Keston System s30 Guida utente
August 2016
UIN 215352 A01
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specication 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 specication and maintenance practices visit our website
www.keston.co.uk where you can download the relevant information in PDF format.
System s30
Installation and Servicing Instructions
FAN POWERED HIGH EFFICIENCY
MODULATING DOMESTIC CONDENSING
GAS SYSTEM BOILER
2
Installation and Servicing
MODEL
SYMBOL UNITS 30
Condensing Boiler n/a n/a yes
Low Temperature Boiler n/a n/a no
B1 Boiler n/a n/a no
Cogeneration Space Heater n/a n/a no
Equipped with a Supplementary Heater n/a n/a no
Combination Heater n/a n/a no
Nominal Heat Output for Space Heating
Full Load P4kW 30
Part Load P1kW 9.8
Auxiliary Electricity Consumption
Full Load elmax kW 0.048
Part Load elmin kW 0.013
Standby PSB kW 0.005
Seasonal Space Heating Energy Efciency
Full Load ƞ4%89.8
Part Load ƞ1%98.2
Standby Loss Pstby kW 0.055
Ignition Pign kW 0
Emissions NOxmg/kWh 29
Annual Energy Consumption QHE GJ 93
Sound Power Level, Indoors LWA dB 48
ERP DATA
3
Installation and Servicing
KESTON SYSTEM S BOILER
Keston Heating
ERP DATA
SYMBOL UNITS MODEL
30
Condensing boiler Yes
Seasonal Space heating efciency class A
Rated heat output kW 30
Seasonal space heating energy efciency ƞs% 93*
Annual energy consumption QHE GJ 93.0
Sound power level, indoors LWA dB 48
Seasonal Space Heating Energy Efciency of the Boiler *%
Temperature control (from che of temperature control) %
Class I Class II Class III Class IV Class V Class VI Class VII Class VIII
1% 2% 1.5% 2% 3% 4% 3.5% 5%
PRODUCT FICHE
The energy efciency of the package of products provided for in this document may not correspond to its actual energy efciency once installed in a
building, as the efciency is inuenced by further factors such as heat loss in the products in relation to the building size and its characteristics
Collector Size
(in m2)
Tank Volume
(in m3)
Collector
Efciency
(in %)
Tank rating
A* = 0.95
A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
Solar Contribution (from che of solar device)
Seasonal Space Heating Energy Efciency of Package TOTAL: A+B+C=
Seasonal Space Heating Energy Efciency Class of Package
= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x = %
%
GG F E D C B A A+ A++ A+++
< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%
A
B
C
4
Installation and Servicing
5
Installation and Servicing
Keston reserve the right to vary specication without notice
Relevant Installation changes implemented in this book from Mod Level..................................A01 (Aug 16)
DOCUMENT AMENDMENTS
FOR ANY TECHNICAL QUERIES PLEASE RING THE KESTON
INSTALLER/TECHNICAL HELPLINE : 01482 443005
NOTE. BOILER RESTART PROCEDURE -
To restart the boiler press the RESTART button. The boiler will repeat the ignition sequence if a heat
demand is present.
NOTES FOR THE INSTALLER
6
Installation and Servicing
7
Installation and Servicing
CONTENTS
1 GENERAL.................................................................... 8
1.1 Introduction ................................................................ 10
1.2 Operation ................................................................... 10
1.3 Safe Handling ............................................................. 10
1.4 Optional Extra Kits ..................................................... 10
1.5 Safety ......................................................................... 11
1.6 Safe Handling of Substances ..................................... 11
1.7 Location of Boiler ...................................................... 11
1.8 Gas Supply ................................................................. 12
1.9 Water Circulation System ........................................... 12
1.10 Boiler Control Interlocks ............................................. 12
1.11 Electrical Supply ......................................................... 12
1.12 Condensate Drain .................................................... 12
1.13 Boiler Dimensions, Services & Clearances ................ 13
1.14 System Requirements ................................................ 14
1.15 System Balancing ...................................................... 15
1.16 Water Treatment......................................................... 15
1.17 Boiler Assembly - Exploded View ............................... 16
1.18 Unpacking .................................................................. 17
1.19 Front Panel Removal ................................................. 17
2 INSTALLATION ......................................................... 18
2.1 Flue System ............................................................... 18
2.2 Flue Installation Example Keston System S 30 ......... 20
2.3 Flue Installation Example Keston System S 30 ......... 20
2.4 Flue Termination Position ........................................... 21
2.5 Installing The Boiler .................................................... 22
2.6 Wall Mounting Template ............................................. 22
2.7 Preparing The Wall ..................................................... 22
2.8 Fitting The Wall Mounting Plate ................................. 23
2.9 Mounting The Boiler ................................................... 23
2.10 Assembly Practice ...................................................... 24
2.11 Fitting The Sleeving ................................................... 25
2.12 Condensate Drain ...................................................... 26
2.13 Connections & Filling ................................................. 28
2.14 Electrical Connections ................................................ 29
2.15 Installer Wiring ........................................................... 29
2.16 Replacing Pre-Fitted Mains Cable ............................. 31
2.17 Fitting The Weather Compensation Kit ...................... 31
2.18 External Electrical Controls ........................................ 32
2.19 Fitting The Weather Compensation Kit ..................... 32
2.20 Wiring Diagram .......................................................... 33
2.21 Commissioning And Testing ....................................... 34
2.22 Initial Lighting ............................................................. 35
2.23 General Checks ......................................................... 36
2.24 Restart Procedure ...................................................... 36
2.25 Accessing The Installer Mode .................................... 37
2.26 Handing Over ............................................................. 37
3 SERVICING
3.1 Servicing Schedule .................................................... 38
3.2 Boiler Front Panel Removal / Replacement ............... 39
3.3 Fan and Venturi Assembly Removal and Cleaning .... 39
3.4 Burner Removal and Cleaning ................................... 40
3.5 Cleaning the Condensate Trap/Siphon ...................... 40
3.6 Cleaning the Heat Exchanger .................................... 41
3.7 Reassembly ............................................................... 41
3.8 Replacement of Components ..................................... 42
3.9 Fan Replacement ....................................................... 42
3.10 Burner Injector Replacement ..................................... 43
3.11 Burner Replacement .................................................. 43
3.12 Return Thermistor Replacement ............................... 44
3.13 Ignition Electrode Replacement ................................. 44
3.14 Flame Detection Electrode Replacement ................... 45
3.15 Spark Generator Replacement .................................. 45
3.16 Gas Control Valve Replacement ................................ 46
3.17 Condensate Trap / Siphon Replacement ................... 46
3.18 PCB Replacement ...................................................... 47
3.19 Draining the Boiler ...................................................... 47
3.20 Pressure Gauge Replacement ................................... 48
3.21 Safety Relief Valve Replacement ............................... 48
3.22 Pump Automatic Air Vent Replacement ..................... 48
3.23 Pump Head Replacement .......................................... 49
3.24 CH Water Pressure Switch Replacement .................. 49
3.25 Control / No Flow Thermistor Replacement ............... 49
3.26 Heat Engine Replacement ......................................... 50
3.27 Expansion Vessel Recharging & Replacement .......... 51
4 FAULT FINDING ........................................................ 52
4.1 Fault Finding Chart Main Menu .................................. 52
4.2
‘L1’-Flow Temp Ov’heat Lockout/No Water Flow Lockout
... 53
4.3 ‘L2’ - Ignition Lockout ................................................. 53
4.4 ‘L6’ - False Flame Lockout ........................................ 54
4.5 ‘F1’ - Low Water Pressure .......................................... 54
4.6 ‘F2’ or ‘Fn’ or ‘Ln’ - Flame Loss .................................. 54
4.7 ‘F3’ - Fan Fault ........................................................... 54
4.8 ‘L4’ or ‘F4’ - Control / No Flow Thermistor Fault ......... 55
4.9 ‘F5 or L5’ - Return Thermistor Fault ........................... 55
4.10 ‘F6’ - Outside Sensor Fault......................................... 55
4.11 No CH Operation ........................................................ 56
4.12 No Display .................................................................. 56
4.13 No HW ........................................................................ 56
5 SPARE PARTS .......................................................... 57
6 BENCHMARK & COMMISSIONING ......................... 58
8
Installation and Servicing
SECTION 1 - GENERAL
30
Gas supply 2H - G20 - 20mbar
Gas Supply Connection 15mm copper compression
Injector Size (mm) 4.65
Flow Connection Central Heating 22mm copper compression
Return Connection Central Heating 22mm copper compression
Flue Terminal Diameter mm (in) 50 (2)
Average Flue Temp-Mass Flow Rate 69oC - 13g/s
Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)
Electrical Supply 230 V ~ 50 Hz.
Power Consumption W 100
Fuse Rating External : 3A Internal : T4A HRC L250 V
Water content litre (gal) 1.2 (0.26)
Packaged Weight kg 31.6
Maximum Installation Weight kg 26.2
Boiler Casing Size Height mm 700
Width mm 395
Depth mm 278
Table 1 - General Data
Note. Gas consumption is calculated using a
caloric value of 38.7 MJ/m3 (1038 Btu/ft3) gross or
34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different caloric
value:
a. For l/s - divide the gross heat input (kW) by the
gross C.V. of the gas (MJ/m3)
b. For Btu/h - multiply the gross heat input (kW) by
26.8
c. For ft3/h - divide the gross heat input (Btu/h) by
the gross C.V. of the gas (Btu/ft3)
d. For m3/h - multiply l/s by 3.6
Key to symbols
GB = United Kingdom IE = Ireland (Countries of destination)
PMS = Maximum operating pressure of water
C13 C53 = A room sealed appliance designed for connection via ducts to a horizontal
terminal, which admits fresh air to the burner and discharges the products
of combustion to the outside. The fan is up stream of the combustion
chamber.
I2H = An appliance designed for use on 2nd Family gas, Group H only.
* The 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 certied by a notied body.
30
MIN MAX
Boiler Input :
Boiler Input ‘Q’ Nett CV kW 6.1 30.4
Gross CV kW 6.7 33.7
Gas Consumption m3/h 0.622 3.135
(ft3/h) (22) (111)
Boiler Output :
Non Condensing kW 6.1 30.3
70oC Mean Water temp.
Condensing kW 6.4 31.0
40oC Mean Water temp.
Seasonal efciency* SEDBUK 2005 91.1%
Seasonal efciency* SEDBUK 2009 89.6%
NOx Classication CLASS 5
Table 2 - Performance Data - Central Heating
9
Installation and Servicing
SECTION 1 - GENERAL
Boiler size G.C. Appliance No. PI No.
(Benchmark No.)
30 41-930-45 86 CR 18
Natural Gas only
Destination Country: GB, IE
Boiler Page
Make and model ......................................................... 9
Appliance serial no. on data badge .......... Front Cover
SEDBUK No. % .......................................................... 8
Controls
Time and temperature control to heating ................. 32
Time and temperature control to hot water ........... N/A
Heating zone valves ................................................. 32
TRV’s........................................................................ 12
Auto bypass ............................................................. 12
Boiler interlock .......................................................... 12
For .................................................................... all boilers
Flushing to BS.7593 ................................................. 15
Inhibitor .................................................................... 15
Central heating mode
Heat input ...................................................to be calculated
For assistance see Technical Helpline on the back page
Page
Burner operating pressure ...................................... n/a
Central heating ow temp. ...........measure and record
Central heating return temp. ........measure and record
For combination boilers only
Scale reducer ........................................................... 15
Hot water mode
Heat input ............................................to be calculated
Max. operating burner pressure .............................. n/a
Max. operating water pressure ........ measure & record
Cold water inlet temp ...................... measure & record
Hot water outlet temp. ..................... measure & record
Water ow rate at max. setting ........ measure & record
For condensing boilers only
Condensate drain ................................................ 26,35
For all boilers: complete, sign & hand over to customer
For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be tted in accordance with the
manufacturer’s instructions. Self-certication that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.
Before installing this boiler, read the Code of Practice sheet at the rear of this book.
BENCHMARK COMMISSIONING CHECKLIST DETAILS
NOTE TO THE INSTALLER:
COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
Keston System S
10
Installation and Servicing
SECTION 1 - GENERAL
1.1 INTRODUCTION
The Keston System S boiler is wall mounted, full sequence,
automatic spark ignition, low water content, fanned ue, high
efciency, condensing, system gas boiler.
Note. Due to the high efciency of the boiler a plume of water
vapour will form at the ue terminal during operation.
Central heating (CH) output is fully modulating with a range of:
30 6.1 to 30.3kW
The boiler is supplied fully assembled with circulating pump,
pressure gauge, safety valve and CH expansion vessel.
A variable CH temperature control is tted on the user control.
The boiler includes as standard:
- Boiler frost protection
- Daily pump exercise
- Weather compensation
The boiler casing is of white painted mild steel with a white
polymer front panel.
The boiler temperature control is visibly located in the control
panel on the front of the boiler.
The heat exchanger is manufactured from cast aluminium.
The boiler is suitable for connection to fully pumped, sealed
heating systems ONLY. Adequate arrangements for completely
draining the system by provision of drain cocks MUST be
provided in the installation pipework.
Pipework from the boiler is routed downwards.
Data Plate
The boiler model and serial number can be located on the bottom of
the boiler casing, shown in Section 1.13 - Water & Gas Connection
Diagram.
1.2 OPERATION
When there is a demand for CH, the heating system is supplied at
the selected temperature of between 30oC and 80oC.
The boiler features a comprehensive diagnostic system which
gives detailed information on the boiler status when operating,
and performance of key components to aid commissioning and
fault nding.
1.3 SAFE HANDLING
This boiler may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during
movement into its installation location. Manoeuvring the boiler may
include the use of a sack truck and involve lifting, pushing and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques
when performing these tasks and the following precautions should
be considered:
• Grip the boiler at the base.
• Be physically capable.
• Use personal protective equipment as appropriate, e.g.
gloves, safety footwear.
During all manoeuvres and handling actions, every attempt
should be made to ensure the following unless unavoidable and/
or the weight is light.
• Keep back straight.
• Avoid twisting at the waist.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds.
• Keep load as close to the body as possible.
• Always use assistance if required.
1.4 OPTIONAL EXTRA KITS
Please visit www.keston.co.uk to access the Flue and Accessories
Guide for this boiler.
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1
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