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Combi 30 & 35
Installation and Servicing Instructions
FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS COMBINATION BOILER
CE/PI No. 86-CL-38
Combi 30 - GC No. 47-930-04
Combi 35 - GC No. 47-930-05
These instructions must be left either with the
user or next to the site gas meter.
Keston Heating
PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN
Tel. +44 (0) 1482 443005
Fax. +44 (0) 1482 467133
email : info@keston.co.uk
web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2
SEDBUK A RATED
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Summary of Contents for Keston Combi 30
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Page 1: Installation And Servicing Instructions
FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE/PI No. 86-CL-38 Combi 30 - GC No. 47-930-04 Combi 35 - GC No. 47-930-05 These instructions must be left either with the user or next to the site gas meter. - Page 2 BACK Keston Combi - Installation and Servicing...
- Page 3 The boiler will repeat the ignition sequence if a heat demand is present. DOCUMENT AMENDMENTs Relevant Installation changes implemented in this book from Mod Level ........A01 (Nov 12) Keston reserve the right to vary specification without notice Keston Combi - Installation and Servicing...
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Page 4: Electrical Supply
= An appliance designed for use on 2nd Family gas, Group H only. b. For ft /h - divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft c. For m /h - multiply l/s by 3.6. Keston Combi - Installation and Servicing... -
Page 5: Table Of Contents
BACK general CONTENTs KEsTON Combi 30 & 35 Natural gas only Benchmark Commissioning Checklist ..... 66 Boiler size g.C. Appliance No. pI No. Boiler Clearances ............9 (Benchmark No.) Boiler Exploded Diagram ........... 12 47-930-04 86 CL 38 Condensate Drain .......... 8,22,23,39... -
Page 6: Safe Handling
INTRODUCTION This boiler may require 2 or more operatives to move it to its The Keston Combi boiler is a wall mounted, full sequence, installation site, remove it from its packaging base and during automatic spark ignition, low water content, fanned flue, high movement into its installation location. -
Page 7: Gas Safety Regulations
Keston in writing. If in doubt please enquire. compartment design, including airing cupboard installation, are to Any direct connection of a control device not approved by Keston conform to the following: could invalidate the certification and the normal appliance •... -
Page 8: Gas Supply
BS6891:2005. Whilst the of temperature in individual rooms should also be fitted with a principle of the 1:1 gas valve ensures the Keston Combi range room thermostat controlling the temperature in a space served by is able to deliver its full output at inlet pressures as low as 14mb, radiators not fitted with such a valve. - Page 9 Bottom clearance after installation can be reduced to 5mm. This must be obtained with an easily removable panel, to enable the consumer to view the system pressure gauge, and to provide the 100mm clearance required for servicing. Keston Combi - Installation and Servicing...
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Page 10: Pump
RETURN to the boiler. minimum system design pressure is reached; 1.0 bar if the system is to be pre-pressurised. Guidance on vessel sizing is given in Table above. continued ..Keston Combi - Installation and Servicing... -
Page 11: Domestic Hot Water
Benchmark Guidance Notes on Water Treatment in Central Heating branded Ideal, which must be used in accordance with the Systems. manufacturers’ instructions. If water treatment is used Keston recommend only the use of For further information contact: Scalemaster Gold 100, FERNOx, MBI AND F1 or SENTINEL x100... - Page 12 When ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output. Check boiler serial letter code on data plate to obtain correct BCC. Keston Combi - Installation and Servicing...
- Page 13 Flue pack Contents Flue Adaptor Air Spigot Terminals - 2 off Flue Sleeve Wall Plate Wall Seal Outside Sensor Screws - 4 off Wall Plugs - 4 off continued ..Keston Combi - Installation and Servicing...
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Page 14: Flue System
50mm x 88.5 deg bend 50mm swept tee Consideration MUST be given to expansion and contraction of the flue. Refer to Assembly Practice Frame in this installation and Servicing Instructions for further guidance. continued.... Keston Combi - Installation and Servicing... - Page 15 Only swept elbows can be used. Air inlet pipework can be truly horizontal or vertical, or sloping in a downward direction towards the boiler but in each case rain, etc., must be prevented from entering the pipe. There must be no troughs in any of the pipework, whether it be air inlet or flue outlet. Keston Combi - Installation and Servicing...
- Page 16 BACK INSTALLATION 10 FLUE INsTALLATION ExAMpLE KEsTON COMBI 30 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 back to boiler 8 10 12 14 16 18 20 22 24 26 28 30...
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Page 17: Air Supply
Rubber collars are available for flue and air terminals to finish the external wall face around the terminals (Part No C.08.00.07.0). AIR sUppLy The Keston Combi is a room-sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air. -
Page 18: Installing The Boiler
3. Locate 2 No.14 x 50mm screws in the wall mounting plate (one at each side, in any of the 3 holes provided at each side) and screw home. Section through wall Note. Check all of the hole positions before drilling. Keston Combi - Installation and Servicing... -
Page 19: Mounting The Boiler
Choose one of the 2 sets of slots in left and right bank. Introduction section for safe handling advice), locating it Ensuring that at least one of the screws is fitted into a top slot. over the two tabs. Example of fixing esp9496 Keston Combi - Installation and Servicing... -
Page 20: Assembly Practice
(remount the boiler if removed). When pushing pipe through walls, ensure grit and dust is not allowed to enter the pipe. Ensure pipes are fully engaged into sockets and solvent welded with no leaks. Keston Combi - Installation and Servicing... - Page 21 8. Affix flue terminal 9. During boiler test check that the flue end is free to expand and contract with flexible wall seal. Flue Terminal Flue Pipe Flue Sleeve Flange Flue Sleeve Flexible Wall Wall Plate Seal Keston Combi - Installation and Servicing...
- Page 22 Boilers without 75mm sealed condensate trap must be fitted with condensate trap must be fitted with a 75mm trap and visible air break a 75mm trap and visible air break continued ..Keston Combi - Installation and Servicing...
- Page 23 75mm trap and visible air break ≥ 500 2 rows of three Ø12mm holes 25mm centres, 50mm from the bottom of the tube, facing away from the house Keston Combi - Installation and Servicing...
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Page 24: Connections & Filling
Outlet (Shown in closed position) Supply Inlet Return Black Handle Blue Yellow Handle Handle Note that all isolation handles Safety Drain are shown in the open postion. Valve Black Handle Black Handle Filling Loop Keston Combi - Installation and Servicing... -
Page 25: Electrical Connections
2. Remove the front panel. Refer to Frame 39. 3. Swing the control box down into the servicing position. The Keston Combi boiler comes pre-fitted with a link wire Refer to Frame 45. between the room thermostat/Timer connections on the terminal strip. - Page 26 INSTALLATION 25 INTERNAL WIRINg..CONT’D Keston offer 2 kits as follows: (see individual kits for installation instructions) Electronic Timer (7 day) kit - 7 day electronic CH timer fits into the control box of the boiler. This can be fitted in conjunction with a room thermostat.
- Page 27 Part P of the Building Regulations. Avoid running this cable alongside mains voltage cables. Wiring the Weather Compensation Kit to the Keston Combi. 1. Isolate the electricity supply to the boiler. 2. Remove the boiler front panel (refer to boiler installation instructions).
- Page 28 The On and Off time control of central heating should be controlled by a separate timer. This can be a standard unit or either of the options available from Keston Combi range. During programmed On times the Central Heating Radiator Flow Temperature is controlled by the boiler relative to the Outside Temperature as shown in the following diagram.
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Page 29: External Electrical Controls
3G9990a OpenTherm programmable Room Temperature Control Note. These terminals MUST ONLY be connected to an OpenTherm Controller, (such as the Keston Chronothern Room Controller (c.17.4.21.00.0). Connecting any other device / control wiring may destroy the primary PCB. 1. Isolate the mains supply to the boiler. - Page 30 BACK INSTALLATION 30 WIRINg DIAgRAM Keston Combi - Installation and Servicing...
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Page 31: Commissioning And Testing
“Venting Boiler Off” - “Pump and Diverter Valve Cycling” - Duration 5 mins” - “Reset to End” ATTENTION ! IT Is A CONDITION OF ThE MANUFACTURERs WARRANTy ThAT ThE BENChMARK COMMIssIONINg ChECKLIsT Is FULLy COMpLETED AND LEFT WITh ThE AppLIANCE Keston Combi - Installation and Servicing... -
Page 32: Initial Lighting
When the burner is established the BLUE ‘Burner On’ neon isolation of the mains electricity supply. (F) will be illuminated, the LCD will display “Central Heating” and “Radiator Temp XX C”. continued..Keston Combi - Installation and Servicing... - Page 33 Mode knob moved to summer position Summer mode Central heating off Hot water on Mode knob moved to winter position Winter mode Central heating on Hot water on Mode knob moved to reset position Reset Keston Combi - Installation and Servicing...
- Page 34 To reset boiler, turn the mode control knob (D) to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present. Legend A. Pre-heat On/off D. Off/Summer/Winter/Reset Control B. DHW temperature control E. Boiler Status C. CH temperature control F. Burner ‘on’ indicator Keston Combi - Installation and Servicing...
- Page 35 5. Reset the system initial pressure to the design requirement. 80 (176) 64 (147) 6. Balance the system. Refer to Frame 4. 7. Check the condensate drain for leaks and check that 45 (113) 40 (104) it is discharging correctly. Keston Combi - Installation and Servicing...
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Page 36: Handing Over
6. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system. 7. If a timer is fitted draw attention to the timer Users Instructions and hand them to the householder. Keston Combi - Installation and Servicing... -
Page 37: Servicing Schedule
SERVICING 38 sERVICINg sChEDULE For the very latest copy of literature for specification & maintenance practices, visit our website www.keston.co.uk, where you will be able to download the relevant information. Warning. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing. -
Page 38: Fan And Venturi Assembly Removal And Cleaning
3. Remove the extended nut on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5. Inspect the injector for blockage or damage. 6. Inspect fan outlet sealing gasket and replace if necessary. Injector Keston Combi - Installation and Servicing... -
Page 39: Burner Removal And Cleaning
2. Disconnect the condensate drain pipe. 5. Re-assemble in reverse order. 3. Turn the siphon clockwise to disengage and lift to B When re-assembling ensure the trap is full of water. remove. Note. Keep siphon upright when removing 3G9690 Keston Combi - Installation and Servicing... -
Page 40: Cleaning The Heat Exchanger
9. Turn on the gas supply at the gas service cock. 4. Reconnect the fan electrical leads. 10. Reconnect the electrical supply. 5. Remove the sump cover and refit the lower flue manifold as shown. Keston Combi - Installation and Servicing... -
Page 41: Replacement Of Components
Refit the extended nut. 9. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket. 10. Check the operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing... -
Page 42: Burner Injector Replacement
8. Fit the new burner, replacing any damaged or deteriorating sealing gasket. 9. Reassemble in reverse order. Refer to Frame 44. 10. Check the operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing... - Page 43 5. Unscrew the two M3.5 screws that connect the thermostat to the manifold. 6. Replace thermostat with new part and then refit the two screws, remembering to fit rubber gasket and sealing clamp. Flue Thermostat Keston Combi - Installation and Servicing...
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Page 44: Ignition Electrode Replacement
6. Fit the new flame detection electrode, using the new gasket supplied. 7. Reassemble in reverse order. 8. Check the operation of the boiler. Refer to Frame 36. a i g S t r . 5 m Keston Combi - Installation and Servicing... -
Page 45: Spark Generator Replacement
6. Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections. 7. Check operation of the boiler. Refer to Frame Keston Combi - Installation and Servicing... -
Page 46: Diverter Valve Actuator Replacement
Note. Keep siphon upright when removing 5. Clean siphon with water. 6. Re-assemble in reverse order. 7. When re-assembling ensure the trap is full of water. 8. Check operation of the boiler. Refer to Frame 36. 3G9690 Siphon Keston Combi - Installation and Servicing... - Page 47 4 corner retaining posts. 7. Take the new Primary PCB and attach the appropriate Boiler Chip Card (BCC). Note. Ensure the correct orientation of BCC by placing “TOP” side up as shown. Plastic Clip Ribbon Cable Connection Keston Combi - Installation and Servicing...
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Page 48: User Control Pcb Replacement
3. Lift off the flow turbine sensor plastic retaining clip. 4. Unplug the electrical connection and transfer to new turbine sensor. 5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing... -
Page 49: Draining The Boiler
3. Unscrew the pressure gauge and discard. 4. Fit new pressure gauge, using suitable jointing compound. 5. Refill the boiler. Refer to Frame 22. 6. Check operation of the boiler. Refer to Frame 36. 3G9690 Keston Combi - Installation and Servicing... -
Page 50: Pump Automatic Air Vent Replacement
7. Ensure the air vent cap is loose. 8. Refill the boiler. Refer to Frame 22. Check for leaks around the new air vent joint. 9. Check the operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing... -
Page 51: Diverter Valve Internal Cartridge Replacement
9. Fit the new valve mechanism ensuring the correct fit of the pin. Frame 36. 10. Reassemble in reverse order. 11. Refill the boiler. Refer to Frame 22. 12. Check operation of the boiler. Refer to Frame 36. FRONT CARTRIDgE REAR CARTRIDgE Keston Combi - Installation and Servicing... -
Page 52: Pump Head Replacement
5. Remove the pump head. 6. Fit the new pump head. 7. Reassemble in reverse order. 8. Refill the boiler. Refer to Frame 22. 9. Check operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing... - Page 53 6. Remove the filter. 7. Clean or replace filter as necessary. 8. Reassemble in reverse order. 9. Refill the boiler. Refer to Frame 22. 10. Check Operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing...
- Page 54 5. Fit the new thermistor using the sealing washer provided. 6. Reassemble in the reverse order. 7. Refill the boiler. Refer to Frame 22. 8. Check the operation of the boiler. Refer to Frame Keston Combi - Installation and Servicing...
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Page 55: Heat Engine Renewal
19. Refill the boiler. Refer to Frame 22. 11. Remove the 2 M5 screws retaining the gas valve mounting bracket and transfer bracket to the new heat exchanger. 20. Check operation of the boiler. Refer to Frame 36. Keston Combi - Installation and Servicing... -
Page 56: Expansion Vessel Recharging & Replacement
5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frame 36. Note. Ensure that the boiler front panel is correctly sealed, compressing the seal to make an airtight joint. Keston Combi - Installation and Servicing... -
Page 57: Fault Finding
No DHW but CH operates OK Go to Frame 88 No Display No Display REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Keston Combi - Installation and Servicing... - Page 58 Check if burner is damaged Replace burner REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Replace heat exchanger Keston Combi - Installation and Servicing...
- Page 59 Fill and vent the system and open all isolation valves all isolation and radiator valves open (check pressure gauge is between 1 to 1.5 bar)? Are connections on water pressure sensor secure? Re-fit connections Replace water pressure sensor Keston Combi - Installation and Servicing...
- Page 60 * note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve. Keston Combi - Installation and Servicing...
- Page 61 Is the Outside Sensor value correct? Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB? Replace PCB Keston Combi - Installation and Servicing...
- Page 62 Are the Radiator Valves Open? Is there 230Vac at (A)? Replace the There is no Voltage from the Diverter Valve Timer/Room Stat. This is not boiler fault. Ensure Voltage is supplied to boiler by rectifying external wiring. Keston Combi - Installation and Servicing...
- Page 63 Is the ribbon cable from the main PCB to the User Connect the ribbon from the main PCB to the User Interface PCB connected securely? Interface PCB securely Replace the Is ribbon cable damaged? User Interface Replace ribbon cable Keston Combi - Installation and Servicing...
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Page 64: Spare Parts
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. Failure to do so could affect safety or performance of this appliance. -
Page 65: Short List Of Parts
BACK Short liSt of partS Keston Combi - Installation and Servicing... - Page 66 BACK Gas Safe Register ID Number...
- Page 67 BACK Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number...
- Page 68 BACK Keston heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN October 2012 UIN 207895 A02 Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk K e s t o n p u r s u e s a p o l i c y o f c o n t i n u i n g i m p r o v e m e n t i n t h e d e s i g n a n d p e r f o r m a n c e o f i t s p r o d u c t s .