Johnson & Starley Warmcair C10D, WARMCAIR C36D, Warmcair C46D, 42-415-21 Installation, Commissioning & Servicing Instructions
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INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
WARMCAIR C10D
Condensing Air Heater
High Efciency Downow
Condensing Air Heater
Warmcair C10D - G.C. No. 42-416-99
These instructions are to be left with the User
Publication No. ZZ 1339
April 2013
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CONTENTS
The Benchmark Scheme 2
1 Features 3
2 General Description 3
3 Building Standards & Regulations 4
4 Safety & Gas Information 4
5 Technical Data 5
6 Heater Positioning 5
7 Heater Compartment Clearances 5
8 Duct System 6
9 Flue Instructions 7
10 Condensate Pump & Drain Tube 11
11 Gas 12
12 Electrical 12
13 Fitting Instructions 13
14 Commissioning 13
15 Handling Over 15
16 Servicing & Maintenance 15
17 Replacement Parts 19
18 Control Panel Modes 22
19 Fault Code Table 23
20 Faut Finding Flow Chart 22
21 Defect Diagnosis for the Circulation Air Fan 25
22 Functional Wiring Diagrams 26
23 Dimensions 28
24 Exploded Spare Diagrams 29
25 Important Information & Ancillaries 32
26 Benchmark Checklist 33
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
STARTING INSTALLATION. LEAVE THESE INSTRUCTION WITH
THE USER OR AT THE GAS METER AFTER INSTALLATION
The Benchmark Scheme
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the
manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the
customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
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.
In the interest of continuous development Johnson and Starley reserve the right to change specification without prior notice.
Johnson and Starley prides itself on it’s ability to supply spare parts quickly and efficiently.
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
3
1. FEATURES
Appliance Classification:
The Warmcair C10D has been tested
and CE certified by B.S.I Ltd for use
with NATURAL gas G20.
FEATURES
1. Flue Adapter
2. Combustion Measuring Point
3. Time Control
4. PCB Control Wiring Panel
5. Sliding Flue Connector
6. Flue Collector Box
7. Flue Sensor
8. Condense Outlet
9. Inspection Glass
10. Condense Trap Assembly
11. Condensing Pump Outlet Pipe Hose
12. Condense Pump
13. Duct Temperature Sensor
14. Condense Pump Filter
15. Gas Cock
16. ESYS
17. Gas Valve
18. Ignition & Detection Electrode Leads
19. High Limit Temperature Sensor
20 Combustion Air fan Assembly
21. Return Air Sensor
22. Fan Failure Sensor
23. Air Circulation Fan
24. MMI Control Panel
25. Return Air Filter
2. GENERAL DESCRIPTION
2.1 The Warmcair C10D is a highly efficient condensing gas fired downflow forced convection air heater.
Significant reductions in Low Carbon and NOx emissions are achieved.
It has been designed to provide the user with on demand Warm Air Central Heating. Using sophisticated
controls and enabling it to provide the precise amount of heat output to match demand. 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.
2.2 The air heater output modulates 8.8kW (31.68MJ/h, 30,026 Btuh) down to 4.4kW (15.84MJ/h, 15,013Btu/h)
“Summer Air Circulation” of unheated air is available by manual selection (see the user’s instructions).
FIGURE 1. C10D FEATURES
13
15
14
18
19
16
17
20
21
22
23
24
25
1
2
3
4
5
7
9
10
12
11
8
6
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3. BUILDING STANDARDS & REGULATIONS
Installation shall be in accordance with the current editions of:-
• BuildingStandards(Scotland)(Consolidation)Regulations
• BuildingRegulations
• GasSafety(InstallationandUse)Regulations(asamended)
• BS7671InstituteofElectricalEngineers(I.E.E.)WiringRegulations
• BS6891InstallationofLowPressureGasPipeworkofupto28mm(R1)indomesticpremises
(2nd family gases).
• BS5440Pt.1(FluesforGasAppliances)
• BS5440Pt.2(AirSupplyforGasAppliances)
• BS5864InstallationofGasFiredDuctedAirHeaters
• BritishSystemDesignManual“GasFiredWarmAirHeating”
• ModelandLocalAuthorityBye-laws
• EN1196SupplementaryInstructions-CondensingAirHeaters
IMPORTANT: IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE
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.
4. SAFETY & GAS INFORMATION
4.1 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.
4.1.3 Ensure safety regulations and practices are adhered to when installing and using this
equipment
4.1.4 The weight of this appliance exceeds that recommended for a one-man lift. It will therefore be
necessary to gain assistance at times during the installation procedure.
4.1.5 It should be noted that this appliance may contain sharp edges. Care MUST be taken when
handling the appliance to prevent injury.
4.1.6 Once the appliance has been fired beware that certain parts will be hot to the touch.
4.1.7 Do not install flues during rain, high winds or in severe weather conditions.
4.2 GAS INFORMATION
4.2.1 Gas Categories
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 capable of providing a steady inlet working pressure to the appliance
of 20mbar at a rate of 0.93m³/h or 32.9ft²/h (Calculated with a Gas C of 38.7MJ/m³)
c. The installation must be tested for gas tightness using suitable methods. The Pipework
should also be purged of air in accordance with the IG Publication Standard.
GAS LEAKS
DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED FLAME. TURN OFF GAS
SUPPLY. VENTILATE THE AREA BY OPENING THE DOORS AND WINDOWS.
CALL THE NATIONAL GAS EMERGENCY SERVICES ON
0800 111999
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5. TECHNICAL DATA
6. HEATER POSITIONING
6.1 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.
6.2 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).
6.3 BS 6798 gives details of the essential features for a compartment or cupboard where a gas appliance is to
be installed. An existing cupboard may require modifications.
6.4 If the heater is installed in a room containing a bath or shower it is important to locate the electrical switch
in a position where it cannot be touched by anyone using the bath or shower. The current IEE Wiring
Regulations (BS 7671) for England and electrical provision of the Building Regulations for Scotland gives
details.
6.5 Room ventilation for the heater is not necessary as the heater draws its combustion air from the outside of
the building, cupboard or compartment ventilation is not necessary providing that the minimum clearances
are maintained. However, reference should be made to BS 5440 Pt. 2.
IMPORTANT:
This appliance must be completely level. It MUST NOT lean in any direction. Otherwise it will
cause problems with the condense draining.
7. HEATER COMPARTMENT CLEARANCES
(see BS 5864)
7.1 IMPORTANT - If the heater is to be fitted to an existing base duct (warm air plenum), always ensure when
installing the appliance, the rear of the heater is aligned with the rear of the base duct. If there is any overhang
or blanking off it will be at the front of the heater. In any event, blanking plates must be mechanically secured
and all joints sealed.
7.2 When the heater is fitted into a compartment, a minimum clearance from 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 be of a fixed rigid structure. However,
there is no requirement for the use of non-combustible material at the front of the unit. Consideration should
also be given to the space required for the removal and replacement of the filter tray and the entry of the
gas and electrical supplies. If gas connections are made from a side entry, a minimum clearance of 75mm
(3”) is required at that side.
7.3 For service access, a minimum of 450mm (18”) is required at the front of the heater. Space must also be
allowed, in a compartment installation, to permit the removal of the heater.
TABLE 1. C10D TECHNICAL DATA
C10D
WEIGHT
48kg
GAS
G20
GAS SUPPLY PRESSURE
20mbar
GAS CATEGORY
I 2 H
COUNTRIES OF INSTALLATION
GB & IE
ELECTRICAL SUPPLY
230v ~ 50hZ fused 5A (150 watts)
MAXIMUM MINIMUM
KW MJ/h Btu/h KW MJ/h Btu/h
INPUT (GROSS)
10.0 36 34,120 5.0 18.0 17,060
OUTPUT
8.8 31.68 30,026 4.4 15.84 15,013
GAS RATE CV 1037Btu/FT³
0.93m³/h (32.9ft³/h) 0.466m³/h (16.45ft³/h)
BURNER % CO²
8 ± 1 8 ± 1
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7.4 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. See BS 5440: Part 1.
7.5 In under-stairs installations, the compartment must comply with the relevant section of BS 5864, provided
that in addition all internal surfaces (including the base) are non-combustible or lined with non-combustible
material. This requirement is applicable only to dwellings of more than two storeys.
7.6 In free-standing installations, (Refer to the instructions packed with top closure kit), only one or two walls will
be in close proximity to the air heater. These must be non-combustible.
7.7 Where the air heater is to be installed onto a combustible surface and under-floor ducting used, a suitable
base tray MUST be used in order to provide insulation.
NB: Where a base plenum is used no base tray is required!
7.8 Although two permanent ventilation openings are not required, consideration should be given to the amount
of heat emitted by any ductwork present in the compartment, otherwise the compartment temperature could
increase and will affect the safe operation of the appliance and its controls.
8. DUCT SYSTEM
(See British Design Manual - Gas fired Warm Air Heating)
8.1 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. The return air grille MUST have a free area of
not less than 900cm
2
(140in2). It is recommended that the return air duct not be routed directly from
the main living area, but from a convenient central area serving the remainder of the dwelling.
8.1.2 The return air system should be constructed of fire-resistant material. The flue shall not be run
through an area serving as a return air plenum. It is extremely important that the correct size of
return air grilles and ducting is used. The return air duct area should not be less than 450cm²
(70in²). If flexible duct is used the duct diameter should not be less than 300mm (12”) diameter.
8.1.3 An adequate and unobstructed return air path is essential from areas not served by a directly
ducted return and to which warm air is delivered. All such rooms should be fitted with relief grilles
which have a free area of 0.0088m
2
/kW (1in2/250Btu/h) of heat supplied to the room. The only
exceptions are kitchens, bathrooms and WC.’s.
8.1.4 The return air duct should allow for ease of removal for access to the flue.
8.1.5 All duct work in the room or internal space in which the heater is installed shall be mechanically
secured and sealed with ducting tape.
8.2 WARM DELIVERED AIR
8.2.1 All duct work, including riser ducts, should be fully insulated with 50mm (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. They must also be protected from crushing.
8.2.2 The duct system should be carefully designed (as given in the guidelines in the British System
Design Manual) to suit the needs of specific heating requirements and building layout. The type of
duct system (e.g. radial/extended plenum stepped) should be installed using the least number of
fittings to minimise airflow resistance. The base duct, which equalises the air pressure to supply
ducts, must be constructed to support the weight of the heater, which must be sealed using selfadhesive foam strip, ducting tape or sealing compound. All ducting and blanking plates must be
mechanically secured and sealed.
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FIGURE 2. HORIZONTAL TERMINAL DIMENSIONS & POSITION
9. FLUE INSTRUCTIONS
9.1 The Warmcair C10D 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.
9.2 The installation of the warm air heater and flue system must be in accordance with the Gas Safety (Installation
and Use) Regulations 1998 and the Building Regulations. If no specific instructions are given, reference
should be made to the relevant codes of practice.
THESE 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 rated heating input not exceeding 70kW (net) :
Air Supply
Ensure all legislation, regulations and directives mentioned are observed.
9.3 The air/flue duct operates at very low temperatures therefore no clearance is necessary between the air
duct and the adjacent services.
9.4 Ensure while installation work is being carried out that no debris such as swarf, filings or fragments of mortar
are allowed to remain in the air/flue duct.
9.5 TYPE OF FLUE SYSTEMS
Two types of flue systems are available for the C10D.
i) The standard concentric flue system 60/100mm (100mm diameter).
ii) A Flexible flue kit (FFK 5) 60/100mm (100mm diameter). For further information contact the sale
office at Johnson & Starley Ltd. Telephone 01604 707000
9.6 FLUE TERMINAL POSITIONS
9.6.1 The following information provides the general requirements for siting flue terminals. As part of the
recommendation given in BS 1550 Part 1. For IE recommendations, see the current issue of I.S. 813
“Domestic Gas Installations.” Also publication a “Guide for Gas Installations in Timber Framed Housing
DM2” or consult your local gas region. They MUST be consulted when installing the appliance into a timberframed building.
NOTE: Due to the nature of the warm air heater, water vapour will discharge from the flue. This should be taken into
account when siting the flue
9.6.2 Both the horizontal and vertical terminals must be positioned on the outside of the building and the free
passage of air must be available at all times. It is not recommended to position the terminal close to
projections especially under a balcony or near to a drainpipe. See Figure 3.
9.6.3 Ensure that combustion products cannot enter the building where the heater is installed or near to any other
building where doors or windows may be open.
9.6.4 Recommended terminal positions for both horizontal and vertical flues are shown and flue components and
installation options are also detailed.
9.6.5 The flue MUST NOT be installed under a car port.
CORRECT
POSITION OF
HORIZONTAL
TERMINAL END
100mm
19mm
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FIGURE 3. TERMINAL POSITIONS
TABLE 2. TERMINAL DIMENSIONS
P
K
J
I
A
M
M
B
F
G
H
H
N
N
C
D, E
Q
TERMINAL POSITION MINIMUM DISTANCE
A Directly below an opening, air brick, opening window etc. 300mm
B Above an opening, air brick, opening window, etc. 300mm
C Horizontally to an opening, air brick, opening window etc. 300mm
D Below gutters, soil pipes or drain pipes. 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 balcony level. 300mm
J From a surface facing the terminal. 600mm
K From a terminal facing the terminal. 1,200mm
M Vertically from a terminal on the same wall. 1,500mm
N Horizontally from a terminal on the same wall. 300mm
Q Above intersection with roof. 530mm
P From a vertical structure on the roof 300mm
R From the terminal to the boundary 300mm
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9.8 TYPICAL FLUE CONFIGURATIONS
HORIZONTAL FLUES
VERTICAL FLUE
Note: Vertical Appliance adaptor is fitted as part of the air heater.
EXTENDED HORIZONTAL REAR FLUE
Can be fitted to the left or the right.
Vertical Appliance Adaptor
Horizontal Terminal
90˚Elbow
Required Extension Length
Vertical Appliance Adaptor
Required Extension Lengths
Vertical Terminal
9.7 PLUME TERMINAL OUTLETS
FIGURE 4. PLUME TERMINAL OUTLET DIMENSIONS
FIGURE 5. EXTENDED HORIZONTAL REAR FLUE
FIGURE 6. VERTICAL FLUE
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.
9.7.2 It is recommended the terminals are not sited within 2m of an opening in an adjacent building or within 2m of
the boundary facing the terminal if the plume is likely to cause a nuisance to a neighbour, e.g. discharging
over a walkway or patio.
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TABLE 3. 60/100 FLUE COMPONENTS
9.9 FLUE PERFORMANCE & GENERAL INFORMATION
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
applianceof3˚(52mm)permeter.Thisensuresthatcondensaterunsbackintotheappliancefrom
the flue system for safe discharge via the condensate waste pipe. Reference should be made to
Table C for relevant part numbers.
9.9.3 The maximum length of flue permissible is 12 meters excluding terminal
9.9.4 The minimum vertical flue length is 1.25m from the top of the appliance case to the top of the
terminal.
9.9.5 Elbows may be fitted within the flue system with a corresponding reduction in overall flue length.
9.9.6 Guidelines for the maximum flue length are as follows.
1x90˚Elbow+12metresstraight
2x90˚Elbow+10metresstraight
3x90˚Elbow+8metresstraight
4x90˚Elbow+6metresstraight
Whenusing45˚elbows
1x90˚Elbowisequivalentto2x45˚Elbows
ITEM DESCRIPTION QTY PARTS INCLUDED APPLICATION PART No.
1 HORIZONTAL TERMINAL WHITE
1
800mm Horizontal Terminal
Horizontal 1000-0019830
1
Inside Wall Cover Plate
1
Outside Wall Cover Plate
2 45˚ ELBOW WHITE 1
Elbow
Horizontal + Vertical
1000-0018980
3 90˚ ELBOW WHITE 1
Elbow
Horizontal + Vertical
1000-0018980
4 250mm STRAIGHT EXTENSION WHITE
1 250mm Straight Extension
Horizontal + Vertical
1000-00189601 100mm Diameter Clamp
2 Screws
5 500mm STRAIGHT EXTENSION WHITE
1 500mm Straight Extension
Horizontal + Vertical
1000-00189501 100mm Diameter Clamp
2 Screws
6 1000mm STRAIGHT EXTENSION WHITE
1 1000mm Straight Extension
Horizontal + Vertical
1000-00189401 100mm Diameter Clamp
2 Screws
6 2000mm STRAIGHT EXTENSION WHITE
1 2000mm Straight Extension
Horizontal + Vertical
1000-00232001 100mm Diameter Clamp
2 Screws
9 RIDGE TERMINAL 1 Condensing Concentric Ridge Terminal Vertical 1000-0021030
10 WALL FIXING BRACKET 100mm 1 Clamp for 100mm tube
Horizontal + Vertical
1000-0020050
11 1140mm VERTICAL TERMINAL
1 Vertical Terminal Assembly
Vertical 1000-0018930
1 Support Bracket
12 PLUME MANAGEMENT KIT (BLACK) 60mm 1
Horizontal
1000-0020730
13 1000mm EXTENSION FLUE 60mm 1 1000mm Extension (60mm)
Horizontal
1000-0020740
14 90˚ ELBOW BLACK 60mm 1 Elbow
Horizontal
1000-0020680
15 45˚ ELBOW (BLACK) 60mm 2 Elbow
Horizontal
1000-0020670
16 WALL FIXING BRACKET 60mm 1 Support Bracket
Horizontal
1000-0020770
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10. 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.
10.1.4 TECHNICAL DATA
a) Tank capacity : 0.5L
b) High level safety cut out
c) Outlet size 6mm I.D.
d) Maximum water temperature: 60°
e) Maximum noise level: 21 dB(A) at 1m
10.1.5 Where the tubing from the pump is connected 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 is connected to an external soil and
vent stack extra care is necessary to ensure that the condense pipe
could not be blocked through the condense freezing.
10.1.7 The tank pump uses small bore (approx. 10mm) flexible hose which
can be routed above or below doors, windows and under kitchen
cabinets.
B
C
D
A
NOTE:
10m MAXIMUM LENGTH
OF CONDENSE TUBE
RESERVOIR F LOAT
FILTER
FIGURE 7. CONDENSE PUMP
10.2 CONDENSE TUBE ROUTING OPTIONS
Option A. Routing to outside drain via sink
Option B. Routing to drain pipe via roof
Option C. Routing to bath waste
Option D. Routing under floor to sink waste
FIGURE 8. CONDENSATE ROUTING OPTIONS
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11. 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. This supply should be suitably sized to conform to British Standards
requirements of no more than 1.0 mbar (0.4” wg) pressure drop (See table of discharge in BS 6891).
11.3 The ½” union gas cock (supplied) MUST be fitted to the gas inlet of the heater for easy isolation during
servicing. The gas pipe should be fitted and installed so as to be durable, substantial and gas tight. To
assist in determining where a gas connection may not be tight, a leak detection fluid should be applied
around the connection. Under no circumstances should a flame be used to locate a gas leak. Gas entry to
the air heater is through either side or the base, to a 15mm compression fitting.
12. ELECTRICAL
WARNING: THIS APPLIANCE MUST BE EARTHED!
12.1 MAINS SUPPLY
The heater is supplied with mains cable (PVC sheathed, heat resisting to
85˚C), 3 core: Brown; Blue; Green/Yellow, 6A, 0.75mm²), connected to
the PCB control panel and exiting through the heater at the left hand top.
The cable is suitable for a 230V 50Hz supply and requires connection to
the fixed wiring using a double pole switched, fused spur with a contact
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 reason, the heater is re-wired, then 3 core cable that meets the
above specification MUST be used. Under NO circumstances, should 5
core cable be used for the combined purpose of supplying power to the
heater and connecting the thermista-stat!
a. Fan delay and overheat (limit controls) are not adjustable and are factory
set.
b. An Open Therm Controller is supplied which acts like a room thermostat.
12.2 THERMISTA-STAT AND ITS LOCATION
This appliance can be interfaced with the following:-
1) Open therm room units (supplied).
2) 33k NTC room temperature sensor.
3) 230 VAC room thermostats.
12.2.1 The room-stat should be located where there is free air circulation and positioned approx. 1.5m
(5ft) from the floor.
12.2.2 Avoid the following locations:
a. In a room where temperature is greatly affected by the sun or any other heat source, e.g.
radiant fire, wall light fittings or TV set.
b. Near an outside door or windows, or on an outside wall.
c. Where it will be affected by warm air ducts, diffusers, waste pipes or the heater itself.
d. Where it will be subjected to vibration.
12.2.3 Refer to wiring diagram 1 for the installation of the thermista-stat. See Figure 23.
FIGURE 9. CABLE POSITIONING
CONDENSATE DRAIN
TUBE
MAINS SUPPLY
OPEN THERM CABLE
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13. 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 Making sure the plenum is clear from all debris, lift the appliance into place.
13.1.2 Using a spirit level it is important the appliance is completely level, this appliance MUST NOT lean
or tilt in any direction. This will cause problems with the condense draining.
13.1.3 Seal the unit to the plenum, using 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 connections to the appliance ready for commissioning.
14. COMMISSIONING
14.1 After installation of the appliance, you MUST do the following:
14.1.1 Test for gas leakage using proprietary detection fluid and seal any leaks found.
14.1.2 Carry out preliminary electrical system checks.
14.1.3 Ensure that:
a. the filter, fan and fan compartments are free from obstructions.
b. all registers or grilles are open and conform to design specifications.
c. the return, relief and ventilation air installations are adequate.
14.2 Switch the air heater electrical Supply ON.
14.3. To fill the flue condensate trap, disconnect the sliding flue connector and slowly pour tap water into the elbow until you hear the condensate pump operating. Failure to do this will result in a whistling sound. Check
for leaks.
NOTE: T
he appliance must be connected to the mains for the pump to operate.
14.4 SYSTEM BALANCING
14.4.1 Press button ‘7’ to put the appliance into Summer Air Circulation mode.
14.4.2 Balance the system to provide the required volume proportions at the warm air outlets.
10
FIGURE 10. CONTROL PANEL
FIGURE 11. LED READ OUT
CONTROL PANEL
1
Time control
2
A +
3
B -
4
LED Display
5
E +
6
D -
7
Summer Air Circulation
8
C
9
Reset
LED READ OUT
1
Open therm symbol
2 Installer mode
indicator
3
Service indicator
4
Stand by
5
Degrees
6
Error - ‘e’ or celsius - ‘c’
7
Reset button indicator
8
Flame indicator
9
Button ‘c’ indication
10
Summer circulation
11
Central heating
11
1
2
3 4
7
6
89
5
1 2 3 4 5 6
7
9
8
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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.
14.3.2 Set both switches on the time control unit to the “OFF” position.
14.2.3 Set the thermista-stat to “MAX”.
14.3.4 Turn on the mains power supply to the heater.
14.3.5 Set the “AIR HEATER” switch on the time control to “ON” and observe the ESYS status indicator.
14.3.6 The ESYS on the control panel will run through the ID setting, when finished it shows a flashing “--”
sign. This shows its ready.
14.3.7 The ignitor will spark for 5 seconds during which time the main burners SHOULD ignite and the
igniter will stop.
14.3.8 If, after the 5 second period, the main burner has ignited the ESYS will show “ON” and the blue LED
“ON” light on the indicator panel will remain 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 to Table 4 in the fault finding section of these instructions in order to establish the fault
condition.
14.3.11 Allow the air heater to operate for a minimum of 15 minutes to ensure stability.
14.3.12 Reset the thermista-stat to the desired comfort level.
14.3.13 Set the time control to the desired “on and “off” periods.
14.4 GAS RATE CHECK
14.4.1 There is no burner pressure test with this air heater. It has a 1-1 ratio
Valve.
14.4.2 Natural Gas (G20) consumption is calculated using gross CV 38.7
MJm³ or 34.9 MJ/m³ net. Maximum rate 32.9ft³/h 0.93m³/h
(0.93m³/h) and minimum rate 16.45ft³/h (0.466m³/h).
14.5 Complete all relevant sections of the Benchmark Commissioning Checklist
located on the inside back pages.
NOTE
The gas valve is factory
preset and must not be
adjusted. A replacement
valve must only be supplied
by Johnson & Starley Ltd.
FIGURE 12. C10D FAN PERFORMANCE GRAPH
Resistance External to Heater
Fan Performance
0 100 200 300 400 500 600 700 800 900m³/h
70
60
50
40
30
20
10
0
PASCALS
FAN MODULATION RANGE
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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.
15.4 In order to gain the best possible fuel economy in relation to the heating requirements of the household,
carefully explain the operation of the appliance and the use/adjustment of all the system controls.
15.5 Adviseontheprecautionsrequiredtopreventdamagetotheappliance;thesystemandthebuildinginthe
event of the appliance being shut down in very cold weather.
15.6 Explain how, in the event of a fault, the appliance will display a fault code, emphasising that if 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 demonstrate the function/operation of time/temperature controls, emphasising the economic
use of the appliance.
15.8 A comprehensive service should be carried out ANNUALLY. Stress the importance of regular servicing by a
Gas Safe Registered Engineer. In IE servicing work must be carried out by a Registered Gas Installer (RGI).
NOTE
This appliance is not intended for use by persons (including children) with reduced physical, sensory
or mental capabilities, or lack of experience and knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
REMINDER: At the time of commissioning, complete all
relevant sections of the Benchmark Checklist located on the
inside back pages of this document prior to handing over the
appliance to the occupier.
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FIGURE 14. SERVICING SEQUENCE
16. 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.
IMPORTANT: It is a statutory requirement that ALL work be carried out by a “competent
person” which in normal circumstances would be a GAS SAFE registered engineer.
NOTE: In order to carry out either servicing or replacement of components the heater
front door must be removed.
16.2 SERVICING SEQUENCE
16.2.1 Light the heater and carry out a pre-service check, noting any
operational faults.
16.2.2 Check the gas consumption.
16.2.3 Put the appliance in test mode (See paragraph 8.1) and connect a
suitable ue gas analyser to the sampling point on the top of the air
heater or into the ue terminal if access is possible (optional test).
See Figure 13.
16.2.4 For correct air heater operation, the CO to CO² ratio should be
checked at the maximum and minimum in test mode.
16.2.5 Check that the gas input is at least 90% of the nominal.
WARNING. Always turn OFF the gas supply at the gas service cock and switch
OFF. Disconnect the electricity supply to the appliance before servicing.
16.2.6 Clean and check the main burner and electrodes. See paragraph
16.4 & 16.5.
16.2.7 Visually check combustion chamber, removing any debris. See
section 16.6.
16.2.8 Remove the Combustion Air Fan (CAF) and clean. See section 16.7.
16.2.9 Check the condensate pipe & tube for blockages.
16.2.10 Check that the ue terminal is unobstructed and that the ue system
is fully assembled correctly.
16.2.11 Remove the Air Circulation Fan (ACF) and lter, inspect and clean..
See paragraph 16.7.
16.2.12 After completing the servicing or exchange of components, always
test for gas tightness and carry out functional checks as described
above.
16.2.13 When work is complete, check the condition of the sealing foam in the
inside of the front door panel. When the door is refitted you must make
ensure a good seal is made.
16.2.14 After servicing, complete the
relevant Service Interval Record
section of the Benchmark
Checklist located on the inside
back pages of this document.
16.3 GAINING ACCESS FOR SERVICING
16.3.1 Ensure the electrical & gas supply is isolated.
16.3.2 Remove the return air filter and pull off the bottom trim.
16.3.3 Remove the front panel by unscrewing the 4 retaining screws at top
and bottom of the panel.
FIGURE 13. GAS FLUE TEST POINT
FLUE GAS TEST
POINT
AIR FILTER
BOTTOM TRIM
2
2
4
1
3
3
4
1
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FIGURE 16. ELECTRODE GAPS
4.4mm
4.5mm
FLAME DETECTION
ELECTRODE GAP
IGNITION
ELECTRODE
GAP
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.
16.4.5 Remove the 4 nuts and washers securing the burner assembly to the heat exchanger and withdraw
the assembly, taking care not to damage the internal ceramic pad.
16.4.6 Inspect the inside of the burner assembly for debris. Clean with a soft brush if necessary.
16.4.7 Inspect the gaskets and replace if necessary.
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 sensing electrode.
16.4.9 Once reassembled re-check electrode and igniter nuts are tight.
16.4.10 Refit in reverse order ensuring a good seal is made.
16.5 IGNITION & FLAME DETECTION ELECTRODES
16.5.1 Refer to section 16.3.
16.5.2 Follow 16.4.4 to remove the valve/venturi.
16.5.3 Unscrew the two nuts that retain the electrode to the
cover plate and remove the assembly.
16.5.4 Inspect and clean the electrode, removing any debris
and oxidization. If necessary use an abrasive paper or
cloth.
16.5.5 Inspect the gasket and replace if necessary during re-
assembly.
16.5.6 Repeat sequence for the flame detection electrodes
with the exception of the earth lead.
16.5.7 Refit in reverse order and tighten nuts.
FIGURE 15. MAIN BURNER ASSEMBLY REMOVAL
ESYS
Panel
Screw
Electrical Con-
nections
Burner
Assembly Nuts
Burner Arm
Combustion
Chamber
Electrode Nuts
Burner
Assembly Nut
Cover Plate
Gas Cock
Flame Detection Electrode Lead
Ignition Electrode Lead
Gas Valve
Venturi
ESYS
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16.6 COMBUSTION CHAMBER/HEAT EXCHANGER
16.6.1 Refer to section 16.3.
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.
16.7.2 Unplug sensor wires, main power connector and low voltage flying
leads from the fan.
16.7.3 Release the fan assembly securing screws and withdraw the fan
from the heater cabinet, avoiding damage to the fan blades.
16.7.4 Remove all dust from both the impellor and motor, taking care not to
disturb the balance of the fan.
16.7.5 Refit in reverse order.
16.8 COMBUSTION AIR FAN (CAF)
16.8.1 Refer to section 16.3.
16.8.2 To release the sliding flue connection, slide upwards.
16.8.3 Unplug the multi pin plug connections from the top of the fan and
carefully remove the 2 spade connectors from the flue sensor. See
Figure 18.
16.8.4 Carefully remove the condensate pipe from the bottom of the flue
elbow. This will contain water.
16.8.5 Rotate the CAF and elbow assembly 45˚clockwise and withdraw
complete assembly.
16.8.6 Carefully inspect both the impellor and the mesh in the collection
box for debris.
16.8.7 Refit in reverse order.
16.9 CONDENSATE DRAIN PIPES
16.9.1 Refer to section 16.3.
16.9.2 These pipes will contain water, drain as necessary.
16.9.3 The flexible condensate pipe are push fit. Cut the cable ties on the bottom bends and disconnect
the pipes.
16.9.4 The flexible pipe MUST be routed so the pipe forms a ‘U’ shaped trap. Cable tie the “U” to hold in
place. Cable tie the bottom of the bends.
16.9.5 Reconnect the condense drain pipe to the condense pump.
FIGURE 18. COMBUSTION AIR FAN
FIGURE 17.
FILTER & AIR CIRCULATION FAN
Flying
Leads
Screws
Sensors
Sliding Flue Pipe
Condense
Pipe Outlet
Filter
Combustion
Air Fan
Electrical Multi Pin
Connection
Flue Elbow
Flue Seal
Flue Sensor
45°
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FIGURE 20.
SENSORS & CONDENSE DRAIN PIPE
16.10.2 Disconnect the condensate pipes and tube. These will contain water.
16.10.3 Remove the 2 screws holding the condense pump in position and
remove the pump.
16.10.4 Check for debris in the tank. Remove any material that might block
the condense pipes or condense tube.
16.10.5 Clean the tank, filter and floats with warm soapy water. Rinse
completely when finished.
16.10.6 Check the inlet and outlet pipe ensuring there are no restrictions in
the tubing.
16.10.7 Refit the filter and the float making sure it is sitting in the correct
position.
16.10.8 Re-fit in reverse order.
17. 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 that are removed should be replaced and refitted in reverse
order, ensuring correct seals are made and wires are connected
correctly.
17.1.2 Remove any debris from within the appliance.
17.1.3 When gas-carrying components are replaced the appliance must be
tested for gas tightness.
17.2 CONTROL PANEL
17.2.1 Refer to section 16.3.
17.2.2 Because of the complexity and delicate nature of the control panel
assembly, it is supplied as a complete kit in a plastic housing.
17.2.3 Remove the control panel by unscrewing the 2 screws that hold the
module in place, withdraw the module and unplug the flying leads at
the rear and remove the assembly
17.2.4 Fit new and re-fit in reverse order.
17.3 AIR CIRCULATION FAN ASSEMBLY
17.3.1 Refer to section 16.3.
17.3.2 Unplug sensor wires. Main power connector and low voltage flying
leads.
17.3.3 Release the fan assembly securing screws and withdraw the fan
assembly from the heater cabinet.
17.3.4 Fit new 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 Circulatrion Fan. Refer to16.7.
17.4.3 Unplug the 2 wires from the temperature sensor and remove the 2
retaining screws. See Figure 19.
17.4.4 Fit new and re-fit in reverse order.
17.5 RETURN AIR TEMPERATURE SENSOR
17.5.1 Refer to section 16.3.
17.5.2 Remove the air circulation fan assembly as described in section 16.7.
17.5.3 Unscrew securing nut and remove sensor.
17.5.4 Fit new and re-fit in reverse order.
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.
FIGURE 19.
AIR CIRCULATION FAN ASSEMBLY
Fan Failure
Sensor
Return Air Temperature
Sensor
High Limit
Temperature
Sensor
Condense Drain
Pipe
Condense Drain
Tube
Flue Temperature
Sensor
Flying Leads
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FIGURE 22.
CONDENSE PUMP REMOVAL
17.6 FLUE TEMPERATURE SENSOR
17.6.1 Refer to section 16.3.
17.6.2 Carefully remove the 2 spade connectors from the sensor and unscrew
the sensor from the plastic flue elbow. See Figure 20.
17.6.3 Fit new and re-fit in reverse order.
17.7 HIGH LIMIT TEMPERATURE SENSOR
17.7.1 Refer to section 16.3.
17.7.2 Unplug the 2 wires from the temperature sensor and remove the 2
retaining screws. See Figure 20.
17.7.3 Fit new and re-fit in reverse order.
17.8 CONDENSATE PUMP
17.8.1 Refer to section 16.3.
17.8.2 Remove the wires from the electrical panel for the float switch and
condensate pump.
17.8.3 Unscrew the 2 fixing screws. See Figure 22.
17.8.4 NOTE: There will be water in the condensate pump.
17.8.5 Disconnect the condensate pipe, condense drain tube from the top of the pump and lift out of the
bottom of the unit.
17.8.6 Fit new and re-fit in reverse order.
17.9 MAIN IGNITION/CONTROL PCB (ESYS Red Housing on Gas Valve)
17.9.1 Refer to section 16.3.
17.9.2 Unplug the connections from the ESYS control and remove the ignition spark detection/ignition
wires. See Figure 21.
17.9.3 Unscrew the single retaining screw. Remove cover & unplug the multi pin connection from the
control. Slide the housing off the gas valve connections.
17.9.4 Fit new and re-fit in reverser order.
Screws
FIGURE 21. MAIN BURNER ASSEMBLY
ESYS
Panel
Screw
Electrical Con-
nections
Valve/Venturi
Screws
Burner Assembly Nuts
Burner Arm
Combustion
Chamber
Electrode Nuts
Burner Assembly Nut
Flame Detection Electrode
Ignition Electrode
Gasket
Gas Valve
Venturi
Gas Cock
ESYS
Condense Pump
Lower
Cover
Condense
Pipe Connections
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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 & Figure 21.
17.10.3 Remove the 2 fixing screws securing the venturi (and gas valve to the burner and carefully remove
the assembly from the burner remove the gasket.
17.10.4 Fit new and re-fit in reverse order, ensuring all the seals are in good condition and correctly
positioned.
17.10.5 Check the gas rate and combustion as described in Section 5.
17.11 BURNER ASSEMBLY
17.11.1 Refer to section 16.3.
17.11.2 Unscrew the gas joint at the top of the gas cock.
17.11.3 Remove the ESYS (red ignition box) & gas valve/venturi assembly. Refer to 17.9 & 17.10 and
Figure 21.
17.11.4 Remove the 4 nuts and washers securing the burner assembly.
17.11.5 Carefully withdraw the assembly from the heat exchanger.
17.11.6 Remove the spark detection electrodes, allowing the burner sealing plates to be separated.
17.11.7 Fit new and re-fit in reverse order. Make sure all gaskets are replaced with new ones, ensure
the rotation position of the burner is correct (indicated by 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.
17.12.2 Unplug the lead from the ESYS (red ignition box) and earth wire from the back of the electrode.
Refer to 17.9 and Figure 19.
17.13.3 Remove the 2 remaining nuts and withdraw the electrode.
17.13.4 Replace with a new unit, ensuring the gasket is replaced with a new one, or if the existing gasket
if reused is in good condition.
17.13.5 Re-fit in reverse order.
17.13 FLAME DETECTION ELECTRODES
17.13.1 Refer to section 16.3.
17.13.2 Unplug the lead from the ignition control. See Figure 21.
17.13.3 Remove the two retaining nuts and withdraw the electrode.
17.13.4 Replace with new unit, ensuring the gasket is replaced with a new one
.
17.13.5 Re-fit in reverse order.
IMPORTANT: When either the
ignition or flame detection
electrodes have been serviced
or replaced you MUST set the
clearances as shown in Figure 16.
17.14 COMBUSTION AIR FAN (CAF)
17.14.1 Refer to section 16.3.
17.14.2 To remove the CAF refer
to 16.8.2 to 16.8.6 and
Figure 18.
17.14.3 Remove the 4 retaining
screws that attach the
CAF and flue elbow. See
Figure 23.
17.14.4 Fit new and re-fit in
reverse order.
FIGURE 23. COMBUSTION AIR FAN ASSEMBLY
Condense Pipe Outlet
Combustion
Air Fan
Electrical
Connections
Flue Elbow
Flue Seal
Flue Sensor
Gasket
Seal
Ring
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18. CONTROL PANEL MODES
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.)
t100 is displayed
along with the flame symbol.
18.1.2 Whilst in test mode, the appliance overrides all temperature setting and defaults to maximum rate.
Pressing the D and E buttons allows you to scroll between maximum and minimum rates, whilst
maintaining all protection and error conditions.
18.1.3 Press RESET to take the appliance out of test mode. If no changes are made, the appliance will
stay in test mode for 30 minutes.
18.2 AIR CIRCULATION FAN TEST MODE
18.2.1 This mode can be used to adjust the maximum and minimum fan speed output value allowed to
drive the ACF fan. (minimum value of 50 to 100 being maximum)
18.2.2 Put appliance into test mode. Refer to 18.1. The ACF fan will run with the fan speed value showing
on the LCD display, the Value from the ESYS is bypassed.
18.2.3 On the display, letter F and the fan speed value is will display, this value can be changed by
pressing the D and E buttons accordingly. Once the required value is reached the values can be
saved as:
- minimum by pressing button B
- maximum by pressing buttonA
18.2.4 The display will flash for 2 seconds to confirm it has been saved to the ESYS.
18.2.5 Timeout mode is set for 30 minutes, this can be terminated by pressing RESET.
18.2.6 The backlight stays on when the test mode is active.
18.3 ERROR HISTORY MODE
18.3.1 The control panel can store the last 8 error codes. To access these codes press the RESET button
for more than 1 second, this will then flash ‘H1’ on the LCD display.
13.3.2 Error 1 being the most recent, along with the error code after the dot. To scroll though the error
history press the ‘C’ button.
18.3.3 The unit will stay in error history mode for 30 seconds.
18.3.4 To take the unit out of the error history mode press RESET.
18.3.5 In order to limit the warm air temperature the heater will shut off the burner and Lt will be displayed
in the centre of the display. This will be stored as error 57.
18.3.6 Check the filter is clean and the warm air outlets are open.
CONTROL PANEL
1
Time control
2
A +
3
B -
4
LED Display
5
E +
6
D -
7
Summer Air Circulation
8
C
9
Reset
1 2 3 4 5 6
7 98
FIGURE 24. CONTROL PANEL
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19. 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. When gas-carrying components are serviced
the appliance must be tested for gas tightness after re-assembly. On completion of a service carry out a full
functional test of all appliance components and ensure system controls are operating correctly.
TABLE 4 ERROR CODES
CODE SYMPTOM POSSIBLE CAUSE ACTION
N/A Heater will not run No call for heat to heater control board
Check all external controls (if fitted)
Check setting on time clock
Check setting of heater controls
1 Flame lockout after several attempts Flame not detected
Check gas supply and gas cock
If burner lights, check flame 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 or restrictions
5 No tacho from fan Fan not running or wiring fault
Check that fan runs
Check wiring between ESYS and fan
7 Flue gas protection High flue gas temperature Check airflow and fan operation
8 Flame circuit error Flame sensing lead shorted to earth
Check flame detection lead between sensing probe
and ignition control board
9 Valve driver circuit error Gas valve not detected
Check that ESYS is corrected fitted on gas valve
Replace ignition control board or gas valve
13 Remote reset lockout Exceeded 5 remote resets per hour Reset it by power off/on
21 ADC error Change ESYS
25 CRC error Different software versions Change ESYS
26
Flame lost signal lost 5 times in 4
minutes
Flame sensing error. Failing gas pressures.
Fan fault. Flue blockage.
Check flame detection lead between sensor and
ignition control board
Check the gas supply, does pressure fall when burner
fires?
Check that flue system is not blocked
BLOCKING CODES
30
Duct air temperature sensor short
circuit
Temperature sensor shorted to earth or
failed
Check wiring and connections for shorting to earth
Check sensor resistance
31
Duct air temperature sensor open
circuit
Temperature sensor not connected or failed
Check wiring connections
Check sensor continuity
34 Low mains supply voltage
Electrical supply fault to property Check incoming mains supply
Faulty wiring to appliance Check wiring to appliance
43 Return air temperature short circuit 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 wiring connections
Check sensor continuity
45
Flue gas temperature sensor short
circuit
Short circuit in wiring between sensor and
control board
Check wiring to sensor
Check electrical resistance of the sensor
46
Flue gas temperature sensor open
circuit
Temperature sensor not connected or failed
Check wiring connections
Check sensor continuity
57 Restricted airflow Blocked filter and return air filter/Duct Check blockage from filter and return air filter/ducts
99 Communication MMI-ESYS lost
Connection between MMI & ESYS
incorrectly made
Check wiring and connections
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20. FAULT FINDING FLOW CHART
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21. 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 Avoltageshouldbemeasuredandblue(-)andyellow(+).Voltageapprox.10VDC.
21.1.3 If voltage is present and fan is not running at maximum. Replace ACF.
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22. 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
TERMINA
L L/N/E TO UNIT TERMINAL
TIMER
red (r) 1 L
PCB INTERFACE
18
ESYS
brown (br) X1 - 5
PCB INTERFACE
14
blue (bl) 2 N
PCB INTERFACE
19 blue (bl) X1 - 10
PCB INTERFACE
15
blue (bl) 2 DSP (MMI) X1 - 1 yellow (y) X2 - 1 DSP (MMI) X4 - 4
brown (br) 3
PCB INTERFACE
22
orange (or)
X2 - 2 DSP (MMI) X4 - 2
brown (br) 4 DSP (MMI) X1 - 3
green (gr)
X2 - 3 DSP (MMI) X4 - 3
DSP (MMI)
green (gr) X2 - 1
PCB INTERFACE
X2 - 1 black (bk) X2 - 4 DSP (MMI) X4 - 4
green (gr) X2 - 2
PCB INTERFACE
X2 - 2 blue (bl) X2 - 5 DSP (MMI) X4 - 5
orange (or) X2 - 3
PCB INTERFACE
X2 - 4 yellow (y) X3 - 2
PCB INTERFACE
X3 - 1
orange (or) X2 - 4
PCB INTERFACE
X2 - 5 red (r) X3 - 3
PCB INTERFACE
X3 - 3
GAS VALVE
green/yellow (g/y)
1 E
PCB INTERFACE
13 red (r) X3 - 10
PCB INTERFACE
X3 - 4
green/yellow (g/y)
1 E
ELECTRODE
yellow (y) X3 - 13
PCB INTERFACE
X3 - 2
CLEANFLOW
orange (or)
Transformer
E
PCB INTERFACE
10
CONDENSATE
PUMP
black (bk) A1
PCB INTERFACE
30
grey (gy) L
PCB INTERFACE
11 black (bk) A2
PCB INTERFACE
29
- N
PCB INTERFACE
9 blue (bl) B1 N
PCB INTERFACE
18
brown (br) B2 L
PCB INTERFACE
17
()
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
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
COMBUSTION
AIR FAN
(CAF)
white (w) A1 - 2 ESYS X3 - 1
AIR
CIRCULATION
FAN
(ACF)
blue (bl) X9 - 2 N
PCB INTERFACE
6
black (bk) A1 - 3 ESYS x3 - 12
green/yellow (g/y)
X9 - 3 E
PCB INTERFACE
4
yellow (y) A1 - 4 ESYS X3 - 5 brown (br) X9 - 4 L
PCB INTERFACE
5
brown (br) A2 - 1 L
PCB INTERFACE
8 black (bk) X10 - 1 DSP (MMI) X3 - 3
green/yellow (g/y)
A2 - 2 N
PCB INTERFACE
7 yellow (y) X10 - 2 DSP (MMI) X3 - 1
blue (bl) A1 - 3 E
PCB INTERFACE
9
ACF LIMIT
SWITCH
purple (pr) E1
ESYS
X3 - 4
CAF FLUE
PROTECTION
SENSOR
black (bk) B1 ESYS X3 - 9 purple (pr) E2
BULKHEAD LIMIT SWITCH
D1
black (bk) B2 ESYS X3 - 6
ACF RETURN
AIR SENSOR
green (gr) F1 ESYS X3 - 8
BULKHEAD
LIMIT SWITCH
purple (pr) D1
ACF LIMIT SWITCH
E2 green (gr) F2 ESYS X3 - 14
purple (pr) D2
ESYS
15
BULKHEAD DUCT
AIR SENSOR
orange (or) C1 ESYS X3 - 8
orange (or) C2 ESYS X3 - 16
()
www.johnsonandstarley.co.uk
28
23. DIMENSIONS
FIGURE 27. WARMCAIR C10D DIMENSIONS
300
1200
550
244
267
32
46
72
123
1340
146
171
52
102
172
482
23
16
130
45
185
mCaire C10
War
D
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29
24. EXPLODED SPARES DIAGRAMS
ITEM PART No. G. C. No. DESCRIPTION QTY
A C10D-0501005 CONTROL PANEL ASSEMBLY 1
ITEM PART No. G. C. No. DESCRIPTION QTY
B C10D-0140005 COMPLETE COMBUSTION FAN ASSEMBLY 1
LIST OF SPARES
ITEM PART No. DESCRIPTION QTY
1 1000-2501505 Flue Seal 1
2 1000-0522645 Flue Gas Sensor 1
3 1000-0022195
Exhaust Flue Drain Elbow 1
Flue Seal 1
Gasket Seal Ring 1
4 1000-0525215
Combustion Air Fan 1
Gasket Seal Ring 1
‘O’ Ring 1
5 1000-2501675 ‘O’ Ring 1
FLANGE
CONNECTION
COMBUSTION
AIR FAN
2
1
4
5
3
EXHAUST
FLUE
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30
ITEM PART No. G. C. No. DESCRIPTION QTY
C C10D-0700005 MAIN BURNER ASSEMBLY 1
ITEM PART No. G. C. No. DESCRIPTION QTY
D C10D-0503005 AIR CIRCULATION FAN ASSEMBLY 1
LIST OF SPARES
ITEM PART No. DESCRIPTION QTY
1 1000-0710215
Burner Arm Assembly 1
Burner Gasket A 1
Burner Gasket B 1
2 1000-0710495
Valve/Venturi Assembly 1
Venturi Gasket 1
Cork Gasket 1
3 1000-0710455
Ignition Electrode 1
Ignition Electrode Gasket 1
4 1000-0710445
Detection Electrode 1
Detection Electrode Gasket 1
FLYING LEAD
LIST OF SPARES
ITEM PART No. DESCRIPTION QTY
1 1000-0517635 Fan Failure Sensor 1
2 1000-0522645 Return Air Sensor 1
4
1
2
3
1
2
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31
ITEM PART No. G. C. No. DESCRIPTION QTY
E C10D-0132005 COMBUSTION AIR PASSAGE ASSEMBLY 1
F C10D-0190005 CONDENSATE PUMP ASSEMBLY 1
G C10D-0300005
C10D HEAT EXCHANGER 1
H 1000-0501055
HIGH LIMIT
TEMPERATURE SENSOR
1
I 1000-0522645
DUCT TEMPERATURE
SENSOR
1
BACK PLATE
CASING
RESTRICTOR
CONDENSATE PUMP
OUTLET
‘Y’ CONNECTION
FILTER
FLOAT
M 1000-0022250
VERTICAL FLUE
ADAPTOR 60/100mm
1
L 1000-0022225
TELESCOPIC
FLUE TUBE
1
K 1000-0525145
ESYS CONTROL BOX 1
J C10D-0137005
ELECTRICAL PCB ASSEMBLY 1
NOTE: Back Plate is not included as part of the spare.
FLANGE SOCKET
BACK NUT
CONDENSATE BOX
RING SEAL
SEAL
SEALING FRAME
CONDENSATE CONNECTOR
www.johnsonandstarley.co.uk
32
Fully complies with
Part L of the Building Regulations
by following the guidance in the
British Standard BS 5864
and the
Heating Compliance Guide
For further information contact
Johnson & Starley Ltd
on Telephone 01604 762881
WARMCAIR C10D ANCILLARY’S
Description Product Code
1 Cleanow Air Filter CF10
2 Return Air Kits RAK10
3 Slot Fix Panels TS10
4 Top Closure panels TCB10
5 Base Duct WBX10
6 Base Tray BT10
7 Top Closure 2 Panel Kit TP10
8 Slot Fix & Grille TSG10
9 Rear Riser Kit CJ1032
These kits are readily available from Johnson & Starley Ltd
Telephone the Sales Office for further information
25. IMPORTANT INFORMATION & ANCILLARIES
Sales/Spares 01604 707012 Replacement Help Line 01604 707011
33
This Log Book should be
filled out at each annual
service
COMMISSIONING CHECKLIST
& SERVICE RECORD
C10D
26. BENCHMARK CHECKLIST
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.
Always use the manufacturer’s specifi ed spare part when replacing controls.
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Date:
Engineer Name:
Company Name:
Telephone No.
Operative ID No.
Comments:
Signature:
Service 1 Service 2
Service 3 Service 4
Service 5 Service 6
Service 7 Service 8
Service 9 Service 10
Anniversary 1922 - 2012
Johnson & Starley Ltd
Rhosili Road, Brackmills,
Northampton NN4 7LZ
sales@johnsonandstarley.co.uk
marketing@johnsonandstarley.co.uk
Reception
01604 762881
Sales/Spares
01604 707012
Service/Warm air upgrade
01604 762881
Warm air upgrade
01604 707011
Johnson & Starley Dravo Division Industrial H&V
Sales
01604 707022
dravo@johnsonandstarley.co.uk
www.dravo.co.uk
In the interest of continuous development Johnson & Starley reserve the right to change specication without prior notice.
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