Do not use reconditioned or copy parts that have not been clearly authorised by Keston. For the very latest copy of literature for specification and maintenance practices visit our website www.keston.co.uk where you can download the relevant information in PDF format.
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ERP DATA MODEL SYMBOL UNITS Condensing Boiler Low Temperature Boiler B1 Boiler Cogeneration Space Heater Equipped with a Supplementary Heater Combination Heater Nominal Heat Output for Space Heating Full Load 24.2 24.2 Part Load Auxiliary Electricity Consumption Full Load 0.032 0.042 Part Load 0.013...
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PRODUCT FICHE KESTON COMBINATION BOILER Ideal Boilers ERP DATA SYMBOL UNITS MODEL Condensing boiler Seasonal Space heating efficiency class Rated heat output ƞ Seasonal space heating energy efficiency Annual energy consumption 74.1 Sound power level, indoors Water heating energy efficiency class...
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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 ......A01 (July 2016) Keston reserve the right to vary specification without notice Installation and Servicing...
SECTION 1 - GENERAL Table 1 - General Data Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size 4.65 Inlet Connection 15mm copper compression Outlet Connection 15mm copper compression Flow Connection 22mm copper compression Return Connection 22mm copper compression Flue Terminal Diameter...
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SECTION 1 - GENERAL KESTON COMBI C30 & C35 Natural Gas only Boiler size G.C. Appliance No. PI No. (Benchmark No.) 47-930-07 86CR18 47-930-08 86CR18 Destination Country: GB, IE For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions.
At low DHW draw-off rates the maximum temperature may The Keston Combi boiler is a wall mounted, full sequence, exceed 65ºC. automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boiler.
Keston in writing. If in doubt please enquire. compartment design, including airing cupboard installation, are to conform to the following: Any direct connection of a control device not approved by Keston could invalidate the certification and the normal appliance •...
BS6891:2005. Whilst the principle of the 1:1 gas valve ensures the Keston Combi range all valves be in the closed position. is able to deliver its full output at inlet pressures as low as 14mb, other gas appliances in the property may not be as tolerant.
SECTION 1 - GENERAL 1.13 BOILER DIMENSIONS, SERVICES & CLEARANCES The boiler connections are made on the boiler connection tails. Additional space will be required for installation, depending Refer to Section 2.15. upon site conditions. The following minimum clearances must be maintained for operation and servicing.
SECTION 1 - GENERAL 1.14 SYSTEM REQUIREMENTS - Central Heating Safety valve setting Notes Vessel charge pressure 0.5 to 0.75 a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose System pre-charge pressure bar None connection is only allowed if acceptable to the local water...
Ideal, Heating Systems. which must be used in accordance with the manufacturers’ instructions. If water treatment is used Keston recommend only the use of SCALEMASTER GOLD 100, FERNOX, MBI, ADEY MC1, SENTINEL inhibitors and associated water X100 or CALMAG CM100...
SECTION 2 - INSTALLATION 2.3 FLUE SYSTEM IMPORTANT When installing a replacement boiler a new flue system is recommended. However re-using the existing boiler flue installation is acceptable if the installer checks and confirms: • The flue pipe is the approved Marley/Polypipe/Terrain 50mm muPVC solvent weld flue system •...
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It is possible to have variable flue and air lengths as described within the shaded area of graphs below. Keston Combi C35 - Flue & Air Pipe Length Keston Combi C30 - Flue & Air Pipe Length SLOPE ‘Horizontal’ flue outlet pipework MUST slope at least 1.5 degrees (26mm per metre run) downwards towards the boiler.
SECTION 2 - INSTALLATION 2.4 FLUE INSTALLATION EXAMPLE KESTON COMBI C30 Keston Combi 30 - Flue & Air Pipe Length 1.5º back Sleeve 15.5 to boiler Bracket at each 1 metre 1.5m 0.15m 10.15 Acceptable Operating Area 1.5º back to boiler...
The boiler casing must always be correctly fitted 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 Combi 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.
SECTION 2 - INSTALLATION INSTALLING 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. The order in which the components are installed will depend upon particular site conditions, but in general it will be easiest and most accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal - this is the sequence described.
SECTION 2 - INSTALLATION 2.10 FITTING THE WALL MOUNTING 2.11 MOUNTING THE BOILER PLATE 1. Ensure the plastic plugs are removed from both the CH and DHW connections before mounting the boiler. Screw the wall mounting plate to the wall using 2 wall plugs (previously fitted) with the 2 screws provided.
SECTION 2 - INSTALLATION 2.12 ASSEMBLY PRACTICE Remove all plastic debris and burrs when installing air intake piping. Plastic fillings 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 filings or other debris will not be covered by guarantee.
SECTION 2 - INSTALLATION 2.13 FITTING THE FLUE SLEEVE 1. Cut hole in wall. 7. Locate wall plate over flexible wall seal and clamp in place using the raw plug pack. 2. Measure wall Thickness 8. Affix flue terminal 3. Cut sleeve length to match wall thickness & remove burrs. 9.
SECTION 2 - INSTALLATION 2.14 CONDENSATE to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water Condensate discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc.
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SECTION 2 - INSTALLATION CONDENSATE.... CONT’D Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler sealed...
SECTION 2 - INSTALLATION 2.15 CONNECTIONS & FILLING NOTES. Note. The domestic hot water flow rate is Ensure all boss blanking plugs are removed before connecting hardware. Each automatically regulated to a maximum: valve must be fitted to the correct boss as shown in the picture. 30 = 12.4 l/m (2.8 gpm) Ensure each union is fitted with fibre seals provided.
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SECTION 2 - INSTALLATION FILLING IMPORTANT - when filling: When filling there may be a slight water leak from the air vent therefore electrical connections should be protected. Filling Top Up Ensure filling loop is connected and all washers in place. 1.
SECTION 2 - INSTALLATION 2.16 ELECTRICAL CONNECTIONS 0.75mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for WARNING. This appliance MUST be earthed. electrical installations. A mains supply of 230Vac ~ 50 Hz is required. Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch The fuse rating should be 3A.
SECTION 2 - INSTALLATION 2.18 EXTERNAL WIRING External Controls – 230V 50Hz Optional External Controls – Extra Frost Protection Low Voltage If parts of the pipework run outside the Wiring a 230V 50Hz Room Thermostat, house or if the boiler will be left off for more Diagram A (with optional timer, Diagram B) Wiring OpenTherm Room Control DIAGRAM A:...
This can be a standard unit or Essentially rotating the knob clockwise increases the room either of the options available from Keston Combi range. temperature and rotating the knob anti-clockwise decreases the During programmed On times the Central Heating Radiator room temperature.
Part P of the Building Regulations. Avoid running this cable alongside mains voltage cables. Wiring the Weather Compensation Kit to the Keston Combi. 1. Isolate the electricity supply to the boiler.
SECTION 2 - INSTALLATION 2.23 COMMISSIONING AND TESTING A. Electrical Installation B. Gas Installation 1. Checks to ensure electrical safety should be carried out by 1. The whole of the gas installation, including the meter, a competent person. should be inspected and tested for tightness and purged in accordance with the recommendations of BS.6891.
SECTION 2 - INSTALLATION 2.24 INITIAL LIGHTING BOILER Legend A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler Status Display HOT WATER CENTRAL HEATING MODE E. Burner ‘on’ Indicator Central Heating Economy Setting G.
SECTION 2 - INSTALLATION 2.25 THE DISPLAY The user control has a dot matrix LCD to inform the user about Notes: Boiler frost protection - boiler fires if temperature is below 5º C. the status of the boiler. The temperatures shown below are for illustration purposes only. The measured temperatures will be shown on the boiler.
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SECTION 2 - INSTALLATION MENU OPERATIONS Efficiency Level Change Service Time Fault Help To view the efficiency level of the boiler This feature provides a list of potential The time until the next service required press “Menu” and the following screen will corrective actions at an installer level for all message is shown can be changed as follows be displayed:...
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SECTION 2 - INSTALLATION MENU OPERATIONS Sensor Readings Maximum Flow Temperature Service Mode Maximum DHW Rate It is possible to limit the maximum flow This feature will run the burner at minimum To view the current Water Pressure, temperature that can be set from the CH rate.
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SECTION 2 - INSTALLATION MENU OPERATIONS Pump Modulation Diverter Valve Mid Position The boiler is factory set for 70% minimum To move the diverter valve to the mid CH pump speed. This can be increased position, ensure there are no demands to 100%.
SECTION 2 - INSTALLATION 2.26 GENERAL CHECKS Make the following checks for correct operation in: CENTRAL HEATING & DOMESTIC HOT WATER MODE. 1. Ensure that the CH external controls are calling for heat. 1. Fully open all DHW taps in turn and ensure that water flows freely from them.
SECTION 2 - INSTALLATION 2.27 RESTART PROCEDURE To restart the boiler, press the RESTART button (H). Legend A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler Status Display E. Burner ‘on’ Indicator Central Heating Economy Setting BOILER G.
SECTION 3 - SERVICING 3.1 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.
SECTION 3 - SERVICING 3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Loosen the two screws retaining the front panel. 3. Hook the panel onto the top retaining clips. 2. Pull the two spring clips down to disengage and pull panel 4.
SECTION 3 - SERVICING 3.4 BURNER REMOVAL AND CLEANING 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.
SECTION 3 - SERVICING 3.8 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the front panel must be correctly When replacing ANY component refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes. 1. In order to assist fault finding, the control panel has 2.
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.
SECTION 3 - SERVICING 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 lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor and reassemble in reverse order, ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown.
SECTION 3 - SERVICING 3.14 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Section 3.8. Flame Detection Electrode 2. Remove the burner. Refer to Section 3.4. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode.
SECTION 3 - SERVICING 3.17 DIVERTER VALVE ACTUATOR REPLACEMENT Refer to Section 3.8. To remove the motor: 1. Remove the condensate trap/siphon. Refer to Section 3.5. 2. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. 3.
SECTION 3 - SERVICING 3.19 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.
SECTION 3 - SERVICING 3.20 DRAINING THE BOILER Filling Loop 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.
SECTION 3 - SERVICING 3.23 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.20. 3. 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.
SECTION 3 - SERVICING 3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 16. Twist and remove the DHW manifold. 1. Refer to Section 3.8. 17. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly. 2.
SECTION 3 - SERVICING 3.29 CH WATER PRESSURE SWITCH REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.20. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip.
SECTION 3 - SERVICING 3.31 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. 13.
SECTION 3 - SERVICING 3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING Recharge Point 1. Refer to Section 3.8. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order. 5. Check that the boiler operates in both DHW & CH modes.
SECTION 4 - FAULT FINDING 4.1 FAULT FINDING CHART MAIN MENU Overheat Lockout 3/4 Overheat Lockout 4/4 Overheat Lockout 1/4 Overheat Lockout 2/4 Restart Boiler Check Radiator Valves With Boiler Off & Bleed Radiators Go to Section 4.2 And Boiler Valves If Fault Persists Flow Temperature System Cold...
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SECTION 4 - FAULT FINDING Low Mains Voltage Low Mains Voltage Contact Electricity Provider Contact Electricity Provider Menu PCB Fault Replace PCB Contact Installer Restart Menu Spare PCB Not Set Switch Off Follow instructions Wait 5s in Section 3.19 Switch On Restart Menu High Mains Voltage...
SECTION 4 - FAULT FINDING 4.2 OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then restart boiler Check that the Pump is rotating freely. Is Is the Flow/Return Differential across the Boiler in the Differential now below 20°C? excess of 30°C?
SECTION 4 - FAULT FINDING 4.4 FLAME ON BEFORE GAS VALVE ON Check routing and integrity of internal boiler wiring is OK. Check Restart the boiler, does Boiler Work OK? condition of Flame Sense Electrode and replace if deteriorated. Replace Flame Detection Electrode Separate the flame detection electrode in-line connector.
SECTION 4 - FAULT FINDING FAN FAULT Does the wiring from the Fan to the PCB have Rectify Wiring & secure connections at both ends and has not connections deteriorated? Does the wiring have continuity? Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan? Replace Fan 4.8 FLOW THERMISTOR FAULT...
SECTION 4 - FAULT FINDING 4.10 OUTSIDE SENSOR FAULT Securely connect the wiring at both the Is the wiring securely connected at both the boiler and boiler and Outside Sensor Outside Sensor? Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins.
SECTION 4 - FAULT FINDING 4.11 NO CH OPERATION BUT DHW WORKS OK Move the mode knob to the Winter position Is the mode knob in the Winter position? Are the Timer and the Room Thermostat switched Switch the Timer and Room Thermostat On Open the Radiator Valves Are the Radiator Valves Open? There is no Voltage from the Timer/Room Stat.
SECTION 4 - FAULT FINDING 4.12 NO HW BUT CH ON Does the display show a similar screen to the screen shown? Adjust flow rates to achieve 35º Are the flow rates correct as per Table 3. temp rise and check filter is not blocked with debris.
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.
SECTION 6 - BENCHMARK & COMMISSIONING Installation and Servicing...
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SECTION 6 - BENCHMARK & COMMISSIONING 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.
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...
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 SERVICE 02 ² % ² % ² % ² % (Where Possible) (Where Possible) Signature Signature SERVICE 03 SERVICE 04...
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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) sepa- rate guidance is provided with the conversion kit supplied and this must be followed.
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Start Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser In accordance with boiler instructions, Insert analyser probe into air inlet test point (where available) and allow set boiler to operate at maximum rate readings to stabilise. (full load condition).
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NOTES Keston Combi - Installation and Servicing...
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NOTES Keston Combi - Installation and Servicing...
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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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