HEATING BOILERS Astra G-18 Astra G-25 Astra G-32 Astra G
Contents
1.2. X Ww AN Ajddng waists Pune H AJLA AUG OM KeM E V P A9 eAA 10H J0SS2201d uais s bunear 3 qeuiueiboJg uonduinsuo 3eaH AJLA Jaljay anssald Ja WOWLAY A ddns 9 8 HX SUONEION 1940 id AAPA 9 Buxy onersouuau 19 NeWOINY Z ewoppey D 69 UIN 0559 uorsuedx SURIWA A 6 Y Q Jonuo dwn yuej uonejnuinaoy 2 Jou dung Q A wd v ui jpnojly XJ X E UotejnoJpay e 1M 215910 133e M w04 n 1 NEA BUKIN PEER Y 6 501191 Q uone1edalg JANG Aly Jale onseuioq Duneag 1PM uononpoud 199 ans o Jojiog buneap AS Fig 5 Principle scheme of the house heating system including heat accumulation 9 HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 The heat consumption circle uses the heat accumulated in the tank The circle consists ofa room thermostat or a programmed control processor room or and outside temperature sensors 3 way servo drive mixing valve underfloor heating system radiators piping fittings The programmed processor controls a 3 way mixing valve which allows more or less heat 45 60 C into the radiators according to demand This way of heat consumption allows the heating of the house as long as the tank stores heat independently from the boiler
3. A The doors of the boiler combustion chambers should be tightly closed there should be no flue gases seeping into the ambience through them Door tightness is regulated by screwing or unscrewing the hinge and lock screws of the door FIRE BED AND TIPS FOR EFFECTIVE BOILER STOKING The hot embers and charcoal in the boiler are called the fire bed Combustible gases emerge from there and are further burned in the lower chamber of the boiler The optimal fire bed height during boiler operation is approximately 4 5 cm above the bottom of the fuel chamber The output of the boiler ventilator is deliberately chosen with the purpose of sufficiently supplying the fire bed with air Then the most effective combustion of wood gases takes place Avoid a situation when the volume of the fire bed expands several times This situation can occur if very dry and thinly cut wood gets loaded into the fuel chamber Consequently the volume of the fire bed increases rapidly during the burning process and soon a lack of air occurs allowing the combustible gases to escape unburned through the chimney into the atmosphere An indicator of this undesirable course is dense fumes emerging from the chimney The best way to stoke a boiler is the so called two stages method During the first stage the boiler is stoked with a small amount of fuel The aim of this phase is to warm up the boiler and form the optimal fire bed The second stage is intended for full fuel loading and
4. ASTRA MACHINERY PLANT ANNO 1929 HEATING BOILERS Astra G 18 Astra G 25 Astra G 32 Astra G 40 INSTALLATION AND OPERATION MANUAL CONTACT INFORMATION OF THE FACTORY MACHINERY PLANT ASTRA AB ULONU G 33 LT 62161 ALYTUS LITHUANIA TEL 370 315 75449 FAX 370 315 52265 E MAIL INFO ASTRA LT WWW ASTRA GAS LT TABLE OF CONTENTS 1 SAFETY REQUIREMENTS sisscvicucscicsccnvssnsscasoccnssdesesnsevsesehastvosesncnsasardetsraveoasnsnees 3 2 TECHNICAL DESCRIPTION scis cos pee xt rep EYE YHPVE ERU CHE EXE EY EFC PX i 4 lt General View OF TREUBOL BEL pl e RR d eu ate eat d eta anten 4 s TechnicaliData of the Boiler E 5 Ceramic Elementsof th BOIIGE ascscacosscsce cnr tec o doe eot unte ttem 6 Po ppm eM DEDI MAL TE 6 S INTENDED USE ee 7 4 TRANSPORTATION STORAGE 7 5 INSTALLATION REX EFE KE DIRE 8 8 e Description of the Emergency Cooling System Diagram seen 8 e Description of the House Heating System Scheme eene tentent 8 e Requirements for Connection of the Boiler to the Heating System 10 e Circuit Diagram of the 11 e Connection of the Circulation Pump css oni otn enda dmn Canton ptm d am 12 e
5. G 18 Astra G 25 Astra G 32 Astra G 40 firewood kW 18 25 32 40 Nominal heat output wooden briquettes kW 20 28 33 Class of boiler according to EN 303 5 3 3 3 Class of protection against electric impact 1 1 1 Efficiency rate Power of emergency cooling system kW 12 15 15 Water volume in the boiler 52 62 71 Setting range of the temperature regulator C Maximum operating draught in the flue mbar Working pressure of water in the system bar max 2 0 2 0 2 0 Testing pressure of the boiler bar 3 0 3 0 3 0 Max allowable water temperature in the boiler C 108 108 108 Max allowable operating water temperature in the boiler C 95 95 95 voltage V frequency Hz 220 50 220 50 220 50 220 50 Electric characteristics average power used W 14 21 21 21 Level of electric protection of the boiler IP30 IP30 IP30 IP30 height mm 1156 1156 1246 1176 Dimensions width mm 646 646 646 660 depth mm 750 965 965 1176 Weight of boiler kg 260 310 330 380 Threaded connection diameter 1 y 1 yw 1 yw 1 yw Volume of fuel chamber 67 105 130 140 Dimensions of the loading aperture mm 350x285 350x285 350x285 350x285 Flue g
6. Mounting of the Draught Regulator suos vti tirar ERUY EVERRE rhv Mo Eun 12 e Regulation of the Primary Air Damper usas anteire dd entr or ns 12 e Controlling the Temperature of Water Returning to the Boiler ees 13 e Heating Output Water Temperature and Water Flow Relationship sss 13 e Installation of the Boiler NEUE 13 s Requirements Tor tlie Ren des He d 14 6 FUEL 15 e 16 16 e Rear 17 PPD 17 e Kindling Procedure of the Boiler ORE FR vet 17 Fire Bed and Tips for Effective Boiler Stokings iss sssssssssssasssiessassosenessssacscascensssonssdeatostoussesscenessossvenssees 18 e Regulation of the Boiler Temperature c ssccsssssssessssssssssssccsssessesssssscsssessssessnscesssesssccsssessssesnseees 19 Addition of Lr mE 19 COMBUSTION 19 19 e Emergency Shut Down of the 0 61 20 8 POSSIBLE S 20 9 WARRANTY AND ITS VALIDITY TERMG sccsssssssssssssscsessccsssscsssscc
7. e REQUIREMENTS FOR CONNECTION OF THE BOILER TO THE HEATING SYSTEM The following requirements should be fulfilled when installing the boiler e The boiler should be installed in a closed heating system with a closed membranous expansion vessel the volume of which should beno less than 10 of the total volume of the system A closed heating system is a kind of system with no free access to atmospheric air which actuates corrosion Due to this drainage of water from the system without an important reason is undesirable e g in summer It is also necessary to ensure watertightness of the system in order to need fewer refills with fresh water containing free oxygen The quantity of the additional water let in should not exceed 5 of the system water volume per year e The boiler is connected to the heating system through connection pipes 6 water supplied to the heating system and 11 water returning from the heating system Fig 1 e Internal threads G T7 of pipes 6 and 11 e There is a nipple 12 for water filling or draining from the boiler Fig 1 e Internal thread G 1 of the nipple 12 e A pressure relief valve conforming to norm EN1268 1 is to be installed in the heating system as close to the boiler as possible at a location easy to reach by hand e pressure relief valves and control devices must conform to the following technical characteristics Instrument Technical characteristics Type of boiler Pressure relief valve Con
8. each boiler model should correspond to the referred value of draught in the table Technical data The liner should be factory made Minimum permissible height of the chimney should be at least 6m The top of the chimney should be above the ridge at least by 0 5m If the chimney is further from the ridge than 1m the angle horizon mem 7 1 gt max4s N max 0 TN d N i Ed mmm L 22717721 YY YY M A TICE ALI I EE Li Aus LLL y ff 7 as Fig 9 Positioning of a chimney in respect to vicinity objects 14 INSTALLATION AND OPERATION MANUAL the ridge the cap of the chimney should consist 10 or less degrees Draught of the chimney can also be negatively affected by various obstructions near the building trees hills other buildings Fig 9 presents the recommended minimal angles between the chimney nearby objects and the horizon Angles larger than those indicated will cause reduction of draught of the chimney A The connection of other devices to the chimney to which the boiler is connected is prohibited A The chimney should be cleaned
9. to perform the main combustion The first stage Prepare thin cut wood and paper for an easy start The volume of loaded fuel should be about 15 20 of the fuel chamber s capacity Open the upper flue damper 3 Fig 1 and both boiler doors put the wood and paper inside Kindle the paper make sure that the firing starts and close the upper door After the temperature of water in the boiler reaches 45 C close the damper and the lower door and turn on the ventilator Let the boiler burn further for 30 minutes The second stage Load the boiler fully If wood briquettes are used for stoking load approx 70 96 of the fuel chamber s capacity Before opening the door turn off the ventilator Open the damper 3 Fig 1 by pulling the handle towards yourself and after some time open the upper boiler door very slowly to avoid smoke escaping into the room Load the fuel close the door and push the handle of the damper 3 Fig 1 Press the ventilator knob 4 Fig 10 on the front control panel into the 00 95 C position The ventilator will start and the boiler will continue its firing mode If you lack time to stoke the boiler in the two stages mode as described above then stoke it by one stage The boiler will operate as usual But if there is the possibility to do so use the two stages mode in order to achieve an even more effective combustion 18 INSTALLATION AND OPERATION MANUAL e REGULATION OF THE BOILER TEMPERATURE See the chapt
10. 25 Astra 1 32 Astra G 40 7 OPERATION FRONT CONTROL PANEL T c 1 0 60 95 C Fig 10 Front control panel 1 Operation thermostat knob 2 Thermometer 3 Green button for switching the voltage of the boiler on and off 4 Red button for switching on the ventilator The front control panel contains the operation thermostat 1 Fig 10 the thermometer 2 the green button 3 of the main supply and the red button 4 for switching on the ventilator The buttons light up in the ON position The function of the operation thermostat 1 is to switch off the boiler ventilator when the targeted water temperature is reached Then the combustion in the boiler slows down and the water temperature in the boiler does not rise further The position of the operation thermostat 1 knob should be set so that its targeted temperature would be several degrees less than targeted temperature of the draught regulator see the chapter Mounting of the draught regulator Then the operation thermostat 1 will switch off the ventilator a little bit earlier than the draught regulator would descend the damper 4 Fig 8 into its lowest position The appropriate position of the operation thermostat knob should be found and marked with a pencil or a scratch should be made on the case of the knob This position should be defined in the next way first turn the thermostat knob to maximum Then set the draught regulator 2 Fig 8 to the targeted tem
11. aiu e nai E Name surname signature of the client 22 INSTALLATION AND OPERATION MANUAL WARRANTY AND POST WARRANTY REPAIR CARD Boiler repaired by Company rabat dd EE RES OR RR CH SH Cul M m DON MED UNTEN Ust DU HD INNEN DOING SU RR SII Eee Signature OF Chu DEC DICH I coeleste pn RF nde HONDA Boiler repaired by Company EOD E arva PANES fon E PRORA nl 9 E E E LU BULUM Signature 23 DECLARATION OF CONFORMITY C Manufacturer Machinery plant Astra AB Address Ulonu g 33 62161 Alytus Lithuania Product designation heating boilers Astra G 18 Astra G 25 Astra G 32 Astra G 40 We declare that the above mentioned products conform to the requirements of directives 97 23 EEC Article 2 3 and 2006 95 EEC The following standards were applied for the above mentioned products LST EN 303 5 LST EN 12828 LST EN 60335 1 LST EN 60529 Procedure of conformity evaluation in accordance with Article 2 3 of 97 23 EEC was performed by Inspecta www inspecta com Certification No 2 4 2 1 619 2012 Alytis 20 Grazvydas Eimanavicius project manager
12. as duct diameter mm Length of wood pieces mm 152 330 152 500 152 500 152 550 Average temperature of the flue gases at the nominal heat output C 165 188 195 205 e CERAMIC ELEMENTS OF THE BOILER HEATING BOILERS Astra G 18 Astra G 25 Astra G 32 Astra G 40 The boiler has ceramic elements of three types ceramic burner 1 ceramic chopper 2 and two ceramic segments 3 Fig 2 The chopper 2 must be moved to the back wall of the boiler chamber during operation of the boiler segments 3 resting upon the front edge of the chopper If needed the ceramic burner 1 can be removed For this purpose use a screwdriver to remove the sealing rope from between the ceramic burner and the frame of the boiler then this ceramic insert can be removed Fig 2 Ceramic inserts and their positions 1 Ceramic burner 2 Ceramic chopper 3 Ceramic segments Fig 3 Turbulence plate technology 1 Inspection aperture 2 Turbulence plates 3 Poker 4 Heat exchanger of the boiler flue Ceramic Boiler type element G 25 G 32 1 Burner G 18 00 003 K 30 00 007 5K 50 07 001 2 Chopper G 32 01 G 32 02 3 Segments G 18 00 004 G 18 00 004 01 e TURBULENCE PLATES Turbulence plates a technology invented and patented by Astra engineers used for capturing more heat from the hot exhaust smoke It forces the exhaust smoke to hold be
13. at least once a year 6 FUEL The boiler is fired only by wood logs and wood briquettes It is possible to fire it with fuel peat briquettes however the operation of the boiler becomes less comfortable for the user as it is necessary to remove the ashes of these highly ash producing briquettes after each loading The ceramic elements of the lower chamber can be damaged if they are removed every day when cleaning thus their lifetime will be shorter Therefore we recommend usage of fuel peat briquettes only in rare exceptional cases It is recommended to fire dry firewood with a moisture content of 12 20 96 The drier the firewood the larger its calorific capacity When the moisture content of the firewood is 20 the heat potential of 1 kg is approximately 4 kWh when the moisture content is 50 its heat potential is reduced by half The length of the firewood should be at least 5cm shorter than the length of the boiler combustion chamber Type of boiler Astra G 18 Astra G 25 Astra G 32 Astra G 40 Length of firewood mm 310 500 500 550 The recommended thickness of the wood logs is 100 150mm Thicker pieces of firewood should be split at least once Up to 15 of the fuel load can consist of fine wooden splinters and sawdust However they must be loaded in such a way so as not to block the opening of the ceramic burner 22 Fig 1 connecting the upper and lower chambers of the boiler Do not fire freshly prepared and excessively damp p
14. come turbulent and thus transfer more heat to the adjacent heat exchanger The core of the device consists of the turbulence plates positioned at an angle in the rectangular shaped flue channel of the boiler The inspection aperture 1 is installed on the top part of the flue channel Fig 3 covered with a screw on cover with a gasket This aperture is used for cleaning the flue channel and placing removing the turbulence plates The turbulence plates 2 shown in Fig 3 maintain their position in the flue due to their force of gravity alone They are inserted into the flue channel or removed using a poker 3 which is provided with the boiler Poker 3 Fig 3 is bent at an angle of approximately 80 to the handle so that the hooked plate does not slide off In order to be able to hook the turbulence plate 2 with a poker a hole has been made in its upper part for hooking with a poker The plate rests upon the heat exchanger 4 of the boiler flue on four supports two bottom and two upper supports When inserting the plate 2 with a poker 3 into the flue channel first the lower position is found and after slightly loosening the poker yet without removing it from the hole the plate is allowed to descent onto the opposite side of the heat exchanger due to the force of gravity until it touches the wall of the heat exchanger with INSTALLATION AND OPERATION MANUAL its upper supports Then the tool can be removed and the next plate can be in
15. connect the heating system circulation pump to the boiler The smoke exhaust pipe of the boiler should be connected to the chimney through a metal duct The internal diameter of the metal connecting duct should be at least the same as the external diameter of the smoke exhaust pipe of the boiler To improve the draught the connecting duct between the boiler and the chimney should be installed at an inclination towards the boiler All junctions should be carefully tightened using a heat resistant material and insulated using thermal insulation If an additional damper is installed between the boiler and the chimney for the draught control purpose the damper should not close more than 2 3 of the cross section area of the opening in its fully closed position e REQUIREMENTS FOR THE CHIMNEY It is recommended to insert acid resistant stainless steel liner if the chimney is made from masonry It improves draught of the chimney and protects the masonry from destruction due to the impact of condensate Internal diameter of the liner should be no less than the external diameter of the smoke exhaust pipe of the boiler The chimney liner can be round or oval It is not recommended to use rectangular shaped liner as due to the temperature fluctuations its walls deform gaps appear at the element junction points through which the condensate falls on the walls of the bricks chimney Additional air is sucked in which reduces draught of the chimney Draught for
16. d for the boiler is the following for the heat exchanger of the boiler against leaking 60 months for other parts of the boiler 24 months e the warranty repairs are performed when the fault has occurred due to the manufacturer s fault e the warranty term is not extended after removing the faults which have occurred during the warranty period boiler cleaning and heating system adjustment works are not covered by the warranty e the damage caused to the premises and the property in the premises due to the boiler fault will not be compensated e the warranty repair works and replacement of parts during the warranty period are free e the warranty period starts from the boiler purchase date e the warranty is valid only ifthe boiler is installed connected to the heating system and operated following the requirements of this manual The warranty does not apply in the following cases in case the heat exchanger is limed e in case the water or other liquid inside the boiler has been frozen case of fault of the boiler due to improper operation e in case of fault of the boiler due to improper connection to power supply in case the boiler parts are mechanically damaged ein case the boiler is connected to the heating system not in accordance with the diagrams and requirements of the operation manual The post warranty repair works will be carried out at the expense of the owner of the boiler A The buyer must fo
17. e external thread 14 is screwed onto the socket on the rear wall of the boiler Technical data of the thermostatic safety valve are the following Opening temperature 95 C Maximum operating temperature 110 C Operating pressure 10 bar Bulb of the sensor L 142 mm external thread A The emergency cooling system protecting the boiler from overheating cannot be used for heating domestic water DESCRIPTION OF THE HOUSE HEATING SYSTEM SCHEME The house heating system with an accumulation tank could be divided functionally into two circles heat production and heat consumption Both circles operate independently and interact in the accumulation tank The heat production circle consists of a boiler Laddomat 21 thermostatic mixing unit with a circulation pump installed in it expansion vessel fittings and accumulation tank The intended use of this circle is to charge the accumulation tank only To charge the tank the boiler could operate on its maximum heat output and outflowing water temperature 85 C That mode of boiler operation is optimal for the boiler and combustion process itself INSTALLATION AND OPERATION MANUAL EA ox anea unay P lt 19 4 tonno 1v Jneulo ny aea Dd dung NLA UUM J9jouloue Jojouloue IDJO am Winjay 5 Dunear AJLA
18. ers Mounting of the draught regulator and Front control panel e ADDITION OF FUEL While adding firewood into the combustion chamber during boiler operation or after a load has burned off keep strictly to the following procedure 1 Open the damper of the upper flue 19 by pulling the handle 3 towards yourself Fig 1 2 Switch off the ventilator switch 3 Fig 9 3 Wait at least 20 seconds allowing the smoke to be removed by draught then slowly open the upper door 4 Put the firewood in and close the door tightly 5 Switch on the ventilator to the 0 60 C position if the actual water temperature is lower than 60 C 6 Close the damper of the upper flue 19 by pushing handle 3 7 Switch the ventilator button to the 60 90 C position after the actual water temperature has rised over 60 C If operated following this order smoke and carbon monoxide will not enter the room Water temperature and pressure in the system are checked by readings of the thermometer manometer installed in the heating system e COMBUSTION CONTROL The status of the boiler firing process can be seen from the indications of the thermometer 2 Fig 10 The firing is active if the temperature of water in the boiler exceeds approximately 60 C The flame in the boiler can be checked by opening the door of the lower combustion chamber when the ventilator is on The visible tongue of flame has to be yellow or yellow red and reach the ceramic element t
19. fftake water If this is not done periodically the parts of the valve can stick together due to high temperature and fail to open when required In case the safety valve fails to open in an emergency situation serious damage to the boiler and the heating system can occur as well as hazard to the health and life of people INSTALLATION AND OPERATION MANUAL A In order to guarantee natural water circulation of water in the boiler the pipework between the boiler and the mixing valve in the line boiler mixing valve boiler is to be of the same diameter and correspond to the diameter of the connection pipes of the boiler CIRCUIT DIAGRAM OF THE BOILER MV 1 2 3 41 7 191 ul wp ulus Fig 6 Circuit diagram of the boiler 1 power supply switch S2 ventilator switch SK emergency ventilator shutdown 95 C thermostat SK2 circulation pump thermostat SK3 operation thermostat F fuse M ventilator Q circulation pump of the heating system U water temperature sensors e An electric installation with earthing in accordance with the electric safety regulations in force is to be installed when connecting the electric part of the boiler Protect the isolation of the mains cable against damage 11 HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 e CONNECTION OF THE CIRCULATION PUMP In order to insure a continuous flow of water a circulation pumpisto be i
20. he length of the connecting chain of the draught regulator First decide at what temperature to keep the flow water during the boiler s use 75 C or even higher is recommended By reaching this water temperature the boiler should considerably lower the air supply to the combustion chambers and the burning process must slow down as a consequence At this moment the damper 4 must go down to its lowest position Fire up the boiler and observe the indications on the boiler thermometer When the targeted water temperature 75 C is reached fix the damper 4 to the lowest position by fastening the lever of the draught regulator and choosing the length i Tee 2 Doaiohtfe btr d Primary of the connecting chain Remember a 3 8 mm gap should be left between the damper zir damper 4 Main air supply damper and the air supply opening The exact size of the gap depends upon the draught of your 5 Ventilator chimney The worse the draught the greater the gap should be e REGULATION OF THE PRIMARY AIR DAMPER The primary air damper 3 Fig 8 is set up in the factory To inspect the positioning of the damper loosen the fixing screw and push the shaft of the damper forward until it gets stuck Then pull the shaft 5 mm backwards and fix it with the screw Fig 8 Mounting of the draught regulator 12 INSTALLATION AND OPERATION MANUAL CONTROLLING THE TEMPERATURE OF WATER RETURNING TO THE BOILER It is absolutely necessary to maintain the
21. his means the firing is proceeding in an optimal manner not keep the lower door of the boiler open for extended periods of time during firing the lower chamber contains gases which when escaping into the boiler room in larger amounts can impair human health e CLEANING THE BOILER Ashes are removed from the boiler every 4 7 days Open the door of the upper combustion chamber and shovel ashes down to the lower chamber Open the door of the lower chamber take out only ceramic segments 3 Fig 2 pour ashes to a metal box It is not necessary to take out the triangle ceramic chopper 2 Fig 2 at the time of cleaning ashes underneath it may be raked using scraper A In any case strictly follow the established procedure when opening the upper door open the damper of the upper flue then after 20 seconds open the boiler door Clean boiler chambers from tar pitch and scurf once or twice a month Clean the boiler when the fuel has been completely burned and the boiler is cooled down to at least 40 C Open the upper cap 15 for cleaning the flue Fig 1 Remove the turbulence plates from the flue by hooking them and pulling them out with the poker then clean them using a scraper Clean tar and scurf from combustion chambers and flue walls using a scraper and metal hog Clean with the doors of the combustion chambers open The soot residues falling down from the flue walls during the cleaning process are raked out of the boiler through the l
22. ieces of firewood The operation of the boiler becomes inefficient deposits of resin emerge on its inside walls as well as excessive condensate Corrosion of the boiler takes place several times faster when firing it with freshly prepared wood or wood that has been dried outside for several months only Recommendations for firewood preparation e put split wood in a properly ventilated place if possible in a sunlit place e firewood should be well sheltered from rain and snow pieces of split wood should be stacked with sufficient gaps between them so that the freely circulating air can blow away the moisture evaporated from the pieces of firewood e there should be sufficient space above the heap of firewood below the roof and sufficient ventilation to remove the moist air e it is not advisable to store freshly cut firewood in a basement since the firewood needs sun and free air movement to dry Dry wood can be stored in the basement where sufficient ventilation is guaranteed e itis recommended to dry the split firewood outdoors under the above mentioned conditions Depending on the type of wood soft wood alder asp fir poplar must be dried for at least 8 months and hard wood oak ash birch for at least 20 months Firing the boiler with coal rubber or plastics is prohibited However loading wood briquettes into the boiler together with their plastic packaging bags is allowed 15 HEATING BOILERS Astra G 18 Astra 1
23. lectrical resistance of the protective circuit does not exceed 0 10 e resistance of the electrical insulation at least 1 0 MQ resistance of electrical insulation was checked at 50 Hz 1 000 V voltage HEATING BOILERS Astra G 18 Astra 1 25 Astra 1 32 Astra G 40 2 TECHNICAL DESCRIPTION e GENERAL VIEW OF THE BOILER Fig 1 General view of the boiler A front view B rear view C top view D section 1 Front control panel 2 Rooftop cover 3 Handle of the upper flue damper 4 Doors of the combustion chambers 5 Adjustable support legs 6 Flow water pipe 7 Rear control panel 8 Sensor immersion pocket 7 of the safety temperature limiter 95 C valve 9 Primary air regulation damper 10 Ventilator 11 Return water pipe 12 Water drain nipple 13 Connections of the cooling serpentine 14 Flue pipe 15 Flue cleaning cap 16 Temperature sensors of operation pump and safety thermostats 17 Thermometer 18 Combustion chambers 19 Upper combustion chamber opening to the flue 20 Primary air inlet opening 21 Secondary air inlet opening 22 Ceramic burner 23 Ceramic chopper 24 Ceramic segment 25 Opening to the flue Astra G boiler model d Astra G 18 at 1 2 Astra G 25 G1 1 2 Astra G 32 Gt 1 2 Astra G 40 G1 1 2 e TECHNICAL DATA OF BOILER Name of indicator INSTALLATION AND OPERATION MANUAL Indicator value Astra
24. ler at such operating temperatures more tar accumulates on the internal walls of the boiler and metal corrosion intensifies When operating the boiler with an accumulation tank it is possible and advisable to maintain constantly maximum temperature of outflowing and returning water respectively 85 C and 72 C then condensation of water vapour and metal corrosion will be significantly lower Recommended capacity of the accumulation tank is approximately 50 litres per 1 kW of nominal power of boiler Boiler model Astra G 18 Astra G 25 Astra G 32 Astra G 40 Required volume of the accumulation tank litres 900 1200 1500 2000 A The boiler is to be operated only with an emergency cooling system installed e DESCRIPTION OF THE EMERGENCY COOLING SYSTEM DIAGRAM 4 2 3 puces Fig 4 Connection diagram of the emergency cooling system 1 To sewage 2 Thermostatic safety temperature limiter 95 C valve 3 Filter 4 Water from public water supply pressure 2 6 bar temperature 12 C 5 Sensor of the thermostatic safety temperature limiter 95 C valve A thermostatic safety temperature limiter 95 C valve Fig 4 protects the boiler form the overheating If the water temperature in the boiler exceeds 95 C the valve automatically opens the flow of cold water from the public water supply network through the cooling serpentine where it absorbs the excessive heat energy and flows out into the sewage The sensor of the valve with th
25. llow all the requirements of this operation manual during transportation storage and operation otherwise the manufacturer warranty does not apply 10 ACCEPTANCE CERTIFICATE The heating boiler Astra G Serial conforms to the technical documentation and requirements of standard EN 303 5 and is approved as fit for operation Manufacturing date ZU ist hip adn rn RR EIER E 21 HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 SELLING CARD Boiler sold by cee ied M ibe ROTEN POLE ANNIE BOILER INSTALLATION PROTOCOL Boiler was installed by Installation data Height ofthe chimney adc the fl t or Other information concerning installation RN eR Dt i The boiler was tested on site the control and safety elements were checked and found to be operating properly Person responsible for installation Name surname signature of the employee accept the installation
26. me kindle the boiler using only paper and small pieces of wood in order to safely remove the moisture remaining in the ceramic elements Switch on the voltage using button 3 Fig 10 on the front control panel Set the required outflowing boiler water temperature using the operation thermostat knob and draught regulator see more in the chapter Front control panel we recommend a temperature of at least 75 C or even better a higher temperature Close the door of the upper combustion chamber open the lower door and set the kindling material on fire Observe the rising water temperature in the thermometer 2 Fig 10 display Keep the lower door open until the boiler water will heat up to 40 C Then close the lower door close the damper 19 of the upper flue by pushing its handle 3 Fig 1 Then switch on the ventilator switch 4 on the control panel Fig 10 into the position 0 60 C The ventilator will start rotating and the water temperature will rise further After the temperature passes 60 C turn the ventilator switch to the 60 90 C position The boiler then will operate in automatic mode it will try to reach and maintain the setpoint temperature of the water outflowing from the boiler When firing the boiler for the first time the condensation of the residual moisture and drainage of water in the lower combustion chamber occurs This is not a shortcoming After kindling the boiler several times this phenomenon disappears
27. nection diam does not exceed 12 set opening pressure 2 bar Astra G 18 Astra G 25 Astra G 32 Pressure relief valve Connection diam does not exceed 34 set opening pressure 3 bar Astra 1 40 Thermometer manometer Range of temperature 0 120 C pressure 0 4 0 bar All boilers A There must be no ball valves installed between the boiler and the pressure relief valve e Water from the pressure relief valve should be conducted via an offtake pipe It should be conducted in a way that will allow the water passing through the pressure relief valve to flow safely avoiding exposure of people and electrical parts of the boiler The diameter of the offtake pipe should be no less than the diameter of the offtake opening connection nipple of the safety valve The total length of the offtake pipe should not exceed 2 m No more than 2 elbow joints at angles of 90 are to be used when installing this duct No ball mixing or other valves are to be installed in the water offtake pipe This offtake pipe is to be installed in a way that will make the flow of the passing water visible If part of the pipe installed is hidden e g in a sewerage pipe then such a pipe should have a special funnel enabling visual observation of the offtake flow of water Operation of the pressure relief valve is to be checked at least once a month The valve is opened for a short period of time by turning its head to reveal a small amount of the o
28. ng output kW system depends directly upon the difference of 25 32 flow and return water temperatures At and the At C Water flow l min intensity of the water flow circulating through the boiler The boiler will fail to reach the desired temperature of the flow water if the returning water temperature is too cold or the circulation pump is too powerful This will happen because the boiler will be forced to produce a larger heating output than it has been designed for The most effective boiler operation occurs when the difference between the flow and return water temperatures is 12 14 C If the boiler is forced to operate with a 20 C or even greater temperature difference it will work ineffectively consume too much of fuel and the combustion period of one fuel load will consequently shorten If the previously mentioned difference of temperatures is kept less than 10 C the fuel in the boiler will again burn inefficiently and fume because of a lack of air supply If you know the water flow intensity near your boiler in the above presented table you can check what the difference of flow and return temperatures your boiler is capable to maintain when operating at the nominal heating output A Do not forget to keep the returning water temperature as high as possible at least 65 C or even higher It is necessary to assure that a thermometer is installed on the returning water pipe in order to be able t
29. nstalled in the system on the return water pipe behind the mixing valve The electronic controller of the boiler controls the pump Before connecting the circulation pump remove the rooftop cover of the boiler Fig 7 The cover is removed in the following sequence 1 unscrew two fastening bolts 2 lift the backside part of the cover 3 push the cover forward and then lift it up Connect the wire of the circulation pump to the 12 way 11 and 12 marked with the si gn gt See 1 Unscrew bolts 2 Lift the backside of the cover 3 Push the cover forward then raise Fig 6 Circuit diagram of the boiler Connect the earthing wire of the pump to the contact No 1 on the same connector e MOUNTING OF THE DRAUGHT REGULATOR I Atfirst mount the tee 1 Fig 8 present in the supply set on the boiler flow pipe 6 Fig 1 Then install the draught regulator 2 Fig 8 into the lateral pipe of the tee Connect the lever of the draught regulator with the ventilator lid When the temperature of the water in the boiler rises the lever descends and the main air supply damper 4 cloaks the opening of the air duct thus restricting the air supply to the combustion chambers Damper 4 Fig 8 should not completely close the air supply opening in any mode of the boiler operation It is recommended to sustain at least a 3 8 mm gap to the opening in the lowest position of the damper The position of the damper 4 is set by changing t
30. ntrol thermostat SK2 Fig 6 is also located inside the front control panel and is not observable from the outside It has two functions 1 Turn on the circulation pump when the water temperature in the boiler reaches 60 C 2 Turn on the ventilator if the button 4 Fig 10 is in the 60 90 C position and the water temperature in the boiler is higher than 60 C Consequently this thermostat will switch off both the ventilator and the circulation pump when the water temperature in the boiler drops below 60 C To learn more about the control devices of the front control panel please refer to the chapter Kindling procedure of the boiler 16 INSTALLATION AND OPERATION MANUAL e REAR CONTROL PANEL The following safety devices are installed in the rear control panel thermal fuse 1 and electric fuse 2 Fig 10 The purpose of the thermal fuse otherwise called the maximum 2E P boiler temperature emergency thermostat is to switch offthe boiler ventilator if water 195C 220 V temperature in the boiler exceeds the maximum permissible 95 C due to unforeseen reasons The temperature sensor of the thermostat is installed in a dedicated sleeve o 16 Fig 1 The burning intensity decreases when the ventilator is switched off and the water temperature decreases When the emergency thermostat trips the lamp of the ventilator switch 3 on the front panel switches off Fig 9 and the lighting indicator bulb 4 Firing off on the elec
31. o observe this temperature at any time e INSTALLATION OF THE BOILER ROOM The boiler room should be ventilated The required air inflow necessary for combustion should be also ensured For this purpose boiler room doors should have ventilation grating or there should be a sufficient gap between the doors and the floor If there is no possibility to supply air in from another rooms or the house is very tight it will be necessary to install an opening in the exterior wall The cross section area of the opening should be at least 0 001 m2 kW Place the boiler as close to the flue as possible on a hard concrete levelled basement Leave at least 600 mm gap between the backside casing of the boiler and the room wall for boiler servicing and cleaning The smallest distance between a lateral casing 13 HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 of the boiler and a building structure is 400 mm If the building structure is made of flammable materials this distance should be doubled A freely approachable space of at least 800 mm should be then left from the opposite side of the boiler to ensure access to the backside of the boiler for its servicing and cleaning The floor under the boiler within the distance of 50 cm in front of it and within the distance of 30 cm around the boiler should be made of inflammable materials Screw supporting legs onto the base of the boiler and level the boiler with screw nuts using a level then
32. olume of the fuel chamber complete fuel combustion ensures cost efficient fuel usage e the turbulence plates installed in the flue of the boiler enhance heat exchange in the boiler and reduce the temperature of the smoke in the chimney e itis sufficient to remove the ashes 1 2 times per week 4 TRANSPORTATION STORAGE UNPACKING The heating boiler is to be transported and packaged in accordance with the documentation of the manufacturer protected from precipitation and dust It can be transported only in vertical position fastened to avoid sliding and falling If the boiler is transported in other than vertical position decorative surfaces may be damaged cladding battered control and regulation equipment broken built in ceramic inserts may fall down and splinter The heating boiler should be carefully loaded unloaded and transported without any significant impact The boiler should also be stored in a vertical position It is not allowed to put one boiler on top of another as a packaging frame is not designed for this purpose The boiler should be stored in a closed room protected from precipitation The air humidity of the room should not exceed 8096 in order to avoid condensate forming on the surfaces of the boiler Storage temperature may vary from 40 C to 60 C If the boiler was transported or stored in minus temperatures then before it is kindled it should be kept in plus temperature for no less than 2 hours After the hea
33. ower opening of the combustion chamber 25 Fig 1 pulling them outwards When finished place the turbulence plates back and close the cleaning cap Control water pressure in the heating system at least once every two weeks If the pressure drops raise it by filling up the system with more water If the boiler is not being heated for a longer time drain the water out of the system when air temperature is below 0 C 19 HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 e EMERGENCY SHUT DOWN OF THE BOILER If for some reason you must immediately shut down the operating boiler by any means do not pour water on the kindling wood The boiler can burst It is very convenient to use dry sand for emergency extinction There should be 50kg of dry sand in the boiler room Sand not only isolates burning firewood well from the air oxygen but also cools down the burning zone Then when the boiler cools down sand can be easily cleaned and removed 8 POSSIBLE FAULTS Fault 1 The set temperature cannot be reached Cause Not enough water in the heating system Problem solution Fill up Too low temperature of the return water Raise the return water temperature Thermoregulator or ventilator is defective Repair or replace Poor quality fuel high moisture content too large pieces of firewood Use dry fuel split firewood Heating surfaces of the boiler are very dirty Clean No dra
34. perature for example to 75 C Start the boiler and allow it to reach a 75 C temperature Then turn the thermostat knob in the direction of the lower temperature until you hear a click sound Turn the knob a little bit further and mark this position on the knob case with a pencil Now you have found the appropriate setting position of the operation thermostat 1 Fig 10 The green ventilator button 4 Fig 10 has three positions The position 0 60 C is used to turn on the ventilator during the ignition of the boiler At this state the ventilator will be operating permanently The central position OFF is intended to switch off the ventilator the button lamp then does not light After the initial phase of kindling the boiler when the water temperature in the boiler overlaps 60 C the ventilator is usually turned to the position 60 90 C This setting switches off the ventilator automatically after the combustion in the boiler has ended and the water temperature has dropped below 60 C If you forget to switch the ventilator to the 60 90 C position nothing serious will happen just the ventilator will be rotating permanently even after the combustion in the boiler will come to the end A The ventilator will be switched off equally in both the 0 60 Cand the 60 90 C positions when the safety temperature limiter 95 C thermostat 2 Fig 11 trips the operation thermostat 1 Fig 10 switches it off The circulation pump co
35. r the boilers Astra G 18 Astra 1 25 Astra G 32 and a maximal response pressure of 3 bar for the boiler Astra 1 40 please see Chapter 5 Requirements for connection of the boiler to the heating system 1 6 Remove the accumulated soot and resin from the boiler flues as instructed in this manual 17 The room where the boiler is installed should have fire extinguishing tools fire extinguishers sand box shovel and other tools 1 8 Do not place flammable materials on or near the boiler 19 Connect the boiler to the electric system only via a three pole plug plugged into an adequate three pole socket with earthing Protect connection cable from damages 1 10 Observe operation of temperature control devices and gauge readings when operating the boiler In case of faulty 111 operation of the boiler stop operation and remove the fault Kindle the boiler and put the firewood into the boiler only as indicated in Chapter 7 of this manual 1 12 Keep children away from the boiler The boiler can be serviced only by adults 1 13 Before kindling the boiler check if the heating system is filled with water and deaerated 1 14 The operating pressure in the heating system should not exceed the following 2 bar for boilers Astra G 18 Astra G 25 Astra G 32 3 bar for boiler Astra G 40 1 15 The electrical connections are factory tested and the following parameters were confirmed integrity of the protective circuit e
36. ssessssssees 21 TO ACCEPTANCE CERTIFICATE 21 SELLING CARD Luise niic oi 22 BOILER INSTALLATION PROTOCOL vs ssssesssossessesvssccsncensssosveursucssecussennsoresspusosnsesnands 22 WARRANTY AND POST WARRANTY REPAIR CARD ssccsssssssssssscssscssssssescsessees 23 DECLARATION OF 24 INSTALLATION AND OPERATION MANUAL This user manual was compiled following the requirements of EN 12171 Heating systems in buildings Procedure for the preparation of documents for operation maintenance and use Heating systems not requiring a trained operator 1 SAFETY REQUIREMENTS 11 The room where the boiler is to be installed should be ventilated 12 Free inflow of air into the room should be ensured 13 The boiler flue connection with the chimney should be tight Do not heat up the boiler with leaking flue connections 14 The boiler should be installed in a closed heating system with a closed membranous expansion vessel the volume of which should be no less than 1096 of the total volume of the heating system including the boiler the volume of the expansion vessel can be calculated according to the standard EN 12828 annex D 1 5 A safety valve for no more than 2 bar response pressure should be fitted onto the boiler in the heating system fo
37. stalled in a similar way Turbulence plates decrease the temperature of the exhaust smoke The boiler can be operated without the plates but then greater losses of heat through the chimney will occur 3 INTENDED USE The heating boiler is designed for the heating of residential and public buildings manufacturing shops and other buildings where a closed heating system has been installed Control and regulation devices are installed in the boiler which automatically maintain the set water temperature ensure economically efficient usage of the boiler and safe operation Boilers of this type are designed to burn wood partially generating gases Gas is extricated generated from the burning firewood in the upper combustion chamber of the boiler and burned in the lower chamber The intensity of gas generation and combustion is regulated by the frequency and duration of air inflow into the combustion chambers Advantages of the boiler are the following e gas generating combustion ensures effective burning of wood and a high efficiency coefficient since the burning process takes place at a high temperature of 900 C e the heat output of the boiler can be regulated within the range of 40 100 The boiler is automatically controlled using an electronic regulator by switching the ventilator inflowing into the combustion chambers off or on or by regulating the speed of its rotation e the combustion period of one fuel load is long due to the large v
38. t must not exceed the operating pressure of the boiler After filling the system with water perform a visual check of the tightness of the entire system Perform it before kindling the boiler then again after kindling and reaching the nominal operating mode Check if the heating system is properly deaerated KINDLING PROCEDURE OF THE BOILER Before kindling the boiler check whether all requirements indicated in the section 1 are executed Open the damper of the upper flue 19 by pulling the handle 3 Fig 1 towards yourself Open the door of the upper combustion chamber put dry smaller kindling wood pieces and paper on the ceramic bottom so that the paper protrudes into the lower combustion chamber through the rectangular opening of the ceramic burner 1 Fig 2 this way it will be easy to kindle the boiler through the lower combustion chamber Put some of the easily flammable materials and larger pieces of kindling wood and firewood atop Load the wood without any large gaps at the top of combustion chamber Bigger pieces of firewood should be loaded in the middle and smaller prices at the sides because the walls of the combustion chamber slow down the combustion of the bigger pieces of wood due to their lower temperature not cover the entire opening of the upper flue 19 Fig 1 with the wood because it will make kindling more difficult 17 HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 first ti
39. temperature of the water returning from the heating system to the boiler at a constant level no less than 65 C as this will prolong the lifetime of the boiler and will make the combustion process more effective This is because when a constant high temperature of water returning to the boiler is maintained there arises significantly less water vapour condensation inside the boiler The heavy water condensation is harmful to the boiler because deposits of tar pitch and soot accumulate on the walls of the heat exchanger causing intense metal corrosion Moreover the resulting layer of soot impedes effective heat transfer and the efficiency of the boiler falls In order to maintain the temperature we recommend installing the small circulation circle together with a Swedish made thermoregulation device Laddomat 21 60 Make sure that the Laddomat is supplied with the 78 C or 72 C thermostat cartridge The mentioned temperature is the one at which the valve of the device opens completely However the actual temperature of the water returning from the system and getting into the boiler after mixing is 5 6 C lower The higher the temperature of the return water is the better it is for the boiler Thermoregulation devices of other manufacturers could be used for maintaining the temperature of the returning water as well e HEATING OUTPUT WATER TEMPERATURE AND WATER FLOW RELATIONSHIP The heating output supplied to a heating Difference Heati
40. ting boiler is delivered to the site take off the packing frame and polyethylene film unscrew boiler bolts and fastening to the packaging base remove the boiler from the packaging base A Open the doors of the boiler and check if all elements listed in a delivery kit are included The delivery kit consists of the following boiler 1 pc poker 1 pc scraper 1 pc draught regulator 1 pc tee 1 pc operation manual 1 pc support legs 4 pcs Check if painted surfaces have not been damaged during transportation if the components are not bent and if control and regulation equipment is intact In case you notice any inadequacies present your claims to the vendor company 7 5 INSTALLATION HEATING BOILERS Astra G 18 Astra 1 25 Astra G 32 Astra G 40 e ACCUMULATION TANK These solid fuel boilers are intended to be fully loaded during the operation the most efficient mode of their exploitation is at the nominal or maximum heat output It is advisable to install an accumulation tank of sufficient size in their proximity which could accumulate the excessive heat If the boiler is operated without the accumulation tank its lifetime can be shortened because in such a case a relatively low temperature of the outflowing water is maintained in the boiler 65 70 C Therefore the temperature of the water returning to the boiler from the heating system is as low as 55 60 C More water vapour condenses in the boi
41. tronic regulator lights up Fig 11 In this case it is necessary Fig 11 Rear control panel to find out the causes of tripping and to remove them After the boiler cools down the 1 Thermal fuse 2 Electric fuse emergency thermostat can be returned to its normal operating mode For this purpose unscrew its cover and depress the red button A The cause of overheating of the boiler and tripping of the emergency thermostat must be found and removed If this is not done the risk of serious damage to boiler equipment as well as hazard to human health and life remains If the user cannot locate and remove the cause of tripping of the emergency thermostat a professional servicing company must be consulted The electric fuse is designated to protect the elements of the electric circuit in case the current in the mains exceeds 2 A If the fuse is damaged the boiler will not switch on and its indicator lamps will not light In this case remove and replace the fuse The rear control panel of the boiler is grounded e PREPARATION FOR FIRING Before kindling the boiler check the position of the ceramic chopper 2 in the lower combustion chamber the edge of the chopper must be in contact with the rear wall of the boiler Fig 2 Place two ceramic segments 3 Fig 2 on the chopper so that they contact the walls of the boiler chamber Fill the heating system with water The filling pressure should be 0 2 bar bigger than the hydrostatic pressure yet i
42. ught in the chimney due to accumulated impurities Clean The ceramic burner is congested Clean Ventilator damper is stuck Move or clean 2 Smoke escapes The door sealing rope is damaged Replace with a new one through the Door is not tight along the entire perimeter Adjust hinge supports and door lock regulated boiler door screwing or unscrewing of door hinge or lock screws see Fig 13 Fig 13 Adjustment of the door and lock mechanism No draught in the chimney due to accumulated Clean impurities 3 Ventilatoris Emergency thermostat has tripped light ofthe Unsrew the thermostat 1 Fig 10 cover and not operating ventilator switch is off press the button under it It is absolutely required to define and remove the causes of tripping of this thermostat in order to avoid hazards to property and human health Power supply failure Check electric fuses of the electric panel of the building call electrician 20 INSTALLATION AND OPERATION MANUAL 9 WARRANTY AND ITS VALIDITY TERMS The manufacturer provides a warranty for the boilers the main conditions of which are the following e the connection of the boiler to the heating system as well as the initial kindling adjustment and repairs are carried out by an authorised company e the boiler is connected to the heating system and operated following the requirements of this operation manual e the duration of the warranty perio
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