Astra G-100E User manual

HEATING BOILERS
Astra G-100E
ASTRA MACHINERY PLANT AB • ANNO 1929
CONTACT INFORMATION OFTHE FACTORY:
MACHINERY PLANT“ASTRA”AB
ULONŲ G. 33, LT62161 ALYTUS, LITHUANIA
TEL.: [phone]
FAX: [phone]
EMAIL: INFOASTRA.LT
WWW.ASTRAGAS.LT
INSTALLATION AND OPERATION MANUAL

TABLE OF CONTENTS
1. SAFETY REQUIREMENTS.................................................................................. 3
2. TECHNICAL DESCRIPTION................................................................................ 4
• General View of the Boiler...................................................................................................................4
• Technical Data of the Boiler................................................................................................................. 5
• Ceramic Elements of the Boiler............................................................................................................6
• Turbulence Plates ................................................................................................................................ 6
3. INTENDED USE............................................................................................... 7
4. TRANSPORTATION, STORAGE, UNPACKING ........................................................ 7
5. INSTALLATION............................................................................................... 7
• Accumulation Tank..............................................................................................................................7
• Description of the Emergency Cooling System Diagram.......................................................................8
• Description of the House Heating System Scheme...............................................................................8
• Requirements for Connection of the Boiler to the Heating System .................................................... 10
• Circuit Diagram of the Boiler.............................................................................................................. 10
• Connection of the Circulation Pump .................................................................................................. 11
• Connection of the Ventilator.............................................................................................................. 11
• Controlling the Temperature of Water Returning to the Boiler........................................................... 12
• Heating Output, Water Temperature and Water Flow Relationship.................................................... 12
• Installation of the Boiler Room.......................................................................................................... 13
• Requirements for the Chimney.......................................................................................................... 13
6. FUEL ...........................................................................................................14
7. OPERATION ..................................................................................................15
• Front Control Panel ........................................................................................................................... 15
• Rear Control Panel............................................................................................................................. 15
• Controller KR–5................................................................................................................................. 16
• Verication Of The Controller Program Version.................................................................................. 17
• Indication Of Temperature Of A Dhw Boiler, Smoke Temperature And Rotations Of A Ventilator........ 18
• Programming Of The KR–5 Controller .............................................................................................. 18
• Preparation for Firing........................................................................................................................ 19
• Kindling Procedure of the Boiler........................................................................................................ 19
• Fire Bed and Tips for Eective Boiler Stoking..................................................................................... 20
• Regulation Of Primary Air Supply ...................................................................................................... 20
• Regulation of the Boiler Temperature................................................................................................ 21
• Addition of Fuel................................................................................................................................. 21
• Combustion Control .......................................................................................................................... 21
• Cleaning the Boiler............................................................................................................................ 22
• Emergency Shut Down of the Boiler .................................................................................................. 23
8. POSSIBLE FAULTS..........................................................................................23
• Error Indication ................................................................................................................................. 24
• Erasing The Error Indication............................................................................................................... 24
9. WARRANTY AND ITS VALIDITY TERMS..............................................................25
10. ACCEPTANCE CERTIFICATE.............................................................................25
SELLING CARD .................................................................................................26
BOILER INSTALLATION PROTOCOL.......................................................................26
WARRANTY AND POST-WARRANTY REPAIR CARD..................................................27
DECLARATION OF CONFORMITY ..........................................................................27

3
INSTALLATION AND OPERATION MANUAL
1. SAFETY REQUIREMENTS
1.1. The room where the boiler is to be installed should be ventilated.
1.2. Free inow of air into the room should be ensured.
1.3. The boiler ue connection with the chimney should be tight. Do not heat up the boiler with leaking ue connections!
1.4. 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 10% 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 3 bar response pressure should be tted onto the boiler in the heating system (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 ues, as instructed in this manual.
1.7. The room where the boiler is installed should have re-extinguishing tools: re extinguishers, sand box, shovel and
other tools.
1.8. Do not place ammable materials on or near the boiler.
1.9. 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
operation of the boiler, stop operation and remove the fault.
1.11. Kindle the boiler and put the rewood 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 lled with water and deaerated.
1.14. The operating pressure in the heating system should not exceed 3 bar.
1.15. The electrical connections are factory tested and the following parameters were conrmed:
• integrity of the protective circuit – electrical resistance of the protective circuit does not exceed 0.1;
• resistance of the electrical insulation – at least 1.0 M;
• resistance of electrical insulation was checked at 50 Hz, 1 000 V voltage.

4
HEATING BOILERS: Astra G-100E
2. TECHNICAL DESCRIPTION
• 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 ue damper; 4. Door of the fuel chamber; 5. Adjustable support legs; 6. Flow water pipe; 7.
Rear control panel; 8. Sensor immersion pocket ½” 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. Smoke temperature sensor; 17. Safety
ventilator shutdown 95°C thermostat sensor; 18. Water temperature sensor; 19. Upper combustion chamber opening to the ue; 20. Secondary air inlet
opening; 21. Primary air inlet opening; 22. Ceramic burner; 23. Ceramic chopper; 24. Revision lateral hole; 25. Opening to the ue
1594
912
1
2
3
4
5
1239
384
279
283
180
G1 1/2"
G3/4"
7
8
10
9
11
12
18
14
24
G1 1/2"
1369
G1/2"
6
15 19
21
20
22
23
25
AB
C D

5
INSTALLATION AND OPERATION MANUAL
• TECHNICAL DATA OF THE BOILER
Name of indicator Indicator value
Astra G-100E
Nominal heat output, kW 100
Class of boiler according to EN 303-5 3
Class of protection against electric impact 1
Eciency rate,% 81-89
Power of emergency cooling system, kW 18
Water volume in the boiler, l 100
Setting range of the temperature regulator, °C 65-90
Recommended draught, Pa 21
Working pressure of water in the system, bar, max. 3,0
Testing pressure of the boiler, bar 4,5
Max. allowable water temperature in the boiler, °C 108
Max. allowable operating water temperature in the boiler, °C 95
Electric characteristics: voltage, V / frequency, Hz 220/50
average power used, W 50
Level of electric protection of the boiler IP30
Dimensions:
height, mm 1592
width, mm 912
depth, mm 1369
Weight of boiler, kg, 690
Threaded connection diameter 1½"
Volume of fuel chamber, l 405
Dimensions of the loading aperture, mm 434x348
Flue gas duct diameter, mm 150
Length of wood pieces, mm 550
Average temperature of the ue gases at the nominal heat output, °C 205

6
HEATING BOILERS: Astra G-100E
Fig. 3 Turbulence plate technology
1. Inspection aperture; 2. Turbulence plates; 3. Poker;
4. Heat exchanger of the boiler ue.
33
2
1
2
3
1
• CERAMIC ELEMENTS OF THE BOILER
The boiler has ceramic elements of three types: ceramic burner 1, 2 and ceramic chopper 3 (Fig. 2). The chopper 2 must be
moved to the back wall of the boiler chamber during operation of the boiler. 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, 2. Ceramic burner; 3. Ceramic chopper. • 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, become turbulent and thus transfer
more heat to the adjacent heat exchanger. The core of the device consists
oftheturbulenceplates,positionedatanangleintherectangular-shaped
uechannel of theboiler. The inspectionaperture1 is installed on the top
part of the ue channel (Fig. 3), covered with a screw-on cover with a
gasket. This aperture is used for cleaning the ue channel and placing/
removing the turbulence plates.
When removing the turbulence plates, always lift
them the triangle part upside.
The turbulence plates 2, shown in Fig. 3, maintain their position in the
ue due to their force of gravity alone. They are inserted into the ue
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 o. 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. Each plate rests upon lower plate or heat
exchanger 4 supports. When inserting the plate 2 with a poker 3 into
the ue channel, rst 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 forceof gravity until ittouchesthe wall of theheatexchanger with its
upper supports. Then the tool can be removed and the next plate can be
installed 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.
1
2
3
3
Ceramic element Boiler type
G-100E
Burner
1. G-80M.00.004 1
2. ŠK-50.00.008 1
Chopper
3G-80.00.003 2

7
INSTALLATION AND OPERATION MANUAL
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 ecient 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
rewood 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 inow into the combustion chambers.
Advantages of the boiler are the following:
• gas generating combustion ensures eective burning of wood and a high eciency coecient since the burning process
takes place at a high temperature of 900°C;
• theheatoutputoftheboilercanberegulatedwithintherangeof40-100%.Theboilerisautomaticallycontrolledusinganelectronic
regulator, by switching the ventilator inowing into the combustion chambers o or on, or by regulating the speed of its rotation;
• the combustion period of one fuel load is long due to the large volume of the fuel chamber;
• complete fuel combustion ensures cost-ecient fuel usage;
• the turbulence plates installed in the ue of the boiler enhance heat exchange in the boiler and reduce the temperature
of the smoke in the chimney;
• it is sucient 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
equipmentbroken,built-inceramicinsertsmayfalldownandsplinter.Theheatingboilershouldbecarefullyloaded,unloaded
and transported, without any signicant 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 80%, in order to avoid condensate forming on the surfaces of the boiler. Storage
temperature may vary from -40°C to +60°C.
Ifthe boilerwastransportedor storedinminustemperatures,thenbefore it is kindled,itshouldbekept inplustemperature
for no less than 2 hours.
After the heating boiler is delivered to the site, take o the packing frame and polyethylene lm, unscrew boiler bolts and,
fastening to the packaging base, remove the boiler from the packaging base.
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.; ventilator - 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.
5. INSTALLATION
• ACCUMULATION TANK
These solid fuel boilers are intended to be fully loaded during the operation; the most ecient mode of their exploitation is at the
nominal or maximum heat output. It is advisable to install an accumulation tank of sucient size in their proximity, which could

8
HEATING BOILERS: Astra G-100E
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 outowing 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 boiler at such
operating temperatures, more tar accumulates on the internal walls of the boiler and metal corrosion intensies. When operating
the boiler with an accumulation tank, it is possible and advisable to maintain constantly maximum temperature of outowing and
returning water, respectively 85°C and 70°C, then condensation of water vapour and metal corrosion will be signicantly lower.
Recommended capacity of the accumulation tank is approximately 50 litres per 1 kW of nominal power of boiler:
Boiler model Astra G-100E
Required volume of the accumulation tank, litres 5000
The boiler is to be operated only with an emergency cooling system installed!
• DESCRIPTION OF THE EMERGENCY COOLING SYSTEM DIAGRAM
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 ow of cold water from the public water supply network through
the cooling serpentine, where it absorbs the excessive heat energy and ows out into the sewage. The sensor of the valve with
the external thread ½” 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 ½“.
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, ttings 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 outowing water temperature 85°C. That mode of boiler
operation is optimal for the boiler and combustion process itself.
The heat consumption circle uses the heat accumulated in the tank.
The circle consists of a room thermostat or a programmed control
processor, room or/and outside temperature sensors, 3-way servo
drive, mixing valve, underoor heating system, radiators, piping,
ttings. 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.
1
2 3 4
5
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.

9
INSTALLATION AND OPERATION MANUAL
Fig. 5 Principle scheme of the house heating system including heat accumulation
Laddomat 21 Thermostatic Mixing Valve
Pump Control
Flow Control Valve
Heating Boiler
Flow Control Valve
Air Outlet Water Heating
Domestic Water Recirculation
Pump Control Thermostatic Switch
Membrane Expansion Vessel
Thermostatic Mixing Valve
Domestic Water Preparation
From Water Supply
Hot Water
Air Outlet
Other Notations:
Automatic Water Addition Valve
Accumulation Tank
Thermometer
3-Way Servo Drive Mixing Valve
Return Overflow Valve
Filter
Heating System Supply
Heating System Return
Automatic Air Outlet
Return ValveValvePressure Relief
Valve Pump
Thermometer - Manometer Manometer
With Valve
Water Supply
Programmable Heating System Processor
Min 65oC!
Heat production Heat consumption

10
HEATING BOILERS: Astra G-100E
• REQUIREMENTS FOR CONNECTION OF THE BOILER TO THE HEATING SYSTEM
The following requirements should be fullled when installing the boiler:
•Theboilershould beinstalledin aclosedheatingsystemwith aclosedmembranousexpansion vessel,thevolume ofwhichshould
benolessthan10%ofthetotalvolumeofthesystem.Aclosedheatingsystemisakindofsystemwithnofreeaccesstoatmospheric
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 rells 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;
• 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);
• Internal threads G 1½” of pipes 6 and 11 ;
• There is a nipple 12 for water lling or draining from the boiler (Fig. 1);
• Internal thread G ½” of the nipple 12;
• 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;
• pressure relief valves and control devices must conform to the following technical characteristics:
Instrument Technical characteristics Type of boiler
Pressure relief valve Connectiondiam.does not exceed¾”,set openingpressure3 bar Astra G-100E
Thermometer-manometer Range of temperature 0-120°C, pressure 0 – 4.0 bar All boilers
There must be no ball valves installed between the boiler and the pressure relief valve.
• Water from the pressure relief valve should be conducted via an otake pipe. It should be conducted in a way that will
allow the water passing through the pressure relief valve to ow safely, avoiding exposure of people and electrical parts of
the boiler. The diameter of the otake pipe should be no less than the diameter of the otake opening connection nipple of
the safety valve. The total length of the otake 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 otake pipe. This otake
pipe is to be installed in a way that will make the ow 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 otake ow 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take 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.
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
• 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.

11
INSTALLATION AND OPERATION MANUAL
Protect the isolation of the mains cable against damage.
• CONNECTION OF THE CIRCULATION PUMP
In order to insure a continuous ow of water, a circulation pump is to be installed in the system, on the return water pipe
behind the mixing valve. The electronic controller of the boiler controls the pump. The circulation pump is connected to the
socket on the rear control panel indicated with symbol .
• CONNECTION OF THE VENTILATOR
The boiler is transported with the ventilator removed and fastened using adhesive tape to the top of the packaging frame
of the boiler.
Fig. 6 Circuit diagram of the boiler
S1 - power supply switch; S2 – ventilator switch; SK – emergency ventilator shutdown 95°C thermostat; F - fuse; M - ventilator;
J - socket of a circulation pump of the heating system; BP - DHW boiler pump (optional); KR – electronic controller; U1,2 - water temperature
sensors; U3- smoke temperature sensor; U4- DHW boiler temperature sensor (optional)..
1 2
N
3
L
4
L1
5
L1
6
L14
7 8 9
N
10
L3
11
N
12
L4
L1 N L2 L3 L4
M
PNL
PNLP N L
X4 X2
X1
L5
L N
L2
L14
L1
L
U1U4U2
KR-5
S1 S2
SK
F
220 V
2
N
L
2A
2B
3
1
2
X3
1
1A
1B
3
12
1
C
J
U3
X5
L5 N
P N
L
BP

12
HEATING BOILERS: Astra G-100E
Unpack the ventilator, screw its case on at
the ventilator installation bed 10 (Fig. 1) using
the existing bolts and check the stiness
of the connection. The ventilator cable has
already been connected during fabrication.
• CONTROLLING THE
TEMPERATURE OF WATER
RETURNING TO THE BOILER
It is absolutely necessary to maintain the
temperature of the water returning fromthe
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 eective.
This is because when a constant high
temperature of water returning to the boiler
is maintained, there arises signicantly 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 eective heat transfer and the eciency of the boiler falls.
In order to maintain the temperature, we recommend installing the small circulation circle together with a Swedish-made
thermoregulationdevice,“Laddomat21-100”. Makesurethatthe“Laddomat”issuppliedwiththe72°Cthermostatcartridge.
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.
• HEATING OUTPUT, WATER TEMPERATURE AND WATER FLOW RELATIONSHIP
Theheatingoutputsuppliedtoaheatingsystemdependsdirectlyuponthedierenceofowandreturnwatertemperatures
tandtheintensity ofthewaterowcirculatingthroughtheboiler.Theboilerwillfailto reachthedesiredtemperatureofthe
ow 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 eective boiler operation
occurs when the dierence between the ow and return water temperatures is 13-18°C. If the boiler is forced to operate
with a 20°C or even greater temperature dierence, it will work ineectively, consume too much of fuel, and the combustion
period of one fuel load will consequently shorten. If the previously mentioned dierence of temperatures is kept less than
10°C, the fuel in the boiler will again burn ineciently and fume because of a lack of air supply. If you know the water ow
intensity near your boiler, in the above presented table you can check, what the dierence of ow and return temperatures
your boiler is capable to maintain, when operating at the nominal heating output.
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 to
observe this temperature at any time!
Fig. 7 Removing the rooftop cover of the boiler
1. Unscrew bolts; 2. Lift the backside of the cover; 3. Push the cover forward , then raise.
3
1
1
2

13
INSTALLATION AND OPERATION MANUAL
• INSTALLATION OF THE BOILER ROOM
The boiler room should be ventilated. The required air
inow necessary for combustion should be also ensured.
For this purpose, boiler room doors should have ventilation
gratingor thereshould be a sucientgapbetweenthe doors
and the oor. 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 m/kW.
Place the boiler as close to the ue 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
of the boiler and a building structure is 400 mm. If the building structure is made of ammable 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
tothe backsideof theboiler, for its servicingand cleaning.The oor underthe boiler, withinthe distanceof 50cm in front ofit and
within the distance of 30 cm around the boiler should be made of inammable materials. Screw supporting legs onto the base
of the boiler and level the boiler with screw nuts using a level; then 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.
• 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 uctuations, 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 each boiler model
Dierence of water
temperatures
t, °C
Heating output, kW
100
Water ow, l/min
15 98
16 92
17 86
18 81
19 77
20 73
21 70
22 67
Fig. 8 Positioning of a chimney in respect to vicinity objects

14
HEATING BOILERS: Astra G-100E
should correspond to the referred value of draught in the table “Technical data”. The liner should be factory made. Minimum
permissible height of thechimney should be atleast 7m. Thetop ofthe chimney shouldbe above theridge at least by 0.5m. If the
chimneyis further from the ridge than1m,the anglehorizon-the ridge- the capof thechimney should consist 10° or less degrees.
Draught of the chimney can also be negatively aected by various obstructions near the building: trees, hills, other buildings. Fig.
8 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.
The connection of other devices to the chimney to which the boiler is connected is prohibited.
The chimney should be cleaned at least once a year!
6. FUEL
Theboilerisredonlybywoodlogsandwoodbriquettes.Itispossibletoreitwithfuelpeatbriquettes,howevertheoperation
of the boilerbecomesless comfortable forthe useras it is necessary to removethe 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 re dry rewood with a moisture content of 12-20 %. The drier the rewood, the larger its caloric capacity.
When the moisture content of the rewood 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 rewood should be at least 5cm shorter than the length of the boiler combustion chamber.
Type of boiler Astra G-100E
Length of rewood, mm 750
The recommended thickness of the wood logs is 100-200mm. Thicker pieces of rewood should be split at least once. Up to
15% of the fuel load can consist of ne 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 re freshly prepared and excessively damp pieces of rewood. The operation of the boiler
becomes inecient, deposits of resin emerge on its inside walls as well as excessive condensate. Corrosion of
the boiler takes place several times faster when ring it with freshly prepared wood or wood that has been
dried outside for several months only!
Recommendations for rewood preparation:
• put split wood in a properly-ventilated place – if possible, in a sunlit place;
• rewood should be well sheltered from rain and snow;
• pieces of split wood should be stacked with sucient gaps between them so that the freely-circulating air can blow away
the moisture evaporated from the pieces of rewood;
• there should be sucient space above the heap of rewood below the roof and sucient ventilation to remove the moist air;
• it is not advisable to store freshly-cut rewood in a basement since the rewood needs sun and free air movement to dry.
Dry wood can be stored in the basement where sucient ventilation is guaranteed;
• itis recommendedto dry thesplitrewoodoutdoors under theabove-mentionedconditions. Depending on the type ofwood,
soft wood (alder, asp, r, poplar) must be dried for at least 8 months, and hard wood (oak, ash, birch) for at least 20 months.

15
INSTALLATION AND OPERATION MANUAL
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.
7. OPERATION
• FRONT CONTROL PANEL
The front control panel has an electronic boiler regulator 1, a green button for switching voltage to the boiler on/o 2 and
a red button for switching on the ventilator 3. The ventilator button possesses two operational positions:
-START - turns on the ventilator and launches the controller program;
-PAUSE-temporarilyfor5minutestopstheventilatorandthecontrollerprogram.After5minute haselapsed, theventilator
is turned on and the controller program is continued further from the point of interruption. Duration of the pause could be
prolonged by means of service programming.
• 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 boiler temperature emergency thermostat,
is to switch o the boiler ventilator if water 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 16
(Fig. 1). The burning intensity decreases when the ventilator is switched o
and the water temperature decreases. When the emergency thermostat
trips, the lamp of the ventilator switch 3 on the front panel switches o (Fig. 9) and the lighting indicator bulb 4 “Firing o” on the
electronicregulatorlightsup(Fig. 11).In this case, itisnecessaryto ndout thecausesoftrippingandto removethem.Afterthe boiler
cools down, theemergencythermostatcanbe returnedto its normaloperating mode. For this purpose, unscrewits coveranddepress
the red button.
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!
FUSE
! 95°C 220 V
FUSE
1 2
Fig. 10 Rear control panel
1. Thermal fuse ; 2. Electric fuse; 3. Socket for connection of
a circulation pump.
3
Fig. 9 Front control panel
1. Electronic boiler regulator; 2. Green button for switching the voltage of the boiler on and o; 3. Red button for switching on the ventilator.
PAUSE
START
START
12 3

16
HEATING BOILERS: Astra G-100E
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.
• CONTROLLER KR5
ThecontrollerKR–5 isdesignedfor commandinga
solid fuel boiler. It controls:
1. Ventilator of the boiler.
2. Central heating (CH) pump.
3. Additional device, for example, a domestic
hot water (DHW) pump.
The ventilator is commanded in accordance with
the PID regulation law. The controller adjusts the
rotation speed of the ventilator using the impulse
method, thus intensifying or slowing down the
burning process. The speed of the ventilator is
dened in proportion to the actual temperature
deviation from the set temperature, the duration of
the deviation and the speed of temperature change of the boiler. The controller reacts to the water temperature in the boiler
and smoke temperature in the ue. A NTC–type sensor for measuring water temperature is installed in the special immersion
pocket 19 (Fig. 1), the outer side of which is submerged in water inside the boiler. A PT–type sensor for measuring smoke
temperature is installed in the special sleeve 8 (Fig. 1), which is located in the ue gases duct of the boiler.
The digital temperature indicator 1 (Fig. 11) indicates both the measured and the set temperature of water in the boiler.
The setpoint temperature is adjusted using the buttons 2. After a short press of “+” or “–”, the digital indicator 1 starts
showing the setpoint temperature of the boiler water. In order to change it, the appropriate button must be pressed: “+” for
increasing and “–” for decreasing the temperature.When several seconds pass after the last press of the button, the setpoint
temperature is saved and the indicator returns to showing the measured temperature of the boiler water. When it indicates
the setpoint temperature, a dot lights up beside the readout . When the indicator indicates the real measured
temperature, the dot does not appear . The controller allows adjustment of the temperature within the range of
65–90°C.
Lamp 3 “Firing on” indicates the active status of the boiler. This lamp lights up when the ventilator is switched on using the
button 3 (Fig. 9) on the front control panel and regulation of the ventilator speed starts. The ventilator can be in operation
mode only when the signal lamp 3 (Fig. 11) lights. When the button 3 (Fig. 9) of the ventilator is pressed to the “PAUSE”
position, the symbol blinks on the screen, and the ventilator switches to the fuel loading mode. To exit this mode,
press the button 3 (Fig. 9) to “START” position or do nothing and wait for 5 minutes. Duration of the fuel loading mode could
be programmed in the range of 1–5 minutes (see “Programming of the controller KR–5”).
Lamp 4 lights up whenthe boiler turns to the mode “Firingo”.Thisboiler operationmode isestablished if duringoperation
the temperature of ue gases drops below 75°C and does not rise for some time, for example, 20 minutes. Both values– the
“Firing o” temperature of ue gases and the delay period– could be programmed in the 50–99 °C and 1–30 min ranges
Fig. 11 Front panel of regulator KR-5
1 - digital temperature indicator; 2 - temperature setting buttons; 3 - lamp
“Firing on”, 4 - lamp “Firing o”, 5 - lamp “Pump on”, 6 - lamp “Ventilator on”,
7 - lamp “Programmable channel on”, 8 - Button 8 is a multipurpose service
programming button.
PAUSE
START
START
1 2
7
3 4 5 6 8

17
INSTALLATION AND OPERATION MANUAL
respectively (see “Programming of the controller KR–
5”).
Lamp 5 “Pump on” lights up when the controller
switches on the central heating (CH) pump. The CH
pump can be turned on in two ways: 1) at once,
together with the electrical supply of the boiler, 2)
when the boiler water exceeds some temperature, for
example 60°C. The turn on temperature in the second
case can be programmed in the range of 55–73 °C (see
“Programming of the controller KR–5”). The CH pump
becomes always switched o, when the ring in the
boilernearstheendandthe“Firing o”modeconditions
are fullled: the smoke temperature decreases to less
than the programmed value (75 °C) and lasts on that
level for the set period (20 min). Then, pump indicator
lamp 5 switches o as well.
Lamp 6 “Ventilator on” lights up when the boiler
ventilator is operating. The more frequently it blinks,
the higher the rotational speed of the ventilator is, since its blinking frequency corresponds to the impulse frequency of
the power supply to the ventilator. If this lamp is lighting constantly, it means that the ventilator is operating at 100% of its
capacity. The ventilator becomes always switched o, when the ring in the boiler nears the end and the “Firing o” mode
conditions are fullled: the smoke temperature decreases to less than the programmed value (75 °C) and lasts on that level
for the set period (20 min).
Lamp 7 lights up when the output channel of the additional device is activated and works (see “Programming of the
controller KR–5”).
Button 8 (P) is multipurpose, and is used for some support functions and service programming.
The boiler controller is connected to the boiler circuit in accordance with the scheme shown in Fig. 12. The ventilator of the
boiler gets power supply from L2 only if the emergency thermostat has not tripped. The impulse commutator regulating
the ventilator connects periodically L2 to L3. When the boiler switches to status “Firing o”, L3 does not supply power to
the ventilator and lamp 4 (Fig. 11) lights up. To quit the mode “Firing o”, the ventilator switch 3 (Fig. 9) should be pressed
to “START” position or the power supply button 2 (Fig. 9) should get turned o and later – on. The CH pump control relay
connects L4 to N. The relay of the additional device channel connects P to L1. The power of the operating ventilator ranges
between 20÷100 VA. The maximum allowed power of the CH circulation pump connected to the regulator is 250 VA. The
maximum allowed power of the additional device channel is 250 VA.
• VERIFICATION OF THE CONTROLLER PROGRAM VERSION
Switch o the electrical supply of the boiler with button 2 (Fig. 9). Press and hold the button “P” on the controller panel.
While pressing, simultaneously turn on the electrical supply of the boiler with button 2 (Fig. 9). A number of the program
version will light up on the screen shortly, later the controller will return to a normal operating mode. The number of the
version consists of 6 digits being exposed in sets of 3 digits one after the other. For example, if “151” and “118” are shown
subsequently, then the program version is “151118”.
X-2 X-3 X-5 X-4 X-1
U2 U3 U4
1 2 3 L1 N L2 L3 L4 P
KR-5
Rear panel of the regulator
Fig. 12 Regulator connection diagram
L1, N – power supply to the regulator; L2- power supply from front control
panel to the ventilator; L3 – voltage to the ventilator; L4 – voltage to the
pump; P – voltage to the programmable channel; U2 – water temperature
sensor; U3 - smoke temperature sensor; U4 – DHW boiler temperature sensor;
1, 2, 3 - fan control.

18
HEATING BOILERS: Astra G-100E
• INDICATION OF TEMPERATURE OF A DHW BOILER, SMOKE TEMPERATURE AND ROTATIONS OF A
VENTILATOR
When in a normal operation mode, shortly (up to 3 sec) press the button “P”. The symbol ” will appear on a
screen. Scroll with “+”and “–“ buttons to exhibit the next indications: (rotations of the ventilator),
(temperature of smoke), (the DHW boiler temperature). Press once again the button “P” shortly to see the desired
indication. For example, if the indication will light shortly and after it, value will be shown on the screen,
then it means that the smoke temperature is 129 °C. When the ventilator parameter has been chosen, the symbol
lights on the screen and, for example, value . This means that the ventilator works at 79% of its capacity. If the DHW
boiler indication has been chosen, the symbol lights alternately with the temperature readout . Press the
button “P” to quit the indications mode. Then the water temperature of the boiler will appear on the screen.
• PROGRAMMING OF THE KR5 CONTROLLER
The controller operates in accordance with set parameters which can be changed. Below is presented a list of parameters
and their short description:
P00 – type of a central heating (CH) pump control (“1” – turned on constantly, “0” – turned on at a set temperature).
Factory setting: “0”;
P01 –turn on temperature of the CH pump (45..72 °C). Factory setting: 60 °C;
P04 – additional device turn on temperature (0..300 °C). Factory setting: 2 °C. Important: if the additional device is a
charging pump of a domestic hot water (DHW) boiler, then the turn on temperature is dependent from turn o temperature
and is entered as a dierence (hysteresis) from it. For example, if the turn on temperature needs to be 62 °C, and turn o
temperature– 65 °C, then the value of P04 parameter must be 3;
P05 – additional device turn o temperature (0..300 °C). Factory setting: 2 °C. If the DHW pump is controlled, then this
parameter represents turn o temperature of this pump;
P07 – time period measured in minutes and intended for fuel addition into the running boiler. During the period,
the controller pauses the ongoing ring program, and at the end of the period, returns to the previous operation point
automatically. Factory setting: 5 minutes, range of setting: 1–5.
P08 – type of the boiler ventilator: “0”– pressurizing, “1”– exhausting.
P10 – temperature of smoke designated as “Firing o” mode start temperature (50..99 °C). Factory setting: 75 °C;
P11 – optimal temperature of smoke. The temperature helps the controller to guide a combustion process towards it (from
„P10“+10 °C to 200 °C). Factory setting: 130 °C;
P16 – output control mode of an additional device: “0”–related with water temperature of the boiler input, “1” – related
with smoke temperature input; “2”– turns on while fuel addition mode is active (P07); “3”– the DHW pump control mode.
The turn o temperature of the DHW pump is set with parameter P05, and the turn on temperature dierence – with P04.
For the DHW pump to be turned on, the next conditions must be fullled:
• the boiler is in the “Firing on” mode;

19
INSTALLATION AND OPERATION MANUAL
• the measured water temperature in the DHW boiler is lower than turn o temperature (P05);
• the water temperature in the boiler must be at least 5 °C degrees higher than in the DHW boiler.
If one of the above mentioned prerequisites ceases to exist, the DHW pump is turned o. The pump is turned o either
when the set turn o temperature (P05) of the DHW boiler is achieved. After water in the DHW boiler cools down below
the calculated turn on temperature (P04), the pump is turned on again. If during a period of charging of the DHW boiler
temperature of water in the wood boiler starts falling, then the DHW pump is switched o when the dierence between the
DHW boiler and the wood boiler temperatures diminishes to 3 °C. Factory setting of the parameter P16: “0”;
P17 – “strict” control mode. “Strict” means that the ventilator is switched o completely when the measured water
temperature in the boiler reaches the set water temperature plus 5 °C. The ventilator is turned on again when the measured
water temperature drops to the set temperature. Alternative to “strict” control means that the ventilator continues working
at the lowest output after reaching the set water temperature and is stopped only in emergency cases. “0”– “strict” control
is turned o, “1”– turned on. Factory setting: “1”;
To enter a programming mode, press the button “P” and hold it for 3 seconds. symbol appears on the screen. To
reach another parameter, scroll with “+”and “–“ buttons. To enter the particular parameter submenu, press “P”. To change a
valueof the parameterappearingonthescreen,pressthe button“P”andholditfor3 secondsuntiltheparametervaluestarts
blinking. Change the value with “+”and “–“ buttons. Save the new value by pressing the button “P”. To quit the parameter
changing mode, press “+”and “–“ buttons simultaneously or simply wait 30 seconds without pressing any buttons.
• 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 lling pressure should be 0.2 bar bigger than the hydrostatic pressure, yet it must
not exceed the operating pressure of the boiler. After lling 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 ue 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 ammable materials and larger pieces of
kindling wood and rewood atop. Load the wood without any large gaps at the top of combustion chamber. Bigger pieces of
rewood 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.
Do not cover the entire opening of the upper ue 19 (Fig. 1) with the wood, because it will make
kindling more dicult.
The rst time, kindle the boiler using only paper and small pieces of wood in order to safely remove the
moisture remaining in the ceramic elements.

20
HEATING BOILERS: Astra G-100E
Switch on the voltage, using button 2 on the front control panel. The boiler water temperature indicator will light up on the
electronic regulator (Fig. 9). Set the required outowing boiler water temperature using the temperature setting buttons; we
recommend a temperature of at least 75°C or – even better – a higher temperature. Close the door of the upper combustion
chamber, open thelower door andset thekindling material onre.Observe the rising water temperature inthe regulatordisplay.
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
ue by pushing its handle 3 (Fig. 1). Then press shortly the ventilator button 3 into the „START“ position (Fig. 9). After that, the
boiler will operate in automatic mode: it will try to reach and maintain the setpoint temperature of the water outowing from
the boiler.
When ring the boiler for the rst 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.
The doors of the boiler combustion chambers should be tightly closed, there should be no ue 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 re bed. Combustible gases emerge from there and are further
burned in the lower chamber of the boiler. The optimal re 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 suciently
supplying the re bed with air. Then, the most eective combustion of wood gases takes place. Avoid a situation when the
volume of the re 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 re 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 rst 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 re bed. The second stage is intended for
full fuel loading and to perform the main combustion.
The rst 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 ue damper 3 (Fig.1) and both boiler doors, put the wood and paper inside.
Kindle the paper, make sure that the ring 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 % of the fuel chamber’s
capacity. Before opening the door, press shortly the ventilator button 3 into the „PAUSE“ position (Fig. 9) The letter
will appear on the display and the ventilator will stop. 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 shortly the ventilator button 3 into the „START“ position (Fig. 9). The
ventilator will start and the boiler will continue its ring 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 eective
combustion.
• REGULATION OF PRIMARY AIR SUPPLY
There is a possibility to regulate the primary air supply in the boiler. Volume of the primary air is regulated by means of the