Viadrus HERCULES Green Eco Therm Series User manual

VIADRUS HERCULES Green Eco Therm
Manual for boiler operation and installation
GB_2015_11

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Contents: page
1. Produced variants of boiler..........................................................................................................................3
2. Technical data of the boiler .........................................................................................................................4
3. Boiler description.........................................................................................................................................6
3.1 Boiler drum construction.....................................................................................................................6
3.2 Control, regulation and safety elements .............................................................................................6
3.2 The construction of burner and transport routes of the fuel................................................................9
4. Location and installation............................................................................................................................11
4.1 Regulations and directives................................................................................................................11
4.2 Positioning possibilities.....................................................................................................................12
5. Order, delivery and assembly....................................................................................................................14
5.1 Order.................................................................................................................................................14
5.2 Delivery and accessories..................................................................................................................14
5.3 Assembly procedure.........................................................................................................................16
5.3.1 Boiler drum installation..................................................................................................................16
5.3.2 Mounting of partitions of the combustion chamber and turbulators..............................................17
5.3.3 Mounting of burner........................................................................................................................17
5.3.4 Mounting of the fuel reservoir .......................................................................................................19
5.3.5 Mounting of the shells...................................................................................................................20
5.3.6 Installation of electrical wiring.......................................................................................................21
5.3.6.1 Version VIADRUS HERCULES Green Eco Therm XJ.........................................................21
5.3.6.1 Version VIADRUS HERCULES Green Eco Therm XS.........................................................22
5.3.7 Assembly tools for brush...............................................................................................................22
5.3.8 Filling of the heat system with water.............................................................................................22
5.3.9 Electrical scheme..........................................................................................................................23
5.3.10 Boiler hydraulic diagram ...............................................................................................................27
6. Putting into operation - instructions for contractual service organization ..................................................28
6.1 Inspections before start-up...............................................................................................................28
6.2 Boiler putting into operation..............................................................................................................28
7. Boiler operation by user.............................................................................................................................29
7.1 Version VIADRUS HERCULES Green Eco Therm XJ.....................................................................29
7.1.1 Setting of the heat output of burner ..............................................................................................31
7.2 Version VIADRUS HERCULES Green Eco Therm XS.....................................................................35
7.2.1 Setting of the heat output of burner ..............................................................................................37
8. IMPORTANT WARNINGS ........................................................................................................................40
9. Maintenance..............................................................................................................................................41
10. Faults and their removal ........................................................................................................................43
11. Instructions for product liquidation after its operating life.......................................................................45
12. Warranty and defect liability...................................................................................................................45

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Dear customer,
thank you for the purchase of VIADRUS HERCULES Green Eco Therm boiler; this purchase
demonstrates your confidence in VIADRUS a.s.
In order to get used to a proper treatment of your new product from the start please read these
instructions for its use (first of all the chapter no. 7 – Boiler attendance by user, chapter
no. 11 – Important warnings and chapter no. 12 – Maintenance by user). Please observe the
information given below in order to ensure a longstanding trouble-free operation of boiler so that
both you and we are satisfied.
1. Produced variants of boiler
• Order specification code
VIADRUS HERCULES Green Eco Therm X X
The fuel tank is included in the standard boiler accessories
• Optional accessories (see chapter no. 5.2)
The boiler design you received is only destined for wooden pellets combustion (specification see page 4)
and its trade name is VIADRUS HERCULES Green Eco Therm. It is the boiler with automatic fuel supply.
The burner is cleaned manually.
The boiler is manufactured as warm-water boiler with forced heating water circulation and working
overpressure up to 400 kPa (4 bar). The boiler is tested for tightness by applying 800 kPa (8 bar)
overpressure before despatch.
The use:
The version of boiler VIADRUS HERCULES Green Eco Therm 25X is particularly destined for heating
of individual housing units, weekend houses, cottages etc.
The version of boiler VIADRUS HERCULES Green Eco Therm 32X is particularly destined for heating
of cottages, weekend houses, small business premises, smaller leisure amenities etc.
Advantages of boiler:
automatic boiler operation guarantees the heating comfort,
mechanical fuel feed from any reservoir
automatic ignition
simple, not time-consuming attendance and maintenance
high efficiency reaching 87,9 %,
boiler drum construction proven on a long-term basis
high service life of the cast iron boiler drum
five-year guarantee for the boiler drum
Type of burner:
J: Junior
S: Senior
Burner output:
25: 25 kW
32: 32 kW

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2. Technical data of the boiler
Tab. no. 1 Dimensions, thermal parameters of boiler
Version of boiler VIADRUS HERCULES
Green Eco Therm VIADRUS HERCULES Green Eco Therm
25S 25J 32S 32J
Section number pcs 5 7
Class of boiler according to EN 303-5 - 4 3 3 4
Weight including the supplied fuel tank kg 332 401
Fuel tank weight on demand kg 65 65
Water space volume l 40,9 50,3
Diameter of smoke socket mm 156 156
Boiler dimensions (incl. burner): - height x width mm 1218 x 1309 1218 x 1309
- depth mm 1335 1527
Capacity of the supplied fuel tank dm
3
130 130
kg 85 85
Fuel tank capacity on demand dm
3
725 725
kg 470 470
Water operating overpressure kPa (bar) 400 (4) 400 (4)
Testing water overpressure kPa (bar) 800 (8) 800 (8)
Hydraulic loss (∆T 20 K) Pa 80 110
Recommended heat water operating temperature °C 60 - 80 60 - 80
Recommended return water operating temperature °C 60 60
Noise level dB Doesn´t exceed level
65 dB (A) Doesn´t exceed level 65 dB (A)
Chimney draught mbar 0,15 - 0,25 0,20 - 0,30
Boiler connections - heat water G 1 1/2" G 1 1/2"
- return water G 1 1/2" G 1 1/2"
Connected voltage 1/N/PE 230 V AC 50 Hz
TN-S 1/N/PE 230 V AC 50 Hz TN-S
Operating electric power/max.
W 100/1200 100/1200
Electric protection IP 20 IP 20
Tab. no. 2 Heat - technical parameters of the boiler
Version of boiler VIADRUS HERCULES
Green Eco Therm 25X VIADRUS HERCULES Green Eco Therm 32X
Section number pcs 5 7
Nominal output kW 25 32
Minimum output kW 7,5 9,6
Efficiency % up to 86,8 up to 87,9
The approximate fuel consumption at rated output kg.h
-
1
5,8 8,2
The approximate fuel consumption at minimum
output kg.h-1 1,74 2,45
Burning time at nominal output - supplied tank / the
tank by request. h 14,17/78,33 10,625/58,75
Burning time at minimum output - supplied tank /
the tank by request h 60,7/335,71 35,42/195,83
Heating value MJ. kg
-
1
17,189 17,189
Flue gas temperature °C 120 - 210 120 - 210
Flue gases mass flow rate at nominal output kg.s
-
1
0,018 0,021
Flue gases mass flow rate at minimum output kg.s
-
1
0,009 0,014
Specified fuel:
The pellets must comply at least with one of the standards or regulations as follows:
Direction no. 14-2000 MŽP ČR
DIN 517 31
ÖNORM M 7135
Specified pellets granularity: between 6 and 8 mm
Maximum fuel water content. 12%.
Ash content max. 1,5 %
WARNING! A poor quality of fuel can markedly negatively affect the boiler output and emission
parameters.

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Hydraulic losses of boiler drum
0
500
1000
1500
2000
2500
3000
0 0,5 1 1,5 2 2,5 3 3,5 4
HERCULES Green Eco Therm 25X
HERCULES Green Eco Therm 32X
Q [dm
3.
s
-1
p
z
[Pa
Version of boiler VIADRUS HERCULES Green Eco Therm 25X VIADRUS HERCULES Green Eco Therm 32X
L 1335 1527
L1 809 1001
Fig. no. 1 Boiler dimensions

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3. Boiler description
3.1 Boiler drum construction
The cast iron section boiler drum is the main part of boiler and it is manufactured of grey cast iron according
to EN 1561
• central sections – quality 150 (previously ČSN 42 2415)
• front and rear sections – quality 200 (previously ČSN 42 2420)
The pressure parts of boiler conform to the strength requirements according to EN 303-5.
The boiler drum is assembled of sections by means of pressed on boiler insertions and secured by means of
anchor bolts. The sections create the combustion and ash-pan space, the water space and convection part.
The inlet and outlet of heating water are situated in the rear part of boiler.
The rear section of boiler in its upper part has a smoke extension piece and heating water flange, in the lower
part there is the return water flange with a sleeve piece for inlet and outlet cocks. The cleaning door and ash
door with mounted burner are affixed to the front boiler section.
The whole boiler drum is insulated by means of a health harmless mineral insulation which reduces the
losses caused by the heat transfer into ambient. The steel shell colour is treated by means of high-quality
komaxit spray.
3.2 Control, regulation and safety elements
Elements for control, regulation and safety placed in the control cabinet
Thermomanometer serves for measuring the temperature and pressure of water in the heating system and
is located in the upper part of the boiler shell. The check valve for pressure gauge connection is located in the
upper part of the rear boiler section.
Operating thermostat switches off / switches on the operation of the burner according to the set
temperature of heating water.
Signalling of safety thermostat signals the activation of the safety thermostat (overheating of the heating
system above 97 °C)
The safety thermostat is placed in the control box and serves for ensuring the heating system against
overheating. This thermostat is set by the manufacturer to a temperature of 95°C, i.e. to a higher temperature
than can be set as the desired temperature on the boiler. When you turn off the safety thermostat unblocking
must be done manually. The safety thermostat can be turned on only after the temperature has dropped
below the set value. We have to unscrew the black cap of the safety thermostat and by using a suitable
object we press the button.
In case of repeated switching of the thermostat the boiler must be shut down and the reason of repeated
overheating of the boiler must be found out.
The thermostat of the pump switches on and switches off the pump of heating water according to the set
temperature.
1. Termomanometer
2. Operating thermostat
3. The switch "start of burner"
4. Signalling of safety thermostat
5. Fuse 10A
6. Main switch
7. Safety thermostat
8. Thermostat of pump
Fig. no. 2 Control box
Elements for control, regulation and safety placed on the boiler body
The air rosette of cleaning door and the lower stifling element is not used at the boiler with an automatic
combustion of wooden pellets and must be permanently closed.

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Elements for control, regulation and safety placed on the burner
• Control Module of boiler (version VIADRUS HERCULES Green Eco Therm XJ) or automatic (version
VIADRUS HERCULES Green Eco Therm XS).
• LCD display with control buttons, that is designed for change of the values of operating parameters
(version VIADRUS HERCULES Green Eco Therm XJ).
• Potentiometer – for setting the boiler output (version VIADRUS HERCULES Green Eco Therm XS).
• Photo sensor, which monitors the intensity of the combustion process.
• Transport hose with reinforcing spiral, which melts in the case of penetration of fuel back through the
knee of burner, thus preventing further supply of pellets into the burner.
• Sensor of penetration of fuel (TD) is placed on the knee of burner and is activated in case of the
surface temperature above 90 °C. Burner and fuel feeder are stopped in case of activation of this sensor
and the system is switched over into reporting of a failure. The failure mode is deactivated by switching
off and on of the main switch. It is necessary to determine the cause of the failure and take appropriate
measures, namely before restarting of the burner;
• Reversible thermal label displays the operating temperature of the burner body. This temperature is an
indicator for operating mode of the burner and temperature of flue gases which pass the combustion
chamber back into the fuel tank. The initial state is shown in black colour for all thermally active parts. If
the temperature is increased, the segments gradually are getting a light colour, according to the
temperature range of individual heat-active segments. The reversible thermal label should be checked
as needed. Increased temperature in this section signals the necessity to clean the boiler, grate of
burner or routes of flue gasses and smoke flue. During cooling of the main burner body the colour of the
label returns to its original state (all segments are black).
• Irreversible thermal label displays overheating of the knee of burner. This label in case exceeding of
temperature of the burner knee irreversibly changes its colour.
The initial status, the active segment is white, the temperature hasn’t
reached the degree of activation 104 °C;
The status at activation, the active segment is dark, the temperature
has exceeded the degree for activation 104 °C; activation of 104 °C;
°C
104 °F
219
THERMAX
°C
104 °F
219
THERMAX
CAUTION:
•Activation of irreversible thermal label is signalling overheating of the knee of burner. Status of this
label is irreversible and in case of damage it has to be replaced. Control and service of burner may be
performed only by an authorized technician.
•This thermal label is activated for example when hot combustion products pass back via the fuel feeder
due to an increased resistance of the smoke flue or a lower draft in the chimney. In such cases the
transport hose that connects the fuel feeder and burner body can be damaged and will be necessary its
replacement.
•In case of these emergency statuses the warranty for the burner is void.

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1. Boiler drum
2. Boiler shell with ashtray
3. Cleaning door
4. Burner
5. Transitionary flange
6. Insulation of burner
7. The ash door
8. Fuel tank
9. Fuel feeder
10. Transport hose with reinforcing spiral
11. Control box
12. Flange of heating water
13. Flange of return water
14. Fill and drain cock
15. Sealing 90 x 60 x 3
16. Assembly of smoke adapter
17. Turbulators
18. Partition of flue way
19. Partition of the combustion chamber- the
front section
20. Partition of the combustion chamber
21. Hose clamp
22. Screw M10 x 50
23. Screw M10 x 30
Fig. no. 3 Boiler assembly

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3.2 The construction of burner and transport routes of the fuel
The version VIADRUS HERCULES Green Eco Therm XJ
•Control module with microprocessor;
•LCD display with control buttons, that is designed for change of the values of operating parameters;
Version VIADRUS HERCULES Green Eco Therm XS
•Control panel on which there is placed a potentiometer for setting the boiler output;
•Colour scale on which we can set the position of throttle flap of the fan (the output power of fan) to the
same colour as the setting of the thermal output potentiometer.
•Manual setting of throttle flap of the fan.
Version of boiler VIADRUS HERCULES Green Eco Therm
25J 25S 32J 32S
Nominal heat output 25 25 32 32
power range 7,5 - 25 7,5 - 25 9,6 - 32 9,6 - 32
The burner consists of following components:
• Combustion chamber, which serves for burning pellets and made from high quality stainless steel;
• Removable grate of combustion chamber;
• Electric spiral, by means of which the fuel is ignited. It is located behind the inclined plate of grate in the
combustion chamber;
• Fan for intake of air, equipped with Hall effect sensor for sensing the rotational speed;
• Photo sensor, which monitors the intensity of the combustion process;
• Sensor for penetration of burning fuel (TD) which stops the operation of the burner in case of break
forth of flame into the fuel feeder;
• Socket for connecting the fuel feeder, which ensures power supply into the motor of the fuel feeder;
• Reversible thermal label from a liquid crystal with the indicator of current temperature of the
body of burner.
• Irreversible thermal label from a liquid crystal which signals the high temperature of the knee of
burner, preliminarily sets the conditions for the non-warranty service of the main module of burner and of
any kind of damage to the hose for fuel supply;
• Fuel feeder with an inlet cable and 1 ~ plug.
• Transport hose with reinforcing spiral, which is made partly of a transparent heat-resistant material
(in case of burning does not emit toxic substances and does not maintain the process of burning), that
interconnects the fuel feeder and the knee of burner;
Fig. no. 4 Burner and fuel feeder
Fuel feeder
Transport hose with reinforcing
spiral
Burner
Knee of
the burner

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Fig. no. 5 Basic components of the burner of boiler VIADRUS HERCULES Green Eco Therm XJ
Fig. no. 6 Basic components of the burner of boiler VIADRUS HERCULES Green Eco Therm XS
Sensor for penetration of burning fuel
(TD)
LCD display with control buttons
Photo sensor
Combustion chamber
Control module of boiler
Transitionary flange for mounting the
burner to the door of boiler
Inlet of electricity
Socket for connection of the fuel feeder
Sensor for penetration of burning
fuel (TD)
Photo sensor
Combustion chamber
Control module of boiler
Throttling flap of the fan
Transitionary flange for mounting the
burner to the door of boiler
Inlet of electricity
Control panel