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Installation and Servicing Instructions

FAN POWERED HIGH EFFICIENCY

MODULATING CONDENSING

GAS BOILER

Heat 45 & 55

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.

June 2015

UIN 208964 A04

Содержание HEAT 45

Страница 1: ...t 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 June 2015 UIN 208964 A04 ...

Страница 2: ... no no Nominal Heat Output for Space Heating Full Load P4 kW 45 55 Part Load P1 kW 14 6 18 Auxiliary Electricity Consumption Full Load elmax kW 0 135 0 128 Part Load elmin kW 0 03 0 026 Standby PSB kW 0 009 0 009 Seasonal Space Heating Energy Efficiency Full Load ƞ4 88 7 89 5 Part Load ƞ1 97 7 98 5 Standby Loss Pstby kW 0 08 0 11 Ignition Pign kW 0 0 Emissions NOx mg kWh 34 5 34 7 Annual Energy Co...

Страница 3: ...ass VIII 1 2 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 Efficie...

Страница 4: ...4 Keston Heat Installation Servicing ...

Страница 5: ...5 Keston Heat Installation Servicing ...

Страница 6: ...t connection of a control device not 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 Heat Model 45 55 Boiler Output non condensing Mean 70 C Max kW 42 6 52 1 Btu hr 145400 177800 Min kW 12 12 Btu hr 40900 40900 Boiler Output condensing Mean 40 C Max kW 45 55 Btu hr 153500 1877...

Страница 7: ...2 Water Treatment 10 Wiring Diagrams 29 Key to symbols IE Ireland GB United Kingdom Countries of destination RO Romania PMS Maximum operating pressure of water C53 A room sealed boiler which is connected via its separate ducts to two terminals that may terminate in zones of different pressure C13 A room sealed boiler which is connected via its ducts to a horizontally installed terminals that termi...

Страница 8: ...The Keston Heat boilers have been tested and certified to EN 483 EN 677 BSEN 60335 2 102 BSEN 55014 1 and BSEN 55014 2 for use with Natural Gas Detailed recommendations are contained in the following Codes of Practice BS 6891 Installation of low pressure gas pipework of up to 28mm R1 in domestic premises 2nd family gas BS 5440 Inst and maintenance of flues and ventilation for gas appliances of rat...

Страница 9: ...en the terminal MUST be protected by a purpose designed guard The minimum spacing between the balcony and the terminal should be 75mm in order to allow a terminal guard to be fitted Terminal guards are available from boiler suppliers Ensure that the guard is fitted centrally The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Det...

Страница 10: ...on recommend the use of Fernox Copal or MB1 or GE Betz Sentinel X100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions For further information contact Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ Tel 44 0 870 601 500 or Sentinel Performance Solutions The Heath Business and Technical Park Runcorn Ches...

Страница 11: ...tween multiple boiler installations 25mm Flue Air 850 59 59 Gas Flow Return 299 Flue Centre Line Flue Centre Line 500 118 86 206210 10155 Gas Pipe Flow Return Condensate Drain Flue Centre Line Flue Centre Line 131 360 70 155 81 68 30mm Minimum Top Clearance Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still req...

Страница 12: ... is for boiler protection only in the event that the flow and return isolators have been turned off If converting to a sealed system a separately sized PRV suitably sized will need to be fitted in addition on the heating circuit b A manual testing device c Provision for connection of a discharge pipe The valve or discharge pipe should be positioned so that the discharge of water or steam is visibl...

Страница 13: ...105 Auto Air Vent 208 Burner Fixings Kit 230 Fan 231 Gas Valve Kit 232 Venturi Kit 301 Dry Fire Thermistor Kit 302 Lead Ignition Kit 304 Ignitor Unit 305 Electrode Detection Kit 306 Ignition Electrode Kit 308 Fascia Plastic 309 HMI Board 310 Primary PCB 501 Jacket Assembly Keston Heat Kit 502 Door Assembly Keston Heat Kit 508 Flue Stat 509 Bulk Head Acccess plate 510 Pump ...

Страница 14: ...eck the contents against the list in Frame 6 Unpacking Note some items are contained within the top packing piece 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 INSTALLATION B A C D F G E H Pack Contents A Fully assembl...

Страница 15: ...ng outside of the building does not cause damage or personal injury 1 Drill 4 boiler top fixing holes with a 12mm 1 2 masonry drill and insert the plastic plugs provided for the wall mounting plate 2 Drill the 2 boiler lower fixing holes with a 12mm 1 2 masonry drill insert the plastic plugs provided 3 Fix the wall bracket supplied with boiler into place with 4 M10x70 hex head coach screws provide...

Страница 16: ...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 edition of I S 820 INSTALLATION Ke...

Страница 17: ...ternal diameter of 51mm i e nominal 50mm diameter muPVC solvent weld waste pipe Marley muPVC PVC C Solvent Weld Waste System 50mm and Polypipe System 2000 muPVC PVC C solvent weld waste 50mm are the only systems approved for this application The following pipes and fittings are approved Polypipe System 2000 muPVC solvent Weld Waste System 50mm Poly Pipe Code MU 301 4m length muPVC wastepipe 5 225 ...

Страница 18: ... from ground level a terminal guard must be fitted TERMINAL POSITIONS Flue Pipe Elbow Minimum Separation 140mm Acceptable range of air pipe siting Terminal Air Pipe 150mm Maximum lengths Due to the resistance presented by extended flue length a slight reduction in maximum boiler output will occur where combined flue and air lengths in excess of 16 0m 50mm muPVC are used In such cases the boiler ou...

Страница 19: ...n the outlet should not be nearer than 150mm fanned draught to an opening into the building fabric formed for the purpose of accommodating a built in element such as a window frame The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions boundary boundary J H L F I G I A B C D E H H K M N General Installations All parts of th...

Страница 20: ...from within the pipe Assemble using solvent weld 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 sock...

Страница 21: ...al face 5 Slide flue pipe into sleeve checking it 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 Term...

Страница 22: ... back to boiler Air Sleeve 3 5º back to boiler Bracket every 1 metre Flue 3 x 90º elbows 3 Straight lengths 2 5 1 5 3 5 4 14 5 Overall Flue Air 30m Air 4 x 90º elbows 4 Straight lengths 2 2 3 5 4 15 5 Calculations Fig 3 2 4 6 8 10 12 14 16 18 2 6 10 14 18 22 26 30 34 38 Acceptable operating area Keston Evomax55 Flue Air Pipe Length Flue Pipe Length m Air Pipe Length m 10 15 5 Keston Heat 55 Flue A...

Страница 23: ... where the heat load is greater than the boiler capacity a solution is to use multiple boiler arrangements The ideal way to control a multiple boiler installation is with our modulating sequencer See below a typical installation with our optional modulating sequencer kit This device is capable of controlling up to 5 boilers Additional kits are required for greater than this Legend 1 Non return val...

Страница 24: ...l Drain Connections The use of an externally run condensate drainage 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 min...

Страница 25: ... the house Minimum connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min Ø 19mm Internal pipe Min Ø 30mm Internal pipe Water weather proof insulation 75 Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Visible air break at plug hole Min Ø 19mm Internal pipe Sink basin bath or shower with integral overflow ...

Страница 26: ...ns as the building acts as a storage heater and can normally be left at least 24 hours without frost damage However if parts of the pipework run outside the building or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system see Frame 47 INSTALLATION Flow Return Tee supplied Tee supplied Isolation Valve supplied Isolation Valve supplied Safe...

Страница 27: ...A mains supply of 230V 50Hz is required The supply wiring MUST be suitable for mains voltage Wiring should be 3 core PVC insulated cable NOT LESS than 0 75mm2 24 x 0 2 mm and to BS 6500 Table 16 The fuse rating should be 5A Wiring external to the boiler MUST be in accordance with the current I E E BS7671 Wiring Regulations and any local regulations For Ireland reference should be made to the curre...

Страница 28: ...ional 5V DHW Tank Sensor Input Optional 0 10V Input SL1 SL2 1 The Lockout Volt Free Relay contacts will close 4 minutes after a Fault occurs 2 The Burner On Volt Free Relay contacts will close when the Burner is on 3 Only Keston Outside Sensor and DHW Tank Sensor kits should be connected to the boiler 4 The External Interlock and Interlock Relay Contacts connections are only used in conjunction wi...

Страница 29: ...ermistor Flame Sensor Electrode Pump Spark Electrode Spark Generator PCB Gas Valve SL1 KESTON SL2 Water Pressure Switch Diagnostic Connection Flue Therm istor Chassis Earth w bk bk bk bk br b b b b b b r or r bk bk bk bk bk bk bk bk bk pk or or bk y y b b r pk gry pk y g y g y g y br b g y g y g y g y g y br br g y br br br br br br r or or bk bk y o LEGEND b blue bk black br brown r red pk pink y...

Страница 30: ...t Demand a screen similar to the following will be displayed line 5 may vary depending on setup Line 5 indicates Switched Live or OpenTherm or 0 10V depending on which controls are connected to the boiler DHW 230V Operation Switched Live 2 On Burner On DHW Thermostat Flow Temp 80 C Domestic Hot Water Mode DHW Thermostat If there is an ongoing Domestic Hot Water Demand using a DHW Thermostat screen...

Страница 31: ...ler operates See Frame 40 for adjusting the system frost protection temperature setpoint Cylinder Frost Protect Burner Power 100 Outside Temp 10 C Frost Setpoint 5 C Hot Water Temp 4 C Cylinder Frost Protection Mode If a Domestic Hot Water Thermistor is connected to the boiler and the DHW temperature drops below 5C a screen similar to the following will be displayed Line 3 indicates the current op...

Страница 32: ...following is displayed Set Off Sum Win Standby Summer Winter Press for more Press SELECT and a screen similar to the following will be displayed Press and to change to required setting press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Setting Summer Winter and Standby Operation Note that Standby Mode will ...

Страница 33: ...e outputs will vary as the boiler operates Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Viewing the Fault History of the Boiler Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the maximum output of the boiler Kes...

Страница 34: ...d Set to 0 10V Input 0 10V Off 0 10V Capacity 0 10V Temperature Press and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation 10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Minimum CH Fan Speed Maximum CH Fan Speed Heat request is OFF Capacity Control 0 10V Ca...

Страница 35: ...er Press SELECT and the following screen will be displayed Set Night Setback On Off Press and to change to required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp Note Booster Function is only operational if Outside Sensor ...

Страница 36: ...he following screen is displayed Installer Mode Set Max Flow Temp Set Min Flow Temp Sys Frost Protect Soft Start Time Press SELECT and the following screen will be displayed Set Max Flow Temp 30 C Press and to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation 40 Keston He...

Страница 37: ...then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Note that the minimum setpoint after adjustment is 60s Enabling the Domestic Hot Water Thermistor Installer Mode Normal Operation Set Stat 1 Temp Set Stat 2 Temp The default is for a DHW Heat Demand to be indicated by a DHW Thermostat providing a 230V input...

Страница 38: ...otate the 1st stat clockwise until the following screen is displayed Installer Mode DHW Sensor Factory Settings Anti Legion Temp Anti Legion Enable Press SELECT and the following screen will be displayed Factory Settings Reset Press ENTER and a screen similar to the following will be displayed Factory Settings Are you sure Press Enter to Reset Press Select not to Reset Press ENTER and a screen sim...

Страница 39: ...r terminal block should be removed and a wire added from position 10 to the DHW Call input on the boiler Note that a hydraulic bypass is required to allow pump overrun Note that a Frost Stat can be connected into CH call S Plan Valve g g b b g y g y br o o br SL1 KESTON SL1 44 Keston Heat with Y plan system Boiler L Timer Fused Spur N L N CH On HW On HW Off Y Plan Valve E CH On R S On R S HW On HW...

Страница 40: ...The Outside Senor provided can be used with this configuration Note 2 The boiler can use a Tank Sensor rather than a Cylinder Thermostat which is available from Keston as a kit Note 3 A Frost Thermostat can be connected into CH Call SL1 KESTON SL1 INSTALLATION 45 Keston Heat with boiler control of Pump and diverter valve 46 Keston Heat with Single low loss header ...

Страница 41: ...er Fused Spur Switched Live External Controls L N E 47 Keston Heat with External Controls via switched live 0 10V input or opentherm The boiler must be set fpr 0 10V input See Frame 38 Boiler Fused Spur L N E 206210 10236 0 10V Source SL1 KESTON SL1 The boiler will automatically configure itself to an Opentherm input Boiler Open Therm External Controls Fused Spur L N E 206210 10236 SL1 KESTON SL1 ...

Страница 42: ...nstallation 1 Checks to ensure electrical safety should be carried out by a competent person 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable meter WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO...

Страница 43: ...r is set for winter operation see Keston Heat user interface basic 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 Keston Heat...

Страница 44: ... the kit 51 General Checks 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 ret...

Страница 45: ...ns of aluminium oxide build up spray water down the flueways Refer to Frame 58 6 Remove the sump cover and scrape out any deposits Refer to Frame 59 7 Remove the condensate trap and flush through with water Refer to Frame 60 8 Check that the flue terminal is unobstructed and that the flue system is sealed correctly 9 After completion of servicing refer to Frame 53 for reference to final safety che...

Страница 46: ...ve 5 Disconnect condensate pipe from upper flue elbow 6 Remove the flue tube elbow fixing screws and remove elbow by pulling downwards 7 Disconnect the electrical connections from the gas valve s 8 Disconnect the electrical connections from the fan 9 Undo the gas valve union nut nuts and retain the fibre washer s 10 Remove the four nuts screws retaining the fan assembly and remove the fan assembly...

Страница 47: ... panel Refer to frame 55 3 Remove the fan and gas assembly Refer to frame 56 4 Remove the burner Refer to frame 57 5 Remove the ignition and detection electrodes Refer to frame 64 and 65 6 Inspect the heat exchanger for signs of aluminium oxide deposits If necessary clean the heat exchanger by spraying water down the flue ways 7 Re assemble in reverse order checking seals and gaskets and replacing...

Страница 48: ...r damaged 9 Check the operation of the boiler Refer to frame 53 61 Fan Replacement 1 Refer to Frame 53 2 Remove the upper front panel Refer to frame 55 3 Remove the fan and gas assembly Refer to frame 56 4 Remove the screws retaining the venturi to the fan 5 Remove the extended nuts holding the venturi to the fan 6 Remove the screws retaining the fan plate 7 Transfer venturi and gas valve assembly...

Страница 49: ...efer to Frame 53 2 Remove the front panel Refer to frame 55 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 4mm 7 Reassemble in reverse order 8 Check the operation of the boiler Refer to frame 53 1 Refer to Frame 53 2 Remove the f...

Страница 50: ...n the boiler 4 Disconnect the 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 frame 53 68 Flow Return Thermistor Replacement 1 Refer to Frame 53 2 Remove the front panel Refer to ...

Страница 51: ...the control panel door 6 Remove the four M4 screws securing the access aperture cover plate 7 Remove the cover plate by pulling forward the flange at the top 8 Disconnect the pump power supply at the left hand terminal strip 9 Withdraw the power supply cable through the grommet 10 Remove the four M5 allen bolts securing the pump head to body A high torque is required to release these bolts a long ...

Страница 52: ...eck the operation of the boiler Refer to Frame 53 4 72 User Interface Board 1 Refer to Frame 53 2 Remove the upper front panel put the control panel into the service position Refer to Frame 57 3 Fit the earth strap provided with the spare PCB to your wrist and to a suitable earthed metal 4 Pull off all of the main PCB edge connectors refer to Frame 71 5 Remove the four plastic nuts retaining the m...

Страница 53: ...der Thermistor Wiring Check Cylinder Thmr 10K 25 C 2K at 66 C Go to Frame 84 CylinderThermistor Fault Ext Interlock Off External Interlock Operated Reset Interlock Go to Frame 85 Ext Interlock Off Ignition Lockout Check Gas to Boiler Check Condensate Pipe Refer to Instructions Reset Boiler False Flame Lockout Check Flame Sense Electrode Check Flame Sense Electrode Wiring Low Water Pressure Fill Sy...

Страница 54: ...r continuity visual condition and position refer to Frame 65 Check if the condensate pipe is blocked yes no Is the gas pressure available at the boiler 18mbar Check gas supply and rectify fault no yes Is the following voltage available at the Gas Valve approximately 215Vdc Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB no yes Unplug the Gas Valve is the ...

Страница 55: ...ition and position refer to Frame 65 Check if the Condensate Pipe is blocked Check if the Flue is blocked Replace as necessary yes If the boiler is Reset does the 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 See note Check wi...

Страница 56: ...sing a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 KΩ At 60 C expect 2 400 2 600 KΩ At 85 C expect 1 000 1 100 KΩ Is the thermistor value correct yes Check and replace wiring as necessary Replace main PCB no yes Is there continuity between the PCB and the Thermistor 81 Return Thermistor Fault Fit a new thermistor no Remove the Return Thermistor f...

Страница 57: ...expect 19 000 21 000 KΩ At 20 C expect 12 000 13 000 KΩ Is the thermistor value correct yes Ensure the wiring has continuity and is securely connected no Does the Outside Sensor wiring between the boiler terminal strip and the PCB have continuity and is securely connected yes Replace main PCB Securely connect the wiring at both the boiler and Outside sensor no Is the wiring securely connected at b...

Страница 58: ...mistor no Is the wiring securely connected at both the boiler and cylinder thermistor yes 85 External Interlock off Is an External Interlock connected to the boiler yes Has the External Interlock operated no Does the wiring from the Interlock Relay mounted within the boiler to the terminal strip have continuity and is securely connected Replace the Interlock Relay Kit Ensure that a link wire is se...

Страница 59: ...device connected to the boiler note that the Keston Prog Room Stat is an OpenTherm device Does the wiring from the boiler to the OpenTherm device have continuity yes no Rectify wiring from boiler to OpenTherm device no Is there 230Vac at A There is no voltage from the Timer Room Stat This is not a boiler fault Ensure voltage is supplied to the boiler by correcting external wiring no yes Is there 2...

Страница 60: ...Timer Cylinder Stat This is not a boiler fault Ensure voltage is supplied to the boiler by correcting external wiring Rectify wiring from boiler to OpenTherm device no yes Is the Diverter Valve stuck Replace the diverter valve no D C SL1 KESTON SL1 Is an OpenTherm device connected to the boiler note that the Keston programmable Room Stat is an OpenTherm device no Does the wiring from the boiler to...

Страница 61: ...ck to the main PCB connected securely yes yes Connect the cable from the main PCB to the user interface PCB securely no Is the cable from the main PCB to the user interface PCB connected securely yes yes Replace cable from main PCB to user interface PCB no Does the cable from the main PCB to the user interface PCB have continuity and is un damaged yes yes Check for shorts on Pumps Diverter Valve F...

Страница 62: ...er to Winter Mode see Frame 38 no Is the boiler set to Winter Mode yes yes Ensure between 2V and 10V is correctly connected to these terminals from the external device no Is a voltage of between 2V and 10V being supplied to F with positive and negative connected correctly yes yes Ensure that the wiring is securely connected and has continuity no Is the wiring from the boiler terminal strip to the ...

Страница 63: ...ditioned or copy parts that have not been clearly authorised by Keston Failure to do so could affect safety or performance of this appliance Our Parts team are also available to help with your Keston Spare Parts enquiries on 01482 498665 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 Appliance GC Numb...

Страница 64: ...d e s i g n a n d p e r f o r m a n c e o f i t s p r o d u c t s The right is therefore reserved to vary specification without notice Keston Heating PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 44 0 1482 443005 Fax 44 0 1482 467133 www keston co uk ...

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