HDG K10, K15, K21, K26, K33 Operating Manual

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HDG K10/15/21/26/33

Operating manual

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Operating manual HDG K10 - 33 - Content

Content

1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2 Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Basic system design principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Basic principles for the content of the operating manual . . . . . . . . . . . . . . . . . . . . 7

Proper and improper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.3 Warnings and safety symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.4 Safety instructions for the pellet storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5 Duty of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Cross section of HDG K10 - 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Boiler and weather-compensated heating control HDG Control . . . . . . . . . . . .14

Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Pellet suction system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Required room sizes and minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Furnace room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Removing the transport pallet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Fitting the filling and drain cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Converting the flue pipe connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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Operating manual HDG K10 - 33 - Content

Installing the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fitting the cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Installing the ash container. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Mounting the expansion modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Connecting the suction and return hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.5 Connecting the chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.6 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.7 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Setting the fuel quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Perform actuator test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.1 Control unit for HDG Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.2 Filling the pellet storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.3 Filling the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.4 Performing a chimney sweep measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.5 Switching off the heating system for repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7 Cleaning and servicing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.1 Cleaning and servicing schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Generally applicable safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Emptying the ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Cleaning the combustion chamber and burner pot . . . . . . . . . . . . . . . . . . . . . . . 49

Cleaning the flue gas fan and cleaning shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Cleaning the flue gas pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Check the fill level of the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checking and cleaning the reservoir and flap of the delivery unit . . . . . . . . . . 54

Cleaning the pellet storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

9 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

10 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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1 Notes on this manual – Introduction

1 Notes on this manual

1.1 Introduction

EASY AND SAFE OPERATION This operating manual contains important instructions on the

• HDG K10

• HDG K15

• HDG K21

• HDG K26

• HDG K33

and how to operate it properly and safely. Following these instructions helps to avoid dangers, prevent repair costs and downtimes, maintain reliability and extend the life expectancy of the heating system.

EADING THE OPERATING

MANUAL

This operating manual must be read and observed by everyone who operates or works on the HDG K10 - 33.

ECHNICAL CHANGES We continuously develop and improve our boilers. The information

in this edition was correct at the time of going to press. All details in these instructions on standards, regulations and

worksheets should be checked before use and should be compared with the regulations applying locally at the site where the system is installed.

We reserve the right to make changes which may then differ from the technical details and illustrations in this operating manual.

OPYRIGHT Written permission is required from HDG Bavaria GmbH for

reprinting, storage in a data-processing system or transmission by electronic, mechanical, photographic or any other means, and for copies or translations of this publication, in whole or in part.

UARANTEE The terms and conditions of the guarantee of your boiler can be

found in the enclosed information sheet.

YMBOLS USED In this operating manual, the following designations and symbols are

used for particularly important information:

1. Instructions to the operator

✓ Result of the action described ✎ Cross reference for more explanation

• List

–List

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1 Notes on this manual – Glossary

1.2 Glossary

Term Explanation

Actuator This is a component which carries out a certain function in the

heating system e.g. the worm feed stoking unit.

Automatic cleaning At intervals, automatically cleans the surface of the heat

exchangers.

Delivery system Pellet transport system in the pellet storage room.

Display Display of the boiler control unit.

Extinguishing device Extinguishes the contents of the reservoir if the temperature of the

contents exceeds 90°C.

HDG Control Boiler and heating system controller.

HDG K10 - 33 Heating system for burning wood pellets.

Heating system Comprised of boiler and corresponding accessories.

Pellet suction system Pellet transport system which connects the reservoir with the

delivery system.

Reservoir A container which supplies pellets to be burnt in the boiler via the

conveying auger.

Sensor Records certain parameters (temperature, fill level) and forwards

them to the control for analysis.

Wood pellets Binder-free pellets made of pressed, untreated wood.

Table 1/1 - Glossary

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2 Safety notes – Intended use

2 Safety notes

2.1 Intended use

BASIC SYSTEM DESIGN PRINCIPLES

BASIC PRINCIPLES The heating system was built using state-of-the-art technology and

conforms to recognised safety regulations. Nevertheless, there is still a risk of injury or death to users or bystanders, and of adverse effects upon the heating system or upon other material goods.

Have your specialist heating company provide you with a detailed explanation of the operation of the heating system.

SING THE HEATING SYSTEM Only use the heating system when it is in perfect condition. Use it

properly, as intended, be aware of safety and hazards, and observe the Operating manual. Have any faults which could impair safety fixed immediately.

This device can be used by children over 8 years old and people with reduced physical, sensory or mental capabilities or a lack of experience and knowledge, provided they are supervised or have been instructed on the safe use of the device and understand the resulting risks. Children may not play with the device. Cleaning and user maintenance must not be carried out by children without supervision.

BASIC PRINCIPLES FOR THE CONTENT OF THE OPERATING MANUAL

SCOPE The content of this operating manual is intended exclusively for the

planning, installation and operation of the HDG K10 - 33 heating systems. The further implementation of applicable standards and guidelines, for example regarding 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 OPERATION

PURPOSE OF THE HEATING

SYSTEM

The heating system HDG K10 - 33 was designed to burn wood pellets in hot water heating systems.

Any other application is considered improper use. The manufacturer will accept no liability for any damage resulting from improper use. The operator bears sole responsibility in such cases.

Proper use includes adherence to the installation, operation and maintenance requirements specified by the manufacturer.

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2 Safety notes – Residual risks

Modification of the specified operating values will affect the heating system’s control programme and could lead to malfunctions. Only trained maintenance and operating personnel may undertake modifications to the operating values.

2.2 Residual risks

Despite all precautions, the following residual risks remain:

For more information on fuel, see chapter “3 Mode of operation”, section “3.4 Fuel quality requirements”.

Caution!

Hot surfaces Contact with the hot surfaces of the boiler can lead to burns. Wait until the boiler has cooled down before touching non-

insulated components.

Danger!

Danger of asphyxiation due to lack of oxygen If the boiler is in operation, carbon monoxide can be emitted

through the open doors and lids. Do not leave the doors and lids open any longer than necessary.

Warning!

Danger of fire Opening doors and lids to hot combustion residues during

operation can pose the danger of fires. Keep the openings closed during operation, and when performing

cleaning work, allow the combustion residues to cool down before you place them in a fireproof container.

Warning!

Danger from suspended loads The boiler weighs over 300 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 placing the boiler.

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2 Safety notes – Warnings and safety symbols used

2.3 Warnings and safety symbols used

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

Danger!

Danger of explosion due to carbon monoxide Filling the burner pot with pellets manually may result in too much

fuel in the burner pot. Consequently the pellets will not be optimally ignited and too much low temperature carbonisation gas may result which can lead to an explosion.

Do not fill the burner pot manually.

Danger!

Dangerous electrical current or voltage The circuit boards and other electrical components carry current. Have work on electrical components performed only by a qualified

electrician and turn the main switch off.

Warning!

The boiler is under pressure.

Danger!

Dangerous electrical current or voltage Work in areas marked with this symbol may only be performed by a

qualified electrician.

Warning!

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.

Caution!

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

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2 Safety notes – Warnings and safety symbols used

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.

Caution!

Danger of explosion When working in areas marked with this symbol, there is a danger

of explosion due to high concentrations of carbon monoxide.

Warning!

Suspended loads When working in areas marked with this symbol, there is a danger

of falling objects.

Caution!

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

to automatic start-up.

Important!

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

Instructions regarding disposal

Additional information for the operator

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2 Safety notes – Safety instructions for the pellet storage room

2.4 Safety instructions for the pellet storage room

After the storage room is filled, odourless carbon monoxide may form and a lack of oxygen may arise. Therefore, in the first 6 weeks after filling the storage room, it is prohibited to enter the storage room, and only trained personnel may do so.

For pellet storage rooms, a special sticker (issued by the German Association of wood and pellet fuels - DEPV) must be attached to the access hatch to the fuel storage room.

It lists the following instructions.

• Access prohibited to unauthorised persons, keep children away!

• Smoking, flames and other sources of ignition prohibited.

• Turn the pellet boiler off for at least 1 hour before filling.

• Ensure adequate ventilation before entering.

• Beware of a risk of injury from moving components.

• Make sure filling is carried out properly.

2.5 Duty of information

READING THE OPERATING

MANUAL

Any person performing tasks on this system must read the Operating manual prior to beginning work, particularly the chapter “2 Safety notes”.

This is especially important for persons who only occasionally work on the heating system, for example when cleaning or servicing it.

The Operating manual must always be kept readily accessible at the place where heating system is installed.

In addition, observe the VDI guideline 3464 “Storage of wood pellets at the consumer”.

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3 Mode of operation – Overview

3 Mode of operation

3.1 Overview

CROSS SECTION OF HDG K10 - 33

1 Vacuum fan 2 Flap of the delivery unit 3 Reservoir 4 Reservoir level indicator 5 Conveyor auger 6 Drive motor of stoker auger 7 Sensor for auger pipe safety thermostat

Figure 3/1 - Cross section of HDG K10 - 33

7 11

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3 Mode of operation – Functional description

8Ash container 9 Combustion grate drive motor 10 Ignition element 11 Ash compartment 12 Ash removal / cleaning system drive motor 13 Primary air pin 14 Burner pot 15 Drop chute 16 Heat exchanger surfaces incl. turbulators 17 Combustion chamber temperature sensor 18 Control unit HDG Control Touch

3.2 Functional description

COMBUSTION PROCESS

In boiler HDG K10 - 33, the pellets are automatically transported from the fuel storage room to the reservoir using the delivery system with the assistance of the pellet suction system. The feeding system conveys the pellets to the burner pot of the boiler.

The automatic pellet suction system does not need to be fitted. In this case the reservoir will be filled manually.

The combustion process starts with a preliminary flushing. The flue gas fan and the combustion chamber of the boiler is flushed with fresh air. The next step is the ignition phase. The supplied pellets are automatically ignited with a heating element. In the subsequent flame stabilisation phase, even combustion is established.

The system then changes to modulation mode. In this mode, combustion is carried out according to the required output.

The boiler HDG K10 - 33 is equipped as standard with an automatic heat exchanger cleaning system. This ensures a consistently high heat transfer and consequently a high level of efficiency.

If the extracted power falls below the minimum nominal thermal power or there is no heating request, the boiler goes into burn-out mode. The flue gas fan continues running until the burner pot has cooled down.

To prevent the grating from slagging up and to ensure ash removal occurs, the grate plate is moved at intervals. The automatic ash removal system transports the accumulated fly and combustion ash to the external ash container.

The air necessary for combustion is supplied as required via a speedcontrolled flue gas fan.

Sensors are used to:

– Continuously monitor the firing

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3 Mode of operation – Functional description

– Adapt the boiler output to the heat requirements

– Minimise emissions

– To optimise boiler efficiency

BOILER AND WEATHER-COMPENSATED HEATING CONTROL HDG CONTROL

BOILER CONTROL UNIT The boiler control unit of the pellet boiler HDG K10 - 33 is the

electronic hub. It consists of the ready-to-use control panel and control unit on the top right side of the boiler. Using the control unit, you can regulate the boiler and call up information on the current process.

If the heating circuits issue a request for more heat, the pellet system automatically switches to the flushing operating mode and the combustion process begins.

Once the desired boiler temperature has been reached, i.e. the need for heat has been met, the heating system changes to Burn out mode and subsequently to the operating status Standby.

EATING CIRCUIT CONTROL The HDG Control controls the entire energy management of the

heating system including the following, depending on the version:

• Accumulator management

• Weather-compensated heating circuits

• Domestic hot water heating

• Control of the second boiler

• Transfer of heat into the district heating grid

• Solar system for hot water and support of the heating system

✎ For a description of the HDG Control boiler and weather-compen-

sated heating control, refer to the “HDG Control” operating manual.

DELIVERY SYSTEM

The delivery system is in the pellet storage room. Various delivery system options are available.

• Suction probes: The pellets are drawn up through 8 suction

probes in the fuel storage room.

• Auger: Via an auger, the pellets on the sloping floor are

transported to the transfer station.

• Pellet mole: The pellet mole moves freely in the fuel storage room.

• Pellet fabric silo: External pellet storage made from polyester.

The delivery system is controlled by the control system HDG Control.

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3 Mode of operation – Functional description

PELLET SUCTION SYSTEM

The pellet suction system links the delivery system with the reservoir of the HDG K10 - 33 boiler. This process is monitored by sensors and, using the boiler control system, can be limited to various times of day.

RESERVOIR

Various versions are available:

Reservoir

Automatic

Reservoir

Manual, small

(Day container)

Reservoir

Manual, large

(Week container)

Filling Automatic (pellet

suction system)

By hand By hand

Volume 107 kg 107 kg 200 kg

Table 3/1 - Reservoir

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3 Mode of operation – Technical data

3.3 Technical data

*Maximum operating temperatures of up to 110 °C can also briefly occur.

Type of boiler HDG K10 HDG K15 HDG K21 HDG K26 HDG K33

Performance data (measured according to DIN EN 303-5)

Nominal thermal power 9.9 kW 15 kW 21 kW 25.9 kW 32.5 kW

Minimum thermal power 3.0 kW 4.3 kW 6.3 kW 7.6 kW 9.8 kW

Boiler efficiency at nominal thermal power 94.4 % 93.8 % 93.9 % 93.9 % 94.8 %

Electrical power consumption at nominal thermal power 28 W 33 W 41 W 48 W 77 W

Electrical connection:

• Voltage

• Frequency

• Back-up fuse

230 V 50 Hz

13 A (slow-blow)

General boiler data

Boiler class 5

Maximum permissible operating pressure 3.0 bar

Maximum supply temperature 85 °C*

Minimum return temperature 20 °C

Water capacity 39 l 47 l

Weight 261 kg 283 kg

Planning data for flue calculation (DIN EN 13384-1)

Flue gas temp. (Tw) at nominal thermal power Flue gas temp. (Tw) at lowest thermal power

98 °C 78 °C

119 °C

82 °C

127 °C

87 °C

134 °C

90 °C

138 °C

92 °C

Flue gas mass flow, nominal thermal power Flue gas mass flow, minimum thermal power

0.0058kg/s

0.0025kg/s

0.0085kg/s

0.0034kg/s

0.0118kg/s

0.0044kg/s

0.0146kg/s

0.0049kg/s

0.0180kg/s

0.0060kg/s

CO2 content at nominal thermal power CO

content at minimum thermal power

13.4 %

9.7 %

14.2 %

10.1 %

14.2 %

11.3 %

14.2 %

12.1 %

14.6 %

12.3 %

Flue draught requirement (Pw) 5 Pa

Diameter of flue pipe connection 130 mm

Height at middle of flue gas pipe connection 1050 mm (top) / 750 mm (rear)

Water-side connections

Supply and return connections DN 25, outside thread

Recommended pipe dimensions (minimum) DN 25

Water-side resistance, 10 K Water-side resistance, 20 K

360 Pa 100 Pa

760 Pa 210 Pa

1430 Pa

390 Pa

2150 Pa

580 Pa

3110 Pa

860 Pa

Other information

Sound pressure level

45.3 dB(A) 45.7 dB(A) 46.1 dB(A) 46.5 dB(A) 47.6 dB(A)

Min. Air inlet cross section 150 cm²

Table 3/2 - Technical data

Page 17

3 Mode of operation – Fuel quality requirements

3.4 Fuel quality requirements

Only wood pellets are permissible as fuel for the HDG K10 - 33 boiler.

Wood pellets are pressed into a cylindrical shape. They consist of untreated shavings and sawdust from the wood processing industry as well as unprocessed forestry waste. They have a standardised diameter and length. They are pressed at a very high pressure and have a very low water content. The energy contained in 2 kg of pellets corresponds approximately to the energy contained in a litre of heating oil.

Essential criteria for the definition of the property classes are the length and diameter, moisture content and ash content of the fuel.

ENGTH AND DIAMETER The diameter of the pellets used must be in accordance with D06, i.e.

6 mm +/- 1 mm. The length of the pellets must measure between

3.15 mm and 40 mm. A maximum of 1.0% by weight of the pellets may be longer than 45 mm.

ATER CONTENT The water content must be less than 10% (M10) for property classes

A1, A2 and B.

SH CONTENT The ash content of the property class A2 and B is higher than that of

A1 due to the higher proportion of bark, needles and leaves. The maximum ash content for property class A1 is 0.7% by weight (A0.7), for property class A2 the maximum ash content is 1.2 % by weight (A1.2) and for property class B the maximum ash content is 2.0 % by weight (A2.0). In accordance with the 1st Federal Emission Control Ordinance, operation with pellets in Germany is limited to property class A1.

Alternatively pellets with the “ENplus” or “DINplus” certificate are also suitable as they meet the quality requirements of property class A1.

RECOMMENDED FUEL

It is important that fuel is used according to HGD fuel specifications In particular, all fuel requirements concerning size, water content and ash content must be met..

With regard to the quality standards for pellets, DIN EN ISO 17225-2 “Biogenic solid fuel - fuel specifications and classes - classification of pellets” applies.

In accordance with this standard, the properties of pellets that can be used with the HDG K10 - 33 are specified below in more detail.

Pay particular attention to the fuel quality, both when ordering and at delivery.

Important!

If there is a significant change of fuel, the system must be reset accordingly and checked for emissions by authorised specialists.

Page 18

4 Planning and installation – Planning the heating system

4 Planning and installation

4.1 Planning the heating system

REQUIRED ROOM SIZES AND MINIMUM CLEARANCES

* for HDG K21/26/33. For HDG K10/15 = 710 mm ** with 107 kg reservoir. With 200 kg reservoir = 1425 mm

Minimum room height: 1850 mm

Recommended room height: 2250 mm

Figure 4/1 - Room sizes and minimum clearances in mm

Flue pipe behind Flue pipe above

Page 19

4 Planning and installation – Planning the heating system

DIMENSIONS AND CONNECTIONS

* with 107 kg reservoir. With 200 kg reservoir = 1470 mm ** with 107 kg reservoir. With 200 kg reservoir = 1425 mm

1 Boiler supply connection (DN 25, outside thread) 2 Boiler return connection (DN 25, outside thread)

FURNACE ROOM

APPLICABLE REGULATIONS Local building regulations always apply. In Germany, individual state

regulations on boilers and furnaces (FeuVO) also apply.

Make sure there is an adequate supply of fresh air to the boiler room so that there is enough air available for the combustion process and to protect the operator from the hazards of insufficient oxygen.

NSTALLATION A base is not necessary for installation of the heating system. Ensure

alignment on a horizontal plane.

To ensure unhindered operation and maintenance of the heating system, it is imperative that the heating system is installed in accordance with the specifications of HDG Bavaria and that the minimum spacing requirements are observed.

Figure 4/2 - Dimensions (mm) and connections

Important!

Building regulations may differ from country to country and state to state.

For this reason, consult a qualified specialist for the planning and installation of your boiler room.

Observe the fire safety regulations.

Page 20

4 Planning and installation – Connections

Also note that the thresholds in DIN 4109 “Soundproofing in building construction” may not be exceeded.

More detailed information can be found in the relevant local and national regulations.

We recommend that objects which are not needed for the operation or maintenance of the heating system not be stored in the boiler room.

4.2 Connections

CHIMNEY

The benefits of the HDG K10 - 33 can only be enjoyed if all of the prerequisites for good combustion are ensured. The heating system and chimney form a single functional unit and must be adapted to one another in order to guarantee fault-free and economical operation.

Since the flue temperature may lie below 100°C when the system is partially loaded, 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 engineer.

Another essential criterion is to achieve the correct flue draught. This depends on three major factors.

HIMNEY CHARACTERISTICS The requirements for minimising the draught loss in the chimney are:

• Good thermal insulation to avoid the flue gases cooling down too

quickly.

• Smooth interior surface to reduce the flow resistance.

• Chimney well-sealed to avoid outside air leaking in. Air

penetrating from the outside speeds up the cooling of the flue gases.

Also observe the accident prevention regulations of the official safety organisations.

According to EN 303-5, the entire flue system must be installed in such a way that contamination, condensation and insufficient flue draught are avoided. Note here that in the accessible operational area of the boiler, flue gas temperatures of less than 160 K above room temperature may arise.

✎ The required flue gas values are listed in chapter “3 Mode of

operation”, section “3.3 Technical data”.

When planning the flue system, a flue calculation based on DIN EN 13384-1 must be performed by authorised specialists.

Page 21

4 Planning and installation – Connections

These requirements correspond to chimneys of the type according to DIN EN 13384-1: 2003-03 “Thermal and fluid dynamic calculation methods”.

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 and are unsuitable.

Free-standing chimneys require particularly good insulation.

HIMNEY DIMENSIONS The system may only be connected to a chimney which has been

dimensioned in accordance with DIN EN 13384-1, taking into account the fuel planned and the expected load, and which meets local building regulations for the installation site.

A chimney can only be designed with full knowledge of the on-site conditions. This includes taking into account the following factors:

• Building location

– Surrounding hills/slopes

– Wind direction

• Location of the chimney in the roof

– The opening of the chimney must be at least 0.5 m above the

highest edge of roofs with a slope of more than 20° or at least

1.0 m higher than roof surfaces which slope at 20° or less.

• The effective height of a chimney is measured from the flue

entrance into it to the end of the chimney.

ONNECTING THE BOILER TO

THE CHIMNEY

The firing system must be connected 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 fitting results in a greater pressure loss in the exhaust path and should thus be avoided. The same is true for overly long connecting pieces. If, for constructional reasons, they have to be longer than 1 m, they should be adequately insulated (at least 5 cm of mineral wool or equivalent material) and, if possible, should be fitted with an upward inclination.

1 Auxiliary air unit 2Cleaning door

A) Chimney approx. 30° - 45°

B) Clearance at least 50 cm

Figure 4/3 - Chimney connection

Page 22

4 Planning and installation – Connections

To compensate for irregularities in the flue draught of the chimney, HDG Bavaria recommends installing an auxiliary air unit in the flue gas pipe, or even better, in the chimney itself as shown in Figure 4/3

- Chimney connection.

The following should also be considered:

• The connecting piece may not protrude into the chimney.

• If the system flue gas pipe has a larger diameter than the chimney,

the connecting piece must reduce its diameter to that of the connection. In this case, the connecting piece should taper as gently as possible.

• Use bends rather than elbows; the radius of the elbow may not be

less than the diameter of the pipe.

• The chimney should be vertical and straight, if possible without

deformations (take particular care in older buildings).

• All of the cleaning doors and measurement hatches on the

chimney must have tight seals.

• To reduce the entry of additional cold air, only one heat source

should be attached to each chimney.

• To prevent dust from escaping, the flue gas pipe must be sealed

with heat-resistant silicone.

ELECTRICAL SYSTEM

The instructions in 2006/95/EC (low voltage directive) must be followed for the electrical connections to the system.

No electrical installations, such as power sockets, distribution boxes, lights or light switches may be located in the pellet storage room. Any lights must be suitable for use in areas at risk of explosion. The VDE regulations for rooms with a risk of dust explosion must be followed.

✎ The required connection values are listed in chapter “3 Mode of

operation”, section “3.3 Technical data”.

IGHTNING/SURGE PROTECTION

WATER

The coatings formed by stones in the heat generator can have a detrimental effect on the efficiency (energy efficiency) of the heating/boiler system and can lead to damage and faults.

Important!

To operate the heating system safely and properly we recommend protecting the electronic components with a lightning and surge protection according to DIN EN 62305 or DIN VDE 0100-443. Please contact your specialist electrical service.

Page 23

4 Planning and installation – Connections

OPERATION WITHOUT AN

ACCUMULATOR

In principle the heating system HDG K10 - 33 does not need an accumulator. This requires a guaranteed minimum heat transfer capacity, for example, a demand circuit that cannot be disabled or no thermostat valves on any radiator.

Exception: If the entire heat requirement of the object according to calculations in accordance with DIN EN 12831 is less than 50% of the nominal thermal power, we recommend installing an accumulator. This means that the HDG K10 - 33 boiler charges the accumulator by means of a return flow boost assembly.

SING AN ACCUMULATOR When calculating the thermal requirements of buildings, e.g.

according to DIN EN 12831 “Method for calculating the normal heating load”, the lowest outside temperature of the relevant climate zone (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 on most days when heating is needed.

For this reason, the HDG K10 - 33 is fitted with power control as standard and with automatic ignition.

It is, however, highly recommended to use an accumulator even with automatic boiler systems.

The size of the accumulator will depend on the nominal thermal power of the boiler and on the thermal requirements of the building. As a guide, the recommended value of 20 litres per kW boiler output can be used. An advantage of using an accumulator lies in the lower operating hours of the system and fewer start-up phases due to the extension of the heating intervals. This leads to a reduction in the proportion of external energy supplied and to lower wear of the mechanical components.

For the above-mentioned reasons, we recommend an accumulator even for automatic boiler systems.

AFETY DEVICES Safety devices (e.g. boiler safety module, low-water-level switch etc.)

must be installed in accordance with DIN EN 12828: “Design for water-based heating systems in buildings”.

ETURN TEMPERATURE Operating temperatures which are too low, significantly shorten the

service life of the boiler. Water vapour contained in the flue gas could be released in the form of condensation if the temperature drops below the dew point (approx. 50 - 55 °C), especially in the area

Important!

The heating system must be filled with water in accordance with VDI guideline 2035, “Avoiding damage in hot water heating systems”.

Antifreeze agents may only be used after prior consultation with HDG.

Page 24

4 Planning and installation – Scope of delivery

around the water-cooled heat-exchanger surfaces. This condensation, in combination with combustion residue, can lead to corrosion.

As a result of the built-in standard return flow boost assembly, the HDG K10 - 33 boiler can be operated up to a return temperature of at least 20°C. In this case no external return temperature control is required.

Exception: For heating systems with accumulators, which are directly charged by the boiler, an external return temperature control must be used.

The return temperature control causes the water from the boiler return flow to be mixed with the water from the boiler supply flow 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 control of the return temperature is handled by the HDG Control control unit.

The return temperature control consists of a 3-way mixing valve with a 230 V servo drive (running time 120-240 s) and a circulation pump from energy efficiency class A. For the HDG K10 - 33, we recommend

• Wilo 25/1-6, 3-way mixing valve DN 25 (or equivalent)

The return temperature control may not be further than 5 metres from the boiler.

The hydraulic system must be installed in accordance with specific technical principles of the heating construction industry. Take into account the stop cocks required for maintenance work and repairs.

The return temperature control must be installed according to the specifications of HDG Bavaria.

4.3 Scope of delivery

BOILER The boiler and the reservoir are delivered wrapped in plastic foil,

each in a sturdy transport crate. The cladding and components to be installed are in separate boxes. The cleaning tools are enclosed with the boiler.

The pipe dimensions must be adapted to meet the requirements at the site. Take the water-side connections of the boiler for the supply and return into account.

✎ See chapter “3 Mode of operation”, section “3.3 Technical data”.

The return temperature control is not designed for the use of a gravity brake and this should therefore not be installed.

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4 Planning and installation – Installing the heating system

ORIGINAL STATE ON DELIVERY

1Boiler 2 Day container 3Week container 4Cladding 5Ash container

4.4 Installing the heating system

The heating system is installed by specialists from HDG Bavaria GmbH or an authorised HDG partner and a qualified electrician.

Figure 4/4 - Original state on delivery

612

812

1161

1115

225

515

670

235

660

767

6821

1015

820

5 1 6 1

720

(BW 212/262)

670

(BW 102/152)

Danger!

Risk of material damage and injury due to incorrect installation Installing the heating system requires comprehensive specialist

knowledge. If installed by untrained persons, the heating system can be damaged and persons may be injured due to secondary damage.

Only allow authorised specialists to perform the installation.

Danger!

Dangerous electrical current or voltage Switch off the mains supply to the heating system during the

installation.

Danger!

Dust explosion due to build-up of static charge Only qualified electricians certified according to TRBS 1203-1 may

perform work on electrical systems in areas at risk of explosion.

Page 26

4 Planning and installation – Installing the heating system

SUPPLY

If possible, the boiler and the reservoir are brought by lift truck to the installation site in their crates.

1Boiler 2 Reservoir with suction system 3 Reservoir with suction system (day container) 4 Week container

Caution!

Danger of injury Some of the components being installed are heavy. Hands and feet

could be crushed if installation is not performed properly.

Net weight HDG K10/15 HDG K21/26/33

Boiler incl. transport crate 218 kg 239 kg

Boiler 200 kg 221 kg

Minimum boiler weight (without combustion chamber door, cleaning shaft lid, cone, primary air pin)

170 kg 191 kg

Day container incl. transport crate 56 kg

Day container 42 kg

Week container incl. transport crate 107 kg

Week container 81 kg

Ash container 12 kg

Table 4/1 - Net weight

Figure 4/5 - Boiler and reservoir without crate

714

650 (BW 102/152)

720 (BW 212/262)

1146

584

592

1231

584

592

1471

680

936

3 7 4 1

714

650 (BW 102/152)

720 (BW 212/262)

1146

584

592

1231

584

592

1471

680

936

3 7 4 1

1 2 3 4

Page 27

4 Planning and installation – Installing the heating system

REMOVING THE TRANSPORT PALLET

MANUALLY

1. Remove the wood block at the base (1).

2. Lay the dismantled crate planks (2) on the pallet to use as a ramp.

3. Grip into the auger pipe (2) and the flue pipe connection (1).

4. Push the boiler (3) off the pallet.

Caution!

Danger from suspended loads The boiler weighs over 200 kg. If the boiler is dropped during

transport, persons can be seriously injured and the boiler can be damaged.

Make sure that you use appropriate lifting gear when installing the boiler.

Figure 4/6 - Removing the transport pallet - 1

1 2

Figure 4/7 - Removing the transport pallet - 2

Page 28

4 Planning and installation – Installing the heating system

WITH A SACK TRUCK

5. Lay the ratchet strap (1) around the star-grip screw (2) on the

cleaning shaft lid.

6. Fasten the ratchet strap (1) to the sack truck.

7. Lift the boiler (3) off the pallet with the sack truck.

Y CRANE

8. Remove the star-grip screw (2) from the cleaning shaft lid.

9. Screw an M12 crane eyelet (1) (not supplied) into the threaded

pin.

10.Lift the boiler (3) off the pallet by crane.

✓ The transport pallet has been removed.

INSTALLING THE BOILER

1. Place the boiler in the planned location.

2. Ensure the minimum clearances.

✎ See section “4.1 Planning the heating system”, under “Required

room sizes and minimum clearances”.

Figure 4/8 - Removing the transport pallet using a sack truck

Figure 4/9 - Removing the transport pallet using a crane

Page 29

4 Planning and installation – Installing the heating system

FITTING THE FILLING AND DRAIN COCK

1. Pull the handle (1) off the filling and drain cock (2).

2. Screw the filling and drain cock (2) into the bottom left connection

on the boiler.

3. Make sure the handle is on the right.

4. Push the handle (1) back onto the filling and drain cock (2).

✓ The filling and drain cock is now fitted.

CONVERTING THE FLUE PIPE CONNECTION

3. Adjust the boiler horizontally

or slightly sloping upwards to the rear using the four positioning screws (1).

✓ The boiler is erected.

Figure 4/10 - Aligning the boiler

Figure 4/11 - Fitting the filling and drain cock

On delivery, the flue pipe connection is at the top. If necessary, the flue pipe connection can be moved to the rear.

Page 30

4 Planning and installation – Installing the heating system

1. Remove the insulation (1) above the cleaning shaft lid.

2. Release the star-grip screw (2).

3. Lift off the cleaning shaft lid (3).

4. Break out the perforation (1) on the rear wall.

5. Remove the insulation around the (2) flue gas casing.

6. Cut the cable ties (3) on the fan cable.

7. Undo the four hex socket screws (1) in the cleaning shaft lid.

8. Carefully take off the flue gas housing.

9. Turn the flue gas housing (3) by 90° and screw it on again.

10.Put the insulation (2) back in on the left (enclosed, on the side

below the flue gas housing).

✓ The flue gas connection gas been converted.

Figure 4/12 - Opening the cleaning shaft lid

1 2

Figure 4/13 - Removing the rear wall

Figure 4/14 - Turning the flue gas housing

Important!

The seal between the flue gas housing and the boiler must not be damaged.

Page 31

4 Planning and installation – Installing the heating system

INSTALLING THE RESERVOIR

1. Attach the auger motor (1) (contained in the combustion chamber

on delivery) to the holder with the lug at the back and the centring screw at the front.

2. Fasten the auger motor with the two M8 screws (SW13) (2).

3. Screw the gear wheel (3) using the M6 screw (SW10) and a washer

onto the auger at the bottom of the reservoir.

4. Thread the in the reservoir with the conveyor auger (2) into the

auger pipe (1).

5. Attach the reservoir at the top by the yellow markings into the two

hooks (3).

The auger motor is installed under the reservoir on the auger.

Figure 4/15 - Installing the auger motor

Figure 4/16 - Attaching the reservoir

Page 32

4 Planning and installation – Installing the heating system

6. Screw the upper fastening screws (2) all the way in (to the

marking).

7. At the bottom, fasten the reservoir using the M8 screw (SW13)

(enclosed in a plastic bag in the reservoir) (3).

ESERVOIR WITH SUCTION

SYSTEM

Figure 4/17 - Fastening the reservoir

8. Push the sensor (1) for the

auger pipe safety thermostat all the way into the holder.

Figure 4/18 - Installing the safety thermostat

9. Connect the plugs (1) of the

auger motor and the proximity switch.

Figure 4/19 - Connecting the plugs

Depending whether or not the reservoir is fitted with a suction system, either the mains plug and the upper proximity switch, or corresponding plugs with jumpers must be connected to the automatic burner.

10.Lay the mains plug (2) from

the vacuum fan to the automatic burner.

11.Lay the cable from the upper

proximity switch (1) to the automatic burner.

Figure 4/20 - Connecting the vacuum fan mains plug

Page 33

4 Planning and installation – Installing the heating system

12.Fold back the cover (2) of the control panel.

13.Connect the line from the upper proximity switch to the plug X22

(1).

14.Connect the mains plug (2) of the vacuum fan to the plug (4) of the

connecting line to the automatic burner.

ESERVOIR FOR MANUAL

FILLING

15.Connect the plug (3 pin) with a jumper to the socket X22 (1).

16.Connect the plug (6 pin) with a jumper to the socket (4) for the

vacuum fan mains plug.

✓ The reservoir is installed.

FITTING THE CLADDING

RESERVOIR CLADDING

Figure 4/21 - Connecting in the plugs and jumpers

1. Attach the rear cladding (2) to

the pins (1) on the reservoir and the rear cladding of the boiler.

Figure 4/22 - Fitting the rear cladding

If the flue pipe connection is fitted at the top, the upper cladding of the reservoir must be broken out.

2. Break out the perforation (1)

on the rear wall if necessary.

Figure 4/23 - Breaking out the upper left cladding

Page 34

4 Planning and installation – Installing the heating system

7. Mount the right container cladding (2) to the side of the reservoir

on the 2nd and 3rd hole (1) from the top with the Torx screws.

8. Mount the right container cladding (2) to the front of the reservoir

with the Torx screws.

3. Place the upper cladding (1)

above the water tank onto the boiler.

4. Mount the upper cladding (1)

with the Phillips screws.

Figure 4/24 - Installing the upper cladding

5. Push the middle orifice plate

(1) under the cladding or sideways into the recesses on the boiler.

6. Fasten the middle orifice

plate (1) with the Phillips screws (2).

Figure 4/25 - Mounting the middle orifice plate

Figure 4/26 - Mounting the right container cladding

9. Mount the lower front

cladding (1) with the coated Torx screws on the middle orifice plate and the left container cladding.

Figure 4/27 - Installing the front cladding at the bottom

Page 35

4 Planning and installation – Installing the heating system

10.Hang the front cladding (1) in the left and right container cladding

and fasten it at the bottom with the Torx screws.

OILER CLADDING

11.Mount the lower door hinge (1) with the four Torx screws.

12.Mount the upper door hinge (2) loosely - so that it can still move -

with the two Phillips screws.

Figure 4/28 - Installing the front cladding at the top

Figure 4/29 - Mounting the door hinges

13.Attach the side wall (1).

Figure 4/30 - Attaching the side wall

14.Hang the housing door (3) in

the upper and lower hinge.

15.Tighten the Phillips screws (2)

of the upper door hinge.

16.Fasten the side wall with the

Phillips screw (1).

Figure 4/31 - Mounting the housing door and the side wall

Page 36

4 Planning and installation – Installing the heating system

17.Fit the control panel (1) on the support plate from the rear with

the four Phillips screws.

18.Plug the outside temperature sensor – if present – into the control

unit.

19.Connect the connecting lines according to the control unit (1).

✎ See “Electrical plans for HDG K10 - 60”.

20.Mount the support plate (1) with the Phillips screws.

21.Break out the perforation on the upper cover (1) if necessary.

22.Place the upper cover (1) on the boiler.

✓ The cladding is installed.

Figure 4/32 - Installing the control unit

Figure 4/33 - Mounting the support plate

If the flue pipe connection is fitted at the top, the upper cover must be broken out.

Figure 4/34 - Installing the upper cover

Page 37

4 Planning and installation – Installing the heating system

INSTALLING THE ASH CONTAINER

1. Push the ash container (1) diagonally from the left under the

reservoir.

2. Push the handle (2) all the way in.

✓ The opening s in the ash container are open.

3. Close the clamp lock (3).

✓ The ash container is installed.

MOUNTING THE EXPANSION MODULES

1. Attach the base plate (1)

under the reservoir on the boiler and bend the front part down to the ground.

Figure 4/35 - Mounting the base plate

Figure 4/36 - Mounting the support plate

4. Adjust the foot (1) of the ash

container.

Figure 4/37 - Adjusting the foot

Important!

If an EM4 or EM8 expansion module is used, these can be mounted directly on the plate above the automatic burner.

✎ For connecting the expansion module, see the “Electrical plans

for the HDG K10 - 60”.

Page 38

4 Planning and installation – Installing the heating system

1. Mount the EM4 expansion module (2) if necessary.

2. Mount the EM8 expansion module (1) if necessary.

3. Connect the EM4 expansion modules (1 + 2).

✎ See “Electrical plans for HDG K10 - 60”.

4. Install the cables and sensors on the expansion modules

according to the hydraulic wiring diagram.

✓ The EM4 / EM8 expansion modules are fitted.

ERVICE PLUG

Figure 4/38 - Mounting the expansion modules

Figure 4/39 - Service plug

Important!

The service plug (1) is only intended for HDG customer service and may not be connected to any module!

Page 39

4 Planning and installation – Connecting the chimney

CONNECTING THE SUCTION AND RETURN HOSES

1. Lay bare about 10 cm of the end of the braid (1) embedded in the

return hose.

2. Bend the braid (1) inwards into the hose.

3. Undo the four screws and remove the cover (4) of the reservoir.

4. Fit the suction hose (2) with a hose clip on the left connecting port

of the reservoir.

5. Fit the return hose (3) with a hose clip on the right connecting port

of the reservoir.

✓ The suction and return hose is connected.

4.5 Connecting the chimney

1. Connect the flue gas 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.

4.6 Electrical system

The electrical connections should be made in accordance with VDE guideline 0100, “Electrical systems in buildings”.

✎ The technical details are described in chapter “3 Mode of

operation”, section “3.3 Technical data”.

✎ The circuit diagrams for the HDG K10 - 33 can be found in

“Electrical plans for the HDG K10 - 60”. The connections for the mains supply line can also be found in this document.

Figure 4/40 - Removing the packaging

In the event that the connections do not move easily when attached, only moisten with water (do not use grease).

Page 40

4 Planning and installation – Water

4.7 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 the system into operation, heat up the system to the maximum boiler temperature and bleed air from the system again to make sure that there are no air pockets.

The safety devices must be implemented in accordance with DIN EN 12828 “Heating systems in buildings” and the correspondingly harmonised national standard DIN 4751, Part 2 “Closed, thermostatically safeguarded heat generating systems with supply temperatures of up to 120°C; safety equipment”.

In Germany, the requirements of the German energy conservation ordinance (EnEV) must be met.

Important!

The heating system must be filled with water in accordance with VDI guideline 2035, “Avoiding damage in hot water heating systems”.

Page 41

5 Commissioning the system – Requirements

5 Commissioning the system

The heating system is initially commissioned by specialists from HDG Bavaria or from an authorised HDG partner.

The commissioning includes an introduction to the operation and maintenance of the heating system as well as performing measurements on the system to determine exhaust emissions and firing performance.

5.1 Requirements

The following conditions must be met before the system can be commissioned without faults:

WITCH OFF THE MAINS SUPPLY • Is the circuit breaker of the mains supply to the heating system

switched off?

HECK THE MECHANICAL

ASSEMBLY

• Have the system components been correctly installed?

• Have all of the mechanical components been firmly screwed

together?

• Does the mechanical structure of the boiler meet the

specifications of this operating manual?

• Has the water tank been filled with water?

HECK THE HYDRAULIC

CONNECTIONS

• Do the hydraulic connections meet the specifications of this

operating manual?

• Has the safety equipment been installed to conform to the

applicable standards and guidelines?

• Has the system been flushed, filled and bled (heat transfer must

be possible)?

HECK THE ELECTRICAL

CONNECTIONS

• Are all of the sensors and actuators correctly connected and

properly plugged in to the control panel?

• Has the mains power supply cable been correctly connected?

Danger!

Material damage and injury due to incorrect commissioning Commissioning the system requires comprehensive expertise. If

this commissioning is done by an untrained person, the heating system could be damaged.

Only allow authorised specialists to perform the commissioning.

Danger!

Dangerous electrical current or voltage Isolate the mains cable to the heating system.

Page 42

5 Commissioning the system – Procedure

FUEL • Is there a sufficient quantity of fuel?

5.2 Procedure

✎ See also operating manual “HDG Control”, Chapter “4

Commissioning the system”.

SETTING THE FUEL QUANTITY

1. Start the conveyor auger in manual mode.

2. Collect the pellets with a suitable container.

3. Repeat the cycle two (with HDG K21/26/33) or three times (with

HDG K10/15).

4. Weigh the amount of pellets collected in the second or third cycle.

5. Multiply the weight by a factor of 10 (= fuel quantity in kg/h).

6. Enter the calculated value in the boiler control system.

✎ See operating manual “HDG Control”, chapter “7 HDG K10 - 60

parameters”.

✓ The fuel quantity has been calculated.

PERFORM ACTUATOR TEST

In addition to the automatic self-test, individual actuators can also be manually activated as required.

✎ See operating manual “HDG Control”, chapter “7 HDG K10 - 60

parameters”.

ADAPTING PARAMETERS

If the heating system does not work correctly, the parameters must be adjusted accordingly.

✎ See operating manual “HDG Control”, chapter “7 HDG K10 - 60

parameters”.

Important!

Commission the HDG K10 - 33 heating system in accordance with the specifications from the supplied commissioning protocol.

One cycle of the conveyor auger lasts 6 mins.

Page 43

6 Using the heating system – Control unit for HDG Control

6 Using the heating system

6.1 Control unit for HDG Control

✎ You can find all information and instructions for setting up and

operating the boiler and weather-compensated heating control of the HDG Control in the “HDG Control” operating manual.

6.2 Filling the pellet storage room

REQUIREMENTS

The following requirements must be met before the pellet storage room can be filled:

• The pellet storage room has been initially approved by an

authorised specialist.

• The pellet storage room is dry and free of any foreign bodies.

• Thick layers of dust must be removed.

✎ See chapter “3 Mode of operation”, section “3.4 Fuel quality

requirements”.

• The requirements of government safety organisations must be

met.

PROCEDURE

1. Switch the heating system off.

✓ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Double check that the heating system is switched off.

To prevent negative pressure from being created in the boiler during filling of the pellet storage room, you can open the combustion chamber door.

3. Open the housing door (2).

4. Open the combustion

chamber door (1).

Figure 6/1 - Opening the doors

Page 44

6 Using the heating system – Filling the reservoir

5. Inform the tanker driver that the pellet storage room can be filled.

6. After filling is completed, close the injection and extraction

nozzles.

7. Close the reservoir inspection hatch.

9. Switch the heating system on.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.2 Switching on the heating system”.

✓ The filling of the pellet storage is completed.

6.3 Filling the reservoir

MANUAL FILLING When operating without an automatic pellet suction system, the

reservoir is manually filled.

1. Open the reservoir cover.

2. Fill the reservoir with pellets up to a maximum of 1 cm below the

rim.

✓ The reservoir is filled.

ELLET SUCTION SYSTEM The reservoir is filled by the automatic pellet suction system. Initial

filling is performed during commissioning of the system. Each further filling is automatic as required by the boiler control system.

6.4 Performing a chimney sweep measurement

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.8 Performing a chimney sweep measurement”.

8. Document the filling of the

storage room on the “Filling the fuel storage room” sticker.

Figure 6/2 - Filling the fuel storage room

002357/00

01/2010

Befüllung Lagerraum

Filling date and volume

Remplissage du silo de stockage

Datum/Date/Date

Menge/Volume/Quantité

Page 45

6 Using the heating system – Switching off the heating system for repair work

6.5 Switching off the heating system for repair work

1. Allow the fire in the boiler to burn out and cool off.

2. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

3. Lift off the top right cover (1) of the boiler.

4. Pull out the machine’s mains plug (2).

✓ The heating system is switched off and without current.

Important!

Frost danger Only completely shut off the power to the heating system if the

danger of frost can be ruled out.

There is still electrical voltage in the system.

Figure 6/3 - Removing the mains plug

Page 46

7 Cleaning and servicing the heating system – Cleaning and servicing schedule

7 Cleaning and servicing the heating system

GENERAL INFORMATION To ensure fault-free and safe operation, certain cleaning and

maintenance work is necessary. This effort will also help you avoid expensive repairs, provided you observe the recommended intervals.

The cleaning and maintenance work can also be performed by an authorised specialist heating company where a servicing contract has been concluded.

The HDG K10 - 33 heating system is fitted a cleaning and de-ashing interval display. The "clean" or “main cleaning” prompt appears on the boiler control system display and must be reset after cleaning/ de-ashing.

PARE PARTS

7.1 Cleaning and servicing schedule

Only use genuine HDG spare parts. You can obtain HDG spare parts from your specialist heating company.

The specified cleaning intervals are guidelines. Depending on the quality of the pellets and the power used by the heating system (more frequent on/off operation) the intervals may be extended.

Interval Component See page ...

Indication in display:

Cleaning Emergency cleaning

• Empty the ash box

• Clean the combustion chamber and burner pot

(Confirm cleaning)

48 49

Indication in display:

Main cleaning Emergency main cleaning

or At least 1 x per heating period

• Clean flue gas fan and cleaning shaft

• Clean the flue gas pipe

• Check the fill level of the water tank

• Check and clean the reservoir and flap of the

delivery unit

• Clean the pellet storage room

(Confirm main cleaning)

53 53 54

Indication in display:

Mainten.

• Have maintenance carried out by HDG or an

authorised specialist heating installer within 3 months

Table 7/1 - Cleaning and servicing schedule

Page 47

7 Cleaning and servicing the heating system – Procedure

7.2 Procedure

GENERALLY APPLICABLE SAFETY INSTRUCTIONS

Warning!

Danger of asphyxiation due to lack of oxygen If the boiler is in operation, carbon monoxide can be emitted

through the open doors, lids or other cleaning openings. When performing cleaning and maintenance work, do not leave the

cleaning openings, doors and lids open any longer than necessary.

Caution!

Danger of burns from hot surfaces During operation, the boiler surfaces under the cladding are hot.

Even when turned off, they only cool down slowly. Switch the heating system off and only start with the cleaning and

maintenance work when the surfaces have cooled down.

Caution!

Danger of fire from combustion residues Hot combustion residues (ash, coal etc) can pose the danger of fires. Allow the hot combustion residues to cool down in the cleaning

and maintenance work before pouring these into a non-flammable container.

Turn the heating system off before carrying out the tasks described below.

✎ See chapter “6 Using the heating system”, section “6.5 Switching

off the heating system for repair work”.

Only turn the heating system back on again after carrying out the tasks described below.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.2 Switching on the heating system”.

Page 48

7 Cleaning and servicing the heating system – Procedure

CLEANING TOOLS

1 Cleaning brush 2Scraper 3Allen key 4Scraper 5 Pellet scuttle (optional)

EMPTYING THE ASH CONTAINER

1. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Allow the fire in the heating system to burn out and cool down.

Figure 7/1 - Cleaning tools

1 2 3 4 5

Important!

Observe the “Generally applicable safety instructions” in this section.

Important!

The combustion chamber door must not be opened during continuous operation. Always switch off the boiler first and wait until burn-out mode has finished.

3. Open the housing door (2).

4. Open the combustion

chamber door (1).

Figure 7/2 - Opening the doors

Page 49

7 Cleaning and servicing the heating system – Procedure

9. Open the lid of the ash container (1) and empty the combustion

residues into a non-flammable container.

10.Reinstall the ash container (1) in the reverse sequence.

11.Re-starting the heating system.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.2 Switching on the heating system”.

✓ The ash container has been emptied.

CLEANING THE COMBUSTION CHAMBER AND BURNER POT

1. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Allow the fire in the heating system to burn out and cool down.

3. Open the housing door and the combustion chamber door.

5. Pull the handle (1) of the ash

container all the way out.

✓ The side openings of the ash

container are locked.

6. Release the lower right clamp

lock (2).

Figure 7/3 - Locking the ash container

7. Push the ash container (1)

slightly to the left.

8. Pull out the ash container (1).

Figure 7/4 - Removing the ash container

Important!

Observe the “Generally applicable safety instructions” in this section.

Important!

The combustion chamber door must not be opened during continuous operation. Always switch off the boiler first and wait until burn-out mode has finished.

Page 50

7 Cleaning and servicing the heating system – Procedure

CLEANING THE COMBUSTION

CHAMBER

LEANING THE BURNER POT

4. Clean the combustion

chamber temperature sensor (1) using the cleaning brush.

Figure 7/5 - Cleaning the combustion chamber temperature sensor

5. Clean the drop chute (1) if

necessary, for example using a screwdriver.

Figure 7/6 - Cleaning the drop chute

6. Remove the combustion

residue from the combustion chamber with a vacuum cleaner.

Figure 7/7 - Cleaning the combustion chamber

7. Lift the upper part of the cone

(1) out of the burner pot.

Figure 7/8 - Removing the upper part of the cone

8. Lift the lower part of the cone

(1) out of the burner pot.

Figure 7/9 - Removing the lower part of the cone

Page 51

7 Cleaning and servicing the heating system – Procedure

9. Clean the cone (1) on all sides using a brush and remove any hard

deposits with a scraper.

10.Clean the burner pot (1) with a vacuum cleaner.

11.Make sure that the secondary air openings in the burner pot (1)

are free.

12.Take the primary air pin (2) out of the burner pot.

13.Carefully clean the primary air pin (2) and the primary air holes

with a suitable tool (such as a screwdriver).

14.Make sure that the primary air holes are free.

16.Clean the remaining combustion residues in the burner pot and

the primary air pipe (1) using a vacuum cleaner.

17.Ensure that there are no more combustion residues in the primary

air pipe since otherwise the ignition element can be damaged.

Figure 7/10 - Cleaning the cone

Important!

Always remove all the ash from the combustion chamber and burner pot first. Only then can you take out the primary air pin for cleaning.

Figure 7/11 - Cleaning the combustion chamber and primary air pin

1 2

15.Use the cleaning tool to

remove any combustion residue from the bottom of the burner pot (1).

Figure 7/12 - Cleaning the primary air pipe

Page 52

7 Cleaning and servicing the heating system – Procedure

18.If necessary clean the primary air pipe once again with a vacuum

cleaner.

19.Reinstall the burner pot in the reverse order.

20.Reset the cleaning prompt in the boiler control system for the

combustion chamber and burner pot.

✓ The combustion chamber and the burner pot are now clean.

CLEANING THE FLUE GAS FAN AND CLEANING SHAFT

1. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Allow the fire in the heating system to burn out and cool down.

3. Remove the top right cladding.

Important!

Observe the “Generally applicable safety instructions” in this section.

4. Remove the insulation (1)

from the cleaning shaft lid.

Figure 7/13 - Removing the insulation

5. Release the star-grip screw (1)

and lift off the cleaning shaft lid (2).

Figure 7/14 - Dismantling the cleaning shaft lid

6. Clean the fan wheel (1) with a

brush or a vacuum cleaner.

Figure 7/15 - Cleaning the fan wheel

Page 53

7 Cleaning and servicing the heating system – Procedure

✓ The flue gas fan and the cleaning shaft are now clean.

CLEANING THE FLUE GAS PIPE

1. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Allow the fire in the heating system to burn out and cool down.

7. Screw the inspection hatch (2) securely onto the flue gas pipe (3)

with the wing nut (1).

✓ The cleaning of the flue gas pipe is completed.

CHECK THE FILL LEVEL OF THE WATER TANK

7. Clean the cleaning shaft lid (1)

using a scraper.

8. Remove the flue ash in the

cleaning shaft (1) with a vacuum cleaner.

9. Close the boiler in the reverse

order.

Figure 7/16 - Cleaning the cleaning shaft

Important!

Observe the “Generally applicable safety instructions” in this section.

3. Unscrew the wing nut (1) on

the inspection hatch lid (2).

4. Remove the inspection hatch

lid (2) from the flue gas pipe (3).

5. Check whether the flue gas

pipe (3) needs cleaning.

6. If necessary, suction the ash

out of the flue gas pipe using a vacuum cleaner (3).

Figure 7/17 - Clean the flue gas pipe

Important!

Observe the “Generally applicable safety instructions” in this section.

Page 54

7 Cleaning and servicing the heating system – Procedure

✓ The fill level of the water tank has been checked.

CHECKING AND CLEANING THE RESERVOIR AND FLAP OF THE DELIVERY

UNIT

The reservoir and the flap of the delivery unit have to be cleaned when too much dust has accumulated or there is a foreign body in the reservoir. If no pellets can be delivered to the reservoir by the pellet suction system, emergency manual filling is possible via the inspection hatch.

1. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Allow the fire in the heating system to burn out and cool down.

1. Check the fill level of the

water tank (1) (volume approx. 8 l).

✓ If the minimum fill level

indicator is not reached, water must be added.

2. Top up the water tank (1).

Figure 7/18 - Water tank fill level

Important!

Observe the “Generally applicable safety instructions” in this section.

Caution!

Risk of serious injury if the stoker auger starts up The stoker auger can start up unexpectedly. When the inspection

hatch is open, you hands or fingers can be crushed. Before opening the inspection hatch on the reservoir, always

disconnect the boiler from the power supply (pull out the mains plug) and secure it against being switched on again.

3. Lift off the top right cover (1)

of the boiler.

Figure 7/19 - Removing the upper cover

Page 55

7 Cleaning and servicing the heating system – Procedure

6. Have a container ready for the pellets.

7. Undo the four screws of the inspection hatch (1) and remove

them.

8. Remove the pellets and dust from the reservoir.

9. Remove the dust in the on the flap (2) of the delivery unit and the

proximity switch (4) with a vacuum cleaner.

10.Check that the flap (2) moves smoothly.

11.Ensure that the entire surface of the flap (2) touches the seal (3).

4. Pull out the mains plug (1).

Figure 7/20 - Removing the mains plug

5. Undo the four screws and

remove the lower front cladding (1) of the reservoir.

Figure 7/21 - Removing the lower front cladding

Figure 7/22 - Checking and cleaning the reservoir and flap of the delivery unit

Page 56

7 Cleaning and servicing the heating system – Procedure

EMERGENCY FILLING OF THE

RESERVOIR

15.Close the reservoir and the boiler in the reverse order.

✓ The reservoir and the flap of the delivery unit have been cleaned.

CLEANING THE PELLET STORAGE ROOM

HDG AUGER

HDG

SUCTION SYSTEM WITH

SUCTION PROBES

GENERAL INFORMATION 1. Switch the heating system off.

✎ See the “HDG Control” operating manual, chapter “5 Using the

control unit”, section “5.3 Switching off the heating system”.

2. Allow the fire in the heating system to burn out and cool down.

3. Open the access hatch of the pellet storage room.

4. Remove the wooden boards inside the access hatch.

12.Mount the inspection hatch

(2) as touch protection on the opening for the conveyor auger.

13.If necessary, fasten the pellet

scuttle (1) to the reservoir.

14.Fill the pellets into the

reservoir (using the pellet scuttle (1) if necessary).

Figure 7/23 - Emergency filling

Caution!

Danger of injury from the rotating auger! When the heating system is turned on, the auger rotates in the

pellet storage room. Hands and feet could thereby be crushed. Switch the heating system off before you enter the pellet storage

room.

Caution!

Material compression at the suction probes If the pellet storage room is entered, there can be material

compression in the suction probes. This can lead to the pellet delivery being impaired.

When you enter the pellet storage room, be sure not to stand on the pellets in the area of the suction sensors.

Page 57

7 Cleaning and servicing the heating system – Procedure

5. Check the pellet storage room for foreign objects and remove

them if necessary.

6. Clean the pellet storage room with a vacuum cleaner.

7. Check tha t no p ellets are swollen, if moistur e has gotten inside the

pellet storage room.

8. Close the access hatch in the reverse sequence.

✓ The pellet storage room has been cleaned.

Leading pellet suppliers recommend completely emptying the pellet storage room every 2–3 years. When operating the heating system with HDG suction system and suction probes, you can deactivate the automatic changeover between the three suction probes using the boiler control system.

✎ See chapter “6 Using the heating system”, section “Operator

level”, paragraph “Sensor changeover”.

In this way you can completely empty the fuel storage room at a probe (that is, 1/3 of the fuel storage room) and continue heating with the other two suction probes. If you repeat this process every year with one of the other sensors, "renew" your entire pellet supply every three years.

Page 58

8 Notes on dismantling and disposal – Dismantling

8 Notes on dismantling and disposal

8.1 Dismantling

The heating system can be dismantled as follows.

1. Allow the fire in the boiler to burn out and cool off.

2. Switch the heating system off.

✎ See chapter “6 Using the heating system”, section “6.5 Switching

off the heating system for repair work”.

3. Switch the circuit breaker for the heating system off.

4. Disconnect the heating system from the electrical power supply.

5. Once it has cooled down, drain the heating water from the system.

6. Observe the safety regulations for personnel when disconnecting

the boiler from the heating system.

7. Dismantle the individual components of the heating system.

✓ The heating system has been dismantled.

8.2 Disposal

The following components are made of steel and can be recycled via a local recycling centre.

• Boiler

• Cladding

• Reservoir

• Conveyor auger without motor

• Transfer station without motor

• Delivery system

• Pressure relief baffle

• Sloping floor supports

Danger!

Material damage and injury due to incorrect dismantling. Dismantling the system requires comprehensive specialist

knowledge. If the heating system is dismantled by an untrained person, injuries are possible.

Only allow authorised specialists to dismantle the system.

Page 59

8 Notes on dismantling and disposal – Disposal

The electrical components can also be recycled via a local recycling centre.

Fibreglass, 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 dismantled into its separate

components and cleaned if necessary.

3. Metal parts should be recycled.

Oily or greasy components and condensers may only be disposed of through a specialist waste disposal centre.

Page 60

9 Declaration of Conformity

EC Declaration of Conformity

in accordance with Section A of Part 1 of Annex II of the

EC Directive 2006/42 on machinery

Producer:

HDG Bavaria GmbH

Heating syst em for wood Siemensstraße 22

D - 84323 Massing

Resident of the EC authorized to assemble the adequate technical documentation

Stefan Holfelder

HDG Bavaria GmbH

Heating syst em for wood Siemensstraße 22

D - 84323 Massing

Description and identification of the machinery

Product HDG pellet boiler

Type

HDG K10/15/ 21/26

/33

We definitely declare hereby that the machinery complies with each and every relevant provision of the following EC Directives

2006/42/EC

2004/108/EC

Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending D irective 95/16/EC (recast) (1 )

Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member 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 303-5:2012

Part 5: Heating boilers for solid fuels, hand and automatically fired, nominal heat output of up to 500 kW. Terminology, requirements, testing and marking

Massing, 02.08.2017

Place, date

Signature Martin Eck er CEO

Page 1/1

Page 61

10 Index

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air inlet cross section . . . . . . . . . . . . . . . . . . . . . . . 16

Ash compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Boiler class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Boiler control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Boiler flow

- Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Boiler installation site . . . . . . . . . . . . . . . . . . . . . . 19

Boiler return

- Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Burner pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

- Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chimney sweep test . . . . . . . . . . . . . . . . . . . . . . . . 44

Cleaning and servicing schedule . . . . . . . . . . . . 46

Cleaning shaft

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Combustion chamber

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Combustion chamber temperature sensor . . 13

Combustion process . . . . . . . . . . . . . . . . . . . . . . . 13

Commissioning the system . . . . . . . . . . . . . . . . . 41

Conveyor auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Declaration of Conformity . . . . . . . . . . . . . . . . . . 60

Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . 6, 14

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DIN EN 13384-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIN EN ISO 17225 . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DINplus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Drop chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical connection . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical system . . . . . . . . . . . . . . . . . . . . . . . 22, 39

ENplus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Expansion module EM4

- Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Expansion modules . . . . . . . . . . . . . . . . . . . . . . . . 37

Flap of the delivery unit . . . . . . . . . . . . . . . . . . . . 12

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Flue calculation . . . . . . . . . . . . . . . . . . . . . . . . 16, 20

Flue draught requirement . . . . . . . . . . . . . . . . . . 16

Flue gas fan

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Flue gas mass flow . . . . . . . . . . . . . . . . . . . . . . . . . 16

Flue gas pipe

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Flue gas pipe connection . . . . . . . . . . . . . . . . . . . 16

Flue gas temperature . . . . . . . . . . . . . . . . . . . . . . 16

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

HDG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 43

Heating system

- Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . 28

Level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Lightning/surge protection . . . . . . . . . . . . . . . . . 22

Low voltage directive . . . . . . . . . . . . . . . . . . . . . . 22

Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . 18

Nominal thermal power . . . . . . . . . . . . . . . . . . . . 16

Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . 16

Original state on delivery . . . . . . . . . . . . . . . 25, 26

Pellet storage room

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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10 Index

- Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

- Safety instructions . . . . . . . . . . . . . . . . . . . . . 11

Pellet suction system . . . . . . . . . . . . . . . . . . . . 6, 15

Pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pipe dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Primary air pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Proper and improper operation . . . . . . . . . . . . . . 7

Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, 12

- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

- Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Return temperature . . . . . . . . . . . . . . . . . . . . . . . . 23

Return temperature, minimum . . . . . . . . . . . . . 16

Room sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

running time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . 16

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Supply temperature, maximum . . . . . . . . . . . . . 16

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

VDI 2035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 40

VDI 3464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Warnings and safety symbols . . . . . . . . . . . . . . . . 9

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 40

Water capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Water tank

- Checking the fill level . . . . . . . . . . . . . . . . . . 53

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Page 64

HDG Bavaria GmbH

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

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