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Keston C90 Installation And Servicing Instrucnion

Fan powered high efficiency modulating commercial condensing gas boiler
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WD352/0/2003
The Keston C90 & C110
C90 & C110
C90 & C110
C90 & C110
C90 & C110
Fan Powered High Efficiency
Modulating Commercial Condensing Gas Boiler

Installation and Servicing Instructions

C90 and C110 Models
CE/PI No : 87BN14
ISSUE:
4/2010
These instructions must be left either with
the user or next to the site gas meter.
KESTON BOILERS LIMITED
34 West Common Road, Bromley, Hayes, Kent BR2 7BX, UK
Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459
email : info@keston.co.uk
web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L2 2002

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  • Page 1: Installation And Servicing Instructions

    WD352/0/2003 The Keston C90 & C110 C90 & C110 C90 & C110 C90 & C110 C90 & C110 Fan Powered High Efficiency Modulating Commercial Condensing Gas Boiler Installation and Servicing Instructions C90 and C110 Models CE/PI No : 87BN14 ISSUE:...

  • Page 2: Table Of Contents

    WD352/0/2003 The Keston C90 & C110 CONTENTS Section Description HANDLING INSTRUCTIONS List of contents Recommended handling procedure GENERAL INSTRUCTION Description Boiler Schematic Related Documents Physical Data Performance Data C90 Performance Data C110 Optional Accessories BOILER LOCATION Dimensions & Minimum Clearances...
  • Page 3 WD352/0/2003 The Keston C90 & C110 COMMISSIONING OF THE BOILER Initial Flushing Gas Supply Electrical Installation Initial Firing Hot Flushing Combustion Testing Checking The Gas Pressure Timing The Gas Meter Handing Over To The User FAULT FINDING Electrical Control Sequence...

  • Page 4: Handling Instructions

    The Keston C90 and C110 are supplied almost totally pre-assembled. Since the units use 100 mm Keston Composite pipe for the flue and air intake systems the boiler is packed in a single box without additional flue kit. All additional components are packed inside the boiler cabinet itself.
  • Page 5 Safety footwear and gloves are recommended PPE when lifting this appliance - to protect against sharp edges and ensure good grip. The C90 and C110 boilers can be fitted in compartments with very small clearances required around the appliance (refer to Section 2.1). Due consideration should therefore be given to access within the compartment for lifting and positioning.

  • Page 6: General Instruction

    Grundfos pumps within the appliance cabinet ensures the heat exchanger receives correct water flow when firing. The C90 and C110 are not high water content boilers and do not contain the metal mass, or water volume, of a cast iron or steel boiler. The boiler is of low mass and low water content and therefore responds faster when there is a call for heat.
  • Page 7 It is not harmful to the waste disposal system and may be disposed of as normal waste water. The flue gases are piped in a 100 mm Keston Composite pipe. The temperature of the flue gases are usually around 5 C to 10 C above the temperature of the return water.

  • Page 8: Related Documents

    Keston Boilers Ltd declare that there are no substances harmful to health within the appliance or used during the production of the appliance. The C90 and C110 are intended for domestic and commercial EMC environments and on a governed G20 meter supply.
  • Page 9 WD265/0/2002 Chapter 1 : General Instruction The Keston C90 and C110 PERFORMANCE DATA - C90 Max. Input (Gross CV) kW/(Btu/h) 91.2 (311,200) Min. Input (Gross CV) kW/(Btu/h) 25.8 (88,000) Max. Output To Water (80/60 C Flow/Return) kW/(Btu/h) 79.9 (272,500) (50/30...

  • Page 10: Optional Accessories

    Children should be supervised to ensure that they do not play with the appliance. OPTIONAL ACCESSORIES A range of accessories are available from Keston Boilers Ltd to compliment an installation. Description Part Number Floor Standing Support Frame C.34.0.06.00.0...

  • Page 11: Boiler Location

    DHW/Zone 2 connection 1 10 (When appliance is operating) inch BSP female POSITION The C90 and C110 are not suitable for external installation. The boiler may be installed in any room or internal space, although particular attention is drawn to the Figure 2.1.2...
  • Page 12 The Keston C90 and C110 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.

  • Page 13: Boiler Size Selection

    Reduction in dynamic gas supply pressure will result in intermittent ignition failures. Ensure gas supply pipe work is adequately sized for the length of run from the meter to the boiler at a supply rate of 92kW for the C90 and 114kW for the C110 model.
  • Page 14 Where thermal stores are to be used the thermal store supplier should be consulted as to the compatibility of the thermal store with a Keston C90 and C110. Thermal store units where the boiler directly heats an open vented thermal store are not suitable for use with the C90 or C110.
  • Page 15 The Keston C90 & C110 Although suitable for open vented systems with combined feed and vent arrangements, the C90 and C110 are low water content boilers. 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 16 The hot water storage vessel must be of the indirect type. DIRECT CYLINDERS MUST NOT BE USED. Further guidance is provided in BS 1394. The Keston Spa range of stainless steel unvented cylinders are an ideal option for use with the Keston range. The Keston Spa range combine exceptional recovery times with durable, long life stainless steel construction and all associated controls.

  • Page 17: Flue System

    Individual air supply and flue outlet pipes are used. The material used for flue outlet &/or air inlet must be Keston Composite Pipe of an internal diameter of not less than 100mm. Suitable pipe and fittings can be obtained from Keston Boilers Ltd via its appointed distributors.
  • Page 18 Drain points, with suitable traps, must therefore be incorporated within the flue system at the base of vertical flue sections in excess of 8m, for 100mm Keston Composite pipe flue systems. These additional condensate drains must be run to discharge as Installation &...
  • Page 19 Table 2.8.4 Minimum Flue Terminations & Air Inlet Dimensions The Keston C90 and C110, 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” when selecting a location for the flue terminal.

  • Page 20: Compartment Installation

    However, the cupboard or compartment must not be used for storage. 2.11 CONDENSATE DRAINAGE Being a condensing boiler, the C90 and C110 are 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 21: 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 22: Condensate Drainage

    WD352/0/2003 Chapter 3 : Installation The Keston C90 & C110 whilst drilling. Under no circumstances must debris from the wall or cut pipes be allowed to enter the appliance or the plastic pipework. Drill the two holes in the wall/ceiling, preferably using a core drill.

  • Page 23: Exchanging A Boiler

    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 3.9...
  • Page 24 WD352/0/2003 Chapter 3 : Installation The Keston C90 & C110 factors as soundness of the air and flue pipe joints, pressure sensible joints and the gas inlet pressure (20 mbar required). If all joints are sound and the gas inlet pressure is satisfactory set the gas pressure.

  • Page 25: Commissioning Of The Boiler

    INITIAL FLUSHING All waterways within the Keston C90 and C110 are either copper, high alloy stainless steel or aluminium. As a result water treatment chemicals for central heating boilers such as Fernox MB1, Sentinel X100 or equivalent, are suitable. In any event reference must be made to BS 7593 : Treatment Of Water In Hot Water Central Heating Systems.
  • Page 26 (CO ) levels will be between 8 & 8.2% (C90 low rate), 8.3 & 8.5% (C110 low rate), 8.2 & 8.7% (C90 high rate) and 8.6 & 9% (C110 high rate) and carbon oxide (CO) levels Installation & Servicing Instructions...
  • Page 27 The CO reading must be 8% to 8.2% for C90 and 8.3% to 8.5% for C110 with a corresponding CO level of 5 to 20 ppm for natural gas. THE CO2 LEVEL AT LOW RATE MUST ALWAYS BE LESS THAN THE CO2 LEVEL AT HIGH RATE.
  • Page 28 If following the above procedure, combustion levels described above at both high and low rate could not be obtained, please turn off the appliance and isolate the gas to the appliance. Telephone KESTON BOILERS technical support (phone no. 0208 462 0262) To revert to normal modulation Press the “Mode”...
  • Page 29 WD352/0/2003 Chapter 4 : Commissioning The Keston C90 & C110 HANDING OVER TO THE USER It is important to fully explain the following: Procedure to light and turn off the boiler, including isolation of the electrical supply if necessary. The function of the lockout feature must be explained : If the display shows “E 02”...
  • Page 30 5. FAULT FINDING ELECTRICAL CONTROL SEQUENCE The C90 and C110 feature digital displays to detail the operating status of each of the two modules contained in the boiler. When serving a demand signal on SL1 only both displays will show very similar temperatures (the last two digits) and matching status, allowing for a small delay between operation of each module.

  • Page 31: Normal Operation

    Chapter 5 : Fault Finding The Keston C90 & C110 NORMAL OPERATION The C90 and C110 boilers feature a user display which shows actual flow temperature of each module at all times (the last two digits of the display) and a status number (the first digit) which identifies what the module is doing at any given time.

  • Page 32: Error Codes

    WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 5.3.2 LOCKOUT If the fault is persistent or more severe the module will lockout with a error code. When the module has entered this error mode it will not attempt to restart until the “Reset” button is pressed.
  • Page 33 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 28...
  • Page 34 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 29...
  • Page 35 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 30...
  • Page 36 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 Exploded Assembly Diagrams 5.7.1 Boiler Controls Assembly 5.7.2 Waterway, Condensate & Flue Assembly. Installation & Servicing Instructions Page : 31...
  • Page 37 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 Installation & Servicing Instructions Page : 32...
  • Page 38 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 5.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 33...
  • Page 39 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 5.7.4 Casing Assembly Installation & Servicing Instructions Page : 34...
  • Page 40 WD352/0/2003 Chapter 5 : Fault Finding The Keston C90 & C110 5.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 5.7.1) GC Number Code Description E93-126 Main Control Box (C.17.4.01.00.0 A) E93-130 Control Panel (C.17.4.02.00.0) HV Terminal Block (C.17.4.41.00.0) LV Terminal Block (C.17.4.42.00.0)
  • Page 41 It should be noted that setting the user controls to “Standby” does not isolate the electrical supply and parts of the boiler will remain live. Hazardous materials are not used in the construction of the C90 and C110. However, due care should be taken when handling boiler components.
  • Page 42 WD352/0/2003 Chapter 6 : Servicing The Keston C90 & C110 If necessary clean the burner with a mild household detergent and rinse under a hot running tap. If necessary, from visual inspection, 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 43 WD352/0/2003 Chapter 7 : Replacement Of Parts The Keston C90 & C110 7. REPLACEMENT OF PARTS CONTENTS GENERAL PRECAUTIONS ACCESS REPLACEMENT PROCEDURE ELECTRICAL COMPONENTS 7.4.1 CONTROL PANEL 7.4.2 MODULE FLOW & RETURN THERMISTORS 7.4.3 CABINET TEMPERATURE SENSOR 7.4.4 FLUE PROTECTION THERMOSTAT 7.4.5...
  • Page 44 WD352/0/2002 Chapter 7 : Replacement Of Parts The Keston C90 & C110 7.4.2 Module Flow and Return Thermistors (Fig. 5.7.2 item 67) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions.
  • Page 45 WD352/0/2003 Chapter 7 : Replacement Of Parts The Keston C90 & C110 7.4.8 Gas Control Valve / Venturi Assembly (Fig. 5.7.3 item 193) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connector block to the gas valve.
  • Page 46 WD352/0/2002 Chapter 7 : Replacement Of Parts The Keston C90 & C110 xii) Remove the heat exchanger xiii) Reassemble (Section 7.3) xiv) Recommission (Section 4 - Commissioning) CONDENSATE TRAP (Fig. 5.7.2 item 76) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Disconnect the condensate line from the base of the heat exchanger.

  • Page 47: Short Spare Parts List

    WD352/0/2003 Chapter 8 : Spare Parts Listings The Keston C90 & C110 8. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No Part Denomination E93-137 C110 Burner E93-141 Burner Gasket E93-138 C90 Burner E93-142 Ignitor Gasket E93-143...
  • Page 48 WD352/0/2003 Chapter 8 : Spare Parts Listings The Keston C90 & C110 SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination E93-145 Flow/Return Temperature Thermistor 114-045 Water Pressure Switch E72-332 Flue Protection Thermostat E93-126...
  • Page 49 WD352/0/2003 The Keston C90 & C110 KESTON CONDENSING BOILERS IMPORTANT C90 & C110 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 .

This manual is also suitable for:

C110

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