heatco HERO DIRECT User manual

CONTENTS
 HEAT HERO DIRECT DESCRIPTION - INSTRUCTIONS BEFORE LIGHTING 1
 INSTALLATION INSTRUCTIONS 2
 HOW TO CONNECT HEAT HERO DIRECT TO AN OIL/GAS BOILER WITH A
PRESSURE CYLINDER, SOLAR PANELS, RADIATORS AND UNDERFLOOR HEATING 3
 HOW TO CONNECT HEAT HERO DIRECT WITH A HIGH PRESSURED GAS BOILER 4
 THERMAL SAFETY VALVE & 44KW COOLING LOOP 5
 TECHNICAL DATA 6
Understanding Solid Fuel Boilers
A solid fuel boiler can achieve twice the heat of an oil or gas boiler and will
not turn off automatically. Efficiency can only be achieved with strong
circulation and fast heat transfer.
This is not possible when an open vent is installed in front of the circulating
pump or a heat exchanger is installed on the solid fuel boiler.
Heat Hero solves this problem and allows you get full efficiency from your
solid fuel boiler.

It is important that this information booklet is read and understood fully before installation.
*This unit MUST only be installed by a fully qualified person who understands and adheres
to all relevant regulations.
CAUTION - HEAT HERO DIRECT MUST NOT BE INSTALLED AS A CONCEALED UNIT
The following instructions are given to help the installer ensure a safe and efficient
IMPORTANT - INSTRUCTIONS BEFORE LIGHTING THE STOVE:
1. Make sure the system is full of water.
2. Make sure that all of the valves are open.
3. Turn On and Off the circulating pump to clear any air in the heating system.
4. Turn On the circulating pump and light the stove slowly until radiators start to heat.
5. The solid fuel circulation pump should be turned up to the maximum speed and the pipe
thermostat should be set 50°-55°.
HEAT HERO DIRECT DESCRIPTION
Heat Hero Direct operates at 0.7 par of pressure and has strong circulation. It is designed to
control single or dual solid fuel heating systems and directly circulate the water from the solid fuel
boiler to the radiators and DHW with out the use of an Heat exchanger. Safety is guaranteed
with an open vent, a built in 44KW cooling loop and an optional gravity circuit to the radiators.
Up until now heat exchangers were used to control and transfer the heat from a solid fuel boiler
to the radiators and domestic hot water. Because a solid fuel boiler is a non-controllable heat
source a heat exchanger is a very inefficient and problematic way to transfer heat. Heat
exchangers work fully efficiently on controlled heat sources like a high pressure gas boiler. Solid
fuel boilers can only achieve full efficiency with direct strong circulation.
Heat Hero Direct does not use a heat exchanger. It circulates the water safely with pressure and
strong circulation directly to the radiators and DHW as required. It is the most efficient controlled
solid fuel heating system on the market that allows the solid fuel boiler inter-link with oil or gas
boilers and operate fully efficiently within the manufacturer’s recommendations.
1

2
INSTALLATION INSTRUCTIONS FOR DUAL HEATING SYSTEM:
 Heat Hero Direct is installed above the solid fuel boiler to allow gravity pass through the
solid fuel boiler and Heat Hero Direct.
 The pipe thermostat must be of good quality and should be fitted as close to the solid fuel
boiler as per diagrams. (Caution should be taken that the heat from the stove does not
damage the workings of the pipe thermostat.)
 The circulation pump should be an 8m Head pump and should be fitted beside the Heat
Hero Direct.
 The Cold Feed must be connected to the Heat Hero Direct Port 5 (see page 6).
 The Heating Storage Tank should be a minimum of 1m above the highest point of the
heating System (e.g. above the Heat Hero Direct or above the radiators)
 Expansion pipe of minimum ¾ “ diameter must be connected to the Heat Hero Direct Port
6 (see page 6) and piped to the heating tank as per diagram.
 The Non return Valves should be of good quality and installed as per the diagram.
 Auto air vents should be of good quality and installed as per the diagram.
 Blow off valves should be installed at the secondary heat source.
 Heating Zones If a heating system is zoned, At least one radiator zone must open
automatically when the solid fuel thermostat turns on the circulating pump.
 Pressurised Cylinder Heat Hero Direct can be connected with solar and a DHW
pressurised cylinder safely and efficiently.
 44KW Cooling Loop is built into the Heat Hero Direct. If the solid fuel boiler heats above
99° the liquid filled temperature probe will open the thermal safety valve and mains water
will cool the gravity circuit and the solid fuel boiler.
 With Heat Hero Direct a solid fuel boiler, pressure cylinder, solar and oil or gas boiler can
operate fully efficiently together within the manufacturers recommendations.

DIAGRAM SHOWING HEAT HERO DIRECT IN A DUAL HEATING SYSTEM CONNECTED TO AN OIL OR GAS
BOILER WITH A PRESSURE CYLINDER, SOLAR AND RADIATORS
See detailed Video on website www.heathero.ie
3
OPTIONAL GRAVITY
CIRCUIT TO RADIATORS

4
A high pressure gas boiler can be connected eciently to a solid fuel boiler by installing a
heat exchanger on the gas boiler as shown in the diagram below. A gas boiler is a
controlled heat source which will allow a heat exchanger operate at its full 98% eciency.
A heat exchanger CAN NOT operate at its full eciency when connected to a solid fuel
boiler because a solid fuel boiler is a non-controllable heat source that can achieve twice
the heat of an oil or gas boiler. When Heat Hero Direct is installed the water circulates
from the Solid Fuel Boiler directly to the radiators, underoor heang and DHW without
going through a heat exchanger achieving full eciency and good heat transfer
throughout the home.
DIAGRAM SHOWS HEAT HERO DIRECT CONNECTING A SOLID FUEL BOILER TO A
HIGH PRESSURE GAS BOILER USING A HEAT EXCHANGER ON THE GAS BOILER
HEAT HERO DIRECT CONNECTED TO A HIGH PRESSURE GAS BOILER

The AFRISO thermal safety valve TAS 03 is used for thermal protection of sealed or open solid fuel heating systems
as per EN 12828 with a heating capacity of up to 100 kW (86,000 kcal). The thermal safety valve consists of a valve
housing, a valve, two independent bellow type displacement probes with liquid-filled temperature probes and a
pocket. The pocket is installed in the upper part of the boiler. The capillary tube (1,300 or 4,000 mm) integrated in the
pocket is protected by a flexible metal hose. The thermal safety valve is connected to the hot water outlet of the
water heater or to the inlet of the safety heat exchanger. If the response temperature of 99 °C is exceeded, the heat
expansion of the silicone oil in the probe system causes a stroke via the bellows which opens the valve to supply
cooling water from the mains system. This keeps the maximum permissible temperature in the boiler from being
exceeded. If one of the temperature probes fails, the second temperature probe provides redundancy. Correct
operation of the thermal safety valve TAS 03 can be verified quickly and easily by simply pressing the valve head.
TAS 03 can be mounted horizontally or vertically. It must be ensured that hazards caused by hot water or vapour at
the free outlet of the discharge line into the funnel are excluded. The thermal safety valve TAS 03 is suitable for
operating temperatures from 5 to 115 °C and an operating pressure of up to 10 bar. Connections include two G¾
female threads for the pocket and a G´ male thread.
AFRISO Thermal Safety Valve TAS 03
44 Kw Stainless Steel Heat Exchanger used for Cooling Loop
Number of plates 20
Length / Width / Height
(without connections, in mm) 191 / 73 / 51,8
Max. flow 4 m³ / h
Connecting height 12 mm
Capacity 0,018 l per plate = 0,36 Litre
Effective exchange surface 0,012 m² per plate = ca. 0,24 m²
Temperature range -195°C up to +225 °C
Temperature range 20 bar
Power max. 44 kW
Plate material stainless steel AISI 304
Connecting piece material stainless steel AISI 304
Circulation F1 -> F3 / F4 -> F2
5

GENERAL TECHNICAL INFORMATION HEAT HERO DIRECT
PORT 5
PORT 4
PORT 7
PORT 1 PORT 2
PORT 6
TECHNICAL DATA – HEAT HERO DIRECT
Maximum test pressure 6 Bar
Maximum work pressure 4 Bar
Maximum Heat Capacity 44 KW
Material Mild Steel
PORT 1 1’’ BSP FEMALE Gravity Return
PORT 2 1” BSP FEMALE Gravity Flow
PORT 3 1” BSP FEMALE Radiator Flow
PORT 4 1” BSP FEMALE Radiator Return
PORT 5 3/4’’ BSP FEMALE Gravity Water Feed
PORT 6 1’’ BSP FEMALE Open Air Vent
PORT 7 1/2” BSP FEMALE Mains Cooling Loop Out
PORT 8 1/2” BSP FEMALE Mains Cooling Loop In
Overall Length 205 mm
Overall Depth 85 mm
Overall Height 180 mm
Overall Weight 2.8 KG
6
PORT 3
PORT 8