Viadrus HERCULES DUO Instruction Manual

Hercules U26
Návod k obsluze
HERCULES DUO
MANUAL FOR BOILER OPERATION
AND INSTALLATION

Table of contents: page.
1. Use of boiler and its advantages.................................................................................................................3
2. Boiler technical data ....................................................................................................................................3
3. Description...................................................................................................................................................7
3.1 Boiler construction...............................................................................................................................7
4. Positioning and installation........................................................................................................................10
4.1 Regulations and directives ................................................................................................................10
4.2 Positioning options ............................................................................................................................11
4.3 Hydraulic connection diagram...........................................................................................................13
5. Boiler installation........................................................................................................................................14
5.1 Delivery and accessories...................................................................................................................14
5.2 Installation procedure........................................................................................................................15
5.2.1 Installation of boiler drum with the basement..............................................................................15
5.2.2 Shells assembly..........................................................................................................................17
5.2.3 Fuel reservoir assembly..............................................................................................................19
5.2.4 Mounting of the service board to the fuel reservoir.....................................................................20
5.2.5 Mounting of cleaning tools ..........................................................................................................20
5.2.6 Mounting of emergency fire extinguishing equipment.................................................................21
5.2.7 Boiler conversion from right-hand design to the left-hand design...............................................21
5.2.8 Wiring diagram............................................................................................................................26
6. Boiler operation by user.............................................................................................................................28
6.1 Control, regulation and security elements.........................................................................................28
6.1.1 Saphir regulator...........................................................................................................................28
6.1.2 Safety thermostat........................................................................................................................28
6.1.3 Temperature sensor on the fuel feeder ......................................................................................29
6.1.4 Emergency fire-extinguishing system .........................................................................................29
6.1.5 Forced withdrawal of superfluous heat .......................................................................................29
6.1.5.1 Forced withdrawal of superfluous boiler heat ......................................................................29
6.1.5.2 Forced withdrawal of superfluous water heater heat...........................................................29
6.2 HMI (ACX84.910/ALG) service unit for Saphir regulator operation...................................................29
6.2.1 Positioning and connection to Saphir regulator...........................................................................30
6.2.2 Service elements.........................................................................................................................30
6.2.3 Configuration...............................................................................................................................31
6.2.4 Structure......................................................................................................................................31
6.2.5 Changing parameters .................................................................................................................36
6.2.6 Failures .......................................................................................................................................36
6.4 Service board ....................................................................................................................................38
6.5 Control activity before start................................................................................................................38
6.5 Setting of parameters before the equipment start-up........................................................................39
6.6 Boiler putting into operation...............................................................................................................40
6.7 Superior control.................................................................................................................................41
7. Important warnings....................................................................................................................................42
8. Maintenance..............................................................................................................................................43
9. Instructions for product disposal after expiration of its lifetime..................................................................43
10. Guarantee and liability for defects .........................................................................................................44

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Dear customer,
Thank you for the purchase of automatic solid fuel boiler HERCULES DUO whereby you expressed your
trust to VIADRUS a.s.
Please read this manual (particularly chapter no. 6 – Boiler operation by user, chapter no. 7 – Important
warnings and chapter no. 8 – Maintenance) that provides you with instructions for the proper use of your new
product that you have to get familiarized with at the very beginning. Please follow the current information and
take notice of instructions issued by the manufacturer or installation company that installed your boiler so that
the long-life trouble-free operation of your boiler can be guaranteed both to your and our satisfaction.
1. Use of boiler and its advantages
Hot-water automatic solid fuel boiler HERCULES DUO is destined particularly for heating the family houses,
cottages, office buildings, small premises etc.
Boiler advantages
• automatic boiler operation, equithermal control
• possibility of HW heating
• possibility of biomass – wood pellets combustion
• mechanical fuel fedd from inbuilt reservoir
• simple, time non-consuming boiler attendance and maintenance
• low operating costs
2. Boiler technical data
Tab. no. 1 Boiler dimensions, technical parameters
Size 4 sect. 5 sect. 6 sect. 7 sect.
Boiler weight
- small reservoir kg 465 517 569 621
- large reservoir kg 496 547 598 649
Water space volume dm
3
60 71,9 83,8 95,8
Diameter of smoke socket mm 156
Fuel reservoir capacity – small dm
3
269
Fuel reservoir capacity – large dm
3
528
Boiler dimensions
(including small fuel reservoir):
width x depth x height mm See fig. no. 1
Boiler dimensions
(including large fuel reservoir):
width x depth x height mm See fig. no. 1
Filling hole dimensions – small reservoir mm 422 x 545
Filling hole dimensions – large reservoir mm 422 x 1210
Boiler degree acc. to EN 303 - 5 - 3
Working water overpressure bar (kPa) 2,5 (250)
Testing water overpressure bar (kPa) 5 (500)
Recommended operating temperature of
heating water °C 50 – 85 65 – 85
Minimum return water temperature °C 45 50
Boiler hydraulic loss
mbar 0,72 0,96 1,32 1,59
Noise level dB Doesn´t exceed level 65 dB (A)
Chimney draught
mbar 0,15 – 0,20 0,20 – 0,25
Boiler connections – heating water Js G 2”
– return water Js G 2”
Connecting voltage
1/N/PE 230 V AC 50 Hz TN - S
Electric input W 100
Electric coverage IP 44

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Tab. no. 2a)Thermal technical parameters of the boiler during combustion of brown coal
Size 4 sect. 5 sect. 6 sect. 7 sect.
Nominal output kW 20 25 30 35
Regulated output kW 6 - 20 7,5 - 25 9 - 30 10,5 - 35
Fuel consumption at nominal output kg.h
-
1
4,5 5,6 6,65 7,65
Fuel consumption at minimum output kg.h
-
1
1,4 1,7 2,02 2,32
Fuel consumption in upkeep regime kg.h
-
1
0,1 0,1 0,1 0,1
Fuel value MJ.kg
-
1
19,17 19,17 19,17 19,17
Burning time at nominal output – small
reservoir h 36 h 15 min 29 h 10 min 24 h 30 min 21 h 15 min
Burning time at nominal output – large reservoir h 71 h 30 min 57 h 20 min 48 h 15 min 42 h
Efficiency % up to 83,1 up to 85 up to 87 up to 89
Flue gas temperature °C 115 – 195 100 – 180 95 – 170 90 – 160
Flue gas mass flow at outlet kg.s
-
1
0,007 – 0,015 0,009 – 0,019 0,011 – 0,022 0,013 – 0,025
Tab. no. 2b)Thermal technical parameters of the boiler during combustion of black coal
Size 4 sect. 5 sect. 6 sect. 7 sect.
Nominal output kW 20 25 30 35
Regulated output kW 6 - 20 7,5 - 25 9 - 30 10,5 - 35
Fuel consumption at nominal output kg.h
-
1
3,4 4,21 5 5,8
Fuel consumption at minimum output kg.h
-
1
1,03 1,28 1,52 1,76
Fuel consumption in upkeep regime kg.h
-
1
0,13 0,13 0,13 0,13
Fuel value MJ.kg
-
1
25,1 25,1 25,1 25,1
Burning time at nominal output – small
reservoir h 45 h 10 min 36 h 30 min 30 h 35 min 26 h 25 min
Burning time at nominal output – large reservoir h 88 h 40 min 71 h 35 min 60 h 15 min 52 h
Efficiency % up to 84,2 up to 85 up to 86 up to 87
Flue gas temperature °C 110 – 195 90 – 170 85 – 165 80 – 150
Flue gas mass flow at outlet kg.s
-
1
0,007 – 0,014 0,010 – 0,017 0,012 – 0,021 0,014 – 0,024
Tab. no. 2c)Thermal technical parameters of the boiler during combustion of wood pellets
Size 4 sect. 5 sect. 6 sect. 7 sect.
Nominal output kW 20 25 30 35
Regulated output kW 6 - 20 7,5 - 25 9 - 30 10,5 - 35
Fuel consumption at nominal output kg.h
-
1
4,85 6,06 7,26 8,47
Fuel consumption at minimum output kg.h
-
1
1,5 1,84 2,21 2,57
Fuel consumption in upkeep regime kg.h
-
1
0,35 0,35 0,35 0,35
Fuel value MJ.kg
-
1
17 17 17 17
Burning time at nominal output – small
reservoir h 27 h 10 min 21 h 45 min 18 h 10 min 15 h 30 min
Burning time at nominal output – large reservoir h 53 h 20 min 42 h 40 min 35 h 35 min 30 h 30 min
Efficiency % up to 87,3 up to 87,4 up to 87,5 up to 87,5
Flue gas temperature °C 95 – 175 90 – 165 90 – 160 85 – 145
Flue gas mass flow at outlet kg.s
-
1
0,007 – 0,015 0,009 – 0,018 0,010 – 0,022 0,012 – 0,025
! Important warning:
The stated thermal technical parameters vary in dependance on the sort, quality and moisture of
used fuel. Therefore some corrections might be necessary when setting the stoking cycle (time for
fuel feed versus time for fuel afterburning). For example if unburned fuel slivers appear on the grate
and in the ash-pan it stands to reason that stoking is faster than burning and the stoking cycle must
be reduced – see parameters description
Parameters of prescribed fuel – fuel used for tests in SZÚ:
• water content max. 12 % (hard coal, wood pellets),
max. 20 % (lignite)
12 – 20 % (wood)
• volatile combustible content 28 – 40 %
• ash deformation by melting temperature > 1150 °C
• low sintering capacity
• small moisture expansion

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Tab. no. 3 Specified fuel
Fuel Sort of fuel Granularity
[mm] Fuel value [MJ.kg
-1
]
Hard coal Peas 10 – 25 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
Fuel Granulari ty
[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
combustibl
e matter [%]
Screened lignite –
nub 2 10 - 25 17,6
9,8
(in
anhydrous
condition)
max. 20 0,77 0,44 15,1 15,71
Pellets must conform at least to one of following directives or standards:
Directive no. 14-2000 MŽP ČR
DIN 517 31
ÖNORM M 7135
Specified granularity of pellets 6 to 8 mm
Water content in fuel max. 12 %
Ash content max. 1,5 %
ATTENTION! A low fuel quality can distinctly negatively influence the boiler output and emission
parameters.

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Length 4 5 6 7
L [mm] 754 865 976 1087
L1 [mm] 498 609 720 831
Fig. no. 1 Main dimensions of HERCULES DUO boiler (right-hand version)
(dimensions after the slash apply to the variant with a large reservoir)

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3. Description
3.1 Boiler construction
1. Basement
2. Burner
3. Boiler drum
4. Smoke adapter
5. Cleaning door
6. Cleaning door
7. Ash-pan door
8. Smoke control draw rod
9. Basement shell
10. Boiler drum shell incl. ash-pan
11. Safety thermostat
12. Turbulators
13. Partition of the combustion chamber front
14. Partition of the combustion chamber
15. Deflector
16. Ash-pan
17. Fuel feeder
18. Geared engine
19. Fan
20. Fuel reservoir
21. Service board
22. Filling and drain taps G ½“
23. Heating a return water flanges
24. Safety valve
25. Stopper with male thread Js 1 / 2 "
26. Stopper of boiler Js 1 / 2 "
27. Stopper of keg Ø 52.5 mm
28. Hook
29. Ceramics front
30. Ceramics lower
31. Fireclay top plate
32. Insulation back
Fig. no. 2a) Main components of boiler

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Fig. no. 2b) Main components of boiler
The pressure components of boiler correspond to strength requirements according to:
EN 303-5 Boilers for central heating– Part 5: Solid fuel boilers for central heating with manual or
automatic feed and nominal heat output maximum 300 kW – Terminology, requirements,
testing and marking.
The cast iron body positioned on the basement welded of steel sheets is the core part of the boiler. The boiler
drum consists of sections connected by means of pressed-on boiler inserts of 56 mm diameter and secured
by anchor bolts. The sections form the combustion space, water space and convective part. Heating water
inlet and outlet are situated at the rear of the boiler by means of two flanges 2” for connection to the heating
system. The temafast Ø 60 x 48 x 2 mm sealing is between the boiler and flange.
The rear boiler section has the smoke adapter and heating water flange in the upper part and the return water
flange is in the lower part of the basement. The cleaning door and ash-pan door are fastened to the front
section. The folding grate is positioned behind the cleaning door (6).
Under the cast iron body there is positioned the burner with mixer (see. Fig. no. 3) that consists of cast iron
grate and retort. We use 4 types of cast-iron grates with regard to the size of the boiler and fuel used. The
various types of grates are marked with an identification symbol, see Figure 3 - a detail In table No. 5 there is
shown the assignment of individual types of grates to a given boiler and fuel type. The fuel is fed from the
reservoir through the feed screw emptying into retort on the cast iron grate.
The ash-pan drawer is under the combustion chamber. Next to the boiler there is positioned the fuel reservoir
that empties into fuel feed screw.
Fan for combustion air is positioned behind the fuel reservoir and is connected to the burner. Fan has control
by SAPHIR regulator.
All components (boiler drum, basement) are insulated by means of health non-detrimental mineral insulation
that reduces the heat transmission losses.
The high-quality komaxit spray is used for boiler shell colour treatment.

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The boiler is made in left & right design.
1. Mixer
2. Retort
3. Countersunk screw with internal hexagon M8 x 20
4. Cast iron grate
5. Sealing
6. Cap
7. Washer 8,4
8. Screw M8 x 20
Detail A – Identification symbol
Fig. no. 3 Burner with mixer
Tab. No. 5 Assignment of the type of grate according to size of boiler and type of fuel
Marking of the grate
(identification symbol)
Number of boiler sections and type of fuel
4 sections 4 sections 5 sections 6 a 7
sections 6 a 7 sections
black coal
brown coal pellets black coal
brown coal
pellets pellets black coal
brown coal
no identification symbol x
1 identification symbol x
2 identification symbols x
3 identification symbols x x

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4. Positioning and installation
4.1 Regulations and directives
The solid fuel boiler can only be installed by a company holding a valid license for boiler installation
and maintenance.
The project according to valid regulations must be elaborated for installation.
The heating system must be filled with water that meets the requirements of ČSN 07 7401 and
especially its hardness must not exceed the desired parameters.
Recommended values
Hardness mmol/l 1
Ca
2+
mmol/l 0,3
Total Fe + Mn concentration mg/l (0,3)*
*) recommended value
WARNING!!! The use of anti-freeze mixture is not recommended by the manufacturer.
In case of two-way safety device response regarding the water refill permit in case the water does not
conform to ČSN 07 7401 it is necessary to treat water in system so that it again conforms to this
standard.
a) regarding the heating system
ČSN 06 0310 Thermal systems in buildings – Design and installation
ČSN 06 0830 Thermal systems in buildings – Protecting devices
ČSN 07 7401 Water and steam for thermal energetic devices with steam working pressure up
to 8 MPa.
EN 303-5 Boilers for central heating – Part 5: Solid fuel boilers for central heating with
manual or automatic feed and max. 300 kW nominal thermal output:
terminology, requirements, testing and marking.
b) regarding the chimney
ČSN 73 4201 Designing the chimneys and smoke flues
c) regarding the fire regulations
ČSN 06 1008 Fire safety of thermal equipments
EN 13501-1 + A1 Fire classification of construction products and building elements – Part 1:
Classification using test data from reaction to fire tests.
d) regarding the electric network
ČSN 33 0165 Electrical regulations; marking the leading wires by colours or digits;
implementing regulations
ČSN 33 1500 Electrical regulations; revision of electrical equipments
ČSN 33 2000-1 ed. 2 Low-voltage electrical installations – Part 1: Fundamental principles,
assessment of general characteristics, definitions.
ČSN 33 2000-4-41 ed. 2 Low voltage electrical installations - Part 4- 41: Protection for safety - Protection
against electric shock
ČSN 33 2000-5-51 ed. 3 Electrical installations of buildings – Part 5-51: Selection and erection of
electrical equipment – Common rules
ČSN 33 2130 ed. 2 Low-voltage electrical installations – Internal electric distribution lines
ČSN 33 2180 Electrical regulations: Connection of electric instruments and appliances
ČSN 34 0350 ed. 2 Safety requirements for flexibile cords and cables
EN 60 079-10 Electrical regulations: Regulations for electrical equipments at the places with
explosion hazard with flammable gases and vapours.
EN 60 252-1 Capacitors for AC motors – Part 1: In general – Design, testing, dimensioning –
Safety requirements – Instructions for installation and operation.
EN 60 335-1 ed.2 Electric appliances for household and similar purposes – Safety – Part 1:
General requirements
EN 60 335-2-102 Electric appliances for household and similar purposes – Safety – Part 2-102:
Special demands on appliances containing the electric connections and burning
the gas, oil and solid fuels
EN 60445 ed. 4 Basic and safety principles for man-machine interface, marking and
identification – Identification of equipment terminals, conductor terminations and
conductors
EN 61000 – 6 – 3 EMC – Part 6 – 3: Basic standards – Emissions – residaytial, commercial and
light industry environment.