Windhager BioWIN XL BWE 450 NA Installation Instructions Manual
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Windhager BioWIN XL BWE 450 NA Installation Instructions Manual

Biowin xl series pellet central heating boiler/furnace
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WOOD PELLETS

Installation Instructions

BioWIN XL
Pellet central heating boiler/furnace
Pellet central heating boiler/furnace
03/2015
03/2015
094886/01
094886/01
FOR USE IN CANADA / USA
FOR USE IN CANADA / USA
SAVE THESE INSTRUCTIONS

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  • Page 1: Installation Instructions

    WOOD PELLETS Installation Instructions BioWIN XL Pellet central heating boiler/furnace Pellet central heating boiler/furnace FOR USE IN CANADA / USA FOR USE IN CANADA / USA 03/2015 03/2015 094886/01 094886/01 SAVE THESE INSTRUCTIONS...

  • Page 2: Table Of Contents

    Table of contents Table of contents 1. Important Information for the Technician ........4 1.1 Safety precautions .
  • Page 3 Table of contents 3. For the Electrician ............48 3.1 Electrical connections .

  • Page 4: Important Information For The Technician

    Important Information for the Technician Important Information for the Technician 1.1 Safety precautions The boiler/heater and related accessories are state of the art and meet all applicable safety regulations. Your boiler/heater and all accessories operate using 110–120 V AC electric current. Improper installation or repair can pose a threat of life-threatening electric shock.

  • Page 5: Liability Exclusion

    (e.g., impairment), then the local regulations should be adhered to in any event and the working instruction should not be carried out; WINDHAGER ZENTRALHEIZUNG GMBH, ÖSTERREICH and WINDHAGER ZENTRALHEIZUNG TECHNIK GmbH, ÖSTERREICH do not accept any liability for any injury to persons or damage to property caused by incorrectly following the instructions and/or violating the local safety regulations! Subject to modifications.
  • Page 6 Important Information for the Technician Removing the ash tray can crush and cut. CAUTION Never insert hands between frame of boiler/heater and ash tray when removing the ash tray. Mounting the ash tray can crush and cut. CAUTION Never insert hands between frame of boiler/heater and ash tray when mounting the ash tray.
  • Page 7 Important Information for the Technician Fire hazard. Do not vacuum hot ash - may cause fire in vacuum cleaner. WARNING Prior to vacuuming ash or dirt, wait until unit has shut down completely and has cooled for at least 2 hours. Machine starts automatically.
  • Page 8 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 9 The pellet feed unit is for use with the day hopper only. The feed unit must be braced, anchored, or strapped to avoid falling/shifting during an earthqua- ke. Instructions can be obtained from your local Windhager dealer or wholesaler. DANGER Pellet feed automatic changeover unit: Fire and explosion hazard Fire and explosion hazard can lead to serious injury or death.

  • Page 10: Flue

    Important Information for the Technician 1.2 Flue A properly dimensioned flue is required for the optimal and safe function of this device. The design of the entire flue system must meet local building codes, and all components must meet UL 2523 / UL 103. All relevant data to size a flue properly is listed under“technical data for flue gas calculations.“ Because of the device‘s low minimum flue gas temperature, a moisture and water resistant flue gas system is required.

  • Page 11: Fuel Storage

    Important Information for the Technician – You must comply with the minimum clearances for connections, cleaning and maintenance – see section 2.2 Minimum service clearances. – Sufficient ventilation of the set-up area must be guaranteed - see section 2.4 Combustion air. –...

  • Page 12: For The Installer

    For the Installer For the Installer 2.1 Scope of delivery, packaging 2.1.1 Boiler The boiler is supplied on a wooden pallet covered with a plastic sack – Fig. 3. The cladding parts are in a separate cardboard box. Cleaning tools are packed in the combustion chamber and the ash chamber. In addition, the pellet feed unit is packed in several cardboard boxes.

  • Page 13: System

    For the Installer 2.3 System These boilers/heaters are designed and approved as heat generators for hot water heating systems with permissible flow temperatures of up to 194 °F / 90 °C. The maximum flow temperature is factory-set at 185 °F / 85°C. They may be installed only in sealed systems. 2.3.1 Standards The following UL listed components must be completely unobstructed on the boiler/heater: –...
  • Page 14 For the Installer The heating system must only be filled with fresh, untreated drinking water (pH between 8.2 and 10.0). Observe the information in the table to avoid any problems with the boiler or system. If one or more of the conditions can- not be met, it is recommended to treat the heating water.

  • Page 15: Water-Side Resistance (Pressure Loss)

    For the Installer Important general comments on water quality for existing systems – De-sludge the system. – Rinse the system. – Clean the system with a universal cleaning agent to remove waste material (copper, fiber mass, welding paste). – Carefully rinse the system until the water is clean and free of any impurities. Check the connection tightness of the combustion air supply and extraction.

  • Page 16: Combustion Air

    For the Installer 2.4 Combustion air An adequate supply of combustion air is absolutely essential. The combustion air must be free of pollutants (gases, vapors, and dust), or malfunctions and increased wear (e.g., corrosion) may occur. Malfunctions or complaints occasioned by inadequate combustion air will not be INFORMATION covered by the guarantee! 2.4.1 Operating with room air...
  • Page 17 For the Installer Hearth with flue gas blower to DIN 18897-1 (type FX 42X ) for connection with a pressure-equal air/flue gas system Examples of models: Air/flue system with parallel Air/flue system with concentric supply supply air/flue layout air/flue layout 1 ...

  • Page 18: Installation Sequence

    For the Installer 2.5 Installation sequence a) Transport boiler to installation site and remove transport protection – see section 2.6. b) Fit side integral fuel hopper and cladding – see section 2.7. c) Fit exhaust pipe – see section 2.8. 2.6 Setting up, preparing for installation –...

  • Page 19: Installation

    For the Installer 2.7 Installation The cladding of the BioWIN XL consists of the following parts: Fig. 10 Parts of BioWIN XL 1 ... Rear wall 14 ..Floor plate 2 ... Cladding cover 15 ..Integral fuel hopper support 3 ...
  • Page 20 For the Installer – Fit floor plate (part 14, attached to integral fuel hopper for transport, see Fig. 9) on left side – Fig. 11, Fig. 12. Fig. 11 Attaching the floor plate Fig. 12 Attaching the floor plate – Align the boiler and floor plate with the set screws horizontally or slightly inclined toward the rear – Fig. 13. –...
  • Page 21 For the Installer – Screw auger tube rotary feeder to boiler with 2 hexagon screws (M10 x 20) – Fig. 17, Fig. 18. CAUTION Ensure tight seal between rotary feeder and boiler. M10 x 20 Fig. 17 Mounting auger tube Fig.
  • Page 22 For the Installer – Fit 2 TT screws (M8 x 16) about 1/3 of the way into the side of the integral fuel hopper – Fig. 22. – Fit integral fuel hopper (part 16) with inserted screws into the 2 lugs at the top. Tighten screws – Fig. 23, Fig. 24. –...
  • Page 23 For the Installer – Screw hopper to auger tube flange plate with 6 x M8 U-washers and 6 hexagon screws (M8 x 25) – Fig. 28. CAUTION Ensure tight seal. 6 each of U-washer M8 M8 x 25 Fig. 28 Fitting auger with 6 U-washers and 6 hexagon screws –...
  • Page 24 For the Installer – Fit right side panel (part 4); at bottom, position cut-out in base – Fig. 33. PLUS – Thread InfoWIN cable into side panel as shown in Fig. 34 and press in strain relief. Strain relief PLUS Fig.
  • Page 25 For the Installer – Secure vertical center panel at top with 2 self-tapping screws (Fig. 39) and at bottom with previously removed 2 TT screws (M5 x 12) – Fig. 40. M5 x 12 Fig. 39 Securing center panel at top Fig.
  • Page 26 For the Installer – Remove prefitted TT screw at rear – Fig. 44. Slide side anti-contact protection plate (part 23) into guide slot from the back (Fig. 45) and secure with the previously removed TT screw (M5 x 12) (Fig. 46) and 2 self-tapping screws at the front –...
  • Page 27 For the Installer – Fit rear wall (part 1); secure with 4 self-tapping screws – Fig. 50. – Fit hopper cladding at top right (part 21) – Fig. 51; secure at front and side with 1 self-tapping screw in each case (Fig.
  • Page 28 For the Installer – Remove cladding door cover (part 6) from cladding door; remove 4 self-tapping screws (Fig. 56), push cover back and lift – Fig. 57. Fig. 56 Demounting cladding door cover – Fig. 57 Removing cladding door cover removing screws –...
  • Page 29 For the Installer Fig. 62 Mounting InfoWIN PLUS on cladding door cover – Screw grounding cables to cover (with saw tooth ring between cover and ground) (Fig. 63) and connect 4-pin PLUS plug for InfoWIN cable (5-pin plug remains unconnected)– Fig. 64. PLUS Fig.
  • Page 30 For the Installer – Place the cone in the burner pot – Fig. 66. – 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. 67. BioWIN XL 350 NA BioWIN XL 450 NA / 600 NA Ash wedge...
  • Page 31 For the Installer – Slide in the ash container – Fig. 71. – Push the ash container slightly to the right and slide the handle all the way in – Fig. 72. Fig. 71 Sliding in the ash container Fig. 72 Pressing the container slightly to the right and sliding the handle all the way in –...
  • Page 32 For the Installer - Mount intake fitting (part 3) on rear of boiler with 4 self-tapping screws and connect both pressure hoses – Fig. 76. Set the orifice in the intake fitting to the value set on the sticker (0–7). To do this, unfasten 2 screws, turn the orifice (orifice fully open = 0) and retighten the screws –...

  • Page 33: Installing The Exhaust Pipe

    EN 1856-1 and EN1856-2. Please ensure a sufficient immersion depth when fitting (e.g., when using Windhager stainless steel flue systems). g) The entire exhaust line (particularly after 3.28 ft / 1 m length) should be insulated in order to prevent or minimise condensation.

  • Page 34: Installation Instructions For 3-Way Changeover Unit, Suction Probes, Suction Turbine

    For the Installer 2.10 Installation instructions for 3-way changeover unit, suction probes, suction turbine 2.10.1 Scope of delivery, packaging Automatic changeover unit with cover plate, 3x suction probes – BIO 020 Part Quantity Designation M8 x 30 hexagon screw M8 x 30 brass dowel 05/2010 007057/01 U-washers 8...

  • Page 35: Notes On Installing The Suction Probes

    For the Installer 2.10.2 Notes on installing the suction probes For information on installing the suction probes in a sheet steel tank or fabric tank, INFORMATION refer to the installation instructions for sheet steel and fabric tanks. To achieve even emptying of pellets, arrange the suction probes so they are evenly and appropriately spaced for the size of the pellet storage room.

  • Page 36: Notes On Installing The Supply And Return Air Hoses

    For the Installer 2.10.3 Notes on installing the supply and return air hoses 2.10.3.1 Maximum transport length and height for pellet feed system Max. distance of 82 ft / 25 m between furthest probe and pellet boiler/heater with max. total height difference of 5.9 ft / 1.8 m Max.
  • Page 37 The pellet feed unit is for use with the day hopper only. The feed unit must be braced, anchored, or strapped to avoid falling/shifting during an earthqua- ke. Instructions can be obtained from your local Windhager dealer or wholesaler. DANGER Pellet feed automatic changeover unit: Fire and explosion hazard Fire and explosion hazard can lead to serious injury or death.

  • Page 38: Notes On Installing The Changeover Unit

    For the Installer 2.10.4 Notes on installing the changeover unit Some states/cities may require a fire stop between the bulk wood pellet hopper (main wood pellet storage) and the room where the appliance is installed (mechanical room). If your state/city requires this, follow your local building codes to install a proper fire stop.

  • Page 39: Installation 3-Way Changeover Unit, Suction Probes

    For the Installer 2.10.5 Installation 3-way changeover unit, suction probes Path of pellets The pellets move from probes A1, A2, and A3 through the corresponding cover plate holes A1, A2, and A3, to the rear of the changeover unit (A). They then pass through the front of the changeover unit (A) to the pellet boiler (A). Path of return air The return air follows a path from the pellet boiler (C) to the suction turbine (C) and from the suction turbine (B) to the front of the changeover unit (B).
  • Page 40 For the Installer 2. Fit cover plate inside storage room – Drill 4 mounting holes 0.31 inch / 8 mm in diameter. – Insert 4 x F8 screw anchors – Temporarily screw down the cover plate with four 6 x 50 hexagon head wood screws and U-washers 6 [large diameter] –...
  • Page 41 For the Installer 4. Mounting the changeover unit To make fitting the hoses easier, the changeover unit should be at the same height INFORMATION as the hoses (wooden boards or similar items can be laid underneath). – Drill holes for metal dowels 0.39 inch / 10 mm in diameter and insert brass dowels. Please note! The changeover unit should be attached only with the brass dowels provided.
  • Page 42 For the Installer 5. Fill masonry feed-through with mineral wool – Unscrew the cover plate in the storage room, and fill the masonry feed-through with mineral wool – Fig. 94. – Securely screw down the cover plate inside the storage room – Fig. 95. Fig.
  • Page 43 For the Installer 7. Trim the delivery hose to the appropriate length and lay inside plastic tubes We recommend that the hoses be laid in plastic tubes secured with clips – Fig. 97. INFORMATION – The hoses must be long enough at the changeover unit end, and must not be tightly fixed (hoses turn 180°). Maintain the required distance and hose length from the first fastening point –...

  • Page 44: Installation Suction Turbine

    For the Installer 2.10.6 Installation suction turbine 2.10.6.1 Scope of supply 1x ..suction turbine 2x ..screws 8 x 60 2x ..U-washer 8 2x ..dowel 10 Fig. 101 Suction turbine with installation accessories 2.10.6.2 Suction turbine The hose connection (3) to the changeover unit can be turned through up to 180° to the other side. To do this, rota- te the top cover (1) clockwise and lift up and off.
  • Page 45 For the Installer 2.10.6.3 Installation sequence The suction turbine must be in the same room as the pellet boiler. The distance between the BioWIN XL and the suction turbine must not exceed 9.8 ft / 3 m. 1. Drill 2 holes in the masonry as shown in Fig. 103. 2.

  • Page 46: Affixing Stickers

    For the Installer Fig. 105 Connecting the delivery and return hoses Fig. 106 Making the electrical connection 2.10.7 Affixing stickers Affix the enclosed yellow ”Wood pellet storage room“ sticker and white ”Filling date and volume“ sticker on the pellet storage room door. Every time the storage room is filled, record the date and volume on the ”Filling date and volume“...

  • Page 47: Initial Commissioning And Operating Instructions

    For the Installer 2.11 Initial commissioning and operating instructions 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 commissioning.

  • Page 48: For The Electrician

    For the Electrician For the Electrician 3.1 Electrical connections The boiler/heater and related accessories are designed to be installed in dry areas only (protection type IP 10). Installation of electrical components may only be performed by a qualified technician. The regulations and specifications of local ordinances must be followed.

  • Page 49: Opening And Closing The Control Panel

    For the Electrician 3.1.1 Opening and closing the control panel – Loosen 1 screw on top of control panel cover and take off cover – Fig. 110. – Fold up control panel top until it engages in lock at side – Fig. 111. Control panel top part Lock...

  • Page 50: Electrical Connection For Power Supply 110 V Ac, External Control, Changeover Unit, Suction Turbine

    For the Electrician 3.1.3 Electrical connection for Power supply 110 V AC, external control, changeover unit, suction turbine 3.1.3.1 Power supply 110 V AC – We recommend using fine-wire PVC sheathed cables, e.g. 3 x AWG 15 nominal cross-section. Information! Be sure to note the separate wiring of the extra-low voltage line (sensor) and low-voltage line (110-120 V AC)! –...
  • Page 51 For the Electrician 3.1.3.3 Changeover unit, suction turbine Note! Each cable must be routed separately together with the delivery and return air hoses. The cables can be routed together with the hoses through the fire protection collars to the suction turbine or to the changeover unit.

  • Page 52: For The Service Technician

    For the Service Technician 4.1 Start-up and operating instructions The Windhager Customer Service or customer service partner will start the boiler/heater and familiarize the customer with the system operations and cleaning procedures. Start-up and maintenance are part of the guaran- tee requirements of the “guarantee limitations”...

  • Page 53: Service Level

    For the Service Technician 4.4 Service level System parameters, start-up tests, or actuator tests can be displayed, modified and/or performed on the Service level. Only trained service personnel may perform system modifications on the Service WARNING level. Structure on the Service level: Language selection Boiler InfoWIN...
  • Page 54 For the Service Technician Service level Boiler temperature Press the Menu button (Fig. 117) to show the “Operator le- °F vel”, “Service level”, “Information level”, and “MES Module” on the display – Fig. 118. (Operating phases) Info Menu Fig. 117 Use the arrow buttons to select “Service level”...
  • Page 55 For the Service Technician Select the required item: “Parameters”, “Start-up”, “Actua- Parameters tor test” or “Settings.“ Use the choose button to confirm the Start-up choice – Fig. 121. Actuator test Settings For further settings, see chapters 4.4.1 – 4.4.4. choose back Fig.

  • Page 56: Parameters

    For the Service Technician 4.4.1 Parameters Use the arrow buttons to select the following parameters. Use the choose button to confirm the choice. – Number of burner starts – Fuel quantity auger conveyor – Delivery time ignition phase – Hysteresis Burner ON –...
  • Page 57 For the Service Technician Maximum value of set temperature Maximum value of set temperature This is the maximum setpoint achievable in normal heating operation. Actual value 167°F min. 140 °F Factory setting: 167 °F / 75 °C max. 185 °F Setting range: 140 –...
  • Page 58 For the Service Technician Correction of cleaning interval Correction of Cleaning interval Actual value The cleaning interval is dependent both on the ash removal profile, and on the min. -50 % proportion of ash in the pellets. This setting can be used to extend or shorten max.

  • Page 59: Start-Up

    For the Service Technician 4.4.2 Start-up The auger conveyor and the feed can be selected on the Start-up level with the arrow buttons, and confirmed using the choose button. A self-test is started at the end of the start-up. Auger conveyor Start-up Auger conveyor The auger conveyor can be turned on for 6 minutes.
  • Page 60 For the Service Technician Boiler no Boiler no If a individual boiler is not required, a number must be assigned to each heat generator (boiler) in a cascade system (only when MESplus KAS+ module is used). Factory setting: – save back Selection: 0 to 4...

  • Page 61: Installation Of Mes

    For the Service Technician PLUS 4.4.5 Installation of MES modules Installation procedure active Display if an MESplus module is installed (connected) or uninstalled (Animated symbol) (disconnected). Fig. 151 PLUS 4.5 InfoWIN basic settings The basic settings are used to: – set whether the InfoWIN PLUS controls a wood or pellet boiler/heater, or if it is solely used for master operation;...
  • Page 62 For the Service Technician Language selection Language selection Deutsch PLUS The InfoWIN can show the display texts in various languages. The language English required can be selected in this sub-menu. Française Italiano Dansk save back Fig. 155 Boiler Boiler Pellets PLUS Setting to determine what kind of boiler/heater the InfoWIN controls, e.g.
  • Page 63 For the Service Technician Update Software Update Software MAC-Adresse PLUS The update procedure to update the InfoWIN software via the Ethernet in- 0C-E5-D3-00-00-05 terface is being started. V4.00.00.001 start back Fig. 161 Update Firmware Update Firmware The update procedure to update the LON Controller firmware is being started. The LON Controller firmware is included in the InfoWIN PLUS software, therefore...

  • Page 64: Technical Data

    Technical Data Technical Data 5.1 Technical data for calculating the flue gas system acc. to EN 13384-1 BWE 350 NA BWE 450 NA BWE 600 NA Formula BioWIN XL pellet boiler Unit symbols min. max. min. max. min. max. kBTU 34.1 119.4 46.1...

  • Page 65: Dimensional Sketches

    Technical Data 5.3 Dimensional sketches All dimensions in inches / mm: Front view Side view 1,46in 37mm 62,32in 1583mm 57,99in 1473mm 55,12in 1400mm 54,72in 1390mm 53,27in 1353mm 50,39in 1280mm 27,3in 693mm 3,78in 96mm 6,69in 170mm Fig. 164 BioWIN XL pellet boiler KV ..

  • Page 66: Electric Connecting Diagrams

    Electric Connecting Diagrams 6.1 Basic BioWIN XL circuitry safety temperature motor for conveyor limiter screw boiler 100°C -M2.1 motor for ash removal -M0c -M12.1 -B8.1 induced draught motor fan motor heating motor ash surface cleaning removal -M1.1 -M4.1 230V 230V 500VA rotation monitor 110V...

  • Page 67: Biowin Xl Connection Diagram

    6.2 BioWIN XL connection diagram low voltage 110V - 120V/60Hz low voltage 230 VAC extra low voltage 12V suction turbine LWCO emergency heating off switch 110V - 120V 110V - 120V changeover unit -M12.1 changeover unit -M9.1 motor external internal connecting terminal ZSP 4630-SO not used...

  • Page 68: Connection Diagram For External Controllers

    6.3 Connection diagram for external controllers -XE 8 external heat demand conn. diagram/1.7B -XE 9 external heat demand conn. diagram/1.7B Heating Zone Controller -XE 10 L Transfer/ boiler circuit pump conn. diagram/1.3B Transfer/ boiler circuit pump max. rated 200W heat demand -P3.1 -XE 11 N Transfer/ boiler circuit pump conn.

  • Page 69: Biowin Xl Pellet Feed Connection Diagram With Mixer For Buried Tank

    6.4 BioWIN XL pellet feed connection diagram with mixer for buried tank Operation with a mixer must be set on the service level – see section 4.6.1 Parameters; Type of pellet feed system. Connection for buried tank mixer suction turbine 110 - 120 V -M12.1 -Mx.1...

  • Page 70: Connection Diagram For Air Intake/Exhaust Flap

    6.5 Connection diagram for air intake/exhaust flap The air intake/exhaust flap is directly connected to the main PCB (see basic circuit diagram 4.8) at plugs X4 (motor) and X14 (limit switch). See section 4.6.1 Para- meters; Flue gas thermostat or Air intake flap.

  • Page 71: Connection Diagram For Flue Gas Thermostat

    6.6 Connection diagram for flue gas thermostat The flue gas thermostat is directly connected to the main PCB (see basic circuit diagram 4.8) at plugs X4 (motor) and X14 (limit switch). See section 4.6.1 Parame- ters; Flue gas thermostat or Air intake flap.
  • Page 72 Austria Windhager Zentralheizung GmbH Anton-Windhager-Straße 20 A-5201 Seekirchen bei Salzburg T. +43(0)6212/2341-0 F. +43(0)6212/4228 info@at.windhager.com www.windhager.com Subject to technical modifications. AWP-vor...

This manual is also suitable for:

Biowin xl bwe 350 naBiowin xl bwe 600 na

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