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INSTALLATION
& SERVICING
COMBI
2
C30 C35
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 236467 A03
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Table of Contents
Related Manuals for Ideal Heating Keston COMBI2 C30
Summary of Contents for Ideal Heating Keston COMBI2 C30
- Page 1 INSTALLATION & SERVICING COMBI C30 C35 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.
- Page 2 ERP DATA MODEL SYMBOL UNITS 30 kW 35 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 24.3 24.3 Part Load Auxiliary Electricity Consumption Full Load elmax 0.028...
- Page 3 PRODUCT FICHE KESTON COMBI² Ideal Heating ERP DATA SYMBOL UNITS MODEL 30 kW 35 kW Condensing boiler Seasonal space heating efficiency class Rated heat output Seasonal space heating energy efficiency ƞs Annual energy consumption Sound power level, indoors Water heating energy efficiency class...
- 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 CAUTION: Risk of damage to objects IMPORTANT: Important information...
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Page 5: Table Of Contents
CONTENTS Section 1 - General ..................6 2.36 Restart Procedure ............... 37 Introduction ................... 8 2.37 Handing Over................37 Operation ..................8 Safe Handling ................8 Section 3 - Servicing ................. 38 Optional Accessories ..............8 Servicing Schedule ..............38 Safety.................... -
Page 6: Section 1 - General
Section 1 - General Table 1 General Data 30 kW 35 kW Gas Supply 2H - G20 - 20 mbar Gas Supply Connection 15 mm copper compression Injector Size 4.65 Inlet Connection Cold Water 15 mm copper compression Outlet Connection Cold Hot Water 15 mm copper compression Flow Connection... - Page 7 Section 1 - General KESTON COMBI Natural Gas Only G.C. Applicance No BOILER SIZE kW (Benchmark No.) 47-930-09 47-930-10 Destination Country: GB, IE, RO For UK intallations, to comply with Building Regulations Part L1 (Part 6 in Scotland), the boiler should be fitted in accordance with the manufacturer’s instructions.
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Page 8: Introduction
Section 1 - General INTRODUCTION The DHW draw off rate specified above is the nominal that the boiler flow regulator will give. Due to system variations and seasonal temperature fluctuations DHW flow rates/temperature The Keston Combi range of boilers are wall mounted, rise will vary, requiring adjustment at the draw off tap. -
Page 9: Safe Handling Of Substances
Section 1 - General In IE , the Installation must be carried out by a Registered Gas WARNING: Rear access to the boiler is not permitted. Installer (RGII) and installed in accordance with the current edition of I.S.813 “Domestic Gas Installation”, the current Building Regulations and reference made to the current ETCI CAUTION: Do not fit the boiler outside. -
Page 10: Air Supply
Section 1 - General Compartment Installations The complete installation MUST be tested for gas tightness and purged as described, for the majority of installations the A boiler installed in a compartment does not require ventilation. appropriate standard is IGEM/UP/1B [23], but alternatively However, a boiler installed in a compartment must provide IGEM/UP/1 [21] or IGEM/UP/1A [22], as appropriate, can be adequate clearances for servicing. -
Page 11: Boiler Dimensions, Services & Clearances
Section 1 - General 1.14 BOILER DIMENSIONS, SERVICES & CLEARANCES Refer to Section 2.18 The following minimum clearances must be maintained The boiler connections are made on the boiler connection for operation and servicing. tails. Additional space will be required for installation, depending upon site conditions. -
Page 12: System Requirements - Central Heating
Section 1 - General 1.15 SYSTEM REQUIREMENTS - CENTRAL HEATING Table 4 Vessel Sizing The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the PRV setting mains via a temporary hose connection is only allowed if acceptable to the local water authority. -
Page 13: System Requirements - Dhw
Section 1 - General 1.16 SYSTEM REQUIREMENTS - DHW b. Hot and cold water supplies to the shower are of Domestic Hot Water equal pressure. 1. The DHW service must be in accordance with BS.5546 & 5. Hard Water Areas BS6700. -
Page 14: Section 2 - Installation
Section 2 - Installation BOILER ASSEMBLY - EXPLODED VIEW CH Return Valve Expansion Vessel Ignitor Unit CH Flow Valve Return Group Manifold Burner Thermistor DHW Inlet & Outlet Flow Group Manifold Gasket - Burner Ignition Lead Filling Loop Pipe Plate Heat Exchanger Sump Clean Out Cover Control Box Lid Pump Head... -
Page 15: Unpacking
Section 2 - Installation Unpack and check the contents UNPACKING The boiler is supplied fully assembled in Pack A. Pack A Contents Boiler Hardware Pack Box Wall Mounting Plate These Installation/Users Instructions Boiler Warranty Wall Mounting Template PRV Pipe Hardware Pack Box Contents HP Box Dividers - 289 x 111 x 57.5 mm Plug Male and Clip... -
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 recommended. However re-using the existing boiler flue standard. 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
Section 2 - Installation FLUE SYSTEM - CONTINUED Termination of the flue and air The flue and air pipes may terminate independently through TERMINAL POSITIONS any external walls within the same dwelling except on opposing walls, within the maximum lengths shown in Minimum Separation graph below. -
Page 19: Flue Installation Example Keston Combi
Section 2 - Installation FLUE INSTALLATION EXAMPLE KESTON COMBI Keston Combi C30 - Flue & Air Pipe Length 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... -
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 Air Supply The Keston Combi is a room-sealed appliance and All parts of the system must be constructed in accordance with BS 5440 Part 1, except where specifically mentioned in therefore does not require purpose provided ventilation to 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 Flue Sleeve Flange 3. Cut sleeve length to match wall thickness & remove Flexible burrs. 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 - Cont
Section 2 - Installation 2.17 CONDENSATE DRAIN - CONT. Figure 2 - Connection of a Condensate Drainage Pipe Figure 1 - Connection of Condensate Drainage Pipe to 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 15 mm pipe. CAUTION: Heating the isolation valves may damage A 15 mm compression coupling is supplied to assist in the fibre seals removal of pipework if required. -
Page 26: Connections & Filling Cont
Section 2 - Installation 2.19 CONNECTIONS & FILLING CONT. FILLING WARNING: Protect electrical connections from water Connect the filling loop, ensuring the washers are in Top Up place. Connect the filling loop, ensuring the washers are in Loosen the auto air vent dust cap. place. -
Page 27: Electrical Connections
Section 2 - Installation 2.20 ELECTRICAL CONNECTIONS For IE reference should be made to the current ETCI rules WARNING: This appliance must be earthed for electrical installations A mains supply of 230 V ~ 50 Hz is required. Wiring should be 3 core PVC insulated cable, not less (24 x 0.2 mm), and to BS EN 50525-1:2011 than 0.75 mm 3 A fuse required. -
Page 28: External Wiring
Section 2 - Installation 2.22 EXTERNAL WIRING External Controls – 230 V 50 Hz Frost Protection If parts of the pipework run outside the house or if the Wiring a 230 V Programmable Room Stat (Diagrams A & C) boiler will be left off for more than a day or so then a frost or 230 V Timer &... -
Page 29: Wiring Diagram
Section 2 - Installation 2.23 WIRING DIAGRAM Installation and Servicing... -
Page 30: Replacing Pre-Fitted Mains Cable
Section 2 - Installation 2.24 REPLACING PRE-FITTED MAINS CABLE Strain If it is necessary to use an alternative mains cable to the one Relief pre-fitted then use the following guide. Replacement wiring should comply with notes and be carried out by a qualified person. Refer to Section 2.21 1. -
Page 31: Operation
Section 2 - Installation 2.26 CH OPERATION Examples: The ON and OFF time control of central heating should be 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 32: The Weather Compensation Kit - Supplied As Standard
Section 2 - Installation 2.27 THE WEATHER COMPENSATION KIT - SUPPLIED AS STANDARD This kit provides the facility to apply outside air temperature Kit Contents control to the boiler water flow temperature which provides A. Outside Air Sensor energy savings. The outside sensor provided measures outside air temperature and sends a signal to the boiler, which adjusts the maximum boiler flow temperature in response. -
Page 33: Initial Lighting
Section 2 - Installation 2.28 INITIAL LIGHTING Legend A. Domestic Hot Water Temperature Knob B. Central Heating On at 60°C Ready Temperature Knob Target 60°C Radiator Target 60°C Room Thermostat or Timer Off C. Hot Keys Preheat Menu Mode D. Boiler Status Display E. -
Page 34: User Interface Commissioning
Section 2 - Installation 2.29 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 and to vent the system. Set your contact details for boiler Vent the system? service? (defaults to... -
Page 35: Menu Operation
Section 2 - Installation 2.33 MENU OPERATION The menu option contains a list of attributes that show the operating state of the boiler. The installer should scroll down the menu and press enter to select the desired option. Menu Service Contact Name Service Phone Number Change Service Time Note. -
Page 36: General Checks
Section 2 - Installation 2.35 GENERAL CHECKS Make the following checks for correct operation in: The display should show: 1. Fully open all DHW taps in turn and ensure that water flows freely from them. Ready Ready The display should show: Radiator Target Target 60°C 60°C... -
Page 37: Restart Procedure
Section 2 - Installation 2.36 RESTART PROCEDURE To restart the boiler, press the Restart button. 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 38: 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 39: Removal / Replacement Of Components
Section 3 - Servicing REMOVAL / REPLACEMENT OF COMPONENTS Notes. WARNING: Do not operate the boiler without a front 1. In order to assist fault finding, the control panel has an panel fitted LCD diagnostic display. The key to boiler fault conditions is shown in Section 4. -
Page 40: 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 41: 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 42: Burner Removal And Cleaning
Section 3 - Servicing BURNER REMOVAL AND CLEANING SCAN for video Refer to Section 3.5 & 3.6 1. Remove the 2 burner front fixing screws and the 4. Pull the burner out from the left hand side of the boiler once it is in the vertical 2 rear extended nuts. -
Page 43: Ignition / Detection Electrode Replacement / Inspection
Section 3 - Servicing IGNITION / DETECTION ELECTRODE REPLACEMENT / INSPECTION Refer to Section Ignition /Detection 1. Remove the fan. Electrode Refer to Section 2. Remove the flue manifold. 3. Remove the burner. Refer to Section 3.13 4. When servicing the boiler inspect the condition of the electrode and check the dimensions shown. -
Page 44: Dhw Filter & Dhw Flow Regulator Cleaning / Replacement
Section 3 - Servicing 3.11 DHW FILTER & DHW FLOW REGULATOR CLEANING / REPLACEMENT Refer to Section 2. Turn the housing anti clockwise and pull forward to remove the cartridge. Be prepared for some water release. 1. Isolate the DHW system. 3. -
Page 45: Return Thermistor Replacement
Section 3 - Servicing 3.14 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. 3. Disconnect the electrical lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor and reassemble, Check the ‘O’... -
Page 46: Gas Control Valve Replacement
Section 3 - Servicing 3.16 GAS CONTROL VALVE REPLACEMENT Refer to Section 1. Disconnect and remove the trap and rubber connector. Refer to Section 3.18 2. Unplug the electrical lead connection from the gas control valve. 3. Remove the outlet gas valve clip and slide the pipe upwards. -
Page 47: Primary Pcb Replacement
Section 3 - Servicing 3.19 PRIMARY PCB REPLACEMENT 1/4, Combi 30kW, Natural Gas It is critical that the correct boiler size WARNING: 2/4, Combi, 30kW, Propane and fuel type is entered in to the boiler. 3/4, Combi, 35kW, Natural Gas CAUTION: Fit the earth strap provided with the PCB 4/4, Combi, 35kW, Propane to your wrist and secure to a suitable earth on the... -
Page 48: Dhw Flow Turbine Sensor Replacement
Section 3 - Servicing 3.20 DHW FLOW TURBINE SENSOR REPLACEMENT 4. Use the clip to ease the turbine sensor from its housing. Refer to Section 5. Reassemble with new sensor. 1. Drain the DHW system. 6. Check that the boiler operates in both DHW & CH modes. -
Page 49: Prv Replacement
Section 3 - Servicing 3.22 PRV REPLACEMENT SCAN for video 8. Check the operation of the PRV by raising the Refer to Section water pressure until the valve lifts. This should occur within 0.3 bar of the preset lift pressure. 1. -
Page 50: Replacement Of Dhw Thermistor
Section 3 - Servicing 3.24 REPLACEMENT OF DHW THERMISTOR Refer to Section 4. Fit the replacement thermistor and reassemble. 5. Re-establish the DHW supply, turn on a hotwater tap checking for leaks. 1. Isolate the DHW system. 2. Remove the retaining clip and extract the thermistor. Be prepared for some water release. -
Page 51: Diverter Valve Body Assembly Replacement
Section 3 - Servicing 3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT Refer to Section To remove the valve body assembly: 9. Loosen the nut above pump and rotate the pipe. 1. Drain the boiler. 10. If required remove expansion vessel connection hose. Refer to Section Refer to Section 3.31... -
Page 52: Water Pressure Switch Replacement
Section 3 - Servicing 3.27 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 53: Flow Thermistor Replacement
Section 3 - Servicing 3.29 FLOW THERMISTOR REPLACEMENT Refer to Section 1. Drain down the boiler. 5. Reassemble. Refer to Section 6. Refill the boiler. Refer to Section 2.18 2. Unplug the electrical lead. 3. Remove the clip from the flow pipe and remove the thermistor. -
Page 54: Heat Engine Replacement
Section 3 - Servicing 3.30 HEAT ENGINE REPLACEMENT Refer to Section 17. Reassemble, ensuring the heat exchanger is located correctly in the LHS retaining bracket. Replace any new ‘O’ rings supplied with new heat exchanger and replace CAUTION: Protect the gas and electrical controls with gaskets or seals if any sign of damage is evident. -
Page 55: Expansion Vessel Recharging & Replacement
Section 3 - Servicing 3.31 EXPANSION VESSEL RECHARGING & REPLACEMENT Refer to Section RECHARGING 1. Remove the charge point cap. 2. Recharge the tank pressure to 0.75 bar. 3. Reassemble. 4. Check that the boiler operates in both DHW & CH modes. -
Page 56: Section 4 - Fault Finding
Section 4 - Fault Finding Section 4 - Fault Finding MAIN MENU, FAULT HELP Fault finding help can be accessed through the menu. Fault finding help lists all the common faults with the necessary checks. More detailed fault checks and actions are described in the following pages. -
Page 57: 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 24 Vdc supply available at from gas valve to... -
Page 58: 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 Gas Valve while the flame is on? Check the electrode and associated gas valve to PCB for... -
Page 59: 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 across the Thermistor’s terminal pins. -
Page 60: 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 61: No Dhw But Ch Works Ok
Section 4 - Fault Finding 4.12 NO DHW BUT CH WORKS OK Does tap symbol change from blue to Correct pipe work Are hot & cold pipe work crossed? orange when a tap is turned on? Re-connect wiring Is wiring connected between PCB &... -
Page 62: No Display
Section 4 - Fault Finding 4.13 NO DISPLAY Supply power to the boiler Is there 230 V AC to the boiler at L and N? Is the wiring from the terminal block to the PCB Connect the wiring from the terminal block to the connected securely? PCB securely Replace the PCB... -
Page 63: Section 5 - Spare Parts
Section 5 - Spare Parts Section 5 - Spare Parts When replacing any part on this appliance use only spare parts that you can be assured conform to the safety LINK and performance specification that we require. DO NOT use reconditioned or copy parts that have not been to spares clearly authorised by Keston. -
Page 64: Section 6 - Benchmark To Commissioning
Section 6 - Benchmark to Commissioning Installation and Servicing... - Page 65 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’ To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation.
- Page 66 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 67 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 68 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 69 Start Set Boiler to Maximum Gas Rate. Carry Out Flue Integrity Check Using Analyser. Refer to Section In accordance with boiler instructions, set 2.34 on Insert analyser probe into air inlet test point (where boiler to operate at maximum rate (full load page 35 available) and allow readings to stabilise.
- Page 70 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.