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Keston K260 Installation And Servicing Instructions

Fan powered high efficiency commercial condensing gas boiler
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WD53/0/1999
The Keston 260 & 340 Condensing Boilers
Fan Powered High Efficiency
Commercial Condensing Gas Boiler

Installation And Servicing Instructions

Keston 260
Keston 340
PI No : 87AU111
GB/IE
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)208 462 0262 Fax. +44 (0)208 462 4459
e-mail: info@keston.co.uk
http: //www.keston.co.uk
0087

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  • Page 1: Installation And Servicing Instructions

    WD53/0/1999 The Keston 260 & 340 Condensing Boilers Fan Powered High Efficiency Commercial Condensing Gas Boiler Installation And Servicing Instructions Keston 260 Keston 340 PI No : 87AU111 GB/IE These instructions must be left either with the user or next to the site gas meter.

  • Page 2: Table Of Contents

    WD53/0/1999 The Keston 260 & 340 Condensing Boilers CONTENTS Section Description GENERAL INSTRUCTION Description Boiler Schematic Related Documents Performance Data BOILER LOCATION Dimensions & Minimum Clearances Service Connections Position Electrical Gas Supply Water Systems Flue System Air Supply Compartment Installation 2.10...
  • Page 3 WD53/0/1999 The Keston 260 & 340 Condensing Boilers Combustion Fine Tuning Handing Over To The User FAULT FINDING Electrical Control Sequence Fault Finding Flow Chart Continuity Checking Module Functional Flow Wiring Diagram Full Electrical Wiring Diagram Full Illustrated Wiring Diagram...

  • Page 4: General Instruction

    While the application for which the boilers were designed is the same as those which other boilers are used, the Keston boiler has the added advantage of very high efficiency, and small diameter plastic flue which can be extended to 20 metres horizontally or vertically.

  • Page 5: 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 (as amended after 1996), current IEE Wiring Regulations, Building Regulations, Building Standards (Scotland) Consolidation, and the Bye Laws of the local Water Undertaking.

  • Page 6: Performance Data

    WD53/0/1999 Chapter 1 : General Instruction The Keston 260 & 340 Condensing Boilers CP342.2 Centralised HW Supply IM/2 Purging procedure for non-domestic gas installations IM/16 Guidance for installation of gas pipework boosters and compressors for customers premises IM/22 Installation guide for high efficiency (condensing) boilers...

  • Page 7: Boiler Location

    WD53/0/1999 Chapter 2 - Boiler Connections The Keston 260 & 340 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, and safe operation.

  • Page 8: Electrical

    WD53/0/1999 Chapter 2 - Boiler Connections The Keston 260 & 340 Condensing Boilers Before locating the boiler near a living space consider whether the sounds generated by the boiler will be objectionable. The boiler may be located within a cupboard enclosure to reduce noise levels if located within a living space.

  • Page 9: Water Systems

    Central Heating Systems. Pump isolating valves must be positioned as close to the pump as possible. The Keston 260 and 340 are suitable for use on open, vented water systems with combined feed and vent of 32mm nominal diameter. It is preferable for use on sealed water systems, provided the appropriate components required (see Section 2.7.2 Sealed Systems) are included in the...
  • Page 10 BS6644. Although suitable for open vented systems with combined feed and vent arrangements, the Keston is a low water content boiler. As such, any air entrainment within the system water will produce boiler “kettling”. It is therefore recommended, if in any doubt, to consider the use of sealed systems where possible.
  • Page 11 WD53/0/1999 Chapter 2 - Boiler Connections The Keston 260 & 340 Condensing Boilers All components of the system including the heat exchanger of any calorifiers used must be suitable for a working pressure of 3 bar and a temperature of 110 Care should be taken in making all connections that the risk of leakage is minimised.

  • Page 12: Flue System

    2.6.7 Pump Selection The Keston 260 and Keston 340 boilers are supplied complete with integral boiler shunt pumps. However, these pumps are sized purely to provide adequate flow rate through the boiler at the pressure drop caused by the boiler itself. No allowance has be provided in the shunt pump size for system resistance.
  • Page 13 4m. These additional condensate drains must be run to discharge as detailed in section 2.10. Such drain points can be formed using standard Keston Composite flue fittings. Refer to the example in Figure 2.7.3.
  • Page 14 WD53/0/1999 Chapter 2 - Boiler Connections The Keston 260 & 340 Condensing Boilers The flue outlet terminal is designed to face outwards but can, if desired, be adapted to face in any direction BUT must not be directed in the region of the air inlet.

  • Page 15: Air Supply

    The Keston is a room sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air. COMPARTMENT INSTALLATION The casing temperatures of the Keston 260 and Keston 340 are very low. Due to this fact, no compartment ventilation is required for cooling purposes. 2.10...

  • Page 16: Installation Of The Boiler

    Remove all plastic debris and burrs when installing air intake piping. Plastic filings caused by cutting Keston Composite plastic pipe must not be allowed to be drawn into the combustion air blower. Prevent dust entering the air intake when cutting on building sites.

  • Page 17: Condensate Drainage

    WD53/0/1999 Chapter 3 : Installation The Keston 260 & 340 Condensing Boilers From the two connections on the boiler, mark the positions of the two holes for the flue and air pipes on the wall(s) or ceiling. To allow access to drill the holes it may be necessary to temporarily remove the boiler.

  • Page 18: Electrical Supply

    It is essential that sludge or scale is removed from an existing system. The guarantee provided with the Keston does not cover damage caused by system debris or sludge. Connect the new boiler as instructed in this manual and fit in accordance with Sections 3.1 to 3.8...
  • Page 19 WD53/0/1999 Chapter 3 : Installation The Keston 260 & 340 Condensing Boilers Reduce the pressure to the Initial System Design Pressure for sealed systems, if applicable. Vent the system. Gas Supply The complete gas installation up to the boiler service cock must be checked for soundness.

  • Page 20: Commissioning Of The Boiler

    INITIAL FLUSHING All waterways within the Keston are either copper, bronze 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 21: Hot Flushing

    WD53/0/1999 Chapter 4 : Commissioning The Keston 260 & 340 Condensing Boilers Set the left hand module on/off switch to "ON". The amber light will illuminate on the On/Off switch, the red “lockout” light will illuminate for approximately 2 seconds. The module blower and pump will start and, after about 15 seconds, a spark will light gas at the main burner, provided all air has been purged from the gas supply to the boiler.
  • Page 22 To measure CO levels in the Keston boiler remove the 1/8" plug from the flue outlet pipe inside the boiler (item 101, fig. 5.7.2). Insert the probe of a combustion analysis meter and sample the gases as instructed in the test equipment's instructions.

  • Page 23: Fault Finding

    WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler 5. FAULT FINDING ELECTRICAL CONTROL SEQUENCE When the power supply is established to the boiler and the main boiler on/off switch is in the "on" position the main on/off switch will be illuminated. Subsequently when the external controls are calling for heat, power will be fed back to the boiler connection strip at terminal 18.
  • Page 24 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler FAULT FINDING FLOW CHART Apply power START to boiler Is main on/off switch light on ? Is main on/off switch Switch On in "on" position ? Is there 230VAC betw een...
  • Page 25 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler Continued from sheet 1. Is the module fan running ? Boiler flow is too hot. Is the integral sequence controller Adjust set point higher or calling the module on? allow to cool or faulty sequence control.
  • Page 26 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler Continued from Continued from Sheet 2 sheet 1. Does the module ignition sequence start ? Is the fan motor relay stuck ? Replace Relay. Switch off & if problem...
  • Page 27 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler Continued from Continued on Sheet 3 Sheet 3 Is module burner setting pressure as per spec. Adjust burner pressure (Section 4.7)? Faulty gas valve or Is the gas valve opening? solenoid - replace.
  • Page 28 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler Continued from sheet 4 Does flame stop after 5 to 10 seconds ? Is boielr earthed correctly? Earth Boiler Are live and neutral supply lines crossed at main Correct Wiring.
  • Page 29 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler 5.3 CONTINUITY CHECKING To check continuity connect one probe to a neutral and use the other probe to check 230V AC START Check external controls Is there 230V at and supply.
  • Page 30 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler MODULE FUNCTIONAL FLOW WIRING DIAGRAM Main On/Off Switch 230V 50Hz Sequence Controller Blower Return Relay Thermostat Module ON/OFF Blower Switch Module Filter Shunt Lockout Pump Relay Flue Overheat Thermostat...
  • Page 31 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler FULL ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 28...
  • Page 32 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 29...
  • Page 33 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler Exploded Assembly Diagrams 5.7.1 Casing Assembly Installation & Servicing Instructions Page : 30...
  • Page 34 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler 5.7.2 Waterway, Condensate & Flue Assembly Installation & Servicing Instructions Page : 31...
  • Page 35 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler 5.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 32...
  • Page 36 WD53/0/1999 Chapter 5 : Fault Finding The Keston 260 and 340 Condensing Boiler 5.7.4 Controls Assembly Installation & Servicing Instructions Page : 33...
  • Page 37 WD53/0/1998 Chapter 5 : Fault Finding The Keston 260 & 340 Condensing Boiler 5.7.5 Exploded Diagrams Parts Reference List Casing Assembly (Fig 5.7.1) GC Number Code Description Frame Cabinet Name Plate Front Panel Waterway, Condensate & Flue Assembly (Fig. 5.7.2)
  • Page 38 WD53/0/1999 Chapter 6 : Servicing The Keston 260 & 340 Condensing Boilers 6. ROUTINE (ANNUAL) SERVICING To ensure the continued safe and efficient operation of the boiler it is necessary to carry out routine servicing at regular intervals. The frequency of the servicing will depend upon the particular operating conditions, but it is recommended that an annual service should be carried out by a qualified engineer.
  • Page 39 WD53/0/1999 Chapter 6 : Servicing The Keston 260 & 340 Condensing Boilers Flue Pressure Test Point A Pressure Test Point B Pressure Test Heat Point C Exchanger & Shell Combustion Test Point Flue Overheat Burner Heat (From Above) Thermostat Fig 6.1.1 Module Pressure Test Point Locations Recommended Routine Service The procedure detailed below should be carried out on each boiler module in turn.

  • Page 40: Replacement Of Parts

    WD53/0/1999 Chapter 7 : Replacement Of Parts The Keston 260 and 340 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 FLOW OVERHEAT, FLOW HIGH LIMIT & FLUE PROTECTION THERMOMSTATS 7.4.4...
  • Page 41 WD53/0/1999 Chapter 7 : Replacement Of Parts The Keston 260 & 340 Condensing Boilers GENERAL The following must always be carried out by a competent/qualified person. PRECAUTIONS Always switch off the mains electricity supply Gain access to the appliance (Section 7.2) and turn off the gas supply at the appliance service cock.
  • Page 42 WD53/0/1999 Chapter 7 : Replacement Of Parts The Keston 260 and 340 Condensing Boilers Drain the system to below the level of the appliance using the drain off tap at the base of each heat exchanger. Remove the push on connectors from the water pressure switch taking note of the correct positions.
  • Page 43 WD53/0/1999 Chapter 7 : Replacement Of Parts The Keston 260 & 340 Condensing Boilers xii) Reassemble (Section 7.3) xiii) Reset the gas rate (See Section 4 - Commissioning) 7.4.9 Module Gas Low Pressure Switch (Fig. 5.7.3 item 134) Isolate the appliance (Section 7.1) Gain access (Section 7.2)
  • Page 44 WD53/0/1999 Chapter 7 : Replacement Of Parts The Keston 260 and 340 Condensing Boilers MODULE HEAT EXCHANGER (Fig. 5.7.2 item 77) 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 45 WD53/0/1999 Chapter 7 : Replacement Of Parts The Keston 260 & 340 Condensing Boilers 7.12 MODULE SIGHT GLASS (Fig. 5.7.2 item 71) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Unscrew the sight glass fitting from the burner head.
  • Page 46 WD53/0/1999 Chapter 8 : Spare Parts Listings The Keston 260 & 340 Condensing Boilers 8. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No Part Denomination Burner 114 118Burner Manifold Gasket 375 527 Ignitor Gasket Ignitor/Sensor Probe...
  • Page 47 WD53/0/1999 Chapter 8 : Spare Parts Listings The Keston 260 & 340 Condensing Boilers Item GC No Part Denomination Item GC No Part Denomination 375 534Flow High Limit Stat 375 535Gas Valve Outlet Gasket 375 536Gas Valve 114 122Flexible Hose Gasket...
  • Page 48 WD53/0/1999 Chapter 8 : Spare Parts Listings The Keston 260 & 340 Condensing Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination Burner 114 118 Burner Manifold Gasket 375 527 Ignitor Gasket Ignitor/Sensor Probe...
  • Page 49 WD180/0/99 KESTON CONDENSING BOILERS IMPORTANT KESTON 260 & 340 INSTALLATION KEY POINTS † Read Installation Manual Carefully † Ensure that there is at least 9 feet head of water pressure at the top of the boiler. † Ensure that the boiler(s) is connected to the system via a low loss balance header.

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K340

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