Keston Combi 30 Installation And Servicing Instructions Download Page 1

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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

Combi 30 & 35

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

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

207895-2.indd 1

02/01/2013 09:37:49

Summary of Contents for Combi 30

Page 1: ...No 47 930 04 Combi 35 GC No 47 930 05 Combi 30 35 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 4...

Page 2: ...2 Keston Combi Installation and Servicing...

Page 3: ...e right to vary specification without notice For any technical queries plese ring the KESTON installer technical helpline 01482 443005 NOTE BOILER RESET PROCEDURE To reset boiler turn mode knob to res...

Page 4: ...copper compression Return Connection CH 22mm copper compression Flue Terminal Diameter mm in 50 nominal Average Flue Temp Mass Flow Rate DHW 68o C 13g s 73 C 15g s Maximum Working Pressure Sealed Syst...

Page 5: ...r assistance see Technical Helpline on the back page Page Burner operating pressure n a Central heating flow temp measure and record Central heating return temp measure and record For combination boil...

Page 6: ...the selected temperature of between 45o C and 83o C until DHW is drawn off The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW...

Page 7: ...control device not approved by Keston could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF...

Page 8: ...lastic piping The central heating system should be in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 Water treatment see Frame 5 Boiler Control Interlocks Central...

Page 9: ...ont clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Bot...

Page 10: ...n an additional vessel must be installed on the RETURN to the boiler Guidance on vessel sizing is given in Table above Notes a The method of filling refilling topping up or flushing sealed primary hot...

Page 11: ...lve is fitted to the DHW inlet or a water meter with a non return valve is installed Cold water rising main and pipework in exposed areas need to be suitably lagged to prevent freezing 5 water treatme...

Page 12: ...206 Pipe Gas Injector 211 Injector Assembly 214 Venturi 215 Fan 217 Burner 218 Gasket Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose...

Page 13: ...heck valve fitting 3 Valve Filling Loop 4 Plastic Chain x2 5 Filling Loop 6 3 8 Blanking Rubber Washer x2 Return Valve Pack 1 Pipe CH Return 2 Washer CH 3 Valve Return DHW Pack 1 Pipe DHW Outlet 2 Val...

Page 14: ...s approved for this application The following pipe and fittings are approved Polypipe System 2000 muPVC solvent Weld System 50mm Poly Pipe Code MU 301 4m length muPVC wastepipe 5 225 MU 313 50mm x 45...

Page 15: ...0mm from the wall surface Condensing boiler emit a visible plume of water vapour from the flue terminal this is normal It is the responsibility of the installer to judiciously select a terminal locati...

Page 16: ...m 2 5m 1 5m 2m 4m 4m 0 15m 3 5m 3 5m 1 5 back to boiler Air Sleeve 1 5 back to boiler Bracket every 1 metre Flue 3 x 90 elbows 3 Straight lengths 2 5 1 5 3 5 4 14 5 Overall Flue Air 30 15m Air 4 x 90...

Page 17: ...ing fabric formed for the purpose of accommodating a built in element such as a window frame The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depend...

Page 18: ...ss by hanging a plumbline as shown 2 Mark onto the wall the following a The wall mounting plate screw positions choose one from each group b The position of the air and flue when exiting straight out...

Page 19: ...ift the boiler onto the wall mounting plate refer to the Introduction section for safe handling advice locating it over the two tabs 16 Fitting the Wall Mounting Plate Screw the wall mounting plate to...

Page 20: ...s to pass to the exit from the wall s or ceiling Always thoroughly deburr all pipes and most important remove shavings from within the pipe Assemble using solvent weld cement the pipework from the boi...

Page 21: ...atch wall thickness remove burrs 4 Grout sleeve into wall with flange on external face 5 Slide flue pipe into sleeve checking it is free to slide 6 Slide Flexible wall seal over flue pipe and push cen...

Page 22: ...ternal Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system mu...

Page 23: ...mum connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Min 30mm Internal pipe Water weather proof insulation 75 Boilers without 75mm s...

Page 24: ...he safety valve connection located at the bottom right hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a compression joint on the end of the stub pipe This assists...

Page 25: ...el note grommets are blind and will require puncturing and secure using clamps and screws provided in hardware pack 5 Pull off rubber terminal block cover 6 Connect wires to terminal block as shown be...

Page 26: ...om stat has a neutral connection connect this to terminal N load in the fused spur 3G9707a L N FROST STAT OPTIONAL ROOM STAT TIMER OpenTherm Harness Weather Compensation Optional Frost Stat Outside Se...

Page 27: ...fect from the boiler flue To fix the air sensor to the wall unscrew the sensor box plastic cover and screw plug the sensor body to the wall Wire a twin core 0 5mm2 cable from the sensor to the boiler...

Page 28: ...r an Outside Temperature of 0 C a Flow Temperature of 78 C will be provided with the relationship varying lineally in between these 2 points line on the graph 2 5 If the Central Heating Temperature Co...

Page 29: ...t never be omitted 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...

Page 30: ...stor Return Thermistor Earth y g br b bk bk r b br y g Service Connector Selv Timer blue black brown red pink yellow white yellow green grey orange violet b bk br r p y w y g g or v KEY p y Flame Sens...

Page 31: ...andle Blue Handle 3G9927a CH Flow DHW Outlet Gas Supply CH Return DHW Inlet Gas Pressure Test Point ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST...

Page 32: ...boiler refer to Frame 40B The boiler will repeat its ignition sequence If reset occurs 5 times within 15 minutes then Too many resets will be shown If power is removed this will be reset When the bur...

Page 33: ...r or room stat off Domestic hot water operation Hot water Temperature 64 C High efficiency Central heating operation Radiator Temp 80 C High efficiency Pre heat operation Pre heat Central heating Temp...

Page 34: ...sition in the following format MESSAGE 1 CURRENT VALUES Flow temp 80 C Return temp 60 C DHW temp 64 C DHW flow rate 8 l min Diverter valve DHW position 3G9714 Note If you would like to hold one of the...

Page 35: ...ull DHW output Check at the gas meter with no other appliance in use Refer to Tables 2 and 3 for gas rates 4 Close the DHW tap The burner should remain on and the boiler will display Central heating R...

Page 36: ...ation of the boiler and the use and adjustment of all system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with the household requiremen...

Page 37: ...Refer to Frame 70 The cleaning procedures are covered more fully in Frames 40 45 and must be carried out in sequence Important 6 After completing the servicing or exchange of components always test fo...

Page 38: ...ngage ensuring the 4 control knobs line up with the holes in the front panel 5 Re tighten the two retaining screws 40 fan and venturi assembly removal and cleaning 1 Disconnect the electrical leads fr...

Page 39: ...e burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush off any deposits that may b...

Page 40: ...Check that the ignition and detection gaps are correct Refer to Frames 51 52 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon...

Page 41: ...ame 60 THE BOILER MUST NOT BE OPERATED without THE FRONT PANEL FITTED 46 fan replacement 1 Refer to Frame 45 2 Disconnect the electrical leads from the fan 3 Undo the gas pipe union connection to the...

Page 42: ...ied is located correctly in the injector housing 10 Check operation of the boiler Refer to Frame 36 2 4 3 6 48 burner REPLACEMENT 6 6 7 1 See Frame 39 2 Refer to Frame 45 3 Disconnect 2 flag terminals...

Page 43: ...rmistor locator tabs as shown 5 Check the operation of the boiler Refer to Frames 29 35 3 Thermistor Locator Tab with thermistor fitted 5 50 flue thermostat replacement 1 Refer to Frame 45 2 Undo the...

Page 44: ...d Check dimensions as shown 8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Frame 36 Ignition Electrode 3mm Straight edge Spark Gap 3 5mm 52 flame detection electrode replac...

Page 45: ...t and withdraw the valve forwards 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 Fr...

Page 46: ...ration of the boiler Refer to Frame 36 Diverter Valve Actuator Retaining Clip 3G9690 56 condensate trap Siphon replacement 3 2 Siphon 1 Refer to Frame 45 2 Pull off the rubber pipe at the sump drain 3...

Page 47: ...n Standby Summer or Winter 11 Check operation of the boiler Refer to Frame 36 1 Refer to Frame 45 2 Note the control knob positions 3 Remove the 2 screws retaining the control box cover 4 Carefully li...

Page 48: ...obs which must be in a vertical position 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frame 36 58 User control PCB replacement 3 59 DHW FLOW TURBINE Sensor REPLACEMENT 1 Refe...

Page 49: ...f components 4 After replacing any component on the boiler close tap close the drain valve and open all system isolating valves re pressurise as appropriate by re connecting the filling loop refer to...

Page 50: ...fer to Frame 22 Check operation of boiler Refer to Frames 36 63 Pump automatic air vent replacement 1 Refer to Frame 45 2 Drain the boiler Refer to frame 60 3 Remove the expansion vessel Refer to Fram...

Page 51: ...6 Fit the new turbine cartridge 7 Refit the turbine flow sensor 8 Reassemble in reverse order 9 Refill the boiler Refer to Frame 22 10 Check operation of the boiler Refer to Frames 36 5 REAR CARTRIDGE...

Page 52: ...nt 1 Refer to Frame 45 2 Drain the boiler Refer to Frame 60 3 Disconnect the electrical plug from the pump 4 Remove the 4 Allen screws retaining the pump head 5 Remove the pump head 6 Fit the new pump...

Page 53: ...er Refer to Frame 22 10 Check Operation of the boiler Refer to Frame 36 6 5 5 68 CH Water Pressure sensor Replacement 1 Refer to Frame 45 2 Drain the boiler Refer to Frame 60 3 Remove condensate trap...

Page 54: ...22 8 Check the operation of the boiler Refer to Frame 36 71 NO FLOW Thermistor Replacement 4 3 70 DHW Flow REGULATOR Cleaning Replacement 1 Refer to Frame 45 2 Isolate the mains cold water supply to t...

Page 55: ...placing the spring clips located on both the flow and return pipe connections ensure clip is oriented to correctly match connecting pipe diameters 18 Ensure the trap siphon is filled with water Refer...

Page 56: ...ew the 2 screws from the securing clamp located on the top of the boiler and remove Note the position of the bracket on the vessel 10 Remove the expansion vessel 11 Fit the new expansion vessel 12 Rea...

Page 57: ...lt Contact installer Go to Frame 82 Return Thermistor Fault Outside sensor fault Contact installer Go to Frame 83 Outside sensor fault Low mains voltage Contact electricity provider Low mains voltage...

Page 58: ...ndition and position Refer to Frame 52 Check if the condensate pipe is blocked Replace as necessary no Check gas supply and rectify fault no yes Is approx 215Vdc supply available at the Gas Valve See...

Page 59: ...inals pins connected to the electrode YES Replace Flame Detection Electrode yes NO Check routing and integrity of internal boiler wiring 79 LOW WATER PRESSURE 1 FILL SYSTEM TO 1 0 BAR 2 BLEED RADIATOR...

Page 60: ...ectrode and associated harness for continuity visual condition and position Refer to Frame 51 Are these functioning correctly Check siphon and condensate drain pipe work for blockage and rectify if ne...

Page 61: ...ntinuity yes Rectify Wiring connections Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan NO Replace PCB NO YES Replace Fan yes Replace PCB Check and replace wiring...

Page 62: ...BCC for the boiler securely inserted into the slot at the front left of the PCB identified by the label on the BCC yes no Securely attach the BCC for the boiler onto the PCB and after switching power...

Page 63: ...cy no Is the red neon illuminated on the turbine sensor yes Are the flow rates correct as per Frame 2 Is the wiring between the PCB and the diverter valve motor connected yes yes Check diverter head f...

Page 64: ...nditioned or copy parts that have not been clearly authorised by Keston Failure to do so could affect safety or performance of this appliance Our Parts team are also available to help with your Keston...

Page 65: ...65 Short list of parts Keston Combi Installation and Servicing...

Page 66: ...Gas Safe Register ID Number...

Page 67: ...ister 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 Registe...

Page 68: ...nt 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 The right is therefore reserved to vary specification without notice Keston Heating PO Box 103 National Avenue Kingston U...

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