Windhager BioWIN series Assembly Instructions Manual Download

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Assembly instructions

BioWIN

windhager.com

Pellet central heating boiler

Output range: 2,9 to 25,9 kW

Cascae options up to 78 kW

Pellets

03/2013

091698/09

Summary of Contents for BioWIN series

Page 1: ...Assembly instructions BioWIN windhager com Pellet central heating boiler Output range 2 9 to 25 9 kW Cascae options up to 78 kW Pellets 03 2013 091698 09 ...

Page 2: ...e room air 10 2 4 Taking in 10 2 4 1 Removing reserve supply container 11 2 4 2 Removing the floor plate underneath the integral fuel hopper 13 2 4 3 Removing control panel 13 2 5 Minimum clearances 15 2 6 Dimensional sketches 16 2 7 Installation sequence 16 2 8 Installing preparing for installation 17 2 9 Fitting reserve supply container cover only BioWIN Klassik 18 2 10 Fitting cleaning lever on...

Page 3: ...arameters 30 4 6 2 Start up 34 4 6 3 Actuator test 34 4 6 4 Settings 34 4 6 5 Installation of MESplus modules 35 4 7 InfoWINplus basic settings 36 4 8 Basic BioWIN 100 260 circuitry 38 4 9 BioWIN 100 260 connecting diagram 39 4 10 BioWIN 100 260 pellet feed connecting diagram with mixer for buried tank 40 4 11 Circuit diagram for BioWIN 100 260 pellet feed with solo probe 41 4 12 Connecting diagra...

Page 4: ...ording to DIN 18160 T1 or other appro priate officially approved may be connected to the hearths The flue gas system must display at least the following classification Temperature class T400 nominal operating temperature 400 C Soot fire resistance class G flue gas system with soot fire resistance Corrosion resistance class 2 suitable for unprocessed wood fuels We would recommend fitting an energy ...

Page 5: ...fficiency The pellets can be stored in bulk in a storage room sheet steel tank fabric tank or a buried tank The requirements for pellet storage are defined in ÖNORM M7137 for Austria or the Firing Ordinance FeuV for Germany See the separate planning documents for planning information about pellet storage Maximum transport length or height for a pellet feed system These max values require a stable ...

Page 6: ...w from above Fig 3 Storage room Boiler room view from above Furthest away probe changeover unit Storage room Suction turbine BioWIN 100 260 Boiler room Furthest away probe changeover unit Storage room Suction turbine BioWIN 100 260 Boiler room BioWIN 100 260 3 probe BioWIN 100 260 8 probe ...

Page 7: ...ries for fully automatic pellet feed Fully automated changeover unit with without fire protection collars including 3x suction probes Fully automated changeover unit with without fire protection unit including 8x suction probes and masonry feed through Fastening clips for delivery hose pack of 6 Delivery hose with flexible earth leads DN 50 25 m supply and return air hoses Connecting piece for ret...

Page 8: ...thermal safety device not present with all boiler models should always be used with the thermal process safeguard 2 2 3 Heating circuits A motorised mixing valve is always required for the BioWIN 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 2 2 4 Circulation pump We recommend using pumps eff...

Page 9: ...erature setpoint via the analogue 0 10 V interface 2 2 8 Heating water a The chemical composition of the heating water must meet the specifications of ÖNORM H 5195 Part 1 or VDI 2035 P1 According to ÖNORM M 5195 Part 1 2010 edition the condition of the heating water must be checked every 2 years by a heating technician in order to avoid corrosion and sediment accumulation in the heating system b T...

Page 10: ...egral fuel hopper Fig 5 c in addition to point b also without control panel and right side panel Fig 6 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 2 3 1 Operating with room air Combustion air supply directly from the installat...

Page 11: ...IN as above also without control panel and right hand side wall kg 192 202 200 211 approx 2 5 hours Fig 4 BioWIN 100 260 in crate Fig 5 BioWIN 100 260 without crate clad ding and reserve supply container Fig 6 BioWIN 100 260 without control panel 2 4 1 Removing reserve supply container Order for disassembly Remove wood partitions with the exception of the base pallet see section 2 8 Unhook claddin...

Page 12: ... panel Fig 10 and remove the side panel Remove sensor from safety thermostat auger tube loosen sensor guard Fig 11 and take out sensor Unscrew both nuts from the side of the auger tube flange Fig 10 Removing screws from inside next to side panel Fig 11 Loosening sensor guard Fig 12 Unscrewing nuts 2 items Disconnect plug from auger motor Fig 13 Remove reserve supply container support feet unscrew ...

Page 13: ...ct cable s from InfoWINplus on firing PCB and remove strain relief cable ties Fig 22 Remove cladding cover control panel remove 2 bolts with nuts Fig 23 and take off cover Fig 21 Loosening 2 bolts removing control panel cover Fig 22 Disconnecting cable s from InfoWINplus Fig 23 Unscrewing cladding cover Cable s Remove boiler sensor safety thermostat sensor and exhaust gas sensor unscrew cover on r...

Page 14: ...l cables from cable harness and unscrew complete cable harness with strain relief pinch off cable ties Fig 30 Take off control panel Fig 31 Fig 29 Removing retaining bracket Fig 30 Unscrewing strain relief Fig 31 Control panel removed Remove cladding bracket 2 screws bottom front Fig 32 Unhook and remove right side panel at bottom Fig 33 Fig 32 Unscrewing connection bracket Fig 33 Unhinging right ...

Page 15: ... 1900 mm the switchboard cannot be locked anymore when lifted up bracing has to be done on site Also maintenance costs can increase by a lower room height Attention Follow the installation guidelines for boiler rooms Note The control panel must be folded all the way up for cleaning work Fig 35 Therefore do not route the exhaust pipe and connection pipes or position any hydraulic components directl...

Page 16: ... 2 Exklusiv Premium types only Fig 37 BioWIN pellet boiler 100 260 Side view 2 7 Installation sequence a Transport boiler to installation site and remove crate see section 2 8 b Fit reserve supply container cover BioWIN Klassik only see section 2 9 c Fit cleaning lever BioWIN Klassik and Premium only see section 2 10 d Install the exhaust pipe see 2 11 e Fit cleaning tools see section 2 12 f Fit f...

Page 17: ... be taken to the installation site in the crate remove the crate and various attachments see section 2 4 The boiler can be installed directly on a non flammable surface and does not require special foundations Using the four set screws position horizontally or slightly inclined toward the rear Removing the crate Fig 38 Fig 39 Fig 40 Fig 41 Fig 42 Fig 43 Fig 44 Fig 45 Fig 46 Fig 47 Fig 48 Fig 49 ...

Page 18: ... beforehand Fig 51 Fit gas springs on reserve supply container Fig 52 Fig 50 Inserting protective grille Fig 51 Fitting belts bearings Fig 52 Screwing on gas springs 2 10 Fitting cleaning lever only BioWIN Klassik and Premium Punch through cut out in right hand side wall for cleaning lever and attach cleaning lever for heating surface cleaning on side for BioWIN Premium Klassik Fig 53 Fig 53 BioWI...

Page 19: ...tainless steel flue systems g The entire exhaust line particularly after 1 m length should be insulated in order to prevent or minimise condensation 2 12 Fitting cleaning tools 1 Cleaning brush 2 Spatula 3 Cleaning tool cone removal tool Fig 54 BioWIN cleaning instruments 2 13 Installing the thermal process safeguard Not needed for all boiler models only if the boiler has a thermal safety device C...

Page 20: ...ple are needed for assembly Fig 56 Sliding cardboard box upwards Fig 57 Feed unit without cardboard box Cut open tensioning belts Lift cardboard box up and off Fig 56 1 Feed unit with suction turbine 2 Front cover 3 Transport protection Open left cladding doors on BioWIN Unscrew bottom inspection cover 2 knurled screws and top inspection cover 6 screws Fig 58 59 Fig 58 Unscrewing bottom inspection...

Page 21: ...st be able to move easily Fig 62 Refit both inspection covers Fig 58 59 Supply and return air hose assembly 1 Loosen cover of feed unit 2 screws at front and 2 screws at rear Fig 63 2 Remove the cover Alternatively the rear wall can be removed instead of removing the top cover 3 Expose approx 5 cm of the flexible earth leads on all hose ends and bend inwards into the hose Fig 64 Important Also ref...

Page 22: ... consumption must be possible 4 Boiler connected to domestic water and filled 5 Sufficient quantity of fuel available pellets split logs oil or gas 6 The customer must be present during start up The initial start up cannot be carried out if any of these points are neglected The customer will be charged for any unnecessary costs arising as a result Start up and maintenance by Windhager Customer Ser...

Page 23: ... short circuit By special order up to 3 MESplus modules including boiler sensor will be installed in the control panel and wired at the factory Fig 67 if there are more than 3 modules they are installed in the wall mount casing accessory MES 004 and need to be electrically wired on site Maximum MESplus module switching capacity Relay outputs 230 V AC 6 A 2 A inductive 50 Hz WVF and B PLM modules w...

Page 24: ...he control panel bottom part the control panel top part must be folded up To do this loosen the front screw on the control panel Fig 70 and fold up the control panel top part until it snaps into the lock at the side Fig 71 Information Be sure to note the separate wiring of the extra low voltage line sensor and low voltage line 230 VAC Fig 73 The connection to the terminal blocks screwless spring t...

Page 25: ... and lift off the cover Remove blind plugs and guide cable of proximity switch with strain relief must snap into opening from rear into the control panel and connect Fig 75 Refit control panel cover with 2 screws and close cladding cover at front 2 screws Fig 76 Connecting plugs rear view Fig 77 Attaching cladding cover at rear rear view Power supply 230 V AC mains plug Connect mains plug for feed...

Page 26: ...ion After the emergency shut off switch trips the boiler and accessories are not completely without power When replacing system components pumps mixing valves etc prevent all power input e g by removing the mains power plug 4 3 Checking and servicing the thermal process safeguard Not needed for all boiler models only if the boiler has a thermal safety device Please inform your customer Attention T...

Page 27: ...iler water volume l 59 59 53 53 Water side resistance T 20 K T 10 K mbar 1 3 5 0 2 9 11 2 5 6 21 6 7 0 26 7 Boiler temperature control range C 60 75 Operating pressure max bar 3 Test pressure bar 4 5 Pellet reservoir l kg 232 150 8 Net weight of fully assembled boiler Exklusive Premium Klassik kg 333 318 318 344 329 329 Dimensions W x D x H Exklusive Premium Klassik mm 1028 x 733 x 1745 1102 x 733...

Page 28: ... Suction turbine Ignition element Ash removal Heating surfaces cleaning Probe switching Air intake exh flap Pumping time ignition phase Set temperature ext heating requirement Cleaning interval correction Limits for blower speed Boiler pump Settings Install display module Language selection Time format Temperature format Date format Minimum operating time with buffer Operator level Settings on the...

Page 29: ...ack Fig 83 Operator level Service level Information level MES Module1 Choose Back Fig 84 Service level only for trained service personnel 5s Use the arrow buttons to select the Service level sub menu Fig 82 Press and hold the Choose button for 5 seconds Fig 83 The display shows Service level only for trained service personnel Fig 84 Press for 5 seconds Press for 5 seconds 1 only displayed when an ...

Page 30: ...ssing the Back button or after a delay of 45 seconds Fig 86 4 6 1 Parameters The following parameters can be selected with the arrow buttons then confirmed using the Choose button Number of burner starts Fuel quantity auger conveyor Delivery time ignition phase Hysteresis Burner ON Maximum value of set temperature Set temperature ext heating requirement Type of pellet feed system Operating time of...

Page 31: ...value 120 s min 96 s max 144 s Save Back Fig 90 Hysteresis Burner ON Actual value 5 K min 0 K max 20 K Save Back Delivery time ignition phase Fuel quantity in the ignition phase BioWIN BW 100 BW 150 BW 210 BW 260 Factory setting 120 s 90 s 110 s 85 s Setting range 96 144 s 72 108 s 88 132 s 68 102 s Hysteresis Burner ON Switching hysteresis for burner control Factory setting 5 K Setting range 0 20...

Page 32: ...ype of pellet feed system Suction turbine with 8 probe Suction turbine with mixer Choose Back Operating time of suction turbine Factory setting 30 sec Einstellbereich 20 70 sec Diagram for suction time setting by feed hose length and suction height Fig 95 Operating time of suction turbine Actual value 30 sec min 20 sec max 70 sec Save Back 0 5 10 15 20 25 0 30 s 40 s 50 s 60 s 1 8 2 8 4 5 60 s max...

Page 33: ... setting Fig 99 Factory setting Operating time 300 sec Setting range 30 600 sec Fig 98 Flue gas thermostat or Air in take exhaust flap Flue gas thermostat Air intake exh flap Choose Back Information The set operating time should be twice as long as the actual opera ting time of the Air intake exh flap Limits for blower speed BW 100 BW 150 Minimum Maximum Minimum Maximum Factory setting rpm 1000 20...

Page 34: ...using the Choose button The actuators are switched off again after 1 minute A self test is started at the end of an actuator test Fig 103 Induced draught fan Auger conveyor Ash removal Ignition element Ash removal Heating surf cleaning Choose Back Induced draught fan Auger conveyor Ash removal Ignition element Ash removal Heating surface cleaning Suction turbine Probe switching Air intake exh flap...

Page 35: ...s are displayed in the chosen format e g 30 6 C or 87 0 F Factory setting C Selection C and F Fig 109 Time format 24h 12h Choose Back Time format The time is displayed in the chosen format e g 14 12 or 02 12 PM Factory setting 24 h Selection 24 h or 12 h Fig 110 Date format DD MM YYYY MM DD YYYY Choose Back Date format The date is displayed in the chosen format e g Wed 17 02 2010 or Wed 02 17 2010...

Page 36: ...and then switched on The following settings are available in the basic settings Language selection Boiler MB SMS Fig 113 Boiler temperature Operating phases Info Menu 42 C Fig 114 Version V2 00 16 3 2012 Press for 5 seconds 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 functio...

Page 37: ...118 MB Yes No Save Back MB Master operation Setting to define whether MESplus system control is present Factory setting is set in the factory before delivery as per the order Selection yes with MESplus system control no no MESplus system control Fig 119 SMS Yes No Save Back SMS Setting to define whether remote switching by text message is possible Factory setting is set in the factory before deliv...

Page 38: ...38 4 For the Service Technician 4 8 Basic BioWIN 100 260 circuitry 092175 02 ...

Page 39: ...1505 00 Information Two separate cables are needed to connect the changeover unit Cable for limit switch extra low voltage min 3 x 0 5 mm 2 no earth we recommend using a shielded cable if the cable is longer than 5 m Cable for changeover unit motor low voltage 4 x 1 5 mm 2 ...

Page 40: ...rvice Technician 4 10 BioWIN 100 260 pellet feed connecting 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 091673 00 ...

Page 41: ... Service Technician 4 11 Circuit diagram for BioWIN 100 260 pellet feed with solo probe Operation with a solo probe must be set in the service level see section 4 6 1 Parameters type of pellet feed system 093276 00 ...

Page 42: ...ap The air intake exhaust flap is directly connected to the automatic firing device see basic circuit diagram 4 8 at plug X4 motor and X14 limit switch To set parameters for air intake exhaust flap see section 4 6 1 Parameters Flue gas thermostat or Air intake exhaust flap 093182 01 ...

Page 43: ...as thermostat The flue gas thermostat is directly connected to the automatic firing device see basic circuit diagram 4 8 at plug X4 motor and X14 limit switch To set parameters for flue gas thermostat see section 4 6 1 Parameters Flue gas thermostat or Air intake ex haust flap ...

Page 44: ...NS The guarantee and warranty limitations require that the boiler and related accessories be properly installed and started up by Windhager Customer Service or Customer Service Partner otherwise the manufacturer s guarantee will not be honoured Malfunctions resulting from improper operation or adjustment as well as use of poor or not recommended fuel types are not covered by the guarantee and warr...

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