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Keston K170 Installation And Servicing Instructions

Fan powered high efficiency condensing gas boiler
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WD51/2/1997
The Keston 170 Condensing Boiler
170,000 Btu/h (50 kW) Model
Fan Powered High Efficiency
Condensing Gas Boiler

Installation And Servicing Instructions

Keston 170 - GC No 41 930 04
CE No : 87AR50
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. 0181 462 0262 Fax. 0181 462 4459

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  • Page 1: Installation And Servicing Instructions

    170,000 Btu/h (50 kW) Model Fan Powered High Efficiency Condensing Gas Boiler Installation And Servicing Instructions Keston 170 - GC No 41 930 04 CE No : 87AR50 These instructions must be left either with the user or next to the site gas meter.

  • Page 2: Table Of Contents

    WD51/2/1997 The Keston 170 Condensing Boiler 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 Flue System Air Supply 2.10...
  • Page 3 SPARE PARTS LISTINGS BENCHMARK INITIATIVE As part of the industry wide “Benchmark” Initiative all Keston 170 boilers now include a Benchmark Installation, Commissioning and Service Record Log Book. Please read this carefully and complete all sections relevant to the appliance installation. The details of the Log Book will be required in the event of and warranty work being required.

  • Page 4: General Instruction

    15 metres horizontally or vertically. The Keston uses a high power combustion blower to deliver a pre-mix of gas and air to a downward firing burner in a high efficiency, single pass heat exchanger. Normally the...

  • 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, current IEE Wiring Regulations, Building Regulations, Building Standards (Scotland) Consolidation, and the Bye Laws of the local Water Undertaking.

  • Page 6: Performance Data

    The Keston 170 Condensing Boiler WD51/2/1997 Chapter 1 : General Instruction BS 5440.2 Air Supply BS 5482.1 Domestic Propane & Butane Burning Installations BS 7074.1 Expansion Vessels BS 7593 Treatment of Water in Hot Water Central Heating Systems BS 7671 Requirments for Electrical Installations.IEE Wiring...

  • Page 7: Boiler Location

    WD51/2/1997 Chapter 2 - Boiler Connections The Keston 170 Condensing Boiler 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. SERVICE CONNECTIONS...

  • Page 8: Electrical

    Section 2.8.3] Condensate drain The Keston can be located virtually anywhere desired provided that all regulations are complied with. 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 9: Boiler Size Selection

    WD51/2/1997 Chapter 2 - Boiler Connections The Keston 170 Condensing Boiler unswitched three pin plug and a shuttered socket-outlet, both 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.
  • Page 10 Central Heating Systems. Pump isolating valves must be positioned as close to the pump as possible. The Keston 170 is suitable for use on open vented water systems with combined feed and vent. 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 11 WD51/2/1997 Chapter 2 - Boiler Connections The Keston 170 Condensing Boiler Expansion Expansion Tank Pipe Minimum 9ft Height Boiler 28mm Minimum Cylinder Keston Valve Pump By-pass Valve Bal. Strainer Valve Valve Rad. 2 Rad. 1 Figure2.7.1 : Open Vented System Diagram 2.7.2...
  • Page 12 WD51/2/1997 Chapter 2 - Boiler Connections The Keston 170 Condensing Boiler Make -up vessel. Max. capacity of Air Vent 3 lt. (5pt) Hose Non-Return Union Valve bib tap Auto Air Boiler Vent Keston Strainer RETURN Pressure By-pass Guage Bal. HEATING CIRCUIT...
  • Page 13 WD51/2/1997 Chapter 2 - Boiler Connections The Keston 170 Condensing Boiler 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 14: Flue System

    WD51/2/1997 Chapter 2 - Boiler Connections The Keston 170 Condensing Boiler system and a pump selected that is capable of meeting the flow rate required at the total pressure loss generated by the boiler and the rest of the system. The selected pump must comply with BS 1394.
  • Page 15 There must be no troughs in any of the pipework, whether it be air inlet or flue outlet. If a 80 mm per meter slope is not possible, contact Keston Boilers Technical Department for further guidance. Due the low temperature of the flue gases further condensate Figure 2.8.3 :...
  • Page 16 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. Consideration must therefore be given to the effect of this “plume”...

  • Page 17: Air Supply

    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 18: Low Water Volume Boiler Vs. Cast Iron Boiler

    Lower water temperatures in the system tend to increase the efficiency of the boiler and will help assure that the boiler is subjected to a sufficient load to avoid short-cycling. 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.

  • Page 19: Installation Of The Boiler

    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 20: Installing Flue And Air Pipes

    WD51/2/1997 Chapter 3 : Installation The Keston 170 Condensing Boiler The combustion air filter will prevent plugging of the burner caused by dirt being trapped in the burners outer mesh. The filter element supplied with the boiler is obtainable from Keston Boilers or its distributors.

  • Page 21: Condensate Drainage

    WD51/2/1997 Chapter 3 : Installation The Keston 170 Condensing Boiler 88 mm Measure, cut and check the air and flue pipes to pass to the exit from the wall(s) or ceiling. Always thoroughly deburr all pipes and, most important, remove shavings from within the pipe.

  • Page 22: Water System

    WD51/2/1997 Chapter 3 : Installation The Keston 170 Condensing Boiler 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 23: Exchanging A Boiler

    As a safety precaution it is advisable to fit an 'in line' strainer before the boiler. The guarantee provided with the Keston 170 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 24: 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 25 Vent the water system. Important: The Keston heat exchanger consists of a single coil which can trap an air pocket. Great care must be taken to ensure that water flow has been established through the heat exchanger and thus ensuring no air pockets remain in the heat exchanger and pipe work.

  • Page 26: Hot Flushing

    2 cu ft dial) or 0.1 cubic metres if the meter is of the new metric digital type. The Keston 170, when correctly set, should take 39.8 seconds for 2 cubic feet of natural gas and 70.3 seconds for 0.1 cubic metres of natural gas (assuming 1038 btu/h per cubic foot).
  • Page 27 To measure CO levels in the Keston boiler remove the 1/8" plug from the flue outlet pipe inside the boiler (Figure 5.7.2 item 69). Insert the probe of a combustion analysis meter and sample the gases as instructed in the test equipment's instructions.

  • Page 28: Fault Finding

    WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler 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 29 WD51/2/1997 Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler FAULT FINDING FLOW CHART START Apply Power To Boiler. Is amber switch light on? Is there 230V between Check External Controls. terminals SL & N? Is the boiler switched on? Switch On Boiler.
  • Page 30 WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler Continued from sheet 1 Does ignition sequence start? Switc h off & if problem persists Is lockout light on? replace control box. Blocked air filter - replace Has the Air Press. Switc h...
  • Page 31 WD51/2/1997 Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler Continue d fro m Sheet 2 Contin ued o n sh eet 2 ye s Is there 230V at val ve Faulty Gas V alve - Replace. ye s Is there 230V at Gas Low Faulty Gas Low P ressure Press.
  • Page 32 WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler CONTINUITY CHECKING T o c h e c k c o n t in u it y c o n ne c t o n e pro b e t o a n e u tr a l an d us e th e o th e r pro b e to c he c k f o r 23 0 V .
  • Page 33 WD51/2/1997 Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler FUNCTIONAL FLOW WIRING DIAGRAM EMC Filter Pump L Pump N EMC Filter Installation & Servicing Instructions Page : 30...

  • Page 34: Electrical Wiring Diagram

    WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler ELECTRICAL WIRING DIAGRAM APS-AIR PRESSURE SWITCH LEGEND L -INCOMING LIVE -BLUE BK -BLACK N -INCOMING NEUTRAL OR -ORANGE RAM-2EMC22 -RED -INCOMING EARTH PK -PINK IGNITION CONTROL -WHITE -GREEN BR -BROWN...

  • Page 35: Illustrated Wiring Diagram

    WD51/2/1997 Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler ILLUSTRATED WIRING DIAGRAM ILLUSTRATED WIRING DIAGRAM Flow Overheat Stat Thermal Fuse Boiler Stat Control 51PK 52BK Flow High Limit Stat 92OR 93OR 10BK Low Water Pressure Switch Gas Low Pressure Switch...
  • Page 36 WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler Exploded Assembly Diagrams 5.7.1 Boiler Controls Asembly SCREW BOILER CONTROLS 04.1.00.78.0 K170 - 17.4.00.00.0 TR2 THERMOSTAT 17.4.11.00.0 OPTIONAL FUSE ISOLATOR 04.4.20.00.0 IGNITION CONTROL PACTROL 04.4.01.00.0 SECTION 1 04.4.01.00.1 FUSE SOCKET 04.4.19.00.0...
  • Page 37 WD51/2/1997 Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler 5.7.2 Waterway, Condensate & Flue Assembly SCREW WATER WAY, CONDENSATE 04.1.00.80.1 & FLUE ASSEMBLY K170 - 17.2.00.00.0 IGNITER 04.2.13.00.1 IGNITER GASKET 04.2.00.28.2 GASKET SCREW 17.2.00.05.2 04.1.00.79.1 PRESS. TEST FITT. 04.2.28.00.0 SCREW 04.2.00.29.1...
  • Page 38 WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler 5.7.3 Air - Gas Assembly PRESS. TEST FITT. SCREW AIR-GAS ASSEMBLY 04.2.28.00.0 04.3.00.28.0 K170 - 17.3.00.00.0 GAS TEE 04.3.00.34.1 LOW GAS PRESSURE SWITCH 04.3.09.00.0 AIR HOSE CLAMP REGULATOR GAS VALVE 17.3.00.07.0...
  • Page 39 WD51/2/1997 Chapter 5 : Fault FindingThe Keston 170 Condensing Boiler 5.7.4 Casing Assembly SCREW SCREW BURNER ACCESS COVER CASING ASSEMBLY 04.1.00.40.0 04.1.00.41.0 17.1.00.01.0 K170 - 17.1.00.00.0 56mm GROMMET 17.1.00.04.0 35mm GROMMET 17.1.00.05.0 GAS VALVE EXHAUST FLUE LABEL 17.1.13.00.0 04.1.00.52.0 FLOW LABEL...
  • Page 40 WD51/2/1997 Chapter 5 : Fault Finding The Keston 170 Condensing Boiler 5.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 5.7.1) GC Number Code Description E01 074 Ignition Control Box 170 084 Air Pressure Switch 114 076 Electrical Terminal Block...
  • Page 41 WD51/2/1997 Chapter 6 : Servicing The Keston 170 Condensing Boiler 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 42 WD51/2/1997 Chapter 6 : Servicing The Keston 170 Condensing Boilers Flue Pressure Test Point A Pressure Test Point B 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 43 WD51/2/1997 Chapter 6 : Servicing The Keston 170 Condensing Boiler If necessary, either from visual inspection or a high pressure differential between points B & C in the pre-service checks, clean the heat exchanger using a suitable stiff plastic bristle brush, vacuum out any large particles and flush the heat exchanger with fresh water until the water flowing from the condensate drain is clear.
  • Page 44 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 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 45 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 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. (If a switch only is used then remove the fuse.) Gain access to the appliance (Section 7.2) and turn off the gas supply at the...
  • Page 46 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 Condensing Boilers Reassemble (Section 7.3) When fitting the new thermostat it is an advantage to smear a thin film of heat sink compound between the thermostat and plate. This, combined with fitting the new thermostat tightly to the plate, ensures a good contact.
  • Page 47 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 Condensing Boilers Reassemble (Section 7.3) 7.4.7 Air Pressure Switch (Fig. 5.7.1 item 109) 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 48 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 Condensing Boilers Gain access (Section 7.2) iii) Remove the push on connectors to the gas low pressure switch taking note of the correct positions. Unscrew the gas low pressure switch from the brass holder.
  • Page 49 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 Condensing Boilers HEAT EXCHANGER (Fig. 5.7.2 item 42) 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 50 WD51/2/1997 Chapter 7 : Replacement Of Parts The Keston 170 Condensing Boilers 7.11 PRESSURE GAUGE (Fig. 5.7.1 item 116) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Shut off the pressure measurement point at the return drain valve located at the base of the heat exchanger.
  • Page 51 WD51/2/1997 Chapter 8 : Spare Parts Listings The Keston 170 Condensing Boiler 8. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No Part Denomination 114 105Air Filter 114 117Burner 114 118Burner Manifold Gasket 375 527Ignitor Gasket 114 120Ignitor/Sensor Probe...
  • Page 52 WD51/2/1997 Chapter 8 : Spare Parts Listings The Keston 170 Condensing Boiler Item GC No Part Denomination Item GC No Part Denomination 375 535Gas Valve Outlet Gasket 114 122Flexible Hose Gasket 375 536Gas Valve E01 074 Ignition Control Box 170 084Air Pressure Switch...
  • Page 53 WD51/2/1997 Chapter 8 : Spare Parts Listings The Keston 170 Condensing Boiler SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination 114 105 Air Filter 114 117 Burner 114 118 Burner Manifold Gasket 375 527...
  • Page 54 WD 93/0/1997 KESTON CONDENSING BOILERS IMPORTANT KESTON 170 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. † DO NOT remove the dust caps from the air and exhaust pipes until ready to connect.

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