Viadrus Hercules U 24 Manual de instrucciones

MANUAL

FOR BOILER OPERATION AND INSTALLATION

VIADRUS HERCULES U 24

Updating date 39/2007

Table of contents page

1. Technical information...................................................................................................................................................3

1.1 Usage ......................................................................................................................................................................3

1.2 Boiler advantages....................................................................................................................................................3

1.3 VIADRUS HERCULES U 24 boiler technical date...............................................................................................4

1.4 Basic boiler dimensions..........................................................................................................................................7

2. Assembly manual..........................................................................................................................................................8

2.1 Boiler construction..................................................................................................................................................8

2.2 Rules and directives................................................................................................................................................9

2.3 Positioning possibilities ........................................................................................................................................10

2.4 Delivery and accessories....................................................................................................................................... 11

2.5 Assembly technique.............................................................................................................................................. 11

2.6 Boiler commissioning...........................................................................................................................................13

2.6.1 Verification activities before commissioning ................................................................................................13

2.6.2 Boiler commissioning.................................................................................................................................... 13

2.7 Regulation and control elements........................................................................................................................... 14

2.8 Equipment for surplus heat withdaral................................................................................................................... 14

2.9 Equipment for heat withdrawal – accumulation tank ...........................................................................................15

3. Manual for operation ..................................................................................................................................................16

3.1 Boiler operation by user........................................................................................................................................ 16

3.2 Boiler cleaning - maintenance ..............................................................................................................................16

3.3 IMPORTANT NOTICE .......................................................................................................................................18

4. Instruction for product disposal after its service life................................................................................................... 19

5. Guarantee and the liability for defects........................................................................................................................ 19

Dear customer,

we thank you that you have bought VIADRUS HERCULES U 24 universal boiler, thus having shown your

confidence in ŽDB GROUP a.s., KKCG Industry Group member, Heating technique division VIADRUS.

For you to get used to a correct way of hadling your new product from the beginning please read at first this

manual for its usage. Please follow the stated information whereby a longlife and trouble-free boiler operation will

be guaranteed for both your and our satisfaction.

1. Technical information

VIADRUS HERCULES U 24 is cast-iron low-pressure boiler designed for combustion of solid fuels – light coal,

hard coal and coke. As a complement fuel it is possible to use wood.

Combustion of other materials, like plastics is impermissible.

1.1 Usage

Three-sectional size of VIADRUS HERCULES U 24 boiler is suitable for heat sources reconstruction in

independent tenements, for smaller residentian premises and leisure amentities. Bigger sizes of boiler (4 – 10 sections)

meet the demands on heating of family houses, shps, schoolds, etc.

The boiler is manufactured as a hot-water boiler with both natural and forced heating water circulation and working

overpressure up to 4 bar. Before dispatch the boiler is tested for tightness by applying 8 bar testing overpressure.

The boiler is designed for heating both closed and open heating systems.

1.2 Boiler advantages

1. Long lifetime of the cast-iron heat exchange 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. Combustion efficiency 80 %.

5. Easy operation and maintenance.

6. Output graduation according to the sections number.

VIADRUS U 24

Závislost tlakové ztráty na průtoku pz-Q

500

1000

1500

2000

2500

3000

3500

4000

0.0 0.2 0.4 0.6 0.8 1.0 1.2

(10-3m3.s-1)

Průtok Q

Tlaková ztráta pz(P

10 článků9 článků

8 článků7 článků

6 článků5 článků

4 články 3 články

Pressure loss independence on pz– Q flow

Flow rate Q

Pressure loss Pz (Pa)

sections

Figure. no. 1 Hydraulic loss of boiler drum

1.3 VIADRUS HERCULES U 24 boiler technical date

Tab. no. 1 Dimensions, technical parameters – coke as fuel

granularity 24 – 60 mm, fuel moisture max. 15 %

caloric value of fuel: 26 - 30 MJ.kg-1

Number of sections pc 3 4 5 6 7 8 9 10

Nominal heat output kW 16 25 38 46 52 58 66 74

Fuel consumption at the nominal output kg/h 2,4 3,75 5,7 6,9 7,8 8,7 9,9 11,1

Minimum heat output kW 4,8 7,5 11,4 13,8 15,6 17,4 19,8 22,2

Fuel consumption at minimum heat output kg/h 0,72 1,125 1,71 2,07 2,34 2,61 2,97 3,3

Combustion chamber volume l 40,1 49,9 59,7 69,5 79,3 89,1 98,9 108

Burning tim at the nominal output hod 4

Flue gases temperature at nominal heat

output °C 200 – 280

Flue gases temperature at minimum heat

output °C 120 - 190

Flue gases mass flow rate at nominal heat

output g/sec 7,55 11,8 17,94 21,71 24,54 27,38 31,15 34,93

Flue gases mass flow rate at minimum heat

output g/sec 2,27 3,54 5,38 6,51 7,36 8,21 9,35 10,48

Efficiency % 80

Boiler class according to EN 303 - 5 - 3

Waer space volume l 39,5 49,3 59,1 68,9 78,7 88,5 98 107,8

Weight kg 262 312 362 412 462 512 562 612

Combustion chamber depth mm 220 330 440 550 660 770 880 990

Connecting dimensions of smoke flue mm 156 176

Boiler dimensions: height x width mm 1076 x 642

depth L mm 302 413 524 635 766 857 968 1079

Filing opening dimensions mm 245x 195

Maximum working water overpressure bar 4

Minimum working water overpressure bar 0,5

Testing water overpressure bar 8

Boiler hydraulic loss mbar See Fig. no. 1

Minimum output water temperature °C 60

Control range of water temperature °C 60 – 85

Noise level dB Does not exceed the level 65 dB (A)

Required chimney draugt mbar 0,2 0,22 0,25 0,28 0,3 0,32 0,35 0,4

Boiler connections – heating water “ 6/4

– regurn water “ 6/4

Cooling water temperature for safety after-

cooling exchanger °C 5 – 20

Cooling water overpressure for safety after-

cooling exchanger bar 2 – 6

Tab. no. 2 Dimensions, technical parameters – hard coal as fuel

granularity 24 – 60 mm, fuel moisture max. 15 %

Calorific value of fuel: 26 - 28 MJ.kg-1

Number of sections pc 3 4 5 6 7 8 9 10

Nominal heat output kW 18 25 32 39 46 53 60 67

Fuel consumption at the nominal heat output kg/h 2,93 4,07 5,2 6,35 7,48 8,63 9,76 10,9

Minimum heat output kW 5,4 7,5 9,6 11,7 13,8 15,9 18 20,1

Fuel consumption at minimum heat output kg/h 0,88 1,22 1,56 1,91 2,24 2,59 2,93 3,27

Combustion chamber volume l 40,1 49,9 59,7 69,5 79,3 89,1 98,9 108

Burning time at nominal heat output hod 4

Flue gases temperature at nominal heat output °C 250 – 270

Flue gases temperature at minimum heat output °C 130 – 200

Flue gases mass flow rate at nominal heat output g/sec 2,55 3,54 4,53 5,52 6,51 7,5 8,49 9,486

Flue gases mass flow rate at minimum heat

output g/sec 8,49 11,8 15,1 18,4 21,71 25 28,3 31,62

Efficiency % 79

Boiler class according to EN 303 - 5 - 3

Water space volume l 39,5 49,3 59,1 68,9 78,7 88,5 98 107,8

Weight kg 262 312 362 412 462 512 562 612

Combustion chamber depth mm 220 330 440 550 660 770 880 990

Smoke flue connecting dimesion mm 156 176

Boiler dimensions: height x widht mm 1076 x 642

depth L mm 302 413 524 635 766 857 968 1079

Filling opening dimensions mm 245x 195

Maximum working water overpressure bar 4

Minimum working water overpressure bar 0,5

Testing water overpressure bar 8

Boiler hydraulic loss - See. Fig. no. 1

Minimum output water temperature °C 60

Control range of water temperature °C 60 – 85

Noise level dB Does not exceed the level 65 dB (A)

Required chimney draught mbar 0,15 0,16 0,17 0,20 0,24 0,28 0,32 0,35

Boiler connections – heating water “ 6/4

– return water “ 6/4

Cooling water temperature for safety after-

cooling exchanger °C 5 – 20

Cooling water temperature for safety after-

cooling exchanger bar 2 – 6

Tab. no. 3 Dimensions, technical data – hard coal as fuel

granularity 24 – 60 mm, fuel moisture max. 15 %

calorific value of fuel: 14 – 18 MJ.kg-1

Number of sections pc 3 4 5 6 7 8 9 10

Nominal heat output kW 13 19 25 31 37 43 49 55

Fuel consumption at nominal heat output kg/h 3,29 4,8 6,33 7,85 9,37 10,89 12,4 13,9

Minimum heat output kW 3,9 5,7 7,5 9,3 11,1 12,9 14,7 16,5

Fuel consumption at minimum heat output kg/h 0,99 1,44 1,9 2,36 2,81 3,27 3,6 4,18

Combustion chamber volume l 40,1 49,9 59,7 69,5 79,3 89,1 98,9 108

Burning time at nominal output hod 4

Flue gases temperature at nominal heat

output °C 220 – 250

Flue gases temperature at minimum heat

output °C 110 – 120

Flue gases mass flow rate at nominal output g/sec 5,89 8,6 11,33 14,05 16,77 19,48 22,2 24,92

Flue gases mass flow rate at minimum heat

output g/sec 1,78 2,58 3,4 4,22 5,03 5,84 6,66 7,48

Efficiency % 78

Boiler class acccording to EN 303 - 5 - 3

Water space volume l 39,5 49,3 59,1 68,9 78,7 88,5 98 107,8

Weight kg 262 312 362 412 462 512 562 612

Combustion chamber depth mm 220 330 440 550 660 770 880 990

Smoke flue connecting dimensions mm 156 176

Boiler dimensions: height x width mm 1076 x 642

depth L mm 302 413 524 635 766 857 968 1079

Filling opening dimensions mm 245x 195

Maximum working water overpressure bar 4

Minimum working water overpressure bar 0,5

Testing water overpressure bar 8

Boiler hydraulic loass - See Fig. no. 1

Minimum output water temperature °C 60

Control range of water temperature °C 60 – 85

Noise level dB Does not exceed the level 65 dB (A)

Required chimney draught mbar 0,13 0,14 0,15 0,2 0,22 0,28 0,3 0,32

Boiler connections – heating water “ 6/4

– return water “ 6/4

Cooling water temperature for safety after-

cooling exchanger °C 5 – 20

Cooling water overpressure for safety after-

cooling exchanger bar 2 – 6

1.4 Basic boiler dimensions

3 4 5 6 7 8 9 10

L mm 302 413 524 635 766 857 968 1079

L1 mm 121 138

D mm 156 176

Fig. no. 2 Basic boiler dimensions

1 upper part of shell

2 left side part of shell

3 stoking door

4 right front part of shell

5 left front part of shell

6 draught regulator

7 ash door

8 tertiary air rosette

9tertiary air closure

10 tilting grate

11 cleaning cover

12 right side part of shell

13 back part of shell

14 input water pipe

15 safety overpressure

equipment

16 boiler drum

17 smoke adapter

18 smoke control rod

19 output water pipe

20 thermomanometer

21 combustion space

partition

Fig. no. 3 Basic boiler parts

2. Assembly manual

2.1 Boiler construction

The main boiler part is the cast-iron sectional boiler drum made of the grey cast-iron according to ČSN EN 1561,

quality 150.

The pressure parts meet the strenght demands according to ČSN EN 303- 5 Boilers for central heating – part 5: Solid

fuel boilers for central heating with either manual or automatic supply and maximum nominal heat output 300 kW –

terminology, requirements, testing and marking.

The boiler drum is assembled of sections by means of pressed boiler nipples with 56 mm diameter and secured by

anchor bolts. The boiler sections create the feed space, combustion and ash space, water space and convectional space.

The heating water input and output is situated at the rear boiler part.

There is placed the smoke adapter and heating water connection at the upper part of rear boiler section and the return

water connection at the bottom part. The water connections is possible to connect by means of thread pipes. The stoking

door (possibility of left-right opening the stoking doors see Fig. no. 4), ash door and cleaning cover are connected to the

front boiler section. Under the ash pan door there is installed the tilting grate.

There are placed the combustion space barriers behind the clearing cover. Their quantity differs for each size of

boiler (see Tab. no. 4).

The whole boiler drum is insulated by the health harmless mineral insulation, which reduces the losses caused by

heat transmission into the environment. The boiler sell is coloured by a good quality comaxit spray.

Tab. no. 4 Quantity of combustion space barriers

Size of boiler 3 sec. 4 sec. 5 sec. 6 sec. 7 sec. 8 sec. 9 sec. 10 sec.

Single channel barier of

combustion space (pc) 1 - - 1 1 - - 1

Double channel barier of

combustion chamber (pc) - 1 1 1 1 2 2 2

Fig. no. 4 Left-right opening the stoking doors

2.2 Rules and directives

The solid fuel boiler can be installed by the company holding a valid certification for its installation and

maintenance. There must be made lay-out according to the valid rules for the boiler installation. Before the boiler

installation to the older heating system the installation company must make the flush (cleaning) of the whole heating

system. The heating system must be filled with water meeting the requirements ČSN 07 7401: 1992, especially its

hardness must not exceed the required parameters.

Recommended values

hardness mmol/l 1

Ca2+ mmol/l 0,3

Concentration of whole Fe + Mn mg/l (0,3)*

*) recommended value

The producer doesn´t recommend to use the anti-freeze mixture.

a) concerning the heating system

ČSN 06 0310 Central heating, Lay-out and assembly

ČSN 06 0830 Safety equipments for central heating and hot service water preparation

ČSN 07 7401 Water, steam for heating energy equipments with working steam pressure up to 8 MPa

ČSN EN 303–5 Boilers for central heating - Part 5: Central heating solid fuel boiler with manual or automatic

supply, with nominal output not more than 300 kW – terminology, requirements, testing and

marking

b) concerning the chimney

ČSN 73 4201 Chimneys and smoke flue projecting

c) concerning the fire regulations

ČSN 06 1008 Fire safety of heating equipments.

ČSN 73 0823 Fire-technical nature of material. Combustibility grade of building materials.

2.3 Positioning possibilities

VIADRUS HERCULES U 24 boiler is approved for installation in non-residential premises (like celars,

corridors, etc.).

Boiler positoning with regard to the fire regulations:

1. The boiler can be installed on a fire-proof floor (Fig. no. 5)

−Place the boiler on fire-proof base exceeding the boiler platform by 20 mm on 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 minimum 50 mm hight.

−Install the boiler in the middle of the retaining wall.

2. Safety distance from the combustible materials

−When installing and operating the boiler it is necessary to keep a safety distance 200 mm from combustible

materials with combustibility grade B, C1 a C2 (according to ČSN 06 1008)

−For easily flammable materials with combustibility grade C3, which burn quickly and by themselves, also after the

ignition source removal (like. Paper, millboard, stiff paper, asphalt and tar boards, wood and fireboards, plastics and

flooring materials) the safety distance is doubled, it means to 400 mm

−The safety distance it is necessary to double also in case that the combustibility grade of building material wasn´t

proved.

Quantity of sections 3 4 5 6 7 8 9 10

L mm] 302 413 524 635 766 857 968 1079

Fig. no. 5 Boiler base dimensions

Tab. no. 5 Combustibility grade of building materials and products

Combustibility degrees of

building materials and

products

Building materials and products ranked in combustibility degrees i

(extract from ČSN 73 0823)

A– incombustible Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters,...

B– combustible with difficulty Acumin, izumin, heraklit, lignos, boards and basalt wools, fiberglass boards,...

C1– hardly combustible Beech and oak wood, hobrex boards, plywood, werzalit, formica, sirkolit,...

C2– medium combustible Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,...

C3– easily combustible Asphaltboard, fireboards, cellulos materials, polyurethane, polystyrene, polyethylene, PVC,...

Boiler positioning with regard to the necessary handling space:

−Basic environment AA5/AB5 according to ČSN 33 2000-3

−In front of the boile there must be left a minimum handling area of 1000 mm

−The minimum distance between the rear part of boiler and the wall 400 mm

−At least from one side part keep the acces area to the back boiler part of minimum 400 mm

Fuel positioning:

−It is interdicted to store the fuel behind the boiler or next to the boiler within a distance smaller than 400 mm

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