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Hercules Boiler Model 2
HERCULES MULTIFUEL SAFETY BOILER STOVE
INSTALLATION AND OPERATION MANUAL
Thank You
May we take this opportunity to thank you for choosing a Hercules, cast iron
Multi-fuel Boiler stove. Please take time to read this manual and follow the guidelines
on how to install and operate your new stove, as we feel sure it will enable you to
use it to its best advantage for many years.
The term multi-fuel refers to the fact that the appliance is capable of burning both
wood and coal. Both of these fuels have very different requirements if they are to
burn correctly. The air controls on the appliance allow the chosen fuel to burn
efficiently. On an open fire, the necessary conditions to allow both wood and coal to
burn is done so at the expense of efficiency, sending more than 80% of the heat
produced straight up into the chimney. The efficiency figures for our M/F stoves are
much higher as there is far greater control over the combustion air entering and
leaving the appliance.
SEE THE SECTIONS ON PAGE 15 - “Burning Wood” and “Burning Coal” FOR
A FULL LIST OF RECOMMENDED FUELS. After reading this document, if there is
anything you are unsure about, please contact your dealer or our Technical Support
Department on 01743 461444.
Useful organizations
Solid Fuel Association 0845 601 4406 www.solidfuel.co.uk
The National Association
of Chimney Sweeps 01785 811732 www.chimneyworks.co.uk
HETAS Ltd. 0845 634 5626 www.hetas.co.uk
Health and safety precautions
Special care must be taken when installing the stove such that the requirements of
the Health and Safety at Work Act are met.
Handling
Adequate facilities must be available for loading, unloading and site handling.
Fire Cement
Some types of fire cement are caustic and should not be allowed to come into
contact with the skin. In case of contact, wash immediately with plenty of water.
Asbestos
This stove contains no asbestos. If there is a possibility of disturbing any asbestos in
the course of installation then please seek specialist guidance and use appropriate
protective equipment.
Metal Parts
When installing or servicing this stove care should be taken to avoid the possibility of
personal injury.

Hercules Boiler Model 3
INSTALLATION OF STOVE
These instructions cover the basic principles to ensure the satisfactory installation of
the stove, although detail may need slight modification to suit particular local site
conditions. In all cases the installation must comply with current Building
Regulations, Local Authority Byelaws and other specifications or regulations as they
affect the installation of the stove.
It should be noted that the Building Regulations requirements may be met by
adopting the relevant recommendations given in British Standards BS 8303, BS 6461
and BS 7566 as an alternative means to achieve an equivalent level of performance
to that obtained following the guidance given in Approved Document J.
We recommend that you seek the services of an installer who is conversant with
stove installations and Building Regulations. It is most likely that the shop where
you purchased the stove will be able to help in this respect. It is our general policy to
supply specialist Fireplace shops. These shops can offer an after sales service and
will be able to offer advice when necessary.
Please note that it is a legal requirement to comply with Building
Regulations and that the installation of the stove is certified by Local
Authority Building Control. It is the responsibility of the appliance owner
to notify Building control for certification. It is also a requirement under
the guarantee that all installations and operation complies to the
instructions to follow. No installation should be undertaken unless the
installer is suitably qualified.
Stove Performance
The Hercules stove range has been CE approved as an intermittent operating
appliance for burning manufactured or naturally occurring smokeless fuels and wood
logs only. It should be noted that it is an offence to burn wood logs in this stove if it
is installed within a Smoke Control Area in the UK.
12B 20B 30B
Maximum heat output to room (kW) 4 6 8
Maximum heat output to water (kW) 8 14 22
Flue diameter MINIMUM* 7 inch
*please note a larger flue diameter may be required if the flue design demands it.
Efficiency % 73 75.4 75.4
Temperature exhaust gas – wood (ºC) 190
Optimal working temperature 70º - 75º
Boiler capacity (litres) 18 20 22
Flow & return pipe fitting (female) 1 ½ BSP 1 ½ BSP 1 ½ BSP
Flue draft Pressure 0.17 – 2 0.17 – 2 0.17 – 2
(tested when hot) WOOD (mbar/Pa) 17 – 2.0 17 – 2.0 17 – 2.0
Maximum working temperature 94º - 95º
Stove depth (mm) 440 510 620
Stove Height (mm) 768 768 768
Stove Width (mm) 747 747 747
Stove Weight (Kg) 201 225 252

Hercules Boiler Model 4
Additional Air A permanent air entry opening or openings with a total
free area of at least 550mm2 per Kw of appliance rated
output above 5Kw. If a flue draught stabiliser is used,
extra ventilation will be required.
There must not be an extractor fan fitted in the same room as the stove as
this can cause the stove to emit fumes into the room.
Hearth And Clearances
Your stove must be installed on a solid, level non-combustible hearth and with a gap
of at least 600mm from any combustible material such as beams or skirting. The
hearth protrusion in front of the stove to carpets or wooden floors must be at least
300mm. As it is possible, that on opening the door of the stove for fuel to fall out, a
fender must be fitted if the hearth is flush with the carpet. These are just a few
hearth specifications. Please refer to Building Regulations Approved Document J
(Hearths) for more specific details.
Minimum hearth thickness 12mm
Constructional hearth required of 125mm minimum
The appliance should be sited in a properly constructed brick fireplace or recess
allowing a gap of 100mm all round, at the rear and both sides. The fireplace walls
must be made of solid non combustible material and at least 75mm thick. The hearth
should be level and the appliance fitted at right angles to it. Fireplace walls need to
be at least 1.2m above the hearth and at least 300mm above the appliance. The
hearth has to be able to support the weight of the appliance and any flue bearing
down upon it. The clearance distances to combustible material beneath, surrounding
or upon the hearth and walls adjacent to the hearth should comply with the guidance
on the separation of combustible material given in Building Regulations Approved
Document J and also in these stove instructions.
Stove
Clearances A B C Above
Non-Combustible 100mm 100mm 300mm 200mm
Combustible 200mm 400mm 300mm 600mm

Hercules Boiler Model 5
Chimney
This appliance must not be fitted into a chimney serving another heating appliance.
It is most important that there is no obstruction in the flue or chimney. Please ensure
that any existing chimney is clear of obstruction and swept clean immediately before
installation of the stove. If the chimney has been used for an open fire it is
recommended that it be swept for a second time having been used for a month
following installation. As a closed appliance operates at a higher flue temperature, it
is possible for deposits that were previously adhered, to be dislodged, with the
consequent risk of flue blockage.
Flue Draught
Performance of a flue is dependent on its materials, size and configuration, and the
position of its outlet. In the final design of all these parameters must be considered
to insure that the appliance performs to its full potential. When commissioning, a flue
draught measurement must be taken, if excessive corrective measures must be
implemented. The flue draught is taken when the appliance is running at its working
temperature. Please see data table for correct figures. An excessive flue draught
will potentially damage the appliance, flue and/or the property and void
any warranty.
The outlet from the chimney should be above the roof of the building in accordance
with the provisions of Building Regulations Approved Document J. If installation is
into an existing chimney then it must be sound and have no cracks or other faults
which might allow fumes into the house. Older properties, especially, may have
chimney faults or the cross section may be too large i.e. more than 230 mm x 230
mm. Remedial action should be taken, if required, seeking expert advice, if
necessary. If it is found necessary to line the chimney then a flue liner suitable for
solid fuel must be used in accordance with Building Regulations Approved Document
J.
If there is no existing chimney then either a prefabricated block chimney in
accordance with Building Regulations Approved Document J or a twin walled
insulated stainless steel flue to BS 4543 can be used. These chimneys must be fitted
in accordance with the manufacturer’s instructions and Building Regulations.
The liner diameter must not be less than 7”. If the draw on the chimney is excessive,
a flue draught stabiliser will help to slow this down. An excessive draw may cause
over firing and thus cause the internal components of the stove to wear out quicker..
Any bend in the chimney or connecting fluepipe should not exceed 45°. 90°bends
should not be used. Adequate provision e.g. easily accessible soot door or doors
must be provided for sweeping the chimney and connecting fluepipe.

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Hercules Boiler Model 7
Figure 1b

Hercules Boiler Model 8
Connection to Chimney Flue
A single wall metal fluepipe is suitable for connecting the stove to the chimney but is
not suitable for using for the complete chimney. It is important that the connection
between the stove spigot and the flue pipe is effectively sealed with heat resistant
fire cement and/ or glass fibre rope to prevent harmful gases leaking into the room.
The diameter of the flue spigot (pre fibre roped) provided with the stove is 8”
(200mm) and can only be fitted to the top of the stove and must be tightly fitted to
the opening. Air must not be drawn in at this point as it will affect the stoves
performance. The stove may be fitted with a 7” (175 mm) flue (In most situations
175mm diameter flue pipe will not be suitable for chimneys less than 7.5m high, and
must be used in conjunction the ‘reducer ring’ supplied with the stove as a standard
part).
To get the best transfer of heat from the stove into the room there are two factors to
consider when installing into a fireplace recess.
Firstly, the flue pipe from the stove must pass through a top ‘register plate’. A top
register plate is the term used for a flat plate which is installed inside the chimney
(usually out of sight) to prevent heat in the room being drawn up the chimney to
waste when using the top or rear flue outlet. This register plate must be made of a
non-combustible material such as steel, asbestolux, or masterboard. It is advisable to
seal this register plate to the walls of the chimney and also around the flue pipe.
Provision of a trap door in this closure plate, or a soot door in the flue for access to
clean the chimney from time to time, is recommended.
Secondly, the more forward the stove can be sited on the hearth, the more heat will
be radiated into the room. But remember the 600mm clearance distance from
combustible materials and the 300mm distance to the front of the hearth.
Combustion Air Supply
In order for the stove to perform efficiently and safely there should be an adequate
air supply into the room in which the stove is installed to provide combustion air.
This is particularly necessary in modern houses where drafts have been almost
eliminated by double glazing etc.
There must not be an extractor fan fitted in the same room as the stove as this can
cause the stove to emit fumes into the room. It is necessary to install a wall vent to
provide the necessary combustion air and to prevent the depletion of oxygen in the
room.
Plumbing the Appliance
The plumbing must be in accordance with all the relevant regulations and practices.
The central heating should be pump driven as with other types of boilers. 28mm
diameter flow and return piping must be used for the initial run to the tank or heat
store. The shorter the run of pipe work the more effective the water heating will be,
the cylinder and pipe work should be lagged to minimise heat loss.

Hercules Boiler Model 9
Boiler Connections
All boiler models are fitted with 4 connections for piping. These connections are 1 ½
Inch BSP and are a female thread. It is possible to only use 2 of these connections,
however opposite angles must be used – For example Flow top right, return bottom
left. The 2 excess connections can then be capped off.
Checks on Initial Firing
Before connecting up the boiler the installer must ensure that they thoroughly flush
all of the systems pipes in order to remove any residue which could compromise the
correct operation of all system components (Pumps, valves etc).
It is also important to verify the chimney has sufficient draught, there are no
blockages and that no other appliance exhausts are inserted into the flue.
Filling up the System
Once all connections are complete the installer can proceed with the boiler
connection. Open all the vent pipes of the radiators, the boiler and the system.
Gradually open the load valve, ensuring that the air vent pipes are working correctly.
Assembly of Stove
For top outlet flue assembly
Place the Top Plate casting on the hearth and use a plumb line to determine the
centre point for the flue alignment from the opening in the closure plate to the flue
outlet opening of the Top Plate.
Mark the position of the four corners of the Top Plate with a piece of chalk (these
correspond exactly with the four corners of the Base Plate casting).
Place the Base Plate over the chalk marks
Use the chalk marks as the ‘template’ to accurately position the Base Plate (the use
of the four Base Cups is optional but when used ensure these are squarely seated
and accurately located under the Base Plate). Check the Base Plate with a spirit level
and if necessary adjust the height by turning the cups.
From this stage onwards the final position of the stove assembly is set.
Fit the Boiler Unit
Place the Boiler Unit onto the Base Plate and ensure that the bottom edges are
properly located onto the rebated Rope Seal that runs around the four sides of the
Base Plate.
It may also be advantageous to fit the plumbing elbows and the first lengths of pipe
to the Boiler Unit before locating on the Base Plate close to the rear wall of the
fireplace opening within which the stove is to be located.
Ensure that the ‘flow’ and ‘return’ pipes to the primary and secondary circuits
respectively, are fitted ‘diagonally-opposed’ for efficient water circulation within the
Boiler Unit.

Hercules Boiler Model 10
Fit the Front Plate
Offer the vertically recessed rope seals to the leading edges of the Boiler Unit (the
top edge of the Top Plate should be about 50mm above the top edge of the Boiler
Unit) and allow the Front Plate to slide down until the catches engage with the pins
located on the Boiler Unit.
To ensure that the Front Plate has been securely located place a woodblock on the
top edge of the Front Plate and apply a sharp tap with a lump hammer to the
woodblock.
WARNING !!!
DO NOT HIT THE CASTING DIRECTLY - IF THE FRONT PLATE IS STILL NOT
SECURE CHECK THE LOCATION AND SEATING OF THE FRONT PLATE AND
LOCATION OF THE CATCHES AND PINS - THIS IS A SIMPLE AND STRAIGHT
FORWARD OPERATION AND EXCESSIVE FORCE MUST NOT BE USED.
The Front Plate will be easier to handle if the Doors are taken off by removing the
Fixing Pins which can be tapped out from underneath the Hinge Blocks.
Fit the Baffle Plate
Place the Baffle Plate on the supporting brackets. The bracket on the baffle faces the
base of the stove.
Fit the Fire Grates
Place the two half Fire Grates on the supporting ledges (ribbed face underside).
Fit the Fuel Retainer Bars
Place the first Fret Rail with the flat ash deflector bar between the back face of the
Front Plate and the steel Retaining Plates.
Place the second and third Fret Rails on top of the first Fret Rail
The notched ends of the Fret Rails face inwards and are loose fitting.
Fit the two Ash Pans
Place the Ash Pans side-by-side in the ash-pan compartment below the Grates.
Fit the Top Plate
Place the Top Plate onto the stove body and check that it is centrally located and
seated onto the wide recessed rope seal. The Top Plate relies upon self-weight to
seal (do not use fire cement to seal).

Hercules Boiler Model 11
Commission/Handover
Ensure loose parts are fitted in accordance with the instructions for “Assembly” given
above.
On completion of the installation allow a suitable period of time for any fire cement
and mortar to dry out, when a small fire may be lit and checked to ensure the smoke
and fumes are taken from the stove up the chimney and emitted safely to
atmosphere. Do not run at full output for at least 24 hours.
On completion of the installation and commissioning ensure that this installation and
operation manual for the stove is left with the customer. Ensure to advise the
customer on the correct use of the appliance with the fuels likely to be used on the
stove and warn them to use only the recommended fuels for the stove.
Advise the user what to do should smoke or fumes be emitted from the stove. The
customer should be warned to use a fireguard to BS 6539 in the presence of
children, aged and/or infirm persons. Advise the user not to fit an extract fan in the
same room as the stove as this can cause the stove to emit fumes into the room.
Insure the boiler system is fully operational and performs to the design specification.
Insure any safety features are fully operational.
Also check the following points and insure they have been addressed:
1. Flue draught is correct
2. Flue draught measurement =
3. Flue soundness
4. Flue operation correct
5. Flue data plate completed
6. Appliance smoke tested
7. Hearth fitted to current standards
8. Correct air brick/ventilation installed
9. Ensure the heating system is functioning correctly

Hercules Boiler Model 12
OPERATION OF STOVE
READ THESE INSTRUCTIONS CAREFULLY BEFORE USING THE STOVE
It is very important not to leave the stove running with
the doors open. This allows far too much air into the stove
causing the fire to burn excessively hot and will severely
damage the stove.
MAINTAINANCE REQUIREMENTS
The product you have purchased is a working appliance. It is important
that routine maintenance is carried out to ensure its longevity.
Rope seals on doors and glass should be checked on installation to ensure
a good seal. Place a strip of paper in the door and close it. If the paper can
be pulled out without tearing it the rope seal should be adjusted or may
need to be replaced. This test should be carried out every few months as
the rope seal will degrade with use. Replacement glass rope and high
temperature rope glue should be available from your local stockist. The
doors of the Hercules are mounted on adjustable hinge blocks. If these
have become misaligned during transportation or fitting they should be
adjusted so that they close securely. Routine clean out of the firebox,
removing grates and cleaning is equally important.
Controls Layout
Figure 2 – Control Layout
SecondaryAirControl
TertiaryAirControl
PrimaryAirControls

Hercules Boiler Model 13
Ash Pan
The ash pans can be removed using the double end of the poker which fits under the
top lip of the ash pan. Care must be exercised when opening the doors as the handle
and this part of the stove will be very hot. Use the glove provided. Do not put hot
ashes into anything other than a metal container unless you know the ashes are
cold. Ash pan removal is best done when either the contents of the ash pan have
cooled or the stove is out, as some red hot coals can be covered by the ash and may
be unseen. Take care not to drop any of the contents of the ash pan on carpet or
soft furnishings. Only a slight contact of hot ash may burn a hole. If you remove hot
ashes from the stove, use some protection for the floor covering adjacent to the
hearth, to account for accidental spillage and always use gloves.
Air Controls
The stove is fitted with a primary air control and a secondary air control (air wash)
which together control the rate at which the fuel is burned. The sections “Air-wash
system” and “Starting and maintaining the fire” give more detail of their operation
and usage.
The Hercules stove also features a tertiary air control found on the right hand side of
the stove.
Air-wash System
This is a system where secondary air is drawn into the stove (by combustion)
through the top knob and deflected down the back face of the glass, thus preventing
the smoke coming into contact with the glass. It does not mean that you will never
have to clean the glass, but substantially lengthens the periods between having to do
so. The air-wash system works best when burning dry wood at high temperature.
Wet and pitchy wood will produce more deposits on the glass. Also, deposits will
form on the back of the glass when the stove is operated on low heat for extended
periods.
The ‘air wash’ is controlled via the knob situated towards the top of the stove; it is
this ‘air-wash’ that keeps a clean and uninterrupted view of the fire, and good
secondary combustion of the fuel. This helps to reduce emissions into the chimney
and environment. rotating the knob to the left opens the vent allowing more air into
the fire so making it burn faster and hotter. Closing the vent slows the combustion
rate and in this way you are able to control the rate at which the fire burns.
The fire needs some air to burn so closing down all the air supply will make the fire
go out. Experience with the fire will show you the right balance of fuel and air to get
the best out of your stove. This can be achieved by closing down the secondary air
and running the primary air at a minimum, which would usually be set at about one
third of the usual running position. In the morning, open the air controls fully to re-
establish the fire. Then de-ash and refuel in the normal way adjusting the air
controls accordingly.

Hercules Boiler Model 14
The tertiary air control
The tertiary air control, or afterburner control, is used to burn the smoky fumes and
volatile gasses that would normally be lost up the chimney. Because of the lack of
oxygen within these gasses, they would not burn any more. When the tertiary air
control is used, additional heat will be generated. Using this control helps prevent
excessive creosote formation and smoke pollution, it also makes the fire burn at a
more efficient rate as extra heat is generated when using this control.
Tertiary Air
Control
Figure 3 – Tertiary Air Control
Curing the Stove
Before lighting the stove check with the installer that the installation work and
commissioning checks described in the installation instructions have been carried out
correctly and that the chimney has been swept clean, is sound and free from any
obstructions. This curing process may have been undertaken by your installer as part
of the stoves’ commissioning and handover and the installer should have shown you
how to operate the stove correctly.
Your stove is made of a number of cast iron components and we recommended that
the first burn should be a small fire for about 30 minutes. This enables the stresses
and strains at the joints to be taken up and settle gradually. The second burn can be
a larger fire for an hour. During the curing process, the stove will give off a pungent
smell and some fumes. This is the paint curing and is quite normal. Provide
ventilation whilst this is happening since the fumes can be quite strong and may set
off smoke alarms in the room. The paint may become slightly lighter in colour when
the stove is cured, particularly in the hottest spots. Fire
Grate polish can be used to keep the stove in good condition, or stove spray paint
can be used to re-touch the stove. The correct stove spray can be obtained from
your stove stockist.

Hercules Boiler Model 15
Permanent air vent
The stove requires a permanent and adequate air supply in order for it to operate
safely and efficiently. In accordance with current Building Regulations the installer
should have fitted a permanent air supply vent into the room in which the stove is
installed to provide combustion air. This air vent should not under any circumstances
be shut off or sealed.
Recommended Fuels
This appliance has obtained CE approval for burning the following fuels –
Manufactured and natural smokeless fuels, and wood logs only.
The Hercules range have been CE certified burning Manufactured and
natural smokeless fuels, and wood logs not exceeding 35cms in length.
Approval does not cover the use of other fuels either alone or mixed with
the suitable fuels listed above, nor does it cover instructions for the use of
other fuels.
Although CE certification covers the use of the smokeless fuels listed, the
claimed rated output, has been obtained burning a single representative
smokeless fuel, under standard test conditions. However, in the home, a
variety of operating conditions can occur and the performance of the
appliance may vary to some degree with these conditions and different
fuels may need to be burnt at different rates to provide the same heat
output.
The recommended fuels are Wood logs no longer than 35cms (dry, seasoned
for a minimum of one year) and solid mineral fuels (e.g. Natural smokeless
fuels) The larger briquettes are recommended as they concentrate less
heat in one spot reducing the likelihood of damage to the grate. Please find
a recommended and non recommended list below.
RECOMMEDED FUELS
•Dry Seasoned wood logs no longer than 35cms
The Solid Fuel Association also lists the following manufactured smokeless
coals as suitable for use in a CLOSED APPLIANCE.
•Ancit,
•Therma,
•Briteheat,
•Briteflame,
•Coalite Ovals,
•Ecoal,
•Homefire,
•Homefire Ovals,
•Maxibrite,
•Newflame,
•Pureheat,
•Supacite,
•Surefire,
•Taybrite,
Anthracite can also be used however as it has a
high calorific value. A controlled burn rate is
critical, else considerable damage can be caused to
the appliance.

Hercules Boiler Model 16
NON RECOMMENDED FUELS
•Wood off cuts and building materials must not be used as fuel at any
time. Off cuts can contain chemicals etc that accelerate the burn
rate or produce excessive tar deposits and on some occasions
harmful gases.
The fuels below are suitable for open fires and therefore are not
recommended to burn in a closed appliance.
•Premium Coal
•House Coal
•Premium Doubles
•Coal and Doubles Blend
•Triple Heat
•Lignite Nuggets
•Rough Slack
•Peat Briguettes
•Turf
Only authorised smokeless fuels may be used in smoke control areas.
Under NO circumstances burn ‘petroleum coke’ or ‘House Coal’ as it will burn
out the internal grate and baffle plates in a very short period of time and may
damage the stove beyond repair.
Only burn dry, seasoned wood. This will give a good heat yield and help to keep
the glass clean. A growing tree contains 50-95% water. Burning unseasoned wood
turns most of the energy released into water vapour which goes into the flue and
little heat is given off to the room. The moisture will combine with other combustion
products forming a sticky surface and the risk of obstruction, or worse still a chimney
fire, is greater. Wood logs are best stored in a stack, sheltered from the weather, in
a well ventilated area and raised off the ground. This allows the air to circulate and
prevents mildew.
Starting and Maintaining the Fire
Do not use gasoline, lighter fluid, Kerosene or other flammable liquids to
start or rekindle the fire for obvious safety reasons.
Build a fire directly on the grate with crumpled newspaper, kindling wood and/or
commercially available “firelighters”. Do not allow single pieces of paper to float
up the chimney especially alight. This is a common cause of a chimney fire and
can cause structural damage to the property. Ensure all air controls (primary and
secondary) are fully open to begin with as shown in the pictures above. When the
kindling is burning well, add larger pieces of wood or solid fuel to gradually increase
the size of the fire. The stove will work more efficiently with the main door closed as
you will be able to control the combustion air and the rate of fuel burning. It is not
recommended to operate the stove with the fuel loading door open other than to
load fuel. When alight the loading door handle and the ash pan handle will become
very hot. Please use the glove provided to avoid touching hot parts.
There are IMPORTANT differences in the method of operation for burning solid fuel
or wood in your stove. Please read both sections even if only one fuel type is
relevant to you.

Hercules Boiler Model 17
Burning Solid Fuel
Solid fuel needs a flow of air for combustion though the bottom of the grate. Wood
does not require this and will readily burn on a bed of ash with a flow of air over the
top. Use the single end of the poker provided to push the ash and debris through the
grate before refuelling. This will allow the passage of air and prevent the grate from
clogging. Make sure there is sufficient hot fuel left to allow the fire to pick up once
refuelling has occurred. This will look like a level, shallow bed of hot embers with no
spaces. After prolonged use you will have a better idea of the refuelling interval and
procedure. Control the rate of burn by opening and closing the primary air. The fuel
will burn fastest with the primary air fully open. To get the fire going open the air
controls. Once it is established, close the secondary air and use the primary air for
controlling the rate of burn. Once the fire is running, you may find that opening the
secondary air a little, will help to keep the glass clean. This is good practice but
remember to control the fire using the primary air.
Burning Wood Logs
If you are only burning wood logs, you may allow a bed of ash to build up on top of
the grate to a level of about 20mm forming a flat surface on which the wood may
burn. You will then use the “air-wash” vent slide to provide the combustible air and
control the burn rate of the fire. For fully open, turn the knob to the left. Fully open
will produce the fastest burn producing most heat. To establish the fire it is
acceptable to open the primary air as well. Once the fire is bright close the primary
air control and use the secondary air to control the rate of burn for the fire. You will
not have to clean out your stove after every firing as wood will burn better with a
slight build up of ash in the ashpan. It is not advisable to burn painted or recovered
wood (such as railway sleepers) as this contains harmful toxins or flammables which
may cause the wood to ‘spit’.
For an extra boost of heat you can use the tertiary air control to create extra
combustion in the fire chamber see instructions on ‘Tertiary Air Operation’ below.
If you are burning solid fuel or a mixture with wood DO NOT allow a bed of ash to
build up above the level of the sides of the ash can. Solid fuel needs combustible air
to flow through it from underneath. When burning solid fuel, this air is needed to
keep the grate from overheating. Failure to allow a sufficient flow of air through the
grate will result in the grate burning out in a very short period of time. This will not
be covered by any warranty claim. You will get some spillage of ash to the back and
sides of the ashcan itself and you must ensure that this is cleaned out regularly and
from behind the internal baffle plate. If you do not do this, you may buckle the
baffle plate or in the extreme, burn it out.
Tertiary Air Operation
Open the Afterburner control (Tertiary Air) by rotating the cover plate, located
externally at the right hand side of the stove towards the rear. When the
temperature in the fire chamber is high enough (usually about ten to fifteen minutes
after lighting) the ‘smoky’ fumes and volatile gases will ignite in the secondary
airflow, entering the Fire Chamber through the Afterburner control (Tertiary Air)
tube. This is the stainless steel tube that you can see mounted half way up the rear
wall of the fire chamber. When the fire is burning ‘clean’ with very little or no ‘visible’
smoke coming out of the chimney, the Afterburner control (Tertiary Air) may be shut
off or used as an additional source of ‘controlled’ top ventilation if burning wood.

Hercules Boiler Model 18
WARNING NOTE
Properly installed, operated and maintained this appliance will not emit fumes
into the dwelling. Occasional fumes from de-ashing and re-fuelling may occur.
However persistent fume emission is potentially dangerous and must not be
tolerated. If fume emission does persist, the following immediate actions should
be taken:-
a) Open doors and windows to ventilate the room.
b) Let the fire out or eject and safely dispose of fuel from the appliance.
c) Check for flue or chimney blockage and clean if required.
d) Do not attempt to relight the fire until the cause of the fume emission has
been identified and corrected. If necessary seek expert advice.
Use of fireguard
When using the stove in situations where children, aged and/or infirm persons are
present a fireguard must be used to prevent accidental contact with the stove. The
fireguard should be manufactured in accordance with BS 6539.
Aerosol sprays
Do not use an aerosol spray on or near the stove when it is alight.
Use of operating tools
Always use the operating tools provided when handling parts likely to be hot when
the stove is in use.
Chimney Fires
If the chimney is thoroughly and regularly swept, chimney fires should not occur.
However, if a chimney fire does occur turn the air control setting to the minimum,
and tightly close the doors of the stove. This should cause the chimney fire to go
out in which case the control should be kept at the minimum setting until the fire in
the stove has gone out. The chimney and flueways should then be cleaned. If the
chimney fire does not go out when the above action is taken then the fire brigade
should be called immediately.
After a chimney fire the chimney should be carefully examined for any damage.
Expert advice should be sought if necessary
Cleaning the Stove and Summer Shutdown
Only clean the stove when cold. To clean the glass, either use an oven cleaning fluid
or dip a wet cloth in the wood ash (not coal ash – this will scratch the glass) and
gently rub clean. The outside can be cleaned with a soft brush. Use a lint free cloth if
necessary but test an area first. Do not use abrasive cleaners as this will remove the
paint and may leave a chalky deposit. Under no circumstances use a yellow duster as
the fibres will stick to the rough surface of the stove and will produce a pungent
odour next time the stove is used! If the stove has a period of non-use leave the
primary and secondary air controls in the open position to allow ventilation through
the stove. The side and rear baffles can be easily removed and are not fixed. Lift the
side baffle clear of the grate with both hands and then tilt the bottom of the plate
into the stove. At the same time lower it to the grate floor. Repeat with the other
side. The rear plate will lift out. The throat plate baffles are held in a cradle and will
slide out for inspection and cleaning. Remove them to sweep the chimney. Replace
all removed parts before using the stove.

Hercules Boiler Model 19
Trouble-Shooting
1. Smoke comes out of the stove when the loading door is opened.
•The chimney cavity into which the flue pipe has been installed may be less
than the minimum requirement.
•Deposits (soot) may have built up in the chimney and be restricting the flow
of waste products. This flow rate is known as the ‘draw’.
2. The Stove does not produce the expected heat into the room.
•Has the flue pipe been sealed to the chimney to prevent heat being drawn up
the chimney to waste?
•Green or wet wood is being burnt.
•There is insufficient draw in the chimney. Seek installer advice with regards to
fitting a cowl.
•The chimney has excessive draw (this is unusual). Seek installer advice with
regard to installing a Flue Draught Stabiliser.
•The stove has been recessed into the existing fireplace and a lot of heat is
absorbed be the surrounding fireplace walls rather than being radiated into
the room. Pull the stove forward.
•For the maximum efficiency of heat transference into the room the stove
should be sited on the hearth of the fireplace rather than recessed.
•There is insufficient air supply into the room.
•An extractor fan has been fitted in the same room.
3. The Stove burns too fast.
•Use whole logs rather than split ones.
•The wood being used may be generally too small.
•The “air-tight” seal between the fibre rope on the doors and the casting may
have been lost, adjust door handle lock nuts/washers to reinstate this seal.
•The chimney has excessive draw (seek installers advice on this point).
•The fibre rope seal between the door and the glass may be leaking. Tighten
or replace.
•The glass is not sealed, gently tighten glass retaining clips. Do not over
tighten as this will stress or break the glass.
4. Over Firing
•If the appliance is over fired it will cause premature failure to the internal
parts of the appliance. Over firing occurs when excessive heat is generated
by the fuel being burnt due to a lack of control of the fire.
•Insure the door seals are kept in good condition and that the doors are
sealing correctly.
•Insure the thermostat control and other air controls are functioning correctly
•The correct fuel for the appliance is being used i.e. you are burning fuel
suitable for a closed appliance.
5. Lack of Heat to Radiators/Hot Water
a) The fire is burning properly – if not then carry out the checks on the ‘The
Stove does not produce the expected heat into the room’
b) The baffle plate is fitted correctly
c) The door seals are in good condition
d) If there is a lack of hot water or the water goes cold when the pump is
turned on, or if some radiators are hotter than others the system may need
to be balanced. The pump may be pumping water around your system to
quickly or some or all of the radiators may need bleeding. Your installer can
check on these points.

Hercules Boiler Model 20
Hercules 30B Dimensions