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HDG F20 Operating Manual

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Operating manual
HDG F20/25/30
HDG F40/50
hdg-bavaria.com

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  • Page 1 Operating manual HDG F20/25/30 HDG F40/50 hdg-bavaria.com...

  • Page 3: Table Of Contents

    Rear and side views HDG F20-50........
  • Page 4 Installing the HDG controls control unit........
  • Page 5 Operating manual HDG F20-50 - Content Checking the doors are tight ..........78 Cleaning the ignition fan .

  • Page 6: Notes On This Manual

    We reserve the right to make changes which may then differ from the technical details and illustrations in this Operating manual. Written permission is required from HDG Bavaria GmbH for OPYRIGHT 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.

  • Page 7: Glossary

    HDG F20-50 Boiler for burning untreated wood. HDG F20-50 Hybrid Boiler for burning untreated wood. The HDG F Hybrid is also intended for combined used with a HDG K Hybrid pellt unit Lambda sensor This is an electrical component which monitors residual oxygen levels in the flue gas.

  • Page 8: Safety Notes

    HDG F20-50 boiler. The further implementation of applicable standards and guidelines, for example regarding installation of the heating system (pipework, etc.), is not part of this operating manual. HDG Bavaria does not as- sume any liability for this. ROPER AND IMPROPER OPERATION...

  • Page 9: Residual Risks

    2 Safety notes – Residual risks Modification of the specified operating values will affect the heating system’s control programme and could lead to malfunctions. Only trained maintenance and operating personnel may undertake modi- fications to the operating values. For more information on fuel, see chapter “3 Mode of operation”, section “3.4 Fuel quality requirements”.

  • Page 10: Warnings And Safety Symbols Used

    2 Safety notes – Warnings and safety symbols used Danger! Danger of explosion A concentration of carbon monoxide that is too high can result in an explosion. Observe the flue draught requirement of the chimney. Caution! Risk of injury from automatically driven components Working on the flue gas fan can lead to hand injuries due to the moving parts.
  • Page 11 2 Safety notes – Warnings and safety symbols used Warning! Danger of fire Working in areas marked with this symbol can lead to a fire. Danger! Danger of asphyxiation due to lack of oxygen When working in areas marked with this symbol, there is a danger of asphyxiation due to high concentrations of carbon monoxide.

  • Page 12: Duty Of Information

    2 Safety notes – Duty of information 2.4 Duty of information Any person performing tasks on this system must read the Operating EADING THE PERATING manual prior to beginning work, particularly the chapter “2 Safety MANUAL notes”. This is especially important for persons who only occasionally work on the heating system, for example when cleaning or servicing it.

  • Page 13: Mode Of Operation

    3 Mode of operation – Overview 3 Mode of operation 3.1 Overview HDG F20-50 RONT VIEW Figure 3/1 - Front view HDG F20-50 1 Control unitHDG Control Touch 2 Flue gas flap actuating handle 3 Fuel chamber 4 Ash pan...

  • Page 14: Cross Section Of Hdg F20-50

    3 Mode of operation – Overview HDG F20-50 ROSS SECTION OF Figure 3/2 - Cross section of HDG F20-50 1 Central module 2 EM4 extension module (optional) 3 Side panels 4 Burner nozzle 5 Ash compartment 6 Combustion chamber 7 Nozzle brick...

  • Page 15: Rear And Side Views Hdg F20-50

    3 Mode of operation – Overview HDG F20-50 EAR AND SIDE VIEWS Figure 3/3 - Rear and side views HDG F20-50 1 Safety heat exchanger inlet (DN 15 male) 2 Immersion sleeve for boiler temperature and STL sensor 3 Safety heat exchanger outlet (DN 15 male)

  • Page 16: Functional Description

    3.2 Functional description HDG F20-50 OILER The HDG F20-50 is a special boiler for the firing of wood up to 50 cm ENERAL INFORMATION in length. The HDG controls system regulates the combustion and output as well as the weather-compensated heating. The HDG F20- 50 boiler and the HDG controls system are harmonised with one another and form a functional unit.

  • Page 17: Boiler And Weather-Compensated Heating Control Hdg Controls

    OILER CONTROL UNIT boiler. It consists of the ready-to-use control panel and control unit HDG Control Touch on the front of the boiler. Using the control unit, you can regulate the boiler and call up information on the current process.

  • Page 18: Technical Data

    DN 15, inside thread Recommended pipe dimensions (minimum) DN 32 Water-side resistance at nominal thermal power 1600 Pa / 400 Pa 2000 Pa / 500 Pa 2400 Pa / 600 Pa 10 K / 20 K Table 3/1 - HDG F20/25/30 technical data...

  • Page 19: Hdg F40/50

    Spruce: up to 4 h Sound pressure level < 70 dB(A) Min. Air inlet cross section 150 cm Table 3/1 - HDG F20/25/30 technical data *Maximum operating temperatures of up to 110 °C can also briefly occur. HDG F40/50 Type of boiler...

  • Page 20: Fuel Quality Requirements

    Essential criteria are the length, diameter and water content of the fuel. For the log wood boiler HDG F20-50, firewood with a length of up to ENGTH AND DIAMETER 50 cm (L50) can be used. The maximum diameter of the firewood is specified as D15 (diameter of maximum 15 cm).

  • Page 21: Pressed Wood Briquettes

    (approx. two years). The maximum permissible water content of log wood for the HDG F20-50 is 20% (M20). For technical considerations, a representative calorific value is selected depending on water content.

  • Page 22: Permitted Fuel In Accordance With 1St Federal Emission Control

    Additional quality requirements apply in Germany independently of the fuel specification in accordance with DIN EN ISO 17225. In accordance with section 3 (1) of German law (1. BimSchV), the fuel classes 4, 5, 6, and 7 may be used in the HDG F20-50 heating system.

  • Page 23: Planning And Installation

    4 Planning and installation – Dimensions 4 Planning and installation 4.1 Dimensions Figure 4/1 - Dimensions HDG F20/25/30 HDG F40/50 Boiler height 1590 mm 1650 mm Width of boiler 660 mm 760 mm Height to centre of flue gas connecting pipe...

  • Page 24: Structural Requirements

    To ensure unhindered operation and maintenance of the heating system, it is imperative that the heating system is installed in accordance with the specifications of HDG Bavaria GmbH and that the minimum spacing requirements are observed. Also note that the thresholds in DIN 4109 “Soundproofing in building construction”...
  • Page 25 1025 x 650 x 1585 mm 1075 x 750 x 1645 mm (without cladding and attachments) Table 4/2 - Room sizes and minimum clearances *does not apply in connection with HDG automatic ignition system / automatic cleaning system...

  • Page 26: Connections

    The required flue gas values are listed in chapter “3 Mode of operation”, section “3.3 Technical data”. The benefits of the HDG F20-50 can only be enjoyed if all of the prerequisites for good combustion are ensured. The heating system...
  • Page 27 4 Planning and installation – Connections • Location of the chimney in the roof – The opening of the chimney must be at least 0.5m 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°...

  • Page 28: Electrical System

    55 litres per kW of nominal thermal power must be maintained. For the HDG F20/25/30 boiler, the minimum accumulator volume is 2000 litres and for the HDG F40/50 it is 3000 litres.

  • Page 29: Hydraulic Connection

    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 controls control unit. The return temperature control consists of a 3-way mixing valve with a 230 V servo drive (running time 120-240 s) and a circulation pump from energy efficiency class A.

  • Page 30: Scope Of Delivery

    HDG F20-50 boiler. 4.6 Installing the heating system EQUIREMENTS The heating system is installed by specialists from HDG Bavaria GmbH or 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.

  • Page 31: Installing The Boiler

    4 Planning and installation – Installing the heating system NSTALLING THE BOILER Caution! Beware of suspended loads. The boiler weighs over 650 kg. If the boiler is dropped during transport, persons can be seriously injured and the boiler can be damaged.
  • Page 32 11.Align the boiler with plastic plates or flat steel strips (not included in the scope of delivery) so that it is horizontal. ✓ The HDG F20-50 boiler has been placed in position. RANSPORT WITH A CRANE Figure 4/7 - Crane eyelet...

  • Page 33: Installing Hydraulic Connections

    (2 + 4). ✓ The hydraulic connections are attached. HDG F20-50 H YBRID The following tasks must be performed if the boiler is intended for use as HDG F20-50 Hybrid in combination with an HDG K Hybrid pellet unit.
  • Page 34 4 Planning and installation – Installing the heating system 30° 30° Figure 4/9 - Hydraulic connection set HDG F20-50 Hybrid Mount the double nipple (4 + 6) on the connection for the flow (7) or the return (5). Important! When installing the three-way switch valve (2) and the T-piece (8), ensure the proper installation angle! Install the three-way switch valve (2) on the double nipple (4).

  • Page 35: Installing The Hdg Controls Control Unit

    From behind, set the two spacer plates (3 + 6) onto the welded screws on the support plate (1). Move the HDG Control Touch control unit (5) from behind to the welded screws on the support plate (1). Fasten the HDG Control Touch control unit (5) on the support...
  • Page 36 4 Planning and installation – Installing the heating system Plug the connection cable (4) on the control unit HDG Control Touch (5) at slot X3. ✎ Also refer to “Electrical plans for the HDG log wood boiler”. Mount the support plate (1) in the reverse sequence.

  • Page 37: Installing The Automatic Ignition

    ✎ See “Electrical plans for the HDG log wood boiler”. Please note that here only the assembly of the HDG controls unit is described. The remaining electrical installations depend on the hydraulic system and can be installed based on the specifications for the respectively selected system.
  • Page 38 4 Planning and installation – Installing the heating system Figure 4/13 - Installing the differential pressure switch and ignition fan Install the ignition pipe (11) with the seal (9) placed in between with the M5 hexagon socket screws (SW4) onto the connection provided on the boiler.

  • Page 39: Installing The Automatic Cleaning System

    13.Run the cable from the differential pressure switch (2) to the central module and plug it in at slot X34. ✎ Also refer to “Electrical plans for the HDG log wood boiler”. 14.Push the ignition fan (10) into the ignition pipe (11). Important! Make sure that the line from the ignition fan is fitted so that it does not come into contact with the ignition pipe.

  • Page 40: Fitting The Cladding

    11.Run the cable from the cleaning system motor and from the limit switch to the central module and insert it at slot x50 or X33. ✎ Also refer to “Electrical plans for the HDG log wood boiler”. ✓ The automatic cleaning system is now installed.
  • Page 41 4 Planning and installation – Installing the heating system Figure 4/16 - Overview of cladding parts 1 Top rear cover 2 Top centre cover 3 Top rear cladding 4 Top left side cladding 5 Bottom left side cladding 6 Bottom rear cladding 7 Base plate 8 Ash pan 9 Front cladding...
  • Page 42 HDG automatic cleaning system. The large perforated recess (2) only needs to be cleared out if the boiler is configured as HDG F Hybrid for combined use with a HDG K Hybrid pellet unit. If necessary, clear out the small perforated recess (3) from the right side cladding (1) using a side cutter or hacksaw and deburr the opening.
  • Page 43 4 Planning and installation – Installing the heating system Figure 4/20 - Fitting the upper side cladding Hang the upper side cladding (4) into the lower side cladding and into the two upper cladding brackets (1 + 2). If necessary, hang the side cover (5) into the side cladding (4) and fasten it at the bottom with the two drilling screws.
  • Page 44 4 Planning and installation – Installing the heating system Important! Make sure that the cables for the flue gas fan, the lambda sensor and the flue gas temperature sensor are routed outside the rear cladding to the recess (1) in the side cladding. Place the upper rear cladding (3) into the lower rear cladding and hang it into the two side claddings with the tabs.

  • Page 45: Connecting The Chimney

    4 Planning and installation – Connecting the chimney 12.Put the front cladding (4) onto the nipple on the boiler and ensure that the lines for the primary or secondary air actuator are led out through the recess on the top left. 13.Slide the ash pan (5) under the boiler in the base plate.

  • Page 46: Connecting The Thermal Safety Device

    The TAS must be inspected annually by a qualified technician to test that it is working properly. The thermal safety device must be installed according to guidelines from HDG Bavaria. Important! In order to prevent leaks, avoid turning the connections of the safety heat exchanger anticlockwise when installing the thermal safety device.
  • Page 47 4 Planning and installation – Connecting the thermal safety device Figure 4/23 - HDG F20-50 thermal safety device 1 Safety heat exchanger inlet (DN 15 outsize thread) 2 Thermal safety device (TAS) 3 Safety heat exchanger outlet (DN 15 outside thread)

  • Page 48: Commissioning

    5 Commissioning – Requirements 5 Commissioning The heating system is initially commissioned by specialists from HDG Bavaria or from an authorised HDG partner. Commissioning includes an introduction to the operation and maintenance of the heating system as well as measurements to determine exhaust emissions and combustion performance.

  • Page 49: Switching On The Heating System

    The indicator lamp in the emergency heating switch will light up. ✓ The control is activated. ✎ See the “HDG Control” operating manual, chapter “Commissioning the system”. ESTING SYSTEM COMPONENTS Important! For safety reasons, the system component test may only be conducted when there is no fuel in the boiler and there are no remaining embers.

  • Page 50: Using The Heating System

    You can find all information and instructions for setting up and operating the boiler and weather-compensated heating control of the HDG controls in the “HDG controls” operating manual. The HDG controls control unit is located on the front of the HDG F20- 50 boiler. 6.2 Switching on the heating system EQUIREMENTS ✎...

  • Page 51: Fuel Selection

    6 Using the heating system – Heating up the system UEL SELECTION Important! When changing fuel, e.g. from softwood to hardwood, please also consider the consequential changes in respect of the combustion properties. Otherwise faults may occur in the combustion and in the operation of the heating system.

  • Page 52: Procedure

    Figure 6/1 - Cleaning system actuation Press the Reload button on the HDG Control Touch control unit (2). ✓ The Fill up / Reload window appears in the display. Figure 6/2 - Ignition - changing settings If you do not want to change any settings, confirm your input by pressing the Confirm button (1).
  • Page 53 6 Using the heating system – Heating up the system If you wish to change the settings, press the appropriate setting. HANGING THE SETTINGS Press the Wood type. ✓ The Wood type selection window appears in the display. Figure 6/3 - Query wood type Select the type of wood used.
  • Page 54 6 Using the heating system – Heating up the system Figure 6/5 - Query ignition mode 13.Select the desired ignition mode. 14.Confirm your input by pressing the Confirm button (1). ✓ The display shows - for prior selection of Automatic ignition mode - the Automatic ignition selection window.
  • Page 55 6 Using the heating system – Heating up the system Figure 6/7 - Ignition - changing settings 17.Confirm your input by pressing the Confirm button (1). ✓ The Do not open fuel chamber door message appears in the display. Figure 6/8 - Do not open the fuel chamber door ✓...
  • Page 56 6 Using the heating system – Heating up the system Figure 6/10 - Open the fuel chamber door slowly Figure 6/11 - Filling the fuel chamber 21.Open the fuel chamber door (1). 22.Leave any unburnt pieces of wood and charcoal in the fuel chamber (3).
  • Page 57 33.The Ignite message appears in the display. Figure 6/14 - Ignition ✓ The HDG F20-50 boiler is now heated up. 24.Stack some highly flammable material (small pieces of dry wood) LECTRIC IGNITION in front of the igniter gun (2) and about 10 cm high on the burner...
  • Page 58 6 Using the heating system – Heating up the system 25.Lay some small pieces of cardboard in front of the igniter gun (2) on the wood inside the fuel chamber (3). Only put in as much wood as the heating system and accumulator can absorb as energy.
  • Page 59 The Ignite message appears in the display. Figure 6/18 - Ignition ✓ The HDG F20-50 boiler is now heated up. 24.Stack some highly flammable material (small pieces of dry wood) UTOMATIC IGNITION in front of the igniter gun (2) and about 10 cm high on the burner nozzle (4) so that it is covered.

  • Page 60: Performing A Chimney Sweep Measurement

    The Ready for ignition message appears in the display. Figure 6/21 - Ready for ignition ✓ The HDG F20-50 boiler is ready for automatic ignition. 6.4 Performing a chimney sweep measurement In Germany, there is a legal requirement that heating systems with...

  • Page 61: Before The Test

    At the start of test, the residual oxygen value should be below • Having the test repeated by the combustion engineer or by HDG specialists will incur charges. On the day of test, heat up the boiler one hour before the scheduled appointment.

  • Page 62: During The Test

    ✓ The actuating handle (1) is released from its lock and the flue gas flap closes. Wait about 10 - 15 minutes and then start the HDG controls chimney sweep test. Press the Main menu button in the standard display.
  • Page 63 6 Using the heating system – Switching off the heating system for repair work Figure 6/23 - Chimney sweep test security query 10.Press Yes (1). ✓ The display switches to the chimney sweep test. Figure 6/24 - Chimney sweep test ✓...

  • Page 64: Switching Off The Heating System For Repair Work

    6 Using the heating system – Troubleshooting ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.3 Switching off the heating system”. There is still electrical voltage in the system. Switch off the emergency heating switch (if installed) or the corresponding mains electricity circuit breaker.

  • Page 65: Cleaning And Servicing The Heating System

    PARE PARTS Only use genuine HDG spare parts. You can obtain HDG spare parts from your specialist heating company. 7.1 Cleaning and servicing schedule The specified cleaning intervals are guidelines.

  • Page 66: Procedure

    Let the combustion residue cool off before you vacuum and put the ashes in an appropriate, non-flammable container. Important! Before the start of the cleaning and maintenance tasks, the display of the HDG Control Touch control unit must show the Ready message.

  • Page 67: Cleaning Tools

    Allow the fire in the boiler to burn out and cool off. Press the Reload button on the HDG Control Touch control unit. The Fill up / Reload window appears in the display. Confirm your entry by pressing the Confirm button.
  • Page 68 7 Cleaning and servicing the heating system – Procedure Figure 7/2 - Cleaning the fuel chamber and secondary air openings Open the fuel chamber door (2). Pull the actuating lever (1) of the flue gas flap to the front until it latches into place.

  • Page 69: Cleaning The Secondary Combustion Chamber And The Ash Compartment

    7 Cleaning and servicing the heating system – Procedure LEANING THE SECONDARY COMBUSTION CHAMBER AND THE ASH COMPARTMENT Important! ✎ Observe the “Generally applicable safety instructions” in this section. During the heating period, the secondary combustion chamber and the ash compartment must be cleaned two to three times a week. Allow the fire in the boiler to burn out and cool off.

  • Page 70: Checking And Cleaning The Lambda Sensor

    7 Cleaning and servicing the heating system – Procedure HECKING AND CLEANING THE LAMBDA SENSOR Important! ✎ Observe the “Generally applicable safety instructions” in this section. Allow the fire in the boiler to burn out and cool off. Figure 7/4 - Cleaning the lambda sensor Unscrew the union nut (1) with a pipe wrench.

  • Page 71: Cleaning The Flue Gas Temperature Sensor

    7 Cleaning and servicing the heating system – Procedure LEANING THE FLUE GAS TEMPERATURE SENSOR Important! ✎ Observe the “Generally applicable safety instructions” in this section. Allow the fire in the boiler to burn out and cool off. Figure 7/5 - Cleaning the flue gas temperature sensor Loosen the M10 union nut (SW 17) (2) and pull the flue gas temperature sensor (1) out of the clamp screw connections.

  • Page 72: Cleaning The Flue Gas Pipe

    7 Cleaning and servicing the heating system – Procedure LEANING THE FLUE GAS PIPE Important! ✎ Observe the “Generally applicable safety instructions” in this section. Allow the fire in the boiler to burn out and cool off. Unscrew the wing nut (1) on the inspection hatch cover (2).
  • Page 73 Pull the actuating handle (1) of the flue gas flap to the front until it latches into place. HDG F20/25/30 Figure 7/8 - Cleaning the flue gas flap Inspect the cleaning shaft (1) for deposits.
  • Page 74 20.Make sure that the cleaning shaft lid is closed properly. ✓ The cleaning system, the heat exchanger surfaces and the flue gas flap have been cleaned. HDG F40/50 Figure 7/10 - Cleaning the flue gas flap Inspect the cleaning shaft (1) for deposits.
  • Page 75 7 Cleaning and servicing the heating system – Procedure If necessary, remove deposits and dust with a vacuum cleaner. 10.Clean the flue gas flap (6) and the suction channel behind it with a suitable cleaning tool (e.g. scraper) or with a vacuum cleaner. 11.Unlatch the actuating handle of the flue gas flap.

  • Page 76: Cleaning The Flue Gas Fan

    7 Cleaning and servicing the heating system – Procedure LEANING THE FLUE GAS FAN Important! ✎ Observe the “Generally applicable safety instructions” in this section. Caution! Risk of injury from automatically driven components Working on the flue gas fan can lead to hand injuries due to the moving parts.

  • Page 77: Cleaning The Air Control Unit

    7 Cleaning and servicing the heating system – Procedure LEANING THE AIR CONTROL UNIT Important! ✎ Observe the “Generally applicable safety instructions” in this section. Allow the fire in the boiler to burn out and cool off. Figure 7/13 - Cleaning the air control unit Pull the cladding (2) of the air regulation unit (1) carefully forwards.

  • Page 78: Checking The Doors Are Tight

    7 Cleaning and servicing the heating system – Procedure Allow the fire in the boiler to burn out and cool off. Figure 7/14 - Clean the panels Open the fuel chamber door (1). Unhook the side, rear and front panels (2). Clean the panels (2) with the scraper.
  • Page 79 7 Cleaning and servicing the heating system – Procedure Clamp a sheet of paper (approx. 30 cm long and 2 cm wide) between the contact surface (3) and the seal (2) of the fuel chamber door. Close the fuel chamber door (1). Pull on the paper.

  • Page 80: Cleaning The Ignition Fan

    7 Cleaning and servicing the heating system – Procedure LEANING THE IGNITION FAN The ignition fan is only available in connection with the HDG automatic ignition system. Important! ✎ Observe the “Generally applicable safety instructions” in this section. Caution! Danger of burns from hot surfaces The hot air nozzle of the ignition fan becomes very hot during operation.
  • Page 81 7 Cleaning and servicing the heating system – Procedure Pull the heating element (2) out of the plug contacts (7). Check the heating element (2) for dirt. 10.Remove any dirt by blowing it off. 11.Check the photocell (1) for dirt. 12.Remove any dirt using a cotton swab.

  • Page 82: Notes On Dismantling And Disposal

    8 Notes on dismantling and disposal – Dismantling 8 Notes on dismantling and disposal 8.1 Dismantling Danger! Material damage and personal injury due to incorrect dismantling Dismantling the system requires comprehensive specialist knowledge. If the boiler is dismantled by an untrained person, injuries may occur.

  • Page 83: Disposal

    8 Notes on dismantling and disposal – Disposal 8.2 Disposal The following components are made of steel and can be recycled via a local recycling centre. • Boiler • Cladding The electrical components can also be recycled via a local recycling centre.

  • Page 84: Declaration Of Conformity

    Section A of Part 1 of Annex II of the EC Directive 2006/42 on machinery Producer: HDG Bavaria GmbH, Heating system for wood Siemensstraße 22 D-84323 Massing Resident of the EC authorized to assemble the adequate technical documentation:...

  • Page 85: Index

    CO2 content ......18 HDG F20-50 ....... . . 7 Combustion chamber door .
  • Page 86 Water capacity ......18 © HDG Navora 40/50 - Version 1 - de HDG Bavaria GmbH 06/2008...
  • Page 88 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. 9980001706 - V 02 - en - 05/2016 - Translation of the original operating instructions...

This manual is also suitable for:

F25F40F50F30

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