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Keston Heat 45 Installation And Servicing Instruction

Fan powered high efficiency modulating condensing gas boiler
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Heat 45 & 55
Heat 45P & 55P
Installation and Servicing Instructions
FAN POWERED HIGH EFFICIENCY
MODULATING CONDENSING
GAS BOILER
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.kes-
ton.co.uk where you can download the relevant information in PDF format.
April 2018
UIN 208964 A08

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  • Page 1 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.kes- ton.co.uk where you can download the relevant information in PDF format.
  • Page 2 88.7 89.5 Part Load ƞ 97.7 98.5 97.7 98.5 Standby Loss 0.08 0.11 0.073 0.082 stby Ignition Emissions mg/kWh 34.5 34.7 40.4 54.4 Annual Energy Consumption 139.4 170.3 139.4 170.3 Sound Power Level, Indoors Keston Heat - Installation & Servicing...

  • Page 3: Product Fiche

    PRODUCT FICHE KESTON HEAT BOILER Keston Heating ERP DATA SYMBOL UNITS MODEL Condensing boiler Seasonal Space heating efficiency class Rated heat output ƞ Seasonal space heating energy efficiency Annual energy consumption 139.4 170.3 Sound power level, indoors Seasonal Space Heating Energy Efficiency of the Boiler...
  • Page 4 Keston Heat - Installation & Servicing...
  • Page 5 Keston Heat - Installation & Servicing...
  • Page 6 G31 Gross CV - 2567 Btu/ft G20 Gross CV - 1014 Btu/ft Any direct connection of a control device not approved by Keston For l/s divide the gross heat input (kW) by the gross C.V. of the could invalidate the certification and the normal appliance gas (MJ/m warranty.
  • Page 7 I2H = An appliance designed for use on 2nd Family gases. I3P = An appliance designed for use on 3rd family gases. NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER. Keston Heat - Installation & Servicing...

  • Page 8: Optional Extra Kits

    GENERAL INTRODUCTION The Keston Heat boilers have been tested and certified to; The Keston Heat boilers are fully automatically controlled, wall EN 483, EN 677, BSEN 60335-2-102, BSEN 55014-1 and BSEN mounted, fanned, super efficient condensing appliances. 55014-2 for use with Natural Gas and LPG Propane.

  • Page 9: Safe Handling Of Substances

    813:2002. relevant standards listed on page 8. Pipework from the supply to the boiler MUST be of an adequate The Keston boilers feature an integral circulating pump which size. has sufficient excess head to drive most domestic systems. The available head is indicated in the chart below. If the system...

  • Page 10: Water Treatment

    Keston recommend Water Treatment in accordance with Guidance Notes on Water Treatment in Central Heating Systems. Keston 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’...
  • Page 11 Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required, with the cupboard door open, to allow for servicing. Keston Heat - Installation & Servicing...

  • Page 12: Sealed System Requirements

    System System either lower the pump position or raise the cistern above the minimum flow to return requirement specified by Keston. The isolation valves should be fitted pump as close to the pump as possible. Inverted cold feed entry The boiler is fitted with an automatic air vent, located in the left top side of the interior.

  • Page 13: Boiler Assembly - Exploded View

    INSTALLATION BOILER ASSEMBLY - Exploded View Ignitor Unit Door Assembly Keston Heat Kit Flue Stat Auto Air Vent Electrode Detection Kit Burner Fixings Kit Ignition Electrode Kit Bulk Head Acccess plate Fascia Plastic Pump Gas Valve Kit HMI Board Venturi Kit...

  • Page 14: Packaging Removal

    D Pressure Relief Valve E M1 Tee F Drain Nipple G Drain Nipple Terminals - 2 off Flue Sleeve Wall Plate & Screws Wall Seal Weather Compensation Screws - 4 off Wall Plugs - 4 off Keston Heat - Installation & Servicing...

  • Page 15: Wall Mounting Template

    2. Drill the 2 boiler lower fixing holes with a 12mm ”) masonry drill, insert the plastic plugs provided . 3. Fix the wall bracket, supplied with boiler, into place with 4 M10x70 hex head coach screws provided. Keston Heat - Installation & Servicing...

  • Page 16: Mounting The Boiler

    If installing in a room or internal space then no purpose provided ventilation is required. When installing in a compartment, the table below details the ventilation requirements in line with BS5440. Keston ventilation requirements when installed in a compartment up to 70kW (BS5440) To a room or internal space To outside Air 45 &...

  • Page 17: Flue System

    Both the 50mm flue outlet terminal and the 50mm air inlet terminal are supplied with the flue pack and are illustrated in Fig. 1 and must be used in ALL installations. (Both terminals are identical). Keston Heat - Installation & Servicing...
  • Page 18 It is possible to have variable flue and air lengths as described within the shaded area of Figs 3 & 4. Fig. 3 Fig. 4 Keston Evomax 45 - Flue & Air Pipe Length Keston Evomax 55 - Flue & Air Pipe Length Nat Gas Operating Area...

  • Page 19: Flue Termination Position

    150mm above roof intersection Air Pipe Note. Recomend to fit deflector, with air taken from side wall or low level (min 500mm separation). preventing rain ingress Terminal continued ..Keston Heat - Installation & Servicing...

  • Page 20: Assembly Practice

    The boiler casing must always be correctly fitted to the boiler when leaving the appliance operational. External wall faces and any internal faces of cavity walls must be good. AIR SUPPLY The Keston Heat is a room-sealed appliance and therefore does not require purpose provided ventilation to the boiler room for combustion air. COMPARTMENT INSTALLATION Due to the low casing temperatures generated by the boiler, no compartment ventilation is required.
  • Page 21 8. Affix flue terminal 9. During boiler test check that the flue end is free to expand and contract with flexible wall seal. Flue Terminal Flue Pipe Flue Sleeve Flue Sleeve Flange Flexible Wall Wall Plate Seal Keston Heat - Installation & Servicing...
  • Page 22 Elbows 3 x 1m = 3m Straights 6+2 = 8m Straights 4+6+1.5+1 = 12.5m Total = 10m Total = 15.5m Overall Flue / Air = 25.5m 17 FLUE INSTALLATION EXAMPLE KESTON HEAT 45 3.5º back to boiler Sleeve 3.5m 3.5º back 3.5m...

  • Page 23: Multiple Boilers

    Heat output to a maximum of 330kW can be achieved by cascading up to six Keston Heat boilers. This can be achieved by the use of Keston Heat boilers fitted side by side on the wall or frames in conjunction with the required header kits.
  • Page 24 Boilers without 75mm sealed condensate trap must be fitted with condensate trap must be fitted with a 75mm trap and visible air break a 75mm trap and visible air break continued ..Keston Heat - Installation & Servicing...
  • Page 25 ≥ 500 a 75mm trap and visible air break 2 rows of three Ø12mm holes 25mm centres, 50mm from the bottom of the tube, facing away from the house Keston Heat - Installation & Servicing...

  • Page 26: Boiler Water Connections

    (supplied) operation when isolated. 27 FROST PROTECTION The Keston Heat boiler has built into its control system the Central heating systems fitted wholly inside the building do facility to protect the boiler only against freezing. not normally require frost protections as the building acts as a ‘storage heater’...

  • Page 27: Electrical Connections

    2. 230V AC output is provided optionally for a diverter valve, details. programmer and thermostats. Care must be taken to ensure that the earth conductor is longer than the current carrying conductors for reasons given in Frame 29. Keston Heat - Installation & Servicing...

  • Page 28: Installer Connections

    INSTALLATION 32 INSTALLER CONNECTIONS Keston Heat - Installation & Servicing...

  • Page 29: Internal Wiring

    INSTALLATION 33 INTERNAL WIRING Keston Heat - Installation & Servicing...
  • Page 30 SELECT ENTER CHANGE KESTON HEAT USER INTERFACE Mains On When the mains to the boiler is switched on a screen similar to the following will be displayed The designation at the end of the bottom line indicates whether the boiler is suitable for Natural Gas.
  • Page 31 0-10V Input and Flow Setpoint will vary as the external Building Management System controls them. See Frame 38 for configuring the boiler for 0-10V Temperature Operation. continued ..Keston Heat - Installation & Servicing...
  • Page 32 INSTALLATION 36 KESTON HEAT USER INTERFACE - BASIC OPERATING INSTRUCTIONS SETTING STAT 1 TEMPERATURE SETTING SUMMER, WINTER AND STANDBY OPERATION Note that Standby Mode will disable Domestic Hot Water and Rotate 1st Stat and the following screen will be displayed...
  • Page 33 INSTALLATION 37 KESTON HEAT USER INTERFACE - BASIC OPERATING INSTRUCTIONS CONTINUED... VIEWING THE STATE OF THE BOILER INPUTS VIEWING THE FAULT HISTORY OF THE BOILER Press SELECT and a screen similar to the following will be displayed Press SELECT and a screen similar to the following will be displayed...
  • Page 34 INSTALLATION 38 KESTON HEAT USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS SETTING TO 0-10V Press SELECT and then hold + and - down together for more than 5s, the following screen will be displayed Installer Mode Normal Operation Set Stat 1 Temp’...
  • Page 35 INSTALLATION 39 KESTON HEAT USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CONTINUED..ENABLING NIGHT SETBACK Note- Booster Function is only operational if Outside Sensor has Note- Night Setback is only operational if Outside Sensor has been connected been connected When Night Setback is enabled the boiler will run at the normal flow temp.
  • Page 36 INSTALLATION 40 KESTON HEAT USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CHANGING THE MAXIMUM FLOW TEMPERATURE SETPOINT CHANGING CH / DHW PRIORITY Note: if this menu option is not displayed then the “2nd sL DHW/CH” Boiler default setting is that maximum flow temperature setpoint is 82°C menu option has been set for CH.
  • Page 37 Thermostat providing a 230V input to the DHW Switched Live Care should be taken in adjusting this feature as system noise and/or Instead a DHW Thermistor, available as a kit from Keston, can be boiler lockout could occur connected to the DHW Thermistor input...
  • Page 38 INSTALLATION 42 KESTON HEAT USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CONT’D..REVERTING TO FACTORY SETTINGS DISABLING THE ANTI-LEGIONELLA FUNCTION Press SELECT, hold + and - together for more than 5s, the Note that the Anti-Legionella Temperature Function is only following screen will be displayed...
  • Page 39 INSTALLATION 43 KESTON HEAT WITH S PLAN SYSTEM Use the outside sensor then the link Note that a hydraulic bypass is from position 9 to position 10 in the required to allow pump overrun. installer terminal block should be removed and a wire added from...
  • Page 40 INSTALLATION 45 KESTON HEAT WITH BOILER CONTROL OF PUMP AND DIVERTER VALVE Note 1. 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.
  • Page 41 INSTALLATION 47 KESTON HEAT WITH EXTERNAL CONTROLS VIA SWITCHED LIVE, 0-10V INPUT OR OPENTHERM EXTERNAL CONTROLS VIA SWITCHED LIVE Boiler Notes. 1. The boiler will automatically configure itself to a Switched Live input. Fused 2. The Switched Live must be from the Spur same phase as the boiler mains supply.

  • Page 42: Commissioning And Testing

    INSTALLATION 48 KESTON HEAT WITH OPENTHERM 2 CHANNEL PROGRAMMABLE ROOM STAT Note 1. The OpenTherm 2 Channel Programamble Room thermostat is available from Keston as a kit. Note 2. The Tank Temperature Sensor is available from Keston as a kit.

  • Page 43: Initial Lighting

    Check air in the boiler could damage the heat exchanger. For this reason the boiler is set for winter operation - see Keston Heat airvent located in the left top side must never be shut off.

  • Page 44: General Checks

    0.004 ratio and the CO should match the IMPORTANT. values given in Frame 50. After completing the servicing or replacement of components • Carry out functional checks as appropriate. always: • Test for gas soundness. Keston Heat - Installation & Servicing...

  • Page 45: Servicing Schedule

    The kW output number in the 1st line will vary depending on the Keston does not accept any liability resulting from the maximum output of the boiler. use of unauthorised parts or the repair and servicing...
  • Page 46 12. Re-assemble in reverse order checking seals and gaskets 6. Remove the flue tube elbow fixing screws and remove and replacing if faulty or damaged. elbow by pulling downwards. Inlet Gas Pressure Test Point. Keston Heat - Installation & Servicing...

  • Page 47: Burner Removal

    4. Remove the ball from the condensate trap and flush out with water to remove any debris. 5. Reassemble in reverse order. 6. Check the operation of the boiler (Refer to frame 53) Keston Heat - Installation & Servicing...

  • Page 48: Fan Replacement

    9. Check the operation of the boiler (Refer to frame 53). Gas Management Assembly Part No’s Model Venturi Valve Injector 176273 176360 176313 177038 45/55 45P/55P 176273 176360 176313 179666 Keston Heat - Installation & Servicing...

  • Page 49: Ignition Electrode Replacement

    5. Pull out the electrode and pull off the old gasket. 6. Replace with new electrode and gasket. 7. Reassemble in reverse order. 7. Check the operation of the boiler (Refer to frame 53) Keston Heat - Installation & Servicing...

  • Page 50: Water Pressure Switch Replacement

    7. Refill the system ensuring all the air in the heat exchanger is vented through the air vent. 8. Re-assemble in reverse order. 9. Check the operation of the boiler. Refer to Frame 53. Keston Heat - Installation & Servicing...

  • Page 51: Pump Head Replacement

    Disconnect the pump power supply at the left hand aperture. There is a plug situated in the boiler casing floor terminal strip. directly beneath the pump to allow drainage of any spillage within the casing. Keston Heat - Installation & Servicing...

  • Page 52: Main Pcb Replacement

    8. Unclip the board and lift to clear the six mounting posts. 9. Fit the new user interface. 10. Reassemble in reverse order. 10. Check the operation of the boiler. Refer to Frame 53. Keston Heat - Installation & Servicing...

  • Page 53: Fault Finding Chart - Main Menu

    Installer cannot be increased to 82°C Mode. See Frame 40 Go to Frame 76 Error 20 False Flame Lockout Pump only runs at maximum Check LV wiring from speed PCB to pump Keston Heat - Installation & Servicing...

  • Page 54: Overheat Lockout

    Harness as necessary continuity, visual condition and position (refer to Frame 64). Are these functioning correctly? Check Syphon and condensate drain pipework for blockage Replace Gas Valve and rectify if necessary. Boiler now working OK? Keston Heat - Installation & Servicing...

  • Page 55: Low Water Pressure

    * Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the value. In general terms a reading of greater than 150V indicates that the correct voltage is supplied to the gas valve Keston Heat - Installation & Servicing...

  • Page 56: Fan Fault

    At 60°C expect 2,400 - 2,600 Ω At 85°C expect 1,000 - 1,100 Ω Is the thermistor value correct? Check and replace wiring as necessary Is there continuity between the PCB and the Thermistor? Replace main PCB Keston Heat - Installation & Servicing...

  • Page 57: Outside Sensor Fault

    PCB have continuity and is securely connected securely connected? Replace main PCB 83 FLOW/RETURN REVERSED Is the System Pump connected the correct way? Reverse Pump Check that the system pipework is correct Keston Heat - Installation & Servicing...
  • Page 58 (identified by the label on the BCC) the side marked “TOP” upwards. Replace the BCC with a new BCC (that is correct for the Replace main PCB boiler). After switching power on and resetting the boiler does the fault disappear Keston Heat - Installation & Servicing...
  • Page 59 Open the Radiator Valves Is an OpenTherm device connected to the boiler (note that Does the wiring from the boiler to the the Keston Prog Room Stat is an OpenTherm device)? OpenTherm device have continuity? There is no voltage from the Timer/ Room Stat.
  • Page 60 Frame 36 for setting DHW Temp.) Is an OpenTherm device connected to the Does the wiring from the boiler to the boiler (note that the Keston programmable OpenTherm device have continuity? Room Stat is an OpenTherm device)? There is no voltage from the Rectify wiring Timer/Cylinder Stat.
  • Page 61 PCB have continuity and is un-damaged? Check for shorts on Pumps/Diverter Valve/ Is the Fuse on the main PCB OK? Fan/Spark Generator/Gas Valve and replace Fuse Replace main PCB Replace the user interface PCB, still no display? KESTON Keston Heat - Installation & Servicing...
  • Page 62 (F), with positive and negative connected correctly? external device Ensure that the wiring is securely Is the wiring from the boiler terminal strip to the main connected and has continuity PCB securely connected and has continuity? Replace main PCB Keston Heat - Installation & Servicing...

  • Page 63: Spare Parts

    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. Failure to do so could affect safety or performance of this appliance.
  • Page 64 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 K e s t o n p u r s u e s a p o l i c y o f c o n t i n u i n g i m p r o v e m e n t i n t h e 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 .
  • Page 65 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.kes- ton.co.uk where you can download the relevant information in PDF format.
  • Page 66 Introduction of the appliance in a safe way and understand the hazards The Keston Heat is a wall mounted, room sealed, super efficient involved. Children shall not play with the appliance. Cleaning condensing boiler featuring full sequence automatic spark ignition and user maintenance shall not be made by children without and fan assisted combustion.
  • Page 67 Ignition or Burner On or Pump Overrun) Flow Temp 80°C Flow Temp 80°C Outside temperature will only be shown if an outside sensor is connected to the boiler Burner Power and Flow Temp will vary as the boiler operates Keston Heat - User’s...
  • Page 68 KESTON HEAT USER INTERFACE - BASIC OPERATING INSTRUCTIONS SETTING STAT 1 TEMPERATURE SETTING SUMMER, WINTER AND STANDBY OPERATION Note that Standby Mode will disable Domestic Hot Water and Rotate Stat 1 and the following screen will be displayed. Central Heating, Summer Mode will disable Central Heating Press SELECT and a screen similar to the following will be displayed Set Stat 1 Temp’...
  • Page 69 Frost Protection Place the heating on continuous and turn the room stat down to The Keston Heat boiler has built into its control system the facility 15ºC overnight or when unoccupied. (Return to normal after cold to protect the boiler only against freezing.
  • Page 70 Keston Heat - User’s...
  • Page 71 Keston Heat - User’s...
  • Page 72 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 K e s t o n p u r s u e s a p o l i c y o f c o n t i n u i n g i m p r o v e m e n t i n t h e 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 .

This manual is also suitable for:

Heat 55Heat 45pHeat 55p

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