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Johnson & Starley Warmcair C10D Installation, Commissioning & Servicing Instructions

High efficiency downflow condensing air heater
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Publication No. ZZ 1339
April 2013
WARMCAIR C10D
Condensing Air Heater
High Efficiency Downflow
Condensing Air Heater
INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
Warmcair C10D
-
G.C. No. 42-416-99
These instructions are to be left with the User
www.johnsonandstarley.co.uk

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  • Page 1 Publication No. ZZ 1339 April 2013 WARMCAIR C10D Condensing Air Heater High Efficiency Downflow Condensing Air Heater INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS Warmcair C10D G.C. No. 42-416-99 These instructions are to be left with the User www.johnsonandstarley.co.uk...
  • Page 2 CONTENTS The Benchmark Scheme Features General Description Building Standards & Regulations Safety & Gas Information Technical Data Heater Positioning Heater Compartment Clearances Duct System Flue Instructions Condensate Pump & Drain Tube Electrical Fitting Instructions Commissioning Handling Over Servicing & Maintenance Replacement Parts Control Panel Modes Fault Code Table...

  • Page 3: Features

    It is room sealed, with a stainless steel heat exchanger, using a vertical or horizontal Concentric Flue System. The Warmcair C10D air heater is ideally suited for new built dwellings and the replacement of existing non- condensing air heaters.

  • Page 4: Building Standards & Regulations

    BUILDING STANDARDS & REGULATIONS Installation shall be in accordance with the current editions of:- • Building Standards (Scotland) (Consolidation) Regulations • Building Regulations • Gas Safety (Installation and Use) Regulations (as amended) • BS 7671 Institute of Electrical Engineers (I.E.E.) Wiring Regulations • BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises (2nd family gases). • BS 5440 Pt. 1 (Flues for Gas Appliances) • BS 5440 Pt. 2 (Air Supply for Gas Appliances) • BS 5864 Installation of Gas Fired Ducted Air Heaters • British System Design Manual “Gas Fired Warm Air Heating” • Model and Local Authority Bye-laws • EN 1196 Supplementary Instructions - Condensing Air Heaters IMPORTANT: IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, (i.e.

  • Page 5: Technical Data

    TECHNICAL DATA C10D 48kg WEIGHT 20mbar GAS SUPPLY PRESSURE GAS CATEGORY GB & IE COUNTRIES OF INSTALLATION 230v ~ 50hZ fused 5A (150 watts) ELECTRICAL SUPPLY MAXIMUM MINIMUM MJ/h Btu/h MJ/h Btu/h 10.0 34,120 18.0 17,060 INPUT (GROSS) 31.68 30,026 15.84 15,013 OUTPUT...

  • Page 6: Duct System

    In airing cupboard installations, the part used as the air heater compartment must comply with the relevant section of BS 5864 and must be completely separated by either a non-combustible partition or a perforated metal partition with the perforations not exceeding 13mm (½”). The secondary flue must be a tight fit where it passes through the partition and must be suitably protected.

  • Page 7: Flue Instructions

    FLUE INSTRUCTIONS The Warmcair C10D Condensing Air Heater is certified as a warm air heater with corresponding flue sys- tems according to EU Directive 2009/142/EC on gas-fired devices. These installation instructions are cov- ered by this certification and are referred to in the design approval test certificate.
  • Page 8 D, E FIGURE 3. TERMINAL POSITIONS TERMINAL POSITION MINIMUM DISTANCE Directly below an opening, air brick, opening window etc. 300mm Above an opening, air brick, opening window, etc. 300mm Horizontally to an opening, air brick, opening window etc. 300mm Below gutters, soil pipes or drain pipes. 75mm Below eaves.
  • Page 9 PLUME TERMINAL OUTLETS 9.7.1 A flue duct outlet of an appliance should be at least 600mm from the boundary line when facing it and at least 300mm from the boundary line when running parallel to it. See Figure 4. NOTE: When the flow of products is at an angle to the boundary, the 600mm dimension may be measured in the direction of the flow, as long as the terminal is not less than 300mm from the boundary.
  • Page 10 9.9.1 Horizontal and vertical concentric flues (60/100mm diameter) with balanced terminals may be installed on all the Warmcair C10D warm air heater. 9.9.2 If an extended horizontal flue is being used it must have a continuous fall back towards the appliance of 3˚ (52mm) per meter. This ensures that condensate runs back into the appliance from...

  • Page 11: Condensate Pump & Drain Tube

    CONDENSATE PUMP & DRAIN TUBE 10.1 CONDENSATE PUMP 10.1.1 Supplied with 6mm x 10m condense tube. Condense adapter and 2 x clips. SAFETY NOTE: If the pump fails, the safety float switch will shut off the heater operation. 10.1.2 DO NOT HANDLE PUMP IN WET CONDITIONS OR WITH WET HANDS 10.1.3 To reduce the risk of electric shock, ensure the electrical supply is permanently wired to earth.

  • Page 12: Electrical

    GAS (See BS 5864 and BS 6891) 11.1 The local gas supply conditions MUST be adequate for the specified burner pressures as stated in the technical specification (section 5). 11.2 An independent gas supply pipe from the meter is to be preferred wherever possible. Where this is not possible, the pipe must be capable of taking the complete input of the heater and all other gas appliances being served by the same pipe.

  • Page 13: Fitting Instructions

    FITTING INSTRUCTIONS CAUTION: This appliance exceeds the recommended weight for a one man lift as detailed in the Manual Handling Operations, 1992 Regulations. It should be noted that this appliance could contain sharp edges and care MUST be taken when handling. 13.1 FITTING THE APPLIANCE 13.1.1...
  • Page 14 Note: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5m/s (300ft/ min), except for very small rooms, (i.e. bathrooms etc.). Outlet faces may require partial blanking in order to achieve this. 14.3 LIGHTING MAIN BURNER 14.3.1 Turn on the gas supply to the heater.
  • Page 15 HANDING OVER 15.1 After commissioning, the installer should hand the appliance over to the occupier of the house by the following procedure: 15.2 Hand the User Instructions ZZ1340 to the occupier and explain their responsibilities in respect of current legislation and regulations, both national and local. 15.3 Explain and demonstrate how to light and shut down the appliance.

  • Page 16: Servicing & Maintenance

    SERVICING & MAINTENANCE 16.1 SERVICING SCHEDULE To ensure that the appliance gives continued operation that is both safe and efficient, it is necessary to carry out regular service checks and whilst the period between servicing will depend on the installation condition and the demands placed upon the appliance, it is recommended that the appliance be serviced annually.
  • Page 17 16.4 MAIN BURNER ASSEMBLY 16.4.1 Refer to section 16.3. 16.4.2 Disconnect the gas pipe at the top of the isolation valve. 16.4.3 Disconnect the electrode, igniter and earth leads from the ESYS. The remove the screw and panel on the ESYS and remove. Disconnect the electrical connections. 16.4.4 Remove the two screws from the valve/venturi assembly and withdraw.
  • Page 18 16.6 COMBUSTION CHAMBER/HEAT EXCHANGER 16.6.1 Refer to section 16.3. Filter 16.6.2 Inspect the inside of the combustion chamber for debris. If the inner insulation is damaged, do NOT try to clean. Replace the heat exchanger. 16.7 AIR CIRCULATION FAN (ACF) 16.7.1 Refer to section 16.3.

  • Page 19: Replacement Parts

    16.9.6 Disconnect the flue outlet disconnected and pour water into the flue pipe outlet to fill the condensate drain pipe and check for leaks. Re-connected the pipe to the flue outlet. 16.9.7 Refit in reverser order. 16.10 CONDENSE PUMP 16.10.1 Refer to section 16.3. 16.10.2 Disconnect the condensate pipes and tube.
  • Page 20 Flame Detection Electrode Ignition Electrode ESYS Burner Assembly Nuts Burner Arm Gasket ESYS Panel Electrical Con- Screw nections Combustion Gas Valve Chamber Valve/Venturi Screws Venturi Electrode Nuts Burner Assembly Nut Gas Cock FIGURE 21. MAIN BURNER ASSEMBLY 17.6 FLUE TEMPERATURE SENSOR Condense Condense Pump Pipe Connections...
  • Page 21 17.10 GAS VALVE & VENTURI ASSEMBLY NOTE: The gas valve is factory preset and must not be adjusted. A replacement valve must only be supplied by Johnson & Starley Ltd. 17.10.1 Refer to section 16.3. 17.10.2 Unscrew the gas joint at the top of the gas cock and remove the ESYS (red ignition box). Refer to 17.9 &...

  • Page 22: Control Panel Modes

    18. CONTROL PANEL MODES FIGURE 24. CONTROL PANEL CONTROL PANEL Time control LED Display Summer Air Circulation Reset 18.1 TEST MODE 18.1.1 To put the appliance in test mode, press Summer Air Circulation (SAC) and C buttons together for more than 3 seconds, until the display changes. (Possible 5 second time delay.) 100 is displayed along with the flame symbol.

  • Page 23: Fault Code Table

    FAULT CODE TABLE 19.1 CAUTION Before commencing any mechanical servicing the appliance should be isolated from the electrical supply and the gas service cock on the appliance closed. All parts that are removed during a service operation should be replaced in reverse order, ensuring correct seals are made and wires are connected correctly. During the service remove any debris from within the appliance.
  • Page 24 FAULT FINDING FLOW CHART www.johnsonandstarley.co.uk...

  • Page 25: Defect Diagnosis For The Circulation Air Fan

    DEFECT DIAGNOSIS FOR THE CIRCULATION AIR FAN 21.1 CIRCULATION AIR FAN 21.1.1 Ensure Air Circulation Fan is runnning at maximum. 21.1.2 A voltage should be measured and blue (-) and yellow (+). Voltage approx. 10 VDC. 21.1.3 If voltage is present and fan is not running at maximum. Replace ACF. Sales/Spares 01604 707012 Replacement Help Line 01604 707011...

  • Page 26: Functional Wiring Diagrams

    FUNCTIONAL WIRING DIAGRAMS FIGURE 25. WIRING DIAGRAM No. 1 WIRING ROUTING TABLE FROM UNIT WIRE COLOUR TERMINAL L/N/E TO UNIT TERMINAL FROM UNIT WIRE COLOUR TERMINAL L/N/E TO UNIT TERMINAL red (r) PCB INTERFACE brown (br) X1 - 5 PCB INTERFACE blue (bl) PCB INTERFACE blue (bl)
  • Page 27 FIGURE 26. WIRING DIAGRAM No. 2 WIRING ROUTING TABLE FROM UNIT WIRE COLOUR TERMINAL L/N/E TO UNIT TERMINAL FROM UNIT WIRE COLOUR TERMINAL L/N/E TO UNIT TERMINAL white (w) A1 - 2 ESYS X3 - 1 blue (bl) X9 - 2 PCB INTERFACE black (bk) A1 - 3...

  • Page 28: Dimensions

    DIMENSIONS mCaire FIGURE 27. WARMCAIR C10D DIMENSIONS www.johnsonandstarley.co.uk...

  • Page 29: Exploded Spare Diagrams

    EXPLODED SPARES DIAGRAMS ITEM PART No. G. C. No. DESCRIPTION C10D-0501005 CONTROL PANEL ASSEMBLY ITEM PART No. G. C. No. DESCRIPTION C10D-0140005 COMPLETE COMBUSTION FAN ASSEMBLY FLANGE CONNECTION COMBUSTION AIR FAN EXHAUST FLUE LIST OF SPARES ITEM PART No. DESCRIPTION 1000-2501505 Flue Seal 1000-0522645...
  • Page 30 ITEM PART No. G. C. No. DESCRIPTION C10D-0700005 MAIN BURNER ASSEMBLY LIST OF SPARES ITEM PART No. DESCRIPTION Burner Arm Assembly 1000-0710215 Burner Gasket A Burner Gasket B Valve/Venturi Assembly 1000-0710495 Venturi Gasket Cork Gasket Ignition Electrode 1000-0710455 Ignition Electrode Gasket Detection Electrode 1000-0710445 Detection Electrode Gasket...
  • Page 31 ITEM PART No. G. C. No. DESCRIPTION C10D-0132005 COMBUSTION AIR PASSAGE ASSEMBLY RING SEAL SEALING FRAME FLANGE SOCKET CONDENSATE BOX BACK NUT SEAL CONDENSATE CONNECTOR C10D-0190005 CONDENSATE PUMP ASSEMBLY ‘Y’ CONNECTION RESTRICTOR CONDENSATE PUMP OUTLET BACK PLATE CASING FLOAT FILTER NOTE: Back Plate is not included as part of the spare.

  • Page 32: Important Information & Ancillaries

    For further information contact Johnson & Starley Ltd on Telephone 01604 762881 These kits are readily available from Johnson & Starley Ltd Telephone the Sales Office for further information WARMCAIR C10D ANCILLARY’S Description Product Code Cleanflow Air Filter CF10 Return Air Kits...

  • Page 33: Benchmark Checklist

    BENCHMARK CHECKLIST C10D COMMISSIONING CHECKLIST & SERVICE RECORD This Log Book should be filled out at each annual service Sales/Spares 01604 707012 Replacement Help Line 01604 707011...

  • Page 35: Service Record

    Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 36 Johnson & Starley Ltd Johnson & Starley Dravo Division Industrial H&V Rhosili Road, Brackmills, Northampton NN4 7LZ Sales 01604 707022 sales@johnsonandstarley.co.uk dravo@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk www.dravo.co.uk Reception 01604 762881 Sales/Spares 01604 707012 Service/Warm air upgrade 01604 762881 Warm air upgrade 01604 707011 Anniversary 1922 - 2012 In the interest of continuous development Johnson &...

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