Keston System 30kw Installation Manual

System 30

Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCY

MODULATING DOMESTIC CONDENSING

GAS BOILER

CE/PI No. 86-CL-08

System 30 - GC No. 41-930-39

These instructions must be left either with the user or next to the site gas meter.

Keston Heating

PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN

Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133 email : [email protected] web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

2

Keston System - Installation and Servicing

NOTEs FOR ThE INsTALLER

FOR ANy TEChNICAL qUERIEs pLEAsE RINg ThE KEsTON

INsTALLER/TEChNICAL hELpLINE : 01482 443005

NOTE. BOILER REsET pROCEDURE -

To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

The boiler will repeat the ignition sequence if a heat demand is present.

DOCUMENT AMENDMENTs

Relevant Installation changes implemented in this book from Mod Level ........ A03 (Oct 13) to A04 (Feb 14) page 10

4.b. - Statement updated page 30

Item 3 added to Electrical Installation

Statement added ref to commissioning process of combustion page 57

New Page Added - Benchmark Commissiong & Servicing Section page 58 & 59

New updated Commissioning Checklist & Service Record Sheets page 60 & 61

New pages added, Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler

Keston reserve the right to vary specification without notice


3

general

Table 1 - general Data

Keston system

Gas supply

Gas Supply Connection

Injector Size (mm)

Flow Connection

Return Connection

Flue Terminal Diameter

Maximum Working Pressure (Sealed Systems)

Electrical Supply

Power Consumption

Fuse Rating

Average Flue Temp-Mass Flow Rate

Water content

Packaged Weight

Maximum Installation Weight

Boiler Casing Size Height

Width

Depth

Central Heating

Central Heating mm (in) bar (lb/in 2 )

W litre (gal) kg (lb) kg (lb) mm (in) mm (in) mm (in)

30

2H - G20 - 20mbar

15mm copper compression

4.65



69 o

50 (2)

C - 13g/s

2.5 (36.3)

230 V ~ 50 Hz.

152

External : 3A Internal : T4H HRC L250 V

1.2 (0.26)

34.5 (76)

28 (61.7)

700 (27.5)

395 (15.5)

278 (11)

Table 2 - performance Data - Central heating

30

MIN

Boiler Input :

Boiler Input ‘Q’ Nett CV kW

(Btu/h)

Gross CV kW

(Btu/h)

Gas Consumption m 3 /h

(23,000)

0.622

(ft 3 /h) (22)

Boiler Output :

Non Condensing kW 6.1

70 o C Mean Water temp.

Condensing

(Btu/h) kW

40 o C Mean Water temp. (Btu/h)

Seasonal efficiency* SEDBUK 2005

Seasonal efficiency* SEDBUK 2009

NOx Classification

6.1

(20,700)

6.7

(20,700)

6.4

(21,800)

91.1%

89.6%

CLASS 5

MAX

30.4

(103.600)

33.7

(115,000)

3.135

(111)

30.3

(103,300)

31.0

(105,800)

* The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by a notified body.

Note. Gas consumption is calculated using a calorific value of 38.7 MJ/m or 34.9 MJ/m 3 (935 Btu/ft

3 (1038 Btu/ft 3 ) gross

3 ) 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/m 3 )

b. For ft 3 /h - divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft 3 )

c. For m 3 /h - multiply l/s by 3.6.

4

Key to symbols

gB = United Kingdom IE = Ireland

pMs = Maximum operating pressure of water

(Countries of destination)

C

13

C

53

= A room sealed appliance designed for connection via ducts to a horizontal terminal, which admits fresh air to the burner and discharges the products of combustion to the outside. The fan is up stream of the combustion chamber.

I

2h

= An appliance designed for use on 2nd Family gas, Group H only.


Keston System

Natural gas only

Boiler size g.C. Appliance No.

(Benchmark No.)

30 41-930-39

Destination Country: GB, IE

pI No.

86 CL 08 general

CONTENTs

Benchmark Commissioning Checklist ..................... 58

Boiler Clearances ......................................................... 9

Boiler Exploded Diagram ........................................... 12

Condensate Drain .................................................. 21,22

Commissioning & Testing ......................................... 30

Electrical Connections ............................................... 24

Electrical supply ........................................................... 8

Fault Finding ............................................................... 49

Flue Installation .......................................................... 14

gas safety Regulations ............................................... 7

gas supply .................................................................... 8

Initial Lighting ............................................................ 31

Installation ............................................................. 14-32

pump ........................................................................... 46

safe handling ................................................................ 6

servicing ................................................................ 33-48

short List of parts ...................................................... 55

Thermostatic Radiator Valves ..................................... 8

Water and systems ........................................... 8,10-11

Water Connections ..................................................... 23

Water Treatment .........................................................11

Wiring Diagram ........................................................... 29

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist.

Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENChMARK COMMIssIONINg ChECKLIsT DETAILs

B

oiler page

Make and model ......................................................... 5

Appliance serial no. on data badge .......... Front Cover

SEDBUK No. % .......................................................... 4

Controls

Time and temperature control to heating ................. 28

Time and temperature control to hot water ........... N/A

Heating zone valves .................................................28

TRV’s.......................................................................... 8

Auto bypass ............................................................... 8

Boiler interlock ............................................................ 8

For .................................................................... all boilers

Flushing to BS.7593 .................................................12

Inhibitor .................................................................... 12

Central heating mode

Heat input ...................................................to be calculated page

Burner operating pressure ...................................... n/a

Central heating flow temp. ...........measure and record

Central heating return temp. ........measure and record

For combination boilers only

Scale reducer ........................................................... 11

Hot water mode

Heat input ............................................to be calculated

Max. operating burner pressure .............................. n/a

Max. operating water pressure ........ measure & record

Cold water inlet temp ...................... measure & record

Hot water outlet temp. ..................... measure & record

Water flow rate at max. setting ........ measure & record

For condensing boilers only

Condensate drain ................................................21,22

For all boilers: complete, sign & hand over to customer

For assistance see Technical Helpline on the back page

NOTE TO ThE INsTALLER: COMpLETE

ThE BENChMARK COMMIssIONINg

ChECKLIsT AND LEAVE ThEsE

INsTRUCTIONs WITh AppLIANCE


5

general

INTRODUCTION

The Keston system boiler is wall mounted, full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, system gas boiler.

Note. Due to the high efficiency of the boiler a plume of water vapour will form at the flue terminal during operation.

Central heating (CH) output is fully modulating with a range of:

30 6.1 to 30.3kW (20,700 to 103,300 Btu/h)

The boiler is supplied fully assembled with circulating pump, pressure gauge, safety valve and CH expansion vessel.

A variable CH temperature control is fitted on the user control.

-

-

The boiler includes as standard:

- Boiler frost protection

Daily pump exercise

Weather compensation

The boiler casing is of white painted mild steel.

The boiler temperature control is visibly located in the control panel on the front of the boiler.

The heat exchanger is manufactured from cast aluminium.

The boiler is suitable for connection to fully pumped, sealed heating systems ONLY. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework.

Pipework from the boiler is routed downwards.

OpTIONAL ExTRA KITs

• Air Terminal Finishing Kit

• Chronotherm Room Controller

• Flue Sleeve Kit

• Room Sensor

OpERATION

When there is a demand for CH, the heating system is supplied at the selected temperature of between 30 o C and 80 o C.

The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating, and performance of key components to aid commissioning and fault finding.

sAFE hANDLINg

This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered:

• Grip the boiler at the base.

• Be physically capable.

• Use personal protective equipment as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.

• Keep back straight.

• Avoid twisting at the waist.

• Avoid upper body/top heavy bending.

• Always grip with the palm of the hand.

• Use designated hand holds.

• Keep load as close to the body as possible.

• Always use assistance if required.

6


sAFE hANDLINg OF sUBsTANCEs general sAFETy

Current gas safety (installation and use) regulations or rules in force:

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.

In GB, the installation must be carried out by a Gas Safe

Registered Engineer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

• The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), Building

Regulations (Northern Ireland).

• The Water Fittings Regulations or Water byelaws in Scotland.

• The Current I.E.E. Wiring Regulations.

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

In IE, the installation must be carried out by a Registered Gas

Installer (RGII) and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building

Regulations and reference should be made to the current ETCI rules for electrical installation.

Detailed recommendations are contained in the following British

Standard Codes of Practice:

Bs. 5440:1 Flues (for gas appliances of rated input not exceeding 70 kW).

Bs. 5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW).

BsEN. 12828:2003 Heating Systems in buildings: Design for water based heating systems.

BsEN 12831:2003 Heating Systems in buildings: Method for calculation of the design heat load.

BsEN 14336:2004 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

Bs. 6891

Installation of gas fired hot water boilers of rated input not exceeding 70 kW.

Low pressure installation pipes.

health & safety Document No. 635.

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.

IMpORTANT. These appliances are CE certificated for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Keston in writing. If in doubt please enquire.

Any direct connection of a control device not approved by Keston could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical internal wall, capable of adequately supporting the weight of the boiler and any ancillary equipment.

The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary, unless required by the local authority.

For electrical safety reasons there must be no access available from the back of the boiler.

The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document

IGE/UP/7:1998.

Bathroom Installations

This appliance is rated Ip20.

The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current

IEE (BS.7671) Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. For IE reference should be made to the current

ETCI rules for electrical installations and I.S. 813:2002.

If the appliance is to be installed in a room containing a bath or shower then, providing water jets are not going to be used for cleaning purposes (as in communal baths/showers), the appliance must be installed beyond Zone 2, as detailed in BS.7671.

Compartment Installations

Ceiling

2.25m

Zone 1

Zone 0

0.6m

Recessed window

Zone 2

3G8913a

A compartment used to enclose the boiler should be designed and constructed specially for this purpose.

An existing cupboard or compartment may be used, provided that it is modified for the purpose.

In both cases, details of essential features of cupboard / compartment design, including airing cupboard installation, are to conform to the following:

• BS 6798 (No cupboard ventilation is required - see ‘Air Supply’ for details).

• The position selected for installation MUST allow adequate space for servicing in front of the boiler.

• For the minimum clearances required for safety and subsequent service, see the wall mounting template and

Frame 1. In addition, sufficient space may be required to allow lifting access to the wall mounting plate.


7

general gAs sUppLy

The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier.

WATER CIRCULATION sysTEM

IMpORTANT.

A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping.

The boiler MUST be installed on a gas supply with a governed meter only.

The central heating system should be in accordance with BS.6798 and, in addition, for smallbore and microbore systems, BS.5449.

A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer. In IE by a Registered Gas

Installer (RGII).

WATER TREATMENT - see Frame 4

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required.

BOILER CONTROL INTERLOCKs

Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating, in compliance with Building Regulations.

It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891:2005. Whilst the principle of the 1:1 gas valve ensures the Keston 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.

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).

Heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve.

When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the minimum boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves.

However, if the system employs thermostatic radiator valves on all radiators, or two port valves, then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position.

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.

ELECTRICAL sUppLy

Warning.

This appliance must be earthed.

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations which apply. For IE reference should be made to the current ETCI rules for electrical installations.

The mains supply to the boiler and system wiring centre shall be through one common fused double pole isolator. For new heating systems, and where practicable replacement boiler installations, the isolator shall be situated adjacent to the appliance.

IMpORTANT.

Installation pipes must be fitted in accordance with BS.6891. In IE refer to IS.813:2002.

The complete installation MUST be tested for gas tightness and purged as described in the above code.

CONDENsATE DRAIN

Refer to Frames 20, 21 & 41

A condensate drain is provided on the boiler. This drain must be connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other materials may be used.

IMpORTANT.

Any external runs must be in accordance with BS 6798.

The drain outlet on the boiler is sized for standard 21.5mm (3/4”) overflow pipe. It is a universal fitting to allow use of different brands of pipework.

8


general

1 BOILER DIMENsIONs, sERVICEs & CLEARANCEs

The boiler connections are made on the boiler connection tails.

Refer to Frame 23.

The following minimum clearances must be maintained for operation and servicing.

Additional space will be required for installation, depending upon site conditions.

all dimensions in mm wall thicknesses do not exceed 600mm (24”). Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside.

side and Rear Flue

a. Provided that the flue hole is cut accurately, e.g. with a core drill, the flue can be installed from inside the building where

Installation from inside ONLy

b. If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool.

2.5

Air Flue

2.5

from case

62

395

198

30mm

Minimum Top Clearance

155

89

700

395

400

100

*

43 122

Gas Inlet

38 104

Front clearance

The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required, with the cupboard door open, to allow for servicing.

*

Bottom clearance

Bottom clearance after installation can be reduced to 5mm.

This must be obtained with an easily removable panel, to enable the consumer to view the system pressure gauge, and to provide the 100mm clearance required for servicing.


9

general

2 sysTEM REqUIREMENTs - Central heating

Notes

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 aluminium heat exchangers may be used in the central heating system.

general

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

2. The installation should be designed to work with flow temperatures of up to 86 o C.

3. All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 minimised. o C. Extra care should be taken in making all connections so that the risk of leakage is

The following components are incorporated within the appliance:

a. Circulating pump.

b. Safety valve, with a non-adjustable preset lift pressure of 3 bar.

c. Pressure gauge, covering a range of 0 to 4 bar.

d. An 8-litre expansion vessel, with an initial charge pressure of 0.75 bar.

4. ‘Make-up’ Water. Provision must be made for replacing water loss from the system, either :

a. From a manually filled ‘make-up’ vessel with a readily visible water level. The vessel should be mounted at least 150mm above the highest point of the system and be connected through a non-return valve to the system, fitted at least

150mm below the ‘make-up’ vessel on the return side of the radiators. or

b. Where access to a ‘make-up’ vessel would be difficult, by pre-pressurisation of the system.

The maximum cold water capacity of the system should not exceed 143 litres. This is the maximum system volume for the boiler expansion vessel. If the capacity of the vessel is not considered sufficient for this, or for any other reason, an additional vessel MUST be installed on the return to the boiler.

Guidance on vessel sizing is given in table opposite.

5. Filling

The system may be filled by the following method:

Through a temporary hose connection from a ‘draw-off’ tap, supplied from a service pipe under mains pressure. Where the mains pressure is excessive, a pressure reducing valve must be used to facilitate filling. When installing the filling device, it must be connected as below to fully comply with the water regulations.

This may involve the fitting of an additional WRAS approved isolator valve to the mains supply.

i. Thoroughly flush out the whole system with cold water.

ii. Fill and vent the system until the pressure gauge registers 1.5 bar, and examine for leaks.

iii. Check the operation of the safety valve by raising the water pressure until the valve lifts. This should occur within 0.3 bar of the preset lift pressure.

iv. Release water from the system until the minimum system design pressure is reached; 1.0 bar if the system is to be prepressurised.

safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

None 1.0

system pre-charge pressure bar system volume

(litres)

25

50

75

100

125

150

175

190

200

250

300

For other system volumes multiply by the factor across

Expansion vessel volume (litres)

1.6 1.8

3.1 3.7

4.7 5.5

6.3 7.4

7.8 9.2

9.4 11.0

10.9 12.9

11.9 14.0

12.5 14.7

15.6 18.4

18.8 22.1

0.063 0.074

Model 30

Max CH uutput kW 30.3

(Btu/h) (103,300)

Water flow rate l/min 21.5

(gal/min) (4.7)

Temp differential o C 20

( o F) (36)

Head available m.w.g. for system (ft.w.g.)

1.9

(6.2)

CH Return

Ecl 6053

Hose unions

Temporary hose

(disconnect after filling)

Mains water supply

Additional stop valve

Double check valve assembly

( note direction of flow )

10


general

3 sysTEM BALANCINg

The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 8.

Note. Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass.

BALANCINg

1. Set the programmer to ON.

Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the OPEN position.

Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator.

These valves should now be left as set.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20 o C temperature drop at each radiator.

3. Adjust the room thermostat and programmer to NORMAL settings.

4 WATER TREATMENT

CENTRAL hEATINg

The Keston system range of boilers have an ALUMINIUM alloy heat exchanger.

IMpORTANT.

The application of any other treatment to this product may render the guarantee of Keston Invalid.

Keston recommend Water Treatment in accordance with the

Benchmark Guidance Notes on Water Treatment in Central

Heating Systems.

If water treatment is used Keston recommend only the use of

SCALEMASTER GOLD 100, FERNOX, MBI, ADEY MC1 or SENTINEL

X100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers’ instructions.

Notes.

1. It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers’ instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS

7593:2006 details the steps necessary to clean a domestic heating system.

3. In hard water areas, treatment to prevent lime scale may be necessary - however the use of artificially softened water is

NOT permitted.

4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

For further information contact:

Fernox Cookson Electronics

Forsyth Road

Sheerwater

Woking

Surrey GU21 5RZ

+44 (0) 0870 601 5000

Sentinel Performance Solutions

The Heath Business & Technical Park

Runcorn

Cheshire WA7 4QX

Tel: 0800 389 4670 www.sentinel-solutions.net

Scalemaster Water Treatment Products

Emerald Way

Stone

Staffordshire ST15 0SR

Tel: +44 (0) 1785 811636

Calmag Ltd.

Unit 3-6, Crown Works

Bradford Road

Sandbeds, Keighley

West Yorkshire BD20 5LN

Tel: +44 (0) 1535 210 320

Adey Professional Heating Solutions

Gloucester Road,

Cheltenham GL51 8NR

Tel: +44 (0) 1242 546700


11

general

5 BOILER AssEMBLy - Exploded View

Note that item numbers are linked to the spares list

CH RETURN VALVE

105

108

110

113 PRESSURE RELIEF VALVE

114

115

116

117 PIPE - EXPANSION VESSEL

118

120

121 BY-PASS KIT

WATER PRESSURE TRANSDUCER

135 PRESSURE GAUGE

136 SAFETY VALVE DRAIN PIPE

GAS COCK

204

GAS VALVE

206

211

214

215 FAN

217

218

219

223 FLUE MANIFOLD

FLUE MANIFOLD TOP

227

228

229

231 CONDENSATE OUTLET CONNECTION

301

PRIMARY PCB*

303

504 227

224

505

CONTROL THERMISTOR (RETURN)

306

307

308

309 THERMISTOR CONTROL/NO FLOW

313

314

324

325 CONTROL BOX FRONT

332 FLUE THERMOSTAT

HEAT ENGINE

503

504

FASCIA

BRACKET - GAS VALVE

BRACKET - EXPANSION VESSEL

* Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output.

503

12

313

215

211

309

217

306

308

214

206

205

204

223

218

401

507

118

307

506

115

116

219

304 229

303

301

231

228

332

120

324

121

105

135

131

113

110

108

203

136

117

104

114

314

BCC

325 302


general

6 UNpACKINg

Unpack and check the contents.

pack A Contents

A Boiler

B Hardware Pack Box

C Wall Mounting Plate

D These Installation/Users Instructions

E Wall Mounting Template

(located on internal protective packaging)

F Turret Clamp

G Safety Valve Drain Pipe

H Boiler Guarantee & Registration Pack

A

C

B

E

D

G

F

H

Boiler Guarantee

HARDWARE PACK CONTENTS

Gas Valve Pack

1. Pipe - Gas Inlet

2. Washer - Gas (blue)

3. Gas Cock

Return Valve Pack

1. Pipe CH Return

2. Washer CH

3. Valve Return

Accessory Pack

1. Screw (x2)

2. Wallplug (x2)

3. Turret Clamp Screw (X1)

Flow Valve Pack

1. Pipe CH Flow

2. Washer CH

3. Valve Flow (with gauge)

Flue pack Contents

A Flue Adaptor

B Air Spigot

C Terminals - 2 off

D Flue Sleeve

E Wall Plate

F Wall Seal

G Outside Sensor

H Screws - 4 off

J Wall Plugs - 4 off

Gas Valve Pack

1

2

Return Valve Pack

1

3

2

3

A

G

B

H

C

J

D

Accessory Pack

1

2

3

Flow Valve Pack

1

2

E

3

3G9945

F

7 FRONT pANEL REMOVAL

1. Loosen the 2 screws retaining the front panel.

2. Pull the two spring clips downwards to disengage.

3. Pull the front panel forward and upwards to remove.


1

2

13

INSTALLATION

8 FLUE sysTEM

When installing a replacement boiler a new flue system must be used. DO NOT re-use the existing boiler flue installation.

The following pipes and fittings are approved:

DEsIgN

Individual air supply and flue outlet pipes are used as standard.

The material used for flue outlet &/or air inlet must be mupVC (pVC-C) to Bs 5255 and/or BsEN 1566-1 and BsEN

1329 of an internal diameter of 51mm. (i.e. nominal 50mm diameter mupVC solvent weld waste pipe).

Marley mupVC (pVC-C) solvent Weld Waste system

(50mm) and polypipe system 2000 mupVC (pVC-C) solvent weld waste (50mm) are the only systems approved for this application.

polypipe system 2000 mupVC solvent Weld Waste system

(50mm) poly pipe Code

MU 301 4m length muPVC wastepipe 5/225

MU 313

MU 314

MU 310

MU 316

50mm x 45 deg muPVC obtuse bend

50mm x 92.5 deg muPVC swept bend

50mm muPVC straigh coupling

50mm x 92.5 deg muPVC swept pipe

Marley mupVC solvent Weld Waste system (50mm)

Marley Code

KP 304 50mm x 4m double spigot pipe

KP32

KSC3

50mm x 45 deg bend

50mm straight coupling

KB3

KT3

50mm x 88.5 deg bend

50mm swept tee

14

continued............


INSTALLATION

9 FLUE sysTEM.... CONT’D

TERMINATION OF ThE FLUE AND AIR

The flue and air pipes may terminate independently through any external walls within the same dwelling except on opposing walls, within the maximum lengths shown in graph below.

The air pipe must have an elbow and 150mm length of pipe directed downwards with a termination grill fitted.

The air pipe can be situated at the side or beneath the flue pipe to a minimum dimension of 140mm (see diagram opposite). It must not be sited above the flue pipe.

The flue and air pipes must extend by at least 40mm from the wall surface.

Condensing boiler emit a visible plume of water vapour from the flue terminal, this is normal. It is the responsibility of the installer to judiciously select a terminal location that does not cause a nuisance.

If either the flue or air terminal is below a height of 2m from ground level a terminal guard must be fitted.

Acceptable range of air pipe siting

TERMINAL POSITIONS

Flue

Pipe

Minimum Separation

140mm

Air Pipe

Terminal

Elbow

MAxIMUM LENgThs

Due to the resistance presented by extended flue length a slight reduction in maximum boiler output will occur where combined flue and air lengths in excess of 18.0m (50mm muPVC) are used. In such cases the boiler output will be reduced by

0.6% per additional metre.

The maximum lengths of both air inlet pipe and flue outlet pipe, when no bends are used, are as detailed in graph below.

However, each bend used has an equivalent length that must be deducted from the maximum straight length stated in graph below. Knuckle bends must not be fitted.

A 92.5º swept elbow is equivalent to 1.0m straight length. A 45º bend is equivalent to 0.5m straight length.

It is possible to have variable flue and air lengths as described within the shaded area of graph below.

Keston System 30 - Flue & Air Pipe Length

38

34

30

26

22

18

14

10

6

Acceptable Operating Area

2

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Flue Pipe Length [m]

sLOpE

‘Horizontal’ flue outlet pipework MUST slope at least 1.5 degrees (26mm per metre run) downwards towards the boiler. Pipework can be vertical. Only swept elbows can be used.

Air inlet pipework can be truly horizontal or vertical, or sloping in a downward direction towards the boiler but in each case rain, etc.,

must be prevented from entering the pipe. There must be no troughs in any of the pipework, whether it be air inlet or flue outlet.


15

INSTALLATION

10 FLUE INsTALLATION ExAMpLE KEsTON sysTEM 30

4m

38


15.5

1.5º back to boiler

34

30

2m

6m

1.5m

1m

Bracket at each 1 metre


6m

0.15m

26

22

18

14

10 10.15

6


2

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30


Calculations

Air

Elbows 2 x 1m = 2m

Straights 6+2+0.15 = 8.15m

Total = 10.15m

Flue

Elbows 3 x 1m = 3m

Straights 4+6+1.5+1 = 12.5m

Total = 15.5m

Overall Flue / Air = 25.65m

11 FLUE INsTALLATION ExAMpLE KEsTON sysTEM 30

Sleeve

Air

0.15m

4m

4m


3.5m

3.5m

Bracket every

1 metre


2m

2m

1.5m

2.5m

Air

4 x 90º elbows

Straight lengths

Calculations

4

2

2

3.5

4

0.15

15.65

Flue

3 x 90º elbows

Straight lengths

3

2.5

1.5

3.5

4

14.5

Overall Flue / Air = 30.15m

38

34

30

26

22

18

14

10


14.5

15.65

6


2

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30


16


12 FLUE TERMINATION pOsITION

INSTALLATION

Twin Flue Positions Flue Minimum Spacing Air Minimum Spacing

I.

J.

K.

L.

M.

N.

E.

F.

G.

H.

A.

B.

C.

D.

Below an opening (1)

Above an opening (1)

Horizontally to an opening (1)

Below gutters, soil pipes or drain pipes

Below eves

Below balcony or car port roof

From a vertical drain pipe or soil pipe

From an internal or external corner or to a boundary alongside the terminal

Above ground, roof or balcony level

From a surface or a boundary facing the terminal

From a terminal facing the terminal

From an opening in the car port into the building

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

300 mm

300 mm

300 mm

75 mm

200 mm

200 mm

150 mm

300 mm

300 mm

600 mm

1200 mm

1200 mm

1500 mm

300 mm

12"

12"

12"

3"

8"

8"

6"

12"

12"

24"

48"

48"

60"

12"

50 mm

50 mm

50 mm

75 mm

50 mm

50 mm

50 mm

50 mm

100 mm

100 mm

1200 mm

100 mm

1500 mm

300 mm

4"

4"

48"

4"

60"

12"

2"

2"

2"

2"

2"

2"

2"

3"

(1) An opening here means an openable element, such as a openable window, or a fixed opening such as an air vent. However, in addition, the outlet should not

be nearer than 150mm (fanned draught) to an opening into the building fabric formed for the purpose of accommodating a built in element, such as a window frame.

The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions.

boundary

J

H boundary

I

L

F

G

I

A

B

C

D, E

F

F

M

N

K

gENERAL INsTALLATIONs

All parts of the system must be constructed in accordance with BS 5440 Part 1, except where specifically mentioned in these instructions.

All pipe work must be adequately supported.

All joints other than approved push-on or plastic compression connectors must be made and sealed with solvent cement suitable for muPVC pipes and conforming to BS 6209: 1982.

Consideration must be given to Corgi/Gas Safe bulletin TB200/TB008 regarding flues in voids.

The boiler casing must always be correctly fitted to the boiler when leaving the appliance operational.

External wall faces and any internal faces of cavity walls must be good.

AIR sUppLy

The Keston Combi is a room-sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air.

COMpARTMENT INsTALLATION

Due to the low casing temperatures generated by the boiler, no compartment ventilation is required. However, the cupboard or compartment must not be used for storage.


17

INSTALLATION

13 INsTALLINg ThE BOILER

Installation of the boiler is straightforward but consideration must be given to access to allow flue and air pipes to be pushed through walls and ceilings. The order in which the components are installed will depend upon particular site conditions, but in general it will be easiest and most accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal - this is the sequence described.

14 WALL MOUNTINg TEMpLATE

The wall mounting template is located on the internal protective packaging.

Note.

The template shows the positions of the fixing holes and the rear flue hole centre for standard installation. Care MUST be taken to ensure the correct holes are drilled.

1. Tape template into the selected position. Ensure squareness by hanging a plumbline as shown.

2. If fitting a side flue extend the flue centre line onto the side wall and measure in 155mm for standard installation.

3. Mark onto the wall the following:

a The wall mounting plate screw positions (choose one from each group).

b. The position of the flue duct hole (see diagram below).

Note. Mark the centre of the hole as well as the circumference.

4. Remove the template from the wall.

3G10378

18

15 pREpARINg ThE WALL

IMpORTANT.

Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury.

1. Cut the flue and air holes (preferably with 60mm core bore tool) ensuring the holes are square to the wall.

2. Drill 2 holes with a 7.5mm / 8mm masonry drill and insert the plastic plugs, provided, for the wall mounting plate.

3. Locate 2 No.14 x 50mm screws in the wall mounting plate

(one at each side, in any of the 3 holes provided at each side) and screw home.

Rear flue only

60mm diameter holes

X

Section through wall

Note. Check all of the hole positions before drilling.


INSTALLATION

16 FITTINg ThE WALL MOUNTINg pLATE 17 MOUNTINg ThE BOILER

Screw the wall mounting plate to the wall using 2 wall plugs

(previously fitted) with the 2 screws provided.

Choose one of the 2 sets of slots in left and right bank.

Ensuring that at least one of the screws is fitted into a top slot.

1. Ensure the plastic plug is removed from the CH connections before mounting the boiler.

2. Lift the boiler onto the wall mounting plate (refer to the

Introduction section for safe handling advice), locating it over the two tabs.

Example of fixing

3G9948

18 AssEMBLy pRACTICE

Remove all plastic debris and burrs when installing air intake piping.

Plastic fillings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower. Prevent dust entering the air intake when cutting on building sites. Blower failure which is determined to be caused by plastic filings or other debris will not be covered by guarantee.

INsTALLINg FLUE AND AIR pIpEs

Important - When installing the boiler on an existing system a new flue and air intake system MUST also be installed. You MUsT NOT re-use existing flue or air pipework components.

•

Remove the flue adaptor and air spigot from the flue pack supplied with the boiler.

•

Remove boiler front panel - Frame 38.

•

Remove air intake blanking plate by unscrewing 4 x M5 screws and put to one side, leaving sponge gasket in place.

•

Fix air spigot to boiler using the 4 M5 screws, see diag. below.

Ensure sponge gasket is in place and not damaged.

•

Insert the flue adaptor into the flue manifold on the top of the boiler ad secure using the clamp provided in the packaging box, see diagram below.

•

Measure, cut and check the air and flue pipes to pass to the exit from the wall(s) or ceiling.

•

Always thoroughly deburr all pipes and most important, remove shavings from within the pipe.

•

Assemble, using solvent weld cement, the pipework from the boiler connections to the exit from the first wall/ceiling, (remount the boiler if removed). When pushing pipe through walls, ensure grit and dust is not allowed to enter the pipe.

Ensure pipes are fully engaged into sockets and solvent welded with no leaks.

•

Using the same methods drill any further holes (always covering existing pipework), cut and assemble the pipework.

•

From outside, complete the two terminations - See Frame

9 Flue System and make good all holes. (Wall sealing collars are available to make good hole areas on the wall face (part number C.08.0.00.07.0).

•

support any pipes whose route could be displaced either of its own accord or by accident. Any horizontal run over 1m or vertical runs of any length must always be supported. Brackets should be placed at intervals of approximately 1m. Brackets should be loose enough on the pipe to allow thermal expansion and contraction movement.

•

Flue pipework through walls MUsT be sleeved to allow thermal expansion and contraction movement.

•

Check all connections for security and re-seal any joints using solvent cement where soundness may be in doubt.

Note. It is equally important to seal the air inlet with solvent cement as the flue outlet pipe joints.


19

INSTALLATION

19 FITTINg ThE sLEEVINg

1. Cut hole in wall.

2. Measure wall Thickness

3. Cut sleeve length to match wall thickness & remove burrs.

4. Grout sleeve into wall with flange on external face.

5. Slide flue pipe into sleeve, checking it is free to slide.

6. Slide Flexible wall seal over flue pipe and push centre ring up to sleeve flange when cold.

7. Locate wall plate over flexible wall seal and clamp in place using the raw plug pack.

8. Affix flue terminal

9. During boiler test check that the flue end is free to expand and contract with flexible wall seal.

Flue

Terminal

Flue Pipe

Flue Sleeve Flue Sleeve Flange

Flexible

Wall

Seal

Wall

Plate

20


INSTALLATION

20 CONDENsATE DRAIN

47

203

Condensate

Drain

149

T his appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the

1st time or after maintenance.

All condensate pipework should conform to the following: a. Where a new or replacement boiler is being installed, access to an internal ‘gravity discharge’ termination should be one of the main factors considered in determining boiler location.

b. Plastic with push fit or solvent connections.

c. Internal plastic pipe work a minimum of 19mm ID (typically

22mm OD) d. External plastic pipe must be a minimum of 30mm ID (typically

32 OD) before it passes through the sleeved wall.

e. All horizontal pipe runs, must fall a minimum of 45mm per metre away from the Boiler.

f. External & unheated pipe work should be kept to a minimum and insulated with Class “O” waterproof pipe insulation.

g. All installations must be carried out in accordance to the relevant connection methods as shown in the “Condensate installation diagrams” & BS6798:2009 h. Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage (through freezing) i. All internal burrs should be removed from the pipe work and any fittings.

In order to minimise the risk of freezing during prolonged very cold spells, one of the following methods of terminating condensate drainage pipe should be adopted.

Internal Drain Connections

Wherever possible, the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc. See Figs 1 and 2.

Condensate pump

Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc. (fig 3).

External Drain Connections

The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously. An external system must terminate at a suitable foul water discharge point or purpose designed soak away.

If an external system is chosen then the following measures must be adopted:

The external pipe run should be kept to a minimum using the most direct and “most vertical” route possible to the discharge point, with no horizontal sections in which condensate might collect.

- For connections to an external soil/vent stack see Fig 4.

Insulation measures as described should be used.

- When a rainwater downpipe is used, an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen, see Fig 5.

- Where the condensate drain pipe terminates over an open foul drain or gully, the pipe should terminate below the grating level, but above water level, to minimise “wind chill” at the open end. The use of a drain cover (as used to prevent blockage by leaves) may offer further prevention from wind chill. See Fig 6.

- Where the condensate drain pipe terminates in a purpose designed soak away (see BS 6798) any above ground condensate drain pipe sections should be run and insulated as described above. See Fig 7

Unheated Internal Areas

Internal condensate drain pipes run in unheated areas, e.g. lofts basements and garages, should be treated as external pipe.

Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual.

Figure 1 - Connection of Condensate Drainage Pipe to

Internal Soil & Vent Stack

Boiler with 75mm sealed condensate trap

Min Ø 19mm

Internal pipe

Minimum connection height up to 3 storeys

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break


Figure 2 - Connection of a Condensate Drainage Pipe

Downstream of a Sink, Basin, Bath or Shower Water Trap to

Internal Soil Vent Stack


Min Ø 19mm

Internal pipe

Sink/basin/ bath or shower

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued . . . . .

21

INSTALLATION

21 CONDENsATE DRAIN - CONT’D.......

Figure 3 - Connection of a Condensate Pump Typical

Method (see manufacturers detailed instructions)

Figure 4 - Connection of condensate Drainage Pipe to

External Soil & Vent Stack


Min Ø 19mm

Internal pipe

Visible air break


Min Ø 19mm

Internal pipe

Min Ø 30mm

Internal pipe

Water/weather proof insulation

Condensate pump

(Install in accordance with manufacturers instructions) Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break

Minimum connection height up to 3 storeys

Figure 5 - Connection of a Condensate Drainage Pipe to an

External Rainwater Downpipe (only combined foul/rainwater drain)


Min Ø 19mm

Internal pipe

Min Ø 30mm

Internal pipe

Terminated and cut at 45º

43mm 90º male/ female bend

Water/ weather proof insulation combined foul/ rain water drain

External air break

Air gap

68mm Ø PVCU

Strap on fitting

Figure 6 - Connection of Condensate Drainage Pipe

Upstream of a Sink, Basin, Bath or Shower Waste Trap to

External Drain, Gulley or Ranwater Hopper


Min Ø 19mm

Internal pipe

Sink, basin, bath or shower with integral overflow and 75mm trap

Visible air break at plug hole

Minimum 30mm internal pipe

Water/ weather proof insulation

45º pipe termination

22

Figure 7 - Connection of a Condensate Drainage Pipe to an

External Purpose Made Soak Away.


Min Ø 19mm

Internal pipe

Min Ø 30mm

Internal pipe

Water/Weather proof insulation

Max 3m external pipework

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break

2 rows of three Ø12mm holes

25mm centres, 50mm from the bottom of the tube, facing away from the house

≥ 500

Limestone chippings


INSTALLATION

22 CONNECTIONs & FILLINg

NOTEs.

Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture.

Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged.

WATER CONNECTIONs Ch

1. Connect the CH flow service valve provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler.

2. Connect the CH return valve.

3. If connecting the boiler to heating loads in excess of

60,000 Btu/h, connecting flow and return heating systems pipework must be sized in 28mm diameter at the point of pipe connection to the boiler tails. Use 22mm x 28mm pipe adaptors as appropriate.

gAs CONNECTION

IMpORTANT. The gas service cock is sealed with a non-metallic blue fibre washer, which must not be overheated when making capillary connections. Refer to Frame 1 for details of the position of the gas connection.

For additional gas supply information refer to “Gas Supply” on page 8.

FILLINg

IMpORTANT - when filling:

A. Ensure the dust cap on air vent located at the rear of the pump chamber is slightly unscrewed.

B. When filling, there may be a slight water leak from the air vent therefore electrical connections should be protected.

Dust Cap

1. Ensure that the Ch isolating handles are open.

2. Fill and vent the system. Refer to Frame 2 for filling and setting pressure procedure.

3. Check for water soundness.

sAFETy VALVE DRAIN

The safety valve connection, located at the bottom right-hand side of the boiler, comprises a 15mm diameter stub pipe.

The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring.

A purpose made safety valve drain pipe is provided with the boiler to allow safe discharge through a wall to the outside of the building. This is particularly relevant to

‘high rise’ installations but can be used for all installations.

Safety Valve

Drain Connection

15mm elbow or fittings

(not supplied)

Safety Valve

Drain Pipe

Keston System -

Note that all isolation handles are shown in the open position.

205552-10119

Black

Handle

CH Flow

Yellow

Handle

Gas

Supply

Installation and Servicing

Black

Handle

CH Return

Safety

Drain

Valve

23

INSTALLATION

23 ELECTRICAL CONNECTIONs

Warning. This appliance MUST be earthed.

A mains supply of 230Vac ~ 50 Hz is required.

The fuse rating should be 3A. All external controls and wiring must be suitable for mains voltage.

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations.

Wiring should be 3 core PVC insulated cable, not less than

0.75mm

2 (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for electrical installations.

Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm (1/8”) contact separation in both poles. The means of isolation must be accessible to the user after installation.

24 INTERNAL WIRINg

The Keston System boiler comes pre-fitted with 1.8m of mains cable. This must be connected to a permanent live supply and NOT switched by thermostats/programmers.

For installers wishing to change this cable refer to Frame 26.

Connecting the Switched Live to the Boiler

1. Consult the Y Plan and S Plan diagrams below.

2. Isolate the mains supply to the boiler

3. Remove the front panel. Refer to Frame 7.

4. Swing the control box down into the servicing position.

5. Route incoming cable through a grommet in the bottom panel (note that the grommets are “blind” and will require puncturing) and secure using the clamp and screws provided in the hardware pack.

6. Connect the switched live to the terminal block as shown.

FROsT ThERMOsTAT - WIRINg

If parts of the system are vulnerable to freezing or the programmer is likely to be left off during cold weather, a frost stat should be fitted in conjunction with a pipe thermostat.

24

KesTon sysTem BoiLer, y PLan sysTem WiThouT WeaTher ComPensaTion

L N E b g/y

FUSED

SPUR g w

R/S C/S

Y PLAN

VALVE o

L N E

BOILER sL

L N E

CH

ON

R/S

ON

HW

ON

HW

OFF

C/S

ON

TIMER

L N CH ON

HW ON

HW OFF

3G10022

See overleaf for S Plan System..................


INSTALLATION

25 INTERNAL WIRINg CONT’D.......

KesTon sysTem BoiLer, s PLan sysTem WiThouT WeaTher ComPensaTion

FUSED

SPUR

L N E g g/y b br o

CH

S PLAN

VALVE g b g/y br

R/S C/S o

L

L N E

CH

ON

R/S

ON

HW

ON

HW

OFF

C/S

ON

N

HW

S PLAN

VALVE

E

BOILER sL

TIMER

L N CH ON

HW ON

3G10023

26 REpLACINg pRE-FITTED MAINs CABLE

If it is necessary to use an alternative mains cable to the one pre-fitted then use the following guide.

Replacement wiring should comply with notes in Frame 23.

1. Isolate the mains supply to the boiler.

2. Remove the front panel. Refer to Frame 7.

3. Swing the control box down into the service position. Refer to frame

46.

4. Remove the live, neutral and earth wires from the terminal block.

5. Loosen the cable clamp and withdraw the mains cable.

6. Route replacement cable back through the cable clamp and grommet and re-tighten to provide cord anchorage.

7. Connect the live, neutral and earth wires to the terminal strip. When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors, such that if the cord anchorage should slip, the current carrying conductors become taut before the earthing conductor.

8. Swing the control box back up into the operating position and re-fit the front panel ensuring a good seal is made.

5


25

26

INSTALLATION

27 FITTINg ThE WEAThER COMpENsATION KIT - sUppLIED As sTANDARD

This kit provides the facility to apply outside air temperature control to the boiler water flow temperature which provides energy savings. The outside sensor provided measures outside air temperature and sends a signal to the boiler, which adjusts the maximum boiler flow temperature in response. If outside air temperature is greater than the system design temperature, the boiler flow temperature is reduced providing running cost savings. The boiler will operate in the condensing mode more frequently increasing savings.

Once the sensor is fitted it is automatically detected.

The sensor operation may be configured by adjustment of the boiler operating parameters, if necessary.

Kit Contents

A. Outside Air Sensor

A

FITTINg ThE KIT

Fitting the sensor

The air sensor should be located on an external wall of the building to be heated. Fix the sensor to a north/north-east facing wall to avoid direct radiation from the sun. The air sensor should be located to avoid any heating effect from the boiler flue.

To fix the air sensor to the wall, unscrew the sensor box plastic cover and screw/plug the sensor body to the wall.

3G10011

Wire a twin core 0.5mm

2 cable from the sensor to the boiler through an RH grommet located on the underside of the boiler. Cable length between sensor and boiler should be no greater than 20m. Note that this connection is safety extra low voltage. It is not necessary for the person carrying out the wiring to be approved to Part P of the Building Regulations.

Avoid running this cable alongside mains voltage cables.

The signal DHW OFF from the system wiring centre and a common neutral must be wired into the appliance through another

RH grommet located on the underside of the boiler. The wire shall be suitable for mains voltages and be 0.5mm

2 twin core with sheath (Double insulated) construction according to current wiring regulations.

Fitting the kit

1. Isolate the electricity supply to the boiler and system controls.

2. Remove the boiler front panel (refer to boiler installation instructions).

3. Hinge down the control box and remove the 2 screws retaining the control box cover, release the 4 retaining clips

(refer to boiler installation instructions).

OUTsIDE sENsOR

WIRINg

WIRINg

CENTRE

CONNECTIONs

Wiring the kit

1. Carefully pierce a grommet using a suitably sized screwdriver.

2. Pass the wire from the outside sensor through this grommet, strip and prepare the ends for termination.

3. Wire the outside sensor into the 2 LHS terminals of the terminal block as shown and labelled.

4. Secure the wire with one bar clamp and two screws, ensure that there is only a small loop between the bar clamp and the grommet, and that the wire can not be trapped.

5. Carefully pierce a separate grommet using a suitably sized screwdriver.

6. Pass the 2 core sheathed wire from the wiring centre through this grommet and strip back the outer sheath, strip and prepare the ends for termination.

7. Wire the switched live signal, DHW OFF, from the wiring centre along with the permanent neutral into the 2 RHS terminals of the terminal block

8. Secure the wire with the other bar clamp and two screws, ensure that there is only a small loop between the bar clamp and the grommet, and that the wire can not be trapped.

9. Re-assemble in reverse order.


INSTALLATION


KEy b - blue br - brown g - green g/y - green/yellow o - orange w - white

Keston system Boiler with y plan system & Weather Compensation Kit

L N E

FUSED

SPUR b g/y w g

Y PLAN

VALVE

R/S C/S o

L N E

BOILER sL

L N E

CH

ON

R/S

ON

HW

ON

HW

OFF

C/S

ON

OUTSIDE

SENSOR

TIMER

L N CH ON

HW ON

HW OFF sL N

‘HW OFF’

Wiring

Centre

Keston system Boiler with s plan system & Weather Compensation Kit

FUSED

SPUR

TIMER

L N E

L N CH ON

HW ON

HW OFF g b g/y

HW

S PLAN

VALVE g g/y b

R/S br

C/S o

CH

S PLAN

VALVE br o

L N E

BOILER sL

L N E CH

ON

R/S

ON

HW

ON

HW

OFF

C/S

ON

OUTSIDE

SENSOR

NOTE. Changes to cylinder stat connections and addition of HW OFF from timer.

sL N

‘HW OFF’

Wiring

Centre


27

INSTALLATION


Ch OpERATION

The On and Off time control of central heating should be controlled by a separate timer.

Weather Compensation Control / Room Setpoint = +20ºC

Heating slope

2.5

2.2 2.0

1.8 1.6

1.4

1.2

1.0

100

During programmed On times the Central Heating Radiator Flow

Temperature is controlled by the boiler relative to the Outside

Temperature as shown in the diagram.

90

80

70

The Room temperature can be adjusted using the Central Heating

Temperature Control Knob on the boiler as follows. Essentially rotating the knob clockwise increases the room temperature and rotating the knob anti-clockwise decreases the room temperature.

If the Central Heating Temperature Control Knob is rotated fully clockwise then for an Outside Temperature of 15°C a Flow

Temperature of 40°C will be provided. For an Outside Temperature of 0°C a Flow Temperature of 78°C will be provided with the

20 relationship varying lineally in between these 2 points (line on the graph 2.5)

10 0 -10 -20

Outside Temperature [ºC]

-30

60

50

40

30

-40

20

If the Central Heating Temperature Control Knob is in its mid position then for an Outside Temperature of 15°C a Flow

Temperature of 36°C will be provided. For an Outside Temperature of 0°C a Flow Temperature of 65°C will be provided with the relationship varying lineally in between these 2 points (line on the graph between 1.6 and 1.8)

If the Central Heating Temperature Control Knob is rotated fully anti-clockwise then for an Outside Temperature of 15°C a Flow

Temperature of 30°C will be provided. For an Outside Temperature of 0°C a Flow Temperature of 44°C will be provided with the relationship varying lineally in between these 2 points (line on the graph 1.0)

DhW OpERATION

When the system is in a timed on period for DHW and the tank stat is not satisfied, a call for heat will be generated on the switched live into the boiler.

At the same time, the HW OFF signal will not be present, this will release the Relay and place a short across the DHW thermistor input on the Main Control board, this will ensure that Weather Compensation adjustment is ignored at this time. The set point will be fixed at 70 degrees.

The demand is indicated on the display by a ‘C’ and the burner on LED as appropriate.

30 ExTERNAL ELECTRICAL CONTROLs

28

Wiring External to the Boiler

The fuse rating should be 3A.

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations.

Frost protection

If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system.

The frost thermostat should be sited in a cold place but where it can sense heat from the system.

Note. If the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework.


31 WIRINg DIAgRAM

Fused at 4A

INSTALLATION

Chassis Earth

Flame Sensor Electrode

Outside Sensor

HW of

Service Connector

Gas Valv

- blue - black - brown - red - pink - yellow - white - yellow/green - grey - orange - violet b bk br r p y w y/g g or v


Pressure Sensor

29

INSTALLATION

32 COMMIssIONINg AND TEsTINg

A. Electrical Installation

1. Checks to ensure electrical safety should be carried out by a competent person.

2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter.

3. After wiring the boiler, all grommets in the bottom panel

MUST be in place to ensure that the boiler case sealing is maintained.

B. gas Installation

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.813:2002.

2. Purge air from the gas installation by the approved methods only.

Warning.

Whilst effecting the required gas tightness test and purging air from the gas installation, open all windows and doors, extinguish naked lights and Do not SmokE.

gENERAL

Please note: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type defined on the appliance data plate. No measurement of the combustion is necessary. DO NOT adjust the air/gas ratio valve.

Having checked:

- That the boiler 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:

ChECK ThE OpERATIONAL (WORKINg) gAs

INLET pREssURE

Set up the boiler to operate at maximum rate.

With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point complies with the requirements - refer to “Gas

Supply” on page 8.

Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.

Gas

Supply

30

205552-10118

Gas Pressure

Test Point

As part of the commissioning process, the combustion of this appliance must be checked and the Benchmark Checklist completed. A flow chart to assist is provided on page 61.

ATTENTION !

IT Is A CONDITION OF ThE MANUFACTURERs WARRANTy ThAT ThE

BENChMARK COMMIssIONINg ChECKLIsT Is FULLy COMpLETED

AND LEFT WITh ThE AppLIANCE


INSTALLATION

33 INITIAL LIghTINg

Legend

A. CH temperature control

B. Mode Control Knob

C. Boiler Status

D. Burner ‘on’ indicator

E. CH Flow Isolating Valve

F. Pressure Gauge

g. Gas Inlet Pressure Test Point

h. Gas Service Cock

J. CH Return Isolating Valve

K. Drain Valve

A

F

CH Flow

E

10121

Note. Valves shown are in the open position.

H

C D

K

B

G

Gas Supply

Drain

Valve

J CH Return

Safety

Drain

Valve

1. Check that the system has been filled and that the boiler is not airlocked. Ensure the automatic air vent cap is open. Refer to

Frame 22.

Note.

It is important the burner is not operated before the system is fully vented of air. If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off.

2. Refit the boiler front panel. Refer to Frame 38.

3. Check that the drain valve (K) is closed and that the CH isolating valve (E and J) are OPEN.

4. Check that the electrical supply is OFF.

5. Check that the boiler mode control knob (B) is off.

6. Check that the gas service cock (H) is OPEN.

7. Slacken the screw in the inlet pressure test point (G) and connect a gas pressure gauge via a flexible tube.

8. Switch the electricity supply ON and check all external controls are calling for heat.

CENTRAL hEATINg

9. Set the CH temp control (A) to max and turn the mode control knob

(B) to ON. The boiler control should now go through its ignition sequence until the burner is established.

10. If the boiler does not light after 5 attempts the boiler will lock out and display fault code constantly. Reset the boiler (Refer to

Frame 37). The boiler will repeat its ignition sequence. If reset occurs 5 times within 15 minutes then is removed this will be reset.

will be shown. If power

When the burner is established the BLUE ‘Burner On’ neon (D) will be illuminated, the LED display (C) will show status .

11. Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2.

IMpORTANT

The gas input to the burner is regulated by the gas valve according to the air flow 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.

For additional gas supply information refer to “Gas Supply” on page 8.

ThE DIspLAy

The user control has one neon and one display to inform the user about the status. The display will show the status of the boiler. The neon will show the status of the flame.

If no flame is detected the neon is off. When the flame is detected the neon will be lit permanently.

Below is a list with display function in normal operation.

Standby, no demand for heat present.

Boiler is active for central heating or hot water.

Boiler is active for boiler frost protection.

Boiler is in lockout for a specific error. Display will be blinking, alternating with a number or letter to show which error is detected.

Boiler has a fault for a specific error. Display will be blinking, alternating with a number or letter to show which error is detected.

Note: Boiler frost protection - boiler fires if temperature is below 5 degrees C.

Note. The boiler incorporates a fan overrun cycle which

MUST NOT be prematurely interrupted by isolation of the mains electricity supply.


31

INSTALLATION

34 gENERAL ChECKs

Make the following checks for correct operation:

CENTRAL hEATINg (Ch) MODE

1. Ensure that the CH external controls are calling for heat.

The display should read:

2. Check the boiler gas rate when the boiler is at full output.

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

3. Set the central heating external controls to OFF. The burner should go off and the pump continue to run for 4 minutes

The display should read:

4. Check the correct operation of the timer and all other system controls. Operate each control separately and check that the main burner responds.

WATER CIRCULATION sysTEM

1. With the system COLD, check that the initial pressure is correct to the system design requirements.

For pre-pressurised systems, this should be 1.0 bar.

2. With the system HOT, examine all water connections for soundness. The system pressure will increase with temperature rise but should not exceed 2.5 bar.

3. 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 Frame 4.

4. Refill and vent the system, add inhibitor (see Frame 4), clear all air locks and again check for water soundness.

5. Reset the system initial pressure to the design requirement.

6. Balance the system. Refer to Frame 3.

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

8. Finally, set the controls to the User’s requirements.

Note: The pump will operate briefly as a self-check once every 24 hours in the absence of any system demand.

WATER TEMpERATUREs

Temperatures can be selected using the

CH temperature control (A)

Knob Setting CH Flow Temp ºC (ºF)

Max 80 (176)

Min 30 (86)

35 REsET pROCEDURE

Legend

A. CH temperature control

B. Mode Control Knob

C. Boiler Status

D. Burner ‘on’ indicator

To reset boiler, turn the mode control knob (B) to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence.

A C D B

36 hANDINg OVER

After completing installation and commissioning of the system the installer should hand over to the householder by the following actions:

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

2. Explain and demonstrate lighting and shut down procedures.

3. The operation of the boiler 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 the building, in the event of the system remaining inoperative during frosty conditions.

4. Explain the function and the use of the boiler heating controls.

5. Explain the function of the boiler fault mode.

Emphasise that if a fault is indicated refer to “Fault Codes” in the

User Guide.

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

7. If a timer is fitted draw attention to the timer Users Instructions and hand them to the householder.

8. Loss of system water pressure

Explain that the dial underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated. Explain the re-pressurising procedure and if unable to re-pressurise or if the pressure continues to drop a registered local heating installer should be consulted.

9. Explain Boiler reset procedure.

10. After installation and commissioning please complete the

Benchmark Commissioning Checklist before handover to the customer. For IE, its is necessary to complete a “Declaration of

Conformity” to indicate compliance to I.S. 813:2002.

IMpORTANT

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).

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

32


SERVICING

37 sERVICINg sChEDULE

For the very latest copy of literature for specification & maintenance practices, visit our website www.keston.co.uk, where you will be able to download the relevant 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.

Combustion testing must be carried out by a competent person using a combustion analyser conforming to Bs7927.

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.

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).

INspECTION

1. Light the boiler and carry out a pre-service check, noting any operational faults.

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

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, vented and re-pressurised.

CLEANINg pROCEDURE

Note. In order to carry out either servicing or replacement of components the boiler front panel must be removed.

Refer to Frame 38.

1. Clean the main burner. Refer to Frame 40.

2. Clean the heat exchanger & condensate trap/siphon.

Refer to Frames 42 & 41.

3. Check the main injector for blockage or damage. Refer to

Frame 46.

4. Check that the flue terminal is unobstructed and that the flue system is sealed correctly.

The cleaning procedures are covered more fully in Frames

40-44 and MUST be carried out in sequence.

IMpORTANT.

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

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

Do noT oPeraTe the boiler if the front panel is not fitted.

8. If, for any reason, the condensate trap/siphon has been removed ensure the trap is refilled with water before reassembling.

9. Check the gas consumption.

10. Check combustion by connecting the flue gas analayser to the flue gas sampling point as shown in the diagram and measure CO & CO

2

.

If the CO/CO

2 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 Keston.

11. Complete the service section in the Benchmark

Commissioning Checklist.

gENERAL

Please note: During routine servicing, and after any maintenance or change of part of the combustion circuit, the following must be checked:

- The integrity of the flue system and the flue seals,

- The integrity of the boiler combustion circuit and the relevant seals

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

- The gas rate

- The combustion performance.

COMpETENCE TO CARRy OUT ThE ChECK OF

COMBUsTION pERFORMANCE

Please note: BS 6798:2009 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.

- The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers requirements, and

- Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS7967, Parts 1 to 4.

Flue sampling point


33

SERVICING

38 BOILER FRONT pANEL REMOVAL / REpLACEMENT

REMOVAL

1. Loosen the two screws retaining the front panel.

2. Pull the two spring clips down to disengage and pull panel forward and upward and remove.

REpLACEMENT

3. Hook the panel onto the top retaining clips.

4. Push the panel until the 2 bottom spring clips engage ensuring the 4 control knobs line up with the holes in the front panel.

5. Re-tighten the two retaining screws.

3

1

2 view from bottom of boiler

34

view from top of boiler

39 FAN AND VENTURI AssEMBLy REMOVAL AND CLEANINg

1. Disconnect the electrical leads from the fan.

2. Undo the gas pipe union connection to the injector housing.

3. Remove the extended nut on the fan mounting bracket.

4. Lift off fan and venturi assembly.

5. Inspect the injector for blockage or damage.

6. Inspect fan outlet sealing gasket and replace if necessary.

3

5

Injector

2

1


SERVICING

40 BURNER REMOVAL AND CLEANINg

1. Ensure the sump is fully drained

2. Undo the two screws and remove the sump cover retaining the lower flue manifold.

3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

4. Remove the 2 burner front fixing screws and loosen the 2 rear extended nuts by at least ten turns.

5. Lift off the burner from the combustion chamber. To facilitate the removal angle the burner as shown.

IMpORTANT

The burner head is a ceramic plaque construction. Care must be taken to ensure that the burner is not placed down upon

its face as this may cause damage to the ceramic.

6. Brush off any deposits that may be on the ceramic with a

SOFT brush.

7. Inspect the sealing gasket around the burner for any signs of damage. Replace as necessary.

2

5

3

4

4

41 CLEANINg ThE CONDENsATE TRAp/sIphON

1. Pull off the rubber pipe at the sump drain.

2. Disconnect the condensate drain pipe.

3. Turn the siphon clockwise to disengage and lift to remove.

Note. Keep siphon upright when removing

4. Clean siphon with water.

5. Re-assemble in reverse order.

B When re-assembling ensure the trap is full of water.

2

4

2


35

36

SERVICING

42 CLEANINg ThE hEAT ExChANgER

note: Ensure the condensate trap/siphon

is fully drained before cleaning. Refer to

Frame 55.

1. Remove ignition and flame detection electrodes. Refer to Frames 51 & 52.

2. It is advisable to replace the sump cover prior to the water flush process.

3. Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered.

4. Remove the sump cover and clean loose deposits from the sump.

5. Inspect the ignition and detection electrodes. Ensure that they are clean and in good condition - replace if necessary.

6. Re-fit the ignition and flame detection electrodes, ensuring that both earth tabs are fitted to ignition electrode.

7. Check that the ignition and detection gaps are correct. Refer to Frames 51 & 52.

1

Ignition Electrode

3

Flame Detection

43 REAssEMBLy

Reassemble the boiler in the following order:

1. Ensure that the condensate trap/siphon is full of water.

2. Refit the burner ensuring the sealing gasket is correctly positioned and free from damage (tighten the 4 fixing screws in the sequence shown below).

3. Refit the fan / venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly positioned and free from damage.

4. Reconnect the fan electrical leads.

5. Remove the sump cover and refit the lower flue manifold as shown.

6. Refit the sump cover.

7. Refit the boiler front panel.

IMpORTANT. Ensure that the boiler front panel is correctly fitted and that a good seal is made.

8. Swing the control box back into its working position and secure.

9. Turn on the gas supply at the gas service cock.

10. Reconnect the electrical supply.

11. Check the operation of the boiler. refer to Frame 32-34

4

2

.

5

1

3


SERVICING

44 REpLACEMENT OF COMpONENTs

gENERAL

When replacing ANy component

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel. Refer to Frame 38.

4. Release the retaining clip and swing the control box down into its servicing position.

After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion test.

IMpORTANT.

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

Notes.

1. In order to assist fault finding, the control panel has an LED diagnostic display. The key to boiler fault

conditions is shown in Frame 67.

2. In order to replace components in Frames 58-64 it is necessary to drain the boiler. Refer to Frame 57.

4

ThE BOILER MUsT NOT BE OpERATED WIThOUT ThE FRONT pANEL FITTED

45 FAN REpLACEMENT

1. Refer to Frame 44.



4. Remove the extended nut retaining the fan mounting bracket.

5. Lift and remove the fan and venturi assembly.

6. Remove the screw and twist venturi anticlockwise to remove venturi assembly, noting the orientation of the venturi in relation to the fan body.

7. Transfer the venturi assembly to the new fan, replacing the ‘o’ ring if evidence of damage or deterioration is visible.

8. Fit the new fan / venturi assembly ensuring the retaining tabs are correctly positioned and the fan outlet sealing gasket is correctly positioned and free from damage. Refit the extended nut.

9. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket.

10. Check the operation of the boiler. Refer to

Frames 32-34.


4

8

3

6

Retaining Tabs

2

37

SERVICING

46 BURNER INJECTOR REpLACEMENT

4 1. Refer to Frame 44.



4. Loosen the screw retaining the fan mounting bracket.

5. Lift and remove the fan and venturi assembly.

6. Remove the 2 injector housing screws.

7. Withdraw the injector housing.

8. Fit the new injector housing complete with injector.

9. Reassemble in reverse order, ensuring that the new gas seal supplied is located correctly in the injector housing.

10. Check operation of the boiler. Refer to Frames

32-34.

6

3

2

47 BURNER REpLACEMENT

1. See Frame 40.


3. Undo the two screws and remove the sump cover.

4. Lift the manifold to clear the bottom sealing gasket and remove manifold.

5. Remove the 2 front fixing screws and loosen the 2 rear extended nuts.

6. Lift off the burner from the combustion chamber. To facilitate the removal angle the burner as shown.

7. Fit the new burner, replacing any damaged or deteriorating sealing gasket.

8. Reassemble in reverse order. Refer to Frame 43.

9. Check the operation of the boiler. Refer to Frames 32-34.

3

6

4

5

38

3

5


SERVICING

48 RETURN ThERMIsTOR RENEWAL


2. Unclip the return thermistor from the return pipe and withdraw it from the boiler.

3. Disconnect the electrical leads from the thermistor.

4. Reconnect the electrical lead to the new thermistor and reassemble in reverse order, ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown.


4

Thermistor Locator Tab

(with thermistor fitted)

2

49 FLUE ThERMOsTAT REpLACEMENT


2. Undo the two screws and remove the sump cover plate.

3. Disconnect the two flag terminals from the flue thermostat.

4. Lift the manifold to clear the bottom

.

sealing gasket and remove manifold.

5. Unscrew the two M3.5 screws that connect the thermostat to the manifold.

6. Replace thermostat with new part and then refit the two screws, remembering to fit rubber gasket and sealing clamp.

Flue Thermostat


39

SERVICING

50 IgNITION ELECTRODE REpLACEMENT


2. Remove the burner. Refer to Frame 47.

3. Unplug the ignition lead from the electrode.

4. Remove the earth lead from the ignition electrode.

5. Remove the 2 screws holding the ignition electrode to the combustion chamber.

6. Remove the electrode.

7. Fit the new ignition electrode, using the new gasket supplied. Check dimensions as shown.

8. Reassemble in reverse order.

9. Check the operation of the boiler. Refer to

Frames 32-34.

Ignition Electrode

Str aig ht ed ge

Spark Gap

3.5mm

3mm

51 FLAME DETECTION ELECTRODE REpLACEMENT


2. Remove the burner. Refer to Frame 47.

3. Unplug the flame detection lead from the electrode.

4. Remove the 2 screws retaining the detection electrode.

5. Remove the electrode.

6. Fit the new flame detection electrode, using the new gasket supplied.


8. Check the operation of the boiler. Refer to

Frames 32-34.

Str aig ht ed ge

Flame Detection Electrode

12.5mm

40


SERVICING

52 spARK gENERATOR REpLACEMENT


2. Disconnect the leads from the spark generator.

3. Remove the M5 screws securing the spark generator to the boiler chassis.

4. Fit the new spark generator and reassemble in reverse order ensuring the two earth leads are correctly replaced.

5. Check operation of the boiler. Refer to Frames 32-34.

2

Spark Generator

4 3

2

3

53 gAs CONTROL VALVE REpLACEMENT


2. Unplug the electrical lead connection from the gas control valve and disconnect the earth wire.

3. Undo the union nut on the outlet of the gas control valve.

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

5. Loosen the back nut retaining the valve to the bracket and withdraw the valve forwards.

6. Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections.

7. Check operation of the boiler. Refer to Frames

32-34.


4

2

3

5

41

SERVICING

54 CONDENsATE TRAp/sIphON REpLACEMENT


Note: Ensure condensate trap is fully drained before removal.

2. Pull off the rubber pipe at the sump drain.

3. Disconnect the condensate drain pipe.

4. Turn the siphon clockwise to disengage and lift to remove.


6. When reassembling ensure the trap is full of water.

7. Check operation of the boiler. Refer to Frames 32-34.

4

2

Siphon

3

42


SERVICING

55 MAIN pCB REpLACEMENT

Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output.

Note. Fit the earth strap provided with the

PCB to your wrist and secure to a suitable earth on the boiler chassis.


2. Note the control knob positions.

3. Remove the 2 screws retaining the control box cover.

4. Carefully lift the 4 retaining clips and remove control box cover.

5. Unplug all lead connections to the PCB including the ribbon cable (to facilitate ribbon cable removal, ease side clips apart and pull upwards), also where applicable, push the small plastic clip with an electrical screwdriver to facilitate plug removal.

6. Spring out the two side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts.

7. Take the new Primary PCB and attach the appropriate Boiler Chip Card (BCC)

Note. Ensure the correct orientation of

BCC by placing “TOP” side up as shown.

8. Re-connect all plug connections.


10. Turn power back on to the boiler, after a few moments the display will start alternating between “F” and “0”. Turn the reset knob fully clockwise and when the display shows “ - ” turn the knob fully anticlockwise IMMEDIATELY.

Finally move the knob into the required position.

11. Check operation of the boiler. Refer to

Frames 32-34.

5

Plastic

Clip

3

5

4

6

Ribbon Cable Connection

7


43

SERVICING

56 UsER CONTROL pCB REpLACEMENT

Note. Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis.


2. Remove the main PCB, refer to Frame 55.

3. Unclip the PCB and lift to clear the mounting posts.

4. Fit the new PCB ensuring the 2 potentiometer spindles line up with the control knobs which must be in a vertical position.



32-34.

4

PCB

3

Potentiometer spindle

Control Knobs (to be in vertical position)

3G9954

57 DRAININg ThE BOILER

CENTRAL hEATINg CIRCUIT


2. Close all the CH water isolating valves on the boiler inlet.

3. To drain the primary heat exchanger circuit:

Open the drain valve and attach a length of hose to the CH drain point.

4. After replacing any component on the boiler, remove the hose, close the drain valve and open all system isolating valves (re-pressurise as appropriate) before proceeding to check operation of the boiler.


32-34.

CH

Flow

44

Gas

CH

Circuit

Drain

CH

Retrun

3G9955


58 pREssURE gAUgE RENEWAL


2. Drain the heating system. Refer to

Frame 57.

3. Unscrew the pressure gauge and discard.

4. Fit new pressure gauge, using suitable jointing compound.

5. Refill the boiler. Refer to Frame 22.

6. Check operation of the boiler. Refer to

Frames 32-34.

SERVICING

59 sAFETy RELIEF VALVE RENEWAL


2. Drain the boiler. Refer to Frame 57.

3. Remove the condensate trap/siphon. Refer to

Frame 54.

4. Remove expansion vessel. Refer to Frame 65.

5. Disconnect the electrical connection from the return thermistor.

6. Disconnect the 22mm pipe connection at the rear of the pump outlet.

7. Pull off the clip retaining the pipe to the heat exchanger swing the pipe to clear the pump and remove pipe.

8. Undo the safety valve union connection.

9. Withdraw the clip securing the safety valve.

10. Lift safety valve from boiler.

11. Fit the new safety valve and reassemble in reverse order ensuring the new ‘o’ ring is fitted to the top of the return pipe.

12. Refill boiler. Refer to Frame 22. Check operation of boiler. Refer to Frames 32-34.

9

10

7

5

8

6

60 pUMp AUTOMATIC AIR VENT REpLACEMENT



3. Remove the expansion vessel. Refer to Frame 65.

4. Firstly, increase access area by disconnecting the 22mm pipe connection at top of pump chamber and bottom of heat exchanger and remove pipe

Refer to Frame 59 (no’s 5,6 & 7).

5. The automatic air vent head is retained in the pump body with a bayonet connection. The air vent head and float assembly is removed by turning the head anti-clockwise (viewed from above) and pulling upwards.

6. Reassembly is the reverse of the above. Ensure the air vent head ‘o’ ring seal is in place when refitting and the new ‘o’ ring is fitted to the return pipe top connection.

7. Ensure the air vent cap is loose.

8. Refill the boiler. Refer to Frame 22. Check for leaks around the new air vent joint.



Dust Cap

5

45

61 pUMp hEAD REpLACEMENT



3. Disconnect the electrical lead from the pump.

4. Remove the 4 Allen screws retaining the pump head.

5. Remove the pump head.

6. Fit the new pump head.



9. Check operation of the boiler. Refer to Frames 35,

32-34.

SERVICING

4

3

62 Ch WATER pREssURE sENsOR REpLACEMENT


2. Drain the boiler. Refer to frame 57.

3. Remove condensate trap/siphon. Refer to Frame 54.

4. Using a suitable tool pull out the retaining clip.

5. Pull the pressure sensor upwards to remove.

6. Unplug the electrical connection and transfer to the new pressure sensor.

7. Push the new pressure sensor onto the rear pump housing and fit retaining clip.



10. Check Operation of the boiler. Refer to

Frames 32-34.

4 5

6

63 CONTROL / NO FLOW ThERMIsTOR REpLACEMENT


2. Drain down the boiler. Refer to Frame 57.

3. Unplug the electrical lead.

4. Unscrew the thermistor (to facilitate removal a

13mm socket spanner should be used).

5. Fit the new thermistor using the sealing washer provided.

6. Reassemble in the reverse order.


8. Check the operation of the boiler. Refer to Frames

32-34.

4

3

46


SERVICING

64 hEAT ENgINE RENEWAL

Refer also to Frame 5 - ‘Boiler Exploded View’

IMpORTANT

Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.



3. Remove the fan / venturi assembly and place on one side.

Refer to Frame 45.

4. Remove the burner and place on one side. Refer to Frame

47.

5. Remove the ignition and detection electrodes. Refer to

Frames 50 & 51.

6. Remove the spark generator. Refer to Frame 52.

7. Remove the gas valve. Refer to Frame 53.

8. Remove the expansion vessel. Refer to Frame 65.

9. Remove the control/no flow thermistor. Refer to Frame 63.

10. Remove the 2 M5 screws retaining the gas valve mounting bracket and transfer bracket to the new heat exchanger.

11. Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe.

12. Undo the flow pipe union nut and remove pipe.

13. Remove the condensate rubber pipe. Refer to Frame 54, no.

2.

14. Remove the two heat exchanger fixing screws.

15. Remove the Heat exchanger.

16. Reassemble in reverse order, ensuring the heat exchanger

LH retaining bracket is correctly positioned. Replace any new ‘o’ rings supplied with new heat exchanger and replacing gaskets or seals if any sign of damage is evident. When replacing the spring clips located on both the flow and return pipe connections, ensure clip is oriented to correctly match connecting pipe diameters.

17. Ensure the trap/siphon is filled with water. Refer to Frame 55.

18. Refill the boiler. Refer to Frame 22.

19. Check operation of the boiler. Refer to Frames 32-34.

12

10


14

11

47

48

SERVICING

65 ExpANsION VEssEL REChARgINg & REpLACEMENT

REChARgINg

1. Remove the charge point cover.

2. Recharge the tank pressure to 0.75 bar.

3. Re-assemble in reverse order


Frames 32-34.

REpLACEMENT


6. Drain the boiler CH circuit. Refer to Frame 57.

7. Unscrew the union nut on the vessel water connection pipe.

8. Support the expansion vessel and unscrew the 2 screws from the securing clamp, located on the top of the boiler, and remove. (Note the position of the bracket on the vessel)

9. Remove the expansion vessel.

10. Fit the new expansion vessel.

11. Reassemble in reverse order.

12. Refill the boiler. Refer to Frame 22.

13. Check operation of the boiler. Refer to

Frames 32-34.

7

9

66 BOILER sEALINg pANEL sEAL REpLACEMENT


2. Remove the old seal from the casing and thoroughly clean the casing surfaces.

3. Fit the new seal, ensuring the bottom joint provides an air tight seal.



Frames 32-34.

Note. Ensure that the boiler front panel is correctly sealed, compressing the seal to make an airtight joint.

Recharge

Point


Fault Finding

67 FAULT FINDINg ChART MAIN MENU

In order to assist fault finding the boiler has a 7 segment display. The key to the display codes is as follows:

ALTERNATINg ‘L’ and ‘1’

gO TO FRAME 68 -

FLOW TEMpERATURE OVERhEAT LOCKOUT or NO WATER FLOW LOCKOUT




ALTERNATINg ‘F’ and ‘0’









ALTERNATINg ‘c’ and ‘2’

gO TO FRAME 69 -

IgNITION LOCKOUT

5 REsETs WIThIN 15 MINs -

TURN pOWER OFF AND ON gO TO FRAME 70 -

FALsE FLAME LOCKOUT

BCC (BOILER ChIp CARD) NOT FITTED sEE FRAME 55 gO TO FRAME 71 -

LOW WATER pREssURE gO TO FRAME 72 -

FLAME LOss gO TO FRAME 73 -

FAN FAULT gO TO FRAME 74 -

CONTROL/NO FLOW ThERMIsTOR FAULT gO TO FRAME 75 -

RETURN ThERMIsTOR FAULT gO TO FRAME 76 -

OUTsIDE sENsOR FAULT

LOW MAINs VOLTAgE -

CONTACT ELECTRICITy pROVIDER pCB FAULT -

**REpLACE pCB gO TO FRAME 77 -

BCC FAULT (BOILER ChIp CARD)

ALTERNATINg ‘c’ and ‘0’

REsET BOILER

NO Ch

gO TO FRAME 78

NO hW

gO TO FRAME 80

Ch & hW OpERATION REVERsED

ChECK sysTEM CONTROLs WIRINg TO

BOILER sEE FRAME 28

NO DIspLAy

gO TO FRAME 79

Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output.

**If PCB replaced as a spare ensure that the BCC (boiler chip card - small plastic part) is fitted to the PCB otherwise replace PCB.

REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.


49

Fault Finding

68 ALTERNATINg ‘L’ AND ‘1’ - FLOW TEMpERATURE OVERhEAT LOCKOUT OR NO

WATER FLOW LOCKOUT

Is the Boiler and CH System filled with water and all isolation and radiator valves open?

YES

If the PCB has been replaced check a BCC has been fitted then reset the boiler.

NO Fill and vent the system and open all isolation valves, then reset boiler

YES

Is the Flow/Return Differential across the Boiler in excess of 30°C?

NO

Check the Control/No Water Flow and Return

Thermistors (Refer to Frame 48 & 63)

Check that the Pump is rotating freely. Is the Differential now below 20°C?

NO YES

Replace the Pump, then reset boiler

OK, now reset boiler


69 ALTERNATINg ‘L’ AND ‘2’ - IgNITION LOCKOUT

50

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

YES

Check the detection electrode and associated harness for: continuity, visual condition and position (Refer to

Frame 51). Check if the condensate pipe is blocked. Replace as necessary

NO

Check ignition electrode and associated harness for: continuity, visual condition and position. (Refer to Frame 50) Are these functioning correctly?

YES

YES NO

Check siphon and condensate drain pipe work for blockage and rectify if necessary. Boiler now working OK?

NO

Check flue for obstruction

NO

YES

YES Check wiring to thermostat

NO

Check flue temperature always remains below 90ºC

NO

YES

YES

Check if burner is damaged

NO

Replace heat exchanger

Is the Gas Pressure available at the Boiler Inlet (>18 mbar)?

YES

Is approx 215Vdc supply available at the Gas Valve? (* See note)

YES

Unplug gas valve. Is resistance between outside pins 4KΩ (±2)?

YES

Check spark generator and associated harness for: continuity and visual condition. (Refer to Frame 52) Are these functioning correctly?

Replace Ignition Electrode and associated harness as necessary

Clear obstruction

Ensure wiring correctly connected

Replace Thermostat

Replace burner

NO

NO

NO

NO

Check gas supply and rectify fault

Check wiring connection from gas valve to PCB for continuity. If the wiring is

OK then replace the PCB

Replace Gas Valve

Replace Spark

Generator and harness as necessary

* note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.



Fault Finding

70 ALTERNATINg ‘L’ AND ‘6’ - FALsE FLAME LOCKOUT

Reset the boiler, does Boiler Work OK?

NO

YES

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

Electrode and replace if deteriorated.

YES

Separate the flame detection electrode in-line connector. Is there continuity between the terminals pins connected to the electrode?

NO

Replace Flame Detection Electrode

Check routing and integrity of internal boiler wiring.


71 ALTERNATINg ‘F’ AND ‘1’ - LOW WATER pREssURE

NO

Is the Boiler and CH System filled with water and all isolation and radiator valves open (check pressure gauge is between 1 to 1.5 bar)?

Fill and vent the system and open all isolation valves

NO

YES

Re-fit connections

Are connections on water pressure sensor secure?

YES

Replace water pressure sensor

72 ALTERNATINg ‘F’ AND ‘2’ - FLAME LOss

Does the boiler ignite for a short time and then extinguish?

NO

Is the Gas Pressure available at the Boiler Inlet (18 mbar)?

YES YES

Check the detection electrode and associated harness for: continuity, visual condition and position (Refer to Frame 51).

Check if condensate pipe is blocked. Check if flue is blocked. Replace as necessary

Is 215Vdc supply available at the

Gas Valve while the flame is on?

(* See note)

Check siphon and condensate drain pipe work for blockage and rectify if necessary. Boiler now working OK?

NO

Check flue for obstruction

NO

Check wiring to thermostat

YES

YES

Check spark generator and associated harness for: continuity and visual condition. (Refer to Frame 52) Are these functioning correctly?

YES

Check ignition electrode and associated harness for: continuity, visual condition and position. (Refer to Frame 56) Are these functioning correctly?

NO

NO

NO

NO

NO

Check flue temperature always remains below 90ºC

NO

Check if burner is damaged

NO

Replace heat exchanger

YES

YES

YES

Replace Gas Valve

Clear obstruction

Ensure wiring correctly connected

YES

Replace Thermostat

YES

Replace Burner

Check gas supply and rectify fault

Check wiring from gas valve to PCB for continuity.

If the wiring is OK then replace the PCB

Replace Spark Generator and Harness as necessary.

Replace Ignition

Electrode and associated harness as necessary

* note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.


51

Fault Finding

73 ALTERNATINg ‘F’ AND ‘3’ - 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?

YES

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

NO

NO

YES

Rectify Wiring & connections

Replace PCB

Replace Fan

74 ALTERNATINg ‘F’ AND ‘4’ - CONTROL / NO FLOW ThERMIsTOR FAULT

Remove the Control/No Flow Thermistor from the

Heat Exchanger and disconnect the wires.

Check the resistance using a suitable multimeter connected across the thermistors terminal pins.

At 25 o C expect

At 60 o C expect

At 85 o C expect

9,700 - 10,300 Ohms

2,400 - 2,600 Ohms

1,000 - 1,100 Ohms

Is the Thermistor value correct?

NO

Fit a new Thermistor

YES

Is there continuity between the PCB and Thermistor?

YES NO

Replace PCB

Check and replace wiring as necessary

75 ALTERNATINg ‘F’ AND ‘5’ - RETURN ThERMIsTOR FAULT

52

Remove the Return Thermistor from the CH Return

Pipe and disconnect the wires.

Check the resistance using a suitable multimeter connected across the thermistors terminal pins.

At 25 o C expect 9,700 - 10,300 Ohms

At 60

At 85 o o

C expect

C expect

2,400 - 2,600 Ohms

1,000 - 1,100 Ohms

Is the Thermistor value correct?

NO

Fit a new Thermistor

YES

Is there continuity between the PCB and Thermistor?

YES NO

Replace PCB

Check and replace wiring as necessary


Fault Finding

76 ALTERNATINg ‘F’ AND ‘6’ - OUTsIDE sENsOR FAULT

NO Securely connect the wiring at both the boiler and Outside Sensor

Is the wiring securely connected at both the boiler and

Outside Sensor?

YES

Disconnect the wires to the outside sensor.

Check the resistance using a suitable multimeter connected across the Outside Sensors terminal pins.

At 0 o C expect 31,000 - 35,000 Ohms

At 15 o C expect 15,000 - 16,500 Ohms

At 30 o C expect 7,700 - 8,500 Ohms

Is the Outside Sensor value correct?

NO

Fit a new Outside Sensor

YES

Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB?

YES NO

Replace PCB Securely connect the wiring at the Terminal Block and the PCB

77 ALTERNATINg ‘c’ AND ‘2’ - BCC FAULT (BOILER ChIp CARD)

NO

Is the correct BCC for the boiler securely inserted into the slot at the front left of the PCB?

(identified by the label on the BCC)

YES

Replace the BCC with a new BCC (that is correct for the boiler). After switching power on and ‘c0’ being shown, press reset. Is ‘c2’ still shown?

YES

Securely insert the correct BCC for the boiler into the PCB and after switching power on and

‘c0’ being shown, reset boiler.

Note. Ensure the correct orientation of BCC by placing “TOP” side up.

Replace PCB


78 NO Ch OpERATION

Is the mode knob in the ON position?

YES

Are the Timer and the Room Thermostat or cylinder thermostat switched on?

YES

Are the Radiator Valves Open?

YES

Is there 230Vac at (A)?

YES

Check wiring from terminal strip to

PCB.

NO

There is no Voltage from the

Timer/Room Stat. This is not boiler fault. Ensure Voltage is supplied to boiler by rectifying external wiring.

NO

NO

NO

L

N

Move the mode knob to the ON position

Switch the Timer, Room Stat and Cylinder Stat On

Open the Radiator Valves

A


53

54

Fault Finding

79 NO DIspLAy

Is there 230Vac to the boiler at L and N (see Frame 78)?

YES

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

NO

NO

YES

Is the ribbon cable from the main PCB to the User

Interface PCB connected securely?

NO

YES

Is ribbon cable damaged?

YES

Replace ribbon cable

NO Replace the

User Interface

PCB

Supply power to the boiler

Connect the wiring from the terminal block to the

Main PCB securely.

Connect the ribbon from the main PCB to the User

Interface PCB securely

80 NO hW

Is the cylinder stat calling for heat?

YES

Is DHW timer on?

YES

Is boiler mode knob in the ON position?

YES

Is there 230V at (A) Refer to Frame 78?

YES

Check wiring from terminal strip to PCB.

NO

NO

NO

NO

Adjust cylinder stat

Switch timer on

Move the mode knob to the ON position

Check system controls and wiring


Short liSt of partS

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Keston. Failure to do so could affect safety or performance of this appliance.

-

-

-

Our parts team are also available to help with your Keston spare parts enquiries on 01482 498665.

When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have the following to hand;

Boiler Model

Appliance GC Number

Boiler Serial Number


55

Benchmark Commissioning and

Servicing Section

It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full.

To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation.

To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed.

The service details should be recorded on the Benchmark Service Interval

Record and left with the householder.

www.centralheating.co.uk

© Heating and Hotwater Industry Council (HHIC)

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

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

CONTROLS

Automatic bypass to system

Boiler interlock

ALL SYSTEMS

CENTRAL HEATING MODE

Central heating return temperature

COMBINATION BOILERS ONLY

DOMESTIC HOT WATER MODE

Cold water inlet temperature

CONDENSING BOILERS ONLY

ALL INSTALLATIONS

Programmable room thermostat

Optimum start control

Combination Boiler

Fitted

Fitted

Fitted

Fitted

Yes

Yes mbar OR

OR mbar

Yes

Yes mbar OR

AND

AND

OR

Yes Temperature

Yes

² Ratio

² Ratio

Yes

Yes

Yes

Yes mbar

* All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

SERVICE 01 SERVICE 02

AND

AND

² %

² % (Where Possible)

Signature

SERVICE 03

AND

AND

² %


Signature

SERVICE 04

AND

AND

² %


Signature

SERVICE 05

(Where Possible)

Signature

SERVICE 07

AND

AND

² %


Signature

SERVICE 06

AND

AND

² %


Signature

SERVICE 08

AND

AND

² %

² %

(Where Possible)

Signature

SERVICE 09

AND

AND

² %


Signature

SERVICE 10

AND

AND

² %

² %

(Where Possible)

AND

AND

² %


AND

AND

² %

² %

Signature Signature

* All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO

CHECK ON COMMISSIONING A CONDENSING BOILER

Important Preliminary Information on Checks

The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING.

If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance is provided with the conversion kit supplied and this must be followed.

PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK

The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as required prior to commissioning.

As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN

THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).

The ECGA should be of the correct type, as specified by BS 7967.

Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer must have the relevant competence for use of the analyser.

Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions.

KEY:

CO = carbon monoxide

CO

2

= carbon dioxide

O2 = oxygen

Combustion Ratio = The CO reading measured in ppm divided by the CO

2

reading first converted to ppm

ppm = parts per million

GS(I&U)R = Gas Safety (Installation and Use) Regulations

60

*setting to Minimum Rate:

1. Turn the CH temperature control knob into the 10 O’clock position.

2. Create a heat demand by ensuring that the system controls are requesting heat and the boiler

Mode Knob is in the On Position.

3. Within an overall time of 3 seconds, turn the CH temperature control knob fully clockwise, back to

10 O’clock and then fully clockwise again.

4. “S” will be shown on the display and the boiler output will be reduced to minimum.

5. The boiler will remain at minimum rate for 5 minutes before reverting to normal operation.


Start

Set Boiler to Maximum Gas Rate

In accordance with boiler instructions, set boiler to operate at maximum rate

(full load condition). Allow sufficient time for combustion to stabilise.

Note. Do not insert analyser probe during this period to avoid possible flooding of sensor.

Carry Out Flue Integrity Check Using Analyser

Insert analyser probe into air inlet test point (where available) and allow readings to stabilise.

Note. Where no air inlet test point is provided then a flue integrity check with the analyser is not possible. The installer should verify that flue integrity has been visually checked in accordance with the “ Prior to CO level and

combustion ratio check” (see opposite page) before proceeding to the

“ check CO level and combustion ratio at maximum rate” stage below.

Verify Flue Integrity

Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of the flue is therefore required.

Check that flue components are assembled, fixed and supported as per instructions. Check that flue and flue terminal are not obstructed.

No

Is

O2 more than or equal to 20.6% OR CO

2 less than or equal to

0.2%?

Yes

Is

O

2

more than or equal to 20.6% OR CO

2 less than or equal to

0.2%?

No

Yes

Turn off appliance and call Ideal Technical Helpline for advice

The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from the gas supply in accordance with GSIUR.

Check that no seals, e.g. Those on flue extensions, have been displaced during installation. Rectify if necessary.

Is

CO level less than 350ppm AND CO/CO

2 ratio less than

0.0040?

No

Yes

Check CO level and Combustion Ratio at Maximum Gas Rate

With boiler still set at maximum gas rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.

No

Is

CO level less than 350ppm AND CO/CO

2 ratio less than

0.0040?

Yes

Set Boiler to Minimum Gas Rate

(*see opposite page)

In accordance with boiler instructions, set boiler to operate at minimum rate (to minimum load condition).

Allow sufficient time for combustion to stabilise.

Check CO and Combustion Ratio at Minimum Gas Rate

With boiler set at minimum rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.

Turn off Appliance and Call Ideal Technical Helpline

The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from the gas supply in accordance with GS(I&U)R. NOTE:

Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal.

No

Is

CO level less than 350ppm AND CO/CO ratio less than

0.0040?

2

Yes

Boiler is Operating Satisfactorily

No further actions required.

Ensure test points are capped, boiler case is correctly replaced and all other commissioning procedures are completed. Complete Benchmark

Checklist, recording CO and combustion ratio readings as required.


61

Keston heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN

Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk

February 2014 UIN 208893 A04

Keston pursues a policy of continuing improvement i n t h e d e s i g n a n d p e r f o r m a n c e o f i t s p r o d u c t s .

The right is therefore reserved to vary specification without notice.

System 30

User Instructions



GAS BOILER

CE/PI No. 86-CL-08

System 30 - GC No. 41-930-39


Keston Heating




SEDBUK A RATED

System 30

User Instructions



GAS BOILER

CE/PI No. 86-CL-08

System 30 - GC No. 41-930-39


Keston Heating




SEDBUK A RATED

FOR ANy qUERIEs pLEAsE RINg ThE

KEsTON CONsUMER hELpLINE : 01482 443005

NOTE. BOILER REsET pROCEDURE -

To reset boiler, turn mode control knob to reset position and immediately turn knob back to required setting.

Introduction

The Keston system is a wall mounted, room sealed, condensing system boiler, featuring full sequence automatic spark ignition and fan assisted combustion.

Due to the high efficiency of the boiler, condensate is produced from the flue gases and this is drained to a suitable disposal point through a plastic waste pipe at the base of the boiler. A condensate ‘plume’ will also be visible at the flue terminal.

Safety

Current Gas Safety (Installation & Use) regulations or rules in force.

In your own interest, and that of safety, it is the law that this boiler must be installed by a Gas Safe Registered Engineer, in accordance with the above regulations.

In IE, the installation must be carried out by a Registered Gas Installer

(RGII) and installed in accordance with the current edition of I.S. 813

“Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

It is essential that the instructions in this booklet are strictly followed, for safe and economical operation of the boiler.

Electricity Supply

this appliance must be earthed.

supply: 230 V ~ 50 hz. The fusing should be 3A.

minimum Clearances

Clearances of 165mm (6 1/2 ”) above, 100mm (4”) below,

2.5mm (1/8”) at the sides and 450mm (17 3/4”) at the front of the boiler casing must be allowed for servicing.

Bottom clearance

Bottom clearance after installation can be reduced to 5mm.

This must be obtained with an easily removable panel, to enable the consumer to view the system pressure gauge, and to provide the 100mm clearance required for servicing.

To light the boiler. refer to Frame 1

If a programmer is fitted refer to separate instructions for the programmer before continuing.

1. CHECK THAT THE ELECTRICITY SUPPLY TO BOILER IS

OFF.

2. Set the mode control knob (B) to ‘Off’.

3. Set the Central Heating temperature control (A) to ‘max’.

4. Switch ON electricity to the boiler and check that all external controls, e.g. programmer and room thermostat, are ON.

5. Set the mode control knob to ON.

The boiler will commence the ignition sequence supplying heat to the central heating, if required.

Note. In normal operation the boiler status display (C) will

show codes:

Important notes

 This appliance must not be operated without the casing correctly fitted and forming an adequate seal.

 If the boiler is installed in a compartment then the compartment

MUST NOT be used for storage purposes.

 If it is known or suspected that a fault exists on the boiler then it MUST NOT BE USED until the fault has been corrected by a

Gas Safe Registered Engineer or in IE a Registered Gas Installer

(RGII).

 Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with.

 This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instructions concerning use of the appliance by a person responsible for their safety.

 Children should be supervised to ensure that they do not play with the appliance.

In cases of repeated or continuous shutdown a Gas Safe Registered

Engineer or in IE a Registered Gas Installer (RGII) should be called to investigate and rectify the condition causing this and carry out an operational test. Only the manufacturers original parts should be used for replacement.

Standby - no demand for heat.

Heat being supplied.

Boiler frost protection - boiler will fire if temperature is

below 5 degrees C.

During normal operation the burner on indicator (D) will remain illuminated when the burner is lit.

Note: If the boiler fails to light after five attempts the fault code

will be displayed.

REsET pROCEDURE

To reset boiler, turn the mode control knob (B) to reset position and immediately turn knob back to ON. The boiler will repeat the ignition sequence. If the boiler still fails to light consult a Gas Safe Registered Engineer or in IE a Registered Gas

Installer (RGII).

2

All Gas Safe Register installers carry a Gas Safe Register ID card, and have a registration number. Both should be recorded in the

Benchmark Commissioning Checklist. You can check your installer by calling Gas Safe Register direct on 0800 4085500.

Keston is a member of the Benchmark scheme and fully supports the aims of the programme.

Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

ThE BENChMARK sERVICE INTERVAL RECORD MUsT BE COMpLETED AFTER EACh sERVICE

Keston System - User’s

operation

note. The pump will operate briefly as a self-check once every 24 hours, regardless of system demand.

Control of water temperature

The boiler controls the central heating radiator temperature to a maximum of 80 o C, adjustable via the CH temperature control

(A) or is automatically set by the weather compensation device provided, the potentiometer adjusts the heating slope.

The Keston System is a high efficiency condensing boiler which is most efficient when operating in condensing mode.

The boiler will operate in this mode if the CH temperature control

(A) is set to the ‘e’ position (economy mode). This control should be set to maximum for very cold periods

Loss of system water pressure

The gauge (E) indicates the central heating system pressure. If the pressure is seen to fall below the original installation pressure of 1-2 bar over a period of time then a water leak may be indicated. In this event conduct the re-pressurising procedure as follows:

Re-pressurise via the filling loop to 1 bar (if unsure contact your installer), turn off the tap on the filling loop and turn switch (B) to the reset position and then back on again to reset the boiler.

If unable to do so or if the pressure continues to drop after filling a

Gas Safe Registered Engineer or in IE a Registered Gas Installer

(RGII) should be consulted. noTe. The BoiLer WiLL noT oPeraTe iF Pressure has rEDUCED to LESS tHAn 0.3 BAr UnDEr tHIS ConDItIon.

to shut down the boiler

Set the mode control knob to OFF.

To relight the boiler

Repeat the procedure detailed in ‘To light the boiler’.

Frost protection

If no system frost protection is provided and frost is likely during a short absence from home, leave the heating controls (if fitted) at a reduced temperature setting. For longer periods, the entire system should be drained.

If the system includes a frost thermostat then, during cold weather, the boiler should be turned OFF at the time switch (if fitted) ONLY. The mains supply should be left switched ON, with the boiler thermostat left in the normal running position.

Condensate Drain

The condensate drain (F) must not be modified or blocked.

Blockage of the condensate drain, caused by debris or freezing, can cause automatic shutdown of the boiler.

If freezing is suspected and the pipe run is accessible an attempt may be made to free the obstruction by pouring hot water over the exposed pipe and clearing any blockage from the end of the pipe.

If this fails to remedy the problem the assistance of a Gas Safe

Registered Engineer or in IE a Registered Gas Installer (RGII) should be sought.

Escape of gas

Should a gas leak or fault be suspected contact the National Gas

Emergency Service without delay. Telephone 0800 111 999

Do not search for gas leaks with a naked flame.

Boiler overheat Protection

The boiler controls will shut down the boiler in the event of overheating. Should this occur, a fault code will be displayed.

Refer to fault chart.

Cleaning

For normal cleaning simply dust with a dry cloth.

To remove stubborn marks and stains, wipe with a damp cloth and finish off with a dry cloth.

Do not use abrasive cleaning materials.

Flame Failure

Should this occur a fault code will be displayed. Refer to fault chart.

maintenance

The appliance should be serviced at least once a year by a Gas

Safe Registered Engineer or in IE a Registered Gas Installer (RGII).

1

BoiLer ConTroLs

Legend

A. CH Temperature Control

B. Mode Control

C. Boiler Status

D. Burner ‘on’ Indicator

E. Pressure Gauge

F. Condensate Drain

g. Economy Mode


E

A G C D B

F

3

4

pOINTs FOR ThE BOILER UsER

Note. In line with our current warranty policy we would ask that you check through the following guide to identify any

problems external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained by the engineer.

TROUBLEshOOTINg

NO CENTRAL hEATINg

Check the mains switch (fused spur) is turned on and ensure mode control knob (B) is in the

ON position

NO hOT WATER

Check the mains switch (fused spur) is turned on and ensure mode control knob (B) is in the

ON position

Check the programmer is in an “ON” position and the room thermostat is turned up

Does the boiler operate and provide central heating?

YES

Check the time settings on the programmer are as you require and adjust if necessary

NO

See boiler “Operation Modes” and “Fault Codes” section. If “0” is displayed then contact a Gas

Safe Registered Engineer or in

IE a Registered Gas Installer

(RGII)

Check the programmer is in an

“ON” position and the cylinder thermostat is turned up

Does the boiler operate and provide hot water?

YES

Check the time settings on the programmer are as you require and adjust if necessary

NO

See boiler “Operation Modes” and “Fault Codes” section. If “0” is displayed then contact a Gas

Safe Registered Engineer or in

IE a Registered Gas Installer

(RGII)

OpERATION MODEs

DIspLAy CODE ON BOILER DEsCRIpTION

The boiler is in standby mode awaiting either a central heating call or hot water demand.

The boiler has a call for central heating / hot water but the appliance has reached the desired temperature set on the boiler.

The boiler is operating for central heating / hot water.

The boiler is operating in frost mode.

continued . . . . . .


FAULT CODEs

DIspLAy CODE ON BOILER DEsCRIpTION

Boiler Chip Card (BCC)

Not Fitted

Outside Sensor Failure

Low Mains Voltage

ACTION

Please contact Keston (if under warranty) or alternatively a Gas Safe

Registered Engineer if outside of the warranty period. In IE contact a

Registered Gas Installer (RGII).

Reset the appliance - if the boiler fails to operate then please contact

Keston (if under warranty) or alternatively a Gas Safe Registered

Engineer if outside of the warranty period. In IE contact a Registered

Gas Installer (RGII).

Contact a qualified electrician or your electricity provider.

PCB Fault PCB Fault. Please contact Keston (if under warranty) or alternatively a

Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII).

5 Boiler Resets in 15 minutes 1. Turn power off and on at the fused spur.

2. If the boiler fails to operate please contact Keston (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII).

False Flame Lockout Reset the appliance - if the boiler fails to operate then please contact




BCC Activation Fault Reset the appliance - if the boiler fails to operate then please contact




BCC Fault

Low Water Pressure

Flow Temperature Overheat

Check system pressure is between 1 & 1.5bar on the pressure gauge.

If the boiler fails to operate then please contact Keston (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII).

Flame Loss 1. Check other gas appliances in the house are working to confirm a supply is present in the property.

2. If other appliances do not work or there are no other appliances, check the gas supply is on at the meter and/or pre payment meter has credit. If the boiler fails to operate then please contact Keston

(if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas

Installer (RGII).

Fan Fault Reset the appliance - if the boiler fails to operate then please contact




Control / No Flow Thermistor Reset the appliance - if the boiler fails to operate then please contact




Return Thermistor Reset the appliance - if the boiler fails to operate then please contact





5

Keston heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN

Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk

Keston pursues a policy of continuing improvement i n t h e d e s i g n a n d p e r f o r m a n c e o f i t s p r o d u c t s .

The right is therefore reserved to vary specification without notice.

Keston System 30kw Installation Manual

System 30

Installation and Servicing Instructions

Keston Heating

PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN

Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133 email : [email protected] web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

2

NOTEs FOR ThE INsTALLER

FOR ANy TEChNICAL qUERIEs pLEAsE RINg ThE KEsTON

INsTALLER/TEChNICAL hELpLINE : 01482 443005

NOTE. BOILER REsET pROCEDURE -

To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

The boiler will repeat the ignition sequence if a heat demand is present.

DOCUMENT AMENDMENTs

Relevant Installation changes implemented in this book from Mod Level ........ A03 (Oct 13) to A04 (Feb 14) page 10

4.b. - Statement updated page 30

Item 3 added to Electrical Installation

Statement added ref to commissioning process of combustion page 57

New Page Added - Benchmark Commissiong & Servicing Section page 58 & 59

New updated Commissioning Checklist & Service Record Sheets page 60 & 61

New pages added, Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler

3

general

4

Keston System

Natural gas only

Boiler size g.C. Appliance No.

(Benchmark No.)

30 41-930-39

pI No.

86 CL 08 general

CONTENTs

BENChMARK COMMIssIONINg ChECKLIsT DETAILs

B

NOTE TO ThE INsTALLER: COMpLETE

ThE BENChMARK COMMIssIONINg

ChECKLIsT AND LEAVE ThEsE

INsTRUCTIONs WITh AppLIANCE

5

general

INTRODUCTION

OpTIONAL ExTRA KITs

OpERATION

sAFE hANDLINg

6

sAFE hANDLINg OF sUBsTANCEs general sAFETy

LOCATION OF BOILER

7

general gAs sUppLy

WATER CIRCULATION sysTEM

IMpORTANT.

BOILER CONTROL INTERLOCKs

ELECTRICAL sUppLy

IMpORTANT.

CONDENsATE DRAIN

Refer to Frames 20, 21 & 41

IMpORTANT.

8

general

1 BOILER DIMENsIONs, sERVICEs & CLEARANCEs

9

general

2 sysTEM REqUIREMENTs - Central heating

10

general

3 sysTEM BALANCINg

BALANCINg

4 WATER TREATMENT

CENTRAL hEATINg

11

general

5 BOILER AssEMBLy - Exploded View

12

general

6 UNpACKINg

7 FRONT pANEL REMOVAL

13

INSTALLATION