Planning and installation guide HDG Compact 50/65 with HDG Hydronic

Transcription

1 Planning and installation guide HDG Compact 50/65 with HDG Hydronic HDG Bavaria GmbH November 2006 HDG Compact - Version - en

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3 Planning and installation guide HDG Compact - Content Content Notes on this guide Introduction Structure of the Planning and installation guide Glossary Safety notes Intended use Basic principles for the construction of the system Proper and improper manner of operation Permissible fuel Residual risk Warnings and safety symbols used Duty to inform Planning the heating system Overview Mode of operation The HDG Compact boiler HDG Compatronic Delivery system HDG Hydronic (option) HDG Hydronic controller functions (option) Technical data Fuel quality requirements Wood fuel products Wood pellets Burning characteristics of the wood pellets Building requirements Necessary room sizes and minimum spacing Boiler room Fuel bunker Connections Chimney Electrical system Water Installing the heating system Requirements Scope of delivery HDG Compact Installing the boiler Installing the automatic ash removal system HDG Bavaria GmbH November 2006 HDG Compact - Version - en

4 Planning and installation guide HDG Compact - Content Wiring the circuit boards Installing the boiler cladding Mounting and adjusting the ash boxes Connecting the chimney HDG Hydronic Installing the control unit Installing the sensors Electrical system Water Starting the system HDG hydraulic systems Circuit diagrams HDG Compatronic circuit diagram HDG Hydronic circuit diagram HDG Compact - Version - en HDG Bavaria GmbH November 2006

5 Notes on this guide Introduction Notes on this guide. Introduction Plan and install easily and safely This Planning and installation guide contains important information on planning and installing the following components properly and safely: HDG Compact boiler Fuel bunker Hydronic (optional) Reading the Planning and installation guide Technical changes Copyright Symbols used Following these instructions means that danger can be avoided, repair costs and breakdowns can be prevented, reliability can be maintained and that the operational life of the heating system can be increased. The Planning and installation guide must be read and applied by everyone who plans or carries out the installation of the HDG Compact boiler. We continuously develop and improve our boilers. The information in this version was correct at the time of going to press. All details in these instructions on standards, regulations and worksheets should be checked before use and should be compared with the regulations applying locally at the installation location. We reserve the right to make changes which may then deviate from the technical details and illustrations in this Planning and installation guide. Written agreement is required from HDG Bavaria GmbH for any reprints, storage in a data-processing system or transmission by electronic, mechanical, photographic or any other means, for copies or translations of this publication, in whole or in part. In this Planning and installation guide the following presentation or symbols will be used for particularly important information:. Instructions to the operator 2. Work through the steps in the sequence specified. The result of the action described Cross reference for more explanation List Turn the main switch of the heating system on/off. 5 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

6 Notes on this guide Structure of the Planning and installation guide.2 Structure of the Planning and installation guide Chapter Here you see,... The Planning and installation guide are structured as follows: Notes on this guide... how to use this Planning and installation guide. 2 Safety notes... everything on the subject of safety that you should consider when using the heating system. 3 Planning the heating system... what you need to consider when planning the heating system. 4 Installing the heating system... what you need to consider when installing the heating system. 5 Appendix... how to properly connect the heating system. Table / - Structure of the Planning and installation guide 6 HDG Compact - Version - en HDG Bavaria GmbH November 2006

7 Notes on this guide Glossary.3 Glossary Term Actuator Ash removal motor Delivery system Feed system Display Ash removal worms Main switch HDG Compact HDG Compatronic HDG Hydronic Extinguisher Emergency off switch Grating motor Sliding tray Sensor Stoker worm Rotary feeder Explanation This is a component which carries out a certain function in the heating system, e.g. the combustion fan Powers the ash removal worms and the sliding tray Fuel transport system - carries fuel from the bunker to the dosing unit or to the intermediate container Feeds the fuel to the boiler by means of the stoker worm Display of the HDG Compatronic control unit Transports the combustion chamber ash and fly ash into the exterior ash containers Switches off the mains supply to the entire heating system Boiler for burning wood chips, shavings and wood pellets Electronic control of the boiler, feed system and delivery system Heating system regulator for controlling the hydraulic systems Extinguishes the contents of the delivery system if the temperature of the contents exceeds 90 C Must be used in an emergency - interrupts all actuators, does not switch off the mains supply to the entire heating system Electric motor which moves the dumping grate Transport of the fly ash of the downstream heating areas into the flay ash chamber Records certain parameters (temperature, fill level) and forwards them to the control system for analysis Carries the fuel from the rotary feeder into the combustion chamber Part of the feed system - separates the combustion chamber from the silo and transport unit and serves as a protection against the fire burning back into the feed Table /2 - Glossary 7 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

8 2 Safety notes Intended use 2 Safety notes 2. Intended use Basic principles for the construction of the system Basic principles Using the heating system The heating system was built using state of the art technology and conforms to recognised safety regulations. However, its use can result in the injury or death of the user or a third party or in impairments to the heating system itself or to other material goods. Have your specialist heating company provide you with a detailed explanation of the operation of the heating system. Only use the heating system when it is in perfect condition. Use it properly, as intended, staying aware of safety and of the dangers involved, following the Planning and installation guide. Have any faults which could impair safety immediately fixed. Proper and improper manner of operation Application of the heating system The heating system is designed for the burning of wood fuel products made from untreated wood and for fuels from wood processing plants. Any other use is improper. The manufacturer will accept no responsibility for any damage resulting from improper use. The operator will bear sole responsibility. Proper use includes maintaining the installation, operation and maintenance conditions specified by the manufacturer. You may only enter or change the operating values specified in this guide. Any other entries will affect the heating system's control program and could lead to a malfunction. 8 HDG Compact - Version - en HDG Bavaria GmbH November 2006

9 2 Safety notes Intended use Permissible fuel The heating system HDG Compact is designed for the use of wood fuel products from untreated wood and for fuels from wood processing plants, such as shavings and wood pellets. Fuel class 4 Fuel class 5 Fuel class 6 Fuel class 7 In accordance with section 3 () of German law (. BimSchV), the fuel classes 4, 5, 6, and 7 may be used. Untreated log wood including adhering bark, in the form of wood shavings for example. Untreated wood (not log wood), in the form of shavings for example. Painted, varnished or coated wood including remains thereof, providing no wood protection agents have been applied or added and the coatings are not made of organic halogen compounds. Plywood, chipboard, fibreboard or otherwise glued wood including remains thereof, providing no wood protection agents have been applied or added and the coatings are not made of organic halogen compounds. Should the fuel classes 6 or 7 be used in a wood processing plant at 50 kw or more nominal thermal power, it should be noted that in the case of painted, varnished or coated wood, greater demand can be placed on the wearing parts such as wall lining, fill level sensors and exhaust sensors, reducing their service lives. Wood pellets Wood pellets are pressed into a cylindrical shape. They consist of untreated shavings and sawdust from the wood processing industry as well as unprocessed forestry waste. They have a standardised diameter and length. They are pressed at a very high pressure and have a very low water content. Recommended fuel HDG Bavaria recommends fuel of grain size G 30 and a maximum 0% proportion of finer content. The fuel should have as little moisture as possible, with 20% moisture being ideal. The drier the fuel, the higher the thermal value and the higher the burning efficiency that is achieved. High quality fuel aids in energy conservation and maintains the operating safety of your heating system. The specifications of ÖNORM 733 are to be used as recommended values. For HDG Compact heating systems, it is possible to use wood fuel products of grain size G 50 with a maximum moisture content of up to 45%. However, reduced efficiency may thereby result. Fuels with a higher moisture content are not suitable for burning. For operation of the heating system with wood pellets, HDG Bavaria recommends pellets certified as DIN plus. This certification incorporates the standards of both DIN 573 and ÖNORM 735. The manufacturing plants which produce products with this certification undergo voluntary unannounced inspections twice annually by an independent centre. 9 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

10 2 Safety notes Residual risk Pay particular attention to the fuel quality, both when ordering and during the delivery. In regard to the quality requirements for wood fuel products, the standard ÖNORM 733 concerning the requirements and testing regulations of wood fuel products for energy production is applicable. For more information on fuel, see section 3.4 Fuel quality requirements in chapter 3 Planning the heating system". 2.2 Residual risk Despite all precautions, the following residual risks remain: Caution! Hot surface Contact with the hot surface of the boiler can lead to burns. Wait until the boiler has cooled down before touching uninsulated components. Warning! Danger of asphyxiation due to carbon monoxide. If the boiler is operating, carbon monoxide can be emitted through the cleaning or inspection openings. Do not leave these open any longer than necessary. Caution! Danger from suspended loads. The boiler weighs over 250 kg. If the boiler is dropped during transport, people can be seriously injured and the boiler can be damaged. Make sure that you use appropriate lifting gear when installing the boiler. 0 HDG Compact - Version - en HDG Bavaria GmbH November 2006

11 2 Safety notes Warnings and safety symbols used Caution! Danger of injury The cleaning shaft lid is heavy and can fall shut. Hands and arms can thereby be crushed. Take care not to bump into the opened cleaning shaft lid and cause it to fall shut. 2.3 Warnings and safety symbols used The following warnings and safety symbols are used in this Planning and installation guide: Danger! Danger from electrical current or voltage. Work on areas marked with this symbol may only be done by a qualified electrician. Warning! Warning about a dangerous location. Work on areas marked with this symbol can lead to serious injuries or to extensive material damage. Caution! Hand injuries Work on locations marked with this symbol can lead to hand injuries. Caution! Hot surface Work on locations marked with this symbol can lead to burns. Caution! Danger of fire Work on locations marked with this symbol can lead to a fire. HDG Bavaria GmbH November 2006 HDG Compact - Version - en

12 2 Safety notes Duty to inform Caution! Frost danger Work on locations marked with this symbol can lead to frost damage. Notes on disposal. Additional information for the operator. 2.4 Duty to inform Reading the Planning and installation guide Everyone who works on the system must have read the Planning and installation guide before starting work and, in particular, have read the chapter 2 Safety notes. This holds especially true for persons who only occasionally work on the system, e.g. when cleaning or maintaining the heating system. This Planning and installation guide must be kept easily accessible at the heating system's installation location. 2 HDG Compact - Version - en HDG Bavaria GmbH November 2006

13 3 Planning the heating system Overview 3 Planning the heating system 3. Overview The heating system HDG Compact is available in the following versions: Standard version with inserted ash boxes, without cleaning system and delivery worms Feed system on left Feed system on right Convenience model with automatic cleaning system and ash removal system Feed system on left Feed system on right In this Planning and installation guide, the convenience version with left-mounted feed system is described and depicted. Specifications on the delivery systems are not included. The heating system contains the following components: Figure 3/ - Overview Access hatch 2 Sloping floor 3 Delivery system 4 HDG Hydronic (option) 5 Feed system 6 HDG Compact boiler with HDG Compatronic 3 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

14 -6,3% 3 Planning the heating system Mode of operation 3.2 Mode of operation Front side The HDG Compact boiler Figure 3/2 - Front side of the HDG Compact boiler HDG Compatronic control panel 2 Drive for automatic cleaning 3 Emergency off switch 4 Oxygen sensor 5 Downstream heating areas with turbulaters 6 Sliding tray 7 Automatic ash removal system 8 Dumping grate for combustion chamber primary burning 9 Feed system with stoker worm 0 Combustion chamber secondary burning 4 HDG Compact - Version - en HDG Bavaria GmbH November 2006

15 3 Planning the heating system Mode of operation Back side Figure 3/3 - Back side of HDG Compact boiler Immersion sensor bushing, thermal safety device 2 Connections of safety heat exchanger 3 Main switch 4 Pressure equalisation hose 5 Combustion fan 6 Primary air servo motor 7 Ash removal motor 8 Dumping grate motor 9 Secondary air servo motor 0 Ignition fan In the HDG Compact boiler, the fuel introduced into the combustion chamber is automatically ignited with an electrical ignition fan. In order to remove the produced ash from the grate, the grate is tilted. The ash falls into the ash boxes for the ash of the combustion chamber or is transported into the ash containers by the automatic ash removal system (optional). 5 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

16 3 Planning the heating system Mode of operation The produced fly ash falls into the ash boxes or is conveyed into the ash container by the automatic ash removal system (optional). The air necessary for combustion is supplied as required via two servo drives. Via sensors: the firing is permanently monitored, the boiler power is adjusted to the heat requirement, emissions are minimised and boiler efficiency is optimised. HDG Compatronic Figure 3/4 - HDG Compatronic control unit The boiler control unit of the HDG Compatronic is the electronic hub. It consists of the central unit and the transport module in the switching cabinet and the control unit on the front side of the HDG Compact boiler. Via the control unit, you can adjust the HDG Compact and obtain information on the current process status. If the HDG Compatronic issues a request for more heat, the HDG Compact automatically goes into the Fill operating mode and the combustion chamber is filled with fuel. Once the desired boiler temperature has been reached, i.e. the need for heat has been met, the heating system changes to the operating status Burn out and subsequently to the operating status No demand. 6 HDG Compact - Version - en HDG Bavaria GmbH November 2006

17 3 Planning the heating system Mode of operation You can choose between three control versions: Without control: Constant feed rate and constant combustion air flow-rate (even in emergency operation) Combustion control: Constant specified combustion chamber temperature and optimal combustion (standard version, most frequently implemented) Control of combustion and power: The power supplied is adjusted to the heat used with optimised combustion Delivery system The delivery system is in the fuel bunker. Depending on the delivery version, the fuel is transported from the fuel bunker to the dosing unit or to the intermediate container. The delivery system is controlled via the HDG Compatronic. HDG Hydronic (option) The HDG Hydronic is a heating system regulator, which is attuned to the HDG hydraulic systems. HDG Hydronic deals with the entire energy management for the heating system and, depending on the version, controls up to three weather-controlled heating circuits, as well as: Heating hot water District heating transfer Connection to second boiler Solar system for hot water and support of the heating system The HDG Hydronic can be extended to up to 24 heating circuits. HDG Hydronic controller functions (option) Basic functions of the heating circuit control The heating circuit control always operates at a characteristic heating curve controlled by the outdoor air temperature. For each heating system the characteristic heating curve is used to calculate the supply water temperature which is appropriate for the current outdoor temperature. Other factors which influence the calculated water temperature are the steepness of the characteristic heating curve, the correction for this (parallel shift) and the preset value for the room temperature. 7 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

18 3 Planning the heating system Mode of operation If the heating circuit control is operating, room temperature will be adjusted to a preset daytime or night-time value. Supply temperature ,5 Figure 3/5 - Diagram of the temperature of water leaving the boiler 3, Outside temperature Example: Outdoor temperature - 5 C Steepness.6 Parallel shift 5 C With these presumed values, from Figure 3/5 - Diagram of the temperature of water leaving the boiler you can read off a temperature for water leaving the boiler of 67 C. If an indoor thermostat unit is also connected, the comparison between the preset and the actual room temperature and the room influence factor are also included in the calculation of the required water temperature leaving the boiler. The temperature difference is multiplied by the room influence factor and is then added to the preset room temperature. The room influence factor expresses how strongly any deviation of the room temperature should affect the water temperature leaving the boiler. If no indoor thermostat unit is connected, the preset day and night temperatures are used for the calculation. 2,5 2,0,6,5 Parallel shift,0 0,8 0,5 External temperature switch off If the outdoor temperature exceeds the preset room temperature or the preset outdoor switch-off temperature, the status of the heating circuit changes to OFF. 8 HDG Compact - Version - en HDG Bavaria GmbH November 2006

19 3 Planning the heating system Mode of operation Indoor thermostat unit (room sensor) If an indoor thermostat unit is connected, the target room temperature is calculated from the preset day and night room temperatures, the room influence factor and the current measured room temperature. Heating systems for the heating circuits In the group of parameters for the hydraulic system, for each of the various heating circuits the corresponding heating system is configured. You have a choice of five heating systems: None This is selected when a heating circuit is not needed. All submenus for this heating circuit are then disabled. Radiators If this heating system is selected, the corresponding parameters are loaded and a characteristic heating curve issued. Floor heating If this heating system is selected, the corresponding parameters are calculated for a flatter characteristic heating curve and a lower design temperature. With this heating system, you also have the option of activating a screed drying program. Constant This system operates independently from the temperature outdoors and maintains a constant water temperature as it leaves the boiler. This system is suitable for instance to control the heating of a swimming pool. An indoor thermostat unit is not possible with this heating system. Uncontrolled In an uncontrolled heating system, only the enable temperature and the time program are active. This heating system works without a heating circuit mixer and, if combined with an indoor thermostat unit, switches the pump off after reaching the preset room temperature. 9 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

20 3 Planning the heating system Mode of operation Screed drying program If the heating system includes a newly laid floor heating system, you can configure a drying period. Floor heating must be set as the heating system. After starting, the supply water temperature is adjusted to minimum screed drying temp. The supply water temperature is increased in defined daily cycles by screed drying temp. increase, until the maximum screed drying temp. is reached. At this temperature, the supply water temperature is held for screed drying hold time. Subsequently, following the principle described above, the water supply temperature is reduced until the minimum screed drying temperature is reached. The heating circuit changes to the status OFF. Hold time Supply maximum Temperature Increas Increase in preset Minimum sup Days Figure 3/6 - Diagram of the screed drying program Anti-seizing protection For the boiler status OFF or NO DEMAND, the hot water pump and heating circuit mixer are activated every 7 days to help prevent the pumps from seizing. Hot water Depending on the installed hydraulic system, the hot water supply can be delivered via a combination buffer tank or via an external hot water tank. If a hydraulic system with a hot water tank is installed, the following points must be considered: For hot-water, a weekly program (two periods per day) can be selected. Only during this time is hot water available, taking into account the enable temperature for the hot water pump. You can specify the temperature of the hot water supply. If this temperature falls below the preset hot water temperature by the amount of the hysteresis (temperature difference between target and actual temperature e.g. 5 K), the hot water heating pump starts. 20 HDG Compact - Version - en HDG Bavaria GmbH November 2006

21 3 Planning the heating system Mode of operation Hot water priority You can give priority to hot water. This means that if hot water is on, the supply temperature to the heating circuit is reduced. The duration of the priority is also configurable. Protection from Legionnaire's disease If protection from Legionnaire's disease is active, once per week the hot water will be heated up to the temperature specified to provide protection. Control of the solar heating system Depending on the hydraulic system, three different types of control for the solar heating system are possible: The solar heating system heats the hot-water tank The solar heating system heats the combination buffer tank The solar heating system heats both the hot-water and the buffer tanks With the solar heating parameter you can choose between none, hot water tank, combination buffer tank or hot water tank / buffer No solar heating This setting can be selected if a solar heating system is to be installed at a later point. No commands are sent to the solar heating pump and sensors are ignored. Solar heating of the hotwater tank The solar heating pump is driven at a controlled speed, taking into account the temperature difference Collector temp. to hotwater, lower sensor. The temperature of the solar collector must exceed the Hot water lower sensor temperature by the solar hysteresis value for solar heating to start. The heating of the hot water by the solar heating system can be limited via a maximum temperature setting. Solar heating system combination buffer tank The solar heating pump is driven at a controlled speed taking into account the temperature difference Collector temperature to buffer tank lower sensor. The temperature of the solar collector must exceed the Buffer lower sensor temperature by the solar hysteresis value for solar heating to start. The heating of the hot water by the solar heating system can be limited via a maximum temperature setting. 2 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

22 3 Planning the heating system Mode of operation Solar heating hot water/ buffer If the Hot water lower sensor temperature exceeds the maximum, or if the temperature of the solar collector is not sufficient to heat the hot water, the solar buffer pump will switch on (speed controlled). The buffer tank will now be heated and the sun's energy can be used for heating. If the maximum temperature of the hot water tank has not yet been reached, the solar buffer pump will switch off to establish whether the energy from the sun would be sufficient to heat up the hot water tank. If this proves to be the case, the solar pump will switch on again. If not, the solar buffer pump will switch on again for the preset period. Protecting the collector from overheating Speed-controlled solar hot water and solar buffer pumps This is only active when solar heating is being used for the hot water tank or for the combination buffer tank. If the protection temperature for the solar collector parameter 8-2 (factory setting 0 C) is exceeded, the solar pump will start, even if the maximum temperature for solar heating has been exceeded. This protects the collector from overheating. See the details supplied by the manufacturer of the solar collector for the collector protection temperature and modify the setting accordingly. The speed of the solar pump is calculated from the temperature difference between the collector and the tank, multiplied by the solar pump factor. When the solar pump starts, it runs for a configurable time at maximum speed, before it is then adjusted to run between the minimum and maximum pump speed. District heating connection Operating with district heating is very similar to heating hot water. A measurement of the temperature difference between the heat source and the district heating transfer station is used to activate the district heating pump. If operated without a buffer, the boiler supply temperature is used as a reference. If operated with a buffer, the Upper buffer sensor temperature is used. District heating operation must be enabled via a parameter. The district heating pump must be enabled via the District heating available parameter, or, depending on the hydraulic system set, may already be active. The district heating pump is started when the temperature in the transfer station falls below the Transfer station preset temperature by the value of the district heating hysteresis. Priority for district heating can be set via the parameter priority for district heating. For the other mixing circuits, this means that the supply temperature can be lowered to the reduced temperature for district heating priority. 22 HDG Compact - Version - en HDG Bavaria GmbH November 2006

23 3 Planning the heating system Mode of operation Control of second boiler The oil-burning boiler is activated when the temperature falls below the maximum enable temperature for the heating circuit or for the hot water tank, for longer than the oil-fired boiler enable time. If the temperature falls below the enable temperature for heating hot water, the oil-fired boiler will start. In this mode of operation, the preset oil-fired boiler temperature is Max. oil-fired boiler temp. The oil-fired boiler will stop on reaching the necessary Preset hot water temp. or Max. oil-fired boiler temp. If the temperature falls below the enable temperature of the heating circuit, the oil-fired boiler is started. The preset target temperature for the oil-fired boiler is calculated from the outdoor temperature, characteristic heating curve, room temperature, parallel shift and oil-fired boiler overtemperature. When the oil-fired boiler reaches either its preset temperature or Max. oil-fired boiler temp. it switches off, restarting when it has cooled down by the oilfired boiler hysteresis. If two different enable temperatures have been specified for hot water and for heating circuits, and if there is no demand on the hot water tank, the oil-fired boiler will only start once the temperature has fallen below the enable temperature for the heating circuit. If there is no demand on the heating circuit or for hot water and if the buffer is under the enable temperature, the oil-fired boiler must maintain the Min. oil-fired boiler temp. (e.g. for summer operation). If the oil-burner is in operation, the enable temperatures of the loads (heating circuits, hot water tank) are compared with the temperature of the oil-fired boiler and are used as the current temperature for control purposes. 23 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

24 3 Planning the heating system Technical data 3.3 Technical data Type of boiler HDG C 50 HDG C 65 Max. power 50.0 kw 65.0 kw Dimensions Length Width Height Weight 278 mm 428 mm 95 mm 725 kg Nominal thermal power kw kw Max. operational pressure Max. supply temperature Configurable boiler temperature 3.0 bar 95 C C Boiler efficiency 92 % 89 % Boiler class 3 Water capacity Thermal safety device Minimum flow pressure Required volume flow Water-side resistance at the nominal load Δ t=0k Δ t=20k 2 bar 800 l 67 l 2 bar 800 l 6 hpa.5 hpa Minimum return temperature 60 C 60 C Diameter of exhaust connection 80 mm 80 mm Necessary working pressure Exhaust mass flow Nominal load Partial load Exhaust temperature Nominal load Partial load Maximum kg/s kg/s 50 C 75 C 220 C 20 Pa kg/s kg/s 80 C 75 C 240 C Electrical connection Voltage 400 V fuse protection max. 6.0 A 24 Table 3/ - Technical data HDG Compact - Version - en HDG Bavaria GmbH November 2006

25 3 Planning the heating system Technical data Type of boiler HDG C 50 HDG C 65 Necessary auxiliary energy Constant operation at nominal power Ignition fan 355 W 600 W Table 3/ - Technical data 25 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

26 3 Planning the heating system Fuel quality requirements 3.4 Fuel quality requirements Wood fuel products Essential criteria are nominal length and water content of the fuel. The testing of the heating system is performed using B wood fuel products with a water content ( 5 < w < 35 %). Fine wood fuel products (wood chips) Medium wood fuel products Thermal value Typical nominal length of less than 3 cm (G30). As a machine-compatible material, this wood fuel product is especially suitable for small systems. Oversized pieces (end pieces) could lead to malfunctions during system operation. Higher proportions of finer content (dust) can lead to high emissions and ejection of glowing particles. Typical nominal length of less than 5 cm (G50). This material is used more in larger systems, but can however, depending on the diameter of the conveyor worm, also still be suitable for small systems. In the selection of fuel, it should be considered that the thermal value of the wood is primarily dependent upon the water content. The more water contained in the wood, the smaller the thermal value since the water vaporises in the course of the burning process and thereby consumes heat. This results in lower efficiency and thereby leads to greater wood consumption. Increasing moisture in the fuel material also causes reduced efficiency, greater amounts of ash and smoke, as well as making it increasingly unfit for storage. Further specifications can be found in ÖNORM HDG Compact - Version - en HDG Bavaria GmbH November 2006

27 3 Planning the heating system Fuel quality requirements For technical considerations, a representative thermal value is selected depending on water content. For burning that is both economical and low on emissions, the thermal value should not be less than 3 kwh/kg. Water content Moisture Thermal value Relative wood consumption Combustion temperature 0.0 %. % 3.9 kwh/kg 3 % 50 C 20.0 % 25.0 % 3.4 kwh/kg 30 % 00 C 26.0 % 35.0 % 3. kwh/kg 5 % 070 C 30.0 % 42.9 % 2.9 kwh/kg 7 % 040 C 40.0 % 66.7 % 2.3 kwh/kg 27 % 960 C 50.0 % 00.0 %.8 kwh/kg 286 % 870 C Table 3/2 - Thermal value depending on water content Wood pellets DIN 573 ÖNORM M 735 DINplus Wood pellets in the group size HP5 are made of pressed, untreated wood including bark, without any binder. The energy contained in 2 kg of pellets corresponds approximately to the energy contained in a litre of heating oil. The Austrian standard contains technical fuel requirements, a test for suitability, internal and external monitoring and the labelling. The certification to DINplus combines the two previously mentioned standards, taking the stricter value in each case. The certification procedure is carried out at the pellet manufacturer by a test institute approved by DIN Certco. Independent tests are made at regular intervals so that the quality of the pellets can be ensured. 27 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

28 3 Planning the heating system Fuel quality requirements Burning characteristics of the wood pellets Standard DIN 573 ÖNORM M 735 DINplus AS/NZS Length max. 50 mm max. 5 x Ø max. 5 x Ø max. 38 mm Diameter Ø 4 0 mm max. 0 mm 4 0 mm max. 0 mm Thermal value MJ/kg min. 8.0 MJ/kg min. 8.0 MJ/kg MJ/kg Density (spec. gravity).0.4 kg/dm 3 min..2 kg/dm 3 min..2 kg/dm 3 not specified Piled weight min. 650 kg/m 3 min. 650 kg/m 3 not specified min. 640 kg/m 3 Water content max. 2% max. 0% max. 0% max. 8% Ash fraction max..5% max..5% max. 0.5% max. 0.5% Abrasion not specified max. 2.3% max. 2.3% not specified Sulphur content not specified max. 0.04% max. 0.04% not specified Nitrogen content not specified max. 0.3% max. 0.3% not specified Chlorine content not specified max. 0.02% max. 0.02% not specified Pressing additives not specified max. 2.0% max. 2.0% none Table 3/3 - Characteristics of the wood pellets 28 HDG Compact - Version - en HDG Bavaria GmbH November 2006

29 3 Planning the heating system Building requirements 3.5 Building requirements Necessary room sizes and minimum spacing A F C D B E Figure 3/7 - Necessary room sizes and minimum spacing Boiler room Min. room height 225 cm Ideal room height 250 cm A) Width min. 230 cm B) Length min. 300 cm C) 66 cm D) 57 cm E) 20 cm F) 90 cm 29 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

30 3 Planning the heating system Building requirements Boiler room Applicable regulations Installation Your local building regulations will always apply. In Germany, individual state regulations on boilers and furnaces also apply. German regulations on the room to install a boiler with a total nominal thermal capacity of up to 50 kw: No requirements on the building Ventilation opening of at least 50 cm 2 Distance of furnace to fuel at least.0 m, or 0.5 m with thermal radiation protection Up to 5,000 kg of wood chips and pellets may be stored in the room where the furnace is installed. The heating system can be placed on any level, firm floor. A base is not necessary. Ensure that it is aligned horizontally. To ensure unhindered operation and maintenance of the heating system, you must make sure that the heating system is installed to our specifications and that the minimum spacings are maintained. The specifications above are applicable for systems with a nominal thermal power of maximally 50 kw. Systems of greater thermal power are subject to boiler room guidelines and thus require a separate boiler room. In the individual German states, the specifications of the furnace ordinance are to be observed. Additionally, the limit values of DIN 409 Soundproofing in building construction are not to be exceeded. More detailed information can be found in the respective ordinances of the German states. Also observe the requirements of the accident prevention and work safety regulations of the government safety organisations. 30 HDG Compact - Version - en HDG Bavaria GmbH November 2006

31 3 Planning the heating system Building requirements Fuel bunker The fuel bunker should have the following characteristics: dry dust-proof statically suitable accessible for the filling process without other installations, especially in the existing buildings adapted to fuel requirements Dimensions The refilling intervals should be kept as long as possible. The heating system should be located so that the noise generated does not exceed DIN 409 Soundproofing in building construction. The size of the fuel bunker depends on the heating system, the determined thermal load, the resulting annual fuel requirements and existing building conditions. Practice has shown that filling the fuel bunker four to six times per heating period is desirable. Example: For a thermal load of 50 kw, fuel consumption of approximately 5 kg/h with a thermal value of 3.5 kwh/kg is to be expected. The annual fuel requirement for 800 full-capacity hours is thus 27,000 kg. With a specific weight of 225 kg/m 3, this amounts to 20 m 3 fuel. To realise the rate of four to six refillings, the fuel bunker must comprise a volume of 30 or 20 m 3. 3 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

32 3 Planning the heating system Building requirements Passage through the wall The passage through the wall normally has to be made in the wall between the boiler room and the fuel bunker. Its position depends on the distance and the position of the HDG Compact heating system in the room. The passage should be 70 cm wide and 70 cm high. A B Figure 3/8 - Overview Passage through the wall A) min. 70 cm B) min. 70 cm Ventilation of fuel bunkers Wood fuel products with higher moisture can cause relatively high air humidity in the fuel bunker. Cold surfaces may thereby experience a drop below the dew point and develop condensation water. This condensation water often occurs on non-insulated lids, doors or cold walls and can result in a further moistening of the fuel. It is therefore recommended to provide a suitable ventilation system that corresponds to the building's features. 32 HDG Compact - Version - en HDG Bavaria GmbH November 2006

33 3 Planning the heating system Connections 3.6 Connections Chimney The benefits of the HDG Compact can only be reaped if all of the factors necessary for good combustion are carefully adjusted. The heating system and chimney form a single functional unit and must be adapted for one another in order to guarantee fault-free and economical operation. Since the flue temperature may lie below 00 C when the system is partially loaded, a chimney/flue is required which meets the requirements of DIN EN Thermal and fluid dynamic calculation methods. If this is not the case, contact our service department. Chimney characteristics Another essential criterion is to achieve the correct working pressure. This depends on three major factors. The requirements for minimising the draw loss in the chimney are: Good thermal insulation This is to avoid the flue gases cooling down too quickly. A smooth inner surface This is to reduce the flow resistance. A well sealed chimney This is to avoid outside air leaking in. Outside air would speed up the cooling of the flue gases. These requirements correspond to chimneys of the type according to DIN EN 3384-: 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) must be assigned to groups I - II. Uninsulated chimneys made of bricks or similar material correspond to design type III and are unsuitable. Free-standing chimneys require particularly good insulation. 33 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

34 3 Planning the heating system Connections Chimney dimensions The system may only be connected to a chimney which has been dimensioned in accordance with DIN 3384-, taking into account the fuel planned and the expected load, and which meets local building regulations for the erection site. A chimney can only be designed when the local circumstances are understood. This includes taking into account the following factors: The location of the house Hillside situation Wind direction Location of the chimney in the roof The opening of the chimney must be at least 0.5 m above the highest edge of roofs with a slope of more than 20 or at least.0 m away from roof surfaces which slope at 20 or less. The effective height of a chimney is measured from the entrance into the flue to the end of the chimney. Connecting the boiler to the chimney The boiler must be connected to the flue with a connecting piece which is as short as possible, at an angle which is less than to the chimney. You should aim for a connecting piece with a maximum length of mm using just one fitting. Every additional fitting results in a greater pressure loss in the exhaust path and should thus be avoided. The same is true for overlong connecting pieces. If, for constructional reasons, they have to be longer than m, they should be adequately insulated (at least 5 cm of mineral wool or equivalent material) and, if possible, should be fitted with an upward inclination. A 2 Figure 3/9 - Connection to the chimney Auxiliary air unit 2 Cleaning hatch A) Angle to the chimney approx HDG Compact - Version - en HDG Bavaria GmbH November 2006

35 3 Planning the heating system Connections To compensate for irregularities of conveyor pressure in the chimney, HDG Bavaria recommends installing an auxiliary air unit in the flue, or even better, in the chimney itself as shown in Figure 3/9 - Connection to the chimney. The following should also be considered: The connecting piece may not protrude into the chimney. If the system flue pipe has a larger diameter than the chimney, the connecting piece must reduce to the diameter of the connection. The connecting piece should taper as gently as possible. Use bends rather than elbows, whereby the radius of the bend may not be less than the diameter of the pipe. A vertical, straight chimney, if possible without bends (take particular care in older buildings). All of the cleaning and measurement hatches on the chimney must be tightly sealed. To reduce the entry of additional cold air, only one heat producer should be attached to each chimney. Electrical system Controller housing The EC 73/ 23/EEC - L 77/73 (low voltage guidelines) must be followed for the electrical connections to the system. No electrical installations, such as power sockets, distribution sockets, lights or light switches may be located in the fuel bunker. Any lights must be suitable for use in areas at risk of explosion. The VDE regulations for rooms where there is a danger of a dust explosion must be followed. The required connection values are listed in the 3.3 Technical data section in this chapter. The controller housing should, if possible, be placed near the control elements, taking into account the ambient temperatures, and be easy to access in a dry location. Outdoor sensor The outdoor temperature sensor should be fixed about one third of the way up the building (at least 2m from the ground) on the coldest side of the building (north or north-east). When installing the sensor, you should take into account sources of heat which might falsify the result of the measurement (chimneys, warm air from air shafts, direct sunlight, etc.). The cable outlet must always point down to avoid moisture penetration. For the electrical installation a cable type JYSTY 2 x 2 x 0.6 mm 2 with a maximum length of 50 m should be used. 35 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

36 3 Planning the heating system Connections Heating circuit sensor The heating circuit temperature sensor serves to measure the supply temperature for heating circuits controlled by mixers. The sensor should be installed at a distance of approx. 30 cm after the circulation pump on a bright metal part of the supply line. Buffer tank sensor and hot water sensor The temperature sensors are immersion sensors with a moulded cable and serve to measure the temperature of the buffer tank and the hot water tank. Indoor thermostat unit (room sensor) With the room sensor, the preset room temperature can be altered by 2-3 C. A selection switch allows the operating status for each heating circuit to be changed. Before installing the room sensor, a suitable installation location must first be found. This must not be in an area where sunlight falls, where there's a draft, a radiator, a chimney etc. so that only the actual room temperature is measured. It should also be on an interior wall. The most appropriate room is the room where the inhabitants spend most time (e.g. living or dining room). In this room, no other source of heat should be used (e.g. open fire). If there are thermostatic valves on the radiators, these must be set higher than the room temperature in the control system. Otherwise, the room sensor would be affected. Their influence would distort the supply to the heating circuit and all other rooms would become too warm. In all of the other rooms however, thermostatic radiator valves must be fitted. Water The use of a buffer tank The system must be filled with water which conforms to the VDI guideline 2035 "Avoiding damage in hot water heating systems". When calculating the thermal requirements of buildings, e.g. to DIN 470, the lowest outdoor temperature for the climate zone concerned (e.g. -5 C) is used. This condition only applies a few days per year so that the thermal performance of the heating system is overdesigned for most of the days when heating is needed. For this reason, the HDG Compact is fitted as standard with power control and automatic ignition. It is, however, highly recommended to use a buffer tank even with automatic boiler systems. The size of the buffer tank depends on the nominal thermal power of the boiler and on the thermal requirement of the building. As a benchmark value, 20 litres per kilowatt boiler power can be used. This results in a boiler burning duration of approximately one hour at full-capacity operation, during which the buffer tank is completey 36 HDG Compact - Version - en HDG Bavaria GmbH November 2006

37 3 Planning the heating system Connections filled. The emptying time of the buffer tank at 25% nominal load amounts to 3.7 hours for this type of design, with an assumed usable temperature difference of 40 Kelvin. One advantage of a buffer tank is the low number of operating hours for the system and fewer start phases due to extended heating periods, which leads to a reduction in the proportion of external energy and to lower wear of the mechanical components. One further advantage of the buffer tank is in summer operation when only hot water is required. When operating in this mode, the buffer tank avoids frequent ON/OFF changes. For the above-mentioned reasons we recommend a buffer tank, even for automatic boiler systems. Safety devices Safety devices are to be installed in accordance with DIN EN 2828: 2003 Design of water-based heating systems in buildings. 37 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

38 3 Planning the heating system Connections Flue pipe side Figure 3/0 - Flue pipe side Boiler supply bushing /4 inch, nominal diameter 32 2 Boiler return bushing /4 inch, nominal diameter 32 3 Filling Emptying bushing /2 inch, nominal diameter 5 4 Flue pipe connection Ø 80 mm 38 HDG Compact - Version - en HDG Bavaria GmbH November 2006

39 3 Planning the heating system Connections Thermal safety device Hydraulic connection Figure 3/ - Thermal flow Thermal safety device bushing /2 inch, nominal diameter 5 2 Cold water inflow 3/4 inch, nominal diameter 20 3 Cold water outflow 3/4 inch, nominal diameter 20 4 Safety heat exchanger 3/4 inch outer thread There are hydraulic solutions for every application. An excerpt of the options for hydraulic connection can be found in the chapter 4 Installing the heating system in the 4.8 HDG hydraulic systems section. 39 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

40 4 Installing the heating system Requirements 4 Installing the heating system 4. Requirements The heating system will initially be commissioned by specialists from HDG Bavaria or from an authorised HDG partner and a qualified electrician. Danger! 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 subsequent damage. Only allow authorised specialists to perform the installation. Danger! Danger from electrical current or voltage. Switch off the power supply and isolate the mains cable to the heating system during the installation. 4.2 Scope of delivery The heating system is delivered with all components on pallets. Check that the scope of delivery matches the information on the delivery note. 40 HDG Compact - Version - en HDG Bavaria GmbH November 2006

41 4 Installing the heating system HDG Compact 4.3 HDG Compact Installing the boiler Caution! Danger from suspended loads. The boiler weighs over 250 kg. If the boiler is dropped during transport, people can be seriously injured and the boiler can be damaged. Make sure that you use appropriate lifting gear when installing the boiler. Transport with a crane. Remove the packaging from the boiler. Figure 4/ - Removing hoods 2. Remove the top hoods (). 4 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

42 4 Installing the heating system HDG Compact Figure 4/2 - Fastening the crane hooks 3. Attach the crane hook to the ring bolts () on the boiler. 4. Carefully lift the boiler 5. Transport the boiler to its installation location. Erection site Figure 4/3 - Erection site 6. Place the boiler on the planned location. 7. Maintain the minimum spacings. See the section 3.5 Building requirements in the chapter 3 Planning the heating system. 8. Align the boiler with plastic plates or flat steel strips (not included in the scope of delivery) so that it is horizontal. 9. Unscrew the ring bolts from the boiler. The boiler has been put in place. 42 HDG Compact - Version - en HDG Bavaria GmbH November 2006

43 4 Installing the heating system HDG Compact Installing the automatic ash removal system Dismantling the rear covers Figure 4/4 - Dismantling the circuit board cover. Unscrew the rear cover of the circuit board () with a Phillips-tip screwdriver. Figure 4/5 - Dismantling the ash removal cover 2. Unscrew the rear ash removal cover () with a Phillips-tip screwdriver. 43 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

44 4 Installing the heating system HDG Compact Figure 4/6 - Unscrewing the blind side cladding 3. Unscrew the inner cladding of the bottom blind side () with a Phillips-tip screwdriver. 2 Figure 4/7 - Dismantling the rear inner cover 4. Remove the cover (2) together with the insulation (). The rear covers are dismantled. 44 HDG Compact - Version - en HDG Bavaria GmbH November 2006

45 4 Installing the heating system HDG Compact Installing the combustion chamber hopper 2 3 Figure 4/8 - Installing the combustion chamber hopper 5. Push the combustion chamber hopper (3) from the front under the combustion chamber (). 6. Bolt on the combustion chamber hopper (3) with a screw and welded on M 0 nut (2) through the dividing wall from the combustion chamber ash box and fly ash chamber using a 7 mm open-end spanner. 2 3 Figure 4/9 - Installing the alignment plate 7. Bolt the alignment plate () onto the hopper plate (3) with two screws (2) and M 0 nuts using a 7 mm spanner. The hopper plate is installed. 45 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

46 4 Installing the heating system HDG Compact Installing the ash removal system 2 Figure 4/0 - Inserting the automatic ash removal system 8. Insert the automatic ash removal system () under the combustion chamber (2). Figure 4/ - Bolting on the automatic ash removal system 2 9. Bolt on the automatic ash removal system () with six M 2 nuts (2) using a 9 mm spanner. Due to a soft seal, the screws may not be screwed in up to the limit. Only tighten until a resistance is detected. 46 HDG Compact - Version - en HDG Bavaria GmbH November 2006

47 4 Installing the heating system HDG Compact 3 2 Figure 4/2 - Bolting on the automatic ash removal system 0.Check the tension of the chain (3) in the chain centre (2).. The chain may have a maximum of cm play in an upward and downward direction. 2.If necessary, correct the play in the chain centre (2) with the eccenntric tappet (). 2 3 Figure 4/3 - Installing the bracket 3.Place the bracket () on the sliding tray (3) with the canting toward the front. The bracket must have approximately 3 mm clearance from the top to the inner wall edge of the combustion chamber. 4.Bolt on the bracket () by screwing two M 0 nuts (2) on the welded bolts of the sliding tray (3) using a 7 mm spanner. The automatic ash removal system is installed. 47 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

48 4 Installing the heating system HDG Compact Attaching the ash door 2 Figure 4/4 - Sliding in the ash removal door 3 5.Fold both clamp handles (3) upward. 6.Slide the ash removal door () onto the combustion chamber or sliding tray worm (2) Figure 4/5 - Bolting on the ash removal door 7.Bolt on the ash removal door () with a long screw (2) and four M 2 short screws (4) using a 9 mm spanner. Due to a soft seal, the screws may not be screwed in up to the limit. Only tighten until a resistance is detected. 48 HDG Compact - Version - en HDG Bavaria GmbH November 2006

49 4 Installing the heating system HDG Compact 8.Tighten the screws (2 + 4) to the same tightness. The combustion chamber or sliding tray worm (3) may not contact the ash removal door (). Due to a soft seal, the screws may not be screwed in up to the limit. Only tighten until a resistance is detected. 9.Align the combustion chamber worm or sliding tray worm (3) if necessary with the nuts of the ash removal system and the screws of the ash removal door. The ash removal door is attached. Attaching the cover plate of the ash door Figure 4/6 - Installing the cover plate of the ash door 20.Position both clamp handles () so that they are horizontal. 49 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

50 4 Installing the heating system HDG Compact 2 Figure 4/7 - Installing the cover plate of the ash door 2.Insert the bottom of the cover plate () with the recesses in the guides on the boiler (2). 22.Press the top of the cover plate () onto the boiler (2). The cover plate of the ash door is attached. 50 HDG Compact - Version - en HDG Bavaria GmbH November 2006

51 4 Installing the heating system HDG Compact Attaching the cleaning shaft lid Figure 4/8 - Unscrewing the nuts 23.Unscrew the two nuts () on the hinges of the cleaning shaft lid on the boiler. 24.Fold the hinges upward. 5 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

52 4 Installing the heating system HDG Compact Caution! Danger of injury The cleaning shaft lid is very heavy. Hands can become crushed when installing it. Always take care not to grasp under the cleaning shaft lid when putting it on. 2 Figure 4/9 - Putting on the cleaning shaft lid 25.Place the cleaning shaft lid () on the boiler (2). 52 HDG Compact - Version - en HDG Bavaria GmbH November 2006

53 4 Installing the heating system HDG Compact 2 Figure 4/20 - Bolting on the cleaning shaft lid 26.Guide the screws () of the hinges into the holes on the cleaning shaft lid (2). 27.Bolt on the cleaning shaft lid (2) with the M 2 nuts on the hinges using a 9 mm spanner. The cleaning shaft lid is attached. 53 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

54 4 Installing the heating system HDG Compact Installing the crossbeams Caution! Danger of injury The cleaning shaft lid is heavy and can fall shut. Hands and arms can thereby be crushed. Take care not to bump into the opened cleaning shaft lid and cause it to fall shut. Figure 4/2 - Opening the cleaning shaft lid 28.Fold open the cleaning shaft lid () Figure 4/22 - Installing the short crossbeam 29.Place the short crossbeam () on the turbulaters (2). HDG Compact - Version - en HDG Bavaria GmbH November 2006

55 4 Installing the heating system HDG Compact Figure 4/23 - Installing the short crossbeam 30.Using a 9 mm spanner, bolt the short crossbeam () with two M 2 screws (3) onto the turbulaters (2), allowing approximately 2 mm play between nut and turbulater crossbeam retainer (4). 3.Secure the M 2 nut with the M 2 lock nut using a 9 mm ratchet. 32.Install the long crossbeam as described above. Figure 4/24 - Installing the short crossbeam 33.Align the crossbeams (2) centred to the boiler inner walls. 34.Slowly close the cleaning shaft lid. 55 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

56 4 Installing the heating system HDG Compact Figure 4/25 - Installing the short crossbeam 35.Bolt the crossbeams with two M 0 screws () onto the cleaning shaft lid using a 0 mm hexagon socket wrench. 36.Align the crossbeams if necessary through the inspection flap of the combustion chamber or the flue pipe. 37.Tighten the star-grip screw. The crossbeams are installed. 56 HDG Compact - Version - en HDG Bavaria GmbH November 2006

57 4 Installing the heating system HDG Compact Installing the combustion air fan 2 Figure 4/26 - Installing the combustion air fan 38.Bolt the combustion air fan () onto the air regulating unit (2) with four M 6 screws and a 5 mm hexagon socket wrench. The combustion air fan is installed. Installing the feed system 2 3 Figure 4/27 - Attaching the adapter pipe 39.Slide the adapter pipe () with a seal (2) into the feed channel (3). 57 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

58 4 Installing the heating system HDG Compact 3 2 Figure 4/28 - Attaching the adapter pipe 40.Align the seal (2) with the holes. 4.Insert the M 2 screws () from the boiler through the holes. 42.Poke holes through the seal () for both centring screws (3). 43.Insert the centring screws (3) toward the boiler through the holes and screw them tight with the M 6 nuts using a 0 mm spanner. 2 Figure 4/29 - Attaching the adapter pipe 44.Insert the second seal () on the adapter pipe (2) Slide the feed system () onto the adapter pipe (2). HDG Compact - Version - en HDG Bavaria GmbH November 2006

59 4 Installing the heating system HDG Compact Caution! Danger of injury The feed system is very heavy. Hands and feet could be crushed when it is lifted. Only lift the feed system using suitable lifting equipment. 2 Figure 4/30 - Lifting the feed system 2 Figure 4/3 - Bolting on the feed system 46.Bolt on the feed system () with the M 2 nuts (2) using a 9 mm spanner. 59 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

60 4 Installing the heating system HDG Compact Figure 4/32 - Attaching the supporting foot 47.Bolt the supporting foot (3) with an M 2 screw (2) onto the feed system () using a 9 mm spanner. 48.Fasten the supporting foot (3) as required to the floor (screws and screw anchors are not included in the scope of delivery). 49.Align the feed system () horizontally with the two M 0 screws (4). The feed system is installed. 60 HDG Compact - Version - en HDG Bavaria GmbH November 2006

61 4 Installing the heating system HDG Compact Connecting the pressure equalisation hose Figure 4/33 - Setting the pressure equalisation regulator 50.Set the position indicator () for the pressure equalisation regulator to approximately o'clock. 2 3 Figure 4/34 - Connecting the pressure equalisation hose 5.Place the rubber seal on the connections of the pressure equalisation hose (). 52.Attach the pressure equalisation hose () to the feed system (2) and to the boiler (3). The pressure equalisation hose is connected. 6 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

62 4 Installing the heating system HDG Compact Connecting the cleaning system 2 Figure 4/35 - Removing the top cover 53.Unscrew the two shaped studs (2) using a 6 mm spanner. 54.Unscrew the top cover () with a Phillips-tip screwdriver. 2 Figure 4/36 - Connecting the cleaning system 55.Lay the cables of the cleaning system (2) to the circuit boards, placing them on the insulation (). When laying the cable, ensure that there is enough cable for the cleaning shaft lid to be opened. 62 HDG Compact - Version - en HDG Bavaria GmbH November 2006

63 4 Installing the heating system HDG Compact 56.Connect the plug of the cleaning system to the circuit board. See the section 4.8 HDG hydraulic systems in the chapter 4 Installing the heating system. The cleaning system is now connected. Installing the sensors Figure 4/37 - Installing the sensors The sensors () for the buffer tank are attached under the top cladding cover next to the circuit boards for further use. Figure 4/38 - Mounting sensors 57.Seal the immersion sleeves of the sensors with a suitable sealing material and position them at the points indicated in Figure 4/38 - Mounting sensors. 63 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

64 4 Installing the heating system HDG Compact 58.Guide the sensors into the immersion sleeves. 59.Insert the prefabricated plug connections into the terminals specified in the circuit diagram. The sensors are installed. For a hydraulic diagram without buffer tank, these sensors are not present and must be taken out of the corresponding parameters. Wiring the circuit boards 2 3 Figure 4/39 - Wiring the circuit boards. Open the cable duct (2). 2. Connect all plugs to the circuit board central unit () and transport module (3) in accordance with the circuit diagram. See the section 5. HDG Compatronic circuit diagram in the chapter 5 Circuit diagrams. 64 HDG Compact - Version - en HDG Bavaria GmbH November 2006

65 4 Installing the heating system HDG Compact 2 Figure 4/40 - Wiring the circuit boards 3. Lay the condensor () of the combustion air fan in the cable duct (2). 2 Figure 4/4 - Wiring the circuit boards 4. Lay the cable of the automatic cleaning system () so that it does not contact the drive chain (2). 5. Fasten all cables with cable clips. 6. Close the cable ducts. The circuit boards are wired. 65 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

66 4 Installing the heating system HDG Compact Installing the boiler cladding Figure 4/42 - Installing the boiler cladding. Cut out the right pre-punched sheet part () for the opening of the ash removal motor using a side cutter or other suitable tool. 2. Mount all cladding on the system. The boiler cladding is installed. 66 HDG Compact - Version - en HDG Bavaria GmbH November 2006

67 4 Installing the heating system HDG Compact Mounting and adjusting the ash boxes. Remove the ash boxes from the packaging. 2. Pull the two latching bolts and turn them simultaneously Fold the transport handles upward. 4. Turn the latching bolts by 90 and jiggle them slightly by the handle grips. The latching bolts latch into the holes of the ash boxes. 2 Figure 4/43 - Attaching the ash boxes 5. Lift up the clamp handles (). 6. Insert the ash boxes (2) on the ash removal pipe. 7. Press the clamp handles () downward. Grasp the clamp handles and press the ash boxes against the seal of the ash removal door. 8. If the clamp handles do not clamp, adjust them as follows. 9. Open the ash boxes. 67 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

68 4 Installing the heating system HDG Compact Figure 4/44 - Attaching the ash boxes 0.Release the cap nuts () in the ash boxes and unscrew these approximately 4 revolutions.. Release the nuts under the cap nuts and unscrew them until the clamp handles latch in place. 2.Screw on the nuts and check that the clamp handles clamp firmly. Grasp the clamp handles and tighten the ash boxes solidly on the ash removal door. 3.Lock the nuts with the cap nuts. 4.Close the ash boxes in the reverse sequence. The ash boxes are mounted and adjusted. 68 HDG Compact - Version - en HDG Bavaria GmbH November 2006

69 4 Installing the heating system HDG Compact Connecting the chimney. Connect the chimney pipe to the chimney connection. 2. Make sure that the connecting piece does not protrude into the chimney. 3. Seal the connection to the chimney with very fireproof silicone or with a suitable mortar. The boiler has been connected to the chimney. See the section 3.6 Connections as described in the chapter 3 Planning the heating system. 69 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

70 4 Installing the heating system HDG Hydronic 4.4 HDG Hydronic Danger! Danger from electrical current or voltage. Remove all power and isolate the mains cable to the heating system during the installation. Caution! Material damage due to static discharge. Electronic components can be damaged by static discharge. Do not touch any electronic components during the installation. Installing the control unit Installing the control unit housing The "bus" cable between the Pelletronic and the Hydronic equipment must be protected from inductive coupling from 230 V wires. Only use screened cables for sensor extensions. Figure 4/45 - Control unit housing. Fix the control unit housing at its intended position on the wall. For the holes to be drilled, see (). Mounting it near the distributor is recommended. See the section 3.6 Connections in the chapter 3 Planning the heating system. 70 HDG Compact - Version - en HDG Bavaria GmbH November 2006

71 4 Installing the heating system HDG Hydronic Installing the sensors Depending on the hydraulic system installed, corresponding sensors must be installed and connected. See the hydraulic plan and the circuit diagram for the plug connections and the necessary sensors for your particular hydraulic system. The available hydraulic systems can be found in the section 4.8 HDG hydraulic systems in the chapter 4 Installing the heating system. Take great care that you use the correct sensors (contact sensors, immersion sensors, outdoor sensors) as, if used incorrectly, error messages and resulting malfunctions in the control system can then occur. All of the sensors in the HDG Hydronic are PT 000 sensors. Temperature PT C Ohm -40 C Ohm -30 C Ohm -20 C Ohm -0 C Ohm 0 C Ohm 0 C Ohm 20 C Ohm 25 C Ohm 30 C 6.70 Ohm 40 C Ohm 50 C Ohm 60 C Ohm 70 C Ohm 00 C Ohm 50 C Ohm Table 4/ - The characteristics of PT HDG Bavaria GmbH November 2006 HDG Compact - Version - en

72 4 Installing the heating system HDG Hydronic Installing an outdoor sensor. Install the outdoor sensor at its intended position on the wall with its cable outlet downwards. See the section 3.6 Connections in the chapter 3 Planning the heating system. Figure 4/46 - Outdoor sensor Installing a heating circuit sensor 2 Figure 4/47 - Heating circuit sensor 2. Fix the heating circuit sensor () to the pipe using the hose-clip (2) supplied, flush to the surface of the pipe. See the section 3.6 Connections in the chapter 3 Planning the heating system. 72 HDG Compact - Version - en HDG Bavaria GmbH November 2006

73 4 Installing the heating system HDG Hydronic Installing sensors for buffer and hot water tanks Figure 4/48 - Sensors for buffer and hot water tanks 3. Make sure that the sensors for buffer and hot water tanks are not bent. 4. Carefully insert the buffer and hot water tank sensors into the immersion sleeves. Installing a room sensor. Fix the room sensor at its intended position on the wall. See the section 3.6 Connections in the chapter 3 Planning the heating system. Figure 4/49 - Room sensor Figure 4/50 - Room sensor without cover 73 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

74 4 Installing the heating system Electrical system Hydraulic systems Hydraulic systems must be implemented as specified by HDG from page 78 onwards. The available hydraulic systems can be found in the section 4.8 HDG hydraulic systems in the chapter 4 Installing the heating system. 4.5 Electrical system The electrical connections must be made in accordance with DIN IEC Setting up low-voltage electrical installations. The technical details are described in the section 3.3 Technical data in the chapter 3 Planning the heating system. The circuit diagram is in the chapter 5 Circuit diagrams. 4.6 Water The heating system must be filled with water which conforms to the VDI guidelines 2035 Avoiding damage in hot water heating systems. The membrane expansion container must be constructed in accordance with DIN EN 383 Closed expansion containers with built-in membrane for integration in water installations. Before putting the system into operation, the pressure of the membrane expansion container must be adjusted for the conditions in the heating system and in the building. After putting the system into operation, heat up the system to the maximum boiler temperature and bleed air from the system again to make sure that there are no air pockets. The safety devices must be implemented in accordance with DIN EN 2828 Heating systems in buildings and the correspondingly harmonised national standard DIN 475, Part 2 Closed, thermostatically safeguarded heat generating systems with supply temperatures of up to 20 C; safety equipment. The flow pressure for the thermal safety device must be at least 2 bar and ensure a flow volume of 800 l/h. Own water supply systems are not safe enough due to dependence upon the power supply! In Germany, the requirements of the German energy conservation ordinance (EnEV) are to be met. 74 HDG Compact - Version - en HDG Bavaria GmbH November 2006

75 4 Installing the heating system Starting the system 4.7 Starting the system The heating system will initially be 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 the taking of measurements on the system for pollution and heating capacity. Danger! Material damage and injury due to incorrect commissioning. Commissioning the system requires comprehensive specialist knowledge. If this commissioning is done by an untrained person, the heating system can be damaged. Only allow authorised specialists to perform the commissioning. The initial commissioning is described in the operating instructions in chapter 7 Commissioning the heating system. 75 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

76 4 Installing the heating system HDG hydraulic systems 4.8 HDG hydraulic systems Hydraulic system 0 OT Bt ST RT Bb Figure 4/5 - Hydraulic system 0 HDG Compatronic OTS ST RT Bt Bb Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Buffer top sensor Buffer bottom sensor 76 HDG Compact - Version - en HDG Bavaria GmbH November 2006

77 4 Installing the heating system HDG hydraulic systems Hydraulic system a OT A7/8 A4 F4 CCT CCT2 F5 A5 A9/0 F0 ST Bt RT Bb A Figure 4/52 - Hydraulic system A HDG Compatronic OTS ST RT Bt Bb Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Buffer top sensor Buffer bottom sensor HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Solar pump F2 Unused A2 Unused F3 Unused A3 Unused F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Unused F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 Unused A9 Heating circulation mixer CCT2 open F0 Solar collector temperature A0 Heating circulation mixer CCT2 closed 77 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

78 4 Installing the heating system HDG hydraulic systems Hydraulic system 2 OT A4 A7/8 F4 CCT CCT2 CCT3 ST Bt RT F5 Bb A5 A9/0 F9 A6 A/2 Figure 4/53 - Hydraulic system 2 HDG Compatronic HDG Hydronic P OTS ST RT Bt Bb Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Buffer top sensor Buffer bottom sensor Inputs (sensors) Outputs (Aggregate) F Unused A Heating circulation mixer CCT3 open F2 Unused A2 Heating circulation mixer CCT3 closed F3 Unused A3 Heating circulation pump CCT3 F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Unused F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 Supply CCT3 A9 Heating circulation mixer CCT2 open F0 Unused A0 Heating circulation mixer CCT2 closed 78 HDG Compact - Version - en HDG Bavaria GmbH November 2006

79 4 Installing the heating system HDG hydraulic systems Hydraulic system 3 OT A4 F4 CCT CCT2 DH A7/8 ST RT Bt F5 A5 A9/0 F9 A2 Bb Figure 4/54 - Hydraulic system 3 HDG Compatronic OTS ST RT Bt Bb Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Buffer top sensor Buffer bottom sensor HDG Hydronic P Inputs (sensors) F Unused A Unused Outputs (Aggregate) F2 Unused A2 District heating pump F3 Unused A3 Unused F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Unused F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 The temperature of the district heating circuit A9 Heating circulation mixer CCT2 open F0 Unused A0 Heating circulation mixer CCT2 closed 79 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

80 4 Installing the heating system HDG hydraulic systems Hydraulic system 4A F4 CCT CCT2 A4 F0 OT Bt A7/8 A3 ST F5 A5 F2 RT Bb A9/0 F3 A Figure 4/55 - Hydraulic system 4A A2 HDG Compatronic OTS ST RT Bt Bb Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Buffer top sensor Buffer bottom sensor HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Solar pump F2 Hot water tank top A2 Buffer tank pump F3 Hot water tank bottom A3 Hot water pump F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Unused F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 Unused A9 Heating circulation mixer CCT2 open F0 Solar collector temperature A0 Heating circulation mixer CCT2 closed 80 HDG Compact - Version - en HDG Bavaria GmbH November 2006

81 4 Installing the heating system HDG hydraulic systems Hydraulic system 5 A4 F4 CCT CCT2 DH F9 OT Bt A7/8 A3 F0 ST F5 A2 F2 RT A5 A9/0 F3 Bb A Figure 4/56 - Hydraulic system 5 HDG Compatronic OTS ST RT Bt Bb Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Buffer top sensor Buffer bottom sensor HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Solar pump F2 Hot water tank top A2 District heating pump F3 Hot water tank bottom A3 Hot water pump F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Unused F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 The temperature of the district heating circuit A9 Heating circulation mixer CCT2 open F0 Solar collector sensor A0 Heating circulation mixer CCT2 closed 8 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

82 4 Installing the heating system HDG hydraulic systems Hydraulic system 6 F4 CCT CCT2 CCT3 A4 OT A7/8 Bt ST F5 F9 RT Bb A5 A9/0 A6 A/2 A3 F2 Figure 4/57 - Hydraulic system 6 HDG Compatronic OTS ST RT Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Heating circulation mixer CCT3 open F2 Hot water tank A2 Heating circulation mixer CCT3 closed F3 Unused A3 Hot water pump Bt Bb 82 Buffer top sensor Buffer bottom sensor F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Heating circulation pump CCT3 F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 Supply CCT3 A9 Heating circulation mixer CCT2 open F0 Unused A0 Heating circulation mixer CCT2 closed HDG Compact - Version - en HDG Bavaria GmbH November 2006

83 4 Installing the heating system HDG hydraulic systems Hydraulic system 7 F4 CCT CCT2 DH F9 OT A4 A7/8 F0 ST X F2 A RT F5 A5 A2 A3 F3 A9/0 Figure 4/58 - Hydraulic system 7 HDG Compatronic OTS ST RT X Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Hydraulic switch HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Solar pump F2 Hot water tank A2 District heating pump F3 Unused A3 Hot water pump F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Unused F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 Supply CCT3 A9 Heating circulation mixer CCT2 open F0 Unused A0 Heating circulation mixer CCT2 closed 83 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

84 4 Installing the heating system HDG hydraulic systems Hydraulic system 8 F4 CCT CCT2 CCT3 OT A4 A7/8 ST X F2 RT F5 F9 A3 A5 A9/0 A6 A/2 Figure 4/59 - Hydraulic system 8 HDG Compatronic OTS ST RT Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Heating circulation mixer CCT3 open F2 Hot water tank A2 Heating circulation mixer CCT3 closed F3 Unused A3 Hot water pump X 84 Hydraulic switch F4 Supply CCT A4 Heating circulation pump CCT F5 Supply CCT2 A5 Heating circulation pump CCT2 F6 Unused A6 Heating circulation pump CCT3 F7 Unused A7 Heating circulation mixer CCT open F8 Unused A8 Heating circulation mixer CCT closed F9 Supply CCT3 A9 Heating circulation mixer CCT2 open F0 Unused A0 Heating circulation mixer CCT2 closed HDG Compact - Version - en HDG Bavaria GmbH November 2006

85 4 Installing the heating system HDG hydraulic systems Hydraulic system 0 BH BH2 OT ST CP CP2 RT X Figure 4/60 - Hydraulic system 0 HDG Compatronic OTS ST RT Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor BH Buffer house BH2 Buffer house CP CP2 X Conveyor pump house Conveyor pump house 2 Hydraulic switch 85 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

86 4 Installing the heating system HDG hydraulic systems Hydraulic system F4 CCT F5 CCT2 F2 A3 A4 A7/8 A5 A9/0 A6 F3 X X OT Bt CP CP2 ST RT Bb Figure 4/6 - Hydraulic system HDG Compatronic OTS ST RT CP CP2 X Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Conveyor pump house Conveyor pump house 2 Hydraulic switch HDG Hydronic P Inputs (sensors) F Unused A Unused F2 Boiler house A2 Unused Outputs (Aggregate) F3 Boiler house 2 A3 Hot water pump house F4 Supply CCT house A4 Heat circulation pump house F5 Supply CCT house 2 A5 Heat circulation pump house 2 F6 Unused A6 Hot water pump house 2 F7 Unused A7 Mixer house open F8 Unused A8 Mixer house closed F9 Unused A9 Mixer house 2 open F0 Unused A0 Mixer house 2 closed 86 HDG Compact - Version - en HDG Bavaria GmbH November 2006

87 4 Installing the heating system HDG hydraulic systems Hydraulic system 2 F4 HYH HYH2 A3 A4 A7/8 CCT CCT2 CCT CCT4 CCT CCT6 F4 F2 F9 A4 A6 A/2 A7/8 A3 F5 X X OT A5 A9/0 CP CP2 F5 A5 F9 A6 F2 ST Bt A9/0 A/2 RT Bb Figure 4/62 - Hydraulic system 2 HDG Compatronic OTS ST RT CP CP2 X Outdoor temperature sensor Supply temperature sensor (boiler temperature) Return temperature sensor Conveyor pump house Conveyor pump house 2 Hydraulic switch HYH Hydronic house HYH2 Hydronic house 2 HDG Hydronic P Inputs (sensors) Outputs (Aggregate) F Unused A Mixer CCT3 (CCT6) open F2 Hot water tank A2 Mixer CCT3 (CCT6) closed F3 Unused A3 Hot water pump house F4 Supply CCT (CCT4) A4 Heat circulation pump CCT (CCT4) F5 Supply CCT2 (CCT5) A5 Heat circulation pump CCT2 (CCT5) F6 Unused A6 Heat circulation pump CCT3 (CCT6) F7 Unused A7 Mixer CCT (CCT4) open F8 Unused A8 Mixer CCT (CCT4) closed F9 Supply CCT3 (CCT6) A9 Mixer CCT2 (CCT5) open F0 Unused A0 Mixer CCT2 (CCT5) closed 87 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

88 4 Installing the heating system HDG hydraulic systems Notes 88 HDG Compact - Version - en HDG Bavaria GmbH November 2006

89 L N N 2 7 PE N 6 5 PE N 4 PE N 3 PE N 2 PE N PE N 7 PE N 6 PE N 5 PE N 4 3 PE N N OFF ON N L PE N 7 PE N OFF ON N 7 PE N 6 N 4 PE N PE M ~ 8 N N N 5 Circuit diagrams HDG Compatronic circuit diagram 5 Circuit diagrams 5. HDG Compatronic circuit diagram Circuit diagram HAICO COMPATRONIC CAUTION! PHASES MUST BE CONNECTED CORRECTLY. MMI.0 NPE PE MAINS to HAICO 20 Connect Mains supply phases correct! PE Complete isolation from mains CLOSED? RMZ via switch or plug arrangement Mains 3 x 230VAC + 0/-5%, 50Hz max. 3A fuse CAN -BUS Mixer Return 230VAC M ~ 3 PE N F3 UP? DOWN T35mA CAN VCC CAN H CAN L PE L Dumping grate 230VA C M ~ UP 6 PE N 5 PE N 4 L2 CA N GND Shielding L3 CAN -BUS D IP switch Standard setting BOTH "OFF" (I/O6.0 + MMI.0 + HS 3.0 with HAICO CAN) CAN -BUS CAN Re serve 5 Suction 230VAC M ~ I2C Feed system 230VA C M ~ DA Q F4 T3,5 A Return motor 230VAC PE N N PE N PE N PE N PE PC-RS232 RMA RR Mains supply F7 F8 CAN RL District heating pump Hydr. system 0,,2 PE M ~ Mains supply I/O Platine 6.0 SS CAN Safety chain SZ Motor 3 Delivery M3 3~ F7 F8 F4 Heizung F5 M ~ Oxygen sensor Motor 2 Dosing system M2 3~ F5 F6 F4 Fault F6 F2 Operating status 230VAC I/O Platine 6.0 Flue gas temp. (NiCrNi) Operation Comb. chamber temp.(nicrni) Cleaning 230VA C M ~ Supply temp. (PT000) District heating pump 2 Hydr. system 0,,2 Return temp. (PT000) M 3~ 5 PE 8 9 Ignition heating Buffer temp. (PT000) AB 5 6 CDE 3 Ingnition fan 230VAC 2 F 0 Buffer temp. lower (PT000) Ignition fan F Outdoor temp. lower (PT000) T0A F2 5 PE N 4 PE N 3 2 N PE 0 F F F3 F0 F2 24VDC M 24V DC Secondary air servo motor 52 Motor Feed system 0..0VDC 24VDC F3 F Primary air servo motor 0..0VDC M 24V DC 0..0VDC Analog output Reserve 0..0 IN VDC IN 2 Signal feedback 45 T35mA 39 PE PE PE PE 32 3 PE PE PE PE PE PE PE PE N 8 PE N 2 PE 20 9 PE N 27 PE 25 PE PE PE 32 3 PE 29 PE PE 37 PE PE 38 F20 F VDC Reserve Relay normally open contact Re lay EX- Requirements 230VAC HALLsensor 2 Signal 2 5VDC Reserve 2 Relay normally open contact 5 PE N 4 PE N 3 2 N PE N PE N PE N PE N PE A_TS_L3 VG CAN-BUS DIP switch Standard setting BOTH "ON" (I/O6.0 + I/ O2.0 + MMI.0) A_TS_L2 Enable external conveying devices EF_A EF_B A_TS_L A2_TS_L3 A2_TS_L2 RP A2_TS_L RM_2 T4A RM_ La mbda_ Heiz O2+ RGT+ BRT+ VT BP A3_TS_L3 Aout_2 A3_TS_L2 M ~ ST A3_TS_L ZH RT PTO PTU ZG AT CA NM ODU L Adress Standard setting: Position "0" (I/O6.0 + I/ O2.0 + MMI.0) Aout_ Aout_3 AIn_5a AIn_6a AS TSB AB SK_WM SK_ESÜ SK_STB ERA ERZ EUD FSW FSL EX F A4_KS I/O Platine 2.0 E2 Re lay HALLsensor A5_KS E red black w/b Signal 5VDC AIn_4a Signal 36 Negative pressure measuring T35mA E6 E5 E4 E3 E2 E E7 E8 E9 E0 M ~ Reserve 2 230VAC Ash worm 230VAC ES Ash worm 230VAC ES Insufficient water 230VAC Emergency Off 230VAC STB 230 VA C ES Grate up 230 VA C Reserve 230VAC Malfunction external conveying devices 230VAC Door combustion chamber 230 VA C Combustion chamber 230VA C PE PE PE PE PE PE PE PE PE PE B ANP HAICO TRI Fill level ES Klixon Klixon ES ES ES Klixon Klixon Klixon compiled: bu, Dosing system Cleaning Cleaning Ash removal Congestion Door Feed Dosing Delivery Congestion approved: 230VAC 230VAC boiler worm Dosing chip bunker system system system Feed system 230VAC 230VAC 230VAC system 230VAC 230VAC 230VAC 230VAC 230VAC Figure 5/ - HDG Compatronic circuit diagram 89 HDG Bavaria GmbH November 2006 HDG Compact - Version - en

90 5 Circuit diagrams HDG Hydronic circuit diagram 5.2 HDG Hydronic circuit diagram Copyright according to DIN34 H H2 H3 Schirm (SH) SH - L H + Remote control CCT Remote control CCT 2 + H L H4 H5 H6 H7 H8 H H2 H3 H4 H5 H6 H7 H8 Supply CCT - H9 H0 H H2 H3 H4 H5 H6 H7 H8 H9 H20 H2 H9 SH H0 HH2 H3 H4 H5 H6 H7 H8 H9 Boiler upper Temp. of oil-fired boiler DH temp./ supply CCT 3 Solar coll. temp. H20 H2H22 H23 H24 Reserve H22 H23 H24 Reserve Bus cabel LiYCY 2x2x0,25 (or JYSTY 2x2x0,8) screened, twisted pairs (max. 00 m length) bus cable is not included in the delivery! H25 H25 PE N H26 PE N PE N H26 PE N M ~ HKP 2 H27 PE N H28 PE H27 PE N H28 PE F: electronic (if H lights up, F is OK.) F2: Solar pump mixer 3 open Solar buffer pump/ dist. heat. pump mixer 3 closed Mixer Mixer 2 Hot water heating pump HKP HKP 2 Enable oil firing/ HKP 3 OPEN CLOSED OPEN CLOSED L M ~ HKP M ~ HAICO CAN I/O 20. N H29 PE N H30 N H29 PE N H30 M ~ Mixer 2 230VAC H H3 CAUTION! Rotary switch setting: first module : "0" second module : "" PE N H32 H33 H3 PE N H32 H33 M ~ Mixer PE PE M ~ F N H34 PE N N H34 PE N M ~ F2 H35 H35 Mains 230VAC / ~ single phase completely isolated! Connection diagram HDG Bavaria HDG Hydronic Date Revision Siemensstraße 6 und 22 Desig-Nr Massing Page / Figure 5/2 - HDG Hydronic circuit diagram 90 HDG Bavaria GmbH November 2006 HDG Compact - Version - en 0 8 Remote control CCT 3 EF C D AB 7 Supply CCT 2 Boiler lower PE N PE N PE N Enable oil firing/ HKP 3 Hot water heating pump Solar buffer pump/ dist. heat. pump mixer 3 closed Solar pump/ mixer 3 open Plug CAN -BUS MMI.0 od. I/O 6.0 Schirm (SH) Slide switch position: Use of one module : ON CAN VCC CAN out H CAN out L CAN GND Schirm

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92 HDG Bavaria GmbH Heizsysteme für Holz Siemensstraße 6 und 22 D Massing Tel. +49 (0) Fax +49 (0) Internet info@hdg-bavaria.com