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Keston C45 Installation And Servicing Instructions

Fan powered high efficiency modulating domestic condensing gas boiler
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WD536
C45 C40P C55 C55P
Fan Powered High Efficiency
Modulating Domestic Condensing Gas Boiler

Installation and Servicing Instructions

C45, C40P, C55 & C55P Models
These instructions must be left either with
the user or next to the site gas meter.
34 West Common Road, Bromley, Hayes, Kent BR2 7BX, UK
Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459
email : info@keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2 2002
ISSUE:
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
KESTON BOILERS LIMITED
SEDBUK A RATED
The Keston C45, C40P, C55 & C55P
1/2010
web : www.keston.co.uk

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Summary of Contents for Keston C45

  • Page 1: Installation And Servicing Instructions

    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...

  • Page 2: Table Of Contents

    WD536 The Keston C45, C40P, C55 & C55P CONTENTS Section Description HANDLING INSTRUCTIONS List of contents Recommended handling procedure GENERAL INSTRUCTION Description Boiler Schematic Related Documents Physical Data Performance Data C45 and C40P Performance Data C55 and C55P Optional Accessories BOILER LOCATION Dimensions &...
  • Page 3 WD536 The Keston C45, C40P, C55 & C55P 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 4.10 Handing Over To The User...

  • Page 4: List Of Contents

    0. HANDLING INSTRUCTION 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.
  • Page 5 Safety footwear and gloves are recommended PPE when lifting this appliance. The C45 and C55 boilers can be fitted in compartments with very small clearances required around the appliance (refer to Section 1.4). Due consideration should therefore be given to access within the compartment for lifting and positioning.

  • Page 6: General Instruction

    The unit automatically adjusts gas and air rate according to demand to give an output in the range of 12.6kW to 44.9kW (C45 & C40P) and 14.3kW to 55.2kW (C55 & C55P). The integral Grundfos pump is automatically controlled to best match water flow rate to heat output &...

  • Page 7: Related Documents

    The boiler will turn off when the flow temperature exceeds 10 The C45, C40P and C55(P) feature an integral pump exercise function which will run the pump, without firing the boiler, for 10 seconds in the event the boiler is on standby for in excess of 24 hours without firing.

  • Page 8: Physical Data

    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 Low Pressure Installation Pipes BS 6798 Installation of Gas Fired Hot Water Boilers of...
  • Page 9 WD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 and C55P PERFORMANCE DATA - C45 & C40P C40P Nat. Gas (G20) LPG (G31) Min. Input (Gross CV) kW/(Btu/h) 12.9/(43,900) 12.6/(43,000) Max. Input (Gross CV) kW/(Btu/h) 45.6/(155,600) 43.2/(147,400) Max. Output To Water...
  • Page 10 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.

  • Page 11: Optional Accessories

    Chapter 1 : General Instruction The Keston C45, C40P, C55 and C55P 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.

  • Page 12: Boiler Location

    WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P 2. BOILER LOCATION All dimensions in mm. DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown to allow subsequent servicing, and safe operation. However, larger clearances may be required during installation.
  • Page 13 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.

  • Page 14: Boiler Size Selection

    2.4.4 Wiring Expample - Honeywell S-Plan for DHW and (Optional) Weather Compensated Heating Control BOILER SIZE SELECTION The C45, C40P and C55(P) will automatically adjust heat output and pump speed to match the system requirements at any given time. Efficiency and combustion levels are maintained at optimum levels throughout the possible output range.

  • Page 15: Water Systems

    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 at a supply rate of 46kW for the C45 and 57kW for the C55 model.
  • Page 16 9 ft at the top of the boiler. Although suitable for open vented systems with combined feed and vent arrangements, the C45, C40P and C55(P) are low water content boilers. 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.
  • Page 17 WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P Air Vent Hose Union bib tap Expansion Vessel Double Check Valve RETURN By-pass Bal. HEATING CIRCUIT Hosepipe Valve ( disconnected Drain FLOW after filling ) Cock Safety...
  • Page 18 1394. It is advisable to fit a locksheild valve on the cylinder return to enable balancing of the flow rate through the cylinder. The Keston Spa range of stainless steel unvented cylinders are an ideal option for use with the Keston range. The Keston Spa range combine exceptional recovery times with durable, long life stainless steel construction and all associated controls.

  • Page 19: Flue System

    WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P C45/C55 Safety Valve Additional system pump. Primary flow Expansion 42mm Vessel 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.
  • Page 20 WD536 Chapter 2 - Boiler Location The Keston C45, C40P, C55 & C55P 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.
  • Page 21 The Keston C45, C40P and C55(P), 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”...

  • Page 22: Compartment Installation

    2.10 COMPARTMENT INSTALLATION The C45, C40P and C55(P) models operate with very low heat emission levels. As a results the boilers can be installed in a compartment without ventilation. Installation & Servicing Instructions...

  • Page 23: Condensate Drainage

    The Keston C45, C40P, C55 & C55P 2.11 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.

  • Page 24: Installation Of The Boiler

    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.

  • Page 25: Condensate Drainage

    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 92.5 bends. 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.

  • Page 26: Water System

    WD536 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...

  • Page 27: Exchanging A Boiler

    It is essential that sludge or scale is removed from an existing system. The guarantee provided with the Keston C45, C40P and C55(P) does not cover damage caused by system debris or sludge.

  • Page 28: Commissioning Of The Boiler

    INITIAL FLUSHING All waterways within the Keston C45 and C55 are either copper, high alloy stainless steel or aluminium. As a result water treatment chemicals for central heating boilers such as Fernox MB1, Sentinel X100 or equivalent, are suitable.
  • Page 29 ) levels will be between 8 & 8.2% (C45 low rate), 8.3 & 8.5% (C55 low rate), 8.2 & 8.7% (C45 high rate) and 8.6 & 9% C55 (high rate) and carbon oxide (CO) levels will be between 5 to 20 ppm (low rate) and 50 to 150 ppm (high rate) for natural gas. For LP gas, carbon dioxide (CO ) levels will be between 9.3 &...
  • Page 30 8% to 8.2% for C45 and 8.3% to 8.5% for C55 with a corresponding CO level of 5 to 20 ppm for natural gas and 9.3% to 9.5% for C40P and 9.6% to 9.8% for C55P with a corresponding CO level of 5 to 20 ppm for LPG.
  • Page 31 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. Telephone KESTON BOILERS technical support (phone no. 0208 462 0262) To revert to normal modulation Press the “Mode”...
  • Page 32 WD536 Chapter 4 : Commissioning The Keston C45, C40P, C55 & C55P 4.10 HANDING OVER TO THE USER It is important to fully explain the following: Procedure to light and turn off the boiler, including isolation of the electrical supply if necessary.
  • Page 33 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5. FAULT FINDING 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”...

  • Page 34: Normal Operation

    QUICK REFERENCE 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. The table below shows the range of status codes which...
  • Page 35 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.
  • Page 36 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 31...
  • Page 37 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 32...
  • Page 38 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 33...
  • Page 39 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P Exploded Assembly Diagrams 5.7.1 Boiler Controls Assembly Installation & Servicing Instructions Page : 34...
  • Page 40 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5.7.2 Waterway, Condensate & Flue Assembly Installation & Servicing Instructions Page : 35...
  • Page 41 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 36...
  • Page 42 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5.7.4 Casing Assembly Installation & Servicing Instructions Page : 37...
  • Page 43 WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55P 5.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 5.7.1) GC Number Code Description E93-126 C55/C55P/C45 Main Control Box (C.17.4.01.00.0 A) E93-127 C40P Main Control Box (C.13.4.03.00.0 A)
  • Page 44 It should be noted that setting the user controls to “Standby” does not isolate the electrical supply and parts of the boiler will remain live. Hazardous materials are not used in the construction of the C45, C40P and C55(P). However, due care should be taken when handling boiler components.
  • Page 45 WD536 Chapter 6 : Servicing 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.

  • Page 46: Replacement Of Parts

    WD536 Chapter 7 : Replacement Of Parts The Keston C45, C40P, C55 & C55P 7. REPLACEMENT OF PARTS CONTENTS GENERAL PRECAUTIONS ACCESS REPLACEMENT PROCEDURE 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...
  • Page 47 WD536 Chapter 7 : Replacement Of Parts The Keston C45, C40P, C55 & C55P 7.4.2 Boiler Flow and Return Thermistors (Fig. 5.7.2 item 47) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions.
  • Page 48 WD536 Chapter 7 : Replacement Of Parts The Keston C45, C40P, C55 & C55P 7.4.8 Gas Control Valve / Venturi Assembly (Fig. 5.7.3 item 163) Isolate the appliance (Section 7.1) Gain access (Section 7.2) iii) Remove the push on connector block to the gas valve.
  • Page 49 WD536 Chapter 7 : Replacement Of Parts 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) xii) Remove the heat exchanger xiii) Reassemble (Section 7.3)

  • Page 50: Short Spare Parts List

    WD536 Chapter 8 : Spare Parts Listings The Keston C45, C40P, C55P & C55P 8. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No PartDenomination E93-137 C55 Burner E93-141 Burner Gasket E93-138 C55P/C45/C40P Burner E93-142 Ignitor Gasket...
  • Page 51 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 E93-145 Flow/Return Temperature Thermistor 114-045 Water Pressure Switch E72-332 Flue Protection Thermostat...
  • Page 52 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. ____________________ CONTROLS To comply with the Building Regulation, each section must have a tick in one or other of the boxes TIME &...

  • Page 53: Service Interval Record

    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.
  • Page 54 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 .

This manual is also suitable for:

C40pC55C55p

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