Johnson & Starley WARMCAIR C16D Manual Download Page 1

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WarmCair

Condensing Warm Air

Johnson & Starley Ltd

Rhosili Road

Brackmills, Northampton

NN4 7LZ

FM 525200

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

Summary of Contents for WARMCAIR C16D

Page 1: ...rackmills Northampton NN4 7LZ FM 525200 Publication No ZZ 1408 4 September 2021 WARMCAIR C16D Condensing Air Heater High Efficiency Downflow Condensing Air Heater INSTALLATION COMMISSIONING SERVICING...

Page 2: ...ED BELOW AND SHOULD BE NOTED BEFORE COMMENCING WITH ANY INSTALLATION WORK Date of Amendment Version No Page Description 01 02 2021 ZZ1408 3 15 Invalidation of guarantee by the fitting on NON Open Ther...

Page 3: ...ge and promote the Scheme Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Visit www cen...

Page 4: ...ir Filter 2 BRIEF DESCRIPTION 2 1 The WarmCair C16D is a highly efficient condensing gas fired downflow forced convection air heater Significant reductions in Low Carbon and NOx emissions are achieved...

Page 5: ...ngineers I E E Wiring Regulations British System Design Manual Gas Fired Warm Air Heating EN Regulations No 1196 Supplementary Instructions Condensing Air Heaters 3 2 BUILDING STANDARDS AND REGULATION...

Page 6: ...ategories a The appliance is certified as a CAT I 2H 20 appliance 4 2 2 Gas Supply a The gas installation must be completed in accordance with the relevant standards BS 6891 b The supply must be capab...

Page 7: ...om the compartment walls of 3mm 1 8 at the sides rear and front must be left Where clearances are less than 75mm internal surface must be lined with non combustible material and the compartment must b...

Page 8: ...0088 m2 kW 1 in 250 Btu h of heat supplied to the room The only exceptions are kitchens bathrooms and WCs 8 1 5 The return air duct should allow for ease of removal for access to the flue 8 1 6 All d...

Page 9: ...RELEVANT STANDARDS SHOULD BE FOLLOWED BS 5440 1 Flues and ventilation for gas appliances of rated heating input not exceeding 70kW net Flues BS 5440 2 Flues and ventilation for gas appliances of rate...

Page 10: ...ipes 75mm E Below eaves 200mm F Below balconies 200mm G From a vertical drain pipe or soil pipe 150mm H From an internal or external corner Greater than 450mm protrusion 300mm I Above ground roof or b...

Page 11: ...OUTLETS 9 8 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 6 NOTE...

Page 12: ...Vertical 1000 0020730 15 1000mm Extension Flue 60mm Black 1 Horizontal Vertical 1000 0020740 16 90 Elbow 60mm Black 1 Horizontal Vertical 1000 0020680 17 45 Elbow 60mm Black 2 Horizontal Vertical 1000...

Page 13: ...F OPTION A Pitched Roof Collar can be fitted on a pitched roof with an angle of between 20 to 50 pitch 9 14 RIDGE TERMINAL OPTION The Ridge Terminal replaces a single 450mm ridge tile and connects to...

Page 14: ...onnected directly to the soil stack or waste pipe there must always be either a waste trap after the tubing connections or a 75mm U trap formed within the tubing 10 1 6 Where the tubing from the pump...

Page 15: ...ntact separation of at least 3mm in ALL poles The fuse fitted must be rated 5A to BS 1362 Connections must also be in accordance with the current edition of I E E Regulations BS 7671 NOTE If for any r...

Page 16: ...sing ducting tape not supplied Ensure a good seal is made 13 1 3 Installation of the condense tube is a maximum of 10 meters There should be no trapped kinks in this length of tube 13 1 4 Fix all conn...

Page 17: ...steady 14 3 9 If the main burner fails to ignite you have 4 more attempts at ignition 14 3 10 In the event of a lockout 1 and the ignition and main burners failing to ignite reference should be made...

Page 18: ...a fault is indicated they should note the fault code turn off the appliance and contact a competent person which in normal circumstances would be a GAS SAFE registered engineer 15 7 Explain and demon...

Page 19: ...VICING 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...

Page 20: ...16 4 8 Inspect and clean the spark ignition and flame sensing electrode removing any debris and oxidization Check the spark gap and position of the spark electrode and the positioning of the flame sen...

Page 21: ...assembly 45 clockwise and withdraw complete assembly 16 7 6 Carefully inspect both the impellor NOTE Pre 2016 models inspect the mesh in the collection box for debris If the mesh is full replace with...

Page 22: ...ipe to the flue outlet 16 9 7 Refit in reverse order 16 10 CONDENSATE PUMP 16 10 1 Refer to section 16 3 See Figure 25 16 10 2 Disconnect the electrical connections on the electrical panel for Condens...

Page 23: ...sembly and re fit in reverser order 17 4 FAN FAILURE TEMPERATURE SENSOR 17 4 1 Refer to section 16 3 17 4 2 Remover the Air Circulation Fan Refer to 16 7 17 4 3 Unplug the 2 wires from the temperature...

Page 24: ...o fill the condensate drain pipe and check for leaks Re connected the pipe to the flue outlet IMPORTANT The condensing tube from the combustion tray MUST be routed so the tube forms a S shape making a...

Page 25: ...y a notch and the viewing window is in correct position 17 11 8 Re fit in reverse order 17 12 IGNITION ELECTRODES 17 12 1 Refer to section 16 3 See Figure 29 17 12 2 Unplug the lead from the ESYS red...

Page 26: ...n speed value is will display this value can be changed by pressing the A and B buttons accordingly Once the required value is reached the values can be saved as minimum by pressing button D maximum b...

Page 27: ...sensor and wiring to control board Check operation of gas valve 2 False flame lockout False flame detected Check wiring on ESYS 3 Condense pump failure Power to the pump Check for any blockages restr...

Page 28: ...Temperature sensor shorted to Check wiring connections not shorting to earth Check sensor resistance 44 Return air temperature sensor open circuit Temperature sensor not connected or failed Check wir...

Page 29: ...29 Sales Spares Replacement Help Line 01604 762881 20 FAULT FINDING FLOW CHART...

Page 30: ...HE 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...

Page 31: ...own B2 L PCB INTERFACE 17 5 4 3 2 1 M n CONTROL PANEL TIMER BURNER ARM X1 1 2 4 5 X5 X4 X2 X3 3 6 1 2 3 4 5 1 2 3 4 1 3 DSP MMI 1 3 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 1 2 3 1 4 2 5...

Page 32: ...een F2 ESYS X3 14 purple D2 ESYS 15 BULKHEAD DUCT AIR SENSOR orange C1 ESYS X3 8 orange C2 ESYS X3 16 X1 1 2 4 5 X5 X4 X2 X3 3 6 1 2 3 4 5 1 2 3 4 1 3 DSP MMI 1 3 ESYS 10 5 1 16 8 3 6 1 15 9 9 8 7 6 4...

Page 33: ...16D DIMENSIONS 400 1200 665 150 129 1340 344 381 72 80 185 104 57 113 272 15 98 522 25 mCaire C16 War D FRONT VIEW SIDE VIEW TOP VIEW FRONT BASE VIEW 400 1200 665 150 129 1340 344 381 72 80 185 104 57...

Page 34: ...J24 833 7 FLUE GAS SENSOR 1 1000 0522645 J24 836 8 GAS VALVE VENTURI Includes 9 10 1 1000 0710495 J24 773 9 VENTURI GASKET 1 1000 1508285 J24 771 10 CORK GASKET 2 1000 2501175 H38 674 11 BURNER ARM AS...

Page 35: ...22645 J24 833 19 COMBUSTION AIR BOX ASSEMBLY Includes 21 22 1 C16D 0139005 J24 826 21 SEALING RING 1 1000 2501685 J24 825 22 CONNECTOR SEAL 1 1000 2501715 23 CONDENSATE PUMP 1 C10D 0190005 J24 893 24...

Page 36: ...0516835 29 ESYS CONTROL BOX 1 1000 0526535 J24 895 30 ESYS SCREW 1 1000 3004035 J24 855 31 ESYS COVER 1 1000 0522610 J24 856 33 CONDENSATE TRAP 1 1000 0024525 J24 749 34 VERTICAL FLUE ADAPTER 60 100mm...

Page 37: ...ENT PADS Pack of 6 A0212X0212 3 CLEANFLOW TRANSITION KIT CTK16 4 RETURN AIR KIT Includes 4 5 RAK16 5 FLEXIBLE DUCTING 1000 0001390 6 QUICK RELEASE DUCT CLIP 1000 0013770 7 SLOT FIX PANELS TS16 8 SLOT...

Page 38: ...t is ultimately their responsibility to register with the manufacturer within the allotted time period It is essential that the boiler is serviced in line with the manufacturers recommendations at lea...

Page 39: ...ed Yes DOMESTIC HOT WATER MODE Measure and record DW Models Gas rate m hr or ft hr Dynamic gas inlet pressure at maximum rate mbar Cold water inlet temperature C Hot water has been checked at all outl...

Page 40: ...Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Gas...

Page 41: ...Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 16 Date Engineer name Company name Telephone No Gas...

Page 42: ...NOTES...

Page 43: ...NOTES...

Page 44: ...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...

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