Johnson & Starley WarmCair C26D Installation, Commissioning & Servicing Instructions
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Johnson & Starley WarmCair C26D Installation, Commissioning & Servicing Instructions

High efficiency downflow condensing air heater
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WarmCair
Condensing Warm Air
Publication No. ZZ 1409-5
September 2018
WARMCAIR C26D
Condensing Air Heater
High Efficiency Downflow
Condensing Air Heater
INSTALLATION,
COMMISSIONING
& SERVICING
INSTRUCTIONS
WarmCair C26D
-
G.C. No. 42-417-98
These Instructions are to be left with the User
Johnson & Starley Ltd
Rhosili Road
Brackmills, Northampton
NN4 7LZ

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  • Page 1 WarmCair Condensing Warm Air Publication No. ZZ 1409-5 September 2018 WARMCAIR C26D Condensing Air Heater High Efficiency Downflow Condensing Air Heater INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS WarmCair C26D G.C. No. 42-417-98 These Instructions are to be left with the User Johnson &...
  • Page 2 TECHNICAL UPDATES INFORMATION REGARDING UPDATES TO THIS MANUAL ARE LISTED BELOW AND SHOULD BE NOTED BEFORE COMMENCING WITH ANY INSTALLATION WORK. Date of Amendment Version No Page Description Invalidation of guarantee by the fitting on NON Open-Therm 01/02/2021 ZZ1446-3 Controllers.

  • Page 3: Table Of Contents

    CONTENTS 15. Handing Over The Benchmark Scheme 1. Features 16. Servicing & Maintenance Servicing Schedule 2. General Description Servicing Sequence Component Servicing Checklist 3. Building Standards & Regulations Gaining Access for Servicing Main Burner Assembly 4. Safety & Gas Information Ignition &...

  • Page 4: Features

    It is room sealed, with a stainless steel heat exchanger, using a vertical or horizontal Concentric Flue System. The WarmCair C26D air heater is ideally suited for new built dwellings and the replacement of existing non- condensing air heaters.

  • Page 5: Building Standards & Regulations

    BUILDING STANDARDS & REGULATIONS STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY COMPETENT PERSONS, i.e. GAS SAFE REGISTERED INSTALLERS. GAS SAFE MEMBERSHIP ENQUIRIES TEL: 0800 408 5500 IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.

  • Page 6: Safety & Gas Information

    SAFETY & GAS INFORMATION PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING WITH THE INSTALLATION GENERAL SAFETY INFORMATION 4.1.1 Ensure the mains supply voltage, frequency, number of phases and power rating comply with details on the rating label. 4.1.2 All wiring must be in accordance with the appropriate standards. The equipment must be supplied with a double pole isolator switch.

  • Page 7: Heater Positioning

    HEATER POSITIONING This heater is not suitable for external installation unless it is protected from the elements by a suitable enclosure. The enclosure must provide the clearance for installation, servicing and maintenance as well as the correct level of ventilation. The selected position should allow for a suitable flue system to be installed.

  • Page 8: Duct System

    DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating) RETURN AIR 8.1.1 Room-sealed appliances may be installed without return air ducting, provided that the path between the return air grille and the appliance return air inlet is protected in such a manner that the required air-flow will be maintained at all times.

  • Page 9: Flue Instructions

    FLUE INSTRUCTIONS The WarmCair C26D Condensing Air Heater is certified as a warm air heater with corresponding flue systems according to EU Directive 2009 / 142 / EC on gas-fired devices. These installation instructions are covered by this certification and are referred to in the design approval test certificate.
  • Page 10 FIGURE 5. TERMINAL POSITIONS TERMINAL POSITION MINIMUM DISTANCE Directly below an opening, air brick, opening window, etc. 300 mm Above an opening, air brick, opening window, etc. 300 mm Horizontally to an opening, air brick, opening window, etc. 300 mm Below gutters, soil pipes or drain pipes.

  • Page 11: Flue Terminal Positions

    9.9.1 Extended horizontal and vertical concentric flues (60/100 mm diameter) with balanced terminals may be installed on the WarmCair C26D 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°...
  • Page 12 9.10 CONVENTIONAL 60 / 100mm FLUE ACCESSORY PARTS No’s DESCRIPTION COLOUR APPLICATION PART No. 800 mm Horizontal Terminal White Horizontal 1000-0019830 45° Elbow White Horizontal & Vertical 1000-0018970 90° Elbow White Horizontal & Vertical 1000-0018980 500 mm Straight Extension White Horizontal &...

  • Page 13: Optional Roof Outlets

    9.11 EXTENDED HORIZONTAL FLUE SYSTEM CLAMP Extended horizontal flue set up comprises of: 90° ELBOW The required flue lengths up to a length of 10 m HORIZONTAL 800 mm Horizontal Terminal TERMINAL 90° Elbow EXTENSION Inside Wall Cover Plate LENGTH Outside Wall Cover Plate CLAMP 100 mm Diameter Clamp (1 per flue length)

  • Page 14: Condensate Pump & Drain Tube

    CONDENSATE PUMP & DRAIN TUBE 10.1 CONDENSATE PUMP 10.1.1 Supplied with 6 mm x 10 m 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...

  • Page 15: Gas

    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 16: 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 17: Lighting Main Burner

    NOTE: If the system includes ceiling diffusers, the air through these should be NOT LESS THAN 1.5 m/s (300 ft / 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...

  • Page 18: Handing Over

    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 ZZ 1340 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 19: 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.

  • Page 20: Gaining Access For Servicing

    16.3 GAINING ACCESS FOR SERVICING 16.3.1 Ensure the electrical & gas supply is isolated as needed. 16.3.2 Remove the return air filter and pull the bottom front panel off. 16.3.3 Remove the front panel by unscrewing the 4 retaining screws at top and bottom. 16.3.4 Remove the front cover.

  • Page 21: Heat Exchanger/Combustion Chamber

    16.6 HEAT EXCHANGER/COMBUSTION CHAMBER 16.6.1 Refer to section 16.3 and 16.4. See Figure 29. 16.6.2 Once the burner assembly has been removed inspect the inside of the combustion chamber for debris. If the inner insulation is damaged, do NOT try to clean. Replace the heat exchanger.

  • Page 22: 16.9 Condensate Drain Pipes

    COMBUSTION TRAY ‘Y’ CONNECTOR CONDENSE PIPE FLUE OUTLET FROM CONDENSE COMBUSTION PIPE OUTLET TRAY FROM COMBUSTION FLOAT FILTER RESERVOIR CONDENSATE FIGURE 24. CONDENSE PUMP PIPE TO OUTSIDE DRAIN CONDENSATE PUMP CONDENSING DRAIN PIPE FROM FLUE CONDENSE PIPE COMBUSTION TRAY FROM COMBUSTION FAN FIGURE 25.

  • Page 23: Replacement Plant

    REPLACEMENT PARTS 17.1 IMPORTANT: Before commencing with any part replacement, the appliance should be isolated from the electrical supply and the gas service cock on the appliance closed. 17.1.1 All parts removed should be replaced and refitted in reverse order, ensuring correct seals are made and wires are connected correctly.

  • Page 24: Condensate Drain Pump

    17.9 CONDENSATE DRAIN PUMP “Y” SCREW 17.9.1 Refer to section 16.3. See Figures 24 & 28. 17.9.2 Disconnect the electrical connections on the electrical panel for the Condense Pump and float switch. MAIN SUPPLY 17.9.3 Disconnect the condensate pipes from the “Y” connection and from the flue outlet.

  • Page 25: Gas Valve & Venturi Assembly

    17.11 GAS VALVE & VENTURI ASSEMBLY NOTE: The gas valve is factory preset and must not be adjusted. A replacement valve can only be supplied by Johnson & Starley Ltd. 17.11.1 Remove the 2 fixing screws securing the Venturi (and gas valve) to the burner and remove the assembly from the burner, carefully removing the gasket.

  • Page 26: Control Panel Modes

    CONTROL PANEL MODES FIGURE 31. 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 27: 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.
  • Page 28 BLOCKING CODES CODE SYMPTOM POSSIBLE CAUSE ACTION Check wiring and connections for shorting to earth Duct air temperature sensor Temperature sensor shorted to short circuit earth or failed Check sensor resistance Check wiring connections Duct air temperature sensor Temperature sensor not open circuit connected or failed Check sensor continuity...

  • Page 29: Fault Finding Flowcharts

    FAULT FINDING FLOW CHART Sales/Spares & Replacement Help Line 01604 762881...

  • Page 30: 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 running 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. www.johnsonandstarley.co.uk...

  • Page 31: Functional Wiring Diagrams

    FUNCTIONAL WIRING DIAGRAMS FIGURE 32. 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 brown PCB INTERFACE X1 - 5 PCB INTERFACE blue blue PCB INTERFACE X1 - 10 PCB INTERFACE...
  • Page 32 COLOUR COLOUR DSP (MMI) GREY BLACK BLUE ORANGE GREEN YELLOW 1 2 3 4 BROWN VIOLET WHITE GNYE GREEN/YELLOW GNYE PCB - INTERFACE ESYS FLUE COMBUSTION PROTECTION AIR FAN SENSOR BULK HEAD DUCT AIR SENSOR CIRCULATION GNYE GNYE BULK HEAD LIMIT SWITCH GNYE GNYE...

  • Page 33: Dimensions

    DIMENSIONS FRONT VIEW SIDE VIEW mCaire TOP VIEW BASE VIEW FIGURE 34. C26D DIMENSIONS Sales/Spares & Replacement Help Line 01604 762881...

  • Page 34: Exploded Spares Diagrams

    EXPLODED SPARES DIAGRAMS EXPLODED SPARES DIAGRAMS ITEM DESCRIPTION PART No. G. C. No. CONTROL PANEL ASSEMBLY C10D-0501005 FLANGE COMBUSTION AIR FAN (CAF) CONNECTION ASSEMBLY J24-837 1000-0525215 Includes 3 & 4 CAF GASKET SEALING RING H36-837 1000-1507865 CAF ‘O’ RING J24-909 1000-2501675 EXHAUST FLUE ELBOW AS- SEMBLY...
  • Page 35 ITEM DESCRIPTION PART No. G. C. No. AIR CIRCULATION FAN AS- J24-886 C26D-0503005 SEMBLY FLYING LEADS FAN FAILURE SENSOR 1000-0517635 RETURN AIR SENSOR DUCT TEMPERATURE SEN- J24-833 1000-0522645 FLUE GAS SENSOR CONDENSATE COMBUSTION AIR BOX AS- AIR BOX SEAL SEMBLY J24-826 C26D-0132005 Includes 21 &...
  • Page 36 ITEM DESCRIPTION PART No. G. C. No. HIGH LIMIT TEMPERATURE 1000-0516835 SENSOR ESYS CONTROL BOX J24-857 1000-0525645 ESYS SCREW J24-855 1000-3004035 ESYS COVER J24-856 1000-0522610 CONDENSATE TRAP J24-749 1000-0024525 VERTICAL FLUE ADAPTER J24-784 1000-0022255 60/100mm TELESCOPIC FLUE J24-811 1000-0022225 OPEN THERM SWITCH 1000-0525305 www.johnsonandstarley.co.uk...

  • Page 37: List Of Ancillaries

    LIST OF ANCILLARIES Description Product Code CLEANFLOW AIR FILTER CF26 FILTER REPLACEMENT PADS A0212X0212 (Pack of 6) CLEANFLOW TRANSITION KIT CTK26 RETURN AIR KIT RAK26 Includes 4 & 5 FLEXIBLE DUCTING 1000-0001390 QUICK RELEASE DUCT CLIP 1000-0013770 WBX26 BASE DUCT Sales/Spares &...

  • Page 38: Code Of Practice

    Code Of Practice For the installation, commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on Standards of Work both manufacturers and installers.* • Be competent and qualified to undertake the work required. The purpose is to ensure that •...

  • Page 39: Benchmark Checklist And Service Record

    CONDENSING WARM AIR HEATING AND WATER HEATING COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the wsnn air unit and associated equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to Install and commission this equipment to the manufacturer's instructions may Invalidate the warranty but does not affect statutory rights.
  • Page 40 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 Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. SERVICE 01 SERVICE 02 Date:...
  • Page 41 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 Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. SERVICE 01 SERVICE 02 Date:...
  • Page 42 NOTES:...
  • Page 43 NOTES:...
  • Page 44 Johnson & Starley Ltd Rhosili Road, Brackmills, Northampton NN4 7LZ sales@johnsonandstarley.co.uk customer.service@johnsonandstarley.co.uk service@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881...

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