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HDG Euro V3.0 Operation Manual

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Operation Manual
HDG Euro V3.0 with HDG
Lambda Control 1
hdg-bavaria.com
V 01 - 06/2008

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Summary of Contents for HDG Euro V3.0

  • Page 1 Operation Manual HDG Euro V3.0 with HDG Lambda Control 1 hdg-bavaria.com V 01 - 06/2008...

  • Page 3: Table Of Contents

    4.6 Lighting and reloading the HDG Euro........30...
  • Page 4 Operation Manual HDG Euro V3.0 with HDG Lambda Control 1 - Content Cleaning and maintaining the HDG Euro ......39 5.1 Cleaning and maintenance plan.

  • Page 5: Notes On This Manual

    1.1 Introduction This Operation Manual contains important information for proper Safe and simple and safe operation of the HDG Euro V3.0 with HDG Lambda Control 1. operation Following these instructions serves in avoiding dangers, preventing repair costs and downtimes, maintaining reliability and extending the service life of the heating system.

  • Page 6: Structure Of The Operating Manual

    6 Troubleshooting ... how to rectify faults in the heating system. 7 Commissioning the HDG Euro ... how the HDG Euro is to be put into initial service. 8 Notes on dismantling and ... what has to be considered when dismantling and disposing of disposal the HDG Euro.

  • Page 7: Glossary

    Safety device which allows cold water to flow through the safety heat exchanger if the boiler becomes too hot. Table 1/2 - Glossary © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 8: Safety Notes

    In the event of a chimney fire the appliance should be turned to its minimum setting and the fire brigade informed. Do not re-light until the complete installation has been inspected by a qualified engineer. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 9: Useful Organisations

    Proper and improper manner of operation The HDG Euro V3.0 with HDG Lambda Control 1 is designed to burn Application of the untreated wood in the form of split logs up to 500 mm (19"), pressed...

  • Page 10: Residual Risk

    Do not leave the combustion chamber and/or fuelling chamber door open any longer than necessary. Caution! Hand injuries Working in areas marked with this symbol can lead to hand injuries. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 11 Work in areas marked with this symbol may only be performed exactly as specified by HDG Bavaria. Improper operation can lead to explosions. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 12: Warnings And Safety Symbols Used

    Working in areas marked with this symbol can lead to a fire. Caution! Frost danger Working in areas marked with this symbol can lead to frost damage. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 13: Duty To Inform

    The Operation Manual must be kept easily accessible at the heating system's installation location. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 14: Functional Description

    6 Flue gas deflector plate 7 Safety heat exchanger 8 Secondary combustion chamber with chamber stones 9 Flue gas heat exchanger (downstream heating surfaces) © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 15 22 Air adjustment flap for secondary air with servo motor 23 Front cover 24 Filling hatch handle 25 Filling hatch unlocking device 26 Filling hatch © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 16 38 Lambda sensor connection nozzle 39 Supply connection 1 1/4" BSP (DN 32 IG) 40 Lambda sensor 41 Flue gas temperature sensor © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 17: Mode Of Operation

    HDG Euro V3.0 with HDG Lambda Control 1 Figure 3/3 - HDG Euro V3.0 with HDG Lambda Control 1 Inside the HDG Euro V3.0 with HDG Lambda Control 1, fuel which has been manually placed in the fuel chamber (1) and ignited is degassed through the addition of primary air.

  • Page 18: Technical Data

    5 h with spruce up to 4 h with spruce Table 3/1 - Technical data HDG Euro V3.0 with HDG Lambda Control 1 © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 19 Air inlet cross section 15.000 mm 15.00o mm 15.000 mm Table 3/1 - Technical data HDG Euro V3.0 with HDG Lambda Control 1 © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 20: Fuel Quality Requirements

    HDG Bavaria recommends split logs in lengths of 500 mm (19"), with a max. edge length of 120 mm (4 3/4") and a moisture content of 20 %. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 21: Using The Hdg Euro

    8 “Reload” button 9 Unlocking knob for the safety temperature limiter (STB) The HDG Lambda Control 1 control panel is located on the top of the HDG Euro V3.0 with HDG Lambda Control 1. Using the control panel, you can regulate the HDG Lambda Control 1 system and call up information on the current operating status.
  • Page 22 HDG Lambda Control 1. ✎ See section “4.6 Lighting and reloading the HDG Euro” in this chapter. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 23: Initialising The System

    80˚C. The fault is automatically reset. 4.2 Initialising the system Requirements In order for the HDG Euro to be switched on, it must first have been put into service by an authorised specialist. ✎ See chapter “7 Commissioning the HDG Euro”.

  • Page 24: Structure Of The Menus

    4 Using the HDG Euro – Structure of the menus 4.3 Structure of the menus “Heat production off” menu structure Figure 4/2 - “Heat production off” menu structure © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 25: Heat Production On" Menu Structure

    4 Using the HDG Euro – Structure of the menus “Heat production on” menu structure Figure 4/3 - “Heat production on” menu structure © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 26: Displaying Information

    4 Using the HDG Euro – Displaying information 4.4 Displaying information You can call up a variety of information on the display of the HDG Lambda Control 1. Certain information and settings can only be accessed and changed in “Heat production on” or “Heat production off”.
  • Page 27 No access ETA-F • Cumulative operating hours in “Heat Operating hours production on” mode. No access Table 4/1 - Target value information © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 28 Table 4/2 - Control program information Indication in display when the alternative “TA control program” is automatically initiated. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 29: User Changeable Settings

    ✓ The boiler target temperature is set. ✎ See section “4.3 Structure of the menus” in this chapter for more information. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 30: Lighting And Reloading The Hdg Euro

    HDG Bavaria. Improper operation can lead to explosions. Caution! Hand injuries Working in areas marked with this symbol can lead to hand injuries. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 31 Figure 4/4 - Heating up / reloading Raise the filling hatch (1) up to the stop. Wait for approx. 10 seconds until the message “Careful, open slowly” appears. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 32 (1) on the grate (2) and stack it 150 to 200 mm high. Ignite it with a bit of newspaper. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 33 Figure 4/7 - Heating up / reloading Close the filling hatch (1) and open the cleaning door (2). Figure 4/8 - Heating up / reloading © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 34 “Heat production on” appears in the display (2). 13.Close the cleaning door. ✎ See number (2) Figure 4/8 - Heating up / reloading. ✓ The boiler is now operating. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 35 See also section “4.1 Overview of the controls and display components”, paragraph “ Control panel HDG Lambda Control 1” in this chapter. Press the Reload button. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 36 Lift the lock of the filling hatch (1) and open the filling hatch slowly until horizontal. Figure 4/11 - Heating up / reloading ✓ The filling hatch opens automatically. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 37 Figure 4/12 - Heating up / reloading Close the filling hatch (1) and open the cleaning door (2). Figure 4/13 - Heating up / reloading © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 38: Switching Off The Hdg Euro For Maintenance Or Repair Work

    4 Using the HDG Euro – Switching off the HDG Euro for maintenance or repair work Hold the cleaning door open until the indicator lamp “Heat production on” (1) lights up and the message “Heat production on” appears in the display (2).

  • Page 39: Cleaning And Maintaining The Hdg Euro

    Inspecting the integrity of the door seals • Cleaning the control unit • Calibrating the lambda sensor Table 5/1 - Cleaning and maintenance plan © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 40: How To Proceed

    Caution! Danger of fire Working in areas marked with this symbol can lead to a fire. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 41: Cleaning Tools

    The surfaces of the boiler can be hot. Even when turned off, they only cool down slowly. Do not start with the maintenance work until the surfaces have cooled down. Press the “Reload” button. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 42 Lift the lock of the filling hatch (1) and open the filling hatch slowly until horizontal. Figure 5/3 - Cleaning the flat grate and ash compartment ✓ The filling hatch opens automatically. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 43 Figure 5/5 - Cleaning the flat grate and ash compartment Use the scraper to sweep the ash into the ash pan (2). © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 44: Inspecting And Cleaning Downstream Heating Surfaces

    Do not start with the maintenance work until the surfaces have cooled down. Remove the upper cladding (1) by lifting it upward. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 45 Figure 5/6 - Cleaning the burner nozzle Pull out the flue gas deflector plate (1) in an upward direction. Figure 5/7 - Cleaning the burner nozzle © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 46: Inspecting And Cleaning The Flue Pipe

    “4 Using the HDG Euro”. Allow the boiler and the flue pipe (3) to cool down. Unscrew the wing nut (1) on the inspection hatch (2). © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 47 Your flue connection configuration may not match the information above. Your installer will have provided access to clean the boilers flue outlet and the chimney system. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 48: Inspecting And Cleaning The Lambda Sensor

    Steel bristles will damage the lambda sensor. Clean out any deposits found inside the installation fitting (5). Reinstall the lambda sensor (2) in the reverse sequence. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 49: Inspecting And Cleaning The Flue Gas Sensor

    Clean the sensor surface. Reinstall the flue gas sensor (1) in the reverse sequence. ✓ The cleaning of the flue gas sensor is completed. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 50: Inspecting And Cleaning The Flue Fan

    Use a 13 mm hand ratchet to unscrew the four M8 nuts (3). Figure 5/12 - Cleaning the flue fan Remove the exhaust fan (2), including the flange plate (4), from the boiler. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 51: Inspecting And Cleaning The Fan Unit

    The surfaces of the boiler can be hot. Even when turned off, they only cool down slowly. Do not start with the maintenance work until the surfaces have cooled down. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 52: Inspecting The Integrity Of The Door Seals

    The surfaces of the boiler can be hot. Even when turned off, they only cool down slowly. Do not start with the maintenance work until the surfaces have cooled down. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 53 The surfaces of the boiler can be hot. Even when turned off, they only cool down slowly. Do not start with the maintenance work until the surfaces have cooled down. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 54 If the seal is not tight, use a 19 mm fork wrench to tighten the hexagon head nut (2) one turn. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 55: Cleaning The Control Unit

    For stubborn dirt, use a mild cleaning agent. Dry the control unit with a soft cloth. ✓ The cleaning of the control unit is completed. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 56: Calibrating The Lambda Sensor

    HDG installer. Press the Plus and Minus buttons simultaneously. ✓ The system component test menu closes. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 57: Cleaning The Primary Air Inlets

    Vacuum each primary air inlet with a vacuum cleaner until cleared. Close the boiler in the reverse sequence. ✓ The cleaning of the primary air inlets is completed. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 58: Cleaning The Burner Nozzle

    Do not use the vacuum cleaner if the ash is still hot and do not place hot ash in flammable containers. Close the boiler again properly. ✓ The cleaning of the burner nozzle is completed. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 59: Inspecting The Pneumatic Springs

    Press the lock (2) of the filling hatch (1) downward. Figure 5/21 - Inspecting the pneumatic springs Raise the filling hatch (1) up to the stop. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 60 (2) must be replaced. Close the log wood boiler. ✓ The pneumatic spring inspection is completed. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 61: Troubleshooting

    6 Troubleshooting – How to proceed 6 Troubleshooting If a fault occurs in the HDG Euro, it will be indicated in the display of the HDG Lambda Control 1 and by the indicator lamp on the HDG Lambda Control 1 control panel.

  • Page 62: Possible Faults

    • Reset by pressing the Arrow button • Return valve Return valve Plug/cable Motor/controller Table 6/1 - Faults with flashing indicator lamp © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 63: Faults Which Interrupt The Production Of Heat

    Have the fault repaired by an Data loss authorised installer Controller is faulty Table 6/2 - Faults which cause indicator lamp to stay on © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 64: Commissioning The Hdg Euro

    • Air supply for combustion has been provided. • A sufficient amount of fuel is available. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 65: Commissioning The Hdg Euro

    Use the Plus or Minus button to select the appropriate hydraulic system. ✓ The selected hydraulic system will appear in the display. Confirm using the Arrow button. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 66 (for hybrid systems). ✓ The selected minimum buffer tank temperature will appear in the display. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 67 25.Use the Plus or Minus button to select the runtime for the installed servo drive for the loading valve. ✓ The selected runtime will appear in the display. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 68: Setting The Target Boiler Temperature

    Record the data and set values in the following table so that the parameters are readily available in case service is needed. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 69: Customer Data

    • 100 ˚C Return valve runtime [sec] • 150 sec. Loading valve runtime [sec] • 150 sec. Table 7/2 - Set values © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 70: Testing System Components

    HDG Euro”. ✓ The O2 sensor test is completed. Press the Arrow button. ✓ The display advances to the next component: primary pump. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...
  • Page 71 The switch (1) of the servo motor has to be moved in the position as shown in figure 7/4. Figure 7/4 - Switch servo motor © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 72 “Heat production off” mode. The HDG Lambda Control 1 system does not require any additional settings. ✓ The component test is completed. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 73: Setting The Primary Air Guide And The Grate Height For The Respective Fuel

    Table 7/3 - Presetting the inputs. Tighten the retaining screws (1 + 5). ✓ The primary air guide is now set. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...
  • Page 74 7 Commissioning the HDG Euro – Commissioning the HDG Euro Grate lifter In the HDG Euro V3.0 with HDG Lambda Control 1 for log wood, the grate lifter is already installed in a horizontal position! The position of the grate lifter (2) 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 75: Notes On Dismantling And Disposal

    Only dismantle the boiler after you have thoroughly read the manual. The HDG Euro can be dismantled as follows. Allow the fire in the HDG Euro to burn out and for the system to cool off. Danger! Danger from electrical current or voltage The HDG Euro can only be completely de-energised by switching off the mains circuit breaker or the emergency heating switch.

  • Page 76: Disposal

    Fibreglass, mineral wool and plastic parts should be brought to the relevant waste disposal centres. Oily or greasy components and condensers may only be disposed of through a specialist waste disposal centre. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 77: Warranty And Extended Warranty

    The fuel quality must correspond to the requirements specified by HDG Bavaria GmbH. • The apparent defect is to be remedied by HDG Bavaria GmbH. © HDG Bavaria GmbH 06/2008 HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en...

  • Page 78: Warranty Exclusions

    • Damages caused by subjecting the boiler sheeting to extreme heat, as the result of boiler blockages on the water side. © HDG Euro V3.0 with HDG Lambda Control 1 - V 1 - en HDG Bavaria GmbH 06/2008...

  • Page 79: Declaration Of Conformity

    10 Declaration of conformity 10 Declaration of conformity © HDG Bavaria GmbH 06/2008 HDG Navora 20/25/30 with HDG Lambda Control 1 - V 2 - en...
  • Page 80 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: 9980000366 - V 01 - en - 06/2008 - Translation of the original operating instructions...

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