Windhager BioWIN XL Installation Instructions

WOOD PELLETS

Installation Instructions

BioWIN XL

FOR USE IN CANADA / USA

03/2015 094886/01

Pellet central heating boiler/furnace

/

USA

2015 0948

86/

SAVE THESE INSTRUCTIONS

2

Table of contents

Table of contents

1. Important Information for the Technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.1.1 Important information before you begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1.2 Caution symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1.3 Liability exclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.4 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.3 Boiler room/Installation room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.4 Fuel storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2. For the Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1 Scope of delivery, packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.1.1 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.2 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2 Minimum clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.3.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3.2 Operation with external control and buffer only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3.3 Heating water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3.4 Water-side resistance (pressure loss) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4 Combustion air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.4.1 Operating with room air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.4.2 Operating independently of the room air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.5 Installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.6 Setting up, preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.8 Installing the exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

2.9 Installing the thermal discharge safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

2.10 Installation instructions for 3-way changeover unit, suction probes, suction turbine . . . . . . . . . . . . . .34

2.10.1 Scope of delivery, packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.10.2 Notes on installing the suction probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.10.3 Notes on installing the supply and return air hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.10.4 Notes on installing the changeover unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.10.5 Installation 3-way changeover unit, suction probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.10.6 Installation suction turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.10.7 Affixing stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.11 Initial commissioning and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

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Table of contents

3. For the Electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.1 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

3.1.1 Opening and closing the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.1.2 Connecting the InfoWIN

PLUS

cable to the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.1.3 Electrical connection for Power supply 110 V AC, external control, changeover unit, suction turbine . . . . . . 50

4. For the Service Technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.1 Start-up and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

4.2 Service and repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

4.3 Checking and servicing the thermal discharge safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.4 Service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.4.1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.4.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.4.3 Actuator test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.4.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.4.5 Installation of MES

PLUS

modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.5 InfoWIN

PLUS

basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

5. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.1 Technical data for calculating the flue gas system acc. to EN 13384-1 . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.2 Technical data – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

5.3 Dimensional sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6. Electric Connecting Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.1 Basic BioWIN XL circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6.2 BioWIN XL connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6.3 Connection diagram for external controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

6.4 BioWIN XL pellet feed connection diagram with mixer for buried tank . . . . . . . . . . . . . . . . . . . . . . . . . .69

6.5 Connection diagram for air intake/exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

6.6 Connection diagram for flue gas thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

4

1. Important Information for the Technician

1.1.2 Caution symbols

1.1.1 Important information before you begin

This manual contains data with US units. The units in the original manual are European units. If there is a data
conflict between these units, the data with European units is always valid.

The original manual is written in German – this is an English translation. In case of conflicts, the German version
is always valid.

1. 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. Installation should be performed only by appropriately qualified
technicians.

DANGER

Please follow the safety instructions (symbols) on the machine!
Please refer to the instructions in chapter 1.1.4!

DANGER

The specified safety requirements are to be followed in accordance with nationally
applicable regulations, standards, and guidelines.

CAUTION

This means you must follow the safety instructions. There is a slight risk of injury.

WARNING

This means that you must follow the safety instructions. There is a slight risk of
injury.

LabelidentGmbH Art.-N o.:W 08-05

DANGER

This indicates that there is a very serious risk of injury or death by high voltage.

INFORMATION

Ignoring the warnings identified can lead to malfunction of, or damage to, the boi­ler/heater or heating system.

DANGER

This means that it is essential that you follow the safety instructions. There is a
very serious risk of injury or death.

Note!

The blocks of text highlighted provide information and tips for operation.

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1. Important Information for the Technician

1.1.4 Safety instructions

1.1.3 Liability exclusion

All work should be performed exclusively by trained personnel. Local safety regulations must be complied with in
all cases; in the event of a conflict and/or contradiction between these regulations and the working instructions
in this document (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. No liability is accepted for errors in translation.

CAUTION

Risk of fire or explosion.

Do not use chemicals or fluids to start the fire.

CAUTION

Health and environmental hazard.

Do not burn garbage, gasoline, naphtha, engine oil, or other inappropriate materials.

CAUTION

Opening heating chamber door can crush and cut.

When opening door, never insert hands between the door and frame on the hinge
side of the heating chamber.

CAUTION

Closing heating chamber door can crush and cut.

When closing door, never insert hands between the door and frame of the heating
chamber. Be aware of other people, especially children.

WARNING

Entanglement hazard.

Do not open cover of auger conveyor when heating.
Handle with care when servicing charging screw.

CAUTION

Ash tray can crush and cut.

Never insert hands between ash tray and frame.
Never insert hands into closing bracket.
Never insert hands between ash tray and closing bracket.

CAUTION

Cover plate for pellet chamber can crush and cut.

Use caution when opening the cover plate.
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 pellet chamber when closing the door. Never insert hands into the hinge
area when opening door.

CAUTION

Opening pellet chamber door can crush and cut.

Never insert hands between door and frame on the hinge side of the pellet cham­ber when opening door. Never insert hands between door and closing bracket.

6

1. Important Information for the Technician

CAUTION

Removing the ash tray can crush and cut.

Never insert hands between frame of boiler/heater and ash tray when removing
the ash tray.

CAUTION

Mounting the ash tray can crush and cut.

Never insert hands between frame of boiler/heater and ash tray when mounting
the ash tray.

CAUTION

Displacing the ash tray can crush and cut.

When moving the ash tray, never insert hands between floor of the heating boiler
and ash tray.

CAUTION

Pinch point hazard.

Never insert hands between the cover plate and housing of heating chamber when
opening or closing.

DANGER

Danger - smoke gas.

Ensure adequate ventilation in the boiler room.
Smoke gas may cause poisoning.

CAUTION

Hot water and hot steam. Injury hazard.

Safety devices (such as the relief valve) will open automatically and release hot
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

DANGER

Risk of fire or explosion.

Exposure may result in severe injury or death.
Do not fill with garbage, waste oil, gasoline, other flammable liquids, or any fuel
other than those listed on the rating plate.
Do not use chemicals to ignite fuel.
Do not use chemicals, sprays, or flammable substances to clean combustion room
or any other burner component.
Do not use boiler/heater cleaners.
Do not manually fill or light burner.
Do not smoke! Do not expose to open flame.

Do not expose to ignition sources.
Do not open combustion chamber door during operation, power failure, or alarms.

WARNING

Fall hazard.

Do not sit, stand, or walk on machine.
Keep children away.

7

1. Important Information for the Technician

WARNING

Fire hazard.

Do not vacuum hot ash - may cause fire in vacuum cleaner.
Prior to vacuuming ash or dirt, wait until unit has shut down completely and has
cooled for at least 2 hours.

WARNING

Machine starts automatically.

Moving parts can crush and cut.
Do not remove guarding.
Do not touch rotating parts.
Keep children away.
Keep pets away.

LabelidentGmbH Art.-N o.:W 08-05

DANGER

Hazardous voltage.

Do not remove cover.
Keep away from electric components.
Disconnect power before servicing or cleaning.

WARNING

Injury hazard.

All components/surfaces remain hot for a long period of time after turning off unit!

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 hazard.

Combustion particulates may contain harmful substances.
Use a fine-dust face mask during cleaning.

WARNING

Rotating parts can crush and dismember.

Keep hands out of feed opening.
Do not remove cover during normal operation.

WARNING

Burn hazard – hot surface.

Do not touch frame, cover, or inside of heating chamber during heating.
Allow heating chamber to cool completely before cleaning and servicing.
Keep children and pets away from heating chamber.
Do not touch backside, chimney, or any other pipework during operation.
Maximum draft marked on nameplate.

WARNING

Hand crush hazard.

Automatic start-up if safety switch is activated.
Do not push safety switch.
Moving parts behind the combustion chamber door may start automatically, which
can lead to loss of fingers or other serious bodily injury.
Disconnect power before opening the combustion chamber door.

WARNING

Risk of health hazard.

Do not connect to an existing boiler/heater system.

8

1. Important Information for the Technician

WARNING

Risk of hand injury.

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.

CAUTION

Pinch point hazard.

Use caution when closing the cover of the smoke funnel chamber.

WARNING

Crush hazard.

Remain alert and aware of surroundings when moving the machine with crane or
fork lift.

DANGER

Smoke gas danger.

Mount a warning plate against smoke gas on the boiler room door.

WARNING

Health hazard.

In case of an unexpected fire or if flue pipe turns red, disconnect power if the main
switch or main circuit breaker is safe to reach. Call the fire department (911) and
evacuate the building. Do not enter smoke-filled rooms to disconnect power.

CAUTION

Injury hazard by hot water or steam.

Safety devices (such as relief or drain valve) will open automatically and relieve hot
water or steam. Keep away from safety devices. Do not manually operate safety
devices when the system is hot.

WARNING

Health hazard from chemical substances.

Some states list chemical substances known to cause cancer, birth defects, death,
serious illness, or other reproductive harm in propositions. This product may con­tain such substances, either from the fuel, fuel combustion, or in components of
the product itself.

LabelidentGmbH Art.-N o.:W 08-05

WARNING

Necessary tasks.

The heat exchanger, flue pipe, and chimney must be cleaned regularly to remo­ve accumulated creosote and ash. Ensure that the heat exchanger, flue pipe, and
chimney are cleaned at the end of each heating season to minimize corrosion du­ring the summer months. The appliance, flue pipe, and chimney must be in good
condition. These instructions also apply to a draft inducer, if used.

WARNING

Pellet feed system: service, maintenance and rules

The pellet feed system operates automatically. All service and maintenance must
be completed by trained specialists only. Do not alter the equipment or accesso­ries in any way.
For use in combination with Windhager BioWIN XL pellet-fueled central heating
boiler/furnace only.
Do not use to transport any material other than wood pellet fuel listed on the boiler
nameplate or in the boiler manuals.
Do not use for vacuum cleaning.
The pellet feed system starts automatically and will make noise. People who are
easily startled or have cardiac problems should keep away.

9

1. Important Information for the Technician

DANGER

Pellet feed unit: fire and explosion hazard

Can lead to serious injury/death! Ground suction hoses must be installed as de­scribed 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
must be braced, anchored, or strapped to avoid falling/shifting during an earthqua­ke. Instructions can be obtained from your local Windhager dealer or wholesaler.
Pellet feed automatic changeover unit: Fire and explosion hazard
Fire and explosion hazard can lead to serious injury or death.
Do not use the pellet feed automatic changeover unit inside pellet storage room
or where there is a lot of dust present. Connect delivery hoses to pellet feed auto­matic changeover unit as described in the installation instructions to avoid static
sparking or dust ignition.

LabelidentGmbH Art.-N o.:W 08-05

WARNING

Pellet feed automatic changeover unit: injury hazard by moving parts and elec­tricity

Can lead to serious injury or death.
Device starts automatically. Device restarts automatically after power failure.
Do not remove cover.
This part should be serviced by trained personnel only.

WARNING

Clearances and installation instructions

Minimum clearances from combustible or noncombustible construction:
2 inches left, 12 inches back, 24 inches top (right),
6 inches right side, 22 inches front.

Access to the back side is required to allow the service of parts such as the drain
valve, relief valve, and inspection fittings.
This unit is for dry indoor installation only. Not for installation on combustible floo­ring. Not for installation in manufactured homes or mobile homes.

DANGER

Risk of serious bodily injury or death.

This boiler/heater is equipped for one type of wood pellet only. Read the nameplate
behind top lid for the correct type of pellet. Do not use this boiler/heater with any
fuel other than the one listed on the name plate. Failure to use the correct fuel
may cause problems resulting in death, serious bodily injury or property damage.

WARNING

Fire hazard.

Do not operate with incorrect draft. Check nameplate behind top lid for correct
draft.
Do not operate while refilling the bulk hopper.
Do not operate with door or ash removal covering open or when the ash box is
removed.
Do not store fuel or other combustible material in the boiler room.
Regularly inspect and clean flues and chimney.
Have a trained professional regularly inspect safety devices, such as the relief and
drain valves.

LabelidentGmbH Art.-N o.:W 08-05

CAUTION

Caution

For supply connections, only use 10 AWG or larger wires acceptable for at least
176°F (80 °C) on a GFCI circuit!

10

1. Important Information for the Technician

1.3 Boiler room/Installation room

DANGER

The configuration of the entire system must comply with technical fire protection
requirements in accordance with regional legislation, applicable regulations, stan­dards and guidelines.

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. The use of a double wall stainless steel system is required.

A brick chimney may be used if it is damp and water resistant (e.g., refractory brick), properly insulated, and
fulfills the requirements of technical calculations. In the case of an existing chimney that is non-damp and water
resistant, a single wall stainless steel pipe that is properly designed and insulated may be used. In either case,
ask a local building inspector or flue expert for the correct design and flue sizing.

For directions on installing and supporting your chimney, follow instructions provided by your flue system‘s
manufacturer.
A pressure relief valve needs to be installed in the flue gas system. Whenever possible, a barometric damper should

be installed according to local building codes. DO NOT install a barometric damper in sleeping or living areas!

The minimum draft required at the flue gas collar is -0.02 in H2O (-0.05 mbar).
The maximum draft allowed at the flue gas collar is -0.08 in H2O (-0.2 mbar).
The minimum flue pipe diameter required is 5.1 inches / 130 mm. The use of a flue pipe diameter greater than

5.9inches / 150 mm first requires a calculation from your local building inspector or flue expert.

DANGER

Injury hazard.

Draft regulators which open inwards and outwards can release fumes which can
lead to asphyxiation.

DANGER

Injury hazard.

The use of galvanized flue gas pipes is at your own risk - this may cause
condensation and consequently damage the pipes.

1.2.1 Adjusting the barometric damper

Adjust barometric damper according to the manufacturer‘s instructions. To access the measurement open,ing,
remove the back lid and plug at the flue gas collar. Measure the draft with an appropriate analyzer. Adjust for the
flue draft listed on the boiler/heater name plate. Replace the plug and close the lid after measuring the draft.

CAUTION

Do not alter for increased firing for any reason!

READ and FOLLOW installation instructions for proper flue sizing and flue design! All flue systems must meet
UL103. All flue systems must be water resistant (st ainless steel) and insulated (double wall system).
DO NOT INSTALL BAROMETRIC DAMPER OR PRESSURE RELIEF VALVE IN LIVING OR SLEEPING AREA!

INFORMATION

Frequently, overhauling existing systems involves over-sized flue cross-sections
or flues not designed for low-temperature operation. We recommend an evalua­tion by the local building inspector before installing the boiler system. In this way
appropriate modifications can be made to the flue before system installation (see
technical data for flue calculation values).

11

1. Important Information for the Technician

1.4 Fuel storage

The pellets must be stored in a dry location in order to achieve trouble-free operation with optimum combustion
at maximum efficiency. The pellets can be stored in bulk in a storage room, sheet steel tank, fabric tank or buried
tank. The requirements for pellet storage are defined in ÖNORM M7137 for Austria, the Firing Ordinance FeuV
for Germany, or the Pellets Fuel Institute (PFI) Standard for the USA/Canada.

Maximum transport length or height for a pellet feed system:

These max. values require a stable power supply (min. 110 V AC under load!). The suction turbine must be in the
same room as the pellet boiler. The distance between the pellet boiler and the suction turbine must not exceed

9.8 ft / 3 m – Fig. 2.
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. distance of 50 ft / 15 m between furthest probe and pellet boiler/heater with max. total height difference of

9.2 ft / 2.8 m
Max. distance of 33 ft / 10 m between furthest probe and pellet boiler/heater with max. total height difference of

14.8 ft /4.5 m
Total height difference: Sum of lengths of all rising pipes

Fig. 2 Storage room, heating room – view from above

Furthest away probe

Changeover unit

Storage room

Suction turbine

BioWIN XL

Boiler room

Suction pipe from BioWIN XL to suction turbine: Max. length 9.8 ft/3 m

CAUTION

The pellets must be transported carefully in and out of the storage room in order
to maintain good pellet quality.

– 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.
– The boiler must be installed in a dry location.
– The boiler must not be installed in rooms that are very dusty or humid.
Permissible limit values: Air humidity: 85 % at room temperature of 77 °F / 25 °C (non-condensing)

Room temperature: 35.6 °F to 104 °F / +2 to +40 °C
– Sufficient lighting must be provided for service and maintenance.

12

2. For the Installer

2.2 Minimum clearances

All dimensions in mm:

A = Distance from edge of base
B = Distance from edge of cladding

1220mm

48,03in

996mm

39,19in

min.

400mm

15,75in

(B) min.

700mm

27,56in

(A) min.

652mm

25,66in

(A) min.

122mm

4,79in

(B) min.

600mm

23,62in

(B) min.

100mm

3,94in

(A) min.

871mm

34,27in

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Fig. 4 BioWIN XL – view from above

Minimum room height: 1900 mm / 74.8 in.

2. 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.

2.1.2 Optional accessories

Accessories 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
– Delivery hose with flexible ground leads, DN 50 - 25 m / 82 ft (sup-

ply and return air hoses)

30,71in

780mm

70,47in

1790mm

38,39in

975mm

Fig. 3 Installation dimensions – BioWIN XL

CAUTION

Follow the installation guidelines for boiler rooms!

13

2. 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:
– Pressure Relief Valve with 30 psi opening pressure Article no.: 003493

– Low Water Cut-Off with Manual Reset for 110–120 V 15 A Article no.: 003495
– Pressure Gauge Article no.: 003494
– Expansion Tank with at least 15% total system water volume capacity Article no.: 003496, 003497, 003498
– Automatic Air Vent Article no.: 003499

READ and FOLLOW installation instructions for proper flue sizing and flue design!
All flue systems must meet UL103. All flue systems must be water resistant (stainless steel) and insulated (double
wall system).

DO NOT INSTALL BAROMETRIC DAMPER OR PRESSURE RELIEF VALVE IN LIVING OR SLEEPING AREA!

2.3.2 Operation with external control and buffer only

The following requirements must be met.
– an acumulatorr tank (min 100 gal) is mandatory
– a return hold up group = boiler protection group (113 °F / 45 °C) is mandatory
– To ensure the boiler minimum temperatures and the pump lag time, the transfer/hot water tank circuit pump

and the external heat requirement must be connected on the electrical panel to the intended terminals.(see

BioWINXL connection diagram).

2.3.3 Heating water

CAUTION

The chemical composition of the heating water must conform with local legislation
and meet the directives, guidelines and standards.

Applicable for Austria (excerpt from ÖNORM H 5195):

a) According to ÖNORM M 5195 (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) The pipe lines and heating appliances should be thoroughly rinsed before the boiler is connected.
c) To protect the boiler from contamination from the heating system, installation of a dirt trap is required in old

or existing systems 5 with maintenance cocks installed in the return line.
d) If oxygen diffusion or sludge build-up cannot be prevented, the system must be segregated by means of a heat

exchanger.
e) If antifreeze is used, a minimum volume of 25 % antifreeze is required, otherwise corrosion prevention is not

guaranteed.

14

2. For the Installer

Water hardness according to ÖNORM H5195-1 (2010 edition)

Highest permissible hardness of filling water for heating systems, heat generator with a water content of > 0.3 l/kW:
Specific water volume of the system < 1.55 gal/kBTU (20 l/kW): *

Overall performance of heat output Total alkaline earth °dH °fH

≤ 170.6 kBTU/hr up to 3.0 mmol/l up to 16.8 30

> 170.6 kBTU/hr to ≤ 682.4 kBTU/hr up to 2.0 mmol/l up to 11.2 20

Specific water volume of the system ≥ 1.55 gal/kBTU (20 l/kW) but < 3.87 gal/kBTU (50 l/kW) : *

Overall performance of heat output Total alkaline earth °dH °fH

≤ 170.6 kBTU/hr up to 2.0 mmol/l up to 11.2 20

> 170.6 kBTU/hr to ≤ 682.4 kBTU/hr up to 1.0 mmol/l up to 5.6 10

Specific water volume of the system ≥ 3.87 gal/kBTU (50 l/kW) : *

Overall performance of heat output Total alkaline earth °dH °fH

≤ 170.6 kBTU/hr up to 1.0 mmol/l up to 5.6 10

> 170.6 kBTU/hr to ≤ 682.4 kBTU/hr up to 0.5 mmol/l up to 2.8 5

* At an annual replenishment of maximum 5% of the system‘s water content; additionally, we comply with ÖNORM H5195 part 1 and VDI 2035 T1.

Important general comments on water quality

The boilers are intended for operation with clean, good quality tap or drinking water. The water should be clear
and free from visible impurities and suspended matter.

Most heating systems are comprised of different materials. Therefore, a water treatment is recommended to
prevent or limit problems (metal corrosion, calcification and sludge formation, microbiological contamination,
chemical changes in unprepared system water).

Reduce the oxygen volume in the heating circuit as much as possible.
Annually refill a maximum of 5 % of the system‘s water capacity.

Important general comments on water quality for new systems

New systems must be fully cleaned from any residue (plastic waste, lubricants, etc.) by means of a universal
cleaning agent. Rinse with a minimum of three times the installation volume of the central heating system.
Cleaning with chemical products must be done by a professional. Carefully rinse the system until the rinse water
is clear and free from any impurities.

The water must not be softened to less than 0.5°dH, as water any softer harms the system. An inhibitor must be
used in combination with a water softener.

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 can­not be met, it is recommended to treat the heating water. In cases of improperly cleaned systems or poor water
quality, the guarantee and warranty are void.

Heating water quality

Acidity 8.2 – 10.0 pH
Electrical conductivity ≤ 800 μS/cm at 25 °C
Chloride ≤ 30 mg/l
Other substances < 1 mg/l

15

2. For the Installer

2.3.4 Water-side resistance (pressure loss)

Pressure loss (psi)

BioWIN XL

Diagram 1

1

0,1

200 2000

INFORMATION

If using a buffer, the BioWIN XL return flow temperature must be increased – see
hydraulic diagram in the planning documents.

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.
The thorough cleaning of the system must be performed by a professional. A sufficient and controlled flow is
required to remove all impurities and residues from the heating circuit. In the case of cleaning with chemical
products, the above points are especially important for avoiding any residues from corrosive products.

In the event of considerable impurities/clogging (deposits of lime), the boiler must be cleaned by a professional
with appropriate tools.

Circulation filter/dirt trap

The installation of a dirt trap is recommended. In accordance with ÖNORM H5195, a filter sharpness of ≤ 25 μm
is required.

Water treatment

The compatibility of the product with all system materials must be checked when using a water treatment system.
Observe the manufacturer’s instructions.

The water must be regularly checked, and if necessary, changed.

Practical advice:

The system‘s water quality must be regularly checked by a professional (at least every two years), especially
after filling or refilling the water. Record all treatment measures in a report to document the maintenance work
on the boiler and system.

Flow rate (gal/h)

16

2. For the Installer

Pellet boiler BioWIN XL

Max. induction length

(Air intake)

49.2 ft / 15 m, each 90° bend reduces induction length by 3.3 ft / 1 m

Air intake cross-section

Min. diameter 5.9 inches / 150 mm

(or technically equivalent cross-section)

Combustion air line

(Air intake)

DN 160

Seal integrity: min. 3.53 ft3/hr or 0.1 m3/h at 0.1 mbar; temperature resistance: 203 °F / 95 °C

(commercially available plastic drain pipes with correctly inserted seal)

Connecting piece

(Flue gases)

Max. length 9.8 ft / 3 m,

only pipes with minimum classification acc. to EN 1851-1:

T200 H1 D V2 L(xxxx) G(xx) are to be used.

Shaft head Tested wind protection fixture or design in accordance with DIN V 18160-1 – Fig. 5.

Air/flue gas system

(sketch Fig. 5)

Configuration as equal-pressure system

(induction opening for air intake and opening for flue gas discharge are within a

square with a max. edge length of 1.6 ft / 0.5 m)

Required accreditations: for solid fuels; moisture-resistant

Swinging draught flap,

explosion flap

Energy-saving intake regulators or explosion flaps are not allowed to be installed in the living

area. Comply with the statutory regulations and directives.

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.

2.4.1 Operating with room air

Combustion air supplied directly from the installation room

If combustion air is drawn directly by the system from the boiler/heater room, the room must be adequately ven­tilated. The combustion air should be directed near the boiler.

The minimum area of free cross-section must be 0.11 in2 / kBTU (2.5 cm2 / per kW) of the boiler‘s nominal total output1.
The ventilation opening to the outdoors for combustion air should be designed as follows:

– the flow of air must not be restricted in any way by the weather (e.g., snow, leaves),
– the free cross-section area remains the same when taking the cover grille, discs, etc. into consideration.

2.4.2 Operating independently of the room air

Combustion air supplied from ventilation draught in the flue

The combustion air is drawn in through an unobstructed ventilation draught in the chimney – Fig. 5. The openings
for the intake air and the flue gas are only allowed to be located with a square with a 19.7 inches / 500 mm side
length. This ensures that the same air pressure is always present in the openings (even in very windy conditions).

Only flue gas systems that have been tested and approved for solid fuel applications may be used.
In the BioWIN XL, the air intake pipe can be connected directly (without accessories).

The lengths stated are only a guideline and should not take the place of an actual flue calculation.

1

The boiler‘s nominal total output is the sum of the nominal outputs of all heat generators installed in the same boiler / installation room.

INFORMATION

Malfunctions or complaints occasioned by inadequate combustion air will not be
covered by the guarantee!

17

2. For the Installer

Fig. 5 Sketch of ventilation draught in flue

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
supply air/flue layout

Air/flue system with concentric supply
air/flue layout

1 ...........Pellet boiler

2 ...........Combustion air line (intake air)

3 ...........Connecting piece (flue gas)

4 ...........Air/flue gas system

Detail X, Y
Opening (shaft head in accordance
with DIN V 18160-1)

DH .......flue gas diameter

HÜ .......spacing of opening

HA ........spacing of dispersion plate

E ..........protrusion of dispersion plate

5 ...........Flue gases

6 ...........Combustion air (intake air)

Requirements:

HÜ ≥ 2 x DH
HA = min. 3.9 inches / 10 cm
E= 0 to 3.1 inches / 0 to 8 cm

Requirements:
HÜ ≥ DH

HA = min. 3.9 inches / 10 cm
E= 0 to 3.1 inches / 0 to 8 cm

The connection for the chimney connecting piece should be designed so that the condensate is prevented from
flowing back into the connecting piece from the chimney.

18

2. 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

– Transport boiler to installation site on wooden pallet.

Fig. 6 Removing transport screws Fig. 7 Removing transport protection

Fig. 8 Removing transport bracket Fig. 9 Removing crate and unscrewing

floor plate of integral fuel hopper

– The boiler can be installed directly on a non-flammable surface and does not require special foundations.

If foundations have been provided, we recommend that they be made according to the boiler dimensions to

ensure that the four set screws make contact properly.
– Remove 2 x transport screws at front and back – Fig. 6.
– Remove transport protection and transport bracket – Fig. 7 and Fig. 8.
– Remove crate and unscrew floor plate of integral fuel hopper – Fig. 9.

Tip!

The rear transport bracket is intended for clamping to a barrow – Fig. 6.

INFORMATION

For information on installing the suction probes in a sheet steel tank or fabric tank,
refer to the installation instructions for sheet steel and fabric tanks. For informa­tion about configuring pellet stores, see the planning document ”Pellet stores for
pellet boilers.”

19

2. For the Installer

1

2

4

5

6

7

8

9

10

21

22

11

18 19

20

23

12

15

16

14

3

13

24

26

25

2.7 Installation

The cladding of the BioWIN XL consists of the following parts:

Fig. 10 Parts of BioWIN XL

1 ...........Rear wall

2 ...........Cladding cover

3 ...........Intake fitting

4 ...........Right side panel

5 ...........Hinges

6 ...........Cladding door cover

7 ...........InfoWIN

PLUS

8 ...........Cladding door, right

9 ...........Base panel

10 .........Centre panel, horizontal

11 .........Cladding door, left

12 .........Auger tube rotary feeder unit

13 .........Access ramp

14 .........Floor plate

15 .........Integral fuel hopper support

16 .........Integral fuel hopper

18 .........Left side panel

19 .........Integral fuel hopper cladding cover

20 .........Top right fuel hopper cladding

21 .........Centre panel, vertical

22 .........Hand guard bracket

23 .........Side anti-contact protection

24 .........Ash wedge (BioWIN XL 350 NA only)

25 .........Top and bottom cone parts (BioWIN XL 350 NA)

26 .........Top and bottom cone parts (BioWIN XL 450 NA / 600 NA)

20

2. 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.
– Remove support for integral fuel hopper (part 15) from boiler by removing transport attachments (cable ties)

– Fig. 14.

– Unscrew auger tube rotary feeder (part 12) with transport attachments (sheet metal brackets) from boiler

(Fig. 15) and remove transport attachments – Fig. 16.

Fig. 13 Aligning boiler Fig. 14 Boiler aligned with floor plate

Fig. 15 Unscrewing transport attachments

from boiler

Fig. 16 Unscrewing transport attachments

from rotary feeder

Integral fuel
hopper support

Auger tube

21

2. For the Installer

– Screw auger tube rotary feeder to boiler with 2 hexagon screws (M10 x 20) – Fig. 17, Fig. 18.

Fig. 17 Mounting auger tube

rotary feeder unit

Fig. 18 Auger tube rotary

feeder unit - mounted

– Slide sensor for auger tube safety thermostat together with sensor guard (Fig. 19) into sensor holder as far as

it will go – Fig. 20.

– Connect 3-pin plug for rotary feeder proximity switch – Fig. 21.

Fig. 19 Sensor and sensor guard Fig. 20 Inserting sensor and sensor guard

into holder on auger tube

Fig. 21 Connecting 3-pin plug for proximity switch

2x

M10 x 20

CAUTION

Ensure tight seal between rotary feeder and boiler.

22

2. 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.
– Secure integral fuel hopper below at front with 1 x M10 nut – Fig. 25.

Fig. 22 Inserting screws by approx. 1/3 Fig. 23 Fitting the integral fuel hopper

– Remove 1 TT screw (M8 x 16) from the floor plate (Fig. 26) and use it to mount the one support (attached to the

side of boiler) on the floor plate.

Fig. 24 Tightening 2 TT screws at top Fig. 25 1 nut at bottom of integral fuel hopper

Fig. 26 Removing 1 TT screw

2x

M8 x 16

Fig. 27 Attach support first to hopper and

then to floor plate

2x

M8 x 16

1x

M10

Note!

First secure the support to the fuel hopper at the top with 1 TT screw (M8 x 16) and then attach it to
the floor plate with 1 TT screw (M8 x 16) – Fig. 27.