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General Information

16

4.3

Main Boiler Parts

Fig.

№

. 4

The VIADRUS K4 boiler assembly (version shown - K4G2HXXXX)

1

three-way valve (only for versions K4G2HXXXX and K4G3HXXXX)

2

HSW temperature sensor (only for version K4G2HXXXX)

3

HSW exchanger (only for version K4G2HXXXX)

4

gas valve

5

siphon

6

safety valve

7

circulation pump

8

gas supply pipe

9

bleeder valve

10

boiler electronics

11

burner plate

12

heating water temperature sensor

13

mixer

14

safety thermostat

15

combination electrode

16

boiler frame

17

exchanger

18

fan

19

expansion tank

20

pressure gauge

21

boiler front cover

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Summary of Contents for NAOS K4

Page 1: ...VIADRUS K4 Manual for boiler operation and installation GB_2015_31 GB_2017_24 ...

Page 2: ...stem and Water Filling 31 10 5 Gas Connection 31 10 6 Electric Power Supply Connection 31 10 7 Condensate Discharge 31 10 8 Flue Gas Ducting 31 10 9 Boiler Electrical Wiring 32 10 9 1 Main components of boiler electrical equipment 32 10 9 2 Connection of the higher level regulation and external boiler sensors 32 10 9 3 Connecting terminal 33 11 Flue Gas Ducting 38 11 1 Flue gas ducting examples of...

Page 3: ...ropane X6 Cover color W white R red S silver B black Conversion of the VIADRUS K4 boiler from natural gas to propane and vice versa can be performed by a contracted service provider only Chimney flue made by ALMEVA has been certified for this boiler If you use chimney flue made by a different producer it is necessary to use a system with identical parameters as for the certified type of the chimne...

Page 4: ...ut Js 3 4 heating water input to the heater Js 1 2 1 2 return heating water input Js 3 4 return water input from the heater Js 1 2 3 4 system water filling inlet Js 1 2 condensate outlet mm Ø 25 safety valve output mm Ø 21 2 gas inlet Js 3 4 Connecting voltage 1 N PE 230VAC 50 Hz TN S El power input including pump W 110 El covering IP 40 Tab 2 Thermal technical parameters VIADRUS K4GXH24XX compari...

Page 5: ...ng water input to the heater Js 1 2 1 2 return heating water input Js 3 4 return water input from the heater Js 1 2 3 4 system water filling inlet Js 1 2 condensate outlet mm Ø 25 safety valve output mm Ø 21 2 gas inlet Js 3 4 Connecting voltage 1 N PE 230VAC 50 Hz TN S El power input including pump W 110 El covering IP 40 Tab 4 Thermal technical parameters VIADRUS K4GXH33XX comparison conditions ...

Page 6: ...General Information 6 Diagram no 1 A diagram of the boiler heating circuit hydraulic loss Fig 1 The main boiler dimensions ...

Page 7: ...v TV T 30 C 7 00 9 00 11 00 13 00 15 00 17 00 19 00 21 00 23 00 2 50 3 50 4 50 5 50 6 50 7 50 8 50 9 50 Výkon kotle kW Průtok TV l min K4G2H24 Ohřev TV T 35 C Graph No 2 Dependence of boiler power on flow rate of heated hot water version VIADRUS K4G2H24XX K4G2H24 Hot water heating T 25 C K4G2H24 Hot water heating T 30 C K4G2H24 Hot water heating T 35 C Boiler power kW Boiler power kW Boiler power ...

Page 8: ...3 Ohřev TV T 30 C 4 00 9 00 14 00 19 00 24 00 29 00 34 00 3 00 5 00 7 00 9 00 11 00 13 00 Výkon kotle kW PrůtokTV l min K4G2H33 Ohřev TV T 35 C Graph No 3 Dependence of boiler power on flow rate of heated hot water version VIADRUS K4G2H33XX K4G2H33 Hot water heating T 25 C K4G2H33 Hot water heating T 30 C K4G2H33 Hot water heating T 35 C Boiler power kW Boiler power kW Boiler power kW Hot water fl...

Page 9: ...tput and high temperature regime P4 24 kW At rated heat output and high temperature regime ƞ4 97 53 At 30 of rated heat output and low temperature regime P1 4 kW At 30 of rated heat output and low temperature regime ƞ1 105 72 Auxiliary electricity consumption Other items At full load elmax 0 02 kW Standby heat loss Pstby 0 045 kW At part load elmin 0 011 kW Ignition burner power consumption Pign k...

Page 10: ...gime ƞ4 97 53 At 30 of rated heat output and low temperature regime P1 4 kW At 30 of rated heat output and low temperature regime ƞ1 105 72 Auxiliary electricity consumption Other items At full load elmax 0 02 kW Standby heat loss Pstby 0 045 kW At part load elmin 0 011 kW Ignition burner power consumption Pign kW In standby mode PSB 0 003 kW Emissions of nitrogen oxides NOx 25 mg kWh For combinat...

Page 11: ...gime ƞ4 97 53 At 30 of rated heat output and low temperature regime P1 4 kW At 30 of rated heat output and low temperature regime ƞ1 105 72 Auxiliary electricity consumption Other items At full load elmax 0 02 kW Standby heat loss Pstby 0 045 kW At part load elmin 0 011 kW Ignition burner power consumption Pign kW In standby mode PSB 0 003 kW Emissions of nitrogen oxides NOx 25 mg kWh For combinat...

Page 12: ...utput and high temperature regime P4 30 3 kW At rated heat output and high temperature regime ƞ4 98 4 At 30 of rated heat output and low temperature regime P1 6 kW At 30 of rated heat output and low temperature regime ƞ1 104 8 Auxiliary electricity consumption Other items At full load elmax 0 11 kW Standby heat loss Pstby 0 044 kW At part load elmin 0 04 kW Ignition burner power consumption Pign k...

Page 13: ... regime ƞ4 98 4 At 30 of rated heat output and low temperature regime P1 6 kW At 30 of rated heat output and low temperature regime ƞ1 104 8 Auxiliary electricity consumption Other items At full load elmax 0 11 kW Standby heat loss Pstby 0 044 kW At part load elmin 0 04 kW Ignition burner power consumption Pign kW In standby mode PSB 0 003 kW Emissions of nitrogen oxides NOx 26 mg kWh For combinat...

Page 14: ...regime ƞ4 98 4 At 30 of rated heat output and low temperature regime P1 6 kW At 30 of rated heat output and low temperature regime ƞ1 104 8 Auxiliary electricity consumption Other items At full load elmax 0 11 kW Standby heat loss Pstby 0 044 kW At part load elmin 0 04 kW Ignition burner power consumption Pign kW In standby mode PSB 0 003 kW Emissions of nitrogen oxides NOx 26 mg kWh For combinati...

Page 15: ...p and a three way valve ready to be used in combination with a reservoir type hot water heater The Honeywell automatics is an electronic control and ignition automatics designed for gas fired central heating boilers with a modulated fan and burner with preliminary mixing The combustion air inlet and the flue gas outlet may be implemented by several means as follows to the chimney through the wall ...

Page 16: ...ensor only for version K4G2HXXXX 3 HSW exchanger only for version K4G2HXXXX 4 gas valve 5 siphon 6 safety valve 7 circulation pump 8 gas supply pipe 9 bleeder valve 10 boiler electronics 11 burner plate 12 heating water temperature sensor 13 mixer 14 safety thermostat 15 combination electrode 16 boiler frame 17 exchanger 18 fan 19 expansion tank 20 pressure gauge 21 boiler front cover ...

Page 17: ...ee way valve 9 flow type water heater 10 input of water to the flow type water heater 11 output of water from the flow type water heater 12 pressure relief valve Fig 6 VIADRUS K4G2HXXXX with a flow type heater hydraulic diagram of the version and the sketch of the hydro block 1 condensing exchanger 2 input of return water to the exchanger 3 pump 4 input of return water to the pump 5 heating system...

Page 18: ...ion The boiler can only be commissioned by organizations that are authorized and trained for this purpose by the manufacturer The installation shall comply with the regulations that are applicable for this equipment The boiler shall be compatible with the local connecting conditions checking the parameters of the boiler with the information on the name plate During the first start of operation of ...

Page 19: ...es OFF mode heat demands are ignored except for CH and DHW frost protection calling STAND BY CH mode DHW mode TEST or INSTALLER MODE option for the installer to test and set boiler parameters ERROR FAULT conditions like high temperature lockout sensor fault etc The priority of operating modes is fixed as follows 1 Error fault mode 2 Test or Installer mode 3 DHW mode 4 CH mode 5 Stand by mode 6 OFF...

Page 20: ...hen K6 or K7 is operated the LCD displays the temperature setting in 1 C steps in flashing mode 5 sec since last acting on K6 or K7 has been made LCD come back to the previous display condition Burner ignition In case of valid heat demand request ignition sequence will be started In case of failed ignition controller will try to reignite for a defined number of times At the first ignition trial th...

Page 21: ...ations During a DHW heat demand the temperature value read by the supply sensor is continuously monitored 5 3 Lockout condition codes Lockout condition is given with the capital E error on the status display and error code on the temperature display Symbols or are being shown only in case of lockout condition which needs to be solved by Service people Error code Description E01 Ignition Lockout in...

Page 22: ...me 4 minutes or the HD is removed 5 4 Blocking codes Temporary blocking condition is given with the capital F on the status display and error code on the temperature display The boiler controller recognizes also the fault situations that can block the heat demands but do not lead to lockout condition When the error condition becomes resolved error will disappear but will be also written into the h...

Page 23: ...rt circuit or open circuit If NTC sensor goes outside the range 5 125 C and this condition lasts for more than 3 seconds error will be generated In case sensor is back to the normal operating range error is gone In error mode heat demands will be disabled In case 2 or more sensors are broken controller will pick up the first that was outside the operating range Resolving situation can be achieved ...

Page 24: ...tomatically leaves this mode after 2 minutes 5 7 2 In as Inquiry mode Selecting In the display starts with showing i00 By means of the K6 and K7 push buttons is possible to select the parameters Selecting one of these parameters by means of the K1 and K2 push buttons is possible to see his value not flashing only in case of negative outdoor temperature the value is flashing i00 Supply sensor Tempe...

Page 25: ...mation By pressing the K5 push button for 5 seconds longer is possible to reset all the History information to confirm that the system automatically leave the Installer mode 6 Maintenance Before cleaning always turn off the equipment The plastic cover of the product does not require any extensive maintenance The cover of the boiler can be wiped off by a dry cloth or by a cloth dipped in a detergen...

Page 26: ... boilers with flue gas exhaust into the surrounding environment through the peripheral external wall of the building it is necessary to check whether the condensed water from flue gas in the exhaust basket does not freeze in a frosty weather The boiler is fed with 230 V 50 Hz electric power supply While checking the tightness of the gas distribution and the valve connection it is necessary to be c...

Page 27: ...cing organization authorized by the manufacturer i e by VIADRUS a s The contacted servicing organization is obliged to record and document all records on the implemented warranty and after warranty repairs and on the execution of the regular annual inspections of the boiler in the annexure to the warranty sheet in this manual Each defect shall be reported immediately after its detection always by ...

Page 28: ...d cabins with sauna stoves ČSN 33 2130 ed 2 Low voltage electrical installations Internal electric distribution lines ČSN 33 2180 Electrical regulations Connection of electric instruments and appliances ČSN 34 0350 ed 2 Safety requirements for flexibile cords and cables EN 60079 10 1 Explosive atmospheres Part 10 1 Classification of areas Explosive gas atmospheres EN 60079 14 ed 3 Explosive atmosp...

Page 29: ... of materials with individual degrees of flammability and information of the flammability degree of common building materials if necessary for appliances which can be operated in the immediate vicinity of walls made of flammable materials will be defined with the maximum permissible temperatures of surface or wall temperature increase according to ČSN EN 13 501 1 A1 Tab 6 Grade of reaction to fire...

Page 30: ...due to the use of condensation The condensing boiler can also be used for old gravitational systems that usually were overdesigned and thanks to this fact condensation can be efficiently used even for this system but it is necessary to expand this system with a corresponding expansion tank Condensing boilers are equipped with a modulating pump Wilo Connecting to the DHW heating system and to the g...

Page 31: ...of the heating system shall be equipped with a drain valve 10 5 Gas Connection Prior to connecting the gas pipeline to the boiler the gas pipeline shall be tested and subjected to revision inspection After connecting the boiler to gas pipeline all gas connections shall be tested again by means of a detector or foaming solution The input pressure of natural gas shall correspond to the value in tabl...

Page 32: ...combination electrode sensor TV option K4G2 NORDGAS TPO2BHIREV Option K4G1 pump Wilo connector pressure gauge sensor Lumberg Option K4G2 pump Wilo connector pressure gauge sensor Lumberg flow switch 2 x 6 3 three way valve 3 x 6 3 exchanger 14 plates K4GXH24XX exchanger 18 plates K4GXH33XX Option K4G3 pump Wilo connector pressure gauge sensor Lumberg three way valve 3 x 6 3 gas valve Honeywell VK8...

Page 33: ...VIADRUS K4G2HXXXX with through flow heater Connection of the connection terminal of the boiler without a parent control boiler standard supply Room thermostat connection Parent control connection controller with communication OPENTHERM X201 2 X201 2 X201 2 Fig 18 VIADRUS K4G3HXXXX in the boiler option Connection of the connection terminal of the boiler without a parent control boiler standard supp...

Page 34: ...CHANGER THERMAL FUSE BTr ROOM THERMOSTAT MV1 FAN PS1 WATER PRESSURE SENSOR P2 HW FLOW SENSOR Q1 PUMP Y100 GAS VALVE LEGEND A1 CONTROL BOARD WITH LCD SCREEN A6 ROOM INSTRUMENT OPENTHERM B2 HEATING WATER SENSOR B3 HOT WATER SENSOR B7 RETURN WATER SENSOR B8 FLUE GAS SENSOR B9 EXTERNAL SENSOR ...

Page 35: ...ating water sensor 15 DHW sensor 16 Water pressure sensor 17 Water flow sensor 18 Gas valve 22 Upper storage tank sensor 28 Connector for connecting the boiler 8 poles 29 Internal bonding connector 6 poles 30 Internal bonding connector 2 poles Fig 21 Boiler electrical equipment wiring diagram extra low voltage bk black bu blue bn brown rd red wh white vt purple og orange ye yellow gn green gnye gr...

Page 36: ... brown gnye green yellow LEGEND A1 CONTROL BOARD WITH LCD SCREEN IOP IGNITION AND IONIZATION ELECTRODE MV1 FAN Q1 PUMP Y100 GAS VALVE Y3 THREE WAY VALVE X60 MV1 fan power connector X61 Q1 pump power connector X101 Euro connector the boiler power supply X110 bonding connector ...

Page 37: ...screen 3 Fan 4 Pump 5 Three way valve 6 Ignition and Ionization electrode 7 External sensor 18 Gas valve 24 Euro connector the boiler power supply bk black bu blue bn brown gnye green yellow Fig 23 Boiler electrical equipment wiring diagram low voltage ...

Page 38: ...ted inside a square with a side of 50 cm The wind protection equipment can be placed on the wall and or the roof depending on the installation Version C3 A boiler in version C whose ducting is connected to the protection inlet installed vertically Terminal outlets of these ducts are either concentric or they are located so close one to the other that they are subject to the same climatic condition...

Page 39: ...g 26 11 3 STARR D80 and FLEX 80 system connection Fig 27 1 reducing insert 2 transition piece 3 flue gas exhaust measuring piece 4 air intake pipe In case of using the flue gas exhaust with the diameter of 60 100 mm it is necessary to use reducing insert of the exchanger In case of using the flue gas exhaust with the diameter of 80 125 mm this insert must be removed from the exchanger ...

Page 40: ...e with socket Inspection T piece Inspection door Pipe with socket Foot elbow starr 87 with anchoring LIB pipe piece with flange Inspection T piece Pipe with socket Inspection T piece with drainage Elbow 45 Inspection T piece with change of direction Inspection elbow 87 Boiler reducing piece centric Inspection T piece with drainage and change of direction Long John siphon for overpressure ...

Page 41: ...capital flex complete set Plastic chimney capital starr complete set Universal distance clamp Inspection door Ventilation grill Inspection T piece flex starr Inspection T piece flex flex Flexible pipe Adapter starr flex Foot elbow starr 87 with anchoring Inspection T piece with drainage and change of direction flex Long John siphon for overpressure Adaptor starr flex 87 ...

Page 42: ...m for connection to the VIADRUS boiler the outside air supply pipe shall be by 35 mm shorter than the flue gas removal pipe It is necessary to ensure a gap of 10 15 mm between the exchanger and the air supply pipe to ensure air supply to the boiler In case that a fume pipe with the diameter of 60 100 mm is used it is necessary to use the adapter of the exchanger In case that a fume pipe with the d...

Page 43: ...capital starr complete set LIK pipe piece with flange Adjustable LIK pipe piece with clamp LIL wall clamp LIK inspection T piece with measuring opening LIK inspection T piece with drainage LIK elbow 45 LIK inspection T piece with change of direction and measuring opening LIK elbow 87 LIK elbow 87 short LIK inspection elbow 87 with measuring opening LIK pipe with socket LIK measuring piece with 2 m...

Page 44: ...36 LPASK8 80 125 LIK tube piece for façade chimney flue 3 5 5 4 20225 DPDS48 80 125 Roof extension a set 9 1 14 0 20169 FVIA01 60 100 80 125 LIK boiler reducer 2 3 2 12 Commissioning The entire installation shall comply with the regulations that are applicable for this equipment The boiler shall be compatible with the local connecting conditions checking the parameters of the boiler with the infor...

Page 45: ...iler electronics from water leakage Loosen a screw at the valve If the system is being breathed air starts coming out from the exchanger At the moment when water starts coming out the exchanger is deaerated So the screw might be retightenend Repeat this procedure several times until the system is completely deaerated Automatic pump bleeder valve may remain permanently open The minimum water pressu...

Page 46: ...tion By pressing K1 and K2 push button for 10 seconds is possible to enter the chimney sweeper function After 10 s to be displayed fan speed x10 Can adjust burning at maximum performance Operate K2 decrease and K1 increase pushbuttons to adjust fan speed By long pressing K2 push button the fan speed slows down to a minimum x10 Can adjust burning at minimum performance Operate K2 decrease and K1 in...

Page 47: ...ropane diaphragm diameter 4 3 mm Note 3 Sealing Note 5 Gas valve Software for propane fuel must be downloaded 12 4 Boiler Electronics Setting Setting parameters The product meets the values for Environment Friendly Product Note The actual values measured depend on the type of connection of the combustion air supply and flue gas removal for the given appliance Checking the boiler parameters setting...

Page 48: ...20 C x x x x x x P16 Solar disable temperature 5 20 C x x x x x x P17 Solar pump min running time 0 120 sec x x x x x x P18 Solar limit temperature 100 150 C x x x x x x P19 Solar storage tank limit temperature 50 100 C x x x x x x P20 Solar mode functionality 0 0 solar priority num x x x x x x 1 parallel P21 Heat demand delay after Solar pump activation 0 60 sec x x x x x x P22 Delta for virtual ...

Page 49: ...20 C x x x x x x P16 Solar disable temperature 5 20 C x x x x x x P17 Solar pump min running time 0 120 sec x x x x x x P18 Solar limit temperature 100 150 C x x x x x x P19 Solar storage tank limit temperature 50 100 C x x x x x x P20 Solar mode functionality 0 0 solar priority num x x x x x x 1 parallel P21 Heat demand delay after Solar pump activation 0 60 sec x x x x x x P22 Delta for virtual ...

Page 50: ...ions Main points of the inspection Check of liquids leakage from boiler s joints Check of pressure in the expansion tank Check of the adjustment of CO2 of the gas valve emission should be performed 1 x per year Disassembling of the burner and check of exchanger and electrodes state Check of siphon clogging for condensate discharge Bleeding of the exchanger Check of chimney flue Attention Before yo...

Page 51: ...l packaging unit EN 13429 NO 3 1 Recovery by material recycling ensure recyclability in all terms of the standard for the functional packaging unit EN 13430 YES 3 2 Recovery in the form of energy ensure that calorific gain is achievable for the functional packaging unit EN 13431 YES Iron NO 3 3 Recovery by composting ensure compost ability in all terms of the standard for the functional packaging ...

Page 52: ...Servicing 52 ...

Page 53: ...tificate for the Customer User A record of warranty and after warranty repairs and regular annual product inspections performed Date of entry Activity performed Contracted service organization signature stamp Customer s signature ...

Page 54: ......

Page 55: ......

Page 56: ...VIADRUS K4 VIADRUS a s Bezručova 300 CZ 735 81 Bohumín E mail info viadrus cz www viadrus cz ...

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