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HDG Compact 99 User Manual

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Operation Manual
HDG Compact 99 - 200
hdg-bavaria.com

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Summary of Contents for HDG Compact 99

  • Page 1 Operation Manual HDG Compact 99 - 200 hdg-bavaria.com...

  • Page 3: Table Of Contents

    3.1 Overview..............16 Front side of HDG Compact 99/100/105/115 .......17 Back side of HDG Compact 99/100/105/115.
  • Page 4 Dimensions of the flue pipe side of the HDG Compact 150 - 200 ... 43 Dimensions of the back side of HDG Compact 150 - 200 ....44 4.3 Scope of delivery .
  • Page 5 Operation Manual HDG Compact 99 - 200 - Content Changing the cleaning system setting ........82 Modifying the dust removal setting .
  • Page 6 Operation Manual HDG Compact 99 - 200 - Content Moving floor ............106 6.10 SERVICE menu.
  • Page 7 Operation Manual HDG Compact 99 - 200 - Content Checking the plug contacts ..........145 Inspecting the fuel bunker .

  • Page 8: 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 99 - 200. 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 9: Structure Of The Operating Manual

    ... what has to be considered when dismantling and disposing of disposal the heating system. 10 Warranty . . . the terms and conditions of the warranty. Table 1/1 - Structure of the operating manual © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 10: Glossary

    Part of the feeding system - separates the combustion chamber from the silo and transport unit and acts as back-burn protection. Table 1/2 - Glossary © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 11: Safety Instructions

    ROPER AND IMPROPER MANNER OF OPERATION The HDG Compact 99 - 200 heating system is designed for the stan- URPOSE OF THE HEATING dard use of burning wood fuel products made from untreated wood...

  • Page 12: Residual Risks

    Make sure that you use appropriate lifting gear when placing the boiler. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 13 The circuit boards and electrical components carry current. Have work on electrical components performed only by a qualified electrician and turn the main switch off. Warning! The boiler is under pressure. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 14: Warnings And Safety Symbols Used

    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. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 15: Duty Of Information

    The Operating manual must always be kept readily accessible at the place where heating system is installed. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 16: Mode Of Operation

    • on the left side. When selecting the feeding unit for the HDG Compact 99 - 200 hea- ting system, you can choose between the following: • TBZ 150 for feeding wood chips, planing shavings and pellets.

  • Page 17: Front Side Of Hdg Compact 99/100/105/115

    11 Combustion chamber ash removal auger 12 Servo motor for secondary air 13 Ignition fan 14 Servo motor for primary air 15 Pressure equalisation hose 16 Feeding system © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 18: Back Side Of Hdg Compact 99/100/105/115

    3 Eyebolt for crane transport 4 Combustion chamber 5 Fill level indicator 6 Stepped grate 7 Ash removal motor 8 Heat exchanger surfaces with cleaning turbulators in between © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 19: Front Side Of Hdg Compact 150/194/199/200

    10 Combustion chamber ash removal auger 11 Servo motor for secondary air 12 Ignition fan 13 Servo motor for primary air 14 Pressure equalisation hose 15 Feeding system © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 20: Back Side Of Hdg Compact 150/194/199/200

    3 Eyebolt for crane transport 4 Fill level indicator 5 Stepped grate 6 Combustion chamber 7 Ash removal motor 8 Heat exchanger surfaces with cleaning turbulators in between © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 21: Functional Description

    6 Accumulator OMBUSTION PROCESS With the HDG Compact 99 - 200 heating system, the fuel is automati- cally fed from the bunker into the combustion chamber of the boiler via the delivery and feeding systems. The combustion fan is already...

  • Page 22: Delivery System

    ONTROL Figure 3/6 - HDG Control control unit The boiler control HDG Control unit in the control cabinet is the elec- tronic hub. This is a freely programmable PLC control. Via the control unit, you can adjust the heating system HDG Compact 99 - 200 and obtain information on the current process status.

  • Page 23: Control Modes

    – Operation without accumulator • Oil burner – An oil burner is also fitted to the boiler. • Log wood: – Only suitable for emergency operation © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 24: Technical Data

    250 cm 250 cm 260 cm 280 cm Table 3/1 - Technical data *in combination with the HDG cyclone dust separator with flue gas fan © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 25 350 cm 438 cm 468 cm 430 cm Table 3/2 - Technical data *in combination with the HDG cyclone dust separator with flue gas fan © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 26: Fuel Quality Requirements

    3.4 Fuel quality requirements ERMISSIBLE FUEL The HDG Compact 99 - 200 heating system is designed for the stan- dard use of burning wood fuel products made from untreated wood in the form of wood chips, shavings and wood pellets.

  • Page 27: Wood Chips

    Wood chips from category 45 can be used as fuel in all HDG HDG Compact 99 - 200 wood chip boilers. For P45 wood chips at least 75% by weight of the wood chips must measure between 8 mm and 45 mm.

  • Page 28: Wood Pellets

    The ash content for wood in category 2 is higher than that of cate- SH CONTENT gory A1 due to the higher proportion of bark, needles and leaves. The maximum permissible ash content of wood chips for the HDG Compact 99 - 200 is 1.5 % by weight (A1.5). OOD PELLETS With regard to the quality standards for wood pellets, DIN EN 14961-2 "Solid biofuels - fuel specifications and classes - wood pel-...

  • Page 29: Recommended Fuel

    The optimal ash content is 1% by weight (A1.0). For HDG Compact 99 - 200 heating systems, it is possible to use wood fuel products of grain size P45 with a maximum water content of up to 30 %.
  • Page 30 The following table indicates the maximum nominal thermal value OMINAL THERMAL VALUE depending on water content, in reference to the fuels approved for DEPENDING ON WATER the HDG Compact 99 - 200 in accordance with DIN EN 14961 "Solid CONTENT biofuels - fuel specifications and classes". Wood chips...

  • Page 31: Planning And Installation

    4 Planning and installation – Planning the heating system 4 Planning and installation 4.1 Planning the heating system EQUIRED ROOM SIZES AND MINIMUM SPACING Figure 4/1 - Necessary room sizes and minimum spacing HDG Compact 99/100/105/115 2280 3500 1000 HDG Compact 150/194/199/200...

  • Page 32: Dimensions

    4 Planning and installation – Planning the heating system IMENSIONS The following table contains the dimensions of the boiler. HDG Compact 99/100/105/115 HDG Compact 150/194/199/200 Length 1130 mm* 1370 mm* Width 1980 mm 2410 mm Height 1890 mm 1940 mm...

  • Page 33: Fuel Bunker

    ASSAGE THROUGH THE WALL between the heating room and the fuel bunker. Its position depends on the distance and the position of the HDG Compact heating system within the room and the customer's installation diagram. The passage through the wall between the heating room and the fuel bunker should have a width of 70 cm and height of 70 cm in order to allow the assembly of the delivery auger.

  • Page 34: 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 do- sage system)
  • Page 35 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 36: Connections

    The required flue gas values are listed in chapter “3 Mode of ope- ration”, section “3.3 Technical data”. The benefits of the HDG Compact 99 - 200 can only be reaped if all of the factors necessary for good combustion are carefully adjusted.
  • Page 37 4 Planning and installation – Connections Since the flue temperature may lie below 100 °C when the system is partially loaded, a chimney/flue is required which meets the require- ments of DIN EN 13384-1: 2003-03 “Thermal and fluid dynamic calcu- lation methods”.

  • Page 38: Electrical System

    Figure 4/7 - Connection to the chimney To compensate for irregularities in the flue draught of the chimney, HDG Bavaria recommends installing an auxiliary air unit in the flue pipe, or even better, in the chimney itself as shown in Figure 4/7 - Connection to the chimney.

  • Page 39: Water

    For this reason, the HDG Compact 99 - 200 is fitted as standard with power control and automatic ignition. It is, however, highly recommended to use an accumulator even with automatic boiler systems.
  • Page 40 For these reasons, a return temperature control must be installed for the HDG Compact 99 - 200 heating system. The return temperature control causes the water from the boiler return line to be mixed with the water from the boiler supply line until the minimum return tem- perature has been reached.

  • Page 41: Dimensions Of The Flue Pipe Side Of The Hdg Compact 99 - 115

    99 - 115 IMENSIONS OF THE FLUE PIPE SIDE OF THE OMPACT Figure 4/8 - Dimensions of the flue pipe side of the HDG Compact 99 - 115 1 Boiler supply connection (DN 65 flange) 2 Flue pipe connection Ø 250 mm...

  • Page 42: Dimensions Of The Back Side Of Hdg Compact 99 - 115

    99 - 115 IMENSIONS OF THE BACK SIDE OF OMPACT Figure 4/9 - Dimensions of the back side of HDG Compact 99 - 115 1 Connection of immersion sleeve for thermal safety device (DN 15, inside thread) 2 Safety heat exchanger inlet (DN 20, inside thread)

  • Page 43: Dimensions Of The Flue Pipe Side Of The Hdg Compact 150 - 200

    IMENSIONS OF THE FLUE PIPE SIDE OF THE OMPACT Figure 4/10 - Dimensions of the flue pipe side of the HDG Compact 150 - 200 1 Flue pipe connection Ø 300 mm 2 Filling / draining connection (DN 25, inside thread)

  • Page 44: Dimensions Of The Back Side Of Hdg Compact 150 - 200

    3 Safety heat exchanger inlet (DN 20, inside thread) 4 Safety heat exchanger outlet (DN 20, inside thread) Model Compact 150/200 1100 1014 1650 1374 1304 Table 4/6 - Dimensions of the flue pipe side of HDG Compact 150 - 200 (mm)

  • Page 45: Scope Of Delivery

    Figure 4/12 - HDG Compact 100 boiler condition as delivered The heating system HDG Compact 99 - 200 (1) is delivered on two rectangular wooden planks (2). These wooden planks are intended only for transportation and should be removed before installing the...

  • Page 46: Installing The Heating System

    The following figures and diagrams show the version of the heating system HDG Compact 99 - 200 with the 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 47: Placing The Boiler

    Ensure that the chain hoist is correctly secured to the eyebolt of the boiler during crane transport of the heating system. There are several options for transporting the HDG Compact 99 - 200 boiler. It can be performed with a crane, forklift or a lifting truck.
  • Page 48 4 Planning and installation – Installing the heating system 4. Insert the centring screw (1) toward the boiler through the holes and screw it tight with the M6 nut using a 10 mm spanner. TTACHING THE FEEDING SYSTEM Warning! Danger of injury The feeding system is very heavy.

  • Page 49: Attaching The Pressure Equalisation Hose

    4 Planning and installation – Installing the heating system ITTING THE SUPPORT LEG 9. Bolt the support leg (3) with an M12 screw (2) onto the fee- ding system (1) using an SW19 spanner. 10.Fix the support leg (3) to the floor as required (screws and screw anchors are not in- cluded in the scope of deli-...

  • Page 50: Installing Ash Container(S)

    4 Planning and installation – Installing the heating system Figure 4/17 - Setting the pressure equalisation regulator 4. Set the position indicator (1) for the pressure equalisation regu- lator to approximately “Half open” using a 5 mm hexagon socket screw. 5.

  • Page 51: Installing The Central Ash Removal System

    The ash containers are mounted and adjusted. SH CONTAINER Optionally, for the HDG Compact 99 - 200 heating system 140 l ash containers can be installed instead of 80 l ash containers. Installation and adjustment is performed in the same way as with the 80 l ash containers.
  • Page 52 4 Planning and installation – Installing the heating system Figure 4/21 - Removing clamping devices 1. Remove both clamping devices (1) from the ash removal doors using an SW13 spanner. Figure 4/22 - Pre-assembling the central ash removal system 2. Push the auger trough (5) through the flange plates (1) and seals into the ash accumulation bins (3, 4).
  • Page 53 4 Planning and installation – Installing the heating system Figure 4/23 - Installing the ash accumulation bins 7. Push both ash accumulation bins (4) onto the door necks of the ash removal doors (1). 8. Use the spacers (2) during installation of the ash accumulation bins (4).

  • Page 54: Fitting The Buffer Probe

    4 Planning and installation – Installing the heating system 13.Install the drive motor (1) on the ash removal auger using the M8 screw (spanner size SW13) including the spring ring and washers. 14.Slide the ash bin (6) with the intermediary seal (5) onto the auger trough (4).

  • Page 55: Installing The Emd-C 215 Exclusiv Control Cabinet

    Observe the following when installing the EMD-C 215 Exclusiv con- trol cabinet: • The HDG Compact 99 - 200 heating system is supplied with a 10 m cable for connecting the boiler with the control cabinet. Install the control cabinet within range of the connection cable.

  • Page 56: Hdg Hose Junction

    4 Planning and installation – Delivery system HOSE JUNCTION In order to combine several HDG PSS or FRA-PSS pellet delivery sys- tems on an HDG pellet vacuum container, the HDG hose junction can be used. It is positioned between the transfer stations of the PSS augers and pellet vacuum container.
  • Page 57 4 Planning and installation – Delivery system A wall penetration of ca. 220 mm is necessary to mount the hose ALL PENETRATION junction on a wall. Figure 4/27 - Wall penetration for hose junction 1. Mount the cover plate provisionally on the interior wall using the NSTALLATION dowels, diameter 8 mm, and the provided screws.
  • Page 58 4 Planning and installation – Delivery system Fig. 1-10 Schlauchklemmen aufstecken Fig. 1-11 Schläuche mit Schlauchklemmen be Figure 4/29 - Installing hose on hose junction 6. Drill the mounting holes (1) for the metal dowels, diameter 10 mm, in the wall. 7.
  • Page 59 The earthing leads in the hoses must be in contact with the connec- tion nozzles! 20.Place the labelled hoses (1) on the hose junction connections. 21.Secure the hoses (1) with the aid of the hose clamps. 22.Replace the cover (2) on the hose junction. ✓ The HDG hose junction is now installed.

  • Page 60: Hdg Cyclone Dust Extractor

    ✎ For further procedures in the attachment of the hoses, see the operating manual for the HDG pellet delivery system PSS or FRA- PSS and the HDG pellet vacuum system, chapter 4 "Planning and Installation", section 4.5 "HDG pellet vacuum system", paragraph "Installing the vacuum and return hose".

  • Page 61: Thermal Safety Device

    The thermal safety device is to be inspected annually by an autho- rised, qualified technician to verify that it is functional. 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 sa- fety heat exchanger anticlockwise when installing the thermal sa- fety device.
  • Page 62 HDG C 99 - 115 OMPACT Figure 4/33 - Installing the HDG Compact 99 - 115 thermal safety device 1 Connection of immersion sleeve for thermal safety device (DN 15 female) 2 Safety heat exchanger connections (DN 20, inside thread)

  • Page 63: Hydraulic System

    4 Planning and installation – Hydraulic system 4.10 Hydraulic system Figure 4/35 - Hydraulic system HDG Control Supply temperature sensor (boi- ler temperature) Return temperature sensor Acc. top Acc. bottom The hydraulic system is only suitable for the indicated purpose and in the specified manner.

  • Page 64: Commissioning The System

    • Does the mechanical structure meet the specifications of this ope- HECK THE MECHANICAL HDG C rating manual? STRUCTURE OF OMPACT © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 65: Procedure

    HECKING THE ACTUATORS IN MANUAL OPERATION In the MANUAL menu you can manually test the functionality of all actuators, e.g. drive motors, fans and electrical mounted parts. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 66 OSE JUNCTION AND PELLET responding pellet auger. AUGER ✎ See chapter “6 Using the heating system”, section “6.9 MANUAL menu”, paragraph “Hose junction and pellet auger”. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 67: Filling The Ash Accumulation Bin

    “Moving floor”. Once the functionality of all the actuators is checked in manual ope- ration, the HDG Compact 99 - 200 heating system can be operated in accordance with the set control mode. ILLING THE ASH ACCUMULATION BIN...

  • Page 68: Filling The Fuel Bunker

    Only allow authorised specialists to make adjustments to the para- meters. The parameters of the HDG Control unit are programmed with the predefined factory settings upon delivery. The predefined values of the factory settings are intended for operation with wood chips.

  • Page 69: Using The Heating System

    Acknowledge fault key • flashes when there is a fault. • lights up when a fault is eliminated. • must be pressed after rectifying a fault. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 70: Control Cabinet Model Emd-C 215 Exclusiv

    2 Main switch 3 Emergency stop 4 Acknowledge fault button with fault light 5 “System operation” indicator light 6 Engage switch 7 HDG Control control unit © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 71: Hdg Controlunit

    10 Enter or Input button 11 Function buttons (F1 to F6) 12 CE button The control unit of the HDG Control is located in the front plate of the control cabinet. Through the control unit, you can adjust the HDG Control and obtain information on current processes.

  • Page 72: Switching On The Heating System

    One step forwards. Configuration button • If the HDG Control is traded, the configuration key is used to con- firm adoption of the previous hours of operation. 6.2 Switching on the heating system Before the heating system is switched on, the following require-...

  • Page 73: Switching Off The Heating System

    Allow the heating system to burn out until the combustion air fan switches off. Turn the heating system main switch off. ✓ No operating mode is displayed on the control unit of the HDG Control. ✓ The heating system has been de-energised.
  • Page 74 Emergency operation • The boiler operates in accordance with the parameter values from active the submenu “Fixed value settings”. Table 6/1 - Operating statuses (continuation) © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 75: Calling Up Information, Selecting And Modifying Parameters

    6.5 Calling up information, selecting and mo- difying parameters On the display of the control panel for the HDG Control, you can call up various information as well as select and modify parameters. Due the freely programmable design and the numerous options in heating system combinations, especially in regard to the extraction technology, the number of parameters can vary greatly.
  • Page 76 If the parameters are changed by untrained indivi- duals, the heating system can be damaged and dangerous operating conditions can arise. Have changes to the following parameters made only by authorised specialists. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 77: On/Off Menu

    ✎ See “Procedure” in this section. Changeover base load/peak load 1-01 Base load Peak load Boiler-1 Boiler-2 After operating hours 0 hr FIELD CHOOSE © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 78 Press the F4 key under the CHOOSE command in the display to se- lect the day of the week that is to be reset. Set the times using the numerical keypad. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 79 The cursor moves to the next digit pair. Press the F6 key under the END command to exit the Switch on/off time - Hopper 1-04 submenu. ✓ The standard display is restored. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 80 : Accumulator tempera- ture sensor Ignition : On Lambda stop : On FIELD CHOOSE The standard setting for systems with accumulators is Combus- tion control. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 81 AUTOMATIC IGNITION ✎ See “Procedure” in this section. The standard setting is On. Sustaining the embers is only performed in emergency operation! © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 82: Adjusting The Ash Removal Setting

    The automatic heat exchanger cleaning system can be switched off. ✎ See “Procedure” in this section. Setting 1-07 Cleaning system : On CHOOSE The standard setting is On. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 83: Modifying The Dust Removal Setting

    6 Using the heating system – ON/OFF menu ODIFYING THE DUST REMOVAL SETTING The fan for the HDG cyclone dust extractor, if available, can be set to four different operating modes. • 0-Off – In this mode, the fan for the de-dusting function is not available or not in operation.

  • Page 84: Modifying The Extraction Setting

    2 or 3 suction points. ✎ See “Procedure” in this section. Setting Pellet vacuum delivery system 1-10 Vacuum delivery system : 1 Suction point Operating mode : Automatic FIELD © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 85: Modifying The Moving Floor Setting

    The manual control function in the Manual menu is enabled. ✎ See “Procedure” in this section. Setting 1-11 Moving floor : Manual mode FIELD © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 86: C/Quantity Menu

    This is an optional submenu and only available when operating the boiler with flue gas temperature sensor. ✎ See “Procedure” in this section. °C / Quantity 2-01 Flue gas temperature 99 °C © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 87: Reading Values From The Controller

    Fixed value settings 2-04 Material quantity : 40.0 /.40.0 % Primary air 15 / Secondary air 80 / Comb. chamber temp. 600 / 331 °C © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 88 • Temp. acc. bottom above – If the temperature set for the bottom accumulator sensor is ex- ceeded, the boiler switches off. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 89: Integrating The Peak Load Boiler

    See “Procedure” in this section. Peak load boiler 2-07 On: Temp. acc. top below 55 / 68°C Off: Temp. acc. middle above 65 / 65°C © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 90: Peak Load Boiler Monitoring

    Lambda Stop”. ✎ See “Procedure” in this section. Comb. chamber temp. PID-1 6-01 MAX: 600°C T_SET: 80°C 5.00 MIN: 400°C T_ACT: 0°C 900.00 10.00 SET: 600°C © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 91: Entering Material And Temperature Settings

    See section “6.6 ON/OFF menu”, under “Setting the control, boiler activation, ignition and Lambda Stop”. ✎ See “Procedure” in this section. Primary air 6-03 Air_Max Fue_Set: 15.0% Air_Min : 25% Set_Air: 25.0% © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 92: Entering The Residual Oxygen Setting

    Combustion and output control. ✎ See section “6.6 ON/OFF menu”, under “Setting the control, boiler activation, ignition and Lambda Stop”. ✎ See “Procedure” in this section. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 93 6-06 Delta_FUE_MIN: -10% FUE_SET: 15.0% Delta_FUE_MAX: FUE_ACT: 15.0% Delta_FUE_ACT: Delay The standard setting for Delta FUE_MIN is -10 % and 10 % for Delta FUE_MAX. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 94: Time Menu

    6 Using the heating system – TIME menu ETTING UNDERPRESSURE CONTROL VALUES In this menu, the settings for fan speed with the HDG cyclone dust extractor and the underpressure value for the underpressure control can be defined. ✎ See “Procedure” in this section.
  • Page 95 Ignition parameter is set to Off. The Keep glow setting is only used as an “emergency” function should the ignition fan fail! ✎ See “Procedure” in this section. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 96 This parameter is an optional submenu and only available for hea- ting systems with metering tank and fill level indicator. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 97 Moving floor pause time : 10.0 / 0.0 s Moving floor delay time : 10.0 / 0.0 s Moving floor lead time 0.0 / 0.0 s © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 98 This setting is only available when the delivery system is set to “Cy- cles”. ✎ See section “6.6 ON/OFF menu”, under “Modifying the extraction setting”. ✎ See “Procedure” in this section. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 99 See “Procedure” in this section. Pellet hopper 3-12 Max. vacuum fan runtime 25 / Max. vacuum fan pause time : 25 / Number of fill attempts © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 100 The "0" setting deactivates this function. ✎ See “Procedure” in this section. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 101: Main Cleaning - Setting Times

    Cleaning time ETTING THE DAY DATE AND TIME In this submenu you can enter the current day, date and time. ✎ See “Procedure” in this section. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 102: Manual Menu

    Press the F4 or F5 key to test the actuators in manual operation. Press the F6 key under the END command to exit the submenu. ✓ The standard display is restored. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 103: Combustion Air And Ignition Fan

    This submenu is used to activate the return pump and return mixing valve. ✎ See “Procedure” in this section. Manual 4-03 Return pump Open return valve Close return valve FIELD © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 104: Feeding And Dosage

    Material damage and injury due to incorrect operation. Activation of the BACK parameter is only possible during feeding and may only be used for short cycles of max. 3 seconds. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 105: Feeding, Metering, Vacuum Fan And Delivery System

    In this submenu, if there is a walking floor delivery system the fee- ding and the transverse auger can optionally be activated together with the dosing auger lying in between. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 106: Moving Floor

    HDG Bavaria GmbH! Press the F5 key under the display of the standard display screen. ✓ You are in the SERVICE menu. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 107 Repeat steps 5 to 7 for additional parameters. Press the F6 key under the END command to exit the submenu. ✓ The standard display is restored. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 108: Chimney Sweep Test

    3 seconds resets all operating hours. ✎ See “Procedure” in this section. Operating hours counter 5-04 Boiler 0:00:00 Dosage 0:00:00 Feeding 0:00:00 Ash removal 0:00:00 © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 109 – The maximum number of possible reverse attempts can be set. • Ignition temperature – If the temperature in the hot combustion chamber exceeds this value, the HDG Control does not switch on the ignition fan for starting the heating system. ✎ See “Procedure” in this section.

  • Page 110: Temperature And Combustion Chamber Stop Temperature

    – After a prior Lambda stop, combustion chamber temperature stop or material stop, the feed system starts early by the amount of the set value. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 111: Ignition Fan

    ✎ See “Procedure” in this section. Service 5-09 Fuel quantity 1st filling 25.0 % Primary air start 25 % Secondary air start 80 % © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 112: Ash Removal System Minimum Pause

    Open the SERVICE menu and scroll to the Service 5-03 sub- menu. ✎ See “Procedure” in this section. Simultaneously press the keys F3, F4 and F5 under the display. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 113: Flue Gas Temperature

    – The fault message "Flue gas temperature too high" appears after this set delay time has elapsed. • Incline – System-specific parameter, can only be set and modified by au- thorised HDG technicians. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 114: Underpressure Control

    – After this set boiler temperature is exceeded, the chimney sweep test is enabled. • Enabling combustion chamber temperature – After this set combustion chamber temperature is exceeded, the chimney sweep test is enabled. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 115 – Modbus RTU web server – Modbus RTU DDC – Profibus DP DDC ✎ See “Procedure” in this section. Setting interface RS485 5-16 Interface type :without interface FIELD © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 116: Modbus Rtu - Setting Web Server

    – Setting of PLC address for a Profibus network • Profibus rights – Setting of the minimum required rights or enabling of only cer- tain PLC parameters in a Profibus network © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 117: Entering Password

    All settings that were previously made will be irrevocably over- written! Press the F4 and F5 keys to adopt the factory settings. ✓ The factory settings are adopted. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 118: Info Menu

    The fuel bunker must be dry and free of any foreign bodies. • Large dust deposits must be removed (for pellet bunkers). • The requirements of government safety organisations must be met. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 119: Procedure For Filling With Wood Fuel Products

    To ensure a stable opera- ting ability, sufficient heat transfer must occur while operating at full load. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 120: Before The Test

    • No fault should be present in the system. Press the F5 key under the standard display screen. ✓ You are in the Service menu. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 121 Press the F6 key under the End command to cancel the chimney sweep test. The chimney sweep test is also cancelled if the specified time for the measurement is exceeded. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 122: Cleaning And Servicing The Heating System

    The cleaning and maintenance work can also be performed by an au- thorised specialist heating company through a servicing contract. PARE PARTS Only use genuine HDG spare parts. You can obtain HDG replace- ment parts from your specialist heating company. 7.1 Cleaning and maintenance schedule The specified maintenance intervals are guidelines.

  • Page 123: Procedure

    When applying lubricants, oils and grease, observe the specifica- tions of the respective manufacturer. The following illustrations of the HDG Compact 150/200 serve to vi- sualise the cleaning and maintenance work. The construction of the HDG Compact 100/105 heating system differs only slightly. The ap- proach to cleaning and maintenance work, however, is identical.

  • Page 124: Cleaning Tools

    See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The cleaning of the stepping grate is completed. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 125: Checking And Emptying The Ash Container

    Lift up the lid (1) and remove it. Check the fill level of the ash containers (2). ✓ If the ash containers (2) are full, empty them. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 126 See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 127 See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The central ash removal system has been checked and emptied. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 128: Lubricating The Feeding System

    See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 129 7 Cleaning and servicing the heating system – Procedure Figure 7/7 - Checking the drive chain of the HDG Compact 100/105 ash removal sys- Unscrew the cover screws on the back of the heating system and remove the cover (3).
  • Page 130 7 Cleaning and servicing the heating system – Procedure Figure 7/8 - Checking the drive chain of the HDG Compact 150/200 ash removal sys- Unscrew the screws of both the covers on the back of the heating system and remove the covers (4).
  • Page 131 See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The check of the feeding system drive chain is completed. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 132: Cleaning The Control Unit

    See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 133 See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Figure 7/12 - Folding out the cleaning shaft lid © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 134 ✎ See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. 19.Move the cleaning system upward in manual operation. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 135 “Ash removal, main cleaning, dust removal and cleaning system”. Hold the F4 key under the On command down longer than three seconds. ✓ The cleaning system moves downward. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 136 14.Visually inspect the cleaning turbulators for encrustations and re- move these with a suitable tool. 15.Brush off the heat exchanger surfaces(3) with a suitable tool (e.g.cleaning brush, included in delivery). © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 137: Checking And Cleaning The Ignition Fan

    See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 138 See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The inspection and cleaning of the ignition fan system is com- pleted. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 139: Checking And Cleaning The Lambda Sensor

    See chapter “6 Using the heating system”, section “6.10 SERVICE menu”, paragraph “Calibrating the lambda sensor”. ✓ The cleaning of the lambda sensor is completed. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 140: Inspecting And Cleaning The Flue Pipe

    See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The cleaning of the flue pipe is completed. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 141: Checking And Cleaning The Ash Removal System

    See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The inspection and cleaning of the ash removal system is com- pleted. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 142: Checking And Cleaning The Pressure Equalisation Hose

    See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 143: Checking The Fill Level Indicator

    See the chapter entitled “6 Using the heating system”, section “6.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down. Remove the ash containers. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 144 (6). Remove the pressure equalisation hose (4) from the front hatch (2). ✎ See section “Checking and cleaning the pressure equalisation hose” in this chapter. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 145: Checking The Plug Contacts

    Check the electrical plug contacts are securely fit. ✓ The electrical plug contacts have been checked. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 146: Inspecting The Fuel Bunker

    Switch the heating system on again. ✎ See the chapter entitled “6 Using the heating system”, section “6.2 Switching on the heating system”. ✓ The fuel bunker is cleaned. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 147: Troubleshooting

    • Clean heat exchanger ES017 Overpressure in tion chamber • Press the Acknowledge fault the combustion • Heat exchanger contamina- chamber Table 8/1 - Faults © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 148 Check STB • Connection cable faulty • Check the electrical connec- • STB faulty tion • Press the Acknowledge fault Table 8/1 - Faults (continuation) © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 149 • Line from exhaust tempera- if necessary faulty ture sensor faulty • Press the Acknowledge fault Table 8/1 - Faults (continuation) © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 150 Check the electrical connec- • Connection cable faulty tion • Material blockage • Remedy material blockage • Press the Acknowledge fault Table 8/1 - Faults (continuation) © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 151 • Connection cable faulty tion position 1 • Material blockage • Remedy material blockage • Press the Acknowledge fault Table 8/1 - Faults (continuation) © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 152 Check the electrical connec- overfilling • Connection cable faulty tion • Material blockage • Remedy material blockage • Press the Acknowledge fault Table 8/1 - Faults (continuation) © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 153 Check the motor • • Motor cable faulty Check the motor cable • Faulty limit switch • Check limit switch Table 8/1 - Faults (continuation) © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...
  • Page 154 Pellet storage space 2 empty Check pellet storage space 2 WA220 Check pellet and fill if necessary storage space 2 filling level Table 8/1 - Faults (continuation) © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...
  • Page 155 Lubricate cleaning system WA227 Please lubri- • cleaning system exceeded Reset time in the parameter cate cleaning 3-14 with RESET system! Table 8/1 - Faults (continuation) © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 156: Notes On Dismantling And Disposal

    Observe the safety regulations for personnel when disconnecting the boiler from the heating system. Dismantle the individual components of the heating system. ✓ The heating system has been dismantled. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 157: Disposal

    Metal parts should be recycled. Oily or greasy components and condensers may only be disposed of through a specialist waste disposal centre. © HDG Bavaria GmbH 07/2008 HDG Compact 99 - 200 - Version 1 - en...

  • Page 158: Warranty

    (such as seals, etc). • Damage due to an excessively high number of hours of boiler ope- ration. © HDG Compact 99 - 200 - Version 1 - en HDG Bavaria GmbH 07/2008...

  • Page 159: 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, 10.04.2012 -------------------------------------------------------------------------------------------------------------------------------------------- Place, date Signature p. p. Martin Ecker head of development © HDG Bavaria GmbH 07/2008 HDG Compact 150/200 - Version 1 - de...

  • Page 160: Index

    - Checking ......146 © HDG Compact 100/105/150/200 - Version 1 - de HDG Bavaria GmbH Juli 2005...

  • Page 161: Setting Operating Times

    12 Index - Filling ......68, 118 Return temperature control ....40 Fuel class .
  • Page 162 12 Index OTICE © HDG Compact 100/105/150/200 - Version 1 - de HDG Bavaria GmbH Juli 2005...
  • Page 164 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: 9980001520 - V 03.1 - en - 03/2013 - Translation of the original operating instructions...

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