thermal insulation of the boiler body...................................................................................................................................................... 7
2.7 Installation of the gas armature .............................................................................................................................................................. 8
2.8 Boiler casing installation ........................................................................................................................................................................ 8
3 Electrical Panel installation .......................................................................................................................................................................... 9
3.1 Installation of the Distributing Box .......................................................................................................................................................... 9
3.1.1 Electrical Panel installation ......................................................................................................................................................... 10
3.1.2 Completion of the Electrical Installation ...................................................................................................................................... 10
3.2 Version 10, 12, 15 links automatics HONEYWELL, valve HONEYWELL ............................................................................................. 11
3.2.1 Installation of the Distributing Box .............................................................................................................................................. 11
3.2.2 Electrical Panel installation ......................................................................................................................................................... 11
3.2.3 Completion of the Electrical Installation ...................................................................................................................................... 12
3.3 Version 10, 12, 15 links automatics HONEYWELL, valve DUNGS ...................................................................................................... 12
3.3.1 Installation of the Distributing Box .............................................................................................................................................. 12
3.3.2 Electrical Panel installation ......................................................................................................................................................... 13
3.3.3 Completion of the Electrical Installation ...................................................................................................................................... 13
4 Electrical connections flow sheet ............................................................................................................................................................... 14
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1 Boiler technical data
Tab. №. 1 Dimensions, service temperatures and electric parameters of the boiler
Number of sections pc 8 10 12 15
Appliance category I2H
Weight kg 242 339 399 489
Water space volume l 27,7 34,3 40,9 50,8
Diameter of smoke socket mm 200 200 225 250
Boiler overall dimensions - depth mm 995 1155 1315 1555
Max. water operating overpressure kPa (bar) 400 (4)
Min. water operating overpressure kPa (bar) 30 (0,3)
Testing water overpressure kPa (bar) 800 (8)
Max. heating water operating temperature °C 85
Min. return water temperature °C 50
Input gas overpressure mbar 20
Noise level dB Does not exceed the 55 dB (A) level
Chimney draught mbar Minimum 0,025
Boiler connections - heating water Js 6/4"
Connecting voltage 1/N/PE 230 V AC 50 Hz TN-S
Electric input W 50
Electric protection IP 40
Tab. №. 2 Thermal parameters of boiler
(heating value 33,99 MJ. m-3, gas temperature 15°C and bar. air pressure 1013,25 mbar)
Number of sections pcs 8 10 12 15
Rated thermal output max. kW 64 80 96 120
Rated thermal output min. kW 49 56 67 84
Rated thermal output max kW 71 87 105 127
Rated thermal output min kW 55 61 73 94
Volume gas flow at the maximum thermal output m3.h
Volume gas flow at the minimum thermal output m3.h
Efficiency at the maximum thermal output
Efficiency at the minimum thermal output
Temperature of the combustion gases after the draught diverter at the
maximum thermal output
Temperature of the combustion gases after the draught diverter at the
minimum thermal output
Volume of dry combustion gases actual at the maximum thermal output m3.m
Volume of dry combustion gases actual at the minimum thermal output m3.m
Emission values - CO mg.m
- NOx mg./kWh 33 33 27 23
Grade of NOx grade V
Nozzle diameter
Honeywell VR 4601 and VR 4605 valves
Informative gas pressure at the nozzle for the nominative output at the
maximum thermal output
Informative gas pressure at the nozzle for the nominative output at the
minimum thermal output
Dungs MB – ZRDLE 412 valve
Informative gas pressure at the nozzle for the nominative output at the
maximum thermal output
Informative gas pressure at the nozzle for the nominative output at the
minimum thermal output
- width x height mm 878,5 x 1160 941x1160
- return water Js 6/4"
- gas Js 1/2" 1“
7,16 9,25 11,32 13,61
5,56 6,5 7,85 10,05
%
%
91 92
89 92
°C 122 129 114 118
°C 98 95 95 88
20,18 15,8 21,6 18,13
23,63 20,1 24,8 23,6
5 6 8 7
mm 2,42
mbar 15 14,8 14,5 14
mbar 9 7,6 7,5 7,5
mbar - 13,8
mbar - 7
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Number of sections 8 10 12 15
L [mm] 995 1155 1315 1555
L1 [mm] 815 975 1135 1375
A [mm] 878,5 941 941 941
D [mm] 200 200 225 250
Gas inlet
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2 Boiler Installation
Important Cautions:
Boiler Installation may be carried out exclusively by contractual arrangement with approved and manufacturer’s
accredited service organization
Connections for heating and return water are situated always on one side of the boiler, right or left, in conformance to
the space disposition of the boiler room.
• Installation of the gas manifold to pedestal equipped with cover sheet metal for combustion chamber
• Fastening boiler body to the pedestal.
• Installation of the horizontal draught interrupter onto the boiler body
• Installation of tubing for heating and return water with distributor pipe
• Burner installation
• Connecting gas armature with the burner
• Thermal insulation of the boiler body
• Partial jacketing of the boiler
• Mounting the electrical panel
• Carrying out the electrical installation
• Electrical conduit connections, placement of sensors, affixing manometer detecting sensor
• Electrical interconnection of the gas manifold
• Completion of the boiler jacketing
2.1 Pedestal Installation
List of parts needed
1 pc of boiler pedestal
1 pc cover for the combustion chamber
Installation procedure
Position the cover sheet metal over future combustion
chamber on the pedestal
cover sheet
metal – burning
space
boiler pedestal
2.2 Binding of the Boiler Body
Using 800 kPa (8 bar) testing overpressure over at least 15 minutes, test the integrity of the boiler assembly. Visual control to be
carried out AFTER this test period.
List of parts needed
Boiler links
1 pc boiler link left
1 pc boiler link right
8, 10; 13 pc of middle links, number is determined by size
18, 22; 28 pc boiler inserts – as per boiler size
3 pc anchoring screws M 10 x L
1 pc mounting brace
2 pcs cover sheet metal lid
of the boiler
(as per respective size)
Installation procedure
1. All sockets and drilled socket holes in boiler links must be thoroughly cleaned from
conservation agents leftovers.
2. Outer edges of the openings to be removed by a half-circular file.
3. Paint the holes and sockets by oil or varnish paint.
4. Deposit boiler glue paste on prepared cleanly grinded off surfaces of the links joint
5. Tightening of the boiler body parts to be done on the prepared pedestal with cover sheet
metal installed such that the combustion chamber is directed towards the front part of the
pedestal Inserts to be evenly deposited into the socket holes, using a light tap of the rubber
or wooden mallet.
6. Affix the boiler link over the protruding inserts, tap in place and carry out binding of the link
with aid of the bonding tools; this step to be repeated until final size is tightened together
Tightening is to be done by hydraulic or manual fastening clamps
7. It is not permitted to tighten more than one link at a time.
8. Boiler links to be pulled together evenly both on the upper as well as lower level.
Always keep ensuring that the links are installed parallel to each other. Using anchoring
bolts, secure in place. Anchor nuts should be tightened only lightly (when tapping the bolt by
a metal device, the sound must never be jingly). This is to allow dilatation of the boiler body
when thermally stressed.
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6 pc of washer Ø 10
1 pc of completed boiler pedestal
4 pc of bolt M 8
4 pc of nut M 8
4 pc of washer Ø 8
6 pc of nut M 10
Oil or varnish colour for painting of the boiler inserts
Boiler binder sealant
9. Ensure that the sealant paste supplied by the manufacturer is providing a perfect seal.
10. Boiler body is to be fastened to the pedestal, using 4 pc of M8 x 25 bolts, M 8 nuts and washers Ø 8.
11. Boiler sealant then should be liberally and thoroughly applied to the contact surface between the protective pedestal cover and the boiler
body; excess glue to be removed.
12. Place plugging blanks to the openings in the bottom part of outer links and ensure good seal by using a silicone sealant supplied by the
manufacturer
2.3 Installation of tubing, fittings and a well
List of parts needed
2 pcs of drain taps ID1/2”
1 pc reducer G 1 1/2”/G 1”
1 pc plugging stopper with external thread 1”
1 pc attachable check valve with a manometer G 1/2
1 pc four-seat well G 1/2”
1 pc stopper plug G 1 1/2”
Right version
• Mounting of left end section:
- To the upper orifice G 1 1/2” mount tube Js 1 1/2“ for heating water.
- To the lower orifice G 1 1/2” after mounting the distribution tube mount the reverse water tube Js 1 ½“ (plug welded on the tube
must be directed upwards).
• Mounting of right end section:
- To the upper orifice G 1 1/2” mount the reduction G 1 1/2" to G ½“.
- To the reduction G 1 1/2"/G 1/2 mount the four-place reservoir G ½“.
- To the thread G ½“ under the reduction G 11/2“ mount the check valve of the manometer.
- To the lower orifice G 1 1/2" mount a complete distribution tube.
Into the threads G ½“ in the lower part of both end sections screw the outlet and inlet cocks.
Screw the cover sheet of the combustion chamber to the backside of the boiler drum by using 4 pc screws M6 with washers and nuts
Assembly of distribution tube (right)
Insert the plastic distribution tube into plug G 1“ with the opposite end than the rectangular cut out on the distribution tube, then insert it into
reduction G 1 1/2“/ 1/2“ a screw together. Insert the whole set of the distribution tube (with plug and reduction) into the do lower distance orifice
of the right end section and screw up (plug welded on the tube must be directed upwards).
1 pc of complete distributing pipe assembled with a
bent tube for return water (left or right styling)
1 pc tubing for return water
4 pcs screw M6
2 pc of washer Ø 6
2 pc of nut M6
2 pcs of rosette washer 6
Heating water
tube Js 11/2“
left end section
reverse water
tube Js 11/2“
reduction G11/2“/G1/2“
right end section
distribution tube with a
plug G1“ and reduction
G11/2“/G1“
Installation of heating water and reverse water tubes (right version)
Left version
• Mounting of the right end section:
- To the upper orifice G 1 1/2” mount tube Js 1 1/2“ for heating water.
- To the lower orifice G 1 1/2” after mounting the distribution tube mount the reverse water tube Js 1 ½“ (plug welded on the tube must be
directed upwards).
• Mounting of the left end section:
- To the upper orifice G 1 1/2” mount the reduction G 1 1/2" to G ½“.
- To the reduction G 1 1/2"/G 1/2" mount the four-place reservoir G ½“.
- To the thread G 1/2“ under the reduction G 11/2“ mount the check valve of the manometer.
- To the lower orifice G 1 1/2" mount a complete distribution tube.
Into the threads G 1/2“ in the lower part of both end sections screw the outlet and inlet cocks.
Screw the cover sheet of the combustion chamber to the backside of the boiler drum by using 4 pc screws M6 with washers and nuts
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Assembly of distribution tube (left)
Insert the plastic distribution tube into plug G 1“ with the opposite end than the rectangular cut out on the distribution tube, then insert it into
reduction G 1 1/2“/ 1/2“ a screw together. Insert the whole set of the distribution tube (with plug and reduction) into the do lower distance orifice
of the right end section and screw up (plug welded on the tube must be directed upwards).
2.4 Installation of a partitioned horizontal draught interrupter
List of parts needed
1 pc horizontal draught interrupter – front part
1 pc horizontal draught interrupter – rear part
4 pc screws M8 with nuts and washers
21 pc of sheet metal screws 4.8 (sizes with 10, 12 links)
Installation procedure
1. Cover the top joining surface of the boiler body with silicone sealant/binder
2. Fasten the horizontal draught interrupter – front part
3. Put the supports on the bends of the horizontal draught diverter (the bend of supports is directed downwards).
4. Secure it to the boiler body using 4 bolts M8 with nuts and washers
5. After the boiler is completely covered with its jacket, affix the horizontal draught interrupter – rear part onthe horizontal interrupter – front
part, and secure with aid of requisite number of sheet metal screws
Note: at the 8-section the horizontal draught diverter is compact.
Front part
Support
Installation of the horizontal draught interrupter
23 pc of sheet metal screws 4.8
(size with 15 links)
2 pc support
Silicone sealant/binder (from manufacturer)
Rear part
Protecting
metal sheet
2.5 Installation of burner
List of parts needed
1 pc burner complete assembly
4 pcs screw M6
4 pc of washer Ø 6
4 pc of nut M6
Boiler binder sealant
Installation procedure
1. Combustion chamber of the boiler’s body is to be cleaned up from eventual impurities.
2. Put the boiler cement on the contact surface between the burner insulation and boiler drum.
3. Burner is to be inserted into the combustion chamber of the boiler’s body and secured using 4 screws M6 with nuts and washers.
4. Mount the lighting burner and watching electrode to the burner plate with gas distributor and nozzles (on one side of the burner gas
distributor there is mounted a blind flange. The opposite end is prepared for connection of a complete gas fitting. Remount the blind flange
from the right or left side depending on the selected side of gas connection).
2.6 Thermal insulation of the boiler body
List of parts needed
1 pc tightening sling with a clasp
1 pc insulation Rotaflex L (2900, 3200, 3650 mm) as per size of the boiler
Installation procedure
1. Wrap the insulation over the perimeter of the boiler vessel.
2. Remaining insulation to be utilized for upper part of the horizontal draught interrupter before the upper lid of the jacket is secured.
3. Cut out the insulation from: intake and discharge of the heating water, sensor well, check valve and burner places.
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2.7 Installation of the gas armature
List of parts needed
1 gas armature assembly (twins of gas valves HONEYWELL or a gas manifold DUNGS ZRDLE 412 with attached gas branch)
1 pc gas intake tube leading to the pilot from left (right)
Installation procedure
1. Mount the gas armature over the flange from the side opposite to that where the gas distributor is blanked out, in keeping the selected
direction (from left or right)
2. Interconnect the pilot with the gas armature, using the gas intake tubing provided.
2.8 Boiler casing installation
List of parts needed
1pc casing side part A right (1)
1pc casing side part A right (2)
1pc casing side part B right (3)
1pc casing side part B right (4)
I pc jacket console (5)
1 pc front part of the jacket (6)
1 pc front part of the jacket (7)
1pc rear casing part bottom (8)
1 pc side portion left of the rear part - cover (9)
1 pc side portion left of the rear part - cover (10)
2 pcs braces (11)
2 pcs cover (12)
1 pc burner cover (13)
1 pc side part of front jacket portion left (14)
1 pc side part of front jacket portion left (15)
1 pc top part of the jacket (16)
1 pc front part of the jacket with sign (17)
1 pc electrical panel console (18)
Installation procedure
1. When looking at the burner left side of the support fasten at the back the side part of the shell B left (4) by means of one inbus screw
M5.
2. To the rear side of the side part of the shell B left (4) screw up the backside of the shell lower (8) by means of screws M 5 – do not
tighten up.
3. When looking at the burner right side of the support fasten at the back the side part of the shell B right (3) by means of one inbus screw
M5 and screw together with the rear part of the shell lower (8) by means of screws M5
4. When looking at the burner left side of the support in front fasten the side part of shell A left (2) into the riveting nut by means of 1 screw
M5 and screw together by means of self-drilling screws 4,2 with already fastened side part B left (4).
5. When looking at the burner right side of the support in front fasten side part of shell A right (1) into the riveting nut by means of 1 screw
M5 and screw together by means of self-drilling screws with already fastened side part B right (3).
6. The screwed together side parts join with the shell bracket (5) by means of two screws M5.
7. By means of 8 self-drilling screws screw the bracket of the front part of the shell (7) to the lower bend of the front part of the shell (6).
Then put it through the side parts of the shell A,B in the front part and hang it in the upper part through the shell bracket (5) and screw
together with the side parts of shell A (1, 2).
8. In the backside at the top put the side part of the shell left and right of the rear part of the shell (9,10) and screw the rear part of the shell
to the lower part (8) by means of 4 screws to the sheet 4,2 and to the side parts by means of screws M5 – do not tighten up.
9. On the side part of the shell where there is planned the mounting of an electro-panel we loosen up the inbus screws M5 on the right and
left side. We insert underneath the side part of the front part of the shell left and right and we again screw up by means of screws M5.
We mind that the edges of the bends are at the same level as the others. Then in the upper part we screw up the bracket of the electropanel (18) by means of 2 screws M5 and screw it together with the side parts of the front part of the shell (14, 15).
10. By means of left and right reinforcements (23, 24) reinforce the side parts of the front part of the shell (14, 15) with the side parts A, B.
11. Screw the front mounting plate from the side of the boiler drum above the switch box by means of 2 self-drilling screws 4,2.
12. Screw the rear mounting plate from the opposite side of the boiler by means of 2 self-drilling screws 4,2.
13. Put the covers (12) on the protruding screws of the burner plate from both sides and tighten four nuts M6 with washers.
14. Mount 4 shape springs in orifices in the side parts from the side of burner. Mount 4 shape cones in the burner cover (13). Put on the
burner cover on the shape springs.
15. Put on the upper part of the shell (16) and the front part of the shell (17).
1 pc switch (distribution) box (19)
1 pc switch (distribution) box cover (20)
1 pc assembly console large (21)
1 pc assembly console small (22)
1 pc reinforcement right (23)
1 pc reinforcement left (24)
1 pc support (25)
1 pc insulation of the boiler drum
and horizontal draught interrupter (26)
2 pc fastening bracket (27)
1 pc mounting plate front (28)
1 pc mounting plate rear (29)
12 pcs taper plug
8 pcs gussets
17 pcs screw M5x10
28 pcs screw to sheet metal 4,2x9
2 pcs screw M4x4
9 pcs inbus screw 2,9x16
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