Viadrus EKORET SAPHIR Series Manual For Operation And Installation
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Viadrus EKORET SAPHIR Series Manual For Operation And Installation

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EKORET SAPHIR
Hercules U26
MANUAL FOR BOILER OPERATION
Návod k obsluze
AND INSTALLATION

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Summary of Contents for Viadrus EKORET SAPHIR Series

  • Page 1 EKORET SAPHIR Hercules U26 MANUAL FOR BOILER OPERATION Návod k obsluze AND INSTALLATION...

  • Page 2: Table Of Contents

    Table of content: page Boiler usage and advantages ........................3 Boiler technical data ..........................3 Description ...............................6 Boiler construction ..........................6 Positioning and installation ........................8 Rules and regulations ...........................8 Positioning possibilities.........................9 Hydraulic connection diagram ......................12 Boiler commissioning – instructions for the contracting service organization ........14 Delivery and accessories ........................14 Boiler mounting ..........................16 5.2.1...

  • Page 3: Boiler Usage And Advantages

    EKORET SAPHIR 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.
  • Page 4 Tab. no. 2a) Heating technical parameters of EKORET SAPHIR 15 boiler HARD COAL LIGNITE PELLETS Nominal output Fuel consumption kg.h 2,58 3,34 Fuel efficiency MJ.kg 25,16 19,17 16,78 Fuel consumption in the holding regime kg.h 0,13 0,10 0,70 Burning time at nominal output – small reservoir 67 h 40 min 52 h 30 min 41 h 50 min...
  • Page 5 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...

  • Page 6: Description

    Description Boiler construction The stand with the burner Cast iron boiler drum Smoke adapter Ash door Ash door Ceramic plate front Ceramic plate rearí Ceramic plate side 10. Boiler shell incl. ash pan 11. Safety thermostat 12. Turbulators 13. Heating water flange 14.
  • Page 7 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 main part of the boiler is a boiler body (3-sectional, 4-sectional), that stands on a welded pedestal made from steel sheets.

  • Page 8: Positioning And Installation

    Positioning and installation 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.

  • Page 9: Positioning Possibilities

    Positioning possibilities 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.
  • Page 10 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, •...
  • Page 11 In case the assembled body boiler with boiler pedestral can not be placed into the boiler room there is necessary to proceed by the following method (see Fig. no. 6): • Disassemble arch welder including sealing by unbolting the nuts M10 and washers. •...

  • Page 12: Hydraulic Connection Diagram

    Hydraulic connection diagram Fig. no. 7 Hydraulic diagram with HW preparation– Pump heating circuit Fig. no. 8 Hydraulic diagram without HW preparation– Pump heating circuit Legend to Fig. no. 7 and 8: QAA 88 device Fuel feeder motor Safety thermostat Air fanmotor Boiler outlet temperature sensor Safety valve...
  • Page 13 Fig. no. 9 Hydraulic diagram with HW preparation– Mixing heating circuit Fig. no. 10 Hydraulic diagram without HW preparation– Mixing heating circuit Legend to figures no. 9 and 10: QAA 88 device Safety valve Safety thermostat Boiler primary circuit pump Thermostat HW Heating circuit pump Heating branch temperature sensor...

  • Page 14: Boiler Commissioning - Instructions For The Contracting Service Organization

    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.
  • Page 15 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 division offer) The optional boiler equipment is not included in the boiler standard price.

  • Page 16: Boiler Mounting

    Boiler mounting 5.2.1 Installation of boiler drum with the basement Position horizontally the boiler shell with the pedestal on a sockle. Apply the binding material on the bottom of cast iron grate and settle the mixer down. There is necessary a tightness of cast iron grate and mixer.
  • Page 17 1 – Boiler without shell 11 – Insulation of shell front part 2 – Left side part of shell 12 – Cover of the shell 3 – Insulation of shell left side part 13 – Cover of the shell insulation 4 –...

  • Page 18: Fuel Reservoir And Feeder Assembly

    5.2.4 Fuel reservoir and feeder assembly Fuel feeder Nut M6 (4 pcs) Stud bolt M10x30 (4 pcs) Fuel reservoir Washer 10,5 10. Screw M8 x 20 (4 pcs) Nut M10 (4 pcs) 11. Washer 8,4 (8 pcs) Ventilator 12. Nut M8 (4 pcs) Screw M6x16 (4 pcs) 13.

  • Page 19: Mounting Of The Service Board To The Fuel Reservoir

    5.2.5 Mounting of the service board to the fuel reservoir Service board Screw M6 x 16 (4 pcs) Washer 6,4 (4 pcs) Nut M6 (4 pcs) Sticker – LED of the safety thermostat signalization Fig. no. 14 Mounting of the service board to the fuel reservoir Screw the service board to the side of fuel reservoir.

  • Page 20: Boiler Conversion From Right-Hand Design To The Left-Hand Design

    1 – Clearing opening cover 2 – Sensor holder Fig. no. 15 Assembly of the emergency fire extinguishing equipment 5.2.8 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 21 Conversion of already installed boiler: − We let the boiler burn out. − We disconnect the boiler from mains − We disconnect the geared motor, ventilator (we disconnect the connector), boiler primary pump, safety thermostat from regulator and we pull out the sensor against fire penetration from the basin and outlet sensor from the boiler basin, we disconnect the outside sensor and QAA 88 device.
  • Page 22 − We remove the boiler shell. − Break out an opening in the left side shell. − 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 10,5, 6 pc nut M10). −...
  • Page 23 ! ! ! ! Apply boiler mastic to the point marked with caterpillar and put the grate on the retort with mixer. It is necessary to ensure the tightness between the burner and grate. We jacket the boiler (see chap. 5.2.3). We apply mastic to the fuel feeder flange and connect it to the boiler basement (the connection accessories are as follows: 4 pc screw M10 x 20, 4 pc washer 10,5).

  • Page 24: Wiring Diagram

    5.2.9 Wiring diagram Single-phase circuit breaker 16A Fuel feeder motor Regulator Siemens ACX 38.030 Air fan motor Boiler output temperature sensor QAZ 36.526/109 Ventilator socket Temperature sensor HW QAZ 36.526/109 X10.1 Ventilator plug QAA 88 device Boiler primary circuit pump Fuel feeder temperature sensor QAZ 36.526/109 HW three-way valve Outside temperature sensor QAC 34/101...
  • Page 25 Fig. no. 20 Connection diagram– Pump heating circuit...
  • Page 26 Single-phase circuit breaker 16A K3, K4 Technological relays Regulator Siemens ACX 38.030 Fuel feeder motor Heating branch temperature sensor QAD 36/101 Air fan motor Boiler output temperature sensor QAZ 36.526/109 Air fan motor socket QAA88 device X10.1 Ventilator plug Fuel feeder temperature sensor QAZ 36.526/109 Boiler primary circuit pump Outside temperature sensor QAC 34/101 Heating circuit pump...
  • Page 27 INLET BOILER HEATING PRIMARY CIRCUIT CIRCUIT PUMP PUMP SERVICE Fig. no. 22 Connection diagram – Mixing heating circuit...

  • Page 28: Checking Activities Before Commissioning

    Checking activities before commissioning Before the boiler is put into operation it is necessary to check: a) Filling the heating system with water Water for filling the boiler and heating system must be clear and colourless, without any suspended substances, oil and chemically aggressive substances. Its hardness must comply with ČSN 07 7401 and in case of dissatisfactory hardness the water must be trated.

  • Page 29: Setting Of Parameters Before The Equipment Start-Up

    Connect the equipment to the mains (insert the plug into socket). Put the main switch (circuit breaker) in the service box into the 1 position. By starting the ventilator (by pressing the blue button) in the service box the burner tightness is checked. All air must flow into the combustion are in a retort and boiler grate. The check must be focused on the seating faces: Of the fan in the mouthpiece Around the burner cleaning opening...

  • Page 30: Boiler Commissioning

    Boiler commissioning 1. Making fire in the boiler. − Connect the equipment to the mains (insert plug into the socket). − Put the main switch (circuit breaker) in the service box into the 1 position. − Check whether QAA 88 device is switched off or switch it off by means of OK key; cursor will move into ON/OFF position.

  • Page 31: Hmi (Acx84.910/Alg) Service Unit For Saphir Regulator Operation

    The manufacturer recommends the superior control of Siemens series RVS (RVS 43,345 + additional modules), because for its use has been already processed the design documentation of VIADRUS. In the case of using the superior control is necessary to do the following: •...

  • Page 32: Boiler Operation By User

    Boiler operation by user 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 33 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 34 Pump heating circuit – configuration Boiler equipment Type of operation Necessary boiler accessories Note: The equithermal control at the pump heating circuit is possible in the range from minimum set boiler temperature to maximum set heating circuit temperature. • QAA 88 device – space unit Equithermal control with space effect •...
  • Page 35 • HMI service unit for Saphir regulator operation Equithermal control without space effect (ACX84.910/ALG) – only by request • 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) •...

  • Page 36: Safety Thermostat

    • QAA 88 device – space unit Space control • HMI Service unit for Saphir regulator operation (ACX84.910/ALG) – only by request • Outside sensorQAC34/101 – is not used • Thermostatic valve (Filling valve) - series VTC312 (external thread) from ESBE (minimum return water temperaturem45 C) (ord.

  • Page 37: Forced Withdrawal Of Superfluous Heat

    6.1.5 Forced withdrawal of superfluous heat 6.1.5.1 Forced withdrawal of superfluous boiler heat In case the boiler temperature has exceeded 90 °C so called forced withdrawal of the superfluous heat into the heating circuit will start. The fan and feeder are not active. In case the temperature is lower than the current desired boiler temperature the boiler comes back into actual automatic regime (in case the boiler temperature has reached 100 °C and the safety thermostat has been blocked the thermostat must be manually de-blocked).
  • Page 38 Set by the Parameter Description Units Range Resolution manufacturer P 56 Heating circuit pump off/on 0 … 1 P 57 Heating circuit pump slowing-down [min.] 0 … 60 P 58 Day of heating circuit pump spinning 0 … 8 P 59 Warm water pump man/auto 0 …...
  • Page 39 Set by the Parameter Description Units Range Resolution manufacturer P 169 Ventilator output in the attenuation – lignite 10 … 100 P 170 Feeder X1 hard coal P 171 Feeder Y1 hard coal (3 sect./4 sect.) 120/105 70..150/60..150 P 172 Feeder X2 hard coal P 173 Feeder Y2 hard coal (3 sect./4 sect.)
  • Page 40 Tab. no. 7 Parameters – Pump heating circuit Set by the Parameter Description Units Range Resolution manufacturer Current outside temperature -20 … 50 Current boiler temperature 5 … 100 Desired heating circuit temperature 0 … 80 Current temperature HW 5 … 100 Desired boiler temperature in case of HW 0 …...
  • Page 41 Set by the Parameter Description Units Range Resolution manufacturer P 127 Third period HW switched on [h:min.] 23:59 0:00 … 23:59 1 min. P 128 Third period HW switched off [h:min.] 23:59 0:00 … 23:59 1 min. P 129 Desired temperature HW in the third period 10 …...

  • Page 42: Description Of Saphir Regulator Parameters

    Set by the Parameter Description Units Range Resolution manufacturer P 225 Ventilator Y3 pellets 24/37 14…40/25…50 P 226 Ventilator X4 pellets P 227 Ventilator Y4 pellets 32/41 20…45/25…60 Ventilator slowing-down in the attenuation P 228 1 … 60 regime– pellets P 229 Ventilator output in the attenuation –...
  • Page 43 Slope of heating curve P 21 The value in this parameter shows the preset curve for heating of the heating circuit. The value depends on many factors. The correct value must be found out. Ventilator output when making fire Setting of desired ventilator output when making fire depending on the type of used fuel. P 22 Recommended values: lignite and hard coal 40 - 50 %...
  • Page 44 Boiler temperature increase from the heating circuit Setting of boiler temperature increase from currently desired heating circuit temperature P 41 Note: This value set by the manufacturer can be reduced to approx. 1 – 2 C if the three-way mixing valve is installed in such distance from the boiler that no outlet water temperature losses into the space occur.
  • Page 45 Warm water pump man/auto Setting of type of pump control; Man –pump manual run, Auto – pump automatic run according to the current requirements. Value 0 – Man P 59 Value 1 – Auto Attention! The value 0 is only designed for HW pump service testing. The permanent setting of pump manual run can result in water heater chilling.
  • Page 46 Maximum heating circuit temperature P 77 Setting of maximum desired temperature for heating circuit. 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 P 80 parameter.
  • Page 47 P 103 Desired space temperature in the first period Setting the desired space temperature in the first HC period P 104 Second HC period switched on [h:min.] Setting the switching-on time of the second period for HC heating P 105 Second HC period switched off [h:min.] Setting the switching-off time of the second period for HC heating...
  • Page 48 P 131 HW time schedule reset By this parameter activation the time regime returns to the manufacturer’s setting Value 1 – activation P 140 Feeder runtime Feeder runtime in automatic regime Feeder X1 lignite It regards the percentage value of output. P 150 The value 0 represents the min.
  • Page 49 Ventilator Y4 lignite P 167 Setting the actual ventilator output for HU relating to 100% ventilator output Ventilator slowing-down in the attenuation regime– lignite P 168 Setting the ventilator slowing-down in the attenuation regime against the feeder runtime in the attenuation regime Ventilator output in the attenuation regime–...
  • Page 50 Ventilator X4 hard coal It regards the percentage value of ventilator output P 206 The value 100 represents 100% ventilator and actual ventilator output of parameter 207 is assigned to this value.Note: This parameter cannot be changed Ventilator Y4 hard coal P 207 Setting the actual ventilator output for ČU as the fuel relating to 100% ventilator output Ventilator slowing-down in the attenuation regime–...
  • Page 51 P 225 Ventilator Y3 pellets Setting the actual ventilator output for pellets as the fuel relating to 66% ventilator output P 226 Ventilator X4 pellets It regards the percentage value of ventilator output Value 100 represents 100% ventilator output and the actual ventilator output of parameter 227 is assigned to this value.

  • Page 52: Qaa 88 Device

    QAA 88 device The space or output water current temperature is displayed on the display during the operation depending on the use of this device (parameter P 28). The value is displayed in resolution 0,5 By pressing the key plus or minus the desired temperature is displayed.

  • Page 53: Parameters Setting And Displaying

    6.3.1 Parameters setting and displaying Parameters setting If you want to change parameters take following steps: • Press simultaneously the keys OK, ESC and – minus – blank display will appear. • Press 2x key – minus and n0 appears on the display. •...

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

    6.3.1.1 Fuel feeder and ventilator performance curve – lignite The feeder runtime is given by P 140 parameter and it applies to all fuels. The change in fuel is selected by P 20 parameter. The delays and percentage outputs are already preset. HNĚDÉ...

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

    6.3.1.2 Fuel feeder and ventilator performance curve – hard coal The feeder runtime is given by P 140 parameter and it applies to all fuels. The change in fuel is selected by P 20 parameter. The delays and percentage outputs are already preset. ČERNÉ...

  • Page 56: Fuel Feeder And Ventilator Performance Curve - Wood Pellets

    6.3.1.3 Fuel feeder and ventilator performance curve – wood pellets The feeder runtime is given by P 140 parameter and it applies to all fuels. The change in fuel is selected by P 20 parameter. The delays and percentage outputs are already preset. WOOD PELLETS –...

  • Page 57: Faults

    6.3.2 Faults The faults are displayed by flickering display of QAA 88 device. Current fault number is displayed in P 15 parameter. In case more faults occur simultaneously first of all the fault with higher number will be displayed. The non-reversible fault 4 must be quitted after its elimination which is done on the introductory display of QAA device (i.e.

  • Page 58: Service Board

    FAULT MESSAGES IN CASE OF SHORT CIRCUIT OR SENSORS DISCONNECTION Heating branch temperature HC heating shut-down Boiler operation shut-down. The 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 59: Important Cautions

    IMPORTANT CAUTIONS • The boiler only can be used for the purpose that it is destined for. • The boiler can only be operated by adults who are acquainted with this operation manual. It is not permitted to leave the children unattended by adults at the boiler being in operation. •...

  • Page 60: Maintenance

    Instructions for product disposal after its service life VIADRUS a.s. is a contracting partner of the firm EKO–KOM a. s. with the client number F00120649. The packages comply with EN 13427. We recommend to dispose the packages in the following way:...

  • Page 61: Guarantee And Liability For Defects

    6 and 8 to a contractual service organization accredited by the boiler manufacturer VIADRUS a.s., otherwise the guarantee for a boiler proper function does not apply If the boiler is operated according to the instructions mentioned in this “Operation and installation manual”, the boiler does not require any special technical interference of service.
  • Page 62 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 levels...
  • Page 63 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 VIADRUS a.s. provides the guarantee: – For boilers 24 months after the boiler putting into operation, but maximum 30 months after the date it was dispatched from the manufacturing factory.
  • Page 64 Annex to the guarantee certificate for customer- the user Record of accomplished guarantee and post-guarantee repairs and regular product checks Contracting service Record Customer´s Carried out activity organization date signature stamp, signature)
  • Page 65 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 VIADRUS a.s. provides the guarantee: – For boilers 24 months after the boiler putting into operation, but maximum 30 months after the date it was dispatched from the manufacturing factory.
  • Page 67 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 VIADRUS a.s. provides the guarantee: – For boilers 24 months after the boiler putting into operation, but maximum 30 months after the date it was dispatched from the manufacturing factory.
  • Page 68 Update: 42/2012 – GB...

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