Keston HEAT 2 45 Installation & Servicing Download Page 1

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When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and

performance

specification 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 specification and maintenance practices visit our website www.keston.co.uk

where you can download the relevant information in PDF format.

August 2020
UIN 220446 A01

INSTALLATION

& SERVICING

HEAT 2

45 55 45P 55P

Summary of Contents for HEAT 2 45

Page 1: ...e require Do not use reconditioned or copy parts that have not been clearly authorised by Keston For the very latest copy of literature for specification and maintenance practices visit our website www keston co uk where you can download the relevant information in PDF format August 2020 UIN 220446 A01 INSTALLATION SERVICING HEAT 2 45 55 45P 55P ...

Page 2: ...4 kW 45 55 45 55 Part Load P1 kW 14 6 18 14 6 18 Auxiliary Electricity Consumption Full Load elmax kW 0 135 0 128 0 113 0 130 Part Load elmin kW 0 03 0 026 0 026 0 024 Standby PSB kW 0 009 0 009 0 002 0 002 Seasonal Space Heating Energy Efficiency Full Load ƞ4 88 7 89 5 88 7 89 5 Part Load ƞ1 97 7 98 5 97 7 98 5 Standby Loss Pstby kW 0 08 0 11 0 073 0 082 Ignition Pign kW 0 0 0 0 Emissions NOx mg ...

Page 3: ... 1 5 2 3 4 3 5 5 PRODUCT FICHE The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a building as the efficiency is influenced 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 Efficiency in Tank ...

Page 4: ...4 Installation Servicing ...

Page 5: ...ing Circuit Configuration 45 2 29 7 DHW Configuration 47 2 29 8 Menu Configuration General Access level 50 2 29 9 Menu Configuration 50 2 30 Initial Lighting 51 2 31 General Checks 52 2 32 Handing Over 52 2 33 Safety 52 3 SERVICING 53 3 1 Servicing Schedule 53 3 2 Removal of Casing 54 3 3 Removal of Fan and Gas Valve Assembly 55 3 4 Removal of Non Return Valve 55 3 5 Removal of Burner 56 3 6 Heat ...

Page 6: ...approved by Keston could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations Keston Heat2 Model 45 45P 55 55P Boiler Output non condensing Mean 70 C Max kW 42 6 42 6 52 1 52 1 Min kW 12 12 12 12 Boiler Output condensing Mean 40 C Max kW 45 45 55 55 Min kW 12 7 12 7 12 7 12 7 Boiler Input Max Rate Nett kW 43 2 43...

Page 7: ...inal that terminates within a common pressure zone C53 A room sealed boiler which is connected via its separate ducts to two terminals that may terminate in zones of different pressure I2H An appliance designed for use on 2nd Family gases I3P An appliance designed for use on 3rd family gases II2H3P An appliance designed for use on 2nd and 3rd Family gases KESTON HEAT2 45 55 45P 55P Natural Gas Pro...

Page 8: ...Regulations Northern Ireland The Water Fittings Regulations or Water byelaws in Scotland The Current I E T Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations or...

Page 9: ...utlet pipes are used The material used for the flue outlet and the air intake systems must be muPVC PVC C to BS 5255 In addition the flue outlet and air intake pipework must be marked BSEN 1566 1 and the fittings must be marked BSEN 1329 Marley muPVC Solvent Weld System 50mm Polypipe System 2000 muPVC Solvent Weld System 50mm Wavin Osma Solvent Weld System and Polypipe Terrain 200 muPVC Solvent We...

Page 10: ...differential pressure valve which is installed in a bypass between the flow and return pipes The bypass should be fitted at least 6m from the boiler and should use a minimum size of 28mm pipe The bypass should be capable of allowing a minimum flow rate to achieve a temperature differential of no greater than 35o C at minimum rate 1 10 WATER TREATMENT These boilers incorporate an ALUMINIUM heat exc...

Page 11: ...acent to the boiler 1 12 CONDENSATE DRAIN Refer to Sections 2 15 3 7 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Installation must be in accordance with BS 6798 The drain outlet on the boiler is sized for standard 21 ...

Page 12: ...mm Sides of boiler 25mm Above boiler dependent upon the flue system see drawings Below boiler 300mm Clearance between multiple boiler installations 25mm 500 59 59 209 299 118 118 FLOW RETURN CONNECTIONS 81 GAS CONDENSE OUTLETS 68 B A 850 FLOW RETURN GAS CONDENSE Boiler Dim A Dim B 45 55 360 130 12 Installation Servicing SECTION 1 GENERAL ...

Page 13: ...ter undertakings b The installation should be capable of working with flow temperatures of up to 90o C and a temperature differential of up to 35o C at minimum rate only c All components of the system including the heat exchanger of the indirect cylinder must be suitable for a working pressure of 6 bar 87lbf in2 and temperature of 110o C Care should be taken in making all connections so that the r...

Page 14: ...or Unit 305 Electrode Detection Kit 306 Ignition Electrode Kit 308 Fascia Plastic 309 System Manager Board 310 Primary PCB 325 Bulkhead 501 Jacket Assembly Kit 502 Door Assembly Kit 510 Pump 511 Non return Valve Assembly 512 Air Inlet Damper 613 Air Inlet 700 Flue Adapter KEY 309 310 501 308 502 325 105 Data Plate 202 203 700 613 301 512 232 231 230 208 301 306 302 304 301 201 510 14 Installation ...

Page 15: ... contents against the list in Section 2 3 Unpacking Note some items are contained within the top packing piece 7 The boiler may now be stood on its base with the cardboard bottom packing piece still in place to protect the connections Due care should be taken when standing up the boilers with respect to their weights see Table 2 on page 6 x6 x6 x2 x1 x1 x1 x1 x1 x1 x1 x1 x1 x1 Boiler Connector Kit...

Page 16: ... operation masonry falling outside of the building does not cause damage or personal injury 1 Drill 4 boiler top fixing holes with a 12mm masonry drill and insert the plastic plugs provided for the wall mounting plate 2 Drill the 2 boiler lower fixing holes with a 12mm masonry drill insert the plastic plugs provided 3 Fix the wall bracket into place with 4 M10x70 hex head coach screws provided Not...

Page 17: ...e should be made to BS 6644 for inputs between 70kW and 1 8MW net In IE refer to the current edition of I S 820 The following notes are for general guidance only If ventilation is to be provided by means of permanent high and low vents communicating direct with outside air then reference can be made to the sizes below For other ventilation options refer to BS 6644 In IE refer to the current editio...

Page 18: ...m 50mm Polypipe Code MU 301 4m length muPVC wastepipe 5 225 MU 313 50mm x 45 deg muPVC obtuse bend MU 314 50mm x 92 5 deg muPVC swept bend MU 310 50mm muPVC straight coupling MU 316 50mm x 92 5 deg muPVC swept tee Marley muPVC Solvent Weld System 50mm Marley Code KP 304 50mm x 4m double spigot pipe KP32 50mm x 45 deg bend KSC3 50mm straight coupling KB3 50mm x 88 5 deg bend KT3 50mm swept tee Poly...

Page 19: ...6 0m 50mm muPVC are used In such cases the boiler output will be reduced by 0 8 per additional metre The maximum lengths of both air inlet pipe and flue outlet pipe when no bends are used are as detailed in figs 3 4 However each bend used has an equivalent length that must be deducted from the maximum straight length stated in figs 3 4 Knuckle bends must not be fitted A 92 5º swept elbow is equiva...

Page 20: ... for fanned draught appliances TERMINAL POSITIONS Flue Pipe Elbow Minimum Separation 140mm Acceptable range of air pipe siting Terminal Air Pipe 150mm A A B A A 600mm B 2000mm The flue terminal shall not penetrate the shaded area of the roof If chimney penetrates dotted area such that A is less than 300mm B shall not be less than 300mm When running flue pipes vertically they MUST be a minimum of 1...

Page 21: ...eld cement the pipework from the boiler connections to the exit from the first wall ceiling remount the boiler if removed Care must be taken when applying solvent weld to ensure it does not come into contact with the sample plug When pushing pipe through walls ensure grit and dust is not allowed to enter the pipe Ensure pipes are fully engaged into sockets and solvent welded with no leaks Using th...

Page 22: ... is free to slide 6 Slide Flexible wall seal over flue pipe and push centre ring up to sleeve flange when cold 7 Locate wall plate over flexible wall seal and clamp in place using the raw plug pack 8 Affix flue terminal 9 During boiler test check that the flue end is free to expand and contract with flexible wall seal Flue Sleeve Flue Pipe Flue Terminal Flexible Wall Seal Wall Plate Flue Sleeve Fl...

Page 23: ...3 x 1m 3m Straights 4 6 1 1 12m Total 15 5m Calculations 2 13 FLUE INSTALLATION EXAMPLE KESTON HEAT 45 1 5m 2 5m 1 5m 1 5m 3m 2m 3 5m 3m Air Sleeve Bracket every 1 metre Flue 3 x 90º elbows 3 Straight lengths 2 5 1 5 3 5 3 13 5 Overall Flue Air 25 5m Air 4 x 90º elbows 4 Straight lengths 1 5 1 5 3 2 12 Calculations 3 5º back to boiler 3 5º back to boiler 23 Installation Servicing SECTION 2 INSTALL...

Page 24: ...can be achieved by cascading up to six Keston Heat 2 boilers This can be achieved by the use of the Keston Heat 2 boilers fitted side by side on the wall or frames in conjunction with the required header kits 24 Installation Servicing SECTION 2 INSTALLATION FLUE OUTLET ...

Page 25: ...nage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to t...

Page 26: ...ensate Pump Typical Method see manufacturers detailed instructions Figure 4 Connection of condensate Drainage Pipe to External Soil Vent Stack Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Figure 6 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away 2 16 BOILER WATER CONNECTIONS The boiler flow and ...

Page 27: ...in the internal boiler pipe work and is irrespective of the fact that manifold headers are used This pressure drop will be experienced on each individual boiler regardless of single or multiple installation In order to determine the actual working gas pressure at the boiler inlet the figure from the table below must be added to the measured pressure refer to Section 3 3 Keston Heat Gas Line Pressu...

Page 28: ...r run S OT or P2 P PC2 Room S RT SC Boiler fault Outside S OT P1 0 10V P PC Tank S HWS or P2 SL1 RT PC P3 P HWSC SL2 TS HWS Standalone Boiler Partial Hydraulics Single Boiler with a CT Pump Circuit and DHW Tank S RT PC RT PC T HWS S OT P PC P HWSC TS HWS S HWS Opentherm or SL1 Boiler CT Pump Circuit Hot Water Storage SL2 or SL2 and T HWS Opentherm DHW bit Single Boiler with 2 x CT Pump Circuits S ...

Page 29: ... CT1 P1 0 10V V CT1 SL2 TS HWS or P2 S OT or P2 Tank S RT CT2 P1 0 10V Opentherm1 or SL1 Opentherm2 or SL2 Boiler CT Pump Circuit CT Pump Circuit Single Boiler with CT and HWS Zone Circuits S RT PC1 RT PC1 TS HWS S OT V CT V HWS TS HWS S HWS Opentherm or SL1 Boiler CT Pump Circuit Hot Water Storage SL2 or SL2 and T HWS Opentherm DHW bit Single Boiler with 2 x CT Zone Circuits S RT CT1 RT PC1 S RT ...

Page 30: ... 4A Wiring external to the boiler MUST be in accordance with the current I E T BS7671 Wiring Regulations and any local regulations For Ireland reference should be made to the current ETCI rules for electrical installations Connection should be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm contact separation in both poles or a plug a...

Page 31: ...cal setting SL1 Heating Circuit 1 SL2 Heating Circuit 2 DHW l3 Optional Interlock input 230V 50Hz l4 Auxiliary Mains Supply Output 230V 50Hz Live Neutral Internal Pump power connection I5 Multifunction Volts Free Relay Outputs 24V DC to 230V 50Hz Typical setting MFR1 Heating Circuit 1 Pump MFR2 DHW Circuit Pump Internal Pump PE connection I6 MFR3 Burner On Indication MFR4 Boiler Fault Indication P...

Page 32: ...phase as the boiler mains supply preferable through the same isolator External controls via switched live demand Showing internal Boiler Pump controlled directly from PELV PWM control I1 I2 I3 I4 I5 I6 1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 L N PE Demand inputs 230V 50Hz Interlock PE C MFR1 MFR2 L N 230V 50Hz Auxiliary Fused Spur Isolator SL1 L SL2 L L N PE Mains Supply Switched Live Volts Free...

Page 33: ...ed via remote volts free enabled from MFR1 External controls via OpenTherm Master HC Pump controlled via remote Volts Free enable from MFR1 I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8 L N PE PELV Volts Free Contacts Mains Voltage 230V 50Hz SL2 L L L N PE SL1 L N C NO PE C GND S4 GND OT2 OT2 S1 GND S2 10V 10V GND OT1 OT1 GND S3 NO I...

Page 34: ...ontrols via Switched Live or OpenTherm or Room temperature sensors for Two Heating Circuits Heating Circuit Pumps controlled directly from MFR1 and MFR2 I1 I2 I3 I4 I5 I6 I8 I9 I10 1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8 Not an available option L N PE Heating Circuit 2 Pump Pump Room Thermostat HC2 Optional HC Room Thermostats Heating Circuit 1 Room Temperat...

Page 35: ...ld be inspected and tested for soundness and then purged in accordance with the recommendations of the relevant standards listed on page 8 by the installer In IE refer to I S 813 2002 Connecting Multiple Room Sensors Connecting Multiple Room Sensors One Two Three Four Note Where multiple sensors are used the overall accuracy of temperature measurement is reduced this can be compensated for by trim...

Page 36: ...and highlight the first menu item Enter the highlighted menu sub menu or parameter if in a menu or sub menu If in a parameter setting select a parameter which will then flash for adjustment once adjusted using the rotary knob press again to store and move on E BACK BUTTON In a menu return to the previous menu layer In parameter setting exit the parameter without storing the value In a guided assis...

Page 37: ...ump used to circulate water through the Heating and or DHW circuits as well as either the boiler or the secondary side of a LLH or Plate H X Shared boiler pump used to only circulate water through more than one boiler Shunt pump used to circulate an amount of water between flow and return to limit the temperature differential Boiler pump used to only circulate water through a single boiler HC pump...

Page 38: ...hen scan the bus to determine if any other devices are present The current date followed by the time can now be set Controller Slave Master Controller Slave Master Language English Francais Nederlands Date Year 2018 Month 7 Day 4 Done Time Hour 0 Minute 0 Auto su wi time Done Date Year 2018 Month 7 Day 4 Done Time Hour 0 Minute 0 Auto su wi time Done Date Year 2018 Month 7 Day 4 Done Time Hour 0 M...

Page 39: ... config 2 Standalone non VariCAN cascade boiler with the following configuration Plant control enable on SL1 with a modulating boiler pump and with options for Boiler run and Boiler fault on MFR3 and MFR4 respectively Basic pre config 3 Standalone boiler with the following configuration Plant options for a modulating System pump with Boiler run and Boiler fault on MFR3 and MFR4 respectively One He...

Page 40: ...has a pump that is shared across the plant then select the output that is used to control it from the list Otherwise select None System Pump If the boiler has a Plant System Pump connected then select the output that is used to control it from the list Otherwise select None Once an output has been configured the selected function is shown in brackets behind the output name Set HC number HC 01 Boil...

Page 41: ...mand This setting determines the switching point at which demand is expected by the system anything below this is at keep alive voltage Select loc n of shunt pump None PWM 0 10V MFR1 Select loc n of shunt pump None PWM 0 10V MFR1 MFR2 Select loc n of shunt pump PWM 0 10V MFR1 MFR2 MFR3 Select loc n of shunt pump MFR1 MFR2 MFR3 MFR4 System fault indication MFR1 MFR2 MFR3 MFR4 Configure 0 10V input ...

Page 42: ...ne Single Thursday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Friday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Saturday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Sunday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Monday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 ...

Page 43: ... 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Sat Sun Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Holidays Period 2 Start 01 01 2000 End 01 01 2000 Done Holidays Period 1 Start 01 01 2000 End ...

Page 44: ...rn to Note The boiler number now has a tick next to it showing that it has been configured If you completed the boiler configuration select Done Boiler fault indication None PWM 0 10V MFR1 Local boiler pump Boiler fault indication None PWM 0 10V MFR1 Local boiler pump MFR2 Boiler fault indication PWM 0 10V MFR1 Local boiler pump MFR2 MFR3 Boiler on indication Boiler fault indication MFR1 Local boi...

Page 45: ...mperature unless specific configuration options are chosen Switched Live 1 input function The SL1 input can be configured as a HC function if this is not required select None Select loc n of HC pump None PWM 0 10V MFR1 Select HC to configure HC1 Boiler1 1 Done Select loc n of HC pump None PWM 0 10V MFR1 MFR2 Select loc n of HC pump PWM 0 10V MFR1 MFR2 MFR3 Select loc n of HC pump MFR1 MFR2 MFR3 MF...

Page 46: ... 00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Configure holiday prog No Yes Holidays Period 1 Start 01 01 2000 End 01 01 2000 Done Single Tuesday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Sat Sun Period 1 06 00 22 00 Period...

Page 47: ...lect Yes if not select No DHW pump location If the DHW circuit has an individual DHW Pump connected then select the output that is used to control it from the list Otherwise select None Configure pump protection No Yes Configure pump protection No Yes DHW priority No Yes DHW priority No Yes Select HC to configure HC1 Boiler1 1 ü Done Select HC to configure HC1 Boiler1 1 ü Done Select DHW to config...

Page 48: ...clock No Yes Use an internal timeclock No Yes Time clock Single Multiple Single Monday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Tuesday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Wednesday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Thursday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 0...

Page 49: ...to re configure a function in the boiler then the appropriate access level needs to be enabled Time clock Single Multiple Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Sat Sun Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Mon Fri Period...

Page 50: ...pending upon which access level was selected Installer 1 Installer 1 Confirm 2 29 9 Menu Configuration All menus and setting will now be available for that particular access level There will now also be the chance to reconfigure different functions within the system Configuration General Recommission system Recommission Plant Configuration General Recommission System Recommission Plant Recommissio...

Page 51: ... operating instructions 7 The boiler will commence the ignition sequence If after 5 attempts the boiler has failed to light then it will lock out Press the reset button to restart the ignition sequence 8 Operate the boiler for 10 minutes and check the gas rate Table 1 You should be able to read at least 90 of the nominal If this is not possible contact the boiler manufacturer Standby yes yes yes y...

Page 52: ... HANDING OVER IMPORTANT Point out to the owner that the boiler must have regular maintenance and cleaning at least annually in order to ensure reliable and efficient operation Regular attention will also prolong the life of the boiler and should preferably be performed at the end of the heating season After servicing complete the service Section of the log book and return to the owner or their rep...

Page 53: ... the nominal unless the maximum length of flue air inlet is used then gas input is at least 80 of the nominal once compliance with the note above is ensured then no further action need be taken If not proceed to 4 4 Remove and clean the burner Refer to Sections 3 6 If after cleaning the burner the gas input is not at least 90 of the nominal then contact the boiler manufacturer 5 Inspect the heat e...

Page 54: ...ft the panel to remove 3 Lower the control panel to the service position 3 2 REMOVAL OF CASING Side Panels Note Removal of side panels is not required for normal service 4 Remove the screws from the top and bottom of the side panels 5 Re assemble in reverse order 54 Installation Servicing SECTION 3 SERVICING SERVICING ...

Page 55: ...t clean as necessary 11 Re assemble in reverse order replacing all gaskets 3 5 3 9 7 6 8 Inlet Gas Pressure Test Point 3 4 REMOVAL OF NON RETURN VALVE 1 Refer to Section 2 32 2 Remove the upper front panel Refer to Section 3 2 3 Remove the screw retaining the lower flue manifold to the heat exchanger 4 Lift up the flue Sections and disengage from the sump then pull the flue Sections downwards and ...

Page 56: ...d following a diagonal tightening sequence twice All fittings should be secured firmly 9 Check the operation of the boiler Refer to Section 2 32 4 7 6 3 5 REMOVAL OF BURNER 1 Refer to Section 2 32 2 Remove the front panel Refer to Section 3 2 3 Remove the fan and gas assembly Refer to Section 3 3 4 Remove the burner 5 Remove the ignition and detection electrodes Refer to Sections 3 12 3 13 6 Inspe...

Page 57: ...he venturi to the fan 5 Transfer venturi and gas valve assembly to the new fan 6 Reassemble in reverse order replacing all gaskets 7 Check the operation of the boiler 8 Refer to Section 2 32 3 10 REMOVAL OF GAS VALVE 1 Refer to Section 2 32 2 Remove the upper front panel Refer to Section 3 2 3 Remove the fan and gas assembly and air inlet damper Refer to Section 3 3 4 Remove the 3 screws holding t...

Page 58: ... Section 2 32 2 Remove the front panel Refer to Section 3 2 3 Pull off the spark lead and earth connection 4 Remove the two retaining cap head screws 5 Pull out the electrode and pull off the old gasket 6 Replace with new electrode and gasket supplied checking the spark gap is 3 5mm 1 7 Reassemble in reverse order 8 Check the operation of the boiler Refer to Section 2 32 1 Refer to Section 2 32 2 ...

Page 59: ...electrical connections from the switch 5 Unscrew the water pressure switch 6 Refit new switch 7 Connect electrical connections 8 Refill the system ensuring all the air escapes via the air vent 9 Reassemble in reverse order 10 Check the operation of the boiler Refer to Section 2 32 3 16 REMOVAL OF FLOW RETURN HEAT EXCHANGER THERMISTOR 1 Refer to Section 2 32 2 Remove the front panel Refer to Sectio...

Page 60: ... remove from the bracket 6 Replace unit and reasseble in reverse order ensuring all connections are fully inserted 7 Check the operation of the boiler Refer to Section 2 32 4 1 Refer to Section 2 32 2 Remove the front panel Refer to Section 3 2 3 Disconnect the electrical connections from the thermistor 4 Unscrew the thermistor 5 Fit the new thermistor with gasket seal DO NOT overtighten 6 Re asse...

Page 61: ...s a long 4mm T bar Allen key is required 11 Withdraw the pump head from the body 12 Remove the PWM cable plug from the pump head 13 Remove the pump head through the bulkhead aperture Removal of side panel will allow pump head to be rotated through the space between the bulkhead and the sump Care should be taken to avoid water spillage onto the PCB connections when withdrawing the pump head through...

Page 62: ... 2 32 3 21 REMOVAL OF SYSTEM MANAGER 6 6 7 7 6 3 20 REMOVAL OF MAIN PCB 1 Refer to Section 2 32 2 Isolate the electrical supply to the boiler and fully isolate the boiler from any external supply 3 Remove the upper front panel and put the control panel into the service position Refer to Section 3 2 4 Fit the earth strap provided with the spare PCB to your wrist and to a suitable earthed metal 5 Th...

Page 63: ...rmistors Flue Flue Heat Ex Heat Ex 0 10V 1 OpenTherm 0 10V CAN 5V CAN GND CAN 24V GV Chassis PE C Chassis PE NO PE C NO PE CH1 Boiler System To internal boiler pump CH2 DHW Shunt Valve Pump C NO C NO Boiler Run Boiler Fault PELV X7 ChipCom Pump DHW NO Burner ON NO Burner ON COM Lockout NO Lockout COM Pump DHW COM X9 Pump CH COM 0 10V OT Turbine 5V APS b IGN Neutral Valve AC L1 Valve DC Valve DC Va...

Page 64: ...s CAN Bus CAN VCCon CAN Mode CAN Tx CAN Bus CAN Bus 4 2 SYSTEM MANAGER WIRING DIAGRAM 4 3 OPTIONAL VARICAN ADAPTER WIRING DIAGRAM 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 7 OpenTherm lead CC 5V CC GND CC 24V Varican TTL lead from KM821 i5 X8 ChipCom SM X3 CC TX CC RX CAN Mode CAN Tx CAN Rx CAN 5V CAN GND OpenTherm SM X2 OT2 OT2 OT1 OT1 CAN 24V Terminal CAN TTL SM X1 CAN VCCon From I9 64 Installation Servicin...

Page 65: ...lled and any of the faults may be selected to retrieve the fault description KESTON HEAT2 55kW Operation Htg With temp Flow setp 82 ºC Flow temp 40 4ºC Fault List Fault Fault Fault Fault Description Fault description for the actual error Press Reset Fault List Fault Fault Fault Fault List Fault Fault Fault Description Fault description for the actual error Press Reset Fault Operation Htg With temp...

Page 66: ...rheat 32 n a B Flow return reversed 33 5 11 B Flow gradient supervision 36 5 3 B Flue gradient supervision reserved 37 n a B Blocking delta temp flow return 38 5 3 L Lockout flow overheat 39 5 3 L Lockout return overheat 40 5 3 L Lockout flue overheat flue thermistor Lockout thermal fuse thermal fuse 41 1 6 B Blocking due to heat exchanger overheat 42 5 SYSTEM FLAME FAN HYDRAULIC ETC B Blocking du...

Page 67: ...rtz crystal error 80 contact service provider B 0 10V Input out of range 81 Info INTERNAL SYSTEM L Retails supervision error COM Valve Retails 93 Reset contact service if repeated L Request for re update 94 contact service provider B Blocking due to programming mode 95 contact service provider L Lockout parameter mismatch 96 contact service provider L Lockout parameter set 97 contact service provi...

Page 68: ...oximately 215Vdc for 45 55kW Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB no yes Unplug the Gas Valve is the resistance between the outside pins between 1kΩ and 10kΩ Replace Gas Valve no yes Check Spark Generator and associated Harness for continuity visual condition and position Refer to Section 3 18 Are these functioning correctly Replace Spark Gener...

Page 69: ...he boiler Ignite for a short time and then Extinguish no Check Gas Supply and rectify fault no Is the Gas Pressure available at the boiler 18mBar yes Is the following voltage available at the Gas Valve approximately 215Vdc for 45 55kW Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB no yes Check Spark Generator and associated Harness for continuity visual ...

Page 70: ...s no Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated Does the wiring have continuity yes Replace main PCB Replace Fan no yes Is there 230Vac at the blue and brown connections to the 3 way connection on the Fan 5 9 FLOW RETURN THERMISTOR HEAT EXCHANGER OR FLUE THERMISTOR FAULT Fit a new thermistor no Disconnect the electrical connection to the F...

Page 71: ...place main PCB Change menu setting for DHW Sensor to Switched Live no Is a DHW Thermistor connected to the boiler yes Securely connect the wiring at both the boiler and cylinder thermistor no Is the wiring securely connected at both the boiler and cylinder thermistor yes yes Is an External Interlock connected to the boiler yes Has the External Interlock operated no Does the wiring from the Interlo...

Page 72: ... configuraiton 1 230V supply from isolate or boiler MFR 2 Volts free enable from MFR 3 0 10V signal from boiler 0 10V output Rectify fault as required Set for day or in a timed on period operation Ensure that the Timer and Room Thermostat are calling for heat Open the Radiator Valves Check wiring continuity R 25ºC 10 000 Ω Check system for water circulation This is not a boiler fault Ensure voltag...

Page 73: ...or the pump depending on the configuraiton 1 230V supply from isolate or boiler MFR 2 Volts free enable from MFR 3 0 10V signal from boiler 0 10V output Rectify fault as required There is no voltage from the timer cylinder stat This is not a boiler fault Ensure voltage is supplied to the boiler by correcting external wiring Check thermister and external wiring and replace as necessary Does the wir...

Page 74: ...s the Fuse on the combination manager PCB OK yes yes Replace combination manager PCB no Replace the system manager PCB still no display 5 17 0 10V INTERFACE Configure the boiler to accept a 0 10V input no Is the boiler configured to accept a 0 10V Input yes yes Set the boiler to Day mode no Is the boiler set to Day mode yes yes Ensure the configured voltage demand threshold and 10V is correctly co...

Page 75: ...that have not been clearly authorised by ourselves Failure to do so could affect safety or performance of this appliance When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model e g 55 Appliance GC Number UK only e g 41 930 51 Boiler Serial Number e g ACK 205962000000480101 75 Installation Servicing SECTION 6 S...

Page 76: ... BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as sp...

Page 77: ...eck that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas su...

Page 78: ...78 Installation Servicing NOTES ...

Page 79: ...79 Installation Servicing NOTES ...

Page 80: ... Hull East Yorkshire HU5 4JN Tel 01482 443005 Registration No London 322 137 Keston by Ideal Heating Helpline 01482 443005 Ideal Heating Parts 01482 498665 www keston co uk Manufactured under an ISO 9001 registered quality management system FM 59915 Ideal Boilers Ltd pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary spe...

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