Astra G-18 MS Specification sheet

MACHINERY FACTORY “ASTRA”
LT- 62161 Alytus, Ulonų 33 Lithuania
tel. [phone]
fa . [phone]
HEATING BOILERS
Astra G-18MES
Astra G-25MES
Astra G-31,5MES
Astra G-40MES
Astra G-50MES
Astra G-80MES
Astra G-100ES
MANUAL OF INSTALLATION
AND EXPLOITATION
2011

Heating boilers are transported packed nder the man fact rer’s doc mentation, protected from
atmospheric precipitation and d st.
The transporter sho ld ens re the q ality of prod ct transportation and protect from damages.
The vendor (man fact rer) does not accept claims for prod ction damaged d ring transportation.
The BUYER sho ld lay claims to the transporter for the prod ct damaged d ring transportation.
The BUYER ( ser) sho ld follow all req irements of this g idebook d ring transportation, storage
and exploitation, otherwise he loses the vendor’s (man fact rer’s) g arantees.
1. SAFETY REQUIREMENTS
1.1. The room where the boiler is to be installed should be ventilated.
1.2. The air should freely access the room.
1.3. The boiler flue connection with the chimney should be tight. Don’t heat up the boiler
with leaking flue connections!
1.4. The boiler should be installed in a closed heating system with a closed (membranous)
e pansion vessel, the volume of which should be no less than 10% of the total volume of a
heating system (including the boiler) (the volume of the e pansion vessel can be calculated
according to the standard EN 12828 anne D).
1.5. Safety valve for no more than 2 bar response pressure should be installed at the boiler
in the heating system for the boilers (Astra G-18 and Astra G-25) and ma imal 3 bar
response pressure for the boilers Astra G-31,5, Astra G-40, Astra G-50, Astra G-80 and
Astra G-100. Please consult the chapter 5.
1.6. Clean boiler flues from smoke and pitch scurf, as indicated in this passport. The
chimney should be cleaned as required by fire prevention regulations.
1.7. The room where the boiler is installed should have fire-e tinguishing tools: fire-
e tinguishers, sand bo , shovel and other tools.
1.8. Don’t put flammable materials on or near the boiler.
1.9. Connect the boiler to the electric system only by a three-pole plug plugged into an
adequate three-pole socket with earthling. Protect connection cable from damages.
1.10. Monitor operation of temperature regulation devices and manometer readings.
If notice an abnormal boiler operation, stop heating and eliminate damages.
1.11. Kindle the boiler and put the firewood into the boiler only as indicated in section
6 of this passport.
1.12. Keep children away from the boiler! Only adults can serve the boiler.
1.13. Before kindling the boiler, check, if the heating system is filled up with water and
aired.
1.14. Operating pressure in the heating system should not e ceed:
- 0, 2 MPa (2.0 kg/cm
2
) – for the boilers Astra G-18, Astra G-25;
- 0, 3 MPa (3.0 kg/cm
2
) – for the boilers Astra G-31,5, Astra G-40, Astra G-50 , Astra G-80,
Astra G- 100.
1.15. The electrical connections of the boiler are tested:
- evenness of the protective chain–electric resistance of the protective chain does not
e ceed 0, Ω,
- the minimal resistance of the electric insulation is 1.0 MΩ,
- the resistance of the electric insulation is checked using 50 Hz, 1000V.
2. PURPOSE OF THE PRODUCT
Heating boilers are designed for heating of dwelling houses, public, industrial and similar
purpose buildings where water-heating systems are installed. Boilers are fired only with wood
(firewood) or (saw dust, peat, chaff, etc.) briquettes. It is recommended to fire dry (20% moisture
content) wood. It is possible to fire fine wood waste and saw dust in small quantities (to 10%), mi ing
them with firewood. Control and regulation equipment installed in the boilers automatically maintains
the set heat carrier (water) temperature, ensures cost-efficient operation of the boilers, and safe
e ploitation.
The boilers of this type are constructed for wood firing with a partial gas generation. In the
upper combustion chamber of the boiler, gas is e tricated (generated) from the burning firewood and
burned in the lower chamber. Intensity of gas generation and its combustion is regulated by the
frequency and duration of air inlet into combustion chambers.
Advantages of the boilers:
 Gas generation from firewood ensures a high effective operation coefficient.
 Boiler is equipped with the e cess heat distribution system (serpentine of the
emergency cooling).

 Power of the boiler (temperature of a heat carrier) is controlled automatically by a
thermo-regulator, by turning on or off a ventilator (ventilators) of the air inlet into
combustion chambers; and by a traction regulator, by closing or opening air supply
opening cap of the ventilator.
 Long load combustion period.
 Complete fuel combustion ensures cost-efficient fuel e ploitation.
 Ashes might be removed only 1-2 times per week.
3. TRANSPORTATION, STORAGE, UNPACKING, PREPARATION TO EXPLOITATION
Heating boiler should be carefully loaded, unloaded and transported, suffering no big
impacts. The boiler can be transported only in a vertical position, fastened in order to avoid sliding and
falling. If the boiler is transported in other than vertical position, decorative surfaces may be damaged,
tins battered, control and regulation equipment broken, built-in ceramic kindling details may fall down
and splinter.
The boiler should be stored also in a vertical position. It is not allowed to put one boiler on
another, as a safety-packaging frame is not designed for this purpose. The boiler should be stored in
closed space protected from atmospheric precipitations. Air humidity of the room should not e ceed
80% in order to avoid condensate (dew) forming on the surfaces of the boiler. Storage temperature may
vary from -40 ºC to +60 ºC.
If the boiler was transported or stored in minus temperatures, then before it is kindled, it
should be kept in plus temperature no less than for 2 hours (for the order and requirements of the first
kindling see section 6 of this passport).
After the heating boiler is delivered to the site, take off the packing frame and polyethylene
film and unscrew bolts of boiler fastening to the packaging base. Take off the boiler from the packaging
base.
WARNING Opening the doors of the boiler, check, if all tools listed in the section “THE
BOILER KIT” are there. Check, if painted s rfaces haven’t been damaged, components – not battered,
control and reg lation eq ipment – not broken d ring transportation.
If notice any inadequacies of the listed above, lay your claims to the transportation or vendor company.
The kit consists of:
1. Boiler 1 unit
2. Poker 1 unit
3. Scraper 1 unit
4. Guidebook for e ploitation 1 unit
6. Leg 4 units
7. Fan/ventilator
1 unit
4. INSTALLATION
These boilers of solid fuel are boilers of complete loading. For this reason they reach the
highest effectiveness when they are working at the nominal power and due to this the boilers must be
equipped with the accumulation tank of sufficient size which could accumulate the e cessive heat
volume.
Recommended capacity of the accumulation tank is about 50 liters for 1 kW of nominal
power of boiler:
Model of boiler G-18 G-25 G- 31,5 G- 40 G- 50 G- 80 G- 100
Required volume of
accumulation tank , liters 700 900 1500 1800 2500 3200 5000
The boiler has to be e ploited only with the installed emergency cooling system.
Description of the connection scheme of the emergency cooling serpentine.
Thermostatic safety valve protects the boiler form the overheating. If the water temperature in the
boiler e ceeds 95
0
C the valve automatically opens the flow of water from the water supply system
through the cooling serpentine . This water absorbs the e cessive heat energy and flows out. Sensor of
valve with the e ternal thread ½“ is screwed in the socket on the rear wall of the boiler.
Technical data of the thermostatic safety valve :
Opening temperature 95
0
C
Highest working temperature 110
0
C

Working pressure 10 bar
Pipe of sensor L=142 mm, e ternal thread ½“
ATTENTION The system of the emergency cooling of the boiler can not be used for the
heating of water.
Description of the principal scheme of the boiler room. When the water temperat re in
the boiler reaches 60
0
C there is launched circulation pump connected with the boiler. Water circulates
through the thermostatic mi ing valve in the cycle „boiler – thermostatic mi ing valve – boiler“.
Heating system is equipped with the programmed automatic control processor and 3-way mi ing valve
with electric drive (if the heating system is not equiped with the programmed automatic control
processor and 3-way mi ing valve with electric drive there can be installed manual operation 3-way
mi ing valve and to perform the regulation of heating system in manual way). When the water
temperature rises further the programmed processor control and regulate the temperature of the water
supplied from the accumulation tank to the heating system. This temperature depends very much on
the outside and ambient temperatures measured with the sensor.
In order to avoid the corrosion of boiler caused by the water condensate in the temperatures below
55
0
C thermostatic mi ing valve automatically ensures that the minimal temperature of water returning
to the heating boiler is 60
0
C.
Installing the boiler, the following requirements should be fulfilled:
 The boiler should be installed in a closed heating system with a closed (membranous)
e pansion vessel, the volume of which should be no less than 10% of the total volume
of a heating system (including the boiler). The closed heating system is the system with
no free access to atmospheric air, which actuates corrosion. Due to this, it is restricted
to drain water from the system without a particular reason (e.g. in summer, etc.). It is
also necessary to ensure tightness of the system in order to need fewer refills with
fresh water having free o ygen. Quantity of the additional water should not e ceed 5%
of water volume of the system per year. If an open e pansion vessel is installed at the
highest point of the heating system, it should be disconnected from the system and an
automatic air escaper installed instead as well as a closed e pansion vessel at the
boiler (see fig. 4).
 There must be no shut-off valves between the boiler and safety valve.
The technical characteristics of the safety valve:
Instrument Technical characteristics Type of boiler
Safety valve Connection diameter does
not e ceed ½”, opening
pressure 2 bar
Astra G-18, Astra G-25,
Safety valve Connection diameter does
not e ceed 3/4”, opening
pressure 3 bar
Astra G-31,5, Astra G-40,
Astra G-50, Astra G-80,
Astra G-100,
Temperature – pressure
gauge
Range of pressure 0-4 bar
Temperature 0-120°C
All the boilers
Water from the safety valve sho ld be cond cted via an offtake d ct. It sho ld be
cond cted in the way that the water let by the valve wo ld safely flow, avoiding expos re with people
and electrical parts of the boiler. The diameter of the offtake d ct sho ld be no less than the diameter of
the offtake opening connection branch of the safety valve. Total length of the offtake d ct sho ld not
exceed 2 metres. Installing this d ct, no more than 2 elbow joints at 90
0
angles sho ld be sed. No
closed, adj stable or other reinforcements sho ld be installed in the valve water offtake d ct. This d ct
sho ld be installed in the way to see the offtake flow of the water. If the end of the d ct is to be hidden
(e.g. in the sewerage pipe), then this d ct sho ld have a special f nnel enabling to see the offtake flow
of the water.
WARNING Operation of the safety valve sho ld be checked at least once per month. The
valve is opened for a while by t rning its head to see a small q antity of the offtake water. Avoiding this,
d e to a high temperat re impact, the components of the valve may stick together and serio s
damages of the boiler and the heating system may occ r as well as danger arise for h man health and
life.
 The temperature of the returning water from the heating system to the boiler should be
no less than 60°C. This is the only way to prevent the walls of the boiler combustion
chambers from weeping, and the boiler will be protected from corrosion. To ensure the
temperature of the returning water to the boiler and to regulate water temperature of

the heating system, it is necessary to install a four-way mi ing valve between the boiler
and the heating system. Water temperature supplied from the boiler during e ploitation
should be no less than 70°C.
WARNING In order to g arantee a nat ral water circ lation in the boiler, the pipeline
between the boiler and the fo r-way mixing valve (boiler – fo r-way mixing valve – boiler) sho ld be of
the same diameter and meet the diameter of the boiler connection branches (see fig. 4, I - boiler ring).
Fo r-way mixing valve sho ld be installed above the boiler.
 The boiler will operate in the most effective and economic way, if a circulating pump is
installed in the system. It should be installed behind the water supplied by the four-way
mi ing valve in the pipe. This guarantees a constant water flow in the heating system.
The boiler may also operate in a natural circulation (gravitational, without a pump)
system, however in this case, it won’t be totally used and its operation conditions won’t
be optimal. In case when reconstruction of natural (gravitational) circulation systems is
performed by installing the pump, in order to avoid emergencies, when the pump is
broken, it should be installed on the edging line together with reverse valves, as shown
in fig. 4 and 5. The pump is controlled with the electronic controller of boiler and is
connected to the electric socket on the rear wall of the boiler.
 Dirt collector should be installed in the returning water pipe of the heating system.
 Boiler room should be ventilated. The required airflow necessary for combustion and
ventilation should be also guaranteed. For this purpose, boiler room doors should have
grille or there should be a gap between the doors and the floor. If there is no possibility
to bring air in from another rooms or the house is very tight, it will be necessary to
make an opening in the e terior wall. Air quantity should be no less than 1, 6 m
3
/kW
per hour. Cross-section area of the opening should be no less than 0,001 m
2
/kW. The
required air quantities and areas of the opening are presented in the table below.
For e ample: the area of airflow opening should be 0,025 m
2
or 250 cm
2
, i.e. 16 16 cm; or
the height of the gap under the door - about 4 cm when door width is 60 cm.
Put the boiler on the hard (e.g. concrete) and even ground, closer to the chimney pot.
Leave at least 600 mm gap between the back wall of the boiler and building structure for boiler
servicing and cleaning. The smallest distance between a lateral wall of the boiler and building structure
is 400 mm. If building structure is of the flammable materials, this distance should be doubled. At least
800 mm gap should be left from the other side of the boiler to have an access to the backside of the
boiler, its servicing and cleaning. From three sides of the boiler the floor of 300 mm and from the front
of the boiler the floor of 500 mm should be of inflammable materials. Screw supporting legs in to the
base of the boiler and level the boiler with screw nuts using a level.
Smoke e haust opening of the boiler should be connected with the chimney by a metal
pipe. Internal diameter of the metal connecting pipe should be at least of the e ternal diameter of the
smoke e haust opening of the boiler. To improve the traction, a connecting pipe between the boiler and
the chimney should be installed with an inline towards the boiler. All junctions should be carefully
tightened by a heat-resistant material.
If the boiler is installed higher than the heating equipment, the water level measuring
instrument must be installed in the heating system.
When the boiler is installed in the open heating system, on the highest point of the heating
system there has to be mounted the open e pansion vessel. The volume of e pansion vessel has to
be about 10 % of the total volume of water in the heating system (including the volume of the boiler).
The diameter of the overflow pipe of the e pansion vessel has to e ceed the diameter of
the safety inlet pipe by one unit.
Safety return pipe has to be connected to the return pipe of the heating system and to the
bottom of the e pansion vessel.
It is forbidden to install any fittings in the safety inlet and return pipes between the boiler
and e pansion pipe.
Chimney requirements. It is recommended to install acid-resistant stainless steel shell
into the stone chimney. It improves traction of the chimney and protects the stone chimney from
destr ction d e to the condensate (moist re) impact. Internal diameter of the shell sho ld be no less
than the external diameter of the smoke exha st opening of the boiler. Chimney shell may be ro nd or
Boiler type G-18 G-25 G- 31,5 G- 40 G- 50 G- 80 G- 100
Required air quantity
per hour, m
3
/h 29 40 40 50 80 128 160
Area of airflow
opening, m
2
0,018 0,025 0,025 0,03 0,05 0,08 0,1

oval. It is not recommended to se rectang lar shell, as d e to the temperat re fl ct ations, its walls
deform, gaps appear at the element j nction points, thro gh which the condensate falls on the walls of
the stone chimney, and an additional air is s cked in, which red ces traction of the chimney.
Traction of
smoke sho ld correspond to the calc lated val e of traction (see the table of technical data). The shell
sho ld be constr cted by the factory and certified.
Minim m permissible height of the chimney sho ld be at least 6 m. The top of the chimney
sho ld be above the top roof at least by 0, 5 m. If the chimney is in bigger distance than 1 m from the
top roof, the top of the chimney sho ld level with the line going down from the top roof with no bigger
than 10° angle from the horizon. Yo sho ld also eval ate the infl ence of different obstacles present
aro nd the b ilding (trees, other b ildings, etc.) (see fig. 3).
There can not be connected any other
eq ipment to the chimney connected with the boiler.
Electrical installation with earthing should be installed for connection of the electrical part of
the boiler pursuant to electrical safety requirements (see a
principal electricity scheme, fig. 4).
PROTECT isolation of the connection cable from damages!
5. FUEL
The boiler is fired only by firewood and different briquettes. It is prohibited to fire by coal. It
is recommended to fire dry firewood (15-20% moisture content). The drier is the firewood, the bigger its
caloric content. When a moisture content of the firewood is 20%, thermal value of 1 kg is appro imately
4 kWh; when the moisture content is 50%, its thermal value reduces in half.
The length of the firewood should be at least 5 cm shorter than the length of the boiler
combustion chamber, i.e.:
Boiler type G-18 G- 25 G- 31,5 G- 40 G- 50 G- 80 G- 100
The ma imal length of
the firewood in mm 310 450 550 550 750 750 750
The recommended thickness of the firewood is 100-150 mm. Larger firewood should be
split at least once.
WARNING! Don’t fire newly prepared and too damp firewood!
Recommendations for firewood preparation:
- Put split firewood into well ventilated and, if possible, well sun lightened place.
Firewood should be well protected from rain and snow;
- stow the split firewood with sufficient gaps in between in order for a freely circulating air
to withdraw the moisture evaporated from the firewood;
- there should be a sufficient space atop of the firewood up to the roof and such
ventilation that wet air could drift away;
- it is not recommended to store freshly cut (undried) firewood in the cellar, as its drying
requires sun and free air circulation. Dry firewood could be stored in the cellar where
sufficient ventilation is guaranteed;
- It is recommended to dry split firewood under above described conditions in
dependence with the type of the wood: soft wood (alder, asp, fir, willow etc.) – no
shorter than 8 months, hard wood (oak, ash, birch, etc.) – no shorter than 20 months.
6. EXPLOITATION
Preparation for heating
Before kindling the boiler, check the edge (5) position at the lower combustion chamber
(see fig. 2): the edges should be pressed to the rear wall of the boiler; ~ 100 mm gap should be
between the wall and the edge in the front.
At the rear part of the boiler at the air inlet above the ventilator there is a damper to
regulate the air inlet to the upper burning chamber and heater (fig. 12). Operation of the damper: after
loosening the screw push the damper until the support and then pull by 15 mm (till the marking on the
damper plate) and then tighten it with screw. This damper has to be adjusted during the preparation for
handling. It is recommended to check the position of this damper at the beginning of the heating
season.
During heating season don’t put firewood and other flammable materials on the boiler (or at
unsafe distance). You can cause a fire!
Fill the heating system with water. The filling pressure has to e ceed the hydrostatic
pressure by 0, 2 bars but no e ceeding the working pressure of the boiler. When the system is filled up
with water, check tightness of the whole system before kindling the boiler and afterwards when the
operation reaches its standard mode.
Check if the air is sufficiently drained from the heating system.

Kindling order of the boiler
Before kindling the boiler, check whether all requirements indicated in the section 1 are
e ecuted.
Open the damper of the pper fl e (C) by p shing the handle (12) towards yo rself (see fig. 2).
Open the door (9) of the pper comb stion chamber (2) and p t dry kindling wood on the heat-
resistant shell (3) to form 2-3 cm gap between the opening of the shell and kindling wood. P t some
of the easy flammable materials and bigger kindling wood and firewood atop. Fire the kindling
wood, wait till the firewood comb sts, close the door and t rn the handle (12) of the fl e damper
from yo rself to the end. Load the wood witho t any bigger spaces ntil the top of comb stion
chamber. Bigger pieces of firewood should be loaded in the middle and smaller prices – at
the sides, because the walls of the combustion chamber due to their lower temperature
slows down the combustion of the bigger pieces of wood. Do not cover with the wood the hole
of the smoke extraction valve C . With the boiler control panel switch the tension of the electronic
controller with the b tton „0“-„I“ ( see the technical description of the electronic controller). There
will be switched on the lights and temperat re indicator. Using the b ttons of the temperat re
reg lation set req ired temperat re of the water flowing of the boiler – it is recommended to set on
the 70
0
C. Close the pper door of the comb stion chamber, open the lower door, b rn the wood
pieces ., Leave the lower door open ntil the water temperat re in the boiler reaches 40
0
C. Close
the lower door, close the valve of the pper smoke traction by p shing the handle of valve (12) to
the end. Switch-on the ventilator with the control panel. Afterwards the boiler will work on the
a tomatic range and will maintain the set temperat re of the water from the boiler.
WARNING The door of the boiler comb stion chambers sho ld be tightly closed, there
sho ld be no flammable prod cts accessing the exterior. Door tightness is reg lated by screwing or
nscrewing hinge and lock screws of the door.
Reg lation of the boiler temperat re – see the technical description of the electronic
reg lator.
Emergency thermostat of the water temperat re (safety switch 95
o
C ).
If the water temperat re d e to the nforeseen reasons exceeds the maximal allowable limit ,
safety thermostat (emergency switch), switches off the ventilator of the air s pply. Comb stion
intensity will decrease and the temperat re of water will drop.
When the emergency thermostat comes into action (switches off) – the light of the ventilator switch
and electronic controller is off , it is necessary to detect the reasons and to remove them.
Emergency thermostat is t rned on by taking off the cover of thermostat 108
o
C and pressing the
red b tton. .
The attempts of p rchaser to repair the thermostat and to recover its f nctions on his own witho t
removal of reasons which ca sed the over-heating of boiler can res lt not only serio s damages of
boiler, b t also the danger for the health and life. If the reasons of the switch of the emergency
thermostat can not be detected and removed, it is necessary to call the servicing company !
Addition of the firewood
While putting firewood into the combustion chamber (during boiler operation or after load
burning off), keep strictly to the set order:
1) Open the damper of the upper flue by pulling the handle (12) (see fig. No. 2).
2) Switch off the ventilator.
3) Wait at least 20 s, open the upper door.
4) Put the firewood in and close the door tightly.
5) Switch on the ventilator.
6) Close the damper.
If operated following this order, smoke and carbon won’t enter the room.
Combustion control
The combustion control of boiler is described in the chapter “COMBUSTION CIONTROL”
of the technical description of regulator KR-4.
The flame in the boiler can be checked by opening the lower door of the combustion
chamber when the ventilator is on.
Temperature regulation of the heating system – See the description of the scheme
of boiler room ( beginning of the chapter ).
Cleaning of the boiler
Aches are removed from the boiler each 4-7 days. Open the door of the upper combustion
chamber and shovel aches down to the lower chamber. Open the door of the lower chamber, take out
the ceramic inserts and shovel ashes to the metal bo .
WARNING In any case keep strictly to the determined order: open the damper of the
pper fl e, then after 20 s open the boiler door.

Clean boiler chambers from smoke-black and pitch scurf once or twice a month. Clean the
boiler when the fuel is completely burned and the boiler is cooled down to at least +40 °C.
Clean smoke-black and scurf from combustion chambers and flue walls using a scraper
and metal hog. Clean after the doors of the combustion chambers are open and caps of flue upper
openings unscrewed . When finished, check, whether no ashes or smoke-black fell into the ventilator
opening and tightly screw the caps of the flue openings.
Control water pressure in the heating system at least every two weeks. If necessary, fill it
up. If the boiler is not being heated, drain the water off the system when air temperature is below 0 °C!
Emergency extinction of the boiler
If due to any reasons you must immediately e tinct the heated boiler, by any means don’t
pour water on the kindling wood! The boiler can burst.
It is very convenient to use dry sand for emergency e tinction. There should be ~50 kg of
dry sand in the boiler room. Sand not only well isolates burning firewood from the air o ygen but also
cools down the burning zone. Then, when the boiler cools down, sand can be easily cleaned and
removed.
7. POSSIBLE DAMAGES
Damage Cause Ways of elimination
1. The set temperature
(power) cannot be
reached
- Not enough water in the heating
system;
- Thermo regulator or ventilator is
broken;
- Bad quality fuel (high moisture
content, very large firewood);
- Heating surfaces of the boiler are
very impure;
- No traction in the chimney (impure) –
the upper ignition is congested;
- Ceramic burner is foul.
Fill up
Replace
Use dry fuel, split firewood
Clean
Clean
Clean
Clean
2. Smoke breaks through
the doors
- Tightening rope is damaged;
- Doors are leaky along the whole
perimeter.
- No traction in the chimney
Replace with a new one
Adjust hinge supports and door
lock (regulated screwing or
unscrewing door hinge or lock
screws)
Clean.
3. Ventilator isn’t
operating
- Emergency thermostat went off
(switch light of ventilator is off);
- Thermo regulator or ventilator is
broken;
- Disconnection of electricity supply.
Call representatives of the service
company; turn on after indication of
the causes (see section 5)
Replace
Check electric fuses of the building,
call the electrician

8. TECHNICAL DATA
Meanings of the indicators
Indicators G-18 G-25 G-31,5 G- 0 G-50 G-80 G-100
Nominal heating power -tire wood kW
- wooden briquets, kW
Class of boiler according to EN 303-5
18
23
1
25
28
1
31,5
33
1
40
42
1
50
54
1
80
84
1
100
100
1
Class of protection against electric impact 1 1 1 1 1 1 1
Usage coefficient,% 78 78 78 80 80 80 80
Area of the internal heated surface of boiler, m
2
, 1,92 2,08 2,08 2,2 3,39 3,8 6,45
Power of the cooling serpentine, kW 15 15 15 18 18 18 18
Water volume in the boiler, litres 63 78 78 85 96 98 100
Setting range of the temperature regulator
O
C 60-85 60-85 60-85 60-85 60-85 60-85 60-85
Ma working smoke traction, mbar 0,25 0,25 0,30 0,30 0,32 0,35 0,38
Working pressure of water in the system , bar, ma 2,0 2,0 3,0 3,0 3,0 3,0 3,0
Testing pressure of boiler, bar 4,0 4,0 4,5 4,5 4,5 4,5 4,5
Ma . allowable water temperature in the boiler,
O
C,
Ma . allowable working water temperature in the boiler,
O
C,
108
95
108
95
108
95
108
95
108
95
108
95
108
95
Electric characteristics - voltage, V/ frequency, Hz 220/50 220/50 220/50 220/50 220/50 220/50 220/50
- used power, W 50 50 50 50 80 80 80
Level of electric protection of boiler
Dimensions - height, mm 1320 1320 1320 1235 1420 1590 1590
- width, mm 585 585 630 710 710 710 910
- depth, mm 835 910 1010 1210 1210 1230
Weight of boiler, kg, 240 310 320 380 500 535 640
Diameter of the connection nozzles 1
1
/
2
” 1
1
/
2
” 1
1
/
2
” 1
1
/
2
” 1
1
/
2
” 2” 2”
Volume of combustion , l 90 95 120 140 280 315 405
Dimensions of the loading hole, mm 350 285 350 285 350 285 350 285 350 285 350 285 350 285
Al diameter of the smoke e traction, mm 152 152 152 152 152 180 180
Length of wood pieces, mm 330 450 450 550 750 750 750
Temperature of the outlet gases at the nominal heating power,
0
C 210 210 200 200 190 190 190

9. GUARANTEE AND ITS VALIDATION CONDITIONS
1. The manufacturer gives 2 year guarantee*, if the installation, start-up and regulation (the first
kindling and adjustment) and maintenance are performed by the certified company and the 6 months guarantee
if the mentioned works are e ecuted by the non certified company :
- the guarantee repairs are performed, if the faults occur due to the manufacturer’s fault or used
bad quality materials;
- guarantee period is not e tended after boiler faults have been eliminated during the guarantee
period;
- boiler cleaning as well as boiler and heating system regulation are not included into the list of
guarantee repair works;
- guarantee doesn’t mean that losses suffered due to the boiler fault occurred during the guarantee
period will be compensated;
- guarantee repair works and replacements of the parts are free of charge during the guarantee
period;
- the client pays for boiler installation and the first kindling and regulation works.
* One year g arantee is given to the boiler ventilator, thermo reg lators and door st ffing (tightening
ropes).
2. Guarantee validation conditions:
- guarantee is valid from the boiler selling date;
- guarantee is valid, if the boiler is installed, connected to the heating system and e ploited under
the requirements of this passport.
3. Guarantee is not applied in the following cases:
- when heat e changer is limed;
- in case the heat transmitter is frozen;
- when the boiler is broken due to improper e ploitation;
- when the boiler is broken due to improper connection of the electric input;
- when the boiler parts are mechanically damaged;
- if the boiler is connected to the heating system not under the schemes and requirements of this
passport.
4. The owner of the boiler pays himself for repair works performed after the guarantee period.
10. ACCEPTANCE CERTIFICATE
The heating boiler “Astra G “ serial No. _________ meets the standard (EN 303-5)
requirements and is accepted suitable for e ploitation.
Manufacturing date _________________
Head of Quality
Service ____________________

BOILER GUARANTEE CARD
Boiler Astra G ........
Boiler serial No.
Selling date, place, seal
Seller’s name, surname, signature
BOILER START-UP AND ADJUSTMENT CARD
Start-up, adjustment date
Start-up and adjustment performing company
Certificate No .
Employee’s name, surname, signature
Employee’s qualification certificate No.

4
8
9
S pplied
6
17
12
12
13
C
A
3
6
16
1
2
B
5
7
B
80
10
k
reg lator
reg lator
180
a b
b
1
a
1
18 18
Rear viev
L
H
11
h
Trap
Trap
Ret rning
Cross-section
18
18
19
o152
Boiler type B L H h k a
1
b
1
a b D d
ASTRA G-18 MS/MES 835 --- ---
ASTRA G-25 MS/MES
585
--- ---
ASTRA G-31,5 MS/MES 615
970
1320 990 130 75 915
--- ---
ASTRA G-40 MS/MES 1010 1235 890 --- --- 845
ASTRA G-50 MES 1420 1080 --- --- 1025
152 G1 ½“
ASTRA G-80 MES
710
1210
170
--- ---
105
1215
ASTRA G-100 MES 810 1230
1590 1220
185 115 1200 --- ---
180 G2“
1. Frame 12. Damper hinge of upper combustion chamber
2. Combustion chambers opening the flue
3. Ceramic shell 13. Control panel
4. Air path with ventilator 14. Outlet of water
5. Ceramic e ge 16. Flue cleaning cap
6. Flue 17. A justable legs
7. Sensors of the thermoregultors an 18. Connection of the cooling serpentinre ½"
emergency thermostate 19. Nozzle of the cooling serpentine ½"
8. Take off cap
9. Combustion chamber oors
10, 11. Connection branches А – Air inlet opening
В – Opening to the flue
С – Upper combustion chamber to the flue
Fig. 2. General picture of t e boiler
d

Fig. 3. Zones of wind infl ence
Bigger angles form an increased resistance of the chimney traction
Thermical
sofety
valve
Fig.4Heating energy istribution scheme (Scheme for the
wunection of serpertine of emergency cooling)
Filter
To sewage
Water from the
watersupply
sistem pressure is
2-6 bar.
Temperature 10-
15
0
C
Sensor of
Thermostatic
Safety valve
Astra G-31,5
Thermical
sofety
valve
Water from the
watersupply
sistem pressure is
2-6 bar.
Temperature 10-
15
0
C
To sewage
Filter
Astra G
-
0

1
PE
2
N
3
L
L1
5
L1
6
L1
7 8
9
N
10
L3
11
N
12
L
N L
N L
N L
L1 N1 L2 L3 L4 P
L N
L13
L2
N
L13
L14
E
E
E
KM
220 V
PE
M
F
SK S2
S1
KR
L1
L
5. pic. Electric scheme ( electronic
control)
S1 – lilet switch (R595KMET2F)
S2 –ventiliator switch (R392KYFT2C)
SK – emergency thermostat ( LA322-
96111338)
F – safety plug 2A
M1 – ventiliator (GR03710/
L25X0E12/03
KM – syocket connection
KR – controller (KR-4)

Ceramic inserts and their position in heat boiler
No
Ceramic
Type of heat
boiler
insert G-31,5 G-40
1 1 Burner
ŠK-23.07.001 1 0
2 ŠK-50.07.001 0 1
2 Chopper
ŠK-23.00.006 1 0
ŠK-50.00.010 0 1
3 Segments
3 G-18.00.004 2 0
G-18.00.004-01 0 2

Declaration of Confirmity
Manufacturer: Machinery plant “Astra” AB
Address: Ulonu st. 33, 62161 Alytus, Lithuania
roduct designation: Heating boiler
Heating
boiler
ower,
kW
Waking
pressure, bar
Astra G-31,5 31,5 2,0
Astra G-40 40 3,0
We confirm, thwart this product designated comply with the conditions of the following:
1. Requirements of the directives :
9 /23 EC, p2.3
2006/95 EC
These standards were applied for the above mentioned products:
EN 303-5
EN 12828
EN 60335-1
EN 60529
Procedure of conformity evaluation according to regalement 9 /23 EC 2.3 is executed by „TÜV
Thüringen‘‘. Certification No 0662/03 3/05
No 0662/0528/06
Alytus 2009 ...........................
(date)
Vaidas Liesionis , marketing director
GB

Technical description of the control device KR-4
Designation:
Control device is designed for the control of the solid fuel boiler. Fan is controlled according to the law of proportional –
integral- differential regulation ( ID) and the pump, air valve or electric heating device are regulated positionaly.
Connection:
Control device is connected according to the scheme designed on the fig, No. 1:
L1, N – supply of electricty to the control device;
L2 – supply of electricity to the fan;
L3 – voltage to the fan;
L4 – voltage to the pump;
– voltage to the programmed output.
Fig. 1. Scheme of the connection of control device
Temperature sensor RK ( T-100) is installed in the water tight capsule which is immerged into the water of boiler.
Voltage of the fan L2 is connected from the control pannel of the boiler to the control device when the boiler works in the
heating regime (the fuel is loaded and the limit thermical relay is not in action). Impulse commutator of the fan connects
L3 to L2. The relay of control of pump connects L4 to L1. It connects with L1.
The power of the fan is 20÷100 VA. The maximal power of the controlled pump is 250 VA. Maximal controlled power of
the relays of programmed output is 250 VA.
Exploitation
After the loading of fuel the fan is put into operation with the swith on the control panel. There appears green signal light
"Heating" 3 (Fig. 2.) and the process of the fan control begins. The fan is working only when the green signal light No. 3 is
on.
The desired water temperature of the boiler is set with the keys 2 (2 pav.). By short pressing of “+” or “-“, digital indicator
1 starts to indicate the temperature of the water in the boiler. For the change of the temperature it is necessary to press and
to keep the related key (for the increasing “+”, for decreasing “-“ ). After the few seconds after the last press of the key the
set temperature is saved and the indicator starts to show the measured temperature of the water (when indicator shows the
set temperature , there is a point lighting near the digits ; when indicator shows the real measured temperature there is no
point lighting near the digits).
1 – digital temperature indicator;
2 – temperature setting keys;
3-6,8 – signal lights:
3 – "heating",
4 – "heating off",
5 – "pump",
6 – “fan“,
8 – “programmed output“.
7 – programmed output control key
Fig. 2. Front pannel of the regulating device
The speed of the fan is proportional to the deviation of the temperature, to its duration and to the rate of the
increase/decrease of the water temperature in the boiler.
Each time at the start there is launched the electric magnet, which opens air valve and there appears light 8.
Control of the pump
The pump of the heating system can be switched on for the continuing operation or it can be switched on and off depending
on the water temperature. The operation of the pump and the temperatures for the switch on / off are defined by the
servicing staff, referring to the characteristics of the heating system. When the pump is on there is a signal light 5 on the
front pannel of the control device (fig 2.).
Burning control
The state of work „heating off“ is indicated in the following cases:
- if the temperature after two hours from the beginning of heating is T≤45
o
C;
- if the temperature drops below 45
o
C and does not increases within the period of 30 min.;
- if during the operation of boiler the pump is switched off for longer than 1 hour. (it is not applied when the pump is put
on the constant operation ).

The state of operation „heating off“ switches off the fan and switches on the corresponding light signal. This state can be
left by switching off the voltage L2 or the supply of the electricity to the control device.
Programmed output
Depending on the design of the boiler the programmed output can control air valve or electric heating. If there is installed
electric heating it can be swicthed off automaticaly when the boiler is on the mode „heating off“. In order to activate or
desactivate this control it is necessary to keep pressed the key “ ” 7. There will apear “On” at the indicator (activated) ir
“OF” (switched off). The servicing personnel set the temperatures of switching on/off for the electric heating referring to
the characteristics of rthe heating system.
Control device No.: . . . . . . . . . . . . . .
Date of installation: . . . . . . . . . . . . . . . . . . . . . . .
* - depending on the design of th