WARMCAIR C16DW INSTALLATION INSTRUCTIONS

WARMCAIR C16DW

Condensing Air & Water Heater

High Effi ciency Downfl ow

Publication No. ZZ 1447

July 2014

INSTALLATION, COMMISSIONING

& SERVICING INSTRUCTIONS

NG

WarmCair C16DW

- G.C. No. 43-417-60

These instructions are to be left with the User

www.johnsonandstarley.co.uk

CONTENTS

The Benchmark Scheme

3

4

Building Standards & Regulations

Safety, Gas & Water Information

7 Heater Compartment Clearances

11

13

15

17

19

21

22

Condensate Drain & Drain Tube

Warm Air Fan Performance

Domestic Hot Water Commissioning

Warm Air Heating Commissioning

Servicing & Maintenance

Fault Finding Flowcharts & Blocking Codes

Functional Wiring Diagrams

25 List of Spares

22

26

32

33

16

17

17

18

34

35

36

37

14

14

14

15

9

13

7

7

6

6

4

5

3

4

2

3

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE

STARTING INSTALLATION. LEAVE THESE INSTRUCTION WITH

THE USER OR AT THE GAS METER AFTER INSTALLATION

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.


2

1. FEATURES

Appliance Classification:

The WarmCaire C16DW has been tested and CE certified by B.S.I Ltd for use with

NATURAL gas G20.

FEATURES

1. Flue

2. Flue Test Point

3. Inspection Glass

4. Ignition Detection Electrode

6. Flow & Return Sensors

7. Pressure Differential Tube

12. Circulation Fan

14. Return Water Temperature Sensor

15. Heat Exchanger (Warm Air)

20. Condensate Drain Tube

21. Electronic Air Filter & LED

23. Combustion Fan

24. Warm Air PCB

25. Heat Generator (water)

1

2

3

4

5

6

7

8

9

10

11

12

13

FIGURE 1. CONTROL PANEL

2.1

2.2

2.3

The WarmCair C16DW 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, enabling it to provide a warm air heat output of 16.0kW and hot water output of 24.2kW 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 C16DW combinds air heater is ideally suited for new built dwellings and the replacement of existing non-condensing air heaters. For Indirect system applications only.

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

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.

Sales/Spares 01604 707012 Replacement Help Line 01604 707011

17

16

15

14

26

25

20

19

18

24

23

22

21

3

3. BUILDING STANDARDS & REGULATIONS

This appliance must be installed by a Gas Safe Registered Engineer in accordance with the current editions of:

• Building Standards (Scotland) (Consolidation) Regulations

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

• The Water Fittings Regulations or Water byelaws in Scotland

• Model and Local Authority Byelaws

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

• Effi 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

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

BS 5440:1

BS 5440:2

Flues (for gas appliances of rated input not exceeding 70 kW).

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

Health & Safety Document No. 635.

The Electricity at Work Regulations, 1989.

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

Tel: 01604 762881.

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

* When a radiator system is also connected.

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 boiler 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.

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

IMPORTANT: 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.

4. SAFETY, GAS & WATER INFORMATION

4.1 SAFETY INFORMATION

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

4.2

4.3

4.4

All wiring must be in accordance with the appropriate standards. The equipment must be supplied with a double pole isolator switch.

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

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.

4.5

4.6

4.7

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

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

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


4.2 GAS SUPPLY

4.2.1 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.

4.2.2 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).

4.2.3 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.

4.3 WATER SUPPLY

4.3.1 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.

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

3

2.5

2

1.5

1

0.5

0

0.0 0.5 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0

heat input to heater (kW)

FIGURE 2. GAS COCK PRESSURE DROP

TABLE 1

Maximum weight lift

Gas supply

Gas connection

Gas Injector size

Heating flow and return

Flue terminal diameter

Condense drain

Electrical supply

Electrical rating

External fuse rating

WARM AIR HEATING

Nominal Rated Output

Air on Temperature

Air off Temperature

Water Supply Temperature

Water Return Temperature

Water Flow Rate

Air Volume

Sales/Spares 01604 707012 Replacement Help Line 01604 707011 kg mbar mm mm mm mm mm

V ~ Hz

W

A kW

˚C

˚C

˚C

˚C l/s m³/h

C16DW

76.5

2H - G20 - 20mbar

15mm copper

4.75mm

22mm copper

100mm (4”)

6mm ID

230V ~ 50Hz

215

3

72

0.5

938

15

20

67

80

5

TABLE 2.

PERFORMANCE DATA

Burner CO² (%) case off case on

MAXIMUM

9.4

9.6

C16DW

MINIMUM

8.5

8.7

± 0.5

PERFORMANCE DATA FOR WATER HEATING

Input Q

Net

Gross

Gas Consumption

Output

Seasonal Effi ciency

Non condensing

Condensing

SEDBUK 2005

SEDBUK 2009

NOx Classifi cation

Central Heating set point temperature range kW kW m³/h kW kW

24

26.6

2.48

23.4

25.6

A

89.6

CLASS 5 34mg/kWh

20 - 82°C

4.7

5.21

0.48

5.17

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

6.1

6.2

6.3

6.4

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.

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).

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.

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.

This appliance must be completely level. It MUST NOT lean in any direction. This will cause problems with the condense draining.

7.

7.1

7.2

HEATER COMPARTMENT CLEARANCES

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.

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.


7.6

7.7

7.8

7.3

7.4

7.5

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.

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).

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.

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.

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!

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

(See British Design Manual - Gas fired Warm Air Heating)

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 1400cm 2 (217in 2 ). 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 0.0088m

2 /kW (1in 2 /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.

9.1

9.2

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.

ADDITIONAL RADIATOR SYSTEM IF FITTED

9.2.1 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.

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.


7

FIGURE 3. WATER FLOW SCHEMATIC

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.

9.5.3 Minimum head must be achieved.

9.5.4 If there is no minimum head achieved, use a Johnson &

Starley seal system kit.


9.4 WATER t 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 and in accordance with the Benchmark Guidance Notes on

Water Treatment in Central Heating Systems.

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.

FIGURE 4. HOT WATER SYSTEM SCHEMATIC

8

10. FLUE

10.1 The WarmCair C16DW 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

10.4

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.

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 C16DW.

i) ii)

The standard concentric flue system 60/100 (100mm diameter)

A Flexible flue kit (FFK 5) 60/100mm (100mm diameter) For further information contact the sale office at Johnson & Starley Ltd. Telephone 01604 707000

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 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, 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.

19mm

100mm

FIGURE 5. HORIZONTAL TERMINAL DIMENSIONS & POSITION


9

FIGURE 6. TERMINAL POSITIONS

F

G

H

D

E

TABLE 3

A

B

C

N

Q

P

R

K

M

I

J

TERMINAL POSITION

Directly below an opening, air brick, opening window etc

Above an opening, air brick, opening window, etc.

Horizontally to an opening, air brick, opening window etc.

Below gutters, soil pipes or drain pipes.

Below eaves.

Below balconies.

From a vertical drain pipe or soil pipe.

From an internal or external corner. Greater than 450mm protrusion.

Above ground, roof or balcony level.

From a surface facing the terminal.

From a terminal facing the terminal.

Vertically from a terminal on the same wall.

Horizontally from a terminal on the same wall.

Above intersection with roof.

From a vertical structure on the roof

From the terminal to the boundary www.johnsonandstarley.co.uk

MINIMUM DISTANCE

300mm

300mm

300mm

75mm

200mm

200mm

150mm

300mm

300mm

600mm

1,200mm

1,500mm

300mm

530mm

300mm

300mm

10

10.7 PLUME TERMINAL OUTLETS

10.7.1 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 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.

10.7.2 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.

FIGURE 7. PLUME TERMINAL OUTLET DIMENSIONS

10.8 TYPICAL FLUE CONFIGURATIONS

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

VERTICAL FLUE

Vertical Appliance Adaptor

Required Extension Lengths

Vertical Terminal

90˚ Elbow

FIGURE 8. EXTENDED HORIZONTAL REAR FLUE


FIGURE 9. VERTICAL FLUE

11

10.9 FLUE REQUIREMENTS & GENERAL INFORMATION

10.9.1 Horizontal and vertical concentric flues (60/100mm diameter) with balanced terminals may be installed on all the WarmCair C16DW appliance.

10.9.2 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 5 for relevant part numbers.

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

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

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

10.9.6 Guidelines for the maximum flue length are as follows.

HORIZONTAL FLUE

Turret + 10 metres straight

Turret + 1 X 90° Elbow + 8 metres straight



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

10.10 CONVENTIONAL 60/100mm FLUE ACCESSORY PARTS No

6

7

4

5

TABLE 4 DESCRIPTION

1 60/100 Standard horizontal flue kit

2

3

Turret

800mm Horizontal Terminal

Vertical Appliance Adaptor

45° Elbow

90° Elbow

250mm Straight Extension

8

9



10 2000mm Straight Extension

11 Flat Roof Weather Collar

12 Pitched Roof Collar

13 Ridge Terminal

14 Wall Fixing Bracket 100mm

15 1140mm Vertical Terminal

16 Plume Management Kit

17 1000mm Extension Flue 60mm

18 90° Elbow 60mm Ø

19 45° Elbow 60mm Ø

20 Wall Fixing Bracket 60mm

Black

Terracotta

1

1

1

1

1

1

1

1

1

1

1

1

1

QTY

1

White

White

White

White

COLOUR

White

White

White

White

White

White

Black

Black

Black

Black

1

1

1

1

2

1

APPLICATION

Horizontal

Horizontal

Horizontal

Vertical

Horizontal & Vertical






Vertical

Vertical



Vertical






PART No.

1000-0020070

1000-0020020

1000-0019830

1000-0018990

1000-0018980

1000-0018970

1000-0018960

1000-0018950

1000-0018940

1000-0025570

1000-0020060

1000-0020030

1000-0021030

1000-0018930

1000-0020740

1000-0020730

1000-0020740

1000-0020680

1000-0020670

1000-0020770 www.johnsonandstarley.co.uk

12

11. CONDENSATE PUMP & DRAIN TUBE

11.1.1 Supplied with 6mm x 10m condense tube. Condense adapter and 2 x clips on.

11.1.2 DO NOT HANDLE PUMP IN WET CONDITIONS OR WITH WET HANDS a) b) c) d)

Tank capacity : 0.5L

High level safety cut out

Outlet size 6mm I.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.

11.2 CONDENSE TUBE ROUTING OPTIONS

Option A.

Option B.

Option C.

Option D.

RESERVOIR

FILTER

FLOAT

FIGURE 10. CONDENSE PUMP

A

NOTE:

10m MAXIMUM

HEAD LENGTH OF

CONDENSE TUBE


D

C

B

13

12. ELECTRICAL

12.1

12.2

12.3

The appliance is supplied with PVC sheathed, 3 core (Brown-Blue-Green/Yellow) 0.75mm

2 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.

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.

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

2 csa rated at 3A, to terminals 3 & 4 on the PCB in accordance with Figure52 and observing correct polarity.

13. WARM AIR FAN PERFORMANCE

FIGURE 12. FAN PERFORMANCE GRAPH

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 heating circuit to the domestic hot water cylinder instructions for use and installation will be provided within the solar heating kit.


14

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.

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.

FIGURE 13.

GAS PRESSURE TEST POINT

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.

FIGURE 14

AIR PURGE LED

READ OUT 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.

15.5 RESET

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

Item

K1

K2

K3

K4

K5

K6

K7

Description

+ Installer function only

- Installer function only

Installer information

-

-

Reset

Summer/Winter mode

K7

K6

K3

K4

K1

K2

K5

FIGURE 15. LED DISPLAY FUNCTIONS


15

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 fl 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.

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.

FIGURE 16.

LED READ OUT

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 fi 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.

r

16.5.2 Check fan stops when water cools to minimum temperature.

m

Button Setting

Max

Min

TABLE 5.

CH Flow Temperature °C

80

45 www.johnsonandstarley.co.uk

16

17. WARM AIR HEATING COMMISSIONING

17.1

17.2

17.3

17.4

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

Switch on electrical supply.

Setting maximum speed.

a. Remove the PCB cover plate.

b. Make a short across thermista-stat 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.

Setting minimum fan speed.

a. Make a short across the pipe sensor 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 Check for 230V on switch live out.

17.5.3 With the water at the required temperature ensure fan starts

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

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

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

17.5.7 Check fan stops when water cools to minimum temperature.

17.6 WITH NO THERMISTA-STAT FITTED

17.6.3 With the water at the required temperature ensure fan starts

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

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.

18.9 Explain heater reset procedure.

18.10 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:

18.11 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).


17

19. SERVICING & MAINTENANCE

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).

heat generator

2

3

4

5

6

7

1

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.

3

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 fi 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 condeate trap.

19.3.7 Remove and clean the air fi 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.

2

1

7

air water heater

FIGURE 17. SERVICING SEQUENCE www.johnsonandstarley.co.uk

4

6

5

18

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

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:

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

FIGURE 18. FLUE GAS TEST POINTS

servicing the heat generator

GAINING ACCESS TO THE HOT WATER HEATER

(Top section)

19.5 UPPER PANEL REMOVAL

19.5.1 To remove the upper panel remove the air filter.

19.5.2 Remove the two fixing screws and pull panel forward and remove.

19.5.3 To refit slide panel up into the two location lugs reposition and replace the two screws.

LOCATION

LUGS

FIXING

SCREWS

FIGURE 19. DOOR REMOVAL

19.6.1 Remove the air filter and unscrew the 2 fixing screws on the upper panel. Remove the door.

19.6.2 Remove the 2 fixing screw on the lower panel. Remove the door.

19.6.3 Slacken off the 2 screws under the diaphram and swing the control panel down.

FIGURE 20. OPENING CONTROL PANEL


19

19.7 COMBUSTION AIR FAN

Refer to paragraph 19.5 & 19.6

17.7.1 Disconnect the electrical leads from the fan.

17.7.3 Remove the pressure differential tube.

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

17.7.3 Refit in reverse order.

Refer to paragraphs 19.5 and 19.6

19.8.1 Remove the gas pipe securing clip from the venturi.

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

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

19.8.4 Lift out the burner from the combustion chamber.

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

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

19.8.6 Inspect the sealing gasket around the burner for any signs of damage.

Replace if necessary.


19.9 WATER HEAT EXCHANGER

Refer to paragraphs 19.5 to 19.8.

19.9.1 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.

19.9.2 Inspect the heat exchangers insulation at the front and back of the combustion chamber for any signs of damage, then it must be replaced.

19.9.3 If there are any signs of damage on the flue outlet then this must be replaced.


CLIP

ELECTRICAL

CONNECTION

FIGURE 21. FAN REMOVAL

FIXING

NUTS

FIGURE 22. BURNER ARM &

WATER HEAT EXCHANGER

servicing the warm air heating

GAINING ACCESS FOR SERVICING THE HEAT GENERATOR

(Lower section)

19.10 LOWER PANEL REMOVAL

19.10.1 To remove the lower panel remove the air filter.

19.10.2 Remove the two fixing screws and pull panel forward and up to remove.

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

FIXING

SCREWS

19.11 AIR CIRCULATION FAN

19.11.1 Remove the air filter and lower panel.

19.11.2 Disconnect the 2 inline connectors on the fan assembly.

19.11.3 Release the screws securing the fan and withdraw.

19.11.4 Remove all dust from both the impellor and motor and taking care not to disturb the balance of the fan.

19.11.5 Refit or replacement is in reverse order.

FIGURE 23. DOOR REMOVAL

FIGURE 24. AIR CIRCULATION FAN www.johnsonandstarley.co.uk

20

19.12 AIR HEAT EXCHANGER

Refer to section 19.10

19.12.1 Peel back the magnetic panel to gain access into the air heat exchanger.

19.12.2 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.

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


19.13.1 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.

19.13.2 Check for debris in the pump tank. Remove any material that might block the condense pipes or condense tube.

19.13.3 Clean the holding tank, filter and floats with warm water and soap. Rinse completely when finished.

19.13.4 Check the inlet and outlet pipe ensuring there are no restrictions in the tubing.

19.13.5 Check filter is in correct position when refitting and the float is sitting in the correct position.

FIGURE 25. AIR HEAT EXCHANGER.

FIGURE 26. CONDENSATE PUMP


19.14.1 Pull off the rubber pipe noting the position.

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

19.14.3 Reassembly and refit in reverse order.

19.15 AIR FILTER REMOVAL

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

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

FIGURE 27. CONDENSATE TRAP


21

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.

FLUE

TEMPERATURE

SENSOR

HEAT

GENERATOR


BURNER

ARM

BURNER

INJECTOR

IGNITION & FLAME

DETECTION

ELECTRODE

COMBUSTION

AIR FAN

FLOW & RETURN

SENSORS

hot water heater compartment

GAS

VALVE

FIGURE 29. HOT WATER COMPARTMENT

PART REPLACEMENTS WITHOUT DRAINING THE SYSTEM

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.


20.2.3 Re-connect all wiring and plug connections.

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

CLIP

INJECTOR

‘O’ RING

FIGURE 30. BURNER INJECTOR www.johnsonandstarley.co.uk

22

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.


Refer to paragraph 19.5 and 19.6

20.5.1 Remove the gas pipe securing clip from the venturi.

20.5.2 Remove the ignition/detection lead. Refer to paragraph 20.7.

20.5.3 Remove the 4 burner fixing nuts.

20.5.4 Lift out the burner from the combustion chamber.

20.5.5 Replace with new burner assembly.

20.5.6 Replace the sealing gasket around the burner.


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.

FIGURE 31. BURNER ASSEMBLY


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.


20.7.6 Check the operation of the heater. See Section 15

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 diaphram 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


20.9.2 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.

3.5mm ±1

FIGURE 33. ELECTRODE GAP

FIGURE 34. GAS VALVE


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.

CORNER CLIPS

FIGURE 35. PCB INTERFACE


23

AUTOMATIC AIR

VENT

SPEED

SELECTOR

CONDENSE

TAP

GAS

COCK

DIVERTER

HEAD

AIR

CIRCULATION

FAN

PUMP

HEAD

DIVERTER

VALVE


SPEED

SELECTOR

air water heater compartment

DRAIN

VALVE

PUMP

AIR TO

WATER

HEAT

EXCHANGER

WATER FLOW

TEMPERATURE

SENSOR

FIGURE 36. AIR WATER HEATER COMPONENTS

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.


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.


FIGURE 37. AIR CIRCULATION FAN


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.


20.14 DIVERTER ACTUATOR HEAD


20.14.1 Unplug the electrical connections.

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


FIGURE 38. CONDENSATE PUMP

FIGURE 39. CONDENSATE TRAP www.johnsonandstarley.co.uk

24

20.14.4 Check the operation of the appliance.

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 refil the system.

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

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.


20.16.4 Refil and check operation of the appliance.

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.



20.18 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


20.18.3 Refil 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.


FIGURE 40. PUMP HEAD

FIGURE 41. DIVERTER CARTRIDGE

FIGURE 42. AUTOMATIC AIR VENT

FIGURE 43. AIR CIRCULATION FAN


25

21. FAULT FINDING FLOWCHARTS & BLOCKING CODES

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

HOT WATER FAULT FINDING - BLOCKING CODES

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

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

YES

Problem with switched live output going from High Voltage terminal 3 to switch live of heater

NO


YES

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

Is measured voltage greater than 4.19V?

NO


YES

Is there an external clock fitted?

YES

Check clock is on & measure output

NO

There must be a link between High Voltage terminals 1 & 6 and high voltage terminals 3 & 6.

Make sure both links are present

NO

Unit mains supply is missing.

Check spur e.g. fuse is intact

Check connections to high voltage terminals

2 & 3

NO

Measure DC voltage (5.1V DC

Max.) across Low Voltage terminals 5 & 6

Is measured voltage greater than 4.7V

YES

Is measured voltage greater than 4.7V

YES

Check pipe sensor and connections. If sound, isolate from mains & measure resistance across plug J2 pins

5 & 6

YES

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

NO

Check harness connections to PCB. If all OK Replace

PCB

NO

NO

Is measured resistance greater than 11K?

Is 230 ~ 250VAC present?

NO

Check for live supply into clock.

Replace clock if live is present

YES

Open circuit between clock out & High Voltage terminal block 1

Remove MAF stat connections and link Low Voltage terminals

TPV & 3. Is there 230 ~ 250VAC across High Voltage terminals

2 & 4?


26

FAN NOT OPERATING WHEN PIPE IS ABOVE 60°C

Is the MAF stat connected?

YES

Link out low voltage terminals 3 & 4.

Make sure clock or room stat supplies mains voltage to high voltage terminals 1 & 2. No mains - no fan operation (except for summer vent)

Is fan now running?

YES

Measure voltage across Low Voltage terminals 5 & 6

NO

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

Check for mains going into fan plug

Is measured voltage greater than 4.7V DC?

YES

Check pipe and connections.

If sound, isolate from mains

& measure resistance across plug J2 pins 5 & 6

NO

Does the actual pipe temp. match the approx. pipe temp. for the measured voltage in

Table A?

Is measured resistance greater than 11K?

NO

Check sensor is fitted correctly.

If it is then replace sensor.

YES

Faulty

PCB

PCB is not seeing sensor.

Confirm by measuring sensor resistance. Replace sensor if resistance is greater then 28K.

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

(blue & yellow)

Is measured voltage greater than 2V?

YES

Faulty fan

NO

Faulty PCB

APPROX. PIPE

TEMP.

°C

18

19

20

21

15

16

17

10

11

12

13

14

30

31

32

27

28

29

22

23

24

25

26

DC VOLTAGE

ACROSS PIPE

SENSOR

2.99

2.94

2.89

2.84

2.79

2.75

2.70

3.24

3.19

3.14

3.09

3.04

2.40

2.36

2.31

2.26

2.22

2.17

2.65

2.60

2.55

2.50

2.45

DC VOLTAGE

ACROSS PIPE

SENSOR

1.91

1.87

1.83

1.79

1.75

1.71

1.67

2.13

2.08

2.04

1.99

1.95

1.45

1.42

1.39

1.35

1.32

1.29

1.63

1.59

1.56

1.52

1.49

APPROX. PIPE

TEMP.

°C

41

42

43

44

38

39

40

33

34

35

36

37

53

54

55

50

51

52

45

46

47

48

49

DC VOLTAGE

ACROSS PIPE

SENSOR

1.12

1.09

1.07

1.04

1.02

0.99

0.97

1.26

1.23

1.20

1.17

1.15

0.84

0.82

0.80

0.78

0.76

0.75

0.95

0.92

0.90

0.88

0.86

APPROX. PIPE

TEMP.

°C

64

65

66

67

61

62

63

56

57

58

59

60

76

77

78

73

74

75

68

69

70

71

72

DC VOLTAGE

ACROSS PIPE

SENSOR

0.65

0.63

0.63

0.60

0.59

0.58

0.56

0.73

0.71

0.70

0.68

0.66

0.49

0.48

0.47

0.46

0.45

0.55

0.54

0.53

0.51

0.50

TABLE 4

APPROX. PIPE

TEMP.

°C

87

88

89

90

84

85

86

79

80

81

82

83

96

97

98

99

100

91

92

93

94

95


27

HOT WATER FAULT FINDING - BLOCKING CODES

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

If the boiler is reset does the boiler ignite for a short time and then extinguish?

NO

IGNITION LOCKOUT

Is the gas pressure available at the inlet

(>18mbar)?

NO

YES

Check the detection electrode and associated harness for: continuity, visual condition and position. Check if the condensate pipe is blocked. Replace if necessary.

YES

Is approx 24 VDC supply available at the gas valve?

NO

Check siphon and condensate drain pipe work for blockage and rectify if necessary.

Is heater working?

YES

NO

Check the pressure control pipe between fan and gas valve for continuity, visual condition, replace as necessary. Is heater working?

NO

YES

Unplug the gas valve. Is resistance between outside pins 114Ω

NO

YES

Check board and associated harness for: continuity and visual condition. Are these functioning correctly?

YES

Check ignition and associated harness for : continuity visual condition and position. Are these functioning correctly?

NO

NO

Replace the Gas Valve.

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 gas valve

Replace board and harness as necessary.

Replace PCB and associated harness as necessary.

Reset the heater. Is the heater working?

NO

Remove ignition lead and earth tag. Is there continuity between the terminal pins connected to the electrode?

NO

Check routing and integrity of internal heater wiring.

YES

FALSE FLAME LOCKOUT

YES

Check routing and integrity of the internal boiler wiring is working OK. Check condition of the Flame

Sensor Electrode and replace if necessary.

Replace flame detection electrode.

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

NO

OVERHEAT LOCKOUT

Fill & vent the system & open all isolation valves, then reset heater.

YES

Is the Flow/Return differential across the heater in excess of 30°C?

NO

Check the Flow & Return thermistors.

Check resistance using a suitable multi-meter connection across the thermistor’s terminal pins

NO

YES

Check that the pump is rotating freely. Is the differential now below 20°C?

YES

Replace the pump, the reset the heater.

RESET PROCEDURE

To reset the heater, press the reset button.

Reset the heater.


28

FAN FAULT

Does the wiring from the fan to the PCB have secure connections at both ends and has not deteriorated? Does the wiring have continuity?

NO

YES

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

NO

YES

Replace the Fan.

Rectify wiring & connections

Replace the PCB.

Replace the PCB.

FLAME CIRCUIT FAILURE

VALVE FEED BACK ERROR

NO

Replace Gas Valve.

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

YES

Replace Board.

EEPROM LOCKOUT

Replace the PCB.

FAN FAULT

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

NO

Fill and vent the system and open all isolation valves, check as supply, then reset heater

YES

Reset the heater. Is the heater working?

NO

Replace the Sensor.


29

ADC LOCKOUT

Replace the PCB.

RETURN THERMISTOR FAULT

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?

NO

YES

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

NO

YES

Replace the PCB.

Fit a new Thermistor.

Check and replace wiring as necessary.

FLOW THERMISTOR FAULT

Is the wiring securely connected to the Flow thermistor?

NO

Securely connect the wiring to the flow Thermistor.

YES

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?

YES

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

NO

NO

YES

Fit new Thermistor.

Check & replace as necessary.

Replace the PCB.


FIGURE 51. SENSOR TEMPERATURE/RESISTANCE DIAGRAM

30

BLOCKING CODES

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

EXHAUST SENSOR FAULT

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

NO

Fill and vent the system and open all isolation valves, check as supply, then reset heater

YES

Check flue thermistor. Check resistance using a suitable multi-meter connection across the thermistor’s terminal pins. (Refer to graph on E03).

NO

Replace the flue thermistor.

YES

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

YES

Replace PCB.

NO

Secure to PCB.

REMOTE RESET LOCKOUT

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

VALVE FEED BACK ERROR

NO

Correct electrical fault.

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

YES

Replace PCB.

CONDENSATE PUP SAFETY FLOAT SWITCH

NO

Check power supply.

Check power to the pump?

YES

Check for any blockages or restrictions.

NO

Replace condense pump.

Is the wiring securely connected to sensor?

YES

See graph Figure 51.

YES

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

YES

Replace the PCB

NO

NO

Connect the wiring.

Secure connection.

NO DISPLAY

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

NO

YES

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

NO

Supply power to heater.

Connect the wiring from the terminal block to the

Main PCB securely.

YES

Replace the PCB


31

22. FUNCTIONAL WIRING DIAGRAMS


FIGURE 52. WARMCAIR C16DW COMBINED WIRING DIAGRAM

32

23. DIMENSIONS

FIGURE 53. WARMCAIR C16DW COMBINED DIMENSIONS


33

15

9

7

6

5

8

11

10

1

2

12

4

14

3 www.johnsonandstarley.co.uk

13

HOT WATER

RETURN FROM

HEAT SOURCE

HOT WATER

FLOW FROM

HEAT SOURCE

16

FIGURE 54. WARMCAIR C16DW COMBINED EXPLODED DIAGRAMS

17

34

25. LIST OF SPARES

ITEM PART No.

1 1000-0526275 Aquair PCB

DESCRIPTION

2 1000-0527035 PCB Interface

3 1000-0302245 Pump Head Assembly

4 1000-0525395 Air Circulation Fan

5 1000-0711785 Ignition/Detection Electrode

6 1000-0711835 Burner Assembly

7 1000-0526525 Flue Sensor

8 1000-0526415 Combustion Fan

9 1000-0710925 Gas Valve

10 1000-0710785 Venturi (034)

11 1000-0711135 Injector (4.75)

12 1000-0024525 Condensate Trap


QTY

35

ITEM PART No.

DESCRIPTION

13 AQ16-0138005 Air To Water Heat Exchanger

14 1000-0023085 Condensate Pump

15 1000-0526505 Return Water Temperature Sensor

16 1000-0526515 Flow & Return Water Temperature Sensor (x 2)

17 C16DW-0138005 Air Filter

QTY

26. ANCILLARIES

6

7

4

5

1

2

3

Cleanfl ow Air Filter

Return Air Kits

Slot Fix Panels

Top Closure panels

Base Duct

Top Closure 2 Panel Kit

Slot Fix & Grille

WARMCAIR C16DW ANCILLARY’S

Description Product Code

CF16W

RAK16W

TS16W

TC16W

WBX16W

TP16W

TSG16W


36

27. BENCHMARK LOG BOOK

C16DW

COMMISSIONING

CHECKLIST

& SERVICE RECORD

This Log Book should be filled out at each annual service


37

Johnson & Starley Ltd

Rhosili Road, Brackmills,

Northampton NN4 7LZ [email protected]

[email protected]

Reception

01604 762881

Sales/Spares

01604 707012

Service/Warm air upgrade

01604 762881

Warm air upgrade

01604 707011

Johnson & Starley Dravo Division Industrial H&V

Sales

01604 707022

[email protected]

www.dravo.co.uk

Anniversary 1922 - 2012

In the interest of continuous development Johnson & Starley reserve the right to change specifi cation without prior notice.

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