Keston 50 - GC Installation And Servicing Instructions
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Keston 50 - GC, 5.5 ELECTRICAL WIRING DIAGRAM WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Installation & Servicing Instructions Page : 33 IGNITION CONTROL RAM-2EMC22 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 4 3 5 7 6 8 10 9 11 12 N L FILTER ON/OFF SWITCH GREEN LAMP FLUE OVERHEAT THERMOSTAT WATER PRESSURE SWITCH FLOW HIGH LIMIT THERMOSTAT FLOW OVERHEAT THERMOSTAT BLOWER A.P.S. GAS SWITCH GAS VALVE M P 5R BR B B BR 6W 5BR 4B 91/OR 10/BK 9G HV 92/OR 59PK 51/OR 52BK 53W 54G 55BR 90 R Y/G W 12V 11W 93 OR 7W LEGEND B -BLUE BK -BLACK OR -ORANGE R -RED PK
Keston 50 - GC, room containing a bath or shower, any electrical switch or appliance control, utilising mains electricity, should be so situated that it cannot be touched by a person using the bath or shower. Compartment installation is permitted - such compartments must be constructed in accordance with BS 6798. The wall on which the boiler is mounted must be of suitable load bearing capacity and must be non-combustible. Important : It is not recommended to install the boiler on a studded wall or similar - it is possible that the vibration from the fan would be amplified and transmitted to other parts of the house. Ch
Keston 50 - GC, 5.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 5.7.1) GC Number Code Description E01 074 108 Ignition Control Box 170084 110A Air Pressure Switch (Keston 80) 379 744 110B Air Pressure Switch (Keston 50 & 60) 114 076 113 Electrical Terminal Block 114 077 115 On/Off Switch 114 078 116 Green (Run) Lamp 114 079 117 Red (Lockout) Lamp 114 080 119 Pressure Gauge Waterway, Condensate & Flue Assembly (Fig. 5.7.2) GC Number Code Description 114 022 43A Heat Exchanger (Keston 50 & 60) 114 023 43B Heat Exchanger (Keston 80) 375 523 46A Burner (Keston 50) 375 524 46B Burner (Keston 60) 375 525 4
Keston 50 - GC, 1.4 PERFORMANCE DATA Keston 50 Keston 60 Keston 80 10 to 1510 to 1510 to 15 o CRecommended Temperature Differential 3.432.712.38mmGas Orifice Size 8.08.08.0in. w g 20.020.020.0mbarInlet Gas Pressure 8.0 8.08.0 Ft 2.5 2.5 2.5MMinimum Head (Open Systems) 2.702.702.70BarMaximum Pressure (Sealed Systems) 100.0100.0100.0Ft i OtiFlT t 30.5030.5030.50MMaximum Head (Open Systems) 80.0080.0080.00 o CMaximum Operating Flow Tt (CV of Gas - 38.7 MJ/m 3 ) (1038 Btu/Ft 3 ) 89.1165.854.43Ft 3 /HrRunning 0.70.510.43L/SGas Consumption After 10 mins 3.943.
Keston 50 - GC, 2.7.2 Sealed Systems Sealed systems must be designed in accordance with BS 5449 and BS 7074 Pt1. A typical sealed system is shown in Figure 2.7.2. It must include : (i) A safety valve fitted on the flow, adjacent to the boiler. It must be non adjustable and preset to 3 bar. A drain pipe must be attached, at least as big as the valve connection, and routed to drain 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 must be positioned on the inlet to the
Keston 50 - GC, v) Turn off the electrical supply to the boiler. vi) Remove the pressure point screw from point C and transfer the tube from point A to C, replacing the screw on point A. vii) Turn on the electrical supply to the boiler (gas still off), wait for the fan to reach full speed. viii) The pressure difference should be below 11 mbar. If not, clean heat exchanger. ix) Disconnect the gauge from point B. Refit the screw. x) Read pressure of point C. xi) The maximum pressure should be 3 mbar. If the pressure is greater than this, check the flue f
A gas cock is supplied loose with the boiler. This cock should be fitted in the gas line to the boiler as close to the boiler as possible so that it is easily identified as the cock to isolate the boiler. 2.7 WATER SYSTEMS All piping must be installed in accordance with all applicable local and Water Supply Bylaws for forced hot water heating systems. Consideration must be given to
Combustion air filters are fitted to the Keston condensing boilers as standard. This filter must be examined at least once every year, and more often in particularly dusty and dirty areas. The combustion air filter will prevent plugging of the burner caused by dirt being trapped in the burner's outer mesh. The filter element supplied with the boiler is obtainable from Kes
Keston 50 - GC, 3.6 WATER SYSTEM Connect the flow and return pipework to the boiler. Ensure a detachable coupling is used at connection to the boiler (ie compression fitting) to enable heat exchanger removal if required. Details of system requirements are given in Chapter 2 - Section 2.7 Water Systems. Connections : 28mm copper 3.7 GAS SUPPLY Connect the gas supply to the appliance. Details of gas supply requirements are given in Chapter 2 - Section 2.6 Gas Supply. Connections : 0.5 inch BSP male. (15mm connection to gas cock). 3.8 ELECTRICAL SUPPLY The entry point for the electrical supply cable is in
Keston 50 - GC, 5. FAULT FINDING 5.1 ELECTRICAL CONTROL SEQUENCE When the external controls are calling for heat, power will be fed to the boiler connection strip at terminals L (Live) and N (Neutral). If the ON/OFF switch is also in the ON position the boiler ON lamp (amber) will be illuminated. Provided all temperature thermostats and pressure switches are closed, power will be fed to pin 2 on the control box, initiating the following sequence. (1) The boiler lockout lamp (red) will be illuminated (2) The fan will start. (3) When the fan reaches
Keston 50 - GC, 0.1m 3 ) of natural gas. Adjust the gas valve screw clockwise to increase the input (speed up the meter) or anticlockwise to decrease the input(slow down the meter) accordingly. 4.9 HANDING OVER TO THE USER It is important to fully explain the following : a. Procedure to light and turn off the boiler, including isolation of the electrical supply if necessary. b. The function of the lockout feature must be explained : If the red light only is illuminated for more than four minutes, this means that the boiler has failed to light. Turn off the electrical supply and wait 20 seconds. Turn ON again an
1. GENERAL INSTRUCTION 1.1 DESCRIPTION The Keston Condensing Boiler is unique in its concept and design. While the application for which the boiler was designed is the same as those which other boilers are used the Keston boiler has the added advantage of very high efficiency, and small diameter plastic flue which can be extended to 10 metres horizontally or vertically. The Ke
Keston 50 - GC, 5.7.2 Waterway, Condensate & Flue Assembly WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Installation & Servicing Instructions Page : 36 K50 - 05.2.00.00.0 K60 - 06.2.00.00.0 K80 - 08.2.00.00.0 75 THERMOSTAT WATER FLOW OUT 04.2.21.00.0 WATER WAY, CONDENSATE & FLUE ASSEMBLY 04.1.00.80.1 SCREW 52 51 04.2.13.00.1 IGNITER 50 04.2.00.28.2 IGNITER GASKET 54 04.2.28.00.0 PRESS. TEST FITT. 53 04.2.00.29.1 SCREW 48 04.2.00.25.0 MANIFOLD 49 04.2.12.00
† Read Installation Manual Carefully † For open systems ensure that there is at least 8 feet head of water pressure at the top of the boiler. † DO NOT remove the dust caps from the air and exhaust pipes until ready to connect. † Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe. † If the installation is a replacement the syst
c. If necessary, either due to discolouration or a high pressure differential between points A & B in the pre-service checks, clean the burner with a mild household detergent and rinse under a hot running tap. d. If necessary, either from visual inspection or a high pressure differential between points B & C in the pre-service checks, clean the heat exchanger using a suitable
Keston 50 - GC, 5.3 CONTINUITY CHECKING WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Installation & Servicing Instructions Page : 31 START Is there 230V at terminal L? Is there 230V at the ON/OFF switch (both terminals)? Is there 230V at the boiler thermostat (both terminals)? Is there 230V at the flow overheat thermostat (both terminals)? Is there 230V at the thermal fuse link (both terminals)? Is there 230V at the flow high limit thermostat (both terminals)? Is there 230V at the water press. switch (both terminals)? Is there 230V at the flue protection thermostat (both terminals)? Check external controls. Faulty switch - Replace. T
Keston 50 - GC, 2.8.3 Slope 'Horizontal' flue outlet pipework MUST slope at least 2.5 degrees (45 mm per metre run) downwards towards the boiler. Pipework can be vertical. Only swept elbows can be used. Air inlet pipework can be truly horizontal or vertical, or sloping in a downward direction towards the boiler but in this case rain, etc, must be prevented from entering the pipe. There must be no troughs in any of the pipework, whether it be air inlet or flue outlet. If a 45 mm per meter slope is not possible, contact Keston Boilers Technical Department for further guidance.
Keston 50 - GC, The method of connection to the mains electricity supply must facilitate complete electrical isolation of the boiler complying with the requirements of BS 1363. The appliance must be connected to the supply via a fused double-pole switch, having at least 3mm (1/8 inch) contact separation in both poles, serving only the boiler and the system controls. The connection point to the mains supply should be readily accessible and adjacent to the boiler, except for rooms containing a bath or a shower. Refer to section 2.3 Position. 2.4.2 Externa
Keston 50 - GC, It is important to note that the minimum flow rate must be maintained whenever the boiler is firing. Systems using zone valves must be specifically designed to only fire the boiler when the pump is running and the minimum flow rate can be achieved. The Wilo Salmson Gold Star pump, or the Grundfoss 15/60 pump is normally suitable for use with the Keston condensing boiler range. However, in all cases due consideration must be given to the resistance to flow offered by the rest of the system when making
Keston 50 - GC, 3. INSTALLATION OF THE BOILER Read Chapter 2 - Boiler Location and decide upon the position of the boiler. Installation of the boiler is straightforward but consideration must be given to access to allow flue and air pipes to be pushed through walls and ceilings. The order in which the components are installed will depend upon particular site conditions, but in general it will be easiest and most accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal - this is the sequence described. 3.1 WALL MOUNTING BRACKET a Place the bracket
Keston 50 - GC, 5.4 FUNCTIONAL FLOW WIRING DIAGRAM WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Installation & Servicing Instructions Page : 32 ON/OFF Switch Boiler Flow Overheat Thermal Fuse Flow High Limit Low Water Flue Overheat RAM-2EMC22 IGNITION CONTROL Thermostat Thermostat Thermostat Thermostat Pressure Switch 5 2 1 4 610 Lockout (Red) Run(Green) Indicator Gas Valve Gas Low Pressure ON/OFF Switch Blower N L Air Pressure Switch EMC Filter EMC Filter 8 230V 50Hz Fuse 5A Link Switch Indicator HT
Keston 50 - GC, CONTENTS Section Description 1 GENERAL INSTRUCTION 1.1 Description 1.2 Boiler Schematic 1.3 Related Documents 1.4 Performance Data 1.5 General Data 2 BOILER LOCATION 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 Installation 2.11 Condensate Drainage 2.12 Radiant Floor Heating 2.13 Low Water Volume Boiler vs. Cast Iron Boiler 2.14 Determine Radiation Needed Room-By-Room 3 INSTALLATION OF THE BOILER 3.1 Wall Mounting Bracket 3.2 Mounting The Boiler 3.3 Assembly Practice 3.4 Installing Flue And Air Pi
Keston 50 - GC, It is advisable for horizontal flue terminals to place a 45 o elbow at the end of the flue to direct the condensate plume up and away from the property. Table 2.8.4 Minimum Flue Terminations & Air Inlet Dimensions 2.8.5 Clearances From Wall Flue outlet and air inlet termination must be at least 60 mm and 95 mm respectively from the wall face. 2.8.6 Distance Between Flue Outlet & Air Inlet There is no maximum - the terminations can be on opposite sides of the dwelling if desired. WD50/2/1997 Chapter 2 - Boiler Connections The Keston 50, 60 &
Keston 50 - GC, WD50/2/1997 Chapter 5 : Fault Finding The Keston 50, 60 & 80 Condensing Boilers Installation & Servicing Instructions Page : 29 From sheet 3 yes yes no Continued on sheet 3 no yes no yes yes yes yes no yes no no no no yes no yes no Continued from sheet 1 yes Does ignition sequence start? Is lockout light on? Has the Air Press. Switch changed over? Are tubes and connections to the Air Press. Switch sound? Is the air press. across the Air Press. Switch more than 4 in water? Is the air filter dirty or the air inlet, exhaust or condensate pipe blocked? Is the Burner blocked Fan faulty - change Is the gas flow rate to the boiler correct for the gas type in use (ie LPG or N
Keston 50 - GC, 7.4.3 Neons (Fig. 5.7.1 items 116 & 117) i) Isolate the appliance (Section 7.1) ii) Gain access (Section 7.2) iii) Remove the push on connectors from the neon taking note of the correct positions. iv) Press in the catches and push the neon forward through the control panel. v) Pull the centre core of the neon from its housing to expose the bayonet fitting bulb. vi) Reassemble (Section 7.3) vii) Check for correct operation of the neons. 7.4.4 Flow Overheat (Fig. 5.7.2 item 75) , Flow High Limit (Fig. 5.7.2 item 78) & Flue Protection Thermostats (Fig. 5.7.2 item 70) i) Isolate the appliance (Section
Keston 50 - GC, 6. ROUTINE (ANNUAL) SERVICING To ensure the continued safe and efficient operation of the boiler it is necessary to carry out routine servicing at regular intervals. The frequency of the servicing will depend upon the particular operating conditions, but it is recommended that an annual service should be carried out by a competent engineer. The appliance has an integral air filter, mounted at the top right hand side of the boiler, to which the air intake pipe is connected. This filter should be examined every time the boiler is serviced. It may need more frequent inspection according to the conditio
Keston 50 - GC, 7.4.7 Air Pressure Switch (Fig. 5.7.1 item 110) i) Isolate the appliance (Section 7.1) ii) Gain access (Section 7.2) iii) Remove the push on connectors from the air pressure switch taking note of the correct positions. iv) Disconnect the union to one plastic tube connection and pull off the second plastic tube from the air pressure switch. v) Unscrew the two screws mounting the air pressure switch body to the boiler casing. vi) Reassemble (Section 7.3) NB: Ensure the yellow/green earth connection tag is securely fixed behind the lower mounting screw. 7.4.8 Combustion Blower (Fig. 5.7.3 item 80) i) Isolate the appliance (Section 7.1) ii) Gain access (Section 7.2) iii) Remove the cove
Keston 50 - GC, 8. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No Part Denomination 22 114 105Air Filter 46 375 523Burner 375 524 375 525 47 375 526Burner Manifold Gasket 50 375 527Ignitor Gasket 51 114 120Ignitor/Sensor Probe 56 114 030Flexible Hose Gasket 64 375 530Boiler Thermostat 70 375 532Flue Thermostat 75 375 533Flow Overheat Thermostat 78 375 534Flow High Limit Stat WD50/2/1997 Chapter 8 : Spare Parts Listings The Kest
Keston 50 - GC, 4.6 HOT FLUSHING a. Allow the system to heat up, checking for water soundness. b. Follow instructions provided with the cleaning agent, ie Fernox Supafloc. Turn off the boiler and flush the water system while still hot. Thoroughly flush the system with clear water. c. Refill the system using a quality water treatment such as Fernox MB1 or Fernox Super Concentrate. If aluminium radiators are used then Fernox Copal should be used. For sealed systems, fill to the required Initial Design Pressure. 4.7 CHECKING THE GAS PRESSURE With the boiler running measure the burner pressure at the burner pressure test nipple. The gas setting is factory adjusted to withi
7.0 GENERAL The following must always be carried out by a competent/qualified person. 7.1 PRECAUTIONS i) Always switch off the mains electricity supply and disconnect the plug at the isolating switch and socket. (If a switch only is used then remove the fuse.) ii) Gain access to the appliance (Section 7.2) and turn off the gas supply at the appliance service cock. 7.2 ACCE
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