Windhager BioWIN XL Operating Manual
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Windhager BioWIN XL Operating Manual

Pellet central heating boiler/furnace
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WOOD PELLETS
WOOD PELLETS
WOOD PELLETS
Operating Manual
Operating Manual
BioWIN XL
Pellet central heating boiler/furnace
03/2015
094885/01
FOR USE IN CANADA / USA
FOR USE IN CANADA / USA
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  • Page 1 WOOD PELLETS WOOD PELLETS WOOD PELLETS Operating Manual Operating Manual BioWIN XL Pellet central heating boiler/furnace FOR USE IN CANADA / USA FOR USE IN CANADA / USA SAVE THESE MANUAL 03/2015 094885/01...

  • Page 2: Table Of Contents

    Table of contents Table of contents 1. Important Information for System Operators ........4 1.1 Safety precautions .
  • Page 3 5.4 BioWIN XL pellet central heating boiler ........

  • Page 4: Important Information For System Operators

    On the following pages, we have provided specific information and important tips regarding system operation, unit functions, and cleaning. Please pay close attention to these instructions. Familiarity with the material in this document will allow you to enjoy long-term operation of this unit. We wish you all the best with your Windhager boiler! 1.1 Safety precautions...

  • Page 5: General Information

    WARNING safety devices only when unit is turned off and has cooled completely. If you have an annual maintenance contract with a certified Windhager partner, these tests will be completed during their routine maintenance work. EN 12828 and ÖNORM B8131 require that the function of the system and related safety equipment be checked and certified yearly by a qualified technician (installer, heating system contractor).

  • Page 6: Fuel

    Important Information for System Operators 1.4 Fuel The boilers/heaters are designed to burn the following fuels: Pellets according to ÖNORM M7135 or DINplus, or Super Premium Wood Pellets listed in the Pellets Fuel Insti- tute (PFI) Standard. Significant criteria based on the standards are as follows: Diameter 0.24 in / 6 mm Length: 5-40 mm / 0.20-1.6 in.

  • Page 7: Commissioning And Maintenance

    Important Information for System Operators 1.5 Commissioning and maintenance A Windhager representative or one of its partners must commission your new Windhager boiler system. Our representatives will ensure that all systems are thoroughly checked and can provide additional information at the time of start-up.

  • Page 8: Filling The Pellet Store

    To prevent negative pressure arising in the pellet boiler, remove the inspection cover (Fig. 3) and leave open during the filling process. Inspection cover, top Fig. 2 Turning off BioWIN XL Fig. 3 Opening inspection cover during the filling process Every time the day-hopper is filed the ‚date and time‘...

  • Page 9: Sources Of Danger

    Important Information for System Operators 1.7 Sources of danger 1.7.1 Power failure (or if the ID fan is not running) Do not open the combustion chamber door! There is an increased risk of defla- gration (rapid burning) if the combustion chamber door is opened. A self-test is DANGER performed by the system following a power failure during combustion, after which operation is continued automatically.

  • Page 10: Caution Symbols

    Important Information for System Operators 1.7.4 Caution symbols CAUTION This means you must follow the safety instructions. There is a slight risk of injury. Please note, that the call sign includes all icons showed in the safety instructions. WARNING This means you must follow the safety instructions. There is a serious risk of injury. Please note, that the call sign includes all icons showed in the safety instructions.
  • Page 11 Important Information for System Operators Hot water and hot steam. Injury hazard. Safety devices (such as the relief valve) will open automatically and release hot CAUTION water or hot steam. Keep away from safety devices. Do not operate safety devices manually when system water is hot or when device is in operation.
  • Page 12 Important Information for System Operators Pinch point hazard. CAUTION Never insert hands between the cover plate and housing of heating chamber when opening or closing. Health hazard. CAUTION All cover plates, enclosures, and guards must be maintained in place at all times, except during maintenance and servicing.
  • Page 13 Important Information for System Operators Risk of hand injury. WARNING Use caution when opening the cleaning flap, as it can open suddenly. When opening the cleaning flap, use the tool provided and wear protective gloves. Machine starts automatically. WARNING Moving parts can crush and cut. Do not remove guarding.
  • Page 14 Important Information for System Operators Pinch point hazard. CAUTION Use caution when closing the cover of the smoke funnel chamber. Crush hazard. WARNING Remain alert and aware of surroundings when moving the machine with crane or fork lift. Smoke gas danger. DANGER Mount a warning plate against smoke gas on the boiler room door.
  • Page 15 The pellet feed system operates automatically. All service and maintenance must be completed by trained specialists only. Do not alter the equipment or accesso- ries in any way. For use in combination with Windhager BioWIN XL pellet-fueled central heating WARNING boiler/furnace only.

  • Page 16: Operation

    Operation 2.1 Functional description The BioWIN XL pellet boiler and the Modular Energy System MESplus combine to form a perfect unit. The BioWIN  XL automatically ignites when the control system signals a heating requirement. Following “purging” (a safety function), ignition starts and the pellet metering auger turns on. The burner pot is automatically filled with pellets.

  • Page 17: Functional Elements And Operating Controls

    Operation 2.1.1 Functional elements and operating controls Fig. 5 BioWIN XL Exklusiv with open cladding door and combustion chamber door 1 ... Cladding door, left 10 ..Fuseboard 2 ... Ash container 11 ..Combustion chamber door, top 3 ... Auger motor 12 ..

  • Page 18: Check Before Commissioning

    2.3 Filling the integral hopper The integral fuel hopper is filled by the fully automatic pellet feed. A Windhager representative or partner will fill the hopper for the first time during start-up, and will start the boiler and familiarize the customer with the...

  • Page 19: Infowin Plus

    Operation PLUS 2.4 InfoWIN The InfoWIN PLUS unit is the indicator and operation panel on the boiler. The InfoWIN PLUS unit consists of a large text display, an ON/OFF button with an LED signal lamp indicating Operation (green), a button for manual ope- ration / chimney sweeper function, as well as four individual menu buttons.

  • Page 20: Operating Modes

    Operation 2.5 Operating modes 2.5.1 OFF mode The boiler is turned off when in OFF mode. At this point in time, the display and all buttons, with the exception of the ON/OFF button, will not function. The LED on the PLUS InfoWIN will not light up –...

  • Page 21: Pellet Feed

    Operation 2.5.3 Pellet feed Pellet feed – burnout Pellet feed During burnout, pellet transportation from the storage room into the hopper °F has been requested. Combustion is stopped. Pellet transportation into the burner pot is stopped, and the induced draft (ID) fan continues to run until all the remaining pellets have been burned and the Burnout burner pot has cooled down.

  • Page 22: Manual Operation

    Operation 2.5.4 Manual operation The various operating phases are displayed here, including Burner in operation, Burner OFF, etc. CAUTION: The manual operation mode is used to start the boiler only if heating demand from the external heating Manual operation control system (modular energy system, MES) fails. All Boiler temperature °F heating components (pumps, valves, and mixers) need to be...

  • Page 23: Chimney Sweeper Function

    Operation 2.5.5 Chimney sweeper function The various operating phases are displayed here, including Burner in operation, Burner OFF, etc. This function aids the performance of legally required emis- sions testing. Chimney sweeper func. Power 100% 45 min Note! The chimney sweeper function cannot be started in °F “solid fuel/buffer mode”.

  • Page 24: Operating Phases

    Operation 2.6 Operating phases 2.6.1 Standby Boiler temperature °F During this operating phase, the controls do not transmit requests for heat. The burner is turned off and the boiler temperature setpoint is 32 °F / 0 °C. After an hour in standby mode, the display is turned off, and only the green LED Standby light remains activated.

  • Page 25: Information Text

    Operation 2.7 Information text Boiler temperature °F Pressing the Info button or accessing the information level menu displays the most important boiler information – (Operating phases) Fig. 28. Info Menu The arrow buttons select and display sub-menus – Fig. 29. Pressing the back button (Fig.

  • Page 26: Operating Hours

    Fig. 35 2.7.7 Switch/buffer temperature Switch/buffer temperature °F The switch/buffer temperature is not displayed for an individual BioWIN XL boiler. The current switch/buffer temperature is only displayed for a BioWIN XL cascade (system with 2 or 3 BioWINs). back Fig. 36...

  • Page 27: Display Module Software Version

    With an individual BioWIN XL boiler, the boiler model is always displayed and 0 Boiler is always displayed as the boiler. With a BioWIN XL cascade (system with 2 or 3 BioWINs), the boiler model and the number of the pellet boiler are displayed (only when MESplus KAS+ is used). back Fig.

  • Page 28: Menu Guide

    Operation 2.8 Menu guide Boiler temperature °F Press the Menu button to change the menu display to the Operator level, Service level, Information level, or to MES (Operating phases) Module – Fig. 41. Info Menu Use the arrow buttons to select the Operator level, Service level, or Information level (Fig.

  • Page 29: Menu Structure

    Operation Menu structure: Menu Service level MES Module Operator level Information level (reserved for trained ser- (see separate instructions for (see chapter 2.7) (see chapter 2.8.1) vice personnel only) PLUS InfoWIN Master operation) Next boiler Total pellet Boiler temperature Switch/buffer Software version cleaning consumption...

  • Page 30: Operator Level

    Operation 2.8.1 Operator level Boiler temperature °F Press the Menu button to show the “Operator level,“ “Ser- vice level,“ “Information level,“ and “MES Module “ on the display – Fig. 45. (Operating phases) Info Menu Fig. 45 Use the arrow buttons to select “Operator level,” and use Operator level the choose button to confirm the choice –...
  • Page 31 Operation 2.8.1.1 Boiler cleaning – resetting the cleaning Boiler temperature request °F The user must confirm that boiler cleaning has been per- formed (section 3), so that the operating time until the next (Operating phases) boiler cleaning is reset. Lighting ON If cleaning has not been performed, operating time INFORMATION...
  • Page 32 Operation Confirm the selected “Boiler cleaning” sub-menu by pres- Boiler cleaning sing the choose button – Fig. 53. Time Feed operating mode Time profile feed Probe switching choose back Fig. 53 Reset the boiler cleaning by pressing the Yes button – Has boiler and Fig.

  • Page 33: Time Setting

    °F This setting is used to control timing of the pellet feed and automatic heating surface cleaning. If the BioWIN XL is operated with an MESplus control, the (Operating phases) time is automatically adopted from the module and the time Lighting ON set here is overwritten.
  • Page 34 Operation Confirm the selected sub-menu “Time” by pressing the Boiler cleaning choose button – Fig. 61. Time Feed operating mode Time profile feed Probe switching choose back Fig. 61 Use the + or – button to set the required time – Fig. 62. Time 13:50 –...
  • Page 35 Operation 2.8.1.3 Feed operating mode Boiler temperature °F This menu option sets: – whether the feed is turned off, or – whether the feed should fill the pellet boiler with or (Operating phases) with out time control. Lighting ON Turn on the lighting and display by pressing one of the six buttons –...
  • Page 36 Switched off Burning duration with 264.4 lb / 120 kg pellets choose back BioWIN XL Burning duration at nominal output BWE 350 NA 15 h BWE 450 NA 12 h BWE 600 NA Fig.
  • Page 37 Operation 2.8.1.4 Time profile feed Boiler temperature °F The “Time profile feed” menu option displays the corre- sponding setting option, depending on the setting in the “Feed operating mode” menu option (see section 2.8.1.3). (Operating phases) Setting: “With enable time” – see page 38 Lighting ON Setting: “With start time”...
  • Page 38 Operation Confirm the selected sub-menu “Time profile feed” by Boiler cleaning pressing the choose button – Fig. 79. Time Feed operating mode Time profile feed Probe switching choose back Fig. 79 “With enable time” Feed with enable time Start 07:00 am The start and end of the enable time frame can be set in the 10:00 pm “Time profile feed”...
  • Page 39 Operation Confirm the changed time by pressing the save button – Feed with enable time Fig. 83. Start 07:30 am 10:00 pm The display will show “Parameter is saved” for a few se- conds (Fig. 84) and then return to the previous screen – Fig.
  • Page 40 Operation “With start time” Feed start time Start 10:00 pm A time for filling the hopper can be set in the “Time profile feed” menu, if the “With start time” setting is active in the “Feed operating mode” menu (see section 2.8.1.3). The hopper is filled every day at the specified time.
  • Page 41 “Type of pellet feed system“ menu. Only trained service personnel may perform system modifications on the service level. (Directions for these settings can be found in the BioWIN XL installation in- INFORMATION...
  • Page 42 Operation Turn on the lighting and display by pressing one of the six Boiler temperature buttons – Fig. 91. °F (Operating phases) Lighting ON Fig. 91 Press the Menu button – Fig. 92. Boiler temperature °F (Operating phases) Info Menu Fig.
  • Page 43 Operation Confirm the selected “Probe switching” sub-menu by pres- Boiler cleaning sing the choose button – Fig. 95. Time Feed operating mode Time profile feed Probe switching choose back Fig. 95 Use the arrow buttons to select the probe switching (for op- Probe switching tions, see table on page 41) –...

  • Page 44: Service Level

    Only trained service per- sonnel may perform system modifications on the Service WARNING level. (Directions for these settings can be found in the BioWIN XL installation inst- Fig. 100 ructions) Service level only for trained service personnel 5sec Fig. 101...

  • Page 45: Heating System Operation

    The signal lamp will turn green and a self-test will be performed at this time (see chapter 2.5.2). After a successful self-test (and if a setpoint is communicated by the external system control), the BioWIN XL automatically starts operation. PLUS...

  • Page 46: Care, Cleaning, And Maintenance

    Do not enter smoke-filled rooms to disconnect power. 3.1 Overview of intervals between cleaning (maintenance) The BioWIN XL is equipped with a cleaning and ash removal interval display. The “Clean boiler and burner” request is PLUS displayed on the InfoWIN and must be reset after cleaning/ash removal is completed –...

  • Page 47: Cleaning And Operating Implements

    Care, Cleaning, and Maintenance 3.2 Cleaning and operating implements Supplied as standard: 1 ... Folder containing instructions 2 ... Cleaning brush 3 ... Spatula 4 ... Key for opening cladding doors 5 ... Down chute cleaning tool 6 ... Hanger (for installation on the wall) 7 ...
  • Page 48 PLUS – Using the ON/OFF button on the InfoWIN , turn off the BioWIN XL (Fig. 105) and wait until the display has gone out. – Open the cladding door on the left. To do this, turn the key a quarter turn to the right to unlock the door –...
  • Page 49 Care, Cleaning, and Maintenance Assembly: – Replace container by completing these steps in reverse order. Important: Ensure that the ash container handle is slid back completely. When reinstalling the ash container and cover, ensure that they are in the correct INFORMATION position and are airtight.

  • Page 50: Cleaning The Combustion Chamber, Thermocontrol Sensor

    PLUS – Using the ON/OFF button on the InfoWIN , turn off the BioWIN XL (Fig. 112) and wait until the display has gone out. – Open the cladding door on the right. To do this, turn the key a quarter turn to the left to unlock the door –...

  • Page 51: Burner Pot

    – see chapter 2.8.1.1. – Lift out the cone [2, 3] and ash wedge [4, with BioWIN XL 350 NA only] – Fig. 120–Fig. 123. – Remove deposits from these parts with a cleaning brush or spatula. The secondary air holes in the cone must be clear, clean them with a small screwdriver or drill bit if necessary.
  • Page 52 Important: Groove must engage in anti-twist device – Fig. 124. – Place the cone in the burner pot. – Fit the ash wedge (BioWIN XL 350 NA only) on the burner pot in the right-hand corner, making sure the limit stop is behind the screw head – Fig. 120.

  • Page 53: Induced Draft Fan (Id Fan), Fan Box

    PLUS – Before disconnecting the power supply, turn off the BioWIN XL using the ON/OFF button on the InfoWIN (Fig. 125) and wait until the display has gone out. – Remove the cladding cover – Fig. 126.

  • Page 54: Vacuum Ash Chamber Under Coasting Surfaces

    – Insert the cladding cover at rear into fastener. 3.7 Vacuum ash chamber under coasting surfaces The ash chamber is automatically checked and cleaned as part of the annual maintenance by Windhager Customer Service or the customer service partner. – Turn off the BioWIN XL with the ON/OFF button on the InfoWIN PLUS (Fig.

  • Page 55: Cleaning The Integral Fuel Hoppers, Coarse Filter, And Fill Level Switches

    The integral fuel hopper / coarse filter and fill level switches have to be cleaned if too much dust has collected. Cleaning and inspection: PLUS – Switch off the BioWIN XL with the ON/OFF button on the InfoWIN (Fig. 134) and wait until the display has gone out.

  • Page 56: Pellet Storage Room Or Storage Hopper

    Care, Cleaning, and Maintenance Fill level switch Fig. 139 Removing dust from the bottom fill level switch Assembly: To assemble, complete these steps in reverse. All following instructions in this chapter must be completed by trained service WARNING personnel only! 3.10 Pellet storage room or storage hopper/bulk hopper Please also note the hazard information in section 1.7.3 ”Entering the pellet sto- WARNING...
  • Page 57 Care, Cleaning, and Maintenance Filling should only be completed under conditions specified by boiler/heater and WARNING pellet suppliers. WARNING Protect wood pellets from moisture. WARNING Pellet dust may contain harmful substances - use a fine dust mask when handling. When entering the pellet storage room or storage hopper/bulk hopper, do not INFORMATION stand on the pellets surrounding the suction probe.

  • Page 58: Troubleshooting

    Fig. 140 Fig. 141 If you wish to call Windhager Customer Service or your customer service partner due to a malfunction, please first make note of the following data from the rating plate: – Model – Factory number –...

  • Page 59: No Display On Infowin

    The boiler is in operation. Monitoring of auger conveyor def. FE 206 Press the Reset button. If the fault reoccurs after a reset, inform Windhager Press reset. Customer Service or a heating technician. Motor for heating surface cleaning no longer moves or no longer reaches the end position, boiler is in operation.
  • Page 60 Code Display on InfoWIN Cause/remedy Pellets are not able to feed into boiler. The boiler does not operate. Press the Reset button. If the fault recurs after a reset, inform Windhager Probe switching defective Customer Service or a heating technician.

  • Page 61: Alarm Messages

    Press the Reset button. If the fault reoccurs after a reset, Heating surf. cleaning defective a) Heating surfaces very dirty - clean – inform Windhager Customer Service AL 008 or a heating technician.
  • Page 62 Check the boiler sensor and connections. Service or a heating technician. Press Reset. b) Replace the boiler sensor; inform Windhager Customer Service or a hea- ting technician. The boiler switches to burnout mode a) Thermocontrol sensor is too cold (<32 °F / 0 °C). Allow sensor to warm up.
  • Page 63 Device fuse F2-5 AT Device fuse F3-12.5 AT Cover of safety thermostat auger tube Fig. 143 BioWIN XL control panel cladding raised, combustion chamber door open PLUS Code Display on InfoWIN Cause/remedy Boiler enters burnout mode and transports pellets into combustion chamber.

  • Page 64: Spare Parts

    Spare parts 5.1 3-way changeover unit, shut-off unit, suction probes, fire protection collars Spare part designation Spare part no. Cover disc for fire protection - PMX042 and BIO021 042444 Cover disc with entry - BIO020 045982 Retaining bracket 046284 Bolt for mounting 006927 Fire protection collars (2x) for 3-way changeover unit –...

  • Page 65: Suction Turbine

    5.2 Suction turbine Spare part designation BioWIN XL Top feed cover 009892 Bottom feed cover 009893 Collar screw M4 x 23 003980 Turbine attachment 045022 Wago terminal block attachment 045016 Seal section 044667 Terminal bar MS 8-pin 009929 Blower motor...

  • Page 66: Thermal Discharge Safeguard

    5.3 Thermal discharge safeguard Spare part designation BioWIN XL Spring 010835 Piston complete with seal 010841 Screw cap complete with O-ring 010843 Compression gland unit 010837 Immersion sleeve 010838 Temperature sensor complete 010842 Valve complete 009162...

  • Page 67: Biowin Xl Pellet Central Heating Boiler

    Spare parts 5.4 BioWIN XL pellet central heating boiler 1210 1180 1170 1130 1145 1150 1110 1135 1010 1120 1160 1110 1040 1030 1000 1120 1200 1190 1020 1050 1240 1140 1070 1060 1080 1090 1250 1100...
  • Page 68 BioWIN XL pellet central heating boiler Spare part designation BioWIN XL Spare part designation BioWIN XL Motor cover plate 047423 Blower cover 047989 Insulating stone cover 047156 Blower wheel 047354 Axle for ash container 043523 Gear motor for auger 044664...
  • Page 69 BioWIN XL pellet central heating boiler Spare part designation BioWIN XL Spare part designation BioWIN XL Bottom cleaning profile 047065 Locking nut M8 016553 Cleaning scraper for downpipe 048123 Baffle rod 047652 Cleaning auger 047059 Dust separator for integral fuel hopper...
  • Page 70 BioWIN XL Burner...
  • Page 71 BioWIN XL Burner Spare part designation BioWIN XL Spare part designation BioWIN XL Ash removal cover 046713 Hexagon screw M10x20 020060 Scraper 047960 Hexagon screw M10x35 016712 Front ash agitator 047496 Hexagon screw M5x12 031545 Microswitch retainer 047983 Hexagon screw M6x12, grooving...
  • Page 72 BioWIN XL Cladding Not illustrated: Pos. 390, 430, 500...
  • Page 73 BioWIN XL Cladding Spare part designation BioWIN XL Spare part designation BioWIN XL Burner cover plate 047567 Pellet container right side panel 047594 Rear wall cover plate 047551 Right side panel 048188 Door cover plate 047342 Left side panel 051431...
  • Page 74 BioWIN XL Control Panel Not illustrated: Pos. 345...
  • Page 75 BioWIN XL Control Panel Spare part designation BioWIN XL Spare part designation BioWIN XL Collar screw M4x11, 8mm 016006 Locking arm for control panel 043808 Display and operating module (InfoWIN) 011985 Wago terminal block, 11-pin, orange (extra-low voltage), 040926 Bolt, DIN 1445 - 8h11 x 4 x 10 - St - galvanised...
  • Page 76 Austria Windhager Zentralheizung GmbH Anton-Windhager-Straße 20 A-5201 Seekirchen bei Salzburg T. +43 (0) 62 12/23 41-0 F. +43 (0) 62 12/42 28 info@at.windhager.com www.windhager.com Subject to technical modifications. AWP-vor...

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