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Keston 355123 HEAT 2 45 Condensing Boiler Natural Gas Owner's Manual

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INSTALLATION & SERVICING - Keston Boilers

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.

Keston Heat 2 45

Keston Boiler Error Codes / Fault Codes | WarmZilla

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INSTALLATION & SERVICING
HEAT 2 45 55 45P 55P
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 keston.co.uk where you can download the relevant information in PDF format. December 2020 UIN 220446 A03

ERP DATA

Condensing Boiler
Low Temperature Boiler
B1 Boiler
Cogeneration Space Heater
Equipped with a Supplementary Heater
Combination Heater
Nominal Heat Output for Space Heating Full Load Part Load Auxiliary Electricity Consumption Full Load Part Load Standby Seasonal Space Heating Energy Efficiency Full Load Part Load Standby Loss Ignition

SYMBOL UNITS

n/a

n/a yes

n/a

P4 P1
elmax elmin PSB
4 1 Pstby Pign

kW 14.6

kW 0.135 kW 0.03 kW 0.009

% 88.7

% 97.7

kW 0.08

Emissions Annual Energy Consumption Sound Power Level, Indoors

NOx mg/kWh 28.5

QHE

GJ 139

LWA

dB 60.6

MODEL

45P

yes

55 18
0.128 0.026 0.009
89.5 98.5 0.11
0
35.4 170 60.6

45 14.6
0.113 0.026 0.002
88.7 97.7 0.073
0
43.1 137 64.2

55P yes no no no no no
55 18
0.130 0.024 0.002
89.5 98.5 0.082
0
48.4 167 64.2

Installation & Servicing

PRODUCT FICHE

KESTON HEAT2 BOILER Keston Heating ERP DATA
Condensing boiler Seasonal Space heating efficiency class Rated heat output Seasonal space heating energy efficiency Annual energy consumption Sound power level, indoors

SYMBOL UNITS

son

QHE

LWA

45
45 93* 139 60.6

MODEL

45P

55P

Yes

93*

137

170

167

60.6

64.2

Seasonal Space Heating Energy Efficiency of the Boiler

Temperature control (from fiche of temperature control)

Class I 1%

Class II 2%

Class III 1.5%

Class IV 2%

Class V 3%

Class VI 4%

Class VII 3.5%

Class VIII 5%

*%
A
%
B

Solar Contribution (from fiche of solar device)

Collector Size (in m2)

Tank Volume (in m3)

Collector
Efficiency (in %)

Tank rating A* = 0.95 A = 0.91 B = 0.86 C = 0.83 D-G = 0.81

= (`III 'x

+ `IV ' x

) x 0.9 x (

/ 100 x

%
C

Seasonal Space Heating Energy Efficiency of Package

TOTAL: A+B+C=

Seasonal Space Heating Energy Efficiency Class of Package

G < 30%

F 30%

E 34%

D 36%

C 75%

B 82%

A 90%

A+ 98%

A++ 125%

A+++ 150%

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

Installation & Servicing

CONTENTS

1. GENERAL ......................................................................... 8 1.1 Introduction........................................................................ 8 1.2 Optional Extra Kits............................................................. 8 1.3 Safety ................................................................................ 8 1.4 Safe Handling .................................................................... 9 1.5 Safe Handling of Substances ............................................ 9 1.6 Location of Boiler............................................................... 9 1.7 Gas Supply ........................................................................ 9 1.8 Flue Installation ................................................................. 9 1.9 Water Circulation System .................................................. 9 1.10 Water Treatment.............................................................. 10 1.11 Electrical Supply .............................................................. 11 1.12 Condensate Drain............................................................ 11 1.13 Boiler Clearances and Connections ................................ 12 1.14 Open Vented System Requirements ............................... 13 1.15 Sealed System Requirements ......................................... 13
2. INSTALLATION............................................................... 14 2.1 Boiler Assembly - Exploded View .................................... 14 2.2 Packaging Removal......................................................... 15 2.3 Unpacking ....................................................................... 15 2.4 Wall Mounting Template .................................................. 16 2.5 Preparing the wall............................................................ 16 2.6 Mounting the Boiler.......................................................... 17 2.7 Ventilation ........................................................................ 17 2.8 Flue Systems................................................................... 18 2.9 Flue Termination Position ................................................ 20 2.10 Assembly Practice ........................................................... 21 2.11 Fitting the Flue Sleeving .................................................. 22 2.12 Flue Installation Example Keston Heat 55....................... 23 2.13 Flue Installation Example Keston Heat 45....................... 23 2.14 Boiler Frame and header Kits.......................................... 24 2.15 condensate drain ............................................................. 25 2.16 Boiler Water Connections................................................ 26 2.17 Frost Connection ............................................................. 27 2.18 Gas Connection............................................................... 27 2.19 Fitting the Weather Compensation Kit ............................ 27 2.20 Stand Alone Boiler - Partial Hydraulics............................ 28 2.21 Abbreviations................................................................... 30 2.22 Electrical Connections ..................................................... 30 2.23 External Wiring ................................................................ 30 2.24 Installer Connections ....................................................... 31 2.25 Boiler with External Controls .......................................... 32 2.26 Controls Configuration, Commissioning and Testing....... 35 2.27 User Interface .................................................................. 36 2.28 Glossary of Terms............................................................ 37 2.28.1 Menu function resource definitions.................................. 37 2.28.2 Pump definitions .............................................................. 37 2.29 Boiler Guided Configuration Stand Alone Boiler ............. 38 2.29.1 Initial Settings .................................................................. 38 2.29.2 Boiler setup options - Pre configuration selection .......... 38 2.29.3 Advanced Configuration .................................................. 39 2.29.4 Plant Settings .................................................................. 40 2.29.5 Boiler Configuration: ........................................................ 43 2.29.6 Heating Circuit Configuration:.......................................... 45 2.29.7 DHW Configuration.......................................................... 47 2.29.8 Menu � Configuration � General � Access level.............. 50 2.29.9 Menu - Configuration ....................................................... 50 2.30 Initial Lighting................................................................... 51 2.31 General Checks............................................................... 52 2.32 Handing Over .................................................................. 52 2.33 Safety .............................................................................. 52

3. SERVICING..................................................................... 53 3.1 Servicing Schedule.......................................................... 53 3.2 Removal of Casing .......................................................... 54 3.3 Removal of Fan and Gas Valve Assembly ...................... 55 3.4 Removal of Non-Return Valve ......................................... 55 3.5 Removal of Burner........................................................... 56 3.6 Heat Exchanger Inspection / Cleaning ........................... 56 3.7 Removal of Condensate Trap.......................................... 56 3.8 Removal of Sump Cover ................................................. 57 3.9 Removal of Fan ............................................................... 57 3.10 Removal of Gas Valve .................................................... 57 3.11 Removal of Venturi / Air Inlet Damper ............................. 58 3.12 Removal of Ignition Electrode.......................................... 58 3.13 Removal of Detection Electrode ...................................... 58 3.14 Removal of Automatic Air Vent ........................................ 59 3.15 removal of Water Pressure Switch .................................. 59 3.16 Removal of Flow / Return / Heat exchanger Thermistor ... 59 3.17 Flue Thermistor Replacement ......................................... 60 3.18 Removal of Spark Generator........................................... 60 3.19 Pump Head replacement................................................. 61 3.20 Removal of Main PCB ..................................................... 62 3.21 Removal of System Manager .......................................... 62
4. WIRING ........................................................................... 63 4.1 Internal Wiring Combustion Manager .............................. 63 4.2 System Manager Wiring Diagram.................................... 64 4.3 Optional Varican Adapter wiring Diagram........................ 64
5. FAULT FINDING ............................................................. 65 5.1 Fault Finding Screens...................................................... 65 5.2 Fault Finding Menu.......................................................... 66 5.3 Overheat Lockout ............................................................ 68 5.4 Ignition Lockout ............................................................... 68 5.5 False Flame Lockout / Error 20 ....................................... 69 5.6 Low Water Pressure ........................................................ 69 5.7 Flame Loss ...................................................................... 69 5.8 Fan Fault ......................................................................... 70 5.9 Flow / Return Thermistor, Heat Exchanger or Flue
Thermistor Fault .............................................................. 70 5.10 Outside / HEADER / ROOM Sensor Fault (if fitted)......... 70 5.11 Flow/Return Reversed..................................................... 71 5.12 Cylinder Thermistor Fault (if fitted) .................................. 71 5.13 External Interlock Open ................................................... 71 5.14 No CH but DHW OK ........................................................ 72 5.15 No DHW but CH OK ........................................................ 73 5.16 No Display ....................................................................... 74 5.17 0-10V Interface ................................................................ 74
6. SPARE PARTS ............................................................... 75
7. COMBUSTION AND FLUE INTEGRITY......................... 76 7.1 Flowchart for CO Level and Combustion Ratio Check
on Commissioning A Condensing Boiler.......................... 76

Installation & Servicing

SECTION 1 - GENERAL

Table 1 Performance Data (Natural Gas & Propane)

Keston Heat2 Model

45P

55P

Boiler Output

Max

42.6

52.1

(non-condensing)

Mean 70�C

Min

Boiler Output

Max

(condensing)

Mean 40�C

Min

12.7

Boiler Input

Nett

43.2

52.7

Max Rate

Gross

47.9

58.5

Boiler Input

Nett

12.2

Min Rate

Gross

13.5

Gas Rate

Max Rate

m3/hr

4.56

1.78

5.57

2.18

Flue Gas Flow Rate

Max Rate

m3/hr

65.8

68.03

80.6

83.71

Max Rate

9.5

10.8

9.7

10.7

CO2 (�0.5%)

Min Rate

8.7

9.9

8.7

9.9

60.6

64.2

NOx

Weighted

mg/kWh

28.5

43.1

35.4

48.4

Seasonal

96.7

Efficiency

*SEDBUK 2009

89.2

89.6

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy ratings of dwellings. The test data from which it has been calculated have been certified by a notified body.

Table 2 General Data

Keston Heat2 Model Gas Supply Gas Supply Connection Flow Connection Return Connection Max Pressure (sealed sys) Maximum Static Head Electricity Supply Fuse Rating Power Consumption IP Rating Nominal flue dia - Concent. Condensate Drain Water Content Packaged Weight Unpackaged Weight

Bar (psi) m
A W
L Kg Kg

45P 3P-G31-37mbar
180

2H � G20 � 20mbar G 3/4 G1 1/4 G1 1/4

6.0 (87.0)

61.0

230V - 50Hz

4.0

180

241

IP20

Twin 50mm

5.0

66.75

60.10

55P 3P - G31 - 37mbar
241

Note.
Gas consumption is calculated using the following calorific values at 15oC and 1013.25 mbar.
G31 Gross CV - 95.7 MJ/m3
G20 Gross CV - 37.8 MJ/m3
G31 Gross CV - 2567 Btu/ft3
G20 Gross CV - 1014 Btu/ft3 For l/s divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m3) For ft/h3 divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft3). For m3/h multiply l/s by 3.6.

HEALTH & SAFETY DOCUMENT NO. 635
The electricity at work regulations, 1989. The manufacturer's notes must NOT be taken, in any way, as overriding statutory obligations.
IMPORTANT. These appliances are CE certified for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Keston in writing. If in doubt please enquire.
Any direct 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.

Installation & Servicing

SECTION 1 - GENERAL

KESTON HEAT2
45, 55 45P, 55P
Natural Gas & Propane Destination Countries: GB, IE, RO

CE No. 701341

Boiler size
45 55 45P 55P

G.C. Appliance No. (Benchmark No.)
41-930-50 41-930-51 41-930-52 41-930-53

Key to symbols

IE =

Ireland

GB =

United Kingdom

RO =

Romania

PMS = Maximum operating pressure of water

B23 =

An appliance intended to be connected to a flue which evacuates the products of combustion to the outside of the room containing the boiler. The combustion air is drawn directly from the room. The fan is up stream of the combustion
chamber. Note: Air Inlet Kit must be used.

C13 =

A room sealed boiler which is connected via its ducts to a horizontally installed terminal that terminates within a common pressure zone.

C53 =

A room sealed boiler which is connected via its separate ducts to two terminals that may terminate in zones of different pressure.

I2H =

An appliance designed for use on 2nd Family gases.

I3P =

An appliance designed for use on 3rd family gases.

II2H3P = An appliance designed for use on 2nd and 3rd Family gases.

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

Installation & Servicing

SECTION 1 - GENERAL

1. GENERAL
1.1 INTRODUCTION
The boilers are fully automatically controlled, wall mounted, fanned, super efficient condensing appliances. The condensing boilers can be installed either on the wall or into a prefabricated floor mounted frame. The boilers are suitable for use with a room sealed flue or open flue application. Through a sophisticated control system combined with premix burner arrangement the boilers are capable of high seasonal efficiencies of >96% and low emissions. These boilers are fitted with an integral flue non-return valve. These boilers are certified to meet the requirements of the EC Gas Appliance Directive, Boiler Efficiency Directive, EMC and Low Voltage Directive. Note. These boilers cannot be used on systems that include gravity circulation. The boiler are suitable for connection to fully pumped, open vented or sealed water systems. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework.
1.2 OPTIONAL EXTRA KITS
SYSTEM � Frame and Header Kits & accessories CONTROLS � Outside temperature sensor � DHW tank sensor/Flow sensor/Header sensor. Pocket version � DHW tank sensor/Flow sensor/Header sensor. Strap-on
version � Room temperature sensor � OpenTherm room control � Safety interlock kit � Cascade, first boiler � Cascade, subsequent boiler � Extension module � Modulating sequencer kit � Sequencer, OpenTherm room control � 6 relay zone expansion kit � Sequencer and zone expansion pocket sensor, DHW or flow
temperature � RDG, remote diagnostic gateway � OpenTherm to Modbus gateway � OpenTherm to BACnet gateway � OpenTherm to LONworks gateway � OpenTherm to KNX gateway
8

1.3 SAFETY
Current Gas Safety (Installation and Use) Regulations or rules in force

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force. In GB, the installation must be carried out by a suitably qualified Gas Safe registered engineer or in IE by a competent person. It must be carried out in accordance with the relevant requirements of the:
� Gas Safety (Installation and Use) Regulations
� The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).
� The Water Fittings Regulations or Water byelaws in Scotland.

� The Current I.E.T. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a Competent Person and installed in accordance with the current edition of I.S.813 "Domestic Gas Installations" or I.S. 820 "Non-Domestic Gas Installations" as appropriate, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

The boilers have been tested and certified to;

BSEN 15502-1, BSEN 15502-2, BSEN 15502-2-1, BSEN 60335-1, BSEN 60335-1, BSEN 60335-2-102, BSEN 55014-1 and BSEN 55014-2 for use with Natural Gas & Propane.

Detailed recommendations are contained in the following Codes of Practice:

BSEN 60529

IPX4D using test method: Figure 4 - Test device to verify protection against spraying and splashing water; second characteristic numerals 3 and 4 (oscillating tube).

BS. 6891

Installation of low pressure gas pipework of up to 28mm (R1) in domestic premises (2nd family gas).

BS. 5440
Part 1 Part 2

Inst. and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW
net (1st, 2nd and 3rd family gases).
Specification for installation of flues. Specification for installation and maintenance of ventilation for gas appliances.

BS. 6798

Installation and maintenance of gas fired hot water boilers of rated input not exceeding 70kW net.

BS. 6880

Low temperature hot water heating systems of output greater than 45kW.

Part 1 Fundamental and design considerations. Part 2 Selection of equipment. Part 3 Installation, commissioning and maintenance.

BSEN.12828:2012 Heating Systems in buildings: Design for water based systems.

BSEN.12831:2017 Heating Systems in buildings: Method for calculation of the design heat load.

BSEN.13831

Specification for: Expansion vessels using an internal diaphragm, for sealed hot water heating
systems.

BSEN.14336:2004 Heating Systems in buildings: Installation and commissioning of water based heating systems.

IGEM/UP/1

Soundness testing and purging of industrial and commercial gas installation.

IGEM/UP/2

Gas installation pipework, boosters and compressors on industrial and commercial premises.

IGEM/UP/10

Installation of gas appliances in industrial and commercial premises.

Installation & Servicing

SECTION 1 - GENERAL

ICOM

Water treatment and conditioning of commercial

heating systems guide.

Where reference is made throughout these instructions I.S.813:2002

"Domestic Gas Installations" reference should also be made to

I.S.820:2000 "Non-Domestic Gas Installations" as applicable.

1.4 SAFE HANDLING
This boiler will require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling. Caution should be exercised during these operations. Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered: � Grip the boiler at the base. � Be physically capable.
� Use personal protective equipment as appropriate, e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/ or the weight is light.
� Keep back straight. � Avoid twisting at the waist. � Avoid upper body/top heavy bending. � Always grip with the palm of the hand. � Use designated hand holds. � Keep load as close to the body as possible.
� Always use assistance if required.

1.5 SAFE HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.

1.6 LOCATION OF BOILER
The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment or on a boiler frame supplied in kit form.
The wall must be 90� (�5�) from the perpendicular. This is to allow safe operation of the integral flue non-return valve.
The boiler must not be fitted outside.

1.7 GAS SUPPLY
IMPORTANT
Ensure all gas valve connections are gas tight with a gas soundness check up to the gas multi-functional control valve.
The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or by a suitably qualified Gas Safe registered engineer or in IE by a competent person.
An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required. A minimum working gas pressure of 17.5mbar MUST be available at the boiler inlet for Natural gas and 32mbar for Propane.
Do not use pipes of smaller size than the boiler inlet gas connection.
The complete installation MUST be tested for gas soundness and purged in accordance with the appropriate standards listed on page 8.

1.8 FLUE INSTALLATION
Individual air supply and flue outlet pipes are used. The material used for the flue outlet and the air intake systems, must be muPVC (PVC-C) to BS 5255. In addition the flue outlet and air intake pipework must be marked BSEN 1566-1 and the fittings must be marked BSEN 1329. Marley muPVC Solvent Weld System (50mm), Polypipe System 2000 muPVC Solvent Weld System (50mm), Wavin Osma Solvent Weld System and Polypipe Terrain 200 muPVC Solvent Weld System are recommended.
DO NOT USE ABS PIPE OR FITTINGS.
IMPORTANT
It is the responsibility of the installer to ensure, in practice, that products of combustion discharging from the terminal cannot
re-enter the building or any other adjacent building through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled as `unsafe' and corrective action taken.
Where the lowest part of the terminal is fitted less than 2m above a balcony, above ground or above a flat roof to which people have access then 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 to combustible material. Detailed recommendations on the protection of combustible material are given in BS. 5440-1. In IE refer to I.S.813.
The flue must be installed in accordance with Building Regulations and the recommendations of BS. 5440-1 for inputs up to 70kW nett.
1.9 WATER CIRCULATION SYSTEM
The boiler must NOT be used for direct hot water supply. The hot water storage cylinder MUST be of the indirect type.
Single feed, indirect cylinders are not recommended and MUST NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any possible freezing - particularly where pipes run through roof spaces and ventilated underfloor spaces.
The boiler must be vented.
Draining taps MUST be located in accessible positions, which permit the draining of the whole system - including the boiler and hot water storage vessel. They should be at least 1/2" BSP nominal size and be in accordance with BS. 2879.
The central heating system should be in accordance with the relevant standards listed on page 8.
The Keston boilers feature an integral circulating pump which has sufficient excess head to drive most domestic systems. The available head is indicated in the chart below. If the system resistance, at the desired flow rate, is in excess of the available head from the integral pump an additional system pump will be required.

Installation & Servicing

SECTION 1 - GENERAL

Pressure [m WG]

8 Available System Capacity

30 deg C differential

25 deg C differential

20 deg C differential

15 deg C differential

Water Flow Rate [L/m]

Keston Heat 2 55 - Hydraulic System Capacity

8 Available System Capacity

25 deg C differential

20 deg C differential

15 deg C differential

11 deg C differential

Water Flow Rate [L/m]

Keston Heat 2 45 - Hydraulic System Capacity

Note.
� With the boiler firing at minimum rate, the temperature differential should not be greater than 35oC. Lower flow rates generating higher temperature differentials will lead to lock out of the boiler.
In installations where all radiators have been provided with thermostatic radiator valves, it is essential that water circulation through the boiler is guaranteed. This can be best achieved by means of a differential pressure valve, which is installed in a bypass between the flow and return pipes. The bypass should be fitted at least 6m from the boiler, and should use a minimum size of 28mm pipe. The bypass should be capable of allowing a minimum flow rate to achieve a temperature differential of no greater than 35oC at minimum rate.
1.10 WATER TREATMENT
These boilers incorporate an ALUMINIUM heat exchanger.
IMPORTANT. The application of any other treatment to this product may render the warrnaty of Keston Heating INVALID.
Keston recommend Water Treatment in accordance with Guidance Notes on Water Treatment in Central Heating Systems.
If water treatment is used Keston recommend only the use of SCALEMASTER SM-1 PRO, FERNOX, MBI, ADEY MC1, SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers' instructions.
For further information contact: Fernox www.fernox.com Tel: +44 (0) 3301 007750
Sentinel Performance Solutions www.sentinelprotects.com Tel: +44 (0) 1928 704330
Scalemaster Water Treatment Products www.scalemaster.co.uk Tel: +44 (0) 1785 811636

Pressure [m WG]

The schematic below illustrates a recommended approach to using an additional system pump. The additional system pump should be sized to overcome the index circuit resistance only as the boilers integral pump will overcome boiler resistance. If an additional pump is required the selected pump must comply with BS 1394.
Boiler

Safety Valve AAV

Additional System Pump

42mm Header

Primary Flow 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 reventing in a day or so after all air has been driven out of solution.

Calmag Ltd. www.calmagltd.com Tel: +44 (0) 1535 210320
Adey www.adey.com Tel: +44 (0) 1242 546700
Notes. 1. It is most important that the correct concentration of the water
treatment products is maintained in accordance with the manufacturers' instructions. 2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. 3. In hard water areas, treatment to prevent lime scale may be necessary - however the use of artificially softened water is NOT permitted. 4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

Installation & Servicing

SECTION 1 - GENERAL
1.11 ELECTRICAL SUPPLY
Wiring external to the appliance MUST be in accordance with the current I.E.T. (BS7671) Wiring Regulations and any local regulations which apply. For Ireland reference should be made to the current ETCI rules for electrical installations
The point of connection to the mains should be readily accessible and adjacent to the boiler.
1.12 CONDENSATE DRAIN
Refer to Sections 2.15 & 3.7
A condensate drain is provided on the boiler. This drain must be connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other materials may be used. IMPORTANT.
Installation must be in accordance with BS 6798. The drain outlet on the boiler is sized for standard 21.5mm overflow pipe. It is a universal fitting to allow use of different brands of pipework.

Installation & Servicing

SECTION 1 - GENERAL

1.13 BOILER CLEARANCES AND CONNECTIONS
The following minimum clearances must be maintained for operation and servicing. Front of boiler - 450mm Sides of boiler - 25mm Above boiler - dependent upon the flue system see drawings Below boiler - 300mm Clearance between multiple boiler installations - 25mm

Boiler 45, 55

Dim. A Dim. B

360

130

A B

500

118

850

GAS & CONDENSE OUTLETS 68 FLOW &RETURN CONNECTIONS 81

FLOW CONDENSE GAS

209

299

RETURN 59

Installation & Servicing

SECTION 1 - GENERAL

1.14 OPEN VENTED SYSTEM REQUIREMENTS
Detail reference should be made to the appropriate standards listed on page 8.
The information and guidance given below is not intended to override any requirements of the above publications or the requirements of the local authority, gas or water undertakings.
The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturer's minimum requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Keston Heating. The isolation valves should be fitted as close to the pump as possible.
The boiler is fitted with an automatic air vent, located in the left top side of the interior. This air vent must never be shut off, as this could result in dry firing of the boiler and subsequent damage to the heat exchanger.

3000 minimum

Feed/expansion cistern
Water level (cold)
Open vent
System return
Connections to boiler

500mm minimum

Cold Feed

3000mm minimum

System flow to pump
Inverted cold feed entry

ima5351

1.15 SEALED SYSTEM REQUIREMENTS

Note. The method of filling, refilling, topping up or flushing sealed primary hot water circuit from the mains for a non-domestic property is shown below.

1. General

3. Pressure Gauge

a. Detail reference should be made to the appropriate standards listed on page 8. The information and guidance given below is not intended to override any requirements of these publications or the requirements of the local authority, gas or water undertakings.
b. The installation should be capable of working with flow temperatures of up to 90oC and a temperature differential of up to 35oC at minimum rate only.

A pressure gauge covering at least the range 0-6 bar must be fitted to the system. The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.
IMPORTANT NOTE: If the boilers are installed on to an Ideal frame & header kit and operated in excess of 3 bar then all safety relief valves will require upgrading. The boiler has a maximum operating pressure of 6 bar.

c. All components of the system, including the heat exchanger of the indirect cylinder, must be suitable for a working pressure of 6 bar (87lbf/in2) and temperature of 110oC. Care should be taken in making all connections so that the risk of leakage is minimised.

4. Expansion Vessel
Expansion vessels used must comply with BS. EN 13831. Connection to the system must not incorporate an isolating valve.

d. The boiler is fitted with an automatic air vent, located in the left top side of the interior. This air vent must never be
shut off, as this could result in dry firing of the boiler and subsequent damage to the heat exchanger.

e. Suitable isolation valves and drain points must be provided by the installer.

2. Safety Valve
A spring loaded safety valve complying with the relevant requirements of BS. 6759 Pt. 1 must be fitted in the flow pipe as close to the boiler as possible and with no intervening valve or restriction. The valve should have the following features:
a. A non-adjustable preset lift pressure not exceeding 6 bar (87lbf/in2).

primary flow and return

Type BA backflow prevention device (RPZ valve assembly)
Strainer

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 visible, but will not cause hazard to user or plant.

ima7349

CV = Control Valve DT = Drain Tap

CV
Air gap DT

Tundish

CV Resillient seat control
valves
Supply pipe

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION 2. INSTALLATION 2.1 BOILER ASSEMBLY - Exploded View

613 Data Plate

700 301

230

231

512

232

501

208

105

302 306

203

301

304 301

201

202

510
325

308

502

309

310

KEY 105 201 202 203 208 230 231 232 301

Auto Air Vent Gas pipe Flue manifold (lower) Flue manifold (upper) Burner Fixings Kit Fan Gas Valve Kit Venturi Kit Thermistor Kit

302 Lead Ignition Kit 304 Ignitor Unit 305 Electrode Detection Kit 306 Ignition Electrode Kit 308 Fascia Plastic 309 System Manager Board 310 Primary PCB 325 Bulkhead 501 Jacket Assembly Kit

502 Door Assembly Kit 510 Pump 511 Non-return Valve Assembly 512 Air Inlet Damper 613 Air Inlet 700 Flue Adapter
Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.2 PACKAGING REMOVAL

1. The boiler should be laying on its back with the straps removed.
2. Carefully read the installation instructions before proceeding.
3. Remove the outer packing sleeve.
4. Remove the protective cardboard wall mounting template from the front of the boiler.
5. Remove the packing piece from the top of the boiler.
6. Check the contents against the list in Section 2.3 `Unpacking'. Note: some items are contained within the top packing piece.
7. 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.

3
4 5
7

2.3 UNPACKING
The boiler is supplied fully assembled in one pack. When unpacking the boiler check the contents against the items below. Do not dispose of the packaging until all contents are accounted for, as some parts are held within the cardboard packing pieces.

Boiler

Wall Mounting Template

Installation Guide

Grommet

Condensate Trap

x1 Connector Kit

x1 Wall Mounting Bracket

x1 User Guide
x1 Log Book
x1 Warranty

x2 Hex Head Coach Screws

x6 Wall Plugs

x1 Gas Cock

ACCESSORY BOX

Ball Valve

M1 Tee

Pressure Relief Valve Brass Union

Drain Cock Weather Compensation Wood Screws Wall Plugs

Terminals

Wall plate

Wall Seal

Flue Sleeve

Installation & Servicing

INSTALLATION
17 mm 850mm to top of boiler

SECTION 2 - INSTALLATION

2.4 WALL MOUNTING TEMPLATE
Note. The template shows the positions for the top fixing holes. Care must be taken to ensure the correct holes are drilled. 1. Tape template into the selected position. 2. Ensure squareness by hanging a plumbline. 3. Mark on to the wall:
a. The top 4 wall mounting plate screw positions.
b. The 2 boiler lower fixing positions using diagram below
c. The position of the flue duct. Mark the centre of the hole as well as the circumference.
4. Remove the template from the wall.

Note: Horizontal flue runs must be inclined at 1.5-3o to the horizontal to allow condensate to drain back to the boiler.

BOILER LOWER FIXING POSITIONS

�12mm

332 mm

2.5 PREPARING THE WALL
IMPORTANT. The wall must be vertical 90� (�5�) from the perpendicular to allow safe operation of the integral flue non-return valve. Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. 1. Drill 4 boiler top fixing holes with a 12mm
masonry drill and insert the plastic plugs provided, for the wall mounting plate. 2. Drill the 2 boiler lower fixing holes with a 12mm masonry drill, insert the plastic plugs provided . 3. Fix the wall bracket into place with 4 M10x70 hex head coach screws provided.
16

Vertical Offset From X mm 120 Y

245

365

490

X 2m
4m
6m
8m
Distance from flue centre line (Y) to outside wall surface. For lengths greater than 8m, increase offset (X) by 60mm for every additional 1m. Does not apply to air intake.

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION 2.6 MOUNTING THE BOILER

� Due care should be taken when lifting the

boilers, with respect to their weights, see

Table 2 on Page 6. Also refer to Section 1.4

Safe Handling.

1. Lift the boiler onto the wall mounting plate as

shown. Note: It is not necessary to hold the

boiler at an angle to engage the wall mounting

plate.

2. Using the remaining coach screws, secure the bottom of the boiler to the wall through the attached brackets.
IMPORTANT NOTE It is essential that these bolts be fitted prior to making up the flow and return connections to the boiler to prevent the boiler becoming detached .

2.7 VENTILATION
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

Model

45 & 45P

55 & 55P

45 & 45P

55 & 55P

Min Free Area (cm2)

432

527

216

263

Keston Heat 45/55 (multiple boiler applications)
Detail reference should be made to BS. 6644 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 & Servicing

SECTION 2 - INSTALLATION
2.8 FLUE SYSTEMS
IMPORTANT
When installing a replacement boiler a new flue system is recommended. However re-using the existing boiler flue installation is acceptable if the installer checks and confirms:
� The flue pipe is the approved Marley/Polypipe/Terrain/Wavin 50mm muPVC solvent weld flue system � The flue installation is upgraded to the most recent flue standards taking particular care to comply with
flues in voids � A risk assessment is conducted to confirm the effectiveness of the flue � The existing flue will last the lifetime of the new appliance

DESIGN
Individual air supply and flue outlet pipes are used as standard.
The material approved for this application which MUST be used are:
- Marley muPVC Solvent Weld System (50mm) - Polypipe System 2000 muPVC solvent weld (50mm) - Polypipe Terrain 200 muPVC Solvent Weld System (50mm) - Wavin OSMA PVC-C Solvent Weld System (50mm)
to BS5255 and/or BSEN1566-11 and BSEN1329, are the only systems approved for this application.

The following pipe and fittings are approved.

Polypipe System 2000 muPVC solvent Weld System (50mm)

Polypipe Code MU 301

4m length muPVC wastepipe 5/225

MU 313

50mm x 45 deg muPVC obtuse bend

MU 314

50mm x 92.5 deg muPVC swept bend

MU 310

50mm muPVC straight coupling

MU 316

50mm x 92.5 deg muPVC swept tee

Polypipe Terrain Solvent Weld System (50mm)

Polypipe Code 200.2.40

4m length muPVC wastepipe

201.2.135 200.2.91

50mm x 135 deg muPVC bend 50mm x 91 1/4 deg muPVC swept bend

210.2

50mm muPVC straight coupling

204.2.135

50mm muPVC swept tee

Marley muPVC Solvent Weld System (50mm)

Marley Code KP 304 KP32

50mm x 4m double spigot pipe 50mm x 45 deg bend

KSC3 KB3

50mm straight coupling 50mm x 88.5 deg bend

KT3

50mm swept tee

Wavin OSMA PVC-C Solvent Weld System (50mm)

Wavin Code

2M073

3M lenght waste pipe 50mm

2M163

50mm x 45 deg bend

2M161

50mm x 87.5 deg bend

2M104

50mm double socket

2M190

50mm x 8.75 tee

Consideration MUST be given to expansion and contraction of the flue. Refer to Assembly Practice (Section 2.10) in this installation and Servicing Instructions for further guidance.

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).

Fig.1

FLUE OUTLET

continued . . . . .

Installation & Servicing

SECTION 2 - INSTALLATION

Fig.2
TERMINATION OF THE FLUE AND AIR

The flue and air pipes may terminate independently through any external walls within the same dwelling except on opposing walls, within the maximum lengths shown in Fig 3 & 4. (Alternatively a vertical flue pipe termination is acceptable.)
The air pipe must have an elbow and 150mm length of pipe directed downwards with a termination grill fitted.
The air pipe can be situated at the side or beneath the flue pipe to a minimum dimension of 140mm (see diagram below). It must not be sited above the flue pipe.
The flue and air pipes must extend by at least 40mm from the wall surface.
Condensing boiler emit a visible plume of water vapour from the flue terminal, this is normal. It is the responsibility of the installer to judiciously select a terminal location that does not cause a nuisance.
If either the flue or air terminal is below a height of 2m from ground level a terminal guard must be fitted.

TERMINAL POSITIONS

Flue Pipe

Minimum Separation 140mm

Acceptable range of air pipe siting

Air Pipe Terminal

150mm

Elbow

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 output will be reduced by 0.8% per additional metre.
The maximum lengths of both air inlet pipe and flue outlet pipe, when no bends are used, are as detailed in figs 3 & 4.
However, each bend used has an equivalent length that must be deducted from the maximum straight length stated in figs 3 & 4. Knuckle bends must not be fitted.
A 92.5� swept elbow is equivalent to 1.0m straight length. A 45� bend is equivalent to 0.5m straight length.
It is possible to have variable flue and air lengths as described within the shaded area of Figs 3 & 4.
SLOPE
`Horizontal' flue outlet pipework MUST slope at least 3.5 degrees (60mm per metre run) downwards towards the boiler. Pipework can be vertical. Only swept elbows can be used.
Air inlet pipework can be truly horizontal or vertical, or sloping in a downward direction towards the boiler but in each case rain, etc., must be prevented from entering the pipe. There must be no troughs in any of the pipework, whether it be air inlet or flue outlet.

Due to the low temperature of the gases,
further condensate will form within the
flue system. Drain points, with suitable traps, must therefore be incorporated
within the flue system at the base of the vertical flue sections in excess of 3m, for 50mm muPVC pipe flue systems. These additional condensate drains must be run
to discharge as detailed in Section 2.15.
Such drain points can be formed using
standard plastic fittings. Refer to the example in Fig. 5.

Fig.5
Flue Condensate Drain Point Example

To Terminal

To Boiler

Tee Fitting

6 in min.

Fig.3

Air Pipe Length [m]

Keston Heat 2 - 45 &45P - Flue & Air Pipe Length 42

Acceptable Operating Area

2 2 4 6 8 10 12 14 16 18 20 22

Flue Pipe Length [m]

Air Pipe Length [m]

Fig.4 Keston Heat 2 - 55 & 55P - Flue & Air Pipe Length
42

Acceptable operating area

2 2 4 6 8 10 12 14 16 18 20

Flue Pipe Length [m]

FLUE OUTLET

Installation & Servicing

SECTION 2 - INSTALLATION

2.9 FLUE TERMINATION POSITION

Twin Flue Positions

When Flue & Air Terminals are When Flue & Air Terminals are

less than 500mm apart

more than 500mm apart

Flue min. spacing Air min. spacing Flue min. spacing Air min. spacing

A Below an opening (1)

300mm

50mm

300mm

50mm

B Above an opening (1)

300mm

50mm

300mm

50mm

C Horizontally to an opening

300mm

50mm

300mm

50mm

D Below gutters,soil pipes or drain pipes

75mm

E Below eaves

200mm

50mm

200mm

50mm

F Below balcony or car port roof

200mm

50mm

200mm

50mm

G From a vertical drain pipe or soil pipe

150mm

50mm

150mm

50mm

H From an internal or external corner or to a boundary

200mm

50mm

200mm

50mm

alongside the terminal (2)

I Above ground,roof or balcony level

300mm

100mm

300mm

100mm

J From a surface or boundary facing the terminal

600mm

100mm

600mm

100mm

K From a terminal facing a terminal

1200mm

L From an opening in the car port into the building

1200mm

100mm

1200mm

100mm

M Vertically from a terminal on the same wall

1500mm

N Horizontally from a terminal on the same wall

300mm

O From the wall on which the terminal is mounted

40mm

P From a vertical structure on the roof

300mm

Q Above intersection with roof

150mm

,(1) In addition, for temperature and structural reasons, the terminal should not be nearer than 150 mm (fanned draught) to an

opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame

,(2) The reference to external corners does not apply to building protrusions not exceeding 450 mm, such as disused chimneys on

external walls for: fanned draught appliances

FLUE OUTLET

300mm min

Pitched roof with structure

150mm min

Vertical termination must have an elbow with terminal fitted directed from roof, 150mm above roof intersection with air taken from side wall or low level (min 500mm separation).

Air Terminal
Note. Recomend to fit deflector, preventing rain ingress

When running flue pipes vertically they MUST be a minimum of 140mm apart and termination MUST comply with Sections 2.8

TERMINAL POSITIONS

Flue Pipe

Minimum Separation 140mm

Elbow

150mm

If chimney penetrates dotted area such that A is less than 300mm, B shall not be less than 300mm.

A = 600mm B = 2000mm
The flue terminal shall not penetrate the shaded area of the roof

Acceptable range of air pipe siting

Air Pipe Terminal

GENERAL INSTALLATIONS
All parts of the system must be constructed in accordance with BS 5440 Part 1, except where specifically mentioned in these instructions.
All pipe work must be adequately supported.
All joints other than approved pushon or plastic compression connectors must be made and sealed with solvent cement suitable for muPVC pipes and conforming to BS 6209.

Consideration must be given to Gas Safe bulletin TB200/TB008 regarding flues in voids.
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. However, the cupboard or compartment must not be used for storage.

Installation & Servicing

SECTION 2 - INSTALLATION

2.10 ASSEMBLY PRACTICE
Remove all plastic debris and burrs when installing air intake piping. Plastic filings caused by cutting muPVC pipe must not be allowed to be drawn into the combustion air blower. Prevent dust entering the air intake when cutting on building sites. Blower failure which is determined to be caused by plastic filings or other debris will not be covered by guarantee.
INSTALLING FLUE AND AIR PIPES
Important - When installing a replacement boiler, a new flue system is recommended.
However re-using the existing boiler flue installation is acceptable if the installer adheres to Section 2.7 Flue System - Important, and also checks and confirms the following:
� Remove the flue adaptor and air spigot from the flue pack
supplied with the boiler.
� Remove boiler front panel - Refer to Section 3.2.
� Remove air intake blanking plate by unscrewing 4 x M5
screws and put to one side, leaving sponge gasket in place.
� Fix air spigot to boiler using the 4 M5 screws, see diag.
below. Ensure sponge gasket is in place and not damaged.
� Insert the flue adaptor into the flue manifold on the top of the
boiler and secure using the 6 M5 screws provided
� Measure, cut and check the air and flue pipes to pass to the
exit from the wall(s) or ceiling.
� Always thoroughly deburr all pipes and most important,
remove shavings 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 sockets and solvent welded with no leaks.

� Using the same methods drill any further holes (always
covering existing pipework), cut and assemble the pipework.
� From outside, complete the two terminations - Se
Section 2.7 Flue System and make good all holes. (Wall sealing collars are available to make good hole areas on the wall face (part number C.08.0.00.07.0).
� Support any pipes whose route could be displaced
either of its own accord or by accident. Any horizontal run over 1m or vertical runs of any length must always be supported. Brackets should be placed at intervals of approximately 1m. Brackets should be loose enough on the pipe to allow thermal expansion and contraction movement.
� Flue pipework through walls MUST be sleeved to
allow thermal expansion and contraction movement.
� Check all connections for security and re-seal any joints
using solvent cement where soundness may be in doubt.
� Check Sample plug for free movement and seating.
Note. It is equally important to seal the air inlet with solvent cement as the flue outlet pipe joints.

Optional Extra / Alternative Flue Connector available.

Flue Sampling Point

Kit number UIN 355139 / 221509

FLUE OUTLET

Installation & Servicing

SECTION 2 - INSTALLATION
2.11 FITTING THE FLUE SLEEVING
1. Cut hole in wall (preferably with 60mm core bore tool). 2. Measure wall Thickness 3. Cut sleeve length to match wall thickness & remove burrs. 4. Grout sleeve into wall with flange on external 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 Terminal

Flue Pipe

Flue Sleeve

Flue Sleeve Flange

Flexible Wall Seal

Wall Plate

FLUE OUTLET

Installation & Servicing

SECTION 2 - INSTALLATION 2.12 FLUE INSTALLATION EXAMPLE KESTON HEAT 55
4m 3.5� back Sleeve to boiler

6m Bracket at each 1 metre
6m
1m
2m 1m 3.5� back to boiler

Calculations

Air Elbows 2 x 1m = 2m Straights 6+2 = 8m Total = 10m

Flue Elbows 3 x 1m = 3m Straights 4+6+1+1 = 12m Total = 15.5m

Overall Flue / Air = 25m

FLUE OUTLET

2.13 FLUE INSTALLATION EXAMPLE KESTON HEAT 45

Sleeve

3.5� back to boiler

Air

2m
Bracket every 1 metre

3m 1.5m

3.5m 1.5m

1.5m

3.5� back to boiler
2.5m

Calculations

Air

Flue

4 x 90� elbows

3 x 90� elbows

Straight lengths

1.5 Straight lengths

2.5

1.5

3.5

13.5

Overall Flue / Air = 25.5m

Installation & Servicing

SECTION 2 - INSTALLATION
2.14 BOILER FRAME AND HEADER KITS
Heat output to a maximum of 330kW can be achieved by cascading up to six Keston Heat 2 boilers. This can be achieved by the use of the Keston Heat 2 boilers fitted side by side on the wall or frames in conjunction with the required header kits.

FLUE OUTLET

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.15 CONDENSATE DRAIN
This appliance is fitted with a 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance. All condensate pipework should conform to the following: a. Where a new or replacement boiler is being installed, access to
an internal `gravity discharge' termination should be one of the main factors considered in determining boiler location. b. Plastic with push fit or solvent connections. c. Internal plastic pipe work a minimum of 19mm ID (typically 22mm OD) d. External plastic pipe must be a minimum of 30mm ID (typically 32 OD) before it passes through the sleeved wall. e. All horizontal pipe runs, must fall a minimum of 45mm per metre away from the boiler at a minimum gradient of 1:19. f. External & unheated pipe work should be kept to a minimum and insulated with Class "O" waterproof pipe insulation. g. All installations must be carried out in accordance to the relevant connection methods as shown in the "Condensate installation diagrams" & BS6798:2009 h. Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage (through freezing) i. All internal burrs should be removed from the pipe work and any fittings. In order to minimise the risk of freezing during prolonged very cold spells, one of the following methods of terminating condensate drainage pipe should be adopted.

Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc. See Figs 1 and 2.
Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc. (fig 3).
External 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 minimum using the most direct and "most vertical" route possible to the discharge point, with no horizontal Sections in which condensate might collect.
- For connections to an external soil/vent stack see Fig 4. Insulation measures as described should be used.
- When a rainwater downpipe is used, an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen, see Fig 5.
- Where the condensate drain pipe terminates over an open foul drain or gully, the pipe should terminate below the grating level, but above water level, to minimise "wind chill" at the open end. The use of a drain cover (as used to prevent blockage by leaves) may offer further prevention from wind chill.
- Where the condensate drain pipe terminates in a purpose designed soak away (see BS 6798) any above ground condensate drain pipe Sections should be run and insulated as described above. See Fig 6.
Unheated Internal Areas Internal condensate drain pipes run in unheated areas, e.g. lofts basements and garages, should be treated as external pipe.
Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual.

Figure 1 - Connection of Condensate Drainage Pipe to Internal Soil & Vent Stack

Boiler with 75mm
sealed condensate
trap

Min � 19mm Internal pipe

Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil Vent Stack

Boiler with 75mm
sealed condensate
trap

Min � 19mm Internal pipe

Internal soil & vent stack

Soil & vent stack

100

minimum gradient
1:19
Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break
Installation & Servicing

450

Minimum connection height up to 3 storeys

Sink/basin/ bath or shower
minimum gradient
1:19

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break
continued . . . . .
25

INSTALLATION

SECTION 2 - INSTALLATION

Figure 3 - Connection of a Condensate Pump Typical Method (see manufacturers detailed instructions)

Figure 4 - Connection of condensate Drainage Pipe to External Soil & Vent Stack

Boiler with 75mm
sealed condensate
trap
Min � 19mm Internal pipe

Visible air break
minimum gradient
1:19 Condensate pump (Install in accordance with manufacturers instructions)

Soil & vent stack

Boiler with 75mm
sealed condensate
trap
Min � 19mm Internal pipe

Water/weather proof insulation

Min � 30mm Internal pipe

minimum gradient
1:19

Boilers without 75mm sealed condensate trap must be fitted with
a 75mm trap and visible air break

450

Minimum connection height up to 3 storeys

Figure 5 - Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe (only combined foul/rainwater drain)

Boiler with 75mm
sealed condensate
trap
Min � 19mm Internal pipe
Min � 30mm Internal pipe
minimum gradient
1:19

3000

Water/ weather proof insulation
Terminated and cut at 45�
43mm 90� male/ female bend

combined foul/ rain water drain External air break Air gap
68mm � PVCU Strap on fitting

Figure 6 - Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away.

Boiler with 75mm
sealed condensate
trap
Min � 19mm Internal pipe

minimum gradient
1:19
Min � 30mm Internal pipe

Water/Weather proof insulation
Max 3m external pipework

75 300
25

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break
2 rows of three �12mm holes 25mm centres, 50mm from the bottom of the tube, facing away from the house

500 3000

Limestone chippings

2.16 BOILER WATER CONNECTIONS
The boiler flow and return pipes are terminated with a 1 1/4" BSP male taper connection located at the bottom of the appliance.
Note. This appliance is NOT suitable for use with a direct hot water cylinder.
Plastic plugs if fitted into the open ends of the flow and return pipes must be removed before connecting the system pipework.
Upon installation a tee connection, isolation valve and safety relief valve/drain point must be fitted to the boiler flow/return connection respectively. (See image opposite). This hardware is provided within the boiler carton. This allows isolation for the water connections in the event of servicing the water circulation pump fitted within the boiler casing.
IMPORTANT: Correct fitment of the safety pressure relief valve must be made to protect the boiler in the event of inadvertent operation when isolated.

Flow Return

Tee (supplied)

Isolation Safety

Valve

(supplied) (supplied)

Drain Point (supplied)

Isolation Valve
(supplied)

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION 2.17 FROST CONNECTION

The boiler has built into its control system the facility to protect the boiler, only against freezing.
If the boiler flow temperature T1, falls below 5oC the boiler pump and burner run until the temperature exceeds 19oC.
Central heating systems fitted wholly inside the building do not normally require frost protections 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.

2.18 GAS CONNECTION
Refer to Section 1.13 for details of the position of the gas connection.
A MINIMUM working gas pressure of 17.5 mbar (7" w.g.) must be available at the boiler inlet for natural gas and minimum of 32mbar for propane with the boiler firing. Refer to Section 3.3 for details of the pressure test point position.
Extend a gas supply pipe NOT LESS THAN 22mm O.D. to the boiler and connect using the gas cock provided. IMPORTANT. The gas service cock contains a non-metallic seal so must not be overheated when making capillary connections.

In order to determine the actual working gas pressure at the
boiler inlet the figure from the table below must be added to the measured pressure (refer to Section 3.3).

Keston Heat Gas Line Pressure Drop

(Natural Gas & Propane)

Boiler Model

mbar

45P

0.5

1.4

55P

0.6

Note. It should be noted that this pressure drop is present within the internal boiler pipe work and is irrespective of the fact that manifold headers are used. This pressure drop will be experienced on each individual boiler regardless of single or multiple installation.

2.19 FITTING THE WEATHER COMPENSATION KIT
SUPPLIED IN ACCESSORY BOX
This kit provides the facility to apply outside air temperature correction to the Boiler or System water flow temperature which therefore provides energy savings. The outside sensor provided allows the actual outside air temperature to be measured at the point of location. The system then adjusts the boiler or system flow temperature in proportion based upon the heating curve. This will reduce the flow temperature set point to reduce running costs. If the outside air temperature is above the required Heating Circuit room temperature setting then the Boiler and/or HC will be switched off. The Boiler or System will also operate the boiler in condensing mode more frequently increasing savings. Once the sensor is fitted it must be configured during the Boiler configuration process.

Kit Contents A. Outside Air Sensor
A
3G10011

Installation & Servicing

continued............

Standalone Boiler - Partial Hydraulics
Single Boiler with a CT Pump Circuit and DHW Tank
Standalone Boiler - Partial Hydraulics
Single Boiler with a CT PuS-mRTp-PCCircuit and RDT-HPCW, T-THWanS k

S-OT

S-RTP-PC

RT-PC, T-HWS

P-HWSC

S-OT

P-PC

P-HWSC

Boiler

CT Pump Circuit

Hot Water Storage

Boiler

CT Pump Circuit

Single Boiler with 2 x CT Pump Circuits

Single Boiler with 2 x CT PS-uRTm-PCp1 Circuits RT-PC1

Hot Water Storage

S-RT-PC2

RT-PC2

S-OT

S-RTP-PC1

RT-PC1

S-RTP-PC2

RT-PC2

S-OT

P-PC1

P-PC2

TS-HWS TS-SH-HWWSS S-HWS

Boiler

CT Pump Circuit

Boiler

CT Pump Circuit

Single Boiler with CT and HWS Zone Circuits

CT Pump Circuit

Single Boiler with CT andS-HRTW-PCS1Zone CircuRTit-PsC1, TS-HWS

S-OT

S-RT-PC1

RT-PC1, TS-HWS

INSTALLATION

Boiler Connections

Inputs

Outputs

Opentherm RT-PC Boiler run

Room

SB-RoTil-eSrCConnBeocilteiornfasult

OutsideInputs S-OT OpeTnatnhkerm SR-TH-WPCS

P1 (0-10OVu) tputs Booiler rPr2un

P-PC

RSoLo1m

SR-RTT-P-SCC BoilePr3fault P-HWSC

OuStLs2ide Tank

TSS--HOWT S S-HWS

P1 (0-10V) or P2

P-PC

SL1

RT-PC

P-HWSC

SL2

TS-HWS

*Opentherm or SL1 SL2 or (SL2 and T-HWS:Opentherm DHW bit)
*Opentherm or SL1 SL2 or (SL2 and T-HWS:Opentherm DHW bit)

Boiler Connections

Inputs

Outputs

Opentherm1 RT-PC1 Boiler run

Opentherm2 RBTo-PilCer2ConnBeocilteiornfasult

Room InputSs-RT-PC1 OpOeunthsiedrem1 RST-OPCT1

PB1ooi(l0er-rP1r20uOVnu) tputsP-PC1

OpeTnathnekrm2 SR-RTT-P-PCC22 BoilePr3fault P-PC2

RSoLo1m OuStLs2ide

SR-RTT-P-PCC11 P1 (0-10V)

RST-OPCT2

or P2

P-PC1

Tank

S-RT-PC2

P-PC2

SL1

RT-PC1

SL2

RT-PC2

*Opentherm1 or SL1, Opentherm2 or SL2 *Opentherm1 or SL1, Opentherm2 or SL2

Boiler Connections

Inputs

Outputs

Opentherm RT-PC1 Boiler run

Room

S-BRoTi-lPeCr 1ConnBeocilteior nfasult

OutsideInputs S-OT P1 (0-10OVu) tputs

OpeTnatnhkerm SR-RTT-P-CCT12 BooilerrPr2un

SECTION 2 - INSTALLATION 2.20 STAND ALONE BOILER - PARTIAL HYDRAULICS

Installation & Servicing

Boiler

CT Pump Circuit

SBoinilegrle Boiler with CT anCTdPHumWp CSircZuoitne Circuits

CT Pump Circuit

Single Boiler with CT andS-HRTW-PCS1 Zone CircRuTi-tPsC1, TS-HWS

S-OT S-OT

S-RT-PC1 V-CT
V-CT

RT-PC1, TS-HWS

V-HWS

Boiler

CT Pump Circuit

Hot Water Storage

SBoinilegrle Boiler with 2 x CCTT ZPuomnpeCiCrciuritcuits

Hot Water Storage

Single Boiler with 2 x CT SZ-RoTn-CeT1Circuits RT-PC1

S-RT-CT2

RT-PC2

S-OT

V-CT1

V-CT2

S-RT-CT1

RT-PC1

S-RT-CT2

RT-PC2

S-OT

V-CT1

V-CT2

Boiler Boiler

CT Pump Circuit CT Pump Circuit

TS-HWS S-HWS TS-HWS S-HWS

*Opentherm1 or SL1, Opentherm2 or SL2

Boiler Connections

Inputs

Outputs

Opentherm RT-PC1 Boiler run

Room S-RT-PC1 Boiler fault

Outside

BS-oOilTer ConnPe1c(t0io-1n0sV)

Tank InputSs-RT-CT2

or P2Outputs

OpeSnLt1herm RRTT--CPTC11 PB1o(i0le-r1r0uVn)

RSoLo2m

ST-SR-TH-WPCS1 BoiolerrPf2ault

V-CT1

Outside

S-OT

P1 (P03-10V) V-HWS

Tank

S-RT-CT2

or P2

SL1 SL2

RT-CT1 P1 (0-10V)

TS-HWS

or P2

V-CT1

V-HWS

*Opentherm or SL1 SL2 or (SL2 and T-HWS:Opentherm DHW bit)

Boiler Connections

Inputs

Outputs

Opentherm1 RT-PC1 Boiler run

Opentherm2 RT-PC2 Boiler fault

Room

S-RBTo-iPleCr1ConnPe1c(t0io-1n0sV)

OutsideInputs S-OT

or P2Outputs

OpeTnatnhkerm1 S-RRTT--PCCT12 OpenSLth1erm2 RRTT--CPTC12

PB1o(i0le-r1r0uVn) BoiolerrPf2ault

V-CT1

RSoLo2m

SR-RT-TC-PT2C1 P1 (P03-10V) V-CT2

Outside

S-OT

or P2

Tank SL1

S-RT-CT2 P1 (0-10V)

RT-CT1

or P2

V-CT1

SL2

RT-CT2

V-CT2

*Opentherm1 or SL1, Opentherm2 or SL2 *Opentherm1 or SL1, Opentherm2 or SL2

INSTALLATION

SECTION 2 - INSTALLATION

INSTALLATION

SECTION 2 - INSTALLATION

2.21 ABBREVIATIONS

Abbreviation Description

AH-HC

Air heater of Heater Circuit

On/Off Boiler n

Circulating pump (controlled by Sequence Control)

F-PP-HWSC Fault contact of primary pump of Hot Water Storage Circuit

Fault Messages Function

F-B

Fault contact of Boiler

F-CP

Fault contact of Circulating pump

F-P-HWSC Fault contact of pump of Hot Water Storage Circuit

Gen

General Function

Heater Circuit Function

HD-SC

Heat demand contact of Sequence Control

HWS

Hot Water Storage Circuit Function

Mixing Circuit Function

No Connection

Pump Circuit Function

P-HWSC

Pump of Hot Water Storage Circuit

P-MC

Pump of Mixing Circuit

P-PC

Pump of Pump Circuit

PP-HWS

Primary pump of Hot Water Storage Circuit

Abbreviation Description

S-FT

Flow temperature sensor

S-FT-HC

Flow temperature sensor of Heating Circuit

S-FT-MC

Flow temperature sensor Mixing Circuit

S-FT-SC-PT Common Flow temperature sensor of Sequence Control and Pump Circuit

S-HWS

Water temperature sensor Hot Water Storage Circuit

S-OT

Outdoor temperature sensor

S-RT-HC

Room temperature sensor of Heating Circuit

S-RT-MC

Room temperature sensor Mixing Circuit

S-RT-PC

Room temperature Pump Circuit

S-RT-SC

Room temperature sensor Sequence Control

Sequence Control Function (Plant Control)

T-HC

Overtime contact of Heater Circuit

T-HWS

Overtime contact of Hot Water Storage Circuit

T-MC

Overtime contact of Mixing Circuit

T-PC

Overtime contact of Pump Circuit

T-SC

Overtime contact of Sequence Control

T-SC-HWS

Overtime contact of both Sequence Control and Hot Water Storage Circuit

V-MC

3-Way valve of Mixing Circuit

2.22 ELECTRICAL CONNECTIONS
Warning. This appliance MUST be efficiently earthed. 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 4A. Wiring external to the boiler MUST be in accordance with the current I.E.T. (BS7671) Wiring Regulations and any local

regulations. For Ireland reference should be made to the current ETCI rules for electrical installations.
Connection should be made in a way that allows complete isolation of the electrical supply - such as a double pole switch, having a 3mm contact separation in both poles, or a plug and unswitched socket serving only the boiler and system controls. The means of isolation must be accessible to the user after installation.

2.23 EXTERNAL WIRING

External wiring MUST be in accordance with the current I.E.T. (BS7671) Wiring Regulations. For Ireland reference should be made to the current ETCI rules for electrical installations.
The wiring diagrams illustrated in Section 2.25 covers examples of the range of systems that may be used with this appliance.
For wiring external controls to the boiler, reference should be made to the systems wiring diagram supplied by the relevant manufacturer in conjunction with the connection diagram shown in Section 2.25.
Difficulty in wiring should not arise, providing the following directions are observed: 1. The appliance must be wired with a permanent live supply.
2. Four Multi Function Relay Volts free outputs are provided that may be configured to control Pumps, Valves and other devices over the voltage ranges specified: 24V DC to 230V 50Hz. An additional option kit may be added to control a Pump using a modulating 0-10V DC control signal.
3. Input terminals are available for connecting a variety of system controls for heating demand, and optionally for DHW demand.

Heating demand can be controlled by: � 230V SL1 and SL2 inputs where configured for two
heating circuits
� Two OpenTherm bus interfaces for the connection of OpenTherm compatible room control kits. One per heating circuit.
� Modulating sequencer kit
� an external BMS
� an outside temperature sensor.
� Optional Room Temperature sensor kit, one for each heating circuit configured.
� Optional Header Temperature sensor where hydraulic separation or a combined flow temperature control is required
DHW demand can be controlled by: � 230V programmer and/or cylinder thermostat
� tank sensor kit.
� One 2 channel OpenTherm interface for a Heating and a DHW circuit.
The electrical supply and other inputs for the boiler can be seen in Section 2.24.

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION 2.24 INSTALLER CONNECTIONS

I1 123
L N PE Mains Supply

Mains Voltage/230V 50Hz

I2 1234

I3 12

SL1 L SL2 L Demand inputs

~~
230V 50Hz Interlock

I4 12
LN 230V 50Hz Auxiliary

KEY
l1 Mains Supply Connector, 230V 50Hz. Live, Neutral, PE.
l2 Demand inputs, Multifunctional, 230V 50Hz. Typical setting: SL1, Heating Circuit 1 SL2, Heating Circuit 2/DHW
l3 Optional Interlock input, 230V 50Hz
l4 Auxiliary Mains Supply Output, 230V 50Hz. Live, Neutral. Internal Pump power connection

Volts Free Contacts

I5 123456

I6 1234

C NO PE C NO PE

MFR1

MFR2

C NO C NO

MFR3

MFR4

KEY
I5 Multifunction Volts Free Relay Outputs, 24V DC to 230V 50Hz. Typical setting: MFR1 Heating Circuit 1 Pump MFR2 DHW Circuit Pump Internal Pump PE connection
I6 MFR3 Burner On Indication MFR4 Boiler Fault Indication

I7 12

I8 123

PELV
I9 123456

I10 12345678

I0 I1
PELV Interlock

PWM GND 10V Pump control

10V GND OT1+ OT1- OT2+ OT2-

0-10V

OpenTherm

S1 GND S2 GND S3 GND S4 GND

DHW Tank /

Header

Room 2

Room 1

Outside Temp.

PELV Only I7 Optional Interlock input. I8 N/A. I9 Boiler Control:
0-10V Capacity or Temperature. OpenTherm Interface 1. Boiler, Heating Circuit 1 and/or DHW Circuit Control. OpenTherm Interface 2. Heating Circuit 2 Control.

KEY
I10 Optional Sensors: Header Sensor for Cascade Control. DHW Tank Temperature or Heating Circuit 2 Room Temperature. Heating Circuit 1 Room Temperature. Outside Temperature Sensor for Heating Curve.

*Note: The items grayed out are not standard and are connections provided by the relevant option kits.

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.25 BOILER WITH EXTERNAL CONTROLS
1. If the boiler circulating pump is not controlled by the boiler then the overrun time of this pump MUST be set to a minimum of 30 seconds. Failure to do so may invalidate the warranty.
2. It is preferable that any pump used to circulate water through an individual boiler is controlled by the local boiler. Either as a 230V 50Hz supply as shown, enabled by the Volts Free Contacts e.g. MFR1 or controlled by the option kit for 0-10V pump control. If not then a pump overrun function MUST be provided by the controlling system.

3. The pump load and switch on surge current must be within the limits of the output if it is powered directly from the Volts Free Contact. The limits are as specified in the Electrical Specification Table below.
A slave contactor may be used to power the pump where needed.
4. If the switched live is provided without a Volts Free Contact then this MUST be taken from the same phase as the boiler mains supply, preferable through the same isolator.

Input - SL1, SL2 Input - 0-10V Sensor - Outside Sensor - Header Sensor - Room Sensor - DHW Tank
Output - MFR1..4 output
Bus - OT1, OT2 Bus - VariCAN

Electrical Specifications for External Connections
Voltage 230V 50Hz 0 to 10V DC

Load 3k min 5mA max

5V DC

10k @ 25�C (25/85)=3977

24 V DC to 230V 50Hz

1.0 A max at Cos� = 0.6

230V 50Hz

Peak Surge 20A < 20ms

230V 50Hz

Peak Transient 100A < 10uS

OpenTherm V 4.0

CAN Open, proprietary protocol

External Controls via Switched Live Demand

External controls via switched live demand Showing internal Boiler Pump controlled directly from PELV PWM control

I1 L

N PE

Mains Supply

123

Mains Voltage/230V 50Hz

I2 SL1 L SL2 L
Demand inputs

I3 ~~
230V 50Hz Interlock

1234

I4 LN
230V 50Hz Auxiliary
12

Volts Free Contacts

I5 C NO PE C NO PE

I6 C NO C NO

MFR1

MFR2

MFR3

MFR4

123456

1234

Fused Spur / Isolator

Switched Live / Volts Free
Contact

L N PE Mains Supply

External Controls

Internal Boiler Pump

PELV PWM pump connection
continued............
Installation & Servicing

Installation & Servicing

External Controls via 0-10V Input

External controls via 0-10V input HC Pump controlled via remote Volts Free enable from MFR1

I1 L

N PE

Mains Supply

123

Mains Voltage/230V 50Hz

I2 SL1 L SL2 L
Demand inputs

I3 ~~
230V 50Hz Interlock

1234

I4 LN
230V 50Hz Auxiliary
12

Volts Free Contacts

I5 C NO PE C NO PE

I6 C NO C NO

MFR1

MFR2

MFR3

MFR4

123456

1234

I7 I0 I1 PELV Interlock
12

I8 PWM GND 10V
Pump control
123

PELV
I9 10V GND OT1+ OT1- OT2+ OT2-

0-10V

OpenTherm

I10 S1 GND S2 GND S3 GND S4 GND

DHW Tank / Header Room 2 Room 1

Outside Temp.

123456

12345678

Not an available option

SECTION 2 - INSTALLATION

Fused Spur / Isolator
L N PE Mains Supply

0-10V Source
BMS

External Controls via OpenTherm Master

External controls via OpenTherm Master HC Pump controlled via remote Volts Free enable from MFR1

I1 L

N PE

Mains Supply

123

Mains Voltage/230V 50Hz

I2 SL1 L SL2 L
Demand inputs

I3 ~~
230V 50Hz Interlock

1234

I4 LN
230V 50Hz Auxiliary
12

Volts Free Contacts

I5 C NO PE C NO PE

I6 C NO C NO

MFR1

MFR2

MFR3

MFR4

123456

1234

I7 I0 I1
PELV Interlock
12

I8 PWM GND 10V
Pump control
123

PELV
I9 10V GND OT1+ OT1- OT2+ OT2-

0-10V

OpenTherm

I10 S1 GND S2 GND S3 GND S4 GND

DHW Tank / Header Room 2 Room 1

Outside Temp.

123456

12345678

Not an available option

continued............
33

Fused Spur / Isolator

L N PE Mains Supply

External Controls

OpenTherm Master
BMS or Room Control

INSTALLATION

SECTION 2 - INSTALLATION

INSTALLATION

External Controls via OpenTherm Master and Optional Tank Temperature Sensor Heating Circuit Pump/Valve and DHW Tank Charge Pump/Valve controlled directly from MFR1

External controls via OpenTherm Master and Optional Tank Temperature Sensor Heating Circuit Pump and DHW Tank Charge Pump controlled directly from MFR1 and MFR2

I1 L

N PE

Mains Supply

123

Mains Voltage/230V 50Hz

I2 SL1 L SL2 L
Demand inputs

I3 ~~
230V 50Hz Interlock

1234

I4 LN
230V 50Hz Auxiliary
12

Volts Free Contacts

I5 C NO PE C NO PE

I6 C NO C NO

MFR1

MFR2

MFR3

MFR4

123456

1234

I0 I1 PELV
Interlock
12

I8 PWM GND 10V
Pump control
123

PELV
I9 10V GND OT1+ OT1- OT2+ OT2-

0-10V

OpenTherm

I10 S1 GND S2 GND S3 GND S4 GND

DHW Tank / Header Room 2 Room 1

Outside Temp.

123456

12345678

Not an available option

Fused Spur / Isolator
L N PE Mains Supply

Tank Overheat and optional
Control Thermostat
External Controls

Heating Circuit Pump

DHW Tank Charging Pump

OpenTherm Master
BMS or Room Control

Tank Temperature
Sensor

External Controls via Switched Live or OpenTherm or Room Temperature Sensors for Two Heating Circuits Heating Circuit Pumps/Valves controlled directly from MFR1 and MFR2

External controls via Switched Live/ or OpenTherm/ or Room temperature sensors for Two Heating Circuits Heating Circuit Pumps controlled directly from MFR1 and MFR2

I1 L

N PE

Mains Supply

123

Mains Voltage/230V 50Hz

I2 SL1 L SL2 L
Demand inputs

I3 ~~
230V 50Hz Interlock

1234

I4 LN
230V 50Hz Auxiliary
12

Volts Free Contacts

I5 C NO PE C NO PE

I6 C NO C NO

MFR1

MFR2

MFR3

MFR4

123456

1234

I0 I1 PELV
Interlock
12

I8 PWM GND 10V
Pump control
123

PELV
I9 10V GND OT1+ OT1- OT2+ OT2-

0-10V

OpenTherm

I10 S1 GND S2 GND S3 GND S4 GND

DHW Tank / Header Room 2 Room 1

Outside Temp.

123456

12345678

Not an available option

continued............

Installation & Servicing

Fused Spur / Isolator
L N PE Mains Supply

Room Thermostat
HC1

Room Thermostat
HC2

Optional HC Room Thermostats

Heating Circuit 1

Heating Circuit 2

OpenTherm Master HC 1

OpenTherm Master HC 2

Optional HC Room Controls

Heating Circuit 2 Room
Temperature Sensor

Heating Circuit 1 Room
Temperature Sensor

Optional HC Room Temperature Sensors

INSTALLATION

SECTION 2 - INSTALLATION

Connecting Multiple Room Sensors

One

Two

Connecting Multiple Room Sensors

Three

Four

Sensor 1

10k
1% 0.25W

Sensor 1

Sensor 3

Sensor 1

Sensor 2

10k
1% 0.25W

Sensor 2

10k
1% 0.25W

Note. Where multiple sensors are used the overall accuracy of temperature measurement is reduced, this can be compensated for by trimming the parallel resistors Siting of multiple room sensors for large spaces should be carefully considered to avoid significant temperature differences between sensors

Sensor 3

Sensor 3 Sensor 4

2.26 CONTROLS CONFIGURATION, COMMISSIONING AND TESTING

A. ELECTRICAL INSTALLATION
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.

B. GAS INSTALLATION
1. The whole of the gas installation, including the meter, should be inspected and tested for soundness and then purged in accordance with the recommendations of the relevant standards listed on page 8, by the installer. In IE refer to I.S.813:2002.

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 NOT SMOKE.

Installation & Servicing

INSTALLATION

2.27 USER INTERFACE

SECTION 2 - INSTALLATION

OK BACK

A. ROTARY KNOB � Enter a menu, if in the normal
operation screen, and highlight the first menu item. � Scroll up (anti-clockwise) or down (clockwise) in a menu � Change the value in parameter setting. � If an error is showing in the title bar, scroll to the associated error screen(s), and return.
B. LCD DISPLAY SCREEN � Menu and status display.

C. BURNER LED � Will be on if the burner is lit.
D. SELECT BUTTON � Enter a menu, if in the normal
operation screen, and highlight the first menu item. � Enter the highlighted menu (sub menu or parameter), if in a menu or sub menu. � If in a parameter setting, select a parameter which will then flash for adjustment, once adjusted using the rotary knob press again to store and move on.

E. BACK BUTTON � In a menu, return to the previous
menu layer. � In parameter setting, exit the
parameter without storing the value. � In a guided assistant, go back to the
previous screen.
F. RESET BUTTON � Reset the associated boiler module
error, if a resettable (lockout) error is active. � Return to the normal operation screen.

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.28 GLOSSARY OF TERMS

2.28.1 Menu function resource definitions
� Plant � related to the master or standalone boiler for plant control (common) functions
� Boiler � only related to an individual boiler and only used by that boiler
� Heating Circuit � only related to an individual heating circuit
� DHW circuit � only related to an individual DHW circuit

2.28.2 Pump definitions
� System pump � used to circulate water through the Heating and/or DHW circuits as well as either the boiler or the secondary side of a LLH or Plate H/X
� Shared boiler pump � used to only circulate water through more than one boiler
� Shunt pump � used to circulate an amount of water between flow and return to limit the temperature differential
� Boiler pump � used to only circulate water through a single boiler
� HC pump � a pump or valve that allows flow through a HC
� DHW pump � a pump or valve that allow flow through a DHW circuit

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.29 BOILER GUIDED CONFIGURATION STAND ALONE BOILER

Power up the boiler
Initailly the software revision of the System Manager with be displayed in the top LHS of the screen.
The following screens will then be sequentially displayed:
443.NNN.NN

The system will then scan the bus to determine if any other devices are present:
Scan devices

2.29.2 Boiler setup options Pre configuration selection
A standalone or non-VariCAN cascade boiler can be set up quickly to a selected configuration at this step. One of the following options can be selected:
Set setup options

Pairing devices

Advanced configuration Basic pre config 1 Basic pre config 2

2.29.1 Initial Settings
At start up the default language is selected and shown on the display, this can be changed if required or just confirmed:
Language
English Francais Nederlands
Once the language is either confirmed or selected then this is stored and set as the default. For a standalone boiler the controller must be selected as a Master:
Con t r oller
Slave Mast er

Slave Mast er

Con t r oller

I nitialize communication

The current date followed by the time can now be set:

Year : Mon t h : Day: Done

Dat e
2018 7 4

Year : Mon t h : Day: Done

Dat e
2018 7 4

Year : Mon t h : Day: Done

Dat e
2018 7 4

Year : Mon t h : Day: Done

Dat e
2018 7 4

Time

Hour:

Minute: 0

Auto su/ wi time:

Done

Set setup options Advanced configuration Basic pre config 1 Basic pre config 2 Basic pre config 3
Set setup options Basic pre config 1 Basic pre config 2 Basic pre config 3
Set setup options Basic pre config 2 Basic pre config 3
By selecting Advanced Configuration the system will continue to follow the guided configuration as detailed in Section 2.29.3. If one of the basic pre config options is selected then the configuration will be set to a specific set up, then the system will reboot:
Co m m i ssi o n i n g
Followed by the boiler status screen.

Configure as master

Time

Hour:

Min u t e:

Auto su/ wi time:

Done

Keston Heat 2 45kW
Basic pre Operation: Off Flow temp: 0.0� C Flow temp: 35.4�C

Time

Hour:

Min u t e:

Auto su/ wi time:

Done

Time

Hour:

Min u t e:

Auto su/ wi time:

Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

For each of the selected basic pre config options the setting for the boiler are detailed below.
These pre configurations can also be used as a starting point and then adapted to match the requirement.
Basic pre config 1 (Not for Keston Heat 2)
Standalone boiler with the following configuration:
Plant options for Boiler run and Boiler fault on MFR3 and MFR4 respectively.
One Heating circuit with HC enable on SL1 with an ON/OFF Pump/Valve on MFR1. Maximum and minimum flow temperature settings of 80 and 30 degrees respectively. With DHW priority and set to run immediately in Day operating mode.
One DHW circuit with DHW enable (Overheat and control) on SL1 with an ON/OFF Pump/Valve on MFR2. Set to run in Time clock single day operating mode.

2.29.3 Advanced Configuration
The display will now prompt for selection of the boiler number, this is necessary to identify the boiler should it become part of a iCCS (Commercial Control System), by default a Master boiler will have a setting of 01:
Set boiler number
Boiler 01 Master Done
Set boiler number
Boiler 01 Master Done
The system will now scan the known devices on the bus to determine what Heating Circuits are available in the boiler for configuration:

Two Heating Circuits:
Set HC number
HC 01 Boiler 1.1 HC # # Boiler 1.2 Done
Set HC number HC 01 Boiler 1.1 HC 02 Boiler 1.2 Done
Set HC number HC 02 Boiler 1.2 Done
The system will now scan the known devices on the bus to determine what DHW circuits are available in the boiler for configuration:

Basic pre config 2
Standalone/non-VariCAN cascade boiler with the following configuration:
Plant control enable on SL1 with a modulating boiler pump, and with options for Boiler run and Boiler fault on MFR3 and MFR4 respectively.
Basic pre config 3
Standalone boiler with the following configuration:
Plant options for a modulating System pump with Boiler run and Boiler fault on MFR3 and MFR4 respectively.
One Heating circuit with HC enable on SL1 with an ON/OFF Valve on MFR1. Maximum and minimum flow temperature settings of 80 and 30 degrees respectively. With DHW priority and set to run immediately in Day operating mode.
One DHW circuit with DHW enable (Overheat and control) on SL1 with an ON/OFF Valve on MFR2. Set to run in Time clock single day operating mode.

Once this is completed, the display will prompt with the available heating circuits so that they may have HC numbers allocated, and then later configured.
Set HC number
HC # # Boiler 1.1 HC # # Boiler 1.2 Done
If any heating circuits are required for the boiler, then number them sequentially from 1. If there are no heating circuits to be configured to this boiler just move on past by selecting "Done". Examples: Single Heating Circuit:
Set HC number
HC 01 Boiler 1.1 HC # # Boiler 1.2 Done
Set HC number HC 01 Boiler 1.1 HC # # Boiler 1.2 Done

Once this is completed, the display will prompt with the available DHW circuits so that they may have DHW circuit numbers allocated, and then later configured.
Set DHW number
DHW # # Boiler 1 Done
If any DHW circuits are required for the boiler then number them sequentially from 1. If there are no DHW circuits to be configured to this boiler just move on past by selecting 'Done'. Example:
Set DHW number
DHW 01 Boiler 1 Done
Set DHW number DHW 01 Boiler 1 Done
The system will now configure the System Manager for these circuits.

Set HC number HC # # Boiler 1.2 Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

The system will now scan the known devices on the bus to determine what Plant functions are available in the boiler for configuration:
2.29.4 Plant Settings
If you wish to configure any of the following plant functions, then select 'Yes', if not continue by selecting 'No' and move to Section 2.29.5. ONLY configure these functions here if you are not going to use them in any HC's or DHW circuits.
Configure plant?
No Yes
Configure plant? No Yes
Hydraulic Separation: If the boiler has Hydraulic Separation from the intermediate or final circuits in the heating system, or if the boilers have a combined flue system then set this option to either `Header' or `Plate heat exchanger'.
Hydraulic separation?
No Header Plate heat exchanger
Hydraulic separation? No Header Plate Heat exchanger
Hydraulic separation? Header Plate heat exchanger

Set Flue System: If the boilers are connected into a common or cascade flue system then you can choose multiline flue system where the minimum capacity of the boiler in a cascade can be increased in order to ensure no backflow in the flue system.
Set flue system
St an d ar d Mu lt ilin e
Set flue system St an d ar d Mu lt ilin e
Shared Boiler Pump: If the Master boiler has a pump that is shared across the plant then select the output that is used to control it from the list. Otherwise select `None'.
Loc'n of shared boiler pump?
None PWM/ 0-10V () MFR1 ()
Loc'n of shared boiler pump? None PWM/ 0-10V () MFR1 () MFR2 ()
Loc'n of shared boiler pump? PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()
Loc'n of shared boiler pump? MFR1 () MFR2 () MFR3 () MFR4 ()
Loc'n of shared boiler pump? MFR2 () MFR3 () MFR4 ()

System Pump: If the boiler has a Plant System Pump connected then select the output that is used to control it from the list. Otherwise select `None'. Once an output has been configured the selected function is shown in brackets behind the output name.
Select loc'n of system pump?
None PWM/ 0-10V () MFR1
Select loc'n of system pump? None PWM/ 0-10V () MFR1 () MFR2 ()
Select loc'n of system pump? PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()
Select loc'n of system pump? MFR1 MFR2 () MFR3 () MFR4 ()
Select loc'n of system pump? MFR2 () MFR3 () MFR4 ()
Select loc'n of system pump? MFR3 () MFR4 ()

Header Thermistor:
If the system has a header sensor fitted, combined flow, then select `Yes', otherwise the system will use the average flow temperature of all running boilers.

Loc'n of shared boiler pump? MFR3 () MFR4 ()

Installation & Servicing

SECTION 2 - INSTALLATION

INSTALLATION

Shunt Pump: Shunt Pump. If the boiler has a Plant Shunt Pump connected between the Flow and Return headers then select the output that is used to control it from the list. Otherwise select `None'. Once an output has been configured the selected function is shown in brackets behind the output name.
Select loc'n of shunt pump
None PWM/ 0-10V () MFR1 ()
Select loc'n of shunt pump None PWM/ 0-10V () MFR1 () MFR2 ()
Select loc'n of shunt pump PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()
Select loc'n of shunt pump MFR1 MFR2 () MFR3 () MFR4 ()
Select loc'n of shunt pump MFR2 () MFR3 () MFR4 ()
Select loc'n of shunt pump MFR3 () MFR4 ()
System Fault Indication: If the Master boiler has Slave boilers or Extension Modules connected and the requirement to signal errors for the plant then select the output that is used to control it from the list. Otherwise select `None'.
System fault indication
None PWM/ 0-10V () MFR1 (HC1 pump)
System fault indication None PWM/ 0-10V () MFR1 () MFR2 ()
System fault indication PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()

System fault indication MFR1 () MFR2 () MFR3 () MFR4 ()
System fault indication MFR2 () MFR3 () MFR4 ()
System fault indication MFR3 () MFR4 ()
0-10V Input: If the Plant is to be controlled by a single 0-10V signal, this can be configured. Otherwise set to `None'. The options are Capacity or Temperature control, with additional parameters for Temperature control:
Configure 0-10V input
None 0-10V Capacity 0-10V Temperature
Configure 0-10V input None 0-10V Capacity 0-10V Temperature
Configure 0-10V input 0-10V Capacity 0-10V Temperature

0-10V input Temp. Setp. 0V:
Temp. setp. 0V
8� C
Done
Temp. setp. 0V
8� C
Done
0-10V input Temp. Setp. 10V:
Temp. setp. 10V
80� C
Done
Temp. setp. 10V
80� C
Done
Configure 0-10V Parameters:
Configure 0-10V parameter?
No Yes
Configure 0-10V parameter? No Yes
Voltage demand. This setting determines the switching point at which demand is expected by the system, anything below this is at keep alive voltage:
Configure voltage demand
1.0V
Done
Configure voltage demand
1.0V
Done
Voltage life zero. This setting determines the minimum keep alive voltage where the system expects a voltage to be present on an operational interface, anything below this indicates a wiring fault:
Configure voltage life zero
0.0V
Done
Configure voltage life zero
0.0V
Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

Switched Live 1 Input Function: The SL1 input can be configured as a Plant function, if this is not required select `None'.
Configure SL1
None Enable
Configure SL1 None Enable

Outside Sensor: This sensor can be selected and used for all demands to the boiler, if this is not required select `None':
Outside sensor available?
None Yes
Outside sensor available? None Yes

Plant Setp. SL1
85� C
Done
Plant Setp. SL1
85� C
Done

Internal Time Clock: Internal timeclock. A timeclock can be set for the Plant, this will control all functions. It can be set as a single or multiple day timer.
Use an internal time clock
No Yes

Plant OpenTherm interface:
Plant OpenTherm control. If the boiler has the requirement to use the OpenTherm interface then select the connection type used from the list. Otherwise set to `None'.

Use an internal time clock No Yes

Configure OpenTherm

None On demand Temperature demand

Configure OpenTherm None On demand Temperature demand Capacity demand
For On demand there is an associated flow temperature setpoint:
OpenTherm Temp. Setpoint
60� C
Done

OpenTherm Temp. Setpoint
60� C
Done

Configure OpenTherm On demand Temperature demand Capacity demand

Configure OpenTherm Temperature demand Capacity demand

Internal Time Clock Single: Single day timer is programmable for each of the 7 days with 3 periods per day, Monday through Sunday:
Time Clock
Single Mu lt ip le
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Tuesday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Wednesday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Th u r sd ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Fr i d ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Sat u r d ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Sunday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Once all days and times are set, select `Done' to continue.

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

Internal Timeclock Multiple: Multiple day timer is programmable for Mon-Fri and Sat-Sun with 3 periods per group of days:
Time Clock Single Mu lt ip le

2.29.5 Boiler Configuration:
Select boiler to configure
Boiler 1 Done
Select boiler to configure Boiler 1 Done

Boiler On Indication: If the boiler has the requirement to signal when the burner is lit then select the output that is used to control it from the list. Otherwise select `None'.
Boiler on indication
None PWM/ 0-10V () MFR1 (Boiler pump)

Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Sat - Su n Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Once all days and times are set, select `Done' to continue.
Holiday Programme: Holiday programme. Up to 8 holiday periods can be set, each has a start and end date.
Configure holiday prog?
No Yes

Boiler Pump Location: If the boiler has an individual Boiler Pump connected then select the output that is used to control it from the list. Otherwise select `None'.
Select loc'n of boiler pump
None PWM/ 0-10V () MFR1 ()
Select loc'n of boiler pump
PWM/ 0-10V () MFR1 () MFR2 ()
Select loc'n of boiler pump PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()
Select loc'n of boiler pump MFR1 () MFR2 () MFR3 () MFR4 ()
Select loc'n of boiler pump MFR2 () MFR3 () MFR4 ()

Boiler on indication None PWM/ 0-10V () MFR1 (Boiler pump) MFR2 ()
Boiler on indication PWM/ 0-10V () MFR1 (Boiler pump) MFR2 () MFR3 ()
Boiler on indication MFR1 (Boiler pump) MFR2 () MFR3 () MFR4 ()
Once an output has been configured the selected function is shown in brackets behind the output name:
Example MFR3 as a boiler on indication:
Boiler on indication MFR2 () MFR3 (Boiler on indication) MFR4 ()

Configure holiday prog? No Yes

Select loc'n of boiler pump MFR3 () MFR4 ()

Holiday Programme Holidays:
Holidays Period 2 Start 01/ 01/ 2000 End 01/ 01/ 2000 Done
Holidays Period 1 Start 01/ 01/ 2000 End 01/ 01/ 2000 Done
Once all are set select `Done' to continue.

Once an output has been configured the selected function is shown in brackets behind the output name:
Example MFR1 as a boiler pump.
Select loc'n of boiler pump PWM/ 0-10V () MFR1 (Boiler pump) MFR2 () MFR3 ()

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

Boiler Fault Indication: Boiler fault indication. If the boiler has the requirement to signal when the Boiler is at fault then select the output that is used to control it from the list. Otherwise select `None'.
Boiler fault indication
None PWM/ 0-10V () MFR1 (Local boiler pump)
Boiler fault indication None PWM/ 0-10V () MFR1 (Local boiler pump) MFR2 ()
Boiler fault indication PWM/ 0-10V () MFR1 (Local boiler pump) MFR2 () MFR3 (Boiler on indication)
Boiler fault indication MFR1 (Local boiler pump) MFR2 () MFR3 (Boiler on indication) MFR4 ()
Boiler fault indication MFR2 () MFR3 (Boiler on indication) MFR4 ()
Once an output has been configured the selected function is shown in brackets behind the output name: Example MFR4 as a boiler fault indication.
Boiler fault indication MFR3 (Boiler on indication) MFR4 (Boiler fault indication)

LPG Valve:
If the boiler has the requirement to control an external LPG valve then select the output that is used to control it from the list. Otherwise select 'None'.

Flue Damper:
If the boiler has the requirement to control an external flue damper then select the output that is used to control it from the list. Otherwise select 'None'.

LPG Valve

Flue damper

None PWM/ 0-10V () MFR1 (Local boiler pump)

LPG Valve None PWM/ 0-10V () MFR1 (Local boiler pump) MFR2 ()

Flue damper None PWM/ 0-10V () MFR1 (Local boiler pump) MFR2 ()

LPG Valve PWM/ 0-10V () MFR1 (Local boiler pump) MFR2 () MFR3 ()

Flue damper PWM/ 0-10V () MFR1 (Local boiler pump) MFR2 () MFR3 ()

LPG Valve MFR1 (Local boiler pump) MFR2 () MFR3 () MFR4 ()
Once an output has been configured the selected function is shown in brackets behind the output name:
Example MFR3 as an LPG valve control.
LPG Valve MFR2 () MFR3 (LPG valve) MFR4 ()

Flue damper MFR1 (Local boiler pump) MFR2 () MFR3 () MFR4 ()
Once an output has been configured the selected function is shown in brackets behind the output name:
Example MFR3 as a flue damper control:
Flue damper MFR2 () MFR3 (Flue damper) MFR4 ()

The boiler has now been configured and the display will return to:
Select boiler to configure
Boiler 1 � Done

Note. The boiler number now has a tick next to it showing that it has been configured. If you completed the boiler configuration, select 'Done'.
Select boiler to configure Boiler 1 � Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.29.6 Heating Circuit Configuration:
Heating circuit selection for configuration. Select the HC from the available heating circuits in the list:
Select HC to configure
HC1 Boiler1.1 Done
HC pump location. If the HC has an individual HC Pump connected then select the output that is used to control it from the list. Otherwise select `None'.
Select loc'n of HC pump
None PWM/ 0-10V () MFR1 ()
Select loc'n of HC pump None PWM/ 0-10V () MFR1 () MFR2 ()
Select loc'n of HC pump PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()
Select loc'n of HC pump MFR1 () MFR2 () MFR3 () MFR4 ()
Select loc'n of HC pump MFR2 () MFR3 () MFR4 ()
Select loc'n of HC pump MFR3 () MFR4 ()
Once an output has been configured the selected function is shown in brackets behind the output name: Example, MFR1 as a HC pump:
Select loc'n of HC pump PWM/ 0-10V () MFR1 (HC1 pump) MFR2 () MFR3 ()

The HC maximum temperature set-point can be set, it defaults to the maximum output of the boiler model, but this can be decreased:
Set max flow temp
80� C
Done
Set max flow temp
80� C
Done
The HC minimum set-point can be set, it defaults to the minimum output of the boiler model, but this can be increased:
Set min flow temp
15� C
Done
Set min flow temp
15� C
Done
Room Sensor. If the HC has a Room Sensor connected then select 'Yes' from the list. Otherwise set to 'None'.
Room sensor available?
None Yes
Room sensor available? None Yes
Outside Sensor. If the HC has a specific Outside Sensor connected then select 'Yes' from the list. Otherwise set to 'None'.
Outside sensor available?
None Yes
Outside sensor available? None Yes

Control variant. The HC must have a control variant that is used to determine the demand. This is usually set to Flow Temperature unless specific configuration options are chosen.
Control Variant
Flow Weat h er Room
Control Variant Flow Weat h er Room Weather and Room
Control Variant Weat h er Room Weather and Room
Control Variant Room Weather and Room
Switched Live 1 input function. The SL1 input can be configured as a HC function, if this is not required select 'None'.
Configure SL1
None HC enable Ov er r i d e
Configure SL1 None HC enable Ov er r i d e Holiday
Configure SL1 HC enable Ov er r i d e Holiday Frost
Configure SL1 Ov er r i d e Holiday Frost
Configure SL1 Holiday Frost

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

OpenTherm input function. The OpenTherm interface can be configured as a HC function, if this is not required select 'None'.
Configure OpenTherm
None On/ Off Temperature control
Configure OpenTherm None On/ Off Temperature control
Configure OpenTherm On/ Off Temperature control

Single day timer is programmable for each of the 7 days with 3 periods per day, Monday through Sunday:

Multiple day timer is programmable for Mon-Fri and Sat-Sun with 3 periods per group of days:

Time clock
Single Mu lt ip le

Time clock Single Mu lt ip le

Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Tuesday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Sat - Su n Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

If the external OpenTherm device has its own timeclock then confirm this on the next screen Internal timeclock. A timeclock can be set for the HC, this will control all functions. It can be set as a single or multiple day timer.
Use an internal timeclock
No Yes
Use an internal timeclock No Yes

Single Wednesday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Th u r sd ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Fr i d ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Sat u r d ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Once all days and times are set, select 'Done' to continue.
Holidy programme. Up to 8 holiday periods can be set, each has a start and end date. Once all are set select 'Done' to continue:
Configure holiday prog?
No Yes

Single Sunday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

Configure holiday prog? No Yes

Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

Holidays Period 1 Start 01/ 01/ 2000 End 01/ 01/ 2000 Done
Holidays Period 1 Start 01/ 01/ 2000 End 01/ 01/ 2000 Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

Pump protection. To enable seizure protection on pumps/valves connected to the HC, select 'Yes'.
Configure pump protection?
No Yes
Configure pump protection? No Yes
DHW priority. If the HC is requried to give priority to any DHW demands in the system then select 'Yes'.
DHW priority?
No Yes
DHW priority? No Yes
Operating mode. The operating mode of the HC can be set from a scrolling field, once this is set then the HC configuration is completed by selecting 'Done'.
Operating mode
St an d b y Done
Operating mode
Time clock single day Done

The HC has now been configured and the display will return to:
Select HC to configure

DHW pump location. If the DHW circuit has an individual DHW Pump connected then select the output that is used to control it from the list. Otherwise select 'None'.

HC1 Boiler1.1 � Done

Select loc'n of DHW pump

Note, that the HC number now has a tick next to it showing that it has been configured. If you have completed the HC configuration, select 'Done'.
Select HC to configure HC1 Boiler1.1 � Done

None PWM/ 0-10V () MFR1 ()
Select loc'n of DHW pump None PWM/ 0-10V () MFR1 () MFR2 ()

2.29.7 DHW Configuration
DHW circuit selection for configuration. Select the DHW circuit from the available DHW circuits in the list:
Select DHW to configure
DHW1 Boiler 1 Done
Local DHW Circuit If the Master boiler has its own independent DHW circuit then select `Yes', if not select `No'.
Local DHW circuit
No Yes

Select loc'n of DHW pump PWM/ 0-10V () MFR1 () MFR2 () MFR3 ()
Select loc'n of DHW pump MFR1 () MFR2 () MFR3 () MFR4 ()
Select loc'n of DHW pump MFR2 () MFR3 () MFR4 ()
Select loc'n of DHW pump MFR3 () MFR4 ()

Local DHW circuit No Yes

Operating mode
Time clock multiple day Done

Operating mode
Day Done

Operating mode
Night Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

Example, MFR2 as a DHW pump:
Select loc'n of DHW pump MFR1 () MFR2 (DHW1 pump) MFR3 () MFR4 ()
The DHW maximum tank temperature setpoint can be set, it defaults to the maximum DHW output of the boiler model, but this can be decreased:
Set max tank temp

Tank Sensor. If the DHW has a Tank Sensor connected then select 'Yes' from the list. Otherwise set to 'None'.
Tank Sensor?
None Yes

None Yes

Tank Sensor?

60� C
Done
Set max tank temp
60� C
Done
Antilegionella. If the DHW tank requires the Antilegionella function then select either 'Weekday' or 'Interval' from the list. Otherwise set to 'None'.
Antilegionella?
None Weekday I nterval
Antilegionella? None Weekday I nterval

SL2 input function: The SL2 input can be configured to act as an enable, in the case of a tank thermostat with the internal timer, or as an override switch/tank thermostat with external timer. By default the SL2 input must be wired via a safety thermostat and isolating valve on a pressurised DHW tank, and must always be present for the DHW tank charge to operate.
Configure SL2
None DHW enable DHW override
OpenTherm Input Function. The OpenTherm interface can be configured as a DHW circuit control function, if this is not required, select 'None'.
Configure OpenTherm

Single day timer is programmable for each of the 7 days with 3 periods per day, Monday through Sunday:
Time clock
Single Mu lt ip le
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Tuesday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Wednesday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Th u r sd ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Fr i d ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

For weekday set the following parameters, followed by 'Done':
Antilegionella timing Weekday: Saturday Start time: 01: 00 Done

None Temperature demand
Configure OpenTherm None Temperature demand

Antilegionella timing Weekday: Saturday Start time: 01: 00 Done
Antilegionella timing Weekday: Saturday Start time: 01: 00 Done
Then set the desired Antilegionalla temperature, followed by 'Done':
Antilegionella temperature
65� C
Done

Internal timeclock. A timeclock can be set for the DHW circuit, this will control all functions. It can be set as a single or multiple day timer.
Use an internal timeclock
No Yes
Use an internal timeclock No Yes

Single Sat u r d ay Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Sunday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Single Monday Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done

Antilegionella temperature

65� C
Done

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

Multiple day timer is programmable for Mon-Fri and Sat-Sun with 3 periods per group of days:
Time clock Single Mu lt ip le
Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Sat - Su n Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Mu lt ip le Mo n - Fr i Period 1 06: 00-22: 00 Period 2 00: 00-00: 00 Period 3 00:00-00:00 Done
Once all days and times are set, select 'Done' to continue. Holiday programme. Up to 8 holiday periods can be set, each has a start and end date. Once all are set select 'Done' to continue:
Configure holiday prog?
No Yes
Configure holiday prog? No Yes

Operating mode. The operating mode of the DWH Circuit can be set from a scrolling field, once this is set then the DHW Circuit configuration is completed by selecting 'Done'.
Operating mode
St an d b y Done
Operating mode
Time clock single day Done
Operating mode
Time clock multiple day Done
The DHW circuit has now been configured and the display will return to:
Select DHW to configure DHW1 Boiler1 � Done
Note, that the DHW circuit number now has a tick next to it showing that it has been configured. If you have completed the DHW circuit configuration, select 'Done':
Select DHW to configure DHW1 Boiler 1 � Done
The system will now reboot:

The boiler configuration is now complete and the display will show the boiler status screen:
< Boiler Name & Model No. > Operation: Off Flow temp: 0.0� C Flow temp: 37.5�C
If you need to re-configure a function in the boiler then the appropriate access level needs to be enabled.

Holidays Period 1 Start 01/ 01/ 2000 End 01/ 01/ 2000 Done
Holidays Period 1 Start 01/ 01/ 2000 End 01/ 01/ 2000 Done

System will reboot Loading system table

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.29.8 Menu � Configuration � General � Access level
The Access level screen is then displayed and each item can be selected and the default access level code can be changed:

2.29.9 Menu - Configuration
All menus and setting will now be available for that particular access level. There will now also be the chance to reconfigure different functions within the system:

Access level

Configuration

Advanced user I nstaller 1 I nstaller 2

General Recommission system Recommission Plant

Access level
Advanced user I nstaller 1 I nstaller 2 Ex p er t

Configuration
General Recommission System Recommission Plant Recommission Boiler

Access level
I nstaller 1 I nstaller 2 Ex p er t

Configuration
Recommission System Recommission Plant Recommission Boiler Recommission HC

Access level I nstaller 2 Ex p er t
Once an access level is selected then the display will allow the current access level code to be entered. Each access level has its own initial code:
Advanced user
####

Configuration Recommission Plant Recommission Boiler Recommission HC Recommission DHW
Configuration Recommission Boiler Recommission HC Recommission DHW
Configuration Recommission HC Recommission DHW

Default code 2222
I nstaller 1
####

Depending upon the access level, not all configuration options will be available.
Once selected, refer to the Configuration section above for guidance.

Default code 3333
I nstaller 2
####

Default code 4444 Once the correct code has been entered the following confirmation screen will be displayed for a short period, depending upon which access level was selected:
I nstaller 1
I nstaller 1 Confirm

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.30 INITIAL LIGHTING

1. Check that the system has been filled and the boiler is not air locked - air in the boiler could damage the heat exchanger. For this reason the air vent located in the left top side must never be shut off.
2. Check that all the drain cocks are closed and any valves in the flow and return are open.
3. Check that the GAS SERVICE COCK IS ON.
4. Fill the condensate trap with water before putting the unit into operation (see Section 3.7 for condensate trap removal).
5. Check the indication on the pressure gauge. If the pressure is less than 1 bar the installation should be filled up first (sealed system only).

6. Switch the electricity supply ON and check that all the external controls are calling for heat. Check boiler is set for winter operation - see boiler 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. If this is not possible contact the boiler manufacturer.

Keston Heat2 ~ Flue CO2 % measurements (hot condition)

45P

55P

Max Rate � 0.5%

9.5

9.7

10.8

10.7

Min Rate � 0.5%

8.7

9.9

OPERATING SEQUENCE
Standby

no Heat demand on?
yes Pump On

Temp. < setpoint?

yes

Fan On

Fan Pre-purge

Spark Generator On Gas Valve On
3s Ignition Period

no Flame detected?
yes

yes

Soft Start

Spark Generator Off 1st Stabilisation Period

Demand On & Temp. <Set point & Anti-cycle
done?
Fan off. Pump off Standby

Burner Output controlled relative to

Heat Demand by varying Fan Speed

Burner On

Demand

off or Temp. >setpoint?

yes

Gas Valve Off Pump Overrun

yes

Heat Demand Off?

Installation & Servicing

INSTALLATION

SECTION 2 - INSTALLATION

2.31 GENERAL CHECKS

Make the following checks for correct operation.
1. The correct operation of ANY secondary system controls should be proved. Operate each control separately and check that the main burner or circulating pump, as the case may be, responds.
2. Water circulation system; a. With the system HOT examine all water connections for soundness.
b. With the system still HOT, turn off the gas, water and electricity supplies to the boiler and drain down to complete the flushing process.

c. Refill and vent the system, clear all air locks and again check for water soundness.
d. Balance the system.
3. Check the condensate drain for leaks and check it is discharging correctly.
4. Finally set the controls to the User's requirements.
Note. If an optional programmer kit is fitted then refer to the instructions supplied with the kit.

2.32 HANDING OVER

ROUTINE OPERATION
Full instructions covering routine lighting and operation of the boiler are given in the User Guide located on the inside of the lower controls door.
Draw the attention of the boiler owner or his representative to the User Guide. Give a practical demonstration of the lighting and shutting down of the boiler.
Describe the function of the boiler and system controls and show how they are adjusted and used.
Hand these Installation and Servicing Instructions, and Log book to the customer and request him to keep them in a safe place for ready reference. Place the User Guide back into the lower controls door. For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance to the appropriate standard.

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 return to the owner or their representative.
Recommend that a contract for this work should be made with the regional gas authority or a suitably qualified Gas Safe Registered Engineer. In IE servicing work must be carried out by a competent person.

2.33 SAFETY
It is the law that any service work must be carried out by a Suitably qualified Gas Safe Registered Engineer. In IE service work must be carried out by a competent person.
WARNING. Always turn off the gas supply at the gas service cock, and switch off and disconnect the electricity supply to the appliance and any external controls before servicing or replacing components.
IMPORTANT.
After completing the servicing or replacement of components always: � Test for gas soundness.
� Check the water system is correctly filled and free of air. Air in the boiler could cause damage to the heat exchanger. For this reason the automatic air vent / vent tube in the left top side must never be blocked.

� Check the jacket front panel is correctly fitted, ensuring that a good seal is made. Secure the controls fascia in place.
� With the system hot examine all water connections for soundness.
� Check the gas rate and measure the combustion CO/ CO2 content. The CO/CO2 ratio of the flue gas should not be greater than 0.004 ratio & the CO should not exceed 350ppm.
� Carry out functional checks as appropriate.

Installation & Servicing

SECTION 3 - SERVICING

3. SERVICING
3.1 SERVICING SCHEDULE
Note. Refer to "System Set up information" at rear of User Guide.
To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually.
Keston Heating does not accept any liability resulting from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the Company's recommendations and specifications. Note. Some aluminium oxide build-up within the heat exchanger assembly is quite usual with this type of condensing boiler. Though removal and cleaning is recommended annually, the heat exchanger, sump and condensate trap must be inspected and cleaned after a maximum of 2 years operation.
1. Light the boiler and carry out function checks, noting any operational faults.
2. Run the boiler for 5 minutes and then check the gas consumption rate. Refer to procedure opposite on how to force the burner to maximum rate.
3. Optional test - Connect a suitable gas analyser to the sampling point fitted in the flue adapter. For correct boiler operation the CO/CO2 ratio of the flue gas should not be greater than 0.004 ratio and the CO2 values should match those in table 1. If this is the case and the gas input is at least 90% of the nominal, unless the maximum length of flue/air inlet is used then gas input is at least 80% of the nominal, once compliance with the note above is ensured, then no further action need be taken. If not proceed to 4.
4. Remove and clean the burner. Refer to Sections 3.6. If after cleaning the burner the gas input is not at least 90% of the nominal then contact the boiler manufacturer.
5. Inspect the heat exchanger through the burner opening. If there are signs of aluminium oxide build up, spray water down the flueways. Refer to Section 3.5.
6. Remove the sump cover/Helmholtz where fitted and scrape out any deposits. Refer to Section 3.8.
7. Remove the condensate trap and flush through with water. Refer to Section 3.7.
8. Check that the flue terminal is unobstructed and that the flue system is sealed correctly.
9. After completion of servicing Refer to Section 2.32 for reference to final safety checks.

SETTING TO MAXIMUM OR MINIMUM OUTPUT Ensure that there is a current CH demand to the boiler (e.g. the CH Switched Live is on)
KESTON Heat2 50kW Operation: Off Flow setp: 0.0� C Flow temp.: 40.4� C
Press "OK" and the following screen witll be displayed.
Menu
Configuration Boiler Menu Plant
Menu
Boiler Menu Plant Heating circuits
Boiler Menu
Ser v i ce Hours run Fault history
Service
Service min Service max Service variable
Service Service min Service max Service variable
Service max
Boiler 1
Boiler 1 Service Operation: Service max Flow temp.: 40.4� C Capacity: 100%

Press "OK" and the boiler will go to Maximum Rate for 10 minutes after which normal operation will resume.

SERVICING

Installation & Servicing

SECTION 3 - SERVICING
3.2 REMOVAL OF CASING
Refer to Section 2.32.
Front Panels 1. Open the control casing door. 2. Remove the two screws retaining the front panel, lift the
panel to remove. 3. Lower the control panel to the service position.

SERVICING

Side Panels Note. Removal of side panels is not required for
normal service.
4. Remove the screws from the top and bottom of the side panels.
5. Re-assemble in reverse order.

Installation & Servicing

SERVICING

SECTION 3 - SERVICING 3.3 REMOVAL OF FAN AND GAS VALVE ASSEMBLY

MODELS: 45 & 55

1. Refer to Section 2.32.

2. Remove the upper front panel, Refer to Section 3.2.

3. Remove the three screws retaining the upper and lower flue manifold.

4. To remove the flue manifold lift up the flue Sections and disengage from the sump then pull the flue Sections downwards and remove.

5. Remove the air inlet damper and seal.

6. Disconnect the electrical connections

from the gas valve.

7. Disconnect the electrical connections from the fan.

8. Undo the gas valve union nut and replace the fibre washer.
9. Remove the three screws retaining the fan assembly and remove the fan assembly.

10. Inspect & clean as necessary.

11. Re-assemble in reverse order replacing all gaskets.

5 7

Inlet Gas

Pressure Test

Point

8 9

3.4 REMOVAL OF NON-RETURN VALVE

1. Refer to Section 2.32.
2. Remove the upper front panel. Refer to Section 3.2.
3. Remove the screw retaining the lower flue manifold to the heat exchanger.
4. Lift up the flue Sections and disengage from the sump then pull the flue Sections downwards and remove.
5. Remove the non-return Valve assembly and check for damage and that the nonreturn valve moves freely. If any damage is apparent the whole assembly must be replaced. Ensure correctly sized nonreturn valve is fitted.
6. Reassemble in reverse order, ensuring all flue manifold seals are located and undamaged. Replace if required.
7. Check the operation of the boiler. Refer to Section 2.32.

3 4
3
5

Installation & Servicing

SECTION 3 - SERVICING

3.5 REMOVAL OF BURNER
4

1. Refer to Section 2.32.

2. Remove the front panel. Refer to Section 3.2.

3. Remove the fan and gas valve assembly. Refer to

Section 3.3.

4. Remove the four or six screws and the two extended

nuts securing the burner to release the burner body.

5. Lift the burner body by lifting out of its recess.

6. The burner can now be cleaned on the back face

only, the metal fibre surface must not be touched. The

burner must be replaced if it shows signs of damage.

7. After cleaning the burner replace it in the recess and check the burner body seal for signs of damage. If damage is apparent it must be replaced. The upstream (stainless steel) side may be cleaned of dust and debris.

8. Reassemble in reverse order. Ensure the notch in the burner aligns with the up-stand feature in the heat engine. The four or six screws and 2 extended nuts should be fitted following a diagonal tightening sequence twice. All fittings should be secured firmly.
9. Check the operation of the boiler (Refer to Section 2.32).

SERVICING

3.6 HEAT EXCHANGER INSPECTION / CLEANING
1. Refer to Section 2.32. 2. Remove the front panel. Refer to Section 3.2. 3. Remove the fan and gas assembly. Refer to Section 3.3. 4. Remove the burner. 5. Remove the ignition and detection electrodes. Refer to
Sections 3.12 & 3.13. 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. Reassemble in reverse order replacing all gaskets. 8. Check the operation of the boiler. Refer to Section 2.32.
3.7 REMOVAL OF CONDENSATE TRAP
1. Refer to Section 2.32. 2. Unscrew the nut and disconnect the flexible pipe. 3. Unscrew the top nut and remove the condensate trap. 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 Section 2.32.

PLAN VIEW

Installation & Servicing

SECTION 3 - SERVICING
3.8 REMOVAL OF SUMP COVER
1. Refer to Section 2.32. 2. Remove the front panel. Refer to
Section 3.2. 3. Prepare boiler for possible condensate
spillage during the process. 4. Remove the two screws from the sump
cover and pull away from the boiler. 5. Scrape out any deposits. 6. Reassemble in reverse order replacing
all gaskets. 7. Check the operation of the boiler.
Refer to Section 2.32.

SERVICING

3.9 REMOVAL OF FAN
1. Refer to Section 2.32. 2. Remove the upper front panel (Refer to Section 3.2). 3. Remove the fan and gas assembly and air inlet
damper (Refer to Section 3.3). 4. Remove the screws retaining the venturi to the fan. 5. Transfer venturi and gas valve assembly to the new
fan. 6. Reassemble in reverse order replacing all gaskets. 7. Check the operation of the boiler. 8. Refer to Section 2.32
3.10 REMOVAL OF GAS VALVE
1. Refer to Section 2.32. 2. Remove the upper front panel (Refer to Section 3.2). 3. Remove the fan and gas assembly and air inlet damper
(Refer to Section 3.3). 4. Remove the 3 screws holding the gas valve to the
venturi. 7. Remove the 4 screws retaining the inlet flange to gas
valve & transfer to new valve. 8. Fit new gas valve to venturi using the new seal
provided, ensure gas nozzle is fitted correctly. 9. Reassemble in reverse order replacing all gaskets. 10. Check the operation of the boiler. 11. Refer to Section 2.32.
Installation & Servicing

SECTION 3 - SERVICING

3.11 REMOVAL OF VENTURI / AIR INLET DAMPER

1. Refer to Section 2.32. 2. Remove the front panel. Refer to Section 3.2.

3. Remove the flue manifold complete with seal and remove the air damper Section refer to Section 3.3. If the air inlet damper is damaged go to points 6-8.
4. Remove the fan and gas assembly. Refer to Section 3.3.
5. Remove venturi from fan and gas valve. Refer to Sections 3.9 & 3.10.

6. Replace with new venturi/ air inlet damper if necessary ensuring the gas orifice is fitted and seal is replaced.
7. Reassemble in reverse order replacing all gaskets.

Venturi Air inlet damper

8. Check the operation of the boiler. Refer to Section 2.32

3.12 REMOVAL OF IGNITION ELECTRODE

1. Refer to Section 2.32.

2. Remove the front panel. Refer to Section 3.2.

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 3.5mm �1.

7. Reassemble in reverse order.

8. Check the operation of the boiler (Refer to

Section 2.32.

3.5mm �1
4 3

SERVICING

3.13 REMOVAL OF DETECTION ELECTRODE
1. Refer to Section 2.32. 2. Remove the front panel. Refer to Section 3.2. 3. Pull off the detection 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. 7. Reassemble in reverse order. 7. Check the operation of the boiler. Refer to
Section 2.32.

5 4
3 3

Installation & Servicing

SECTION 3 - SERVICING

3.14 REMOVAL OF AUTOMATIC AIR VENT

1. Refer to Section 2.32.
2. Remove the front panel. Refer to Section 3.2.
3. Unscrew the air vent (A) from the self sealing fitting (B) on the top left of the flow pipe.
4. Remove the clear tubing from the air vent spigot.
5. Fit the new air vent.
6. Refit the clear plastic drain tubing ensuring there are no kinks as air in the boiler could cause damage to the heat exchanger.
7. Re-assemble in reverse order.
8. Check the operation of the boiler. Refer to Section 2.32.

4
A B

3.15 REMOVAL OF WATER PRESSURE SWITCH
1. Refer to Section 2.32. 2. Remove the front panel. Refer to Section 3.2.
5 3. Isolate the water circuit and drain 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 Section
2.32.

4 x2

SERVICING

3.16 REMOVAL OF FLOW / RETURN / HEAT EXCHANGER THERMISTOR

1. Refer to Section 2.32.

2. Remove the front panel. Refer to Section 3.2.

3. Isolate the water circuit and drain the system.

4. Disconnect the electrical connections from the

thermistor.

5. Unscrew the thermistor.

6. Fit the new thermistor and seal. Do not overtighten.

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 Section 2.32.

HX
Return Flow

Installation & Servicing

SECTION 3 - SERVICING

3.17 FLUE THERMISTOR REPLACEMENT

1. Refer to Section 2.32.

2. Remove the front panel. Refer to Section 3.2.

3. Disconnect the electrical connections from the thermistor.

4. Unscrew the thermistor.

5. Fit the new thermistor with gasket seal - DO NOT overtighten.

6. Re-assemble in reverse order.

7. Check the operation of the boiler. Refer to

Section 2.32.

3.18 REMOVAL OF SPARK GENERATOR
4
1. Refer to Section 2.32.
2. Remove the front panel. Refer to Section 3.2.
3. Isolate the electrical supply to the boiler and fully isolate the boiler from any external supply.
4. Remove the three electrical connections from the spark generator.
5. Gently push down the ignitor to remove from the bracket.
6. Replace unit and reasseble in reverse order, ensuring all connections are fully inserted.
7. Check the operation of the boiler. Refer to Section 2.32.

SERVICING

Installation & Servicing

SECTION 3 - SERVICING

3.19 PUMP HEAD REPLACEMENT
1. Refer to Section 2.32.
2. Remove the front panel. Refer to Section 3.2.
3. Isolate water at the flow & return shut-off valves beneath boiler.
4. Drain the water from the boiler via the drain cock adjacent to the shut-off valve.
5. Remove the RHS casing panel to allow access. Refer to Section 3.2.
6. Remove condensate assembly (elbow, union, preformed hose).
7. Drop down the control panel door.
8. Disconnect the pump power supply at the left hand terminal plug.
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 4mm `T bar' Allen key is required).
11. Withdraw the pump head from the body.
12. Remove the PWM cable plug from the pump head.
13. Remove the pump head through the bulkhead aperture. Removal of side panel will allow pump head to be rotated through the space between the bulkhead and the sump.
Care should be taken to avoid water spillage onto the PCB connections when withdrawing the pump head through the aperture. There is a plug situated in the boiler casing floor directly beneath the pump to allow drainage of any spillage within the casing.
13. Fit replacement pump head.
14. Reconnect all connections in reverse order, ensuring all sealing grommets are correctly located. Refer to Section 2.32.
15. Re-fit side panel ensuring corner grommet is located correctly. Re-fit front panel.

10 8

SERVICING

Installation & Servicing

SECTION 3 - SERVICING

3.20 REMOVAL OF MAIN PCB

1. Refer to Section 2.32.

2. Isolate the electrical supply to the boiler and fully

isolate the boiler from any external supply.

3. Remove the upper front panel and put the control

panel into the service position. Refer to Section 3.2.

4. Fit the earth strap provided with the spare PCB to your wrist and to a suitable earthed metal.

5. Remove the PELV harness from the securing clips located on the rear of the control box cover

6. Pull off all of the main PCB connectors.

7. Remove the 4 PCB retaining screws.

8. Fit new PCB, refit in reverse order and refer to Replacement PCB Instructions.

9. Check the operation of the boiler. Refer to Section 2.32.

SERVICING

6
3.21 REMOVAL OF SYSTEM MANAGER
1. Refer to Section 2.32. 2. Isolate the electrical supply to the boiler and fully
isolate the boiler from any external supply.
7
3. Remove the upper front panel and put the control panel into the service position. Refer to Section 3.2.
4. Fit the earth strap provided with the spare PCB to your wrist and to a suitable earthed metal.
5. The System Manager is fitted beneath the main PCB. To access follow points 5 - 7 in Section 3.21.
6. With access to the System Manager, remove the electrical connections
7. Remove the six retaining screws. 8. Replace with new system manager, refit in reverse
order and refer to System Manager Replacement Instructions. 9. Check the operation of the boiler. Refer to Section 2.32.
62

Installation & Servicing

SECTION 4 - WIRING
4. WIRING
ti
4.1 INTERNAL WIRING COMBUSTION MANAGER

FS 2 1

PCB

Internal Boiler Pump

PELV PWM pump connection
Boiler Boiler Run Fault I6 C NO C NO

1234

To internal boiler pump

CH1/Boiler System

CH2/DHW/ Shunt Valve/
Pump

C NO PE C NO PE I5

123456

Chassis PE

GV 8765
4321

Chassis PE IGN
123

Chassis PE

To internal boiler pump 230V 50Hz
Auxiliary
I4 L N

Mains Supply L N PE
I1

123

CH/CH2 DHW Demand I2 SL1 L SL2 L
1234

Chassis PE

3 ION Analogue 2 ION PE 1 ION Digital
5 Lockout COM 4 Lockout NO 3 2 Burner ON COM 1 Burner ON NO
5 Pump DHW COM 4 Pump DHW NO 3 2 Pump CH COM 1 Pump CH NO
8 Valve AC N2 7 Valve AC N1 6 Valve DC+ 5 Valve DC4 Valve AC L2 3 Valve AC L1 2 IGN Neutral 1 IGN Live
5 Mains Aux Live 4 Mains Neutral 3 Mains Live 2 DHW SWL 1 CH SWL

Mains Voltage X1

Mains Voltage X2

Volts Free 24V - 230VAC X3

Volts Free 24V - 230VAC X4

230VAC - 350VDC X5

X14 Digital inputs

X13 Sensors / Switches

X12 Fan ctrl Pump ctrl

PELV
X11 Thermistors

X10 Thermistors

X9 0-10V & OpenTherm Slave

X8 Terminal (CAN TTL)

X7 ChipCom

DP View from rear

CC TX 1 CC RX 2 CC 5V 3 CC GND 4 CC 24V 5
CAN VCCon 1 CAN Mode 2
CAN Tx 3 CAN Rx 4 CAN 5V 5 CAN GND 6 CAN 24V 7
OT- 1 OT+ 2 0-10V - 3 0-10V + 4
Header - 1 Header + 2
Room - 3 Room + 4 OWC - 5 OWC + 6 DHW GND 7 DHW + 8
Flue - 1 Flue + 2 Flow - 3 Flow + 4 Return - 5 Return + 6 Heat Ex - 7 Heat Ex + 8
P PWM 1 P GND 2 P 0-10V 3 F PWM 4 F GND 5
F FB 6
Turbine Signal 1 Turbine GND 2
Turbine 5V 3 WPS Signal 4 WPS GND 5
WPS 5V 6
S Interlock b 1 APS b 2 3
S Interlock a 4 5
APS a 6

Varican TTL lead To SM X1 0-10V

OpenTherm

Header Tank Room Outside Sensor Sensor Sensor Sensor

10V

OT1+

OT2+

S GND S GND S GND S GND

I9 GND

OT1- OT2- I10

123456

12345678

OpenTherm lead To SM X2

Flow 12

Ret 12

H/X 12

Pump control

*Option Kit

PWM GND 10V I8

To internal boiler pump

PCB

PCa

FC 54321

WPSa WPSb

PELV *Option Interlock Kit I0 I1 I7

SIa SIb

WIRING

Installation & Servicing

SECTION 4 - WIRING 4.2 SYSTEM MANAGER WIRING DIAGRAM

CC TX CC RX CC 5V CC GND CC 24V OT2+ OT2- OT1+ OT1- CAN VCCon CAN Mode CAN Tx CAN Rx CAN 5V CAN GND CAN 24V

SM X3 ChipCom
12345

SM X2 OpenTherm
1234

SM X1 Terminal (CAN TTL)
1234567

OpenTherm lead From I9

Varican TTL lead from KM821-i5 X8

4.3 OPTIONAL VARICAN ADAPTER WIRING DIAGRAM
4321 CAN Bus (High power)

Varican TTL lead To SM X1

CAN 5V H
CAN GND

CAN Mode -
CAN Tx

CAN Rx

To SM Terminal (CAN TTL)
12 345 67

CAN 24V

RJ11 6P4 / 1 CAN Bus

CAN Bus External Interface

RJ11 6P4 / 2 CAN Bus

CAN Bus External Interface

CAN VCCon

Varican TTL lead from KM821-i5 X8

Installation & Servicing

WIRING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING
5. FAULT FINDING 5.1 FAULT FINDING SCREENS

Fault management When a fault occurs on the boiler the status screen with alternate as shown below:

KESTON HEAT2 55kW >
Operation: Htg. With temp. Flow setp: 82.� C Flow temp.: 40.4� C

Fault

Operation: Htg. With temp.

Flow setp: 82.0� C

Flow temp.: 40.4� C

To show the fault description scroll right (Clockwise) to show the detail. If a single fault is present then the screen will show:
Fault # # { Description} { Fault description
for the actual error}
Press Reset

If multiple faults are present a list will appear in fault priority order:

Fault List
Fault # # Fault # # Fault # #

Fault List Fault # # Fault # #

The list can now be scrolled and any of the faults may be selected to retrieve the fault description:

Fault # # { Description} { Fault description
for the actual error}
Press Reset

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING 5.2 FAULT FINDING MENU

ERROR TYPE (Warning, Blocking,
Lockout)
B B B B / W B / W B W W W B L L L L L L L L B B W W W W
B B B B B B B L L
L
B
B B W W L W L L L B/L L B/L W W B W L B

DESCRIPTION
HARDWARE (THERMISTORS, ACTUATORS) Flow thermistor open circuit (blocking) Flow thermistor short circuit (blocking) Return thermistor open circuit (blocking) Return thermistor short circuit (blocking) Flue thermistor open circuit (blocking) Flue thermistor short circuit (blocking) DHW thermistor open circuit DHW thermistor short circuit Outside thermistor defect (open / short) Water pressure sensor defect Flow thermistor open circuit (lockout after 24h) Flow thermistor short circuit (lockout after 24h) Return thermistor open circuit (lockout after 24h) Return thermistor short circuit (lockout after 24h) Flue thermistor open circuit (lockout after 24h) Flue thermistor short circuit (lockout after 24h) Heat thermistor open circuit (lockout after 24h) Heat thermistor short circuit (lockout after 24h) Heat thermistor open circuit (blocking) Heat thermistor short circuit (blocking) Header thermistor open circuit Header thermistor short circuit Room (hc1) thermistor open circuit Room (hc1) thermistor short circuit TEMPERATURE SUPERVISIONS Blocking due to flow overheat Blocking due to return overheat Blocking due to flue overheat Flow & return reversed Flow gradient supervision Flue gradient supervision (reserved) Blocking delta temp flow/return Lockout flow overheat Lockout return overheat Lockout flue overheat (flue thermistor) Lockout thermal fuse (thermal fuse) Blocking due to heat exchanger overheat SYSTEM (FLAME, FAN, HYDRAULIC, ETC.) Blocking due to no CH water flow Low water pressure No flame signal at start (restart) Flameloss during operation => endless restarts (Parameter "endless restarts" activated) Flameloss during operation, => Lockout after restarts attempts are used (Parameter "endless restarts" deactivated) Flameloss during stabilisation => restart attempts
Flameloss during stabilisation => Lockout after restarts attempt are used False flame (with heat demand) No flame after restarts Fan speed, stand still check Fan speed not achieved, e.g. Pre-purge-test, post-purge-test etc. Error fan speed during pre-purge (5* restarts => lockout ) Error min/max supervision fan speed during operation (restart) Warning due to mains overvoltage Blocking due to mains undervoltage Opentherm plus error (communication faulty; no connection anymore , etc) Too many remote resets HX water flow fault (feedback < min flow rate)

ERROR CODE (OpenTherm)

REFER TO SECTION...

5.9

n/a

5.12

5.10

n/a

5.9

n/a

5.9

5.10

5.3

n/a

5.11

5.3

n/a

5.3

1-6

1-4, 6

5.6

5.7

5.4

5.8

check mains supply

5.14, 5.15

power cycle the boiler

n/a

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING 5.2 FAULT FINDING MENU - CONTINUED

ERROR TYPE (Warning, Blocking,
Lockout)
B B W B L W B B/L W W B
L L B L L B/L L

DESCRIPTION
SYSTEM (FLAME, FAN, HYDRAULIC, ETC.) - CONTINUED PWM pump dry run error (feedback 80%) Warning code from pump (feedback 75%) VariCAN Error Safety Interlock Function activated (controlled shutdown) Air Pressure Switch error Air Pressure Switch warning (restart)
High water pressure Min water flow rate Maximum water flow rate exceeded Quartz crystal error 0-10V Input out of range INTERNAL SYSTEM Retails supervision error (COM-, Valve-Retails) Request for re-update Blocking due to programming mode Lockout parameter mismatch Lockout parameter set Internal blocking error System lockout (internal lockout error)

ERROR CODE (OpenTherm)

REFER TO SECTION...

Check Bus

Info

n/a

contact service provider

Info

Reset, contact service if repeated

contact service provider

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING

5.3 OVERHEAT LOCKOUT

Has PCB just been replaced?

yes Reset Boiler

Are the boiler and CH/DHW system

filled with water and are all isolation

valves and radiator valves open?

yes
no Is the flow/return differential across the boiler in excess of 30�C?

yes

Check that the pump is rotating freely.

Is the differential now below 20�C?.

yes

Fill and vent the system and open all isolation valves, then reset the boiler.
Check the flow, return and heat exchanger thermistors (Refer to Section 3.16)
Replace the pump, then restart the boiler Restart the boiler

5.4 IGNITION LOCKOUT
If the boiler is reset, does it ignite for a yes short time and then extinguish?
no

Check the detection electrode and associated harness for continuity, visual condition and position (Refer to Section 3.13). Check if the condensate pipe is blocked.

Is the gas pressure available at the boiler > 18mbar?

no Check gas supply and rectify fault

yes

Is the following voltage available at the Gas Valve? (approximately 215Vdc for 45 & 55kW)

Check wiring from Gas Valve to PCB

and replace if necessary, otherwise

replace the main PCB

yes

Unplug the Gas Valve, is the resistance between the

outside pins between 1k and 10k?

yes

no Check Spark Generator and associated Harness for continuity, visual condition and position (Refer to Section 3.18). Are these functioning correctly?
yes

no Check Ignition Electrode and associated Harness for continuity, visual condition and position (Refer to Section 3.12). Are these functioning correctly?

yes

no Check condensate trap and condensate drain pipework for blockage and rectify if necessary. Boiler now working OK?

Replace Gas Valve
Replace Spark Generator and Harness as necessary
Replace Ignition Electrode and associated Harness as necessary
Replace Gas Valve

* 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.

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING 5.5 FALSE FLAME LOCKOUT / ERROR 20

Reset the boiler, does boiler work OK? no

yes Check routing and integrity of internal boiler wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated.

yes Disconnect the electrical connection to the Flame Sense Electrode. Is there continuity between the no Electrode and earth?

Replace Flame Detection Electrode Check routing and integrity of internal boiler wiring

5.6 LOW WATER PRESSURE

Are the boiler and CH system filled with water and all Isolation and Radiator Valves open?

Fill and vent the system and open all

Isolation Valves

yes

Ensure wiring has continuity and is

Does the wiring from the Water Pressure Switch to the

securely connected

PCB have continuity and is it securely connected?

yes Replace Water Pressure Switch

5.7 FLAME LOSS
yes If the boiler is Reset, does the boiler Ignite for a short time and then Extinguish
no

Check the Detection Electrode and associated Harness for continuity, visual condition and position (Refer to Section 3.13). Check if the Condensate Pipe is blocked. Check if the Flue is blocked. Replace as necessary.

Is the Gas Pressure available at the boiler > 18mBar?

Check Gas Supply and rectify fault

yes

Is the following voltage available at the Gas Valve?

(approximately 215Vdc for 45 & 55kW)

yes

Check Spark Generator and associated Harness

for continuity, visual condition and position (Refer to

Section 3.18). Are these functioning correctly?

yes

Check Ignition Electrode and associated Harness

for continuity, visual condition and position (Refer to

Section 3.12). Are these functioning correctly?

yes

Check Syphon and condensate drain pipework for

blockage and rectify if necessary. Boiler now working OK?

Check wiring from Gas Valve to PCB and replace if necessary, otherwise replace the main PCB
Replace Spark Generator and Harness as necessary
Replace Ignition Electrode and associated Harness as necessary
Replace Gas Valve

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

5.8 FAN FAULT

SECTION 5 - FAULT FINDING

Does the wiring from the Fan to the PCB have secure

Rectify wiring & connections

connections at both ends and has not deteriorated?

Does the wiring have continuity?

yes no
Is there 230Vac at the blue and brown connections to the 3 way connection on the Fan? yes

Replace main PCB Replace Fan

5.9 FLOW / RETURN THERMISTOR, HEAT EXCHANGER OR FLUE THERMISTOR FAULT

Disconnect the electrical connection to the Flow

Fit a new thermistor

Thermistor and check the resistance using a suitable

multimeter connected across the thermistor's terminal

pins.

At 25�C expect 9,700 - 10,300

At 60�C expect 2,400 - 2,600

At 85�C expect 1,000 - 1,100

Is the thermistor value correct?

yes no
Is there continuity between the PCB and the Thermistor? yes

Check and replace wiring as necessary Replace main PCB

5.10 OUTSIDE / HEADER / ROOM SENSOR FAULT (IF FITTED)

no Is the wiring securely connected at both the boiler and Sensor?
yes
no Disconnect the wires to the Sensor. Check the resistance using a suitable multimeter connected across the thermistor's terminal pins. At 0�C expect 32,000 - 33,000 At 10�C expect 19,000 - 21,000 At 20�C expect 12,000 - 13,000 Is the thermistor value correct?
yes
no Does the Sensor wiring between the boiler terminal strip and the PCB have continuity and is securely connected?
yes

Securely connect the wiring at both the boiler and sensor Fit a new sensor
Ensure the wiring has continuity and is securely connected Replace main PCB

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING 5.11 FLOW/RETURN REVERSED

Is the Pump connected the correct way? yes
Check that the system pipework is correct

no Reverse Pump

5.12 CYLINDER THERMISTOR FAULT (IF FITTED)
no Is a DHW Thermistor connected to the boiler?

yes

Is the wiring securely connected at both the boiler and

cylinder thermistor?

yes

no Disconnect the wires to the cylinder thermistor. Check

the resistance using a suitable multimeter connected

across the thermistor's terminal pins.

At 25�C expect 9,700 - 10,300

At 60�C expect 2,400 - 2,600

At 85�C expect 1,000 - 1,100

Is the thermistor value correct?

yes

Change menu setting for DHW Sensor to "Switched Live"
Securely connect the wiring at both the boiler and cylinder thermistor Fit a new cylinder thermistor
Ensure the wiring has continuity and is securely connected

Does the cylinder thermistor wiring between the boiler terminal strip and the PCB have continuity and is securely connected?

yes Replace main PCB

5.13 EXTERNAL INTERLOCK OPEN

Is an External Interlock connected to the boiler? yes

no Ensure that a link wire is securely connected across the terminals marked "External Interlock" in the boiler terminal strip

Has the External Interlock operated?

yes Reset the External Interlock

no no Ensure the wiring has continuity and is

Does the wiring from the Interlock Relay (mounted

securely connected

within the boiler) to the terminal strip have continuity and is securely connected?

yes

Replace the Interlock Relay Kit

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING 5.14 NO CH BUT DHW OK

Is the heating circuit set for day or in a timed (on) period operation? no
yes

Are the Timer and Room Thermostat calling for Heat?

yes

Are the Radiator Valves open? no yes

Is an OpenTherm device connected yes to the boiler?
no
Is there a room sesnor configured yes and connected for the heating circuit?
no
Is there an outside sensor configured and connected for the
heating circuit? no

Set for day or in a timed (on) period operation?

Ensure that the Timer and Room Thermostat are calling
for heat

Open the Radiator Valves

Does the wiring from the boiler to the
OpenTherm device have continuity?

no Rectify wiring from boiler to OpenTherm device
yes

Check wiring continuity: R(25�C) = 10,000

no Is a switched live being used as a heating circuit demand?

yes

Is there a 230 av at SL1?

yes

Does the boiler have a system or heating circuit pump connected? no

yes
Check the control signal for the pump depending on the configuraiton.
1. 230V supply from isolate or boiler MFR 2. Volts free enable from MFR 3. 0-10V signal from boiler 0-10V output
(Rectify fault as required)

This is not a boiler fault. Ensure voltage is supplied to the boiler by correcting ther
external wiring
Check system for water circulation

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SECTION 5 - FAULT FINDING

5.15 NO DHW BUT CH OK

Is there a 230V on SL2 input

yes

If a tank thermistor is configured and fitted in place of a cylinder thermostat,

check the connection continuity and

thermistor

R(25�C) = 10,000

Is the resistance correct?

yes

Is an OpenTherm device connected to the boiler (note that the Ideal yes programmable room stat is an OpenTherm device)?
no

Is the DHW circuit set for day or in a timed (on) period, or if it has an OpenTherm device connected adn configured for DHW check that it is no
calling for DHW.
yes

There is no voltage from the timer/cylinder stat. This is not a boiler fault. Ensure voltage is supplied to the
boiler by correcting external wiring.
Check thermister and external wiring and replace as necessary.

Does the wiring from the

Rectify wiring from

boiler to the OpenTherm no boiler to OpenTherm

device have continuity?

device.

yes

Set the DHW system to call for heat

Does the system hav a DHW pump or no diverter valve? yes

Check system for water circulation

Is the boiler correctly set for a DHW no pump or diverter valve?

Set boiler correctly

Installation & Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

5.16 NO DISPLAY

SECTION 5 - FAULT FINDING

no Is there 230Vac to the boiler at the mains supply inlet?
yes no
Is the wiring from the boiler terminal block to the combination manager PCB connected securely?
yes no
Is the cable from the combination manager PCB to the system manager PCB connected securely?
yes no
Does the cable from the combination manager PCB to the system manager PCB have continuity and is un-damaged?
yes no
Is the Fuse on the combination manager PCB OK?
yes no
Replace the system manager PCB, still no display?

Supply power to the boiler
Connect the wiring from the terminal block to the combination manager PCB securely
Connect the cable from the combination manager PCB to the system manager PCB securely
Replace cable from combination manager PCB to system manager PCB
Check for shorts on Pumps/Diverter Valve/ Fan/Spark Generator/Gas Valve and replace Fuse
Replace combination manager PCB

5.17 0-10V INTERFACE
no Is the boiler configured to accept a 0-10V Input?
yes
no Is the boiler set to Day mode?
yes
no Is a voltage of between the configured voltage demand threshold and 10V being supplied to the 0-10V input, with positive and negative connected correctly?
yes no
Is the wiring from the boiler terminal strip to the combustion manager PCB securely connected and has continuity?
yes
Replace combustion manager PCB

Configure the boiler to accept a 0-10V input
Set the boiler to Day mode
Ensure the configured voltage demand threshold and 10V is correctly connected to these terminals from the external device
Ensure that the wiring is securely connected and has continuity

Installation & Servicing

6. SPARE PARTS

SECTION 6 - 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 ourselves. Failure to do so could affect safety or performance of this appliance.

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 e.g. 55
- Appliance GC Number (UK only) e.g. 41-930-51
- Boiler Serial Number e.g. ACK 205962000000480101

Installation & Servicing

SECTION 7 - COMBUSTION & FLUE INTEGRITY CHECKS
7. COMBUSTION AND FLUE INTEGRITY 7.1 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER
Important Preliminary Information on Checks
The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance is provided with the conversion kit supplied and this must be followed.
PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as required prior to commissioning. As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids). The ECGA should be of the correct type, as specified by BS 7967. Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer must have the relevant competence for use of the analyser. Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer's instructions.
KEY: CO = carbon monoxide CO2 = carbon dioxide O2 = oxygen Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm ppm = parts per million GS(I&U)R = Gas Safety (Installation and Use) Regulations

continued.........

Installation & Servicing

SECTION 7 - COMBUSTION & FLUE INTEGRITY CHECKS

Start

Set Boiler to Maximum Gas Rate
In accordance with boiler instructions, set boiler to operate at maximum rate (full load condition). Allow sufficient
time for combustion to stabilise.
Note. Do not insert analyser probe during this period to avoid possible
flooding of sensor.

Carry Out Flue Integrity Check Using Analyser
Insert analyser probe into air inlet test point (where available) and allow readings to stabilise.
Note. Where no air inlet test point is provided then a flue integrity check with the analyser is not possible. The installer should verify that flue integrity has
been visually checked in accordance with the "Prior to CO level and combustion ratio check" (see previous page) before proceeding to the "check CO level and combustion ratio at maximum rate" stage below.

Verify Flue Integrity

Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of the flue is therefore required.

Check that flue components are assembled, fixed and supported as per instructions. Check that flue and flue terminal are not obstructed.

Is O2 more than or equal to 20.6% OR CO2 less than or equal to
0.2%?
Yes

O2 more than or

equal to 20.6% OR CO2

Yes

less than or equal to

0.2%?

Check CO level and Combustion Ratio at Maximum Gas Rate
With boiler still set at maximum gas rate, insert analyser probe into flue gas
sampling point. Allow readings to stabilise before recording.

Turn off appliance and call Ideal Technical Helpline for advice
The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance
must be disconnected from the gas supply in accordance with GSIUR.

Is CO level less No than 350ppm AND CO/CO2 ratio less than
0.0040?

Check that no seals, e.g. Those on flue extensions, have been displaced during installation. Rectify if necessary.

CO level less

Yes

than 350ppm AND CO/CO2

ratio less than

0.0040?

Yes
Set Boiler to Minimum Gas Rate (refer to Section 3.1)
In accordance with boiler instructions, set boiler to operate at minimum rate (to minimum load condition).
Allow sufficient time for combustion to stabilise.
Check CO and Combustion Ratio at Minimum Gas Rate With boiler set at minimum rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.

Turn off Appliance and Call Ideal Technical Helpline
The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from the gas supply in accordance with GS(I&U)R. NOTE: Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal.

CO level less

than 350ppm AND CO/CO2

ratio less than

0.0040?

Yes

Boiler is Operating Satisfactorily
No further actions required.
Ensure test points are capped, boiler case is correctly replaced and all other commissioning procedures are completed. Complete Benchmark
Checklist, recording CO and combustion ratio readings as required.

Installation & Servicing

NOTES

Installation & Servicing

NOTES

Installation & Servicing

FM 59915 Manufactured under
an ISO 9001 registered quality management system
Technical Training Our Expert Academy offer a range of training options designed and delivered by our experts in heating. For details please contact: expert-academy.co.uk Ideal Boilers Ltd., pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.
Registered Office Ideal Boilers Ltd., National Avenue, Hull, East Yorkshire, HU5 4JN
Tel 01482 443005 Registration No. London 322 137
Keston by Ideal Heating Helpline: 01482 443005 Ideal Heating Parts: 01482 498665
keston.co.uk

Keston 355123 HEAT 2 45 Condensing Boiler Natural Gas Owner's Manual

INSTALLATION & SERVICING - Keston Boilers

Keston Heat 2 45

Full PDF Document

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References