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Keston C55: C55P User Manual

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Fan Powered High Efficiency
Modulating Domestic Condensing Gas Boiler
Installation And Servicing Instructions
C40, C40P, C55 & C55P Models
CE/PI No : 87BN14
C40 - GC No : 41-930-07
C40P - GC No : 41-930-08
C55 - GC No : 41-930-09
C55P - GC No : 41-930-10
These instructions must be left either with
the user or next to the site gas meter.
34 West Common Road
Hayes, Bromley, Kent BR2 7BX
Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459
email : info@keston.co.uk web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2 2002
SEDBUK A RATED
WD265/0/2002 The Keston C40, C40P, C55 & C55P
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Keston C55: C55P Specifications

General IconGeneral
ModelC55P
TypeCondensing Boiler
Fuel TypeNatural Gas
MountingWall-mounted
Water Connections22 mm
Maximum Working Pressure3 bar
Operating Temperature Range20 - 80°C
Flue SystemConcentric or Twin Flue

Summary

HANDLING INSTRUCTION

Recommended handling procedure

Procedure for safe handling and lifting of the boiler unit.

GENERAL INSTRUCTION

DESCRIPTION

Overview of the Keston C40/C55 boiler concept, design, and features.

BOILER SCHEMATIC

Diagram illustrating the boiler's internal layout and component connections.

RELATED DOCUMENTS

Lists essential regulations and standards for boiler installation.

PHYSICAL DATA

Technical specifications and dimensions of the C40 and C55 models.

PERFORMANCE DATA - C40 & C40P

Technical performance figures for C40 and C40P models on Nat Gas and LPG.

PERFORMANCE DATA - C55 & C55P

Technical performance figures for C55 and C55P models on Nat Gas and LPG.

OPTIONAL ACCESSORIES

Details of available accessories to complement the boiler installation.

BOILER LOCATION

DIMENSIONS AND MINIMUM CLEARANCES

Specifies required clearances for boiler installation and servicing access.

SERVICE CONNECTIONS

Identifies connection points for gas, water, air, flue, and electrical services.

POSITION

Guidance on suitable locations for boiler installation, including safety considerations.

Electrical Connections

Details on power supply requirements and connection methods for the boiler.

External Wiring & Controls

Information on connecting external controls like programmers and thermostats.

BOILER SIZE SELECTION

Guidance on selecting the appropriate boiler size for system requirements.

GAS SUPPLY

Requirements for natural gas and LPG supply pressure and pipe sizing.

WATER SYSTEMS

Guidelines for connecting the boiler to open vented and sealed water systems.

FLUE SYSTEM

Requirements for flue pipe material, lengths, termination, and slope.

AIR SUPPLY

Information on the room-sealed appliance's air intake requirements.

COMPARTMENT INSTALLATION

Notes on installing the boiler within a compartment.

CONDENSATE DRAINAGE

Instructions for connecting and routing the condensate drain pipe.

INSTALLATION OF THE BOILER

WALL MOUNTING BRACKET

Instructions for fitting the wall mounting bracket correctly.

MOUNTING THE BOILER

Steps for lifting and securing the boiler onto the wall bracket.

ASSEMBLY PRACTICE

General advice on preventing debris ingress during pipe installation.

INSTALLING FLUE AND AIR PIPES

Guidance on connecting flue and air pipes, including replacement of old systems.

CONDENSATE DRAINAGE

Detailed steps for assembling and connecting the condensate trap.

WATER SYSTEM

Instructions for connecting the flow and return pipework to the boiler.

GAS SUPPLY

Procedures for connecting the gas supply and checking its soundness.

ELECTRICAL SUPPLY

Wiring instructions, safety precautions, and terminal connections for the electrical supply.

EXCHANGING A BOILER

Procedures and considerations when replacing an existing boiler.

COMMISSIONING OF THE BOILER

INITIAL FLUSHING

Steps for flushing the system and filling the boiler with water.

GAS SUPPLY

Checking the gas supply installation for soundness.

ELECTRICAL INSTALLATION

Performing preliminary electrical safety checks.

LP GAS

Note regarding LPG installations and model suitability.

INITIAL FIRING

Procedures for starting the boiler for the first time, including safety checks.

HOT FLUSHING

Steps for flushing the system while hot and refilling.

COMBUSTION TESTING

Measuring and adjusting CO2/CO levels for optimal combustion.

CHECKING THE GAS PRESSURE

Verifying gas inlet pressure and joint soundness.

TIMING THE GAS METER

Procedure for determining gas input by timing the meter.

HANDING OVER TO THE USER

Explaining boiler operation, safety features, and maintenance to the user.

FAULT FINDING

ELECTRICAL CONTROL SEQUENCE

Describes the sequence of operations during boiler startup and running.

NORMAL OPERATION

Explains the meaning of status codes displayed during normal boiler operation.

FAULT MODES

Details the boiler's reaction to faults and display of block codes.

Automatic Lockout Avoidance

How the boiler reacts to faults and displays block codes.

LOCKOUT

Explains error codes and what to do when the boiler enters a lockout state.

FUNCTIONAL FLOW WIRING DIAGRAM

Diagram showing the functional electrical connections within the boiler.

ELECTRICAL WIRING DIAGRAM

Detailed wiring diagram illustrating all electrical connections.

ILLUSTRATED WIRING DIAGRAM

Pictorial representation of the boiler's electrical wiring.

EXPLODED ASSEMBLY DIAGRAMS

Provides exploded views of various boiler component assemblies.

Boiler Controls Assembly

Exploded view of the boiler's control components.

Waterway, Condensate & Flue Assembly

Exploded view of water, condensate, and flue system parts.

Air - Gas Assembly

Exploded view of air intake and gas control components.

Casing Assembly

Exploded view of the boiler's external casing components.

Exploded Diagrams Parts Reference List

A list of parts corresponding to the exploded diagrams.

ROUTINE (ANNUAL) SERVICING

Pre-Service Checks

Recommended inspection steps before performing annual service.

Recommended Routine Service

Detailed procedures for carrying out annual servicing of the boiler.

REPLACEMENT OF PARTS

GENERAL

General advice that servicing must be done by a qualified person.

PRECAUTIONS

Essential safety precautions before working on the appliance.

ACCESS

Instructions on how to gain access to the boiler's internal components.

REPLACEMENT PROCEDURE

General guidance on the order and method of replacing parts.

ELECTRICAL COMPONENTS

Details procedures for replacing various electrical components.

CONTROL PANEL

Procedure for replacing the boiler's control panel.

Boiler Flow and Return Thermistors

Steps for replacing the flow and return thermistors.

Cabinet Temperature Sensor

Procedure for replacing the cabinet temperature sensor.

Flue Protection Thermostat

Steps for replacing the flue protection thermostat.

Water Pressure Switch

Procedure for replacing the water pressure switch.

Main Control Box

Steps for replacing the main control box.

Combustion Blower

Procedure for replacing the combustion blower.

Gas Control Valve / Venturi Assembly

Steps for replacing the gas control valve and venturi assembly.

SPARK IGNITION/FLAME DETECTION ELECTRODE

Procedure for replacing the spark ignition/flame detection electrode.

BURNER

Steps for removing and replacing the boiler's burner.

HEAT EXCHANGER

Procedure for replacing the heat exchanger.

CONDENSATE TRAP

Steps for removing and replacing the condensate trap.

PUMP

Procedure for replacing the circulating pump.

SHORT SPARE PARTS LIST

GAS BOILER COMMISSIONING CHECKLIST

SERVICE INTERVAL RECORD

Record for tracking annual servicing and maintenance of the heating system.

INSTALLATION KEY POINTS

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