Johnson & Starley WARMCAIR C36U User guide

INSTALLATION, COMMISSIONING
& SERVICING INSTRUCTIONS
WARMCAIR C36U
Condensing Air Heater
High Efciency Upow
Condensing Air Heater
WarmCair C36U - G.C. No. 42-451-27
These instructions are to be left with the User
Publication No. ZZ 1414-4
December 2016
www.johnsonandstarley.co.uk

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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.
CONTENTS
The Benchmark Scheme 2
1 Features 3
2 General Description 3
3 Building Standards & Regulations 4
4 Safety &Gas Information 5
General Safety Information
Gas Categories
Gas Supply
5 Technical Data 5
6 Heater Positioning 6
7 Heater Compartment Clearances 6
8 Duct System 7
Return Air
Warm Air Delivered
9 Flue Instructions 8
Flue Configuration
Diagram of Terminal Position
Types of Flue Systems
Flue Terminal Positions
Plume Terminal Outlets
Flue Requirements & General Information
Conventional 80/125mm Flue Accessories Part No.s
Extended Horizontal Flue System
Optional Roof Outlets
Flat Roof & Pitched Roof
11 Condensate Pump & Drain Tube 13
Condensate Pump
Technical Data
Condensate Tube Routing Options
11 Gas 14
12 Electrical 14
Mains Supply
Thermista-stat & It’s Location
13 Fitting Instructions 15
14 Commissioning 15
System Balancing
Lighting the Main Burner
Gas Rate Check
15 Handing Over 17
16 Servicing & Maintenance 18
Servicing Schedule
Servicing Sequence
Component Servicing Checklist
Gaining Access for Servicing
Main Burner Assembly
Ignition & Flame Detection Electrode
Heat Exchanger/Combustion Chamber
Combustion Air Fan
Flue Collection Box & Heat Exchanger
Air Circulations Fan
Condensate Drain Pipes
Condensate Pump
17 Parts Replacements 22
Control Panel
Air Circulation Fan
Return Air Temperature Sensor
Flue Temperature Sensor
High Limit Temperature Sensor
Air Pressure Switch
Condensate Drain Pump
Main Ignition/Control PCB
Gas Valve & Venturi Assembly
Burner Assembly
Ignition Electrode
Flame Detection Electrode
Combustion Air Fan
18 Control Panel Modes 25
19 Fault Code & Blocking Code Table 26
20 Fault Finding Flowcharts 28
21 Defect Diagnosis for the Circulation Air Fan 29
22 Functional Wiring Diagrams 30
23 Dimensions 32
24 List of Spares 33
25 Important Information & Ancillaries 36
26 Code of Practice 37
27 Benchmark Checklist and Service Record 38

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1. FEATURES
Appliance Classification:
The WarmCair C36U has been tested
and CE certified by B.S.I Ltd for use with
NATURAL gas G20.
FEATURES
1. 60/100mm to 80/125mm Adapter
2. 60/100mm Flue Turret
3. Combustion Measuring Point
4. Time Control
5. Condensing Pump Drain Tube
6. Inspection Glass
7. Sliding Flue Connector
8. Flue Sensor
9. Condense Outlet
10. Condense Pipe
11. Condensate Trap
12. Air Pressure Switch
13. Condensate Pump
14. Return Air Filter
15. Air Circulation Fan
16 PCB Control Wiring Panel
17. Return Air Sensor
18. Flue Collector Box
19. Combustion Air fan Assembly
20. High Limit Temperature Sensor
21. Gas Cock
22. ESYS
23. Burner Assembly
24. Gas Valve
25. Ignition & Detection Electrodes
26. MMI Control Panel
27. Duct Temperature Sensor
(behind control panel)
2. GENERAL DESCRIPTION
2.1 The WarmCair C36U is a highly efficient condensing gas fired upflow 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 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 C36U 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 31.68kW (114.05MJ/h, 108,092 Btu/h) down to 9.68kW (34.85MJ/h,
33,028Btu/h) “Summer Air Circulation” of unheated air is available by manual selection (see the user’s
instructions).
FIGURE 1. C36U FEATURES
7
9
15
16
17
20
21
22
18
19
23
25
26
27
14
24
4
6
1
2
3
8
10
5
12
11
13

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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. BUILDING STANDARDS & REGULATIONS
STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY
COMPETENT PERSONS, i.e. GAS SAFE REGISTERED INSTALLERS.
GAS SAFE MEMBERSHIP ENQUIRIES TEL: [phone] IN ACCORDANCE WITH
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION).
FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
3.1 INSTALLATION REGULATIONS
• Gas Safety (Installation and Use) Regulations (as amended)
• Model and Local Authority Byelaws
• Health & Safety Document No. 635.
• The Electricity at Work Regulations
• Institute of Electrical Engineers (I.E.E) Wiring Regulations
• British System Design Manual “Gas Fired Warm Air Heating”
• EN Regulations No. 1196 Supplementary Instructions - Condensing Air Heaters
3.2 BUILDING STANDARDS AND REGULATIONS
Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.
Building Standards (Scotland) (Consolidation) Regulations
Building Regulation (Northern Ireland)
Building Regulations Part L
BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic premises
(2nd family gases).
BS 5440:1 Flues (for gas appliances of rated input not exceeding 70 kW).
BS 5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW).
BS 5864 Installation of Gas Fired Ducted Air Heaters
IMPORTANT: This appliance is CE certificated for safety and performance. It is important that no modifications are
made to this appliance, unless fully approved in writing by Johnson & Starley Ltd. If in doubt please ring Johnson &
Starley Ltd on Telephone [phone].

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4. SAFETY & GAS INFORMATION
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING WITH THE INSTALLATION
4.1 GENERAL 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
20 mbar at a rate of 1.94m³/h or 52.64ft²/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.
5. TECHNICAL DATA
TABLE 1. C36U TECHNICAL DATA
C36U
WEIGHT
96kg
GAS
G20
GAS SUPPLY PRESSURE
20mbar
GAS CATEGORY
I2 H
COUNTRIES OF INSTALLATION
GB & IE
ELECTRICAL SUPPLY
250v ~ 50Hz fused 5A 530 watts
MAXIMUM MINIMUM
KW MJ/h Btu/h KW MJ/h Btu/h
INPUT (GROSS)
36 129.6 122,832 11 39.6 37,532
OUTPUT
31.86 114.05 108,092 9.68 34.85 33,028
GAS RATE CV 1037Btu/FT³
3.35m³/h (118.45ft³/h) 1.025m³/h (36.2ft³/h)
BURNER % CO²
9 ± 1 9 ± 1

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6. HEATER POSITIONING
6.1 This heater is not suitable for external installation unless it is protected from the elements by a suitable
enclosure. The enclosure must provide the clearance for installation, servicing and maintenance as well as
the correct level of ventilation. The selected position should allow for a suitable flue system to be installed.
6.2 When installed in a timber frame building guidance should be taken from the Gas Industry Publication IGE/
UP-7 (Guide for Gas Installations in Timber Frame Housing).
6.3 BS 6798 gives details of the essential features for a compartment or cupboard where a gas appliance is to
be installed. An existing cupboard may require modification.
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 this
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 that
installation is carried out such that the rear of the heater is aligned with the rear of the base duct, so that any
overhang or blanking off will be at the front. In any event, blanking plates must be mechanically secured
and all joints sealed.
7.2 When the heater is fitted into a compartment, a minimum clearance from the compartment walls of 3mm
(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.
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 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.

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8. DUCT SYSTEM (See British Design Manual - Gas fired Warm Air Heating)
8.2 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 3200cm2 (469in2). 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 1600cm²
(248in²). If flexible duct is used the duct diameter should not be less than 450mm (18”) diameter.
8.1.3 An adequate and unobstructed return air path is essential from areas not served by a directly
ducted return and to which warm air is delivered. All such rooms should be fitted with relief grilles
which have a free area of 0.0088m2/kW (1in2/250Btu/h) of heat supplied to the room. The only
exceptions are kitchens, bathrooms and WC.’s.
8.1.4 The return air duct should allow for ease of removal, for access to the flue.
8.1.5 All duct work in the room or internal space in which the heater is installed shall be mechanically
secured and sealed with ducting tape.
8.1.6 This unit is also designed to use a side return air kit. For further details telephone Johnson & Starley
Ltd.
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.

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VERTICAL FLUE
FIGURE 2.
EXTENDED HORIZONTAL REAR FLUE
FIGURE 3. VERTICAL FLUE
FIGURE 4. HORIZONTAL TERMINAL DIMENSIONS & POSITION
CORRECT
POSITION OF
HORIZONTAL
TERMINAL END
100mm
19mm
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
EXTENDED HORIZONTAL
REAR FLUE
9. FLUE INSTRUCTIONS
9.1 The WarmCair C36U Condensing Air Heater is certified as a warm air heater with corresponding flue systems
according to EU Directive 2009/142/EC on gas-fired devices. These installation instructions are covered by
this certification and are referred to in the design approval test certificate.
9.2 The installation of the warm air heater and flue system must be in accordance with the Gas Safety (Installation
and Use) Regulations 1998 and the Building Regulations. If no specific instructions are given, reference
should be made to the relevant codes of practice.
THESE RELEVANT STANDARDS SHOULD BE FOLLOWED
BS 5440:1 Flues and ventilation for gas appliances of rated heating input not exceeding 70kW (net) : Flues
BS 5440:2 Flues and ventilation for gas appliances of rated heating input not exceeding 70kW (net) : Air Supply
Ensure all legislation, regulations and directives mentioned are observed.
9.3 The air/flue duct operates at very low temperatures therefore no clearance is
necessary between the air duct and the adjacent services.
9.4 Ensure while installation work is being carried out that no debris such as swarf,
filings or fragments of mortar are allowed to remain in the air/flue duct.
10.5 FLUE CONFIGURATIONS
NOTE: Vertical Appliance adaptor is fitted as part of the air heater.

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FIGURE 5. TERMINAL POSITIONS
TABLE 2. TERMINAL DIMENSIONS
TERMINAL POSITION MINIMUM DISTANCE
ADirectly below an opening, air brick, opening window etc 300mm
BAbove an opening, air brick, opening window, etc. 300mm
CHorizontally to an opening, air brick, opening window etc. 300mm
DBelow gutters, soil pipes or drain pipes. 75mm
EBelow eaves. 200mm
FBelow balconies. 200mm
GFrom a vertical drain pipe or soil pipe. 150mm
HFrom an internal or external corner. Greater than 450mm protrusion. 300mm
IAbove ground, roof or balcony level. 300mm
JFrom a surface facing the terminal. 600mm
KFrom a terminal facing the terminal. 1,200mm
MVertically from a terminal on the same wall. 1,500mm
NHorizontally from a terminal on the same wall. 300mm
QAbove intersection with roof. 530mm
PFrom a vertical structure on the roof 300mm
RFrom the terminal to the boundary 300mm

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9.5 TYPE OF FLUE SYSTEMS
Two types of flue systems are available for the C36U.
i) The standard concentric flue system 80/125mm (125mm diameter)
ii) A Flexible flue kit (FFK) 80/125mm (125mm diameter) For further information contact the sales
office at Johnson & Starley Ltd. Telephone [phone]
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 extended 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 5.
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 extended 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.
9.7 PLUME TERMINAL OUTLETS
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 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.
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.
9.8 FLUE REQUIREMENTS & GENERAL INFORMATION
9.8.1 Extended horizontal and vertical concentric flues (80/125mm diameter) with balanced terminals may be
installed on the WarmCair C36U warm air heater.
9.8.2 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 3 for relevant part
numbers.
9.8.3 The maximum length of flue permissible is 10
meters including terminal
9.8.
4 The minimum vertical flue length is 1.25m from
the top of the appliance case to the top of the
terminal.
9.8.5 Longer flues may be fitted, however the input
of the appliance will be reduced accordingly.
9.8.6 Elbows may be fitted within the flue system
with a corresponding reduction in overall flue.
9.8..7 Guidelines for the maximum flue length are as
follows.
FIGURE 6. PLUME TERMINAL OUTLET DIMENSIONS
HORIZONTAL FLUE VERTICAL FLUE
UNIT
TURRET 90° ELBOW STRAIGHT 1m FLUE 90° ELBOW STRAIGHT 1m FLUE
1 - 12 - 12
1 1 8 1 8
1 2 6 2 6
1 3 4 3 4
When using 45° elbows: 2 x 45° elbow = 1 x 90° elbow
TABLE 3