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 Record
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 7 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 trained and competent
engineer. A service history must be maintained in Section 8 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: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.warmflow.co.uk
For Parts, Service, Technical & Warranty Contact
Great Britain & N. Ireland, Tel: [phone]
Republic of Ireland, Tel: [phone]
LISBURN TELFORD
Lissue Industrial Estate, Moira Road, Unit D1, Hortonpark,
Lisburn, Co. Antrim, N. Ireland, BT28 2RF Hortonwood 7, Telford, TF1 7GX
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
E-mail: [email protected] E-mail: [email protected]k
[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................................................................................................................7
2.4.1 Home Screen Icons and their meaning. ...............................................................................................8
2.4.2 Using the Main Menu............................................................................................................................9
2.5 Cleaning...................................................................................................................................19
2.5.1 Cleaning Scheduler.............................................................................................................................19
2.5.2 Cleaning Status...................................................................................................................................20
2.5.3 Cleaning Procedure............................................................................................................................23
3 INSTALLATION REQUIREMENTS ....................................................................................36
3.1 General Requirements.............................................................................................................36
3.1.1 Transportation aids and hearth...........................................................................................................36
3.1.2 Service Access ...................................................................................................................................37
3.1.3 Heating System...................................................................................................................................37
3.1.4 Air Vents .............................................................................................................................................37
3.1.5 Drain Cock ..........................................................................................................................................38
3.1.6 Pipework .............................................................................................................................................38
3.1.7 Heating System Design ......................................................................................................................38
3.2 Sealed Systems.......................................................................................................................38
3.2.1 Expansion Vessel (WS 18 Models only).............................................................................................38
3.2.2 System Filling......................................................................................................................................39
3.2.3 System Pressure (WS 18 only)...........................................................................................................39
3.2.4 Pressure Relief Valve .........................................................................................................................39
3.2.5 Low Pressure Switch ..........................................................................................................................39
3.2.6 Condensate Trap................................................................................................................................39
3.3 Wiring Layout...........................................................................................................................42
3.4 Flue System.............................................................................................................................44
4 COMMISSIONING AND SERVICING.................................................................................46
4.1 Commissioning – Approximate time to complete: 2 hours ........................................................46
4.2 Servicing..................................................................................................................................55
4.2.1 Service Schedule................................................................................................................................55
5 ALARMS AND TROUBLESHOOTING...............................................................................56
5.1 Alarms......................................................................................................................................56
5.2 Troubleshooting .......................................................................................................................63
6 YOUR GUARANTEES, TERMS & CONDITIONS...............................................................65

7 APPLIANCE INSTALLATION/COMMISSIONING CERTIFICATE & REGISTRATION......69
8 APPLIANCE SERVICE RECORDS....................................................................................72
9 APPENDIX A – SUPPLEMENTARY INSTALLATION AND OPERATING INSTRUCTIONS
FOR THE UK MARKET.............................................................................................................83
10 APPENDIX B – CUSTOMER CONNECTION WIRING SCHEMATIC .............................91

1
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. Extension pieces, bends and bracketry can be
purchased from Warmflow stockists. The appliance is also fitted with a flue draught stabiliser.
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.

2
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.

3
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.
Description Model WS18/WP18
Type 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 (⁰C) 170
Exhaust gas temperature at minimum output (⁰C) 65
Exhaust gas mass flow at maximum output (⁰C) 0.015
Exhaust gas mass flow at maximum output (⁰C) 0.005
Electrical Supply 230V Single Phase @50Hz
Maximum Current (Amps) 5
Maximum Wattage 420
Standby Wattage 20
Performance/Efficiency
(kW)/(%) Maximum Output 18/92.9
Minimum Output 4/90.1
Fuel Type Wood Pellets
Quality ENPlus A1
Maximum Allowable Pressure (bar) 3
Maximum Allowable Flow Temperature (⁰C) 80
Water-side resistance ∆t 10k (mbar) 9
Water-side resistance ∆t 20k (mbar) 4.2
Water Capacity (Litres) 60
Fuel Hopper Capacity (kg) 120
Boiler Class Efficiency 5
Emissions 5
Combustion Ventilation
@20⁰C for internal Installation Low Level (mm x mm) 250 x 250
High Level (mm x mm) 250 x 250
Table 1: Product Data

4
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 NOxas 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.

5
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 Value
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 sources of ignition,
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.

6
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.
System Pressure = 0bar System Pressure = 1bar
2.3 System Filling
After the system has been properly filled the pressure gauge should read 1 bar when the
system is cold (refer to the image on the right in Figure 4). 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 38).
Figure 4: Reading System Pressure.