HERCULES Green Hercules Eco Therm U26 MANUAL FOR BOILER Návod OPERATION k obsluze AND INSTALATION
Contents: page 1. Produced variants of boiler ..........................................................................................................................3 2. Technical data of the boiler .........................................................................................................................4 3. Boiler description .........................................................................................................................................6 3.
Dear customer, thank you for the purchase of 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).
2. Technical data of the boiler Tab. no. 1 Dimensions, thermal parameters of boiler pcs HERCULES Green Eco Therm 25X 5 HERCULES Green Eco Therm 32X 7 - 3 3 kg 332 401 kg l mm 65 40,9 156 65 50,3 156 mm 1218 x 1309 1218 x 1309 mm 3 dm kg 3 dm kg kPa (bar) kPa (bar) - 1335 130 85 725 470 400 (4) 800 (8) See picture Nr.1 1527 130 85 725 470 400 (4) 800 (8) See picture Nr.
300 250 Pa 200 150 100 50 0 15 20 25 30 35 40 45 50 55 60 Power in kW Fig. no. 1 Version of boiler L L1 Hydraulic loss of the boiler drum HERCULES Green Eco Therm 25X 1335 809 Fig. no.
3. Boiler description 3.
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. Elements for control, regulation and safety placed on the burner • Control Module of boiler (version HERCULES Green Eco Therm XJ) or automatic (version HERCULES Green Eco Therm XS).
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Boiler drum Boiler shell with ashtray Cleaning door Burner Transitionary flange Insulation of transitionary flange The ash door Fuel tank Fuel feeder Transport hose with reinforcing spiral Control box Flange of heating water Fig. no. 4 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
3.
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 Fig. no.
Irreversible thermal label Reversible thermal label with indicator of current temperature of the body of burner Fig. no. 8 Positioning of thermal labels on the burner 4. Location and installation 4.1 Regulations and directives The solid fuel boiler can only by mounted by a company holding a valid authorization to install these equipments. A project according to the valid regulations must be prepared for the installation.
ČSN 33 2000-4-41 ČSN 33 2000-5-51 ed. 2 ČSN 33 2130 ČSN 33 2180 ČSN 34 0350 EN 60 079-10 EN 60 252-1 EN 60 335-1 ed.2 EN 60 335-2-102 EN 60 445 ed. 3 EN 60 446 Electrical equipments: part 4: Safety chap.
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.
• the manufacturer recommends that min. 1000 distance is kept between the boiler and fuel or the fuel is placed in a room different from that where the boiler is installed Boiler positioning with regard to electricity network: • • • the boiler must be placed so that the plug in socket (230V/50Hz) is always accessible; the boiler is connected to the mains by a fixed movable inlet with a normalized plug; the electric shock prevention must be guaranteed according to valid EN (see chap. 5.1.
washer 5,3 screw into the plate ST 4,2 x 9,5 spring clamp bushing PG 9 control box screw M5 x 12 serrated washer 5,3 cleaning equipment hook brush with handle pike cleaning equipment holder handling key turbulator partition of combustion chamber – the front segment the partition of combustion chamber the partition of smoke channel burner fasteners for mounting of burner screw M10 x 50 screw M10 x 30 spring washer 10 washer 10,5 nut M10 insulation of burner transitionary flange of the burner fuel feeder tran
5.3 Assembly procedure 5.3.1 Boiler drum installation 1. 2. 3. 4. 5. 1 2 Position the boiler body on a retaining wall. Put sealing 90 x 60 x 3 (1) onto the upper flange of the rear boiler section and screw the flange of heating water (2) and then interconnect the other end with the heating system.
5.3.2 Mounting of partitions of the combustion chamber and turbulators 1. 2. 3. 1.According to Fig no. 13 insert the partitions of the combustion chamber (1, 2) into the combustion chamber in number of 4 pcs (for HERCULES Green Eco Therm 5X) or 5 pcs (for HERCULES Green Eco Therm 7X). Insert 2 pcs partitions of the smoke channel (3) between the front and middle boiler section. 3.Put 4 pcs turbulators (4) into the route of flue gases 1. 2. 3. 4.
1. 2. 3. 4. Please screw the flange of burner (see Fig. no. 15) onto the ash door by means of 3 pcs screws M10 x 30 (2), 1 pc screw M10 x 50 (2), 4 pcs nuts M10, 4 pcs washers 10,5 and 4 pcs spring washers 10,5. Screw the knee of the burner on the body of burner with the throat directed onto the positioning of the fuel reservoir. Mount the burner insulation onto the flange of the burner.
5.3.4 Mounting of the fuel reservoir ATTENTION! In the event that it is installed the supplied wooden fuel reservoir, it is necessary to place a fireproof bulkhead between it and the boiler. • • • • • According to Fig no. 16 you must screw the flange of fuel feeder (3) to the lateral part of the fuel reservoir (6) by using 6 pcs screw M8 x 20 (5), M8 nuts (2) and washers 8.4 (4); Then you must screw together inclined bottom (7) by means of 4 pcs screw M8 x 30 (8), M8 nuts (2) and washers 8.
5.3.5 Mounting of the shells 1 2 3 4 5 6 7 8 9 10 Anchor screw Console 1 Washer 10,5 Nut M10 Console 2 Right side part of shell Insulation of the side part of shell Connecting pin Washer 6,4 Screw M5 x 12 11 12 13 14 15 16 17 18 19 20 Right side part of shell Screw ST 4,2 x 9,5 Insulation of the rear part of shell Rear part of shell Upper part of shell Insulation of the upper part of shell Spring clamp Control box Washer 5,3 Cable gland PG 9 Fig. no. 17 Mounting of jacketing 1. 2. 3.
4. You will mount the connecting pins 2 pcs (8) on the right side part of the shell (6) and then insert the insulation (7). Then you will install the jacket (shell) (6) on lower anchor screws and connect the upper part with consoles 1 and 2 by using 2 pcs M5 x12 screw (10) and 2 pcs 5.3 washers (9). 5. Put the consoles 1 (2) and 2 (5) on the threads of the left upper anchor screw and screw them by using the 2 pcs M10 nuts (4) and 2 pcs 10.5 washers (3). 6.
5.3.6.1 Version HERCULES Green Eco Therm XS 1. 2. 3. 4. 5. 6. 7. 8. 9. According to Fig no. 17 equip the upper part of the shell (15) with the glands PG 9 (20) Attach the control box (18) to the upper part of the shell (15) by using of screws M5 x 12 (10) and serrated lock washers 5.3 (19) and pull the capillary tube of safety thermostat, capillary tubes of thermomanometer and the capillary tube of the thermostat of pump through the hole..
Fig. no. 18a) Circuit diagram of HERCULES Green Eco Therm XJ Q1 BT3 F1 Z1 S1 H1 MAIN SWITCH SIGNALLING „SWITCHED ON“ FUSE 10 A SUPPRESSOR FILTER X31.
Central heating pump (HO5VV - F 3Cx0,5) Supply cable of burner (HOSRR - F 4G1) Room thermostat (HO5VV - F 2Dx0,5) Supply flexo-cord HO5VV - F 3Cx0,75 BN (A1:K11) BN BK (A1:K22) GNYE In case of a bad draw-off of the flue gases Flue gases fan (HO5VV - F3Gx0,5) BU Box BU (A1:K10) Box cover GNYE BU GNYE (A1:PE) BN GR * (A1:K1) GR (A1:K23) BN (A1:K3) Control of burner (HO5VV - F 5Cx0,5) BK (A1:K2) GNYE BU BN Fig. no.
Fig. no. 19a) Circuit diagram of HERCULES Green Eco Therm XS 25 Q1 BT3 F1 Z1 S1 H1 MAIN SWITCH SIGNALLING „SWITCHED ON“ FUSE 10 A SUPPRESSOR FILTER X31.
Box cover Central heating pump (HO5VV - F 3Cx0,5) Supply cable of burner (HOSRR - F 4G1) Supply flexo-cord HO5VV - F 3Cx0,75 Box GNYE BU GNYE (A1:PE) BN GR * (A1:K1) BN (A1:K3) Room thermostat (HO5VV - F 2Dx0,5) BK (A1:K2) GNYE BU BN Fig. no. 19b) Circuit diagram of HERCULES Green Eco Therm XS 26 MAIN SWITCH SIGNALLING „SWITCHED ON“ FUSE 10A SUPPRESSOR FILTER X31.
5.3.10 Boiler hydraulic diagram Fig. no. 20 Fig. no. 21 HERCULES Green Eco Therm boiler hydraulic diagram HERCULES Green Eco Therm boiler hydraulic diagram with HWS reservoir and Danfoss valve Legend: 1. Boiler 2. Heating system 3. Thermostatic valve 4. Pump 5. 6. 7. 8.
6. Putting into operation - instructions for contractual service organization The boiler can only be put into operation by a contractual service organization authorized to carry out this activity. 6.1 Inspections before start-up Before putting the boiler into operation it I necessary to check: 1. 2. 3. 4. 6.2 Filling the heat system with water (thermomanometer check). Tightness of heating system. Connection to the chimney – it must be approved by a chimney-sweepers’ company.
7. Boiler operation by user Before putting the boiler into operation or in case that the fuel feeder is empty during operation and it is necessary to fill the fuel feeder with pellets: • pull out the plug 230 V from the socket of burner; • insert the plug of power supply (230 V/50 Hz); • wait until the wooden pellets start to discharge from the throat of the fuel feeder; • pull out the plug from the power supply and insert it back into the socket of burner. 7.
After putting the burner into operation the following message appears on the display: TEST – BLOWING ON 32 o S FC: 0% - + ESC The display shows information about the current operating mode of the burner: • • • TEST - BLOWING (blowing through the burner) the burner performs the initial blowing through with the purpose to remove all debris from the grate of burner; 32° actual water temperature in the boiler.
After a successful ignition of fuel the operation of burner will continue to operate according to the factory setting in order to stabilize the combustion process according to the data on the display - see the Figure below: TRANS.: 10kW ON 32o - S TRANS.:10kW FC: 65% + ESC the burner is in the mean operating mode and it works with a heat output of 10 kW; The burner from the mode of stabilization passes into automatic mode.
Items of user menu of control module of burner The user menu starts up on the display by a long pressing the button "S". By pressing the button "S" you go to the selection of menu of control module of burner. To exit the current item of menu press "ESC". COMBUST 5 32kW ON 75 o S FC: 98% - + ESC 7.1.1 Setting of the heat output of burner You can set the heat output of burner through the selection of the degree of heat output (EFFECT LEVEL).
Effect level [n] O:5 S N:5 - + ESC ATTENTION: In case that the fuel has changed (for instance the class of pellets has changed), then an additional adjustment of operating parameters of the burner should be done.
Make final comb.? [YES] S [NO] - + ESC After the extinction of the burner, the display shows "Activate" (initial screen display). If the burner is not in use for a long time, unplug it from the power supply and then clean the combustion chamber, combustion grate and photosensor from deposition of ashes. Switching off the burner by means of external control module Turn off the burner by pressing START OF BURNER.
The list of latest 10 faults that occurred during the burner operation To check the latest faults that occurred during the burner operation, enter into the menu „LOG“. LOG error 1:22 EXIT S - + ESC The display of control module of burner shows the selected item „LOG“ in menu, i.e. the number of faults in the list of faults and their codes. To exit the menu press the button „ESC“. Fault conditions and the procedure for their solution are described in Tab. no.
Tab. no. 5 The faults which are displayed on the display of the burner (25J and 32J).
7.2 Version HERCULES Green Eco Therm XS Putting the burner into operation: • The main switch must be in the position on(I) - (green light of main switch on the control box is alightsee Fig. no. 3 and signalling "POWER" on the burner drum - see Figure 22); • By pressing the switch "START OF BURNER" on the control box (see Fig no. 3) the burner is put into operation. Also operational thermostat and the room instrument have to be switched. The signalling of "START" (see Fig no.
Colour scale Lever for setting the position of the throttling flap of the fan Fig. No.23 The burner is automatically shut down after reaching the desired temperature that is set by the operating thermostat (the fan carries out cleaning of the combustion grate). In case of a request for heating the fan carries out the operations of blowing through, filling fuel and ignition. In the event that the first portion of fuel is not ignited then a second ignition is performed.
Putting the burner out of operation • • • The burner is put out of operation by pressing "START OF BURNER" button (signalling of "START" on the body of the burner is off). The burner during becoming extinct performs so called "process of controlled switching off" during which the fan keeps working (and the burner gradually is cooled down) and the operating parameters are monitored.
Tab. no. 7 Description of operating parameters of control module of burner 32S Index of potentiometer number of flickers of P1 P2 P3 P4 P5 yellow LED Operating time (s) Index 0 30 1,50 30 45 0 1 45 1,65 60 90 1 2 60* 1,82 90 135 2 3 75 2,18 120 180 3 4 90 2,83 150* 225 4 5 105 3,68 180 270 5 6 120 4,79 210 315 6 7 135 6,22 240 360 7* 8 150 7,46 270 405 8 9 165 8,21 300 450* 9 * factory setting Tab. no.
Example of calculating the heat output of the burner: • Determine the amount of fuel supplied per hour - mfuel = 5.3 kg / hr. Calculate the instantaneous amount of supplied fuel m'fuel: Mfuel (kg/h) m'fuel = = 0,001472 kg/s 3600 (s) • Take into account fuel efficiency –e.g. wood pellets have a calorific value Hfuel = 17,2 MJ/kg = 17200 kJ/kg.
8. IMPORTANT WARNINGS 1. The boiler must not be used for other purposes than those it is designed for. 2. The boiler can only be operated by adults who are acquainted with this operation manual. It is forbidden to leave children unattended near the boiler that is working. 3.
9. 1) 2) 3) 4) 5) 6) 7) 8) Maintenance Regularly remove ashes from the combustion chamber and the ash drawer. The ashes must be thrown out into non-combustible containers with lids. When working is necessary to use protective equipment and respect the personal safety. The boiler has to be put out of operation at least 1 hour before cleaning (incl. the electric disconnection). Boiler cleaning frequency is dependent on the quality of fuel. In case of pellets that do not contain more than 0.
The body of burner Inclined grate of combustion chamber 1. Initial position of the grate 2. End position of the grate Small feet of the grate Fig. no. 25 Fig. no.
10. Faults and their removal Tab. no.
Operating fault The cause Solution Flame has a purple colour and at the outlet to the chimney can be observed smoke Fuel of poor quality Fuel ignition was successful, but the unit did not reach a stable operating mode Incorrect placement of photoreceptor Burner operation is not stable Setting of incorrect operating parameters Photosensor is dirty on the surface Photosensor is functionless- its working surface is damaged and burned areas can be observed Malfunction of photosensor The operating param
11. Instructions for product liquidation after its operating life VIADRUS a.s. is contractual partner of firm EKO–KOM a.s. with client number F00120649. The packages comply with EN 13427.
Information for customer Packaging edentification Assessment reference PE Plastic sacks, folie, corrugaled board, iron and plastic fix line Identification od principál materials used. Paper, Polyethylene, iron, wood Part 1: Summary of assessment Standard/Report Assessment requirement 1.1 Prevention by source reduction 1.2 Heavy metals and ensure below maximum permitted levels for components (CR 13695-1:2000) 1.
Destined for user VIADRUS a.s Bezručova 300 735 81 Bohumín Guarantee certificate and Quality & completeness certificate for HERCULES Green Eco Therm boiler Boiler serial number ..............................………… Boiler output ............................................ User (surname, name) ………………………………………………………………………………………... Address (street, city, postcode) ………………………………………………………………………………………... Telephone/Fax ………………………………………………………………………………………...
Annex to the guarantee certificate for the customer-user Record of the carried out guarantee and after-guarantee repairs and regular product inspections Date of record Contractual service organization (signature, stamp) Carried out activity 50 Customer’s signature
Destined for service organization VIADRUS a.s Bezručova 300 735 81 Bohumín Guarantee certificate and Quality & completeness certificate for HERCULES Green Eco Therm boiler Boiler serial number ..............................………… Boiler output ............................................ User (surname, name) ………………………………………………………………………………………... Address (street, city, postcode) ………………………………………………………………………………………... Telephone/Fax ………………………………………………………………………………………...
Destined for manufacturer VIADRUS a.s Bezručova 300 735 81 Bohumín Guarantee certificate and Quality & completeness certificate for HERCULES Green Eco Therm boiler Boiler serial number ..............................………… Boiler output ............................................ User (surname, name) ………………………………………………………………………………………... Address (street, city, postcode) ………………………………………………………………………………………... Telephone/Fax ………………………………………………………………………………………...
Update 2/2013 – GB
