Viadrus HERCULES E68 Series Instruction Manual

Heat for your home
since 1888
HERCULES E68
Manual for boiler operation and installation
EN_
2015_39
EN_2020_20
5735002050000
-----
CZ_2015_38

Table of content page
1Boiler usage and advantages...................................................................................................................................................................3
2Technical parameters of the boiler HERCULES E68................................................................................................................................3
3Description...............................................................................................................................................................................................5
3.1 Boiler structure...................................................................................................................................................................................5
3.2 Regulating and safety elements.........................................................................................................................................................5
3.3 Excessive heat exhausting device .....................................................................................................................................................6
3.4 Heat Removal Device - Accumulating Tanks......................................................................................................................................8
4Positioning and installation.......................................................................................................................................................................8
4.1 Regulations and directives.................................................................................................................................................................8
4.2 Possibilities of placement...................................................................................................................................................................9
5Delivery and assembly...........................................................................................................................................................................11
5.1 Delivery and accessories content.....................................................................................................................................................11
5.2 Mounting procedure.........................................................................................................................................................................12
5.2.1 Boiler drum installation...............................................................................................................................................................12
5.2.1.1 Boiler drum installation –DBV 1 - 02 two-way safety valve...............................................................................................12
5.2.1.2 Placement of the shaped pieces set, tertiary air nozzle and inclined grate for the boiler with a size of 6 to 9 sections
(Fig. No. 16).....................................................................................................................................................................13
5.2.1.3 Placement of the shaped pieces set, tertiary air nozzle and inclined grate for the boiler with a size of 5 sections
(Fig. No. 19).....................................................................................................................................................................14
5.2.2 Mounting of claddings and electric wiring...................................................................................................................................15
5.2.3 Setting of the boiler control unit..................................................................................................................................................17
5.2.3.1 Boiler power settings........................................................................................................................................................17
5.2.3.2 Perform remaining setting according to the heating system and the boiler type................................................................17
5.2.4 Hydraulic scheme of the boiler...................................................................................................................................................18
5.2.5 Electric connection diagram.......................................................................................................................................................19
5.2.6 Mounting of the cleaning tool.....................................................................................................................................................21
5.2.7 Filling the heating system with water..........................................................................................................................................21
6Commissioning - instructions for contractual service organizations ........................................................................................................22
6.1 Verification activities before commissioning.....................................................................................................................................22
6.2 Commissioning the boiler.................................................................................................................................................................22
7Operating the boiler by user...................................................................................................................................................................22
7.1 Kindling............................................................................................................................................................................................24
7.2 Operation.........................................................................................................................................................................................25
8Maintenance ..........................................................................................................................................................................................25
9IMPORTANT WARNINGS .....................................................................................................................................................................26
10 Instructions for product liquidation after the lapse of its service life.........................................................................................................26
11 Warranty and responsibility for defects...................................................................................................................................................27
12 Recommended procedure for mounting and putting into operation (Instruction for mounting companies)..............................................27
13 Wrong methods of the connection of the boiler to the chimney...............................................................................................................29
14 Boiler information sheet..........................................................................................................................................................................30
15 Information specified on the name-plate.................................................................................................................................................35
16 Warranty certificate and certificate of quality and completeness for the VIADRUS boiler........................................................................37

3
Dear customer,
We thank you that you have bought a HERCULES E68 boiler, thus having shown your confidence in VIADRUS brand.
To get you accustom from the very beginning to correct handling with your new boiler, please firstly read this manual for its using, especially
Chapter No. 7. –Boiler servicing by an user, Chapter No. 8 –Maintenance, and Chapter No. 9 –Important warning. Please observe the below
mentioned information, in order to ensure a long-term trouble-free operation to your and our satisfaction.
HERCULES E68 boiler is a cast-iron sectional gasifying boiler designed for the combustion of wood.
Combustion of other substances (for example, plastics) is not allowable.
1 Boiler usage and advantages
The HERCULES E68 boiler meets the requirements for heating of one-family houses, shops, etc.
The boiler is manufactured as a warm-water boiler with forced circulation of heating water and work overpressure up to 400 kPa (4 bar). Before
dispatching, the unit is tested with the testing overpressure of 800 kPa (8 bar). The control of the HERCULES E68 boiler is solved with help of
automatic regulation.
Advantages of the boiler:
1. Ecological operation
2. High effectiveness of the boiler
3. Low fuel consumption
4. High service life of the cast-iron heat-exchanger and all other parts thanks to the quality of the used materials.
5. Long-term proven structure.
6. Sophisticated production technology on the automatic forming lines with permanent and proven quality of the production process (ISO 9001,
ISO 14 001).
7. Simple manipulation and maintenance.
8. Possibility of hot water heating
9. Possibility of the control of one heating circuit
10. Cooperation with storage tank
2 Technical parameters of the boiler HERCULES E68
Tab. №. 1 Boiler's sizes and technical parameters
Boiler size- number of sections
5
6
7
8
9
Combustion chamber volume
dm3
32
32
45
59
73
Water content
l
40.5
46.5
52.5
58.5
64.5
Weight
kg
348
413
458
503
549
Combustion chamber depth
mm
255
255
365
475
585
Chimney throat diameter Ø D
mm
160
160
160
160
160
Boiler sizes: - height x width
mm
1160x683
1160x683
1160x683
1160x683
1160x683
- depth L
mm
1070
1180
1290
1400
1510
Feed port sizes
mm
310 x 236
310 x 236
310 x 236
310 x 236
310 x 236
Maximum operation water overpressure
kPa (bar)
400 (4)
400 (4)
400 (4)
400 (4)
400 (4)
Minimum operation water overpressure
kPa (bar)
50 (0.5)
50 (0.5)
50 (0.5)
50 (0.5)
50 (0.5)
Testing water overpressure
kPa (bar)
800 (8)
800 (8)
800 (8)
800 (8)
800 (8)
Hydraulic loss
mbar
see Fig. No. 1
see Fig. No. 1
see Fig. No. 1
see Fig. No. 1
see Fig. No. 1
Minimum input water temperature
°C
50
50
50
50
50
Recommended minimum output water
temperature
°C
70
70
70
70
70
Noise level
dB
< 65
< 65
< 65
< 65
< 65
Boiler connections: - heating water
2“
2“
2“
2“
2“
- return water
2“
2“
2“
2“
2“
Cooling water temperature for the
redundant heat exhaust device
°C
5 –20
5 –20
5 –20
5 –20
5 –20
Cooling water overpressure for the
redundant heat exhaust device
kPa (bar)
200–600 (2-6)
200–600 (2-6)
200–600 (2-6)
200–600 (2-6)
200–600 (2-6)
Electrical voltage
1/N/PE 230 V AC 50 Hz, TN-S
Electrical input at nominal power
W
11
15
13
21
34
Electrical input at standby state
W
4
Electric cover
IP 40
Tab. №. 2 Technical parameters of HERCULES E68, Values corresponds to the fuel used upon certification:
Hard wood - class A; fuel humidity: max. 16-18 %; calorific value: min.15 –18 MJ. kg-1
Boiler size- number of sections
5
6
7
8
9
Boiler class according to EN 303 –5
-
5
5
5
5
5
Nominal power
kW
15
18
23
27
34
Fuel consumption
kg/h
3.7
4.3
5.3
6.9
8.5
Max. fuel weight in the feeding chamber
kg
13
13
18
22
25
Flue gases temperature at the nominal power
°C
140-180
140-180
140-180
140-180
140-180
Flue gases mass flow rate at the nominal power
kg/s
0.011
0.014
0.017
0.019
0.026
Chimney draught
mbar
0.18
0.16
0.18
0.20
0.20
Combustion time
h
min. 2
min. 2
min. 2
min. 2
min. 2
Efficiency
%
88.3
88.3
89.1
88.5
89.0
Energy efficiency class
A+
A+
A+
A+
A+
Energy efficiency index
114
114
114
113
114
Season energy efficiency
%
77
77
78
77
77

4
Tab. №. 3 Recommended sizes of wood chocks
Chocks diameter
mm
Ø 40 to 120
Chocks length
mm
≤350
The boiler is operated at under-pressure on the output of flue gases.
The boiler works under the conditions without condensation.
Fig. №. 1 Hydraulic loss of the boiler drum
Boiler size - number of sections
-
5
6
7
8
9
Length A
mm
1070
1180
1290
1400
1510
Length B
mm
620
730
840
950
1060
Fig. №. 2 Main sizes of the HERCULES E68 boiler
Dependence of pressure loss on flow-rate

5
3 Description
3.1 Boiler structure
The main part of the boiler is a cast-iron sectional boiler drum made of grey cast iron according to ČSN EN 1561, EN-GJL-150.
Pressurized parts of the boiler meet requirements for the stiffness according to ČSN EN 303-5.
The boiler drum is compiled from sections with help of pressed boiler inserts with a diameter of 56 mm and is fixed by boiler screws. The
sections create a filling well, combustion chamber and ash-pan, water space and convective part of the boiler. The input and output of heating
water is situated in the rear part of the boiler.
The rear section of the boiler, in its upper part, has a chimney pot and a heating water flange; and its bottom parts - a return water flange.
Stocking and ash-pan doors are fixed to the front section. An inclined grate is placed in the feeding chamber. The entire boiler drum is insulated
with health harmlessness mineral insulation that decreases losses by heat transmission into the environment. The steel cladding of the boiler is
painted with high-quality komaxit spray-type painting.
1. Front section
2. Middle section
3. Front section of the combustion chamber
4. Middle section of the combustion chamber
5. Rear section of the combustion chamber
6. Cladding
7. Ash-pan door throttle valve
8. Stocking door throttle valve
9. Rear throttle valve
10. Chimney pot
11. Ash-pan door
12. Stocking door
13. Blind flange
14. Electric fan
15. Control cabinet
Fig. №. 3 Main parts of the HERCULES E68 boiler
3.2 Regulating and safety elements
The stocking door throttle valve regulates the supply of the primary combustion air above the fuel. It is controlled manually with help of a throttle
valve set screw.(see Fig. No.3 position 8) The ash-pan door throttle valve regulates the supply of the secondary combustion air under the
boiler grate. It is controlled manually with help of a throttle valve set screw. (see Fig. No.3 position 7)
The throttle valve in the bottom part of the boiler is designed for the supply of the tertiary air. It is regulated by a adjusting screw. (see Fig. No.3
position 9)
The manometer serves for the determination of water pressure. The well of the manometer sensor is situated in the upper part of the boiler front
section.
The control unit VERA BORD 360 - processes data from boiler output-water temperature sensor (central heating), hot-water temperature in
reservoir (HW) and flue-gases temperature. Based on the data, the system controls the modulating exhaust fan, the CH (central heating) pump
and HW (hot water) pump. Is necessary to thoroughly rinse out the heating system to ensure washing-up of all impurities.
The end-limit switch of the stocking door –switches-on the exhaust fan upon each opening of the stocking door (opening of the end-limit switch)
to maximum power, and - by this - prevents from escaping smoke flue gases into the room where the boiler is installed. After the stocking door
is closed (closing of the end-limit switch), the fan power will return to the automatic mode.
Excessive heat exhausting device - See chapter 3.3.

6
1. Bottom left shaped piece
2. Bottom right shaped piece
3. Tertiary air supply nozzle
4. Middle front shaped piece
5. Middle rear shaped piece
6. Upper front shaped piece
7. Upper rear shaped piece
8. Inclined grate
9. Secondary air throttle valve
10. Primary air throttle valve
11. Tertiary air throttle valve
Fig. №. 4 HERCULES E68 boiler assembly
3.3 Excessive heat exhausting device
The final-cooling loop or the DBV 1 - 02 two-way safety valve is designed for the exhaust of excessive heat in the case that water
temperature is exceeded over 95 °C. The final-cooling loop is connected to the boiler flanges according to Fig. No. 5; the two-way
safety valve - according to Fig. No. 7).
In the case of boiler overheating (input water temperature is higher than 95 °C), a thermostatic valve will be initiated, and surplus heat is
exhausted through the final-cooling loop.
Fig. №. 5 Hydraulic scheme of final-cooling loop connection
In case that the system is equipped with the DBV 1 - 02 two-way safety valve and the boiler is overheated (output water temperature is higher
than 95 °C), then the two-way safety valve creates a cool water circuit until the temperature decreases under the limit temperature. In this
moment, there will simultaneously closed the discharge cooling device and the input of cool water which is refilled into the system.
1. Heating water output into the system 2“
2. Return water input from the final-cooling loop 1 1/2 “
3. Return water input into the boiler from the system 2“
4. Cooling water output
5. Thermostatic valve TS 130 (STS 20)
6. Heating water output from the boiler 2“
7. Cooling water input

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Fig. №. 6 DBV 1 - 02 Two-Way Safety Valve
A safety valve with the maximum overpressure of 400 kPa (4 bar), the dimensions of which have to comply to the nominal power of
the boiler, has to be installed in the system. The safety valve must be positioned directly behind the boiler. No shut-off valve can be
placed between the safety valve and the boiler. In case of other questions, please contact our contractual mounting companies and
service organizations.
Technical data of the DBV 1 –02 two-way safety valve (from Regulus Company)
Opening temperature (limit): 100 °C (+0° - 5 °C)
Maximum temperature: 120 °C
Maximum pressure at the boiler side: 400 kPa (4 bar)
Maximum pressure at the water side: 600 kPa (6 bar)
Nominal flow rate at p 100 kPa (1 bar): 1,9 m3/h
Usage
The DBV 1 –02 two-way safety valve is destined for the protection of the central heating against overheating. The discharge and refill valve in
the valve body is controlled by a thermostatic block. When reaching the limit temperature, the discharge and refill valve is simultaneously
opened; it means that cool water flows into the boiler, and at the same time hot water is drained from the boiler. While lowering the temperature
under the limit one, the discharge and refill valve will be closed.
WARNING!!! It does not replace a safety valve
In case of triggering the two-way safety device, when water which does not comply with requirements of ČSN 077401 can be refilled, it
is necessary to prepare water in the system so that it met the requirements of this standard.
Fig. №. 7 Recommended Wiring Diagram of the DBV 1 - 02 Two-Way Safety Valve
Installation
Only qualified person may perform installation. To ensure correction functionality of the thermostatic two-way safety valve, it is necessary to
follow prescribed conditions for its installation and respect marking of the flow rate directions marked on the valve body. The safety valve is
always mounted into the output pipeline of the boiler or directly on the boiler in a place of its upper part, where heated water leaves the boiler
and is conveyed into the heating system. While installing the valve, it is necessary to check whether the use of the 3/4“ mouthpiece (which can
be either in the pipeline or on the boiler) ensures full submersion of the thermostatic module of the valve. After having mounted into the
mouthpiece, connect the draining pipeline in the place „C“ (Fig. No. 6) in which hot water will outflow from the boiler. In the place „A“ (Fig. No. 6),
connect (according to Fig. No. 7) the cooling water supply line which - after putting the valve into operation - will ensure boiler cooling-down. It is
necessary to install a filter for capturing mechanical impurities on the cooling water supply line. In the place „B“ (Fig. No. 6), connect the pipeline
and - according to Fig. No. 7 - lead it into the return line of the system near the boiler.
Regular Maintenance
Once a year rotate the head of the safety valve to remove possible impurities deposited in it. Clean-up the filter on the cooling water input.
In the case of the use of an opened expansion tank, there is no need in a safety device against overheating.
Each heat source in the opened heating system has to be connected with an opened expansion tank which is situated in the highest point of the
heating system. Expansion tanks have to be dimensioned so that they can cover changes of the water volume which occurred as a result of
heating and cooling.
Opened expansion tanks have to be equipped with non-lockable de-aerating and overflow pipelines. The overflow pipeline has to be proposed
so that it reliably lead away the highest supply rate incoming into the system. It can be achieved by dimensioning of the overflow pipeline by one
DN higher than the feeding pipeline has. The expansion tanks and their connecting pipelines have to be designed and placed in order to reliably
avoid their freezing.
A –cooling water input
B –output into the boiler
C –output into the sewage
D –input from the boiler
1. Boiler
2. DBV 1 - 02 Two-Way Safety Valve
3. Safety valve
4. Pressure control valve
5. Filter
6. Ball-valve
7. Pump
8. Excessive heat removal
9. Discharge valve
I. –Cooling water input
II. –Heating water output
III. –Return water input

8
Fig. №. 8 Examples of connection of opened expansion tanks
3.4 Heat Removal Device - Accumulating Tanks
Boilers of Hercules E68 series meet - according to EN-305 - conditions of the emission class 5. It matches the requirements of this class while
being operated with the nominal power.
If the nominal power is higher than the immediate request of the facility for heating, it is necessary to exhaust the excessive heat into the
accumulating tank.
If the tank is fully charged, it is necessary to shut down the boiler and heat up with heat from the accumulating tank. After the heat in the tank is
spent, put the boiler into operation again. The accumulating tank enables you to ensure thermal comfort and at the same time a quality
operation of the boiler.
Calculation of the smallest volume of the tank heat-exchanger.
Vsp = 15Tbx QN(1-0,3 x (QH/Qmin))
where:
Vsp accumulation tank volume in l
QNnominal heating power in kW
Tbcombustion time in hours
QHthermal load of buildings in kW
Qmin smallest heating power in kW
Dimensions of the accumulating tank must be determined according to the boiler power and used fuel. It is necessary to consider the highest
calculated volume, whereas the minimal used volume of the accumulating tank has to be 300 l.
The hydraulic scheme of connection of the boilers with the accumulating tanks are available in the project supporting documents of Viadrus,
at http://www.viadrus.cz/projekcni-podklady-76.html.
4 Positioning and installation
4.1 Regulations and directives
A solid fuel boiler may be only installed by a company with a valid authorization to perform its installation and maintenance. A project according
to the valid regulations must be prepared for installation. Before installation of the boiler in an old heating system, installation companies have to
perform rinsing (cleaning-up) of the whole system. The heating system has to be filled up with water, which complies with requirements
of ČSN 07 7401, and mainly its hardness mustn't exceed the required parameters.
Tab. №. 4
Recommended values
Hardness
mmol/l
1
Ca2+
mmol/l
0.3
concentration of total Fe + Mn
mg/l
(0,3)*
*) recommended values
WARNING!!! The manufacturer doesn't recommend using of antifreeze mixtures.
In case of triggering the two-way safety device, when water which does not comply with requirements of ČSN 077401 can be refilled, it
is necessary to prepare water in the system so that it met the requirements of this standard.
a) for the heating system
ČSN 06 0310 Heat systems in buildings –Design and mounting
ČSN 06 0830 Heat systems in buildings –Securing devices
ČSN 07 7401 Water and steam for heat energetic equipment with steam operation pressure up to 8 MPa
ČSN EN 303-5 Boilers for central heating - Part 5: Solid fuel boilers for central heating, with manual and automatic supply, with
nominal heating power at most of 500 kW –Terminology, requirements, testing and marking.
b) for the chimney
ČSN 73 4201 Design of chimneys and flue gas ducts –Design, fulfillment and connection of fuel consumers
c) regarding to fire-fighting regulations
ČSN 06 1008 Fire safety of heat equipment.
ČSN EN 13501 -1 + A1 Fire classification of building products and building structures –Part 1: Classification according to results of
tests for reaction to fire.
d) for the hot water heating system
ČSN 06 0320 Heat systems in buildings –Preparation of hot water –Development and design
ČSN 06 0830 Heat systems in buildings –Securing devices
ČSN 75 5409 Indoor water distributions
1. Heat source
2. Expansion tank
3. Safety pipeline
4. Expansion pipeline
5. Overflow pipeline
6. Feeding pipeline
7. Water lever limiter
8. Return pipeline

9
4.2 Possibilities of placement
Boiler placement in dwelling premises (including corridors) is prohibited!
It is necessary to ensure permanent supply of air for combustion and ventilation to the room where the boiler will be installed.
Upon installation and usage of the boiler, it is necessary to observe all requirements of ČSN 06 1008.
The boiler in the central heating system has to be connected to a separate venting unit. The chimney with a correct draught is the
basic assumption for a good function of the boiler. It influences both boiler power and its efficiency. It is nut suitable to use flue gas
elbows. The flue gas ducting from the boiler to the venting unit must be as short as possible, preferably without elbows with a slope
from the boiler upwards. The chimney has to have a prescribed draught (depending on the boiler size - see manual). It must be well
tightened and insulated to avoid condensation of water steam and tar.
Fig. №. 9 Connection of the boiler to the chimney.
Boiler positioning with regard of fire-fighting regulations:
While installing a boiler with a size of 5, 6 and 7 sections, we recommend that you to use original cast-iron pedestal (see Fig. No. 10) supplied
by the manufacturer. In case of placement of the boiler without a pedestal, it is necessary to observe conditions specified in Art. 1.
Boiler size- number of sections
-
5
6
7
8
9
Length L
mm
620
730
840
950
1060
Fig. №. 10 Bedding sizes
Fig. №. 11 Cast-iron pedestal of the
boiler
1. Positioning on the floor made of non-flammable material (Fig. No. 10):
place the boiler on the non-flammable pad exceeding the boiler layout on all sides by 20 mm and just on the depth of the boiler drum;
If the boiler is installed in a cellar we recommend installing it on a bedding at least 50 mm high.
the boiler has to be placed in the center of the pedestal.
2. Safety distance from flammable materials:
when installing and operating the boiler, it is necessary to keep a safety distance of 200 mm from the
materials of combustibility grade of A1, A2, B and C (D);
for lightly combustible materials with the combustibility grade E (F), which quickly burn and burn themselves even after removal of the
ignition source (for example, paper, paste-board, cardboard, asphalt- and tarboard, wood and fiberboards, plastics, floor cloths) the
safety distance is doubled, it means to 400 mm;
the safety distance is to be also doubled in case when the grade of reaction to fire is not proven.

10
Tab. №. 5 Grade of reaction to fire
Grade of reaction to fire
Examples of building materials and products included in the reaction of fire
(extract from ČSN EN 13501-1+A1)
A1 –incombustible
Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters,...
A2 –hardly combustible
Acumin, izumin, heraklit, lignos, boards and basalt felt, fibreglass boards,...
B–heavily combustible
Beech and oak wood, hobrex boards, plywood, werzalit, umakart, sirkolit,...
C (D) –moderately
combustible
Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,...
E (F) –lightly combustible
Asphaltboard, fibreboards, cellulose materials, polyurethane, polystyrene, polyethylene, PVC,...
Positioning of a boiler with regard to the necessary handling
space:
basic environment AA5/AB5 according to ČSN 33 2000-1 ed. 2;
in front of boiler there the handling space at least 1000 mm must be
left;
minimum distance between the rear part of boiler and the wall is
400 mm;
at least from one side part, the space for accessing the rear part of
boiler (minimum 400 mm) must be kept.
Placement of fuel:
to ensure correct combustion in the boiler, it is necessary to
use dry fuel. The manufacturer recommend that you stock fuel in
basement premises or at least under a shelter;
it is prohibited to lay fuel behind the boiler or stock it near the boiler
in a distance lower than 400 mm;
It is prohibited to store fuel in front of the boiler.
it is prohibited to lay fuel between two boilers in the boiler-room;
the manufacturer recommend that you observe distance between
the boiler and fuel at least 1000 mm or place fuel in other room
than the room where the boiler is situated.
Fig. №. 12 Positioning of boilers in a boiler room

11
5 Delivery and assembly
5.1 Delivery and accessories content
The boiler is supplied according to a purchase order so that a boiler drum and boiler cladding are placed on a pallet. The lining of the
combustion chamber is packed separately. Accessories is placed inside the boiler drum, and is available after opening the stocking door. The
boiler is packed in transport package and it is not allowed to tip it during transportation.
Standard content of the boiler supply:
boiler on a pallet
- return water flange with a thread 1 pcs
- heating water flange with a thread 1 pcs
- sealing90 x 60 x 3 2 pcs
- washer 10,5 8 pcs
- nut M10 8 pcs
- filling and discharge cock Js 1/2“ 1 pcs
- sealing60 x 48 x 2 1 pcs
- capillary spring 1 pc
- wave spring 1 pc
- manipulation key 1 pc
- throttle valve screw 2 pcs
assembly of combustion chamber lining
- refractory glue, 50 ml, for gluing the nozzle 1 pc
inclined grate 1 pc
cladding including ash-pan and insulation
- lowered bracket 2 pcs
- washer 10,5 4 pcs
- nut M10 4 pcs
- spring clip 4 pcs
- screw M5 x 12 10 pcs
- connecting spine 4 pcs
- manometer 1 pc
- screw M8 x 12 4 pcs
cleaning tools
- hook 1 pc
- brush with a extending stick 1 pc
- spike 1 pc
- cleaning tool holder 1 pc
chute for the lining (only for the size of 8 and 9 sections) 1 pc
electric accessories of the boiler 1 pc
shell with a ventilator 1 pc
pack of accessories of the boiler 1 pc
commercial and technical documentation
Additional accessories (it is not a part of supply):
Cast-iron pedestal for the 5-section boiler (ordering code 17657)
Cast-iron pedestal for the 6-section boiler (ordering code 18522)
Cast-iron pedestal for the 7-section boiler (ordering code 17658)
Necessary accessories (it is not a part of supply):
Final-cooling loop (1 pc), including a flange, or two-way safety valve DBV 1 - 02, including siseal (10 g). This equipment doesn't need to be
used in the case of an opened heating system.
Thermostatic valve TS 130 (STS 20) –TV 95°C – can be bought in supermarkets (only in case of delivery with the final-cooling loop)
Safety valve 1 pc
Accessories delivered by user's request (it is not a part of supply):
Filter 3/4“ (for the boiler with a two-way safety valve DBV 1 –02)
Boiler equipment ordered as "additional accessories, necessary accessories and accessories delivered by user's request" in not
included into the basic price of the boiler.

12
5.2 Mounting procedure
5.2.1 Boiler drum installation
5.2.1.1 Boiler drum installation –DBV 1 - 02 two-way safety valve
1. Install the boiler drum on the pedestal or bedding (pad).
2. insert a sealing Ø 90 x 60 x 3 between the heating water flange and boiler; afterwards mount with help of 4 pcs of the nuts M 10 and 4 pcs
washers 10,5 to the boiler. (depending on the boiler-room layout). Interconnect the output of heating water by a weld-joint with to the
heating system.
3. insert a sealing Ø 90 x 60 x 3 between the return water flange and boiler; afterwards mount with help of 4 pcs of the nuts M 10 and 4 pcs
washers 10,5 to the boiler. Interconnect the bottom output of return water by a weld-joint with to the heating system.
4. According to Fig. No. 7, interconnect the DBV 1 –02 two-way safety valve with the return water flange, heating water flange and cooling
water input and excessive heat output.
5. Mount the single-place well for an output water sensor G1/2 (6)
6. Mount the discharge valve to the return water flange.
7. Before installation of the flange of the ventilator shell, it is necessary to cement (11) the surface where the flange touches-down - see
figure No. 13. Connect the ventilator to the chimney pot with help of 4 pcs of M8 nuts and 4 pcs of 10.5 washers.. Put on the stove pipe. The
chimney pipe diameter is 160 mm.
8. Blind the hole with a JS 6/4“ thread in the front section with a JS 6/4“ plug. Place a sealing of Ø 60 x 48 x 2 under the plug.
9. It is recommend that you use shut-off valves for the heating water input and output, because in case these valves are not used, while
cleaning the filter it would be necessary to clean the whole system.
Fig. №. 13 Boiler drum installation
1. Sealing90 x 60 x 3
2. aReturn water flange
2. bReturn water flange with a
distribution tube (for size of 8 and
9 sections)
3. Washer 10.5
4. Nut M10
5. Filling and discharge cock
6. Single-place well for an output
water sensor G1/2 - short
7. DBV 1 -02 two-way safety valve
(is not a part of standard delivery)
8. Heating water flange
9. Electric fan
10. Nut M8
11. Boiler cement

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5.2.1.2 Placement of the shaped pieces set, tertiary air nozzle and inclined grate for the boiler with a size of 6
to 9 sections (Fig. No. 16)
1. Place to the bottom part of the combustion chamber the bottom left shaped piece (1), bottom right shaped piece (2) and up to it - middle
rear shaped piece (3) and upper rear shaped piece. (5)
Fig. №. 14
2. Apply heat-resistant glue (glue-fibers of 3-4 mm) to the bottom part of the nozzle of the supply-line of tertiary air (7),
and place the nozzle straightly into the circular hole of the shaped piece (1)(2).
Fig. №. 15
3. Close the combustion chamber by inserting the middle front shaped piece (4) and upper front shaped piece (6).
4. Insert carefully the inclined grate (8) into the combustion space, and prop its upper part on the front section.
Fig. №. 16 Placement of the shaped pieces into the combustion chamber of the HERCULES E68 boiler
1. Bottom left shaped piece
2. Bottom right shaped piece
3. Middle rear shaped piece
4. Middle front shaped piece
5. Upper rear shaped piece
6. Upper front shaped piece
7. Tertiary air nozzle
8. Inclined grate

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5.2.1.3 Placement of the shaped pieces set, tertiary air nozzle and inclined grate for the boiler with a size of 5
sections (Fig. No. 19)
1. Insert the upper front and rear shaped pieces (1, 9) (with their elevated part in the triangle shape towards the stocking door according to
Figure) into the upper part of the combustion chamber and fix their position by inserting the arresting split plug (2) into the hole (3).
2. Place to the bottom part of the combustion chamber the bottom shaped piece (4), and up to it - middle rear shaped piece (5).
Fig. №. 17
3. Apply heat-resistant glue (glue-fibers of 3-4 mm) to the bottom part of the nozzle of the supply-line of tertiary air (6),
and place the nozzle straightly into the circular hole of the bottom shaped piece (4).
Fig. №. 18
4. Close the combustion chamber by inserting the middle front shaped piece (7).
5. By slow pulling, push out the arresting split plug, by this the both upper shaped pieces (1, 9) will sit down on the middle shaped pieces (5,
7).
6. Insert carefully the inclined grate (8) into the combustion space, and prop its upper part on the front section.
Fig. №. 19 Placement of the shaped pieces into the combustion chamber of the HERCULES E68 boiler with a size of 5 sections
1. Upper front shaped piece
2. Arresting split plug
3. Hole for the arresting split plug
4. Bottom shaped piece
5. Middle rear shaped piece
6. Tertiary air nozzle
7. Middle front shaped piece
8. Inclined grate
9. Upper rear shaped piece

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5.2.2 Mounting of claddings and electric wiring
Fig. №. 20 Side-wall part of the cladding
1. Extract the claddings from the card-board package. Cable of the electric wiring mustn't contact the boiler drum.
2. According to Fig. No. 21, with help of 4 pcs of M8 x 12 (8) screws, screw the front cover (7).
3. According to Fig. No. 21, put on 2 pcs of lowered bracket (3) to the threads of the upper anchor bolts, and screw them with help of 4 pcs
of the washers 10,5 (9) and 4 pcs of the nuts M10 (10).
4. Take out the insulation from the left part of the cladding and screw the assembly of the end-limit switch holder (fig. No. 21) by means of 2
pcs screws M4 x 10 and secure 2 pcs of nuts M4 and washers 4.3. The cable of the end-limit switch must be terminated in the upper part
of the left side-wall part of the cladding.
5. According to Fig. No. 20, install the left side-wall part of the cladding (1) with help of 2 pcs of the spring clips (3), screw 2 pcs of the bolts
M5 x 12 (4) –do not tighten, leave a play of 1–2 mm and insert the insulation (5). According to Fig. No.17, put the cladding (1) on the
anchor bolts, and connect the upper part with the lowered brackets (3) with help of 2 pcs of the bolts M5 x 12 (4).
6. According to Fig. No. 20, install the right side-wall part of the cladding (2) with help of 2 pcs of the spring clips (3), screw 2 pcs of the bolts
M5 x 12 (4) –do not tighten, leave a play of 1–2 mm and afterward insert the insulation (6). According to Fig. No.19, put the cladding (2)
on the anchor bolts, and connect the upper part with the lowered brackets (3) with help of 2 pcs of the bolts M5 x 12 (4).
Fig. №. 21 Mounting of the side-wall parts of the cladding and the end-limit switch assembly
7. According to Fig. No. 22, equip the upper part of the cladding (6) with 4 pcs of the connecting rods (4) and insert the manometer (5).
8. Screw the manometer sensor into the manometer back-pressure valve.
9. Insert the insulation (3) into the upper part of the cladding (6), and put it on the side-wall parts of the cladding (1,2).
1. Left side-wall part of the cladding
2. Right side-wall part of the cladding
3. Lowered bracket
4. Screw M5 x 12
5. Insulation of the left side-wall part of the
cladding
6. Insulation of the right side-wall part of the
cladding
7. Front sheet-metal cover
8. Screw M8 x 12
9. Washer 10
10. Nut M10
11. Washer 4.3
12. Spring washer 4
13. Screw M4 x 10
14. End-limit switch holder
1. Left side-wall part of the cladding
2. Right side-wall part of the cladding
3. Spring clip
4. Screw M5 x 12
5. Insulation of the left side-wall part of the cladding
6. Insulation of the right side-wall part of the cladding

16
Fig. №. 22 Mounting of the upper part of the cladding
10. According to Fig. No. 23, put the rear part of the cladding (3) onto 4 pcs of the screws M5 x 12 (4) between the side-wall parts of the
cladding (1 and 2). Cable of the electric wiring mustn't contact the boiler drum and the chimney pot.
11. As necessary, screw the holder of the cleaning tools (5) to the left or right side-wall part of the cladding (1 and 2) with help of 2 pcs of the
bolts M5 x 12 (4).
Fig. №. 23 Mounting of the rear part of the cladding and the cleaning tool holder
Fig. №. 24 Demounting of the control cabinet upper part
1. Right side-wall part of the cladding
2. Left side-wall part of the cladding
3. Insulation of upper part of the cladding
4. Connecting rod
5. Manometer
6. Upper part of the cladding
7. Thermometer well
8. Manometer back-pressure valve
9. Control cabinet
10. Cover
11. Washer 3.2
12. Screw M3 x 12
1. Left side-wall part of the cladding
2. Right side-wall part of the cladding
3. Rear part of the cladding
4. Screw M5 x 12
5. Cleaning tool holder
6. Insulation of the rear sheet-metal cover
7. Screw M5 x 10
8. Flue gases temperature sensor
9. Single-place well for the
G1/2“ output-water sensor - short
1. Control cabinet lower part
2. Screw
3. Control cabinet lower part

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5.2.3 Setting of the boiler control unit
Detailed information on the control unit is specified in a separate manual “VERA BORD 360. Control unit”
5.2.3.1 Boiler power settings
WARNING!!! Before commissioning the boiler, it is necessary to set boiler power. Parameter “Boiler model”
The minimal and maximal rpm of the ventilator are preset in the control unit (it means the boiler power). Each boiler size has different values. It
is necessary to set the boiler power according to the rated value.
Push-button press (min 3 seconds) Service menu enter the code 2003 Boiler settings Boiler model
Choose a correct power row press the START push-button (YES)
Tab. №. 6 Preset values
Boiler model
15 kW
18 kW
23 kW
27 kW
34 kW
Max. rotation speed of the ventilator
15 %
25 %
35 %
40 %
60 %
Min. rotation speed of the ventilator
15 %
20 %
25 %
30 %
50 %
WARNING!!! When activating the parameter “Renewal of factory settings”, boiler power is returned onto the factory
settings. (Factory settings of 15 kW) According to data on the production label of the boiler - Rated heat power has to
be set again “Boiler model”.
5.2.3.2 Perform remaining setting according to the heating system and the boiler type.
Detailed information of the control unit is in a separate manual “Control unit VERA BORD 360”.
Service menu
Boiler settings
Boiler model
15 kW
16 kW
23 kW
27 kW
34 kW
18 kW
30 kW

18
5.2.4 Hydraulic scheme of the boiler
In the case of using of the shut-off valve, it is necessary to mount a safety valve between the boiler and shut-off valve.
Version with an storage tank, with one heating circuit and a HW heating circuit.
Fig. №. 25 Mounting of the rear part of the cladding and the cleaning tool holder
Legend:
1. Heating system (radiator-type, floor-type heating-up)
2. Two-way safety valve DBV 1-02
3. Expansion tank
4. Waste
5. Valve 1 room thermostat (mixed heating circuit)
6. Storage tank
7. Expansion tank - additional
8. Stack heater of hot water - combined
9. Expansion tank of the stack heater of hot water
Separately bought accessories of regulation; it is not part of supply of the boiler:
Electric devices connected from the boiler’s control unit:
B1 –Valve 1 temperature sensor (mixed heating circuit)
B2 –Boiler temperature sensor
B3 –Domestic hot water (DHW) temperature sensor
B4 –Storage tank upper temperature sensor
B41 –Storage tank lower temperature sensor
B9 –Outdoor temperature sensor
Q1 –Storage tank pump
Q2 –Valve 1 pump (mixed heating circuit)
Q3 –Domestic hot water (DHW) pump
Y1 –Valve 1 servo drive (mixed heating circuit)

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5.2.5 Electric connection diagram
.
Legend: A1 –Regulator BRAGER VERABORD 360 B1 –Temperature sensor TO1 B2 –Boiler output temperature sensor B3 –DHW heating sensor B4 –Storage tank upper temperature sensor B8 –Flue gases temperature sensor B9 –Outdoor temperature sensor B41 –Storage tank lower temperature sensor D –Control unit (display) BTr –Room thermostat TO1 Hall –Ventilator rotation speed sensor MV1 –Boiler exhaust ventilator Q1 –Storage (boiler) tank pump Q2 –Pump TO1 Q3 –Domestic hot water (DHW) pump S1 –Main switch; S10 –Switch of door opening signalization X10 –Ventilator power supply connector X11 –Ventilator rotation speed sensor connector X12 –Connection of switch of door opening signalization TR_DISP –Control unit (display) connector TR2 –Auxiliary module connector -+AB –Clamps of auxiliary modules’ connection Conductor colour: gnye green-yellow bk black bn brown bu blue rd red wh white

20
I6
Ventilator rotation speed sensor
T1
Boiler temperature sensor –B2
T2
DHW temperature sensor –B3
T3
Temperature sensor of the valve 1 (mixed heating circuit) –B1
T4
Upper temperature sensor of the storage tank –B4
T5
Lower temperature sensor of the storage tank –B41
T6
Outdoor temperature sensor –B9
TR2_DISP
Display connector
TR2
Auxiliary modules connector
- + AB
Auxiliary modules connectors
Symbol
Description
Q1
Output of the boiler ventilator
Q3
Output of the storage tank pump –Q1
Q4
Output of the DHW pump –Q3
Q7
Q2 –Output of the valve 1 pump (mixed heating circuit) –Q2
Q8
Output of the valve 1 servo drive (mixed heating circuit) –Y1
L1 + N
Opening of the mixing valve 1
L2 + N
Closing of the mixing valve 1
I1
Flue gases temperature sensor
I4
Room thermostat of the valve 1
I5
Switch of door opening signalization