VIADRUS CLAUDIUS K 2 Manual for boiler operation and installation

Transcription

1 VIADRUS CLAUDIUS K 2 Manual for boiler operation and installation GB_2016_43 GB_2016_35

2 Content p. 1 Manufactured boiler versions Boiler Uses and Advantages Specifications Boiler description Boiler construction Storage heater VIADRUS OV - H Placement and installation Regulations and guidelines Positioning options Delivery and accessories Boiler Installation Wiring diagram Commissioning Connection to the heating system and filling with water Gas connection Connection to the mains Condensate drain Flue gas exhaust Pressure losses of flue gas exhaust components for the boiler VIADRUS CLAUDIUS K Boiler commissioning Boiler settings Boiler operation by user General description Display description Energy saving Settings overview Error messages Faults Maintenance Checking the device IMPORTANT NOTICE Instructions for product disposal after its service life Warranty and liability for defects

3 Dear customer, Thank you for purchasing VIADRUS CLAUDIUS K 2 and hence your confidence in the company VIADRUS a.s. To get used to a correct way of handling your new product, please read at first this manual for its use, particularly Chapter no. 8 - Boiler operation by users and Chapter no Important information. We ask you to follow further presented information, particularly regarding required annual inspections by a professional company, thus ensuring trouble-free boiler operation to our satisfaction. 1 Manufactured boiler versions In the order, please specify the following order specification code: VIADRUS CLAUDIUS K 2 x 1 x 2 x 3 x 1 Gas valve: L: produced by SIEMENS x 2 Size: 3: 3-section version 5: 5-section version x 3 Equipment: 1: without set three-way valve with pump 3: with three-way valve and pump 5: without set three-way valve with pump 2 Boiler Uses and Advantages Condensing boiler VIADRUS CLAUDUS K 2 is intended for combustion of low pressure natural gas. The size of the condensing boiler is suitable for heating of houses, recreation facilities and also for reconstruction of heat sources in individual flats. Heat output of the condensing boiler is 3.8 to 24 kw (K 2 L3X) and 7.8 to 48.1 kw (K 2 L5X). The boiler body consists of castings made from special aluminium alloy. Individual sections are connected by means of silicon rings and tightened by threaded bars. The maximum working overpressure of the boiler is 250 kpa (2.5 bar). The body is tested by the test overpressure of 600 kpa (6 bar). Combustion mixture is mixed in a mixer in a predetermined ratio of air - gas in its control range. Water volume of the three-section boiler body is 9 l and the water volume of the five-section body is 13 l. The efficiency of the boiler body at a temperature gradient of 50/30 C ranges from 102 to 108% depending on the desired performance. Boiler advantages: Low gas consumption. High combustion efficiency. Continuous output modulation. Easy operation and maintenance. The boiler enables connection to a storage hot service water heater and guarantees its preferential heating. Reliability of regulation and safety elements. Low weight. Automatic detection of faults. Independent time program also for HW. Equithermal boiler regulation. 3

4 3 Specifications Tab.. 1 Sizes, operation temperature and electrical variables K 2 L3X K 2 L5X Fuel type [-] ZP ZP Appliance category [-] I 2H I 2H Weight [kg] Water content [l] 9 13 Boiler dimensions - width (L2) [mm] depth [mm] height [mm] Ø connection of the combustion air [mm] Ø smoke socket [mm] Maximum working water overpressure [kpa]/[bar] 250/ /2.5 Testing water overpressure [kpa]/[bar] 600/6 600/6 Dissipation factor [-] Maximum allowable operating temperature [ C] Connecting fuel overpressure G20 [mbar] Noise level [db] < 55 < 55 Boiler connection - heating water outlet [Js] 3/4 3/4 - heating water outlet to the heater [Js] 3/4 3/4 - return heating water inlet [Js] 3/4 3/4 - return water inlet from the heater [Js] 3/4 3/4 - condensate outlet [mm] Ø 25 Ø 25 - safety valve outlet [Js] 3/4 3/4 - gas inlet [Js] 3/4 3/4 Supply voltage 1/N/PE 230 VAC 50 Hz TN-S Input power including pumps [W] El. protection IP Tab.. 2 Heat-technical parameters Comparative conditions 15 C and 1013,25 mbar, dry gas K 2 L3X K 2 L5X Performance B 23, B 53, C 83 B 23, B 53, C 83 Boiler power range [kw] Rated heat output 80/60 C [kw] Minimum heat output 80/60 C [kw] Rated heat output 50/30 C [kw] Minimum heat output 50/30 C [kw] Rated heat input [kw] Minimum heat input [kw] Efficiency at rated heat output 80/60 C [%] Efficiency at rated heat output 50/30 C [%] Efficiency at minimum heat output 50/30 C [%] Volumetric flow rate of fuel [m 3.h -1 ] Flue gas mass flow [kg.h -1 ] NOx Class [-] 5 5 Flue gas temperature [ C] sect. 5 sect. Fig.. 1 Dependence of the pressure loss on flow 4

5 Information requirements relating to boiler heaters for space heating, boiler combined heaters and cogeneration heaters for space heating Model/Models: Condensing boiler: Low-temperature boiler: Boiler type B1: VIADRUS CLAUDIUS K2 L3X YES NO NO Cogeneration heater for space heating: NO If YES, featured with an auxiliary heater: Combined heater: NO Item Designatio n Value Unit Item Designatio n Value Unit Rated heat output Prated 22.7 kw For the boiler heaters for space heating and boiler combined heaters: useful heat output Seasonal energy efficiency of heating (***) ƞ s 92 % For the boiler heaters for space heating and boiler combined heaters: useful efficiency At rated heat output and high temperature mode (*) P kw At rated heat output and high temperature mode (*) ƞ % At 30% of rated heat output and low temperature regime (**) P kw At 30% of rated heat output and low temperature regime (**) ƞ % Consumption of auxiliary electrical power: Other items: At full load el max kw Heat loss in standby mode P stby kw At partial load el min kw Electricity consumption of the pilot burner P ign - kw In standby mode P SB kw Emissions of nitrogen oxides NO x 12 mg/ kwh Contact information VIADRUS a.s. Bezručova 300 Bohumín (*) High temperature mode for condensing boilers mean return temperature of 60 C at the inlet to the heater and the inlet temperature 80 C at the outlet of the heater. (**) Low temperature for condensing boilers mean return temperature of 30 C, for low temperature boilers it is 37 C, and for other heaters it is 50 C (at the inlet of the heater). (***) For seasonal energy efficiency, the value is based on the gross calorific value according to EU regulation no. 813/2013 5

6 Information requirements relating to boiler heaters for space heating, boiler combined heaters and cogeneration heaters for space heating Model/Models: Condensing boiler: Low-temperature boiler: Boiler type B1: VIADRUS CLAUDIUS K2 L5X YES NO NO Cogeneration heater for space heating: NO If YES, featured with an auxiliary heater: Combined heater: NO Item Designatio n Value Unit Item Designatio n Value Unit Rated heat output Prated 46.1 kw For the boiler heaters for space heating and boiler combined heaters: useful heat output Seasonal energy efficiency of heating (***) ƞ s 93 % For the boiler heaters for space heating and boiler combined heaters: useful efficiency At rated heat output and high temperature mode (*) P kw At rated heat output and high temperature mode (*) ƞ % At 30% of rated heat output and low temperature regime (**) P kw At 30% of rated heat output and low temperature regime (**) ƞ % Consumption of auxiliary electrical power: Other items: At full load el max kw Heat loss in standby mode P stby kw At partial load el min kw Electricity consumption of the pilot burner P ign - kw In standby mode P SB kw Emissions of nitrogen oxides NO x 13 mg/ kwh Contact information VIADRUS a.s. Bezručova 300 Bohumín (*) High temperature mode for condensing boilers mean return temperature of 60 C at the inlet to the heater and the inlet temperature 80 C at the outlet of the heater. (**) Low temperature for condensing boilers mean return temperature of 30 C, for low temperature boilers it is 37 C, and for other heaters it is 50 C (at the inlet of the heater). (***) For seasonal energy efficiency, the value is based on the gross calorific value according to EU regulation no. 813/

7 4 Boiler description 4.1 Boiler construction The heat exchanger of the condensing boiler consists of a front, middle (the number depends on the size of the boiler) and the rear section. These castings are connected by means of silicon rings and tightened by threaded bars. This boiler is equipped with a premixing burner. Combustion mixture is mixed in a mixer in a predetermined ratio of air - gas at the whole performance range. Air is supplied to the mixer using the modulation ventilator. The boiler is constructed for heating with preferred heating of HW. To heat HW, the manufacturer recommends combination with the water heater. Further, the boiler is equipped with LMS automatics and a gas valve. LMS automatic is an electronic control and ignition automatics designed for gas central heating boilers with the modulated ventilator and pre-mixing burner. if the boiler is to be controlled equithermally, it is necessary to connect the outdoor sensor. In this case, we recommend using one of the communication devices, see chap To increase the number of heating circuits, expansion module can be used according to project documentation. Combustion air can be fed and flue gas can be exhausted to the chimney or through the wall. The boiler is an appliance of B or C version. 1 Condensing body 2 Burner plate with burner 3 Ignition electrode (guard electrode) 4 Supply of the mixture to the burner 5 Fan 6 Gas valve 7 Pump with a PWM control 8 Three-way valve 9 Condensate drain 10 Exhaust piping 11 Suction piping 12 Inlet pipe to the boiler 13 Outlet pipe from the boiler 14 Manometer check valve Fig.. 2 Assembly of the boiler 15 SIEMENS display 16 Reset button 17 Manometer 18 Console electro 19 Control panel SIEMENS LMS 20 Housing electro 21 Boiler frame 22 Right side casing part with insulation 23 Left side casing part with insulation 24 Upper casing part with insulation 25 Rear casing part with insulation 26 Front casing part 27 Outlets 28 Blinds 7

8 gas inlet gas inlet 1. Complete burner 2. Extension tube 3. Gasket Ø mix strainer 5. Screw M5 6. Washer Nut M5 Fig.. 3 Location mix strainer in the gas pipeline of the burner K 2 L5X 5 Storage heater VIADRUS OV - H 100 Water heater VIADRUS OV H 100 is a pressure device adapted to operate at a maximum water pressure of 0.6 MPa (6 bar). Hot service water heater is a device designed for heating and storing hot water. The main part of the heater is a vessel made of steel sheet coated with a layer of enamel. The heater is equipped with a heating coil with large heat exchange surface, which ensures fast heating of large quantities of water. All connections are located in the upper part of the heater and are terminated with an external thread. The heater also offers the possibility of connecting a circulation pump for circulating hot water, and s temperature sensor. There is an outlet at the bottom part of the heater through which the vessel can be drained. The heater is equipped with an additional anticorrosive device in the form of a magnesium anode whose function is based on the utilization of the electrochemical potential difference between the anode and the tank. The magnesium anode is placed in the upper part in the plug 2. Thermal insulation of the heater is made of polyurethane foam free from freon, which minimizes heat loss. An electric heater can be installed in the heater. Tab.. 3 Technical parameters Technical parameters VIADRUS OV H 100 Volume l 100 Maximum allowable temperature C 100 Maximum allowable pressure bar 6 Heat exchanger surface m Heat exchanger volume l 5.6 Consumption of heating water from central heating m 3 /h 2.5 Constant efficiency (70/10/45 o C) l/h 700 Output kw 29 Dimensions A mm 140 B mm 60 C mm 40 D mm 100 E mm 120 Device height L 990 Tank dimensions (without insulation) Ø 400 Tank dimensions (with insulation) mm 455x455 Insulation of soft polyurethane foam mm 30 8

9 Connections Cold water / hot water R 3/4 Circulation R 3/4 Central heating circulation (supply, return pipeline) R 3/4 E-socket (heating coil) R 5/4 Sensor housing R 3/8" Thermometer 1/2 internal thread Water drain 3/4" Magnesium anode An. stopper 2 Weight (empty) kg 57 ANODE PROTECTION DRAIN Fig.. 4 Water heater VIADRUS OV - H 100 9

10 6 Placement and installation 6.1 Regulations and guidelines a) for the heating system CSN Heating systems in buildings Design and installation CSN Heating systems in buildings Safety devices CSN Water and steam for heating equipment with steam working pressure up to 8 MPa EN Gas-fired central heating boilers - Part 1: General requirements and tests EN Gas-fired central heating boilers - Part 2-1: Specific standard for boilers of design C and designs B2, B3 and B5, with a nominal heat input not exceeding 1,000 kw EN 677 Gas-fired central heating boilers Specific requirement for condensing boilers with a nominal heat input not exceeding 70 kw b) for chimneys CSN Chimneys and flues Design, implementation and connection of fuel appliances c) regarding the fire regulations CSN Fire safety of heat installations. EN A1 Fire classification of construction products and building elements Part 1: Classification using test data from reaction to fire tests d) for the system HW heating CSN Thermal systems in buildings Hot water preparation Designing and Installation CSN Heating systems in buildings Safety devices CSN Internal Water Supply e) for the electricity network CSN Electrical regulations. Marking the conductors with colours or digits. Implementing regulations. CSN Electrical regulations. Revision of electrical devices. CSN ed. 2 Low-voltage electrical installations Part 1. Basic terms of determining the fundamental characteristics of the definition. CSN ed. 2 Low-voltage electrical installations Part 4-41, Protective measures to ensure safety Protection against electric shock CSN ed. 3 Low-voltage electrical installations Part Selection and erection of electrical equipment Common rules. CSN ed.2 Electrical installations of buildings Part 7-703: Requirements for special installations or locations Rooms and cabins containing sauna heaters. CSN ed. 2 Low-voltage electrical installations Internal electric distribution lines. CSN CSN electric engineering regulations. Rules for installation of electrical apparatus and appliances. ČSN ed.2 Safety requirements for flexible cords and cables. EN Explosive atmospheres Part 10-1: Classification of areas Explosive gas atmospheres. EN ed.3 Explosive atmospheres Part 14: Electrical installations design, selection and erection. EN ed.3 Household and similar electrical appliances - Safety Part 1: General requirements. EN Household and similar electrical appliances - Safety Part 2 102: Particular requirements for gas, oil and solid-fuel burning appliances having electrical connections. EN ed. 4 Basic and safety principles for man-machine interface, marking of terminals of electrical equipment, ends of cables and wires. f) for the gas distribution EN 1775 Gas supply Gas pipework for buildings Maximum operating pressure <= 5 bar Functional recommendations. EN Gas supply systems Pipelines for maximum operating pressure up to and including 16 bar Part 1: General functional recommendations. EN Gas supply systems Pipelines for maximum operating pressure up to and including 16 bar Part 2: Specific functional requirements for polyethylene (MOP up to and including 10 bar) EN Gas supply systems Pipelines for maximum operating pressure up to and including 16 bar Part 3: Specific functional requirements for steel. EN Gas supply systems Pipelines for maximum operating pressure up to and including 16 bar Part 4: Specific recommendations concerning reconstructions. CSN Boiler rooms with gas fuel-operated equipments CSN Gas equipment, operation principles. 10

11 Act No. 458/2000 Coll. The Act on business conditions and the performance of state administration in the energy sectors and on amendments to certain laws (Energy Act) 6.2 Positioning options When installing and using the boiler, all requirements of CSN must be complied with. Positioning and connection of the boiler must correspond to the project documentation. Flue gas exhaust must comply with the applicable regulations (Technical Regulations TPG ) and the project documentation. The space near and above the boiler must be equal to min. 0.2 m and min. 1 m before the boiler for the assembly and repair. The manufacturer recommends to mount these products into closed heating systems. The boiler may be installed in living rooms. It can be situated in the basic environment according to CSN ed. 2. K 2 L3X K 2 L5X L (mm) Fig.. 5 Main dimensions of the boiler Boiler positioning with regard to fire regulations: Safe distance from flammable materials: When installing and operating the boiler it is necessary to keep the safe distance of 200 mm from flammable materials A1, A2, B and C (D); For easily flammable materials of flammability class E (F), which burn quickly and by themselves also after the ignition source removal (e.g. paper, cardboard, asphalt and tar boards, wood and fibreboards, plastics, flooring materials) the safe distance is doubled, it means that the distance is 400 mm; The safe distance is to be doubled also in case when the fire reaction class is not proven. Tab.. 4 Fire reaction class Fire reaction class Examples of building materials and products classified in reaction to fire class (selection from CSN EN A1) A1 non-combustible material granite, sandstone, concrete, bricks, ceramic tiles, mortars, anti-fire plasters, A2 limited combustibility material akumin, izumin, heraklith, lignos, boards and basalt felt, fibreglass boards, B difficult to ignite Beech, oak, hobrex boards, plywood, werzalit, Formica, sirkolit, C (D) medium inflammable pine, larch, spruce wood, chipboard and cork boards, rubber flooring, E (F) easily flammable Asphalt board, fibreboards, cellulose materials, polyurethane, polystyrene, polyethylene, PVC, Delivery and accessories The boiler VIADRUS CLAUDIUS K 2 is supplied as assembled on a pallet, packed in a carton cover and foil protected. Standard accessories to all boiler variants: Operating instructions and installation manual, which includes a warranty card The list of contractual service organizations For the variant CLAUDIUS K 2 LX3, boiler sensor QAZ 36 Recommended accessories to all boiler variants: One of spatial communication devices Siemens QAA74, QAA75, QAA55, QAA58 (wireless) QAA78 (wireless) 1 pc Outside sensor QAC 34/101 1 pc Recommended accessories are not included in the basic price of the boiler. 11

12 6.4 Boiler Installation According to the marked outlets, the boiler is connected to the heating system including HW (if used) and gas distribution as shown in Fig. No. 6. Condensate drain should be connected in compliance with the applicable standards CSN and EN. Further, the flue gas exhaust is connected according to the project. 1 Heating water outlet from the boiler (if a water heater, it is necessary to make connections via T - piece behind the boiler) 2 Cable bushings 3 Bushings for the sensor 4 Return water from the central heating 5 Output from the safety valve 6 Condensate drain 7 Return water from the water heater 8 Gas inlet 9 Intake flange (diameter 80 mm) 10 Flue gas output (diam. D mm) K 2 L3X K 2 L5X L (mm) L1 (mm) L2 (mm) V1 (mm) diam. D (mm) Fig.. 6 Rear view of the boiler 12

13 6.5 Wiring diagram LEGEND: A1 Control unit A2 Kindling transformer with gas valve A3 Control panel AVS37 B2 Boiler temperature sensor - output B3 HW temperature sensor - output B7 Boiler temperature sensor - input B9 External temperature sensor B38 HW temperature sensor - input BTr Room thermostat E1 Kindling electrode E2 Monitoring electrode MV1 Fan MV1 Fan Q1 Pump X1a Power supply connector 230В X1b Three-way valve and selected output connector X1f Fan and pump power supply connector X2 Protective thermostat connector X4 Temperature sensors and Reset button connector X5a Selected inputs connector X6a Selected inputs connector X7a Connection of room devices (QAA 74, 75 ) X8 PWM fan control connector X10a PWM/1-10В outputs connector X12, 13 Programmable connectors X15 PWM pump control connector X30 Control panel connector Y3 Three-way valve Protective clamps Fig.. 7 Circumferential diagram 13

14 Fig.. 8 Wiring diagram 14 LEGEND: A1 Control unit A2 Kindling transformer with gas valve A3 Control panel AVS37 B2 Boiler temperature sensor - output B3 HW temperature sensor - output B7 Boiler temperature sensor - input B9 External temperature sensor B38 HW temperature sensor - input E1 Kindling electrode E2 Monitoring electrode MV1 Fan Q1 Pump X1a Power supply connector 230В X1b Three-way valve and selected output connector X1f Fan and pump power supply connector X2 Kindling transformer and gas valve connector X4 Temperature sensors and Reset button connector X5a Selected inputs connector X6a Selected inputs connector X7a Connection of room devices (QAA 74, 75 ) X8 PWM fan control connector X10a PWM/1-10В outputs connector X11 Connector for connection of OCI 345 X12, 13 Programmable connectors X15 PWM pump control connector X17 Earth connector X18 Protective thermostat connector X30 Control panel connector X50 RVS regulator connector X54 Water pressure sensor connector Y3 Three-way valve Protective clamps CONDUCTORS COLORS bn (brown) bu (blue) bk (black) gn (green) gnye (green/yellow) rd (red) ye (yellow)

15 7 Commissioning 7.1 Connection to the heating system and filling with water Before filling the heating system with water the system should be duly cleaned, it means that the system should be twice filled with clean water and drained. Water for the boiler and the heating system filling must be clear and colourless, without suspended solids, oil and aggressive chemicals. The heating system must be filled with water that meets the requirements of CSN and especially its hardness must not exceed the required parameters. The parameters of circulating and make-up water must correspond to the following: Tab.. 5 The maximum permissible values of heating water according to CSN Recommended values Hardness mmol/l 1 Ca 2+ mmol/l 0.3 Total Fe + Mn concentration mg/l (0,3)* *recommended value ATTENTION!!! The manufacturer does not recommend the use of antifreeze. If the water hardness is unsuitable it has to be adjusted. Even the multiple heating of water with a higher hardness does not exclude salts on the boiler body walls. Precipitation of 1 mm calcite reduces at a given point the heat transfer from the metal to water by 10%. During the heating season, it is necessary to maintain a constant volume of heating water in the heating system and ensure that the heating system is vented. Water from the boiler and the heating system must never be drained or taken for usage except for the emergency cases like repairs etc. Heating water discharge and filling with new water increases the danger of corrosion and scaling. If it is necessary to refill water in the heating system, refill only the cold boiler in order to avoid disruption. Before filling the system with water, shift a three-way valve control lever into the intermediate position using a screwdriver or manually by pulling it toward yourself slightly down (if the boiler has the option of feeder water preparation) Fig. No. 9. After filling the heating system, dismantle the water valve drive by pushing the metal push button and turning right. After remounting the water valve drive, the lever comes back to the position for heating the heating system. Lever shifted in the intermediate position when filling the heating system and water heater Lever in the position for HW heating Lever in the position for heating the heating system Fig.. 9 Three-way valve VC 4013 When filling the boiler with water the system must be disconnected from the mains. Bleeder valve on the boiler and on the heating system must be open and functional. Adjust the expansion vessel to a pressure of 10 kpa (0.1 bar) higher than the pressure required in the heating system (only for the version CLAUDIUS K 2 L31, CLAUDIUS K 2 L33). The system is pressurized to the desired pressure of about 100 kpa (1 bar) and again vented. For filling water, it is recommended to use a filter on the heating system inlet. The heating system must have a sufficient number of vents. Drain valve must be installed at the lowest point of the heating system. The expansion tank is 8 L volume and its volume is sufficient for 150 l of water in the heating system. The expansion tank is not mounted for the version CLAUDIUS K 2 L5X. The system should be designed to a temperature gradient of 55/45 C with respect to condensation use. Condensing boiler can be used also for old self-load systems which were pre-dimensioned and thus condensation can be efficiently used also for this system, but the system should be supplemented with a corresponding expansion tank. 15

16 Condensing boiler is equipped with low energy pump with a PWM driving Wilo Yonos Para RS 15/7.5. Modulating pump is controlled by the control unit of the boiler according to the chosen strategy. The connection to the heating system, HW and gas is carried out through ball valves. Fig.. 10 Wilo Yonos Para RS 15/7.5 pump characteristics 7.2 Gas connection Before connecting the gas pipeline to the boiler, the gas pipeline should be tested and checked. After the boiler connection to the gas pipeline, all gas connections gas must be re-tested by a gas detector or foam solution. Inlet natural gas pressure is 2 kpa (20 mbar). 7.3 Connection to the mains The boiler is equipped with a movable mains supply and a plug. According to ČSN EN ed. 2 Art , the boiler must be positioned so that the plug is accessible. Near the boiler, a socket 230 V/50 Hz must be placed at the distance of 1.5 meters. The socket must comply with applicable regulations and must be checked. 7.4 Condensate drain To drain condensate, a built-in siphon connected to a sewerage overflow is used. Before the boiler commissioning, check whether the condensate is drained. Size of a waste PVC pipe is of Ø 16 mm. The condensate ph is 4.5 and it can be drained into the sewer system without treatment. The boiler condensate drain must be made so as to not prevent continuous condensate drain. 7.5 Flue gas exhaust The boiler is made in the version B or C according to the way of flue gas exhaust and combustion air inlet. Gas appliances for the version B suck the combustion air from the boiler room. Appliances for the version C suck the combustion air from the outside or from the space outside the boiler room. The boiler is supplied in a standard version. The boiler flue gas exhaust is not part of the boiler supply. It is necessary to use special piping intended for condensing boilers with a wall thickness of 1.5 mm. It is necessary to keep a 3% inclination to the boiler. Pressure loss for the flue gas exhaust must not exceed 150 Pa. Glue gas exhaust and air inlet including their lengths shall be made by a designer in the technical documentation. The boiler must be installed only with a wind protective device which meets the requirements of EN (See Annex N). The boiler must be installed with the necessary accessories (pipeline for the combustion air supply and flue gas exhaust). 16

17 Fig.. 11 Flue gas exhaust and air intake connection options The boiler version B and C is specified by a double digit: - the first digit in the index relates to the possible boiler installation with regard to the way of combustion air inlet and flue gas exhaust, - the second digit in the index relates to the use and positioning of the built-in ventilator in the boiler. The boiler is a boiler with a fan before the combustion chamber/heat exchanger (boiler body) and is marked with a second digit of the index 3. Version B 2 Boiler version B without the flue gas rectifier. Version B 5 Boiler version B without the flue gas rectifier, which is designed for connection via its own flue gas exhaust to the protective orifice. The chimney must be equipped with a special liner intended for the condensation boiler and a condensate drain from the chimney. For the boiler, it is possible to use a plastic liner with the temperature resistance of 120 C. Version C 8 The boiler draws combustion air from the outside and transfers it to the chimney. The combustion chamber and flue gas ways of the appliance are gastight separated from the space in which the appliance is located. If the flange for the air intake is used according to Fig. No. 15, the break-out plate in the rear of the boiler must be removed. Pro the version CLAUDIUS K 2 L5X, the flue gas exhaust has a diameter of 110 mm. The air supply diameter remains 80 mm. The boiler is designed for connection to an individually approved and sold pipeline system for combustion air supply and flue gas exhaust. - The least pressure loss = 17 Pa - The highest pressure loss = 150 Pa - Flue gas temperature for minimum output 30 C - Flue gas temperature for maximum output 85 C 17

18 7.6 Pressure losses of flue gas exhaust components for the boiler VIADRUS CLAUDIUS K2 max. fan pressure 150 Pa Split flue gas exhaust - flue gas K 2 L3X VIADRUS order code code DN Name Loss in Pa PPSB48 80 Bend PPSB98 80 Bend PPRM18 80 Pipe 1m PPSAS8 80 Plastic chimney head starr (set) 2.5 Split flue gas exhaust - flue gas K 2 L5X VIADRUS order code code DN Name Loss in Pa PPSB Bend PPSB Bend PPRM Pipe 1m 3.4 PPSAS1 110 Plastic chimney head starr (set) 2.5 Split flue gas exhaust - intake K2 LXX VIADRUS order code code DN Name Loss in Pa PPSB48 80 Bend PPSB98 80 Bend PPRM18 80 Pipe 1m 2.5 Note: The number of components for each version depends on the location of the boiler. For the boiler, the flue gas exhaust by ALMEVA is approved see accessories in the price list of VIADRUS a. s. In the case of an assembly of two or more boilers in a cascade we recommend contacting the company Almeva for the offer and calculation of the relevant flue gas exhaust. 7.7 Boiler commissioning The entire installation must comply with regulations related to this equipment. The boiler must be compatible with local connecting conditions (check the boiler parameters with those on the nameplate). Putting the boiler in operation may only be performed by organizations authorized and trained by the manufacturer. The minimum pressure in the heating system is 80 kpa (0.8 bar). It is necessary to open all closures and check whether gas leaks. Connect the boiler to the mains. Since the boiler is not equipped with a main switch, the boiler will start. Check the gas distribution behind the gas valve. Check the safety valve functionality. It is also necessary to check the pump operation. Check the functionality of the three-way valve (if used). During the boiler operation it is necessary to check the condensate drain both from the boiler and from the chimney liner. During the first boiler commissioning it is needed to train users in accordance with these instructions and pass this manual to the user with the confirmation of the commissioning. It is also required: - to check revisions prior to commissioning, - to check the water leakage, - to check regulation and safety elements. 18

19 7.8 Boiler settings The product meets the values for Green product. The specific measured values depend on the type of connection of the combustion air supply and flue gas exhaust to a given appliance. Therefore, when the boiler commissioning, CO 2 value should be checked or adjusted. The gas valve is factory set to CO 2 value in the flue gas in the range from 8.4 to 8.8%. Max. CO value must be to 100 mg/m 3 converted to 3% oxygen. 1 Gas supply to the valve 2 Fan 3 Mixer 4 Gas supply to the mixer 5 Gas valve 6 Adjusting screw CO 2 max 7 Adjusting screw CO 2 min 8 Measuring point for the gas output pressure 1 9 Measuring point for the gas input pressure 10 Measuring point for the gas output pressure 11 Measuring point for the flue gas Fig.. 12 CLAUDIUS K 2 L setting 1. Use the control knob to select the symbol and confirm by pressing the control knob. The display shows the line Special Operations (chimney sweep function). 2. Use the control knob scroll to the line Off, confirm by pressing the control knob and then using the control knob select the line ON and confirm again. 3. On the newly displayed line Burner output select Max. heating load using the control knob and confirm. 4. The boiler will heat at the rated output. 5. Unscrew the plug and insert the probe of the flue gas analyser in the flue gas measuring point (see Fig. No Pos. 10). 6. Check the amount of CO 2 in the flue gas which must be in the range of 8.4 to 8.8%. The recommended value is 8.5%. 7. Wait about 120 seconds until the boiler operation gets stabilized and check or adjust the CO 2 max. value using the CO 2 max. regulating screw (Fig. no. 16 pos. 6). 8. On the line Burner output select Partial performance using the control knob and confirm. 9. Wait about 120 seconds until the boiler operation gets stabilized and check or adjust the CO 2 min. value using the CO 2 min. regulating screw (Fig. no. 16 pos. 7). 10. When turning the adjusting screw clockwise, theco 2 volume increases, when turning the adjusting screw counter-clockwise, the CO 2 volume decreases. 11. Screw the cover of the gas valve adjusting screw, remove the flue gas analyser probe and screw the plug into the flue gases measuring point (watch its tightness). 12. After the adjustment, turn off the chimney sweep function. Note: For the boiler version K 2 L3X, the slide ø 7 mm is positioned at the output of the gas valve. 19

20 8 Boiler operation by user 8.1 General description The boiler is equipped with a control unit LMS14. To set the parameters, use the display AVS37. For the proper operation of the boiler, it is important to observe the hydraulic connection. For these purpose, design documentation is prepared. The boiler is factory set so that it heats to the set temperature of the boiler (parameter 742). Switching is via a jumper at the input H5. When connecting the switching room unit to the input H5, the jumper should be removed. It is also recommended to use an outdoor sensor, due to weather-compensated heating and time programs use. Further, we recommend using a communication room device according to the menu, see chap Using the expansion modules, the control unit can manage up to 3 mixed heating circuits, hot water, cascade, solar, pool, wood-fired boiler etc. (see VIADRUS design documents). Another possible method of the boiler switching boiler is using 0-10 V via the input H1. The boiler is then only a heat source. 8.2 Display description Press the button OK (E) to enter the setup mode, where you can move through the menu or adjust the value of the parameter using the control knob (D). Press the OK button to enter the desired menu or parameter, and confirm the selected parameter value. A B C D E F G H I J A B C D E F G H I J Feed water operating mode switch RESET button ESC button Room temperature adjustment knob Confirmation button OK Manual operation button Chimney sweep function button Operation mode switch for the heating circuits Display Info button Fig.. 13 A Operation mode switch FV - OFF/ON for the HW heating B RESET button - burner fault unblocking (press for about 3 s) C ESC button - returning one step back in the menu (the selected value is not stored) D Room temperature adjustment knob - room temperature option or selection in the menu E Confirmation button - shifting one step forward in the menu and confirmation of the selected value F Manual operation button - the boiler running at a preset temperature of 60 C, all the pumps are running, the G H I J mixer is not controlled - the display shows the symbol. Chimney sweep function button - after short pressing, the boiler enters the emission measurement mode. This button is intended for an authorized service technician. Operation mode switch for the heating circuits: - operation according to preset time mode (transition to summer mode depending on the outdoor temperature is active) - continuous operation at nominal set room temperature - continuous operation at setback set room temperature - maintaining the anti-frost desired room temperature Display Info button - information about the current state of the boiler, heating circuits, HW and error messages. 20

21 8.2.1 Energy saving Use automatic operation. Set the desired comfortable temperature. Use your time program. The main rule is that the Automatic mode must be set as operating mode: In this mode, the controller monitors the heating for optimal heat consumption (e.g.: summer/winter switching). Or you can individually adjust the operating mode for anti-frost, permanent setback, comfort, according to your needs. Set comfort temperature which has to be maintained during the use of the room, that means during the time set in the time program. Use the time program for setting the time during which the comfortable temperature must be maintained, and outside the comfortable temperature the controller will heat up to the setback temperature. Setting the time program should correspond to room occupancy or night setback. The time program is only used in the Automatic mode of operation. Hot water heating... Settings for the operating mode, temperature and time program for HW heating are identical with settings for heating. 8.3 Settings overview The table shows all available user settings. Time and date Parameter Function Factory settings Min. Max. Units 1 Time :00 23:59 hh:mm 1 Date dd:mm 5 Summer time start dd:mm 6 Summer time end dd:mm Current date and time must be set due to the correct function of the time programs for heating circuits and hot water. Time program HC1 Parameter Function Factory settings Min. Max. Units 500 Preset Mo-Su 00:00 24:00 hh:mm 501 Mo-Su : 1. Phase ON 6:00 00:00 24:00 hh:mm 502 Mo-Su : 1. Phase OFF 22:00 00:00 24:00 hh:mm 503 Mo-Su : 2. Phase ON 24:00 00:00 24:00 hh:mm 504 Mo-Su : 2. Phase OFF 24:00 00:00 24:00 hh:mm 505 Mo-Su : 3. Phase ON 24:00 00:00 24:00 hh:mm 506 Mo-Su : 3. Phase OFF 24:00 00:00 24:00 hh:mm 516 Standard values NO 1. (2, 3) Phase On start of the heating phase at the selected comfortable temperature. 1. (2, 3) Phase Off end of the heating phase at the selected comfortable temperature and switching to the setback temperature. Default values reset of the time program to factory settings Time program HC2 (only if activated) Parameter Function Factory settings Min. Max. Units 520 Preset Mo-Su 00:00 24:00 hh:mm 521 Mo-Su : 1. Phase ON 6:00 00:00 24:00 hh:mm 522 Mo-Su : 1. Phase OFF 22:00 00:00 24:00 hh:mm 523 Mo-Su : 2. Phase ON 24:00 00:00 24:00 hh:mm 524 Mo-Su : 2. Phase OFF 24:00 00:00 24:00 hh:mm 525 Mo-Su : 3. Phase ON 24:00 00:00 24:00 hh:mm 526 Mo-Su : 3. Phase OFF 24:00 00:00 24:00 hh:mm 536 Standard values NO 21

22 Time program 3/HC3 Parameter Function Factory settings Min. Max. Units 540 Preset Mo-Su 00:00 24:00 hh:mm 541 Mo-Su : 1. Phase ON 6:00 00:00 24:00 hh:mm 542 Mo-Su : 1. Phase OFF 22:00 00:00 24:00 hh:mm 543 Mo-Su : 2. Phase ON 24:00 00:00 24:00 hh:mm 544 Mo-Su : 2. Phase OFF 24:00 00:00 24:00 hh:mm 545 Mo-Su : 3. Phase ON 24:00 00:00 24:00 hh:mm 546 Mo-Su : 3. Phase OFF 24:00 00:00 24:00 hh:mm 556 Standard values NO Time program 4/HW Parameter Function Factory settings Min. Max. Units 560 Preset Mo-Su 00:00 24:00 hh:mm 561 Mo-Su : 1. Phase ON 6:00 00:00 24:00 hh:mm 562 Mo-Su : 1. Phase OFF 22:00 00:00 24:00 hh:mm 563 Mo-Su : 2. Phase ON 24:00 00:00 24:00 hh:mm 564 Mo-Su : 2. Phase OFF 24:00 00:00 24:00 hh:mm 565 Mo-Su : 3. Phase ON 24:00 00:00 24:00 hh:mm 566 Mo-Su : 3. Phase OFF 24:00 00:00 24:00 hh:mm 576 Standard values NO Time program 5 Parameter Function Factory settings Min. Max. Units 600 Preset Mo-Su 00:00 24:00 hh:mm 601 Mo-Su : 1. Phase ON 6:00 00:00 24:00 hh:mm 602 Mo-Su : 1. Phase OFF 22:00 00:00 24:00 hh:mm 603 Mo-Su : 2. Phase ON 24:00 00:00 24:00 hh:mm 604 Mo-Su : 2. Phase OFF 24:00 00:00 24:00 hh:mm 605 Mo-Su : 3. Phase ON 24:00 00:00 24:00 hh:mm 606 Mo-Su : 3. Phase OFF 24:00 00:00 24:00 hh:mm 616 Standard values NO Holidays HC1 Parameter Function Factory settings Min. Max. Units 641 Preset Start dd.mm 643 End dd.mm 648 Type of operation Anti-frost protection Anti-frost protection, hh:mm Setback Holidays the selected operating mode for heating for a long period. The function is activated by the date set in parameter 642 and ends at 00:00 of the date set in the parameter 643. Holidays HC2 (only if activated) Parameter Function Factory settings Min. Max. Units 651 Preset Start dd.mm 653 End dd.mm 658 Type of operation Anti-frost protection Anti-frost protection, hh:mm Setback Holidays HC3 (only if activated) Parameter Function Factory settings Min. Max. Units 661 Preset Start dd.mm 663 End dd.mm 668 Type of operation Anti-frost protection Anti-frost protection, hh:mm Setback 22

23 Heating circuit 1 Parameter Function Factory settings Min. Max. Units 710 Comfort temperature 20 Line 712 Line 716 C 712 Setback temperature 16 Line 714 Line 710 C 714 Anti-frost temperature 10 4 Line 712 C 720 Heating curve slope Summer / winter automatic /8 30 C 742 Req. T Run-up Room Thermostat 65 Line 740 Line 741 C 855 Cur. req. drying temp C 856 Current drying day Comfortable temperature required room temperature that will be maintained at the heating phase. Setback temperature required room temperature that will be maintained at the setback phase. Anti-frost temperature setting of the required anti-frost room temperature. Heating curve slope the value shows the heat curve setting, see Fig. No. 18 Summer/winter automatic temperature limit for switching between summer and winter mode. Req. T Run-up Room Thermostat the temperature to which the boiler will heat when the outside sensor is not used. Current req. drying temp setting of the temperature for drying of the floor heating. Current drying day setting of the drying day for the floor heating. Hot water Parameter Function Factory settings Min. Max. Units 1610 Rated temperature C Nominal temperature setting the required comfortable hot water temperature. Set heating curve uses the required room temperature of 20 C. If the required/room temperature changes, the heating curve changes as well. The heating curve shows the required temperature to the heating circuit depending on the corrected outside temperature. When using the room unit QAA74, QAA75 etc, in addition, the heating curve is corrected by the parameters Set room temperature and Room influence. 23

24 8.4 Error messages Table 6 shows a list of the most common fault conditions of the boiler. In case of displaying a different error message, please contact service. Error messages If you see this symbol, it is the fault. Press the info button and read further information. Maintenance or special operation If you see this symbol, it presents a service message or a special operation. Press the info button and read further information. Tab.. 6 Error code Description of error Reason/Solution 10 Short-circuit/interruption of the outside Check the outside temperature sensor temperature sensor Contact service 50 Short-circuit/interruption of the HW Check the HW sensor sensor Contact service 110 The boiler is overheated, electronic Let the device cool down and restart it by pressing the Reset safety thermostat is off. button 111 The pump is defective or thermostatic valves are closed, there was the initiation of the temperature sensor. 119 There is and initiation of the water pressure switch. In case of recurrence of the error contact service Open the thermostatic valves In case of recurrence of the error contact service Check the water pressure, refill water is the pressure is low 128 Loss of flame during operation Rerun the boiler by pressing the Reset button In case of recurrence of the error contact service 133 Controlling and regulating control panel Rerun the boiler by pressing the Reset button is locked. Possible causes: lack of gas, In case of recurrence of the error contact service no ignition. 8.5 Faults Fault Reason Solution The boiler No voltage at the boiler Check whether the power cord is plugged in and whether there does not is voltage in the socket. ignite Insufficient or stopped gas supply Check opening of the gas main supply and shut-off valve of the boiler. There is no requirement for heating and Check the settings of the operating mode HW Room temperature of the room does not match No HW heating Shutdown at the fault Incorrect Date and Time settings Set Date and Time The boiler is in summer mode (switched off from the outside temperature) Low water pressure Refill water to the system Time program of the heating does not match the required one Set room temperature does not match the required one The boiler can be put into operation by switching the operating mode for permanent comfort Check and, if necessary, adjust setting of the day of the week, time and date Change of the time program of the heating Check and, if necessary, adjust the room temperature, adjust the parameter 720 Heating curve slope and Room influence (parameter of the Service settings) HW heating is off Check and, if necessary, turn on the hot water heating (see Fig. no Pos. A) Comfort required temperature is too Check and, if necessary, adjust the comfort required low temperature Incorrect Date and Time settings Check and, if necessary, adjust setting of the day of the week, time and date HW sensor has poor contact with the Check HW sensor tightening heater housing Three-way valve does not switch Check the connection and switching of the three-way valve. See Table. no. 6 See Table. no. 6 Contact service 24

25 ATTENTION! Boiler sensors do not work as the signalling equipment. When the floor heating is used, it must be provided by an external thermostat. Otherwise, in the case of manual opening of the three-way valve, the floor heating may be damaged. 9 Maintenance The boiler housing can be washed using lukewarm detergent solution. All other maintenance can be performed only by a contractual service organization trained by the manufacturer! 9.1 Checking the device 1. Unplug the boiler by unplugging the cord from the mains. Close the gas supply, remove the front cover of the boiler. 2. Disconnect the fan connectors. 3. Disconnect the gas supply to the mixer. 4. Disconnect the silicone hose from the mixer. 5. Disconnect the grounding conductor of the electrode. 6. Remove the burner plate and the fan (unscrew 4 nuts M6). 7. Clean the burner using a steel brush and purge with air. Remove possible impurities on the ignition electrode using emery paper. 8. Check mixer visually. 9. The body should be cleaned using one of the following ways: a) Spray Metanotherm through the burner chamber on the body convection surface. b) Pour diluted soap solution through the burner chamber - leave for 10 min. and rinse with clean water. Any impurities will be discharged through a siphon. 10. Install the burner plate by means of 4 nuts and washers M6, connect the fan connectors according to the wiring. Then connect: - silicone hose to the mixer, - gas inlet to the mixer, - grounding wire to the ignition electrode. When assembling various parts, it is necessary to take care they are assembled in the correct order and direction. All seals that were removed during assembly, must be checked and replaced, if necessary. 11. Open gas supply uwing the ball valve. 12. Check all el. parts which had to be disconnected, whether they are connected to the respective locations according to the wiring diagram, and plug the cord to the mains. 13. Check for gas leaks using a gas detector or foaming solution. 14. It is necessary to check whether the burner plate is well-sealed and tightened using the gas detector. 15. Check the pressure in the heating system using a pressure gauge on the boiler and check the safety valve functionality. If there is the pressure drop in the system, refill the central heating system with water to the required value. 80 kpa (0.8 bar). 16. Mount the front cover 17. Check the boiler setting according to chap. no. 7.7 and check the performance according to the consumption readings at the gas meter. 25

26 10 IMPORTANT NOTICE For the installation and adjustment of the boiler it is necessary to call a service organization trained by the manufacturer. The boiler may only be used for the intended purposes. The boiler may be operated only by adult persons in accordance with these instructions. The boiler is not intended for use by persons (including children) whose physical, sensory or mental disability or lack of experience and knowledge prevents them from safe use of the appliance, unless they are supervised or instructed on the use by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. The boiler is fully automatic, it is not recommended to disconnect it from the mains. The boiler is equipped with automatic anti-freeze protection (if it is plugged to the mains). it is forbidden to interfere with the secured parts. No flammable objects must be placed, installed or hung near the boiler and the flue gas exhaust (safety distance of an appliance from flammable materials in the direction of the main radiation is 50 mm, in other directions it is 10 mm). The safe distance of boiler and flue gas exhaust from flammable materials must be observed. If there are any construction works performed near the boiler, switch the boiler off and protected against pollution. If there are any adjustment works performed near the boiler (works with paints, glues, etc.), switch the boiler off and protected against pollution. Do not clean the boiler by flammable or explosive means. In winter (e.g. when going on holiday), checking of the boiler functions and the whole heating system must be ensured to the necessary extent, to avoid water freezing and the damage to the device due to the external causes (electricity failure, fuel gas supply failure etc.). Due to a long-term electricity failure in the heating period, it is necessary to add to the system a manufacturer-approved antifreeze for this type of boiler or drain the system to avoid freezing of the heating system and the boiler. For the boilers with flue gas exhaust into the surroundings through an external wall of the building, it is necessary to check at a frosty weather that the condensed water from flue gas in the exhaust basket does not freeze. The boiler is supplied with electric power of 230 V. In case of fire, extinguish the boilers as an el. device. Beware of gas leaks (if you have suspicion of gas escaping, shut off the gas intake, ventilate - contact service organization). The gas valve under the boiler must always be accessible. It is necessary to avoid combustion air pollution with halogen hydrocarbons (contained in sprays, solvents, paints, glues etc.) and dust. When assembling, installing and operating the appliance, it is necessary to comply with the rules that apply in the country of destination. In case of failure to comply with these conditions, it is not possible to claim warranty repairs. 11 Instructions for product disposal after its service life VIADRUS a.s. is a contract partner of EKO KOM a.s. with the client number F Packages comply with CSN EN Packaging should be disposed of as follows: - plastic foil, cardboard - waste disposal organization - metal strapping tape - waste disposal organization - wooden packing is designed for a single use and cannot be used further as a product. Its disposal is subject to the Act 477/2001 Coll. and 185/2001 Coll. as amended. Individual parts of the boiler should be disposed of as follows: - exchanger (aluminum alloy) - waste disposal organization - pipe distributions, housing - waste disposal organization - other metal parts - waste disposal organization - insulating material - waste disposal organization With the loss of useful properties of the product, it is possible to return the product back (if applicable), if the originator has declared that it is waste, the waste should be disposed according to the valid legislation of the relevant country. 26