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Hercules U26 HERCULES DUO

1. td 26 6 Boiler operation Dy 28 6 1 Control regulation and security elements U naa 28 6 1 1 Saphir regulator tuna ua Rania ites aa 28 6 1 2 Safety thermostats s ae ne a he OR een h pug esee has 28 6 1 3 Temperature sensor on the fuel feeder 2 29 6 1 4 Emergency fire extinguishing 29 6 1 5 Forced withdrawal of superfluous heat 29 6 1 5 1 Forced withdrawal of superfluous boiler heat a 29 6 1 5 2 Forced withdrawal of superfluous water heater 29 6 2 HMI ACX84 910 ALG service unit for Saphir regulator 29 6 2 1 Positioning and connection to Saphir regulator 30 6 222 Service elements ep a ieee iain 30 62 3 Configuratio isisisi a et een el eee tend a 31 6 24 Structures tus MIT 31 6 2 5 Changing 36 6 2 6 ie ee BO ee 36 6 4 Service MERE d Me ent ee een Du eet aQ u yu aap 38 6 5 Control activity before Start u en eee 3
2. L 60L 9ZS 9E 7 0 Josues eunjeJeduue 601 926 9 7 0 10sues 9 1ndino 1ejrog 1 S1 A 1 uJejs s 060786 su uu ls gl eg sg cd LS LV Fig no 17 Elementary wiring diagram 26 2 8 Gr i O gO S Im m ri 5 PP 4 r s a G OXQZ idea E99 am E ea Iv E S 9 0 00 W eg Lv gt 38 UM 5 o gt s oxaz mw D ri 25209 gt 25 5 omnmmoo gt mx 1 2 WIS IY 9 5 rA 5 ise d i I8 IN za 5 gt u 9 a 2 022 Ommmoozzszr m zo LY ee Pee CIS ONE G oxo LY wap EE 601M ZX g ase Oros six i k i u c Set E 75 c oxoc NELOTIY m c Q s oxaz Wq IV hieu i LOW 8 OLX e 0x E99 NM iz E559 I lt PEO WS m tu COTM Li na tc 5 lt gt a gt HI Cr lt qg Sow 065 sSphek T L eer CG soc tro Seu eu NIV GONWd ng TAX ag I SON
3. for boilers for 24 months after the product has been put into service but maximum 30 months after the date of dispatch from the production plant for cast iron boiler drum for 5 years after the date of dispatch from the production plant Validity conditions of the guarantee The boiler must be installed according to Boiler service and installation manual by a professional installation company The boiler must be put into service according to Boiler service and installation manual by a contractual service organization accredited by the manufacturer e The faults must be removed by a contractual service organization accredited by the manufacturer The delivery completeness is guaranteed by the seller The unfilled guarantee certificate is not valid The guarantee conditions and liability for defects follow chap no 10 this manual Measured values Numeric value Chimney draught mbar Flue gas temperature C The user confirms that e boiler adjusted by the contractual service organization did not prove any fault during the heat test e obtained the Boiler service and installation manual with properly filled out Guarantee certificate and Quality certificate e hewas made acquainted with boiler attendance and maintenance Date of installation Installation company User s signature stamp signature Date of putting into service Contractual service organization User s signature
4. Mount the left and right side part of shell incl insulation to the anchor screws screw the junction studs into both side parts of shells and mount the HEYCO bushings in the left shell Pull the smoke control draw rod through the left side part of the shell and secure by a plug Mount the smoke control lever on the draw rod and secure by means of 2 pc washers and plugs Connect the smoke control lever with smoke adapter flap and secure with a lock the screw the bakelite ball Stick the label for signalling the smoke flap on the left hand side part of the shell at the point of smoke control draw rod Mount the front part of the shell incl insulation Screw the rear part of the shell to the side parts Seat the face with insulation on the side parts Insert the spring clips into the upper part of shell with insulation and mount on junction studs of shell side parts 5 2 3 Fuel reservoir assembly Fuel feeder 9 Fuel reservoir de 2 Screw M10 x 30 4 pc 10 Screw M8 x 20 4 pc 3 Washer 10 5 4 pc 11 Nut M8 4 pc 4 Nut M10 4 pc 12 Washer 8 4 8 pc 5 Fan 13 Adjustable foot 6 Screw M6 x 16 4 pc 14 Intermediate flange 7 Washer 64 4 pc 15 Screw M6 x 20 4 pcs 8 Nut M6 4 pc Fig no 11 Mounting of fuel feeder and reservoir to the boiler 19 Screw on the adjustable legs of the the fuel feeder assembly see Fig No 11 Detail D Apply sealant onto the base of boiler then mount the fuel feeder assembly
5. T I 2 1 io l Lak ECGS He OBER 1 TI Tal BI WO e a ls EE SUB ss Has c L 90H GONE Ges 014 ca m T lt m H Wwe E s oc u z u 1 2 2 ua dA OM lt gt I g al o2im rrmis 2 a a E N co m gt gt gt Fig 18 Connection diagram 27 6 Boiler operation by user 6 1 Control requlation and security elements 6 1 1_ Saphir requlator Heating automatic mode The boiler must be in the ON state boiler display HMI The requirement for heating will be generated by switching of contact D2 room unit or the superior system of regulation The boiler starts to heat to the set desired temperature The fan starts to run constant speed and also the fuel feeder according to parameters set for the operation and delay of feeder The pump switches on reaching a defined temperature of boiler If during heating the outlet temperature has decreased by 5 C below the set temperature of switching on the pump the pump will be turned off When demand for heating has ceased the pump will stop When the set temperature of boiler has been exceeded the boiler goes to attenuation mode If there is still the requirement for heating the pump continues to run In case of a decrease in outlet temperature of boiler set temperature minus hysteresis the will be again t
6. 20s Feeder Pause 5 120 StbFdrRun 3 20s StbFdrPause 5 120 min StbFanOvRun 3 240s PumpMinTemp 20 70 Setting of desired boiler temperature HW Temp On Setting of desired HW temperature and switch off on of HW preparation MinBoilerTemp Setting of boiler temperature which will be maintained in the attenuation mode 32 BoilerHysterese Feeder Run Feeder Pause StbFdrRun StbFdrPause StbFanOvRun PumpMinTemp After pressing the button Setting of boiler hysteresis in case of output boiler temperature decrease by this value the automatic boiler operation will be reset The value is deducted from the set desired boiler temperature Setting of the time of feeder run in automatic mode Setting of the time of feeder delay in automatic mode Setting of the time of feeder run in attenuation mode Setting of the time of feeder delay in attenuation mode Setting of fan slowing down in attenuation mode after stopping the run of fuel feeder Setting of temperature at which the pump switches on Current statuses the current status of boiler is displayed The LED lights up in case of requirement for hot water flashes in attenuation mode or in case of requirement for minimum temperature of the boiler and is turned off when boiler is turned off Displaying on the display of HMI unit Parameter Description Current statuses Without password With password Fe
7. Boiler drum with basement Left side part of basement shell Safety thermostat holder Safety thermostat Washer 10 5 1 pc Draw rod of smoke control Control mechanism lever Washer 10 5 1 pc Screw M4 x 6 2 pcs 30 Plug 23 x 25 1 pc Screw ST 4 8 x 13 2 pcs 31 Lock 2 5 x 32 1 pc Insulation of left side part of basement shell 32 Bakelite ball Insulation into cut out 33 Right side part of the shell Right side part of basement shell 34 Side part of the shell insulation Bushing PG 13 5 2 pcs 35 Junction stud 2 pcs Remove the shell from the cardboard package Insulation of left side part of basement shell 36 Screw ST 4 8 x 13 6 pcs Washer 8 4 4 pcs 37 Face Nut M8 4 pcs 38 Face insulation rotaflex Screw ST 4 8 x 13 4 pcs 39 Face insulation sibral Front lower part of shell 40 Upper part of the shell Front lower part of the shell insulation 41 Spring clip 4 pcs Front upper part of shell 42 Upper part of the shell insulation Front upper part of the shell insulation sibral 43 Front part of the shell Front upper part of the shell insulation 44 Front part of the shell insulation rotaflex rotaflex 45 Front part of the shell insulation sibral Rear part of shell 46 Rear part of the shell upper insulation Screw ST 4 2 x 9 5 4 pc 47 Rear part of the shell Left side part of the shell 48 Screw ST 4 8 x 13 4 pcs Side part of the shell insulation 49 Rear part of the shell insulation Gromm
8. Off On PumpOverRun 0 30 PumpKickDay Set Low Temp Low T Delay InFireFdrRun InFireFdrStop FeederMaxTemp Max Fdr Man Max Fan Man Pump Mode Pump Man PumpOverRun PumpKickDay Mo Sun AlwaysOff T Setting of desired minimum temperature of boiler thatbhas to be achieved up to the set value in the parameter Low T Delay Failing to achieve the value set in parameter Set Low T during the time set in this parameter occurs the fault message LowBoilerTemp extinction of the boiler and the consequent shut down of the boiler Setting of running time of feeder if the current temperature of feeder is above the set maximum temperature of feeder Factory Setting of 90 C Setting of delay of feeder if the current temperature of feeder is above the set maximum temperature of feeder Factory Setting of 90 C When this temperature is reached at the sensor of fuel feeder then the feeder starts to move fuel at an accelerated pace until such time as there is a drop in temperature below the set value If there is no temperature drop of feeder for 7 minutes firmly set software value the feeder will be shut down The manufacturer recommends leaving the factory preset value Setting of running time of feeder when firing up Fuel feeder feeds continuously for the time set in this parameter Interrupting or re commissioning of the feeder into operation can be done using
9. stamp signature 51 Update 16 2013 GB model 2013
10. It is not necessary to use the second and third periods By activating this parameter will return time mode to the factory settings Note Functionality of time plan is conditioned by switching on the preparation of HW 35 6 2 5 Changing parameters The values that are displayed in black backlighting can be changed Flashing black backlighting indicates the position where we are and the parameter can be changed as follows Press the Enter key to change the parameter Fig 20 The given field stops flashing Fig 21 By means of setting button we change the value Confirm by pressing the key Enter Figure 22 In case you do not want to change a given parameter continue to the next line by using the button to select rows l Param Setting l Setting Setting BoilerTemp 1 70 C BoilerTemp c Hwremp 5 5 c c c Mi nBoilerTem Mi n Boi c Mi n Boi 7 c BoilerHyster mE Boi I er Hyst er c Boi l er Hyst er BEBE c Feeder Run s Feeder Run s Feeder Run s FeederPause s FeederPause s FeederPause FdrStbyRun 5 FdrStbyRun FdrStbyRun s 29 e 9 99 a 4 U ED J 3 Fig 20 Fig 21 Fig no 22 6 2 6 Failures The failure either existing or already reso
11. TimeFault Time validity If there is absence of voltage on the regulator longer than approx 3 days then the time date time counting is stopped is necessary to set the actual time and date Signalling of failures on the display of boiler HWOvrhtMsg Exceeding of the safety temperature in the reservoir of HW 80 C HW heating termination Three way valve turns to central heating FAULT REPORTS IN CASE OF SHORT CIRCUIT OR SENSORS DISCONNECTION BoilerTemp Boiler outlet temperature Boiler operation shutdown The protection against fuel fire penetration is active Primary pump is active HW Temp HW reservoir temperature HW heating shutdown Feeder Temp Temperature of feeder to the fuel reservoir 37 Shut down of the boiler 6 4 i Service board Cable gland ABB thermoplastic Safety thermostat signal lamp orange Dummy plug 28 0 colour white Dummy plug 14 3 colour white Fig no 23 Service board 6 5 Control activity before start Only the contractual service organization qualified for such type of activity is allowed to put boiler into operation Following checks must be carried out before putting the boiler into operation a b c d Filling the heating system with water Water for filling the boiler and heating system must be clear and colourless with no suspended matters oil and chemically aggressive substances Its hardness must corres
12. 1 Delivery and accessories HERCULES DUO boiler based on the order is delivered in such a way that the complete boiler drum including the basement is put on the pallet and packed boiler shell is gripped at the side of it The accessories are put inside the boiler drum and are accessible after opening the stoking door The fuel reservoir depending on the requirement small 269 or large 528 including the fuel feeder set is put on another pallet The boiler is packed in transport package and must not be tipped over during the transport Standard boiler delivery e boiler drum with basement e fuel feeder set e fuel reservoir e service board SIMBOX WP 8GB1 373 3 set incl electric pack e HMI ACX84 910 ALG service unit for Saphir regulator operation Siemens e fan e intermediate flange e round head screw and cross recessed screw M6 x 16 4 pc for fan gripping to the intermediate flange e countersunk screw M6 x 20 4 pcs M6 nuts 4 pcs and washer 6 4 4 pcs for attaching of the intermediate flange to the assembly of fuel feeder e safety thermostat e round head screw and cross recessed screw M4 x 6 2 pc for safety thermostat gripping e boiler drum shell incl ash pan e connection accessories for boiler drum shell 4 pcs spring clip 4 pcs junction stud 10 pcs screw ST4 8 x 13 e basement shell e connection accessories for basement shell 16 pcs screw ST 4 8 x 13 connection accessories for basement s
13. By welding connect the lower return water outlet with the heating system 4 Mount the drain valve into the hole at the rear of the basement 5 Put the stove pipe on the smoke adapter and insert into chimney hole The stove pipe diameter is 160 mm 6 Blind the threaded hole JS 6 4 in the front section with plug JS 6 4 Put the sealing under the plug 15 7 t is recommended to install shut off valves before and after the pump with a filter for reason of cleansing the strainer of filter or replacement of pump 8 Open the cleaning door see Figure No 2 Item 6 and hang hook with deflector so that the center of the deflector is above the center of the burner grate see Figure No 9 9 Open the cleaning door see Figure No 2a Item 5 and insert 8 turbulators see Figure No 2a Item 12 5 pieces of ceramics see Figure No 9 and partitions of the combustion space see Figure No 9 S 7 i T Vay Var Ta gi d q J ar Grate Deflector Hook Bottom ceramics Top ceramic plate Partition of the combustion space Partition of the combustion space front 8 Front ceramics ae Co Oo Fig No 9 Location of components ceramics inside the boiler 5 2 2 Shells assembl a lt gt YO 4 C x i Fig no 10 Boiler shell Legend to Fig No 10 O OO DEO OT SCO c
14. Positioning and connection to Saphir regulator Position A suitable position of HMI service unit is on the front side of HERCULES DUO boiler fuel reservoir Magnet installed at the unit backside belongs to HMI service unit ATTENTION With regard to device operating temperatures do not position HMI service unit on the front parts of the boiler shell Connection to Saphir regulator The connecting cable with the mains connector belongs to the service unit li is FORBIDDEN to prolong or shorten the cable HMI service unit connection to Saphir regulator Disconnect the boiler from the electricity supply Demount the cover of service board that is fixed with four screws Cut through reasonably the cable padding ABB for mains connector of HMI device the cable with mains connector through the cable padding ABB and connect to the input for mains connector on Saphir regulator Mount the cover of service board Connect the boiler to the electricity supply 6 2 2 Service elements 1 LCD display 2 Home key 3 Backspace key 4 Key of time programs 5 Key of faults display with LED diode 6 Line selection keys A V 7 Setting key 8 Enter key Fig no 19 Service elements of HMI unit for Saphir regulator control 30 Service element key Function description Image name Home key Return to original page Backspace koy Cursor moved back by one menu Schedule key The
15. after the product has been put into service but maximum 30 months after the date of dispatch from the production plant for cast iron boiler drum for 5 years after the date of dispatch from the production plant In case of a complaint regarding the shell the customer is obliged to submit the packaging label of the boiler shell It is put on cardboard in which the shell is dispatched The user is obliged to entrust a professional installation company with putting the boiler into service and a professional contractual service accredited by VIADRUS a s with and faults removal otherwise the guarantee does not apply to the proper function of boiler The HERCULES DUO boiler quality and completeness certificate serves for infilling as the Guarantee certificate The user is obliged to carry out a regular maintenance on the boiler Every fault must be announced in writing or by telephone immediately after it has been detected In case the above instructions are not observed the guarantees provided by the manufacturer are not admitted The manufacturer reserves the right to make changes within the product innovation that needn t be contained in this manual The guarantee does not apply to faults caused by wrong mounting and improper product attendance and faults caused by improper maintenance see chap 8 product damage caused by transport or other mechanical damage faults caused by improper storage faults and damage caused
16. burner Note Turning of cutting off of the grate according to the Figure No 3 Apply boiler mastic to the point marked and put the grate on the retort with mixer It is necessary to ensure the tightness between the burner and grate 22 Service board Nut M6 4 pc Washer 6 4 4 pc Screw M6 x 16 4 pc Fuel reservoir Nut M8 4 pc Washer 8 4 8 pc Screw 8 x 20 4 pc Fuel feeder 10 Screw M10 x 20 4 pc 11 Washer 10 5 4 pc 12 Nut M10 4 pc Fig no 14 Boiler conversion from the right hand to left hand design fuel reservoir and feeder disconnection 23 pM 5 oO 85 a T O g 0 x SOT o 5940 QK 5 Ne G gee 2 damoozzm t sibral mat Insulation of the opening otvoru of insulation Holder bracket Fig no 15 Boiler conversion from the right hand to left hand design dismantling of burner and blind flange 24 On the left side part of the jacket of the base cut out a metal plate for the connection of the feeder Transfer the insulation from the left lateral part of the jacket of the base into a slot in the right lateral part of the jacket of the base We jacket the boiler see chap 5 2 2 We apply mastic to the fuel feeder flange and connect it to the boiler basement the conn
17. 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 6 Grade of reaction to fire Grade otireaction to fire Examples of building materials and products included in the reaction to fire Extract from EN 13 501 1 A1 A1 incombustible Granite sandstone concrete bricks ceramic tiles mortars fireproof plasters A2 combustible with difficulty acumin izumin heraklit lignos boards and basalt felt fibreglass boards B hardly combustible Beech and oak wood hobrex boards plywood werzalit umakart sirkolit C D medium combustible Pinewood larch whitewood chipboard and cork boards rubber flooring Asphaltboard fibreboards cellulose materials polyurethane polystyrene polyethylene E F easily combustible Boiler positioning with regard to the necessary handling space basic environment AA5 AB5 according to CSN 33 2000 1 ed 2 min 1000 mm handling space must be left in front of the boiler minimum distance between the boiler rear side and wall is 400 mm min 1000 mm is left on the side of fuel reservoir in case of feed screwremoval minimum dist
18. flammable substances within 1500 mm from the boiler The ash must be collected in a non flammable ashbin with a cover Use the protection aids e After the end of heating season the boiler including the smoke flue must be properly cleaned The boiler room must be kept clean and dry e _ It is forbidden to interfere with construction and electric installation of boiler n case the two way safety device has responded to refill with water not conforming to CSN 07 7401 it is necessary to treat the water in the system so that it again conforms to this standard The safety valve of max 250 kPa 2 5 bar overpressure must be installed in the system and its dimensions must correspond to boiler nominal output In case of further questions please contact our contractual installation firms and service organizations n case of malfunction turning off the boiler or in the absence of fuel there is not ensured the protection against freezing The regulation of boiler does not solve the protection of heating circuit of boiler against freezing If the heating system is not in the winter daily used it is necessary to drain the water of it poor fuel quality 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
19. schedules selection is displayed 2 taus display wiy CED Image and alarm acknowledgement Line selection keys A V Selection of menu parameters lines Setpoint values Cursor horizontal control lt gt Enter key Confirmation of the set value JEP c ee OO 6 2 3 Configuration Boiler equipment Type of control e HMI service unit for ACX84 910 ALG Saphir regulator control The control to the set temperature of the boiler Thermostatic valve Filling valve series or the control by using a room device 12 or VTC512 external thread higher level regulation contact D2 Necessary boiler accessories Three way valve V4044C only in case the boiler is used for HW heating QAZ36 Hot water sensor only in case the boiler is used for HW heating 6 2 4 Structure Through menu original page and other submenus you will get to the names of parameters or directly to the setting lines All lines on the HMI service unit display are not always displayed at once depending on the display possibilities You will get to other lines by means of the key for lines selection A The cursor is displayed on the first line that can be changed e g on Boiler Menu line in case of the original page and then always on each of next lines enabling the change 31 The initial side of HMI control unit for controlling of the controller Saphir Explanation Z the imaging parameter specifie
20. the display of boiler when firing up in boiler Setting of fan run time when firing up The fan is running continuously for the time set in this parameter Interruption or reactivation fan operation when firing up can be done using the display of the boiler Setting of the mode of pump With this parameter it is possible to verify its functionality By default the Auto mode is selected Manual Switch on switch off the pump when the pump mode Man is selected Note After verifying the functionality of the pump is required again to select Auto mode Setting of pump slowing down time At the appointed day will pump kick at 12 00 for 30 sec Value 1 7 corresponds to days Monday to Sunday Value 0 pump kick of primary pump is not active Value 8 pump kick of primary pump is active every day Note If at this time the pump is running the function is not active 34 Displaying on the display of HMI unit IMenu HW Parameter Description Menu HW Without SUD password With password Preparation Off On Increas HW 5 20 Hysteresis HW 1 10 Valve mode HW Man Auto Valve HW Man Off On ForcedExh ToHW Preparation Increas HW Hysteresis HW Valve mode HW Valve HW Man ForcedExh ToHW Displaying on the display of HMI unit Yes No Preparation of HW On Off Setting of the boiler temperature increase from the currently desired hot water temperat
21. 0 short burning on a small area After a short time there occurs a reduction of the boiler output due to the small area of the flame and unburnt fuel at the edge of the burner The unburnt fuel will fall into the ash pan Too little combustion air will result in incomplete combustion which results in visible smoke from the chimney After setting of combustion air tighten the screw of the throttle to avoid coming loose A Air control is effective only if the grid is properly centred and sealed Fig No 24 Optimal shape of the flame Fig No 25 Awkward shape of the Fig 26 Throttle of fan 6 7 Superior control The manufacturer recommends the superior control of Siemens series RVS RVS 43 345 additional modules because for its use has been already processed the design documentation of VIADRUS In the case of using the superior control is necessary to do the following electrical connection of the superior control is used the input D2 on the controller Saphir S1 on e The right segment of the switch S1 must be in position off als e Due to the forced exhaust of excess heat must be connected the sensor from the superior control at the output from the boiler see Design documents VIADRUS 41 7 Important warnings boiler must not be used for other purposes than those it is designed for Th
22. 130 or STS 20 interconnection The interconnection can be carried out by means of flexible stainless hose On the ground of possible disassembly it must regard the demountable connection of valve with the pipe in the cleaning hole cover The valve sensor is to be positioned in the sensor holder that is on the fuel feeder Note The valve sensor is to be positioned in the sensor holder without the valve basin that is included in the delivery 1 Cleaning hole cover 2 Sensor holder Fig 13 Mounting of emergency fire extinguishing equipment Emergency fire extinguishing equipment function In case of fuel fire penetration into feeder temperature in feeder has reached 95 C BVTS or TS 130 or STS 20 valve opens the cold water inlet into hopper and the burning fuel is extinguished After the temperature on the sensor has dropped by 6 C the water supply is stopped Then it is necessary to dismount the motor with worm shaft and stainless insert and do cleaning This is followed by the re assembly and check whether the valve does not let flowing the cold water into the reservoir if yes exchange the valve 5 2 7 Boiler conversion from right hand design to the left hand design Boiler conversion after delivery before installation We remove the grate and pull out the burner with mixer from the basement the connection accessories are as follows 6 pc screw M10 x 30 12 pc washer a 10 5 6 pc nut M10 Fro
23. 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 above this packaging is claimed to comply with the requirements of EN 13427 45 46 Adressed to the user VIADRUS a s Bezru ova 300 735 81 Bohumin Certificate of warranty and Quality and completeness certificate for HERCULES DUO boiler Boiler serial number Boiler Output 2 2 1 User s rname name UN HER ee IE RR a eee ee eas Address Street city zipcode xis ade eds eed leet aeta Phone Fax HR end e ERI ee The boiler corresponds to requirements EN 303 5 Boiler for central heating Part 5 Solid fuel boiler for central heating with manual or automatic feed and nominal heat output maximum 300 kW Terminology requirements testing and marking VIADRUS a s provides the guarantee for boilers for 24 months after the product has been put into service but maximum 30 months after the date of dispatch from the production plant for cast iron boiler drum for 5 years after the date of dispatch from the production plant Validity conditions of the guarantee The boiler must be installed according to Boiler service and installation manual by a professional installation compa
24. 300 735 81 Certificate of warranty Quality completeness certificate for HERCULES DUO boiler Boiler serial number Boiler Output 2 2 1 User s rname name UN HER ee IE RR a eee ee eas Address Street city zipcode xis ade eds eed leet aeta Phone Fax c ee end e ERI UB E The boiler corresponds to requirements EN 303 5 Boiler for central heating Part 5 Solid fuel boiler for central heating with manual or automatic feed and nominal heat output maximum 300 kW Terminology requirements testing and marking VIADRUS a s provides the guarantee for boilers for 24 months after the product has been put into service but maximum 30 months after the date of dispatch from the production plant for cast iron boiler drum for 5 years after the date of dispatch from the production plant Validity conditions of the guarantee The boiler must be installed according to Boiler service and installation manual by a professional installation company The boiler must be put into service according to Boiler service and installation manual by a contractual service organization accredited by the manufacturer The faults must be removed by a contractual service organization accredited by the manufacturer The delivery completeness is guaranteed by the seller The unfilled guarantee certificate i
25. 8 6 5 Setting of parameters before the equipment start up 39 6 6 Boiler putting into operation aan ir ei ee dete xe e eda ie dieta eene qa qes 40 6 7 E 41 Important Warnlngs teta toc 42 MaINtGN ANCE ana EE 43 Instructions for product disposal after expiration of its 43 10 Guarantee and liability for 44 Dear customer Thank you for the purchase of automatic solid fuel boiler HERCULES DUO whereby you expressed your trust to VIADRUS a s Please read this manual particularly chapter no 6 Boiler operation by user chapter no 7 Important warnings and chapter no 8 Maintenance that provides you with instructions for the proper use of your new product that you have to get familiarized with at the very beginning Please follow the current information and take notice of instructions issued by the manufacturer or installation company that installed your boiler so that the long life trouble free operation of your boiler can be guaranteed both to your and our satisfaction 1 Use of boiler and its advantages Hot water automatic solid fuel boiler HERCULES DUO is destined particularly for heating the family houses cottages office buildings small premises etc Boiler advantages automatic boiler operation equithermal control possibility of HW heating possibility of bi
26. VIADRUS HERCULES DUO MANUAL FOR BOILER OPERATION AND INSTALLATION Table of contents page 1 Use of boiler and its 3 Bollertechnical data seit e ea dte p bem 3 a SDesclptiona 35 ete tet ed nx etes at kasa Saa eden etel 7 3 1 Boiler coristr ctiOn s cs cu rro Qua at ha a e o Bep de Ga irt Pe e kta qaa E vr eee 7 4 Positioning and iristallatiol terret E Oe verte EYE ge cov egre tente ti eter bue 10 4 1 Regulations and directives eee et cott cete ede cote 10 4 2 Positioning OptlOris 11 4 3 Hydraulic connection diagram 24404 aS Aaa as ayaka as entere 13 5 Boiler installation u nete eet Q q a ua een aa pee o aec ee aeta 14 5 1 Delivery and 14 5 2 Installation procedure 15 5 2 1 Installation of boiler drum with the basement a 15 5 2 22 ShellS assembly iis un ign ae eee P decet eee eed Deo 17 5 2 3 Fuel reservoir assembly iaceo cage tee dece ee de ded re d e e ne 19 5 2 4 Mounting of the service board to the fuel reservoir u n 20 5 2 5 Mounting of cleaning 0 5 20 5 2 6 Mounting of emergency fire extinguishing 21 5 2 7 Boiler conversion from right hand design to the left hand 21 5 2 8 Wiring
27. aling Cap Washer 8 4 Screw M8 x 20 OY O1 pp Coc NO c Detail A Identification symbol Countersunk screw with internal hexagon M8 x 20 Fig no Burner with mixer Tab No 5 Assignment of the type of Marking of the grate identification symbol no identification symbol grate according to size of boiler and type of fuel Number of boiler sections and type of fuel 4 sections 4 sections 5 sections 6a7 sections 6a7 sections black coal brown coal pellets black coal brown coal pellets pellets black coal brown coal 1 identification symbol 2 identification symbols 3 identification symbols 4 Positioning and installation 4 1 Regulations and directives The solid fuel boiler can only be installed by a company holding a valid license for boiler installation and maintenance The project according to valid regulations must be elaborated for installation The heating system must be filled with water that meets the requirements of CSN 07 7401 and especially its hardness must not exceed the desired parameters Recommended values Hardness mmol l Ca mmol l 53 Total concentration 0 3 recommended value WARNING The use of anti freeze mixture is not recommended by the manufacturer In case of two way safety device response regarding the water refill permit in case the water does not confor
28. ance from the side wall is 100 mm at least 450 mm are left above the boiler Boiler positioning with regard to electrical network mains e boiler must be placed in such a way that the plug in socket 230V 50Hz is always accessible Placing of fuel e Dry fuel has to be used in order to ensure its proper burning in the boiler Fuel stored in cellar or at least sheltered is recommended by the manufacturer e It is out of the question to store fuel behind the boiler or next to the boiler in the distance shorter than 400 mm e Min 1 000 mm distance kept between the boiler and fuel is recommended by the manufacturer or the fuel has to be stored in a room separated from the boiler room 11 It must be ensured the continuous air supply into the room where the boiler is installed for burning and eventual ventilation Air consumption of HERCULES DUO boiler Number of section 4 5 6 7 air consumption Im n 60 75 90 110 WARNING When connecting the boiler to the heating system the drain tap must be installed at the lowest point and closest possible to the boiler 7 Z 2 6 7 P min 1000 4 Z 2 2 the boiler room Fig no 4 HERCULES DUO boiler positioning in 1 1931 1588 Fig no 5 Boiler HERCULES DUO right hand design with small reservoir with
29. ase of decrease by 5 C below this temperature It is not recommended disconnect the boiler from the mains In case of boiler disconnection from mains time in regulator might stop and consequently the time regimes will switch incorrectly applies to the time mode of hot water if activated In an extreme case also the fuel fire penetration into reservoir pellets used the fuel can occur At the switched off boiler but not disconnected from mains the protection against fuel fire penetration into reservoir is active In case of a long term electricity outage pellets should be removed from the burner in order to prevent their fire penetration to the reservoir In this way we prevent the burning fuel from being poured with water which is the function of emergency fire extinguishing system see chap 5 2 6 and we are spared of complicated removal of soaked pellets from the fuel feeder Boiler cursor is above symbol heating circuit parameter P 40 or HW preparation parameter P 42 can be switched of by means of QAA 88 device 6 1 2 Safety thermostat The safety thermostat is mounted on the left hand side part of basement shell and it serves for boiler shutdown in case the safety temperature has been exceeded The safety thermostat must be set to 100 C temperature i e to the temperature higher than the set maximum boiler temperature 90 C After the safety thermostat switch off the safety thermostat signal lamp will light up The fuel feed
30. by failure to observe water quality in heating system see chap no 4 1 and 6 5 or by using the anti freeze mixture faults caused by instructions specified in this manual non observance faults caused by boiler operation with non specified fuel see tab no 3 and 4 44 Information for customer Packaging identification PE Plastic sacks folie corrugated board iron and plastic fix line Assessment reference Identification of principal materials used Paper Polyethylene iron wood Part 1 Summary of assessment Standard Report Assessment requirement Claim Note 1 1 Prevention by source YES reduction 1 2 Heavy metals and ensure below maximum permitted levels for components YES CR 13695 1 1 3 Other ensure in compliance with noxious hazardous CSN 77 0150 2 EN 13428 YES substances 2 Reuse ensure reusability in all terms of the standard for the functional packaging unit NO EN 13429 3 1 Recovery by material ensure recyclability in all terms of the recycling standard for the functional packaging unit YES EN 13430 3 2 Recovery in the form ensure that calorific gain is achievable for of energy the functional packaging unit YES Iron NO EN 13431 3 3 Recovery by ensure compost ability in all terms of the composting standard for the functional packaging unit NO EN 13432 NOTE Conformity with EN 13427 requires affirmative responses to sections 1 1 1 2 1
31. d value can not be changed parameter value can be changed HW hot water gt the step to the second level by pressing Enter Note The text descriptions of the parameters correspond to the display of the HMI unit Displaying on the display of HMI unit Parameter Without password Description Example With password 5 1 2012 Boiler Status Off On Boiler Temp 5 100 HW Temp 5 100 Feeder Man Off On Fan Man Off On Param Setting Password Polish French Select language English Czech English German DUO model 2013 Boiler Status Boiler switched on off Boiler Temp Display of current boiler temperature HW Temp Display of current hot water temperature if the status of HW preparation is active Feeder Man Switch on switch off of the feeder for a defined time use when making fire Fan Man Switch on switch off of the fan for a defined time use when making fire Param Setting Input into menu of setting parameters Password Input into menu of boiler HW and time plans of HW Select language Setting language possibility Parameters Setting Displaying on the display of HMI unit Parameter UN Without Description Example password With password Parameters Setting Boiler Temp 50 85 HW Temp On 10 65 20 70 BoilerHysterese 1 10 Feeder Run 3
32. e boiler only can be operated by adults who are acquainted with this service manual It is forbidden to leave unattended children in the vicinity of operating boilers boiler is not destined for use by persons including children whose physical sensory or mental disability or lack of experience and knowledge prevent them from a safe use of the appliance if they are not supervised or were not instructed regarding the use of the appliance by a person responsible for their safety Children should be watched to make sure that they do not play with the appliance e If there occurs the danger of flammable vapours or gases development and their penetration into boiler room or during the works that are accompanied by temporary danger of fire or explosion gluing the flooring materials painting with combustible paints etc the boiler must be put out of service prior to the start of such works When transporting fuel into combustion chamber before firing up the volume of fuel in retort must be checked visually and not by putting hands into fireplace There is a danger of injury caused by rotating worm shaft itis forbidden to use flammable liquids in making fire in boiler During the boiler operation it is forbidden to overheat it in any way e Itis forbidden to put any things made of flammable materials on the boiler or within the distance less than the safe distance e When removing the ash from boiler there must not be found any
33. e matter 96 Granulari sulphur Ash content s 4 9 8 Screened lignite in nub 2 anhydrous condition Pellets must conform at least to one of following directives or standards gt Directive no 14 2000 MZP CR gt DIN51731 gt ONORM M 7135 Specified granularity of pellets 6to8mm Water content in fuel max 12 Ash content max 1 5 ATTENTION A low fuel quality can distinctly negatively influence the boiler output and emission parameters 1167 1815 1592 1339 623 1272 1335 1986 Length i L mm 754 865 976 1087 L1 mm 498 609 720 831 Fig no 1 Main dimensions of HERCULES DUO boiler right hand version dimensions after the slash apply to the variant with a large reservoir 3 Description 3 1 Boiler construction QGO G G EF A NS p 2 a fons 12 N 18 13 31 N 32 N G 30 NZ 20 Oo p E 2 24 Z Nas oe N _ NZ f a f s 16 4 27 UA Meu DWG RNA DONE 1 Basement 17 Fuel feeder 2 Burner 18 Geared engine 3 Boiler drum 19 Fan 4 Smoke adapter 20 Fuel reservoir 5 Cleaning door 21 Service board 6 Cleaning door 22 Filling and drain taps G V2 7 Ash pan door 23 Heating a return water flanges 8 Smoke control draw rod 24 Safety valve 9 Bas
34. ection accessories are as follows 4 pc nut M10 4 pc washer 10 5 We turn the motor in such a way that it is in the rear when viewing the boiler from the front We remove the old sealant from the flange of the fuel feeder and we apply a reasonable amount of a new sealant to the seating surface Then we connect the fuel feeder with the fuel reservoir connecting material is as follows 4 screws M8 x 20 4 pcs washer 8 4 and 4 pcs nut M8 We connect the emergency fire extinguishing equipment We connect the service board incl consoles to the fuel reservoir We reconnect the components in case the conversion was done already after the primary installation the length of cables must be trimmed as need may be J VIADRUS Z v YO m WAY Fig 16 HERCULES DUO boiler left hand design 25 diagram 5 2 8 Wirin 22 Ajunoes Aejay 043009 JO 1961u02 jong MH JO OUJ YIHdVS 303 d3OIAd3S 016 8 Ly A LW euueu Ajejes Ajejes 601 925 96 ZVO MH 103 9
35. eder Off On Fan Off On Pump Off On Valve HW Off On Feeder Fire OK Err Feeder Temp 5 100 ActualDmnd Feeder Fan Pump Valve HW Feeder Fire Feeder Temp ActualDmnd Displaying on the display of HMI unit 0 85 Displaying of current status of fuel feeder Off On Displaying of current status of fan Off On Displaying of current status of pump Off On Displaying of current status of valve HW Off On Displaying of current status whether fire penetrates into fuel reservoir OK no fire penetration of the fuel Err penetration of the fuel The function against fire penetration of the fuel is activated Displaying of current temperature of fuel feeder Displaying of current requirement dor boiler temperature Password Parameter Description Without Fxampie password With password Enter the password 33 After entering the correct password 9000 the following menu appears below the line Displaying on the display of HMI unit Password Menu Boiler Parameter Description Menu Boiler Without ze password With password Set Low Temp 10 Low T Delay 10 InFireFdrRun 10 InFireFdrStop 5 15 FeederMaxTemp 85 Max Fdr Man 1 10 1 30
36. em Open the stop valves between boiler and heating system Check the pump Clean the burner and ash pan drawer in case fire isn t made for the first time Ash pan door during fire making and boiler operation must be permanently closed Fill the fuel reservoir with specified fuel and then close the reservoir carefully in order to prevent possible air intake into the burner through the feeder Feeder of fuel for transport the fuel to the burner is switched on by means of HMI on the row line FeederMan On Fuel must supplied about 2 cm below the edge of the cast iron grate If the fuel feeder is empty the fuel supply to the burner takes 6 6 5 min After 6 minutes the screw feeder automatically is switched off and by using the HMI unit you can put it into operation if needed Switching off of feeder is performed by switching into the status Off Put the kindling e g paper wood chips PEPO solid alcohol etc on the fuel Ignite and let flare up Shovel a small volume of specified fuel to the burning kindling Close the door and turn on the fan by means of HMI unit run of fan is signalled in the current statuses on the HMI The fan can be turned off as needed on the HMI unit otherwise the fan will turn off automatically after 15 minutes Fan for making a fire can be regulated by a throttle During making a fire please maintain sufficient height of fuel If the fuel sufficiently burns turn off the fan in manual mode or wait until it i
37. ement shell 25 Stopper with male thread Js 1 2 10 Boiler drum shell incl ash pan 26 Stopper of boiler Js 1 2 11 Safety thermostat 27 Stopper of keg 52 5 mm 12 Turbulators 28 Hook 13 Partition of the combustion chamber front 29 Ceramics front 14 Partition of the combustion chamber 30 Ceramics lower 15 Deflector 31 Fireclay top plate 16 Ash pan 32 Insulation back Fig no 2a Main components of boiler 7 y 13 1 m Po UJI eg 30 _ TINS B 29 28 Le 15 28 s Fig no 2b Main components of boiler The pressure components of boiler correspond to strength requirements according to EN 303 5 Boilers for central heating Part 5 Solid fuel boilers for central heating with manual or automatic feed and nominal heat output maximum 300 kW Terminology requirements testing and marking The cast iron body positioned on the basement welded of steel sheets is the core part of the boiler The boiler drum consists of sections connected by means of pressed on boiler inserts of 56 mm diameter and secured by anchor bolts The sections form the combustion space water space and convective part Heating water inlet and outlet are situated at the rear of the boiler by means of two flanges 2 for connection to the heating system T
38. emperature is lower than the current desired boiler temperature the boiler comes back into actual automatic regime in case the boiler temperature has reached 100 C and the safety thermostat has been blocked the thermostat must be manually de blocked 6 1 5 2 Forced withdrawal of superfluous water heater heat If the temperature in water heater has exceeded 80 C the forced withdrawal of the superfluous heat into the heating circuit will start 6 2 HMI ACX84 910 ALG service unit for Saphir regulator operation As display of boiler is used the control unit HMI ACX84 910 ALG to control the controller Saphir The connection of the control unit HMI is conditioned by preservation of the left segment of the switch S1 in position off blbec HMI service unit cannot be used as the space device Technical data Supply DC 12 V supply from Saphir regulator Rated current 50 mA Cable length 3 m max 15 m without reinforcement interface Serial interface 8 eight wire socket RJ45 Protection IP 50 as unit for manual operation EN 60529 Ambient conditions Temperature range e 70 Storage 30 70 C standards Casing 99 3 x 153 5 x 23 mm LCD display Visible surface 70 x45 mm Active surface 61 x 39 mm General data Casing Weight 0 124 pc Colour Anthracite RAL 7016 LCD display Image Latin characters 8 lines 20 characters in line Resolution 128 x 80 points 29 6 2 1
39. ensor with three way valve HW We remove the service board including the consoles for service board gripping We disconnect the emergency fire extinguishing equipment First of all we empty the reservoir We dismantle the fuel reservoir from the fuel feeder the connection accessories are as follows 4 pc screw 8 x 20 8 pc washer 8 4 a 4 pc nut M8 We disconnect the fuel feeder from the boiler basement the connection accessories are as follows 4 pc washer 10 5 and 4 pc nut M10 We remove the boiler shell We remove the grate and pull out the burner with mixer from the basement the connection accessories are as follows 6 pc screw M10 x 30 12 pc washer 10 5 6 pc nut M10 From the left side of the base we unscrew the blind flange insulation insulation bracket see Figure 15 Detail B and install them on the right side connecting material is as follows 4 pc screw M10 x 30 8 pc washer 10 5 4 pcs nuts M10 We remove the old sealant The metal plates must be sealed with a sealant between the base and bracket of insulation and between the bracket of insulation and blind flange We apply mastic to the burner with mixer flange and we put the burner into the basement from the left hand side and screw it the connection accessories are as follows 6 pc screw M10 x 30 12 pc washer 10 5 6 pc nut M10 We remove the old mastic from the grate We apply a reasonable quantity of new mastic to the bearing surfaces and we mount the grate in the
40. er and fan will stop The safety thermostat de blocking must be done manually after the cover dismantling and then pressing the trap In case of safety thermostat repeated switch offs it is necessary to put the boiler out of service and find the reason of boiler repeated overheating After the safety thermostat switch off the primary pump is still working 28 6 1 3_ Temperature sensor on the fuel feeder If the temperature set in P26 parameter appears on the temperature sensor the fuel feed will be accelerated in order to move the burning fuel to the burner Once the temperature has dropped below the set value the boiler will come back into the original regime This security only functions in case the boiler is supplied with electricity If the feeder temperature hasn t dropped within 7 minutes preset value the feeder will be shut down 6 1 4 Emergency fire extinguishing system In case of fuel fire penetration into the feeder 95 C temperature reached on the feeder the BVTS TS 130 STS 20 valve opens the water inlet into the hopper in order to extinguish the burning fuel once the temperature on sensor has dropped by 6 C the water inlet will be closed 6 1 5 Forced withdrawal of superfluous heat 6 1 5 1 Forced withdrawal of superfluous boiler heat In case the boiler temperature has exceeded 90 C so called forced withdrawal of the superfluous heat into the heating circuit will start The fan and feeder are not active In case the t
41. es VTC512 external thread made by ESBE minimum temperature of return water is 45 C ord code 5100 15 00 for HERCULES DUO 5 7 sect e sticker LED for the safety thermostat signalization e boiler service and installation manual incl the certificate of warranty Obligatory accessories not included in the delivery e Hot water sensor QAZ36 526 109 in case boiler will be used for HW heating Siemens e Three way valve V4044F in case boiler will be used for HW heating Honeywell in this case only the phase working and protective conductors will be connected Note also V4044C valve can be used e Safety valve 1 pc according to the maximum boiler operating overpressure see tab no 1 By request e Circulating pump Grundfos UPS 25 40 e Water heater according to VIADRUS a s offer The boiler equipment ordered as obligatory accessories and request is not included in the basic price of boiler 5 2 Installation procedure 5 2 1 Installation of boiler drum with the basement 1 Position the boiler drum with basement on the substructure pad into the horizontal position 2 Insert the sealing between the heating water flange and boiler then mount by means of four screws to the boiler follow the boiler room dispositions By welding connect the heating water outlet with the heating system 3 Insert the sealing between the return water flange and boiler then mount by means of four screws to the boiler
42. eservoir 27 h 10 min 21 h 45 min 18 h 10 min 15 h 30 min Burning time at nominal output large reservoir 58 h 20 min 42 h 40 min 35h35 min 30 h 30 min Efficiency up to 87 3 up to 87 4 up to 87 5 up to 87 5 Flue gas temperature 95 175 90 165 90 160 85 145 Flue gas mass flow at outlet Important warning 0 007 0 015 0 009 0 018 0 010 0 022 0 012 0 025 The stated thermal technical parameters vary in dependance on the sort quality and moisture of used fuel Therefore some corrections might be necessary when setting the stoking cycle time for fuel feed versus time for fuel afterburning For example if unburned fuel slivers appear on the grate and in the ash pan it stands to reason that stoking is faster than burning and the stoking cycle must be reduced see parameters description Parameters of prescribed fuel fuel used for tests in SZU e water content max 12 96 hard coal wood pellets max 20 lignite 12 20 96 wood e volatile combustible content 28 40 96 e ash deformation by melting temperature gt 1150 C e low sintering capacity small moisture expansion Tab no 3 Specified fuel mm MJ kg Hard coal Peas Nub 2 Nub 3 Biomass Wood pellets Lignite Tab no 4 Specified fuel lignite Specific Tar Tar content sulphur content in in content dry matter combustibl g MJ 96
43. et Heyco 50 Stopper of keg 52 5 mm Junction stud 2 pc 51 Cover 52 Screw ST 4 8 x 13 4 pcs Mount the relevant connection accessories on the steel sheet components according to Fig no 10 Jacket the boiler according to Fig no 10 Screw the safety thermostat 2 pc screw M4 x 6 to the safety thermostat holder Screw the holder with the safety thermostat to the left shell of basement 2 pc screw ST 4 8 x 13 see detail A Note lead the safety thermostat capillary between the shell and insulation The electric connection of safety thermostat is done before jacketing the boiler The cable goes in the bushing through the side part of the basement shell depending on the design either in the left or right part of basement shell The boiler output temperature sensor must be positioned in the boiler basin across the bushing in the side part of the basement shell depending on the right or left design also before the boiler jacketing Mount the left and right side part of basement shell incl insulation Depending on the left or right design selection break out the steel sheet for feeder connection Screw the cover by means of 4 screws ST 4 8 x 13 to a part of the cut out hole Grip the side parts to the basement by means of M8 nuts and 8 4 washers only to the front part of the basement Mount the front parts of basement shell incl insulation upper and lower and screw the rear part of basement shell to the side parts of basement shell
44. he automatic mode Hot water Request for hot water is generated from the sensor B3 The requirement occurs when the temperature in the water heater has decreased by the set hysteresis This state is indicated by the green LED that is illuminated on the display of boiler The three way valve is turned into the hot water circuit The pump switches on when reaching a defined temperature of boiler with the condition that the temperature of the boiler is by 7 C higher than the current temperature of the hot water in the heater Otherwise the pump is suspended to prevent cooling in the water heater When demand for heating has ceased there will occur the defined deceleration of three way valve to the water heater If the requirement for heating will be active then deceleration of the three way valve will not occur Attenuation mode If there is no requirement for heating and hot water the boiler goes into attenuation mode This mode is signalled by a flashing green LED of display of boiler In this mode the minimum boiler temperature is maintained If has been reached the minimum temperature of boiler then the fan and the feeder are switched on only in a defined time delay for a certain period of time to avoid fire blow out in the boiler The fan is running longer compared to the feeder so the fuel can sufficiently begin to burn In the attenuation mode the pump switches when the temperature of boiler reaches 70 C The pump turns off during in c
45. he temafast 2 60 x 48 x 2 mm Sealing is between the boiler and flange The rear boiler section has the smoke adapter and heating water flange in the upper part and the return water flange is in the lower part of the basement The cleaning door and ash pan door are fastened to the front section The folding grate is positioned behind the cleaning door 6 Under the cast iron body there is positioned the burner with mixer see Fig no 3 that consists of cast iron grate and retort We use 4 types of cast iron grates with regard to the size of the boiler and fuel used The various types of grates are marked with an identification symbol see Figure 3 a detail In table No 5 there is shown the assignment of individual types of grates to a given boiler and fuel type The fuel is fed from the reservoir through the feed screw emptying into retort on the cast iron grate The ash pan drawer is under the combustion chamber Next to the boiler there is positioned the fuel reservoir that empties into fuel feed screw Fan for combustion air is positioned behind the fuel reservoir and is connected to the burner Fan has control by SAPHIR regulator All components boiler drum basement are insulated by means of health non detrimental mineral insulation that reduces the heat transmission losses The high quality komaxit spray is used for boiler shell colour treatment 8 The boiler is made in left amp right design Mixer Retort Cast iron grate Se
46. hell gripping to the basement 4 pcs washer 8 4 4 pcs nut M8 e ash pan e boiler mastic tube 310 ml e bushings PG 13 5 2 pcs e bushings PG 11 2 pcs e stud bolt M10 x 30 4 pc and washers 10 5 4 pcs for gripping the fuel feeder set to the basement hexagon head screws M8 x 20 4 pc and washers 8 4 pcs for gripping the fuel reservoir to the fuel feeder filling and drain tap Js 1 2 1 plug Js 6 4 blind 1 pc sealing 60 x 48 x 2 1 pc hook 1 pc deflector 1 pc ceramics into the boiler drum 5 pcs partitions of the combustion chamber 4 sections 2 pcs 5 sections 3 pcs 6 sections 4 pcs 7 sections 5 pcs turbulators 8 pcs draw rod with hanaccording to for smoke flap control 1 pc grommet HEYCO 2 pc label for smoke flap control 1 pc flange of heating and return water 2 2 pcs sealing 0 90 x 60 x 3 2 pcs handling key 1 pc cleaning tools hook brush with hanaccording to tang dowel 8 mm 2 pc straight threaded rivet 5x60 2 pcs siseal 10 g thermostatic valve BVTS Danfoss or TS 180 Honeywell or STS 20 Watts cast iron grate for boiler size 6 a 7 sect boiler sensor QAZ 36 526 109 sensor against fuel fire penetration QAZ 36 526 109 thermostatic valve filling valve series VTC312 external thread made by ESBE minimum temperature of return water is 45 C ord code 5100 15 00 for HERCULES DUO 4 sect e thermostatic valve filling valve seri
47. himney sweepers company burner tightness Connect the equipment to the mains insert the plug into socket By starting the fan via a display is carried out the check of burner sealing All air must flow into the combustion space of retort and cast iron grate The check must be focused on bearing surfaces ofFanto the flange round the burner cleaning hole of the cast iron grate with burner In case a leakage appears the grate must be removed the old boiler mastic must be removed from bearing surfaces and an adequate quantity of new mastic must be applied 38 to them then the grate is remounted into burner Note Turning of the cutting off of grate according to Figure No 3 Repeat the check Apply boiler mastic to the point marked and put the grate on the retort with mixer It is necessary to ensure the tightness between the burner and grate e connection to the mains The boiler is connected through a movable lead by means of a plug into the standardized socket 230 V 50 Hz 10 A Protection against electric shock must be ensured according to CSN 33 2000 4 41 ed 2 f open the water inlet into valve BVTS or TS 130 or STS 20 g check the opening of chimney flap The installation and heating test completion must be recorded in the Guarantee certificate 6 5 Setting of parameters before the equipment start u Parameters necessary for equipment start up Before the first firing upt is necessary to set the year date
48. id its damage After the smoke adapter has been cleaned we mount back the cleaning cover whereas we are particular about the tightness between the cleaning cover and smoke adapter 9 Instructions for product disposal after expiration of its lifetime VIADRUS a s a contract partner of s with client number F00120649 The packages conform to EN 13427 The packages are recommended to be disposed of in following way plastic foil cardboard package use the salvage service metal strapping band use the salvage service wood base is destined for a single use and no longer can be used as the product Its disposal is subject to law 477 2001 Coll and 185 2001 Coll as amended Because the product is constructed of common metal materials the individual components are recommended to be disposed of in following way heat exchanger grey cast iron use the salvage service tube distribution shell use the salvage service other metal components use the salvage service insulation material ROTAFLEX through the company engaged in waste collection and disposal In case the product has lost its manufacture qualities then so called reverse product withdrawal if it is introduced can be used if the originator declares that it regards the waste it will be handled according to the legislation valid in relevant country 43 10 Guarantee and liability for defects VIADRUS a s provides the guarantee boilers for 24 months
49. lved is signalled by a flashing LED diode on the button of D displaying failures After pressing the button is displayed list of failures and also are confirmed deblocked the failures that already have passed away or have been removed In the list of failures is necessary by pressing the key display also the history of failures and then re press the button to stop the signalling of the failure i e flashing of LED diodes From the list or history of faults will return to the starting page by pressing the Home button 36 Sensor Fault description Boiler response BoilerOverTemp Excess of security max boiler value temperature Boiler operation shutdown Pump s are still running FeederFire Excess of fuel feeder temperature Fuel feeding according to the set algorithm so that the burning fuel is transferred again to the burner Engine thermal protection ThermoContact Excess of fuel feeder motor winding temperature Boiler operation shutdown The primary pump keeps running After the winding has cooled down and the boiler thermal protection switched again put again into operation LowBoilerTemp Boiler extinction The outlet temperature in a given time interval does not increase The absence of fuel feeder blockage etc might be the reasons Boiler operation shutdown The protection against fuel fire penetration is active It is necessary confirm unblock the fault
50. m the left side of the base unscrew the blind flange insulation bracket of insulation see Figure 15 Detail B and install them on the right side connecting material is as follows 4 pc screw M10 x 30 8 pc washer 10 5 4 pcs nuts M10 We will remove the old sealant The metal plates must be sealed with a sealant between the base and bracket of insulation and between the bracket of insulation and blind flange We apply mastic to the burner with mixer flange and we put the burner into the basement from the left hand side and screw it the connection accessories are as follows 6 pc screw M10 x 30 12 pc washer 10 5 6 pc nut M10 21 C We remove the old mastic from the grate We apply a reasonable quantity of new mastic to the bearing surfaces and we mount the grate in the burner Note Turning of the cutting off of the grate according to the Figure No 3 Apply boiler mastic to the point marked and put the grate on the retort with mixer It is necessary to ensure the tightness between the burner and grate Then we proceed according to chap 5 2 Installation procedure onversion of already installed boiler We let the boiler burn out We disconnect the boiler from mains We disconnect the geared motor fan we disconnect the connector boiler primary pump safety thermostat from regulator and we will pull out the sensor against fire penetration from the sump and the output sensor from the sump of boiler Unplug the HW s
51. m to CSN 07 7401 it is necessary to treat water in system so that it again conforms to this standard a regarding the heating system CSN 06 0310 Thermal systems in buildings Design and installation CSN 06 0830 Thermal systems in buildings Protecting devices CSN 07 7401 Water and steam for thermal energetic devices with steam working pressure up to 8 MPa EN 303 5 Boilers for central heating Part 5 Solid fuel boilers for central heating with manual or automatic feed and max 300 kW nominal thermal output terminology requirements testing and marking b regarding the chimney CSN 73 4201 Designing the chimneys and smoke flues c regarding the fire regulations CSN 06 1008 Fire safety of thermal equipments EN 13501 1 A1 Fire classification of construction products and building elements Part 1 Classification using test data from reaction to fire tests d regarding the electric network CSN 33 0165 Electrical regulations marking the leading wires by colours or digits implementing regulations CSN 33 1500 Electrical regulations revision of electrical equipments CSN 33 2000 1 ed 2 Low voltage electrical installations Part 1 Fundamental principles assessment of general characteristics definitions CSN 33 2000 4 41 ed 2 Low voltage electrical installations Part 4 41 Protection for safety Protection against electric shock CSN 33 2000 5 51 Electrical installations of buildings Part 5 51 Selec
52. mitation of voltage fluctuation and flicker in low voltage supply systems for equipment with a rated input current greater than 16 A e regarding the system for HW heating CSN 06 0320 Thermal systems buildings Hot water preparation Design and project engineering CSN 06 0830 Thermal systems in buildings Protecting devices CSN 75 5409 Water installations inside buildings 4 2 Positioning options The boiler is equipped with the movable mains supply and plug Boiler according to EN 60 335 1 ed 2 Art 7 12 4 must be positioned in such a way that the plug is accessible Boiler positioning in the living space including corridors is prohibited The installation of the boiler must comply with all requirements of CSN 06 1008 Boiler positioning with regard to fire regulations 1 Positioning on the floor made of incombustible material putthe boiler on a fireproof and heat insulating pad exceeding the boiler plan by 20 mm on the sides n case the boiler is installed in a cellar it should be put on a minimum 50 mm high substructure The boiler must be installed straight any possible inequalities of retaining wall are eliminated by means of adjustable foot see Figure No 11 2 safe distance from the combustible materials when installing and operating the boiler it is necessary to keep a safety distance of 200 mm from the materials of combustibility grade A1 A2 B and C D for easily combustible materials of
53. ny The boiler must be put into service according to Boiler service and installation manual by a contractual service organization accredited by the manufacturer The faults must be removed by a contractual service organization accredited by the manufacturer The delivery completeness is guaranteed by the seller The unfilled guarantee certificate is not valid The guarantee conditions and liability for defects follow chap no 10 this manual Measured values Numeric value Chimney draught mbar Flue gas temperature C The user confirms that e boiler adjusted by the contractual service organization did not prove any fault during the heat test e obtained the Boiler service and installation manual with properly filled out Guarantee certificate and Quality certificate e hewas made acquainted with boiler attendance and maintenance Date of installation Installation company User s signature stamp signature Date of putting into service Contractual service organization User s signature stamp signature 47 Appendix to the guarantee certificate for customer user Record of carried out guarantee and after guarantee repairs and product controls Date of Contractual service Customers Carried out activity organization signature signature stamp record 48 Adressed to the service organization VIADRUS a s
54. omass wood pellets combustion mechanical fuel fedd from inbuilt reservoir simple time non consuming boiler attendance and maintenance low operating costs 2 Boiler technical data Tab no 1 Boiler dimensions technical parameters Boiler weight small reservoir large reservoir 547 598 Water space volume 71 9 83 8 Diameter of smoke socket 156 Fuel reservoir capacity small 269 Fuel reservoir capacity large 528 Boiler dimensions including small fuel reservoir See fig no 1 width x depth x height Boiler dimensions including large fuel reservoir See fig no 1 width x depth x height Filling hole dimensions small reservoir 422 x 545 Filling hole dimensions large reservoir 422 x 1210 Boiler degree acc to EN 303 5 3 Working water overpressure 2 5 250 Testing water overpressure 5 500 Recommended operating temperature of 50 85 65 85 heating water Minimum return water temperature 45 50 Boiler hydraulic loss 0 72 0 96 1 32 1 59 Noise level Doesn t exceed level 65 dB A Chimney draught 0 15 0 20 0 20 0 25 Boiler connections heating water G2 return water G2 Connecting voltage 1 N PE 230 V AC 50 Hz TN S Electric input 100 Electric coverage IP 44 Tab no 2a Thermal technical parameters of the boiler during combustion of brown coal Nominal output 6 sect Regulated output Fuel con
55. open fuel reservoir 12 4 3 Hydraulic connection diagram Y A D 954 P v1 JIN Ex Fig no 7 Hydraulic diagram without HW preparation Legend to Fig no 6 and 7 BT 1 Safety thermostat M2 Air fanmotor Boiler outlet temperature sensor PV Safety valve HW temperature sensor Q1 Boiler primary circuit pump Fuel feeder temperature sensor Y3 HW heating three way valve Expansion vessel V1 Thermostatic valve Fuel feeder motor ZK Clack valve Sensor cables can anyhow be shortened or prolonged provided following principles are observed do not cut the sensor cable in the distance shorter than 0 5 m from the jacket cable sensor prolongation by more than 10 m is not recommended H 2 x 0 5 mm cable is recommended for cable prolongation Cable connection in case of prolongation is to be done very carefully Ensure the conductive joint when you shorten or prolong the cable Note to the three way valve V4044C V4044F made by Honeywell Connection AB heating water outlet from boiler Connection A outlet to the water heater Connection B outlet to the heating circuit 1435 1339 Fig no 8 Connecting dimensions of boiler 5 Boiler installation 5
56. pond to CSN 07 7401 and it is necessary to treat water in case its hardness is unsatisfactory Even the multiple heating of water with a higher hardness does not prevent the salts from precipitation on the walls of the boiler drum The precipitation of 1 mm of calcite in a given place reduces the heat transfer from metal to water by 10 95 Heating systems with an open expansion tank allow the direct contact between the heating water and atmosphere During the heating season the water expanding in the tank absorbs oxygen which increases its corrosive effects and at the same time a considerable volume of water evaporates Only water treated according to CSN 07 7401 can be used for refilling The heating system must be thoroughly flushed in order to wash out all impurities During the heating season it is necessary to keep a constant volume of water in the heating system Refilling the heating System with water must be done carefully in order to prevent air sucking into the system Water in boiler and heating system must never be discharged or taken for use with the exception of exigencies such as the repairs etc By water discharging and new water filling the risk of corrosion and scale formation is increased If it is necessary to refill water in heating system we only refill the cooled down boiler in order to prevent the steel basement and cast iron heat exchanger from damage heating system tightness connection to the chimney it must be approved by a c
57. rform these operations A dry brush must be used for cleaning At this time boiler must be disconnected from the electricity supply If pieces of stone metal or wood appear in the fuel the feed screw might get blocked In this situation accompanied by engine overheating followed by its stopping the boiler must be switched off and the obstacle removed WARNING before performing this operation you must make certain that the boiler is disconnected from the electricity supply the plug pulled out of the socket Because a slight overpressure is developed in the burner during the fan operation it is necessary to mind the perfect boiler tightness door of the fireplace door of the ash pan burner cleaning hole fuel reservoir cover etc The fuel reservoir tightness is given by the proper closing of its cover by means of rotary closure and undamaged rubber sealing of the bearing surfaces In case of emergency electricity outage lasting longer etc and fuel fire penetration to the fuel reservoir the valve BVTS TS 130 STS20 responds due to the increased temperature and fuel is extinguished Regularly once a month clean the boiler walls inside the fireplace boiler smoke draughts and smoke adapter by means of a brush at cooled down boiler the temperature of which does not exceed 40 C The cleaning cover in the lower part of the smoke adapter serves for ash removal When dismantling the cleaning cover the screw of securing swivel must be loosened to avo
58. s automatically switched off Turn the boiler on the HMI unit into status ON If the fuel after 5 minutes does not sufficiently flare up turn the fan on the time required Then switch on the boiler by using the display Set the throttle of fan see tab No 7 9 Now the boiler is in the automatic regime Check the boiler tightness again Carry out the heat test according to relevant standards see the Guarantee certificate Make the user acquainted with boiler attendance Make a record in the Guarantee certificate The boiler only can be put into operation by a professional installation company qualified for conducting this activity Operation Check of shape of flame fuel brown coal The shape of flame gives us information about the correct setting of boiler to the rated output You are advised to check it with each purchase of a new coal By means of the throttle of fan Fig 26 adjust the quantity of required air so the shape of flame corresponds the picture No 24 This amount is dependent on the performance and quality of fuel Generally in case of the reduction of the boiler output i e increase of the delay time of feeder or decrease of run time of feeder we must reduce the amount of combustion air When increasing the boiler output i e decrease of delay time of feeder or increase of run time of feeder we must increase the amount of combustion air ATTENTION Too much combustion air will result in very intense 4
59. s not valid The guarantee conditions and liability for defects follow chap no 10 this manual Measured values Numeric value Chimney draught mbar Flue gas temperature C The user confirms that e boiler adjusted by the contractual service organization did not prove any fault during the heat test e obtained the Boiler service and installation manual with properly filled out Guarantee certificate and Quality certificate e hewas made acquainted with boiler attendance and maintenance Date of installation Installation company User s signature stamp signature Date of putting into service Contractual service organization User s signature stamp signature 49 50 Adressed to the manufacturer VIADRUS a s Bezru ova 300 735 81 Bohumin Certificate of warranty and Quality and completeness certificate for HERCULES DUO boiler Boiler serial number Boiler Output 2 2 1 User s rname name EN A See I RR a eee ee ee aa wasa Address Street city zipcode ie aol he eee et obe need eel eee Phone Fax c Rx e ERI UB ee The boiler corresponds to requirements EN 303 5 Boiler for central heating Part 5 Solid fuel boiler for central heating with manual or automatic feed and nominal heat output maximum 300 kW Terminology requirements testing and marking VIADRUS a s provides the guarantee
60. sumption at nominal output Fuel consumption at minimum output Fuel consumption in upkeep regime Fuel value Burning time at nominal output small reservoir 36 h 15 min 29 h 10 min 24h30 21h 15 min Burning time at nominal output large reservoir 71h30 min 57 h 20 min 48 h 15 min 42h Efficiency up to 83 1 up to 85 up to 87 up to 89 Flue gas temperature 115 195 100 180 95 170 90 160 Flue gas mass flow at outlet Nominal output 0 007 0 015 0 009 0 019 0 011 0 022 0 013 0 025 Regulated output Fuel consumption at nominal output Fuel consumption at minimum output Fuel consumption in upkeep regime Fuel value Burning time at nominal output small reservoir 45 h 10 min 36 h 30 min 30 h 35 min 26 h 25 min Burning time at nominal output large reservoir 88 h 40 min 71 h 35 min 60 h 15 min 52h Efficiency up to 84 2 up to 85 up to 86 up to 87 Flue gas temperature 110 195 90 170 85 165 80 150 Flue gas mass flow at outlet Nominal output 0 007 0 014 0 010 0 017 0 012 0 021 0 014 0 024 Regulated output Fuel consumption at nominal output Fuel consumption at minimum output Fuel consumption in upkeep regime 0 35 Fuel value 17 Burning time at nominal output small r
61. the guarantee repairs 42 Maintenance It is necessary to be mindful of timely fuel refilling If only a small volume of fuel is left in the reservoir it must be immediately refilled Mind the proper closing of the fuel reservoir cover If the boiler is correctly adjusted the fuel is burnt out in case it has reached the edges of the combustion grate The ash and slag fall into do ash pan drawer At an average boiler output the ash pan drawer must be emptied every other day protective gloves must be used Sometimes a piece of slag can get stuck between the edge of the combustion grate and boiler wall Then it must be removed by means of a poker In case of non stop boiler operation the boiler drum convective surface should be cleaned once a month the heat exchange surfaces are covered with deposits thus both the heat transfer and boiler efficiency can be adversely affected When combusting the pellets the fuel is agglomerated in the retort therefore this agglomerate must be mechanically removed once a month otherwise the feed screw stops moving It is necessary to clean the mixer as needed because when covered with deposits the combustion air flow to the burner gets worse At least one hour before cleaning the boiler must be put out of service Then the geared motor and fan have to be externally cleaned from time to time The operator must not remove the cover from the fan or interfere with these units Only the qualified service worker can pe
62. time for proper preparation of the time plan for preparation of HW if the HW and time plan are active If the heating of water is not used no sensor connected HW turn off the preparation of HW to prevent signaling failures Set the following parameters according to the type of fuel used Regarding the production the parameters are set for 4 sectional boiler size brown coal as the fuel The parameters in Tables 7 9 only serve as informative and they can be modified depending on the fuel used Tab No 7 Setting parameters before start up of equipment brown coal Parameters Feeder Run s Feeder Pause s StbFdrRun s StbFdrPause min StbFanOvRun s Fan throttle 96 MinBoilerTemp C Parameters Feeder Run s Feeder Pause s StbFdrRun s StbFdrPause min StbFanOvRun s Fan throttle 96 MinBoilerTemp C 39 Tab No 9 Setting parameters before start up of equipment pellets Parameters Feeder Run s Feeder Pause s StbFdrRun s StbFdrPause min StbFanOvRun s Fan throttle 96 MinBoilerTemp C 6 6 Boiler putting into operation 1 o RON Making fire in the boiler Connect the equipment to the mains insert plug into the socket Check switching off the unit HMI Check setting of parameters see chap 6 5 On the pressure gauge check volume of water in heating syst
63. tion and erection of electrical equipment Common rules CSN 33 2130 ed 2 Low voltage electrical installations Internal electric distribution lines CSN 33 2180 Electrical regulations Connection of electric instruments and appliances CSN 34 0350 ed 2 Safety requirements for flexibile cords and cables EN 60 079 10 Electrical regulations Regulations for electrical equipments at the places with explosion hazard with flammable gases and vapours EN 60 252 1 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 EN 61000 6 3 EMC Part 6 3 Basic standards Emissions residaytial commercial and light industry environment 10 EN 61000 3 2 EMC Part 3 2 Limits Limits for harmonic currents emissions device with input phase current up to 16 A inclusive EN 61000 3 3 EMC Part 3 Limits section 3 Specifies the li
64. to the base of the boiler and tighten Thus we have ensured a precise position of the fuel feeder assembly perpendicularly to the boiler base Loose the adjustable legs so that they sit on the floor Apply sealant to the flange for the fan on the the fuel feeder assembly Then mount the fan Apply sealant to the fuel feeder assembly at the point of sitting surface of the fuel tank Settle the fuel tank and tighten the screws ATTENTION Before the fuel reservoir is loaded with fuel it is necessary to check the free rotation of fuel feed screw 5 2 4 Mounting of the service board to the fuel reservoir Service board Screw M6 x 16 4 pcs Washer 6 4 4 pcs Nut M6 4 pcs Sticker LED for the safety thermostat signalization ROD 2 Key Fig no 12 Mounting of the service board to the fuel reservoir 1 Screw the service board to the side of fuel reservoir 2 Carry out the wiring system according to diagram in chap 5 2 8 3 To stick the sticker LED of the safety thermostat signalization 5 the switchboard 1 5 2 5 Mounting of cleaning tools The ordinary assembly tools and leather gloves are to be used for mounting and demounting of the brush and spike on tang if it is included in the delivery 20 5 2 6 Mounting of emergency fire extinguishing equipment In the cleaning hole cover there is a pipe for water inlet with 1 2 connection that serves for BVTS valve or TS
65. ure This value refers to the desired temperature HW When the HW temperature drops by this value from the setpoint of hot water HW then HW will be heated again Setting of mode of the three way valve With this parameter it is possible to verify its functionality By default the Auto mode is selected Manual Switch on switch off of three way valve in case the selected mode valve Man Note After verifying the functionality of the valve is necessary again to select Auto mode Setting of exhaust of the excess heat factory setting of 90 C from the boiler to the hot water tank ATTENTION Setting the value of YES is only possible if the construction of HW reservoir and material of the connecting pipe is sized up to a minimum temperature of 90 Time plan of HW Parameer Description Time plan of HW Without EM password With password Select a day Mon No all Period 1 00 00 23 5 00 00 23 59 Period 2 23 59 23 5 00 00 23 59 Period 3 23 59 23 5 00 00 23 59 Reset plan Select a day Period 1 Reset plan Passive Active Passive Setting of the desired day of the week for setting of individual periods of heating of HW The value Mon to Sun corresponds to days Monday to Sunday each day is to be set separately The value All Setting of all days at once Setting of time on and off of the first period of heating of HW Note

Hercules U26 HERCULES DUO

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