Keston Combi 30kw, Combi 35kw User Manual

Installation and Servicing Instructions
FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS COMBINATION BOILER
CE/PI No. 86-CL-38
Combi 30 - GC No. 47-930-04
Combi 35 - GC No. 47-930-05
These instructions must be left either with the
user or next to the site gas meter.
Keston Heating
PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN
Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133
email : info@keston.co.uk web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2
SEDBUK A RATED
2
Keston Combi -
Installation and Servicing
NOTES FOR THE INSTALLER
FOR ANY TECHNICAL QUERIES PLEASE RING THE KESTON
INSTALLER/TECHNICAL HELPLINE : 01482 443005
NOTE. BOILER RESET PROCEDURE ­To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present.
DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level ..... A02 (Oct 12) and A03 (Feb 14)
Page 11
Water Treatment - Addition of Adey Professional Heating Solutions
Page 31
Item “3” added to Electrical Installation Statement added ref to commissioning process of combustion
Page 67
New Page Added - Benchmark Commissiong & Servicing Section
Page 68 & 69
New updated Commissioning Checklist & Service Record Sheets
Page 70 & 71
New pages added, Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler
Keston reserve the right to vary specication without notice
3Keston Combi - Installation and Servicing
general
Table 1 - General Data
Keston Combi 30 35
Gas supply 2H - G20 - 20mbar
Gas Supply Connection 15mm copper compression
Injector Size (mm) 4.65 4.9
Inlet Connection DHW 15mm copper compression
Outlet Connection DHW 15mm copper compression
Flow Connection CH 22mm copper compression
Return Connection CH 22mm copper compression
Flue Terminal Diameter mm (in) 50 (nominal)
o
Average Flue Temp-Mass Flow Rate (DHW) 68
Maximum Working Pressure (Sealed Systems) bar (lb/in
Maximum Domestic Hot Water Inlet Pressure bar (lb/in
Minimum Domestic Hot Water Inlet Pressure* bar (lb/in
2
) 2.5 (36.3)
2
) 10.0 (145)
2
) 1.3 (18.9) 1.3 (18.9)**
Electrical Supply 230 V ~ 50 Hz.
Power Consumption W 152 177
Fuse Rating External : 3A Internal : T4H HRC L250 V
Water content CH litre (gal) 1.2 (0.26)
DHW litre (gal) 0.5 (0.11)
Packaged Weight kg (lb) 37.8 (83.3) 38 (83.8)
Maximum Installation Weight kg (lb) 32.8 (72.3) 33 (72.8)
Boiler Casing Size Height mm (in) 700 (27.5)
Width mm (in) 395 (15.5)
Depth mm (in) 278 (11)
*Required for maximum ow rate. Boiler operates down to 2 l/min DHW delivery ** In areas of low water pressure the DHW restrictor can be removed
C - 13g/s 73ºC - 15g/s
Table 2 - Performance Data - Central Heating
Boiler Input : Max. Min. 30 Min. 35
Boiler Input ‘Q’ Nett CV kW 24.3 6.1 7.1
(Btu/h) (82,900) (20,700) (24,100)
Gross CV kW 27.0 6.7 7.9
(Btu/h) (92,000) (23,000) (26,900)
Gas Consumption m
Boiler Output :
Non Condensing kW 24.2 6.1 7.1
o
70
C Mean Water temp. (Btu/h) (82,600) (20,700) (24,100)
Condensing kW 25.6 6.4 7.5
o
40
C Mean Water temp. (Btu/h) (87,400) (21,800) (25,500)
Seasonal efciency* SEDBUK 2005
NOx Classication CLASS 5
3
/h 2.512 0.623 0.734
3
(ft
/h) (89) (22) (25.9)
91.1%
SEDBUK 2009
89%
88.9%
91%
Table 3 - Performance Data - Domestic Hot Water
Maximum DHW Input : 30 35
Nett CV kW 30.4 35.4
(Btu/h) (103,600) (120,900)
Gross CV kW 33.7 39.3
(Btu/h) (115,000) (134,200)
Gas Consumption m
Maximum kW 30.3 35.3
DHW Output (Btu/h) (103,300) (120,500)
DHW Flow Rate l/min 12.4 14.5
at 35°C temp. rise. (gpm) (2.8) (3.2)
DHW Specic Rate l/min 14.5 16.9
3
/h 3.135 3.658
3
(ft
/h) (111) (129)
(gpm) (3.2) (3.7)
* 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 certied by a notied body.
Note. Gas consumption is calculated using a caloric value of 38.7 MJ/m
3
(1038 Btu/ft3) gross
or 34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different caloric value:
a. For l/s - divide the gross heat input
(kW) by the gross C.V. of the gas (MJ/m
3
b. For ft
/h - divide the gross heat input (Btu/h)
3
)
Key to symbols
PMS = Maximum operating pressure of water
C
= A room sealed appliance designed for connection via ducts to
13 C53
a horizontal terminal, which admits fresh air to the burner and discharges the products of combustion to the outside. The fan is up stream of the combustion chamber.
I
= An appliance designed for use on 2nd Family gas, Group H only.
2H
by the gross C.V. of the gas (Btu/ft3)
3
c. For m
/h - multiply l/s by 3.6.
4
Keston Combi -
Installation and Servicing
general
KESTON Combi 30 & 35
Natural Gas only
Boiler size G.C. Appliance No. PI No.
(Benchmark No.)
30 47-930-04 86 CL 38
35 47-930-05 86 CL 38
CONTENTS
Benchmark Commissioning Checklist ..................... 66
Boiler Clearances ......................................................... 9
Boiler Exploded Diagram ........................................... 12
Condensate Drain .......................................... 8,22,23,39
Electrical Connections ............................................... 25
Electrical Supply ........................................................... 8
Fault Finding .......................................................... 57-63
Flue System ........................................................... 14-17
Gas Safety Regulations ............................................... 7
Gas Supply .................................................................... 8
Installation .............................................................. 12-36
Pump ........................................................................... 50
Safe Handling ................................................................ 6
Servicing ................................................................ 37-56
Short List of Parts ...................................................... 64
Thermostatic Radiator Valves ..................................... 8
Water and Systems .......................................... 8, 10-11
Water Connections ..................................................... 24
Water Treatment .........................................................11
Wiring Diagram ........................................................... 30
For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be tted in accordance with the manufacturer’s instructions. Self-certication 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 ................. 26
Time and temperature control to hot water ............. 26
Heating zone valves ................................................ n/a
TRV’s.......................................................................... 8
Auto bypass ............................................................... 8
Boiler interlock ............................................................ 8
For .................................................................... all boilers
Flushing to BS.7593 ................................................. 11
Inhibitor .................................................................... 11
Central heating mode
Heat input ...................................................to be calculated
Page
Burner operating pressure ...................................... n/a
Central heating ow temp. ........... measure and record
Central heating return temp. ........ measure and record
For combination boilers only
Scale reducer ........................................................... 11
Hot water mode
Heat input ............................................ to be calculated
Max. operating burner pressure .............................. n/a
Max. operating water pressure ........ measure & record
Cold water inlet temp ...................... measure & record
Hot water outlet temp. ..................... measure & record
Water ow rate at max. setting ........ measure & record
For condensing boilers only
Condensate drain ..................................................... 22
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
NOTE TO THE INSTALLER:
COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
5Keston Combi - Installation and Servicing
general
INTRODUCTION
The Keston Combi boiler is a wall mounted, full sequence,
automatic spark ignition, low water content, fanned ue, high efciency, condensing, combination gas boiler.
Note. Due to the high efciency of the boiler a plume of water vapour will form at the terminal during operation.
Central heating (CH) output is fully modulating with a range of:
30 6.1 to 24.2kW (20,700 to 82,600 Btu/h)
35 7.1 to 24.2kW (24,100 to 82,600 Btu/h)
Instantaneous domestic hot water (DHW) output is also fully modulating with a maximum of :
30 30.3kW (103,300 Btu/h)
35 35.3kW (120,500 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 tted 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.
- Weather Compensation Kit
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.
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
Electronic Timer (7 day) kit
Electronic Programmable Room Thermostat kit
Stand Off kit
• AirTerminalFinishingKit
• FlueSleeveKit
OPERATION
With no demand for CH, the boiler res only when DHW is drawn
off, or periodically for a few seconds without any DHW draw-off, in
order to maintain the DHW calorier 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 45 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:
o
30 12.4 l/min at 35
35 14.5 l/min at 35
When using the outside sensor provided please refer to page 27.
The DHW draw off rate specied above is the nominal that the boiler ow regulator will give. Due to system variations and seasonal temperature uctuations DHW ow rates/temperature
rise will vary, requiring adjustment at the draw off tap.
At low DHW draw-off rate the maximum temperature is limited to
o
C by the modulating gas control.
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 nding.
C temperature rise.
o
C temperature rise.
o
C and 83oC, until DHW
6
Keston Combi -
Installation and Servicing
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 specic 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 red 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 certicated for safety
and performance. It is, therefore, important that no external
control devices, e.g. ue 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 certication 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.
LOCATION OF BOILER
The boiler must be installed on a at and vertical internal wall,
capable of adequately supporting the weight of the boiler and any ancillary equipment.
The boiler may be tted 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 tted outside.
Timber Framed Buildings
If the boiler is to be tted in a timber framed building it should be tted in accordance with the Institute of Gas Engineering document
IGE/UP/7:2006 Edition 2.
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 modied 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, sufcient space may be required to
allow lifting access to the wall mounting plate.
• The boiler must be installed on a re resistant surface.
7Keston Combi - Installation and Servicing
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 installation pipework in accordance with BS6891:2005. Whilst the principle of the 1:1 gas valve ensures the Keston Combi range 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 external gas cock could further reduce the operating pressure when measured at its test point. The pressure drop is relative to the heat input to the boiler (kW), refer to graph below.
WATER CIRCULATION SYSTEM
IMPORTANT.
A minimum length of 1 metre of copper pipe MUST be tted to both ow 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 tted with a
room thermostat controlling the temperature in a space served by
radiators not tted with such a valve.
When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the minimum boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves. However, if the system employs thermostatic radiator valves on all
radiators, or two port valves, then a bypass circuit must be tted with an automatic bypass valve to ensure a ow 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.
IMPORTANT.
Installation pipes must be tted 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.
8
CONDENSATE DRAIN
Refer to Frames 20 & 21
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and ttings in
the condensate drainage system MUST be made of plastic - no
other materials may be used.
IMPORTANT.
Any external runs must be in accordance with BS 6798.
The drain outlet on the boiler is sized for standard 21.5mm (3/4”)
overow pipe. It is a universal tting to allow use of different
brands of pipework.
Keston Combi -
Installation and Servicing
general
395
198
89
155
62
30mm
Minimum Top Clearance
100395
400
700
FlueAir
2.5
2.5 from case
*
43 65 57 38
Gas Inlet
39 65
1
BOILER DIMENSIONS, SERVICES & CLEARANCES
The boiler connections are made on the boiler connection tails. Refer to Frame 22.
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.
9Keston Combi - Installation and Servicing
2
SYSTEM REQUIREMENTS - Central Heating
general
Notes
a. The method of lling, relling, topping up or ushing sealed
primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority.
b. Antifreeze uid, corrosion and scale inhibitor uids 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 lled ‘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, tted at least
150mm below the ‘make-up’ vessel on the return side of the radiators. or
b. Where access to a ‘make-up’ vessel would be difcult, 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 efciency 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 sufcient for this,
or for any other reason, an additional vessel MUST be installed on the RETURN to the boiler.
Guidance on vessel sizing is given in Table above.
o
C.
o
C. Extra care should
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
(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 access 0.063 0.074
Water Flow Rate and Pressure Loss
Max CH Output kW 24.2
(Btu/h) (82,600)
Water ow 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 lled by the following method:
Where the mains pressure is excessive a pressure
reducing valve must be used to facilitate lling.
a. Thoroughly ush 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
22 for lling 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.
Expansion vessel
volume (litres)
o
C 20
o
F) (36)
(
10
Keston Combi -
continued . . . . . .
Installation and Servicing
3
SYSTEM REQUIREMENTS cont’d
general
4
SYSTEM BALANCING
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
ow turbine cartridge. Refer to Frame 70. The boiler will require the ow rate to be set to obtain a temperature rise of
o
C at the tap furthest from the boiler.
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 tted with an approved anti-
vacuum or syphon non-return valve.
b.
5. Hard Water Areas
IMPORTANT
Provision MUST be made to accommodate the expansion of DHW
contained within the appliance, if a non-return valve is tted to the
DHW inlet, or a water meter with a non-return valve is installed.
Cold water rising main and pipework in exposed areas need to be suitably lagged to prevent freezing.
Hot and cold water supplies to the shower are of equal pressure.
Where the water hardness exceeds 200mg/litre, it is recommended that a proprietary scale reducing device is
tted into the boiler cold supply within the requirements of the
local water company.
The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 8.
Note. Systems incorporating zone valves which could completely cut off the ow through the system must also include a bypass.
BALANCING
1. Set the programmer to ON.
Close the manual or thermostatic valves on all
radiators, leaving the twin lockshield valves (on the radiators referred to above) in the OPEN position.
Turn up the room thermostat and adjust the
lockshield valve to give an uninterrupted ow through
the radiator.
These valves should now be left as set.
2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20 each radiator.
3. Adjust the room thermostat and programmer to NORMAL settings.
o
C temperature drop at
5
WATER TREATMENT
CENTRAL HEATING
The Keston Combi range 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 SCALEMASTER GOLD 100, FERNOX, MBI, ADEY MC1 or
SENTINEL X100
products, which must be used in accordance with the manufacturers’ instructions.
Notes.
1. It is most important that the correct concentration of the
water treatment products is maintained in accordance with the manufacturers’ instructions.
2. If the boiler is installed in an existing system any
unsuitable additives MUST be removed by thorough cleansing. BS 7593:2006 details the steps necessary to clean a domestic heating system.
3. In hard water areas, treatment to prevent lime scale may
be necessary - however the use of articially softened water is NOT permitted.
4. Under no circumstances should the boiler be red
before the system has been thoroughly ushed.
inhibitors and associated water treatment
DOMESTIC HOT WATER
In hard water areas where mains water can exceed 200ppm
Total Hardness (as dened by BS 7593:2006 Table 2) a scale reducing device should be tted into the boiler cold supply within the requirements of the local water company. The use of articially
softened water, however, is not permitted. Keston recommend the use of Fernox Quantomat, Sentinel Combiguard or Calmag CalPhos I scale reducing devices together with scalemaster in-line scale inhibitor branded Ideal, which must be used in accordance with the manufacturers’ instructions.
For further information contact:
Fernox Cookson Electronics
Forsyth Road, Sheerwater, Woking, Surrey GU21 5RZ +44 (0) 870 601 500
Sentinel Performance Solutions
The Heath Business & Technical Park, Runcorn, Cheshire WA7 4QX Tel: 0800 389 4670 www.sentinel-solutions.net
Scalemaster Water Treatment Products
Emerald Way, Stone, Staffordshire ST15 0SR Tel: +44 (0) 1785 811636
Calmag Ltd.
Unit 3-6, Crown Works, Bradford Road, Sandbeds, Keighley, West Yorkshire BD20 5LN Tel: +44 (0) 1535 210 320
Adey Professional Heating Solutions
Gloucester Road, Cheltenham GL51 8NR Tel: +44 (0) 1242 546700
11Keston Combi - Installation and Servicing
6
BOILER ASSEMBLY - Exploded View
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 Diverter 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 136 Safety Valve Drain Pipe 203 Gas Cock 204 Pipe - Gas Inlet 205 Gas Valve 206 Pipe - Gas Injector 211 Injector Assembly 214 Venturi 215 Fan 217 Burner
INSTALLATION
505
INSTALLATION
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 231 Condensate Outlet Connection 301
Ctrs Box Fixings Hinge & Spring
302 Primary PCB* 303 CUI Board 304 Control Thermistor (Return) 306 Electrode Ignition 307 Electrode Detection 308 Igniter Unit
504
227
224
309 Thermistor No Flow 313 Ignition Lead 314 Control Box Lens 324 Controls Box Lid 325 Control Box Front 326 Programmer Insert 332 Flue Thermostat 401 Heat Engine 503 Wall Mounting Bracket 504 Front Panel 505 Fascia 506 Bracket - Gas Valve 507
Bracket - Exp. Vessel
136 Safety Valve Drain Pipe 512 Drop Down Door 332 Flue Thermostat
* Note that production boiler PCBs are factory pre-set to operate for boiler range and output. When ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specic boiler range and output.
Check boiler serial letter code on data plate to obtain correct BCC.
503
313
215
214
206
205
211
512
204
308
309
217
306
506
115
219
303
304
307
116
229
218
401
301
228
231
112
507
120
108
127
111
128
131
119
121
118
110
136
113
114
117
12
223
314
326
332
325
324
302
105
135
106
107
*
203
106
104
Keston Combi - Installation and Servicing
7
C
A
D F
G
B
E
H
Boiler Guarantee
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)
3. Turret Clamp Screw (x1)
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
3
1
1
1
1
1
5
2
3
3
3
1
2
3
4
6
5
4
2
2
2
2
3
3
UNPACKING
Unpack and check the contents.
Pack 1 Contents
A Boiler
B Hardware Pack Box
C Wall Mounting Plate
D These Installation Instructions E Wall Mounting Template (located on internal protective packaging)
F Turret Clamp
G Safety Valve Drain Pipe
H Boiler Guarantee / Registration pack
INSTALLATION
INSTALLATION
Flue Pack Contents
A Flue Adaptor B Air Spigot C Terminals - 2 off D Flue Sleeve E Wall Plate F Wall Seal G Outside Sensor H Screws - 4 off J Wall Plugs - 4 off
Keston Combi - Installation and Servicing
A
A
G
G
B
B
C
C
J
H
H
J
D
D
E
E
F
F
continued . . . . .
13
INSTALLATION
8
FLUE SYSTEM
IMPORTANT
When installing a replacement boiler a new ue system must be used. DO NOT re-use the existing boiler ue installation.
DESIGN
Individual air supply and ue outlet pipes are used as standard.
The material approved for this application is which MUST be used is:
Marley muPVC Solvent Weld System (50mm) and Polypipe System 2000 muPVC solvent weld (50mm), to BS5255 and/or BSEN1566-11 and BSEN1329, are the only systems approved for this application.
Thefollowingpipeandttingsareapproved.
Polypipe System 2000 muPVC solvent Weld 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 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
Consideration MUST be given to expansion and contraction of the ue. Refer to Assembly Practice Frame in this installation and
Servicing Instructions for further guidance.
FLUE OUTLET
14
continued............
Keston Combi - Installation and Servicing
INSTALLATION
TERMINAL POSITIONS
Flue Pipe
Elbow
Minimum Separation
140mm
Acceptable range of air
pipe siting
Terminal
Air Pipe
150mm
9
FLUE SYSTEM.... CONT’D
TERMINATION OF THE FLUE AND AIR
The ue and air pipes may terminate independently through any
external walls within the same dwelling except on opposing walls, within the maximum lengths shown in graph below.
The air pipe must have an elbow and 150mm length of pipe
directed downwards with a termination grill tted.
The air pipe can be situated at the side or beneath the ue pipe to
a minimum dimension of 140mm (see diagram below). It must not
be sited above the ue pipe.
The ue and air pipes must extend by at least 40mm from the wall
surface.
Condensing boiler emit a visible plume of water vapour from the
ue terminal, this is normal. It is the responsibility of the installer
to judiciously select a terminal location that does not cause a nuisance.
If either the ue or air terminal is below a height of 2m from ground level a terminal guard must be tted.
MAXIMUM LENGTHS
Due to the resistance presented by extended ue length a slight reduction in maximum boiler output will occur where combined ue and air lengths in excess of 18.0m and 16.0m (50mm muPVC) are used. In such cases the boiler output will be
reduced by 0.6% and 0.8% per additional metre.
The maximum lengths of both air inlet pipe and ue outlet pipe, when no bends are used, are as detailed in graphs below.
However, each bend used has an equivalent length that must be deducted from the maximum straight length stated in graphs
below. Knuckle bends must not be tted.
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 ue and air lengths as described within the shaded area of graphs below.
SLOPE
‘Horizontal’ ue outlet pipework MUST slope at least 1.5 degrees (26mm per metre run) downwards towards the boiler. Pipework
can be vertical. Only swept elbows can be used.
Air inlet pipework can be truly horizontal or vertical, or sloping in a downward direction towards the boiler but in each case rain, etc.,
must be prevented from entering the pipe. Theremustbenotroughsinanyofthepipework,whetheritbeairinletorue outlet.
Keston Combi - Installation and Servicing
FLUE OUTLET
15
INSTALLATION
6m
2m
Bracket at each 1 metre
1m
4m
1.5m
6m
1.5º back to boiler
1.5º back to boiler
Air
Elbows 2 x 1m = 2m Straights 6+2+0.15 = 8.15m Total = 10.15m
Overall Flue / Air = 25.65m
Flue
Elbows 3 x 1m = 3m Straights 4+6+1.5+1 = 12.5m Total = 15.5m
Calculations
0.15m
Sleeve
2m
2.5m
1.5m
2m
4m
4m
0.15m
3.5m
3.5m
1.5º back to boiler
Air
Sleeve
1.5º back to boiler
Bracket every 1 metre
Flue
3 x 90º elbows 3 Straight lengths 2.5
1.5
3.5 4
14.5
Overall Flue / Air = 30.15m
Air
4 x 90º elbows 4 Straight lengths 2 2
3.5 4
0.15
15.65
Calculations
2
4
6
8
10
12
14
16
18
20
22
24
26
28
2
6
10
14
18
22
26
30
Accep table Op erating Area
Keston Combi 35 - Flue & Air Pipe Length
Flue Pip e Length [m]
Air Pipe Length [m]
15.65
14.5
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
2
6
10
14
18
22
26
30
34
38
Accep table Op erating Area
Keston Combi 30 - Flue & Air Pipe Length
Flue Pip e Length [m]
Air Pipe Length [m]
10.15
15.5
10
FLUE INSTALLATION EXAMPLE KESTON COMBI 30
11
FLUE INSTALLATION EXAMPLE KESTON COMBI 35
FLUE OUTLET
16
Keston Combi - Installation and Servicing
12
a built in element, such as a window frame.
The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions.
FLUE TERMINATION POSITION
INSTALLATION
Twin Flue Positions
A.
Below an opening (1)
B.
Above an opening (1)
C.
Horizontally to an opening (1)
D.
Below gutters, soil pipes or drain pipes
E.
Below eves
F.
Below balcony or car port roof
G.
From a vertical drain pipe or soil pipe
H.
From an internal or external corner or to a boundary alongside the terminal
I.
Above ground, roof or balcony level
J.
From a surface or a boundary facing the terminal
K.
From a terminal facing the terminal
L.
From an opening in the car port into the building
M.
Vertically from a terminal on the same wall
N.
Horizontally from a terminal on the same wall
(1) An opening here means an openable element, such as a openable window, or a fixed opening such as an air vent. However, in addition, the outlet should not be nearer than 150mm (fanned draught) to an opening into the building fabric formed for the purpose of accommodating
boundary
I
Flue Minimum Spacing Air Minimum Spacing
300 mm 300 mm 300 mm
75 mm 200 mm 200 mm 150 mm 300 mm 300 mm 600 mm
1200 mm 1200 mm 1500 mm
300 mm
D, E
12" 12" 12"
3" 8" 8"
6" 12" 12" 24" 48" 48" 60" 12"
50 mm 50 mm 50 mm 75 mm 50 mm 50 mm 50 mm
50 mm 100 mm 100 mm
1200 mm
100 mm
1500 mm
300 mm
2" 2" 2" 3" 2" 2" 2" 2" 4" 4"
48"
4" 60" 12"
B
J
boundary
H
F
L
G
C
A
H
H
I
N
M
K
GENERAL INSTALLATIONS
All parts of the system must be constructed in accordance with BS 5440 Part 1, except where specically mentioned in these
instructions.
All pipe work must be adequately supported.
All joints other than approved push-on or plastic compression connectors must be made and sealed with solvent cement suitable for muPVC pipes and conforming to BS 6209: 1982.
Consideration must be given to Corgi/Gas Safe bulletin TB200/TB008 regarding ues in voids.
The boiler casing must always be correctly tted to the boiler when leaving the appliance operational.
External wall faces and any internal faces of cavity walls must be good.
AIR SUPPLY
The Keston Combi is a room-sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air.
COMPARTMENT INSTALLATION
Due to the low casing temperatures generated by the boiler, no compartment ventilation is required. However, the cupboard or compartment must not be used for storage.
Keston Combi - Installation and Servicing
FLUE OUTLET
17
INSTALLATION
3G10030
X
Section through wall
Note. Check all of the hole positions before drilling.
Rear flue only 60mm diameter holes
13 INSTALLING THE BOILER
Installation of the boiler is straightforward but consideration must be given to access to allow ue 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 ue outlet and air inlet pipes to the terminal
- this is the sequence described.
14
INSTALLATION
WALL MOUNTING TEMPLATE
The wall mounting template is located on the internal protective packaging.
Note.
The template shows the positions of the xing holes and the position of the air and ue connections. 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 ue when exiting straight out of
the wall where the boiler is mounted.
Note. Mark the centre of the hole as well as the circumference.
3. Remove the template from the wall.
15
18
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 ue 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 Combi - Installation and Servicing
esp9496
Example of fixing
16
FITTING THE WALL MOUNTING PLATE
INSTALLATION
17
MOUNTING THE BOILER
Screw the wall mounting plate to the wall using 2 wall plugs
(previously tted) 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 tted into a top slot.
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.
INSTALLATION
Keston Combi - Installation and Servicing
19
INSTALLATION
18 ASSEMBLY PRACTICE
Remove all plastic debris and burrs when installing air intake
piping. Plastic llings 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 lings or other
debris will not be covered by guarantee.
INSTALLING FLUE AND AIR PIPES
Important - When installing the boiler on an existing system a
new ue and air intake system MUST also be installed. You MUST NOT re-use existing ue or air pipework components.
• Remove the ue adaptor and air spigot from the ue pack
supplied with the boiler.
• Remove boiler front panel - Frame 39.
• Remove air intake blanking plate by unscrewing 4 x M5
screws and put to one side, leaving sponge gasket in place.
• Fix air spigot to boiler using the 4 M5 screws, see diag.
below. Ensure sponge gasket is in place and not damaged.
• Insert the ue adaptor into the ue manifold on the top of the
boiler and secure using the clamp provided in the packaging box, see diagram below.
• Measure, cut and check the air and ue pipes to pass to the
exit from the wall(s) or ceiling.
• Always thoroughly deburr all pipes and most important,
remove shavings from within the pipe.
• Assemble, using solvent weld cement, the pipework from
the boiler connections to the exit from the rst wall/ceiling,
(remount the boiler if removed). When pushing pipe through walls, ensure grit and dust is not allowed to enter the pipe.
Ensure pipes are fully engaged into sockets and solvent
welded with no leaks.
• Using the same methods drill any further holes (always
covering existing pipework), cut and assemble the pipework.
• From outside, complete the two terminations - See Frame
8 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 ue outlet pipe joints.
FLUE OUTLET
20
Keston Combi - Installation and Servicing
INSTALLATION
19
FITTING THE FLUE SLEEVE
1. Cut hole in wall.
2. Measure wall Thickness
3. Cut sleeve length to match wall thickness & remove burrs.
4. Grout sleeve into wall with ange on external face.
5. Slide ue pipe into sleeve, checking it is free to slide.
6. Slide Flexible wall seal over ue pipe and push centre ring up to sleeve ange when cold.
7. Locate wall plate over exible wall seal and clamp in place using the raw plug pack.
8. Afx ue terminal
9. During boiler test check that the ue end is free to expand and contract with exible wall seal.
Flue
Terminal
Flue Pipe
Flue Sleeve
Flue Sleeve Flange
Flexible
Wall
Seal
Wall
Plate
Keston Combi - Installation and Servicing
FLUE OUTLET
21
INSTALLATION
203
47
149
Condensate
Drain
Sink/basin/
bath or shower
Boiler
with 75mm
sealed
condensate
trap
Min Ø 19mm Internal pipe
Internal soil & vent stack
Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break
75
≥ 100
≥ 100
20
CONDENSATE DRAIN
This appliance is tted with a siphonic 75mm condensate trap
system that requires lling before operating the appliance for the rst time or after maintenance.
INSTALLATION
All condensate pipework should conform to the following: a. Where a new or replacement boiler is being installed, access to
an internal ‘gravity discharge’ termination should be one of the main factors considered in determining boiler location.
b. Plastic with push t or solvent connections.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD)
d. External plastic pipe must be a minimum of 30mm ID (typically
32 OD) before it passes through the sleeved wall.
e. All horizontal pipe runs, must fall a minimum of 45mm per metre
away from the Boiler.
f. External & unheated pipe work should be kept to a minimum
and insulated with Class “O” waterproof pipe insulation.
g. All installations must be carried out in accordance to the
relevant connection methods as shown in the “Condensate installation diagrams” & BS6798:2009
h. Pipe work must be installed so that it does not allow spillage
into the dwelling in the event of a blockage (through freezing)
i. All internal burrs should be removed from the pipe work and any
ttings.
In order to minimise the risk of freezing during prolonged very cold spells, one of the following methods of terminating condensate
drainage pipe should be adopted.
Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc. See Figs 1 and 2.
Condensate Pump
Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a
specication recommended by the boiler or pump manufacturer
should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal
kitchen or bathroom waste pipe etc. (g 3).
External Drain Connections
The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously. An external system must terminate at a suitable foul water discharge point or purpose designed soak away. If an external system is chosen then the following measures must be adopted:
The external pipe run should be kept to a minimum using the most direct and “most vertical” route possible to the discharge point, with no horizontal sections in which condensate might collect.
- For connections to an external soil/vent stack see Fig 4. Insulation measures as described should be used.
- When a rainwater downpipe is used, an air break must be installed between the condensate drainage pipe and the
downpipe to avoid reverse ow of rainwater into the boiler should the downpipe become ooded or frozen, see Fig 5.
- Where the condensate drain pipe terminates over an open foul drain or gully, the pipe should terminate below the grating level, but above water level, to minimise “wind chill” at the open end. The use of a drain cover (as used to prevent blockage by leaves) may offer further prevention from wind chill. See Fig 6.
- Where the condensate drain pipe terminates in a purpose designed soak away (see BS 6798) any above ground condensate drain pipe sections should be run and insulated as described above. See Fig 7
Unheated Internal Areas
Internal condensate drain pipes run in unheated areas, e.g. lofts basements and garages, should be treated as external pipe.
Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual.
22
Figure 1 - Connection of Condensate Drainage Pipe to Internal Soil & Vent Stack
Boiler
with 75mm
sealed
condensate
trap
Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break
75
Min Ø 19mm Internal pipe
Soil & vent stack
Minimum connection height up to 3
≥ 450
storeys
Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil Vent Stack
continued . . . . .
Keston Combi - Installation and Servicing
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