Windhager VarioWIN Operating Manual
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Windhager VarioWIN Operating Manual

Pellet central heating boiler pneumatic + direct
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VarioWIN
Pellet central heating boiler
pneumatic + direct
05/2010
092945/01

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Summary of Contents for Windhager VarioWIN

  • Page 1 VarioWIN Pellet central heating boiler pneumatic + direct 05/2010 092945/01...

  • Page 2: Table Of Contents

    2.5.3 VarioWIN Premium/Exklusiv-D – Direct pellet feed ....... . .12 InfoWIN .
  • Page 3 2.10.2 VarioWIN with REG standard control ........

  • Page 4: Important Information For System Operators

    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 resour- ces.

  • Page 5: Fuel

    Start-up and maintenance Have Windhager Customer Service or one of our customer service PARTNERS put your new boiler into servi- ce. 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.

  • Page 6: Operating Noises

    Important information for system operators 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.

  • Page 7: Sources Of Danger

    Important information for system operators 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) Do not open the combustion chamber door, there is an increased risk of deflagration when opening the combustion chamber door.

  • Page 8: Operation

    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 requi- rement. Following „purging“ (safety function), ignition starts and the pellet metering auger switches on. The burner pot is automatically filled with pellets.

  • Page 9: Functional Elements And Operating Controls

    Operation Functional elements and operating controls 2.2.1 VarioWIN with direct pellet feed 19 * Fig. 3 VarioWIN with direct pellet feed – View from right Ash pan Ash door Filling and evacuation cock Primary air pin Pressure gauge Burner pot...

  • Page 10: Variowin With 41 Kg Reserve Supply Container, Manual Loading

    Exhaust pipe cleaning opening Blower motor Blower box Motor for ash compactor Fig. 4 VarioWIN with 41 kg reserve supply container – View from right 2.2.3 VarioWIN with pneumatic pellet feed Ash pan Ash door Filling and evacuation cock Primary air pin...

  • Page 11: Opening The Cladding Door

    Operation Opening the cladding door 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. Fig.

  • Page 12: Filling The Reserve Supply Container

    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. WIND- HAGER 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.

  • Page 13: Infowin

    Operation 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.

  • Page 14: Operating Modes

    Operation 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. RESET Fig.

  • Page 15: Pellet Feed

    Solid fuel/ buffer mode °C If the VarioWIN pellet central heating boiler is combined with a solid fuel boi- ler or an buffer tank, the WVF or BUL module automatically switches over bet- Burnout ween pellet and solid fuel/buffer mode.

  • Page 16: Manual Operation

    Operation 2.7.5 Manual operation 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.

  • Page 17: Flue Cleaning Function

    Operation 2.7.6 Flue cleaning function This function aids the performance of legally-required emissions testing. 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 star- ted if there is no solid fuel boiler installed or if this is not operating and only the buffer tank is active.

  • Page 18: Operating Phases

    2.8.2 Purging Boiler temperature °C 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 Purging fires – Fig. 27.

  • Page 19: Information Text

    Operation Information text Boiler temperature °C Pressing the Info button calls up the most important VarioWIN infor- mation – Fig. 33. (Operating phases) The arrow buttons select and display sub-menus – Fig. 34. By pres- Info Menu sing the Back button (Fig. 35) or waiting 45 seconds, the screen returns to the standard display.

  • Page 20: Total Pellet Consumption

    The current software version of the firing automate (main PCB) is displayed – Fig. 43. Fig. 43 Back 2.9.9 Boiler model Boiler model Pellet boiler 120K The boiler model of the VarioWIN is displayed – Fig. 44. Boiler Fig. 44 Back...

  • Page 21: Menu Guide

    Operation 2.10 Menu guide Boiler temperature °C Pressing the Menu button changes the menu display to operator level or service level – Fig. 45. (Operating phases) Use the arrow buttons to select the operator level or service level Info Menu (Fig.

  • Page 22: Menu Structure

    Automatic Only probe 1 Only probe 2 Only probe 3 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.

  • Page 23: Operator Level

    Time profile ash compression: see section 2.10.1.6 Fig. 51 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 activa- ted.

  • Page 24: Boiler Cleaning

    Operation 2.10.1.1 Boiler cleaning - Boiler temperature Resetting the cleaning request °C After boiler cleaning has been performed (section 3.1), boiler cle- aning must be confirmed so that the operating time until the next (Operating phases) boiler cleaning is restarted. Lighting ON Boiler cleaning must not be reset if cleaning has not been carried out.
  • Page 25 Operation Pressing the Yes button resets the boiler cleaning – Fig. 58. The Has boiler and display shows „Parameter is saved“ for a few seconds (Fig. 59) and burner cleaning then changes back to the previous level – Fig. 60. been performed? Confirm –...
  • Page 26 This time is used for the time control of the pellet feed, automatic °C heating surface cleaning and automatic ash compression. If the VarioWIN is operated with an MES control, the time is auto- (Operating phases) Lighting ON matically adopted from the module and the time set here is over- written.
  • Page 27 Operation Save the changed time by pressing the Yes button – Fig. 66. The Set time display shows „Parameter is saved“ for a few seconds (Fig. 67) and then changes back to the previous level – Fig. 68. 13:50 Save –...
  • Page 28 Probe switching Time profile ash comp. Choose Back Only displayed with a VarioWIN - VAE 120 P with pneumatic feed (suction RESET system) when the unit has been adjusted by a trained service technician in the service level. Fig. 73...
  • Page 29 Tip: A complete fill sucks in about 25 kg of pellets. Even if more Fig. 75 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. Parameter is saved ..
  • Page 30 Probe switching Time profile ash comp. Choose Back RESET 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. Fig. 82...
  • Page 31 Operation „with start time“ Feed start time A time can be set here in the „ Time profile feed“ menu item for fil- Start 20:00 ling the reserve supply container if the „with start time“ setting is active in the „Feed operating mode“ menu item (see section Save 2.10.1.3).
  • Page 32 Operation „with enable time“ Feed The start and end of the enable time can be set here in the „ Time enable time Start 07:00 profile feed“ menu item if the „with enable time“ setting is active 22:00 in the „Feed operating mode“ menu item (see section 2.10.1.3). Choose Back Factory setting „Feed enable time“:...
  • Page 33 Operation The menu item or sub-menu item is exited by pressing the Back Feed button (Fig. 92) or after a delay of 45 seconds. enable time Start 07:00 22:00 Choose Back RESET Fig. 92 The menu item or sub-menu item is exited by pressing the Back Boiler cleaning button (Fig.
  • Page 34 Probe switching Time profile ash comp. Choose Back Only displayed with a VarioWIN - VAE 120 P with pneumatic feed (suction RESET system) when the unit has been adjusted by a trained service technician in the service level. Fig. 99...
  • Page 35 Operation Use the arrow buttons to select the required probe switching – Probe switching Fig. 100. Automatic Only probe 1 Only probe 2 Only probe 3 Save RESET Fig. 100 Save the changed probe switching by pressing the Yes button – Probe switching Fig.
  • Page 36 Operation 2.10.1.6 Time profile ash compression (Exklusiv version only) Boiler temperature The ash in the ash pan is only compressed at the 2 set start times °C 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).
  • Page 37 Operation Use the arrow buttons to select the start time you want to change, Start times for 1 or 2 – Fig. 109. ash compression Start time 1 08:00 Confirm the selected start time by pressing the Choose button – Start time 2 22:00 Fig.

  • Page 38: Service Level

    Choose Back Changes in the service level may be performed only by trai- ned service personnel (for setting instructions, see the VarioWIN „Assembly instructions“). RESET Fig. 114 Service level only for trained...

  • Page 39: Heating System Operation

    (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“...

  • Page 40: Variowin With Reg Standard Control

    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”...
  • Page 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.

  • Page 42: Care, Cleaning And Maintenance

    (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.
  • Page 43 Care, cleaning and maintenance Care, cleaning and VarioWIN Premium-D VarioWIN Exklusiv-S VarioWIN Exklusiv-P/D ash removal intervals Depending on pellet con- sumption Add pellets to – – reserve supply container Approx. every 41 kg (~ 20 operating hours) Empty the ash pan...

  • Page 44: Heating Surfaces

    – 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. Ash pan for combustion chamber Ash pan for heating surfaces Fig.

  • Page 45: Combustion Chamber

    Care, cleaning and maintenance 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“...

  • Page 46: Burner Pot

    Care, cleaning and maintenance 3.6.2 Burner pot 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 befo- re cleaning.

  • Page 47: Variowin Reserve Supply Container

    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.
  • Page 48 Care, cleaning and maintenance 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.

  • Page 49: Top Heating Surfaces And Linkage

    – 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.

  • Page 50: Blower Wheel, Blower Box, Exhaust Pipe And Rotary Feeder

    Blower wheel, blower box, exhaust pipe and rotary feeder These parts are automatically checked and cleaned as part of the annual maintenance by WINDHAGER Custo- mer Service or the customer service PARTNER. It is essential to let the boiler cool down before cleaning.

  • Page 51: Rotary Feeder

    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.

  • Page 52: Troubleshooting

    Troubleshooting The VarioWIN pellet boiler is self-monitoring during operation. All deviations from normal operation are display- ed 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 –...

  • Page 53: No Display On Infowin

    Code Meaning/effect Cause/remedy Boiler continues to heat until the remaining fuel quantity has been consumed. a) VarioWIN without feed or with direct pellet feed: Replenish fuel Fill fuel into the reserve supply or year-round container (see section 2.5). IN 581...

  • Page 54: Fault Messages

    No pellet feed is possible. The boiler does not operate. Press the Reset button. If the fault reoccurs after a reset, inform Windhager Probe switching defective Customer Service or a heating technician.

  • Page 55: Alarm Messages

    Clean the burner pot. Press Reset. place, repeat the process or inform Windhager Customer Service or a hea- ting technician. b) Grate plate not inserted correctly or check correct installation position (see section 3.6).
  • Page 56 Check the boiler sensor and connec- ce or your heating technician. tions. Press Reset. b) Renew the boiler sensor, inform Windhager Customer Service or a heating technician. The boiler switches to burnout mode. a) Thermocontrol sensor is too cold < 0 °C. Sensor warm up.
  • Page 57 AL 187 inform Windhager Customer Service or a heating technician. Check connection for main PCB and b) Connect the main PCB, inform Windhager Customer Service or a heating connections. Press Reset. technician. Internal communication error. The boiler switches to burnout mode.

  • Page 58: Declaration Of Conformity

    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: Document no. Title Standard Edition EN 14785...

  • Page 60: Guarantee And Warranty Limitations

    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.

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