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HDG K10 Operating Manual

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Operating manual
HDG K10/15/21/26/33
hdg-bavaria.com

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  • Page 1 Operating manual HDG K10/15/21/26/33 hdg-bavaria.com...

  • Page 3: Table Of Contents

    Cross section of HDG K10 - 33 ........
  • Page 4 6.1 Control unit for HDG Control........

  • Page 5: Notes On This Manual

    This operating manual must be read and observed by everyone who EADING THE OPERATING operates or works on the HDG K10 - 33. 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 6: Glossary

    Extinguishes the contents of the reservoir if the temperature of the contents exceeds 90°C. HDG Control Boiler and heating system controller. HDG K10 - 33 Heating system for burning wood pellets. Heating system Comprised of boiler and corresponding accessories. Pellet suction system Pellet transport system which connects the reservoir with the delivery system.

  • Page 7: Safety Notes

    (pipework, etc.), is not part of this operating manual. HDG Bavaria does not assume any liability for this. ROPER AND IMPROPER OPERATION The heating system HDG K10 - 33 was designed to burn wood pellets URPOSE OF THE HEATING in hot water heating systems.

  • Page 8: 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 9: Warnings And Safety Symbols Used

    2 Safety notes – Warnings and safety symbols used Danger! Danger of explosion due to carbon monoxide Filling the burner pot with pellets manually may result in too much fuel in the burner pot. Consequently the pellets will not be optimally ignited and too much low temperature carbonisation gas may result which can lead to an explosion.
  • Page 10 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 11: Safety Instructions For The Pellet Storage Room

    2 Safety notes – Safety instructions for the pellet storage room 2.4 Safety instructions for the pellet storage room After the storage room is filled, odourless carbon monoxide may form and a lack of oxygen may arise. Therefore, in the first 6 weeks after filling the storage room, it is prohibited to enter the storage room, and only trained personnel may do so.

  • Page 12: Mode Of Operation

    3 Mode of operation – Overview 3 Mode of operation 3.1 Overview HDG K10 - 33 ROSS SECTION OF Figure 3/1 - Cross section of HDG K10 - 33 1 Vacuum fan 2 Flap of the delivery unit 3 Reservoir 4 Reservoir level indicator...

  • Page 13: Functional Description

    The system then changes to modulation mode. In this mode, combustion is carried out according to the required output. The boiler HDG K10 - 33 is equipped as standard with an automatic heat exchanger cleaning system. This ensures a consistently high heat transfer and consequently a high level of efficiency.

  • Page 14: Boiler And Weather-Compensated Heating Control Hdg Control

    OILER AND WEATHER COMPENSATED HEATING CONTROL ONTROL The boiler control unit of the pellet boiler HDG K10 - 33 is the OILER CONTROL UNIT electronic hub. It consists of the ready-to-use control panel and control unit on the top right side of the boiler. Using the control unit, you can regulate the boiler and call up information on the current process.

  • Page 15: Pellet Suction System

    ELLET SUCTION SYSTEM The pellet suction system links the delivery system with the reservoir of the HDG K10 - 33 boiler. This process is monitored by sensors and, using the boiler control system, can be limited to various times of day.

  • Page 16: Technical Data

    3 Mode of operation – Technical data 3.3 Technical data Type of boiler HDG K10 HDG K15 HDG K21 HDG K26 HDG K33 Performance data (measured according to DIN EN 303-5) Nominal thermal power 9.9 kW 15 kW 21 kW 25.9 kW...

  • Page 17: Fuel Quality Requirements

    3 Mode of operation – Fuel quality requirements 3.4 Fuel quality requirements Only wood pellets are permissible as fuel for the HDG K10 - 33 boiler. With regard to the quality standards for pellets, DIN EN ISO 17225-2 “Biogenic solid fuel - fuel specifications and classes - classification of pellets”...

  • Page 18: Planning And Installation

    Flue pipe above Figure 4/1 - Room sizes and minimum clearances in mm * for HDG K21/26/33. For HDG K10/15 = 710 mm ** with 107 kg reservoir. With 200 kg reservoir = 1425 mm Minimum room height: 1850 mm...

  • Page 19: Dimensions And Connections

    Observe the fire safety regulations. 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 and that the minimum spacing requirements are observed.

  • Page 20: Connections

    The required flue gas values are listed in chapter “3 Mode of operation”, section “3.3 Technical data”. The benefits of the HDG K10 - 33 can only be enjoyed if all of the prerequisites for good combustion are ensured. The heating system...
  • Page 21 4 Planning and installation – Connections These requirements correspond to chimneys of the type according to DIN EN 13384-1: 2003-03 “Thermal and fluid dynamic calculation methods”. Insulated chimneys used today, consisting of a fireclay or stainless steel pipe with an insulating jacket and cladding bricks (three shell design), are to be assigned to groups I - II.

  • Page 22: Electrical System

    4 Planning and installation – Connections To compensate for irregularities in the flue draught of the chimney, HDG Bavaria recommends installing an auxiliary air unit in the flue gas pipe, or even better, in the chimney itself as shown in Figure 4/3 - Chimney connection.
  • Page 23 For this reason, the HDG K10 - 33 is fitted with power control as standard and with automatic ignition. It is, however, highly recommended to use an accumulator even with automatic boiler systems.

  • Page 24: Scope Of Delivery

    As a result of the built-in standard return flow boost assembly, the HDG K10 - 33 boiler can be operated up to a return temperature of at least 20°C. In this case no external return temperature control is required.

  • Page 25: Installing The Heating System

    4 Cladding 5 Ash container 4.4 Installing the heating system 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 heating system requires comprehensive specialist knowledge.

  • Page 26: Supply

    UPPLY If possible, the boiler and the reservoir are brought by lift truck to the installation site in their crates. Net weight HDG K10/15 HDG K21/26/33 Boiler incl. transport crate 218 kg 239 kg...

  • Page 27: Removing The Transport Pallet

    4 Planning and installation – Installing the heating system EMOVING THE TRANSPORT PALLET Caution! Danger from suspended loads The boiler weighs over 200 kg. If the boiler is dropped during transport, persons can be seriously injured and the boiler can be damaged.

  • Page 28: Installing The Boiler

    4 Planning and installation – Installing the heating system ITH A SACK TRUCK Figure 4/8 - Removing the transport pallet using a sack truck Lay the ratchet strap (1) around the star-grip screw (2) on the cleaning shaft lid. Fasten the ratchet strap (1) to the sack truck. Lift the boiler (3) off the pallet with the sack truck.

  • Page 29: Fitting The Filling And Drain Cock

    4 Planning and installation – Installing the heating system Adjust the boiler horizontally or slightly sloping upwards to the rear using the four positioning screws (1). ✓ The boiler is erected. Figure 4/10 - Aligning the boiler ITTING THE FILLING AND DRAIN COCK Figure 4/11 - Fitting the filling and drain cock Pull the handle (1) off the filling and drain cock (2).
  • Page 30 4 Planning and installation – Installing the heating system Figure 4/12 - Opening the cleaning shaft lid Remove the insulation (1) above the cleaning shaft lid. Release the star-grip screw (2). Lift off the cleaning shaft lid (3). Figure 4/13 - Removing the rear wall Break out the perforation (1) on the rear wall.

  • Page 31: Installing The Reservoir

    4 Planning and installation – Installing the heating system NSTALLING THE RESERVOIR The auger motor is installed under the reservoir on the auger. Figure 4/15 - Installing the auger motor Attach the auger motor (1) (contained in the combustion chamber on delivery) to the holder with the lug at the back and the centring screw at the front.
  • Page 32 4 Planning and installation – Installing the heating system Figure 4/17 - Fastening the reservoir Screw the upper fastening screws (2) all the way in (to the marking). At the bottom, fasten the reservoir using the M8 screw (SW13) (enclosed in a plastic bag in the reservoir) (3). Push the sensor (1) for the auger pipe safety thermostat all the way into the holder.

  • Page 33: Fitting The Cladding

    4 Planning and installation – Installing the heating system Figure 4/21 - Connecting in the plugs and jumpers 12.Fold back the cover (2) of the control panel. 13.Connect the line from the upper proximity switch to the plug X22 (1). 14.Connect the mains plug (2) of the vacuum fan to the plug (4) of the connecting line to the automatic burner.
  • Page 34 4 Planning and installation – Installing the heating system Place the upper cladding (1) above the water tank onto the boiler. Mount the upper cladding (1) with the Phillips screws. Figure 4/24 - Installing the upper cladding Push the middle orifice plate (1) under the cladding or sideways into the recesses on the boiler.
  • Page 35 4 Planning and installation – Installing the heating system Figure 4/28 - Installing the front cladding at the top 10.Hang the front cladding (1) in the left and right container cladding and fasten it at the bottom with the Torx screws. OILER CLADDING Figure 4/29 - Mounting the door hinges 11.Mount the lower door hinge (1) with the four Torx screws.
  • Page 36 19.Connect the connecting lines according to the control unit (1). ✎ See “Electrical plans for HDG K10 - 60”. Figure 4/33 - Mounting the support plate 20.Mount the support plate (1) with the Phillips screws. If the flue pipe connection is fitted at the top, the upper cover must be broken out.

  • Page 37: Installing The Ash Container

    OUNTING THE EXPANSION MODULES Important! If an EM4 or EM8 expansion module is used, these can be mounted directly on the plate above the automatic burner. ✎ For connecting the expansion module, see the “Electrical plans for the HDG K10 - 60”.
  • Page 38 ✓ The EM4 / EM8 expansion modules are fitted. ERVICE PLUG Figure 4/39 - Service plug Important! The service plug (1) is only intended for HDG customer service and may not be connected to any module!

  • Page 39: Connecting The Suction And Return Hoses

    “3.3 Technical data”. ✎ The circuit diagrams for the HDG K10 - 33 can be found in “Electrical plans for the HDG K10 - 60”. The connections for the mains supply line can also be found in this document.

  • Page 40: Water

    4 Planning and installation – Water 4.7 Water Important! The heating system must be filled with water in accordance with VDI guideline 2035, “Avoiding damage in hot water heating systems”. The diaphragm expansion vessel must be constructed in accordance with DIN EN 13831 “Closed expansion vessels with built-in diaphragm for integration in water installations”.

  • 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. The commissioning includes an introduction to the operation and maintenance of the heating system as well as performing measurements on the system to determine exhaust emissions and firing performance.

  • Page 42: Procedure

    • Is there a sufficient quantity of fuel? 5.2 Procedure Important! Commission the HDG K10 - 33 heating system in accordance with the specifications from the supplied commissioning protocol. ✎ See also operating manual “HDG Control”, Chapter “4 Commissioning the system”.

  • Page 43: Using The Heating System

    6 Using the heating system – Control unit for HDG Control 6 Using the heating system 6.1 Control unit for HDG Control ✎ You can find all information and instructions for setting up and operating the boiler and weather-compensated heating control of the HDG Control in the “HDG Control”...

  • Page 44: Filling The Reservoir

    Figure 6/2 - Filling the fuel storage room Switch the heating system on. ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.2 Switching on the heating system”. ✓ The filling of the pellet storage is completed.

  • Page 45: 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 46: Cleaning And Servicing The Heating System

    The HDG K10 - 33 heating system is fitted a cleaning and de-ashing interval display. The "clean" or “main cleaning” prompt appears on the boiler control system display and must be reset after cleaning/ de-ashing.

  • Page 47: Procedure

    Only turn the heating system back on again after carrying out the tasks described below. ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.2 Switching on the heating system”.

  • Page 48: Cleaning Tools

    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”. Allow the fire in the heating system to burn out and cool down.

  • Page 49: Cleaning The Combustion Chamber And Burner Pot

    10.Reinstall the ash container (1) in the reverse sequence. 11.Re-starting the heating system. ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.2 Switching on the heating system”. ✓ The ash container has been emptied.
  • Page 50 7 Cleaning and servicing the heating system – Procedure LEANING THE COMBUSTION CHAMBER Clean combustion chamber temperature sensor (1) using the cleaning brush. Figure 7/5 - Cleaning the combustion chamber temperature sensor Clean the drop chute (1) if necessary, for example using a screwdriver.
  • Page 51 7 Cleaning and servicing the heating system – Procedure Figure 7/10 - Cleaning the cone Clean the cone (1) on all sides using a brush and remove any hard deposits with a scraper. Important! Always remove all the ash from the combustion chamber and burner pot first.

  • Page 52: Cleaning The Flue Gas Fan And Cleaning Shaft

    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”. Allow the fire in the heating system to burn out and cool down. Remove the top right cladding.

  • Page 53: Cleaning The Flue Gas Pipe

    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”. Allow the fire in the heating system to burn out and cool down. Unscrew the wing nut (1) on the inspection hatch lid (2).

  • Page 54: Checking And Cleaning The Reservoir And Flap Of The Delivery Unit

    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”. Allow the fire in the heating system to burn out and cool down.
  • Page 55 7 Cleaning and servicing the heating system – Procedure Pull out the mains plug (1). Figure 7/20 - Removing the mains plug Undo the four screws and remove lower front cladding (1) of the reservoir. Figure 7/21 - Removing the lower front cladding Have a container ready for the pellets.

  • Page 56: Cleaning The Pellet Storage Room

    Switch the heating system off. ENERAL INFORMATION ✎ See the “HDG Control” operating manual, chapter “5 Using the control unit”, section “5.3 Switching off the heating system”. Allow the fire in the heating system to burn out and cool down.
  • Page 57 Leading pellet suppliers recommend completely emptying the pellet storage room every 2–3 years. When operating the heating system with HDG suction system and suction probes, you can deactivate the automatic changeover between the three suction probes using the boiler control system.

  • Page 58: 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 injury due to incorrect dismantling. Dismantling the system requires comprehensive specialist knowledge. If the heating system is dismantled by an untrained person, injuries are possible.
  • Page 59 8 Notes on dismantling and disposal – Disposal The electrical components can also be recycled via a local recycling centre. Fibreglass, mineral wool and plastic parts such as suction hoses etc. should be handed in to the respective waste disposal centres. The geared motors used consist largely of materials which can be recycled.

  • Page 60: Declaration Of Conformity

    Part 5: Heating boilers for solid fuels, hand and automatically fired, nominal heat output of up to 500 kW. Terminology, requirements, testing and marking Massing, 02.08.2017 Place, date Signature Martin Ecker Page 1/1 © HDG K10 - 33 - Version 1 - de HDG Bavaria GmbH 07/2008...

  • Page 61: Index

    Cleaning shaft HDG Control ......14, 43 - Cleaning ......52 Heating system Cleaning tools .
  • Page 62 Weight ........16 © HDG Compact 25/35 - Version 2 - de HDG Bavaria GmbH Oktober 2007...
  • Page 64 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: 9980001814 - V 05 - en - 08/2017 Translation of the original operating instructions...

This manual is also suitable for:

K15K21K26K33

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