Ideal Heating Keston COMBI2 C30, Installation & Servicing

Page 1: ...that we require Do not use reconditioned or copy parts that have not been clearly authorised by Keston For the very latest copy of literature for specification and maintenance practices visit our webs...

Page 2: ...no Equipped with a Supplementary Heater n a n a no no Combination Heater n a n a yes yes Nominal Heat Output for Space Heating Full Load P4 kW 24 3 24 3 Part Load P1 kW 8 8 Auxiliary Electricity Cons...

Page 3: ...building size and its characteristics Collector Size in m2 Tank Volume in m3 Collector Efficiency in Tank rating A 0 95 A 0 91 B 0 86 C 0 83 D G 0 81 Solar Contribution from fiche of solar device Sea...

Page 4: ...ES FOR THE INSTALLER WARNING Risk of injury or death CAUTION Risk of damage to objects Table of Acronyms CH Central Heating DHW Domestic Hot Water TRV Thermostatic Radiator Valve PRV Pressure Relief V...

Page 5: ...eral Checks 36 2 36 Restart Procedure 37 2 37 Handing Over 37 Section 3 Servicing 38 3 1 Servicing Schedule 38 3 2 Removal Replacement of Components 39 3 3 Draining the Boiler 39 3 4 Boiler Front Pane...

Page 6: ...Inlet Connection Cold Water 15 mm copper compression Outlet Connection Cold Hot Water 15 mm copper compression Flow Connection Central Heating 22 mm copper compression Return Connection Central Heatin...

Page 7: ...ater outlet temp measure record Water flow rate at max setting measure record For condensing boilers only Condensate drain 23 24 For all boilers Complete sign hand over to customer For UK intallations...

Page 8: ...variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap At low DHW draw off rates the maximum temperature may exceed 65 C Th...

Page 9: ...bt please enquire Unapproved control devices could invalidate the warranty of this appliance and infringe the Gas Safety Regulations 1 6 SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are inc...

Page 10: ...g to allow use of different brands of pipework Refer to Section 2 16 Compartment Installations A boiler installed in a compartment does not require ventilation However a boiler installed in a compartm...

Page 11: ...61 36 21 33 32 43 5 94 Refer to Section 2 18 278 700 100 Flue terminal 2 5 2 5 from case Underside View Water and Gas Connections CH Flow DHW Outlet Gas DHW Inlet CH Return CH Circuit Drain Data Plate...

Page 12: ...necessary If the vessel s capacity is not sufficient an additional vessel must be installed on the return to the boiler If the system is not pressurised the cold water capacity must not exceed 143 li...

Page 13: ...ce with the manufacturers instructions 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS7593 2019 details the steps necessary to clea...

Page 14: ...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 Condensate Internal 229 Condensate Trap 231...

Page 15: ...1x Valve CH G3 4 x 22 mm Filling Loop 15 1x Cap Female 16 1x Valve CH G3 4 x 22 mm 17 1x Pipe DHW Inlet 18 1x Nut G1 2 x 16 Brass Flat 19 1x Gas Cock 20 1x Coupling Accessory Bag Contents 21 9x Washe...

Page 16: ...the flue and air holes preferably with 60mm core bore tool ensuring the holes are square to the wall 2 Drill 2 holes with a 7 5mm 8mm masonry drill and insert the plastic plugs provided for the wall...

Page 17: ...ation Polypipe System 2000 muPVC Solvent Weld System 50mm Polypipe 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 50m...

Page 18: ...surface Condensing boilers 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 location that does not...

Page 19: ...elbows 4 Straight lengths 2 2 3 5 4 0 15 15 65 Calculations 2 4 6 8 10 12 14 16 18 20 22 24 26 28 2 6 10 14 18 22 26 30 Acceptable Operating Area Keston Combi 35 Flue Air Pipe Length Flue Pipe Length...

Page 20: ...e terminal is mounted 40 mm 40 mm 40 mm 40 mm P From a vertical structure on the roof NA NA 300 mm NA Q Above intersection with roof NA NA 150 mm NA 1 In addition for temperature and structural reason...

Page 21: ...flue pack supplied with the boiler Remove boiler front panel Section 3 2 Remove air intake blanking plate by unscrewing 4 x M5 screws and put to one side leaving sponge gasket in place Fix air spigot...

Page 22: ...ll Plate Flue Sleeve Flange 1 Cut hole in wall 2 Measure wall thickness 3 Cut sleeve length to match wall thickness remove burrs 4 Grout sleeve into wall with flange on external face 5 Slide flue pipe...

Page 23: ...ions 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 must terminate at a su...

Page 24: ...oof insulation 68 mm PVCU Strap on fitting Boiler with 75 mm sealed condensate trap Boiler with 75 mm sealed condensate trap Min 19 mm Internal pipe Min 30 mm Internal pipe Water Weather proof insulat...

Page 25: ...ter installation and maintenance guide Failure to install the system filter correctly will affect boiler warranty WATER CONNECTIONS DHW 1 Fit the DHW inlet service valve blue handle and copper tail to...

Page 26: ...ing loop Top Up 1 Connect the filling loop ensuring the washers are in place 2 Loosen the auto air vent dust cap Refer to Section 3 23 3 Turn the DHW Inlet handle blue to the horizontal position 4 Slo...

Page 27: ...he control box into the service position unclip and swing back the installer wiring cover and latch into the retaining clips 4 Carefully pierce the grommet release the cable clamp via the screws and p...

Page 28: ...e Room Stat on the RHS of the boiler installer connections labelled OpenTherm Frost Protection If parts of the pipework run outside the house or if the boiler will be left off for more than a day or s...

Page 29: ...rter Valve 2 3 4 5 1 3 2 1 X7 1 2 3 4 5 6 7 8 X1 X2 X3 X4 X5 X6 X8 X9 1 2 3 1 2 3 4 5 6 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 5 4 3 2 1 X10 br b r bk r br bk b bk b r r b Chass...

Page 30: ...hat this inlet pressure can be obtained with all other gas appliances in the property working Refer to Gas Supply page 10 2 25 COMMISSIONING AND TESTING Strain Relief If it is necessary to use an alte...

Page 31: ...en the Outside Temperature Sensor is connected The graph only shows temperatures between 12 and 30 degrees for clarity Examples 1 If the CH Potentiometer Knob is set to display 22 C on the Boiler Disp...

Page 32: ...ng effect 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 5 mm2 cable from the sensor to the b...

Page 33: ...the radiator symbol DOMESTIC HOT WATER 12 With the boiler firing rotate the DHW Temp Knob A clockwise until a target of 65 C is shown and fully open a DHW tap The boiler should continue to run and the...

Page 34: ...oom Thermostat or Timer Off Ready Press 2 31 PREHEAT FUNCTION Preheating will occur when the flow Temperature drops 15 C below the DHW target It will run until the flow temperature reaches 5 C below t...

Page 35: ...maining 10 mins Exit Maximum DHW Rate Press The boiler will run at Maximum DHW Rate for 10mins as long as there is sufficient cooling load Target Fan Speed 1400rpm Actual Fan Speed 1400rpm Time remain...

Page 36: ...temperature rise of approximately 35o C at the flow rate stated on page 8 under operation 3 Reduce the DHW draw off rate to about 3 l min 0 7 gpm and check that the boiler modulates to deliver DHW at...

Page 37: ...consistent with the household requirements of both heating and hot water consumption 5 Explain the precautions necessary to prevent damage to the system and to the building in the event of the system...

Page 38: ...eck is carried out if applicable and the water system is correctly refilled vented and re pressurised 2 Proceed to IMPORTANT IMPORTANT 1 If for any reason the condensate trap has been removed ensure t...

Page 39: ...75 61 36 21 33 32 43 5 94 CH Flow DHW Outlet Gas DHW Inlet CH Return CH Circuit Drain 3 3 DRAINING THE BOILER DOMESTIC HOT WATER CIRCUIT 1 Close all the DHW water isolating valves on the boiler inlet...

Page 40: ...2 bottom spring clips engage ensuring the 2 knobs and 4 buttons line up with the holes in the front panel 5 Re tighten the two retaining screws View from bottom of boiler View from top of boiler 1 2 3...

Page 41: ...for blockage or damage 7 Clean the outside of the injector and use a small flue brush to clean the injector hole Do not use anything abrasive such as a file 8 Remove the screw and twist venturi anti c...

Page 42: ...position 5 Carefully brush the ceramic burner with a soft non metallic bristle brush 1 1 Place thumb here Insert two fingers 1 SCAN for video 3 8 CLEANING THE HEAT EXCHANGER 1 Replace the sump cover p...

Page 43: ...nsions shown If there is damage to the electrode continue to follow steps below for replacment 5 Unplug the ignition lead from the electrode 6 Remove the earth lead from the electrode 7 Remove the 2 s...

Page 44: ...ti clockwise and pull forward to remove the cartridge Be prepared for some water release 3 Using a pair of pliers pull out the plastic filter flow regulator 4 Clean or replace filter as necessary Refe...

Page 45: ...thermistor and reassemble Check the O ring is fitted thermistor is fully engaged and the clip correctly located Refer to Section 3 2 3 15 SPARK GENERATOR REPLACEMENT 1 Disconnect the leads from the sp...

Page 46: ...connect gas and electrical connections 7 Refit the trap 8 Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve Refer to Section 3 2 Refer to Section 3...

Page 47: ...hows Installer Initialise spare PCB Yes Press Yes and the following screen is shown Select boiler type Option 1 of 2 Keston Press Next until Keston is shown Press Select Select Boiler Brand Option 1 o...

Page 48: ...DHW FLOW TURBINE SENSOR REPLACEMENT 2 3 4 3 21 PRESSURE GAUGE REPLACEMENT 1 Drain the boiler 2 Remove the boiler front see section 3 2 lower the control panel and remove the control box cover 3 Ensur...

Page 49: ...air vent head O ring seal is fitted 6 Check that the air vent cap is loose 7 Refill the boiler Check for leaks around the new air vent joint Refer to Section 3 31 Refer to Section 2 16 Refer to Secti...

Page 50: ...s Refer to Section 3 2 Refer to Section 3 3 Refer to Section 3 18 Refer to Section 2 18 SCAN for video 1 Drain the boiler 2 Remove condensate trap 3 Remove the 2 hex screws securing the plate heat exc...

Page 51: ...ate heat exchanger note orientation Refer to Section 3 25 9 Loosen the nut above pump and rotate the pipe 10 If required remove expansion vessel connection hose Refer to Section 3 31 11 If required re...

Page 52: ...ection 2 18 3 Refer to Section 3 2 Refer to Section 3 3 Refer to Section 2 18 52 Installation and Servicing Section 3 Servicing SERVICING 3 28 PUMP HEAD REPLACEMENT 3 27 CH WATER PRESSURE SWITCH REPLA...

Page 53: ...the thermistor 4 Fit the new thermistor check that the O ring is fitted and replace clip 3 29 FLOW THERMISTOR REPLACEMENT Refer to Section 3 2 Refer to Section 3 3 Refer to Section 2 18 5 Reassemble...

Page 54: ...the condensate rubber pipe Refer to Section 3 18 No 2 14 Remove the two heat exchanger fixing screws 15 Remove the heat exchanger slide out of location bracket 16 If replacement sump required Rotate h...

Page 55: ...the boiler CH circuit 6 Remove the retaining clip on the vessel water connection pipe and remove the pipe 7 Support the expansion vessel and unscrew the 2 screws from the securing bracket located on t...

Page 56: ...3 60 o C 2 4 2 6 85 o C 1 0 1 1 Keston Technical Help Line 01482 443005 Spares 01482 498665 Exit Next Fault Help Only carry out the following tests if you are gas safe qualified Exit Next Fault Help...

Page 57: ...from gas valve to PCB for continuity If the wiring is OK then replace the PCB NO Replace Spark Generator and harness as necessary NO Replace Electrode and associated harness as necessary NO Replace G...

Page 58: ...wiring is OK then replace the PCB NO Replace Spark Generator and Harness as necessary NO YES Check electrode and associated harness for continuity visual condition and position Are these functioning...

Page 59: ...Flow Thermistor Check the resistance using a suitable multimeter connected across the Thermistor s terminal pins Is the Thermistor value correct YES Is the wiring securely connected to the low voltag...

Page 60: ...Sensor YES NO Securely connect the wiring at both the boiler and Outside Sensor NO 4 11 NO CH OPERATION BUT DHW WORKS OK Is Off shown underneath the rad on the display NO YES Press Mode button C unti...

Page 61: ...turbine check for debris in turbine filter Replace turbine if necessary NO Adjust flow rates to achieve 35 C temp rise and check filter fitted in turbine is not blocked with debris NO Reconnect wirin...

Page 62: ...nnection Check the resistance using a suitable multi meter connected across the thermistor s terminal pins Temperature Resistance k 25 o C 9 7 10 3 60 o C 2 4 2 6 Is the thermistor value correct YES N...

Page 63: ...appliance Comprehensive spares parts information and details of approved Keston Parts Distributors are available on idealparts com Our Parts team are also available to help with your Keston Spare Part...

Page 64: ...64 Installation and Servicing Section 6 Benchmark to Commissioning...

Page 65: ...ually This must be carried out by a competent Gas Safe registered engineer The service details should be recorded on the Benchmark Service and Interim Boiler Work Record and left with the householder...

Page 66: ...r or ft3 hr Central heating output left at factory settings Yes No If no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar Central heating flow temperature C Centr...

Page 67: ...nufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component S...

Page 68: ...ly check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has b...

Page 69: ...al are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Turn off appliance and call Ideal Technical Helpline for advice The...

Page 70: ...ating Helpline 01482 443005 Ideal Heating Parts 01482 498665 keston co uk Ideal Boilers Ltd pursues a policy of continuing improvement in the design and performance of its products The right is theref...