Viadrus HERCULES U 26 Instruction Manual

Hercules U26
Návod k obsluze
VIADRUS HERCULES U 26
MANUAL FOR BOILER OPERATION
AND INSTALLATION

Table of contents: page
1. Boiler use and advantages...................................................................................................................... 3
2. Boiler technical data................................................................................................................................ 3
3. Description............................................................................................................................................... 8
3.1 Boiler construction............................................................................................................................. 8
3.2 Regulation and safety elements ........................................................................................................ 8
3.3 Equipment for surplus heat removal................................................................................................ 11
3.4 Superfluous heat removal equipment- storage reservoirs............................................................... 13
4. Positioning and installation.................................................................................................................... 14
4.1 Regulations and guidelines.............................................................................................................. 14
4.2 Positioning possibilities.................................................................................................................... 14
5. Delivery and assembly.......................................................................................................................... 16
5.1 Delivery and accessories................................................................................................................. 16
5.2 Assembly procedure........................................................................................................................ 17
5.2.1 Installation of smoke extension (only for the size of 8 – 10 sections) ......................................... 17
5.2.2 Boiler drum installation ................................................................................................................ 17
5.3.3 Boiler shells assembly................................................................................................................. 19
5.2.4 Mounting of draw bar of smoke flap control................................................................................. 21
5.2.5 Draught regulator......................................................................................................................... 22
5.2.6 Assembly tools for brush ............................................................................................................. 22
5.2.7 Filling the heating system with water:.......................................................................................... 22
6. Commissioning...................................................................................................................................... 23
6.1 Verification activities before commissioning.................................................................................... 23
6.2 Boiler commissioning....................................................................................................................... 23
7. Boiler operation by user ........................................................................................................................ 23
8. IMPORTANT WARNING....................................................................................................................... 24
9. Maintenance.......................................................................................................................................... 25
10. Instructions for product disposal after its lifetime extinction.................................................................. 25
11. Guarantee and reliability for defects...................................................................................................... 26

3
Dear customer
We thank you that you have bought VIADRUS HERCULES U 26, a universal boiler thus having shown your
confidence in VIADRUS a.s..
For you to get used to a correct way of handling your new product from the beginning please read at first this
manual for its usage (first of all the chapter no. 7 – Boiler operation by user and chapter no. 8 – IMPORTANT
WARNING). Please follow the stated information whereby a longstanding and trouble-free boiler operation
will be guaranteed to both your and our satisfaction.
VIADRUS HERCULES U 26 is a cast-iron sectional low-pressure boiler designated for combustion of solid
fuels – coke, hard coal, wood. Combustion of other materials like plastics is impermissible.
1. Boiler use and advantages
Three-sectional size of VIADRUS HERCULES U 26 boiler is suitable for heat sources reconstructions in
independent tenements, for smaller residential premises and leisure amenities. Bigger sizes of boilers meet
the demands on heating the houses, shops, schools etc.
The boiler is manufactured in warm-water design with both natural and forced heating water circulation and
working overpressure up to 400 kPa (4 bar). Before dispatch the boiler is tested for tightness by applying
800 kPa (8 bar) overpressure.
The boiler is designated for heating both closed and open heating systems.
Boiler advantages:
1. A high lifetime of the cast-iron heat exchanger and all other parts with regard to the quality of used
materials.
2. Long-term verified construction.
3. Sophisticated manufacturing technology on the automatic forming lines with a constant and verified
quality of the manufacturing process. (ISO 9001, ISO 14 001).
4. Coke combustion efficiency 80%
5. Simple operation and maintenance.
6. Output graduation by the number of sections.
2. Boiler technical data
Tab. no. 1 Dimensions, technical parameters of boiler
Number of sections
pcs
3
4
5
6
7
8
9
10
Boiler category according to
EN 303 - 5 - 1
Combustion chamber volume dm
3
23 37 51 64,5 78 91,5 105 118,5
Water space volume l 27,6 33,3 35 44,7 50,4 56,1 61,8 67,5
Weight kg 218 258 298 348 398 448 498 548
Combustion chamber depth mm 185 295 405 515 625 735 845 955
Diameter of smoke socket Ø D mm 156 176
Boiler dimensions: - height x width mm 1158 x 600
- depth L mm 387 498 609 720 831 942 1053 1164
- depth L1 mm 643 754 865 976 1087 1198 1309 1420
Filling hole dimensions mm 300 x 320
Maximum water operating
overpressure kPa (bar) 400 (4)
Minimum water operating
overpressure kPa (bar) 50 (0,5)
Water test overpressure kPa
(bar) 800 (8)
Hydraulic loss - see Fig. No.1
Minimum water inlet temperature °C 60
Recommended heating water
operating temperature °C 60 – 85
Noise level dB Does not exceed the level 65 dB (A)
Chimney draught mbar 0,10 0,15 0,20 0,25 0,30 0,30 0,35 0,40
Boiler connections - heating water 2“
- reverse water 2“
Maximum fuel weight in the
chamber kg 16,1 25,9 35,7 45,15 54,6 64,05 73,5 82,95
Temperature of cooling water for
equipment for surplus heat removal °C 5 – 20
Overpressure of cooling water for
equipment for surplus heat removal kPa (bar) 200 – 600 (2 - 6)

4
Tab. no. 2 Dimensions, technical parameters –coke as fuel
granularity 24 – 60 mm, fuel moisture max. 15 % fuel efficiency: 26 - 30 MJ.kg
-1
Number of sections
pcs
3
4
5
6
7
8
9
10
Rated power kW 15 22,5 30 37,5 43,5 50 56 63
Fuel consumption at the rated
power kg/h 2,43 3,64 4,86 6,07 7,04 8,09 9,07 10,2
Minimum output kW 7,5 11,3 15 18,5 22,5 15 16,8 18,9
Fuel consumption at the minimum
output kg/h 1,21 1,83 2,43 3,0 3,64 2,43 2,72 3,06
Fuel efficiency MJ.kg
-
1
27,8
Burning time at the rated power h 4
Flue gases temperature at the rated
power °C 220-250
Flue gases temperature at the
minimum output °C 120-180
Flue gases mass flow rate at the
minimum output g/sec 3,53 5,33 7,08 8,73 10,6 7,08 8,2 11,2
Flue gases mass flow rate at the
rated power g/sec 7,08 10,6 14,15 17,69 21,2 24,4 27,3 30,7
Efficiency % 80
Tab. no. 3 Dimensions, technical parameters– hard coal as the fuel
granularity 24 – 60 mm, fuel moisture max. 15 % fuel efficiency: 26 - 28 MJ.kg
-1
Number of sections
pcs
3
4
5
6
7
8
9
10
Rated power kW 11 16,5 22,5 31 39,5 45,5 51,5 58
Fuel consumption at the rated
power kg/h 1,87 2,8 3,82 5,26 6,7 7,72 8,73 9,83
Minimum output kW 5,5 8,25 11,25 15,5 19,75 13,65 15,45 17,4
Fuel consumption at the minimum
output kg/h 0,93 1,4 1,9 2,63 3,35 2,32 2,62 2,95
Fuel efficiency MJ.kg
-
1
28,31
Burning time at the rated power h 4
Flue gases temperature at the rated
power °C 220 – 300
Flue gases temperature at the
minimum output °C 120 – 190
Flue gases mass flow rate at the
minimum output g/sec 4,295 6,445 8,78 12,105 15,43 6,66 7,53 8,616
Flue gases mass flow rate at the
rated power g/sec 8,59 12,89 17,56 24,21 30,86 22,2 25,1 28,72
Efficiency % 75
Tab. no. 4 Dimensions, technical parameters – wood as the fuel
fuel moisture max 20 % fuel efficiency: 14 – 18 MJ. kg
-1
Number of sections
pcs
3
4
5
6
7
8
9
10
Rated power kW 8 15,75 20 28,25 33 35 40,5 46
Fuel consumption at the rated
power kg/h 2,56 5,04 7,52 9,03 10,55 11,19 12,95 14,71
Minimum output kW 4 4,73 6,5 8,4 9,7 10,5 12,15 13,8
Fuel consumption at the minimum
output kg/h 1,28 1,51 2,08 2,69 3,1 3,36 3,89 4,41
Fuel efficiency MJ.kg
-
1
15,01
Burning time at the rated power h 2
Flue gases temperature at the rated
power °C 220 – 300
Flue gases temperature at the
minimum output °C 120 – 190
Flue gases mass flow rate at the
minimum output g/sec 1,796 2,870 3,950 4,670 5,380 5,124 5,929 6,735
Flue gases mass flow rate at the
rated power g/sec 5,99 9,59 13,18 15,58 17,97 17,96 19,76 22,45
Efficiency % 75

5
0
50
100
150
200
250
300
350
4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64
výkon kotle [kW]
hydraulická ztráta[Pa]
Fig. No. 1 Hydraulic loss of the boiler drum
5 10 15 20 25 30
51
45
38
34
29
27
24
22
20
19
18
17
15
13
10
45
40
35
30
25
22
20
18
sv
ě
t
l
ý
p
r
ů
ř
e
z
v
c
m
K
o
m
í
n
o
v
ý
t
a
h
[
P
a
]
Účinná výška komínu [m]
10
9
7 - 8
6
5
4
3
P
o
č
e
t
č
l
á
n
k
ů
Fig. No. 2 Stack diameter setting
Rated power (kW)
Hydraulic loss (Pa)
Actual stack height [m]
Draft
[Pa]
Number of sections
inside diameter
in cm

6
Numbe
r of sections
3
4
5
6
7
L 387 498 609 720 831
L1 643 754 865 976 1087
D 156
Fig.no.3a) Connecting dimensions of VIADRUS HERCULES U 26 3 – 7 sect. boiler

7
Number of sections
8
9
10
L 942 1053 1164
L1 1198 1309 1420
D 176
Fig. no. 3b) Connecting dimensions of VIADRUS HERCULES U 26 8 – 10 sect. boiler.

8
3. Description
3.1 Boiler construction
The main part of boiler is the cast-iron sectional boiler drum made of the grey cast-iron according to
EN 1561, quality 150.
The pressure parts of boiler meet the demands on the strength according to:
EN 303-5 Heating boilers – Part 5: Heating boilers for solid fuels, hand and automatically stocked,
nominal heat output of up to 300 kW – Terminology, requirements, testing and marking
The boiler drum is assembled of sections by means of pressed-in boiler insertions with 56 mm diameter and
secured by anchor bolts. The sections create the combustion chamber and the ash pan space, the water
space and the convective part. The heating water inlet and outlet are situated in boiler rear part.
The rear part of boiler in its upper part has a smoke extension/adapter and the heating water flange. In the
lower part there is the reverse water flange. To the front section there are mounted the stoking and ash-pan
doors. Under the ash-pan door there is installed a tilting grate.
The whole boiler drum is insulated by the health harmless mineral insulation which reduces the losses
caused by heat transmission into the environment. The steel shell is coloured by a good quality comaxit
spray.
3.2 Regulation and safety elements
The smoke shutter of the smoke extension/adapter regulates the flue gases outlet volume from the boiler
into the chimney. It is operated by a handle with drawbar in the left upper part of boiler next to the stoking
door.
The ash pan door choker regulates the combustion air inlet under the boiler grate. It is operated by a draught
regulator. Another draught regulator (for 8, 9, 10 sectional boiler) regulates the rear choker. The regulator is
set on the same temperature as the regulator in the front part of the boiler.
The stoking door choker serves for secondary air supply into the combustion chamber.
A combined device- the thermomanometer serves for heating water temperature and pressure detection in
heating system. The reservoir of thermomanometer sensor is installed in upper part of the front boiler
section.

9
1. Boiler drum
2. Stoking door
3. Ashpan door
4. Middle part
5. Tilting grate
6. Tilting grate holder
7. Rosette
8. Choker
9. Choker screw
10. Suspension pin
11. Heating water flange
12. Outlet neck
13. Return water flange
14. Filling and draining cock
15. Lowered console
16. Upper part of the shell with insulation í
17. Left side part of the shell with insulation
18. Right side part of the shell with insulation
19. Rear part of the shell with insulation
20. Thermomanometer
21. Draught controller
22. Two-way safety valve DVB 1 – 02
23. Safety valve
24. Draw bar
25. Bushing HEYCO
26. Slant bushing
27. Plastic ball
28. Label for smoke flap control
Fig. no. 4a) VIADRUS HERCULES U 26 3 – 7 sect. boiler assembly

10
1. Boiler drum
2. Stoking door
3. Ashpan door
4. Middle part
5. Tilting grate
6. Tilting grate holder
7. Rosette
8. Choker
9. Choker screw
10. Suspension pin
11. Heating water flange
12. Outlet neck
13. Return water flange
14. Filling and draining cock
15. Lowered console
16. Upper part of the shell with insulation
17. Left side part of the shell with insulation
18. Right side part of the shell with insulation í
19. Rear part of the shell with insulation
20. Thermomanometer
21. Draught controller
22. Two-way safety valve DVB 1 – 02
23. Safety valve
24. Draw bar
25. Bushing HEYCO
26. Slant bushing
27. Plastic ball M10
28. Label of smoke flap control
29. Left choker console for the rear section
30. Choker for the rear section
31. Choker axis for the rear section
32. Right choker console for the rear section
Fig. no. 4b) VIADRUS HERCULES U 26 8 – 10 sect. boiler assembly.

11
Fig.no.4c) Diagram of VIADRUS HERCULES U 26 boiler - location of additional equipment
3.3 Equipment for surplus heat removal
The after-cooling loop or the two way safety vent DBV 1 - 02 serves for surplus heat removal in case
the water temperature in boiler exceeds 95 °C.
The after-cooling loop is connected to the boiler flanges according to Fig. No. 5, the two way safety
vent according Fig. No. 7.
In case of boiler overheating (the output water temperature exceeds 95 °C) the thermostatic valve switches
on and the superfluous heat is led off via an after-cooling loop.
Fig. No. 5 Hydraulic chart of after-cooling loop connection
In case the system is equipped with a two way safety vent and the boiler becomes overheated (the output
temperature exceeds 95 °C) the two way safety vent creates a cold water circuit which is kept until the
temperature drops below the limit temperature. At this moment there are simultaneously closed the
discharge cooling equipment and the cold water inlet of refilling the system.
1 – Heating water outlet into the system 2”
2 – Reverse water inlet from the after-cooling loop 1 1/2 “
3 – Reverse water inlet into the boiler from system 2”
4 – Cooling water outlet
5 – Thermostatic valve TS 130 (STS 20)
6 – Heating water outlet from boiler 2 “
7 – Cooling water inlet
1 – rear lining
2 – upper lining
3 – ceramic insert (3 – 10 sect.)
4 – additional grate (3 – 10 sect.)

12
Fig. No. 6 The two way safety vent DVB 1 - 02
1 – Boiler
2 – Two way safety vent DBV 1 – 02
3 – Safety valve
4 – Transforming valve
5 – Filter
6 – Ball-shaped cock
7 – Pump
8 – Surplus heat removal
9 – Bleed valve
I – Cooling water inlet
II – Heating water outlet
III – Return water inlet
Fig. No. 7 The recommended scheme of the two way safety vents DBV 1 – 02 connection
It is necessary to install a safety valve for maximum overpressure of 400 kPa (4 bar) on the system
and its dimension must correspond to the rated boiler output. The safety valve must be located
directly behind the boiler. Any stop valve must not be located between the safety valve and boiler. If
you have any questions, please contact our contractual assembly firm and service organizations.
The two way safety vent DBV 1 – 02 technical data (from the firm Regulus)
Opening temperature (limit): 100 °C (+0° - 5 °C)
Maximum temperature: 120 °C
Maximum stress on boiler side 400 kPa (4 bar)
Maximum stress on water side 600 kPa (6 bar)
Nominal flow at p 100 kPa (1 bar): 1,9 m
3
/h
Usage
The two way safety vent DBV 1 – 02 is used as a protection of heating boilers against overheating. In the
valve body there is the bleed and supply valve controlled by thermostatic element. When the limit
temperature is reached, the bleed and supply valve is simultaneously opened meaning that the cold water is
running in and the hot water is running out. When the temperature drops below limit, the bleed and supply
valve is simultaneously closed.
Caution! It is not a compensation for safety valve.
In case of two way safety vent reaction, when there is a possibility of boiler having been filled with
the water, which does not meet the ČSN 077401 requirements it is necessary to change the water in
the heating system so that it meets the ČSN 077401 requirements again.
A – cold water inlet
B – output to boiler
C – output to drain
D – input from boiler

13
Installation
Installation can be only carried out by a qualified person. For the correct operation of the thermostatic, two
ways safety vent it is necessary to comply with the conditions for its installation and keep the flow directions
marking on its body. The safety vent is always mounted in the output pipe of boiler or directly on the upper
part of boiler, where the hot water leaves boiler and is transported into heating system. When installing the
vent it is necessary to check, if the 3/4“ socket usage, which can be both in pipeline and on boiler, ensures
complete immersion of the thermostatic vent element after the vent installation. After the vent has been
installed in socket, connect the down pipe, in which the hot water from boiler will flow to drain, to „C“(see. fig.
No. 6). The cooling water inlet, which will cool the boiler after setting the vent in operation, is connected (see
fig. No. 7) to „A“ (see fig. No. 6). The filter for mechanical impurities must be installed in the cooling water
inlet. It is necessary to connect the pipeline to „B“ (see. fig. No. 6) and the pipeline is to be led into reverse
flow pipe of heating system near the boiler (see fig. No. 7).
Regular maintenance
Once a year it is necessary to turn the safety vent’s head to remove possible impurities formed in the vent.
Clean the cooling water inlet filter.
In case of using an open expansion tank it is not necessary to use a protecting device against
overheating.
Every heat source in an open heat system must be connected with an open expansion tank positioned at the
highest point of the heat system. The expansion tanks must be rated in the way that they can contain the
changes in water volume resulting from heating and cooling.
The open expansion tanks must be equipped with non-closable bleeder and a overflow pipes. The overflow
pipe must be designed in the way that it safely drains off the maximum flow volume entering the system. This
can be achieved by rating the overflow pipes by one DN higher than that of the filling piping. The expansion
tanks and their connecting pipes must be designed and positioned in the way that freezing is reliably
inhibited.
Fig. no. 8 The examples of open expansion tanks connection
3.4 Superfluous heat removal equipment- storage reservoirs
In case that the required volume exceeds 300 l we recommend to install a storage reservoir.
Because the minimum output of this boiler is higher than 30% of the rated power we recommend to remove
the heat into the storage reservoirs.
The calculation of the minimum volume of stack heat exchanger
V
sp
= 15T
b
x Q
N
(1-0,3 x (Q
H
/Q
min
))
where
V
sp
the volume of storage reservoir in l
Q
N
rated thermal output in kW
T
b
burning time in h
Q
H
thermal load of buildings in kW
Q
min
minimum thermal output in kW
The dimensions of storage reservoirs at the boilers for central heating that are operated with individual
prescribed fuels must be set according to the fuel which needs the biggest storage reservoir. This storage
reservoir isn’t necessary if the calculated volume is smaller than 300 l.
1 Heat source
2 Expansion tank
3 Safety piping
4 Expansion piping
5 Overflow piping
6 Filling piping
7 Water level limiter
8 Reverse piping

14
4. Positioning and installation
4.1 Regulations and guidelines
The solid fuel boiler can only be installed by a firm holding a valid licence to carry out its installation and
maintenance. A project according to the valid regulations must be elaborated for installation. Before the
boiler installation on an older heating system the installation firm must flush out(clean) the whole system.The
heating system must be filled with water meeting the ČSN 07 7401 requirements; especially its
hardness must not exceed the required parameters
Tab.no.4 Recommended values
Hardness mmol/l 1
Ca
2+
mmol/l 0,3
The 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 vent reaction, when there is a possibility of boiler having been filled with
the water, which does not meet the ČSN 077401 requirements it is necessary to change the water in
the heating system so that it meets the ČSN 077401 requirements again.
a) to the heating system
ČSN 06 0310 Heating systems in buildings – Designing and installation
ČSN 06 0830 Heating systems in buildings – protecting device
ČSN 07 7401 Water and steam for thermal energy equipments with working pressure up to 8 MPa
EN 303-5 Heating boilers – Part 5: Heating boilers for solid fuels, hand and automatically
stocked, nominal heat output of up to 300 kW – Terminology, requirements, testing
and marking
b) to the chimney
ČSN 73 4201 Chimneys and flue gas ducting – designing, implementation and connection of fuel
consumers.
c) regarding the fire regulations
ČSN 06 1008 Fire safety of heat installations.
EN 13501-1 + A1 Fire classification of construction products and building elements – Part 1:
Classification using test data from reaction to fire tests.
d) to the system of HWS heating
ČSN 06 0320 Heating systems in buildings – Hot water preparation – Designing and planning
ČSN 06 0830 Heating systems in buildings – Safety devices.
ČSN 75 5409 Water installations inside buildings
4.2 Positioning possibilities
Boiler positioning in the living space (including corridors) is prohibited!
The installation of the boiler must comply with all requirements of ČSN 06 1008.
The boiler positioning with regard to the fire regulations:
1. Installation on a floor made of incombustible material (Fig. No. 9)
−The boiler can be installed on a fireproof floor exceeding the boiler platform by 20 mm on the sides
and only up to the boiler drum depth.
−If the boiler is positioned in a cellar we recommend to install it on a retaining wall (substruction)
minimum 50 mm high
−install the boiler in the middle of the retaining wall
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.

15
number of sections
3
4
5
6
7
8
9
10
L mm]
387 498 609 720 831 942 1053 1164
Fig. No. 9 Substruction (retaining wall) dimensions
Tab. no. 5 Grade of reaction to fire
Grade of reaction to fire
Examples of building materials an
d 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,…
Boilers positioning with regard to the necessary
handling space:
−Basic AA5/AB5 environment according to
ČSN 33 2000-1 ed. 2.
−In front of the boiler there must be left a minimum
handling area of 1000 mm.
−Keep minimum 400 mm distance between the rear
part of the boiler and the wall.
−At least from one lateral face keep minimum
400 mm space for access to rear part of the boiler.
Fuel storage:
−Dry fuel has to be used for a proper combustion
in the boiler. The manufacturer recommends
fuel storage in cellars or at least under shelter. It
is out of question to store the fuel behind the boiler
or next to the boiler within a distance smaller than
400 mm.
−It is out of question to store the fuel between two
boilers in the boiler room.
−The manufacturer recommends to keep minimum
1000 mm distance between the boiler and the fuel
or to store the fuel in a room different from that
where the boiler is installed.
Fig.no. 10 Location of boilers in the
boiler room

16
5. Delivery and assembly
5.1 Delivery and accessories
Boiler is delivered according to the purchase order on the pallet on which the complete boiler drum is placed
and on the side there is attached the wrapped boiler shell. The accessories are put inside the boiler drum,
accessible only after opening the stoking door. The boiler is wrapped in a transport package and it must not
be tilted over during the transport.
Standard boiler delivery
• Boiler on a pallet, with an adequate number of sections
- boiler heating water flange with a thread (curved) 1 pc
- reverse water flange (3 – 7 sect.) 1 pc
- reverse water flange with distribution tube (8 – 10 sect.) 1 pc
- sealing φ90 x 60 x 3 2 pcs
- washer 10,5 8 pcs
- nut M10 8 pcs
- filling and discharge tap Js 1/2“ 1 pc
- draught regulator complete (3 – 7 sect.) 1 pc
draught regulator complete (8 – 10 sect). 2 pcs
- suspension pin (8 – 10 sect.) 1 pc
- Js 6/4“ blinding plug 1 pc
- sealing φ60 x 48 x 2 1 pc
• The shell incl. the ash pan, adequately sized incl. insulation
- lowered console 2 pc
- washer 10,5 4 pcs
- nut M10 4 pcs
- spring clip 4 pcs
- screwM5 x 12 4 pcs
- washer 6,4 4 pcs
- bushing HEYCO SB – 625 – 8 1 pc
- slant bushing 1 pc
- screwST 4,2 x 9,5 10 pcs
- connecting plug 4 pcs
- thermomanometer 1 pc
• Draw bar 1 pc
- lock 2,5 x 32 1 pc
- plastic ball M10 1 pc
• Smoke shutter operation label 1 pc
• Choker screw 1 pc
• Cleaning tools
- hook 1 pc
- brush with a handle 1 pc
- spike 1 pc
- holder for cleaning tools 1 pc
• Handling key 1 pc
• Commercial& technical documentation
Supplementary outfit (is not included in delivery):
• ceramic plate for hard coal combustion 1 pc
• rear lining for wood combustion for 8 – 10 sections 1 pc
• auxiliary grate for wood combustion 2 pcs according to the size
• upper lining for wood combustion for 8 – 10 sections (8 sect.-10 pcs, 9 sect.-12 pcs, 10 sect.-14 pcs)
Necessary accessories: (is not included in delivery):
• After-cooling loop (1 pc) (for the 3 – 7 sectional boiler) incl. flange or the two way safety vent DBV 1 - 02
(for the 3 – 10 sectional boiler) incl. siseal 10 g. This equipment needn’t be used in case of an open
heating system.
• Thermostatic valve TS 130 (STS 20) – TV 95°C – can be delivered directly from the wholesale (only at
the delivery with after-cooling loop)
• Safety valve 1 pc

17
By request (is not included in delivery):
• Filter 3/4“ – for delivery with the two way safety vent DBV 1 - 02
The supplementary outfit, necessary accessories and optional boiler accessories is not included in
the boiler standard price.
5.2 Assembly procedure
5.2.1 Installation of smoke extension (only for the size of 8 – 10 sections)
Fig. No. 11 Installation of smoke extension
1. Insert the sealing cord (1) into the groove in the rear section.
2. Screw the smoke extension (2) by means of washers 8,4 (3) and nuts M8 (4). Be careful when
tightening due to the fragility of the material of the smoke extension.
5.2.2 Boiler drum installation
Boiler drum installation- after-cooling loop
1. Set the boiler drum on the retaining wall (substruction)
2. On the weldment of after-cooling loop weld in advance the after-cooling loop heating water flange
(according to the boiler room layout), insert the sealing Ø 90 x 60 x 30 between the flange and the
boiler, then mount the weldment to the boiler by means of 4 pcs nut M 10 and 4 pcs washer 10,5. The
upper outlet of heating water interconnect with the heating system by means of a weld.
3. Interconnect the lower outlet from the after-cooling loop by welding a 1 1/2“ tube with reverse water
outlet (reverse water flange) to the boiler.
4. Mount the thermostatic valve on one of after-cooling loop outlets (mount the sensor into the reservoir
and connect the cold water inlet 1/2“) mind the flow direction marked by an arrow; it must correspond to
that shown in Fig. No. 5.
5. Other 1/2“ outlet from the after-cooling loop interconnect with the drain (warning: for the check of
thermostatic valve function we recommend to interconnect the water outlet with the drain by means of a
funnel.)
6. After the boiler connection to the heating system screw a filling and discharge taps to the rear section
according to Fig. No. 12
7. To the smoke extension (adapter) set the smoke tube and insert into the chimney opening. The smoke
tube diameter is 160 mm for the sizes with 3 – 7 sections, 180 mm for 8 – 10 sections.
8. Screw the draught regulator into the opening in upper part of the front section. The boiler draught
regulator adjustment procedure is shown in manual enclosed to particular regulator. For the
8 – 10 sectional boiler screw two draught regulators according to Fig. No. 4.
1. Sealing cord
2. Smoke extension
3. Washer 8.4
4. Nut M8

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9. Blind the threaded opening JS 6/4“ in the front section with JS 6/4“ plug. Insert the sealing Ø 60 x 48 x 2
under the plug.
10. It is recommended to use shut-off valves for heating water inlet and outlet since without the valves it will
be necessary to drain the whole system during the filter cleaning.
Boiler drum installation – the two way safety vent DBV 1 - 02
1. Set the boiler drum on the retaining wall (substruction)
2. Insert the sealing Ø 90 x 60 x 30 between the heating water flange and the boiler, then mount to the
boiler by means of 4 pcs nut M 10 and 4 pcs washer 10,5 (according to the boiler room layout). By
welding connect the upper heating water outlet with heating system.
3. Insert the sealing Ø 90 x 60 x 30 between the reverse water flange (at the 8 – 10 sectional boiler the
reverse water flange with distribution tube) and the boiler, then mount by means of 4 pcs nut M 10 and
4 pcs washer 10,5 to the boiler. By welding connect the lower heating water outlet with heating system.
4. According to Fig. no. 7 interconnect the two-way safety valve DBV 1 – 02 with the flange of the return
and heating water (the return water flange with a distribution pipe at the version with 8-10 sections) and
with cooling water inlet plus superfluous heat outlet.
5. Mount the discharge valve in the return water flange.
6. Set the smoke tube to the smoke extension/adapter and insert into the chimney opening. The smoke
tube diameter is 160 mm for sizes 3 – 7 sections, 180 mm for 8 – 10 sections.
7. Screw the draught regulator into the opening in the upper part of the front section and the upper part of
the rear section. The chimney draught regulator adjustment is shown in manual enclosed to particular
regulator. For the 8 – 10 sectional boiler screw two draught regulators according to Fig. No. 4.
8. Blind the threaded opening JS 6/4“ in the front section with JS 6/4“ plug. Insert the sealing Ø 60 x 48 x 2
under the plug.
9. It is recommended to use shut-off valves for heating water inlet and outlet since without the valves it will
be necessary to drain the whole system during the filter cleaning.
Fig.no.12 Boiler drum installation
1. Sealing φ90 x 60 x 3
2. Heating water flange
3. Washer 10,5
4. Nut M10
5. Sealing φ90 x 60 x 3
6. Return water flange
7. Washer 10,5
8. Nut M10
9. Filling and draining cock

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5.3.3 Boiler shells assembly
1. Take the shells out of the cardboard cover.
2. Put two lowered consoles(1) on the threads of upper anchor bolts and screw them by means of four
nuts M10 (3) and four washers 10,5 (2) - (see Fig.no.13).
Fig.no.13 Mounting of boiler shell consoles
1. Sie part of the shell
2. Spring clip
1. Side part of the shell
2. Spring clip
3. Bushing HEYCO
4. Slant bushing
5. Draw bar of the smoke flap control
Fig.no.14 Right side part of the shell Fig.no.15 Left side part of the shell
1. Lowered console (2 pc)
2. Washer 10,5
3. Nut M10
4. Thermometer well
5. Manometer well

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3. Mount two spring clips (2) on the right side part of the shell (1), then insert the insulation (see
Fig.no.14). Put the boiler shell on the lower anchor bolts and connect the upper part with the lowered
consoles by means of two screws M5 x12 and two washers 6,4 (see Fig.no.17).
4. Mount two spring clips (2) on the left side part of the shell (1), insert the bushings (3, 4), then insert the
draw bar of smoke flap control (5) and the insulation (see Fig.no.15). Put the shell on the lower anchor
bolts and connect the upper part with the lowered consoles by means of two screws M5 x12 and two
washers 6,4 (see Fig. no. 17).
5. Mount the insulation on the rear part of the shell (10 – Fig.no.17) and screw it to the side parts of the
shell by means of the screws ST 4,2 x 9,5 (11 – Fig.no.17).
6. Mount four connecting plugs (2) on the upper part of the shell (1) and insert the thermomanometer
(8 – Fig. no. 17).
7. Insert the thermometer sensor into the thermometer well (4 – Fig.no.13) and screw the manometer into
the manometer well (5 – Fig.no.13).
8. Insert the insulation into the upper part of the shell and put it on the side parts of the shell.
9. Screw the rear part of the shell to the upper part of the shell by means of two screws ST 4,2 x 9,5
(11 – Fig. no. 17).
Fig. no. 16 Upper part of the boiler shell
1. Upper part of the shell
2. Connecting plug