Viadrus VULCANUS Instruction Manual

Hercules U26
Návod k obsluze
VULCANUS
MANUAL FOR BOILER OPERATION
AND INSTALLATION

Table of content: page
1. Boiler usage and advantages......................................................................................................................3
2. Boiler technical data....................................................................................................................................3
3. Description...................................................................................................................................................7
3.1 Boiler construction................................................................................................................................7
4. Positioning and installation..........................................................................................................................9
4.1 Rules and regulations...........................................................................................................................9
4.2 Positioning possibilities.......................................................................................................................11
4.3 Hydraulic connection diagram............................................................................................................13
5. Boiler installation........................................................................................................................................16
5.1 Delivery and accessories ...................................................................................................................16
5.2 Installation procedure.........................................................................................................................17
5.2.1 Installation of boiler drum with the basement..............................................................................17
5.2.2 Shells assembly..........................................................................................................................19
5.2.3 Fuel reservoir assembly..............................................................................................................21
5.2.4 Mounting of the service board to the fuel reservoir.....................................................................22
5.2.5 Mounting of cleaning tools ..........................................................................................................22
5.2.6 Assembly of the emergency fire extinguishing equipment..........................................................23
5.2.7 Boiler conversion from right-hand design to the left-hand design...............................................23
5.2.8 Wiring diagram............................................................................................................................28
6. Boiler operation by user.............................................................................................................................32
6.1 Control, regulation and security elements..........................................................................................32
6.1.1 Saphir regulator...........................................................................................................................32
6.1.2 Safety thermostat........................................................................................................................36
6.1.3 Temperature sensor on the fuel feeder ......................................................................................36
6.1.4 Emergency fire-extinguishing system .........................................................................................36
6.1.5 Forced withdrawal of superfluous heat .......................................................................................36
6.2 SAPHIR regulator parameters............................................................................................................36
6.2.1 Description of SAPHIR regulator parameters.............................................................................45
6.3 QAA 88 device ...................................................................................................................................54
6.3.1 Parameters setting and displaying..............................................................................................55
6.3.2 Faults ..........................................................................................................................................58
6.4 Service board.....................................................................................................................................59
6.5 Checking activities before commissioning.........................................................................................60
6.6 Setting of parameters before the equipment start-up.........................................................................61
6.7 Boiler commissioning .........................................................................................................................61
6.8 HMI (ACX84.910/ALG) service unit for Saphir regulator operation....................................................62
6.9 Superior control..................................................................................................................................63
7. IMPORTANT CAUTIONS..........................................................................................................................63
8. Maintenance..............................................................................................................................................64
9. Instructions for product disposal after its service life.................................................................................65
10. Guarantee and liability for defects .........................................................................................................65

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Dear customer,
We thank you that you have bought VULCANUS automatic solid fuel boiler and 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 usage (mainly chapter no. 6 – Boiler operation by user, chapter no. 7 – Important
cautions and chapter no. 8 – Maintenance). Please follow the bellow stated information at once – and
respect the producer´s, eventually assembly company´s which installed the boiler, instructions to be
provided a longterm failure-free boiler operation to your satisfaction.
1. Boiler usage and advantages
The hot-water automatic boiler VULCANUS for solid fuel is designated first of all for heating the houses,
weekend houses, small premises, ect.
Boiler advantages:
•automatic boiler operation, equithermal control
•possibility of HW heating
•mechanical fuel fedd from inbuilt reservoir
•simple, time non-consuming boiler attendance and maintenance
•low operating costs
•high efficiency
2. Boiler technical data
Tab. no. 1 Boiler dimensions, technical parameters
Size 4 sect. 5 sect. 6 sect. 7 sect.
Boiler weight
- small reservoir kg 465 517 569 621
- large reservoir kg 496 547 598 649
Water space volume dm
3
60 71,9 83,8 95,8
Diameter of smoke socket mm 156
Fuel reservoir capacity – small dm
3
269
Fuel reservoir capacity – large dm
3
528
Boiler dimensions (including small fuel reservoir):
width x depth x height mm See fig. no. 1
Boiler dimensions (including large fuel reservoir):
width x depth x height mm See fig. no. 1
Filling hole dimensions – small reservoir mm 422 x 545
Filling hole dimensions – large reservoir mm 422 x 1210
Boiler degree acc. to EN 303 - 5 - 3
Working water overpressure bar (kPa) 2,5 (250)
Testing water overpressure bar (kPa) 5 (500)
Recommended operating temperature of heating
water °C 50 – 85 65 – 85
Minimum return water temperature °C 45 50
Boiler hydraulic loss mbar 0,72 0,96 1,32 1,59
Noise level dB Doesn´t exceed level 65 dB (A)
Chimney draught Pa 15 –20 20 –25
Boiler connections – heating water Js G 2”
– return water Js G 2”
Connecting voltage 1/N/PE 230 V AC 50 Hz TN - S
Electric input W 100
Electric coverage IP 44

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Tab. no. 2a)Thermal technical parameters of the boiler during combustion of brown coal
Size 4 sect. 5 sect. 6 sect. 7 sect.
Nominal output kW 20 25 30 35
Regulated output kW 6 - 20 7,5 - 25 9 - 30 10,5 - 35
Fuel consumption at nominal output kg.h
-
1
4,5 5,6 6,65 7,65
Fuel consumption at minimum output kg.h
-
1
1,4 1,7 2,02 2,32
Fuel consumption in upkeep regime kg.h
-
1
0,1 0,1 0,1 0,1
Fuel value MJ.kg
-
1
19,17 19,17 19,17 19,17
Burning time at nominal output – small
reservoir h 36 h 15 min 29 h 10 min 24 h 30 min 21 h 15 min
Burning time at nominal output – large reservoir h 71 h 30 min 57 h 20 min 48 h 15 min 42 h
Efficiency % up to 83,1 up to 85 up to 87 up to 89
Flue gas temperature °C 115 – 195 100 – 180 95 – 170 90 – 160
Flue gas mass flow at outlet kg.s
-
1
0,007 – 0,015 0,009 – 0,019 0,011 – 0,022 0,013 – 0,025
Tab. no. 2b)Thermal technical parameters of the boiler during combustion of black coal
Size 4 sect. 5 sect. 6 sect. 7 sect.
Nominal output kW 20 25 30 35
Regulated output kW 6 - 20 7,5 - 25 9 - 30 10,5 - 35
Fuel consumption at nominal output kg.h
-
1
3,4 4,21 5 5,8
Fuel consumption at minimum output kg.h
-
1
1,03 1,28 1,52 1,76
Fuel consumption in upkeep regime kg.h
-
1
0,13 0,13 0,13 0,13
Fuel value MJ.kg
-
1
25,1 25,1 25,1 25,1
Burning time at nominal output – small
reservoir h 45 h 10 min 36 h 30 min 30 h 35 min 26 h 25 min
Burning time at nominal output – large reservoir h 88 h 40 min 71 h 35 min 60 h 15 min 52 h
Efficiency % up to 84,2 up to 85 up to 86 up to 87
Flue gas temperature °C 110 – 195 90 – 170 85 – 165 80 – 150
Flue gas mass flow at outlet kg.s
-
1
0,007 – 0,014 0,010 – 0,017 0,012 – 0,021 0,014 – 0,024
Tab. no. 2c)Thermal technical parameters of the boiler during combustion of wood pellets
Size 4 sect. 5 sect. 6 sect. 7 sect.
Nominal output kW 20 25 30 35
Regulated output kW 6 - 20 7,5 - 25 9 - 30 10,5 - 35
Fuel consumption at nominal output kg.h
-
1
4,85 6,06 7,26 8,47
Fuel consumption at minimum output kg.h
-
1
1,5 1,84 2,21 2,57
Fuel consumption in upkeep regime kg.h
-
1
0,35 0,35 0,35 0,35
Fuel value MJ.kg
-
1
17 17 17 17
Burning time at nominal output – small
reservoir h 27 h 10 min 21 h 45 min 18 h 10 min 15 h 30 min
Burning time at nominal output – large reservoir h 53 h 20 min 42 h 40 min 35 h 35 min 30 h 30 min
Efficiency % up to 87,3 up to 87,4 up to 87,5 up to 87,5
Flue gas temperature °C 95 – 175 90 – 165 90 – 160 85 – 145
Flue gas mass flow at outlet kg.s
-
1
0,007 – 0,015 0,009 – 0,018 0,010 – 0,022 0,012 – 0,025
! Important notice:
The above mentioned values vary according to the type, quality and moisture of the fuel used.
Therefore there may be necessary corrections at setting of feeding time (proportion of fuel feeding
and fuel afterburning time). For example, if there occur the sliver parts of fuel on the fire grate and in
the ash pan, it is evident, that the speed of feeding is higher than the speed of afterburning, in this
case it is necessary to decrease the feeding cycle.
Specified fuel parameters – fuel which was tested by SZÚ:
•Water content max. 12 % (hard coal, wood pellets),
max. 20 % (lignite)
•Volatile combustible content 28 - 40 %
•Ash deformation temperature by melting > 1150 °C
•Low agglutinating power
•Low creeping

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Tab. no. 3 Specified fuel
Fuel Sort of fuel Granularity
[mm] Fuel value [MJ.kg-1]
Hard coal Peas 10 – 25 21 – 28,5
Lignite Nub 2 10 – 25 16,5 – 19,5
Nub 3 10 – 16 16,5 – 19,5
Biomass Wood pellets Ø 6 - 8 15 – 19
Tab. no. 4 Specified fuel – lignite (Automatic operation)
Fuel Granularity
[mm]
Fuel
value
[MJ.kg-1]
Ash content
[%]
water
content
[%]
sulphur
content
[%]
Specific
sulphur
content
[g/MJ]
Tar
content in
dry matter
[%]
Tar content
in
combustible
matter [%]
Screened lignite –
nub 2 10 - 25 17,6 9,8
(in anhydrous
condition) max. 20 0,77 0,44 15,1 15,71
The pellets must comply at least with on of the following directions or standards:
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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Length 4 5 6 7
L [mm] 754 865 976 1087
L1 [mm] 498 609 720 831
Fig. no. 1 Main dimensions of boiler (right version)
(dimensions after the slash apply to the variant with a large reservoir)

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

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

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Fig. no. 3 Burner with mixer
Tab. No. 5 Assignment of the type of grate according to size of boiler and type of fuel
Marking of the grate
(identification symbol)
Number of boiler sections and type of fuel
4 sections 4 sections 5 sections 6 a 7
sections 6 a 7 sections
black coal
brown coal pellets black coal
brown coal
pellets pellets black coal
brown coal
no identification symbol x
1 identification symbol x
2 identification symbols x
3 identification symbols x x
4. Positioning and installation
4.1 Rules and regulations
A solid fuel boiler can only be installed by a firm holding a valid concession for boiler installation and
maintenance.
A project according to the valid regulations must be prepared for the installation.
The heating system must be filled with water, that meets the ČSN 07 7401 requirements, especially its
harness must not exceed the required parameters.
Recommended values
Hardness mmol/l 1
Ca
2+
mmol/l 0,3
Concentration of total Fe + Mn mg/l (0,3)*
*) recommended value
WARNING!!! The use of anti-freeze mixture is not recommended by the manufacturer.
1. Mixer
2. Retort
3. Countersunk screw with internal
hexagon M8 x 20
4. Cast iron grate
5. Sealing
6. Cap
7. Washer 8,4
8. Screw M8 x 20
Detail A – Identification symbol

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In case the two-way safety device has responded to refill with water not conforming to
ČSN 07 7401 it is necessary to treat the water in the system so that it again conforms to this
standard.
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 fuele, 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 electrical network
ČSN 33 0165 Electrical regulations; marking the leading wires by colours or digits;
implementing regulations
ČSN 33 1500 Electrical regulations; revision of electrical equipments
ČSN 33 2000-1 ed. 2 Low-voltage electrical installations – Part 1: Fundamental principles,
assessment of general characteristics, definitions.
ČSN 33 2000-4-41 ed. 2 Low voltage electrical installations - Part 4-41: Protection for safety - Protection
against electric shock
ČSN 33 2000-5-51 ed. 3 Electrical installations of buildings – Part 5-51: Selection and erection of
electrical equipment – Common rules
ČSN 33 2130 ed. 2 Low-voltage electrical installations – Internal electric distribution lines
ČSN 33 2180 Electrical regulations: Connection of electric instruments and appliances
ČSN 34 0350 ed. 2 Safety requirements for flexibile cords and cables
EN 60 079-10 Electrical regulations: Regulations for electrical equipments at the places with
explosion hazard with flammable gases and vapours.
EN 60 252-1 Capacitors for AC motors – Part 1: In general – Design, testing, dimensioning –
Safety requirements – Instructions for installation and operation.
EN 60 335-1 ed.2 Electric appliances for household and similar purposes – Safety – Part 1:
General requirements
EN 60 335-2-102 Electric appliances for household and similar purposes – Safety – Part 2-102:
Special demands on appliances containing the electric connections and burning
the gas, oil and solid fuels
EN 60445 ed. 4 Basic and safety principles for man-machine interface, marking and
identification – Identification of equipment terminals, conductor terminations and
conductors
EN 61000 – 6 – 3 EMC – Part 6 – 3: Basic standards – Emissions – residaytial, commercial and
light industry environment.
EN 61000 -3 – 2 EMC - Part 3 – 2: Limits – Limits for harmonic currents emissions (device with
input phase current up to 16 A inclusive).
EN 61000 – 3 –3 EMC – Part 3 - Limits - section 3: Specifies the limitation of voltage fluctuation
and flicker in low-voltage supply systems for equipment with a rated input
current greater than 16 A.
e) 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 House water plumbing

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4.2 Positioning possibilities
The boiler is equipped with the movable mains supply and plug. Boiler according to EN 60 335–1
ed. 2 Art. 7.12.4 must be positioned in such a way that the plug is accessible.
Boiler positioning in the living space (including corridors) is prohibited!
The installation of the boiler must comply with all requirements of ČSN 06 1008.
Boiler positioning with regard to the fire regulations:
1. Positioning on the floor made of incombustible material
- The boiler can be installed on a fireproof and thermally instulating bottom which exceeds the boiler
platform by 20 mm on the sides.
- If the boiler is installed in a cellar, we recommend to install it on a minimum 50 mm high retaining wall
(bedding). The boiler must be installed straight, any possible inequalities of retaining wall are
eliminated by means of adjustable foot (see Figure No. 13)..
2. Safety distance from the combustible materials
-when installing and operating the boiler it is necessary to keep a safety distance of 200 mm from the
materials of combustibility grade A1, A2, B and C (D);
- for easily combustible materials of combustibility grade E (F), which quickly burn and burn
themselves even after removal of ignition source (such as paper, cardboard, asphalt and tar paper,
wood and wood-fiber boards, plastics, floor coverings) the safe distance has to be doubled, i.e. to
400 mm;
- safe distance should be doubled as bulb where the grade of reaction to fire has not been proved.
Tab. no. 6 Grade of reaction to fire
Grade of reaction to fire Examples of building materials and products included in the reaction to fire
(Extract from EN 13 501-1 + A1)
A1 – incombustible Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters, …
A2 – combustible with difficulty
acumin, izumin, heraklit, lignos, boards and basalt felt, fibreglass boards,...
B– hardly combustible Beech and oak wood, hobrex boards, plywood, werzalit, umakart, sirkolit,...
C (D) – medium combustible Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,...
E (F) – easily combustible Asphaltboard, fibreboards, cellulose materials, polyurethane, polystyrene,
polyethylene, PVC,…
Boiler positioning with regard to the necessary handling space:
•Basic environment AA5 / AB5 according to ČSN 33 2000-1 ed. 2
•In front of the boiler there must be left a minimum handling area of 1000 mm
•The minimum distance between the rear part of boiler and wall 400 mm.
•On the side of fuel reservoir there must be left min. space 800 mm in case of screw feed removal
•Minimum distance from the left side wall 100 mm
•Above the boiler in min. 450 mm.
Boiler positioning with regard to electricity network:
•The boiler must be placed so that the plug in socket (230 V/50 Hz) is always accessible.
Fuel positioning:
•For the right burning in the boiler it is necessary to use the dry fuel. The producer recommends to
store the fuel in the cellar area or at least under the shelter.
•It is interdicted to store the fuel behind the boiler or next to the boiler within a distance smaller than
400 mm,
•The producer recommends to keep the distance between the boiler and fuel min. 1 000 mm, or to store
the fuel in a different room that where the boiler is installed.
It must be ensured the continuous air supply into the room, where the boiler is installed for burning and
eventual ventilation
Air consumption of boiler:
Number of section 4 5 6 7
air consumption [m
3
.h
-
1
] 60 75 90 110
CAUTION: When connecting the boiler to the heating system there must be installed a drain tap
in the lowest point and as near as possible to the boiler.

12
Fig. no. 4 Boiler positioning in the boiler room
Fig. no. 5 VULCANUS boiler (the right version with a small reservoir) with the open fuel reservoir

13
4.3 Hydraulic connection diagram
Fig. no. 6 Hydraulic diagram with HW preparation– Pump heating circuit
Fig. no. 7 Hydraulic diagram without HW preparation– Pump heating circuit
Legend to Fig. no. 6 and 7:
A6 QAA 88 device
BT1 Safety thermostat
B2 Boiler outlet temperature sensor
B3 HW temperature sensor
B5 Fuel feeder temperature sensor
B9 Outside temperature sensor
EX Expansion vessel
M1 Fuel feeder motor
M2 Air fanmotor
PV Safety valve
Q1 Boiler primary circuit pump
Y3 HW heating three-way valve
V1 Thermostatic valve
ZK Clack valve

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Fig. no. 8 Hydraulic diagram with HW preparation– Mixing heating circuit
Fig. no. 9 Hydraulic diagram without HW preparation– Mixing heating circuit
Legend to figures no. 8 and 9:
A6 QAA 88 device
BT1 Safety thermostat
BT3 Thermostat HW
B1 Heating branch temperature sensor
B2 Boiler outlet temperature sensor
B5 Fuel feeder temperature sensor
B9 Outside temperature sensor
EX Expansion vessel
M1 Fuel feeder motor
M2 Air fan motor
PV Safety valve
Q1 Boiler primary circuit pump
Q2 Heating circuit pump
Q3 HW charging pump
Y1 Heating circuit three-way mixing valve
drive
V1 Thermostatic valve
V2 Stop valve
ZK1 Clack valve

15
Note:
Select the dimension of shorting pipe with stop valve V2 up to the half of other piping dimension. Shorting
pipe is necessary. In case the thermostatic valve V1 is only closed through the boiler and mixing valve Y1 is
open to the heating circuit the heating circuit with the heating circuit pump will be secured through this
shorting pipe.
Sensor cables can anyhow be shortened or prolonged provided following principles are observed:
-do not cut the sensor cable in the distance shorter than 0,5 m from the jacket;
-cable sensor prolongation by more than 10 m is not recommended;
-CMSM – H 2 x 0,5 mm cable is recommended for cable prolongation;
-Cable connection in case of prolongation is to be done very carefully. Ensure the conductive joint
when you shorten or prolong the cable.
Note to the three-way valve V4044C (V4044F) made by Honeywell:
Connection AB –heating water outlet from boiler
Connection A – outlet to the water heater
Connection B – outlet to the heating circuit
Note to the three-way mixing valve VBI31.20 with drive SQK34.00 (Siemens):
After the connection of the three-way mixing valve it is necessary to check whether the valve opens in case
heating is required. If it be to the contrary revert the phases L (Y1) and L1 (Y2). It is also important to observe
the correct hydraulic connection of three-way mixing valve according to the enclosed manual.
Recommendation for the check!
Select the value 4 in P 20 parameter which means boiler manual operation. At this type of operation HMI
ACX84.910 ALG service unit displays the word Wood.
Three-way mixing valve must open up to maximum into the heating circuit.
Floor heating
Floor heating can be used in mixing heating circuit. Following parameters have to be set:
-Parameter P 21 – Slope of heating curve to the value 0,8,
-Parameter P 76 – Minimum temperature of heating circuit (can be reduced to the value of 20 oC),
-Parameter P 77 – Maximum temperature of heating circuit max. 40 oC.
In case of superfluous heat withdrawal into the heating circuit the temperature will be mixed to the maximum
set temperature of the heating circuit.
Note: In case of radiators and floor heating combination the floor heating must have its own regulation
including the three-way mixing valve.
Fig. no. 10 Connecting dimensions of boiler

16
5. Boiler installation
5.1 Delivery and accessories
VIADRUS HERCULES DUO boiler based on the order is delivered in such a way that the complete
boiler drum including the basement is put on the pallet and packed boiler shell is gripped at the side
of it. The accessories are put inside the boiler drum and are accessible after opening the cleaning
door. The fuel reservoir (depending on the requirement small – 269 dm3or large – 528 dm3) including
the fuel feeder set is put on another pallet. The boiler is packed in transport package and must not be
tipped over during the transport.
Standard boiler delivery:
•boiler drum with basement
•fuel feeder set
•fuel reservoir
•service board SIMBOX WP 8GB1 373-3 – set incl. electric pack
•QAA 88 device
•ventilator
•connector for fan plug + socket
•round head screw and cross-recessed screw M6 x 16 (4 pc) for ventilator gripping to the feeder flange
washer 6,4 (4 pc) to ventilator gripping to the feeder flange
•nut M6 (4 pc) to ventilator gripping to the feeder flange
•Safety thermostat
•round head screw and cross-recessed screw M4 x 6 (2 pc) for safety thermostat gripping
•boiler drum shell
•connection accessories for boiler drum shell (spring clip – 4 pc, junction stud – 4 pc,
screw ST4,8 x 13 – 10 pc)
•basement shell
•connection accessories for basement shell (screw ST 4,2 x 9,5 – 4 pc, screw ST 4,8 x 13 – 8pc)
•connection accessories for basement shell gripping to the basement (washer 8,4 – 4 pc, nut M8 – 4 pc)
•ash-pan
•boiler mastic – tube 310 ml
•bushings PG 13,5 (2 pc)
•bushings PG 11 (2 pc)
•stud bolt M10 x 30 (4 pc) and washers 10 (4 pc) for gripping the fuel feeder set to the basement
•hexagon head screws M8 x 20 (4 pc) and washers 8 (4 pc) for gripping the fuel reservoir to the fuel
feeder
•filling and drain tap Js 1/2“ (1 pc)
•plug Js 6/4“ blind (1 pc)
•sealing φ60 x 48 x 2 (1 pc)
•hook (1 pc)
•deflector (1 pc)
•ceramics into the boiler drum (5 pcs)
•partitions of the combustion chamber (4 sections - 2 pcs, 5 sections - 3 pcs, 6 sections - 4 pcs, 7
sections - 5 pcs)
•turbulators (8 pcs)
•draw rod with hanaccording to for smoke flap control (1 pc)
•grommet HEYCO (2 pc)
•label for smoke flap control (1 pc)
•flange of heating and return water 2“ (2 pc)
•sealing φ90 x 60 x 3 (2 pc)
•handling key (1 pc)
•cleaning tools (hook, brush with hanaccording to, tang, dowel 8 mm – 2 pc, straight threaded rivet 5x60 –
2 pc)
•siseal 10 g
•thermostatic valve BVTS (Danfoss) or TS 130 (Honeywell) or STS 20 (Watts)
•cast iron grate (see tab. no. 5)
•boiler sensor QAZ 36.526/109
•sensor against fuel fire penetration QAZ 36.526/109
•outside sensor QAC 34/101 (necessary for the full and basic version for equithermal control)
•thermostatic valve (filling valve) - series VTC312 (external thread) made by ESBE (minimum temperature
of return water is 45 oC) (ord. code: 5100 15 00) - for 4 sect.
•thermostatic valve (filling valve) - series VTC512 (external thread) made by ESBE (minimum temperature
of return water is 45 oC) (ord. code: 5100 15 00) - for 5 - 7 sect.

17
•sticker - LED for the safety thermostat signalization
•boiler operation and installation manual, a guarantee list is its part
•list of contract service organization
Obligatory accessories for mixing heating circuit (not included in the delivery):
•Heating branch sensor QAD 36/101 (Siemens)
•Three-way mixing valve VBI31.20 with drive SQK34.00 (Siemens) for 4 - 6 sect.
•Three-way mixing valve VBI31.25 with drive SQK34.00 (Siemens) for 7 sect.
•Water heater thermostat type: 7K1.6R326.00A (capillary length: 1000 mm, range: 0 - 60 oC) (in case
boiler will be used for HW heating)
Obligatory accessories for pump heating circuit (not included in the delivery):
•Hot water sensor QAZ36.526/109 (in case boiler will be used for HW heating) (Siemens)
•Three-way valve V4044F (in case boiler will be used for HW heating) (Honeywell). – in this case only the
phase, working and protective conductors will be connected. Note: also V4044C valve can be used.
Obligatory accessories (not included in the delivery):
•Safety valve (1 pc) according to the maximum boiler operating overpressure (see tab. no. 1)
Optional:
•HMI (ACX84.910/ALG) service unit for Saphir regulator operation – Siemens
•Circuit pump UPS 25-40
•Water heater (see the VIADRUS a.s. offer)
The optional boiler equipment is not included in the boiler standard price.
5.2 Installation procedure
5.2.1 Installation of boiler drum with the basement
1. Position the boiler drum with basement on the substructure (pad) into the horizontal position.
2. Insert the sealing between the heating water flange and boiler, then mount by means of four screws to
the boiler (follow the boiler-room dispositions). By welding connect the heating water outlet with the
heating system.
3. Insert the sealing between the return water flange and boiler, then mount by means of four screws to the
boiler. By welding connect the lower return water outlet with the heating system.
4. Mount the drain valve into the hole at the rear of the basement.
5. Put the stove-pipe on the smoke adapter and insert into chimney hole. The stove-pipe diameter is
160 mm.
6. Blind the threaded hole JS 6/4“ in the front section with plug JS 6/4“. Put the sealing under the plug.
7. It is recommended to install shut-off valves before and after the pump with a filter, for reason of
cleansing the strainer of filter or replacement of pump.
8. Open the cleaning door (see Figure No. 2 - Item 6) and hang hook with deflector so that the center of the
deflector is above the center of the burner grate (see Figure No. 11).
9. Open the cleaning door (see Figure No. 2a - Item 5) and insert 8 turbulators (see Figure No. 2a - Item
12), 5 pieces of ceramics (see Figure No. 11) and partitions of the combustion space (see Figure No.
11).

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Fig.No. 11 Location of components and ceramics inside the boiler
1. Grate
2. Deflector
3. Hook
4. Bottom ceramics
5. Top ceramic plate
6. Partition of the
combustion space
7. Partition of the
combustion space-
front
8. Front ceramics

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5.2.2 Shells assembly
Fig. no. 12 Boiler shell

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