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Keston 50 - GC Installation And Servicing Instructions

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WD50/2/1997
The Keston 50, 60 & 80 Condensing Boilers
Fan Powered High Efficiency Condensing Gas Boiler

Installation And Servicing Instructions

Keston 50 - GC No 41 930 01
Keston 60 - GC No 41 930 02
Keston 80 - GC No 41 930 03
PI No. : 87AQ306
These instructions must be left either with the user or next to
the household gas meter.
34 West Common Road
Hayes, Bromley, Kent BR2 7BX
Tel. (44)0208 462 0262 Fax. (44)0208 462 4459
0087

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  • Page 1: Installation And Servicing Instructions

    The Keston 50, 60 & 80 Condensing Boilers Fan Powered High Efficiency Condensing Gas Boiler Installation And Servicing Instructions Keston 50 - GC No 41 930 01 Keston 60 - GC No 41 930 02 Keston 80 - GC No 41 930 03 PI No.

  • Page 2: Table Of Contents

    WD50/2/1997 The Keston 50, 60 & 80 Condensing Boilers CONTENTS Section Description GENERAL INSTRUCTION Description Boiler Schematic Related Documents Performance Data General Data BOILER LOCATION Dimensions & Minimum Clearances Service Connections Position Electrical Boiler Size Selection Gas Supply Water Systems...
  • Page 3 WD50/2/1997 The Keston 50, 60 & 80 Condensing Boilers Timing The Gas Meter Handing Over To The User FAULT FINDING Electrical Control Sequence Fault Finding Flow Chart Continuity Checking Functional Flow Wiring Diagram Electrical Wiring Diagram Illustrated Wiring Diagram Exploded Assembly Diagrams...

  • Page 4: General Instruction

    Allow a pressure drop through the boiler of 3.2 ft head and a water flow of 4.2 gallons (19 litres) per minute for the Keston 50, 4.3 ft head and 5 gallons (23 litres) per minute for the Keston 60 and 9 ft head and 6.7 gallons (30.5 litres) per minute for the Keston 80.
  • Page 5 WD50/2/1997 Chapter 1 : General Instruction The Keston 50, 60 & 80 Condensing Boiler Figure 1.2 Boiler Schematic LEGEND 1 Heating Return 13 Ignition Control Box 14 Gas Low Pressure Switch 2 Water Return Thermostat 3 Downstream Pressture Test Nipple...

  • Page 6: Related Documents

    RELATED DOCUMENTS The Keston Condensing Boiler must be installed in accordance with the current issue of the Gas Safety (Installation and Use) Regulations, current IEE Wiring Regulations, Safety document no. 635 - The Electricity At Work Regulations 1989, Building Regulations, Building Standards (Scotland) Consolidation, and the Bye Laws of the local Water Undertaking.

  • Page 7: Performance Data

    WD50/2/1997 Chapter 1 : General Instruction The Keston 50, 60 & 80 Condensing Boiler PERFORMANCE DATA Keston 50 Keston 60 Keston 80 Boiler Input 16.6 19.9 27.1 Btu/h 56,500 68,300 92,500 Boiler Output To Water 14.7 17.5 23.5 C Flow 60...

  • Page 8: General Data

    WD50/2/1997 Chapter 1 : General Instruction The Keston 50, 60 & 80 Condensing Boiler GENERAL DATA Keston 50 Keston 60 Keston 80 Main Burner Keston Premix Keston Premix Keston Premix Gas Control White Rogers White Rogers White Rogers 36E Series...

  • Page 9: Boiler Location

    WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 & 80 Condensing Boilers 2. BOILER LOCATION All dimensions in mm. DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown to allow subsequent servicing, safe operation.

  • Page 10: Electrical

    Section 2.8.3] Condensate drain The Keston can be located virtually anywhere desired provided that all regulations are met. Because of the boiler's compact size and venting flexibility, the installation is not limited to a boiler room setting. Before locating the boiler near a living space consider whether the sounds generated by the boiler will be objectionable.

  • Page 11: Boiler Size Selection

    WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 & 80 Condensing Boilers The method of connection to the mains electricity supply must facilitate complete electrical isolation of the boiler complying with the requirements of BS 1363. The appliance must be connected to the supply via a fused double-pole switch, having at least 3mm (1/8 inch) contact separation in both poles, serving only the boiler and the system controls.

  • Page 12: Water Systems

    The system must be so arranged that there shall always be a minimum flow of 4.2 gpm (19 litres/min) [Keston 50], 5 gpm (23 litres/min) [Keston 60] or 6.7 gpm (30.5 litres/min) [Keston 80] when the boiler is firing. This can be via a specially installed by-pass arrangement.
  • Page 13 WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 & 80 Condensing Boilers Expansion Expansion Tank Pipe Minimum 8ft Height Boiler 22mm pipe (minimum) 3 Way Cylinder Keston Pump Valve By-pass Bal. Strainer Valve Rad. 2 Rad. 1 Figure2.7.1 : Open Vented System Diagram 2.7.2...
  • Page 14 WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 & 80 Condensing Boilers Make -up vessel. Max. capacity of Air Vent 3 lt. (5pt) Hose Non-Return Union Valve bib tap Auto Air Vent Boiler Keston Strainer RETURN Pressure Safety...
  • Page 15 WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 & 80 Condensing Boilers 2.7.5 Air Elimination In the initial charge of water to the boiler system and in all subsequent additions of water to the system some air will be dissolved in the water. As the water is heated the air is driven out of the solution and will collect in high spots in the system.

  • Page 16: Flue System

    The Wilo Salmson Gold Star pump, or the Grundfoss 15/60 pump is normally suitable for use with the Keston condensing boiler range. However, in all cases due consideration must be given to the resistance to flow offered by the rest of the system when making a final pump selection.
  • Page 17 The K4 terminal guard, manufactured by Tower Flue Components Ltd, is suitable for this purpose and can be obtained from Keston Boilers. The Keston Condensing Boiler, as with any condensing boiler, will generate a condensate "plume" from the flue terminal in all weather conditions.
  • Page 18 WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 & 80 Condensing Boilers Flue Outlet Terminal Air Intake Terminal Figure 2.8.1 : Terminals It is advisable for horizontal flue terminals to place a 45 elbow at the end of the flue to direct the condensate plume up and away from the property.

  • Page 19: Air Supply

    The boiler will run sufficiently cool without ventilation. 2.11 CONDENSATE DRAINAGE Being a condensing boiler, the Keston is fitted with a condensate trap at the base of the heat exchanger and flue assembly, with facility to connect to a drain point underneath the appliance.

  • Page 20: Low Water Volume Boiler Vs. Cast Iron Boiler

    The Keston boilers are capable of temperatures of up to 80 C but the higher the temperature of the return water, the lower the efficiency of the system. This is true of all boilers, though all non-condensing boiler must be kept at higher temperatures to avoid condensation in the boiler which destroys such boilers quickly.

  • Page 21: Installation Of The Boiler

    WD50/2/1997 Chapter 3 : Installation The Keston 50, 60 & 80 Condensing Boilers 3. INSTALLATION OF THE BOILER Read Chapter 2 - 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 22: Installing Flue And Air Pipes

    Chapter 3 : Installation The Keston 50, 60 & 80 Condensing Boilers Combustion air filters are fitted to the Keston condensing boilers as standard. This filter must be examined at least once every year, and more often in particularly dusty and dirty areas.

  • Page 23: Condensate Drainage

    WD50/2/1997 Chapter 3 : Installation The Keston 50, 60 & 80 Condensing Boilers Wall depth 2.3 m Socketed Pipe 50 mm Diameter Hole 50+{2.3x10} 50+23 73 mm Measure, cut and check the air and flue pipes to pass to the exit from the wall(s) or ceiling.

  • Page 24: Water System

    WD50/2/1997 Chapter 3 : Installation The Keston 50, 60 & 80 Condensing Boilers WATER SYSTEM Connect the flow and return pipework to the boiler. Ensure a detachable coupling is used at connection to the boiler (ie compression fitting) to enable heat exchanger removal if required.
  • Page 25 The Keston 50, 60 & 80 Condensing Boilers Important The Keston condensing boiler contains components which could be damaged or blocked by grease, dirt or solder etc. It is essential that sludge or scale is removed from an existing system.

  • Page 26: Commissioning Of The Boiler

    INITIAL FLUSHING All waterways within the Keston are either copper or high alloy stainless steel. As a result standard water treatment chemicals for conventional central heating boilers are suitable. In any event reference must be made to BS 7593 : Treatment Of Water In Hot Water Central Heating Systems.
  • Page 27 Note the reading on the pressure gauge caused by the suction of the blower. This should be approximately minus 12 mbar for the Keston 80, minus 26 mbar for the Keston 60 and minus 32mbar for the Keston 50. If it is not, check the system as follows: If the negative pressure exceeds the required figure, then it suggests that there is a possible restriction in the air inlet pipework.

  • Page 28: Hot Flushing

    WD50/0/1996 Chapter 4 : Commissioning The Keston 50, 60 & 80 Condensing Boilers Fig 4.7 GAS VALVE HOT FLUSHING Allow the system to heat up, checking for water soundness. Burner pressure Follow instructions provided with Adjustment the cleaning agent, ie Fernox Supafloc.
  • Page 29 WD50/0/1996 Chapter 4 : Commissioning The Keston 50, 60 & 80 Condensing Boilers 0.1m ) of natural gas. Adjust the gas valve screw clockwise to increase the input (speed up the meter) or anticlockwise to decrease the input(slow down the meter) accordingly.

  • Page 30: Fault Finding

    WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers 5. FAULT FINDING ELECTRICAL CONTROL SEQUENCE When the external controls are calling for heat, power will be fed to the boiler connection strip at terminals L (Live) and N (Neutral). If the ON/OFF switch is also in the ON position the boiler ON lamp (amber) will be illuminated.
  • Page 31 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers FAULT FINDING FLOW CHART STA RT Apply Power To B oiler. Is amber switch light on? Is there 230V between Check External Controls. terminals L & N? Is the boiler switched on? Switch On B oiler.
  • Page 32 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Continued from sheet 1 Does ignition sequence start? Switch off & if problem persists Is lockout light on? replace control box. Blocked air filter - replace Has the Air Press.
  • Page 33 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Continued from Sheet 2 Continued on sheet 2 Is there 230V at valve Faulty Gas Valve - Replace. Is there 230V at Gas Low Faulty Gas Low P ressure Press.
  • Page 34 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers CONTINUITY CHECKING T o c h ec k co n t in u it y c o n ne c t o n e pr o b e t o a n e u tra l an d us e th e o th e r pr o b e to c he c k f o r 23 0 V .

  • Page 35: Ignition Control

    WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers FUNCTIONAL FLOW WIRING DIAGRAM 230V 50Hz EMC Filter Fuse 5A ON/OFF Switch Boiler Thermostat Flow Overheat Thermostat Lockout (Red) Indicator Thermal Fuse Link Flow High Limit...

  • Page 36: Electrical Wiring Diagram

    WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers ELECTRICAL WIRING DIAGRAM LEGEND RAM-2EMC22 -BLUE APS-AIR PRESSURE SWITCH BK -BLACK IGNITION CONTROL OR -ORANGE L -INCOMING LIVE -RED PK -PINK N -INCOMING NEUTRAL -WHITE -GREEN...
  • Page 37 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers ILLUSTRATED WIRING DIAGRAM ILLUSTRATED WIRING DIAGRAM Thermal Fuse Overheat Stat Boiler Stat Control 59PK 52BK Flow High Limit Stat 92OR 93OR 10BK Low Water Pressure Switch Gas Low...
  • Page 38 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Exploded Assembly Diagrams 5.7.1 Boiler Controls Assembly BOILER CONTROLS ASSEMBLY K50 - 05.4.00.00.0 K60 - 06.4.00.00.0 K80 - 08.4.00.00.0 FUSE ISOLATOR SECTION 1 IGNITION CONTROL 04.4.20.00.0 PACTROL 04.4.01.00.0...
  • Page 39 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers 5.7.2 Waterway, Condensate & Flue Assembly SCREW WATER WAY, CONDENSATE 04.1.00.80.1 & FLUE ASSEMBLY K50 - 05.2.00.00.0 IGNITER K60 - 06.2.00.00.0 04.2.13.00.1 K80 - 08.2.00.00.0 IGNITER GASKET 04.2.00.28.2...
  • Page 40 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers 5.7.3 Air - Gas Assembly SCREW PRESS. TEST FITT. AIR-GAS ASSEMBLY 04.2.28.00.0 04.3.00.28.0 K50 - 05.3.00.00.0 K60 - 06.3.00.00.0 K80 - 08.3.00.00.0 GAS TEE 04.3.00.34.1 LOW GAS PRESSURE SWITCH 04.3.09.00.0...
  • Page 41 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers 5.7.4 Casing Assembly BURNER ACCESS COVER SCREW CASING ASSEMBLY 04.1.00.41.0 04.1.00.32.0 K50 - 05.1.00.00.0 K60 - 06.1.00.00.0 28mm GROMMET K80 - 08.1.00.00.0 04.1.00.49.1 RETURN LABEL 04.1.00.54.0 42mm GROMMET 04.1.00.47.0...
  • Page 42 WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers 5.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 5.7.1) GC Number Code Description E01 074 Ignition Control Box 170084 110A Air Pressure Switch (Keston 80)
  • Page 43 The pressure difference should be lower than : 8 mbar on the Keston 50, 8.4 mbar on the Keston 60 and 11.2 mbar on the Keston 80. If not, clean the burner. Installation & Servicing Instructions...
  • Page 44 WD50/2/1997 Chapter 6 : Servicing The Keston 50, 60 & 80 Condensing Boilers Flue Pressure Test Pressure Test Point B Point A Heat Flue Overheat Exchanger Thermostat Shell Combustion Test Point & Pressure Test Burner Heat (From Above) Point C Fig 6.1.1 Pressure Test Point Locations...
  • Page 45 WD50/2/1997 Chapter 6 : Servicing The Keston 50, 60 & 80 Condensing Boilers If necessary, either due to discolouration or a high pressure differential between points A & B in the pre-service checks, clean the burner with a mild household detergent and rinse under a hot running tap.
  • Page 46 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers 7. REPLACEMENT OF PARTS INDEX GENERAL PRECAUTIONS ACCESS PROCEDURES - GENERAL ELECTRICAL 7.4.1 ON/OFF SWITCH 7.4.2 BOILER THERMOSTAT 7.4.3 NEONS 7.4.4 FLOW OVERHEAT, FLOW HIGH LIMIT & FLUE PROTECTION THERMOMSTATS 7.4.5...
  • Page 47 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers GENERAL The following must always be carried out by a competent/qualified person. PRECAUTIONS Always switch off the mains electricity supply and disconnect the plug at the isolating switch and socket.
  • Page 48 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers 7.4.3 Neons (Fig. 5.7.1 items 116 & 117) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connectors from the neon taking note of the correct positions.
  • Page 49 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers 7.4.7 Air Pressure Switch (Fig. 5.7.1 item 110) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connectors from the air pressure switch taking note of the correct positions.
  • Page 50 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers 7.4.10 Gas Low Pressure Switch (Fig. 5.7.3 item 105) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connectors to the gas low pressure switch taking note of the correct positions.
  • Page 51 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers HEAT EXCHANGER (Fig. 5.7.2 item 43) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Shut of the water supply to the appliance. Remove the burner head (Section 7.7) Drain the system to below the level of the appliance using the drain off tap at the base of the heat exchanger.
  • Page 52 WD50/2/1997 Chapter 7 : Replacement Of Parts The Keston 50, 60 & 80 Condensing Boilers 7.11 PRESSURE GAUGE (Fig. 5.7.1 item 119) Isolate the appliance (Section 7.1) and shut off the boiler from the water circuit. Gain access (Section 7.2)
  • Page 53 WD50/2/1997 Chapter 8 : Spare Parts Listings The Keston 50, 60 & 80 Condensing Boilers 8. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No Part Denomination 114 105Air Filter 375 523Burner 375 524 375 525 375 526Burner Manifold Gasket...
  • Page 54 WD50/2/1997 Chapter 8 : Spare Parts Listings The Keston 50, 60 & 80 Condensing Boilers Item GC No Part Denomination Item GC No Part Denomination 375 535Gas Valve Outlet Gasket 375 529Flexible Hose Gasket 375 536Gas Valve 375 537Gas Inlet Gasket...
  • Page 55 WD50/2/1997 Chapter 8 : Spare Parts Listings The Keston 50, 60 & 80 Condensing Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination 114 105 Air Filter 375 523 Burner (Keston 50) 375 524...
  • Page 56 WD 92/0/1997 KESTON CONDENSING BOILERS IMPORTANT KESTON 50, 60 & 80 INSTALLATION KEY POINTS † Read Installation Manual Carefully † For open systems ensure that there is at least 8 feet head of water pressure at the top of the boiler.

This manual is also suitable for:

80 - gc60 - gc508060

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