HDG Compact 25 Operation Manual Download

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HDG Bavaria GmbH 10/2007

HDG Compact 25 - 80 - Version 2 - en

2 Safety instructions – Warnings and safety symbols used

Warning!

Hand injuries can occur

Working in areas marked with this symbol can lead to hand injuries.

Warning!

Automatic start-up

Working in areas marked with this symbol can lead to injuries due
to automatic start-up.

Caution!

Hot surfaces

Working in areas marked with this symbol can lead to burns.

Warning!

Danger of fire

Working in areas marked with this symbol can lead to a fire.

Danger!

Danger of asphyxiation due to lack of oxygen

When working in areas marked with this symbol, there is a danger
of asphyxiation due to high concentrations of carbon monoxide.

Danger!

Danger of explosion

When working in areas marked with this symbol, there is a danger
of explosion due to high concentrations of carbon monoxide.

Warning!

Suspended loads

When working in areas marked with this symbol, there is a danger
of falling objects.

Important!

Frost danger

Only install the heating system in a frost-proof room.

Summary of Contents for Compact 25

Page 1: ...hdg bavaria com HDG Compact 25 80 Operation Manual ...

Page 2: ......

Page 3: ... 15 HDG Compact 25 35 front side 16 HDG Compact 25 35 back side 17 HDG Compact 45 50 65 80 front side 18 HDG Compact 45 50 65 80 back side 19 3 2 Functional description 20 Version of the heating system 20 Combustion process 21 Delivery system 22 HDG Compatronic 22 Control modes 23 HDG Hydronic 23 HDG Hydronic control functions 23 3 3 Technical data 30 HDG Compact 25 35 30 HDG Compact 45 50 65 80 3...

Page 4: ... system 65 Installing the feeding system and pressure equalisation hose 69 Installing the sensors 72 Wiring the circuit boards 72 Attaching covers and hoods 73 Installing and adjusting the ash containers 73 Connecting the chimney 74 4 5 Delivery system 74 4 6 HDG Hydronic 75 Installing the controller housing 75 Installing the sensors 75 Hydraulic systems 78 4 7 Electrical system 78 4 8 Water 78 4 ...

Page 5: ... heating circuits and heating hot water 104 6 6 Changing operating mode 105 6 7 Operating statuses 105 6 8 Filling the fuel bunker 107 Requirements 107 Procedure for filling with wood fuel products 107 Procedure for filling of pellets 108 6 9 Performing the chimney sweep test 108 Before the test 109 On the day of the test 109 During the test 110 After the measurement 110 6 10 Structure of the menu...

Page 6: ...62 Checking and cleaning the flue gas fan 163 Cleaning the flue gas temperature sensor 164 Checking and lubricating the fill level indicator 164 Inspecting the fuel bunker 165 8 Troubleshooting 167 8 1 Procedure 167 8 2 Possible faults 167 8 3 Configuring emergency operation 177 9 Notes on dismantling and disposal 178 9 1 Dismantling 178 9 2 Disposal 179 10 Warranty 180 10 1 Scope 180 10 2 Conditi...

Page 7: ...s correct at the time of going to press All details in these instructions on standards regulations and works heets should be checked before use and should be compared with the regulations applying locally at the site where the system is ins talled We reserve the right to make changes which may then differ from the technical details and illustrations in this Operating manual COPYRIGHT Written permi...

Page 8: ...es of the heating system 4 Planning and installation how to properly plan and install the heating system 5 Commissioning the system how the heating system is put into initial service 6 Using the heating system how to properly operate the heating system 7 Cleaning and servicing the heating system how to clean the heating system and who is responsible for its maintenance 8 Troubleshooting how to rec...

Page 9: ...tem HDG Compact 25 80 Boiler for burning wood chips shavings and wood pellets HDG Compatronic Electronic control unit of the boiler feeding system and delivery system HDG Hydronic Heating system regulator for controlling the hydraulic systems Heating system Comprised of boiler and corresponding accessories Extinguishing device Extinguishes what is within the delivery system if the temperature of t...

Page 10: ... systems Any further implementation of applicable standards for example with regard to the installation of the heating system pi pework etc is not part of this operating manual HDG Bavaria does not assume any liability for this PROPER AND IMPROPER MANNER OF OPERATION PURPOSE OF THE HEATING SYSTEM The HDG Compact 25 80 heating system is designed for the stan dard use of burning wood fuel products m...

Page 11: ...n the boiler is in operation carbon monoxide escaping from open cleaning or inspection hatches can cause asphyxiation or ex plosions Do not leave these open any longer than necessary Warning Danger of fire Opening doors and lids to hot combustion residues can pose the danger of fires Keep the openings closed during operation and when performing cleaning work allow the combustion residues to cool d...

Page 12: ...ents When working on the automatic ash removal or automatic cleaning systems hands and arms could be injured Turn off the main switch when performing any work on these com ponents Danger Dangerous electrical current or voltage The circuit boards and electrical components carry current Have work on electrical components performed only by a qualified electrician and turn the main switch off Warning ...

Page 13: ...o burns Warning Danger of fire Working in areas marked with this symbol can lead to a fire Danger Danger of asphyxiation due to lack of oxygen When working in areas marked with this symbol there is a danger of asphyxiation due to high concentrations of carbon monoxide Danger Danger of explosion When working in areas marked with this symbol there is a danger of explosion due to high concentrations ...

Page 14: ...ed to read the Operating manual prior to beginning work particularly the chapter 2 Safety instructions This is especially important for persons who only occasionally work on the heating system for example when cleaning or servicing it The Operating manual must always be kept readily accessible at the place where heating system is installed Instructions regarding disposal Additional information for...

Page 15: ...lso optionally available for the HDG Compact 25 65 When selecting the feeding unit for the HDG Compact 25 80 hea ting system you can choose between the following TBZ 150 for feeding wood chips planing shavings and pellets Pellet vacuum delivery system with TBZ 80 for feeding the pellets The HDG Compact 25 80 heating system can also be equipped with the following delivery systems Flexi blade delive...

Page 16: ...e gas fan 6 Lambda sensor 7 Flue pipe connection 8 Flue gas temperature sensor 9 Heat exchanger surfaces with cleaning turbulators in between 10 Ash removal augers 11 Tilting grate 12 Combustion chamber primary burning 13 Ignition pipe 14 Feeding system 15 Combustion chamber secondary burning Figure 3 1 Front side of the HDG Compact 25 35 boiler 13 8 6 5 4 3 2 15 14 7 1 12 11 9 10 ...

Page 17: ...e for thermal safety device DN 15 female 2 Safety heat exchanger connections DN 15 outside thread 3 Main switch 4 Ignition fan 5 Servo motor for primary air 6 Servo motor for secondary air 7 Ash removal motor 8 Grate tilting motor Figure 3 2 HDG Compact 25 35 boiler back side 8 7 6 5 4 3 2 1 ...

Page 18: ... temperature sensor 6 Lambda sensor 7 Flue pipe connection 8 Heat exchanger surfaces with cleaning turbulators in between 9 Walking floor for ash removal 10 Ash removal augers 11 Combustion chamber primary burning 12 Tilting grate 13 Ignition pipe 14 Feeding system 15 Combustion chamber secondary burning Figure 3 3 Front side of the HDG Compact 45 50 65 80 boiler 2 8 7 4 6 3 13 15 14 1 5 10 11 12 ...

Page 19: ...N 15 inside thread 2 Safety heat exchanger connections DN 15 outside thread 3 Main switch 4 Ignition fan 5 Pressure equalisation hose 6 Combustion fan 7 Servo motor for primary air 8 Ash removal motor 9 Grate tilting motor 10 Servo motor for secondary air Figure 3 4 HDG Compact 45 50 65 80 boiler back side 1 8 7 6 3 2 9 4 5 10 ...

Page 20: ...Functional description VERSION OF THE HEATING SYSTEM The HDG Compact 25 80 heating system may contain the following components 1 Delivery system 2 Feeding system 3 HDG Compact 25 80 boiler with HDG Compatronic 4 Accumulator Figure 3 5 Overview 1 2 3 4 ...

Page 21: ...ut according to the entered control options In order to remove the produced ash from the grate 7 the grate is tilted at regular intervals The optionally available automatic cleaning system 3 cleans the heat exchanger surfaces 2 with the aid of the cleaning turbulators which move up and down The ash falls into the ash pan for the combustion chamber ash or can optionally be transported by the automa...

Page 22: ...ntrol unit of the HDG Compatronic is the electronic hub It consists of the central unit and the transport module in the swit ching cabinet on the back side and the control unit on the front side of the HDG Compact 25 80 boiler With the control unit you can adjust the HDG Compact 25 80 and obtain information on the current process status If the HDG Compatronic issues a request for more heat the HDG...

Page 23: ...ment for the heating system and depending on the version controls up to three weather controlled heating circuits as well as Heating hot water Transfer of heat into the district heating grid Integration of second boiler Solar system for hot water and support of the heating system HDG HYDRONIC CONTROL FUNCTIONS BASIC FUNCTIONS OF THE HEATING CIRCUIT CONTROL The heating circuit control always operat...

Page 24: ...er temperature leaving the boiler If no indoor thermostat unit is connected the preset day and night temperatures are used for the calculation OUTSIDE TEMPERATURE SWITCH OFF If the outside temperature exceeds the preset room temperature or the preset outside switch off temperature the status of the heating circuit changes to OFF INDOOR THERMOSTAT UNIT If an indoor thermostat unit is connected the ...

Page 25: ... thermostat unit cannot be integrated with this heating system Uncontrolled In an uncontrolled heating system only the enable tempera ture and the time program are taken into account This heating system operates without a heating circuit mixer If combined with an indoor thermostat unit the pump switches off after the desired room temperature is reached SCREED DRYING PROGRAM If the heating system i...

Page 26: ...ng occur taking into ac count the enable temperature for the hot water pump You can specify the temperature of the hot water supply If the temperature falls below the preset hot water temperature by the hysteresis value minus the preset hot water hysteresis value the hot water heating pump will start up HOT WATER PRIORITY You can give priority to the heating of the hot water tank This means that i...

Page 27: ...or solar heating to start The heating of the hot water by the solar heating system can be limited by setting a maximum temperature SOLAR HEATING COMBINATION ACCUMULATOR The solar heating pump is driven at a controlled speed taking into account the temperature difference Collector temp Acc bottom The temperature of the solar collector must exceed the Acc bottom temperature by the amount of the sola...

Page 28: ...hen adjusted to run between the mi nimum and maximum pump speed DISTRICT HEATING OPERATION Operation with district heating is very similar to heating hot water A measurement of the temperature difference between the heat source and the district heating transfer station is used to activate the district heating pump If operated without an accumulator the boiler supply temperature is used as a refere...

Page 29: ...cuits and if there is no demand on the hot water tank the oil fired boiler will only start once the temperature has fallen below the enable temperature for the heating circuits If there is no demand on the heating circuits or the hot water tank and if the accumulator temperature is under the enable temperature the oil fired boiler must maintain the Min oil burner temp e g for summer operation If t...

Page 30: ...ture 60 C Water content 110 l Weight 650 kg Planning data for flue calculation DIN EN 13384 1 Flue gas temperature Tw at Nominal thermal power minimum thermal power 160 C 110 C Flue gas mass flow at Nominal thermal power minimum thermal power 0 0210 0 0170 kg s 0 0070 kg s 0 0210 0 0230 kg s 0 0070 kg s Flue draught requirement Pw 7 Pa Diameter of flue gas pipe connection 150 mm Height at middle o...

Page 31: ...r flue calculation DIN EN 13384 1 Flue gas temperature Tw at Nominal thermal power minimum thermal power 160 C 105 C 160 C 105 C 180 C 110 C 160 C 105 C Flue gas mass flow at Nominal thermal power minimum thermal power 0 029 0 026 kg s 0 0125 kg s 0 0326 kg s 0 0125 kg s 0 0451 kg s 0 0125 kg s 0 0520 kg s 0 0250 kg s Flue draught requirement Pw 10 Pa 13 Pa 15 Pa 16 Pa Diameter of flue gas pipe co...

Page 32: ...ontaining heavy metals FUEL CLASS 7 Plywood chipboard fibreboard or otherwise glued wood including remains thereof provided no wood protection agents have been ap plied or are present as the result of a treatment and coatings do not contain organic halogen compounds or heavy metals Fuel classes 6 or 7 may only be used in a wood processing plant at 30 kW or more nominal thermal power In the case of...

Page 33: ...31 5 wood chips at least 75 of the wood chips by weight must be between 8 mm and 31 5 mm The fine content 31 5 mm may not exceed a max of 8 by weight A max of 6 by weight of the wood chips may be longer than 45 mm lengths gre ater than 120 mm are not allowed The numeric value of the P class refers to the size of the wood chips in mm which fit through a round opening with the indicated sieve openin...

Page 34: ...cess and thereby consumes heat This results in lower efficiency and thereby leads to greater wood consumption Increasing moisture in the fuel material also causes re duced efficiency greater amounts of ash and smoke as well as ma king it increasingly unfit for storage The maximum permissible water content of the wood chips for the HDG Compact 25 35 is 20 M30 for the HDG Compact 45 50 65 80 25 M25 ...

Page 35: ...st be less than 10 M10 the ash content must be less than 0 7 by weight A0 7 A2 D06 The diameter of the pellets must be 6 mm 1 mm The length of the pellets must measure between 31 5 mm and 40 mm A maximum of 1 by weight of the pellets may be longer than 45 mm The water content must be less than 10 M10 the ash content must be less than 1 5 by weight A1 5 With regard to the quality standards for wood...

Page 36: ... systems it is possible to use wood fuel products of grain size P45 with a maximum water content of up to 25 M25 However reduced nominal thermal power re duced efficiency increased fuel consumption and greater wear and tear on the heating system may then result Fuels with a higher water content are not suitable for burning The maximum permissible ash content is 1 5 by weight A1 5 WOOD PELLETS For ...

Page 37: ...els fuel specifications and classes Wood chips P31 5 M20 A1 0 A1 5 or Pellets A1 A2 Wood chips P45 M25 A1 0 A1 5 Shaving briquet tes A1 A2 D60 L50 Planing saw sha vingsA1 A2 M20 A1 0 A1 5 HDG Compact 25 31 kW HDG Compact 35 31 kW HDG Compact 45 45 kW 43 kW 42 kW 43kW 42 kW 40 kW HDG Compact 50 50 kW 48 kW 47 kW 48 kW 47 kW 45 kW HDG Compact 65 65 kW 63 kW 62 kW 63 kW 62 kW 60kW HDG Compact 80 80 k...

Page 38: ...D ROOM SIZES AND MINIMUM SPACING Figure 4 1 Necessary room sizes and minimum spacing B D C E A A B C D E Minimum room height Recommen ded room height HDG Compact 25 35 2900 1800 700 1200 400 1950 2250 HDG Compact 45 50 65 2900 2000 800 1200 400 2250 2500 HDG Compact 80 3150 2100 800 1200 400 2450 2750 Table 4 1 Minimum size mm ...

Page 39: ...rizontal plane To ensure unhindered operation and maintenance of the heating system you must ensure that the heating system is installed to our specifications and that the minimum spacings are maintained Also note that the thresholds in DIN 4109 Soundproofing in building construction may not be exceeded More detailed information can be found in the respective ordinances of the German states We rec...

Page 40: ...illing the fuel bunker four to six times per heating period is desirable PASSAGE THROUGH THE WALL The passage through the wall normally has to be made in the wall between the boiler room and the fuel bunker Its position depends on the distance and the position of the HDG Compact heating system within the room and the customer s installation diagram Due to the auger assembly the passage through the...

Page 41: ...y version 1 Dosage directly to TBZ 1 Dosage 2 Feeding system Delivery version 2 Dosage conveyor auger to TBZ 1 Dosage system II motor of delivery system runs along with do sage system 2 Dosage 3 Feeding system Figure 4 2 Delivery system version 1 1 2 Figure 4 3 Delivery system version 2 1 3 2 ...

Page 42: ...ivery 1 Delivery system 2 Dosage 3 Feeding system 4 Fill level indicator Delivery version 4 sloping auger delivery silo delivery system 1 Delivery system 2 Fill level indicator 3 Dosage 4 Feeding system Figure 4 4 Delivery system version 3 1 4 3 2 Figure 4 5 Delivery system version 4 3 2 4 1 ...

Page 43: ... flue temperature may lie below 100 C when the system is partially loaded a chimney flue is required which meets the require ments of DIN EN 13384 1 2003 03 Thermal and fluid dynamic calcu lation methods If it does not meet this standard contact your specialist heating company or chimney technician Figure 4 6 Delivery system version 5 1 2 3 4 5 6 According to EN 303 5 the entire flue system must b...

Page 44: ...e conditions This includes taking into account the following factors Location of the house Surrounding hills slopes Wind direction Location of the chimney in the roof The opening of the chimney must be at least 0 5 m above the highest edge of roofs with a slope of more than 20 or at least 1 0 m higher than roof surfaces which slope at 20 or less The effective height of a chimney is measured from t...

Page 45: ... take particular care in older buildings All of the cleaning and measurement hatches on the chimney must have tight seals To reduce the entry of additional cold air only one heat source should be attached to each chimney To prevent dust from escaping the flue pipe must be sealed with heat resistant silicone ELECTRICAL SYSTEM The directives of 2006 95 EC low voltage guidelines must be fol lowed for...

Page 46: ...ion sensors with a moulded cable and serve to measure the temperature of the accumulator and the hot water tank INDOOR THERMOSTAT UNIT With the indoor thermostat unit the preset room temperature can be altered by 2 3 C A selection switch allows the operating status for each heating circuit to be changed Before installing the indoor thermostat unit a suitable location must first be found To ensure ...

Page 47: ...lies in the lower operating hours of the system and fewer start up phases due to the extension of the heating intervals This leads to a reduction in the proportion of external energy supplied and to lower wear of the mechanical com ponents One further advantage of the accumulator is in summer operation when only hot water is required When operating in this mode the accumulator helps avoid frequent...

Page 48: ...industry Take into account the stop cocks required for maintenance work and repairs The return temperature control must be installed according to the specifications of HDG Bavaria HYDRAULIC CONNECTION There are hydraulic solutions for every application An excerpt of the hydraulic solution options can be found in the section 4 10 HDG hydraulic systems in this chapter or in the in formation booklet ...

Page 49: ...pe connection Ø 150 mm 4 Boiler return connection DN 32 inside thread 5 Filling draining connection DN 15 inside thread Figure 4 8 Dimensions on flue pipe side HDG Compact 25 35 B F G H I J A 1 4 E D C 5 2 3 1 5 4 3 2 Model A B C D E F G H I J HDG Compact 25 35 1174 1064 820 340 312 235 371 466 510 680 Table 4 3 Dimensions on flue pipe side HDG Compact 25 35 mm ...

Page 50: ... Connection of immersion sleeve for thermal safety device DN 15 female 2 Inlet outlet of safety heat exchanger DN 15 outside thread Figure 4 9 HDG Compact 25 35 back side A B C D 2 1 Model A B C D HDG Compact 25 35 1150 670 910 1140 Table 4 4 Dimensions on back side HDG Compact 25 35 mm ...

Page 51: ...t 45 50 65 Ø 180 mm HDG Compact 80 Ø 200 mm 3 Boiler return connection HDG Compact 45 50 65 DN 32 inside thread HDG Compact 80 DN 40 inside thread 4 Filling draining connection DN 15 inside thread Figure 4 10 Dimensions on flue pipe side HDG Compact 45 50 65 80 B E F G H I A D C 1 4 3 2 Model A B C D E F G H I HDG Compact 45 50 65 80 1400 1280 340 310 234 445 615 646 830 Table 4 5 Dimensions on ba...

Page 52: ...safety device DN 15 female 2 Safety heat exchanger inlet DN 15 outside thread 3 Safety heat exchanger outlet DN 15 outside thread Figure 4 11 HDG Compact 45 50 65 80 back side A C D 1 3 2 B Model A B C D HDG Compact 45 50 65 1380 1340 655 1145 HDG Compact 80 1390 1350 850 1450 Table 4 6 Dimensions on back side HDG Compact 45 50 65 80 mm ...

Page 53: ...due to incorrect installation Installing the system requires comprehensive specialist knowledge If installed by untrained persons the heating system can be da maged and persons may be injured due to secondary damages Only allow authorised specialists to perform the installation Danger Dangerous electrical current or voltage Working on live components can result in an electric shock Switch off the ...

Page 54: ...ard off the shaped studs The following figures and diagrams show the version of the heating system HDG Compact 25 80 with feeding system TBZ 150 on the left side of the boiler Please keep this in mind if your version has a feeding system on the right Caution Danger from suspended loads The boiler weighs over 600 kg If the boiler is dropped during trans port persons can be seriously injured and the...

Page 55: ...ker 1 7 Carefully lift the boiler INSTALLATION SITE 8 Transport the boiler to its installation site 9 Place the boiler at the planned location while observing the mi nimum clearances See 4 1 Planning the heating system section Required room sizes and minimum spacing in this chapter 10 Align the boiler with plastic plates or flat steel strips not included in the scope of delivery so that it is hori...

Page 56: ...ease the four 5 mm M6 hexagon socket screws 3 of the intake for the combustion fan on the air control unit 4 Fasten the combustion fan 1 with a seal placed in between to the air control unit using the four 5 mm M6 hexagon socket screws The combustion fan is installed The combustion air fan is only available with the HDG Compact 45 50 65 80 boiler Figure 4 14 Installing the combustion fan 2 1 3 Fig...

Page 57: ...t of the combustion chamber 4 Slide the second ash plate 2 from the front into the fly ash com partment 5 Bolt on the two ash plates with the M8 screws using a 13 mm spanner The two ash plates are installed 1 Unscrew the cover of the cir cuit boards 1 with a Phillips tip screwdriver 2 Unscrew the ash removal cover 2 with a Phillips tip screwdriver Figure 4 16 Remove the rear covers 2 1 Figure 4 17...

Page 58: ...rovided for them on the auger shafts 9 Align the cogs 1 5 flush on the auger shafts and fasten them with the two hexagon socket screws 10 Place the feather key 4 in the recess provided on the feed side auger shaft 11 Mount the drive chain 8 on the two cogs 1 5 12 Fasten the ash removal motor 7 with the M8 screws size 13 on the torque support 6 13 Insert the ash removal motor 7 with the torque supp...

Page 59: ...r cable 3 in such a way that it cannot contact the drive chain 2 17 Connect the plug of the ash removal motor to the board See the enclosed circuit diagram HDG Compatronic 18 Fasten all cables with cable clips The ash removal motor is connected ATTACHING THE ASH REMOVAL DOOR For the version of the boiler with the feeding system on the left side the chain tensioner must be fastened in the upper pos...

Page 60: ...tion both clamp handles so that they are horizontal 23 Insert the cover plate 1 below with the recesses in the guides 2 on the boiler 24 Press the cover plate 1 above into the pre mounted shaped studs on the boiler The cover plate of the ash removal door is attached The automatic ash removal system is installed Important The two ash removal augers for the ash removal door do not come into contact ...

Page 61: ...ews size 13 3 INSTALLING THE ASH PLATE 5 Slide the ash plate 3 from the front into the ash compartment 4 6 Tighten the ash plate 3 with the M10 screw size 17 5 7 Mount the alignment plate 1 on the ash plate 3 with the two M10 screws 2 without however tightening the screws Figure 4 23 Removing the sealing plates 1 2 3 4 Remove the alignment plate 3 from the ash plate 1 using a 17 mm spanner Figure ...

Page 62: ...sert the centre tray 2 in the ash compartment 4 11 Fit the left 1 and the right 3 tray on the centre tray 2 12 Fit the two moving ash floors 1 5 on the trays 13 Connect the two moving ash floors 1 5 by means of the bracket 3 with the M10 screws 17 mm 14 Install the two guide plates 2 4 with the M8 screws 13 mm Figure 4 26 Installing the trays 2 3 1 4 Figure 4 27 Installing the moving ash floor 2 5...

Page 63: ...lace the feather key 6 in the recess provided on the feed side auger shaft 21 Mount the drive chain 5 on the two cogs 3 7 22 Fasten the ash removal motor 9 with the M8 hexagon socket screws 6 mm on the torque support 8 23 Insert the ash removal motor 9 with the torque support 8 on the feed side auger shaft and fasten the support plate onto the boiler with the nut M10 17 mm 24 Mount the chain tensi...

Page 64: ...o the board See the enclosed circuit diagram HDG Compatronic The ash removal motor is connected ATTACHING THE ASH REMOVAL DOOR 29 Slide the ash removal door 5 onto the two ash removal augers 1 30 Bolt on the ash removal door 5 with the long screw 3 and four short 19 mm M12 short screws 2 4 31 If necessary align the ash removal augers 1 with the screws of the ash removal door 2 4 The ash removal do...

Page 65: ...s attached The ash removal system is installed INSTALLING THE AUTOMATIC CLEANING SYSTEM INSTALLING THE CROSSBEAMS 1 Release the pre mounted M12 nuts from the short or long cross beam 2 Place the two crossbeams 1 on the turbulators in the cleaning shaft 3 Bolt the crossbeams 1 onto the turbulators with the M12 19 mm screws 4 and allowing about 2 mm clearance between nuts and turbulator crossbeam re...

Page 66: ...ce the cleaning shaft lid 1 on the boiler 9 Guide the screws 2 of the hinges into the holes on the cleaning shaft lid 1 10 Bolt on the cleaning shaft lid 1 with the M12 nuts on the hinges using a 19 mm spanner 11 Open the cleaning shaft lid 1 Warning Danger of injury The cleaning shaft lid is very heavy Hands can become crushed when installing it Always take care not to grasp under the cleaning sh...

Page 67: ...e boiler inner walls 13 Slowly close the cleaning shaft lid 1 Figure 4 34 Aligning the crossbeams 1 2 Warning Danger of injury The cleaning shaft lid is very heavy and can fall shut Hands and arms can thereby be crushed Take care not to bump into the opened cleaning shaft lid and cause it to fall shut ...

Page 68: ...in the cable duct 2 19 Push the two cables through the cable duct up to the opening next to the circuit board on the back side of the boiler 20 Connect the plug of the cleaning system to the board See the enclosed circuit diagram HDG Compatronic 21 Mount the cover in the reverse sequence The cleaning system is now connected The automatic cleaning system is installed Figure 4 35 Fastening the cross...

Page 69: ...he boiler through the holes and screw it tight with the M6 nut using a 10 mm spanner ATTACHING THE FEEDING SYSTEM 6 Insert the second seal 1 on the adapter pipe 3 7 Slide the feeding system 4 onto the adapter pipe 3 8 Insert the M12 screws 2 from the boiler through the holes 9 Bolt on the feeding system 4 with the M12 nuts 2 using a 19 mm spanner Figure 4 36 Attaching the adapter pipe 2 1 3 4 5 Wa...

Page 70: ...ualisation hose 2 16 Mount the pressure equalisation hose 2 to the connection bus hing of the feeding system 3 or the connection bushing of the boiler 1 using a pipe wrench 12 Bolt the support leg 4 with a 19 mm M12 screw 3 onto the feeding system 1 13 Fix the support leg 4 to the floor as required screws and screw anchors are not in cluded in the scope of deli very 14 Align the feeding system 1 h...

Page 71: ...e pressure equalisation hose is connected CONNECTING THE FEEDING SYSTEM 18 Insert the cable of the feeding system through the opening pro vided for it on the cladding 19 Connect the plug of the feeding system to the circuit board See the enclosed circuit diagram HDG Compatronic The feeding system is connected Figure 4 40 Attaching the pressure equalisation hose 1 ...

Page 72: ...oard cover next to the circuit boards for further use 1 Seal the immersion sleeves of the sensors with a suitable sealing material and position them at the points indicated in the figure 4 41 2 Guide the sensors into the im mersion sleeves 3 Insert the prefabricated plug connections into the termi nals specified in the circuit diagram The circuit diagrams are enc losed with the supplied docu menta...

Page 73: ... clamp handles 1 downward Grasp the clamp handles and press the ash containers against the seal of the ash removal door 5 If the clamp handles do not clamp adjust them as follows 1 Mount the cover of the circuit boards 2 on the boiler with the Phillips head screws 2 Mount the cover of the ash re moval system 3 on the boiler with the Phillips head screws 3 Mount the three hoods 1 on the boiler in t...

Page 74: ...tion 2 Make sure that the connecting piece does not protrude into the chimney 3 Seal the connection to the chimney with highly fireproof silicone or with a suitable mortar The boiler is now connected to the chimney 4 5 Delivery system The description for planning installation and operation of the em ployed delivery system can be found in the corresponding operating manual See the operating manual ...

Page 75: ...sponding sensors must be mounted and connected Danger Dangerous electrical current or voltage Switch off the mains supply to the heating system during the instal lation Caution Material damage due to static discharge Electronic components can be damaged by static discharge Do not touch any electronic components during the installation The bus cable between the HDG Compatronic and HDG Hydronic must...

Page 76: ...ges and resulting malfunctions in the control system could then occur All of the sensors in the HDG Hydronic are PT 1000 sensors INSTALLING THE OUTSIDE TEMPERATURE SENSOR Temperature PT 1000 Temperature PT 1000 50 C 803 10 Ohm 25 C 1097 40 Ohm 40 C 842 70 Ohm 30 C 1116 70 Ohm 30 C 882 20 Ohm 40 C 1155 40 Ohm 20 C 921 60 Ohm 50 C 1194 00 Ohm 10 C 960 60 Ohm 60 C 1232 40 Ohm 0 C 1000 00 Ohm 70 C 127...

Page 77: ... HOT WATER TANKS INSTALLING THE INDOOR THERMOSTAT UNIT Figure 4 48 Heating circuit sensors 2 1 1 Make sure that the sensors for the accumulator and hot water tanks are not bent 2 Carefully insert the accumu lator and hot water tank sen sors into the immersion sleeves Figure 4 49 Sensors for accumulator and hot water tanks 1 Mount the indoor thermostat unit on the intended position on the wall See ...

Page 78: ...cted in accordance with the circuit diagram The circuit diagram is enclosed with the supplied documentation 4 8 Water The heating system must be filled with water in accordance with VDI guideline 2035 Avoiding damage in hot water heating systems The diaphragm expansion vessel must be constructed in accordance with DIN EN 13831 Closed expansion vessels with built in dia phragm for integration in wa...

Page 79: ...not be stopped as quickly as with an oil or gas fired boiler When the ma ximum operating temperature is exceeded the thermal safety device TAS is triggered and cold water flows through the safety heat ex changer The excess energy generated is thus dissipated by the emergency cooling This is an alternative to fast regulation However the safety heat exchanger and thermal safety device can only serve...

Page 80: ...Connection of immersion sleeve for thermal safety device DN 15 inside thread 2 Safety heat exchanger connections DN 15 outside thread Important In order to prevent leaks avoid turning the connections of the sa fety heat exchanger anticlockwise when installing the thermal sa fety device Figure 4 52 Installing the thermal safety device HDG Compact 25 35 1 2 Figure 4 53 Installing the thermal safety ...

Page 81: ...diagrams of the HDG Compatronic hydraulic system 0 and 10 are shown with the corresponding connections on the circuit board A brief description of the menu system is also provided in tabular form for the selection of the res pective hydraulic system Important The hydraulic systems stated in this section are only shown in sche matic form They serve as an overview and planning aid For the ac tual in...

Page 82: ...Outside temperature sensor 40 41 ST Supply temperature sensor boi ler temperature 48 49 RT Return temperature sensor 46 47 At Accumulator sensor top 44 45 Ab Accumulator sensor bottom 42 43 No Description Notes 8 01 Select hydraulic system 0 8 02 Select accumulator type 8 12 Option of activating an additional heating circuit module 8 00 Hydraulic system setting process completed ...

Page 83: ...nic Connection OTS Outside temperature sensor 40 41 ST Supply temperature sensor boi ler temperature 48 49 RT Return temperature sensor 46 47 AH1 Accumulator sensor house 1 44 45 AH2 Accumulator sensor house 2 42 43 CP1 District heating pump 1 14 CP2 District heating pump 2 15 No Description Notes 8 01 Select hydraulic system 10 8 00 Hydraulic system setting process completed ...

Page 84: ...tched off CHECK THE MECHANICAL STRUCTURE OF THE FEEDING SYSTEM Does the mechanical structure of the feeding system meet the specifications of this operating manual CHECK THE HYDRAULIC CONNECTIONS Do the hydraulic connections meet the specifications of this ope rating manual Has the safety equipment been installed to conform to the appli cable standards and guidelines CHECK THE MECHANICAL STRUCTURE...

Page 85: ...1 Switch on the circuit breaker for the mains electricity supply or otherwise ensure the unit is provided with power The heating system is now under voltage 2 Turn the heating system main switch on The control is activated After a start up phase the display will first show a switch on mes sage and then show the standard display of i 01 The heating system is now switched on SETTING THE DISPLAY LANG...

Page 86: ...7 Press the Up button until you reach the parameter Boiler type 1 23 You are now in the submenu Boiler type 1 23 8 Press the Enter button 9 Use the Plus or Minus button to select the boiler type 10 Press the Enter button The boiler type is now set No Display Description 1 24 Language D German GB English The desired display language can be selected Table 5 1 Setting the display language Enter Enter...

Page 87: ...changes to the service level The cursor is positioned on the parameter group 1 General 2 Using the Down button select the parameter group 7 Deli very system 3 Press the Enter button The display will change to the parameter Delivery type 7 01 4 Press the Enter button 5 Use the Plus or Minus button to select the version of the delivery system 6 Press the Enter button No Display Description 1 25 Powe...

Page 88: ...1 Simultaneously press the Plus and Enter buttons The display changes to the service level The cursor is positioned on the parameter group 1 General 2 Using the Down button select the parameter group 8 Hyd raulic system 3 Press the Enter button The display will change to the parameter Hydraulic system 8 01 The cursor flashes on 0 4 Use the Plus or Minus button to select the installed hydraulic sys...

Page 89: ...systems can be found in the chapter 4 Planning and installation section 4 10 HDG hyd raulic systems or in the information booklet Hydraulic Solu tions for the HDG Hydronic Enter All parameters specific to the installed hydraulic system are called up successively For an overview of the hydraulic systems with their hydraulic specific parameters see the chapter 4 Planning and installa tion section 4 ...

Page 90: ...em runs opposite to the direc tion of turning h 03 Delivery system Current 0 000 A Off Forward Back Delivery system Plus button Delivery system runs in the direction of tur ning Minus button Delivery system runs opposite to the direc tion of turning h 04 Fill system Quantity 60 Off Start Stop Fill system Plus button Feeding system runs in continuous operation Minus button Feeding system switches o...

Page 91: ...r primary air Plus button Servo motor for primary air opens percentu ally Minus button Servo motor for primary air closes percen tually h 12 Secondary air flap 0 plus 1 minus 1 Servo motor for secondary air Plus button Servo motor for secondary air opens percen tually Minus button Servo motor for secondary air closes per centually h 13 Ignition fan Fan Off Heating Off Start Stop Ignition fan 1 x P...

Page 92: ...9 Manual HC Mixing valve HC 1 Open 0 Close 0 Mixing valve HC 1 Plus button Mixing valve is opened Minus button Mixing valve is closed h 20 Manual HC HCP Thermostat 1 HCP 1 0 Room VL 1 20 50 C Pumps Indoor thermostat for heating circuit 1 Plus button Heating circuit pump 1 switches on off h 21 Manual HC Mixing valve HC 2 Open 0 Close 0 Mixing valve HC 2 Plus button Mixing valve is opened Minus butt...

Page 93: ... HC 6 Open 0 Close 0 Mixing valve HC 6 Plus button Mixing valve is opened Minus button Mixing valve is closed h 30 Manual HC HCP Thermostat 6 HCP 6 0 Room VL 6 20 50 C Pumps Indoor thermostat for heating circuit 6 Plus button Heating circuit pump 6 switches on off h 31 Manual HC DHW 1 Top Bottom 50 50 DHW pump 1 0 DHW 1 Plus button Hot water pump 1 switches on off h 32 Manual HC DHW 2 Top Bottom 5...

Page 94: ...r Plus button Oil fired boiler enabling switches on off h 37 Manual HC Acc DHW pump 0 On Off wih button Combi Acc DWH pump Plus button Combi heating pump switches on off h 38 Calib lambda Corr value 0 0mV U O2 55 0 55 0mV Start with button Calibration of the lambda sensor Plus button Calibration of the lambda sensor starts h 39 Heating pump 1 Off Start Stop District heating pump 1 Plus button Dist...

Page 95: ...us and Enter buttons The display changes to the service level 4 Check the basic settings for the following parameter groups 1 General 2 Boiler 3 Ignition 4 Control 5 Return 6 Cleaning 7 Delivery system and the basic settings of the additional hydraulic system dependent parameter groups 8 Hydraulic system to 21 Heating pump Combi The fuel bunker may only be filled if the actuators and sensors have ...

Page 96: ...he following boiler program will run in automatic mode FILLING The delivery system stoker auger and flue gas fan are switched on IGNITION The ignition fan and flue gas fan are switched on HEATING UP The delivery system stoker auger and flue gas fan are switched on CONTROL The delivery system stoker auger and flue gas fan are switched on BURN OUT The flue gas fan is switched on Enabled for the foll...

Page 97: ...nter button 3 Using the Down button scroll to the parameter group General 1 06 4 Press the Enter button The cursor flashes on 0 5 Increase the value to 1 with the Plus button 6 Press the Enter button The settings of the initial commissioning are saved and can be re loaded at any time if lost by calling up the parameter General 1 07 The setting of the parameters is completed Enter Enter No Display ...

Page 98: ...mergency Stop switch is pulled out the main switch must be turned off and back on again Only then can all moving parts of the hea ting system be switched back on CONTROL UNIT OF HDG COMPATRONIC 1 Display 2 Buttons 3 Safety temperature limiter 4 Operating mode indicator Danger Danger from electrical current or voltage The heating system is not rendered voltage free by switching off with the Emergen...

Page 99: ...Reduces the displayed value Menu button Back to the standard display One step backwards Enter button Enables the displayed value to be changed Confirms the changed value One step forwards Mode button Select the operating mode SAFETY TEMPERATURE LIMITER The safety temperature limiter STL protects the heating system In the event of excessive supply temperature the STL switches off the power to the f...

Page 100: ...ns and for manu ally operating the drives Using the Up and Down buttons you can switch to another display window All functions are switched on or off with the Plus or Minus buttons CHIMNEY SWEEP TEST This mode is used to perform the biannual chimney sweep test The boiler is heated for this to the nominal thermal power Working to gether with the HDG Hydronic heating control the loads are acti vated...

Page 101: ...elected 3 Press the Enter button OFF mode has been confirmed The OFF symbol lights up The heating system switches to OFF mode 4 Turn the heating system main switch off The heating system is switched off and without current 6 4 Displaying information You can call up a variety of information on the display of the HDG Compatronic control unit See section 6 10 Structure of the menus in this chapter 1 ...

Page 102: ...utton to select the desired parameter group 3 Press the Enter button 4 Select the parameter to be changed 5 Press the Up or Down button The display will change to show the previous or the next para meter 6 Repeat the procedure until the parameter to be changed appears on the display The parameter to be changed is shown on the display CHANGING PARAMETERS 7 Press the Enter button The cursor flashes ...

Page 103: ...he Down button until the parameter Enable boiler 2 10 appears in the display The display then shows Enable boiler 2 10 5 Press the Enter button The cursor flashes beneath the first day of the week Mo The displayed value can now be changed 6 Press the Plus or Minus button The weekday is hidden or displayed 7 Press the Down button The cursor flashes beneath the next weekday 8 Where no enable or redu...

Page 104: ... level as follows 1 Press the Enter button The customer level is shown on the display 2 Using the Down button select the parameter group 10 Hea ting circuit 1 3 Press the Enter button 4 Repeatedly press the Down button until Program 1 HC1 10 05 or Program 2 HC2 10 06 appears in the display Either Program 1 HC 10 05 or Program 2 HC2 10 06 are shown in the display 5 Press the Enter button The cursor...

Page 105: ...ol for the desired operating mode flashes The desired operating mode has been preselected 2 Press the Enter button The selected operating mode has been confirmed The symbol for the selected operating mode lights up The heating system switches to the selected operating mode 6 7 Operating statuses The heating system goes through the following states during opera tion Enter Enter Operating status Ope...

Page 106: ...ture in the combustion chamber have been reached Control The heating system runs automatically according to the configured control mode This operating status is maintained until a change is made to a different status Burn out The pre set boiler temperature is reached or the it is time for grate emptying in continous operation The boiler has been switched off This operating status is maintained unt...

Page 107: ...tem is running Combustion chamber temperature stop The maximum permitted temperature in the combus tion chamber has been exceeded The heating system waits until the combustion cham ber falls back below the maximum permitted tempera ture frost protection The main switch is turned on Frost protection and the protective programs are active This operating status is maintained until a change is made to...

Page 108: ...ually by a qualified combustion engineer to see that federal immission limits for small and medium sized boiler systems are met 1st Federal Immission Control Ordinance INITIAL INSPECTION The operating company must notify the responsible combustion en gineer of the installation of the heating system before it is commissi oned and must also arrange an appointment for the chimney sweep test within fo...

Page 109: ...7 1 Cleaning and maintenance schedule ON THE DAY OF THE TEST Once the chimney sweep has completed the preparations for the test 1 Press the Mode button repeatedly until the Chimney sweep test symbol flashes The operating mode Chimney sweep test is preselected 2 Press the Enter button The operating mode Chimney sweep test is confirmed The Chimney sweep test symbol lights up The heating system switc...

Page 110: ...lowing menu structure In the display depending on the configuration of the system and the equipment installed in the heating system some parameters may not be shown as they are possibly not required for the particular hy draulic system These will only be displayed if the corresponding hydraulic system was selected during the commissioning process AVAILABLE LEVELS The control of the heating system ...

Page 111: ...rised specialists by entering a combi nation of buttons The values displayed can be changed CONTENTS OF THE LEVELS 1 General 2 Boiler 3 Ignition 4 Control 5 Return 6 Cleaning 7 Delivery system 8 Hydraulic system 9 Accumulator 10 Heat circuit 1 11 Heat circuit 2 12 Heat circuit 3 16 Domestic hot water 1 18 Solar 19 District heating 20 Oil burner 21 Combi heating pump The following pages show all pr...

Page 112: ...g times of the operational states i 05 Demand External 0 C Accumulator 80 C Required preset boiler temperature via an external contact via accumulator i 06 Demand HC ctrl HC1 33 C HC2 45 C HC3 30 C HC4 32 C HC5 45 C HC6 31 C Demand on the respective heating circuits i 07 Demand DHW DHW1 60 C DHW2 60 C Demand on the respective domestic hot water tanks i 08 Boiler Dosage 60 Primary air 38 Secondary ...

Page 113: ...eating circuit HC 4 Operating status of heating circuit 4 Supply temperature set actual Status of mixer Status of heat circulation pump i 16 Heat circuit 5 Heating Supply 45 19 C Mixer Off HCP On Information on heating circuit HC 5 Operating status of heating circuit 5 Supply temperature set actual Status of mixer Status of heat circulation pump i 17 Heat circuit 6 Heating Supply 31 15 C Mixer Off...

Page 114: ...tem 0h Dosage 0h Operating hours information Boiler running time during heat production Stoker auger running time Running time of dosing unit i 28 Operating hours Times emptied 0a Cleaning 0a Operating hours information Number of grate emptyings Running time of cleaning program i 29 Digital values IN Bit 0123456789abcdef OUT Signal status of central unit Status of digital inputs Bit significance S...

Page 115: ...rent temperature at top of accumulator Current temperature at bottom of accumulator Status of district heating pump Date and time Tu 09 09 2008 14 49 37 Date and time Weekday date Time i 35 Remote maintenance Status Modem init Remote maintenance HDG Bavaria Wood chip boiler TRI Fuel 1 2010 06 23 GB NL FR Software version No Display Description Table 6 2 Information level Danger Material damage and...

Page 116: ...peration Switches emergency operation on off 0 1 1 05 Fuel type Fuel 1 Fuel 2 Fuel 3 pellets Fuel type Selection of different parameter sets for various fuels 1 06 General information Operating parameters save 0 0 Saving operating parameters Current settings of parameters are stored in a separate memory 0 1 1 07 General information Operating parameters load 0 0 Load operating parameters All settin...

Page 117: ...da sensor Maximum correction voltage for the lambda sensor at calibration 1 19 General information Correction voltage Lambda sensor min mV 6 0 6 0 Minimum correction voltage for lambda sensor Minimum correction voltage for the lambda sensor at calibration 1 20 General information Comb chamb temp for calibrating lambda 50 50 Combustion chamber temperature for calibrating lambda Set the combustion c...

Page 118: ...control and constant boiler tempera ture with external demand and variable boiler temperature 2 01 Terminal 38 39 Demand Blockage Terminal 38 39 Selecting the functions assigned to terminals 38 and 39 2 02 Boiler Set temperature Minimum 60 60 Minimum preset boiler temperature Minimum target temperature to be preset for the boiler 50 65 C 2 03 Boiler Set temperature Maximum 80 80 Maximum preset boi...

Page 119: ...p mode 65 65 Supply temperature for enabling the chimney sweep test After this supply temperature is exceeded the chimney sweep test is enabled 20 80 C 2 15 Boiler Comb chamb temp for chimney sweep mode 450 450 Combustion chamber temperature for enabling the chimney sweep test After this combustion chamber temperature is exceeded the chimney sweep test is enabled 300 1000 C 2 16 Boiler Frost prote...

Page 120: ...he combustion chamber temp exceeds this presetting the material feed is stopped 300 1000 C 2 26 Flue fan avail no Uncontrolled Controlled Setting options for flue gas fan No flue gas fan Uncontrolled retrofitted flue gas fan Controlled flue gas fan 2 27 Boiler Flue gas fan Amplification P 0 02 0 02h Amplification factor for flue gas fan 2 28 Boiler Flue gas fan Lag time I 10 10s Lag time for flue ...

Page 121: ...etting option for the primary air quantity which is sup plied during the first filling 0 100 3 05 Ignition Fill comb chamber Secondary air 10 10 Secondary air volume for combustion chamber filling Setting option for the secondary air quantity which is sup plied during the first filling 0 100 3 06 Ignition Fill comb chamber Flue gas fan 20 20 Flue gas fan setting for first filling Setting option fo...

Page 122: ...etting for pre ventilation Setting option for the speed of a flue gas fan for pre ven tilation 0 100 3 17 Ignition Heating up Duration 5 5m Heating up time Setting option for the heating up phase duration 1 30 min 3 18 Ignition Start heating up Fuel quantity 6 6 Fuel quantity for start of heating up phase This preset value determines the fuel quantity with which the heating up phase begins 0 100 3...

Page 123: ...dary air volume supplied during burning out 0 100 3 26 Ignition Burn out Flue gas fan 60 60 Flue gas fan setting for burning out Setting option for the speed of a flue gas fan for burning out 0 100 3 31 Ignition Log wood Primary air 20 20 Primary air for log wood emergency operation Setting option for the primary air volume supplied during log wood emergency operation 0 100 3 32 Ignition Log wood ...

Page 124: ...ration 0 100 4 04 Control Fixed value Secondary air 10 10 Secondary air volume for Fixed value type of control Option for setting a fixed secondary air volume for Fixed value operation 0 100 4 05 Control Fixed value Flue gas fan 30 30 Flue gas fan setting for Fixed value Setting option for the speed of a flue gas fan for Fixed value operation 0 100 4 06 Control Combustion control Chamber set temp ...

Page 125: ...4 14 Control PID_2 Fuel Lag time I 257 3 257 3s Lag time for fuel quantity For Combustion and output control mode 4 15 Control PID_2 Fuel Advance time D 0 0 0 0s Advance time for fuel quantity For Combustion and output control mode 4 17 Control PID_2 Fuel Minimum 10 0 10 0 Minimum fuel quantity For Combustion and output control mode 0 100 4 18 Control PID_2 Fuel Maximum 20 0 20 0 Maximum fuel quan...

Page 126: ...r Combustion control or Combustion and output control mode 4 27 Control PID_3 O2 Lag time I 86 0 86 0s Lag time for residual oxygen For Combustion control or Combustion and output control mode 4 28 Control PID_3 O2 Advance time D 0 0 0 0s Advance time for residual oxygen For Combustion control or Combustion and output control mode 4 30 Control PID_3 sec air O2 Minimum 10 10 Secondary air volume mi...

Page 127: ...80 Input for combustion fan speed 0 100 4 37 Control Combustion fan speed Log wood 50 50 Input for combustion fan speed For Log wood emergency operation 0 100 No Display Description Table 6 6 System level 4 Control Warning Falling below dew point Do not set the return temperature below 60 C No Display Description 5 01 Return Pumps on off at boiler temperature 57 57 Enabling of the return pump If t...

Page 128: ...ime D 10 0 10 0s Advance time of the return flow mixer 5 09 Resid heat via Acc top Acc bottom Use residual heat Selection option for comparing the boiler temperature for residual heat utilisation No Display Description Table 6 7 System level 5 Return No Display Description 6 01 Tip grate Off On Tip grate Switching the automatic grate emptying function on or off 6 02 Cleaning Operating hours Stand ...

Page 129: ...rate After the set time has elapsed the monitoring limit switch should not yet be triggered 0 900 s 6 09 Cleaning Ash auger impulse time 100 100s Ash auger impulse Running time of the ash auger when grate emptying is activated 0 999 s 6 10 Cleaning preselection None Manual Automatic Setting of the cleaning system 6 11 Cleaning system Off On Cleaning system Switch automatic cleaning of the heat exc...

Page 130: ...y system 1 Flexi blade or hinged arm delivery system 2 Delivery and conveyor auger 3 Delivery system intermediate container and dosage auger 4 Silo delivery system intermediate container and dosage auger 5 Pellet vacuum delivery system pellet vacuum contai ner 7 02 Feeding system Continuous running Cycles Feeding system Setting option for continuous running or clocked cycles together with the dosa...

Page 131: ...0 60 s 7 11 Delivery system Dosage shortest pause 3 3s Shortest pause time of dosage system How long the pause time should minimally be 0 60 s 7 12 Delivery system Dosage reverse current 3 0 3 0A Dosage After exceeding the set motor current the motor reverses up to three times Then a fault message is issued 0 1 10 0 A 7 14 Delivery system Dosage reverse runtime 1 1s Dosage Reverse running time whe...

Page 132: ... Set the switch on delay of the fill level indicator in the dosage transition 7 25 Delivery system Delivery system Maximum runtime 25 25m Delivery system Set the maximum runtime of the vacuum fan in the pellet vacuum container 7 26 Delivery system Enable times On 00 00 On 00 00 Off 24 00 Off 00 00 Enable times Time block Enable times for the delivery system can be defined 7 27 Delivery system Fill...

Page 133: ...No Display Description 8 01 Hydraulic system Hydraulic system 0 0 Hydraulic system Enter the installed HDG hydraulic system The default set ting without the HDG Hydronic is System 0 0 13 8 02 Accumulator type No accumulator Accumulator Combi Acc DHW Accumulator type Setting of the accumulator type 8 03 Hydraulic system Use residual heat Heat circuit ctrl 50 50 Heating circuit control for residual ...

Page 134: ...tic hot water tank accumulator and heat exchangers 8 09 Dist heat operation no yes District heating operation Activate operation with a district heating circuit 8 10 Oil fired boiler avail no yes Oil burner Activate an additional oil fired boiler 8 11 Acc HWpump avail no yes Combination accumulator DHW heating pump Activate a combination accumulator DHW heating pump 8 12 HC mod 1 avail no yes Avai...

Page 135: ...6 10 System level 8 Hydraulic system The accumulator level is only displayed if an accumulator has been configured Accumulator type 8 02 parameter No Display Description 9 02 Accumulator Accumulator max End heating up 65 65 Temperature at bottom of accumulator at maximum After exceeding the preset temperature at the Acc bot tom sensor the boiler is turned off 20 90 C 9 03 Accumulator Accumulator m...

Page 136: ...t heating pump 1 or 2 will start 9 09 Accumulator Differential tempera ture Stop pumps 2 2 Accumulator hydraulic system 10 If the difference between the boiler temperature and the accumulator temperature of house 1 or house 2 is smaller than this set value district heating pump 1 or 2 will switch off 9 10 Accumulator Start pumps Return greater 65 65 Accumulator hydraulic system 10 Start district h...

Page 137: ...elow this temperature on the accumulator house 1 top the boiler switches on 9 18 Accumulator Acc house 2 bottom End heating up 65 65 Accumulator house 2 After exceeding this temperature on the accumulator house 2 bottom the boiler switches off 9 19 Accumulator Acc house 2 top Start heating up 60 60 Accumulator house 2 After falling below this temperature on the accumulator house 2 top the boiler s...

Page 138: ...tside temperature Shut down 20 20 The temperature outside If the preset outside temperature is not met the heating circuit pump is turned off 0 50 C 10 08 Heat circuit 1 Room influencing fac tor 1 0 1 0 Room influencing factor The room influencing factor expresses how strongly any deviation of the room temperature should affect the temperature of supply water leaving the boiler 0 1 5 0 10 09 Heat ...

Page 139: ...et the mixing valve runtime 10 300 s 10 18 Screed drying no yes Screed drying program Activate the screed drying program 10 19 Heat circuit 1 Set supply temp increase Screed drying 5 5 Increase in room temperature Set the increase in room temperature for screed drying 1 10 C 10 20 Rise HC1 Every day After two days After three days After four days After five days Day cycle temperature increase Set ...

Page 140: ... Heat circuit 1 The parameter groups 13 Heat circuit 4 14 Heat cir cuit 5 and 15 Heat circuit 6 are only available if an addi tional heating circuit module is installed The layout of the parameter structure in service levels 13 14 and 15 are identical to service level 10 Heat circuit 1 No Display Description 16 01 DHW 1 Set temperature 60 60 Preset temperature for the hot water tank Set the temper...

Page 141: ...e hot water tank priority Set the duration of priority for the hot water tank 1 0 10 0 h 16 08 Anti legionella no yes Program to protect from Legionnaire s disease Activate the Legionnaire s disease protection program 16 09 DHW 1 Temperature Protection from Legionnaire s disease 75 75 Temperature of Legionnaire s protection program Set the target temperature for the activated program to protect ag...

Page 142: ...Solar acc pump 15 15m Waiting time before restarting the solar accumulator pump in order to check the available collector tempe rature hot water tank priority 0 100 m 18 06 Solar Runtime Solar acc pump 15 15m Runtime of the solar accumulator pump until the next monitoring of the collector temperature 0 100 m 18 07 Solar Factor n Solar acc pump 10 10 Multiplication factor for solar pump Set the mul...

Page 143: ...t heating If the temperature of the district heating falls below its preset value by the amount of the hysteresis the district heating pump or system will start 0 30 C 19 03 Dist heat priority no yes Priority for district heating Activate priority for district heating 19 04 District heating Reduce temp district hea ting priority 40 40 Reduced temperature for district heating If district heating pr...

Page 144: ...l fired boiler Increase 5 5 To increase the temperature of the oil fired boiler Set an increase in temperature above the set value for the oil fired boiler 10 100 C 20 04 Oil burner Oil fired boiler hys teresis 5 5 Hysteresis of the oil fired boiler Set the difference between the switching on and swit ching off temperatures for the oil fired boiler 10 100 C 20 05 Oil burner Oil fired boiler enab l...

Page 145: ... 145 MANUAL MODE The actuators and sensors have been checked in the manual mode See the chapter entitled 5 Commissioning the system section 5 2 Procedure paragraph Checking the actuators in manual operation or Checking the sensors in manual operation ...

Page 146: ...ls are guidelines Depending on the quality of the fuel and the power used by the heating system more frequent on off operation the intervals may vary Interval Component See page Weekly as required Check and clean the tilting grate Check and empty the ash container Lubricate the feeding system every 150 opera ting hours 149 149 152 monthly Checking the drive chains 152 every 6 months Cleaning the c...

Page 147: ...ger of burns from hot surfaces During operation the boiler surfaces under the cladding are hot Even when turned off they only cool down slowly Switch the heating system off and only start with the cleaning and maintenance work when the surfaces have cooled down Warning Risk of injury from automatically driven components If the heating system is switched on automatically driven compo nents can unex...

Page 148: ... Secondary combustion chamber Figure 7 2 HDG Compact 45 50 65 80 combustion chamber temperature sensor 1 2 Caution Damage to the combustion chamber temperature sensor The combustion chamber temperature sensor consists of a ceramic part that can be damaged by mishandling Take care to ensure that the combustion chamber temperature sensor is not damaged during cleaning and maintenance work 1 Wall hol...

Page 149: ...tuators in manual operation 8 After cleaning close the combustion chamber door 2 and the front door 1 of the boiler 9 Switch the heating system on again See the chapter entitled 6 Using the heating system section 6 2 Switching on the heating system The tilting grate is cleaned CHECKING AND EMPTYING THE ASH CONTAINER Important See Generally applicable safety instructions in this section 4 Open the ...

Page 150: ...r the combustion chamber ash 3 7 Pull out the ash pan 1 8 Empty the ash 1 into a fireproof container 9 Reinsert the ash pan 1 and lock the ash doors in the reverse se quence 10 Repeat the procedure described above for the fly ash pan 11 Place the cover of the ash module 5 on the boiler 12 Switch the heating system on again See the chapter entitled 6 Using the heating system section 6 2 Switching o...

Page 151: ...p the clamp handle 6 and release the stop on the ash con tainer 5 10 Pull the ash container 5 forward away from the ash channel 1 of the ash removal system 11 Empty the ash into a fireproof container 12 If the ash containers 5 are not yet full reclose them 13 Mount the lid 4 on the ash container 5 and install the ash con tainer 5 in the boiler in the reverse sequence Important See Generally applic...

Page 152: ...E DRIVE CHAINS Important See Generally applicable safety instructions in this section 1 Place the grease gun on the lubricating nipple 1 2 Press three strokes of grease into the feeding system Figure 7 7 Lubricating the feeding system 1 Important See Generally applicable safety instructions in this section Warning Risk of injury from automatically driven components When the heating system is switc...

Page 153: ...ioner 2 downwards until the drive chain again has sufficient tension 8 Secure the chain tensioner 2 in this position 9 Replace the cover on the boiler 10 Switch the heating system on again See the chapter entitled 6 Using the heating system section 6 2 Switching on the heating system The check of the ash removal system drive chain is completed CHECKING THE DRIVE CHAIN OF THE FEEDING SYSTEM 1 Set t...

Page 154: ... drive chain is tightened 9 Mount the chain guard 3 back on the feeding system 10 Switch the heating system on again See the chapter entitled 6 Using the heating system section 6 2 Switching on the heating system The check of the feeding system drive chain is completed Warning Risk of injury from automatically driven components When the heating system is switched on the gears and drive chains that...

Page 155: ...e operating mode OFF The OFF symbol lights up 2 Allow the fire in the heating system to burn out and cool down 3 Remove the three hoods 1 4 Move the cleaning system downward in manual operation Figure 7 10 HDG Compatronic control unit Important See Generally applicable safety instructions in this section Warning Danger of injury The cleaning shaft lid is very heavy and can fall shut Hands and arms...

Page 156: ...rection 10 Visually inspect the cleaning turbulators for encrustations and re move these with a suitable tool 11 Brush off the heat exchanger surfaces with a suitable tool e g cleaning brush included in delivery 12 Clean the guide crossbars 1 and lubricate them with heat resis tant grease 13 Reassemble the cleaning system and the cleaning shaft lid in the reverse sequence 14 Reattach the three hoo...

Page 157: ...e rear lower cover 1 using a screwdriver Ensure that the cable of the cleaning system does not get pinched when closing the cleaning shaft lid Tighten the two hexagon socket screws of the cleaning shaft lid Then turn the screws a quarter turn back in the opposite direction Important See Generally applicable safety instructions in this section Caution Danger of burns from hot surfaces The hot air n...

Page 158: ... for dirt 13 Remove any dirt using a cotton swab 14 Reassemble the ignition fan back into the heating system in the reverse sequence 15 Switch the heating system on again See the chapter entitled 6 Using the heating system section 6 2 Switching on the heating system The cleaning of the ignition fan is completed CHECKING AND CLEANING THE LAMBDA SENSOR 1 Set the control to the operating mode OFF The...

Page 159: ...bda sensor See chapter 5 Commissioning the system section 5 2 Procedure paragraph Calibrating the lambda sensor The lambda sensor has been checked and cleaned 4 Using a pipe wrench unscrew the DN 40 union nut 1 5 Remove the lambda sensor 2 and the insulating washer underneath it from the con nection nozzle 3 of the flue gas pipe Figure 7 16 Cleaning the lambda sensor 1 2 3 Important Steel bristles...

Page 160: ...e OFF The OFF symbol lights up 2 Allow the fire in the heating system to burn out and cool down Important See Generally applicable safety instructions in this section Caution Danger of burns from hot surfaces The surface of the flue pipe becomes very hot during operation Even when turned off it only cools down slowly Switch the heating system off and only start with the cleaning and maintenance wo...

Page 161: ...ews 8 with a hand ratchet or a 19 mm spanner 8 Pull the ash removal doors 3 forward off the ash removal augers 9 Check the ash chamber 9 and the fly ash chamber 2 for foreign bodies encrustations or clumps of ash and remove these if neces sary using a cleaning utensil e g a poker included in delivery 10 Mount the components in the reverse sequence 11 Switch the heating system on again See the chap...

Page 162: ...nd on the boiler connection nozzle 1 5 Detach the pressure equalisation hose 3 6 Inspect the pressure equalisation hose 3 for dirt and dislodge it if necessary by forceful shaking and careful bending 7 Mount the pressure equalisation hose in the reverse sequence The inspection and cleaning of the pressure equalisation hose is completed The pressure equalisation hose is only available with the HDG ...

Page 163: ... on the heating system The inspection and cleaning of the flue gas fan is completed The flue gas fan is only available with the HDG Compact 25 35 boiler Important See Generally applicable safety instructions in this section Warning Risk of injury from automatically driven components When working on the flue gas fan unexpected start up of the fan wheel poses the danger of hand injuries Switch the h...

Page 164: ...heating system The cleaning of the flue gas temperature sensor is completed CHECKING AND LUBRICATING THE FILL LEVEL INDICATOR 1 Set the control to the operating mode OFF The OFF symbol lights up 2 Allow the fire in the heating system to burn out and cool down 3 Turn the main switch off 4 Open the front door Important See Generally applicable safety instructions in this section 4 Release the flue g...

Page 165: ...witch plate 3 is maximally 3 mm If the contact is correct an LED lights up on the limit switch The cleaning and lubricating of the fill level indicator is com pleted INSPECTING THE FUEL BUNKER 1 Set the control to the operating mode OFF The OFF symbol lights up 2 Allow the heating system to burn out 3 Turn the main switch off Figure 7 22 Cleaning and lubricating the fill level indicator 4 1 3 2 Im...

Page 166: ...ss hatch 5 Inspect the fuel bunker for the burning of unsuitable residues or foreign bodies and remove these if necessary 6 Close the access hatch 7 Turn the main switch on The control is activated 8 Set the desired operating mode The inspection of the fuel bunker is completed ...

Page 167: ... longer shown in the display The fault is fixed 8 2 Possible faults Enter No Fault Cause Remedy No text display shown Main circuit breaker tripped Mains supply is not connec ted Heating Emergency Stop switched off Main switch not switched on Check fuses power supply and main switch No text display Power supply OK Microfuse F3 on I O circuit board is faulty Data cable not plugged in properly Displa...

Page 168: ...tch is faulty or incor rectly set Grate motor is faulty Test functioning of limit switch Test functioning of grate motor replace grate motor F006 Grate blocked up Grate is jammed Limit switch is not correctly set Limit switch is incorrectly connected Grate motor is faulty Check grate mechanics Readjust limit switch Have limit switch connection checked by a qualified electri cian Have the grate mot...

Page 169: ...nsor If a different fault appears the sensor should be replaced If the same fault appears the I O circuit board should be replaced F012 Boiler supply temp short circuit Short circuit in the sensor or sensor cable Connect sensor Replace cable Check terminal check plug for secure fit Exchange the faulty sensor plug on the I O circuit board with a different sensor If a different fault appears the sen...

Page 170: ... the sensor should be replaced If the same fault appears the I O circuit board should be replaced F016 Outside tempera ture short cir cuit Short circuit in the sensor or sensor cable Connect sensor Replace cable Check terminal check plug for secure fit Exchange the faulty sensor plug on the I O circuit board with a different sensor If a different fault appears the sensor should be replaced If the ...

Page 171: ...pen circuit in sensor cable Sensor not connected Connect sensor Replace cable Check terminal check plug for secure fit Exchange the faulty sensor plug on the I O circuit board with a different sensor If a different fault appears the sensor should be replaced If the same fault appears the I O circuit board should be replaced F023 Temp acc bot tom short cir cuit Short circuit in the sensor or sensor...

Page 172: ... control EPROM all parameters will be reset to factory defaults Check all settings and adjust current values F028 Safety circuit Emergency Stop Emergency Stop activated Unlock emergency stop Acknowledge fault with main switch off on F029 Safety circuit Low on water Check water pressure Unlock insufficient water cutout Acknowledge fault with main switch off on Check plug on circuit board 22 23 F032...

Page 173: ...ician F046 Indoor therm unit HC1 open circuit Sensor not connected Sensor is faulty Have the fault fixed by a qua lified electrician F047 Indoor therm unit HC1 short circuit Short circuit in sensor or in cable Both sensor connections joi ned in a single terminal Have the fault fixed by a qua lified electrician F048 to F061 Open circuit or short circuit in temp sensors or indoor thermos tat units s...

Page 174: ... Replace heating circuit module F110 Temp acc top house 2 short circuit Short circuit in sensor or in cable Have the fault fixed by a qua lified electrician F111 Temp acc top house 2 open circuit Sensor not connected Sensor is faulty Have the fault fixed by a qua lified electrician F112 Temp acc bot tom house 2 short circuit Short circuit in sensor or in cable Have the fault fixed by a qua lified ...

Page 175: ...K108 110 F12 F15 F16 Fuse is faulty Motor is not connected Have the fault fixed by a qua lified electrician F147 Delivery syst fault K105 K107 F14 F17 F18 Fuse is faulty Motor is not connected Have the fault fixed by a qua lified electrician F148 Transport module IO21 defective Transport module is faulty Have circuit board replaced by a qualified electrician F150 Safety circuit Overfilling Lub ric...

Page 176: ...le not connected Motor overload Check current consumption and connection F170 No connection to GSM module No telephone card in GSM module No GSM module available Check GSM module Cable not connected Parameter 1 10 incorrectly set F171 GSM error no signal No network or SIM card Radio network not available Antenna connection No SIM card in the modem Insert SIM card Connect antenna cable F172 Modem n...

Page 177: ... display will change to General 1 04 4 Press the Enter button The cursor will flash underneath the value 0 The displayed value can now be changed 5 Press the Plus button The value of the parameter is increased to 1 6 Press the Enter button The changed value is confirmed Emergency operation has been configured 7 Press the Menu button twice The standard display of i 01 is shown FURTHER MEASURES Have...

Page 178: ...control is deactivated 4 Switch the circuit breaker for the heating system off 5 Disconnect the heating system from the electrical power supply 6 Once it has cooled down drain the heating water from the system 7 Observe the safety regulations for personnel when disconnecting the boiler from the heating system 8 Dismantle the individual components of the heating system The heating system has been d...

Page 179: ...ic parts such as suction hoses etc should be handed in to the respective waste disposal centres The geared motors used consist largely of materials which can be re cycled If a geared motor cannot be handed over complete to a sui table company for proper disposal proceed as follows 1 The gear oil must be drained into a suitable container 2 The geared motor should be dismantled into its separate com...

Page 180: ...allation of the heating system and the hydraulic compo nents must meet the requirements in the operating manual and the specified HDG hydraulic diagrams The heating system must be installed according to the applicable rules regulations and guidelines The fuel quality must correspond to the requirements specified by HDG Bavaria GmbH An HDG delivery system must be used 10 3 Warranty exclusions The w...

Page 181: ...liament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC 97 23 EC Pressure Equipment Directive 97 23 EC of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment In accordance with section 2 o...

Page 182: ...e of the European Parliament and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to Electrical Equipment designed for use within certain voltage limits codified version 1 2004 108 EC Directive 2004 108 EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic c...

Page 183: ...Checking and cleaning the pressure equalisation hose 162 Checking and cleaning the tilting grate 149 Checking and emptying the ash container 149 Checking and lubricating the fill level indicator 164 Checking the drive chains 152 Chimney 43 Connection 74 Chimney sweep test Operating mode 100 Performing 108 Cleaning Parameter group 128 Cleaning and maintenance schedule 146 Cleaning the flue gas temp...

Page 184: ...8 Furnace room 39 H Heating circuit Parameter group 137 Heating circuit sensors 46 Installation 77 Heating system Switching off 101 Switching on 85 100 Heating systems for the heating circuits 24 Hydraulic system 78 81 Parameter group 133 Selecting 88 Hydronic 9 23 75 I Ignition Parameter group 121 Ignition fan 17 19 Indoor thermostat unit 24 46 Installation 77 Information level 111 112 Inspecting...

Page 185: ... Sensor 9 Service level 102 111 115 Servo motor Primary air 17 Secondary air 17 Servo motor for the primary and secondary air supply 19 Solar Control 27 Parameter group 142 Sound pressure level 30 31 Stoker auger 9 Supply and return connections 30 31 Supply temperature maximum 30 31 Supply voltage 87 System level 111 T Technical data 30 Thermal safety device 17 19 50 52 79 Tilting grate 16 18 Tran...

Page 186: ...12 Index 186 HDG Compact 25 35 Version 2 de HDG Bavaria GmbH Oktober 2007 ...

Page 187: ......

Page 188: ...ria GmbH Heizsysteme für Holz Siemensstraße 22 D 84323 Massing Tel 49 0 8724 897 0 info hdg bavaria com www hdg bavaria com Art Nr 9980001529 V 05 1 en 04 2013 Translation of the original operating instructions ...

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HDG Compact 25, Operation Manual

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