HDG F20, Operating Manual

Page 1: ...hdg bavaria com HDG F20 25 30 HDG F40 50 Operating manual ...

Page 2: ......

Page 3: ...iews HDG F20 50 15 3 2 Functional description 16 Boiler HDG F20 50 16 Boiler and weather compensated heating control HDG controls 17 3 3 Technical data 18 HDG F20 25 30 18 HDG F40 50 19 3 4 Fuel quality requirements 20 Log wood 20 Pressed wood briquettes 21 Recommended fuel 21 Permitted fuel in accordance with 1st Federal Emission Control Ordinance Germany 22 4 Planning and installation 23 4 1 Dim...

Page 4: ...ch 50 Fuel selection 51 6 3 Heating up the system 51 General information 51 Procedure 52 6 4 Performing a chimney sweep measurement 60 Before the test 61 On the day of the test 61 During the test 62 6 5 Switching off the heating system for repair work 64 6 6 Troubleshooting 64 7 Cleaning and servicing the heating system 65 7 1 Cleaning and servicing schedule 65 7 2 Procedure 66 Generally applicabl...

Page 5: ...ng manual HDG F20 50 Content 5 Checking the doors are tight 78 Cleaning the ignition fan 80 8 Notes on dismantling and disposal 82 8 1 Dismantling 82 8 2 Disposal 83 9 Declaration of Conformity 84 10 Index 85 ...

Page 6: ... was correct at the time of going to press We reserve the right to make changes which may then differ from the technical details and illustrations in this Operating manual COPYRIGHT Written permission is required from HDG Bavaria GmbH for reprinting storage in a data processing system or transmission by electronic mechanical photographic or any other means and for copies or translations of this pu...

Page 7: ...tended for combined used with a HDG K Hybrid pellt unit Lambda sensor This is an electrical component which monitors residual oxygen levels in the flue gas Safety temperature limiter An automatic device that interrupts and locks the supply of energy and combustion air when the maximum permissible boiler temperature is reached The energy supply or combustion air supply can only be re enabled after ...

Page 8: ...fe use of the device and understand the resulting risks Children may not play with the device Cleaning and user main tenance must not be carried out by children without supervision BASIC PRINCIPLES FOR THE CONTENT OF THE OPERATING MANUAL SCOPE The content of this operating manual is intended exclusively for the planning installation and operation of the HDG F20 50 boiler The further implementation...

Page 9: ...as cooled down before touching non insu lated components Danger Danger of asphyxiation due to carbon monoxide If the boiler is in operation carbon monoxide can be emitted through the open doors or lids Always keep the doors and lids closed Only open them when the boiler has finished burning Do not leave them open any longer than necessary and never leave them open unattended Warning Danger of fire...

Page 10: ...s fan disconnect it from the mains Danger Electric shock Working on live components such as the plug board can result in an electric shock Work on the live components may only be carried out by a qualified electrician Make sure the system is disconnected from the mains and prevented from being switched on again Warning The boiler is under pressure Danger Dangerous electrical current or voltage Wor...

Page 11: ... carbon monoxide Warning Automatic start up Working in areas marked with this symbol can lead to injuries due to automatic start up Danger Danger of explosion A concentration of carbon monoxide that is too high can result in an explosion Caution Danger from suspended loads Working in areas with this symbol may involve danger from falling objects Important Frost danger Only install the heating syst...

Page 12: ... must read the Operating manual prior to beginning work particularly the chapter 2 Safety notes This is especially important for persons who only occasionally work on the heating system for example when cleaning or servicing it The Operating manual must always be kept readily accessible at the place where heating system is installed ...

Page 13: ...tHDG Control Touch 2 Flue gas flap actuating handle 3 Fuel chamber 4 Ash pan 5 Combustion chamber door 6 Actuator secondary air 7 Actuator primary air 8 Fuel chamber door 9 Cleaning system actuating handle 10 Overheat cut off device release button Figure 3 1 Front view HDG F20 50 5 2 8 9 1 4 7 6 3 10 ...

Page 14: ...EM4 extension module optional 3 Side panels 4 Burner nozzle 5 Ash compartment 6 Combustion chamber 7 Nozzle brick 8 Back panels 9 Tubular heat exchanger 10 Cleaning turbulators 11 Flue gas flap 12 Cleaning shaft lid Figure 3 2 Cross section of HDG F20 50 6 7 11 9 8 12 5 4 2 1 3 10 ...

Page 15: ...sleeve for thermal safety device DN 15 IG 5 Supply connection DN 32 inside thread 6 Cleaning motor optional 7 Ignition fan optional 8 Filling draining connection DN 15 IG 9 Flue pipe connection 150 mm 10 Flue gas temperature sensor 11 Lambda sensor 12 Flue gas fan 13 Immersion sleeve for return temperature sensor 14 Return connection DN 32 inside thread Figure 3 3 Rear and side views HDG F20 50 4 ...

Page 16: ... the HDG F20 50 boiler fuel which has been manually placed in the fuel chamber 4 and ignited is degassed through the addition of primary air It can also be ignited automatically using the ignition fan 7 The resulting wood gas is mixed with secondary air in the combustion chamber 2 where it is burnt off Ashes are collected in the large ash compartments 6 for combustion ash and fly ash The air neces...

Page 17: ...nsists of the ready to use control panel and control unit HDG Control Touch on the front of the boiler Using the control unit you can regulate the boiler and call up information on the current process HEATING CIRCUIT CONTROL The HDG controls controls the entire energy management of the heating system including the following depending on the version Accumulator management Weather compensated heatin...

Page 18: ...lculation DIN EN 13384 1 Flue gas temperature Tw at Nominal thermal power lowest thermal power 120 C 120 C 130 C 120 C 140 C 120 C Flue gas mass flow at Nominal thermal power lowest thermal power 0 013 0 010 kg s 0 013 0 010 kg s 0 013 0 010 kg s CO2content at Nominal thermal power lowest thermal power 14 2 13 3 14 2 13 3 14 2 13 3 Required flue draught Pw 10 Pa 10 Pa 10 Pa Diameter of flue pipe c...

Page 19: ...74 W 63 W Voltage frequency AC 1 x 230 V 50 Hz Back up fuse 10 A General boiler data Boiler class 5 Maximum permissible operating pressure 3 bar Maximum supply temperature 95 C Minimum return temperature 60 C Water capacity 180 l Fuel chamber capacity 205 l Weight 830 kg Layout data for flue calculation DIN EN 13384 1 Flue gas temperature Tw at Nominal thermal power lowest thermal power 130 C 120 ...

Page 20: ...value since the water vaporises in the course of the burning process and thereby consumes heat This leads to a decreased efficiency and thus to higher fuel consumption A higher water content in the fuel also results in a steadily decreasing output of the central heating boiler Connection for filling draining bushing DN 15 inside thread Recommended pipe dimensions minimum DN 32 Water side resistanc...

Page 21: ...roperty classes are the length and diameter moisture content and ash content of the fuel LENGTH AND DIAMETER D100 L500 The diameter of the briquettes must not exceed 100 mm and the length must not exceed 500 mm WATER CONTENT The water content must not exceed a maximum of 12 M12 for property class A1 and a maximum of 15 M15 for property class A2 and B ASH CONTENT The ideal ash content is a maximum ...

Page 22: ... we recommend log wood with a diameter of D5 2 5 cm PERMITTED FUEL IN ACCORDANCE WITH 1ST FEDERAL EMISSION CONTROL ORDINANCE GERMANY Additional quality requirements apply in Germany independently of the fuel specification in accordance with DIN EN ISO 17225 In accordance with section 3 1 of German law 1 BimSchV the fuel classes 4 5 6 and 7 may be used in the HDG F20 50 heating system Pay particula...

Page 23: ... mm 1650 mm B Width of boiler 660 mm 760 mm C Height to centre of flue gas connecting pipe 1040 mm 1070 mm D Total length with opened fuel chamber door 1660 mm 1760 mm E Boiler length 1050 mm 1100 mm F Overhang of flue pipe connection 140 mm 140 mm G Diameter of flue pipe connection 150 mm 150 mm Fill opening dimension 470 x 420 mm 520 x 540 mm Table 4 1 Dimensions ...

Page 24: ...ed 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 may not be exceeded More detailed information can be found in the relevant local and national regulations We recommend that objects which are not needed for the operation or maintenance of the heating sy...

Page 25: ... 300 mm at least 300 mm B at least 100 or 600 mm at least 100 or 600 mm C at least 600 or 100 mm at least 600 or 100 mm D 800 mm 800 mm E 660 mm 760 mm F at least 2200 mm at least 2300 mm G at least 1400 mm at least 1500 mm Minimum ceiling height 1900 mm 2000 mm Recommended room height 2300 mm 2300 mm min installation dimensions without cladding and attachments 1025 x 650 x 1585 mm 1075 x 750 x 16...

Page 26: ...ng in Air penetrating from the outside speeds up the cooling of the flue gases These requirements correspond to chimneys of the type conforming to DIN EN 13384 1 2003 03 Thermal and fluid dynamic calculation methods Free standing chimneys require particularly good insulation CHIMNEY DIMENSIONS The system may only be connected to a chimney which has been dimensioned in accordance with DIN EN 13384 ...

Page 27: ...1 m they should be adequately insulated at least 5 cm of mineral wool or equivalent material and if possible fitted with an upward inclination The following should also be considered The connecting piece may not protrude into the chimney If the system flue gas pipe has a larger diameter than the chimney the connecting piece must reduce its diameter to that of the connection In this case the connec...

Page 28: ...equirements In terms of 1 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 SAFETY DEVICES Safety devices e g boiler safety module insufficient water cutout etc must be installed in accordance with DIN EN 12828 2003 Design of water based heating systems in buildings RETUR...

Page 29: ...iciency class A For the HDG F20 50 we recommend Wilo 30 1 7 5 3 way mixing valve DN 32 or equivalent The return temperature control may not be further than 5 metres from the boiler The hydraulic system must be installed in accordance with specific technical principles of heating engineering Take into account the stop cocks required for maintenance work and repairs The return temperature control mu...

Page 30: ...rised HDG partner and a qualified electrician Important Upon delivery small parts are located in the fuel chamber of the HDG F20 50 boiler Danger Risk of material damage and injury due to incorrect installation Installing the system requires comprehensive specialist knowledge If installed by untrained persons the heating system can be damaged and persons may be injured due to secondary damage Only...

Page 31: ... pallet 1 from either the front or rear of the boiler 5 Slide the pallet truck 3 under the boiler 6 Lift the boiler with a lifting truck 3 Caution Beware of suspended loads The boiler weighs over 650 kg If the boiler is dropped during transport persons can be seriously injured and the boiler can be damaged Make sure that you use appropriate lifting gear when placing the boiler Figure 4 4 Removing ...

Page 32: ...laced in position TRANSPORT WITH A CRANE 1 Attach suitable lifting equipment to the crane eyelet 1 provided for this purpose The boiler can now be moved with a crane 2 Remove the transport pallet See section Transporting with a pallet truck 3 Transport the boiler to the desired installation site 4 Place the boiler at the planned location while observing the minimum clearances Figure 4 6 Transporti...

Page 33: ...the flow 1 and the return 3 using the double pipe nipple supplied 2 Insulate the connection extensions with the insulating hoses supplied 2 4 The hydraulic connections are attached HDG F20 50 HYBRID The following tasks must be performed if the HDG F20 50 is configured only as a log wood boiler If the boiler is intended for combined use with a pellet unit proceed with section HDG F20 50 Hybrid Figu...

Page 34: ...uator 10 to the central module and insert the connector in the central module See Electrical plans for the HDG log wood boiler 5 Install the T piece 8 on the double nipple 6 Figure 4 9 Hydraulic connection set HDG F20 50 Hybrid 30 30 2 1 3 4 9 8 6 5 7 10 11 Important When installing the three way switch valve 2 and the T piece 8 ensure the proper installation angle Important If the pellet unit wil...

Page 35: ...ews on the support plate 1 4 Fasten the HDG Control Touch control unit 5 on the support plate 1 with the M4 nut SW7 Important For the further installation of the log wood pellet combination HDG FK Hybrid see the HDG K hybrid operating manual Figure 4 10 Installing the control unit 2 1 4 6 5 3 Important Damage caused by improper disassembly The overheat cut off device 2 is already pre mounted on th...

Page 36: ... boiler 3 Install the cables and sensors on extension module EM4 according to the hydraulic wiring diagram Extension module EM4 is installed The flow return and STL sensors are already installed upon delivery Depending on the hydraulic application an EM4 extension module may have to be used Important If the EM4 extension module is used this must be installed on the top next to the central module I...

Page 37: ...orrect cabling If live cables and sensor cables are installed in the same ducts it can cause the sensors to malfunction Ensure that the live wires and the sensor cables are installed in different cable ducts 3 Please note that here only the assembly of the HDG controls unit is described The remaining electrical installations depend on the hydraulic system and can be installed based on the specific...

Page 38: ...witch on the boiler 9 Slide the empty pipe 5 in the area of the cleaning system lever over the silicone hose 7 10 Insert the silicone hose 7 on the hose nozzle 8 and on the top connection on the differential pressure switch 4 11 Insert the flat plug receptacle of the brown wire from the cable for the differential pressure switch into socket 1 1 12 Insert the flat plug receptacle of the white wire ...

Page 39: ...s for the HDG log wood boiler The automatic ignition is now installed INSTALLING THE AUTOMATIC CLEANING SYSTEM 1 Unscrew the M8 nut SW13 and pull the actuating lever 1 of the cleaning system forward 2 Unscrew the M5 hexagon socket screws SW4 and remove the small lever 3 3 Remove the perforated insulation 2 Important Make sure that the line from the ignition fan is fitted so that it does not come i...

Page 40: ...n the threaded pin 3 10 With the help of the M8 nuts SW13 set the spacing of the support plate 4 so that the hook 5 runs centred on the roller of the lever 6 11 Run the cable from the cleaning system motor and from the limit switch to the central module and insert it at slot x50 or X33 Also refer to Electrical plans for the HDG log wood boiler The automatic cleaning system is now installed FITTING...

Page 41: ...late 8 Ash pan 9 Front cladding 10 Bottom right side cladding 11 Automatic ignition cleaning system cover optional 12 Top right side cladding 13 Top front cover BASE PLATE 1 Slide the base plate 3 under the boiler until the holes 3 in the base plate overlap into the recesses 1 in the base Figure 4 16 Overview of cladding parts 3 4 1 2 5 6 7 8 9 10 12 13 11 Figure 4 17 Sliding in the base plate 2 3...

Page 42: ...sing a side cutter or hacksaw and deburr the opening Figure 4 18 Fitting the lower side cladding 3 2 4 1 Figure 4 19 Fitting the upper side cladding 1 3 2 Important The small perforated recess 3 only needs to be cleared out if the boiler is equipped with the HDG automatic ignition system and or HDG automatic cleaning system The large perforated recess 2 only needs to be cleared out if the boiler i...

Page 43: ...de cover 5 into the side cladding 4 and fasten it at the bottom with the two drilling screws 6 Proceed in the same manner described above for fitting the cladding on the left side REAR CLADDING 7 Hang the lower rear cladding 4 into the base plate and into the two bottom cladding brackets 2 5 Figure 4 20 Fitting the upper side cladding 1 5 4 2 Figure 4 21 Installing the rear cladding 3 2 4 5 1 ...

Page 44: ...the recesses of the left and right hand side cladding 11 Put the top front cover 3 with the tabs into the recesses of the left and right hand side cladding and lock it with a flathead screwdriver Important Make sure that the cables for the flue gas fan the lambda sensor and the flue gas temperature sensor are routed outside the rear cladding to the recess 1 in the side cladding Important The suppe...

Page 45: ... system The electrical connections must be made in accordance with DIN IEC 60364 Setting up low voltage electrical installations The technical details are described in chapter 3 Mode of operation section 3 3 Technical data The circuit diagram is enclosed with the supplied documentation This is created based on the system selected 4 9 Water Before putting the system into operation the pressure of t...

Page 46: ...st regulation However the safety heat exchanger and thermal safety device can only serve their purpose if the following requirements have been met A flow pressure of at least two bar must be available at the cold water inlet of the safety heat exchanger The distance between the supply and return lines of the thermal safety device and the safety heat exchanger should not be less than their nominal ...

Page 47: ...eat exchanger inlet DN 15 outsize thread 2 Thermal safety device TAS 3 Safety heat exchanger outlet DN 15 outside thread 4 Connection bushing for TAS immersion sleeve DN 15 inside thread 5 Runoff connection to drainage system Figure 4 23 HDG F20 50 thermal safety device 2 1 5 4 3 ...

Page 48: ...een adapted to on site conditions All required DIN EN 12828 safety devices have been installed and are ready for operation The power supply to all components is ensured Makeshift solutions are not sufficient The chimney installation corresponds to the legal regulations All doors and openings on the boiler and on the chimney connection pipe have been checked for a proper seal Air supply for combust...

Page 49: ...ing switch will light up The control is activated See the HDG Control operating manual chapter Commissioning the system TESTING SYSTEM COMPONENTS PROCEDURE See the HDG Control operating manual 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 The system component test can only be conducted in the Boile...

Page 50: ...CH The system is connected to the mains supply through an emergency heating switch provided by the customer or through a circuit breaker in the mains distribution box of the building 1 Switch on the heating system at the corresponding circuit breaker or the emergency heating switch provided by the customer The heating system is now under voltage The control is activated The heating system is switc...

Page 51: ...e g inside doors can result in burns Wait until the boiler has cooled down before touching non insulated components Warning Danger of asphyxiation due to carbon monoxide If the boiler is operating carbon monoxide can be emitted through open doors Do not leave the doors open any longer than necessary Caution Danger of fire When the boiler is in operation open doors constitute a fire danger Do not l...

Page 52: ... is running 4 Continue without changing the settings with point 18 We recommend wearing leather gloves when heating up the system Caution Damage caused by unintended fuel fomentation Residual embers in the fuel chamber can lead to unintended fuel fomentation This can cause the heating system to overheat and subsequently for dangerous operating conditions to arise Ensure when filling that residual ...

Page 53: ...oisture of the fuel 11 Confirm your input by pressing the Confirm button 1 The Fill up Reload window appears in the display again 12 Press the Ignition mode The Ignition mode selection window appears in the display Figure 6 3 Query wood type 1 Figure 6 4 Query wood moisture 1 Ignition modes Manual The fuel is ignited manually with firelighters Electrical The fuel is automatically ignited by the ig...

Page 54: ...rature 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 Accumulator temperature and requirement The automatic ignition starts after the set accumulator temperature is undershot and if there is a requirement from a consumer heating circuits domestic hot...

Page 55: ...ÄNDERN 18 Wait until the progress bar is full The Open fuel chamber door to safety position message appears in the display 19 Open the fuel chamber door to the safety position 20 Wait until the progress bar is full The Openfuelchamberdoorslowly message appears in the display Figure 6 7 Ignition changing settings 1 Figure 6 8 Do not open the fuel chamber door Figure 6 9 Opening the fuel chamber doo...

Page 56: ...cardboard on top of the wood inside the fuel chamber 3 25 Ignite the fuel 26 Allow the fuel to generate a good fire Figure 6 10 Open the fuel chamber door slowly Figure 6 11 Filling the fuel chamber 3 1 4 2 For kindling we recommend log wood with a diameter of D5 2 5 cm We recommend using bio firelighters consisting of wood shavings soaked in paraffin In contrast to newsprint these firelighters ar...

Page 57: ...the display 31 Make sure that all of the doors are closed 32 Wait until the progress bar is completely full 33 The Ignite message appears in the display The HDG F20 50 boiler is now heated up ELECTRIC IGNITION 24 Stack some highly flammable material small pieces of dry wood in front of the igniter gun 2 and about 10 cm high on the burner nozzle 4 so that it is covered Figure 6 12 Filling the fuel ...

Page 58: ...layed 29 Confirm your input by pressing the Confirm button 1 The Close doors message appears in the display 30 Make sure that all of the doors are closed 31 Wait until the progress bar is full The Underpressure test message appears in the display 32 Wait until the progress bar is full Only put in as much wood as the heating system and accumulator can absorb as energy Figure 6 15 Filling the fuel c...

Page 59: ...iter gun 2 on the wood inside the fuel chamber 3 26 Fill the fuel chamber 3 according to the percentage specified on the display 27 Close the fuel chamber door 1 28 The message Fill fuel chamber and confirm ignition is displayed 29 Confirm your input by pressing the Confirm button 1 The Close doors message appears in the display The differential pressure switch enables the ignition fan if the pres...

Page 60: ...ral emission limits for small and medium sized boiler systems are met 1st Federal Emission Control Ordinance INITIAL TEST The operating company must notify the responsible combustion engineer of the installation of the heating system before it is commissioned and must also arrange an appointment for the chimney sweep test within four weeks of commissioning To ensure a stable operating ability suff...

Page 61: ...jury due to incorrect chimney sweep test The chimney sweep test requires comprehensive technical knowledge Only allow authorised specialists to perform the chimney sweep test Important The boiler must have been heated at least once during the period between the cleaning and the chimney sweep test Oakwood wood briquettes boards scrap wood and wood chips are not suitable for the chimney sweep test A...

Page 62: ... controls chimney sweep test 7 Press the Main menu button in the standard display The display switches to the main menu 8 Press the Messages Maintenance field The display switches to the Messages Maintenance area 9 Press the Chimney sweep test field A security query appears Danger Danger of asphyxiation and explosion from carbon monoxide When the boiler is in operation carbon monoxide can be emitt...

Page 63: ...n show Measurement done The chimney sweep test can be started 6 5 Switching off the heating system for repair work 1 Allow the fire in the boiler to burn out and cool off 2 Switch the heating system off Figure 6 23 Chimney sweep test security query 1 Figure 6 24 Chimney sweep test 1 Pressing the Cancel test button 1 cancels the chimney sweep test If you do not change the operating mode within 45 m...

Page 64: ...f the emergency heating switch if installed or the corresponding mains electricity circuit breaker The heating system is switched off and without current 6 6 Troubleshooting If a fault occurs in the heating system this is shown in the display of the HDG controls See the HDG Control operating manual chapter 10 Troubleshooting There is still electrical voltage in the system ...

Page 65: ...e parts from your specialist heating company The specified cleaning intervals are guidelines These intervals may vary according to the quality of the fuel and the power used by the heating system Interval Component See page Weekly as required Clean the fuel chamber and secondary air openings Clean the secondary combustion chamber and ash compartment 67 69 Every 6 months approx 900 operating hours ...

Page 66: ...g system off and only start with the cleaning and maintenance work when the surfaces have cooled down Warning Danger of fire When the heating system is in operation open doors and lids constitute a fire hazard Always keep the doors and lids closed Only open them when the boiler has finished burning Do not leave them open any longer than necessary and never leave them open unattended Warning Danger...

Page 67: ...appears in the display 3 Confirm your entry by pressing the Confirm button The Donotopenfuelchamberdoor message appears in the display The flue gas fan is running 4 Wait until the progress bar is full The Open fuel chamber door to safety position message appears in the display 5 Open the fuel chamber door to the safety position 6 Wait until the progress bar is full The Openfuelchamberdoorslowly me...

Page 68: ... wood and charcoal in the fuel chamber 4 11 Remove the two piece burner nozzle 3 12 Clean the secondary air openings 5 with the cleaning tool supplied or with a vacuum cleaner 13 Carefully reinsert the burner nozzle 3 14 Close the fuel chamber door 2 The actuating lever 1 of the flue gas flap is unlocked 15 Press the Confirm button on the display On the display of the control unit the Ready messag...

Page 69: ...out moving the combustion chamber stones carefully pull out the combustion residue from the secondary combustion chamber 1 in the ash compartment 3 8 Using the supplied cleaning tools pull the combustion residue out of the ash compartment 3 into the ash pan 4 9 Empty the combustion residue into a fireproof container 10 Close the boiler in the reverse order The secondary combustion chamber and the ...

Page 70: ...ozzle 4 6 Reinstall the lambda sensor 2 in the reverse sequence 7 Check the lambda sensor 2 for a secure fit 8 Carefully tighten the lambda sensor 2 with a 22 mm spanner The lambda sensor has been checked and cleaned Important Observe the Generally applicable safety instructions in this section Figure 7 4 Cleaning the lambda sensor 1 3 2 4 Important Steel bristles will damage the lambda sensor Imp...

Page 71: ...e clamp screw connections 3 Clean the sensor surface with a moist cloth 4 Mount the flue gas temperature sensor 1 in the reverse sequence The flue gas temperature sensor has been cleaned Important Observe the Generally applicable safety instructions in this section Figure 7 5 Cleaning the flue gas temperature sensor 2 1 The flue gas temperature sensor must be installed so that the sensor element p...

Page 72: ...Observe the Generally applicable safety instructions in this section 2 Unscrew the wing nut 1 on the inspection hatch cover 2 3 Remove the inspection hatch cover 2 from the flue gas pipe 3 4 Check whether the flue gas pipe 3 needs cleaning 5 If necessary extract the ash from the flue gas pipe 3 using a vacuum cleaner Figure 7 6 Clean the flue gas pipe 1 2 3 Important Observe the Generally applicab...

Page 73: ...s and check whether the cleaning mechanism moves freely 7 Pull the actuating handle 1 of the flue gas flap to the front until it latches into place HDG F20 25 30 8 Inspect the cleaning shaft 1 for deposits 9 If necessary remove deposits and dust with a vacuum cleaner 10 Clean the flue gas flap 4 and the suction channel behind it with a suitable cleaning tool e g scraper or with a vacuum cleaner 11...

Page 74: ...n the reverse sequence 19 Close the boiler in the reverse sequence 20 Make sure that the cleaning shaft lid is closed properly The cleaning system the heat exchanger surfaces and the flue gas flap have been cleaned HDG F40 50 8 Inspect the cleaning shaft 1 for deposits Figure 7 9 Pulling out the cleaning turbulators 5 4 2 1 3 Important When cleaning the heat exchanger surfaces always first push th...

Page 75: ...bar 5 in an upward direction 16 Pull out the cleaning turbulators 2 in an upward direction 17 Clean the heat exchanger pipes 3 using the round cleaning brush 18 Mount the cleaning turbulators in the reverse sequence 19 Close the boiler in the reverse sequence 20 Make sure that the cleaning shaft lid is closed properly The cleaning system the heat exchanger surfaces and the flue gas flap have been ...

Page 76: ...and the annular gap behind it with a cleaning tool 6 Inspect the contact surfaces 2 4 of the flue fan and the flue gas collection box 7 Reinstall the flue gas fan in the reverse sequence The flue gas fan has been cleaned Important Observe the Generally applicable safety instructions in this section Caution Risk of injury from automatically driven components Working on the flue gas fan can lead to ...

Page 77: ...r to remove dust deposits from the fan control unit 1 4 Carefully press on the two rotary vanes behind the actuators and make sure that these can move 5 Close the air control unit in reverse order The air control unit is cleaned CLEANING THE PANELS Important Observe the Generally applicable safety instructions in this section Figure 7 13 Cleaning the air control unit 1 2 Important Observe the Gene...

Page 78: ...stall the panels 2 in reverse order 7 Close the fuel chamber door 1 Cleaning of the panels is complete CHECKING THE DOORS ARE TIGHT FUEL CHAMBER DOOR 1 Allow the fire in the boiler to burn out and cool off 2 Open the fuel chamber door 1 See Cleaning the fuel chamber and secondary air openings in this section Figure 7 14 Clean the panels 1 2 Important Observe the Generally applicable safety instruc...

Page 79: ...ave inspected all four of the contact surfaces 3 8 Remove the paper and close the fuel chamber door 1 The inspection of the fuel chamber door is complete COMBUSTION CHAMBER DOOR 9 Check the sealing of the ash door 1 exactly as described above under Fuel chamber door The combustion chamber door has been checked for tightness CLEANING SHAFT LID Figure 7 16 Checking the combustion chamber door for le...

Page 80: ...of the hot air nozzle 5 6 Pull off the hot air nozzle 5 7 Remove the insulating tube 6 and the seal 3 The ignition fan is only available in connection with the HDG automatic ignition system Important Observe the Generally applicable safety instructions in this section Caution Danger of burns from hot surfaces The hot air nozzle of the ignition fan becomes very hot during operation Even when turned...

Page 81: ... the heating element 2 for dirt 10 Remove any dirt by blowing it off 11 Check the photocell 1 for dirt 12 Remove any dirt using a cotton swab 13 Reinstall the ignition fan into the heating system in the reverse sequence 14 Fit the side cover 15 Re starting the heating system The cleaning of the ignition fan is completed ...

Page 82: ...r supply 4 Once it has cooled down drain the heating water from the system 5 Observe the safety regulations for personnel when disconnecting the boiler from the heating system 6 Dismantle the individual components of the boiler The boiler has been dismantled Danger Material damage and personal injury due to incorrect dismantling Dismantling the system requires comprehensive specialist knowledge If...

Page 83: ...ia a local recycling centre Boiler Cladding The electrical components can also be recycled via a local recycling centre 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 ...

Page 84: ... of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC 97 23 EC Pressure Equipment Directive 97 23 EC on the approximation of the laws of the Member States concerning pressure equipment In accordance with section 2 of article 7 the applied harmonized regulations are to be found under EN ...

Page 85: ...f Conformity 84 Dimensions 23 DIN EN ISO 17225 20 Dismantling 82 Display 7 Disposal 83 E Efficiency 18 19 Electrical power consumption 18 19 Electrical system 28 45 EM8 extension module 36 EM8 4 extension module 36 Emergency heating switch 50 Extension module EM4 Mounting 36 F Filling draining 18 20 connection 15 Flue calculation 18 19 26 Flue draught requirement 26 61 Flue gas fan 15 Cleaning 76 ...

Page 86: ...sidual risks 9 Return connection 15 18 19 Return temperature control 28 Room height 25 S Safety heat exchanger 15 connection 18 19 Scope of delivery 30 Secondary combustion chamber 14 Sensor 7 Sound pressure level 19 20 Spare parts 65 Supply connection 15 18 19 Supply temperature 18 19 T Target 18 19 Technical data 18 Thermal safety device 7 46 Transport 32 Tubular heat exchanger 14 V Voltage 18 W...

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Page 88: ...aria GmbH Heizsysteme für Holz Siemensstraße 22 D 84323 Massing Tel 49 0 8724 897 0 info hdg bavaria com www hdg bavaria com Art Nr 9980001706 V 02 en 05 2016 Translation of the original operating instructions ...