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Keston 86-CM-44 User, Installation And Servicing Instructions

Fan powered high efficiency modulating domestic condensing gas combination boiler
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C36 Combi
User, Installation and Servicing
Instructions
FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS COMBINATION BOILER
CE/PI No. 86-CM-44
C36 Combi - GC No. 47-930-01
C36P Combi – GC No. 47-930-02
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
W D 3 8 8
i s s u e 6 - 2 0 1 1

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  • Page 1 Instructions FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE/PI No. 86-CM-44 C36 Combi - GC No. 47-930-01 C36P Combi – GC No. 47-930-02 These instructions must be left either with the user or next to the site gas meter.
  • Page 2 WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers CONTENTS NB : These instructions are an integral part of the appliance. This document must be handed over to the user on completion of the installation to ensure compliance with the Gas Safety (Installation &...
  • Page 3 WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers Combustion Testing Checking The Gas Pressure Timing The Gas Meter 5.10 Handing Over To The User FAULT FINDING Electrical Control Sequence Normal Operation Fault Modes Functional Flow Wiring Diagram Electrical Wiring Diagram...
  • Page 4 0. HANDLING INSTRUCTIONS LIST OF CONTENTS The Keston C36 Combi and C36P Combi are supplied almost totally pre-assembled. The units use standard 50 mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329) pipe for the flue and air intake systems. The boiler is packed in a single box without additional flue kit. All additional components are packed inside the boiler cabinet itself.
  • Page 5 WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers side. At this stage it is assumed that the wall bracket is correctly positioned and secured on the wall face. Have the wall bracket nut and washer to hand so that they can be accessed whilst holding the boiler in position on its mounting bracket.
  • Page 6 1. USER INSTRUCTIONS INTRODUCTION Thank you for choosing this Keston C36 Combi for your household heating and hot water needs. The boiler is designed to be very straightforward to operate and has no user serviceable parts inside the cabinet. The following instructions are to provide you with information on the operation and maintenance of your C36 Combi and what to do in the unlikely event of a fault.
  • Page 7 WD388/0/2004 Chapter 1 : User Instructions The Keston C36 Combi & C36P Combi Boilers Boilers Normal Operation During normal operation the digital display will dhow the current boiler temperature and will show a “.” In the lower right corner of the display when the burner is alight. If the green lamp near the CH or DHW+ - keys is illuminated the boiler is receiving a demand for that function.
  • Page 8 WD388/0/2004 Chapter 1 : User Instructions The Keston C36 Combi & C36P Combi Boilers Boilers your installer at the end of the installation and commissioning process. The details of the Checklist will be required in the event of any warranty work being required. There is also Service Interval Record (Chapter 10) to be completed after each annual service visit.
  • Page 9 20 metres horizontally or vertically. The Keston C36 Combi uses a variable speed combustion blower to deliver a premix of gas and air to a downward firing burner in a high efficiency, single pass heat exchanger.
  • Page 10 The flue gases are piped in a 50 mm muPVC (BS5255 and/or BSEN1566-1 BSEN1329) plastic alternatively, 75mm Keston composite plastic pipe to outside. The temperature of the flue gases are usually Installation & Servicing Instructions Page : 5...
  • Page 11 Once the controls are set the boiler operates automatically. Further, a Keston outside sensor can be connected to the boiler which will automatically invoke weather compensated heating which further boosts user comfort and boiler efficiency.
  • Page 12 Building Regulation and reference should be made to the current ETC1 rules for electrical installations. No alterations should be made to the boiler without written permission from KESTON Heating. Any unauthorised modification will invalidate the warranty and may affect the safe and efficient operation of the boiler.
  • Page 13 WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers Description Part Number Pre-Installation Jig Plate C.10C.0.11.00.0 Flue Terminal Wall Sealing Collar (50mm) C.08.0.00.07.0 Air Terminal Wall Sealing Collar (50mm) C.08.0.00.07.0 50/75mm Flue Adapter C.17.2.00.60.0 Flue Outlet Terminal (75mm) C.17.2.26.00.0...
  • Page 14 The test data from which it has been calculated have been certified by Advantica Technologies Ltd KESTON Heating declare that there are no substances harmful to health within the appliance or used during the production of the appliance.
  • Page 15 WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers 3. BOILER LOCATION $OO GLPHQVLRQV LQ PP DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown allow subsequent servicing, and safe operation. However, larger clearances may be required during installation.
  • Page 16 BS 6798. The wall on which the boiler is mounted must be of suitable load bearing capacity and must be non-combustible. The Keston C36 Combi can be located virtually anywhere desired provided that all &KLPQH\V QRW XVHG IRU YHQWLQJ DQ\ RWKHU...
  • Page 17 The boiler will automatically detect this connection and will operate on a "weather compensation" basis when receiving a heating demand signal from the SL terminal or from a Keston Room Controller. Screened cable (80% density) must be used to connect the outside temperature sensor.
  • Page 18 In IE the requirements given in the current edition of IS813 and the current Building Regulations must be followed. The Keston C36 Combi is designed for installation on sealed water systems only. With fully pumped water circulation. The pump, an 8l expansion vessel and associated safety devices are fitted within the boiler.
  • Page 19 WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers The boiler is supplied with an integral expansion vessel of 8l capacity. This is suitable for systems of up to 125 Litres system volume. Table 3.7 Expansion Vessel Selection provides guidance for the correct additional expansion vessel size to use for systems with a water content larger than 125 Litres.
  • Page 20 WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 & C36P Combi Boilers driven out of the solution and will C36 Com bi Available pum p head collect in high spots in the system. These air bubbles can interfere with pumping and heat transfer and must be eliminated.
  • Page 21 WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers FLUE SYSTEM When installing a replacement boiler a new flue system must be used. Do not re-use the existing boiler flue installation. 3.8.1 Design Individual air supply and flue outlet pipes are used.
  • Page 22 The two terminals are subject to the requirements of BS 5440 Pt 1 for clearances from features of the building although some can be decreased to the values indicated. The Keston C36 Combi and C36P Combi, as with any condensing boiler, will generate a condensate “plume” from the flue terminal in all weather conditions.
  • Page 23 Rubber collars are available for flue and air terminals to finish the external wall face around the terminals (Part No C.08.0.00.07.0) AIR SUPPLY The KESTON C36 Combi and C36P Combi are room sealed appliances and therefore do not require purpose provided ventilation to the boiler room for combustion air. 3.10...
  • Page 24 WD388/0/2004 Chapter 3 : Boiler Location The Keston C36 Combi & C36P Combi Boilers The connection to the condensate drain of the boiler, and the condensate drain pipework itself, should be properly sealed to ensure there is no possibility of leakage into the dwelling.
  • Page 25 WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers 4. INSTALLATION OF THE BOILER Read Chapter 3 - Boiler Location and decide upon the position of the boiler. Installation of the boiler is straightforward but consideration must be given to access to allow flue and air pipes to be pushed through walls and ceilings.
  • Page 26 WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers ASSEMBLY PRACTICE Remove all plastic debris and burrs when installing air intake piping. Plastic filings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower.
  • Page 27 WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers iii) replace the nut from the frame bottom Connect the condensate drainage system to the boiler. It is advisable to use a detachable fitting at connection to the boiler to enable easy removal for servicing.
  • Page 28 It is essential that sludge or scale is removed from an existing system before fitting the boiler. The guarantee provided with the Keston C36 Combi and C36P Combi does not cover damage caused by system debris or sludge.
  • Page 29 INITIAL FLUSHING All waterways within the Keston C36 Combi and C36P Combi are either copper or high alloy stainless steel. As a result water treatment chemicals for central heating boilers such as Fernox MB1, Sentinel X100 or equivalent, are suitable.
  • Page 30 To measure CO levels in the Keston boiler remove the 1/8" plug from the flue outlet pipe spigot (Figure 6.7.4 item 7). Insert the probe of a calibrated combustion analysis meter and sample the gases as instructed in the test equipment's instructions.
  • Page 31 WD388/0/2004 Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers used during manufacture curing within the combustion chamber. On boilers which have been fired for more than one hour since installation, the CO levels should not exceed 150 ppm at high rate and 50 ppm at low rate.
  • Page 32 WD388/0/2004 Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers TIMING THE GAS METER Set the boiler DHW temperature to 65C and open two hot taps in the property fully. With no other appliances using gas, time the gas meter to be certain that the unit is running at the proper gas input.
  • Page 33 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6. FAULT FINDING ELECTRICAL CONTROL SEQUENCE 6.1.1 HEATING DEMAND When the external control(s) are calling for heat, power will be fed to the boiler connection strip at terminal SL (Switched Live) and N (Neutral) and the CH green light will illuminate.
  • Page 34 If the lamp is not lit then no demand for that function (ie CH or DHW) is present. In CH mode a demand is received by a 230V signal to SL or via the Keston Room Control unit.
  • Page 35 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ERROR CODES Display Description of fault Ignition failure - the boiler has attempted to light five times and not succeeded - check gas supply, air supply, flue, ignitor condition and spark gap.
  • Page 36 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 31...
  • Page 37 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 32...
  • Page 38 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 33...
  • Page 39 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers Exploded Assembly Diagrams 6.7.1 Boiler Controls Assembly Installation & Servicing Instructions Page : 34...
  • Page 40 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.2 Waterway, Condensate & Flue Assembly 57-1 57-4 57-2 57-3 Installation & Servicing Instructions Page : 35...
  • Page 41 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 57-1 57-4 57-3 57-2 Installation & Servicing Instructions Page : 36...
  • Page 42 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 37...
  • Page 43 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.4 Casing Assembly Installation & Servicing Instructions Page : 38...
  • Page 44 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code Description Main Control Box (C.10C.4.01.00.0 B) Control Panel (C.10C.4.04.00.0 A) Terminal Block (C.12.4.00.03.0) Terminal Block (C.10C.4.28.00.0)
  • Page 45 WD388/0/2004 Chapter 7 : Servicing The Keston C36 Combi & C36P Combi Boilers 7. ROUTINE (ANNUAL) SERVICING To ensure the continued safe and efficient operation of the boiler it is necessary to carry out routine servicing at regular intervals. Servicing must be carried out at least once per year. The frequency of the servicing will depend upon the particular operating conditions.
  • Page 46 WD388/0/2004 Chapter 7 : Servicing The Keston C36 Combi & C36P Combi Boilers If necessary, from visual inspection, clean the heat exchanger using a suitable stiff plastic bristle brush, vacuum out any large particles and flush the heat exchanger with fresh water until the water flowing from the condensate drain is clear.

  • Page 47: Table Of Contents

    WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers 8. REPLACEMENT OF PARTS CONTENTS GENERAL PRECAUTIONS ACCESS REPLACEMENT PROCEDURE ELECTRICAL COMPONENTS 8.4.1 CONTROL PANEL 8.4.2 BOILER FLOW & RETURN THERMISTORS 8.4.3 CABINET TEMPERATURE SENSOR 8.4.4...

  • Page 48: Boiler Flow & Return Thermistors

    WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers 8.4.2 Boiler Flow and Return Thermistors (Fig. 6.7.2 - 2/3 item 67) Isolate the appliance (Section 8.1) Gain access (Section 8.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions.

  • Page 49: Gas Control Valve / Venturi Assembly

    WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers When reassembling inspect any gaskets for damage and replace if necessary. 8.4.8 Gas Control Valve /Venturi Assembly (Fig. 6.7.3 item 215) Isolate the appliance (Section 8.1) Gain access (Section 8.2)

  • Page 50: Heat Exchanger

    WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers iii) Remove the combustion blower (Section 8.4.7) Remove the 4 nuts fixing the burner to the top of the heat exchanger. Withdraw the burner from the top of the heat exchanger.
  • Page 51 WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers Gain Access (section 8.2) iii) Shut off the water supply (CWS) to the DHW heat exchanger. Isolate the waterways to the pump using the system isolation valves.
  • Page 52 WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers 9. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No PartDenomination Burner Burner Gasket Ignitor Gasket 48 Ignitor/Sensor Probe Flow/Return Flue Thermistor Thermistors...

  • Page 53: Dhw Heat Exchanger

    WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers C36 Combi Gas Valve - Mixer Assem. C36P Combi Gas Valve - Mixer Assem. Control Box Fascia Panel Pump Block DHW Heat Exchanger Expansion Vessel Installation & Servicing Instructions...
  • Page 54 WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination Burner Burner Gasket Ignitor Ignitor Gasket DHW Thermistor Flow/Return Thermistor Flue Thermistor...
  • Page 55 WD388/0/2004 Chapter 10 : Benchmark Checklist Final The Keston C36 Combi & C36P COMBI Boilers 10. GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. ___________________ NOTIFICATION No. ____________________ CONTROLS To comply with the Building Regulation, each section must have a tick in one or other of the boxes 7,0( 7(03(5$785( &21752/ 72...
  • Page 56 WD388/0/2004 Chapter 10 : Benchmark Checklist Final The Keston C36 Combi & C36P COMBI Boilers SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 57 WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers KESTON CONDENSING BOILERS IMPORTANT C36 and C36P Combi INSTALLATION KEY POINTS Read Installation Manual Carefully Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe.

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