Keston Frame Header Kits Installation Manual

FRAME & HEADER KIT

INSTRUCTIONS

Keston Heat 45
Keston Heat 55

Keston Heating

PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN

Tel. [phone] Fax. [phone]

email : [e-mail] web : www.keston.co.uk

This kit is suitable for the following boilers:

Keston Heat 45 & 55

CONTENTS

1 Introduction and General Description ..........................3

2 General Description of Cascade System .....................4

3 Multiple Boiler System Components ............................5

4 Installation Drawings for Multiple Boiler Systems ......8

5 Wall Mounted Installation Procedure .........................11

6 Frame Kit Installation Procedure ................................13

7 Header Kit Assembly ....................................................14

8 Electrical Connections .................................................17

9 Commissioning and Testing ........................................ 17

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Keston Heat - Frame & Header Kits

1 INTRODUCTION

This technical data contains information for dimensioning & assembly of a cascade system kit for the Keston Heat range of
products.

Header and Frame kits are available in line (from 2 to 6 boilers long).

GENERAL DESCRIPTION OF FRAME & HEADER KITS

A requirement to spread the total required heat output over several boilers can be accommodated by the use of the Keston Heat
multiple boiler frame & header kit options.

An optional sequencer kit can be specied to switch boilers in cascade on or off dependent on total heat demand.

Keston Heat - Frame & Header Kits

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2 GENERAL DESCRIPTION OF CASCADE SYSTEMS

2.1 FRAME AND HEADER KIT DESIGN OPTIONS

The Keston Heat boilers are suitable for use in a multiple boiler conguration. The multiple boiler system is available as a wall
or frame mounted side by side conguration with the use of the relevant frame / header kits. This gives opportunity to choose

the optimum footprint size or wall space for a given output. The table below states options available and gives the minimum

number of appliances required, the appropriate oor space & the kit product number (N.B. The kits do not include the boilers).

Side by side kits do not include the support frame as the boilers can be wall mounted but a frame kit is available if wall space

etc. does not facilitate boiler/header wall mounting.

Flue conguration for the appliance is C53 and C13 only (see appliance manual).

FRAME AND HEADER KIT SYSTEM DESIGN OPTIONS

Total Output

Required Kw

Side By Side Option –

Number Of Boilers/Output

Required

Side by Side

Footprint Size

W x D (mm)

90 2 x 45 1500x560 355014
100 1 x 45 - 1 x 55 1500x560 355014
110 2 x 55 1500x560 355014
135 3 x 45 2055x560 355015
145 1 x 55 - 2 x 45 2055x560 355015
155 2 x 55 - 1 x 45 2055x560 355015
165 3 x 55 2055x560 355015
180 4 x 45 2600x560 355016
190 1 x 55 - 3 x 45 2600x560 355016
200 2 x 55 - 2 x 45 2600x560 355016
210 3 x 55 - 1 x 45 2600x560 355016
220 4 x 55 2600x560 355016
225 5 x 45 3150x560 355017
235 1 x 55 - 4 x 45 3150x560 355017

Header Kit

Product No.

Side By Side

245 2 x 55 - 3 x 45 3150x560 355017
255 3 x 55 - 2 x 45 3150x560 355017
265 4 x 55 - 1 x 45 3150x560 355017
275 5 x 55 3150x560 355017
280 1 x 55 - 5 x 45 3700x560 355018
290 2 x 55 - 4 x 45 3700x560 355018
300 3 x 55 - 3 x 45 3700x560 355018
310 4 x 55 - 2 x 45 3700x560 355018
320 5 x 55 - 1 x 45 3700x560 355018
330 6 x 55 3700x560 355018

In line frame kit 355013

Header Low Loss DN80 Kit 355019

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Keston Heat - Frame & Header Kits

2.2 MULTIPLE BOILER INSTALLATIONS

For installing 2 to 6 boilers, the product range includes water and gas headers capable of assembly using threaded socket,compression

and ange connections.

2.3 HYDRAULIC ISOLATION: MIXING HEADER (HEADER KITS INCLUDE A LOW LOSS MIXING HEADER)

A low loss header allows ow separation within a hydronic system.

This essentially creates linked stand alone ow circuits with their own ow rates and pressure drops. Allowing for the modern high
resistant high efciency boilers to operate under their optimum conditions, while the main heating circuit operates to its own controlled

optimum requirements.

2.4 OUTPUT CONTROL

An optional sequencer kit is available to maximise the efciency of a multiple boiler installation. Instructions for installation and use are
contained in the sequencer kit. The sequencer kit facilitates control of up to ve boilers in cascade.

2.5 GAS SUPPLY

The 45-55kW boilers are suitable for use with natural gas. Connect the boilers to the gas mains in accordance with the applicable

regulations The gas header connection is a 2” female thread with test points at each end. It is the test point nearest the inlet of the
group of appliances that becomes the appliance inlet pressure point. Refer to the boiler Installation & Servicing Instructions for general
GAS SUPPLY details.

2.6 ASSEMBLY

The frames and headers must stand on a at and level oor of suitable load bearing capacity.

2.7 SAFE HANDLING

This boiler may 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.

3 MULTIPLE BOILER SYSTEM COMPONENTS

3.1 GENERAL

The multiple boiler systems consist of the following components:

• Frame kit. (Optional only with In-line kits)

• Boiler gas header.

• Boiler ow and return headers supported on mounting skid

• Low loss mixing header

• Hardware packs (includes essential connection and valve components)

3.2 MAIN WATER HEADERS

The main water headers consist of: insulated water ow, insulated water return headers custom sized for all boilers. It is possible to
extend the system to a maximum of 6 boilers in a linear conguration.Each header kit provides water ow and return headers sized

either DN80 or DN100 dependent on total maximum combined heating output required.

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3.3 GAS HEADER

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The Gas header consists of a custom manufactured 2” manifold. This is located in a cradle incorporated within the header mounting skid.

3.4 MIXING HEADER

The mixing headers are insulated and are supplied with an auto air vent and drain point as standard.

3.5 BOILER CONNECTION KITS

Legend

1. 11/4" x 3/4" x 11/4" Te e

2. Close Taper Nipple

3. Safety Relief Valve 6 bar

4. Isolation Valve

5. 11/4" x 1/2" x 11/4" Te e

6. Drain O Cock

7. Connection Pipe Assembly

8. Non Return Valve

9. 11/4" Taper Male to 11/4" Parallel Hex Adapter

10. Boiler Flow Flexible Connection from Header

11. Boiler Return Flexible Connection from Header

Items 1,2,3,4,5 & 6 are supplied with the boiler. (AL-208973
Isolation Valve Kit)

Items 7, 8 & 9 are supplied with the Header Kit

Items 10 & 11 are pre-assembled to the water header.

Assemble ttings together as shown using appropriate sealing
material. Do not t the safety relief valve (item 3) at this stage.
When assemblies are complete t to boiler ow and return stubs

with suitable sealing material. The safety valve (item 3) can now

be tted using suitable sealing material.

Ensure all isolation valves, pressure relief valves and drain valves
are tted to allow unrestricted operation.

3.6 FREE-STANDING FRAMES

If boilers in cascade are positioned in-line the installer has the option to either wall mount the boilers or mount boilers on optional frame

kits available. If mounting in-line product on frames, optional frame kit UIN 355013 must be specied in the correct quantity, one frame

kit for each boiler installed in cascade.

3.7 INSTALLATION AREA AND DIMENSIONS

Care must be taken to ensure adequate access for boiler / cascade system installation and servicing.

A minimum of 450mm must be provided from the front of the installed boilers in cascade to facilitate boiler servicing.

Consideration to connecting heating ow and return pipework, gas supply and condensate drainage must be given. Routing of the

condensate drain must be made to allow a minimum fall of 1 in 20 away from the installed boilers in cascade, throughout its length.

Adequate room above the boilers must be provided to install and service the boiler ue system. Further information with respect to ue

and condensate drain connection is provided in the installation and servicing instructions provided within the boilers packaging carton.

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Keston Heat - Frame & Header Kits