HERCULES U 32 Manual for boiler operation and installation

Transcription

1 HERCULES U 32 Manual for boiler operation and installation GB_2017_20 GB_2015_46

2 Content p. 1 Boiler Use and Advantages Technical parameters of the boiler Description Boiler Construction Regulation and safety elements Device for removing excess heat Equipment for heat exhausting accumulating reservoir Location and installation Regulations and guidelines Placement options Delivery and installation Delivery and accessories Installation procedure Installation of boiler drum Installation of boiler drum after-cooling loop Installing the boiler drum two-way safety valve DBV Location of the assembly of ceramic inserts, the secondary air nozzle, the inclined grate (fig. no. 15) Shell installation Draught regulator Cleaning tool mounting Filling the heating system with water Putting into operation instructions for contractual service organization Verification activities before start-up Putting into operation Boiler operation by user Firing Operation Maintenance IMPORTANT NOTICE Instructions for the product disposal after its useful life period Warranty and liability for defects Product fiche... 20

3 Dear Customer, Thank you for purchasing a universal boiler HERCULES U 32 and thus showing your confidence in the company VIADRUS a.s. For the correct way of handling your new boiler, please read the instructions for its use, especially the Chap. no. 7. Boiler operation by user, the Chap. no. 8 - Maintenance and the Chap. No. 9 - Important warnings. Please follow further information, ensuring trouble-free boiler operation to both your and our satisfaction. The boiler HERCULES U 32 is cast-iron sectional gasification boiler designed to burn: HERCULES U32 D HERCULES U32 B HERCULES U32 fuel: hard wood fuel: lignite fuel: hard coal Burning of other materials (e.g. plastic) is forbidden. 1 Boiler Use and Advantages The boiler HERCULES U 32 meets the requirements for heating of houses, shops, etc. The boiler is manufactured as hot water boiler with natural and forced circulation of hot water and working overpressure up to 400 kpa (4 bar). Before dispatch it is checked for tightness with the test pressure of 800 kpa (8 bar). The boiler is designed for heating in both closed and open heating systems. The Boiler Advantages: 1. High service life of cast iron exchanger and all other parts due to the quality of the materials used. 2. Long-term proven design. 3. Sophisticated manufacturing technology on the automatic forming lines with consistent and approved quality of the production process (ISO 9001, ISO ). 4. Combustion efficiency 86,5-90 %. 5. Low fuel consumption. 6. Simple operation and maintenance. 2 Technical parameters of the boiler Tab.. 1 Dimensions and technical parameters of the boiler Number of sections Combustion chamber volume dm Water content l 40,5 46,5 52,5 Weight kg Combustion chamber depth mm Flue socket diameter mm Boiler dimensions: height x width mm 1240 x x x683 depth L mm Filling hole dimensions mm 310x x x 236 Maximum water operating pressure kpa (bar) 400 (4) 400 (4) 400 (4) Minimum water operating pressure kpa (bar) 50 (0,5) 50 (0,5) 50 (0,5) Test water overpressure kpa (bar) 800 (8) 800 (8) 800 (8) Hydraulic loss - see Fig. 1 see Fig. 1 see Fig. 1 Input water minimum temperature C Heating water recommended operating C temperature Noise level db < 65 < 65 < 65 Boiler connections: heating water return water Temperature of cooling water for the device for removing excess heat C Overpressure of cooling water for the device for removing excess heat kpa (bar) (2-6) (2-6) (2-6) Tab.. 2 HERCULES U32 D technical parameters - fuel: hard wood fuel moisture max. 20 % calorific power: MJ. kg -1 Number of sections Boiler class in accordance with EN Rated power kw Fuel consumption kg/h 3,7 4,8 5,5 Max. fuel mass in the filling chamber kg Flue gas temperature at rated output C Flue gas mass flow at rated power kg/sec 0,01 0,0137 0,015 Chimney draught mbar 0,18 0,20 0,22 Burning time hours min. 2 min. 2 min. 2 Efficiency % 88,9 88,3 88,0 Energy efficiency class A+ A+ A+ Energy efficiency index Season energy efficiency %

4 Tab.. 3 Recommended dimensions of wood blocks Block diameter mm Ø 40 to 120 Block length mm 350 Tab.. 4 HERCULES U32 B technical parameters - fuel: lignite grain size mm, fuel moisture max. 15 % calorific power: MJ.kg -1 Number of sections Boiler class in accordance with EN Rated power kw Fuel consumption kg/h 2,3 3,2 3,5 Max. fuel mass in the filling chamber kg Flue gas temperature at rated output C Flue gas mass flow at rated power kg/sec 0,008 0,0112 0,0123 Chimney draught mbar 0,18 0,23 0,25 Burning time hours min. 4 min. 4 min. 4 Efficiency % 89,9 86,5 90,1 Energy efficiency class B C B Energy efficiency index Season energy efficiency % Tab.. 5 HERCULES U32 technical parameters - fuel: hard coal grain size mm, fuel moisture max. 15 % calorific power: MJ.kg -1 Number of sections Boiler class in accordance with EN Rated power kw Fuel consumption kg/h 2,1 3,1 3,5 Max. fuel mass in the filling chamber kg Flue gas temperature at rated output C Flue gas mass flow at rated power kg/sec 0,008 0,0127 0,0133 Chimney draught mbar 0,18 0,23 0,25 Burning time hours min. 4 min. 4 min. 4 Efficiency % 89,6 88,6 89,4 Energy efficiency class C C C Energy efficiency index Season energy efficiency % pz (Pa) ,5 1 1,5 2 2,5 3 3,5 Qz (10-3 m 3.s -1 ) Fig.. 1 Hydraulic loss of the boiler drum 4

5 Number of sections Lenght A mm Lenght B mm Fig.. 2 Connection dimensions of boiler HERCULES U 32 3 Description 3.1 Boiler Construction The main part of the boiler is cast iron sectional boiler drum made of grey cast iron according to EN 1561, quality 150. Pressure parts of boiler correspond to strength requirements according to EN The boiler drum is assembled of sections by means of pressed boiler inserts with 56 mm diameter and secured by anchor bolts. Sections create the feed space, combustion and ash space, water space and convective part of the boiler. Input and output of heating water is located in the rear of the boiler. Rear boiler section has the smoke adapter and heating water flange at its top, and the return water flange at the bottom. The stoking and ash door are mounted to the front section. Inclined grate is placed to the filling space. The whole boiler drum is insulated by using a harmless mineral insulation which reduces losses by sharing heat into the surroundings. The high-quality komaxit spray is used for boiler shell colour treatment. 1. Front section 2. Middle section 3. Penultimate section 4. Rear section 5. Ash door 6. Stoking door 7. Ash door choker 8. Stoking door choker 9. Rear choker 10. Smoke adapter 11. Shell Fig.. 3 Main part of the boiler 5

6 3.2 Regulation and safety elements Stoking door choker regulates the supply of primary combustion air above the fuel. It is operated by the draught regulator or manually by the setting screw of the choker. The ash door choker regulates the supply of secondary combustion air under the boiler grate. It is operated manually by the setting screw of the choker. For the tertiary air inlet, the choker in the lower rear part of the boiler is used. It is controlled with help of an adjusting screw, but it is adjusted to the ideal position in the production plant. For detecting the heating water temperature and water pressure in the heating system, the associated device - thermomanometer is used. Thermomanometer sensor well is located in the upper part of the front boiler section. 1. Upper ceramic liner 2. Locking pin for the upper lining 3. Hole for the locking pin 4. Lower ceramic liner 5. Middle ceramic liner - rear part 6. Tertiary air inlet nozzle 7. Middle ceramic liner - front part 8. Inclined grate 9. Tertiary air choker 10. Secondary air choker 11. Primary air choker 12. Shorting flap Fig.. 4 Assembly of the boiler HERCULES U Device for removing excess heat After-cooling loop or two-way safety valve DBV 1-02 serve to remove excess heat in the event that the water temperature in the boiler exceeds 95 C. After-cooling loop is connected to the flange of the boiler according to Fig. 5, two-way safety valve according to Fig. 7). In case of the boiler overheating (outlet water temperature is higher than 95 C), thermostatic valve switches and the excess heat is removed by the after-cooling loop. 1. Heating water outlet into the system 2 2. Return water inlet from the after-cooling loop 1 1/2 3. Return water inlet to the boiler from the system 2 4. Cooling water outlet 5. Thermostatic valve TS 130 (STS 20) 6. Heating water outlet from the boiler 2 7. Cooling water inlet Fig.. 5 Hydraulic diagram of after- cooling loop connection If the system is equipped with the two-way safety valve DBV 1-02 and the boiler becomes overheated (outlet water temperature is higher than 95 C), the two-way safety valve creates cold water circuit until the time the temperature drops below the limit temperature. At this moment, the discharge cooling equipment and the cold water inlet for the system refilling are simultaneously closed. 6

7 A - cold water inlet B - output to the boiler C - output to the drain D - input from the boiler Fig.. 6 Two way safety valve DBV 1-02 In the system, it is necessary to install a safety valve with max. overpressure of 400 kpa (4 bar), which dimensions must correspond to the boiler nominal output. The safety valve must be installed immediately behind the boiler. Shut-off valve must be installed between the safety valve and the boiler. For further questions please contact our contractual installation companies and service organizations. Specifications of the two-way safety valve DBV 1-02 (from Regulus) Opening temperature (limit): 100 C (+0-5 C) Maximum temperature: 120 C Maximum pressure on the boiler side: 400 kpa (4 bar) The maximum pressure on the water side: 600 kpa (6 bar) Nominal flow at p 100 kpa (1 bar): 1.9 m 3 /h Use Two-way safety valve DBV 1-02 is designed for central heating boilers protection against overheating. In the valve drum, the discharge and refill valves are controlled by thermostatic element. When achieving the limit temperature the discharge and refill valve open simultaneously, which means that cold water flows into the boiler while hot water is drained from the boiler. When the temperature drops below the limit, the discharge and filling valves are closed simultaneously. ATTENTION! Do not replace the safety valve. In case of reaction of the two-way safety valve, when there could be refilled water that does not conform to CSN , it is necessary to adjust water in the system so that it again conforms to this standard. 1. Boiler 2. Two-way safety valve DBV Safety valve 4. Reducing valve 5. Filter 6. Ball valve 7. Pump 8. Excess heat removal 9. Discharge valve I Cold water inlet II Heating water outlet III Return water inlet Fig.. 7 Recommended diagram of the two-way safety valve DBV 1-02 connection Installation Installation may only be performed by a qualified person. For proper operation of the thermostatic two-way safety valve it is necessary to comply with the prescribed conditions for its installation and respect the flow directions indicated on its body. The safety valve is always mounted in the output pipe of the boiler or directly on the boiler in its upper part where the heated water leaves boiler and is transported into the heating system. When installing the valve, it is necessary to check whether the use of the 3/4 socket, which can be both in the pipeline and on the boiler, ensures complete immersion of the valve thermostatic element after the valve installation. After mounting into the socket, at the point "C" (Fig. 6), the discharge pipe is connected through which the hot water from the boiler will flow to drain. At the point "A" (Fig. 6), the supply of cooling water is connected (Fig. 7), which ensures cooling the boiler down after the valve putting into operation. At the cooling water inlet, a filter to remove mechanical impurities must be installed. At the point "B" (Fig. 6) there is connected the pipeline, which according to Fig. 7 leads to the return line of the heating system near the boiler. Regular maintenance 1x per year, turn the safety valve head to remove possible contaminants seated in it. Clean the filter at the cooling water inlet. In case of using an open expansion tank, the safety device against overheating is not necessary. Every heat source in an open heating system must be connected with the open expansion tank positioned located at the highest point of the heating system. The expansion tanks must be designed to accommodate changes in water volume resulting from heating and cooling. The open expansion tanks must be equipped with non-closable vent and overflow pipes. The overflow pipe must be designed to safely drain the maximum flow volume entering the system. This can be achieved by rating the overflow pipes by one DN higher than the filling pipe. The expansion tanks and their connecting pipes must be designed and positioned so as to reliably prevent them from freezing. 7

8 1. Heat source 2. Expansion tank 3. Safety valve 4. Expansion pipe 5. Overflow pipe 6. Filling pipe 7. Water level limiter 8. Return pipe Fig.. 8 Examples of the open expansion tanks connection 3.4 Equipment for heat exhausting accumulating reservoir The boiler has to be operated with an accumulating reservoir. Calculation of the smallest capacity of the accumulating heat exchanger, where: V sp accumulating reservoir capacity in liters Q N nominal heat power in kw combustion time in hours T b V sp = 15T b x Q N (1-0,3 x (Q H/Q min)) Q H Q min buildings heat load in kw smallest heat power in kw The sizes of the accumulating reservoir have to be determined on the basis of the boiler power and the used fuel. The biggest capacity has to taken into consideration, whereas the minimum used capacity of the reservoir has to be 300 l. In case that the reservoir is fully charged, it is necessary to shut down the boiler and heat up by heat from the accumulating reservoir. After the heat is spent in the reservoir, put the boiler into operation again. The accumulating reservoir enables provision of heat comfort and at the same time the boiler operation. ATTENTION! Failure of it will cause extreme pollution of the boiler drum. Hydraulic schemes of the boilers with an accumulating reservoir are at disposal in the project materials of Viadrus at 4 Location and installation 4.1 Regulations and guidelines The solid fuel boiler may be installed by a company holding a valid certification for its installation and maintenance. For the installation, a project must be elaborated in accordance with applicable regulations. Before the boiler installation to an older heating system, the installation company must flush (clean) the whole system. The heating system must be filled with water that meets the requirements of CSN and especially its hardness must not exceed the required parameters. Tab.. 6 Recommended values Hardness mmol/l 1 Ca 2+ mmol/l 0.3 concentration of total Fe + Mn mg/l (0.3)* *) recommended value ATTENTION!!! The manufacturer does not recommend to use antifreeze. In case of reaction of the two-way safety valve, when there could be refilled water that does not conform to CSN , it is necessary to adjust water in the system so that it again conforms to this standard. a) to the heating system CSN CSN CSN EN b) on the chimney CSN Heating systems in buildings Design and installation. Heating systems in buildings Safety devices. Water and steam for thermal energy equipments with working pressure up to 8 MPa. Boilers for central heating Part 5: Boilers for central heating for solid fuels, manually and automatically stocked, with nominal heat output of up to 500 kw Terminology, requirements, testing and marking. Chimneys and flues Design, implementation and connection of fuel consumers. c) regarding the fire regulations CSN Fire safety of heat installations. EN A1 Fire classification of construction products and building structures Part 1: Classification using data from reaction to fire tests. d) to the system for the HW heating CSN Heating systems in buildings - Hot water preparation - Design and projection. CSN Heating systems in buildings Safety devices. CSN Internal water piping. 8

9 4.2 Placement options Placement of the boilers in living areas (including halls) is prohibited! Steady supply of air for combustion and ventilation must be ensured to the room where the boiler is installed. When installing and using the boiler, all requirements of CSN must be complied with. Boilers in the central heating system have to be connected to a separate venting unit. The chimney with a correct draught is the basic presumption for correct function of the boiler. It influence both the boiler power and its effectiveness. A flue-gas ducting from the boiler to the venting unit has to be as short as possible, preferably without elbows with a slope from the boiler upwards. The chimney has to have a prescribed draught (according to the boiler size see the manual). It has to be well-tightened and insulated to avoid condensation of water vapor and tar. Placement of the boiler regarding the fire regulations: When installing the boiler, we recommend to use original cast iron basement (see Fig. 10) supplied by the manufacturer. When installing the boiler without the basement, it is necessary to comply with the conditions set out in the point Placement on the floor made of incombustible material (Fig. 9): place the boiler on a fireproof base exceeding the boiler dimensions only by the boiler drum depth and on the sides by 20 mm; if the boiler is installed in a cellar, we recommend to install it on a substructure at least 50 mm high; the boiler must be placed in the centre of the basement. 2. 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 with combustibility grade A1, A2, B and C (D); for easily flammable materials with combustibility grade 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, that is 400 mm; the safe distance is to be doubled also when the fire reaction class is not proven. Number of sections Lenght L mm Fig.. 9 Substructure dimensions Fig.. 10 Cast iron basement of the boiler Tab.. 7 Fire reaction class Fire reaction class Examples of building materials and products classified to the fire reaction class (a choice from EN A1) A1 incombustible granite, sandstone, concrete, bricks, ceramic tiles, mortars, fire plasters,... A2 combustible with difficulty acumin, izumin, heraklith, lignos, boards and basalt felt, fibreglass boards,... B hardly combustible beech and oak wood, hobrex boards, plywood, werzalit, gypsum plasterboard, sirkolit,... C (D) medium combustible pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,... E (F) easily combustible asphalt board, fibreboards, cellulose materials, polyurethane, polystyrene, polyethylene, PVC, Boiler positioning with regard to the necessary handling space: basic environment AA5/AB5 according to ČSN ed. 2; min mm handling space must be left in front of the boiler; minimum distance between the boiler rear side and wall is 400 mm; at least from one side part, keep the access area to the rear boiler part of 400 mm. Placing of fuel: dry fuel has to be used in order to ensure its proper burning in the boiler. Fuel stored in cellar or at least sheltered is recommended by the manufacturer; it is prohibited to store the fuel behind the boiler or next to the boiler in the distance shorter than 400 mm; it is prohibited to store the fuel between two boilers in the boiler room; the manufacturer recommends to keep the distance between the boiler and the fuel min mm or store the fuel in a different room than the boiler is installed. Fig.. 11 Boilers positioning in boiler room 9

10 5 Delivery and installation 5.1 Delivery and accessories The boiler is supplied according to the order so that the complete boiler drum is placed on the palette. The boiler shell is packed separately. Accessories are stored inside the boiler drum, accessible by opening the stoking door. The boiler is packed in a shipping container and must not be tilted during transport. Standard boiler delivery: Boiler on the palette - heating water flange with thread 2 pc - return water flange with a distribution pipe 1 pc - only for 7 sect. version - sealing φ 90 x 60 x 3 2 pc - washer pc - nut M10 8 pc - fill and drain tap Js 1/2 1 pc - complete draught regulator 1 pc - blind plug Js 6/4 1 pc - sealing φ 60 x 48 x 2 1 pc - capillary spring 1 pc - wave spring 1 pc lining of the combustion changer - lower ceramic liner (box 4) 1 pc - middle ceramic liner - rear part (box 3) 1 pc - middle ceramic liner - front part (box 5) 1 pc - upper ceramic liner (box 6) 1 pc - tertiary air inlet nozzle (box 2) 1 pc pin for the upper lining or Allen wrench 4 1 pc inclined grate 1 pc shell including insulation and ash-pan - reduced bracket 2 pc - washer pc - nut M10 4 pc - spring clamp 4 pc - screw M5 x pc - connecting pin 4 pc - thermomanometer 1 pc - screw M8 x 12 4 pc cleaning tools - hook 1 pc - brush with handle 1pc - spike 1 pc - cleaning tool holder 1pc handling key 1pc refractory adhesive 50 ml to back the nozzle 1pc sales and technical documentation Additional equipment (not included into the delivery): Cast iron boiler basement 5 sections (ord. code 17659) Cast iron boiler basement 6 sections (ord. code 17751) Cast iron boiler basement 7 sections (ord. code 18569) Necessary accessories (not included into the delivery): After-cooling loop (1 pc) inlc. the flange of the two-way safety valve DBV 1-02 incl. siseal (10 g). This equipment may not be used in case of open heating system. Thermostatic valve TS 130 (STS 20) TV 95 C can be bought in warehouses (only in case of delivery with the after-cooling loop) Safety valve 1 pc At the customer's request (not included into the delivery): Filter 3/4 (for the boiler with the two-way safety valve DBV 1-02) The boiler equipment ordered as "additional equipment, necessary accessories and at the customer's request" is not included in the basic price of the boiler. 5.2 Installation procedure Installation of boiler drum Installation of boiler drum after-cooling loop 1. Set the boiler drum on the basement or substructure. 2. Pre-weld the heating water flange of the after-cooling loop on the after-cooling loop weldment (according to the boiler room dispositions), insert the seating Ø 90 x 60 x 3 between the flange and the boiler, then mount the weldment by means of 4 nuts M 10 and 4 washers 10.5 to the boiler. Connect the upper heating water outlet and the heating system by welding. 3. Connect the lower outlet from the after-cooling loop to the boiler by welding the 1 1/2 pipe to the outlet of the return water (return water flange). 10

11 Mount the thermostatic valve on one of the outlets of the after-cooling loop (mount the sensor into the well and connect to the cold water inlet 1/2 ). Pay attention to the indication of the direction of water flow by the arrow, it must be identical to the Fig. 5. Connect the second 1/2 outlet of the after-cooling loop with the drain (note: for checking the function of the thermostatic valve, we recommend connecting of the water outlet to the drain by means of a funnel). After the boiler connection to the heating system, screw the discharge valve to the boiler according to Fig. 12. Put the smoke pipe to the smoke adapter and insert into chimney hole. Smoke pipe diameter is 160 mm. Screw the draught regulator into the hole in the upper part of the front section. The procedure of the draft regulator setting is shown in the manual, which is attached to the regulator. Blind the threaded hole JS 6/4 in the front section with the plug JS 6/4. Place the sealing Ø 60 x 48 x 2 under the plug. It is recommended to use shut-off valves at the inlet and outlet of heating water, because without these valves it well be necessary to drain the entire system during cleaning Installing the boiler drum two-way safety valve DBV 1-02 Set the boiler drum on the basement or substructure. Insert the sealing Ø 90 x 60 x 3 between the heating water flange and the boiler, then mount it by means of 4 nuts M 10 and 4 washers 10.5 to the boiler (according to the boiler room dispositions). Connect the heating water outlet and the heating system by welding. Insert the sealing Ø 90 x 60 x 3 between the return water flange and the boiler, then mount it by means of 4 nuts M 10 and 4 washers 10.5 to the boiler. Connect the lower return water outlet and the heating system by welding. According to the Fig. 7, connect the two-way safety valve DBV 1 02 with the return water flange, heating water flange and with the cooling water inlet and excess heat outlet. Mount the discharge valve to the return water flange. Put the smoke pipe to the smoke adapter and insert into chimney hole. Smoke pipe diameter is 160 mm. Screw the draught regulator into the hole in the upper part of the front section. The procedure of the draft regulator setting is shown in the manual, which is attached to the regulator. Blind the threaded hole JS 6/4 in the front section with the plug JS 6/4. Place the sealing Ø 60 x 48 x 2 under the plug. It is recommended to use shut-off valves at the inlet and outlet of heating water, because without these valves it well be necessary to drain the entire system during cleaning Fig Sealing φ 90 x 60 x 3 Heating water flange, in version with 7 sections is the bottom backward flange with a distribution tube Washer 10.5 Nut M10 Fill and drain tap Safety valve (not included into the standard delivery) The two-way safety valve DBV 1-02 (not included into the standard delivery) Installation of boiler drum Location of the assembly of ceramic inserts, the secondary air nozzle, the inclined grate (fig. no. 15) Insert the upper ceramic insert (1) (by raised portion in a triangular shape toward the stoking door, see fig.) into the upper part of the combustion chamber and fix its location by inserting a locking pin (2) into the hole (3). Place the lower ceramic insert (4) into the lower part of the combustion chamber and put the rear part of the middle ceramic insert (5) on it. Fig Apply refractory glue (hairpin 3-4 mm) on the lower part of the tertiary air inlet nozzle (6) and place the nozzle upright into the circular hole of the lower ceramic insert (4). 11

12 Fig Close the combustion chamber by inserting the front part of the middle ceramic insert (7). 5. By slow movement, pull the locking pin out and release the upper ceramic insert (1) which abuts the middle ceramic inserts (5, 7). 6. Into the fuel chamber, carefully insert the inclined grate (8) and rest its upper part on front section. 1. Upper ceramic liner 2. Locking pin 3. Hole for the locking pin 4. Lower ceramic liner 5. Middle ceramic liner - rear part 6. Tertiary air nozzle 7. Middle ceramic liner - front part 8. Inclined grate Fig.. 15 Placement of the ceramic inserts into the combustion chamber of the boiler HERCULES U Shell installation 1. Left side part of the shell 2. Right side part of the shell 3. Spring-type fixture 4. Screw M5 x Insulation of left side part of the shell 6. Insulation of right side part of the shell Fig.. 16 Side parts of the cladding 1. Remove the shell from the cardboard packaging. 2. Screw the front metal plate (2) by means of 4 screws M8 x 12 (1). 3. On the threads of the upper anchor bolts, mount 2 reduced brackets (1) and screw them using 4 nuts M10 (3) and 4 washers 10.5 (2) - (see Fig. 17). 4. According to figure No. 16, equip the left side part of the shell (1) with 2 pcs of the spring-type fixtures (3), screw-up 2 pcs of M5 x 12 (4) don t tighten, keep a gap of 1 2 mm and insert the insulation (5). According to picture No. 17, put the shell (1) onto the bottom anchoring bolt, and connect the upper part with the lowered brackets (3) with help of 2 pcs of screws of M5 x 12 (4). 5. According to figure No. 16, equip the right side part of the shell (2) equip the left side part of the shell (6). According to fig No. 17 put the 12

13 shell (2) onto the bottom anchoring bolt, and connect the upper part with the lowered brackets (3) with help of 2 pcs of screws of M5 x12 (4). 1. Left side part of the shell 2. Right side part of the shell 3. Reduced bracket 4. Screw M5 x Insulation of left side part of the shell 6. Insulation of right side part of the shell 7. Front steel-plate cover 8. Screw M8 x Washer Nut M10 Fig.. 17 Shell side parts mounting 6. According to the Fig. 18, mount 4 connecting pins (4) on the top part of the shell (6) and insert the thermomanometer (5). 7. Insert the thermometer sensor into the thermometer well (7) and screw the manometer sensor into the well for the manometer (8). 8. Insert insulation (3) to the upper part of the shell (6) and mount it to the side parts of the shell (1,2). 1. Right side part of the shell 2. Left side part of the shell 3. Insulation of the shell upper part 4. Connecting pin 5. Thermomanometer 6. Shell upper part 7. Thermometer well 8. Manometer well Fig.. 18 Shell upper part mounting 13

14 9. As shown on the Fig. 19, mount the rear part of the shell (3) onto 4 screws M5 x 12 between the side parts of the shell (1 and 2). 10. If necessary, screw the cleaning tool holder (5) to the left or right side part of the shell (1 and 2) by means of 2 screwsm5 x 12 (4). 1. Left side part of the shell 2. Right side part of the shell 3. Shell rear part 4. Screw M5 x Cleaning tool holder 6. Rear part insulation Fig.. 19 Installation of the rear part of the shell and the cleaning tools holder 1. Draught regulator 2. Draught regulator lever 3. Chain 4. Hinge pin Fig Draught regulator The procedure of the draft regulator setting is shown in the manual, which is attached to the regulator Cleaning tool mounting To mount or dismount the brush and tip for the spike (if included), use common assembly tools and leather gloves Filling the heating system with water Water hardness must correspond to CSN and it is essential, in case the water hardness does not comply, treat water in accordance with the Chap Heating systems with the open expansion tank allow direct contact of the heating water with atmosphere. During the heating season the water expanding in the tank absorbs oxygen, which increases the corrosive effects while there is a considerable evaporation of water. To refill, only water treated according to CSN may be used. The heating system must be thoroughly flushed in order to wash out all impurities. During the heating season it is necessary to keep a constant volume of water in the heating system. When refilling the heating system with water it must be ensured that no air is sucked into the system. Water from the boiler and the heating system must never be discharged or taken for usage except for the emergency cases like repairs etc. Water discharge and filling with new water increases the danger of corrosion and scale development. If it is necessary to refill water in the heating system, refill water only into the cold boiler in order to prevent cracking of the sections. After filling the boiler and the heating system, all connections tightness should be checked. When using the two-way safety valve DBV 1-02, the cooling water is refilled gradually into the return water. The assembly completion and heating test execution must be recorded in the "Warranty card". 14

15 6 Putting into operation instructions for contractual service organization Putting into operation can be performed only by specialized installation companies authorized to carry out this activity. 6.1 Verification activities before start-up Before the boiler commissioning it is necessary to check: 1. Filling the heating system with water (check thermomanometer) and tightness of the system. 2. Connection to the chimney this connection can be made only with the agreement of a chimney firm (chimney revision). In case the chimney doesn t comply with the requirements for minimum chimney draught, specified in tables No. 2, 4 and 5 (0,18 0,25 mbar depending of fuel type), we recommend using an exhaust electric fan. 3. Functionality of the draught regulator and the thermostatic valve. 6.2 Putting into operation 1. Fire the boiler. 2. Bring the boiler to the necessary operating temperature. The recommended output water temperature is 80 C. 3. Adjust the draught regulator including the chain length (according to the enclosed draught regulator manual). 4. Check the functionality of the safety equipment against overheating (after-cooling loop or two-way safety valve DBV 1-02). 5. Operate the boiler in operating condition according to relevant standards. 6. Check again the boiler tightness. 7. Familiarize users with the boiler operation. 8. Make a record to the warranty card. 7 Boiler operation by user Incorrect operation and improper combustion of fuel leads to damage to the product. During the first firing of the cold boiler, water condenses therein, which flows down the inner walls. The condensation of water on the boiler stops once the boiler reaches the operating temperature. When operating the boiler at the temperature lower than 60 C, water can condense on the boiler drum, that can lead to the so called low-temperature corrosion, which shortens the life of the boiler exchanger. Therefore we recommend to operate the boiler at 60 C and higher. LIGNITE The most suitable fuel is lignite with the grain size of mm. Burning time at rated output is 4 hours. HARD COAL The most suitable fuel is hard coal with the grain size of mm. Burning time at rated output is 4 hours. WOOD To achieve the rated output of the boiler, wood moisture content must be max. 20%. Fuel must be stored in a dry place. Tab.. 8 Recommended dimensions of wood blocks block diameter [mm] Ø 40 to 100 block length [mm] 350 Guarantee of the clean and good combustion is using only dry natural wood. Wood moisture content must be max. 20%. If the wood moisture content is higher than 20%, the boiler output declines. Damp wood burning releases water which condenses on the walls of the boiler and the chimney, this leads to an increased formation of tar and water vapour, which reduces the life of the heat exchanger. Furthermore, improper combustion causes corrosion of cast iron, the so called "metal dusting", which leads to carbon diffusion into the material, and thereby the degradation of the material to powder (dust). This process is gradual and prolonged. The flue gas stream with solid particles then causes abrasion or erosion of the material from the surface, which leads to gradual thinning of the section walls, and this may cause perforation of the boiler body. Fuel must be stored in a dry place. For heating, do not use plastics, household waste, chemically treated wood residues, waste paper, wood chips, brushwood, waste from pressed sheets of bark or chipboard. Follow the instructions for the boiler operation. When operating the boiler follow the recommended operating temperature. When operating the boiler, use only approved fuel. 15

16 7.1 Firing 1. Check the water volume in the heating system on the thermomanometer. 2. Open the shut-off valves between the boiler and the heating system. 3. Clean-up the space in the bottom part of the combustion chamber (the space in front of the nozzle),the fire grate, the ash-pan, flue-gas channels and the boiler walls. 4. Put cleft firewood on the bottom fire grate up to the high of the sloping fire grate to avoid closing the hole in the bottom part of the combustion chamber (fig. No.. 22). 5. Put a pale from kindling to these prepared firewood (as close as possible to the shortening tilting shutter). 6. Insert fire-ignitor onto the kindling and kindle it (fig. No. 21). You may also put some kindling onto the flame to ensure more intensive inflammation. Fig.. 21 Kindling from basis 7. With help of the control lever, open the shortening tilting shutter above the throttle valve of the stocking door (it will ensure withdrawal of flue gases through the shortening hole into the chimney; and as a result of it the chimney will be heated-up). 8. Adjust the upper throttle valve of primary air supply in the front part of the boiler into the maximum opening position. 9. Keep closed the bottom throttle valve of air supply under the fire grate, or adjust it into the position of the opening at the most of 1-2 mm. 10. Close the stocking door of the boiler and keep fire burning. 11. When flame starts disappear and only glow basis remains, open slowly the stocking door and add fuel as needed. 12. Leave the newly added fuel burn-up, close the shortening tilting shutter, and adjust the upper throttle valve of primary air supply with help of the regulator as needed. 13. In case of heating-up with pit-coal, adjust the set-screw of the bottom throttle valve of secondary air supply under the fuel by 2 to 3 mm. In case of heating-up with firewood and brown coal, keep closed the bottom throttle valve. From the reason of thermal features of cast-iron, the operation characteristics of the Hercules U32 boiler is different from boilers with a steel boiler body. Heating to the operation temperature lasts longer, but after the boilers are heated-up, they have higher thermal inertia. Fig.. 22 Firing in Hercules U32 boiler 16

17 I. primary air II. secondary air III. tertiary air Fig.. 23 Combustion air flow 7.2 Operation 1. After reaching the heating water temperature, adjust the combustion air supply. Output control is made by the choke on the stoking door which regulates the air supply over the fuel by means of the draft regulator or adjusting screw of the choker. The draught regulator has to be adjusted so as the choker of the stoking door is slightly closed at 3-4 mm at the moment the desired temperature of heating water is reached. 2. According to heat needs and burning intensity, it is necessary to refuel during the boiler operation. Hot layer suitable for adding the fuel is about 15 cm. Before adding the fuel, make manual cleaning - from below, through a hole in the lower part of the grate, and through the stoking door for firewood. Before refuelling, release the orifice of the hole in the bottom part of the lining of the combustion chamber so as to allow continuous fuel burning off. Max. fuel filling height is determined by the upper edge of the inclined grate. 3. Before refuelling, it is recommended to open the shorting flap located above the stoking door choker, and after refuelling, close it again. 4. The ash door must be permanently closed during the operation. 5. If necessary, clean the ash-pan (the gloves needed). 6. In case the shut-off valves are installed, the safety valve must be mounted between the boiler and the shut-off valve. 7. We recommend to clean the filter after the heat test and then before the heating season starting. 8 Maintenance 1. Check and if necessary remove ash from the ash-pan because full pan prevents the proper distribution of combustion air under the fuel and causes unequal burning of the fuel on the grate. Remove all fuel remnants in the furnace and in the burn-off hole before each new firing. Because of achieving high temperatures during combustion, the lining of the combustion chamber is not clogged and there is no necessity to dismount it fully. We recommend once every14 days extrusion of its front middle part (see fig. No15 - pos. 7) and clean-up the space under the nozzle of tertiary air. 2. The ash must be put into incombustible containers with lids. During the work, it is necessary to use protective equipment and ensure personal safety. 3. 1x per week, clean the boiler walls inside the furnace, boiler smoke drafts and smoke adapter with a brush (cooled down boiler, the temperature does not exceed 40 C). For the ash removal from the smoke adapter, use the cleaning cover at the its bottom part. When dismantling the cleaning cover, loosed the screw securing the latch to avoid its damage. After cleaning the smoke adapter, mount the cleaning cover back and pay attention to the tightness of the cleaning cover and the smoke adapter. 4. If using fuels with higher development of gas leading to tar depositing on the walls of the fuel space, remove it by scraping or burning dry hard wood (or coke) at the boiler max. operating temperature. 5. After the heating season, clean the space behind the choker of the tertiary air inlet, treat the pivots of the smoke flap, shorting flaps and all doors. 6. Cracks caused by tension or slight corrosion on the refractory lining are caused by temperature fluctuations and the temperature over 1000 C in the combustion chamber. Decisive for the functionality of the device is the dimensional stability of the components. Cracks do not affect the functionality and can be considered, similar to the tiled stove, normal. 7. If there are impurities on the cover parts and control elements, it is best to remove them with a soft damp cloth. We recommend gentle cleansers without solvents. Solvents such as alcohol, gasoline or thinners should not be used because they could damage the surface of the device. 8. We recommend to clean the glass part of the stoking door more often and do not let the creation of the too thick layer of sediment. We recommend to use products for cleaning glass of fireplaces and stoves. When cleaning, follow the detergent manufacturer's instructions. 17

18 9 IMPORTANT NOTICE 1. The boiler can be operated only by adults familiar with this instruction manual. Do not leave unattended children near the boiler. Interventions into the boiler design that could threaten the health of operators or housemates are forbidden. 2. 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 using the appliance safely, if they are not supervised or were not instructed to use the appliance by a person responsible for their safety. 3. Children should be supervised to ensure that they do not play with the appliance. 4. If there is a danger of development and penetration of combustible vapours or gases into the boiler room or at works with temporarily developed fire or explosion danger (gluing the floorings, painting with flammable paints), the boiler must be put out of operation before such works. 5. IT IS FORBIDDEN to use flammable liquids for the boiler firing. 6. IT IS FORBIDDEN to overheat boiler during operation. 7. Do not put any objects made of flammable materials on the boiler and within a distance smaller than the safe distance from the boiler. 8. When removing the ash from the boiler, no flammable substances must be at the minimum distance of 1500 mm from the boiler. 9. When operating the boiler at the temperature lower than 50 C, water can condense on the boiler drum, that can lead to the so called low-temperature corrosion, which shortens the life of the boiler drum. Therefore we recommend to operate the boiler at 50 C and higher. 10. In case of the storage tank use, the boiler can be again lit or the fuel can be added if the boiler is burned to the base of the fireplace and the storage tank is empty or cooled. ATTENTION! Ignoring leads to extreme heat exchanger clogging. 11. After the heating season, it is necessary to clean the boiler, the flues and the smoke adapter. Spread the graphite grease on the pivots, the smoke flap mechanism and other moving parts on the boiler. The boiler room must be kept clean and dry. 12. If the heating system is not used daily during the winter period, it is necessary to drain the water. 13. Possible signs of corrosion on the boiler drum are not defects and do not affect the boiler function. 14. In the system, it is necessary to install a safety valve with max. overpressure of 400 kpa (4 bar), which dimensions must correspond to the boiler nominal output. The safety valve must be installed immediately behind the boiler. Shut-off valve must be installed between the safety valve and the boiler. For further questions please contact our contractual installation companies and service organizations. 15. In case of reaction of the two-way safety valve, when there could be refilled water that does not conform to CSN , it is necessary to adjust water in the system so that it again conforms to this standard. 16. When mounting, installation and operation of the appliance it is necessary to meet the standards valid in the relevant destination country. In case of failure to comply with these conditions, warranty repairs cannot be claimed. 10 Instructions for the product disposal after its useful life period VIADRUS a.s. is the contract partner of the company EKO-KOM a.s. with the client number F The packaging complies with EN The packaging should be disposed of as follows: - plastic foil, cardboard package - use the special waste collection point - metal tightening tape - use the special waste collection point - wooden base is intended for single use and cannot be further used as a product. Its disposal is subject to the law 477/2001 Sb. and 185/2001 Coll. as amended. Individual parts of the boiler should be disposed of as follows: - exchanger (grey cast iron) - use the special waste collection point - piping, shell - use the special waste collection point - other metal parts - use the special waste collection point - insulation material - through a firm dealing with waste collection and disposal In case of loosing the use properties of the product, back collection service can be used (if applicable), in case the manufacturer states it is waste, the waste should be disposed according to the valid legislation of the country. 18

19 11 Warranty and liability for defects For the boiler, VIADRUS a.s. provides basic warranty for the period of 24 months from the date of purchase, max. 30 months from date of shipment from the factory. Condition for the warranty is compliance with the instructions for installation, mainly: Putting in operation and admission of warranty related to it is conditioned by commissioning the boiler by a contractual qualified mounting company authorized to perform this operation. Compliance with the instructions included in the boiler operation and installation manual. Performance of periodic inspections set by the manufacturer by a service company with a valid service certificate. Usage of the original spare parts supplied by the manufacturer. Sending information on the boiler putting into operation (sent by the end user - the consumer) to the manufacturer. In particular, it is necessary to specify when and by whom the boiler was put into operation and the precise address of the boiler operation. VIADRUS a.s. provides an extended warranty on the boiler body for a period of 60 months from the date of purchase, max. 66 months from date of shipment from the factory: Condition for recognition of the extended warranty period is: Fulfilment of conditions for recognition of the basic warranty period. Sending information on the boiler putting into operation (sent by a service company - the consumer) to the manufacturer. Performance of the regular service inspections to the extent prescribed by the manufacturer, by the service company with a valid service certificate. For any claim regarding the shell the customer is obliged to submit the packaging label of the boiler shell. It is located on the cardboard in which the shell is dispatched. "Certificate of quality and completeness of the boiler" serves as the "Warranty card after its filling. The user is obliged to perform regular maintenance of the boiler. Each notice of defect must be made immediately after its finding always in writing and by a telephone agreement. In case of failure to comply with these guidelines, the warranty will not be recognized by the manufacturer. The manufacturer reserves the right to make changes within the product innovations that need not be included in this manual. The guarantee does not apply to: - defects caused by improper mounting and improper operation of the product and faults caused by improper maintenance see Chap. 8; - product damage during transport or other mechanical damage; - defects caused by improper storage; - defects caused by failure to observe water quality in the heating system see Chapter 4.1 and or by using antifreeze; - defects caused by failure to follow instructions provided in this manual; - defects caused by natural disasters or other unforeseen events. 19

20 12 Product fiche HERCULES U32 D 5 sect. Condensing boiler no Solid fuel cogeneration boiler no Combination boiler no Fuel Preferred fuel (only one): Other suitable fuel(s): Log wood, moisture content 25 % YES no Chipped wood, moisture content % no no Chipped wood, moisture content > 35 % no no Compressed wood in the form of pellets or briquettes no no Sawdust, moisture content 50 % no no Other woody biomass no no Non-woody biomass no no Bituminous coal no YES Brown coal (including briquettes) no YES Coke no no Anthracite no no Blended fossil fuel briquettes no no Other fossil fuel no no Blended biomass (30-70 %) and fossil fuel briquettes no no Other blend of biomass and fossil fuel no no Characteristics when operating with the preferred fuel: Seasonal space heating energy efficiency η s [%]: 79 Energy efficiency index EEI: 116 Useful heat output Useful efficiency At rated heat output P n 15 kw At rated heat output ƞ n 88,9 % P p kw ƞ p % For solid fuel cogeneration boilers: Auxiliary electricity consumption Electrical efficiency at rated heat output ƞ el, n - % At rated heat output el max - kw el min - kw Of incorporated secondary emission abatement equipment, - kw if applicable In standby mode P SB - kw Contact details VIADRUS a.s. Bezručova 300 Bohumín