Viadrus HERCULES U 22 BASIC Operation And Installation Manual
Hercules U26
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VIADRUS HERCULES U 22 BASIC
MANUAL FOR BOILER OPERATION
AND INSTALLATION
2
Contents:
page
1. Usage and advantages of the boiler ......................................................................................................... 3
2. Technical data of the boiler ...................................................................................................................... 4
3. Description ................................................................................................................................................ 6
3.1 Construction of the boiler .................................................................................................................... 6
3.2 Regulating and security elements ....................................................................................................... 6
4. Placing and installation ............................................................................................................................. 8
4.1 Regulations and instructions ............................................................................................................... 8
4.2 Placing possibilities ............................................................................................................................. 8
5. Order, delivery and assembly ................................................................................................................. 10
5.1 Order ................................................................................................................................................. 10
5.2 Delivery and accessories .................................................................................................................. 10
5.3 Assembly procedure ......................................................................................................................... 10
6. Putting into operation – instructions for a contractual service organization ............................................ 13
6.1 Control operation before starting ...................................................................................................... 13
6.2 Putting the boiler into operation ........................................................................................................ 13
7. User’s boiler service ............................................................................................................................... 14
8. IMPORTANT NOTICE ............................................................................................................................ 15
9. Maintenance ........................................................................................................................................... 15
10. Instructions for product liquidation after its operating life ....................................................................... 16
11. Warranty and defect liability ................................................................................................................... 16
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Dear customer,
thank you for buying the general – purpose VIADRUS HERCULES U 22 BASIC boiler and thus
showing belief in the company VIADRUS a.s.
At first read this operating manual (especially Chapter Nr.7 – User’s boiler service and Chapter Nr. 8 –
Important notice) to get used to a proper usage with your new product from the very beginning. We
request to maintain the further mentioned information and particularly to perform the prescribed
annual checks by an authorized specialized company by which a long – time failure – free operation
of your boiler - to your and our satisfaction - is secured.
VIADRUS HERCULES U 22 BASIC is a cast-iron sectional low-pressure boiler designated for combustion of
solid fuels – coke, hard coal, wood.
Burning of other materials such as plastic is unallowable.
1. Usage and advantages of the boiler
Three – sectional size of the boiler VIADRUS HERCULES U 22 BASIC is appropriate for heat source
reconstruction in self – contained flats, for smaller residential and recreational facilities. Bigger sizes of the
boiler meet the requirements of heating the family 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.
Advantages of the boiler:
1. High operating life of cast iron exchanger and all other parts with respect to the quality of used materials.
2. Design approved in the long term.
3. Elaborate production technology on automatic forming lines with consistent and approved quality of the
production process (ISO 9001, ISO 14 001).
4. Efficiency of coke and anthracite burning – 75 – 80 %, efficiency of wood burning – 75 %.
5. Simple service and maintenance.
6. Low demandingness for chimney draught.
7. Power gradation according to the sections.
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2. Technical data of the boiler
Chart Nr. 1 Dimensions, technical parameters of the boiler
Section number pcs 3 4 5 6 7 8 9 10
Weight kg 218 252 282 312 347 377 417 448
Water space volume l 31,5 36,2 40,9 45,6 50,3 55,0 59,7 64,4
Firing chamber volume l 34 47 60 73 86 99 112 125
Firing chamber depth mm 244 339 434 529 624 719 814 909
Diameter of smoke socket mm 156 176
Boiler dimensions:
- height x width
mm
917 x 508
- depth mm 682,5 778,5 874,5 970,5 1066,5 1162,5 1258,5 1354,5
Water operating overpressure kPa
(bar)
400
(4)
Testing water overpressure kPa
(bar)
800
(8)
Hydraulic loss - See Fig. no.1
Recommended heat water
operating temperature
°C 60 - 90
Recommended return water
operating temperature
°C 60
Noise level dB Not exceeding the level of 65 dB (A)
Minimum chimney draught mbar 0,14 0,16 0,18 0,20 0,22 0,24 0,26 0,28
Boiler connections:
- heat water
DN 50
- returnable water DN 50
Chart Nr. 2 Heat - technical parameters of the boiler
granularity 30 – 60 mm heating value: 26 - 30 MJ. kg-1 – coke and antracite
humidity 15 - 25 % heating value: 12 - 15 MJ. kg-1 - wood
Section number pcs 3 4 5 6 7 8 9 10
Rated power kW 17,7 23,3 29,1 34,9 40,7 46,5 52,3 58,1
Efficiency % 75 - 80
Orientation fuel consumption –
coke
kg.h-1
2,87 3,77 4,71 5,65 6,59 7,53 8,47 9,41
Heating value – coke MJ. kg
-
1
27,8
Orientation fuel consumption –
anthracite
kg.h-1
3,0 3,95 4,93 5,92 6,9 7,88 8,87 9,85
Heating value – anthracite MJ. kg
-
1
28,31
Orientation fuel consumption –
wood
kg.h-1
5,0 6,4 8,0 9,59 11,19 12,79 14,39 15,67
Heating value – wood MJ. kg
-
1
15,01
Product of consumption
temperature
°C max. 280
0
50
100
150
200
250
300
15 20 25 30 35 40 45 50 55 60
Fig. no. 1 Hydraulic loss of the boiler drum
Pa
Power in kW
5
Section number 3 4 5 6 7 8 9 10
L 328 424 520 616 712 808 904 1000
L1 682,5 778,5 874,5 970,5 1066,5 1162,5 1258,5 1354,5
Ø D 156 156 156 156 156 156 176 176
Fig. no. 2 Main dimensions of boiler
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3. Description
3.1 Construction of the boiler
The main part of the boiler is the cast iron section boiler drum made of grey cast iron according to:
ČSN 42 2415 Grey iron 42 2415 with luminated graphite, or
ČSN 42 2420 Grey iron 42 2420 with luminated graphite
Pressure parts of the boiler correspond to the demands on solidity according to:
ČSN 07 0240 Warm-water and law-pressure steam boilers
ČSN 07 0245 Warm-water and law-pressure steam boilers. Warm-water boilers up to 50 kW output.
The boiler drum consists of sections with the help of pressured boiler nipples and is secured with boiler
screws. The sections create burning and ash space, water space and a convective part. Heat water input and
output are situated at the back part of the boiler.
The back section of the boiler has a smoky chimney – pot and a heat water flange in the upper part, and a
returnable water flange with a socket for filling and draining cock. Stoker and ash door and a firebox door
under them are fixed to the front section.
The whole boiler drum is isolated with a stifling, mineral isolation that reduces losses by sharing heat into the
surroundings. The steel jacket is fitted in colour with a quality comaxite paint.
At the boiler three types of medium sections are used: in the front part of the boiler (except the three and four
– section size) there is a section with a recess for easier fuel inserting to the average up to 220 mm, then
sections without a molding, in the back part with a molding. The molding closes the burning space and carries
back the flame and product of consumption from the back space to the front part of the boiler, i.e. by the back
path in smoky draughts it is perfectly taken advantage of the product of consumption heat.
Chart Nr. 3 Medium sections of the boiler
Section number 3 4 5 6 7 8 9 10
Medium section with a recess - - 1 1 1 1 1 1
Medium section with a molding 1 2 2 3 4 5 5 6
Medium section without a molding - - - - - - 1 1
3.2 Regulating and security elements
Smoke flap of the smoke extension regulates the output amount of flue gases from the boiler to the chimney.
It is controlled by a handgrip at the rear of the boiler.
The choker (stifling) of the ashpan door regulates the supply of combustion air under the grate of boiler. It is
controlled manually by means of an adjusting screw of the choker (stifling).
The air rosette of stoking door is used for supply of the secondary air into the combustion chamber. To
control the rosette it is necessary to use a tool because of a higher surface temperature of the stoking door.
The small cover for cleaning of the smoke extension that is located in its bottom part serves for cleaning the
deposits resulting from the combustion.
A combined device - thermo-manometer is used to detect the temperature of heating water and water
pressure in the heating system. This device is placed in the upper part of the jacket. The thermowell of the
sensor of the thermo-manometer is located at the top of the rear boiler section.
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1. Boiler drum
2. Stoker door
3. Ash door
4. Smoky chimney – pot
5. Boiler drum insulation
6. Jacket
7. Thermomanometer
8. Sealing Ø 90 x 60 x 3
9. Heat water flange
10. Returnable water flange
11. Filling and draining cock
Fig. no. 3 Main parts of boiler
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4. Placing and installation
4.1 Regulations and instructions
The boiler for solid fuels can be installed by a company with a valid authorization to perform its
installation and maintenance. For installation a project in accordance with valid regulations must be
executed.
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
Ca2+ 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.
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 0240 Warm-water and law-pressure steam boilers
ČSN 07 0245 Warm-water and law-pressure steam boilers. Warm-water boilers up to 50 kW output.
ČSN 07 7401 Water and steam for thermal energy equipments with working pressure up to 8 MPa.
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 Placing 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.
Boiler placing with regard to fire regulations:
1. Placing on floor of flame resistant material (Fig. no. 4)
- boiler to be put on a flame resistant backing exceeding the boiler platform over 20 mm at sides and
only on the boiler drum depth.
- if the boiler is situated in a cellar we recommend to place it on a bedding of minimum 50 mm height.
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.
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