WarmFlow WS18, User Instructions

Page 1: ...8 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...

Page 2: ...e 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 mee...

Page 3: ...tion 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 Ve...

Page 4: ...TION 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...

Page 5: ...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...

Page 6: ...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...

Page 7: ...e 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 Allo...

Page 8: ...he 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 renewabl...

Page 9: ...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...

Page 10: ...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 a...

Page 11: ...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 servici...

Page 12: ...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 ale...

Page 13: ...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...

Page 14: ...or the Up Arrow key can then be used to scroll through the alarms Refer to Section 5 for more information on the alarm messages that can be displayed and the appropriate action to take in each case C...

Page 15: ...me are set correctly as shown in Figure 13 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 altere...

Page 16: ...anger displayed in degrees Celsius Ambient temperature if the appliance is cold No greater than 85 C in normal operation Return Temp The temperature of the water in the return pipe connected to the bo...

Page 17: ...perature of the property increases the Heat Req value will decrease Draught Set Indicates the draught required for good combustion displayed in Pascals Pa This value is determined by the operating mod...

Page 18: ...creen 1 see Figure 15 Further explanation of each operating mode is given in Table 5 Mode Description Standby Awaiting heat demand System Check Ensuring that the appliance is ready and safe to start P...

Page 19: ...ing 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 an...

Page 20: ...16 Figure 18 Flow Chart...

Page 21: ...eeze Risk Mode is an integral part of the control system in the appliance and cannot be bypassed Be aware it is only included to protect the appliance from freeze risk damage not the central heating s...

Page 22: ...ry Reset Tests In Out Help Selecting the help menu as shown in Figure 20 below displays the contact details for Warmflow who should be contacted if you require further assistance or if you encounter a...

Page 23: ...red When the Display Active Alarms key is pressed a cleaning alert screen will be displayed to indicate the remaining time for a clean to be completed A typical example of a cleaning alert message is...

Page 24: ...nu using the Down Arrow and confirm selection using the Enter key Figure 23 The cleaning status screen should now be displayed If the cleaning status screen in Figure 24 is displayed a scheduled clean...

Page 25: ...tatus will be displayed for a further three days with a daily count down indicating the remaining time before the appliance shuts down If the screen in Figure 27 is displayed the appliance has shut do...

Page 26: ...ve cleaning may be of benefit for example where the product may be unattended when the next scheduled cleaning us due Cleaning in advance of this time will avoid the unnecessary shutdown of the applia...

Page 27: ...when placed in contact with hot ash or combustion deposits There are 16 steps to cleaning a WS18 WP18 Wood Pellet Boiler Appliance Please complete all steps with care in order to prolong the life of t...

Page 28: ...eaning preparation time can vary depending on the temperature of the appliance when cleaning preparation utility is initiated STEP 3 Wait for Cleaning Preparation to Complete The screen in Figure 32 w...

Page 29: ...ase the latch The front casing door can now be opened Do NOT turn the appliance off at any stage during this procedure using the isolator switch on the front of the appliance see Figure 34 The applian...

Page 30: ...interlock can be heard to release when this button is pressed Push down firmly on the combustion door handle while still holding the door release button as shown in Figure 35 Push DOWN Push DOWN Lift...

Page 31: ...larm will clear automatically when all steps of this cleaning procedure are complete STEP 6 Clean the Combustion Shelf Use a suitable brush to remove any build up of ash dust off the combustion shelf...

Page 32: ...Pot Removing the Ash Pan STEP 8 Remove the Ash Pan See Figure 38 Ensure the combustion door is fully opened to make the ash pan more accessible and easier to remove Lift the ash pan from the ash pan a...

Page 33: ...suitable brush to dislodge any build up of combustion deposits from the inside of the combustion pot as shown in Figure 40 A dedicated ash vacuum cleaner may also be used Make sure the ash is sufficie...

Page 34: ...for a second time See Figure 39 Ensure all air holes in the combustion pot are cleaned and unblocked See Figure 42 Failure to clean the combustion pot as directed may restrict the flow of air within...

Page 35: ...own in Figure 43 Make sure the ash is sufficiently cool before vacuuming Use a suitable brush to remove any build up of ash dust from the ash pan area of the heat exchanger A dedicated ash vacuum clea...

Page 36: ...his seal is removed or has become worn or damaged it should be replaced by a Warmflow engineer or other trained and competent engineer This seal is critical for efficient operation of the appliance Lo...

Page 37: ...on It will be difficult to close the combustion door if the ash pan is not correctly placed in the ash pan area of the heat exchanger Should you find the combustion door difficult to close return to S...

Page 38: ...his cleaning procedure is confirmed The cleaning procedure is now COMPLETE If the screen in Figure 48 is not displayed at the end of the cleaning procedure an interruption has occurred For example the...

Page 39: ...r by completing STEP 5 of the cleaning procedure o Close the combustion door by completing STEP 14 of the cleaning procedure o The Cleaning Confirm Screen See Figure 53 should now be displayed and com...

Page 40: ...e edge of the appliance Insert the axle through the now exposed holes Secure 1 wheel to each side of the boiler with the supplied washers on each side of each wheel Insert the supplied R clips on each...

Page 41: ...eating 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 othe...

Page 42: ...onnections to the appliance must be made with compression fittings 3 1 7 Heating System Design The heating system must be designed for a fully pumped appliance 3 2 Sealed Systems 3 2 1 Expansion Vesse...

Page 43: ...perature If the pressure is outside this range contact your installer Frequent or routine refilling and topping up of the system should not be necessary on an ongoing basis and may prove harmful to th...

Page 44: ...40 The drainage hose must not be affected by any blockage which could lead to condensation backfilling into the heat exchanger of the appliance causing corrosion Figure 55 Condensate Trap Plumbing...

Page 45: ...nised base which allow for the pipes to exit the casing below ground level see Figure 56 and 57 below It is advised that the pipe work from the appliance to the interior of the property must be 28mm a...

Page 46: ...s shown in Figure 1 see page 1 The other end of the cable with the RJ12 plug connects into the back of the user interface controller supplied Max 50m shielded CAT5e cable All connections are made to t...

Page 47: ...competent Engineer after determining the reason for failure Fuses are located adjacent to the mains supply wiring connections and protect the following circuits Fuse 1 5x20mm F 500mA 250 VAC 24V DC P...

Page 48: ...lding regulations If an additional length of flue and fittings are used manufacturer s instructions for correct fastening and support must be followed If the flue terminal is to be within 2 3 meters o...

Page 49: ...flue gas leakage when firing appliance 5 Insert the 500mm long flue terminal into the flue section and push firmly into place 6 After Flue gas analysis has been completed ensure silicone plug is firm...

Page 50: ...g transportation or installation reporting this before proceeding The IP Ingress Protection rating of the product should be maintained by the use of correct cable glands and pipework grommets for inst...

Page 51: ...P 4 Assignment of Required Parameters To ensure correct operation of the unit several site specific parameters must be assigned to the appliance via the Engineer menu of the user interface controller...

Page 52: ...er key to confirm Select 1 Parameters using the Enter key as shown in Figure 67 The parameters menu consists of 2 pages as shown in Figures 68 and 69 which may be selected and entered using the Up Arr...

Page 53: ...mand has been met Decreasing this value will increase startup frequency of the appliance by permitting a lower flow temperature decrease after the heating demand has been met I Lock Temp 50 0 C This i...

Page 54: ...e setting is called a Preset Drop Test This semi automated test facility runs the auger mechanism for a timed period of 10 minutes during which the dropped pellets will be collected and then weighed T...

Page 55: ...gineer password into the engineer password screen Figure 72 using the Up Arrow key and Down Arrow key and then the Enter key to advance to the next character Press the Enter key to confirm Scroll usin...

Page 56: ...rder to collect the dropped pellets Press the Enter key on the User Interface Controller to allow selection of the word No Use the up arrow to change this option to Yes as shown in Figure 75 The Prese...

Page 57: ...door and casing green casing door STEP 7 Flue gas analysis Now that the drop test has been completed and the auger mode checked and adjusted if necessary the heating demand may be enabled and the app...

Page 58: ...the combined installation commissioning certificate See Section 7 of this manual returned to Warmflow within 30 days from the date of installation and 90 days from the date code stamped on the applia...

Page 59: ...Refer to the inhibitor manufacturer for further guidance The below table is a typical list of service operations and is not exhaustive Item Inspect Clean Replace Combustion pot and sealing rope Ash pa...

Page 60: ...in the following pages suggest possible causes for the activation of each alarm Suggested actions for each alarm condition are also included The suggested actions are attributed to the user typically...

Page 61: ...to cover the pellet level sensor Test the operation of the pellet level sensor and repair replace if necessary The appliance has not been cleaned within the time period indicated in the cleaning aler...

Page 62: ...ait for the green light beside the isolator switch to illuminate Open the combustion door Refer to Section 2 5 3 Cleaning Procedure STEP 5 Remove the combustion pot and empty it Re install the combust...

Page 63: ...self Test the operation of the flow temperature sensor and re connect replace if necessary The return temperature sensor is faulty or disconnected Test the operation of the return temperature sensor a...

Page 64: ...connected Test the operation of the photocell and re connect replace if necessary The water pressure in the central heating system is low For pressurised systems Raise the water pressure in the system...

Page 65: ...s exceeded a high limit value due to inadequate cleaning or servicing The flue gas temperature sensor is faulty Clean the appliance following the cleaning procedure detailed in Section 2 5 3 Service t...

Page 66: ...s faulty The switch on the grate cleaning mechanism is faulty Test the operation of the grate cleaning motor mechanism and switch and repair replace if necessary The fuel delivery system is faulty Tes...

Page 67: ...Anti condensation valve fault Anti condensation valve actuator set to CCW rotation Circulating pump fault Increase flow temperature in user menu Temperature Bleed heating system to remove airlocks Per...

Page 68: ...fy water ingress replace pellets Water is flowing from vent in open vented system Max pump speed set too high Reduce max pump speed parameter Flue fan is running but Draught Act value is around 0 Drau...

Page 69: ...installation and any other conditions of this warranty are met Please note that periods of guarantee will not be extended under any circumstances Warmflow s Obligations Where components are found to...

Page 70: ...ter the date of installation and thereafter at twelve 12 monthly intervals or sooner if required by the variable service schedule in the controller Warmflow reserves the right to determine at its abso...

Page 71: ...e other than an authorised service provider carry out works to your Boiler this warranty will automatically become null and void Other property In no event shall Warmflow have any liability or respons...

Page 72: ...the improper use or storage of the boiler and in particular but without limitation Warmflow shall not be liable in the case of defects arising from normal deterioration or improper or faulty handling...

Page 73: ...ibly Ensure that the certificate is signed by both the Competent Person and the Customer Carbon copies of the certificate are produced automatically Register the Appliance Remove the white copy of the...

Page 74: ...tion Date Fuel Brand ENplus 1 CO2 Concentration Boiler Parameters See Section 4 of the product manual CO Concentration ppm Fuel Alarm Mins Water Press NO NC O2 Concentration Pump Diff C Mode 1 On Off...

Page 75: ...71 INTENTIONALLY LEFT BLANK...

Page 76: ...e record sheets by the Warmflow or other competent engineer conducting the service Service records must be retained for inspection upon request by the manufacturer All product warranties will be inval...

Page 77: ...eat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifica...

Page 78: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 79: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 80: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 81: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 82: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 83: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 84: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 85: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 86: ...Heat Exchanger Door Seals Electrical Connections Security Photocell Corrosion Inhibitor Concentration Combustion Door Interlock Interlock Controls Appliance Safety Controls Mechanisms 3 System Modifi...

Page 87: ...83 9 APPENDIX A SUPPLEMENTARY INSTALLATION AND OPERATING INSTRUCTIONS FOR THE UK MARKET...

Page 88: ...ilding Control approval or is installed by a Competent Person registered with a Government approved Competent Persons Scheme HETAS Ltd operate such a Scheme and a listing of their Registered Competent...

Page 89: ...oiler runs at high efficiencies the temperature of the flue gases is at times lower than conventional solid fuel appliances Although it is not classed as a condensing appliance the low flue gas temper...

Page 90: ...stion air supply Adequate provision e g easily accessible soot door or doors must be provided for sweeping the chimney and connecting fluepipe Hearth The hearth should be able to accommodate the weigh...

Page 91: ...3 Code of Practice for low temperature hot water heating systems of output greater than 45kW where appropriate Electrical connections The installation of any electrical services during the installatio...

Page 92: ...e kept clean at all times IMPORTANT NOTES General Before lighting the boiler check with the installer that the installation work and commissioning checks described above have been carried out correctl...

Page 93: ...of time then it should be given a thorough clean to remove ash and unburned fuel residues Empty the hopper of unburned fuel To enable a good flow of air through the appliance to reduce condensation an...

Page 94: ...Remember also that during the main heating season the cleaning interval will shorten as the load on the boiler will be higher Recommended fuels The boiler is designed to burn only specialized either c...

Page 95: ...91 10 APPENDIX B CUSTOMER CONNECTION WIRING SCHEMATIC...

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Page 97: ...ccurate at the date of printing E OE but will be superseded and should be disregarded if specifications and or appearances are changed in the interests of continued product improvement CODE 4220 ISSUE...