Viadrus Hercules Duo Manual For Operation And Installation
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Viadrus Hercules Duo Manual For Operation And Installation

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Summary of Contents for Viadrus Hercules Duo

  • Page 2: Table Of Contents

    Table of contents: page. 1. Use of boiler and its advantages ......................... 3 2. Boiler technical data ............................ 3 3. Description..............................5 3.1 Boiler construction ..........................5 4. Positioning and installation .......................... 9 4.1 Regulations and directives........................9 4.2 Positioning options..........................11 4.3 Hydraulic connection diagram ......................

  • Page 3: Use Of Boiler And Its Advantages

    Dear customer, Thank you for the purchase of automatic solid fuel boiler VIADRUS HERCULES DUO whereby you expressed your trust to ŽDB GROUP a.s., member of KKCG Industry, VIADRUS plant. Please read this manual (particularly chapter no. 6 – Automatic operation and chapter no. 7 – Manual operation) that provides you with instructions for the proper use of your new product that you have to get familiarized with at the very beginning.
  • Page 4 For example if unburned fuel slivers appear on the grate and in the ash-pan it stands to reason that stoking is faster than burning and the stoking cycle must be reduced – see parameters description Tab. no. 3 Thermal technical parameters of VIADRUS HERCULES DUO boiler – Manual operation COKE...

  • Page 5: Description

    Pellets must conform at least to one of following directives or standards: Directive no. 14-2000 MŽP ČR DIN 517 31 ÖNORM M 7135 Specified granularity of pellets 6 to 8 mm Water content in fuel max. 12 % Ash content max.
  • Page 6 Length Small reservoir Large reservoir L [mm] 1272 L1 [mm] 1168 1817 L2 [mm] 1335 1985 Fig. no. 1 Main dimensions of VIADRUS HERCULES DUO boiler with two-way safety valve DBV 1 – 02 (right-hand version)
  • Page 7 Length Small reservoir Large reservoir L [mm] 1272 L1 [mm] 1168 1817 L2 [mm] 1335 1985 Fig. no. 2 Main dimensions of VIADRUS HERCULES DUO boiler with after- cooling loop (right-hand version)
  • Page 8 22 – Valve DBV 1 – 02 11 – Draught regulator 23 – After-cooling loop 12 – Safety thermostat 24 – Thermostatic valve BVTS or TS 130 or STS 20 Fig. no. 3 Main components of VIADRUS HERCULES DUO boiler...

  • Page 9: Positioning And Installation

    1 – Mixer 2 – Retort 3 – Countersunk screw with internal hexagon M8 x 20 4 – Cast iron grate (small diameter) 5 – Sealing 6 – Cap 7 – Washer 8,4 8 – Screw M8 x 20 Fig. no. 4 Burner with mixer (fuel – lignite and hard coal) 1 –...
  • Page 10 WARNING!!! The use of anti-freeze mixture is not recommended by the manufacturer. In case of two-way safety device response regarding the water refill permit in case the water does not conform to ČSN 07 7401 it is necessary to treat water in system so that it again conforms to this standard.

  • Page 11: Positioning Options

    Min. 1 000 mm distance kept between the boiler and fuel is recommended by the manufacturer or the fuel has to be stored in a room separated from the boiler-room. The boiler-room must be permanently supplied with the air both for burning and ventilation (VIADRUS HERCULES DUO boiler air consumption is approx. 75 m The heating system piping or heater heating element piping must be connected by the qualified person.
  • Page 12 Fig. no. 6 VIADRUS HERCULES DUO boiler positioning in the boiler-room Fig. no. 7 Boiler VIADRUS HERCULES DUO (right-hand design with small reservoir) with open fuel reservoir...

  • Page 13: Hydraulic Connection Diagram

    4.3 Hydraulic connection diagram Fig. no. 8 Hydraulic diagram with HW preparation– Pump heating circuit Fig. no. 9 Hydraulic diagram without HW preparation– Pump heating circuit Legend to Fig. no. 8 and 9: QAA 88 device Fuel feeder motor Safety thermostat Air fanmotor Boiler outlet temperature sensor Safety valve...
  • Page 14 Fig. no. 10 Hydraulic diagram with HW preparation– Mixing heating circuit Fig. no. 11 Hydraulic diagram without HW preparation– Mixing heating circuit Legend to figures no. 10 and 11: QAA 88 device Safety valve Safety thermostat Boiler primary circuit pump Thermostat HW Heating circuit pump Heating branch temperature sensor...

  • Page 15: 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.
  • Page 16 • Safety thermostat • round head screw and cross-recessed screw M4 x 6 (2 pc) for safety thermostat gripping • boiler drum shell incl. ash-pan – manual regime • connection accessories for boiler drum shell (spring clip – 4 pc, junction stud – 4 pc, screw ST4,8 x 13 –...

  • Page 17: Installation Procedure

    HMI (ACX84.910/ALG) service unit for Saphir regulator operation – Siemens • Circulating pump Grundfos UPS 25-40 • Water heater (according to VIADRUS offer) • Pressure gauge type 50 (400 kPa) with rear connection by Regulus • Thermometer type 63 with rear connection by Regulus •...
  • Page 18 Shells assembly 1 – Boiler drum 4 sec. with basement 25 – Washer 10,5 (1 pc) 2 – Left side part of basement shell 26 – Draw rod of smoke control 3 – Safety thermostat holder 27 – Control mechanism lever 4 –...
  • Page 19 Mount the relevant connection accessories on the steel sheet components according to Fig. no. 12. Jacket the VIADRUS HERCULES DUO boiler according to Fig. no. 12. 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) –...
  • Page 20 Warning: In case of mounting the fuel feeder to the basement and fuel reservoir to the fuel feeder we first of all position all components into horizontal position and then finally tighten the screws and nuts Apply mastic to the boiler basement and then mount the fuel conveyer to the boiler basement. Then mount the ventilator.

  • Page 21: Boiler Conversion When Switching Over From Automatic To Manual Operation

    pipe in the cleaning hole cover. The valve sensor is to be positioned in the sensor holder that is on the fuel feeder. Note: The valve sensor is to be positioned in the sensor holder without the valve basin that is included in the delivery.

  • Page 22: Boiler Conversion From Right-Hand Design To The Left-Hand Design

    5.2.3 Boiler conversion from right-hand design to the left-hand design Boiler conversion after delivery before installation: − We remove the grate and pull out the burner with mixer from the basement (the connection accessories are as follows: 6 pc screw M10 x 30, 12 pc washer a 10,5, 6 pc nut M10). −...
  • Page 23 1 – Service board 2 – Nut M6 (4 pc) 3 – Washer 6,4 (4 pc) 4 – Screw M6 x 16 (4 pc) 5 – Fuel reservoir 6 – Nut M8 (4 pc) 7 – Washer 8,4 (8 pc) 8 –...
  • Page 24 We connect the service board incl. consoles to the fuel reservoir. We reconnect the components (in case the conversion was done already after the primary installation the length of cables must be trimmed as need may be). Fig. no. 18 VIADRUS HERCULES DUO boiler (left-hand design)

  • Page 25: Wiring Diagram

    5.2.4 Wiring diagram Single-phase circuit breaker 16A K3, K4 Technological relays Regulator Siemens ACX 38.030 Fuel feeder motor Boiler output temperature sensor QAZ 36.526/109 Air fan motor Temperature sensor HW QAZ 36.526/109 Ventilator socket QAA 88 device X10.1 Ventilator plug Fuel feeder temperature sensor QAZ 36.526/109 Boiler primary circuit pump Outside temperature sensor QAC 34/101...
  • Page 26 SERVICE INLET SAFETY VENTILATOR VENTILATOR FUEL FEEDER BOILER PRIMARY CIRCUIT THERMOSTAT SUPPLY SPEED PUMP REGULATION SAFETY ROOM DEVICE Color of conduit: THERMOSTAT Black Brown Blue GNYE Green-yellow GREY Grey WHITE White YELOW Yellow SERVICE SERVICE Fig. no. 20a) Connection diagram– Pump heating circuit...
  • Page 27 SERVICE INLET SAFETY VENTILATOR VENTILATOR FUEL FEEDER BOILER PRIMARY CIRCUIT THERMOSTAT SUPPLY SPEED PUMP REGULATION SAFETY ROOM DEVICE Color of conduit: THERMOSTAT Black Brown Blue GNYE Green-yellow GREY Grey WHITE White YELOW Yellow SERVICE SERVICE Fig. no. 20b) Connection diagram – Pump heating circuit...
  • Page 28 Single-phase circuit breaker 16A K3, K4 Technological relays Regulator Siemens ACX 38.030 Fuel feeder motor Heating branch temperature sensor Air fan motor QAZ 36.526/109 Air fan motor socket Boiler output temperature sensor QAZ 36.526/109 X10.1 Ventilator plug QAA88 device Boiler primary circuit pump Fuel feeder temperature sensor QAZ 36.526/109 Heating circuit pump Outside temperature sensor QAC 34/101...
  • Page 29 SERVICE INLET SAFETY VENTILATOR VENTILATOR FUEL MIXING BOILER HEATING THERMOSTAT SUPPLY SPEED FEEDER VALVE PRIMARY CIRCUIT REGULATION CIRCUIT PUMP PUMP SAFETY Color of conduit: ROOM DEVICE THERMOSTAT Black Brown Blue GNYE Green-yellow GREY Grey WHITE White YELOW Yellow SERVICE SERVICE Fig.
  • Page 30 SERVICE INLET FUEL FEEDER VENTILATOR SERVICE SERVICE SERVICE SERVICE Fig. no. 22b) Connection diagram – Mixing heating circuit...

  • Page 31: Automatic Operation

    6. Automatic operation 6.1 Control, regulation and security elements 6.1.1 Saphir regulator SAPHIR ACX 38 is the regulator destined for solid fuel boiler control, heating circuit control and hot water preparation by means of external reservoir control. The regulator is equipped with boiler sensor, hot water sensor or hot water thermostat (depending on the pump or mixing heating circuit), heating branch sensor (mixing heating circuit), sensor against the fire penetration and outside sensor.
  • Page 32 revolutions and the fuel quantity is allocated adequately to the air volume. The boiler temperature increase against the heating branch desired temperature is 5 °C (set by the manufacturer). b) attenuation regime – after the requirement for heat has ceased the boiler goes over to the attenuation regime.
  • Page 33 QAA 88 device – space unit Space control • Outside sensorQAC34/101 – is not used • Thermostatic valve (Filling valve) - series VTC312 • (external thread) from ESBE (minimum return water temperature 45 C) (ord. code: 5100 15 00) Three-way valve V4044C (only in case boiler is •...
  • Page 34 QAA 88 device – boiler unit Equithermal control without space effect • Outside sensor QAC34/101 • Thermostatic valve (Filling valve) - series VTC312 • (external thread) from ESBE (minimum return water temperature 45 C) (ord. code: 5100 15 00) Three-way mixing valve VBI31.20 with drive •...

  • Page 35: Safety Thermostat

    The heating curve can be tuned by the parallel shift (parameter P 19). By increasing the value we increase the desired heating circuit temperature thus we increase the temperature in the space. The parallel shift parameter shifts the whole heating curve. The heating curve slope parameter only changes the slope of the curve.
  • Page 36 Tab. no. 7 Parameters – Mixing heating circuit Set by the Resolution Parameter Description Units Range manufacturer Current outside temperature -20 … 50 Current boiler temperature 5 … 100 Current heating circuit temperature 5 … 100 Desired heating circuit temperature 0 …...
  • Page 37 Set by the Resolution Parameter Description Units Range manufacturer P 102 First HC period switched off [h:min.] 22:00 0:00 … 23:59 1 min. P 103 Desired space temperature in the first period 10 … 30 P 104 Second period HC switched on [h:min.] 23:59 0:00 …...
  • Page 38 Set by the Resolution Parameter Description Units Range manufacturer P 200 Ventilator X1 hard coal P 201 Ventilator Y1 hard coal 23 … 33 P 202 Ventilator X2 hard coal P 203 Ventilator Y2 hard coal 29 … 39 P 204 Ventilator X3 hard coal P 205 Ventilator Y3 hard coal...
  • Page 39 Set by the Resolution Parameter Description Units Range manufacturer P 22 Ventilator output when making fire 1 … 100 P 23 Minimum boiler temperature 20 … 70 P 24 Type of requirement (auto/fixed) 0 … 1 P 25 Boiler hysteresis 1 …...
  • Page 40 Set by the Resolution Parameter Description Units Range manufacturer P 131 Time schedule reset HW 0 … 1 P 140 Feeder runtime 5 … 10 P 150 Feeder X1 lignite P 151 Feeder Y1 lignite 55 … 75 P 152 Feeder X2 lignite P 153 Feeder Y2 lignite...

  • Page 41: Description Of Saphir Regulator Parameters

    Set by the Resolution Parameter Description Units Range manufacturer P 220 Ventilator X1 pellets P 221 Ventilator Y1 pellets 6 … 13 P 222 Ventilator X2 pellets P 223 Ventilator Y2 pellets 11 … 21 P 224 Ventilator X3 pellets P 225 Ventilator Y3 pellets 31 …...
  • Page 42 Faults P 15 Current boiler fault displayed. Description of individual faults see tab. no. 9. In case 0 is on the line no fault is detected. Parallel shift in the heating curve P 19 By increasing the value the parallel shift in heating curve will occur (parameter P 21) thus the desired heating water temperature will be increased Fuel type Selection of required fuel (value 1, 2, 3 or 4)
  • Page 43 Boiler heating deficiency [min.] If 40 °C boiler temperature hasn’t been reached within the time set in this parameter the fault message „4“ - boiler extinction followed by boiler shut down P 27 will occur. Note: The boiler display is flickering and the fault number is displayed by parameter P 15.
  • Page 44 Boiler primary pump slowing-down [min.] P 52 We select boiler pump slowing-down on this line. Boiler primary pump switch-on temperature Once this set boiler temperature has been achieved the boiler primary pump will P 53 switch on. The pump will switch off once the temperature has dropped by 5 °C below the temperature set for pump switching-on.
  • Page 45 Day of warm water pump spinning On the determined day the pump spinning will be done at 12:00 h for 30 sec. Value 1 - 7 – corresponds to days from Monday to Sunday P 62 Value 0 –primary pump spinning is not active Value 8 –...
  • Page 46 Building constant Heating is influenced by setting this parameter. The linkage of building temperatures responses to changing outside temperature depending on current building structure is taken into account by this parameter. Value 0, 1 – wood structure (setting the value 1 is recommended by the P 80 manufacturer) Value 1, 2 or 3 –...
  • Page 47 Setting the day of time schedule for HC Setting the day of week required for setting the individual heating periods P 100 Value 1 - 7 – corresponds to the days from Monday to Sunday, we set it separately every day Value 0 –...
  • Page 48 Second period HW switched off [h:min.] P 125 Setting the time of switching -off the second period for HW heating Desired HW temperature in the second period Setting the desired HW temperature in the second period P 126 Note: In application with HW thermostat the value must correspond to the temperature set on HW thermostat.
  • Page 49 Feeder runtime in the attenuation – lignite P 158 Setting the feeder runtime in the attenuation regime for HU fuel Standstill time(delay) of feeder in the attenuation – lignite [min.] P 159 Standstill of feed screw in the attenuation regime for HU fuel Ventilator X1 lignite It regards the percentage value of ventilator output.
  • Page 50 Feeder X3 hard coal It regards the percentage value of output. P 174 The value 66 represents 66% output and feeder standstill time of parameter 175 is assigned to this value. Note: This parameter cannot be changed Feeder Y3 hard coal P 175 Setting the feeder standstill time for ČU as the fuel relating to 66% output Feeder X4 hard coal...
  • Page 51 Feeder X1 pellets It regards the percentage value of output. P 210 The value 0 represents min. output and feeder standstill time of parameter 211 is assigned to this value.Note: This parameter cannot be changed Feeder Y1 pellets P 211 Setting the feeder standstill time for pellets as the fuel relating to 0% output Feeder X2 pellets It regards the percentage value of output.

  • Page 52: Qaa 88 Device

    Ventilator Y3 pellets P 225 Setting the actual ventilator output for pellets as the fuel relating to 66% ventilator output Ventilator X4 pellets It regards the percentage value of ventilator output P 226 Value 100 represents 100% ventilator output and the actual ventilator output of parameter 227 is assigned to this value.

  • Page 53: Parameters Setting And Displaying

    Then the cursor moves according to the boiler current status. Small ventilator symbol represents – 33 % ventilator output, middle-sized ventilator symbol represents 33 - 66 % ventilator output and big ventilator symbol 66 - 100 % ventilator output. On the left –hand side part of display the cursor is displayed case...

  • Page 54: Fuel Feeder And Ventilator Performance Curve - Lignite

    Parameters displaying If you only want to display the set parameters without the possibility to make any change take following steps: • Press simultaneously the keys OK, ESC a – minus – blank display will appear. • Press 2x key – minus and n0 appears on the display. •...

  • Page 55: Fuel Feeder And Ventilator Performance Curve - Hard Coal

    6.3.1.2 Fuel feeder and ventilator performance curve – hard coal HARD COAL ČERNÉ UHLÍ Výkonová křivka podavače paliva (závislost podavače paliva na skutečném The fuel feeder performance curve (fuel feeder dependence on actual výkonu ventilátoru) ventilator output) Výkonová křivka ventilátoru vzduchu (závislost skutečných otáček ventilátoru The air fan performance curve (dependence of actual fan revolutions on na procentuálním nastavení) percentage setting)

  • Page 56: Faults

    The feeder runtime is given by P 140 parameter and it applies to all fuels except the fuel type 4 – Manual operation. The change in fuel is selected by P 20 parameter. The delays and percentage outputs are already preset.

  • Page 57: Service Board

    FAULT MESSAGES IN CASE OF SHORT CIRCUIT OR SENSORS DISCONNECTION Heating branch temperature HC heating shut-down Boiler operation shut-down. Boiler outlet temperature protection against fuel fire penetration is active. Primary pump is active. HW reservoir temperature HW heating shut-down Feeder reservoir temperature Boiler operation shut-down.
  • Page 58 higher hardness does not prevent the salts from precipitation on the walls of the boiler drum. The precipitation of 1 mm of calcite in a given place reduces the heat transfer from metal to water by 10 %. Heating systems with an open expansion tank allow the direct contact between the heating water and atmosphere.

  • Page 59: Setting Of Parameters Before The Equipment Start-Up

    6.6 Setting of parameters before the equipment start-up Parameters necessary for equipment start-up Before you make a fire you must set following parameters: Set by the Parameter Description Units manufacturer P 20 Fuel type P 238 Year P 239 Date P 240 Time These parameters are necessary for equipment start-up and other parameters can be modified as need may...

  • Page 60: Important Warnings

    Immediately after the visual check of flame the choker must be properly closed. • During the VIADRUS HERCULES DUO boiler operation it is forbidden to overheat it in any way. • It is forbidden to put any things made of flammable materials on the boiler or within the distance less than the safe distance.

  • Page 61: Maintenance

    6.9 Maintenance It is necessary to be mindful of timely fuel refilling. If only a small volume of fuel is left in the reservoir it must be immediately refilled. Mind the proper closing of the fuel reservoir cover! If the boiler is correctly adjusted the fuel is burnt out in case it has reached the edges of the combustion grate.
  • Page 62 In case of boiler overheating (outlet temperature is higher than 95 °C) the thermostatic valve switches (starts to operate) and the superfluous heat is withdrawn via the after cooling loop. Fig. no. 27 Boiler withs after- cooling loop – connecting dimensions Heating water outlet into system 2”...
  • Page 63 1 – Heating water outlet into system 2” 2 – Return water inlet from after-cooling loop 1 1/2 “ 3 – Return water inlet into boiler from system 2” 4 – Cooling water outlet 5 – Thermostatic valve BVTS (STS 20) 6 –...
  • Page 64 A –cold water inlet G 3/4“ B – outlet into boiler G 3/4“ C – outlet into drain G 3/4“ D – outlet from boiler G 3/4“ Fig. no. 31 Two-way safety valve DVB 1 – 02 1 – Boiler 5 –...

  • Page 65: Control Activity Before Start

    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 Installation Only the professionally qualified person is allowed to carry out the installation. It is always necessary to observe the conditions specified for two-way safety valve installation and follow the flow directions indicated on the valve body in order to guarantee its proper function.

  • Page 66: Setting And Description Of Saphir Regulator - Manual Operation

    position the ash-pan on the insulation put on the retort (otherwise the ember could fall into burner with mixer and consequently fuel in fuel feeder and reservoir could catch fire); the fuel reservoir cover must be left closed. 7.3 Setting and description of Saphir regulator – Manual operation The Saphir regulator is used also in the manual operation.

  • Page 67: Boiler Attendance By User

    As soon as the burning fuel becomes a dark red glow slightly open the rosettes on stoking door for secondary air inlet. In case of burning wood and hard coal the stoking door rosette must be open. Bring the boiler to the necessary operating temperature: 80 °C is the recommended outlet water temperature.

  • Page 68: Important Warnings

    (gluing the flooring materials, painting with combustible paints etc.) the boiler must be put out of service prior to the start of such works • It is forbidden to use flammable liquids in making fire in VIADRUS HERCULES DUO boiler. • it is forbidden to overheat boiler during its operation.

  • Page 69: Instructions For Product Disposal After Expiration Of Its Lifetime

    „The guarantee VIADRUS HERCULES DUO boiler quality and completeness certificate “ serves for infilling as the „Guarantee certificate“. The user is obliged to carry out a regular maintenance on the boiler.
  • Page 70 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 Claim Note 1.1 Prevention by source reduction 1.2 Heavy metals and ensure below maximum permitted...
  • Page 71 The guarantee conditions and liability for defects follow chap. no. 9 this manual. ŽDB GROUP a.s., member of KKCG Industry, VIADRUS plant provides the guarantee: for boilers for 24 months after the product has been put into service, but maximum 30 months after the –...
  • Page 72 Appendix to the guarantee certificate for customer - user Record of carried out guarantee and after-guarantee repairs and product controls Contractual service Date of Customer’s Carried out activity organization(signature, record signature stamp)
  • Page 73 The guarantee conditions and liability for defects follow chap. no. 9 this manual. ŽDB GROUP a.s., member of KKCG Industry, VIADRUS plant provides the guarantee: for boilers for 24 months after the product has been put into service, but maximum 30 months after the –...
  • Page 75 The guarantee conditions and liability for defects follow chap. no. 9 this manual. ŽDB GROUP a.s., member of KKCG Industry, VIADRUS plant provides the guarantee: for boilers for 24 months after the product has been put into service, but maximum 30 months after the –...
  • Page 76 Update: 10/2010 – GB – Saphir...

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