MACHINERY FACTORY ASTRA

LT- 62161 Alytus, Ulon 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 manufacturers 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 vendors (manufacturers) 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. Dont 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: fireextinguishers, sand box, shovel and other tools. 1.8. Dont 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: 2 - 0, 2 MPa (2.0 kg/cm ) for the boilers Astra G-18, Astra G-25; 2 - 0, 3 MPa (3.0 kg/cm ) 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 chainelectric resistance of the protective chain does not exceed 0, , - the minimal resistance of the electric insulation is 1.0 M , - 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 C to +60 C. 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 havent 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 2. Poker 3. Scraper 4. Guidebook for exploitation 6. Leg 7. Fan/ventilator

1 unit 1 unit 1 unit 1 unit 4 units 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 Required volume of accumulation tank , liters G-18 700 G-25 900 G- 31,5 1500 G- 40 1800 G- 50 2500 G- 80 3200 G- 100 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 0 boiler exceeds 95 C 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 is screwed in the socket on the rear wall of the boiler. Technical data of the thermostatic safety valve : 0 Opening temperature 95 C 0 Highest working temperature 110 C

Working pressure 10 bar Pipe of sensor L=142 mm, external thread 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 0 the boiler reaches 60 C 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 0 55 C thermostatic mixing valve automatically ensures that the minimal temperature of water returning 0 to the heating boiler is 60 C. 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 Safety valve Connection diameter does not exceed , opening pressure 2 bar Safety valve Connection diameter does not exceed 3/4, opening pressure 3 bar Range of pressure 0-4 bar Temperature 0-120C

Type of boiler Astra G-18, Astra G-25,

Temperature pressure gauge

Astra G-31,5, Astra G-40, Astra G-50, Astra G-80, Astra G-100, 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 0 exceed 2 metres. Installing this duct, no more than 2 elbow joints at 90 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 60C. 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 70C. 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 wont be totally used and its operation conditions wont 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 3 make an opening in the exterior wall. Air quantity should be no less than 1, 6 m /kW 2 per hour. Cross-section area of the opening should be no less than 0,001 m /kW. The required air quantities and areas of the opening are presented in the table below. Boiler type Required air quantity 3 per hour, m /h Area of airflow 2 opening, m G-18 29 0,018 G-25 40 0,025 G- 31,5 40 0,025 G- 40 50 0,03
2

G- 50 80 0,05

G- 80 128 0,08
2

G- 100 160 0,1

For example: the area of airflow opening should be 0,025 m or 250 cm , 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

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 The maximal length of the firewood in mm G-18 310 G- 25 450 G- 31,5 550 G- 40 550 G- 50 750 G- 80 750 G- 100 750

The recommended thickness of the firewood is 100-150 mm. Larger firewood should be split at least once. WARNING! Dont 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 dont 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 heatresistant 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 0 the 70 C. Close the upper door of the combustion chamber, open the lower door, burn the wood 0 pieces ., Leave the lower door open until the water temperature in the boiler reaches 40 C. 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 C ). 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. o Emergency thermostat is turned on by taking off the cover of thermostat ! 108 C 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 wont 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.
o

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 dont 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 Cause 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. Tightening rope is damaged; Doors are leaky along the whole perimeter.

Damage 1. The set temperature (power) cannot be reached

Ways of elimination Fill up Replace Use dry fuel, split firewood Clean Clean Clean Clean Replace with a new one Adjust hinge supports and door lock (regulated screwing or unscrewing door hinge or lock screws) Clean. 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

2. Smoke breaks through the doors

3. Ventilator isnt operating

No traction in the chimney Emergency thermostat went off (switch light of ventilator is off);

Thermo regulator or ventilator is broken; Disconnection of electricity supply.

8. TECHNICAL DATA
Indicators -tire wood kW - wooden briquets, kW Class of boiler according to EN 303-5 Class of protection against electric impact Usage coefficient,% 2 Area of the internal heated surface of boiler, m , Power of the cooling serpentine, kW Water volume in the boiler, litres O Setting range of the temperature regulator C Max working smoke traction, mbar Working pressure of water in the system , bar, max Testing pressure of boiler, bar O Max. allowable water temperature in the boiler, C, O Max. allowable working water temperature in the boiler, C, Electric characteristics - voltage, V/ frequency, Hz - used power, W Level of electric protection of boiler Dimensions - height, mm - width, mm - depth, mm Weight of boiler, kg, Diameter of the connection nozzles Volume of combustion , l Dimensions of the loading hole, mm Al diameter of the smoke extraction, mm Length of wood pieces, mm 0 Temperature of the outlet gases at the nominal heating power, C Nominal heating power G-18 18 23 1 1 78 1,92 15 63 60-85 0,25 2,0 4,0 108 95 220/50 50 1320 585 835 240 1 1 /2 90 350x285 152 330 210 G-25 25 28 1 1 78 2,08 15 78 60-85 0,25 2,0 4,0 108 95 220/50 50 1320 585 310 1 1 /2 95 350x285 152 450 210 Meanings of the indicators G-31,5 G-40 G-50 31,5 40 50 33 42 54 1 1 1 1 1 1 78 80 80 2,08 2,2 3,39 15 18 18 78 85 96 60-85 60-85 60-85 0,30 0,30 0,32 3,0 3,0 3,0 4,5 4,5 4,5 108 108 108 95 95 95 220/50 220/50 220/50 50 50 80 1320 630 910 320 1 1 /2 120 350x285 152 450 200 1235 710 1010 380 1 1 /2 140 350x285 152 550 200 1420 710 1210 500 1 1 /2 280 350x285 152 750 190 G-80 80 84 1 1 80 3,8 18 98 60-85 0,35 3,0 4,5 108 95 220/50 80 1590 710 1210 535 2 315 350x285 180 750 190 G-100 100 100 1 1 80 6,45 18 100 60-85 0,38 3,0 4,5 108 95 220/50 80 1590 910 1230 640 2 405 350x285 180 750 190

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 manufacturers 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 doesnt 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

Sellers name, surname, signature

BOILER START-UP AND ADJUSTMENT CARD Start-up, adjustment date Start-up and adjustment performing company

Certificate No . Employees name, surname, signature

Employees qualification certificate No.

12

10 19 18 4
b
Trap regulator

Rear viev Supplied

18 6

9
Trap regulator

11
18

180 h a 80 B
Cross-section

6 16

o152

Returning

13 12 2 1

Boiler type ASTRA G-18 MS/MES

L 835

a1

b1

a ---

a1

17

b1

18

C A

3 5

B
b ------845 105 1025 1215 180 185 115 1200 ----G2 152 G1 D d

585 ASTRA G-25 MS/MES 970 ASTRA G-31,5 MS/MES ASTRA G-40 MS/MES ASTRA G-50 MES ASTRA G-80 MES 1590 ASTRA G-100 MES 810 1230 1220 710 1210 ----615 1010 1235 1420 890 1080 170 ----------1320 990 130 75 915 ---

1. Frame 2. Combustion chambers 3. Ceramic shell 4. Air path with ventilator 5. Ceramic edge 6. Flue 7. Sensors of the thermoregultors and emergency thermostate 8. Take off cap 9. Combustion chamber doors 10, 11. Connection branches

12. Damper hinge of upper combustion chamber opening the flue 13. Control panel 14. Outlet of water 16. Flue cleaning cap 17. Adjustable legs 18. Connection of the cooling serpentinre " 19. Nozzle of the cooling serpentine "

Air inlet opening Opening to the flue Upper combustion chamber to the flue

Fig. 2. General picture of the boiler

Fig. 3. Zones of wind influence Bigger angles form an increased resistance of the chimney traction

Sensor of Thermostatic Safety valve

Filter

Thermical sofety valve

Water from the watersupply sistem pressure is 2-6 bar. Temperature 1015 0C

Astra G-31,5

To sewage

Water from the watersupply sistem pressure is 2-6 bar. Temperature 1015 0C

Filter

Thermical sofety valve

Astra G-40

To sewage

Fig.4Heating energy distribution scheme (Scheme for the wunection of serpertine of emergency cooling)

PE N PE PE M N L 220 V NL L KM

1 PE

2 N

3 L

4 L1

5 L1

6 L14

9 N

10 L3

11 N

12 L4 4

L1 L
L13 L14

L13 L2 N

L N

L1

N1

L2

L3

L4

F SK

S2

S1

KR

5. pic. Electric scheme ( electronic control) S1 lilet switch (R595KMET2F) S2 ventiliator switch (R392KYFT2C) SK emergency thermostat ( LA32296111338) F safety plug 2A M1 ventiliator (GR03710/L25X0E12/03 KM syocket connection KR controller (KR-4)

PE

Ceramic inserts and their position in heat boiler Type of heat boiler G-31,5 G-40 1 0 1 0 2 0 0 1 0 1 0 2

No 1 2 2 1

3 3

Ceramic insert Burner K-23.07.001 K-50.07.001 Chopper K-23.00.006 K-50.00.010 Segments G-18.00.004 G-18.00.004-01

Declaration of Confirmity
Manufacturer: Machinery plant Astra AB Address: Ulonu st. 33, 62161 Alytus, Lithuania Product designation: Heating boiler Heating Power, Waking boiler kW pressure, bar Astra G-31,5 31,5 2,0 Astra G-40 40 3,0

GB

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 TV Thringen. Certification No 0662/0373/05 No 0662/0528/06

Alytus 2009 ........................... (date) Vaidas Liesionis , marketing director

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 20100 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 T45 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