Page 1
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...
Page 2
A service history must be maintained in Section 7 of this manual. NI Customers Only Warmflow Engineering customer care (NI) provides an excellent backup service, operating a team of trained engineers who can meet all the servicing, commissioning and breakdown requirements for your appliance. Tel: 028 9262 1515...
CONTENTS KEY INFORMATION The Clean Air Act 1993 and Smoke Control Areas USER INSTRUCTIONS Filling the Pellet Hopper System Pressure System Filling User Control Interface 2.4.1 Home Screen Icons and their meaning. 2.4.2 Using the Main Menu INSTALLATION REQUIREMENTS General Requirements 3.1.1 Hearth 3.1.2 Service Access 3.1.3 Heating System 3.1.4 Air Vents 3.1.5 Drain Cock 3.1.6 Pipework 3.1.7 Heating System Design Sealed Systems 3.2.1 Expansion Vessel 3.2.2 System Filling 3.2.3 System Pressure 3.2.4 Pressure Relief Valve 3.2.5 Low Pressure Switch 3.2.6 Condensate Trap Plumbing layout Wiring Layout...
Page 4
APPLIANCE INSTALLATION/COMMISSIONING CERTIFICATE & REGISTRATION. APPLIANCE SERVICE RECORDS.
The appliance is rated to IP45 and has a weatherproof 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. ...
Page 6
Figure 2 Service Access. (Service Lid and Insulation Removed) 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. Figure 3: Combustion Door and Ash Pan Assembly. 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 ...
Page 7
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 WS18/WP18 Type Wood Pellet Boiler Width Dimensions (mm) Depth 1170 Height 1135 Dry weight (kg)
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 NO 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 ...
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.
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 ...
The home screen appears as shown in Figure 6. Fuel Status Current Page Boiler Status Cleaning Status Figure 6: Icon Descriptions. Boiler Status Icon Status Meaning Boiler OK The appliance is functioning normally. There are no faults or alerts. Servicing is not due. 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 Boiler Alert ‘Display active alarms’ key. You should arrange servicing as soon as possible and before servicing is overdue otherwise the appliance will shut down. The appliance has shut down due to a fault or alert. This may be a fault with the appliance, Boiler Fault an overdue service/clean or an empty hopper. Fuel Status Icon Status Meaning Fuel Level The pellet level in the hopper is fine. There are no faults or alerts. The pellet level in the hopper is low. The appliance will typically run as normal for 1 hour Fuel Level 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 The pellet hopper is now empty. The appliance will shut down. You should fill the hopper Empty immediately. Filling the hopper will automatically reset this alert. Cleaning Status Icon Status Meaning Cleaning The appliance is functioning normally. There are no faults or alerts. Cleaning is not due.
Page 12
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. Figure 7: Main Menu Page 1. Figure 8: Main Menu Page 2. 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’.
Page 13
Figure 10: Alarms Screen. 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 ...
Page 14
Figure 13: Appliance Ready for Cleaning Screen. 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 ...
Page 15
Figure 15: Cleaning Confirm Screen. 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 submenu 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 submenus include date/time, temperature and information as shown in Figure 16 below.
Page 16
Temperature: Selecting the temperature submenu 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 ...
Page 17
Mode Description Standby Awaiting heat demand System Check Ensuring that the appliance is ready and safe to start Preload 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 Anticycling function that activates a time delay before a Blocked restart is possible or the combustion door can be opened Table 3: Appliance Modes.
Page 19
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. Figure 22: Help Screen. This appliance must be serviced annually or as indicated by the user ...
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, nonporous, noncombustible 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 ...
3.2.1 Expansion Vessel Refer to BS7074: PART 1, BS EN 12828, BS EN 12831 and BS EN 14336 for details of expansion vessel sizing. The values given in the Table 4 below are for total system volumes which include the water content of the appliance which can be found in Table 1: Product Data (See page 3). The WS18 appliance is supplied with an 18 litre expansion vessel charged to 1.0 bar. This can accommodate a maximum combined appliance and system volume of 160 litres. If these maximum total system volumes are to be exceeded, additional expansion capacity will be required. The WP18 appliance is not supplied with an expansion vessel and if connected to a ...
When measuring the expansion vessel bladder precharge pressure, using a tyre gauge, the system must be cold (less than 25°C) and the system pressure must be relieved (by manually operating the system pressure relief valve) in order to obtain an accurate reading. 3.2.2 System Filling For the WS18 appliance a filling point complete with a filling loop is supplied fitted to the expansion vessel. The filling loop must be disconnected from the mains supply after filling. A system pressure when cold of 1 bar is recommended. After filling, vent all air from the system. The plastic plugs of the auto air vent(s) factory fitted to the appliance must be loosened when ...
Page 23
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 24: Condensate Trap Plumbing.
Plumbing layout Casing knockouts can be found on both sides and rear of the appliance along with cutouts in the galvanised base which allow for the pipes to exit the casing below ground level, see Figure 25 and 26 below. 28mm elbows have been supplied with the appliance for connection. It is advised that the pipe work from the appliance to the interior of the property must be 28mm and insulated with a minimum of 9mm pipe insulation. The appliances anticondensation valve is factoryfitted to ensure a return temperature of 55°C. The integrated variable speed circulating pump modulates with the modulating heat output of the appliance. Figure 25: Casing Knock out Positions for Installer Plumbing and Wiring. Figure 26: Plumbing Options. 3.4 Wiring Layout...
Page 25
All wiring must be carried out in accordance with current IEE wiring regulations. It is recommended the user interface controller is mounted in an easily accessible location within the property. The wiring connection to the user interface is via a pLAN connection and must be wired from the wiring panel to the user interface controller with the supplied CAT5e cable. The following section details the connection of the appliance to the user interface controller via the supplied 20m CAT5e cable. Figure 27 below shows the colour coding of the wiring into the pLAN terminals. These terminals are located in the Installer's wiring panel at the front of the appliance as shown in Figure 1 (see page 1). The other end of the cable, with the RJ12 plug ...
Figure 29: System Wiring Layout. 3.5 Flue System The appliance comes with an 80/100mm twin wall flue comprising a 1000mm long flue section and a 600mm long flue terminal. To assemble the flue supplied, insert the1000mm long flue section into the flue spigot on top of the appliance. Secure with supplied selfdrilling screws. Place weatherproof collar over the joint and apply a bead of silicone sealant around the collar prevent water ingress (refer to Figure 30). This flue system is adequate only if the flue terminal is more than 2.3 meters from an adjacent wall or surface as required by building regulations. If the flue terminal is to be within 2.3 meters then please refer to Figure 31. Installations must comply with the combustion appliance and fuel storage systems directive of regional building regulations. Apply Secure silicone flue with sealant to selfdrilling prevent screws water ingress...
The appliance has an anticondensation valve factoryfitted which must not be removed or tampered with in any way. The valve is controlled by the appliance’s user interface controller and will ensure a return temperature of 55°C to promote longevity of the heat exchanger. Note: All product warranties will be invalidated if the appliance is not commissioned by a Warmflow engineer or other trained and competent technician and the installation/commissioning certificate (see Section 6 of this manual) completed and returned to Warmflow within 30 days from the date of installation and 90 days from the date code stamped on the appliance.
Note: All product warranties will be invalidated if the appliance is not serviced at least annually or as indicated by the user interface controller by a Warmflow or trained technician and details recorded in the service record section of this manual. 4.2.2 Servicing the heat exchanger ...
and checked for excess wear before replacing. It is possible to split the turbulators for cleaning by removing the R pin. 4.2.3 Emptying the hopper Should the wood pellets within the hopper become damp or if excessive amounts of pellet dust should accumulate in the hopper it may be necessary to empty the hopper and refill it with fresh pellets. First, isolate the appliance from the mains electrical supply, then remove the hopper safety guard by unfastening the seven screws shown in Figure 33 below. This will allow access to remove damp pellets or dust from the hopper. Figure 33: Removing Hopper Guard. The end cap of the auger can be removed to ...
Figure 35: Door Assembly Cleaning Access. The combustion pot sits on a shelf on the door which houses the pot grate and cleaning mechanism. The shelf must be cleaned out during the appliances annual service by a Warmflow Engineer or other competent technician. Refer to Figure 35. To gain access to the inner part of the shelf the motor must be unplugged and the motor, motor bracket and cleaning mechanism must be withdrawn horizontally from the combustion door. Next the locating pins must also be withdrawn horizontally allowing the cleaning knives to lift vertically from the shelf. The knives should be checked for signs of wear and oxidation and replaced if needed. ...
Page 33
In the event that components are not capable of repair, Warmflow will provide replacement parts for any such components. Warmflow reserves the right to repair or replace components within the period of guarantee at a time and location that is most convenient to the company. All removed parts and components of your Boiler shall become the property of Warmflow. All replaced and/or repaired parts shall assume the status of the original part for the purposes of this warranty and this warranty shall not be extended by the replacement of such parts. This guarantee applies to Warmflow boilers installed in GB (including Scottish Isles), Isle of ...
Page 34
The commissioning certificate in respect of your Boiler must be returned to Warmflow within thirty (30) days from the date of installation. Please note if your Boiler has not been installed within three (3) months of the date of dispatch from Warmflow, then this guarantee will be deemed to have commenced upon such date of dispatch. Please also note that failure to complete and return the commissioning certificate at the time of ...
Page 35
Scratches, nicks, minor dents, and cosmetic damages to external surfaces and exposed parts of your Boiler are also excluded. Repairs All repairs and/or replacements must be authorised in writing by Warmflow prior to any works being carried out. Warmflow will have no responsibility or liability for repairs or works performed by a person who has not been authorised by Warmflow. Warmflow will accept no liability for the cost of repairs resulting from incorrect installation, inadequate commissioning, lack of annual ...
Page 36
(m)Any problems caused by inadequate supply of services such as electricity or water to the property; Claims for consequential loss or damage however caused are not covered by this guarantee. Please note that your statutory rights are not affected by this guarantee.
Page 37
6 APPLIANCE INSTALLATION/COMMISSIONING CERTIFICATE & REGISTRATION. Instructions. Complete the Installation/Commissioning Certificate. Complete the Installation/Commissioning Certificate overleaf. Fill out all relevant sections of the Installation/Commissioning Certificate using BLOCK CAPITALS. Please write legibly. 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 Installation/Commissioning Certificate. Send the certificate to Warmflow By post using the envelope provided to: Warmflow Engineering Co. Ltd. Lissue Industrial Estate Moira Road Lisburn Co. Antrim Northern Ireland BT28 2RF By fax on 02892620869 If the appliance is not registered, warranty may be invalidated.
Page 38
Flue Gas Analyser Make & Model: Appl i a nce Model No.: Output: Calibration Date: Fuel Brand: ENplus 1: Appl i a nce Seri a l No.: Da te Code: Concentration (%) MCS Approva l No.: WS18: BSI KM 608787/2 WS18: BSI KM 608787/2 CO Concentration (ppm) Householder & Installation Address Details. Flue Gas Temperature (°C) Hous ehol der’s Na me: Draught (Pa) Hous ehol der’s Addres s : Fan (RPM)
Page 40
7 APPLIANCE SERVICE RECORDS. Instructions. The appliance must be serviced in accordance with the service schedule and instructions laid out in this manual. Details of the service conducted must be fully recorded on the following service record sheets by the competent person conducting the service. Service records must be retained for inspection upon request by the manufacturer.
Page 41
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 1. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 42
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 2. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 43
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 3. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 44
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 4. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 45
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 5. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: (LandLine) (Mobile) Contact Telephone No.: Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 46
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 6. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 47
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 7. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 48
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 8. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 49
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 9. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: (LandLine) (Mobile) Contact Telephone No.: Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 50
Yes P PLEASE COMPLETE USING BLOCK CAPITALS. Service Record 10. Date of Servicing: 1. Service Engineer Details. MCS/SEAI Registration No. Service Company Name: Service Company Address: Contact Telephone No.: (LandLine) (Mobile) Service Engineer’s Name: Service Engineer's's EMail: Condition of Installation. Fuel Stora ge Ti mers & Thermos ta ts El ectri ca l Sa fety Hea ti ng Zone Va l ves Appl i a nce Venti l a ti on Thermos ta ti c Ra di a tor Va l ves Condens a te Dra i n Sys tem Bypa s s Va l ve...
Page 51
This manual is accurate at the date of printing (E&OE) but will be superseded CODE 4220 and should be disregarded if specifications and/or appearances are changed ISSUE 3 in the interests of continued product improvement. JULY 2014...
Need help?
Do you have a question about the WS18 and is the answer not in the manual?
Questions and answers