Keston C55 Installation Manual

C45 C40P C55 C55PFan Powered High Efficiency Modulating Domestic Condensing Gas BoilerInstallation and Servicing InstructionsC45, C40P, C55 & C

Keston Boilers Ltd declare that there are no substances harmful to health within theappliance or used during the production of the applia

1.7 OPTIONAL ACCESSORIESA range of accessories are available from Keston Boilers Ltd to compliment an installation.Terminal wall sealing

2. BOILER LOCATION2.1 DIMENSIONS AND MINIMUMCLEARANCESThe boiler must be installed in minimumclearances shown to allow subsequentservicing, and s

cannot be touched by a person using the bath or shower. The C45, C40P and C55(P) areclassified as IP20 (IPX0) and are therefore suitable for installat

BS 1363. There must be only one common method of isolation for the boiler andits control system.The appliance must be connected to the 3A supply via a

Gas pressures above or below these levels will lead to problems associated with the gasvalve's internal pressure regulator.Supply pipes to the bo

valves are closed, then the safety valve may be omitted. Note that the minimumstatic head required is 9 ft at the top of the boiler. Although suitabl

All components of the system including the heat exchanger of the indirect cylindermust be suitable for a working pressure of 3 bar and a temperature o

2.7.3 Hot Water System (if applicable)The hot water storage vessel must be of the indirect type (certain direct cylinderscan be used provided they are

Installation of air bleed valves at the high spot(s) in the system will allow for airelimination when filling the system and will allow re-venting in

CONTENTSSection Description0 HANDLING INSTRUCTIONS0.1 List of contents0.2 Recommended handling procedure1 GENERAL INSTRUCTION1.1 Description1.2 Boiler

Alternatively, where flue or air intakelengths of up to 45m are require,Glynwed Friatec DN70 pipe may beused. Both 50mm flue outlet terminal and

2.8.3 Boiler Output vs Flue LengthDue to the resistance presented by extended flue length a slight reduction inmaximum boiler output wi

300300L Horizontally from terminal on same wall.1,5001,500K Vertically from terminal on same wall.1001,200J From opening in a car port.1,2001,200I Fro

2.11 CONDENSATE DRAINAGEBeing a condensing boiler, the C45, C40P and C55(P) are fitted with a condensate trap atthe base of the heat exchanger and flu

3. INSTALLATION OF THE BOILERRead Chapter 2 - Boiler Location and decide upon the position of the boiler.Installation of the boiler is straightforward

Remember the flue pipe must slope downwards back towards the boiler and thisis best achieved using 92.5o bends.a Using the template supplied within th

3.6 WATER SYSTEMConnect the flow and return pipework to the boiler. Details of system requirements aregiven in Chapter 2 - Section 2.7 Water Systems

3.9 EXCHANGING A BOILERBefore removing an existing boiler add Fernox Supafloc , or equivalent cleaning agent, inaccordance with the manufacturers’

4. COMMISSIONING OF THE BOILERImportant:This condensing boiler contains components which could be damaged or blocked by grease, dirt,solder etc., fr

e. Adjust the upper rotary control knob, central heating temperature, to themaximum clockwise position. Adjust the lower rotary control know, DHWtempe

4 COMMISSIONING OF THE BOILER4.1 Initial Flushing4.2 Gas Supply4.3 Electrical Installation4.4 LP Gas 4.5 Initial Firing4.6 Hot Flushing4.7 Combustion

To measure CO2 levels in the Keston boiler remove the 1/8" plug from the flue outlet pipespigot (Figure 5.7.4 item 18). Insert the probe of a cal

LESS THAN THE CO2 LEVEL AT HIGH RATE. ADJUSTMENTS, IF MADE, SHOULD BEIN STEPS OF NO MORE THAN 1/8 OF A TURN. YOU MUST WAIT 1 MINUTE AFTEREACH ADJUSTME

4.10 HANDING OVER TO THE USERIt is important to fully explain the following:a. Procedure to light and turn off the boiler, including isolation of the

5. FAULT FINDING5.1 ELECTRICAL CONTROL SEQUENCEWhen the external controls are calling for heat, power will be fed to the boiler connectionstrip at te

QUICK REFERENCE5.2 NORMAL OPERATIONThe C45, C40P and C55(P) boilers feature a user display which shows actual flow temperature atall times (the last t

5.3.2 LOCKOUT If the fault is persistent or more severe the boiler will lockout with a error code. When the boilerhas entered this error mode it will

5.4 FUNCTIONAL FLOW WIRING DIAGRAMWD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & Servicing Instructions Page

5.5 ELECTRICAL WIRING DIAGRAMWD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & Servicing Instructions Page :

5.6 ILLUSTRATED WIRING DIAGRAMWD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & Servicing Instructions Page :

5.7 Exploded Assembly Diagrams5.7.1 Boiler Controls Assembly WD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & S

0. HANDLING INSTRUCTION0.1 LIST OF CONTENTSThe Keston C40P,C45 and C55(P) are supplied almost totally pre-assembled. Since the unitsuse standard 50 mm

5.7.2 Waterway, Condensate & Flue AssemblyWD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & Servicing Instru

5.7.3 Air - Gas AssemblyWD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & Servicing Instructions Page : 36

5.7.4 Casing AssemblyWD536 Chapter 5 : Fault Finding The Keston C45, C40P, C55 & C55PInstallation & Servicing Instructions Page : 37

5.7.5 Exploded Diagrams Parts Reference ListBoiler Controls Assembly (Fig. 5.7.1)GC Number Code DescriptionE93-126 88 C55/C55P/C45 Main Control Box (

6. ROUTINE (ANNUAL) SERVICINGTo ensure the continued safe and efficient operation of the boiler it is necessary to carry outroutine se

b. Remove the burner head (Section 7.6) and inspect the burner appearance. Blackmarkings or other discoloration's on the gauze indicate too much

7. REPLACEMENT OF PARTSCONTENTS7.0 GENERAL7.1 PRECAUTIONS7.2 ACCESS7.3 REPLACEMENT PROCEDURE7.4 ELECTRICAL COMPONENTS7.4.1 CONTROL PANEL7.4.2 BOILER F

7.4.2 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 o

7.4.8 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 pus

xi) Remove the two screws fixing the heat exchanger to the top mounting bracket(Fig 5.7.2 item 63)xii) Remove the heat exchangerxiii) Reassemble (Sect

In the event the appliance must be fitted by one operative the integral circulating pump headand complete combustion fan/gas valve/venturi assembly ca

8. SHORT SPARE PARTS LISTItem GC No Part Denomination Item GC No PartDenomination77 E93-137 C55 Burner 44 E93-141 Burner GasketE93-138 C55P/C45/C40P

SHORT SPARE PARTS LIST FOR THE KESTONCONDENSING BOILER RANGEItem GC No Part Denomination47 E93-145 Flow/Return Temperature Thermistor48 114-045 Water

WD536 Chapter 9 : Benchmark Checklist Final The Keston C45, C40P, C55 & C55P Installation & Servicing Instruction

WD536 Chapter 9 : Benchmark Checklist Final The Keston C45, C40P, C55 & C55P Installation & Servicing Instruction

†Read Installation Manual Carefully†Ensure that there is at least 9 feet head of water pressure at thetop of the boiler .†Ensure that ALL dust p

1. GENERAL INSTRUCTION1.1 DESCRIPTIONThe Keston C45, C40P and C55(P) are unique in concept and design. They comprise ahigh efficiency stainless ste

the flueway and is drained at the base of the flue connection to the heat exchanger ordrain points within the flue.Fig. 1.2 - Boiler LayoutThe conde

In addition, due account must be taken to the following Codes Of Practice:BS 6891 : Low Pressure Installation PipesBS 6798 : Installation of Gas Fired

1.5 PERFORMANCE DATA - C45 & C40P1.6 PERFORMANCE DATA - C55 & C55PWD536 Chapter 1 : General Instruction The Keston C45, C40P, C55 and C55PIn