Viadrus EKORET SAPHIR Series Instruction Manual

Hercules U26
Návod k obsluze
EKORET SAPHIR
MANUAL FOR BOILER OPERATION
AND INSTALLATION

Table of content: page
1. Boiler usage and advantages ..................................................................................................................3
2. Boiler technical data.................................................................................................................................3
3. Description...............................................................................................................................................6
3.1 Boiler construction................................................................................................................................6
4. Positioning and installation.......................................................................................................................8
4.1 Rules and regulations...........................................................................................................................8
4.2 Positioning possibilities.........................................................................................................................9
4.3 Hydraulic connection diagram............................................................................................................12
5. Boiler commissioning – instructions for the contracting service organization........................................14
5.1 Delivery and accessories ...................................................................................................................14
5.2 Boiler mounting ..................................................................................................................................16
5.2.1 Installation of boiler drum with the basement..............................................................................16
5.2.2 The ceramic plates mounting......................................................................................................16
5.2.3 Boiler jacketing of EKORET SAPHIR (see. Fig. no. 12).............................................................16
5.2.4 Fuel reservoir and feeder assembly............................................................................................18
5.2.5 Mounting of the service board to the fuel reservoir.....................................................................19
5.2.6 Mounting of cleaning tools ..........................................................................................................19
5.2.7 Assembly of the emergency fire extinguishing equipment..........................................................19
5.2.8 Boiler conversion from right-hand design to the left-hand design...............................................20
5.2.9 Wiring diagram............................................................................................................................24
5.3 Checking activities before commissioning.........................................................................................28
5.4 Setting of parameters before the equipment start-up.........................................................................29
5.5 Boiler commissioning .........................................................................................................................30
5.6 HMI (ACX84.910/ALG) service unit for Saphir regulator operation....................................................31
5.7 Superior control..................................................................................................................................31
6. Boiler operation by user.........................................................................................................................32
6.1 Control, regulation and security elements..........................................................................................32
6.1.1 Saphir regulator...........................................................................................................................32
6.1.2 Safety thermostat........................................................................................................................36
6.1.3 Temperature sensor on the fuel feeder ......................................................................................36
6.1.4 Emergency fire-extinguishing system .........................................................................................36
6.1.5 Forced withdrawal of superfluous heat .......................................................................................37
6.1.5.1 Forced withdrawal of superfluous boiler heat......................................................................37
6.1.5.2 Forced withdrawal of superfluous water heater heat...........................................................37
6.2 SAPHIR regulator parameters............................................................................................................37
6.2.1 Description of SAPHIR regulator parameters.............................................................................42
6.3 QAA 88 device ...................................................................................................................................52
6.3.1 Parameters setting and displaying..............................................................................................53
6.3.1.1 Fuel feeder and ventilator performance curve – lignite........................................................54
6.3.1.2 Fuel feeder and ventilator performance curve – hard coal..................................................55
6.3.1.3 Fuel feeder and ventilator performance curve – wood pellets.............................................56
6.3.2 Faults ..........................................................................................................................................57
6.4 Service board.....................................................................................................................................58
7. IMPORTANT CAUTIONS......................................................................................................................59
8. Maintenance ..........................................................................................................................................60
9. Instructions for product disposal after its service life.............................................................................60
10. Guarantee and liability for defects .........................................................................................................61

3
Dear customer,
we thank you that you have bought EKORET SAPHIR automatic solid fuel boiler and thus having
shown your confidence in VIADRUS a.s.
For you to get used to a correct way of handling your new product from the beginning, please read at
first this manual for usage (mainly chapter no. 6 – Boiler operation by user and chapter no.
7 – Important cautions). Please follow the bellow stated information at once – and respect the
producer´s, eventually assembly company´s which installed the boiler, instructions to be provided a
longterm failure-free boiler operation to your satisfaction.
1. Boiler usage and advantages
The hot-water automatic boiler EKORET SAPHIR for solid fuel is designated first of all for heating the
houses, weekend houses, small premises, ect.
Boiler advantages:
•Boiler automatic operation controlled by an indoor device providing a convenience
•HWS (hot service water) preparation possibility
•Mechanical fuel supply from the built-in reservoir
•Simple, time saving operation and maintenance
•Low operating costs
•Low emissions
•High efficiency
2. Boiler technical data
Tab. no. 1 Boiler dimensions, technical parameters
EKORET SAPHIR 15
3 sect. EKORET SAPHIR 25 4 sect.
Boiler weight including small reservoir kg 359 385
Boiler weight including large reservoir kg 392 418
Water space volume l 34,1 45,5
Diameter of smoke socket mm 150 150
Fuel reservoir capacity – small dm
3
269 269
Fuel reservoir capacity – large dm
3
528 528
Boiler dimensions
(including small fuel reser.):
width x depth x height mm 1218 x 693 x 1592 1218 x 693 x 1592
Boiler dimensions (including large reser.):
width x depth x height mm 1867 x 693 x 1592 1867 x 693 x 1592
Filling hole dimensions – small reservoir mm 422 x 545 422 x 545
Filling hole dimensions – large reservoir mm 422 x 1210 422 x 1210
Working water overpressure kPa (bar) 250 (2,5) 250 (2,5)
Testing water overpressure kPa (bar) 500 (5) 500 (5)
Recommended operating temperature of
heating water °C 50 - 85 50 - 85
Minimum return water temperature °C 45 45
Hydraulic resistance collector 2,015 2,015
Noise level dB Doesn´t exceed level 65 dB (A)
Chimney draught mbar 0,10 – 0,20 0,10 – 0,20
Boiler connections – heating water Js G 1 1/2” G 1 1/2”
– return water Js G 1 1/2” G 1 1/2”
Connecting voltage 1/N/PE 230V AC 50 Hz TN - S
Electric input W 100
Electric coverage IP 40

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Tab. no. 2a) Heating technical parameters of EKORET SAPHIR 15 boiler
HARD COAL LIGNITE PELLETS
Nominal output kW 15 15 15
Fuel consumption kg.h
-
1
2,58 3,34 3,8
Fuel efficiency MJ.kg
-
1
25,16 19,17 16,78
Fuel consumption in the holding regime kg.h
-
1
0,13 0,10 0,70
Burning time at nominal output – small reservoir h 67 h 40 min 52 h 30 min 41 h 50 min
Burning time at nominal output – large reservoir h 132 h 49 min 103 h 82 h 7 min
Efficiency % Up to 83,2 Up to 84,3 Up to 84,7
Flue gas temperature °C 160 160 160
Flue gas mass flow at nominal output g.s
-
1
15,97 18,00 18,01
Boiler class 3 3 3
Tab. no. 2b) Heating technical parameters of EKORET SAPHIR 25 boiler
HARD COAL LIGNITE PELLETS
Nominal output kW 22 22 22
Fuel consumption kg.h
-
1
3,65 4,72 5,45
Fuel efficiency MJ.kg
-
1
25,16 19,17 16,78
Fuel consumption in the holding regime kg.h
-
1
0,13 0,10 0,70
Burning time at nominal output – small reservoir h 45 h 50 min 35 h 30 min 25 h 10 min
Burning time at nominal output – large reservoir h 90 h 10 min 69 h 40 min 49 h 24 min
Efficiency % Up to 86,4 Up to 87,7 Up to 86,6
Flue gas temperature °C 190 160 180
Flue gas mass flow at nominal output g.s
-
1
16,04 17,64 16,18
Boiler class 3 3 3
! Important notice:
The above mentioned heating technical parameters vary according to the type, quality and moisture
of the fuel used. Therefore there may be necessary corrections at setting of feeding time (proportion
of fuel feeding and fuel afterburning time). For example, if there occur the sliver parts of fuel on the
fire grate and in the ash pan, it is evident, that the speed of feeding is higher than the speed of
afterburning, in this case it is necessary to decrease the feeding cycle.
Specified fuel parameters – fuel which was tested by SZÚ:
•Granularity 5 - 25 mm
•Recommended heating value > 15 MJ. kg-1
•Ash content max. 15 %
•Water content max. 12 % (hard coal, wood pellets),
max. 20 % (lignite)
•Volatile combustible content 28 - 40 %
•Ash deformation temperature by melting > 1150 °C
•Low agglutinating power
•Low creeping
Values state in fig. no. 1 and Fig. no. 2 were measured out by using the specified fuel in tests.
Tab. no. 3 Specified fuel
Fuel Sort of fuel Granularity
[mm] Fuel value [MJ.kg-1]
Hard coal Peas 10 – 18 21 – 28,5
Lignite Nub 2 10 – 25 16,5 – 19,5
Nub 3 10 – 16 16,5 – 19,5
Biomass Wood pellets Ø 6 - 8 15 – 19
Tab. no. 4 Specified fuel – lignite (Automatic operation)
Fuel Granularity
[mm]
Fuel
value
[MJ.kg-1]
Ash content
[%]
water
content
[%]
sulphur
content
[%]
Specific
sulphur
content
[g/MJ]
Tar
content in
dry matter
[%]
Tar content in
combustible
matter [%]
Screened lignite from
Bílina mine
(coal cleaning plant) –
nub 2
10 - 25 17,6
9,8
(in
anhydrous
condition)
max. 20 0,77 0,44 15,1 15,71

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The pellets must comply at least with on of the following directions or standards:
Direction no. 14-2000 MŽP ČR
DIN 517 31
ÖNORM M 7135
Specified pellets granularity: between 6 and 8 mm
Maximum fuel water content. 12%.
Ash content max. 1,5 %
WARNING! A poor quality of fuel can markedly negatively affect the boiler output and emission
parameters
Length Small reservoir Large reservoir
L [mm] 590 1239
L1[mm] 1218 1867
L2 [mm] 1385 2034
Fig. no. 1 Main dimensions of boiler (right version)

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3. Description
3.1 Boiler construction
Fig. no. 2 Main parts of boiler (right version)
1. The stand with the burner
2. Cast iron boiler drum
3. Smoke adapter
4. Ash door
5. Ash door
6. Arc
7. Ceramic plate front
8. Ceramic plate rearí
9. Ceramic plate side
10. Boiler shell incl. ash pan
11. Safety thermostat
12. Turbulators
13. Heating water flange
14. Return water flange
15. Arch welder
16. Filling and discharge cock 1/2“
17. Fuel feeder
18. Motor with gearbox
19. Ventilator
20. Fuel reservoir
21. Service board

7
The pressure parts of boiler correspond to the strength requirements according to:
EN 303-5 Heating boilers – Part 5: Heating boilers for solid fuele, hand and automatically stocked, nominal
heat output of up to 300 kW – Terminology, requirements, testing and marking
The main part of the boiler is a boiler body (3-sectional, 4-sectional), that stands on a welded pedestal made
from steel sheets. There are turbulators in the channels of the cast iron body. In case of any necessity of
boiler draught increase, for flue gas temperature reduction a number of turbulators can be reduced. The
burner with a mixer is placed under the cast iron body (fig. no. 3), that is formed by cast iron grate, ceramic
plates, arc and retort. Fuel supply is provided from reservoir with a screw feeder through retort on the cast
iron grate. Ceramic plates regulate burning, they reduce a dustness, they baffle a heat back to the burner and
abet to a complete combustion.
There is place under the combustion chamber the ashtray. Beside the boiler there is placed the fuel reservoir,
joining to the screw conveyor equipment.
The combustion air fan is placed in front of the fuel reservoir and is connected to the burner. The heating
water inlet and outlet is placed in the back part of boiler and it is made of two flanges with external threads
G 1 ½”, for the connection to the heating system. There is a sealing between the boiler and flange made from
temafast Ø 60 x 48 x 2 mm. The threaded terminal G ½” serves for installation of discharging cock. The
smoke adapter to flue gas exhaust to the chimney is placed in the back upper part of boiler.
All parts (boiler shell, pedestal) are insulated by health harmless mineral insulation which reduces the losses
caused by the heat transmission to the environment.
The boiler shell is coated by by the high quality komaxit.
The boiler is made either in left-hand or right-hand version.
Fig. no. 3a) Burner with mixer (fuel – lignite and hard coal)
Fig. no. 3b) Burner with mixer (fuel – wood pellets)
1 – Mixer
2 – Retort
3 – Countersunk screw with internal
hexagon M8 x 20
4 – Cast iron grate (small diameter)
5 – Sealing
6 – Cap
7 – Washer 8,4
8
–
Screw M8 x 20
1 – Mixer
2 – Retort
3 – Setscrew with internal hexagon
M12 x 16
4 – Countersunk screw with internal
hexagon M8 x 20
5 – Cast iron grate(large diameter)
6 – Sealing
7 – Cap
8 – Washer 8,4
9 – Screw M8 x 20

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4. Positioning and installation
4.1 Rules and regulations
A solid fuel boiler can only be installed by a firm holding a valid concession for boiler installation and
maintenance.
A project according to the valid regulations must be prepared for the installation.
The heating system must be filled with water, that meets the ČSN 07 7401 requirements, especially its
harness must not exceed the required parameters.
Recommended values
Hardness mmol/l 1
Ca
2+
mmol/l 0,3
Concentration of total Fe + Mn mg/l (0,3)*
*) recommended value
WARNING!!! The use of anti-freeze mixture is not recommended by the manufacturer.
a) to the heating system
ČSN 06 0310 Heating systems in buildings – Designing and installation
ČSN 06 0830 Heating systems in buildings – protecting device
ČSN 07 7401 Water and steam for thermal energy equipments with working pressure up to
8 MPa
EN 303-5 Heating boilers – Part 5: Heating boilers for solid fuele, hand and automatically
stocked, nominal heat output of up to 300 kW – Terminology, requirements,
testing and marking
b) to the chimney
ČSN 73 4201 Chimneys and flue gas ducting– designing, implementation and connection of
fuel consumers.
c) regarding the fire regulations
ČSN 06 1008 Fire safety of heat installations.
EN 13501-1 + A1 Fire classification of construction products and building elements – Part 1:
Classification using test data from reaction to fire tests.
d) to the electrical network
ČSN 33 0165 Electrical regulations. Marking the conductors with colours or digits.
Implementing regulations.
ČSN 33 1500 Electrical regulations. Electrical equipments revision
ČSN 33 2000-3 Electrical regulations. Electrical equipments Part 3: Setting the basic
characteristics.
ČSN 33 2000-4-41 Electric equipments: part 4: Safety chap. 41: Protection against electrical
accident.
ČSN 33 2000-5-51 ed.2 Electrical regulations. Electrical equipments construction.
ČSN 33 2130 Electrical regulations. Internal wiring.
ČSN 33 2180 Electrical regulations. Connection of electrical devices and appliances.
ČSN 34 0350 Electrical regulations. Regulations for mobile connections and cord extension
sets.
EN 60079-10 Electrical apparatus for explosive gas atmospheres – Part 10: Classification of
hazardous areas.
EN 60 252-1 AC motor capacitors – Part 1: General – Performance, testing and rating –
Safety requirements – Guide for installation and operation.
EN 60 335-1 ed.2 Household and similar electrical appliances – Safety – Part 1: General
requirements.
EN 60 335-2-102 Household and similar electrical appliances – Safety – Part 2-102: Particular
requirements for gas, oil and solid-fuel burning appliances having electrical
connections.
EN 60445 ed. 3 Basic and safety principles for man – machina interface, marking and
identification – Identification of equipment terminals and conductor terminations
EN 60446 Basic and safety principles for man – machina interface, marking and
identification – Identification of conductors by colours or numerals
e) to the system of HWS heating
ČSN 06 0320 Heating systems in buildings – Hot water preparation – Designing and planning
ČSN 06 0830 Heating systems in buildings – Safety devices.
ČSN 73 6660 House water plumbing

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4.2 Positioning possibilities
The installation of the boiler must comply with all requirements of ČSN 06 1008
Boiler positioning with regard to the fire regulations:
1. Positioning on the floor made of incombustible material
−The boiler can be installed on a fireproof and thermally instulating bottom which exceeds the boiler
platform by 20 mm on the sides.
−If the boiler is installed in a cellar, we recommend to install it on a minimum 50 mm high retaining wall
(bedding). The boiler must be installed straight, possible unevenness of the retaining wall can be
eliminated by means of the engine bed regulation screw.
2. Safety distance from the combustible materials
−when installing and operating the boiler it is necessary to keep a safety distance of 200 mm from the
materials of combustibility grade A1, A2, B and C (D);
−for easily combustible materials of combustibility grade E (F), which quickly burn and burn
themselves even after removal of ignition source (such as paper, cardboard, asphalt and tar paper,
wood and wood-fiber boards, plastics, floor coverings) the safe distance has to be doubled, i.e. to
400 mm;
−safe distance should be doubled as bulb where the grade of reaction to fire has not been proved.
Tab. no. 5 Grade of reaction to fire
Grade of reaction to fire Examples of building materials and products included in the reaction to fire
(Extract from EN 13 501-1 + A1)
A1 – incombustible Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters, …
A2 – combustible with difficulty
acumin, izumin, heraklit, lignos, boards and basalt felt, fibreglass boards,...
B– hardly combustible Beech and oak wood, hobrex boards, plywood, werzalit, umakart, sirkolit,...
C (D) – medium combustible Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,...
E (F) – easily combustible Asphaltboard, fibreboards, cellulose materials, polyurethane, polystyrene,
polyethylene, PVC,…
Boiler positioning with regard to the necessary handling space:
•Basic environment AA5 / AB5 according to ČSN 33 2000-3
•In front of the boiler there must be left a minimum handling area of 1000 mm
•The minimum distance between the rear part of boiler and wall 400 mm.
•On the side of fuel reservoir there must be left min. space 800 mm in case of screw feed removal
•Minimum distance from the left side wall 100 mm
•Above the boiler in min. 450 mm to clean the convection part of boiler exchanger.
Boiler positioning with regard to electricity network:
•The boiler must be placed so that the plug in socket (230V/50Hz) is always accessible.
Fig. no. 4 Boiler positioning in the boiler room

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Fuel positioning:
•For the right burning in the boiler it is necessary to use the dry fuel. The producer recommends to
store the fuel in the cellar area or at least under the shelter.
•It is interdicted to store the fuel behind the boiler or next to the boiler within a distance smaller than
400 mm,
•The producer recommends to keep the distance between the boiler and fuel min. 1 000 mm, or to store
the fuel in a different room that where the boiler is installed.
It must be ensured the continuous air supply into the room, where the boiler is installed for burning and
eventual ventilation (the air consumption of EKORET SAPHIR boiler makes for 15 kw boiler 45 m3. h-1, and
for 25 kW boiler 75 m3. h-1). The heating system pipe connection, eventually the heater heating insert
connection, must be done by the authorized person.
CAUTION: When connecting the boiler to the heating system there must be installed a drain tap in the
lowest point and as near as possible to the boiler.
Fig. no. 5 Boiler (the right version with a small reservoir) with the open fuel reservoir

11
In case the assembled body boiler with boiler pedestral can not be placed into the boiler room there is
necessary to proceed by the following method (see Fig. no. 6):
•Disassemble arch welder including sealing by unbolting the nuts M10 and washers.
•Unbolt nuts M8 with washers, that connect the boiler body with the boiler pedestral together. At
15 kW boiler unbolt boiler body by the help of screw M6 x 16 and washers from distance plate.
•Take off boiler body (shell).
•Clean boiler body and boiler pedestral from old boiler binding material.
•This way ready pedestral place in the boiler room.
•Apply binding material on the boiler pedestral and placet the boiler body. Tightness of the pedestral
with boiler body is very important.
•Than screw up the arch welder including sealing.
•Screw up the boiler body to the pedestral by the help of nuts M8 and at 15 kW boiler vision screw up
the boiler body to the distance plate by the help of the screws M6 x 16.
1 – Pedestal with a burner
2 – Boiler shell with a smoke adapter
3 – Washer 8,4
4 – Nut M8
5 – Sealing 60x48x2
6 – Arch welder
7 – Washer 10,5
8 – Nut M10
9 – Check plate
10 – Screw M8x16
11 – Washer 6,4
12 – Screw M6x16
Fig. No. 6 Boiler pedestal and boiler body disassembly

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4.3 Hydraulic connection diagram
Fig. no. 7 Hydraulic diagram with HW preparation– Pump heating circuit
Fig. no. 8 Hydraulic diagram without HW preparation– Pump heating circuit
Legend to Fig. no. 7 and 8:
A6 QAA 88 device
BT1 Safety thermostat
B2 Boiler outlet temperature sensor
B3 HW temperature sensor
B5 Fuel feeder temperature sensor
B9 Outside temperature sensor
EX Expansion vessel
M1 Fuel feeder motor
M2 Air fanmotor
PV Safety valve
Q1 Boiler primary circuit pump
Y3 HW heating three-way valve
V1 Thermostatic valve
ZK Clack valve

13
Fig. no. 9 Hydraulic diagram with HW preparation– Mixing heating circuit
Fig. no. 10 Hydraulic diagram without HW preparation– Mixing heating circuit
Legend to figures no. 9 and 10:
A6 QAA 88 device
BT1 Safety thermostat
BT3 Thermostat HW
B1 Heating branch temperature sensor
B2 Boiler outlet temperature sensor
B5 Fuel feeder temperature sensor
B9 Outside temperature sensor
EX Expansion vessel
M1 Fuel feeder motor
M2 Air fan motor
PV Safety valve
Q1 Boiler primary circuit pump
Q2 Heating circuit pump
Q3 HW charging pump
Y1 Heating circuit three-way mixing valve
drive
V1 Thermostatic valve
V2 Stop valve
ZK1 Clack valve

14
Note:
Select the dimension of shorting pipe with stop valve V2 up to the half of other piping dimension. Shorting
pipe is necessary. In case the thermostatic valve V1 is only closed through the boiler and mixing valve Y1 is
open to the heating circuit the heating circuit with the heating circuit pump will be secured through this
shorting pipe.
Sensor cables can anyhow be shortened or prolonged provided following principles are observed:
-do not cut the sensor cable in the distance shorter than 0,5 m from the jacket;
-cable sensor prolongation by more than 10 m is not recommended;
-CMSM – H 2 x 0,5 mm cable is recommended for cable prolongation;
-Cable connection in case of prolongation is to be done very carefully. Ensure the conductive joint
when you shorten or prolong the cable.
Note to the three-way valve V4044C (V4044F) made by Honeywell:
Connection AB –heating water outlet from boiler
Connection A – outlet to the water heater
Connection B – outlet to the heating circuit
Note to the three-way mixing valve VBI31.20 with drive SQK34.00 (Siemens):
After the connection of the three-way mixing valve it is necessary to check whether the valve opens in case
heating is required. If it be to the contrary revert the phases L (Y1) and L1 (Y2). It is also important to observe
the correct hydraulic connection of three-way mixing valve according to the enclosed manual.
Recommendation for the check!
Select the value 4 in P 20 parameter which means boiler manual operation. At this type of operation HMI
ACX84.910 ALG service unit displays the word Wood.
Three-way mixing valve must open up to maximum into the heating circuit.
Floor heating
Floor heating can be used in mixing heating circuit. Following parameters have to be set:
-Parameter P 21 – Slope of heating curve to the value 0,8,
-Parameter P 76 – Minimum temperature of heating circuit (can be reduced to the value of 20 oC),
-Parameter P 77 – Maximum temperature of heating circuit max. 40 oC.
In case of superfluous heat withdrawal into the heating circuit the temperature will be mixed to the maximum
set temperature of the heating circuit.
Note: In case of radiators and floor heating combination the floor heating must have its own regulation
including the three-way mixing valve.
5. Boiler commissioning – instructions for the contracting service
organization
Boiler commissioning must be only done by a contracting service organization authorized to do this
activity.
5.1 Delivery and accessories
Standard accessories:
•Boiler shell with a pedestal
•Fuel feeder set
•Fuel reservoir
•Service board SIMBOX WP 8GB1 373-3 – set incl. electric pack
•QAA 88 device
•Fan
•Screw with a cup head and cross-slot M6 x 16 (4 pcs) for fan gripping to the flange of feeder
•Washer 6,4 (4 pcs) for ventilator mounting to the flange of feeder
•Nut M6 (4 pcs) for ventilator mounting to the flange of feeder
•Safety thermostat
•Screw with a cup head and cross-slot M4 x 6 (2 pcs) for safety thermostat gripping
•SK tape (2 pcs)
•Boiler jacket including ash-tray
•connection accessories for boiler drum shell – spring clip (4 pcs), junction stud (4 pcs), screw M5 x 25
(4 pcs), washer 5,3 (4 pcs), screw M4 x 6 (2 pcs), screw ST4,8 x 13 (11 pcs)

15
•Ceramic plates (5 pcs.)
•Clearing brush
•Binding material
•Distance clamp (2 pcs.)
•Screws ST 4,8 x 13 (2 pcs.) for distance clamp gripping
•Bushing PG 13,5 (2 pcs.)
•Bushing PG 11 (2 pcs.)
•Stud bolt M10 x 30 (4 pcs), washers 10,5 (4 pcs) and nuts M10 (4 pcs) for gripping of fuel feeder set to
the pedestal
•Hexagon screws M8 x 20 (4 pcs.), washers 8,4 (4 pcs.) and nuts M8 (4 pcs) for gripping of fuel reservoir
to the fuel feeder
•Screws M6 x 16 (4 pcs), washers 6,4 (4 pcs) and nuts M6 (4 pcs) for attaching the service board to the
fuel tank
•Inlet and outlet valve 1/2 "
•Cast iron grate (large diameter)
•Silicon sealant – a tube 310 ml
•Thermostatic valve BVTS (Danfoss) or TS 130 (Honeywell) or STS 20 (Watts)
•Boiler sensor QAZ 36.526/109
•Sensor against fuel fire penetration QAZ 36.526/109
•Outside sensor QAC 34/101 (required for equitherm control of the pump and mixing heating circuit)
•Thermostatic valve (filling valve) - series VTC312 (external thread) made by ESBE (minimum
temperature of return water is 45 oC) (ord. code: 5100 15 00)
•Sticker - LED for the safety thermostat signalization
•Boiler operation and installation manual, a guarantee list is its part
•List of contract service organization
•Thermostatic valve TS 130 (STS 20) (1 pc)
Obligatory accessories for mixing heating circuit (not included in the delivery):
•Heating branch sensor QAD 36/101 (Siemens)
•Three-way mixing valve VBI31.20 with drive SQK34.00 (Siemens)
•Water heater thermostat type: 7K1.6R326.00A (capillary length: 1000 mm, range: 0 - 60 oC) (in case
boiler will be used for HW heating)
Obligatory accessories for pump heating circuit (not included in the delivery):
•Hot water sensor QAZ36.526/109 (in case boiler will be used for HW heating) (Siemens)
•Three-way valve V4044F (in case boiler will be used for HW heating) (Honeywell). – in this case only the
phase, working and protective conductors will be connected. Note: also V4044C valve can be used.
Obligatory accessories (not included in the delivery):
•Safety valve (1 pc) according to the maximum boiler operating overpressure (see tab. no. 1)
Optional:
•HMI (ACX84.910/ALG) service unit for Saphir regulator operation – Siemens
•Circuit pump UPS 25-40
•Water heater (see the VIADRUS division offer)
The optional boiler equipment is not included in the boiler standard price.

16
5.2 Boiler mounting
5.2.1 Installation of boiler drum with the basement
1. Position horizontally the boiler shell with the pedestal on a sockle.
2. Apply the binding material on the bottom of cast iron grate and settle the mixer down. There is necessary
a tightness of cast iron grate and mixer.
5.2.2 The ceramic plates mounting
1. Insert the ceramic plates, which are delivered out of boiler, above the burner space in the boiler.
2. The ceramic plates mounting is evident from fig. no. 11.
1. Arc
2. Ceramic plate front
3. Ceramic plate rear
4. Ceramic plate sideí
Fig. no. 11 The burner space cut of boiler 15 and 25 kW
5.2.3 Boiler jacketing of (see. Fig. no. 12)
1. Take out the shells from the cardboard package.
2. Mount 4 pcs of connecting spindles into the left and right side part of shell and insert the insulation.
3. Set the left and right side part of shell incl.the insulation on the anchor bolts of exchanger (fix the
bushing PG 13,5 according to connection) and screw be means of 4 pcs of screws M5 x 25 and 4 pcs
washer 5,3 to stand.
4. Mount the spring clamps into the front shell and insert the insulation. Fix the front part of the shell
incl.the insulation and to the side parts of shell.
5. Fix the emergency thermostat by use of 2 pcs of screws M4 x 6 to the back part of shell and screw it to
the side parts of shell by means of 11 pcs screws ST 4,8 x 13. (Note: The capillary tube of the safety
thermostat must be led between the jacket and insulation). The electrical connection of the safety
thermostat will be carried out before screwing the rear part of the jacket. The cable passes along the
grommet through the side part of the jacket either in left or right side part, depending on the design. The
boiler outlet temperature sensor must be placed into a pit of the boiler through the grommet in the side
part of the jacket (either in left or right side part, depending on the design) also before the jacketing.
6. Insert the insulation into the shell cover and the whole set prepared in this way put on the boiler.

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1 – Boiler without shell
2 – Left side part of shell
3 – Insulation of shell left side part
4 – Right side part of shell
5 – Insulation of shell right side part
6 – Connecting spindle (4 pcs)
7 – Spring clamp (4 pcs)
8 – Washer 5,3 (4 pcs)
9 – Screw M5x25 (4 pcs)
10 – Front part of shell
11 – Insulation of shell front part
12 – Cover of the shell
13 – Cover of the shell insulation
14 – Back part of shell
15 – Insulation of shell back part
16 – Emergency termostat
17 – Screw M4x6 (2 pcs)
18 – Screw ST 4,8x13 (11 pcs)
19 – Bushing PG 13,5 (2 pcs)
Fig. no. 12 Boiler jacketing

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5.2.4 Fuel reservoir and feeder assembly
1. Fuel feeder
2. Stud bolt M10x30 (4 pcs)
3. Washer 10,5
4. Nut M10 (4 pcs)
5. Ventilator
6. Screw M6x16 (4 pcs)
7. Washer 6,4 (4 pcs)
8. Nut M6 (4 pcs)
9. Fuel reservoir
10. Screw M8 x 20 (4 pcs)
11. Washer 8,4 (8 pcs)
12. Nut M8 (4 pcs)
13. Spacing clip (2 pcs)
14. Screw ST 4,8 x 13 (2 pcs)
Fig. no. 13 Fuel reservoir and feeder assembly
Notice:
At assembly of fuel feeder to the pedestral and fuel reservoir to the fuel feeder position everything
horizontally and afterwards provide a final drawing up the screws and nuts.
1. Apply binding material on the boiler pedestral, afterwards assembly a set of fuel conveyer to the boiler
pedestral. Further assembly a fan.
2. Apply the binding material on set of fuel conveyor on the surface of fuel reservoir binding face. Settle the
fuel reservoir and tighten the screw.
3. Fix distance clamps for caballing on the sides of fuel reservoir.
ATTENTION!!! Before the fuel reservoir is loaded with fuel it is necessary to check the free
rotation of fuel feed screw.

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5.2.5 Mounting of the service board to the fuel reservoir
Fig. no. 14 Mounting of the service board to the fuel reservoir
1. Screw the service board to the side of fuel reservoir.
2. Carry out the wiring system according to diagram in chap. 5.2.9. Lead the cables by means of spacing
fasteners gripped to the side of fuel reservoir.
3. To stick the sticker – LED of the safety thermostat signalization (5) on the switchboard (1).
5.2.6 Mounting of cleaning tools
The ordinary assembly tools and leather gloves are to be used for mounting and demounting of the brush and
spike on tang (if it is included in the delivery).
5.2.7 Assembly of the emergency fire extinguishing equipment
In the cover of the cleaning opening there is a pipe for water supply with 1/2“ connection which serves for TS
130 (STS 20) valve interconnection. The interconnection is to be carried out by means of a flexible (stainless)
hose. It must regard a detachable connection of the valve with a pipe in the cover of the cleaning opening by
reason of the possibility of disassembly. The valve sensor is to be installed in the sensor holder which is
positioned on the fuel feeder.
The function of the emergency fire extinguishing equipment :
In case of fire penetration to the feeder (temperature on the feeder reaches 95 oC), TS 130 (STS 20) valve
switches on the cold water supply to the hopper and the burning fuel is extinguished; then the water supply is
stopped. Then it is necessary to dismantle the engine with the worm shaft and stainless insert and clean
them. It is followed by the reassembly. Check the valve: if it still lets water into the reservoir replace the valve.
1. Service board
2. Screw M6 x 16 (4 pcs)
3. Washer 6,4 (4 pcs)
4. Nut M6 (4 pcs)
5. Sticker – LED of the safety
thermostat signalization

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Fig. no. 15 Assembly of the emergency fire extinguishing equipment
5.2.8 Boiler conversion from right-hand design to the left-hand design
Boiler conversion after delivery before installation:
−We remove the grate and pull out the burner with mixer from the basement (the connection accessories
are as follows: 6 pc screw M10 x 30, 12 pc washer a 10,5, 6 pc nut M10).
−We unscrew the blind flange from the left side of the basement and screw it to the right-hand side (the
connection accessories are as follows: 4 pc screw M10 x 30, 8 pc washer 10,5, 4 pc nut M10). The blind
flange with basement must be sealed with mastic.
−We apply mastic to the burner with mixer flange and we put the burner into the basement from the left-
hand side and screw it (the connection accessories are as follows: 6 pc screw M10 x 30, 12 pc washer
10,5, 6 pc nut M10).
−We remove the old mastic from the grate. We apply a reasonable quantity of new mastic to the bearing
surfaces and we mount the grate in the burner. (Note: In front view to boiler the grate trimming must
always be to the rear wall)
−Then we proceed according to chap. 5.2.
1 – Clearing opening cover
2 – Sensor holder
!
!!
!
Apply boiler mastic to the point
marked with caterpillar and put the
grate on the retort with mixer. It is
necessary to ensure the tightness
between the burner and grate.