Keston 47-930-01 User, Installation And Servicing Instructions Download | Manualshive

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WD388/0/2004

Chapter 6 : Fault Finding

The Keston C36 & C36P Combi Boilers

Installation & Servicing Instructions

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Summary of Contents for 47-930-01

Page 1: ...GC No 47 930 01 C36P Combi GC No 47 930 02 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...

Page 2: ...ries 2 6 Performance Data C36 Combi and C36P Combi 3 BOILER LOCATION 3 1 Dimensions Minimum Clearances 3 2 Service Connections 3 3 Position 3 4 Electrical 3 5 Boiler Size Selection 3 6 Gas Supply 3 7...

Page 3: ...am 6 7 Exploded Assembly Diagrams 7 SERVICING 7 1 Pre Service Checks 7 2 Recommended Routine Service 8 REPLACEMENT OF PARTS 8 0 General 8 1 Precautions 8 2 Access 8 3 Replacement Procedure 8 4 Electri...

Page 4: ...ument bag Installation Template 1 In document bag Remove the cabinet shell by removing the two retaining screws in the top of the cabinet and the two retaining screws in the bottom of the cabinet 0 2...

Page 5: ...cate onto the stud and the two pegs of the wall mounting bracket e Place the wall mounting bracket washers over the bracket stud protruding through the back plate of the boiler f Secure the boiler ont...

Page 6: ...ired to the front for servicing Cleaning Normal case cleaning only requires dusting with a dry cloth To remove more stubborn marks wipe with a damp cloth and finish with a dry cloth 1 3 BOILER SETUP O...

Page 7: ...e the boiler has attempted to light five times and not succeeded check the gas supply is on E01 Description of fault Display The above is an abbreviate list of possible error codes If the code is not...

Page 8: ...life of the boiler The boiler should be installed and serviced only by GAS SAFE REGISTER registered operatives All GAS SAFE REGISTER registered Installers carry a GAS SAFE REGISTER ID card and have a...

Page 9: ...d firing burner in a high efficiency single pass heat exchanger The flue system is room sealed and fan powered The ignition is direct spark and fully automatic The boiler housing is not waterproof and...

Page 10: ...f condensation This condensate falls to the bottom of the heat exchanger where it is separated from the flue gases and exits from the boiler through the condensate drain Any condensate formed in the f...

Page 11: ...firing This is to help prevent seizing of the pump due to long periods of inactivity 2 3 RELATED DOCUMENTS The Keston C36 Combi and C36P Combi Combination Condensing Boiler must be installed in accord...

Page 12: ...Compression Condensate Connection overflow 22mm plastic Safety Valve Connection discharge 15mm copper IP Rating IP20 IPX0 Flue and Air Intake Material 50mm muPVC BS5255 and or BSEN1566 1 and BSEN1329...

Page 13: ...28 000 8 1 27 600 Max Domestic Hot Water Flow Rate litre min 14 5 14 5 at 35O C Rise Specific DHW Rate 30O C Rise litre min 17 0 17 0 Min Domestic Hot Water Flow Rate litre min 0 35 0 35 Max Domestic...

Page 14: ...as a stable non reactive hazardous waste and may be disposed at a landfill licensed to accept such waste Protective clothing is not required when handling these articles but we recommend you follow th...

Page 15: ...mm compression An optional stand off frame is also available which mounts behind the boiler to leave a 50mm deep space behind the boiler This is to permit pipe routing behind the boiler if required Se...

Page 16: ...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 s...

Page 17: ...weather compensation basis when receiving a heating demand signal from the SL terminal or from a Keston Room Controller Screened cable 80 density must be used to connect the outside temperature senso...

Page 18: ...rease dirt and debris prior to connection with the boiler A trap may be installed in the flow line to collect any solder or other debris from the installation c All water systems must be constructed t...

Page 19: ...iling or steam cannot create any danger to persons damage to property or external electrical components or wiring To ease future servicing it is advisable to use a compression type fitting to extend t...

Page 20: ...pump will overcome boiler resistance If an additional pump is required the selected pump must comply with BS 1394 Provision must be made in the system design for control of the additional pump 3 7 4 F...

Page 21: ...mum Lengths The maximum lengths of both air inlet pipe and flue outlet pipe when no bends are used are as detailed below However each bend used has an equivalent length that must be deducted from the...

Page 22: ...ired be adapted to face in any direction BUT must not be directed in the region of the air inlet The flue terminal and air inlet terminal can be located on different but not opposing wall faces The tw...

Page 23: ...boiler casing must always be correctly fitted to the boiler when leaving the appliance operational External wall faces and any internal faces of cavity walls must be made good Rubber collars are avail...

Page 24: ...leakage into the dwelling A minimum slope downwards towards the drain of 1 in 20 is essential Freezing of the termination and pipework must be prevented Any drainage pipes outside the property must b...

Page 25: ...n for the pre installation jig dictated by the lower ends of the cross spacer g Drill and plug the holes for the pre installation jig h Screw the pre installation jig to the wall using screws of an ap...

Page 26: ...vings from within the pipe d Mount the boiler on the wall bracket and fix the air spigot packed loose with the boiler and with appropriate gasket to the boiler air inlet connection tightly to ensure t...

Page 27: ...g systems This must involve the use of a proprietary cleaner such as Fernox Superfloc or BetzDearborn s Sentinel X300 or X400 Full instructions are supplied with the products but for immediate informa...

Page 28: ...C36P Combi 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 4 1 to 4 8 Fill to a pressure of about 2 5 b...

Page 29: ...be rectified using flux and solder the system must be flushed cold again before proceeding e Reduce the pressure to the Initial System Design Pressure Vent the system 5 2 GAS SUPPLY The complete gas...

Page 30: ...f gas fired boilers of rated input not exceeding 70kW net advises that y The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and t...

Page 31: ...be 8 6 to 9 with a corresponding CO level of 5 to 20 ppm for natural gas and 9 6 to 10 with a corresponding CO level of 5 to 20 ppm for LPG THE CO2 LEVEL AT LOW RATE MUST ALWAYS BE LESS THAN THE CO2...

Page 32: ...necessary b The function of the lockout feature must be explained If the display shows E 01 this means that the boiler has failed to light Press the Reset button and wait i If lockout recurs immediate...

Page 33: ...e gas supply causes loss of the flame the control box will pause for approximately 10 seconds and then attempt to re ignite the unit If this attempt fails i e due to continued lack of gas supply the b...

Page 34: ...ore than 20C above return temperature may lead to overheat and noise problems Check the pump performance and the system for blockages 3 Actual CH flow temperature maximum 84C 2 The flame current in mi...

Page 35: ...st 4 times in 24 hours possible leak check system and boiler E24 Water filling error check water pressure sensor E23 Control box errors possible faulty control box E12 to E22 The automatic test for ca...

Page 36: ...6 4 FUNCTIONAL FLOW WIRING DIAGRAM WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 31...

Page 37: ...6 5 ELECTRICAL WIRING DIAGRAM WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 32...

Page 38: ...6 6 ILLUSTRATED WIRING DIAGRAM WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 33...

Page 39: ...6 7 Exploded Assembly Diagrams 6 7 1 Boiler Controls Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 34...

Page 40: ...6 7 2 Waterway Condensate Flue Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 35 57 4 57 1 58 58 56 57 3 57 57 2 56 39...

Page 41: ...WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 36 57 2 56 56 39 56 57 4 57 3 56 57 1 39...

Page 42: ...6 7 3 Air Gas Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 37...

Page 43: ...6 7 4 Casing Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 38...

Page 44: ...0 A 48 Spark Electrode C 10C 2 06 00 1 51 Condensate Trap C 10C 2 07 00 0 67 Flow Return Sensor C 10C 2 23 00 0 68 Flue Sensor C 10C 2 11 00 0 108 DHW Sensor C 10C 2 16 00 0 112 Pressure Sensor C 10C...

Page 45: ...s described in Section 5 9 y The combustion performance as described in Section 5 7 7 1 Pre Service Checks It is recommended that an inspection should be carried out prior to shutting down the unit fo...

Page 46: ...e gas air supply Ensure the flanged gas air supply joint is air tight h Turn on the electrical supply to the boiler and allow the boiler to reach operating temperature levels i Remove the combustion t...

Page 47: ...cock WARNING Parts of the boiler internal wiring will remain live even after setting the User Controls to Standby Shut off the power supply at the isolating switch before working on the appliance 8 2...

Page 48: ...g 6 7 2 2 3 item 112 i Isolate the appliance Section 8 1 ii Shut off the water supply to the appliance iii Gain access Section 8 2 iv Drain the system to below the level of the appliance using the dra...

Page 49: ...a good contact 8 4 10 Flow Sensor Fig 6 7 2 3 3 item 94 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Shut off the water supply CWS to the DHW heat exchanger Fig 6 7 2 1 3 item 5...

Page 50: ...tion 8 3 xiv Recommission Section 5 Commissioning 8 8 CONDENSATE TRAP Fig 6 7 2 1 3 item 51 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Disconnect the condensate line from the b...

Page 51: ...ON VESSEL Fig 6 7 2 1 3 item 58 i Isolate the appliance Section 8 1 ii Gain Access section 8 2 iii Isolate the waterways to the pump using the system isolation valves iv Drain the system to below the...

Page 52: ...rner 161 Burner Gasket 49 Ignitor Gasket 48 Ignitor Sensor Probe 67 Flow Return 68 Flue Thermistor Thermistors 108 DHW Thermistor 94 Flow Sensor 112 Pressure Sensor WD388 0 2004 Chapter 9 Spare Parts...

Page 53: ...C36P Combi Gas Valve Mixer Assem 135 Control Box 138 Fascia Panel 56 Pump Block 57 DHW Heat Exchanger 58 Expansion Vessel WD388 0 2004 Chapter 9 Spare Parts Listings The Keston C36 C36P Combi Boilers...

Page 54: ...rmistor 68 Flue Thermistor 94 Flow Sensor 112 Pressure Sensor 119 Fan 215 Gas Valve Mixer Air Gas Assembly NG C36 Combi 215 Gas Valve Mixer Air Gas Assembly LPG C36P Combi 138 Control Panel 135 Contro...

Page 55: ...OLLOWING 7 6 67 0 6 1 86 1 25 1 7 7 2 5 0 18 785 5 6 16758 7 216 7 6 67 0 1 5 86 7 1 725 86 FOR THE CENTRAL HEATING MODE MEASURE RECORD 6 5 7 P KU IW KU 851 5 23 5 7 1 35 6685 33 1 PEDU 175 7 1 2 7 03...

Page 56: ...E TEL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COM...

Page 57: ...ure that the exhaust pipe terminates away from windows or vents and is out of reach b Make sure that the air inlet and exhaust pipe outlets are at least 200mm apart b Check tightness of all connection...

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