Windhager BioWin 2 Assembly Instruction Manual
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Windhager BioWin 2 Assembly Instruction Manual

Pellet central heating boiler
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PELLETS

Assembly instructions

BioWIN 2
Pellet central heating boiler
Output range: 3 to 25,9 kW
07/2014
093403/01

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Summary of Contents for Windhager BioWin 2

  • Page 1: Assembly Instructions

    PELLETS Assembly instructions BioWIN 2 Pellet central heating boiler Output range: 3 to 25,9 kW 07/2014 093403/01...

  • Page 2: Table Of Contents

    2.4.14 Assembly of the feed and return line (BioWIN 2 Premium/Exklusiv only) ......
  • Page 3 6.3 BioWIN 2 connecting diagram changeover unit ..........54 6.4 BioWIN 2 pellet feed connecting diagram with mixer for buried tank ......55 6.5 Circuit diagram for BioWIN 2 pellet feed with 1-probe suction solution .

  • Page 4: Important Initial Information For The Technician

    Important initial information for the Technician Important initial information for the Technician 1.1 Safety precautions The boiler and related accessories are state of the art and meet all applicable safety regulations. Your boiler and all accessories operate using 230 V AC electric current. Improper installation or repair can pose the danger of life-threatening electric shock.

  • Page 5: Boiler Room/Installation Room

    These max. values require a stable power supply (min. 220 V under load!) The BioWIN 2 can be operated with 1 probe (Fig. 2), 2–3 probes (Fig. 3) or with up to 8 probes (Fig. 4). Max. distance of 25 m between furthest away probe and pellet boiler with max. total height difference of 1.8 m Max.
  • Page 6 Important initial information for the Technician BioWIN 2 102–262 (1 probe): BioWIN 2 10–26 kW Storage room Boiler room Suction turbine Fig. 2 Storage room, Boiler room – view from above Information! For storage rooms smaller than 2 m² without a sloping floor, for storage rooms between 2 and 4 m² with a sloping floor.

  • Page 7: Initial Start-Up And Operating Instructions

    1.5 Initial start-up and operating instructions Windhager Customer Service or the customer service partner will start up the boiler first of all, and will familia- rize the customer with the system operation and cleaning of the boiler, with reference to the Operating Manual.

  • Page 8: For The Installer

    When delivered, the boiler and reserve supply container are covered in a plastic bag and packed inside a stable crate. Cladding and installation parts are in 2 or 3 separate boxes. Cleaning devices are packed inside the boiler. Fig. 5 Scope of delivery of BioWIN 2 Transport weight including crate/packaging Klassik Premium...

  • Page 9: System

    2.2.3 Heating circuits A motorised mixing valve is always required for the BioWIN 2 in order to protect the boiler and one must be fitted in each heating circuit. A feed contact thermostat (FK-001) must be installed for underfloor circuits.

  • Page 10: Operating With External Control

    If antifreeze is used, a minimum volume of 25 % antifreeze is required, otherwise corrosion prevention is not guaranteed. 2.2.9 Water-side resistance (pressure loss) 1000 BioWIN 2 102–262 1000 10000 Diagramm 1 Water-side resistance - BioWIN 2 102–262...

  • Page 11: Combustion Air

    For the Installer 2.3 Combustion air An adequate supply of combustion air is absolutely essential. The combustion air must be free from pollutants (gases, vapours and dusts), otherwise malfunctions and increased wear (e.g. corrosion) may occur. Information! Malfunctions or complaints occasioned by inadequate combustion air will not be covered by the guarantee! 2.3.1 Operating with room air Combustion air supply directly from the installation room The combustion air is drawn directly by the device from the installation room, therefore the installation room has...

  • Page 12: Installation Sequence

    15 ..Cover for reserve supply container 16 ..Cover below for reserve supply container below (only in BioWIN 2 Klassik / Premium) 17 ..Ash box base (only BioWIN 2 Exklusiv) 18 ..Ash box (only BioWIN 2 Exklusiv) Reserve supply container L 200 kg: 19 ..

  • Page 13: Taking Into The Building And Installing

    For the Installer 2.4.2 Taking into the building and installing It is best to transport the boiler and reserve supply container to the place of installation inside the crate. If transporting via stairs etc., the boiler should be secured as is appropriate. For installation dimensions and weights –...
  • Page 14 For the Installer 2.4.2.2 Take the boiler off the installation pallet and transport it where it is to be installed a) by hand – Fig. 9–12. b) with hand cart and tension belt – Fig. 13-14. c) with eyelet and crane (not included in scope of delivery) – Fig. 15-16. a) by hand Fig.

  • Page 15: Installation (Observe Minimum Clearances! - Section 2.4.4)

    For the Installer c) with eyelet and crane (not included in scope of delivery) Screw eyelet M12 for the crane hook to the screw connection of the threaded bolt on the coasting surface lid and lift the boiler off the pallet with the crane. Fig.
  • Page 16 For the Installer Hydraulic adapter distributor 1“ See separate, provided installation instructions for the hydraulic adapter distributor 1“ – BIO 061. Fig. 18 Hydraulic adapter distributor 1“ – view from behind without rear panel Align boile Move the boiler into position and use the 4 set screws to align it horizontally or inclined slightly upwards towards the rear.

  • Page 17: Minimum Service Clearances For Fire Protection, Cleaning And Maintenance

    Minimum room height: 1850 mm Flue connection top Minimum clearances when ue connection at the top min. 30 min. 50 min. 30 min. 30 1075 1422 Fig. 20 BioWIN 2 Exklusiv/Premium/Exklusiv-S/Klassik – Fig. 21 BioWIN 2 Exklusiv-SL/Klassik-L – view from above view from above...

  • Page 18: Install The Filling And Evacuation Cock

    50 1075 1422 Fig. 22 BioWIN 2 Exklusiv/Premium/Exklusiv-S/Klassik – Fig. 23 BioWIN 2 Exklusiv-SL/Klassik-L – view from above view from above 2.4.5 Install the filling and evacuation cock – Remove handle from filling and evacuation cock – Fig. 24.

  • Page 19: Changing Flue Connection On The Back

    For the Installer 2.4.6 Changing flue connection on the back On delivery, the flue connection is at the top. The flue connection can be moved to the rear by dismounting the flue gas blower. – Remove insulation from the coasting surfaces cover – Fig. 26. –...

  • Page 20: Mount Reserve Supply Container L (200 Kg)

    For the Installer – Remove the 4 hexagon screws from the inside of the coasting surfaces – Fig. 32. Carefully remove the flue gas blower. Information! The seal between the flue gas blower and the boiler may not be damaged. –...

  • Page 21: Install Reserve Supply Container

    For the Installer 2.4.8 Install reserve supply container – First insert the reserve supply container together with the auger into the auger tube (Fig. 34) and hook into place into the 2 hooks, marked yellow – Fig. 35. – Tighten the fastening screws at the top as securely as possible (marker) – Fig. 36. –...
  • Page 22 For the Installer – Insert sensor for safety thermostat-auger tube into the holder as far as they will go – Fig. 42. – Suspend auger motor at back via lug and at front from centring screw – Fig. 43. – Secure auger motor with 2 M8x 16 screws – Fig. 44. –...

  • Page 23: Reserve Supply Container Cladding

    For the Installer only for BioWIN 2 Premium/Exklusiv i.e. with automatic pellet feed: – Connect the suction turbine plug – Fig. 48. – Remove 3 screws at front of cover from the control panel, and pull out the cable plus grommet from the Info- WIN.
  • Page 24 For the Installer – If the flue connection is at the top, punch out the cut-out on the cladding at top left – Fig. 54. If the flue connec- tion is at the rear, do not punch out. Punch out cladding = flue connection at top Do not punch out cladding = flue connection at rear Information! Carefully insert the cladding, top left, to ensure that the reserve supply container is not scratched...

  • Page 25: Cladding Door And Side Panel

    For the Installer 2.4.10 Cladding door and side panel – Secure bottom of door hinge with 4 self-threading M5 x 10 screws – Fig. 59. – Leave door hinge loose at top as it should be allowed to move and hold in place with 2 self-tapping screws – Fig. 60.

  • Page 26: Infowinplus And Switch Cover

    For the Installer 2.4.11 InfoWINplus and switch cover – Push the InfoWIN cable and grommet into the slot in the control panel cover. Hook rear of cover into place and secure it at front with 3 self-tapping screws – Fig. 65. –...

  • Page 27: Ash Box (Only Biowin 2 Exklusiv) Or Cover Underneath Reserve Supply Container (Only Biowin 2 Klassik/Premium)

    – Fig. 72. – Close the bracket fastener – Fig. 73. – Adjust the ash-box set screw (BioWIN 2 Exklusiv only) on the boiler – Fig. 74. Note! The floor underneath the ash box has to be level. If necessary compensate, e.g. by screwing sheet to floor.

  • Page 28: Assembly Of The Feed And Return Line (Biowin 2 Premium/Exklusiv Only)

    (BioWIN Klassik/Premium only) 2.4.14 Assembly of the feed and return line (BioWIN 2 Premium/Exklusiv only) – Expose approx. 5 cm of the flexible earth leads on all hose ends and bend inwards into the hose – Fig. 76. Important: Also refer to assembly instructions for supply and return air hose in enclosed manual for storage room accessories (changeover unit).

  • Page 29: Cleaning And Operating Implements

    2.4.15 Cleaning and operating implements 1 ... Cleaning brush 2 ... Spatula 3 ... Allen key 4 ... Scrapers (BioWin 2 Klassik and Premium only) 5 ... Pellet pile (accessory for BioWIN 2 Premium/Exklusiv only) 6 ... Folders containing instructions Fig.

  • Page 30: Installing The Exhaust Pipe

    The Induced draught fan can cause sound transmissions that create noise pollution. f) The BioWIN 2 is a low-pressure boiler and this means that the flue gas system needs to meet the „N1“ seal integrity requirement according to EN 1856-1 and EN1856-2. Please ensure a sufficient immersion depth when fitting (e.g.
  • Page 31 For the Installer Fig. 81 Exhaust connection at rear – view from front, (drawing Fig. 82 Exhaust connection at top – view from front, (drawing does does not show exhaust pipe insulation) not show exhaust pipe insulation) Fig. 83 Exhaust connection at rear – view from top, (drawing does Fig.

  • Page 32: For The Electrician

    Fuse T 6.3 A MESplus module Fig. 85 Control panel BioWIN 2 102–262 Information! Electrical cables must not touch heating and exhaust pipes, nor must they come in contact with no- ninsulated boiler components. They are to be sufficiently braced and provided with a protective tube.
  • Page 33 For the Electrician All of the electrical connections are at the top, underneath the control panel cover. On the left of the control panel is the main board; the connection terminals (screwless cage-spring-type terminals) for MESplus control or REG control are on the right – Fig. 92. To access the control panel: –...
  • Page 34 MESplus control or REG control Fig. 92 Open control panel, BioWIN 2 with MESplus control – view from front Fig. 93 Cable feed-throughs in the cladding of the BioWIN 2 – view from rear...

  • Page 35: For The Service Technician

    4.1 Start-up and operating instructions The Windhager Customer Service or Partner Customer Service will start up the boiler and will familiarize the customer with the system operator and cleaning of the boiler. Start-up and maintenance are part of the guarantee requirements of the “Warranty conditions”...

  • Page 36: Service Level

    Display contrast Menu Operator level Information level Service level MES Module Settings on the operator level Reserved for trained service (see BioWIN 2 Operating (see separate instructions for see BioWIN 2 personnel only. InfoWINplus Master operation) Manual) Operating Manual. Parameters...
  • Page 37 For the Service Technician Service level Boiler temperature Pressing the Menu button (Fig. 96) shows the „Opera- °C tor level“, „Service level“, „Information level“ and „MES Module “ in the display – Fig. 97. (Operating phases) Info Menu Fig. 96 Use the arrow buttons to select the “Service level”...

  • Page 38: Parameters

    For the Service Technician Select the required item, „Parameters“, „Start-up“, Parameters „Actuator test“ or „Settings“ and confirm by pressing Start-up the Choose button – Fig. 100. Actuator test Settings For further settings, see sections 4.3.1 - 4.3.4. Choose Back Fig. 100 Parameters The menu item or sub-menu item is exited by pressing Start-up...
  • Page 39 For the Service Technician Fuel quantity auger conveyor Fuel quantity Auger conveyor The calculated fuel quantity (actual value) and the range is displayed in kg/h, Actual value 6.5 kg and can be adjusted. Range 6.5 kg Correction BioWIN BW 102/152 BW 212/262 Choose Back...
  • Page 40 For the Service Technician Operating time of suction turbine Operating time of suction turbine Factory setting: 30 sec. Actual value 30 sec. Einstellbereich: 20 – 70 sec. min. 20 sec. max. 70 sec. Diagram for suction time setting – Save Back by feed hose length and suction height: Fig.
  • Page 41 For the Service Technician Input X14/5 Input X14/5 Flue gas thermostat This adjuster can be used to change the flue gas thermostat function (factory Air intake flap setting) to air intake flap or External combustion air supply. External combustion air supply Factory setting: Flue gas thermostat Choose...

  • Page 42: Start-Up

    For the Service Technician 4.3.2 Start-up The auger conveyor and the feed can be selected on the Start-up level with the arrow buttons, then confirmed or selected using the Choose button. A self-test is started at the end of the start-up. Auger conveyor Start-up Auger conveyor...
  • Page 43 For the Service Technician Install display module Start installation procedure Is not needed with an individual BioWIN 2 boiler, only needs to be used with a Please press LON button on auto- cascade system – see “Planning and assembly” instructions for pellet cascade.

  • Page 44: Installation Of Mesplus Modules

    For the Service Technician Function Function With „Function“ you can change the name (e.g. BioWIN 2) of the boiler. < BioWIN 2 Save Back Fig. 130 4.3.5 Installation of MESplus modules Installation procedure active Display if an MESplus module is installed (connected) or uninstalled (Animated symbol) (disconnected).

  • Page 45: Infowinplus Basic Settings

    For the Service Technician 4.4 InfoWINplus basic settings The basic settings are used to – set whether the InfoWINplus controls a wood or pellet boiler or whether it is solely used as master operation; – switch the master operation functions on and off; –...
  • Page 46 Heating oil Combi boiler Factory setting: is set in the factory before delivery as per the order. Selection: Pellets: BioWIN 2, BioWIN XL, FireWIN, VarioWIN usw. Choose Back Wood: LogWIN, SilvaWIN usw. Fig. 136 Heating oil:...
  • Page 47 For the Service Technician Update Software Update Software MAC-Adresse The update procedure to update the InfoWINplus software via the Ethernet in- 0C-E5-D3-00-00-05 terface is being started. V4.00.00.001 start Back Fig. 141 Update Firmware Update Firmware The update procedure to update the LON Controller firmware is being started. The LON Controller firmware is included in the InfoWINplus software, therefore no external update tool is required.

  • Page 48: Technical Data

    Technical data Technical data 5.1 Technical data for calculating the flue gas system acc. to EN 13384-1 Formula BW 102 BW 152 BW 212 BW 262 BioWIN 2 pellet boiler Unit symbols min. max. min. max. min. max. min. max.

  • Page 49: Technical Data - General

    Technical data 5.2 Technical data – General BioWIN 2 pellet boiler Unit BW 102 BW 152 BW 212 BW 262 Boiler class according to EN 303-5 low-pressure boiler; non-condensing; Operation mode suction fan Fuel type to EN 303-5:2012 allowed Pellet acc. to EN 14961-2 A1 Ø 6 mm, C1...

  • Page 50: Dimensional Sketches

    AH ..flue connection rear ( (Ø 130 mm) EA ..Electrical connections Z ..External combustion air (Ø 100 mm) 1075 Fig. 145 BioWIN 2 Exklusiv/Premium/Exklusiv-S/Klassik – view from above Height when the pellet Reserve supply container lid is open: 1793 mm...
  • Page 51 KT ..Boiler temperature sensor AO ..flue connection top (Ø 130 mm) AH ..flue connection rear ( (Ø 130 mm) EA ..Electrical connections Z ..External combustion air (Ø 100 mm) 1422 Fig. 147 BioWIN 2 Exklusiv-SL/Klassik-L – view from above...

  • Page 52: Electric Connecting Diagrams

    Electric connecting diagrams 6.1 Basic BioWIN 2 Exklusiv/Premium circuitry motor for conveyor screw motor for ash -B7.1 -M2.1 changeover unit removal safety temperature supply -M9.1 limiter boiler 100°C 230V Fuse 6,3 A induced draught -M12.1 motor fan motor ash motor heating removal -M6.1...

  • Page 53: Basic Biowin 2 Klassik Circuitry

    6.2 Basic BioWIN 2 Klassik circuitry motor for conveyor -B7.1 screw safety temperature -M2.1 limiter boiler 100°C supply motor for ash 230V removal Fuse 6,3 A induced draught motor fan -M12.1 -M6.1 -B8.1 conveyor screw 100°C safety temperature limiter -XZF 230V -T2.1...

  • Page 54: Biowin 2 Connecting Diagram Changeover Unit

    6.3 BioWIN 2 connecting diagram changeover unit Two separate cables are needed to connect the changeover unit. – Cable for limit switch (extra-low voltage): min. 3 x 0.5 mm2 (no earth), we recommend using a shielded cable if the cable is longer than 5 m.

  • Page 55: Biowin 2 Pellet Feed Connecting Diagram With Mixer For Buried Tank

    6.4 BioWIN 2 pellet feed connecting 6.5 Circuit diagram for BioWIN 2 pellet diagram with mixer for buried tank feed with 1-probe suction solution Operation with a mixer must be set on the service level – see section 4.3.1 Parame- Operation with a „1-probe suction solution“...

  • Page 56: Connecting Diagram For Air Intake Flap

    6.6 Connecting diagram for air intake flap Operation with a „air intake flap“ must be set in the service level – see section 4.3.1 Parameters; Input X14/5. Air intake flap with limit switch Air intake flap without limit switch -M11.1 -M11.1 20min -K50...

  • Page 57: Connection Plan For Shut-Off Unit (Ext. Combustion Air)

    Operation with a flue gas thermostat must be set on the service level, see section 4.3.1 Parameters; Input X14/5. -M10.1 -S12 -V15.1 -S11.1 -S10.1 FA-BioWIN 2 FA-BioWIN 2 -B7.1 M10.1 ... motor V15.1 ..Flue gas thermostat B2 S10.1 ... limit switch motor S11.1 ... limit switch motor S12 ..

  • Page 58: Connection Plan For Switch For Reserve Supply Container Cover

    6.9 Connection plan for switch for reserve supply container cover EDV NR.: 011990 –P9.1 Lon- Lon+ P9.1 ..Proximity switch - cover 1 ... Black +12V 2 ... Blue Lon- 3 ... Brown Lon+ FA-BioWIN 2 +12V 094770/00...

  • Page 59: Warranty

    Further, the warranty shall be void if equipment other than those provided by Windhager are installed. The special warranty restrictions for your system are available in the “Warranty Conditions”...

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