Windhager BioWIN XL Operating Manual Download Page 1

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WOOD PELLETS

Operating Manual

BioWIN XL

FOR USE IN CANADA / USA

WOOD PELLETS

Operating Manual

FOR USE IN CANADA / USA

Pellet central heating boiler/furnace

03/2015

094885/01

SAVE THESE MANUAL

Summary of Contents for BioWIN XL

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

Page 2: ...hopper 9 1 7 4 Caution symbols 10 1 7 5 Safety instructions 10 2 Operation 16 2 1 Functional description 16 2 1 1 Functional elements and operating controls 17 2 2 Check before commissioning 18 2 3 Fi...

Page 3: ...3 Care of cladding and keyboard foil 47 3 4 Emptying ash container 47 3 5 Cleaning the combustion chamber thermocontrol sensor 50 3 5 1 Burner pot 51 3 6 Induced draft fan ID fan fan box 53 3 7 Vacuum...

Page 4: ...d on the boiler DANGER Please follow the safety instructions symbols on the machine Please refer to the instructions in chapter 1 6 DANGER Ignoring the warnings identified can lead to personal injury...

Page 5: ...en who have physical or mental disabilities or sensory impairment or who have no experience or knowledge of the correct use of the unit unless supervised or trained by a person responsible for their s...

Page 6: ...in pellet quality cannot be remedied as part of a repair under guarantee The use of lower quality pellets will lead to malfunctions increasing the need for service It will also lead to the loss of war...

Page 7: ...commissioning 1 Boiler installed correctly 2 System fully electrically wired 3 System rinsed filled and vented heat consumption must be possible 4 Boiler must be properly connected to the heating syst...

Page 8: ...r heater must be prevented from operating during the filling procedure 1 6 Filling the pellet store Fig 2 Turning off BioWIN XL Fig 3 Opening inspection cover during the filling process Inspection cov...

Page 9: ...cient ventilation before entering Keep the door open while inside Only enter the storage room under the supervision of a second person standing outside No smoking flames or other sources of ignition a...

Page 10: ...s showed in the safety instructions La belident GmbH Ar t No W 08 0 5 DANGER This indicates a very serious risk of injury or death by high voltage INFORMATION Ignoring the warnings identified can lead...

Page 11: ...Only authorized personnel are allowed to open cover plate CAUTION Closing pellet chamber door can crush and cut Never insert hands between door and frame or between door and closing bracket of the pel...

Page 12: ...e and housing of heating chamber when opening or closing CAUTION Health hazard All cover plates enclosures and guards must be maintained in place at all times except during maintenance and servicing W...

Page 13: ...t Before cleaning or touching combustion chamber or any other components turn off unit completely and allow to cool for at least 2 hours Use heat resistant gloves Use tools provided WARNING Health haz...

Page 14: ...Some states list chemical substances known to cause cancer birth defects death serious illness or other reproductive harm in propositions This product may con tain such substances either from the fuel...

Page 15: ...oses must be installed as de scribed in the installation instructions at every connection to avoid static sparking dust ignition The pellet feed unit is for use with the day hopper only The feed unit...

Page 16: ...XL integral fuel hopper fully automati cally with pellets from a pellet storage room or storage container The pellet feed is switched on by the lower fill level switch proximity switch in the integral...

Page 17: ...r 3 Auger motor 4 Inspection cover bottom 5 Integral fuel hopper 6 Inspection cover top 7 Safety thermostat auger tube 8 Thermocontrol sensor 9 Safety thermostat boiler temperature 10 Fuseboard 11 Com...

Page 18: ...sure heating water pressure The system must be filled and vented When the system is cold pressure should be at minimum 14 5 psi 1 0 bar and at maximum 26 psi 1 8 bar If you have any questions your ins...

Page 19: ...pressed or if another operating mode is activated Fig 6 InfoWINPLUS Boiler temperature Standby Info Menu 144 F Operating phases are displayed here inclu ding Standby Burner OFF etc Menu line Signal la...

Page 20: ...perature standard display The LED signal lamp will turn green and the desired functions can be selected using the buttons Fig 9 If the self test was unsuccessful an information message e g information...

Page 21: ...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 burner pot has cooled down Pellet f...

Page 22: ...This sets the boiler temperature to the setpoint fixed for manual operation standard value 140 F 60 C The current automatic setting is not affec ted by this The lighting is turned off after the lighti...

Page 23: ...to approx 140 F 60 C for 45 minutes Fig 17 Chimney sweeper func Power 100 45 min Operating phases 30 Cancel 100 107 F Symbol flashes The various operating phases are displayed here including Burner i...

Page 24: ...etected the system switches over to flame stabilization mode 2 6 4 Flame stabilization Following the ignition procedure even combustion is established and the sys tem switches over to modulation mode...

Page 25: ...ut h Operating hours h Total pellet consumption t Flue gas temperature F C Boiler temperature setpoint F C Current boiler output Switch buffer temperature Software version display module Software vers...

Page 26: ...the burner Fig 34 Boiler temperature setpoint back 145 F 2 7 6 Current boiler output The current boiler output is displayed in The boiler output modulation mode can be set from 30 to 100 Fig 35 Curre...

Page 27: ...ate main PCB is displayed Fig 39 Software version firing automate 1 00 back 2 7 10 Boiler model With an individual BioWIN XL boiler the boiler model is always displayed and 0 is always displayed as th...

Page 28: ...43 Exit the menu or sub menu by pressing the back button Fig 44 or by waiting 10 minutes Fig 42 Operator level Service level Information level MES Module1 choose back Fig 43 Operator level Service le...

Page 29: ...be 5 Only probe 7 Only probe 8 1 Only displayed when an MESplus control is present and the basic settings have been adjusted by a trained service technician 2 This is only displayed if there is a feed...

Page 30: ...equired sub menu Fig 47 use the choose button to con firm the choice For adjusting the Boiler cleaning see chapter 2 8 1 1 Time see chapter 2 8 1 2 Feed operating mode see chapter 2 8 1 3 Time profile...

Page 31: ...es Info Menu 107 F Fig 51 Operator level Service level Information level MES Module1 choose back Fig 52 Boiler cleaning Time Feed operating mode Time profile feed Probe switching choose back Press the...

Page 32: ...ng been performed Confirm Yes back Reset the boiler cleaning by pressing the Yes button Fig 54 The display will show Parameter is saved for a few seconds Fig 55 and then return to the previous screen...

Page 33: ...essing one of the six buttons Fig 57 Fig 58 Boiler temperature Operating phases Info Menu 107 F Fig 59 Operator level Service level Information level MES Module1 choose back Fig 60 Boiler cleaning Tim...

Page 34: ...quired time Fig 62 Exit the menu or sub menu by pressing the back button Fig 65 or by waiting 10 minutes Fig 63 Time 13 50 save back Confirm the changed time by pressing the save button Fig 63 The dis...

Page 35: ...l Service level Information level MES Module 2 choose back Fig 69 Boiler cleaning Time Feed operating mode Time profile feed Probe switching choose back Press the Menu button Fig 67 Confirm the select...

Page 36: ...e display will show Parameter is saved for a few seconds Fig 73 and then return to the previous screen Fig 74 Exit the menu or sub menu by pressing the back button Fig 74 or by waiting 10 minutes Fig...

Page 37: ...Fig 76 Boiler temperature Operating phases Info Menu 107 F Fig 77 Operator level Service level Information level MES Module 2 choose back Fig 78 Boiler cleaning Time Feed operating mode Time profile...

Page 38: ...me profile feed menu option if the Feed with enable time setting is active in the Feed operating mode menu option see section 2 8 1 3 Factory setting Feed with enable time Start 7 00 am End 10 00 pm U...

Page 39: ...se conds Fig 84 and then return to the previous screen Fig 85 Fig 83 Feed with enable time Start 07 30 am End 10 00 pm save back Fig 84 Parameter is saved Animated symbol Fig 85 Feed with enable time...

Page 40: ...back Press the save button to confirm the changed time Fig 87 The display will show Parameter is saved for a few se conds Fig 88 and then return to the previous screen Fig 89 Fig 88 Parameter is saved...

Page 41: ...Removal from probe 2 only no switching Removal from probe 3 only no switching Removal from probe 4 only no switching Europe only Suction turbine with 6 probes all probes only zone 1 only zone 2 only p...

Page 42: ...Information level MES Module 1 choose back Fig 94 Boiler cleaning Time Feed operating mode Time profile feed Probe switching choose back Press the Menu button Fig 92 Confirm the selected menu item op...

Page 43: ...2 Only probe 1 save back Fig 98 Parameter is saved Animated symbol Fig 99 Boiler cleaning Time Feed operating mode Time profile feed Probe switching choose back Use the arrow buttons to select the pro...

Page 44: ...vice personnel 5sec Fig 102 Parameters Start up Actuator test Settings choose back Exit the menu or sub menu by pressing the back button Fig 102 or by waiting 10 minutes 1 Only displayed when an MESpl...

Page 45: ...n OFF the power e g for repairs disconnect via the circuit breaker ON OFF button InfoWINPLUS operating unit Fig 103 Turning on the BioWIN XL 2 9 Heating system operation 2 9 1 BioWIN XL with external...

Page 46: ...e cleaning and ash removal intervals may be reduced or extended depending on the pellets used e g ash content the power consumed by the heating system frequently turning on and off and the boiler size...

Page 47: ...t Never insert hands between frame of boiler and ash tray when mounting the ash tray WARNING Fire hazard Risk of fire if ash hasn t cooled Store ash in a locked non combustible container on a non comb...

Page 48: ...g door on the left To do this turn the key a quarter turn to the right to unlock the door Fig 106 Fig 107 Opening the bracket fastener Fig 108 Moving container slightly to the left Pull handle on ash...

Page 49: ...erwise locally dispersed they should be kept in the closed container until completely cooled 3 4 2 Creosote formation and need for removal When wood is burned slowly it produces tar and other organic...

Page 50: ...ble completing these steps in reverse order Fig 115 Cleaning the thermocontrol sensor BioWIN XL 350 NA 450 NA WARNING Do not open the combustion chamber door during operation Always turn off the boile...

Page 51: ...mber and the burner pot must be reset on the InfoWINPLUS see chapter 2 8 1 1 Turn off the BioWIN XL with the ON OFF button on the InfoWINPLUS Fig 117 and wait until the display has gone out Open the c...

Page 52: ...600 NA 1 Primary air pin 2 Cone bottom part 3 Cone top part 4 Ash wedge 5 Suction tube Fig 123 Vacuuming out the primary air tube using the suction tube Fig 124 Insert the primary air pin Assembly Im...

Page 53: ...ve fly ash with a vacuum cleaner Raise blower box at front and take out Fig 129 Vacuum top parts of coasting surface or use a cleaning brush to clean them Fig 130 Before disconnecting the power supply...

Page 54: ...n and release the cover from the boiler wall by removing the 4 nuts Remove cover and vacuum out ash chamber Fig 133 Assembly Complete the previous steps in reverse order or Insert fan box Mount the fa...

Page 55: ...display has gone out Open the cladding door with the key Fig 135 Fig 134 Turning off the BioWIN XL Fig 135 Opening the cladding door with the key Remove 4 wing nuts and the inspection cover Fig 136 Fi...

Page 56: ...oom DANGER Enter the storage room only under the supervision of a second person standing out side WARNING Pellet dust is flammable and may explode under certain circumstances if it beco mes airborne K...

Page 57: ...ayer of dust on top of pellets from agitation during bulk fillings and removal is normal if pellets have swelled up against the wall if the storage room is not fully dry Tip 1 Pellet dust can be dispo...

Page 58: ...on after rectifying the cause of the information fault or alarm message In these cases Reset is displayed in the menu line Fig 140 If Reset is not displayed in the menu line the boiler starts operatin...

Page 59: ...dicating that the pellet boiler must be cleaned in the next 50 operating hours see sections 3 4 to 3 5 Once cleaning is complete press the Reset button on the InfoWINPLUS Cleaning must be confirmed on...

Page 60: ...381 Integral fuel hopper empty The programmed schedule will not allow pellet feed Change enable time in menu operator level Feed enable time has been set too short which means the pellets in the inte...

Page 61: ...o longer reaches the end position boiler switches to burnout mode Press the Reset button If the fault reoccurs after a reset a Heating surfaces very dirty clean inform Windhager Customer Service or a...

Page 62: ...1 Check the exhaust pipe to the flue and clean it if necessary see sections 3 9 Press the Reset button b Burner component e g grate disc not inserted correctly after cleaning check installation positi...

Page 63: ...exceeded Clean burner pot Press Reset No flame formation when heating up Heating up procedure is cancelled a Clean the burner pot see section 3 5 empty the ash container see sec tion 3 4 Confirm clea...

Page 64: ...otection collar bracket 045979 140 Motor bracket 042441 150 Axial ball bearing 006925 160 Collar complete with insert 042539 170 Microswitch 006936 180 Mounting plate 045988 190 Relay for shut off uni...

Page 65: ...045016 60 Seal section 044667 70 Terminal bar MS 8 pin 009929 80 Blower motor 006236 90 Rivet nut M8 016156 100 Hose clip 40 60 006875 105 Hexagon screw M6 x 12TT 031545 110 Hexagon screw M8 x 80 0164...

Page 66: ...Spare part designation BioWIN XL 10 Spring 010835 20 Piston complete with seal 010841 30 Screw cap complete with O ring 010843 40 Compression gland unit 010837 50 Immersion sleeve 010838 60 Temperatu...

Page 67: ...0 85 150 120 130 1070 1030 1020 730 430 230 780 870 960 500 1080 500 970 520 660 750 300 220 250 300 670 975 1100 820 810 470 930 840 910 190 380 560 370 800 600 1110 930 810 1250 500 540 1090 680 70...

Page 68: ...047548 240 Combustion chamber sensor flange 043756 250 Ash conveyor flange plate 047539 260 M8x16 butterfly screw 019408 No Spare part designation BioWIN XL 270 Blower cover 047989 280 Blower wheel 04...

Page 69: ...art designation BioWIN XL 930 Locking nut M8 016553 940 Baffle rod 047652 945 Dust separator for integral fuel hopper 047959 950 Spur gear 67 teeth 047410 960 Ash conveyor spur gear 047544 970 Ash con...

Page 70: ...320 380 640 640 640 660 650 670 330 630 640 540 400 620 10 160 180 150 170 130 560 200 200 20 300 190 220 250 125 590 680 30 230 350 600 340 240 50 60 520 520 570 580 480 490 500 510 80 370 70 530 27...

Page 71: ...441 310 Feather key 5x5x20 007186 320 Feather key 6x6x28 006766 330 Shoulder screw M10 x 12 013802 340 Primary air pin 048950 350 Primary air tube 047281 360 Grate plate 047274 370 Spur gear protectio...

Page 72: ...L Cladding 130 30 30 190 350 20 340 240 210 100 420 330 370 380 360 50 470 450 120 110 40 170 250 80 290 320 300 10 410 90 60 200 230 220 310 440 180 270 70 450 480 260 490 330 425 140 280 460 Not ill...

Page 73: ...op 007255 230 Boiler insulation right 007265 240 Boiler insulation rear wall 007257 250 Centre panel insulation 007267 260 Side panel insulation 011998 270 L bracket 047555 280 Driver 047891 290 Centr...

Page 74: ...74 5 Spare parts BioWIN XL Control Panel 20 70 290 60 330 50 300 430 440 270 265 210 245 220 180 250 260 280 200 10 10 10 240 350 320 310 340 35 312 275 305 450 360 315 Not illustrated Pos 345...

Page 75: ...m 18 pin 009928 210 Capacitor for motor MAB 500 V 3 F 007330 220 Module connection PCB 048754 230 Mains connection socket 041430 240 Power supply unit 12 V 1 A 051645 250 PCB FMF 009923 260 PCB holder...

Page 76: ...to technical modifications AWP vor Austria Windhager Zentralheizung GmbH Anton Windhager Stra e 20 A 5201 Seekirchen bei Salzburg T 43 0 6212 23 41 0 F 43 0 6212 42 28 info at windhager com www windha...

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