Keston System 30 Installation And Servicing Instructions
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Keston System 30 Installation And Servicing Instructions

Fan powered high efficiency modulating domestic condensing gas combination boiler
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System 30

Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS COMBINATION BOILER
CE/PI No. 86-CL-08
System 30 - GC No. 41-930-39
These instructions must be left either with the
user or next to the site gas meter.
Keston Heating
PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN
Tel. +44 (0) 1482 443005
Fax. +44 (0) 1482 467133
email : info@keston.co.uk
web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2
SEDBUK A RATED

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  • Page 1: Installation And Servicing Instructions

    FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE/PI No. 86-CL-08 System 30 - GC No. 41-930-39 These instructions must be left either with the user or next to the site gas meter. Keston Heating PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN Tel.
  • Page 2 BACK Keston System - Installation and Servicing...
  • Page 3 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 ........A01 (Oct 12) Keston reserve the right to vary specification without notice Keston System - Installation and Servicing...
  • Page 4 /h - divide the gross heat input (Btu/h) = An appliance designed for use on 2nd Family gas, Group H only. by the gross C.V. of the gas (Btu/ft c. For m /h - multiply l/s by 3.6. Keston System - Installation and Servicing...

  • Page 5: Table Of Contents

    For all boilers: complete, sign & hand over to customer For assistance see Technical Helpline on the back page NOTE TO ThE INsTALLER: COMpLETE ThE BENChMARK COMMIssIONINg ChECKLIsT AND LEAVE ThEsE INsTRUCTIONs WITh AppLIANCE Keston System - Installation and Servicing...

  • Page 6: Safe Handling

    BACK general INTRODUCTION OpTIONAL ExTRA KITs The Keston system boiler is wall mounted, full sequence, • Air Terminal Finishing Kit automatic spark ignition, low water content, fanned flue, high • Chronotherm Room Controller efficiency, condensing, system gas boiler. • Flue Sleeve Kit Note.

  • Page 7: Gas Safety Regulations

    In both cases, details of essential features of cupboard / compartment design, including airing cupboard installation, are to Any direct connection of a control device not approved by Keston conform to the following: could invalidate the certification and the normal appliance warranty.

  • Page 8: Electrical Supply

    BS6891:2005. Whilst of temperature in individual rooms should also be fitted with a the principle of the 1:1 gas valve ensures the Keston range is room thermostat controlling the temperature in a space served by able to deliver it’s full output at inlet pressures as low as 14mb,...
  • Page 9 Bottom clearance after installation can be reduced to 5mm. This must be obtained with an easily removable panel, to enable the consumer to view the system pressure gauge, and to provide the 100mm clearance required for servicing. Keston System - Installation and Servicing...
  • Page 10 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 pre- pressurised. Keston System - Installation and Servicing...

  • Page 11: Water Treatment

    Sentinel Performance Solutions Heating Systems. The Heath Business & Technical Park Runcorn Cheshire WA7 4QX If water treatment is used Keston recommend only the use of Tel: 0800 389 4670 Scalemaster Gold 100, FERNOX, MBI & F1 or SENTINEL X100 www.sentinel-solutions.net inhibitors and associated water treatment products, which must be used in accordance with the manufacturers’...

  • Page 12: Installation And Servicing

    * Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output. Keston System - Installation and Servicing...
  • Page 13 Wall Plugs - 4 off FRONT pANEL REMOVAL 1. Loosen the 2 screws retaining the front panel. 2. Pull the two spring clips downwards to disengage. 3. Pull the front panel forward and upwards to remove. Keston System - Installation and Servicing...

  • Page 14: Flue Installation

    Marley mupVC solvent Weld Waste system (50mm) Marley Code KP 304 50mm x 4m double spigot pipe KP32 50mm x 45 deg bend KSC3 50mm straight coupling 50mm x 88.5 deg bend 50mm swept tee continued.... Keston System - Installation and Servicing...
  • Page 15 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 flue and air lengths as described within the shaded area of graph below. Keston System 30 - Flue & Air Pipe Length Acceptable Operating Area...
  • Page 16 BACK INSTALLATION 10 FLUE INsTALLATION ExAMpLE KEsTON sysTEM 30 Keston System 30 - Flue & Air Pipe Length 15.5 1.5º back to boiler Bracket at each 1 metre 10.15 1.5m 0.15m Acceptable Operating Area 8 10 12 14 16 18 20 22 24 26 28 30 1.5º...

  • Page 17: Air Supply

    Rubber collars are available for flue and air terminals to finish the external wall face around the terminals (Part No C.08.00.07.0). AIR sUppLy The Keston Combi is a room-sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air.

  • Page 18: Installing The Boiler

    3. Locate 2 No.14 x 50mm screws in the wall mounting plate (one at each side, in any of the 3 holes Note. Check all of the hole provided at each side) and screw home. positions before drilling. Keston System - Installation and Servicing...

  • Page 19: Mounting The Boiler

    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. Keston System - Installation and Servicing...
  • Page 20 8. Affix flue terminal 9. During boiler test check that the flue end is free to expand and contract with flexible wall seal. Flue Terminal Flue Pipe Flue Sleeve Flue Sleeve Flange Flexible Wall Wall Plate Seal Keston System - Installation and Servicing...

  • Page 21: Condensate Drain

    Boilers without 75mm sealed condensate trap must be fitted with condensate trap must be fitted with a 75mm trap and visible air break a 75mm trap and visible air break continued ..Keston System - Installation and Servicing...
  • Page 22 75mm trap and visible air break ≥ 500 2 rows of three Ø12mm holes 25mm centres, 50mm from the bottom of the tube, facing away from the house Keston System - Installation and Servicing...

  • Page 23: Water Connections

    Safety Valve (not supplied) Drain Pipe Note that all isolation handles are shown in the open position. Black Handle CH Flow Yellow Supply Safety Handle 205552-10119 Drain Valve Black Handle CH Return Keston System - Installation and Servicing...

  • Page 24: Electrical Connections

    24 INTERNAL WIRINg The Keston System boiler comes pre-fitted with 1.8m of mains cable. This must be connected to a permanent live supply and NOT switched by thermostats/programmers. For installers wishing to change this cable refer to Frame 26.
  • Page 25 BACK INSTALLATION 25 INTERNAL WIRINg CONT’D..KesTon sysTem BoiLer, s PLan sysTem WiThouT WeaTher ComPensaTion S PLAN VALVE S PLAN FUSED VALVE SPUR BOILER CH ON TIMER HW ON 3G10023 26 REpLACINg pRE-FITTED MAINs CABLE If it is necessary to use an alternative mains cable to the one pre-fitted then use the following guide.
  • Page 26 8. Secure the wire with the other bar clamp and two screws, ensure that there is only a small loop between the bar clamp and the grommet, and that the wire can not be trapped. 9. Re-assemble in reverse order. Keston System - Installation and Servicing...
  • Page 27 As sTANDARD b - blue br - brown g - green g/y - green/yellow o - orange w - white Keston system Boiler with y plan system & Weather Compensation Kit Y PLAN FUSED VALVE SPUR BOILER OUTSIDE SENSOR...

  • Page 28: External Electrical Controls

    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 fit a pipe thermostat, preferably on the return pipework. Keston System - Installation and Servicing...

  • Page 29: Wiring Diagram

    BACK INSTALLATION 31 WIRINg DIAgRAM Keston System - Installation and Servicing...

  • Page 30: Commissioning & Testing

    Gas Pressure 205552-10118 Test Point ATTENTION ! IT Is A CONDITION OF ThE MANUFACTURERs WARRANTy ThAT ThE BENChMARK COMMIssIONINg ChECKLIsT Is FULLy COMpLETED AND LEFT WITh ThE AppLIANCE Keston System - Installation and Servicing...

  • Page 31: Initial Lighting

    11. Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2. Note. The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply. Keston System - Installation and Servicing...

  • Page 32: Handing Over

    7. If a timer is fitted draw attention to the timer Users Instructions the envelope pack and the requirement to register it to receive and hand them to the householder. the full benefit of the warranty. Keston System - Installation and Servicing...

  • Page 33: Servicing Schedule

    SERVICING 37 sERVICINg sChEDULE For the very latest copy of literature for specification & 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.

  • Page 34: Fan And Venturi Assembly Removal And Cleaning

    3. Remove the extended nut on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5. Inspect the injector for blockage or damage. 6. Inspect fan outlet sealing gasket and replace if necessary. Injector Keston System - Installation and Servicing...

  • Page 35: Burner Removal And Cleaning

    2. Disconnect the condensate drain pipe. 5. Re-assemble in reverse order. 3. Turn the siphon clockwise to disengage and lift to B When re-assembling ensure the trap is full of water. remove. Note. Keep siphon upright when removing Keston System - Installation and Servicing...

  • Page 36: Cleaning The Heat Exchanger

    4. Reconnect the fan electrical leads. 11. Check the operation of the boiler. refer to Frame 32-34 5. Remove the sump cover and refit the lower flue manifold as shown. 6. Refit the sump cover. Keston System - Installation and Servicing...

  • Page 37: Replacement Of Components

    Refit the extended nut. 9. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket. 10. Check the operation of the boiler. Refer to Frames 32-34. Keston System - Installation and Servicing...

  • Page 38: Burner Injector Replacement

    7. Fit the new burner, replacing any damaged or deteriorating sealing gasket. 8. Reassemble in reverse order. Refer to Frame 43. 9. Check the operation of the boiler. Refer to Frames 32-34. Keston System - Installation and Servicing...
  • Page 39 5. Unscrew the two M3.5 screws that connect the thermostat to the manifold. 6. Replace thermostat with new part and then refit the two screws, remembering to fit rubber gasket and sealing clamp. Flue Thermostat Keston System - Installation and Servicing...

  • Page 40: Ignition Electrode Replacement

    6. Fit the new flame detection electrode, using the new gasket supplied. 7. Reassemble in reverse order. 8. Check the operation of the boiler. Refer to Frames 32-34. a i g S t r . 5 m Keston System - Installation and Servicing...

  • Page 41: Spark Generator Replacement

    6. Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections. 7. Check operation of the boiler. Refer to Frames 32-34. Keston System - Installation and Servicing...
  • Page 42 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 Frames 32-34. Siphon Keston System - Installation and Servicing...
  • Page 43 “ - ” turn the knob fully anti- clockwise IMMEDIATELY. Finally move the knob into the required position. 11. Check operation of the boiler. Refer to Plastic Frames 32-34. Clip Ribbon Cable Connection Keston System - Installation and Servicing...

  • Page 44: Draining The Boiler

    (re-pressurise as appropriate) before proceeding to check operation of the boiler. 5. Check operation of the boiler. Refer to Frames Circuit 32-34. Drain 3G9955 Flow Retrun Keston System - Installation and Servicing...
  • Page 45 7. Ensure the air vent cap is loose. 8. Refill the boiler. Refer to Frame 22. Check for leaks around the new air vent joint. 9. Check the operation of the boiler. Refer to Frames 32-34. Keston System - Installation and Servicing...

  • Page 46: Pump

    5. Fit the new thermistor using the sealing washer provided. 6. Reassemble in the reverse order. 7. Refill the boiler. Refer to Frame 22. 8. Check the operation of the boiler. Refer to Frames 32-34. Keston System - Installation and Servicing...

  • Page 47: Heat Engine Renewal

    19. Check operation of the boiler. Refer to Frames 32-34. 11. Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe. Keston System - Installation and Servicing...

  • Page 48: Expansion Vessel Recharging & Replacement

    5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frames 32-34. Note. Ensure that the boiler front panel is correctly sealed, compressing the seal to make an airtight joint. Keston System - Installation and Servicing...

  • Page 49: Fault Finding

    **If PCB replaced as a spare ensure that the BCC (boiler chip card - small plastic part) is fitted to the PCB otherwise replace PCB. REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Keston System - Installation and Servicing...
  • Page 50 Check if burner is damaged Replace burner REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Replace heat exchanger Keston System - Installation and Servicing...
  • Page 51 * note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve. Keston System - Installation and Servicing...
  • Page 52 At 25 expect 9,700 - 10,300 Ohms At 60 expect 2,400 - 2,600 Ohms At 85 expect 1,000 - 1,100 Ohms Check and replace wiring as Replace PCB Is the Thermistor value correct? necessary Keston System - Installation and Servicing...
  • Page 53 Is there 230Vac at (A)? Check wiring from There is no Voltage from the terminal strip to Timer/Room Stat. This is not PCB. boiler fault. Ensure Voltage is supplied to boiler by rectifying external wiring. Keston System - Installation and Servicing...
  • Page 54 Move the mode knob to the ON position Is boiler mode knob in the ON position? Check system controls and wiring Is there 230V at (A) Refer to Frame 78? Check wiring from terminal strip to PCB. Keston System - Installation and Servicing...

  • Page 55: 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 specification 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.
  • Page 56 BACK Notes Keston System - Installation and Servicing...
  • Page 57 BACK Short liSt of partS Keston System - Installation and Servicing...
  • Page 58 BACK Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect he customer’s statutory rights. Gas Safe Register Number Telephone Number If yes, and if required by the manufacturer, has a water scale reducer been fitted? If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
  • Page 59 BACK Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number...
  • Page 60 BACK Keston heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN November 2012 UIN 208893 A01 Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk K e s t o n p u r s u e s a p o l i c y o f c o n t i n u i n g i m p r o v e m e n t i n t h e d e s i g n a n d p e r f o r m a n c e o f i t s p r o d u c t s .

  • Page 61: User Instructions

    FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE/PI No. 86-CL-08 System 30 - GC No. 41-930-39 These instructions must be left either with the user or next to the site gas meter. Keston Heating PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN Tel.

  • Page 62: Minimum Clearances

    Benchmark Commissioning Checklist. You can check your installer by calling Gas Safe Register direct on 0800 4085500. Keston is a member of the Benchmark scheme and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

  • Page 63: Frost Protection

    If unable to do so or if the pressure continues to drop after filling a Gas Safe Registered Engineer or in IE a Registered Gas Installer The Keston System is a high efficiency condensing boiler which is (RGII) should be consulted.

  • Page 64: Troubleshooting

    The boiler has a call for central heating / hot water but the appliance has reached the desired temperature set on the boiler. The boiler is operating for central heating / hot water. The boiler is operating in frost mode. continued ..Keston System - User’s...

  • Page 65: Fault Codes

    5 Boiler Resets in 15 minutes 1. Turn power off and on at the fused spur. 2. If the boiler fails to operate please contact Keston (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.
  • Page 66 BACK Keston System - User’s...
  • Page 67 BACK Keston System - User’s...
  • Page 68 BACK Keston heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk K e s t o n p u r s u e s a p o l i c y o f c o n t i n u i n g i m p r o v e m e n t i n t h e d e s i g n a n d p e r f o r m a n c e o f i t s p r o d u c t s .

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