5.2 HDG Hydronic circuit diagram - Shop

Planning and installation guide 

HDG Compact 50/65 

with HDG Hydronic 

© HDG Bavaria GmbH November 2006 HDG Compact - Version 1 - en

Content 

Planning and installation guide HDG Compact - Content 

1 Notes on this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 

1.2 Structure of the Planning and installation guide . . . . . . . . . . . . . . . . . . . . . . . . .6 

1.3 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 

2 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 

Basic principles for the construction of the system . . . . . . . . . . . . . . . . . . . . . .8 

Proper and improper manner of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 

Permissible fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 

2.2 Residual risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 

2.3 Warnings and safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 

2.4 Duty to inform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 

3 Planning the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

3.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

3.2 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

The HDG Compact boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

HDG Compatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 

Delivery system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

HDG Hydronic (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

HDG Hydronic controller functions (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 

3.4 Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 

Wood fuel products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 

Wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 

Burning characteristics of the wood pellets . . . . . . . . . . . . . . . . . . . . . . . . . . .28 

3.5 Building requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 

Necessary room sizes and minimum spacing. . . . . . . . . . . . . . . . . . . . . . . . . .29 

Boiler room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 

Fuel bunker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

3.6 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 

Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 

4 Installing the heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 

4.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 

4.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 

4.3 HDG Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 

Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 

Installing the automatic ash removal system . . . . . . . . . . . . . . . . . . . . . . . . . .43 

© HDG Bavaria GmbH November 2006 HDG Compact - Version 1 - en 

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Planning and installation guide HDG Compact - Content 

Wiring the circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 

Installing the boiler cladding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 

Mounting and adjusting the ash boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 

Connecting the chimney. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 

4.4 HDG Hydronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 

Installing the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 

Installing the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 

4.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 

4.6 Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 

4.7 Starting the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 

4.8 HDG hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 

5 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 

5.1 HDG Compatronic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 

5.2 HDG Hydronic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 

HDG Compact - Version 1 - en © HDG Bavaria GmbH November 2006

1 Notes on this guide 

1.1 Introduction 

Plan and install easily 

and safely 

Reading the Planning and 

installation guide 

1 Notes on this guide – Introduction 

This Planning and installation guide contains important information 

on planning and installing the following components properly and 

safely: 

• HDG Compact boiler 

• Fuel bunker 

• Hydronic (optional) 

Following these instructions means that danger can be avoided, 

repair costs and breakdowns can be prevented, reliability can be 

maintained and that the operational life of the heating system can be 

increased. 

The Planning and installation guide must be read and applied by 

everyone who plans or carries out the installation of the HDG 

Compact boiler. 

Technical changes We continuously develop and improve our boilers. The information 

in this version was correct at the time of going to press. 

All details in these instructions on standards, regulations and 

worksheets should be checked before use and should be compared 

with the regulations applying locally at the installation location. 

We reserve the right to make changes which may then deviate from 

the technical details and illustrations in this Planning and 

installation guide. 

Copyright Written agreement is required from HDG Bavaria GmbH for any 

reprints, storage in a data-processing system or transmission by 

electronic, mechanical, photographic or any other means, for copies 

or translations of this publication, in whole or in part. 

Symbols used In this Planning and installation guide the following presentation or 

symbols will be used for particularly important information: 

1. Instructions to the operator 

2. Work through the steps in the sequence specified. 

✓ The result of the action described 

✎ Cross reference for more explanation 

• List 

Turn the main switch of the heating system on/off. 


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1 Notes on this guide – Structure of the Planning and installation guide 

1.2 Structure of the Planning and installation 

guide 

Chapter Here you see, ... 

The Planning and installation guide are structured as follows: 

1 Notes on this guide ... how to use this Planning and installation guide. 

2 Safety notes ... everything on the subject of safety that you should consider 

when using the heating system. 

3 Planning the heating system ... what you need to consider when planning the heating system. 

4 Installing the heating system ... what you need to consider when installing the heating system. 

5 Appendix ... how to properly connect the heating system. 

Table 1/1 - Structure of the Planning and installation guide 


1.3 Glossary 

Term Explanation 

1 Notes on this guide – Glossary 

Actuator This is a component which carries out a certain function in the 

heating system, e.g. the combustion fan 

Ash removal motor Powers the ash removal worms and the sliding tray 

Delivery system Fuel transport system - carries fuel from the bunker to the dosing 

unit or to the intermediate container 

Feed system Feeds the fuel to the boiler by means of the stoker worm 

Display Display of the HDG Compatronic control unit 

Ash removal worms Transports the combustion chamber ash and fly ash into the 

exterior ash containers 

Main switch Switches off the mains supply to the entire heating system 

HDG Compact Boiler for burning wood chips, shavings and wood pellets 

HDG Compatronic Electronic control of the boiler, feed system and delivery system 

HDG Hydronic Heating system regulator for controlling the hydraulic systems 

Extinguisher Extinguishes the contents of the delivery system if the 

temperature of the contents exceeds 90˚C 

Emergency off switch Must be used in an emergency - interrupts all actuators, does not 

switch off the mains supply to the entire heating system 

Grating motor Electric motor which moves the dumping grate 

Sliding tray Transport of the fly ash of the downstream heating areas into the 

flay ash chamber 

Sensor Records certain parameters (temperature, fill level) and forwards 

them to the control system for analysis 

Stoker worm Carries the fuel from the rotary feeder into the combustion 

chamber 

Rotary feeder Part of the feed system - separates the combustion chamber from 

the silo and transport unit and serves as a protection against the 

fire burning back into the feed 

Table 1/2 - Glossary 


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2 Safety notes – Intended use 

2 Safety notes 

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. However, its use can 

result in the injury or death of the user or a third party or in 

impairments to the heating system itself or to 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, staying aware of safety and of the dangers 

involved, following the Planning and installation guide. Have any 

faults which could impair safety immediately fixed. 

Application of the 

heating system 

Proper and improper manner of operation 

The heating system is designed for the burning of wood fuel 

products made from untreated wood and for fuels from wood 

processing plants. 

Any other use is improper. The manufacturer will accept no 

responsibility for any damage resulting from improper use. The 

operator will bear sole responsibility. 

Proper use includes maintaining the installation, operation and 

maintenance conditions specified by the manufacturer. 

You may only enter or change the operating values specified in this 

guide. Any other entries will affect the heating system's control 

program and could lead to a malfunction. 


Permissible fuel 

2 Safety notes – Intended use 

The heating system HDG Compact is designed for the use of wood 

fuel products from untreated wood and for fuels from wood 

processing plants, such as shavings and wood pellets. 

In accordance with section 3 (1) of German law (1. BimSchV), the fuel 

classes 4, 5, 6, and 7 may be used. 

Fuel class 4 Untreated log wood including adhering bark, in the form of wood 

shavings for example. 

Fuel class 5 Untreated wood (not log wood), in the form of shavings for example. 

Fuel class 6 Painted, varnished or coated wood including remains thereof, 

providing no wood protection agents have been applied or added 

and the coatings are not made of organic halogen compounds. 

Fuel class 7 Plywood, chipboard, fibreboard or otherwise glued wood including 

remains thereof, providing no wood protection agents have been 

applied or added and the coatings are not made of organic halogen 

compounds. 

Should the fuel classes 6 or 7 be used in a wood processing plant at 

50 kW or more nominal thermal power, it should be noted that in the 

case of painted, varnished or coated wood, greater demand can be 

placed on the wearing parts such as wall lining, fill level sensors and 

exhaust sensors, reducing their service lives. 

Wood pellets Wood pellets are pressed into a cylindrical shape. They consist of 

untreated shavings and sawdust from the wood processing industry 

as well as unprocessed forestry waste. They have a standardised 

diameter and length. They are pressed at a very high pressure and 

have a very low water content. 

Recommended fuel HDG Bavaria recommends fuel of grain size G 30 and a maximum 

10% proportion of finer content. 

The fuel should have as little moisture as possible, with 20% 

moisture being ideal. The drier the fuel, the higher the thermal value 

and the higher the burning efficiency that is achieved. High quality 

fuel aids in energy conservation and maintains the operating safety 

of your heating system. The specifications of ÖNORM 7133 are to be 

used as recommended values. 

For HDG Compact heating systems, it is possible to use wood fuel 

products of grain size G 50 with a maximum moisture content of up 

to 45%. However, reduced efficiency may thereby result. Fuels with 

a higher moisture content are not suitable for burning. 

For operation of the heating system with wood pellets, HDG Bavaria 

recommends pellets certified as “DIN plus”. This certification 

incorporates the standards of both DIN 51731 and ÖNORM 7135. The 

manufacturing plants which produce products with this certification 

undergo voluntary unannounced inspections twice annually by an 

independent centre. 


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2 Safety notes – Residual risk 

2.2 Residual risk 

Pay particular attention to the fuel quality, both when ordering and 

during the delivery. In regard to the quality requirements for wood 

fuel products, the standard ÖNORM 7133 concerning the 

requirements and testing regulations of wood fuel products for 

energy production is applicable. 

✎ For more information on fuel, see section “3.4 Fuel quality 

requirements” in chapter “3 Planning the heating system". 

Despite all precautions, the following residual risks remain: 

Caution! 

Hot surface 

Contact with the hot surface of the boiler can lead to burns. 

Wait until the boiler has cooled down before touching uninsulated 

components. 

Warning! 

Danger of asphyxiation due to carbon monoxide. 

If the boiler is operating, carbon monoxide can be emitted through 

the cleaning or inspection openings. 

Do not leave these open any longer than necessary. 

Caution! 

Danger from suspended loads. 

The boiler weighs over 250 kg. If the boiler is dropped during 

transport, people can be seriously injured and the boiler can be 

damaged. 

Make sure that you use appropriate lifting gear when installing the 

boiler. 


2 Safety notes – Warnings and safety symbols used 

Caution! 

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. 

2.3 Warnings and safety symbols used 

The following warnings and safety symbols are used in this Planning 

and installation guide: 

Danger! 

Danger from electrical current or voltage. 

Work on areas marked with this symbol may only be done by a 

qualified electrician. 

Warning! 

Warning about a dangerous location. 

Work on areas marked with this symbol can lead to serious injuries 

or to extensive material damage. 

Caution! 

Hand injuries 

Work on locations marked with this symbol can lead to hand 

injuries. 

Caution! 

Hot surface 

Work on locations marked with this symbol can lead to burns. 

Caution! 

Danger of fire 

Work on locations marked with this symbol can lead to a fire. 


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2 Safety notes – Duty to inform 

2.4 Duty to inform 

Reading the Planning and 

installation guide 

Caution! 

Frost danger 

Work on locations marked with this symbol can lead to frost 

damage. 

Notes on disposal. 

Additional information for the operator. 

Everyone who works on the system must have read the Planning and 

installation guide before starting work and, in particular, have read 

the chapter “2 Safety notes”. 

This holds especially true for persons who only occasionally work on 

the system, e.g. when cleaning or maintaining the heating system. 

This Planning and installation guide must be kept easily accessible 

at the heating system's installation location. 


3 Planning the heating system – Overview 

3 Planning the heating system 

3.1 Overview 

The heating system HDG Compact is available in the following 

versions: 

• Standard version with inserted ash boxes, without cleaning 

system and delivery worms 

– Feed system on left 

– Feed system on right 

• Convenience model with automatic cleaning system and ash 

removal system 

– Feed system on left 

– Feed system on right 

In this Planning and installation guide, the convenience version with 

left-mounted feed system is described and depicted. Specifications 

on the delivery systems are not included. 

The heating system contains the following components: 

1 2 3 4 

5 

Figure 3/1 - Overview 

1 Access hatch 

2 Sloping floor 

3 Delivery system 

4 HDG Hydronic (option) 

5 Feed system 

6 HDG Compact boiler with HDG Compatronic 


6 

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3 Planning the heating system – Mode of operation 

3.2 Mode of operation 

Front side 

The HDG Compact boiler 

9 

10 

Figure 3/2 - Front side of the HDG Compact boiler 

1 HDG Compatronic control panel 

2 Drive for automatic cleaning 

3 Emergency off switch 

4 Oxygen sensor 

5 Downstream heating areas with turbulaters 

6 Sliding tray 

7 Automatic ash removal system 

8 Dumping grate for combustion chamber primary burning 

9 Feed system with stoker worm 

10 Combustion chamber secondary burning 

HDG Compact - Version 1 - en © HDG Bavaria GmbH November 2006 

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8 7 

-6,3% 

6 

2 

5 

3 

4

Back side 

1 

10 

2 

9 

Figure 3/3 - Back side of HDG Compact boiler 


1 Immersion sensor bushing, thermal safety device 

2 Connections of safety heat exchanger 

3 Main switch 

4 Pressure equalisation hose 

5 Combustion fan 

6 Primary air servo motor 

7 Ash removal motor 

8 Dumping grate motor 

9 Secondary air servo motor 

10 Ignition fan 

In the HDG Compact boiler, the fuel introduced into the combustion 

chamber is automatically ignited with an electrical ignition fan. 

In order to remove the produced ash from the grate, the grate is 

tilted. 

The ash falls into the ash boxes for the ash of the combustion 

chamber or is transported into the ash containers by the automatic 

ash removal system (optional). 


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7 

6 

5 

4 

3 

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The produced fly ash falls into the ash boxes or is conveyed into the 

ash container by the automatic ash removal system (optional). 

The air necessary for combustion is supplied as required via two 

servo drives. 

Via sensors: 

– the firing is permanently monitored, 

– the boiler power is adjusted to the heat requirement, 

– emissions are minimised and 

– boiler efficiency is optimised. 

HDG Compatronic 

Figure 3/4 - HDG Compatronic control unit 

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 and the control unit on the front side of the HDG 

Compact boiler. 

Via the control unit, you can adjust the HDG Compact and obtain 

information on the current process status. 

If the HDG Compatronic issues a request for more heat, the HDG 

Compact automatically goes into the Fill operating mode and the 

combustion chamber is filled with fuel. 

Once the desired boiler temperature has been reached, i.e. the need 

for heat has been met, the heating system changes to the operating 

status Burn out and subsequently to the operating status No 

demand. 


Basic functions of the 

heating circuit control 


You can choose between three control versions: 

• Without control: 

– Constant feed rate and constant combustion air flow-rate 

(even in emergency operation) 

• Combustion control: 

– Constant specified combustion chamber temperature and 

optimal combustion (standard version, most frequently 

implemented) 

• Control of combustion and power: 

– The power supplied is adjusted to the heat used with 

optimised combustion 

Delivery system 

The delivery system is in the fuel bunker. 

Depending on the delivery version, the fuel is transported from the 

fuel bunker to the dosing unit or to the intermediate container. 

The delivery system is controlled via the HDG Compatronic. 

HDG Hydronic (option) 

The HDG Hydronic is a heating system regulator, which is attuned to 

the HDG hydraulic systems. 

HDG Hydronic deals with the entire energy management for the 

heating system and, depending on the version, controls up to three 

weather-controlled heating circuits, as well as: 

• Heating hot water 

• District heating transfer 

• Connection to second boiler 

• Solar system for hot water and support of the heating system 

The HDG Hydronic can be extended to up to 24 heating circuits. 

HDG Hydronic controller functions (option) 

The heating circuit control always operates at a characteristic 

heating curve controlled by the outdoor air temperature. For each 

heating system the characteristic heating curve is used to calculate 

the supply water temperature which is appropriate for the current 

outdoor temperature. Other factors which influence the calculated 

water temperature are the steepness of the characteristic heating 

curve, the correction for this (parallel shift) and the preset value for 

the room temperature. 


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External temperature 

switch off 

If the heating circuit control is operating, room temperature will be 

adjusted to a preset daytime or night-time value. 

Supply temperature 

20 30 40 50 60 70 80 

20 15 19 5 0 -5 -10 -15 -20 

Outside temperature 

Figure 3/5 - Diagram of the temperature of water leaving the boiler 

Example: 

Outdoor temperature - 5 ˚C 

Steepness 1.6 

Parallel shift 5˚C 

With these presumed values, from Figure 3/5 - Diagram of the 

temperature of water leaving the boiler you can read off a 

temperature for water leaving the boiler of 67 ˚C. 

If an indoor thermostat unit is also connected, the comparison 

between the preset and the actual room temperature and the room 

influence factor are also included in the calculation of the required 

water temperature leaving the boiler. The temperature difference is 

multiplied by the room influence factor and is then added to the 

preset room temperature. The room influence factor expresses how 

strongly any deviation of the room temperature should affect the 

water temperature leaving the boiler. 

If no indoor thermostat unit is connected, the preset day and night 

temperatures are used for the calculation. 

If the outdoor temperature exceeds the preset room temperature or 

the preset outdoor switch-off temperature, the status of the heating 

circuit changes to OFF. 


3,5 

3,0 

2,5 

2,0 

1,6 

1,5 

Parallel shift 

1,0 

0,8 

0,5

Indoor thermostat unit 

(room sensor) 

Heating systems for the 

heating circuits 


If an indoor thermostat unit is connected, the target room 

temperature is calculated from the preset day and night room 

temperatures, the room influence factor and the current measured 

room temperature. 

In the group of parameters for the hydraulic system, for each of the 

various heating circuits the corresponding heating system is 

configured. 

You have a choice of five heating systems: 

• None 

– This is selected when a heating circuit is not needed. All 

submenus for this heating circuit are then disabled. 

• Radiators 

– If this heating system is selected, the corresponding 

parameters are loaded and a characteristic heating curve 

issued. 

• Floor heating 

– If this heating system is selected, the corresponding 

parameters are calculated for a flatter characteristic heating 

curve and a lower design temperature. With this heating 

system, you also have the option of activating a screed drying 

program. 

• Constant 

– This system operates independently from the temperature 

outdoors and maintains a constant water temperature as it 

leaves the boiler. This system is suitable for instance to control 

the heating of a swimming pool. An indoor thermostat unit is 

not possible with this heating system. 

• Uncontrolled 

– In an uncontrolled heating system, only the enable 

temperature and the time program are active. This heating 

system works without a heating circuit mixer and, if combined 

with an indoor thermostat unit, switches the pump off after 

reaching the preset room temperature. 


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Screed drying program If the heating system includes a newly laid floor heating system, you 

can configure a drying period. Floor heating must be set as the 

heating system. 

After starting, the supply water temperature is adjusted to minimum 

screed drying temp. 

The supply water temperature is increased in defined daily cycles by 

screed drying temp. increase, until the maximum 

screed drying temp. is reached. At this temperature, the 

supply water temperature is held for screed drying hold 

time. Subsequently, following the principle described above, the 

water supply temperature is reduced until the minimum screed 

drying temperature is reached. The heating circuit changes to 

the status OFF. 

Temperature 

Increas 

Hold time 

Figure 3/6 - Diagram of the screed drying program 

Supply maximum 

0 1 2 3 4 5 6 7 8 9 10 

Days 

Increase in preset 

Minimum sup 

Anti-seizing protection For the boiler status OFF or NO DEMAND, the hot water pump and 

heating circuit mixer are activated every 7 days to help prevent the 

pumps from seizing. 

Hot water Depending on the installed hydraulic system, the hot water supply 

can be delivered via a combination buffer tank or via an external hot 

water tank. 

If a hydraulic system with a hot water tank is installed, the following 

points must be considered: 

– For hot-water, a weekly program (two periods per day) can be 

selected. 

– Only during this time is hot water available, taking into 

account the enable temperature for the hot water pump. 

– You can specify the temperature of the hot water supply. If this 

temperature falls below the preset hot water temperature by 

the amount of the hysteresis (temperature difference between 

target and actual temperature e.g. 5 K), the hot water heating 

pump starts. 



Hot water priority You can give priority to hot water. This means that if hot water is 

“on”, the supply temperature to the heating circuit is reduced. The 

duration of the priority is also configurable. 

Protection from 

Legionnaire's disease 

Control of the solar 

heating system 

If protection from Legionnaire's disease is active, once per week the 

hot water will be heated up to the temperature specified to provide 

protection. 

Depending on the hydraulic system, three different types of control 

for the solar heating system are possible: 

• The solar heating system heats the hot-water tank 

• The solar heating system heats the combination buffer tank 

• The solar heating system heats both the hot-water and the buffer 

tanks 

With the solar heating parameter you can choose between 

– none, 

– hot water tank, 

– combination buffer tank or 

– hot water tank / buffer 

No solar heating This setting can be selected if a solar heating system is to be 

installed at a later point. No commands are sent to the solar heating 

pump and sensors are ignored. 

Solar heating of the hotwater 

tank 

Solar heating system 

combination buffer tank 

The solar heating pump is driven at a controlled speed, taking into 

account the temperature difference Collector temp. to hotwater, 

lower sensor. 

The temperature of the solar collector must exceed the Hot water 

lower sensor temperature by the solar hysteresis value for solar 

heating to start. The heating of the hot water by the solar heating 

system can be limited via a maximum temperature setting. 

The solar heating pump is driven at a controlled speed taking into 

account the temperature difference Collector temperature 

to buffer tank lower sensor. 

The temperature of the solar collector must exceed the Buffer 

lower sensor temperature by the solar hysteresis value for solar 

heating to start. The heating of the hot water by the solar heating 

system can be limited via a maximum temperature setting. 


21

22 


Solar heating hot water/ 

buffer 

Protecting the collector 

from overheating 

Speed-controlled solar 

hot water and solar 

buffer pumps 

District heating 

connection 

If the Hot water lower sensor temperature exceeds the 

maximum, or if the temperature of the solar collector is not sufficient 

to heat the hot water, the solar buffer pump will switch on (speed 

controlled). The buffer tank will now be heated and the sun's energy 

can be used for heating. If the maximum temperature of the hot 

water tank has not yet been reached, the solar buffer pump will 

switch off to establish whether the energy from the sun would be 

sufficient to heat up the hot water tank. If this proves to be the case, 

the solar pump will switch on again. If not, the solar buffer pump will 

switch on again for the preset period. 

This is only active when solar heating is being used for the hot water 

tank or for the combination buffer tank. 

If the protection temperature for the solar collector parameter 

18-12 (factory setting 110 ˚C) is exceeded, the solar pump will start, 

even if the maximum temperature for solar heating has been 

exceeded. This protects the collector from overheating. See the 

details supplied by the manufacturer of the solar collector for the 

collector protection temperature and modify the setting accordingly. 

The speed of the solar pump is calculated from the temperature 

difference between the collector and the tank, multiplied by the 

solar pump factor. When the solar pump starts, it runs for a 

configurable time at maximum speed, before it is then adjusted to 

run between the minimum and maximum pump speed. 

Operating with district heating is very similar to heating hot water. A 

measurement of the temperature difference between the heat 

source and the district heating transfer station is used to activate the 

district heating pump. If operated without a buffer, the boiler supply 

temperature is used as a reference. If operated with a buffer, the 

Upper buffer sensor temperature is used. District heating 

operation must be enabled via a parameter. 

The district heating pump must be enabled via the District 

heating available parameter, or, depending on the hydraulic 

system set, may already be active. 

The district heating pump is started when the temperature in the 

transfer station falls below the Transfer station preset 

temperature by the value of the district heating hysteresis. 

Priority for district heating can be set via the parameter “priority for 

district heating”. For the other mixing circuits, this means that the 

supply temperature can be lowered to the “reduced temperature for 

district heating priority”. 



Control of second boiler The oil-burning boiler is activated when the temperature falls below 

the maximum enable temperature for the heating circuit or for the 

hot water tank, for longer than the oil-fired boiler enable time. 

If the temperature falls below the enable temperature for heating 

hot water, the oil-fired boiler will start. In this mode of operation, the 

preset oil-fired boiler temperature is Max. oil-fired boiler 

temp. The oil-fired boiler will stop on reaching the necessary 

Preset hot water temp. or Max. oil-fired boiler 

temp. 

If the temperature falls below the enable temperature of the heating 

circuit, the oil-fired boiler is started. The preset target temperature 

for the oil-fired boiler is calculated from the outdoor temperature, 

characteristic heating curve, room temperature, parallel shift and 

oil-fired boiler overtemperature. When the oil-fired boiler reaches 

either its preset temperature or Max. oil-fired boiler 

temp. it switches off, restarting when it has cooled down by the oilfired 

boiler hysteresis. 

If two different enable temperatures have been specified for hot 

water and for heating circuits, and if there is no demand on the hot 

water tank, the oil-fired boiler will only start once the temperature 

has fallen below the enable temperature for the heating circuit. 

If there is no demand on the heating circuit or for hot water and if the 

buffer is under the enable temperature, the oil-fired boiler must 

maintain the Min. oil-fired boiler temp. (e.g. for summer 

operation). 

If the oil-burner is in operation, the enable temperatures of the 

“loads” (heating circuits, hot water tank) are compared with the 

temperature of the oil-fired boiler and are used as the current 

temperature for control purposes. 


23

24 

3 Planning the heating system – Technical data 

3.3 Technical data 

Type of boiler HDG C 50 HDG C 65 

Max. power 50.0 kW 65.0 kW 

Dimensions 

• Length 

• Width 

• Height 

1278 mm 

1428 mm 

1915 mm 

Weight 725 kg 

Nominal thermal power 12.0 – 50.0 kW 12.0 – 65.0 kW 

Max. operational pressure 3.0 bar 

Max. supply temperature 95 ˚C 

Configurable boiler temperature 60 – 80 ˚C 

Boiler efficiency 92 % 89 % 

Boiler class 3 

Water capacity 167 l 

Thermal safety device 

• Minimum flow pressure 

• Required volume flow 

Water-side resistance at the 

nominal load 

• Δ t=10K 

• Δ t=20K 

2 bar 

1800 l 

2 bar 

1800 l 

6 hPa 

1.5 hPa 

Minimum return temperature 60 ˚C 60 ˚C 

Diameter of exhaust connection 180 mm 180 mm 

Necessary working pressure 20 Pa 

Exhaust mass flow 

• Nominal load 

• Partial load 

Exhaust temperature 

• Nominal load 

• Partial load 

• Maximum 

0.0326 kg/s 

0.0125 kg/s 

150 ˚C 

75 ˚C 

220 ˚C 

0.0451 kg/s 

0.0125 kg/s 

180 ˚C 

75 ˚C 

240 ˚C 

Electrical connection 

• Voltage 400 V 

fuse protection max. 16.0 A 

Table 3/1 - Technical data 


3 Planning the heating system – Technical data 

Type of boiler HDG C 50 HDG C 65 

Necessary auxiliary energy 

• Constant operation at 

nominal power 

• Ignition fan 

Table 3/1 - Technical data 

355 W 

1600 W 


25

26 

3 Planning the heating system – Fuel quality requirements 

3.4 Fuel quality requirements 

Wood fuel products 

Essential criteria are nominal length and water content of the fuel. 

The testing of the heating system is performed using B1 wood fuel 

products with a water content ( 15 < w < 

35 %). 

Fine wood fuel products • Typical nominal length of less than 3 cm (G30). 

(wood chips) 

As a machine-compatible material, this wood fuel product is 

especially suitable for small systems. Oversized pieces (end pieces) 

could lead to malfunctions during system operation. Higher 

proportions of finer content (dust) can lead to high emissions and 

ejection of glowing particles. 

Medium wood fuel 

• Typical nominal length of less than 5 cm (G50). 

products 

This material is used more in larger systems, but can however, 

depending on the diameter of the conveyor worm, also still be 

suitable for small systems. 

Thermal value In the selection of fuel, it should be considered that the thermal 

value of the wood is primarily dependent upon the water content. 

The more water contained in the wood, the smaller the thermal value 

since the water vaporises in the course of the burning process and 

thereby consumes heat. This results in lower efficiency and thereby 

leads to greater wood consumption. Increasing moisture in the fuel 

material also causes reduced efficiency, greater amounts of ash and 

smoke, as well as making it increasingly unfit for storage. 

✎ Further specifications can be found in ÖNORM 7133. 


Water content Moisture Thermal value 


For technical considerations, a representative thermal value is 

selected depending on water content. For burning that is both 

economical and low on emissions, the thermal value should not be 

less than 3 kWh/kg. 

Wood pellets 

Relative 

wood 

consumption 

Combustion 

temperature 

10.0 % 11.1 % 3.9 kWh/kg 113 % 1150 ˚C 

20.0 % 25.0 % 3.4 kWh/kg 130 % 1100 ˚C 

26.0 % 35.0 % 3.1 kWh/kg 151 % 1070 ˚C 

30.0 % 42.9 % 2.9 kWh/kg 171 % 1040 ˚C 

40.0 % 66.7 % 2.3 kWh/kg 217 % 960 ˚C 

50.0 % 100.0 % 1.8 kWh/kg 286 % 870 ˚C 

Table 3/2 - Thermal value depending on water content 

DIN 51731 Wood pellets in the group size HP5 are made of pressed, untreated 

wood including bark, without any binder. The 

energy contained in 2 kg of pellets corresponds approximately to the 

energy contained in a litre of heating oil. 

ÖNORM M 7135 The Austrian standard contains technical fuel requirements, a test 

for suitability, internal and external monitoring and the labelling. 

DINplus The certification to DINplus combines the two previously mentioned 

standards, taking the stricter value in each case. 

The certification procedure is carried out at the pellet manufacturer 

by a test institute approved by DIN Certco. Independent tests are 

made at regular intervals so that the quality of the pellets can be 

ensured. 


27

28 


Burning characteristics of the wood pellets 

Standard DIN 51731 ÖNORM M 7135 DINplus AS/NZS 4014.6 

Length max. 50 mm max. 5 x Ø max. 5 x Ø max. 38 mm 

Diameter Ø 4 – 10 mm max. 10 mm 4 – 10 mm max. 10 mm 

Thermal value 17.5 - 19.5 MJ/kg min. 18.0 MJ/kg min. 18.0 MJ/kg 18.0 - 21.0 MJ/kg 

Density (spec. gravity) 1.0 – 1.4 kg/dm 3 min. 1.12 kg/dm 3 min. 1.12 kg/dm 3 not specified 

Piled weight min. 650 kg/m 3 min. 650 kg/m 3 not specified min. 640 kg/m 3 

Water content max. 12% max. 10% max. 10% max. 8% 

Ash fraction max. 1.5% max. 1.5% max. 0.5% max. 0.5% 

Abrasion not specified max. 2.3% max. 2.3% not specified 

Sulphur content not specified max. 0.04% max. 0.04% not specified 

Nitrogen content not specified max. 0.3% max. 0.3% not specified 

Chlorine content not specified max. 0.02% max. 0.02% not specified 

Pressing additives not specified max. 2.0% max. 2.0% none 

Table 3/3 - Characteristics of the wood pellets 


3.5 Building requirements 

3 Planning the heating system – Building requirements 

Necessary room sizes and minimum spacing 

B 

1 Boiler room 

Min. room height 225 cm 

Ideal room height 250 cm 

A) Width min. 230 cm 

B) Length min. 300 cm 

C) 66 cm 

D) 57 cm 

E) 120 cm 

F) 90 cm 

1 

Figure 3/7 - Necessary room sizes and minimum spacing 


F 

A 

C 

E 

D 

29

30 


Boiler room 

Applicable regulations Your local building regulations will always apply. In Germany, 

individual state regulations on boilers and furnaces also apply. 

German regulations on the room to install a boiler with a total 

nominal thermal capacity of up to 50 kW: 

• No requirements on the building 

• Ventilation opening of at least 150 cm 2 

• Distance of furnace to fuel at least 1.0 m, or 0.5 m with thermal 

radiation protection 

• Up to 15,000 kg of wood chips and pellets may be stored in the 

room where the furnace is installed. 

Installation The heating system can be placed on any level, firm floor. A base is 

not necessary. Ensure that it is aligned horizontally. 

To ensure unhindered operation and maintenance of the heating 

system, you must make sure that the heating system is installed to 

our specifications and that the minimum spacings are maintained. 

The specifications above are applicable for systems with a nominal 

thermal power of maximally 50 kW. 

Systems of greater thermal power are subject to boiler room 

guidelines and thus require a separate boiler room. In the 

individual German states, the specifications of the furnace 

ordinance are to be observed. 

Additionally, the limit values of DIN 4109 “Soundproofing in building 

construction” are not to be exceeded. 

More detailed information can be found in the respective ordinances 

of the German states. 

Also observe the requirements of the accident prevention and work 

safety regulations of the government safety organisations. 


Fuel bunker 


The fuel bunker should have the following characteristics: 

• dry 

• dust-proof 

• statically suitable 

• accessible for the filling process 

• without other installations, especially in the existing buildings 

• adapted to fuel requirements 

The refilling intervals should be kept as long as possible. The 

heating system should be located so that the noise generated does 

not exceed DIN 4109 “Soundproofing in building construction”. 

Dimensions The size of the fuel bunker depends on the heating system, the 

determined thermal load, the resulting annual fuel requirements and 

existing building conditions. Practice has shown that filling the fuel 

bunker four to six times per heating period is desirable. 

Example: 

For a thermal load of 50 kW, fuel consumption of approximately 15 

kg/h with a thermal value of 3.5 kWh/kg is to be expected. 

The annual fuel requirement for 1800 full-capacity hours is thus 

27,000 kg. 

With a specific weight of 225 kg/m 3 •, this amounts to 120 m 3 • fuel. 

To realise the rate of four to six refillings, the fuel bunker must 

comprise a volume of 30 or 20 m 3 . 


31

32 


Passage through the wall The passage through the wall normally has to be made in the wall 

between the boiler room and the fuel bunker. Its position depends 

on the distance and the position of the HDG Compact heating system 

in the room. 

The passage should be 70 cm wide and 70 cm high. 

Ventilation of fuel 

bunkers 

Figure 3/8 - Overview 

B 

1 Passage through the wall 

A) min. 70 cm 

B) min. 70 cm 

Wood fuel products with higher moisture can cause relatively high 

air humidity in the fuel bunker. Cold surfaces may thereby 

experience a drop below the dew point and develop condensation 

water. 

This condensation water often occurs on non-insulated lids, doors or 

cold walls and can result in a further moistening of the fuel. 

It is therefore recommended to provide a suitable ventilation system 

that corresponds to the building's features. 


A 

1

3.6 Connections 

Chimney 

3 Planning the heating system – Connections 

The benefits of the HDG Compact can only be reaped if all of the 

factors necessary for good combustion are carefully adjusted. The 

heating system and chimney form a single functional unit and must 

be adapted for one another in order to guarantee fault-free and 

economical operation. 

Since the flue temperature may lie below 100 ˚C when the system is 

partially loaded, a chimney/flue is required which meets the 

requirements of DIN EN 13384-1. 2003-03 “Thermal and fluid 

dynamic calculation methods”. If this is not the case, contact our 

service department. 

Another essential criterion is to achieve the correct working 

pressure. This depends on three major factors. 

Chimney characteristics The requirements for minimising the “draw” loss in the chimney are: 

• Good thermal insulation 

– This is to avoid the flue gases cooling down too quickly. 

• A smooth inner surface 

– This is to reduce the flow resistance. 

• A well sealed chimney 

– This is to avoid outside air leaking in. Outside air would speed 

up the cooling of the flue gases. 

These requirements correspond to chimneys of the type according to 

DIN EN 13384-1: 2003-03 “Thermal and fluid dynamic calculation 

methods”. 

Insulated chimneys used today, consisting of a fireclay or stainless 

steel pipe with an insulating jacket and cladding bricks (three shell 

design) must be assigned to groups I - II. 

Uninsulated chimneys made of bricks or similar material correspond 

to design type III and are unsuitable. 

Free-standing chimneys require particularly good insulation. 


33

34 


Chimney dimensions The system may only be connected to a chimney which has been 

dimensioned in accordance with DIN 13384-1, taking into account 

the fuel planned and the expected load, and which meets local 

building regulations for the erection site. 

A chimney can only be designed when the local circumstances are 

understood. This includes taking into account the following factors: 

• The location of the house 

– Hillside situation 

– Wind direction 

• Location of the chimney in the roof 

– The opening of the chimney must be at least 0.5 m above the 

highest edge of roofs with a slope of more than 20˚ or at least 

1.0 m away from roof surfaces which slope at 20˚ or less. 

Connecting the boiler to 

the chimney 

• The effective height of a chimney is measured from the entrance 

into the flue to the end of the chimney. 

The boiler must be connected to the flue with a connecting piece 

which is as short as possible, at an angle which is less than 30-45˚ to 

the chimney. 

You should aim for a connecting piece with a maximum length of 1 

mm using just one fitting. 

Every additional fitting results in a greater pressure loss in the 

exhaust path and should thus be avoided. The same is true for 

overlong connecting pieces. If, for constructional reasons, they have 

to be longer than 1 m, they should be adequately insulated (at least 

5 cm of mineral wool or equivalent material) and, if possible, should 

be fitted with an upward inclination. 

A 

Figure 3/9 - Connection to the chimney 

1 Auxiliary air unit 

2 Cleaning hatch 

A) Angle to the chimney approx. 30˚ - 45˚ 


1 

2


To compensate for irregularities of conveyor pressure in the 

chimney, HDG Bavaria recommends installing an auxiliary air unit in 

the flue, or even better, in the chimney itself as shown in Figure 3/9 

- Connection to the chimney. 

The following should also be considered: 

• The connecting piece may not protrude into the chimney. 

• If the system flue pipe has a larger diameter than the chimney, the 

connecting piece must reduce to the diameter of the connection. 

The connecting piece should taper as gently as possible. 

• Use bends rather than elbows, whereby the radius of the bend 

may not be less than the diameter of the pipe. 

• A vertical, straight chimney, if possible without bends (take 

particular care in older buildings). 

• All of the cleaning and measurement hatches on the chimney 

must be tightly sealed. 

• To reduce the entry of additional cold air, only one heat producer 

should be attached to each chimney. 

Electrical system 

The EC 73/ 23/EEC - L 77/73 (low voltage guidelines) must be 

followed for the electrical connections to the system. 

No electrical installations, such as power sockets, distribution 

sockets, lights or light switches may be located in the fuel bunker. 

Any lights must be suitable for use in areas at risk of explosion. The 

VDE regulations for rooms where there is a danger of a dust 

explosion must be followed. 

✎ The required connection values are listed in the 3.3 Technical 

data section in this chapter. 

Controller housing The controller housing should, if possible, be placed near the control 

elements, taking into account the ambient temperatures, and be 

easy to access in a dry location. 

Outdoor sensor The outdoor temperature sensor should be fixed about one third of 

the way up the building (at least 2m from the ground) on the coldest 

side of the building (north or north-east). When installing the sensor, 

you should take into account sources of heat which might falsify the 

result of the measurement (chimneys, warm air from air shafts, 

direct sunlight, etc.). The cable outlet must always point down to 

avoid moisture penetration. For the electrical installation a cable 

type JYSTY 2 x 2 x 0.6 mm 2 with a maximum length of 50 m should be 

used. 


35

36 


Heating circuit sensor The heating circuit temperature sensor serves to measure the supply 

temperature for heating circuits controlled by mixers. The sensor 

should be installed at a distance of approx. 30 cm after the 

circulation pump on a bright metal part of the supply line. 

Buffer tank sensor and 

hot water sensor 

Indoor thermostat unit 

(room sensor) 

The temperature sensors are immersion sensors with a moulded 

cable and serve to measure the temperature of the buffer tank and 

the hot water tank. 

With the room sensor, the preset room temperature can be altered 

by 2-3 ˚C. A selection switch allows the operating status for each 

heating circuit to be changed. 

Before installing the room sensor, a suitable installation location 

must first be found. This must not be in an area where sunlight falls, 

where there's a draft, a radiator, a chimney etc. so that only the 

actual room temperature is measured. It should also be on an 

interior wall. 

The most appropriate room is the room where the inhabitants spend 

most time (e.g. living or dining room). In this room, no other source 

of heat should be used (e.g. open fire). 

If there are thermostatic valves on the radiators, these must be set 

higher than the room temperature in the control system. Otherwise, 

the room sensor would be affected. Their influence would distort the 

supply to the heating circuit and all other rooms would become too 

warm. In all of the other rooms however, thermostatic radiator 

valves must be fitted. 

Water 

The system must be filled with water which conforms to the VDI 

guideline 2035 "Avoiding damage in hot water heating systems". 

The use of a buffer tank When calculating the thermal requirements of buildings, e.g. to 

DIN 4701, the lowest outdoor temperature for the climate zone 

concerned (e.g. -15 ˚C) is used. This condition only applies a few 

days per year so that the thermal performance of the heating system 

is overdesigned for most of the days when heating is needed. 

For this reason, the HDG Compact is fitted as standard with power 

control and automatic ignition. 

It is, however, highly recommended to use a buffer tank even with 

automatic boiler systems. 

The size of the buffer tank depends on the nominal thermal power of 

the boiler and on the thermal requirement of the building. As a 

benchmark value, 20 litres per kilowatt boiler power can be used. 

This results in a boiler burning duration of approximately one hour at 

full-capacity operation, during which the buffer tank is completey 



filled. The emptying time of the buffer tank at 25% nominal load 

amounts to 3.7 hours for this type of design, with an assumed usable 

temperature difference of 40 Kelvin. 

One advantage of a buffer tank is the low number of operating hours 

for the system and fewer start phases due to extended heating 

periods, which leads to a reduction in the proportion of external 

energy and to lower wear of the mechanical components. 

One further advantage of the buffer tank is in summer operation 

when only hot water is required. When operating in this mode, the 

buffer tank avoids frequent ON/OFF changes. 

For the above-mentioned reasons we recommend a buffer tank, even 

for automatic boiler systems. 

Safety devices Safety devices are to be installed in accordance with DIN EN 12828: 

2003 “Design of water-based heating systems in buildings”. 


37

38 


Flue pipe side 

1 

4 

3 

Figure 3/10 - Flue pipe side 

1 Boiler supply 

bushing 1 1/4 inch, nominal diameter 32 

2 Boiler return 

bushing 1 1/4 inch, nominal diameter 32 

3 Filling 

Emptying 

bushing 1/2 inch, nominal diameter 15 

4 Flue pipe connection Ø 180 mm 


2

Thermal safety device 

1 

Figure 3/11 - Thermal flow 

1 Thermal safety device 

bushing 1/2 inch, nominal diameter 15 


2 Cold water inflow 3/4 inch, nominal diameter 20 

3 Cold water outflow 3/4 inch, nominal diameter 20 

4 Safety heat exchanger 

3/4 inch outer thread 

Hydraulic connection There are hydraulic solutions for every application. 

✎ An excerpt of the options for hydraulic connection can be found in 

the chapter “4 Installing the heating system” in the “4.8 HDG 

hydraulic systems” section. 


2 

3 

4 

39

40 

4 Installing the heating system – Requirements 

4 Installing the heating system 

4.1 Requirements 

4.2 Scope of delivery 

The heating system will initially be commissioned by specialists from 

HDG Bavaria or from an authorised HDG partner and a qualified 

electrician. 

Danger! 

Material damage and injury due to incorrect installation. 

Installing the system requires comprehensive specialist 

knowledge. If installed by untrained persons, the heating system 

can be damaged and persons may be injured due to subsequent 

damage. 

Only allow authorised specialists to perform the installation. 

Danger! 


Switch off the power supply and isolate the mains cable to the 

heating system during the installation. 

The heating system is delivered with all components on pallets. 

Check that the scope of delivery matches the information on the 

delivery note. 


4.3 HDG Compact 

Installing the boiler 

Transport with a crane 1. Remove the packaging from the boiler. 

2. Remove the top hoods (1). 

4 Installing the heating system – HDG Compact 

Caution! 

Danger from suspended loads. 

The boiler weighs over 250 kg. If the boiler is dropped during 

transport, people can be seriously injured and the boiler can be 

damaged. 

Make sure that you use appropriate lifting gear when installing the 

boiler. 

1 

Figure 4/1 - Removing hoods 


41

42 


Erection site 

Figure 4/2 - Fastening the crane hooks 

3. Attach the crane hook to the ring bolts (1) on the boiler. 

4. Carefully lift the boiler 

5. Transport the boiler to its installation location. 

Figure 4/3 - Erection site 

6. Place the boiler on the planned location. 

7. Maintain the minimum spacings. 

✎ See the section “3.5 Building requirements” in the chapter 

“3 Planning the heating system”. 

8. Align the boiler with plastic plates or flat steel strips (not included 

in the scope of delivery) so that it is horizontal. 

9. Unscrew the ring bolts from the boiler. 

✓ The boiler has been put in place. 


1

Dismantling the rear 

covers 


Installing the automatic ash removal system 

Figure 4/4 - Dismantling the circuit board cover 

1. Unscrew the rear cover of the circuit board (1) with a Phillips-tip 

screwdriver. 

2. Unscrew the rear ash removal cover (1) with a Phillips-tip 

screwdriver. 


1 

1 

Figure 4/5 - Dismantling the ash removal cover 

43

44 


Figure 4/6 - Unscrewing the blind side cladding 

3. Unscrew the inner cladding of the bottom blind side (1) with a 

Phillips-tip screwdriver. 

1 

2 

4. Remove the cover (2) together with the insulation (1). 

✓ The rear covers are dismantled. 


1 

Figure 4/7 - Dismantling the rear inner cover

Installing the 

combustion chamber 

hopper 


Figure 4/8 - Installing the combustion chamber hopper 

5. Push the combustion chamber hopper (3) from the front under 

the combustion chamber (1). 

6. Bolt on the combustion chamber hopper (3) with a screw and 

welded on M 10 nut (2) through the dividing wall from the 

combustion chamber ash box and fly ash chamber using a 17 mm 

open-end spanner. 

1 

3 

3 

Figure 4/9 - Installing the alignment plate 

7. Bolt the alignment plate (1) onto the hopper plate (3) with two 

screws (2) and M 10 nuts using a 17 mm spanner. 

✓ The hopper plate is installed. 


1 

2 

2 

45

46 


Installing the ash 

removal system 

1 

Figure 4/10 - Inserting the automatic ash removal system 

8. Insert the automatic ash removal system (1) under the 

combustion chamber (2). 

9. Bolt on the automatic ash removal system (1) with six M 12 

nuts (2) using a 19 mm spanner. 


1 

Figure 4/11 - Bolting on the automatic ash removal system 

2 

Due to a soft seal, the screws may not be screwed in up to the limit. 

Only tighten until a resistance is detected. 

2


Figure 4/12 - Bolting on the automatic ash removal system 

10.Check the tension of the chain (3) in the chain centre (2). 

11. The chain may have a maximum of 1 cm play in an upward and 

downward direction. 

12.If necessary, correct the play in the chain centre (2) with the 

eccenntric tappet (1). 

1 

3 

Figure 4/13 - Installing the bracket 

13.Place the bracket (1) on the sliding tray (3) with the canting 

toward the front. 

14.Bolt on the bracket (1) by screwing two M 10 nuts (2) on the 

welded bolts of the sliding tray (3) using a 17 mm spanner. 

✓ The automatic ash removal system is installed. 


1 

2 

The bracket must have approximately 3 mm clearance from the top 

to the inner wall edge of the combustion chamber. 

2 

3 

47

48 


Attaching the ash door 

1 

Figure 4/14 - Sliding in the ash removal door 

15.Fold both clamp handles (3) upward. 

16.Slide the ash removal door (1) onto the combustion chamber or 

sliding tray worm (2). 

1 

Figure 4/15 - Bolting on the ash removal door 

17.Bolt on the ash removal door (1) with a long screw (2) and four M 

12 short screws (4) using a 19 mm spanner. 


3 

3 

34 

2 



2

Attaching the cover plate 

of the ash door 


18.Tighten the screws (2 + 4) to the same tightness. The combustion 

chamber or sliding tray worm (3) may not contact the ash removal 

door (1). 



19.Align the combustion chamber worm or sliding tray worm (3) if 

necessary with the nuts of the ash removal system and the screws 

of the ash removal door. 

✓ The ash removal door is attached. 

Figure 4/16 - Installing the cover plate of the ash door 

20.Position both clamp handles (1) so that they are horizontal. 


1 

49

50 


1 

Figure 4/17 - Installing the cover plate of the ash door 

21.Insert the bottom of the cover plate (1) with the recesses in the 

guides on the boiler (2). 

22.Press the top of the cover plate (1) onto the boiler (2). 

✓ The cover plate of the ash door is attached. 


2

Attaching the cleaning 

shaft lid 



1 

Figure 4/18 - Unscrewing the nuts 

23.Unscrew the two nuts (1) on the hinges of the cleaning shaft lid on 

the boiler. 

24.Fold the hinges upward. 

51

52 


Caution! 


The cleaning shaft lid is very heavy. Hands can become crushed 

when installing it. 

Always take care not to grasp under the cleaning shaft lid when 

putting it on. 

1 

Figure 4/19 - Putting on the cleaning shaft lid 

25.Place the cleaning shaft lid (1) on the boiler (2). 


2

1 

Figure 4/20 - Bolting on the cleaning shaft lid 


26.Guide the screws (1) of the hinges into the holes on the cleaning 

shaft lid (2). 

27.Bolt on the cleaning shaft lid (2) with the M 12 nuts on the hinges 

using a 19 mm spanner. 

✓ The cleaning shaft lid is attached. 


2 

53

54 



crossbeams 

Caution! 


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. 

Figure 4/21 - Opening the cleaning shaft lid 

28.Fold open the cleaning shaft lid (1). 

Figure 4/22 - Installing the short crossbeam 

29.Place the short crossbeam (1) on the turbulaters (2). 


1 

1 

2

4 

1 



30.Using a 19 mm spanner, bolt the short crossbeam (1) with two M 

12 screws (3) onto the turbulaters (2), allowing approximately 

2 mm play between nut and turbulater crossbeam retainer (4). 

31.Secure the M 12 nut with the M 12 lock nut using a 19 mm ratchet. 

32.Install the long crossbeam as described above. 

33.Align the crossbeams (2) centred to the boiler inner walls. 

34.Slowly close the cleaning shaft lid. 


1 


3 

2 

55

56 


1 


35.Bolt the crossbeams with two M 10 screws (1) onto the cleaning 

shaft lid using a 10 mm hexagon socket wrench. 

36.Align the crossbeams if necessary through the inspection flap of 

the combustion chamber or the flue pipe. 

37.Tighten the star-grip screw. 

✓ The crossbeams are installed. 



combustion air fan 

Installing the feed 

system 

1 

Figure 4/26 - Installing the combustion air fan 


38.Bolt the combustion air fan (1) onto the air regulating unit (2) with 

four M 6 screws and a 5 mm hexagon socket wrench. 

✓ The combustion air fan is installed. 

1 

Figure 4/27 - Attaching the adapter pipe 

39.Slide the adapter pipe (1) with a seal (2) into the feed channel (3). 


2 

3 

2 

57

58 



40.Align the seal (2) with the holes. 

41.Insert the M 12 screws (1) from the boiler through the holes. 

42.Poke holes through the seal (1) for both centring screws (3). 

43.Insert the centring screws (3) toward the boiler through the holes 

and screw them tight with the M 6 nuts using a 10 mm spanner. 


44.Insert the second seal (1) on the adapter pipe (2). 

45.Slide the feed system (1) onto the adapter pipe (2). 


3 

1 

2 

2 

1


Caution! 


The feed system is very heavy. Hands and feet could be crushed 

when it is lifted. 

Only lift the feed system using suitable lifting equipment. 

Figure 4/30 - Lifting the feed system 

1 

2 

Figure 4/31 - Bolting on the feed system 

46.Bolt on the feed system (1) with the M 12 nuts (2) using a 19 mm 

spanner. 


1 

2 

59

60 


1 

4 

Figure 4/32 - Attaching the supporting foot 

47.Bolt the supporting foot (3) with an M 12 screw (2) onto the feed 

system (1) using a 19 mm spanner. 

48.Fasten the supporting foot (3) as required to the floor (screws and 

screw anchors are not included in the scope of delivery). 

49.Align the feed system (1) horizontally with the two M 10 

screws (4). 

✓ The feed system is installed. 


3 

2

Connecting the pressure 

equalisation hose 


Figure 4/33 - Setting the pressure equalisation regulator 

50.Set the position indicator (1) for the pressure equalisation 

regulator to approximately 1 o'clock. 

Figure 4/34 - Connecting the pressure equalisation hose 

51.Place the rubber seal on the connections of the pressure 

equalisation hose (1). 

52.Attach the pressure equalisation hose (1) to the feed system (2) 

and to the boiler (3). 

✓ The pressure equalisation hose is connected. 


1 

1 

3 

2 

61

62 


Connecting the cleaning 

system 

1 

Figure 4/35 - Removing the top cover 

53.Unscrew the two shaped studs (2) using a 6 mm spanner. 

54.Unscrew the top cover (1) with a Phillips-tip screwdriver. 

Figure 4/36 - Connecting the cleaning system 

55.Lay the cables of the cleaning system (2) to the circuit boards, 

placing them on the insulation (1). 


1 

2 

When laying the cable, ensure that there is enough cable for the 

cleaning shaft lid to be opened. 

2

Installing the sensors 


56.Connect the plug of the cleaning system to the circuit board. 

✎ See the section “4.8 HDG hydraulic systems” in the chapter 

“4 Installing the heating system”. 

✓ The cleaning system is now connected. 

Figure 4/37 - Installing the sensors 

The sensors (1) for the buffer tank are attached under the top 

cladding cover next to the circuit boards for further use. 

1 

Figure 4/38 - Mounting sensors 

1 

57.Seal the immersion sleeves of the sensors with a suitable sealing 

material and position them at the points indicated in Figure 4/38 

- Mounting sensors. 


63

64 


58.Guide the sensors into the immersion sleeves. 

59.Insert the prefabricated plug connections into the terminals 

specified in the circuit diagram. 

✓ The sensors are installed. 

For a hydraulic diagram without buffer tank, these sensors are not 

present and must be taken out of the corresponding parameters. 

Wiring the circuit boards 

1 

Figure 4/39 - Wiring the circuit boards 

1. Open the cable duct (2). 

2. Connect all plugs to the circuit board central unit (1) and transport 

module (3) in accordance with the circuit diagram. 

✎ See the section “5.1 HDG Compatronic circuit diagram” in the 

chapter “5 Circuit diagrams”. 


2 

3



3. Lay the condensor (1) of the combustion air fan in the cable duct 

(2). 

2 


4. Lay the cable of the automatic cleaning system (1) so that it does 

not contact the drive chain (2). 

5. Fasten all cables with cable clips. 

6. Close the cable ducts. 

✓ The circuit boards are wired. 


1 

1 

2 

65

66 


Installing the boiler cladding 

Figure 4/42 - Installing the boiler cladding 

1. Cut out the right pre-punched sheet part (1) for the opening of the 

ash removal motor using a side cutter or other suitable tool. 

2. Mount all cladding on the system. 

✓ The boiler cladding is installed. 


1


Mounting and adjusting the ash boxes 

1. Remove the ash boxes from the packaging. 

2. Pull the two latching bolts and turn them simultaneously 90 ˚. 

3. Fold the transport handles upward. 

4. Turn the latching bolts by 90˚ and jiggle them slightly by the 

handle grips. 

✓ The latching bolts latch into the holes of the ash boxes. 

Figure 4/43 - Attaching the ash boxes 

5. Lift up the clamp handles (1). 

6. Insert the ash boxes (2) on the ash removal pipe. 

7. Press the clamp handles (1) downward. 

✓ Grasp the clamp handles and press the ash boxes against the seal 

of the ash removal door. 

8. If the clamp handles do not clamp, adjust them as follows. 

9. Open the ash boxes. 


1 

2 

67

68 


Figure 4/44 - Attaching the ash boxes 

10.Release the cap nuts (1) in the ash boxes and unscrew these 

approximately 4 revolutions. 

11. Release the nuts under the cap nuts and unscrew them until the 

clamp handles latch in place. 

12.Screw on the nuts and check that the clamp handles clamp firmly. 

✓ Grasp the clamp handles and tighten the ash boxes solidly on the 

ash removal door. 

13.Lock the nuts with the cap nuts. 

14.Close the ash boxes in the reverse sequence. 

✓ The ash boxes are mounted and adjusted. 


1

Connecting the chimney 


1. Connect the chimney pipe to the chimney connection. 

2. Make sure that the connecting piece does not protrude into the 

chimney. 

3. Seal the connection to the chimney with very fireproof silicone or 

with a suitable mortar. 

✓ The boiler has been connected to the chimney. 

✎ See the section “3.6 Connections” as described in the chapter 

“3 Planning the heating system”. 


69

70 

4 Installing the heating system – HDG Hydronic 

4.4 HDG Hydronic 

Installing the control 

unit housing 

Danger! 


Remove all power and isolate the mains cable to the heating 

system during the installation. 

Caution! 

Material damage due to static discharge. 

Electronic components can be damaged by static discharge. 

Do not touch any electronic components during the installation. 

Installing the control unit 

The "bus" cable between the Pelletronic and the Hydronic 

equipment must be protected from inductive coupling from 230 V 

wires. 

Only use screened cables for sensor extensions. 

1 

Figure 4/45 - Control unit housing 

1. Fix the control unit housing at its intended position on the wall. 

For the holes to be drilled, see (1). Mounting it near the distributor 

is recommended. 

✎ See the section “3.6 Connections” in the chapter “3 Planning the 

heating system”. 


1

Installing the sensors 


Depending on the hydraulic system installed, corresponding sensors 

must be installed and connected. 

See the hydraulic plan and the circuit diagram for the plug 

connections and the necessary sensors for your particular hydraulic 

system. 

✎ The available hydraulic systems can be found in the section 

“4.8 HDG hydraulic systems” in the chapter “4 Installing the 


Take great care that you use the correct sensors (contact sensors, 

immersion sensors, outdoor sensors) as, if used incorrectly, error 

messages and resulting malfunctions in the control system can then 

occur. 

All of the sensors in the HDG Hydronic are PT 1000 sensors. 

Temperature PT 1000 

-50 ˚C 803.10 Ohm 

-40 ˚C 842.70 Ohm 

-30 ˚C 882.20 Ohm 

-20 ˚C 921.60 Ohm 

-10 ˚C 960.60 Ohm 

0 ˚C 1000.00 Ohm 

10 ˚C 1039.00 Ohm 

20 ˚C 1077.90 Ohm 

25 ˚C 1097.40 Ohm 

30 ˚C 1116.70 Ohm 

40 ˚C 1155.40 Ohm 

50 ˚C 1194.00 Ohm 

60 ˚C 1232.40 Ohm 

70 ˚C 1270.70 Ohm 

100 ˚C 1385.00 Ohm 

150 ˚C 1573.10 Ohm 

Table 4/1 - The characteristics of PT 1000 


71

72 


Installing an outdoor 

sensor 

Installing a heating 

circuit sensor 

Figure 4/46 - Outdoor sensor 

Figure 4/47 - Heating circuit sensor 

1. Install the outdoor sensor at 

its intended position on the 

wall with its cable outlet 

downwards. 

✎ See the section 

“3.6 Connections” in the 

chapter “3 Planning the 


2. Fix the heating circuit sensor (1) to the pipe using the hose-clip (2) 

supplied, flush to the surface of the pipe. 

✎ See the section “3.6 Connections” in the chapter “3 Planning the 



1 

2

Installing sensors for 

buffer and hot water 

tanks 

Installing a room sensor 


Figure 4/48 - Sensors for buffer and hot water tanks 

3. Make sure that the sensors for buffer and hot water tanks are not 

bent. 

4. Carefully insert the buffer and hot water tank sensors into the 

immersion sleeves. 

Figure 4/49 - Room sensor 

Figure 4/50 - Room sensor without cover 

1. Fix the room sensor at its 

intended position on the wall. 

✎ See the section 

“3.6 Connections” in the 

chapter “3 Planning the 



73

74 

4 Installing the heating system – Electrical system 

Hydraulic systems Hydraulic systems must be implemented as specified by HDG from 

page 78 onwards. 

✎ The available hydraulic systems can be found in the section 

“4.8 HDG hydraulic systems” in the chapter “4 Installing the 


4.5 Electrical system 

4.6 Water 

The electrical connections must be made in accordance with DIN IEC 

60364 “Setting up low-voltage electrical installations”. 

✎ The technical details are described in the section “3.3 Technical 

data” in the chapter “3 Planning the heating system”. 

✎ The circuit diagram is in the chapter “5 Circuit diagrams”. 

The heating system must be filled with water which conforms to the 

VDI guidelines 2035 “Avoiding damage in hot water heating 

systems”. 

The membrane expansion container must be constructed in 

accordance with DIN EN 13831 “Closed expansion containers with 

built-in membrane for integration in water installations”. 

Before putting the system into operation, the pressure of the 

membrane expansion container must be adjusted for the conditions 

in the heating system and in the building. 

After putting the system into operation, heat up the system to the 

maximum boiler temperature and bleed air from the system again to 

make sure that there are no air pockets. 

The safety devices must be implemented in accordance with DIN EN 

12828 “Heating systems in buildings” and the correspondingly 

harmonised national standard DIN 4751, Part 2 “Closed, 

thermostatically safeguarded heat generating systems with supply 

temperatures of up to 120 ˚C; safety equipment”. 

The flow pressure for the thermal safety device must be at least 2 

bar and ensure a flow volume of 1800 l/h. Own water supply 

systems are not safe enough due to dependence upon the power 

supply! 

In Germany, the requirements of the German energy conservation 

ordinance (EnEV) are to be met. 


4.7 Starting the system 

4 Installing the heating system – Starting the system 

The heating system will initially be commissioned by specialists from 

HDG Bavaria or from an authorised HDG partner. 

The commissioning includes an introduction to the operation and 

maintenance of the heating system as well as the taking of 

measurements on the system for pollution and heating capacity. 

Danger! 

Material damage and injury due to incorrect commissioning. 

Commissioning the system requires comprehensive specialist 

knowledge. If this commissioning is done by an untrained person, 

the heating system can be damaged. 

Only allow authorised specialists to perform the commissioning. 

✎ The initial commissioning is described in the operating 

instructions in chapter 7 “ Commissioning the heating system”. 


75

76 

4 Installing the heating system – HDG hydraulic systems 

4.8 HDG hydraulic systems 

Hydraulic system 0 

OT 


OTS Outdoor temperature 

sensor 

ST Supply temperature 

sensor (boiler 

temperature) 

RT Return temperature 

sensor 

Bt Buffer top sensor 

Bb Buffer bottom sensor 

ST 

RT 

Bt 

Bb 

Figure 4/51 - Hydraulic system 0 


Hydraulic system 1a 

OT 


ST 

RT 


sensor 



temperature) 


sensor 



A7/8 

Figure 4/52 - Hydraulic system 1A 

HDG Hydronic P 

A4 


F4 

CCT1 CCT2 


Bt 

Bb 

A1 

F5 

A5 

A9/10 

F10 

Inputs (sensors) Outputs (Aggregate) 

F1 Unused A1 Solar pump 

F2 Unused A2 Unused 


F4 Supply CCT1 A4 Heating circulation pump 

CCT1 


CCT2 


F7 Unused A7 Heating circulation mixer 

CCT1 open 


CCT1 closed 


CCT2 open 

F10 Solar collector 

temperature 

A10 Heating circulation mixer 

CCT2 closed 

77

78 



OT 


ST 


sensor 



temperature) 


sensor 



RT 



A7/8 


A4 

Bt 

Bb 

F4 

F5 

A5 

A9/10 

CCT1 CCT2 CCT3 

F9 

A6 

A1/2 


F1 Unused A1 Heating circulation mixer CCT3 

open 


closed 

F3 Unused A3 Heating circulation pump CCT3 

F4 Supply CCT1 A4 Heating circulation pump CCT1 

F5 Supply CCT2 A5 Heating circulation pump CCT2 



open 


closed 

F9 Supply CCT3 A9 Heating circulation mixer CCT2 

open 


closed


OT 



sensor 



temperature) 


sensor 



ST 

RT 




A4 F4 CCT1 CCT2 DH 

Bt 

F5 


A7/8 

Bb 

A5 

A9/10 

F9 

A2 



F2 Unused A2 District heating pump 



CCT1 


CCT2 



CCT1 open 


CCT1 closed 

F9 The temperature of the 

district heating circuit 


CCT2 open 


CCT2 closed 

79

80 


Hydraulic system 4A 

OT 


ST 

RT 


sensor 



temperature) 


sensor 



Bb 

Bt 

A4 

A7/8 

F4 

CCT1 CCT2 

A9/10 

Figure 4/55 - Hydraulic system 4A 



F5 

A5 

A3 

F3 

F10 



F2 Hot water tank top A2 Buffer tank pump 

F3 Hot water tank bottom A3 Hot water pump 


CCT1 


CCT2 



CCT1 open 


CCT1 closed 


CCT2 open 

F10 Solar collector 

temperature 

A2 


CCT2 closed 

F2 

A1


OT 


ST 

RT 


sensor 



temperature) 


sensor 



Bt 

Bb 

A4 

A7/8 

F4 

F5 

A5 




CCT1 CCT2 

A9/10 


DH 

A2 

F3 

F9 

A3 

F10 



F2 Hot water tank top A2 District heating pump 

F3 Hot water tank bottom A3 Hot water pump 


CCT1 


CCT2 



CCT1 open 


CCT1 closed 

F9 The temperature of the 

district heating circuit 


CCT2 open 

F10 Solar collector sensor A10 Heating circulation mixer 

CCT2 closed 

F2 

A1 

81

82 



OT 


ST 

RT 


sensor 



temperature) 


sensor 



Bt 

Bb 

A4 

A7/8 

A9/10 




F4 

CCT1 CCT2 

F5 

A5 

F9 

A6 

A1/2 

CCT3 

A3 


F1 Unused A1 Heating circulation 

mixer CCT3 open 

F2 Hot water tank A2 Heating circulation 

mixer CCT3 closed 

F3 Unused A3 Hot water pump 

F4 Supply CCT1 A4 Heating circulation 

pump CCT1 


pump CCT2 


pump CCT3 









F2


OT 



sensor 



temperature) 


sensor 

X Hydraulic switch 

ST 

RT 

F4 

A7/8 

X 

A4 

CCT1 CCT2 

F5 

A5 

A9/10 





DH 

A2 A3 

F9 

F3 

F10 



F2 Hot water tank A2 District heating pump 



pump CCT1 


pump CCT2 










F2 

A1 

83

84 



OT 



sensor 



temperature) 


sensor 


ST 

RT 

X 

F4 

A4 

A7/8 

F5 

A5 

A9/10 

CCT1CCT2 CCT3 

A1/2 




F9 

A6 

A3 




F2 Hot water tank A2 Heating circulation 




pump CCT1 


pump CCT2 


pump CCT3 









F2


OT 


OTS Outdoor 

temperature sensor 



temperature) 


sensor 

BH1 Buffer house 1 

BH2 Buffer house 1 

CP1 Conveyor pump 

house 1 


house 2 


ST 

RT 

BH1 



CP1 CP2 

X 


BH2 

85

86 



F2 

OT 


ST 

RT 

A3 

A4 

A7/8 

OTS Outdoor 




temperature) 


sensor 


house 1 


house 2 


Bt 

Bb 

F4 

CCT1 CCT2 

F5 

X 

CP1 

A9/10 




A5 

CP2 

X 

A6 



F2 Boiler house 1 A2 Unused 

F3 Boiler house 2 A3 Hot water pump house 1 

F4 Supply CCT house 1 A4 Heat circulation pump house 

1 

F5 Supply CCT house 2 A5 Heat circulation pump house 

2 

F6 Unused A6 Hot water pump house 2 

F7 Unused A7 Mixer house 1 open 

F8 Unused A8 Mixer house 1 closed 

F9 Unused A9 Mixer house 2 open 

F10 Unused A10 Mixer house 2 closed 

F3


F2 

A3 

OT 

F4 

A4 

A7/8 


ST 

RT 

F5 

A5 

OTS Outdoor 




temperature) 


sensor 


house 1 


house 2 


HYH1 Hydronic house 1 

HYH2 Hydronic house 2 

X 



CCT CCT2 CCT CCT4 CCT CCT6 

A9/10 

HYH1 HYH2 

A1/2 

F9 

A6 

CP1 CP2 


Bt 

Bb 


F4 

A4 

A7/8 

X 

A5 

A9/10 

F5 

F9 

A6 

A1/2 

A3 


F1 Unused A1 Mixer CCT3 (CCT6) open 

F2 Hot water tank A2 Mixer CCT3 (CCT6) closed 

F3 Unused A3 Hot water pump house 1 

F4 Supply CCT1 (CCT4) A4 Heat circulation pump CCT1 

(CCT4) 

F5 Supply CCT2 (CCT5) A5 Heat circulation pump CCT2 

(CCT5) 

F6 Unused A6 Heat circulation pump CCT3 

(CCT6) 

F7 Unused A7 Mixer CCT1 (CCT4) open 

F8 Unused A8 Mixer CCT1 (CCT4) closed 

F9 Supply CCT3 (CCT6) A9 Mixer CCT2 (CCT5) open 

F10 Unused A10 Mixer CCT2 (CCT5) closed 

F2 

87

Notes 

88 



5 Circuit diagrams – HDG Compatronic circuit diagram 

5 Circuit diagrams 

5.1 HDG Compatronic circuit diagram 

Circuit diagram HAICO COMPATRONIC 

CAUTION! 

PHASES MUS T BE CONNECTED 

CORRECTLY. 

8000491 0 

MMI 1.0 

NPE L 

N PE 1 

MAINS 

to HAICO 1210 

1 

PE 

N 

CLOSED? 

Connect Mains supply 

phases correct! 

Complete isolation from mains 

via switch or plug arrangement 

Mains 3 x 230VAC + 10/-15%, 50Hz 

max. 13A fuse 

2 

RMZ 

Mixer Return 

230VAC 

M 

1~ 

UP? 

DOWN 

3 PE N 

17 PE N 16 15 PE N 14 PE N 13 PE N 12 11 PE N 10 9 8 PE N 7 PE N 6 PE N 5 PE N 4 3 PE N 2 

CAN -BUS 

RMA 

RR 

F3 

Dumping grate 

230VA C 

M 

1~ 

UP 

6 PE N 5 PE N 4 

64 63 62 61 60 59 58 

64 63 62 61 60 59 58 

CAN VCC 

CAN H 

CAN L 

T315mA 

CA N GND 

Shielding 

PE 

N 

L1 

L2 

L3 

PE 

N 

L 

PC-RS232 

Mains supply 

CAN -BUS D IP switch 

Standard setting 

BOTH "OFF" 

(I/O16.0 + MMI 1.0 + HS 3.0 with HAICO CAN) 

CAN 

CAN -BUS 

Re serve 5 

Suction 

230VAC 

M 

1~ 

Feed system 

230VA C 

M 

1~ 

10 9 8 PE N 7 PE N 

I2C 

DA Q 

F4 

T3 ,15 A 

Return motor 

230VAC 

F1 

F2 

57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 

57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 

Heizung 

M 

1~ 

11 PE N 

109 108 N PE 107 106 105 N PE 104 103 N PE 102 101 100 N PE 

F17 F18 

CAN 

RL 

District heating pump 1 

Hydr. system 10,11,12 

Mains supply 

I/O Platine 16.0 

M 

1~ 

OFF 

ON 

SS 

CAN 

Safety chain 

SZ 

Motor3 Delivery 

M3 

3~ 

F17 

F18 

F14 

M2 

3~ 

F15 

Oxygen sensor 

Motor 2 

Dosing system 

F15 F16 

F16 

F12 

F14 

Fault 

Operating status 

230VAC 

80004907 


Flue gas temp. (NiCrNi) 

Operation 

Comb. chamber temp.(NiCrNi) 

Cleaning 

230VA C 

M 

1~ 

Supply temp. (PT1000) 

District heating pump 2 

Hydr. system 10,11,12 

Return temp. (PT1000) 

Ignition heating 

Buffer temp. (PT1000) 

Ingnition fan 

230VAC 

M 

1~ 

17 PE N 16 15 PE N 14 PE N 13 PE N 12 

M1 

3~ 

9 

8 

7 

6 

AB 

5 

C 

4 

D 

3 

E 

1 2 

F 0 

Ignition fan 

Buffer temp. lower (PT1000) 

T10A 

Outdoor temp. lower (PT1000) 

T315mA 

39 PE 38 37 PE 36 35 PE 34 33 PE 32 31 PE 30 29 PE 28 27 PE 26 25 PE 24 23 PE 22 21 PE 20 19 PE N 18 PE N 

39 PE 38 37 PE 36 35 PE 34 33 PE 32 31 PE 30 29 PE 28 

27 PE 26 25 PE 24 23 PE 22 21 PE 20 19 PE N 18 PE N 

115 PE N 114 PE N 

113 112 111 N PE 110 

F11 F13 

F12 

24VDC 

M 

24V 

DC 

Secondary air 

servo motor 

F11 

F13 

F10 

0..10VDC 

Motor1 Feed system 

F10 

24VDC 

M 

24V 

DC 

Primary air 

servo motor 

0..10VDC 

0..10VDC 

Analog output 

Reserve 

0..10 

IN 1 

VDC IN 2 

15VDC 

Signal 

feedback 

Reserve 1 

Relay 

normally open 

contact 

Reserve 2 

Relay 

normally open 

contact 

115 PE N 114 PE N 

113 112 111 N PE 110 109 108 N PE 107 106 105 N PE 104 103 N PE 102 101 100 N PE 

OFF 

ON 

CAN-BUS DIP switch 

Standard setting 

BOTH "ON" 

(I/O16 .0 + I/ O21 .0 + MMI 1.0) 

Enable external 

conveying devices 

VG 

EF_A 

EF_B 

A1_TS_L3 

A1_TS_L2 

A1_TS_L1 

La mbda_ Heiz 

RM_2 

RP 

O2+ 

A2_TS_L3 

A2_TS_L2 

A2_TS_L1 

T4A 

RGT+ 

RM_1 

BRT+ 

VT 

BP 

Aout_2 

M 

1~ 

A3_TS_L3 

A3_TS_L2 

A3_TS_L1 

ST 

ZH 

Aout_1 

CA NM ODU L Adress 

Standard setting: 

Position "0" 

(I/O16.0 + I/ O21 .0 + MMI 1.0) 

Aout_3 

ZG 

RT 

PTO 

PTU 

AT 

AIn_5a 

AIn_6a 

154 153 152 151 150 149 148 147 146 145 144 143 142 141 140 139 138 137 136 

154 153 152 151 150 149 148 147 146 145 144 143 142 141 140 139 138 137 136 

HALLsensor 

2 

AS 

AB 

TSB 

SK_WM 

SK_ESÜ 

SK_STB 

ERA 

ERZ 

EUD 

FSW 

FSL 

EX F 

A4_KS 

Re lay 

80005240 


E12 

Signal 2 

15VDC 

HALLsensor 

1 

A5_KS 

Re lay 

red 

black 

w/b 

E11 

Signal 1 

15VDC 

F20 

F19 

AIn_4a 

Signal 

Negative 

pressure 

measuring 

T315mA 

E6 

E5 

E4 

E3 

E2 

E1 

E7 

E8 

E9 

E10 

M 

1~ 

Reserve 2 

230VAC 

Ash worm 

230VAC 

ES 

Ash worm 

230VAC 

ES 

Emergency Insufficient 

Off water 

230VAC 230VAC 

STB 

230 VA C 

ES 

Grate up 

230 VA C 

Reserve 1 

230VAC 

Malfunction 

external 

conveying 

devices 

230VAC 

Door 

combustion 

chamber 

230 VA C 

Combustion 

chamber 

230VA C 

EX- 

Requirements 

230VAC 

135 N PE 134 133 PE 132 131 130 129 128 

127 PE 126 125 PE 124 123 PE 122 121 120 119 118 117 116 

135 N PE 134 133 PE 132 131 130 129 128 

127 PE 126 125 PE 124 123 PE 122 121 120 119 118 117 116 

80415192-B 

ANP HAICO TRI 

Klixon Klixon 

ES ES 

ES Klixon Klixon Klixon 

Cleaning Ash removal 

Congestion Door Feed Dosing Delivery 

Congestion 

boiler worm 

Dosing chip bunker system system system 

Feed system 

230VAC 230VAC 230VAC system 230VAC 230VAC 230VAC 230VAC 

230VAC 

Fill level ES 

Dosing system Cleaning 

230VAC 230VAC 

compiled: bu, 2004-09-02 

approved: 

Figure 5/1 - HDG Compatronic circuit diagram 

89 


5 Circuit diagrams – HDG Hydronic circuit diagram 

5.2 HDG Hydronic circuit diagram 

Copyright according to DIN34 

Slide switch position: 

Use of one module : ON 

H1 H2 H3 

H1 H2 H3 H4 H5 H6 H7 H8 

Remote control CCT 1 


+ H L 

Supply CCT 1 

- 

SH 

H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15 H16 H17 H18 H19 H20 H21 H22 H23 H24 


H1 

1 

0 

EF 

2 3 4 

C D 

5 6 7 

B 

A 

8 

9 

H9 H10 H11 H12 H13 H14 H15 H16 H17 H18 H19 H20 

Supply CCT 2 

CAUTION! 

Rotary switch setting: 

first module : "0" 

second module : "1" 

Schirm 

(SH) 

Boiler upper 

HAICO CAN 

Boiler lower 

Temp. of oil-fired boiler 

I/O 20.1 

DH temp./ 

supply CCT 3 

F1: 

electronic 

(if H1 lights up, F1 is OK.) 

Solar coll. temp. 

F2 

F1 

F2: 

Solar pump mixer 3 open 

Solar buffer pump/ 

dist. heat. pump mixer 3 closed 

Mixer 1 

Mixer 2 

Hot water heating pump 

HKP 1 

HKP 2 

Enable oil firing/ HKP 3 

H21 H22 H23 H24 

Reserve 

H35 PE N 

N H34 PE N 

N H29 PE N H30 H31 PE N H32 H33 PE 

H27 PE N H28 PE 

H25 PE N H26 PE N 

Reserve 

H35 PE N 

N H34 PE N 

H31 PE N H32 H33 PE 

N H29 PE N H30 

H27 PE N H28 PE 

H25 PE N H26 PE N 

Bus cabel LiYCY 2x2x0,25 (or JYSTY 2x2x0,8) 

screened, twisted pairs 

(max. 100 m length) 

bus cable is not included in the delivery! 

N 

PE 

L 

CLOSED 

OPEN 

CLOSED 

OPEN 

M 

1~ 

M 

1~ 

M 

1~ 

M 

1~ 

M 

1~ 

M 

1~ 

Schirm 

(SH) 

SH - L H + 

M Mains 230VAC / 1~ 

1~ single phase completely isolated! 

Solar pump/ 

mixer 3 open 

Mixer 1 

Solar 

buffer pump/ 

dist. heat. pump 

mixer 3 closed 

Mixer 2 

HKP 1 

HKP 2 

Hot water 

heating pump 

Enable 

oil firing/ 

HKP 3 

Plug 

CAN -BUS 

MMI 1.0 od. I/O 16.0 

64 63 62 61 60 59 58 

230VAC 

CAN VCC 

CAN out H 

CAN out L 

CAN GND 

Schirm 

1 / 1 

Page 

Revision 

Date 

HDG Bavaria 

Desig-Nr. 

2002-10-08 

Siemensstraße 6 und 22 

Connection diagram 

HDG Hydronic 

80414912 

84323 Massing 

Figure 5/2 - HDG Hydronic circuit diagram 

90 


HDG Bavaria GmbH 

Heizsysteme für Holz 

Siemensstraße 6 und 22 

D-84323 Massing 

Tel. +49 (0)8724 897-0 

Fax +49 (0)8724 8159 

E-Mail info@hdg-bavaria.com 

Internet www.hdg-bavaria.com

5.2 HDG Hydronic circuit diagram - Shop

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