HDG Compact 25 User manual

hdg-bavaria.com
HDG Compact 25 - 80
Operation Manual

Operation Manual HDG Compact 25 - 80 - Content
3
Content
1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Structure of the Operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.3 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Basic system design principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Basic principles on the content of the operating manual . . . . . . . . . . . . . . . . . . .10
Proper and improper manner of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3 Warnings and safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.4 Duty of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
HDG Compact 25/35 front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HDG Compact 25/35, back side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
HDG Compact 45/50/65/80 front side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
HDG Compact 45/50/65/80, back side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Version of the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
HDG Compatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Control modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
HDG Hydronic control functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
HDG Compact 25/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
HDG Compact 45/50/65/80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Permissible fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Wood chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Required room sizes and minimum spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Furnace room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Fuel bunker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Operation Manual HDG Compact 25 - 80 - Content
4
Delivery system versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Dimensions on flue pipe side, HDG Compact 25/35 . . . . . . . . . . . . . . . . . . . . . . . 49
Dimensions on back side HDG Compact 25/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Dimensions on flue pipe side, HDG Compact 45/50/65/80 . . . . . . . . . . . . . . . . . 51
Dimensions on back side HDG Compact 45/50/65/80 . . . . . . . . . . . . . . . . . . . . . 52
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Placing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installing the combustion fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installing the automatic ash removal system -
HDG Compact 25/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installing the automatic ash removal system -
HDG Compact 45/50/65/80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Installing the automatic cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installing the feeding system and pressure equalisation hose. . . . . . . . . . . . . . 69
Installing the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Wiring the circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Attaching covers and hoods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Installing and adjusting the ash containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting the chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5 Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.6 HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Installing the controller housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Installing the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.7 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.8 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.9 Thermal safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.10 HDG hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hydraulic system 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Hydraulic system 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Setting the display language, boiler type and supply voltage . . . . . . . . . . . . . . 85
Setting the delivery version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Setting the fuel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Selecting the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Checking the actuators in manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Checking the sensors in manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Operation Manual HDG Compact 25 - 80 - Content
5
Filling the fuel bunker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Checking and adapting the basic parameter settings. . . . . . . . . . . . . . . . . . . . . . .95
Switching to automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Saving operating parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
6.1 Overview of the controls and display components. . . . . . . . . . . . . . . . . . . . . . . . . . .98
Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
EMERGENCY STOP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Control unit of HDG Compatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
6.2 Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.3 Switching off the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.4 Displaying information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.5 Selecting and changing parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Selecting a level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Setting the enable or reduction times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Setting the heating times for heating circuits and heating hot water. . . . . . 104
6.6 Changing operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.7 Operating statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.8 Filling the fuel bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Procedure for filling with wood fuel products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Procedure for filling of pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.9 Performing the chimney sweep test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Before the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
On the day of the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
During the test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
After the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.10 Structure of the menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Available levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Contents of the levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Information level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Customer and service levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Manual mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7 Cleaning and servicing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.1 Cleaning and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Generally applicable safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Checking and cleaning the tilting grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Checking and emptying the ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Lubricating the feeding system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Checking the drive chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Operation Manual HDG Compact 25 - 80 - Content
6
Cleaning the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Check and clean the cleaning shaft and turbulators . . . . . . . . . . . . . . . . . . . . . . 155
Checking and cleaning the ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Checking and cleaning the lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Inspecting and cleaning the flue pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Checking and cleaning the ash removal system . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Checking and cleaning the pressure equalisation hose . . . . . . . . . . . . . . . . . . . 162
Checking and cleaning the flue gas fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Cleaning the flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Checking and lubricating the fill level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Inspecting the fuel bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.3 Configuring emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
9 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
10 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
10.2 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
10.3 Warranty exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
11.1 Declaration of Conformity
HDG Compact 25 - 80181
11.2 Installation declaration HDG TBZ 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Notes on this manual – Introduction
7
1 Notes on this manual
1.1 Introduction
EASY AND SAFE OPERATION This Operating manual contains important instructions on the
•HDG Compact 25/35
•HDG Compact 45/50/65
•HDG Compact 80
and how to operate it properly and safely. Following these instruc-
tions helps to avoid dangers, prevent repair costs and downtimes,
maintain reliability and extend the service life of the heating system.
READING THE OPERATING
MANUAL
This Operating manual must be read and applied by everyone who
operates or works on the heating system HDG Compact 25 - 80.
TECHNICAL CHANGES We continuously develop and improve our boilers. The information
in this edition was correct at the time of going to press.
All details in these instructions on standards, regulations and works-
heets should be checked before use and should be compared with
the regulations applying locally at the site where the system is ins-
talled.
We reserve the right to make changes which may then differ from the
technical details and illustrations in this Operating manual.
COPYRIGHT Written permission is required from HDG Bavaria GmbH for reprin-
ting, storage in a data-processing system or transmission by elect-
ronic, mechanical, photographic or any other means, and for copies
or translations of this publication, in whole or in part.
SYMBOLS USED In this Operating manual, the following designations and symbols
are 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 Operating manual
8
HDG Compact 25 - 80 - Version 2 - en ©HDG Bavaria GmbH October 2007
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 and install the heating system.
5 Commissioning the system ... how the heating system is put into initial service.
6 Using the heating system ... how to properly operate the heating system.
7 Cleaning and servicing 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.
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 hea-
ting system, e.g. the stoker auger.
Delivery system Fuel transport system - carries fuel from the bunker to the dosing
unit or to the intermediate container.
Feeding system Feeds the fuel to the boiler by means of the rotary feeder and the
stoker auger.
Display Display of the HDG Compatronic control unit.
Ash removal motor Drives the ash removal augers.
Ash removal augers These transport the combustion chamber ash and fly ash into the
exterior ash containers.
Wood chips, B1 Machine-chopped wood with a water content of between 15 to 35
percent (in accordance with EN 303-5).
Main switch Switches off the mains supply to the entire heating system.
HDG Compact 25 - 80 Boiler for burning wood chips, shavings and wood pellets.
HDG Compatronic Electronic control unit of the boiler, feeding system and delivery
system.
HDG Hydronic Heating system regulator for controlling the hydraulic systems.
Heating system Comprised of boiler and corresponding accessories.
Extinguishing device Extinguishes what is within the delivery system if the temperature
of the contents exceeds 90°C.
EMERGENCY STOP switch Must be used in an emergency - interrupts all actuators; does not
switch off the mains supply to the entire heating system.
Grate tilting motor Electric motor which moves the tilting grate.
Sensor Records certain parameters (temperature, fill level) and forwards
them to the control for analysis.
Stoker auger Carries the fuel from the rotary feeder into the combustion cham-
ber.
Rotary feeder Part of the feeding system - separates the combustion chamber
from the silo and transport unit and acts as back-burn protection.
Table 1/2 - Glossary

2 Safety instructions – Intended use
10
HDG Compact 25 - 80 - Version 2 - en ©HDG Bavaria GmbH 10/2007
2 Safety instructions
2.1 Intended use
BASIC SYSTEM DESIGN PRINCIPLES
BASIC PRINCIPLES The heating system was built using state-of-the-art technology and
conforms to recognised safety regulations. Nevertheless, there is still
a risk of injury or death to users or bystanders, and of adverse effects
upon the heating system or upon other material goods.
Have your specialist heating company provide you with detailed ins-
tructions on the operation of the heating system.
USING THE HEATING SYSTEM Only use the heating system when it is in perfect condition. Use it
properly, as intended, be aware of safety and hazards, and observe
the Operating manual. Have any faults which could impair safety
fixed immediately.
BASIC PRINCIPLES ON THE CONTENT OF THE OPERATING MANUAL
SCOPE The content of this operating manual is intended exclusively for the
planning, installation and operation of the HDG Compact 25 - 80 hea-
ting systems. Any further implementation of applicable standards,
for example with regard to the installation of the heating system (pi-
pework, etc.) is not part of this operating manual. HDG Bavaria does
not assume any liability for this.
PROPER AND IMPROPER MANNER OF OPERATION
PURPOSE OF THE HEATING
SYSTEM
The HDG Compact 25 - 80 heating system is designed for the stan-
dard use of burning wood fuel products made from untreated wood
in the form of wood chips, shavings and pellets for the purpose of
warm water heating.
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 specified operating values will affect the heating
system's control program and could lead to malfunctions. Only
trained maintenance and operation personnel may undertake modi-
fications to the operating values.
The use of materials with other technical burning characteristics re-
quires comprehensive modification of the control parameters by
qualified specialists.

©HDG Bavaria GmbH 10/2007 HDG Compact 25 - 80 - Version 2 - en
2 Safety instructions – Residual risks
11
2.2 Residual risks
Despite all precautions, the following residual risks remain:
For more information on fuel, see chapter “3 Mode of operation”,
section “ Permissible fuel”.
Caution!
Hot surfaces
Contact with the hot surfaces of the boiler can lead to burns.
Wait until the boiler has cooled down before touching non-insu-
lated components.
Danger!
Danger of asphyxiation and explosion from carbon monoxide
When the boiler is in operation, carbon monoxide escaping from
open cleaning or inspection hatches can cause asphyxiation or ex-
plosions.
Do not leave these open any longer than necessary.
Warning!
Danger of fire
Opening doors and lids to hot combustion residues can pose the
danger of fires.
Keep the openings closed during operation, and when performing
cleaning work, allow the combustion residues to cool down before
you place them in a fireproof container.
Warning!
Danger from suspended loads
The boiler weighs over 700 kg. If the boiler is dropped during trans-
port, persons can be seriously injured and the boiler can be da-
maged.
Make sure that you use appropriate lifting gear when placing the
boiler.

2 Safety instructions – Warnings and safety symbols used
12
HDG Compact 25 - 80 - Version 2 - en ©HDG Bavaria GmbH 10/2007
2.3 Warnings and safety symbols used
The following warnings and safety symbols are used in this Opera-
ting manual:
Warning!
Danger of injury
The cleaning shaft lid is very heavy and can fall shut. Hands and
arms could thereby be crushed.
Take care not to bump into the opened cleaning shaft lid and cause
it to fall shut.
Warning!
Risk of injury from automatically driven components
When working on the automatic ash removal or automatic cleaning
systems, hands and arms could be injured.
Turn off the main switch when performing any work on these com-
ponents.
Danger!
Dangerous electrical current or voltage
The circuit boards and electrical components carry current.
Have work on electrical components performed only by a qualified
electrician and turn the main switch off.
Warning!
The boiler is under pressure.
Danger!
Dangerous 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 inju-
ries or to extensive material damage.

©HDG Bavaria GmbH 10/2007 HDG Compact 25 - 80 - Version 2 - en
2 Safety instructions – Warnings and safety symbols used
13
Warning!
Hand injuries can occur
Working in areas marked with this symbol can lead to hand injuries.
Warning!
Automatic start-up
Working in areas marked with this symbol can lead to injuries due
to automatic start-up.
Caution!
Hot surfaces
Working in areas marked with this symbol can lead to burns.
Warning!
Danger of fire
Working in areas marked with this symbol can lead to a fire.
Danger!
Danger of asphyxiation due to lack of oxygen
When working in areas marked with this symbol, there is a danger
of asphyxiation due to high concentrations of carbon monoxide.
Danger!
Danger of explosion
When working in areas marked with this symbol, there is a danger
of explosion due to high concentrations of carbon monoxide.
Warning!
Suspended loads
When working in areas marked with this symbol, there is a danger
of falling objects.
Important!
Frost danger
Only install the heating system in a frost-proof room.

2 Safety instructions – Duty of information
14
HDG Compact 25 - 80 - Version 2 - en ©HDG Bavaria GmbH 10/2007
2.4 Duty of information
READING THE OPERATING
MANUAL
Every person performing any tasks on the system is required to read
the Operating manual prior to beginning work, particularly the
chapter “2 Safety instructions”.
This is especially important for persons who only occasionally work
on the heating system, for example when cleaning or servicing it.
The Operating manual must always be kept readily accessible at the
place where heating system is installed.
Instructions regarding disposal
Additional information for the operator

3 Mode of operation – Overview
15
3 Mode of operation
3.1 Overview
The version of the HDG Compact 25 - 80 heating system installed de-
pends on whether the feeding system is to be fitted
•on the right-hand side or
•on the left-hand
side.
The heating system is equipped as standard with an automatic heat
exchanger cleaning system.
The HDG Compact 80 is already equipped as standard with a de-as-
hing system for automatic ash removal to external containers. This
component is also optionally available for the HDG Compact 25 - 65.
When selecting the feeding unit for the HDG Compact 25 - 80 hea-
ting system, you can choose between the following:
•TBZ 150 for feeding wood chips, planing shavings and pellets.
•Pellet vacuum delivery system with TBZ 80 for feeding the pellets.
The HDG Compact 25 - 80 heating system can also be equipped with
the following delivery systems:
•Flexi-blade delivery system FRA
•Jointed arm delivery system
•Walking floor delivery system
•Silo delivery system
•Pellet delivery system
✎This operating manual - unless otherwise specified - depicts and
describes the fully equipped version with the TBZ 150 feeding
system on the left-hand side.

3 Mode of operation – Overview
16
HDG COMPACT 25/35 FRONT SIDE
1 Combustion chamber temperature sensor
2. Control unit of HDG Compatronic
3 Cleaning system drive
4EMERGENCYSTOP
5Fluegasfan
6Lambdasensor
7 Flue pipe connection
8 Flue gas temperature sensor
9 Heat exchanger surfaces with cleaning turbulators in between
10 Ash removal augers
11 Tilting grate
12 Combustion chamber primary burning
13 Ignition pipe
14 Feeding system
15 Combustion chamber secondary burning
Figure 3/1 - Front side of the HDG Compact 25/35 boiler
13 8 6
5432
15
14 7
1
12 11 910

3 Mode of operation – Overview
17
HDG COMPACT 25/35, BACK SIDE
1 Connection of immersion sleeve for thermal safety device
(DN 15 female)
2 Safety heat exchanger connections (DN 15, outside thread)
3Mainswitch
4 Ignition fan
5 Servo motor for primary air
6 Servo motor for secondary air
7 Ash removal motor
8 Grate tilting motor
Figure 3/2 - HDG Compact 25/35 boiler back side
8 7 6 5
4
3
21

3 Mode of operation – Overview
18
HDG COMPACT 45/50/65/80 FRONT SIDE
1 Combustion chamber temperature sensor
2 Control unit of HDG Compatronic
3 Cleaning system drive
4EMERGENCYSTOPswitch
5 Flue gas temperature sensor
6Lambdasensor
7 Flue pipe connection
8 Heat exchanger surfaces with cleaning turbulators in between
9 Walking floor for ash removal
10 Ash removal augers
11 Combustion chamber primary burning
12 Tilting grate
13 Ignition pipe
14 Feeding system
15 Combustion chamber secondary burning
Figure 3/3 - Front side of the HDG Compact 45/50/65/80 boiler
2
8 7
4 63
13
15
14
1 5
101112 9

3 Mode of operation – Overview
19
HDG COMPACT 45/50/65/80, BACK SIDE
1 Connection of immersion sleeve for thermal safety device (DN 15,
inside thread)
2 Safety heat exchanger connections (DN 15, outside thread)
3Mainswitch
4 Ignition fan
5 Pressure equalisation hose
6Combustionfan
7 Servo motor for primary air
8 Ash removal motor
9 Grate tilting motor
10 Servo motor for secondary air
Figure 3/4 - HDG Compact 45/50/65/80 boiler back side
1
876
3
2
9
4
5
10

3 Mode of operation – Functional description
20
3.2 Functional description
VERSION OF THE HEATING SYSTEM
The HDG Compact 25 - 80 heating system may contain the following
components:
1 Delivery system
2Feedingsystem
3 HDG Compact 25 - 80 boiler with HDG Compatronic
4Accumulator
Figure 3/5 - Overview
1 2 3 4