Keston 30C Installation And Servicing Instructions
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Keston 30C Installation And Servicing Instructions

Fan powered high efficiency modulating domestic condensing gas combination boiler
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The Keston 30C
30C

Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS COMBINATION BOILER
CE/PI No. 86-CL-38
GC No.
47-930-03
These instructions must be left either with the
user or next to the site gas meter.
34 West Common Road
Hayes, Bromley, Kent, BR2 7BX
Tel. +44 (0) 20 8462 0262
Fax. +44 (0) 20 8462 4459
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

    The Keston 30C Installation and Servicing Instructions FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE/PI No. 86-CL-38 GC No. 47-930-03 These instructions must be left either with the user or next to the site gas meter. 34 West Common Road Hayes, Bromley, Kent, BR2 7BX Tel.
  • Page 2 Keston 30C - Installation and Servicing...
  • Page 3 Pae 37 - Frame 38, Wiring Diagram • Wire removed from flame sensor electrode Page 73 - Short List of Parts • Key No. 111 - part number updated Keston reserve the right to vary specification without notice Keston 30C - 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 30C - 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 30C - Installation and Servicing...

  • Page 6: Safe Handling

    INTRODUCTION This boiler may require 2 or more operatives to move it to its The Keston 30C boiler is a wall mounted, full sequence, installation site, remove it from its packaging base and during automatic spark ignition, low water content, fanned flue, high movement into its installation location.

  • Page 7: Location Of Boiler

    In both cases, details of essential features of cupboard / Installation and Servicing Instructions or as otherwise compartment design, including airing cupboard installation, recommended by Keston in writing. If in doubt please enquire. are to conform to the following: Any direct connection of a control device not approved by •...

  • Page 8: Gas Supply

    BS6891:2005. Whilst the principle of the 1:1 gas valve the current ETCI rules for electrical installations. ensures the Keston 30C is able to deliver its full output at inlet The mains supply to the boiler and system wiring centre shall...
  • 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 30C - Installation and Servicing...
  • Page 10 RETURN to the boiler. minimum system design pressure is reached; 1.0 bar if the system is to be pre-pressurised. Guidance on vessel sizing is given in Table above. continued ..Keston 30C - Installation and Servicing...

  • Page 11: Domestic Hot Water

    3. Adjust the room thermostat and programmer to Turn up the room thermostat and adjust the lockshield NORMAL settings. valve to give an uninterrupted flow through the radiator. These valves should now be left as set. Keston 30C - Installation and Servicing...

  • Page 12: Water Treatment

    Benchmark Guidance Notes on Water Treatment in manufacturers' instructions. Central Heating Systems. If water treatment is used Keston recommend only the use of For further information contact: inhibitors and associated water FERNOX, MBI or SENTINEL X100 treatment products, which must be used in accordance with Fernox Manufacturing Co.
  • Page 13 GAS VALVE HEAT ENGINE PIPE - GAS INJECTOR WALL MOUNTING BRACKET INJECTOR ASSEMBLY FRONT PANEL VENTURI FASCIA BRACKET - GAS VALVE BURNER BRACKET - EXPANSION VESSEL SAFETY VALVE DRAIN PIPE DROP DOWN DOOR FLUE THERMOSTAT Keston 30C - Installation and Servicing...
  • Page 14 INSTALLATION BOILER ASSEMBLY - Exploded View (excluding flue box) 3G9971b Keston 30C - Installation and Servicing...
  • Page 15 5. Nut 1/2" Flow Valve Pack Accessory Pack 1. Screw (x2) 2. Wallplug (x2) Flow Valve Pack 1. Pipe CH Flow 2. Washer CH 3G9687 3. Valve Flow (with gauge) continued ..Keston 30C - Installation and Servicing...
  • Page 16 INSTALLATION UNPACKING..CONT’D Pack 2 Contents 2 Boxes Pack 2a Contents 3 x elbows 2 x 450mm pipe 3 x 100mm pipe Pack 2b Contents Top Flue Box 6 x screws 2 x Terminals Keston 30C - Installation and Servicing...

  • Page 17: Flue System

    500mm of each other ensure that the air terminal is FLUE pointing towards the ground using a 90º bend and one of the 100mm sections of pipe provided within pack 2a. KESTON 30C Flue Box Keston 30C - Installation and Servicing...

  • Page 18: Air Supply

    Rubber collars are available for flue and air terminals to finish can be decreased to the values indicated. the external wall face around the terminals (Part No The Keston 30C, as with any condensing boiler, will generate a C.08.00.07.0). condensate “plume” from the flue terminal in all weather conditions.

  • Page 19: 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 provided at Section each side) and screw home. through wall Note. Check all of the hole positions before drilling. Keston 30C - Installation and Servicing...

  • Page 20: Mounting The Boiler

    The condensate trap also includes a siphon to reduce the possibility of freezing in the drain outlet. If external condensate pipe is used then the pipe should be 32mm nominal diameter. Consideration should be given to insulating external condensate pipe runs. Keston 30C - Installation and Servicing...

  • Page 21: Assembly Practice

    Ensure pipes are fully engaged into sockets and solvent welded with no leaks. Flue Spigot Air Spigot M5 Screw Retaining Clip (assembled) Clamp 3G10101 Keston 30C - Installation and Servicing...
  • Page 22 Where a concentric flue option is chosen the following instruction should be followed and the standard flue in flue box omitted. IMPORTANT. The boiler MUST be installed in a vertical position Only use Keston concentric flue pipe and fittings. FLUE KITS Pack B - telescopic supplied as an optional extra Dimension X - Wall thickness.

  • Page 23: Exploded View

    Rear 420mm LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret clamp. The flue terminal MUST be fitted with the ‘TOP’ uppermost to allow the correct fit and use of the plume management 3G9499a system. Keston 30C - Installation and Servicing...
  • Page 24 3. Locate 2 No.14 x 50mm screws in the wall mounting through wall plate (one at each side, in any of the 3 holes provided at each side) and screw home. Note. Check all of the hole positions before drilling. Keston 30C - Installation and Servicing...
  • Page 25 4. Using a 3.5mm drill bit, drill one hole in outer air duct taking care not to pierce plastic inner flue. 5. Fix to length using self tappers provided. 6. Seal outer air duct using the tape provided. Measurement to be taken from this point nm8945 Keston 30C - Installation and Servicing...
  • Page 26 4. TERMINATION TO DRAIN / GULLY External External wall wall Open end of pipe Termination BOILER BOILER direct into gulley to Soak away below grating but above water level cla7775 cla7774 Ground Level Ground Level minimum DRAIN 500mm Keston 30C - Installation and Servicing...
  • Page 27 1 metre of extension pipe used and a bracket should be used at every joint, to ensure pipes are held at the correct angle. Flue Outlet 3G9847c Retaining Clip (assembled) Plastic Pegs (assembled) 3G9847d 3G9847e Keston 30C - Installation and Servicing...
  • Page 28 CH Flow Outlet Inlet Return Black Handle Yellow Blue Handle Handle Note that all isolation handles are shown in Black the open position. Handle Black Handle Filling 3G9849b Loop Keston 30C - Installation and Servicing...

  • Page 29: Gas Connection

    Black can be used for all Handle installations. Yellow Blue Handle Handle 3G9849d Safety Drain Valve Black Handle Black Handle Safety Valve Drain Connection 15mm elbow or fittings Safety Valve (not supplied) Drain Pipe Keston 30C - Installation and Servicing...
  • Page 30 5. Disconnect filling loop at the LH side, ensuring Black washer is retained and screw on cap. Handle Black Handle 3G9865 Note. Fully open all DHW taps and ensure water is flowing freely. Once satisfied close all taps. Keston 30C - Installation and Servicing...

  • Page 31: Electrical Connections

    2. Remove the front panel. Refer to Frame 44. cable refer to Frame 33. 3. Swing the control box down into the servicing position. The Keston 30C boiler comes pre-fitted with a link wire Refer to Frame 50. between the room thermostat/Timer connections on the 4.
  • Page 32 INSTALLATION 32 INTERNAL WIRING..CONT’D Keston offer 2 kits as follows: (see individual kits for installation instructions) Electronic Timer (7 day) kit - 7 day electronic CH timer fits into the control box of the boiler. This can be fitted in conjunction with a room thermostat.
  • Page 33 Once the sensor is fitted it is automatically detected. The sensor operation may be configured by adjustment of the boiler operating parameters, if necessary. Kit Contents A. Outside Air Sensor 3G10011 Keston 30C - Installation and Servicing...
  • Page 34 Part P of the Building Regulations. Avoid running this cable alongside mains voltage cables. Wiring the Weather Compensation Kit to the Keston 30C. Isolate the electricity supply to the boiler.
  • Page 35 The On and Off time control of central heating should be controlled by a separate timer. This can be a standard unit or either of the options available from Keston 30C range. During programmed On times the Central Heating Radiator Flow Temperature is controlled by the boiler relative to the Outside Temperature as shown in the following diagram.

  • Page 36: External Electrical Controls

    3G9990a OpenTherm Programmable Room Temperature Control Note. These terminals MUST ONLY be connected to an OpenTherm Controller, (such as the Keston Chronothern Room Controller (c.17.4.21.00.0). Connecting any other device / control wiring may destroy the primary PCB. 1. Isolate the mains supply to the boiler.
  • Page 37 INSTALLATION 38 WIRING DIAGRAM Keston 30C - Installation and Servicing...

  • Page 38: Commissioning And Testing

    - refer to “Gas Supply” on page 8. Gas Pressure Ensure that this inlet Test Point pressure can be obtained with all other gas appliances in the property working. Keston 30C - Installation and Servicing...

  • Page 39: Initial Lighting

    When the burner is established the BLUE 'Burner On' neon (F) will be illuminated, the LCD will display “Central Heating” and “Radiator Temp XX C” . continued..Keston 30C - Installation and Servicing...
  • Page 40 Mode knob moved to summer position Summer mode Central heating off Hot water on Mode knob moved to winter position Winter mode Central heating on Hot water on Mode knob moved to reset position Reset Keston 30C - Installation and Servicing...
  • Page 41 To reset boiler, turn the mode control knob (D) to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence. Legend A. Pre-heat On/off D. Off/Summer/Winter/Reset Control B. DHW temperature control E. Boiler Status C. CH temperature control F . Burner ‘on’ indicator Keston 30C - Installation and Servicing...
  • Page 42 4. Refill and vent the system, add inhibitor (see Frame 5), clear all air locks and again check for water soundness. 80 (176) 64 (147) 5. Reset the system initial pressure to the design 30 (86) 40 (104) requirement. Keston 30C - Installation and Servicing...

  • Page 43: Handing Over

    Gas Safe Registered Engineer consulted. In IE contact a Registered Gas Installer (RGII). 6. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system. Keston 30C - Installation and Servicing...

  • Page 44: Benchmark Commissioning Checklist

    SERVICING 43 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 45: 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 30C - Installation and Servicing...

  • Page 46: Burner Removal And Cleaning

    2. Pull off the rubber pipe noting the position and flush out any deposits with clean water. 3. Replace the cleaning plug and refill the siphon with water. 4. Replace the rubber pipe connector with the twin wall seal fitted to the condensate siphon. 3G9690 Keston 30C - Installation and Servicing...

  • Page 47: Cleaning The Heat Exchanger

    9. Turn on the gas supply at the gas service cock. 4. Reconnect the fan electrical leads. 10. Reconnect the electrical supply. 5. Remove the sump cover and refit the lower flue manifold as shown. Keston 30C - Installation and Servicing...

  • Page 48: Replacement Of Components

    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 40 & 41. Keston 30C - Installation and Servicing...

  • Page 49: Burner Injector Replacement

    8. Fit the new burner, replacing any damaged or deteriorating sealing gasket. 9. Reassemble in reverse order. Refer to Frame 49. 10. Check the operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...
  • Page 50 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 30C - Installation and Servicing...

  • Page 51: 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 40 & 41. a i g S t r . 5 m Keston 30C - Installation and Servicing...

  • Page 52: Electrical Connections

    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 40 & 41. Keston 30C - Installation and Servicing...

  • Page 53: Diverter Valve Actuator Replacement

    6. Reassemble in reverse order. 7. When reassembling Siphon ensure the trap is full of water. 8. Check operation of the boiler. Refer to Frames 40 & 41. 3G9690 Keston 30C - Installation and Servicing...
  • Page 54 4 corner retaining posts. 7. Take the new Primary PCB and attach the appropriate Boiler Chip Card (BCC). Note. Ensure the correct orientation of BCC by placing “TOP” side up as shown. Plastic Clip Ribbon Cable Connection Keston 30C - Installation and Servicing...

  • Page 55: User Control Pcb Replacement

    3. Lift off the flow turbine sensor plastic retaining clip. 4. Unplug the electrical connection and transfer to new turbine sensor. 5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...

  • Page 56: Draining The Boiler

    3. Unscrew the pressure gauge and discard. 4. Fit new pressure gauge, using suitable jointing compound. 5. Refill the boiler. Refer to Frame 30. 6. Check operation of the boiler. Refer to Frames 40 & 41. 3G9690 Keston 30C - Installation and Servicing...

  • Page 57: Pump Automatic Air Vent Replacement

    7. Ensure the air vent cap is loose. 8. Refill the boiler. Refer to Frame 30. Check for leaks around the new air vent joint. 9. Check the operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...

  • Page 58: Diverter Valve Internal Cartridge Replacement

    9. Fit the new valve mechanism ensuring the correct fit of the pin. Frames 40 & 41. 10. Reassemble in reverse order. 11. Refill the boiler. Refer to Frame 30. 12. Check operation of the boiler. Refer to Frames 40 & 41. FRONT CARTRIDGE REAR CARTRIDGE Keston 30C - Installation and Servicing...

  • Page 59: Pump Head Replacement

    5. Remove the pump head. 6. Fit the new pump head. 7. Reassemble in reverse order. 8. Refill the boiler. Refer to Frame 30. 9. Check operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...
  • Page 60 6. Remove the filter. 7. Clean or replace filter as necessary. 8. Reassemble in reverse order. 9. Refill the boiler. Refer to Frame 30. 10. Check Operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...
  • Page 61 5. Fit the new thermistor using the sealing washer provided. 6. Reassemble in the reverse order. 7. Refill the boiler. Refer to Frame 30. 8. Check the operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...

  • Page 62: Heat Engine Renewal

    10. Remove the 2 M5 screws retaining the gas valve mounting bracket and transfer bracket to the new heat 18. Refill the boiler. Refer to Frame 30. exchanger. 19. Check operation of the boiler. Refer to Frames 40 & 41. Keston 30C - Installation and Servicing...

  • Page 63: Expansion Vessel Recharging & Replacement

    5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frames 40 & 41. Note. Ensure that the boiler front panel is correctly sealed, compressing the seal to make an airtight joint. Keston 30C - Installation and Servicing...

  • Page 64: Fault Finding

    No DHW but CH operates OK Go to Frame 95 No Display No Display RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Keston 30C - Installation and Servicing...
  • Page 65 (Refer to Frame 54) OK, now Replace the Pump, reset boiler then reset boiler RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Keston 30C - Installation and Servicing...

  • Page 66: Gas Supply

    In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve. RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Keston 30C - Installation and Servicing...

  • Page 67: Pump

    Fill and vent the system and open all isolation all isolation and radiator valves open (check valves pressure gauge is between 1 to 1.5 bar)? Are connections on water pressure sensor secure? Re-fit connections Replace water pressure sensor Keston 30C - Installation and Servicing...
  • Page 68 * 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 30C - Installation and Servicing...
  • Page 69 2,400 - 2,600 Ohms At 85 expect 1,000 - 1,100 Ohms Is the Thermistor value correct? Check and replace wiring as necessary Is there continuity between the PCB and the Thermistor? Replace PCB Keston 30C - Installation and Servicing...
  • Page 70 Is the Thermistor value correct? Securely connect the wiring to the PCB Is the wiring securely connected to the low voltage 11 way connector at the front left hand side of the PCB? Replace PCB Keston 30C - Installation and Servicing...
  • Page 71 Are the Radiator Valves Open? There is no Voltage from the Timer/Room Stat. Is there 230Vac at (A)? This is not boiler fault. Ensure Voltage is supplied to boiler by rectifying external wiring. Replace the Diverter Valve Keston 30C - Installation and Servicing...
  • Page 72 Is the ribbon cable from the main PCB to the User Connect the ribbon from the main PCB to the Interface PCB connected securely? User Interface PCB securely Replace the Is ribbon cable damaged? User Interface Replace ribbon cable Keston 30C - Installation and Servicing...

  • Page 73: 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.

  • Page 74: Short List

    SHORT LIST OF PARTS 96 SHORT LIST 302B 3G9977a Keston 30C - Installation and Servicing...

  • Page 76: Installer Notification Guidelines

    Benchmark Checklist MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS Gas Safe Register will record the data and will send a certificate FULLY COMPLETED AND LEFT of compliance to the property WITH THE APPLIANCE Keston 30C - Installation and Servicing...
  • Page 77 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 78 Gas Safe Register ID Number...
  • Page 79 Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number...
  • Page 80 Keston Boilers, 34 West Common Road, Hayes, Bromley, Kent, BR2 7BX. June 2010 UIN 205531 A03 Telephone: 0208 462 0262 Fax: 0208 462 4459. Keston pursues a policy of continuing improvement in the design performance products. The right is therefore reserved to vary specification without notice.

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