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2 Safety instructions – Warnings and safety symbols used

HDG M299/300/350/400 - Version 1 - en

HDG Bavaria GmbH 07/2008

2.3 Warnings and safety symbols used

The following warnings and safety symbols are used in this
Operating Manual:

Danger!

Dangerous electrical current or voltage

Work in areas marked with this symbol may only be performed by a
qualified electrician.

Warning!

Hazardous area

Working in areas marked with this symbol can lead to serious
injuries or to extensive material damage.

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.

Summary of Contents for M299

Page 1: ...hdg bavaria com HDG M299 300 350 400 Operation Manual ...

Page 2: ......

Page 3: ... 400 front side 17 HDG M299 300 350 400 back side 18 Cross section of HDG M299 300 350 400 19 3 2 Functional description 20 Combustion process 20 Delivery system 21 HDG Control 21 Control modes 22 3 3 Technical data 23 3 4 Fuel quality requirements 24 Permissible fuel 24 Wood chips 26 Wood pellets 27 Recommended fuel 29 4 Planning and installation 31 4 1 Planning the heating system 31 Space requir...

Page 4: ...g the system 71 5 1 Requirements 71 5 2 Procedure 72 Switching on the heating system 72 Setting the display language 72 Checking the actuators in manual operation 73 Filling the transfer station of the central ash removal system 74 Filling the fuel storage 75 Adapting parameters 76 6 Using the heating system 77 6 1 Overview of the controls and display components 77 Main switch 77 Emergency stop 77...

Page 5: ...l augers and ascending auger times 98 Setting times for the heat exchanger ash removal augers and the cleaning system 99 Setting main cleaning 99 Stoker auger delay 100 Setting pause intervals and running time for delivery 100 Setting the agitator 100 Setting the walking floor delivery system 101 Setting the day date and time 101 6 9 MANUAL menu 102 Procedure 102 Combustion air and ignition fan 10...

Page 6: ...ature settings 121 Entering the primary air setting 121 Setting preset values for primary air flaps 122 Entering the residual oxygen setting 122 Entering the secondary air setting 123 Setting preset values for secondary air flaps 123 Adapting the fuel quantity O2 124 Setting vacuum pressure control values 124 Setting air flap delay 125 6 11 INFO menu 125 6 12 Maintenance function 126 6 13 Filling ...

Page 7: ...149 Cleaning and calibrating the lambda sensor 150 Cleaning the flue gas temperature sensor 151 Cleaning the flue gas pipe 152 Cleaning the pressure equalisation hose 153 Cleaning fly ash section 154 Inspecting the fuel storage 155 8 Troubleshooting 156 8 1 Procedure 156 8 2 Possible faults 156 9 Notes on dismantling and disposal 166 9 1 Dismantling 166 9 2 Disposal 167 10 Warranty 168 10 1 Scope ...

Page 8: ...NICAL CHANGES We continuously develop and improve our boilers The information in this edition was correct at the time of going to press 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 processing system or transmission by el...

Page 9: ...s 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 rect...

Page 10: ...uishing device Extinguishes what is within the delivery system if the temperature of the contents exceeds 90 C Feeding system Feeds the fuel to the boiler by means of the rotary feeder and the stoker auger HDG Control Electronic control unit of the boiler feeding system and delivery system HDG M299 300 350 400 Boiler for burning wood chips shavings and wood pellets Heating system Comprised of boil...

Page 11: ...ing systems Any further implementation of applicable standards for example with regard to the installation of the heating system pipework 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 M299 300 350 400 heating system is designed for the standard use of burning wood fuel produc...

Page 12: ...oxygen If the boiler is operating carbon monoxide can be emitted through the cleaning or inspection openings 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 down before you place the...

Page 13: ...or inspection hatches can cause explosions Do not leave these open any longer than necessary Warning Risk of injury from automatically driven components 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 automatically driven components and secure it against being turned back on Danger Dangerou...

Page 14: ...symbol can lead to serious injuries or to extensive material damage 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 area...

Page 15: ...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 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 ...

Page 16: ...eat exchanger surfaces The HDG M299 300 350 400 heating system is equipped with the HDG TBZ 200 for loading wood chips and shavings or with the HDG TBZ 150 for loading pellets The HDG M299 300 350 400 heating system can also be equipped with the following delivery systems Hinged arm delivery system Walking floor delivery system Silo delivery system Walking floor changing container Pellet delivery ...

Page 17: ...fan 6 Actuator for tertiary air 7 Actuator for secondary air 8 Drive motor for central ash removal system 9 Ash bin 10 Drive motor for ash removal auger 11 Inspection window for stepping grate 12 Ignition fan 13 Drive motor for stepping grate 14 Actuator for primary air 1 15 Actuator for primary air 2 16 Primary air fan 17 Feeding system 18 Drive motor for fly ash augers Figure 3 1 HDG M299 300 35...

Page 18: ...mbH 07 2008 HDG M299 300 350 400 BACK SIDE 1 Cleaning shaft lid of combustion unit 2 Cleaning shaft lid of heat exchanger 3 Cleaning system drive motor 4 Lambda sensor 5 Tubular heat exchanger 6 Turbulators 7 Fly ash container Figure 3 2 HDG M299 300 350 400 back side 5 6 4 3 1 2 ...

Page 19: ...299 300 350 400 1 Secondary air openings 2 Safety heat exchanger combustion unit 3 Tertiary air openings 4 Combustion chamber 5 Ash removal auger for fly ash 1 6 Ash removal auger for grate ash 7 Stepping grate 8 Ignition pipe or fill level indicator Figure 3 3 Cross section of HDG M299 300 350 400 5 3 1 2 4 8 7 6 ...

Page 20: ...99 300 350 400 heating system the fuel is automatically fed from the storage room into the combustion chamber of the boiler via the delivery and feeding systems The combustion fan is already activated here in order to eliminate any possible residual combustion gases or negative flue pressure conditions along the combustion path Once the filling cycle is complete the fuel introduced into the combus...

Page 21: ...sh bin Fly ash 2 and 3 are propelled into the external ash containers by the ash removal augers of the automatic ash removal system The air necessary for combustion is supplied as required via two combustion air fans Sensors are used in the following To continuously monitor the firing To adapt boiler output for the heat requirements To minimise emissions To optimise boiler efficiency DELIVERY SYST...

Page 22: ...ombustion air flow rate even in emergency operation Combustion control Constant specified combustion chamber temperature and optimal combustion through modification of primary and secondary air and fuel quantity No output regulation Preferred method of operation with accumulator Control of combustion and output Output supplied is adjusted to heat used with optimised combustion Operation without ac...

Page 23: ...ty 2110 l 2150 l 2200 l Weight of combustion unit 2640 kg 2700 kg 2730 kg Weight of heat exchanger 2860 kg 2900 kg 2920 kg Planning data for flue calculation DIN EN 13384 1 Flue gas temperature Tw at Nominal thermal power Minimum thermal power 140 C 120 C 150 C 120 C 160 C 120 C 170 C 120 C Flue gas mass flow at Nominal thermal power Minimum thermal power 0 167 kg s 0 048 kg s 0 167 0 169 kg s 0 0...

Page 24: ... of a treatment and coatings do not contain organic halogen compounds or containing heavy metals FUEL CLASS 7 Plywood chipboard fibreboard or otherwise glued wood including remains thereof provided no wood protection agents have been applied 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 wo...

Page 25: ...culation and the treatment of operating issues relating to firing technology In addition to combustible substances the fuels also contain varying amounts of non combustible or inert components With an increasing ratio of inert components the calorific value drops considerably the combustion quality deteriorates and the CO emission and the amount of ash and cinder dirt on the heating surfaces is in...

Page 26: ...l HDG wood chip boilers For P31 5 wood chips at least 75 of the wood chips by weight must be between 8 mm and 31 5 mm The fine content 3 15 mm may not exceed a maximum of 8 by weight A maximum of 6 of the wood chips by weight may be longer than 45 mm lengths greater than 120 mm are not permissible The numeric value of the P category refers to the size of the wood chips in mm which fit through a ro...

Page 27: ...y consumes heat This results in lower efficiency and thereby leads to greater wood consumption Increasing moisture in the fuel material also causes reduced efficiency greater amounts of ash and smoke as well as making it increasingly unfit for storage The maximum permissible water content of the wood chips for the HDG M299 300 350 400 is 30 M30 For technical considerations a representative calorif...

Page 28: ... 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 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 3 15 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...

Page 29: ...rating safety of your heating system The optimal ash content is 1 by weight A1 0 For HDG M299 300 350 400 heating systems it is possible to use wood fuel products of grain size P45 with a maximum water content of up to 30 However reduced nominal thermal power reduced efficiency increased fuel consumption and greater wear and tear on the heating system may then result Fuels with a higher water cont...

Page 30: ...h DIN EN 14961 Solid biofuels fuel specifications and classes only with HDG M350 400 Wood chips P45 M20 A1 0 A1 5 or Pellets A1 A2 Wood chips P45 M25 A1 0 A1 5 Wood chips P45 M30 A1 0 A1 5 Shaving briquettes A1 A2 D60 L50 Planing saw shavings A1 A2 M20 A1 0 A1 5 HDG M299 300 300 kW 280 kW 270 kW 270 kW 260 kW 270 kW 280 kW 270 kW HDG M350 350 kW 375 kW 330 kW 320 kW 320 kW 310 kW 320 kW 330 kW 320...

Page 31: ...PACE REQUIREMENTS The automatic de ashing for fly ash 1 or 2 can also be installed in such a way that both fly ash containers are on the opposite side This reduces dimension D to 500 mm Figure 4 1 Space requirements E G D B C A F A B C D E F G HDG M299 300 350 400 4400 4250 600 950 500 1400 2000 Table 4 1 Minimum size mm ...

Page 32: ...ing height 3500 mm Minimum insertion height 2500 mm INSTALLATION DIMENSIONS Dimensions with attachments removed Figure 4 2 Room height requirements Combustion unit Heat exchanger Length 2070 mm 1900 mm 2175 mm 2000 mm Width 1200 mm 1200 mm 1374 mm 1250 mm Height 2160 mm 2070 mm 2175 mm 2070 mm Table 4 2 Installation dimensions ...

Page 33: ...NS Local building regulations always apply In Germany individual state regulations on boilers and furnaces FeuVO also apply Figure 4 3 Minimum clearances D F B C A E A B C D E F HDG M299 300 350 400 600 750 500 950 1400 870 Table 4 3 Minimum clearances mm Building regulations may differ from country to country and state to state For this reason consult a qualified specialist for the planning and i...

Page 34: ...ld have the following characteristics dry dust proof statically suitable accessible for the filling process free of other installations especially in existing buildings adapted to fuel requirements The refilling intervals should be kept as long as possible The heating system should be located within the building so that the noise generated does not exceed the permissible values of DIN 4109 Soundpr...

Page 35: ...temperature may lie below 100 C when the system is under partial load a chimney flue is required which meets the requirements of DIN EN 13384 1 2003 03 Thermal and fluid dynamic calculation methods If it does not meet this standard contact your specialist heating company or chimney technician Another essential criterion is to achieve the correct flue draught This depends on three major factors CHI...

Page 36: ... 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 The firing system must be connected with a connecting piece which is as short as p...

Page 37: ...tly sealed To reduce the entry of additional cold air only attach one heat generator per chimney To prevent dust from escaping the flue pipe must be sealed with heat resistant silicone ELECTRICAL SYSTEM The directive 2006 95 EC low voltage guideline must be followed for the electrical connections to the system No electrical installations such as power sockets distribution boxes lights or light swi...

Page 38: ...hours for this type of design with an assumed usable temperature difference of 40 Kelvin One advantage of an accumulator is the low number of operating hours for the system and fewer start phases due to extended heating periods which leads to a reduction in the proportion of external energy and to lower wear of the mechanical components One further advantage of the accumulator is in summer operati...

Page 39: ...rvo drive running time 120 240 s and a circulation pump For the HDG M299 300 350 400 we recommend Wilo Stratos 50 1 12 3 way mixing valve DN 80 The hydraulic system must be installed in accordance with specific technical principles of the heating construction industry Take into account the stop cocks required for maintenance work and repairs The return temperature control must be installed accordi...

Page 40: ...stion unit 3 Connection DN 50 bushing of combustion unit to heat exchanger 4 Filling draining connection DN 25 inside thread for combustion unit 5 Connection DN 50 bushing of combustion unit to heat exchanger 6 Connection DN 50 bushing of heat exchanger to combustion unit 7 Boiler return connection DN 100 flange Figure 4 5 Water side connections for HDG M299 300 350 400 4 3 7 2 5 6 1 ...

Page 41: ...sensor DN 15 inside thread 5 Immersion sleeve connection for thermal safety device DN 15 inside thread of combustion unit 6 Safety heat exchanger connections DN 20 outside thread of combustion unit 7 Combustion chamber temperature sensor of combustion unit alternative 8 8 Combustion chamber temperature sensor of combustion unit alternative 7 9 Pressure capsule connection for vacuum pressure contro...

Page 42: ...n sleeve connection for supply temperature sensor and safety temperature limiter sensor DN 15 inside thread 3 Safety heat exchanger connections DN 20 outside thread on heat exchanger 4 Immersion sleeve connection for return temperature sensor DN 15 inside thread 5 Filling draining connection DN 25 inside thread for heat exchanger 6 Lambda sensor Figure 4 7 Sensors and connections on rear side of H...

Page 43: ... to combustion unit 4 Connection DN 50 bushing of combustion unit to heat exchanger 5 Connection DN 50 bushing of combustion unit to heat exchanger 6 Circulation pump Wilo 30 1 8 Direction of conveyance from heat exchanger to combustion unit 7 Connection DN 50 bushing of heat exchanger to combustion unit 8 Boiler return connection DN 100 flange 9 Circulation pump Wilo 50 1 12 Figure 4 8 Hydraulic ...

Page 44: ...ifting device able to lift at least 4 tonnes should be made available at the site 4 4 Installing the heating system REQUIREMENTS The heating system will initially be commissioned by specialists from HDG Bavaria or from an authorised HDG partner and a qualified electrician Danger Risk of material damage and injury due to incorrect installation Installing the system requires comprehensive specialist...

Page 45: ...plode No part of the system should be installed or operated in an area where there is a risk of an explosive atmosphere Important Make sure that the boiler is erected on an adequately dimensioned foundation Important Due to the noise we recommend acoustic insulation measures for components which are in contact with the floor or walls of the boiler room Important When laying the pipelines observe t...

Page 46: ...ice must be fitted If the room height is not sufficient for the assembly the height of the fall protection device must be adjusted Figure 4 9 Fall protection Warning Danger from suspended loads The individual modules of the boiler weigh more than 1000 kg If the modules are dropped during transport persons can be seriously injured and the boiler can be damaged Make sure that you use appropriate lif...

Page 47: ... to each other 3 Align the two units with plastic plates or flat steel strips not included in the scope of delivery so they are in a horizontal plane 4 Join the combustion unit 2 and heat exchanger 1 together on both sides at the intended points 3 using the M12 screws 19 mm spanner The boiler is erected Figure 4 10 Connecting modules 1 3 2 ...

Page 48: ...using the M12 hexagon socket screws 10 mm spanner 3 Mount the auger trough 1 of the ascending auger on the flange of the transfer station 4 with the M8 screws 13 mm spanner 4 Insert the downpipe 2 in the opening of the lid of the ash bin 3 The central ash removal system is now installed INSTALLING THE FEEDING SYSTEM HDG TBZ 200 Figure 4 11 Installing the central ash removal system 1 4 5 3 2 6 Figu...

Page 49: ...he rotary wheel 1 on the stoker pipe connection with the M12 screws 19 mm spanner The HDG feeding system TBZ 200 is installed HDG TBZ 150 1 Place the seal 13 on the insertion flange 15 2 Fasten the adapter piece 12 to the insertion flange 15 with the M12 nuts 19 mm spanner 3 Slide the adapter pipe 8 with the seal 9 into the feed channel 10 4 Align the seal 9 with the holes Warning Danger of injury...

Page 50: ... onto the feeding system 1 12 Fix the support leg 4 to the floor as required screws and screw anchors are not included in the scope of delivery 13 Align the feeding system 1 horizontally with the two M10 screws 3 14 Place the rubber seal on the connections of the pressure equalisation hose 14 15 Mount the pressure equalisation hose 14 with the aid of the union nut DN 32 on the connection 5 of the ...

Page 51: ...mm spanner 2 Mount the connection 1 for the flue gas pipe on the housing 2 of the flue gas fan using the M8 screws 13 mm spanner The housing of the flue gas fan is now installed Figure 4 14 Installing the housing of the flue gas fan 2 1 3 Warning Danger of injury The housing for the flue gas fan is very heavy Hands and feet could be crushed when installing it Only lift the housing using suitable l...

Page 52: ... depending on whether the HDG M299 300 350 400 heating system is equipped with TBZ 150 or TBZ 200 The procedure described is for installation with equipment version TBZ 200 Installation with equipment version TBZ 150 is specified explicitly where necessary The substructure of the cladding is inscribed with letters which are located on the upper end of the visible face for elements that are to be i...

Page 53: ...the boiler INSTALLING THE CLADDING SUPPORTS 4 Install the cladding supports A on each of the four corners with the M8 hexagon socket screws 6 mm spanner and M8 nuts 13 mm spanner with intermediate washers on the cladding brackets but do not tighten the screws Figure 4 16 Installing the cladding brackets fl_t fl_b left front Figure 4 17 Installing the cladding supports fl_t A ...

Page 54: ...6 mm spanner with intermediate washers on the cladding brackets but do not tighten the screws 6 Install corner support B on the fl corner with the M8 hexagon socket screws 6 mm spanner with intermediate washers on the cladding supports but do not tighten the screws Figure 4 18 Installing the corner supports C B Corner support B differs from corner support C due to the two pre assembled rivets ...

Page 55: ...he right end in the corner support and fasten it with the M6 hexagon socket screws 5 mm spanner and intermediate washer 10 Insert the two suspension rails G with the right ends in the corner supports and fasten them with the M6 hexagon socket screws 5 mm spanner and intermediate washer 11 Set the vertical rail H in the suspension rails 12 Insert suspension rail I with the right end in the corner s...

Page 56: ...port and fasten it with the M6 hexagon socket screws 5 mm spanner and intermediate washer 17 Insert the three suspension rails E with the right ends in the corner supports and fasten them with the M6 hexagon socket screws 5 mm spanner and intermediate washer 18 Insert suspension rail F with the right end in the corner support and fasten it with the M6 hexagon socket screws 5 mm spanner and interme...

Page 57: ...ail N and fasten it with the M6 hexagon socket screws 5 mm spanner and intermediate washer to the vertical rail N or the corner support 22 Insert suspension rail P with the right end in the vertical rail N and fasten it with the M6 hexagon socket screws 5 mm spanner and intermediate washer to the corner support or the vertical rail N 23 Set the vertical rail Q in the suspension rails 24 Set the ve...

Page 58: ...r 27 Insert suspension rail F with the right end in the corner support and fasten it with the M6 hexagon socket screws 5 mm spanner and intermediate washer 28 Insert suspension rail G with the right end in the corner support and fasten it with the M6 hexagon socket screws 5 mm spanner and intermediate washer 29 Insert suspension rail M with the right end in the corner support and fasten it with th...

Page 59: ... 35 Tighten the three M6 hexagon socket screws 5 mm spanner 36 Align the support rail 1 horizontally using the adjusting screw in the cladding bracket and a spirit level 37 Align the corner support 2 vertically with the aid of a spirit level 38 Tighten the three M6 hexagon socket screws 5 mm spanner 39 Proceed with the alignment of the suspension rails in the same manner as described above for the...

Page 60: ...g system 60 40 Insert the base cladding 1 7 in the suspension rails in the specified sequence Important The description in the following section applies only to systems with an HDG TBZ 200 Figure 4 23 Installing the base cladding TBZ 200 1 4 2 7 5 6 3 ...

Page 61: ...INGTHEBASECLADDING HDG TBZ 150 41 Insert the base cladding 1 7 in the suspension rails in the specified sequence Important The description in the following section applies only to systems with an HDG TBZ 150 Figure 4 24 Installing the base cladding TBZ 150 1 4 2 7 5 6 3 ...

Page 62: ...ions in the two middle suspension rails 1 on each side Figure 4 25 Installing the assembly plates 1 2 3 2 1 Individual steps for installing the assembly plates 2 Push the assembly plate through the recess from below 1 Turn the assembly plate 90 anticlockwise 2 Lift the assembly plate and push it to the left 3 Allow the assembly plate to latch in position ...

Page 63: ...dding P1 through P12 in the insertion plates Important The description in the following section applies only to systems with an HDG TBZ 200 Figure 4 26 Installing the side cladding TBZ 200 S S S S S S S S S S S S U T U S S S P2 S S P1 P11 P7 P6 P9 P8 P4 P5 P10 P12 Important Adhere to the specified sequence when installing the side cladding P1 P12 The sequence is indicated by the number ...

Page 64: ...ugh P12 in the insertion plates The cladding is installed Important The description in the following section applies only to systems with an HDG TBZ 150 Figure 4 27 Installing the side cladding TBZ 150 S S S S S S S S S S S S U T U S S S P2 S S P1 P11 P7 P6 P9 P8 P4 P5 P10 P12 Important Adhere to the specified sequence when installing the side cladding P1 P12 The sequence is indicated by the numbe...

Page 65: ...6 If the handles do not clamp adjust them as follows Grasp the clamp handles and seal the ash containers solidly on the ash removal door 5 Close the ash containers in the reverse sequence 6 Adjust the two support feet on the underside of the ash container to the appropriate height The ash containers are mounted and adjusted Figure 4 28 Installing ash containers 2 1 3 4 1 Remove the cover from the ...

Page 66: ...NNECTING THE CHIMNEY See section 4 2 Connections in this chapter 1 Connect the flue pipe to the chimney connection 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 GENERAL INFORMATION The description for planning instal...

Page 67: ...e found in the supplied documentation 4 8 Water The diaphragm expansion vessel must be constructed in accordance with DIN EN 13831 Closed expansion vessels with built in diaphragm for integration in water installations Before putting the system into operation the pressure of the diaphragm expansion vessel must be adjusted for the conditions in the heating system and in the building After putting t...

Page 68: ...ents have been met A flow pressure of at least two bar and a flow rate of 1800 l h must be available at the cold water inlet of the safety heat exchanger The distance between the supply and return lines of the thermal safety device and the safety heat exchanger should not be less than their nominal width The supply line may not be equipped with a shut off valve Water must be able to flow freely th...

Page 69: ...inlet DN 20 male 3 Safety heat exchanger outlet DN 20 male 4 Thermal safety device TAS 5 Runoff connection to drainage system Figure 4 30 Installing the thermal safety device 2 1 1 3 2 3 4 5 4 5 Figure 4 31 Thermal safety device pipework 1 The pipe work of the combustion unit s safety heat exchanger can be fed outside via hole 1 in the cladding at the side ...

Page 70: ...ttom Figure 4 32 Hydraulic system accumulator 1 HDWLQJ FLUFXLW GLVWULEXWRU 5 2 1 3 4 Figure 4 33 Hydraulic system accumulator 2 HDWLQJ FLUFXLW GLVWULEXWRU 3 4 5 1 2 These hydraulic systems are only suitable for use in the specified manner and for the intended purpose Any deviation from this usage could make adjustments necessary Consult with a trained specialist on issues relating to the hydraulic...

Page 71: ...aker of the mains supply to the heating system switched off CHECK THE MECHANICAL STRUCTURE OF THE FEEDING SYSTEM Does the mechanical structure meet the specifications of this operating manual CHECK THE HYDRAULIC CONNECTIONS Do the mechanical connections meet the specifications of this operating manual Has the safety equipment been installed to conform to the applicable standards and guidelines CHE...

Page 72: ...r and the control cabinet 5 2 Procedure SWITCHING ON THE HEATING SYSTEM 1 Turn the heating system main switch on The control is activated After a start up phase the display will first of all show a switch on message and then the standard display 2 Set the engage switch to 1 The display switches to Heating ON The heating system is now switched on SETTING THE DISPLAY LANGUAGE Different languages can...

Page 73: ... See chapter 6 Using the heating system section 6 9 MANUAL menu paragraph Central ash removal grate ash removal auger and grate drive HEAT EXCHANGER ASH REMOVAL AUGERS AND CLEANING SYSTEM This submenu is used to manually activate the heat exchanger ash removal auger and cleaning system See chapter 6 Using the heating system section 6 9 MANUAL menu paragraph Heat exchanger ash removal auger and cle...

Page 74: ...Material conveying auger and agitator MOVING FLOOR TRANSVERSE AUGER In this submenu the transverse auger can be activated manually in connection with the HDG walking floor feeding system TAK See chapter 6 Using the heating system section 6 9 MANUAL menu paragraph Moving floor transverse auger MOVING FLOOR HYDRAULIC SYSTEM In this submenu the drive of the walking floor can be activated manually in ...

Page 75: ...g plate of the delivery system 2 Fill the fuel storage See chapter 6 Using the heating system section 6 13 Filling the fuel storage The fuel storage is filled Figure 5 1 Filling the ash accumulation bin 1 The fuel storage may only be filled once the actuators have been tested Warning Damage to extraction system during filling If the heating system is not switched on during filling of the fuel stor...

Page 76: ...esult from for example the sit specific requirements or the heating fuel If the heating system is operated with wood pellets or chips the relevant parameters must be changed In all cases it is necessary to check the predefined parameters and if necessary change them accordingly before commissioning the system Danger Material damage and injury due to incorrect settings Adjusting these parameters re...

Page 77: ...ng system are switched off If the emergency stop switch is pulled out the Acknowledge fault button must first be pressed Only then will all moving parts of the heating system be switched back on and operational ADDITIONAL CONTROLS Engage switch switches the heating system on or off System operation indicator light lights up when the heating system is switched on Acknowledge fault button flashes wh...

Page 78: ... Bavaria GmbH 07 2008 CONTROL CABINET MODEL EMD C 215 EXCLUSIV 1 Lock mechanism of control cabinet 2 Main switch 3 Emergency stop 4 Acknowledge fault button with fault light 5 System operation indicator light 6 Engage switch 7 Control unit HDG Control Figure 6 1 Control cabinet model EMD C 215 Exclusiv 1 3 2 7 6 4 5 ...

Page 79: ...E button The control unit of the HDG Control is located in the front plate of the control cabinet Through the control unit you can adjust the HDG Control and obtain information on current processes DISPLAY The display shows the selected information and parameters BUTTONS The heating system can be operated using the buttons Figure 6 2 Control unit for HDG Control POmH POJUPS J 1 3 4 5 6 7 8 10 11 1...

Page 80: ...n END is always visible Press the F6 button to exit any submenu and return to the standard display Keys of the numerical keypad The keys of the numerical keypad are used to enter settings and times Enter or Input key Confirms the changed value One step forwards Configuration button If the HDG Control is traded the configuration key is used to confirm adoption of the previous hours of operation 6 2...

Page 81: ...heating system to burn out until the combustion air fan switches off 3 Turn the heating system main switch off No operating mode is displayed on the control unit of the HDG Control The heating system has been de energised 6 4 Operating statuses The heating system goes through the following states during operation Warning Frost danger Only switch off the heating system completely if you are certain...

Page 82: ...rolled Operation of the heating system in Fixed value mode Burn out The preset boiler temperature has been reached The boiler has been switched off This operating status is maintained until the preset burn out time has elapsed Temperature reached The current boiler temperature is higher than the preset boiler temperature No demand on accumulator The boiler temperature is higher than the set temper...

Page 83: ...boiler temperature and the time Material stop The level indicator in the combustion chamber has signalled There is too much material in the combustion chamber The heating system waits until the level indicator enables filling again Combustion chamber temperature stop The maximum permitted temperature in the combustion chamber has been exceeded The heating system waits until the combustion chamber ...

Page 84: ...programme Programme file M300_TVV Programme date 16 04 2012 Programme update Language selection 1 13 Language 1 German FIELD CHOOSE END By pressing the F6 key under the END command you can exit the Language selection menu window without changing the setting The following pages show all practically available menu windows In actuality only those menu windows are available to the operator which are r...

Page 85: ...h a double heating system both boilers store energy in the accumulator If the base load boiler cannot charge the accumulator by itself the peak load boiler switches on for support This menu allows you to configure which heating system will be the base load boiler and the which will be the peak load boiler in a double heating system A changeover is required once a certain number of operating hours ...

Page 86: ...IMES In this menu you can view and set the operating times of the heating system There are two switch on and switch off cycles available per weekday BOILER OPERATING TIMES See Procedure in this section 1 In the Show switch on off time 1 01 submenu press the F4 key under the EDITcommand in the display The display switches to the Enter switch on off time 1 11 submenu The day of the week and the firs...

Page 87: ...m can be operated in different control modes These are Fixed value In this version the combustion is not optimised and there is no output regulation The combustion air supply and fuel quantity is fixedly set and remains unchanged Combustion control This version optimises the combustion The primary and secondary air supplies and the fuel quantity are adapted automatically within a specified range o...

Page 88: ...a simultaneous external demand On In this version the heating system is switched on and off through the boiler supply temperature sensor The accumulator temperature sensors are ignored Thermostat In this version the heating system is switched off through the boiler supply temperature sensor and switched on through the accumulator thermostat External In this version the heating system is switched o...

Page 89: ... On this setting the flue gas fan works at a set speed according to the existing vacuum pressure conditions Not controlled On this setting the flue gas fan works at a constant preset value See Procedure in this section ADJUSTING THE ASH REMOVAL SETTING The movement of the stepped grate and the ash removal system can be switched off See Procedure in this section Setting 1 03 Flue gas fan controlled...

Page 90: ...e delivery system can be employed for extraction in combination with an additional conveyor auger Extraction can be controlled in various ways Cycles In this version the extraction runs in a cycle with configurable pause intervals and runtimes For setting options see the section 6 8 TIME menu in this chapter Continuous running In this version the extraction runs continuously upon demand See Proced...

Page 91: ...both scraper blades of the walking floor are alternately controlled MANUAL In this version the walking floor scrapers can be controlled by hand The manual control function in the Manualmenu is enabled See Procedure in this section 6 7 C QUANTITY menu In this menu you can view and set temperatures combustion air quantity fuel type quantity and control parameters All target values can be modified Th...

Page 92: ...n and off of the boiler can be changed by adapting the temperature Temp acc top below If this temperature set for the top accumulator sensor is not met the boiler switches back on Temp acc bottom above If the temperature set for the bottom accumulator sensor is exceeded the boiler switches off See Procedure in this section Temperature adjustment using the accumulator sensors is only available if t...

Page 93: ...f See Procedure in this section SETTING THE BOILER AND RETURN TEMPERATURE This submenu is used to set the boiler and return temperature The furnace temperature in the combustion unit is also set This switches the intermediate pump between the combustion unit and heat exchanger See Procedure in this section This is an optional submenu and only available with double heating systems if necessary also...

Page 94: ...er temperature 2 in the heat exchanger or view the flue gas temperature See Procedure in this section SELECTING A FUEL TYPE In this submenu you can choose from four different heating material settings The varying quality of the heating material can also be taken into account All parameters can be newly defined and reset for each type of material The current return temperature can also be read here...

Page 95: ...sually Fuel 1 Independent modification of settings for adapting to the fuel should be made under another fuel type so as not to change the startup settings For example save the start up setting under Fuel 2 and only then modify this setting Settings fixed value 2 06 Fuel 60 0 55 0 Primary air 30 30 Secondary air 30 15 Comb chamb temp 600 411 C END In this menu the settings of the fuel and air quan...

Page 96: ... control and the following paragraphs in this chapter 6 8 TIME menu In this menu you can view and set all time parameters relating to ignition de ashing cleaning and delivery systems All target values can be modified The actual values displayed indicate the current status PROCEDURE 1 Press the F3 key under the standard display screen You are in the Time menu 2 Scroll with the F1 or F2 key to the p...

Page 97: ...ime for the initial filling with fuel and the running time of the ignition fan You can also set the time after which the combustion fan is added during the igniting phase See Procedure in this section SETTING PRE AIR HEATING UP AND BURNING OUT This submenu enables you to set the pre ventilation time for fanning the fuel without material feeding the heating up time during which the fuel quantity is...

Page 98: ...s section Pre ventilation 30 0 s Heating up 10 0 0 0 m Burning out 60 0 0 0 m END Time 3 03 Grate runtime cycles 1 0 i Cleaning system pause time 3 0 0 0 m Grate runtime cycles long 2 0 i Grate pause time long 9 0 0 0 m END When changing the heating material the burn out behaviour must be checked on the grate of the boiler If necessary adjust the Grate pause time parameter In general only this par...

Page 99: ...the main cleaning Cleaning and ash removal are activated at the preset time See Procedure in this section Time 3 05 Ash auger exch Runtime 60 0 s Ash auger exch Pause time 60 0 0 0 m Cleaning system pause time 12 0 0 0 h Cleaning system runtime 140 0 s END When changing the heating material the burn out behaviour of the boiler must be checked in the area of the heat exchanger surfaces If necessary...

Page 100: ...and running time for delivery See Procedure in this section SETTING THE AGITATOR In this submenu you can enter the settings for the lag time of the agitator in connection with a walking floor delivery system See Procedure in this section Time 3 11 Filling delay Stoker auger 3 0 s END This is an optional submenu and only available with feeding system TBZ 150 Time 3 13 Delivery system runtime 2 0 0 ...

Page 101: ...ess the F2 key under the display and scroll to the Time 3 20 submenu The Day parameter is shown in black 3 Change the setting with the numerical keypad 4 Press the Enter button This parameter is an optional submenu and only available with walking floor delivery systems Walking floor 3 15 Walking floor runtime 10 0 0 0 s Walking floor pause time 10 0 0 0 s Walking floor delay time 10 0 0 0 s Walkin...

Page 102: ...ally test all actuators such as drive motors fans and electrical mounted parts PROCEDURE 1 Press the F4 key under the display of the standard display screen You are in the MANUAL menu 2 Scroll with the F1 or F2 key to the previous or next submenu 3 Use the F3 key under the FIELD command in the respective submenu to select the desired parameter 4 Press the F4 or F5 key to test the actuators in manu...

Page 103: ...gers and grate drive See Procedure in this section HEAT EXCHANGER ASH REMOVAL AUGER AND CLEANING SYSTEM This submenu is used to manually activate the heat exchanger ash removal auger and cleaning system See Procedure in this section RETURN PUMP RETURN MIXER AND INTERMEDIATE PUMP This submenu is used to manually activate the return pump and return mixing valve Manual mode 4 02 Primary_1 100 Seconda...

Page 104: ...ystem auger trough 2 and dosage See Procedure in this section Manual mode 4 05 Return pump Return mix v OPENED Return mix v CLOSED Intermediate pump FIELD On Off END The following actuators are only available when using the HDG feeding system TBZ 200 Manual mode 4 06 Stoker auger Rotary feeder Fuel convey auger FIELD FOR WARD BACK END Danger Material damage and injury due to incorrect operation Ac...

Page 105: ...Material damage and injury due to incorrect operation Activation of the BACK parameter is only possible during feeding and may only be used for short intervals of no more than 3 seconds The following actuators are only available when using a distributing container Manual mode 4 08 Mat convey auger Agitator FIELD FOR WARD BACK END Danger Material damage and injury due to incorrect operation Activat...

Page 106: ...rd display screen You are in the SERVICE menu The display switches to the Service 5 01 submenu in which the signal states of the digital inputs and outputs are shown Manual mode 4 08 Transverse auger FIELD On END The following actuators are only available when using the HDG walking floor feeding system Manual mode 4 09 Hydraulic walking floor Cylinder1 walking floor Cylinder2 walking floor FIELD O...

Page 107: ...using the numerical keypad 6 Confirm each change with the Enter key The desired parameter is set 7 Scroll with the Up or Down key to the next parameter The next resettable parameter is shown in black 8 Repeat steps 5 to 7 for additional parameters 9 Press the F6 key under the END command to exit the submenu The standard display is restored CHIMNEY SWEEP TEST Digital inputs 0 15 00000000 00000000 D...

Page 108: ...p test 5 11 submenu 3 Press the F3 or F4 key to start the chimney sweep test The chimney sweep test is carried out OPERATING HOURS COUNTER Various operating hours are displayed Pressing the RESET key for more than 3 seconds resets all operating hours 1 Open the Service 5 02 submenu See Procedure in this section 2 Using the F1 key select service hour counter 11 01in the submenu Chimney sweep mode 5...

Page 109: ...he 0 setting deactivates this function WA Lubricate stoker auger When the preset runtime of the stoker auger is exceeded the warning Please lubricate the screw stoker bearing appears The heating system does not shut off at the appearance of this warning The 0 setting deactivates this function 1 Open the Service 5 02 submenu See Procedure in this section 2 Using the F1 key select service messages 1...

Page 110: ...the times SERVICE MESSAGES 3 SETTING REMINDER TIME Filling WA_1 fuel storage room When the preset runtime of the ash removal auger is exceeded the warning Please fill fuel storage room soon appears The heating system does not shut off at the appearance of this warning The 0 setting deactivates this function Filling WA_2 fuel storage room When the preset runtime of the ash removal auger is exceeded...

Page 111: ...mperature When the set boiler temperature is exceeded by this set value the boiler shuts off Boiler temperature hysteresis The boiler temperature hysteresis is used to set a temperature difference between the temperature at which the heating system is switched on and the temperature at which it is switched off only for Boiler activation on Minimum return temperature Set the minimum return temperat...

Page 112: ...rse moving attempts Setting the maximum number of reverse moving attempts Ignition temperature If the temperature in the hot combustion chamber exceeds this value the HDG Control does not switch on the ignition fan for starting the heating system See Procedure in this section MODIFYING THE DOSAGE PAUSE MIN OR IMPULSE MIN AND FEEDING UNITS LAG TIME OR LEAD TIME PARAMETERS Dosage pause min and dosag...

Page 113: ...ING AND AIR START SETTING Fuel quantity 1st filling Change the fuel quantity of the first filling in heating up mode Air start setting These parameters determine the air quantity of the primary air and secondary air for heating up mode See Procedure in this section IGNITION FAN You can set the phase and form in which the ignition fan is switched on to aid the start up procedure Three settings are ...

Page 114: ...cuum fan rotational speed uncontrolled The constant rotational speed for an uncontrolled flue gas fan can be set See Procedure in this section CALIBRATING THE LAMBDA SENSOR Ignition fan 5 08 1st filling Off Pre ventilation Off Heating up Off END Vacuum pressure control settings 5 09 Negative pressure limit 350 400 pa Positive pressure limit 0 400 pa Delay press control grate 5 0 0 0 m Vacuum fan s...

Page 115: ...e secondary air supply opens If the voltage of 7 0 mV is reached after 15 minutes the lambda sensor test has been successfully completed The testing of the lambda sensor is completed 5 Press the F6 key under the END command to exit the Service 5 07 submenu The standard display is restored CHIMNEY SWEEP TEST Enabling boiler temperature After this set boiler temperature is exceeded the chimney sweep...

Page 116: ...ature If the set value for the temperature increase is not reached within the specified delay time the peak load boiler is automatically activated See Procedure in this section FLUE GAS TEMPERATURE Cleaning system start When this set temperature is exceeded the cleaning system starts up Max flue gas temperature Chimney sweep mode 5 12 Enable boiler temperature 70 60 C Enable comb chamb temp 550 32...

Page 117: ...c parameter can only be set and modified by authorised HDG technicians See Procedure in this section SETTING INTERFACE RS485 Interface RS485 Setting options without interface Modbus RTU web server Modbus RTU DDC Profibus DP DDC See Procedure in this section SETTING MODBUS RTU WEB SERVER The address of the controller can be set here especially with multiple systems Flue gas temperature 5 14 Cleanin...

Page 118: ...in PLC parameters in a Modbus network See Procedure in this section SETTING PROFIBUS DP DDC Profibus address Setting the PLC address for a Profibus network Profibus rights Setting the minimum required rights or enabling only certain PLC parameters in a Profibus network See Procedure in this section Setting Modbus RTU Webserver 10 02 Modbus address Address 1 FIELD END Setting Modbus RTU DDC 10 03 M...

Page 119: ...ll to the Service 5 02 submenu See Procedure in this section 2 Simultaneously press the keys F3 F4 and F5 under the display 3 Press the F2 button and scroll to the Service 5 20 submenu The Operat hours parameter is shown in black and the hours of operation can be read 4 Press the F4 and F5 keys to adopt the factory settings The factory settings are adopted 5 Press the F6 key under the END command ...

Page 120: ...submenu See Procedure in this section 2 Press the F5 key under the Control command The display changes to the Output control 6 01 submenu 1 In the Output control 6 01 submenu press the F3 key under the Ccommand in the display The display changes to the Preset value output control 6 11 submenu 2 In the Preset value output control 6 11 submenu press the F3 key under the FIELDcommand in the display 3...

Page 121: ...in this section The fuel settings apply for Combustion control as well as Combustion and output control See section 6 6 ON OFF menu under Setting the control boiler activation and Lambda Stop Material controller 6 02 Max 50 0 Output_Set 100 0 Min 10 0 Material_Set 50 0 END The difference between fuel quantity MAX and MIN should be specified as a range approx 25 adapting to the required value The p...

Page 122: ...n should be specified as a range adapting to the required value approx 25 The primary air settings apply for Combustion control as well as Combustion and output control See section 6 6 ON OFF menu under Setting the control boiler activation and Lambda Stop Preset value primary air flaps 6 05 P1_Partial load 40 P2_Partial load 0 P1_Level 1 100 P2_Level 1 20 P1_Level 2 100 P2_Level 2 35 P1_Full load...

Page 123: ...2_Max and O2_Min is 7 0 The secondary air setting applies for Combustion control as well as Combustion and output control See section 6 6 ON OFF menu under Setting the control boiler activation and Lambda Stop Secondary air fan 6 07 Max 70 SET 7 0 KP 65 0 Min 15 ACT 12 8 TN 50 0 ACT 15 MIN 5 0 TV 0 0 END The standard setting for the secondary air is 70 for Max and 15 for Min If this O2 minimum val...

Page 124: ...ad 12 S2_Partial load 0 S1_Level 1 50 S2_Level 1 100 S1_Level 2 100 S2_Level 2 100 S1_Full load 100 S2_Full load 100 END The fuel quantity O2 settings apply for Combustion control as well as Combustion and output control See section 6 6 ON OFF menu under Setting the control boiler activation and Lambda Stop Fuel quant modification by O2 R 3 6 09 Delta_FUE_MIN 10 FUEL_SET 50 0 Delta_FUE_MAX 10 Fuel...

Page 125: ...o the Errors pending submenu 2 In the display press the F1 key under the plus sign or F2 under the minus sign to scroll forward or backward through the error messages 3 Press the F4 or F3 key to switch between the most recent fault and the archived faults 4 In the fault archive press the F5 key under the RESET command to delete the fault 5 Press the F6 key under the END command to exit the Fault i...

Page 126: ...aintenance work is completed the function must be deactivated The boiler switches back to the previous mode 1 Press the F5 key under the standard display screen You are in the Service menu The display changes to the Service 5 01 submenu 2 Press the F3 key under the Maintenance command The display changes to the Function 1 10 submenu 3 Press the F4 key under the On command The message Waiting for e...

Page 127: ...l storage REQUIREMENTS The following requirements must be met before the fuel storage can be filled The fuel storage has been initially approved by an authorised specialist The fuel storage is dry and free of any foreign bodies Large dust deposits must be removed with pellet fuel The requirements of government safety organisations must be met PROCEDURE FOR FILLING WITH WOOD CHIPS 1 Turn the heatin...

Page 128: ...engineer to ensure that federal pollution limits are met ordinance regarding smaller and medium sized boiler systems 1 BImSchV INITIAL TEST The operating company must notify the responsible combustion engineer of the installation of the heating system before it is commissioned and must also arrange an appointment for the chimney sweep test within four weeks of commissioning To ensure a stable oper...

Page 129: ...der the standard display screen You are in the Service menu The display changes to the Service 5 01 submenu Warning Material damage and injury due to incorrect chimney sweep test The chimney sweep test requires comprehensive technical knowledge Only permit authorised specialists to perform the chimney sweep test At the start of the measurement the boiler temperature should not exceed 75 C If there...

Page 130: ...ing up message appears in the display Once the specified temperatures have been reached the display shows the Measurement enabled message The measurement is carried out Chimney sweep mode 5 11 Heating OFF Enable boiler temperature 75 0 C Enable comb chamb temp 450 0 C Measurement duration 75 0 m 30 100 END When operating the heating system without an accumulator the chimney sweep test can also be ...

Page 131: ...e power used by the heating system more frequent on off operation the intervals may vary Interval Component See page after approx 150 and 1000 operating hours respectively Lubricating the feeding system 136 after approx 500 operating hours Cleaning the stepping grate Cleaning the combustion chamber Check and empty the ash container 137 138 140 after approx 2000 operating hours Cleaning the cleanin...

Page 132: ...diant heat during cleaning and maintenance work After the cleaning and maintenance work is completed the function must be deactivated The boiler switches back to the previous mode 1 Press the F5 key under the standard display screen You are in the Service menu The display changes to the Service 5 01 submenu 2 Press the F3 key under the Maintenance command The display changes to the Function 1 10 s...

Page 133: ... the command End The standard display is restored GENERALLY APPLICABLE SAFETY INSTRUCTIONS Function 5 22 Maintenance On Maintenance enabled FIELD On Off END Warning Danger of asphyxiation due to carbon monoxide If the boiler is in operation carbon monoxide can be emitted through opened doors lids or other cleaning openings When performing cleaning and maintenance work do not leave the cleaning ope...

Page 134: ...y driven components If the heating system is switched on automatically driven components can unexpectedly start running Limbs or fingers could become caught and crushed Turn off the main switch when performing any work on automatically driven components and secure it against being turned back on Important When applying lubricants oils and grease observe the specifications of the respective manufac...

Page 135: ...cleaning and maintenance tasks parts of the boiler cladding must be removed 1 Insert a screwdriver 4 in the recess on the underside of the cladding section 2 Pry the mounting plate 2 upward with the screwdriver 4 3 Unhook the cladding section 1 4 Proceed in the same manner with the other cladding sections The cladding is removed Figure 7 2 Removing the cladding 2 3 1 ...

Page 136: ...his section 1 Place the grease gun on the lubricating nipple 1 2 Press three strokes of grease into the feeding system The HDG feeding system TBZ 150 is lubricated Figure 7 3 Lubricating the feeding system TBZ 150 1 1 Place the grease gun on the three lubricating nipples 1 2 3 2 Press three strokes of grease each into the feeding system Figure 7 4 Lubricating the feeding system TBZ 200 2 3 1 3 Pla...

Page 137: ...the heating system to burn out and cool down 3 Remove the three cladding sections 1 See Removing the cladding in this section Important Observe the Generally applicable safety instructions in this section Caution Danger of fire from combustion residues Hot combustion residues can lead to a fire Allow the ash to cool and place it only in a suitable fireproof container Figure 7 6 Removing the claddi...

Page 138: ... tools or with a vacuum cleaner 10 Check the grate ash removal auger for wear 11 Close the boiler in the reverse order 12 Deactivate the maintenance function See section Maintenance function in this chapter The cleaning of the stepping grate is completed CLEANING THE COMBUSTION CHAMBER 1 Activate the maintenance function See section Maintenance function in this chapter 2 Allow the fire in the heat...

Page 139: ...mm spanner and open the combus tion chamber door 3 6 Remove the insulation block 4 7 Clean the combustion chamber area 1 2 with the supplied cleaning tools or with a vacuum cleaner 8 Check the fly ash removal auger for wear 9 Close the boiler in the reverse order 10 Deactivate the maintenance function See section Maintenance function in this chapter The cleaning of the combustion chamber is comple...

Page 140: ... ash to cool and place it only in a suitable fireproof container Caution Backfiring or smoke can cause injuries or material damage If the transfer station is not at least half filled when commissioning or re starting after a cleaning there is a danger of backfiring or smoke from the boiler This can cause damage to the heating system or injury to persons Make sure that the transfer station is at le...

Page 141: ...iner 8 Reattach the ash bin 3 to the heating system by reversing these steps 9 Deactivate the maintenance function See section Maintenance function in this chapter The emptying of the ash bin is completed FLY ASH CONTAINER 1 Activate the maintenance function See section Maintenance function in this chapter 2 Allow the fire in the heating system to burn out and cool down Figure 7 9 Checking and emp...

Page 142: ...hannel 5 of the ash removal system 8 Empty the ash into a fireproof container 9 Reinsert the ash container 2 in the heating system in the reverse order 10 Deactivate the maintenance function See section Maintenance function in this chapter The ash containers have been emptied CLEANING THE CLEANING SHAFT Figure 7 10 Checking and emptying the fly ash container 1 5 2 4 3 Important Observe the General...

Page 143: ...fire in the heating system to burn out and cool down 3 Release the two M16 screws 2 24 mm spanner 4 Fold open the cleaning shaft lid 1 towards the back Important When working on the boiler the fall protection device must be fitted If the room height is not sufficient for the assembly the height of the fall protection device must be adjusted Figure 7 11 Fall protection Figure 7 12 Cleaning the clea...

Page 144: ... chapter The cleaning of the cleaning shaft is completed CLEANING THE VACUUM PRESSURE PIPE FOR THE PRESSURE SWITCHES 1 Activate the maintenance function See section Maintenance function in this chapter 2 Allow the fire in the heating system to burn out and cool down 3 Remove the upper cladding 1 by lifting it upward 4 Detach the hose from the vacuum pressure pipe 2 5 Inspect the vacuum pressure pi...

Page 145: ...ow the fire in the heating system to burn out and cool down 3 Take the cladding 2 off toward the front 4 Detach the hose from the vacuum pressure pipe 1 5 Inspect the vacuum pressure pipe 1 for dirt and dislodge it if nec essary with a wire or a compressor 6 Attach the hose to the vacuum pressure pipe 1 7 Mount the cladding 2 in the reverse sequence 8 Deactivate the maintenance function See sectio...

Page 146: ... CHAINS 1 Activate the maintenance function See section Maintenance function in this chapter Figure 7 15 Control unit for HDG Control POmH POJUPS J Important Observe the Generally applicable safety instructions in this section Warning Risk of injury from automatically driven components If the heating system is switched on the gears and drive chains may start unexpectedly Body parts could be crushe...

Page 147: ...chain has more play it must be tightened 5 Loosen the locking screw on the chain tensioner 2 The chain tensioner can be moved 6 Move the chain tensioner 2 downwards until the drive chain again has sufficient tension 7 Secure the chain tensioner 2 in this position The drive chain is tightened 8 Mount the cladding on the boiler in the reverse sequence 9 Deactivate the maintenance function See sectio...

Page 148: ... the chain tensioner 4 The chain tensioner can be moved 6 Move the chain tensioner 4 to the side until the drive chain has sufficient tension again 7 Secure the chain tensioner 4 in this position The drive chain is tightened 8 Replace the cover 3 on the feeding system 9 Deactivate the maintenance function See section Maintenance function in this chapter The check of the drive chain of the feeding ...

Page 149: ...air nozzle 5 5 Pull off the hot air nozzle 5 6 Remove the insulating tube 6 and the seal 3 7 Pull the heating element 2 out of the plug contacts 7 Important Observe the Generally applicable safety instructions in this section Caution Danger of burns from hot surfaces The hot air nozzle of the ignition fan becomes very hot during operation Even when turned off it cools down very slowly Switch the h...

Page 150: ...ing system in the reverse se quence 13 Deactivate the maintenance function See section Maintenance function in this chapter The inspection and cleaning of the ignition fan system is completed CLEANING AND CALIBRATING THE LAMBDA SENSOR 1 Activate the maintenance function See section Maintenance function in this chapter 2 Allow the fire in the heating system to burn out and cool down Important Obser...

Page 151: ...t the upper cladding 1 12 Deactivate the maintenance function See section Maintenance function in this chapter 13 Calibrate the lambda sensor See chapter 6 10 SERVICE menu section Flue gas temperature The lambda sensor is cleaned and calibrated CLEANING THE FLUE GAS TEMPERATURE SENSOR 1 Activate the maintenance function See section Maintenance function in this chapter Important Steel bristles will...

Page 152: ... with a moist cloth 6 Reinstall the flue gas temperature sensor 2 in the reverse se quence 7 Mount the upper cladding 1 8 Deactivate the maintenance function See section Maintenance function in this chapter The cleaning of the flue gas temperature sensor is completed CLEANING THE FLUE GAS PIPE 1 Activate the maintenance function See section Maintenance function in this chapter 2 Allow the fire in ...

Page 153: ...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 work when the surfaces have cooled down 3 Unscrew the wing nut 1 on the inspection hatch cover 2 4 Remove the inspection hatch cover 2 from the flue pipe 3 5 Check whether the flue gas pipe 3 needs cleaning 6 If...

Page 154: ...enance function See section Maintenance function in this chapter The pressure equalisation hose is cleaned CLEANING FLY ASH SECTION 1 Activate the maintenance function See section Maintenance function in this chapter 2 Allow the fire in the heating system to burn out and cool down 3 Do this by lifting up the clamp handle 4 and releasing the stop on the ash container 5 3 Unscrew the DN 40 union nut...

Page 155: ...4 Inspect the fuel storage for the burning of unsuitable residues or foreign bodies and remove these if necessary 5 Close the access hatch 6 Deactivate the maintenance function See section Maintenance function in this chapter The inspection of the fuel storage is completed Important Observe the Generally applicable safety instructions in this section Caution Risk of injury from automatically drive...

Page 156: ...again after waiting a few seconds The fault message is no longer shown in the display The fault is fixed 8 2 Possible faults Possible fault and warning messages are divided into three categories ES Emergency stop The boiler switches off FA Fault The boiler switches to the burn out phase and then switches off WA Warning The boiler continues to run No Fault Cause Remedy ES001 Emergency stop Emergenc...

Page 157: ...emperature Low on water Overfilling triggered Fuel storage door end switch is disconnected Check relay in control cabinet Check for excessive temperature Check for insufficient water Check for overfilling Check fuel storage door end switch FA036 Analogue module failed Analogue module faulty Analogue module without power Bus cable disconnected or not connected properly Check the analogue module and...

Page 158: ...bustion chamber temperature sensor is faulty Line to combustion chamber temperature sensor faulty No material available Check ignition fan Check the electrical connection Check combustion chamber temperature sensor Check fuel storage FA052 Water pressure out of range Water pressure outside of the set range Check pressure switch min max FA053 Low on water Too little water in cycle Relay in control ...

Page 159: ...e faulty Material blockage Close overfilling cover Check limit switch Check the electrical connection Eliminate material blockage FA066 Dosage overfilling The overfilling cover was opened Faulty limit switch Connection cable faulty Material blockage Close overfilling cover Check limit switch Check the electrical connection Eliminate material blockage FA067 Overfilling Delivery system The overfilli...

Page 160: ...level indicator ST075 Foreign bodies in rotary feeder 2 Foreign bodies in feed system or stoker auger Transformer in control cabinet faulty Motor is faulty Check for foreign bodies Moving forwards and backwards in the manual menu Check transformer in control cabinet Check the motor FA077 Pellet auger overfilling The overfilling cover was opened Faulty limit switch Connection cable faulty Material ...

Page 161: ...top switch of the walking floor was pressed Cable faulty Unlock emergency stop button Check the cable FA084 Walking floor lateral auger overfilling The overfilling flap was opened Faulty limit switch Connection cable faulty Material blockage Close the overfilling flap Check switch Check the electrical connection Eliminate material blockage FA085 Walking floor motor protection triggered Motor incor...

Page 162: ... Return pump faulty Relay in control cabinet faulty Return pump faulty Control unit 0 10V faulty Check the relay Check return pump Check control unit ST098 Container 1 2 empty Faulty limit switch Removable container empty Check limit switch Fill removable container WA193 Boiler temperature sensor faulty Supply sensor faulty Line faulty Analogue module faulty Check supply temperature sensor Check t...

Page 163: ...ture sensor is faulty Line faulty Analogue module faulty Check combustion chamber temperature sensor Check the electrical connection Replace analogue module WA203 Flue gas sensor faulty Flue gas temperature sensor faulty Line from flue gas temperature sensor faulty Check the flue gas temperature sensor line and replace if necessary WA205 Accumulator top middle temperature sensor faulty Accumulator...

Page 164: ... converter blocked Faulty reference limit switch Fuse triggered Motor incorrectly connected Motor overload Motor is faulty Motor cable faulty Check tube converter Check reference limit switch Check fuse Check the motor connection Check the drive Check the motor Check the motor cable WA216 Runtime vacuum junction clockwise Tube converter blocked Faulty reference limit switch Fuse triggered Motor in...

Page 165: ...time for emptying fly ash container exceeded Empty fly ash container Reset time in the parameter 11 04 with RESET WA241 Container 1 not in position Faulty limit switch Removable container not in position Check limit switch Check position of removable container WA242 Container 1 empty Faulty limit switch Removable container empty Check limit switch Fill removable container WA243 Container 2 not in ...

Page 166: ...combustion air fan switches off 3 Turn the heating system main switch off The system has been de energised 4 Switch the circuit breaker for the heating system off 5 Disconnect the boiler 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 t...

Page 167: ...reglass mineral wool and plastic 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 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 dism...

Page 168: ...n the operating manual The installation of the heating system and the hydraulic components 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 A HDG delivery system must be used 1...

Page 169: ...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 compatibility and repealing Directive 89 336 EEC In accordance with section 2 of article 7 the applied harmonized regulations are to be found under EN 60335 1 2002 Household and similar electrical ap...

Page 170: ...ng 52 Installing the control cabinet 66 Lubricating the feeding system 136 Removing the cladding 135 Setting the return temperature 93 Switching off the heating system 81 Switching on the heating system 80 Symbols System operation indicator light 77 78 C QUANTITY menu 91 A Accumulator 38 Acknowledge fault button 77 78 Actuator 10 73 Air inlet cross section 24 Antifreeze agents 38 Ash bin 17 Ash co...

Page 171: ... dimensions 23 Primary air fan 17 Proper and improper operation 11 R Residual risks 12 Return temperature control 38 Return temperature sensor 42 Return temperature minimum 23 Room height 32 Room sizes and minimum clearances 31 32 Rotary feeder 10 S Safety devices 38 Safety heat exchanger 19 68 connection 23 41 42 Scope of delivery 44 Secondary air fan 17 Selecting a fuel type 96 Sensor 10 SERVICE...

Page 172: ...172 HDG M299 300 350 400 Version 1 de HDG Bavaria GmbH Juli 2005 NOTICE ...

Page 173: ...173 NOTICE ...

Page 174: ...174 HDG M299 300 350 400 Version 1 de HDG Bavaria GmbH Juli 2005 NOTICE ...

Page 175: ......

Page 176: ...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 9980001542 V 03 en 03 2014 Translation of the original operating instructions ...

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HDG M299, Operation Manual

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