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Keston C36 Combi User, Installation And Servicing Instructions

Modulating condensing combination gas fired boiler
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WD388/0/2004
C36 Combi
C36
C36
C36
Modulating Condensing Combination
User, Installation and Servicing
These instructions must be left either with
the user or next to the site gas meter.
email : info@keston.co.uk web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2
Gas Fired Boiler
Instructions
CE/PI No : 87BQ006
C36 Combi - GC No : 47 930 01
C36P Combi - GC No : 47 930 02
ISSUE:
34 West Common Road
Hayes, Bromley, Kent BR2 7BX
Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459
SEDBUK A RATED
The Keston C36 Combi & C36P Combi Boilers
Combi
Combi
Combi
3/2010

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  • Page 1 Modulating Condensing Combination Gas Fired Boiler User, Installation and Servicing Instructions CE/PI No : 87BQ006 C36 Combi - GC No : 47 930 01 C36P Combi - GC No : 47 930 02 ISSUE: 3/2010 These instructions must be left either with the user or next to the site gas meter.

  • Page 2: Table Of Contents

    WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers CONTENTS NB : These instructions are an integral part of the appliance. This document must be handed over to the user on completion of the installation to ensure compliance with the Gas Safety (Installation &...
  • Page 3 WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers Combustion Testing Checking The Gas Pressure Timing The Gas Meter 5.10 Handing Over To The User FAULT FINDING Electrical Control Sequence Normal Operation Fault Modes Functional Flow Wiring Diagram Electrical Wiring Diagram...

  • Page 4: Handling Instructions

    0. HANDLING INSTRUCTIONS LIST OF CONTENTS The Keston C36 Combi and C36P Combi are supplied almost totally pre-assembled. The units use standard 50 mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329) 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 C36 Combi and C36P Combi boilers can be fitted in compartments with very small clearances required around the appliance (refer to Section 3.1). Due consideration should therefore be given to access within the compartment for lifting and positioning.

  • Page 6: User Instructions

    These user instructions should be read carefully to ensure safe and economical use of your C36 Combi. The C36 Combi model is for use with natural gas only, the C36P Combi model is for use with LPG only.

  • Page 7: Safety Information

    In addition, the air intake and flue exhaust terminals must be free from obstruction at all times. Frost Protection The C36 Combi has an integral frost protection function. However, care should also be taken that any exposed pipework is adequately insulated to prevent freezing. SAFETY INFORMATION...

  • Page 8: General Instruction

    The C36 Combi is not a high water content boiler and does not contain the metal mass, or water volume, of a cast iron or steel boiler. This boiler is of low mass and low water content and therefore responds faster when there is a call for heat.
  • Page 9 Boilers WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi system and burns with a blue flame just off surface burner. As the hot products combustion pass downwards, they are cooled by exchanging heat with circulating water which...

  • Page 10: Related Documents

    In the event of the boiler overheating the safety devices will cause a safety shutdown. A safety discharge valve and discharge pipe is fitted to the boiler. The C36 Combi features an integral frost protection function which will operate the pump, regardless of the external controls, should the boiler temperature fall below 10 C.

  • Page 11: Physical Data

    ** Flue lengths between 48 and 60m will create a 1% reduction in DHW output OPTIONAL ACCESSORIES A range of accessories are available from Keston Boilers Ltd to compliment an installation. Terminal wall sealing collars are available to make good the external all face whilst working from the inside of the building using 50mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329) pipe.
  • Page 12 Keston Boilers Ltd declare that there are no substances harmful to health within the appliance or used during the production of the appliance. The C36 Combi is intended for domestic and commercial EMC environments and on a governed G20 meter supply.
  • Page 13 Children should be supervised to ensure that they do not play with the appliance. Benchmark Initiative As part of the industry wide “Benchmark” initiative C36 Combi boiler manual includes Gas Boiler Commissioning Checklist (Chapter 10). This form should be completed by your installer at the end of the installation and commissioning process.

  • Page 14: Boiler Location

    WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers 3. BOILER LOCATION All dimensions in mm. DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown allow subsequent servicing, and safe operation. However, larger clearances may be required during installation.
  • Page 15 The C36 Combi and C36P Combi are classified as IP20 (IPX0) and are therefore suitable for installation in Zone 3 areas, unless subject to hose down.

  • Page 16: Boiler Size Selection

    (80% density) must be used to connect the outside temperature sensor. BOILER SIZE SELECTION The C36 Combi will automatically adjust heat output and pump speed to match the system requirements at any given time. Efficiency and combustion levels are maintained at optimum levels throughout the possible output range.

  • Page 17: Ch & Dhw Water Systems

    In IE the requirements given in the current edition of IS813 and the current Building Regulations must be followed. The Keston C36 Combi is designed for installation on sealed water systems only. With fully pumped water circulation. The pump, an 8l expansion vessel and associated safety devices are fitted within the boiler.
  • Page 18 WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers The boiler is supplied with an integral expansion vessel of 8l capacity. This is suitable for systems of up to 125 Litres system volume. Table 3.7 Expansion Vessel Selection provides guidance for the correct additional expansion vessel size to use for systems with a water content larger than 125 Litres.
  • Page 19 WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 & C36P Combi Boilers driven out of the solution and will C36 Com bi Available pum p head collect in high spots in the system. These air bubbles can interfere with pumping and heat transfer and must be eliminated.

  • Page 20: Flue System

    51 mm. (i.e. nominal 50 mm diameter muPVC solvent weld waste pipe) Alternatively, where flue or air intake lengths of up to 60m are require, Keston Composite 75mm flue and air pipe can be used (contact your Keston stockist for details). Keston Composite 75mm pipe MUST be painted where exposed to UV light.
  • Page 21 BS 5440 Pt 1 for clearances from features of the Flue Outlet/Air Inlet Terminals building although some can be decreased to the Figure 3.8.1 : Terminals values indicated. The Keston C36 Combi and C36P Combi, as with condensing boiler, will generate condensate “plume”...

  • Page 22: Compartment Installation

    3.11 CONDENSATE DRAINAGE Being a condensing boiler, the C36 Combi and C36P Combi 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 23: Installation Of The Boiler

    WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers 4. INSTALLATION OF THE BOILER Read Chapter 3 - 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 24: Assembly Practice

    WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers ASSEMBLY PRACTICE Remove all plastic debris and burrs when installing air intake piping. Plastic filings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower.

  • Page 25: Water System

    WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers iii) replace the nut from the frame bottom Connect the condensate drainage system to the boiler. It is advisable to use a detachable fitting at connection to the boiler to enable easy removal for servicing.

  • Page 26: Exchanging A Boiler

    It is essential that sludge or scale is removed from an existing system before fitting the boiler. The guarantee provided with the Keston C36 Combi and C36P Combi does not cover damage caused by system debris or sludge.

  • Page 27: Commissioning Of The Boiler

    INITIAL FLUSHING All waterways within the Keston C36 Combi and C36P Combi are either copper or high alloy stainless steel. As a result water treatment chemicals for central heating boilers such as Fernox MB1, Sentinel X100 or equivalent, are suitable.

  • Page 28: Hot Flushing

    50 ppm at low rate. If CO levels above these values are experienced, the combustion chamber and flue system should be investigated. The C36 Combi is factory set for combustion and should need no adjustment. However, in the event adjustment is required.
  • Page 29 WD388/0/2004 Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers Using the “+” button for CH temperature control, adjust the display back to “t99” and check the CO level is in the range indicated at point 3)

  • Page 30: Fault Finding

    WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6. FAULT FINDING ELECTRICAL CONTROL SEQUENCE 6.1.1 HEATING DEMAND When the external control(s) are calling for heat, power will be fed to the boiler connection strip at terminal SL (Switched Live) and N (Neutral) and the CH green light will illuminate.
  • Page 31 If the lamp is not lit then no demand for that function (ie CH or DHW) is present. In CH mode a demand is received by a 230V signal to SL or via the Keston Room Control unit.

  • Page 32: Error Codes

    WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ERROR CODES Display Description of fault Ignition failure - the boiler has attempted to light five times and not succeeded - check gas supply, air supply, flue, ignitor condition and spark gap.

  • Page 33: Functional Flow Wiring Diagram

    WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 28...

  • Page 34: Electrical Wiring Diagram

    WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 29...
  • Page 35 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 30...
  • Page 36 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers Exploded Assembly Diagrams 6.7.1 Boiler Controls Assembly Installation & Servicing Instructions Page : 31...
  • Page 37 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.2 Waterway, Condensate & Flue Assembly 57-1 57-4 57-2 57-3 Installation & Servicing Instructions Page : 32...
  • Page 38 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 57-1 57-4 57-3 57-2 Installation & Servicing Instructions Page : 33...
  • Page 39 WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 34...

  • Page 40: Casing Assembly

    WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6.7.4 Casing Assembly Installation & Servicing Instructions Page : 35...

  • Page 41: Exploded Diagrams Parts Reference List

    Hydroblock (C.10C.2.08.00.0) Air - Gas Assembly (Fig. 6.7.3) GC Number Code Description Combustion Blower (C.10C.3.01.00.1) C36 Combi Gas Valve - Mixer Air Gas Assembly (C.10C.3.06.00.0) C36P Combi Gas Valve - Mixer Air Gas Assembly (C.10C.3.07.00.0) Casing Assembly (Fig. 6.7.4) GC Number...
  • Page 42 WD388/0/2004 Chapter 7 : Servicing The Keston C36 Combi & C36P Combi Boilers 7. 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. Servicing must be carried out at least once per year. The frequency of the servicing will depend upon the particular operating conditions.
  • Page 43 WD388/0/2004 Chapter 7 : Servicing The Keston C36 Combi & C36P Combi Boilers Turn on the electrical supply to the boiler and allow the boiler to reach operating temperature levels. Remove the combustion test point plug from the flue pipe. This is situated on the flue spigot out of the cabinet.

  • Page 44: Replacement Of Parts

    WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers 8. REPLACEMENT OF PARTS CONTENTS GENERAL PRECAUTIONS ACCESS REPLACEMENT PROCEDURE ELECTRICAL COMPONENTS 8.4.1 CONTROL PANEL 8.4.2 BOILER FLOW & RETURN THERMISTORS 8.4.3 CABINET TEMPERATURE SENSOR 8.4.4...
  • Page 45 WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers 8.4.2 Boiler Flow and Return Thermistors (Fig. 6.7.2 - 2/3 item 67) Isolate the appliance (Section 8.1) Gain access (Section 8.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions.
  • Page 46 WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers When reassembling inspect any gaskets for damage and replace if necessary. 8.4.8 Gas Control Valve /Venturi Assembly (Fig. 6.7.3 item 215) Isolate the appliance (Section 8.1) Gain access (Section 8.2)
  • Page 47 WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers iii) Remove the combustion blower (Section 8.4.7) Remove the 4 nuts fixing the burner to the top of the heat exchanger. Withdraw the burner from the top of the heat exchanger.
  • Page 48 WD388/0/2004 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boilers Gain Access (section 8.2) iii) Shut off the water supply (CWS) to the DHW heat exchanger. Isolate the waterways to the pump using the system isolation valves.

  • Page 49: Short Spare Parts List

    WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers 9. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No PartDenomination Burner Burner Gasket Ignitor Gasket 48 Ignitor/Sensor Probe Flow/Return Flue Thermistor Thermistors...
  • Page 50 WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers C36 Combi Gas Valve - Mixer Assem. C36P Combi Gas Valve - Mixer Assem. Control Box Fascia Panel Pump Block DHW Heat Exchanger Expansion Vessel Installation & Servicing Instructions...
  • Page 51 WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination Burner Burner Gasket Ignitor Ignitor Gasket DHW Thermistor Flow/Return Thermistor Flue Thermistor...
  • Page 52 WD388/0/2004 Chapter 10 : Benchmark Checklist Final The Keston C36 Combi & C36P COMBI Boilers 10. GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. ___________________ NOTIFICATION No. ____________________ CONTROLS To comply with the Building Regulation, each section must have a tick in one or other of the boxes TIME &...

  • Page 53: Service Interval Record

    WD388/0/2004 Chapter 10 : Benchmark Checklist Final The Keston C36 Combi & C36P COMBI Boilers SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 54 WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers KESTON CONDENSING BOILERS IMPORTANT C36 and C36P Combi INSTALLATION KEY POINTS † Read Installation Manual Carefully † Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe.

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