Johnson & Starley WARMCAIR C20DW, WARMCAIR C16DW, WARMCAIR C10DW Installation, Commissioning & Servicing Instructions

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INSTALLATION, COMMISSIONING & SERVICING INSTRUCTIONS

WARMCAIR C20DW

Condensing Air & Water Heater

High Efciency Downow Condensing Air & Water Heater

WarmCair C20DW - G.C. No. 43-417-61

These instructions are to be left with the User

Publication No. ZZ 1448-4

December 2016

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CONTENTS

The Benchmark Scheme 2

1 Features 3

2 General Description 3

3 Building Standards & Regulations 4

4 Safety, Electrical & Gas Information 4

General Safety Information Power Flushing Electrical Connections Handling the unit Operating the Appliance Gas Supply Water Supply

5 Technical Data 6

Technical Data Performance Data

6 Heater Positioning 7

7 Heater Compartment Clearances 7

8 Duct System 7

Return Air

9 Heating System 8

Warm Delivered Air System Additional Radiator System If Fitted Schematics Pipework Sizing Water Treatment Hot Water System For DHW

10 Flue Instructions 10

Types of Flue Systems Flue Terminal Positions Flue Requirements & General Information Extended Horizontal Flue Configuration Examples Vertical Flue Configuration Example Optional Roof Outlets Plume Terminal Outlets Conventional 60/100mm Flue Accessories Part No.s

11 Condensate Pump & Drain Tube 15

Condensate Pump Condensate Tube Routing Options

12 Electrical 16

13 Warm Air Fan Performance 16

14 Operating Modes 16

15 Domestic Hot Water Heating Commissioning 17

Check Gas Installation Check the Operational Gas Inlet Pressure Air Purge Function Reset Procedure

16 Initial Lighting 18

Warm Air Central Heating Water Circulation System Balance the System

Central Heating Water Temperatures

17 Warm Air Heating Commissioning 19

With Thermista-stat Fitted With No Thermista-stat Fitted

18 Handing Over 19

19 Servicing & Maintenance 20

Service Schedule Initial Inspection Servicing Sequence Flue Inspection & Checks

Gaining Access to the Appliance

Air Filter Removal Upper Panel Removal Control Panel Combustion Air Fan Burner Assembly Water Heat Exchanger Servicing the Warm Air Heating

Gaining Access for Servicing the Heat Generator

Lower Panel Removal Air Circulation Fan Air to Water Heat Exchanger Condensate Pump Condensate Trap

20 Parts Replacements 24

Part Replacements without Draining the System

Control Panel Burner Injector Combustion Air Fan Burner Assembly Flow & Return Thermistor Sensors Ignition/Detection Electrode Gas Valve Warm Air PCB PCB Interface Air Circulation Fan Condensate Pump Condensate Trap Diverter Acuator Head

Parts Replacement By Draining the System

Draining the Appliance Pump Head Diverter Cartridge Automatic Air Vent Air To Water Heat Exchanger

21 Fault Finding 28

22 Wiring Diagram 34

23 Dimensions 35

24 Exploded Spares Diagram 36

25 List of Spares 38

26 List of Ancillaries 39

27 Benchmark Checklist and Service Record 41

Code of Practice Commissioning Checklist Service Record

In the interest of continuous development Johnson and Starley reserve the right to change specication without prior notice.

Johnson and Starley prides itself on it’s ability to supply spare parts quickly and efciently.

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.

Visit www.centralheating.co.uk for more information.

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 Hot water Industry Council who manage and promote the Scheme.

Sales/Spares & Replacement Help Line 01604 762881

1. FEATURES

Appliance Classification:

The WarmCair C20DW has been tested and CE certified by B.S.I Ltd for use with NATURAL gas G20.

FEATURES

1. Flue Adapter

(shown fitted but not supplied)

2. Flue Test Point

3. Inspection Glass

4. Ignition Detection Electrode

5. Burner Injector

6. Flow & Return Sensors

7. Pressure Differential Tube

8. Gas Valve

9. Air Filter

10. Condensate Trap

11. Gas Cock

12. Circulation Fan

13. Pump/Diverter Assembly

14. Return Water Temperature Sensor

15. Heat Exchanger

(Warm Air)

16. Drain Cock

17. Access Panel

18. Condensate Pump

19. Condensate Pipe

20. Condensate Drain Tube

21. Electronic Air Filter & LED 22 PCB Interface

23. Combustion Fan

24. Warm Air PCB

25. Heat Generator

(water)

26. Flue Sensor

2. BRIEF DESCRIPTION

2.1 The WarmCair C20DW is a highly efficient combined condensing gas fired water to air downflow forced convection air heater and water heater. Significant reductions in Carbon and NOx emissions are achieved.

This appliance has been designed with two compartments, one to provide the user with Warm Air Central

Heating and one to provide Domestic Hot Water. Using sophisticated controls and enabling it to provide a warm air heat output of 16.0kW and hot water output of 24.2 fully modulating down to 4.8kW. It is room sealed, with a stainless steel heat exchanger, using a vertical or horizontal Concentric Flue System.

The WarmCair C20DW combinds air heater is ideally suited for new built dwellings and the replacement of

existing non-condensing air heaters. For Indirect system applications only.

2.2 “Summer Air Circulation” of unheated air is available by manual selection (see the user’s instructions)

2.3 The air is drawn in through the air filter or air cleaner (if fitted) and the heat exchanger by a centrifugal fan, and is discharged through the base of the unit. A Summer Air Circulation switch (optional) provides the facility to supply unheated air to the air outlets during warm weather. Modairflow control is incorporated for modulating of the air circulation fan.

FIGURE 1. CONTROL PANEL

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3. 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.

3.1 INSTALLATION REGULATIONS

• Building Standards (Scotland) (Consolidation) Regulations

• Building Regulations Part L

• Gas Safety (Installation and Use) Regulations (as amended)

• The Water Fittings Regulations or Water bylaws in Scotland

• Model and Local Authority Byelaws

• Health & Safety Document No. 635.

• The Electricity at Work Regulations, 1989.

• Institute of Electrical Engineers (I.E.E) Wiring Regulations

• EU Regulation No 811/2013 and No. 812/2013 supplement Directive 2013/20/EU

This appliance has been Tested and Certified in order to meet the necessary European Directives and comply with the latest Building Regulations.

• Efciency of Hot Water Boilers Directive 92/42/EEC

• Gas Appliance Directive 2009/142/EC

• Low Voltage Directive 2006/95/EEC

• Electromagnetic Compatibility Directive 2004/108EC

3.2 BUILDING STANDARDS AND REGULATIONS

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

BS 5440:1 Flues (for gas appliances of rated input not exceeding 70 kW). BS 5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW). BS EN 12828 Heating Systems in buildings: Design for water based heating systems.

BS EN 12831 Heating Systems in buildings: Method for calculation of the design heat load. BS EN 14336

Heating Systems in buildings: Installation and commissioning of water based heating systems.

BS 5546 Installation of gas hot water supplies for domestic purposes (2nd Family Gases) BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW. BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises

(2nd family gases). BS 7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations

IMPORTANT: This appliance is CE certificated for safety and performance. It is important that no modifications are made to this appliance, unless fully approved in writing by Johnson & Starley Ltd. If in doubt please Ring Johnson & Starley Ltd on Telephone 01604 762881.

4. SAFETY, ELECTRICAL, GAS & WATER INFORMATION

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING WITH THE INSTALLATION

4.1 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 manufacturers instructions supplied must not be taken as overriding any statutory requirements.

4.1.3 No artificially softened water must not be used to fill the central heating system.

4.2 POWER FLUSHING - When a radiator system is also connected.

4.2.1 The system can be damaged by debris entering the heat exchanger and reduce efficiency. It is

recommended that the appliance is flushed, follow these guidelines as this will protect the unit and prolong its life.

4.2.2

It is important that the system is flushed thoroughly before the appliance is left to operate (as recommended in BS 7593) in order to maintain an efficiently operating heating system. For replacement installations, the system MUST be flushed with the old unit in situ, in order to prevent the appliance becoming a trap for system debris. Once the system has been flushed, an inhibitor (suitable for stainless steel heat exchangers) should be added. Appropriate inhibitors are available, for example Sentinel, Fernox and Salamader. We also recommend a Magnetic & Non Magnetic Filtration system is fitted between the last radiator and the boiler.

4.2.2 Failure to carry out the above procedure will invalidate the guarantee!

Sales/Spares & Replacement Help Line 01604 762881

4.3 ELECTRICAL INFORMATION

4.3.1 Ensure the mains supply voltage, frequency, number of phases and power rating comply with details on the

rating label.

4.3.2 All wiring must be in accordance with the appropriate standards. The equipment must be supplied with a

double pole isolator switch.

4.4 HANDLING THE UNIT

4.4.1 Ensure safety regulations and practices are adhered to when installing and using this equipment

4.4.2 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.

4.4.3 It should be noted that this appliance may contain sharp edges. Care MUST be taken when handling the

appliance to prevent injury.

4.4.4 Once the appliance has been fired beware that certain parts will be hot to the touch.

4.4.5 Do not install flues during rain, high winds or in severe weather conditions.

4.5 GAS SUPPLY

4.5.1 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 Combined DHW range is able to deliver it’s full output at inlet pressures as low as 14mb, other gas appliances in the property may not be as tolerant. When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation.

4.5.2 Allowing for the acceptable pressure loss of 1mb across the installation pipework, it can be assumed that

a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance. (Reference BS 6400-1 Clause 6.2 Pressure Absorption).

4.5.3 The external gas cock could further reduce the operating pressure when measured at its test point. The

pressure drop is relative to the heat input to the boiler (kW), refer to graph below.

IMPORTANT: Installation pipes must be fitted in accordance with BS 6891. In IE refer to IS.813.

4.6 WATER SUPPLY

4.6.1 Water connections to the unit should be by 22mm compression fittings that are suitable for the duty.

NOTE: UNDER NO CIRCUMSTANCES SHOULD ISOLATION VALVES BE FITTED.

IMPORTANT: It is recommended that the water system be drained and flushed prior to the installation of the unit. A strainer should be fitted upstream of the unit. See Paragraph 4.2.

FIGURE 2. GAS COCK PRESSURE DROP

2.5

1.5

0.5

PRESSURE DROP (mbar)

0.0 0.5 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0

HEAT INPUT TO BOILER (kW)

GAS LEAKS

DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED FLAME

TURN OFF THE GAS SUPPLY. VENTILATE THE AREA BY OPENING DOORS AND

WINDOWS. CALL THE NATIONAL GAS EMERGENCY SERVICE ON

0800 111999

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Note: Gas consumption is calculated using a calorific value of 38.7 MJ/m³ gross or 34.9 MJ/m³ nett. To obtain the gas consumption at a different calorific value:

a. For l/s - divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m³) b. For ft³/h - divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft³)

c. For m³/h - multiply l/s by 3.6

TABLE 2. C20DW

PERFORMANCE DATA

MAXIMUM MINIMUM

Burner CO² (%)

case off

9.4 8.5

case on

9.6 8.7

± 0.5

PERFORMANCE DATA FOR WATER HEATING

Input Q

Net

kW 24 4.7

Gross

kW 26.6 5.21

Gas Consumption

m³/h 2.48 0.48

Output

Non condensing kW 23.4

Condensing

kW 25.6 5.17

NOx Classication

CLASS 5 34mg/kWh

Recommended Central Heating set point

20 - 82°C

5. TECHNICAL DATA

TABLE 1 C20DW

Maximum weight lift kg 82.5

Gas supply mbar 2H - G20 - 20mbar

Gas connection mm 15mm copper

Gas Injector size mm 4.75mm

Heating flow and return mm 22mm copper

Flue terminal diameter mm 100mm (4”)

Condense drain mm 6mm ID

Electrical supply V ~ Hz 230V ~ 50Hz

Electrical rating W 530

External fuse rating A 3

WARM AIR HEATING

Nominal Rated Output kW 20

Air on Temperature ˚C 20

Air off Temperature ˚C 67

Water Supply Temperature ˚C 80

Water Return Temperature ˚C 71

Water Flow Rate l/s 0.6

Air Volume m³/h 1224

Sales/Spares & Replacement Help Line 01604 762881

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 modification.

IMPORTANT: This system can only be used in conjunction with an indirect system application.

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. This will cause problems with

the condense draining.

7. HEATER COMPARTMENT CLEARANCES

7.1 IMPORTANT - If the heater is to be fitted to an existing base duct (warm air plenum), always ensure that installation is

carried out such that the rear of the heater is aligned with the rear of the base duct, so that any overhang or blanking off will be at the front. 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 (

/8”) at the sides, rear and front must be left. Where clearances are less than 75mm, internal surface must be lined with noncombustible 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 clearance of 500mm (20”) is required at the front of the heater. Space must also be allowed, in a compartment installation, to permit the complete removal of the heater.

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, (see 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 2118cm² (328in²). 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 750cm² (116.25in²). If flexible duct is used the duct diameter should not be less than 350mm (14”) 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 0.0088m2/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.

8.1.6 If a return air duct is not to be fitted, the top of the unit must be suitably guarded to prevent blockage.

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9. HEATING SYSTEM

9.1 WARM DELIVERED AIR SYSTEM

9.1.1 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.

9.1.2 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.

9.2 ADDITIONAL RADIATOR SYSTEM IF FITTED

9.2.1 Any additional radiators must be connected to pipe tails provided as detailed in Figure 3.

9.2.2 The installation must comply with all relevant national and local regulations.

All components of the system must be suitable for a working pressure of 3 bar and temperature

of 110°C. Extra care should be taken in making all connections so that the risk of leakage is minimised.

NOTE: a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from

the mains via a temporary hose connection is only allowed if acceptable to the local water authority.

b. Antifreeze fluid, corrosion and scale inhibitor fluids suitable for use with boilers having

stainless steel heat exchangers may be used in the central heating system.

FIGURE 3. WATER FLOW SCHEMATIC

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9.3 PIPEWORK SIZING

In order to keep the noise of the system to a minimum, the velocity of water should be kept below 1.5 m/s

and it should be noted that the appliance is designed to operate with a temperature differential of 20˚C

between flow and return. The maximum flow rates are 0.3 kg/s which, through a 22mm pipe, gives velocities of 1.00 m/s. Therefore, the recommended minimum pipe size is 22mm.

9.4 WATER TREATMENT

9.4.1 For replacement installations, the system MUST be flushed with the old boiler in situ, in order to

prevent the boiler becoming a trap for system debris. Once the system has been flushed, an inhibitor (suitable for stainless steel heat exchangers) should be added.

9.4.2 Appropriate inhibitors are available, for example Sentinel, Fernox and Salamader. Failure to carry

out the above procedure will invalidate the guarantee!

NOTE: Water supplied from a water softener MUST NOT be used unless a specially formulated

corrosion inhibitor is added (see BS 6798)

IMPORTANT: This appliance can only be used with a Indirect heating System.

9.5 HOT WATER SYSTEM FOR DHW

9.5.1 A cylinder with a thermostat must be fitted.

9.5.2 Separate timing of DHW is required for connections see Figure 52.

FIGURE 4. HOT WATER SYSTEM SCHEMATIC

COLD WATER

STORAGE

EXPANSION

VESSEL

HOT WATER

DRAIN COCK

INDIRECT STORAGE

CYLINDER

NOTE: Johnson & Starley Ltd recommend the use of a

sealed system kit. The pressure vessel and PVR must be

tted in the ow before any auxiliary diverter valves.

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10. FLUE INSTRUCTIONS

10.1 The WarmCair C20DW 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.

10.2 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.

10.3 The air/flue duct operates at very low temperatures therefore no clearance is necessary between the air duct and the adjacent services.

10.4 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.

10.5 TYPE OF FLUE SYSTEMS

Two types of flue systems are available for the C10DW.

i) The standard concentric flue system 60/100

(100mm diameter)

FIGURE 6. 60/100mm FLEXIBLE FLUE EXAMPLEFIGURE 5. 60/100mm HORIZONTAL CONCENTRIC FLUE EXAMPLE

VERTICAL TERMINAL

ii) A Flexible flue kit (FFK 5) 60/100mm (100mm

diameter) For further information contact the sale office at Johnson & Starley Ltd. Telephone 01604 762881.

10.6 FLUE TERMINAL POSITIONS

10.6.1 The following information provides the general requirements for siting flue terminals. As part of the

recommendation given in BS 5440 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, MUST be consulted when installing the appliance into a timber-framed 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

10.6.2 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.

10.6.3 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.

10.6.4 Recommended terminal positions for both horizontal and vertical flues are shown and flue

components and installation options are also detailed.

10.6.5 The flue MUST NOT be installed under a car port.

FLEXIBLE

FLUE

VERTICAL ADAPTOR

FLUE

SUPPORT

90˚ ELBOW

45˚ ELBOW

1m EXTENSION

EXTENSIONS

HORIZONTAL

TERMINAL

WEATHER COLLAR

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FIGURE 7. TERMINAL POSITIONS

D, E

TABLE 3 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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10.8 EXTENDED HORIZONTAL FLUE CONFIGURATION EXAMPLE

NOTE: Vertical Appliance adaptor is fitted as part of the air heater.

Can be fitted to the left or the right.

FIGURE 8. EXTENDED FLUE CONFIGURATION

100mm

19mm

CORRECT

POSITION OF

HORIZONTAL

TERMINAL END

Flue Extensions

as Required

60/100mm

Adapter

Clamps

90° Elbow

ITEM DESCRIPTION QTY

1 Vertical 60/100mm Adaptor 1

2 Appliance Seal 1

3 EPDM Outside Wall Cover Plate 1

4 Inside Wall Cover Plate 1

5 100mm Diameter Clamps -

6 Required Extension Flue Length up to 8m

7 90° Elbow 1

8 800mm Horizontal Terminal 1

10.7 FLUE REQUIREMENTS & GENERAL INFORMATION

10.7.1 Horizontal and vertical concentric flues (60/100mm diameter) with balanced terminals may be installed on all the WarmCair C10DW appliance.

10.7.2 If an extended horizontal flue is being used it must have a continuous fall back towards the appliance of 3° (52mm) per meter. This ensures that condensate runs back into the appliance from the flue system for safe discharge via the condensate waste pipe. Reference should be made to Table 5 for relevant part numbers.

10.7.3 The maximum length of flue permissible is 10 meters excluding terminal.

10.7.4 The minimum vertical flue length is 1.25m from the top of the appliance case to the top of the terminal.

10.7.5 Elbows may be fitted within the flue system with a corresponding reduction in overall flue length.

10.7.6 Guidelines for the maximum flue lengths are as follows.

EQUIVALENT HORIZONTAL FLUE LENGTHS

Adaptor + 10 metres straight Adaptor + 1 x 90° Elbow + 8 metres straight lengths Adaptor + 2 x 90° Elbow + 6 metres straight lengths Adaptor + 3 x 90° Elbow + 4 metres straight lengths

When using 90˚ Elbows = 1 x 90° Elbow is equivalent to 2m Straight lengths

When using 45˚ Elbows = 2 x 45˚ Elbows are equivalent to 1 x 90˚ Elbow

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FIGURE 9. VERTICAL FLUE

10.11 PLUME TERMINAL OUTLETS

10.11.1 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: 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.

10.11.2 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.

ITEM DESCRIPTION QTY

1 Vertical 60/100mm Adaptor 1

2 Vertical Terminal 1

3 1m Extensions for required length 1

FIGURE 10. PLUME TERMINAL OUTLET DIMENSIONS

10.9 VERTICAL FLUE CONFIGURATION EXAMPLE

NOTE: Vertical Appliance adaptor is fitted as

part of the air heater. Can be fitted to the left or the right.

10.10 OPTIONAL ROOF OUTLETS

FLAT ROOF PITCHED ROOF

PITCHED ROOF PITCHED ROOF SIDE VIEW

500mm

Pitched

Roof

Weather

Collar

500mm

Flat Roof

Weather

Collar

20˚ to 50˚

Ridge

Terminal

Ridge

Terminal

Clamps

Flue Extensions

Vertical

Appliance

Adaptor

Adjustable

length

60/100mm

Adapter

Clamps

1140mm

Vertical

Terminal

1m Extension

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TABLE 5. DESCRIPTION COLOUR QTY APPLICATION PART No.

60/100 Standard Horizontal Flue Kit

White 1 Horizontal 1000-0020070

Turret White 1 Horizontal 1000-0020020

800mm Horizontal Terminal White 1 Horizontal 1000-0019830

Vertical Appliance Adaptor White 1 Vertical 1000-0024940

90° Elbow White 1 Horizontal & Vertical 1000-0018980

45° Elbow White 1 Horizontal & Vertical 1000-0018970

250mm Straight Extension White 1 Horizontal & Vertical 1000-0018960

500mm Straight Extension White 1 Horizontal & Vertical 1000-0018950

1000mm Straight Extension White 1 Horizontal & Vertical 1000-0018940

2000mm Straight Extension White 1 Horizontal & Vertical 1000-00025570

Flat Roof Weather Collar 1 Vertical 1000-0014900

Pitched Roof Collar Black 1 Vertical 1000-0014890

Ridge Terminal Terracotta 1 Horizontal & Vertical 1000-0021030

Wall Fixing Bracket 100mm 1 Horizontal & Vertical 1000-0014970

1140mm Vertical Terminal

White/Black

1 Vertical 1000-0015930

Plume Management Kit

Black 1 Horizontal & Vertical 1000-0020730

1000mm Extension Flue 60mm Black 1 Horizontal & Vertical 1000-0020740

90° Elbow 60mm Ø Black 1 Horizontal & Vertical 1000-0020680

45° Elbow 60mm Ø Black 2 Horizontal & Vertical 1000-0020670

Wall Fixing Bracket 60mm 1 Horizontal & Vertical 1000-0020770

Flexible Flue Kit 60/100mm Black 1 Flexible FFK5

Flexible Black Outer Pipe Black 1 Flexible 1000-0023410

Flexible Grey Inner Pipe Grey 1 Flexible 1000-0023420

Outer Rigid to Flex Adapter Grey 1 Flexible 1000-0023430

Inner Rigid to Flex Connector Grey 1 Flexible 1000-0023440

Outer Flex to Rigid Adapter Grey 1 Flexible 1000-0023450

Inner Flex to Rigid Connector Grey 1 Flexible 1000-0023460

Outer Seal Pipe Rings 2 Flexible 1000-0023470

Inner Seal Pipe Rings 2 Flexible 1000-0023480

Centralising Spacer Ring 1 Flexible 1000-0023490

Flue Support Kit 1 Flexible 1000-0023500

Draw Cone & Rope 1 Flexible 1000-0023510

Chimney Terminal Kit 60/100mm

Black 1 Vertical CTK-60/100

Skyline Terminal & Outer Flue Cowl Black 1 Vertical 1000-0023990

Locking Ring Grey 1 Vertical 1000-0026610

Flashing Ring Grey 1 Vertical 1000-0026660

Chimney Cover Plate 1 Vertical 1000-0026600

10.12 CONVENTIONAL 60/100mm FLUE ACCESSORY PARTS No

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FIGURE 12. CONDENSATE ROUTING OPTIONS

11. CONDENSATE PUMP & DRAIN TUBE

11.1 CONDENSATE PUMP

11.1.1 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.

11.1.2 DO NOT HANDLE PUMP IN WET CONDITIONS OR WITH WET HANDS

11.1.3 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

11.1.4 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.

11.1.5 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.

11.1.6 The tank pump uses small bore (6mm) flexible hose which can be

routed above or below doors, windows and under kitchen cabinets.

IMPORTANT: Ensure the condensate tube is protected and can

not freeze in an unheated area.

11.2 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 to under floor

to sink waste

NOTE:

10m MAXIMUM

HEAD LENGTH OF

CONDENSE TUBE

RESERVOIR

FL OAT

FILTER

FIGURE 11. CONDENSE PUMP

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FIGURE 13 FAN PERFORMANCE GRAPH

12. ELECTRICAL

12.1 The appliance is supplied with PVC sheathed, 3 core (Brown-Blue-Green/Yellow) 0.75mm2 CSA rated at 6A, connected to a terminal block and exiting through the casing at the top left hand front. The cable is suitable for a 230V 50Hz single phase supply.

12.2 The means of isolating the appliance MUST be via a double pole switch with a contact separation of at least 3mm in both poles, and fused at 3A. If switched live is fitted, a triple pole switch should be used.

12.3 A Thermista-stat is supplied with the unit, which is to be connected using PVC sheathed to BS 6500, 2 core

cable of 0.5mm

CSA rated at 3A, to terminals 29 & 30 on the PCB in accordance with Figure 52 and

observing correct polarity.

13. WARM AIR FAN PERFORMANCE

14. OPERATING MODES

14.1 Operating modes are covered in the User Instructions, ZZ1449 packed with the appliance, for both Domestic Hot Water and Central Heating.

14.2 For heating systems that include additional heating circuits e.g. radiators circuit instructions for use and installation will be provided within additional control packages provided.

14.3 For installations that include a solar water circuit to the domestic hot water cylinder instructions for use and installation will be provided within the solar heating kit.

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15. DOMESTIC HOT WATER HEATING COMMISSIONING

15.1 CHECK GAS INSTALLATION

15.1.1 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. In IE refer to IS.813.

15.1.2 Purge air from the gas installation by the approved methods only. PLEASE NOTE: The combustion for this appliance has been checked, adjusted and preset at the

factory for operation on the gas type defined on the appliance data plate. No measurement of the combustion is necessary. Do not adjust the air/gas ratio valve.

15.1.3 Having checked the heater has been installed in accordance with these instructions. The integrity

of the flue system and the flue seals, as described in the Flue Installation section. Proceed to put the boiler into operation as follows:

15.2 CHECK THE OPERATIONAL GAS INLET PRESSURE

15.2.1 Set up the heater to operate at maximum rate by opening hot tap to

maximum flow.

15.2.2 With the heat generator operating in the maximum rate condition check the

operational gas

pressure at the inlet gas pressure test point complies with

the requirements. See figure 13.

15.2.3 Ensure that this inlet pressure can be obtained with all other gas appliances

in the property working.

15.3 AIR PURGE FUNCTION

15.3.1 On initial power up an air purge cycle is initiated.

15.3.2 Ensure air bleed valve is open.

15.3.3 Ensure air bleed valve is open on initial power up and air purge cycle is

indicated.

15.3.4 During this function, heat demand is switched off and combustion fan will

run at maximum for 120 seconds.

15.3.5 Also at the same time, the circulation pump will be switched on for 5 seconds

and off for 5 seconds continuously.

15.3.6 Diverting 3 WV will be moved in CH position for the firsts 30 seconds, then in DHW

position for 30 seconds, then in CH position for 30 seconds and finally in DHW position for 30 seconds.

15.3.7 In this way, air is expelled from the circuit. On completion of this function normal

operation of the circulation pump will occur.

15.3.8 During the fan on period, there will be an indication on the LCD display:

15.3.9 Function can be skipped pressing K4 push button twice. This function can be activated by four conditions:

a. If the controller is plugged in to the Mains for the first time. b. After a manual reset to reset the lockout fault E03: High limit temperature protection. c. When the central heating water pressure is built up to the normal level after the fault F37 or fault

F40.

15.3.10 If there is no heat demand afterwards, the controller will switch to standby mode.

FIGURE 15.

AIR PURGE LED

READ OUT

FIGURE 16. LED DISPLAY FUNCTIONS

K7 K1

K6 K2

K3 K5

Item Description

+ Installer function only

- Installer function only

Installer information

Reset

Summer/Winter mode

15.5 RESET PROCEDURE - To reset boiler press the reset button ‘K4’ twice.

FIGURE 14.

GAS PRESSURE TEST POINT

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16. INITIAL LIGHTING

16.1.1 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 ow produced

by the fan. It is not user-adjustable. Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void.

16.1.2 Refit the boiler front panel. See paragraph 17.5.

16.1.3 Check that the electrical supply is OFF.

16.1.4 Check that the gas service cock is OPEN.

16.1.5 Slacken the screw in the inlet pressure test point and connect a gas pressure gauge via a flexible

tube.

16.1.6 Switch the electricity supply ON and check all external controls are OFF. The heat generator will

select ‘self purge’

16.2 WARM AIR CENTRAL HEATING

16.2.1 Set the CH temperature to maximum and switch on external control. The heat generator control

should now go through its ignition sequence until the burner is established.

16.2.2 If the heat generator does not light code E-01 will be displayed.

16.2.3 Reset the heat generator (see paragraph 15.5). The heat generator will repeat its ignition sequence.

If reset occurs 5 times within 15 minutes then F-15 will be shown. If power is removed this will be reset.

16.2.4 When the burner is established the display will show the ‘flame symbol’.

16.2.5 Ensure that the CH external controls are calling for heat. The burner should light.

16.2.6 Gas Rate: Check the heat generator gas rate when the heat generator is at full CH

output.

Check at the gas meter, with no other appliance in use. Refer to Tables 2 for gas rates.

16.2.7 Set the central heating external controls to OFF. The burner should go off and the

pump continue to run for two minutes

16.2.8 Check the correct operation of the timer (if fitted) and all other system controls. Operate each

control separately and check that the main burner responds.

16.3 WATER CIRCULATION SYSTEM

16.3.1 With the system still hot, turn off the gas, water and electricity supplies to the boiler and drain down

to complete the flushing process.

NOTE: A flushing solution should be used during the flushing procedure. Flushing solutions: Fernox

Superfloc, Sentinel X300 (new systems) or X400 (existing systems). Refer to paragraph 8.8.

16.3.2 Refill and vent the system, add inhibitor, clear all air locks and again check for water tightness.

16.3.3 Reset the system initial pressure to the design requirement.

16.4 BALANCE THE SYSTEM (if radiator system is tted)

16.4.1 The heat generator does not normally need a bypass but at least some radiators on the heating

circuit, of load of at least 10% of the minimum heat generator output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves.

NOTE: Systems incorporating zone valves which could completely cut off the flow through the system

must also include a bypass.

16.4.2 Check the condensate drain for leaks and check that it is discharging correctly.

16.4.3 Finally, set the controls to the User’s requirements. NOTE: The circulation pump will operate briefly as a self-check once every 24 hours in the absence of any

system demand.

16.5 CENTRAL HEATING WATER TEMPERATURES

Temperatures can be selected using the CH

thermostat See Table 5.

16.5.1 Set water differential to 20°C using lockshield

valve or equivalent.

16.5.2 Check fan stops when water cools to

minimum temperature.

TABLE 5.

Button Setting CH Flow Temperature °C

Max 80

Min

FIGURE 17.

LED READ OUT

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17. WARM AIR HEATING COMMISSIONING

17.1 Ensure the heater is correctly filled with water and all air vented from the flow and return circuits.

17.2 Switch on electrical supply.

17.3 Setting maximum speed.

a. Remove the PCB cover plate. b. Make a short across summer vent connections on the PCB interface and adjust the fan speed as

required using a small screw driver on the warm air PCB to turn the relevant pot. Remove the short.

17.4 Setting minimum fan speed.

a. Make a short across the pipe sensor or minimum fan adjustment of PCB interface and adjusted the fan

speed as required, using a small screw

driver on the warm air PCB to turn the relevant pot. Remove short.

17.5 WITH THERMISTA-STAT FITTED

17.5.1 Turn up thermista-stat to call for heat.

17.5.2 With the water at the required temperature ensure fan starts. (When the display shows 62° to 68°.)

17.5.3 Allow the system to warm up and check temperature rise across unit is 40°C.

17.5.4 Set water differential to 20°C using lockshield valve or equivalent.

17.5.5 Turn off thermista-stat and check there is NO 230V on switch live out.

17.5.6 Check fan stops when water cools to minimum temperature.

17.6 WITH NO THERMISTA-STAT FITTED

17.6.1 With the water at the required temperature ensure fan starts. (The display shows 62° to 68°.)

12.6.2 Allow the system to warm up and check temperature rise across unit is 40°C.

18. HANDING OVER

18.1 Hand the User Instructions to the householder and explain his/her responsibilities under the relevant national regulations.

18.2. Explain and demonstrate the lighting and shutting down procedures.

18.3 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. Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions.

18.4 Explain the function and the use of the boiler heating.

18.5 Explain the function of the heater fault mode. Emphasise that if a fault is indicated refer to “Fault Codes” in the User Guide.

18.6 Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system.

18.7 If a timer is fitted draw attention to the Users.

18.8 Explain heater reset procedure.

18.9 After installation and commissioning please complete the Commissioning Checklist before handover to the customer. For IE, its is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S.

813.

IMPORTANT:

18.10 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 (RGII).

18.11 Inform the householder of the guarantee/registration found within the folder pack and the requirement to register it to receive the full benefit of the warranty.

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FIGURE 18. SERVICING SEQUENCE

19. SERVICING & MAINTENANCE

19.1 SERVICING SCHEDULE

NOTE: It is a statutory requirement that ALL work is carried out by a “competent person” which in normal

circumstances would be a GAS SAFE registered engineer.

19.1.1 For the very latest copy of literature for servicing & maintenance instructions, visit our website www.johnsonandstarley.co.uk - where you can download the information.

WARNING. ALWAYS TURN OFF THE GAS SUPPLY AT THE GAS SERVICE COCK, AND SWITCH OFF AND

DISCONNECT THE ELECTRICITY SUPPLY TO THE APPLIANCE BEFORE SERVICING.

19.1.2 Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS 7927.

19.1.3 To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually.

19.1.4 It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be carried out by a Registered Gas Installer (RGII).

19.2 INITIAL INSPECTION

19.2.1 Light the heat generator and carry out a pre-service check, noting any operational faults.

19.2.2 Check the flue terminal (and terminal guard if fitted) is undamaged and clear of any obstruction.

19.2.3 Check all water and gas joints for signs of leakage. Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly refilled and vented.

19.3 SERVICING SEQUENCE

NOTE: In order to carry out either servicing or replacement

of components the heaters front panel must be removed. paragraph 19.5 & 19.10

19.3.1 Remove the combustion air fan (CAF) and clean. Check the main injector for blockage or damage.

19.3.2 Clean and check the main burner and electrodes.

19.3.3 Visually check the combustion chamber in the heat exchanger, removing any debris.

19.3.4 Remove the Air Circulation Fan (ACF), inspect and clean. For Air lter refer to 19.3.15

19.3.5 Inspect and clean the Air Heat Exchanger.

19.3.6 Remove and clean the condensate pump and condensate trap.

19.3.7 Remove and clean the air lter.

19.3.8 Check that the flue terminal is unobstructed and that the flue system is sealed correctly. See paragraph 19.4.

19.3.9 After completing the servicing or exchange of components always test for gas tightness.

19.3.10 When work is complete the front panel MUST be correctly refitted, ensuring that a good seal is made.

DO NOT OPERATE THE APPLIANCE IF THE FRONT PANEL IS

NOT FITTED.

19.3.11 Check the gas consumption.

19.3.12 Check combustion by connecting the flue gas analyser to the flue gas sampling point as shown in the diagram and measure CO & CO².

If the CO/CO² ratio is greater than 0.004 and the integrity of the

complete flue system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have been verified, then contact Johnson & Starley Ltd.

19.3.13 Once the service is complete, fill in the relevant section in the Benchmark Checklist located at the back of this book.

heat generator

air water heater

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FIGURE 2. CONTROL PANEL FIGURE 22. FILTER SCREWS & DOOR LUGS

FIGURE 19. FLUE GAS TEST POINTS

FIGURE 21. SWING DOWN CONTROL PANEL

GAINING ACCESS TO THE HOT WATER HEATER

(Upper Section)

19.5 AIR FILTER REMOVAL

19.5.1 The air filter is removed by sliding it out from the front of the unit.

19.5.2 Check that the air filter is being regularly cleaned in accordance with the User’s Instructions.

19.6 UPPER PANEL REMOVAL

19.6.1 To remove the upper panel remove the air filter.

19.6.2 Remove the two fixing screws, slacken the second two screws and

pull panel forward and swing open. Refit in reverse order.

19.6.3 To refit upper panel slide panel up into the two location lugs

reposition and replace the two screws.

19.7 CONTROL PANEL

19.7.1 Remove the air filter, upper door and lower door (see Paragraph

19.10) to access the control panel fixing screws.

19.7.2 Remove the 2 central fixing screw securing the control panel to the

diaphragm.

19.7.3 Slacken off the second 2 screws under the diaphragm, this will

allow the control panel to swing down.

19.7.4 Refit in reverse order.

19.4 FLUE INSPECTION & CHECKS

Please Note: During routine servicing, and after any maintenance or change of part

of the 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

• The operational (working) gas inlet pressure at maximum rate.

• The gas rate.

• The combustion performance.

Competence to carry out the check of combustion performance

Please Note: BS 6798 Specification for installation and maintenance of gas-fired boilers of rated input not

exceeding 70kW net advises that:

• The person carrying out a combustion measurement should have been assessed as competent in the

use of a flue gas analyser and the interpretation of the results.

19.4.1 After completing the servicing or exchange of components, always test for gas tightness and carry

out functional checks as described above.

19.4.2 When work is complete, check the condition of the sealing foam in the inside of the front doors

panels. When the door is refitted you must make ensure a good seal is made.

FLUE GAS

TEST POINTS

LOCATION

LUGS

FLUE GAS

TEST POINTS

FIXING

SCREWS

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FIGURE 26.

AIR CIRCULATION FAN

GAINING ACCESS FOR SERVICING THE HEAT GENERATOR

(Lower section)

19.11 LOWER PANEL REMOVAL

19.11.1 To remove the lower panel remove the air filter.

19.11.2 Remove the two fixing screws and pull panel forward and up to

remove.

19.11.3 To refit, slot panel back into position. Replace the two screws.

19.12 AIR CIRCULATION FAN

19.12.1 Remove the air filter and lower panel.

19.12.2 Disconnect the 2 inline connectors on the fan assembly.

19.12.3 Release the screws securing the fan and withdraw.

19.12.4 Remove all dust from both the impellor and motor and taking care

not to disturb the balance of the fan.

19.12.5 Refit or replacement is in reverse order.

19.8 COMBUSTION AIR FAN

Refer to paragraph 19.5 & 19.6

19.8.1 Disconnect the electrical leads from the fan.

19.8.2 Remove the pressure differential tube.

19.8.3 Remove the red securing clip and slide fan backwards off the

venturi.

19.8.4 Refit in reverse order.

19.9 BURNER ASSEMBLY

Refer to paragraphs 19.5 and 19.6

19.9.1 Remove the gas pipe securing clip from the venturi.

19.9.2 Remove the ignition/detection lead. See Figure 35.

19.9.3 Remove the 4 burner fixing nuts. See Figure 34.

19.9.4 Lift out the burner from the combustion chamber.

19.9.5 Brush off any deposits that may be on the burner with a soft brush.

Inspect the ignition/detection electrode and check the electrode gaps.

19.9.6 Inspect the sealing gasket around the burner for any signs of

damage. Replace if necessary.

19.9.7 Refit in reverse order.

19.10 WATER HEAT EXCHANGER

Refer to paragraphs 19.5 to 19.8.

19.10.1 Inspect the inside of the combustion chamber, with a soft brush

remove any deposits that may have occurred. Flush with clean water. DO NOT use any chemicals.

19.10.2 Inspect the heat exchangers insulation at the front and back of

the combustion chamber for any signs of damage, then it must be replaced.

19.10.3 If there are any signs of damage on the flue outlet then this must be

replaced.

19.10.4 Refit in reverse order.

FIGURE 25.

DOOR REMOVAL

FIXING

SCREWS

CLIP

ELECTRICAL

CONNECTION

FIGURE 24.

BURNER ARM & WATER HEAT EXCHANGER

FIXING

NUTS

FIGURE 23.

COMBUSTION AIR FAN REMOVAL

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FIGURE 29.

CONDENSATE PUMP & TRAP

19.13 AIR HEAT EXCHANGER

Refer to section 19.10

19.13.1 Peel back the magnetic panel to gain access into the air heat

exchanger.

19.13.2 Check the heat exchanger airways are free from obstructions. If

necessary, clean with a vacuum cleaner from the air inspection panel, taking care to not damage the airways.

CAUTION: THE ELEMENTS OF THE HEAT EXCHANGER ARE VERY FRAGILE.

19.13.3 Check the condition of the external strainer, cleaning as necessary.

19.14 CONDENSATE PUMP

Refer to section 19.10

19.14.1 Disconnect the mains.

a. Disconnect the condensate pipes. b. Unscrew the 2 screws on the bracket and slide the Condense

Pump out.

c. Be careful as this will contain water.

19.14.2 Check for debris in the pump tank. Remove any material that might

block the condense pipes or condense tube.

19.14.3 Clean the holding tank, filter and floats with warm water and soap.

Rinse completely when finished.

19.14.4 Check the inlet and outlet pipe

ensuring there are no restrictions in the tubing.

19.14.5 Check filter is in correct position

when refitting and the float is sitting in the correct position.

19.15 CONDENSATE TRAP

Refer to section 19.10

19.15.1 Remove the Air Circlulation Fan. See paragraph 19.11.

19.15.2 Pull off the rubber pipe noting the position.

19.15.3

Remove the trap and clean by removing the top cap and clean float.

19.15.4 Reassembly and refit in reverse order.

FIGURE 28.

AIR HEAT EXCHANGER

MAGNETIC

PANEL

FIGURE 27.

AIR HEAT EXCHANGER.

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FIGURE 32.

BURNER INJECTOR

CLIP

INJECTOR

‘O’ RING

IGNITION & FLAME

DETECTION

ELECTRODE

VIEWING

PORT

VENTURI/BURNER

INJECTOR

(behind Burner Arm)

BURNER

ARM

HEAT

EXCHANGER

FLUE GAS

SENSOR

FLOW & RETURN

SENSORS

COMBUSTION

AIR FAN

PCB BOARD

GAS

VALVE

PRESSURE

DIFFERENTIAL

TUBE

FIGURE 30.

CONTROL PANEL

20. PARTS REPLACEMENT

20.1 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.

20.1.1 All parts that are removed should be replaced and refitted in reverse order, ensuring correct seals

are made and wires are connected correctly.

20.1.2 Remove any debris from within the appliance.

20.1.3 When gas-carrying components are replaced the appliance must be tested for gas tightness.

20.1.4 On completion carry out a full functional test of all appliance components and ensure system

controls are operating correctly.

PART REPLACEMENTS WITHOUT DRAINING THE SYSTEM

20.2 CONTROL PANEL

Refer to paragraph 19.5 and 19.6.

20.2.1 Undo the back of the control panel and disconnect the wiring and unplug all lead connections.

20.2.2 Refit in reverse order.

20.2.3 Re-connect all wiring and plug connections.

20.3 BURNER INJECTOR

20.3.1 Refer to paragraph 19.5 and 19.6

20.3.2 Swing down control panel.

20.3.3 Remove the gas pipe securing clip from venturi. See Figure 36.

20.3.4 Undo the gas pipe union from the gas valve.

20.3.5 Withdraw gas pipe from venturi.

20.3.6 Remove injector from gas pipe.

20.3.7 Replace and refit in reverse order.

20.4 COMBUSTION AIR FAN

Refer to paragraph 19.5 and 19.6

20.4.1 Disconnect the electrical leads from the fan.

20.4.2 Remove the pressure differential tube.

20.4.3 Remove the red securing clip and slide fan backwards off the venturi.

20.4.4 Replace and refit in reverse order.

FIGURE 31. HOT WATER COMPARTMENT

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FIGURE 35. ELECTRODE GAP

FIGURE 36. GAS VALVE

FIGURE 34. THERMISTOR SENSOR

FIGURE 33. BURNER ASSEMBLY

20.5 BURNER ASSEMBLY

Refer to paragraph 19.5 and 19.6

20.5.1 Remove the gas pipe securing clip from the venturi.

20.5.2 Unclip the ignition/detection lead.

20.5.3 Remove the 4 burner fixing nuts.

20.5.4 Carefully lift out the burner from the combustion chamber.

20.5.5 Replace the sealing gasket around the burner.

20.5.6 Replace with new burner assembly.

20.5.7 Refit in reverse order.

20.6 FLOW & RETURN THERMISTOR SENSORS

20.6.1 Refer to paragraph 19.5

20.6.2 Unclip the flow thermistor at the front, from the flow pipe and disconnect

the red wire. Withdraw from the heater.

20.6.3 Unclip the return thermistor at the rear, from the return pipe and withdraw it

from the heater.

20.6.4 Disconnect the blue wires.

20.6.5 Reconnect the electrical leads to the new thermistors and re-assemble in

reverse order, ensuring that the thermistors are securely fitted to the pipes on the thermistor locator tabs as shown.

20.6.6 Check the operation of the heater. See Section 15.

20.7 IGNITION/DETECTION ELECTRODE

20.7.1 Refer to paragraph 19.5

20.7.2 Remove the 2 screws holding the ignition electrode to the combustion

chamber.

20.7.3 Remove the electrode.

20.7.4 Check dimensions as shown. Fit the new ignition electrode, using the new

gasket supplied.

20.7.5 Refit in reverse order.

20.7.6 Check the operation of the heater. See Section 15

20.8 GAS VALVE

20.8.1 Refer to paragraph 19.5 & 19.10.

20.8.2 Unplug the electrical lead and pressure differential tube connection from

the gas control valve.

20.8.3 Undo the union nut on the outlet of the gas control valve, rotate out of the

way.

20.8.4 Undo the gas inlet pipe union at the inlet to the gas control valve.

20.8.5 Remove screws retaining the valve to the diaphragm and lift the valve

forwards.

20.8.6 Fit the new gas control valve ensuring the two sealing washers are in place

and reconnect gas and electrical connections.

20.8.7 Check operation of the heater. See Section 15.

20.9 WARM AIR PCB

20.9.1 Refer to paragraph 19.5

20.9.2 Remove the PCB cover.

20.9.3 Disconnect the wiring at the PCB terminal block.

20.9.4 Release the 4 clips securing the PCB and withdraw the panel.

20.9.5 Replacement and refit is in reverse order.

20.10 PCB INTERFACE

20.10.1 Refer to paragraph 19.5

20.10.2 Remove the PCB box cover.

20.10.3 Unplug all lead connections to the PCB assembly

20.10.4 Disconnect all the wires.

20.10.5

Release the 4 corner clips securing the PCB and withdraw the panel.

20.10.6 Fit new PCB and re-connect all plug and wire connections.

20.10.7 Check operation of the

heater. See Section 15.

3.5mm ±1

FIGURE 37. PCB INTERFACE

CORNER

CLIPS

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FIGURE 40. AIR CIRCULATION FAN

20.11 AIR CIRCULATION FAN

Refer to paragraph 19.10.

20.11.1 Disconnect the 2 inline connectors on the fan assembly.

20.11.2 Release the screws securing the fan and withdraw.

20.11.3 Replace and refit in reverse order.

20.12 CONDENSATE PUMP

Refer to paragraph 19.10

20.12.1 Disconnect the mains

20.12.2 Disconnect the condensate pipes

20.12.3 Unscrew the 2 screws on the bracket and slide the condense

pump out.

20.12.4 Be careful as this will contain water.

20.12.5 Replace and refit in reverse order.

20.13 CONDENSATE TRAP

Refer to paragraph 19.10

20.13.1 Pull off the rubber pipe noting the position.

20.12.2 Unscrew the top pipe from the trap.

20.13.3 Unclip the trap and replace.

20.13.4 Refit in reverse order.

20.14 DIVERTER ACTUATOR HEAD

Refer to paragraph 19.10

20.14.1 Unplug the electrical connections.

20.14.2 Pull out the retaining clip and lift diverter head from body of the

valve.

20.14.3 Replace and refit in reverse order.

20.14.4 Check the operation of the appliance.

FIGURE 41. CONDENSATE PUMP & TRAP

FIGURE 42. DIVERTER HEAD REMOVAL

PUMP

FIGURE 38. PUMP/DIVERTER ASSEMBLY

WATER FLOW

TEMPERATURE

SENSOR

SCREW

FIGURE 39. AIR WATER HEATER COMPONENTS

AIR

CIRCULATION

FAN

AUTOMATIC AIR

VENT

AIR TO WATER

HEAT

EXCHANGER

GAS COCK

CONDENSE TRAP

(at the back)

DIVERTER

HEAD

DIVERTER

VALVE

DRAIN VALVE

RETURN FLOW FOR

RADIATORS

RADIATOR

CAPPED

FLOW PIPE

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FIGURE 45.

AIR TO WATER HEAT EXCHANGER REMOVAL

FIGURE 43.

PUMP HEAD REMOVAL

FIGURE 44.

AUTOMATIC AIR VENT REMOVAL

PART REPLACEMENTS BY DRAINING THE SYSTEM

20.15 DRAINING THE APPLIANCE

20.15.1 To drain the appliance, attach a length of hose to the drain point

then open the drain valve.

20.15.2 Replace the necessary component.

20.15.3 After replacement close the drain valve and open all isolation

valves and refill the system.

20.15.4 Ensure that all air locks are expelled, and check for water

soundness.

20.16 PUMP HEAD

Refer to paragraph 19.10. Drain appliance. See section 20.15.

20.16.1 Disconnect the electrical lead from the pump head.

20.16.2 Remove the 4 allen screws securing the pump head and remove.

20.16.3 The Red Dial on the pump head is set to maximim

20.16.4 Replace and refit in reverse order.

20.16.5 Refill and check operation of the appliance.

20.17 DIVERTER CARTRIDGE

Refer to paragraph 19.10 Drain appliance. See section 20.15.

20.17.1 Remove the diverter head.

20.17.2 Pull out the retaining clip and lift out the mechanism.

20.17.3 Replace and refit in reverse order.

20.17.4 Refill and check operation of the appliance.

20.18 AUTOMATIC AIR VENT

Refer to paragraph 19.10 Drain appliance See section 20.15.

20.18.1 Remove the air vent head clip and lift upwards

20.18.2 Replace and refit in reverse order.

20.18.3 Refill and a check operation of the appliance.

20.19 AIR HEAT EXCHANGER

Refer to paragraph 19.10 Drain appliance. See section 20.15.

20.19.1 Disconnect the water flow temperature sensor.

20.19.2 Release the flow and return pipe nuts to loosen off the pipe.

20.19.3 Release the clip and remove the heat exchanger by sliding it

forward.

NOTE: There will still be water in the heat exchanger.

20.19.4 Replacement and refit in reverse order.

20.19.5 Refill and check operation of the appliance.

SCREWS

CLIP

TEMPERATURE

SENSOR

RETAINING

CLIP

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21. FAULT FINDING FLOWCHARTS & BLOCKING CODES

Should a fault occur, the boiler will shut down and these error codes will be displayed.

There must be a link

between High Voltage

terminals 1 & 6 and high

voltage terminals 3 & 6.

Make sure both links are

present

MAF STAT CONNECTED NOT CALLING FOR HEAT (HEATER NOT FIRING) WHEN MAF STAT ON MAXIMUM

YES

Is there 230 ~ 250VAC across High Voltage terminals 2 & 4?

Is there 230 ~ 250VAC across High Voltage terminals 1 & 2?

Measure DC voltage (5.1V DC Max.) across Low Voltage terminals 3 & 4

Is measured voltage greater

than 4.7V

Is measured resistance

greater than 11K?

Is measured voltage greater

than 4.7V

Check pipe sensor and

connections. If sound, isolate

from mains & measure

resistance across plug J2 pins

5 & 6

Is measured voltage greater than 4.19V?

Is there an external clock fitted?

Measure DC voltage (5.1V

DC Max.) across Low Voltage

terminals 5 & 6

Check black wire of MAF stat goes to Low Voltage terminal 3 and red wire of MAF stat goes

to low voltage terminal 4. Ensure

all connections are sound

Check clock is on & measure

output

Check for live supply into clock.

Replace clock if live is present

Is 230 ~ 250VAC present?

Check harness connections

to PCB. If all OK Replace

PCB

Remove MAF stat connections and link Low Voltage terminals

TPV & 3. Is there 230 ~ 250VAC

across High Voltage terminals

2 & 4?

Open circuit between clock

out & High Voltage terminal

block 1

Unit mains

supply is

missing.

Check spur

e.g. fuse is

intact

Check

connections

to high

voltage

terminals

2 & 3

Problem with switched live output going from High Voltage terminal 3

to switch live of heater

Is there 230 ~ 250VAC across High Voltage terminals 2 & 3?

HOT WATER FAULT FINDING - BLOCKING CODES

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FAN NOT OPERATING WHEN PIPE IS ABOVE 60°C

YES

YES NO

YES

Check for mains going into fan plug

Measure DC voltage (0 to 10V) within Low Voltage fan connector

(blue & yellow)

Is measured voltage greater than 2V?

Check pipe and connections. If sound, isolate from mains &

measure resistance across plug

J2 pins 5 & 6

Does the actual pipe temp.

match the approx. pipe temp.

for the measured voltage in

Table 4?

Is measured resistance greater

than 11K?

Faulty fan

Faulty

PCB

Check sensor is fitted correctly. If

it is then replace sensor.

Faulty PCB

PCB is not seeing sensor.

Confirm by measuring sensor

resistance. Replace sensor if resistance is greater then

28K.

Make sure mains is present across High Voltage terminals 2 & 3

Is the MAF stat connected?

Is fan now running?

Link out low voltage terminals 3 & 4.

Measure voltage across

Low Voltage

terminals 5 & 6

Is measured voltage greater than 4.7V DC?

Make sure clock or room stat supplies mains voltage to high voltage

terminals 1 & 2. No mains - no fan operation (except for summer vent)

DC VOLTAGE

ACROSS PIPE

SENSOR

APPROX. PIPE

TEMP. °C

DC VOLTAGE

ACROSS PIPE

SENSOR

APPROX. PIPE

TEMP. °C

DC VOLTAGE

ACROSS PIPE

SENSOR

APPROX. PIPE

TEMP. °C

DC VOLTAGE

ACROSS PIPE

SENSOR

APPROX. PIPE

TEMP. °C

3.24 10 2.13

1.26 56 0.73

3.19 11 2.08 34 1.23 57 0.71 80

3.14 12 2.04 35 1.20 58 0.70 81

3.09 13 1.99 36 1.17 59 0.68 82

3.04 14 1.95 37 1.15 60 0.66 83

2.99 15 1.91 38 1.12 61 0.65 84

2.94 16 1.87 39 1.09 62 0.63 85

2.89 17 1.83 40 1.07 63 0.63 86

2.84 18 1.79 41 1.04 64 0.60 87

2.79 19 1.75 42 1.02 65 0.59 88

2.75 20 1.71 43 0.99 66 0.58 89

2.70 21 1.67 44 0.97 67 0.56 90

2.65 22 1.63 45 0.95 68 0.55 91

2.60 23 1.59 46 0.92 69 0.54 92

2.55 24 1.56 47 0.90 70 0.53 93

2.50 25 1.52 48 0.88 71 0.51 94

2.45 26 1.49 49 0.86 72 0.50 95

2.40 27 1.45 50 0.84 73 0.49 96

2.36 28 1.42 51 0.82 74 0.48 97

2.31 29 1.39 52 0.80 75 0.47 98

2.26 30 1.35 53 0.78 76 0.46 99

2.22 31 1.32 54 0.76 77 0.45 100

2.17 32 1.29 55 0.75 78 TABLE 6

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IGNITION LOCKOUT

OVERHEAT LOCKOUT

FALSE FLAME LOCKOUT

YESYES

YES

Check siphon and condensate drain pipe

work for blockage and rectify if necessary. Is

heater working?

Check routing and integrity of internal heater

wiring.

Check the gas supply

Check wiring connection from gas valve to

PCB for continuity. If the wiring is OK then

replace the PCB.

Replace the pump, the reset the heater.

Replace the gas valve

Replace board and harness as necessary.

Replace PCB and associated harness as

necessary.

YES

Check the pressure control pipe between fan and gas valve for continuity, visual condition,

replace as necessary. Is heater working?

Check the Flow & Return thermistors.

Check resistance using a suitable multi-meter

connection across the thermistor’s terminal

pins

RESET PROCEDURE

To reset the heater,

press the reset button.

Is the gas pressure available at the inlet

(>18mbar)?

Fill & vent the system & open all isolation

valves, then reset heater.

Check routing and integrity of the internal boiler

wiring is working OK. Check condition of the Flame

Sensor Electrode and replace if necessary.

Is approx 24 VDC supply available at the

gas valve?

Check that the pump is rotating freely. Is the

differential now below 20°C?

Replace flame detection electrode.

Unplug the gas valve. Is resistance between

outside pins 114Ω

Reset the heater.

Check board and associated harness for:

continuity and visual condition. Are these

functioning correctly?

Check ignition and associated harness for :

continuity visual condition and position. Are

these functioning correctly?

Replace the Gas Valve.

If the heater is reset does the heater ignite for

a short time and then extinguish?

Is the heater & CH system filled with water

and all isolation & radiator valves open?

Reset the heater. Is the heater working?

Check the detection electrode and associated

harness for: continuity, visual condition and

position. Check if the condensate pipe is

blocked. Replace if necessary.

Is the Flow/Return differential across the

heate

r in excess of 30°C?

Remove ignition lead and earth tag. Is

there continuity between the terminal pins

connected to the electrode?

Should a fault occur, the heater will shut down and these blocking codes will be displayed.

HOT WATER FAULT FINDING - BLOCKING CODES

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FAN FAULT

VALVE FEED BACK ERROR

FLAME CIRCUIT FAILURE

YES

Replace the Fan.

Rectify wiring & connections

Replace Gas Valve.

Replace the PCB.

Does the wiring from the fan to the PCB have secure connections at both

ends and has not deteriorated? Does the wiring have continuity?

Unplug the Gas Valve. Is there resistance between pins 114Ω.

Replace the PCB.

Is there 230Vac at the Blue Brown connections to the 3 way connection on

the fan

Replace Board.

FLOW/RETURN SENSOR CALIBRATION CHECK

EEPROM LOCKOUT

YES

Fill and vent the system and open all isolation

valves, check as supply, then reset heater

Replace the Sensor.

Is the heater & CH system filled with water & all isolation valves open?

Replace the PCB.

Reset the

heate

r. Is the heater working?

SENSOR STUCK LOCKOUT

YES

Check resistance at 2 different temperatures. See Graph Figure 46.

Replace the PCB.

Does the flow pipe temperature increase by more than 1°C within 30

seconds of ignition?

Fill and vent the system and open all isolation

valves, check as supply, then reset heater.

Secure Sensors and reset.

Replace Sensor.

Check pump is rotating.

Is the heater filled with water and all isolation valves open?

Are the sensors secured firmly to the flow and return pipes?

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ADC LOCKOUT

Replace the PCB.

RETURN THERMISTOR FAULT

YES

Replace the PCB.

Fit a new Thermistor.

Check and replace wiring as necessary.

Remove the return thermistor from the CH return pipe and disconnect the

wires.

Check the resistance using a suitable multi-meter connected across

the thermistor’s terminal pins. Is the thermistor valve correct?

Is the wiring securely connected to the low voltage 9 way connector X5 on

the PCB?

FLOW THERMISTOR FAULT

YES

Is the wiring securely connected to the low voltage 9 way connector X5 on

the PCB?

Securely connect the wiring to the flow Thermistor.

Fit new Thermistor.

Is the wiring securely connected to the Flow thermistor?

Disconnect the wiring from the Flow Thermistor.

Check the resistance using a suitable multi-meter connected across the

Thermistor’s terminal pins.

Is the Thermistor value correct?

Check & replace as necessary.

YES

Replace the PCB.

FIGURE 51. SENSOR TEMPERATURE/RESISTANCE DIAGRAM

5000

10000

15000

20000

25000

30000

0 20 40 60 80 100 120

Ohms

Sensor temperature/resistance diagram

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EXHAUST SENSOR FAULT

BLOCKING CODES

YES

Check wiring & connections to 9 way connector on PCB X5.

Replace PCB.

Fill and vent the system and open all isolation

valves, check as supply, then reset heater

Replace the flue thermistor.

Secure to PCB.

Is the heater & CH system filled with water and all isolation & radiator

valves open?

Check flue thermistor.

Check resistance using a suitable multi-meter

connection across the thermistor’s terminal pins. (Refer to graph on E03).

FLUE TEMPERATURE SENSOR LOCKOUT

YES

Is the wiring secure to 9 way connector X5 on Interface PCB

Replace the PCB

Connect the wiring.

Secure connection.

Is the wiring securely connected to sensor?

See graph Figure 51.

NO DISPLAY

YES

Replace the PCB

Supply power to heater.

Connect the wiring from the terminal block to the

Main PCB securely.

Is there 230VAC to the heater at L & N?

Is the wiring from the terminal block to the main PCB connected securely?

REMOTE RESET LOCKOUT

Turn power on and off, reset heater. The heater will correct original lockout

error.

VALVE FEED BACK ERROR

CONDENSATE PUMP SAFETY FLOAT SWITCH

YES

Correct electrical fault.

Check power supply.

Replace condense pump.

Is mains supply to heater between 190V - 256V @ 50 Hz?

Check power to the pump?

Replace PCB.

Check for any blockages, restrictions or frozen pipes.

Should a fault occur, the boiler will shut down and these blocking codes will be displayed.

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22. FUNCTIONAL WIRING DIAGRAMS

-ve

3 4

6 7 8

3 4

6 7 8

9 10

2223242526

2829303132

678

3 4

2 1

5 6

2 1

87654321

1211109

16151413 20191817

2 1

GAS VALVE

PIPE

SENSOR

(FLOW)

COMBUSTION

AIR FAN

NEXSYS PCB

AIR

CURCULATION

FAN

gnye

REMOVE LINK WIRES WHEN

REMOTE CLOCK FITTED

LABEL REF No. 1000-2222920-2

PIPE SENSOR

RETURN LINE

MIN FAN

ADJ

PIPE

SENSOR

CONDENSE

FLOAT

SWITCH

INTERFACE

PCB

CONDENSATE

PUMP

gnye

HT CONNECTOR

THERMAL

FUSE

MAINS

INPUT

PIPE

SENSOR

(RETURN)

CLEANFLOW

(optional)

AQUAIR PCB

PUMP/DIVERTER

VALVE

CONDENSING

HEAT EXCHANGER

FLUE

SENSOR

C18

X12

C11

C19

C14

C12

C16

EARTH

TAB

EARTH CHASSIS

VOLT FREE STAT

CYLINDER

STAT

MAF STAT

SUMMER

VENT

C10

C13

X11

SUMMER

VENT

CYLINDER

STAT

HW / SL

CH / SL

CLOCK

CONDENSE

PUMP

- MAF +

STAT

VOLT FREE

STAT

FIGURE 46. WARMCAIR C10DW COMBINED WIRING DIAGRAM

COLOUR

Red RD Brown BN

White WH Grey GY

Yellow YE Pink PK

Black BK Violet VT

Orange OG Green/Yellow GNYE

Blue BU

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23. DIMENSIONS

550

722

1350

1480

537

628

181

194

335

123

341

164

399

483

146

198

251

327

302

286

222

416

FIGURE 47. WARMCAIR C20DW COMBINED DIMENSIONS

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HOT WATER

FLOW FROM

HEAT SOURCE

HOT WATER RETURN FROM HEAT SOURCE

24. SPARES DIAGRAMS

FIGURE 48. WARMCAIR C10DW COMBINED EXPLODED DIAGRAMS

Sales/Spares & Replacement Help Line 01604 762881

ITEM DESCRIPTION QTY PART No. G. C. No.

PCB Nexsys Boiler Control

1000-0527185

J24-704

PCB Assembly (Aquair)

1000-0526275

J24-745

PCB Interface

1000-0527035

J21-741

PWM High Efciency Pump Head

Includes 5

1 1000-0531015

Pump Head Gasket

1 1000-1508935 J21-281

Burner Arm Assembly

Includes 7 - 11

1 1000-0711815 J21-311

Burner Arm Fibre Seal Braid Gasket

1 1000-1509000 J21-236

Burner Door Seal

1 1000-1509860 J21-237

Venturi Gasket

1 1000-1508630 J21-243

M5 Screws

2 1000-3003330 J21-244

M5 Nuts

2 1000-3003820 J21-238

Ignition/Detection Electrode

Includes 13 & 14

1 1000-0711785 J21-229

Electrode Gasket

1 1000-2501275 H38-677

M4 x 8 Torx Screws

2 1000-3003395 J21-240

Gas Valve

Includes 16 & 17

1 1000-0710925 J21-261

Sealing Washer

2 1000-3004280 J21-231

M4 X 10 Screws

2 1000-3000100

Combustion Air Fan

Includes 19

1 1000-0526415 J21-313

Combustion Air Fan Clip

1 1000-0711745 J21-245

Venturi (034)

Includes 9

1 1000-0710785 J21-671

25. LIST OF SPARES

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ITEM DESCRIPTION QTY PART No. G. C. No.

Injector (4.75)

Includes 22

1 1000-07111135 J21-234

‘O’ Ring

1 1000-2501860 J21-235

Air Circulation Fan

1000-0525255

J24-686

Flue Gas Sensor

1000-0526525

J21-253

Air To Water Heat Exchanger

AQ20-0138005

J24-

Condensate Pump

1000-0023085

J24-746

Condensate Trap

1000-0024525

J24-749

Return Water Temperature Sensor

(water to air heat exchanger)

1000-0526505

J24-758

Flow/Return Water Temperature Sensor

1000-0526515

J21-334

Air Filter

C20DW-0138005

J24-716

Sales/Spares & Replacement Help Line 01604 762881

26. LIST OF ANCILLARIES

WARMCAIR C10DW ANCILLARY’S

Description Product Code

Cleanow Air Filter

CF20W

2 Filter Replacement Pads

(Pack of 6)

A0212X0212

Return Air Kit

RAK20W

Base Duct Kit

WBX20W

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NOTES

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Code Of Practice

For the installation, commissioning and servicing of domestic heating and hot water products

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. Installers are required to carry out work in accordance with the following:

Standards of Work

• Be competent and qualiﬁed to undertake the work required.

• Install, commission, service and use products in accordance with the manufacturer’s instructions provided.

• Ensure that where there is responsibility for design work, the installation is correctly sized and ﬁt for purpose.

• Meet the requirements of the appropriate Building Regulations. Where this involves notiﬁable work be a member of a Competent Persons Scheme or conﬁrm that the customer has notiﬁed Local Authority Building Control (LABC), prior to work commencing.

• Complete all relevant sections of the Benchmark Checklist/Service Record when carrying out commissioning or servicing of a product or system.

• Ensure that the product or system is left in a safe condition and, whenever possible, in good working order.

• Highlight to the customer any remedial or improvement work identiﬁed during the course of commissioning or servicing work.

• Refer to the manufacturer’s helpline where assistance is needed.

• Report product faults and concerns to the manufacturer in a timely manner.

Customer Service

• Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request.

• Give a full and clear explanation/demonstration of the product or system and its operation to the customer.

• Hand over the manufacturer’s instructions, including the Benchmark Checklist, to the customer on completion of an installation.

• Obtain the customer’s signature, on the Benchmark Checklist, to conﬁrm satisfactory demonstration and receipt of manufacturer’s instructions.

• Advise the customer that regular product servicing is needed, in line with manufacturers’ recommendations, to ensure that safety and efﬁciency is maintained.

• Respond promptly to calls from a customer following completion of work, providing advice and assistance by phone and, if necessary, visiting the customer.

• Rectify any installation problems at no cost to the customer during the installer’s guarantee period.

* The use of the word “installer” is not limited to installation itself and covers

those carrying out installation, commissioning and/or servicing of heating and hot water products, or the use of supporting products (such as water treatment or test equipment).

**Customer includes householders, landlords and tenants.

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This Commissioning Checklist is to be completed in full by the competent person who commissioned the wsnn air unit and associated equipment as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference

Failure to Install and commission this equipment to the manufacturer's instructions may Invalidate the warranty but does not affect statutory rights.

CONDENSING WARM AIR HEATING AND WATER HEATING COMMISSIONING CHECKLIST

Customer name: Telephone number:

Address:

Warm Air Unit Make and Model:

Warm Air Unit Serial Number:

Commissioned by (PRINT NAME): Gas safe register number:

Company name: Telephone number:

Company address:

Commissioning date:

CONTROLS (tick the appropriate boxes)

Time and temperature control to heating

Room thermostat and programmer/timer Programmable Roomstat

Load/weather compensation Optimum start control

Heating zone control Fitted Not required

WARM AIR HEATER

Has the system been balanced in accordance with the heater manufacture's instructions? Yes No

Was an anemometer used? Yes No

Yes No

WARM AIR HEATING: measure and record:

Bumer operating pressure (at maximum rate) mbar

Heat input kW

Temperature difference between return air inlet and nearest outlet °C

WATER HEATING: (If fitted)

Water inlet temperature

Water outlet temperature

°C

CONDENSATE

The condensate drain has been installed in accordance with the manufacture's instructions and/or BS 5546/BS6798 Yes

INSTALLATION

The heating and hot water system complies with the appropriate Building Regulations Yes

The system and associated products have been installed and commissioned in accordance with the manufacturers instructions Yes

Yes

The manufacturer's literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

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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 RECORD

SERVICE 01

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 02

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 03

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 04

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 05

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 06

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 07

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 08

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 09

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

SERVICE 10

Date:

Engineer name:

Company name:

Telephone No:

Gas safe register No:

Record:

At max. rate: CO ppm AND CO² %

At min. rate:

(Where Possible) CO ppm AND CO

Comments:

Signature

*All installations in England and Wales must be

to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

Johnson & Starley Ltd

Rhosili Road, Brackmills, Northampton NN4 7LZ

sales@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk

Reception/Customer Service

01604 762881

Fax

01604 767408

Anniversary 1922 - 2012

Johnson & Starley WARMCAIR C20DW, WARMCAIR C16DW, WARMCAIR C10DW Installation, Commissioning & Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual