Broseley Hercules User manual

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INSTALLATION AND OPERATING INSTRUCTIONS
HERCULES
These Instructions Cover the:
12, 20 & 30 RANGE OF MULTI-FUEL STOVES
(WITH AND WITHOUT BOILERS)
Revision: GB07
Revision: GB07Revision: GB07
Revision: GB07c
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Thank you for choosing a Hercules cast iron multi-fuel stove.
Please take time to read this manual and follow the guidelines on how to install and operate
your new stove. This will help you to enjoy, for many years to come, safe and cost effective
use of your stove.
The term ‘multi-fuel’ means that the stove is capable of burning a variety of solid fuels, for
example, wood logs, coal, Phurnacite, peat and various pre-formed briquettes or a
combination of these fuels. The specially designed multi-fuel grate inside your stove allows
a flow of air through the base of the fire that is necessary when burning coal, or a hot ash
bed to be supported when burning wood. See the section on ‘Operation’ for more details.
INSTALLATION - ALL MODELS
 The stove must be installed and commissioned by a fully qualified, registered engineer. A
“Declaration of Completion Certificate” must be obtained for the installation and retained by the end
user. Failure to comply with these requirements may void the warranty.
 The stove must be stood on a level hearth constructed of an incombustible material such as
stone, brick, quarry tile or slate etc and project at least 300mm in front and 225mm on each side of
the stove.
 The stove must have sealed connections from the Top Plate flue outlet through a flue pipe of
200mm diameter and appropriate length into a chimney. (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).
 The sealed connection can be achieved by passing the flue pipe from the Top Plate flue outlet
through a closure plate that seals off the fireplace opening vertically or the base of the chimney
horizontally (the plate must be made of rigid fireproof material and for durability stainless steel sheet
is recommended) or directly into a pre-lined chimney.
All joints at stove and flue connections must be made airtight with ceramic rope of appropriate
diameter using fire cement only to point-up and finish. Glass-fibre rope may be used for joints in
other locations.
•If the flue pipe is connected to a vertical closure plate the outlet end must terminate not
less than 100mm from the back wall of the chimney.
•If the flue pipe is connected to a horizontal closure plate the outlet end must project a
minimum of 50mm above the plate with steep haunching in sand/cement mortar and
skimmed with fireclay cement, to prevent soot deposits building-up within the chimney on
top of the closure plate. (If the closure plate is large and haunching impracticable, an
access panel must be fitted in the closure plate or the chimney-breast above the closure
plate level from which soot deposits can be removed - particular attention must be given to
the fixing and sealing detail of the closure plate within the chimney construction to achieve
airtight construction at this location).
•If the flue pipe is connected directly into a pre-lined chimney the outlet end must
project a minimum of 75mm into the lining. The internal diameter of the lining should be
25mm or less than the external diameter of the flue pipe.
Access for chimney sweeping can be achieved from within the stove by removal of the baffle
plate. The baffle plate can be removed by raising either the right-hand or left-hand edge to the
underside of the Top Plate and lowering the opposite handed edge into the fire chamber space
where there is sufficient room to rotate and remove it through the front of the stove. Alternatively,
a section of flue pipe incorporating an access door can

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INSTALLATION - BOILER MODELS ONLY
 All boiler models are fitted with four water pipe connection bosses each with a 1.5 inch BSP
female tapping located on the outside rear face of the wrap-round boiler.
 The primary circuit supply to the hot water cylinder must be 28mm diameter pipe with the ‘flow’
pipe rising vertically from one of the top connection bosses to ensure good convectional flow and
permit all air to evacuate the boiler. If horizontal pipe runs are essential air bleed valves must be
incorporated where air locks are prone to occur. The hot water cylinder must be of the ‘indirect’ type
(where the domestic hot water tap supply remains separate from the water circulating through the
boiler and radiators - if standard radiators and hot water cylinder are already installed this will
normally be an ‘indirect’ system but the fitter or plumber will be able to confirm the type of system
installed). It is strongly recommended that a pipe mounted thermostat is fitted to the ‘primary return’
pipe, close to the stove location but shielded from the direct heat of the stove or, alternatively, a
surface mounted thermostat fitted directly to the hot water cylinder. The thermostat should be set to
switch the water pump ‘ON’ when the water temperature reaches approximately 55 degrees C (a
safe temperature for domestic hot water tap supply). The thermostat will ensure that the hot water
cylinder will have priority to the supply of heat from the boiler, this is particularly important when the
fire in the stove has been damped down for overnight burning.
 The secondary circuit supply to the radiators must have pipe diameter sizes appropriate to the
system design for a solid fuel appliance. Pipe sizes will depend on length, height of pipe runs and
number and sizes of radiators and their sequence on the circuit.
ASSEMBLY
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 Non-Boiler/Boiler Unit
Place the Non-Boiler/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 is convenient at this stage to use a ‘gun’ applicator of fire cement to form a horizontal ‘fillet seal’ at
the internal junction between the Non-Boiler/Boiler Unit and 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.
 Fit the Front Plate
Offer the vertically recessed rope seals to the leading edges of the Non-Boiler/Boiler Unit (the top
edge of the Top Plate should be about 50mm above the top edge of the Non-Boiler/Boiler Unit) and
allow the Front Plate to slide down until the catches engage with the pins located on the Non-
Boiler/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.

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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.
It is convenient at this stage to use a ‘gun’ applicator of fire cement to form a vertical ‘fillet seal’ at
the internal junctions between the leading vertical edges of the Non-Boiler/Boiler Unit and the Front
Plate and a horizontal ‘fillet seal’ at the internal junction of the Base Plate and the Front Plate.
 Fit the Fire Chamber Steel Plate Panels (Non-Boiler Models only)
The Fire Chamber Panels are fitted by locating the top edge behind the down standing face of the
top retaining rail, lifting and dropping so that the bottom edge is located behind the upstanding face
of the bottom retaining rail.
Note on fitting:
The panel with the large cut-out fits around the afterburner.
The panel with a cut ledge fits along the rear on the left side.
The narrow panel fits along the rear.
The other two panels (smaller than the rest) fit left and right.
 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 Fret Rails
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).
To dismantle the stove, follow the above sequence in reverse.
IMPORTANT NOTICE !!!
It is essential that the chimney is of sound construction and swept clean before fitting the
stove.
IF IN DOUBT - CHECK IT OUT (Contact a Flue Specialist or Experienced Chimney Sweep)

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OPERATION
IMPORTANT NOTICE !!!
On the first occasion that a fire is lit in the stove, it must only be controlled to run at a ‘moderate’
temperature to allow the large cast iron panels to ‘cure’ through three daily cycles of even heating
and cooling.
This simple precaution will significantly reduce the risk of excessive ‘distortion’ and possibly
‘cracked’ panels.
To maintain a clear view of the fire, always adjust the Top Spinner to allow sufficient down draught
to prevent soot and tar deposits on the internal surfaces of the glass panels. See additional note on
how to ‘clean the glass’ in the Maintenance and Safety section.
 Setting and Lighting the Fire (General)
Open the Bottom Spinners fully, use paper and small pieces of wood, topped with small pieces of
solid fuel, light the paper and close the doors. Add larger pieces of fuel then close the doors again.
When the fire is well alight use the Spinners to control the rate of burning.
 Maintaining the Fire (Day-time Cycle)
Coal Burning:: To start, fully open the Bottom Spinners and the Top Spinner by about one
quarter; when the fire is well alight use the Bottom Spinners to control the rate of burning, close
down the Top Spinner to ‘trickle’ ventilation but sufficient to prevent ‘smoke’ and ‘tar’ staining
deposits forming on the glass panels of the doors.
Wood Burning: : To start, fully open the Bottom Spinners and the Top Spinner; when the fire is
well alight use the Top Spinner to control the rate of burning, close down the Bottom Spinners to
‘trickle’ ventilation.
If the fire is ‘smoky’ - Coal and Wood: (This is usual in the early stages of combustion). Open
the Afterburner Control (Tertiary Air) by rotating the cover plate, located externally on 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 (volatile gases) will ignite in the
secondary airflow entering the Fire Chamber through the Afterburner Control (Tertiary Air) tube
(located on and about half-way up the rear wall of the Fire Chamber). When the fire is burning
‘clean’ (very little or no ‘visible’ smoke) the Afterburner Control (Tertiary Air) may be shut off or
used as an additional source of ‘controlled’ top ventilation if wood burning.
 Maintaining the Fire (Night-time Cycle
Coal Burning: Ensure that the grates are clear of excessive ash. Open the Bottom Spinners fully
and allow sufficient time for a ‘sound’ hot bed of embers to be formed. Fully load the fire chamber
with fresh dry fuel. Close the Top and Bottom Spinners to ‘trickle’ ventilation. Leave the
Afterburner Control (Tertiary Air) fully open.
Wood Burning: Do not clear the grates of ash. Open the Top and Bottom Spinners fully and allow
sufficient time for a ‘sound’ hot bed of embers to be formed. Fully load the fire chamber with fresh
dry fuel. Close the Top and Bottom Spinners to ‘trickle’ ventilation. Leave the Afterburner Control
(Tertiary Air) half open.
 In the Morning (Re-Establishing the Fire)
Coal Burning: Open the Bottom Spinners fully. Riddle the fire effectively to clear the overnight ash
deposits and allow sufficient time for a ‘sound’ hot bed of embers to be formed. Open the doors and
fully load the fire chamber with fresh dry fuel and then close the doors to establish the Day-time
Cycle.
Wood Burning: Do not clear the grates of ash. Open the Top Spinner fully and it may be helpful to
leave the doors partly open for a short time, fully load the fire chamber with fresh dry fuel and close
the doors to establish the Day-time Cycle.
 Operating Tool
Use the ‘U’ shaped end to lift the Ash Pans and turn the door handle. Use the ‘V’ shaped end to turn
the Spinners and operate the Riddling Mechanism located externally at low level, about halfway
back, on both sides of the stove casing.

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FUEL
 COAL (or Coal Derivative produced for Domestic Use)
Use unrestricted, but check Local Authority Regulations which may require the use of ‘smokeless
fuels’. Seek the advice of your local Coal Merchant on choice of fuel.
WARNING !!!
DO NOT USE ‘PETRO-COKE.
This ‘coal derivative’ burns at very high temperatures and is both dangerous and unsuitable
for domestic use.
USE OF ‘PETRO-COKE’ WILL INVALIDATE ANY FORM OF WARRANTY OFFERED BY THE
MANUFACTURER.
 WOOD
Use only dry well seasoned wood. (max 20% moisture content) Generally, wood should be
‘seasoned’ for at least one year before burning.
‘Hard’ woods burn longer than ‘soft’ woods. Wood has a lower calorific value than coal derivatives.
These will require a longer curing period.
MAINTENANCE AND SAFETY
 Empty the Ash Pans regularly
Never allow the ash level to build-up to the underside of the Grates. This will prevent under-draught
ventilation, reduce efficiency and create ‘hot spots’ in the Grates causing heat distortion and
cracking requiring premature replacement of the Grates.
 Clean the Baffle Plate
Check regularly to ensure that the top of the Baffle Plate does not accumulate soot deposits (about
once each month but experience will determine the required frequency).
 Clean the Glass
Use a proprietary cleaner and follow the manufacturers’ instructions.
 Hot Surfaces
Use a fireguard to prevent small children from touching hot surfaces and do not leave combustible
materials close to the stove. Never store items on top of the stove when not lit.
PLEASE REMEMBER THAT YOUR HEATING NEEDS, HOUSE DESIGN, LAYOUT OF PIPEWORK,
LIVING STYLE AND LOCAL AUTHORITY REGULATIONS MAY BE DIFFERENT TO OTHER
FAMILIES IN THEIR HOMES. SO, IT IS VERY IMPORTANT THAT YOU RECEIVE GOOD QUALITY
ADVICE FROM YOUR LOCAL RETAILER AND INSTALLER ABOUT WHICH HERCULES STOVE
TO BUY AND HOW IT SHOULD BE INSTALLED TO SATISFY THE REQUIREMENTS FOR YOUR
HOME.
PLEASE KEEP A RECORD OF YOUR LOCAL CONTACTS FOR FUTURE REFERENCE JUST IN
CASE YOU DO HAVE A PROBLEM OR REQUIRE A MAINTENANCE SERVICE BECAUSE THESE
PEOPLE ARE IN THE BEST POSITION TO HELP YOU.
PLEASE REMEMBER THAT BROSELEY FIRES LTD IS THE MANUFACTURER OF YOUR STOVE
AND NOT IN A POSITION TO GIVE ADVICE ON THE DESIGN, INSTALLATION AND OPERATION
OF SPACE HEATING, CENTRAL HEATING AND DOMESTIC HOT WATER SUPPLY SYSTEMS IN
YOUR HOME. HOWEVER, WE ARE VERY PLEASED TO ACCEPT TELEPHONE CALLS ABOUT
ANY QUERIES RELATING TO THE DESIGN, TECHNICAL SPECIFICATION AND CONSTRUCTION
OF THE HERCULES RANGE OF MULTI-FUEL STOVES.

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ANNUAL SERVICE RECORD
INSTALLATION DATE OF APPLIANCE:
1ST YEAR SERVICE completion date:
SERVICE ENGINEER: . REG. No.
COMPANY NAME: .
COMPANY ADDRESS: .
POSTCODE:
CONTACT NUMBER
2ND YEAR SERVICE completion date:
SERVICE ENGINEER: . . REG. No.
COMPANY NAME: .
COMPANY ADDRESS: .
POSTCODE:
3RD YEAR SERVICE completion date:
SERVICE ENGINEER: . . REG. No.
COMPANY NAME: .
COMPANY ADDRESS: .
POSTCODE:
4T YEAR SERVICE completion date:
SERVICE ENGINEER: . . REG. No.
COMPANY NAME: .
COMPANY ADDRESS: .
POSTCODE:
5T YEAR SERVICE completion date:
SERVICE ENGINEER: . . REG. No.
COMPANY NAME: .
COMPANY ADDRESS: .
POSTCODE:
6T YEAR SERVICE completion date:
SERVICE ENGINEER: . . REG. No.
COMPANY NAME: .
COMPANY ADDRESS: .
POSTCODE:

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LIMITED WARRANTY
This applian e must be installed and ommissioned by a fully qualified, registered
engineer. A “De laration of ompletion Certifi ate” must be obtained for the
installation and retained by the end user. Failure to omply with these requirements
may void your warranty.
You, as the end user, have a ontra t by law with the supplier / dealer from whom you
pur hased the produ t., That dealer then has the same ontra t with the manufa turer
or wholesaler and these have a ontra t with their suppliers.
ALL CLAIMS MUST FOLLOW THIS PROCEDURE.
Thank you for hoosing a Produ t from Broseley Fires Ltd. This warranty gives you spe ifi legal rights.
The statutory rights of the onsumer are not affe ted by the warranty, nor the onsumers rights against
the dealer arising from their sales / pur hase ontra t.
The manufa turers’ warranty:
Your Produ t will be free from defe tive parts, material, and workmanship at the time of its original
pur hase for a period of one (1) year.
This warranty does not over any failure of the unit due to normal wear and tear, misuse, abuse, a ident,
illegal modifi ation, installation or repair, damage resulting from improper use or failure to maintain the
produ t.
The onsumable items within the produ t are not overed by the warranty, nor are the glass.
If during the warranty period, this Produ t fails to operate under normal use and servi e, due to defe ts in
material and / or workmanship, Broseley Fires will either repair or repla e the produ t. The repaired or
repla ed produ t shall be warranted for the remaining period of the original warranty or ninety (90) days
from the date of repair, whi hever is longer.
Repair or repla ement may involve the use of fun tionally equivalent re onditioned units. Repla ed parts or
omponents will be ome the property of Broseley Fires.
Should you wish to laim under the warranty, please onta t the supplier / dealer from whom you pur hased
the applian e from. Do not laim dire tly to Broseley Fires, as they are unable to pro ess any dire t laim
from an end user.
Produ t design and any spe ifi ations are subje t to hange without noti e. This is due to our ontinuous
produ t development and improvement. The buyer will not be entitled to request free upgrades to the new
design or ompensation for previously pur hased produ ts.
•This Warranty overs all Broseley Fires osts within the Warranty period.
If the applian e remains uninstalled for a period greater than six months from date of delivery the
Warranty will be ome a tive six months from the date of original invoi e to the distributor.
I N NO EVENT SHALL B ROSELEY F IRES BE LIABLE FOR INCIDENTAL OR CONCEQUENTIAL DAMAGES OF ANY NATURE
WHATSOEVER , INCLUDING BUT NOT LIMITED TO LOST PROFITS OR COMMERCIAL LOSS , TO THE FULL EXTENT THOSE
DAMAGES CAN BE DISCLAIMED BY LAW . (if appli able)
A copy of our full terms and conditions is available on request.