Keston K130 User guide

Fan Powered High Efficiency
Condensing Gas Boiler
Installation And Servicing Instructions
Keston 130 - GC No 41 930 05
CE No : 87AT9
These instructions must be left either
with the user or next to the site gas
meter.
34 West Common Road
Hayes, Bromley, Kent BR2 7BX
Tel. [phone] Fax. [phone]
WD52/0/1997 The Keston 130 Condensing Boiler

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 Pipes
3.5 Condensate Drainage
3.6 Water System
3.7 Gas Supply
3.8 Electrical Supply
3.9 Exchanging A Boiler
4 COMMISSIONING OF THE BOILER
4.1 Initial Flushing
4.2 Gas Supply
4.3 Electrical Installation
4.4 LP Gas Conversion
4.5 Initial Firing
4.6 Hot Flushing
4.7 Checking The Gas Pressure
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Page : i

4.8 Timing The Gas Meter
4.9 Handing Over To The User
5 FAULT FINDING
5.1 Electrical Control Sequence
5.2 Fault Finding Flow Chart
5.3 Continuity Checking
5.4 Functional Flow Wiring Diagram
5.5 Electrical Wiring Diagram
5.6 Illustrated Wiring Diagram
5.7 Exploded Assembly Diagrams
6 SERVICING
6.1 Pre Service Checks
6.2 Recommended Routine Service
7 REPLACEMENT OF PARTS
7.1 General
7.2 Precautions
7.3 Access
7.4 Electrical
7.5 Gas Orifice
7.6 Spark Ignition/Flame Detection Electrode
7.7 Burner Head & Burner
7.8 Heat Exchanger
7.9 Air Filter
7.10 Condensate Trap
7.11 Pressure Gauge
7.12 Sight Glass
7.13 HT Ignition Lead
7.14 Air Vent
7.15 Air Orifice
8 SPARE PARTS LISTINGS
BENCHMARK INITIATIVE
As part of the industry wide “Benchmark” Initiative all Keston 130 boilers now include a Benchmark
Installation, Commissioning and Service Record Log Book. Please read this carefully and complete all
sections relevant to the appliance installation. The details of the Log Book will be required in the event
of and warranty work being required. There is also a section to be completed after each regular
service visit. The completed Log Book should be left with the customer.
CORGI CONTACT INFORMATION
The boiler should be installed and serviced only by CORGI registered operatives. All CORGI
registered Installers carry a CORGI ID cad, and have a registration number. Both should be
recorded in the Benchmark Log Book. You can call CORGI direct on 01256 372300.
WD52/0/1997 The Keston 130 Condensing Boiler
Page : ii

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 15 metres horizontally or vertically.
The Keston uses a high power combustion blower to deliver a pre-mix of gas and air to a
downward firing burner in a high efficiency, single pass heat exchanger. Normally the
combustion temperature of the air gas mixture is around 1800
o
C but the Keston achieves
combustion at an amazing 1000
o
C thereby reducing the NOx emissions.
The flue system is room sealed and fan powered. The ignition is direct spark and fully
automatic. The boiler housing is not waterproof and should be installed in a position
where it will always be dry. Consideration should also be given to the noise levels
generated by the combustion fan when in operation. A small air intake point is
incorporated within the appliance cabinet to ensure that the interior of the cabinet is
maintained under a slight negative pressure. This is a safety feature to ensure no
products may leak out of the cabinet into the installation space.
The boiler is suitable for connection to open vented or, preferably, sealed systems. The
system must be pumped central heating or pumped central heating with combined indirect
sanitary hot water. Gravity circuits must not be used.
Forming part of the boiler is the heat exchanger which is made from a highly corrosion
resistant stainless steel, formed into tightly wound coil. The hot combustion gases from
the central down firing burner pass through this coil imparting heat into the system water.
Head characteristics of the boiler coil must be taken into consideration when calculating
the pump size. The Keston boiler is not a high water content boiler and does not contain
the metal mass, or water volume, of a cast iron or steel boiler. This boiler is of low mass
and low water content and therefore responds faster when there is a call for heat. This
feature requires a higher water pumping rate through the boiler otherwise localised boiling
will occur within the boiler. Allow a pressure drop through the boiler of 9.8 ft head (30
kPa) and a water flow of 11 gallons (50 litres) per minute.
The boiler selected must be sized relative to the total calculated heat loss of the building.
The boiler rated output should not be greater than the total required to make up the
calculated heat loss plus the heat required to provide sanitary hot water, if the system is
not hot water priority design. If there are special conditions such as excessive sanitary hot
water usage consult the manufacturer.
1.2 BOILER SCHEMATIC
Air is drawn into the boiler through a 50mm muPVC pipe. The air flow is proved by a
differential pressure across the air control orifice. Gas is mixed with combustion air at the
inlet to the fan. The gas flow is regulated by an orifice located in the housing downstream
of the gas valve.
The gas and air are thoroughly mixed in the blower and fed into the burner located at the
top end of the heat exchanger module. The gas and air mixture is ignited by a direct spark
ignition control 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 coil at the bottom of the heat
exchanger
.
WD52/0/1997 Chapter 1 : General Instruction The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 1

Fig. 1.2 - Boiler Schematic
When the return water temperature is below 54o
C, part of the water vapour in the combustion products will
condense inside the heat exchanger, thus increasing the boiler efficiency by releasing the
latent heat of condensation. This condensate falls to the bottom of the heat exchanger
where it is separated from the flue gases and exits from the boiler through the condensate
drain. Any condensate formed in the flue runs back down the flueway and is drained at the
base of the flue connection to the heat exchanger or drain points within the flue.
The condensate is very slightly acidic (about the same acidity as vinegar) and should be
piped in a plastic pipe. It is not harmful to the waste disposal system and may be disposed
of as normal waste water.
The flue gases are piped in a 50mm muPVC pipe to the outside. The temperature of the
flue gases are usually around 5
o
C 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, hot water cylinder thermostats,
programmer time clocks and energy management systems.
1.3 RELATED DOCUMENTS
The Keston Condensing Boiler must be installed in accordance with the current issue of
the Gas Safety (Installation and Use) Regulations 1996, current IEE Wiring Regulations,
Building Regulations,Building Standards (Scotland) Consolidation, and the Bye Laws of
the local Water Undertaking.
In addition, due account must be taken to the following Codes Of Practice:
BS 6891 : Gas Supplies
BS 6798 : Installation Central Heating Boilers
BS 5449 : Installation Pumped Central Heating
BS 5482.1 : Domestic Propane & Butane Burning Installations
WD52/0/1997 Chapter 1 : General Instruction The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 2

BS 5546 : Installation Domestic Hot Water
BS 5440.1 : Flues
BS 5440.2 : Air Supply
BS 7074.1 : Expansion Vessels
BS 7593 : Treatment of Water in Hot Water Central Heating
Systems
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'.
1.4 PERFORMANCE DATA
1.5 GENERAL DATA
WD52/0/1997 Chapter 1 : General Instruction The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 3
Boiler Input kW 42.0
Btu/h 143,300
Boiler Output To Water kW 37.7
(80
o
C Flow 60
o
C Return) Btu/h 128,600
Boiler Output To Water kW 39.5
(60
o
C Flow 40
o
C Return) Btu/h 134,800
Boiler Output To Water kW 40.5
(50
o
C Flow 30
o
C Return) Btu/h 138,200
Burner Setting Pressure Factory Preset
(Hot)
to 4.0 mbar
Gas Comsumption After l/s 1.09
10 mins Ft
3
/hr 138.78
(CV of Gas - 38.7 MJ/m
3
)
(1038 Btu/Ft
3
)
Max. Operating Flow Temp.
o
C 80.00
Max. Head (Open Systems) m 30.50
Ft 100.0
Max. Press. (Sealed Sys.) Bar 2.70
Min. Head (Open Systems) m 3.0
Ft 9.0
Inlet Gas Pressure mbar 20.0
in wg 8.0
Gas Orifice Size mm 3.8
Recommended Temperature
o
C 10 to 15
Differential
Main Burner Keston Premix
Gas Control White Rogers 36E Series
Combustion Fan Keston
Type LPB 103 220/240
0.6 kW 2900 RPM
Direct Spark RAM 2EMC22
Ignition Full Sequence Control
Air Press. Switch Tridelta FS6717-1428
Filter Keston Filter
Gas Supply 0.75 inch BSPT Male
Connection (22mm to gas cock)
Flow Connection 35mm Copper
Return Connection 35mm Copper
Power Supply 230V 50Hz
Pwr Consumption 610 W
Ext Fuse Rating 10 Amp
Weight - Full 68 kg (150 lbs)
Weight - Empty 61 kg (134 lbs)
Data Badge Posn Right Hand Panel Inside
Case
Water Content 7.0 litres

2. BOILER LOCATION
2.1 DIMENSIONS AND MINIMUM
CLEARANCES
The boiler must be installed in minimum
clearances shown to allow subsequent
servicing, and safe operation.
2.2 SERVICE CONNECTIONS
Gas, water, air and flue pipe,
condensation, and electrical
connections are as shown. Gas : 0.75
inch BSP male. Flow/Return 35 mm
copper.
2.3 POSITION
The Keston is not
suitable for external
installation. The boiler
may be installed in any
room or internal space,
although particular
attention is drawn to the
requirements of the
current IEE Wiring
Regulations and, in
Scotland, the electrical
provisions of the Building
Regulations 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 containg a bath or
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 4
All dimensions in mm.
254
305
127 Figure2.1.1
MinimumClearances
1
1
All dimensions in mm.
500
327
Figure 2.1.2
Dimensions
AirIntake
Flue
Flow
Return
50
113
Condense Gas
890
30 44
97
BaseView
ServiceConnectionLocations All dimensions are in mm.
190
405
Top View
65
50
263
244
37
85
152
50
35

shower, any electrical switch or appliance control, utilising mains alectricity, 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 property.
Chimneys notusedfor
venting anyother
appliancemaybe used.
Figure2.3
Condensatedrain
Secure air & fluepipes at
chimneyoutlet.
[NB: Refer to
Section 2.8.3]
The Keston can be located virtually anywhere desired provided that all regulations are
complied with. Because of the boiler's compact size and venting flexibility, the installation
is not limited to a boiler room setting. Before locating the boiler near a living space
consider whether the sounds generated by the boiler will be objectionable. The boiler may
be located within a cupboard enclosure to reduce noise levels if located within a living
space.
2.4 ELECTRICAL
2.4.1 Electrical Connections
The boiler must be connected to a permanent 230V ~ 50Hz supply, fused at 10A.
An additional switched live supply 230V ~ 50Hz rated at 2A must be
provided from the external system controls. All external controls and
wiring must be suitable for mains voltage. A pump connection point is
provided within the boiler to enable the optional pumpover-run facility to be
used. Alternatively, the appliance can be fed by a single switched 10A supply by
linking the switched and permanent live connection points (see Section 3.8). If a
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 5

single 10A switched supply is used then the pump over-run facility will not be
enabled.
Wiring external to the boiler must be in accordance with current I.E.E wiring
regulations and local regulations.
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.
The appliance must be connected to the 10A 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 External Wiring & Controls
1. The boiler is designed so that all control wiring is external to the boiler.
2. System designs which allow the boiler to fire when there is no pumped
circulation must NOT be used. Provision is made in the boiler for boiler
pump connection with pump over-run facility.
3. A programmer may be used with zone valves to give independent control
of central heating and hot water.
2.5 BOILER SIZE SELECTION
The size of the boiler to be used is determined by the total calculated heat loss of the
building. Match the calculated heat loss with the boilers rated output. If a boiler is installed
with an output rating greatly exceeding the total capacity of the distribution system the
efficiency of the boiler will be reduced.
2.6 GAS SUPPLY
A gas meter should be connected to the service pipe by the local gas region or their
contractor. An existing meter should be checked preferably by the gas region to ensure
that the meter is adequate to deal with the rate of gas supply required. Installation pipes
should be fitted in accordance with BS 6891.
Minimum/Maximum Natural Gas Pressure:
Natural gas pressure before the gas valve must be maintained at 20 mbar (8 in WG) while
the boiler is running.
Gas pressures above or below this level 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
(22 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. Ensure gas supply pipe work is adequately sized for
the length of run from the meter to the boiler.
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.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 6

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 pipe capabilities and pressure drop through the piping.
Water treatment must be carried out to BS 7593 : Treatment of Water in Hot Water
Central Heating Systems.
Pump isolating valves must be positioned as close to the pump as possible.
a The Keston 130 is suitable for use on open, vented water systems with combined
feed and vent.
b It is preferable for use on sealed water systems, provided the appropriate
components required (see Section 2.7.2 Sealed Systems) are included in the
system.
c Any system must be thoroughly flushed clean of grease, dirt and debris, prior to
connection with the boiler. A trap should be installed in the flow line to collect any
solder, or other debris, from the installation.
d All water systems must be constructed to comply with requirements of the Local
Water Authority.
e Only fully pumped systems can be used - gravity systems are strictly not suitable.
f Always use a system complying with the requirements of BS 5449 and BS 6798.
g The system must be so arranged that there shall always be a minimum flow of 11
gpm (50 litres/min) when the boiler is firing. This can be via a specially installed
by-pass arrangement.
h Copper tubing to BS 2871 Part 1 is recommended.
i Jointing should be either with capillary, threaded or compression fittings. Pipes
should have a gradient to ensure air is passed easily to vent points and water
flows readily to drain points.
j Draining taps must be located in accessible positions which permit the draining of
the boiler and hot water storage vessel. Draining taps should be at least 22 mm in
nominal size and be in accordance with BS 2879.
AIR VENT POINTS
h These must be fitted at all high points where air will naturally collect and must be
sited to allow complete draining of the system.
2.7.1 Open Vented Systems
A typical system is shown in Figure 2.7.1 which includes a combined feed and
vent. Note there must be no valve between the boiler flow and the open vent.
Note that the minimum static head required is 9 ft at the top of the boiler. If the
cold feed/vent is not brought to the flow pipe as shown, then the pressure loss
across the heat exchanger may have to be taken into account when estimating
the static pressure.
Although suitable for open vented systems with combined feed and vent
arrangements, the Keston is a low water content boiler. As such, any air
entrainment within the system water will produce boiler “kettling”. It is therefore
recommended, if in any doubt, to consider the use of sealed systems where
possible.
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Installation & Servicing Instructions Page : 7

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 pump.
(iii) A filling point, in accordance with local water authority requirements.
(iv) A method of system make-up (automatic or manual), in accordance with
local water authority requirements.
(v) There must be no permanent connection of mains water to the boiler
system.
(vi) The installation must be designed to work with flow temperatures of up to
110
o
C.
All components of the system including the heat exchanger of the indirect cylinder
must be suitable for a working pressure of 3 bar and a temperature of 110
o
C.
Care should be taken in making all connections that the risk of leakage is
minimised.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 8
Boiler
Rad. 2 Rad. 1
Pump
Minimum
9ftHeight
Cylinder
Figure2.7.1 : Open VentedSystemDiagram
Keston
Valve
Valve
Expansion
Pipe
Expansion
Tank
28mm
Minimum
By-pass
Bal.
Valve
L/S
Valve
Strainer

2.7.3 Hot Water System (if applicable)
The hot water storage vessel must be of the indirect type (certain direct cylinders
can be used provided they are suitably adapted by fitting an immersioncalorifier).
DIRECT CYLINDERS MUST NOT BE USED. Further guidance is provided in BS
1394. It is advisable to fit a locksheild valve on the cylinder return to enable
balancing of the flow rate through the cylinder.
2.7.4 Boiler By-pass Piping
Boiler water flows are critical to the operation of the boiler. If flow cannot be
maintained through the system piping to meet the minimums required by the
boiler (see paragraph 2.7 (g)). Insufficient water flows through the boiler will cause
the boiler to "kettle" or even produce steam which can damage the heat
exchanger and will invalidate the heat exchanger warranty.
It is normally advisable to incorporate a boiler by-pass in the system, especially if
thermostatic radiator valves are used. The by-pass should be fitted with an
automatic by-pass valve to permit balancing of the by-pass flow rate. The
flow/return differential should be 10
o
C to 15
o
C. The valve should be adjusted to
maintain this condition with all thermostatic radiator valves closed.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 9
Boiler
Figure2.7.2:SealedSystemDiagram
Keston
Pressure
Guage
Expansion
Vessel DoubleCheck
Valve
Pump
AirVent
Make -upvessel.
Max. capacityof
3lt.(5pt)
Non-Return
Valve
AutoAir
Vent
Hose
Union
bibtap
Hosepipe
(disconnected
afterfilling)
Hose
Connector
BS 1010:2
StopTap
Test Cock
Drain
Coc
k
HEATINGCIRCUIT
RETURN
FLOW
Safety
Valve
By-pass
Bal.
Valve
L/S
Strainer

2.7.5 Air Elimination
In the initial charge of water to the boiler system and in all subsequent additions
of water to the system some air will be dissolved in the water. As the water is
heated the air is 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.
2.7.6 Strainers
Debris in the heating
system can cause noise if
it enters the heat
exchanger. Fitting of a
Y-strainer ahead of the
circulating pump will trap
any debris left in the
system and will protect
the pump from damage.
The boiler guarantee
does not cover heat
exchanger failure due to
debris abrasion within the
system.
2.7.7 Pump Selection
The Keston boilers have low
water content heat
exchangers with a high
resistance to flow, when
compared with cast iron heat
exchanger boilers. As a result
selection of the correct pump
is essential in order to avoid
localised boiling within the
heat exchanger. The selected
pump must be capable of
maintaining the required flow
rate for the boiler against the
pressure losses contributed
by the boiler.
The Keston 130
condensing boiler offers a
hydraulic resistance of
3.0m (9.8ft) water at the
required flow rate of 50 l/m
(11 gpm).
If a single pump is to be used
for the entire installation the
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 10
Y-Strainerwill
collectanyloose
debrisinthepiping.
Figure 2.7.6 Strainers
Figure2.7.7: PressureLossGraph
10 20 30 40 50 60
0.5
1.0
1.5
2.0
2.5
3.0
WaterFlow -L/min
StaticPressure-mWC
3.5
4.0
4.5
70

boiler resistance must be added to the pressure loss caused by the rest of the
system and a pump selected that is capable of meeting the flow rate required at
the total pressure loss generated by the boiler and the rest of the system. The
selected pump must comply with BS 1394. 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.
2.8 FLUE SYSTEM
2.8.1 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 an of an internal diameter of 51
mm. (ie nominal 50mm diameter muPVC solvent weld waste pipe)
Both flue outlet terminal and air inlet terminal are supplied and are illustrated in
Figure 2.8.1 above.
2.8.2 Maximum Lengths
The maximum lengths of both air inlet pipe and flue outlet pipe, when no bends
are used, are as detailed below.
Maximum Air Inlet Length : 15.0 m
Maximum Flue Outlet Length : 15.0 m
However, each bend used has an equivalent length that must be deducted from
the maximum straight length stated above. Knuckle bends must not be used.
A 92.5
o
sweep elbow is equivalent to 1.0m straight length.
Example:
Air inlet uses two one 92.5
o
sweep elbows. Hence, maximum length permissible
(ie a+b in figure 2.8.2) = 15.0m - 1.0m - 1.0m = 13.0m
Flue outlet uses one 92.5
o
sweep elbow. Hence, maximum length permissible (ie
c+d in figure 7 = 15.0m - 1.0 m = 14.0m
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 11
Flue Outlet Terminal Air Intake Terminal
Fi
g
ure 2.8.1 : Terminals
O56
80
40 87
211
O56
O83

2.8.3 Slope
'Horizontal' flue outlet pipework MUST slope at least 5 degrees (80 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.
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 2m.
These additional condensate
drains must be run to
discharge as detailed in
section 2.11. Such drain points
can be formed using standard
muPVC fittings. Refer to the
example in Figure 2.8.3.
2.8.4 Terminations
Air inlet terminals must be
facing upwards and positioned
to ensure only fresh air is
drawn into the boiler. The air
terminal must be located
outside of the building.
Drawing of combustion air directly from a ventilated boiler room invalidates the
heat exchanger warranty.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 12
FLUE AIR
cd
a
Figure2.8.2 :Flue& AirMaximumLengthExample
Keston
b
6inmin.
Figure2.8.3 :
FlueCondensate Drain
PointExample
50mmTeeFitting
To Boiler
To Terminal

Table 2.8.4 Minimum Flue Terminations & Air Inlet Dimensions
The air inlet terminal must face upwards to prevent entry of rain into the air intake
pipework.
The flue outlet terminal is designed to face outwards but can, if desired, be
adapted to face in any direction BUT must not be directed in the region of the air
inlet.
The two terminals are subject to the requirements of BS 5440 Pt 1 for clearances
from features of the building although some can be decreased to the values
indicated.
If either the air inlet or the flue outlet terminate at a height of less than 2m (6ft)
above ground level the termination must be protected by a suitable guard. The K4
terminal guard, manufactured by Tower Flue Components Ltd, is suitable for this
purpose and can be obtained from Keston Boilers.
The Keston Condensing Boiler, as with any condensing boiler, will generate
a condensate “plume” from the flue terminal in all weather conditions.
Consideration must therefore be given to the effect of this “plume” when
selecting a location for the flue terminal.
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.
2.8.5 Clearances From Wall
Flue outlet and air inlet terminations 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.
A minimum clearance of at least 500 mm must be left between the terminations.
2.8.7 General Installations
All parts of the system must be constructed in accordance with BS 5440 Part 1,
except where specifically mentioned in these instructions.
All pipe work must be adequately supported.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 13
300300L Horizontally from terminal on same wall. 1,5001,500K Vertically from terminal on same wall. 1001,200J From opening in a car port. 1,2001,200I From terminal facing a terminal. 100600H From surface facing a terminal 100300G Above ground or balcony or roof. 50600F From internal or external corner. 5075E From vertical drain or soil pipes. 50200D Below balconies or car port roof. 50300C Below eaves. 7575B Below gutters, soil pipes, drain pipes. 50300A Below openable window, air brick, etc.
Air
Inlet
Flue
Terminal
Dimensions (mm)

All joints other than push-on or plastic compression connectors must be made
and sealed with solvent cement suitable for muPVC pipes and conforming to BS
6209: 1982.
External wall faces and any internal faces of cavity walls must be made good.
2.9 AIR SUPPLY
The Keston is a room sealed appliance and therefore does not require purpose provided
ventilation to the boiler room for combustion air.
2.10 COMPARTMENT INSTALLATION
The casing temperature of the Keston 130 is very low. Due to this fact, no compartment
ventilation is required for cooling purposes.
2.11 CONDENSATE DRAINAGE
Being a condensing boiler, the Keston is fitted with a condensate trap at the base of the
heat exchanger and flue assembly, with facility to connect to a drain point underneath the
appliance.
Use only plastic piping and do not reduce below 15mm internal diameter within the
dwelling. Condensate should preferably be drained into the sanitary waste system or,
alternatively, the rainwater system of the property.
Termination of the pipe must be either at a branch or stack internal to the house, or
externally at an open gully. Alternatively, discharge into a purpose madecondensate
soakaway can be considered. Existing or purpose built drains must use suitable corrosion
resistant material as condensate is mildly acidic.
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.
2.12 RADIANT FLOOR HEATING
The low operating temperatures of this type of system lead to very good operating
efficiencies. In fact, under floor heating can produce in excess of 95% operating efficiency
from a Keston condensing boiler.
Water temperatures in radiant floor heating systems must be kept relatively low, generally
under 48
o
C, so that surfaces do not become uncomfortably warm to the touch. If radiant
heating is only one application for a multi-zone system which also requires higher delivery
water temperatures for other zones (i.e. water heating, skirting heaters etc.) then the
radiant floor zone temperature will need to be controlled separately from the boiler.
If radiant floor heating is the only application of the boiler, the boilers maximum operating
temperature can be lowered accordingly by introducing a supplementary control
thermostat within the control system of the installation.
Mixing valves are also available which will mix return water from the system with boiler
output water to dilute the temperature of water transmitted to the distribution system.
Mixing valves may create problems with low flow and high temperatures through the
boiler, unless care is taken to design a system which will provide proper flows and will fully
load the boiler. Keeping the boiler's temperature high will prevent the boiler from operating
at peak efficiencies. Systems which maintain boiler temperatures in this way should be
avoided.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 14

If only a portion of the boiler's available output is to be used for radiant floor heating a
thermal storage tank will improve the boiler's operation and give adequate control of
temperature for the distribution system. By heating water to be distributed to the radiant
floor zone to the proper temperature in an indirect-fired water heater, full load conditions
will be available to the boiler because the heat exchanger in the tank can be sized to
match the boiler's output. The tank's thermostat can be set at the optimum operating
temperature needed by the distribution system and short-cycling of the boiler will be
prevented.
2.13 LOW WATER VOLUME BOILER VS. CAST IRON BOILER
Because of their high water content and mass of metal, cast iron and steel boilers are less
responsive but somewhat more forgiving of design errors. Short-cycling of the burner on
the temperature limit control is less pronounced, though no less detrimental to operation,
because the boiler itself will absorb and radiate a significant amount of heat. Low water
volume boilers respond more quickly to a call for heat, can be made more compact and
lightweight, but must have adequate heat delivery systems to avoid short-cycling of the
burner on the temperature limit control. The heat delivery system's output must be equal
to or greater than the boiler's output to fully load the boiler or short-cycling will occur.
Likewise, pumping rates of water through low water volume boilers must be maintained so
that water is moved through the boiler fast enough so as not to reach boiling
temperatures. The slower the water moves through the boiler the more heat it will absorb
and the higher the temperatures will rise. Consequently, the pump selected must be
adequate to maintain that critical flow of water.
2.14 DETERMINE RADIATION NEEDED ROOM-BY-ROOM
A radiator or convector's ability to deliver heat is related to the water temperature and the
rate of delivery to the unit. Most systems in the past have been rated at about 80
o
C.
Higher efficiencies can be gained from a condensing boiler if ratings published at lower
temperatures are used. However, this is not imperative. With normal 80
o
C ratings used a
condensing boiler will still deliver significantly higher efficiencies than a non-condensing
boiler. Lower water temperatures in the system tend to increase the efficiency of the boiler
and will help assure that the boiler is subjected to a sufficient load to avoid short-cycling.
The Keston boilers are capable of temperatures of up to 80
o
C but the higher the
temperature of the return water, the lower the efficiency of the system. This is true of all
boilers, though all non-condensing boiler must be kept at higher temperatures to avoid
condensation in the boiler which destroys such boilers quickly. Materials used in the
Keston are made to withstand the condensates corrosive nature.
WD52/0/1997 Chapter 2 - Boiler Connections The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 15

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 on the wall
horizontally with the pre-drilled
holes at the bottom.
b Drill through the centre hole of
the bracket, plug the hole and fix
in position.
c Using a spirit level make sure
the bracket is completely level
and mark the position of the
other screw holes.
d Remove the bracket and drill the
holes in the positions marked.
Plug these holes.
e Screw the bracket to the wall
using screws of an appropriate
size for the wall type (No. 12 x 2
inch wood screws normally
suffice).
f Mark the bottom fixing hole and
drill for a No 8 x 1 inch wood
screw. Insert plug.
3.2 MOUNTING THE BOILER
a Lift and locate the upper rear lip on the boiler to the boiler wall bracket.
b Move the boiler sideways to centralise the boiler on the bracket.
c Screw in the lower fixing screw.
3.3 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 filter or 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.
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.
WD52/0/1997 Chapter 3 : Installation The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 16
Alldimensionsinmm.
Figure 3.1 Wall Mounting Fixing Locations
93
280
250

The combustion air filter will prevent plugging of the burner caused by dirt being trapped in
the burners outer mesh. The filter element supplied with the boiler is obtainable from
Keston Boilers or its distributors.
3.4 INSTALLING FLUE AND AIR PIPES
Remember the flue pipe must slope downwards back towards the boiler and this is best
achieved using 92.5
o
bends.
a From the two connections on the boiler, mark the positions of the two holes for
the flue and air pipes on the wall(s) or ceiling. To allow access to drill the holes it
may be necessary to temporarily remove the boiler. If the boiler stays put then it is
imperative that the front panel and top access plate are replaced and the two
plastic pipes capped off whilst drilling. Under no circumstances must debris from
the wall or cut pipes be allowed to enter the appliance or the plasticpipework.
b Drill the two holes in the wall/ceiling, preferably using a core drill.
3.4.1 Diameter of holes.
i) Allowance must be made for
socketed lengths if these are
to be passed through the
holes :
du = unsocketted
diameter
= 56 mm
ds = socketed
diameter
= 65 mm
ii) For 'horizontal' runs of flue
pipe the holes must either be
oversized or cut at a 5
o
slope
(the latter may be difficult on
long holes).
3.4.2 Oversizing
For every 1m length of run, L, the minimum diameter of the horizontal hole, D,
must be du + 10 mm or ds + 10 mm respectively, assuming the pipe touches the
wall at points T otherwise D will have to be increased by clearance from T. See
Section 3.4.3 - Examples.
3.4.3 Examples
a. Wall Depth L = 750 mm
Unsocketted pipe du = 56 mm
Diameter hole D = 56+[(
750
/
1000
)x10]
= 56+7.5
= 63.5 mm
b. Wall depth L = 2300 mm
Socketed Pipe ds = 65 mm
Diameter Hole D = 65
+
[(
2300
/
1000
)x10]
= 65+23
= 88 mm
WD52/0/1997 Chapter 3 : Installation The Keston 130 Condensing Boiler
Installation & Servicing Instructions Page : 17
D
L
du
T
ds
FluePipe