1. Order and Auxiliaries

Transcription

1 VIADRUS Hercules G U26 90 MANUAL FOR ASSEMBLY Návod OF BOILER k obsluze

2 Contents: page 1. Order and Auxiliaries Order Delivery a accessories Boiler Uses and Advantages VIADRUS G 90 boiler technical data Description Boiler Installation Pedestal Installation Binding of the Boiler Body Installation of tubing, fittings and a well Installation of a partitioned horizontal draught interrupter Installation of burner Thermal insulation of the boiler body Installation of the gas armature Boiler casing installation Electrical Panel installation Installation of the Distributing Box Electrical Panel installation Completion of the Electrical Installation Version 10, 12, 15 links automatics HONEYWELL, valve HONEYWELL Installation of the Distributing Box Electrical Panel installation Completion of the Electrical Installation Version 10, 12, 15 links automatics HONEYWELL, valve DUNGS Installation of the Distributing Box Electrical Panel installation Completion of the Electrical Installation Electrical connections flow sheet

3 1. Order and Auxiliaries 1.1 Order Order specification code (type designation) G 90 X X X X X Number of sections: 8: 8 sections 10: 10 sections 12: 12 sections 15: 15 sections Fuel: Z: natural gas Gas valve: H: HONEYWELL D: DUNGS Way of delivery: S: composed state R: decomposed state Regulation: 0 Standard delivery: electric panel equipped with only a network module, thermomanometer and blind flanges 6 Regulation A1: 1 pc regulator RVA set of connectors SVA , terminal board WAGO 63 with a conductor bundle 43, submersible sensor B2 (type QAZ 21). 7 - Regulation A2: 1 pc regulator RVA , 1 pc regulator RVA , set of connectors SVA a SVA , terminal board WAGO 46 with a conductor bundle 46, submersible sensor B2 (type QAZ 21). 8 - Regulation A3: 1 pc regulator RVA , set of connectors SVA , terminal board WAGO 63 with a conductor bundle 63, submersible sensor B2 (type QAZ 21), outside sensor B9 (type QAC 31). 9 - Regulation A4: 1 pc regulator RVA , set of connectors SVA , terminal board WAGO 33 with a conductor bundle 33, submersible sensor B2 (type QAZ 21) Regulation is delivered in a separate package. The regulators must be connected to the electric panel in place of the boiler installation. At the regulation A2 in case of the only one pump circuit required there isn t necessary to order a mixing circuit RVA incl. the accessories. In the purchase order it is necessary to specify: 1. The boiler size and the required regulation (according to the order specification code) In the purchase order it is necessary to specify the data according to the order specification code. In case of a delivery in the composed state it is necessary to specify the execution of the right (when looking at the electric panel the smoke flue is situated on the right) or left (when looking at the electric panel the smoke flue is situated on the left). 2. Number and types of sensors: - outside temperature sensor QAC 31 - submersible temperature sensor QAZ 21 (can also be used for HSW heating) - surface temperature sensor QAD Space instrument type: - indoor sensor QAA 70 - indoor sensor QAA Delivery a accessories Delivery VIADRUS G 90 boiler is delivered on a pallet equipped with a cardboard package and as a standard in a composed state equipped only with a network module. At request a delivery in a decomposed state is possible. The accessories delivered at request are not included in the boiler basic price: - regulation A1 - A4 (according to the order specification code) including 1 pc submersible sensor QAZ 21 - electromagnetic gas valve (according to the order specification code) - ordered number of necessary types of sensors (see chapter no. 1.1) - ordered type of space instrument (see chapter no. 1.1) 3

4 2. Boiler Uses and Advantages Cast-iron sectional gas boiler VIADRUS G 90 is equipped with law-emission atmospheric burner and is intended for burning pf low-pressure natural gas. The boiler is made in B 11BS design it means it is equipped with combustion gases reflux fuse. It is suitable first of all for heating the middle sized and bigger premises. The use of gas valves with an automatic control and watch of the gas cap tightness at the burner makes it possible to install the boilers in the boiler rooms of categories I and II. The boiler is only made as the hotwater boiler with a forced circulation and work overpressure up to 400 kpa (4 bar). Before the dispatch the boiler is tested for tightness by 800 kpa (8 bar) testing overpressure. Boiler advantages: 1. High service life of the cast-iron boiler drum. 2. Simple operation and maintenance. 3. Reliable security and control elements 4. Gas combustion efficiency 92 %. 5. As a standard equipped with combustion gases reflux fuse. 6. Silent running and law electricity consumption. 7. Gas connected either from the left-hand side or from the right-hand side. 8. Connection of the output and return water either from the left-hand side or from the right-hand side (it doesn t apply to the 8-sectional version). 9. Possibility to connect the boiler in an cascade. 10. Possibility to equip with an equitherm regulation. 11. Two-stage burner (nominal/ reduced output). 12. Possible delivery in a decomposed state. 13. The content of harmful substances in the combustion gases is significantly lower than the values prescribed by the guideline MŽP Environmentally friendly product and meets the requirements of the most strict European standards. 3. Boiler technical data Tab. no. 1 Dimensions, service temperatures and electric parameters of the boiler Number of sections pc Appliance category I 2H Weight kg Water space volume l 27,7 34,3 40,9 50,8 Diameter of smoke socket mm Boiler overall dimensions - depth mm width x height mm 878,5 x x1160 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 18 Noise level db Does not exceed the 55 db (A) level Chimney draught mbar Minimum 0,025 Boiler connections - heating water Js 6/4" - return water Js 6/4" - gas Js 1/2" 1 Connecting voltage 1/N/PE 230 V AC 50 Hz TN-S Electric input W 50 Electric protection IP 40 4

5 Tab. no. 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 Rated thermal output max. kw Rated thermal output min. kw Rated thermal output max kw Rated thermal output min kw Volume gas flow at the maximum thermal output m 3.h -1 7,16 9,25 11,32 13,61 Volume gas flow at the minimum thermal output m 3.h -1 5,56 6,5 7,85 10,05 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 C Temperature of the combustion gases after the draught diverter at the minimum thermal output C Volume of dry combustion gases actual at the maximum thermal output m 3.m -3 20,18 15,8 21,6 18,13 Volume of dry combustion gases actual at the minimum thermal output m 3.m -3 23,63 20,1 24,8 23,6 Emission values - CO mg.m NO x mg./kwh Grade of NO x grade V Nozzle diameter mm 2,42 Honeywell VR 4601 and VR 4605 valves Informative gas pressure at the nozzle for the nominative output at the maximum thermal output mbar 15 14,8 14,5 14 Informative gas pressure at the nozzle for the nominative output at the minimum thermal output mbar 9 7,6 7,5 7,5 Dungs MB ZRDLE 412 valve Informative gas pressure at the nozzle for the nominative output at the maximum thermal output mbar - 13,8 Informative gas pressure at the nozzle for the nominative output at the minimum thermal output mbar Description The main boiler segment is the iron-cast sectional boiler drum made of grey cast-iron in compliance with EN cast-iron 200 The pressure segments of the boiler conform to the strength requirements in compliance with EN 656 Gas fired central heating boilers Type B boilers of nominal heat input exceeding 70 kw but not exceeding 300 kw. The main boiler segment is the iron-cast sectional boiler drum. The individual sections are connected by means of forced-on insertions and tightened by means of the anchor bolts, thus creating a combustion space with convection surface for combustion gases heat transfer into the heating water. In the upper part of outer sections on the side where the electric panel is positioned there is screwed a basin for thermometer, the capillary thermostats sensors and the clack valve for thermomanometer. The connecting points (heating water input and output, gas) are situated in the rear end of the boiler. The whole boiler drum is insulated with a harmless mineral insulation which reduces the losses caused by heat transmittance into the surroundings. To the upper part of the boiler drum there is mounted by means of the screws a built-in draught diverter with a mouthpiece for setting-on a stove-pipe to lead away the combustion gases into the chimney. The draught diverter is made of the stain steel and equipped with a dismountable cleaning cover. The whole boiler drum is seated on a steel basement a part of which is the protective plate made of the stain steel. The atmospheric burner composed of oval low-emission burner tubes is made of the stain steel. Individual tubes are mounted on the burner plate by means of four screws screwed in the plate. A progressive burner construction enables to close fully the boiler combustion space. All air needed for combustion is brought into the burner tubes through the diffusers. To the burner plate there is welded a gas distributor with nozzles and there is mounted a pilot burner and a watching electrode. The boiler control is situated on the control panel in the upper front end of the boiler. The steel surface of the boiler shell is in colour treated by applying a good quality comaxite coat. 5

6 Gas inlet Number of sections L [mm] L1 [mm] A [mm] 878, D [mm] Fig. no. 1 Boiler assembly 6

7 5. 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 5.1 Pedestal Installation 1 pc of boiler pedestal 1 pc cover for the combustion chamber Position the cover sheet metal over future combustion chamber on the pedestal cover sheet metal burning space boiler pedestal Fig. no. 2 Boiler Pedestal 5.2 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. Boiler links 1 pc boiler link left 1 pc boiler link right 8, 10; 13 pc of middle links, number is determined by size of the boiler 18, 22; 28 pc boiler inserts as per boiler size 3 pc anchoring screws M 10 x L (as per respective size) 1 pc mounting brace 2 pcs cover sheet metal lid 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 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. 7

8 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. 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 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 5.3 Installation of tubing, fittings and a well 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 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 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). 8

9 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 Fig. no. 3 Installation of heating water and reverse water tubes (right versioné) 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 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 (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). 5.4 Installation of a partitioned horizontal draught interrupter 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) 23 pc of sheet metal screws 4.8 (size with 15 links) 2 pc support Silicone sealant/binder (from manufacturer) 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 on the 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. 9

10 Front part Rear part Protecting metal sheet Support Fig. no. 4 Installation of the horizontal draught interrupter 5.5 Installation of burner 1 pc burner complete assembly 4 pcs screw M6 4 pc of washer Ø 6 4 pc of nut M6 Boiler binder sealant Fig. No. 5 Burner Assembling 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). 5.6 Thermal insulation of the boiler body 1 pc tightening sling with a clasp 1 pc insulation Rotaflex L (2900, 3200, 3650 mm) as per size of the boiler 10

11 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. 5.7 Installation of the gas armature 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) 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. 5.8 Boiler casing installation 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) 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 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. 11

12 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 electro-panel (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, Screw the rear mounting plate from the opposite side of the boiler by means of 2 self-drilling screws 4, 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)

13 6. Electrical Panel installation 6.1 Installation of the Distributing Box 1 pc Switch box 1 pc Installation Console (large) 1 pc Installation Console (small) 16 pcs Screw AM 5 x 8 mm 16 pcs Rosette washer Ø 5,2 mm 1 pc Cover plate HONEYWELL 2 pcs Rubber bushing Ø 13 mm 10 pcs Entry bushing PG 9 8 pcs Entry Bushing PG 11 1 pc Fuse box 1 pc Tube fuse 4 A 1 pc End piece of the tube PG 48 1 pc Nut of the end piece of the tube PG mm Protection tube PG 48 1 pc End piece of the tube PG 36 1 pc Nut of the end piece of the tube PG mm Protection tube PG 36 1 pc Ionization automatics HONEYWELL S 4563B pcs Screw AM 4 x 8 1 pc Bundle of conduits 1. With aid of 8 screws M5 with rosette washers, the installation console is to be mounted on a side portion of the jacket left cover B. Above, a smaller console shall be installed to assist in securing the terminals. 2. Sequentially, 8 pc of entry bushing PG11,to be mounted on the distribution box. Then, 8 pc of entry bushings PG9, end pieces of cover tubes PG39 a PG48, a fuse box with 4A fuse, and two screws M5 are used to secure the cover HONEYWELL, containing already installed from left two bushings PG9 and two rubber bushings Ø 13 mm. 3. The box so equipped is to be mounted on a side part B left using four screws M5. 4. At the box s bottom on left, using two M4 screws, the ionization automatics HONEYWELL is to be fastened such, that the connector leading to the igniter is orientated right down. 5. The terminal X10 with conduits and suppression component Z1 is fastened into the lower portion of the installation console (Large) Anti-jamming element is to be fastened using the fastener band to the console. 6. Following the schematics, line wires 1, 2 are connected to the fuse box. 7. Further line wires No.10,11,15,22,,27,28,45 and 55 are connected to the ionization automatics. 8. The remaining line wires put through the end piece of the protective tube PG48, and then the actual tube is inserted over the conductors. 9. Line wire 90, connected to the igniting electrode, is to be inserted through the rubber bushing Ø Conduit no. 90, connected to the guardian electrode, is to be inserted through the rubber bushing Ø Conduit no. 92 to burner is to be iserted through bushing PG Cable W1 is to be inserted through the last bushing PG9 and its conduits are to be connected in the distributing box as follows: Black J3: 2 Brown X10: 23 Grey X10: 24 Blue X10: 5 Green-yellow Terminal plate console 13. The cable W1 opposite end is to be connected to X6 gas valve connection outlet as follows: Black X6: L1 Brown X6: L2 Grey X6: L3 Blue X6: N Green-yellow PE 14. The outlet X6 before covering is to be affixed using two self-cutting screws 2,9x19 onto a side piece under the distributing box. Cover it after its affixing. 15. Into the X6* gas valve connector are to be connected gas valve Y1 - X8.1 outlet cables. 16. (small burner+1 st step) and X8.2 (High-Low coil) as follows: X8.1 Green - Yellow X6*: PE Blue X6*: N Brown 6*: L2 Black X6*: L1 X8.2 Green - Yellow X6*: PE Blue X6*: N Brown X6*: L3 13

14 6.1.1 Electrical Panel installation 1 pc Power module preconnected 1 pc End piece of the tube PG 48 1 pc Nut of the end piece of the tube PG 48 1 pc End piece of the tube PG 36 1 pc Nut of the end piece of the tube PG End pieces of the tubes PG36 and PG48 are to be fastened into the electrical panel console 2. Wires are to be put through the end piece PG48, and the cover tube secured 3. Following the connection schematics, instruments are to be connected within the power network module: BT2 c.n.. 13,14,18,56 BT1 c.n. 15,17,18,57 BT4 c.n. 7,8,58 S1 c.n. 2,3 H1 c.n. 40 H2 c.n H3 c.n S3 c.n. 27 S2 c.n. 24,25 F2 c.n. 6,7 4. Green and yellow wire no.59 connect to the electrical panel console 5. Green-yellow wire no.70 will connect the panel console with the Boiler body 6. Cable cover tube PG36 should be fastened into end pieces situated on the Distribution Box and the Electrical Panel Console Completion of the Electrical Installation 1 pc Electrical Panel 2 pcs Blank L&G large 1 pc L&G small plug with thermomanometer 1 pc Flexo cable 1. The sensing capillary of the instruments are to be inserted into appropriate wells, the manometer sensor then screwed into the return valve. 2. The electrical panel is to be mounted on the electrical panel console Insert into the electrical panel opening sequentially: the power module, two large blanks L & G, and a small blank L & G with a thermomanometer. Using the bushing PG11, put through the incoming power cord into the distribution box and connect it to the terminal X10: Green-yellow X10: PE Blue X10: N Brown X10: U 3. Sockets X8.1 and X8.2 to be connected to the gas valve. 4. Connector X6* to be connected to X6 socket. 14

15 6.2 Version 10, 12, 15 links automatics HONEYWELL, valve HONEYWELL Installation of the Distributing Box 1 pc Switch box 1 pc Installation Console (large) 1 pc Installation Console (small) 16 pcs Screw AM5x8mm 16 pcs Rosette washer Ø 5,2mm 1 pc Cover plate HONEYWELL 2 pcs Rubber bushing Ø 13 mm 2 pcs Entry bushing PG 9 10 pcs Entry Bushing PG11 1 pc Fuse box 1 pc Tube fuse 4A 1 pc End piece of the tube PG 48 1 pc Nut of the end piece of the tube PG mm Protection tube PG 48 1 pc End piece of the tube PG 36 1 pc Nut of the end piece of the tube PG mm Protection tube PG 36 1 pc Ionization automatics HONEYWELL S 4563B pcs Screw AM4 x 8 1 pc Bundle of conduits 1. With aid of 8 screws M5 with rosette washers, the installation console is to be mounted on a side portion of the jacket left cover B. Above, a smaller console shall be installed to assist in securing the terminals 2. Sequentially, 8 pc of entry bushing PG11,to be mounted on the distribution box. Then, 8 pc of entry bushings PG9, end pieces of cover tubes PG39 a PG48, a fuse box with 4A fuse, and two screws M5 are used to secure the cover HONEYWELL, containing already installed from left two bushings PG9 and two rubber bushings Ø 13 mm. 3. The box so equipped is to be mounted on a side part B left using four screws M5. 4. At the box s bottom on left, using two M4 screws, the ionization automatics HONEYWELL is to be fastened such, that the connector leading to the igniter is orientated right down. 5. The terminal X10 with conduits and suppression component Z1 is fastened into the lower portion of the installation console (Large) Anti-jamming element is to be fastened using the fastener band to the console. 6. Following the schematics, line wires 1, 2 are connected to the fuse box 7. Further line wires No.10,11,15,22,,27,28,45 and 55 are connected to the ionization automatics. 8. The remaining line wires put through the end piece of the protective tube PG48, and then the actual tube is inserted over the conductors 9. Line wire 90, connected to the igniting electrode, is to be inserted through the rubber bushing Ø Conduit no. 90, connected to the guardian electrode, is to be inserted through the rubber bushing Ø Conduit no. 92 to burner is to be iserted through bushing PG Cable W1 is to be inserted through the last bushing PG9 and its conduits are to be connected in the distributing box as follows: Black J3: 2 Brown X10: 23 Grey X10: 24 Blue X10: 5 Green-yellow Terminal plate console 13. The cable W1 opposite end is to be connected to X6 gas valve connection outlet as follows: Black X6: L1 Brown X6: L2 Grey X6: L3 Blue X6: N Green-yellow PE 14. The outlet X6 before covering is to be affixed using two self-cutting screws 2,9x19 onto a side piece under the distributing box. Cover it after its affixing. 15. Into the X6* gas valve connector are to be connected gas valve Y1 X8.1 outlet cables. 16. (small burner+1 st step) and X8.2 (High-Low coil) as follows: X8.1 Green Yellow X6*: PE Blue X6*: N Brown 6*: L2 Black X6*: L1 X8.2 Green Yellow X6*: PE Blue X6*: N Brown X6*: L3 15

16 17. Similarly are to be connected cable conduits of the Gas valve Y2 X9.1 (1st step) and X9.2 (High-Low coil) Electrical Panel installation 1 pc Power module preconnected 1 pc End piece of the tube PG 48 1 pc Nut of the end piece of the tube PG 48 1 pc End piece of the tube PG 36 1 pc Nut of the end piece of the tube PG End pieces of the tubes PG36 and PG48 are to be fastened into the electrical panel console 2. Wires are to be put through the end piece PG48, and the cover tube secured 3. Following the connection schematics, instruments are to be connected within the power network module: BT2 c.n.. 13,14,18,56 BT1 c.n. 15,17,18,57 BT4 c.n. 7,8,58 S1 - c.n. 2,3 H1 - c.n. 40 H2 - c.n H3 - c.n S3 - c.n. 27 S2 - c.n. 24,25 F2 - c.n. 6,7 4. Green and yellow wire no.59 connect to the electrical panel console 5. Green-yellow wire no.70 will connect the panel console with the Boiler body 6. Cable cover tube PG36 should be fastened into end pieces situated on the Distribution Box and the Electrical Panel Console Completion of the Electrical Installation 1 pc Electrical Panel 2 pc Blank L&G large 1 pc L&G small plug with thermomanometer 1 pc Flexo cable 1. The sensing capillary of the instruments are to be inserted into appropriate wells, the manometer sensor then screwed into the return valve. 2. The electrical panel is to be mounted on the electrical panel console Insert into the electrical panel opening sequentially: the power module, two large blanks L & G, and a small blank L & G with a thermomanometer. Using the bushing PG11, put through the incoming power cord into the distribution box and connect it to the terminal X10 Green-yellow X10: PE Blue X10: N Brown X10: U 3. Sockets X8.1 and X8.2 to be connected to the gas valve. 4. Sockets X9.1 and X9.2 to be connected to the gas valve. 5. Connector X6* to be connected to X6 socket. 6. Connector X7* to be connected to X7 socket. 16

17 6.3 Version 10, 12, 15 links automatics HONEYWELL, valve DUNGS Installation of the Distributing Box 1 pc Switch box 1 pc Installation Console (large) 1 pc Installation Console (small) 16 pcs Screw AM5x8mm 16 pcs Rosette washer Ø 5,2mm 1 pc Cover plate DUNGS 2 pcs Plug ST 18/3 1 pc Plug ST1 8/4 8 pcs Entry bushing PG 9 8 pcs Entry Bushing PG11 1 pc Fuse box 1 pc Tube fuse 4A 1 pc End piece of the tube PG 48 1 pc Nut of the end piece of the tube PG mm Protection tube PG 48 1 pc End piece of the tube PG 36 1 pc Nut of the end piece of the tube PG mm Protection tube PG 36 1 pc Ionization automatics HONEYWELL S 4563B pcs Screw AM4 x 8 1 pc Bundle of conduits 1. With aid of 8 screws M5 with rosette washers, the installation console is to be mounted on a side portion of the jacket left cover B. Above, a smaller console shall be installed to assist in securing the terminals. 2. Sequentially, 8 pc of entry bushing PG11,to be mounted on the distribution box. Then, 8 pc of entry bushings PG9, end pieces of cover tubes PG39 a PG48, a fuse box with 4A fuse, and two screws M5 are used to secure the cover DUNGS to the bottom of the distribution box. The cover DUNGS, containing already installed from left the following ST 18/3 (X11), ST1 8/4 (X12), ST 18/3 (X13). 3. And two rubber bushings Ø 13 mm. 4. The box so equipped is to be mounted on a side part B left using four screws M5. 5. At the box s bottom on left, using two M4 screws, the ionization automatics HONEYWELL is to be fastened such, that the connector leading to the igniter is orientated right down. 6. The terminal X10 with conduits and suppression component Z1 is fastened into the lower portion of the installation console (Large) Anti-jamming element is to be fastened using the fastener band to the console. 7. Following the schematics, line wires 1, 2 are connected to the fuse box. 8. Further line wires No.10,11,15,22,,27,28,45 and 55 are connected to the ionization automatics. 9. Into the conductor plug X11, the line wires 20,46 and Into the conductor plug X12, the line wires 21,23,47 and Into the conductor plug X13, the line wires 26,48 and The remaining line wires put through the end piece of the protective tube PG48, and then the actual tube is inserted over the conductors. 13. Line wire 90, connected to the igniting electrode, is to be inserted through the rubber bushing Ø Conductor 91 leading to the guardian electrode and 92 to the burner, shall be put through the other rubber bushing Ø

18 6.3.2 Electrical Panel installation 1 pc Power module preconnected 1 pc End piece of the tube PG 48 1 pc Nut of the end piece of the tube PG 48 1 pc End piece of the tube PG 36 1 pc Nut of the end piece of the tube PG End pieces of the tubes PG36 and PG48 are to be fastened into the electrical panel console 2. Wires are to be put through the end piece PG48, and the cover tube secured 3. Following the connection schematics, instruments are to be connected within the power network module: BT2 c.n.. 13,14,18,56 BT1 c.n. 15,17,18,57 BT4 c.n. 7,8,58 S1 - c.n. 2,3 H1 - c.n. 40 H2 - c.n H3 - c.n S3 - c.n. 27 S2 - c.n. 24,25 F2 - c.n. 6,7 4. Green and yellow wire no.59 connect to the panel Console 5. Green-yellow wire no.70 will connect the panel console with the Boiler body 6. Cable cover tube PG36 should be fastened into end pieces situated on the Distribution Box and the Electrical Panel Console Completion of the Electrical Installation 1 pc Electrical Panel 2pcs Blank L&G large 1 set Leading cables of the valve DUNGS 1 pc L&G small plug with thermomanometer 1 pc Flexo cable 1. The sensing capillary of the instruments are to be inserted into appropriate wells, the manometer sensor then screwed into the return valve. 2. The electrical panel is to be mounted on the electrical panel console Insert into the electrical panel opening sequentially: the power module, two large blanks L & G, and a small blank L & G with a thermomanometer. Using the bushing PG11, put through the incoming power cord into the distribution box and connect it to the terminal X10 Green-yellow X10: PE Blue X10: N Brown X10: U 3. With aid of Leading cables of the valve DUNGS, we interconnect X11 with Y0 (pilot burner) X12 with Y1/1 Y1/2 (I. step) X13 s Y3 (II. STEP) 18

19 7. Electrical connections flow sheet ϑ P P ϑ ϑ A1 Automatics Honeywell 4563B1011 E1 Ignition electrode E2 Ionization electrode F1 Fuse 4 A F2 Fuse 2,5 A H1 Signalling "Boiler under voltage" H2 failure signalling H3 ionising failure signalling S1 Main power switch S2 Reduced/rated output switch S3 Pushbutton RESET X10 Boiler s terminal plate Y1 Gas Valve Honeywell VR4601QB 2001 Z1 Anti-interference element BT1 safety thermostat BT2 combustion products thermostat BT4 boiler thermostat PS3 Minimal water level guard SP1 Minimal gas pressure guard SP2 Gas flange leaktightness guard X6 Gas valve connector Fig. no. 6 Elementary wiring diagram of VIADRUS G 90 8 sectional boiler for Honeywell version At VIADRUS G 90 version 8 sections there isn t used the tightness watching system at SP2 gas fitting 19

20 console Burner El. distribution box Terminal plate console Color marking: GNYE Green-yellow BK Black BN Brown BU Blue RD Red GR Grey II. step Small burner I. step A1 Automatics Honeywell 4563B1011 F1 Fuse 4 A X10 Boiler s terminal plate Y1 Gas Valve Honeywell VR4601QB 2001 Z1 Anti-interference element PS3 Minimal water level guard SP1 Minimal gas pressure guard SP2 Gas flange leaktightness guard X6 Gas valve connectors Q1 Circulating pump network Fig. no. 7a) Wiring diagram of 8 sectional VIADRUS G 90 boiler for Honeywell version 20

21 Panel console Burner Panel console Boiler s body Panel console Boiler s body E1 Ignition electrode E2 Small burner ionization electrode E3 Burner ionization electrode F2 Fuse 2,5 A H1 Signalling "Boiler under voltage" H2 failure signalling H3 ionising failure signalling S1 Main power switch S2 Reduced/rated output switch S3 Pushbutton RESET BT1 safety thermostat BT2 combustion products thermostat BT4 boiler thermostat network module Fig. no. 7b) Wiring diagram of 8 sectional VIADRUS G 90 boiler for Honeywell version 21

22 ϑ ϑ ϑ P P A1 Automatics Honeywell 4563B1011 E1 Ignition electrode E2 Ionization electrode F1 Fuse 4 A F2 Fuse 2,5 A H1 Signalling "Boiler under voltage" H2 failure signalling H3 ionising failure signalling S1 Main power switch S2 Reduced/rated output switch S3 Pushbutton RESET X10 Boiler s terminal plate Y1 Gas Valve Honeywell VR4601QB 2001 Y2 Gas Valve Honeywell VR4605QB 2002 Z1 Anti-interference element BT1 safety thermostat BT2 combustion products thermostat BT4 boiler thermostat PS3 Minimal water level guard SP1 Minimal gas pressure guard SP2 Gas flange leaktightness guard X6, X7 Gas valve connectors Fig. no. 8 Elementary wiring diagram of VIADRUS G 90 10, 12, 15 sectional boiler for Honeywell version 22

23 console Color marking: GNYE Green-yellow BK Black BN Brown BU Blue RD Red GR Grey Burner II. step I. step II. step Small burner I. step A1 Automatics Honeywell 4563B1011 F1 Fuse 4 A X10 Boiler s terminal plate Y1 Gas Valve Honeywell VR4601QB 2001 Y2 Gas Valve Honeywell VR4605QB 2002 Z1 Anti-interference element PS3 Minimal water level guard SP1 Minimal gas pressure guard SP2 Gas flange leaktightness guard X6, X7 Gas valve connectors Q1 Circulating pump El. distribution box Terminal plate console network Fig. no. 9a) Wiring diagram of 10, 12, 15 sectional VIADRUS G 90 boiler for Honeywell version 23

24 Panel console Burner Panel console Boiler s body Panel console Boiler s body E1 Ignition electrode E2 Small burner ionization electrode E3 Burner ionization electrode F2 Fuse 2,5 A H1 Signalling "Boiler under voltage" H2 failure signalling H3 ionising failure signalling S1 Main power switch S2 Reduced/rated output switch S3 Pushbutton RESET BT1 safety thermostat BT2 combustion products thermostat BT4 boiler thermostat network module Fig. no. 9b) Wiring diagram of 10, 12, 15 sectional VIADRUS G 90 boiler for Honeywell version 24

25 ϑ P P ϑ ϑ A1 Automatics Honeywell 4563B1011 E1 Ignition electrode E2 Ionization electrode F1 Fuse 4 A F2 Fuse 2,5 A H1 Signalling "Boiler under voltage" H2 failure signalling H3 ionising failure signalling S1 Main power switch S2 Reduced/rated output switch S3 Pushbutton RESET X10 Boiler s terminal plate Y1 Gas Valve Dungs MB-ZRDLE 412B01S22 Z1 Anti-interference element BT1 safety thermostat BT2 combustion products thermostat BT4 boiler thermostat PS3 Minimal water level guard SP1 Minimal gas pressure guard SP2 Gas flange leaktightness guard X11,X12,X13 Gas valve connectors Fig. no. 10 Elementary wiring diagram of VIADRUS G 90 10, 12, 15 sectional boiler for DUNGS version 25

26 El. distribution box A1 Automatics Honeywell 4563B1011 F1 Fuse 4 A X10 Boiler s terminal plate Y1 Gas Valve Dungs MB- ZRDLE 412B01S22 network Z1 Anti-interference element PS3 Minimal water level guard SP1 Minimal gas pressure guard SP2 Gas flange leaktightness guard Q1 Circulating pump X11,X12,X13 Gas valve connectors Terminal plate console Burner Terminal plate console Color marking: GNYE Green-yellow BK Black BN Brown BU Blue RD Red GR Grey Small burner I. step II. step Fig. no. 11a) Wiring diagram of 10, 12, 15 sectional VIADRUS G 90 boiler for DUNGS version 26

27 Panel console Burner Panel console Boiler s body Panel console Boiler s body E1 Ignition electrode E2 Small burner ionization electrode E3 Burner ionization electrode F2 Fuse 2,5 A H1 Signalling "Boiler under voltage" H2 failure signalling H3 ionising failure signalling S1 Main power switch S2 Reduced/rated output switch S3 Pushbutton RESET BT1 safety thermostat BT2 combustion products thermostat BT4 boiler thermostat network module Fig. no. 11b) Wiring diagram of 10, 12, 15 sectional VIADRUS G 90 boiler for DUNGS version Additional directives for installation and operation are contained in the Manual for operation and Installation of Boiler VIADRUS G 90, also included in the shipment. Manufacturer reserves the rights to changes made in the context of product innovation; these might not be included in this Manual hereto presented. 27

28 28 Date of revision 45/2012 ND GB