HDG K10 User manual

hdg-bavaria.com
HDG K10/15/21/26/33
Operating manual

Operating manual HDG K10 - 33 - Content
3
Content
1 Notes on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Basic system design principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Basic principles for the content of the operating manual . . . . . . . . . . . . . . . . . . . .7
Proper and improper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.3 Warnings and safety symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4 Safety instructions for the pellet storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5 Duty of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Cross section of HDG K10 - 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Combustion process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Boiler and weather-compensated heating control HDG Control . . . . . . . . . . . .14
Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pellet suction system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.4 Fuel quality requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Recommended fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4 Planning and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.1 Planning the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Required room sizes and minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dimensions and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Furnace room. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.4 Installing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Removing the transport pallet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Fitting the filling and drain cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Converting the flue pipe connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Operating manual HDG K10 - 33 - Content
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Installing the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fitting the cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installing the ash container. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mounting the expansion modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting the suction and return hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5 Connecting the chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.6 Electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.7 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 Commissioning the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Setting the fuel quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Perform actuator test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adapting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Using the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.1 Control unit for HDG Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Filling the pellet storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.3 Filling the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 Performing a chimney sweep measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.5 Switching off the heating system for repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7 Cleaning and servicing the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.1 Cleaning and servicing schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Generally applicable safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cleaning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Emptying the ash container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cleaning the combustion chamber and burner pot . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the flue gas fan and cleaning shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cleaning the flue gas pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check the fill level of the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking and cleaning the reservoir and flap of the delivery unit . . . . . . . . . . 54
Cleaning the pellet storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8 Notes on dismantling and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.1 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1 Notes on this manual – Introduction
5
1 Notes on this manual
1.1 Introduction
EASY AND SAFE OPERATION This operating manual contains important instructions on the
•HDG K10
•HDG K15
•HDG K21
•HDG K26
•HDG K33
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 K10 - 33.
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 system is
installed.
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.
GUARANTEE The terms and conditions of the guarantee of your boiler can be
found in the enclosed information sheet.
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 – Glossary
6
1.2 Glossary
Term Explanation
Actuator This is a component which carries out a certain function in the
heating system e.g. the worm feed stoking unit.
Automatic cleaning At intervals, automatically cleans the surface of the heat
exchangers.
Delivery system Pellet transport system in the pellet storage room.
Display Display of the boiler control unit.
Extinguishing device Extinguishes the contents of the reservoir if the temperature of the
contents exceeds 90°C.
HDG Control Boiler and heating system controller.
HDG K10 - 33 Heating system for burning wood pellets.
Heating system Comprised of boiler and corresponding accessories.
Pellet suction system Pellet transport system which connects the reservoir with the
delivery system.
Reservoir A container which supplies pellets to be burnt in the boiler via the
conveying auger.
Sensor Records certain parameters (temperature, fill level) and forwards
them to the control for analysis.
Wood pellets Binder-free pellets made of pressed, untreated wood.
Table 1/1 - Glossary

2 Safety notes – Intended use
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2 Safety notes
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 a detailed
explanation of 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.
This device can be used by children over 8 years old and people with
reduced physical, sensory or mental capabilities or a lack of
experience and knowledge, provided they are supervised or have
been instructed on the safe use of the device and understand the
resulting risks. Children may not play with the device. Cleaning and
user maintenance must not be carried out by children without
supervision.
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 K10 - 33 heating
systems. The further implementation of applicable standards and
guidelines, for example regarding 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 OPERATION
PURPOSE OF THE HEATING
SYSTEM
The heating system HDG K10 - 33 was designed to burn wood pellets
in hot water heating systems.
Any other application is considered improper use. The manufacturer
will accept no liability for any damage resulting from improper use.
The operator bears sole responsibility in such cases.
Proper use includes adherence to the installation, operation and
maintenance requirements specified by the manufacturer.

2 Safety notes – Residual risks
8
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.
2.2 Residual risks
Despite all precautions, the following residual risks remain:
For more information on fuel, see chapter “3 Mode of operation”,
section “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 in operation, carbon monoxide can be emitted
through the open doors and lids.
Do not leave the doors and lids open any longer than necessary.
Warning!
Danger of fire
Opening doors and lids to hot combustion residues during
operation 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 300 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.

2 Safety notes – Warnings and safety symbols used
9
2.3 Warnings and safety symbols used
The following warnings and safety symbols are used in this
Operating manual:
Danger!
Danger of explosion due to carbon monoxide
Filling the burner pot with pellets manually may result in too much
fuel in the burner pot. Consequently the pellets will not be
optimally ignited and too much low temperature carbonisation gas
may result which can lead to an explosion.
Do not fill the burner pot manually.
Danger!
Dangerous electrical current or voltage
The circuit boards and other 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
injuries or to extensive material damage.
Warning!
Hand injuries can occur
Working in areas marked with this symbol can lead to hand injuries.
Caution!
Hot surfaces
Working in areas marked with this symbol can lead to burns.

2 Safety notes – Warnings and safety symbols used
10
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.
Caution!
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!
Automatic start-up
Working in areas marked with this symbol can lead to injuries due
to automatic start-up.
Important!
Frost danger
Only install the heating system in a frost-proof room.
Instructions regarding disposal
Additional information for the operator