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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).