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WarmCair
WARMCAIR RANGE
Condensing Air Heater
High Efficiency Downflow, Upflow
& Combined Condensing
Warm Air Heaters
TECHNICAL DATA &
FAULT FINDING
Condensing Warm Air
FM 525200
Brackmills, Northampton
www.johnsonandstarley.co.uk
Publication No. ZZ 1624
June 2022
Johnson & Starley Ltd
Rhosili Road
NN4 7LZ
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Summary of Contents for Johnson & Starley WARMCAIR C Series
- Page 1 WarmCair Condensing Warm Air Publication No. ZZ 1624 June 2022 WARMCAIR RANGE Condensing Air Heater High Efficiency Downflow, Upflow & Combined Condensing Warm Air Heaters TECHNICAL DATA & FAULT FINDING FM 525200 Johnson & Starley Ltd Rhosili Road Brackmills, Northampton NN4 7LZ www.johnsonandstarley.co.uk...
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Page 2: Table Of Contents
CONTENTS Description Page WarmCair C Range Upflow and Downflow Technical Data and Fault Finding Technical Data Fault Finding Fault Finding Flow Chart Defect Diagnosis for the Circulation Air Fan Functional Wiring Diagrams Condense Pump Re-Wire Circuit Diagram for Condensing Air Heaters Heat Exchanger Update WarmCair C26D Technical Data and Fault Finding WarmCair DW Range Technical Data... -
Page 3: Technical Data
WARMCAIR C RANGE Condensing Air Heater High Efficiency Downflow, Upflow Condensing Warm Air Heaters. TECHNICAL DATA & FAULT FINDING Models Covered C10D C16D C26D C36D C46D C16U... - Page 4 WARMCAIR DOWNFLOW & UPFLOW TECHNICAL DATA C10D 48 kg WEIGHT 20 mbar GAS SUPPLY PRESSURE GAS CATEGORY COUNTRIES OF INSTALLATION United Kingdom, Ireland 230 V ~ 50 Hz fused 5 A (150 W) ELECTRICAL SUPPLY MAXIMUM MINIMUM MJ/h Btu/h MJ/h Btu/h 10.0 34,120...
- Page 5 WARMCAIR DOWNFLOW & UPFLOW TECHNICAL DATA C36D WEIGHT 96 kg 20 mbar GAS SUPPLY PRESSURE GAS CATEGORY United Kingdom, Ireland COUNTRIES OF INSTALLATION 250 V ~ 50 Hz fused 5 A (530 W) ELECTRICAL SUPPLY MAXIMUM MINIMUM MJ/h Btu/h MJ/h Btu/h 129.6 122,832...
- Page 6 WARMCAIR DOWNFLOW & UPFLOW TECHNICAL DATA C26U 68 kg WEIGHT GAS SUPPLY PRESSURE 20 mbar GAS CATEGORY United Kingdom, Ireland COUNTRIES OF INSTALLATION 230 V ~ 50 Hz fused 5 A (530 W) ELECTRICAL SUPPLY MAXIMUM MINIMUM MJ/h Btu/h MJ/h Btu/h 26.0 93.6...
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Page 7: Fault Finding
WARMCAIR DOWNFLOW & UPFLOW FAULT FINDING TABLE 4 ERROR CODES CODE SYMPTOM POSSIBLE CAUSE ACTION Check all external controls (if fitted) Heater will not run No call for heat to heater control board Check setting on time clock Check setting of heater controls Check gas supply and gas cock Check ignition electrode condition &... -
Page 8: Fault Finding Flow Chart
FAULT FINDING FLOW CHART CHECK WIRING TO OPENTHERM STAT... -
Page 9: Defect Diagnosis For The Circulation Air Fan
DEFECT DIAGNOSIS FOR THE CIRCULATION AIR FAN 21.1 CIRCULATION AIR FAN 21.1.1 Ensure Air Circulation Fan is running at maximum. 21.1.2 A voltage should be measured and blue (-) and yellow (+). Voltage approx. 10 VDC. 21.1.3 If voltage is present and fan is not running at maximum. Replace ACF. Refer to res/temp graph... -
Page 10: Functional Wiring Diagrams
FUNCTIONAL WIRING DIAGRAMS DSP (MMI ) CONTROL PANEL TIMER 2 3 4 CONDENSATE PUMP GN GN COLOUR BLACK BLUE GREEN BROW N OPENTHERM PCB - INTERF ACE UNIT PCB - INTERF ACE GNYE GREEN/YELL OW AMBIENT GREY ROOM SENSOR ROOM STAT (OPTIONAL) ORANGE (OPTIONAL) - Page 11 FUNCTIONAL WIRING DIAGRAMS COLOUR COLOUR DSP (MMI) BLACK GREY BLUE ORANGE YELLOW GREEN 1 2 3 4 VIOLET BROWN WHITE GNYE GREEN/YELLOW GNYE PCB - INTERFACE ESYS FLUE COMBUSTION PROTECTION AIR FAN SENSOR BULK HEAD DUCT AIR SENSOR CIRCULATION GNYE GNYE BULK HEAD LIMIT SWITCH...
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Page 12: Condense Pump Re-Wire
CONDENSE PUMP RE-WIRE The wiring of this unit has been modified as per the updated wiring diagram fixed to the door. The condensate float switch wiring has been moved fromthe PCB interface terminals 29 and 30 to terminals 21 and 23. Condensate pump HI limit error will no longer be shown on E3 but with 2 horizontal lines when the clock is in the ‘On’... -
Page 13: Circuit Diagram For Condensing Air Heaters
CIRCUIT DIAGRAM FOR CONDENSING AIR HEATERS... -
Page 14: Heat Exchanger Update Warmcair C26D
The gasket between the heat exchanger drum and the Warmcair C26D technical update is designed to absorb the expansion of the drum as it e HEAT EXCHANGER UPDATE WARMCAIR C26D From Serial number below the following changes have been introduced From the serial number below the following changes have been introduced. -
Page 15: Technical Data And Fault Finding Warmcair Dw Range
WARMCAIR DW RANGE Condensing Air Heater High Efficiency Downflow Combined Warm Air Heaters. TECHNICAL DATA & FAULT FINDING Models Covered C10DW C16DW C20DW... - Page 16 WARMCAIR DW TECHNICAL DATA TABLE 1 C10DW Maximum weight lift Gas supply mbar 2H - G20 - 20 mbar Gas connection 15 mm copper Gas Injector size Heating flow and return 22 mm copper Flue terminal diameter 100 (4”) Condense drain 6 ID Electrical supply V ~ Hz...
- Page 17 WARMCAIR DW TECHNICAL DATA TABLE 1 C16DW Maximum weight lift 76.5 Gas supply mbar 2H - G20 - 20 mbar Gas connection 15 mm copper Gas Injector size 4.75 Heating flow and return 22 mm copper Flue terminal diameter 100 (4”) Condense drain 6 ID Electrical supply...
- Page 18 WARMCAIR DW TECHNICAL DATA TABLE 1 C20DW Maximum weight lift 82.5 Gas supply mbar 2H - G20 - 20mbar Gas connection 15 mm copper Gas Injector size 4.75 mm Heating flow and return 22 mm copper Flue terminal diameter 100 mm (4”) Condense drain 6 mm ID Electrical supply...
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Page 19: Warmcair Dw Fault Finding
WARMCAIR DW FAULT FINDING Should a fault occur, the boiler will shut down and these error codes will be displayed. UNIT DOES NOT FIRE Check there is a fault codes Follow Fault Code Procedure Check Radiator symbol is displayed in control panels. Press K5 on control panel until radiator symbol appears Check unit fires in test mode. -
Page 20: Circulating Fan Not Working
WARMCAIR DW FAULT FINDING NOT OPERATING IN HOT WATER MODE Press K5 on control panel untill radiator Check radiator symbol is displayed in control panel symbol appears Check there is a hot water demand Measure 230V AC across terminals 46 (neutral) & 35 HW (switched live from clock) Is there heat demand from external controls 46 (neutral) &... -
Page 21: Heating Comes On In Hot Water Demand
WARMCAIR DW FAULT FINDING HEATING COMES ON IN HOT WATER DEMAND Is diverter valve in the correct position Check pin position on diverter head (pin in heat should be free to move in and pin in pump up) 230V interface PCB white and black wires Measure 230V AC across terminals 7 (neutral black) and 8 (diverter 7 &... -
Page 22: Fan Not Operating When Pipe Is Above 60ºc
WARMCAIR DW FAULT FINDING FAN NOT OPERATING WHEN PIPE IS ABOVE 60°C Is the MAF stat connected? Link out interface PCB terminals 31 & 32 Check for 240V AC to earth on J2 plug 9 & 10 Make sure mains is present across High Voltage terminals 2 Is fan now running? &... -
Page 23: Ignition Lockout
WARMCAIR DW FAULT FINDING Should a fault occur, the heater will shut down and these blocking codes will be displayed. IGNITION LOCKOUT If the heater is reset does the heater ignite for a Is the gas pressure available at the inlet Check the gas supply short time and then extinguish? (>18mbar)? -
Page 24: Combustion Fan Fault
FAN FAULT WARMCAIR DW FAULT FINDING COMBUSTION FAN FAULT Does the wiring from the fan to the PCB have secure connections at both ends Rectify wiring & connections and has not deteriorated? Does the wiring have continuity? Is there 230Vac at the Blue Brown connections to the 3 way connection on the Replace the PCB. -
Page 25: Adc Lockout
WARMCAIR DW FAULT FINDING 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- Fit a new Thermistor. 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 Check and replace wiring as necessary. -
Page 26: Exhaust Gas Temperature Too High
WARMCAIR DW FAULT FINDING Should a fault occur, the boiler will shut down and these blocking codes will be displayed. EXHAUST GAS TEMPERATURE TOO HIGH Is the heater & CH system filled with water and all isolation & Fill and vent the system and open all isolation radiator valves open? valves, check as supply, then reset heater Measure working temperature of flue gas. -
Page 27: Functional Wiring Diagrams
FUNCTIONAL WIRING DIAGRAMS... -
Page 28: Reference Data
REFERENCE DATA DC VOLTAGE DC VOLTAGE DC VOLTAGE DC VOLTAGE APPROX. PIPE APPROX. PIPE APPROX. PIPE APPROX. PIPE ACROSS PIPE ACROSS PIPE ACROSS PIPE ACROSS PIPE TEMP. °C TEMP. °C TEMP. °C TEMP. °C SENSOR SENSOR SENSOR SENSOR 3.24 2.13 1.26 0.73 3.19... - Page 29 NOTES: NOTES...
- Page 30 NOTES: NOTES...
- Page 31 NOTES: NOTES...
- Page 32 Johnson & Starley Ltd Rhosili Road, Brackmills, Northampton NN4 7LZ sales@johnsonandstarley.co.uk marketing@johnsonandstarley.co.uk Reception/Customer Service 01604 762881 01604 767408...
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