WarmFlow WAH 100 User guide

INSTALLATION & SERVICING
MANUAL FOR
WARMFLOW
OIL FIRED
WARM AIR HEATERS
MODELS
WAH 100/150
WAH 200/300
WAH 500/600
LEAVE THESE INSTRUCTIONS WITH THE END USER
OIL FIRING TECHNICAL
ASSOCIATION FOR THE
PETROLEUM INDUSTRY
OIL FIRING EQUIPMENT
GROUP MEMBER
NATIONAL
ACCREDITATION
OF CERTIFICATION
BODIES
BSI
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I
S
T
E
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D
F
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CERT. No. FM 29884
BS 5750 PART 2
ISO 9002

ISSUE 2
APR ’99
COMMISSIONING
*THIS APPLIANCE MUST
BE COMMISSIONED
Refer to the commissioning details at rear of this handbook.
SERVICING
To ensure continued reliable operation and
fuel economy it is recommended that the
heater is serviced annually.
Warmflow Engineering Service division
provides an excellent back-up service,
operating a team of Oftec trained
engineers who can meet all the servicing,
commissioning and breakdown
requirements for your appliance.
Simply telephone
TEL: [phone]
FAX: [phone]
E-MAIL: [e-mail]
*Failure to commission the heater may invalidate warranty

Contents Page
1.0 Introduction 2
1.1 General Requirements 2
1.2 Installation 2
2.0 User Instructions 3
2.1 Controls 3
2.2 Components 4
3.0 General Data 7
3.1 Technical Data 7
3.2 Dimensions 8
3.3 Installation Clearances 9
3.4 Air Supply 9
3.5 Ductwork 10
3.6 Filters 10
3.7 Electrical Supply 11
4.0 Oil Supply 18
4.1 One Pipe Systems 18
4.2 Two Pipe Systems 19
5.0 Flues 20
6.0 Burners 21
6.1 Components 21
6.2 Oil Supply 22
6.3 Air Damper Adjustment 23
6.4 Electrode Setting 23
6.5 Burner Start Up Cycle 23
7.0 Fault Finding 24
8.0 Burner Spares 25
Page 1

1.0 Introduction
All Warmflow oil fired warm air heaters are suitable for space heating of industrial and
commercial premises. The heaters are automatic in operation and are designed for
free-standing operation, supplied as standard for free blowing via the air discharge
hoods or for connection to a ductwork distribution system. (Contact Warmflow for
details).
The heaters are indirect fired with the products of combustion being carried via the
flue to atmosphere.
Warmflow warm air heaters are designed to burn 28 second redwood No1 (Kerosene
class C2) fuel or with some adjustment 35 second redwood No1 (gas oil class D).
On the 500/600 WAH only gas oil may be used.
The construction of the heaters provides a framework of exceptional strength and
pleasing design, while the integral base pallet guarantees safe stable handling.
All the external panels are of a double skin construction, which insures low surface
temperatures. The panels are all easily removable for complete access to any part of
the heater while the front panel has been split to allow for easy access to the combustion
chamber door.
As standard the burner, heater and controls are covered by the manufacturers parts
and labour warranty valid for 12 months (from the heater date stamp). However this
warranty will be invalidated if the heater is improperly installed or commissioned.
1.1 General Requirements
The installation of the air heater must be in accordance with the following regulations:
BS 5410: Parts 1 & 2: 1977: Code of practice for oil firing.
Current fire regulations.
Current building regulations.
Current IEE wiring regulations.
1.2 Installation
The heaters must be placed on a level non-porous, non-combustible surface which is
capable of supporting the weight of the heater. The heaters must be stable or rigidly
fixed in order to prevent vibration in the appliance, which can lead to the premature
failure of the heater components.
Page 2

2.0 User Instructions
2.1 Controls
The main user controls are the 2 rocker switches on the left hand side of the control panel.
The three position rocker switch at the top is marked ‘Fan Only’, ‘Off’ and ‘Heating On’.
At the ‘Fan Only’ position the heater provides summer time ventilation by delivering
air at the ambient temperature with the burner switched off.
At the ‘Off’ position the heater will not operate.
When the switch is positioned at ‘Heating On’ the heater will fire and deliver warm air
automatically controlled by the fan stat and the room thermostat.
The sequence of firing will be as follows. The burner will go through its ignition cycle
and fire. When the combustion chamber has been sufficiently heated the fan stat will
automatically start the main air fan and discharge warm air through the swivel hoods
or ducting.
When the heater is shutdown either via the room stat or any other controls the burner
will stop firing although the main air fan will continue to operate until the combustion
chamber has been properly cooled down. At which point the fan stat will shut the main
air fan down.
Because of residual heat within the combustion chamber the fan stat may re-start the
main air fan until sufficient cooling of the combustion chamber has taken place.
When the burner is firing the indicator lamp on the panel will be illuminated.
The 2 position rocker switch is marked ‘Automatic’ and ‘Manual’.
At the ‘Automatic’, position the heater will be operated automatically via the time
clock.
When positioned at ‘Manual’ the end user controls the time of operation.
NOTE:WHEN FIRING ORWHEN HOT,THE HEATER MUST NEVER BE SWITCHED
OFF AT THE MAINS SUPPLY.
This is to allow proper cooling of the combustion chamber thus preventing tripping out
on the high limit stat and heat damage to the combustion chamber.
If the high limit fan stat should trip out wait until the combustion chamber has cooled
sufficiently before pressing the red reset button on the fan stat. If the high limit continues
to trip, switch the heater to ‘off’ and contact the Warmflow Service Department.
If the fan motor draws more current than the set limit the overload relay can be reset
by pressing the red button in the control panel.
If the relay continues to trip contact the Warmflow Service Department.
Page 3

2.2 Components
2.2.1 Heater
Fan Stat
Air Inlet Grills
Fan
Fan Motor Base Pallet
Control Panel
Burner
Combustion
Chamber Door
Air Discharge
Hoods
Heat Exchanger
Page 4

2.2.2 Fan Stat (Cover Removed)
2.2.3 Air Heater Control Panel
Fan Override Button (White)
Keep Pulled Out
High Limit Stat Setting Peg (100°C)
Fan on Setting Peg (40°C)
Fan Off Setting Peg (20°C)
High Limit Reset Button (Red)
Overload Relay
Reset Button (Red)
Contactor
5 Pin Mains In Plug
Room Stat
5 Amp Fuse
Burner Cable
3 Position
Rocket Switch
Burner on
Lamp
2 Position
Rocker Switch
Clock
Page 5

2.2.4 Time Clock
2.2.5 Room Stat
Each heater is supplied as standard with
a 7-day analogue clock.
To set the day of the week and the time
turn the minute hand in a clockwise
direction until the correct day and time is
opposite the indicator arrow.
The required on/off switching time is set
by pushing the timing segments to the
outer rim of the clock. The minimum time
period for each segment is 2 hours.
Before operating the heater ensure that
the selector switch is in its mid position.
A room thermostat is mounted on the main
control panel and controls the operation
of the burner. If the heater is not installed
in the area being heated or it has been
fitted with a separate fresh air intake then
an additional remote room thermostat
must be fitted.
Timing Segments Selector Switch
Indictor Arrow
Page 6

3.0 General Data
3.1 Technical Data
WAH MODEL 100/150 200/300 500/600
Output Range kW 29.3-44.0 58.6-88.0 146.5-175.8
Nominal Heat kW 52.4 102.3 206.9
Input (max) Btu 178,800 349,000 705,900
Nominal Heat kW 44.0 88.0 175.8
Output (max) Btu 150,000 300,000 600,000
Nominal combustion efficiency gross % 84 86 85
Burner Riello RDB 2 G10 G20s
Head LD3 A G10 G20s
Flue Dia mm 127 152 203
Flue Dia in 5 6 8
Exit Flue Gas Mass Flow Kg/h
Co2 % 11.0 11.0 11.0
Smoke Bacarach 0-1 0-1 0-1 0-1
NFGT °C225 185 195
Nozzle Danfoss or Delevan
(Kerosine) 1.25 x 60°S2.5 x 60°S—
Pump Bar 10 9 —
Pressure psi 145 130 —
Nozzle Danfoss or Delevan
(Gas Oil) 1.0 x 60°S2.0 x 60°S4.0 x 60°S
Pump Bar 13 12.5 13.0
Pressure psi 190 180 190
Approx Fuel L/h 5.2 10.1 20.4
Flow Rate Gal/h 1.14 2.22 4.49
Fan Motor kW 0.37 1.1 2.2
Motor Speed rpm 1,440 1,440 1,440
Running Current Amps 1.8 4.8 5.6
Electrical Supply at 50hz Volts 230 ±6% 1PH 230 ±6% 1PH 400 ±6% 1PH
Fuse Rating (per phase) Amps 5 8 16
Temp Rise °C40 4240
Inlet Air Flow @ 15 C CFM 1,590 2,755 7,355
M3/h 2,700 4,680 12,500
No of Discharge Hoods 2 2 4
Fan Speed (Nominal) rpm 650 900 925
Weight (including burner) Kg 195 360 680
Page 7

MODEL 100/150 200/300 500/600
A1625 1860 2145
B615 790 1020
C950 1090 1445
D1410 1640 1895
E285 375 375
F285 380 380
G280 380 380
H202 260 290
I342 400 430
J900 1095 1190
K127 152 203
3.2 Dimensions
Page 8

Note: Any combustible material adjacent to the air heater and the flue system must be
so placed or shielded as to ensure that its temperature does not exceed 65°C (150°F).
In addition to the dimensions mentioned above the following minimum clearances
must be available at the front of the heater to enable it to be serviced.
Heater Model Clearance
100 & 150 760mm
200 & 300 1000mm
500 & 600 1000mm
Note: To give additional access to the fan stat when installed in a confined space the
left and right side panels are interchangeable.
3.4 Air Supply
In all cases there must be provision for an adequate supply of air for both combustion
and general ventilation.
(a) Where heater is sited within area to be heated
So far as any ventilation requirements are concerned, the installer should take note of
any mandatory requirements for the provision of permanent air vents direct to outside.
Any such air vents should have negligible resistance and must not be sited in any
position where it is likely to become easily blocked or flooded nor in a position where
it is possible for the ingress of toxic or flammable vapour. However, if the heater is
sited within a building with an air infiltration rate of less than 0.5 per hour or where the
3.3 Installation Clearances
The space in which the heater is to be fitted must have the following minimum
dimensions:
600mm
1000mm
600mm600mm
A x B
ACCESS
DOOR
A - Width
B - Height
Refer to
Section 3.2
Page 9

building volume is less than 2.2m3per kW of heater input, then ventilation should be
provided in accordance with our table of recommended minimum sizes.
(b) Where heater is supplied within a plant room or confined area
Where the heater is sited within a plant room or other confined area, then provision
must be made for the positive connection of either return air with high/low level
ventilation in accordance with BS 6230 or if return air is through a louver arrangement
then the return air louver must be of adequate size so as not to starve the main air
distribution fan of air. Under no circumstances must the burner be left to operate within
an area of negative pressure without a combustion air duct.
It is recommended that for applications such as these that you contact our Technical
Department.
(c) The heater should not be operated within a toxic, corrosive or flammable
atmosphere
The basic minimum effective area requirement of the air (not return air louvres) including
air for combustion is as follows.
Heater Model Min air vent area per heater (free area)
100/150 2300 CM2
200/300 3000 CM2
500/600 6500 CM2
3.5 Ductwork
All heaters are supplied for free standing and free blowing operation and are not suitable
for connection to a ducted system unless the necessary drive modifications have been
made. Warmflow can make the necessary drive modifications in the factory to suit a
range of ductwork resistances (i.e. 0.5", 1.0", 1.5" and 2.0" wg).
Warmflow cannot guarantee the correct fan/drive configuration unless we have either
designed the ductwork system or were supplied with a set of as installed drawings for
the existing ductwork. Prior to installation all existing ductwork and distribution grilles
must be thoroughly cleaned to ensure there is no additional resistance within the
system.
As an additional safeguard against overheating Warmflow would recommend the
installation of a thermostat within the ductwork to control the operation of the burner.
The thermostat should be installed as close to the heater as possible. (Consult our
technical department for details).
3.6 Filters
Before fitting any inlet or outlet filters, insure that the resistances are maintained or the
correct modifications to belts, pulleys and motor have been made. (Contact Warmflow
for details and advice).
Page 10

3.7 Electrical Supply
Wiring external to the air heater must be installed in accordance with IEE Wiring
Regulations and any local regulations which apply.
Models 100 to 300 are supplied for 240 volts, 50Hz, single phase, neutral and earth.
Models 500 to 600 are supplied for 400 volts, 50Hz, 3 phase, neutral and earth.
The method of connection to the mains electricity supply must facilitate complete
electrical isolation of the air heater by an isolator having a contact separation of at
least 3mm in all poles and the supply should serve only the air heater. The method of
connection should be provided adjacent to the air heater in a readily accessible position.
The minimum recommended cable size for the mains supply is 2.5mm2.
All external wiring must be enclosed within approved conduit. Conduit from isolator
switch must run so as not to interfere with the removal of the service panels of the air
heater.
Whether a single heater or a number of heaters are to be wired as part of a single
installation an isolator must be provided to each heater so that each heater can be
separately disconnected. The isolator switch should be located in a readily accessible
position. Each heater should be independently fused.
The interwiring of controls from one heater to another heater is not permitted.
3.7.1 R40 Burner Control Box G10 & G20S
M
~
231456789
NL
GREEN/YELLOW
BROWN
REMOTE LOCK-OUT IF REQUIRED
BLUE
FAN HOUSING
BROWN
BLUE
BLACK
BLUE
50V
WHITE
BROWN
MOTOR
CAPACITOR
BLACK
SOLENOID
COIL
Page 11

3.7.2 RDB Burner Control Box
3.7.3 Fitting External Room Thermostat
CONTROL BOX
535SE/LD
M
M
Oil Valve
Photoresistance
Black
White
Blue
Motor
Capacitor
Lock Out Live Neutral Earth
Fan
Housing
54321
ROOM THERMOSTAT
REMOVE
LOOP ‘A’
MAIN THERMINAL BLOCK
6789
3.7.4 Fitting a Frost Thermostat
The frost thermostat must be located in the coldest part of the building but where is
can respond to rise in temperature as a result of switching on the heater. A frost
thermostat should not be fitted on an outside wall.
The frost thermostat can be connected as per the room thermostat.
Page 12

3.7.5 Mains Plug
3.7.6 Motor Wiring
3 PhaseSingle Phase
By inserting a small screwdriver into the slots as shown, the retaining clips can be
prised open so allowing the cover to be hinged up revealing the wiring connections.
Before closing, ensure the cable clamp has properly been fitted.
Page 13

3.7.7 Wiring Diagram for Single Phase Control Panel
Page 14

3.7.8 Wiring Schematic for Single Phase Control Panel
Page 15

3.7.9 Wiring Diagram forThree Phase Control Panel
Note: If the fan (and motor) are turning
the wrong direction, simply swap over the
brown and black wire on the motor plug.
Page 16

3.7.10 Wiring Schematic for Three Phase Control Panel
Page 17

4.0 Oil Supply
1. Oil Tank
Steel tanks constructed to BS 799 Part 5 1987 should be painted on the outside only
and mounted on piers to prevent corrosion. Plastic oil tanks are also available and can
be suitable for installation at ground level. However, oil should never be stored in
translucent plastic containers.
2. The pipe from the oil tank to the burner should be run in copper, steel or aluminium
pipework. Galvanised pipe and fittings should not be used. The pipework should
terminate close to the boiler and be fitted with an isolating valve and filter. It is also
recommended that a remote sensing fire valve should be fitted to the oil line preferably
before the oil line enters the building. (I.E. BS 5410)
The fire valve sensor can be connected to heater casing above the burner by attaching
a retaining clip.
Depending on the position of the tank a two pipe system may be required. One and
two pipe oil systems are shown below. As an alternative to a two pipe system a Tigerloop
or other approved de-aerator may be used.
4.1 One Pipe System
Total Maximum Pipe Length (m)
0.5
10
20
1
20
40
1.5
40
80
2
60
100
I.D.
10 mm
I.D.
8 mm
Head H(m)
FIRE VALVE
SENSOR
FILTER MAY BE
POSITIONED
OUTSIDE
STEEL TANK SHOWN
PLASTIC TANK ALSO SUITABLE
FIRE VALVE
MAX OIL LEVEL 4 metres ABOVE BURNER
FILTER SHUT OFF
VALVE
Note: The ‘head’ of oil refers to
the distance the outlet from the
oil tank is above the oil pump.
Page 18