Astra G-50 User manual

HEATING BOILER
Astra G-50
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............................................................................................... 8
• Accumulation Tank..............................................................................................................................8
• 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.............................................................................................................. 11
• Connection of the Circulation Pump .................................................................................................. 12
• Connection of the Ventilator.............................................................................................................. 12
• Mounting of the Draught Regulator .................................................................................................. 12
• Regulation of the Secondary Air Damper........................................................................................... 13
• Controlling the Temperature of Water Returning to the Boiler........................................................... 13
• Heating Output, Water Temperature and Water Flow Relationship.................................................... 13
• Installation of the Boiler Room.......................................................................................................... 14
• Requirements for the Chimney.......................................................................................................... 14
6. FUEL ...........................................................................................................15
7. OPERATION ..................................................................................................16
• Front Control Panel ........................................................................................................................... 16
• Rear Control Panel............................................................................................................................. 17
• Preparation for Firing........................................................................................................................ 17
• Kindling Procedure of the Boiler........................................................................................................ 17
• Fire Bed and Tips for Eective Boiler Stoking..................................................................................... 18
• Regulation of the Boiler Temperature................................................................................................ 19
• Addition of Fuel................................................................................................................................. 19
• Combustion Control .......................................................................................................................... 19
• Cleaning the Boiler............................................................................................................................ 19
• Emergency Shut Down of the Boiler .................................................................................................. 20
8. POSSIBLE FAULTS..........................................................................................20
9. WARRANTY AND ITS VALIDITY TERMS..............................................................21
10. ACCEPTANCE CERTIFICATE.............................................................................22
SELLING CARD .................................................................................................22
BOILER INSTALLATION PROTOCOL.......................................................................22
WARRANTY AND POST-WARRANTY REPAIR CARD..................................................23
DECLARATION OF CONFORMITY..........................................................................24

3
INSTALLATION AND OPERATION MANUAL
This user manual was compiled following the requirements of EN 12171 “Heating systems in buildings. Procedure for the
preparation of documents for operation, maintenance and use. Heating systems not requiring a trained operator”.
1. SAFETY REQUIREMENTS
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 BOILER: Astra G-50
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. Secondary air regulation damper; 10. Ventilator and
ventilator duct inspection aperture; 11. Return water pipe; 12. Water drain nipple; 13. Connections of the cooling serpentine; 14. Flue pipe; 15. Flue cleaning
cap; 17. Safety ventilator shutdown 95°C thermostat sensor; 18. Water temperature sensor; 19. Upper combustion chamber opening to the ue; 20.
Primary air inlet nozzle; 21. Secondary air inlet opening; 22. Ceramic burner; 23. Ceramic chopper; 24. Ceramic segment; 25. Opening to the ue.
Astra G boiler model B L H h k D d N S
Astra G-50 660 1230 1315 1075 150 152 G1 1/2“ 210 180
2
4
5
3
19
20
23
15
25
24
17
d
H
h
12
6
13
B
11
8
10
22
21
1
7
B
S
N
9
18
A
C D
d
k
D
L
14
10

5
INSTALLATION AND OPERATION MANUAL
• TECHNICAL DATA OF THE BOILER
Name of indicator Indicator value
Astra G-50
Nominal heat output, kW 50
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 20
Water volume in the boiler, l 115
Setting range of the temperature regulator, °C 65-85
Recommended draught, Pa 25
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 1315
width, mm 660
depth, mm 1230
Weight of boiler, kg, 505
Threaded connection diameter 11/2"
Volume of fuel chamber, l 230
Dimensions of the loading aperture, mm 350x285
Flue gas duct diameter, mm 152
Length of wood pieces, mm 750
Average temperature of the ue gases at the nominal heat output, °C 205

6
HEATING BOILER: Astra G-50
• 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
of the turbulence plates, positioned at an angle in the rectangular-
shaped ue channel of the boiler. The inspection aperture 1 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. 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. The plate
rests upon the heat exchanger 4 of the boiler ue on four supports: two
bottom and twoupper supports. When inserting the plate 2 witha 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 force of gravity until it touches the wall of the heat exchanger 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.
Fig. 3 Turbulence plate technology
1. Inspection aperture; 2. Turbulence plates; 3. Poker;
4. Heat exchanger of the boiler ue.
33
2
1
2
4
• CERAMIC ELEMENTS OF THE BOILER
The boiler has ceramic elements of three types: ceramic burner 1, ceramic chopper 2 and two ceramic segments 3 (Fig. 2). The
chopper 2 must be moved to the back wall of the boiler chamber during operation of the boiler, segments 3 – resting upon the
front edge of the chopper. If needed, the ceramic burner 1 can be removed. For this purpose, use a screwdriver to remove the
sealing rope from between the ceramic burner and the frame of the boiler, then this ceramic insert can be removed.
Fig.2 Ceramic inserts and their positions
1. Ceramic burner; 2. Ceramic chopper; 3. Ceramic segments.
Ceramic
element
Boiler type
G-50
1. Burner
1 a ŠK-50.00.008 1
1 b ŠK-50.07.001 1
2. Chopper
2 a G-32.01 2
2 b G-32.02 1
3. Segments
3G-18.00.004-01 2
2 b
2 a
3
1a
2 a
1b

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 boilerwastransportedorstored in minustemperatures,thenbeforeit is kindled, it shouldbe kept in plustemperature
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.; draught regulator - 1 pc.; tee - 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.

8
HEATING BOILER: Astra G-50
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
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 72°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-50
Required volume of the accumulation tank, litres 2500
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
owsoutintothesewage.Thesensorofthevalvewiththeexternal
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.
1
2 3
5
4
4 pav. Avarinio aušinimo sistemos pajungimo schema
1. Į kanalizaciją;
2.Terminis apsauginis vožtuvas;
3. Filtras;
4.Vanduo iš vandentiekio.
Slėgis 2-6 bar.Temperatūra °C;
5.Terminio apsauginio vožtuvo sensorius.
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 Overow Valve
Filter
Heating System Supply
Heating System Return
Automatic Air Outlet
Return Valve
Valve
Pressure Relief Valve Pump
Thermometer - Manometer Manometer
With Valve
Water Supply
Programmable Heating System Processor
Min 65oC!
Heat production Heat consumption

10
HEATING BOILER: Astra G-50
Theheatconsumptioncircleusestheheataccumulatedinthetank.Thecircleconsistsofaroomthermostatoraprogrammed
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.
• REQUIREMENTS FOR CONNECTION OF THE BOILER TO THE HEATING SYSTEM
The following requirements should be fullled when installing the boiler:
•Theboilershould beinstalledin aclosedheatingsystemwith aclosed membranous expansion vessel,thevolume of which should
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 opening pressure3bar Astra G-50
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.