HDG M299 User manual

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HDG M299/300/350/400
Operation Manual

Operation Manual HDG M299/300/350/400 - Content
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Content
1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.2 Structure of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Basic system design principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Basic principles for the content of the operating manual . . . . . . . . . . . . . . . . . . .11
Proper and improper manner of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.2 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.3 Warnings and safety symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.4 Duty of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HDG M299/300/350/400 front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
HDG M299/300/350/400 back side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Cross section of HDG M299/300/350/400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
HDG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Control modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Permissible fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Wood chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Space requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Room height requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Installation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Water-side connections for HDG M299/300/350/400 . . . . . . . . . . . . . . . . . . . . . . .40
Sensors and connections of the HDG M299/300/350/400. . . . . . . . . . . . . . . . . . .41

Operation Manual HDG M299/300/350/400 - Content
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Hydraulic connection of combustion unit to heat exchanger . . . . . . . . . . . . . . 43
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the central ash removal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the housing of the flue gas fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing the cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing ash containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fitting the accumulator sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installing the EMD-C 215 Exclusiv control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connecting the chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.5 Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.6 Vacuum pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.7 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.8 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.9 Thermal safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.10 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Switching on the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Setting the display language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking the actuators in manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Filling the transfer station of the central ash removal system . . . . . . . . . . . . . . 74
Filling the fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 Overview of the controls and display components. . . . . . . . . . . . . . . . . . . . . . . . . . 77
Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Additional controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control cabinet model EMD-C 215 Exclusiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control unit for HDG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.2 Switching on the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.3 Switching off the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.4 Operating statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.5 Calling up information, selecting and modifying parameters . . . . . . . . . . . . . . . . 83
6.6 ON/OFF menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Setting the base load / peak load boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Setting operating times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Setting the control, boiler activation and Lambda Stop. . . . . . . . . . . . . . . . . . . . 87
Modifying fan settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Adjusting the ash removal setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Operation Manual HDG M299/300/350/400 - Content
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Changing the cleaning system setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Modifying the extraction setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Modifying the walking floor setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
6.7 °C/QUANTITY menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Defining the switch on/off times for the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Integrating the peak load boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Setting the boiler and return temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Viewing combustion chamber temperature, residual oxygen and vacuum
pressure in the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Setting combustion chamber temperature 2 and viewing flue
gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Selecting a fuel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fixed value - Setting the fuel and air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Setting the return pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Setting the return mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Other parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
6.8 TIME menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Setting the filling, ignition and fan activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Setting pre-air, heating up and burning out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Setting the grate times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Setting grate ash removal augers and ascending auger times . . . . . . . . . . . . . .98
Setting times for the heat exchanger ash removal augers and the
cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Setting main cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Stoker auger delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Setting pause intervals and running time for delivery . . . . . . . . . . . . . . . . . . . . 100
Setting the agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Setting the walking floor delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Setting the day, date and time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.9 MANUAL menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Combustion air and ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Primary and secondary air flaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Central ash removal, grate ash removal auger and grate drive . . . . . . . . . . . . 103
Heat exchanger ash removal auger and cleaning system . . . . . . . . . . . . . . . . . 103
Return pump, return mixer and intermediate pump. . . . . . . . . . . . . . . . . . . . . . 103
Feed system, rotary wheel and material conveying auger . . . . . . . . . . . . . . . . 104
Feed system, auger trough 2 and dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Material conveying auger and agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Moving floor - transverse auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Moving floor - hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.10 SERVICE menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Chimney sweep test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Operating hours counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Service messages 1 - setting reminder time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Service messages 2 - setting reminder time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Service messages 3 - setting reminder time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Operation Manual HDG M299/300/350/400 - Content
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Setting the boiler overheating temperature or hysteresis, minimum return
temperature and combustion chamber stop temperature . . . . . . . . . . . . . . . . 111
Setting reverse feeding and ignition temperature. . . . . . . . . . . . . . . . . . . . . . . . 112
Modifying the dosage pause min. or impulse min. and feeding units
lag time or lead time parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fuel quantity 1st Modifying filling and air start setting . . . . . . . . . . . . . . . . . . . 113
Ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Setting vacuum pressure controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Calibrating the lambda sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Chimney sweep test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Peak load boiler monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Flue gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Setting interface RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Setting Modbus RTU - Web server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Setting Modbus RTU - DDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Setting Profibus DP- DDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Entering passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Resetting parameters to the factory default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Setting output control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Entering fuel and temperature settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Entering the primary air setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Setting preset values for primary air flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Entering the residual oxygen setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Entering the secondary air setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Setting preset values for secondary air flaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Adapting the fuel quantity/O2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Setting vacuum pressure control values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Setting air flap delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.11 INFO menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.12 Maintenance function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.13 Filling the fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Procedure for filling with wood chips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Procedure for filling with pellets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.14 Performing the chimney sweep test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Before the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
During the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7 Cleaning and servicing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.1 Cleaning and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Maintenance function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Generally applicable safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Removing the cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Lubricating the feeding system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Cleaning the stepping grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Checking and emptying the ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Cleaning the cleaning shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Operation Manual HDG M299/300/350/400 - Content
7
Cleaning the vacuum pressure pipe for the pressure switches . . . . . . . . . . . . 144
Cleaning the vacuum pressure pipe for the differential
pressure transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Cleaning the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Checking the drive chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Cleaning the ignition fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Cleaning and calibrating the lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Cleaning the flue gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Cleaning the flue gas pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Cleaning the pressure equalisation hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cleaning fly ash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Inspecting the fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.1 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.2 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
12 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1 Notes on this manual – Introduction
8
HDG M299/300/350/400 - Version 1 - de ©HDG Bavaria GmbH 07/2008
1 Notes on this manual
1.1 Introduction
SAFE AND SIMPLE OPERATION This operating manual contains important instructions on the
heating system
•HDG M299/300/350/400
and how to operate it properly and safely. Following these
instructions helps to avoid dangers, prevent repair costs and
downtimes, maintain reliability and extend the life expectancy of the
heating system.
READING THE OPERATING
MANUAL
This operating manual must be read and observed by everyone who
operates or works on the HDG M299/300/350/400.
TECHNICAL CHANGES We continuously develop and improve our boilers. The information
in this edition was correct at the time of going to press.
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
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 designations and symbols are
used for particularly important information:
1. Instructions to the operator
2. Work through the steps in the sequence specified.
✓Result of the action described
✎Cross reference for more explanation
•List
–List

©HDG Bavaria GmbH 07/2008 HDG M299/300/350/400 - Version 1 - de
1 Notes on this manual – Structure of the operating manual
9
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
10
HDG M299/300/350/400 - Version 1 - de ©HDG Bavaria GmbH 07/2008
1.3 Glossary
Term Explanation
Actuator This is a component that carries out a certain function in the
heating system, for example the stoker auger.
Ash removal augers These transport the combustion chamber ash and fly ash into the
exterior ash containers.
Ash removal motor Powers the ash removal augers and the ash walking floor
Delivery system Fuel transport system - carries fuel from the storage to the dosing
unit or to the intermediate container.
Display Display of the HDG Control unit in the refrigerator.
Emergency stop Must be used in an emergency - interrupts all actuators; does not
switch off the mains supply to the entire heating system.
Extinguishing device 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.
HDG Control Electronic control unit of the boiler, feeding system and delivery
system.
HDG M299/300/350/400 Boiler for burning wood chips, shavings and wood pellets
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.
Turbulator Component for improving heat transfer from the flue gas to the
heat exchanger surface
Table 1/2 - Glossary

©HDG Bavaria GmbH 07/2008 HDG M299/300/350/400 - Version 1 - en
2 Safety instructions – Intended use
11
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
instructions 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 FOR THE CONTENT OF THE OPERATING MANUAL
SCOPE The content of this operating manual is intended exclusively for the
planning, installation and operation of the HDG M299/300/350/400
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
PURPOSE OF THE HEATING
SYSTEM
The HDG M299/300/350/400 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 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 programme and could lead to malfunctions. Only
trained maintenance and operating personnel may undertake
modifications to the operating values.
The use of materials with other technical burning characteristics
requires comprehensive modification of the control parameters by
qualified specialists.

2 Safety instructions – Residual risks
12
HDG M299/300/350/400 - Version 1 - en ©HDG Bavaria GmbH 07/2008
2.2 Residual risks
Despite all precautions, the following residual risks remain:
✎For more information on fuel, see section “3 Mode of operation”
in chapter “3.4 Fuel quality requirements”.
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-
insulated components.
Danger!
Danger of asphyxiation due to lack of oxygen
If the boiler is operating, carbon monoxide can be emitted through
the cleaning or inspection openings.
Do not leave these open any longer than necessary.
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
Each of the boiler units weight more than 2500 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 placing the
boiler.

©HDG Bavaria GmbH 07/2008 HDG M299/300/350/400 - Version 1 - en
2 Safety instructions – Residual risks
13
Warning!
Danger of injury
The cleaning shaft lids are 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.
Danger!
Danger of explosion due to carbon monoxide
When the boiler is in operation, carbon monoxide escaping from
open cleaning or inspection hatches can cause explosions.
Do not leave these open any longer than necessary.
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
automatically driven components and secure it against being
turned back on.
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.

2 Safety instructions – Warnings and safety symbols used
14
HDG M299/300/350/400 - Version 1 - en ©HDG Bavaria GmbH 07/2008
2.3 Warnings and safety symbols used
The following warnings and safety symbols are used in this
Operating Manual:
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
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.

©HDG Bavaria GmbH 07/2008 HDG M299/300/350/400 - Version 1 - en
2 Safety instructions – Duty of information
15
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.
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.
Caution!
Frost danger
Work on locations marked with this symbol can lead to frost
damage.
Instructions regarding disposal
Additional information for the operator

3 Mode of operation – Overview
16
HDG M299/300/350/400 - Version 1 - en ©HDG Bavaria GmbH 07/2008
3 Mode of operation
3.1 Overview
The HDG M299/300/350/400 is constructed in two parts. It consists of
the combustion unit and the heat exchanger.
The HDG M299/300/350/400 heating system is equipped as standard
with the following:
•Central ash removal system for grate ash and fly ash 1
•Automatic ash removal of fly ash 2 and 3 into exterior ash
containers
•Automatic cleaning of the heat exchanger surfaces
The HDG M299/300/350/400 heating system is equipped with the
HDG TBZ 200 for loading wood chips and shavings or with the HDG
TBZ 150 for loading pellets.
The HDG M299/300/350/400 heating system can also be equipped
with the following delivery systems:
•Hinged arm delivery system
•Walking floor delivery system
•Silo delivery system
•Walking floor changing container
•Pellet delivery system
Regarding the volume of the ash container, there are three different
options:
•240 l (central ash removal system)
•80 l or 140 l (fly ash)
Unless otherwise specified, the product version with the TBZ 200
feed system will be illustrated and described in this Operating
Manual.

©HDG Bavaria GmbH 07/2008 HDG M299/300/350/400 - Version 1 - en
3 Mode of operation – Overview
17
HDG M299/300/350/400 FRONT SIDE
1Fluegasfan
2 Flue pipe connection
3 Boiler supply connection (DN 100 flange)
4 Boiler return connection (DN 100 flange)
5 Secondary air fan
6 Actuator for tertiary air
7 Actuator for secondary air
8 Drive motor for central ash removal system
9Ashbin
10 Drive motor for ash removal auger
11 Inspection window for stepping grate
12 Ignition fan
13 Drive motor for stepping grate
14 Actuator for primary air 1
15 Actuator for primary air 2
16 Primary air fan
17 Feeding system
18 Drive motor for fly ash augers
Figure 3/1 - HDG M299/300/350/400 front side
9
5
8
21
18 17 16
43
1113
6 7
15 14 1012

3 Mode of operation – Overview
18
HDG M299/300/350/400 - Version 1 - en ©HDG Bavaria GmbH 07/2008
HDG M299/300/350/400 BACK SIDE
1 Cleaning shaft lid of combustion unit
2 Cleaning shaft lid of heat exchanger
3 Cleaning system drive motor
4Lambdasensor
5 Tubular heat exchanger
6 Turbulators
7 Fly ash container
Figure 3/2 - HDG M299/300/350/400 back side
56 4
31 2

©HDG Bavaria GmbH 07/2008 HDG M299/300/350/400 - Version 1 - en
3 Mode of operation – Overview
19
CROSS SECTION OF HDG M299/300/350/400
1 Secondary air openings
2 Safety heat exchanger, combustion unit
3 Tertiary air openings
4 Combustion chamber
5 Ash removal auger for fly ash 1
6 Ash removal auger for grate ash
7 Stepping grate
8 Ignition pipe or fill level indicator
Figure 3/3 - Cross section of HDG M299/300/350/400
5 3
1 2
48 7 6

3 Mode of operation – Functional description
20
HDG M299/300/350/400 - Version 1 - en ©HDG Bavaria GmbH 07/2008
3.2 Functional description
The HDG M299/300/350/400 heating system may contain the
following components:
1Controlcabinet
2 Delivery system
3 HDG material conveying auger TFQ 200
4Feedingsystem
5 HDG M299/300/350/400 boiler
6Accumulator
COMBUSTION PROCESS
With the HDG M299/300/350/400 heating system, the fuel is
automatically fed from the storage room into the combustion
chamber of the boiler via the delivery and feeding systems. The
combustion fan is already activated here in order to eliminate any
possible residual combustion gases or negative flue pressure
conditions along the combustion path.
Once the filling cycle is complete, the fuel introduced into the
combustion chamber is automatically ignited with an electrical
ignition fan. During the subsequent heating-up phase, the specified
fuel feed quantity is set.
Figure 3/4 - Overview
65431 2