Johnson & Starley WARMCAIR C16D Manual
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Johnson & Starley WARMCAIR C16D Manual

High efficiency downflow condensing air heater
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WarmCair
WARMCAIR C16D
Condensing Air Heater
High Efficiency Downflow
Condensing Air Heater
INSTALLATION,
COMMISSIONING
& SERVICING INSTRUCTIONS
WarmCair C16D
These instructions are to be left with the User
Condensing Warm Air
-
G.C. No. 42-415-19
Publication No. ZZ 1408-4
FM 525200
Brackmills, Northampton
www.johnsonandstarley.co.uk
September 2021
Johnson & Starley Ltd
Rhosili Road
NN4 7LZ

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  • Page 1 WarmCair Condensing Warm Air Publication No. ZZ 1408-4 September 2021 WARMCAIR C16D Condensing Air Heater High Efficiency Downflow Condensing Air Heater INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS WarmCair C16D G.C. No. 42-415-19 These instructions are to be left with the User FM 525200 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 ZZ1408-3 Controllers. 13/05/2021 ZZ1408-3 Amendment to Return Air duct system...

  • Page 3: Table Of Contents

    CONTENTS The Benchmark Scheme 15 Handing Over Features 16 Servicing & Maintenance Servicing Schedule General Description Servicing Sequence Component Checklist Building Standards & Regulations Gaining Access for Servicing Main Burner Assembly Ignition & Flame Detection Electrode Safety & Gas Information Heat Exchanger/Combustion Chamber Combustion Air Fan General Safety Information...

  • Page 4: Features

    It is room sealed, with a stainless steel heat exchanger, using a vertical or horizontal Concentric Flue System. The Warmcair C16D 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. When installed in a timber frame building guidance should be taken from the Gas Industry Publication IGE/UP-7 (Guide for Gas Installations in Timber Frame Housing).

  • Page 8: Duct System

    DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating) RETURN AIR 8.1.1 A room-sealed heater can be installed without positive return air ducting, provided that the path between the return air grille and the heater return air inlet is protected in such a manner that the required airflow is maintained at all times (BS5864).

  • Page 9: Flue Instructions

    FLUE INSTRUCTIONS The WarmCair C16D 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 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 11: Plume Terminal Outlets

    TYPE OF FLUE SYSTEMS Two types of flue systems are available for the C16D. The standard concentric flue system 60/100mm (100mm diameter) A Flexible flue kit (FFK) 60/100mm (100mm diameter) For further information contact the sales office at Johnson & Starley Ltd. Telephone 01604 762881 FLUE TERMINAL POSITIONS 9.7.1 The following information provides the general requirements for siting flue terminals.
  • Page 12 9.10 CONVENTIONAL 60/100mm FLUE ACCESSORY PARTS No’s DESCRIPTION COLOUR APPLICATION PART No. 800mm Horizontal Terminal White Horizontal 1000-0019830 Vertical Appliance Adaptor White Vertical 1000-0018990 45° Elbow White Horizontal & Vertical 1000-0018970 90° Elbow White Horizontal & Vertical 1000-0018980 250mm Straight Extension White Horizontal &...
  • Page 13 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 10m HORIZONTAL 800mm Horizontal Terminal TERMINAL 90° Elbow EXTENSION Inside Wall Cover Plate LENGTH Outside Wall Cover Plate CLAMP 100mm Diameter Clamp (1 per flue length) VERTICAL...
  • Page 14 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 perma- nently wired to earth.
  • Page 15 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 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 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 18 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 19 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 20 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 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. 16.7 COMBUSTION AIR FAN (CAF) 16.7.1...
  • Page 22 COMBUSTION TRAY ‘Y’ CONNECTOR FLUE CONDENSE PIPE CONDENSE OUTLET FROM PIPE OUTLET COMBUSTION TRAY FROM COMBUSTION FLOAT FILTER RESERVOIR CONDENSATE FIGURE 24. CONDENSE PUMP PIPE TO OUTSIDE DRAIN CONDENSATE PUMP CONDENSING DRAIN PIPE FROM COMBUSTION TRAY FLUE CONDENSE PIPE FROM COMBUSTION FAN FIGURE 25.
  • Page 23 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 17.8 CONDENSATE PUMP 17.8.1 Refer to section 16.3. See Figure 24 & 28. 17.8.2 Disconnect the electrical connections on the electrical panel for the Condense Pump and float switch. ‘Y’ SCREW 17.8.3 Disconnect the condensate pipes from the ‘Y’ connection and from the flue outlet.
  • Page 25 17.10 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. 17.10.1 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 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 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 28 BLOCKING CODES CODE SYMPTOM POSSIBLE CAUSE ACTION Check wiring and connections for shorting to earth Duct air temperature sensor short Temperature sensor shorted to earth circuit or failed Check sensor resistance Check wiring connections Duct air temperature sensor open Temperature sensor not connected circuit or failed Check sensor continuity...
  • Page 29 FAULT FINDING FLOW CHART Sales/Spares & Replacement Help Line 01604 762881...
  • Page 30 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 DSP (MMI ) CONTROL PANEL TIMER 2 3 4 CONDENSATE PUMP GN GN COLOUR BLACK BLUE GREEN BROW N OPENTHERM PCB - INTERF ACE UNIT GNYE PCB - INTERF ACE GREEN/YELL OW AMBIENT GREY ROOM SENSOR ROOM STAT (OPTIONAL) ORANGE (OPTIONAL)
  • Page 32 COLOUR COLOUR DSP (MMI) BLACK GREY ORANGE BLUE 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 FRONT VIEW SIDE VIEW FRONT VIEW SIDE VIEW mCaire mCaire TOP VIEW BASE VIEW TOP VIEW BASE VIEW FIGURE 34. WARMCAIR C16D DIMENSIONS Sales/Spares & Replacement Help Line 01604 762881...
  • Page 34 EXPLODED SPARES DIAGRAMS EXPLODED SPARES DIAGRAMS ITEM DESCRIPTION PART No. G. C. No. CONTROL PANEL ASSEMBLY C10D-0501005 FLANGE COMBUSTION AIR FAN (CAF) ASSEMBLY CONNECTION 1000-0525215 J24-837 Includes 3 & 4 CAF GASKET SEALING RING 1000-1507865 H36-837 CAF ‘O’ RING 1000-2501675 J24-909 EXHAUST FLUE ELBOW ASSEMBLY 1000-0022195...
  • Page 35 ITEM DESCRIPTION PART No. G. C. No. AIR CIRCULATION FAN ASSEMBLY C16D-0503005 J24-887 FLYING LEADS FAN FAILURE SENSOR 1000-0517635 RETURN AIR SENSOR DUCT TEMPERATURE SENSOR 1000-05222645 J24-833 FLUE GAS SENSOR CONDENSATE COMBUSTION AIR BOX ASSEMBLY AIR BOX SEAL C16D-0139005 J24-826 Includes 21 &...
  • Page 36 ITEM DESCRIPTION PART No. G. C. No. HIGH LIMIT TEMPERATURE SENSOR 1000-0516835 ESYS CONTROL BOX 1000-0526535 J24-895 ESYS SCREW 1000-3004035 J24-855 ESYS COVER 1000-0522610 J24-856 CONDENSATE TRAP 1000-0024525 J24-749 VERTICAL FLUE ADAPTER 60/100mm 1000-0022255 J24-784 TELESCOPIC FLUE 1000-0022225 J24-811 OPEN THERM SWITCH 1000-0525305 www.johnsonandstarley.co.uk...
  • Page 37 LIST OF ANCILLARIES Description Product Code CLEANFLOW AIR FILTER CF16 FILTER REPLACEMENT PADS A0212X0212 (Pack of 6) CLEANFLOW TRANSITION KIT CTK16 RETURN AIR KIT RAK16 Includes 4 & 5 FLEXIBLE DUCTING 1000-0001390 QUICK RELEASE DUCT CLIP 1000-0013770 TS16 SLOT FIX PANELS TSG16 SLOT FIX &...
  • Page 38 Benchmark Commissioning & Guarantee Validation Service Record It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation.
  • Page 39 CONDENSING WARM AIR COMMISSIONING CHECKLIST AND GUARANTEE VALIDATION RECORD Address: Warm Air Heater make and model: Warm Air Heater serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water sytems complies with the appropriate Building Regulations? Optional: Building Regulations Notification Number (if applicable) Time, temperature control and boiler interlock provided for central heating and hot water: WATER QUALITY (DW Models)
  • 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 11 SERVICE 12 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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