Keston Combi C30, Combi C35 Installation And Servicing Instructions

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Page 1

July 2016

UIN 215348 A01

Combi C30 & C35

When replacing any part on this appliance, use only spare parts that you can be

assured conform to the safety and performance specication that we require.

Do not use reconditioned or copy parts that have not been clearly authorised by Keston.

For the very latest copy of literature for specication and maintenance practices visit our website

www.keston.co.uk where you can download the relevant information in PDF format.

FAN POWERED HIGH EFFICIENCY

MODULATING DOMESTIC CONDENSING

GAS COMBINATION BOILER

Installation and Servicing Instructions

Page 2

Installation and Servicing

MODEL

SYMBOL UNITS 30 35

Condensing Boiler n/a n/a yes yes

Low Temperature Boiler n/a n/a no no

B1 Boiler n/a n/a no no

Cogeneration Space Heater n/a n/a no no

Equipped with a Supplementary Heater n/a n/a no no

Combination Heater n/a n/a yes yes

Nominal Heat Output for Space Heating

Full Load P

4 kW 24.2 24.2

Part Load P

1 kW 7.9 7.9

Auxiliary Electricity Consumption

Full Load el

max kW 0.032 0.042

Part Load el

min kW 0.013 0.013

Standby P

SB kW 0.005 0.005

Seasonal Space Heating Energy Efciency

Full Load

% 90 90

Part Load

% 98.6 98.6

Standby Loss P

stby kW 0.05 0.05

Ignition P

ign kW 0 0

Emissions NO

x mg/kWh 27.8 33.1

Annual Energy Consumption Q

HE GJ 74.1 74.1

Sound Power Level, Indoors L

WA dB 46 44

Domestic Hot Water

elec kWh 0.075 0.074

% 78 78.4

fuel kWh 7.7 7.7

AEC kWh 16.3 16

AFC GJ 5.8 5.7

ERP DATA

Page 3

Installation and Servicing

KESTON COMBINATION BOILER

Ideal Boilers

ERP DATA

SYMBOL UNITS MODEL

30 35

Condensing boiler Yes Seasonal Space heating efciency class A Rated heat output kW 24 Seasonal space heating energy efciency

ƞs

% 94

Annual energy consumption Q

HE GJ 74.1

Sound power level, indoors L

WA dB 46 44

Water heating energy efciency class A

Seasonal Space Heating Energy Efciency of the Boiler *%

Temperature control (from che of temperature control) %

Class I Class II Class III Class IV Class V Class VI Class VII Class VIII

1% 2% 1.5% 2% 3% 4% 3.5% 5%

PRODUCT FICHE

 

The energy efciency of the package of products provided for in this document may not correspond to its actual energy efciency once installed in a building, as the efciency is inuenced by further factors such as heat loss in the products in relation to the building size and its characteristics

Collector Size

(in m2)

Tank Volume

(in m3)

Collector

Efciency

(in %)

Tank rating

A* = 0.95

A = 0.91 B = 0.86 C = 0.83

D-G = 0.81

Solar Contribution (from che of solar device)

Seasonal Space Heating Energy Efciency of Package

TOTAL: A+B+C=

Seasonal Space Heating Energy Efciency Class of Package

= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x =

GG F E D C B A A+ A++

A+++

< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%

Page 4

Installation and Servicing

Page 5

Installation and Servicing

Relevant Installation changes implemented in this book from Mod Level ..............................A01 (July 2016)

DOCUMENT AMENDMENTS

Keston reserve the right to vary specication without notice

FOR ANY TECHNICAL QUERIES PLEASE RING THE KESTON

INSTALLER/TECHNICAL HELPLINE : 01482 443005

NOTE. BOILER RESTART PROCEDURE -

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

NOTES FOR THE INSTALLER

Page 6

Installation and Servicing

Page 7

Installation and Servicing

CONTENTS

1 GENERAL .................................................................... 8

1.1 Introduction ................................................................10

1.2 Operation ...................................................................10

1.3 Safe Handling ............................................................. 10

1.4 Optional Extra Kits .....................................................10

1.5 Safety ......................................................................... 11

1.6 Safe Handling Of Substances .................................... 11

1.7 Location Of Boiler ...................................................... 11

1.8 Gas Supply ................................................................. 12

1.9 Water Circulation System ........................................... 12

1.10 Boiler Control Interlocks .............................................12

1.11 Electrical Supply ......................................................... 12

1.12 Condensate Drain .................................................... 12

1.13 Boiler Dimensions, Services & Clearances ................ 13

1.14 System Requirements - Central Heating .................... 14

1.15 System Balancing ......................................................15

1.16 Water Treatment......................................................... 15

2 INSTALLATION .........................................................16

2.1 Boiler Assembly - Exploded View ...............................16

2.2 Unpacking .................................................................. 17

2.3 Flue System ............................................................... 18

2.4 Flue Installation Example Keston Combi C30 ............ 20

2.5 Flue Installation Example Keston Combi C35 ............ 20

2.6 Flue Termination Position ........................................... 21

2.7 Installing The Boiler .................................................... 22

2.8 Wall Mounting Template ............................................. 22

2.9 Preparing The Wall .....................................................22

2.10 Fitting The Wall Mounting Plate ................................. 23

2.11 Mounting The Boiler ................................................... 23

2.12 Assembly Practice ...................................................... 24

2.13 Fitting The Flue Sleeve .............................................. 25

2.14 Condensate ................................................................ 26

2.15 Connections & Filling .................................................28

2.16 Electrical Connections ................................................ 30

2.17 Installer Wiring ...........................................................30

2.18 External Wiring ........................................................... 31

2.19 Replacing Pre-Fitted Mains Cable .............................31

2.20 Ch Operation .............................................................. 32

2.21 The Weather Compensation Kit ................................. 33

2.22 Wiring Diagram ..........................................................34

2.23 Commissioning And Testing ....................................... 35

2.24 Initial Lighting ............................................................. 36

2.25 The Display ................................................................ 37

2.26 General Checks .........................................................41

2.27 Restart Procedure ...................................................... 42

2.28 Handing Over ............................................................. 42

3 SERVICING ............................................................... 43

3.1 Servicing Schedule ...................................................43

3.2 Boiler Front Panel Removal / Replacement ............... 44

3.3 Fan And Venturi Assembly Removal And Cleaning ....44

3.4 Burner Removal And Cleaning ................................... 45

3.5 Cleaning The Condensate Trap/Siphon ..................... 45

3.6 Cleaning The Heat Exchanger ................................... 46

3.7 Reassembly ...............................................................46

3.8 Replacement Of Components .................................... 47

3.9 Fan Replacement ....................................................... 47

3.10 Burner Injector Replacement .....................................48

3.11 Burner Replacement .................................................. 48

3.12 Return Thermistor Replacement ................................ 49

3.13 Ignition Electrode Replacement ................................. 49

3.14 Flame Detection Electrode Replacement ................... 50

3.15 Spark Generator Replacement ..................................50

3.16 Gas Control Valve Replacement ................................ 50

3.17 Diverter Valve Actuator Replacement ........................ 51

3.18 Condensate Trap/Siphon Replacement ..................... 51

3.19 PCB Replacement ...................................................... 52

3.20 Draining The Boiler ....................................................53

3.21 DHW Flow Turbine Sensor Replacement .................. 53

3.22 Pressure Gauge Replacement ................................... 53

3.23 Safety Relief Valve Replacement ............................... 54

3.24 Pump Automatic Air Vent Replacement .....................54

3.25

DHW Filter & Flow Regulator Cleaning/Replacement .....

3.26 Diverter Valve Body Assembly Replacement ............. 55

3.27 DHW Plate Heat Exch. Replacement ......................... 55

3.28 Pump Head Replacement .......................................... 55

3.29 CH Water Pressure Switch Replacement .................. 56

3.30 Flow Thermistor Replacement ................................... 56

3.31 Heat Engine Replacement ......................................... 57

3.32 Expansion Vessel Recharging & Replacement .......... 58

4 FAULT FINDING ........................................................ 59

4.1 Fault Finding Chart Main Menu .................................. 59

4.2 Overheat Lockout ....................................................... 61

4.3 Ignition Lockout .......................................................... 61

4.4 Flame On Before Gas Valve On .................................62

4.5 Low Water Pressure ................................................... 62

4.6 Flame Loss ................................................................. 62

4.7 Fan Fault .................................................................... 63

4.8 Flow Thermistor Fault ................................................63

4.9 Return Thermistor Fault ............................................. 63

4.10 Outside Sensor Fault .................................................64

4.11 No CH Operation But DHW Works OK ...................... 65

4.12 No HW But CH On ..................................................... 66

4.13 No Display .................................................................. 66

5 SPARE PARTS .......................................................... 67

6 BENCHMARK & COMMISSIONING ......................... 68

Page 8

Installation and Servicing

SECTION 1 - GENERAL

Table 1 - General Data

*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

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)

Average Flue Temp-Mass Flow Rate (DHW) 68

C - 13g/s 73ºC - 15g/s

Maximum Working Pressure (Sealed Systems) bar (lb/in

) 2.5 (36.3)

Maximum Domestic Hot Water Inlet Pressure

bar (lb/in2) (kPa)

10.0 (145) (1000)

Minimum Domestic Hot Water Inlet Pressure*

bar (lb/in2) (kPa)

1.3 (18.9) (130) 1.3 (18.9)** (130)

Minimum DHW Inlet Pressure to operate at 0.6

bar system pressure

bar 0.5

Electrical Supply 230 V ~ 50 Hz.

Power Consumption W 101 114

Fuse Rating External : 3A Internal : T4A HRC L250 V

Water content CH litre (gal) 1.2 (0.26)

DHW litre (gal) 0.5 (0.11)

Packaged Weight kg 34.40 34.50

Maximum Installation Weight kg 31.40 31.50

Boiler Casing Size Height mm 700

Width mm 395

Depth mm 278

Note. Gas consumption is calculated using a caloric value of 38.7 MJ/m3 (1038 Btu/ft3) gross or 34.9 MJ/m

(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

)

b. For Btu/h - multiply the gross heat input (kW)

by 26.8

c. For ft

/h - divide the gross heat input (Btu/h)

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

d. For m

/h - multiply l/s by 3.6

Key to symbols

GB = United Kingdom IE = Ireland (Countries of destination)

PMS = Maximum operating pressure of water

C13 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

orices 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.

* 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.

Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water

Boiler Input : Max. Min. 30 Min. 35

Boiler Input ‘Q’ Nett CV kW 24.3 6.1 7.1

Gross CV kW 27.0 6.7 7.9

Gas Consumption m

/h 2.512 0.623 0.734

(ft

/h) (89) (22) (25.9)

Boiler Output :

Non Condensing 70

C Mean Water temp. kW 24.2 6.1 7.1

Condensing 40

C Mean Water temp. kW 25.6 6.4 7.5

Seasonal efciency* SEDBUK 2005

SEDBUK 2009

91.1%

89.6%

91.1%

89.6%

NOx Classication CLASS 5

Maximum DHW Input : 30 35

Nett CV kW 30.4 35.4

Gross CV kW 33.7 39.3

Gas Consumption m

/h 3.135 3.658

(ft

/h) (111 ) (129)

Maximum kW 30.3 35.3

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

(gpm) (3.2) (3.7)

Page 9

Installation and Servicing

SECTION 1 - GENERAL

Boiler Page

Make and model ......................................................... 9

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

SEDBUK No. % .......................................................... 8

Controls

Time and temperature control to heating .................31

Time and temperature control to hot water .............31

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

TRV’s........................................................................ 12

Auto bypass ............................................................. 12

Boiler interlock .......................................................... 12

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

Flushing to BS.7593 ................................................. 14

Inhibitor ....................................................................15

Central heating mode

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

For assistance see Technical Helpline on the back page

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 ........................................................... 15

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

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

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

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

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

(Benchmark No.)

30 47-930-07 86CR18

35 47-930-08 86CR18

Natural Gas only

Destination Country: GB, IE

KESTON COMBI C30 & C35

Page 10

Installation and Servicing

SECTION 1 - GENERAL

1.1 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

35 7.1 to 24.2kW

Instantaneous domestic hot water (DHW) output is also fully modulating with a maximum of :

30 30.3kW

35 35.3kW

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 with a white polymer front panel.

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.

Data Plate

The boiler model and serial number can be located on the bottom of the boiler casing, shown in Frame 1 - Water & Gas Connection Diagram.

1.2 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 30

C and 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:

30 12.4 l/min at 35

C temperature rise.

35 14.5 l/min at 35

C temperature rise.

When using the outside sensor provided please refer to page 33.

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 rates the maximum temperature may exceed 65ºC.

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.

1.3 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.

1.4 OPTIONAL EXTRA KITS

Please visit www.keston.co.uk to access the Flue and Accessories Guide for this boiler.

Page 11

Installation and Servicing

SECTION 1 - GENERAL

1.5 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.

1.6 SAFE HANDLING OF SUBSTANCES

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

1.7 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.

0.6m

Zone 0

Recessed window Zone 2

Ceiling

3G8913a

2.25m

Zone 1

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 Section 1.13. 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.

Page 12

Installation and Servicing

SECTION 1 - GENERAL

1.8 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.

0.5

1.5

2.5

0 10 20 30 40 50

Pressure drop (mbar )

Heat Input to Boiler (kW)

Gas Cock Pressure Drop

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.

1.9 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 Section 1.16

1.10 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.

1.11 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.

1.12 CONDENSATE DRAIN

Refer to Section 2.14

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.

Page 13

Installation and Servicing

SECTION 1 - GENERAL

395

198

155

30mm

Minimum Top Clearance

100

Air Flue

400

700

2.5

2.5 from case

CH FLOW

DATA PLATE

DHW OUTLET

COND. DRAIN

GAS INLET

Centre line

of boiler

DHW INLET

CH RETURN

PRV

43.5 65

28.5 28.5

60.6 75 37.556.4

Underside View - Dimensions to Wall

1.13 BOILER DIMENSIONS, SERVICES & CLEARANCES

The boiler connections are made on the boiler connection tails. Refer to Section 2.15.

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

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

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 provide the

100mm clearance required for servicing.

Page 14

Installation and Servicing

SECTION 1 - GENERAL

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)

Expansion vessel

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

Water ow rate l/min 17.3

(gal/min) (3.8)

Temperature Differential

C 20

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

1.14 SYSTEM REQUIREMENTS - Central Heating

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 84

3. All components of the system must be suitable for a working

pressure of 3 bar and a maximum design temperature of 110

C. Extra care should 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.

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 opposite.

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 Section

2.15 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.

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 Section 3.25. The boiler will require the ow rate to be set to obtain a

temperature rise of 35

C at the tap furthest from the boiler.

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.

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

5. Hard Water Areas

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.

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.

Page 15

Installation and Servicing

SECTION 1 - GENERAL

1.15 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 12.

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

C temperature drop at each radiator.

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

1.16 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, SENTINEL X100 or CALMAG CM100 inhibitors and associated water

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

Notes.

1. It is most important that the correct concentration of the

water treatment products is maintained in accordance with the manufacturers’ instructions.

2. If the boiler is installed in an existing system any unsuitable

additives MUST be removed by thorough cleansing. BS 7593:2006 details the steps necessary to clean a domestic heating system.

3. In hard water areas, treatment to prevent lime scale may be

necessary - however the use of articially softened water is NOT permitted.

4. Under no circumstances should the boiler be red before

the system has been thoroughly ushed.

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

Page 16

Installation and Servicing

SECTION 2 - INSTALLATION

504

227

224

503

505

215

309

306

308

204

211

214

206

205

223

110

114

113

121

118

131

127

124

120

119

117

104

106

203

106

107

105

112

228

229

304

116

115

219

401

218

307

506

217

111

108

326

135

325

302

324

313

507

231

320

INSTALLATION

2.1 BOILER ASSEMBLY - EXPLODED VIEW

104 CH Return Valve 105 CH Flow Valve 106 DHW Inlet & Outlet 107 Filling Loop Pipe 108 Pump Head 110 Auto Air Vent 111 Divertor Valve Motor 112

Divertor Valve Body & Paddle

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 124 Flow Regulator 127 Flow Sensor/Turbine 131 Water Pressure Switch 135 Pressure Gauge 203 Gas Cock 204 Pipe - Gas Inlet 205 Gas Valve 206 Pipe - Gas Injector 211 Injector Assy 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 231

Condensate Outlet Connection

302 PCB 304

Control Thermistor (Return) 306 Electrode Ignition 307 Electrode Detection 308 Ignitor Unit

309 Thermistor Flow 313 Ignition Lead 320 Detection Lead 324 Control Box Lid 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

Page 17

Installation and Servicing

SECTION 2 - INSTALLATION

Boiler Guarantee

HARDWARE PACK CONTENTS

Gas Valve Pack DHW Pack

Accessory Pack

Flow Valve Pack

Return Valve Pack

Filling Loop

Gas Valve Pack

1. Pipe - Gas Inlet

2. Washer - Gas (blue)

3. Gas Cock

Filling Loop Pack

1. 3/8" Top Hat Washer

2. Valve Filling Loop

3. Pipe Filling Loop

4. Washer

Return Valve Pack

1. Pipe CH Return

2. Washer

3. Valve Return

DHW Pack

1. 1/2" Top Hat Washer (x2)

2. Cap Female

3. Plug Male and Clip

4. Nut G1/2 16 Brass (Flat)

5. Washer 18.5 x 11 x 11.8 (x2)

6. Pipe DHW Outlet

7. Pipe DHW Inlet

8. Valve DHW Inlet

Accessory Pack

1. Screw (x2)

2. Wallplug (x2)

3. Turret Clamp Screw (spare)

Flow Valve Pack

1. Pipe CH Flow

2. Washer CH

3. Valve Flow

1 2

2.2 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 Safety Valve Drain Pipe

G Boiler Guarantee / Registration pack

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

INSTALLATION

Page 18

FLUE OUTLET

Installation and Servicing

SECTION 2 - INSTALLATION

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

2.3 FLUE SYSTEM

IMPORTANT

When installing a replacement boiler a new ue system is recommended. However re-using the existing boiler ue installation is acceptable if the installer checks and conrms:

• The ue pipe is the approved Marley/Polypipe/Terrain 50mm muPVC solvent weld ue system

• The ue installation is upgraded to the most recent ue standards taking particular care to comply with ues in voids

• A risk assessment is conducted to conrm the effectiveness of the ue

• The existing ue will last the lifetime of the new appliance

DESIGN

Individual air supply and ue outlet pipes are used as standard.

The material approved for this application which MUST be used are:

- Marley muPVC Solvent Weld System (50mm)

- Polypipe System 2000 muPVC solvent weld (50mm)

- Polypipe Terrain 200 muPVC Solvent Weld System (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)

Polypipe 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 straight coupling

MU 316 50mm x 92.5 deg muPVC swept tee

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

Polypipe Terraine Solvent Weld System (50mm)

Polypipe Code

200.2.40 4m length muPVC wastepipe

201.2.135 50mm x 135 deg muPVC bend

200.2.91 50mm x 91

/4 deg muPVC swept bend

210.2 50mm muPVC straight coupling

204.2.135 50mm muPVC swept tee

Consideration MUST be given to expansion and contraction of the ue. Refer to Assembly Practice (Section 2.12) in this installation and Servicing Instructions for further guidance.

Page 19

FLUE OUTLET

Installation and Servicing

SECTION 2 - INSTALLATION

TERMINAL POSITIONS

Flue

Pipe

Elbow

Minimum Separation

140mm

Acceptable range of air

pipe siting

Terminal

Air Pipe

150mm

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. (Alternatively a vertical ue pipe termination is acceptable.)

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.

Note. Any veritcal termination MUST have the terminals tted and the air intake comply with the dimensions above.

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 C35 - Flue & Air Pipe Length Keston Combi C30 - Flue & Air Pipe Length

Page 20

FLUE OUTLET

Installation and Servicing

SECTION 2 - INSTALLATION

Bracket at each 1 metre

1.5m

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

2.5m

1.5m

0.15m

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

Accep t able 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

Accep t able Op erating Area

Keston Combi 30 - Flue & Air Pipe Length

Flue Pip e Length [m]

Air Pipe Length [m]

10.15

15.5

2.4 FLUE INSTALLATION EXAMPLE KESTON COMBI C30

2.5 FLUE INSTALLATION EXAMPLE KESTON COMBI C35

Page 21

FLUE OUTLET

Installation and Servicing

SECTION 2 - INSTALLATION

Twin Flue Positions

Below an opening (1) Above an opening (1) Horizontally to an opening (1) Below gutters, soil pipes or drain pipes Below eves Below balcony or car port roof From a vertical drain pipe or soil pipe From an internal or external corner or to a boundary alongside the terminal Above ground, roof or balcony level From a surface or a boundary facing the terminal From a terminal facing the terminal From an opening in the car port into the building Vertically from a terminal on the same wall Horizontally from a terminal on the same wall

300 mm 300 mm 300 mm

75 mm 200 mm 200 mm 150 mm 300 mm 300 mm 600 mm

1200 mm 1200 mm 1500 mm

300 mm

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"

12" 12" 12"

3" 8" 8"

6" 12" 12" 24" 48" 48" 60" 12"

A. B. C. D. E. F. G. H. I. J. K. L. M. N.

Flue Minimum Spacing Air Minimum Spacing

(1) An opening here means an openable element, such as a openable window, or a fixed opening such as an air vent. However, in addition, the outlet should not be nearer than 150mm (fanned draught) to an opening into the building fabric formed for the purpose of accommodating

a built in element, such as a window frame.

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

boundary

D, E

2.6 FLUE TERMINATION POSITION

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.

Note. When running ue pipes vertically they MUST be a minimum of 140mm apart and termination MUST comply with Section 2.3 and 2.6.

Page 22

Installation and Servicing

SECTION 2 - INSTALLATION

3G10030

Section through wall

Note. Check all of the hole positions before drilling.

Rear flue only 60mm diameter holes

2.7 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.

2.8 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.

2.9 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.

INSTALLATION

Page 23

Installation and Servicing

SECTION 2 - INSTALLATION

esp9496

Example of fixing

INSTALLATION

2.10 FITTING THE WALL MOUNTING PLATE

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.

2.11 MOUNTING THE BOILER

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.

Page 24

FLUE OUTLET

Installation and Servicing

SECTION 2 - INSTALLATION

2.12 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 a replacement boiler a new ue system is recommended. However re-using the existing boiler ue installation is acceptable if the installer checks and conrms:

• Remove the ue adaptor and air spigot from the ue pack

supplied with the boiler.

• Remove boiler front panel - Section 3.2.

• 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.

• Ensure the condense trap/siphon is lled with water.

• 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 Section

2.3 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.

Page 25

FLUE OUTLET

Installation and Servicing

SECTION 2 - INSTALLATION

Flue Sleeve

Flue Pipe

Flue

Terminal

Flexible

Wall

Seal

Wall

Plate

Flue Sleeve Flange

2.13 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.

Page 26

Installation and Servicing

SECTION 2 - INSTALLATION

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Minimum connection height up to 3 storeys

Soil & vent stack

≥ 450

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

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

≥ 100

Figure 1 - Connection of Condensate Drainage Pipe to Internal Soil & Vent Stack

Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil Vent Stack

continued . . . . .

INSTALLATION

2.14 CONDENSATE

137

149

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.

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.

Page 27

Installation and Servicing

SECTION 2 - INSTALLATION

Visible air break

Condensate pump (Install in accordance with manufacturers instructions)

Min Ø 19mm Internal pipe

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Min Ø 30mm Internal pipe

Air gap

External air break

combined foul/ rain water drain

Terminated and cut at 45º

43mm 90º male/ female bend

Water/ weather proof insulation

68mm Ø PVCU Strap on fitting

Boiler

with 75mm

sealed

condensate

trap

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Min Ø 30mm Internal pipe

Water/Weather proof insulation

Max 3m external pipework

Limestone chippings

≥ 500

≥ 300

≥ 25

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

2 rows of three Ø12mm holes 25mm centres, 50mm from the bottom of the tube, facing

away from the house

Minimum connection height up to 3 storeys

Soil & vent stack

≥ 450

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Min Ø 30mm

Internal pipe

Water/weather proof insulation

Boilers without 75mm sealed

condensate trap must be fitted with

a 75mm trap and visible air break

Visible air break

at plug hole

Min Ø 19mm Internal pipe

Sink, basin, bath or

shower with integral

overflow and 75mm trap

Minimum 30mm

internal pipe

Water/ weather proof insulation

≥ 25 Below grate

45º pipe

termination

Boiler

with 75mm

sealed

condensate

trap

≥ 100

Figure 3 - Connection of a Condensate Pump Typical

Method (see manufacturers detailed instructions)

Figure 4 - Connection of condensate Drainage Pipe to External Soil & Vent Stack

Figure 5 - Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe (only combined foul/rainwater

drain)

Figure 7 - Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away.

Figure 6 - Connection of Condensate Drainage Pipe Upstream of a Sink, Basin, Bath or Shower Waste Trap to External Drain, Gulley or Ranwater Hopper

INSTALLATION

CONDENSATE............ CONT’D

Page 28

Installation and Servicing

SECTION 2 - INSTALLATION

INSTALLATION

3G9705

Safety Valve

Drain Connection

15mm elbow

or fittings

(not supplied)

Safety Valve Drain Pipe

Note. The domestic hot water ow rate is automatically regulated to a maximum:

30 = 12.4 l/m (2.8 gpm) 35 = 14.5 l/m (3.2 gpm)

Filling

Loop

CH Flow

DHW

Outlet

Gas

Supply

DHW

Inlet

Return

2.15 CONNECTIONS & FILLING

NOTES.

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

Ensure each union is tted with bre seals provided.

Do not subject any of the isolating valves to heat as the seals may be damaged.

WATER CONNECTIONS CH

1. Connect the CH ow service valve (black handle) 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 rtn. valve (black handle) and copper tail.

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

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

GAS CONNECTION

IMPORTANT. The gas service cock is sealed with a non-

metallic blue bre washer, which must not be overheated when making capillary connections. Refer to Section 1.16 for details of the position of the gas connection.

For additional gas supply info refer to “Gas Supply” on page 10.

SAFETY VALVE DRAIN

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

The Installer to provide a compression joint on the end of the stub pipe. This assists with pipe removal when servicing.

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

A purpose made safety valve drain pipe is provided with the boiler to allow safe discharge through a wall to the outside of the building. This is particularly relevant to ‘high rise’ installations but can be used for all installations.

Page 29

Installation and Servicing

SECTION 2 - INSTALLATION

Filling Loop

(Blue)

Filling Loop

(Blue)

CH Return

(Black)

CH Return

(Black)

DHW Inlet

(Blue)

DHW Inlet

(Blue)

Cap

Plug

Filling

Loop

Filling

Loop

Filling Positions shown

Top Up Positions shown

INSTALLATION

FILLING

IMPORTANT - when lling:

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

Filling

1. Ensure lling loop is connected and all washers in place.

2. Ensure dust cap on auto air vent is slackened off refer to Section 3.24.

3. Check the following isolation handles on water connections are in the horizontal lling position (blue handle on DHW inlet

and black handle on CH return C).

Note. The CH ow isolation valve handle MUST be in the vertical position to enable lling.

4. Slowly turn the lling loop handle (blue B) to the horizontal open position until the pressure gauge reads between 1 to

1.5 bar.

5. Once the pressure gauge dial reads between 1 to1.5 bar turn the lling loop handle (blue

) back to the closed

(vertical) position.

6. Turn the CH Return handle (black

) and the DHW Inlet

handle (blue

) to the open (vertical) position.

7. Disconnect the lling loop from the DHW Inlet valve and t the grey cap to the open end.

8. Fit the Plug to the free end of the lling loop.

Note open all DHW taps to ensure water is owing freely-once satised close all taps.

Top Up

1. Ensure lling loop is connected and all washers in place.

2. Ensure dust cap on auto air vent is slackened off refer to Section 3.24.

3. Turn the DHW Inlet handle (blue

) to the horizontal

position.

4. Slowly turn the lling loop handle (blue

) to the

horizontal open position until the pressure gauge reads between 1 to 1.5 bar

5. Once the pressure gauge dial reads between 1-1.5 bar turn

the handle (blue

) on the lling loop back to the closed

(vertical) position.

6. Turn the DHW Inlet handle (blue

) to the open (vertical)

position.

7. Disconnect the lling loop from the DHW Inlet valve and t the grey cap to the open end.

8. Fit the Plug to the free end of the lling loop.

Note open all DHW taps to ensure water is owing freely-once satised close all taps.

Page 30

Installation and Servicing

SECTION 2 - INSTALLATION

INSTALLATION

INSTALLER CONNECTIONS (LHS) INSTALLER CONNECTIONS (RHS)

2.16 ELECTRICAL CONNECTIONS

WARNING. This appliance MUST be earthed.

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

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

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

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

0.75mm

(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 contact separation in both poles. The means of isolation must be accessible to the user after installation.

2.17 INSTALLER WIRING

The Logic boiler comes pre-tted with 1.8m of mains cable. This must be connected to a permanent live supply and NOT switched by thermostats/programmers. If the supply cord is

damaged, it must be replaced by the manufacturer, service

agent or similarly qualied persons in order to avoid hazard.

Accessing the installer wiring

1. Isolate the mains supply from the boiler.

2. Remove the front panel. Refer to section 3.2.

3. Swing down the control box into the service position, unclip and swing back the installer wiring cover and latch into the retaining clips. Refer to Section 3.8.

All of the connections can now be readily accessed, the plugs can be removed to aid wiring.

Note the cable strain relief system and grommets. Once any wiring is completed, to secure the boiler, reverse the order above.

Note 1 The link wire on the 230V installer room stat/timer connection gives a demand in conjunction with the timer option plug inside the timer option cover (located on the front of the new control box).

Page 31

Installation and Servicing

SECTION 2 - INSTALLATION

DIAGRAM A:

DIAGRAM B:

Room Stat with External Timer

Programmable Room Stat or

Room Stat with Internal Timer

Optional Room Stat or

Optional

Frost Programmable

Frost

Stat Room Stat

Stat

Room Stat Tim er

F ro st

Room

F ro st

Room

Stat

Stat/

L N

Stat

Stat/

L N

(Optional)

Timer

(Optional)

Timer

DIAGRAM A: DIAGRAM B:

Room Stat with External Timer

Programmable Room Stat or

Room Stat with Internal Timer

Optional Room Stat or

Optional

Frost Programmable

Frost

Stat Room Stat

Stat

Room Stat Timer

F ro s t

Room

F ro s t

Room

Stat

Stat/

L N

Stat

Stat/

L N

(Optional)

Timer

(Optional)

Timer

DIAGRAM C:

Use of General Live for Room Stat

Optional

Room Stat

Frost

Stat

Mains In

F ro s t

Room

Stat

Stat/

L N

(Optional)

Timer

DIAGRAM B:

Room Stat with External Timer

Optional

Frost

Stat

Room Stat Tim er

F ro st

Room

Stat

Stat/

L N

(Optional)

Timer

DIAGRAM D:

OpenTherm Device

DO NOT CONNECT 230V TO THESE

TERMINALS OR THE BOILER ELECTRONICS

WILL BE DAMAGED

Outside

Sensor

Open

Therm

OpenTherm Device E.G. Honeywell OT Bridge R8810

Strain Relief

2.18 EXTERNAL WIRING

External Controls – 230V 50Hz

Wiring a 230V 50Hz Room Thermostat, Diagram A (with optional timer, Diagram B)

1. Remove the link wire from the room stat/timer plug.

2. Connect the external cable from

the room stat/timer across these

two connections, if a general live

connection is used for the room stat or timer then connect this to the fused spur, on the load side (see Diagram

3. If the room thermostat has compensation and requires a neutral connection, make this connection to the fused spur, on the load side.

Optional External Controls – Extra

Low Voltage

Wiring OpenTherm Room Control or other OpenTherm Master Device, Diagram D.

1. Remove the timer link plug inside the

timer option cover, located on the front of the control box

2. Unclip the timer link socket from the

aperture on the rear of the control box, locate the plug on the same harness

branch and connect these together.

3. Using the rubber bung located adjacent to these connections, insert it into the open aperture.

4. Locate the OpenTherm connection on

the right hand side of the boiler installer connections area and connect the 2 core

cable from the OpenTherm device.

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.

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.

Wiring a system frost thermostat, see

digarams A, B and C. Wire the frost thermostat across the two connections as shown.

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

2.19 REPLACING PRE-FITTED MAINS CABLE

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

Replacement wiring should comply with notes in Section 2.18 and be carried out by a qualied person to avoid a hazard.

1. Isolate the mains supply to the boiler.

2. Remove the front panel. Refer to Section 3.2.

Swing the control box down into the service position, unclip and swing back the installer wiring cover to latch into the retaining clips. Refer to Section 3.8.

4. Unplug the mains connector and release the cable from strain relief.

5. Unscrew the L N & E connections & remove wires from connector.

6. Remove the mains cable by pulling back through the grommet .

7. Route the replacement through the grommet and re-t in reverse order.

8. Close the installer wiring cover ensuring that it is located correctly and that the cable is retained into the strain relief as shown.

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

NOTE. 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.

INSTALLATION

Page 32

Installation and Servicing

SECTION 2 - INSTALLATION

INSTALLATION

2.20 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 Combi 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.

20 10 0 -10 -20 -30 -40

100

Weather Compensation Control / Room Setpoint = +20ºC

Outside Temperature [ºC]

CH Temperature Setpoint [C]

Heating slope

2.5 2.2 2.0 1.8 1.6 1.4 1.2 1.0

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).

Page 33

Installation and Servicing

SECTION 2 - INSTALLATION

Kit Contents

A. Outside Air Sensor

2.21 THE WEATHER COMPENSATION KIT - SUPPLIED AS STANDARD

This kit provides the facility to apply outside air temperature control to the boiler water ow 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 ow temperature in response. If outside air temperature is greater than the system design temperature, the boiler ow temperature is reduced providing running cost savings. The boiler will operate in the condensing mode more frequently increasing savings.

Once the sensor is tted it is automatically detected.

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

FITTING THE KIT

Note. A timer should be tted 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 ue.

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

Avoid running this cable alongside mains voltage cables.

Wiring the Weather Compensation Kit to the Keston Combi.

1. Isolate the electricity supply to the boiler.

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

Swing the control box down into the service position, unclip and swing back the installer wiring cover to latch into the retaining clips. Refer to Section 3.8.

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

strain relief .

5. Re-assemble in reverse order.

INSTALLER CONNECTIONS (RHS)



Note. If tting this with the boiler, then plese complete product Fische system label, adding % efciency. This is a Class II Control (2%).

Page 34

Installation and Servicing

SECTION 2 - INSTALLATION

3 2 1

6 5 4 3 2 1 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1

SERVICE

CONNECTOR

234

1 PE 1 5

2 N 2

1 2

3 L 3

Chassis

Earth

CH L 4

2 5CH SWL

3 6F L

1 2

4 7F SWL

3 2 1

2 3 4

123

3 2 1

123

PELV

230V 50Hz Mains

NO. 2 B2 24V

NO. 5 A2 24V

NO. 6 B1

NO. 4 B3

NO. 3 A3

NO. 1 A1

WPS 5V

FLOW +

FAN FEEDBACK

FAN PWM

FAN GND

PUMP FEEDBACK

PUMP PWM

NC GAS VALVE -

GAS VALVE +

TURBINE SIGNAL

TURBINE GND

TURBINE 5V

CH LIVE

IGNITION LIVE

PUMP LIVE

DHW LIVE

PUMP GND

X9X8

OWC +

OWC -

OPENTHERM +

OPENTHERM -

OPENTHERM 5V

CHIP COM BUS TX

CHIP CO

M BUS 24V

CHIP COM BUS GND

CHIP COM BUS 5

CHIP COM BUS RX

MAINS LIVE

MAINS NEUTRAL

AUXILIARY LIVE

IONISATION

FLOW -

DHW +

DHW -

3 2 1

1 2 3 4 5 6

WPS SIGNAL

WPS GND

FLUE +

FLUE -

RETURN +

RETURN -

13 2

3 2 1

TIMER LINK

3 2

black

grey

red

green

blue

brown

green/yellow

orange

pink

violet

yellow

-----------

g/y

KEY

DIVERTOR

VALV E

DETECTION

ELECTRODE

FAN

PUMP

DHW FLOW

TURBINE

WATER

PRESSURE

SWITCH

RETURN

THERM

FLOW

THERM

GAS

VALV E

SPARK

GENERATOR

IGNITION

ELECTRODE

g/y g/y

g/y

r bk bkw brbbr

y p

bk bk bk bk

r r

INSTALLATION

2.22 WIRING DIAGRAM

Page 35

Installation and Servicing

SECTION 2 - INSTALLATION

As part of the commissioning process, the combustion of this appliance must be checked

and the Benchmark Checklist completed. A ow chart to assist is provided on page 73.

Gas Pressure

Test Point

Gas

Supply

ATTENTION !

IT IS A CONDITION OF THE MANUFACTURER’S WARRANTY THAT THE

BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED

AND LEFT WITH THE APPLIANCE

INSTALLATION

2.23 COMMISSIONING AND TESTING

A. Electrical Installation

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

a competent person.

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

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.

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

WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation, open all windows

and doors, extinguish naked lights and DO NOT SMOKE.

GENERAL

Please Note: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type dened on the appliance data plate. 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 ue system and the ue

seals, as described in the Flue Installation

section.

Proceed to put the boiler into operation as follows:

CHECK THE OPERATIONAL

(WORKING) GAS INLET PRESSURE

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

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 12.

Ensure that this inlet pressure can be obtained with all other

gas appliances in the property

working.

“SERVICE REQUIRED” Function

When the boiler has been installed for more than 1 year the following screen will appear:

To cancel this message press “RESTART”.

“AIR VENTING” Function

Refer to page 38.

Page 36

Installation and Servicing

SECTION 2 - INSTALLATION

Filling

Loop

CH Flow

DHW

Outlet

Return

DHW

Inlet

Gas

Supply

Legend

A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler Status Display E. Burner ‘on’ Indicator F. Central Heating Economy Setting G. CH Flow Isolating Valve H. Gas Inlet Pressure Test Point I. Gas Service Cock J. DHW Inlet Valve K. CH Return Isolating Valve L. DHW Outlet M. Filling Loop Valve N. Pressure Gauge

INSTALLATION

2.24 INITIAL LIGHTING

1. Check that the system has been lled and that the boiler is

not airlocked. Ensure the automatic air vent cap is open.

Note.

It is important the burner is not operated before the system is fully vented of air. Refer to Vent System section page 38. 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. Ret the boiler front panel. Refer to Section 3.2.

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

isolating valves (G,K & J) are OPEN.

4. Check that the electrical supply is OFF.

5. Check that the boiler mode knob (C) is OFF.

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

7. Slacken the screw in the inlet pressure test point (H) and connect a gas pressure gauge via a exible tube.

8. Switch the electricity supply ON and check all external controls

are calling for heat.

CENTRAL HEATING

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

’. The boiler control should now go through its

ignition sequence until the burner is established.

10. If the boiler does not light then after 5 attempts the boiler will lock out and display “Ignition Lockout”.

Restart the boiler (Refer to Section 2.27). The boiler will

repeat its ignition sequence. If restart occurs 5 times within 15 minutes then “Too Many Restarts” will be shown.

When the burner is established a screen similar to the

following will be shown.

DOMESTIC HOT WATER

11. With the boiler ring, set the DHW Temp Knob (A) to

maximum and fully open a DHW tap.

The boiler should continue to run and the display should

change from showing

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

IMPORTANT

The gas input to the burner is regulated by the gas valve

according to the air ow 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 12.

13. Turn off the DHW tap.

14. Remove gas pressure guage, tighten inlet pressure test

point and check for gas tightness.

MINMAX MIN

MODECENTRAL HEATINGHOT WATER

BOILER

OFF

MAX

AN DE B F

INSTALLATION

Page 37

Installation and Servicing

SECTION 2 - INSTALLATION

The user control has a dot matrix LCD to inform the user about the status of the boiler.

Notes: Boiler frost protection - boiler res if temperature is below 5º C.

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

Display Functions - Normal Operation

Mode Knob in “BOILER OFF” position:

Mode knob in “ ” position and no heat demand:

Mode knob in “ ” and no heat demand:

Domestic hot water operation without call for CH:

Domestic hot water operation with call for CH:

Central Heating Operaton:

Preheat operation:

Boiler frost protection:

Service required:

Display Functions - Settings Changed

DHW temperature knob moved:

CH temperature knob moved:

CH temperature knob moved with outside sensor connected:

Pre-Heat

If preheat is switched on, then the boiler will periodically re the burner. Thereby reducing the time taken to provide hot water. If preheat is switched off the response time will be reduced, although gas consumption will also be reduced.

To switch preheat on press the “Hot Water Preheat Off” button:

To switch preheat off press the “Hot Water Preheat On” button:

2.25 THE DISPLAY

INSTALLATION

Page 38

Installation and Servicing

SECTION 2 - INSTALLATION

MENU OPERATIONS

Efciency Level

To view the efciency level of the boiler press “Menu” and the following screen will be displayed:

Press Enter and a screen similar to the following will be displayed:

Press “Exit” to return to normal operation.

Service Phone Number

The service required message which

is displayed after 12 months can be

customised to show the installer’s telephone number. To record your telephone number press “Menu” and the following screen will be displayed:

Press “Next” and the following screen will be displayed:

Press “Enter” and the following screen will be displayed:

Press “Change” to change the number and “Next” to accept.

Press “Exit” to return to nomral operation.

Change Service Time

The time until the next service required message is shown can be changed as follows

Press “Next” until the following screen will be displayed:

Press “Enter” and the following screen will be displayed:

Press “Change” to change the time.

Press “Exit” to return to normal operation.

Fault History

To view the Fault History of the boiler press “Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed:

Press “Enter” and a screen similar to the following will be displayed:

Press “More” to see more faults.

Press “Exit” to return to normal operation.

Fault Help

This feature provides a list of potential

corrective actions at an installer level for all

faults detectable by the boiler electronics. Press “Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed:

Press “Enter” and the following screen will be displayed.

Press “More” for help information.

Press “Exit” to return to normal operation.

Vent System

The Vent System feature aids removal of air from the heat exchanger. The pump will be switched on for 50s and then off for 10s while the diverter valve is moved between DHW and CH every 30s. This feature lasts for 5 mins.

Press “Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed:

Press “Enter” and the following screen will be displayed:

This feature will end automatically after 5 mins. To end manually press “Exit”.

INSTALLATION

Page 39

Installation and Servicing

SECTION 2 - INSTALLATION

MENU OPERATIONS

Sensor Readings

To view the current Water Pressure, Switched Live Status, DHW Flow Rate, DHW Temperature, Flow Temperature, Return Temperature, Flame Status, Outside Temperature, DHW switch Live Status, and OpenTherm Status, press “Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed.

Press “Enter” and a screen similar to the following will be displayed:

Press “More” to see the full list.

Press “Exit” to return to normal operation.

Pump / Fan / Valves

To view the current status of the pump,

diverter valve, fan and gas valve press

“Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed:

Press “Enter” and a screen similar to the following will be displayed:

Press “More” to view the full list.

Press “Exit” to return to normal operation.

Maximum Flow Temperature

It is possible to limit the maximum ow temperature that can be set from the CH ow temperature knob using this feature. Note that this could prevent adequate

room temperature being achieved in

winter. Press “Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed.

Press “Enter” and a screen similar to the following will be displayed:

Press “Change” until the desired

temperature is displayed

Press “Exit” to return to normal operation.

Service Mode Minimum Rate

This feature will run the burner at minimum rate. Note that a CH demand has to

already be present for this feature to

be active. To activate the feature press “Menu” and the folloiwng screen will be displayed.

Press “Next” until the following screen is displayed.

Press “Enter” and a screen similar to the following screen will be displayed.

Press “Exit” to return to normal operation.

Service Mode Maximum DHW Rate

This feature will run the burner at minimum rate. Note that a CH demand has to

already be present for this feature to

be active. To activate the feature press “Menu” and the folloiwng screen will be displayed.

Press “Next” until the following screen is displayed.

Press “Enter” and a screen similar to the following screen will be displayed.

Press “Exit” to return to normal operation.

Service Mode Maximum CH Rate

This feature will run the burner at minimum rate. Note that a CH demand has to

already be present for this feature to

be active. To activate the feature press “Menu” and the folloiwng screen will be displayed.

Press “Next” until the following screen is displayed.

Press “Enter” and a screen similar to the following screen will be displayed.

Press “Exit” to return to normal operation.

INSTALLATION

Page 40

Installation and Servicing

SECTION 2 - INSTALLATION

Pump Modulation

The boiler is factory set for 70% minimum CH pump speed. This can be increased to 100%. Press “Enter” and the following screen will be displayed:

Press “next” until the following screen is displayed:

Press “Enter” and the following screen will be displayed:

Press “Change” to change the setting.

Press “Exit to return to normal operation.

Outside Sensor Slope

This feature is only accessible if an outside sensor has been tted to the boiler. Boiler performance can be adjusted relative to the insulation level of the building. To change the slope press “Menu” and the following screen will be displayed:

Press “Next” until the following screen is displayed:

Press “Enter” and the following screen will be displayed.

Press “Change” until the desired setting is displayed.

Note. The slope is active for settings between 5 and 40. Default is 17.

Press “Exit” to return to normal operation.

Diverter Valve Mid Position

To move the diverter valve to the mid

position, ensure there are no demands

for heat and press “Menu”. The following screen will be displayed:

Press “next” until the following screen is displayed:

Press “Enter” and the diverter valve will move to mid position and the following screen will be displayed:

Press “Exit to return to normal operation.

MENU OPERATIONS

Outside Sensor Slope

Diverter Valve Mid Position

Exit

Diverter Valve Mid Position

Page 41

Installation and Servicing

SECTION 2 - INSTALLATION

INSTALLATION

WATER TEMPERATURES

Temperatures can be selected using the CH and DHW thermostats.

Knob Setting CH Flow Temp DHW Outlet Temp

Max 80 65

Min 30 40

2.26 GENERAL CHECKS

Make the following checks for correct operation in:

1. Fully open all DHW taps in turn and ensure that water ows freely from them.

The display should show:

2. Close all taps except the furthest one from the boiler and check that the boiler is ring at maximum rate. This is factory set to give a DHW temperature rise of approximately 35oC at the ow rate stated on page 10 under “operation”.

Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and check that the boiler modulates to deliver DHW at approximately 65oC.

4. Close the DHW tap and check that the main burner extinguishes. The pump should overrun for 60 seconds.

When the pump stops the display sequence should read:

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

pressure governor may be required to prevent water noise.

CENTRAL HEATING & DOMESTIC HOT WATER MODE.

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

The display should show:

2. Fully open a DHW tap and check that hot water is delivered. The display should show:

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 & 3 for gas rates.

4. Close the DHW tap.

5. Set the central heating external controls to OFF. The burner

should go off and the pump continue to run for two minutes.

The display should read:

6. Check the correct operation of the timer (if tted) and all other system controls. Operate each control separately and

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 ushing process.

Note: A ushing solution should be used during the ushing

procedure. Flushing solutions: Fernox Superoc, Sentinel X300 (new systems) or X400 (existing systems). Refer to Section 1.16.

4. Rell and vent the system, add inhibitor (see Frame 5), clear all air locks and again check for water soundness.

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

6. Balance the system. Refer to Section 1.15.

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 briey to prevent seizure

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

Due to system variations and seasonal temperature uctuations DHW ow rates/temperature rise will vary, requiring adjustment at the draw off tap : the lower the rate the higher the temperature, and vice versa.

Page 42

Installation and Servicing

SECTION 2 - INSTALLATION

2.28 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 uctuations DHW ow 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.

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 tted draw attention to the timer Users Instructions and hand them to the householder.

8. Loss of system water pressure

Explain that the dial on the boiler indicates the central

heating system pressure and that if the normal COLD

pressure of the system is seen to decrease over a period

of time then a water leak is indicated. Explain the re-

pressurising procedure and if unable to re-pressurise or if the pressure continues to drop a registered local heating

installer should be consulted.

9. Explain boiler restart procedure (refer to Section 2.27).

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 benet of the warranty.

To restart the boiler, press the RESTART button (H).

2.27 RESTART PROCEDURE

Legend

A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler Status Display E. Burner ‘on’ Indicator F. Central Heating Economy Setting G. Pressure Gauge H Restart Button

MINMAX MIN

MODECENTRAL HEATINGHOT WATER

BOILER

OFF

MAX

AG D HE B F

INSTALLATION

Page 43

Installation and Servicing

SECTION 3 - SERVICING

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

WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing.

Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927.

To ensure the continued safe and efcient 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 ue terminal (and terminal guard if tted) 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 relled, vented and re-pressurised.

CLEANING PROCEDURE

Note. In order to carry out either servicing or replacement of

components the boiler front panel must be removed. Refer to Section 3.2.

1. Clean the main burner. Refer to Section 3.4.

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

Sections 3.5 & 3.6.

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

3.3.

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

ALSO IF THE DHW FLOW RATE IS IN QUESTION :-

5. Check the DHW lter for blockage. Refer to Section 3.25.

The cleaning procedures are covered more fully in Sections 3.3 to 3.7 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 retted, ensuring that a good seal is made.

Do NOT OPERATE the boiler if the front panel is not

tted.

8. If, for any reason, the condensate trap/siphon has been removed

ensure the trap is relled with water before reassembling.

9. Check the gas consumption.

10. Check combustion by connecting the ue gas analyser to the ue

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

If the CO/CO

ratio is greater than 0.004 AND the integrity of the complete ue system and combustion circuit seals have been veried and the inlet gas pressure (and gas rate) have been veried, then contact Keston.

11. Complete the service section in the Benchmark Commissioning Checklist.

GENERAL

Please Note: During routine servicing, and after any

maintenance or change of part of the combustion

circuit, the following must be checked:

- The integrity of the ue system and the ue seals,

- The integrity of the boiler combustion circuit and

the relevant seals

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

- The gas rate

- The combustion performance.

COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE

Please Note: BS 6798:2009 Specication for installation and maintenance of gas-red 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 ue gas analyser and the interpretation of the results.

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

- Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which

covers the use of electronic portable combustion

gas analysers in accordance with BS7967, Parts 1 to 4.

Flue

Sampling

Point

Air

Sampling

Point

3.1 SERVICING SCHEDULE

SERVICING

Ensure all caps and seals

are re-tted after use.

Page 44

Installation and Servicing

SECTION 3 - SERVICING

view from top of boiler

view from bottom of boiler

1. Disconnect the electrical leads from the

fan.

2. Remove the clip from the gas control valve outlet and ease the pipe upwards rotate and then ease down to remove.

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

4. Lift off fan and venturi assembly.

5. Undo the two M4 screws and release the

nozzle assembly.

6. Inspect the injector for blockage or damage.

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

Injector

3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT

REMOVAL

1. Loosen the two screws retaining the front panel.

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

forward and upward and remove.

REPLACEMENT

3. Hook the panel onto the top retaining clips.

4. Push the panel until the 2 bottom spring clips engage

ensuring the 4 control knobs line up with the holes in the front panel.

5. Re-tighten the two retaining screws.

3.3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

SERVICING

Page 45

Installation and Servicing

SECTION 3 - SERVICING

1. Ensure the sump is fully drained

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

ue manifold.

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

4. Remove the 2 burner front xing 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.

Circuit

Drain

Flow

Condensate

Drain

Gas DHW

Inlet

DHW

Outlet

Return

Filling Loop

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

2. Disconnect the condensate drain pipe.

3. Turn the siphon clockwise to disengage and lift to

remove.

Note. Keep siphon upright when removing

4. Clean siphon with water.

5. Re-assemble in reverse order.

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

3.4 BURNER REMOVAL AND CLEANING

3.5 CLEANING THE CONDENSATE TRAP/SIPHON

SERVICING

Page 46

Installation and Servicing

SECTION 3 - SERVICING

Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to

Section 3.20.

1. Remove ignition and ame detection electrodes. Refer to Sections 3.13 & 3.14.

2. It is advisable to replace the sump cover

prior to the water ush process.

3. Thoroughly ush 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-t the ignition and ame detection

electrodes, ensuring that both earth tabs

are tted to ignition electrode.

7. Check that the ignition and detection gaps are correct. Refer to Sections 3.13 & 3.14.

Ignition Electrode

Flame Detection

Reassemble the boiler in the following order:

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

2. Ret the burner ensuring the sealing gasket is correctly

positioned and free from damage (tighten the 4 xing screws in the sequence shown below).

3. Ret 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 ret the lower ue manifold as

shown.

6. Ret the sump cover.

7. Ret the boiler front panel.

IMPORTANT. Ensure that the boiler front panel is

correctly tted 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.

3.6 CLEANING THE HEAT EXCHANGER

3.7 REASSEMBLY

SERVICING

Page 47

Installation and Servicing

SECTION 3 - 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 Section 3.2.

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

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

IMPORTANT.

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

Notes.

1. In order to assist fault nding, the control panel has an LCD diagnostic display. The key to boiler fault conditions is shown in Section 4.

2. In order to replace components in Sections 3.21-3.32 it is necessary to drain the boiler. Refer to Section 3.20.

THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED

3.8 REPLACEMENT OF COMPONENTS

1. Refer to Section 3.8.

2. Disconnect the electrical leads from

the fan.

3. Remove the clip from the gas control valve outlet.

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, noting the orientation of the venturi in relation to the fan body.

7. Transfer the venturi assembly to the new fan, replacing the ‘o’ ring if

evidence of damage or deterioration

is visible.

8. Fit the new fan / venturi assembly

ensuring the retaining tabs are correctly positioned and the fan

outlet sealing gasket is correctly positioned and free from damage. Ret the extended nut.

9. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket and ensure all gas ‘o’ rings

are in place

10. Check that the boiler operates in both DHW and CH Modes.

Retaining Tabs

3.9 FAN REPLACEMENT

SERVICING

Page 48

Installation and Servicing

SECTION 3 - SERVICING

1. See Section 3.2.

2. Refer to Section 3.8.

3. Disconnect 2 ag terminals from the ue 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 xing 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 Section 3.7.

10. Check the operation of the boiler. Refer to Sections 2.23 & 3.24.

3.10 BURNER INJECTOR REPLACEMENT

1. Refer to Section 3.8.

2. Disconnect the electrical leads from the fan.

3. Remove the clip from the gas valve to

venturi pipe and ease the pipe upwards, rotate and ease down to remove.

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 that the boiler operates in both DHW & CH modes.

Injector

3.11 BURNER REPLACEMENT

SERVICING

Page 49

Installation and Servicing

SECTION 3 - SERVICING

Thermistor Locator Tab (with thermistor tted)

1. Refer to Section 3.8.

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

boiler.

3. Disconnect the electrical lead from the thermistor.

4. Reconnect the electrical lead to the new thermistor and reassemble in

reverse order, ensuring that the thermistor is securely tted to the pipe on the thermistor locator tab as shown.

5. Check that the boiler operates in both DHW & CH Mode.

3.12 RETURN THERMISTOR REPLACEMENT

1. Refer to Section 3.8.

2. Remove the burner. Refer to Section

3.11.

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 Section 2.23 & 2.24.

Ignition Electrode

3mm

Straight edge

Spark Gap

3.5mm

3.13 IGNITION ELECTRODE REPLACEMENT

SERVICING

Page 50

Installation and Servicing

SECTION 3 - SERVICING

3.14 FLAME DETECTION ELECTRODE REPLACEMENT

Flame Detection Electrode

12.5mm

Straight edge

1. Refer to Section 3.8.

2. Remove the burner. Refer to

Section 3.4.

3. Unplug the ame detection lead from the electrode.

4. Remove the 2 screws retaining the detection electrode.

5. Remove the electrode.

6. Fit the new ame detection

electrode, using the new gasket supplied.

7. Reassemble in reverse order.

8. Check that the boiler operates in

both DHW & CH modes.

1. Refer to Section 3.8

2. Disconnect the leads from the spark generator.

3. Gently push down the generator to release the top clip from the gas valve mounting bracket.

4. Lift the spark generator up and out of the bottom retaining moulding.

5. Fit the new spark generator and re-assemble in reverse order ensuring that the the earth lead is replaced.

6. Check that the boiler operates in both DHW & CH modes.

Spark Generator

1. Refer to Section 3.8.

Unplug the electrical lead connection from the gas control valve.

3. Remove the outlet gas valve clip and slide the pipe upwards.

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

5. Undo the single screw xing the gas valve to the mounting bracket and withdraw the valve forwards.

6. Fit the new gas control valve ensuring that the ‘o’ ring and sealing washer are in place and reconnect gas and electrical connections.

7. Check that the boiler operates in both DHW & CH modes.

3.15 SPARK GENERATOR REPLACEMENT

3.16 GAS CONTROL VALVE REPLACEMENT

SERVICING

Page 51

Installation and Servicing

SECTION 3 - SERVICING

1. Refer to Section 3.8.

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

3. Disconnect the condensate drain pipe.

4. Turn the siphon clockwise to disengage and lift

to remove.

Note. Keep siphon upright when removing.

5. Clean siphon with water or replaced if

damaged.

6. Re-assemble in reverse order.

7. When re-assembling ensure the trap is full of

water.

8. Check that the boiler operates in both DHW and CH modes.

Refer to Section 3.8.

To remove the motor:

1. Remove the condensate trap/siphon. Refer to Section 3.5.

2. Place a at bladed screwdriver in the actuator slot provided and ease out the actuator.

3. Disconnect the electrical plug from the motor.

4. Fit the new motor ensuring the arm is correctly engaged in the metal fork and re-assemble in

reverse order ensuring the condensate trap/

siphon is relled with water. Ret electrical plug.

5. Check the operation of the boiler.

Note. All spares will be delivered in mid-position.

Siphon

3.17 DIVERTER VALVE ACTUATOR REPLACEMENT

3.18 CONDENSATE TRAP/SIPHON REPLACEMENT

SERVICING

Page 52

Installation and Servicing

SECTION 3 - SERVICING

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 Section 3.8.

2. Ensure the control knobs are in the 12 o clock position.

3. Carefully release the six retaining clips and remove control

box cover.

4. Unplug all lead connections to the PCB, also where applicable, push the small plastic clip with an electrical screwdriver to facilitate plug removal.

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

Take the new PCB.

7. Re-connect all plug connections.

8. Reassemble in reverse order.

9. Turn power on, display shows:

Installer

Turn all dials

to mimimum position

Turn all dials to minimum position and

the following screen will be shown:

Installer

Initialise spare PCB?

Yes

Press “Yes” and the following screen will be shown:

Installer

Switch mains off

After 5s switch mains on

Switch mains off. After 5s switch mains on. The following

screen will be shown:

Select Boiler Model

1/4

Combi 24kW

Natural Gas

More Select

Press “More” until the desired output and gas type is

displayed, then press “Select”. The following screen will be shown:

Installer

Program this model?

Back Yes

Press “Yes” and the model will be set and normal operation

begins. Turn the dials to the desired positions.

10.

Check that the boiler operates in both DHW and CH modes.

Plastic clip

IMPORTANT. IT IS CRITICAL FOR SAFE OPERATION THAT THE CORRECT BOILER SIZE AND FUEL TYPE IS ENTERED INTO THE BOILER.

3.19 PCB REPLACEMENT

SERVICING

Page 53

Installation and Servicing

SECTION 3 - SERVICING

1. Refer to Section 3.8.

2. Drain the DHW system. Refer to Section 3.20.

3. Pull off the electrical connection.

4. Using a suitable tool, lift and remove the retaining clip.

5. Use the clip to ease the turbine sensor from its housing.

6. Re-assemble in reverse order.

7. Check that the boiler operates in both DHW & CH modes.

DOMESTIC HOT WATER CIRCUIT

1. Refer to Section 3.8.

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 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 lling loop, refer to Section 2.16) before proceeding to check operation of the boiler.

5. Disconnect lling loop. Refer to Section 2.16.

6. Check that the boiler operates in both DHW & CH modes.

Circuit

Drain

Flow

Condensate

Drain

Gas DHW

Inlet

DHW Outlet

Filling Loop

Return

CENTRAL HEATING CIRCUIT

1. Refer to Section 3.8.

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 lling loop, refer to Section 2.16) before proceeding to check operation of the boiler.

5. Disconnect lling loop. Refer to Section 2.16.

6. Check that the boiler operates in both DHW & CH modes.

1. Refer to Section 3.8.

2. Drain the heating system. Refer to Section 3.20.

3. Remove the boiler front (See Section 3.2), lower the control

panel and remove the control box cover.

4. Ensuring there is no pressure in the system unclip the C clip from the ow manifold port and remove the capillary connection together with ‘o’ ring.

5. Releasing the two retaining clips on the pressure gauge

ease the pressure gauge through the front of the control

panel.

6. Fit the new pressure gauge from the front of the control panel ensuring correct orientation. Locate push t

connection into port ensuring ‘o’ ring in place and secure

with the C clip.

7. Rell the boiler. Refer to Section 2.15.

8. Check that the boiler operates in both DHW & CH modes.

3.20 DRAINING THE BOILER

3.21 DHW FLOW TURBINE SENSOR REPLACEMENT

3.22 PRESSURE GAUGE REPLACEMENT

SERVICING

Page 54

Installation and Servicing

SECTION 3 - SERVICING

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

3. Remove the clip on return thermistor. Refer to Section 3.12.

4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve.

5. Undo the safety valve pipe compression tting positioned outside the boiler casing.

6. Lift out the safety valve/pipe assembly.

7. Remove the safety valve pipe and transfer to the new safety valve.

8. Reassemble in reverse order ensuring the retaining clip is correctly tted, the pipe compression tting retightened and return thermistor is re-clipped.

9. Rell the boiler. Check that the boiler operates in both DHW & CH modes.

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

3. Remove the expansion vessel. Refer to Section 3.32.

4. Firstly, increase access area by disconnecting the 22mm pipe connection at

top of pump manifold and bottom of heat exchanger and remove pipe. Refer to Section 3.26.

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

6. Reassemble in reverse order. Ensure the air vent head ‘o’ ring seal is tted.

7. Ensure the air vent cap is loose.

8. Rell the boiler. Refer to Section 2.15. Check for leaks around the new air vent

joint.

9. Check that the boiler operates in both DHW & CH modes.

3 4

Dust Cap

1. Refer to Section 3.8.

2. Drain the DHW system. Refer to Section

3.20.

3. Turn the housing anti clockwise and pull forward to remove the cartridge.

4. Using a pair of pliers, pull out the plastic lter/ow regulator.

5. Clean or replace lter as necessary.

6. Reassemble in reverse order.

7. Rell the boiler.

8. Check that the boiler operates in both DHW & CH modes.

3.23 SAFETY RELIEF VALVE REPLACEMENT

3.24 PUMP AUTOMATIC AIR VENT REPLACEMENT

3.25 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT

SERVICING

Page 55

Installation and Servicing

SECTION 3 - SERVICING

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

3. Remove condensate trap/siphon. Refer to Section 3.18.

4. Remove the diverter valve actuator. Refer to Section 3.17.

5. Remove the 2 allen screws securing the plate heat exchanger

to the composite housings.

6. Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area. Be aware of any water spillage.

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

Note. Ensure that the depressions are on the bottom prior to tting.

8. Reassemble in reverse order.

9. Rell the boiler. Refer to Section 2.15.

10. Check that the boiler operates in both DHW & CH modes.

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

3. Disconnect the two electrical leads 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. Rell the boiler. Refer to Section 2.15.

9. Check that the boiler operates in both DHW & CH

modes.

To remove the valve body assembly:

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

3. Remove the condensate trap/siphon. Refer to Section 3.18.

4. Remove the electrical plug. Refer to Section 3.17.

5. Place a at bladed screwdriver in the diverter valve motor body slot provided and ease out the motor. Refer to Section

3.17.

6. Remove the return thermistor electrical connection. Refer to Section 3.12.

7. Remove the pump electrical connections. Refer to Section

3.28 no. 3.

8. Remove DHW Turbine electrical connection. Refer to Section 3.21 no. 3.

9. Remove the DHW plate heat exchanger (note orientation). Refer to Section 3.27.

10. Undo the safety valve pipe compression tting. See No.5 Section 3.23.

11. Loosen the nut above pump and rotate the pipe.

12. If required remove expansion vessel connection hose. Refer to Section 3.32.

13. Remove the DHW inlet and CH return connection situated beneath the boiler.

14. Remove the four torx head screws xing the return manifold to the boiler sheet steel base.

15. Lift the manifold assembly and remove from boiler.

16. Twist and remove the DHW manifold.

17. Remove the two diverter valve body xing screws and withdraw the diverter valve body assembly.

18. Fit the new diverter valve body assembly and replace the two xing screws.

19. Ret the DHW manifold, t the assembly back to the boiler and reassemble in reverse order.

20. Rell the boiler. Check that the boiler operates in both DHW & CH modes.

3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT

3.27 DHW PLATE HEAT EXCH. REPLACEMENT 3.28 PUMP HEAD REPLACEMENT

SERVICING

Page 56

Installation and Servicing

SECTION 3 - SERVICING

1. Refer to Sections 3.8.

2. Drain down the boiler. Refer to Sections 3.20.

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. Rell the boiler. Refer to Section 2.15.

8. Check that the boiler operates in both DHW &

CH modes.

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

3. Pull off the two electrical connections.

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

5. Carefully withdraw the pressure switch.

6. Fit the new pressure switch and re-assemble in reverse order.

7. Rell the boiler. Refer to Section 2.15.

8. Check that the boiler operates in both DHW & CH modes.

3.29 CH WATER PRESSURE SWITCH REPLACEMENT

3.30 FLOW THERMISTOR REPLACEMENT

SERVICING

Page 57

Installation and Servicing

SECTION 3 - SERVICING

SERVICING

Refer also to Section 2.1 - ‘Boiler Exploded View’

IMPORTANT

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

13. Remove the condensate rubber pipe. Refer to Section 3.18, no. 2.

14. Remove the two heat exchanger xing screws.

15. Remove the Heat exchanger, slide out of location bracket.

16. If replacement sump required: Rotate heat exchanger

assembly 180º. Place new sump onto heat exchanger, ensuring correct orientation and seal is in place. Then gently apply pressure to the base of the sump at each tab xing point and engage tabs onto the heat exchanger.

17. Reassemble in reverse order, ensuring the heat exchanger is located correctly in the LHS retaining bracket. Replace any new ‘o’ rings supplied with new heat exchanger and replace gaskets or seals if any sign of damage is evident.

When replacing the spring clips located on the return pipe connection, ensure clip is oriented to correctly match

connecting pipe diameters.

18.

Ensure the trap/siphon is lled with water. Refer to Section 3.18.

19. Rell the boiler and check for leaks. Refer to Section 2.15.

20. Check that the boiler operates in both DHW & CH modes.

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.20.

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

side. Refer to Section 3.3.

Remove the burner and place on one side. Refer to

Section

3.4

5. Remove the ignition and detection electrodes. Refer to Section 3.13 & 3.14.

6. Remove the spark generator. Refer to Section 3.15.

7. Remove the gas valve. Refer to Section 3.16.

8. Remove the expansion vessel. Refer to Section 3.32.

9. Remove the ow and return thermistors. Refer to

Sections 3.12 & 3.30.

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

11. Undo the pump union nut and remove pipe.

12. Remove the two retaining pipe clips and remove pipes.

Shown as 180º position

3.31 HEAT ENGINE REPLACEMENT

Page 58

Installation and Servicing

SECTION 3 - SERVICING

RECHARGING

1. Refer to Section 3.8.

2. Remove the charge point cover.

3. Recharge the tank pressure to 0.75 bar.

4. Re-assemble in reverse order.

5. Check that the boiler operates in both DHW &

CH modes.

REPLACEMENT

6. Refer to Section 3.8.

Drain the boiler CH circuit. Refer to Section 3.20.

8. Remove the retaining clip on the vessel water connection pipe and remove the pipe.

9. Support the expansion vessel and unscrew the 2 screws from the securing bracket, 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 ensuring the seal

is in place.

13. Rell the boiler and check for leaks. Refer to Section 2.15.

14. Check tht the boiler operates in both DHW & CH modes.

Recharge Point

SERVICING

3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT

Page 59

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

4.1 FAULT FINDING CHART MAIN MENU

RESTART PROCEDURE: TO RESTART BOILER PRESS THE RESTART BUTTON.

Overheat Lockout 1/4

With Boiler Off &

System Cold

Fill system to 1.0 Bar

Restart Menu

Water Pressure 1/3

With Boiler Off &

System Cold

Fill system to 1.0 Bar

Overheat Lockout 2/4

Bleed Radiators

Rell System to 1.0 Bar

Restart Menu

Water Pressure 2/3

Bleed Radiators

Rell System to 1.0 Bar

Restart Menu

Overheat Lockout 3/4

Check Radiator Valves

And Boiler Valves

Are Open

Restart Menu

Water Pressure 3/3

If fault persists

Contact Installer

Restart Menu

Ignition Lockout 1/2

Check Other Gas

Appliances Work

Restart Boiler

Restart Menu

Overheat Lockout 4/4

Restart Boiler

If Fault Persists

Contact Installer

Restart Menu

Ignition Lockout 2/2

Check Other Gas Appliances Work

Restart Boiler

Restart Menu

Too Many Restarts

Contact Installer

Restart Menu

Flame On Before Gas On

Contact Installer

Restart Menu

Flame Loss

Contact Installer

Fan Fault

Contact Installer

Restart Menu

Flow Thermistor Fault

Contact Installer

Restart Menu

Return Thermistor Fault

Contact Installer

Restart Menu

Outside Sensor Fault

Contact Installer

Restart Menu

Go to Section 4.2

Flow Temperature Overheat Lockout

Go to Section 4.5

Low Water

Pressure

Go to Section 4.3

Ignition Lockout

5 restarts within

15 minutes

Turn power off and on

Go to Section 4.4

False Flame

Lockout

Go to Section 4.6

Flame Loss

Go to Section 4.7

Fan Fault

Go to Section 4.8

Flow Thermistor

Fault

Go to Section 4.9

Return Thermistor

Fault

Go to Section 4.10

Outside Sensor

Fault

continued.......

Page 60

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

Spare PCB Not Set

Switch Off

Wait 5s

Switch On

Restart Menu

PCB Fault

Contact Installer

Restart Menu

Low Mains Voltage

Contact Electricity

Provider

High Mains Voltage

Contact Electricity

Provider

Flow/Return Reversed

Contact Installer

Room Stat Fault

Check Room Stat

Batteries

No CH operation but DHW operates OK

No DHW operation but CH operates OK

No Display

Follow instructions

in Section 3.19

Replace PCB

Low Mains Voltage

Contact

Electricity Provider

Contact

Electricity

Provider

Check

Return Thermistor

Check

Room Stat

Batteries

Go to Section 4.11

Go to Section 4.12

Go to Section 4.13

Page 61

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

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

YES

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

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

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

YES

Replace the Pump,

then restart boiler

OK, now

restart boiler

YES

If the boiler is restarted does the boiler ignite for a short time and

then extinguish?

YES

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

Check the detection electrode and associated harness for:

continuity, visual condition and

position (Refer to Frame 3.14). Check if the condensate pipe is blocked. Replace as necessary

Check gas supply and

rectify fault

YES

Is approx 24Vdc supply available at the Gas Valve? (* See note)

YES

Check spark generator and associated harness for: continuity and visual condition. (Refer to Frame 3.15) Are these functioning correctly?

YES

Check ignition electrode and associated harness for: continuity, visual condition and position. (Refer to Frame 3.13) Are these functioning correctly?

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

Check wiring connection 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

Replace Gas Valve

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

YES

Replace Gas Valve

YES

Check the Flow and Return Thermistors

(Refer to Frame 3.30 & 3.12)

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

At 25

C expect 9,700 - 10,300 Ohms

At 60

C expect 2,400 - 2,600 Ohms

At 85

C expect 1,000 - 1,100 Ohms

4.2 OVERHEAT LOCKOUT

4.3 IGNITION LOCKOUT

Page 62

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

Restart the boiler, does Boiler Work OK?

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

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

YES

Replace Flame Detection Electrode

Check routing and integrity of internal boiler wiring

YES

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

YES

Fill and vent the system and open all isolation valves

Does the boiler ignite for a short

time and then extinguish?

YES

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

Check the detection electrode and associated harness for: continuity,

visual condition and position

(Refer to Section 3.14). Check if condensate pipe is blocked. Check if ue is blocked. Replace as necessary

Check gas supply and

rectify fault

YES

Is 24Vdc supply available at the Gas Valve while the ame is on?

YES

Check spark generator and associated harness for: continuity and visual condition. (Refer to Section 3.15) Are these functioning correctly?

YES

Check ignition electrode and associated harness for: continuity, visual condition and position. (Refer to Section 3.13) Are these functioning correctly?

YES

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

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

Replace Gas Valve

YES

Are connections on water pressure sensor secure?

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

Re-t connections

Replace water pressure sensor

4.4 FLAME ON BEFORE GAS VALVE ON

4.5 LOW WATER PRESSURE

4.6 FLAME LOSS

Page 63

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - 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

Rectify Wiring &

connections

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

Replace PCB

Replace Fan

YES

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

C expect 9,700 - 10,300 Ohms

At 60

C expect 2,400 - 2,600 Ohms

At 85

C expect 1,000 - 1,100 Ohms

Is the Thermistor value correct?

YES

Is there continuity between the PCB and the Thermistor?

YES

Replace PCB

Fit a new Thermistor

Check and replace wiring as necessary

Disconnect the wiring from the Flow Thermistor

Check the resistance using a suitable multimeter connected

across the Thermistor’s terminal pins.

At 25

C expect 9,700 - 10,300 Ohms

At 60

C expect 2,400 - 2,600 Ohms

At 85

C expect 1,000 - 1,100 Ohms

Is the Thermistor value correct?

YES

Is the wiring securely connected to the low voltage 6 way connector at the front left hand side of the PCB?

YES

Replace PCB

Fit a new Thermistor

Securely connect the wiring to the PCB

Is the wiring securely connected to the Flow Thermistor (located in the top of the Heat Exchanger?)

YES

Securely connect the wiring to the Flow Thermistor

4.7 FAN FAULT

4.8 FLOW THERMISTOR FAULT

4.9 RETURN THERMISTOR FAULT

Page 64

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

Disconnect the wires to the outside sensor.

Check the resistance using a suitable multimeter

connected across the Outside Sensor’s terminal pins.

At 0

C expect 31,000 - 35,000 Ohms

At 15

C expect 15,000 - 16,500 Ohms

At 30

C expect 7,700 - 8,500 Ohms

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?

Replace PCB

Fit a new Outside Sensor

Securely connect the wiring at the Terminal Block and the PCB

Is the wiring securely connected at both the boiler and Outside Sensor?

YES

Securely connect the wiring at both the boiler and Outside Sensor

4.10 OUTSIDE SENSOR FAULT

Page 65

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

Is the mode knob in the Winter position?

YES

Move the mode knob to the Winter position

Are the Timer and the Room Thermostat switched on?

YES

Switch the Timer and Room Thermostat On

Are the Radiator Valves Open?

YES

Open the Radiator Valves

Is there 230Vac at (A)?

YES

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

Replace the Divertor Valve

4.11 NO CH OPERATION BUT DHW WORKS OK

Page 66

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Installation and Servicing

SECTION 4 - FAULT FINDING

L N

YES

Are the ow rates correct as per Table 3.

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

Adjust ow rates to achieve 35º temp rise and check lter is not blocked with debris.

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?

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

YES

Re-connect wiring

Replace turbine sensor

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

YES

Supply power to the boiler

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

YES

Connect the wiring from the terminal block to the Main PCB securely.

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

Connect the ribbon from the main PCB to the User Interface PCB securely

YES

Replace the

User Interface

PCB

Is ribbon cable damaged?

YES

Replace ribbon cable

4.12 NO HW BUT CH ON

4.13 NO DISPLAY

Does the display

show a similar

screen to the

screen shown?

Page 67

Installation and Servicing

SECTION 5 - SPARE PARTS

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance

specication that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Keston. Failure to do so could affect safety or performance of this appliance.

Our Parts team are also available to help with your Keston Spare Parts enquiries on 01482 498665.

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

hand;

- Boiler Model

- Appliance GC Number

- Boiler Serial Number

Page 68

Installation and Servicing

SECTION 6 - BENCHMARK & COMMISSIONING

Page 69

Installation and Servicing

SECTION 6 - BENCHMARK & COMMISSIONING

www.centralheating.co.uk

Benchmark Commissioning and Servicing Section

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

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

To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed. The service details should be recorded on the Benchmark Service Interval Record and left with the householder.

Page 70

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

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

www.centralheating.co.uk

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Programmable room thermostat

Optimum start control

Combination Boiler

Fitted

Automatic bypass to system Fitted

Boiler interlock

ALL SYSTEMS

Yes

CENTRAL HEATING MODE

mbar OR mbar

Central heating return temperature

COMBINATION BOILERS ONLY

Yes

DOMESTIC HOT WATER MODE

mbar OR mbar

Cold water inlet temperature

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND

Ratio

AND

Ratio

Yes

www.centralheating.co.uk

Page 71

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

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

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

Service Provider

SERVICE RECORD

SERVICE 01

AND

(Where Possible) AND

Signature

SERVICE 02

AND

(Where Possible) AND

Signature

SERVICE 03

AND

(Where Possible) AND

Signature

SERVICE 04

AND

(Where Possible) AND

Signature

SERVICE 05

AND

(Where Possible) AND

Signature

SERVICE 06

AND

(Where Possible) AND

Signature

SERVICE 07

AND

(Where Possible) AND

Signature

SERVICE 08

AND

(Where Possible) AND

Signature

SERVICE 09

AND

(Where Possible) AND

Signature

SERVICE 10

AND

(Where Possible) AND

Signature

Page 72

Installation and Servicing

FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO

CHECK ON COMMISSIONING A CONDENSING BOILER

Important Preliminary Information on Checks

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

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

PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK

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

As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).

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

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

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

KEY:

CO = carbon monoxide

= carbon dioxide

O2 = oxygen

Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm

ppm = parts per million

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

*Setting to Minimum Rate:

Refer to Service Mode, Minimum Rate (Page 39)

Page 73

Installation and Servicing

Yes

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

Turn off Appliance and Call Ideal Technical Helpline

The appliance must not be commissioned until problems

are identified and resolved. If commissioning cannot be

fully completed, the appliance must be disconnected from

the gas supply in accordance with GS(I&U)R. NOTE:

Check and record CO level and combustion ratio at both

maximum AND minimum rate before contacting Ideal.

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

Set Boiler to Maximum Gas Rate

In accordance with boiler instructions,

set boiler to operate at maximum rate

(full load condition). Allow sufficient

time for combustion to stabilise.

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

flooding of sensor.

Check CO level and Combustion Ratio

at Maximum Gas Rate

With boiler still set at maximum gas rate,

insert analyser probe into flue gas

sampling point. Allow readings to stabilise

before recording.

Set Boiler to Minimum Gas Rate

(*see opposite page)

In accordance with boiler instructions, set boiler to

operate at minimum rate (to minimum load condition).

Allow sufficient time for combustion to stabilise.

Verify Flue Integrity

Analyser readings indicate that combustion products and inlet air

must be mixing. Further investigation of the flue is therefore required.

Check that flue components are assembled, fixed and supported as

per instructions. Check that flue and flue terminal are not obstructed.

Check that no seals, e.g. Those on flue extensions, have

been displaced during installation. Rectify if necessary.

Turn off appliance and call Ideal Technical Helpline for advice

The appliance must not be commissioned until problems are identified

and resolved. If commissioning cannot be fully completed, the appliance

must be disconnected from the gas supply in accordance with GSIUR.

Carry Out Flue Integrity Check Using Analyser

Insert analyser probe into air inlet test point (where available) and allow

readings to stabilise.

Note. Where no air inlet test point is provided then a flue integrity check with the analyser is not possible. The installer should verify that flue integrity has

been visually checked in accordance with the “Prior to CO level and

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

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

O2 more than or

equal to 20.6% OR CO

less than or equal to

0.2%?

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

2 more than or

equal to 20.6% OR CO

less than or equal to

0.2%?

Boiler is Operating Satisfactorily

No further actions required.

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

Checklist, recording CO and combustion ratio readings as required.

Check CO and Combustion Ratio at Minimum Gas Rate

With boiler set at minimum rate, insert analyser probe into flue

gas sampling point. Allow readings to stabilise before recording.

Start

Page 74

NOTES

Keston Combi - Installation and Servicing

Page 75

NOTES

Keston Combi - Installation and Servicing

Page 76

Keston pursues a policy of continuing improvement

in the design and performance of its products. The right is therefore reserved to vary specication without notice.

Keston Heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk

Keston Combi C30, Combi C35 Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual