Varmebaronen Viking Bio 20 Installation and operating instructions

Installation, operation and maintenance
18/01/2011
Ver.: konv012
Replaces:
Pellet burner

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Contents
Notes .................................................................................................. 3
Combustion values ............................................................................ 3
General............................................................................................... 4
Operation............................................................................................ 5
Technical data.................................................................................... 5
Installation......................................................................................... 6
Boiler
Chimney
Draught damper
Supply air to boiler room
Installation of burner
Installation......................................................................................... 7
Downpipe
Breakaway openings
Pellet store
Feed auger
Flue gas thermometer
Electrical installation......................................................................... 8
Electrical connection
Connections to burner
Connector - 230V~ power cable
Alarm
Hatch safety switch
Boiler temperature control via burner
Boiler thermostat controls boiler temperature
Electrical connection check
Electrical installation......................................................................... 9
Connection to Värmebaronen boilers
Pellmax CU
Pellmax VX
Pellmax UB
Wiring diagram .................................................................................. 10
Indicators and settings ..................................................................... 11
Startup ............................................................................................... 12
Check before first start
Position of grate
Feed auger
Draught requirements
Flue gas temperature
Turbulators
Smoke in boiler room
Combustion values
Adjustment......................................................................................... 13
Adjustment
Choice of operating mode
Boiler temperature control via the burner
Start delay
Pellet firing......................................................................................... 14
Pellet quality
Handling and storing pellets
Combustion
Flame
Flue gas temperature
Turbulators
Draught damper
Smoke from the chimney
Efficiency
Hot water heating in summer
Boiler temperature control via the burner
Smoke in boiler room
Safety
Operation, start to stop...................................................................... 16
Operation, start to stop
Start
Establish flame
Operation
Cooling/blowing clean
Long operating time
Operation and maintenance.............................................................. 17
Sweeping
Cleaning the burner
Ash and soot
Position of grate
Cleaning the pellet store
Safety system
Resetting the thermal relay
Changing ignition element
Changing inner burner pipe
Troubleshooting ................................................................................. 19
Troubleshooting
External fault sources
Checking the feed auger's capacity
Resetting the alarm
Temperature sensor's resistance (accessory)
Alarm indication
Component specification .................................................................. 21
Accessories........................................................................................ 22

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Notes
To be completed when the Viking Bio is installed.
Production number: .........................................................................................................................................
Installation date: .........................................................................................................................................
Installed in boiler,
make/type: .........................................................................................................................................
Installer: .........................................................................................................................................
Tel.: .........................................................................................................................................
Other: .........................................................................................................................................
.........................................................................................................................................
.........................................................................................................................................
.........................................................................................................................................
.........................................................................................................................................
.........................................................................................................................................
Combustion values
1 2 3 4
Date Date Date Date
Draught Pa Draught Pa Draught Pa Draught Pa
Soot no. Soot no. Soot no. Soot no.
O2% O2% O2% O2%
CO ppm CO ppm CO ppm CO ppm
CO2% CO2% CO2% CO2%
Gas temp. °C Gas temp. °C Gas temp. °C Gas temp. °C
Air temp. °C Air temp. °C Air temp. °C Air temp. °C
Temp. diff. °C Temp. diff. °C Temp. diff. °C Temp. diff. °C
Eta % Eta % Eta % Eta %
qA % qA % qA % qA %

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Read these instructions carefully before installation, adjustment or service is
carried out. Follow the instructions.
• Keep these instructions close to the burner.
• Värmebaronen AB reserves the right to change the specification, in ac-
cordance with its policy of continuous improvement and development,
without prior notice.
• The burner must not be modified, changed or converted in any way.
• If the burner is correctly installed and adjusted serviced continually,it
will operate reliably.
• A chimney-sweep must be contacted before a different type of fuel is
used.
• No building permit or notification is normally required if the existing
boiler can be fired with pellets. Contact your municipality regarding
restrictions on burning solid fuel in a densely built-up area.
• Correct settings are important for good heating economy and the service
life of the parts in contact with flames.
Optimum adjustment is possible only using flue gas analysis instruments.
• The burner's parts in contact with flames, grate and inner burner pipe
are wearing parts that need replacement as required.
• Use only original spare parts. Spare parts that do not meetVärmebar-
onen's specifications may have an impact on safety.
• The type and production number of the burner must always be specified
when ordering spare parts. See the rating plate.
• Contact your installer for service.
The following icons are used in these instructions to indicate
important information:
Information that is important for optimum operation.
Tells you what you should or should not do to avoid personal
injury.
Tells you what you should or should not do to avoid a com-
ponent, the burner, a process or the environment from being
damaged or destroyed.
Key to symbols
< means less than ≤means less than or equal to
> means greater than ≥means greater than or equal to
10 Pa ≈1 mm column of water
General

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Operation
Technical data
The Viking BIO is a forward-burning pellet burner for wood pellets.
Fuel and air are mixed in a controlled fashion in the burner. This is the ba-
sis for environmentally-friendly combustion and high efficiency.
The Viking BIO can be installed on a conventional oil or wood-fired boiler.
The Viking BIO operates in a similar way to an oil burner. It is fully auto-
matic and controlled by the boiler thermostat. A temperature sensor is
available as an accessory. This causes the burner to control the boiler
temperature.This function is particularly advantageous in boilers in
which hot water is produced in a heat exchanger.
The safety system in the pellet system with the Viking Bio
consists of overheating protection, a thermal relay on the
downpipe, a non-combustible hose be-
tween the feed auger and the downpipe,
a fan with a fan guard, flame monitoring
and blocking if the ambient temperature
is high.
Different operating modes can be selected:high pow-
er, low power or modulating. The burner can have a
start delay, which extends the running time and thus in-
creases the efficiency.
There are four indicators on the burner. By flashing in different ways,they
provide information about operating phases and alarms.
Pel-lets are fed to the burner automatically from the fuel store
via a feed auger controlled by the burner. The safety in the
supply system consists of overheating protection on the
downpipe, a meltable hose between the feed auger and
the burner and overload protection for the feed auger mo-
tor.
To simplify installation and maintenance,the burner has quick
attachments that make it easy to attach the burner to the boiler
and remove it.All electrical connections have quick couplers.
The burner is supplied with a feed auger, connection cable, flue
gas thermometer and ash rake.
art. no. RSK
VIKING BIO 33 00 639 07 46
VIKING BIO with 1500 mm feed auger 33 03 639 07 64
VIKING BIO with 2500 mm feed auger 33 04 639 07 65
1500 mm feed auger 33 01 639 07 47
2500 mm feed auger 33 02 639 07 48
Weight: 12 kg Fuse protection: 10 A Pressure in combustion chamber: ±15 Pa
Ambient temperature: 10- 30 °C Power consumption high power: 16 W Sound pressure: 65 dBA
Heat output low: 15 kW low power: 11 W Wood pellet corresponding to: SS 187120, group 1
high: 20 kW standby: 5 W Pellet size: Ø6-8 mm
Voltage: 230 V~, ±10%, 50 Hz Enclosure protection class: IP21 Emission class according to EN 15270: 4
Current: 2.8 A Draught required: 0-5 Pa Feed auger: 230 V~ / 15 W
To guarantee the correct pellet supply, only one of the
feed augers indicated below may be used.

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Installation
Installation must take place according to existing regula-
tions. The installer must familiarise himself with the existing
rules.
Boiler
The Viking Bio can be installed on most domestic boilers. The boiler's
power range must match the burner's power so that the flue gases are
cooled sufficiently.
The boiler's flues may not be so narrow that they can easily be clogged by
ash. Pellet firing produces a fair amount of ash which needs space. It must
also be easy to remove it from the boiler.
The boiler's hatches and dampers must be airtight so that no false air can
get in.
For simple maintenance, it should be possible to open the hatch without
the burner needing to be removed.
Wood-fired boilers have a large area for ash and are usually easier to
sweep. An old wood-fired boiler is not usually a good choice as the heat-
absorbing surfaces are too small to cool the flue gases sufficiently.
365 mm
150 mm
50 mm
50 mm
In a double boiler, the burner should be installed on the oil hatch. If the pel-
let burner is located on the oil side, it is possible to fire with wood.
The flame may not touch the walls of the combustion chamber. The mini-
mum dimensions of the combustion chamber are 230 x 230 x 365 mm (h
x w x d).
If the depth dimension cannot be achieved, a spacer is available as an
accessory.
The distance to the base of the combustion chamber should be high
enough for there to be space for the quantity of ash formed during a
weeks' firing in winter. The highest quantity of ash is to be found at the
rear of the combustion chamber.
Chimney
A chimney for oil firing is usually also appropriate for pellet firing. A chim-
ney for wood firing may have too large a flue. These are the requirements:
Min.: height 2 m, Ø100 mm or equivalent.
Max.: draught <15 Pa.
The draught is measured with a warm chimney and in normal operation.
Draught damper
The chimney must be fitted with a draught damper that is
appropriate for the chimney.
The combustion is affected by the draught. Therefore, stable draught con-
ditions are the objective.
Supply air to boiler room
There must be a supply air valve to the boiler room. The valve's free sur-
face must correspond to the cross-sectional area of the chimney.
Installation of burner
The burner hatch must be well insulated from the burner.
A. Unscrew the screws holding the burner cover in place and remove the
cover.
Open the quick attachments and release the burner from the outer
burner pipe.
Mark out where the burner will be located and make holes as shown in
the drawing.
B. Fit the burner flange and flange gasket on the burner hatch and screw it
in place with four M6 screws.
The burner must be installed horizontally or so that it inclines down-
wards by a few degrees in the combustion chamber.
Burner hatch
Flange gasket
(asymmetrical)
Burner flange
C. Fit the burner on the burner flange and lock the quick attachments.
Check that the burner is tight against the silicone gasket on the burner
flange.

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Installation
Downpipe
The downpipe is screwed to the body of the burner. The downpipe can be
rotated in increments of 22° to obtain a suitable angle to the feed auger.
There is a thermal relay with a cable on the downpipe. It must be con-
nected as shown in the figure.
a
b
c
d
a. Thermal relay with cable on downpipe.
b. Connect the cable's connector here.
c. Fix the cable to the body of the burner with a cable tie after it has been
laid as shown in the figure.
d. Quick coupler, reducer.
Press the contacts together properly.
Breakaway openings
Combimax 30 UB and Vedolux
Comet, Joker and Star
There are breakaway openings on the sides of the cover of the burner.
These are broken off when the burner is installed on Värmebaronen boil-
ers.
Pellet store
Ready-made pellet stores are available on the market. These are prefer-
able to homemade stores. A store designed for pellets makes the supply
more regular.
It should be possible to remove the feed auger for cleaning without having
to empty the store first.
The size of a weekly store depends on the building's heating require-
ments. However, we recommend that the store have a volume of at least
300 litres.
To guarantee that the correct quantity of pellets is supplied,
the burner must have one of the appropriate feed augers.
Feed auger
Fit the feed auger motor on the feed auger. Tighten the locking screw well
so that the motor does not slip on the feed auger shaft.
The feed auger must be well anchored as it will work its way into the
store. Anchor the feed auger with a chain on the ceiling. The chain must be
perpendicular to the fixing lug on the feed auger.
The intake of the feed auger should be at least 50 mm from the base of
the store. It is important for the intake to be completely free. Check the
position of the feed auger before the store is filled with pellets. Use tape or
similar to mark on the feed auger's pipe how far it extends into the store.
This makes it easy to see whether the feed auger has worked its way into
the store and it becomes easier to refit the feed auger when it has been
taken out of a full store.
Use the enclosed hose to connect the feed auger to the burner's quick
coupler on the downpipe. Secure the hose at both ends with hose clips.
Connect the feed auger's power cable to the power socket on the burner.
Before starting the feed auger and the burner, the feed auger must be filled
with pellets. See 'Startup'.
A flexible feed auger can be used via an intermediate store into which
some of Viking Bio's feed augers are placed to supply the burner with
pellets.
The inclination of the feed auger from the horizontal plane
must be 40°±5°.
40°±5°
H dimension at 40° inclination: 1500 mm feed auger: 750 mm
2500 mm feed auger: 1400 mm
Risk of entrapment!
Before any work is done on the feed auger, its power cable
must be disconnected from the burner.
Flue gas thermometer
The enclosed flue gas thermometer is fitted to the usual connection on the
boiler's flue pipe.

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Electrical installation
Electrical connection
The electrical installation must be carried out according to
existing rules under the supervision of a qualified electrician.
The burner must be preceded by an all-pole switch, protected with a max.
10 A fuse.
The design depends on which boiler the burner is installed on, whether the
boiler has existing electrical equipment and whether the burner is to con-
trol the boiler temperature.
Connections to burner
Feed auger
Temperature
sensor
Power cable
Thermal relay, downpipe
Press the contacts
together properly.
Connector - 230 V~ power cable
The septuple-pole plug, a, is inserted in the
socket, b, located on the burner until the
catch on the pushbutton, c, engages and
locks the plug in place.
For disconnection, the power to the burner
must be switched off first. Then press the
pushbutton while pulling the plug out of the
socket.
N: Neutral conductor.
: Earth conductor.
L1: Black, supply via overheating protection.
B4: Brown, connected to the boiler thermostat.
S3: Grey, alarm signal, 230 V~, from burner, max. load 1 A.
T1, T2: To any safety switch on the combustion chamber hatch.
Alarm
In the event of an alarm, the burner generates a 230 V~ signal. The signal
can be used for a visual/acoustic presentation. If the function is not used,
the cable end must be insulated.
Hatch safety switch
A hatch switch must be installed if the combustion chamber hatch can be
opened without tools. Safety can also be guaranteed if the supply hose is
made so short that it has to be detached before the hatch can be opened.
The jumper, T1 - T2, in the power cable's contact part must be removed
when a hatch switch is connected.
Boiler temperature control via the burner
The boiler temperature sensor (accessory) is connected to a contact on the
burner.
The burner's temperature control has a high connection difference, 10°C,
which reduces the number of starts and extends the operating time. It is
advantageous to have the burner control the boiler temperature if hot ser-
vice water is heated in a heat exchanger.
The temperature sensor should preferably be placed in an immersion
pocket high up on the boiler. If there is no immersion pocket, the sensor
is glued to the body of the boiler with epoxy glue. The sensor must have
good thermal contact.
In an exchanger boiler, the sensor is placed so that it senses the exchang-
er's return flow, but not on the return pipe.
When the burner is to control the boiler temperature, the
phase supply and control phase must be preceded by over-
heating protection.
230V~, 50Hz
10A
LNPE
BLUE
BLACK
BROWN
GREY
YELLOW/GREEN
N
L1
B4
S3
T2
T1
OVERHEATING
PROTECTION
SAFETY SWITCH
BURNER SWITCH
ALARM 230V/1A
Boiler thermostat controls boiler temperature
The burner's phase supply must be preceded by overheating
protection and the control phase by a thermostat.
230V~, 50Hz
10A
LNPE
BLUE
BLACK
BROWN
GREY
YELLOW/GREEN
N
L1
B4
S3
T2
T1
OVERHEATING
PROTECTION
AND THERMOSTAT
SAFETY SWITCH
BURNER SWITCH
ALARM 230V/1A
Electrical connection check.
1. The power switch and thermostat must be in the position '0'.
2. Switch the power switch to 'I'; all the burner's indicators
should light up briefly. Subsequently, only 'OPERATION'
should light up.
3. Turn the thermostat so that it requires heat; the 'FLAME'
indicator should start to flash.
If this does not happen, the connection must be checked.
b
a
c

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Electrical installation
Connection to Värmebaronen boilers
The diagrams below show how the burner is connected to some of Värme-
baronen's boilers. See also the instructions for the boiler.
Pellmax CU
230V~
CP
N
N
N
S3
L
B4
N
F
N
N
BLUE
BLACK
BROWN
GREY
YELLOW/GREEN
N
L1
B4
S3
T2
T1
SAFETY SWITCH
ALARM 230V/1A
Burner connection difference
The temperature difference between the burner's start and stop tempera-
tures can be set in the range 8-16 °C.
A low temperature difference gives the burner a shorter operating time
and results in more starts/stops. A high temperature difference results in a
longer operating time and fewer starts/stops but higher fluctuation in boiler
temperature.
Pellmax VX
Boiler thermostat controls boiler temperature Boiler temperature control via the burner
N
N
CP
N
N
N
S3
L
B4
N
F
2
1
VX
L1
L2
L3
N
230V~
BLUE
BLACK
BROWN
GREY
YELLOW/GREEN
N
L1
B4
S3
T2
T1
SAFETY SWITCH
ALARM 230V/1A
The burner is preceded by a boiler thermostat. Therefore, it must be set to
its highest value.
The temperature setting on the burner must be set 10-15 °C lower than the
boiler thermostat.
Pellmax UB
Boiler thermostat controls boiler temperature Boiler temperature control via the burner
CP
L
N
N
N
S3
L1
B4
230V~
X
BLUE
BLACK
BROWN
GREY
YELLOW/GREEN
N
L1
B4
S3
T2
T1
SAFETY SWITCH
ALARM 230V/1A
The burner is preceded by a boiler thermostat. Therefore, it must be set to
its highest value.
The temperature setting on the burner must be set 10-15 °C lower than the
boiler thermostat.
There are electric cables, etc. behind the front panel of the
boiler. Check where they are before drilling for any cable
clamps.

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Wiring diagram
Disconnect the plug before service or if the burner is removed
from the boiler.
BLUE
BLUE
BLUE BLUE
BLUE
BLUE
BLUE
N
2 x 300 W
N
N
X2
L1 B4 S3 T2 T1
X2
N
L1 B4 S3 T2 T1
THERMOSTAT
THERMAL RELAY
ALARM
FEED AUGER
EARTH
EARTH
EARTH
CONTROL SIGNAL TACHOMETER GENERATOR
EARTH
CONTROL
SIGNAL
TACHOMETER
GENERATOR
BLACK
BLACK
WHITE
BLACK
BLACK
BLACK
BROWN
BROWN
YELLOW
YELLOW
YELLOW
YELLOW
WHITE
WHITE WHITE
GREY
PURPLE
BLACK
BLACK
BLACK
BLACK
RED RED
BLUE
WHITE
RED
YELLOW
BLUE
WHITE
RED
BROWN
BROWN
THERMOSTAT
PHASE SUPPLY
ALARM
THE FAN’S CONNECTOR
(FROM THE CABLE SIDE)
TEMP
START DOSE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1. Connector for supply thermostat, etc. See electrical installation.
230V~ in all conductors.
L1: supply to burner via overheating protection.
B4: connected to boiler thermostat.
S3: alarm signal from burner.
T1: to any safety switch on the combustion chamber hatch.
T2: from any safety switch on the combustion chamber hatch.
2. Cable part of connector. See 1.
3. Suppression capacitor.
4. Connector for boiler temperature sensor.
5. Boiler temperature sensor (accessory).
6. Connector for feed auger, 230V~.
7. Ignition elements.
8. Current transformer.
9. Transformer for supply to printed circuit board and fan motor.
10. Semiconductor relay with indicator, to control ignition elements.
11. Fan with adapter circuit board.
12. Flame monitoring, photoresistor.
13. Connector for thermal relay in downpipe.
14. Thermal relay in downpipe.