HDG Compact 25 User manual

hdg-bavaria.com
HDG Compact 25/35
Operation Manual
V 02 - 04/2010

Operation Manual HDG Compact 25/35 - Content
V 02 - 04/2010 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 principles for the construction of the system . . . . . . . . . . . . . . . . . . . . . . . . .10
Basic principles regarding the content of the operating manual . . . . . . . . . . . .10
Proper and improper manner of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 Residual risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3 Warnings and safety symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.4 Duty to inform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
HDG Compact 25/35 front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HDG Compact 25/35 back side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Version of the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
HDG Compatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Control modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
HDG Hydronic control functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Permissible fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Wood chips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Necessary room sizes and minimum spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fuel bunker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Delivery system versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Operation Manual HDG Compact 25/35 - Content
4 V 02 - 04/2010
4.2 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dimensions on flue pipe side, HDG Compact 25/35 . . . . . . . . . . . . . . . . . . . . . . . 43
Dimensions on back side, HDG Compact 25/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the automatic ash removal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installing the automatic cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing the feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installing the accumulator sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wiring the circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Attaching covers and hoods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installing and adjusting the ash containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Connecting the chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.5 HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Installing the controller housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Installing the sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.6 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.7 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.8 Thermal safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.9 HDG hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Hydraulic system 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Hydraulic system 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 Starting the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Setting the display language, boiler type and supply voltage . . . . . . . . . . . . . . 68
Setting the delivery version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Setting the fuel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Selecting the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Checking the actuators in manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking the sensors in manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Filling the fuel bunker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Checking and adapting the basic parameter settings. . . . . . . . . . . . . . . . . . . . . . 78
Switching to automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Saving operating parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Operation Manual HDG Compact 25/35 - Content
V 02 - 04/2010 5
6 Using the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
6.1 Overview of the controls and display components. . . . . . . . . . . . . . . . . . . . . . . . . . .81
Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Control unit of HDG Compatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
6.2 Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.3 Switching off the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
6.4 Displaying information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
6.5 Selecting and changing parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Selecting a level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Setting the enable or reduction times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Setting the heating times for heating circuits and heating hot water. . . . . . . .87
6.6 Changing operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
6.7 Operating statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
6.8 Filling the fuel bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Procedure for filling of wood fuel products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Procedure for filling of pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.9 Performing the chimney sweep test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Before the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
On the day of the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
During the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
After the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
6.10 Structure of the menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Available levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Contents of the levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Information level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Customer and service levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Manual operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7 Cleaning and servicing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.1 Cleaning and maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Generally applicable safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Checking and cleaning the tilting grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Checking and emptying the ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Lubricating the feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Checking the drive chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Cleaning the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cleaning the cleaning shaft and turbulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Checking and cleaning the ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Checking and cleaning the lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Inspecting and cleaning the flue pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Checking and cleaning the ash removal system . . . . . . . . . . . . . . . . . . . . . . . . . 143

Operation Manual HDG Compact 25/35 - Content
6 V 02 - 04/2010
Checking and cleaning the flue gas fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Cleaning the flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Checking and lubricating the fill level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Inspecting the fuel bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.3 Configuring emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
9 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.2 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3 Warranty exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
12 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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
•HDG Compact 35
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 OPERATING
MANUAL
This operating manual must be read and applied by everyone who
operates or works on the heating system HDG Compact 25/35.
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
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 operating manual.
COPYRIGHT Written permission is required from HDG Bavaria GmbH for
reprinting, storage in a data-processing system or transmission by
electronic, mechanical, photographic or any other means, and for
copies or translations of this publication, in whole or in part.
SYMBOLS USED In this operating 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 operating manual
8
HDG Compact 25/35 - 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 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 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 stoker auger.
Ash removal augers These transport the combustion chamber ash and fly ash into the
exterior ash containers.
Ash removal motor Drives the ash removal augers.
Delivery system Fuel transport system - carries fuel from the bunker to the dosing
unit or to the intermediate container.
Display Display of the HDG Compatronic control unit
EMERGENCY STOP Must be used in an emergency - interrupts all actuators, however,
it does not switch off the mains supply to the heating system.
Extinguisher Extinguishes what is within the delivery system if the temperature
of the contents exceeds 90 °C.
Feeding system Feeds the fuel to the boiler by means of the rotary feeder and the
stoker auger.
Grate tilting motor Electric motor which moves the tilting grate.
HDG Compact 25/35 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.
Main switch Switches off the mains supply to the entire heating system.
Rotary feeder Part of the feeding system - separates the combustion chamber
from the silo and transport unit and acts as back-burn protection.
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
chamber.
Wood chips, B1 Machine-chopped wood with a water content of between 15 to
35 percent (in accordance with EN 303-5).
Table 1/2 - Glossary

2 Safety instructions – Intended use
10
HDG Compact 25/35 - Version 2 - en ©HDG Bavaria GmbH 10/2007
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 operating manual. Have any faults which
could impair safety fixed immediately.
BASIC PRINCIPLES REGARDING 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 25/35
heating systems. Any further implementation of applicable
standards, 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 HDG Compact 25/35 heating system is designed for the standard
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 operating company 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 operating personnel may undertake
modifications to the operating values.

©HDG Bavaria GmbH 10/2007 HDG Compact 25/35 - Version 2 - en
2 Safety instructions – Residual risk
11
The use of materials with other technical burning characteristics
requires comprehensive modification of the control parameters by
qualified specialists.
UK SMOKE CONTROL AREAS The HDG Compact 25/35 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”.
2.2 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.
Wait until the boiler has cooled down before touching uninsulated
components.
Danger!
Danger of asphyxiation and explosion from carbon monoxide
When the boiler is in operation, carbon monoxide escaping from
opened cleaning or inspection hatches can pose a danger of
asphyxiation or explosions.
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.

2 Safety instructions – Residual risk
12
HDG Compact 25/35 - Version 2 - en ©HDG Bavaria GmbH 10/2007
Warning!
Danger from suspended loads
The boiler weighs over 500 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.
Warning!
Danger of injury
The cleaning shaft lid is heavy and can fall shut. Hands and arms can
thereby be crushed.
Take care not to bump into the opened cleaning shaft lid and cause
it to fall shut.
Warning!
Risk of injury from automatically driven components
When working on the automatic ash removal or automatic cleaning
systems, or on the flue gas fan, hands and arms could be injured.
Turn off the main switch when performing any work on
automatically driven components.
Danger!
Danger from electrical current or voltage
The circuit boards and electrical components conduct electricity.
Have work on electrical components performed only by a qualified
electrician and turn the main switch off.
Warning!
The boiler is under pressure.

©HDG Bavaria GmbH 10/2007 HDG Compact 25/35 - Version 2 - en
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 operating
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.
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.

2 Safety instructions – Duty to inform
14
HDG Compact 25/35 - Version 2 - en ©HDG Bavaria GmbH 10/2007
2.4 Duty to inform
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 holds especially true for persons who only occasionally work on
the heating system, e.g. when cleaning or servicing it.
The operating manual must always be kept readily accessible at the
heating system’s installation site.
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.
Instructions regarding disposal
Additional information for the operator

3 Mode of operation – Overview
15
3 Mode of operation
3.1 Overview
The versions of the HDG Compact 25/35 heating system distinguish
between whether the feeding system is fitted
•on the right side or
•on the left side
.
Available as accessories for the heating system are an automatic
cleaning function for the heat exchanger surfaces and an ash
removal system for automatic ash extraction to external containers.
You can choose from the following versions of feeding units for the
HDG Compact 25/35 heating system:
•TBZ 150 for feeding wood chips, planing shavings and pellets.
•Pellet vacuum delivery system with TBZ 80 for feeding the pellets.
The HDG Compact 25/35 heating system can also be equipped with
the following delivery systems:
•Flexi-blade delivery system FRA
•Hinged arm delivery system KAPA 501
•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 Control unit of HDG Compatronic
2Cleaningmotor
3EMERGENCYSTOP
4Fluegasfan
5 Flue pipe connection
6Lambdasensor
7 Ash removal augers
8Tiltinggrate
9 Combustion chamber primary burning
10 Ignition pipe
11 Feeding system
12 Combustion chamber secondary burning
Figure 3/1 - Front side of the HDG Compact 25/35 boiler
10 98765
4
3
2
1
12
11

3 Mode of operation – Overview
17
HDG COMPACT 25/35 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 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
87 6 5
4
3
2
1

3 Mode of operation – Functional description
18
3.2 Functional description
VERSION OF THE HEATING SYSTEM
The HDG Compact 25/35 heating system may comprise the following
components:
1Accesshatch
2Slopingfloor
3 Delivery system
4 HDG Hydronic (option)
5Feedingsystem
6 HDG Compact 25/35 boiler with HDG Compatronic
COMBUSTION PROCESS
With the HDG Compact 25/35 heating system, the fuel is
automatically fed from the bunker into the combustion chamber of
the boiler via the delivery and feeding systems.
After completion of the filling process, ignition mode follows. The fed
fuel is automatically ignited with an electric ignition fan. During the
subsequent heating-up phase, the specified fuel feed quantity is set.
Following the heating-up phase, the system switches to automatic
operation. In this mode, combustion is carried out according to the
entered control options.
Figure 3/3 - Overview
123456

3 Mode of operation – Functional description
19
In order to remove the produced ash from the grate during
combustion, the grate is tilted at regular intervals. The optionally
available automatic cleaning system cleans the heat exchanger
surfaces with the aid of the cleaning turbulators which move up and
down.
The ash falls into the combustion chamber ash pan or can
(optionally) be transported by the automatic ash removal system to
an external ash container. The fly ash falls into the fly ash chamber
pan or can (optionally) be transported by the automatic ash removal
system to an external ash container.
The air necessary for combustion is supplied as required via a flue gas
fan and two servo motors.
The lambda sensor, the boiler temperature sensor and the flue gas
temperature sensor are used to do the following:
– Continuously monitor the firing
– Adapt boiler output for the heat requirements
– Minimise emissions
– Optimise boiler efficiency
DELIVERY SYSTEM
The delivery system is in the fuel bunker.
The fuel is transported from the fuel bunker to the dosing unit or to
the intermediate container.
The delivery system is controlled by the HDG Compatronic.
HDG COMPATRONIC
The boiler control unit of the HDG Compatronic is the electronic hub.
It consists of the central unit and the transport module in the
switching cabinet on the back side and the control unit on the front
side of the HDG Compact 25/35 boiler.
With the control unit, you can adjust the HDG Compact 25/35 and
obtain information on the current process status.
If the HDG Compatronic issues a request for more heat, the HDG
Compact 25/35 automatically switches to the Fill operating mode
and the combustion chamber is filled with fuel.
Figure 3/4 - HDG Compatronic control unit

3 Mode of operation – Functional description
20
Once the desired boiler temperature has been reached, i.e. the
heating demands have been met, the heating system changes to
Burn out mode and subsequently to the operating status No
demand.
CONTROL MODES
You can choose between four control modes:
•Fixed value:
– constant feed rate and constant combustion air flow rate (also
in emergency operation)
•Combustion control:
– constant, specified combustion chamber temperature and
optimal combustion
– preferred method of operation with accumulator
•Control of combustion and output:
– output supplied is adjusted to heat used with optimised
combustion
– operation without accumulator
•Log wood
– only suitable for emergency operation
HDG HYDRONIC
The HDG Hydronic is a heating system regulator which is attuned to
the HDG hydraulic systems.
The HDG Hydronic handles the overall 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