C36 Combi User, Installation and Servicing Instructions FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS COMBINATION BOILER CE/PI No. 86-CM-44 C36 Combi - GC No. 47-930-01 C36P Combi – GC No. 47-930-02 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 : info@keston.co.uk web : www.keston.co.
WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers CONTENTS NB : These instructions are an integral part of the appliance. This document must be handed over to the user on completion of the installation to ensure compliance with the Gas Safety (Installation & Use) Regulations Section Description 0 0.1 0.2 HANDLING INSTRUCTIONS List of contents Recommended handling procedure 1.1 1.2 1.3 1.4 USER INSTRUCTIONS Introduction Maintenance Boiler Setup and Operation Safety Information 2.1 2.2 2.3 2.4 2.
WD388/0/2004 5.7 5.8 5.9 5.10 6 The Keston C36 Combi & C36P Combi Boilers Combustion Testing Checking The Gas Pressure Timing The Gas Meter Handing Over To The User 6.1 6.2 6.3 6.4 6.5 6.6 6.7 FAULT FINDING Electrical Control Sequence Normal Operation Fault Modes Functional Flow Wiring Diagram Electrical Wiring Diagram Illustrated Wiring Diagram Exploded Assembly Diagrams 7.1 7.2 SERVICING Pre Service Checks Recommended Routine Service 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.
WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers 0. HANDLING INSTRUCTIONS 0.1 LIST OF CONTENTS The Keston C36 Combi and C36P Combi are supplied almost totally pre-assembled. The units use standard 50 mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329) pipe for the flue and air intake systems. The boiler is packed in a single box without additional flue kit. All additional components are packed inside the boiler cabinet itself.
WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers side. At this stage it is assumed that the wall bracket is correctly positioned and secured on the wall face. a) b) c) d) e) f) Have the wall bracket nut and washer to hand so that they can be accessed whilst holding the boiler in position on its mounting bracket. If the optional pre-installation jig is not being used discard the Pre-Installation Jig Locator Cross.
WD388/0/2004 Boilers Chapter 1 : User Instructions The Keston C36 Combi & C36P Combi Boilers 1. USER INSTRUCTIONS 1.1 INTRODUCTION Thank you for choosing this Keston C36 Combi for your household heating and hot water needs. The boiler is designed to be very straightforward to operate and has no user serviceable parts inside the cabinet. The following instructions are to provide you with information on the operation and maintenance of your C36 Combi and what to do in the unlikely event of a fault.
WD388/0/2004 Boilers Chapter 1 : User Instructions The Keston C36 Combi & C36P Combi Boilers Normal Operation During normal operation the digital display will dhow the current boiler temperature and will show a “.” In the lower right corner of the display when the burner is alight. If the green lamp near the CH or DHW+ - keys is illuminated the boiler is receiving a demand for that function.
WD388/0/2004 Boilers Chapter 1 : User Instructions The Keston C36 Combi & C36P Combi Boilers your installer at the end of the installation and commissioning process. The details of the Checklist will be required in the event of any warranty work being required. There is also Service Interval Record (Chapter 10) to be completed after each annual service visit. These forms (Chapter 10) should be kept in a safe place for the life of the boiler.
WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers 2. GENERAL INSTRUCTION 2.1 DESCRIPTION The KESTON C36 Combi and C36P Combi combination boilers utilise the latest in condensing technology to produce a high efficiency boilers that deliver an exceptional hot water flow rate with SEDBUK A rated efficiency. The C36 Combi and C36P Combi are unique in concept and design.
WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers system and burns with a blue flame just off the surface of the burner. As the hot products of combustion pass downwards, they are cooled by exchanging heat with the circulating water which enters the heat exchanger at the bottom of the heat exchanger. The optimum heat input is detected by monitoring flow and return temperatures and is adjusted by controlling the speed of the fan.
WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers around 5oC to 10oC above the temperature of the return water. The flue pipe should be terminated outside the building from where they cannot re-enter the building or any other adjacent building. The heating level may be controlled by room thermostats, programmer time clocks and compatible energy management systems.
WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers For Timber 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 Systems'.
WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers Description Part Number Pre-Installation Jig Plate Flue Terminal Wall Sealing Collar (50mm) Air Terminal Wall Sealing Collar (50mm) 50/75mm Flue Adapter Flue Outlet Terminal (75mm) Air Inlet Terminal (75mm) Stand Off Back Plate Keston Chronotherm Room Controller C.10C.0.11.00.0 C.08.0.00.07.0 C.08.0.00.07.0 C.17.2.00.60.0 C.17.2.26.00.0 C.17.2.26.00.0 C.10C.0.01.00.0 C.17.4.21.00.0 2.
WD388/0/2004 Chapter 2 : General Instruction The Keston C36 Combi & C36P Combi Boilers Seasonal Efficiency (SEDBUK) =90.7 (C36 Combi) & 92.8 (C36P Combi) This value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by Advantica Technologies Ltd KESTON Heating declare that there are no substances harmful to health within the appliance or used during the production of the appliance.
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers 3. BOILER LOCATION $OO GLPHQVLRQV LQ PP 3.1 DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown to allow subsequent servicing, and safe operation. However, larger clearances may be required during installation. 3.2 SERVICE CONNECTIONS Without Optional Pre-Installation Jig: Gas, water, air and flue pipe, condensation, and electrical connections are as shown.
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 & C36P Combi Boilers applicable in Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. Where a room-sealed appliance is installed in a 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.
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers The method of connection to the mains electricity supply must facilitate complete electrical isolation of the boiler, preferably by the use of a fused, unswitched three pin plug and a shuttered socket-outlet, both complying with the requirements of BS 1363. There must be only one common method of isolation for the boiler and its control system.
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 & C36P Combi Boilers Gas pressures above or below these levels will lead to problems associated with the gas valve's internal pressure regulator. Supply pipes to the boiler must not be sized less than the boiler inlet connection (15 mm). Due consideration must be given to the supply pressure to other gas appliances in the premises. Reduction in dynamic gas supply pressure will result in intermittent ignition failures.
l m DOMESTIC HOT WATER n The Keston C36 Combi & C36P Combi Boilers The boiler is supplied with an integral expansion vessel of 8l capacity. This is suitable for systems of up to 125 Litres system volume. Table 3.7 Expansion Vessel Selection provides guidance for the correct additional expansion vessel size to use for systems with a water content larger than 125 Litres. Any additional vessel must be fitted on the boiler primary return.
WD388/0/2004 Chapter 3 - Boiler Location driven out of the solution and will collect in high spots in the system. These air bubbles can interfere with pumping and heat transfer and must be eliminated. Installation of air bleed valves at the high spot(s) in the system will allow for air elimination when filling the system and will allow re-venting in a day or so after all air has been driven out of solution.
WD388/0/2004 3.8 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers FLUE SYSTEM NB: When installing a replacement boiler a new flue system must be used. Do not re-use the existing boiler flue installation. 3.8.1 Design Individual air supply and flue outlet pipes are used. The material used for flue outlet &/or air inlet must be muPVC to BS 5255 and/or BSEN1566-1 and BSEN1329 of an internal diameter of 51 mm. (i.e. nominal 50 mm diameter muPVC solvent weld waste pipe).
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 & C36P Combi Boilers There must be no troughs in any of the pipework, whether it be air inlet or flue outlet. 3.8.4 ! - . )/ 0 0 Due the low temperature of the flue gases further condensate will form within the flue system. Drain points, with suitable traps, must therefore be incorporated within the flue system at the base of vertical flue sections in excess of 6m, for 50mm muPVC pipe flue systems.
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 Combi & C36P Combi Boilers It is advisable for horizontal flue terminals to place a 45o elbow at the end of the flue to direct the condensate plume up and away from the property. If the air intake is within 500mm of the flue outlet the air must not terminal at a level above that of the flue If either the air inlet or flue outlet terminate at a height of less than 2.1m above ground level, the terminal must be protected by a suitable guard.
WD388/0/2004 Chapter 3 - Boiler Location The Keston C36 & C36P Combi Boilers A minimum slope downwards towards the drain of 1 in 20 is essential. Freezing of the termination and pipework must be prevented. Any drainage pipes outside the property must be at least 32 mm inside diameter.
WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers 4. INSTALLATION OF THE BOILER Read Chapter 3 - 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.
WD388/0/2004 Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers 4.3 ASSEMBLY PRACTICE Remove all plastic debris and burrs when installing air intake piping. Plastic filings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower. Prevent dust entering the air intake when cutting on building sites. Blower failure which is determined to be caused by plastic filings or other debris will not be covered by guarantee. 4.
WD388/0/2004 Chapter 4 : Installation iii) The Keston C36 Combi & C36P Combi Boilers replace the nut from the frame bottom Connect the condensate drainage system to the boiler. It is advisable to use a detachable fitting at connection to the boiler to enable easy removal for servicing. Fill the condensate trap by pouring water into the boiler flue until water is seen to flow freely from the condensate drainage system. Make the final connection of flue pipe to the boiler.
WD388/0/2004 4. Chapter 4 : Installation The Keston C36 Combi & C36P Combi Boilers Securely tighten the terminal screws and route the cable(s) through the re-openable cable clips. Ensure all cables are secured and that the cord grip bush is tightened to securely grip the main cable at entry to the cabinet. Remove the factory fitted link wire between the room thermostat terminals on the boiler.
WD388/0/2004 Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers 5. COMMISSIONING OF THE BOILER Important: This condensing combination boiler contains components which could be damaged or blocked by grease, dirt, solder etc., from the water system. The following commissioning procedures must be followed precisely. It is essential that combustion is checked at high and low rate , as per Section 5.7, using a calibrated flue gas analyser set for the relevant gas type. 5.
WD388/0/2004 f. Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers flow temperature of the boiler. Also press the “Summer” button until the green light above this button is extinguished. Once a heating demand is received the fan will start and the boiler will enter the pre-purge phase. During this phase the boiler pump will also start to run. After 5 Seconds the boiler will start to spark and will energise the gas valve.
WD388/0/2004 Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers used during manufacture curing within the combustion chamber. On boilers which have been fired for more than one hour since installation, the CO levels should not exceed 150 ppm at high rate and 50 ppm at low rate. If CO levels above these values are experienced, the combustion chamber and flue system should be investigated. The C36 Combi is factory set for combustion and should need no adjustment.
WD388/0/2004 5.9 Chapter 5 : Commissioning The Keston C36 Combi & C36P Combi Boilers TIMING THE GAS METER Set the boiler DHW temperature to 65C and open two hot taps in the property fully. With no other appliances using gas, time the gas meter to be certain that the unit is running at the proper gas input. Determine the cubic feet of gas passing through the meter and determine the input in Btu per hour. Input must be within plus or minus 5% of the rated input.
WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 6. FAULT FINDING 6.1 ELECTRICAL CONTROL SEQUENCE 6.1.1 HEATING DEMAND When the external control(s) are calling for heat, power will be fed to the boiler connection strip at terminal SL (Switched Live) and N (Neutral) and the CH green light will illuminate.
WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers QUICK REFERENCE 6.2 NORMAL OPERATION The C36 Combi and C36P Combi boilers feature a user display which shows actual flow temperature at all times when not serving a DHW demand. If a DHW demand is detected the boiler display changes to show the actual DHW temperature. However, the display can also be used to show other information about the operation of the boiler.
WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers ERROR CODES Display E01 E02 E03 E05 E07 E08 E09 E10 E11 E12 to E22 E23 E24 E25 E26 E30 E31 E32 E33 E34 E35 E37 E38 E40 E41 E43 E44 E45 E46 E99 Description of fault Ignition failure - the boiler has attempted to light five times and not succeeded check gas supply, air supply, flue, ignitor condition and spark gap. False flame - the unit is detecting a flame BEFORE ignition.
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WD388/0/2004 6.7 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers Exploded Assembly Diagrams 6.7.
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WD388/0/2004 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers 39 57-1 56 39 56 57-4 56 56 57-3 57-2 Installation & Servicing Instructions Page : 36
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WD388/0/2004 6.7.5 Chapter 6 : Fault Finding The Keston C36 & C36P Combi Boilers Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code 135 138 146 206 E72-401 153 136 Description Main Control Box (C.10C.4.01.00.0 B) Control Panel (C.10C.4.04.00.0 A) Terminal Block (C.12.4.00.03.0) Terminal Block (C.10C.4.28.00.0) Thermal Fuse (C.08.4.21.00.0) Ignitor Cable (C.10C.4.02.00.0) Waterway, Condensate & Flue Assembly (Fig. 6.7.
WD388/0/2004 Chapter 7 : Servicing The Keston C36 Combi & C36P Combi Boilers 7. 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. Servicing must be carried out at least once per year. The frequency of the servicing will depend upon the particular operating conditions. It is the law that any service work must be carried out by competent qualified persons.
WD388/0/2004 d. e. f. g. h. i. j. k. l. m. n. Chapter 7 : Servicing The Keston C36 Combi & C36P Combi Boilers If necessary, from visual inspection, clean the heat exchanger using a suitable stiff plastic bristle brush, vacuum out any large particles and flush the heat exchanger with fresh water until the water flowing from the condensate drain is clear. Remove the condensate trap (Section 8.8) and clean by flushing through with clean running water.
WD388/0/2004 Boilers Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers 8. REPLACEMENT OF PARTS CONTENTS 8.0 GENERAL 8.1 PRECAUTIONS 8.2 ACCESS 8.3 REPLACEMENT PROCEDURE 8.4 ELECTRICAL COMPONENTS 8.4.1 CONTROL PANEL 8.4.2 BOILER FLOW & RETURN THERMISTORS 8.4.3 CABINET TEMPERATURE SENSOR 8.4.4 FLUE THERMISTOR 8.4.5 PRESSURE SENSOR 8.4.6 MAIN CONTROL BOX 8.4.7 COMBUSTION BLOWER 8.4.8 GAS CONTROL VALVE / VENTURI ASSEMBLY 8.4.9 DHW THERMISTOR 8.4.10 FLOW SENSOR 8.
WD388/0/2004 Boilers 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.4.7 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Boiler Flow and Return Thermistors (Fig. 6.7.2 - 2/3 item 67) i) Isolate the appliance (Section 8.1) ii) Gain access (Section 8.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions. iv) Unclip the thermistor from the pipe. v) Reassemble (Section 8.
WD388/0/2004 Boilers Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers NB: When reassembling inspect any gaskets for damage and replace if necessary. 8.4.8 Gas Control Valve /Venturi Assembly (Fig. 6.7.3 item 215) i) Isolate the appliance (Section 8.1) ii) Gain access (Section 8.2) iii) Remove the Main Control Box (Section 8.4.6) iv) Remove the push on connector block to the gas valve. v) Unscrew the bolts (Fig 6.7.
WD388/0/2004 Boilers iii) iv) v) vi) Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Remove the combustion blower (Section 8.4.7) Remove the 4 nuts fixing the burner to the top of the heat exchanger. Withdraw the burner from the top of the heat exchanger. Reassemble (Section 8.3) NB: When reassembling inspect any gaskets for damage and replace if necessary. 8.7 HEAT EXCHANGER (Fig. 6.7.2 - 1/3 item 39) i) Isolate the appliance (Section 8.1) ii) Gain access (Section 8.
WD388/0/2004 Boilers ii) iii) iv) v) vi) vii) viii) 8.11 Chapter 8 : Replacement Of Parts The Keston C36 Combi & C36P Combi Boilers Gain Access (section 8.2) Shut off the water supply (CWS) to the DHW heat exchanger. Isolate the waterways to the pump using the system isolation valves. Drain the system to below the level of the appliance using the drain off tap (Fig. 6.7.4 - 2/2 item 180) at the base of the boiler return pipe. Disconnect the two union nuts from the DHW heat exchanger (Fig. 6.7.
WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers 9.
WD388/0/2004 215 Chapter 9 : Spare Parts Listings C36 Combi Gas Valve - Mixer Assem. 119 C36P Combi Gas Valve - Mixer Assem.
WD388/0/2004 Chapter 9 : Spare Parts Listings The Keston C36 & C36P Combi Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No 46 161 48 49 108 67 68 94 112 119 215 215 138 135 57 56 58 Installation & Servicing Instructions Part Denomination Burner Burner Gasket Ignitor Ignitor Gasket DHW Thermistor Flow/Return Thermistor Flue Thermistor Flow Sensor Pressure Sensor Fan Gas Valve - Mixer Air-Gas Assembly (NG-C36 Combi) Gas Valve - Mixer Air-Gas Assembly (LPG-C36P Combi) Co
WD388/0/2004 Chapter 10 : Benchmark Checklist Final The Keston C36 Combi & C36P COMBI Boilers 10. GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. ___________________ NOTIFICATION No.
WD388/0/2004 Chapter 10 : Benchmark Checklist Final The Keston C36 Combi & C36P COMBI Boilers SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
WD388/0/2004 The Keston C36 Combi & C36P Combi Boilers KESTON CONDENSING BOILERS IMPORTANT C36 and C36P Combi INSTALLATION KEY POINTS b b b b b b b b b b b b b b Read Installation Manual Carefully Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe. If the installation is a replacement the system must be flushed clean. System should be drained hot, then refilled, then drained again until the water is clean. Ensure that there is a proper electrical supply i.e.
