HDG Turbotec series User manual

hdg-bavaria.com
HDG Turbotec
withHDG Lambda-Control 1
Operation Manual

Operation Manual HDG Turbotec mit HDG Lambda-Control 1 - Content
3
Content
1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Structure of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Basic principles for the construction of the system . . . . . . . . . . . . . . . . . . . . . . . . .11
Basic principles for the content of the operating manual . . . . . . . . . . . . . . . . . . .11
Proper and improper manner of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.2 Residual risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.3 Warnings and safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4 Duty to inform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Cross-section HDG Turbotec with HDG Lambda Control 1 . . . . . . . . . . . . . . . . . .16
Back side HDG Turbotec. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Boiler HDG Turbotec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HDG Lambda Control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Permissible fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.5 Declaration of conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.2 Structural requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Installation room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Necessary room sizes and minimum spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.4 Hydraulic connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
HDG hydraulic system 3.0 with buffer tank, hot water tank and one
heating circuit as a stand-alone, wood-fired system . . . . . . . . . . . . . . . . . . . . . . . .30
HDG hydraulic system 3.1 with buffer tank, hot water tank and an
additional oil or gas boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.5 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Operation Manual HDG Turbotec mit HDG Lambda-Control 1 - Content
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4.6 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the claddings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mounting the HDG Lambda Control 1 control unit . . . . . . . . . . . . . . . . . . . . . . . . 42
Installing the air control units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installing the flue gas fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installing the flue gas sensor and lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installing the rear covers and the lever for the upper filling hatch. . . . . . . . . . 48
4.7 Connecting the chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.8 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.9 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.10 Connecting the thermal safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Starting the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Configuring the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Setting the target boiler temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Testing system components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Adjustment of parameters depending on fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Heating up the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 Overview of the controls and display components. . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2 Switching the heating system on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Emergency heating switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3 Structure of the menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
“Heat production off” menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
“Heat production on” menu structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.4 Displaying information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.5 Entering user settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Setting the boiler temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.6 Heating up and reloading the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Heating up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Reloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.7 Chimney inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Before the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Preparations to be made on the day of inspection. . . . . . . . . . . . . . . . . . . . . . . . . 73
6.8 Switching off the heating system for maintenance or repair work . . . . . . . . . . . 74

Operation Manual HDG Turbotec mit HDG Lambda-Control 1 - Content
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7 Cleaning and maintaining the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.1 Cleaning and maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
7.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Cleaning the primary air inlets, fuel chamber and burner nozzle . . . . . . . . . . . .77
Cleaning the flame channel and ash compartment. . . . . . . . . . . . . . . . . . . . . . . . .79
Cleaning the heat exchanger surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Cleaning the flue pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Checking and cleaning the lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Cleaning the flue sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Checking and cleaning the flue gas fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Lubricating the door latch bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Checking and cleaning the flue bypass damper . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Cleaning the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Inspecting and cleaning the air control units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Inspecting the integrity of the door seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Calibrating the lambda sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
8.1 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
8.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Faults which do not interrupt the production of heat. . . . . . . . . . . . . . . . . . . . . . .91
Faults which interrupt the production of heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
9 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
10 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
10.2 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
10.3 Warranty exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

6

1 Notes on this manual – Introduction
7
1 Notes on this manual
1.1 Introduction
SAFE AND SIMPLE OPERATION This Operation Manual contains important instructions on the boiler
HDG Turbotec with HDG Lambda Control 1
heating systems and how to operate them properly and safely.
Following these instructions helps to avoid dangers, prevent repair
costs and downtimes, maintain reliability and extend the service life
of the heating system.
READING THE OPERATION
MANUAL
This Operation Manual must be read and applied by everyone who
operates or works on the HDG Turbotec.
TECHNICAL CHANGES We continuously develop and improve our boilers. The information
in this version was correct at the time of going to press.
We reserve the right to make changes which may then deviate from
the technical details and illustrations in this Operation Manual.
COPYRIGHT 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, and for
copies or translations of this publication, in whole or in part.
SYMBOLS USED In this Operation Manual, the following denotations or symbols will
be used for particularly important information:
1. Instructions to the operator
2. Work through the steps in the sequence specified.
✓Result of the action described
✎Cross reference for more explanation
•List
–List

1 Notes on this manual – Structure of the operating manual
8
1.2 Structure of the operating manual
The operating manual is structured as follows:
Chapter This explains ...
1 Notes on this manual ... how to use this operating manual.
2 Safety notes ... everything on the subject of safety that you should consider
when using the heating system.
3 Mode of operation ... the structure and all of the features of the heating system.
4 Planning and installation ... how to properly plan for and install the heating system.
5 Commissioning the system ... how the heating system is to be put into initial service.
6 Using the heating system ... how to properly operate the heating system.
7 Cleaning and maintaining
the heating system
... how to clean the heating system and who is responsible for its
maintenance.
8 Troubleshooting ... how to rectify faults in the heating system.
9 Notes on dismantling and
disposal
... what has to be considered when dismantling and disposing of
the heating system.
10 Warranty ... the terms and conditions of the warranty.
11 Appendix ... where the connections are located on the plug board.
Table 1/1 - Structure of the operating manual

1 Notes on this manual – Glossary
9
1.3 Glossary
Term Explanation
Actuator This is a component which carries out a certain function in the
heating system, e.g. the thermal safety device (TAS).
Display Display on HDG Lambda Control 1 control panel.
HDG Turbotec Boiler for burning untreated according to 1.BImSchV §3 (1) item 4.
HDG Lambda Control 1 Microprocessor controller to regulate combustion and the heating
of the buffer tank.
Lambda probe Electrical component which monitors residual oxygen levels in the
flue gas.
Reload signal Electrical signal (in the form of an LED on the Lambda Control
panel) which serves as a prompt to reload the fuel chamber.
Reload button Button that must be pressed before the boiler is opened for
reloading or heating up.
Flue gas fan Creates a vacuum inside the boiler and provides the boiler with air
for combustion.
Safety temperature limiter Safety device which switches off the boiler when it exceeds its
maximum temperature, and releases a fault message.
Plug board Pre-fabricated connection strip for electrical components
Sensor Monitors certain parameters (e.g. temperature) and forwards them
to the control system for analysis.
Thermal safety device Safety device which allows cold water to flow through the safety
heat exchanger if the boiler becomes too hot.
Table 1/2 - Glossary

10

2 Safety instructions – Intended use
11
2 Safety instructions
2.1 Intended use
BASIC PRINCIPLES FOR THE CONSTRUCTION OF THE SYSTEM
BASIC PRINCIPLES The heating system was built using state of the art technology and
conforms to recognised safety regulations. Nevertheless, its use still
poses the risks of injury or death of the user or a third party, and of
adverse effects upon the heating system itself or upon other material
goods. Have your specialist heating company provide you with
detailed instructions on the operation of the heating system.
USING THE HEATING SYSTEM Only use the heating system if in perfect condition. Use it properly, as
intended, and be aware of safety concerns and the dangers involved
under observance of the Operation Manual. Have any faults which
could impair safety fixed immediately.
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 boiler HDG Turbotec with
HDG Lambda Control 1. Any further implementation of applicable
standards and guidelines, for example with regard to the installation
of the heating system (pipework, etc.) is not part of this operating
manual. HDG Bavaria does not assume any liability for this.
PROPER AND IMPROPER MANNER OF OPERATION
APPLICATION OF THE HEATING
SYSTEM
The boiler HDG Turbotec is designed for standard operation
involving the burning of wood fuel products made from untreated
wood in the form of split logs and coarse wood chips in hot-water
heating systems.
Any other application is considered improper use. The manufacturer
will accept no liability for any damage resulting from improper use.
The operator bears sole responsibility in such cases.
Proper use includes adherence to the installation, operation and
maintenance requirements specified by the manufacturer.
Modification of the indicated operating values will affect the heating
system's control programme and could lead to malfunctions. Only
trained maintenance and operation personnel may undertake
modifications to the operating values.
For more information on fuel, see chapter “3 Mode of operation”,
section “3.4 Fuel quality requirements”.

2 Safety instructions – Residual risk
12
2.2 Residual risk
Despite all precautions, the following residual risks remain:
Caution!
Hot surfaces!
Contact with the hot surfaces of the boiler (e.g. inside doors, flue
pipe, etc.) can lead to burns. Even after deactivation, the surfaces
only cool down slowly.
Wait until the boiler has cooled down before touching uninsulated
components.
Warning!
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 is burnt out. Do not leave them open any longer than
necessary and never leave them open unsupervised.
Warning!
Danger of fire!
When the heating system is in operation, open doors and lids
constitute a fire danger. Also, combustion residues (ash,coal) can
catch fire again after being removed from the boiler.
Always keep the doors and lids closed. Only open them when the
boiler is burnt out. Do not leave them open any longer than
necessary and never leave them open unsupervised. Put the
annealed combustion residues in the ash pan in a non-flammable
and closable container.
Danger!
Danger of explosion
A concentration of carbon monoxide which is too high can lead to
an explosion.
Observed the required conveying pressure of the chimney.

2 Safety instructions – Warnings and safety symbols used
13
2.3 Warnings and safety symbols used
The following warnings and safety symbols are used in this
Operation Manual:
Caution!
Hand injuries can occur!
Working on the flue gas fan or the flue bypass damper can lead to
hand injuries caused by moving parts.
Disconnect the boiler from the power mains when working on the
flue gas fan.
Danger!
Danger from electrical current or voltage!
Work on the plug boards may only be carried out by a qualified
electrician.
Make the system is disconnected from the mains and secured
against re-activation during this work.
Danger!
Danger from electrical current or voltage!
Work in areas marked with this symbol may only be performed by a
qualified electrician.
Warning!
Hazardous area!
Working in areas marked with this symbol can lead to serious
injuries or to extensive material damage.
Caution!
Hand injuries can occur!
Working in areas marked with this symbol can lead to hand injuries.
Caution!
Hot surfaces!
Working in areas marked with this symbol can lead to burns.
Caution!
Danger of fire!
Working in areas marked with this symbol can lead to a fire.

2 Safety instructions – Duty to inform
14
2.4 Duty to inform
READING THE OPERATION
MANUAL
Every person performing any tasks on the system is required to read
the Operation Manual prior to beginning work, particularly the
chapter “2 Safety instructions”.
This especially applies to persons who only occasionally work on the
heating system, e.g. when cleaning or servicing it.
The Operation Manual must always be kept readily accessible at the
heating system's installation site.
Caution!
Frost danger!
Only install the heating system in a frost-proof room.
Danger!
Danger of explosion
A concentration of carbon monoxide which is too high can lead to
an explosion.
Caution!
Danger from suspended loads!
Working in areas with this symbol may involve danger from falling
objects.
Instructions regarding disposal
Additional information for the operator

3 Mode of operation – Overview
15
3 Mode of operation
3.1 Overview
For the boiler version HDG Turbotec with HDG Lambda Control 1, it is
specified whether the door stop is mounted
•on the right side or
•or the left.
Optionally, the HDG Turbotec can be fitted with an additional upper
filling hatch. This is primarily used for filling the fuel chamber with
coarse wood chips.
This operation manual - unless otherwise specified - describes the
boiler version with the door stop on the right side and the upper
filling hatch.

3 Mode of operation – Overview
16
CROSS-SECTION HDG TURBOTEC WITH HDG LAMBDA CONTROL 1
1 Upper filling hatch
2 Control unit HDG Lambda Control 1
3 Actuating handle for flue bypass damper
4 Interior hatch
5 Filling hatch
6Fuelchamber
7 Primary air servo motor
8 Secondary air servo motor
9 Combustion chamber hatch with inspection window
10 Flame channel
11 Ash compartment
12 Combustion chamber
13 Burner nozzle
14 Flue gas deflector plate
15 heat exchanger surfaces
16 Flue gas exhaust flap
17 Cleaning shaft lid
Figure 3/1 - Cross-section HDG Turbotec with HDG Lambda Control 1
17
9
8
7
6
5
4
3
2
1
16
15
14
13121110

3 Mode of operation – Overview
17
BACK SIDE HDG TURBOTEC
1 Flow connection (DN 32 IG)
2Plugboard
3 Lambda probe
4 Flue pipe connection
5Fluegasfan
6 Filling/draining connection (DN 15 IG)
7 Flue sensor
8 Return connection (DN 32 IG)
9 Safety heat exchanger connections (DN 15 AG)
10 Connection of sensor for thermal safety device (DN 15 IG)
Figure 3/2 - Back side HDG Turbotec
9
8
7
6
4
3
2
1
10
5

3 Mode of operation – Functional description
18
3.2 Functional description
BOILER HDG TURBOTEC
Inside the HDG Turbotec, fuel which has been manually placed in the
fuel chamber (1) and ignited is degassed through the addition of
primary air.
The resulting wood gas is mixed with secondary air in the
combustion chamber (3) where it is burnt off.
Ashes are collected in the large ash compartment (4) for combustion
ash and fly ash.
The air necessary for combustion is supplied as required via the flue
gas fan (5) and two servo motors with metering mechanisms (2).
The lambda probe, flue gas temperature sensor (6) and boiler
temperature sensor serve to
•continuously monitor the firing,
•adjust the boiler output,
•minimise emissions and
•optimise boiler efficiency.
Activating the flue bypass damper (7) before filling causes any flue
gas remaining in the fuel chamber to be sucked out.
The HDG Turbotec is a special boiler for the firing of wood up to 1 m
in length. The HDG Lambda Control 1 control system regulates
combustion, boiler output and the charging of the buffer tank. The
boiler HDG Turbotec and the control system HDG Lambda Control 1
Figure 3/3 - Boiler HDG Turbotec
1
7
5
2
4
6
3

3 Mode of operation – Functional description
19
are harmonised with one another and form a functional unit. This
enables wood to be converted into heat energy in an
environmentally sound and convenient manner.
HDG LAMBDA CONTROL 1
The HDG Lambda Control 1 boiler control unit is the electronic hub.
Using the control unit, you can regulate the HDG Lambda Control 1
system and call up information on the current process.
See chapter “6 Using the heating system”, section “6.3 Structure of
the menus”.
Figure 3/4 - Control unit for HDG Lambda Control 1

3 Mode of operation – Technical data
20
3.3 Technical data
Type of boiler HDG Turbotec 50 L HDG Turbotec 60 L
Nominal thermal power 60.0 kW 60.0 kW
Minimum thermal power 50.0 kW
Boiler efficiency at nominal thermal output: 89,9 % 89,5 %
Boiler class 3 3
Maximum positive operating pressure 3 bar 3 bar
Maximum supply temperature 95 °C 95 °C
Minimum return temperature 55 °C 55 °C
Water capacity 370 l 370 l
Fuel chamber volume 340 l 340 l
Weight 940 kg 940 kg
Exhaust temperature at
•Nominal thermal power
•Minimum thermal output:
170 °C 190 °C
170 °C
Exhaust mass flow at
•Nominal thermal power
•Minimum thermal output:
0.0270 kg/s 0.0330 kg/s
0.0270 kg/s
Required feed pressure 15 Pa 15 Pa
Burning duration per filling, in accordance with
fuel recommendations
Beech: up to 7 h
Spruce: up to 6 h
Beech: up to 6.5 h
Spruce: up to 5.5 h
Diameter of flue pipe connection 180 mm 180 mm
Height of flue pipe connection 576 mm 576 mm
Supply and return connections (bushing) DN 32 IG DN 32 IG
Safety heat exchanger connections (bushing) 2 x DN 15 AG 2 x DN 15 AG
Connection for drain (bushing) DN 15 IG DN 15 IG
Electrical connection / voltage: 230 V 230 V
Water-side resistance at nominal thermal
power
•10 K
•20 K
500 Pa
130 Pa
500 Pa
130 Pa
Minimum air inlet cross section 150 cm2170 cm2
Table 3/1 - Technical data HDG Turbotec
Δϑ
Δϑ