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WARMCAIR DW
Condensing Air & Water Heaters
Condensing Air & Water Heaters
Condensing Air & Water Heaters
High Effi ciency Downfl ow
Condensing Air & Water Heater
C10DW, C16DW, C20DW, C25DW
INSTALLATION,
COMMISSIONING
& SERVICING
INSTRUCTIONS
WarmCair C10DW Series II
WarmCair C16DW Series II
WarmCair C20DW Series II
WarmCair C25DW Series II
These instructions are to be left with the User
For Installation in Mainland UK only.
Series
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G.C. No.
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G.C. No.
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G.C. No.
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G.C. No.
www.johnsonandstarley.co.uk
Johnson & Starley Ltd
Phone: 01604 762881
email: info@johnsonandstarley.co.uk
Publication No. ZZ 1670
FM 525200
Rhosili Road
Brackmills
Northampton
NN4 7LZ
March 2025
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Summary of Contents for Johnson & Starley WARMCAIR DW II Series
- Page 1 Johnson & Starley Ltd Rhosili Road Brackmills Northampton NN4 7LZ Phone: 01604 762881 email: info@johnsonandstarley.co.uk Publication No. ZZ 1670 March 2025 WARMCAIR DW Series Condensing Air & Water Heaters Condensing Air & Water Heaters Condensing Air & Water Heaters High Effi ciency Downfl ow Condensing Air &...
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Page 2: Technical Updates
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 PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. LEAVE THESE INSTRUCTION WITH THE USER OR AT THE GAS METER AFTER INSTALLATION The Benchmark Scheme The Benchmark Scheme... -
Page 3: Table Of Contents
CONTENTS Servicing & Maintenance Features Servicing Schedule General Description Initial Inspection Servicing Sequence Building Standards & Regulations Flue Inspection & Checks Safety, Electrical, Gas & Water Air Filter Removal Information Upper Panel Removal General Safety Information Control Panel Power Flushing Combustion Air Fan Magnetic &... -
Page 4: Features
1. FEATURES Appliance Classifi cation: The WarmCair Series II DW range has been tested and UKCA certifi ed by BSI for use with Natural gas G20. Features 1. Aquair PCB 2. 240V Wiring Centre 3. Low Voltage Wiring Centre 4. Circulation Pump 5. -
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, Electrical, Gas & Water
SAFETY, ELECTRICAL, GAS & WATER INFORMATION PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING WITH THE INSTALLATION GENERAL SAFETY INFORMATION 4.1.1 Only use WarmCair original spare parts on this appliance. Failure to do so will invalidate the guarantee. 4.1.2 The manufacturer’s instructions supplied must not be taken as overriding any statutory requirements. -
Page 7: Gas Supply
GAS SUPPLY 4.6.1 It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS 6891. Whilst the principle of the 1:1 gas valve ensures the WarmCair series II, Combined DHW range is able to deliver its full output at inlet pressures as low as 14mb, however other gas appliances in the property may not be as tolerant. -
Page 8: Technical Data Table
TECHNICAL DATA TABLE 1. C10DW C16DW C20DW C25DW Maximum weight lift 71kg 81kg 90kg 115kg Gas supply mbar Gas connection Heating flow and return Flue terminal diameter Condense drain 21.5 21.5 21.5 21.5 230V 230V 230V 230V Electrical supply V ~ Hz - 50hz - 50hz - 50hz... -
Page 9: 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 10: 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. -
Page 11: Heating System
HEATING SYSTEM WARM DELIVERED AIR SYSTEM 9.1.1 All duct work, including riser ducts, should be fully insulated with 50 mm (2”) fibre-glass or similar. If short extended duct runs are taken below floor level, these should be similarly insulated and, in addition, wrapped with a sound vapour proof barrier. - Page 12 NOTE: The WarmCair Combined DHW units MUST be fitted onto a sealed primary. The pressure vessel and PVR must be fitted in the circuit before any auxiliary diverter valves. 2 Port Valve Hot Water Automatic Bypass Valve Expansion Vessel Automatic Air Vent Filling Loop Domestic Cold Water Supply...
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Page 13: Flue Instructions
FLUE INSTRUCTIONS 10.1 The WarmCair DW series II, Condensing Air Heater are certifi ed as a warm air heater with corresponding fl ue systems according to EU Directive 2009/142/EC on gas- fi red devices. These installation instructions are covered by this certifi cation and are referred to in the design approval test certifi cate. - Page 14 D, E FIGURE 5. TERMINAL POSITIONS TABLE 3 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.
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Page 15: Flue Requirements & General Information
10.7 FLUE REQUIREMENTS & GENERAL INFORMATION 10.7.1 Horizontal and vertical concentric fl ues (60/100 mm diameter) with balanced terminals may be installed on all the WarmCair DW series II appliance. 10.7.2 If an extended horizontal fl ue is being used it must have a continuous fall back towards the appliance of 3°... -
Page 16: Conventional 60/100 Flue Accessories
10.9 CONVENTIONAL 60/100 mm FLUE ACCESSORIES PARTS No.s Description Colour Application Part No Ridge Terminal Grey Vertical 1000-0021030 Roof terminals Roof terminals Extension 60-100 1000-0026310 x L500mm Extension 60-100 1000-0026320 x L1000mm Horizontal/ White Vertical Extension 60-100 1000-0026330 x L2000mm Extension pipes 250, 500, 1000 and 2000 mm... -
Page 17: Flue Assembly Instructions
10.10 FLUE ASSEMBLY INSTRUCTIONS 45º 90º ZZ1670 WarmCair DW Series II Installation and Maintenance Manual... - Page 18 FLUE ASSEMBLY INSTRUCTIONS 1. Attaching the flue to the heater 2. Attaching bends to lengths 3. Attaching a flue length to another www.johnsonandstarley.co.uk...
- Page 19 FLUE ASSEMBLY INSTRUCTIONS 4. Attaching a flue length to another ZZ1670 WarmCair DW Series II Installation and Maintenance Manual...
- Page 20 FLUE ASSEMBLY & DISASSEMBLY INSTRUCTIONS 5. Flue assembly information X ≥ 0 mm X ≥ 0 mm X ≥ 0 mm 90° 90° 90° PP = 0 mm PP = 0 mm PP = 0 mm 40 mm 40 mm 40 mm 3°...
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Page 21: External Condensate Pump & Drain Tube Condensate Pump
EXTERNAL CONDENSATE PUMP & DRAIN TUBE 11.1 CONDENSATE PUMP 11.1.1 An external condensate pump and drain tube must be fi tted to the heater. Fit per condensate pump manufacturer’s installation instructions. ELECTRICAL 12.1 The appliance is supplied with PVC sheathed, 3 core (Brown-Blue-Green/Yellow) 0.75 mm CSA rated at 6 A, connected to a terminal block and exiting through the casing at the top left hand front. -
Page 22: Operating Modes
OPERATING MODES 14.1 Operating modes are covered in the User Instructions, ZZ1671 packed with the appliance, for both Domestic Hot Water and Central Heating. 14.2 Additional radiators can be added to the system, with or without separate external zone valves (not supplied). Additional controls may be required to achieve independent operation of separated heating zones. -
Page 23: Commissioning
17. COMMISSIONING 17.1 CHECK GAS INSTALLATION 17.1.1 The whole of the gas installation, including the meter, should be inspected and tested for tightness and purged in accordance with the recommendations of BS 6891. 17.1.2 Purge air from the gas installation by the approved methods only. NOTE: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type defi ned on the appliance data plate. -
Page 24: Initial Lighting
INITIAL LIGHTING 8.1.1 Check that the system has been filled and the heat exchangers are not air- locked. NOTE: It is important the burner is not operated before the system is fully vented of air. IMPORTANT: The gas input to the burner is regulated by the gas valve according to the air flow produced by the combustion air fan. -
Page 25: Combustion Analysis
18.6 COMBUSTION ANALYSIS Sweep test (combustion test mode for minimum and maximum combustion rates). 18.6.1 Press & hold all 3 buttons on the control panel for 10-15 seconds to access the installer mode. 18.6.2 Press and hold + & - button on control panel to access sweep test mode. 18.6.3 “LP”... -
Page 26: Handing Over
20. HANDING OVER 20.1 Hand the User Instructions to the householder and explain his/her responsibilities under the relevant national regulations. 20.2. Explain and demonstrate the lighting and shutting down procedures. 20.3 The operation of the heater and the use and adjustment of all system controls should be fully explained to the householder, to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption. -
Page 27: Servicing And Maintenance
SERVICING & MAINTENANCE 21.1 SERVICING SCHEDULE NOTE: It is a statutory requirement that ALL work is carried out by a DAH1 (Warm Air Heating) GAS SAFE registered engineer. 21.1.1 For the very latest copy of literature for servicing & maintenance instructions, visit our website www.johnsonandstarley.co.uk - where the information can be downloaded. -
Page 28: Flue Inspection & Checks
21.4 FLUE INSPECTION & CHECKS During routine servicing, and after any maintenance or change of part of the NOTE: combustion circuit, the following must be checked: • The integrity of the flue system and the flue seals, • The integrity of the boiler combustion circuit and the relevant seals •... -
Page 29: Burner Assembly
21.9 BURNER ASSEMBLY Refer to sections 21.5, 21.6 and 21.7 21.9.1 Remove all electrical leads from the heat exchanger (ignition lead, flame sensor, earth wire and combustion gas temperature sensor). 21.9.2 Remove 4 screws to detach combustion fan from burner heat exchanger arm. -
Page 30: Parts Replacement
22. PARTS REPLACEMENT 22.1 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. 22.1.1 All parts that are removed should be replaced and refitted in reverse order, ensuring correct seals are made and wires are connected correctly. -
Page 31: Gas Valve
22.7 GAS VALVE Refer to sections 21.5 & 21.6. 22.7.1 Unplug the electrical lead. 22.7.2 Undo the union nut on the outlet of the gas control valve, rotate out of the way. 22.7.3 Undo the gas inlet pipe union at the inlet to the gas control valve. 22.7.4 Fit the new gas valve ensuring the two sealing washers are in place and reconnect gas and electrical connections. -
Page 32: Draining The Appliance
PART REPLACEMENTS BY DRAINING THE SYSTEM 22.13 DRAINING THE APPLIANCE 22.13.1 To drain the appliance, attach a length of hose to the drain point then open the drain valve. 22.13.2 Replace the necessary component. 22.13.3 After replacement close the drain valve and open all isolation valves and refill the system. -
Page 33: Hot Water Fault Finding Blocking Codes
23. HOT WATER FAULT FINDING- BLOCKING CODES Should a fault arise, the display will alternate between “ER” and the fault code number. Any faults marked with N/A in the Corrective Action column should not be present on the appliance and indicate incorrect programming of the PCB - contact Johnson &... - Page 34 DC VOLTAGE DC VOLTAGE DC VOLTAGE DC VOLTAGE APPROX. PIPE APPROX. PIPE APPROX. PIPE APPROX. PIPE ACROSS PIPE ACROSS PIPE ACROSS PIPE ACROSS PIPE TEMP. °C TEMP. °C TEMP. °C TEMP. °C SENSOR SENSOR SENSOR SENSOR 3.24 2.13 1.26 0.73 3.19 2.08 1.23...
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Page 35: Fault Finding Flowcharts & Blocking Codes
24. FAULT FINDING FLOWCHARTS & BLOCKING CODES Should a fault occur, the boiler will shut down and these error codes will be displayed. IGNITION LOCKOUT Does the burner light for a few seconds Check gas supply is turned on and has then extinguish correct inlet pressure RESET... -
Page 36: Flue Sensor
FAULT FINDING. COMBUSTION FAN FAULT Does the wiring from the fan to the PCB have secure connections at both Rectify wiring & connections ends and has not deteriorated? Does the wiring have continuity? Is there 230V at the Blue Brown Replace the PCB. -
Page 37: Failure To Light
FAULT FINDING. FAILURE TO LIGHT Turn on all external controls and turn up MAF stat to full, ensure display is turned on and temperature turned up to 80ºC and no fault codes are present Are the 2 port valves open Replace programmer Check condensate pump high limit. - Page 38 AIR CIRULATION FAN NOT OPERATING Refer to ‘Unit Not Working In Heating Mode’ Turn the set point of the heater above 70ºC. Rated output is achieved at 80ºC Measure DC voltage across pipe sensor on bottm heat exchanger. Refer to Table A below.
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Page 39: Warmcair Dw Series Ii Wiring Diagrams
WARMCAIR DW SERIES II WIRING DIAGRAMS FIGURE 10. WARMCAIR DW SERIES II INTERNAL WIRING DIAGRAM ZZ1670 WarmCair DW Series II Installation and Maintenance Manual... - Page 40 FIGURE 11. WARMCAIR DW SERIES II EXTERNAL WIRING DIAGRAM www.johnsonandstarley.co.uk...
- Page 41 DIMENSIONS C10DW 35 17 FIGURE 47. WARMCAIR C10DW COMBINED DIMENSIONS ZZ1670 WarmCair DW Series II Installation and Maintenance Manual...
- Page 42 DIMENSIONS C16DW 35 17 www.johnsonandstarley.co.uk...
- Page 43 DIMENSIONS C20DW 35 17 ZZ1670 WarmCair DW Series II Installation and Maintenance Manual...
- Page 44 DIMENSIONS C25DW 35 17 www.johnsonandstarley.co.uk...
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Page 45: List Of Spares
LIST OF SPARES ITEM DESCRIPTION PART No. G. C. No. Replacement Kit - Pump CDW II 1000-0303055 Replacement Kit - Gas Valve CDWII 1000-0700755 Combustion Fan Kit CDW II 1000-0527895 Venturi 25kW Sigma 1000-0700765 Kit: Temperature Sensor 1000-0526515 Temperature Sensor Clip On 15mm 1000-0526500 Valve: Bypass 22mm Diff 1000-0303080... - Page 46 ITEM DESCRIPTION PART No. G. C. No. Heat Exchanger MHYTECH 28-32KW 1000-0302090 PCB: WarmCair Series II 1000-0527900 PCB: Assembly: Aquair 1000-0526270 Harness- Spark Lead 1000-0534190 Ionisation Lead 1000-0522690 PCB: Display WarmCair Series II 1000-0528005 Heat Exchanger Assembly AQ10-0138000 Heat Exchanger Assembly AQ16-0138000 Heat Exchanger Assembly AQ20-138000...
- Page 47 ITEM DESCRIPTION PART No. G. C. No. Fan Assembly AQ16-012600 Fan & Flange Assembly AQ20-0126005 Fan Assembly (Nicotra) AQ36-0504000 ZZ1670 WarmCair DW Series II Installation and Maintenance Manual...
- Page 48 LIST OF ANCILLARIES WARMCAIR C1 DW ANCILLARY’S Description C10DW C16DW C20DW C25DW Cleanflow CF10DW CF16DW CF20DW Return Air Kit Base Duct WBX10W WBX16W WBX20W WBX25W Slot Fix Kit TS10W TS16W Slot Fix & Grille Kit TSG10W TSG16DW Top Closure Kit (4 Sided) TC10W TC16W Rear Riser Duct Kit...
- Page 49 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 50 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 51 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 52 WARM AIR HEATING FOR THE FUTURE Johnson & Starley Ltd Rhosili Road, Brackmills, Sustainable Heating Northampton NN4 7LZ sales@johnsonandstarley.co.uk customer.support@johnsonandstarley.co.uk service@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881 sustainable heating solutions In the interest of continuous development Johnson and Starley reserves the right to change specification and or guarantee without prior notice.
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