VIADRUS HERCULES
HerculesUU26
26
MANUAL FOR BOILER Návod
OPERATION
k obsluze
AND INSTALLATION
Table of contents:
page
1.
Boiler use and advantages ...................................................................................................................... 3
2.
Boiler technical data ................................................................................................................................ 3
3.
Description ............................................................................................................................................... 8
3.1
Boiler construction ............................................................................................................................. 8
3.2
Regulation and safety elements ........................................................................................................ 8
3.3
Equipment for surplus heat removal ................................................................................................ 11
3.4
Superfluous heat removal equipment- storage reservoirs ............................................................... 13
4.
Positioning and installation .................................................................................................................... 14
4.1
Regulations and guidelines.............................................................................................................. 14
4.2
Positioning possibilities .................................................................................................................... 14
5.
Delivery and assembly .......................................................................................................................... 16
5.1
Delivery and accessories ................................................................................................................. 16
5.2
Assembly procedure ........................................................................................................................ 17
5.2.1
Installation of smoke extension (only for the size of 8 – 10 sections) ......................................... 17
5.2.2
Boiler drum installation ................................................................................................................ 17
5.3.3
Boiler shells assembly ................................................................................................................. 19
5.2.4
Mounting of draw bar of smoke flap control ................................................................................. 21
5.2.5
Draught regulator ......................................................................................................................... 22
5.2.6
Assembly tools for brush ............................................................................................................. 22
5.2.7
Filling the heating system with water: .......................................................................................... 22
6.
Commissioning ...................................................................................................................................... 23
6.1
Verification activities before commissioning .................................................................................... 23
6.2
Boiler commissioning ....................................................................................................................... 23
7.
Boiler operation by user ........................................................................................................................ 23
8.
IMPORTANT WARNING ....................................................................................................................... 24
9.
Maintenance .......................................................................................................................................... 25
10.
Instructions for product disposal after its lifetime extinction .................................................................. 25
11.
Guarantee and reliability for defects...................................................................................................... 26
Dear customer
We thank you that you have bought VIADRUS HERCULES U 26, a universal boiler thus having shown your
confidence in VIADRUS a.s..
For you to get used to a correct way of handling your new product from the beginning please read at first this
manual for its usage (first of all the chapter no. 7 – Boiler operation by user and chapter no. 8 – IMPORTANT
WARNING). Please follow the stated information whereby a longstanding and trouble-free boiler operation
will be guaranteed to both your and our satisfaction.
VIADRUS HERCULES U 26 is a cast-iron sectional low-pressure boiler designated for combustion of solid
fuels – coke, hard coal, wood. Combustion of other materials like plastics is impermissible.
1.
Boiler use and advantages
Three-sectional size of VIADRUS HERCULES U 26 boiler is suitable for heat sources reconstructions in
independent tenements, for smaller residential premises and leisure amenities. Bigger sizes of boilers meet
the demands on heating the houses, shops, schools etc.
The boiler is manufactured in warm-water design with both natural and forced heating water circulation and
working overpressure up to 400 kPa (4 bar). Before dispatch the boiler is tested for tightness by applying
800 kPa (8 bar) overpressure.
The boiler is designated for heating both closed and open heating systems.
Boiler advantages:
1. A high lifetime of the cast-iron heat exchanger and all other parts with regard to the quality of used
materials.
2. Long-term verified construction.
3. Sophisticated manufacturing technology on the automatic forming lines with a constant and verified
quality of the manufacturing process. (ISO 9001, ISO 14 001).
4. Coke combustion efficiency 80%
5. Simple operation and maintenance.
6. Output graduation by the number of sections.
2.
Boiler technical data
Tab. no. 1 Dimensions, technical parameters of boiler
Number of sections
Boiler category according to
EN 303 - 5
Combustion chamber volume
Water space volume
Weight
Combustion chamber depth
Diameter of smoke socket Ø D
Boiler dimensions: - height x width
- depth L
- depth L1
Filling hole dimensions
Maximum water operating
overpressure
Minimum water operating
overpressure
Water test overpressure
Hydraulic loss
Minimum water inlet temperature
Recommended heating water
operating temperature
Noise level
Chimney draught
Boiler connections - heating water
- reverse water
Maximum fuel weight in the
chamber
Temperature of cooling water for
equipment for surplus heat removal
Overpressure of cooling water for
equipment for surplus heat removal
pcs
3
4
5
6
-
7
8
9
10
78
50,4
398
625
91,5
56,1
448
735
105
61,8
498
845
176
118,5
67,5
548
955
942
1198
1053
1309
1164
1420
0,35
0,40
73,5
82,95
1
3
dm
l
kg
mm
mm
mm
mm
mm
mm
kPa
(bar)
kPa
(bar)
kPa
(bar)
°C
23
27,6
218
185
37
33,3
258
295
51
35
298
405
156
387
643
498
754
609
865
64,5
44,7
348
515
1158 x 600
720
831
976
1087
300 x 320
400
(4)
50
(0,5)
800
(8)
see Fig. No.1
60
°C
60 – 85
dB
mbar
0,10
0,15
Does not exceed the level 65 dB (A)
0,20
0,25
0,30
0,30
2“
2“
kg
16,1
25,9
35,7
45,15
54,6
°C
5 – 20
kPa
(bar)
200 – 600
(2 - 6)
3
64,05
Tab. no. 2 Dimensions, technical parameters –coke as fuel
-1
granularity 24 – 60 mm, fuel moisture max. 15 % fuel efficiency: 26 - 30 MJ.kg
Number of sections
Rated power
Fuel consumption at the rated
power
Minimum output
Fuel consumption at the minimum
output
Fuel efficiency
Burning time at the rated power
Flue gases temperature at the rated
power
Flue gases temperature at the
minimum output
Flue gases mass flow rate at the
minimum output
Flue gases mass flow rate at the
rated power
Efficiency
pcs
kW
3
15
kg/h
kW
kg/h
4
22,5
5
30
6
37,5
7
43,5
8
50
2,43
3,64
4,86
6,07
7,04
8,09
9,07
10,2
7,5
11,3
15
18,5
22,5
15
16,8
18,9
1,21
1,83
2,43
3,0
3,64
2,43
2,72
3,06
-1
MJ.kg
h
27,8
4
°C
220-250
°C
120-180
9
56
10
63
g/sec
3,53
5,33
7,08
8,73
10,6
7,08
8,2
11,2
g/sec
7,08
10,6
14,15
17,69
21,2
24,4
27,3
30,7
%
80
Tab. no. 3 Dimensions, technical parameters– hard coal as the fuel
-1
granularity 24 – 60 mm, fuel moisture max. 15 % fuel efficiency: 26 - 28 MJ.kg
Number of sections
Rated power
Fuel consumption at the rated
power
Minimum output
Fuel consumption at the minimum
output
Fuel efficiency
Burning time at the rated power
Flue gases temperature at the rated
power
Flue gases temperature at the
minimum output
Flue gases mass flow rate at the
minimum output
Flue gases mass flow rate at the
rated power
Efficiency
pcs
kW
3
11
4
16,5
5
22,5
6
31
7
39,5
8
45,5
9
51,5
10
58
kg/h
1,87
2,8
3,82
5,26
6,7
7,72
8,73
9,83
kW
5,5
8,25
11,25
15,5
19,75
13,65
15,45
17,4
kg/h
0,93
1,4
1,9
2,63
3,35
2,32
2,62
2,95
MJ.kg-1
h
28,31
4
°C
220 – 300
°C
120 – 190
g/sec
4,295
6,445
8,78
12,105
15,43
6,66
7,53
8,616
g/sec
8,59
12,89
17,56
24,21
30,86
22,2
25,1
28,72
%
75
Tab. no. 4 Dimensions, technical parameters – wood as the fuel
-1
fuel moisture max 20 %
fuel efficiency: 14 – 18 MJ. kg
Number of sections
Rated power
Fuel consumption at the rated
power
Minimum output
Fuel consumption at the minimum
output
Fuel efficiency
Burning time at the rated power
Flue gases temperature at the rated
power
Flue gases temperature at the
minimum output
Flue gases mass flow rate at the
minimum output
Flue gases mass flow rate at the
rated power
Efficiency
pcs
kW
3
8
4
15,75
5
20
6
28,25
7
33
8
35
9
40,5
10
46
kg/h
2,56
5,04
7,52
9,03
10,55
11,19
12,95
14,71
kW
4
4,73
6,5
8,4
9,7
10,5
12,15
13,8
kg/h
1,28
1,51
2,08
2,69
3,1
3,36
3,89
4,41
5,380
5,124
5,929
6,735
17,97
17,96
19,76
22,45
MJ.kg-1
h
15,01
2
°C
220 – 300
°C
120 – 190
g/sec
1,796
2,870
3,950
4,670
g/sec
5,99
9,59
13,18
15,58
%
75
4
350
300
200
150
100
50
0
4
8
12
16
20
24
28
32
36
40
44
48
52
56
60
64
výkon(kW)
kotle [kW]
Rated power
Fig. No. 1
Hydraulic loss of the boiler drum
51
45
45
40
38
35
34
30
10
inside
diameter
světlý
průřezinvcm
cm
9
25
27
22
24
7-8
6
20
22
18
20
19
5
18
17
4
15
13
3
30
10
5
10
15
20
25
Actual Účinná
stack height
výška[m]
komínu [m]
Fig. No. 2
Stack diameter setting
5
Number Počet
of sections
článků
29
Draft [Pa]
Komínový tah [Pa]
Hydraulic loss (Pa)
hydraulická ztráta[Pa]
250
Number of sections
L
L1
D
Fig.no.3a)
3
387
643
4
498
754
5
609
865
156
6
720
976
7
831
1087
Connecting dimensions of VIADRUS HERCULES U 26 3 – 7 sect. boiler
6
Number of sections
L
L1
D
Fig. no. 3b)
8
942
1198
9
1053
1309
176
10
1164
1420
Connecting dimensions of VIADRUS HERCULES U 26 8 – 10 sect. boiler.
7
3.
Description
3.1
Boiler construction
The main part of boiler is the cast-iron sectional boiler drum made of the grey cast-iron according to
EN 1561, quality 150.
The pressure parts of boiler meet the demands on the strength according to:
EN 303-5
Heating boilers – Part 5: Heating boilers for solid fuels, hand and automatically stocked,
nominal heat output of up to 300 kW – Terminology, requirements, testing and marking
The boiler drum is assembled of sections by means of pressed-in boiler insertions with 56 mm diameter and
secured by anchor bolts. The sections create the combustion chamber and the ash pan space, the water
space and the convective part. The heating water inlet and outlet are situated in boiler rear part.
The rear part of boiler in its upper part has a smoke extension/adapter and the heating water flange. In the
lower part there is the reverse water flange. To the front section there are mounted the stoking and ash-pan
doors. Under the ash-pan door there is installed a tilting grate.
The whole boiler drum is insulated by the health harmless mineral insulation which reduces the losses
caused by heat transmission into the environment. The steel shell is coloured by a good quality comaxit
spray.
3.2
Regulation and safety elements
The smoke shutter of the smoke extension/adapter regulates the flue gases outlet volume from the boiler
into the chimney. It is operated by a handle with drawbar in the left upper part of boiler next to the stoking
door.
The ash pan door choker regulates the combustion air inlet under the boiler grate. It is operated by a draught
regulator. Another draught regulator (for 8, 9, 10 sectional boiler) regulates the rear choker. The regulator is
set on the same temperature as the regulator in the front part of the boiler.
The stoking door choker serves for secondary air supply into the combustion chamber.
A combined device- the thermomanometer serves for heating water temperature and pressure detection in
heating system. The reservoir of thermomanometer sensor is installed in upper part of the front boiler
section.
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Boiler drum
Stoking door
Ashpan door
Middle part
Tilting grate
Tilting grate holder
Rosette
Choker
Choker screw
Suspension pin
Heating water flange
Outlet neck
Return water flange
Filling and draining cock
Fig. no. 4a)
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Lowered console
Upper part of the shell with insulation í
Left side part of the shell with insulation
Right side part of the shell with insulation
Rear part of the shell with insulation
Thermomanometer
Draught controller
Two-way safety valve DVB 1 – 02
Safety valve
Draw bar
Bushing HEYCO
Slant bushing
Plastic ball
Label for smoke flap control
VIADRUS HERCULES U 26 3 – 7 sect. boiler assembly
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Boiler drum
Stoking door
Ashpan door
Middle part
Tilting grate
Tilting grate holder
Rosette
Choker
Choker screw
Suspension pin
Heating water flange
Outlet neck
Return water flange
Filling and draining cock
Lowered console
Upper part of the shell with insulation
Fig. no. 4b)
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Left side part of the shell with insulation
Right side part of the shell with insulation í
Rear part of the shell with insulation
Thermomanometer
Draught controller
Two-way safety valve DVB 1 – 02
Safety valve
Draw bar
Bushing HEYCO
Slant bushing
Plastic ball M10
Label of smoke flap control
Left choker console for the rear section
Choker for the rear section
Choker axis for the rear section
Right choker console for the rear section
VIADRUS HERCULES U 26 8 – 10 sect. boiler assembly.
10
1 – rear lining
2 – upper lining
3 – ceramic insert (3 – 10 sect.)
4 – additional grate (3 – 10 sect.)
Fig.no.4c)
3.3
Diagram of VIADRUS HERCULES U 26 boiler - location of additional equipment
Equipment for surplus heat removal
The after-cooling loop or the two way safety vent DBV 1 - 02 serves for surplus heat removal in case
the water temperature in boiler exceeds 95 °C.
The after-cooling loop is connected to the boiler flanges according to Fig. No. 5, the two way safety
vent according Fig. No. 7.
In case of boiler overheating (the output water temperature exceeds 95 °C) the thermostatic valve switches
on and the superfluous heat is led off via an after-cooling loop.
1 – Heating water outlet into the system 2”
2 – Reverse water inlet from the after-cooling loop 1 1/2 “
3 – Reverse water inlet into the boiler from system 2”
4 – Cooling water outlet
5 – Thermostatic valve TS 130 (STS 20)
6 – Heating water outlet from boiler 2 “
7 – Cooling water inlet
Fig. No. 5
Hydraulic chart of after-cooling loop connection
In case the system is equipped with a two way safety vent and the boiler becomes overheated (the output
temperature exceeds 95 °C) the two way safety vent creates a cold water circuit which is kept until the
temperature drops below the limit temperature. At this moment there are simultaneously closed the
discharge cooling equipment and the cold water inlet of refilling the system.
11
A – cold water inlet
B – output to boiler
C – output to drain
D – input from boiler
Fig. No. 6
The two way safety vent DVB 1 - 02
1 – Boiler
2 – Two way safety vent DBV 1 – 02
3 – Safety valve
4 – Transforming valve
5 – Filter
6 – Ball-shaped cock
Fig. No. 7
7 – Pump
8 – Surplus heat removal
9 – Bleed valve
I – Cooling water inlet
II – Heating water outlet
III – Return water inlet
The recommended scheme of the two way safety vents DBV 1 – 02 connection
It is necessary to install a safety valve for maximum overpressure of 400 kPa (4 bar) on the system
and its dimension must correspond to the rated boiler output. The safety valve must be located
directly behind the boiler. Any stop valve must not be located between the safety valve and boiler. If
you have any questions, please contact our contractual assembly firm and service organizations.
The two way safety vent DBV 1 – 02 technical data (from the firm Regulus)
Opening temperature (limit):
Maximum temperature:
Maximum stress on boiler side
Maximum stress on water side
Nominal flow at p 100 kPa (1 bar):
100 °C (+0° - 5 °C)
120 °C
400 kPa (4 bar)
600 kPa (6 bar)
3
1,9 m /h
Usage
The two way safety vent DBV 1 – 02 is used as a protection of heating boilers against overheating. In the
valve body there is the bleed and supply valve controlled by thermostatic element. When the limit
temperature is reached, the bleed and supply valve is simultaneously opened meaning that the cold water is
running in and the hot water is running out. When the temperature drops below limit, the bleed and supply
valve is simultaneously closed.
Caution! It is not a compensation for safety valve.
In case of two way safety vent reaction, when there is a possibility of boiler having been filled with
the water, which does not meet the ČSN 077401 requirements it is necessary to change the water in
the heating system so that it meets the ČSN 077401 requirements again.
12
Installation
Installation can be only carried out by a qualified person. For the correct operation of the thermostatic, two
ways safety vent it is necessary to comply with the conditions for its installation and keep the flow directions
marking on its body. The safety vent is always mounted in the output pipe of boiler or directly on the upper
part of boiler, where the hot water leaves boiler and is transported into heating system. When installing the
vent it is necessary to check, if the 3/4“ socket usage, which can be both in pipeline and on boiler, ensures
complete immersion of the thermostatic vent element after the vent installation. After the vent has been
installed in socket, connect the down pipe, in which the hot water from boiler will flow to drain, to „C“(see. fig.
No. 6). The cooling water inlet, which will cool the boiler after setting the vent in operation, is connected (see
fig. No. 7) to „A“ (see fig. No. 6). The filter for mechanical impurities must be installed in the cooling water
inlet. It is necessary to connect the pipeline to „B“ (see. fig. No. 6) and the pipeline is to be led into reverse
flow pipe of heating system near the boiler (see fig. No. 7).
Regular maintenance
Once a year it is necessary to turn the safety vent’s head to remove possible impurities formed in the vent.
Clean the cooling water inlet filter.
In case of using an open expansion tank it is not necessary to use a protecting device against
overheating.
Every heat source in an open heat system must be connected with an open expansion tank positioned at the
highest point of the heat system. The expansion tanks must be rated in the way that they can contain the
changes in water volume resulting from heating and cooling.
The open expansion tanks must be equipped with non-closable bleeder and a overflow pipes. The overflow
pipe must be designed in the way that it safely drains off the maximum flow volume entering the system. This
can be achieved by rating the overflow pipes by one DN higher than that of the filling piping. The expansion
tanks and their connecting pipes must be designed and positioned in the way that freezing is reliably
inhibited.
1
2
3
4
5
6
7
8
Fig. no. 8
3.4
Heat source
Expansion tank
Safety piping
Expansion piping
Overflow piping
Filling piping
Water level limiter
Reverse piping
The examples of open expansion tanks connection
Superfluous heat removal equipment- storage reservoirs
In case that the required volume exceeds 300 l we recommend to install a storage reservoir.
Because the minimum output of this boiler is higher than 30% of the rated power we recommend to remove
the heat into the storage reservoirs.
The calculation of the minimum volume of stack heat exchanger
Vsp
QN
Tb
Vsp = 15Tb x QN (1-0,3 x (QH/Qmin))
where
the volume of storage reservoir in l
QH
thermal load of buildings in kW
rated thermal output in kW
Qmin
minimum thermal output in kW
burning time in h
The dimensions of storage reservoirs at the boilers for central heating that are operated with individual
prescribed fuels must be set according to the fuel which needs the biggest storage reservoir. This storage
reservoir isn’t necessary if the calculated volume is smaller than 300 l.
13
4.
Positioning and installation
4.1
Regulations and guidelines
The solid fuel boiler can only be installed by a firm holding a valid licence to carry out its installation and
maintenance. A project according to the valid regulations must be elaborated for installation. Before the
boiler installation on an older heating system the installation firm must flush out(clean) the whole system.The
heating system must be filled with water meeting the ČSN 07 7401 requirements; especially its
hardness must not exceed the required parameters
Tab.no.4
Recommended values
Hardness
mmol/l
2+
Ca
mmol/l
The total Fe + Mn concentration
mg/l
*) recommended value
1
0,3
(0,3)*
WARNING!!! The use of anti-freeze mixture is not recommended by the manufacturer.
In case of two way safety vent reaction, when there is a possibility of boiler having been filled with
the water, which does not meet the ČSN 077401 requirements it is necessary to change the water in
the heating system so that it meets the ČSN 077401 requirements again.
a) to the heating system
ČSN 06 0310
Heating systems in buildings – Designing and installation
ČSN 06 0830
Heating systems in buildings – protecting device
ČSN 07 7401
Water and steam for thermal energy equipments with working pressure up to 8 MPa
EN 303-5
Heating boilers – Part 5: Heating boilers for solid fuels, hand and automatically
stocked, nominal heat output of up to 300 kW – Terminology, requirements, testing
and marking
b) to the chimney
ČSN 73 4201
Chimneys and flue gas ducting – designing, implementation and connection of fuel
consumers.
c) regarding the fire regulations
ČSN 06 1008
Fire safety of heat installations.
EN 13501-1 + A1 Fire classification of construction products and building elements – Part 1:
Classification using test data from reaction to fire tests.
d) to the system of HWS heating
ČSN 06 0320
Heating systems in buildings – Hot water preparation – Designing and planning
ČSN 06 0830
Heating systems in buildings – Safety devices.
ČSN 75 5409
Water installations inside buildings
4.2
Positioning possibilities
Boiler positioning in the living space (including corridors) is prohibited!
The installation of the boiler must comply with all requirements of ČSN 06 1008.
The boiler positioning with regard to the fire regulations:
1.
Installation on a floor made of incombustible material (Fig. No. 9)
− The boiler can be installed on a fireproof floor exceeding the boiler platform by 20 mm on the sides
and only up to the boiler drum depth.
− If the boiler is positioned in a cellar we recommend to install it on a retaining wall (substruction)
minimum 50 mm high
− install the boiler in the middle of the retaining wall
2. A safe distance from the combustible materials:
− when installing and operating the boiler it is necessary to keep a safety distance of 200 mm from the
materials of combustibility grade A1, A2, B and C (D);
− for easily combustible materials of combustibility grade E (F), which quickly burn and burn
themselves even after removal of ignition source (such as paper, cardboard, asphalt and tar paper,
wood and wood-fiber boards, plastics, floor coverings) the safe distance has to be doubled, i.e. to
400 mm;
− safe distance should be doubled as bulb where the grade of reaction to fire has not been proved.
14
number of sections
L mm]
Fig. No. 9
3
387
4
498
5
609
6
720
7
831
8
942
9
10
1053 1164
Substruction (retaining wall) dimensions
Tab. no. 5 Grade of reaction to fire
Examples of building materials and products included in the reaction to fire
(Extract from EN 13 501-1 + A1)
A1 – incombustible
Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters, …
A2 – combustible with difficulty acumin, izumin, heraklit, lignos, boards and basalt felt, fibreglass boards,...
B – hardly combustible
Beech and oak wood, hobrex boards, plywood, werzalit, umakart, sirkolit,...
C (D) – medium combustible
Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,...
Asphaltboard, fibreboards, cellulose materials, polyurethane, polystyrene,
E (F) – easily combustible
polyethylene, PVC,…
Grade of reaction to fire
Boilers positioning with regard to the necessary
handling space:
− Basic AA5/AB5 environment according to
ČSN 33 2000-1 ed. 2.
− In front of the boiler there must be left a minimum
handling area of 1000 mm.
− Keep minimum 400 mm distance between the rear
part of the boiler and the wall.
− At least from one lateral face keep minimum
400 mm space for access to rear part of the boiler.
Fuel storage:
− Dry fuel has to be used for a proper combustion
in the boiler. The manufacturer recommends
fuel storage in cellars or at least under shelter. It
is out of question to store the fuel behind the boiler
or next to the boiler within a distance smaller than
400 mm.
− It is out of question to store the fuel between two
boilers in the boiler room.
− The manufacturer recommends to keep minimum
1000 mm distance between the boiler and the fuel
or to store the fuel in a room different from that
where the boiler is installed.
15
Fig.no. 10
Location of boilers in the
boiler room
5.
Delivery and assembly
5.1
Delivery and accessories
Boiler is delivered according to the purchase order on the pallet on which the complete boiler drum is placed
and on the side there is attached the wrapped boiler shell. The accessories are put inside the boiler drum,
accessible only after opening the stoking door. The boiler is wrapped in a transport package and it must not
be tilted over during the transport.
Standard boiler delivery
•
•
•
•
•
•
•
•
Boiler on a pallet, with an adequate number of sections
boiler heating water flange with a thread (curved)
reverse water flange (3 – 7 sect.)
reverse water flange with distribution tube (8 – 10 sect.)
sealing φ 90 x 60 x 3
washer 10,5
nut M10
filling and discharge tap Js 1/2“
draught regulator complete (3 – 7 sect.)
draught regulator complete (8 – 10 sect).
suspension pin (8 – 10 sect.)
Js 6/4“ blinding plug
sealing φ 60 x 48 x 2
The shell incl. the ash pan, adequately sized incl. insulation
lowered console
washer 10,5
nut M10
spring clip
screwM5 x 12
washer 6,4
bushing HEYCO SB – 625 – 8
slant bushing
screwST 4,2 x 9,5
connecting plug
thermomanometer
Draw bar
lock 2,5 x 32
plastic ball M10
Smoke shutter operation label
Choker screw
Cleaning tools
- hook
- brush with a handle
- spike
- holder for cleaning tools
Handling key
Commercial& technical documentation
1 pc
1 pc
1 pc
2 pcs
8 pcs
8 pcs
1 pc
1 pc
2 pcs
1 pc
1 pc
1 pc
2 pc
4 pcs
4 pcs
4 pcs
4 pcs
4 pcs
1 pc
1 pc
10 pcs
4 pcs
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
Supplementary outfit (is not included in delivery):
•
•
•
•
ceramic plate for hard coal combustion
rear lining for wood combustion for 8 – 10 sections
auxiliary grate for wood combustion
upper lining for wood combustion for 8 – 10 sections
1 pc
1 pc
2 pcs according to the size
(8 sect.-10 pcs, 9 sect.-12 pcs, 10 sect.-14 pcs)
Necessary accessories: (is not included in delivery):
•
•
•
After-cooling loop (1 pc) (for the 3 – 7 sectional boiler) incl. flange or the two way safety vent DBV 1 - 02
(for the 3 – 10 sectional boiler) incl. siseal 10 g. This equipment needn’t be used in case of an open
heating system.
Thermostatic valve TS 130 (STS 20) – TV 95°C – can be delivered directly from the wholesale (only at
the delivery with after-cooling loop)
Safety valve
1 pc
16
By request (is not included in delivery):
•
Filter 3/4“ – for delivery with the two way safety vent DBV 1 - 02
The supplementary outfit, necessary accessories and optional boiler accessories is not included in
the boiler standard price.
5.2
Assembly procedure
5.2.1 Installation of smoke extension (only for the size of 8 – 10 sections)
1.
2.
3.
4.
Fig. No. 11
1.
2.
Sealing cord
Smoke extension
Washer 8.4
Nut M8
Installation of smoke extension
Insert the sealing cord (1) into the groove in the rear section.
Screw the smoke extension (2) by means of washers 8,4 (3) and nuts M8 (4). Be careful when
tightening due to the fragility of the material of the smoke extension.
5.2.2 Boiler drum installation
Boiler drum installation- after-cooling loop
1.
2.
3.
4.
5.
6.
7.
8.
Set the boiler drum on the retaining wall (substruction)
On the weldment of after-cooling loop weld in advance the after-cooling loop heating water flange
(according to the boiler room layout), insert the sealing Ø 90 x 60 x 30 between the flange and the
boiler, then mount the weldment to the boiler by means of 4 pcs nut M 10 and 4 pcs washer 10,5. The
upper outlet of heating water interconnect with the heating system by means of a weld.
Interconnect the lower outlet from the after-cooling loop by welding a 1 1/2“ tube with reverse water
outlet (reverse water flange) to the boiler.
Mount the thermostatic valve on one of after-cooling loop outlets (mount the sensor into the reservoir
and connect the cold water inlet 1/2“) mind the flow direction marked by an arrow; it must correspond to
that shown in Fig. No. 5.
Other 1/2“ outlet from the after-cooling loop interconnect with the drain (warning: for the check of
thermostatic valve function we recommend to interconnect the water outlet with the drain by means of a
funnel.)
After the boiler connection to the heating system screw a filling and discharge taps to the rear section
according to Fig. No. 12
To the smoke extension (adapter) set the smoke tube and insert into the chimney opening. The smoke
tube diameter is 160 mm for the sizes with 3 – 7 sections, 180 mm for 8 – 10 sections.
Screw the draught regulator into the opening in upper part of the front section. The boiler draught
regulator adjustment procedure is shown in manual enclosed to particular regulator. For the
8 – 10 sectional boiler screw two draught regulators according to Fig. No. 4.
17
9.
Blind the threaded opening JS 6/4“ in the front section with JS 6/4“ plug. Insert the sealing Ø 60 x 48 x 2
under the plug.
10. It is recommended to use shut-off valves for heating water inlet and outlet since without the valves it will
be necessary to drain the whole system during the filter cleaning.
Boiler drum installation – the two way safety vent DBV 1 - 02
1.
2.
3.
4.
5.
6.
7.
8.
9.
Set the boiler drum on the retaining wall (substruction)
Insert the sealing Ø 90 x 60 x 30 between the heating water flange and the boiler, then mount to the
boiler by means of 4 pcs nut M 10 and 4 pcs washer 10,5 (according to the boiler room layout). By
welding connect the upper heating water outlet with heating system.
Insert the sealing Ø 90 x 60 x 30 between the reverse water flange (at the 8 – 10 sectional boiler the
reverse water flange with distribution tube) and the boiler, then mount by means of 4 pcs nut M 10 and
4 pcs washer 10,5 to the boiler. By welding connect the lower heating water outlet with heating system.
According to Fig. no. 7 interconnect the two-way safety valve DBV 1 – 02 with the flange of the return
and heating water (the return water flange with a distribution pipe at the version with 8-10 sections) and
with cooling water inlet plus superfluous heat outlet.
Mount the discharge valve in the return water flange.
Set the smoke tube to the smoke extension/adapter and insert into the chimney opening. The smoke
tube diameter is 160 mm for sizes 3 – 7 sections, 180 mm for 8 – 10 sections.
Screw the draught regulator into the opening in the upper part of the front section and the upper part of
the rear section. The chimney draught regulator adjustment is shown in manual enclosed to particular
regulator. For the 8 – 10 sectional boiler screw two draught regulators according to Fig. No. 4.
Blind the threaded opening JS 6/4“ in the front section with JS 6/4“ plug. Insert the sealing Ø 60 x 48 x 2
under the plug.
It is recommended to use shut-off valves for heating water inlet and outlet since without the valves it will
be necessary to drain the whole system during the filter cleaning.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fig.no.12
Boiler drum installation
18
Sealing φ 90 x 60 x 3
Heating water flange
Washer 10,5
Nut M10
Sealing φ 90 x 60 x 3
Return water flange
Washer 10,5
Nut M10
Filling and draining cock
5.3.3 Boiler shells assembly
1.
2.
Take the shells out of the cardboard cover.
Put two lowered consoles(1) on the threads of upper anchor bolts and screw them by means of four
nuts M10 (3) and four washers 10,5 (2) - (see Fig.no.13).
1.
2.
3.
4.
5.
Fig.no.13
1.
2.
Mounting of boiler shell consoles
1.
2.
3.
4.
5.
Sie part of the shell
Spring clip
Fig.no.14
Lowered console (2 pc)
Washer 10,5
Nut M10
Thermometer well
Manometer well
Right side part of the shell
Side part of the shell
Spring clip
Bushing HEYCO
Slant bushing
Draw bar of the smoke flap control
Fig.no.15
19
Left side part of the shell
3.
4.
5.
6.
7.
8.
9.
Mount two spring clips (2) on the right side part of the shell (1), then insert the insulation (see
Fig.no.14). Put the boiler shell on the lower anchor bolts and connect the upper part with the lowered
consoles by means of two screws M5 x12 and two washers 6,4 (see Fig.no.17).
Mount two spring clips (2) on the left side part of the shell (1), insert the bushings (3, 4), then insert the
draw bar of smoke flap control (5) and the insulation (see Fig.no.15). Put the shell on the lower anchor
bolts and connect the upper part with the lowered consoles by means of two screws M5 x12 and two
washers 6,4 (see Fig. no. 17).
Mount the insulation on the rear part of the shell (10 – Fig.no.17) and screw it to the side parts of the
shell by means of the screws ST 4,2 x 9,5 (11 – Fig.no.17).
Mount four connecting plugs (2) on the upper part of the shell (1) and insert the thermomanometer
(8 – Fig. no. 17).
Insert the thermometer sensor into the thermometer well (4 – Fig.no.13) and screw the manometer into
the manometer well (5 – Fig.no.13).
Insert the insulation into the upper part of the shell and put it on the side parts of the shell.
Screw the rear part of the shell to the upper part of the shell by means of two screws ST 4,2 x 9,5
(11 – Fig. no. 17).
1.
2.
Upper part of the shell
Connecting plug
Fig. no. 16 Upper part of the boiler shell
20
1.
2.
3.
4.
5.
6.
Right side part of the shell
Washer 5,3
Screw M5 x 10
Left side part of the shell
Screw M5 x 10
Washer 5,3
7.
8.
9.
10.
11.
Draught controller
Thermomanometer
Upper part of the shell
Rear part of the shell
Screw ST 4,2 x 9,5
Fig. no. 17 Boiler shell
5.2.4 Mounting of draw bar of smoke flap control
1.
2.
3.
4.
Complete the smoke flap control according to the Fig.no.18.
Fasten the draw bar of the smoke flap control (2) to the smoke flap (1) by means of a lock 2,5 x 32 (3).
Screw the plastic ball M10 (4) on the front part of the draw bar
Stick the label of the smoke flap control.
21
1.
2.
3.
4.
5.
Smohe adapter with the smoke flap
Draw bar of the smoke flap control
Lock 2,5 x 32
Plastic ball M10
Label of the smoke flap control
Fig.no.18
6.
7.
8.
9.
Choker screw
Suspension pin
Lever of the draught controller
Chainlet
Smoke flap control
5.2.5 Draught regulator
The instructions for the draught regulator setting are given in the manual attached to the particular regulator.
5.2.6 Assembly tools for brush
Use the leather gloves and common assembly tools for mounting or dismounting of the brush and the spike
point (if they are included in the delivery).
5.2.7 Filling the heating system with water:
The water hardness must correspond to ČSN 07 7401 and it is inevitable to treat the water according
to Chap. no. 5.1. in case the water hardness is unsatisfactory.
The heating systems with an open expansion tank allow the direct contact between the heating water and
the atmosphere. During the heating season the water expanding in the tank absorbs the oxygen, which
increases its corrosive effects and at the same time the water evaporates heavily. Only the water treated to
the values according to ČSN 07 7401 can be used for refilling.
The heating system must be thoroughly flushed out in order to wash out all impurities.
During the heating season it is necessary to keep a constant volume of heating water in heating system and
be particular about bleeding the heating system to avoid the air suction into the system. Water from the
boilers and heating system must never be discharged or taken for usage except in cases of emergency like
the repairs etc. Water discharge and filling with new water increases the danger of corrosion and scale
development. In case we have to refill the heating system with water we only do this operation when
the boiler is cold in order to prevent its sections from getting broken.
After boiler and heating system refilling operation the all joints must be tested for tightness.
When using the two way safety vent DBV 1 - 02 the cooling water is added gradually to the to the
reverse water.
The assembly and stoking test completion must be recorded in the “Guarantee certificate”.
22
6.
Commissioning
The boiler can only be commissioned by professional assembly firms authorized to do this activity.
6.1
Verification activities before commissioning
Before the boiler is put into operation it is necessary to check:
1.
2.
3.
Filling the heating system with water (thermomanometer check) and the system tightness.
Connection to the chimney– this connection can only be done with the agreement of a chimneysweepers´ firm (chimney revision) measure the chimney draught according to tab.no. 1,2,3
depending on particular fuel.
Draught regulator and thermostatic valve functionality.
6.2
1.
2.
3.
4.
5.
6.
7.
8.
Boiler commissioning
Fire a boiler.
Bring the boiler to the necessary operating temperature. The recommended output water temperature is
80 °C.
Adjust the draught regulator incl. the chain length (according to enclosed draught regulator manual).
Check the functionality of protecting device against overheating (after-cooling loop or the two way safety
vent DBV 1 - 02)
Operate the boiler in operating condition according to relevant standards.
Check again the boiler tightness.
Acquaint the user with operation.
Make a record in the Guarantee certificate.
7.
Boiler operation by user
COKE
The most suitable fuel is the coke of 24 – 60 mm granularity.
HARD COAL
The most suitable fuel is the hard coal of 24 – 60 mm granularity
WOOD
The wood maximum moisture of 20% must be observed in order to achieve the rated boiler output.
The fuel must be stored under cover. The grate is cleaned in a way making sure that no glowing fuel gets
through into the ash pan.
Recommended sizes of wooden blocks
number of sections
Blocks diameter [mm]
Blocks length [mm]
3
4
5
6
7
8
9
10
Ø 40 - 100
300 300 350 400 500 600 700 800
Firing a boiler
1.
2.
3.
4.
5.
6.
7.
Check on the thermomanometer the volume of water in the heating system.
Open the stop valve between the boiler and the heating system.
Clear the grate, the ash pan, smoke flues and the boiler walls. (after the clearing you must check the
tightness in the smoke extension).
Through the ash pan door& the furnace door lay out the kindling and wood on the cleared grate within
the whole depth of the boiler.
Bring the smoke shutter in the smoke extension/ adapter into the open position and close the stoking
door.
Fire the kindling through the open ash pan and furnace door.
Shut the ash pan door& the furnace door and open fully the choker. At the 8 – 10 sectional boiler also
the rear choker.
23
8.
9.
On the flaring wood load a thinner layer of basic fuel.
After its good ignition load other fuel up to the lower edge of the stoking door and level the fuel into a
uniform layer along the whole depth of the boiler.
10. As soon as the fuel gets into a dark red glow by means of a tool open slightly the stoking door choker of
the secondary air inlet at the stoking door.
11. After the flames get yellow close the stoking door choker of the secondary air inlet.
Operation
1.
2.
3.
4.
5.
6.
7.
8.
9.
8.
After having achieved the heating water temperature regulate the combustion air inlet. The boiler output
is roughly regulated by the change in chimney draught by means of the smoke shutter in the smoke
extension. The fine output regulation is done by means of the choker which regulates the air inlet under
the grate either manually or by means of the draught regulator. The draught regulator must be set in a
way making sure that the choker in the ash pan door is almost closed at the moment the heating water
temperature has been achieved.
According to the heat need and the burning intensity the boiler must be refilled with fuel during the
operation. Stoke in the way making sure that the fuel layer is evenly high along the whole depth of the
boiler.
When using coke, hard coal and wood the stoking door choker at the secondary air inlet must be
partially open during the whole time of gases and flames development from the freshly stoked fuel.
When switching over to the night inhibited operation clear the grate, let the freshly stoked fuel well burn
up and then subdue the boiler output by throttling the chimney draught by means of the smoke throttle
in the smoke extension and throttling the stoking door choker at the secondary air inlet. The degree of
the smoke throttle and stoking door choker opening must be tested but it is necessary to be particular
about no flue gases escaping into the boiler room. In this case the draught regulator has to be
disconnected (the choker closed completely).
The boiler operation restoration in the morning is to be done by opening the smoke throttle and stoking
door choker and poking the grate after the ash pan door opening.
The ash pan door must be permanently shut during the boiler operation.
According to the need clear the ash pan (it is necessary to use the gloves).
In case of use of stop valves the safety valve should be installed between the boiler and the stop valve.
We recommend cleaning the filter after the heating test and subsequently before the heating season.
IMPORTANT WARNING
1.
2.
The boiler only can be used for the purpose that it is destined for.
The boiler only can be operated by adult persons who are familiar with this operation manual. In
is inadmissible to leave the children at the boiler unattended by adults. The interferences with
boiler that could endanger the health of operators or the roommates are impermissible.
3. The boiler is not destined for the use by persons (incl. children) whose physical, sensual or
mental disability or lack of experience and knowledge prevent them from a safe use of the
appliance unless they are supervised or if they were not instructed on the use of appliance by a
person responsible for their safety.
4. Children should be supervised in order to ensure that they do not play with the appliance.
5. The boiler is not destined for the use by persons (incl. children) whose physical, sensual or
mental disability or lack of experience and knowledge prevent them from a safe use of the
appliance unless they are supervised or if they were not instructed on the use of appliance by a
person responsible for their safety.
6. Children should be supervised in order to ensure that they do not play with the appliance.
7. If there occurs a danger of inflammable vapours and gases development and penetration into
the boiler room or at works accompanied by temporary development of the fire or explosion
danger (gluing of floor covering, painting with combustible painting colours), the boiler must be
duly closed down before the works start.
8. It is FORBIDDEN to use flammable liquids for boiler ignition.
9. During the operation it is FORBIDDEN to overheat the boiler.
10. On the boiler and within the distance shorter than the safe distance from it there must not be put
any objects made of flammable materials.
11. When clearing ashes at boiler there must not be put any flammable materials within minimally
1500 mm distance from the boiler.
24
12. The space at the point of choking valve rotation of the ashtray door must be cleaned in case of
clogging with fuel, ashes or other impurities in order to avoid its rubbing thus wrong
functioning.
13. When operating the boiler at the temperature lower than 60 °C the boiler drum can get bedewed
which means the low-temperature corrosion and reduction of boiler drum lifetime. Therefore we
recommend to operate the boiler at the temperature of 60 °C and higher.
14. After the heating season termination it is necessary to clear thoroughly the boiler, smoke-flues
and the smoke extension/ adaptor. Lubricate the pivots, the smoke throttle mechanism and other
movable parts at the boiler with the graphite grease. Keep the boiler room clean and dry.
15. In case the heating system is not daily used in winter season, then the water from boiler must be
drained.
16. Possible corrosion marks on the boiler drum don’t mean a defect and they do not affect the
boiler function.
17. It is necessary to install a safety valve for maximum overpressure of 400 kPa (4 bar) on the
system and its dimension must correspond to the rated boiler output. The safety valve must be
located directly behind the boiler. Any stop valve must not be located between the safety valve
and boiler. If you have any questions, please contact our contractual assembly firm and service
organizations.
18. During assembly, installation and operation of the appliance it is necessary to comply with
standards that apply in the relevant country of destination.
If you fail to meet these conditions you cannot requisite the guarantee repairs.
9.
Maintenance
1. During the boiler operation remove the ashes from the ash pan several times a day depending on the
kind of the used fuel, because the full ash pan prevents the combustion air from the proper distribution
under the fuel and causes an uneven fire penetration through the fuel on the grate. We remove all
remains from the combustion chamber, especially the clinker before every new firing and when restoring
the boiler operation in the morning. The ashes must be put into fire-resistant covered containers. Use
the protective means at this work and mind your personal safety.
2. When using the coke, hard coal and wood clear regularly once a month the walls of the boiler inside the
combustion chamber 1x, the boiler smoke draughts and the smoke extension/ adaptor (this by means of
a brush into the cooled down boiler where the temperature does nor exceed 40 °C).
3. If in case of using the fuels with a more intensive gases development the tar deposit accumulates on the
combustion chamber walls we remove it by means of a scraper or by burning dry hard wood (or coke)
while bringing the boiler to the maximum working temperature.
4. After the heating season termination treat (by using the Vaseline) the pivots/ swivel pins of the smoke
throttle and all doors.
10.
Instructions for product disposal after its lifetime extinction
VIADRUS a.s. is a contracting partner of the firm EKO–KOM a. s. with the client number F00120649.
The packages comply with EN 13427.
We recommend to dispose the packages in the way as follows:
- plastic foil, cardboard cover, use a salvage point
- metal strapping tape, use a salvage point
- wooden base, is designated for a single and no longer can be used as a product. Its disposal is subject to
Act 477/2001 Coll. and 185/2001 Coll. as amended.
Because the product is constructed of common materials, we recommend to dispose individual parts as
follows:
- the heat exchanger (grey cast-iron), use a salvage
- distribution pipes, shell, use salvage point
- other metal parts, use a salvage point
- ROTAFLEX insulating material, through a firm engaged in waste collection and disposal
In case that the product has lost its manufacture qualities it can be taken advantage of the back
collection service (if this is introduced); if the originator has declared that this is the waste and it will
be handled according to the legislative provisions valid in the particular country.
25
11.
Guarantee and reliability for defects
VIADRUS a.s. provides the guarantee:
– 24 months for boilers, this after the product was put into operation but maximum 30 months after the
date it was dispatched from the manufacturing factory
– 5 years for a boiler drum, this after the date it was dispatched from the manufacturing factory
In case of possible complaint regarding the shell the customer is obliged to submit the packing label
of the boiler shell. This is placed on the cardboard in which the shell has been dispatched.
The user is obliged to entrust a professional assembly firm with the commissioning and a
contractual professional service accredited by VIADRUS a.s., the manufacturer with the removal of
faults. Otherwise the guarantee for boiler proper function does not apply. „VIADRUS HERCULES
U 26 boiler quality and completeness certificate“ after its infilling serves as the „Guarantee certificate
“.
A regular boiler maintenance must be done by its user.
Every notice of a fault must be conveyed immediately after its detection, always via a telephonic
agreement and in writing.
If the above instructions are not observed the guarantees provided by the manufacturer will not be
recognized.
The manufacturer reserves the right to make changes within the product innovations that needn’t be
included in this manual.
The guarantee does not apply to:
•
the faults caused by a wrong assembly or wrong product operation and the faults caused by a
wrong maintenance, see chapter 9.
•
product damage arisen during the transport or other mechanical damage
•
the faults caused by unsuitable storage
•
the faults caused by the failure to observe the water quality in heating system, see chapter
no.5.1 and 6.2 or by using the anti-freeze mixture
•
the faults caused by the failure to observe the instructions stated in this manual
26
Information for customer
Packaging identification
Assessment reference
PE Plastic sacks, folie, corrugated board, iron and plastic fix
line
Identification of principal materials used. Paper, Polyethylene, iron, wood
Part 1: Summary of assessment
Standard/Report
Assessment requirement
1.1 Prevention by source
reduction
1.2 Heavy metals and
ensure below maximum permitted levels
for components
(CR 13695-1)
1.3 Other
ensure in compliance with
noxious/hazardous
(ČSN 77 0150-2, EN 13428)
substances
2 Reuse
ensure reusability in all terms of the
standard for the functional packaging unit
(EN 13429)
3.1 Recovery by material ensure recyclability in all terms of the
recycling
standard for the functional packaging unit
(EN 13430)
3.2 Recovery in the form
ensure that calorific gain is achievable for
of energy
the functional packaging unit
(EN 13431)
3.3 Recovery by
ensure compost ability in all terms of the
composting
standard for the functional packaging unit
(EN 13432)
Claim
Note
YES
YES
YES
NO
YES
YES
Iron - NO
NO
NOTE Conformity with EN 13427 requires affirmative responses to sections 1.1; 1.2; 1.3 and to at
least one of 3.1; 3.2; 3.3. In addition, where a claim of reuse is made section 2 should also
record affirmative responses.
Part 2: Statement of conformity
In the light of the assessment results recorded in part I above, this packaging is claimed to comply
with the requirements of EN 13427.
27
28
Annex to the guarantee certificate for customer- the user
Record of accomplished guarantee and after-guarantee repairs
Record
date
Contractual professional
service organization
(stamp, signature)
Carried out activity
29
Customer ´s
signature
30
31
32 – GB – model 2010
Date of revision 17/2013