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INSTALLATION

Keston Combi -

Installation and Servicing

FLUE OUTLET

8 FLUE sysTEM

IMpORTANT

When installing a replacement boiler a new flue system must be used.

DO NOT

re-use the existing boiler

flue installation.

DEsIgN

Individual air supply and flue outlet pipes are used as standard.

The material approved for this application is which MUsT be used is:
Marley mupVC solvent Weld system (50mm) and polypipe system 2000 mupVC solvent weld

(50mm), to Bs5255 and/or BsEN1566-11 and BsEN1329, are the only systems 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 deg muPVC obtuse bend

MU 314

50mm x 92.5 deg muPVC swept bend

MU 310

50mm muPVC straigh coupling

MU 316

50mm x 92.5 deg muPVC swept pip

Marley mupVC solvent Weld system (50mm)

Marley Code

KP 304

50mm x 4m double spigot pipe

KP32

50mm x 45 deg bend

KSC3

50mm straight coupling

KB3

50mm x 88.5 deg bend

KT3

50mm swept tee

Consideration MUST be given to expansion and contraction of the flue. Refer to Assembly Practice Frame in this installation and

Servicing Instructions for further guidance.

continued............

207895-2.indd 14

02/01/2013 09:38:13

Содержание Combi 30

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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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