keston System S30 User guide

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Page 1

System s30

Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCY

MODULATING DOMESTIC CONDENSING

GAS SYSTEM BOILER

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

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

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

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

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

October 2017

UIN 215352 A05

Page 2

ERP DATA

SYMBOL UNITS 30

Condensing Boiler n/a n/a yes

Low Temperature Boiler n/a n/a no

B1 Boiler n/a n/a no

Cogeneration Space Heater n/a n/a no

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

Combination Heater n/a n/a no

Nominal Heat Output for Space Heating

Full Load P

Part Load P

Auxiliary Electricity Consumption

Full Load el

Part Load el

Standby P

Seasonal Space Heating Energy Efciency

Full Load

Part Load

Standby Loss P

Ignition P

4 kW 30.3

1 kW 9.9

max kW 0.048

min kW 0.013

SB kW 0.005

stby kW 0.055

ign kW 0

MODEL

% 89.8

% 98.2

Emissions NO

Annual Energy Consumption Q

Sound Power Level, Indoors L

x mg/kWh 29

HE GJ 93

WA dB 48

Installation and Servicing

Page 3

PRODUCT FICHE

KESTON SYSTEM S BOILER

Keston Heating

ERP DATA

SYMBOL UNITS MODEL

Condensing boiler Yes Seasonal Space heating efciency class A Rated heat output kW 30 Seasonal space heating energy efciency

Annual energy consumption Q Sound power level, indoors L

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%

ƞs

HE GJ 93

WA dB 48

% 93*

Solar Contribution (from che of solar device)

Collector Size

(in m2)

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

Seasonal Space Heating Energy Efciency of Package

Seasonal Space Heating Energy Efciency Class of Package

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

TOTAL: A+B+C=

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

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

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

 

Installation and Servicing

A+++

Page 4

Installation and Servicing

Page 5

NOTES FOR THE INSTALLER

FOR ANY TECHNICAL QUERIES PLEASE RING THE KESTON

INSTALLER/TECHNICAL HELPLINE : 01482 443005

NOTE. BOILER RESTART PROCEDURE -

To restart the boiler press the RESTART button. The boiler will repeat the ignition sequence if a heat

demand is present.

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ......... A04 (Jun 17) to A05 (Oct 17)

Page 11 - Section 1.7 - Location of Boiler

Compartment Installation - new para added regarding Braces.

Page 12 - Section 1.8 - Gas Supply

New para added checks to gas valve connections.

Page 24 - Section 2.10 - Assembly Practice

New Important note added after “Installing Flue and Air Pipes”.

Page 57 - Spare Parts

Note added ref to Propane Boiler.

USER GUIDE

Front Page

Addition of UIN, Mod Level & Date

Installation and Servicing

Keston reserve the right to vary specication without notice

Page 6

Installation and Servicing

Page 7

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 ................................................ 14

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

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

1.17 Boiler Assembly - Exploded View ...............................16

1.18 Unpacking .................................................................. 17

1.19 Front Panel Removal .................................................17

2 INSTALLATION .........................................................18

2.1 Flue System ............................................................... 18

2.2 Flue Installation Example Keston System S 30 .........20

2.3 Flue Installation Example Keston System S 30 .........20

2.4 Flue Termination Position ........................................... 21

2.5 Installing The Boiler .................................................... 22

2.6 Wall Mounting Template ............................................. 22

2.7 Preparing The Wall .....................................................22

2.8 Fitting The Wall Mounting Plate ................................. 23

2.9 Mounting The Boiler ................................................... 23

2.10 Assembly Practice ...................................................... 24

2.11 Fitting The Sleeving ...................................................25

2.12 Condensate Drain ...................................................... 26

2.13 Connections & Filling .................................................28

2.14 Electrical Connections ................................................ 29

2.15 Installer Wiring ...........................................................29

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

2.17 Fitting The Weather Compensation Kit ...................... 31

2.18 External Electrical Controls ........................................ 32

2.19 Fitting The Weather Compensation Kit ..................... 32

2.20 Wiring Diagram ..........................................................33

2.21 Commissioning And Testing ....................................... 34

2.22 Initial Lighting ............................................................. 35

2.23 General Checks .........................................................36

2.24 Restart Procedure ...................................................... 36

2.25 Accessing The Installer Mode .................................... 37

2.26 Handing Over ............................................................. 37

3 SERVICING

3.1 Servicing Schedule ....................................................38

3.2 Boiler Front Panel Removal / Replacement ............... 39

3.3 Fan and Venturi Assembly Removal and Cleaning .... 39

3.4 Burner Removal and Cleaning ................................... 40

3.5 Cleaning the Condensate Trap/Siphon ...................... 40

3.6 Cleaning the Heat Exchanger .................................... 41

3.7 Reassembly ...............................................................41

3.8 Replacement of Components ..................................... 42

3.9 Fan Replacement ....................................................... 42

3.10 Burner Injector Replacement .....................................43

3.11 Burner Replacement .................................................. 43

3.12 Return Thermistor Replacement ............................... 44

3.13 Ignition Electrode Replacement ................................. 44

3.14 Flame Detection Electrode Replacement ................... 45

3.15 Spark Generator Replacement ..................................45

3.16 Gas Control Valve Replacement ................................ 46

3.17 Condensate Trap / Siphon Replacement ................... 46

3.18 PCB Replacement ...................................................... 47

3.19 Draining the Boiler ...................................................... 47

3.20 Pressure Gauge Replacement ................................... 48

3.21 Safety Relief Valve Replacement ............................... 48

3.22 Pump Automatic Air Vent Replacement .....................48

3.23 Pump Head Replacement .......................................... 49

3.24 CH Water Pressure Switch Replacement .................. 49

3.25 Control / No Flow Thermistor Replacement ............... 49

3.26 Heat Engine Replacement ......................................... 50

3.27 Expansion Vessel Recharging & Replacement .......... 51

4 FAULT FINDING ........................................................ 52

4.1 Fault Finding Chart Main Menu .................................. 52

‘L1’-Flow Temp Ov’heat Lockout/No Water Flow Lockout

4.2

4.3 ‘L2’ - Ignition Lockout ................................................. 53

4.4 ‘L6’ - False Flame Lockout ........................................ 54

4.5 ‘F1’ - Low Water Pressure .......................................... 54

4.6 ‘F2’ or ‘Fn’ or ‘Ln’ - Flame Loss ..................................54

4.7 ‘F3’ - Fan Fault ........................................................... 54

4.8 ‘L4’ or ‘F4’ - Control / No Flow Thermistor Fault ......... 55

4.9 ‘F5 or L5’ - Return Thermistor Fault ........................... 55

4.10 ‘F6’ - Outside Sensor Fault.........................................55

4.11 No CH Operation ........................................................ 56

4.12 No Display .................................................................. 56

4.13 No HW ........................................................................ 56

5 SPARE PARTS .......................................................... 57

6 BENCHMARK & COMMISSIONING ......................... 58

... 53

Installation and Servicing

Page 8

SECTION 1 - GENERAL

Table 1 - General Data

Gas supply 2H - G20 - 20mbar

Gas Supply Connection 15mm copper compression

Injector Size (mm) 4.65

Flow Connection Central Heating 22mm copper compression

Return Connection Central Heating 22mm copper compression

Flue Terminal Diameter mm (in) 50 (2)

Average Flue Temp-Mass Flow Rate 69

Content (± 0.7) Max. CH 9.3 %

Min. CH 8.8 %

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

) 2.5 (36.3)

Electrical Supply 230 V ~ 50 Hz.

Power Consumption W 100

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

Water content litre (gal) 1.2 (0.26)

Packaged Weight kg 31.6

Maximum Installation Weight kg 26.2

Boiler Casing Size Height mm 700

Width mm 395

Depth mm 278

C - 13g/s

Table 2 - Performance Data - Central Heating

MIN MAX

Boiler Input :

Boiler Input ‘Q’ Nett CV kW 6.1 30.4

Gross CV kW 6.7 33.7

Gas Consumption m

(ft

/h 0.622 3.135

/h) (22) (111)

Boiler Output :

Non Condensing kW 6.1 30.3

C Mean Water temp.

Condensing kW 6.4 31.0

C Mean Water temp.

Seasonal efciency* SEDBUK 2005 91.1%

Seasonal efciency* SEDBUK 2009 89.6%

NOx Classication CLASS 5

* The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from

which it has been calculated have been certied by a notied body.

Note. Gas consumption is calculated using a caloric value of 38.7 MJ/m

(1038 Btu/ft3) gross or

34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a different caloric value:

a. For l/s - divide the gross heat input (kW) by the

gross C.V. of the gas (MJ/m

)

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

26.8

c. For ft

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

Key to symbols

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

PMS = Maximum operating pressure of water

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

13 C53

terminal, which admits fresh air to the burner and discharges the products of combustion to the outside. The fan is up stream of the combustion chamber.

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

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

d. For m

/h - multiply l/s by 3.6

Installation and Servicing

Page 9

SECTION 1 - GENERAL

Keston System S

Natural Gas only

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

(Benchmark No.)

30 41-930-45 86 CR 18

Destination Country: GB, IE

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be tted in accordance with the manufacturer’s instructions. Self-certication that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist.

Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page

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

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

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

Controls

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

Time and temperature control to hot water ........... N/A

Heating zone valves ................................................. 32

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

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

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

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

Flushing to BS.7593 ................................................. 15

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

Central heating mode

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

Page

Burner operating pressure ...................................... n/a

Central heating ow temp. ...........measure and record

Central heating return temp. ........measure and record

For combination boilers only

Scale reducer ........................................................... 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 ................................................ 26,35

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

NOTE TO THE INSTALLER:

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

Installation and Servicing

For assistance see Technical Helpline on the back page

COMPLETE

Page 10

SECTION 1 - GENERAL

1.1 INTRODUCTION

The Keston System S boiler is wall mounted, full sequence, automatic spark ignition, low water content, fanned ue, high efciency, condensing, system gas boiler.

Note. Due to the high efciency of the boiler a plume of water vapour will form at the ue terminal during operation.

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

30 6.1 to 30.3kW

The boiler is supplied fully assembled with circulating pump, pressure gauge, safety valve and CH expansion vessel.

A variable CH temperature control is tted on the user control.

The boiler includes as standard:

- Boiler frost protection

- Daily pump exercise

- Weather compensation

The boiler casing is of white painted mild steel with a white polymer front panel.

The boiler temperature control is visibly 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 Section 1.13 - Water & Gas Connection Diagram.

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.

1.2 OPERATION

When there is a demand for CH, the heating system is supplied at the selected temperature of between 30oC and 80oC.

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.

Installation and Servicing

Page 11

SECTION 1 - GENERAL

0.6m

Zone 0

Recessed window Zone 2

Ceiling

3G8913a

2.25m

Zone 1

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 Heating Systems in buildings: Design for water

based heating systems.

BSEN 12831 Heating Systems in buildings: Method for

calculation of the design heat load.

BSEN 14336 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.

Installation and Servicing

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/7:1998.

Bathroom Installations

This appliance is rated IP20.

The boiler may be installed in any room or internal space, although

particular attention is drawn to the requirements of the current IEE (BS.7671) Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland, with respect to

the installation of the boiler in a room or internal space containing

a bath or shower. For IE reference should be made to the current ETCI rules for electrical installations and I.S. 813.

If the appliance is to be installed in a room containing a bath or

shower then, providing water jets are not going to be used for cleaning purposes (as in communal baths/showers), the appliance must be installed beyond Zone 2, as detailed in BS.7671.

Compartment Installations

A compartment used to enclose the boiler should be designed and

constructed specially for this purpose.

An existing cupboard or compartment may be used, provided that

it is modied for the purpose.

Braces for compartments must be easily removable for service access.

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.

Page 12

SECTION 1 - GENERAL

Pressure drop (mbar )

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. Whilst the principle of the 1:1 gas valve ensures the Keston range is able to deliver it’s 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.

Gas Cock Pressure Drop

2.5

1.5

0.5

0 10 20 30 40 50

Heat Input to Boiler (kW)

IMPORTANT.

Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.

Installation pipes must be tted in accordance with BS.6891. In IE refer to IS.813.

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

1.12 CONDENSATE DRAIN

Refer to Sections 2.12

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 overow pipe. It is a universal tting to allow use of different brands of pipework.

Installation and Servicing

Page 13

SECTION 1 - GENERAL

395

100

400

700

2.5

2.5 from case

Air Flue

19862

155

30mm

Minimum Top Clearance

DATA PLATE

Underside View - Pipe Dimensions to Wall

Water Connections and Gas Connection

1.13

BOILER DIMENSIONS, SERVICES & CLEARANCES

The boiler connections are made on the boiler connection tails. Refer to Section 2.13.

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

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

Side and Rear Flue a. Provided that the ue hole is cut accurately, e.g. with a

core drill, the ue can be installed from inside the building

all dimensions in mm

where wall thicknesses do not exceed 600mm (24”). Where the space into which the boiler is going to be installed is less than the length of ue required the ue must be tted from the outside.

Installation from inside ONLY b. If a core boring tool is to be used inside the building the

space in which the boiler is to be installed must be at least wide enough to accommodate the tool.

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.

Installation and Servicing

Page 14

SECTION 1 - GENERAL

CH Return

Ecl 6053

Hose unions

Mains

water supply

Temporary hose

(disconnect after filling)

Additional stop valve

Double check valve

assembly

(

note direction of flow

)

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 86

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

pressure of 3 bar and a maximum design temperature of 110 oC.

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. This is the maximum system volume for the boiler expansion vessel. 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:

Through a temporary hose connection from a ‘draw-off’ tap, supplied from a service pipe under mains pressure. Where the

mains pressure is excessive, a pressure reducing valve must be

used to facilitate lling. When installing the lling device, it must be connected as below to fully comply with the water regulations.

This may involve the tting of an additional WRAS approved isolator valve to the mains supply.

i. Thoroughly ush out the whole system with cold water.

ii. Fill and vent the system until the pressure gauge registers 1.5

bar, and examine for leaks.

iii. Check the operation of the safety valve by raising the water

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

iv. Release water from the system until the minimum system

design pressure is reached; 1.0 bar if the system is to be prepressurised.

Safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar None 1.0

System volume Expansion vessel

(litres) volume (litres)

25 1.6 1.8

50 3.1 3.7

75 4.7 5.5

100 6.3 7.4

125 7.8 9.2

150 9.4 11.0

175 10.9 12.9

190 11.9 14.0

200 12.5 14.7

250 15.6 18.4

300 18.8 22.1

For other system volumes multiply by the factor across 0.063 0.074

Model 30

Max CH uutput kW 30.3

Water ow rate l/min 21.5 (gal/min) (4.7)

Temp differential

C 20

Head available m.w.g. 1.9 for system (ft.w.g.) (6.2)

Installation and Servicing

Page 15

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

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

C temperature drop at each radiator.

1.16 WATER TREATMENT

CENTRAL HEATING

The Keston System S range of boilers have 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 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.

For further information contact:

Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ +44 (0) 0870 601 5000

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

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

system has been thoroughly ushed.

Installation and Servicing

Page 16

SECTION 1 - GENERAL

506

504

227

224

503

505

313

215

309

308

306

217

307

401

218

211

304

214

223

325

302

104

114

117

118

507

203

105

231

229

228

116

115

219

324

135

110

113

120

108

121

206

205

204

131

1.17 BOILER ASSEMBLY - Exploded View

Note that item numbers are linked to the spares list

104 CH RETURN VALVE 105 CH FLOW VALVE 108 PUMP HEAD 110 PUMP AUTO AIR VENT 113 PRESSURE RELIEF VALVE 114 PIPE - PRV OUTLET 115 PIPE - FLOW 116 PIPE - RETURN 117 PIPE - EXPANSION VESSEL 118 EXPANSION VESSEL 120 FLOW GROUP MANIFOLD 121 BY-PASS KIT 131 WATER PRESSURE SWITCH 135 PRESSURE GAUGE 203 GAS COCK 204 PIPE - GAS INLET

205 GAS VALVE 206 PIPE - GAS INJECTOR 211 INJECTOR ASSEMBLY 214 VENTURI 215 FAN 217 BURNER 218 GASKET - BURNER 219 SUMP CLEAN OUT COVER 223 FLUE MANIFOLD 224 FLUE MANIFOLD TOP 227 CLAMP RETAINING FLUE TURRET 228 HOSE CONDENSATE INTERNAL 229 SIPHON TRAP 231 CONDENSATE OUTLET CONNECTION 302 PCB 304 CONTROL THERMISTOR (RETURN)

INSTALLATION

306 ELECTRODE IGNITION 307 ELECTRODE DETECTION 308 IGNITER UNIT 309 THERMISTOR CONTROL/NO FLOW 313 IGNITION LEAD 324 CONTROLS BOX LID 325 CONTROL BOX FRONT 401 HEAT ENGINE 503 WALL MOUNTING BRACKET 504 FRONT PANEL 505 FASCIA 506 BRACKET - GAS VALVE 507 BRACKET - EXPANSION VESSEL

Installation and Servicing

Page 17

SECTION 1 - GENERAL

Boiler Guarantee

HARDWARE PACK CONTENTS

Gas Valve Pack

1. Pipe - Gas Inlet

2. Washer - Gas (blue)

3. Gas Cock

Return Valve Pack

1. Pipe CH Return

2. Washer CH

3. Valve Return

Accessory Pack

1. Screw (x2)

2. Wallplug (x2)

3. Turret Clamp Screw (spare) (x1)

Flow Valve Pack

1. Pipe CH Flow

2. Washer CH

3. Valve Flow

Gas Valve Pack

Accessory Pack

Flow Valve Pack

Return Valve Pack

1.18 UNPACKING

Unpack and check the contents.

Pack A Contents

A Boiler B Hardware Pack Box C Wall Mounting Plate

D These Installation/Users Instructions

E Wall Mounting Template (located on internal protective packaging) F Safety Valve Drain Pipe G Boiler Guarantee & Registration Pack

INSTALLATION

Flue Pack Contents

A Flue Adaptor

B Air Spigot C Terminals - 2 off D Flue Sleeve E Wall Plate F Wall Seal G Outside Sensor H Screws - 4 off J Wall Plugs - 4 off

1.19 FRONT PANEL REMOVAL

1. Loosen the 2 screws retaining the front panel.

2. Pull the two clips downwards to disengage.

3. Pull the front panel forward and upwards to remove.

Installation and Servicing

Page 18

SECTION 2 - INSTALLATION

2.1 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/Wavin 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)

- Wavin OSMA PVC-C 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 Terrain 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

210.2 50mm muPVC straight coupling

204.2.135 50mm muPVC swept tee

Wavin OSMA PVC-C Solvent Weld System (50mm)

Wavin Code

2M073 3M lenght waste pipe 50mm

2M163 50mm x 45 deg bend

2M161 50mm x 87.5 deg bend

2M104 50mm double socket

2M190 50mm x 8.75 tee

/4 deg muPVC swept bend

Consideration MUST be given to expansion and contraction of the ue. Refer to Assembly Practice (Section 2.10) in this installation and Servicing Instructions for further guidance.

FLUE OUTLET

Installation and Servicing

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

Page 19

SECTION 2 - INSTALLATION

TERMINAL POSITIONS

Flue Pipe

Elbow

Minimum Separation

140mm

Acceptable

range of air

pipe siting

Terminal

Air Pipe

150mm

Accep t able Op erating Area

Keston System 30 - Flue & Air Pipe Length

Flue Pip e Length [m]

Air Pipe Length [m]

............. 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 opposite). It must not be sited above the ue pipe.

The ue and air pipes must extend by at least 40mm from the wall surface.

Condensing boiler emit a visible plume of water vapour from the ue terminal, this is normal. It is the responsibility of the installer to judiciously select a terminal location that does not cause a nuisance.

If either the ue or air terminal is below a height of 2m from ground level a terminal guard must be tted.

MAXIMUM LENGTHS

Due to the resistance presented by extended ue length a slight reduction in maximum boiler output will occur where combined ue and air lengths in excess of 18.0m (50mm muPVC) are used. In such cases the boiler output will be reduced by

0.6% per additional metre. The maximum lengths of both air inlet pipe and ue outlet pipe, when no bends are used, are as detailed in graph below. However, each bend used has an equivalent length that must be deducted from the maximum straight length stated in graph 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 graph 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.

Installation and Servicing

FLUE OUTLET

Page 20

SECTION 2 - INSTALLATION

Bracket at each 1 metre

1.5m

1.5º back to boiler

Air

Elbows 2 x 1m = 2m Straights 6+2+0.15 = 8.15m Total = 10.15m

Overall Flue / Air = 25.65m

Flue

Elbows 3 x 1m = 3m Straights 4+6+1.5+1 = 12.5m Total = 15.5m

Calculations

0.15m

2 4 6 8 10

Accep t able Op erating Area

Keston System 30 - Flue & Air Pipe Length

Flue Pip e Length [m]

Air Pipe Length [m]

10.15

15.5

2 4 6 8 10

Accep t able Op erating Area

Keston System 30 - Flue & Air Pipe Length

Flue Pip e Length [m]

Air Pipe Length [m]

15.65

14.5

2.2 FLUE INSTALLATION EXAMPLE KESTON SYSTEM S 30

2.3 FLUE INSTALLATION EXAMPLE KESTON SYSTEM S 30

Sleeve

Air

0.15m

FLUE OUTLET

Bracket every 1 metre

Air

4 x 90º elbows 4 Straight lengths 2 2

3.5 4

0.15

15.65

1.5º back to boiler

3.5m

1.5m

Calculations

Overall Flue / Air = 30.15m

1.5º back to boiler

2.5m

Flue

3 x 90º elbows 3 Straight lengths 2.5

1.5

3.5 4

14.5

Installation and Servicing

Page 21

SECTION 2 - INSTALLATION

2.4 FLUE TERMINATION POSITION

Twin Flue Positions

When Flue & Air Terminals are

less than 500mm apart

When Flue & Air Terminals are

more than 500mm apart

Flue min. spacing Air min. spacing Flue min. spacing Air min. spacing A Below an opening (1) 300mm 50mm 300mm 50mm B Above an opening (1) 300mm 50mm 300mm 50mm C Horizontally to an opening 300mm 50mm 300mm 50mm D Below gutters,soil pipes or drain pipes 75mm 75mm 75mm 75mm E Below eaves 200mm 50mm 200mm 50mm F Below balcony or car port roof 200mm 50mm 200mm 50mm

G From a vertical drain pipe or soil pipe 150mm 50mm 150mm 50mm H From an internal or external corner or to a boundary

200mm 50mm 200mm 50mm

alongside the terminal (2)

I Above ground,roof or balcony level 300mm 100mm 300mm 100mm

J From a surface or boundary facing the terminal 600mm 100mm 600mm 100mm

K From a terminal facing a terminal 1200mm 1200mm 1200mm 1200mm

L From an opening in the car port into the building 1200mm 100mm 1200mm 100mm

M Vertically from a terminal on the same wall 1500mm 1500mm 1500mm 1500mm N Horizontally from a terminal on the same wall 300mm 300mm 300mm 300mm O From the wall on which the terminal is mounted 40mm 40mm 40mm 40mm P From a vertical structure on the roof NA NA 300mm NA Q Above intersection with roof NA NA 150mm NA

,(1) In addition, for temperature and structural reasons, the terminal should not be nearer than 150 mm (fanned draught) to an

opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame

,(2) The reference to external corners does not apply to building protrusions not exceeding 450 mm, such as disused chimneys on

external walls for: fanned draught appliances

When running flue pipes vertically they MUST be a minimum of 140mm apart and termination MUST comply with Section 2.1 an 2.4.

A = 600mm B = 2000mm

The flue terminal shall not penetrate the shaded area of the roof

Pitched roof with structure

300mm

min

150mm

min

RF9807

If chimney penetrates dotted area such that A is less than 300mm, B shall not be less than 300mm.

TERMINAL POSITIONS

Flue Pipe

Minimum Separation

140mm

Elbow

150mm

Installation and Servicing

Vertical termination must have an elbow with terminal fitted directed from roof, 150mm above roof intersection with air taken from side wall or low level (min 500mm separation).

Air Terminal

Acceptable range of air

pipe siting

Air Pipe

Terminal

FLUE OUTLET

Page 22

SECTION 2 - INSTALLATION

..............FLUE TERMINATION

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.

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 System 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.

2.5 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.

2.6 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 rear ue hole centre for standard installation. 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. If tting a side ue extend the ue centre line onto the side wall and measure in 155mm for standard installation.

3. Mark onto the wall the following:

a The wall mounting plate screw positions (choose one from each group).

b. The position of the ue duct hole (see diagram below).

Note. Mark the centre of the hole as well as the circumference.

4. Remove the template from the wall.

FLUE OUTLET

Installation and Servicing

Page 23

SECTION 2 - INSTALLATION

3G9948

Example of fixing

3G10030

Section through wall

Note. Check all of the hole positions before drilling.

Rear flue only 60mm diameter holes

2.7 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.

2.8

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.

2.9 MOUNTING THE BOILER

1. Ensure the plastic plug is removed from the CH connections before mounting the boiler.

2. Lift the boiler onto the wall mounting plate (refer to the

Introduction section for safe handling advice), locating it

over the two tabs.

Installation and Servicing

FLUE OUTLET

Page 24

2.10 ASSEMBLY PRACTICE

SECTION 2 - INSTALLATION

Remove all plastic debris and burrs when installing air intake piping. Plastic llings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower. Prevent dust entering the air intake when cutting on building sites. Blower failure which is determined to be caused by plastic lings or other debris will not be covered by guarantee.

INSTALLING FLUE AND AIR PIPES

Important - When installing a replacement boiler, a new ue system is recommended.

However re-using the existing boiler ue installation is acceptable if the installer adheres to Section 2.3 Flue System

- Important, and also checks and conrms the following:

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

supplied with the boiler.

• Remove boiler front panel - Section 3.2.

• Remove air intake blanking plate by unscrewing 4 x M5

screws and put to one side, leaving sponge gasket in place.

• Fix air spigot to boiler using the 4 M5 screws, see diag.

below. Ensure sponge gasket is in place and not damaged.

• Insert the ue adaptor into the ue manifold on the top

of the boiler and secure using the clamp provided in

the packaging box, see diagram below. Ensure the condensate trap/siphon is lled with water.

• Measure, cut and check the air and ue pipes to pass to

the exit from the wall(s) or ceiling.

• Always thoroughly deburr all pipes and most important,

remove shavings from within the pipe.

• Assemble, using solvent weld cement, the pipework from

the boiler connections to the exit from the rst wall/ceiling, (remount the boiler if removed). When pushing pipe through walls, ensure grit and dust is not allowed to enter the pipe.

Ensure pipes are fully engaged into sockets and

solvent welded with no leaks.

• Using the same methods drill any further holes (always

covering existing pipework), cut and assemble the pipework.

• From outside, complete the two terminations - See

Section 2.1 Flue System and make good all holes. (Wall sealing collars are available to make good hole areas on the wall face (part number C.08.0.00.07.0).

• Support any pipes whose route could be displaced

either of its own accord or by accident. Any horizontal run over 1m or vertical runs of any length must always be supported. Brackets should be placed at intervals of approximately 1m. Brackets should be loose enough on the pipe to allow thermal expansion

and contraction movement.

• Flue pipework through walls MUST be sleeved to

allow thermal expansion and contraction movement.

• Check all connections for security and re-seal any joints

using solvent cement where soundness may be in doubt.

Note. It is equally important to seal the air inlet with solvent cement as the ue outlet pipe joints.

FLUE OUTLET

Installation and Servicing

Page 25

SECTION 2 - INSTALLATION

2.11 FITTING THE SLEEVING

1. Cut hole in wall.

2. Measure wall Thickness

3. Cut sleeve length to match wall thickness & remove burrs.

4. Grout sleeve into wall with ange on external face.

5. Slide ue pipe into sleeve, checking it is free to slide.

6. Slide Flexible wall seal over ue pipe and push centre ring up to sleeve ange when cold.

7. Locate wall plate over exible wall seal and clamp in place using the raw plug pack.

8. Afx ue terminal

9. During boiler test check that the ue end is free to expand and contract with exible wall seal.

Flue

Terminal

Flue Pipe

Flue Sleeve

Flue Sleeve Flange

Flexible

Wall

Seal

Wall

Plate

Installation and Servicing

FLUE OUTLET

Page 26

SECTION 2 - INSTALLATION

137

148

Condensate

Drain

Sink/basin/

bath or

shower

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Internal soil & vent stack

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

≥ 100

2.12 CONDENSATE DRAIN

This appliance is tted with a siphonic 75mm condensate trap

system that requires lling before operating the appliance for the 1st time or after maintenance.

INSTALLATION

All condensate pipework should conform to the following: a. Where a new or replacement boiler is being installed, access to

an internal ‘gravity discharge’ termination should be one of the

main factors considered in determining boiler location. b. Plastic with push t or solvent connections. c. Internal plastic pipe work a minimum of 19mm ID (typically

22mm OD)

d. External plastic pipe must be a minimum of 30mm ID (typically

32 OD) before it passes through the sleeved wall. e. All horizontal pipe runs, must fall a minimum of 45mm per metre

away from the Boiler. f. External & unheated pipe work should be kept to a minimum

and insulated with Class “O” waterproof pipe insulation. g. All installations must be carried out in accordance to the

relevant connection methods as shown in the “Condensate

installation diagrams” & BS6798. h. Pipe work must be installed so that it does not allow spillage

into the dwelling in the event of a blockage (through freezing) i. All internal burrs should be removed from the pipe work and any

ttings.

In order to minimise the risk of freezing during prolonged very cold spells, one of the following methods of terminating condensate

drainage pipe should be adopted.

Internal Drain Connections

Wherever possible, the condensate drainage pipe should be routed

to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc. See Figs 1 and 2.

Condensate Pump

Where gravity discharge to an internal termination is not physically

possible or where very long internal pipe runs would be required

to reach a suitable discharge point, a condensate pump of a

specication recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc. (g 3).

External Drain Connections

The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options

as described previously. An external system must terminate at a suitable foul water discharge point or purpose designed soak away. If an external system is chosen then the following measures must be adopted:

The external pipe run should be kept to a minimum using the most direct and “most vertical” route possible to the discharge point, with no horizontal sections in which condensate might collect.

- For connections to an external soil/vent stack see Fig 4. Insulation measures as described should be used.

- When a rainwater downpipe is used, an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse ow of rainwater into the boiler should the downpipe become ooded or frozen, see Fig 5.

- Where the condensate drain pipe terminates over an open

foul drain or gully, the pipe should terminate below the grating level, but above water level, to minimise “wind chill” at the open end. The use of a drain cover (as used to prevent blockage by leaves) may offer further prevention from wind chill. See Fig 6.

- Where the condensate drain pipe terminates in a purpose

designed soak away (see BS 6798) any above ground

condensate drain pipe sections should be run and insulated as

described above. See Fig 7

Unheated Internal Areas

Internal condensate drain pipes run in unheated areas, e.g. lofts basements and garages, should be treated as external pipe.

Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual.

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

Boiler

with 75mm

sealed

condensate

trap

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

Min Ø 19mm Internal pipe

Soil & vent stack

≥ 450

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

Minimum connection height up to 3 storeys

continued . . . . .

Installation and Servicing

Page 27

≥ 25 Below grate

CONT’D.......

SECTION 2 - INSTALLATION

Figure 3 - Connection of a Condensate Pump Typical

Method (see manufacturers detailed instructions)

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Condensate pump (Install in accordance with manufacturers instructions)

Visible air break

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

drain)

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

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Boilers without 75mm sealed

condensate trap must be fitted with

a 75mm trap and visible air break

Min Ø 30mm

Internal pipe

Water/weather proof insulation

Soil & vent stack

Minimum connection

≥ 450

height up to 3 storeys

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

INSTALLATION

Boiler

with 75mm

sealed

condensate

Min Ø 19mm Internal pipe

Min Ø 30mm Internal pipe

trap

Terminated and cut at 45º

43mm 90º male/ female bend

Water/ weather proof insulation

combined foul/ rain water drain

External air break

Air gap

68mm Ø PVCU Strap on fitting

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

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Min Ø 30mm Internal pipe

Water/Weather proof insulation

Max 3m external pipework

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Sink, basin, bath or

shower with integral

overflow and 75mm trap

≥ 100

Visible air break

at plug hole

Minimum 30mm

internal pipe

Water/ weather proof insulation

45º pipe

termination

Installation and Servicing

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

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

away from the house

≥ 25

≥ 300

≥ 500

Limestone chippings

Page 28

SECTION 2 - INSTALLATION

Yellow

Handle

Black Handle

CH Flow

Gas

Supply

CH Return

Safety

Drain Valve

3G9705

Safety Valve

Drain Connection

15mm elbow

or fittings

(not supplied)

Safety Valve Drain Pipe

2.13 CONNECTIONS & FILLING

NOTES.

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

Ensure each union is tted with bre seals provided. Do not subject any of the isolating valves to heat as the seals may

be damaged.

WATER CONNECTIONS CH

1. Connect the CH ow service valve provided in the hardware

pack to the threaded boss connection provided at the lower rear of the boiler.

2. Connect the CH return valve.

INSTALLATION

GAS CONNECTION

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

blue bre washer, which must not be overheated when making capillary connections. Refer to Section 1.13 for details of the position of the gas connection.

For additional gas supply information refer to “Gas Supply” on page 12.

SAFETY VALVE DRAIN

The safety valve connection, located at the bottom right-hand side of the boiler,

comprises a 15mm diameter stub pipe. The discharge pipe should be positioned so that the discharge of water or

steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring.

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

FILLING

IMPORTANT - when lling:

A. Ensure the dust cap on air vent

located at the rear of the pump

chamber is slightly unscrewed.

B. When lling, there may be a slight

water leak from the air vent therefore

electrical connections should be

protected.

1. Ensure that the CH isolating handles are open.

2. Fill and vent the system. Refer to Section 1.14 for lling and setting pressure procedure.

3. Check for water soundness.

Dust Cap

FLUE OUTLET

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

Installation and Servicing

Page 29

SECTION 2 - INSTALLATION

2.14 ELECTRICAL CONNECTIONS

WARNING. This appliance MUST be earthed.

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

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

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

2.15 INSTALLER WIRING

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

the supply cord is damaged, it must be replaced by the

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

Connecting the Switched Live to the Boiler

1. Consult the Plan diagrams overleaf.

2. Isolate the mains supply to the boiler

3. Remove the front panel. Refer to Section 2.19 .

Swing down the control box into the service position, unclip

and swing back the installer wiring cover and latch into the retaining clips. Refer to Section 3.8.

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

0.75mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for electrical installations.

Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm (1/8”) contact separation in both poles. The

means of isolation must be accessible to the user after

installation.

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

5. Connect the SL1 and SL2 switched lives to the terminal block as required.

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

FROST THERMOSTAT - WIRING

If parts of the system are vulnerable to freezing or the programmer is likely to be left off during cold weather, a frost stat should be tted in conjunction with a pipe thermostat.

INSTALLATION

INSTALLER CONNECTIONS (LHS) INSTALLER CONNECTIONS (RHS)

Installation and Servicing

FLUE OUTLET

Page 30

g/y

BOILER

L N

MAINS IN

SL 1

SL 2

L N E

CHONR/S

R/S /SC

HWONHW

OFF

C/S

L IN L IN

FUSED

SPUR

TIMER

CH ONL N

HW ON

HW OFF

Y PLAN

VALVE

g/y

BOILER

MAINS IN

SL 1SL 2

LNE

CHONR/S

R/SC/S

HWONHW

OFF

C/SONHTG

INLINL

FUSED

SPUR

TIMER

CH ONLN

HW ON

HW OFF

Y PLAN

VALV E

g/y

LNE

CHONR/SONHWONHW

OFF

C/S ON

FUSED

SPUR

TIMER

CH ONLN

HW ON

S PLAN

VALV E

S PLAN

VALV E

R/S

BOILER

MAINS IN

SL 1SL 2

EINLINL

HW OFF

C/S

......... INSTALLER WIRING

KESTON SYSTEM S BOILER WITH Y PLAN SYSTEM

INSTALLATION

Note. If an outside sensor is connected, then see diagram below

SECTION 2 - INSTALLATION

KESTON SYSTEM S BOILER WITH Y PLAN SYSTEM & OUTSIDE SENSOR KIT

KESTON SYSTEM S BOILER WITH S PLAN SYSTEM

Note. If an outside sensor is connected then;

• Fit Link wire ‘L2’

Installation and Servicing

Page 31

SECTION 2 - INSTALLATION

2.16 REPLACING PRE-FITTED MAINS CABLE

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

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

1. Isolate the mains supply to the boiler.

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

Swing the control box down into the service position, unclip and swing

back the installer wiring cover to latch into the retaining clips. Refer to Section 3.8.

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

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

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

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

reverse order.

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

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

NOTE. When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors, such that if the cord anchorage should slip, the current carrying conductors become taut before the earthing conductor.

INSTALLATION

Strain Relief

2.17 FITTING THE WEATHER COMPENSATION KIT

This kit provides the facility to apply outside air temperature control to the boiler water ow temperature which provides energy savings. The outside sensor provided measures outside air temperature and sends a signal to the boiler, which adjusts the maximum boiler ow temperature in response. If outside air temperature is greater than the system design temperature, the boiler ow temperature is reduced providing running cost savings. The boiler will operate in the condensing mode more frequently increasing savings.

Once the sensor is tted it is automatically detected.

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

- SUPPLIED AS STANDARD

FITTING THE KIT

Fitting the sensor

The air sensor should be located on an external wall of the building to be heated. Fix the sensor to a north/north-east facing wall to avoid direct radiation from the sun. The air sensor should be located to avoid any heating effect from the boiler ue.

To x the air sensor to the wall, unscrew the sensor box plastic cover and screw/plug the sensor body to the wall.

Wire a twin core 0.5mm an RH grommet located on the underside of the control box. Cable length between sensor and boiler should be no greater than 20m. Note that this connection is protected extra low voltage. It is not necessary for the person carrying out the wiring to be approved to Part P of the Building Regulations.

Avoid running this cable alongside mains voltage cables.

cable from the sensor to the boiler through

Outside Air Sensor

Installation and Servicing

Page 32

SECTION 2 - INSTALLATION

2.18 EXTERNAL ELECTRICAL CONTROLS

Wiring External to the Boiler

The fuse rating should be 3A.

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

Frost Protection

If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system.

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

Note. If the boiler is installed in a garage it may be necessary to t a

INSTALLATION

pipe thermostat, preferably on the return pipework.

EXAMPLE - Connection to Honeywell Evohome

(for additional information visit www.honeywelluk.com)

2.19 FITTING THE WEATHER COMPENSATION KIT - SUPPLIED AS STANDARD

CH OPERATION

The On and Off time control of central heating should be

controlled by a separate timer, connected to SL1 of the boiler.

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

The Room temperature can be adjusted using the Central Heating Temperature Control Knob on the boiler as follows. Essentially rotating the knob clockwise increases the room temperature and rotating the knob anti-clockwise decreases the room temperature.

The Room Temperature Setpoint in the associated graph is not directly related to the Actual Room Temperature but is the Desirable Room Temperature during a programmed CH period.

This can be adjusted between 5 and 30 degrees by the CH Potentiometer Knob on the Boiler when the Outside Temperature Sensor is connected. The graph only shows temperatures between 12 and 30 degrees for clarity.

Examples:

1. If the CH Potentiometer

Knob is set to display

22ºC on the Boiler Display the Room Temperature Setpoint will be 22ºC and the curve 22 will be followed, indicated

by 11th curve in from

the left hand side. So as

the outside temperature

varies the Flow Setpoint to the CH circuit will

increase and decrease

proportionally.

FLOW SETPOINT

2. If the CH Potentiometer Knob is rotated fully clockwise, the Boiler Display will read 30ºC and the Room Temperature Setpoint will be 30ºC hence the curve 30 will be followed.

3. If the CH Potentiometer Knob is rotated fully anticlockwise, the Boiler Display will read 5ºC and the Room Temperature Setpoint will be 5ºC. This is an unrealistic Room Temperature Setpoint for a CH period during an ON time, but it is calculated internally for managing Frost Protection for the system based upon Outside Temperature.

DHW OPERATION

When the system is in a timed on period for DHW and the tank stat is not satised, a call for heat will be generated on the switched live input SL2 of the boiler.

This will ensure that Weather Compensation adjustment is ignored at this time. The set point will be xed at 70 degrees.

The demand is indicated on the display by a ‘d’ and the burner

on symbol as appropriate.

ROOM TEMPERATURE SETPOINT

OUTSIDE TEMPERATURE

Installation and Servicing

Page 33

2.20 WIRING DIAGRAM

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

SERVICE

CONNECTOR

234

1 PE 1 5

2 N 2

1 2

3 L 3

Chassis

Earth

SL 1 - IN 4

2 5SL 1 - L

SL 2 - IN

SL 2 - L

3 6

1 2

4 7

2 3 4

123

3 2 1

123

PELV

230V 50Hz Mains

NO. 2 B2 24V

NO. 5 A2 24V

NO. 6 B1

NO. 4 B3

NO. 3 A3

NO. 1 A1

WPS 5V

FLOW +

FAN FEEDBACK

FAN PWM

FAN GND

PUMP FEEDBACK

PUMP PWM

NC GAS VALVE -

GAS VALVE +

TURBINE SIGNAL

TURBINE GND

TURBINE 5V

CH LIVE

IGNITION LIVE

PUMP LIVE

DHW LIVE

PUMP GND

X9X8

OWC +

OWC -

OPENTHERM +

OPENTHERM -

OPENTHERM 5V

CHIP COM BUS TX

CHIP COM BUS 24V

CHIP COM BUS GND

CHIP COM BUS 5V

CHIP COM BUS RX

AINS LIVE

MAINS NEUTRAL

AUXILIARY LIVE

IONISATION

FLOW -

DHW +

DHW -

3 2 1

WPS SIGNAL

WPS GND

FLUE +

FLUE -

RETURN +

RETURN -

black

grey

red

green

blue

brown

green/yellow

orange

pink

violet

yellow

-----------

g/y

KEY

WEATHER

COMPENSATION

OPEN

THERM

DETECTION

ELECTRODE

FAN

PUMP

RETURN

THERM

FLOW

THERM

GAS

VALV E

SPARK

GENERATOR

IGNITION

ELECTRODE

WATER

PRESSURE

SWITCH

g/y g/y

g/y

r bk bkw brbbr

y p

bk bk bk

SECTION 2 - INSTALLATION

INSTALLATION

Installation and Servicing

Page 34

SECTION 2 - INSTALLATION

Gas Supply

Gas Pressure

Test Point

2.21

INSTALLATION

COMMISSIONING AND TESTING

A. Electrical Installation

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

competent person.

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

3. After wiring the boiler, all grommets in the bottom panel MUST be in place to ensure that the boiler case sealing is maintained.

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

open all windows and doors, extinguish naked lights and DO NOT SMOKE.

GENERAL

Please Note: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type dened on the appliance data plate. DO NOT adjust the air/gas ratio valve.

Having checked:

- That the boiler has been installed in accordance

with these instructions.

- The integrity of the ue system and the ue seals, as described in the Flue Installation section.

Proceed to put the boiler into operation as follows:

B. Gas Installation

1. The whole of the gas installation, including the meter,

should be inspected and tested for tightness and purged in

accordance with the recommendations of BS. 6891. In IE refer to IS.813.

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

CHECK THE OPERATIONAL (WORKING) GAS

INLET PRESSURE

Set up the boiler to operate at maximum rate.

With the boiler operating in the maximum rate

condition check that the operational (working) gas

pressure at the inlet gas pressure

test point complies with the requirements - refer to “Gas Supply” on page 12.

Ensure that this inlet pressure can be obtained with all other

gas appliances in the property

working.

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

and the Benchmark Checklist completed. A ow chart to assist is provided on page 63.

ATTENTION !

IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE

BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED

AND LEFT WITH THE APPLIANCE

Installation and Servicing

Page 35

ºC

MIN

MAX

RESTART

BOILER BOILER

OFF ON

2.22 INITIAL LIGHTING

CH Flow

SupplyGas

CH Return

Safety

Drain Valve

Legend

A. Central Heating Temperature Knob B. Mode Knob C. Boiler Status D. Burner ‘on’ indicator E. Central Heating Economy Setting F. CH Flow Isolating Valve G. System Pressure Gauge H. Gas Inlet Pressure Test Point J. Gas Service Cock K. CH Return Isolating Valve L. Drain Valve M. Function Button N. Restart Button

SECTION 2 - INSTALLATION

G B C M N AD E

INSTALLATION

Note. Valves shown are in the open position.

1. Check that the system has been lled and that the boiler is not airlocked. Ensure the automatic air vent cap is open. Refer to Section 2.16.

Note.

It is important the burner is not operated before the system is fully vented of air. If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off.

2. Ret the boiler front panel. Refer to Section 3.2.

3. Check that the drain valve (L) is closed and that the CH isolating

valve (F and K) are OPEN.

4. Check that the electrical supply is OFF.

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

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

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

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

are calling for heat.

CENTRAL HEATING

9. Set the CH temp control (A) to “MAX” and turn the mode knob

(B) to “BOILER ON”. The boiler control should now go through its ignition sequence until the burner is established.

10. If the boiler does not light after 5 attempts the boiler will lock out and display fault code L 2 .

Restart the boiler (Refer to Section 2.24). The boiler will repeat

its ignition sequence. If restart occurs 5 times within 15 minutes then LC will be shown.

If power is removed this will be reset.

IMPORTANT

The gas input to the burner is regulated by the gas

valve according to the air ow produced by the fan.

It is NOT user-adjustable. Any interference to sealed

settings on the gas valve will adversely affect operation and render our warranty void.

For additional gas supply information refer to “Gas Supply” on page 12.

THE DISPLAY

The user control has one display to inform the user about

the status of the boiler. The LCD Display shows the status of the ame. If no ame is detected the ame symbol will not be visible. When the ame is detected the ame symbol will be visible permanently.

Below is a list with display function in normal operation.

Standby, no demand for heat present.

There is a demand for heat.

Boiler is active for boiler frost protection.

Boiler is in lockout for a specic error. Display will

show a number after the “ ” to indicate which error is detected.

F Boiler has a fault for a specic error. Display will

show a number after the “ detected.

Note: Boiler frost protection - boiler operates if the ambient temperature is below 5ºC until it reaches 19ºC.

” to indicate which error is

When the burner is established the ‘

with the ‘ON’ indicating central heating operation and the current ow temperature shown in the 2 digit display.

11. Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2.

Installation and Servicing

’ will be shown on the display

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

Page 36

SECTION 2 - INSTALLATION

ºC

MIN

MAX

RESTART

BOILER BOILER

OFF ON

G B C E D F A

2.23 GENERAL CHECKS

Make the following checks for correct operation:

CENTRAL HEATING (CH) MODE

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

The display should show:

‘

’ ‘ON’

2. Gas Rate

Check the boiler gas rate when the boiler is

at maximum output.

Check at the gas meter, with no other

appliance in use. Refer to Table 2 for gas rates.

INSTALLATION

3. Set the central heating external controls

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

The display should read:

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

WATER CIRCULATION SYSTEM

1. With the system COLD, check that the initial pressure is correct to the

system design requirements.

For pre-pressurised systems, this should be 1.0 bar.

With the system HOT, examine all water connections for soundness. The

system pressure will increase with temperature rise but should not exceed 2.5 bar.

3. With the system still hot, turn off the gas, water and electricity supplies to the boiler and drain down to complete the ushing process.

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

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

4. Rell and vent the system, add inhibitor (see Section 1.16), clear all air locks and again check for water soundness.

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

6. Balance the system. Refer to Section 1.15.

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

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

Note: The pump will operate briey as a self-check once every 24 hours in

the absence of any system demand.

WATER TEMPERATURES

Temperatures can be selected using the

CH temperature control (A)

2.24 RESTART PROCEDURE

Legend

A. CH temperature control B. Mode Control Knob C. Boiler Status D. Burner ‘on’ indicator E. Function Button F. Restart Button G. Pressure Gauge

Knob Setting CH Flow Temp ºC

Max 80

Min 30

To restart boiler, press the RESTART button (F)

Installation and Servicing

Page 37

SECTION 2 - INSTALLATION

2.25 ACCESSING THE INSTALLER MODE

To access Installer Mode press the function button and “RESTART” Buttons together for more than 5s.

1. The last 3 faults will be shown See Section 4.1 for Fault Code descriptions

2. “SL” will be shown To run the burner at minimum rate press “RESTART”, otherwise

press the function button.

3. “SH” will be shown To run the burner at maximum rate press “RESTART”, otherwise

press the function button.

4. “VF” will be shown To activate the venting function press “RESTART”, otherwise press

the function button.

The venting function runs for 5 minutes before automatically

returning to normal operation

The Pump alternates between being on for 50s and then off for 10s

2.26 HANDING OVER

5. “dU” will be shown

press the Function button

6. “P1” will be shown To set the minimum CH pump speed to 100% press “RESTART”,

otherwise press the function button.

7. “P7” will be shown To set the minimum CH pump speed to 70% (default) press

“RESTART”, otherwise press the function button to Exit.

INSTALLATION

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

1. Hand the User Instructions to the householder and explain his/ her responsibilities under the relevant national regulations.

2. Explain and demonstrate lighting and shut down procedures.

3. The operation of the boiler and the use and adjustment of all

system controls should be fully explained to the householder,

to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption.

Advise the User of the precautions necessary to prevent

damage to the system and the building, in the event of the

system remaining inoperative during frosty conditions.

4. Explain the function and the use of the boiler heating controls.

10. After installation and commissioning please complete the

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

IMPORTANT

11. A comprehensive service should be carried out ANNUALLY.

Stress the importance of regular servicing by a Gas Safe

Registered Engineer. In IE servicing work must be carried out by a Registered Gas Installer (RGII).

12. Inform the householder of the guarantee/registration found

within the envelope pack and the requirement to register it to receive the full benet of the warranty.

5. Explain the function of the boiler fault mode.

Emphasise that if a fault is indicated refer to “Fault Codes” in

the User Guide.

6. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for economic use of the system.

7. If a timer is tted draw attention to the timer Users Instructions and hand them to the householder.

8. Loss of system water pressure

Explain that the dial on the boiler indicates the central heating

system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated. Explain the re-pressurising procedure and if

unable to re-pressurise or if the pressure continues to drop a

registered local heating installer should be consulted.

9. Explain Boiler restart procedure.

Installation and Servicing

Page 38

SECTION 3 - SERVICING

3.1 SERVICING SCHEDULE

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

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

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

To ensure the continued safe and efcient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually.

It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be carried out by a Registered Gas Installer (RGII).

Note. In order to carry out either servicing or replacement of components the boiler front panel must be removed. Refer to Section 3.2.

PRELIMINARY INSPECTION

1. Light the boiler and carry out a pre-service check, noting any

operational faults (refer to appropriate fault nding chart as necessary).

2. Check the ue terminal (and terminal guard if tted) is undamaged and clear of any obstruction.

3. Check combustion by connecting the ue gas analyser to the ue gas sampling point as shown in the diagram and measure CO and CO

2 at maximum rate. Repeat at minimum rate.

If the CO / CO

“Cleaning Procedure”.

If the CO / CO

“Check Procedure”.

2 ratio is greater than 0.004 please proceed to

2 ratio is less than 0.004 please proceed to

CHECK PROCEDURE

1. Check all water and gas joints for signs of leakage. Remake any

suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly relled, vented and re-pressurised.

SERVICING

2. Proceed to “IMPORTANT”.

CLEANING PROCEDURE

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

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

Section 3.5 & 3.6.

Check the main injector for blockage or damage. Refer to Section 3.3.

4. The cleaning procedures are covered more fully in Sections 3.3 -

3.7 and MUST be carried out in sequence.

5. Proceed to “IMPORTANT”.

Do not operate the boiler if the front panel is not tted.

IMPORTANT

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

ensure the trap is relled with water before re-assembling.

GENERAL

Please Note: During routine servicing, and after any

maintenance or change of part of the combustion circuit,

the following must be checked:

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

- The integrity of the boiler combustion circuit and the relevant seals

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

- The gas rate

- The combustion performance.

COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE

Please Note: BS 6798 Specication for installation and maintenance of gas-red boilers of rated input not exceeding 70kW net advises that:

- The person carrying out a combustion measurement should have been assessed as competent in the use

of a ue gas analyser and the interpretation of the results.

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

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

covers the use of electronic portable combustion gas

analysers in accordance with BS7967, Parts 1 to 4.

Flue

sampling

point

2. After completing the servicing or exchange of components always test for gas tightness.

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

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

Installation and Servicing

Page 39

SECTION 3 - SERVICING

3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT

REMOVAL

1. Loosen the two screws retaining the front panel.

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

and upward and remove.

view from bottom of boiler

REPLACEMENT

3. Hook the panel onto the top retaining clips.

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

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

5. Re-tighten the two retaining screws.

view from top of boiler

3.3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

1. Disconnect the electrical leads from the fan.

2. Remove the clip from the gas control valve

outlet and ease the pipe upwards rotate and then ease down to remove.

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

4. Lift off fan and venturi assembly.

5. Undo the two M4 screws and release the

nozzle assembly.

6. Inspect the injector for blockage or damage.

7. Inspect fan outlet sealing gasket and replace

if necessary.

Injector

SERVICING

Installation and Servicing

Page 40

SECTION 3 - SERVICING

3.4 BURNER REMOVAL AND CLEANING

1. Ensure the sump is fully drained. Refer to Section 3.17.

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

ue manifold.

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

4. Remove the 2 burner front xing screws and loosen the 2 rear extended nuts by at least ten turns.

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

IMPORTANT

The burner head is a ceramic plaque construction. Care must be taken to ensure that the burner is not placed down upon

its face as this may cause damage to the ceramic.

6. Brush off any deposits that may be on the ceramic with a

SOFT brush.

7. Inspect the sealing gasket around the burner for any signs of damage. Replace as necessary.

SERVICING

3.5 CLEANING THE CONDENSATE TRAP/SIPHON

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

2. Disconnect the condensate drain pipe.

3. Turn the siphon clockwise to disengage and lift to

remove.

Note. Keep siphon upright when removing

4. Clean siphon with water.

5. Re-assemble in reverse order.

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

Installation and Servicing

Page 41

SECTION 3 - SERVICING

3.6 CLEANING THE HEAT EXCHANGER

Note: Ensure the condensate trap/siphon

is fully drained before cleaning. Refer to Section 3.17.

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

2. It is advisable to replace the sump cover

prior to the water ush process.

3. Thoroughly ush the heat exchanger by pouring water into the top of the

combustion chamber ensuring the full top

area is covered.

4. Remove the sump cover and clean loose deposits from the sump.

5. Inspect the ignition and detection

electrodes. Ensure that they are clean

and in good condition - replace if

necessary.

6. Re-t the ignition and ame detection

electrodes, ensuring that both earth tabs

are tted to ignition electrode.

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

Ignition Electrode

Flame Detection

3.7 REASSEMBLY

Reassemble the boiler in the following order:

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

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

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

3. Ret the fan / venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly positioned and free from damage.

4. Reconnect the fan electrical leads.

5. Remove the sump cover and ret the lower ue manifold as

shown.

6. Ret the sump cover.

SERVICING

7. Ret the boiler front panel.

IMPORTANT. Ensure that the boiler front panel is

correctly tted and that a good seal is made.

8. Swing the control box back into its working position and secure.

9. Turn on the gas supply at the gas service cock.

10. Reconnect the electrical supply.

11. Check the operation of the boiler. refer to Sections 2.22

& 2.23.

Installation and Servicing

Page 42

SECTION 3 - SERVICING

3.8 REPLACEMENT OF COMPONENTS

GENERAL

When replacing ANY component

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel. Refer to Section 3.2.

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

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

THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED

3.9 FAN REPLACEMENT

IMPORTANT.

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

Notes.

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

2. In order to replace components in Sections 3.20 - 3.27 it is necessary to drain the boiler. Refer to Section 3.19.

Retaining Tabs

1. Refer to Section 3.8.

2. Disconnect the electrical leads from the fan.

SERVICING

3. Remove the clip from the gas control valve

outlet.

4. Remove the extended nut retaining the fan mounting bracket.

5. Lift and remove the fan and venturi assembly.

6. Remove the screw and twist venturi anti-

clockwise to remove venturi assembly, noting

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

7. Transfer the venturi assembly to the new fan,

replacing the ‘o’ ring if evidence of damage or

deterioration is visible.

8. Fit the new fan / venturi assembly ensuring the

retaining tabs are correctly positioned and the

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

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

10. Check the operation of the boiler. Refer to Sections 2.22 & 2.23.

Installation and Servicing

Page 43

SECTION 3 - SERVICING

3.10 BURNER INJECTOR REPLACEMENT

1. Refer to Section 3.8.

2. Disconnect the electrical leads from the

fan.

3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove.

4. Loosen the screw retaining the fan mounting bracket.

5. Lift and remove the fan and venturi

assembly.

6. Remove the 2 injector housing screws.

7. Withdraw the injector housing.

8. Fit the new injector housing complete with

injector.

9. Reassemble in reverse order, ensuring that the new gas seal supplied is located correctly in the injector housing.

10. Check operation of the boiler. Refer to Sections 2.22 & 2.23.

Injector

3.11 BURNER REPLACEMENT

1. See Section 3.4.

2. Refer to Section 3.8.

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

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

manifold.

5. Remove the 2 front xing screws and loosen the 2 rear extended nuts.

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

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

8. Reassemble in reverse order. Refer to Section 3.7.

9. Check the operation of the boiler. Refer to Sections 2.22 & 2.23.

SERVICING

Installation and Servicing

Page 44

SECTION 3 - SERVICING

3mm

Straight edge

Spark Gap

3.5mm

3.12 RETURN THERMISTOR REPLACEMENT

1. Refer to Section 3.8.

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

boiler.

3. Disconnect the electrical leads from the thermistor.

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

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

5. Check the operation of the boiler. Refer to Sections 2.22 & 2.23.

Thermistor Locator Tab

(with thermistor tted)

SERVICING

3.13 IGNITION ELECTRODE REPLACEMENT

1. Refer to Section 3.8.

2. Remove the burner. Refer to Section 3.11.

3. Unplug the ignition lead from the electrode.

4. Remove the earth lead from the ignition

electrode.

5. Remove the 2 screws holding the ignition electrode to the combustion chamber.

6. Remove the electrode.

7. Fit the new ignition electrode, using the

new gasket supplied. Check dimensions as shown.

8. Reassemble in reverse order.

9. Check the operation of the boiler. Refer to

Sections 2.22 & 2.23.

Ignition Electrode

Installation and Servicing

Page 45

SECTION 3 - SERVICING

12.5mm

Straight edge

3.14 FLAME DETECTION ELECTRODE REPLACEMENT

1. Refer to Section 3.8.

2. Remove the burner. Refer to Section 3.11.

3. Unplug the ame detection lead from the

electrode.

4. Remove the 2 screws retaining the detection electrode.

5. Remove the electrode.

6. Fit the new ame detection electrode, using the

new gasket supplied.

7. Reassemble in reverse order.

8. Check the operation of the boiler. Refer to

Sections 2.22 & 2.23.

Flame Detection Electrode

3.15 SPARK GENERATOR REPLACEMENT

1. Refer to Section 3.8.

2. Disconnect the leads from the spark

generator

3. Gently push down the generator

to release the top clip from the gas

valve mounting bracket.

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

5. Fit the new spark generator and re-

assemble in reverse order ensuring that the the earth lead is replaced

6. Check operation of the boiler .Refer to Sections 2.22 & 2.23.

Spark Generator

SERVICING

Installation and Servicing

Page 46

SECTION 3 - SERVICING

3.16 GAS CONTROL VALVE REPLACEMENT

1. Refer to Section 3.8.

Unplug the electrical lead connection from the gas

2. control valve.

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

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

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

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

7. Check operation of the boiler. Refer to Sections

2.22 & 2.23.

SERVICING

3.17 CONDENSATE TRAP/SIPHON REPLACEMENT

1. Refer to Section 3.8.

Note: Ensure condensate trap is fully drained before removal.

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

3. Disconnect the condensate drain pipe.

4. Turn the siphon clockwise to disengage and lift to remove.

5. Reassemble in reverse order.

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

7. Check operation of the boiler. Refer to Sections 2.22 & 2.23.

Installation and Servicing

Page 47

SECTION 3 - SERVICING

Flow

Gas

Return

CH Circuit Drain

3.18 PCB REPLACEMENT

Note. Fit the earth strap provided with the PCB to your wrist and

secure to a suitable earth on the boiler chassis.

1. Refer to Section 3.8.

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

3. Carefully release the six retaining clips and remove control

box cover.

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

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

Take the new PCB.

7. Re-connect all plug connections.

8. Reassemble in reverse order.

9. a. Turn power on, display shows uP.

Rotate both dials fully anti-clockwise.

b. Press RESTART, display shows oF c. Turn power off d. Turn power on, display shows F9 e. Using central heating knob, rotate clockwise or

anticlockwise to show “Su” for System, then press RESTART button.

f. Using central heating knob, rotate clockwise or

anticlockwise to show “n” for Natural Gas, then press restart button.

g. Using central heating knob rotate clockwise or

anticlockwise to show boiler size, select 30, then press

RESTART button. h. Display shows “Su”, “n”, “30”, internal number. j. Press restart. New PCB is now programmed.

10.

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

Plastic clip

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

SERVICING

3.19 DRAINING THE BOILER

CENTRAL HEATING CIRCUIT

1. Refer to Section 3.8.

2. Close all the CH water isolating valves on the

boiler inlet.

3. To drain the primary heat exchanger circuit:

Open the drain valve and attach a length of hose

to the CH drain point.

4. After replacing any component on the boiler, remove the hose, close the drain valve and open all system isolating valves (re-pressurise

as appropriate) before proceeding to check operation of the boiler.

5. Check operation of the boiler. Refer to Sections

2.22 & 2.23.

Installation and Servicing

Page 48

SECTION 3 - SERVICING

3.20 PRESSURE GAUGE REPLACEMENT

1. Refer to Section 3.8.

2. Drain the heating system. Refer to Section 3.19.

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

the control box cover.

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

5. Releasing the two retaining clips on the pressure gauge ease the pressure gauge through the front of the control panel.

6. Fit the new pressure gauge from the front of the control panel ensuring correct orientation. Locate push t connection into port ensuring ‘o’ ring in place and secure with the C clip.

7. Rell the boiler. Refer to Section 2.13.

8. Check the operation of the boiler. Refer to Sections 2.22 & 2.23.

3.21 SAFETY RELIEF VALVE REPLACEMENT

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.19.

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

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

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

SERVICING

6. Lift out the safety valve/pipe assembly.

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

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

9. Rell the boiler. Check operation of the boiler. Refer to Sections 2.22 & 2.23.

3.22 PUMP AUTOMATIC AIR VENT REPLACEMENT

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.19.

3. Remove the expansion vessel. Refer to Section 3.27.

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

at top of pump chamber and bottom of heat exchanger and remove pipe.

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

6. Reassembly is the reverse of the above. Ensure the air vent head ‘o’ ring seal is in place when retting and the new ‘o’ ring is tted to the return pipe top connection.

7. Ensure the air vent cap is loose.

8. Rell the boiler. Refer to Section 2.13. Check for leaks around the new air

vent joint.

9. Check the operation of the boiler. Refer to Sections 2.22 & 2.23.

Dust Cap

Installation and Servicing

Page 49

SECTION 3 - SERVICING

3.23 PUMP HEAD REPLACEMENT

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.19.

3. Disconnect the two electrical leads from the pump.

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

5. Remove the pump head.

6. Fit the new pump head.

7. Reassemble in reverse order.

8. Rell the boiler. Refer to Section 2.13.

9. Check operation of the boiler. Refer to Sections 2.22 & 2.23.

3.24 CH WATER PRESSURE SWITCH REPLACEMENT

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.19.

3. Pull off the two electrical connections.

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

5. Carefully withdraw the pressure switch.

6. Fit the new pressure switch and reassemble in reverse order.

7. Rell the boiler.

8. Check operation of the boiler. Refer to Sections 2.22 & 2.23.

3.25 CONTROL / NO FLOW THERMISTOR REPLACEMENT

1. Refer to Section 3.8.

2. Drain down the boiler. Refer to Section 3.19.

3. Unplug the electrical lead.

4. Unscrew the thermistor (to facilitate removal

a 13mm socket spanner should be used).

5. Fit the new thermistor using the sealing washer provided.

6. Reassemble in the reverse order.

7. Rell the boiler. Refer to Section 2.13.

8. Check the operation of the boiler. Refer to

Sections 2.22 & 2.23.

SERVICING

Installation and Servicing

Page 50

SECTION 3 - SERVICING

3.26 HEAT ENGINE REPLACEMENT

Refer also to Section 2.1 - ‘Boiler Exploded View’

IMPORTANT

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

1. Refer to Section 3.8.

2. Drain the boiler. Refer to Section 3.19.

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

Refer to Section 3.3

Remove the burner and place on one side. Refer to Section

3.4.

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

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

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

8. Remove the expansion vessel. Refer to Section 3.27.

9. Remove the ow and return thermistor. Refer to Sections

3.12 & 3.25.

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

11. Undo the pump union nut and remove pipe.

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

13. Remove the condensate rubber pipe. Refer to Section 3.17, no. 2.

14. Remove the two heat exchanger xing screws.

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

16. If replacement sump required: Rotate heat exchanger assembly

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

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

spring clips located on the return pipe connection, ensure clip is

oriented to correctly match connecting pipe diameters.

18. Ensure the trap/siphon is lled with water. Refer to Secion 3.17.

19. Rell the boiler. Refer to Section 2.13.

20. Check operation of the boiler. Refer to Section 2.22 & 2.23.

Shown as 180º position

SERVICING

Installation and Servicing

Page 51

SECTION 3 - SERVICING

3.27 EXPANSION VESSEL RECHARGING & REPLACEMENT

RECHARGING

1. Remove the charge point cover.

2. Recharge the tank pressure to 0.75 bar.

3. Re-assemble in reverse order

4. Check operation of the boiler. Refer to

Sections 2.22 & 2.23.

REPLACEMENT

5. Refer to Section 3.8.

Drain the boiler CH circuit. Refer to Section

3.19.

7. Remove the retaining clip on the vessel water connection pipe.

8. Support the expansion vessel and unscrew the 2 screws from the securing clamp, located on the top of the boiler, and remove. (Note the position of the bracket on the

vessel)

9. Remove the expansion vessel.

10. Fit the new expansion vessel.

11. Reassemble in reverse order ensuring the

“o” ring is in place.

12. Rell the boiler. Refer to Section 2.13.

13. Check operation of the boiler. Refer to

Sections 2.22 & 2.23.

Recharge Point

SERVICING

Installation and Servicing

Page 52

SECTION 4 - FAULT FINDING

4.1 FAULT FINDING CHART MAIN MENU

In order to assist fault nding the boiler has a 7 segment display. The key to the display codes is as follows:

‘L1’

‘L2’

‘LC’

‘L6’

‘F1’

‘F2’ or ‘Fn’ or ‘Ln’

‘F3’

‘L4’ or ‘F4’

GO TO SECTION 4.2 -

FLOW TEMPERATURE OVERHEAT LOCKOUT

or NO WATER FLOW LOCKOUT

GO TO SECTION 4.3 -

IGNITION LOCKOUT

5 RESTARTS WITHIN 15 MINS -

TURN POWER OFF AND ON

GO TO SECTION 4.4 -

FALSE FLAME LOCKOUT

GO TO SECTION 4.5 -

LOW WATER PRESSURE

GO TO SECTION 4.6 -

FLAME LOSS

GO TO SECTION 4.7 -

FAN FAULT

GO TO SECTION 4.8 -

CONTROL / NO FLOW THERMISTOR FAULT

‘L5’ or ‘F5’

‘F6’

‘F7’

‘F9’ or ‘L9’ or ‘F8’ or ‘L8’

‘FU’

NO CH

NO HW

NO DISPLAY

GO TO SECTION 4.9 -

RETURN THERMISTOR FAULT

GO TO SECTION 4.10 -

OUTSIDE SENSOR FAULT

LOW MAINS VOLTAGE -

CONTACT ELECTRICITY PROVIDER

PCB UNCONFIGURED OR FAULT. SEE SECTION

3.18. IF FAUL PERSISTS REPLACE PCB

DIFF GREATER THAN 50ºC. CHECK ISOLATION

VALVES ARE OPEN, CHECK PUMP, CHECK RAD

VALVES OPEN, CHECK SYSTEM BLOCKAGES.

GO TO SECTION 4.11

GO TO SECTION 4.13

GO TO SECTION 4.12

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

RESTART PROCEDURE - To restart boiler, press the “RESTART” button.

Installation and Servicing

Page 53

SECTION 4 - FAULT FINDING

4.2 ‘L1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT OR NO WATER FLOW LOCKOUT

Is the Boiler and CH System lled with water and all

isolation and radiator valves open?

YES

If the PCB has been replaced check a BCC has been tted then restart the boiler.

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

Check the Control/No Water Flow and Return Thermistors (Refer to Sections 3.12 & 3.25)

RESTART PROCEDURE - To restart boiler, press the “RESTART” button.

YES

4.3 ‘L2’ - IGNITION LOCKOUT

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

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

Replace the Pump,

then restart boiler

YES

OK, now

restart boiler

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

YES

Check the detection electrode and associated harness for:

continuity, visual condition and

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

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

YES

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

YES

Is 24Vdc supply available at the Gas Valve?

YES

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

YES

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

functioning correctly?

YES

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

functioning correctly?

Check gas supply and

rectify fault

Check wiring connection from gas valve to PCB for continuity. If the wiring is OK then replace the PCB

Replace Gas Valve

Replace Spark Generator and harness

as necessary

Replace Ignition Electrode and

associated harness as necessary

Replace Gas Valve

RESTART PROCEDURE - To restart boiler, press the RESTART button.

Installation and Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Page 54

SECTION 4 - FAULT FINDING

4.4 ‘L6’ - FALSE FLAME LOCKOUT

Restart the boiler, does Boiler Work OK?

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

pins connected to the electrode?

RESTART PROCEDURE - To restart boiler, press the “RESTART” button.

YES

4.5 ‘F1’ - LOW WATER PRESSURE

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

YES

Are connections on water pressure sensor secure?

YES

4.6 ‘F2’ OR ‘Fn’ OR ‘Ln’ - FLAME LOSS

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

Replace Flame Detection Electrode

Check routing and integrity of internal boiler wiring.

Fill and vent the system and open all isolation valves

Re-t connections

Replace water pressure sensor

Does the boiler ignite for a short time and then extinguish?

YES

Check the detection electrode and associated harness for: continuity,

visual condition and position

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

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

YES

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

YES

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

these functioning correctly?

YES

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

these functioning correctly?

YES

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

Check gas supply and

rectify fault

Check wiring from gas valve to PCB for continuity. If the wiring is OK then replace the PCB

Replace Spark Generator and Harness as necessary.

Replace Ignition Electrode and

associated harness as necessary

Replace Gas Valve

4.7 ‘F3’ - FAN FAULT

Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated? Does the wiring have continuity?

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

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

YES

Rectify Wiring & connections

Replace PCB

Replace Fan

Installation and Servicing

Page 55

SECTION 4 - FAULT FINDING

4.8 ‘L4’ OR ‘F4’ - CONTROL / NO FLOW THERMISTOR FAULT

Remove the Control/No Flow Thermistor from the

Heat Exchanger and disconnect the wires.

Check the resistance using a suitable multimeter

connected across the thermistors terminal pins.

At 25

At 60

At 85

C expect 9,700 - 10,300 Ohms

C expect 2,400 - 2,600 Ohms

C expect 1,000 - 1,100 Ohms

YES

Is the Thermistor value correct?

4.9 ‘F5 OR L5’ - RETURN THERMISTOR FAULT

Remove the Return Thermistor from the CH Return

Pipe and disconnect the wires.

Check the resistance using a suitable multimeter

connected across the thermistors terminal pins.

At 25

At 60

At 85

C expect 9,700 - 10,300 Ohms

C expect 2,400 - 2,600 Ohms

C expect 1,000 - 1,100 Ohms

Is the Thermistor value correct?

YES

Fit a new Thermistor

Is there continuity between the PCB and Thermistor?

YES

Replace PCB

Check and replace wiring as

necessary

Fit a new Thermistor

Is there continuity between the PCB and Thermistor?

YES

Replace PCB

Check and replace wiring as

necessary

4.10 ‘F6’ - OUTSIDE SENSOR FAULT

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

Disconnect the wires to the outside sensor.

Check the resistance using a suitable multimeter

connected across the Outside Sensors terminal pins.

C expect 31,000 - 35,000 Ohms

At 0

At 15

At 30

Installation and Servicing

C expect 15,000 - 16,500 Ohms

C expect 7,700 - 8,500 Ohms

Is the Outside Sensor value correct?

YES

Replace PCB

Securely connect the wiring at both the boiler and Outside Sensor

Fit a new Outside Sensor

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

YES NO

Securely connect the wiring at the Terminal Block and the PCB

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Page 56

SECTION 4 - FAULT FINDING

4.11 NO CH OPERATION

Is the mode knob in the ON position?

YES

Are the Timer and the Room Thermostat or cylinder thermostat switched on?

YES

Are the Radiator Valves Open?

YES

Is there 230Vac at (A)?

YES NO

Check wiring from

terminal strip to

PCB.

There is no Voltage from the Timer/Room Stat. This is not boiler fault. Ensure Voltage is

supplied to boiler by rectifying

external wiring.

Move the mode knob to the ON position

Switch the Timer, Room Stat and Cylinder Stat On

Open the Radiator Valves

4.12 NO DISPLAY

Is there 230Vac to the boiler at L and N (see Section 4.11)?

YES

Is the wiring from the terminal block to the Main PCB

connected securely?

YES

Replace the PCB

4.13 NO HW

Is the cylinder stat calling for heat?

Supply power to the boiler

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

Adjust cylinder stat

YES

Is DHW timer on?

YES

Is boiler mode knob in the ON position?

YES

Is there 230V at (A)? Refer to Section 4.11

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Check wiring from terminal strip to PCB.

YES

Switch timer on

Move the mode knob to the ON position

Check system controls and wiring

Installation and Servicing

Page 57

SHORT LIST OF PARTS

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

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

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

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

hand;

- Boiler Model

- Appliance GC Number

- Boiler Serial Number

IMPORTANT NOTE.

Propane Boilers - After installation of a conversion kit, and when ordering future spares be sure to quote the serial letter code AAV which indicates a Propane boiler - and the boilers original serial letter code from the original data plate.

Installation and Servicing

Page 58

Page 59

Benchmark Commissioning and Servicing Section

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

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

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

www.centralheating.co.uk

Page 60

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

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

CONTROLS

Programmable room thermostat

Optimum start control

Combination Boiler

Fitted

Automatic bypass to system Fitted

Boiler interlock

ALL SYSTEMS

Yes

CENTRAL HEATING MODE

Central heating return temperature

COMBINATION BOILERS ONLY

DOMESTIC HOT WATER MODE

Cold water inlet temperature

CONDENSING BOILERS ONLY

ALL INSTALLATIONS

Yes

mbar OR mbar

Yes

mbar OR mbar

Yes Temperature

Yes

AND

Ratio

Yes

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

Competent Persons Scheme. A Building Regulations Compliance

will then be issued to the customer.

www.centralheating.co.uk

Page 61

SERVICE RECORD

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

Service Provider

SERVICE 01

(Where Possible) AND

Signature

SERVICE 03

(Where Possible) AND

Signature

SERVICE 05

AND

SERVICE 02

Signature

(Where Possible) AND

AND

SERVICE 04

Signature

(Where Possible) AND

AND

SERVICE 06

(Where Possible) AND

Signature

SERVICE 07

(Where Possible) AND

Signature

SERVICE 09

(Where Possible) AND

AND

Signature

(Where Possible) AND

AND

SERVICE 08

Signature

(Where Possible) AND

AND

SERVICE 10

(Where Possible) AND

AND

Signature

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

Competent Persons Scheme. A Building Regulations Compliance

Signature

will then be issued to the customer.

Page 62

FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO

CHECK ON COMMISSIONING A CONDENSING BOILER

Important Preliminary Information on Checks

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

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

PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK

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

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

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

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

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

KEY:

CO = carbon monoxide

= carbon dioxide

O2 = oxygen

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

ppm = parts per million

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

*Setting to Minimum Rate:

1. Hold the “RESTART” & function buttons together for more than 5s.

2. Last 3 faults will be shown.

3. SL shown, press “RESTART”.

4. Burner will run for 10 minutes at minimum rate.

Installation and Servicing

Page 63

Start

Set Boiler to Maximum Gas Rate

In accordance with boiler instructions,

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

Carry Out Flue Integrity Check Using Analyser

set boiler to operate at maximum rate

(full load condition). Allow sufficient

time for combustion to stabilise.

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

flooding of sensor.

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

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

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

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

Verify Flue Integrity

Analyser readings indicate that combustion products and inlet air

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

Check that flue components are assembled, fixed and supported as

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

2 more than or

equal to 20.6% OR CO

Yes

less than or equal to

0.2%?

readings to stabilise.

O2 more than or

equal to 20.6% OR CO

less than or equal to

0.2%?

Yes

Check CO level and Combustion Ratio

at Maximum Gas Rate

With boiler still set at maximum gas rate,

insert analyser probe into flue gas

sampling point. Allow readings to stabilise

before recording.

Turn off appliance and call Ideal Technical Helpline for advice

The appliance must not be commissioned until problems are identified

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

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

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

been displaced during installation. Rectify if necessary.

CO level less

than 350ppm AND CO/CO

Yes

In accordance with boiler instructions, set boiler to

operate at minimum rate (to minimum load condition).

ratio less than

0.0040?

Check CO and Combustion Ratio at Minimum Gas Rate

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

gas sampling point. Allow readings to stabilise before recording.

Turn off Appliance and Call Ideal Technical Helpline

The appliance must not be commissioned until problems

are identified and resolved. If commissioning cannot be

fully completed, the appliance must be disconnected from

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

Check and record CO level and combustion ratio at both

maximum AND minimum rate before contacting Ideal.

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

Yes

Set Boiler to Minimum Gas Rate

(*see opposite page)

Allow sufficient time for combustion to stabilise.

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

Yes

Installation and Servicing

Boiler is Operating Satisfactorily

No further actions required.

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

Checklist, recording CO and combustion ratio readings as required.

Page 64

Keston pursues a policy of continuing improvement in the design and performance of its products.

The right is therefore reserved to vary speciﬁcation without notice.

Keston Heating, PO Box 103, National Avenue,Kingston Upon Hull, HU5 4JN

Tel +44 (0) 1482 443005 Fax 44 (0) 1482 467133

Consumer Helpline: +44 (0) 1482 498660

www.keston.co.uk