Windhager VarioWIN Operating Manual

VarioWIN

Pellet central heating boiler

pneumatic + direct

Operating Manual

05/2010 092945/01

2

Table of contents: Page

Important information for system operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

1.2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.3 Start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.4 Checking the heating water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.5 Operating noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.6 Filling the pellet store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.7 Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.7.1 Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.7.2 Power failure (or if the blower is not running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.7.3 Burner pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.7.4 Heating door and ash door handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.7.5 Direct pellet feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.7.6 Entering the pellet storage room, storage container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.1.1 VarioWIN Premium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.1.2 VarioWIN Exklusiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.2 Functional elements and operating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.2.1 VarioWIN with direct pellet feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.2.2 VarioWIN with 41 kg reserve supply container, manual loading . . . . . . . . . . . . . . . . . . . . . .10

2.2.3 VarioWIN with pneumatic pellet feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.3 Opening the cladding door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.4 Check before switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5 Filling the reserve supply container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.5.1 VarioWIN Exklusiv-S – Manual filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.5.2 VarioWIN Exklusiv-P – Pneumatic pellet feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.5.3 VarioWIN Premium/Exklusiv-D – Direct pellet feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.6 InfoWIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.7 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.7.1 OFF mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.7.2 ON mode, lighting ON, self-test, lighting OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.7.3 Pellet feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.7.4 Solid fuel / buffer mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.7.5 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.7.6 Flue cleaning function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.7.7 Shutdown procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.8 Operating phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.1 Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.2 Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.3 Ignition phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.4 Flame stabilisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.5 Modulation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.6 Burnout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.8.7 Burner OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3

Table of contents: Page

2.9 Information texts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.9.1 Next boiler cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.9.2 Operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.9.3 Total pellet consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.9.4 Flue gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.9.5 Boiler temperature setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.9.6 Current boiler output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.9.7 Display module software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.9.8 Main PCB software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.9.9 Boiler model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.10 Menu guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2.10.1 Operator level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

2.10.2 Service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

2.10.2 VarioWIN with REG standard control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

2.11 Heating system operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

2.11.1 VarioWIN with MES system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Care, cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.1 Care of cladding and keyboard foil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.2 Cleaning and operating implements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.3 Overview of intervals between maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

3.4 Heating surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

3.5 Ash pan, ash on heating surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

3.6 Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3.6.1 Baffle plate, thermocontrol sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3.6.2 Burner pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

3.7 VarioWIN reserve supply container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

3.8 Top heating surfaces and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

3.9 Blower wheel, blower box, exhaust pipe and rotary feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

3.9.1 Blower wheel, blower box and exhaust pipe to flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

3.9.1 Rotary feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

4.1 No display on InfoWIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.2 Information messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4.3 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.4 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Guarantee and warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

I\n\h\a\l\t\s\v\e\r\z\e\i\c\h\n\i\s\)[2020]>

4

Important information for system operators

Dear Heating System Owners,

We would like to congratulate you on your new environmentally friendly boiler system. With the purchase of
this high-quality product by WINDHAGER ZENTRALHEIZUNG, you have selected a system that provides more
comfort and optimised fuel consumption while utilising an environmentally friendly means of saving resour­ces. Your boiler was manufactured under strict ISO 9001 certified standards, was subjected to extensive tests
and all its components are recyclable.

On the following pages we have provided specific information and important tips regarding system operation,
unit functions and cleaning. Please pay close attention to these instructions. Familiarity with the material in this
document will allow you to enjoy long-term operation of the unit. We wish you all the best with your WIND­HAGER boiler!

Cordially,

WINDHAGER ZENTRALHEIZUNG

Caution symbols

Please take careful note of the following symbols on the pellet boiler and in these instructions.

Ignoring the warnings identified can lead to personal injury.

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

1.1 Safety precautions

The boiler and related accessories reflect the 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. Installation may be performed only by appropriately qualified tech­nicians.

Please note: Risk of crushing from rotating auger.
If you have to touch these parts, always deenergise the boiler.

Warning of hot surface: risk of burns!
Before touching these surfaces, you must switch off the boiler and let it cool.

5

Important information for system operators

1.3 Start-up and maintenance

Have Windhager Customer Service or one of our customer service PARTNERS put your new boiler into servi­ce. In this way, all functions of the new unit will be thoroughly checked; you will also benefit from the detailed
information provided by the system installer. Installation by a qualified technician as well as the maintenance
required by the guarantee limitations will guarantee the optimal use and service life of your boiler system. This
is the only way to assure the benefits of this technologically advanced boiler and guarantee safe, environmentally
friendly and energy-saving system operation.

The following preconditions must be met before you order the initial start-up:

1.) Boiler installed correctly.

2.) System fully wired up electrically.

3.) System rinsed, filled and vented – heat 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 are part of the guarantee requirements as listed in the enclosed „guarantee limita­tions“.

Note:

During the first few weeks after start-up, condensation can occur in the combustion chamber, on the hea-

ting surfaces and in the ash pan. This has no effect on the function and service life of the boiler.

1.4 Checking the heating water

The chemical composition of the heating water must meet the specifications of ÖNORM H 5195 Part 1 or VDI
2035 T1. According to ÖNORM M 5195 Part 1, 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.

The check must be performed once every year in heating systems with more than 1500 litres of heating water.

In the event of repair work requiring a change of water in the heating system, the heating water is to be checked
within 4 to 6 weeks after such work.
Corrosion and sediment resulting from improper heating water are not covered by the guarantee and warranty.

The pellets must be stored in a dry place so that they can be transported without problems and in order to
achieve trouble-free operation with optimum combustion and at maximum efficiency.

1.2 Fuel

The boilers are designed to burn the following fuels:
Pellets according to ÖNORM M7135 and DIN

plus

.

Significant criteria based on the standards are as follows:

Diameter 6 mm Length 80% between 15 – 30 mm
Smooth surface

Density at least 1.1 kg/dm

3

Residual moisture content max. 10%

Energy content min. 18 MJ/kg = 5 kWh/kg

(in water-free condition)
Ash content max. 0.5% Abraded particles max. 2.3%
Chemical/synthetic binding agents are strictly prohibited No impurities from varnish or paint residues, etc.

6

1.6 Filling the pellet store

Fig. 2 Switching off the VarioWIN

Important information for system operators

1.5 Operating noises

The VarioWIN is a modern, fully automated pellet central heating boiler with a high level of convenience in terms
of operation and cleaning. This automation means that operating noises may occur during normal operation.

Normal operating noises are:

Flame noises

– Natural flame noise can be heard depending on the size of the flames.

Light scratching and scraping noises

– Depending on the level of contamination, cleaning noises may occur
during automated cleaning or shake-out. If these become louder over time ⇒ Clean the pellet central heating
boiler, especially the burner pot.

Trickling of pellets and vacuum cleaner noise

– Fully automated pellet supply involves pellets being sucked from
the storage room into the reserve supply container. During filling, the suction turbine generates a „vacuum cle­aner noise“ in the storage room and the feed hose, and the trickling of the pellets can be heard in the reserve
supply container.

Clicking noises

– The relays switch on or off when the control unit is installed.

Liquid noise, gurgling

– This is caused by air in the heating water ⇒ Bleed the system.

Air induction noises

– Air induction noise occurs at the air supply induction point for combustion (air opening

in the device) ⇒ Use air supply pipes to relocate the induction point outside the house or into an adjacent room.

Note:

Due to these operating and flame noises, we do not recommend installing the device in bedrooms or

quiet rooms – see also the information in the VarioWIN „Assembly instructions“.

The pellet boiler must be switched off correctly at least 15 minutes before the store is filled – Fig. 2.

Press the ON/OFF button. Never switch off using the emergency OFF switch!

Pressing one of the six buttons firstly switches just the
lighting and display on. The boiler is only switched off
when the button is pressed for the 2nd time. Wait until
burnout mode has finished (not indicated on the display)
and open the combustion chamber doors.

During filling, negative pressure is created in the pellet
store and this can cause burn-back in the pellet boiler. The­refore, the boiler must be stopped from operating during
the filling procedure.

Fig 2a „Storage room fill“ sticker on the

storage room door

Every storage room fill should be documented by adding
the date and volume to the „Storage room fill“ sticker –
Fig. 2a.

002357/00

01/2010

Befüllung Lagerraum

Filling date and volume

Remplissage du silo de stockage

Datum/Date/Date

Menge/Volume/Quantité

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

kg

7

Never fill the burner pot with pellets by hand. Excessive combustion material in the burner pot means
that the pellets will not be ignited optimally. Too much low temperature carburisation gas will be gene­rated and this can lead to deflagration.

1.7.3 Burner pot

Do not open the combustion chamber door, there is an increased risk of deflagration when opening the
combustion chamber door. A self-test is performed following a power failure during combustion and
then operation is continued automatically.

1.7 Sources of danger

1.7.1 Fire protection

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

1.7.2 Power failure (or if the blower is not running)

Important information for system operators

1.7.5 Direct pellet feed

Do not attempt to enter an unaired storage room (particularly buried tanks).

1.7.6 Entering the pellet storage room, storage container

In certain conditions, higher concentrations of harmful gases (e.g. carbon monoxide) may build up in pellet sto­rage rooms. If these are allowed to build up over long periods, it may present a hazard. Even though there is
no risk under normal circumstances, this scenario cannot be completely ruled out.

– When working in filled pellet storage rooms, in the interests of safety a second person should always remain

outside the storage room. Always air pellet stores thoroughly before entering.

– For stores that are difficult to access or only accessible from above (e.g. buried tanks), the person entering

the store should use additional safety equipment.

– Keep children away from the pellet store!

1.7.4 Heating door and ash door handles

Warning of hot surface: risk of burns!
Before touching the combustion chamber and ash door handles, you must switch off the boiler and let

it cool.

Please note: Risk of crushing from rotating auger.
Before entering the pellet store or handling the unit with the auger open, always de-energise the boiler.
Never operate the boiler with the extraction port (auger) open!

8

Operation

2.1 Functional description

The VarioWIN pellet central heating boiler and the Modular Energy System MES or the REG standard control
combine to form a perfect unit. The VarioWIN automatically fires when the control system signals a heating requi­rement. Following „purging“ (safety function), ignition starts and the pellet metering auger switches on. The
burner pot is automatically filled with pellets. When flame formation has been detected (by the thermocontrol
sensor), the boiler enters flame stabilisation mode and then control mode (modulation mode) and keeps to the
specified boiler temperature setpoint (between 60 °C and 75 °C). The boiler enters burnout mode if the output
drops below the minimum nominal thermal output or no heating requirement is signalled by the control system.
The blower continues to run until the burner pot has cooled down. Therefore, do not switch off the electricity
supply to the device too soon.

2.1.1 VarioWIN Premium

Manual cleaning:

The heating surfaces are cleaned manually using the cleaning lever. The cleaning residues from the heating
surfaces and the combustion residues from the burner pot drop into the ash pan or ash pan space.

VarioWIN Premium-D with direct pellet feed and extraction port for mounting a year-round pellet con­tainer

Direct pellet feed transports the pellets from a sheet steel tank or self-build pellet store via a rotary feeder to
the burner pot.

2.1.2 VarioWIN Exklusiv

Automatic cleaning:

Fully automatic heating surface cleaning:
A motor moves the heating surface cleaning system vertically and the heating surfaces remain clean.

Fully automated ash compactor:
The fully automated ash compactor uses a motor and pressure plate to compress the ash in the ash container.
This makes the emptying intervals up to 3 times longer.

VarioWIN Exklusiv-S with 41 kg pellet reserve supply container

The reserve supply container is loaded by hand.

VarioWIN Exklusiv-P with pneumatic pellet feed

The pellet feed uses a maintenance-free suction turbine to fill the VarioWIN reserve supply container fully auto­matically 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 reserve supply container or at the end of the enable time or the
beginning of the start time, and runs for as long as the reserve supply container is full. Filling is not started if
the boiler is in heating operation or the feed has been blocked by the control unit (outside the enable time, e.g.
at night). If the boiler is operating when filling is necessary, the boiler switches to burnout mode.

Switching between suction probes 1, 2 and 3 is fully automatic. The system changes to the next suction probe
after the reserve supply container has been filled a certain number of times. This means the storage room is
emptied as evenly as possible.

VarioWIN Exklusiv-D with direct pellet feed and extraction port for mounting a year-round pellet con­tainer

Direct pellet feed transports the pellets from a sheet steel tank or self-build pellet store via a rotary feeder to
the burner pot.

9

Fig. 3 VarioWIN with direct pellet feed – View from right

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19 *

22

24

20

21

23

25

26

27

Operation

2.2 Functional elements and operating controls

2.2.1 VarioWIN with direct pellet feed

1 Ash pan
2 Ash door
3 Filling and evacuation cock
4 Primary air pin
5 Pressure gauge
6 Burner pot
7 Down chute
8 Combustion chamber door
9 Baffle plate
10 Thermocontrol sensor
11 Cladding door
12 Heating surface cover
13 Safety valve
14 Down channel
15 Exhaust pipe
16 Exhaust pipe cleaning opening
17 Blower motor
18 Blower box
19 Motor for ash compactor
20 Auger flange
21 Rotary feeder

Rotary feeder cleaning opening
22 Spur gear
23 Auger motor
24 Metering auger
25 Maintenance pipe
26 Rotary feeder proximity switch
27 Extraction port

10

Operation

2.2.2 VarioWIN with 41 kg reserve supply container, manual loading

Fig. 5 VarioWIN with pneumatic pellet feed – View from right

1

2

3

5

6

7

9

10

13

17

16

18

19

20

4

8

11

12

22

21

23

24 25

15

1 Ash pan
2 Ash door
3 Filling and evacuation cock
4 Primary air pin
5 Pressure gauge
6 Burner pot
7 Down chute
8 Combustion chamber door
9 Baffle plate
10 Thermocontrol sensor
11 Cladding door
12 Heating surface cover
13 Safety valve
14 Reserve supply container cover
15 Protective grille
16 Rotary feeder
17 Metering auger and motor
18 Rotary feeder cleaning opening
19 Exhaust pipe
20 Exhaust pipe cleaning opening
21 Blower motor
22 Blower box
23 Motor for ash compactor

2.2.3 VarioWIN with pneumatic pellet feed

1

2

3

5

6

7

9

10

13

14

15

17

16

18

19

20

4

8

11

12

22

21

23

Fig. 4 VarioWIN with 41 kg reserve supply container – View from right

1 Ash pan
2 Ash door
3 Filling and evacuation cock
4 Primary air pin
5 Pressure gauge
6 Burner pot
7 Down chute
8 Combustion chamber door
9 Baffle plate
10 Thermocontrol sensor
11 Cladding door
12 Heating surface cover
13 Safety valve
15 Reserve supply container cover
16 Rotary feeder
17 Metering auger and motor
18 Rotary feeder cleaning opening
19 Exhaust pipe
20 Exhaust pipe cleaning opening
21 Blower motor
22 Blower box
23 Motor for ash compactor
24 Inspection cover
25 Coarse filter

11

Operation

2.4 Check before initial start-up

a) System pressure (heating water pressure):

The system must be filled and vented. With the system cold, pressure should be at least 1.0 bar (maximum

1.8 bar) – Fig. 7. If you have any questions, your installer will gladly answer them.

Pressure gauge (system pressure)

Fig. 7 Filling the system

b) Ventilation:

If you are operating the device with room air, please make sure the room where it is installed is well venti­lated. The air supply must be as free of dust as possible.

c) Flue:

Please have the chimney sweep check the flue, and, if necessary, clean it.

Filling and evacuation cock

2.3 Opening the cladding door

Fig. 6 Opening the cladding door with the key.

Warning of hot surface: risk of burns!
Before touching the combustion chamber and ash door handles, you must switch off the boiler and let

it cool.

Insert the key, turn a quarter turn to the left and open the cladding door – Fig. 6.

12

2.5 Filling the reserve supply container

2.5.1 VarioWIN Exklusiv-S – Manual filling

Fold open the cover of the reserve supply container (Fig. 8) and fill the reserve supply container up to max. 1
cm below the edge. Close the cover.

Tip:

The reserve supply container should always be completely filled with pellets. This allows the incoming pel­lets to drop into the container better, reduces the size of the conical part of the pile and means that the contai­ner empties better.

Fig. 8 Folding open the cover

When filling, make sure no extraneous materials (e.g. shreds of the pellet bags resulting from cutting
open the bags) get into the reserve supply container – they could block the rotary feeder!

2.5.2 VarioWIN Exklusiv-P – Pneumatic pellet feed

The reserve supply container is filled by the fully automatic pellet feed. WINDHAGER Customer Service or the
customer service PARTNER will perform the first fill (start-up), take the boiler and its pellet supply into service
and familiarise the customer with the operation and cleaning of the boiler, with reference to the Operating Manu­al.

Operation

2.5.3 VarioWIN Premium/Exklusiv-D – Direct pellet feed

The VarioWIN is supplied by the direct pellet feed from the year-round pellet reserve supply container. WIND­HAGER Customer Service or the customer service PARTNER will perform the first fill (start-up), take the boiler
and its pellet supply into service and familiarise the customer with the operation and cleaning of the boiler,
with reference to the Operating Manual.

13

5s

RESET

Full-text display
(illuminated display)

Manual operation / flue cleaning
function

Signal lamp (LED)
„Operation“ – green;
„Malfunction“ – red

Menu buttons

ON/OFF button

Menu line

Operating phases are
displayed here, including
Standby, Burner OFF, etc.

Assignment of buttons to
their specific function

Operation

The various operating modes are displayed on InfoWIN together with the corresponding operating phases.

The following operating modes exist:
–OFF

– ON (with self-test, lighting ON, lighting OFF)
– Pellet feed
– Solid fuel / buffer mode
– Manual operation
– Flue cleaning function
– Shutdown procedure

Corresponding operating phases:
– Standby

– Purging
– Ignition phase
– Flame stabilisation
– Modulation mode
– Burnout
– Burner OFF
– Switch off heat generator

è

Boiler temperature

Standby

Info Menu

38

°C

Fig. 9 InfoWIN

2.6 InfoWIN

The InfoWIN is the boiler’s display and operating unit.
The InfoWIN unit consists of a large text display, an ON/OFF button with an LED signal lamp indicating Opera-

tion (green) or Malfunction (red); a switch for the flue cleaning function and four individual menu buttons. The
function of each menu button is displayed on the Menu line.

14

5s

RESET

5s

RESET

5s

RESET

Operation

2.7 Operating modes

2.7.1 OFF mode

The boiler is switched off when in OFF mode. The display and all
buttons, with the exception of the

ON/OFF

button, do not function.

The LED on the InfoWIN is not illuminated – Fig. 10.

2.7.2 ON mode, lighting ON,

self-test, lighting OFF

Press the ON/OFF button, lighting and display are switched on and
the self-test starts automatically – Fig. 11.

Self-test:

Sensors, switches and motors are checked during the self-test.
After a successful self-test, the display shows an operating phase

and the boiler water temperature (standard display). The LED sig­nal lamp lights green and the desired functions can be selected
using the buttons – Fig. 12.

If the self-test was unsuccessful, an information message (e.g. infor­mation, fault, alarm) is displayed (see sections 4.3 and 4.4).

Fig. 12 Standard display

Fig. 13 Display lighting OFF

Lighting ON/OFF

The display lighting switches off automatically after 10 min. (Fig.

13). Pressing one of the six buttons switches the lighting on again
for 10 min.

InfoWIN identifies and stores the various operating modes and sta­tes. Once the system is switched on, other operating modes may
also be displayed instead of the standard display, such as manual
operation or solid fuel/buffer mode; malfunctions are also display­ed. These operating modes and states are described later in these
instructions.

Fig. 11 Self-test

5s

RESET

Fig. 10 OFF mode

Self-test active

.....

(Animated symbol)

Boiler temperature

(Operating phases)

Info Menu

42

°C

Boiler temperature

(Operating phases)

Info Menu

42

°C

15

Operation

2.7.4 Solid fuel/buffer mode

If the VarioWIN pellet central heating boiler is combined with a solid fuel boi­ler or an buffer tank, the WVF or BUL module automatically switches over bet­ween pellet and solid fuel/buffer mode.

Combustion of the VarioWIN is stopped when the WVF or BUL module sends
the request to switch over to solid fuel/buffer mode – Fig. 16.

Following this, the system switches over to solid fuel/buffer mode and the
VarioWIN burner is locked – Fig. 17

If the pellet central heating boiler is switched off using the ON/OFF button on
the InfoWIN, an automatic switchover to solid fuel/buffer mode is performed
in conjunction with a WVF module. Once the InfoWIN unit is switched on, the
pellet central heating boiler may be locked for a maximum of 15 minutes due
to the switch-over delay. This is displayed by InfoWIN – Fig. 17.

After an hour in solid fuel/buffer mode, the display is shut down fully and only
the green LED is lit up. The display is switched back on by pressing a button
or when there is a heating requirement.

Fig. 16

Fig. 17

Solid fuel/
buffer mode

Burnout

Info Menu

42

°C

Solid fuel/
buffer mode

Burner locked

Info Menu

42

°C

2.7.3 Pellet feed

Pellet feed – Burnout

Pellet feed from the storage room into the reserve supply container has been
requested. Combustion is stopped. Pellet transport into the burner pot is stop­ped, the vacuum fan continues to run until all the remaining pellets have been
burned and the burner pot has cooled down – Fig. 14.

Pellet feed in operation

The pellet feed is in operation. Pellets are supplied from the storage room into
the reserve supply container. The burner is locked – Fig. 15.

Fig. 14

Fig. 15

Pellet feed

Burnout

Info Menu

42

°C

Pellet feed
in operation

Burner locked

Info Menu

42

°C

16

5s

RESET5sRESET

5s

RESET5sRESET

Operation

2.7.5 Manual operation

Fig. 18

Pressing the

Cancel

button or the

Manual operation / flue cleaning

function

button terminates the function – Fig. 19. The boiler returns

to automatic operation.

Setpoint adjustment for manual operation

By pressing the + or – button the display switches to the set tem­perature adjustment mode – Fig. 20. Use the

+

or –button to chan­ge the setpoint in 1 K steps. The temperature set in this mode is
not permanently saved. The original set temperature is used once
manual operation ends.

By pressing the

Back

button (Fig. 21) or after waiting 45 seconds,

the screen returns to its previous display.

Press for 5
seconds

The various operating phases are displayed here, inclu­ding Burner in operation, Burner OFF, etc.

Fig. 19

Fig. 20

Fig. 21

Pressing one of the six buttons switches the lighting and display on.
Manual operation starts if the Manual operation / flue cleaning func­tion button is pressed for more than five seconds – Fig. 18. This sets
the boiler temperature to the setpoint fixed for manual operation
(standard value 60 °C). The control system is not affected by this. The
lighting is switched off after the lighting timer has counted down
(10 min.); the function or display remains unchanged.

Note:

Manual operation cannot be started in „solid fuel/buffer mode“. Manual operation must not be started if
an installed solid fuel boiler is operating (heated up). Manual operation may be started if there is no solid fuel
boiler installed or if this is not operating and only the buffer tank is active. In this case, first set the operating
mode switch on the WVF module to relay test 2 or on the BUL module to relay test 1 (see WVF or BUL modu­le operating manual).

16

Manual operation
Boiler temperature

(Operating phases)

– Cancel +

42

°C

(Symbol flashes)

Manual operation
Boiler temperature

(Operating phases)

– Cancel +

42

°C

(Symbol flashes)

Manual operation
Set temperature

– Back +

70

°C

Manual operation
Set temperature

– Back +

70

°C

(Symbol flashes)

17

5s

RESET5sRESET

5s

RESET5sRESET

Briefly pressing the

Manual operation / flue cleaning function

button
switches on the display illumination. Pressing the button again starts
the flue cleaning function – Fig. 22. The boiler temperature is set to
approx. 60 °C for 45 min.

Operation

2.7.6 Flue cleaning function

This function aids the performance of legally-required emissions testing.

The flue cleaning function ends
– when the

Cancel

button is pressed – Fig. 24.

– automatically after about 45 minutes.

The various operating phases are
displayed here, including Burner in
operation, Burner OFF, etc.

Fig. 24

Fig. 23

Fig. 22

2.7.7 Shutdown procedure

The boiler is switched off – Fig. 25.

Fig. 25

The green LED flashes

Note:

The flue cleaning function cannot be started in „solid fuel/buffer mode“. The flue cleaning function must
not be started if an installed solid fuel boiler is operating (heated up). The flue cleaning function may be star­ted if there is no solid fuel boiler installed or if this is not operating and only the buffer tank is active. In this
case, first set the operating mode switch on the WVF module to relay test 2 or on the BUL module to relay test
1 (see WVF or BUL module operating manual).

Pressing the corresponding menu button enables the boiler to be ope­rated with 30 % or 100 % output – Fig. 23. The lighting is switched off
after the lighting timer has counted down (10 min.); the function or
display remains unchanged. When the button is first pressed only the
lighting is switched on.

When the

Manual operation / flue cleaning function

button is pres-

sed again the operating time is reset to 45 min.

Flue cleaning function
Power 100% 45min

(Operating phases)

30% Cancel 100%

42

°C

(Symbol flashes)

Flue cleaning function
Power 30% 45min

(Operating phases)

30% Cancel 100%

42

°C

(Symbol flashes)

Flue cleaning function
Power 30% 45min

(Operating phases)

30% Cancel 100%

42

°C

(Symbol flashes)

Shutdown procedure

Burnout

Info Menu

42

°C

18

2.8.6 Burnout

Combustion is stopped. Pellet transport into the burner pot is stopped, the
vacuum fan continues to run until all the remaining pellets have been burned
and the burner pot has cooled down – Fig. 31.

2.8.7 Burner OFF

There is a heating requirement from the control system, but the boiler tem­perature (actual value) is higher than the boiler temperature setpoint. This
means combustion is stopped and the burner is switched off – Fig. 32.

Fig. 31

Fig. 32

Boiler temperature

Burnout

Info Menu

42

°C

Boiler temperature

Burner OFF

Info Menu

42

°C

2.8 Operating phases

2.8.1 Standby

During this operating phase, the control system does not transmit requests
for heat. The burner is switched off and the boiler temperature setpoint is 0 °C
– Fig. 26.

After an hour in standby mode, the display is shut down fully and only the
green LED is lit up. The display is switched back on by pressing a button or
when there is a heating requirement.

2.8.2 Purging

The vacuum fan runs, the combustion chamber of the VarioWIN is flushed
through with fresh air. This phase can last several minutes before the burner
fires – Fig. 27.

2.8.5 Modulation mode

The burner is in modulation mode. The output can be infinitely varied between
30 % and 100 % – Fig. 30.

Operation

2.8.3 Ignition phase

The vacuum fan runs, pellets are transported into the burner pot and are igni­ted. When flame formation is detected, the system switches over to flame sta­bilisation – Fig. 28.

2.8.4 Flame stabilisation

Following the ignition procedure, even combustion is established and then the
system switches over to modulation mode – Fig. 29.

Fig. 26

Fig. 27

Fig. 28

Fig. 29

Fig. 30

Boiler temperature

Standby

Info Menu

42

°C

Boiler temperature

Purging

Info Menu

42

°C

Boiler temperature

Ignition phase

Info Menu

42

°C

Boiler temperature

Flame stabilisation

Info Menu

42

°C

Boiler temperature

Modulation mode

Info Menu

42

°C

19

5s

RESET5sRESET5sRESET

Operation

Fig. 33

2.9 Information text

Pressing the

Info

button calls up the most important VarioWIN infor-

mation – Fig. 33.
The

arrow

buttons select and display sub-menus – Fig. 34. By pres-

sing the

Back

button (Fig. 35) or waiting 45 seconds, the screen

returns to the standard display.

Fig. 34

Fig. 35

Boiler temperature

(Operating phases)

Info Menu

42

°C

The following information texts exist:
– Next boiler cleaning in about[h]

– Operating hours [h]
– Pellet consumption total [t]
– Flue gas temperature [°C]
– Boiler temperature setpoint [°C]
– Current boiler output [%]
– Display module software version
– Firing automate software version
– Boiler model

Next boiler
cleaning in about

Back

300

h

Next boiler
cleaning in about

Back

300

h

2.9.2 Operating hours

The total number of burner operating hours is displayed – Fig. 37

Fig. 37

2.9.1 Next boiler cleaning

Display of the operating time in hours remaining until the next boiler cleaning
– Fig. 36.

Note:

The operating time remaining until the next boiler cleaning depends on
the operating method and is constantly recalculated. Therefore, there may be
deviations from the normal operating hours.

Fig. 36

Next boiler
cleaning in about

Back

300

h

Operating hours

Back

1.234

h

20

Operation

2.9.6 Current boiler output

The current boiler output is displayed in %. The boiler output (modulation
mode) can be set from 30 % to 100 % – Fig. 41.

Fig. 41

Current
boiler output

Back

70

%

2.9.4 Flue gas temperature

If a flue gas temperature sensor (accessory) is connected, this function displays
the current flue gas temperature – Fig. 39.

Fig. 39

Flue gas temperature

Back

114

°C

2.9.3 Pellet consumption total

The total amount of pellets consumed is displayed in tonnes – Fig. 38.

Note:

The „Pellet consumption total“ is a calculated value and can differ from
the actual value by ±15%.

Fig. 38

Pellet consumption
total

Back

1. 30

t

2.9.5 Boiler temperature setpoint

The display indicates the boiler temperature setpoint as calculated by the con­trol system. This setpoint is used to control the burner – Fig. 40.

Fig. 40

Boiler temperature
setpoint

Back

63

°C

The flue gas temperature is measured directly on the flue outlet. It may
therefore deviate from a standard measurement.

2.9.7 Display module software version

The current software version of the display module (InfoWIN) is displayed –
Fig. 42.

Fig. 42

Software version
display module

Back

4.00

2.9.8 Firing automate software version

The current software version of the firing automate (main PCB) is displayed –
Fig. 43.

Fig. 43

Software version
firing automate

Back

4.10

2.9.9 Boiler model

The boiler model of the VarioWIN is displayed – Fig. 44.

Fig. 44

Boiler model

Pellet boiler 120K
Boiler 0

Back

21

5s

RESET5sRESET

5s

RESET

5s

RESET

Operation

2.10 Menu guide

Pressing the

Menu

button changes the menu display to operator

level or service level – Fig. 45.
Use the

arrow

buttons to select the operator level or service level

(Fig. 46) and confirm with the

Choose

button – Fig. 47.

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 48) or after a delay of 45 seconds.

Fig. 45

Fig. 46

Fig. 47

Fig. 48

Only trained service personnel may perform system modi­fications in the service level.

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Operator level

Service level

Choose Back

Operator level

Service level

Choose Back

22

Menu structure:

Operator level

Service level

(reserved for trained service

personnel only)

Time

Feed

operating mode

1)

Time profile

feed

1)

Probe

switching

1)

Menu

With enable

time

With start time

Without

time control

Switched off

Automatic Only probe 1 Only probe 2 Only probe 3

With enable time:

Start/finish

With start time:

Start

Operation

Time profile

ash com.

Boiler

cleaning

Start time 1

08:00

Start time 2

22:00

1)

Only displayed with a VarioWIN - VAE 120 P with pneumatic feed (suction system) when the unit has been adjusted by a trained
service technician in the service level.

23

5s

RESET5sRESET

5s

RESET5sRESET

Fig. 49

Fig. 50

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 52) or after a delay of 45 seconds.

2.10.1 Operator level

Pressing the

Menu

button changes to the „Operator level“ and

„Service level“ – Fig. 49.

Fig. 51

Operation

Use the

arrow

buttons to select „Operator level“ and confirm with

the

Choose

button – Fig. 50.

On the operator level, use the

arrow

buttons to select the requi-

red sub-menu (Fig. 51) and confirm with the

Choose

button.

Adjusting the:
Boiler cleaning: 2.10.1.1
Time: see section 2.10.1.2.
Feed operating mode: see section 2.10.1.3.
Time profile feed: see section 2.10.1.4.
Probe switching: see section 2.10.1.5.
Time profile ash compression: see section 2.10.1.6

Fig. 52

Note:

The menu items „Feed operating mode“, „Time profile feed“
and „Probe switching“ are only shown with a VarioWIN - VAE 120 P
with pneumatic feed (suction system) when service level is activa­ted.

Boiler cleaning

Time
Feed operating mode
Time profile feed
Probe switching
Time profile ash comp.

Choose Back

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Boiler cleaning

Time
Feed operating mode
Time profile feed
Probe switching
Time profile ash comp.

Choose Back

24

Operation

5s

RESET

5s

RESET

5s

RESET

5s

RESET

5s

RESET

Fig. 53

Fig. 54

Fig. 55

Fig. 56

Press the

Menu

button – Fig. 54.

Confirm the selected menu item „Operator level“ by pressing the

Choose

button – Fig. 55.

Use the

arrow

buttons to select the „Boiler cleaning“ sub-menu

item – Fig. 56.

Confirm the selected „Boiler cleaning“ sub-menu item by pressing
the

Choose

button – Fig. 57.

Fig. 57

Boiler temperature

(Operating phases)

Lighting ON

42

°C

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Boiler cleaning

Time
Feed operating mode
Time profile feed
Probe switching
Time profile ash comp.

Choose Back

Boiler cleaning

Time
Feed operating mode
Time profile feed
Probe switching
Time profile ash comp.

Choose Back

2.10.1.1 Boiler cleaning -

Resetting the cleaning request

After boiler cleaning has been performed (section 3.1), boiler cle­aning must be confirmed so that the operating time until the next
boiler cleaning is restarted.

Pressing one of the six buttons switches the lighting and display
on – Fig. 53.

Boiler cleaning must not be reset if cleaning has not been
carried out.

5s

RESET

5s

RESET

Pressing the

Yes

button resets the boiler cleaning – Fig. 58. The
display shows „Parameter is saved“ for a few seconds (Fig. 59) and
then changes back to the previous level – Fig. 60.

Fig. 58

Fig. 59

Has boiler and
burner cleaning
been performed?

Confirm

– Yes Back +

Parameter is
saved

.....

(Animated symbol)

Operation

25

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 60) or after a delay of 45 seconds.

5s

RESET

Fig. 60

Boiler cleaning

Time
Feed operating mode
Time profile feed
Probe switching
Time profile ash comp.

Choose Back

26

5s

RESET5sRESET

5s

RESET

5s

RESET

5s

RESET

Operation

2.10.1.2 Time

This time is used for the time control of the pellet feed, automatic
heating surface cleaning and automatic ash compression.

If the VarioWIN is operated with an MES control, the time is auto­matically adopted from the module and the time set here is over­written.

If the VarioWIN is operated with REG standard control, the time
must be set here too.

Pressing one of the six buttons switches the lighting and display
on – Fig. 61.

Fig. 61

Fig. 62

Fig. 63

Fig. 64

Fig. 65

Press the

Menu

button – Fig. 62.

Confirm the selected menu item „Operator level“ by pressing the

Choose

button – Fig. 63.

Confirm the selected sub-menu item „Time“ by pressing the

Choo-

se

button – Fig. 64.

Use the

arrow

buttons to set the required time – Fig. 65.

Set time

Save

– Yes No +

13:50

Boiler temperature

(Operating phases)

Lighting ON

42

°C

Boiler cleaning

Time

Feed operating mode
Time profile feed
Probe switc hing
Time profile ash comp.

Choose Back

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

27

5s

RESET

5s

RESET

5s

RESET

Fig. 66

Operation

Save the changed time by pressing the

Yes

button – Fig. 66. The
display shows „Parameter is saved“ for a few seconds (Fig. 67) and
then changes back to the previous level – Fig. 68.

Fig. 67

Fig. 68

Parameter is
saved

.....

(Animated symbol)

Set time

Save

– Yes No +

13:50

Boiler cleaning

Time

Feed operating mode
Time profile feed
Probe switching
Time profile ash comp.

Choose Back

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 68) or after a delay of 45 seconds.

28

5s

RESET5sRESET5sRESET5sRESET

5s

RESET

Operation

2.10.1.3 Feed operating mode

1)

This menu item sets:
– whether the feed is switched off, or

– whether the feed should fill the pellet boiler with or without time

control.

Pressing one of the six buttons switches the lighting and display
on – Fig. 69.

Fig. 69

Fig. 70

Fig. 71

Fig. 72

Press the

Menu

button – Fig. 70.

Confirm the selected menu item „Operator level“ by pressing the

Choose

button – Fig. 71.

Use the

arrow

buttons to select the sub-menu item „Feed opera-

ting mode“ – Fig. 72.

Confirm the selected sub-menu item „Feed operating mode“ by
pressing the

Choose

button – Fig. 73.

Fig. 73

Boiler cleaning
Time

Feed operating mode

Time profile feed
Probe switching
Time profile ash comp.

Choose Back

Boiler temperature

(Operating phases)

Lighting ON

42

°C

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Boiler cleaning
Time

Feed operating mode

Time profile feed
Probe switching
Time profile ash comp.

Choose Back

1)

Only displayed with a VarioWIN - VAE 120 P with pneumatic feed (suction
system) when the unit has been adjusted by a trained service technician in
the service level.

29

Burning duration with 25 kg pellets

VarioWIN Burning duration at nominal output

VAE 120 P approx. 10 h

5s

RESET5sRESET

5s

RESET

5s

RESET

The factory setting for „Feed operating mode“ is „switched off“.

Without time control: Select this if the feed noise (suction turbine)

is not audible or intrusive in the living area (or adjacent premi­ses). This mode guarantees the fewest possible feeds because
the reserve supply container is always „run to empty“.

Functional description: The pellet feed is automatically switched
on if required at any time.

With start time: Select this if you want the feed to start at the same

time every day.
Functional description: The reserve supply container is filled

every day if required at the set time (see page 31). Interim fills
are also performed if the filling amount is not sufficient for 24
hours.

With enable time: Select this if the feed noise (suction turbine) is

audible or intrusive in the living area (or adjacent premises).
Functional description: The pellet feed is enabled during a time

period that can be set (see page 32) and is automatically star­ted at this time if required. The reserve supply container is fully
refilled at the end of the enable time, if required.

Tip: A complete fill sucks in about 25 kg of pellets. Even if more
pellets are required during the blocked time, there is no automatic
fill and the VarioWIN switches off (fault message 381). Therefore,
do not select a lock-out time that is too long.

Fig. 74

Operation

Fig. 75

Fig. 77

It is only ever possible to select one menu item at a time. The
„Time profile feed“ corresponding to this selected menu item
can then be set in section 2.10.1.4.

Fig. 76

Use the

arrow

buttons to select the required sub-menu item – Fig. 74.

Save the changed feed operating mode by pressing the

Yes

button –
Fig. 75. The display shows „Parameter is saved“ for a few seconds
(Fig. 76) and then changes back to the previous level – Fig. 77.

The menu item or sub-menu item is exited by pressing the

Back

but-

ton (Fig. 77) or after a delay of 45 seconds.

Feed operating mode

with enable time
with start time
without time control

switched off

Save

Yes No

Feed operating mode

with enable time

with start time
without time control
switched off

Save

Yes No

Parameter is
saved

.....

(Animated symbol)

Boiler cleaning
Time

Feed operating mode

Time profile feed
Probe switching
Time profile ash comp.

Choose Back

30

5s

RESET

5s

RESET

5s

RESET

5s

RESET

5s

RESET

Operation

2.10.1.4 Time profile feed

1)

The „Time profile feed“ menu item displays the corresponding set­ting option depending on the setting in the „Feed operating mode“
menu item (see section 2.10.1.3).

Setting: „with enable time“ see page 32
Setting: „with start time“ see page 31
Setting: „without time control“ or „switched off“ see page 33

Pressing one of the six buttons switches the lighting and display
on – Fig. 78.

Fig. 78

Fig. 79

Fig. 80

Fig. 81

Press the

Menu

button – Fig. 79.

Confirm the selected menu item „Operator level“ by pressing the

Choose

button – Fig. 80.

Use the

arrow

buttons to select the sub-menu item „Time profile

feed“ – Fig. 81.

Confirm the selected sub-menu item „Time profile feed“ by pres­sing the

Choose

button – Fig. 82.

Fig. 82

Boiler cleaning
Time
Feed operating mode

Time profile feed

Probe switching
Time profile ash comp.

Choose Back

Boiler temperature

(Operating phases)

Lighting ON

42

°C

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Boiler cleaning
Time
Feed operating mode

Time profile feed

Probe switching
Time profile ash comp.

Choose Back

1)

Only displayed with a VarioWIN - VAE 120 P with pneumatic feed (suction
system) when the unit has been adjusted by a trained service technician in
the service level.

31

5s

RESET

5s

RESET

5s

RESET

5s

RESET

„with start time“

A time can be set here in the „Time profile feed“ menu item for fil­ling the reserve supply container if the „with start time“ setting is
active in the „Feed operating mode“ menu item (see section

2.10.1.3). The reserve supply container is filled every day at the set
time. Interim fills are also performed if the filling amount is not suf­ficient for 24 hours.

Factory setting „Feed start time“: Start 20:00

Pressing the

+

or –button changes the time in 1 min. steps – Fig. 83.

Fig. 83

Operation

Fig. 84

Fig. 86

Save the changed time by pressing the

Yes

button – Fig. 84. The
display shows „Parameter is saved“ for a few seconds (Fig. 85) and
then changes back to the previous level – Fig. 86.

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 86) or after a delay of 45 seconds.

Fig. 85

31

Feed start time

Start 20:00

Save

– Yes No +

Feed start time

Start 20:00

Save

– Yes No +

Boiler cleaning
Time
Feed operating mode

Time profile feed

Probe switching
Time profile ash comp.

Choose Back

Parameter is
saved

.....

(Animated symbol)

32

5s

RESET

5s

RESET5sRESET

5s

RESET

5s

RESET

„with enable time“

The start and end of the enable time can be set here in the „Time
profile feed“ menu item if the „with enable time“ setting is active
in the „Feed operating mode“ menu item (see section 2.10.1.3).

Factory setting „Feed enable time“: Start 07:00

End 22:00

Use the

arrow

buttons to select the time you want to change,

„Start“ or „End“ – Fig. 87.
Confirm the selected time by pressing the

Choose

button – Fig. 88.

Fig. 87

Operation

Fig. 88

Fig. 89

Fig. 90

Fig. 91

Pressing the +or –button changes the time in 15 min. steps – Fig.

89.

Save the changed time by pressing the

Yes

button – Fig. 90. The
display shows „Parameter is saved“ for a few seconds (Fig. 91) and
then changes back to the previous level.

Feed
enable time

Start 07:00

End 22:00

Choose Back

Feed
enable time

Start 07:00

End 22:00

Choose Back

Feed
enable time

Start 07:00

End 22:00

Save

– Yes No +

Feed
enable time

Start 07:00

End 22:00

Save

– Yes No +

Parameter is
saved

.....

(Animated symbol)

33

5s

RESET

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 92) or after a delay of 45 seconds.

Operation

Fig. 92

Feed
enable time

Start 07:00

End 22:00

Choose Back

5s

RESET

„without time control“ or „switched off“

No setting is possible here in the „Time profile feed“ menu item if
the „without time control“ or „switched off“ setting is active in the
„Feed operating mode“ menu item (see section 2.10.1.3) – Fig. 94.

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 94) or after a delay of 45 seconds.

Fig. 94

Feed without
time control or
switched off

Back

5s

RESET

Fig. 93

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 93) or after a delay of 45 seconds.

Boiler cleaning
Time
Feed operating mode

Time profile feed

Probe switching
Time profile ash comp.

Choose Back

34

5s

RESET

5s

RESET

5s

RESET

5s

RESET

5s

RESET

34

Operation

2.10.1.5 Probe switching

1)

If the VarioWIN is equipped with a pneumatic feed (suction system)
with 2 or 3 probes, it is possible to set here which probe is used
for sucking pellets from the pellet storage room. There are four dif­ferent setting options:

– Automatic: Removal from all 3 probes, automatic switching.
– Only probe 1:Removal from probe 1 only, no switching
– Only probe 2:Removal from probe 2 only, no switching
– Only probe 3:Removal from probe 3 only, no switching

Note: If „Pellet feed system, operation with 2 probes“ is set in the
„Service level“, the option of „Only probe 3“ is not displayed here.

Fig. 95

Fig. 96

Fig. 97

Fig. 98

Pressing one of the six buttons switches the lighting and display
on – Fig. 95.

Press the

Menu

button – Fig. 96.

Confirm the selected menu item „Operator level“ by pressing the

Choose

button – Fig. 97.

Use the

arrow

buttons to select the „Probe switching“ sub-menu

item – Fig. 98.

Confirm the selected sub-menu item „Probe switching“ by pressing
the

Choose

button – Fig. 99.

Fig. 99

Boiler temperature

(Operating phases)

Lighting ON

42

°C

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Boiler cleaning
Time
Feed operating mode
Feed tiame profile

Probe switching

Time profile ash comp.

Choose Back

Boiler cleaning
Time
Feed operating mode
Time profile feed

Probe switching

Time profile ash comp.

Choose Back

1)

Only displayed with a VarioWIN - VAE 120 P with pneumatic feed (suction
system) when the unit has been adjusted by a trained service technician in
the service level.

35

5s

RESET5sRESET

5s

RESET

5s

RESET

Use the

arrow

buttons to select the required probe switching –

Fig. 100.

Fig. 100

Operation

Fig. 101

Fig. 103

Save the changed probe switching by pressing the

Yes

button –
Fig. 101. The display shows „Parameter is saved“ for a few seconds
(Fig. 102) and then changes back to the previous level.

Tip: This menu item is also needed for „Pellet store maintenance“
in order to switch off one specific probe at a time – see also the pel­let store planning documents.

The menu item or sub-menu item is exited by pressing the

Back

button (Fig. 103) or after a delay of 45 seconds.

Fig. 102

Probe switching

Automatic

Only probe 1
Only probe 2
Only probe 3

Save

Yes No

Parameter is
saved

.....

(Animated symbol)

Probe switching

Automatic

Only probe 1
Only probe 2
Only probe 3

Save

Yes No

Boiler cleaning
Time
Feed operating mode
Time profile feed

Probe switching

Time profile ash comp.

Choose Back

36

5s

RESET

5s

RESET5sRESET

5s

RESET

5s

RESET

2.10.1.6 Time profile ash compression (Exklusiv version only)

The ash in the ash pan is only compressed at the 2 set start times
and when approx. 15 kg of fuel has been consumed. The start times
can be set in steps of 15 minutes (start time 1 and start time 2).

Factory setting: Start time 1: 08:00

Start time 2: 22:00

Pressing one of the six buttons switches the lighting and display
on – Fig. 104.

Fig. 104

Fig. 105

Fig. 106

Fig. 107

Press the

Menu

button – Fig. 105.

Confirm the selected menu item „Operator level“ by pressing the

Choose

button – Fig. 106.

Use the

arrow

buttons to select the sub-menu item „Time profile

ash comp.“ – Fig. 107.

Confirm the selected sub-menu item „Time profile ash comp.“ by
pressing the

Choose

button – Fig. 108.

Fig. 108

Boiler cleaning
Time
Feed operating mode
Time profile feed
Probe switching

Time profile ash comp.

Choose Back

Boiler temperature

(Operating phases)

Lighting ON

42

°C

Boiler temperature

(Operating phases)

Info Menu

42

°C

Operator level

Service level

Choose Back

Operation

Boiler cleaning
Time
Feed operating mode
Time profile feed
Probe switching

Time profile ash comp.

Choose Back

37

5s

RESET5sRESET5sRESET

5s

RESET

5s

RESET

Use the

arrow

buttons to select the start time you want to change,

1 or 2 – Fig. 109.
Confirm the selected start time by pressing the

Choose

button –
Fig. 110.

Fig. 109

Fig. 110

Fig. 111

Fig. 112

Fig. 113

Pressing the +or –button changes the time in 15 min. steps –
Fig. 111.

Save the changed time by pressing the

Yes

button – Fig. 112. The
display shows „Parameter is saved“ for a few seconds (Fig. 113) and
then changes back to the previous level.

Start times for
ash compression

Start time 1 08:00

Start time 2 22:00

Choose Back

Start times for
ash compression

Start time 1 08:00

Start time 2 22:00

Save

– Yes No +

Parameter is
saved

.....

(Animated symbol)

Operation

Start times for
ash compression

Start time 1 08:00

Start time 2 22:00

Choose Back

Start times for
ash compression

Start time 1 08:00

Start time 2 22:00

Save

– Yes No +

38

Operation

5s

RESET

5s

RESET

5s

RESET

2.10.2 Service level

System parameters, start-up and the actuator test can be display­ed, performed and/or modified in the service level.

Fig. 115

Fig. 114

Changes in the service level may be performed only by trai­ned service personnel (for setting instructions, see the
VarioWIN „Assembly instructions“).

Fig. 116

The menu item or sub-menu item is exited by pressing the

Back

but-

ton (Fig. 116) or after a delay of 45 seconds.

Operator level

Service level

Choose Back

Service level only
for trained
service personnel

5 s

Parameters

Start-up
Actuator test

Choose Back

39

Operation

2.11 Heating system operation

2.11.1 VarioWIN with MES system control

Switching on – Automatic operation:

1. Press the ON/OFF button on the InfoWIN panel, the display lighting is switched on, the signal lamp lights

up green and a self-test is performed (see also section 2.7.2). After a successful self-test and if a setpoint is
transferred by the control system, the VarioWIN automatically starts operation.

2. Set the operating mode switch(es) on the MES control module(s) to „Automatic operation“ . The system

is operated (temperatures and operating times set) using the user module (installed in the living area) – ple­ase refer to the instructions.

Fig. 117 InfoWIN operating unit

ON/OFF button

Operating
mode switch

Switching off:

1. Set the operating mode to „Standby“ using the user module (installed in the living area).

2. If the boiler has been out of service for an extended period during the summer months, press the ON/OFF button

on the InfoWIN unit.

Flue cleaning function:

This is operated using the InfoWIN unit – see section 2.7.6.

Emergency operation:

In the event that the control system fails, selecting the „Manual operation“ mode on the MES control module
and InfoWIN unit (see section 2.7.5) will activate emergency operation to maintain heat and hot water .

For operation of the MES and user module(s), please see the respective operating instructions.

The anti-freeze function is not active when the boiler is shut off.

InfoWIN
operating unit

Fig. 118 Control panel behind right side panel

40

Operation

2.10.2 VarioWIN with REG standard control

Switching on – Automatic operation:

1. Press the ON/OFF button on the InfoWIN panel, the display lighting is switched on, the signal lamp lights

up green and a self-test is performed (see also section 2.7.2). After a successful self-test and if a setpoint is
transferred by the control system, the VarioWIN automatically starts operation.

2. Set both manual switches to the “Automatic” position.

3. Set the operating mode switch on the REG standard control unit RAM 786 to “Automatic operation“ . The

REG standard control unit RAM 786 (installed in the living area) is used to operate the system (set the des­ired temperatures and operating times) – please refer to the separate operating instructions.

The time must be set on the InfoWIN (see section 2.10.1.2). The time is used for the time control of the pel­let feed, automatic heating surface cleaning and automatic ash compression.

Operating mode switch

Switching off:

1. Set “Standby” operating mode on the REG standard control unit (installed in the living area).

2. If the boiler has been out of service for an extended period during the summer months, press the ON/OFF

button on the InfoWIN unit.

Flue cleaning function:

This is operated using the InfoWIN unit – see section 2.7.6.

Emergency operation:

If the control system fails, you can use the two manual switches and on the boiler control panel and the
button on the InfoWIN unit (see section 2.7.5) to activate emergency operation to maintain heat and hot
water.

The anti-freeze function is not active when the boiler is shut off.

Manual switch for
heating

Manual switch for hot
water tank

Automatic
operation

Fig. 119 InfoWIN operating unit

Fig. 121

REG standard control RAM 786

ON/OFF button

InfoWIN opera­ting unit

Fig. 120 Control panel behind right side panel

41

Operation

How to switch to emergency (manual) operation

Heating emergency operation:

1. There must be power to the boiler. The unit is switched on (otherwise, press the ON/OFF button on the
InfoWIN unit).

2. Select “Manual operation” on the InfoWIN unit – see section 2.7.5.

3. Set the manual switch to the „Heating manual operation” position.

4. Also set the motorised mixing valve to manual operation and select the desired flow temperature. The boi­ler temperature will be maintained at the selected temperature (60 to 75 °C). Exercise caution if you have

underfloor heating.

Emergency operation of boiler reservoir with feed pump:

1. There must be power to the boiler. The unit is switched on (otherwise, press the ON/OFF button on the
InfoWIN unit).

2. Select „Manual operation” on the InfoWIN unit – see section 2.7.5.

3. Set the manual switch to the „Hot water tank manual operation” position.

4. Once the desired hot water temperature has been reached, set the manual switch to the „Hot water tank auto­matic operation” position.

Emergency operation of hot water tank loading with charging valve:

1. There must be power to the boiler. The unit is switched on (otherwise, press the ON/OFF button on the
InfoWIN unit).

2. Select „Manual operation” on the InfoWIN unit – see section 2.7.5.

3. Set both manual switches and to the „Manual operation“ position.

42

3.1 Care of cladding and keyboard foil

Clean the cladding and the keyboard foil with a damp cloth as needed. In the event of heavy soiling, use soapy
water or diluted suds (do not use strong cleaners or sharp cleaning instruments).

3.3 Overview of intervals between maintenance

A clean boiler saves fuel and protects the environment. Fly ash and combustion residues must be cleaned off the
pellet central heating boiler at regular intervals. Therefore always clean your boiler as required!

Annual maintenance is required in addition to cleaning. This is performed

by WINDHAGER Customer Service or

the customer service PARTNERS and is a prerequisite of the guarantee limitations.
The cleaning and ash removal intervals may be reduced or extended depending on the pellets used (e.g. ash

proportion) and the power consumed by the heating system (frequently switching on and off).
The VarioWIN is equipped with a cleaning interval display. The cleaning request for the combustion chamber

and burner pot is displayed on the InfoWIN and must be reset after cleaning is finished – see section 2.10.1.1.

Care, cleaning and maintenance

3.2 Cleaning and operating implements

Install the hanger with the instructions folder, cleaning and operating implements, dowels and bolts on a wall
in the boiler room / installation room – Fig. 122.

1 . . . . .Folder containing instructions

2 . . . . .Key for cladding door and manual

heating surface cleaning with VarioWIN Premium

3 . . . . .Spatula

4 . . . . .Cleaning brush

5 . . . . .Hanger for installation on the wall

6 . . . . .Cleaning tool or removal device for cone

Fig. 122 Instructions folder, cleaning and ope-

rating implements with hanger

1

2

3

4

5

6

43

Care,

cleaning and

ash removal intervals

VarioWIN Premium-D VarioWIN Exklusiv-S VarioWIN Exklusiv-P/D

Depending on pellet con-

sumption

Approx. every 41 kg

(~ 20 operating hours)

–

Add pellets to

reserve supply container

–

Depending on pellet con-

sumption

Approx. every 400 kg

(~ 250 operating hours)

Empty the ash pan

Operate the heating surface

cleaning lever

Frequent use of the lever increases

efficiency

– –

Display

“

Clean boiler and

burner

“

IN 580

FE 390

Clean combustion chamber

and burner pot

Empty the ash pan

Operate the heating surface

cleaning lever

Frequent use of the lever increases

efficiency

– –

Display

“

Clean boiler and

burner

“

IN 580

FE 390

–

Clean combustion chamber

and burner pot

Check reserve supply

container VarioWIN,

if necessary

remove dust

Empty the ash pan

Clean combustion chamber

and burner pot

Check reserve supply

container VarioWIN,

if necessary

remove dust

Empty the ash pan

At least once per

heating season

Clean top heating surfaces

and linkage

Clean blower wheel and

blower box

Clean exhaust pipe to flue

Check the storage container, if

necessary remove dust

Clean top heating surfaces

and linkage

Clean blower wheel and

blower box

Clean exhaust pipe to flue

Remove dust from reserve

supply container and

clean filter

Clean the top heating surfaces

and linkage

Clean blower wheel and

blower box

Clean exhaust pipe to flue

Remove dust from reserve

supply container and

clean filter

Check the storage room or sto-

rage container, if necessary

remove dust

Care, cleaning and maintenance

44

Tip: Position newspaper or the like to protect the floor against fly ash before opening the combustion chamber
door.

– Open the cladding door and ash door, empty the ash pan under the combustion chamber and the ash pan

for the heating surfaces – Fig. 125.

Assembly:

– Push in the ash pans, close the doors.
– Switch the VarioWIN back on with the ON/OFF button.

Fig. 123 Connect the key and operate it

Fig. 124 Switching off the VarioWIN Fig. 125 Emptying the ash pan

Always switch the boiler off first with the ON/OFF button (Fig. 124) and wait until burnout mode has
finished. Do not open the combustion chamber and ash door during operation.

3.5 Ash pan, ash on heating surface

Care, cleaning and maintenance

3.4 Heating surfaces

VarioWIN Premium

Optimum efficiency is achieved when the heating surfaces are cleaned as often as possible using the key. Howe­ver, no later than before the ash pan is emptied or ash is removed from the heating surfaces, the key should
be connected on the right-hand side and moved back and forth several times – Fig. 123.

Ash pan for
heating surfaces

When emptying the ash pans, remember that there could still be embers in the ash!

VarioWIN Exklusiv

The heating surfaces are cleaned fully automatically after the set start times (see section 2.10.1.6) and when
approx. 15 kg of fuel has been consumed ⇒ on average 1x a day.

Ash pan for
combustion chamber

45

Care, cleaning and maintenance

Do not open the combustion chamber door during operation. Always switch the boiler off first with the
ON/OFF button (Fig. 126) and wait until burnout mode has finished. It is essential to let the boiler cool
down before cleaning.

Thermocontrol sensor

Fig. 127 Removing and cleaning the baffle plate

Fig. 128 Cleaning the thermocontrol sensor

(with cleaning brush)

Fig. 126 Switching off the VarioWIN

3.6 Combustion chamber

The VarioWIN is equipped with a cleaning interval display. The cleaning request for the combustion chamber
and burner pot is displayed and must be reset after cleaning is finished – see section 2.10.1.1. „Boiler cleaning

- Resetting the cleaning request“.

3.6.1 Baffle plate, thermocontrol sensor

– Open the combustion chamber door, lift the baffle plate at the right and guide it out at an angle, sloping

down to the left – Fig. 127, Removing the baffle plate and fly ash.

– If necessary, remove fly ash from the thermocontrol sensor with a cleaning brush. The thermocontrol sen-

sor is located at the top left of the combustion chamber behind the baffle plate – Fig. 128.

Assembly:

By working through these steps in reverse order.

46

Care, cleaning and maintenance

Do not open the combustion chamber door during operation. Always switch the boiler off first with the
ON/OFF button and wait until burnout mode has finished. It is essential to let the boiler cool down befo­re cleaning.

Before cleaning with a vacuum cleaner, check that there are no longer any embers in the combustion
residue!

The glow ignition is located in the primary air tube so avoid shaking the burner pot violently – risk of
breakage!

– Lift out the cone (3) using the cleaning tool (1) – Fig.

129.

– Use the spatula to scrape off the deposits from all

sides of the cone (3), but particularly on the undersi­de.

– Vacuum out the burner pot, remove the primary air pin

(4) and carefully clean the holes with a small screw­driver or drill bit if necessary (holes must be clear).

– Lift out and remove the grate plate (5) from below

through the base of the burner pot. Scrape off ash resi­dues from the grate plate (5) and from the hole in the
middle using the spatula to clean it.
Tip: Dampen stubborn residue with water before scra­ping off.

– Scrape combustion residue off the burner pot base by

turning the cleaning tool (1) – Fig. 129. The pipe for the
primary air pin serves as a guide for the cleaning tool
– see detail. Use the spatula to scrape the edges of the
burner pot base clean. All secondary air holes (6) must
be clear - clean them with a small screwdriver or drill
bit if necessary.

– Remove combustion residue from the burner pot with

a vacuum cleaner. Vacuum the ash out of the primary
air tube (in the middle of the burner pot).

Clean the burner pot once the secondary air holes or the holes in the primary air pin are partly blocked or the
unit prompts you to clean the burner pot with a fault message.

Fig. 129 Fig. 130

Assembly:

– Insert the grate plate (5), making sure the projection/opening of the grate plate (5) projects through the dri-

ver of the driving rod and rests fully on the bottom grate plate – Fig. 130.
Important: Before inserting the primary air pin (4), once again vacuum out the primary air tube in the midd-

le of the burner pot. Make sure there is no debris in the tube (to avoid damage to the ignition element!).
– Insert the primary air pin (4) (groove must engage with anti-twist device).
– Place the cone (3) into the burner pot using the cleaning tool (1). The guide groove (2) on the cone must

engage with the lock (7) – Fig. 129.
– Note: After cleaning, the cleaning request for the combustion chamber and burner pot is reset on the Info-

WIN – see Section 2.10.1.1.

1 Cleaning tool or removal device for cone
2 Guide groove for locking the cone in the burner pot
3 Cone
4 Primary air pin
5 Grate plate
6 Secondary air holes
7 Lock for cone
8 Burner pot

Detail

3.6.2 Burner pot

47

Care, cleaning and maintenance

3.7 VarioWIN reserve supply container

It is necessary to clean the reserve supply container if too much dust has collected on the sides or at the ope­ning above the auger, or there are foreign bodies in the reserve supply container. In order to be able to check
this, there must not be any pellets in the reserve supply container. Therefore, allow the pellets in the reserve
supply container to be consumed or, in the case of the VarioWIN with pneumatic feed (suction system), switch
off the feed on the day before (see section 2.10.1.3 Setting the feed operating mode).

Fig. 131 Switching off the VarioWIN

Fig. 132 Folding open the cover

Cleaning

VarioWIN Exklusiv-S with manual filling:
– Switch off the VarioWIN with the ON/OFF button on the InfoWIN (Fig. 131) and wait until the display has gone

out.
– Open the cover of the reserve supply container (Fig. 132) and vacuum out the pellets, dust or foreign bodies

through the mesh using a vacuum cleaner.

48

Care, cleaning and maintenance

– Remove both knurled screws (Fig. 135) and fold open the inspection cover (Fig. 136).
– Remove dust (bridge formation) from the container and from both Fill level switch (proximity switch) using

a vacuum cleaner.
– Close the inspection cover again and screw it on with knurled screws.

Fig. 135 Removing the two knurled screws

Fig. 136 Folding open the inspection

cover, removing dust

Fig. 137 Removing the knurled screws

Fig. 138 Removing the coarse filter,

removing pellets and dust

– Remove both knurled screws at the back from the coarse filter (Fig. 137) and remove the coarse filter (Fig. 138).
– Remove pellets and dust using a vacuum cleaner.
– Put the coarse filter back on and screw it on with knurled screws.

Assembly:

By working through these steps in reverse order.

VarioWIN Exklusiv with pneumatic feed (suction system):
– Switch off the VarioWIN with the ON/OFF button on the InfoWIN (Fig. 133) and wait until the display has gone

out.
– Open the cover of the reserve supply container – Fig. 134.

Fig. 133 Switching off the VarioWIN

Fig. 134 Folding open the cover

Fill level switch (proximity switch)

49

3.8 Top heating surfaces and linkage

These parts are automatically checked and cleaned as part of the annual maintenance by WINDHAGER Customer
Service or the customer service PARTNER.

Fig. 140 Removing the cover

Fig. 141 Removing the wing nuts and cover

Fig. 142 Removing the jet protection plate

Care, cleaning and maintenance

Fig. 143 Cleaning top heating surfaces and linkage

Fig. 139 Switching off the VarioWIN

– Unscrew two wing nuts from the heating surface cover and remove the complete cover – Fig. 141.
– Remove the jet protection plate (tip: vacuum out fly ash first using a vacuum cleaner) – Fig. 142.

Fig. 144 Connect the key and move it back

and forth several times

Fig. 145 Emptying the ash pan

– Empty the ash pan for heating surfaces – Fig. 145.

– Vacuum down the top heating surfaces and linkage or clean with a cleaning brush – Fig. 143.
– For VarioWIN Premium only (manual heating surface cleaning): Connect the key on the right-hand side and

move it back and forth several times – Fig. 144.

Always switch the boiler off first with the ON/OFF button (Fig. 139) and wait until burnout mode has
finished. It is essential to let the boiler cool down before cleaning.

– Remove the front cover – Fig. 140.

50

3.9.1 Blower wheel, blower box and exhaust pipe to flue

Fig. 147 Disconnecting the blower

plug

Fig. 150 Removing the wing nuts and cleaning

opening – cleaning the exhaust pipe

– Disconnecting the blower plug – Fig. 147.
– Unscrew two wing nuts from the blower box and remove the complete blower unit – Fig. 148.

Fig. 149 Cleaning the blower wheel

Fig. 148 Removing wing nuts, removing the

blower unit

– Clean the blower wheel using a spatula and brush – Fig. 148.
– Inside of blower box: Clean fly ash with a vacuum cleaner.
– Unscrew two wing nuts from the exhaust pipe and remove the cleaning cover (Fig. 150). Clean fly ash out of the

exhaust pipe with a vacuum cleaner. Close the cleaning cover again.

Care, cleaning and maintenance

It is essential to let the boiler cool down before cleaning.

– Unhook the rear right side panel cladding and disconnect the mains power plug over the control panel – Fig. 146
– Remove the screw under the mains power plug on the control panel (Fig. 148) and swivel open the control panel.

These parts are automatically checked and cleaned as part of the annual maintenance by WINDHAGER Custo­mer Service or the customer service PARTNER.

Fig. 146 Removing the power plug and screw

3.9 Blower wheel, blower box, exhaust pipe and

rotary feeder

Mains
power plug

51

Care, cleaning and maintenance

Assembly:

– Screw the screw plug back in and refit the cladding parts 1– 4.
– Close the control panel, connect the securing mechanism and mains power plug at the top using a screw and

hook in the side panel.

3.9.1 Rotary feeder

VarioWIN S/P with 41 kg reserve supply container / pneumatic pellet feed:

Cleaning:

– Unscrew the screw plug (WAF 22) from the rotary feeder (Fig. 151) and vacuum pellet dust out of the rotary fee-

der using a vacuum cleaner.

Fig. 153 Removing dust from the rotary feeder

Screw plug

1

2

3

4

Fig. 152 Removing cladding parts 1–4 in the

case of direct pellet feed

VarioWIN D with direct pellet feed:

Cleaning:

– In the case of the VarioWIN with direct pellet feed, cladding parts 1 to 4 must be removed from the actuator

first – Fig. 152

– Unscrew the screw plug (WAF 22) from the rotary feeder (Fig. 153) and vacuum pellet dust out of the rotary fee-

der using a vacuum cleaner.

Fig. 151 Removing dust from the rotary feeder

Screw plug

Assembly:

– Guide the blower unit in at the back using the stay bolts and attach at the front with two wing nuts.
– Reconnect the blower plug.

Assembly:

– Screw the screw plug back in.
– Close the control panel, connect the securing mechanism and mains power plug at the top using a screw and

hook in the side panel.

52

5s

RESET5sRESET5sRESET

Troubleshooting

The VarioWIN pellet boiler is self-monitoring during operation. All deviations from normal operation are display­ed on the InfoWIN by information, fault or alarm messages. If one of these messages appears, the LED lights
up red, an information, fault or alarm symbol flashes, and an information code is displayed along with a brief
description in full text – Fig. 154.

Pressing the

Info

button (Fig. 154) displays the related information text (Fig. 155). To exit the information text

menu, press the

Back

button (Fig. 155) or wait 10 seconds and the information, fault or alarm message is display-

ed again – Fig. 154.
With almost all messages, it is necessary to press the

Reset

button after rectifying the cause of the informa-

tion, fault or alarm message. In these cases, „Reset“ is displayed in the menu line – Fig. 154.
If „Reset“ is not displayed in the menu line, the boiler starts operating again automatically after the cause of

the information, fault or alarm message has been rectified.
Pressing the

Te st

button changes to the actuator test immediately – Fig. 156. This function is only intended for

trained service personnel (for setting instructions, see the VarioWIN „Assembly instructions“). Pressing the

Back

button (Fig. 157) exits the actuator test.

Fig. 154

LED „red“

Brief description

Flashing symbol

Information code

Information

text

Fig. 155

If you wish to call WINDHAGER Customer Service or your customer
service PARTNER due to a malfunction, please first make a note of
the following data from the rating plate:

- Model

- Factory number

- Year of manufacture
The rating plate is located behind the cladding door between the com-

bustion chamber door and the ash door – Fig. 158.

Rating plate

Fig. 158 Rating plate

Fig. 157

Induced draught fan
defective

AL 016

Info Reset Test

42

°C

!

Clean blower wheel and
blower box.
Press Reset.

Note operating
manual.

Back

Induced draught fan

Auger conveyor
Ash removal
Ignition element
Ash compression
Suction turbine

Choose Back

All safety functions are deactivated during the actuator test!

5s

RESET

Induced draught fan
defective

AL 016

Info Reset Test

42

°C

!

Fig. 156

53

Troubleshooting

4.2 Information messages

Code Meaning/effect Cause/remedy

IN 581

Replenish fuel

The reserve supply container is almost
empty. Top up pellets.

Boiler continues to heat until the remaining fuel quantity has been consumed.
a) VarioWIN without feed or with direct pellet feed:

Fill fuel into the reserve supply or year-round container (see section 2.5).

b) VarioWIN with pneumatic feed (suction system):

Feed is switched off in „feed operating mode“ (see section 2.10.1.3). In
„Feed operating mode“ menu item, set to „with enable time“, „with start
time“ or „without time control“.

IN 582

Reserve supply container empty

The reserve supply container is empty.
Top up pellets. Burner is locked.

The reserve supply container is empty.
a) VarioWIN without feed or with direct pellet feed:

Fill fuel into the reserve supply or year-round container (see section 2.5).

b) VarioWIN with pneumatic feed (suction system):

Feed is switched off in „feed operating mode“ (see section 2.10.1.3). In
„Feed operating mode“ menu item, set to „with enable time“, „with start
time“ or „without time control“.

IN 590

Clean boiler and burner

Perform cleaning and confirm in opera­tor level.

Boiler and burner are still operating.
Boiler and burner must be cleaned or the both ash pans (see Fig. 159) emp-

tied (see sections 3.4, 3.5 and 3.6). Following cleaning, confirm cleaning on
the InfoWIN in operator level (see section 2.10.1.1).

IN 595

Door open

Burner locked. Only open the door
when the burner is switched off.

Cladding door is open, burner locked.

a) Close the cladding door.

b) Door switch on cladding door does not switch correctly, adjust – see assem-

bly instructions.

Code Meaning/effect Cause/remedy

–

No display

Boiler is off, cannot be switched on with
the ON/OFF button.

a) No electricity, check the cable to the device and the building fuse.

b) No electricity, device fuse defective – check and replace if necessary – see

page 56, Fig. 160.

c) InfoWIN plug loose or poorly connected or not connected together during

installation – check and connect together firmly if necessary, plug is loca­ted at top behind cover – see assembly instructions; Installing the cladding.

4.1 No display on InfoWIN

54

Troubleshooting

Code Meaning/effect Cause/remedy

FE 238

Feed is not sucking any pellets in

Check pellet supply in storage room
and feed hose. Press Reset.

No pellet feed is possible. The boiler does not operate.
a) No pellets at the suction probe – Set „probe switching“ to „automatic“ or

select another probe (see section 2.10.1.5). Press the Reset button

b) Feed hose blocked at the cyclone intake or entry to the changeover unit –

clear it. Press the Reset button.

c) Inform Windhager Customer Service or a heating technician.

Emergency operation: Switch off the feed unit (see section 2.10.1.3). Fill the reser­ve supply container with pellets by hand, boiler is allowed to continue operating
without feed.

FE 239

Probe switching defective

Check the changeover unit.
Press Reset.

No pellet feed is possible. The boiler does not operate.
Press the Reset button. If the fault reoccurs after a reset, inform Windhager

Customer Service or a heating technician.

Emergency operation: Switch off the feed unit (see section 2.10.1.3). Fill the reser­ve supply container with pellets by hand, boiler is allowed to continue operating
without feed.

FE 381

Reserve supply container empty

Time programme blocking feed.
Change enable time in menu/operator
level.

Feed is outside the enable time. Enable time for the feed has been set too
short, which means the pellets in the reserve supply container are used up
and the feed is blocked.

Extend the enable time for the feed in the „Feed operating mode“ menu item
(see section 2.10.1.3) or operate „with start time“ or „without time control“.

FE 382

Fill level switch in reserve supply
container defective

Check the switch in the reserve supply
container. Press Reset.

The boiler does not operate.

a) Fill level switch (proximity switch) dirty, remove the dust (see section 3.7),

press the Reset button.

b) Fill level switch (proximity switch) in the reserve supply container defecti-

ve – inform Windhager Customer Service or a heating technician.

Emergency operation: Switch off the feed unit (see section 2.10.1.3). Fill the reser­ve supply container with pellets by hand, boiler is allowed to continue operating
without feed.

FE 390

Emergency operation!
Clean boiler and burner

Perform cleaning and confirm in operator
level.

The boiler is in cyclic operation, i.e. has idle times.
a) Boiler and burner must be cleaned or the both

ash pans (see Fig. 159) emp­tied (see sections 3.4, 3.5 and 3.6). Following cleaning, confirm cleaning
on the InfoWIN in operator level (see section 2.10.1.1).

b) Motor or limit switch of ash compactor defective, inform Windhager Custo-

mer Service or a heating technician.

4.3 Fault messages

Fig. 159 Emptying the ash pan

Ash pan for heating surfaces

Ash pan for combustion chamber

55

Troubleshooting

Code Meaning/effect Cause/remedy

AL 005

Shake-out defective

Shake-out defective or sticking.
Clean the burner pot. Press Reset.

Shake-out motor no longer moves or no longer reaches the end position, boi­ler switches to burnout mode.

a) Burner contamination; close combustion chamber doors, press reset but-

ton; once the alarm message is rectified, clean the burner pot as descri­bed in section 3.6.

If the alarm message remains active, clean the burner pot as described in
section 3.6. Note: Grate plate at top can only be raised and removed when
closed. If the grate plate is not fully closed, vacuum it out. Close combus­tion chamber door, press reset button, if the alarm message remains in
place, repeat the process or inform Windhager Customer Service or a hea­ting technician.

b) Grate plate not inserted correctly or check correct installation position (see

section 3.6).

c) Motor for shake-out defective, inform Windhager Customer Service or a

heating technician.

d) Limit switch defective, inform Windhager Customer Service or a heating

technician.

AL 006

Auger conveyor motor defective

Auger conveyor motor defective.
Press Reset.

Boiler enters burnout mode, vacuum fan is stopped immediately.
a) Auger conveyor or rotary feeder jammed due to a foreign body, clean the

reserve supply container, opening above auger conveyor or rotary feeder
(see section 3.9) and remove the foreign body. Press the Reset button. The
alarm message AL 171 may light on up to 2 occasions until the boiler starts
operating again, press the Reset button.

b) Control thermostat defective, inform Windhager Customer Service or a

heating technician.

c) Press the Reset button. If the malfunction recurs immediately after a short

period, or recurs at regular intervals, contact Windhager Customer Servi­ce or your heating technician.

d) Renew the auger conveyor motor, inform Windhager Customer Service or

a heating technician.

AL 016

Vacuum fan defective

Clean blower wheel and blower box.
Press Reset.

The actual speed is different from the nominal speed. The boiler switches to
burnout mode.

a) The blower wheel and blower box are dirty; clean them (see section 3.9).

Press the Reset button. If the malfunction recurs immediately after a short
period, or recurs at regular intervals, contact Windhager Customer Servi­ce or your heating technician.

b) Renew the vacuum fan motor, inform Windhager Customer Service or a

heating technician.

AL 062

Air intake/exhaust flap defective

Air intake/exhaust flap defective or not
opening. Check flap. Press Reset.

External air choke (optional) does not open.
a) Check the air choke, press the Reset button.

b) Inform Windhager Customer Service or a heating technician.

AL 071

Safety / emergency switch open

Check switch position of safety / emer­gency switches.

Boiler enters burnout mode but the blower does not run.
Switch on emergency heating/OFF switch.

4.4 Alarm messages

The glow ignition is located in the primary air tube so avoid sha­king the burner pot violently – risk of breakage!

56

Troubleshooting

Fig. 160 VarioWIN control panel, rear right side panel removed

Cover of safety thermostat B7

Cover of safety thermostat
auger tube B7a

Device fuse T 6.3 A

Code Meaning/effect Cause/remedy

AL 076

Boiler sensor defective

Check the boiler sensor and connec­tions. Press Reset.

The boiler switches to burnout mode.

a) Press the Reset button. If the malfunction recurs immediately after a short

period, or recurs at regular intervals, contact Windhager Customer Servi­ce or your heating technician.

b) Renew the boiler sensor, inform Windhager Customer Service or a heating

technician.

AL 078

Thermocontrol sensor defective

Check the thermocontrol sensor and
connections. Press Reset.

The boiler switches to burnout mode.
a) Thermocontrol sensor is too cold < 0 °C. Sensor warm up.
b) Press the Reset button. If the malfunction recurs immediately after a short

period, or recurs at regular intervals, contact Windhager Customer Servi­ce or your heating technician.

c) Renew the thermocontrol sensor, inform Windhager Customer Service or

a heating technician.

AL128

No flame formation in control
mode

Clean boiler and burner.
Press Reset.

The flame goes out in modulation mode. The boiler switches to burnout mode.

a) Clean the burner and the boiler. Check the exhaust pipe to the flue and

clean it if necessary, press the Reset button.

b) Auger conveyor or rotary feeder jammed due to a foreign body. Clean the

reserve supply container, opening above auger conveyor or rotary feeder
(see section 3.9) and remove the foreign body. Press the Reset button. The
alarm message AL 171 may light on up to 2 occasions until the boiler starts
operating again, press the Reset button.

c) Inform Windhager Customer Service or a heating technician.

AL 133

Safety temperature shut­down

Check the system and filling pressure.
Press Release button on boiler.

Boiler temperature is above 100 °C, boiler enters burnout mode, vacuum fan
is switched off immediately.

a) Check the water level or pressure in the heating system – refill, bleed the

air.

b) Air in the heating system – bleed air.

c) The heat pump or boiler feed pump is sticking or is defective – start pump

manually or have it repaired.

Once the boiler water temperature falls below 90 °C, remove the cover, press
the Release button of the safety thermostat B7 firmly – Fig. 160.

If the malfunction occurs after a short period, or recurs at regular intervals,
contact Windhager Customer Service or your heating technician.

AL 135

Excess temperature in the auger
tube

Check the burner. Press Release button
B7a on control panel.

The boiler switches to burnout mode.

a) Check the burner, remove all pellets from the burner pot.
b) Remove the cover from the safety thermostat auger tube B7a, press the

Release button firmly (see Fig. 160). If the ignition does not function first
time (AL 171), press the Reset button (pellets in the auger conveyor will
have been damaged due to the higher temperature).

57

Troubleshooting

Code Meaning/effect Cause/remedy

AL 171

Maximum heating up time excee­ded

Clean the burner pot. Press Reset.

a) VarioWIN D without feed or with direct pellet feed:

The reserve supply container is empty. Fill fuel into the reserve supply or
year-round pellet container (see section 2.5). Press the Reset button until
the boiler starts operating again. The alarm message AL 171 may light up
again on up to 2 occasions, press the Reset button.

b) Clean the burner pot (see section 3.6), empty the ash pan, press the Reset

button.

c) Too much dust in the reserve supply container – bridge formation, remo-

ve the dust (see section 3.6), press the Reset button.

d) Auger conveyor or rotary feeder jammed due to a foreign body. Clean the

reserve supply container, opening above auger conveyor or rotary feeder
(see section 3.9) and remove the foreign body. Press the Reset button. The
alarm message AL 171 may light on up to 2 occasions until the boiler starts
operating again, press the Reset button.

e) VarioWIN with pneumatic feed (suction system):

Pellets stuck in the hose before the entry to the reserve supply container
– move the hoses at the connection pieces, press the Reset button.

f) Ignition defective, inform Windhager Customer Service or a heating tech-

nician.

AL 187

No communication with
main PCB

Check connection for main PCB and
connections. Press Reset.

The boiler switches to burnout mode.

a) Check the connection cable or InfoWIN plug connection to the main PCB,

inform Windhager Customer Service or a heating technician.

b) Connect the main PCB, inform Windhager Customer Service or a heating

technician.

AL 188

Internal error occurred
ErrorCode 188
Current TablelD 4

Internal communication error. The boiler switches to burnout mode.
A reset is performed automatically after 1 minute if this error occurs.

If the malfunction occurs after a short period, or recurs at regular intervals,
contact Windhager Customer Service or your heating technician.

58

Declaration of conformity

for the VarioWIN pellet boiler series
Issued by: WINDHAGER ZENTRALHEIZUNG Technik GmbH

Anton-Windhager-Strasse 20
A-5201 Seekirchen

Subject of the declaration: VarioWIN pellet boiler series
The appliances comply with the requirements in the following documents:

Seekirchen, 16. 2. 2010 WINDHAGER ZENTRALHEIZUNG

Technik GmbH

Johann Thalmaier, Board of Directors

Document no. Title

2006/42 EC
2004/108 EC
89/106 EEC

Machinery Directive
EMC Directive
Construction Products Directive

Standard Edition
EN 14785 2006

EN 60335-1 2001
EN 61000-6-1 2001
EN 61000-6-3 2001

59

60

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 warranty. Further, the warranty shall be void if equipment other
than that provided by WINDHAGER is installed. The special warranty restrictions for your system are available
in the „Warranty Conditions“ folder supplied with your boiler.

Guarantee and warranty limitations

Start-up and regular maintenance following the terms of the „Warranty Conditions“ will assure safe,
environmentally friendly and economical operation of your system. We recommend that you obtain a
maintenance service contract.

Subject to technical modifications. AWP-vor-übersetzt von 023821/01

Windhager Zentralheizung GmbH
A-5201 Seekirchen bei Salzburg
Anton-Windhager-Str. 20
Tel. [phone]
Fax [phone]
E-mail: [email protected]

www.windhager.com

Windhager Zentralheizung GmbH
D-86405 Meitingen bei Augsburg
Deutzring 2
Tel. [phone]
Fax [phone]
E-mail: [email protected]

Windhager Zentralheizung Schweiz AG
CH-6203 Sempach-Station bei Luzern
Industriestrasse 13
Tel. [phone]
Fax [phone]
E-mail: [email protected]

Austria: Germany: Switzerland: