Keston C36 Combi User, Installation And Servicing Instructions Download Page 1

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C36

C36 Combi

Combi

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.

34 West Common Road

Hayes, Bromley, Kent BR2 7BX

Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459

email : [email protected] web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

WD388/0/2004

The Keston C36 Combi & C36P Combi Boilers

Summary of Contents for C36 Combi

Page 1: ...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 34 West Common Road Hayes Bromley Kent BR2 7BX Tel 44 0 20 8462 0262 Fax 4...

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: ...ope 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 RECOMM...

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: ...eck that the gas supply from the gas meter is turned on Switch on the electrical supply to the boiler The display will now run through a self check procedure Set any controls to call for heat To light...

Page 7: ...actual pressure by pressing the Installer button repeatedly until the number 5 appears After a few seconds the display with then change to show the system water pressure in bar Set the water pressure...

Page 8: ...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 9: ...t heat of 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...

Page 10: ...The Keston C36 Combi and C36P Combi Combination Condensing Boiler must be installed in accordance with the current issue of the Gas Safety Installation and Use Regulations 1996 current IEE Wiring Reg...

Page 11: ...mm in 75 3 Air Intake Pipe Size nominal bore mm in 75 3 Max Air Intake Length m 117 Max Flue Outlet Length m 60 Max Total Flue Outlet and Air Intake Length m 120 Flue lengths between 48 and 60m will c...

Page 12: ...7 94 500 Min CH Output To Water 80 60o C Flow Return kW Btu h 7 4 25 250 7 4 25 250 50 30o C Flow Return kW Btu h 8 2 28 000 8 1 27 600 Max Domestic Hot Water Flow Rate litre min 14 5 14 5 at 35O C R...

Page 13: ...ore eating or drinking This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have be...

Page 14: ...ional 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 See Section 2 5 Optiona...

Page 15: ...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 space...

Page 16: ...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 17: ...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 18: ...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 19: ...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 20: ...d above Knuckle bends must not be used A 92 5o sweep elbow is equivalent to 1 0m straight length A 45o bend is equivalent to 0 5m straight length 50mm 75mm Maximum Air Inlet Length 39 0m 117 0m Maximu...

Page 21: ...ugh some can be decreased to the values indicated The Keston C36 Combi and C36P Combi as with any condensing boiler will generate a condensate plume from the flue terminal in all weather conditions Co...

Page 22: ...bi are room sealed appliances and therefore do not require purpose provided ventilation to the boiler room for combustion air 3 10 COMPARTMENT INSTALLATION Due to the low casing temperatures generated...

Page 23: ...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 24: ...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 25: ...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 26: ...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 27: ...preliminary electrical safety checks i e Earth continuity Polarity Resistance to Earth Short Circuit using a suitable test meter 5 4 LP GAS The Keston C36 Combi and C36P Combi are supplied preset for...

Page 28: ...e and 50 150 ppm In any event the CO2 level at low rate must ALWAYS be less than CO2 levels at high rate To measure CO2 levels in the Keston boiler remove the 1 8 plug from the flue outlet pipe spigot...

Page 29: ...or 0 1 cubic metres if the meter is of the new metric digital type Model Time for 2 cu ft Time for 0 1 cu m C36 Combi natural gas 54 95 C36P Combi LPG 141 249 If the meter timing is found to be incorr...

Page 30: ...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 31: ...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 32: ...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 33: ...6 4 FUNCTIONAL FLOW WIRING DIAGRAM WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 28...

Page 34: ...6 5 ELECTRICAL WIRING DIAGRAM WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 29...

Page 35: ...6 6 ILLUSTRATED WIRING DIAGRAM WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 30...

Page 36: ...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 31...

Page 37: ...6 7 2 Waterway Condensate Flue Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 32 57 4 57 1 58 58 56 57 3 57 57 2 56 39...

Page 38: ...WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 33 57 2 56 56 39 56 57 4 57 3 56 57 1 39...

Page 39: ...6 7 3 Air Gas Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 34...

Page 40: ...6 7 4 Casing Assembly WD388 0 2004 Chapter 6 Fault Finding The Keston C36 C36P Combi Boilers Installation Servicing Instructions Page 35...

Page 41: ...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 42: ...r intake pipework Joints must be sound and all pipework well bracketed g Check that there is a steady fall back to the boiler from the flue pipe to allow condensate to run back into the boiler h With...

Page 43: ...ocedure detailed in section 5 7 COMBUSTION TESTING MANDATORY k Replace the combustion test point plug l Recheck the burner pressure by following the procedure detailed in Section 4 7 m Check all joint...

Page 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...SED FOR THE CENTRAL HEATING MODE MEASURE RECORD GAS RATE m3 hr ft3 hr BURNER OPERATING PRESSURE IF APPLICABLE N A mbar CENTRAL HEATING FLOW TEMPERATURE O C CENTRAL HEATING RETURN TEMPERATURE O C FOR C...

Page 53: ...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 54: ...ure that the exhaust pipe terminates away from windows or vents and is out of reach Make sure that the air inlet and exhaust pipe outlets are at least 200mm apart Check tightness of all connections in...

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