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WarmFlow WAH 100 Installation & Servicing Manual

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

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  • Page 1 INSTALLATION & SERVICING MANUAL FOR WARMFLOW OIL FIRED WARM AIR HEATERS MODELS 100/150 200/300 500/600 LEAVE THESE INSTRUCTIONS WITH THE END USER BS 5750 PART 2 OIL FIRING TECHNICAL ISO 9002 ASSOCIATION FOR THE PETROLEUM INDUSTRY NATIONAL ACCREDITATION OF CERTIFICATION...
  • Page 2 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.

  • Page 3: Table Of Contents

    Contents Page Introduction General Requirements Installation User Instructions Controls Components General Data Technical Data Dimensions Installation Clearances Air Supply Ductwork Filters Electrical Supply Oil Supply One Pipe Systems Two Pipe Systems Flues Burners Components Oil Supply Air Damper Adjustment Electrode Setting Burner Start Up Cycle Fault Finding Burner Spares...

  • Page 4: Introduction

    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.

  • Page 5: User Instructions

    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.

  • Page 6: Components

    Components 2.2.1 Heater Air Discharge Hoods Heat Exchanger Fan Stat Combustion Chamber Door Burner Air Inlet Grills Fan Motor Base Pallet Control Panel Page 4...
  • Page 7 2.2.2 Fan Stat (Cover Removed) High Limit Stat Setting Peg (100°C) Fan on Setting Peg (40°C) Fan Off Setting Peg (20°C) Fan Override Button (White) Keep Pulled Out High Limit Reset Button (Red) 2.2.3 Air Heater Control Panel Burner Cable Overload Relay Reset Button (Red) Clock...
  • Page 8 2.2.4 Time Clock Indictor Arrow 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.

  • Page 9: General Data

    General Data Technical Data WAH MODEL 100/150 200/300 500/600 Output Range 29.3-44.0 58.6-88.0 146.5-175.8 Nominal Heat 52.4 102.3 206.9 Input (max) 178,800 349,000 705,900 Nominal Heat 44.0 88.0 175.8 Output (max) 150,000 300,000 600,000 Nominal combustion efficiency gross % Burner Riello RDB 2 G20s Head...

  • Page 10: Dimensions

    Dimensions MODEL 100/150 200/300 500/600 1625 1860 2145 1020 1090 1445 1410 1640 1895 1095 1190 Page 8...

  • Page 11: Installation Clearances

    Installation Clearances The space in which the heater is to be fitted must have the following minimum dimensions: 600mm 1000mm ACCESS DOOR A - Width B - Height Refer to Section 3.2 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).

  • Page 12: 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).

  • Page 13: Electrical Supply

    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.
  • Page 14 3.7.2 RDB Burner Control Box CONTROL BOX 535SE/LD Housing Photoresistance Motor Black White Oil Valve Blue Capacitor 3.7.3 Fitting External Room Thermostat MAIN THERMINAL BLOCK REMOVE LOOP ‘A’ ROOM THERMOSTAT 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.
  • Page 15 3.7.5 Mains Plug 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. 3.7.6 Motor Wiring Single Phase 3 Phase...
  • Page 16 3.7.7 Wiring Diagram for Single Phase Control Panel Page 14...
  • Page 17 3.7.8 Wiring Schematic for Single Phase Control Panel Page 15...
  • Page 18 3.7.9 Wiring Diagram for Three Phase Control Panel Page 16...
  • Page 19 3.7.10 Wiring Schematic for Three Phase Control Panel Page 17...

  • Page 20: Oil Supply

    Oil Supply 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.

  • Page 21: Two Pipe Systems

    Two Pipe Systems FILTER MAY BE SAW CUT INSIDE POSITIONED TANK TO PREVENT OUTSIDE SYPHON FILTER FIRE VALVE NON RETURN VALVE RETURN LINE NO FILTERS OR VALVES STEEL TANK SHOWN PLASTIC TANK ALSO SUITABLE Total Maximum Pipe Length (m) Lift H I.D.

  • Page 22: Flues

    Flues The flue should be designed in accordance with the local bye-laws and the Clean Air Act. Draught stabilisers are not recommended. Sharp bends or horizontal runs should be avoided and the flue should terminate 2 feet (600 mm) above the ridge of the dwelling. Terminals which restrict the discharge or allow ingress of water should be avoided.

  • Page 23: Burners

    Burners 6.1.1 RDB Burner The burner is fitted with the correct nozzle and the pressure set. All that is further required before commissioning, is to connect the oil and electricity supply. Pump Air damper adjustment screw Control box Air tube connection (B/F) Reset button with lock-out lamp Pump pressure adjustment screw Flange with insulating gasket...

  • Page 24: Oil Supply

    6.1.3 G20S Burner Return line Hydraulic jack with air-damper Suction line Combustion head adjustment screw Gauge connection Lock-out lamp and reset button Pump pressure regulator Flange with insulating shield Suction gauge connection 10. Start delaying device Oil Supply The burner is supplied for use with a one pipe system. For use on a two pipe system, it is necessary to remove the return port plug and fit a small by-pass plug as shown.

  • Page 25: Air Damper Adjustment

    Air Damper Adjustment The setting is purely indicative. Each installation however, has its own unpredictable working conditions: actual nozzle output; positive or negative pressure in the combustion chamber, the need of excess air, etc. All these conditions may require a different air-damper setting, which should be checked and set during commissioning.

  • Page 26: Fault Finding

    Fault Finding Switch on electricity supply Set rocker switches to heating on and manual Does the fan run? Is white button on the Check fan stat fan stat pulled out? Check contactor Check wiring Pull out button Does burner fire? Is burner motor running Check photocell solenoid continuously without ignition?

  • Page 27: Burner Spares

    Burner Spares Riello RDB Burner NO CODE 3748757 DESCRIPTION NO CODE 3748757 DESCRIPTION 3005787 • Gasket 3008654 • Pump 3006384 • Flange 3007162 • ‘O’ Ring 3008769 • Cup-shaped Head 3008653 • Filter ‘O’ Ring 3007513 • Electrode Assembly 3003602 •...
  • Page 28 Riello 40 – G10 CODE DESCRIPTION CODE DESCRIPTION 3000879 Air Shutter Assembly 3006557 Access Plate 3006913 Tube 3005791 Collar 3005788 3005764 Nozzle Holder 3005798 Condenser 3002278 Control Box Base 3007355 Motor 3001156 Control Box 3007077 Washer 3002297 Igniter 3007450 Pump 3002280 Photocell 3002279...
  • Page 29 Riello 40 – G20S CODE DESCRIPTION CODE DESCRIPTION 3005799 3000443 Joint 3007156 ‘O’ Ring 3005720 Flexible Pipe 3007028 ‘O’ Ring 3005820 Motor 3005801 Washer 3006558 Access Plate 3005800 Tube 3001156 Control Box 3005802 Condenser 3002280 Photocell 3007077 Washer 3002278 Control Box Base 3005771 Pivot 3005809...
  • Page 30 Notes Page 28...
  • Page 31 COMMISSIONING DETAILS To ensure the reliable and efficient operation of your heater it is necessary to have this appliance properly commissioned by a suitably qualified commissioning engineer. The page below is to be completed by the commissioning engineer and the manual retained by the end user.
  • Page 32 ENGLAND, Tel: 01952607750 SCOTLAND & WALES FOR TECHNICAL ASSISTANCE CONTACT WARMFLOW ON TEL: (028) 92621515 E-MAIL: technical@warmflow.co.uk This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/ or appearances are changed in the interests of continued product improvement.

This manual is also suitable for:

Wah 150Wah 200Wah 300Wah 500Wah 600

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