WarmFlow WS18 User manual

BoilerManual
WoodPelletBoilerWS18/WP18
ForusewithENplusA1woodpelletsonly.LookfortheENplusA1symbol.
Incorporating: UserInstructions
InstallationInstructions
ServiceInstructions
GuaranteeTerms&Conditions
RegistrationDocuments
LEAVETHISMANUALWITHTHEENDUSER

IMPORTANT–Readthismanualinfullbeforeinstalling,commissioning,servicingor
operatingthisappliance.
COMMISSIONING
Thisappliancemustbecommissioned.Failuretocommissiontheappliancewillinvalidatethe
warranty.Aftercommissioning,ensurethattheapplianceregistrationdocumentsarecompleted
andreturnedtoWarmflow.SeeSection6ofthismanual.
SERVICING
To ensure continued reliable operation, fuel economy and to validate the guarantee, it is
recommended that the appliance is serviced annually or when indicated by the user control
interface.ServicingmustbeconductedbyaWarmflowengineerorothercompetenttechnician.
AservicehistorymustbemaintainedinSection7ofthismanual.
NICustomersOnly
Warmflow Engineering customer care (NI) provides an excellent backup service, operating a
team of trained engineers who can meet all the servicing, commissioning and breakdown
requirementsforyourappliance.
Tel: 02892621515
Fax: 02892622827
Email: [email protected]
Web: www.warmflow.co.uk
ForParts,Service,Technical&WarrantyContact
GreatBritain&N.Ireland,Tel:02892621515
RepublicofIreland,Tel:04892621515
LISBURN TELFORD
LissueIndustrialEstate,MoiraRoad, UnitD1,Hortonpark,
Lisburn,Co.Antrim,N.Ireland,BT282RF Hortonwood7,Telford,TF17GX
Tel: (028)92621515 Tel: (01952)607750
Fax: (028)92620869 Fax: (01952)603983
Email: [email protected] Email: [email protected]
[email protected] [email protected]
[email protected] [email protected]

CONTENTS
1 KEYINFORMATION 1
1.1 TheCleanAirAct1993andSmokeControlAreas 4
2 USERINSTRUCTIONS 5
2.1 FillingthePelletHopper 5
2.2 SystemPressure 6
2.3 SystemFilling 6
2.4 UserControlInterface 6
2.4.1 HomeScreenIconsandtheirmeaning. 7
2.4.2 UsingtheMainMenu 8
3 INSTALLATIONREQUIREMENTS 16
3.1 GeneralRequirements 16
3.1.1 Hearth 16
3.1.2 ServiceAccess 16
3.1.3 HeatingSystem 16
3.1.4 AirVents 17
3.1.5 DrainCock 17
3.1.6 Pipework 17
3.1.7 HeatingSystemDesign 17
3.2 SealedSystems 17
3.2.1 ExpansionVessel 17
3.2.2 SystemFilling 18
3.2.3 SystemPressure 18
3.2.4 PressureReliefValve 18
3.2.5 LowPressureSwitch 18
3.2.6 CondensateTrap 18
3.3 Plumbinglayout 20
3.4 WiringLayout 21
3.5 FlueSystem 22
4 COMMISSIONINGANDSERVICING 25
4.1 Commissioning 25
4.2 Servicing 25
4.2.1 GeneralRequirements 25
4.2.2 Servicingtheheatexchanger 26
4.2.3 Emptyingthehopper 27
4.2.4 AccessforCleaningtheDoorAssembly 28
5 YOURGUARANTEES,TERMS&CONDITIONS 29

6 APPLIANCEINSTALLATION/COMMISSIONINGCERTIFICATE&REGISTRATION. 33
7 APPLIANCESERVICERECORDS. 35

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1 KEYINFORMATION
TheapplianceisratedtoIP45andhasaweatherproofhousingsuitableforbothinternaland
externalinstallation.
The appliance is supplied with a flue terminal which may need to be extended or adapted
dependingontheinstallationsituation.Itisstronglyrecommendedthatafluestabiliserisfitted.
Extensionpieces,bends,stabilisersandbracketrycanbepurchasedfromWarmflowstockists.
The wood pellet fuel is loaded into the integrated hopper located at the rear of the appliance
(seeFigure1above).Thehopperdoormustbekeptclosedatalltimeswhennotrefilling.An
interlockswitchisfittedtothehopperdoormeaningtheappliancewillnotoperateifthehopper
doorhasbeenleftopen.
The service access lid is located on top of the appliance and should only be removed once
powerhasbeenisolatedusingtheisolatorswitch.Theservicelidandsidepanelsgiveaccess
forplumbing,servicingandmaintenance.
The combustion door is located behind the green coloured front casing door and has an
interlockfittedtoensurethedoorcannotbeopenedduringfiringoftheappliance.
Knockoutsinthecasingareprovidedatanumberoflocationstoaidtheplumbinginstallation.
Theinstallerwiringpanelislocatedbehindthegreencolouredfrontcasingdoor.
Figure1:WoodPelletBoilerOverview.

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Once removed the service lid gives access to the heat exchanger for servicing and routine
maintenance as shown in Figure 2. To clean the internal surfaces of the heat exchanger,
removethemainHEinspectiondoorandtheHEcleaningmechanismdoor.Caution:never
attempttoremovethedoorsaftertheappliancehasjustfinishedoperatingassurfaces
willbeextremelyhotandinjurywillresult.
The combustion pot is located on the inside of the combustion door and can be removed for
servicingandroutinemaintenancebyreleasingthetogglelatchesoneithersideofthepotas
showninFigure3.Oncethetogglelatchesarereleasedthepotwillbefreetoliftverticallyfrom
thecombustionshelf.Caution:neverattempttoremovethepotaftertheappliancehas
justfinishedoperatingasitwillbeextremelyhotandinjurywillresult.
Figure2ServiceAccess.(ServiceLidandInsulationRemoved)
Figure3:CombustionDoorandAshPanAssembly.

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The ash level in the ash pan should be checked periodically. The ash pan must never be
permittedtooverfill.Undernormaloperatingconditionsduringtheheatingseasontheashpan
will typically require emptying on a monthly basis. The appliance should never be operated
without the ash pan in position. The ash may be discarded with garden waste or in line with
local waste disposal regulations, after first ensuring that it is sufficiently cool before emptying
the pan.   Caution: never attempt to remove the ash pan after the appliance has just
finishedoperatingasitwillbeextremelyhotandinjurywillresult.
The combustion pot should be cleaned on a weekly basis removing any carbon residue.
Vacuuming with a dedicated ash vacuum cleaner is recommended. Failure to clean the
combustionpotasdirectedmayrestricttheflowofairwithintheapplianceadverselyaffecting
itsperformance.
Table1:ProductData.
Description Model
Type
WS18/WP18
WoodPelletBoiler
Dimensions(mm) Width 650
Depth 1170
Height 1135
Dryweight(kg) 250
MinimumAllowableDraft(mbar) 0.04
FluePipeDiameter(mm) 80
Exhaustgastemperatureatmaximumoutput(°C) 130
Exhaustgastemperatureatminimumoutput(°C) 65
Exhaustgasmassflowatmaximumoutput(kg/s) 0.015
Exhaustgasmassflowatminimumoutput(kg/s) 0.005
ElectricalSupply 230VSinglePhase@50Hz
MaximumCurrent(Amps) 5
MaximumWattage 420
StandbyWattage 20
Performance/Efficiency
(kW)/(%)
MaximumOutput
MinimumOutput
18/92.9
4/90.1
Fuel Type Woodpellets
Quality ENPlusA1
MaximumAllowablePressure(Bar) 3
MaximumAllowableFlowTemperature(°C) 80
Watersideresistance∆t10k(mbar) 9
Watersideresistance∆t20k(mbar) 4.2
WaterContent(Litres) 60
FuelHopperCapacity(Litres) 120
BoilerClass Efficiency
Emissions
5
5

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1.1 TheCleanAirAct1993andSmokeControlAreas
Bothappliances,theWS18andWP18complywiththerequirementsoftheCleanAirAct1993
and are suitable for installation in smoke control areas. The appliances meet the emissions
limitsforparticulatematterandNOxasstatedbyDEFRA.Assuchtheemissionsarewithinthe
acceptable limit for the appliances to be used in installations wishing to claim the renewable
heatincentive.
Your local authority is responsible for implementing the Clean Air Act 1993 including
designation and supervision of smoke control areas and you can contact them for details of
CleanAirActrequirements.

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2 USERINSTRUCTIONS
2.1 FillingthePelletHopper
The wood pellets used to fuel the appliance must be compliant with the ENPlus A1 pellet
standard.Usingalternativepelletswillinvalidatetheproductwarranty.
ItshouldbealsonotedthattheWarmflowwoodpelletboilerapplianceissuitableforuse
insmokecontrolareaswhenburningENPlusA1pelletsonly.
ThekeyparametersforENPlusA1pelletsarefoundinTable2below.
Property Unit
NetCalorificValueQ MJ/Kg 16.5≤Q≤19
Diameter mm 6
Length mm 3.15to40
MoistureContent % ≤10
AshContent % ≤0.7
MechanicalDurability % ≥97.5
Fines % ≤1.0
ChlorineContent % ≤0.02
SulphurContent % ≤0.03
NitrogenContent % ≤0.3
Table2:ThresholdParametersforENplusAWoodPelletsAccordingtoENISO149612
Thefuelhopperhasawoodpelletcapacityof120kg.Atmaximumoutputtheappliancewillrun
for approximately 30 hours before requiring refilling. Therefore, the fuel hopper will typically
require filling on a weekly basis during the heating season. Care must be taken to avoid
exposureofwoodpelletstorainorothermoistureduringstorageorfilling.Toprotecttheusera
hoppersafetyguardislocatedinthetopofthehopperbeneaththefuelhopperdoor.Thismust
notberemoved.
The wood pellet fuel must be stored in a cool dry area away from condensation, excess
humidityorothersourcesofmoisture.Whetherstoredinbagsorinbulkitisimportantthatcare
istakentohandlethewoodpelletsinsuchawaythatensurestheywon’tdeteriorateandcreate
dust.
The Warmflow wood pellet boiler appliance automatically delivers the correct amount of fuel
fromthehoppertothecombustionchamberusingitsintegralauger.

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2.2 SystemPressure
When the appliance is connected to a sealed central heating
system,thesystempressureshouldbecheckedperiodicallyby
means of the pressure gauge at the expansion vessel (see
Figure 4). The WS18 appliance comes complete with an
integrated expansion vessel, pressure gauge and filling loop.
Theminimumpressure,asindicatedbytheblackneedle,must
notbelessthan0.5barwhentheapplianceiscoldandtypically
around 2.5 bar when the appliance is at normal operating
temperature. If the pressure is outside this range contact
Warmfloworyourinstaller.
2.3 SystemFilling
Afterthesystemhasbeenproperlyfilledthepressuregaugeshouldread1bar(refertoFigure
4)whenthesystemiscold.Thevalvemustbefullyclosedandtheflexiblefillingloopremoved
fromthevalveinaccordancewithbuildingregulations.Expectasmallwaterlossfromthepipe.
At filling or refilling of the system, special attention must be given to the concentration of
corrosioninhibitorsinthesystemwater.Where thereisaneedfortoppingup, concentrations
mustberestoredtoinhibitormanufacturers’recommendationsandmonitoredgoingforward.
Frequentorroutinetoppingupofthesystemshouldnotbenecessaryandmayproveharmfulto
the appliance. Should topping up prove necessary on a frequent or routine basis you must
contactWarmfloworyourinstaller.
ForfurtherinformationrefertoSection3.2SealedSystems(seepage17)
2.4 UserControlInterface
Theappliance’susercontrolinterface(seeFigure5)hasbeendesignedtomaximisetheease
ofuseandefficiencyoftheheatingsystem.
All user interactions with the appliance are via the display panel. Hence the display panel
shouldbemountedataneasilyaccessiblelocation.Theusercontrolinterfaceprovidesaccess
to appliance parameters such as temperatures, cleaning alerts, servicing and pellet level
indicatorstogetherwithcommissioningandservicesettings.
Displayactivealarms
Selectmainmenu
Previousmenu
SelectUP
SelectDOWN
Enter/select
1.1.1 HomeScreenIconsandtheirmeaning.
SystemPressure
Figure5:UserInterfaceDisplayandFunctionKeys.
Figure4:ReadingSystemPressure.

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ThehomescreenappearsasshowninFigure6.
BoilerStatus

Icon Status Meaning
BoilerOK Theapplianceisfunctioningnormally.Therearenofaultsoralerts.Servicingisnotdue.
BoilerAlert
Theappliancehasreachedalertconditionbutwillcontinuetooperateasnormal.Thisalert
meansthatservicingisnowdue.Theservicingtimelimitcanbeseenbypressingthe
‘Displayactivealarms’key.Youshouldarrangeservicingassoonaspossibleandbefore
servicingisoverdueotherwisetheappliancewillshutdown.
BoilerFault Theappliancehasshutdownduetoafaultoralert.Thismaybeafaultwiththeappliance,
anoverdueservice/cleanoranemptyhopper.
FuelStatus
Icon Status Meaning
FuelLevel
OK Thepelletlevelinthehopperisfine.Therearenofaultsoralerts.
FuelLevel
Low
Thepelletlevelinthehopperislow.Theappliancewilltypicallyrunasnormalfor1hour
dependentontheheatdemandoftheproperty.Youshouldfillthehopperwithinthistime.
Fillingthehopperwillautomaticallyresetthisalert.
FuelLevel
Empty
Thepellethopperisnowempty.Theappliancewillshutdown.Youshouldfillthehopper
immediately.Fillingthehopperwillautomaticallyresetthisalert.
CleaningStatus
Icon Status Meaning
Cleaning
not
required
Theapplianceisfunctioningnormally.Therearenofaultsoralerts.Cleaningisnotdue.
Cleaning
Due
Thisalertmeanstheapplianceisdueforcleaning.Thecleaningtimelimitcanbeseenby
pressingthedisplayactivealarmsbutton.Youshouldcleantheapplianceassoonas
possibleandbeforecleaningisoverdueotherwisetheappliancewillshutdown.
Cleaning
Overdue
Cleaningisnowoverdue.Theappliancewillshutdown.Youshouldcleantheappliance
immediately.Cleaningtheappliancewillautomaticallyresetthisalertandresetthe
countdowntimer.
1.1.2 UsingtheMainMenu
Figure6:IconDescriptions.
FuelStatus
BoilerStatus
CurrentPage
CleaningStatus

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Themainmenucanbeaccessedbypressingonceonthe ‘Programkey’.Thisdisplaysthe
mainmenuasshownintheFigures7and8below.
The  ‘Down Arrow’ or the  ‘Up Arrow’ key can then be used to scroll through the menu. 
Confirmselectionwiththe ‘Enterkey’whentherequireditemishighlightedinblack.There
are six options in the main menu including ‘Home’, ‘Alarms’, ‘Cleaning’, ‘Engineer’, ‘Settings’
and‘Help’.
Home:
Selectingthehomemenureturnsthedisplaytothehomescreen.Thisdisplayisasshownin
Figure9anddetailedinsection2.4.1.
Alarms:
Selectingthealarmsmenuentersthealarmsdisplay.Thiscanalsobeenteredatanytimeby
pressingthe ‘Displayactivealarms’key.ThescreenshowninFigure10willbedisplayed
whennoalarmsarepresent.
Figure7:MainMenuPage1.
Figure9:HomeScreen.
Figure8:MainMenuPage2.

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When an alarm is present, the  ‘Display active alarms’ key will flash red. Pressing the
flashingkey orentering thealarm menuwill thendisplay oneor moreactive alarmsor faults.
The  ‘Down Arrow’ or the  ‘Up Arrow’ key can then be used to scroll through the alarms.
Selectingonewiththe ‘Enterkey’thendisplaysthenextscreenwhichwillgivemoredetailsof
thealarmtogetherwithanyactionsrequired.
Cleaning:
Selectingthecleaningmenuoptionentersthecleaningstatusdisplayandcleaningpreparation
utility.  The first screen to be displayed is the cleaning status display as shown in Figure 11
below.
Thisscreenshowsthenumberofdaysbeforecleaningisdue.Itwillalsoindicateifcleaningis
overdue.  Pressing the  ‘Enter key’ in this screen activates the cleaning preparation utility,
preparing the appliance for cleaning.  The progress of the cleaning preparation will be
automaticallydisplayedasshownbelowinFigure12.
Theprogressbaradvancesastheappliancepreparesitselfforcleaning.Thisusuallytakesa
fewminutesbutmaytakelongerdependingontheoperationalconditionoftheappliancewhen
preparation for cleaning is initiated. When the appliance is ready for cleaning, the display will
automaticallychangetothenextscreenwhichisshowninFigure13.
Figure10:AlarmsScreen.
Figure11:CleaningHomeScreen.
Figure12:CleaningPreparationProgressScreen.

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This screen indicates that the appliance is ready to clean and that care should be taken as
somepartsincludingthecombustionpot,ashpanandheatexchangermaybehot.Appropriate
protective wear including gloves should be worn when handling such items.  The combustion
door can now be opened. First ensure the combustion door handle is in the fully downward
position,thenpressandholdthegreeninterlockbutton(locatedbesidetheisolatorswitch,see
Figure1)whilesimultaneouslyliftingthedoor handleupwards.Thecombustiondoormay be
openedtoaccessthecombustionpotandashpanasshowninFigure14below.
Thecombustionpotisreleasedbyunfasteningthetwotogglelatches(oneoneitherside).The
combustion pot can now be lifted away vertically off its locating holes. The combustion pot
should be emptied and cleaned paying particular attention to ensure the small air holes are
cleanandunblocked.Theshelfonwhichthecombustionpotislocatedandwhichhousesthe
potgrateandcleaningmechanismshouldalsobecleaned.Anydebriswhichmayhavefallen
through the grate can be removed through the inspection door. The inspection door can be
removed by unfastening the two screws on its front face.   Replace the inspection door after
cleaningandsecureinplaceusingthetwoscrews.
At this stage the ash pan should also be removed and emptied. After cleaning, the ash pan
shouldbe reinstalledensuring thatno ashhas fallenbehind orbelow it.  The combustion pot
canthenberelocatedandsecuredbyrefasteningthetwotogglelatches.Thecombustiondoor
shouldnowbeclosedandthedisplayontheuserinterfacecontrollerwillautomaticallychange
tothefinalcleaningscreenasshowninFigure15.
Figure13:ApplianceReadyforCleaningScreen.
Figure14:AshPan&CombustionPot.

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This screen prompts for confirmation that cleaning has been performed and that both the
combustionpotandashpanhavebeenreinstalled.Thisisconfirmedbythe ‘Enterkey’.This
returns the display to the home screen and resets the cleaning scheduler.  Only when this
processhasbeenfullycompletedwillthecleaningschedulerbereset.
Settings:
Selectingthesettingmenuentersasubmenu which hasanumberofinformationandsetting
screens.Thesecanbeviewedandadjustedbytheuser.Theinformationandsettingscreens
aredisplayedinthesameformatasthemainmenuscreenandmaybeaccessedinthesame
way.  The submenus include date/time, temperature and information as shown in Figure 16
below.
Date/Time:
Selectingthedate/timesubmenuenterstheapplianceclockanddatemanagementsystem.It
isveryimportantthatthedateandtimearesetcorrectlyasshowninFigure17.
Thedateandtimeareadjustedusingthe‘DownArrow’orthe ‘UpArrow’keys.Confirm
withthe ‘Enterkey’.Thedaywillautomaticallyupdatewhenthedateisaltered.
Figure15:CleaningConfirmScreen.
Figure16:SettingsMenu.
Figure17:Date/TimeHomeScreen.

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Temperature:
Selecting the temperature submenu enters the screen from which the appliances flow
temperature may be adjusted. The flow temperature is the temperature at which the heating
system water which leaves the appliance and enters the central heating circuit.  This can be
adjustedbetween60°Cand80°C.Thetemperatureisadjustedusingthe‘DownArrow’orthe
‘UpArrow’keys.Confirmwiththe ‘Enterkey’asshowninFigure18.
Information:
Selecting the information submenu enters a list of appliance sensor readings as shown in
Figure 19 below.  These readings show important information about how the appliance is
performingandoperating.
Whenviewingtheappliancesoperatingstateintheinformationscreenitwillbenoticedthatthe
appliancehasvariousoperatingmodes(seeTable3,Page13).
TheappliancehasastartupsequenceasshowninFigure20(seepage14)andwillonlybegin
firingifthereisaheatdemandpresent,i.e.asignalfromatimeclockorprogrammer.Asthe
applianceisfullymodulatingthecontrolsystemwillmonitortheheatdemandandworktomeet
thedemandasefficientlyaspossible.Oncetheheatdemandhasbeenmettheappliancewill
modulate down through its power bands and may eventually enter extinguish mode. If
extinguish mode is reached and after final clean, the appliance will enter blocked mode. The
appliance will remain in blocked mode for a period which is preset in order to stop the
appliance cycling which is inefficient. This time delay also prevents immediate opening of the
appliances combustion door ensuring that internal surfaces are cool enough for cleaning if
necessary.
Figure18:TemperatureScreen.
Figure19:InformationScreen(1of3).

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Mode Description
Standby Awaitingheatdemand
SystemCheck Ensuringthattheapplianceisreadyandsafetostart
Preload Loadingthecombustionpotwithpellets
Ignition Ignitingthepelletsinthecombustionpot
Stabilisation Ensuringthattheflameisgiventimetoestablish
Powerband1,2,3,4,5 Outputpowerdeterminedbyheatdemand
Extinguish Shutdowninitiated
FinalCleaning Cleaningofcombustionpotandheatexchanger
Blocked Anticycling function that activates a time delay before a
restartispossibleorthecombustiondoorcanbeopened
Table3:ApplianceModes.

18
Engineer:
Figure20:FlowChart.

19
Selectingtheengineermenuentersasubmenuwhichhasanumberofinformationandsetting
screens intended for an approved engineer only.  For this reason the Engineer utility is
passwordprotected.ThepasswordshouldbeenteredasshowninFigure21.
AsanauthorisedEngineerandhavingenteredyourpasswordthefollowingsubmenusbecome
accessible:commissioning,servicing,engineerandparameters.
Help:
Selecting the help menu, as shown in Figure 22 below, displays the contact details for
Warmflow who should be contacted if you require further assistance or if you encounter a
problemwithyourappliance.
This appliance must be serviced annually or as indicated by the user
interfacecontroller.ContactWarmflowforfurtherdetails.
In the event of a breakdown please contact your commissioning engineer who should then
contactourservicedepartmentwhilstatyourhome,toreportthefault.
Figure22:HelpScreen.
Figure21:EngineerPassScreen.

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3 INSTALLATIONREQUIREMENTS
The installation must comply with regional Building Regulations. The maximum noise level
generatedbytheapplianceiswellwithintheresidentialnoiselimitationsandissimilartothatof
ahighefficiencyoilboiler.
3.1 GeneralRequirements
3.1.1 Hearth
Theappliancehasahearthtemperatureofbetween50°Cand85°Candshouldbestoodona
rigid, nonporous, noncombustible base, which is not softened by heat, to comply with the
BuildingRegulations.
3.1.2 ServiceAccess
Clearanceshouldbeprovidedaboveandinfrontoftheappliancetoallowforroutineservicing.
Therear of the appliance casing and any one side panel may be positioned beside a wall or
boundary.Atleast600mmisrequiredatthefrontandaccessiblesideoftheappliance,although
maximisingaccessisrecommended.
PleaserefertolocalBuildingRegulationsforpermissibledistancesfromcombustiblesurfaces.
IftheapplianceisintendedforinternalinstallationpleaserefertolocalBuildingRegulationsfor
ventilationsizestoensuresufficientcombustionairatmaximumoutput.Itmaybenecessaryto
filtercombustionairasitenterstheroomwheretheapplianceislocatedifthereisapossibility
ofhighlevelsofdustorparticulates.
3.1.3 HeatingSystem
TheheatingsystemshouldbeinstalledtocurrentHVACcodesofpractice.Beforeinstallingthe
appliance the new or existing system must be thoroughly flushed to clear all sludge or other
foreign matter such as solder, steel wool and copper filings.The system must be cleansed,
neutralisedandprotectedfromcorrosioninaccordancewithBSEN12828,BSEN12831,BS
EN 14336 and BS7593 using suitable cleansing agent(s) and inhibitor(s) and carried out in
Figure23:BoilerLocationandAccessibility