HDG K10 Operating Manual Download Page 64

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HDG Bavaria GmbH

Heizsysteme für Holz
Siemensstraße 22
D-84323 Massing
Tel. +49(0)8724/ 897-0
[email protected]
www.hdg-bavaria.com

Art.Nr: 9980001814 - V 05 - en - 08/2017 Translation of the original operating instructions

Summary of Contents for K10

Page 1: ...hdg bavaria com HDG K10 15 21 26 33 Operating manual ...

Page 2: ......

Page 3: ... 12 3 2 Functional description 13 Combustion process 13 Boiler and weather compensated heating control HDG Control 14 Delivery system 14 Pellet suction system 15 Reservoir 15 3 3 Technical data 16 3 4 Fuel quality requirements 17 Recommended fuel 17 4 Planning and installation 18 4 1 Planning the heating system 18 Required room sizes and minimum clearances 18 Dimensions and connections 19 Furnace ...

Page 4: ...3 Procedure 43 6 3 Filling the reservoir 44 6 4 Performing a chimney sweep measurement 44 6 5 Switching off the heating system for repair work 45 7 Cleaning and servicing the heating system 46 7 1 Cleaning and servicing schedule 46 7 2 Procedure 47 Generally applicable safety instructions 47 Cleaning tools 48 Emptying the ash container 48 Cleaning the combustion chamber and burner pot 49 Cleaning ...

Page 5: ...s on standards regulations and worksheets should be checked before use and should be compared with the regulations applying locally at the site where the system is installed We reserve the right to make changes which may then differ from the technical details and illustrations in this operating manual COPYRIGHT Written permission is required from HDG Bavaria GmbH for reprinting storage in a data p...

Page 6: ... contents of the reservoir if the temperature of the contents exceeds 90 C HDG Control Boiler and heating system controller HDG K10 33 Heating system for burning wood pellets Heating system Comprised of boiler and corresponding accessories Pellet suction system Pellet transport system which connects the reservoir with the delivery system Reservoir A container which supplies pellets to be burnt in ...

Page 7: ...rvised or have been instructed on the safe use of the device and understand the resulting risks Children may not play with the device Cleaning and user maintenance must not be carried out by children without supervision BASIC PRINCIPLES FOR THE CONTENT OF THE OPERATING MANUAL SCOPE The content of this operating manual is intended exclusively for the planning installation and operation of the HDG K...

Page 8: ...touching non insulated components Danger Danger of asphyxiation due to lack of oxygen If the boiler is in operation carbon monoxide can be emitted through the open doors and lids Do not leave the doors and lids open any longer than necessary Warning Danger of fire Opening doors and lids to hot combustion residues during operation can pose the danger of fires Keep the openings closed during operati...

Page 9: ...ger Dangerous electrical current or voltage The circuit boards and other electrical components carry current Have work on electrical components performed only by a qualified electrician and turn the main switch off Warning The boiler is under pressure Danger Dangerous electrical current or voltage Work in areas marked with this symbol may only be performed by a qualified electrician Warning Hazard...

Page 10: ...ion 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 Caution Automatic start up Working in areas marked with this symbol can lead to injuries due to automatic start up Important Frost danger Only ins...

Page 11: ...ed persons keep children away Smoking flames and other sources of ignition prohibited Turn the pellet boiler off for at least 1 hour before filling Ensure adequate ventilation before entering Beware of a risk of injury from moving components Make sure filling is carried out properly 2 5 Duty of information READING THE OPERATING MANUAL Any person performing tasks on this system must read the Operat...

Page 12: ...ECTION OF HDG K10 33 1 Vacuum fan 2 Flap of the delivery unit 3 Reservoir 4 Reservoir level indicator 5 Conveyor auger 6 Drive motor of stoker auger 7 Sensor for auger pipe safety thermostat Figure 3 1 Cross section of HDG K10 33 8 1 6 4 7 11 13 14 16 18 10 12 3 5 2 17 15 9 ...

Page 13: ...shed with fresh air The next step is the ignition phase The supplied pellets are automatically ignited with a heating element In the subsequent flame stabilisation phase even combustion is established The system then changes to modulation mode In this mode combustion is carried out according to the required output The boiler HDG K10 33 is equipped as standard with an automatic heat exchanger clean...

Page 14: ...operating status Standby HEATING CIRCUIT CONTROL The HDG Control controls the entire energy management of the heating system including the following depending on the version Accumulator management Weather compensated heating circuits Domestic hot water heating Control of the second boiler Transfer of heat into the district heating grid Solar system for hot water and support of the heating system F...

Page 15: ...boiler This process is monitored by sensors and using the boiler control system can be limited to various times of day RESERVOIR Various versions are available Reservoir Automatic Reservoir Manual small Day container Reservoir Manual large Week container Filling Automatic pellet suction system By hand By hand Volume 107 kg 107 kg 200 kg Table 3 1 Reservoir ...

Page 16: ... DIN EN 13384 1 Flue gas temp Tw at nominal thermal power Flue gas temp Tw at lowest thermal power 98 C 78 C 119 C 82 C 127 C 87 C 134 C 90 C 138 C 92 C Flue gas mass flow nominal thermal power Flue gas mass flow minimum thermal power 0 0058kg s 0 0025kg s 0 0085kg s 0 0034kg s 0 0118kg s 0 0044kg s 0 0146kg s 0 0049kg s 0 0180kg s 0 0060kg s CO2 content at nominal thermal power CO2 content at min...

Page 17: ...ass A2 and B is higher than that of A1 due to the higher proportion of bark needles and leaves The maximum ash content for property class A1 is 0 7 by weight A0 7 for property class A2 the maximum ash content is 1 2 by weight A1 2 and for property class B the maximum ash content is 2 0 by weight A2 0 In accordance with the 1st Federal Emission Control Ordinance operation with pellets in Germany is...

Page 18: ...g the heating system REQUIRED ROOM SIZES AND MINIMUM CLEARANCES for HDG K21 26 33 For HDG K10 15 710 mm with 107 kg reservoir With 200 kg reservoir 1425 mm Minimum room height 1850 mm Recommended room height 2250 mm Figure 4 1 Room sizes and minimum clearances in mm Flue pipe behind Flue pipe above ...

Page 19: ...s enough air available for the combustion process and to protect the operator from the hazards of insufficient oxygen INSTALLATION A base is not necessary for installation of the heating system Ensure alignment on a horizontal plane To ensure unhindered operation and maintenance of the heating system it is imperative that the heating system is installed in accordance with the specifications of HDG...

Page 20: ...d contact your specialist heating company or chimney engineer Another essential criterion is to achieve the correct flue draught This depends on three major factors CHIMNEY CHARACTERISTICS The requirements for minimising the draught loss in the chimney are Good thermal insulation to avoid the flue gases cooling down too quickly Smooth interior surface to reduce the flow resistance Chimney well sea...

Page 21: ...on 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 the flue entrance into it to the end of the chimney CONNECTING THE BOILER TO THE CHIMNEY ...

Page 22: ...only one heat source should be attached to each chimney To prevent dust from escaping the flue gas pipe must be sealed with heat resistant silicone ELECTRICAL SYSTEM The instructions in 2006 95 EC low voltage directive must be followed for the electrical connections to the system No electrical installations such as power sockets distribution boxes lights or light switches may be located in the pel...

Page 23: ...mmended to use an accumulator even with automatic boiler systems The size of the accumulator will depend on the nominal thermal power of the boiler and on the thermal requirements of the building As a guide the recommended value of 20 litres per kW boiler output can be used An advantage of using an accumulator lies in the lower operating hours of the system and fewer start up phases due to the ext...

Page 24: ...g valve with a 230 V servo drive running time 120 240 s and a circulation pump from energy efficiency class A For the HDG K10 33 we recommend Wilo 25 1 6 3 way mixing valve DN 25 or equivalent The return temperature control may not be further than 5 metres from the boiler The hydraulic system must be installed in accordance with specific technical principles of the heating construction industry Ta...

Page 25: ...02 152 1 2 4 5 3 Danger Risk of material damage and injury due to incorrect installation Installing the heating system requires comprehensive specialist knowledge If installed by untrained persons the heating system can be damaged and persons may be injured due to secondary damage Only allow authorised specialists to perform the installation Danger Dangerous electrical current or voltage Switch of...

Page 26: ...t performed properly Net weight HDG K10 15 HDG K21 26 33 Boiler incl transport crate 218 kg 239 kg Boiler 200 kg 221 kg Minimum boiler weight without combustion chamber door cleaning shaft lid cone primary air pin 170 kg 191 kg Day container incl transport crate 56 kg Day container 42 kg Week container incl transport crate 107 kg Week container 81 kg Ash container 12 kg Table 4 1 Net weight Figure...

Page 27: ... auger pipe 2 and the flue pipe connection 1 4 Push the boiler 3 off the pallet Caution Danger from suspended loads The boiler weighs over 200 kg If the boiler is dropped during transport persons can be seriously injured and the boiler can be damaged Make sure that you use appropriate lifting gear when installing the boiler Figure 4 6 Removing the transport pallet 1 1 2 Figure 4 7 Removing the tra...

Page 28: ...rew 2 from the cleaning shaft lid 9 Screw an M12 crane eyelet 1 not supplied into the threaded pin 10 Lift the boiler 3 off the pallet by crane The transport pallet has been removed INSTALLING THE BOILER 1 Place the boiler in the planned location 2 Ensure the minimum clearances See section 4 1 Planning the heating system under Required room sizes and minimum clearances Figure 4 8 Removing the tran...

Page 29: ...ght 4 Push the handle 1 back onto the filling and drain cock 2 The filling and drain cock is now fitted CONVERTING THE FLUE PIPE CONNECTION 3 Adjust the boiler horizontally or slightly sloping upwards to the rear using the four positioning screws 1 The boiler is erected Figure 4 10 Aligning the boiler 1 Figure 4 11 Fitting the filling and drain cock 2 1 On delivery the flue pipe connection is at t...

Page 30: ...able 7 Undo the four hex socket screws 1 in the cleaning shaft lid 8 Carefully take off the flue gas housing 9 Turn the flue gas housing 3 by 90 and screw it on again 10 Put the insulation 2 back in on the left enclosed on the side below the flue gas housing The flue gas connection gas been converted Figure 4 12 Opening the cleaning shaft lid 1 2 3 Figure 4 13 Removing the rear wall 1 2 3 Figure 4...

Page 31: ... motor with the two M8 screws SW13 2 3 Screw the gear wheel 3 using the M6 screw SW10 and a washer onto the auger at the bottom of the reservoir 4 Thread the in the reservoir with the conveyor auger 2 into the auger pipe 1 5 Attach the reservoir at the top by the yellow markings into the two hooks 3 The auger motor is installed under the reservoir on the auger Figure 4 15 Installing the auger moto...

Page 32: ...the way into the holder Figure 4 18 Installing the safety thermostat 1 9 Connect the plugs 1 of the auger motor and the proximity switch Figure 4 19 Connecting the plugs 1 Depending whether or not the reservoir is fitted with a suction system either the mains plug and the upper proximity switch or corresponding plugs with jumpers must be connected to the automatic burner 10 Lay the mains plug 2 fr...

Page 33: ... X22 1 16 Connect the plug 6 pin with a jumper to the socket 4 for the vacuum fan mains plug The reservoir is installed FITTING THE CLADDING RESERVOIR CLADDING Figure 4 21 Connecting in the plugs and jumpers 4 1 3 2 1 Attach the rear cladding 2 to the pins 1 on the reservoir and the rear cladding of the boiler Figure 4 22 Fitting the rear cladding 2 1 If the flue pipe connection is fitted at the t...

Page 34: ...r 4 Mount the upper cladding 1 with the Phillips screws Figure 4 24 Installing the upper cladding 1 5 Push the middle orifice plate 1 under the cladding or sideways into the recesses on the boiler 6 Fasten the middle orifice plate 1 with the Phillips screws 2 Figure 4 25 Mounting the middle orifice plate 1 2 Figure 4 26 Mounting the right container cladding 2 1 9 Mount the lower front cladding 1 w...

Page 35: ... upper door hinge 2 loosely so that it can still move with the two Phillips screws Figure 4 28 Installing the front cladding at the top 1 Figure 4 29 Mounting the door hinges 1 2 13 Attach the side wall 1 Figure 4 30 Attaching the side wall 1 14 Hang the housing door 3 in the upper and lower hinge 15 Tighten the Phillips screws 2 of the upper door hinge 16 Fasten the side wall with the Phillips sc...

Page 36: ...according to the control unit 1 See Electrical plans for HDG K10 60 20 Mount the support plate 1 with the Phillips screws 21 Break out the perforation on the upper cover 1 if necessary 22 Place the upper cover 1 on the boiler The cladding is installed Figure 4 32 Installing the control unit 1 Figure 4 33 Mounting the support plate 1 If the flue pipe connection is fitted at the top the upper cover ...

Page 37: ...ed MOUNTING THE EXPANSION MODULES 1 Attach the base plate 1 under the reservoir on the boiler and bend the front part down to the ground Figure 4 35 Mounting the base plate 1 Figure 4 36 Mounting the support plate 1 3 2 4 Adjust the foot 1 of the ash container Figure 4 37 Adjusting the foot 1 Important If an EM4 or EM8 expansion module is used these can be mounted directly on the plate above the a...

Page 38: ... modules 1 2 See Electrical plans for HDG K10 60 4 Install the cables and sensors on the expansion modules according to the hydraulic wiring diagram The EM4 EM8 expansion modules are fitted SERVICE PLUG Figure 4 38 Mounting the expansion modules 2 1 Figure 4 39 Service plug 1 Important The service plug 1 is only intended for HDG customer service and may not be connected to any module ...

Page 39: ...ection 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 6 Electrical system The electrical connections should be made in accordance with VDE guideline 0100 Electrical systems in buildings The technical details are described in chapter 3 ...

Page 40: ...he system to the maximum boiler temperature and bleed air from the system again to make sure that there are no air pockets The safety devices must be implemented in accordance with DIN EN 12828 Heating systems in buildings and the correspondingly harmonised national standard DIN 4751 Part 2 Closed thermostatically safeguarded heat generating systems with supply temperatures of up to 120 C safety e...

Page 41: ...nical structure of the boiler meet the specifications of this operating manual Has the water tank been filled with water CHECK THE HYDRAULIC CONNECTIONS Do the hydraulic connections meet the specifications of this operating manual Has the safety equipment been installed to conform to the applicable standards and guidelines Has the system been flushed filled and bled heat transfer must be possible ...

Page 42: ...ter the calculated value in the boiler control system See operating manual HDG Control chapter 7 HDG K10 60 parameters The fuel quantity has been calculated PERFORM ACTUATOR TEST In addition to the automatic self test individual actuators can also be manually activated as required See operating manual HDG Control chapter 7 HDG K10 60 parameters ADAPTING PARAMETERS If the heating system does not wo...

Page 43: ...sed specialist The pellet storage room is dry and free of any foreign bodies Thick layers of dust must be removed See chapter 3 Mode of operation section 3 4 Fuel quality requirements The requirements of government safety organisations must be met PROCEDURE 1 Switch the heating system off See the HDG Control operating manual chapter 5 Using the control unit section 5 3 Switching off the heating sy...

Page 44: ...ervoir with pellets up to a maximum of 1 cm below the rim The reservoir is filled PELLET SUCTION SYSTEM The reservoir is filled by the automatic pellet suction system Initial filling is performed during commissioning of the system Each further filling is automatic as required by the boiler control system 6 4 Performing a chimney sweep measurement See the HDG Control operating manual chapter 5 Usin...

Page 45: ...operating manual chapter 5 Using the control unit section 5 3 Switching off the heating system 3 Lift off the top right cover 1 of the boiler 4 Pull out the machine s mains plug 2 The heating system is switched off and without current Important Frost danger Only completely shut off the power to the heating system if the danger of frost can be ruled out There is still electrical voltage in the syst...

Page 46: ...use genuine HDG spare parts You can obtain HDG spare parts from your specialist heating company The specified cleaning intervals are guidelines Depending on the quality of the pellets and the power used by the heating system more frequent on off operation the intervals may be extended Interval Component See page Indication in display Cleaning Emergency cleaning Empty the ash box Clean the combusti...

Page 47: ...wn slowly Switch the heating system off and only start with the cleaning and maintenance work when the surfaces have cooled down Caution Danger of fire from combustion residues Hot combustion residues ash coal etc can pose the danger of fires Allow the hot combustion residues to cool down in the cleaning and maintenance work before pouring these into a non flammable container Turn the heating syst...

Page 48: ...ction 5 3 Switching off the heating system 2 Allow the fire in the heating system to burn out and cool down Figure 7 1 Cleaning tools 1 2 3 4 5 Important Observe the Generally applicable safety instructions in this section Important The combustion chamber door must not be opened during continuous operation Always switch off the boiler first and wait until burn out mode has finished 3 Open the hous...

Page 49: ...g the control unit section 5 3 Switching off the heating system 2 Allow the fire in the heating system to burn out and cool down 3 Open the housing door and the combustion chamber door 5 Pull the handle 1 of the ash container all the way out The side openings of the ash container are locked 6 Release the lower right clamp lock 2 Figure 7 3 Locking the ash container 2 1 7 Push the ash container 1 s...

Page 50: ...r 1 5 Clean the drop chute 1 if necessary for example using a screwdriver Figure 7 6 Cleaning the drop chute 1 6 Remove the combustion residue from the combustion chamber with a vacuum cleaner Figure 7 7 Cleaning the combustion chamber 1 7 Lift the upper part of the cone 1 out of the burner pot Figure 7 8 Removing the upper part of the cone 1 8 Lift the lower part of the cone 1 out of the burner p...

Page 51: ...e primary air holes are free 16 Clean the remaining combustion residues in the burner pot and the primary air pipe 1 using a vacuum cleaner 17 Ensure that there are no more combustion residues in the primary air pipe since otherwise the ignition element can be damaged Figure 7 10 Cleaning the cone 1 Important Always remove all the ash from the combustion chamber and burner pot first Only then can ...

Page 52: ...ystem off See the HDG Control operating manual chapter 5 Using the control unit section 5 3 Switching off the heating system 2 Allow the fire in the heating system to burn out and cool down 3 Remove the top right cladding Important Observe the Generally applicable safety instructions in this section 4 Remove the insulation 1 from the cleaning shaft lid Figure 7 13 Removing the insulation 1 5 Relea...

Page 53: ...HECK THE FILL LEVEL OF THE WATER TANK 7 Clean the cleaning shaft lid 1 using a scraper 8 Remove the flue ash in the cleaning shaft 1 with a vacuum cleaner 9 Close the boiler in the reverse order Figure 7 16 Cleaning the cleaning shaft 1 Important Observe the Generally applicable safety instructions in this section 3 Unscrew the wing nut 1 on the inspection hatch lid 2 4 Remove the inspection hatch...

Page 54: ...he heating system 2 Allow the fire in the heating system to burn out and cool down 1 Check the fill level of the water tank 1 volume approx 8 l If the minimum fill level indicator is not reached water must be added 2 Top up the water tank 1 Figure 7 18 Water tank fill level 1 Important Observe the Generally applicable safety instructions in this section Caution Risk of serious injury if the stoker...

Page 55: ...f the delivery unit and the proximity switch 4 with a vacuum cleaner 10 Check that the flap 2 moves smoothly 11 Ensure that the entire surface of the flap 2 touches the seal 3 4 Pull out the mains plug 1 Figure 7 20 Removing the mains plug 1 5 Undo the four screws and remove the lower front cladding 1 of the reservoir Figure 7 21 Removing the lower front cladding 1 Figure 7 22 Checking and cleanin...

Page 56: ...cess hatch 12 Mount the inspection hatch 2 as touch protection on the opening for the conveyor auger 13 If necessary fasten the pellet scuttle 1 to the reservoir 14 Fill the pellets into the reservoir using the pellet scuttle 1 if necessary Figure 7 23 Emergency filling 1 2 Caution Danger of injury from the rotating auger When the heating system is turned on the auger rotates in the pellet storage...

Page 57: ...pletely emptying the pellet storage room every 2 3 years When operating the heating system with HDG suction system and suction probes you can deactivate the automatic changeover between the three suction probes using the boiler control system See chapter 6 Using the heating system section Operator level paragraph Sensor changeover In this way you can completely empty the fuel storage room at a pro...

Page 58: ...em 6 Observe the safety regulations for personnel when disconnecting the boiler from the heating system 7 Dismantle the individual components of the heating system The heating system has been dismantled 8 2 Disposal The following components are made of steel and can be recycled via a local recycling centre Boiler Cladding Reservoir Conveyor auger without motor Transfer station without motor Delive...

Page 59: ... motors used consist largely of materials which can be recycled If a geared motor cannot be handed over complete to a suitable 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 components and cleaned if necessary 3 Metal parts should be recycled Oily or greasy components and condensers m...

Page 60: ...eby that the machinery complies with each and every relevant provision of the following EC Directives 2006 42 EC 2004 108 EC Directive 2006 42 EC of the European Parliament and of the Council of 17 May 2006 on machinery and amending Directive 95 16 EC recast 1 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 Stat...

Page 61: ...em 6 14 Dimensions 19 DIN EN 13384 1 20 DIN EN ISO 17225 17 DINplus 17 Dismantling 58 Display 6 Disposal 58 Drop chute 13 E Efficiency 16 Electrical connection 16 Electrical system 22 39 ENplus 17 Expansion module EM4 Mounting 37 Expansion modules 37 F Flap of the delivery unit 12 Cleaning 54 Flue calculation 16 20 Flue draught requirement 16 Flue gas fan Cleaning 52 Flue gas mass flow 16 Flue gas...

Page 62: ...ervoir 6 12 Cleaning 54 Filling 44 Residual risks 8 Return temperature 23 Return temperature minimum 16 Room sizes 18 running time 12 S Safety devices 23 Scope of delivery 24 Sensor 6 Sound pressure level 16 Spare parts 46 Supply 26 Supply temperature maximum 16 T Technical data 16 V VDI 2035 23 40 VDI 3464 11 W Warnings and safety symbols 9 Water 22 40 Water capacity 16 Water tank Checking the fi...

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Page 64: ...aria 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 9980001814 V 05 en 08 2017 Translation of the original operating instructions ...

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