MACHINERY FACTORY “ASTRA”

LT- 62161 Alytus, Ulonų 33 Lithuania tel. +370 315 75449 fax. +370 315 75352

HEATING BOILERS

Astra G-18MES

Astra G-25MES

Astra G-31,5MES

Astra G-40MES

Astra G-50MES

Astra G-80MES

Astra G-100ES

MANUAL OF INSTALLATION AND EXPLOITATION

2011

Heating boilers are transported packed under the manufacturer’s documentation, protected from atmospheric precipitation and dust. The transporter should ensure the quality of product transportation and protect from damages. The vendor (manufacturer) does not accept claims for production damaged during transportation. The BUYER should lay claims to the transporter for the product damaged during transportation. The BUYER (user) should follow all requirements of this guidebook during transportation, storage and exploitation, otherwise he loses the vendor’s (manufacturer’s) guarantees.

1. SAFETY REQUIREMENTS

1.1. The room where the boiler is to be installed should be ventilated. 1.2. The air should freely access the room. 1.3. The boiler flue connection with the chimney should be tight. Don’t heat up the boiler with leaking flue connections! 1.4. The boiler should be installed in a closed heating system with a closed (membranous) expansion vessel, the volume of which should be no less than 10% of the total volume of a heating system (including the boiler) (the volume of the expansion vessel can be calculated according to the standard EN 12828 annex D). 1.5. Safety valve for no more than 2 bar response pressure should be installed at the boiler in the heating system for the boilers (Astra G-18 and Astra G-25) and maximal 3 bar response pressure for the boilers Astra G-31,5, Astra G-40, Astra G-50, Astra G-80 and Astra G-100. Please consult the chapter 5. 1.6. Clean boiler flues from smoke and pitch scurf, as indicated in this passport. The chimney should be cleaned as required by fire prevention regulations. 1.7. The room where the boiler is installed should have fire-extinguishing tools: fire-extinguishers, sand box, shovel and other tools. 1.8. Don’t put flammable materials on or near the boiler. 1.9. Connect the boiler to the electric system only by a three-pole plug plugged into an adequate three-pole socket with earthling. Protect connection cable from damages. 1.10. Monitor operation of temperature regulation devices and manometer readings. If notice an abnormal boiler operation, stop heating and eliminate damages. 1.11. Kindle the boiler and put the firewood into the boiler only as indicated in section 6 of this passport. 1.12. Keep children away from the boiler! Only adults can serve the boiler. 1.13. Before kindling the boiler, check, if the heating system is filled up with water and aired. 1.14. Operating pressure in the heating system should not exceed: - 0, 2 MPa (2.0 kg/cm2) – for the boilers Astra G-18, Astra G-25; - 0, 3 MPa (3.0 kg/cm2) – for the boilers Astra G-31,5, Astra G-40, Astra G-50 , Astra G-80, Astra G- 100. 1.15. The electrical connections of the boiler are tested: - evenness of the protective chain–electric resistance of the protective chain does not exceed 0, Ω, - the minimal resistance of the electric insulation is 1.0 MΩ, - the resistance of the electric insulation is checked using 50 Hz, 1000V.

2. PURPOSE OF THE PRODUCT

Heating boilers are designed for heating of dwelling houses, public, industrial and similar

purpose buildings where water-heating systems are installed. Boilers are fired only with wood (firewood) or (saw dust, peat, chaff, etc.) briquettes. It is recommended to fire dry (20% moisture content) wood. It is possible to fire fine wood waste and saw dust in small quantities (to 10%), mixing them with firewood. Control and regulation equipment installed in the boilers automatically maintains the set heat carrier (water) temperature, ensures cost-efficient operation of the boilers, and safe exploitation.

The boilers of this type are constructed for wood firing with a partial gas generation. In the upper combustion chamber of the boiler, gas is extricated (generated) from the burning firewood and burned in the lower chamber. Intensity of gas generation and its combustion is regulated by the frequency and duration of air inlet into combustion chambers.

Advantages of the boilers:

Gas generation from firewood ensures a high effective operation coefficient.

Boiler is equipped with the excess heat distribution system (serpentine of the emergency cooling).

Power of the boiler (temperature of a heat carrier) is controlled automatically by a thermo-regulator, by turning on or off a ventilator (ventilators) of the air inlet into combustion chambers; and by a traction regulator, by closing or opening air supply opening cap of the ventilator.

Long load combustion period.

Complete fuel combustion ensures cost-efficient fuel exploitation.

Ashes might be removed only 1-2 times per week.

3. TRANSPORTATION, STORAGE, UNPACKING, PREPARATION TO EXPLOITATION

Heating boiler should be carefully loaded, unloaded and transported, suffering no big impacts. The boiler can be transported only in a vertical position, fastened in order to avoid sliding and falling. If the boiler is transported in other than vertical position, decorative surfaces may be damaged, tins battered, control and regulation equipment broken, built-in ceramic kindling details may fall down and splinter.

The boiler should be stored also in a vertical position. It is not allowed to put one boiler on another, as a safety-packaging frame is not designed for this purpose. The boiler should be stored in closed space protected from atmospheric precipitations. Air humidity of the room should not exceed 80% in order to avoid condensate (dew) forming on the surfaces of the boiler. Storage temperature may vary from -40 ºC to +60 ºC.

If the boiler was transported or stored in minus temperatures, then before it is kindled, it should be kept in plus temperature no less than for 2 hours (for the order and requirements of the first kindling see section 6 of this passport).

After the heating boiler is delivered to the site, take off the packing frame and polyethylene film and unscrew bolts of boiler fastening to the packaging base. Take off the boiler from the packaging base.

WARNING! Opening the doors of the boiler, check, if all tools listed in the section “THE BOILER KIT” are there. Check, if painted surfaces haven’t been damaged, components – not battered, control and regulation equipment – not broken during transportation. If notice any inadequacies of the listed above, lay your claims to the transportation or vendor company.

The kit consists of: 1. Boiler 1 unit 2. Poker 1 unit 3. Scraper 1 unit 4. Guidebook for exploitation 1 unit 6. Leg 4 units 7. Fan/ventilator 1 unit

4. INSTALLATION

These boilers of solid fuel are boilers of complete loading. For this reason they reach the

highest effectiveness when they are working at the nominal power and due to this the boilers must be

equipped with the accumulation tank of sufficient size which could accumulate the excessive heat

volume.

Recommended capacity of the accumulation tank is about 50 liters for 1 kW of nominal

power of boiler:

Model of boiler G-18 G-25 G- 31,5 G- 40 G- 50 G- 80 G- 100

Required volume of accumulation tank , liters

700 900 1500 1800 2500 3200 5000

The boiler has to be exploited only with the installed emergency cooling system. Description of the connection scheme of the emergency cooling serpentine.

Thermostatic safety valve protects the boiler form the overheating. If the water temperature in the boiler exceeds 950C the valve automatically opens the flow of water from the water supply system through the cooling serpentine . This water absorbs the excessive heat energy and flows out. Sensor of valve with the external thread ½“ is screwed in the socket on the rear wall of the boiler.

Technical data of the thermostatic safety valve : Opening temperature 950C Highest working temperature 1100C

Working pressure 10 bar Pipe of sensor L=142 mm, external thread ½“ ATTENTION ! The system of the emergency cooling of the boiler can not be used for the

heating of water. Description of the principal scheme of the boiler room. When the water temperature in

the boiler reaches 600C there is launched circulation pump connected with the boiler. Water circulates through the thermostatic mixing valve in the cycle „boiler – thermostatic mixing valve – boiler“. Heating system is equipped with the programmed automatic control processor and 3-way mixing valve with electric drive (if the heating system is not equiped with the programmed automatic control processor and 3-way mixing valve with electric drive there can be installed manual operation 3-way mixing valve and to perform the regulation of heating system in manual way). When the water temperature rises further the programmed processor control and regulate the temperature of the water supplied from the accumulation tank to the heating system. This temperature depends very much on the outside and ambient temperatures measured with the sensor. In order to avoid the corrosion of boiler caused by the water condensate in the temperatures below 550C thermostatic mixing valve automatically ensures that the minimal temperature of water returning to the heating boiler is 600C.

Installing the boiler, the following requirements should be fulfilled:

The boiler should be installed in a closed heating system with a closed (membranous) expansion vessel, the volume of which should be no less than 10% of the total volume of a heating system (including the boiler). The closed heating system is the system with no free access to atmospheric air, which actuates corrosion. Due to this, it is restricted to drain water from the system without a particular reason (e.g. in summer, etc.). It is also necessary to ensure tightness of the system in order to need fewer refills with fresh water having free oxygen. Quantity of the additional water should not exceed 5% of water volume of the system per year. If an open expansion vessel is installed at the highest point of the heating system, it should be disconnected from the system and an automatic air escaper installed instead as well as a closed expansion vessel at the boiler (see fig. 4).

There must be no shut-off valves between the boiler and safety valve. The technical characteristics of the safety valve: Instrument Technical characteristics Type of boiler

Safety valve Connection diameter does not exceed ½”, opening pressure 2 bar

Astra G-18, Astra G-25,

Safety valve Connection diameter does not exceed 3/4”, opening pressure 3 bar

Astra G-31,5, Astra G-40, Astra G-50, Astra G-80, Astra G-100,

Temperature – pressure gauge

Range of pressure 0-4 bar Temperature 0-120°C

All the boilers

Water from the safety valve should be conducted via an offtake duct. It should be conducted in the way that the water let by the valve would safely flow, avoiding exposure with people and electrical parts of the boiler. The diameter of the offtake duct should be no less than the diameter of the offtake opening connection branch of the safety valve. Total length of the offtake duct should not exceed 2 metres. Installing this duct, no more than 2 elbow joints at 90

0 angles should be used. No

closed, adjustable or other reinforcements should be installed in the valve water offtake duct. This duct should be installed in the way to see the offtake flow of the water. If the end of the duct is to be hidden (e.g. in the sewerage pipe), then this duct should have a special funnel enabling to see the offtake flow of the water.

WARNING! Operation of the safety valve should be checked at least once per month. The valve is opened for a while by turning its head to see a small quantity of the offtake water. Avoiding this, due to a high temperature impact, the components of the valve may stick together and serious damages of the boiler and the heating system may occur as well as danger arise for human health and life.

The temperature of the returning water from the heating system to the boiler should be no less than 60°C. This is the only way to prevent the walls of the boiler combustion chambers from weeping, and the boiler will be protected from corrosion. To ensure the temperature of the returning water to the boiler and to regulate water temperature of

the heating system, it is necessary to install a four-way mixing valve between the boiler and the heating system. Water temperature supplied from the boiler during exploitation should be no less than 70°C.

WARNING! In order to guarantee a natural water circulation in the boiler, the pipeline between the boiler and the four-way mixing valve (boiler – four-way mixing valve – boiler) should be of the same diameter and meet the diameter of the boiler connection branches (see fig. 4, I - boiler ring). Four-way mixing valve should be installed above the boiler.

The boiler will operate in the most effective and economic way, if a circulating pump is installed in the system. It should be installed behind the water supplied by the four-way mixing valve in the pipe. This guarantees a constant water flow in the heating system. The boiler may also operate in a natural circulation (gravitational, without a pump) system, however in this case, it won’t be totally used and its operation conditions won’t be optimal. In case when reconstruction of natural (gravitational) circulation systems is performed by installing the pump, in order to avoid emergencies, when the pump is broken, it should be installed on the edging line together with reverse valves, as shown in fig. 4 and 5. The pump is controlled with the electronic controller of boiler and is connected to the electric socket on the rear wall of the boiler.

Dirt collector should be installed in the returning water pipe of the heating system.

Boiler room should be ventilated. The required airflow necessary for combustion and ventilation should be also guaranteed. For this purpose, boiler room doors should have grille or there should be a gap between the doors and the floor. If there is no possibility to bring air in from another rooms or the house is very tight, it will be necessary to make an opening in the exterior wall. Air quantity should be no less than 1, 6 m3/kW per hour. Cross-section area of the opening should be no less than 0,001 m2/kW. The required air quantities and areas of the opening are presented in the table below.

For example: the area of airflow opening should be 0,025 m2 or 250 cm2, i.e. 16x16 cm; or the height of the gap under the door - about 4 cm when door width is 60 cm.

Put the boiler on the hard (e.g. concrete) and even ground, closer to the chimney pot.

Leave at least 600 mm gap between the back wall of the boiler and building structure for boiler servicing and cleaning. The smallest distance between a lateral wall of the boiler and building structure is 400 mm. If building structure is of the flammable materials, this distance should be doubled. At least 800 mm gap should be left from the other side of the boiler to have an access to the backside of the boiler, its servicing and cleaning. From three sides of the boiler the floor of 300 mm and from the front of the boiler the floor of 500 mm should be of inflammable materials. Screw supporting legs in to the base of the boiler and level the boiler with screw nuts using a level.

Smoke exhaust opening of the boiler should be connected with the chimney by a metal pipe. Internal diameter of the metal connecting pipe should be at least of the external diameter of the smoke exhaust opening of the boiler. To improve the traction, a connecting pipe between the boiler and the chimney should be installed with an inline towards the boiler. All junctions should be carefully tightened by a heat-resistant material.

If the boiler is installed higher than the heating equipment, the water level measuring instrument must be installed in the heating system.

When the boiler is installed in the open heating system, on the highest point of the heating system there has to be mounted the open expansion vessel. The volume of expansion vessel has to be about 10 % of the total volume of water in the heating system (including the volume of the boiler).

The diameter of the overflow pipe of the expansion vessel has to exceed the diameter of the safety inlet pipe by one unit.

Safety return pipe has to be connected to the return pipe of the heating system and to the bottom of the expansion vessel.

It is forbidden to install any fittings in the safety inlet and return pipes between the boiler and expansion pipe.

Chimney requirements. It is recommended to install acid-resistant stainless steel shell

into the stone chimney. It improves traction of the chimney and protects the stone chimney from destruction due to the condensate (moisture) impact. Internal diameter of the shell should be no less than the external diameter of the smoke exhaust opening of the boiler. Chimney shell may be round or

Boiler type G-18 G-25 G- 31,5 G- 40 G- 50 G- 80 G- 100

Required air quantity per hour, m3/h

29 40 40 50 80 128 160

Area of airflow opening, m2

0,018 0,025 0,025 0,03 0,05 0,08 0,1

oval. It is not recommended to use rectangular shell, as due to the temperature fluctuations, its walls deform, gaps appear at the element junction points, through which the condensate falls on the walls of the stone chimney, and an additional air is sucked in, which reduces traction of the chimney. Traction of smoke should correspond to the calculated value of traction (see the table of technical data). The shell should be constructed by the factory and certified.

Minimum permissible height of the chimney should be at least 6 m. The top of the chimney should be above the top roof at least by 0, 5 m. If the chimney is in bigger distance than 1 m from the top roof, the top of the chimney should level with the line going down from the top roof with no bigger than 10° angle from the horizon. You should also evaluate the influence of different obstacles present around the building (trees, other buildings, etc.) (see fig. 3). There can not be connected any other equipment to the chimney connected with the boiler.

Electrical installation with earthing should be installed for connection of the electrical part of the boiler pursuant to electrical safety requirements (see a principal electricity scheme, fig. 4). PROTECT isolation of the connection cable from damages!

5. FUEL

The boiler is fired only by firewood and different briquettes. It is prohibited to fire by coal. It is recommended to fire dry firewood (15-20% moisture content). The drier is the firewood, the bigger its caloric content. When a moisture content of the firewood is 20%, thermal value of 1 kg is approximately 4 kWh; when the moisture content is 50%, its thermal value reduces in half.

The length of the firewood should be at least 5 cm shorter than the length of the boiler combustion chamber, i.e.:

Boiler type G-18 G- 25 G- 31,5 G- 40 G- 50 G- 80 G- 100

The maximal length of the firewood in mm

310 450 550 550 750 750 750

The recommended thickness of the firewood is 100-150 mm. Larger firewood should be

split at least once. WARNING! Don’t fire newly prepared and too damp firewood! Recommendations for firewood preparation: - Put split firewood into well ventilated and, if possible, well sun lightened place.

Firewood should be well protected from rain and snow; - stow the split firewood with sufficient gaps in between in order for a freely circulating air

to withdraw the moisture evaporated from the firewood; - there should be a sufficient space atop of the firewood up to the roof and such

ventilation that wet air could drift away; - it is not recommended to store freshly cut (undried) firewood in the cellar, as its drying

requires sun and free air circulation. Dry firewood could be stored in the cellar where sufficient ventilation is guaranteed;

- It is recommended to dry split firewood under above described conditions in dependence with the type of the wood: soft wood (alder, asp, fir, willow etc.) – no shorter than 8 months, hard wood (oak, ash, birch, etc.) – no shorter than 20 months.

6. EXPLOITATION

Preparation for heating Before kindling the boiler, check the edge (5) position at the lower combustion chamber

(see fig. 2): the edges should be pressed to the rear wall of the boiler; ~ 100 mm gap should be between the wall and the edge in the front.

At the rear part of the boiler at the air inlet above the ventilator there is a damper to regulate the air inlet to the upper burning chamber and heater (fig. 12). Operation of the damper: after loosening the screw push the damper until the support and then pull by 15 mm (till the marking on the damper plate) and then tighten it with screw. This damper has to be adjusted during the preparation for handling. It is recommended to check the position of this damper at the beginning of the heating season.

During heating season don’t put firewood and other flammable materials on the boiler (or at unsafe distance). You can cause a fire!

Fill the heating system with water. The filling pressure has to exceed the hydrostatic pressure by 0, 2 bars but no exceeding the working pressure of the boiler. When the system is filled up with water, check tightness of the whole system before kindling the boiler and afterwards when the operation reaches its standard mode.

Check if the air is sufficiently drained from the heating system.

Kindling order of the boiler Before kindling the boiler, check whether all requirements indicated in the section 1 are

executed. Open the damper of the upper flue (C) by pushing the handle (12) towards yourself (see fig. 2). Open the door (9) of the upper combustion chamber (2) and put dry kindling wood on the heat-resistant shell (3) to form 2-3 cm gap between the opening of the shell and kindling wood. Put some of the easy flammable materials and bigger kindling wood and firewood atop. Fire the kindling wood, wait till the firewood combusts, close the door and turn the handle (12) of the flue damper from yourself to the end. Load the wood without any bigger spaces until the top of combustion chamber. Bigger pieces of firewood should be loaded in the middle and smaller prices – at the sides, because the walls of the combustion chamber due to their lower temperature slows down the combustion of the bigger pieces of wood. Do not cover with the wood the hole of the smoke extraction valve C . With the boiler control panel switch the tension of the electronic controller with the button „0“-„I“ ( see the technical description of the electronic controller). There will be switched on the lights and temperature indicator. Using the buttons of the temperature regulation set required temperature of the water flowing of the boiler – it is recommended to set on the 70

0C. Close the upper door of the combustion chamber, open the lower door, burn the wood

pieces ., Leave the lower door open until the water temperature in the boiler reaches 400C. Close

the lower door, close the valve of the upper smoke traction by pushing the handle of valve (12) to the end. Switch-on the ventilator with the control panel. Afterwards the boiler will work on the automatic range and will maintain the set temperature of the water from the boiler.

WARNING! The door of the boiler combustion chambers should be tightly closed, there

should be no flammable products accessing the exterior. Door tightness is regulated by screwing or unscrewing hinge and lock screws of the door.

Regulation of the boiler temperature – see the technical description of the electronic

regulator. Emergency thermostat of the water temperature (safety switch ! 95

oC ).

If the water temperature due to the unforeseen reasons exceeds the maximal allowable limit , safety thermostat (emergency switch), switches off the ventilator of the air supply. Combustion intensity will decrease and the temperature of water will drop. When the emergency thermostat comes into action (switches off) – the light of the ventilator switch and electronic controller is off , it is necessary to detect the reasons and to remove them. Emergency thermostat is turned on by taking off the cover of thermostat ! 108

oC

and pressing the

red button. . The attempts of purchaser to repair the thermostat and to recover its functions on his own without removal of reasons which caused the over-heating of boiler can result not only serious damages of boiler, but also the danger for the health and life. If the reasons of the switch of the emergency thermostat can not be detected and removed, it is necessary to call the servicing company !

Addition of the firewood While putting firewood into the combustion chamber (during boiler operation or after load

burning off), keep strictly to the set order: 1) Open the damper of the upper flue by pulling the handle (12) (see fig. No. 2). 2) Switch off the ventilator. 3) Wait at least 20 s, open the upper door. 4) Put the firewood in and close the door tightly. 5) Switch on the ventilator. 6) Close the damper.

If operated following this order, smoke and carbon won’t enter the room. Combustion control

The combustion control of boiler is described in the chapter “COMBUSTION CIONTROL”

of the technical description of regulator KR-4.

The flame in the boiler can be checked by opening the lower door of the combustion

chamber when the ventilator is on. Temperature regulation of the heating system – See the description of the scheme

of boiler room ( beginning of the chapter 4).

Cleaning of the boiler

Aches are removed from the boiler each 4-7 days. Open the door of the upper combustion

chamber and shovel aches down to the lower chamber. Open the door of the lower chamber, take out

the ceramic inserts and shovel ashes to the metal box. WARNING! In any case keep strictly to the determined order: open the damper of the

upper flue, then after 20 s open the boiler door.

Clean boiler chambers from smoke-black and pitch scurf once or twice a month. Clean the

boiler when the fuel is completely burned and the boiler is cooled down to at least +40 °C.

Clean smoke-black and scurf from combustion chambers and flue walls using a scraper

and metal hog. Clean after the doors of the combustion chambers are open and caps of flue upper

openings unscrewed . When finished, check, whether no ashes or smoke-black fell into the ventilator

opening and tightly screw the caps of the flue openings.

Control water pressure in the heating system at least every two weeks. If necessary, fill it

up. If the boiler is not being heated, drain the water off the system when air temperature is below 0 °C!

Emergency extinction of the boiler

If due to any reasons you must immediately extinct the heated boiler, by any means don’t

pour water on the kindling wood! The boiler can burst.

It is very convenient to use dry sand for emergency extinction. There should be ~50 kg of

dry sand in the boiler room. Sand not only well isolates burning firewood from the air oxygen but also

cools down the burning zone. Then, when the boiler cools down, sand can be easily cleaned and

removed.

7. POSSIBLE DAMAGES

Damage Cause Ways of elimination

1. The set temperature

(power) cannot be

reached

- Not enough water in the heating

system;

- Thermo regulator or ventilator is

broken;

- Bad quality fuel (high moisture

content, very large firewood);

- Heating surfaces of the boiler are

very impure;

- No traction in the chimney (impure) –

the upper ignition is congested;

- Ceramic burner is foul.

Fill up

Replace

Use dry fuel, split firewood

Clean

Clean

Clean

Clean

2. Smoke breaks through

the doors

- Tightening rope is damaged;

- Doors are leaky along the whole

perimeter.

- No traction in the chimney

Replace with a new one

Adjust hinge supports and door

lock (regulated screwing or

unscrewing door hinge or lock

screws)

Clean.

3. Ventilator isn’t

operating

- Emergency thermostat went off

(switch light of ventilator is off);

- Thermo regulator or ventilator is

broken;

- Disconnection of electricity supply.

Call representatives of the service

company; turn on after indication of

the causes (see section 5)

Replace

Check electric fuses of the building,

call the electrician

8. TECHNICAL DATA Meanings of the indicators

Indicators G-18 G-25 G-31,5 G-40 G-50 G-80 G-100

Nominal heating power -tire wood kW

- wooden briquets, kW

Class of boiler according to EN 303-5

18

23

1

25

28

1

31,5

33

1

40

42

1

50

54

1

80

84

1

100 100 1

Class of protection against electric impact 1 1 1 1 1 1 1

Usage coefficient,% 78 78 78 80 80 80 80

Area of the internal heated surface of boiler, m2, 1,92 2,08 2,08 2,2 3,39 3,8 6,45

Power of the cooling serpentine, kW 15 15 15 18 18 18 18

Water volume in the boiler, litres 63 78 78 85 96 98 100

Setting range of the temperature regulator OC 60-85 60-85 60-85 60-85 60-85 60-85 60-85

Max working smoke traction, mbar 0,25 0,25 0,30 0,30 0,32 0,35 0,38

Working pressure of water in the system , bar, max 2,0 2,0 3,0 3,0 3,0 3,0 3,0 Testing pressure of boiler, bar 4,0 4,0 4,5 4,5 4,5 4,5 4,5 Max. allowable water temperature in the boiler, OC,

Max. allowable working water temperature in the boiler, OC,

108

95

108

95

108

95

108

95

108

95

108

95

108

95

Electric characteristics - voltage, V/ frequency, Hz 220/50 220/50 220/50 220/50 220/50 220/50 220/50

- used power, W 50 50 50 50 80 80 80

Level of electric protection of boiler

Dimensions - height, mm 1320 1320 1320 1235 1420 1590 1590 - width, mm 585 585 630 710 710 710 910

- depth, mm 835 910 1010 1210 1210 1230

Weight of boiler, kg, 240 310 320 380 500 535 640

Diameter of the connection nozzles 11/2” 11/2” 11/2” 11/2” 11/2” 2” 2”

Volume of combustion , l 90 95 120 140 280 315 405

Dimensions of the loading hole, mm 350x285 350x285 350x285 350x285 350x285 350x285 350x285

Al diameter of the smoke extraction, mm 152 152 152 152 152 180 180

Length of wood pieces, mm 330 450 450 550 750 750 750

Temperature of the outlet gases at the nominal heating power, 0C 210 210 200 200 190 190 190

9. GUARANTEE AND ITS VALIDATION CONDITIONS

1. The manufacturer gives 2 year guarantee*, if the installation, start-up and regulation (the first

kindling and adjustment) and maintenance are performed by the certified company and the 6 months guarantee

if the mentioned works are executed by the non certified company :

- the guarantee repairs are performed, if the faults occur due to the manufacturer’s fault or used

bad quality materials;

- guarantee period is not extended after boiler faults have been eliminated during the guarantee

period;

- boiler cleaning as well as boiler and heating system regulation are not included into the list of

guarantee repair works;

- guarantee doesn’t mean that losses suffered due to the boiler fault occurred during the guarantee

period will be compensated;

- guarantee repair works and replacements of the parts are free of charge during the guarantee

period;

- the client pays for boiler installation and the first kindling and regulation works. * One year guarantee is given to the boiler ventilator, thermo regulators and door stuffing (tightening

ropes).

2. Guarantee validation conditions:

- guarantee is valid from the boiler selling date;

- guarantee is valid, if the boiler is installed, connected to the heating system and exploited under

the requirements of this passport.

3. Guarantee is not applied in the following cases:

- when heat exchanger is limed;

- in case the heat transmitter is frozen;

- when the boiler is broken due to improper exploitation;

- when the boiler is broken due to improper connection of the electric input;

- when the boiler parts are mechanically damaged;

- if the boiler is connected to the heating system not under the schemes and requirements of this

passport.

4. The owner of the boiler pays himself for repair works performed after the guarantee period.

10. ACCEPTANCE CERTIFICATE

The heating boiler “Astra G “ serial No. _________ meets the standard (EN 303-5)

requirements and is accepted suitable for exploitation.

Manufacturing date _________________

Head of Quality

Service ____________________

BOILER GUARANTEE CARD

Boiler Astra G ........ Boiler serial No.

Selling date, place, seal

Seller’s name, surname, signature

BOILER START-UP AND ADJUSTMENT CARD

Start-up, adjustment date

Start-up and adjustment performing company

Certificate No .

Employee’s name, surname, signature

Employee’s qualification certificate No.

48

9

Supplied

6

17

12

12

13

C

A

3

6

16

1

2

B

5

7

B

80

10

k

regulator

regulator

180

ab

b1

a1

1818

Rear viev

L

H

11

h

Trap

Trap

Returning

Cross-section

18

18

19

o152

Boiler type B L H h k a1 b1 a b D d

ASTRA G-18 MS/MES 835 --- ---

ASTRA G-25 MS/MES 585

--- ---

ASTRA G-31,5 MS/MES 615 970

1320 990 130 75 915

--- ---

ASTRA G-40 MS/MES 1010 1235 890 --- --- 845

ASTRA G-50 MES 1420 1080 --- --- 1025

152 G1 ½“

ASTRA G-80 MES

710 1210

170

--- ---

105

1215

ASTRA G-100 MES 810 1230 1590 1220

185 115 1200 --- --- 180 G2“

1. Frame 12. Damper hinge of upper combustion chamber

2. Combustion chambers opening the flue

3. Ceramic shell 13. Control panel

4. Air path with ventilator 14. Outlet of water

5. Ceramic edge 16. Flue cleaning cap

6. Flue 17. Adjustable legs

7. Sensors of the thermoregultors and 18. Connection of the cooling serpentinre ½"

emergency thermostate 19. Nozzle of the cooling serpentine ½"

8. Take off cap

9. Combustion chamber doors

10, 11. Connection branches А – Air inlet opening

В – Opening to the flue

С – Upper combustion chamber to the flue

Fig. 2. General picture of the boiler

d

Fig. 3. Zones of wind influence

Bigger angles form an increased resistance of the chimney traction

Thermical

sofety

valve

Fig.4Heating energy distribution scheme (Scheme for the

wunection of serpertine of emergency cooling)

Filter

To sewage

Water from the watersupply

sistem pressure is

2-6 bar. Temperature 10-

15 0C

Sensor of Thermostatic Safety valve

Astra G-31,5

Thermical

sofety

valve

Water from the

watersupply

sistem pressure is 2-6 bar.

Temperature 10-

15 0C

To sewage

Filter

Astra G-40

1

PE

2 N

3

L

4

L1

5

L1

6

L14

7

8

9 N

10

L3

11

N

12 L44

N L

N L

N L

L1 N1 L2 L3 L4 P

L N L13 L2 N

L13 L14

PE

PE

PE

KM

220 V

PE

M

F

SK S2 S1 KR

L1

L

5. pic. Electric scheme ( electronic control) S1 – lilet switch (R595KMET2F) S2 –ventiliator switch (R392KYFT2C) SK – emergency thermostat ( LA322-96111338) F – safety plug 2A M1 – ventiliator (GR03710/L25X0E12/03 KM – syocket connection KR – controller (KR-4)

Ceramic inserts and their position in heat boiler No Ceramic

Type of heat boiler

insert G-31,5 G-40

1 1 Burner ŠK-23.07.001 1 0

2 ŠK-50.07.001 0 1 2 Chopper ŠK-23.00.006 1 0

ŠK-50.00.010 0 1

3 Segments 3 G-18.00.004 2 0 G-18.00.004-01 0 2

Declaration of Confirmity Manufacturer: Machinery plant “Astra” AB

Address: Ulonu st. 33, 62161 Alytus, Lithuania Product designation: Heating boiler

Heating

boiler

Power,

kW

Waking

pressure, bar

Astra G-31,5 31,5 2,0

Astra G-40 40 3,0

We confirm, thwart this product designated comply with the conditions of the following: 1. Requirements of the directives : 97/23 EC, p2.3 2006/95 EC These standards were applied for the above mentioned products: EN 303-5

EN 12828 EN 60335-1 EN 60529

Procedure of conformity evaluation according to regalement 97/23 EC 2.3 is executed by „TÜV Thüringen‘‘. Certification No 0662/0373/05 No 0662/0528/06 Alytus 2009 ...........................

(date)

Vaidas Liesionis , marketing director

GB

Technical description of the control device KR-4

Designation: Control device is designed for the control of the solid fuel boiler. Fan is controlled according to the law of proportional –

integral- differential regulation (PID) and the pump, air valve or electric heating device are regulated positionaly.

Connection: Control device is connected according to the scheme designed on the fig, No. 1:

L1, N – supply of electricty to the control device;

L2 – supply of electricity to the fan;

L3 – voltage to the fan;

L4 – voltage to the pump;

P – voltage to the programmed output.

Fig. 1. Scheme of the connection of control device

Temperature sensor RK (PT-100) is installed in the water tight capsule which is immerged into the water of boiler.

Voltage of the fan L2 is connected from the control pannel of the boiler to the control device when the boiler works in the

heating regime (the fuel is loaded and the limit thermical relay is not in action). Impulse commutator of the fan connects

L3 to L2. The relay of control of pump connects L4 to L1. It connects P with L1.

The power of the fan is 20÷100 VA. The maximal power of the controlled pump is 250 VA. Maximal controlled power of

the relays of programmed output is 250 VA.

Exploitation After the loading of fuel the fan is put into operation with the swith on the control panel. There appears green signal light

"Heating" 3 (Fig. 2.) and the process of the fan control begins. The fan is working only when the green signal light No. 3 is

on.

The desired water temperature of the boiler is set with the keys 2 (2 pav.). By short pressing of “+” or “-“, digital indicator

1 starts to indicate the temperature of the water in the boiler. For the change of the temperature it is necessary to press and

to keep the related key (for the increasing “+”, for decreasing “-“ ). After the few seconds after the last press of the key the

set temperature is saved and the indicator starts to show the measured temperature of the water (when indicator shows the

set temperature , there is a point lighting near the digits ; when indicator shows the real measured temperature there is no

point lighting near the digits).

1 – digital temperature indicator;

2 – temperature setting keys;

3-6,8 – signal lights: 3 – "heating",

4 – "heating off",

5 – "pump", 6 – “fan“,

8 – “programmed output“.

7 – programmed output control key

Fig. 2. Front pannel of the regulating device

The speed of the fan is proportional to the deviation of the temperature, to its duration and to the rate of the

increase/decrease of the water temperature in the boiler.

Each time at the start there is launched the electric magnet, which opens air valve and there appears light 8.

Control of the pump The pump of the heating system can be switched on for the continuing operation or it can be switched on and off depending

on the water temperature. The operation of the pump and the temperatures for the switch on / off are defined by the

servicing staff, referring to the characteristics of the heating system. When the pump is on there is a signal light 5 on the

front pannel of the control device (fig 2.).

Burning control The state of work „heating off“ is indicated in the following cases:

- if the temperature after two hours from the beginning of heating is T≤45 oC;

- if the temperature drops below 45 oC and does not increases within the period of 30 min.;

- if during the operation of boiler the pump is switched off for longer than 1 hour. (it is not applied when the pump is put

on the constant operation ).

The state of operation „heating off“ switches off the fan and switches on the corresponding light signal. This state can be

left by switching off the voltage L2 or the supply of the electricity to the control device.

Programmed output Depending on the design of the boiler the programmed output can control air valve or electric heating. If there is installed

electric heating it can be swicthed off automaticaly when the boiler is on the mode „heating off“. In order to activate or

desactivate this control it is necessary to keep pressed the key “P” 7. There will apear “On” at the indicator (activated) ir

“OF” (switched off). The servicing personnel set the temperatures of switching on/off for the electric heating referring to

the characteristics of rthe heating system.

Control device No.: . . . . . . . . . . . . . .

Date of installation: . . . . . . . . . . . . . . . . . . . . . . .

* - depending on the design of th