HDG Pelletmaster 15 User manual

hdg-bavaria.com
HDG Pelletmaster 15/25
Operation Manual
V 03 - 08/2008

Operation Manual HDG Pelletmaster 15/25 - Content
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Content
1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Structure of the Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Basic principles for the construction of the system . . . . . . . . . . . . . . . . . . . . . . . . .10
Proper and improper manner of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 Residual risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3 Warnings and safety symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.4 Duty to inform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
HDG Pelletmaster 15/25 front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
HDG Pelletmaster 15/25 side view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HDG Pelletronic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Injection and extraction nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Vacuum delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HDG Hydronic control functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Permissible fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Recommended wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Space requirements and minimum spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Pellet bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Alternative pellet storage options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Dimensions of the hydraulic and flue-side connections. . . . . . . . . . . . . . . . . . . . .42
Installation dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Operation Manual HDG Pelletmaster 15/25 - Content
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4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the feed system and combustion fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installing the ignition fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connecting the pressure equalisation hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Attaching the boiler cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing the pellet vacuum container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installing the wiring in the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Attaching the cladding for the technical components . . . . . . . . . . . . . . . . . . . . . 58
Mounting the ash box and attaching the technical components door. . . . . . 59
Fitting the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connecting the suction and return hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fitting the cover to the technical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connecting the chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.5 HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installing the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installing the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.6 Pellet bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Installing the injection and extraction nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Installing the door rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installing the pellet anti-shatter protective mat . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installing door contact switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installing the sloping floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7 Delivery and vacuum delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.8 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.9 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.10 HDG hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Switchng on the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Setting the boiler output and display language . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Selecting the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Checking the actuators in manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Checking the sensors in manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Filling the intermediate container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Checking the basic parameter settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Switching to automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Parameters for manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Saving operating parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Operation Manual HDG Pelletmaster 15/25 - Content
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6.1 Overview of the controls and display components. . . . . . . . . . . . . . . . . . . . . . . . . 109
Mains power switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Control unit for HDG Pelletronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Operating mode indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.2 Switching the heating system on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.3 Switching the heating system off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.4 Displaying information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.5 Selecting and changing parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Selecting a level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Setting the enable or reduction times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Setting the heating times for heating circuits and heating hot water. . . . . . 115
6.6 Changing operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.7 Operational statuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.8 Filling the pellet bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.9 Performing the chimney sweep test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Before the measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
During the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
After the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.10 Structure of the menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Available levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Contents of the levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Information level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Customer and service levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7 Cleaning and maintaining the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.1 Cleaning and maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Emptying the ash box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Checking and cleaning the stepped grate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cleaning the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Inspecting and cleaning the flue pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Cleaning the cleaning shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Checking and cleaning the ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Checking and cleaning the lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Cleaning the flue sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cleaning the pellet vacuum container and fill level sensor. . . . . . . . . . . . . . . . 154
Cleaning the pellet bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.1 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.3 Configuring emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Operation Manual HDG Pelletmaster 15/25 - Content
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9 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.2 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.3 Warranty exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
11 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 Notes on this manual – Introduction
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1 Notes on this manual
1.1 Introduction
EASY AND SAFE OPERATION This Operation Manual contains important instructions on the
•HDG Pelletmaster 15
•HDG Pelletmaster 25
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 Pelletmaster 15/25.
TECHNICAL CHANGES 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 site where the boiler is
installed.
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
✓Result of the action described
✎Cross reference for more explanation
•List
–List

1 Notes on this manual – Structure of the Operation Manual
8
1.2 Structure of the Operation Manual
The Operation Manual is structured as follows:
Chapter This explains ...
1 Notes on this manual ... how to use this Operation 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 EC Declaration of Conformity
Table 1/1 - Structure of the Operation Manual

1 Notes on this manual – Glossary
9
1.3 Glossary
Term Explanation
Actuator This is a component which performs a certain function in the
heating system, e.g. the stoker auger
Automatic cleaning At intervals, automatically cleans the surface of the tubular heat
exchangers
Delivery system The pellet transport system in the pellet bunker
Display Display on the HDG Pelletronic control unit
Extinguisher Extinguishes the contents of the pellet vacuum container if the
temperature of the contents exceeds 90°C
Feed system Feeds the fuel to the boiler by means of the rotary feeder and the
stoker auger.
Grate motor Electric motor which moves the stepped grate
HDG Hydronic Heating system regulator for controlling the hydraulic systems
HDG Pelletmaster 15/25 Boiler for burning wood pellets
HDG Pelletronic Electronic control of the boiler
Heating system Comprised of the boiler and relevant accessories
Pellet vacuum container A container which supplies pellets to be burnt in the boiler via the
stoker worm
Rotary feeder Burn back protection, separates the pellet vacuum container from
the stoker worm
Sensor Records certain parameters (temperature, fill level) and forwards
them to the control for analysis
Stepped grate Stepped grate in the combustion chamber
Stoker auger Conveys the pellets from the pellet vacuum container to the
combustion chamber
Vacuum delivery system Pellet transport system which connects the pellet vacuum
container with the transfer station
Wood pellets Binder-free pellets made of pressed, untreated wood
Table 1/2 - Glossary

2 Safety instructions – Intended use
10
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 a detailed
explanation of 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.
PROPER AND IMPROPER MANNER OF OPERATION
APPLICATION OF THE HEATING
SYSTEM
The heating system was designed to burn wood pellets.
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.
You may only enter or change operating values as specified in this
manual. Any other inputs will affect the heating system's control
programme and could lead to malfunctions.
UK SMOKE CONTROL AREAS The HDG Pelletmaster 15/25 models have been recommended for
exemption under Section 21 of the Clean Air Act 1993 for use in
smoke control areas when burning wood chips or wood pellets
which are selected in accordance with the recommendations on fuel
in this manual, see section “3 Mode of operation” in chapter “3.4 Fuel
quality requirements”.

2 Safety instructions – Residual risk
11
2.2 Residual risk
Despite all precautions, the following residual risks remain:
Caution!
Hot surfaces!
Contact with the hot surfaces of the boiler can lead to burns. In
particular, the inspection doors and cover heat up greatly during
operation.
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 open ash doors.
Do not leave the ash doors open any longer than necessary.
Caution!
Danger from suspended loads!
The boiler weighs over 250 kg. If the boiler is dropped during
transport, persons can be seriously injured and the boiler can be
damaged.
Make sure that you use appropriate lifting gear when installing the
boiler.

2 Safety instructions – Warnings and safety symbols used
12
2.3 Warnings and safety symbols used
The following warnings and safety symbols are used in this
Operation Manual:
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.
Caution!
Frost danger!
Work on locations marked with this symbol can lead to frost
damage.
Instructions regarding disposal
Additional information for the operator

2 Safety instructions – Duty to inform
13
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.

3 Mode of operation – Overview
14
3 Mode of operation
3.1 Overview
HDG PELLETMASTER 15/25 FRONT VIEW
1 HDG Pelletronic control unit
2 Flue pipe connection
3 Tubular heat exchanger
4 Cleaning turbulators
5 Combustion chamber
6 Control cabinet with power switch
7Ashbox
Figure 3/1 - HDG Pelletmaster 15/25 front side
2
3
67 5
4
1

3 Mode of operation – Overview
15
HDG PELLETMASTER 15/25 SIDE VIEW
1 Suction turbine
2 Pellet vacuum container
3 Cleaning shaft lid with suction fan
4 Combustion chamber door
5Ashremoval
6Steppedgrate
7Combustionfan
8 Pressure equalisation hoses
9 Ignition fan
10 Feed system
Figure 3/2 - HDG Pelletmaster 15/25 side view
4
5
86
3
2
7
9
1
2
4
5
86
3
2
7
9
1
2
5
6
97
4
3
8
10
2
1

3 Mode of operation – Functional description
16
3.2 Functional description
The heating system contains the following components:
1 Injection and extraction nozzles
2Accesshatch
3 Delivery system
4 Sloping floor supports
5 Pellet anti-shatter protective mat
6 Transfer station
7 HDG Hydronic (option)
8 Vacuum delivery system
9 HDG Pelletmaster 15/25 boiler with HDG Pelletronic
COMBUSTION PROCESS
In the HDG Pelletmaster 15/25 boiler, the pellets introduced into the
combustion chamber are automatically ignited with an electrical
ignition fan.
To avoid the grating from slagging up and to ensure ash removal
occurs, the grating is moved at intervals.
The ash and fly ash produced is collected in the ash box.
Figure 3/3 - Overview
9843 721 5 6

3 Mode of operation – Functional description
17
The air necessary for combustion is supplied as required via a speed-
controlled fan. An additional suction fan supports the removal of flue
gases.
Sensors are used to
– continuously monitor the firing,
– adapt the boiler output for the heat requirements,
– minimise emissions and
– optimise boiler efficiency.
HDG PELLETRONIC
The HDG Pelletronic boiler control unit is the electronic hub.
It consists of the ready to use input/output circuit board in the
control cabinet and the control unit on the top left side of the HDG
Pelletmaster 15/25 boiler.
Using the control unit, you can regulate the HDG Pelletronic system
and call up information on the current process.
If the HDG Pelletronic signals a demand for more heat, the pellet
system automatically changes to Fill mode and the combustion
chamber is filled with pellets.
Once the desired boiler temperature has been reached, i.e. the need
for heat has been met, the heating system changes to Burn out
mode and subsequently to the operating status No demand.
You can choose between three control versions:
•Controlled:
– Constant feed rate and constant combustion air flow rate (also
in emergency operation)
•Combustion control:
– Constant, specified combustion chamber temperature and
optimal combustion
•Control of combustion and output:
– The output supplied is adjusted to the heat used with
optimised combustion
Figure 3/4 - Control unit for HDG Pelletronic
Pelletronic
Pelletmaster
Mode
Menu Enter

3 Mode of operation – Functional description
18
INJECTION AND EXTRACTION NOZZLES
The injection and extraction nozzles are on the outer wall of the
pellet bunker.
The injection nozzle is used to blow pellets into the bunker. A
protective mat prevents the pellets from being broken.
The extraction nozzle suctions air out by means of an external fan
whilst the bunker is being filled. This prevents excessive pressure
from building up in the pellet bunker.
DELIVERY SYSTEM
The delivery system is in the pellet bunker.
Via the conveyor auger, the pellets on the sloping floor are
transported to the transfer station.
The delivery system is controlled through the HDG Pelletronic.
VACUUM DELIVERY SYSTEM
The vacuum delivery system links the transfer station with the pellet
vacuum container for the HDG Pelletmaster 15/25 boiler.
This vacuum delivery system transports the pellets from the transfer
station to the vacuum container in the boiler.
This process is monitored by sensors and, using the HDG Pelletronic,
can be limited to various times of day.
HDG HYDRONIC
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
•Transfer of heat into the district heating grid
•Integration of second boiler
•Solar system for hot water and support of the heating system

3 Mode of operation – Functional description
19
HDG HYDRONIC CONTROL FUNCTIONS
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.
If the heating circuit control is operating, room temperature will be
adjusted to a preset daytime or night-time value.
Example:
Outdoor temperature -5 °C
Steepness 1.6
Parallel shift 5°C
With these presumed values, you can see in Figure 3/5 - Diagram of
the temperature of water leaving the boiler that the heating circuit
supply temperature of the water is 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.
OUTDOOR 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.
Figure 3/5 - Diagram of the temperature of water leaving the boiler
Outdoor temperature
Supply temperature
3.5
3.0 2.5
2.0
1.0
1.5
0.5
20 15 19 5 0 -5 -10 -15 -20
20 30 40 50 60 70 80
1.6
0.8
Parallelshift

3 Mode of operation – Functional description
20
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 paramater group “8 - Hydraulic system”, the corresponding
heating system is configured for each of the various heating circuits.
There is a choice of five heating systems:
•None
– This is selected whenever 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
allocated.
•Floor heating
– If this heating system is selected, the corresponding
parameters are calculated for a flatter characteristic heating
curve and a lower laying temperature. With this heating
system, you also have the option of activating a screed drying
programme.
•Constant
– This system operates independently from the outdoor
temperature and maintains a constant water temperature as it
leaves the boiler. This system is suitable, for example, for
controlling the heating of a swimming pool. An indoor
thermostat unit cannot be integrated with this heating system.
•Uncontrolled
– In an uncontrolled heating system, only the enable
temperature and the time programme are taken into account.
This heating system operates without a heating circuit mixer. If
combined with an indoor thermostat unit, the pump switches
off after the desired room temperature is reached.