HDG M299, M300, M350, M400 Operation Manual

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HDG M299/300/350/400

Operation Manual

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Operation Manual HDG M299/300/350/400 - Content

Content

1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.2 Structure of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.3 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Basic system design principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Basic principles for the content of the operating manual . . . . . . . . . . . . . . . . . . .11

Proper and improper manner of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.2 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3 Warnings and safety symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.4 Duty of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

HDG M299/300/350/400 front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

HDG M299/300/350/400 back side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Cross section of HDG M299/300/350/400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

HDG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Control modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Permissible fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Wood chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Space requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Room height requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Installation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Water-side connections for HDG M299/300/350/400 . . . . . . . . . . . . . . . . . . . . . . .40

Sensors and connections of the HDG M299/300/350/400. . . . . . . . . . . . . . . . . . .41

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Operation Manual HDG M299/300/350/400 - Content

Hydraulic connection of combustion unit to heat exchanger . . . . . . . . . . . . . . 43

4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the central ash removal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Installing the feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Installing the housing of the flue gas fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Installing the cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installing ash containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fitting the accumulator sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Installing the EMD-C 215 Exclusiv control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 66

Connecting the chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.5 Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.6 Vacuum pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.7 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.8 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4.9 Thermal safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.10 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Setting the display language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Checking the actuators in manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Filling the transfer station of the central ash removal system . . . . . . . . . . . . . . 74

Filling the fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.1 Overview of the controls and display components. . . . . . . . . . . . . . . . . . . . . . . . . . 77

Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Additional controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Control cabinet model EMD-C 215 Exclusiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Control unit for HDG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

6.2 Switching on the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6.3 Switching off the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

6.4 Operating statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

6.5 Calling up information, selecting and modifying parameters . . . . . . . . . . . . . . . . 83

6.6 ON/OFF menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Setting the base load / peak load boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Setting operating times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Setting the control, boiler activation and Lambda Stop . . . . . . . . . . . . . . . . . . . . 87

Modifying fan settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Adjusting the ash removal setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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Operation Manual HDG M299/300/350/400 - Content

Changing the cleaning system setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Modifying the extraction setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Modifying the walking floor setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

6.7 °C/QUANTITY menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Defining the switch on/off times for the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Integrating the peak load boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Setting the boiler and return temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Viewing combustion chamber temperature, residual oxygen and vacuum

pressure in the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Setting combustion chamber temperature 2 and viewing flue

gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Selecting a fuel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Fixed value - Setting the fuel and air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Setting the return pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Setting the return mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Other parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

6.8 TIME menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Setting the filling, ignition and fan activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Setting pre-air, heating up and burning out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Setting the grate times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Setting grate ash removal augers and ascending auger times . . . . . . . . . . . . . .98

Setting times for the heat exchanger ash removal augers and the

cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Setting main cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Stoker auger delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Setting pause intervals and running time for delivery . . . . . . . . . . . . . . . . . . . . 100

Setting the agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Setting the walking floor delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Setting the day, date and time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.9 MANUAL menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Combustion air and ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Primary and secondary air flaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Central ash removal, grate ash removal auger and grate drive . . . . . . . . . . . . 103

Heat exchanger ash removal auger and cleaning system . . . . . . . . . . . . . . . . . 103

Return pump, return mixer and intermediate pump. . . . . . . . . . . . . . . . . . . . . . 103

Feed system, rotary wheel and material conveying auger . . . . . . . . . . . . . . . . 104

Feed system, auger trough 2 and dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Material conveying auger and agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Moving floor - transverse auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Moving floor - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6.10 SERVICE menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Chimney sweep test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Operating hours counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Service messages 1 - setting reminder time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Service messages 2 - setting reminder time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Service messages 3 - setting reminder time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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Operation Manual HDG M299/300/350/400 - Content

Setting the boiler overheating temperature or hysteresis, minimum return

temperature and combustion chamber stop temperature . . . . . . . . . . . . . . . . 111

Setting reverse feeding and ignition temperature. . . . . . . . . . . . . . . . . . . . . . . . 112

Modifying the dosage pause min. or impulse min. and feeding units

lag time or lead time parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Fuel quantity 1st Modifying filling and air start setting . . . . . . . . . . . . . . . . . . . 113

Ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Setting vacuum pressure controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Calibrating the lambda sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Chimney sweep test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Peak load boiler monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Flue gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Setting interface RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Setting Modbus RTU - Web server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Setting Modbus RTU - DDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Setting Profibus DP- DDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Entering passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Resetting parameters to the factory default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Setting output control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Entering fuel and temperature settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Entering the primary air setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Setting preset values for primary air flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Entering the residual oxygen setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Entering the secondary air setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Setting preset values for secondary air flaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Adapting the fuel quantity/O2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Setting vacuum pressure control values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Setting air flap delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.11 INFO menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.12 Maintenance function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6.13 Filling the fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Procedure for filling with wood chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Procedure for filling with pellets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

6.14 Performing the chimney sweep test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Before the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

During the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

7 Cleaning and servicing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.1 Cleaning and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Maintenance function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Generally applicable safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Removing the cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Lubricating the feeding system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Cleaning the stepping grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Checking and emptying the ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Cleaning the cleaning shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Page 7

Operation Manual HDG M299/300/350/400 - Content

Cleaning the vacuum pressure pipe for the pressure switches . . . . . . . . . . . . 144

Cleaning the vacuum pressure pipe for the differential

pressure transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Cleaning the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Checking the drive chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Cleaning the ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Cleaning and calibrating the lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Cleaning the flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Cleaning the flue gas pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Cleaning the pressure equalisation hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Cleaning fly ash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Inspecting the fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

8.1 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

8.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

9 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

9.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

10 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

10.2 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

10.3 Warranty exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Page 8

1 Notes on this manual – Introduction

HDG M299/300/350/400 - Version 1 - de © HDG Bavaria GmbH 07/2008

1 Notes on this manual

1.1 Introduction

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

heating system

• HDG M299/300/350/400

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

ANUAL

This operating manual must be read and observed by everyone who operates or works on the HDG M299/300/350/400.

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

in this edition was correct at the time of going to press. We reserve the right to make changes which may then differ from the

technical details and illustrations in this operating manual.

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.

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

used for particularly important information:

1. Instructions to the operator

2. Work through the steps in the sequence specified.

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

• List

–List

Page 9

1 Notes on this manual – Structure of the operating manual

1.2 Structure of the operating manual

The operating manual is structured as follows:

Chapter This explains ...

1 Notes on this manual ... how to use this operating manual.

2 Safety notes ... everything on the subject of safety that you should consider

when using the heating system.

3 Mode of operation ... the structure and all of the features of the heating system.

4 Planning and installation ... how to properly plan and install the heating system.

5 Commissioning the system ... how the heating system is put into initial service.

6 Using the heating system ... how to properly operate the heating system.

7 Cleaning and servicing the

heating system

... how to clean the heating system and who is responsible for its maintenance.

8 Troubleshooting … how to rectify faults in the heating system.

9 Notes on dismantling and

disposal

... what has to be considered when dismantling and disposing of the heating system.

10 Warranty ... the terms and conditions of the warranty.

Table 1/1 - Structure of the operating manual

Page 10

1 Notes on this manual – Glossary

HDG M299/300/350/400 - Version 1 - de © HDG Bavaria GmbH 07/2008

1.3 Glossary

Term Explanation

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

heating system, for example the stoker auger.

Ash removal augers These transport the combustion chamber ash and fly ash into the

exterior ash containers.

Ash removal motor Powers the ash removal augers and the ash walking floor

Delivery system Fuel transport system - carries fuel from the storage to the dosing

unit or to the intermediate container.

Display Display of the HDG Control unit in the refrigerator.

Emergency stop Must be used in an emergency - interrupts all actuators; does not

switch off the mains supply to the entire heating system.

Extinguishing device Extinguishes what is within the delivery system if the temperature

of the contents exceeds 90 °C.

Feeding system Feeds the fuel to the boiler by means of the rotary feeder and the

stoker auger.

HDG Control Electronic control unit of the boiler, feeding system and delivery

system.

HDG M299/300/350/400 Boiler for burning wood chips, shavings and wood pellets

Heating system Comprised of boiler and corresponding accessories.

Main switch Switches off the mains supply to the entire heating system.

Rotary feeder Part of the feeding system - separates the combustion chamber

from the silo and transport unit and acts as back-burn protection.

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

them to the control for analysis.

Stoker auger Carries the fuel from the rotary feeder into the combustion

chamber.

Turbulator Component for improving heat transfer from the flue gas to the

heat exchanger surface

Table 1/2 - Glossary

Page 11

2 Safety instructions – Intended use

2 Safety instructions

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 detailed instructions on 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.

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 M299/300/350/400 heating systems. Any further implementation of applicable standards, for example with regard to the installation of the heating system (pipework, etc.) is not part of this operating manual. HDG Bavaria does not assume any liability for this.

PROPER AND IMPROPER MANNER OF OPERATION

PURPOSE OF THE HEATING

SYSTEM

The HDG M299/300/350/400 heating system is designed for the standard use of burning wood fuel products made from untreated wood in the form of wood chips, shavings and pellets for the purpose of warm water heating.

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.

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.

The use of materials with other technical burning characteristics requires comprehensive modification of the control parameters by qualified specialists.

Page 12

2 Safety instructions – Residual risks

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

2.2 Residual risks

Despite all precautions, the following residual risks remain:

✎ For more information on fuel, see section “3 Mode of operation”

in chapter “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 operating, carbon monoxide can be emitted through

the cleaning or inspection openings. Do not leave these open any longer than necessary.

Warning!

Danger of fire Opening doors and lids to hot combustion residues can pose the

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

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

Warning!

Danger from suspended loads Each of the boiler units weight more than 2500 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.

Page 13

2 Safety instructions – Residual risks

Warning!

Danger of injury The cleaning shaft lids are very heavy and can fall shut. Hands and

arms could thereby be crushed. Take care not to bump into the opened cleaning shaft lid and cause

it to fall shut.

Danger!

Danger of explosion due to carbon monoxide When the boiler is in operation, carbon monoxide escaping from

open cleaning or inspection hatches can cause explosions. Do not leave these open any longer than necessary.

Warning!

Risk of injury from automatically driven components When working on the automatic ash removal or automatic cleaning

systems, hands and arms could be injured. Turn off the main switch when performing any work on

automatically driven components and secure it against being turned back on.

Danger!

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

electrician and turn the main switch off.

Warning!

The boiler is under pressure.

Page 14

2 Safety instructions – Warnings and safety symbols used

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

2.3 Warnings and safety symbols used

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

Danger!

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

qualified electrician.

Warning!

Hazardous area Working in areas marked with this symbol can lead to serious

injuries or to extensive material damage.

Warning!

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

Warning!

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

to automatic start-up.

Caution!

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

Warning!

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

Danger!

Danger of asphyxiation due to lack of oxygen When working in areas marked with this symbol, there is a danger

of asphyxiation due to high concentrations of carbon monoxide.

Page 15

2 Safety instructions – Duty of information

2.4 Duty of information

READING THE OPERATING M

ANUAL

Every person performing any tasks on the system is required to read the Operating Manual prior to beginning work, particularly the chapter “2 Safety instructions”.

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

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

Danger!

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

of explosion due to high concentrations of carbon monoxide.

Warning!

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

of falling objects.

Caution!

Frost danger Work on locations marked with this symbol can lead to frost

damage.

Instructions regarding disposal

Additional information for the operator

Page 16

3 Mode of operation – Overview

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

3 Mode of operation

3.1 Overview

The HDG M299/300/350/400 is constructed in two parts. It consists of the combustion unit and the heat exchanger.

The HDG M299/300/350/400 heating system is equipped as standard with the following:

• Central ash removal system for grate ash and fly ash 1

• Automatic ash removal of fly ash 2 and 3 into exterior ash

containers

• Automatic cleaning of the heat exchanger surfaces

The HDG M299/300/350/400 heating system is equipped with the HDG TBZ 200 for loading wood chips and shavings or with the HDG TBZ 150 for loading pellets.

The HDG M299/300/350/400 heating system can also be equipped with the following delivery systems:

• Hinged arm delivery system

• Walking floor delivery system

• Silo delivery system

• Walking floor changing container

• Pellet delivery system

Regarding the volume of the ash container, there are three different options:

• 240 l (central ash removal system)

• 80 l or 140 l (fly ash)

Unless otherwise specified, the product version with the TBZ 200 feed system will be illustrated and described in this Operating Manual.

Page 17

3 Mode of operation – Overview

HDG M299/300/350/400 FRONT SIDE

1Flue gas fan 2 Flue pipe connection 3 Boiler supply connection (DN 100 flange) 4 Boiler return connection (DN 100 flange) 5 Secondary air fan 6 Actuator for tertiary air 7 Actuator for secondary air 8 Drive motor for central ash removal system 9Ash bin 10 Drive motor for ash removal auger 11 Inspection window for stepping grate 12 Ignition fan 13 Drive motor for stepping grate 14 Actuator for primary air 1 15 Actuator for primary air 2 16 Primary air fan 17 Feeding system 18 Drive motor for fly ash augers

Figure 3/1 - HDG M299/300/350/400 front side

18 17 16

1113

6 7

15 14 1012

Page 18

3 Mode of operation – Overview

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

HDG M299/300/350/400 BACK SIDE

1 Cleaning shaft lid of combustion unit 2 Cleaning shaft lid of heat exchanger 3 Cleaning system drive motor 4Lambda sensor 5 Tubular heat exchanger 6 Turbulators 7 Fly ash container

Figure 3/2 - HDG M299/300/350/400 back side

56 4

31 2

Page 19

3 Mode of operation – Overview

CROSS SECTION OF HDG M299/300/350/400

1 Secondary air openings 2 Safety heat exchanger, combustion unit 3 Tertiary air openings 4 Combustion chamber 5 Ash removal auger for fly ash 1 6 Ash removal auger for grate ash 7 Stepping grate 8 Ignition pipe or fill level indicator

Figure 3/3 - Cross section of HDG M299/300/350/400

5 3

1 2

48 7 6

Page 20

3 Mode of operation – Functional description

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

3.2 Functional description

The HDG M299/300/350/400 heating system may contain the following components:

1Control cabinet 2 Delivery system 3 HDG material conveying auger TFQ 200 4Feeding system 5 HDG M299/300/350/400 boiler 6Accumulator

COMBUSTION PROCESS

With the HDG M299/300/350/400 heating system, the fuel is automatically fed from the storage room into the combustion chamber of the boiler via the delivery and feeding systems. The combustion fan is already activated here in order to eliminate any possible residual combustion gases or negative flue pressure conditions along the combustion path.

Once the filling cycle is complete, the fuel introduced into the combustion chamber is automatically ignited with an electrical ignition fan. During the subsequent heating-up phase, the specified fuel feed quantity is set.

Figure 3/4 - Overview

65431 2

Page 21

3 Mode of operation – Functional description

Following the heating-up phase, the system switches to automatic operation. In this mode, combustion is carried out according to the entered control options.

In order to free the grate from ash which collects during combustion, every second segment of the grate moves back and forth periodically. The automatic cleaning system cleans the heat exchanger surfaces using the turbulators which move up and down.

The grate ash and fly ash 1 are conveyed toward the central ash removal system by the automatic ash removal system using ash removal augers in the transfer station. From there an ascending auger conveys the ash into an optional 240 l ash bin. Fly ash 2 and 3 are propelled into the external ash containers by the ash removal augers of the automatic ash removal system.

The air necessary for combustion is supplied as required via two combustion air fans.

Sensors are used in the following:

– To continuously monitor the firing

– To adapt boiler output for the heat requirements

– To minimise emissions

– To optimise boiler efficiency

DELIVERY SYSTEM

The delivery system is in the fuel storage room. The fuel is transported from the fuel storage room to the dosing unit. The delivery system is controlled through the HDG Control.

HDG CONTROL

The HDG Control boiler controller in the control cabinet represents the electronic hub. This is a freely programmable PLC control.

Using the control unit, you can adjust the HDG M299/300/350/400 heating system and obtain information on the current process status.

The current operating status is displayed.

Figure 3/5 - HDG Control control unit



$POmH .POJUPS

Page 22

3 Mode of operation – Functional description

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

CONTROL MODES

You can choose between three control modes:

• Fixed value:

– Constant feed rate and constant combustion air flow rate (even

in emergency operation)

• Combustion control:

– Constant, specified combustion chamber temperature and

optimal combustion through modification of primary and secondary air and fuel quantity

– No output regulation

– Preferred method of operation with accumulator

• Control of combustion and output:

– Output supplied is adjusted to heat used with optimised

combustion

– Operation without accumulator

Page 23

3 Mode of operation – Technical data

3.3 Technical data

Boiler type

HDG M299

Wood chips

HDG M300

Wood chips /

pellets

HDG M350

Wood chips /

pellets

HDG M400

Wood chips /

pellets

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

Nominal thermal power 299 310/328 kW 350/350 kW 400/400 kW Minimum thermal power 85 kW 92/97 kW 105/105 kW 120/120 kW Boiler efficiency at nominal thermal

power

93.2 % 93.2 / 94.2 % 93.2 / 94.2 % 93.3 / 94.2 %

Electrical power consumption at nominal thermal power 856/856 W 899/868 W 952/894 W

Electrical connection: Voltage

Frequency Back-up fuse

400 V

50 Hz

16 A

General boiler data

Boiler class 3 5 Maximum permissible

operating pressure

6.0 bar

Maximum supply temperature 100 °C* Minimum return temperature 60 °C Water capacity 2110 l 2150 l 2200 l Weight of combustion unit 2640 kg 2700 kg 2730 kg Weight of heat exchanger 2860 kg 2900 kg 2920 kg

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

Flue gas temperature (Tw) at

• Nominal thermal power

• Minimum thermal power

140 °C 120 °C

150 °C 120 °C

160 °C 120 °C

170 °C

120°C

Flue gas mass flow at

• Nominal thermal power

• Minimum thermal power

0.167 kg/s

0.048 kg/s

0.167 /

0.169 kg/s

0.051 /

0.047 kg/s

0.186 /

0.177 kg/s

0.051 /

0.047 kg/s

0.210 /

0196 kg/s

0.051 /

0.047 kg/s

CO2content at nominal thermal power 15.6 % 15.6 / 15.0 % 15.5 / 15.1 % 15.4 / 15.2 % CO

content at lowest thermal power 12.3 % 15.6 / 15.1 % 15.6 / 15.1 % 15.6 / 15.1 %

Flue draught requirement (Pw) 10 Pa Diameter of flue pipe connection 300 mm Height at middle of flue pipe connection 2290 mm

Water-side connections

Supply and return connections (flange) DN 100 Connection for safety heat exchanger

(bushing) DN 20, outside thread Connection for drain (bushing) DN 30, inside thread Recommended pipe dimensions

(minimum) DN 100

Table 3/1 - Technical data

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3 Mode of operation – Fuel quality requirements

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

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

3.4 Fuel quality requirements

PERMISSIBLE FUEL

The HDG M299/300/350/400 heating system is designed for the standard use of burning untreated wood in the form of wood chips, shavings and wood pellets.

In accordance with German law (§3 (1) 1. BlmSchV), the fuel classes 4, 5, 5a, 6, and 7 may be used in this heating system.

UEL CLASS 4 Untreated log wood including adhering bark in the form of wood

chips.

UEL CLASS 5 Untreated wood (not log wood), such as shavings.

UEL CLASS 5A Pellets made of untreated wood in the form of wood pellets or wood

briquettes

UEL CLASS 6 Painted, varnished or coated wood including remains thereof,

provided no wood protection agents have been applied or are present as the result of a treatment, and coatings do not contain organic halogen compounds or containing heavy metals.

UEL CLASS 7 Plywood, chipboard, fibreboard or otherwise glued wood including

remains thereof, provided no wood protection agents have been applied or are present as the result of a treatment, and coatings do not contain organic halogen compounds or heavy metals.

Fuel classes 6 or 7 may only be used in a wood processing plant at 30 kW or more nominal thermal power. In the case of painted, varnished or coated wood, it should be noted that greater stress can be placed on the wearing parts such as wall lining, fill level and lambda sensors, which may reduce their service lives.

Water-side resistance at nominal thermal power

• 10 K

• 20 K

9100 Pa

2500 Pa

9100 /

10200 Pa

2500 /

2800 Pa

11500 /

13100* Pa

3100 /

3500* Pa

14600 Pa

4000 Pa

Other information

Sound pressure level emitted < 70 dB(A) Min. air inlet cross section 648 cm² 670 /

700 cm²

750 /

750 cm²

850 /

850 cm²

Boiler type

HDG M299

Wood chips

HDG M300

Wood chips /

pellets

HDG M350

Wood chips /

pellets

HDG M400

Wood chips /

pellets

Table 3/1 - Technical data

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3 Mode of operation – Fuel quality requirements

COMPOSITION OF THE FUEL Knowledge of the fuel composition forms the basis for the

combustion calculation and the treatment of operating issues relating to firing technology. In addition to combustible substances, the fuels also contain varying amounts of non-combustible, or “inert” components.

With an increasing ratio of inert components, the calorific value drops considerably, the combustion quality deteriorates, and the CO emission and the amount of ash and cinder dirt on the heating surfaces is increased.

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3 Mode of operation – Fuel quality requirements

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

WOOD CHIPS

Regarding the origin of the wood, a distinction is made between category A1 and A2. For the category A1, the wood comes from trunk wood and chemically untreated wood residue; for A2 the wood of the entire tree and forestry waste can be used. Wood from both category A1 and A2 can be used in HDG boilers.

Essential criteria are the particle size, moisture content and ash content of the fuel.

ARTICLE SIZE

In accordance with DIN EN 14961-4, the fuel specifications for wood chips are separated into

• P31.5

Wood chips with a typical particle size smaller than 31.5 (P31.5) are a machine-compatible material suitable primarily for small systems. Oversized pieces (end pieces) could lead to malfunctions during system operation. Higher proportions of finer content (dust) can lead to high emissions and ejection of glowing particles.

Wood chips from category P31.5 can be used as fuel in all HDG wood chip boilers. For P31.5 wood chips, at least 75% of the wood chips (by weight) must be between 8 mm and 31.5 mm. The fine content (<3.15 mm) may not exceed a maximum of 8% by weight. A maximum of 6% of the wood chips (by weight) may be longer than 45 mm; lengths greater than 120 mm are not permissible. The numeric value of the P category refers to the size of the wood chips in mm which fit through a round opening with the indicated sieve size. The cross section of the outsized particles must be smaller than 2 cm

• P45

Medium wood chips with a particle size of up to 45 mm (P45) are used in larger systems, but can however, depending on the diameter of the conveyor auger, also still be suitable for small systems.

With regard to the quality standards for wood chips, DIN EN 149614 “Solid biofuels - fuel specifications and classes - wood chips for non-industrial use” applies.

P class

Main content

(mass fraction min.

75%)

Fine content

(wt%)

< 3.15 mm

Coarse content

(% by weight)

Max. length, max. cross section

P31.5 8 mm ≤ P ≤ 31.5 mm ≤ 8 % ≤ 6 % > 45 mm, all < 120 mm, cross

section of the outsized particles < 2 cm

P45 8 mm ≤ P ≤ 45 mm ≤ 8 % ≤ 6 % > 63 mm, ≤ 3.5 % > 100 mm, all <

120 mm, cross section of the outsized

particles < 5 cm

Table 3/2 - Particle size

Page 27

3 Mode of operation – Fuel quality requirements

Wood chips from category P45 can be used as fuel in all HDG HDG M299/300/350/400 wood chip boilers. For P45 wood chips, at least 75% of the wood chips (by weight) must be between 8 mm and 45 mm. The fine content (<3.15 mm) may not exceed a maximum of 8% by weight. A maximum of 6% by weight of the wood chips may be more than 63 mm and 3.5% by weight may be over 100 mm. Lengths greater than 120 mm are not permissible. The numeric value of the P category refers to the size of the wood chips in mm, which fit through a round opening with the indicated sieve size. The cross section of the outsized particles must be smaller than 5 cm

ATER CONTENT When selecting fuel, note that the calorific value of the wood is

primarily dependent on the water content. The more water contained in the wood, the smaller the calorific value, since the water vaporises in the course of the burning process and thereby consumes heat. This results in lower efficiency and thereby leads to greater wood consumption. Increasing moisture in the fuel material also causes reduced efficiency, greater amounts of ash and smoke, as well as making it increasingly unfit for storage.

The maximum permissible water content of the wood chips for the HDG M299/300/350/400 is 30 % (M30).

For technical considerations, a representative calorific value is selected depending on water content. For burning that is both economical and low on emissions, the calorific value should not be less than 4 kWh/kg.

SH CONTENT The ash content for wood in category A2 is higher than that of

category A1 due to the higher proportion of bark, needles and leaves.

The maximum permissible ash content of wood chips for the HDG M299/300/350/400 is 1.5 % by weight (A1.5).

WOOD PELLETS

Water content Moisture Calorific value

Relative wood

consumption

10.0 % 11.1 % 4.6 kWh/kg 87 %

20.0 % 25.0 % 4.0 kWh/kg 100 %

26.0 % 35.0 % 3.7 kWh/kg 110 %

30.0 % 42.9 % 3.4 kWh/kg 120 %

Table 3/3 - Calorific value depending on water content

With regard to the quality standards for wood pellets, DIN EN 14961-2 “Solid biofuels - fuel specifications and classes - wood pellets for non-industrial use” applies.

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3 Mode of operation – Fuel quality requirements

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

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.

In accordance with DIN EN 14961-2, the fuel specifications for wood pellets are separated into categories A1 and A2. The diameter of the pellets used must be in accordance with D06.

• A1/D06

The diameter of the pellets must be 6 mm (+/- 1 mm). The length of the pellets must measure between 3.15 mm and 40 mm. A maximum of 1% by weight of the pellets may be longer than 45 mm. The water content must be less than 10% (M10), the ash content must be less than 0.7% by weight (A0.7).

• A2/D06

Standard A1 wood pellets A2 wood pellets

Length 3.15 - 40 mm 3.15 - 40 mm

Diameter Ø D06: 6 mm +/-1 mm D06: 6 mm +/-1 mm

Calorific value 16.5 - 19 mJ/kg or

4.6 - 5.3 kWh/kg

16.3 - 19 mJ/kg or

4.5 - 5.3 kWh/kg

Density (spec. gravity)

1.0 – 1.4 kg/dm

min. 1.12 kg/dm

Bulk weight

min. 600 kg/m

Water content max. 10 % max. 10%

Ash content max. 0.7 % max. 1.5%

Fine material max. 1.0 % max. 1.0 %

Sulphur content max. 0.03 % max. 0.03%

Nitrogen content max. 0.3 % max. 0.5%

Chlorine content max. 0.02 % max. 0.02%

Additive max. 2.0 % max. 2.0 %

Table 3/4 - Burning characteristics of wood pellets

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3 Mode of operation – Fuel quality requirements

RECOMMENDED FUEL

Fuel which is suitable for the HDG M299/300/350/400 heating system includes wood chips, shavings and wood pellets. In order to uphold the emission values specified under German law (1. BImSchV), all fuel requirements, e.g. size, water content, ash content, must be met.

OOD CHIPS HDG Bavaria recommends wood chips with particle size P31.5. The

fuel should have as little water content as possible, with a 20% water content (M20) being ideal. The drier the fuel, the higher the calorific value and the better the burning that is achieved. High quality fuel aids in energy conservation and maintains the operating safety of your heating system. The optimal ash content is 1% by weight (A1.0).

For HDG M299/300/350/400 heating systems, it is possible to use wood fuel products of grain size P45 with a maximum water content of up to 30%. However, reduced nominal thermal power, reduced efficiency, increased fuel consumption and greater wear and tear on the heating system may then result. Fuels with a higher water content are not suitable for burning. The maximum permissible ash content is 1.5% by weight (A1.5).

OOD PELLETS For operation of the heating system with wood pellets, HDG Bavaria

recommends wood pellets from category A1 according to DIN EN 14961-2 or, alternatively, with the certificate “ENplus” or “DINplus”.

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.

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3 Mode of operation – Fuel quality requirements

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

NOMINAL THERMAL VALUE

DEPENDING ON WATER

CONTENT

The following table indicates the maximum nominal thermal power depending on water content, in reference to the fuels approved for the HDG M299/300/350/400 in accordance with DIN EN 14961 “Solid biofuels - fuel specifications and classes”.

* only with HDG M350/400

Wood chips

P45, M20, A1.0

(A1.5) or

Pellets A1, A2*

Wood chips

P45, M25, A1.0

(A1.5)

Wood chips

P45, M30, A1.0

(A1.5)

Shaving

briquettes A1,

A2, D60, L50

Planing/saw shavings A1,

A2, M20, A1.0

(A1.5)

HDG M299/300 300 kW 280 kW

(270 kW)

270 kW

(260 kW)

270 kW 280 kW

(270 kW)

HDG M350 350 kW / 375

330 kW

(320 kW)

320 kW

(310 kW)

320 kW 330 kW

(320 kW)

HDG M400 400 kW 380 kW

(370 kW)

370 kW

(360 kW)

370 kW 380 kW

(370 kW)

Table 3/5 - Max. nominal thermal power depending on water content

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4 Planning and installation – Planning the heating system

4 Planning and installation

4.1 Planning the heating system

SPACE REQUIREMENTS

* The automatic de-ashing for fly ash 1 or 2 can also be installed in such a way that both fly ash containers are on the opposite side. This reduces dimension D to 500 mm.

Figure 4/1 - Space requirements

A B C D* E F G

HDG M299/300/350/400 4400 4250 600 950 500 1400 2000

Table 4/1 - Minimum size (mm)

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4 Planning and installation – Planning the heating system

ROOM HEIGHT REQUIREMENTS

• Minimum ceiling height: 3200 mm / optimal ceiling height: 3500 mm

• Minimum insertion height: 2500 mm

INSTALLATION DIMENSIONS

* Dimensions with attachments removed

Figure 4/2 - Room height requirements

Combustion unit Heat exchanger

Length* 2070 mm / 1900 mm* 2175 mm / 2000 mm *

Width* 1200 mm / 1200 mm* 1374 mm / 1250 mm*

Height* 2160 mm / 2070 mm* 2175 mm / 2070 mm*

Table 4/2 - Installation dimensions

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4 Planning and installation – Planning the heating system

MINIMUM CLEARANCES

BOILER ROOM

Furnaces for solid fuels with a nominal thermal power of more than 50 kW may only be installed in special boiler rooms.

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

regulations on boilers and furnaces (FeuVO) also apply.

Figure 4/3 - Minimum clearances

A B C D E F

HDG M299/300/350/400 600 750 500 950 1400 870

Table 4/3 - Minimum clearances (mm)

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

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

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4 Planning and installation – Planning the heating system

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 The floor of the boiler room must be of a fireproof design. A base is

not necessary for installation of the heating system. Ensure alignment on a horizontal plane.

For unhindered operation and maintenance of the heating system, you must ensure that it is installed to our specifications and that the minimum clearances are maintained.

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

More detailed information can be found in the respective ordinances of the German states.

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

FUEL STORAGE

The fuel storage should have the following characteristics:

•dry

•dust-proof

• statically suitable

• accessible for the filling process

• free of other installations, especially in existing buildings

• adapted to fuel requirements

The refilling intervals should be kept as long as possible. The heating system should be located within the building so that the noise generated does not exceed the permissible values of DIN 4109, “Soundproofing in building construction”.

ROPER DIMENSIONING The size of the fuel storage depends on the heating system, the

determined heating demand, the resulting annual fuel requirements and existing building conditions. Practice has shown that filling the fuel storage four to six times per heating period is ideal.

ASSAGE THROUGH THE WALL The passage through the wall normally has to be made in the wall

between the boiler room and the fuel storage. Its position depends on the distance and the alignment of the heating system within the room and the customer's installation diagram. The passage through

Observe the fire safety regulations.

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

Ensure adequate illumination in the boiler room.

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4 Planning and installation – Connections

the wall between the boiler room and the fuel storage should have a width of 70 cm and height of 70 cm in order to allow the assembly of the delivery auger.

ENTILATION OF FUEL STORAGE

ROOMS

Wood fuel products with higher moisture can cause relatively high air humidity in the fuel storage. Cold surfaces may thereby experience a drop below the dew point and develop condensation water. This condensation water often occurs on non-insulated lids, doors or cold walls and can result in a further moistening of the fuel.

It is therefore recommended to provide a suitable ventilation system that corresponds to the building's features.

4.2 Connections

CHIMNEY

The benefits of the HDG M299/300/350/400 can only be reaped if all of the factors necessary for good combustion are carefully adjusted. 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 gas temperature may lie below 100°C when the system is under partial load, a chimney/flue is required which meets the requirements of DIN EN 13384-1: 2003-03 “Thermal and fluid dynamic calculation methods”. If it does not meet this standard, contact your specialist heating company or chimney technician.

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

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.

Observe the requirements of the fire regulations for fuel storage rooms.

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. Here it is to be noted 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.

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4 Planning and installation – Connections

• Chimney well-sealed to avoid outside air leaking in. Air penetrating from the outside speeds up the cooling of the flue gases.

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

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 4/4 - Connection to the chimney

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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 pipe, or even better, in the chimney itself as shown in Figure 4/4 -

Connection to the chimney.

The following should also be considered:

• The connecting piece may not protrude into the chimney.

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

connecting piece must reduce to the diameter 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 and measurement hatches on the chimney

must be tightly sealed.

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

generator per chimney.

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

heat-resistant silicone.

ELECTRICAL SYSTEM

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

No electrical installations, such as power sockets, distribution boxes, lights or light switches may be located in the fuel storage. 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 described in chapter “3 Mode

of operation”, section “3.3 Technical data”.

ONTROL CABINET The HDG Control unit is located in the EMD-C215 Exclusiv control

cabinet. The cables are inserted from the top of the control cabinet and the wiring is connected in accordance with the supplied wiring diagrams.

CCUMULATOR SENSOR The temperature sensors are immersion sensors with a moulded

cable and serve to measure the temperature of the accumulator.

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4 Planning and installation – Connections

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.

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. These conditions only apply 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 M299/300/350/400 is fitted as standard with power control and 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 benchmark value, 20 litres per kilowatt boiler power can be used. This results in a boiler burning duration of approximately one hour at full-capacity operation, during which the accumulator is completely filled. The emptying time of the accumulator at 25% nominal load is 3.7 hours for this type of design, with an assumed usable temperature difference of 40 Kelvin.

One advantage of an accumulator is the low number of operating hours for the system and fewer start phases due to extended heating periods, which leads to a reduction in the proportion of external energy and to lower wear of the mechanical components.

One further advantage of the accumulator is in summer operation when only hot water is required. When operating in this mode, the accumulator helps avoid frequent ON/OFF switching.

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

AFETY DEVICES Safety devices (e.g. boiler safety module, insufficient water cutout,

etc.) must be installed in accordance with DIN EN 12828: 2003 “Design of water-based heating systems in buildings”.

ETURN TEMPERATURE

CONTROL

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

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.

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4 Planning and installation – Connections

For these reasons, a return temperature control must be installed for the HDG M299/300/350/400 heating system. The return temperature control causes the water from the boiler return line to be mixed with the water from the boiler supply line 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 is regulated by the HDG 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. For the HDG M299/300/350/400, we recommend:

• Wilo Stratos 50/1-12, 3-way mixing valve DN 80

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

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

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 – Connections

WATER-SIDE CONNECTIONS FOR HDG M299/300/350/400

1 Boiler supply connection (DN 100 flange) 2 Connection (DN 50 bushing) of heat exchanger to combustion

unit

3 Connection (DN 50 bushing) of combustion unit to heat

exchanger

4 Filling / draining connection (DN 25, inside thread) for

combustion unit

5 Connection (DN 50 bushing) of combustion unit to heat

exchanger

6 Connection (DN 50 bushing) of heat exchanger to combustion

unit

7 Boiler return connection (DN 100 flange)

Figure 4/5 - Water-side connections for HDG M299/300/350/400

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4 Planning and installation – Connections

SENSORS AND CONNECTIONS OF THE HDG M299/300/350/400

FRONT SIDE

1 Flue gas temperature sensor 2 Pressure capsule connection for vacuum pressure control of heat

exchanger

3 Hot gas sensor 4 Immersion sleeve connection for boiler temperature sensor and

safety temperature limiter sensor (DN 15 inside thread)

5 Immersion sleeve connection for thermal safety device (DN 15

inside thread) of combustion unit

6 Safety heat exchanger connections (DN 20 outside thread) of

combustion unit

7 Combustion chamber temperature sensor of combustion unit

(alternative 8)

8 Combustion chamber temperature sensor of combustion unit

(alternative 7)

9 Pressure capsule connection for vacuum pressure control of

combustion unit

Figure 4/6 - Sensors and connections on the front side of the HDG M299/300/350/

400

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4 Planning and installation – Connections

10 Filling / draining connection (DN 25 inside thread) for combustion

unit

BACK SIDE

1 Immersion sleeve connection for thermal safety device (DN 15

inside thread) of heat exchanger

2 Immersion sleeve connection for supply temperature sensor and

safety temperature limiter sensor (DN 15 inside thread)

3 Safety heat exchanger connections (DN 20 outside thread) on

heat exchanger

4 Immersion sleeve connection for return temperature sensor (DN

15 inside thread)

5 Filling / draining connection (DN 25 inside thread) for heat

exchanger

6Lambda sensor

Figure 4/7 - Sensors and connections on rear side of HDG Compact 150/200

5 4

321

Page 43

4 Planning and installation – Connections

HYDRAULIC CONNECTION OF COMBUSTION UNIT TO HEAT EXCHANGER

1 Return mixing valve (3-way mixer DN 100) 2 Boiler supply connection (DN 100 flange) 3 Connection (DN 50 bushing) of heat exchanger to combustion

unit

4 Connection (DN 50 bushing) of combustion unit to heat

exchanger

5 Connection (DN 50 bushing) of combustion unit to heat

exchanger

6 Circulation pump (Wilo 30/1-8) (Direction of conveyance from

heat exchanger to combustion unit)

7 Connection (DN 50 bushing) of heat exchanger to combustion

unit 8 Boiler return connection (DN 100 flange) 9 Circulation pump (Wilo 50/1-12)

Figure 4/8 - Hydraulic connection

8 6

431

9 5

Page 44

4 Planning and installation – Scope of delivery

4.3 Scope of delivery

Included in the scope of delivery:

• HDG M299/300/350/400 boiler

• Control cabinet model EMD-C 215 Exclusiv

• Feeding system (customer-specific)

• Delivery system (customer-specific)

•Cleaning tools

• Operating documentation

Upon delivery, check that the scope of delivery matches the information on the delivery note.

The HDG M299/300/350/400 boiler is delivered disassembled. The combustion unit, heat exchanger, cladding and all other components must be assembled on site. To unload individual components, a suitable lifting device able to lift at least 4 tonnes should be made available at the site.

4.4 Installing the heating system

REQUIREMENTS

The heating system will initially be commissioned by specialists from HDG Bavaria or from an authorised HDG partner and a qualified electrician.

Danger!

Risk of material damage and injury due to incorrect installation Installing the system requires comprehensive specialist 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 Working on live components can result in an electric shock. Switch off the mains supply to the heating system during the

installation.

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4 Planning and installation – Installing the heating system

Caution!

Danger due to explosive atmospheres The heating system is not equipped with explosion-proof

components. If parts of the system are installed in areas where there is a risk of an explosive atmosphere forming, they could explode.

No part of the system should be installed or operated in an area where there is a risk of an explosive atmosphere.

Important!

Make sure that the boiler is erected on an adequately dimensioned foundation.

Important!

Due to the noise, we recommend acoustic insulation measures for components which are in contact with the floor or walls of the boiler room.

Important!

When laying the pipelines, observe the minimum required clearances.

✎ See section “4.1 Planning the heating system” in this chapter.

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4 Planning and installation – Installing the heating system

INSTALLING THE BOILER

TRANSPORT

There are several options for transporting the HDG M299/300/350/ 400 boiler. You can use a crane, forklift or a lifting truck.

NSTALLATION SITE 1. Transport the boiler to the installation site using suitable lifting

equipment.

Important!

When working on the boiler, the fall protection device must be fitted. If the room height is not sufficient for the assembly, the height of the fall protection device must be adjusted.

Figure 4/9 - Fall protection

Warning!

Danger from suspended loads The individual modules of the boiler weigh more than 1000 kg. If

the modules are dropped during transport, persons can be seriously injured and the boiler can be damaged.

Make sure that you use appropriate lifting gear to move the modules when erecting the boiler.

Ensure that the chain hoist is correctly secured to the eyebolt of the boiler during crane transport of the heating system.

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4 Planning and installation – Installing the heating system

CONNECTING MODULES

2. Place the heat exchanger (1) and the combustion unit (2) next to

each other.

3. Align the two units with plastic plates or flat steel strips (not

included in the scope of delivery) so they are in a horizontal plane.

4. Join the combustion unit (2) and heat exchanger (1) together on

both sides at the intended points (3) using the M12 screws (19 mm

spanner).

✓ The boiler is erected.

Figure 4/10 - Connecting modules

Page 48

4 Planning and installation – Installing the heating system

INSTALLING THE CENTRAL ASH REMOVAL SYSTEM

1. Slide the transfer station (4) with the ash removal augers into the two ash removal pipes (5).

2. Install the transfer station (4) on the combustion unit (6) using the M12 hexagon socket screws (10 mm spanner).

3. Mount the auger trough (1) of the ascending auger on the flange of the transfer station (4) with the M8 screws (13 mm spanner).

4. Insert the downpipe (2) in the opening of the lid of the ash bin (3).

✓ The central ash removal system is now installed.

INSTALLING THE FEEDING SYSTEM

HDG TBZ 200

Figure 4/11 - Installing the central ash removal system

4 5

Figure 4/12 - Installing the feeding system TBZ 200

52 43

Page 49

4 Planning and installation – Installing the heating system

1. Place the seal (4) on the insertion flange (5).

2. Push the stoker pipe (3) onto the insertion flange (5).

3. Fasten the stoker pipe (3) with the M12 nuts (19 mm spanner).

4. Bolt the support leg (2) onto the stoker pipe (3) with the M12

screws (19 mm spanner).

5. Fix the support leg (2) to the floor if necessary (screws and screw

anchors are not included in the scope of delivery).

6. Mount the rotary wheel (1) on the stoker pipe connection with the

M12 screws (19 mm spanner).

✓ The HDG feeding system TBZ 200 is installed.

HDG TBZ 150

1. Place the seal (13) on the insertion flange (15).

2. Fasten the adapter piece (12) to the insertion flange (15) with the

M12 nuts (19 mm spanner).

3. Slide the adapter pipe (8) with the seal (9) into the feed channel

(10).

4. Align the seal (9) with the holes.

Warning!

Danger of injury The feeding system is very heavy. Hands and feet could be crushed

when it is lifted. Only lift the feed system using suitable lifting equipment.

Figure 4/13 - Installing the feeding system TBZ 150

9654

87 10 1411 13 1512

Page 50

4 Planning and installation – Installing the heating system

5. Poke holes through the seal (9) for the centring screws.

6. Insert the centring screws (2 + 7) toward the boiler through the holes and screw tight with the M6 nuts (10 mm spanner).

7. Insert the M12 screws (11) from the boiler through the holes.

8. Slide the second seal (6) on the adapter pipe (8).

9. Slide the feeding system (1) onto the adapter pipe (8).

10.Bolt on the feeding system (1) with the M12 nuts (19 mm spanner).

11.Bolt the support leg (4) with the M12 screw (19 mm spanner) onto the feeding system (1).

12.Fix the support leg (4) to the floor as required (screws and screw anchors are not included in the scope of delivery).

13.Align the feeding system (1) horizontally with the two M10 screws (3).

14.Place the rubber seal on the connections of the pressure equalisation hose (14).

15.Mount the pressure equalisation hose (14) with the aid of the union nut (DN 32) on the connection (5) of the feeding system (1).

16.Insert the dummy plug in the connection on the opposite-lying side of the feeding system.

✓ The HDG feeding system TBZ 150 is installed.

Warning!

Danger of injury The feeding system is very heavy. Hands and feet could be crushed

when it is lifted. Only lift the feed system using suitable lifting equipment.

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4 Planning and installation – Installing the heating system

INSTALLING THE HOUSING OF THE FLUE GAS FAN

1. Install the housing (2) of the flue gas fan on the flue pipe

connection (3) of the boiler using the M8 screws (13 mm spanner).

2. Mount the connection (1) for the flue gas pipe on the housing (2)

of the flue gas fan using the M8 screws (13 mm spanner).

✓ The housing of the flue gas fan is now installed.

Figure 4/14 - Installing the housing of the flue gas fan

Warning!

Danger of injury The housing for the flue gas fan is very heavy. Hands and feet could

be crushed when installing it. Only lift the housing using suitable lifting equipment.

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4 Planning and installation – Installing the heating system

INSTALLING THE CLADDING

NSTALLING THE CLADDING

BRACKETS

1. Install the cladding brackets with the M10 screws (17 mm spanner) according to the inscriptions “fr”, “br” and “rl” on the corners of the boiler.

2. Screw in the M6 adjusting screw (1) on each of the upper three cladding brackets (10 mm spanner).

When installing the cladding, there are differences depending on whether the HDG M299/300/350/400 heating system is equipped with TBZ 150 or TBZ 200.

The procedure described is for installation with equipment version TBZ 200. Installation with equipment version TBZ 150 is specified explicitly where necessary.

The substructure of the cladding is inscribed with letters which are located on the upper end of the visible face for elements that are to be installed vertically and on the left end of the visible face for elements that are to be installed horizontally.

Figure 4/15 - Installing the cladding brackets

fr_t

fr_b br_t br_t

bl_t

rl_b

bl_t

backright

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4 Planning and installation – Installing the heating system

3. Install the cladding brackets with the M10 screws (17 mm

spanner) according to the inscription “fl” on the corner of the boiler.

NSTALLING THE CLADDING

SUPPORTS

4. Install the cladding supports (A) on each of the four corners with

the M8 hexagon socket screws (6 mm spanner) and M8 nuts (13 mm spanner) with intermediate washers on the cladding brackets, but do not tighten the screws.

Figure 4/16 - Installing the cladding brackets

fl_t

fl_b

left front

Figure 4/17 - Installing the cladding supports

fl_t

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4 Planning and installation – Installing the heating system

INSTALLING THE CORNER

SUPPORTS

5. On each of the corners “fr”, “br” and “bl”, install the corner supports (C) with the M8 hexagon socket screws (6 mm spanner) with intermediate washers on the cladding brackets, but do not tighten the screws.

6. Install corner support B on the “fl”corner with the M8 hexagon socket screws (6 mm spanner) with intermediate washers on the cladding supports, but do not tighten the screws.

Figure 4/18 - Installing the corner supports

Corner support B differs from corner support C due to the two preassembled rivets.

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4 Planning and installation – Installing the heating system

INSTALLING THE SUSPENSION

RAILS

7. Insert suspension rail (D) with the right end in the corner support

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

8. Insert the three suspension rails (E) with the right ends in the

corner supports and fasten them with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

9. Insert suspension rail (F) with the right end in the corner support

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

10.Insert the two suspension rails (G) with the right ends in the corner

supports and fasten them with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

11.Set the vertical rail (H) in the suspension rails.

12.Insert suspension rail (I) with the right end in the corner support

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer on the corner support or the vertical rail (H).

13.Set the vertical rail (J) in the suspension rails.

Figure 4/19 - Installing the suspension rails

FJH

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4 Planning and installation – Installing the heating system

14.Insert suspension rail (K) with the right end in the vertical rail (H) and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer to the vertical rail (H) or the corner support.

15.Set the vertical rail (L) in the suspension rails.

16.Insert suspension rail (D) with the right end in the corner support and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

17.Insert the three suspension rails (E) with the right ends in the corner supports and fasten them with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

18.Insert suspension rail (F) with the right end in the corner support and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

Important!

The description in the following section applies only to systems with an HDG TBZ 200.

Figure 4/20 - Installing the suspension rails (TBZ 200)

FNQ

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4 Planning and installation – Installing the heating system

19.Insert suspension rail (G) with the right end in the corner support

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

20.Set the vertical rail (N) in the suspension rails.

21.Insert suspension rail (O) with the right end in the vertical rail (N)

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer to the vertical rail (N) or the corner support.

22.Insert suspension rail (P) with the right end in the vertical rail (N)

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer to the corner support or the vertical rail (N).

23.Set the vertical rail (Q) in the suspension rails.

24.Set the vertical rail (R) in the suspension rails.

Important!

The description in the following section applies only to systems with an HDG TBZ 150.

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4 Planning and installation – Installing the heating system

25.Insert suspension rail (D) with the right end in the corner support and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

26.Insert the three suspension rails (E) with the right ends in the corner supports and fasten them with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

27.Insert suspension rail (F) with the right end in the corner support and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

28.Insert suspension rail (G) with the right end in the corner support and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

29.Insert suspension rail (M) with the right end in the corner support and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer.

30.Set the vertical rail (N) in the suspension rails.

Figure 4/21 - Installing the suspension rails (TBZ 150)

FNQ

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4 Planning and installation – Installing the heating system

31.Insert suspension rail (O) with the right end in the vertical rail (N)

and fasten it with the M6 hexagon socket screws (5 mm spanner) and intermediate washer to the vertical rail (N) or the corner support.

32.Set the vertical rail (Q) in the suspension rails.

33.Set the vertical rail (R) in the suspension rails.

LIGNING THE SUSPENSION

RAILS

34.Align the corner support (3) vertically with the aid of a spirit level.

35.Tighten the three M6 hexagon socket screws (5 mm spanner).

36.Align the support rail (1) horizontally using the adjusting screw in

the cladding bracket and a spirit level.

37.Align the corner support (2) vertically with the aid of a spirit level.

38.Tighten the three M6 hexagon socket screws (5 mm spanner).

39.Proceed with the alignment of the suspension rails in the same

manner as described above for the remaining three sides of the boiler.

NSTALLING THE BASE CLADDING

HDG TBZ 200

Figure 4/22 - Aligning the suspension rails

Important!

Adhere to the specified sequence when installing the base cladding. The sequence is indicated by the numbers with asterisk (e.g. 1*, 2*, etc.).

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4 Planning and installation – Installing the heating system

40.Insert the base cladding (1* - 7*) in the suspension rails in the specified sequence.

Important!

The description in the following section applies only to systems with an HDG TBZ 200.

Figure 4/23 - Installing the base cladding (TBZ 200)

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4 Planning and installation – Installing the heating system

INSTALLING THE BASE CLADDING HDG TBZ 150

41.Insert the base cladding (1* - 7*) in the suspension rails in the

specified sequence.

Important!

The description in the following section applies only to systems with an HDG TBZ 150.

Figure 4/24 - Installing the base cladding (TBZ 150)

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4 Planning and installation – Installing the heating system

INSTALLING THE ASSEMBLY

PLATES

42.Mount the assembly plates (2) in each of their intended positions in the two middle suspension rails (1) on each side.

Figure 4/25 - Installing the assembly plates

Individual steps for installing the assembly plates (2):

– Push the assembly plate through the recess from below (1*). – Turn the assembly plate 90° anticlockwise (2*). – Lift the assembly plate and push it to the left (3*). – Allow the assembly plate to latch in position.

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4 Planning and installation – Installing the heating system

INSTALLING THE SIDE CLADDING HDG TBZ 200

43.Install the side cladding “S”, “T” and “U” in the insertion plates.

44.Insert the side cladding “P1” through “P12” in the insertion plates.

Important!

The description in the following section applies only to systems with an HDG TBZ 200.

Figure 4/26 - Installing the side cladding (TBZ 200)

P11

P10

P12

Important!

Adhere to the specified sequence when installing the side cladding P1-P12. The sequence is indicated by the number.

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4 Planning and installation – Installing the heating system

INSTALLING THE SIDE CLADDING HDG TBZ 150

45.Install the side cladding “S”, “T” and “U” in the insertion plates.

46.Insert the side cladding “P1” through “P12” in the insertion plates.

✓ The cladding is installed.

Important!

The description in the following section applies only to systems with an HDG TBZ 150.

Figure 4/27 - Installing the side cladding (TBZ 150)

P11

P10

P12

Important!

Adhere to the specified sequence when installing the side cladding P1-P12. The sequence is indicated by the number.

Page 65

4 Planning and installation – Installing the heating system

INSTALLING ASH CONTAINERS

1. Remove the ash containers from the packaging.

2. Mount the two clamp handles (1 + 4) with the M8 hexagon socket

screws (6 mm spanner) and the M8 nuts (13 mm spanner).

3. Lift up the two clamp handles (1 + 4).

4. Insert the ash containers (3) on the ash removal pipe.

5. Press the clamp handles (1 + 4) downward.

✓ Grasp the clamp handles and press the ash containers against the

seal of the ash removal door.

6. If the handles do not clamp, adjust them as follows.

✓ Grasp the clamp handles and seal the ash containers solidly on the

ash removal door.

5. Close the ash containers in the reverse sequence.

6. Adjust the two support feet on the underside of the ash container

to the appropriate height.

✓ The ash containers are mounted and adjusted.

Figure 4/28 - Installing ash containers

21 3

1. Remove the cover from the ash container.

2. Release the external nuts on the ash container.

3. Adjust the ash container with the inside nuts (1) until the clamping handles latch firmly.

4. Screw the outer nuts tight and check that the clamp handles latch firmly.

Figure 4/29 - Adjusting the ash containers

Page 66

4 Planning and installation – Delivery system

FITTING THE ACCUMULATOR SENSORS

INSTALLING THE EMD-C 215 EXCLUSIV CONTROL CABINET

Observe the following when installing the EMD-C 215 Exclusiv control cabinet:

• Install the control cabinet at least one metre from the flue pipe.

• Prevent the control cabinet from tipping by fixing it to the wall securely.

• If possible, install the control cabinet in such a way that you can see the boiler when operating the control panel of HDG Control.

• Install the control cabinet at a height comfortable for you to operate.

CONNECTING THE CHIMNEY

✎ See section “4.2 Connections” in this chapter.

1. Connect the flue pipe to the chimney connection.

2. Make sure that the connecting piece does not protrude into the chimney.

3. Seal the connection to the chimney with highly fireproof silicone or with a suitable mortar.

✓ The boiler is now connected to the chimney.

4.5 Delivery system

GENERAL INFORMATION

The description for planning, installation and operation of the employed delivery system can be found in the corresponding operating manual.

✎ See the operating manual “Delivery system”.

The sensors for the accumulator are stored in the EMD-C 215 Exclusiv control cabinet for further use.

Warning!

Danger of injury The control cabinet is heavy. Hands and feet could be crushed

during installation.

Page 67

4 Planning and installation – Vacuum pressure control

4.6 Vacuum pressure control

Optionally available is an HDG vacuum pressure control with frequency converter and differential pressure transmitter for adapting to changing chimney conditions. It creates an automatic adjustment to the underpressure required for output and combustion control and thereby improves the partial load capacity of the system.

4.7 Electrical system

The electrical connections must be made in accordance with DIN IEC 60364 “Setting up low-voltage electrical installations”.

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

operation”, section “3.3 Technical data”.

1. Install the electrical connections in accordance with the provided

wiring diagrams.

✎ The wiring diagrams can be found in the supplied documentation.

4.8 Water

The diaphragm expansion vessel must be constructed in accordance with DIN EN 13831 “Closed expansion vessels with built-in diaphragm for integration in water installations”.

Before putting the system into operation, the pressure of the diaphragm expansion vessel must be adjusted for the conditions in the heating system and in the building.

After putting 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.

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”.

Once the combustion unit and the heat exchanger have been assembled, the HDG M299/300/350/400 boiler must be submitted to a water pressure test, at a testing pressure of 4 bar.

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4 Planning and installation – Thermal safety device

4.9 Thermal safety device

In accordance with DIN 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. as a regular heat exchanger). If the heat transfer capacity is suddenly lost (for example, if the circulation pump for raising the return temperature fails), heat production cannot be stopped as quickly as with an oil- or gas-fired boiler. When the maximum operating temperature is exceeded, the thermal safety device (TAS) is triggered and cold water flows through the safety heat exchanger. The excess energy generated is thus dissipated by this “emergency cooling”. (This is an alternative to fast regulation.)

However, the safety heat exchanger and thermal safety device can only serve their purpose if the following requirements have been met:

• A flow pressure of at least two bar and a flow rate of 1800 l/h must be available at the cold water inlet of the safety heat exchanger.

• The distance between the supply and return lines of the thermal safety device and the safety heat exchanger should not be less than their nominal width. The supply line may not be equipped with a shut-off valve.

• Water must be able to flow freely through the system.

• The flow pressure at the flue pipe connection on the boiler may not significantly exceed the prescribed value.

The thermal safety device must be installed according to guidelines from HDG Bavaria.

Mains-dependent, stand-alone supply systems are not safe enough due to dependence upon the power supply!

The thermal safety device is to be inspected annually by an authorised, qualified technician to verify that it is functional.

Important!

In order to prevent leaks, avoid turning the connections of the safety heat exchanger anticlockwise when installing the thermal safety device.

Important!

The HDG M299/300/350/400 heating system is equipped with two safety heat exchangers. One is located in the combustion unit and one in the regular heat exchanger.

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4 Planning and installation – Thermal safety device

1 Connection of immersion sleeve for thermal safety device (DN 15

inside thread) 2 Safety heat exchanger inlet (DN 20 male) 3 Safety heat exchanger outlet (DN 20 male) 4 Thermal safety device (TAS) 5 Runoff connection to drainage system

Figure 4/30 - Installing the thermal safety device

Figure 4/31 - Thermal safety device pipework

The pipe work of the combustion unit's safety heat exchanger can be fed outside via hole (1) in the cladding at the side.

Page 70

4 Planning and installation – Hydraulic system

4.10 Hydraulic system

1 Accumulator sensor, top 2 Accumulator sensor, middle 3 Accumulator sensor, (optional) 4 Accumulator sensor, (optional) 5 Accumulator sensor, bottom

Figure 4/32 - Hydraulic system (accumulator 1)

+HDWLQJFLUFXLWGLVWULEXWRU

Figure 4/33 - Hydraulic system (accumulator 2)

+HDWLQJFLUFXLWGLVWULEXWRU

These hydraulic systems are only suitable for use in the specified manner and for the intended purpose. Any deviation from this usage could make adjustments necessary.

Consult with a trained specialist on issues relating to the hydraulic system.

Page 71

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

STRUCTURE OF THE FEEDING

SYSTEM

• Does the mechanical structure meet the specifications of this

operating manual?

HECK THE HYDRAULIC

CONNECTIONS

• Do the mechanical connections meet the specifications of this

operating manual?

• Has the safety equipment been installed to conform to the

applicable standards and guidelines?

HECK THE MECHANICAL

STRUCTURE OF HDG COMPACT

• Does the mechanical structure meet the specifications of this

operating manual?

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.

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5 Commissioning the system – Procedure

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

CHECK THE ELECTRICAL

CONNECTIONS

• Are all the sensors and actuators connected correctly?

• Has the mains power supply cable been correctly connected?

–L1 on terminal X11

–L2 on terminal X12

–L3 on terminal X13

– Neutral conductor on terminal X14

– Earthing conductor on terminal X15.

• Are the connection cables properly attached between the boiler

and the control cabinet?

5.2 Procedure

SWITCHING ON THE HEATING SYSTEM

1. Turn the heating system main switch on.

✓ The control is activated. ✓ After a start-up phase, the display will first of all show a switch-on

message and then the standard display.

2. Set the engage switch to “1”.

✓ The display switches to Heating ON. ✓ The heating system is now switched on.

SETTING THE DISPLAY LANGUAGE

Different languages can be set for the display texts.

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

information, selecting and modifying parameters”.

Danger!

Danger from electrical current or voltage! Isolate the mains cable to the heating system.

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5 Commissioning the system – Procedure

CHECKING THE ACTUATORS IN MANUAL OPERATION

In the MANUAL menu you can manually test the functionality of all actuators, e.g. drive motors, fans and electrical mounted parts.

OMBUSTION AIR AND IGNITION

FAN

The fans can be activated manually in this submenu.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Combustion air and ignition fan”.

RIMARY AND SECONDARY AIR

FLAPS

This submenu is used to manually activate the primary and secondary air flaps.

See chapter “6 Using the heating system”, section “6.9 MANUAL menu”, paragraph “Primary and secondary air flaps”.

ENTRAL ASH REMOVAL, GRATING ASH REMOVAL AUGER AND GRATE DRIVE

This submenu is used to manually activate the central ash removal and the grate drive.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Central ash removal, grate ash removal auger and grate drive”.

EAT EXCHANGER ASH REMOVAL AUGERS AND CLEANING SYSTEM

This submenu is used to manually activate the heat exchanger ash removal auger and cleaning system.

See chapter “6 Using the heating system”, section “6.9 MANUAL menu”, paragraph “Heat exchanger ash removal auger and cleaning system”.

ETURN PUMP, RETURN MIXER

AND INTERMEDIATE PUMP

This submenu is used to manually activate the return pump, the return mixer and the intermediate pump.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Return pump, return mixer and intermediate pump”.

Danger!

Material damage and injury due to incorrect operation. Activating the following parameters requires comprehensive

technical expertise. If the parameters are not activated by trained personnel, the heating system can be damaged and dangerous operating conditions can arise.

Have the commissioning performed only by an authorised specialist.

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5 Commissioning the system – Procedure

HDG M299/300/350/400 - Version 1 - en © HDG Bavaria GmbH 07/2008

STOKER AUGER, ROTARY FEEDER

AND MATERIAL CONVEYING

AUGER

In this submenu, the stoker auger, rotary feeder and material conveying auger can be activated manually in connection with the HDG feeding system TBZ 200.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Feed system, rotary wheel and material conveying auger”.

EED SYSTEM, AUGER TROUGH 2

AND DOSAGE

In this submenu, the feed system, auger trough 2 and dosage can be activated manually in connection with the HDG feeding system TBZ

150.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Feed system, auger trough 2 and dosage”.

ATERIAL CONVEYING AUGER

AND AGITATOR

In this submenu the material conveying auger and agitator can be activated manually in connection with a distributing container.

See chapter “6 Using the heating system”, section “6.9 MANUAL menu”, paragraph “Material conveying auger and agitator”.

OVING FLOOR - TRANSVERSE

AUGER

In this submenu the transverse auger can be activated manually in connection with the HDG walking floor feeding system TAK.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Moving floor - transverse auger”.

OVING FLOOR - HYDRAULIC

SYSTEM

In this submenu the drive of the walking floor can be activated manually in connection with the HDG walking floor feeding system.

✎ See chapter “6 Using the heating system”, section “6.9 MANUAL

menu”, paragraph “Moving floor - hydraulic system”.

Once the functionality of all the actuators is checked in manual operation, the HDG M299/300/350/400 heating system can be operated in accordance with the set control mode.

FILLING THE TRANSFER STATION OF THE CENTRAL ASH REMOVAL

SYSTEM

Caution!

Backfiring or smoke can cause injuries or material damage If the transfer station is not at least half-filled when commissioning

or re-starting after a cleaning, there is a danger of backfiring or smoke from the boiler. This can cause damage to the heating system or injury to persons.

Make sure that the transfer station is at least half-filled with ash, sand, etc.

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5 Commissioning the system – Procedure

1. When commissioning the system, make sure that the transfer

station (1) is at least half-filled with ash, sand, etc.

FILLING THE FUEL STORAGE

✎ See also Chapter “6 Using the heating system”, section

“6.13 Filling the fuel storage”.

1. Before filling the fuel storage, check the rotational direction, the

intermediate base, the leaf springs and the dosing plate of the delivery system.

2. Fill the fuel storage.

✎ See chapter “6 Using the heating system”, section “6.13 Filling the

fuel storage”.

✓ The fuel storage is filled.

Figure 5/1 - Filling the ash accumulation bin

The fuel storage may only be filled once the actuators have been tested.

Warning!

Damage to extraction system during filling. If the heating system is not switched on during filling of the fuel

storage, the overload protection of the delivery system could be triggered when the heating system is switched on after the filling.

When filling the fuel storage for the first time, activate the delivery system by switching in manual operation.

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5 Commissioning the system – Procedure

ADAPTING PARAMETERS

The parameters of the HDG Control unit are programmed with the predefined factory settings upon delivery. The predefined values of the factory settings are intended for operation with wood chips.

In practice, operators usually have their own heating system requirements. Differences result from, for example, the sit-specific requirements or the heating fuel. If the heating system is operated with wood pellets or chips, the relevant parameters must be changed.

In all cases, it is necessary to check the predefined parameters and, if necessary, change them accordingly before commissioning the system.

Danger!

Material damage and injury due to incorrect settings. Adjusting these parameters requires comprehensive specialist

knowledge. If the parameters are adjusted by an untrained person, the heating system can be damaged.

Only allow authorised specialists to make adjustments to the parameters.

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6 Using the heating system – Overview of the controls and display components

6 Using the heating system

6.1 Overview of the controls and display components

MAIN SWITCH

The main switch is located on the side of the control cabinet. The heating system can be shut down using the main switch.

EMERGENCY STOP

The emergency stop switch is located on the front plate of the control cabinet. If the emergency stop switch is pressed, all moving parts of the heating system are switched off.

If the emergency stop switch is pulled out, the Acknowledge fault button must first be pressed. Only then will all moving parts of the heating system be switched back on and operational.

ADDITIONAL CONTROLS

Engage switch:

• switches the heating system on or off.

“System operation” indicator light

• lights up when the heating system is switched on.

Acknowledge fault button

• flashes when there is a fault.

• lights up when a fault is eliminated.

• must be pressed after rectifying a fault.

Danger!

Danger from electrical current or voltage! The heating system is not rendered voltage-free by switching off

with the emergency stop switch. The heating system is only voltage-free if the main switch is turned off.

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6 Using the heating system – Overview of the controls and display components

CONTROL CABINET MODEL EMD-C 215 EXCLUSIV

1 Lock mechanism of control cabinet 2Main switch 3Emergency stop 4 Acknowledge fault button with fault light 5 “System operation” indicator light 6Engage switch 7 Control unit HDG Control

Figure 6/1 - Control cabinet model EMD-C 215 Exclusiv

64 5

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6 Using the heating system – Overview of the controls and display components

CONTROL UNIT FOR HDG CONTROL

1Display 2 Down arrow button 3 No function assigned 4 Plus/minus sign change button 5 Programme version info / Language selection button 6 Up arrow button 7 Configuration button 8 No function assigned 9 Numerical keypad 10 Enter or Input button 11 Function buttons (F1 to F6) 12 CE button

The control unit of the HDG Control is located in the front plate of the control cabinet.

Through the control unit, you can adjust the HDG Control and obtain information on current processes.

DISPLAY The display shows the selected information and parameters.

UTTONS The heating system can be operated using the buttons.

Figure 6/2 - Control unit for HDG Control



$POmH .POJUPS

1 3 4 5 6 7 8

101112 9

Not all keys are always activated on the keypad. Depending on the menu, various buttons may be deactivated. If a button is activated, a diode is lit in the upper right corner of the

button. Pressing the button will trigger the respective function.

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6 Using the heating system – Switching on the heating system

The individual buttons have the following functions: Arrow keys

• Switch between individual parameters in a display.

Plus/Minus button

• Changes the initial sign in front of numerical values.

Program version info key

• Displays the software version and enables changing the language.

Function (1 - 5) keys

• In the standard display, these buttons enable access to various

menus, e.g. the ON/OFF menu, as well as the triggering of functions which are shown in the bottom line of the display.

Function F6 key

• In the bottom line above the F6 button, END is always visible.

Press the F6 button to exit any submenu and return to the standard display.

Keys of the numerical keypad

• The keys of the numerical keypad are used to enter settings and

times.

Enter or Input key

• Confirms the changed value.

• One step forwards.

Configuration button

• If the HDG Control is traded, the configuration key is used to

confirm adoption of the previous hours of operation.

6.2 Switching on the heating system

REQUIREMENTS Before the heating system is switched on, the following

requirements must be met:

• The heating system has been commissioned by authorised

specialists.

• The fuses of the power supply are switched on.

• The main switch on the heating system is turned off.

• No operating mode is displayed on the control unit of the HDG

Control.

• The fuel storage is filled.

✎ See section “6.13 Filling the fuel storage” in this chapter.

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6 Using the heating system – Switching off the heating system

PROCEDURE 1. Turn the heating system main switch on.

✓ The control is activated. ✓ After a start-up phase, the display will first of all show a switch-on

message and then the standard display.

2. Set the engage switch to “1”.

✓ The display switches to Heating ON. ✓ The heating system is now switched on.

6.3 Switching off the heating system

The heating system can be switched off from any operating mode.

1. Set the engage switch to “0”.

✓ The heating system is switched off; the supplying of fuel is

stopped; the combustion air fan continues running for a preset burn-out time.

2. Allow the heating system to burn out until the combustion air fan

switches off.

3. Turn the heating system main switch off.

✓ No operating mode is displayed on the control unit of the HDG

Control.

✓ The heating system has been de-energised.

6.4 Operating statuses

The heating system goes through the following states during operation:

Warning!

Frost danger! Only switch off the heating system completely if you are certain

there is no danger of frost.

Operating status Description

Heating OFF • The main switch is turned on.

• The engage switch is at “0”.

1st filling combustion chamber

• The current combustion chamber temperature is lower than the

preset ignition temperature.

• This operating status is maintained until the preset time for filling

the combustion chamber has been reached, the fill level indicator signals or the combustion chamber temperature exceeds the ignition temperature.

Table 6/1 - Operating statuses

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6 Using the heating system – Operating statuses

Ignition • The preset ignition temperature has not been exceeded.

• The ignition fan runs.

Add fan • The ignition fan runs and the flue fan or primary and secondary air

fan will start after the preset delay.

• This operating status is maintained until the preset time for

ignition has been reached or the combustion chamber temperature exceeds the ignition temperature.

Pre-ventilation • The ignition fan shuts off.

• The flue fan or primary and secondary air fan run.

Heating-up • The feed quantity is increased by increments.

• This operating status is maintained until the preset time for

heating up or the preset temperature in the combustion chamber have been reached.

Automatic control • Only for “Combustion control” or “Combustion and output

control” mode.

• The heating system runs automatically according to the

configured control mode.

Autom. not controlled

• Operation of the heating system in “Fixed value” mode.

Burn out • The preset boiler temperature has been reached.

• The boiler has been switched off.

• This operating status is maintained until the preset burn-out time

has elapsed.

Temperature reached • The current boiler temperature is higher than the preset boiler

temperature.

• No demand on accumulator.

• The boiler temperature is higher than the set temperature on the

regulating thermostat and the burn-out phase is complete.

Timer off • Operating status outside of the set enable time.

• The heating system is not in operation.

Emergency operation active

• A sensor in the heating system is faulty.

• The boiler operates in accordance with the parameter values from

the submenu “Fixed value settings”.

Not enabled • The heating system is controlled via an external heating circuit

regulator.

• There was no enable command from the higher-level heating

circuit regulator.

Lambda stop • The residual oxygen value for combustion has fallen below the

minimum.

• The heating system waits until the minimum residual oxygen

value has been reached again.

Operating status Description

Table 6/1 - Operating statuses (continuation)

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6 Using the heating system – Calling up information, selecting and modifying parameters

6.5 Calling up information, selecting and modifying parameters

On the display of the control panel for the HDG Control, you can call up various information as well as select and modify parameters.

Due the freely programmable design and the numerous options in heating system combinations, especially in regard to the extraction technology, the number of parameters can vary greatly.

TANDARD DISPLAY The standard display shows you various information, such as

operating status of the heating system, hours of operation, boiler temperature and the time.

Material stop • The level indicator in the combustion chamber has signalled.

• There is too much material in the combustion chamber.

• The heating system waits until the level indicator enables filling

again.

Combustion chamber temperature stop

• The maximum permitted temperature in the combustion

chamber has been exceeded.

• The heating system waits until the combustion chamber falls back

below the maximum permitted temperature.

Maintenance On • The maintenance function is activated.

• The burn-out time has elapsed.

• The flue gas fan is running.

Operating status Description

Table 6/1 - Operating statuses (continuation)

When restarting after a power outage, the heating system resumes the operating mode last used if no safety-relevant functions have been triggered.

Heating OFF 0.0 hrs

Boiler temperature : 40 °C 15:55

OFF

°C

QTY

TIME MAN. SERVICE INFO

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6 Using the heating system – Calling up information, selecting and modifying parameters

PROGRAM VERSION / L

ANGUAGE SELECTION

1. Press the Information key.

✓ The programme version will appear in the display.

2. Press the F6 key to select the menu language

✓ The display switches to the submenu Language selection.

3. Press the F3 key under the FIELD command.

4. Press the F4 key under the CHOOSE command and select the

desired menu language.

5. Confirm the desired menu language with the Enter key.

✓ The desired menu language is set.

Programme info

Basic programme: Programme file: M300_TVV

Programme date: 16/04/2012 Programme update:

Language selection 1-13

Language : 1 - German

FIELD CHOOSE END

By pressing the F6 key under the END command, you can exit the Language selection menu window without changing the

setting.

The following pages show all practically available menu windows. In actuality, only those menu windows are available to the operator which are relevant for the heating system version.

Danger!

Material damage and injury due to incorrect settings! Changing the following parameters requires comprehensive

technical expertise. If the parameters are changed by untrained individuals, the heating system can be damaged and dangerous operating conditions can arise.

Have ch ange s to the followi ng parameters made only by au thorised specialists.

Language

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6 Using the heating system – ON/OFF menu

6.6 ON/OFF menu

PROCEDURE

1. Press the F1 key under the standard display screen.

✓ You are in the ON/OFF menu.

2. Scroll with the F1 or F2 key to the previous or next submenu.

3. Use the F3 key under the FIELD command in the respective

submenu to select the desired parameter.

4. Press the F4 key under the CHOOSE command and select the

desired setting.

5. Confirm each change with the Enter key.

✓ The desired parameter is set.

6. Press the F6 key under the END command to exit the submenu.

✓ The standard display is restored.

SETTING THE BASE LOAD / PEAK LOAD BOILER

An additional peak load boiler can be integrated using a third accumulator temperature sensor. With a double heating system, both boilers store energy in the accumulator. If the base load boiler cannot charge the accumulator by itself, the peak load boiler switches on for support.

This menu allows you to configure which heating system will be the base load boiler and the which will be the peak load boiler in a double heating system. A changeover is required once a certain number of operating hours is reached so that both boilers will be in operation approximately the same number of hours over several years.

✎ See “Procedure” in this section.

CTIVATING BOILER-2 Boiler activation must be set to “External” on Boiler 2 with

parameter 1-05 . Boiler 2 is activated by a relay (K21) of Boiler 1. A normally-open contact of K21 is wired to the outgoing terminals 68/

This is an optional submenu and only available with double heating systems.

Changeover base load / peak load 1-09

Base load Peak load Boiler-1 Boiler-2

After operating hours : 0 / 0 h

FIELD CHOOSE END

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6 Using the heating system – ON/OFF menu

69/70 on terminal strip X2. Boiler 2 likewise has terminals 68/69/70 on terminal strip X2, which are internally wired to the PLC input “External demand”. In order to ensure this function works properly, it is necessary to lay a connecting line (recommended: flexible control cable of the type YSLY-JZ 3 x 1.0 mm²) between the two control cabinets.

UNCTION OF THE RETURN

PUMP

The return pump always runs if there is demand on the boilers and the combustion chamber temperature exceeds 200 °C. This means that Boiler 1 must receive demand signals from the accumulator sensor and Boiler 2 must receive the external demand signal from Boiler 1.

SETTING OPERATING TIMES

In this menu you can view and set the operating times of the heating system. There are two switch-on and switch-off cycles available per weekday.

OILER OPERATING TIMES ✎ See “Procedure” in this section.

1. In the Show switch on/off time 1-01 submenu, press the

F4 key under the EDITcommand in the display.

✓ The display switches to the Enter switch on/off time 1-

11 submenu.

✓ The day of the week and the first switch-on time are shown in

black.

2. Press the F4 key under the CHOOSE command in the display to

select the day of the week that is to be reset.

3. Set the times using the numerical keypad.

Show switch on/off time 1-01

On: 00:00 On: 00:00 Time:15:55 Off: 24:00 Off: 00:00

Day : Monday

EDIT END

Enter switch on/off time 1-11

On: 00:00 On: 00:00 Time:15:55 Off: 24:00 Off: 00:00

Day : Monday

CHOOSE END

If you want the heating system to be ready for operation 24 hours a day, the first switch-on time must be set to ON: 00:00 and the first switch-off time to OFF: 24:00!

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6 Using the heating system – ON/OFF menu

4. Confirm each change with the Enter key.

✓ The cursor moves to the next digit pair.

5. Press the F4 key again under the CHOOSE command in the display

to select the next day of the week that is to be reset.

6. Press the F6 key under the END command to exit the Enter

switch on/off time 1-11 submenu.

✓ The operating times of the heating system are set. ✓ The display switches to Show switch on/off time 1-01.

7. Press the F6 key under the END command to exit the Show

switch on/off time 1-01 submenu.

✓ The standard display is restored.

SETTING THE CONTROL, BOILER ACTIVATION AND LAMBDA STOP

SETTING THE CONTROL MODES The heating system can be operated in different control modes.

These are:

• Fixed value

In this version, the combustion is not optimised and there is no output regulation. The combustion air supply and fuel quantity is fixedly set and remains unchanged.

• Combustion control

This version optimises the combustion. The primary and secondary air supplies and the fuel quantity are adapted automatically within a specified range of combustion. There is no output regulation. (Standard setting for use of accumulator).

• Control of combustion and output

In addition to combustion control, this version also adapts the output of the heating system to the demand.

• Control via DDC

This version is set if an overriding control controls the boiler (0 - 10 V).

✎ See “Procedure” in this section.

Setting 1-02

Control : Combustion control Activate boiler : Accumulator sensor Lambda stop : On

FIELD CHOOSE END

The standard setting for systems with accumulators is Combustion control.

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6 Using the heating system – ON/OFF menu

SELECTING AND SETTING BOILER

ACTIVATION

In boiler activation mode, there are various ways of switching the heating system on and off.

• Accumulator temperature sensor

In this version, the heating system is switched on and off through two accumulator temperature sensors. After falling below the preset temperature at the “Acc. top” sensor, the boiler is started. After exceeding the preset temperature at the “Acc. bottom” sensor, the boiler is switched off.

✎ See section “6.7 °C/QUANTITY menu” in this chapter.

• Accumulator and external

In this version, the heating system is switched on and off if the accumulator temperature sensor has enabled this and there is a simultaneous external demand.

• Accumulator or external

In this version, the heating system is switched on and off if the accumulator temperature sensor has enabled this or there is a simultaneous external demand.

• On

In this version, the heating system is switched on and off through the boiler supply temperature sensor. The accumulator temperature sensors are ignored.

• Thermostat

In this version, the heating system is switched off through the boiler supply temperature sensor and switched on through the accumulator thermostat.

• External

In this version, the heating system is switched on and off through an external controller. Observe the terminal connection points on the wiring diagram in the control cabinet.

✎ See “Procedure” in this section.

CTIVATING OR DEACTIVATING

AUTOMATIC IGNITION

The automatic ignition function can be switched off, thus activating the function for sustaining the embers.

✎ See “Procedure” in this section.

CTIVATING THE FUNCTION

“L

AMBDA STOP”

If the specified minimum residual oxygen value is not met, the fuel feeding is interrupted until the residual oxygen values are again within the acceptable range.

✎ See “Procedure” in this section.

The standard setting for systems with accumulators is Acc. temp. sensor.

The standard setting is On. Sustaining the embers is only performed in emergency operation!

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6 Using the heating system – ON/OFF menu

✎ For the setting of the minimum lambda value, see section “6.7 °C/

QUANTITY menu”, paragraph “Entering the residual oxygen setting”.

MODIFYING FAN SETTINGS

This submenu is used to change the settings for the flue gas fan or the primary and secondary air fans. Setting options:

• Controlled

On this setting the flue gas fan works at a set speed according to the existing vacuum pressure conditions.

• Not controlled

On this setting the flue gas fan works at a constant preset value.

✎ See “Procedure” in this section.

ADJUSTING THE ASH REMOVAL SETTING

The movement of the stepped grate and the ash removal system can be switched off.

✎ See “Procedure” in this section.

Setting 1-03

Flue gas fan : controlled Primary air fan : controlled Secondary air fan : controlled

FIELD END

The standard setting is controlled.

Setting 1-04

De-ashing : Automatic

CHOOSE END

The standard setting is Automatic.

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6 Using the heating system – ON/OFF menu

CHANGING THE CLEANING SYSTEM SETTING

The automatic heat exchanger cleaning system can be switched off.

✎ See “Procedure” in this section.

MODIFYING THE EXTRACTION SETTING

The heating system can, for example, include a separate delivery system for a shaving silo. In addition, the flexi-blade delivery system can be employed for extraction in combination with an additional conveyor auger. Extraction can be controlled in various ways.

• Cycles

In this version, the extraction runs in a cycle with configurable pause intervals and runtimes.

✎ For setting options, see the section “6.8 TIME menu” in this

chapter.

• Continuous running

In this version, the extraction runs continuously upon demand.

✎ See “Procedure” in this section.

Setting 1-05

Cleaning system : On

CHOOSE END

The standard setting is On.

Setting 1-06

Delivery system : Continuous running

CHOOSE END

The standard setting is Continuous.

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6 Using the heating system – °C/QUANTITY menu

MODIFYING THE WALKING FLOOR SETTING

A walking floor delivery system can be an optional component of a heating system. The individual scraper blades of the walking floor can be separately controlled.

• Off

In this version, all scraper blades are switched off.

• Auto scraper 1

In this version, only scraper 1 of the walking floor is controlled.

• Auto scraper 2

In this version, only scraper 2 of the walking floor is controlled.

• Auto scraper 1 + 2

In this version, both scraper blades of the walking floor are alternately controlled.

• MANUAL

In this version, the walking floor scrapers can be controlled by hand. The manual control function in the Manualmenu is enabled.

✎ See “Procedure” in this section.

6.7 °C/QUANTITY menu

In this menu, you can view and set temperatures, combustion air quantity, fuel type/quantity and control parameters. All target values can be modified. The actual values displayed indicate the current status.

PROCEDURE

1. Press the F2 key under the standard display screen.

✓ You are in the °C/Quantity menu.

2. Scroll with the F1 or F2 key to the previous or next submenu.

✓ The first resettable parameter is shown in black.

3. Enter the desired value using the numerical keypad.

Setting 1-07

Walking floor : MANUAL

FIELD END

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6 Using the heating system – °C/QUANTITY menu

4. Confirm each change with the Enter key.

✓ The desired parameter is set.

5. Scroll with the Up or Down key to the next parameter.

✓ The next resettable parameter is shown in black.

6. Repeat steps 3 to 5 for additional parameters.

7. Press the F6 key under the END command to exit the submenu.

✓ The standard display is restored.

DEFINING THE SWITCH ON/OFF TIMES FOR THE BOILER

This submenu is used to define the switch on/off times of the boiler based on the temperature sensor of the accumulator. The switching on and off of the boiler can be changed by adapting the temperature.

• Temp. acc. top below

If this temperature set for the top accumulator sensor is not met, the boiler switches back on.

• Temp. acc. bottom above

If the temperature set for the bottom accumulator sensor is exceeded, the boiler switches off.

✎ See “Procedure” in this section.

Temperature adjustment using the accumulator sensors is only available if the boiler activation is set to “Accumulator temperature sensor”.

✎ See section “6.6 ON/OFF menu”, under “Selecting and setting

boiler activation”.

Boiler on/off 2-11

On: acc. top below : 70 / 70°C

acc. temp. middle : 60°C

Off: acc. bottom above : 70 / 57°C

END

The standard setting for the boiler switch-on temperature for acc. top below is 70 °C.

The standard setting for the boiler switch-off temperature for acc. bottom above is 70 °C.

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6 Using the heating system – °C/QUANTITY menu

INTEGRATING THE PEAK LOAD BOILER

An additional peak load boiler can be integrated using a third accumulator temperature sensor. The switch-on and switch-off temperatures of the accumulator for the peak load boiler are set here.

• Temp. acc. top below

If this temperature set for the upper accumulator sensor is not met, the peak load boiler switches on.

• Temp. acc. middle above

If this temperature set for the middle accumulator sensor is exceeded, the peak load boiler switches off.

✎ See “Procedure” in this section.

SETTING THE BOILER AND RETURN TEMPERATURE

This submenu is used to set the boiler and return temperature. The furnace temperature in the combustion unit is also set. This switches the intermediate pump between the combustion unit and heat exchanger.

✎ See “Procedure” in this section.

This is an optional submenu and only available with double heating systems (if necessary, also with oil/gas boilers).

Peak load boiler 2-12

On: Temp. acc. top below 55 / 70°C

Off: Temp. acc. middle above 65 / 60°C

END

°C / Quantity 2-01

Boiler temperature max. : 85 / 79 °C Target boiler temperature : 75 °C Return temperature : 65 / 64 °C Combustion unit : 80 / 64 °C

END

The Boiler temperature must not fall below 70°C and must not exceed 85°C. The Return temperature target value must not fall below 60°C.

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6 Using the heating system – °C/QUANTITY menu

VIEWING COMBUSTION CHAMBER TEMPERATURE, RESIDUAL OXYGEN

AND VACUUM PRESSURE IN THE COMBUSTION CHAMBER

Combustion chamber temperature, residual oxygen and vacuum pressure in the combustion chamber appear in this submenu

✎ See “Procedure” in this section.

SETTING COMBUSTION CHAMBER TEMPERATURE 2 AND VIEWING FLUE

GAS TEMPERATURE

In this submenu you can set the combustion chamber temperature 2 in the heat exchanger or view the flue gas temperature.

✎ See “Procedure” in this section.

SELECTING A FUEL TYPE

In this submenu you can choose from four different heating material settings. The varying quality of the heating material can also be taken into account. All parameters can be newly defined and reset for each type of material.

The current return temperature can also be read here.

°C / Quantity 2-02

Comb. chamber temp. :650 /411 °C Residual oxygen : 7.0/8.7 % Vacuum pressure comb.chamb. : -15/ -30* Pa

END

Combustion.chamber temp., residual oxygen and vacuum pressure comb. chamber cannot be changed!

°C / Quantity 2-03

Comb. chamber temp 2 :1100 / 650 °C Flue gas temperature : 70 °C

END

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6 Using the heating system – °C/QUANTITY menu

✎ See “Procedure” in this section.

FIXED VALUE - SETTING THE FUEL AND AIR QUANTITY

This submenu is used to set the “fixed value” control options.

✎ See “Procedure” in this section.

Material Type 2-05

Fuel 1 : ( Fuel 1 )

END

The standard setting for start-up is usually Fuel: 1. Independent modification of settings for adapting to the fuel

should be made under another fuel type so as not to change the startup settings. For example, save the start-up setting under

Fuel: 2 and only then modify this setting.

Settings fixed value 2-06

Fuel : 60.0 /55.0 % Primary air : 30 / 30 % Secondary air : 30 / 15 % Comb. chamb. temp. : 600 / 411 °C

END

In this menu, the settings of the fuel and air quantities are fixed value presets for “Fixed value” operation only.

✎ See section “6.6 ON/OFF menu”, under “Setting the control,

boiler activation and Lambda Stop”.

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SETTING THE RETURN PUMP

✎ See “Procedure” in this section.

SETTING THE RETURN MIXER

In this menu the settings for a controlled return mixer can be made (0

- 10 V).

✎ See “Procedure” in this section.

OTHER PARAMETERS

Parameter group 6 can also be found in the Service menu

✎ See section “6.10 SERVICE menu”, paragraph “Setting output

control” and the following paragraphs in this chapter.

6.8 TIME menu

In this menu you can view and set all time parameters relating to ignition, de-ashing, cleaning and delivery systems. All target values can be modified. The actual values displayed indicate the current status.

PROCEDURE

1. Press the F3 key under the standard display screen.

✓ You are in the Time menu.

2. Scroll with the F1 or F2 key to the previous or next submenu.

PID return pump 2-09

Boiler_set :75°C MAX: 100% KP: 8.0 Boiler_actual :74°C MIN: 30% TN: 5.0

TV: 0.0

ACT: 100%

END

PID return mixer 2-10

T_SET : 65°C KP: 5.0 T_ACTUAL : 64°C TN: 5.0

TV: 0.0

Position 100%

END

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✓ The first resettable parameter is shown in black.

3. Enter the desired value using the numerical keypad.

4. Confirm each change with the Enter key.

✓ The desired parameter is set.

5. Scroll with the Up or Down key to the next parameter.

✓ The next resettable parameter is shown in black.

6. Repeat steps 3 to 5 for additional parameters.

7. Press the F6 key under the END command to exit the submenu.

✓ The standard display is restored.

SETTING THE FILLING, IGNITION AND FAN ACTIVATION

This submenu is used to set the time for the initial filling with fuel and the running time of the ignition fan. You can also set the time after which the combustion fan is added during the igniting phase.

✎ See “Procedure” in this section.

SETTING PRE-AIR, HEATING UP AND BURNING OUT

This submenu enables you to set the pre-ventilation time for fanning the fuel without material feeding, the heating up time during which the fuel quantity is heated to the target value, and the burn-out time during which material feeding is stopped and the combustion fan switches off after a specified time.

✎ See “Procedure” in this section.

Time 3-01

1st filling : 10.0 / 0.0 m Ignition : 7.0 / 0.0 m Start combustion air fan : 1.0 / 0.0 m

END

When changing the fuel, the parameters 1st filling and Ignition must be regulated to avoid malfunctions during

ignition.

Time 3-02

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6 Using the heating system – TIME menu

SETTING THE GRATE TIMES

This submenu is used to set the time for the grate motion and thus the de-ashing interval.

✎ See “Procedure” in this section.

SETTING GRATE ASH REMOVAL AUGERS AND ASCENDING AUGER TIMES

This submenu is used for setting grate ash removal augers and the ascending auger for the central ash removal.

✎ See “Procedure” in this section.

Pre-ventilation : 30 / 0 s Heating up : 10.0 / 0.0 m Burning out : 60.0 / 0.0 m

END

Time 3-03

Grate runtime cycles : 1 / 0 i Cleaning system pause time : 3.0/ 0.0 m Grate runtime cycles long : 2 / 0 i Grate pause time long : 9.0/ 0.0 m

END

When changing the heating material, the burn-out behaviour must be checked on the grate of the boiler. If necessary, adjust the Grate pause time parameter. In general, only this parameter should be changed, and the Grate runtime cycles parameter should only changed, where necessary, in exceptional cases.

Time 3-04

Ash auger. Grate runtime : 30/0 sAsh auger. Grate pause time : 13.0/0.0 m Ascending auger lag time : 30/0 s

END

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6 Using the heating system – TIME menu

SETTING TIMES FOR THE HEAT EXCHANGER ASH REMOVAL AUGERS AND

THE CLEANING SYSTEM

This submenu is used for setting times for the heat exchanger ash removal augers and the time for the movements of the cleaning system.

✎ See “Procedure” in this section.

SETTING MAIN CLEANING

In this submenu you can set up to two times for the main cleaning Cleaning and ash removal are activated at the preset time.

✎ See “Procedure” in this section.

Time 3-05

Ash auger. exch Runtime : 60 / 0 s Ash auger. exch Pause time : 60.0 / 0.0 m Cleaning system pause time : 12.0 / 0.0 h Cleaning system runtime : 140 / 0 s

END

When changing the heating material, the burn-out behaviour of the boiler must be checked in the area of the heat exchanger surfaces. If necessary, adjust the Cleaning pause time parameter. In general, only this parameter should be changed and the Cleaning system runtime parameter only changed in exceptional instances.

Cleaning 3-06

On: 00:00 On: 00:00 Time 11:50

END

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6 Using the heating system – TIME menu

100

STOKER AUGER DELAY

This submenu is used to set the lag time for the stoker auger. The stoker auger starts later than the rotary wheel by the amount of the preset time.

✎ See “Procedure” in this section.

SETTING PAUSE INTERVALS AND RUNNING TIME FOR DELIVERY

In this submenu you can set the pause intervals and running time for delivery.

✎ See “Procedure” in this section.

SETTING THE AGITATOR

In this submenu you can enter the settings for the lag time of the agitator in connection with a walking floor delivery system.

✎ See “Procedure” in this section.

Time 3-11

Filling delay Stoker auger : 3 / 0 s

END

This is an optional submenu and only available with feeding system TBZ 150.

Time 3-13

Delivery system runtime : 2.0 / 0.0 s Delivery system pause time : 4.0 / 0.0 s

END

This is an optional submenu and only available with walking floor delivery systems and double heating systems.

Agitator 3-14

Agitator lag time : 2.0 / 0.0 s

END