Installation And Servicing Instructions - Heatingspares247.com

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WD209/1/2000 Chapter 4 : Commissioning The Keston Celsius 25 & 25P4. COMMISSIONING OF THE BOILERImportant:This condensing boiler contains components which could be damaged or blocked by grease, dirt,solder etc., from the water system. The following commissioning procedures must be followedprecisely.4.1 INITIAL FLUSHINGAll waterways within the Keston Celsius 25 are either copper, high alloy stainless steel oraluminium. As a result water treatment chemicals for central heating boilers such asFernox MB1, or equivalent, are suitable. In any event reference must be made to BS7593 : Treatment Of Water In Hot Water Central Heating Systems.a. Disconnect the boiler from the system at the flow and return connections andtemporarily link the flow and return pipes on the system.b. Flush the entire system until clean water is discharged, free from dirt, flux, solderetc. The use of a flushing chemical is recommended, e.g. Fernox Supafloc, orequivalent.Sludge and scale must be removed from an existing system. Boiler failure due tosystem debris or sludge shall invalidate the guarantee.c. Connect the system to the boiler and fill in accordance with Section 2.7 - WaterSystems. At this stage, for sealed systems, fill to a pressure of about 2.7 bar.d. Check the complete system for water soundness. If leaks need to be rectifiedusing flux and solder, the system must be flushed cold again before proceeding.e. Reduce the pressure to the Initial System Design Pressure for sealed systems, ifapplicable. Vent the system4.2 GAS SUPPLYThe complete gas installation up to the boiler service cock must be checked forsoundness. BS 6891.4.3 ELECTRICAL INSTALLATIONCarry out preliminary electrical safety checks, i.e. Earth continuity, Polarity, Resistance toEarth, Short Circuit using a suitable test meter.4.4 LP GASThe Keston Celsius 25 is supplied preset for the gas designated on the boiler packing.No field conversion is possible. LPG installations must use Celsius 25P models only.4.5 INITIAL FIRINGImportantChecking the gas pressure to the pre-mix burner requires a special procedure, outlinedbelow, which must be carried out.a. Purge the gas supply in accordance with BS 6891.b. Vent the water system.Important:The Celsius heat exchanger consists of crossflow tubes which can trap an airpocket. Great care must be taken to ensure that water flow has been establishedthrough the heat exchanger and thus ensuring no air pockets remain in the heatexchanger and pipe work. Firing the boiler while an air pocket exists in the heatexchanger could damage it.c. Turn the gas service cock to ON.d. Turn on the electrical supply, setting any external controls to call for heat.e. Set the boiler user control knob clockwise to the desired temperature setting. Themains LED (green) will illuminate continuously. After approx 10 seconds theboiler fan and pump will start on ignition rates. After a few seconds the yellowBoiler ON LED will flash and a spark will light gas at the main burner, provided allair has been purged from the gas supply to the boiler. When the burner is lit andthe boiler is operating normally the yellow Boiler On LED will illuminatecontinuously and the four green modulation LEDs will show the output level theInstallation & Servicing Instructions Page : 19
WD209/1/2000 Chapter 4 : Commissioning The Keston Celsius 25 & 25Pboiler has determined is necessary for the heating load. If an air lock or otherblockage is present the unit may go to overheat or water pressure lockout. If thisoccurs clear the blockage and/or purge the air from the system, turn the usercontrol knob off (fully anticlockwise) and repeat the procedures.If ignition does not occur, the boiler on (yellow) LED will be extinguished and, atapproximately 20 second intervals, the electronic ignition system will make fourfurther attempts to light the burner.If the ignition is successful and the boiler is operating normally, the green (mains)LED and the boiler on (yellow) LED will be illuminated simultaneously.If after five automatic attempts the boiler still fails to ignite, the yellow (boiler on)lamp will be extinguished and the red (lockout) lamp will flash twice every twoseconds.If, after five manual attempts (to allow for purging of any air in the gas line), theboiler still fails to ignite (indicated by the red (lockout) lamp) refer to Section 5.2 -Fault Finding Flow Chart.f. Check for gas soundness between the gas service cock and connection tothe burner manifold.4.6 HOT FLUSHINGa. Allow the system to heat up, checking for water soundness.b. Follow instructions provided with the cleaning agent, ie Fernox Supafloc, orequivalent. 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. For sealedsystems, fill to the required InitialDesign Pressure.4.7 CHECKING THE GAS PRESSUREWith the boiler running measure the burnerpressure at the burner pressure test nipple.(pos. 5).NB:It is advisable to carry out this test withthe user control knob turned tomaximum and the system water cold toensure the boiler is running atmaximum rate.The gas setting is factory adjusted to within therequired range and should not needadjustment. If the reading is incorrect thencheck such factors as soundness of the air and flue pipe joints and the gas inlet pressure(pos. 3) (minimum 18 mbar required for natural gas, minimum 31 mbar required for LPgas). If all joints are sound and the gas inlet pressure is satisfactory check the gas inputby timing the gas meter as detail in Section 4.8 Timing The Gas Meter.4.8 TIMING THE GAS METER - NATURAL GASAfter the boiler has been started, and with no other appliances using gas, time the gasmeter to be certain that the unit is running at the proper gas input. Determine the cubicfeet of gas passing through the meter and determine the input in Btu per hour. Input mustbe within plus or minus 5% of the rated input.Time, in seconds, the time taken to pass 2 cubic feet of gas through the meter (ie onerevolution of a 2 cu ft dial) or 0.1 cubic metres if the meter is of the new metric digital type.The Keston Celsius 25 (natural gas model), when correctly set and operating at maximumrate, should take 84 seconds for 2 cubic feet of natural gas and 148 seconds for 0.1 cubicmetres of natural gas (assuming 1038 btu/h per cubic foot).If the meter timing is found to be incorrect when the boiler is firing at maximum ratecontact Keston Boilers Ltd for further guidance.Installation & Servicing Instructions Page : 20
Page 2 and 3: WD209/1/2000The Keston Celsius 25 &
Page 4 and 5: WD209/1/2000 Chapter 1 : General In
Page 6 and 7: WD209/1/2000 Chapter 1 : General In
Page 8 and 9: WD209/1/2000 Chapter 2 - Boiler Con
Page 18 and 19: WD209/1/2000 Chapter 3 : Installati
Page 20 and 21: WD209/1/2000 Chapter 3 : Installati
Page 24 and 25: WD209/1/2000 Chapter 4 : Commission
Page 26 and 27: WD209/1/2000 Chapter 5 : Fault Find
Page 42 and 43: WD209/1/2000 Chapter 6 : Servicing
Page 44 and 45: WD209/1/2000 Chapter 7 : Replacemen
Page 46 and 47: WD209/1/2000 Chapter 7 : Replacemen
Page 48 and 49: WD209/1/2000 Chapter 8 : Spare Part
Page 50 and 51: WD209/1/2000 Chapter 8 : Spare Part

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