Viadrus | Hercules P 1 | Technical data | Viadrus Hercules P 1 Technical data

VIADRUS HERCULES ECO
Manual for boiler operation and installation
GB_2015_11 SD
Table of contents:
1.
page
Produced boiler variants ..............................................................................................................................3
1.1
Purchase order .....................................................................................................................................3
2.
Boiler usage and advantages ......................................................................................................................3
3.
Boiler technical data ....................................................................................................................................5
4.
Boiler description .........................................................................................................................................7
4.1
Boiler drum construction.......................................................................................................................7
4.2
Construction of combustion chamber and fuel transport lines .............................................................8
4.3
Control, regulation and safety elements ...............................................................................................8
4.4
Boiler outfit and accessories ..............................................................................................................11
5.
Positioning and installation ........................................................................................................................13
5.1
Rules and regulations .........................................................................................................................13
5.2
Positioning possibilities.......................................................................................................................14
5.3
Boiler hydraulic diagram .....................................................................................................................16
6.
Boilers assembly .......................................................................................................................................17
6.1
Boiler drum installation .......................................................................................................................17
6.2
Burner assembly ................................................................................................................................18
6.3
Assembly of combustion chamber .....................................................................................................19
6.4
Assembly of the fuel transport lines ...................................................................................................24
6.5
Boiler shells and regulator assembly..................................................................................................25
6.6
Fuel reservoir assembly (this part is delivered optionally): .................................................................26
6.7
Filling the heating system with water ..................................................................................................27
7.
Commissioning- instructions for contracting service organization.............................................................28
7.1
Verification before commissioning. ....................................................................................................28
7.2
Boilers commissioning .......................................................................................................................28
8.
Boiler operation by user .............................................................................................................................29
8.1
MONEX regulator ...............................................................................................................................29
8.2
Boiler output setting ............................................................................................................................33
8.3
Boiler firing .........................................................................................................................................35
8.4
Boiler operation ..................................................................................................................................35
8.5
Boiler shut-down .................................................................................................................................35
9.
IMPORTANT NOTES ................................................................................................................................36
10.
Maintenance by user ..............................................................................................................................36
11.
Product liquidation instructions after service life ....................................................................................37
12.
Guarantee and liability for defects .........................................................................................................37
2
Dear customer,
we thank you that you have bought the VIADRUS HERCULES ECO automatic 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. 8 – Boiler operation by user, chapter no. 9 –
Important notes and chapter no. 10 – Maintenance by user). Please follow the undermentioned
information in order to guarantee a long-time and trouble-free boiler operation to both your and our
satisfaction.
1.
Produced boiler variants
1.1
Purchase order
In the purchase order there must be specified:
Purchase order specification code
VIADRUS HERCULES ECO X
Size:
5: 5 sectional design
10: 10 sectional design
1.
Boiler design (defined by the fuel reservoir position against the boiler drum in the front view):
left version
right version
2.
Optional accessories (see chapter 4.4.)
!ATTENTION! The fuel reservoir isn’t included in standard boiler accessories!
The version of the boiler you received is only intended for combustion of wooden pellets (see the specification
chp. no. 3) and its trade name is VIADRUS HERCULES ECO.
The boiler is manufactured as in warm-water design with forced heating water circulation and operating
overpressure up to 400 kPa (4 bar). Before dispatch it is checked for tightness by applying 800 kPa (8 bar)
test overpressure.
2.
Boiler usage and advantages
Usage:
•
•
VIADRUS HERCULES ECO 5 boiler is preferentially intended for heating the individual housing units,
cottages, weekend houses, office buildings, small premises, smaller leisure amenities, etc.
VIADRUS HERCULES ECO 10 boiler is preferentially intended for heating the medium size buildingsshops, schools, leisure amenities, medium size premises, big cottages etc.
Boiler advantages:
•
•
•
•
•
•
•
•
•
automatic operation controlled by an indoor device that guarantees a comfortable heating;
mechanical fuel supply from any reservoir;
simple, not time-consuming operation and maintenance;
high efficiency achieving up to 87 %;
low emissions complying with the values defined by „Environmentally friendly product”;
depending on boiler room disposition there can be chosen either the left-or right-hand side boiler version
(given by the fuel reservoir position);
boiler drum verified on a long-term basis;
high service life of the cast-iron boiler drum;
boiler drum guarantee 5 years.
3
Fig.no.1
VIADRUS HERCULES ECO with fuel reservoir front view– left version
Fig.no.2
VIADRUS HERCULES ECO with fuel reservoir rear view– left version
4
3.
Boiler technical data
Tab. no.1
Dimensions, boiler thermal& technical parameters
Number of section
Nominal output
Adjustable output
Fuel consumption
-1
(heating power approx. 17 MJ.kg )
Output in „inhibition“ regime
Fuel Consumption in „inhibition“ regime
Efficiency
Boiler category according to EN 303-5
Weight
Water space volume
Diameter of smoke socket
Delivered fuel reservoir capacity
Burning time at the nominal output
Burning time at the minimum output
Boiler dimensions: width x height x depth
Maximum water operating overpressure
Testing water overpressure
Heating water minimum temperature
Heating water maximum temperature
Minimum return water temperature
Chimney draught
Flue gases temperature
Flue gases mass flow rate at the output:
- at the nominal output
- at the minimum output
Boiler connections - heating water
- return water
Noise level
Connecting voltage
Electric input
Regulator electric coverage
kW
kW
kg. h
VIADRUS HERCULES ECO 5
5
24
7 – 24
VIADRUS HERCULES ECO 10
10
42
13 – 42
1,8 – 5,9
3,9 – 10,8
-1
kW
-1
kg. h
%
1,5
0,37
86,5
4
441
40,9
kg
l
mm
3
dm
kg
h
h
mm
kPa (bar)
kPa (bar)
°C
°C
°C
mbar
°C
87,3
4
645
64,4
156
725
470
80
261
1893 x 1407 x 1217,5
43,5
120,5
1893 x 1407 x 1697,5
400 (4)
800 (8)
60
90
40
-1
kg. s
-1
kg. s
Js
Js
dB
0,15 – 0,25
110 – 170
0,20 – 0,30
110 – 142
0,019
0,013
0,038
0,029
G 1 1/2“
G 1 1/2“
Doesn´t exceed level 60 dB (A)
1/N/PE 230 V AC 50 Hz TN - S
90
IP 65
W
* When keeping the minimum temperature of heating water
pz [Pa]
BOILER HYDRAULIC LOSS
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
HERCULES ECO 10
HERCULES ECO 5
0
0,5
1
1,5
2
5
2,5
3
3,5
4
4,5
3.
-1
Q [dm s ]
Specified fuel:
The pellets must comply at least with one of the standards or regulations as follows:
Regulation no.14-2000 MŽP ČR
DIN 517 31
ÖNORM M 7135
Prescribed pellets granularity: between 6 and 10 mm
Maximum fuel water content. 12%.
Ash content max. 1,5 %
WARNING!
A poor quality of fuel can markedly negatively affect the boiler output and emission
parameters
Fig.no. 3
Boiler dimension
(dimensions behind the slash apply to VIADRUS HERCULES ECO 10)
6
4.
Boiler description
4.1
Boiler drum construction
The main boiler component is the cast iron sectional boiler drum made of grey cast iron according to
EN 1561.
•
Central sections – quality 150 (previously ČSN 42 2415)
•
Front and rear sections – quality 200 (previously ČSN 42 2420)
The boiler pressure components comply with strength requirements according to EN 303-5.
The boiler drum consists of cast iron sections by means of forced on boiler insertions and is secured with
anchor bolts. The sections create a combustion chamber and the ash pan space, the water space and the
convection section. The ash pan space is divided from the combustion chamber through a solid water-cooled
grate.
Between the combustion chamber and the convection part of heat exchanger there are installed the ceramic
plates that regulate combustion and influence positively the emission values.
In the flue gases ducts of the heat exchanger convection part there are inserted the turbulators in order to
reduce the flue gases temperature thus to increase the boiler efficiency.
The boiler rear section has in its upper part a smoke adapter and heating water flange (G 1 1/2“), then in
lower part the return water flange (G 1 1/2“) with a sleeve piece for filling and discharging cocks (G 1/2“). To
the front section there are mounted the stoking and ash pan doors; the combustion chamber door is behind
them.
The whole boiler drum is insulated by using a health harmless mineral insulation which reduces the heat
interchange losses in surroundings. The steel boiler shell is treated by applying a good quality powder paint.
1.
2.
3.
4.
5.
6.
7.
Fig.no. 4
Cast iron boiler drum
7
Front section
Middle section
Rest section
Anchor bolt
Stoking door
Ash pan door
Smoke extension
4.2
Construction of combustion chamber and fuel transport lines
The combustion chamber consists of a longitudinal concave drum made of heat-resisting steel to which there
joins askew from below the piping for fuel supply with a screw conveyer for the combustion chamber. This
conveyer is also connected with pellets reservoir through another height offset (mismatch) screw conveyer
which is equipped with regulators functioning in dependence on discharging the combustion chamber
conveyer. The combustion chamber concave drum which is interconnected with forced air supply is equipped
with a system of slots in the side walls and in the bottom for the purpose of primary air supply.
Thanks to a convenient combustion chamber disposition the combustion chamber functional space doesn’t
get clogged with the combusted material. This after combustion is continually and mechanically expelled by
the fresh fuel supply. The unburnt fuel will not become clinkered neither will it become attached to
combustion chamber walls. The combustion is safe. Thanks to the regulated fuel supply and the screw
conveyer height offset (mismatch) there is excluded the fuel transport lines fire penetration.
The combustion chamber screw conveyer and the fuel reservoir screw conveyer are mutually interconnected
through a flex hose.
Combustion chamber is from above covered by a ceramic arch which directs the flames to the secondary air
inlets. This results in a better combustion with a significant reduction in light ash particles.
4.3
Control, regulation and safety elements
The boiler regulator serves for an automatic control of boiler activities and elements. It processes the input
data from the sensors and external control elements (see chap.8.1) and according to parameters set by the
manufacturer or user it controls automatically the boiler activity in required regimes.
The regulator also enables to operate the boiler manually which can be advantageously used to at boiler
commissioning.
A high variability in setting the limit and operating parameters makes it possible for both the manufacturer and
user to use fully and effectively the characteristics of automatic boilers for pellets it means an economical
boiler operation, controlled combustion process thus the toxicants content in flue gases minimization.
Emergency thermostat is installed in the regulator box and its function is to protect the heating system
against overheating. The manufacturer set it on 95 °C, it means the temperature higher than it can be set as
the required temperature at the boiler. In case that the emergency thermostat was switched off (the red
control lamp on regulator is on) the unblocking process must be done manually.
In case that the emergency thermostat was switched off repeatedly the boiler must be shut down and the
reason for repeated boiler overheating must be found out.
Programmable regulator - digital programmable indoor device (like HONEYWELL CM 27) intended for
automatic heating regulation in cottages and flats.
- 7-day heating time programme
- 6 time sections during a day with individual temperature, setting range 5 – 30 °C with 0,5 °C step
- programmable antifreeze protection for the season when the building isn’t used
- information about the real and required temperature in the room
ATTENTION! For boiler control there can only be used the free potential-free contact, switching
voltage is 5 V DC.
Thermomanometer serves for determination of heating water output temperature and its pressure in heating
system and it is installed in the upper part of boiler shells. The clack valve and the reservoir for
thermomanometer connection are situated in the upper part of rear boiler section.
Forced-draught fan for combustion air is mounted directly in combustion chamber body. The combustion air
volume is regulated by a throttling flap. The flue gases flow from the boiler to the chimney can be reduced by
a smoke flap. This is controlled by a handle with a tow bar in the upper left part of boiler drum next to the
stoking door.
The air rose of stoking door cannot be used at boiler with automatic combustion of wooden pellets and it
must be permanently closed.
Cleaning cover of the smoke adapter positioned in its lower part serves for flue gases ways cleaning.
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
The boiler body with armature
Turbulators
Ceramic plates
Burner
Fan
Sealing pr. 90x60x3
Flange of heating water
Flange of return water
Cock for filling and emptying G 1/2“
Side panel of the shell
11.
12.
13.
14.
15.
16.
17.
18.
19.
Side panel of the shell
Sticker for alarm of smoke damper
Rod
Upper panel of the shell
Thermomanometr
Controller RKU
Partition of combustion chamber
Partition of smoke channel
Gripping of partitions
Fig.no. 5a) Boiler VIADRUS HERCULES ECO 5
9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
The boiler body with armature
Turbulators
Ceramic plates
Burner
Fan
Sealing pr. 90x60x3
Flange of heating water
Flange of return water
Cock for filling and emptying G 1/2“
Side panel of the shell
Side panel of the shell
Fig.no. 5b)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Sticker for alarm of smoke damper
Rod
Upper panel of the shell
Thermomanometr
Controller RKU
Partition of combustion chamber
Partition of smoke channel
Plate for ashes on the sheet metal
Screw M6 x 25
Nut M6
Boiler VIADRUS HERCULES ECO 10
10
1.
2.
3.
4.
5.
6.
Stoking door
Insulation of stoking door upper
Insulation of stoking door lower
Ash pan door
Insulation of ash pan door upper
Insulation of ash pan door lower
•
Fig. No. 5c)
4.4
Stick door insulation by
boiler sealant.
Insulation of stoking door and ash pan door
Boiler outfit and accessories
A) Standard boiler outfit:
the boiler drum including fittings
shell side section incl. insulation
shell upper section incl. insulation
ash pan drawer
ceramic plate central
ceramic plate central with a riser
ceramic plate outer
ceramic plate frontal
turbulator
partition of smoke channel
tow bar of smoke flap control mechanism
burner incl. worm shaft, elbow pipe and adapter
combustion chamber ceramic arch
fuel feeder incl. a transport hose and strapping tapes
regulator
forced draught fan with a cover incl. throttling of the fan
brush butt-end
manual for boiler operation and installation
manufacturing plate
package (see point B)
•
fuel reservoir 725 l
fuel reservoir side
fuel reservoir side with an opening for screw
fuel reservoir leg
fuel reservoir bottom
fuel reservoir bottom A
fuel reservoir cover
handle
bolt M6 x 12
nut M6
bolt M6 x 16
11
1 pc
2 pcs
1 pc
1 pc
1 pcs / 3 pcs
0 pc / 3 pcs
1 pc / 1 pc
1 pc
4 pcs
2 pcs
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
3 pcs
1 pc
4 pcs
2 pcs
2 pcs
1 pc
1 pc
72 pcs
72 pcs
2 pcs
washer 8,4
pendant chainlet
2 pcs
1 pc
Notes:
1.) Number of pieces behind the slash apply to VIADRUS HERCULES ECO 10.
2.) The tow bar of smoke flap control mechanism includes:
- Control mechanism lever
- 2 pc washers 10,5
- 1 pc pins Ø 3 x 26 mm (for the lever mounting)
B) Accessories in the package:
plug blind 6/4”
sealing Ø 60x48x2 mm
bakelite ball for draw bar
split pin 2,5 x 32
label for smoke flap signalling
thermomanometer
logo VIADRUS
SK strip Ø 70 - 90
heating water flange G 1 1/2"
return water flange G 1 1/2"
sealing Ø 90x60x3 mm
elbow 1/2”
filling and discharging cock 1/2“
partition of combustion chamber
gripping of partitions
plate for ashes on the sheet metal
insulation of stoking door upper
insulation of stoking door lower
insulation of ash pan door upper
insulation of ash pan door lower
adapter (reduction)
brush
tip of the spike
dowel 8 mm
clinch straight threaded 5 x 60
flexo 3C x 0,75, L = 4,5 m
cable CMSM 3C x 0,75, L=1,8m
cable CMSM 3C x 0,75, L=2m
bushing PG 9
bushing HEYCO SB - 625-8
dummy plug 15,9
capillary spring
cable holder self-adhesive
binding band – 160 mm
insulating girdle on the flat cup
nut M10
washer 10,5
pad10,5 (large)
bolt ST 4,8 x 13
bolt M6 x 12
spring washer 6,4
panel pin
serrated washer 5,3
nut M 5
bolt M6 x 25
nut M6
boiler cement
1 pcs
2 pcs
1 pc
1 pc
1 pc
1 pc
1 pc
2 pcs
1 pc
1 pc
2 pcs
1 pc
1 pc
2 pc
1 pc/0 pc
0 pc/1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
1 pc
2 pcs
1 pc
1 pc
2 pcs
1 pc
6 pcs
2 pcs
2 pcs
1 pc
4 pcs
5 pcs
3 pcs
12 pcs
8 pcs
4 pcs
4 pcs
4 pcs
4 pcs
4 pcs
4 pcs
4 pcs
2 pcs
2 pcs
1 pc/2 pcs
C) Optional accessories:
digital indoor device (according to VIADRUS a.s. offer)
•
•
u rear section shut
The optional boiler accessories are not included in boiler basic price.
12
5.
Positioning and installation
5.1
Rules and regulations
The solid fuels boiler can only be installed by a firm authorized to mount these equipments. A project
according to valid regulations must be prepared for installation. The heating system must be filled
with water that meets the requirements ČSN 07 7401 and especially its hardness must not exceed the
required parameters.
Recommended values
Hardness
mmol/l
2+
Ca
mmol/l
total o 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.
a) to the heating system
ČSN 06 0310
ČSN 06 0830
ČSN 07 7401
EN 303-5
b) to the chimney
ČSN 73 4201
Heating systems in buildings – Designing and installation
Heating systems in buildings – protecting device
Water and steam for thermal energy equipments with working pressure
up to 8 MPa.
Boilers for central heating – Part 5: Solid fuel boilers for central heating with
manual or automatic feed and max. 500 kW nominal thermal output:
terminology, requirements, testing and marking.
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.
e) regarding the electric network
CSN 33 0165
Electrical regulations. Identification of conductors by colours or numerals.
Procedure provisions
ČSN 33 1500
Electrical regulations; revision of electrical equipments
ČSN 33 2000-1 ed. 2
Low-voltage electrical installations – Part 1: Fundamental principles,
assessment of general characteristics, definitions.
ČSN 33 2000-4-41 ed. 2
Low voltage electrical installations - Part 4- 41: Protection for safety Protection against electric shock
ČSN 33 2000-5-51 ed. 3
Electrical installations of buildings – Part 5-51: Selection and erection of
electrical equipment – Common rules
ČSN 33 2130 ed. 2
Low-voltage electrical installations – Internal electric distribution lines
ČSN 33 2180
Electrical regulations: Connection of electric instruments and appliances
ČSN 34 0350 ed. 2
Safety requirements for flexibile cords and cables
EN 60079-10-1
Explosive atmospheres — Part 10-1: Classification of areas — Explosive gas
atmospheres
EN 60079-14 ed.3
Explosive atmospheres - Part 14: Electrical installations design, selection and
erection
EN 60252-1 ed. 2
Capacitors for AC motors – Part 1: In general – Design, testing, dimensioning
– Safety requirements – Instructions for installation and operation.
EN 60 335-1 ed.2
Electric appliances for household and similar purposes – Safety – Part 1:
General requirements
EN 60 335-2-102
Electric appliances for household and similar purposes – Safety – Part 2-102:
Special demands on appliances containing the electric connections and
burning the gas, oil and solid fuels
EN 60445 ed. 4
Basic and safety principles for man-machine interface, marking and
identification – Identification of equipment terminals, conductor terminations
and conductors
13
EN 61000-6-3 ed. 2
EN 61000-3-2 ed. 3
EN 61000-3-3 ed. 2 (ed. 3)
5.2
Electromagnetic compatibility (EMC) - Part 6-3: Generic standards – Emission
standard for residential, commercial and and light industrial environments
Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic
current emissions (equipment input current ≤16 A per phase)
Electromagnetic compatibility (EMC) - Part 3-3: Limits - Limitation of voltage
changes, voltage fluctuations and flicker in public low-voltage supply systems,
for equipment with rated current ≤16 A per phase and not subject to
conditional connection.
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.
Boilers positioning with regard to the fire regulations:
1. Positioning on the floor made of incombustible material (see Fig.6)
− install the boiler on the fireproof base material exceeding the boiler platform by 20 mm on the sides
and only in boiler drum depth.
− If the boiler is positioned in a cellar we recommend to install it on an under-plate (bedding) minimum
50 mm high; the boiler must be installed horizontally.
Fig. no. 6 Dimensions of a bedding under the boiler drum
(dimensions behind the slash apply to VIADRUS HERCULES ECO 10)
2. Safe distance from 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.
Tab. no. 2 Grade of reaction to fire
Examples of building materials and products included in the reaction to fire
(Extract from EN 13501-1 + A1)
Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters, …
A1 – incombustible
A2 – combustible with difficulty acumin, izumin, heraklit, lignos, boards and basalt felt, fibreglass boards,...
Beech and oak wood, hobrex boards, plywood, werzalit, umakart, sirkolit,...
B – hardly combustible
Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,...
C (D) – medium combustible
Asphaltboard, fibreboards, cellulose materials, polyurethane, polystyrene,
E (F) – easily combustible
polyethylene, PVC,…
Grade of reaction to fire
14
Boilers positioning with regard to the necessary handling space:
•
•
Basic setting AA5 / AB5 according ČSN 33 2000-1 ed. 2
Minimum 2100 mm boiler room height (when the fuel reservoir cover is fully open)
Fig.no. 7
Positioning of boiler in boiler room
(dimension behind the slash applies to VIADRUS HERCULES ECO 10)
Boilers positioning with regard to the electricity network:
•
•
•
Boiler must be installed in a way making sure that the plug in the socket (230 V/50 Hz) is always
accessible.
Boiler is connected to the el. network through a wired in and movable cord terminated by a standardized
plug.
Protection against electric shock must be provided according to valid EN (see chap.5.1.)
Fuel positioning:
•
•
•
for a correct fuel combustion in boiler there must be used dry fuel (up to 12% moisture). We
recommend to store the pellets in their original package from manufacturer (PET bags) on a dry place.
it is out of question to store the fuel behind the boiler or to store it next to boilers in a distance less than
400 mm
the manufacturer recommends to keep min. 1 000 mm distance between boiler and fuel or to store fuel
in a room different from that where boiler is installed.
The room where boiler is installed must be provided with permanent air supply for combustion and
possibly with ventilation (the air consumption at VIADRUS HERCULES ECO 5 boilers is approx.
3
-1
3
-1
80 m . h , (the air consumption at VIADRUS HERCULES ECO 10 boilers is approx. 160 m . h ).
The heating system piping connection must be done by a person authorized according to
regulations.
WARNING:
At a boiler connected to the heating system there must be installed a discharge cock
at the lowest point and as close as possible to boiler.
15
5.3
Boiler hydraulic diagram
Legend of piping, signs and symbols in the diagrams:
Fig. no. 8
Recommended diagram of boiler connection to the heating system
16
6.
Boilers assembly
6.1
Boiler drum installation
1. Set up the e boiler drum on the bedding (see Fig. no 6).
2. Insert the sealing ∅ 90 x 60 x 3 on the upper flanged part of the rear boiler section and bolt the flange of
heating water (see Fig. no 5) and connect the other end with the heating system.
3. Insert the sealing ∅ 90 x 60 x 3 on the bottom flanged part of the rear boiler section and bolt the flange of
return water with a sleeve for the filling and discharge cock (see Fig. no 5) and connect the other end with
the heating system. In order to guarantee the boiler protection against low-temperature corrosion we
recommend to install a thermostatic valve in heating system (like ESBE TV 40).
4. For boiler connection to the heating system there must be screwed an elbow with filling and discharge
cock in the return water flange sleeve.
5. Set the smoke pipe on the smoke adapter and insert it into chimney opening
6. Threaded hole Js 6/4 "in the front boiler section is blinded with a plug Js 6/4" with sealing ∅ 60 x 48 x 22.
7. By means of boiler putty are stuck 4 pieces of insulation according to Fig. no 5c into the stoking and ash
door.
Fig. no. 9
Connection dimensions at boiler
17
6.2
Burner assembly
1.
Spread the boiler cement on the flange of the fan and screw the fan to the air flange (7) by means
of 4 screws M6 x 12 (5) and spring washers (6).
2.
Spread the boiler cement around the rectangular hole in the rear section and put the burner on 4 pieces
of stud bolts M10. Ensure the burner by means of nuts M10 (3) and washers 10.5 (2).
1.
2.
3.
4.
5.
6.
7.
Fig.no.10
Burner assembly
18
Burner
Washer 10,5
Nut M10
Fan
Bolt M6 x 12
Spring washer 6,4
Air flange
6.3
Assembly of combustion chamber
1. Through the stoking door insert the ceramic arch into the combustion chamber (Fig. no. 12) and mount it
on the fireplace with the open part forward (see Fig. no.13 and 14).
2. Insert through the stoking door by using a tool 2 pcs partitions of combustion chamber (see Fig. no. 13a
and 14a), so that they are in a vertical position at the level of head of the ceramic vault. In case of
VIADRUS HERCULES ECO 5 set up the partitions of combustion chamber (1) into the sheet metal for
gripping of partitions (3). In case of VIADRUS HERCULES ECO 10 insert the partitions of combustion
chamber (1) into the combustion chamber of boiler and mount the plate for ashes (3) on the sheet metal
by means of 2 screws M6 x 20 and nuts M6. The whole assembly is inserted up to the stop of ceramic
vault of burner.
3. Through the stoking door mount the ceramic plates into the combustion chamber on the side risers of the
sections (see Fig.13 a 14). For boiler there exist 4 types of ceramic plates (see tab. 3 a Fig. no. 11).
Mount the ceramic plates according to Fig. no. 13 and 14.
When mounting the ceramic plates is necessary to mind that the plates sit properly on the risers of the
sections and fit together with their locks. Possible leakage can be sealed by sealing cement with
resistance up to 1200 °C (like ZWALUW) or heat-resisting concrete.
4. Insert through the stoking door 2 pcs partitions of smoke channel (see Fig. no. 15).
5. Through the stoking door insert into the convection part of cast-iron heat exchanger (4 smokes channels)
4 pc turbulators (see Fig. no. 13a and 14a).
Fig. no. 11
Ceramic plate
central
Ceramic plate
outer
Ceramic
plate central
with risers
Ceramic plate
frontal
Ceramic plate shape for VIADRUS HERCULES ECO 10
Tab. no. 3 Number of ceramic plates for individual sizes of boilers
Boilers size
VIADRUS HERCULES ECO 5
Ceramic plate central
1
Ceramic plate central with risers
0
Ceramic plate outer
1
Ceramic plate frontal
1
Fig.no. 12
VIADRUS HERCULES ECO 10
3
3
1
1
Ceramic arch for VIADRUS HERCULES ECO 10
19
1.
2.
3.
4.
5.
6.
7.
Ceramic plate frontal
Ceramic plate outer
Ceramic plate central
Ceramic arch
Burner
Partition of smoke channel
Partition of combustion chamber
Fig. no. 13
Ceramic plates and partition mounted in VIADRUS HERCULES ECO 5
20
1.
2.
3.
Partition of combustion chamber
Turbulators
Gripping of partitions
Fig. no. 13a)
21
1.
2.
3.
4.
5.
6.
7.
8.
Ceramic plate frontal
Ceramic plate outer
Ceramic plate central
Ceramic plate central with risers
Ceramic arch
Burner
Partition of smoke channel
Partition of combustion chamber
Fig. no. 14
Ceramic plates and partition mounted in VIADRUS HERCULES ECO 10
22
1.
2.
3.
Partition of combustion chamber
Turbulators
Plate for ashes on the sheet metal
Fig. no. 14a)
23
1.
Partition of smoke channel
Fig. No. 15
6.4
1.
2.
3.
4.
5.
Fitting of partitions of smoke channel
Assembly of the fuel transport lines
Fuel tank
Feeder of fuel tank
Pendant chainlet
Transport hose
Burner
6.
7.
8.
9.
Fig.no.16
Fan
Screw conveyor
Knee
Adapter (reduction)
Assembly of the fuel transport lines
24
1. Place the fuel tank (1) on the desired location next to the boiler (see Fig.no.7). Push the screw conveyor
of the fuel tank (7) through the hole in the side of fuel tank and secure it with a pendant chainlet (3).
Insert the elbow pipe (8) into the hole ∅ 76 mm in the burner and insert an adapter (reduction) (9) with a
wider side into the elbow pipe. Connect the adapter (reduction) with worm conveyor of fuel reservoir (7)
through a transport hose (4). Secure both ends of the transport hose (4) with hose clamps.
ATTENTION! The fuel reservoir screw conveyor must be mounted in a way making sure that there
is a sufficient gradient of flex hose against the pellets falling freely on the combustion chamber
screw conveyor without stopping the hoses with pellets.
2. Mount the combustion air ventilator on the combustion chamber sleeve with the choke valve screwed
ahead on the ventilator suction side.
3. Carry out the electrical interconnection of motors and fan with the controller; see the wiring diagrams
(Fig. no. 21 and see chap. 8.1).
6.5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Boiler shells and regulator assembly
Left side panel of the shell
Panel pin
Washer 5,3
Nut M10
Insulation of the side panel of the shell
Bushing HEYCO
Rod
Washer 10,5
Lever of the control mechanism
Pin 3x26
Split pin 2,5x32
Fig.no.17
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Sticker for alarm of the smoke damper
Right side panel of the shell
Insulation of the side panel of the shell
Blind flange 15,9
Upper panel of the shell
Insulation of the upper panel of the shell
Thermomanometer
Controller RKU
Bolt ST4,8x13
Bakelite ball for draw bar
Boiler shell
25
1. Take out the shell from cardboard cover.
2. According to Fig. no. 17 mount the delivered joining material into the shell.
3. Loosen the lower anchorage screws, set on the side boiler shell consoles. Insert the front consoles
between the washers with nuts and the front section body, insert the rear consoles directly on anchorage
bolts. By lifting set the boiler shell bearing edges behind the upper anchorage bolts. Tighten adequately
the lower anchorage bolts nuts.
4. Mount the other boiler shell side part in a similar way.
5. Lead out the heating water sensor and the emergency thermostat capillary from the regulator. Connect
the ventilator cable (1,8 m), combustion chamber screw conveyor cable (1,8 m), fuel reservoir screw
conveyor cable (2 m), possibly the pump cable and indoor thermostat cable to the regulator. Insert the
whole into the opening in the middle part of boiler shell upper part (after having removed the insulation
before). Secure the regulator from below by means of 4 pc bolts C 4,8 x 13. Lead out all cables by
bushings through the openings in rear part of boiler shell upper part.
6. Build in the thermomanometer in the boiler shell upper part. It is necessary to insert back the insulation
before the boiler shell upper part setting. At the assembly insert the thermometer sensors and the
emergency thermostat capillary into the reservoir in the upper middle part of the rear section, screw on
the manometer sensor into the reverse valve for manometer on the rear section of boiler drum. Secure
the sensors in the reservoir by a spring.
7. Stick the manufacture plate on the rear part of boiler shell upper part (this is included in manual for boiler
operation and installation).
8. According to Fig.no.17 continue in smoke flap control completion.
9. Screw on the brush in handle sleeve.
6.6
1.
2.
3.
4.
5.
Fuel reservoir assembly (this part is delivered optionally):
Fuel reservoir side
Fuel reservoir side with the screw hole.
Fuel reservoir leg
Fuel reservoir bottom
Fuel reservoir bottom A
Fig.no. 18
6.
7.
8.
9.
10.
Bolt M6 x 16
Washer 8,4
Fuel reservoir cover
Handle
Bolt M6 x 12
Fuel reservoir assembly
26
1.
2.
Screw together the bottoms of fuel reservoir. The bottom of the reservoir must alternate with the fuel
reservoir A. As the joining material serve:
- Washer 6,4
72 pcs
- Nut M6
72 pcs
- Bolt M6 x 12
72 pcs
- Bolt M6 x 16
2 pcs
- Washer 8,4
2 pcs
To this whole screw on gradually the side and leg of fuel reservoir.
3.
Set together in a similar way other 3 vertical walls of fuel reservoir.
4.
Screw the pendant chainlets to the fuel tank according to Fig.no.19.
5.
Screw the handle to the cover of the fuel reservoir by means of 2 screws M6 x 12
6. Cover the whole with the fuel reservoir cover.
Note.:
Alternatively the rivets can be used as joining material for fuel reservoir assembly, except
position 6 and 7.
1.
2.
3.
4.
5.
Fig. no. 19
6.7
Pendant chainlet
Nut M6
Washer 6,4
Washer 8,4
Screw M6 x 16
Mounting of pendant chainlets to the fuel tank
Filling the heating system with water
Water for boiler and heating system filling must be clear and colourless, with no suspended materials, oil and
aggressive chemicals. Its hardness must correspond to ČSN 07 7401 and it is necessary that in case that the
water hardness doesn’t comply water must be treated. Even heating the water with a higher hardness several
times does not prevent the soils from getting precipitated on the boiler drum walls. Precipitation
of 1 mm calcite reduces at given point the passage of heat from the metal to water by 10%.
The heating systems with an open expansion reservoir allow a direct contact between heating water and
atmosphere. During the heating season the expanding water in the reservoir absorbs the oxygen which
increases the corrosion effect and at same time lot of water gets evaporated. It can only be replenished by
water treated according to ČSN 07 7401.
The heating system must be properly rinsed in order to wash out all impurities.
During the heating season the water volume in heating system must be kept constant. When refilling the
heating system it has to be prevented from air intake. Water from boiler and 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.
In case we have to refill the heating system with water we only do this when the boiler is cold in order
to prevent the cast iron boiler drum from getting damaged.
After the fill-up check all joints at the boiler and heating system for their tightness!
The assembly completion and stoking test accomplishment must be recorded in “Guarantee
certificate”.
27
7.
Commissioning- instructions for contracting service organization
Boilers commissioning can only be done by contracting service organization authorized to do this
activity.
7.1
Verification before commissioning.
Before boilers commissioning there must be checked:
a) Heating system filling with water (thermomanometer check)
b) Heating system tightness
c) Connection to the chimney– must be approved by a chimney firm
d) Connection to the electricity network – must be approved by an authorized firm
The sockets are connected in a way making sure that the protection plug is at the top and the phase
conductor is connected to the left tube when viewed from the front. The same applies to the double
sockets.
7.2
Boilers commissioning
1. Fire the boilers (see chap.8.3.).
2. Bring the boiler to the necessary operating temperature. Recommended temperature of outlet heating
water is between 60 and 90°C.
3. Check again visually the boiler tightness.
4. Carry out the stoking test according to relevant standards (see the guarantee certificate)
5. Make the user acquainted with boiler operation (see chap.8).
6. Make a record in guarantee certificate.
28
8.
Boiler operation by user
8.1
MONEX regulator
The regulator is positioned in an unified compact plastic box. Under the plastic cover able to open there is the
frontal panel which consists of the main circuit breaker, keyboard and indication elements.
3
1 main switch, fuse 6 A
Automatics for biomass combustion boilers
ka pro kotle na spalování biomasy
°C
I
1 2 3
1
0
Outlet
water
temp.
STOP Emergency
automat
manual
Inhib.
4
5
6
7
8
9
*
0
#
7
8 2 emergency thermostat
cover
9
4 3 left part of display output water
5
temperature display
4 right part of display operating status display
6 5 keyboard
Functions on keyb.
thermostat
2
1 - ventilator
2 – fuel feeder
3 – req. outlet water temp.
4 – feeder on
5- feeder off
6 instructions for
keyboard use
6 - max.inhib.time
7 ventilator drifting
* - setting
# - START automat
1 , 2 - STOP automat
7 ventilator symbolu
8 fuel symbol
9 pump symbol
Fig. no. 20
MONEX regulator control panel
It enables the settings as follows:
•
Outlet heating water temperature
•
Automatic regime of screw conveyors and ventilator
•
Parameters for inhibited regime
•
screw conveyor and ventilator manual operation
It is equipped with an inlet for indoor thermostat. It ensures the circulating pump operation (the pump is put
into operation after the heating water temperature of 40 °C has been exceeded) and its after-running before
switching off.
The regulator ensures an automatic drifting of combustion chamber screw conveyor in that sense, that
after every fuel reservoir screw conveyor stop the combustion chamber screw conveyor keeps working for
another 8 seconds.
Tab. no. 4
Technical parameters of MONEX regulator
Nominal supply voltage 230V, 50 Hz, 3 VA max.
Input without the appliances
V / Hz
VA
Inputs
Output heating water temperature sensor
Indoor thermostat
Fuel feeder 230 V / 2 A
ventilator 230 V / 2 A
circulating pump 230 V / 2 A
Outputs
Steady set parameters:
Pump
Ventilator after-running
Conveyor continuous operation
Automatic operation after inhibition
Automatic operation output water temperature drop
below 30 °C
Optional parameters:
output water temperature
Fuel conveyor on
Fuel conveyor off
inhibition
Box coverage grade
230 / 50 + 10% - 15%, TN - S
max. 3
min
s
min
min
min
°C
s
s
min
29
4
5 - 99
max. 10
2
60 / 30
60 - 90
5 - 90
5 - 90
5 - 90
IP 65
STOP
red
(burner)
L spiral worm (screw) 2
L screw 1 - fuel reservoir feeder motor
L screw 2 - burner motor
(fuel reservoir)
Finder
relay
65.31
type
Thermal sensor on the output
Finder
relay
65.31
type
thermal protection
equipment block
Blockage of the boiler free
contact (without potential)
automatic restart choice
timer
L spiral worm (screw) 1
Note:
To the connectors “TP motor 1 and 2”
(thermal overload/ motor protection) no
voltage must be brought
Wiring diagram of RKU 2 for motors with thermal protection
Filtr = filter
Čerp = pump
Vent(il) = valve
Šnek = screw
Clamp TP motor 1 and TP motor 2 are connected with appropriate thermal protections on bin´s motor and
feeder machine´s motor.
In case of motors without thermal protection usage is necessary to clamps TP motor 1 connect and also
clamps motor 2 to connect with conductor.
Fig. no. 21
Wiring diagram of MONEX regulator for motors with thermal protection
30
1. Manual operation
For the boiler ignition it is necessary to operate manually the fuel conveyor
and ventilator. For this purpose there serve the pushbuttons 1 and 2.
Pushbutton 1 operates the ventilator, pushbutton 2 the fuel conveyor. By
pressing the relevant unit is switched on and by repeated pressing the
relevant unit is switched off. The ventilator operation is displayed by
burning line(stroke) under the ventilator symbol. Once the ventilator stops
the line goes out. The same applies to the fuel conveyor operation indication. It is indicated by a line(stroke)
under the fuel symbol. The fact that the boiler is manually operated is indicated on display by abbreviation ru
and burning stroke at the notice „manual“.
2. Fuel conveyor cycles setting
For a correct boilers function it is necessary to set an optimal proportion between the time for fuel feeding
(conveyor works) and the time for fuel afterburning (conveyor in resting stage)
a) By pressing the pushbutton 4 there appears on display the data like on
15 and it means the operation of fuel reservoir screw conveyor 15
(combustion chamber screw conveyor works parallel, but incl. afterrunning). The value can be changed by pressing the pushbutton * and
entering a new digit combination like 20. Then oF 20 is alight on
display. The decision correctness must be confirmed by pushbutton *.
Confirmation o.k. must appear on display. The fuel feeding time can be set within 3 - 90 s, see tab. no.5.
b) By pressing the pushbutton 5 there appears on display the data like oF
20 and it means that the conveyor is in a resting state for 20 s. The
value can be changed by pressing the pushbutton * and entering a new
digit combination like 30. Then oF 30 is alight on display. The decision
correctness must be confirmed by pushbutton *. Confirmation o.k.
must appear on display. The after-combustion time can be set within 3 - 90 s, see tab. no.5.
3. Inhibition duration setting
If the heating water outlet temperature has exceeded the set limit the regulator will shut down the fuel feeder
and ventilator until the temperature drops below the set limit with hysteresis -3 °C. It could happen that this
time is too long and the boiler burns out. That’s why there is set the maximum shut down time so called.
inhibition duration. Once it has passed over the ventilator and fuel conveyor start up automatically within
2 minutes, independently on heating water outlet temperature. Then the regulator comes back into inhibition
status and follows the heating water outlet temperature. The circulating pump is constantly switched on. The
same can be induced by indoor thermostat once the room temperature has been exceeded. Then besides
the induction into the inhibition status there is switched off the circulating pump while keeping the 4 minutes
after-running.
By pressing the pushbutton 6 there appears on display the data like Ut 20 and it means the 20 minutes
inhibition duration. The value can be changed by pressing the pushbutton
* and entering a new digit combination like 30. Then oF 30 is alight on
display. The decision correctness must be confirmed by pushbutton *.
Confirmation o.k. must appear on display. The inhibition duration can be
set between 5 and 90 minutes. Recommended value is 30 min. If in this
regime the heating water temperature significantly rises (first of all in
summer season, when there is a minimum heat take-off from the
system), it is recommended to increase this value.
Inhibition on display is indicated by a burning point in its right lower
Indikace
útlumu
Inhibition
corner.
4. Outlet water temperature setting
The required outlet water temperature is set by means of pushbutton 3.
On display there appears the data like Pt 70 and it means the required
outlet water temperature of 70 °C. The value can be changed by pressing
the pushbutton * and entering a new digit combination like 75. Then Pt 75
is alight on display. The decision correctness must be confirmed by
pushbutton *. Confirmation o.k. must appear on display. The required
outlet water temperature can be set between 60 and 90 °C. It is
recommended to operate boiler at temperatures higher than 65 °C.
31
5. Ventilator after-running time setting
The required ventilator after-running time is set by means of pushbutton
7. On display there appears the data like VE 60 and it means the required
ventilator after-running time of 60 s. The value can be changed by
pressing the pushbutton * and entering a new digit combination like 70.
Then VE 70 is alight on display. The decision correctness must be
confirmed by pushbutton *. Confirmation o.k. must appear on display. The
required outlet water temperature can be set between 5 and 90 seconds.
The recommended value is 50 s.
6. Regulator error conditions
During the operation there might appear the outlet water temperature sensor failure. This will be indicated on
display by blinking Er inscription and the regulator is in inhibition status. There only runs two-minutes stoking
after the inhibition time passed over.
On the display there is blinking Er inscription – heating water temperature measuring is outside the measured
range (0 °C - 99 °C).
Possible reasons:
- temperature sensor damage
- sensor conductor interruption
- temperature –frequency converter faulty
Al these failures can only be eliminated by a special contracting service worker.
Note.:
During the boiler commissioning process and after the regulator has been switched on or
occasionally already during the boiler automatic operation there flickers on display the message
Er, but this means that the converter gets setting and within several minutes this message is
replaced by the measured temperature.
7. Choke valve
The volume of dosed combustion air can be regulated at MONEX regulator by a choke valve on ventilator.
This volume depends on the fuel quality. Generally it applies: the higher the heating power (depending on the
sort of fuel, granularity, moisture, quality etc.), the smaller the need of supplied air.
After adjustment of combustion air to tighten the screw so that would not be spontaneously unscrewed. There
is the strangling flap of the fan on fig. no. 22.
The optimal air supply regulation is that one depending on flue gases temperature. Under the common
operation (the boiler isn’t enormously clogged with fly ash and tar) at the nominal output of VIADRUS
HERCULES ECO 5 (24 kW) the flue gases temperature should not exceed the limit 170 °C, at the nominal
output of VIADRUS HERCULES ECO 10 (42 kW) this limit is 142 °C. If it is the other way round it is
necessary to choke the supplied air volume.
Fig. no. 22
Strangling flap of the fan
32
8.2
Boiler output setting
In following tables (table no. 5 and table no. 6) there are stated only orientation values and are valid
only for tested fuel.
Tested fuel:
pelets Ø 8 mm
Efficiency 16,4 MJ/kg
! Important notice:
Stated values changing in dependence on kind, quality and humidity of used pellets. Therefore may
be necessary some corrections during adjustment of feeding cycle (rate of time for fuel feeding and
time of fuel afterburning). F.e. if will appear on the grill and in the ash-pan sliver, is evident that
feeding speed is higher than burning speed and is necessary the feeding cycle decrease.
Table no. 5 Boiler output adjustment - VIADRUS HERCULES ECO 5
Boiler output
Time for fuel
Time for fuel
Quantity of combustion air [%]/
[kW]
feeding [s]
afterburning [s]
Adjustment of starling flap of the fan on nr.
7,5
7
90
5 / 0,5
8
11
90
5 / 0,5
9
15
90
5 / 0,5
10
18
90
10 / 1
11
21
90
10 / 1
12
25
90
10 / 1
13
30
90
15 / 1,5
14
33
90
15 / 1,5
15
35
90
15 / 1,5
16
35
84
20 / 2
17
35
78
20 / 2
18
35
72
20 / 2
19
35
66
25 / 2,5
20
35
60
25 / 2,5
21
35
56
25 / 2,5
22
35
53
30 / 3
23
35
50
30 / 3
24
35
46
30 / 3
25
35
43
30 / 3
100
90
80
Time for fuel afterburning [s]
70
60
50
40
30
20
10
0
5
7
9
11
13
15
17
19
21
23
25
Boiler output [kW]
Fig. no. 23
Boiler output graph on time of fuel afterburning at the same time for fule feeding (5 s)
for boiler VIADRUS HERCULES ECO 5
33
Table no. 6 Boiler output adjustment - VIADRUS HERCULES ECO 10
Boiler output
Time for fuel
Time for fuel
Quantity of combustion air [%]/
[kW]
feeding [s]
afterburning [s]
Adjustment of starling flap of the fan on nr.
12,1
25
90
5 / 0,5
12,6
27
90
5 / 0,5
13
30
90
10 / 1
14
33
90
10 / 1
15
35
90
15 / 1,5
16
35
84
15 / 1,5
17
35
78
20 / 2
18
35
72
20 / 2
19
35
66
25 / 2,5
20
35
60
25 / 2,5
21
35
56
30 / 3
22
35
53
30 / 3
23
35
50
35 / 3,5
24
35
46
35 / 3,5
25
35
43
40 / 4
26
35
40
40 / 4
27
35
37
45 / 4,5
28
35
35
50 / 5
29
35
32
55 / 5,5
30
35
30
60 / 6
31
35
28
65 / 6,5
32
35
26
70 / 7
33
35
24
70 / 7
34
35
22
75 / 7,5
35
35
20
80 / 8
36
35
18
80 / 8
37
35
16
85 / 8,5
38
35
15
90 / 9
39
35
14
90 / 9
40
35
13
95 / 9,5
41
35
11
100 / 10
42
35
10
100 / 10
100
90
80
Time for fuel afterburning [s]
70
60
50
40
30
20
10
0
10
15
20
25
30
35
40
45
Boiler output [kW]
Fig. no. 24
Boiler output graph on time of fuel afterburning at the same time for fule feeding
(10 s) for boiler VIADRUS HERCULES ECO 10
34
8.3
Boiler firing
1.
2.
3.
4.
5.
6.
7.
Check the water volume in heating system.
Check, whether the closing valves between the boiler and heating system are open.
Check the circulating pump functionality
Clean the combustion chamber, firing chamber and the ash-pan
Check the correct way of mounting the ceramic plates in combustion chamber.
Fill the reservoir with prescribed fuel.
The boiler is put into operation by means of a manual regime of regulator. By means of screw conveyor
we supply the fuel to the combustion space. Let the conveyor in operation until a half of the fire chamber is
filled with fuel.
8. Place the kindling on the fuel (it means paper, wood chips, solidified alcohol or other material intended for
this purpose), light it and let it burn up (approx. 1 - 2 min).Than using a shovel add to burning kindling a
small amount of pellets and switch on the ventilator for a short time. Repeat this procedure 2 - 3 times.
9. Close the door and let the fire flare up properly (approx. 3 - 5 min). The stoking and ash-pan doors must
be kept permanently closed during the boilers operation.
Note: During the boiler firing process the regulator follows the outlet water temperature. There is
expected an increase in temperature above 30 °C. If this doesn’t occur within 60 min, regulator
will pass over into the stop status (ventilator, fuel conveyor and the pump switch off with afterrunning).
The same will happen already after 30 min if during the automatic operation for any reason the
output water temperature drops below 30 °C. The regulator will switch off all units while
respecting the after-running and will be left in stop status until the manual operation has been
carried out. All the time the inscription STOP is alight on the display.
8.4
Boiler operation
After the above parameters have been set and the fuel started to flare properly it is possible to pass into the
automatic operation with ventilator and screw conveyors cycling switched on. On display there is displayed
the actual heating water output temperature and the system status.
Once the water temperature set on the control thermostat has been achieved the boiler operation will become
automatic, with set air and fuel supply. Then the boiler automatically will pass into „inhibition” regime where it
will be left until the heating medium temperature has dropped below the value set on control thermostat
If the heating system takes a minimum volume of thermal energy the boiler is able to work continuously in the
„inhibition” regime (top-fed stove operation) as long as the fuel is in reservoir. In this status like at setting the
inhibition duration of 30 minutes the average boiler output is approx. 1,5 kW at the fuel consumption
of 0,37 kg/h.
In case of feeding voltage (230 V, 50 Hz) outage the regulator remembers its status and keeps it after supply
restoration. If it was in automatic operation then it comes back into automatic operation with water output
temperature control (>30 °C) for 30 minutes. If the temperature during this time does not exceed
30 °C, the regulator switches off the fuel conveyor, ventilator and the pump with after-running. In case that the
regulator before the outage was in inhibition, then after the supply restoration the regulator immediately gets
for 2 minutes into the automatic operation (like in inhibition) and after this time it is controlled according to the
actual status.
Once the critical output water temperature has been exceeded the emergency thermostat will respond and it
will switch off the fuel conveyor and ventilator, independently on regulator. The pump is left in operation.
If the emergency thermostat control lamp is on:
1.) The heating water critical temperature was exceeded and the emergency thermostat responded to it by
disconnecting the fuel conveyor and ventilator supply. The emergency thermostat can only be switched
on after the temperature has dropped below the set value by unscrewing the black cover of the
emergency thermostat and we press the red pushbutton using a suitable object.
2.) The emergency thermostat red control lamp can also signalise the current overloading of screw
conveyor engines. In this case it is necessary to switch off the boiler at the main switch, remove the
obstruction causing the overloading from conveyor and by turning the main switch again put the boiler
into normal operation.
8.5
Boiler shut-down
Before the boiler shut-down it is necessary to push out the hot fuel from the combustion chamber on the grate
and into the ash-pan. This is to be done in manual regime and we do not apply this process in case of shortterm repairs with operators present.
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9.
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IMPORTANT NOTES
Boiler can only be operated by adult persons who became acquainted with this operation manual.
In case there has occurred the danger of combustible vapours or gases development and their
penetration into the boiler room or at works with temporarily developed fire or explosion danger
(floor gluing works, painting works using the flammable paints, etc.), boiler must be shut down
long enough before the works start.
We check visually the fuel transport into the combustion chamber. There is a danger of injury
caused by rotating screw shaft.
It is forbidden to use flammable liquids(petrol, oil, heating oil and others) for firing up the boiler.
Possible combustion process is checked by keeping the door ajar. This method is connected with
a higher danger of sparks flying out into the boiler room. Immediately after having checked the
combustion process visually the door must be shut properly.
It is forbidden to overheat the boiler in any possible way.
Don’t put ay objects made of flammable material on boiler and within a distance smaller than the
safe distance from it.
When removing the ashes from boiler there must not be put any flammable materials within
minimum 1500 mm distance from boiler. The ashes must be collected in non-combustible and
covered container.
When operating the boilers at the temperature below 60 °C the cast-iron heat exchanger gets
bedewed which initiates so-called low-temperature corrosion reducing the boiler service life.
Therefore we recommend to operate boiler at the temperature 60 °C and higher.
After the heating season termination the user is obliged to clean the boiler properly incl. the flue
gas ducting and the smoke adapter. The graphite grease is to be used for lubrication of swivel
pins, smoke flap mechanism and other movable parts on boiler. The boiler room must be kept
clean and dry.
It is forbidden to interfere with boiler structure and electric installation boilers.
WARNING! A poor quality of fuel can markedly negatively affect the boiler output and emission
parameters
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.
10.
Maintenance by user
1. It is necessary to be particular about a timely fuel refilling. If there is only a small amount of fuel left in the
reservoir it must be refilled immediately in order to avoid the secondary air suction. Pay attention to a
correct cover closure on the fuel reservoir!
2. Remove regularly the ashes from the combustion chamber and the ash-pan drawer. Use the protective
gloves when discharging the ash-pan drawer.
3. The boiler cleaning frequency depends on the fuel quality. Cleaning must be done in 3 - 4 week intervals
in case of pellets that don’t exceed 0,5 % ashes. The pellets with ashes content 1,5 % and higher will
cause that boiler must be checked and cleaned once a week, if need be also more often.. To clean the
boiler means to remove ashes or deposits from the boiler body (combustion chamber, flue gases ways
etc.). It is also necessary to check the combustion chamber itself- the combustion air nozzles and
combustion chamber ceramic arch. Possible deposits must be carefully removed.
4. Above the combustion chamber there are positioned the fireproof ceramic plates. We recommend to
remove regularly the fly-ash deposited on the plates surface.
5. Minimum 1 hour before cleaning the boiler must be shut down (incl. the electric disconnection).
6. We recommend to clean occasionally the external surfaces of the screw conveyors and ventilator drives.
(The operators must not remove the covers from ventilator or to interfere in any other way with these
units. This can only do a competent service worker). Cleaning must be done using a dry brush. Boiler
when being cleaned must be disconnected from electricity supply.
7. After the cleaning or after any manipulation with fuel reservoir screw feeder please check the correct flex
hose attachment at both its ends by means of SK tapes.
8. In order to keep a slight overpressure in the combustion chamber during the ventilator operation we pay
attention to a perfect tightness of boiler (stoking door, ash-pan door, smoke adapter cleaning cover etc.).
9. The manufacturer fills standardly the worm-gear units with synthetic oil, therefore their further
maintenance isn’t necessary.
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11.
Product liquidation instructions after service life
VIADRUS a.s., is contractual partner of firm EKO – KOM a.s. with client number F00120649.
The packages comply with EN 13427.
By reason that the product is made of common materials, its individual components is recommended to be
disposed as follows:
the boiler drum (grey cast-iron) - through a firm dealing with waste collection and disposal
piping, shell - through a firm dealing with waste collection and disposal
other metal parts - through a firm dealing with waste collection and disposal
IZOBREX insulation material - into the common waste
ROTAFLEX SUPER insulation material - into the common waste
We recommend to dispose the packages in the following way:
plastic foil, cardboard cover, use a salvage point
metal strapping tape, use a salvage point
wooden base, is designated for a single usage and no longer can be used as a product. Its disposal is
subject to Act. 477/2001 Sb. a 185/2001 Coll. as amended.
In case that the product has lost its manufacture qualities there can be taken the advantage of
product taking back (if this is established), in case that the originator has declared that this is a waste
and it must be handled according to the valid legislation of the relevant country.
12.
Guarantee and liability for defects
VIADRUS a.s. provides the guarantee:
– For boilers 24 months after the boiler putting into operation, but maximum 30 months after the date it was
dispatched from the VIADRUS a.s.;
– For boiler drum 5 years after the date its dispatch from the VIADRUS a.s.
The user is obliged to entrust an assembly firm with boiler installation, and a special contracting service
accredited by VIADRUS a.s., the boiler manufacturer with its commissioning and with defects elimination
in case they exceed the framework of chap. 8 a 10.
If boiler is operated in compliance with instructions stated in this „Boiler operation and installation manual“, it
doesn’t need any special service interventions.
VIADRUS HERCULES ECO boiler quality and completeness certificate” after having been filled in by a
contracting service organization serves as the „Guarantee certificate”.
In case of a complaint customer is obliged to submit the packaging label of the boiler shell positioned on the
cardboard in which the boiler shell was dispatched.
The user is obliged to service the boiler regularly – see chap. 10.
In case that the above instructions aren’t observed the guarantee provided by the manufacturer will
be repudiated.
Every defect must be announced immediately after it has been discovered, this in a written form or by
a telephone agreement.
The guarantee does not apply to the:
•
faults caused by improper assembly and improper attendance of the product and faults caused
by improper maintenance see chap. 10;
•
faults and damage caused by failure to observe water quality in heating system see chap. no. 5.1
and 6.7 or by using the anti-freeze mixture;
•
faults caused by failure to observe instructions stated in this manual;
•
product damaged during transport or in other mechanical way;
•
defects caused by an inconvenient way of storing;
•
faults caused by boiler operation with unspecified fuel;
•
faults caused by natural disasters or force majeure.
The manufacturer reserves the right of changes made within the product innovation that needn’t be
include in this manual.
37
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.
38
Annex to the guarantee certificate for customer- the user
Record of accomplished guarantee and after-guarantee repairs and regular product checks
Record
date
Contracting service
organization
(stamp, signature)
Carried out activity
39
Customer ´s
signature
VIADRUS HERCULES ECO
VIADRUS a.s.
Bezručova 300 | CZ - 735 81 | Bohumín
E-mail: info@viadrus.cz | www.viadrus.cz
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