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HDG Compact 25 Operation Manual

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Operation Manual
HDG Compact 25/35
hdg-bavaria.com
V 02 - 04/2010

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Summary of Contents for HDG Compact 25

  • Page 1 Operation Manual HDG Compact 25/35 hdg-bavaria.com V 02 - 04/2010...

  • Page 3: Table Of Contents

    HDG Hydronic control functions........
  • Page 4 Dimensions on flue pipe side, HDG Compact 25/35 ..... . . 43 Dimensions on back side, HDG Compact 25/35 ......44 4.3 Scope of delivery .
  • Page 5 Control unit of HDG Compatronic ........
  • Page 6 Operation Manual HDG Compact 25/35 - Content Checking and cleaning the flue gas fan ........144 Cleaning the flue gas temperature sensor .

  • Page 7: Notes On This Manual

    This operating manual must be read and applied by everyone who EADING THE OPERATING operates or works on the heating system HDG Compact 25/35. MANUAL We continuously develop and improve our boilers. The information ECHNICAL CHANGES in this edition was correct at the time of going to press.

  • Page 8: Structure Of The Operating Manual

    10 Warranty ... the terms and conditions of the warranty. 11 EC Declaration of Conformity Table 1/1 - Structure of the operating manual © HDG Compact 25/35 - Version 2 - en HDG Bavaria GmbH October 2007...

  • Page 9: Glossary

    Fuel transport system - carries fuel from the bunker to the dosing unit or to the intermediate container. Display Display of the HDG Compatronic control unit EMERGENCY STOP Must be used in an emergency - interrupts all actuators, however, it does not switch off the mains supply to the heating system.

  • Page 10: Safety Instructions

    Bavaria does not assume any liability for this. ROPER AND IMPROPER MANNER OF OPERATION The HDG Compact 25/35 heating system is designed for the standard PPLICATION OF THE HEATING use of burning wood fuel products made from untreated wood in the...

  • Page 11: Residual Risk

    The use of materials with other technical burning characteristics requires comprehensive modification of the control parameters by qualified specialists. UK S The HDG Compact 25/35 models have been recommended for MOKE ONTROL REAS exemption under Section 21 of the Clean Air Act 1993 for use in...
  • Page 12 The circuit boards and electrical components conduct electricity. Have work on electrical components performed only by a qualified electrician and turn the main switch off. Warning! The boiler is under pressure. © HDG Compact 25/35 - Version 2 - en HDG Bavaria GmbH 10/2007...

  • Page 13: Warnings And Safety Symbols Used

    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. © HDG Bavaria GmbH 10/2007 HDG Compact 25/35 - Version 2 - en...

  • Page 14: Duty To Inform

    This holds especially true for persons who only occasionally work on the heating system, e.g. when cleaning or servicing it. The operating manual must always be kept readily accessible at the heating system’s installation site. © HDG Compact 25/35 - Version 2 - en HDG Bavaria GmbH 10/2007...

  • Page 15: Mode Of Operation

    TBZ 150 for feeding wood chips, planing shavings and pellets. • Pellet vacuum delivery system with TBZ 80 for feeding the pellets. The HDG Compact 25/35 heating system can also be equipped with the following delivery systems: • Flexi-blade delivery system FRA •...

  • Page 16: Hdg Compact 25/35 Front Side

    3 Mode of operation – Overview HDG C 25/35 OMPACT FRONT SIDE Figure 3/1 - Front side of the HDG Compact 25/35 boiler 1 Control unit of HDG Compatronic 2 Cleaning motor 3 EMERGENCY STOP 4 Flue gas fan 5 Flue pipe connection...

  • Page 17: Hdg Compact 25/35 Back Side

    HDG C 25/35 OMPACT BACK SIDE Figure 3/2 - HDG Compact 25/35 boiler back side 1 Connection of immersion sleeve for thermal safety device (DN 15, inside thread) 2 Safety heat exchanger connections (DN 15, outside thread) 3 Main switch...

  • Page 18: Functional Description

    3 Mode of operation – Functional description 3.2 Functional description ERSION OF THE HEATING SYSTEM The HDG Compact 25/35 heating system may comprise the following components: Figure 3/3 - Overview 1 Access hatch 2 Sloping floor 3 Delivery system 4 HDG Hydronic (option)

  • Page 19: Delivery System

    HDG Compact 25/35 boiler. With the control unit, you can adjust the HDG Compact 25/35 and obtain information on the current process status. If the HDG Compatronic issues a request for more heat, the HDG Compact 25/35 automatically switches to the Fill operating mode and the combustion chamber is filled with fuel.

  • Page 20: Control Modes

    – only suitable for emergency operation HDG H YDRONIC The HDG Hydronic is a heating system regulator which is attuned to the HDG hydraulic systems. The HDG Hydronic handles the overall energy management for the heating system and, depending on the version, controls up to three weather-controlled heating circuits as well as: •...

  • Page 21: Hdg Hydronic Control Functions

    3 Mode of operation – Functional description HDG H YDRONIC CONTROL FUNCTIONS The heating circuit control always operates at a characteristic heating ASIC FUNCTIONS OF THE curve controlled by the outside air temperature. For each heating HEATING CIRCUIT CONTROL system, the characteristic heating curve is used to calculate the supply water temperature which is appropriate for the current outdoor temperature.
  • Page 22 3 Mode of operation – Functional description If an indoor thermostat unit is connected, the current target room NDOOR THERMOSTAT UNIT temperature is calculated from the preset day and night room temperatures, the room influence factor and the current measured room temperature.
  • Page 23 3 Mode of operation – Functional description principle described above, the water supply temperature is reduced until the Minimum screed drying temp. is reached. The heating circuit changes to the status OFF. Hold time Supply temp maximum Increase in preset supply temperature Increase Supply temp minimum...
  • Page 24 ✎ See the informational booklet “Hydraulic solutions of the HDG Hydronic”, section “Hydraulic system 4.S”.
  • Page 25 3 Mode of operation – Functional description This function is only active when solar heating is being used for the ROTECTING THE COLLECTOR hot water tank or for the combination accumulator. If the protection FROM OVERHEATING temperature for the solar collector (Solar 18-12 parameter), factory setting 110 °C, is exceeded, the solar pump will start, even if the maximum temperature for solar heating has been exceeded.
  • Page 26 3 Mode of operation – Functional description If two different enable temperatures have been specified for hot water and for heating circuits, and if there is no demand on the hot water tank, the oil-fired boiler will only start once the temperature has fallen below the enable temperature for the heating circuits.

  • Page 27: Technical Data

    3 Mode of operation – Technical data 3.3 Technical data HDG Compact 25 HDG Compact 35 Boiler model Wood chips / pellets Wood chips / pellets Performance data (measuring method conforming to DIN EN 303-5) Nominal thermal power 31.0 kW / 26.0 kW 31.0 kW / 35.0 kW...

  • Page 28: Fuel Quality Requirements

    3.4 Fuel quality requirements ERMISSIBLE FUEL 'The HDG Compact 25/35 heating system is designed for the use of wood fuel products from untreated wood and for fuels from wood processing plants, such as shavings and wood pellets. The testing of the heating system was performed with B1 wood chip fuel products with a water content of between 15% and 35%.

  • Page 29: Wood Chips

    3 Mode of operation – Fuel quality requirements OOD CHIPS Essential criteria are nominal length and water content of the fuel. Wood chips with a typical nominal length less than 3 cm (grain size OMINAL LENGTH G 30) are designated as fine chippings. As a machine-compatible material, this wood fuel product is especially suitable for small systems.

  • Page 30: Recommended Fuel

    2.0% Table 3/3 - Burning characteristics of wood pellets ECOMMENDED FUEL Suitable as fuel for the HDG Compact 25/35 heating system are wood chips, shavings and wood pellets. HDG Bavaria recommends wood chips with grain size G30 and a OOD CHIPS maximum 20% proportion of finer content.
  • Page 31 3 Mode of operation – Fuel quality requirements For the HDG Compact 25/35 heating system it is possible to use wood chips with a maximum moisture content of up to 35%. However, reduced efficiency, increased fuel consumption and greater wear and tear on the heating system may then result. Fuels with a higher moisture content are not suitable for burning.

  • Page 32: Planning And Installation

    4 Planning and installation – Planning the heating system 4 Planning and installation 4.1 Planning the heating system ECESSARY ROOM SIZES AND MINIMUM SPACING Figure 4/1 - Necessary room sizes and minimum spacing HDG Compact 25/35 1800 2900 700 / 1150 1200...

  • Page 33: Dimensions

    4 Planning and installation – Planning the heating system To operate the system with an automatic cleaning system, a ceiling height of 1950 mm is necessary. IMENSIONS The following table contains the dimensions of the boiler. HDG Compact 25 HDG Compact 35 Length 1034 mm Width...

  • Page 34: Fuel Bunker

    • adapted to fuel requirements The refilling intervals should be kept as long as possible. The HDG Compact 25/35 heating system should be located so that the noise generated does not exceed DIN 4109 “Soundproofing in building construction”.

  • Page 35: Delivery System Versions

    4 Planning and installation – Planning the heating system ELIVERY SYSTEM VERSIONS Delivery version 1 - Dosage directly to TBZ Figure 4/2 - Delivery system version 1 1 Dosage 2 Feeding system Delivery version 2 - Dosage, conveyor auger to TBZ Figure 4/3 - Delivery system version 2 1 Dosage system II (motor of delivery system runs along with dosage system)
  • Page 36 4 Planning and installation – Planning the heating system Delivery version 3 - External delivery Figure 4/4 - Delivery system version 3 1 Delivery system 2 Dosage 3 Feeding system 4 Fill level indicator Delivery version 4 - sloping auger delivery, silo delivery system Figure 4/5 - Delivery system version 4 1 Delivery system 2 Fill level indicator...

  • Page 37: Connections

    The required flue gas values are listed in chapter “3 Mode of operation”, section “3.3 Technical data”. The benefits of the HDG Compact 25/35 can only be reaped if all of the factors necessary for good combustion are carefully adjusted.
  • Page 38 4 Planning and installation – Connections When planning the exhaust system, a flue calculation based on DIN EN 13384-1 must be performed by authorised specialists. Another essential criterion is meeting the flue draught requirement. This depends on three major factors. The requirements for minimising the draught loss in the chimney are: HIMNEY CHARACTERISTICS •...

  • Page 39: Electrical System

    Figure 4/7 - Connection to the chimney To compensate for irregularities of the flue draught in 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 4/7 - Connection to the chimney.

  • Page 40: Water

    (e.g. -15 °C) is used. This condition only applies a few days per year, thus, the thermal performance of the heating system is greater than required on most days when heating is needed. For this reason, the HDG Compact 25/35 is fitted as standard with power control and automatic ignition.
  • Page 41 The minimum return temperature is listed in chapter “3 Mode of operation”, section “3.3 Technical data”. The control of the return temperature is handled by the HDG Compatronic control. The return temperature control consists of a 3-way mixing valve with a 230 V servo drive (running time 120-140 s) and a circulation pump.

  • Page 42: Hydraulic Connection

    YDRAULIC CONNECTION There are hydraulic solutions for every application. ✎ An excerpt of the hydraulic solution options can be found in the section “4.9 HDG hydraulic systems” in this chapter or in the informational booklet “Hydraulic Solutions for the HDG Hydronic”.

  • Page 43: Dimensions On Flue Pipe Side, Hdg Compact 25/35

    3 Flue pipe connection Ø 150 mm 4 Boiler return connection (DN 32, inside thread) 5 Filling / draining connection (DN 15, inside thread) Model HDG Compact 25/35 1174 1064 Table 4/3 - Dimensions on flue pipe side, HDG Compact 25/35 (mm)

  • Page 44: Dimensions On Back Side, Hdg Compact 25/35

    1 Connection of immersion sleeve for thermal safety device (DN 15, inside thread) 2 Inlet / outlet of safety heat exchanger (DN 15, outside thread) Model HDG Compact 25/35 1150 1140 Table 4/4 - Dimensions on back side, HDG Compact 25/35 (mm)

  • Page 45: Scope Of Delivery

    See section “4.1 Planning the heating system” in this chapter. The following figures and diagrams show the version of the heating system HDG Compact 25/35 with feeding system TBZ 150 on the left side of the boiler. Please keep this in mind if your version has a feeding system on the...

  • Page 46: Installing The Boiler

    4 Planning and installation – Installing the heating system NSTALLING THE BOILER Warning! Danger from suspended loads The boiler weighs over 500 kg. If the boiler is dropped during transport, persons can be seriously injured and the boiler can be damaged.

  • Page 47: Installing The Automatic Ash Removal System

    4 Planning and installation – Installing the heating system Align the boiler with plastic plates or flat steel strips (not included in the scope of delivery) so that it is horizontal. ✓ The boiler has been set up. NSTALLING THE AUTOMATIC ASH REMOVAL SYSTEM Unscrew the cover of the circuit boards (1) with a Phillips-tip screwdriver.
  • Page 48 4 Planning and installation – Installing the heating system NSTALLING THE ASH REMOVAL AUGERS Figure 4/14 - Installing the ash removal augers Insert the ash removal auger with the long shaft end (4) from the front on the feed side through the opening (1) provided for this. Insert the second ash removal auger with the short shaft end (3) from the front through the opening (2) provided for this.
  • Page 49 4 Planning and installation – Installing the heating system For the version of the boiler with the feeding system on the left side, the chain tensioner must be fastened in the upper position. For the version of the boiler with the feeding system on the right side, the chain tensioner must be fastened in the lower position.
  • Page 50 22.Lay the ash removal motor cable (2) in such a way that it cannot contact the drive chain (1). 23.Connect the plug of the ash removal motor to the board. ✎ See the enclosed circuit diagram “HDG Compatronic”. 24.Fasten all cables with cable clips. ✓ The automatic ash removal system is installed.

  • Page 51: Installing The Automatic Cleaning System

    4 Planning and installation – Installing the heating system NSTALLING THE AUTOMATIC CLEANING SYSTEM Release the pre-mounted M12 nuts from the short or long NSTALLING THE CROSSBEAMS crossbeam. Figure 4/20 - Installing the crossbeams Place the two crossbeams (1) on the turbulators in the cleaning shaft.
  • Page 52 4 Planning and installation – Installing the heating system Figure 4/22 - Putting on the cleaning shaft lid Place the cleaning shaft lid (1) on the boiler. Figure 4/23 - Bolting on the cleaning shaft lid Guide the screws (2) of the hinges into the holes on the cleaning shaft lid (1).
  • Page 53 4 Planning and installation – Installing the heating system 12.Slowly close the cleaning shaft lid. Figure 4/24 - Fastening the crossbeams on the cleaning shaft lid 13.Bolt the crossbeams onto the cleaning shaft lid with the two middle M10 screws (2) using a 10 mm hexagon socket wrench. First, screw the two hexagon socket screws of the cleaning shaft lid until tight.

  • Page 54: Installing The Feeding System

    When laying the cable, ensure that there is enough cable for the cleaning shaft lid to be opened. 19.Connect the plug of the cleaning system to the circuit board. ✎ See the enclosed circuit diagram “HDG Compatronic”. 20.Mount the cover in the reverse sequence. ✓ The cleaning system is now connected.
  • Page 55 4 Planning and installation – Installing the heating system Poke a hole through the seal (5) for the centring screw (2). Insert the centring screw (2) toward the boiler through the holes and screw it tight with the M6 nut using a 10 mm spanner. Warning! Danger of injury The feeding system is very heavy.

  • Page 56: Installing The Accumulator Sensor

    SYSTEM 16.Connect the plug of the feeding system to the circuit board. ✎ See the enclosed circuit diagram “HDG Compatronic”. ✓ The feeding system is connected. NSTALLING THE ACCUMULATOR SENSOR The sensors for the accumulator are attached under the circuit board cover next to the circuit boards for further use.

  • Page 57: Wiring The Circuit Boards

    Open the cable duct (2). Connect all plugs to the circuit board central unit (1) and transport module (3) in accordance with the circuit diagram. ✎ See the enclosed circuit diagram “HDG Compatronic”. Close the cable ducts. ✓ The circuit boards are wired.

  • Page 58: Installing And Adjusting The Ash Containers

    4 Planning and installation – Installing the heating system NSTALLING AND ADJUSTING THE ASH CONTAINERS Remove the ash containers from the packaging. Figure 4/33 - Attaching the ash containers Lift up the clamp handles (1). Insert the ash containers (2) on the ash removal pipe. Press the clamp handles (1) downward.

  • Page 59: Hdg Hydronic

    Do not touch any electronic components during the installation. NSTALLING THE CONTROLLER HOUSING The bus cable between the HDG Compatronic and HDG Hydronic must be protected from inductive coupling through 230 V wires! Only use screened cables for sensor extensions.

  • Page 60: Installing The Sensors

    Take great care that you use the correct sensors (contact sensors, immersion sensors, outside temperature sensors) since, if incorrectly applied, error messages and resulting malfunctions in the control system could then occur. All of the sensors in the HDG Hydronic are PT 1000 sensors. Temperature PT 1000 Temperature PT 1000 -50 °C...
  • Page 61 4 Planning and installation – HDG Hydronic NSTALLING HEATING CIRCUIT SENSORS Figure 4/37 - Heating circuit sensors Fasten the heating circuit sensor (1) to the pipe flush with the pipe’s surface using the supplied hose clip (2). ✎ See section “4.2 Connections” in this chapter.

  • Page 62: Hydraulic Systems

    HDG specifications. ✎ The available hydraulic system options can be found in the section “4.9 HDG hydraulic systems” in this chapter or in the informational booklet “Hydraulic Solutions for the HDG Hydronic”. 4.6 Electrical system The electrical connections must be made in accordance with DIN IEC 60364 “Setting up low-voltage electrical installations”.

  • Page 63: Thermal Safety Device

    The thermal safety device is to be inspected annually by an authorised, qualified technician to verify that it is functional. The thermal safety device is to be installed according to guidelines from HDG Bavaria.

  • Page 64: Hdg Hydraulic Systems

    “Hydraulic Solutions for the HDG Hydronic”. In the following, the two basic diagrams of the HDG Compatronic (hydraulic system 0 and 10) are shown with the corresponding connections on the circuit board. A brief description of the menu system is also provided in tabular form for the selection of the respective hydraulic system.

  • Page 65: Hydraulic System 0

    4 Planning and installation – HDG hydraulic systems YDRAULIC SYSTEM Außentem- peraturfühler Figure 4/42 - Hydraulic system 0 HDG Compatronic Connection Outside temperature sensor 40 / 41 Supply temperature sensor 48 / 49 (boiler temperature) Return temperature sensor 46 / 47...

  • Page 66: Hydraulic System 10

    4 Planning and installation – HDG hydraulic systems YDRAULIC SYSTEM Figure 4/43 - Hydraulic system 10 HDG Compatronic Connection OTS Outside temperature sensor 40 / 41 Supply temperature sensor 48 / 49 (boiler temperature) Return temperature sensor 46 / 47...

  • Page 67: Starting The System

    5 Starting the system The heating system will initially be commissioned by specialists from HDG Bavaria GmbH 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.

  • Page 68: Procedure

    5 Starting the system – Procedure • Has the mains power supply cable been correctly connected, 400 V? – L1 on terminal 100 – L2 on terminal 101 – L3 on terminal 102 – Neutral conductor on terminal N – Earthing conductor on terminal PE •...
  • Page 69 5 Starting the system – Procedure Press the Down button until you reach the parameter Language ISPLAY LANGUAGE 1-24. Display Description • The desired display language can be selected. 1-24 Language D - German GB - English Table 5/1 - Setting the display language ✓...

  • Page 70: Setting The Delivery Version

    5 Starting the system – Procedure 11.Press the Down button until you reach the parameter Power UPPLY VOLTAGE supply 1-25. Display Description • The supply voltage can be selected. 1-25 Power supply 3 x 400 V/N 3 x 230 V Table 5/3 - Setting the supply voltage ✓...

  • Page 71: Setting The Fuel Type

    5 Starting the system – Procedure ✎ An overview of the versions of the delivery system can be found in the chapter “4 Planning and installation”, section “4.1 Planning the heating system”, under “Delivery system versions”. Press the Enter button. Enter ✓...

  • Page 72: Checking The Actuators In Manual Operation

    5 Starting the system – Procedure ✎ An overview of the preset hydraulic systems can be found in the chapter “4 Planning and installation”, section “4.9 HDG hydraulic systems”, or in the informational booklet “Hydraulic Solutions for the HDG Hydronic”.
  • Page 73 5 Starting the system – Procedure After selecting the respective actuator, press the Plus or Minus button. ✓ The drives are controlled with the Plus or Minus buttons. Check that the following actuators work properly: Display Description Feeding system h-01 Feeding system Current: 0.000 A...

  • Page 74: Checking The Sensors In Manual Operation

    5 Starting the system – Procedure Display Description Cleaning system h-08 Cleaning system Plus button: Cleaning system switches on Limit switch Minus button: Cleaning system switches off Start (+) Stop (-) Flue gas fan h-10 Flue gas Plus button: Intensity increases percentually plus 5% Minus button: Intensity decreases percentually minus 5%...
  • Page 75 5 Starting the system – Procedure After selecting the respective sensor, press the Plus or Minus button. ✓ The drives are controlled with the Plus or Minus buttons. For the selected hydraulic system, check the function of the following sensors: Display Description Sensor 1...
  • Page 76 5 Starting the system – Procedure Display Description Pumps/Indoor thermostat for heating circuit 3 h-24 Manual HC HCP/Thermostat 3 Plus button: Heating circuit pump 3 switches on/off HCP 3: Room/VL 3: -20/-50°C Mixing valve for heating circuit 4 h-25 Manual HC Mixing valve HC 4 Plus button: Mixing valve is opened Open...
  • Page 77 5 Starting the system – Procedure Display Description Solar accumulator pump h-34 Manual HC Solar acc. pump Plus button: Speed of solar accumulator pump is Acc. pump 1: increased Minus button: Speed of solar accumulator pump is reduced District heating h-35 Manual HC Plus button: District heating pump switches on/off...

  • Page 78: Filling The Fuel Bunker

    Prior to initial start-up or after cleaning it, the lambda sensor must be ALIBRATING THE LAMBDA recalibrated. This involves adjusting the lamba sensor for the oxygen SENSOR content of the air. Select the parameter Calib. lambda h-38. Press the Plus button to start the lambda calibration. ✓...

  • Page 79: Switching To Automatic Mode

    5 Starting the system – Procedure Check the basic settings for the following parameter groups: • 1-General • 2-Boiler • 3-Ignition • 4-Control • 5-Return • 6-Cleaning • 7-Delivery system and the basic settings of the additional hydraulic system-dependent parameter groups 8-Hydraulic system to 21-Heating pump, Combi.

  • Page 80: Adapting Parameters

    5 Starting the system – Procedure DAPTING PARAMETERS If the heating system does not work correctly, the parameters in the service level must be adjusted accordingly. ✎ See the chapter “6 Using the heating system”, section “6.10 Structure of the menus”. AVING OPERATING PARAMETERS Once the heating system has been configured, i.e.

  • Page 81: Using The Heating System

    6.1 Overview of the controls and display components AIN SWITCH The main switch is located on the side of the HDG Compact 25/35 boiler. The heating system can be shut down using the main switch. EMERGENCY STOP The EMERGENCY STOP switch is located next to the control unit of the HDG Compatronic.

  • Page 82: Control Unit Of Hdg Compatronic

    3 Safety temperature limiter restart button 4 Operating mode indicator The control unit for the HDG Compatronic is located on the front of the HDG Compact 25/35 boiler. With the control unit, you can adjust the HDG Compatronic and obtain information on the current process status.
  • Page 83 DOMESTIC HOT WATER (optional) This mode is selected if only hot water heating is required. The mode can only be selected in combination with the HDG Hydronic heating control. In this mode, only the protective programs are active. There is still electrical voltage in the system.

  • Page 84: Switching On The Heating System

    ✓ The heating system is now switched on. ✓ The HDG Compatronic continues working in the mode that it was in before the heating system was switched off. 6.3 Switching off the heating system Important!

  • Page 85: Displaying Information

    ✓ The heating system is switched off and without current. 6.4 Displaying information You can call up a variety of information on the display of the HDG Compatronic control unit. ✎ See section “6.10 Structure of the menus” in this chapter.

  • Page 86: Setting The Enable Or Reduction Times

    The standard display of i-01 is shown again. ETTING THE ENABLE OR REDUCTION TIMES On the HDG Compatronic control unit, you can set the enable or reduction times for the heating system. For each day of the week, you can set a maximum of four different enable times or reduction times.

  • Page 87: Setting The Heating Times For Heating Circuits And Heating Hot Water

    ETTING THE HEATING TIMES FOR HEATING CIRCUITS AND HEATING HOT WATER On the HDG Compatronic control unit you can set heating times for each heating circuit and for hot water. Per weekday, you can set a maximum of four different heating periods. At the set heating periods, the heating circuits will be in Heating or Domestic hot water mode.

  • Page 88: Changing Operating Mode

    6 Using the heating system – Changing operating mode Repeatedly press the Down button until Program 10-05 or Program 2, HC2 10-06 appears in the display. ✓ Either Program 1, HC 10-05 or Program 2, HC2 10-06 are shown in the display. Press the Enter button.

  • Page 89: Operating Statuses

    6 Using the heating system – Operating statuses 6.7 Operating statuses The heating system goes through the following states during operation: Operating Operating status Description mode • The main switch is turned on. • Frost protection and the protective programs are active.

  • Page 90: Filling The Fuel Bunker

    This operating status is maintained until a change is made to a different status. Domestic hot water • Together with the HDG Hydronic heating circuit control, it is possible to implement summer operation. • In this mode the anti-frost and protective functions are active.

  • Page 91: Performing The Chimney Sweep Test

    6 Using the heating system – Performing the chimney sweep test Caution! Damage to delivery system during filling If the heating system is not switched on during filling of the fuel bunker, the overload protection of the delivery system could be triggered when the heating system is switched on after the filling.

  • Page 92: Before The Test

    The Chimney sweep test symbol lights up. ✓ The heating system switches to Chimney sweep test mode. ✓ If the HDG Hydronic is connected, all of the loads will automatically be activated to maximise the heat transfer. ✓ The display will show No test yet.

  • Page 93: After The Measurement

    The chimney sweep test is completed. 6.10 Structure of the menus On the display of the HDG Compatronic control unit you can read off information and parameters for the HDG Compact 25/35 boiler. All of the information and parameters necessary to operate the equipment are listed in the following menu structure.

  • Page 94: Contents Of The Levels

    6 Using the heating system – Structure of the menus • Customer level – Accessible for all users. – The values displayed can be changed. • Service level – Accessible for all users by entering a combination of buttons. – The values displayed can be changed. ✎...

  • Page 95: Information Level

    6 Using the heating system – Structure of the menus NFORMATION LEVEL Display Description • Operating status i-01 Control Configured control type Combustion control Boiler temperature set/actual Boiler temp. 80/75°C Return temperature set/actual Return temp. 60/60°C • Operating status i-02 Control Combustion chamber temp.
  • Page 96 6 Using the heating system – Structure of the menus Display Description • Accumulator info i-11 Accumulator Accumulator status Status heating Current temperature at top of accumulator Temp. top 77°C Current temperature at bottom of accumulator Temp. bottom 65°C • Information on heating circuit HC 1 i-12 Heat circuit 1...
  • Page 97 6 Using the heating system – Structure of the menus Display Description • District heating information i-21 District heating 1 Transfer temperature of district heating Dist.h. temp 65°C Status of district heating pump Dist.h. pump • Information on oil-fired boiler i-22 Oilburn.

  • Page 98: Customer And Service Levels

    14:49:37 • Remote maintenance i-33 Remote maintenance Status Modem init • Software version HDG Bavaria Wood chip boiler Fuel 1 2008-08-14 GB,NL,FR Table 6/2 - Information level USTOMER AND SERVICE LEVELS Danger! Material damage and injury due to incorrect settings! Setting these parameters requires comprehensive specialist knowledge.
  • Page 99 6 Using the heating system – Structure of the menus Use the Up or Down buttons to select the individual parameters. Repeat steps 2 and 3 for each parameter group or parameter. ENERAL Display Description • Date and time Date and time To set the day of the week and date.
  • Page 100 6 Using the heating system – Structure of the menus Display Description • Initial commissioning 1-09 General All settings are adopted from the HDG factory defauts. Initial commissioning (0/1) ( 0) • Serial interface 1-10 Serial port Function switching Status display...
  • Page 101 Display Description • Defining the preset boiler temperature 2-00 Set temp. via with HDG Hydronic system connected HC ctrl/acc. with variable boiler temp. and external controller Outdoor enable via external control and constant boiler temp. External with external demand and variable boiler temperature Outdoor/external •...
  • Page 102 6 Using the heating system – Structure of the menus Display Description • Boiler hysteresis 2-05 Boiler The difference between the boiler temperatures to switch Set temperature on and to switch off. Hysteresis (0 - 20 °C) ( 5) 5° •...
  • Page 103 6 Using the heating system – Structure of the menus Display Description • Preset boiler temperature for frost protection 2-19 Boiler Boiler target temperature if the frost protection places a Set temperature for load on the system. antifreeze (0 - 50 °C) ( 10) 10°...
  • Page 104 6 Using the heating system – Structure of the menus Display Description • Flue gas fan 2-31 Boiler Maximum permissible deviation of the set speed of the Flue gas fan flue gas fan. Hysteresis (0 - 100%) Table 6/4 - System level / 2 - Boiler 3 - I GNITION Display...
  • Page 105 6 Using the heating system – Structure of the menus Display Description • Secondary air for ignition 3-09 Ignition Setting option for the secondary air volume supplied Ignition during ignition. Secondary air (0 - 100%) ( 0) • Flue gas fan setting for ignition 3-10 Ignition Setting option for the speed of a flue gas fan for ignition.
  • Page 106 6 Using the heating system – Structure of the menus Display Description • Primary air for heating-up phase 3-20 Ignition Setting option for the primary air volume supplied during Heating up the heating-up phase. Primary air (0 - 100%) ( 40) •...
  • Page 107 6 Using the heating system – Structure of the menus 4 - C ONTROL The default setting in the automatic mode of the heating system is Combustion control. Display Description • Type of control for the combustion 4-01 Type of boiler control “Fixed value”...
  • Page 108 6 Using the heating system – Structure of the menus Display Description • Advance time of combustion chamber temperature 4-09 Control For “Combustion and output control” PID_1 comb.cham.temp Advance time (D) ( 0.0) • Minimum combustion chamber temperature 4-11 Control For “Combustion and output control”...
  • Page 109 6 Using the heating system – Structure of the menus Display Description • Speed of flue gas fan 4-22 Control For minimum primary air quantity R-2 Flue gas fan Minimum (0 - 100%) ( 40) • Speed of flue gas fan 4-23 Control For maximum primary air quantity...
  • Page 110 6 Using the heating system – Structure of the menus Display Description • Fuel change due to residual oxygen 4-33 Control If the residual oxygen is too low, the specified percentage O2 fuel change value is deducted from the fuel quantity. delta Minimum (-50 - -100%) ( -10)
  • Page 111 6 Using the heating system – Structure of the menus Display Description • Preset temperature of return flow 5-04 Return Set the temperature of the return flow. Set temperature (40 - 80 °C) ( 60) 60°C • Residual heat 5-05 Return Set the time for the return pump.
  • Page 112 6 Using the heating system – Structure of the menus Display Description • Grate emptying 6-04 Cleaning Length of burning out phase prior to grate emptying. Burn out before emptying grate (0 - 200 h) ( 15) 15 m • Grate emptying 6-05 Cleaning...
  • Page 113 6 Using the heating system – Structure of the menus Display Description • Monitoring of the cleaning system functions 6-15 Cleaning The monitoring limit switch of the cleaning system must Monitor trigger within this set time. cleaning system (0 - 180 m) ( 6) •...
  • Page 114 8 - H YDRAULIC SYSTEM Setting of the hydraulic system is done according to the selection in the chapter entitled “4 Planning and installation”, section “4.9 HDG hydraulic systems”. The selection will further depend on whether the HDG Hydronic is connected.
  • Page 115 6 Using the heating system – Structure of the menus Display Description • Hydraulic system 8-01 Hydraulic system Enter the installed HDG hydraulic system. The default Hydraulic system setting without the HDG Hydronic is “System 0”. (0 - 13) • Accumulator type 8-02 Accumulator type Setting of the accumulator type.
  • Page 116 Activate a combination accumulator + DHW heating pump. • Available heating circuit modules 8-12 HC mod. 1 avbl. Select a second HDG heating circuit module (HDG Hydronic). • Heat circuit 4 8-13 Heat system HC4 Setting the system’s heating circuit HC 4.
  • Page 117 6 Using the heating system – Structure of the menus 9 - A CCUMULATOR The accumulator level is only displayed if an accumulator has been configured (Accumulator type 8-02 parameter). Display Description • Temperature at bottom of accumulator at maximum 9-02 Accumulator After exceeding the preset temperature at the “Acc.
  • Page 118 6 Using the heating system – Structure of the menus Display Description • Accumulator house 1 9-17 Accumulator After falling below this temperature on the accumulator Acc. house 1 top house 1, top, the boiler switches on. (Start heating up) ( 60) 60°...
  • Page 119 6 Using the heating system – Structure of the menus Display Description • Heating times 10-05 Progr. 1 HC1 Time block 1: Various enable times can be defined for the Mo Tu We Th Fr Sa Su individual days of the week. On 05:00 On 00:00 Off 22:00...
  • Page 120 6 Using the heating system – Structure of the menus Display Description • Mixing valve runtime 10-17 Heat circuit 1 Set the mixer runtime. Mixing valve runtime (10 - 300 s) (150) 150 s • Screed drying program 10-18 Screed drying Activate the screed drying program.
  • Page 121 6 Using the heating system – Structure of the menus 12 - H EATING CIRCUIT The layout of the parameter structure in service level 12-Heat circuit 3 is identical to service level 10-Heat circuit 1. 13 - H EAT CIRCUIT 14 - H EAT CIRCUIT 15 - H...
  • Page 122 6 Using the heating system – Structure of the menus Display Description • Time period for the hot water tank priority 16-07 DHW 1 Set the duration of priority for the hot water tank. Continuous (1,0 - 10.0 h) hot water priority (1.0) 1.0 h •...
  • Page 123 6 Using the heating system – Structure of the menus Display Description • Maximum speed of the solar pump 18-04 Solar Set the maximum speed for the solar pump. Max. speed solar pump ( (50 - 100%) 100) 100% • Waiting time before restarting the solar accumulator 18-05 Solar pump in order to check the available collector...
  • Page 124 6 Using the heating system – Structure of the menus 19 - D ISTRICT HEATING Display Description • Preset temperature for district heating 19-01 District heating Set the temperature of the transfer station for district Set temp. dist. heat. heating. transfer (20 - 100 °C) ( 65)

  • Page 125: Manual Operation

    6 Using the heating system – Structure of the menus Display Description • Hysteresis of the oil-fired boiler 20-04 Oil burner Set the difference between the switching on and Oil-fired boiler switching off temperatures for the oil-fired boiler. hysteresis (10 - 100 °C) ( 5) 5°...

  • Page 126: Cleaning And Servicing The Heating System

    The cleaning and maintenance work can also be performed by an authorised specialist heating company through a servicing contract. EPLACEMENT PARTS Only use original HDG replacement parts! You can obtain HDG replacement parts from your specialist heating company. 7.1 Cleaning and maintenance schedule The specified cleaning intervals are recommended values.

  • Page 127: Procedure

    7 Cleaning and servicing the heating system – Procedure 7.2 Procedure ENERALLY APPLICABLE SAFETY INSTRUCTIONS Please be sure to observe the following generally applicable safety instructions when performing any cleaning or maintenance work: Warning! Danger of asphyxiation due to carbon monoxide If the boiler is in operation, carbon monoxide can be emitted through opened doors, lids or other cleaning openings.

  • Page 128: Cleaning Tools

    7 Cleaning and servicing the heating system – Procedure OMBUSTION CHAMBER TEMPERATURE SENSOR 1 Combustion chamber temperature sensor 2 Secondary combustion chamber Figure 7/1 - Combustion chamber temperature sensor Caution! Damage to the combustion chamber temperature sensor The combustion chamber temperature sensor consists of a ceramic part that can be damaged by mishandling.

  • Page 129: Checking And Emptying The Ash Container

    7 Cleaning and servicing the heating system – Procedure Open the front door (1) of the boiler. Open combustion chamber door (2). Inspect the grate (3) for encrustations of cinder or foreign bodies. Figure 7/3 - Cleaning the tilting grate Remove any encrustations with a suitable cleaning utensil or empty the grate in manual operation.
  • Page 130 7 Cleaning and servicing the heating system – Procedure Figure 7/4 - Checking and emptying the ash pan (without ash removal system) Reach into the recessed grips (4 + 6) and pull the cover of the ash module (5) off the shaped studs. Lift the cover of the ash module (5) out of the holders on the base plate.

  • Page 131: Lubricating The Feeding System

    7 Cleaning and servicing the heating system – Procedure Turn the main switch off. Figure 7/5 - Checking and emptying ash containers (with ash removal system) Release the star-grip screws (2). Lift up the lid (4) and remove it. Check the fill level of the ash containers (5). If the ash containers (5) are full, empty them.

  • Page 132: Checking The Drive Chains

    7 Cleaning and servicing the heating system – Procedure Place the grease gun on the lubricating nipple (1). Press three strokes of grease into the feeding system. ✓ feeding system lubricated. Figure 7/6 - Lubricating the feeding system HECKING THE DRIVE CHAINS Important! ✎...
  • Page 133 7 Cleaning and servicing the heating system – Procedure Figure 7/7 - Checking the drive chain of the ash removal system Check the chain tension (1). ✓ If the drive chain has approximately 1 cm play, the tension is correct. ✓...

  • Page 134: Cleaning The Control Unit

    ✓ The check of the feeding system drive chain is completed. LEANING THE CONTROL UNIT Figure 7/9 - HDG Compatronic control unit Clean the control unit with a moist, lint-free cloth. For stubborn dirt, use a mild detergent. Wipe the control unit dry with a soft cloth.

  • Page 135: Cleaning The Cleaning Shaft And Turbulators

    7 Cleaning and servicing the heating system – Procedure LEANING THE CLEANING SHAFT AND TURBULATORS Important! ✎ See “Generally applicable safety instructions” in this section. Warning! Danger of injury The cleaning shaft lid is heavy and can fall shut. Hands and arms could thereby be crushed.
  • Page 136 7 Cleaning and servicing the heating system – Procedure Figure 7/11 - Pulling out the turbulators Pull out the turbulators (1) in an upward direction. Visually inspect the cleaning turbulators for encrustations and remove these with a suitable tool. Brush off the heat exchanger surfaces with a suitable tool (e.g. cleaning brush, included in delivery).
  • Page 137 7 Cleaning and servicing the heating system – Procedure Allow the fire in the heating system to burn out and cool down. Figure 7/12 - Removing hoods Remove the three hoods (1). Move the cleaning system downward in manual operation. ✎...
  • Page 138 7 Cleaning and servicing the heating system – Procedure Figure 7/14 - Pulling out the turbulators Pull out the turbulators on the guide crossbars (1) in an upward direction. 10.Visually inspect the cleaning turbulators for encrustations and remove these with a suitable tool. 11.Brush off the heat exchanger surfaces with a suitable tool (e.g.

  • Page 139: Checking And Cleaning The Ignition Fan

    7 Cleaning and servicing the heating system – Procedure HECKING AND CLEANING THE IGNITION FAN Important! ✎ See “Generally applicable safety instructions” in this section. Caution! Danger of burns from hot surfaces The hot air nozzle of the ignition fan becomes very hot during operation.

  • Page 140: Checking And Cleaning The Lambda Sensor

    7 Cleaning and servicing the heating system – Procedure 10.Check the heating element (2) for dirt. 11.Remove any dirt by blowing it off. 12.Check the photocell (1) for dirt. 13.Remove any dirt using a cotton swab. 14.Reassemble the ignition fan back into the heating system in the reverse sequence.
  • Page 141 7 Cleaning and servicing the heating system – Procedure Allow the fire in the heating system to burn out and cool down. Turn the main switch off. Carefully check whether the lambda sensor (2) is still hot. Using a pipe wrench, remove the DN 40 union nut (1).

  • Page 142: Inspecting And Cleaning The Flue Pipe

    7 Cleaning and servicing the heating system – Procedure NSPECTING AND CLEANING THE FLUE PIPE Important! ✎ See “Generally applicable safety instructions” in this section. Caution! Danger of burns from hot surfaces The surface of the flue pipe becomes very hot during operation. Even when turned off, it only cools down slowly.

  • Page 143: Checking And Cleaning The Ash Removal System

    7 Cleaning and servicing the heating system – Procedure HECKING AND CLEANING THE ASH REMOVAL SYSTEM Important! ✎ See “Generally applicable safety instructions” in this section. Set the control to the operating mode OFF. ✓ The OFF symbol lights up. Allow the fire in the heating system to burn out and cool down.

  • Page 144: Checking And Cleaning The Flue Gas Fan

    7 Cleaning and servicing the heating system – Procedure HECKING AND CLEANING THE FLUE GAS FAN Important! ✎ See “Generally applicable safety instructions” in this section. Warning! Risk of injury from automatically driven components When working on the flue gas fan, unexpected start-up of the fan wheel poses the danger of hand injuries.

  • Page 145: Checking And Lubricating The Fill Level Indicator

    7 Cleaning and servicing the heating system – Procedure Turn the main switch off. Release flue temperature sensor (1) using a 13 mm spanner. Pull the sensor (1) out of the flue pipe (2). Clean the sensor (1) with a moist cloth.

  • Page 146: Inspecting The Fuel Bunker

    7 Cleaning and servicing the heating system – Procedure Turn the switch plate (3) with the mounted fill level indicator to the left and carefully pull it forward as far as it will go. Clean the undercut running surfaces of the fill level indicator and lubricate these points with a heat-resistant grease.

  • Page 147: Troubleshooting

    8 Troubleshooting – Procedure 8 Troubleshooting If a fault occurs in the heating system, all of the operating mode symbols flash and the fault is shown in the display. Faults can be fixed as follows. 8.1 Procedure Look for the displayed fault, its cause and remedy in table 8.2 “Possible faults”.
  • Page 148 8 Troubleshooting – Possible faults Fault Cause Remedy • • Excessive boiler temperature Allow boiler to cool to under F001 Safety • Wiring is faulty 90 °C, unscrew protective cap thermostat • Fuse F2 (on I/O circuit board) from STL and press button faulty •...
  • Page 149 8 Troubleshooting – Possible faults Fault Cause Remedy • • Incorrect parameter setting Check parameter 7-12 F008 Dosage • Dosing unit is jammed • Check dosing unit Overcurrent • • Motor is faulty Have a qualified electrician inspect motor, replace if necessary •...
  • Page 150 8 Troubleshooting – Possible faults Fault Cause Remedy • • Sensor is faulty Connect sensor F013 Boiler supply • Open circuit in sensor cable • Replace cable temp. • • Sensor not connected Check terminal (check plug open circuit for secure fit) •...
  • Page 151 8 Troubleshooting – Possible faults Fault Cause Remedy • • Short circuit in the sensor or Connect sensor F016 Outside sensor cable • Replace cable temperature • Check terminal (check plug short circuit for secure fit) • Exchange the faulty sensor (plug on the I/O circuit board) with a different sensor •...
  • Page 152 8 Troubleshooting – Possible faults Fault Cause Remedy • • Sensor is faulty Connect sensor F022 Temp. acc. top • Open circuit in sensor cable • Replace cable open circuit • • Sensor not connected Check terminal (check plug for secure fit) •...
  • Page 153 • Software is not compatible • Use a new software F036 Software not • with this hardware Notify HDG customer service compat. with this hardware • Sensor not connected • Have the fault fixed by a F040 Supply temp. HC1 •...
  • Page 154 8 Troubleshooting – Possible faults Fault Cause Remedy • • Short circuit in sensor or in Have the fault fixed by a F047 Thermostat HC1 cable qualified electrician short circuit • Both sensor connections joined in a single terminal • see F046 and F047 •...
  • Page 155 8 Troubleshooting – Possible faults Fault Cause Remedy • • Short circuit in sensor or in Have the fault fixed by a F110 Temp. acc. top cable qualified electrician house2 short circuit • Sensor not connected • Have the fault fixed by a F111 Temp.
  • Page 156 8 Troubleshooting – Possible faults Fault Cause Remedy • • Fuse is faulty Have the fault fixed by a F147 Delivery syst. • Motor is not connected qualified electrician fault K105-K107 F14,F17,F18 • Transport module is faulty • Have circuit board replaced F148 Transport module by a qualified electrician (IO21) defective...
  • Page 157 • Wrong transport module • Exchange transport module F180 Transport module • Notify HDG customer service (IO21) wrong version • Wrong phase setting • Notify HDG customer service F181 Phase L2+L3 connected • Hall sensor is faulty •...

  • Page 158: Configuring Emergency Operation

    8.3 Configuring emergency operation If the remedy to your problem is listed in “Table 8/1 - Faults” as EQUIREMENTS “Configure emergency operation”, you activate emergency operation on the control unit of the HDG Compatronic as follows. Press the Enter button. ROCEDURE Enter ✓...

  • Page 159: Notes On Dismantling And Disposal

    9 Notes on dismantling and disposal – Dismantling 9 Notes on dismantling and disposal 9.1 Dismantling Danger! Material damage and injury due to incorrect dismantling. Dismantling the system requires comprehensive specialist knowledge. If the heating system is dismantled by an untrained person, injuries are possible.
  • Page 160 9 Notes on dismantling and disposal – Disposal • Feeding system without motor • Transfer station without motor • Delivery system The electrical components can also be recycled via the local recycling centre. Fibreglass, mineral wool and plastic parts such as suction hoses etc. should be handed in to the respective waste disposal centres.

  • Page 161: Warranty

    • The installation of the heating system and the hydraulic components must meet the requirements in the operating manual and the specified HDG hydraulic diagrams. • The heating system must be installed according to applicable rules, regulations and guidelines.

  • Page 162: Appendix

    Part 5: Heating boilers for solid fuels, hand and automatically fired, nominal heat output of up to 300 kW. Terminology, requirements, testing and marking Massing, 05.02.2010 -------------------------------------------------------------------------------------------------------------------------------------------- Place, date Signature Wohlmannstetter Page 1/1 © HDG Compact 150/200 - Version 1 - de HDG Bavaria GmbH 07/2008...

  • Page 163: Index

    12 Index 12 Index ....16 Combustion chamber ..... 20 Combustion control Acc + DHW pump .
  • Page 164 ....... 25 Oil burner © HDG Compact 25/35 - Version 2 - de HDG Bavaria GmbH Oktober 2007...
  • Page 165 12 Index ..13 Warnings and safety symbols used ....... 161 Warranty .
  • Page 166 12 Index © HDG Compact 25/35 - Version 2 - de HDG Bavaria GmbH Oktober 2007...
  • Page 168 HDG Bavaria GmbH Heizsysteme für Holz Siemensstraße 22 D-84323 Massing Tel. +49(0)8724/ 897-0 info@hdg-bavaria.com www.hdg-bavaria.com Art.Nr: 9980000624 - V 02 - en - 04/2010 - Translation of the original operating instructions...

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