wodtke Primarofen PO 03-2 easy.nrg User manual

wodtke Pellet
Primärofen®- Technology
Assembly and Operating Instructions
Control S5
Ofentyp PO 03-2 "easy.nrg®", PO 03-5 "crazy.nrg" and PO 03-7 "family.nrg", Airplus from software S5 007
Thank you for deciding to purchase our product. Please be sure to read the instructions before
installing and commissioning your furnace. By doing so, you will prevent damages which can be
caused by improper installation or operation. Your furnace will reward you and the environment
with optimal functionality.
We wish you cozy warmth and many comfortable hours with your wodtke Pellet Primärofen fur-
nace.
Sincerely, wodtke GmbH

Manual_S5_Airplus_2015_04_20 Page 2 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
Table of Contents:
1Important General Notices............................................................................................................4
2Explanation of Symbols.................................................................................................................5
3System Requirements....................................................................................................................5
3.1 Possible Applications of AIRPLUS Air Units..............................................................................5
3.2 Installation Room......................................................................................................................6
3.3 Connection of External Controllers............................................................................................6
3.4 Important Notices Regarding Room Air Dependent and Room Air Independent Operation.......6
3.5 Chimney Connection.................................................................................................................7
3.6 Combustion Air Connection ......................................................................................................7
3.7 Cleaning, Maintenance and Service..........................................................................................8
3.8 Pellet Quality ............................................................................................................................8
3.9 Pellet Supply / Pellet Storage...................................................................................................9
3.10 Voltage Supply..........................................................................................................................9
4ID Plate and Serial Number............................................................................................................9
5Transport / Unpacking / Inspection.............................................................................................10
6Removal of Outer Panelling.........................................................................................................11
6.1 Removal of Outer Panelling of easy.nrg®................................................................................11
6.2 Removal of Outer Panelling of crazy.nrg.................................................................................13
6.3 Removal of Outer Panelling of family.nrg................................................................................15
7Placement of the Furnace............................................................................................................18
8Electrical Connection / Cabling...................................................................................................18
8.1 Connector Block .....................................................................................................................19
8.2 Internal Wiring Diagram..........................................................................................................20
8.3 Main Board Inputs...................................................................................................................21
8.4 Main Board Outputs................................................................................................................25
9Furnace and Functional Description, Components, Descriptions............................................26
9.1 Cross-Section and Components .............................................................................................27
9.2 Back-Burn Protection..............................................................................................................28
9.3 Safety Temperature Limiter (STB) + Main Fuse (5A Fast) ......................................................28
9.4 wodtke Air Volume Sensor......................................................................................................29
9.5 Pellet chute temperature sensor (TP) .....................................................................................29
9.6 Flue Gas Temperature Sensor (TR)........................................................................................29
10 Fire Safety Regulations................................................................................................................30
11 Approved Fuels ............................................................................................................................31
12 Filling Pellet Container / Pellet Container is Completely Empty ...............................................32
13 Initial Commissioning ..................................................................................................................34
13.1 Important Notices....................................................................................................................34
14 Operation and Heating.................................................................................................................35
15 Cleaning........................................................................................................................................37
15.1 Cleaning the Viewing Window / Vacuuming the Combustion Chamber...................................38
15.2 Inspection and De-Ashing of the Burner Pot...........................................................................38
15.3 Cleaning Burner Pot / Cast Grate and Ash Drawer .................................................................39
15.4 Correct Position of the Cast Grate ..........................................................................................40
15.5 Cleaning Surfaces ..................................................................................................................40
16 Maintenance (WA Display)...........................................................................................................41
16.1 Scope of Maintenance............................................................................................................42

Manual_S5_Airplus_2015_04_20 Page 3 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
16.2 Basic Cleaning with Additional Actions ...................................................................................43
16.3 Cleaning Heating Gas Flues family.nrg...................................................................................44
16.4 Cleaning Heating Gas Flues, easy.nrg®..................................................................................46
16.5 Cleaning Heating Gas Flues crazy.nrg....................................................................................46
16.6 Cleaning Flue Gas Fan and Connector...................................................................................47
16.7 Inspection and Cleaning of Air Volume Sensor and Air Intake ................................................48
16.8 Inspection of Seals and Mechanical and Electrical Components.............................................49
16.9 Inspection and Cleaning of Convection Air Routing ................................................................49
16.10 Inspection and Cleaning of Pellet Chute .................................................................................49
16.11 Inspect and Lubricate Moving Parts........................................................................................49
16.12 Completion of Maintenance Work, Test Run and Maintenance Reset.....................................50
17 Menu Level / Unit Data Query......................................................................................................51
17.1 Output of Operating and Collective Fault Messages (Relay Table).........................................52
18 Fault Analysis, Fault Codes, Safety Functions and Safety Equipment.....................................53
18.1 Overview of Class 1 Error & Fault Codes (Safety-Related).....................................................53
18.2 Overview of Class 2 Error & Fault Codes (Not Safety-Related)...............................................57
18.3 Internal Regulation Function "R.M".........................................................................................57
19 Technical Data / Certifications.....................................................................................................58
20 Dimensions...................................................................................................................................59
20.1 Dimensions of PO 03-2 "easy.nrg®"........................................................................................59
20.2 Dimensions of PO 03-5 "crazy.nrg".........................................................................................60
20.3 Dimensions of PO 03-7 "family.nrg"........................................................................................61
21 Declaration of Performance.........................................................................................................62
22 Proper Use....................................................................................................................................65
22.1 Fuel ........................................................................................................................................65
22.2 Installation Room....................................................................................................................65
22.3 Installation and Assembly.......................................................................................................65
22.4 Modifications...........................................................................................................................65
23 Warranty and Guarantee..............................................................................................................66
24 Customer Service / Spare Parts ..................................................................................................67
25 Your Specialist Company ............................................................................................................68

Manual_S5_Airplus_2015_04_20 Page 4 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
1 Important General Notices
Please read all instructions and information
before installation and commissioning. By do-
ing so, you will prevent malfunctions and op-
erating errors.
The operator must become informed regarding
the particular features of the heating system and
the appropriate fuels before commissioning the
heating system based on the instructions.
The local, applicable regulations and rules (e.g.
state building codes, FeuVo (fire-heating installa-
tions ordinance), industry rules for heating and hot
air heating system construction, etc.) must be ob-
served. We unfortunately can accept no liability for
changes which occur after printing of this docu-
mentation, or for typographical errors. We reserve
the right to make changes without notice. These
units are not intended for use by people (including
children) who have impaired physical, sensory or
mental capabilities or lack experience and/or
knowledge, unless they are supervised by a per-
son responsible for their safety or have received
instructions from said person regarding how the
units are to be used. Children must always be su-
pervised in order to ensure in particular that they
do not play with the units or come into contact with
hot surfaces.
In Germany, the heating system may only be com-
missioned after the authorised district chimney
sweep has issued an operating permit. Inform the
authorities promptly if you are planning the instal-
lation or modification of aheating system. Your au-
thorised district chimney sweep will be happy to
advise and assist you in advance.
Work, such as particularly installation, assem-
bly, initial commissioning and service work as
well as repairs may only be performed by a
trained, specialist company (heating or hot air
heating construction). In the case of improper in-
terventions, all warranties and guarantees are
void. See also the chapter Proper Use.
During final acceptance, the specialist company
must always instruct the operator of the system in
the operation, cleaning and maintenance of the
system, in a thorough and qualified manner. In
particular, the use of appropriate fuels, regularly
required cleaning by the operator, required
maintenance and safety instructions must be ad-
dressed. All warranties and guarantees are void
particularly in the case of non-compliance with in-
structions, as well as with specified cleaning and
maintenance requirements.
Before commissioning, ensure that all accesso-
ries have been removed from the combustion
chamber and ash pan and that the pellet con-
tainer is free of residue (e.g. construction debris,
screws...).
The operator must regularly clean the heating
system.
We recommend the completion of a maintenance
contract between a specialist dealer and the oper-
ator for maintenance of the heating system. Reg-
ular maintenance can also be performed by the
operator, if the operator is technically experienced
and soundly instructed by a specialist company.
Disconnect power plug before working on the fur-
nace!
The power plug and the related socket must be
easily accessible at all times. Operation of the unit
with a damaged power cable is prohibited. If the
power cable is damaged, it must be immediately
replaced by a qualified engineer or wodtke cus-
tomer service, in order to prevent dangers.
Do not pull power plug during operation! First
shut down the unit and wait for the fan stop
delay to complete (G OFF).
With correct operation / control and good
maintenance / service, you will increase the
value retention and extend the service life of
your wodtke Pellet Primärofen. You will save
valuable resources and protect both our envi-
ronment as well as your wallet.
The "crazy.nrg" model PO 03-5 is delivered
with separate side covers. These must be in-
stalled before commissioning. The unit may
not be operated without side covers. See the
enclosed assembly instructions!

Manual_S5_Airplus_2015_04_20 Page 5 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
2 Explanation of Symbols
Danger Symbols:
Attention! This refers to
a danger.
Warning of hot surface.
Warning of heavy load.
Warning of tipping.
Warning: risk of fire.
Warning of electrical
voltage
Notice Symbols:
Notice: See operating instruc-
tions!
Notice: Disconnect power plug!
Notice: Wear heat-resistant
gloves!
Notice: This section contains ad-
ditional important information!
3 System Requirements
wodtke products are manufactured and inspected
according to the latest standards and EU guide-
lines. Our Pellet Primärofens are furnaces in-
spected according to DIN 18894 or EN 14785.
They are always connected to other structural
equipment / products and therefore, like all tech-
nical devices, place certain system requirements
on these external equipment / products to ensure
smooth and faultless interaction. To this end, the
interfaces between all participating components
must be precisely coordinated with each other.
Some particularly important requirements follow
below. This listing makes no claim to being com-
plete. Please observe and read all instructions /
documentation included with the furnace during in-
stallation and before operation. By doing so, you
will prevent malfunctions and operating errors.
1
The heating demand can be estimated at 0.15 KW/m² of living
space for buildings from before 1977, 0.10 kW/m² for normal build-
ings after 1977 and 0.08 kW/m² for well insulated buildings after
1977, and 0.05 kW/m² for low energy houses. This method does not
replace a heat demand calculation! Application examples: Old build-
ing from before 1977; 60 m² required heating output 60 x 0.15
kW/m² = 9 kW. New construction from 2003; 60 m² 60 x 0.05
3.1 Possible Applications of AIR-
PLUS Air Units
Single room heating (Hot air heating of the in-
stallation room or a unit of rooms)
Output range 2-6 kW: Application limit = maxi-
mum producible energy = 9,000 kWh per year at
1500 h with 6 kW. This corresponds to an annual
consumption of approx. 1.8 t of wood pellets (=
approx. 900 l heating oil).
Rule of thumb for sizing: calculated heating de-
mand of the room
1
x factor of 1.2.
Example:
3 kW heat demand in installation room.
Required output of air unit = 3 kW x 1.2 =
3.6 kW peak output
kW/m² = required heating output 3 kW; that is, series with 2-6 kW
output range ideally suited. Our units can also be used in small
rooms (required heating output of < 2 kW). Combined with a room
thermostat, the air units are activated only long enough so that the
room does not become too hot. A great advantage of the wodtke
Primärofen technology over cut firewood.

Manual_S5_Airplus_2015_04_20 Page 6 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
3.2 Installation Room
Wodtke Pellet Primärofen furnaces may only be
installed in residential spaces with ordinary im-
purities, normal relative humidity (dry rooms ac-
cording to VDE 0100) and with room tempera-
tures from +5 °C to +30 °C (environmental tem-
peratures during operation).
The furnaces are not splash-water protected and
may not be installed in wet rooms. Due to the op-
erating and flame noises of the furnaces, we do
not recommend installation in bedrooms or relax-
ation rooms. Operating sounds, such as pellets
dropping and flame/air current and drive motor
noises, are audible during operation. In tempera-
tures of <5 °C (e.g. in summer cottages), certain
minimum settings must be made on the furnace
and appropriatefrost protection devices (e.g. elec-
trical heat monitors) must be provided for. Safety
equipment can be effective in operation at temper-
atures >30 °C. Please observe the respective no-
tices on heating operation in the unit's instructions.
The installation room or combustion air connection
for all furnaces must have at least 4 m³ of volume
per kW nominal heating output: 6 kW 24 m³.
Please observe the specifications on fire protec-
tion regulations. The furnaces must be installed on
a sufficiently load-bearing and non-flammable
base. At least 20 cm of free space must be avail-
able to the rear and sides of the furnaces after in-
stallation for assembly work. Please also note that
the units should be equipped by the customer with
flexible connections (electrical lines) so that they
can be subsequently movedfor possible assembly
work / repairs and are easily accessible.
3.3 Connection of External Con-
trollers
All units can be conveniently and easily activated
and deactivated by hand. In addition, wodtke of-
fers compatible room and clock thermostats for
automatic activation of the units (see price list).
Solid fuels, such as wood pellets, require more
time for ignition than liquid or gaseous fuels.
The ignition process leading to the first flame al-
ready requires several minutes and the furnace's
full output is not available until about 15
minutes after starting, when the warm-up pro-
gramme is complete.
When the furnace is shut off, it also takes sev-
eral minutes - in contrast to oil or gas furnaces
- until all pellets have been burned and the
flame goes out. Consequently, a fan stop delay
of several minutes is programmed into the fur-
nace, which should elapse before the furnace is
restarted.
Due to the required warm-up programme and
the fan stop delay, there is therefore less out-
put available during frequently cycling opera-
tion in comparison to oil or gas furnaces.
In the case of automatic activation of the units with
other controllers, a minimum unit run time of
30, preferably 60 minutes should be observed.
This means that the controller must be configured
so that too-frequent cycling (on-off) of the unit
is prevented. The hysteresis of the external
controller should be selected to be large enough
that at least 15 minutes pass for the fan stop delay
between the "shut-off" and "restart" signals.
For installation of the required electrical connec-
tion lines, we recommend two empty conduits with
at least Ø 30 mm be provided by the customer
(separated into empty conduit for 230V and 24V
connection lines).
3.4 Important Notices Regarding
Room Air Dependent and
Room Air Independent Oper-
ation
3.4.1 General Notices
Please always observe the respective local regu-
lations and rules, in consultation with your author-
ised district chimney sweep. We can accept no li-
ability for changes which occur after printing of
these instructions. We reserve the right to make
changes without notice.
3.4.2 Room Air Dependent Operation
The furnace is standard-delivered as a room air
dependent pellet furnace. That is, the furnace ex-
tracts all of the combustion air from the installation
room via the central air intake on the rear side of
the furnace. A sufficient combustion air supply is
mandatory (approx. 25 m³/h at full output).

Manual_S5_Airplus_2015_04_20 Page 7 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
3.4.3 Room Air Independent
Operation
The required combustion air is supplied to the fur-
nace directly via a sealed connection line from the
outside, and not extracted from the installation
room of the heating system.
The furnace is suitable for room air independent
operation (DIBt approval). The following must be
observed:
The combustion air line and the flue
pipes must be sealed.
In addition, a negative pressure no
greater than 8 Pa relative to the outside
may occur in the installation room, the
residence or a comparable usage unit
due to room air extracting systems.
The general building approval by the DIBt is num-
ber Z-43.12-240.
3.4.4 Combination with Controlled
Venting and Ventilation Systems
If the furnace is installed in the effective range of
a controlled venting and ventilation system, §4 of
the fire-heating installations ordinance (FeuVo)
applies in Germany. The following options there-
fore exist, among others, for operation of the fur-
nace in combination with room air technology sys-
tems:
A room air independent connection or
operating method must be ensured (see
above).
The exhaust gas routing must be moni-
tored by special safety equipment (this
can be done with the wodtke differential
pressure controller DS01, for example;
see price list).
Use of a ventilation system which en-
sures that negative pressures no greater
than 4 Pa relative to the outside occur in
the installation room and that the re-
quired combustion air (approx. 25 m3/h)
is additionally supplied for the heating
system.
3.5 Chimney Connection
A chimney calculation must be performed before
installation (EN 13384). The chimney provides for
the safe removal of flue gases from the furnace,
particularly in case of power failure, and is thus re-
sponsible for an important safety function and
must be properly sized. In the case of a chimney
draught that is too high, we recommend installing
a draught limiter. The conveying pressure (= chim-
ney draught) must be between 3 Pa at minimum
and 20 Pa at maximum.
The heating system must be connected to a
chimney which is suitable for solid fuels. The
connection piece must be made of metal and
fulfil the corresponding requirements accord-
ing to the DIN / EN standard. The authorised
district chimney sweep will be happy to advise
you in advance.
Additional safety equipment is required when
connecting Pellet-Primärofens to chimneys
which have multiple connections.
Please always observe the respective local regu-
lations and rules, in consultation with your author-
ised district chimney sweep. We can accept no
liability for changes which occur after printing of
these instructions. We reserve the right to make
changes without notice.
3.6 Combustion Air Connection
If the furnace is intended for room air independent
operation, the combustion air line must be gas-
tight. wodtke combustion air lines with sealing
rings (see wodtke price list) can be used for this.
To reduce cooling losses and to thereby save en-
ergy, wodtke has the special motorised flue gas
damper, which can be used an intake and flue
gas damper.

Manual_S5_Airplus_2015_04_20 Page 8 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
3.7 Cleaning, Maintenance and
Service
In contrast to liquid or gaseous fuels, ash and
soot are always created when using solid fuels.
The combustion quality and operating conven-
ience of wodtke Pellet-Primärofen units are far
higher than the level of comparable cut firewood
furnaces, but cleaning of the burner plate (by
the operator) at regular, short intervals and
service/inspection at longer intervals are nev-
ertheless required in order to free the units of soot
and ash. Without these measures, malfunctions
can occur, for which we can accept no liability.
Regular service, cleaning and maintenance also
increase the efficiency of your system (because
soot in particular is an exceptional insulator and
can therefore significantly reduce thermal output /
efficiency) as well as prevent unnecessary emis-
sions to the environment.
Cleaning interval: daily visual inspection of the
burner pot, with manual cleaning as required.
Maintenance interval: 1,500 kg pellet consumption
(at 0.25% ash content). Please therefore observe
the following chapter and Chapter 11 in these in-
structions.
3.8 Pellet Quality
According to the 1st Federal Immission Control
Act (1st BImSchV), onlynatural wood pellets are
permitted in Germany.
Pellet quality significantly influences cleaning
and maintenance cycles. We define all of our
specifications and test values based on pellet
qualities with 0.25% ash content, a bulk den-
sity of 650 kg/m³ and a heating value Hu> 4.9
kWh/kg. 500 litres of heating oil thus approxi-
mately correspond to 1,000 kg of such wood pel-
lets. 1,000 kg of these pellets required approx.
1.54 m³ of storage space volume.
Deviations from the values specified above can-
not be avoided, due to the tolerance ranges of
the relevant standards for pellets (incl. ENplus-A1,
DINplus and DIN EN 14961-2 Class A1) for ash
content, bulk density, composition and size/geom-
etry, and necessarily lead to deviations in different
systems. For example, this means that a doubling
of the ash content from 0.25% to 0.5% will also
result in a doubling of the cleaning and mainte-
nance frequency.
2
The recommended pellet diameter is 6 mm; in case of devia-
tions, the fuel throughput may need to be adjusted. The same also
applies for differing lengths.
For our wodtke Pellet-Primärofen technology, the
ash content of the pellets is therefore the most im-
portant parameter by far.
Consequently, we only approve pellets which
are inspected according to ENplus-A1,
DINplus or DIN EN 14961-2 Class A1 and have
an ash content of < 0.7% for use in our units.
Good commercially available brand-name pellets
consistently have an ash content of << 0.3% to-
day. Ask your pellet supplier about ash con-
tent. The less, the better. The use of approved,
natural binding agents in the pellets can cause
slagging of the pellet ashin the burner pot, despite
inspection according to the standards above. We
therefore recommend avoiding binding agents
containing silicate, such as potato starch, and us-
ing wheat starch, for example. Contact your pellet
supplier in case of questions.
In the case of high bulk density and special ge-
ometry or a high pellet heating value, internal
safety equipment can temporarily reduce unit out-
put until the target values are reached again. This
is not a defect. The unit modulates in this case.
In the case of pellets with extremely low bulk den-
sity or low heating value, the specified nominal
output and performance ranges may be slightly
undershot. This is also not a defect, but instead
due to the nature of pourable and dispensable
fuels.
Using the control system, the specialist company
can adjust the furnace within certain ranges to var-
ious bulk densities and pellet qualities.
Cut firewood or other burnable or waste materials
may never be used!
If the furnace is not operated with approved
fuels, any warranty or guarantee claims are
void and dangerous operating conditions may
result. Do not perform any experiments.
A pellet diameter between 5 and 8 mm is per-
mitted
2
.The length of the pellets should not ex-
ceed 30 mm. Pellets with high dust content (>5%)
should likewise not be used.

Manual_S5_Airplus_2015_04_20 Page 9 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
3.9 Pellet Supply /
Pellet Storage
Wood pellets are delivered in an absolutely dry
state. In order to maintain the quality of the pellets,
the pellets must be stored dry and free of contam-
inants. Our units are normally (more than 90%)
loaded conveniently by hand using bagged goods
(15 kg bag). In the case of 3 t of pellet consump-
tion per year, this makes 200 bags over the course
of a year; that is, only 1/2 bag per day on average.
Pellets can also be delivered by tank trucks and
blown into a warehouse /silo in the case ofgreater
annual consumption. For storage of pellets and
transportation of pellets from the warehouse to the
furnace, wodtke offers corresponding conveyance
technology systems (see wodtke price list).
The wodtke "Vario" pellet gate is available for
connection to an individually constructed, external
pellet storage facility (constructed by the cus-
tomer). We recommend feeding the pellets by
gravity, by positioning the pellet stock above
the furnace. The advantages of this are lower
construction costs and simple, reliable and sturdy
design without additional drive units and motors.
With the "Vario," the pellet connection can also be
closed and the furnace can be separated from the
storage facility for maintenance purposes.
If pellet conveyance technology is connected to
the wodtke Pellet-Primärofens of the PO 03 se-
ries, room air independent operation is no longer
possible, since by design, fabric silos and convey-
ance systems cannot be sealed. In that case, a
wodtke DS01 differential pressure controller must
be installed for monitoring.
3.10 Voltage Supply
Required voltage supply: 230 VAC / 50 or 60 Hz.
Voltage ranges from 195 V to 255 V are permitted.
All furnaces have automatic frequency recognition
and change-over from 50 Hz to
60 Hz networks (e.g. Japan).
4 ID Plate and Serial Number
The ID plate and the serial number of the furnace
are located in the pellet drawer (inside; open pellet
drawer with turning handle on the rear side of the
furnace and swing open the pellet drawer). Please
record the serial number of your furnace here and
be sure to keep this document. If you should re-
quire spare parts, you must always specify the se-
rial number of your furnace so that we can supply
you with the correct parts.
Please enter the serial number from the pellet
drawer (inside) here and keep this document:
Ser. No.:________________
Fig. 1: ID Plate

Manual_S5_Airplus_2015_04_20 Page 10 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
5 Transport / Unpacking / In-
spection
The goods must be inspected for recognisable
damage and/or missing quantities immediately
upon delivery. Complaints of any type must be
acknowledged in writing by the delivering freight
forwarder and immediately reported to wodtke.
Transport damages which are only recognisable
after unpacking must be reported in writing to
wodtke no later than 7 days after delivery.
Delayed complaints cannot be considered due to
insurance reasons.
Attention: The furnace is heavy (weighs approx.
150 kg). Inspect floor beforehand for suitability for
transport and installation. The pallet may only be
transported absolutely horizontally and only by
forklift or lift truck.
Fig. 2: Transport lock
Attention: Never manually unload / transport the
pallet from the vehicle.
For manual transport, always first release furnace
from the pallet. Proceed carefully and ensure that
the feet of the furnace do not fall between the
boards of the pallet, as the feet can be broken off.
The transport lock bolts are located under-
neath the pallet. These transport lock bolts must
be released to lift the furnace from the pallet.
Always position hand cart or the like in front on the
door side, because the centre of gravity is here.
When transporting the furnace (e.g. by hand
card), always ensure that the surfaces are pro-
tected against scratching. Place Styrofoam or
the like between the furnace and the hand cart so
that the paint is not damaged during transport.
Recommendation: Remove covers before
transport!
To release the furnace, re-
move the transport lock
bolts on the underside of
the pallet.
Take note of
the feet when
raising the fur-
nace. Do not
tilt / break the
feet.
Adjust feet to
25 mm floor
clearance at
the final instal-
lation location.
25 mm
Place Styrofoam etc. in between!

Manual_S5_Airplus_2015_04_20 Page 11 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
6 Removal of Outer Panelling
6.1 Removal of Outer Panelling
of easy.nrg®
6.1.1 Remove Front Panelling
1. Remove the glass slats (7 pieces) on the top
side of the unit.
Fig. 3: easy.nrg®slats
2. Lift the front decorative panel (shown in white)
upward out of the guide (1) and remove toward
the front (2).
Fig. 4: front decorative panel removal
3. Remove the fastening screws of the panelling
(Fig. 5).
Fig. 5: front panelling screws
4. Lift the entire front bezel (shown in white, Fig.
6) up out of the bottom brackets (Fig. 7) and
remove.
Fig. 6: remove front bezel
Fig. 7: front panelling detail
1
2

Manual_S5_Airplus_2015_04_20 Page 12 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
6.1.2 Remove Side Panelling
1. Remove the front decorative pane (see Chapter 6.1.1 on page 11).
2. Unscrew the fastening screws (Fig. 8).
3. Remove the 6 screws on the rear side (Fig. 9).
4. Tilt the side walls laterally and remove (Fig. 10).
Fig. 8: Front screws
Fig. 9: Rear screws
Fig. 10: side panelling removal
6.1.3 Remove Rear Top / Bottom Panel-
ling
See Chapter 6.3.4 on page 17.

Manual_S5_Airplus_2015_04_20 Page 13 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
6.2 Removal of Outer Panelling
of crazy.nrg
6.2.1 Cover Removal
1. Open pellet container and leave open
Fig. 11: Open container
2. Lift unit cover up. Disconnect the control board
cable from the control board (cable is clipped;
see Fig. 12).
Fig. 12: control board cable connection
6.2.2 Side Panel Removal
1. Open the door with the enclosed socket hex
handle and release upward (Fig. 13).
Fig. 13: Release door
3. Remove the lower panel. To do so, unscrew
the two screws and remove panel upward.
Fig. 14: remove lower panel
4. Remove six screws on the rear side (see Fig.
15 and Fig. 16).
Fig. 15: unscrew rear side screws
Fig. 16: remove bottom rear side screws

Manual_S5_Airplus_2015_04_20 Page 14 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
2. Unscrew four screws per side on the front (Fig.
17 and Fig. 18).
Fig. 17: unscrew front top fastening screws
Fig. 18: unscrew front bottom fastening
screws
3. The side panels can now be removed. To do
so, tilt the panel out in the upper area and then
remove upward (Fig. 19).
Fig. 19: Remove Side Panelling
6.2.3 Remove Rear Top / Bottom Panel-
ling
See Chapter 6.3.4 on page 17.

Manual_S5_Airplus_2015_04_20 Page 15 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
6.3 Removal of Outer Panelling
of family.nrg
6.3.1 Remove Cover
1. Open pellet drawer.
Fig20: opening pellet drawer
2. Lift cover somewhat, disconnect control board
cable on the right-hand side (cable is clipped)
and remove cover.
Fig. 21: Cover Removal
6.3.2 Remove Front Top / Front Bottom
Panelling
1. Open combustion chamber door.
2. Remove the fastening screws of the panelling
(Fig. 22).
Fig. 22: front view, family.nrg
3. Pivot top panel out on bottom end (Fig. 23) and
remove upward.
Fig. 23: removal of upper panel
4. Remove the lower panel by pivoting the upper
area out. Otherwise, proceed the same as the
removal of the upper panel.

Manual_S5_Airplus_2015_04_20 Page 16 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
6.3.3 Remove Left / Right Side Panels
The front top and bottom panels must first be re-
moved (see Chapter 6.3.2).
1. Loosen, but do not unscrew the 6 screws for
the side panels on the rear side (Fig. 24).
,
Fig. 24: rear view, family.nrg
2. Loosen the 4 front screws for the side panels,
see Fig. 25 (do not unscrew).
Fig. 25: front, family.nrg

Manual_S5_Airplus_2015_04_20 Page 17 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
3. Pivot side panel out to the left or right and re-
move upward (Fig. 26).
Fig. 26: Remove Side Panelling
6.3.4 Remove Rear Top / Bottom Panel-
ling
1. Loosen (do not unscrew!) the screws identified
by arrows.
2. Lift and remove the two cover panels.
Fig. 27: rear view, PO 03 series

Manual_S5_Airplus_2015_04_20 Page 18 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
7 Placement of the Furnace
Please observe the specifications on fire protec-
tion regulations in Chapter 10.
The furnace must be installed on a sufficiently
load-bearing and non-flammable base. At least 20
cm of free space must be available to the rear and
sides of the furnace after installation for assembly
work.
Adjust the feet of the furnace to 25 mm floor clear-
ance to the bottom edge of the panelling at the in-
stallation location so that sufficient convection air
can flow in from below / laterally below (see Fig.
2).
8 Electrical Connection / Ca-
bling
The power plug must be disconnected before
performing electrical work on the unit!
Electrical connections on the unit must be made
by a qualified specialist in accordance with appli-
cable local technical rules, particularly the VDE
guidelines. No liability is accepted for damage to
the unit dueto improper connections, and any war-
ranty is void.
No electrical connection cables from and to the
unit may contact hot exterior surfaces of the fur-
nace or of the flue pipe. The installation may not
be made over sharp edges, corners, etc. All elec-
trical connections are located on the main board
of the furnace.
The rear bottom panel and the left side panel or
the front bottom panel of the furnace may have to
be removed for the electrical connection, depend-
ing on the desired connection (for removal of outer
panelling, see Chapter 6). The connection lines
can be installed from below through the floor (hid-
den installation) or above the floor (see diagram
below).
The guard covering over the main board may not
be removed for the external electrical connection
(this covering protects the main board from soot
and dirt and is only removed when replacing com-
ponents)! The furnace may only be operated with
this cover in place!
Fig. 28: connection diagram

Manual_S5_Airplus_2015_04_20 Page 19 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
8.1 Connector Block
The central connector block is located on the rear
side of the furnace behind the lower furnace pan-
elling. From there, the external connection lines
can be installed to the connections on the main
board.
In order to make the connections on the main
board accessible, the left-hand panel of the unit
must be removed. If the "Input "RS 485" or "BB-
S5" connections are used (Chapters 8.3.3 and
8.3.6), the front panel must be removed.
Fig. 29: central connector block, rear
Fig. 30: lateral connections, main board
Fig. 31: front connections, main board
Install all external connection cables within the fur-
nace properly and securely so that no hot combus-
tion chamber parts are contacted (short-circuit
risk). The cables from the central connector block
(PG cable glands) can be installed in the left-hand
frame profile of the furnace on the side or to the
front.

Manual_S5_Airplus_2015_04_20 Page 20 / 68
©Wodtke GmbH - Tübingen. All Rights and Changes Reserved.Printed 04/2015 Part No. 950 976
8.2 Internal Wiring Diagram
Fig. 32: wiring diagram, PO 03 series
PC Tool 2
Diagnostic
system
(accessory)
Control board
Air volume sensor
Thermocouple NiCr-Ni
External Inputs
and Outputs
Analogue (modulation-)
input
or
and
ON
OFF
Pellet drawer
Combustion chamber door
Ash drawer door
Grate open
Grate closed
Control board
Boiler sens. intern
Output
sensor
Unit internal switch
(monitoring functions)
Digital inputs
(internal 24V DC
supply)
Caution!
Voltage
Disconnect power plug
before working on unit!
Internal Outputs
(230 V AC)
Screw motor
Igniter element
red
red
black
black
Capacitor
black
blue
green/yellow
Regulated
draft fan
Cleaning
Screw
Ignition
Fan
Grate
Fuse
violet
violet
black
black
green/yellow
Fuse
Ground
brown
blue
green/yellow
Mains plug
(e.g. for use as fault
message)
(e.g. for use as
operating message)
Mains
Pump
Outputs
Operating message
potential-free
e.g. for connection to DS01