Keston Combi C30, Combi C35 Installation And Servicing Instructions

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
FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS COMBINATION BOILER
Installation and Servicing Instructions
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
ƞ
4
% 90 90
Part Load
ƞ
1
% 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
Q
elec kWh 0.075 0.074
ƞ
WH
% 78 78.4
Q
fuel kWh 7.7 7.7
AEC kWh 16.3 16
AFC GJ 5.8 5.7
ERP DATA
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%
A
B
C
4
Installation and Servicing
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
6
Installation and Servicing
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 .....
54
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
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
o
C - 13g/s 73ºC - 15g/s
Maximum Working Pressure (Sealed Systems) bar (lb/in
2
) 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
3
(935 Btu/ft3) nett
To obtain the gas consumption at a different caloric value:
a. For l/s - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m
3
)
b. For Btu/h - multiply the gross heat input (kW)
by 26.8
c. For ft
3
/h - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
d. For m
3
/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.
I
2H
= 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
3
/h 2.512 0.623 0.734
(ft
3
/h) (89) (22) (25.9)
Boiler Output :
Non Condensing 70
o
C Mean Water temp. kW 24.2 6.1 7.1
Condensing 40
o
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
3
/h 3.135 3.658
(ft
3
/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)
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
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
o
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
o
C temperature rise.
35 14.5 l/min at 35
o
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.
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.
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
0.5
1
1.5
2
2.5
3
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.
13
Installation and Servicing
SECTION 1 - GENERAL
395
198
89
155
62
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.
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
o
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
o
C.
3. All components of the system must be suitable for a working
pressure of 3 bar and a maximum design temperature of 110
o
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.
b.
Safety valve, with a non-adjustable preset lift pressure of 3 bar.
c. Pressure gauge, covering a range of 0 to 4 bar.
d. An 8-litre expansion vessel, with an initial charge pressure
of 0.75 bar.
4. ‘Make-up’ Water. Provision must be made for replacing water loss from the system, either :
a. From a manually lled ‘make-up’ vessel with a readily visible
water level. The vessel should be mounted at least 150mm
above the highest point of the system and be connected
through a non-return valve to the system, tted at least 150mm below the ‘make-up’ vessel on the return side of the radiators. or
b. Where access to a ‘make-up’ vessel would be difcult, by
pre-pressurisation of the system.
The maximum cold water capacity of the system should
not exceed 143 litres, if not pressurized. However, if the system is to be pressurized, the efciency of the expansion vessel will be reduced and a larger vessel (or smaller system volume) may be necessary. If the capacity of the vessel is not considered sufcient for this,
or for any other reason, an additional vessel MUST be installed on the RETURN to the boiler.
Guidance on vessel sizing is given in Table 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
o
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.
b.
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.
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
o
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
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
17
Installation and Servicing
SECTION 2 - INSTALLATION
C
A
G
F
B
E
H
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
1
1
3
2
2
2
3
3
1
2
3
2
8
3
3
1 2
1
7
5
6
4
5
4
B
A
G
H
J
F
E
D
C
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
18
FLUE OUTLET
18
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
1
/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.
19
FLUE OUTLET
19
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
20
FLUE OUTLET
20
Installation and Servicing
SECTION 2 - INSTALLATION
6m
2m
Bracket at each 1 metre
1m
4m
1.5m
6m
1.5º back to boiler
1.5º back to boiler
Air
Elbows 2 x 1m = 2m Straights 6+2+0.15 = 8.15m Total = 10.15m
Overall Flue / Air = 25.65m
Flue
Elbows 3 x 1m = 3m Straights 4+6+1.5+1 = 12.5m Total = 15.5m
Calculations
0.15m
Sleeve
2m
2.5m
1.5m
2m
4m
4m
0.15m
3.5m
3.5m
1.5º back to boiler
Air
Sleeve
1.5º back to boiler
Bracket every 1 metre
Flue
3 x 90º elbows 3 Straight lengths 2.5
1.5
3.5 4
14.5
Overall Flue / Air = 30.15m
Air
4 x 90º elbows 4 Straight lengths 2 2
3.5 4
0.15
15.65
Calculations
2 4 6 8
10
12
14
16
18
20
22
24
26
28
2
6
10
14
18
22
26
30
Accep 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
12
14
16
18
20
22
24
26
28
30
2
6
10
14
18
22
26
30
34
38
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
21
FLUE OUTLET
21
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
boundary
J
H
L
F
I
G
I
A
B
C
D, E
H
H
K
M
N
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.
22
Installation and Servicing
SECTION 2 - INSTALLATION
3G10030
X
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
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.
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