Keston 30C INSTALLATION AND SERVICING INSTRUCTIONS (June 2010 UIN 205531 A03)

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Page 1

Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCY

MODULATING DOMESTIC CONDENSING

GAS COMBINATION BOILER

CE/PI No. 86-CL-38

GC No. 47-930-03

30C

The Keston 30C

These instructions must be left either with the

user or next to the site gas meter.

34 West Common Road

Hayes, Bromley, Kent, BR2 7BX

Tel. +44 (0) 20 8462 0262 Fax. +44 (0) 20 8462 4459

email : info@keston.co.uk web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

Page 2

Keston 30C -

Installation and Servicing

Page 3

NOTES FOR THE INSTALLER

FOR ANY TECHNICAL QUERIES PLESE RING THE KESTON

INSTALLER/TECHNICAL HELPLINE : 0208 462 0262

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.

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ............................... A03 (June 2010)

Page 17 - Frame 9, Flue System

• Approved Solvent Weld Waste added

Pae 37 - Frame 38, Wiring Diagram

• Wire removed from flame sensor electrode

Page 73 - Short List of Parts

• Key No. 111 - part number updated

Keston 30C -

Keston reserve the right to vary specification without notice

Installation and Servicing

Page 4

GENERAL

Table 1 - General Data

Keston 30C 30

Gas supply 2H - G20 - 20mbar

Gas Supply Connection 15mm copper compression

Injector Size (mm) 4.65

Inlet Connection Domestic Hot Water 15mm copper compression

Outlet Connection Domestic Hot Water 15mm copper compression

Flow Connection Central Heating 22mm copper compression

Return Connection Central Heating 22mm copper compression

Flue Terminal Diameter mm (in) 50 (nominal)

Average Flue Temp-Mass Flow Rate (DHW) 68

Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)

Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) 10.0 (145)

Minimum Domestic Hot Water Inlet Pressure* bar (lb/in2) 1.3 (18.9)

Electrical Supply 230 V ~ 50 Hz.

Power Consumption W 152

Fuse Rating External : 3A Internal : T4H HRC L250 V

Water content Central Heating litre (gal) 1.2 (0.26)

Domestic Hot Water litre (gal) 0.5 (0.11)

Packaged Weight kg (lb) 37.8 (83.3)

Maximum Installation Weight kg (lb) 32.8 (72.3)

Boiler Casing Size Height mm (in) 700 (27.5)

Width mm (in) 395 (15.5)

Depth mm (in) 278 (11)

*Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery

C - 13g/s

Table 2 - Performance Data - Central Heating

Boiler Input : Max. Min.

Boiler Input ‘Q’ Nett CV kW 24.3 6.1

(Btu/h) (82,900) (20,700)

Gross CV kW 27.0 6.7

(Btu/h) (92,000) (23,000)

Gas Consumption l/s 0.698 0.173

(ft3/h) (89) (22)

Boiler Output :

Non Condensing kW 24.2 6.1

70oC Mean Water temp. (Btu/h) (82,600) (20,700)

Condensing kW 25.6 6.4

40oC Mean Water temp. (Btu/h) (87,400) (21,800)

Seasonal efficiency* (SEDBUK) Band A (91.1%)

NOx Classification CLASS 5

Table 3 - Performance Data - Domestic Hot Water

Maximum DHW Input : 30

Nett CV kW 30.4

(Btu/h) (103,600)

Gross CV kW 33.7

(Btu/h) (115,000)

Gas Consumption l/s 0.871

(ft3/h) (111)

Maximum kW 30.3 DHW Output (Btu/h) (103,300)

DHW Flow Rate l/min 12.4 at 35°C temp. rise. (gpm) (2.8)

DHW Specific Rate l/min 14.5

(gpm) (3.2)

* 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/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) 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

)

b. For ft3/h - divide the gross heat input (Btu/h)

by the gross C.V. of the gas (Btu/ft3)

Key to symbols

PMS = Maximum operating pressure of water

13 C33 C53

= A room sealed appliance designed for connection via ducts to a

horizontal or vertical terminal, which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which, in this case, are concentric. The fan is up stream of the combustion chamber.

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

c. For m3/h - multiply l/s by 3.6.

Keston 30C -

Installation and Servicing

Page 5

GENERAL

KESTON 30C

Natural Gas only

Boiler size G.C. Appliance No. PI No.

(Benchmark No.)

30 47-930-03 86 CL 38

CONTENTS

Benchmark Commissioning Checklist ..................... 75

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

Boiler Exploded Diagram ....................................... 13,14

Condensate Drain ............................................. 9, 20, 46

Electrical Connections ............................................... 31

Electrical Supply ........................................................... 8

Fault Finding ........................................................... 64-72

Flue Fitting .............................................................. 17, 18

Gas Safety Regulations ................................................ 7

Gas Supply ..................................................................... 8

Installation ............................................................. 15-43

Pump .......................................................................... 59

Safe Handling ................................................................ 6

Servicing ................................................................ 44-63

Short List of Parts ....................................................... 73

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

Water and Systems .......................................... 8, 10-12

Water Connections ............................................... 28, 29

Water Treatment ......................................................... 12

Wiring Diagram ........................................................... 37

30C

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

Boiler Page

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

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

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

Controls

Time and temperature control to heating ............. 32

Time and temperature control to hot water .......... 32

Heating zone valves .............................................. n/a

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

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 ......................................................... 12

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 .................................................. 26

For all boilers:

For assistance see Technical Helpline on the back page

complete, sign & hand over to customer

Page

NOTE TO THE INSTALLER:

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

Keston 30C -

Installation and Servicing

COMPLETE

Page 6

GENERAL

INTRODUCTION

The Keston 30C boiler is a wall mounted, full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boiler.

Due to the high efficiency of the boiler a plume of water

Note.

vapour will form at the terminal during operation.

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

6.1 to 24.2kW (20,700 to 82,600 Btu/h)

Instantaneous domestic hot water (DHW) output is also fully modulating with a maximum of 30.3kW (103,300 Btu/h)

The boiler is supplied fully assembled with DHW plate heat exchanger, diverter valve, circulating pump, pressure gauge, safety valve and CH expansion vessel.

Variable CH and DHW temperature controls are fitted on the user control and the boiler features a DHW preheat facility.

The boiler includes as standard:

- Automatic bypass

- Boiler frost protection

- Daily pump and diverter valve exercise.

The boiler casing is of white painted mild steel.

The boiler temperature controls are visible 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.

OPERATION

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.

OPTIONAL EXTRA KITS

• Telescopic Concentric Flue B pack

• Electronic Timer (7 day) kit

• RF Electronic Programmable Room Thermostat kit

• Stand Off kit

With no demand for CH, the boiler fires only when DHW is drawn off, or periodically for a few seconds without any DHW draw-off, in order to maintain the DHW calorifier in a heated condition. This only occurs if pre-heat knob is in the ‘ON’ period.

When there is a demand for CH, the heating system is supplied at the selected temperature of between 30 80oC, until DHW is drawn off. The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw-off of 12.4 l/min at 35 oC temperature rise.

The DHW draw off rate specified above is the nominal that the boiler flow regulator will give. Due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap.

At low DHW draw-off rate the maximum temperature is limited

C by the modulating gas control.

to 64

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.

C and

Keston 30C -

Installation and Servicing

Page 7

GENERAL

0.6m

Zone 0

Recessed window Zone 2

Ceiling

3G8913a

2.25m

Zone 1

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 Installation of gas fired hot water boilers of rated

input not exceeding 70 kW.

BS. 6891 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.

SAFE HANDLING OF SUBSTANCES

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

Keston 30C -

Installation and Servicing

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

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.

• The boiler must be installed on a fire resistant surface.

Page 8

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.

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

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).

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.

It is the responsibility of the Gas Installer to size 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 30C is able to deliver its 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).

The integral appliance isolation valve and boiler pipework could further reduce the operating pressure by up to 1.5mb when measured at the inlet test point on the appliance gas valve. Therefore it has been identified that an operating pressure as low as 16.5mbar could be measured at the appliance inlet pressure test point on the gas valve.

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.

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.

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 and for new heating systems, and where practical replacement boiler installations, the isolator shall be situated adjacent to the appliance.

CONDENSATE DRAIN

Refer to Frames 15, 25 & 48

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 -

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.

no other materials may be used.

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

WATER TREATMENT - see Frame 5

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.

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.

Keston 30C -

Installation and Servicing

Page 9

GENERAL

3G10044b

395

30mm

Minimum Top Clearance

100395

400

700

Flue Air

2.5

2.5 from case

43 65 57 38

Gas Inlet

39 65

BOILER DIMENSIONS, SERVICES & CLEARANCES

The boiler connections are made on the boiler connection tails. Refer to Frames 27-30.

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

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.

Flue

Air

3G10051

Keston 30C -

Installation and Servicing

Page 10

SYSTEM REQUIREMENTS - Central Heating

GENERAL

Notes

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.

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

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

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.

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, if not pressurized. However, if the system is to be pressurized, the efficiency of the expansion vessel will be reduced and a larger vessel (or smaller system volume) may be necessary. If the capacity of the vessel is not considered sufficient for this, or for any other reason, an additional vessel be installed on the RETURN to the boiler.

Guidance on vessel sizing is given in Table above.

C. Extra care should

MUST

Safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar None 1.0

System volume Expansion vessel

(litres) volume (litres)

25 1.6 1.8

50 3.1 3.7

75 4.7 5.5

100 6.3 7.4

125 7.8 9.2

150 9.4 11.0

175 10.9 12.9

190 11.9 14.0

200 12.5 14.7

250 15.6 18.4

300 18.8 22.1

For other system volumes multiply by the factor across 0.063 0.074

Water Flow Rate and Pressure Loss

Max CH Output kW 24.2

(Btu/h) (82,600)

Water flow rate l/min 17.3

(gal/min) (3.8)

Temperature Differential

Head available for m.w.g. 3.4 system (ft.w.g.) (11.1)

5. Filling

The system may be filled by the following method:

Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling.

a. Thoroughly flush out the whole system with cold

water.

b. Fill and vent the system until the pressure gauge

registers 1bar and examine for leaks. Refer to Frame 33 for filling detail.

c. Check the operation of the safety valve by raising

the water pressure until the valve lifts. This should occur within 0.3bar of the preset lift pressure.

d. Release water from the system until the

minimum system design pressure is reached;

1.0 bar if the system is to be pre-pressurised.

C20

(oF) (36)

Keston 30C -

continued . . . . . .

Installation and Servicing

Page 11

GENERAL

SYSTEM REQUIREMENTS - CH (continued) and Hot Water

DOMESTIC HOT WATER

1. The domestic hot water service must be in accordance

with BS 5546 and BS 6700.

2. Refer to Table 1 for minimum and maximum working pressures. In areas of low mains water pressures the domestic hot water regulator may be removed from the DHW flow turbine cartridge. Refer to Frame 76. The boiler will require the flow rate to be set to obtain a temperature rise of 35

3. The boiler is suitable for connection to most types of washing machine and dishwasher appliances.

4. When connecting to suitable showers, ensure that:

a. The cold inlet to the boiler is fitted with an approved

b. Hot and cold water supplies to the shower are of equal

5. Hard Water Areas

Where the water hardness exceeds 200mg/litre, it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the local water company.

C at the tap furthest from the boiler.

anti-vacuum or syphon non-return valve.

pressure.

IMPORTANT

Provision MUST be made to accommodate the expansion of DHW contained within the appliance, if a non-return valve is fitted to the DHW inlet, or a water meter with a non-return valve is installed.

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.

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

Note.

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.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20

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

C temperature drop at each radiator.

These valves should now be left as set.

Keston 30C -

Installation and Servicing

Page 12

WATER TREATMENT

GENERAL

CENTRAL HEATING

The Keston 30C boiler has 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

FERNOX, MBI or SENTINEL X100 inhibitors and associated water

treatment products, which must be used in accordance with the manufacturers' instructions.

Notes.

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

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.

In hard water areas, treatment to prevent lime scale may be necessary - however the use of artificially softened water is NOT permitted.

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

DOMESTIC HOT WATER

In hard water areas where mains water can exceed 200ppm Total Hardness (as defined by BS 7593:2006 Table

2) a scale reducing device should be fitted into the boiler cold supply within the requirements of the local water company. The use of artificially softened water, however, is not permitted. Keston recommend the use of Fernox Quantomat, Sentinel Combiguard and Calmag CalPhos I scale reducing devices, which must be used in accordance with the manufacturers' instructions.

For further information contact:

Fernox Manufacturing Co. Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ +44 (0) 1799 521133

Sentinel Performance Solutions The Heath Business & Technical Park Runcorn Cheshire WA7 4QX Tel: 0800 389 4670 www.sentinel-solutions.net

Salamander Engineering Ltd The Heath Business & Technical Park Runcorn Cheshire WA7 4QX Tel: 0800 389 4670

Calmag Ltd. Unit 4-6, Crown Works Bradford Road Sandbeds, Keighley West Yorkshire BD20 5LN Tel: +44 (0) 1535 210 320

Keston 30C -

Installation and Servicing

Page 13

INSTALLATION

BOILER ASSEMBLY - Exploded View Legend

Note that item numbers are linked to the spares list

104 CH RETURN VALVE

105 CH FLOW VALVE

106 DHW INLET & OUTLET

107 FILLING LOOP

108 PUMP HEAD

110 AIR VENT PUMP

111 DIVERTER VALVE HEAD

112 DIVERTE R VALVE CARTDRIGE

113 PRESSURE RELIEF VALVE

114 PIPE - PRV OUTLET

115 PIPE - FLOW

116 PIPE - RETURN

117 PIPE - EXPANSION VESSEL

118 EXPANSION VESSEL

119 RETURN GROUP MANIFOLD

120 FLOW GROUP MANIFOLD

121 PLATE HEAT EXCHANGER

127 FLOW SENSOR HALL EFFECT

128 FLOW TURBINE CARTRIDGE

131 WATER PRESSURE TRANSDUCER

135 PRESSURE GAUGE

203 GAS COCK

204 PIPE - GAS INLET

205 GAS VALVE

206 PIPE - GAS INJECTOR

211 INJECTOR ASSEMBLY

214 VENTURI

215 FAN

217 BURNER

218 GASKET - BURNER

219 SUMP CLEAN OUT COVER

223 FLUE MANIFOLD

224 FLUE MANIFOLD TOP

227 CLAMP RETAINING FLUE TURRET

228 HOSE CONDENSATE INTERNAL

229 SIPHON TRAP

230 SIPHON TRAP CAP & SEAL

231 CONDENSATE OUTLET CONNECTION

233 FLUE SENSING NIPPLE

301 CONTROLS BOX FIXINGS HINGE & SPRING

302 PRIMARY PCB

303 CUI BOARD

304 CONTROL THERMISTOR (FLOW / RETURN)

306 ELECTRODE IGNITION

307 ELECTRODE DETECTION

308 IGNITER UNIT

309 THERMISTOR NO FLOW

313 IGNITION LEAD

314 CONTROL BOX LENS

CONTROLS BOX LID

324

325 CONTROL BOX FRONT

326 PROGRAMMER INSERT

401 HEAT ENGINE

503 WALL MOUNTING BRACKET

504 FRONT PANEL

505 FASCIA

506 BRACKET - GAS VALVE

507 BRACKET - EXPANSION VESSEL

136 SAFETY VALVE DRAIN PIPE

512 DROP DOWN DOOR

332 FLUE THERMOSTAT

Keston 30C -

Installation and Servicing

Page 14

INSTALLATION

BCC

3G9971b

227

224

233

503

313

504

505

512

215

217

309

306

308

211

304

214

206

205

204

223

332

326

325

302

104

110

114

113

136

121

118

507

131

128

127

120

119

117

106

203

106

107

135

105

111

231

112

228

229

303

304

116

115

219

301

401

218

307

230

324

108

314

506

30C

BOILER ASSEMBLY - Exploded View (excluding flue box)

Keston 30C -

Installation and Servicing

Page 15

INSTALLATION

D F

3G10046a

HARDWARE PACK CONTENTS

Gas Valve Pack

1. Pipe - Gas Inlet

2. Washer - Gas (blue)

3. Gas Cock

Filling Loop Pack

1. 3/8" Fibre washer (x4)

2. Valve (double check valve) fitting

3. Valve - Filling Loop

4. Plastic Chain (x2)

5. Filling Loop

6. 3/8" Blanking Rubber Washer (x2)

Return Valve Pack

1. Pipe CH Return

2. Washer CH

3. Valve Return

DHW Pack

1. Pipe DHW Outlet

2. Valve - Return DHW

3. Washer DHW (x2)

4. Pipe DHW Inlet

5. Nut 1/2"

Accessory Pack

1. Screw (x2)

2. Wallplug (x2)

Flow Valve Pack

1. Pipe CH Flow

2. Washer CH

3. Valve Flow (with gauge)

Gas Valve Pack DHW Pack

Accessory Pack

Flow Valve Pack

Return Valve Pack

Filling Loop

3G9687

UNPACKING

The boiler is supplied fully assembled in Pack 1, together with Pack 2 for flue lengths up to 450mm.

Unpack and check the contents.

Pack 1 Contents

A Boiler

B Hardware Pack Box

C Wall Mounting Plate

D These Installation Instructions

(includes Warranty/Guarantee)

E Wall Mounting Template

(located on internal protective packaging)

F Turret Clamp

G Safety Valve Drain Pipe

H Weather Compensator

30C

3G10046a

INSTALLATION

Keston 30C -

Installation and Servicing

continued . . . . .

Page 16

8 UNPACKING....CONT’D

Pack 2 Contents

2 Boxes

Pack 2a Contents

1. 3 x elbows

2. 2 x 450mm pipe

3. 3 x 100mm pipe

INSTALLATION

Pack 2b Contents

1. Top Flue Box

2. 6 x screws

3. 2 x Terminals

Keston 30C -

Installation and Servicing

Page 17

INSTALLATION

FLUE SYSTEM

Note. When installing a replacement boiler a new flue system must be used. Do not re-use the existing boiler flue installation.

MAXIMUM LENGTHS

The maximum lengths of both air inlet pipe and flue outlet pipe, when no bends are used, are as detailed in fig.2b.

DESIGN

Individual air supply and flue outlet pipes are used as standard, although a concentric flue kit is available as an optional extra.

The material used for flue outlet &/or air inlet 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.

The following pipes and fittings are approved:

Polypipe System 2000 muPVC solvent Weld Waste System (50mm)

Poly Pipe Code

MU 301 4m length muPVC wastepipe 5/225

MU 313 50mm x 45 deg muPVC obtuse bend

MU 314 50mm x 92.5 deg muPVC swept bend

MU 310 50mm muPVC straigh coupling

MU 316 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 50mm x 45 deg bend

KSC3 50mm straight coupling

KB3 50mm x 88.5 deg bend

KT3 50mm swept tee

Both the 50mm flue outlet terminal and the 50mm air inlet terminal are supplied with the twin flue box (pack 2b) and are illustrated in Fig. 1 and must be used in ALL installations. (Both terminals are identical).

must be

Fig.1

However, each bend used has an equivalent length that must be deducted from the maximum straight length stated in fig. 2b. 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 detailed below.

Fig. 2b

Maximum Combined Flue & Air Intake Lengths

Air Inlet 21m

Flue Outlet 21m

Total Flue & Air Intake 22 m

(does not include allowance for elbow on top of boiler)

Example (assuming 50mm muPVC flue and air pipework)

Air inlet uses two 92.5º swept elbows. Hence, maximum length permissible (i.e. a+b in fig. 2a) = 22m - 1m - 1m = 20m.

Flue outlet uses one 92.5º swept elbow. Hence, maximum length permissible (i.e. c+d in fig. 2a)= 22m - 1m = 21m).

But maximum total flue and air intake must not exceed 19m in the examples above.

Boiler Output Vs Flue Length

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 16.0m (50mm muPVC) are used. In such cases the boiler output will be reduced by 1.0% per additional metre.

When the flue and air terminals are located within 500mm of each other ensure that the air terminal is pointing towards the ground using a 90º bend and one of the 100mm sections of pipe provided within pack 2a.

Keston 30C -

Installation and Servicing

Fig.2a

FLUE AIR

c a

KESTON 30C

Flue Box

3G10025

FLUE OUTLET

Page 18

INSTALLATION

6 in min.

Tee Fitting

To Boiler

To Terminal

FLUE SYSTEM.... CONT’D

SLOPE

‘Horizontal’ flue outlet pipework MUST slope at least 2 degrees (32mm 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.

Due to the low temperature of the flue gases further condensate will form within the flue system. Drain points, with suitable traps, must therefore be incorporated within the flue system at the base of the vertical flue sections in excess of 6m, for 50mm muPVC pipe flue systems. These additional condensate drains must be run to discharge. Such drain points can be formed using standard muPVC fittings. Refer to fig. 3.

Fig.3

Dimensions (mm)

brick, etc.

boundary alongside the terminal. *

Flue

Terminal

Air

Inlet

50300A Below, above or beside openable window, air

7575B Below gutters, soil pipes, drain pipes.

50200C Below eaves.

50200D Below balconies or car port roof (lowest point).

5075E From vertical drain or soil pipes.

50200F From internal or external corner or to a

100300G Above ground or balcony or roof.

100600H From surface or boundary facing a terminal. *

1,2001,200I From terminal facing a terminal.

1001,200J From opening in a car port.(not recommended)

1,5001,500K Vertically from terminal on same wall.

300300L Horizontally from terminal on same wall.

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

CLEARANCES FROM WALL

Flue outlet and air inlet terminations must be at least 40mm from the wall face.

3G10028a

TERMINATIONS

Air inlet terminals must be facing horizontally or downwards to prevent entry of rain into the terminal and positioned to ensure only fresh air is drawn into the boiler. The air terminal must be located outside of the building. Flue terminals must be positioned so that flue products are not drawn into the air inlet. Site specific wind conditions should be considered to achieve this. Drawing of combustion air directly from a ventilated boiler room invalidates the heat exchanger warranty.

The flue outlet terminal is designed to face outwards and must not be directed in the region of the air inlet. The flue terminal and air inlet terminal can be located on different, but not opposing wall faces.

The two terminals are subject to the requirements of BS 5440 Pt 1 for clearances from features of the building although some can be decreased to the values indicated.

The Keston 30C, as with any condensing boiler, will generate a condensate “plume” from the flue terminal in all weather conditions. Consideration must therefore be given to the effect of this “plume” when selecting a location for the flue terminal. It is the responsibility of the installer to ensure the selected terminal location does not cause nuisance.

If either the air inlet or flue outlet terminate at a height of less than 2.1m above ground level, the terminal must be protected by a suitable guard. The K6 terminal guard (with plastic coating), manufactured by Tower Flue Components Ltd is suitable for this purpose.

FLUE OUTLET

DISTANCE BETWEEN FLUE OUTLET & AIR INLET

There is no maximum - the terminations must not be on opposite sides of the dwelling but can be in areas of unequal pressure.

A minimum clearance of at least 500mm must be left between the terminations otherwise a 90º elbow MUST be fitted to air inlet and pointed towards the ground. The absolute minimum clearance between the flue and air terminals is 100mm.

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 pipework 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.

Rubber collars are available for flue and air terminals to finish the external wall face around the terminals (Part No C.08.00.07.0).

AIR SUPPLY

The Keston 30C 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.

Keston 30C -

Installation and Servicing

Page 19

INSTALLATION

3G10056

10 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.

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 position that the twin flue box is located. 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. Mark onto the wall the following:

a The wall mounting plate screw positions (choose one

from each group).

b The position of the air and flue when exiting straight out

of the wall where the boiler is mounted.

Mark the centre of the hole as well as the

Note.

circumference.

3. Remove the template from the wall.

INSTALLATION

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.

Keston 30C -

Installation and Servicing

Rear flue only 60mm diameter holes

Section through wall

Note. Check all of the hole positions before drilling.

3G10030

Page 20

FITTING THE WALL MOUNTING PLATE

INSTALLATION

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.

Example of fixing

INSTALLATION

esp9496

1. Ensure the plastic plugs are removed from both the CH and DHW 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.

30C

3G9974

CONDENSATE DRAIN

Ensure that the siphon is full of water before commissioning the boiler. Refer to Frame 26.

The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.

The drainage pipework must be arranged so that obstruction (e.g. through freezing) of external drainage pipe does not give rise to spillage within the dwelling.

IMPORTANT.

All pipework and fittings in the condensate drain system must be made of plastic. No other materials may be used.

The drain outlet on the boiler is standard 21.5mm overflow pipe and is suitable for either push fit or solvent weld applications. This size must not be reduced in any part of its length.

The boiler includes as standard, a 75mm condensate trap. The condensate trap also includes a siphon to reduce the possibility of freezing in the drain outlet.

If external condensate pipe is used then the pipe should be 32mm nominal diameter. Consideration should be given to insulating external condensate pipe runs.

Keston 30C -

Installation and Servicing

Page 21

16 ASSEMBLY PRACTICE

INSTALLATION

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 ONTO THE TWIN FLUE BOX

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 twin flue box from Pack 2b supplied with

the boiler.

• Remove boiler front panel - Frame 45

• Position flue box on top of the boiler (see diagram)

• Clamp onto boiler using horseshoe clamp provided in

boiler packaging box.

• Fix box to the boiler top panel using 6 x M5 screws

provided.

• Measure, cut and check the air and flue pipes to pass to

the exit from the wall(s) or ceiling.

• 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.

INSTALLATION

• 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.

Retaining Clip (assembled)

Flue Spigot

Air Spigot

M5 Screw

Keston 30C -

Installation and Servicing

Clamp

3G10101

Page 22

INSTALLATION

197mm

Wall Thickness X

Side flue length L

DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED FOR

CONCENTRIC OPTION KIT

Where a concentric flue option is chosen the following instruction should be followed and the standard flue in flue box omitted.

IMPORTANT. The boiler MUST be installed in a vertical position

Only use Keston concentric flue pipe and fittings.

FLUE KITS

Pack B - telescopic supplied as an optional extra

Concentric Flue Screw Retaining Kit - optional kit for

mechanical fixing of flue joints.

Finishing Kit - Supplied as an optional extra.

Refer to 'Flue Extension Ducts'

MAXIMUM HORIZONTAL FLUE LENGTH = 575MM MINIMUM HORIZONTAL FLUE LENGTHS - TELESCOPIC TERMINAL = 350MM

(Centre Line of turret to outside of wall terminal)

Dimension X - Wall thickness.

Dimension L - Wall thickness plus boiler spacing.

Dimension S - Optional stand-off frame depth 45mm.

1. If the telescopic B pack is used, they may be mounted

horizontally. The 1.5 degrees is taken care of by the inclination of the flue within the air pipe.

2. Only use water as a lubricant during assembly.

Total Flue length dimension

(measuring from CL of turret to outside wall)

Rear flue Side flue

dim. X+155 dim. L+197

Up to 575 mm Up to 575 mm

REAR FLUE

155 + S = 200mm

165mm

Minimum Top

Clearance

SIDE FLUE

Note: All other clearances as per Twin Flue Application (See Frame1)

FLUE OUTLET

Wall Thickness X

3G9493a

Keston 30C -

Installation and Servicing

Page 23

INSTALLATION

var9784

Rubber Terminal Wall Seal

TERMINAL WALL SEAL ASSEMBLY / POSITIONING - CONCENTRIC FLUE OPTION

Prior to fitting the flue, the rubber terminal wall seal provided in the flue pack MUST be fitted to the flue terminal as shown below in Figure 1.

FIGURE 1 FIGURE 2

Wall Seal Lip

Step

Ensure lip of wall seal is positioned over step on plastic nose of flue terminal

(note, seal is cut away for clarity)

isfu9783

Once the flue is installed it is IMPORTANT that the rubber terminal wall seal is pressed against the outside wall to create an adequate seal between the flue and wall as shown in Figure 2.

FLUE ASSEMBLY - CONCENTRIC FLUE OPTION - Exploded View

An optional flue duct extension kit is required for wall thicknesses greater than :

Side 378mm

Rear 420mm

LEGEND

1. Duct assembly.

2. Flue turret.

3. Turret clamp.

3G9499a

TOP

The flue terminal MUST be fitted with the ‘TOP’ uppermost to allow the correct fit and use of the plume management system.

Keston 30C -

Installation and Servicing

FLUE OUTLET

Page 24

INSTALLATION

WALL MOUNTING TEMPLATE - CONCENTRIC FLUE OPTION

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

Note.

The template shows the positions of the fixing holes and the position that the twin flue box is located. 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. Mark onto the wall the following:

a The wall mounting plate screw positions (choose one

from each group).

b The position of the air and flue when exiting straight out

of the wall where the boiler is mounted.

Mark the centre of the hole as well as the

Note.

circumference.

3. Remove the template from the wall.

3G10056

PREPARING THE WALL - CONCENTRIC FLUE OPTION

IMPORTANT.

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

1. Cut the flue hole (preferrably with 5” core bore tool for concentric), ensuring that the hole is square to the wall. Both wall faces immediately round the cut hole should be flat.

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.

Section through wall

Rear flue only 5" diameter hole

Note. Check all of the hole positions before drilling.

Side flue only 5" diameter hole

3G9495

FLUE OUTLET

Keston 30C -

Installation and Servicing

Page 25

INSTALLATION

SETTING THE FLUE - REAR - CONCENTRIC FLUE OPTION

TELESCOPIC FLUE - Wall thickness of 195mm to 420mm

Notes.

If the stand-off frame is used it is essential to add

45mm to ‘X’ the measured wall thickness when marking the flue (this will allow for the fitted frame).

1. Measure and note wall thickness X. Refer to Frame

17.

2. Add 75mm to dimension X and set telescopic flue length as indicated in drawing.

3. Using a 3.5mm drill bit, drill one hole in outer air duct taking care not to pierce plastic inner flue.

4. Fix to length using self tappers provided.

5. Seal outer air duct using the tape provided.

Drill hole

nm8944

Adhere sealing tape

X + 75

Measurement to be

taken from this point

SETTING THE FLUE - SIDE - CONCENTRIC FLUE OPTION

TELESCOPIC FLUE - Wall thickness of 150mm to 375mm

1. Measure and note wall thickness X. Refer to Frame 17.

2. Measure distance from side of boiler to inside of wall

and add to wall thickness X=L. Refer to Frame 17.

3. Add 115mm to dimension L and set telescopic flue length as indicated in drawing.

4. Using a 3.5mm drill bit, drill one hole in outer air duct taking care not to pierce plastic inner flue.

5. Fix to length using self tappers provided.

6. Seal outer air duct using the tape provided.

Drill hole

nm8945

Adhere sealing tape

L + 115

Measurement to be

taken from this point

Keston 30C -

Installation and Servicing

FLUE OUTLET

Page 26

INSTALLATION

BOILER

esp8882

CONDENSATE PIPE TERMINATION CONFIGURATIONS

Notes: ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798

1. INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP

BOILER

INSTALLATION

cla7771a

2. INTERNAL CONNECTION TO SOIL AND VENT STACK

* Make connection to SVP using a solvent welded saddle

Open end of pipe direct into gulley below grating but above water level

Ground Level

DRAIN

3. TERMINATION TO SOAK AWAY

External

wall

BOILER

cla7774

to Soak away

minimum

500mm

Termination

Ground Level

4. TERMINATION TO DRAIN / GULLY

External

wall

BOILER

cla7775

DRAIN

Keston 30C -

Open end of pipe direct into gulley below grating but above water level

Ground Level

Installation and Servicing

Page 27

INSTALLATION

3G9847c

Flue Outlet

CONNECTING THE CONCENTRIC FLUE OPTION TO THE BOILER

Notes.

• Before fitting the flue turret fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet (shown below). Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.

• During assembly check that flue seals do not become dislodged.

1. Ensure front panel is removed.

2. Locate the flue into the turret.

3. Insert the flue assembly through

the prepared hole in the wall. Push through and pull back to seal against outside wall face.

4. Locate the flue turret into the flue manifold and secure by applying downward pressure.

5. Engage the clamp in its slide mechanism and push it horizontally backwards

6. Locate BOTH plastic pegs BEFORE the front retaining clip is fully located.

NOTE. SIDE FLUE

Select flue orientation before inserting turret into boiler manifold.

DO NOT twist the turret once inserted.

3G9847a

3G10115

3G9847b

Note - Flues over 1 metre long

It is recommended that a support bracket is fitted for every 1 metre of extension pipe used and a bracket should be used at every joint, to ensure pipes are held at the correct angle.

3G9847d

Retaining Clip (assembled)

Plastic Pegs (assembled)

3G9847e

Keston 30C -

Installation and Servicing

FLUE OUTLET

Page 28

INSTALLATION

WATER CONNECTIONS - CH

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.

CH Flow

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

2. Connect the CH return valve (black handle) and copper tail.

3. If connecting the boiler to heating loads in excess of 60,000

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

INSTALLATION

Black Handle

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

3G9849a

WATER CONNECTIONS - DHW

1. Fit the DHW inlet service valve (blue handle) and copper

tail to the threaded boss connection ensuring the seal provided is correctly located.

2. Fit DHW outlet pipe tail to DHW outlet connection, ensuring the seal provided is correctly located.

Yellow

Handle

Return

Blue

Handle

Black Handle

3. Fit the filling loop provided between the DHW inlet valve and the CH return valve.

Black Handle

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

3G9849b

CH Flow

Black Handle

DHW

Outlet

Yellow

Handle

Filling

Loop

Blue

Handle

DHW

Inlet

Keston 30C -

Return

Black Handle

Installation and Servicing

Page 29

INSTALLATION

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.

Gas

Supply

Black Handle

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

3G9849c

Yellow

Handle

Gas Pressure

Test Point

Blue

Handle

Black Handle

INSTALLATION

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.

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

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

3G9705

3G9849d

Black Handle

Yellow

Handle

Blue

Handle

Black Handle

Safety

Drain Val ve

15mm elbow

or fittings

(not supplied)

Keston 30C -

Installation and Servicing

Safety Valve Drain Pipe

Page 30

INSTALLATION

Black Handle

Yellow

Handle

Black Handle

3G9862

Blue

Handles

Safety

Drain Val ve

Black Handle

Blue

Handle

3G9865

FILLING

IMPORTANT - when filling:

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

1. Ensure Filling Loop is connected

2. Ensure dust cap on auto air vent is slackened off (refer to Frame 68).

INSTALLATION

3. Check all isolation handles

are in the open position

3G9849d

Black Handle

Yellow

Handle

Note.

The domestic hot water flow rate is automatically regulated to a maximum of 12.4 l/m (2.8 gpm).

Note that isolation handles are shown in the OPEN position on this picture.

Blue

Handle

Black Handle

Safety

Drain Val ve

4. Once pressure gauge dial reads between 1 - 1.5 bar turn the filling loop isolation valves back to the closed position.

5. Disconnect filling loop at the LH side, ensuring washer is retained and screw on cap.

Note. Fully open all DHW taps and ensure water is flowing freely. Once satisfied close all taps.

Keston 30C -

Installation and Servicing

Page 31

ELECTRICAL CONNECTIONS

INSTALLATION

WARNING

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.

The Keston 30C 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 33.

The Keston 30C boiler comes pre-fitted with a link wire between the room thermostat/Timer connections on the terminal strip. This creates a permanent call for heat and must be removed when adding a room thermostat/ programmer.

The terminal block cover carries two spare fuses for the main PCB.

. This appliance MUST be earthed.

INTERNAL WIRING

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

0.75mm2 (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.

INSTALLATION

To add thermostat/programmer:

1. Isolate the mains supply to the boiler.

2. Remove the front panel. Refer to Frame 44.

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

Refer to Frame 50.

4. Route incoming cables through the grommets in bottom panel (note, grommets are ‘blind’ and will require puncturing) and secure using clamps and screws provided in hardware pack.

5. Pull off rubber terminal block cover.

Spare PCB fuses

6. Connect wires to terminal block, as shown below

7. Re-assemble in reverse order.

Keston 30C -

Installation and Servicing

continued . . . .

Page 32

INSTALLATION

3G9561

FROST STAT (

OPTIONAL

)

ROOM STAT/ TIMER

Room Stat

Optional

Frost Stat

DIAGRAM B External Timer

INTERNAL WIRING.... CONT’D

Keston offer 2 kits as follows: (see individual kits for installation instructions)

Electronic Timer (7 day) kit - 7 day electronic CH timer fits into the control box of the boiler. This can be fitted in conjunction with a room thermostat. Features English language installation help messages.

INSTALLATION

DIAGRAM A

Internal Timer or Programmable Room Stat

ROOM STAT/ TIMER

Room Stat or Prog. Room Stat

Optional

Frost Stat

(1) ROOM THERMOSTAT WITH INTERNAL BOILER TIMER OR (2) PROGRAMMABLE ROOM THERMOSTAT

1. Remove link wire between room stat/timer terminals.

2. Connect room stat across terminals as shown in diagram A

3. If room stat has a neutral connection, connect this to

terminal N (load) in the fused spur.

FROST STAT (

OPTIONAL

)

DIAGRAM C

Weather Compensation Kit

ROOM STAT/ TIMER

FROST STAT

OPTIONAL

)

(

Timer

Optional

Frost Stat

3G9560

ROOM THERMOSTAT + TIMER

1. Remove link wire between room stat/timer terminals.

2. Connect room stat and programmer in series as shown in diagram B.

3. If room stat has a neutral connection, connect this to terminal N (load) in

the fused spur.

FROST THERMOSTAT

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.

1. Position the frost thermostat in a suitable position, i.e. area vulnerable to freezing.

2. Connect frost stat across terminals marked frost stat shown in diagrams A & B.

WEATHER COMPENSATION KIT

The two wires from the weather compensation kit (outside sensor), must be connected into the two right hand terminals as shown in diagram C.

OpenTherm Harness

Weather Compensation

Outside Sensor

3G9707a

Keston 30C -

Installation and Servicing

Page 33

INSTALLATION

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 31.

1. Isolate the mains supply to the boiler.

2. Remove the front panel. Refer to Frame 44.

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

frame 50.

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.

INSTALLATION

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

Keston 30C -

Installation and Servicing

3G10011

Page 34

INSTALLATION

35 FITTING THE KIT

Note. A timer should be fitted to the system so that CH will be switched off when appropriate.

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.

Wire a twin core 0.5mm 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.

Wiring the Weather Compensation Kit to the Keston 30C.

INSTALLATION

1. Isolate the electricity supply to the boiler.

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

3. Hinge down the control box.

4. Connect the sensor wiring into the RHS of the 4 way terminal block and secure with a cable clamp.

5. Re-assemble in reverse order.

cable from the sensor to the boiler through an RH grommet located on the underside of the boiler.

Keston 30C -

Installation and Servicing

Page 35

INSTALLATION

CH OPERATION

The On and Off time control of central heating should be controlled by a separate timer. This can be a standard unit or either of the options available from Keston 30C range.

During programmed On times the Central Heating Radiator Flow Temperature is controlled by the boiler relative to the Outside Temperature as shown in the following diagram.

INSTALLATION

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

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)

Keston 30C -

Installation and Servicing

Page 36

EXTERNAL ELECTRICAL CONTROLS

INSTALLATION

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.

INSTALLATION

This is usually done at the programmer, in which case the programmer selector switches are set to OFF and all the other controls MUST be left in the running position.

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

If the boiler is installed in a garage it may be

Note.

necessary to fit a pipe thermostat, preferably on the return pipework.

Earths are not shown for clarity but must never be omitted.

Programmable Room Stat

Mains In

Room Stat Frost Stat

Optional

Frost Stat

Use of General Live for Room Stat

Room Stat

Mains In

Room Stat Frost Stat

Optional

Frost Stat

OpenTherm Programmable Room Temperature Control

Note.

These terminals MUST ONLY be connected to an OpenTherm Controller, (such as the Keston Chronothern Room Controller (c.17.4.21.00.0). Connecting any other device / control wiring may destroy the primary PCB.

1. Isolate the mains supply to the boiler.

2. Remove the front panel. Refer to Frame 44.

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

Refer to Frame 50.

4. Remove the control box cover. Refer to Frame 62, no’s 3

and 4.

5. Unclip the 3 way in-line connector containing 2 purple

wires and 2 red wires.

6. Connect this 3 way connector to the 3 way connector

containing 2 purple wires wired from the 4 way terminal block.

7. Connect the two wires from the OpenTherm

Programmable Room Temperature Control to the two LH connections of the terminal block as shown.

8. Re-assemble in reverse order.

3G9990a

Keston 30C -

Installation and Servicing

Page 37

X1A

X1BX1CX1DX2AX2BX3X7AX7B

X6X8

2123123123412341235412312

X7D

1212

X7C

123456123456789

1011

205531-10207

Water

Sensor

Water

Flow

Turbine

Fan

Heat

Exchanger

Thermistor

Flow

Thermistor

Return

Thermistor

Flame

Sensor

Electrode

Spark

Electrode

Spark

Generator

PCB

Gas

Valve

Flue

Thermostat

Pump

Chassis

Earth

Internal

Timer

Low

Voltage

Connection

Internal

Timer

High

Voltage

Connection

Service

Connector

Inline

connector

Fused

at 4AT

Diverter

Val ve

WIRING DIAGRAM

INSTALLATION

Keston 30C -

Installation and Servicing

Page 38

Gas Supply

Gas Pressure

Test Point

COMMISSIONING AND TESTING

INSTALLATION

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.

INSTALLATION

WARNING.

Whilst effecting the required gas tightness test and purging air from the gas installation,

open all windows and doors, extinguish naked lights and

GENERAL

Please Note

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:

: The combustion for this appliance has

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.

DO NOT SMOKE.

CHECK THE OPERATIONAL (WORKING) GAS INLET PRESSURE

Set up the boiler to operate at maximum rate by opening hot tap to maximum flow.

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.

Keston 30C -

Installation and Servicing

Page 39

INITIAL LIGHTING

Legend

A. Pre-heat On/off B. DHW temperature control C. CH temperature control D. Off/Summer/Winter/Reset Control E. Boiler Status F. Burner ‘on’ indicator G. CH Flow Isolating Valve H. Pressure Gauge J. Gas Inlet Pressure Test Point K. Gas Service Cock L. DHW Inlet Valve M. CH Return Isolating Valve N. DHW Outlet

INSTALLATION

A B E F C D

INSTALLATION

3G9863

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 30.

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 44.

3. Check that the drain cock is closed and that the CH and

DHW isolating valves (M, L and G) are OPEN.

4. Check that the electrical supply is OFF.

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

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

7. Slacken the screw in the inlet pressure test point (J) 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 (C) to max and turn the mode

control knob (D) to , ensure the timer/room stat are on. The boiler control will now go through its ignition sequence until the burner is established.

10. If the boiler does not light the following messages will be displayed in rotation

“Ignition Lockout” - “1 Check other gas appliances” - “2 Reset boiler” - “3 Contact installer”

carry on displaying the messages. Reset the boiler (refer to Frame 40B). The boiler will repeat its ignition sequence. If reset occurs 5 times within 15 minutes then

resets”

reset.

When the burner is established the BLUE 'Burner On' neon (F) will be illuminated, the LCD will display

Heating” and “Radiator Temp XXoC”

. After 5 attempts the boiler will lock out and

“Too many

will be shown. If power is removed this will be

“Central

DOMESTIC HOT WATER

11. With the boiler firing, set the DHW Temp Control knob

(B) to maximum and fully open a DHW tap.

The boiler will continue to run and the display (E) will

“Hot Water” - “Temperature XXoC” - “High

show

Efficiency”

12. 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

13. Turn off the DHW tap.

Note. The temperature displayed “XXºC” is that measured at that moment, not the set temperature.

Note. The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply.

Keston 30C -

Installation and Servicing

continued. . . . .

Page 40

INSTALLATION

NORMAL OPERATION MESSAGE 1 MESSAGE 2 MESSAGE 3

Mode knob in standby position and no heat demand

Standby mode For hot water turn mode

knob clockwise

For central heating turn mode knob clockwise twice

Mode knob in summer position and no heat demand

Summer mode For central heating turn

mode knob clockwise

Mode knob in winter position and no heat demand

Winter mode Timer or room stat off

Domestic hot water operation Hot water Temperature 64ºC High efficiency

Central heating operation Radiator Temp 80ºC High efficiency

Pre-heat operation Pre heat

Central heating

Temperature 59ºC High efficiency

Boiler frost protection Boiler frost protection Temperature 5ºC

Pump overrun Pump overrun

Fan post-purge Fan post-purge

High efficiency

Note. High efficiency will not be shown for central heating operation if the central heating flow temperature knob is set to greater than 73ºC.

3G9711

INITIAL LIGHTING . . . . CONT’D

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.

The display scrolls through a maximum of 3 messages under any operational condition as shown below.

Notes:

DISPLAY FUNCTIONS IN NORMAL OPERATION

Boiler frost protection - boiler fires if temperature is below 5º C.

The temperatures shown below are for illustration purposes only. The measured temperatures will be shown on the boiler.

INSTALLATION

DISPLAY FUNCTIONS - SETTINGS CHANGED

NORMAL OPERATION MESSAGE 1 MESSAGE 2 MESSAGE 3

Pre-heat knob moved to off position Pre heat off

Pre-heat knob moved to on position Pre heat on

DHW temperature knob moved 64ºC DHW temp Hot water

temperature 64ºC

CH temperature knob moved 80ºC CH temp Maximum radiator

May not be achieved for high flow rates in winter

temperature 80ºC

Mode knob moved to standby position Central heating off Hot water off

Mode knob moved to summer position Summer mode

Mode knob moved to winter position Winter mode Central heating on

Standby mode

Central heating off Hot water on

Hot water on

Mode knob moved to reset position Reset

3G9712

Keston 30C -

Installation and Servicing

Page 41

INSTALLATION

MESSAGE 1

CURRENT VALUES

Flow temp 80ºC

Return temp 60ºC

DHW temp 64ºC

DHW flow rate 8 l/min

Diverter valve DHW position

3G9714

INITIAL LIGHTING . . . . CONT’D

INSTALLER MODE

Installer Mode is entered as follows:

1. Turn the DHW temperature control knob full anti-clockwise.

2. Turn the CH flow temperature control knob full anti-clockwise.

3. Turn and hold the mode knob in the reset position for more than 5 secs and then turn it to the Winter or Summer position.

The boiler will display

“Installer mode”.

If no faults have occurred the boiler will display

If any faults have occurred a list of faults up to a maximum of 10 including the type of fault and how long ago it occurred will be shown in the following format.

MESSAGE 1 MESSAGE 2 MESSAGE 3

LIST OF FAULTS

Fault 1 (latest fault) Low water pressure 2 days ago

Fault 2 No water flow lockout

Fault 3 Overheat lockout 384 days ago

The boiler will then display the current values of flow temperature, return temperature, domestic hot water temperature, DHW flow rate and diverter valve position in the following format:

“No faults”

78 days ago

Note.

If you would like to hold one of the values on the display to watch its behaviour then turn the reset knob to the reset position while it is displayed and hold it there.

Finally the display will operate in one of two modes. If there is a fault then more extensive corrective actions will be shown than are usually displayed for the end user. If there is not a fault then the information displayed for current operating states will also be more extensive than is usually displayed for the end-user (prepurge, ignition and post purge for example).

Installer mode automatically ends after 10 mins or by moving the mode knob to the standby position.

INSTALLATION

3G9713a

40B

RESET PROCEDURE

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

A B E F C D

Keston 30C -

Installation and Servicing

Legend

A. Pre-heat On/off B. DHW temperature control C. CH temperature control

D. Off/Summer/Winter/Reset Control E. Boiler Status F. Burner ‘on’ indicator

Page 42

INSTALLATION

GENERAL CHECKS

Make the following checks for correct operation in:

DOMESTIC HOT WATER (DHW) MODE

1. Fully open all DHW taps in turn and ensure that water

flows freely and that the mode knob is either in summer or winter position. The boiler will display

“Hot Water” - “Temperature XXoC” - “High Efficiency”

where the temperature shown is the current Domestic Hot Water temperature.

When the burner is lit the light above the display will be

INSTALLATION

on.

2. Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate.

This is factory set to give a DHW temperature rise of approximately 35 “operation”.

3. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and check that the boiler modulates to deliver DHW at approximately 64oC (with the DHW temperature control knob set to maximum).

4. Close the DHW tap and check that the main burner extinguishes. The pump should overrun for 60 seconds during which the boiler will display The fan will then continue to run for a further 3 minutes during which the boiler will display after which the boiler will display one of the following

C at the flow rate stated on page 6 under

“Pump overrun”

“Fan Post Purge”

“Standby mode” - “Summer mode” - “Winter Mode”

Note. On systems in excess of 2 bar inlet pressure a water

pressure governor may be required to prevent water noise.

depending on the position of the mode knob.

CH & DHW MODE

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

boiler mode knob is in the winter position and the CH flow temperature control knob is in the maximum position. The Boiler will display

“Central Heating” - “Radiator Temp XXC”

where the temperature shown is the current flow temperature.

When the burner is lit the light above the display will be on.

2. Fully open the DHW tap and check that hot water is delivered. The boiler will display

“Hot water” -

Temperature XXoC” - High Efficiency”

3. Gas Rate

Check the boiler gas rate when the boiler is at full DHW output. Check at the gas meter, with no other appliance in use. Refer to Tables 2 and 3 for gas rates.

4. Close the DHW tap. The burner should remain on and the boiler will display

Set the central heating external controls to off. The burner

will go off and the fan and pump continue to run for 4

minutes. The boiler will display the boiler will display one of the following:

- “Summer mode” - “Winter mode”

position of the mode knob.

6. Check the correct operation of the timer (if fitted) and all other system controls. Operate each control separately and check that the main burner responds.

“Central heating” - “Radiator temp XXC”.

“Pump overrun”

after which

“Standby mode”

depending on the

Note. The temperature displayed “XXºC” is that measured at that moment, not the set temperature.

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.

A flushing solution should be used during the

Note:

flushing procedure. Flushing solutions: Fernox Superfloc, Sentinel X300 (new systems) or X400 (existing systems). Refer to Frame 5.

4. Refill and vent the system, add inhibitor (see Frame 5), 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 4.

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

discharging correctly.

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

Notes.

1. If the pump has not operated in the last 24 hours it will run briefly to prevent seizure

2. If the diverter valve has not operated in the last 24 hours it will be operated briefly to prevent seizure. These two operations will not occur at the same time.

WATER TEMPERATURES

Temperatures can be selected using the CH and DHW thermostats.

Knob Setting CH Flow Temp DHW Outlet Temp

Max 80 (176) 64 (147)

Min 30 (86) 40 (104)

Keston 30C -

C (oF)

Installation and Servicing

Page 43

INSTALLATION

HANDING OVER

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

1. Make the householder aware that the user instructions

are located in the pocket in the drop down door and explain his/her responsibilities under the relevant national regulations.

2. Explain and demonstrate the lighting and shutting 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 to the building, in the event of the system remaining inoperative during frosty conditions.

4. Explain the function and the use of the boiler heating and domestic hot water controls.

Explain that due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap. It is therefore necessary to draw the users attention to the section in the Users Instructions titled “Control of Water Temperature” and the following statement:

“Additionally, the temperature can be controlled by the user via the draw-off tap: the lower the rate the higher the temperature, and vice versa”.

5. Explain the function of the boiler fault mode.

Emphasise that if a fault is indicated, the boiler should be turned off and a Gas Safe Registered Engineer consulted. In IE contact a Registered Gas Installer (RGII).

6. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the 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 repressurising 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 (refer to Frame 41B).

10. After installation and commissioning please complete the

Commissioning Checklist before

handover to the customer. For IE, its is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813:2002.

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 form and the requirement to register it to receive the full benefit of the warranty.

INSTALLATION

Keston 30C -

Installation and Servicing

Page 44

SERVICING

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.

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

1. Clean the main burner. Refer to frame 46.

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

Frames 47 & 48.

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

SERVICING

45.

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

ALSO IF THE DHW FLOW RATE IS IN QUESTION :-

5. Check the DHW filter for blockage. Refer to Frame 74.

The cleaning procedures are covered more fully in Frames 45-50 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.

Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity

GENERAL

components the boiler front panel must be removed. Refer to Frame 44.

Please Note

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

: During routine servicing, and after any

COMBUSTION PERFORMANCE

Please Note

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 BSEN50379-3 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.

: BS 6798:2009 Specification for

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 analyser to the flue

gas sampling point as shown in the diagram and measure CO &

If the CO/CO 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.

ratio is greater than 0.004 AND the integrity of the

Flue Sampling Point

Keston 30C -

Installation and Servicing

Page 45

SERVICING

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.

Flue sampling point for concentric flue only

view from bottom of boiler

view from top of boiler

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.

Injector

SERVICING

Keston 30C -

Installation and Servicing

Page 46

BURNER REMOVAL AND CLEANING

SERVICING

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.

SERVICING

CLEANING THE CONDENSATE TRAP/SIPHON

1. Remove the cleaning plug taking care with any residual condense.

2. Pull off the rubber pipe noting the position and flush out any deposits with

clean water.

3. Replace the cleaning plug and refill the siphon with water.

4. Replace the rubber pipe connector with the twin wall seal fitted to the

condensate siphon.

Keston 30C -

3G9690

Installation and Servicing

Page 47

CLEANING THE HEAT EXCHANGER

SERVICING

Note:

Ensure the condensate trap/siphon

is fully drained before cleaning. Refer to

Frame 61.

1. Remove ignition and flame detection electrodes. Refer to Frames 56 & 57.

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 56 &

57.

Ignition Electrode

Flame Detection

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.

SERVICING

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.

Keston 30C -

Installation and Servicing

Page 48

REPLACEMENT OF COMPONENTS

SERVICING

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 44.

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 tightness, 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 80

In order to replace components in Frames 66-78 it is

necessary to drain the boiler. Refer to Frame 65.

THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED

SERVICING

FAN REPLACEMENT

1. Refer to Frame 50.

2. Disconnect the electrical leads from the fan.

3. Undo the gas pipe union connection to the

injector housing.

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 anti-

clockwise to remove venturi assembly,

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 40 & 41.

noting

Retaining Tabs

Keston 30C -

Installation and Servicing

Page 49

BURNER INJECTOR REPLACEMENT

SERVICING

1. Refer to Frame 50.

2. Disconnect the electrical leads from the fan.

3. Undo the gas pipe union connection to the

injector housing.

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 40 & 41.

BURNER REPLACEMENT

1. See Frame 46.

2. Refer to Frame 50.

3. Disconnect 2 flag terminals from the flue thermostat.

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

5. Lift the manifold to clear the bottom sealing gasket and

remove manifold.

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

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

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

9. Reassemble in reverse order. Refer to Frame 49.

10. Check the operation of the boiler. Refer to Frames 40

& 41.

SERVICING

Keston 30C -

Installation and Servicing

Page 50

SERVICING

CONTROL THERMISTOR & RETURN THERMISTOR RENEWAL

1. Refer to Frame 50.

2. Unclip the control thermistor from the flow pipe and withdraw it from the

boiler.

3. Unclip the return thermistor from the return pipe and withdraw it from the

boiler.

4. Disconnect the electrical leads from the thermistors.

5. Reconnect the electrical leads to the new thermistors and reassemble in

reverse order, ensuring that the thermistors are securely fitted to the pipes on the thermistor locator tabs as shown.

6. Check the operation of the boiler. Refer to Frames 40 & 41.

Thermistor Locator Tab (with thermistor fitted)

SERVICING

FLUE THERMOSTAT REPLACEMENT

1. Refer to Frame 50.

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

Keston 30C -

Installation and Servicing

Page 51

3mm

Straight edge

12.5mm

Straight edge

IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 50.

2. Remove the burner. Refer to Frame 53.

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 40 & 41.

Spark Gap

3.5mm

SERVICING

Ignition Electrode

FLAME DETECTION ELECTRODE REPLACEMENT

1. Refer to Frame 50.

2. Remove the burner. Refer to Frame 53.

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.

7. Reassemble in reverse order.

8. Check the operation of the boiler. Refer to

Frames 40 & 41.

SERVICING

Flame Detection Electrode

Keston 30C -

Installation and Servicing

Page 52

SPARK GENERATOR REPLACEMENT

1. Refer to Frame 50.

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 40 & 41.

SERVICING

Spark Generator

SERVICING

GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 50.

2. Unplug the electrical plug 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

40 & 41.

Keston 30C -

Installation and Servicing

Page 53

SERVICING

DIVERTER VALVE ACTUATOR REPLACEMENT

1. Refer to Frame 50.

2. Remove the electrical plug.

3. Using a suitable tool pull out the retaining

clip and lift the diverter head from the brass body.

4. Fit new actuator head and reassemble in reverse order.

6. Check operation of the boiler. Refer to Frames 40 & 41.

Diverter Valve Actuator

CONDENSATE TRAP/SIPHON REPLACEMENT

1. Refer to Frame 50.

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. Remove the cleaning plug

5. Turn the siphon clockwise

to disengage and lift to remove.

6. Reassemble in reverse order.

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

8. Check operation of the boiler. Refer to Frames 40 & 41.

Retaining Clip

SERVICING

Siphon

Keston 30C -

Installation and Servicing

3G9690

Page 54

SERVICING

MAIN PCB REPLACEMENT

Note.

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

1. Refer to Frame 50.

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).

Ensure the correct orientation of BCC by placing

Note.

“TOP” side up as shown.

8. Re-connect all plug connections.

9. Reassemble in reverse order.

10. Turn power back on to the boiler, after a few moments the

display will start alternating between “c” and “0”. Turn the reset knob fully clockwise and when the display shows “ - ” turn the knob fully anti-clockwise IMMEDIATELY.

Finally move the knob into the required position (Standby, Summer or Winter).

11. Check operation of the boiler. Refer to Frames 40 & 41.

SERVICING

Plastic

Clip

Ribbon Cable Connection

Keston 30C -

Installation and Servicing

Page 55

USER CONTROL PCB REPLACEMENT

Note.

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

1. Refer to Frame 50.

2. Remove the main PCB, refer to Frame 62.

3. Unclip the PCB and lift to clear the mounting

posts.

4. Fit the new PCB ensuring the 4

potentiometer spindles line up with the control knobs which must be in a vertical position.

5. Reassemble in reverse order.

6. Check operation of the boiler. Refer to

Frames 40 & 41.

SERVICING

PCB

Control Knobs (to be in vertical position)

DHW FLOW TURBINE SENSOR REPLACEMENT

Potentiometer spindle

SERVICING

1. Refer to Frame 50.

2. Remove condensate trap/siphon. Refer

to Frame 61.

3. Lift off the flow turbine sensor plastic retaining clip.

4. Unplug the electrical connection and transfer to new turbine sensor.

5. Reassemble in reverse order.

6. Check operation of the boiler. Refer to

Frames 40 & 41.

Keston 30C -

Installation and Servicing

Page 56

3G9692c

Gas CH

Return

Filling Loop

DHW

Inlet

DHW Outlet

DRAINING THE BOILER

SERVICING

CENTRAL HEATING CIRCUIT

1. Refer to Frame 50.

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 by re-connecting the filling loop, refer to Frame 30) before proceeding to check operation of the boiler.

5. Disconnect filling loop. Refer to Frame 30.

6. Check operation of the boiler. Refer to Frames 40 & 41.

DOMESTIC HOT WATER CIRCUIT

1. Refer to Frame 50.

2. Close all the DHW water isolating valves on the boiler

inlet.

3. To drain the domestic hot water circuit: As there is no direct drain for the domestic hot water circuit, depending

SERVICING

on the location of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual water will be experienced during replacement of components.

4. After replacing any component on the boiler, close tap, close the drain valve and open all system isolating valves (re-pressurise as appropriate by re-connecting the filling loop, refer to Frame 30) before proceeding to check operation of the boiler.

5. Disconnect filling loop. Refer to Frame 30.

6. Check operation of the boiler. Refer to Frames 40 & 41.

Flow

Filling Loop

Circuit

Drain

Gas CH

Return

3G9692b

PRESSURE GAUGE RENEWAL

1. Refer to Frame 50.

2. Drain the heating system. Refer to Frame

65.

3. Unscrew the pressure gauge and discard.

4. Fit new pressure gauge, using suitable

jointing compound.

5. Refill the boiler. Refer to Frame 30.

6. Check operation of the boiler. Refer to

Frames 40 & 41.

Keston 30C -

3G9690

Installation and Servicing

Page 57

SAFETY RELIEF VALVE RENEWAL

SERVICING

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Remove the condensate trap/siphon. Refer to

Frame 61.

4. Remove expansion vessel. Refer to Frame 78.

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 30. Check operation of boiler. Refer to Frames 40 & 41.

PUMP AUTOMATIC AIR VENT REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to frame 65.

3. Remove the expansion vessel. Refer to Frame 78.

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 67 (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 30. Check for leaks

around the new air vent joint.

9. Check the operation of the boiler. Refer to Frames 40 & 41.

SERVICING

Keston 30C -

Installation and Servicing

Page 58

SERVICING

DHW FLOW TURBINE CARTRIDGE REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Remove condensate trap/siphon. Refer to

Frame 61.

4. Remove the DHW flow turbine sensor. Refer to Frame 64.

5. Unscrew the top connection to access the internal part.

6. Fit the new turbine cartridge.

7. Refit the turbine flow sensor

8. Reassemble in reverse order.

9. Refill the boiler. Refer to Frame 30.

10. Check operation of the boiler. Refer to

Frames 40 & 41.

DIVERTER VALVE INTERNAL CARTRIDGE REPLACEMENT

FRONT CARTRIDGE REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Remove the diverter valve head. Refer

to Frame 60.

4. Unscrew the top connection to access the internal cartridge.

SERVICING

5. Fit the new valve mechanism ensuring

the correct fit of the pin.

6. Reassemble in reverse order.

7. Refill the boiler. Refer to Frame 30.

8. Check operation of the boiler. Refer to

Frames 40 & 41.

FRONT CARTRIDGE REAR CARTRIDGE

REAR CARTRIDGE REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Remove the diverter valve head. Refer to Frame 60.

4. Remove the flow pipe. Refer to Frame 77 no. 12.

5. Disconnect the CH flow pipe and DHW outlet pipe union connections

underneath the boiler. Refer to Frame 65.

6. Remove the plate heat exchanger LH fixing screw. Refer to Frame 71.

7. Remove the screw retaining the brass block to the bottom of the boiler casing

and lift the brass block clear of the boiler.

8. Unscrew the rear cartridge connection.

9. Fit the new valve mechanism ensuring the correct fit of the pin.

10. Reassemble in reverse order.

11. Refill the boiler. Refer to Frame 30.

12. Check operation of the boiler. Refer to

Frames 40 & 41.

9 8

Keston 30C -

Installation and Servicing

Page 59

SERVICING

DHW PLATE HEAT EXCHANGER REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Remove condensate trap/siphon. Refer to Frame 61.

4. Remove the diverter valve actuator. Refer to Frame 60.

5. Remove the 2 allen screws securing the plate heat

exchanger to the brass housings.

6. Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area.

7. Fit the new plate heat exchanger, using the new o-rings supplied.

Note.

The mounting pins are offset so the correct position can be defined from the location of the holes on the brass mounting.

8. Reassemble in reverse order.

9. Refill the boiler. Refer to Frame 30.

10. Check operation of the boiler. Refer to Frames 40 & 41.

PUMP HEAD REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Disconnect the electrical plug from the

pump.

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

5. Remove the pump head.

6. Fit the new pump head.

7. Reassemble in reverse order.

8. Refill the boiler. Refer to Frame 30.

9. Check operation of the boiler. Refer to

Frames 40 & 41.

SERVICING

Keston 30C -

Installation and Servicing

Page 60

SERVICING

CH WATER PRESSURE SENSOR REPLACEMENT

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

3. Remove condensate trap/siphon. Refer to

Frame 61.

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.

8. Reassemble in reverse order.

9. Refill the boiler. Refer to Frame 30.

10. Check Operation of the boiler. Refer to

Frames 40 & 41.

SERVICING

DHW FILTER CLEANING / REPLACEMENT

1. Refer to Frame 50.

2. Isolate the mains cold water supply to

the boiler.

3. Drain the boiler DHW circuit. Refer to frame 65.

4. Remove the DHW flow turbine cartridge. Refer to Frame 69.

5. Unscrew the flow regulator housing.

6. Remove the filter.

7. Clean or replace filter as necessary.

8. Reassemble in reverse order.

9. Refill the boiler. Refer to Frame 30.

10. Check Operation of the boiler. Refer to

Frames 40 & 41.

Keston 30C -

Installation and Servicing

Page 61

SERVICING

DHW FLOW REGULATOR CLEANING / REPLACEMENT

1. Refer to Frame 50.

2. Isolate the mains cold water supply to the

boiler.

3. Drain the boiler DHW circuit. Refer to Frame 65.

4. Remove the DHW flow turbine cartridge. Refer to Frame 69.

5. Unscrew the flow regulator housing.

6. Inspect the flow regulator for any blockage

and remove if necessary.

7. Reassemble in reverse order.

8. Refill the boiler. Refer to Frame 30.

9. Check Operation of the boiler. Refer to

Frames 40 & 41.

NO FLOW THERMISTOR REPLACEMENT

1. Refer to Frame 50.

2. Drain down the boiler. Refer to Frame 65.

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.

7. Refill the boiler. Refer to Frame 30.

8. Check the operation of the boiler. Refer to

Frames 40 & 41.

SERVICING

Keston 30C -

Installation and Servicing

Page 62

SERVICING

HEAT ENGINE RENEWAL

Refer also to Frames 6 & 7 - ‘Boiler Exploded View’

IMPORTANT

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

1. Refer to Frame 50.

2. Drain the boiler. Refer to Frame 65.

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

side. Refer to frame 51.

4. Remove the burner and place on one side. Refer to Frame 53.

5. Remove the ignition and detection electrodes and diverter actuator head. Refer to Frames 56, 57 and 60.

6. Remove the spark generator. Refer to Frame 58.

7. Remove the gas valve. Refer to Frame 59.

8. Remove the expansion vessel. Refer to Frame 78.

9. Remove the no flow thermistor. Refer to Frame 76.

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 61, 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 61.

18. Refill the boiler. Refer to Frame 30.

19. Check operation of the boiler. Refer to Frames 40 & 41.

SERVICING

Keston 30C -

Installation and Servicing

Page 63

SERVICING

EXPANSION VESSEL RECHARGING & REPLACEMENT

RECHARGING

1. Refer to Frame 50.

2. Remove the charge point cover.

3. Recharge the tank pressure to 0.75 bar.

4. Re-assemble in reverse order

5. Check operation of the boiler. Refer to Frames

40 & 41.

REPLACEMENT

6. Refer to Frame 50.

7. Drain the boiler CH circuit. Refer to Frame 65.

8. Unscrew the union nut on the vessel water

connection pipe.

9. 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)

10. Remove the expansion vessel.

11. Fit the new expansion vessel.

12. Reassemble in reverse order.

13. Refill the boiler. Refer to Frame 30.

14. Check operation of the boiler. Refer to Frames

40 & 41.

Recharge Point

BOILER SEALING PANEL SEAL REPLACEMENT

1. Refer to Frame 50.

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.

5. Reassemble in reverse order.

6. Check operation of the boiler. Refer to

Frames 40 & 41.

Note.

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

SERVICING

Keston 30C -

Installation and Servicing

Page 64

FAULT FINDING

Overheat lockout 1 Fill system to 1.0 bar 2 Bleed radiators

3 Check radiator valves open

4 Reset boiler 5 Contact installer

Go to Frame 81

Flow Temperature Overheat Lockout

Ignition lockout /

Flue Overheat

1 Check other gas appliances work

2 Reset boiler

3 Contact Installer

Go to Frame 82 Ignition Lockout

Low water pressure 1 Fill system to 1.0 bar

Go to Frame 85

Low Water Pressure

No water flow lockout Fill system to 1.0 bar 2 Bleed radiators

2 Bleed radiators

Flame loss 1 Check other gas appliances

Go to Frame 86

Flame Loss

2 contact installer

3 Check radiator valves open

4 Reset boiler 5 Contact installer

Go to Frame 83

No Water Flow Lockout

Too many resets Contact installer

5 Resets with 15 minutes

Turn power off and on

Fault 8 Contact installer

3 Contact installer

Go to Frame 84

False Flame Lockout

Fan fault Contact installer

Go to Frame 87

Fan Fault

Flow thermistor fault Contact installer

Go to Frame 88

Flow Thermistor Fault

Return thermistor fault Contact installer

Go to Frame 90

Return Thermistor Fault

Outside sensor fault Contact installer

Go to Frame 90

Outside sensor fault

Low mains voltage Contact electricity provider

Low mains voltage

Contact Electricity Provider

PCB Fault Contact installer

If PCB is a spare check Boiler Chip Card

(BCC) fitted otherwise replace PCB

PCB Replaced Reset boiler

Reset the boiler

No water flow thermistor fault Contact installer

Go to Frame 89

Return Thermistor Fault

Boiler Chip Card Fault Contact installer

Go to Frame 92

BCC Fault

Go to Frame 93

No CH operation but DHW works OK

No CH operation but DHW operates OK

Go to Frame 94

No DHW but CH operates OK

No DHW operation but CH operates OK

No Display

Go to Frame 95

No Display

FAULT FINDING CHART MAIN MENU

Note. Boiler status display information is shown in shaded boxes below. Up to six messages will be displayed in rotation.

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

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

Keston 30C -

Installation and Servicing

Page 65

FAULT FINDING

OVERHEAT LOCKOUT - 1 FILL SYSTEM TO 1.0 BAR - 2 BLEED RADIATORS 3 CHECK RADIATOR VALVES OPEN - 4 RESET BOILER - 5 CONTACT INSTALLER

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

YES

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

Check the Flow and Return Thermistors (Refer to Frame 54)

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

YES

Fill and vent the system and open all isolation valves, then reset boiler

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

Replace the Pump, then reset boiler

YES

OK, now

reset boiler

Keston 30C -

Installation and Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Page 66

FAULT FINDING

IGNITION LOCKOUT / FLUE OVERHEAT - 1 CHECK OTHER GAS APPLIANCES WORK

- 2 RESET BOILER - 3 CONTACT INSTALLER

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

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

YES

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 59) 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?

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

Replace Ignition Electrode and associated harness as necessary

Check flue for obstruction

Check wiring to thermostat

Check flue temperature always

remains below 90ºC

Check if burner is

damaged

Replace heat exchanger

YES

Clear obstruction

Ensure wiring correctly

connected

Replace Thermostat

Replace burner

* 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 FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

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

Keston 30C -

Installation and Servicing

Page 67

FAULT FINDING

NO WATER FLOW LOCKOUT - 1 FILL SYSTEM TO 1.0 BAR - 2 BLEED RADIATORS 3 CHECK RADIATOR VALVES OPEN - 4 RESET BOILER - 5 CONTACT INSTALLER

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

YES

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

Check the No Water Flow Thermistor

(Refer to Frame 76).

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

C expect 9,700 - 10,300 Ohms

At 25

At 60 oC expect 2,400 - 2,600 Ohms

C expect 1,000 - 1,100 Ohms

At 85

Does the boiler now work OK?

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

YES

Fill and vent the system and open all isolation valves, reset the boiler

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

Replace the Pump

Check the Flow and Return Thermistors

(Refer to Frame 54)

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

C expect 9,700 - 10,300 Ohms

At 25

At 60 oC expect 2,400 - 2,600 Ohms

C expect 1,000 - 1,100 Ohms

At 85

YES

FAULT 8 - CONTACT INSTALLER (FALSE FLAME LOCKOUT)

Reset the boiler, does Boiler Work OK?

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

Check routing and integrity of internal boiler wiring.

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

LOW WATER PRESSURE - 1 FILL SYSTEM TO 1.0 BAR - 2 BLEED RADIATORS -

YES

Check routing and integrity of internal boiler wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated.

Replace Flame Detection Electrode

3 CONTACT INSTALLER

Are 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

YES

Are connections on water pressure sensor secure?

YES

Replace water pressure sensor

Keston 30C -

Installation and Servicing

Re-fit connections

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Page 68

FAULT FINDING

FLAME LOSS - 1 CHECK OTHER GAS APPLIANCES WORK 2 CONTACT INSTALLER

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

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

YES

Is 215Vdc supply available at the Gas Valve while the flame is on? (* See note)

YES

Check spark generator and associated harness for: continuity and visual condition. (Refer to Frame 58) 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?

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

YES

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

Check flue for obstruction

Check wiring to thermostat

Check flue temperature always

remains below 90ºC

Check if burner is

damaged

YES

Replace Gas Valve

Clear obstruction

Ensure wiring correctly

connected

Replace Thermostat

Replace burner

Replace heat exchanger

* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

the value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.

Keston 30C -

Installation and Servicing

Page 69

FAN FAULT - CONTACT INSTALLER

FAULT FINDING

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?

YES

Replace Fan

FLOW THERMISTOR FAULT - CONTACT INSTALLER

Remove the Flow Thermistor from the CH Flow

Pipe and disconnect the wires.

Check the resistance using a suitable multimeter

connected across the thermistor’s terminal pins.

C expect 9,700 - 10,300 Ohms

At 25

At 60 oC expect 2,400 - 2,600 Ohms

At 85 oC expect 1,000 - 1,100 Ohms

Rectify Wiring & connections

Replace PCB

Fit a new Thermistor

Is the Thermistor value correct?

YES

Is there continuity between the PCB and the Thermistor?

RETURN THERMISTOR FAULT - CONTACT INSTALLER

Remove the Return Thermistor from the CH Return

Pipe and disconnect the wires.

Check the resistance using a suitable multimeter

connected across the thermistor’s terminal pins.

At 25 oC expect 9,700 - 10,300 Ohms

C expect 2,400 - 2,600 Ohms

At 60

At 85 oC expect 1,000 - 1,100 Ohms

Is the Thermistor value correct?

YES

Check and replace wiring as necessary

Replace PCB

Fit a new Thermistor

Is there continuity between the PCB and the Thermistor?

Keston 30C -

YES

Installation and Servicing

YES

Check and replace wiring as necessary

Replace PCB

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Page 70

FAULT FINDING

OUTSIDE SENSOR FAULT - CONTACT INSTALLER

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 Sensor’s terminal

pins.

At 0 oC expect 31,000 - 35,000 Ohms

At 15 oC expect 15,000 - 16,500 Ohms

C expect 7,700 - 8,500 Ohms

At 30

Is the Outside Sensor value correct?

YES

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

YES

Securely connect the wiring at both the boiler and Outside Sensor

Fit a new Outside Sensor

Securely connect the wiring at the Terminal Block and the PCB

Replace PCB

NO WATER FLOW THERMISTOR FAULT - CONTACT INSTALLER

Is the wiring securely connected to the No Water Flow Thermistor (located in the top of the Heat Exchanger?)

YES

Disconnect the wiring from the No Water Flow Thermistor

Check the resistance using a suitable multimeter connected across the Thermistor’s terminal pins.

C expect 9,700 - 10,300 Ohms

At 25

At 60 oC expect 2,400 - 2,600 Ohms

At 85 oC expect 1,000 - 1,100 Ohms

Is the Thermistor value correct?

YES

Is the wiring securely connected to the low voltage 11 way connector at the front left hand side of the PCB?

YES

Securely connect the wiring to the No Water Flow Thermistor

Fit a new Thermistor

Securely connect the wiring to the PCB

Replace PCB

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Keston 30C -

Installation and Servicing

Page 71

FAULT FINDING

BOILER CHIP CARD FAULT - CONTACT INSTALLER

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, reset the boiler. Is ‘c2’ still shown?

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

NO CH OPERATION BUT DHW WORKS OK

Is the mode knob in the Winter position?

YES

Move the mode knob to the Winter position

Securely attach the BCC for the boiler onto the PCB and after switching power on and ‘c0’ being shown, reset the boiler.

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

Replace PCB

Are the Timer and the Room Thermostat switched on?

YES

Are the Radiator Valves Open?

YES

Is there 230Vac at (A)?

YES

Replace the Diverter Valve

Switch the Timer and Room Thermostat On

Open the Radiator Valves

There is no Voltage from the Timer/Room Stat. This is not boiler fault. Ensure Voltage is supplied to boiler by rectifying external wiring.

Keston 30C -

Installation and Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Page 72

NO HW BUT CH ON

Does the display show “

temperature XXºC

“

Are the flow rates correct as per Frame 2.

hot water

” - “

high efficiency

” -

”?

YES

FAULT FINDING

Is the red neon illuminated on the turbine sensor?

Adjust flow rates to achieve 35º temp rise and check filter fitted in turbine is not blocked with debris.

YES

Is hot and cold pipework crossed?

Replace PCB

Is the wiring between the PCB and the diverter valve motor connected?

YES

Check diverter head fully engaged and clip secured onto waterset.

YES

Is diverter stuck in the CH position

YES

Check and replace diverter valve motor head. Is Boiler DHW OK?

Change diverter Valve cartridge - rear section

NO DISPLAY

Reconnect wiring or replace wiring harness if no continuity.

Re-engage diverter head and secure clip to wateset

Replace PCB

Is the wiring connected between PCB and DHW sensor?

YES

Remove the turbine, and check for debris in the turbine & filter. Replace turbine if necessary. Is DHW OK?

Replace turbine sensor

Re-connect wiring

Is there 230Vac to the boiler at L and N?

YES

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

YES

Is the ribbon cable from the main PCB to the User Interface PCB connected securely?

YES

Is ribbon cable damaged?

YES

Replace ribbon cable

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

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Keston 30C -

Installation and Servicing

Page 73

SHORT LIST OF PARTS

The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance.

The list is extracted from the British Gas List of Parts, which contains all available spare parts.

The full list is held by British Gas Services, Keston distributors and merchants.

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.

Key No. G.C. Part No. Description Qty./boiler Product Number

107 Filling Loop 1 KS301175530

108 Pump Head Kit 1 KS301175670

110 Automatic Air Vent 1 KS301174894

111 Diverter Valve Head 1 KS301174813

112 Diverter Valve Cartridges 1 KS301175668

113 Pressure Relief Valve 1 KS301175413

118 Expansion Vessel 1 KS301175551

121 Plate Heat Exchanger 1 KS301175418

127 Flow Sensor (Hall Effect) 1 KS301175590

128 DHW Flow Turbine 1 KS301175661

131 Water Pressure Sensor 1 KS301175596

135 Pressure Gauge 1 KS301175679

205 Gas Valve kit 1 KS301175562

211 Injector & Housing 1 KS301175611

215 Fan Kit 1 KS301175569

217 Burner 1 KS301175571

229 Siphon Trap Kit 1 KS301175583

232 Turret Manifold Gasket 1 KS301175620

302 Primary PCB 1 KS301175939

302B Boiler Chip Card (BCC) 1 KS301175937

303 CUI Board 1 KS301175713

304 Control Thermistor (Flow/Return) 2 KS301175589

306 Ignition Electrode Kit 1 KS301175591

307 Detection Electrode Kit 1 KS301175592

308 Spark Generator 1 KS301175593

309 Thermistor - No Flow 1 KS301175594

313 Ignition lead 1 KS301175598

320 Detection Lead 1 KS301175604

328 Fuse - PCB 1 KS301175627

403 Heat Engine Gasket Kit 1 KS301175618

504 Front Panel 1 KS301175723

512 Front Panel Door 1 KS301175722

332 Flue Thermostat 1 KS301175949

When ordering spares please quote:

1. Boiler model

2. Appliance G.C. No.

3. Description.

4. Quantity.

5. Product number.

Keston 30C -

Installation and Servicing

Page 74

30C

107 108

110

111

118

121

127

128

131

135

205

211

215

217

229

302

303

304

306

307

309

313

320

328

403

504

512

308

232

112

113

3G9977a

302B

332

SHORT LIST

SHORT LIST OF PARTS

Keston 30C -

Installation and Servicing

Page 75

Page 76

INSTALLER NOTIFICATION GUIDELINES

A change to Building Regulations (England and Wales) requires the installer to notify

when installing a heating appliance, as from 1st April 2005.

Competent Person's

SELF CERTIFICATION SCHEME

BUILDING CONTROL

Install and commission

this appliance to

manufacturers' instructions

Complete the

Benchmark Checklist

Choose

Buildings Regulations

notification route

Contact your relevant

Local Authority

Building Control (LABC) who

will arrange an inspection

or contact a government

approved inspector

LABC will record the data

and will issue a

certificate of compliance

If you notify via

Gas Safe Register they will

then notify the relevant

Local Authority Building

Control (LABC) scheme

on members behalf

Gas Safe Register Engineers

log on to the engineers section

of the website at

www.gassaferegister.co.uk

or telephone

0800 408 5577

You must ensure that the

notification number issued by

Gas Safe Register is written

onto the Benchmark Checklist

Gas Safe Register will record the

data and will send a certificate

of compliance to the property

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

Keston 30C -

Installation and Servicing

Page 77

THIS PAGE INTENTIONALLY LEFT BLANK

Page 78

Gas Safe Register ID N

Gas Safe Register ID Number

Page 79

Gas Safe Register ID Number Gas Safe Register ID Number

Gas Safe Register ID Number

Page 80

Keston Boilers, 34 West Common Road, Hayes, Bromley, Kent, BR2 7BX. Telephone: 0208 462 0262 Fax: 0208 462 4459.

Keston pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

June 2010 UIN 205531 A03

Keston 30C INSTALLATION AND SERVICING INSTRUCTIONS (June 2010 UIN 205531 A03)

Specifications and Main Features

Frequently Asked Questions

User Manual