Keston Heat 55kw, Heat 45kw Installation Manual
Installation and Servicing Instructions
FAN POWERED HIGH EFFICIENCY
MODULATING CONDENSING
GAS BOILER
CE/PI No. 86-CN-69
Heat 45 - GC No. 41-930-40
Heat 55 - GC No. 41-930-41
Heat 45 & 55
These instructions must be left either with the
user or next to the site gas meter.
Keston Heating
PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN
Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133
email : info@keston.co.uk web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2
SEDBUK A RATED
Table 1 Performance Data (Natural Gas)
Keston Heat Model 45 55
Boiler Output
(non-condensing)
Mean 70°C
Boiler Output
(condensing)
Mean 40°C
Boiler Input
Max Rate
Boiler Input
Min Rate
Gas Rate Max Rate
Flue Gas Flow Rate Max Rate
CO
(±0.5%)
2
NO
x
Efciency
Max
Min
Max
Min
Nett
Gross
Nett
Gross
Max Rate % 9.3 9.5
Min Rate % 8.4 8.4
Weighted
Seasonal % 96.0 96.7
*SEDBUK 2009 % 89.2 89.6
GENERAL
kW 42.6 52.1
Btu/hr 145400 177800
kW 12 12
Btu/hr 40900 40900
kW 45 55
Btu/hr 153500 187700
kW 12.7 12.7
Btu/hr 43300 43300
kW 43.2 52.7
Btu/hr 147400 179800
kW 47.9 58.5
Btu/hr 163400 199600
kW 12.2 12.2
Btu/hr 41600 41600
kW 13.5 13.5
Btu/hr 46100 46100
3
m
/hr 4.56 5.57
3
ft
/hr 161.2 196.9
3
m
/hr 66.4 81.0
3
ft
/hr 2343 2861
mg/kWh 38.6 38.3
ppm DAF 21.9 21.7
Table 2 General Data
Keston Heat Model 45 55
Gas Supply 2H – G20 – 20mbar / 3P - G31 - 37mbar
Gas Supply Connection G
Flow Connection G1 1/4
Return Connection G1
Max Pressure (sealed sys)
Maximum Static Head
Electricity Supply 230V - 50Hz
Fuse Rating
Power Consumption
IP Rating IP20
Nominal ue dia - Concent. Twin 50mm
Condensate Drain 25
Water Content
Dry Weight
* 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 certied by a notied body.
Note.
Natural gas consumption is calculated using a caloric value of
37.8MJ/m
15
a. For l/s divide the gross heat input (kW) by the gross C.V. of the
b. For ft/h
3
o
(1038Btu/ft3) gross or 34 MJ/m3 (910 Btu/ft3) nett at
C and 1013.25 mbar.
gas (MJ/m
3
)
3
divide the gross heat input (Btu/h) by the gross C.V. of
Bar (psi)
m
A
W
L
Kg
202 262
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 certied for safety
and performance. It is, therefore, important that no external
control devices, e.g. ue 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.
3
/4
1
4.0 (58)
40.7
4.0
5.0
60.3
/4
the gas (Btu/ft3).
c. For m
3
/h multiply l/s by 3.6.
Any direct connection of a control device not approved by Keston
could invalidate the certication and the normal appliance
warranty. It could also infringe the Gas Safety Regulations and
the above regulations.
2
Keston Heat - Installation & Servicing
GENERAL
Keston Heat
45 & 55
Natural Gas
Destination Countries: GB, IE, RO
Boiler size G.C. Appliance No. PI No.
(Benchmark No.)
45 41-930-40 86-CN-69
55 41-930-41 86-CN-69
CONTENTS
Boiler Assembly - Exploded view. ...................................9
Boiler Clearances. .............................................................7
Commissioning and Testing. .......................................... 38
Electrical Connections. ...................................................23
Electrical Supply. ...............................................................6
Fault Finding. ...................................................................49
Flue Installation. ................................................................5
Gas Safety Regulations ...................................................4
Gas Supply. ........................................................................5
Introduction. .......................................................................4
Initial Lighting. .................................................................39
Installer Connections. .....................................................24
Installation. ....................................................................9-40
Mounting Boiler. ..............................................................12
Option Kits. ........................................................................4
Performance Data. .............................................................2
Servicing. ....................................................................41-48
Short List of Parts. ..........................................................59
Ventilation. .......................................................................12
Water Circulation. ..............................................................5
Water Connections. .........................................................22
Water System Requirements. ...........................................8
Water Treatment. ...............................................................6
Wiring Diagrams. .............................................................25
Key to symbols
IE = Ireland,
GB = United Kingdom (Countries of destination)
RO = Romania
PMS = Maximum operating pressure of water
C53 = A room sealed boiler which is connected via
its separate ducts to two terminals that may
terminate in zones of different pressure.
C13 = A room sealed boiler which is connected via
its ducts to a horizontally installed terminals
that terminate within a common pressure
zone
I2H = An appliance designed for use on 2nd Family
gases.
NOTE TO THE INSTALLER:
LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.
Keston Heat - Installation & Servicing
3
GENERAL
INTRODUCTION
The Keston Heat boilers are fully automatically controlled, wall
mounted, fanned, super efcient condensing appliances.
The Keston Heat condensing boilers can be installed either on
the wall or into a prefabricated oor mounted frame.
Through a sophisticated control system combined with premix
burner arrangement the boilers are capable of high seasonal
efciencies of >96% and low emissions.
These boilers are certied to meet the requirements of the EC
Gas Appliance Directive, Boiler Efciency 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.
Boiler is suppled with internal pump
OPTIONAL EXTRA KITS
• Air Terminal Finishing Kit
• Programmable Room Thermostat Kit
• Modulating Sequencer Kit
• Tank Sensor Kit
• Safety Interlock Kit
• Flue Sleeve Kit
• Room Sensor Kit
• Frame and Header Kit
Detailed recommendations are contained in the following Codes
of Practice:
BS. 6891
BS. 5440
Part 1 Specication for installation of ues.
Part 2 Specication for installation and maintenance of
BS. 6798
BS. 6880 Low temperature hot water heating systems of
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BSEN.12828:2003
BSEN.12831:2003
BSEN.13831 Specication for: Expansion vessels using an
BSEN.14336:2004
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.
Installation of low pressure gas pipework of up to
28mm (R1) in domestic premises (2nd family gas).
Inst. and maintenance of ues and ventilation for
gas appliances of rated input not exceeding 70kW
net (1st, 2nd and 3rd family gases).
ventilation for gas appliances.
Installation and maintenance of gas red hot water
boilers of rated input not exceeding 70kW net.
output greater than 45kW.
Heating Systems in buildings: Design for water
based systems.
Heating Systems in buildings: Method for
calculation of the design heat load.
internal diaphragm, for sealed hot water heating
systems.
Heating Systems in buildings: Installation and
commissioning of water based heating systems.
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 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 specic 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 Keston Heat boilers have been tested and certied to;
EN 483, EN 677, BSEN 60335-2-102, BSEN 55014-1 and BSEN
55014-2 for use with Natural Gas.
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.
4
Keston Heat - Installation & Servicing
GENERAL
25 30 35 40 45 50 55 60 65 70
0
1
2
3
4
5
6
7
8
Available System Capacity
20 deg C differential
15 deg C differential
11 deg C differential
Keston Evomax 45 - Hydraulic System Capacity
Water Flow Rate [L/m]
Pressure [m WG]
SAFE HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.
LOCATION OF BOILER
The boiler must be installed on a at and vertical wall, capable of
adequately supporting the weight of the boiler and any ancillary
equipment.
The boiler must not be tted outside.
GAS SUPPLY
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 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
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 4.
FLUE INSTALLATION
Individual air supply and ue outlet pipes are used. The material
used for the ue outlet and the air intake systems, must be
muPVC to BS 5255. In addition the ue outlet and air intake
pipework must be marked BSEN 1566-1 and the ttings must be
marked BSEN 1329. Marley muPVC Solvent Weld Waste System
(50mm) and Polypipe System 2000 muPVC Solvent Weld Waste
System (50mm) 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 inltration,
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 tted less than 2m (80”)
above a balcony, above ground or above a at 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 tted.
Terminal guards are available from boiler suppliers
Ensure that the guard is tted centrally.
The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25mm (1”) to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS. 5440-1: 2008. In IE refer to
I.S.813:2002.
The ue must be installed in accordance with Building
Regulations and the recommendations of BS. 5440-1:2008 for
inputs up to 70kW nett.
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 underoor 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 4.
The Keston boilers feature an integral circulating pump which
has sufcient excess head to drive most domestic systems. The
available head is indicated in the chart below. If the system
resistance, at the desired ow rate, is in excess of the available
head from the integral pump an additional system pump will be
required.
Keston Heat 55 - Hydraulic System Capacity
Keston Evomax 55 - Hydraulic System Capacity
8
7
6
5
4
3
Pressure [m WG]
2
1
0
25 30 35 40 45 50 55 60 65 70
Water Flow Rate [L/m]
Keston Heat 45 - Hydraulic System Capacity
Available System Capacity
20 deg C differential
15 deg C differential
Keston Heat - Installation & Servicing
continued . . . . . .
5
GENERAL
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
42mm
Header
Installation of air bleed valves at the high spot(s) in the system will
allow for air elimination when lling the system and will allow re-
venting in a day or so after all air has been driven out of solution.
Note.
• With the boiler ring at minimum rate, the temperature
differential should not be greater than 35
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 ow and return pipes. The bypass should
be tted at least 6m from the boiler, and should use a minimum
size of 28mm pipe. The bypass should be capable of allowing
a minimum ow rate to achieve a temperature differential of no
greater than 35
o
C at minimum rate.
AAV
Additional
System
Pump
Primary Flow
Primary Return
o
C. Lower ow rates
WATER TREATMENT
These boilers incorporate an ALUMINIUM heat exchanger.
IMPORTANT. The application of any other treatment to this
product may render the guarantee of Keston INVALID.
Keston recommend Water Treatment in accordance with
Guidance Notes on Water Treatment in Central Heating Systems.
Keston recommend the use of Fernox Copal or MB1 or GE
Betz Sentinel X100 inhibitors and associated water treatment
products, which must be used in accordance with the
manufacturers’ instructions.
For further information contact:
Fernox Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey, GU21 5RZ
Tel: +44 (0) 870 601 500
or
Sentinel Performance Solutions, The Heath Business and
Technical Park, Runcorn, Cheshire, WA7 4QX
Tel: 0800 389 4670
www.sentinel-solutions.net
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.
BS7593:1992 details the steps necessary to clean a
domestic heating system.
3. In hard water areas, treatment to prevent limescale may be
necessary - however the use of articially softened water is
NOT permitted.
4. Under no circumstances should the boiler be red before
the system has been thoroughly ushed.
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.
CONDENSATE DRAIN
Refer to Frames 24, 25 & 60
A condensate drain is provided on the boiler. This drain must
be connected to a drainage point on site. All pipework and
ttings 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
(3/4”) overow pipe. It is a universal tting to allow use of
different brands of pipework.
Note that all external runs must be insulated.
6
Keston Heat - Installation & Servicing
GENERAL
299
206210-10155
1
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 - 350mm
Below boiler - 300mm
Clearance between multiple boiler installations - 25mm
500
86
Air
Flue Centre Line
Flow Return
59 59
Flue
Gas
118
Flue Centre Line
850
360
131
Flue Centre Line
Gas Pipe
155
Minimum Top Clearance
70
Flue Centre Line
Condensate Drain
Flow/Return
68
81
30mm
Front clearance
The minimum front clearance when built in to a cupboard is 5mm
from the cupboard door but 450mm overall clearance is still
required, with the cupboard door open, to allow for servicing.
Keston Heat - Installation & Servicing
7
GENERAL
Feed/expansion
cistern
500mm
minimum
3000mm
minimum
System
flow to
pump
Inverted cold
feed entry
Cold
Feed
Water
level
(cold)
Open vent
System
return
Connections
to boiler
ima5351
3000
minimum
CV CV
Resillient
seat control
valves
Supply
pipe
DT
CV = Control Valve
DT = Drain Ta p
Air
gap
Tundish
Strainer
Type BA backflow
prevention device
(RP2 valve assembly)
primary flow
and return
ima7349
2
OPEN VENTED SYSTEM REQUIREMENTS
Detail reference should be made to the appropriate standards listed on
page 4.
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 any additional 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 specied by Keston. The isolation valves should be tted
as close to the pump as possible.
The boiler is tted 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 ring of the boiler and subsequent damage to the heat
exchanger.
3
SEALED SYSTEM REQUIREMENTS
Note. The method of lling, relling, topping up or ushing
sealed primary hot water circuit from the mains for a nondomestic property is shown below.
1. General
a. Detail reference should be made to the appropriate
b.
c. All components of the system, including the heat
d. The boiler is tted with an automatic air vent, located in
2. Safety Valve (supplied with boiler)
A spring loaded safety valve complying with
the relevant requirements of BS. 6759 Pt. 1
must be tted in the ow 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
The supplied Pressure Relief Valve is for
8
standards listed on page 4. 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.
The installation should be capable of working with ow
temperatures of up to 90oC and a temperature differential of
up to 20oC.
exchanger of the indirect cylinder, must be suitable for a
working pressure of 4 bar (60 lbf/in2) and temperature of
110oC. Care should be taken in making all connections so
that the risk of leakage is minimised.
the left top side of the interior. This air vent must never be
shut off, as this could result in dry ring of
the boiler and subsequent damage to the
heat exchanger.
exceeding 4 bar (60 lbf/in
boiler protection only in the event that the
ow and return isolators have been turned
off. If converting to a sealed system a
separately sized PRV suitably sized will
need to be tted in addition on the heating
circuit.
2
).
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.
3. Pressure Gauge
A pressure gauge covering at least the range 0-4bar
must be tted to the system. The gauge should be
easily seen from the lling point and should preferably
be connected at the same point as the expansion
vessel.
4. Expansion Vessel
Expansion vessels used must comply with BS. EN
13831. Connection to the system must not incorporate
an isolating valve.
Keston Heat - Installation & Servicing
4
BOILER ASSEMBLY - Exploded View
230
INSTALLATION
231
501
308
105
302
304
309
306
208
305
310
508
232
301
INSTALLATION
510
502
KEY
105 Auto Air Vent
208 Burner Fixings Kit
230 Fan
231 Gas Valve Kit
232 Venturi Kit
301 Dry Fire Thermistor Kit
302 Lead Ignition Kit
509
304 Ignitor Unit
305 Electrode Detection Kit
306 Ignition Electrode Kit
308 Fascia Plastic
309 HMI Board
310 Primary PCB
Jacket Assembly Keston Heat
501
Kit
502 Door Assembly Keston Heat Kit
508 Flue Stat
509 Bulk Head Acccess plate
510 Pump
Keston Heat - Installation & Servicing
9
5
PACKAGING REMOVAL
iNSTALLATiON
• The boiler should be laying on its back with the straps
removed.
• Carefully read the installation instructions before proceeding.
• Remove the accessory Box.
• Remove the outer packing sleeve.
• Remove the protective cardboard wall mounting template
from the front of the boiler.
• Remove the packing piece from the top of the boiler.
• Check the contents against the list in Frame 6 ‘Unpacking’.
Note: some items are contained within the top packing
piece.
• 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 2.
6
UNPACKING
INSTALLATION
The boiler is supplied fully assembled in one pack. When unpacking the boiler check the contents against the list shown.
Do not dispose of the packaging until all contents are accounted for, as some parts are held within the cardboard packing
pieces.
Pack Contents
A Fully assembled boiler
A
B
D
C
B Installation & Servicing/User
Instructions
E
C Log Book
D Wall mounting template
E Condensate Trap
F
F M10 x 70 Hex Head Coach
Screws - 6 off
G M10 Wall Plug - 6 off
G
Accessory Box
A Gas cock
B Ball Valve - 2 off
C M1 Tee
D Pressure Relief Valve
E M1 Tee
F Drain Nipple
G Drain Nipple
H Wall Mounting Plate
J Terminals - 2 off
K Flue Sleeve
L Wall Plate & Screws
M Wall Seal
N Weather Compensation
P Screws - 4 off
Q Wall Plugs - 4 off
10
A
N
B
J
C
P
D
E
F
K
Q
G
L
H
M
Keston Heat - Installation & Servicing
7
X
Y
120 245 365 490
Vertical Offset From X mm
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.
8m
6m
4m
2m
WALL MOUNTING TEMPLATE
Note. The template shows the positions for the
top xing 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 xing positions using
diagram below
c. The position of the ue duct. Mark
the centre of the hole as well as the
circumference.
4. Remove the template from the wall.
INSTALLATION
Note: Horizontal ue runs must be inclined
at 3.5o to the horizontal to allow condensate
to drain back to the boiler.
INSTALLATION
BOILER LOWER FIXING POSITIONS
Ø12mm
8
PREPARING THE WALL
IMPORTANT. Ensure that, during the cutting
operation, masonry falling outside of the building
does not cause damage or personal injury.
1. Drill 4 boiler top xing holes with a 12mm
1
(
/2”) masonry drill and insert the plastic plugs
provided, for the wall mounting plate.
2. Drill the 2 boiler lower xing holes with a 12mm
1
/2”) masonry drill, insert the plastic plugs
(
provided .
3. Fix the wall bracket, supplied in accessory
box, into place with 4 M10x70 hex head coach
screws provided.
332mm
850mm to top of boiler18mm
Keston Heat - Installation & Servicing
11
9
1
2
MOUNTING THE BOILER
• Due care should be taken
when lifting the boilers, with
respect to their weights, see
Table 2 on Page 2. Also refer
to Safe Handling on Page 4.
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
INSTALLATION
screws, secure the bottom of
the boiler to the wall through
the attached brackets.
iNSTALLATiON
10
VENTILATION
Keston ventilation requirements when installed in a compartment up to 70kW (BS5440)
To a room or internal space To outside Air
Model 45 55 45 55
Min Free Area (cm
2
) 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.
12
Keston Heat - Installation & Servicing
INSTALLATION
11
FLUE SYSTEM
Note. When installing a replacement boiler a new ue system
must be used. Do not re-use the existing boiler ue installation.
Design
Individual air supply and ue outlet pipes are used as standard.
The material used for ue outlet &/or air inlet must be
muPVC (PVC-C) to BS 5255 and/or BSEN 1566-1 and BSEN
1329 of an internal diameter of 51mm. (i.e. nominal 50mm
diameter muPVC solvent weld waste pipe).
Marley muPVC (PVC-C) Solvent Weld Waste System
(50mm) and Polypipe System 2000 muPVC (PVC-C) solvent
weld waste (50mm) are the only systems approved for this
application.
The following pipes and ttings are approved:
Polypipe System 2000 muPVC solvent Weld Waste System
(50mm)
Poly Pipe 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 straigh coupling
MU 316 50mm x 92.5 deg muPVC swept pipe
Marley muPVC solvent Weld Waste System (50mm)
Marley Code
KP 304 50mm x 4m double spigot pipe
KP32 50mm x 45 deg bend
KSC3 50mm straight coupling
KB3 50mm x 88.5 deg bend
KT3 50mm swept tee
Both the 50mm ue
outlet terminal and
the 50mm air inlet
terminal are supplied
with the ue pack and
are illustrated in Fig. 1
and must be used in
ALL installations. (Both
terminals are identical).
Fig.1
Keston Heat - Installation & Servicing
FLUE OUTLET
13
iNSTALLATiON
2 4 6 8 10 12 14 16 18
2
6
10
14
18
22
26
30
34
38
Accep table op erating area
Keston Evomax 55 - Flue & Air Pipe Length
Flue P ip e Length [m]
Air Pipe Length [m]
10
15.5
2 4 6 8 10 12 14 16 18 20 22
2
6
10
14
18
22
26
30
34
38
Acceptable Operating Area
Keston Evomax 45 - Flue & Air Pipe Length
Flue Pipe Length [m]
Air Pipe Length [m]
15.5
14.5
TERMINAL POSITIONS
Flue
Pipe
Elbow
Minimum Separation
140mm
Acceptable
range of air
pipe siting
Terminal
Air Pipe
150mm
12
FLUE SYSTEM.... CONT’D
TERMINATION OF THE FLUE AND AIR
The ue 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.
The air pipe must have an elbow and 150mm length of pipe
directed downwards with a termination grill tted.
The air pipe can be situated at the side or beneath the
ue pipe to a minimum dimension of 140mm (see diagram
below). It must not be sited above the ue pipe.
The ue and air pipes must extend by at least 40mm from
the wall surface.
Condensing boiler emit a visible plume of water vapour from
the ue 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 ue or air terminal is below a height of 2m from
ground level a terminal guard must be tted.
MAXIMUM LENGTHS
Due to the resistance presented by extended ue length a slight reduction in maximum boiler output will occur where
combined ue 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 ue outlet pipe, when no bends are used, are as detailed in gs 3 & 4.
However, each bend used has an equivalent length that must be deducted from the maximum straight length stated in gs 3 &
4. Knuckle bends must not be tted.
A 92.5º swept elbow is equivalent to 1.0m straight length. A 45º bend is equivalent to 0.5m straight length.
It is possible to have variable ue and air lengths as described within the shaded area of Figs 3 & 4.
FLUE OUTLET
14
SLOPE
‘Horizontal’ ue 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 ue outlet.
Fig. 3
Fig. 4
Keston Heat 45 - Flue & Air Pipe LengthKeston Heat 55 - Flue & Air Pipe Length
Keston Heat - Installation & Servicing
13
a built in element, such as a window frame.
The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions.
FLUE TERMINATION POSITION
INSTALLATION
Twin Flue Positions
A.
Below an opening (1)
B.
Above an opening (1)
C.
Horizontally to an opening (1)
D.
Below gutters, soil pipes or drain pipes
E.
Below eves
F.
Below balcony or car port roof
G.
From a vertical drain pipe or soil pipe
H.
From an internal or external corner or to a boundary alongside the terminal
I.
Above ground, roof or balcony level
J.
From a surface or a boundary facing the terminal
K.
From a terminal facing the terminal
L.
From an opening in the car port into the building
M.
Vertically from a terminal on the same wall
N.
Horizontally from a terminal on the same wall
(1) An opening here means an openable element, such as a openable window, or a fixed opening such as an air vent. However, in addition, the outlet should not
be nearer than 150mm (fanned draught) to an opening into the building fabric formed for the purpose of accommodating
boundary
I
Flue Minimum Spacing Air Minimum Spacing
D, E
300 mm
300 mm
300 mm
75 mm
200 mm
200 mm
150 mm
300 mm
300 mm
600 mm
1200 mm
1200 mm
1500 mm
300 mm
12"
12"
12"
3"
8"
8"
6"
12"
12"
24"
48"
48"
60"
12"
50 mm
50 mm
50 mm
75 mm
50 mm
50 mm
50 mm
50 mm
100 mm
100 mm
1200 mm
100 mm
1500 mm
300 mm
2"
2"
2"
3"
2"
2"
2"
2"
4"
4"
48"
4"
60"
12"
B
J
boundary
H
F
L
G
C
A
H
H
I
N
M
K
GENERAL INSTALLATIONS
All parts of the system must be constructed in accordance with BS 5440 Part 1, except where specically mentioned in these
instructions.
All pipe work must be adequately supported.
Marley muPVC (PVC-C) Solvent Weld Waste System (50mm) and Polypipe System 2000 muPVC (PVC-C) solvent weld waste
(50mm) are the only systems approved for this application.
Consideration must be given to Gas Safe Register bulletin TB008 regarding ues in voids and inspection hatches.
The boiler casing must always be correctly tted to the boiler when leaving the appliance operational.
External wall faces and any internal faces of cavity walls must be good.
Rubber collars are available for ue and air terminals to nish the external wall face around the terminals (Part No C.08.00.07.0).
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.
Keston Heat - Installation & Servicing
FLUE OUTLET
15
14 ASSEMBLY PRACTICE
iNSTALLATiON
Remove all plastic debris and burrs when installing air intake
piping. Plastic lings 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 lings or other
debris will not be covered by guarantee.
INSTALLING FLUE AND AIR PIPES
Important - When installing the boiler on an existing system a
new ue and air intake system MUST also be installed. You
MUST NOT re-use existing ue or air pipework components.
• Remove the ue adaptor and air spigot from the ue pack
supplied with the boiler.
• Remove boiler front panel - Frame 55
• 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 ue adaptor into the ue manifold on the top of the
boiler and secure using the 6 M5 screws provided
• Measure, cut and check the air and ue pipes to pass to the
exit from the wall(s) or ceiling.
• Using the same methods drill any further holes (always
covering existing pipework), cut and assemble the
pipework.
• From outside, complete the two terminations - See
Frame 11 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 ue outlet pipe joints.
• 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 rst 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.
Flue
Sampling
Point
FLUE OUTLET
16
Keston Heat - Installation & Servicing
INSTALLATION
15
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 ange on external face.
5. Slide ue pipe into sleeve, checking it is free to slide.
6. Slide Flexible wall seal over ue pipe and push centre ring up to sleeve ange when cold.
7. Locate wall plate over exible wall seal and clamp in place using the raw plug pack.
8. Afx ue terminal
9. During boiler test check that the ue end is free to expand and contract with exible wall seal.
Flue
Terminal
Flue Pipe
Flue Sleeve
Flue Sleeve Flange
Flexible
Wall
Seal
Wall
Plate
Keston Heat - Installation & Servicing
FLUE OUTLET
17
iNSTALLATiON
6m
2m
Bracket at
each 1 metre
1m
4m
1.5m
6m
3.5º back
to boiler
Sleeve
3.5º back
to boiler
Air
Elbows 2 x 1m = 2m
Straights 6+2 = 8m
Total = 10m
Overall Flue / Air = 25.5m
Flue
Elbows 3 x 1m = 3m
Straights 4+6+1.5+1 = 12.5m
Total = 15.5m
Calculations
2 4 6 8 10 12 14 16 18
2
6
10
14
18
22
26
30
34
38
Accep table op erating area
Keston Evomax 55 - Flue & Air Pipe Length
Flue P ip e Length [m]
Air Pipe Length [m]
10
15.5
2 4 6 8 10 12 14 16 18 20 22
2
6
10
14
18
22
26
30
34
38
Acceptable Operating Area
Keston Evomax 45 - Flue & Air Pipe Length
Flue Pipe Length [m]
Air Pipe Length [m]
15.5
14.5
16
FLUE INSTALLATION EXAMPLE KESTON HEAT 55
Fig. 3
Keston Heat 55 - Flue & Air Pipe Length
17
FLUE INSTALLATION EXAMPLE KESTON HEAT 45
Sleeve
Air
FLUE OUTLET
18
4m
4m
3.5º back
to boiler
3.5m
2m
Bracket every
1 metre
3.5º back
to boiler
Air
4 x 90º elbows 4
Straight lengths 2
2
3.5
4
15.5
3.5m
1.5m
2m
Calculations
Overall Flue / Air = 30m
2.5m
Flue
3 x 90º elbows 3
Straight lengths 2.5
1.5
3.5
4
14.5
Fig. 4
Keston Heat 45 - Flue & Air Pipe Length
Keston Heat - Installation & Servicing
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