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

4
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.

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EN 61000 -3 – 2 EMC - Part 3 – 2: Limits – Limits for harmonic currents emissions (device with
input phase current up to 16 A inclusive).
EN 61000 – 3 –3 EMC – Part 3 - Limits - section 3: Specifies the limitation of voltage fluctuation
and flicker in low-voltage supply systems for equipment with a rated input
current greater than 16 A.
e) regarding the system for HW heating
ČSN 06 0320 Thermal systems in buildings– Hot water preparation– Design and project
engineering
ČSN 06 0830 Thermal systems in buildings – Protecting devices
ČSN 75 5409 Water installations inside buildings
4.2 Positioning options
The boiler is equipped with the movable mains supply and plug. Boiler according to EN 60 335–1 ed.
2 Art. 7.12.4 must be positioned in such a way that the plug is accessible.
Boiler positioning in the living space (including corridors) is prohibited!
The installation of the boiler must comply with all requirements of ČSN 06 1008
Boiler positioning with regard to fire regulations:
1. Positioning on the floor made of incombustible material
−put the boiler on a fireproof and heat-insulating pad exceeding the boiler plan by 20 mm on the sides;
−In case the boiler is installed in a cellar it should be put on a minimum 50 mm high substructure. The
boiler must be installed straight, any possible inequalities of retaining wall are eliminated by means of
adjustable foot (see Figure No. 11)
2. A safe 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. 6 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 2000-1 ed. 2;
•min. 1000 mm handling space must be left in front of the boiler;
•minimum distance between the boiler rear side and wall is 400 mm;
•a gap min. 1000 mm is left on the side of fuel reservoir in case of feed screwremoval;
•minimum distance from the side wall is 100 mm;
• at least 450 mm are left above the boiler.
Boiler positioning with regard to electrical network(mains):
•The boiler must be placed in such a way that the plug in socket (230V/50Hz) is always accessible.
Placing of fuel:
•Dry fuel has to be used in order to ensure its proper burning in the boiler. Fuel stored in cellar or at
least sheltered is recommended by the manufacturer;
•It is out of the question to store fuel behind the boiler or next to the boiler in the distance shorter than
400 mm;
•Min. 1 000 mm distance kept between the boiler and fuel is recommended by the manufacturer or the
fuel has to be stored in a room separated from the boiler-room.

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It must be ensured the continuous air supply into the room, where the boiler is installed for burning and
eventual ventilation
Air consumption of HERCULES DUO boiler:
Number of section 4 5 6 7
air consumption [m
3
.h
-
1
] 60 75 90 110
WARNING: When connecting the boiler to the heating system the drain tap must be installed at
the lowest point and closest possible to the boiler.
Fig. no. 4 HERCULES DUO boiler positioning in the boiler-room
Fig. no. 5 Boiler HERCULES DUO (right-hand design with small reservoir) with open fuel reservoir

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4.3 Hydraulic connection diagram
Fig. no. 6 Hydraulic diagram with HW preparation
Fig. no. 7 Hydraulic diagram without HW preparation
Legend to Fig. no. 6 and 7:
BT1 Safety thermostat
B2 Boiler outlet temperature sensor
B3 HW temperature sensor
B5 Fuel feeder 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
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

14
Fig. no. 8 Connecting dimensions of boiler
5. Boiler installation
5.1 Delivery and accessories
HERCULES DUO boiler based on the order is delivered in such a way that the complete boiler drum
including the basement is put on the pallet and packed boiler shell is gripped at the side of it. The
accessories are put inside the boiler drum and are accessible after opening the stoking door. The fuel
reservoir (depending on the requirement small – 269 dm
3
or large – 528 dm
3
) including the fuel feeder
set is put on another pallet. The boiler is packed in transport package and must not be tipped over
during the transport.
Standard boiler delivery:
•boiler drum with basement
•fuel feeder set
•fuel reservoir
•service board SIMBOX WP 8GB1 373-3 – set incl. electric pack
•HMI (ACX84.910/ALG) service unit for Saphir regulator operation – Siemens
•fan
•intermediate flange
•round head screw and cross-recessed screw M6 x 16 (4 pc) for fan gripping to the intermediate flange
•countersunk screw M6 x 20 (4 pcs), M6 nuts (4 pcs) and washer 6.4 (4 pcs) for attaching of the
intermediate flange to the assembly of fuel feeder
•safety thermostat
•round head screw and cross-recessed screw M4 x 6 (2 pc) for safety thermostat gripping
•boiler drum shell incl. ash-pan
•connection accessories for boiler drum shell
(4 pcs spring clip, 4 pcs junction stud 10 pcs screw ST4,8 x 13)
•basement shell
•connection accessories for basement shell (16 pcs screw ST 4,8 x 13)
•connection accessories for basement shell gripping to the basement (4 pcs washer 8,4; 4 pcs nut M8)
•ash-pan
•boiler mastic – tube 310 ml
•bushings PG 13,5 (2 pcs)

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•bushings PG 11 (2 pcs)
•stud bolt M10 x 30 (4 pc) and washers 10,5 (4 pcs) for gripping the fuel feeder set to the basement
•hexagon head screws M8 x 20 (4 pc) and washers 8 (4 pcs) for gripping the fuel reservoir to the fuel
feeder
•filling and drain tap Js 1/2“ (1 pc)
•plug Js 6/4“ blind (1 pc)
•sealing φ60 x 48 x 2 (1 pc)
•hook (1 pc)
•deflector (1 pc)
•ceramics into the boiler drum (5 pcs)
•partitions of the combustion chamber (4 sections - 2 pcs, 5 sections - 3 pcs, 6 sections - 4 pcs, 7
sections - 5 pcs)
•turbulators (8 pcs)
•draw rod with hanaccording to for smoke flap control (1 pc)
•grommet HEYCO (2 pc)
•label for smoke flap control (1 pc)
•flange of heating and return water 2“ (2 pcs)
•sealing φ90 x 60 x 3 (2 pcs)
•handling key (1 pc)
•cleaning tools (hook, brush with hanaccording to, tang, dowel 8 mm – 2 pc, straight threaded rivet 5x60 –
2 pcs)
•siseal 10 g
•thermostatic valve BVTS (Danfoss) or TS 130 (Honeywell) or STS 20 (Watts)
•cast iron grate (for boiler size 6 a 7 sect.)
•boiler sensor QAZ 36.526/109
•sensor against fuel fire penetration QAZ 36.526/109
• thermostatic valve (filling valve) - series VTC312 (external thread) made by ESBE (minimum temperature
of return water is 45
o
C) (ord. code: 5100 15 00) - for HERCULES DUO 4 sect.
• thermostatic valve (filling valve) - series VTC512 (external thread) made by ESBE (minimum temperature
of return water is 45
o
C) (ord. code: 5100 15 00) - for HERCULES DUO 5 - 7 sect.
• sticker - LED for the safety thermostat signalization
• boiler service and installation manual incl. the certificate of warranty
Obligatory accessories (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.
•Safety valve (1 pc) according to the maximum boiler operating overpressure (see tab. no. 1)
By request:
•Circulating pump Grundfos UPS 25-40
•Water heater (according to VIADRUS a.s. offer)
The boiler equipment ordered as „obligatory accessories“ and „by request“ is not included in the
basic price of boiler.
5.2 Installation procedure
5.2.1 Installation of boiler drum with the basement
1. Position the boiler drum with basement on the substructure (pad) into the horizontal position.
2. Insert the sealing between the heating water flange and boiler, then mount by means of four screws to
the boiler (follow the boiler-room dispositions). By welding connect the heating water outlet with the
heating system.
3. Insert the sealing between the return water flange and boiler, then mount by means of four screws to the
boiler. By welding connect the lower return water outlet with the heating system.
4. Mount the drain valve into the hole at the rear of the basement.
5. Put the stove-pipe on the smoke adapter and insert into chimney hole. The stove-pipe diameter is
160 mm.
6. Blind the threaded hole JS 6/4“ in the front section with plug JS 6/4“. Put the sealing under the plug.

16
7. It is recommended to install shut-off valves before and after the pump with a filter, for reason of
cleansing the strainer of filter or replacement of pump.
8. Open the cleaning door (see Figure No. 2 - Item 6) and hang hook with deflector so that the center of the
deflector is above the center of the burner grate (see Figure No. 9).
9. Open the cleaning door (see Figure No. 2a - Item 5) and insert 8 turbulators (see Figure No. 2a - Item
12), 5 pieces of ceramics (see Figure No. 9) and partitions of the combustion space (see Figure No. 9).
Fig.No. 9 Location of components and ceramics inside the boiler
1. Grate
2. Deflector
3. Hook
4. Bottom ceramics
5. Top ceramic plate
6. Partition of the
combustion space
7. Partition of the
combustion space-
front
8. Front ceramics

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5.2.2 Shells assembly
Fig. no. 10 Boiler shell

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Legend to Fig.No. 10:
1. Boiler drum with basement
2. Left side part of basement shell
3. Safety thermostat holder
4. Safety thermostat
5. Screw M4 x 6 (2 pcs)
6. Screw ST 4,8 x 13 (2 pcs)
7. Insulation of left side part of basement shell
8. Insulation into cut-out
9. Right side part of basement shell
10. Bushing PG 13,5 (2 pcs)
11. Insulation of left side part of basement shell
12. Washer 8,4 (4 pcs)
13. Nut M8 (4 pcs)
14. Screw ST 4,8 x 13 (4 pcs)
15. Front lower part of shell
16. Front lower part of the shell insulation
17. Front upper part of shell
18. Front upper part of the shell insulation (sibral)
19. Front upper part of the shell insulation
(rotaflex)
20. Rear part of shell
21. Screw ST 4,2 x 9,5 (4 pc)
22. Left side part of the shell
23. Side part of the shell insulation
24. Grommet Heyco
25. Junction stud (2 pc)
26. Washer 10,5 (1 pc)
27. Draw rod of smoke control
28. Control mechanism lever
29. Washer 10,5 (1 pc)
30. Plug ∅3 x 25 (1 pc)
31. Lock 2,5 x 32 (1 pc)
32. Bakelite ball
33. Right side part of the shell
34. Side part of the shell insulation
35. Junction stud (2 pcs)
36. Screw ST 4,8 x 13 (6 pcs)
37. Face
38. Face insulation (rotaflex)
39. Face insulation (sibral)
40. Upper part of the shell
41. Spring clip (4 pcs)
42. Upper part of the shell insulation
43. Front part of the shell
44. Front part of the shell insulation (rotaflex)
45. Front part of the shell insulation (sibral)
46. Rear part of the shell upper insulation
47. Rear part of the shell
48. Screw ST 4,8 x 13 (4 pcs)
49. Rear part of the shell insulation
50. Stopper of keg Ø 52.5 mm
51. Cover
52. Screw ST 4,8 x 13 (4 pcs)
1. Remove the shell from the cardboard package.
2. Mount the relevant connection accessories on the steel sheet components according to Fig. no. 10.
3. Jacket the boiler according to Fig. no. 10.
4. Screw the safety thermostat (2 pc screw M4 x 6) to the safety thermostat holder. Screw the holder with
the safety thermostat to the left shell of basement (2 pc screw ST 4,8 x 13) – see detail A. (Note: lead
the safety thermostat capillary between the shell and insulation). The electric connection of safety
thermostat is done before jacketing the boiler. The cable goes in the bushing through the side part of the
basement shell depending on the design either in the left or right part of basement shell. The boiler
output temperature sensor must be positioned in the boiler basin across the bushing in the side part of
the basement shell (depending on the right or left design) also before the boiler jacketing.
5. Mount the left and right side part of basement shell incl. insulation. Depending on the left or right design
selection break out the steel sheet for feeder connection. Screw the cover by means of 4 screws ST 4.8
x 13 to a part of the cut out hole. Grip the side parts to the basement by means of M8 nuts and 8,4
washers (only to the front part of the basement).
6. Mount the front parts of basement shell incl. insulation (upper and lower) and screw the rear part of
basement shell to the side parts of basement shell.
7. Mount the left and right side part of shell incl. insulation to the anchor screws (screw the junction studs
into both side parts of shells and mount the HEYCO bushings in the left shell).
8. Pull the smoke control draw rod through the left side part of the shell and secure by a plug. Mount the
smoke control lever on the draw rod and secure by means of 2 pc washers and plugs. Connect the
smoke control lever with smoke adapter flap and secure with a lock; the screw the bakelite ball
9. Stick the label for signalling the smoke flap on the left-hand side part of the shell at the point of smoke
control draw rod.
10. Mount the front part of the shell incl. insulation.
11. Screw the rear part of the shell to the side parts.
12. Seat the face with insulation on the side parts.
13. Insert the spring clips into the upper part of shell with insulation and mount on junction studs of shell side
parts.

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5.2.3 Fuel reservoir assembly
1. Fuel feeder
2. Screw M10 x 30 (4 pc)
3. Washer 10,5 (4 pc)
4. Nut M10 (4 pc)
5. Fan
6. Screw M6 x 16 (4 pc)
7. Washer 6,4 (4 pc)
8. Nut M6 (4 pc)
9. Fuel reservoir
10. Screw M8 x 20 (4 pc)
11. Nut M8 (4 pc)
12. Washer 8,4 (8 pc)
13. Adjustable foot
14. Intermediate flange
15. Screw M6 x 20 (4 pcs)
Fig. no. 11 Mounting of fuel feeder and reservoir to the boiler

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Screw on the adjustable legs of the the fuel feeder assembly, see Fig.No. 11 - Detail D.
Apply sealant onto the base of boiler , then mount the fuel feeder assembly to the base of the boiler and
tighten. Thus we have ensured a precise position of the fuel feeder assembly perpendicularly to the boiler
base. Loose the adjustable legs so that they sit on the floor. Apply sealant to the flange for the fan on the the
fuel feeder assembly. Then mount the fan.
Apply sealant to the fuel feeder assembly at the point of sitting surface of the fuel tank. Settle the fuel tank
and tighten the screws.
ATTENTION!!! Before the fuel reservoir is loaded with fuel it is necessary to check the free
rotation of fuel feed screw.
5.2.4 Mounting of the service board to the fuel reservoir
Fig. no. 12 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. 5.2.8.
3. To stick the sticker – LED of the safety thermostat signalization (5) on the switchboard (1).
5.2.5 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).
1. Service board
2. Screw M6 x 16 (4 pcs)
3. Washer 6,4 (4 pcs)
4. Nut M6 (4 pcs)
5. Sticker - LED for the safety
thermostat signalization