Johnson & Starley WARMCAIR C10D User guide

www.johnsonandstarley.co.uk

INSTALLATION, COMMISSIONING

& SERVICING INSTRUCTIONS

WARMCAIR C10D

Condensing Air Heater

High Efciency Downow

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

www.johnsonandstarley.co.uk

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

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

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3. BUILDING STANDARDS & REGULATIONS

Installation shall be in accordance with the current editions of:-

 • BuildingStandards(Scotland)(Consolidation)Regulations

 • BuildingRegulations

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

 • BS7671InstituteofElectricalEngineers(I.E.E.)WiringRegulations

 • BS6891InstallationofLowPressureGasPipeworkofupto28mm(R1)indomesticpremises

(2nd family gases).

 • BS5440Pt.1(FluesforGasAppliances)

 • BS5440Pt.2(AirSupplyforGasAppliances)

 • BS5864InstallationofGasFiredDuctedAirHeaters

 • BritishSystemDesignManual“GasFiredWarmAirHeating”

 • ModelandLocalAuthorityBye-laws

 • EN1196SupplementaryInstructions-CondensingAirHeaters

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

Sales/Spares 01604 707012 Replacement Help Line 01604 707011

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 I2 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 900cm2 (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 0.0088m2/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.

8.2 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 self-

adhesive foam strip, ducting tape or sealing compound. All ducting and blanking plates must be

mechanically secured and sealed.

Sales/Spares 01604 707012 Replacement Help Line 01604 707011

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 sys-

tems according to EU Directive 2009/142/EC on gas-fired devices. These installation instructions are cov-

ered 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 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

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

D, E

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

Sales/Spares 01604 707012 Replacement Help Line 01604 707011

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

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 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.

  1x90˚Elbow+12metresstraight

  2x90˚Elbow+10metresstraight

  3x90˚Elbow+8metresstraight

  4x90˚Elbow+6metresstraight

 Whenusing45˚elbows

  1x90˚Elbowisequivalentto2x45˚Elbows

ITEM DESCRIPTION QTY PARTS INCLUDED APPLICATION PART No.

1 HORIZONTAL TERMINAL WHITE

1800mm Horizontal Terminal

Horizontal 1000-0019830

1Inside Wall Cover Plate

1Outside Wall Cover Plate

245˚ ELBOW WHITE 1Elbow

Horizontal + Vertical

1000-0018980

390˚ ELBOW WHITE 1Elbow

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

1Support 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 1Support Bracket

Horizontal

1000-0020770

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