WD536 The Keston C45, C40P, C55 & C55P C45 C40P C55 C55P Fan Powered High Efficiency Modulating Domestic Condensing Gas Boiler Installation and Servicing Instructions C45, C40P, C55 & C55P Models ISSUE: 1/2010 CE/PI No : 87CL131 C45 - GC No : 41-930-25 CE/PI No : 87BN14 C40P - GC No : 41-930-08 C55 - GC No : 41-930-09 C55P - GC No : 41-930-10 These instructions must be left either with the user or next to the site gas meter.
WD536 The Keston C45, C40P, C55 & C55P CONTENTS Section 0 Description 0.1 0.2 HANDLING INSTRUCTIONS List of contents Recommended handling procedure 1.1 1.2 1.3 1.4 1.5 1.6 1.7 GENERAL INSTRUCTION Description Boiler Schematic Related Documents Physical Data Performance Data C45 and C40P Performance Data C55 and C55P Optional Accessories 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.
WD536 The Keston C45, C40P, C55 & C55P 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 COMMISSIONING OF THE BOILER Initial Flushing Gas Supply Electrical Installation LP Gas Initial Firing Hot Flushing Combustion Testing Checking The Gas Pressure Timing The Gas Meter Handing Over To The User 5.1 5.2 5.3 5.4 5.5 5.6 5.7 FAULT FINDING Electrical Control Sequence Normal Operation Fault Modes Functional Flow Wiring Diagram Electrical Wiring Diagram Illustrated Wiring Diagram Exploded Assembly Diagrams 6.1 6.
WD536 The Keston C45, C40P, C55 & C55P 0. HANDLING INSTRUCTION 0.1 LIST OF CONTENTS The Keston C40P,C45 and C55(P) are supplied almost totally pre-assembled. Since the units use standard 50 mm muPVC pipe for the flue and air intake systems the boiler is packed in a single box without additional flue kit. All additional components are packed inside the boiler cabinet itself.
WD536 The Keston C45, C40P, C55 & C55P In the event the appliance must be fitted by one operative the integral circulating pump head and complete combustion fan/gas valve/venturi assembly can be removed from the appliance prior to lifting. However, the resulting weight will still be higher than considered acceptable for a one-man lift. Safety footwear and gloves are recommended PPE when lifting this appliance.
WD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 & C55P 1. GENERAL INSTRUCTION 1.1 DESCRIPTION The Keston C45, C40P and C55(P) are unique in concept and design. They comprise a high efficiency stainless steel heat exchanger coupled with a low emissions burner to deliver ultra high efficiency condensing mode operation within a compact wall hung cabinet. The unit automatically adjusts gas and air rate according to demand to give an output in the range of 12.6kW to 44.
WD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 and C55P the flueway and is drained at the base of the flue connection to the heat exchanger or drain points within the flue. Fig. 1.2 - Boiler Layout 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.
WD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 & C55P In addition, due account must be taken to the following Codes Of Practice: BS 6891 BS 6798 Low Pressure Installation Pipes Installation of Gas Fired Hot Water Boilers of Rated Input Not Exceeding 70kW BS 5449 : Installation Pumped Central Heating BS 5546 : Installation of Gas Hot Water Supplies for Domestic Purposes (2nd family gases) BS 5440.1 : Flues (for gas appliances of rated input not exceeding 70kW) BS 5440.
WD536 1.5 Chapter 1 : General Instruction PERFORMANCE DATA - C45 & C40P Nat. Gas (G20) Min. Input (Gross CV) Max. Input (Gross CV) Max. Output To Water (80/60oC Flow/Return) (50/30oC Flow/Return) Min. Output To Water (80/60oC Flow/Return) (50/30oC Flow/Return) Max. Burner Press.-Hot (Factory Preset) Gas Consumption After 10 mins Max. Operating Flow Temp. Max. Head (Open Systems) Max. Press. (Sealed System) Min. Head (Open Systems) Inlet Gas Pressure Recommended Temp Diff.
WD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 & C55P Keston Boilers Ltd declare that there are no substances harmful to health within the appliance or used during the production of the appliance. The C45 and C55 are intended for domestic and commercial EMC environments and on a governed G20 meter supply. The C40P and C55P is intended for domestic and commercial EMC environments and on a governed G31 supply. Seasonal Efficiency (SEDBUK) = 90.4% (C45), 92.5% (C40P), 90.2% (C55) & 92.
WD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 and C55P 1.7 OPTIONAL ACCESSORIES A range of accessories are available from Keston Boilers Ltd to compliment an installation. Terminal wall sealing collars are available to make good the external all face whilst working from the inside of the building using 50mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329) pipe or 75mm (actual dimensions are int.dia. = 68mm, ext.dia. = 78mm) Keston Composite pipe.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P 2. BOILER LOCATION All dimensions in mm. 2.2 SERVICE CONNECTIONS Gas, water, air and flue pipe, condensation, and electrical connections are as shown. Gas : 0.75 inch BSP female. Flow/Return 1 inch BSP female. 150 25 25 305 (W hen servicing appliance ) 10 (W hen appliance is operating ) An optional stand-off frame is also available which mounts behind the boiler to leave a 50mm deep space behind the boiler.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P cannot be touched by a person using the bath or shower. The C45, C40P and C55(P) are classified as IP20 (IPX0) and are therefore suitable for installation in Zone 3 areas, unless subject to hose down. 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.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P 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 3A supply via a fused double-pole switch having at least 3 mm (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.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P Gas pressures above or below these levels 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.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P Figure2.7.1 : Open Vented System Diagram Expansion Tank Expansion Pipe Minimum 9ft Height C45 or C55 Safety Valve 28mm Minimum (See note 2.7.1) Cylinder Valve FLOW RETURN L/S Valve By-pass Valve Rad. 2 Rad. 1 valves are closed, then the safety valve may be omitted. Note that the minimum static head required is 9 ft at the top of the boiler.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P Air Vent Hose Union bib tap C45 or C55 Expansion Vessel L/S Double Check Valve RETURN By-pass Bal. Valve Drain Cock HEATING CIRCUIT FLOW Hosepipe ( disconnected after filling ) Safety Valve Test Cock BS 1010:2 Stop Tap Hose Connector Figure 2.7.2 : Sealed System Diagram 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 oC.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P 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 immersion calorifier). 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.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P C45/C55 Safety Valve Expansion Vessel AAV Additional system pump. Primary flow 42mm Header Primary Return 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. System Pump Selection (if required) The C45, C40P and C55(P) feature an integral circulating 8.
WD536 Chapter 2 - Boiler Location Alternatively, where flue or air intake lengths of up to 45m are require, Glynwed Friatec DN70 pipe may be used. Both 50mm flue outlet terminal and 50mm air inlet terminal are supplied and are illustrated in Figure 2.8.1. Both terminals are identical. The flue and air terminals must be fitted to the appropriate duct using solvent weld adhesive. If 75mm terminals are required these can be obtained from your Keston Boilers stockist. Request part numbers C.17.2.26.00.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P 2.8.3 Boiler Output vs Flue Length Due to the resistance presented by extended flue length a slight reduction in maximum boiler output will occur where flue lengths in excess of 8m (50mm muPVC), or 24m (Friaphon DN70) are used. In such cases the boiler output will be reduced by 1% per additional 1m (50mm muPVC) and 1% per additional 3m (Friaphon DN70). 2.8.4 Slope 'Horizontal' flue outlet pipework MUST slope at least 3.
WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P Dimensions (mm) A Below or beside openable window, air brick, etc. Flue Terminal Air Inlet 300 50 75 75 C Below eaves (unventilated) 200 50 D Below balconies or car port roof. 200 50 E From vertical drain or soil pipes. 75 50 F From internal or external corner or boundary lines 200 50 G Above ground or balcony or roof.
WD536 2.11 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P CONDENSATE DRAINAGE Being a condensing boiler, the C45, C40P and C55(P) are 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. The connection to the boiler condensate outlet and the condensate discharge pipe work within the dwelling must be sealed.
WD536 Chapter 3 : Installation The Keston C45, C40P, C55 & C55P 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.
WD536 Chapter 3 : Installation The Keston C45, C40P,C55 & C55P Remember the flue pipe must slope downwards back towards the boiler and this is best achieved using 92.5o bends. a b c Using the template supplied within the boiler packaging mark the positions of the two holes for the flue and air pipes on the wall(s) or ceiling. Drill the two holes in the wall/ceiling, preferably using a core drill. Measure, cut and check the air and flue pipes to pass to the exit from the wall(s) or ceiling.
WD536 3.6 Chapter 3 : Installation The Keston C45, C40P, C55 & C55P WATER SYSTEM Connect the flow and return pipework to the boiler. Details of system requirements are given in Chapter 2 - Section 2.7 Water Systems. Connections : 1” BSPF For optimum performance after installation, this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS7592:1992, "Treatment of water in domestic hot water central heating systems".
WD536 3.9 Chapter 3 : Installation The Keston C45, C40P,C55 & C55P EXCHANGING A BOILER Before removing an existing boiler add Fernox Supafloc , or equivalent cleaning agent, in accordance with the manufacturers’ instructions. Open all radiator valves and fire the boiler. When the system is fully heated, shut off the gas supply and drain down the central heating system. Important The C45, C40P and C55(P) condensing boilers contain components which could be damaged or blocked by grease, dirt or solder etc.
WD536 Chapter 4 : Commissioning The Keston C45, C40P, C55 & C55P 4. COMMISSIONING OF THE BOILER Important: 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 followed precisely. It is essential that combustion is checked at high and low rate , as per Section 4.7, using a calibrated flue gas analyser set for the relevant gas type. 4.
WD536 Chapter 4 : Commissioning e. f. The Keston C45, C40P, C55 & C55P Adjust the upper rotary control knob, central heating temperature, to the maximum clockwise position. Adjust the lower rotary control know, DHW temperature, to the maximum clockwise position. Once a demand is received the left hand digit of the boiler display will change to “1” to indicate the boiler has entered the 10 second pre-purge phase. During this phase the boiler fan and pump will start to run.
WD536 Chapter 4 : Commissioning The Keston C45, C40P, C55 & C55P To measure CO2 levels in the Keston boiler remove the 1/8" plug from the flue outlet pipe spigot (Figure 5.7.4 item 18). Insert the probe of a calibrated combustion analysis meter and sample the gases as instructed in the test equipment's instructions. When firing the boiler for the first time since installation, the CO level at high rate may be between 100-220 ppm and between 50-80 ppm at low rate.
WD536 Chapter 4 : Commissioning The Keston C45, C40P, C55 & C55P LESS THAN THE CO2 LEVEL AT HIGH RATE. ADJUSTMENTS, IF MADE, SHOULD BE IN STEPS OF NO MORE THAN 1/8 OF A TURN. YOU MUST WAIT 1 MINUTE AFTER EACH ADJUSTMENT TO ALLOW THE SETTING TO STABILISE BEFORE TAKING A READING If following the above procedure, combustion levels described above at both high and low rate could not be obtained, please turn off the appliance and isolate the gas to the appliance.
WD536 4.10 Chapter 4 : Commissioning The Keston C45, C40P, C55 & C55P HANDING OVER TO THE USER It is important to fully explain the following: a. Procedure to light and turn off the boiler, including isolation of the electrical supply if necessary. b. The function of the lockout feature must be explained : If the display shows “E 02” this means that the boiler has failed to light. Press the “Reset” button and wait.
WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5. FAULT FINDING 5.1 ELECTRICAL CONTROL SEQUENCE When the external controls are calling for heat, power will be fed to the boiler connection strip at terminals SL1 (Switched Live 1) &/or SL2 (Switched Live 2) and N (Neutral). If the user control setting on the relevant knob is to a temperature less than the boiler flow temperature the display will show “6 nn” where nn is the actual boiler flow temperature.
WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P QUICK REFERENCE 5.2 NORMAL OPERATION The C45, C40P and C55(P) boilers feature a user display which shows actual flow temperature at all times (the last two digits of the display) and a status number (the first digit) which identifies what the boiler is doing at any given time.
WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5.3.2 LOCKOUT If the fault is persistent or more severe the boiler will lockout with a error code. When the boiler has entered this error mode it will not attempt to restart until the “Reset” button is pressed. ERROR CODES Display Description of fault E 00 Flame detected when not expected. Check boiler earth and probe condition. E 02 No ignition after restart.
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WD536 5.7 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P Exploded Assembly Diagrams 5.7.
WD536 Chapter 5 : Fault Finding 5.7.
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WD536 Chapter 5 : Fault Finding 5.7.5 The Keston C45, C40P, C55 & C55P Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 5.7.1) GC Number Code E93-126 88 E93-127 88 E93-130 106 95 167 109 101 E72-401 E93-135 Description C55/C55P/C45 Main Control Box (C.17.4.01.00.0 A) C40P Main Control Box (C.13.4.03.00.0 A) Control Panel (C.17.4.02.00.0) Terminal Block HV (C.17.4.41.00.0) Terminal Block LV (C.17.4.42.00.0) Thermal Fuse (C.08.4.21.00.0) Ignitor Cable (C.17.4.07.00.
WD536 Chapter 6 : Servicing The Keston C45, C40P, C55 & C55P 6. ROUTINE (ANNUAL) SERVICING To ensure the continued safe and efficient operation of the boiler it is necessary to carry out routine servicing at regular intervals. The frequency of the servicing will depend upon the particular operating conditions, but it is recommended that an annual service should be carried out by a qualified engineer. It is the law that any service work must be carried out by competent qualified persons.
WD536 Chapter 6 : Servicing b. c. d. e. f. g. h. i. j. k. l. m. n. The Keston C45, C40P, C55 & C55P Remove the burner head (Section 7.6) and inspect the burner appearance. Black markings or other discoloration's on the gauze indicate too much gas or a lack of air possibly due to a blocked air inlet. Any breakage's or damage to the burner mesh indicate the burner must be replaced. If necessary clean the burner with a mild household detergent and rinse under a hot running tap.
WD536 Chapter 7 : Replacement Of Parts The Keston C45, C40P, C55 & C55P 7. REPLACEMENT OF PARTS CONTENTS 7.0 GENERAL 7.1 PRECAUTIONS 7.2 ACCESS 7.3 REPLACEMENT PROCEDURE 7.4 ELECTRICAL COMPONENTS 7.4.1 CONTROL PANEL 7.4.2 BOILER FLOW & RETURN THERMISTORS 7.4.3 CABINET TEMPERATURE SENSOR 7.4.4 FLUE PROTECTION THERMOMSTAT 7.4.5 WATER PRESSURE SWITCH 7.4.6 MAIN CONTROL BOX 7.4.7 COMBUSTION BLOWER 7.4.8 GAS CONTROL VALVE / VENTURI ASSEMBLY 7.5 SPARK IGNITION/FLAME DETECTION ELECTRODE 7.6 BURNER 7.
WD536 Chapter 7 : Replacement Of Parts 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 The Keston C45, C40P, C55 & C55P Boiler Flow and Return Thermistors (Fig. 5.7.2 item 47) i) Isolate the appliance (Section 7.1) ii) Gain access (Section 7.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions. iv) Unclip the thermistor from the pipe. v) Reassemble (Section 7.
WD536 Chapter 7 : Replacement Of Parts 7.4.8 The Keston C45, C40P, C55 & C55P Gas Control Valve / Venturi Assembly (Fig. 5.7.3 item 163) i) Isolate the appliance (Section 7.1) ii) Gain access (Section 7.2) iii) Remove the push on connector block to the gas valve. iv) Unscrew the bolts (Fig 6.7.3 item 149) securing the gas inlet pipe to the gas control valve / venturi assembly. v) Unscrew the bolts securing the gas control valve / venturi assembly (Fig 6.7.
WD536 Chapter 7 : Replacement Of Parts xi) xii) xiii) xiv) The Keston C45, C40P, C55 & C55P Remove the two screws fixing the heat exchanger to the top mounting bracket (Fig 5.7.2 item 63) Remove the heat exchanger Reassemble (Section 7.3) Recommission (Section 4 - Commissioning) 7.8 CONDENSATE TRAP (Fig. 5.7.2 item 56) i) Isolate the appliance (Section 7.1) ii) Gain access (Section 7.2) iii) Disconnect the condensate line from the base of the heat exchanger.
WD536 Chapter 8 : Spare Parts Listings The Keston C45, C40P, C55P & C55P 8. SHORT SPARE PARTS LIST Item GC No 77 E93-137 E93-138 43 Part Denomination Item GC No PartDenomination C55 Burner C55P/C45/C40P Burner 44 E93-141 Burner Gasket E93-142 Ignitor Gasket 74 E93-143 Ignitor/Sensor Probe 47 E93-145 Flow/Return Thermistors 46 E72-332 Flue Thermostat 163 C45/C55 Gas Valve/Venturi Assy. C55P Gas Valve/Venturi Assy. C40P Gas Valve/Venturi Assy.
WD536 Chapter 8 : Spare Parts Listings The Keston C45, C40P, C55P & C55P SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination 47 48 46 88 88 106 73 163 163 163 56 74 77 77 36 52 109 E93-145 114-045 E72-332 E93-126 E93-127 E93-130 E93-147 Flow/Return Temperature Thermistor Water Pressure Switch Flue Protection Thermostat Main Control Box (C55/C55P/C45) Main Control Box (C40P) Control Panel Combustion Blower Gas Valve / Venturi Ass.
WD536 Chapter 9 : Benchmark Checklist Final The Keston C45, C40P, C55 & C55P 9. GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. ___________________ NOTIFICATION No.
WD536 Chapter 9 : Benchmark Checklist Final The Keston C45, C40P, C55 & C55P SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
WD536 The Keston C45, C40P, C55 C55P KESTON CONDENSING BOILERS IMPORTANT C45, C40P & C55(P) INSTALLATION KEY POINTS † † † † † † † † † † † † † † † Read Installation Manual Carefully Ensure that there is at least 9 feet head of water pressure at the top of the boiler . Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe. If the installation is a replacement the system must be flushed clean.
