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4

COMMISSIONING OF THE BOILER

4.1

Initial Flushing

4.2

Gas Supply

4.3

Electrical Installation

4.4

LP Gas 

4.5

Initial Firing

4.6

Hot Flushing

4.7

Combustion Testing

4.8

Checking The Gas Pressure

4.9

Timing The Gas Meter

4.10

Handing Over To The User

5

FAULT FINDING

5.1

Electrical Control Sequence

5.2

Normal Operation

5.3

Fault Modes

5.4

Functional Flow Wiring Diagram

5.5

Electrical Wiring Diagram

5.6

Illustrated Wiring Diagram

5.7

Exploded Assembly Diagrams

6

SERVICING

6.1

Pre Service Checks

6.2

Recommended Routine Service

7

REPLACEMENT OF PARTS

7.0

General

7.1

Precautions

7.2

Access

7.3

Replacement Procedure

7.4

Electrical Components

7.5

Spark Ignition/Flame Detection Electrode

7.6

Burner

7.7

Heat Exchanger

7.8

Condensate Trap

7.9

Pump

8

SPARE PARTS LISTINGS

9

GAS BOILER COMMISSIONING CHECKLIST

WD536

The Keston C45, C40P, C55 & C55P

Page :  ii

Содержание C40P

Страница 1: ...7BN14 C40P GC No 41 930 08 C55 GC No 41 930 09 C55P GC No 41 930 10 These instructions must be left either with the user or next to the site gas meter KESTON BOILERS LIMITED 34 West Common Road Bromle...

Страница 2: ...TION 2 1 Dimensions Minimum Clearances 2 2 Service Connections 2 3 Position 2 4 Electrical 2 5 Boiler Size Selection 2 6 Gas Supply 2 7 Water Systems 2 8 Flue System 2 9 Air Supply 2 10 Compartment In...

Страница 3: ...ult Modes 5 4 Functional Flow Wiring Diagram 5 5 Electrical Wiring Diagram 5 6 Illustrated Wiring Diagram 5 7 Exploded Assembly Diagrams 6 SERVICING 6 1 Pre Service Checks 6 2 Recommended Routine Serv...

Страница 4: ...ate 1 In document bag Remove the cabinet shell by removing the four retaining screws in the top of the cabinet and the three retaining screws in the bottom of the cabinet 0 2 Recommended Handling Proc...

Страница 5: ...ght will still be higher than considered acceptable for a one man lift Safety footwear and gloves are recommended PPE when lifting this appliance The C45 and C55 boilers can be fitted in compartments...

Страница 6: ...g burner pass around the stainless steel pipes imparting heat into the system water The integral variable speed Grundfos pump within the appliance cabinet ensures the heat exchanger receives correct w...

Страница 7: ...optimum start to further increase efficiency and comfort levels The C45 C40P and C55 P feature an integral frost protection function which will operate the pump regardless of the external controls sho...

Страница 8: ...Framed Buildings British Gas Publications DM2 Also British Gas Publications Guidance Notes For The Installation Of Domestic Gas Condensing Boilers and Specification For Domestic Wet Central Heating Sy...

Страница 9: ...pe of Gas G20 Natural Gas G31 LPG Optimum Flue Gas CO2 Level 8 3 0 2 9 9 0 2 Expected CO CO2 Ratio at max rate 0 001 0 0013 Destination Countries GB IE GB IE SEDBUK Efficiency 90 4 92 5 C55 C55P Nat G...

Страница 10: ...e 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 the normal hygiene rules of not smoking e...

Страница 11: ...osite pipe Stand off frames are available to leave a 50mm gap behind the boiler to allow routing of pipes behind the boiler Description Part Number Flue Terminal Wall Sealing Collar 50mm C 08 0 00 07...

Страница 12: ...al space although particular attention is drawn to the requirements of the current IEE Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland w...

Страница 13: ...alled in a cellar 2 4 ELECTRICAL 2 4 1 Electrical Connections The boiler must be connected to a permanent 230V 50Hz supply fused at 3A The boiler has two thermostats and will therefore accept up to tw...

Страница 14: ...time Efficiency and combustion levels are maintained at optimum levels throughout the possible output range The C45 C40P and C55 P are therefore suitable for all systems with a total heat load within...

Страница 15: ...her debris from the installation d All water systems must be constructed to comply with requirements of the Local Water Authority e Always use a system complying with the requirements of BS 5449 and B...

Страница 16: ...in any area not hazardous nor where it may be subject to freezing ii An expansion vessel complying with BS 4814 and sized in accordance with the requirements of BS 5449 and BS 7074 Pt 1 The vessel mus...

Страница 17: ...50 litres 19 5 13 6 10 4 125 litres 15 6 10 9 8 3 100 litres 11 7 8 2 6 3 75 litres 7 8 5 4 4 2 50 litres 3 9 2 7 2 1 25 litres Volume Vessel Expansion Total Water Content of system 1 5 bar 1 0 bar 0...

Страница 18: ...ypass must of the automatic type 2 7 5 Balance Headers Multiple Boiler Installations Where multiple boilers are installed on a common distribution system maintenance of balanced flow through each boil...

Страница 19: ...he index circuit resistance only as the boilers integral pump will overcome boiler resistance If an additional pump is required the selected pump must comply with BS 1394 2 8 FLUE SYSTEM 2 8 1 Design...

Страница 20: ...aximum Air Inlet Length 29 0 m 89 0 m Maximum Flue Outlet Length 15 0 m 45 0 m Maximum Total Flue and Air Intake Length 30 0 m 90 0 m However each bend used has an equivalent length that must be deduc...

Страница 21: ...to discharge as detailed in section 2 11 Such drain points can be formed using standard plastic fittings Refer to the example in Figure 2 8 3 2 8 5 Terminations Air inlet terminals must be facing hor...

Страница 22: ...ir intake terminal 2 8 8 General Installations All parts of the system must be constructed in accordance with BS 5440 Part 1 except where specifically mentioned in these instructions All pipe work mus...

Страница 23: ...the property in most cases Ensure in all cases that the disposal of the condensate is in accordance with any local regulations in force Termination of the pipe must be either at a branch or stack inte...

Страница 24: ...rked Plug these holes e Screw the bracket to the wall using screws of an appropriate size for the wall type No 12 x 2 inch wood screws normally suffice 3 2 MOUNTING THE BOILER a Lift and locate the bo...

Страница 25: ...ework cut and assemble the pipework f From outside complete the two terminations See Section 2 8 Flue System and make good all holes g Support any pipes whose route could be displaced either of its ow...

Страница 26: ...net to the connection strip located to the front bottom left of the cabinet 1 The electrical supply must be as specified in Chapter 2 Section 2 4 Electrical Supply WARNING THIS APPLIANCE MUST BE EARTH...

Страница 27: ...m Gas Supply The complete gas installation up to the boiler service cock must be checked for soundness BS 6891 Electrical Installation Carry out preliminary electrical safety checks i e Earth continui...

Страница 28: ...7 bar d Check the complete system for water soundness If leaks need to be rectified using flux and solder the system must be flushed cold again before proceeding e Reduce the pressure to the Initial...

Страница 29: ...ality water treatment such as Fernox MB1 or Sentinel X100 For sealed systems fill to the required Initial Design Pressure 4 7 COMBUSTION TESTING Competence to carry out the check of combustion perform...

Страница 30: ...information The drawing below shows the layout of these buttons and their function To set the fan to maximum Press the Mode button repeatedly until the display shows Stby Press and hold the Mode and...

Страница 31: ...re sound and the gas inlet pressure is satisfactory check the gas input by timing the gas meter as detail in Section 4 9 Timing The Gas Meter If the gas input cannot be measured then it s compulsory t...

Страница 32: ...fault c Advise that a reduction in the water pressure reading on the system pressure gauge for sealed systems indicates a leak which should be rectified before further use d Advise that the appliance...

Страница 33: ...normal run condition 5 The boiler will automatically and continuously adjust its power output and pump speed to best match the demands of the system at any time 6 The burner will continue to operate u...

Страница 34: ...ignition 1 nn Boiler in standby waiting for demand signal 0 nn Meaning Display 5 3 FAULT MODES 5 3 1 Automatic Lockout Avoidance The boiler will react to adverse conditions in two ways If the fault is...

Страница 35: ...h Check circulation E 30 Fan not rotating check fan connection and fan for fault E 28 Flow temperature increased too quickly Check water circulation E 25 Maximum return temperature exceeded Check circ...

Страница 36: ...5 4 FUNCTIONAL FLOW WIRING DIAGRAM WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 31...

Страница 37: ...5 5 ELECTRICAL WIRING DIAGRAM WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 32...

Страница 38: ...5 6 ILLUSTRATED WIRING DIAGRAM WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 33...

Страница 39: ...5 7 Exploded Assembly Diagrams 5 7 1 Boiler Controls Assembly WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 34...

Страница 40: ...5 7 2 Waterway Condensate Flue Assembly WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 35...

Страница 41: ...5 7 3 Air Gas Assembly WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 36...

Страница 42: ...5 7 4 Casing Assembly WD536 Chapter 5 Fault Finding The Keston C45 C40P C55 C55P Installation Servicing Instructions Page 37...

Страница 43: ...gnition Electrode C 17 2 29 00 0 A E93 144 56 Condensate Trap C 17 2 07 00 4 E93 145 47 Flow Return Thermistor C 17 2 04 00 0 E72 332 46 Flue Overheat Stat C 08 2 30 00 0 114 045 48 Water Pressure Swi...

Страница 44: ...ombustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate as described in Section 4 8 The gas rate as described in Section 4 9 The combustion performance as d...

Страница 45: ...ectrode assembly mounted on the heat exchanger If the point is damaged or burnt replace it Check that the spark gap measures 3 mm g Replace the burner head renewing the gasket if necessary and reconne...

Страница 46: ...en after setting the User Controls to Standby Shut off the power supply at the isolating switch before working on the appliance 7 2 ACCESS i Remove the cabinet by removing the screws to the top and bo...

Страница 47: ...ure Switch Fig 5 7 2 item 48 i Isolate the appliance Section 7 1 ii Shut off the water supply to the appliance iii Gain access Section 7 2 iv Drain the system to below the level of the appliance using...

Страница 48: ...the electrode and the earth post is 3 mm Distances above or below 3 mm will affect ignition performance If necessary gently bend the electrode taking care not to damage the ceramic insulator 7 6 BURNE...

Страница 49: ...ble Section 7 3 NB When re fitting the condensate trap pour water onto the condensate hose from the base of the heat exchanger until nearly full Then reconnect the condensate hose to the base of the h...

Страница 50: ...tor Gasket 74 E93 143 Ignitor Sensor Probe 47 E93 145 Flow Return Thermistors 46 E72 332 Flue Thermostat 163 C45 C55 Gas Valve Venturi Assy 88 E93 126 C55 55PC45 Main Contr Box C55P Gas Valve Venturi...

Страница 51: ...ox C40P 106 E93 130 Control Panel 73 E93 147 Combustion Blower 163 Gas Valve Venturi Ass C45 C55 163 Gas Valve Venturi Ass C55P 163 Gas Valve Venturi Ass C40P 56 E93 144 Condensate Trap 74 E93 143 Ign...

Страница 52: ...E 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 COMBINATION...

Страница 53: ...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 COMPANY NAME...

Страница 54: ...sate pipe is not exposed to freezing conditions Make sure 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 l...

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