INSTALLATION INSTRUCTIONS LOGWIN PREMIUM TOUCH WOOD GASIFICATION BOILER 06/ /00

Transcription

1 INSTALLATION INSTRUCTIONS LOGWIN PREMIUM TOUCH WOOD GASIFICATION BOILER 06/ /00 EN

2 Table of contents Table of contents. Important information Safety precautions Caution symbols General safety information...4. Flue Boiler room/installation room Initial start-up and operating instructions Disposal/recycling For the installer...7. Scope of supply. packaging System Area of use Standards Heat accumulator (buffer) Heating circuits Circulation pump Heating water Domestic water (bringing the hot water tank up to temperature in summer) Combination with automatic boiler (e.g. pellet or oil-fired boiler) Water-side resistance (pressure loss) Combustion air Installation sequence Parts designations for installation Taking into the building and installing Minimum clearances for fire protection. cleaning and maintenance Prior to installation Installing the flue connection adapter Converting the door catch from left to right Installing the door handles Installing the flue gas blower. air control and lambda sensor Installing the lighting door with automatic ignition Installing the control panel with carburisation gas duct Installing the side panels and insulation Installing the control panel Installing the thermocontrol sensor Installing the thermocontrol sensor cover Installing the cable channels. routing the blower motor cable and installing the sensor Installing insulation for the rear panel Installing the rear panels Installing the blower housing on the adapter Installing the lever for cleaning heating surfaces Installing the cladding door LON cable from control panel to operating panel Installing the InfoWIN Touch... 3

3 Table of contents.3.3 Operating panel insulation Door safety switch Installing function modules (MES INFINITY control system) Installing the front boiler cover Installing the rear boiler cover Instructions. cleaning and operating implements Installing the exhaust pipe Installing the thermal discharge safeguard For the electrician Electrical connections Installing function modules (MES INFINITY control system) Installing on the wall Installing on the control panel in the boiler Installing the covers and power plug For the service technician Start-up and operating instructions Service and repair work Checking and servicing the thermal discharge safeguard Technical data for calculating the flue gas system acc. to EN (for LWP T) General technical data (for LWP T) Technical data for calculating the flue gas system acc. to EN (for LWP T) General technical data (for LWP T) Dimensional drawings LogWIN Premium Touch basic circuitry LogWIN Premium Touch connection diagram

4 . Important information. Important information All content of this document is the property of WINDHAGER and is therefore protected by copyright. Reproducing this content. passing it on to others or using it for other purposes without the written consent of the owner is strictly prohibited.. Safety precautions The boiler together with its accessories complies with the latest state of the art as well as the relevant safety regulations. and is operated with electric current (30 V AC). Improper installation or repair can pose the danger of life-threatening electric shock. Installation may be performed only by appropriately qualified technicians... Caution symbols Please take note of the following safety information levels in this manual. DANGER Ignoring the warnings identified by this symbol can lead to serious injuries or death. WARNING Ignoring the warnings identified by this symbol can lead to injury. CAUTION Ignoring the warnings identified by this symbol can lead to malfunction of or damage to the boiler or heating system. Note! The blocks of text identified by this symbol provide information and tips for operation... General safety information DANGER Also read and observe the safety information in the operating manual. 4

5 . Important information. Flue A properly dimensioned flue is required for optimum functioning of the combustion system. Calculation of the dimensions must follow EN See the technical data section for the values required for this calculation. Please note that in the lower performance range. flue gas temperature may be below 60 C. The flue gas system must display at least the following classification: Temperature class: T400 = nominal operating temperature 400 C Soot fire resistance class: G = flue gas system with soot fire resistance Corrosion resistance class: = suitable for unprocessed wood fuels We would recommend fitting an energy-saving intake regulator for problem-free operation. This will largely prevent moisture in the flue. and losses resulting from down-time will be reduced (draught interruptions). If you have a feed pressure (flue draught) of more than 0.0 mbar. the energy-saving intake regulator must be fitted. Note! We would recommend fitting the draught limiter outside the flue. around ½ m below where the exhaust pipe enters the flue. CAUTION Frequently. overhauling existing systems involves over-sized flue cross-sections or flues not designed for low-temperature operation. We recommend an evaluation by the local building inspector before installing the boiler system. In this way appropriate modifications can be made to the flue before system installation (see technical data for flue calculation values)..3 Boiler room/installation room DANGER The configuration of the entire system must comply with the requirements of regional legislation. applicable regulations. standards and guidelines. The minimum clearances for connections. cleaning and maintenance must be complied with see Section.3.3 Minimum service clearances. Sufficient ventilation of the set-up area must be assured. See Section..0 Combustion air. The boiler may only be installed in a dry location! The boiler may not be installed in rooms that are very dusty or humid. Permissible limit values: Humidity: max. 85 % at room temperature of 5 C (non-condensing) Room temperature: + to +40 C Sufficient lighting must be provided for service and maintenance. 5

6 . Important information.4 Initial start-up and operating instructions DANGER Unauthorised start-up! Windhager Customer Service or the customer service partner must start up the boiler/ system first of all. and will familiarise the customer with the system operation and cleaning of the boiler. with reference to the operating manual. The following preconditions must be met before you order the initial start-up:.) Boiler installed correctly..) System fully wired up electrically. 3.) System rinsed. filled and vented heat consumption must be possible. 4.) Hot water tank connected to domestic water and filled. 5.) Sufficient quantity of fuel available. 6.) The customer must be present during start-up. The initial start-up cannot be carried out if any of these points are neglected. The customer will be charged for any unnecessary costs arising as a result. Start-up and maintenance by Windhager Customer Service or a customer service partner are part of the guarantee requirements of the enclosed "Warranty conditions". Note! When the boiler is started for the first time. bad smells may result from gas emissions from insulation or paint residue being burnt off. Ensure that the boiler room/installation room is therefore well vented. Condensation may also form near the coasting surfaces and the combustion chamber temperature may only increase after a delay..5 Disposal/recycling Disposing of the packaging The packaging material (wooden crate. cardboard boxes. inserts. plastic films and plastic bags. etc.) must be disposed of correctly in line with the local legal provisions and regulations. Disposing of components or the boiler To dispose of defective components or the heating system (e.g. boiler or control system) after the product life has expired. please observe the following information: Dispose of the items correctly. i.e. separate the parts to be disposed of into material groups. Do not simply dispose of electrical or electronic waste with the general waste under any circumstances; instead. use the public collection points provided for this purpose. As a matter of principle. dispose of items in a way that is as sustainable as possible and that is in line with the current environmental protection. reprocessing and disposal technology. 6

7 . For the installer. For the installer. Scope of supply. packaging Boiler covered with a plastic sack. The cladding. control panel and small parts can be found in separate cardboard boxes and in the filler chamber. Fig. 3 Cardboard boxes with cladding and control panel Fig. LogWIN Premium Touch boiler. System.. Area of use For heating buildings acc. to EN 83. The boilers are designed and approved as heat generators for hot water heating systems with permissible flow temperatures of up to 90 C. They may be installed only in sealed systems. The max. boiler temperature for the LogWIN is limited in the factory to 80 C. The resulting flow temperature depends on the relevant operating status and the line losses to the system... Standards The following European Standard should be followed: EN 88. according to this the following should be fitted: a) A closed expansion tank. b) A reliably functioning safety valve (with max. 3 bar reaction pressure) installed at the highest point of the boiler or at a non-closable line. c) A thermometer. a pressure gauge. d) An automatic device for dissipating heat which will prevent the maximum water temperature in the boiler of 0 C from being exceeded. The built-in thermal safety device (heat exchanger) should always be used with the thermal discharge safeguard. e) A low-water cut-off: A low-water cut-off is not required for systems providing up to 300 kw nominal thermal output. if it can be ensured that a lack of water in the system will not result in excess heating. If the boiler is above the radiators. then a low-water cut-off must be installed. 7

8 . For the installer..3 Heat accumulator (buffer) The installation of a heat accumulator (buffer tank) is required by the following standards and laws: EN BImSchV Art. 5a of the Small Combustion Devices Agreement (Austria) Air Protection Ordinance (Switzerland) Having a correctly sized heat accumulator (buffer tank) is essential for correct operation of a wood-fired heating system. The fuel must always be selected and the heat load of the building calculated. The type of heating (e.g. bringing the hot water tank up to temperature in summer) and system design (underfloor and/or radiator heating circuits) should also be taken into account. CAUTION Rooms that are not heated at times (guest rooms. living areas only used at weekends. etc.) must be subtracted from the calculated heat load (QH) for the tank configuration! Recommended heat accumulator volume (buffer tank volume) Wood gasification boiler Boiler model Recommend heat accumulator volume LWP 80T 305T 000 litres LogWIN LWP 360T / 365T 500 litres LWP 500T / 505T 3000 litres Note! To calculate the minimum heat accumulator volume (buffer tank volume). see the planning documents...4 Heating circuits Several heating circuits: In-line regulating valves must be installed to permit better regulation of the system. In a building without insulation (new building. not yet plastered) the calculated and actually required heating requirements often differ to a considerable extent. Minimum heat consumption: The smallest possible boiler power must be continuously dissipated from the boiler during operation. Suitable measures to ensure minimum heat consumption should be maintained throughout the entire burning time. e.g.: Correctly dimensioned buffer tank. see Section..3 Using the MES INFINITY control function in the buffer load functional module. incl. no thermostatic valves Non-blockable heating circuit. e.g. never fully close manual mixing valve. incl. no thermostatic valves Note! Mixer valve: If operating with a manual mixing valve or the control system. elevated room temperatures may sporadically occur. A 3-way mixer valve is always necessary; in conjunction with outside temperature control. there must be a 3-way motorised mixing valve and a buffer tank. Underfloor heating: Only possible with a buffer tank (with outside temperature control. motorised mixing valve). Return flow temperature increase: This is necessary in all systems with a heat accumulator and a buffer tank and in old systems with a large volume of water (> 00 l). With the LogWIN. it is essential for the temperature of the return flow to be kept to at least 45 C during 8

9 . For the installer heating. otherwise the temperature of the return flow must be increased using a mixing pump or valve. In order to achieve good temperature stratification in the heat accumulator or buffer tank. we recommend setting the boiler circuit to a 5 0 K differential by means of the return hold-up group SK RH. See the enclosed instructions for the return hold-up group for guidance values for the setting. Boiler start-up relief: A boiler start-up relief must be installed and connected in all cases so that the circulation pump(s) turn off when the boiler temperature is below 60 C. This prevents condensation forming in the boiler and extends its service life. This type of boiler start-up relief is included in the MES INFINITY control system buffer load function module and the MES PLUS WVF+ module...5 Circulation pump Since 03. regulations in Europe require that new circulation pumps satisfy a minimum level of energy efficiency. The Energy Efficiency Index (EEI) must be observed...6 Heating water CAUTION The chemical composition of the heating water must comply with the requirements of regional legislation. regulations. guidelines and standards. e.g. ÖNORM H 595. VDI 035. SWKI BT 0-0. Applicable for Austria (excerpt from ÖNORM H 595): a) According to ÖNORM H 595 (issue 00). the condition of the heating water must be checked every years by a heating technician in order to avoid corrosion and sediment accumulation in the heating system. b) The pipe lines and heating appliances should be thoroughly flushed through before the boiler is connected. c) To protect the boiler from contamination from the heating system. installation of a dirt trap is required in old or existing systems with maintenance cocks installed in the return line. d) If oxygen diffusion or sludge build-up cannot be prevented. the system must be segregated by means of a heat exchanger. e) If antifreeze is used. a minimum volume of 5 % antifreeze is required. otherwise corrosion prevention is not guaranteed...7 Domestic water (bringing the hot water tank up to temperature in summer) There may still be fuel in the boiler after the hot water tank has been brought up to temperature. As a result. measures must be taken to dissipate the surplus energy see Section..4 Heating circuits; Minimum heat consumption...8 Combination with automatic boiler (e.g. pellet or oil-fired boiler) If the LogWIN and an automatic boiler (e.g. pellet or oil-fired boiler) are connected to one flue without an MES INFIN- ITY buffer load function module or MES PLUS WVF+ module. in the case of LogWIN a flue gas thermostat (accessory OK-050) must be installed to prevent parallel operation on the same flue. 9

10 . For the installer..9 Water-side resistance (pressure loss) LWP 80T 505T Flow rate (m 3 /h) Diagram LogWIN water-side resistance Pressure loss (mbar)..0 Combustion air The combustion air is drawn directly by the boiler from the installation room. therefore the installation room has to be adequately ventilated. The combustion air should be directed to the vicinity of the boiler and must be free from pollutants (gases. vapours and dusts). otherwise malfunctions and increased wear (e.g. corrosion) may occur. DANGER The configuration of the entire system must comply with the requirements of regional legislation. applicable regulations. standards and guidelines. Applicable for Austria (excerpt from ÖNORM H 570): The area of the free minimum cross-section must be 5 cm per kw of the boiler's nominal total output. The opening to the outdoors for combustion air should be designed as follows: The flow of air must not be restricted in any way by the weather (e.g. snow. leaves). The free cross-section area remains the same when taking the cover grille. discs. etc.. into consideration. Applicable for Germany (excerpt from the Firing Ordinance. September 007): For hearths with a nominal output of not more than 50 kw in total that are dependent on surrounding air. supply of combustion air will be sufficient providing that every installation rooms has an opening that vents to the atmosphere with an unobstructed cross-section of at least 50 cm or two openings of 75 cm each. or pipes leading outside with a technically equivalent cross-section. CAUTION Malfunctions or complaints occasioned by inadequate combustion air will not be covered by the guarantee. The boiler's nominal total output is the sum of the nominal outputs of all heat generators installed in the same boiler / installation room. 0

11 . For the installer.3 Installation sequence.3. Parts designations for installation CAUTION All cladding parts must be fitted in full for air guidance and the dissipation of heat on the boiler Fig. 4 Parts for installation 30 8

12 . For the installer... Front set screws ( pcs.)... Blower seal 3... Flue connection adapter accessories 4... Blower housing 5... Flue gas blower 6... Wing nuts 7... Door handles (3 pcs.) 8... Air control 9... Lambda sensor 0... Lighting door with automatic ignition accessories... M8x60 threaded rod ( pcs.)... Operating panel with carburisation gas duct 3... Lower door hinge 4... Lower left/right insulation 5... Upper left/right insulation 6... Upper insulation 7... Left side panel 8... Right side panel 9... Cleaning cover 0... Upper insulating plate... Control panel... Thermocontrol sensor cover 3... Cable channel ( pcs.) 4... Upper rear insulation 5... Lower rear insulation 6... Upper rear panel 7... Lower rear panel 8... Grommet 9... Lever for cleaning heating surfaces Cladding door 3... Upper door hinge 3... InfoWIN Touch Front operating panel insulation MES INFINITY control system function modules Front boiler cover Rear boiler cover Hanger.3. Taking into the building and installing The appliance must be taken into the building and installed without subjecting it to significant knocks and jolts. in order to avoid damaging the combustion chamber and the shifting of parts. All warranty claims will be invalidated if the appliance is damaged due to having been taken into the building and installed incorrectly or if the appliance malfunctions as a consequence of this. The boiler may only be transported vertically and without its cladding. The easiest way to do this is with a lift truck or by rolling on pipes. If transporting via stairs. etc.. the boiler should be secured appropriately. For installation dimensions. refer to the technical data in Section 4.5 and Section 4.7. Note! There is a crane lug on the top of the LogWIN for transporting using winches. The weight can be reduced by approx kg by removing parts which are easy to take off (e.g. doors. hook-in plates. burn through plates. heating surface cleaning mechanism. etc.). The boiler can be installed directly on a fire-resistant surface and does not require a special foundation..3.3 Minimum clearances for fire protection. cleaning and maintenance The following minimum clearances from flammable materials and for connections. cleaning and maintenance must be complied with. DANGER Follow the installation guidelines for boiler rooms! The configuration of the exhaust line must comply with technical fire protection requirements in accordance with the applicable regulations. standards and guidelines. Minimum clearances between exhaust pipe (piece connecting to flue) and combustible components 400 mm for an uninsulated exhaust pipe 00 mm for an insulated exhaust pipe (min. cm insulation thickness) 50 mm for tested. double-walled exhaust system DIN V in accordance with approval/identification of system flue

13 . For the installer LogWIN Premium Touch: All measurements in mm. Minimum room height: 950 mm Details in brackets apply to WP 360T / 365T. 500T / 505T 885 min. 700 (80) min. 483 min. 400 min. 483 min. 8 min. 400 min.0 min (604) 654 (764) min. 630 (740) min. 550 (660) min. 700 (80) min.0 min (604) 654 (764) min. 630 (740) min. 550 (660) Fig. 5 LogWIN exhaust pipe upwards top view Fig. 6 LogWIN with exhaust pipe adapter top view 3

14 . For the installer.3.4 Prior to installation Move the boiler to its definitive installation position and use the set screws to align it inclined slightly upwards towards the rear. If it is not possible to level the unit using only the rear set screws. additional set screws can be installed at the front Fig. 7. The cladding door and the boiler doors are designed for door catches on either the left or right. Standard delivery always includes a door catch on the left. The catches on the cladding door and boiler doors must be on the same side. Fig. 7 Installing of set screws in the front.3.5 Installing the flue connection adapter Only for LogWIN with flue connection adapter (accessories) Standard installation of the blower housing is directly on the boiler Fig. 8 flue connection at top. With the adapter (accessories). the blower housing is located outside the cladding Fig.. The flue connection is steplessly adjustable from left to right Fig. 0. Unscrew 4 interior nuts in the blower housing (Fig. 8) and remove the housing. Do not remove the seal Fig. 9. Fig. 8 Blower housing directly on boiler standard Fig. 9 Seal on boiler 4

15 . For the installer Secure adapter. with slot position depending on desired angle of flue connection. on boiler according to Fig. 0 with seal and 4 M8 nuts Fig. 0. Fig.. Boiler side Boiler side Boiler side Boiler side Fig. 0 Installation of adapter depending on angle of flue connection Fig. Adapter on the boiler (accessories) Note! Do not screw the blower housing into the adapter until the rear panel has been installed (Section.3.7). otherwise the rear panel cannot be installed. 5

16 . For the installer.3.6 Converting the door catch from left to right The filling. lighting and ash doors can be converted so that the catch is on the right side. If this is not necessary. move on to Section.3.7. Filling door: Remove the filling door knock the hinge pins out and take the filling door off. Unscrew the door mounting and lock mounting from the boiler body and screw them back on the other way round Fig.. In the case of a filling door. undo the 4 screws on the door leaf and remove it entirely (Fig. 3). turn it 80 and screw it back on using fastening screws. Install the filling doors. Install the door handle in the correct position using a collar screw and hook catch bolt Fig. 5. Note! To ensure the collar screw doesn't come loose during operation. it should be fixed with a liquid screw adhesive Fig. 4. Set the filling doors see Section Door leaf Lock mounting Door mounting Fig. switching round the door mounting and lock mounting Fig. 3 Removing the entire door leaf. rotating it 80 and screwing it back on Hook catch bolt Collar screw Door handle Fig. 4 Applying liquid screw adhesive to the collar screw Fig. 5 Installing the door handle using a collar screw and hook catch bolt 6

17 . For the installer Lighting door/ash door: Remove the lighting door/ash door knock the hinge pins out and take the door off. Unscrew the door mounting and lock mounting from the boiler body and screw them back on the other way round Fig. 6. Fig. 7. Install the lighting door/ash door. Install the door handle in the correct operating position using a collar screw. Note! To ensure the collar screw doesn't come loose during operation. it should be fixed with a liquid screw adhesive Fig. 4. Lighting door: unhook the vertical grate and hook it back in on the opposite side Fig. 8. Set the lighting door/ash door see Section Lock mounting Door mounting Lock mounting Door mounting Fig. 6 Lighting door: switching round the door mounting and lock mounting Fig. 7 Ash door: switching round the door mounting and lock mounting Vertical grate Fig. 8 Lighting door: unhooking the vertical grate and hooking it back in on the opposite side 7

18 . For the installer.3.6. Setting the doors The doors must be set so that the doors' rope seals sit centrally against the frame on the boiler creating a complete seal with sufficient pretension. It is fit by adjusting the door mounting and lock mounting on the other side Fig. 9. Fig. 0. Use the strip of paper method to check seal integrity (Fig. ). This involves jamming pieces of paper (around 3 cm wide) all the way round at several points and attempting to pull them out. If the strips of paper cannot be removed. the door is sealed. If they can be removed when the lighting door is closed. the door is not sealed at this point > reset the door. Fig. 9 Tongue must engage fully in locking device Fig. 0 Fit the lighting door by adjusting the door mounting Fig. Strip of paper method.3.7 Installing the door handles If the door handles have not been installed yet. install them on all doors using a collar screw. Note! To ensure the collar screw doesn't come loose during operation. it should be fixed with a liquid screw adhesive Fig. 3. Hook catch bolt Collar screw Door handle Fig. Tongue must engage fully in locking device Fig. 3 Installing the door handle using a collar screw and hook catch bolt 8

19 . For the installer.3.8 Installing the flue gas blower. air control and lambda sensor Hook in the air control at the top and secure with screw at the bottom Fig. 4. Fig. 6. Screw the lambda sensor in finger tight and tighten approx. /4 turn with an open-ended wrench (WAF ) Fig. 5. Fig. 6. Screw the flue gas blower to the blower housing with 4 wing nuts Fig. 6. Flue gas blower Fig. 4 Hooking in air control at the top and screwing on at the bottom Air control Lambda sensor Fig. 5 Lambda sensor installed Fig. 6 Flue gas blower. air control and lambda sensor installed.3.9 Installing the lighting door with automatic ignition Only for LogWIN with automatic ignition (accessories). see separate installation instructions (included). Fig. 7 Automatic ignition Fig. 8 Lighting door with automatic ignition 9

20 . For the installer.3.0 Installing the control panel with carburisation gas duct Screw in M8x60 threaded bolts for the control panel on the boiler above the lower heating door so that they are flush and secure with M8 nuts Fig. 9. Fig. 30. Turn M8 nut to a height of approx. 38 mm on each screw Fig. 3. Attach the control panel with carburisation gas duct and attach loosely with M8 nuts Fig. 3. Fig. 33. x Fig. 9 Installing threaded rods for the control panel and securing with nuts Fig. 30 threaded rods installed x approx. 38 mm Fig. 3 Turning M8 nut to a height of 38 mm on each screw Fig. 3 Attaching the control panel with carburisation gas sheet x Fig. 33 Loosely attaching the control panel with carburisation gas sheet with M8 nut on each screw 0

21 . For the installer.3. Installing the side panels and insulation Screw in M5x0 self-threading TT screws halfway on each side of the base (Fig. 34) and depending on which side the door catch is to be located. install the lower door hinge for attaching the cladding door on either the left or on the right with M5x0 self-threading TT screws Fig. 34. each of M5x0 TT x M5x0 TT Fig. 34 Screwing in screws on each side of the base. installing the cladding door hinge Insert insulation on the left and right side of the boiler. as well as on the top Fig. 35. Fig. 35 Installing insulation

22 . For the installer Release the side panels and hook them into the installed screws at the bottom (Fig. 36. Fig. 37) and loosely screw the top on with self-tapping screws and saw tooth ring for the earth on the inside (Fig. 38). and with self-tapping screw at the front Fig. 39. Fig. 36 Hooking the side panels in with screws at the bottom Fig. 37 Installing the side panels each of each of each of Fig. 38 Attaching the side panels for the control panel on the inside with self-tapping screws Fig. 39 Attaching the side panels for the control panel at the front with self-tapping screw.3. Installing the control panel Remove the cleaning cover Fig. 40. Fig. 40 Removing the cleaning cover

23 . For the installer Upper insulating plate: If no adapter for the flue gas blower (accessories) is being used. break off the cut-out at the top of the back panel Fig. 4. Large cut-out = exhaust pipe insulated Small cut-out = exhaust pipe not insulated Do not break off = adapter for flue connection installed Position the upper insulating plate (Fig. 4). bend it (Fig. 43) and attach it with 6 self-tapping screws and one saw tooth ring for the earth Fig. 44. Fig. 4 If no adapter for the flue connection is being used. break off the cut-out Fig. 4 Positioning the upper insulating plate x x Fig. 43 Bending the upper insulating plate x x Fig. 44 Attaching the upper insulating plate x x 3

24 . For the installer Place the control panel on the boiler (Fig. 45). open the control panel cover and attach on the inside with 4 self-tapping screws and saw tooth ring for the earth Fig. 46. Fig. 45 Placing the control panel on the boiler x x x x Fig. 46 Attaching the control panel 4

25 . For the installer.3.3 Installing the thermocontrol sensor Route the thermocontrol sensor (green cable) at the front of the right side panel down and feed through Fig. 47. Fig. 48. But first bend the cut-out (feed-through) at the bottom of the side panel out of the way. Insert the sensor over the ash door in the front and into the protective tube; hook the spring in place Fig. 49. Fig. 50. CAUTION Pull the protruding thermocontrol sensor cable back into the side panel or control panel. The cable must not sag. as otherwise it could get caught in the ash door. Secure the thermocontrol sensor cable to the side panel with a cable tie Fig. 50. Cut-out feedthrough Fig. 47 Inserting the thermocontrol sensor at the top Fig. 48 Threading through thermocontrol sensor Cable tie Fig. 49 Fixing the thermocontrol sensor with spring Fig Installing the thermocontrol sensor cover Attach the thermocontrol sensor with 4 self-tapping screws Fig. 5. Pulling back the cable and securing it with cable ties each of each of Fig. 5 Attaching the cover in front of the thermocontrol sensor with 4 screws 5

26 . For the installer.3.5 Installing the cable channels. routing the blower motor cable and installing the sensor Attach the cable channels to the front of the control panel at left and right (feed-through at rear) with a drilling screw on each side Fig. 5. Route the sensor lines in the right cable channel towards the back Fig. 5. Plug the flue gas sensor (accessories) in the control panel into Plug X and also route it in the right cable channel toward the back. Route all sensor lines through the feed-through in the cable channel downward. Insert boiler sensor and safety temperature limiter sensor (STB) as far as possible into the immersion sleeve and secure them with the sensor guard to prevent them from slipping out Fig. 53. Install the flue gas sensor with protective tube (accessories) into the flue outlet as described in the installation instructions Fig. 53. Route both cables for the flue gas blower in the cable channel towards the back Fig. 5. Route the mains cable in the left cable channel towards the back and screw the power socket to the rear of the side panel with.9x6 self-tapping screws Fig. 53. Cable channels nels Feed-through Cable with power plug Cable from flue gas blower Cable from lambda sensor Boiler sensor and STB sensor Cable from flue gas blower x Flue gas sensor (accessories) Plug X x Fig. 5 Control panel. cable routing x Flue gas sensor with protective tube (accessories) Power socket Boiler sensor Sensor guard STB sensor Immersion sleeve for thermal discharge guard. NOT standard accessories Fig. 53 LogWIN rear side Note! The immersion sleeve (not standard accessories) for the thermal discharge safeguard must be installed before the rear panels and before the boiled is filled. 6

27 . For the installer Route both cables from the air control upwards in the side panels via the cable channel feed-through into the control panel as shown in Fig. 54 and connect as shown in Fig. 55. Route the lambda sensor cable downwards from the control panel via the cable channel feed-through in the side panel and connect to the lambda sensor Fig. 54. Cable channel Extra-low voltage (0 V DC) Cable channel Low voltage (30 V AC) Connection for immersion sleeve for thermal discharge guard. NOT standard accessories Air control Air control cable with Plug X4 Air control cable with Plug X6/X7 Lambda sensor cable Plug for lambda sensor Fig. 54 LogWIN with rear panels removed rear view Air control cable with Plug X6/X7 Air control cable with Plug X4 Flue gas sensor (accessories) Plug X Fig. 55 LogWIN control panel top view 7

28 . For the installer.3.6 Installing insulation for the rear panel Install insulation on the top and bottom as shown in Fig. 56. Fig. 56 Installing insulation on the rear panel.3.7 Installing the rear panels If no adapter for the flue gas blower (accessories) is being used. break off the cut-out at the top of the back panel Fig. 57. Large cut-out = exhaust pipe insulated Small cut-out = exhaust pipe not insulated Do not break off = adapter for flue connection installed Fasten the rear panel at the top and bottom with 4 screws on each side Fig. 58. Connect the blower plug to the flue gas blower and secure cable at the side with cable ties Fig each of Blower plugs 4 each of Fig. 57 If no adapter for the flue connection is being used. break off the cut-out Fig. 58 Installing the rear panels 8

29 . For the installer.3.8 Installing the blower housing on the adapter Only for LogWIN with flue connection adapter (accessories) First screw the 4 included M8x6 hexagon screws into the blower housing from the inside. the attach the blower housing with seal. 4 nuts and washers to the adapter Fig. 59. Fig. 59 Installing the blower housing on the adapter.3.9 Installing the lever for cleaning heating surfaces Depending on accessibility. either install lever for cleaning heating surfaces on the left or right side. Punch through the cut-out. insert lever through opening in side panel (Fig. 60) and slide inwards through the cleaning heating surfaces axle (limit stop must face upwards Fig. 6) and secure with an M8x30 cylinder screw with hexagon socket (inserted only) Fig. 6. Push the grommet into the cladding on the side panel Fig. 60. x Limit stop Grommet Fig. 60 Punching through the cut-out. inserting lever for cleaning heating surfaces through opening Fig. 6 Sliding lever through axle and securing with screw (inserted only) 9

30 . For the installer.3.0 Installing the cladding door Note! The cladding door and the boiler doors are designed for door catches on either the left or right. Standard delivery always includes a door catch on the left. The catches on the cladding door and boiler doors must be on the same side. The lower door hinge should only be screwed in loosely Fig. 6. Hook the cladding door in at the lower door hinge (Fig. 63) and hook the top of the door into the door hinge (Fig. 64). Then fasten the upper door hinge on the inside of the operating panel with TT screws (with the cladding door hooked in) Fig. 65. Tighten the screws for the lower door hinge. Fig. 6 Door hinge only screwed in loosely to start with Fig. 63 Hooking the bottom of the cladding door into the door hinge x Fig. 64 Hooking the door into the upper hinge Fig. 65 Securing the door hinge with self-threading TT screws Fig. 66 Door installed 30

31 . For the installer.3. LON cable from control panel to operating panel Connect the internal LON cable in the LED bar Fig. 67. Fig. 68. LON cable Fig. 67 Connecting the LON cable Fig. 68 Connecting the LON cable.3. Installing the InfoWIN Touch Connect the short connecting cable from the LED bar to the InfoWIN Touch. Press the InfoWIN Touch into the section; the InfoWIN Touch connections must face upwards Fig. 69. Fig. 70. Fig. 69 Pressing in the InfoWIN Touch Fig. 70 Connecting the InfoWIN Touch.3.3 Operating panel insulation Insert the operating panel insulation into the control panel with the slit facing forwards and the black surface facing downwards Fig. 7. Fig. 7 Inserting the insulation into the operating panel with the slit facing forwards 3

32 . For the installer.3.4 Door safety switch Route the cable from the door safety switch into the control panel and connect at X5 Fig. 7. Fig. 7 Routing the cable from the door safety switch and connecting at X5.3.5 Installing function modules (MES INFINITY control system) The function modules (MES INFINITY control system) can: Be installed on a wall (Fig. 73) or Be installed on the control panel in the boiler Fig. 74. For installation and connection. see Section 3.. Fig. 73 Function modules (MES INFINITY control system) installed on the wall Fig. 74 Function modules (MES INFINITY control system) installed on the control panel in the boiler.3.6 Installing the front boiler cover Hook in the front boiler cover (Fig. 75) and attach at the rear with self-tapping screws Fig. 76. x Fig. 75 Hooking in the boiler cover Fig. 76 Securing boiler cover in places 3

33 . For the installer.3.7 Installing the rear boiler cover If no adapter for the flue gas blower (accessories) is being used. break off the cut-out on the rear boiler cover Fig. 77. Large cut-out = exhaust pipe insulated Small cut-out = exhaust pipe not insulated Do not break off = adapter for flue connection installed Put on the rear boiler cover Fig. 78. Fig. 77 If no adapter for the flue connection is being used. break off the cut-out Fig. 78 Putting on the rear boiler cover.3.8 Instructions. cleaning and operating implements Install the hanger with the instructions folder and cleaning and operating implements on a wall in the boiler room/ installation room. Keep ash pan under boiler. 3 Supplied as standard:... Instructions... Spatula 3... Hanger (for installation on the wall or boiler side panel) 4... Scraper 5... Cleaning brush 6... Poker 7... Ash pan Fig. 79 Installing the hanger 33

34 . For the installer.3.9 Installing the exhaust pipe a) Install the exhaust pipe upward to the flue (45 is the ideal angle). Maximum exhaust pipe length 3 m. CAUTION Any section of this exhaust line that only rises slightly (up to 30 ) or is horizontal is not allowed to be more than m in length. b) Avoid 90 bends. 45 bends are better. c) Do not push the exhaust pipe too far into the flue. d) Do not seal the exhaust pipe completely into the flue. Connection with flexible exhaust pipe inlet into the flue. The included draught blower can cause sound transmissions that create noise pollution. e) The LogWIN is a low-pressure boiler. This means that the flue gas system needs to meet the "N" seal integrity requirement according to EN 856- and EN Please ensure a sufficient immersion depth when fitting (e.g. when using Windhager stainless steel flue systems). f) The entire exhaust line should be insulated to a minimum of cm thickness in order to prevent or minimise condensation. g) A draught limiter is needed if the maximum draught (see technical data. Section 4.4 or 4.6) is exceeded during operation. Note! We would recommend fitting the draught limiter outside the flue. around ½ m below where the exhaust pipe enters the flue. DANGER The configuration of the exhaust line must comply with technical fire protection requirements in accordance with the applicable legislation. regulations. guidelines and standards refer also to Section.3.3. Minimum clearances for fire protection. cleaning and maintenance Installing the thermal discharge safeguard Connecting thermal discharge safeguard to thermal safety device a) The thermal discharge safeguard and cleaning T-piece must still be accessible after installation. b) Water must be seen to be draining out in order to check the function. therefore use a discharge funnel. c) It must not be possible to block the connection manually. Connection according to EN Minimum connection pressure of the thermal safety device: bar. It must not be possible to block the connection manually Pressure reducing valve (only with CW connection of more than 6 bar)... Dirt trap 3... Thermal discharge safeguard (opens at approx. 95 C) 4... Cleaning T-piece 5... Discharge funnel 6... Immersion sleeve for the sensor of the thermal discharge safeguard 7... Boiler return 8... Boiler feed Fig. 80 Thermal safety device connection 34

35 3. For the electrician 3. For the electrician 3. Electrical connections The boiler and related accessories are designed to be installed only in dry areas (protection type IP 0). Installation of electrical components may only be performed by a qualified technician. The regulations and specifications of ÖVE. VDI. SEV and local ordinances must be followed. DANGER The phases of the 30 V electrical power supply must be connected correctly (Fig. 97). otherwise the blower might still be live even after the mains fuse has blown. The mains connection must be protected against short circuit with a 3 A delayed-action fuse. We recommend using fine-wire PVC sheathed cables. e.g. H05VV-F (YMM-J) with a 3x.5 mm nominal cross-section. Each boiler is pre-wired and internally fused with a T 6.3 A fine-wire fuse to protect against short circuit. In areas with increased power surge risk (e.g. lightning strikes in regions prone to storms). we recommend installation of an appropriate surge protector. F fuse T 3.6 A Safety temperature limiter Service plug Control panel Fig. 8 LogWIN control panel rear view CAUTION Electrical cables must not touch heating and exhaust pipes nor must they come in contact with non-insulated boiler components. They are to be sufficiently braced and provided with a protective tube. The electrical connections are located in or behind the control panel and the power plug at the rear of the boiler cladding Fig. 97. The motherboards are located inside the control panel and the connection terminals on the outside on control panel cover (screwless cage-spring-type terminals). MES Infinity control system (if available): The MES INFINITY control system (heating circuit and buffer load/switching function modules) is supplied and must be connected electrically. Maximum switching capacity of the MES INFINITY control system: Relay outputs: 30 V AC. 6 A ( A inductive). 50 Hz Buffer load function module with X/X contact: Solid-state relay: 30 V AC. A The electrical power is dependent upon the number of function modules installed in the unit. that is. the number of actuators powered (pumps. mixing valves. etc.). 35

36 3. For the electrician To access the control panel: Remove rear boiler cover (Fig. 8). loosen the screws from the front boiler cover (Fig. 83). lift up the cover and pull it off to the rear Fig. 84. Fig. 8 Removing the rear boiler cover Fig. 83 Loosening screws Fig. 84 Lifting boiler cover and pulling off to the rear Check the 4-pole cable from the control panel to the LED bar and from the LED bar to the InfoWIN Touch; connect if necessary Fig. 85. Cable from control panel Cable from LED bar to InfoWIN Touch Cable for door switch Fig. 85 Checking the cables and connecting if necessary 36

37 3. For the electrician Remove the screws at the front of the control panel and open the cover Fig. 86. Fig. 86 Removing the screws. opening the cover Make sure that the plugs for the door switch. flue gas sensor X (accessories) and air control X6/X7. X4 are correctly connected in the control panel. Cables and plugs are inscribed Fig. 87. CAUTION Be sure to note the separate wiring of the extra-low voltage line (0 V DC) and low-voltage line (30 V AC)! Route cables in the cable channels available Fig. 87. Cable channel Low voltage (30 V AC) Cable channel Extra-low voltage (0 V DC) Air control plug X6/X7 Air control Plug X4 Door switch plug X5 Flue gas sensor (accessories) Plug X Fig. 87 Control panel open. connecting plugs front view CAUTION Electrical cables should be routed in the cable channels intended for this purpose and are not allowed to be routed over the cleaning cover. The space above the cover must be accessible for cleaning. Connecting automatic ignition (accessories) See separate installation instructions provided. CAUTION After connecting the cables. remove all remaining assembly materials (e.g. wire strands) from the control panel. 37

38 3. For the electrician 3. Installing function modules (MES INFINITY control system) The function modules (MES INFINITY control system) can: Be installed on a wall (Fig. 89) Section 3.. or Be installed on the control panel in the boiler (Fig. 90) Section 3... A 3-pole LON cable is used to connect the function modules (MES INFINITY control system) to the boiler. The + V contact does not need to be connected or attached. as the boiler and also the function module both have their own + V power supply. The LON connection and the connections for the safety components are located on the control panel cover (screwless spring-type terminals). Fine-wire PVC sheathed cables should be used for these connections Fig. 88. Fig. 90. The electrical connections are established on site in line with Section 4.0. The installation procedure for the sensors and actuators is described in the function modules (MES INFINITY control system) instructions. Please also pay close attention to these instructions. CAUTION The resistor for the LON connection and the bridges for the safety components must only be removed when a connection has been established Fig. 88. Fig. 90. CAUTION Be sure to note the separate wiring of the extra-low voltage line (0 V DC) and low-voltage line (30 V AC)! Route cables in the cable channels available Fig. 87. Note! Fasten all cables to the perforated lug with cable ties to relieve the strain Fig. 9. Lug for fastening the cables with cable ties Terminal blocks for safety components 3-pole LON cable Resistor 30 V AC 0 V AC Fig. 88 Connection terminals for the safety components and LON connection for the function modules (MES INFINITY control system) Fig. 89 Function modules (MES INFINITY control system) installed on the wall 30 V AC 3-pole LON cable Terminal blocks for safety components Resistor Fig. 90 Function module (MES INFINITY control system) installed on the control panel in the boiler Fig. 9 Securing the cable with cable ties to relieve strain Remove with LON bus connection 38

39 3. For the electrician 3.. Installing on the wall CAUTION Do not install in plumbed rooms. Ambient temperature not over +50 C. Note! The screws and plugs are included with the function modules. Loosen the screws at the top of the cover for the function module and lift up the cover. Drill mounting holes (Ø 6 mm) in the wall in accordance with the diagram (Fig. 9). Screw the function module onto the wall with the D6 dowels and 3.5x30 screws supplied. Establish all electrical connections in line with Section 4.0 and the instructions supplied for the relevant function modules. Route the cables into the bottom of the function module housing and fasten with cable ties as strain relief. Attach the cover and fasten it at the bottom with the screws. 8, ,5 05 Fig. 9 Dimensional drawing rear view 39

40 3. For the electrician 3.. Installing on the control panel in the boiler Loosen the screws at the top of the cover for the function module and lift up the cover. Screw the function module onto the control panel with the U-washers and self-tapping screws supplied Fig. 93. Establish all electrical connections in line with Section 4.0 and the instructions supplied for the relevant function modules. Route the cables into the bottom of the function module housing and fasten with cable ties as strain relief. Attach the cover and fasten it at the bottom with the screws. Fig. 93 Installing the MES INFINITY control system (function modules) on the control panel 3.3 Installing the covers and power plug Hook in the front boiler cover (Fig. 94) and secure with screws Fig. 95. x Fig. 94 Hooking in the boiler cover Fig. 95 Securing boiler cover in places Put on the rear boiler cover Fig. 96. Connect or plug in the power plug at the rear of the boiler Fig. 97. Power plug Fig. 96 Putting on the rear boiler cover Fig. 97 Inserting or connecting the power plug 40

41 4. For the service technician 4. For the service technician 4. Start-up and operating instructions The Windhager Customer Service or customer service partner will start up the boiler and will familiarise the customer with the system operator and cleaning of the boiler. Start-up and maintenance are part of the guarantee requirements of the "Warranty conditions" see also Section.4. We recommend that you obtain a maintenance agreement. Before start-up: The DIP switch for the function modules (MES INFINITY control system) must be set correctly see function module instructions; Setting the DIP switch. The function modules (MES INFINITY control system) and the boiler(s) must be connected with one another see function module instructions; Connecting the function modules (establishing communication). 4. Service and repair work Service and repair may be performed only by appropriately qualified technicians. DANGER De-energise the boiler before opening the control panel for service or repair purposes. Disconnect the power plug at the rear Fig. 98. Turning off the on/off button on the InfoWIN TOUCH does not mean the boiler and its accessories are completely without power! When replacing system components (pumps. mixing valves. etc.) prevent all power input (e.g. by removing the mains power plug). Power plug Fig. 98 Disconnecting the power plug 4