HDG Turbotec 50 L Page 13 Operation Manual Download

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2 Safety instructions – Warnings and safety symbols used

2.3 Warnings and safety symbols used

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

Caution!

Hand injuries can occur!

Working on the flue gas fan or the flue bypass damper can lead to
hand injuries caused by moving parts.

Disconnect the boiler from the power mains when working on the
flue gas fan.

Danger!

Danger from electrical current or voltage!

Work on the plug boards may only be carried out by a qualified
electrician.

Make the system is disconnected from the mains and secured
against re-activation during this work.

Danger!

Danger from 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.

Caution!

Hand injuries can occur!

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

Caution!

Hot surfaces!

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

Caution!

Danger of fire!

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

Summary of Contents for Turbotec 50 L

Page 1: ...hdg bavaria com HDG Turbotec with HDG Lambda Control 1 Operation Manual ...

Page 2: ......

Page 3: ...h HDG Lambda Control 1 16 Back side HDG Turbotec 17 3 2 Functional description 18 Boiler HDG Turbotec 18 HDG Lambda Control 1 19 3 3 Technical data 20 3 4 Fuel quality requirements 21 Permissible fuel 21 Recommended fuel 21 3 5 Declaration of conformity 22 4 Planning and installation 23 4 1 Dimensions 23 4 2 Structural requirements 24 Installation room 24 Necessary room sizes and minimum spacing 2...

Page 4: ...ing the control 52 Setting the target boiler temperature 55 Testing system components 56 Adjustment of parameters depending on fuel 57 Heating up the heating system 58 6 Using the heating system 59 6 1 Overview of the controls and display components 59 6 2 Switching the heating system on 61 Requirements 61 Emergency heating switch 61 6 3 Structure of the menus 62 Heat production off menu structure...

Page 5: ...83 Cleaning the flue sensor 83 Checking and cleaning the flue gas fan 84 Lubricating the door latch bolts 85 Checking and cleaning the flue bypass damper 86 Cleaning the control unit 87 Inspecting and cleaning the air control units 87 Inspecting the integrity of the door seals 89 Calibrating the lambda sensor 89 8 Troubleshooting 91 8 1 Procedure 91 8 2 Possible faults 91 Faults which do not inter...

Page 6: ...6 ...

Page 7: ...uously develop and improve our boilers The information in this version was correct at the time of going to press We reserve the right to make changes which may then deviate from the technical details and illustrations in this Operation Manual COPYRIGHT Written agreement is required from HDG Bavaria GmbH for any reprints storage in a data processing system or transmission by electronic mechanical p...

Page 8: ...plan for and install the heating system 5 Commissioning the system how the heating system is to be put into initial service 6 Using the heating system how to properly operate the heating system 7 Cleaning and maintaining the heating system how to clean the heating system and who is responsible for its maintenance 8 Troubleshooting how to rectify faults in the heating system 9 Notes on dismantling ...

Page 9: ...orm of an LED on the Lambda Control panel which serves as a prompt to reload the fuel chamber Reload button Button that must be pressed before the boiler is opened for reloading or heating up Flue gas fan Creates a vacuum inside the boiler and provides the boiler with air for combustion Safety temperature limiter Safety device which switches off the boiler when it exceeds its maximum temperature a...

Page 10: ...10 ...

Page 11: ...er HDG Turbotec with HDG Lambda Control 1 Any further implementation of applicable standards and guidelines 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 APPLICATION OF THE HEATING SYSTEM The boiler HDG Turbotec is designed for standard op...

Page 12: ...nly open them when the boiler is burnt out Do not leave them open any longer than necessary and never leave them open unsupervised Warning Danger of fire When the heating system is in operation open doors and lids constitute a fire danger Also combustion residues ash coal can catch fire again after being removed from the boiler Always keep the doors and lids closed Only open them when the boiler i...

Page 13: ...y be carried out by a qualified electrician Make the system is disconnected from the mains and secured against re activation during this work Danger Danger from 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 dama...

Page 14: ...he heating system e g when cleaning or servicing it The Operation Manual must always be kept readily accessible at the heating system s installation site Caution Frost danger Only install the heating system in a frost proof room Danger Danger of explosion A concentration of carbon monoxide which is too high can lead to an explosion Caution Danger from suspended loads Working in areas with this sym...

Page 15: ...e door stop is mounted on the right side or or the left Optionally the HDG Turbotec can be fitted with an additional upper filling hatch This is primarily used for filling the fuel chamber with coarse wood chips This operation manual unless otherwise specified describes the boiler version with the door stop on the right side and the upper filling hatch ...

Page 16: ...ng hatch 6 Fuel chamber 7 Primary air servo motor 8 Secondary air servo motor 9 Combustion chamber hatch with inspection window 10 Flame channel 11 Ash compartment 12 Combustion chamber 13 Burner nozzle 14 Flue gas deflector plate 15 heat exchanger surfaces 16 Flue gas exhaust flap 17 Cleaning shaft lid Figure 3 1 Cross section HDG Turbotec with HDG Lambda Control 1 17 9 8 7 6 5 4 3 2 1 16 15 14 1...

Page 17: ...d 3 Lambda probe 4 Flue pipe connection 5 Flue gas fan 6 Filling draining connection DN 15 IG 7 Flue sensor 8 Return connection DN 32 IG 9 Safety heat exchanger connections DN 15 AG 10 Connection of sensor for thermal safety device DN 15 IG Figure 3 2 Back side HDG Turbotec 9 8 7 6 4 3 2 1 10 5 ...

Page 18: ...the flue gas fan 5 and two servo motors with metering mechanisms 2 The lambda probe flue gas temperature sensor 6 and boiler temperature sensor serve to continuously monitor the firing adjust the boiler output minimise emissions and optimise boiler efficiency Activating the flue bypass damper 7 before filling causes any flue gas remaining in the fuel chamber to be sucked out The HDG Turbotec is a ...

Page 19: ...vironmentally sound and convenient manner HDG LAMBDA CONTROL 1 The HDG Lambda Control 1 boiler control unit is the electronic hub Using the control unit you can regulate the HDG Lambda Control 1 system and call up information on the current process Seechapter 6 Usingtheheatingsystem section 6 3 Structureof the menus Figure 3 4 Control unit for HDG Lambda Control 1 ...

Page 20: ...ss flow at Nominal thermal power Minimum thermal output 0 0270 kg s 0 0330 kg s 0 0270 kg s Required feed pressure 15 Pa 15 Pa Burning duration per filling in accordance with fuel recommendations Beech up to 7 h Spruce up to 6 h Beech up to 6 5 h Spruce up to 5 5 h Diameter of flue pipe connection 180 mm 180 mm Height of flue pipe connection 576 mm 576 mm Supply and return connections bushing DN 3...

Page 21: ...the wood is primarily dependent upon the moisture content For the purpose of simplifying calculations you can assume that 1 kg of wood all types with a moisture content of 20 has a thermal value of approx 4 kWh Firewood must be split and its size must be adapted accordingly to fit in the fuel chamber Unsplit logs and square boards are not suitable for burning Moreover logs should be split before t...

Page 22: ...3 Mode of operation Declaration of conformity 22 3 5 Declaration of conformity ...

Page 23: ...er without fittings 1 605 mm D Length of boiler incl fittings 1 895 mm E Length of front cladding 60 mm F Height of boiler when filling hatch is open 1 850 mm G Width of boiler incl cladding 820 mm H Flue pipe connection height 576 mm I Return connection height 745 mm J Supply connection height 1 220 mm K Height of boiler 1 395 mm Figure 4 1 Dimensions B C D A G K F I H E J ...

Page 24: ...ctangular openings an aspect ratio of 1 5 1 should not be exceeded For grating latticework an appropriate modification must be made to ensure the open cross section meets the specified value INSTALLATION A base is not necessary for the installation of the boiler Ensure that it is aligned on a horizontal plane Additionally the limit values of DIN 4109 Soundproofing in building construction are not ...

Page 25: ...in 50 cm B min 80 cm C min 20 cm D 161 cm E min 350 cm F min 70 cm G min 185 cm ROOM HEIGHT Minimum required room height 190 cm recommended 230 cm REQUIRED FOR INSTALLATION Installation dimensions without housing 130cm x 70 cm x 163 cm Figure 4 2 Necessary room sizes and minimum spacing G E D C A B F ...

Page 26: ...ld speed up the cooling of the flue gases These requirements correspond to chimneys in designs I and II as specified in DIN 4705 Part 2 Insulated chimneys used today consisting of a fireclay or stainless steel pipe with an insulating jacket and cladding bricks three shell design are to be assigned to groups I II Uninsulated chimneys made of bricks or similar material correspond to design type III ...

Page 27: ...ess The effective height of a chimney is measured from the entrance into the flue to the end of the chimney CONNECTING THE BOILER TO THE CHIMNEY The boiler must be connected to the flue with a connecting piece which is as short as possible at an angle which is less than 30 45 to the chimney You should aim for a connecting piece with a maximum length of 1 m using just one fitting Every additional f...

Page 28: ...Avoiding damage in hot water heating systems USING A BUFFER TANK When calculating the thermal requirements of buildings e g according to DIN EN 12831 Method for calculating the normal heating load the lowest outdoor temperature for the climate zone concerned e g 15 C is used This condition only applies a few days per year thus the thermal performance of the heating system is greater than required ...

Page 29: ...talled for the heating system HDG Turbotec with HDG Lambda Control 1 The return temperature control causes the water from the boiler return to be mixed with the water from the boiler advance until the minimum return temperature has been reached The minimum return temperature is listed in chapter 3 Mode of operation section 3 3 Technical data The return temperature control must be installed accordi...

Page 30: ...arging power automatically adjusted based on the preset target value for boiler temperature Residual heat extraction down to minimum boiler temperature differential control Refill signal when buffer temperature drops below preset minimum value 1 Refill signal H1 2 Boiler sensor KF 3 Heating circuit and hot water control 4 Outdoor temperature sensor AF 5 Hot water tank sensor BRF 6 Hot water tank 7...

Page 31: ...e buffer tank After the boiler temperature has dropped below the preset minimum value TK which can be selected under Settings the extraction of residual heat from the boiler is stopped The stored heat can now be transferred to the heating system and or the hot water tank as needed When the buffer tank temperature has dropped below the preset minimum value TSmin which can be selected under Settings...

Page 32: ...ot water tank sensor BRF 7 Hot water tank 8 Boiler sensor 1 KF1 9 Oil or gas boiler 10 Change over valve Y3 11 Buffer tank 12 Buffer tank sensor SF 13 Buffer charging valve Y2 14 Return valve Y1 15 Primary pump M1 16 HDG Turbotec 17 HDG Lambda Control 1 FUNCTIONAL DESCRIPTION OF HYDRAULIC SYSTEM 3 1 When the solid fuel boiler switches to heat production mode reload indicator H1 goes out Figure 4 5...

Page 33: ...erature differential boiler temperature and buffer temperature the remaining heat in the boiler is transferred to the buffer tank After the boiler temperature has dropped below the preset minimum value TK min which can be selected under Settings the extraction of residual heat from the boiler is stopped The stored heat can now be transferred to the heating system and or the hot water tank as neede...

Page 34: ...d on the boiler or in the fuel chamber Control HDG Lambda Control 1 located in the fuel chamber Flue gas fan located in the fuel chamber Two air control units located in the fuel chamber Additional accessories located in the fuel chamber Boiler claddings HDG Turbotec sticker together with operating documentation Operating manual together with the operating documentation Figure 4 6 Scope of deliver...

Page 35: ...lling the 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 Danger from electrical current or voltage Switch off the power supply and isolate the mains cable to the heating system during the installation Caution...

Page 36: ...ing a Phillips tip screwdriver from the boiler 2 4 Remove the remaining objects from the fuel chamber 1 Caution Danger from suspended loads The boiler weighs over 900 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 7 Transporting the boiler 1 2 3 Figure 4 ...

Page 37: ...he boiler has HDG Turbotec been set up INSTALLING THE CLADDINGS REAR BOILER CLADDING 1 Remove the fastening screw 1 from the plate under the supply connection using a Phillips tip screwdriver 2 Remove the filler plug 2 from the flue connection using a SW8 spanner Figure 4 9 Back of boiler 1 2 3 Position the rear boiler cladding 2 above the flue connection 3 on the boiler 4 Fix the cladding in plac...

Page 38: ...r cladding 8 Release the remaining M6 nuts SW10 and the three Phillips head screws on top of the boiler cladding Figure 4 11 Installing the floor cladding 1 2 This operating manual describes the boiler version with the door stop on the right For the version with the left door stop reverse the sides 9 Attach the right boiler cladding 2 using the welded stud bolts in the oblong holes in the floor cl...

Page 39: ...ws from the left boiler cladding 11 Fasten the right boiler cladding with the M6 nuts SW10 1 without tightening them completely Figure 4 13 Fastening the right boiler cladding in place 1 Figure 4 14 Fastening the cladding to the spacer plate 2 3 1 Caution While installing the boiler make sure the lock striker plate of the filling hatch or upper filling hatch does not catch on the door number of th...

Page 40: ...e front insulation on top of the boiler 20 Fasten the right left cladding with the two M6 bolts SW10 2 without tightening them completely 15 Lift the insulation 1 at the front upper corner of the left boiler cladding slightly so that the cable harness 2 incl boiler sensor is visible 16 Lay the cable harness 2 over the upper edge of the boiler cladding facing outward Figure 4 15 Uncovering the cabl...

Page 41: ...eft or right boiler cladding to the back side using the four steel spring clips 1 as shown above at the marked spots The left or right boiler cladding is connected with the back side LEVELLING THE BOILER CLADDING 23 Place the control console 1 on the boiler The spring steel clips are fastened to the front cover control console on delivery Figure 4 17 Inserting the spring steel clips 1 Figure 4 18 ...

Page 42: ...and right boiler claddings with the M6 nuts SW10 29 Tighten the four M6 nuts SW10 1 on the stud bolts on the bottom of the side boiler claddings The boiler cladding is aligned MOUNTING THE HDG LAMBDA CONTROL 1 CONTROL UNIT LAYING THE CABLES 1 Remove the packing from the control unit HDG Lambda Control 1 2 Carefully turn off the capillaries of the safety temperature limiter STL 3 Place the control ...

Page 43: ...illary sensor of the safety temperature limiter is located on the top of the boiler HDG Turbotec 7 If necessary pull the spacer plate 5 upwards in order to insert the capillary sensor of the STL into the immersion sleeve 1 8 Guide the boiler sensor 2 and the sensor of the STL 3 into the immersion sleeve 1 9 Fasten both sensors using the spring clip 4 Figure 4 21 Installing the boiler and STL senso...

Page 44: ...arth cable into the intended socket 4 14 If necessary remove the sticker 3 15 Mount the control unit HDG Lambda Control 1 1 on the control console 3 using the four supplied Phillips head screws 2 16 Carefully pull the control console 3 with the mounted control unit toward the front Figure 4 23 Connecting the control unit 4 2 1 3 Figure 4 24 Mounting the control unit 1 2 3 ...

Page 45: ... SW10 1 and the washers from the stud bolts of the primary and secondary motor retainer 2 Place the two seals 2 on the stud bolts 17 Insert the upper front cover 1 in the shaped studs pre mounted on the side boiler claddings 18 Push the control console back again until it clicks into place in pre mounted shaped studs Figure 4 25 Installing the return sensor 1 Figure 4 26 Seals for air control unit...

Page 46: ...it above with plug connection 11 for secondary air 3 with the washers and the M6 nuts SW10 6 Connect the plug 4 to the front plug board The air containers are installed INSTALLING THE COVER The cover for the air control units is installed Figure 4 27 Installing the air control units 2 4 3 1 7 Attach the cover of the air control units 2 with the mounting links 1 provided for this purpose in the pre...

Page 47: ...ards one quarter turn in an anticlockwise direction out of the holder 4 2 Screw the holder 4 into the flue pipe connection 2 Push the flue gas fan 3 onto the stud bolts 3 Tighten the flue gas fan 3 with the washers and the M8 nuts SW13 2 4 Insert the cable of the flue gas fan 1 according to the markings on the plug board See chapter 11 Appendix The flue gas fan is installed Figure 4 29 Installing ...

Page 48: ...he smaller of the two rear covers 2 in the shaped studs pre mounted on the side boiler claddings 2 Insert the larger of the two rear covers 1 in the shaped studs pre mounted on the side boiler claddings 3 Rotate the lever 4 for the upper filling hatch into the position 3 provided for it The rear covers and the lever for the upper filling hatch are now installed 4 7 Connecting the chimney 1 Connect...

Page 49: ... EN 12828 heating systems must be equipped with safety devices to prevent the maximum operating temperature from being exceeded The safety heat exchanger serves to protect the boiler against overheating and may not be used for other purposes i e utilised as a normal heat exchanger If the heat intake capacity is suddenly lost e g the circulation pump for raising return temperature fails heat produc...

Page 50: ...fety heat exchanger cold water outlet DN 15 external thread 3 Safety heat exchanger cold water outlet DN 15 external thread 1 Thermal safety device TAS 2 Runoff connection to drainage system The TAS is to be inspected annually by a qualified technician to verify that it is functional Caution In order to prevent leaks avoid turning the connections of the safety heat exchanger in an anticlockwise di...

Page 51: ...quired DIN EN 12828 safety devices have been installed and are ready for operation The supply of power to all components has been provided Makeshift solutions are not sufficient The chimney installation corresponds to the legal regulations All doors and openings on the boiler and on the chimney connection duct have been checked for a proper seal Air supply for combustion has been provided A suffic...

Page 52: ...button The language is set and the menu will advance to the next setting BOILER MODEL The message Boiler model HDG Turbotec appears in the display 5 Read off the boiler model from the name plate on the boiler 6 Use the Plus or Minus button to select the appropriate boiler model The selected boiler model will appear in the display 7 Confirm using the Arrow button The boiler model is set and the men...

Page 53: ...t correct values will be obtained for the temperature readings The corresponding value will appear in the display 16 Confirm using the arrow button The cable length is set and the menu will advance to the next setting MINIMUM BUFFER TANK TEMPERATURE The message Min buffer tank TSmin C 45 appears in the display 17 Use the Plus or Minus button to select the desired minimum buffer tank temperature fo...

Page 54: ...e display 23 Use the Plus or Minus button to select the runtime for the installed servo drive for the return valve The selected runtime will appear in the display 24 Confirm using the arrow button The runtime is set and the menu will advance to the next setting LOADING VALVE RUNTIME The Charging valve sec 150 message will appear in the display 25 Use the Plus or Minus button to select the runtime ...

Page 55: ...isplay 4 Select the parameter with the Arrow button The value will flash in the display 5 Use the Plus or Minus button to increase or decrease the value factory default 80 C 6 Confirm the input value with the Arrow button The boiler target temperature is set Seechapter 6 Usingtheheatingsystem section 6 3 Structureof the menus The control system HDG Lambda Control 1 has been set up for your system ...

Page 56: ...n The display changes to Selection component test 4 Press the Arrow button The message O2 sensor test appears in the display 5 Press the Plus button The lambda sensor test will begin Duration 720 seconds See chapter 7 Cleaning and maintaining the heating system section 7 2 Procedure paragraph Calibrating the lambda sensor The lambda sensor test is completed 6 Press the Arrow button The display adv...

Page 57: ...PENDING ON FUEL An optimum gasifying of the fuel and thus an efficient combustion can only be achieved if the boiler is preset for the fuel to be used and its burning properties Adapting to the on site conditions is also of critical importance After the last component has been tested the display will automatically switch the control system HDG Lambda Control 1 to Heat production off mode The HDG L...

Page 58: ...system Procedure 58 HEATING UP THE HEATING SYSTEM 1 Heat up the heating system See chapter 6 Using the heating system section 6 6 Heating up and reloading the heating system The heating system is now fully operational ...

Page 59: ...ws the selected information and settings In the operating mode Heat production on the display is switched on and active In the operating mode Heat production off the display switches off after 15 minutes It can be switched on again by pressing any button In section 6 3 Structure of the menus in this chapter all selectable information and parameters are listed HEAT PRODUCTION ON INDICATOR The Heat ...

Page 60: ...ernative program until the fault is eliminated It goes dark once faults have been resolved and acknowledged KEYPAD The heating system can be operated using the keypad The individual buttons have the following functions Heat production on plus button Pressing this button switches the system to Heat production on mode In the sub menus parameters can be selected and their settings can be altered Heat...

Page 61: ...ystem is connected to the mains supply through an emergency heating switch provided by the customer or through a circuit breaker in the mains distribution box of the home 1 Switch on the heating system at the corresponding circuit breaker or the emergency heating switch provided by the customer The heating system is now under voltage The control is activated The heating system is switched on and r...

Page 62: ...6 Using the heating system Structure of the menus 62 6 3 Structure of the menus HEAT PRODUCTION OFF MENU STRUCTURE Figure 6 2 Heat production off menu structure ...

Page 63: ...6 Using the heating system Structure of the menus 63 HEAT PRODUCTION ON MENU STRUCTURE Figure 6 3 Heat production on menu structure ...

Page 64: ... Arrow button The display is activated 2 Press the Arrow button The selection menu Selection Information appears in the display 3 Press the Arrow button The display changes to Information End 4 Press the Plus button to scroll forward through the information or Minus to scroll backwards through the information The O2 control program information is displayed by pressing the Plus button 5 Continue pr...

Page 65: ...temperature Highest flue gas temperature reached No access O2 S 6 0 O2 I 5 6 Preset target value for residual oxygen Current actual value for residual oxygen Manufacturer CO2 S 15 4 CO2 I 15 8 Target value for carbon dioxide Calculated actual value for carbon dioxide No access Lambda 1 9 ETA F 90 0 Current excess air coefficient Current combustion efficiency No access Operating hours h Cumulative ...

Page 66: ... sub menu 3 Press the Arrow button The menu item is confirmed Boiler target value TK S C appears in the display 4 Use the Plus button to increase the value or the Minus button to reduce the value Control program Indication in display Description Standard control program O2 control program Combustion is regulated according to the residual oxygen content as measured by the lambda sensor Alternative ...

Page 67: ...tion and operation which may damage material goods or even present a danger of injury or death 6 6 Heating up and reloading the heating system Caution Every switch of fuel type e g from spruce wood to beech wood requires a resetting of the boiler to the changed requirements of the fuel Only allow authorised specialists to make adjustments to the parameters Caution Hot surfaces Contact with the hot...

Page 68: ...oiler is in operation open hatches constitute a fire danger Do not leave hatches open any longer than necessary and never leave them open unsupervised Check that the hatches are closed every time you heat or reload Danger Danger of explosion A concentration of carbon monoxide which is too high can lead to an explosion Observed the required conveying pressure of the chimney Caution Hand injuries ca...

Page 69: ...e appears The Careful open slowly message appears the door buzzers are unlocked The filling hatch can be opened 3 Lift up the door handle 2 and open the filling hatch 1 4 Stick the door hook 1 in the hole in the door handle 3 and open the inner hatch 2 slowly Figure 6 5 Opening the filling hatch 1 2 Figure 6 6 Opening the inner hatch 1 2 3 ...

Page 70: ...of wood that corresponds to the heat intake capacity 12 Close the interior hatch 2 until a 10 cm gap remains and the message Heat production on appears in the display The required exhaust temperature has been attained Figure 6 7 Filling up the fuel chamber 2 4 5 1 3 Caution Only fill with as much wood as the heating system and buffer tank can absorb as energy See chapter 3 Mode of operation sectio...

Page 71: ...chapter 2 Press the Reload button 2 On the display 1 of the control unit HDG Lambda Control 1 the following message appears Do not open please wait The flue gas fan starts to run 3 Wait for approx 15 seconds until the Careful open slowly message appears The Careful open slowly message appears the door buzzers are unlocked The filling hatch can be opened 4 Open the filling hatch and the interior ha...

Page 72: ...ue bypass damper The boiler HDG Turbotec is now reloaded 6 7 Chimney inspection In Germany there is a legal obligation for manually loaded heating systems with a power rating above 15 kW to be inspected once by a qualified combustion engineer to ensure that federal pollution limits are met ordinance regarding small and medium sized boiler systems 1 BImSchV The operator must notify the responsible ...

Page 73: ...inspection heat up the log wood boiler one hour before the scheduled appointment See 6 6 Heating up and reloading the heating system in this chapter 2 Fill the fuel chamber until it is half full 3 Use split dry wood with a length of 50 cm and a maximum residual moisture content of 20 25 4 Tamp the embers and remaining logs together in the fuel chamber in the presence of the chimney sweep Danger Ma...

Page 74: ...nd the message Heat production off appears in the display 2 Now switch off the emergency heating switch if installed or the corresponding breaker of the mains electricity supply The heating system is now switched off When starting the measurement the boiler temperature should be at least 60 C and not over 80 C The temperature of the accumulator should not be higher than 60 C Having the measurement...

Page 75: ... Depending on the quality of the fuel and the power used by the heating system the intervals may be extended Interval Component See page Weekly as required Cleaning the primary air inlets fuel chamber and burner nozzle Cleaning the flame channel and ash compartment 77 79 Monthly during the heating period approx 240 operating hours Cleaning the heat exchanger surfaces 80 Biannually approx 900 opera...

Page 76: ...stem off and only start with the cleaning and maintenance work when the surfaces have cooled down Warning Danger of fire When the heating system is in operation open doors and lids constitute a fire danger Always keep the doors and lids closed Only open them when the boiler is burnt out Do not leave them open any longer than necessary and never leave them open unsupervised Warning Danger of fire f...

Page 77: ...ff 2 Press the Reload button On the display of the control unit HDG Lambda Control 1 the following message appears Do not open please wait The flue gas fan starts to run 3 Wait for approx 15 seconds until the Careful open slowly message appears The Careful open slowly message appears The door buzzers are unlocked The filling hatch can be opened Figure 7 1 Supplied cleaning tools 3 4 2 5 6 1 Cautio...

Page 78: ... cinder encrustations and remove these with the supplied flat scraper 8 Check the fuel chamber floor 2 for ash and tar or cinder encrustations and remove these with the supplied flat scraper 9 Push the dirt through the burner nozzle 3 into the flame channel located below it without removing the burner nozzle Figure 7 2 Cleaning the primary air inlets 2 1 3 Figure 7 3 Cleaning the fuel chamber 1 2 ...

Page 79: ...econdary air openings using a vacuum cleaner 13 Reinstall the burner nozzle in reverse order 14 Close the doors of the boiler in reverse order 15 End the Reload function by pressing the Minus key The primary air openings fuel chamber and burner nozzle are clean again CLEANING THE FLAME CHANNEL AND ASH COMPARTMENT 1 Allow the fire in the boiler to burn out and cool off 2 Press the Reload button Fig...

Page 80: ...a fireproof container 7 Close the combustion chamber hatch 3 in the reverse sequence 8 End the Reload function by pressing the Minus key The flame channel and the ash compartment are clean again CLEANING THE HEAT EXCHANGER SURFACES 1 Allow the fire in the boiler to burn out and cool off Figure 7 5 Cleaning the flame channel and ash compartment 1 3 4 2 Caution Make sure no ashes are left in boiler ...

Page 81: ...deflector plate 2 approx 10 cm and fix it in place with the poker 3 or pull the gas deflector plate completely out of the cleaning shaft 2 Pull the plug 1 of the flue gas fan cable out of the plug board 3 Remove the rear cover 2 from the boiler Figure 7 6 Dismantling the plug 2 1 Figure 7 7 Dismantling the cleaning shaft lid 2 1 Figure 7 8 Cleaning the cleaning shaft 2 3 1 ...

Page 82: ...eaning of the heat exchanger surfaces is completed CLEANING THE FLUE PIPE 1 Allow the fire in the boiler to burn out and cool off 6 Sweep any deposits into the flue gas collection box but not in the direction of the boiler 7 Refit the inspection hatch 2 securely onto the flue pipe 3 with the wing nut 1 The cleaning of the flue pipe is completed Caution See the General safety instructions section i...

Page 83: ...mbda sensor 1 in the reverse sequence The inspection of the lambda probe is completed CLEANING THE FLUE SENSOR Caution See the General safety instructions section in this chapter Figure 7 10 Cleaning the lambda probe 1 2 3 Caution To clean the lambda sensor use a fine brass brush instead of a steel brush Steel bristles will damage the lambda sensor Caution When reinstalling the lambda sensor make ...

Page 84: ... turn in an anticlockwise direction 3 Pull the flue gas sensor 1 out of the holder 2 4 Clean the sensor surface 5 Reinstall the flue gas sensor 1 in the reverse sequence Figure 7 11 Clean the flue gas sensor 1 3 Caution See the General safety instructions section in this chapter Caution Hand injuries can occur Working on the flue gas fan can lead to hand injuries due to the moving parts Disconnect...

Page 85: ...reverse sequence The cleaning of the flue gas fan is completed LUBRICATING THE DOOR LATCH BOLTS 1 Allow the fire in the boiler to burn out and cool off 2 Press the Reload button 3 Open the filling hatch 5 In the same way lubricate the bolts of combustion chamber door and the upper filling hatch Figure 7 13 Cleaning the flue gas fan 1 2 3 Caution See the General safety instructions section in this ...

Page 86: ...e fire in the boiler to burn out and cool off 2 Pull the actuating handle 1 of the flue bypass damper on the front of the boiler and latch it into place The flue gas exhaust flap is now open 3 Open the cleaning shaft See the Cleaning the heat exchanger surfaces section in this chapter Caution See the General safety instructions section in this chapter Figure 7 15 Pulling the actuating handle 1 Fig...

Page 87: ...channel 1 The flue bypass damper has been checked and cleaned CLEANING THE CONTROL UNIT 1 Clean the control unit with a moist lint free cloth 2 For stubborn dirt use a mild cleaning agent 3 Wipe the control unit dry with a soft cloth The cleaning of the control unit is completed INSPECTING AND CLEANING THE AIR CONTROL UNITS 1 Allow the fire in the boiler to burn out and cool off Figure 7 17 Cleani...

Page 88: ...0 spanner and remove the two air control lids 1 6 Clean both air channels with an appropriate cleaning tool e g vacuum cleaner CLEANING THE AIR CONTROL UNITS 7 Clean the air box 1 and the two secondary air openings 3 using a vacuum cleaner 8 Check the two seals of the air control units 2 9 Replace the seals if they are damaged 10 Replace the air channel lids air channel units and plug in the rever...

Page 89: ...r is properly sealed 6 Repeat the procedure from step 2 to step 5 until you have inspected all four of the contact surfaces 3 7 Remove the paper and close the filling hatch 1 The inspection of the filling hatch seal is completed CHECKING THE COMBUSTION CHAMBER DOOR AND THE UPPER FILLING HATCH 8 To check the sealing of the combustion chamber hatch and the upper filling hatch proceed as described ab...

Page 90: ... appears in the display 5 Press the Plus button The calibration of the lambda sensor starts The runtime is 720 seconds When the sensor test is complete the message Sensor okay appears in the display The lambda probe is now calibrated 6 Simultaneously press the Plus and Minus buttons The system component test menu closes Caution For the calibration of the lamba sensor to be carried out no residual ...

Page 91: ... the HDG Lambda Control 1 remains continuously lit See section 6 Using the heating system in chapter 6 1 Overview of the controls and display components 8 1 Procedure 1 Look for the displayed fault s cause and remedy in Table 8 1 Faults with flashing indicator 2 Eliminate the fault or have it repaired by an authorised electrician 3 Acknowledge the fault with the Arrow button The fault will be clea...

Page 92: ...y Controller is faulty Return temp reading incorrect Plug cable Sensor is faulty Controller is faulty For system 5 only Boiler temperature too low Return valve Plug cable Motor controller STB is triggered Reset Insufficient heat extraction Pumps valves Incorrect flue gas temperature reading Plug cable Sensor is faulty Controller is faulty ...

Page 93: ...8 Troubleshooting Possible faults 93 Boiler temperature reading incorrect Plug cable Sensor is faulty Controller is faulty Data loss Controller is faulty ...

Page 94: ...94 ...

Page 95: ...l power supply 4 Once it has cooled down drain the heating water from the system 5 Observe the safety regulations for personnel when disconnecting the boiler from the heating system 6 Dismantle the individual components of the boiler The boiler has been dismantled Gefahr Material damage and personal injury due to incorrect dismantling Dismantling the system requires comprehensive specialist knowle...

Page 96: ...a a local recycling centre Boiler Cladding The electrical components can also be recycled via the local recycling centre Fibreglass mineral wool and plastic parts should be brought to the relevant waste disposal centres Oily or greasy components and condensers may only be disposed of through a specialist waste disposal centre ...

Page 97: ...nstallation of the heating system and the hydraulic components must meet the requirements in the operating manual and the specified HDG hydraulic schemes The heating system must be installed according to applicable rules regulations and guidelines The fuel quality must correspond to the requirements specified by HDG Bavaria GmbH The apparent defect is to be remedied by HDG Bavaria GmbH 10 3 Warran...

Page 98: ...t Y1 Y2 N PE L1 N PE PE N1 N2 L1 M M M Servo drive Return valve Primary pump Stage 1 Stage 2 Suction fan Flue gas sensor Heating Sensor Lambda sensor Plug 1 Plug 2 Plug 3 Plug 4 Plug 5 Plug 6 Plug 7 Plug 8 Plug 9 Wiring according to the hydraulic system Heat extraction Do not mistake the with a marked terminal diagram Y1 rather Y2 for the correspondent hydraulic komponents Return mixer and Chargin...

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Page 100: ...HDG Bavaria 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 9980000356 V 01 en 06 2008 Operating Manual ...

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HDG Turbotec 50 L, Operation Manual

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