Keston SYSTEM2 S30 Installation & Servicing
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Keston SYSTEM2 S30 Installation & Servicing

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INSTALLATION
& SERVICING
SYSTEM
2
S30
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.
For the very latest copy of literature for specification and maintenance practices visit our website keston.co.uk
where you can download the relevant information in PDF format.
04 / 2023
UIN 236468 A03

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Summary of Contents for Keston SYSTEM2 S30

  • Page 1 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 2 ERP DATA SYMBOL UNITS 30 kW 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 30.3 Part Load Auxiliary Electricity Consumption Full Load elmax 0.052 Part Load elmin...
  • Page 3 PRODUCT FICHE KESTON SYSTEM S BOILER Keston Heating ERP DATA SYMBOL UNITS MODEL 30 kW Condensing boiler Seasonal space heating efficiency class Rated heat output Seasonal space heating energy efficiency ƞs Annual energy consumption Sound power level, indoors Seasonal Space Heating Energy Efficiency of the Boiler...
  • Page 4 NOTES FOR THE INSTALLER For any technical queries please ring the Keston installer helpline : 01482 443005 BOILER RESTART PROCEDURE - Press the RESTART button. The boiler will repeat the ignition sequence if a heat demand is present. DEFINITIONS WARNING: Risk of injury or death...

  • Page 5: Table Of Contents

    3.21 Pump Head Replacement ............47 Flue System - Continued ............18 3.22 CH Water Pressure Switch Replacement ........48 Air and Flue Example Keston System S30 ....... 19 3.23 Flow Thermistor Replacement ............ 48 2.10 Air and Flue Example Keston System S30 .......

  • Page 6: Section 1 - General

    Section 1 - General Table 1 General Data 30 kW Gas Supply 2H-G20-20mbar Gas Supply Connection 15mm copper compression Injector Size 4.65 Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter Average Flue Temp-Mass Flow Rate 69ºC - 13g/s CO2 Content (±...
  • Page 7 Section 1 - General KESTON SYSTEM Natural Gas Only BOILER SIZE G.C. Applicance No (Benchmark No.) 41-930-54 Destination Country: GB, IE, RO For UK, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions.

  • Page 8: Introduction

    OPTIONAL ACCESSORIES The heat exchanger is manufactured from cast aluminium. The boiler is suitable for connection to fully pumped, Please visit Keston.com to access the optional accessories for sealed heating systems ONLY. Adequate arrangements for this boiler. completely draining the system by provision of drain cocks MUST be provided in the installation pipework.

  • Page 9: Safe Handling Of Substances

    Section 1 - General BSEN12828 Heating Systems in buildings: Design for water Installations in Scotland above 11 meters requires the High based heating systems. Rise Flue Kit. This adheres to the new building standards technical handbook 2020: Domestic Buildings (April 2021 BSEN12831 Heating Systems in buildings: Method for Addendum).

  • Page 10: Water Circulation System

    Whilst the principle of the 1:1 gas valve ensures the Keston by radiators not fitted with such a valve. range is able to deliver it is full output at inlet pressures as low...

  • Page 11: Boiler Dimensions, Services & Clearances

    Section 1 - General 1.14 BOILER DIMENSIONS, SERVICES & CLEARANCES Refer to Section 2.18 The boiler connections are made on the boiler connection tails. Additional space will be required for installation, depending upon site conditions. The following minimum clearances must be maintained for operation and servicing.

  • Page 12: System Requirements - Central Heating

    Section 1 - General 1.15 SYSTEM REQUIREMENTS - CENTRAL HEATING a. The method of filling, refilling, topping up or flushing sealed Table 3 Vessel Sizing primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local PRV setting water authority.

  • Page 13: System Balancing

    3. Adjust the room thermostat and programmer to NORMAL settings. 1.17 WATER TREATMENT Central Heating For further information contact: The Keston range of boilers have an ALUMINIUM alloy heat Fernox exchanger. www.fernox.com Tel: +44 (0) 3301 007750 IMPORTANT The application of any other treatment...

  • Page 14: Section 2 - Installation

    Section 2 - Installation BOILER ASSEMBLY - EXPLODED VIEW CH Return Valve Water Pressure Switch Flue Manifold Top Control Box Front CH Flow Valve Pressure Gauge Clamp Retaining Flue Turret Blank Insert Pump Head Gas Cock Hose Condensate Internal Heat Engine Auto Air Vent Gas Valve Condensate Trap...

  • Page 15: Unpacking

    Section 2 - Installation UNPACKING Unpack and check the contents The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order. Pack A Contents Boiler Hardware Pack Box...

  • Page 16: Wall Mounting Template

    Section 2 - Installation WALL MOUNTING TEMPLATE The wall mounting template is located on the internal IMPORTANT: protective packaging. Ensure the wall Note. The template shows the positions of the fixing holes where the boiler and the position of the air and flue connections. Care MUST will be is flat.

  • Page 17: Flue System

    Section 2 - Installation FLUE SYSTEM DESIGN IMPORTANT Individual air supply and flue outlet pipes are used as When installing a replacement boiler a new flue system is standard. recommended. However re-using the existing boiler flue installation is acceptable if the installer checks and confirms: The material approved for this application which MUST be used are: •...

  • Page 18: Flue System - Continued

    Any vertical termination MUST have the terminals fitted and the air intake comply with the dimensions above. Maximum lengths Keston System 30 - Flue & Air Pipe Length Due to the resistance presented by extended flue length a slight reduction in maximum boiler output will occur where combined flue and air lengths in excess of 18.0 m and 16.0...

  • Page 19: Air And Flue Example Keston System 2 S30

    Section 2 - Installation AIR AND FLUE EXAMPLE KESTON SYSTEM 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 20: Flue Termination Position

    Section 2 - Installation 2.11 FLUE TERMINATION POSITION When Flue & Air Terminals are less When Flue & Air Terminals are than 500 mm apart more than 500 mm apart Twin Flue Positions Flue min. Flue min. Air min. spacing Air min.

  • Page 21: Flue Termination Position - Continued

    Section 2 - Installation 2.12 FLUE TERMINATION POSITION - CONTINUED General Installations The Keston System is a room-sealed appliance and therefore does not require purpose provided ventilation to All parts of the system must be constructed in accordance the boiler room for combustion air.

  • Page 22: Fitting The Flue Sleeve

    Section 2 - Installation 2.14 FITTING THE FLUE SLEEVE Flue Terminal 1. Cut hole in wall. 2. Measure wall thickness. Flue Pipe Flue Sleeve Flange Flue Sleeve 3. Cut sleeve length to match wall thickness & remove burrs. Flexible Wall Wall Plate 4.

  • Page 23: Condensate Drain

    Section 2 - Installation 2.16 CONDENSATE DRAIN 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 soakaway.

  • Page 24: Condensate Drain - Continued

    Section 2 - Installation 2.17 CONDENSATE DRAIN - CONT’D Figure 1 - Connection of Condensate Drainage Pipe to Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil & Vent Stack Internal Soil Vent Stack Boiler Boiler...

  • Page 25: Connections & Filling

    Section 2 - Installation 2.18 CONNECTIONS & FILLING PRV DRAIN The PRV connection, located at the bottom right-hand side of the boiler, comprises an open ended 15mm pipe. A 15mm CAUTION: Heating the isolation valves may damage compression coupling is supplied to assist in removal of the fibre seals pipework if required.

  • Page 26: Installer Wiring

    MAINS IN STAT/ IN OUT TIMER FROST STAT OPTIONAL ROOM MAINS IN MAINS IN STAT/ TIMER Keston System S BOILER WITH Y PLAN SYSTEM (without outside sensor) Y PLAN FUSED VALVE SPUR BOILER SL 1 MAINS IN CH ON TIMER...

  • Page 27: Installer Wiring - Continued

    Section 2 - Installation 2.21 INSTALLER WIRING CONT. Keston System S BOILER WITH S PLAN SYSTEM (without outside sensor) S PLAN VALVE S PLAN FUSED VALVE SPUR BOILER SL 1 MAINS IN IN OUT CH ON TIMER HW ON HW OFF 2.22 REPLACING PRE-FITTED MAINS CABLE...

  • Page 28: Operation

    Section 2 - Installation 2.24 CH OPERATION The ON and OFF time control of central heating should be Examples: controlled by a separate timer. 1. If the CH Potentiometer Knob is set to display 22ºC on During programmed ON times the Central Heating Radiator the Boiler Display the Room Temperature Setpoint will Flow Temperature is controlled by the boiler relative to the be 22ºC and the curve 22 will be followed, indicated by...

  • Page 29: The Weather Compensation Kit - Supplied As Standard

    Part P of the Building Regulations. Avoid running this cable alongside mains voltage cables. Wiring the Weather Compensation Kit to the Keston System 1. Isolate the electricity supply to the boiler. 2. Remove the boiler front panel (Refer to boiler installation instructions).

  • Page 30: Wiring Diagram

    Section 2 - Installation 2.26 WIRING DIAGRAM WPS Gnd WPS Signal Installation and Servicing...

  • Page 31: Commissioning And Testing

    Section 2 - Installation 2.27 COMMISSIONING AND TESTING B. Gas Installation A. Electrical Installation WARNING: WARNING: Electrical safety checks should be Open windows, doors and extinguish carried out by a qualified person. flames before starting the next steps. Do not smoke. 1.

  • Page 32: Initial Lighting

    Section 2 - Installation 2.28 INITIAL LIGHTING Legend A. Hot Keys B. Central Heating Temperature Knob On at 60°C Target 60°C C. Boiler Status Display Menu Mode D. Burner On indicator E. Pressure Gauge F. CH Flow Isolating Valve G. Gas Cock H.

  • Page 33: User Interface Commissioning

    When the boiler is powered up for the first time, you will have the options to set the contact details for boiler servicing. Set your contact details for boiler service? (defaults to Ideal Keston contact information otherwise) 2.30 CHANGING BOILER OPERATING MODE The boiler mode is displayed by default, to change the mode, simply press mode and select the desired mode.

  • Page 34: Menu Operation

    Section 2 - Installation 2.31 MENU OPERATION The menu option contains a list of attributes that informs the user about the operating state of the boiler. The user should scroll down the menu and press enter to select the desired option. Menu Service Contact Name Service Phone Number...

  • Page 35: General Checks

    Section 2 - Installation 2.33 GENERAL CHECKS Make the following checks for correct operation in: CENTRAL HEATING (CH) MODE TEMPERATURE TEMPERATURE SETTING SETTING 1. Ensure that the CH external controls are calling for heat (No Outside Sensor) (With Outside Sensor) and the DHW external controls are not.

  • Page 36: Restart Procedure

    Section 2 - Installation 2.34 RESTART PROCEDURE To restart the boiler, press the Restart button (A). Ignition Lockout 1 Check other gas appliances work. Ignition Lockout 2 Restart boiler. 1 Check other gas appliances work. 2 Restart boiler. 3 If fault persists, contact installer. 3 If fault persists, contact installer.

  • Page 37: Section 3 - Servicing

    Section 3 - Servicing SERVICING SCHEDULE WARNING: Servicing can only be carried out by Gas Safe Registered Engineers. In IE servicing work must be carried out by a Registered Gas Installer (RGII) 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 BS EN 50379-3:2012.

  • Page 38: Removal / Replacement Of Components

    Section 3 - Servicing REMOVAL / REPLACEMENT OF COMPONENTS WARNING: Do not operate the boiler without a front panel fitted Notes. When replacing any component. 1. In order to assist fault finding, the control panel has an 1. Isolate the electricity supply. LCD diagnostic display.

  • Page 39: Boiler Front Panel Removal / Replacement

    Section 3 - Servicing 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 clips down to disengage and pull panel 4.

  • Page 40: Fan And Venturi Assembly Removal And Cleaning

    Section 3 - Servicing FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 9. Inspect fan outlet sealing gasket and replace if necessary. 2. Remove the clip from the gas control valve outlet and 10.

  • Page 41: Burner Removal And Cleaning

    Section 3 - Servicing BURNER REMOVAL AND CLEANING SCAN for video Refer to Section 4. Pull the burner out from the left hand 1. Remove the 2 burner front fixing screws and the side of the boiler once it is in the vertical 2 rear extended nuts.

  • Page 42: Ignition / Detection Electrode Replacement / Inspection

    Section 3 - Servicing IGNITION / DETECTION ELECTRODE REPLACEMENT / INSPECTION Refer to Section Ignition /Detection Electrode 1. Remove the fan. Refer to Section 2. Remove the flue manifold. 3. Remove the burner. Refer to Section 3.14 4. When servicing the boiler inspect the condition of the electrode and check the dimensions shown.

  • Page 43: Burner Injector Replacement

    Section 3 - Servicing 3.12 BURNER REPLACEMENT 3.11 BURNER INJECTOR REPLACEMENT SCAN Refer to Section Refer to Section 3.2 & 3.7 for video 3.13 RETURN THERMISTOR REPLACEMENT Refer to Section 1. Isolate and drain down the boiler. 2. Remove the clip from the pump housing and remove the thermistor.

  • Page 44: Spark Generator Replacement

    Section 3 - Servicing 3.14 SPARK GENERATOR REPLACEMENT Refer to Section 1. Disconnect the leads from the spark generator. 4. Fit the new spark generator and reassemble, ensuring that the the earth lead is replaced. 2. Gently push up the generator to release the bottom clip from the gas valve mounting bracket.

  • Page 45: Pressure Gauge Replacement

    Section 3 - Servicing 3.17 PRESSURE GAUGE REPLACEMENT 4. Releasing the two retaining clips on the pressure gauge Refer to Section ease the pressure gauge through the front of the control panel. 1. Drain the boiler. 5. Fit the new pressure gauge from the front of the lower Refer to Section control panel ensuring correct orientation.

  • Page 46: Primary Pcb Replacement

    Section 3 - Servicing 3.19 PRIMARY PCB REPLACEMENT Program this model? WARNING: It is critical that the correct boiler size System UK and fuel type is entered in to the boiler. 30 kW Natural Gas CAUTION: Fit the earth strap provided with the PCB Back to your wrist and secure to a suitable earth on the boiler chassis.

  • Page 47: Pump Automatic Air Vent Replacement

    Section 3 - Servicing 3.20 PUMP AUTOMATIC AIR VENT REPLACEMENT 5. Reassemble. Ensure the air vent head ‘o’ ring seal is Refer to Section fitted. 6. Ensure the air vent cap is loose. 1. Drain the boiler. 7. Refill the boiler. Check for leaks around the new air vent Refer to Section joint.

  • Page 48: Water Pressure Switch Replacement

    Section 3 - Servicing 3.22 CH WATER PRESSURE SWITCH REPLACEMENT Refer to Section 1. Drain the boiler. Refer to Section 2. Pull off the two electrical connections. 3. Using a suitable tool, pull out the metal retaining clip. 4. Carefully withdraw the pressure switch. 5.

  • Page 49: Expansion Vessel Recharging & Replacement

    Section 3 - Servicing 3.24 EXPANSION VESSEL RECHARGING & REPLACEMENT Refer to Section RECHARGING 1. Remove the charge point cover. 2. Recharge the tank pressure to 0.75 bar. 3. Reassemble. 4. Check that the boiler operates. REPLACEMENT 5. Drain the boiler CH circuit. Refer to Section 6.

  • Page 50: Heat Engine Replacement

    Section 3 - Servicing 3.25 HEAT ENGINE REPLACEMENT 18. Ensure the trap is filled with water. Refer to Section Refer to Section 3.16 CAUTION: Protect the gas and electrical controls with 19. Refill the boiler and check for leaks. a waterproof sheet. Refer to Section 2.16 Refer to Section...

  • Page 51: Section 4 - Fault Finding

    More detailed fault checks and actions are described in the following pages. Menu Fault Help Change Service Time [Keston] Technical Help Line: Fault History [01482 443005] Fault Help Vent System [Spares: 01482 498665]...

  • Page 52: Ignition Lockout

    Section 4 - Fault Finding IGNITION LOCKOUT If the boiler is restarted does the Is the Gas Pressure available at Check gas supply and boiler ignite for a short time and the Boiler Inlet (>18 mbar)? rectify fault then extinguish? Check wiring connection Is approx 24V DC supply available from gas valve to...

  • Page 53: Flame Loss

    Section 4 - Fault Finding FLAME LOSS Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish? the Boiler Inlet (>18 mbar)? rectify fault Check wiring from Is 24V DC supply available at the Check the electrode and associated gas valve to PCB for Gas Valve while the flame is on?

  • Page 54: Flow Thermistor Fault

    Section 4 - Fault Finding FLOW THERMISTOR FAULT Securely connect the wiring to the Flow Is the wiring securely connected to the Flow Thermistor Thermistor Located in the Flow Pipe lower LHS of Boiler Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected Fit a new Thermistor across the Thermistor’s terminal pins.

  • Page 55: Outside Sensor 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.

  • Page 56: No Dhw Operation

    Section 4 - Fault Finding 4.12 NO DHW OPERATION Adjust cylinder stat Is the Cylinder Stat calling for heat? Switch timer on Is DHW timer on? Press mode button until OFF is not shown under the Is OFF shown under Tap symbol? Tap symbol Is there 230V at SL2 IN Check system controls and wiring...

  • Page 57: Section 5 - Spare Parts

    Comprehensive spares parts information and details of approved Keston Parts Distributors are available on idealparts.com 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;...

  • Page 58: Section 6 - Benchmark & Commissioning

    Section 6 - Benchmark & Commissioning Installation and Servicing...
  • Page 59 Section 6 - Benchmark to Commissioning Benchmark Commissioning & Warranty Validation Service Record 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 warranty the boiler needs to be registered with the manufacturer within one month of the installation.
  • Page 60 Section 6 - Benchmark to Commissioning GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Optional: Building Regulations Notification Number (if applicable): Time, temperature control and boiler interlock provided for central heating and hot water...
  • Page 61 Section 6 - Benchmark to Commissioning SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’...
  • Page 62 Section 6 - Benchmark to Commissioning 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.
  • Page 63 Section 6 - Benchmark to Commissioning Start Set Boiler to Maximum Gas Rate. Carry Out Flue Integrity Check Using Analyser. Refer to Section 2.32 on In accordance with boiler instructions, set Insert analyser probe into air inlet test point (where page 34 boiler to operate at maximum rate (full load available) and allow readings to stabilise.
  • Page 64 Notes Installation and Servicing...
  • Page 65 Notes Installation and Servicing...
  • Page 66 At Keston we take our environmental impact seriously, therefore when installing any Keston by Ideal Heating product please make sure to dispose of any previous appliance in an environmentally conscious manner. Households can contact their local authority to find out how.

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