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HDG Euro 50 Operation Manual

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Operation Manual
HDG Euro 30/40/45/50
hdg-bavaria.com

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  • Page 1 Operation Manual HDG Euro 30/40/45/50 hdg-bavaria.com...

  • Page 3: Table Of Contents

    Cross-section of HDG Euro 30/40/45/50........14...
  • Page 4 Installing the HDG automatic ignition........
  • Page 5 Operation Manual HDG Euro 30/40/45/50 - Content Inspecting the door seals for leaks .........77 Cleaning the ignition fan .

  • Page 6: Notes On This Manual

    This Operating manual must be read and observed by everyone who EADING THE PERATING operates or works on the HDG Euro 30/40/45/50. 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 7: Structure Of The Operating Manual

    Pre-fabricated connection strip for electrical components Flue gas fan Creates a vacuum inside the boiler and provides the boiler with air for combustion. HDG Control Boiler and heating system controller. Lambda sensor Electrical component which monitors residual oxygen levels in the flue gas.

  • Page 8: Safety Notes

    (pipework, etc.), is not part of this operating manual. HDG does not assume any liability for this. ROPER AND IMPROPER OPERATION The HDG Euro 30/40/45/50 boiler is designed for the standard use of URPOSE OF THE HEATING burning untreated wood, for example in the form of split logs, SYSTEM pressed wood briquettes and chippings, in water heating systems.

  • 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 modifications 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 Caution! Hand injuries can occur Working in areas marked with this symbol can lead to hand injuries. Caution! Hot surfaces Working in areas marked with this symbol can lead to burns. Warning! Danger of fire Working in areas marked with this symbol can lead to a fire.

  • Page 12: Duty Of Information

    2 Safety notes – Duty of information Instructions regarding disposal Additional information for the operator 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”.

  • Page 13: Mode Of Operation

    3 Mode of operation 3.1 Overview HDG E 30/40/45/50 RONT VIEW OF Figure 3/1 - Front view of HDG Euro 30/40/45/50 1 Control unit HDG Control Touch 2 Fuel chamber door 3 Fuel chamber door locking device 4 Actuator primary air...

  • Page 14: Cross-Section Of Hdg Euro 30/40/45/50

    3 Mode of operation – Overview HDG E 30/40/45/50 ROSS SECTION OF Figure 3/2 - Cross-section of HDG Euro 30/40/45/50 1 Cleaning shaft lid 2 Safety heat exchanger 3 Flue gas deflector plate 4 Heat exchanger surfaces 5 Secondary combustion chamber with chamber stones...

  • Page 15: Rear And Side View Of Hdg Euro 30/40/45/50

    3 Mode of operation – Overview HDG E 30/40/45/50 EAR AND SIDE VIEW OF Figure 3/3 - Rear and side view of HDG Euro 30/40/45/50 1 Flue gas temperature sensor 2 STL release button 3 Lambda sensor 4 EM4 expansion module (optional)

  • Page 16: Functional Description

    HDG E 30/40/45/50 OILER The HDG Euro 30/40/45/50 is a special boiler for the firing of wood up ENERAL INFORMATION to 50 cm in length. The HDG Control Touch system regulates the combustion and output as well as the weather-compensated heating.

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

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

  • Page 18: Technical Data

    Supply and return connections DN 32, inside thread (bushing) Safety heat exchanger connections DN 20, inside thread (bushing) Connection for filling/draining DN 15, inside thread (bushing) Recommended pipe dimensions DN 32 (minimum) Table 3/1 - HDG Euro 30/40/45/50 technical data...

  • Page 19: Fuel Quality Requirements

    *Maximum operating temperatures of up to 110 °C can also briefly occur. 3.4 Fuel quality requirements The HDG Euro 30/40/45/50 boiler is designed for the standard use of burning untreated wood in the form of logs, wood chips, shavings and pressed wood briquettes.

  • Page 20: Wood Chips

    (approx. two years). The maximum permissible water content of log wood for the HDG Euro 30/40/45/50 is 20% (M20). For technical considerations, a representative calorific value is selected depending on water content.

  • Page 21: Pressed Wood Briquettes In Accordance With Din En Iso 17225-3

    (filter technology) may be necessary for complying with the dust emission values according to the 1st Federal Emission Control Ordinance (2nd stage). If shavings are used as fuel for the HDG Euro 30/40/45/50, this will lead to a reduction in the nominal thermal power. ECOMMENDED FUEL...

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

    Section 3 (1) of the 1st Federal Emission Control Ordinance, the fuel classes 4 (log wood), 5 (shavings), 5a (wood briquettes) and also fuel classes 6 and 7 may be used in the HDG Euro 30/40/45/50 heating system.

  • Page 23: Planning And Installation

    4 Planning and installation – Dimensions 4 Planning and installation 4.1 Dimensions Figure 4/1 - Dimensions HDG Euro 30/40/45/ Supply connection height 1184 mm Boiler width (without attachments) 793 mm Return connection height 599 mm Height at middle of the flue gas pipe connection...

  • 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: Required Room Sizes And Minimum Clearances

    800 mm Minimum ceiling height 2000 mm Recommended room height 2300 mm Installation dimensions 1380 x 800 x 1610 mm Table 4/2 - Room sizes and minimum clearances *does not apply in connection with HDG automatic ignition 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 Euro 30/40/45/50 can only be enjoyed if all of the prerequisites for good combustion are ensured. The heating...
  • Page 27 4 Planning and installation – Connections – Wind direction • 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

    BImSchV, the minimum capacity of the accumulator is 12 litres per litre of fuel chamber capacity; however, the required 55 litres per kW of nominal thermal power must be maintained. For the HDG Euro 30/40/50 boiler, the minimum accumulator volume is 3000 litres.
  • Page 29 The minimum return temperature is listed in chapter “3 Mode of operation”, section “3.3 Technical data”. The control of the return temperature is handled by the HDG Control control unit. The return temperature control consists of a 3-way mixing valve with a 230 V servo drive (running time 120 - 240 s) and a circulation pump from energy efficiency class A.

  • Page 30: Hydraulic Connection

    4 Planning and installation – Hydraulic connection 4.4 Hydraulic connection The hydraulic connection depends on the schematic diagram selected in the respective HDG Control system. ✎ See the supplied schematic diagram and electrical circuit diagram. 4.5 Scope of delivery The heating system is delivered on a pallet.

  • Page 31: Installing The Boiler

    Align the boiler (2) with plastic plates or flat steel strips (not included in the scope of delivery) so that it is horizontal. Remove the eyebolt (1). Place the cover cap on the control console. ✓ The HDG Euro 30/40/45/50 boiler has been placed in position.
  • Page 32 4 Planning and installation – Installing the heating system Transport the boiler with a pallet truck in compliance with the RANSPORTING WITH A PALLET minimum clearances to the required installation site. TRUCK ✎ See section “4.2 Structural requirements”, under “Required room sizes and minimum clearances”.

  • Page 33: Removing Transport Safety Device

    11.Remove the installation aid. ✓ The HDG Euro 30/40/45/50 boiler has been placed in position. EMOVING TRANSPORT SAFETY DEVICE The inner transport safety device must be removed from the combustion chamber before commissioning. The outer transport safety device may be left in the boiler.

  • Page 34: Installing The Hdg Control Unit

    The transport safety device has been removed. HDG C NSTALLING THE ONTROL UNIT The cable set for the HDG Control control unit is already connected on the central module at the time of delivery. EMOVING THE COVER Undo the screws (1) on the...
  • Page 35 4 Planning and installation – Installing the heating system Figure 4/11 - Installing the control unit Install the HDG Control Touch control unit (2) with the four Phillips screws on the control console (3). Insert the two side covers (1) onto the control unit.

  • Page 36: Installing The Hdg Automatic Ignition

    ✓ See “Electrical plan HDG Euro 30/40/45/50”. Please note that here only the assembly of the HDG Control 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 37 SW14) connecting the ignition pipe. Figure 4/14 - Dismantling the dummy plugs Figure 4/15 - Installing the HDG automatic ignition Install the ignition pipe (6) (including fibre-glass insulation) on the connection provided on the boiler. Using the self-tapping screws, install the assembly plate (1) with the preassembled differential pressure switch (2) on the side cladding (9).

  • Page 38: Connecting The Chimney

    (8) through the empty pipe (10) to the central module. 14.Using the self-tapping screws, install the side cover (7) on the side cladding (9). ✓ The HDG automatic ignition is now installed. 4.7 Connecting the chimney ✎ See section “4.3 Connections”, paragraph “Chimney” in this chapter.

  • Page 39: 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 40 4 Planning and installation – Connecting the thermal safety device Figure 4/16 - Thermal safety device 1 Connection bushing for TAS immersion sleeve, DN 15 inside thread 2 Safety heat exchanger inlet (DN 20 inside thread) 3 Safety heat exchanger outlet (DN 20 inside thread) 4 Thermal safety device (TAS) 5 Runoff connection to drainage system...

  • Page 41: Commissioning The System

    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. 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 42: 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 43 55 mm Table 5/1 - Setting of the primary air guide and grate height The above settings are suitable for operating the HDG Euro 30/40/ 45/50 boiler for materials with technical burning characteristics in accordance with the recommended fuel.
  • Page 44 ✓ The air damper is adjusted. RATE LIFTER With the log wood boiler HDG Euro 30/40/45/50, the grate lifting bar is delivered separately. The flat grate elements are in the lowest position at the time of delivery. The position of the grate lifter can be changed in order to correct the gas quantity during degassing and thus avoid pulsating (sudden igniting due to lack of oxygen) or insufficient flue gas temperatures.
  • Page 45 5 Commissioning the system – Procedure Figure 5/3 - Grate lifter Open the ash door (1). Open the upright grate flap (2). The three flat grate elements are of differing width. Make sure that the flat grate elements are put back in the correct manner and order.

  • Page 46: Using The Heating System

    HDG Control in the “HDG Control” operating manual. The HDG Control Touch control unit is located on the front of the HDG Euro 30/40/45/50 boiler. 6.2 Switching on the heating system EQUIREMENTS ✎...

  • Page 47: 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 48 When the Reload indicator flashes red, there are no more embers in the fuel chamber. ROCEDURE Figure 6/1 - Pressing the reload button Press the Reload button on the HDG Control Touch control unit (1). ✓ The Fill up / Reload window appears in the display.
  • Page 49 6 Using the heating system – Heating up the system Figure 6/2 - Ignition - changing settings If you do not want to change any settings, confirm your input by pressing the Confirm button (1). ✓ The Do not open fuel chamber door message appears in the display. ✓...
  • Page 50 6 Using the heating system – Heating up the system Figure 6/4 - Query wood moisture Select the wood moisture of the fuel. 10.Confirm your input by pressing the Confirm button (1). ✓ The Fill up / Reload window appears in the display again. 11.Press the Ignition mode.
  • Page 51 6 Using the heating system – Heating up the system Automatic ignition • Accumulator temperature: The automatic ignition starts after the set reloading temperature is undershot. • Accumulator temperature and weekly programme: The automatic ignition starts after the set accumulator temperature is undershot and if the enable time is reached at the same time in accordance with the set weekly programme.
  • Page 52 6 Using the heating system – Heating up the system Figure 6/8 - Do not open the fuel chamber door ✓ The flue gas fan is running. 17.Wait until the progress bar is full. O NOT CHANGE THE SETTINGS ✓ The Open fuel chamber door to safety position message appears in the display.
  • Page 53 6 Using the heating system – Heating up the system Figure 6/12 - Opening the fuel chamber door 20.Lift the lock (2) of the fuel chamber door and open the door (1) slowly until it is horizontal. ✓ The fuel chamber door opens automatically. ✓...
  • Page 54 6 Using the heating system – Heating up the system 26.Fill up the fuel chamber (3) with fuel. Figure 6/14 - Closing the fuel chamber door 27.Press the catch (2) of the fuel chamber door to the back. ✓ The fuel chamber door can now be closed. 28.Close the fuel chamber door (1).
  • Page 55 Figure 6/18 - Closing the doors 32.Close the ash door (1). ✓ The HDG Euro 30/40/45/50 boiler is now heated up. 16.Place some highly flammable material (small pieces of dry wood) LECTRICAL IGNITION in front of the igniter gun and approx. 15 - 20 cm high on the burner nozzle on the grate.
  • Page 56 The differential pressure switch enables the ignition fan if the preset underpressure is reached. 23.Wait until the progress bar is full. ✓ The ignition fan starts. ✓ The Ignite message appears in the display. Figure 6/22 - Ignition ✓ The HDG Euro 30/40/45/50 boiler is now heated up.
  • Page 57 6 Using the heating system – Heating up the system 16.Place some highly flammable material (small pieces of dry wood) UTOMATIC IGNITION in front of the igniter gun and approx. 15 - 20 cm high on the burner nozzle on the grate. 17.Lay some small pieces of cardboard in front of the igniter gun on the wood inside the fuel chamber.

  • Page 58: Performing A Chimney Sweep Test

    6 Using the heating system – Performing a chimney sweep test Figure 6/25 - Ready for ignition ✓ The HDG Euro 30/40/45/50 boiler is ready for automatic ignition. 6.4 Performing a chimney sweep test In Germany, there is a legal requirement that heating systems with...

  • Page 59: On The Day Of The Test

    6%. The boiler must not set to the AFO operating status (firing optimisation - only for HDG LC1 plus/HDG LC2 plus). • 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 60 Fill the fuel chamber half way up evenly and densely with logs according to the fuel recommendation. Close the fuel chamber door. Wait about 10 - 15 minutes and then start the HDG Control chimney sweep test. Press the Main menu button in the standard display.

  • Page 61: Switching Off The Heating System For Repair Work

    Switch the heating system off. ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.3 Switching off the heating system”. There is still electrical voltage in the system.

  • Page 62: Troubleshooting

    6 Using the heating system – Troubleshooting 6.6 Troubleshooting If a fault occurs in the heating system, this is shown in the display of the HDG Control. ✎ See the “HDG Control” operating manual, chapter 10 “Troubleshooting”.

  • Page 63: 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 64: 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 65: Cleaning Tools

    7 Cleaning and servicing the heating system – Procedure LEANING TOOLS Figure 7/1 - Cleaning tools 1 Wall holder 2 Scraper 3 Brush handle 4 Small brush 5 Large brush 6 Poker 7 Flue ash removal plate 8 Ash pan LEANING THE FUEL CHAMBER AND ASH COMPARTMENT Important! ✎...
  • Page 66 7 Cleaning and servicing the heating system – Procedure ✓ The flue gas fan is running. Wait until the progress bar is full. ✓ The Open fuel chamber door to safety position message appears in the display. Figure 7/2 - Unlocking the fuel chamber door Press the lock (1) of the fuel chamber door 1 downward.
  • Page 67 7 Cleaning and servicing the heating system – Procedure Important! Special attention must be paid to the corners of the fuel chamber in order to free them of any tar deposits and encrustations. 11.Use the supplied cleaning tools to remove tar deposits and encrustations from the corners of the fuel chamber (4).

  • Page 68: Inspecting The Pneumatic Springs

    7 Cleaning and servicing the heating system – Procedure NSPECTING THE PNEUMATIC SPRINGS Important! ✎ Observe the “Generally applicable safety instructions” in this section. Allow the fire in the boiler to burn out and cool off. Caution! Danger of injury The fuel chamber door is heavy and may fall shut.

  • Page 69: Cleaning The Heat Exchanger Surfaces And Combustion Chamber

    7 Cleaning and servicing the heating system – Procedure Figure 7/7 - Inspecting the fuel chamber door catch Regularly inspect the spring (1) of the catch (2) for the fuel chamber door for proper tension. ✓ If the spring (1) presses the catch (2) of the fuel chamber door forward all the way to the limit stop, the spring tension is in order.
  • Page 70 7 Cleaning and servicing the heating system – Procedure Pull out the flue gas deflector plate (1) in an upward direction. Figure 7/9 - Removing the flue gas deflector plate Important! When cleaning the heat exchanger surfaces, always first push the cleaning brush all the way down and through before you pull it up again, so that the wire bristles of the brush are not bent.

  • Page 71: Cleaning The Burner Nozzle

    7 Cleaning and servicing the heating system – Procedure Figure 7/11 - Removing the flue ash Place the flue ash removal plate (1) on the threaded rod for the flue ash door. 10.Place the ash pan (2) under the flue ash removal plate (1). 11.Use the scraper to sweep the flue ash into the ash pan (2).

  • Page 72: Cleaning The Flue Gas Pipe

    7 Cleaning and servicing the heating system – Procedure Figure 7/12 - Cleaning the burner nozzle Open the ash door (1). Open the upright grate flap (2) behind the door. Clean the burner nozzle (3) with a vacuum cleaner. Close the boiler in the reverse order. ✓...

  • Page 73: Cleaning The Lambda Sensor

    7 Cleaning and servicing the heating system – Procedure LEANING 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 7/14 - Cleaning the lambda sensor Unscrew the union nut (1) with a pipe wrench.

  • Page 74: 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 7/15 - Cleaning the flue gas temperature sensor Remove the upper cover (1) by lifting it upward.

  • Page 75: Cleaning The Flue Gas Fan

    7 Cleaning and servicing the heating system – Procedure Figure 7/16 - Cleaning the primary air inlets Free both sides of the primary air inlets (1) of dirt deposits with a suitable tool (e.g. the thin end of a poker). Vacuum each primary air inlet (1) with a vacuum cleaner until cleared.

  • Page 76: Clean Air Control Unit

    7 Cleaning and servicing the heating system – Procedure Remove the four M8 nuts (3) with a 13 mm spanner. Remove the flue gas fan (1), including the flange plate (4), from the boiler. Figure 7/18 - Cleaning the flue gas fan Clean the flue gas collection box (1).

  • Page 77: Inspecting The Door Seals For Leaks

    7 Cleaning and servicing the heating system – Procedure Figure 7/19 - Cleaning the air control unit Lift up on the cladding (2) of the air control unit (1 + 3) and pull it out towards the front. Use a fine brush and a vacuum cleaner to remove dust deposits from the air control unit (1 + 3).
  • Page 78 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 (2) and the seal of the fuel chamber door (1). Close the fuel chamber door (1). Pull on the paper.

  • Page 79: Cleaning The Ignition Fan

    15.Close the boiler in the reverse order. ✓ The door seals have been checked. 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.
  • Page 80 7 Cleaning and servicing the heating system – Procedure ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.3 Switching off the heating system”. Figure 7/24 - Removing the cover Undo the Phillips screw and remove the side cover (2).

  • Page 81: 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 82: 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. • (Central heating) boiler • Cladding The electrical components can also be recycled via a local recycling centre.

  • Page 83: 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 84: Index

    Combustion duration ..... . 19 HDG Control ......7 Commissioning the system .
  • Page 85 10 Index Manual Warnings and safety symbols ....10 - ignition ....... 53 Water .
  • Page 86 10 Index © HDG Euro 30/40/45/50 - 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. 9980001630 - V 05 - en - 03/2015 - Translation of the original operating instructions...

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