The Keston 260 and 340 Condensing Boilers are unique in their concept and design. They
comprise two boiler m odules with individual gas valve, fans, bur ners and heat exchanger
assemblies. The two modules are fully independent in operation and are automatically
sequenced to provide optimum load matching. In addition, firing sequence is regularly
rotated to ensure even usage levels. While the application for which the boilers were
designed is the same as those which other boilers are used, the Keston boiler has the
added advantage of very high efficiency, and small diameter plastic flue which can be
extended to 20 metres horizontally or vertically. The Keston 260 and Keston 340 are
designed to be wall hung. However, floor standing installation can be accomm odated by
using the optional floor standing frame.
The Keston module uses a high power combus tion blower to deliver a pre-mix of gas and
air to a downward firing burner in a high efficiency, single pass heat exchanger. The flue
system is room sealed and f an powered. The ignition is direct spark and f ully automatic.
The boiler housing is not waterproof and should be installed in a position where it will
always be dry. Consideration should also be given to the noise levels generated by the
combustion fan when in operation. Small air intake points are incorporated within the
appliance cabinet to ensure that the interior of the cabinet is maintained under a slight
negative pressure. This is a safety feature to reduce the possibility of products leak age
out of the cabinet into the installation space..
The boiler is suitable for c onnection to open vented or, preferably, sealed systems. The
system must be pumped centra l heating or pum ped c entr al heating with combined indirec t
sanitary hot water. Gravity circuits must not be used.
Forming part of each boiler m odule is the heat exchanger which is made from a highly
corrosion resistant stainless steel, formed into tightly wound coil. The hot combustion
gases from the c entral down firing burner pass through this coil imparting heat into the
system water. Integral module shunt pumps within the appliance cabinet ensure each
module receives correct water flow when firing. The Keston boiler is not a high water
content boiler and does not contain the m etal mass, or water volume, of a cast iron or
steel boiler. This boiler is of low mass and low water content and therefore responds
faster when there is a call for heat.
1.2BOILER SCHEMATIC
Air is drawn into the boiler through a 100mm com pos ite plastic pipe. Eac h m odule air flow
is proved by a differential pressure across the air control orifice. Gas is mixed with
combustion air at the inlet to the fan. The gas flow is regulated by an orifice located in the
housing downstream of the gas valve. T he gas and air are thor oughly mixed in the blower
and fed into the burner located at the top end of the heat exchanger module. The gas and
air mixture is ignited by a direct spark ignition control system and burns with a blue flame
just off the surface of the burner. As the hot products of combustion pass downwards,
they are cooled by exchanging heat with the circulating water which enters the heat
exchanger coil at the bottom of the heat exchanger.
When the return water temperature is below 55
combustion products will condense ins ide the heat exchanger, thus increasing the boiler
efficiency further by releasing the latent heat of condensation. This condensate falls to the
bottom of the heat exchanger where it is separated from the flue gases and exits from the
boiler through the condensate drain. Any condensate formed in the flue runs back down
the flueway and is drained at the base of the flue connection to the heat exchanger or
drain points within the flue.
The condensate is very slightly acidic with a pH level of around 5 (about the sam e acidity
as vinegar) and should be piped in a plastic pipe. It is not harmful to the waste disposal
system and may be disposed of as normal waste water.
The flue gases are piped in a 100mm composite plastic pipe to the outside. The
temperature of the flue gas es are usually around 5
water. The flue pipe should be term inated outside the building from where they cannot
re-enter the building or any other adjacent building.
The heating level m ay be controlled by room thermostats, hot water ca lorif ier ther mostats,
programmer time clocks and energy management systems.
1.3RELATED DOCUMENTS
The Keston Condensing Boiler must be ins talled in accordance with the current issue of
the Gas Safety (Installation and Use) Regulations (as amended after 1996), current IEEWiring Regulations, Building Regulations, Building Standards (Scotland) Consolidation,
and the Bye Laws of the local Water Undertaking.
In addition, due account must be taken to the following Codes Of Practice:
BS 6891:Gas Supplies
BS 6644:Installation of gas fired hot water boilers of rated input
BS 6880:Central Heating by LPHW
BS 7593 : Treatment of Water in Hot Water Central Heating
CP342.2:Centralised HW Supply
IM/2:Purging procedure for non-domestic gas installations
IM/16:Guidance for installation of gas pipework boosters and
compressors for customers premises
IM/22:Installation guide for high efficiency (condensing) boilers
(Industrial and commercial appliances)
BS 7593:Treatment of Water in Hot Water Central Heating
Systems
For Timber Framed Buildings please refer to The Institute of Gas Engineers
document IGE/UP/7:1998.
1.4PERFORMANCE DATA
KESTON 260KESTON 340
Max. Input (Gross CV)kW/(Btu/h)84.6/(288,650)110/(375,300)
Max. Output To Water (80/60C Flow/Return)kW/(Btu/h)76.1/(259,650)99.0/(337,800)
Max. Output To Water (60/40C Flow/Return)kW/(Btu/h)79.5/(271,250)104.0/(354,800)
Max. Output To Water (50/30C Flow/Return)kW/(Btu/h)82.9/(282,850)107.8/(367,800)
Burner Setting Pressure - Hot (Factory Preset) mbar/(in w.g)9.8/(3.9)13.0/(5.2)
3
Gas Consumption After 10 mins l/s / (Ft
(CV of Gas - 38.7 MJ/m
Max. Operating Flow Temp.
3
) / (1038 Btu/Ft3)
o
C82.0082.00
/hr)2.19/(278)2.84/(362)
Max. Head (Open Systems)m / (ft)30.50 / (100)30.50 / (100)
Max. Press. (Sealed System)Bar2.702.70
Min. Head (Open Systems)m3.03.0
Inlet Gas Pressurembar/(in w.g)20.0 / (8.0)20.0 / (8.0)
Gas Orifice Sizemm3.754.75
o
Recommended Temperature Differential
C10 to 1510 to 15
Required Water Flow Ratel/s 1.62.0
Electrical Supply230V 50Hz230V 50Hz
Power Consumption (Max)W12001200
Cabinet Heightmm12621262
Cabinet Widthmm10821082
Cabinet Depthmm354354
Weight - Fullkg / (lbs)165/(363)165/(363)
Weight - Emptykg / (lbs)150/(330)150/(330)
Flow and Return ConnectionRp 2" FRp 2" F
Gas ConnectionRp 1.25" FRp 1.25" F
Flue Pipe Size (nominal bore)mm / (in)100 / (4)100 / (4)
Air Intake Pipe Size (nominal bore)mm / (in)100 / (4)100 / (4)
Max. Air Intake Lengthm20.020.0
Max. Flue Outlet Lengthm39.039.0
Max. Total Flue Outlet and Air Intake Lengthm40.040.0
Type of GasG20 Natural Gas Only
Flue & Air Intake Pipe MaterialKeston Composite Pipe Only
Optimum Flue Gas CO2 Level%8.48.4
Destination CountriesGB/IEGB/IE
The boiler must be installed in m inim um
clearances shown to allow subsequent
servicing, and safe operation.
2.2SERVICE CONNECTIONS
Gas, water, air and flue pipe,
condensation, and electrical
connections are as shown. Gas : 1.25
inch BSP female. Flow/Return 2 inch
BSP female.
2.3POSITION
The Keston is not suitable for external
installation. The boiler may be installed
in any room or internal space, although
particular attention is drawn to the
requirements of the current IEE Wiring
Regulations and, in Scotland, 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.
All dimensions in mm.
1
540
127
127
1
Figur e 2.1.1
Minimum Clearances
Compartment installation is
permitted - such compartments
must be constructed in
accordance with BS 6798.
The wall on which the boiler is
mounted must be of suitable load
bearing capacity and must be
non-combustible.
Important : It is not
recommended to install the boiler
on a studded wall or similar - it is
possible that the vibration from
the fan would be amplified and
transmitted to other parts of the
property.
The Keston can be located
virtually anywhere desired
provided that all regulations are
complied with. Because of the
boiler's compact size and venting
flexibility, the installation is not
limited to a boiler room setting.
Before locating the boiler near a living space consider whether the sounds generated by
the boiler will be objectionable. The boiler may be located within a cupboard enclosure to
reduce noise levels if located within a living space.
2.4ELECTRICAL
2.4.1Electrical Connections
The boiler must be connected to 230V ~ 50Hz supply/controls as follows:
Mains Connection (rated at 10A)
On/Off User Control Link (volt free external control)
(230V)
Terminal 19-Module 1
Terminal 20-Module 2
NB:External monitoring controls must be configured to ignore
signal unless present for more than 5 seconds.
[pump on when boiler enabled]
Terminal 4-Live
Terminal 6-Neutral
Terminal 7-Earth
Wiring external to the boiler must be in accordance with current I.E.E wiring
regulations and local regulations.
The method of connection to the mains electricity supply must facilitate complete
electrical isolation of the boiler complying with the requirements of BS 1363.
There must be only one common method of isolation for the boiler and its control
system.The appliance must be connected to the 10A supply via a fused
double-pole switch having at least 3mm (1/8 inch) contact separation in both
poles, serving only the boiler and the system controls.
2.5GAS SUPPLY
A gas meter should be connected to the service pipe by the local gas supplier or their
contractor. An existing meter should be checked preferably by the gas region to ensure
that the meter is adequate to deal with the rate of gas supply required. Installation pipes
should be fitted in accordance with BS 6891. Gas consumption is given in Section 1.4.
The boilers are for use with NATURAL GAS (G20) ONLY.
Minimum/Maximum Natural Gas Pressure:
Natural gas pressure before the gas valve must be maintained at between 17.5 mbar (7 in
WG) and 22.5 mbar (9 in WG) while both modules are running.
Gas pressures above or below this level will lead to problems associated with the gas
valve's internal pressure regulator.
Supply pipes to the boiler must not be sized less than the boiler inlet connection
(1.25 in). Due consideration must be given to the supply pressure to other gas
appliances in the premises. Reduction in dynamic gas supply pressure will result in
ignition failures. Ensure gas supply pipe work is adequately sized for the length of
run from the meter to the boiler.
All piping must be installed in accordance with all applicable local and Water Supply
Bylaws for forced hot water heating systems.
Consideration must be given to pipe capabilities and pressure drop through the piping.
Water treatment must be carried out to BS 7593 : Treatment of Water in Hot Water
Central Heating Systems.
Pump isolating valves must be positioned as close to the pump as possible.
aThe Keston 260 and 340 are suitable for use on open, vented water systems with
combined feed and vent of 32mm nominal diameter.
bIt is preferable for use on sealed water systems, provided the appropriate
components required (see Section 2.7.2 Sealed Systems) are included in the
system.
cAny system must be thoroughly flushed clean of grease, dirt and debris, prior to
connection with the boiler. A strainer should be installed in the system return line
to collect any solder, or other debris, from the installation.
dAll water systems must be constructed to comply with requirements of the Local
Water Authority.
eJointing should be either with capillary, threaded or compression fittings. Pipes
should have a gradient to ensure air is passed easily to vent points and water
flows readily to drain points.
fDraining taps must be located in accessible positions which permit the draining of
the boiler and hot water storage vessel. Draining taps should be at least 22 mm in
nominal size and be in accordance with BS 2879.
AIR VENT POINTS
gThese must be fitted at all high points where air will naturally collect and must be
A typical system is shown in Figure 2.6.1 which includes a combined feed and
vent. Note the valve between the boiler flow and the open vent is a three way
blowdown type valve. Note that the minimum static head required is 3m at the top
of the system pipework. If the cold feed/vent is not brought to the low loss header
as shown, then the pressure loss across the heat exchanger may have to be
taken into account when estimating the static pressure. Cold feed/vent size must
comply with BS6644.
Although suitable for open vented systems with combined feed and vent
arrangements, the Keston is a low water content boiler. As such, any air
entrainment within the system water will produce boiler “kettling”. It is therefore
recommended, if in any doubt, to consider the use of sealed systems where
possible.
Safety Valve
Boiler
Keston
2.6.2Sealed Systems
Sealed systems must be designed in accordance with BS 6644 and BS 7074 Pt1.
A typical sealed system is shown in Figure 2.6.2. It must include :
IV
IV
AV
Low loss
header
IV
IV
DOC
Pump
Strainer
IV
System flow(s)
IV
System return(s)
Fill Point
Expansion
Vessel
Figure 2.6.2
Sealed System
(i)A safety valve fitted on the flow, adjacent to the boiler. It must be non
adjustable and preset to 3 bar. A drain pipe must be attached, at least as
big as the valve connection, and routed to drain in any area not
hazardous nor where it may be subject to freezing.
(ii)An expansion vessel complying with BS 4814 and sized on the basis of
the total system volume and initial charge pressure. The vessel must be
positioned as shown in figure 2.6.2.
(iii)A filling point, in accordance with local water authority requirements.
(iv)A method of system make-up (automatic or manual), in accordance with
local water authority requirements.
(v)The installation must be designed to work with flow temperatures of up to
All components of the system including the heat exchanger of any calorifiers used
must be suitable for a working pressure of 3 bar and a temperature of 110
Care should be taken in making all connections that the risk of leakage is
minimised.
2.6.3Hot Water System (if applicable)
The hot water storage vessel must be of the indirect type). DIRECT CYLINDERS
MUST NOT BE USED. Further guidance is provided in BS 1394.
2.6.4Balance Headers- Multiple Boiler Installations
Boiler water flows are critical to the operation of the boiler. If flow cannot be
maintained through the system pipework to meet the minimums required by the
boiler the boiler will “kettle” or even produce steam which can damage the heat
exchanger and invalidate the heat exchanger warranty. The implementation of a
balance header, as shown in the above schematics, is recommended to ensure
adequate water circulation is maintained through the boiler by the integral boiler
shunt pumps, irrespective of system conditions.
The size of the balance header is dependant on the number of boilers serving the
header. A guide to sizing is given below:
Total Boiler OutputHeader Diameter
up to 100kW3”
up to 200kW4”
up to 300kW4.5”
up to 400kW5”
o
C.
When assembling a balance header the following design considerations must be
observed:
a)Each boiler must have its own flow and return connection to the balance
header pipe. Common flow and return connections with other boilers will
cause reverse circulation effects to occur.
b)The minimum distance between the system flow and return connections
is 600mm
c)A drain off point should be fitted to the base of the header, along with
cleaning access, for sludge removal.
d)The top of the header should be vented.
2.6.5Air Elimination
In the initial charge of water to the boiler system and in all subsequent additions
of water to the system some air will be dissolved in the water. As the water is
heated the air is driven out of the solution and will collect in high spots in the
system. These air bubbles can interfere with pumping and heat transfer and
must be eliminated.
Installation of air bleed valves at the high spot(s) in the system will allow for air
elimination when filling the system and will allow re-venting in a day or so after all
air has been driven out of solution.
2.6.6Strainers
Debris in the heating system can cause noise if it enters the heat exchanger.
Fitting of a Y-strainer on the system return(s) will trap any debris left in the
system. The boiler guarantee does not cover heat exchanger failure due to debris
The Keston 260 and Keston 340 boilers are supplied complete with integral boiler
shunt pumps. However, these pumps are sized purely to provide adequate flow
rate through the boiler at the pressure drop caused by the boiler itself. No
allowance has be provided in the shunt pump size for system resistance.
A system pump(s) should therefore be selected sized to provide the required
system flow rate at the pressure drop created by the system index circuit.
2.7FLUE SYSTEM
2.7.1Design
Individual air supply and flue outlet
pipes are used. The material used
for flue outlet &/or air inlet must be
Keston Composite pipe of an
internal diameter not less than
100mm. Suitable pipe and fittings
can be obtained by Keston Boilers
Ltd via its appointed distributors.
Both flue outlet terminal and air
inlet terminal are supplied and are
illustrated in Figure 2.7.1.
Although the flue outlet and air
inlet terminals are identical great
care must be taken to ensure that
the air intake terminal is positioned
facing downwards or in such a way
as to ensure rain cannot enter the
air intake pipework. Boiler damage due to water entry through the air intake
pipework is not covered under the appliance warranty.
2.7.2Minimum & Maximum Lengths
The flue outlet and air inlet pipes must have lengths of at least 1m each.
The maximum lengths of both air inlet pipe and flue outlet pipe, when no bends
are used, are as detailed below.
Minimum Flue Length:0.5m
Minimum Air Intake Length:0.5m
Maximum Air Inlet Length:20.0 m
Maximum Flue Outlet Length:39.0 m
Maximum Combined Air Inlet:40.0 m
and Flue Outlet Length
Figure 2.7.1
Terminal Design
However, each bend used has an equivalent length that must be deducted from
the maximum straight length stated above. Knuckle bends must not be used.
o
A 92.5
sweep elbow is equivalent to 1.0m straight length.
one 92.5
elbows. Hence,
maximum length
permissible (ie a+b
in figure 2.8.2) =
20.0m - 1.0m - 1.0m
= 18.0m
Flue outlet uses one
92.5
Hence, maximum
length permissible
(ie c+d in figure 7 =
40.0m - 1.0 m - total
air inlet length =
39.0m - total air inlet
length.
2.7.3Slope
'Horizontal' flue outlet pipework
MUST slope at least 2.5
degrees (45 mm 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 this
case rain, etc, must
prevented from entering the
pipe. There must be no
troughs in any of the
pipework, whether it be air
inlet or flue outlet.
o
sweep
o
sweep elbow.
FLUE
d
c
Figure 2.7.2 : Flue & Air Maximum Length Example
To Terminal
To Boiler
be
AIR
b
a
Keston
Figure 2.7.3:
Flue Condensate Drain
Point Example
Tee Fitting
6 in min.
Due the low temperature of the flue gases further condensate will form within the
flue system. Drain points, with suitable traps, must therefore be incorporated
within the flue system at the base of vertical flue sections in excess of 4m. These
additional condensate drains must be run to discharge as detailed in section 2.10.
Such drain points can be formed using standard Keston Composite flue fittings.
Refer to the example in Figure 2.7.3.
2.7.4Terminations
Air inlet terminals must be facing downwards and positioned to ensure only fresh
air is drawn into the boiler. The air terminal must be located outside of the
building.
Drawing of combustion air directly from a ventilated boiler room will invalidate the
heat exchanger warranty.
The air inlet terminal must face downwards to prevent entry of rain into the air
intake pipework.
The flue outlet terminal is designed to face outwards but can, if desired, be
adapted to face in any direction BUT
must not be directed in the region of the air
inlet. Where the air and flue terminals are located in close proximity the flue
terminal should be located above the level of the air inlet terminal.
The two terminals are subject to the requirements of BS 5440 Pt 1 for clearances
from features of the building although some can be decreased to the values
indicated.
If either the air inlet or the flue outlet terminate at a height of less than 2m (6ft)
above ground level the termination must be protected by a suitable guard.
Suitable terminal guards can be obtained from Tower Flue Components Ltd or its
distributors.
The Keston Condensing Boiler, as with any condensing boiler, will generate
a condensate “plume” from the flue terminal in all weather conditions.
Consideration must therefore be given to the effect of this “plume” when
selecting a location for the flue terminal.
o
It is advisable for horizontal flue terminals to place a 45
elbow at the end of the
flue to direct the condensate plume up and away from the property.
Dimensions (mm)
etc.
Table 2.7.4Minimum Flue Terminations & Air Inlet Dimensions
2.7.5Clearances From Wall
Flue
Terminal
Air
Inlet
50500A Below or beside openable window, air brick,
7575B Below gutters, soil pipes, drain pipes.
50300C Below eaves.
50200D Below balconies or car port roof.
5075E From vertical drain or soil pipes.
50600F From internal or external corner.
100300G Above ground or balcony or roof.
100600H From surface facing a terminal
1,2001,200IFrom terminal facing a terminal.
1001,200J From opening in a car port.
1,5001,500K Vertically from terminal on same wall.
300300L Horizontally from terminal on same wall.
Flue outlet and air inlet terminations must be at least 60 mm and 95 mm
respectively from the wall face.
2.7.6Distance Between Flue Outlet & Air Inlet
There is no maximum - the terminations can be on opposite sides of the dwelling
if desired.
A minimum clearance of at least 500 mm must be left between the terminations.
2.7.7General Installations
All parts of the system must be constructed in accordance with BS 5440 Part 1,
except where specifically mentioned in these instructions.
All pipe work must be adequately supported.
All joints other than push-on or plastic compression connectors must be made
and sealed
with solvent cement suitable for Keston Composite pipes.
External wall faces and any internal faces of cavity walls must be made good.
2.8AIR SUPPLY
The Keston is a room sealed appliance and therefore does not require purpose provided
ventilation to the boiler room for combustion air.
2.9COMPARTMENT INSTALLATION
The casing temperatures of the Keston 260 and Keston 340 are very low. Due to this fact,
no compartment ventilation is required for cooling purposes.
2.10CONDENSATE DRAINAGE
Being a condensing boiler, the Keston is fitted with a condensate trap at the base of the
heat exchanger and flue assembly, with facility to connect to a drain point underneath the
appliance.
Use only plastic piping and do not reduce below 28mm internal diameter within the
dwelling. Condensate should preferably be drained into the sanitary waste system or,
alternatively, the rainwater system of the property.
Termination of the pipe must be either at a branch or stack internal to the building, or
externally at an open gully. Alternatively, discharge into a purpose made condensate
soakaway can be considered. Existing or purpose built drains must use suitable corrosion
resistant material as condensate is mildly acidic.
A minimum slope downwards towards the drain of 1 in 20 is essential. Freezing of the
termination and pipework must be prevented. Any drainage pipes outside the property
must be at least 32 mm inside diameter.
2.11UNDER FLOOR HEATING/WEATHER COMPENSATION
Both underfloor heating and weather compensating control demand reduced system
operating temperatures for some of all of the time the system is operating. Traditionally
this is achieved by used of mixing valves to reduce flow temperature by blending return
water.
The Keston Condensing Boiler provides increased operating efficiencies at low return
system temperature. Therefore, in the event the Keston boiler is serving only underfloor
heating or only weather compensated circuits at any time the boiler flow temperature
should be achieved by limiting the boiler temperature and dispensing with the use of a
mixing valve.
The low operating temperatures of this type of system lead to very good operating
efficiencies. In fact, under floor heating can produce in excess of 95% operating efficiency
from a Keston condensing boiler.
Read Chapter 2 - Boiler Location and decide upon the position of the boiler.
Installation of the boiler is straightf orward but consideration m ust be given to access to allow f lue
and air pipes to be pushed through walls and ceilings. The order in which the components are
installed will depend upon particular site conditions, but in general it will be easiest and most
accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal - this
is the sequence described.
3.1WALL MOUNTING BRACKET
aPlace the bracket on the wall
horizontally with the pre-drilled
holes at the bottom.
bDrill through the centre hole of
the bracket, plug the hole and
fix in position.
cUsing a spirit level make sure
the bracket is completely level
and mark the position of the
other screw holes.
dRemove the bracket and drill
the holes in the positions
marked. Plug these holes.
eScrew the bracket to the wall
using screws of an appropriate
size for the wall type (No. 12 x 2
inch wood screws normally
suffice).
3.2MOUNTING THE BOILER
aUsing the detachable side lift
handles supplied or via winch, lift and locate the upper rear lip on the boiler to the
boiler wall bracket.
bMove the boiler sideways to centralise the boiler on the bracket.
All dimensions in mm.
453
346
553
Figure 3.1 Wall Mounting Fixing Locations
3.3FLOOR STANDING FRAME - OPTIONAL
If the optional floor standing frame is selected the frame should first be assemble and
secured firmly to the plant room floor. Suitable assembly instructions are included with the
floor standing frame pack.
Lift the boiler and lower into position onto the frame.
3.4ASSEMBLY PRACTICE
Remove all plastic debris and burrs when installing air intake piping. Plastic filings caused
by cutting Keston Composite plastic pipe must not be allowed to be drawn into the
combustion air blower. Prevent dust entering the air intake when cutting on building sites.
Blower failure which is determined to be caused by plastic filings or other debris will not be
covered by guarantee.
3.5INSTALLING FLUE AND AIR PIPES
Remember the flue pipe must
achieved using 92.5
o
bends.
slope downwards back towards the boiler and this is best
aFrom the two connections on the boiler, mark the positions of the two holes for
the flue and air pipes on the wall(s) or ceiling. To allow access to drill the holes it
may be necessary to temporarily remove the boiler. If the boiler stays put then it is
imperative that the front doors are closed and the two plastic pipes capped off
whilst drilling. Under no circumstances must debris from the wall or cut pipes be
allowed to enter the appliance or the plastic pipework.
bDrill the two holes in the wall/ceiling, preferably using a core drill.
cAlways thoroughly deburr all pipes and, most important, remove shavings from
within the pipe.
d.Assemble the pipework from the boiler connections to the exit from the first
wall/ceiling (remount the boiler if removed). When pushing pipe through walls,
ensure grit and dust is not allowed to enter the pipe.
ENSURE PIPES ARE FULLY ENGAGED INTO SOCKETS.
Connect the condensate drainage system and fill the condensate trap by pouring
water down the boiler flue spigot ( See Section 3.6 Condensate Drainage).
Make the final connection of flue and air pipe to the boiler using push on
plastic couplings. Ensure that the connectors are set vertically otherwise
leakage of condensate may occur which will corrode the casing. Do not use
adhesive on the 'push on' end of connecting couplings.
e.Using the same methods drill any further holes (always covering existing
pipework), cut and assemble the pipework.
f.From outside, complete the two terminations - See Section 2.7 Flue System and
make good all holes.
g.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.
h.Check all connections for security.
3.6CONDENSATE DRAINAGE
Connect the condensate drainage system to the boiler. It is advisable to use a detachable
fitting at connection to the boiler to enable easy removal for servicing.
Fill the condensate trap by pouring water into the boiler flue spigot until water is seen to
flow freely from the condensate drainage system. Make the final connection of flue pipe to
the boiler.
Details are provided in Chapter 2 - Section 2.10 Condensate Drainage
Connection : 22 mm plastic pipe.
3.7WATER SYSTEM
Connect the flow and return pipework to the boiler. Details of system requirements are
given in Chapter 2 - Section 2.6 Water Systems.
Connections: 2" BSP F.
3.8GAS SUPPLY
Connect the gas supply to the appliance. Details of gas supply requirements are given in
Chapter 2 - Section 2.5 Gas Supply. Supply of adequate gas pressure
running) is critical to ensure reliable operation of the boiler.
Connections: 1.25 inch BSP F.
The entry point(s) for the electrical supply cable(s) is in the base of the appliance (see
Section 2.2 Service Connections fig. 2.1.2) via two cord grip bushes. Feed the cable(s)
through its bush and route inside the cabinet to the connection strip located to the front
bottom right of the cabinet.
1.The electrical supply must be as specified in Chapter 2 - Section 2.4 Electrical
Supply.
WARNING : THIS APPLIANCE MUST BE EARTHED.
2.All external controls and wiring must be suitable for mains voltage. Supply wiring
should be in PVC insulated cable not less than 1.0mm
(material code H05VV-F). Pump wiring from the boiler pump connection should
be in 3 core PVC insulated cable not less than 0.5mm
2
to BS 6500 Table 16
2
to BS6500 Table 16
(material code H05VV-F).
3.The permanent live supply connection may be via a 10 amp fused double pole
switch, serving only the boiler. (Refer to Chapter 2 - Section 2.4 Electrical Supply).
4.Securely tighten the terminal screws and route the cable through the re-openable
cable clips. Ensure all cables are secured and that the cord grip bush is tightened
to securely grip the main cable at entry to the cabinet.
The supply cable(s) must be connected to the main terminals as follows:-
Terminal 17 & 18-On/Off User controls volt free control link
The pump cable, if used, must be connected to the pump terminals as follows:Terminal 6N -Pump neutral wire (blue)
Terminal 4L-Pump live wire (brown)
Terminal 7E-Pump earth (yellow/green)
NB:The system circulating pump should not have a locked rotor current rating
exceeding 2A if powered via Terminal 4 of the boiler main terminal block.
Ensure connection is made such that if the cable slips in its anchorage the current
carrying conductors become taut before the earthing conductor.
3.10EXCHANGING A BOILER
Before removing an existing boiler add Fernox Supafloc , or equivalent cleaning agent, in
accordance with the manufacturers instructions. Open all radiator valves and fire the
boiler. When the system is fully heated, shut off the gas supply and drain down the central
heating system.
Important
The Keston condensing boiler contains components which could be damaged or blocked
by grease, dirt or solder etc. It is essential that sludge or scale is removed from an existing
system.
The guarantee provided with the Keston does not cover damage caused by system debris
or sludge.
Connect the new boiler as instructed in this manual and fit in accordance with Sections
3.1 to 3.8
For sealed systems, fill to a pressure of about 2.7 bar. Check the complete system for
water soundness. If leaks need to be rectified using flux or solder the system must be
flushed cold again before proceeding.
Reduce the pressure to the Initial System Design Pressure for sealed systems, if
applicable. Vent the system.
Gas Supply
The complete gas installation up to the boiler service cock must be checked for
soundness. BS 6891.
Electrical Installation
Carry out preliminary electrical safety checks, i.e. Earth continuity, Polarity, Resistance to
Earth, Short Circuit using a suitable test meter.
Initial Firing
The gas pressure setting is factory adjusted to within the required range and
should not normally need re-adjustment. If the reading is incorrect then check such
factors as soundness of the air and flue pipe joints, pressure sensible joints and the gas
inlet pressure (20 mbar required). If all joints are sound and the gas inlet pressure is
satisfactory set the gas pressure. Full details of this procedure are given in Section 4.6
Checking The Gas Pressure. This will ensure that combustion is good enough to allow
combustion fine tuning to take place.
Combustion Fine Tuning
It is advisable on all
carbon dioxide (CO
installations that the combustion quality is checked by measuring the
), or oxygen (O2), level. This procedure is detailed in Section 4.7
2
Combustion Fine Tuning. Badly tuned combustion will lead to reduce the life of the boiler
and invalidate the warranty.
Important:
This condensing boiler c ontains components which could be dam aged or block ed by grease, dirt,
solder etc., from the water system. The following commissioning procedures must be followed
precisely.
4.1INITIAL FLUSHING
All waterways within the Keston are either copper, bronze or high alloy stainless steel. As
a result standard water treatment chemicals for conventional central heating boilers are
suitable. In any event reference must be made to BS 7593 : Treatment Of Water In Hot
Water Central Heating Systems.
a.Disconnect the boiler from the system at the flow and return connections and
temporarily
b.Flush the entire system until clean water is discharged, free from dirt, flux, solder
etc. The use of a flushing chemical is recommended, e.g. Fernox Supafloc.
Sludge and scale must be removed from an existing system. Boiler failure due to
system debris or sludge shall invalidate the guarantee.
c.Connect the system to the boiler and fill in accordance with Section 2.6 - Water
Systems. At this stage, for sealed systems, fill to a pressure of about 2.7 bar.
d.Check the complete system for water soundness. If leaks need to be rectified
using flux and solder, the system must be flushed cold again before proceeding.
e.Reduce the pressure to the Initial System Design Pressure for sealed systems, if
applicable. Vent the system
link the flow and return pipes on the system.
4.2GAS SUPPLY
The complete gas installation up to the boiler service cock must be checked for
soundness. BS 6891.
4.3ELECTRICAL INSTALLATION
Carry out preliminary electrical safety checks, i.e. Earth continuity, Polarity, Resistance to
Earth, Short Circuit using a suitable test meter.
4.4INITIAL FIRING
Important
Checking the gas pressure to the pre-mix burners requires a special procedure, outlined
below, which must be carried out.
a.Purge the gas supply in accordance with BS 6891 & IM/2.
b.Vent the water system.
Important:
Keston heat exchanger module consists of a single coil which can trap an air
The
pocket. Great care must be taken to ensure that water flow has been established
through the heat exchanger and thus ensuring no air pockets remain in the heat
exchanger and pipe work. Firing the boiler while an air pocket exists in the heat
exchanger could damage it.
c.Turn both the integral gas service cocks to ON.
d.Turn on the electrical supply, setting any external controls to call for heat.
e.Set the main boiler On/Off switch to “ON” and adjust the set point temperature to
a value above actual flow temperature. (adjustment is made by holding in the
press button located below the control knob and adjusting the control knob until
the required set point temperature is displayed. Releasing the press button will
cause the control knob to be ineffective and the display to register actual flow
fSet the left hand module on/off switch to "ON". The amber light will illuminate on
the On/Off switch, the red “lockout” light will illuminate for approximately 2
seconds. The module blower and pump will start and, after about 15 seconds, a
spark will light gas at the main burner, provided all air has been purged from the
gas supply to the boiler. When the burner is lit and the boiler is operating normally
the green (run) lamp, the upper lamp adjacent to the flame symbol, will be
illuminated indicating successful ignition (If it does not and the green lamp is
extinguished after 10 seconds, air is indicated - turn off and repeat the
procedure).
If ignition does not occur, the green (run) lamp, the upper lamp adjacent to the
flame symbol, will be extinguished and, at approximately 1 minute intervals, the
electronic ignition system will make two further attempts to light the burner.
If the ignition is successful and the boiler is operating normally, the green (run)
lamp, the upper lamp adjacent to the flame symbol lamp will remain illuminated.
If after three automatic attempts the boiler still fails to ignite, the green (run) lamp,
the upper lamp adjacent to the flame symbol, will be extinguished, the blower will
post purge for 120 seconds and the red (lockout) lamp will illuminate.
If, after five manual attempts (to allow for purging of any air in the gas line), the
boiler still fails to ignite (indicated by the red (lockout) lamp) refer to Section 5.2 Fault Finding Flow Chart.
gTurn of the on/off switch for the left hand module and repeat step (f) for the right
hand module.
hCheck for gas soundness between the gas service cocks and connection to
each burner manifold.
4.5HOT FLUSHING
a.Allow the system to heat up, checking for water soundness.
b.Follow instructions provided with the cleaning agent, ie Fernox Supafloc. Turn off
the boiler and flush the water system while still hot. Thoroughly flush the system
with clear water.
c.Refill the system using a quality water treatment such as Fernox MB1. For sealed
systems, fill to the required Initial Design Pressure.
4.6CHECKING THE GAS PRESSURE
With each module running measure each
burner pressure at the module burner
pressure test nipple.
The gas setting is factory adjusted to within
the required range and should not normally
need re-adjustment. If the reading is
incorrect then check such factors as
soundness of the air and flue pipe joints
and the gas inlet pressure (20 mbar
required). If all joints are sound and the gas
inlet pressure is satisfactory remove the
brass dust cap covering the burner
pressure adjustment screw on the gas
valve (See fig. 4.6). Set the gas pressure to
the required value as stated on the
databadge by turning the exposed burner
pressure adjustment screw (clockwise will increase burner pressure, anti-clockwise will
decrease burner pressure). This will ensure that combustion is good enough to allow
combustion fine tuning to take place. Replace the brass dust cap to cover the burner
pressure adjustment screw.
Although the gas pressure is preset at the factory differing flue arrangements may require
fine tuning of the gas pressures to produce the best combustion and ensure long burner
life. It is advisable to check proper combustion by measuring gas input and the level of
carbon dioxide, or oxygen, in the flue outlet from the boiler. Overfiring or underfiring the
burner will reduce the longevity of the appliance.
Carbon dioxide is a colourless, odourless gas produced by all combustion processes.
When the Keston condensing boiler is operating properly carbon dioxide (CO
be between 8.2 and 8.5% CO
for natural gas.
2
) levels will
2
To measure CO
levels in the Keston boiler remove the 1/8" plug from the flue outlet pipe
2
inside the boiler (item 101, fig. 5.7.2). Insert the probe of a combustion analysis meter and
sample the gases as instructed in the test equipment's instructions.
If the CO
levels need raising increase the gas output by turning the brass screw, under
2
the metal cap in the front of the gas valve, clockwise. Reduce CO
screw anti-clockwise.
levels do not respond to adjustments the burner is probably running with too much
If CO
2
gas pressure. If, for instance, a clockwise adjustment to the brass screw in the gas valve
produces a decrease in CO
the burner is too fuel-rich and not enough oxygen is present
2
for proper and complete combustion.
4.8HANDING OVER TO THE USER
It is important to fully explain the following :
a.Procedure to light and turn off the boiler, including isolation of the electrical supply
if necessary.
b.The function of the lockout feature must be explained :
If the a red light only is illuminated for more than 10 seconds, this means that the
module has failed to light. Turn off the module and wait 20 seconds. Turn ON
again and wait.
i)If lockout recurs immediately then the gas supply should be checked as
ON, otherwise consult a Service Engineer.
ii)If it is not possible to relight, the module must be isolated and a Service
Engineer called in to rectify the fault.
c.Advise that a reduction in the water pressure reading on the gauge, for sealed
systems, indicates a leak which should be rectified before further use.
d.Advise that the appliance should be serviced by a competent person at least once
a year.
e.Advise on frost precautions.
f.Hand over User Instructions.
When the power supply is established to the boiler and the main boiler on/off switch is in
the "on" position the main on/off switch will be illuminated. Subsequently when the
external controls are calling for heat, power will be fed back to the boiler connection strip
at terminal 18. If the integral sequence controller detects the boiler flow temperature is
below the required set point, one of the modules will be enabled causing that modules
on/off switch, subject to being in the "on" position, to be illuminated. Provided all module
temperature thermostats and pressure switches are closed, power will be fed to pins 1 & 2
on the module ignition control box, initiating the following sequence.
(1)The module lockout lamp (red) will be illuminated
(2)The fan will start.
(3)When the fan reaches running speed, the Air Pressure switch, normally open, will
close which will start the ignition sequence and extinguish the red lockout lamp.
(4)After a pre-purge period of about 15 seconds, the module gas valve will open to
allow gas to mix with the air at the suction side of the fan and the ignition spark
will occur at the main burner.
(5)When the burner ignites, the flame is detected by the control box through the
combined flame sensor/ignitor and the ignition spark is stopped. The boiler run
lamp (green), the upper lamp adjacent to the flame symbol, will be illuminated.
The boiler is now in its normal run condition.
(6)The burner will continue to operate until the gas valve interrupts the gas supply.
The gas valve will be closed by the control box if power is interrupted to the boiler
by any external control or the boiler thermostat. If an interruption to the gas supply
causes loss of the flame, the control box will pause for approximately 10 seconds
and then attempt to re-ignite the unit. If this attempt fails, i.e. due to continued
lack of gas supply, the module will make two further attempts to ignite at intervals
of approximately 1 minute and will then go to a lockout state (red lamp illuminated
only). Once the gas supply has been resumed the module can be reset by turning
the module off and then on again on the boiler control panel.
(7)The module can also be shut down by any of the flow limit, flow overheat and the
flue overheat thermostats, gas low pressure switch and by the low water pressure
switch.
In such an event the green (run) lamp, the upper lamp adjacent to the flame
symbol, will be extinguished and only the red (lockout) lamp will be illuminated.
Dependant on the system loading the integral boiler sequence controller may enable the
other module at any time, subject to that modules on/off switch being in the "ON" position.
The sequence of operation shall be identical to that described above.
Any failure of the boiler to sequence in the above manner should be investigated using the
following trouble shooting flow diagram.
Before attempting any electrical fault finding, always carry out preliminary electrical system
checks. On completion of any service/fault finding task which has required the breaking
and remaking of electrical connections, the checks, earth continuity, polarity, short circuit,
resistance to earth must be repeated.
* The integral sequence control can be temporarily by-passed for fault diagnosis purposes
by moving the module link wire from module terminal 8 to module terminal 7.
To check continuity connect one probe to a neutral and
use the other probe to check 230V AC
START
Is there 230V at
terminals 1, 17 & 18?
YY
I s there 230V at the module ON/OFF
sw itch (both terminals) ?
I s there 230V at the module
return thermostat (both
terminals) ?
Y
I s there 230V at the module
flue protection thermostat
(both terminals) ?
YYY
Is there 230V at the gas
low pressure switch
(both terminals) ?
N
N
N
N
Check external controls
and supply.
N
Faulty switch -
Replace
Module is up to tem p erature.
Allow to cool O R pum p n ot
running OR faulty thermostat OR
faulty sequence controller ** -
Replace
Thermostat tripped.
Check thermostat, heat exchanger
and combustion.
C h eck ga s supply to boil e r
OR faulty sw itch - Replace
I s there 230V at the module
wate r pressure switch
(both terminals)?
Is there 230V at the flow
overheat thermostat
(both terminals) ?
Y
Is there 230V at the flow high
limit therm ostat (both terminals) ?
Y
I s there 230V at the module
thermal fuse links
(all terminals)?
N
N
N
Check water level in header tank
O R system pressure O R faulty
switch - replace.
Thermostat tripped.
Check flow rate, reset thermostat
OR faulty thermostat - Replace
N
Hi gh water temperature OR
faulty thermostat - Replace
High cabinet temperature.
Check all joints for product leakage -
reaplce therm al fuse link(s).
** The sequence controller can be temporarily by-passed by moving the link between terminals
8 and 9 on the module terminal block to terminals 7 and 9.
To ensure the continued safe and efficient operation of the boiler it is necessary to carry out
routine servicing at regular intervals. The frequency of the servicing will depend upon the particular
operating conditions, but it is recommended that an annual service should be carried out by a
qualified engineer.
It is the law that any service work must be carried out by competent qualified persons.
6.1Pre-Service Checks
It is recommended that an inspection should be carried out prior to shutting down the unit
for servicing. Open the front doors by turning the door catches 90 degrees. The following
items should be observed:
a.Smooth starting and running of each modules blower.
b.Smooth lighting of each modules burner.
c.Check for leakage of gas, gas/air or combustion products.
d.Check for condensate leaks.
e.Check the colour and appearance of the flame on each module. A sky blue flame
slightly off the burner gauze is normal. The burner itself should appear dark.
f.Check that the temperature differential between the flow and return pipes is less
than 15
g.Check for water soundness.
h.Inspect the flue vent and air intake pipework. Joints must be sound and all
pipework well bracketed.
i.Check that there is a steady fall back to the boiler from the flue pipe to allow
condensate to run back into the boiler.
j.With the boiler operating at a low return temperature (i.e. less than 50
that the condensate flows freely from the condensate line.
o
C. The temperature difference should be between 10oC and 15oC.
i)Turn off the boiler & shut off the gas supply to the boiler.
ii)Remove the pressure point screws from points A & B on the heat
exchanger for the left hand module. Attach a differential gauge.
iii)Turn on the boiler and wait for the fan to reach full speed. Obviously the
burner will not light.
iv)The pressure difference should be less than 10.0 mbar. If not clean the
burner.
v)Turn off the electrical supply to the boiler.
vi)Remove the pressure point screw from point C and transfer the tube from
point A to C, replacing the screw on point A.
vii)Turn on the electrical supply to the boiler (gas still off), wait for the fan to
reach full speed.
viii)The pressure difference should be between 9.5 mbar and 13.5 mbar
(lowest value represents new appliance). If not clean heat exchanger.
ix)Disconnect the gauge from point B. Refit the screw.
x)Read pressure of point C.
xi)The maximum pressure should be 3.5 mbar. If the pressure is greater
than this check the flue for blockage.
xii)Turn off the electrical supply to the boiler
xiii)Repeat the procedure for the right hand module.
xiv)Remove the pressure gauge tube and refit the screw.
xv)Open the gas service cock.
The procedure detailed below should be carried out on each boiler module in turn. The
integral boiler controller ensures both modules are loaded evenly over a year of operation.
a.Remove the burner head (Section 7.7) and inspect the burner appearance. Black
markings or other discolourations on the gauze indicate too much gas or a lack of
air. Any breakages or damage to the burner mesh indicate the burner must be
replaced.
b.If necessary, either due to discolouration or a high pressure differential between
points A & B in the pre-service checks, clean the burner with a mild
detergent and rinse under a hot running tap.
c.If necessary, either from visual inspection or a high pressure differential between
points B & C in the pre-service checks, clean the heat exchanger using a suitable
stiff plastic bristle brush, vacuum out any large particles and flush the heat
exchanger with fresh water until the water flowing from the condensate drain is
clear.
d.Remove the condensate trap (Section 7.10) and clean by flushing through with
clean running water.
e.Check the electrode mounted on the burner head. If the point is damaged or
burnt replace it.
Check that the spark gap measures 4 mm.
f.Replace the burner head, renewing the gasket if necessary, and reconnect the
gas/air supply and the ignition lead. Ensure the flanged gas/air supply joint is air
tight.
g.Turn on the electrical supply to the boiler and allow the boiler to reach operating
temperature levels.
h.Visually inspect the burner through the glass spy hole at the burner head (a small
mirror will prove useful).
i.Recheck the burner pressure by following the procedure detailed in Section 4.7
j.Remove the combustion test point plug from the flue pipe. This is situated around
150mm (6ins) from the bottom of the flue elbow at its connection to the heat
exchanger.
k.Using an approved combustion tester sample the flue products via the
combustion test point. CO
If such levels are not observed tune the combustion as described in Chapter 4 -
Commissioning. Also check the gas flow as detailed in Sections 4.8 and 4.9
l. Replace the combustion test point plug.
m.Check all joints for soundness up to the gas burner.
n.Repeat the procedure for the other module.
Flue
Heat
Exchanger
Shell
Pressure Test
Point C
&
Combustion
Test Point
Flue Overheat
Thermostat
household
levels of between 8.2% and 8.5% should be observed.
2
Installation & Servicing InstructionsPage : 36
WD53/0/1999Chapter 7 : Replacement Of Parts The Keston 260 and 340 Condensing Boilers
7. REPLACEMENT OF PARTS
INDEX
7.0GENERAL
7.1PRECAUTIONS
7.2ACCESS
7.3PROCEDURES - GENERAL
7.4ELECTRICAL
7.4.1ON/OFF SWITCH
7.4.2BOILER THERMOSTAT
7.4.3FLOW OVERHEAT, FLOW HIGH LIMIT & FLUE PROTECTION
THERMOMSTATS
i)Isolate the appliance (Section 7.1)
i)Gain access (Section 7.2)
iii)Remove the push on connectors from the switch taking note of the
correct positions.
iv)Press in the catches and push the switch forwards through the control
panel.
v)Reassemble (Section 7.3)
v)Check for correct operation of the switch.
7.4.2Module Boiler Return Thermostats (Fig. 5.7.2 item 84)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the push on connectors from the thermostat taking note of the
correct positions.
iv)Unscrew the two retaining screws and remove the thermostat.
v)Reassemble (Section 7.3)
NB:When fitting the new thermostat it is an advantage to smear a
thin film of heat sink compound between the thermostat and
mounting surface. This, combined with fitting the new thermostat
tightly to the mounting surface, ensures a good contact.
99) & Flue Protection Thermostats (Fig. 5.7.2 item 86)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the push on connectors from the thermostat taking note of the
correct positions.
iv)Unscrew the two retaining screws and remove the thermostat.
v)Reassemble (Section 7.3)
NB:When fitting the new thermostat it is an advantage to smear a
thin film of heat sink compound between the thermostat and
plate. This, combined with fitting the new thermostat tightly to the
plate, ensures a good contact.
7.4.4Module Water Pressure Switch (Fig. 5.7.2 item 88)
i)Isolate the appliance (Section 7.1)
ii)Shut off the water supply to the appliance.
iii)Gain access (Section 7.2)
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WD53/0/1999Chapter 7 : Replacement Of Parts The Keston 260 and 340 Condensing Boilers
iv)Drain the system to below the level of the appliance using the drain off
tap at the base of each heat exchanger.
v)Remove the push on connectors from the water pressure switch taking
note of the correct positions.
vi)Unscrew the pressure switch.
vii)Reassemble (Section 7.3).
viii)Refill the system (See Section 4 - Commissioning).
7.4.5Module Ignition Control Box (Fig. 5.7.4 item 183)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the HT ignition lead.
iv)Pull off the multi-pin connector away from the box.
v)Unscrew the two screws securing the control box to the casing and
remove the box.
vi)Reassemble (Section 7.3)
7.4.6Module Air Pressure Switch (Fig. 5.7.4 item 202)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the push on connectors from the air pressure switch taking note
of the correct positions.
iv)Disconnect the union to one plastic tube connection and pull off the
second plastic tube from the air pressure switch.
v)Unscrew the two screws mounting the air pressure switch body to the
boiler casing.
vi)Reassemble (Section 7.3)
NB:Ensure the yellow/green earth connection tag is securely fixed
behind the lower mounting screw.
7.4.7Module Combustion Blower (Fig. 5.7.3 item 154)
NB:This unit is heavy and must therefore be handled carefully when
replacing.
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Disconnect the wires connecting the blower in the blower motor
connection box.
vi)Remove the allen screws fixing the air intake pipe flange and the gas/air
mixture pipe flange to the blower.
v)Unscrew the three bolts fixing anti-vibration mounts to the combustion
blower through the base of the blower shelf.
vi)Reassemble (Section 7.3)
NB:When reassembling inspect any gaskets for damage and replace
if necessary.
vii)Reset the gas rate (See Section 4 - Commissioning)
7.4.8Module Gas Control Valve (Fig. 5.7.3 item 136)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the cover concealing the electrical connections on the front of
the gas valve.
iv)Remove the push on connectors exposed taking note of the correct
positions.
v)Remove the push on connectors to the gas low pressure switch taking
note of the correct positions.
vi)Remove the earth connection to the side of the gas valve.
vii)Remove the plastic air tube to the base of the gas valve.
viii)Remove the four allen screws securing the gas inlet flanged connections
to the gas control valve.
ix)Undo the four bolts fixing the base of the gas control valve to the gas
outlet block.
x)Remove the gas valve.
xi)Unscrew the gas low pressure switch at its connection to the gas control
xii)Reassemble (Section 7.3)
xiii)Reset the gas rate (See Section 4 - Commissioning)
7.4.9Module Gas Low Pressure Switch (Fig. 5.7.3 item 134)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the push on connectors to the gas low pressure switch taking
note of the correct positions.
iv)Unscrew the gas low pressure switch from the brass holder.
v)Reassemble (Section 7.3)
7.5MODULE GAS ORIFICE (Fig 5.7.3 item 144)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Unscrew and remove the brass plug from the gas outlet block.
iv)Remove the rubber seal from the injector housing.
v)Insert a flat blade screwdriver into the exposed hole and unscrew the gas injector.
vi)Check the injector is the correct size for the boiler size.
vii)Reassemble (Section 7.3)
NB: Ensure that the injector is screwed fully home
viii)Reset the gas pressure and combustion (See Section 4 - Commissioning)
ii)Gain access (Section 7.2)
iii)Remove the pull off HT lead to the spark ignition electrode.
iv)Remove the burner head (Section 7.7 steps iv) to vi)).
v)Undo the screws to the spark ignition electrode flange located on the burner
head and withdraw the spark ignition electrode.
vi)Reassemble (Section 7.3)
NB:When reassembling inspect the gasket for damage and replace if
necessary.
With the new spark ignition electrode in place it is essential to ensure the
gap between the tip of the electrode and the burner surface is 4mm.
Distances above or below 4mm will affect ignition performance. If
necessary gently bend the electrode taking care not to damage the
ceramic insulator.
7.7 MODULE BURNER HEAD & BURNER (Fig. 5.7.2 items 72 & 74)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the pull off HT lead to the spark ignition/flame detection electrode head.
iv)Remove the two allen screws fixing the flange gas/air mixture pipe connection to
the burner head.
v)Remove the five allen screws fixing the burner head to the top of the heat
exchanger.
vi)Withdraw the burner & burner head from the top of the heat exchanger.
vii)Unscrew the burner from the burner head taking care not to damage the burner
mesh. (grip the burner on the collet only).
viii)Reassemble (Section 7.3)
NB:When reassembling inspect any gaskets for damage and replace if
necessary.
Set the spark gap as detailed in Section 7.6
ix)Reset the gas rate (see Section 4 - Commissioning)
Installation & Servicing InstructionsPage : 43
WD53/0/1999Chapter 7 : Replacement Of Parts The Keston 260 and 340 Condensing Boilers
ii)Gain access (Section 7.2)
iii)Shut of the water supply to the appliance.
iv)Remove the burner head (Section 7.7)
v)Drain the system to below the level of the appliance using the drain off tap at the
base of the heat exchanger.
vi)Remove the boiler thermostat (Section 7.4.2)
vii)Remove the push on connectors to the water pressure switch, flow overheat
thermostat, flow high limit thermostat and flue protection thermostat taking note of
the correct positions.
viii)Remove the condensate trap (Section 7.10)
ix)Remove the pressure gauge phial located next to the drain off tap.
x)Disconnect the flow to the heat exchanger at the union on the heat exchanger
flow manifold.
xi)Undo the nut and olive of the isolating valve fitted directly on the heat exchanger
return pipe.
xii)Remove the nut fixing the strap retaining the base of the heat exchanger and pull
out the strap by unhooking it from its fixing behind the heat exchanger.
xiii)Remove the allen screw securing the top of the heat exchanger to its mounting
bracket.
xiv)Remove the heat exchanger assembly by pulling forward at the top and lifting up
and out of the appliance.
xv)Cut the olive from the heat exchanger return pipe and remove the compression
ii)Gain access (Section 7.2)
iii)Disconnect the condensate line from the base of the heat exchanger.
iv)Disconnect the condensate line from the base of the flue assembly.
v)Disconnect the condense lines from the projection of the condensate trap from
the base of the cabinet.
vi)Withdraw the condensate trap.
vii)Mop up any spilled condensate.
viii)Reassemble (Section 7.3)
NB:When re-fitting the condensate trap pour water onto the condensate hose
from the base of the heat exchanger until nearly full. Then reconnect the
condensate hose to the base of the heat exchanger.
ii)Gain access (Section 7.2)
iii)Unscrew the sight glass fitting from the burner head.
iv)Reassemble (Section 7.3)
7.13MODULE HT IGNITION LEAD (Fig 5.7.4 item 185)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Remove the lead from the electrode and the ignition control box.
iv)Reassemble (Section 7.3)
7.14MODULE AIR ORIFICE (Fig. 5.7.3 item 163)
i)Isolate the appliance (Section 7.1)
ii)Gain access (Section 7.2)
iii)Disconnect the flexible air intake hose from the air/gas manifold (Fig 5.7.3 item
164)
iv)Unscrew the air orifice grub screw (Fig 5.7.3 item 140) to release the air orifice.
v)Lift the air orifice from its seat in the air inlet manifold.
vi)Reassemble (Section 7.3)
NB:When replacing the air orifice ensure that the new orifice is seated with the