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Q28s - Keston boilers

1. Installation amp Servicing Instructions Page 39 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers SS Installation amp Servicing Instructions Page 40 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 7 3 Air Gas Assembly Installation amp Servicing Instructions Page 41 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers EE D REN 6 7 4 Casing Assembly
2. Installation amp Servicing Instructions Page 42 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 7 5 Exploded Diagrams Parts Reference List Boiler Controls Assembly Fig 6 7 1 GC Number Code 131 131 132 E72 401 151 133 Waterway Condensate amp Flue Assembly Fig GC Number Code 51 98 52 81 Air Gas Assembly Fig 6 7 3 GC Number Code 111 183 183 Casing Assembly Fig 6 7 4 GC Number Code 2 8 8 E73 355 17 Installation amp Servicing Instructions Description Q28s Main Control PCB Q 10S 4 01 00 0 F Q28sP Main Control PCB Q 10S 4 15 00 0 F Control Panel Q 10S 4 02 00 0 Thermal Fuse C 08 4 21 00 0 Ignitor Cable Q 10S 4 03 00 0 6 7 2 Description Heat Exchanger Assy Q 10S 0 11 00 0 Expansion Vessel C 08 0 08 00 0 A Burner Kit Q 10S 0 10 00 0 Burner Head Gasket C 10C 2 00 45 0 A Ignitor Gasket C 10C 2 00 52 0 A Ignitor Kit Q 10S 0 09 00 0 Condensate Trap Kit Q 10S 0 16 00 0 Flow Return Thermistor Q 10S 2 08 00 0 Flue Sensor Q 10S 2 09 00 0 Pressure Sensor C 10C 2 17 00 1 Flow Thermostat Q 10S 2 07 00 0 Pump Q 10S 2 10 00 0 Description Combustion Blower Q 10S 3 01 00 1 Q28s Gas Valve Mixer Air Gas Assembly Q 10S 3 04 00 0 Q28sP Gas Valve Mixer Air Gas Assembly Q 10S 3 05 00 0 Des
3. 4 9 EXCHANGING A BOILER Before removing an existing boiler add Fernox Supafloc or equivalent cleaning agent in accordance with the manufacturers instructions Open all radiator valves and fire the boiler When the system is fully heated shut off the gas supply and drain down the central heating system Important The Qudos 28s and Qudos 28sP condensing boilers contain components which could be damaged or blocked by grease dirt or solder etc It is essential that sludge or scale is removed from an existing system before fitting the boiler The guarantee provided with the Keston Qudos 28s and Qudos 28sP does not cover damage caused by system debris or sludge Connect the new boiler as instructed in this manual and fit in accordance with Sections 4 1 to 4 8 Fill to a pressure of about 2 5 bar Check the complete system for water soundness If leaks need to be rectified using flux or solder the system must be flushed cold again before proceeding Reduce the pressure to the Initial System Design Pressure Vent the system Gas Supply The complete gas installation up to the boiler gas control valve must be checked for soundness BS 6891 Electrical Installation Carry out preliminary electrical safety checks i e Earth continuity Polarity Resistance to Earth Short Circuit and earth loop impedance using a suitable test meter Installation amp Servicing Instructions Page 25
4. FLUE SENSOR uo uo3 HI t 5 SANVW3d D a ES x x HT STATS EXT SENSOR ANALI DEMAND DPEN THERM FLOW SWITCH DHW G6 E au print STATS SENSOR Ts SENSOR WET WPT sn SENSOR NaAWADASNVAL lt 2 m 4 con l or n8 co Installation amp Servicing Instructions Page 36 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 6 ILLUSTRATED WIR
5. 1 User Instructions The Keston Qudos 28s amp Qudos 28sP Boilers Normal Operation During normal operation the digital display will show the current boiler temperature and will show relevant operational symbols to confirm what action the boiler is taking If the radiator or L symbol is shown on the display the boiler is receiving a demand for that function Fault Modes In the event that the boiler detects a situation which it considers to be a fault the display will change to show a flashing fault code starting with an E and then a two digit number The table below explains these codes and the action you should take Display Description of fault E02 Ignition lockout the boiler has attempted to light five times and not succeeded check the gas supply is on E04 Flame failure whilst running the boiler is having difficulty maintaining the flame Consult your Service Engineer and check for flue gas supply or condensate drainage obstruction E12 Flow overheat the boiler has exceeded it maximum water temperature Check that any by pass is open and the controls are operating correctly E26 or The system water pressure is too low Check the system has water in and for sealed E67 Systems top up the system water pressure to restore a pressure of between 1 and 2 bar Consult your installer for instruction how to top up water pressure repeated need for restoration of water pressure indicates
6. You can return to the normal display mode at any time by pressing the Reset button During normal operation the radiator symbol will indicate the mode of operation If the radiator symbol is not present then there is no demand on either SL1 or SL2 Other methods of placing a demand on the boiler is via an Opentherm control such as the Keston Room Controller or a 0 10VDC input Either alternative input is indicated by the inverted T symbol on the bottom row of the display Installation amp Servicing Instructions Page 32 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 3 FAULT MODES If a situation is detected which the boiler considers may cause damage to the appliance the boiler will enter a lockout mode and stop functioning After clearing the problem the user must also press the Reset button once to resume boiler operation in most circumstances However certain faults as designated Service Reset Required in the table below will not reset from the fascia button These require the Service Reset button on the main PCB see Fig 6 5 to be pressed IN BOTH TYPES OF LOCKOUT TURNING THE POWER ON THEN OFF WILL NOT CLEAR A LOCKOUT SITUATION ERROR CODES Display Description of fault E01 Flame sequence lockout possible board or electrical supply fault E02 Ignition failure Boil
7. Qudos 28s User Installation and Servicing Instructions FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS SYSTEM BOILER CE PI No 86 CM 43 Qudos 28s GC No 41 930 17 Qudos 28sP GC No 41 930 18 C 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 amp L2 SEDBUK A RATED benchmark gt WD 420 issue 8 2011 WD420 3 2007 The Keston Qudos 28s amp Qudos 28sP Boilers CONTENTS NB These instructions are an integral part of the appliance This document must be handed over to the user on completion of the installation to ensure compliance with the Gas Safety Installation amp Use Regulations Section 0 Description HANDLING INSTRUCTIONS List of contents Recommended handling procedure USER INSTRUCTIONS Introduction Maintenance Boiler Setup and Operation Safety Information GENERAL INSTRUCTION Description Boiler Schematic Related Documents Physical Data Optional Accessories Performance Data BOILER LOCATION Dimensions amp Minimum Clearances Service Connections Position Electrical Boiler Size Selection Gas Supply Water Systems Flue System Air Supply Compartment Installation Condensate Drainage INSTALLATION
8. WD420 3 2007 Chapter 5 Commissioning The Keston Qudos 28s amp Qudos 28sP Boilers 5 8 NB 5 9 5 10 7 Press the RESET button twice to return to the normal operation mode and display CHECKING THE GAS PRESSURE With the boiler running measure the burner pressure at the burner pressure test nipple pos 4 It is advisable to carry out this test with the thermostat set to maximum and the system water cold to ensure the boiler is running at maximum rate The gas setting is factory adjusted to within the required range and should not need adjustment If the reading is incorrect then check such factors as tightness of the air and flue pipe joints and the gas inlet pressure pos 3 minimum 18 mbar required for natural gas minimum 31 mbar required for LP gas If all joints are sound and the gas inlet pressure is satisfactory check the gas input by timing the gas meter as detail in Section 5 9 Timing The Gas Meter If the gas input cannot be measured then it s compulsory to measure the combustion quality as detail in Section 5 7 Combustion Testing TIMING THE GAS METER After the boiler has been started and with no other appliances using gas time the gas meter to be certain that the unit is running at the proper gas input Determine the cubic feet of gas passing through the meter and determine the input in Btu per hour Inout must be within plus or minus 5 of the rated input Time in seconds the time taken to pass 2
9. e z ziz lt E E ORANGE p GREY 9 25 Z N S BLUE BROWN FROM DHW E 8 C 10C 0 09 00 0 gt CONTROLS 2 j 2 g 2 mut ZONE Slo al i a L gt LOW VOLTAGE CONNECTOR Nd ur an season PW aren SEMARD EXTERNAL Y SENSOR err 1 2 1 2 1 2 2 1 1 2 oR 112161 I L Installation amp Servicing Instructions Page 24 WD420 3 2007 5 3 Chapter 4 Installation The Keston Qudos 28s amp Qudos 28sP Boilers Solar Control SOLAR CONTROL WITH DHW SENSOR INPUT gt xl L amp 28 22 s 25 1 b E tc 8 Q28S Ar ORANGE GREY lt a 4g 25 a i BLUE BROWN FROM CH BOILER z 2 d CONTROLS CH ZONE lal Zma VALVE z 5 lt gt Y ORANGE P GREY o 5 2 NA a BLUE BROWN FROM DHW 4 10 0 09 00 0 gt CONTROLS T a d JE d 1 818 LOW VOLTAGE CONNECTOR CREE Ese 20 SENSOR SENSOR M ER BERND Sensor r Y D 1 2 1 2 1 2 wo C 2 1 550v 1 2 E SOLAR PANEL TANK as l Le A r I l LP im TSSENSOR SOLAR PANEL
10. lt u 5 Lis 3 B 5 du 3 b v L L N N N a 3 ac Y ES x L L L I d T 1 1 3 lt L N z a L i i A L DS1ND3 03348 ze aa 1 E E 65 Suz 3 a sa gt m 5 ini x i UTF rm a s M 6 a Noa ra aUSN3S ra 1x3 Sa cor anywa ME lt YNY jsnd DOWNY 9 8 CIPNBESHI 8 el onu S N3en w Bo LU HOLIAS T W LA Te sha YLS HT sum Y Ad U AH aa lt MUSN3S E gt SL amis S z l 105 cs gt _ SERVICE RESET NUIIO3I3d 34vid any Js PS In 8 x a a y Y i go um gr ATddNS 3WS3D3SNV L 170 007 ao ae I uos uo SI q A Z a gt N g a au lt x Uj Tm DR 2 UA gt O o ale gt lt m we a 2 T Y EROS jc rw EC 2 lt jt P w a lt PU mm LO t Sw5 RUM S 5 NE E ED E JE EE E Installation amp Servicing Instructions Page 35 WD420 3 2007 6 5 ELECTRICAL WIRING DIAGRAM Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers XO TWNIWSSL dWnd
11. Section 8 1 ii Gain access Section 8 2 iii Pull off the multi pin connectors and HT lead away from the board iv Remove the plastic box cover by pulling it from support v Remove the control PCB by pulling it from the four support plastic pins vi Reassemble Section 8 3 Installation amp Servicing Instructions Page 47 WD420 3 2007 sess 8 Replacement Of The Keston Qudos 28s amp Qudos 28sP 8 5 8 6 8 4 7 8 4 8 8 4 9 Combustion Blower Fig 6 7 3 item 111 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Disconnect the connector block from the combustion blower iv Unscrew the bolts Fig 6 7 3 item 114 securing the gas inlet pipe to the gas control valve v Remove the four nuts securing the combustion blower fig 6 7 3 item 120 outlet flange to the burner and remove the combustion blower vi Reassemble Section 8 3 NB When reassembling inspect any gaskets for damage and replace if necessary Gas Control Valve Venturi Assembly Fig 6 7 3 item 183 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the push on connector block to the gas valve iv Unscrew the bolts Fig 6 7 3 item 114 securing the gas inlet pipe to the gas control valve v Unscrew the bolts securing the gas valve Fig 6 7 3 item 122 to the inlet port of the combustion blower vi Remove the gas valve venturi assembly as a complete unit vii Unsc
12. amp Servicing Instructions Page 4 WD420 3 2007 Chapter 2 General Instruction The Keston Qudos 28s amp Qudos 28sP Boilers 2 2 The boiler heat exchanger is made from highly corrosion resistant stainless steel in corrugated pipe form which provides massive surface area within a compact dimension The hot combustion gases from the down firing burner pass around the stainless steel pipes imparting heat into the system water On the Qudos 28s integral variable speed pump within the appliance cabinet ensures the heat exchanger receives correct water flow when firing The Qudos 28s is not a high water content boiler and does not contain the metal mass or water volume of a cas
13. 1 MINUTE AFTER EACH ADJUSTMENT TO ALLOW THE SETTING TO STABILISE BEFORE TAKING A READING Press the RESET button once and then press the ENTER button Use the A button until the display shows 32 30 for LPG Press the ENTER button and the boiler will be locked on at Minimum rate If no further buttons are pressed for 10 minutes the boiler will automatically revert to normal operation Measure the CO reading in the flue gases The CO reading must be 8 4 to 8 896 with a corresponding CO level of 5 to 20 ppm for natural gas and 9 596 to 9 996 with a corresponding CO level of 5 to 20 ppm for LPG THE CO2 LEVEL AT LOW RATE MUST ALWAYS BE LESS THAN THE CO2 LEVEL AT HIGH RATE ADJUSTMENTS IF MADE SHOULD BE IN STEPS OF NO MORE THAN 1 8 OF A TURN YOU MUST WAIT 1 MINUTE AFTER EACH ADJUSTMENT TO ALLOW THE SETTING TO STABILISE BEFORE TAKING A READING Press the RESET button once and then use the W button until the display shows 10096 Press the ENTER button and the boiler will be locked on at Maximum rate Check the setting is within the range established in step 3 If not repeat the process again from step 3 If following the above procedure combustion levels described above at both high and low rate could not be obtained please turn off the appliance and isolate the gas to the appliance Telephone KESTON Heating technical support phone no 0208 462 0262 Installation amp Servicing Instructions Page 29
14. 8 1 Both terminals are identical If 75mm terminals are required these can be obtained from your KESTON Heating stockist Request part numbers C 17 2 26 00 0 terminals and C 17 2 00 60 0 50 to 75 adapters 3 8 2 Maximum Lengths The maximum lengths of both air inlet pipe and flue outlet pipe when no bends are used are as detailed below However each bend used has an equivalent length that must be deducted from the maximum straight length stated above Knuckle bends must not be used A 92 5 sweep elbow is equivalent to 1 0m straight length A 45 bend is equivalent to 0 5m straight length 50mm 75mm Maximum Air Inlet Length 39 0m 117 0m Maximum Flue Outlet Length 20 0m 60m Maximum Total Flue and Air Intake Length 40 0m 120 0m Example assuming 50mm muPVC flue and air pipework Air inlet uses two 92 5 sweep elbows Hence maximum length permissible i e a b in figure 3 8 2 39 0m 1 0m 1 0m 37 0m Flue outlet uses one 92 5 sweep elbow Hence maximum length permissible i e Eston Dudes in figure 3 8 2 20 0m 1 0 m 19 0m NB The air and flue pipes can be passed outside the building through only one wall or through two different walls Figure 3 8 2 Flue amp Air Maximum Length Example 3 8 3 Slope Horizontal flue outlet pipework MUST slope at least 2 degrees 35 mm per metre run downwards towards the boiler Pipework can be vertical Only swept elbows can be
15. OF THE BOILER Wall Mounting Bracket Mounting The Boiler Assembly Practice Installing Flue And Air Pipes Condensate Drainage Water System Gas Supply Electrical Supply Exchanging A Boiler COMMISSIONING OF THE BOILER Initial Flushing Gas Supply Electrical Installation LP Gas Initial Firing Page i WD420 3 2007 The Keston Qudos 28s amp Qudos 28sP Boilers Hur 10 5 6 Hot Flushing 5 7 Combustion Testing 5 8 Checking the Gas Pressure 5 9 Timing The Gas Meter 5 10 Handing Over To The User FAULT FINDING 6 1 Electrical Control Sequence 6 2 Normal Operation 6 3 Fault Modes 6 4 Functional Flow Wiring Diagram 6 5 Electrical Wiring Diagram 6 6 Illustrated Wiring Diagram 6 7 Exploded Assembly Diagrams SERVICING 7 1 Pre Service Checks 7 2 Recommended Routine Service REPLACEMENT OF PARTS 8 0 General 8 1 Precautions 8 2 Access 8 3 Replacement Procedure 8 4 Electrical Components 8 5 Spark Ignition Flame Detection Electrode 8 6 Burner 8 7 Heat Exchanger 8 8 Condensate Trap 8 9 Pump 8 10 Expansion Vessel SPARE PARTS LISTINGS GAS BOILER COMMISSIONING CHECKLIST Page ii WD420 3 2007 The Keston Qudos 28s amp Qudos 28sP Boilers HESS 0 1 0 2 0 HANDLING INSTRUCTIONS LIST OF CONTENTS The Keston Qudos 28s and Qudos 28sP are supplied almost totally pre assembled The units use standard 50 mm muPVC BS5255 and or BSEN1566 1 and BSEN1329 pipe for the flue and air
16. The boiler can be wired to a single switched live 230VAC signal input However the boiler has TWO thermosiats and will therefore accept up to TWO switched live 230VAC signal inputs such as heating and hot water or radiators and underfloor heating zones Alternatively a Keston Room Controller can be connected directly via two core low voltage cable to the terminals marked OT The Keston Room Controller will then provide fully room compensated control to ensure the boiler output is matched to the rooms requirements at optimum boiler efficiency This is only recommended for heating only applications The boiler can also be driven by an external 0 10VDC input Wiring external to the boiler must be in accordance with current I E E wiring regulations and local regulations The method of connection to the mains electricity supply must facilitate complete electrical isolation of the boiler preferably by the use of a fused unswitched three pin plug and a shuttered socket outlet both complying with the requirements of Installation amp Servicing Instructions Page 12 WD420 3 2007 d 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers BS 1363 There must be only one common method of isolation for the boiler and its control system The appliance must be connected to the 3A supply via a fused double pole switch having at least 3 mm 1 8 inch contact separation in both poles serving only the boiler and the system controls
17. The connection point to the mains supply should be readily accessible and adjacent to the boiler except for rooms containing a bath or a shower Refer to section 3 3 Position 3 4 2 External Wiring amp Controls 1 The boiler is designed so that all control wiring is external to the boiler 2 Heating control signal inputs must be 230VAC switched live type unless using a Keston Room Controller see below or 0 10VDC input 3 4 2 1 Enhanced Control Options The Qudos 28s can be wired into a conventional heating installation using only permanent and switched live connections However the Qudos 28s features a wide range of OPTIONAL control features normally associated with commercial boilers installations at additional cost These are provided as standard in the Qudos 28s and require low costs sensors to be added to activate them The features provided are detailed below Refer to Chapter 4 8 for further wiring detail Room Compensation Opentherm A Keston Room Controller may be used to provide room compensated control to ensure the boiler output is matched to the rooms requirements at optimum boiler efficiency This is only recommended for heating only applications Weather Compensation Ext Sensor A Keston outside temperature sensor may be connected as an option The boiler will automatically detect this connection and will operate on a weather compensation basis when receiving a heating demand signal from the SL terminal or from a K
18. WD420 3 2007 Chapter 4 Installation The Keston Qudos 28s amp Qudos 28sP Boilers Initial Firing The gas pressure setting is factory adjusted to within the required range and does not need readjustment If the reading is incorrect then check such factors as tightness of the air and flue pipe joints pressure sensible joints and the gas inlet pressure minimum 18 mbar required for Natural Gas and 31 mbar required for LP gas If all joints are sound and the gas inlet pressure is satisfactory set the gas pressure check the gas input Full details of this procedure are given in Section 5 9 Timing The Gas Meter Combustion Testing It is advisable on all installations that the combustion quality is checked by measuring the carbon dioxide CO or oxygen Oz level This procedure is detailed in Section 5 7 Combustion Testing Badly tuned combustion will lead to reduce the life of the boiler and invalidate the warranty Installation amp Servicing Instructions Page 26 WD420 3 2007 Chapter 5 Commissioning The Keston Qudos 28s amp Qudos 28sP Boilers 5 COMMISSIONING OF THE BOILER Important This condensing boiler contains components which could be damaged or blocked by grease dirt solder etc from the water system The following commissioning procedures must be followed precisely It is essential that combustion is checked at high and low rate as per Section 5 7 using a calibrated flue gas analyser set for the relevant gas
19. a system leak which should be investigated E25 The boiler temperature is rising too fast ask your Service Engineer to check for system blockage or pump failure E52 The flue temperature is too high Consult your Service Engineer SERVICE RESET REQUIRED E62 Water pressure too high check that the system water pressure top up valve has not been left open or consult your installer to check the expansion vessel E70 The cabinet has overheated consult your Service Engineer before operating the boiler further SERVICE RESET REQUIRED The above is an abbreviated list of possible error codes If the code is not in the list above consult a GAS SAFE REGISTER registered engineer A full list of codes can be found in Chapter 6 of this manual If a code appears and you feel the original cause has been rectified and it has not been designated as requiring a Service Reset press the Reset button to resume boiler operation Otherwise or if the code persists consult a GAS SAFE REGISTER registered engineer Raise up the system pressure until error E67 or E26 disappears from display the boiler will enter in standby mode or will start to fire up if a heat demand exists To check the system pressure press the W button repeatedly until the display shows the water pressure indicated by the word bar to the right of the number To return to main screen press the RESET button Precautions Care must be taken at all times to ensure that no
20. amp Qudos 28sP Boilers ee ERROR HISTORY The Qudos 28s has an internal memory function that stores the last six errors encountered along with the sensor readings at that time and the time elapsed between each error occurring This is very useful for diagnosing the cause of an error lockout particularly when the error is intermittent Press the W button repeatedly until the display shows SHE and then press the ENTER button you will enter the Error History mode Press the A button to show the error number to investigate Er1 is the most recent and Er6 is the oldest Having selected the error press ENTER Press the A to scroll through the readings stored at the time of the lockout occurring The table below shows the values associated with consecutive A button press No Meaning Enn The error code recorded for the lockout 2 Actual CH flow temperature maximum 84C display indicates a radiator symbol and a 1 3 Actual CH return temperature maximum 72C display indicates a radiator symbol and a 2 NB Flow temperatures more than 20C above return temperature may lead to overheat and noise problems Check the pump performance and the system for blockages 4 Actual DHW temperature display indicates a tap symbol NB Only relevant if the DHW sensor option is connected 5 Actual Flue Temperature display indicates the flame and fan symbols NB Flue temperatures a
21. at the end of the installation and commissioning process The details of the Checklist will be required in the event of any warranty work being required There is also Service Interval Record Chapter 10 to be completed after each annual service visit These forms Chapter 10 should be kept in a safe place for the life of the boiler The boiler should be installed and serviced only by GAS SAFE REGISTER registered operatives All GAS SAFE REGISTER registered Installers carry a GAS SAFE REGISTER ID card and have a registration number Both should be recorded in your boiler manual Chapter 10 GAS BOILER COMMISSIONING CHECKLIST You can check your installer by calling GAS SAFE REGISTER direct on 0800 408 5500 IN THE EVENT OF A GAS LEAK Turn off the gas isolation valve to the property immediately Extinguish all naked flames or other sources of ignition Do not operate electrical Switches on or off Open all doors and windows to ventilate the area Installation amp Servicing Instructions Page 10 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers 3 BOILER LOCATION 3 1 DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown to allow subsequent servicing and safe operation However larger clearances may be required during installation 3 2 SERVICE CONNECTIONS Gas water air and flue pipe condensation and electrical connections are as shown i
22. boiler room invalidates the heat exchanger warranty The flue outlet terminal is designed to face outwards but can if desired be adapted to face in any direction BUT must not be directed in the region of the air inlet The flue terminal and air inlet terminal can be located on different but not opposing wall faces The two terminals are subject to the requirements of BS 5440 Pt 1 for clearances from features of the building although some can be decreased to the values indicated The Keston Qudos 28s and Qudos 28sP as with any condensing boiler will generate a condensate plume from the flue terminal in all weather conditions Consideration must therefore be given to the effect of this plume when selecting a location for the flue terminal It is the responsibility of the installer to ensure the selected terminal location does not cause nuisance Dimensions mm Flue Air Terminal Inlet A Below above or beside openable window air 300 50 brick etc B Below gutters soil pipes drain pipes 75 75 C Below eaves 200 50 D Below balconies or car port roof lowest point 200 50 E From vertical drain or soil pipes 75 50 F From internal or external corner or to a 200 50 boundary alongside the terminal G Above ground or balcony or roof 200 100 H From surface or boundary facing a terminal 600 100 From terminal facing a terminal 1 200 1 200 J From opening in a car port not recommended 1 2
23. burner surface is 4 mm Distances above or below 4 mm will affect ignition performance If necessary gently bend the electrode taking care not to damage the ceramic insulator BURNER Fig 6 7 2 1 2 items 52 i ii iii Isolate the appliance Section 8 1 Gain access Section 8 2 Remove the combustion blower Section 8 4 7 Installation amp Servicing Instructions Page 48 WD420 3 2007 es 8 Replacement Of Parts The Keston Qudos 285 amp Qudos 28sP 8 7 8 8 8 9 8 10 iv Remove the 4 nuts fixing the burner to the top of the heat exchanger Fig 6 7 3 item 120 v Remove the spark ignition flame detection electrode Section 8 5 vi Withdraw the burner from the top of the heat exchanger vii Reassemble Section 8 3 NB When reassembling inspect any gaskets for damage and replace if necessary HEAT EXCHANGER Fig 6 7 2 1 2 item 51 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Shut off the water supply to the appliance iv Remove the burner Section 8 6 v Drain the system to below the level of the appliance vi Remove the flue thermistor Section 8 4 4 vii Remove the spark ignition flame detection electrode Section 8 5 viii Remove the flue connection by slackening the retaining strap and pulling the flue off the heat exchanger spigot ix Remove the condensate trap Section 8 8 x Disconnect the flow and return pipe union nuts Fig 6 7 2 1 2 amp F
24. cubic feet of gas through the meter i e one revolution of a 2 cu ft dial or 0 1 cubic metres if the meter is of the new metric digital type Model Time for 2 cu ft Time for 0 1 cum Qudos 28s natural gas 71 to 78 seconds 125 to 138 seconds Qudos 28sP LPG 152 to 168 seconds 272 to 300 seconds If the meter timing is found to be incorrect when the boiler is firing at_maximum rate contact KESTON Heating for further guidance HANDING OVER TO THE USER It is important to fully explain the following a Procedure to light and turn off the boiler including isolation of the electrical supply if necessary b The function of the lockout feature must be explained If the display shows E 02 this means that the boiler has failed to light Press the Reset button and wait i If lockout recurs immediately then the gas supply should be checked as ON otherwise consult a Service Engineer ii If it is not possible to relight the boiler must be isolated and a Service Engineer called in to rectify the fault Advise that a reduction the water pressure reading the system pressure gauge for sealed systems indicates a leak which should be rectified before further use d Advise that the appliance must be serviced by a competent person at least once a year Complete all sections of the Chapter 10 Gas Boiler Commissioning Checklist that are relevant to the appliance installation The details will be required in the event
25. intake systems The boiler is packed in a single box without additional flue kit All additional components are packed inside the boiler cabinet itself The following is a list of components and their location in the boiler cabinet Equipment List Item Quantity Location Wall Bracket Rawl Plugs 6 Inside accessories bag Wall Bracket Wall Fixing Screws 6 Inside accessories bag Wall Mounting Bracket 1 Secured to inside right hand side of boiler case Wall Mounting Bracket Nuts 1 Inside accessories bag Wall Mounting Bracket Washers 1 1 Inside accessories bag Wall Bracket Bolt Insulation 1 Inside accessories bag 50 mm muPVC Air Flue Terminals 2 Inside accessories bag Air Inlet Spigot 50 mm 1 Inside accessories bag Flue Outlet Spigot 50 mm 1 Inside accessories bag Air Inlet Spigot Gasket 1 Inside accessories bag Air Inlet Spigot Flue Outlet Spigot M6 Screws 4 2 Inside accessories bag Cabinet Cable Entry Clamps 2 Inside accessories bag Gas Isolating Cock 1 Inside accessories bag Condensate Trap 1 Inside accessories bag Condensate Trap fixing screws 2 Inside accessories bag Condensate Trap fixing washers 2 Inside accessories bag Condensate Trap Gasket 1 Inside accessories bag Outside Temperature Sensor 1 Inside accessories bag 50 mm muPVC Pipe 2 Inside boiler case 50 mm muPVC Elbow 2 Inside boiler case Document List Item Quantity Location Boiler Warranty Registration Form 1 In document bag Installation Template 1 In document bag Remove
26. mm 200 Front Clearance for servicing mm 300 Weight Full kg Ibs 47 104 Weight Empty kg Ibs 43 95 Flow and Return Connection G3 4 Gas Connection G1 2 Condensate Connection overflow 22mm plastic Safety Valve Connection discharge 15mm copper IP Rating IP20 IPXO Flue and Air Intake Material 50mm muPVC BS5255 and or BSEN1566 1 and BSEN1329 Flue Pipe Size nominal bore mm in 50 2 Air Intake Pipe Size nominal bore mm in 50 2 Max Air Intake Length m 39 Max Flue Outlet Length m 20 Max Total Flue Outlet and Air Intake Length m 40 Flue and Air Intake Material 75mm Keston Composite Flue Pipe Size nominal bore mm in 75 3 Air Intake Pipe Size nominal bore mm in 75 3 Max Air Intake Length m Max Flue Outlet Length m Max Total Flue Outlet and Air Intake Length m 2 5 OPTIONAL ACCESSORIES A range of accessories are available from KESTON Heating to compliment an installation Terminal wall sealing collars are available to make good the external all face whilst working from the inside of the building using 50mm muPVC BS5255 and or BSEN1566 1 and BSEN1329 pipe Stand off frames are available to leave a 50mm gap behind the boiler to allow routing of pipes behind the boiler Description Part Number Flue Terminal Wall Sealing Collar 50mm C 08 0 00 07 0 Air Terminal Wall Sealing Collar 50mm C 08 0 00 07 0 50 75mm Flue Adapter C 17 2 00 60 0 Flue Outlet Terminal 75mm C 17
27. modern home is often supplemented by alternative or renewable energy sources As a result the Qudos 28s features optional connection of a solar thermal system pump panel and DHW sensor for direct control of solar thermal system from the boiler Other additional energy Source systems such as Ground Source Heat Pump will be accommodated Soon The boilers have the added advantage of very high efficiency and small diameter muPVC plastic flue which can be extended up to 20 metres horizontally or vertically The Keston Qudos 28s uses a variable speed combustion blower to deliver a premix of gas and air to a downward firing burner in a high efficiency single pass heat exchanger The flue system is room sealed and fan powered The ignition is direct spark and fully automatic The boiler housing is not waterproof and should be installed in a position where it will always be dry Combustion air is drawn from the cabinet which is connected to outside atmosphere via a small diameter plastic intake pipe The cabinet therefore remains under negative pressure at all times the boiler is operating These boilers are designed for use as part of a sealed water central heating system with fully pumped circulation The pump an 8l expansion vessel and associated safety devices are all fitted within the Qudos 28s boiler However consideration should be given to additional expansion vessels on larger systems where 8 litres may be inadequate Installation
28. or under firing the burner will reduce the longevity of the appliance and may result in excessive carbon monoxide levels Carbon dioxide and carbon monoxide are colourless odourless gases produced by all combustion processes When the Keston condensing boiler is operating properly carbon dioxide levels will be between 8 4 amp 8 8 low rate and 8 9 amp 9 3 high rate and carbon oxide CO levels will be between 5 to 20 ppm low rate and 50 to 150 ppm high rate for natural gas For LP gas carbon dioxide levels will be between 9 5 amp 9 9 low rate and 10 3 amp 10 796 high rate and the carbon monoxide will be between 5 amp 20 ppm low rate and 50 amp 150 ppm In any event the CO level at low rate must ALWAYS be less than CO levels at high rate Installation amp Servicing Instructions Page 28 WD420 3 2007 Chapter 5 Commissioning The Keston Qudos 28s amp Qudos 28sP Boilers To measure CO levels in the Keston boiler remove the 1 8 plug from the flue outlet pipe spigot Figure 6 7 4 item 17 Insert the probe of a calibrated combustion analysis meter and sample the gases as instructed in the test equipment s instructions When firing the boiler for the first time since installation the CO level at high rate may be between 100 220 ppm and between 50 80 ppm at low rate This is due to compounds used during manufacture curing within the combustion chamber On boilers which have
29. the checks earth continuity polarity short circuit resistance to earth must be repeated Installation amp Servicing Instructions Page 31 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers pL QUICK REFERENCE 6 2 NORMAL OPERATION The Qudos 28s and Qudos 28sP boilers feature a user display which shows actual flow temperature However the display can also be used to show other information about the operation of the boiler Press the W button repeatedly until the display shows SHP and then press the ENTER button you will enter the installer information mode Press the up arrow to the left of the display once to show the first reading flame current Press the up arrow again to move on to the next reading The table below shows the values associated with consecutive up arrow button press INSTALLER INFORMATION MODE SHP Info No Meaning 1 The flame current in micro amps detected from the burner should be 1 when off and 22 5 when burner on Low flame current readings suggest poor combustion and may lead to flame lockouts Check gas supply air supply and combustion setting 2 Actual CH flow temperature maximum 84C display indicates a radiator symbol and a 1 3 Actual CH return temperature maximum 72C display indicates a radiator symbol and a 2 NB Flow temperatures more than 20C above return tempera
30. two holes in the wall ceiling preferably using a core drill C 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 d Mount the boiler on the wall bracket and fix the air spigot packed loose with the boiler and with appropriate gasket to the boiler air inlet connection tightly to ensure there is no leakage Assemble using adhesive the pipework from the boiler connections to the exit from the first wall ceiling remount the boiler if removed 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 e Using the same methods drill any further holes always covering existing pipework cut and assemble the pipework f From outside complete the two terminations See Section 3 8 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 g 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 h Check all connections for security and re seal any joints using solvent cement where soundness may be in doubt It is equally important t
31. 00 100 K Vertically from terminal on same wall 1 500 1 500 L Horizontally from terminal on same wall 300 300 The dimensions given in the table above may need to be increased to avoid wall staining and nuisance depending on site conditions It is advisable for horizontal flue terminals to place a 45 elbow at the end of the flue to direct the condensate plume up and away from the property If the air intake is within 500mm of the flue outlet the air must not terminate at a level above that of the flue If either the air inlet or flue outlet terminate at a height of less than 2 1m above ground level the terminal must be protected by a suitable guard The K4 terminal guard with plastic coating manufactured by Tower Flue Components Ltd is suitable for this purpose 3 8 5 Clearances From Wall Flue outlet and air inlet terminations must be at least 40 mm from the wall face Installation amp Servicing Instructions Page 19 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers E 3 8 6 Distance Between Flue Outlet amp Air Inlet There is no maximum the terminations must not be on opposite sides of the dwelling but can be in areas of unequal pressure A minimum clearance of at least 200 mm must be left between the terminations 3 8 7 General Installations All parts of the system must be constructed in accordance with BS 5440 Part 1 except where specifically mentioned in these instruction
32. 10mm Extended clearance is required to the front for servicing 300mm Cleaning Normal case cleaning only requires dusting with a dry cloth To remove more stubborn marks wipe with a damp cloth and finish with a dry cloth BOILER SETUP amp OPERATION Check that the gas supply from the gas meter is turned on Switch on the electrical supply to the boiler The display will now run through a self check procedure Set any controls to call for heat To light the boiler The Qudos 28s features two temperature controls to allow different settings depending on the source of the demand i e heating or hot water Identify which setting is demanded Using the W on the left of the display select the setpoint you wish to adjust generally the one indicated by a radiator symbol with a 1 to the left Set the required temperature using the or buttons associated with the heating zones or hot water temperature After the selection of the desired temperatures press ENTER and then preset RESET to return to the normal display If the actual temperature is less than the desired temperature the boiler will fire and after a few seconds a flame will appear on the display to show that the boiler is alight NB Where the demand is via 0 10VDC or Opentherm the boiler setpoint is set using the external controller in use Installation amp Servicing Instructions Page 1 WD420 3 2007
33. 2 26 00 0 Air Inlet Terminal 75mm C 17 2 26 00 0 Stand Off Back Plate Q 10S 0 01 00 0 Keston Chronotherm Room Controller C 17 4 21 00 0 DHW Tank Sensor Q 10S 0 04 00 0 Solar Sensors Kit Panel sensor and 2 x DHW Tank Sensors Q 10S 0 05 00 0 Installation amp Servicing Instructions Page 8 WD420 3 2007 Chapter 2 General Instruction The Keston Qudos 28s amp Qudos 28sP Boilers i ma 2 6 PERFORMANCE DATA Qudos 28s amp Qudos 28sP Qudos 28s Qudos 28sP Nat Gas G20 LPG G31 Min Input Gross CV kW Btu h 7 8 26 600 7 6 26 000 Max Input Gross CV kW Btu h 29 4 100 300 28 8 98 300 Max Output To Water 80 60 Flow Return kW Btu h 26 4 90 500 26 4 90 500 50 30 Flow Return kW Btu h 28 4 96 900 28 4 96 900 Min Output To Water 80 60 Flow Return kW Btu h 7 0 24 900 7 0 24 900 50 30 Flow Return kW Btu h 7 8 26 600 7 6 26 000 Max Burner Press Hot Factory Preset mbar in w g 0 0 0 0 Max Gas Cons After 10 mins DHW _ I s Ft hr 0 76 96 6 0 35 45 0 Max Operating Flow Temp C 82 82 Max Press Sealed System bar 2 2 Inlet Gas Pressure mbar in w g 20 0 8 0 37 0 14 8 Recommended Temp Diff C 8 to 20 8 to 20 Electrical Supply 230V 50Hz 230V 50Hz Power Consumption Max W 150 150 Power Consumption Standby W 7 7 Type of Gas G20 Natural Gas 931 LPG Optimum Flue Gas CO Level at max CH rate case on 9 1 0 2 10 5 0 2 Expected CO CO2 Ratio
34. 8s amp Qudos 28sP Boilers 183 Q28s Gas Valve Mixer Assem 119 Fan Q28sP Gas Valve Mixer Assem 132 Control Panel 131 Q28s Control PCB Q28sP Con PCB 60 Pump 98 Expansion Vessel Installation amp Servicing Instructions Page 52 WD420 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28s amp Qudos 28sP Boilers SSS SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination 52 Burner Kit 81 Burner Gasket 53 Ignitor Kit 72 Ignitor Gasket 58 Flow Return Thermistor 59 Flue Thermistor 57 Flow Thermostat 101 Pressure Sensor 111 Fan 183 Gas Valve Mixer Air Gas Assembly NG Q28s 183 Gas Valve Mixer Air Gas Assembly LPG Q28sP 132 Control Panel 131 Control PCB NG Q28s 131 Control PCB LPG Q28sP 60 Pump 98 Expansion Vessel Installation amp Servicing Instructions Page 53 WD420 3 2007 Chapter 10 Benchmark Checklist Final The Keston Qudos 28s amp Qudos 28sP Boilers 10 GAS BOILER COMMISSIONING CHECKLIST BENCHMARK benchmar J GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No NOTIFICATION No CONTROLS To comply with the Building Regulation each section must have a tick in one or other of the boxes Dos a CONTROL TO R ne o PROGRAMMABLE ROOMSTAT 7 TIME amp TEMPERATURE CONTROL TO HOT CYLINDER T STAT amp WATER PROGRAMMER TIMER H COMBI BOILER L HEATING
35. ATE CAS function which will run the pump without Installation amp Servicing Instructions Page 6 WD420 3 2007 Chapter 2 General Instruction The Keston Qudos 28s amp Qudos 28sP Boilers ee 2 3 firing the boiler for 10 seconds in the event the boiler is on standby for in excess of 24 hours without firing This is to help prevent seizing of the pump due to long periods of inactivity RELATED DOCUMENTS The Keston Qudos 28s and Qudos 28sP Condensing Boilers must be installed in accordance with the current issue of the Gas Safety Installation and Use Regulations 1996 current IEE Wiring Regulations Building Regulations Building Standards Scotland Consolidation and the Bye Laws of the local Water Undertaking t is the law that ALL gas appliances are installed by a competent person in accordance with the above regulations In addition due account must be taken to the following Codes Of Practice BS 6891 Low Pressure Installation Pipes BS 6798 Installation of Gas Fired Hot Water Boilers of Rated Input Not Exceeding 70kW BS 5449 2 Installation Pumped Central Heating BS 5546 Installation of Gas Hot Water Supplies for Domestic Purposes 2nd family gases BS 5440 1 Flues for gas appliances of rated input exceeding 70kW BS 5440 2 Air Supply for gas appliances of rated input not exceeding 70kW BS 5482 1 Domestic Propane and Butane Burning Installations BS 7074 1 Expansion Vessel
36. DURE i Always replace in the reverse order unless otherwise stated ii Electrical connections must be remade in accordance with the Electrical Wiring Diagram Section 6 5 iii Test the tightness of any gas carrying or water carrying joint broken during the service procedures ELECTRICAL COMPONENTS 8 4 1 Control Panel Fig 6 7 1 item 132 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the user control cover by removing the four retaining screws Fig 6 7 1 item 143 and item 144 iv Disconnect the Control Panel by unplugging the cable connector Installation amp Servicing Instructions Page 46 WD420 3 2007 odas 8 Replacement Of Parts The Keston Qudos 28s amp Qudos 28sP 8 4 2 8 4 3 8 4 4 8 4 5 8 4 6 v Remove the Control Panel by removing the four retaining screws Fig 6 7 1 item 160 vi Reassemble Section 8 3 vii Check for correct operation of the Control Panel Boiler Flow and Return Thermistors Fig 6 7 2 1 2 amp 2 2 item 58 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the push on connectors from the thermistor taking note of the correct positions iv Unclip the thermistor from the pipe v Reassemble Section 8 3 NB When fitting the new thermistor it is an advantage to smear a thin film of heat sink compound between the thermistor and pipe This combined with fitting the new thermistor tightly to th
37. ING DIAGRAM Installation amp Servicing Instructions Page 37 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers SSS SSS SSS JENNI 6 7 Exploded Assembly Diagrams 6 7 1 Boiler Controls Assembly Installation amp Servicing Instructions Page 38 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 7 2 Waterway Condensate amp Flue Assembly TEST FIM
38. NING THIS APPLIANCE MUST BE EARTHED 2 All external controls and wiring must be suitable for mains voltage Supply wiring should be in PVC insulated cable not less than 0 75mm 8 0mm dia to BS 6500 Table 16 material code HO5VV F 3 The permanent live supply connection may be via a 3 amp fused double pole switch serving only the boiler Refer to Chapter 3 Section 3 4 Electrical Supply Any 230VAC system controls for the boiler must also be supplied via this isolator 4 Basic Wiring Installation Securely tighten the terminal screws and route the cable s through the re openable cable clips Ensure all cables are secured and that the cord grip bush is tightened to securely grip the main cable at entry to the cabinet Remove the factory fitted link wire between the room thermostat terminals on the boiler The supply cable s must be connected to the main terminals as follows Main Supply L Brown wire Live 3A permanent supply Main Supply N Blue wire Neutral for 3A permanent Main Supply E Yellow Green Wire Earth CH Demand SL1 230V Switched Live i e Room Thermostat Ensure connection is made such that if the cable slips in its anchorage the current carrying conductors become taut before the earthing conductor 5 Advanced Features Wiring The Qudos 28s features comprehensive and advance functionality as standard Whilst these advances functions are not mandatory they will provide enhanced boiler operation perform
39. OSITION AND THE AIRING HOSE IS CONNECTED ON THE TOP 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 the boiler on an existing system a new flue and air intake system MUST also be installed You must NOT re use existing flue or air pipework components NB When installing the boiler consider Flue Spigot Assembly The flue spigot 50mm muPVC is inside the accessory bag Installation amp Servicing Instructions Page 21 WD420 3 2007 Note Chapter 4 Installation The Keston Qudos 28s amp Qudos 28sP Boilers Put the flue spigot assembled with the test plug on the cabinet frame and secure it by fastening the two M6 screws Couple the spigot to the internal flue pipe using the flexible couple and fastening clips Ensure the clips are properly secured and no leakage can occur Remember the flue pipe must slope downwards back towards the boiler and this is best achieved using 92 5 bends a Using the template supplied within the boiler packaging mark the positions of the two holes for the flue and air pipes on the wall s or ceiling b Drill the
40. P Boilers 3 5 BOILER SIZE SELECTION The Qudos 28s will automatically adjust heat output and pump speed to match the system requirements at any given time Efficiency and combustion levels are maintained at optimum levels throughout the possible output range The Qudos 28s is therefore suitable for all systems with a total heat load within the maximum range of the boiler 3 6 GAS SUPPLY A gas meter should be connected to the service pipe by the local gas region or their contractor An existing meter should be checked preferably by the gas region to ensure that the meter is adequate to deal with the rate of gas supply required Installation pipes should be fitted in accordance with BS 6891 Minimum Maximum Gas Pressure Natural gas pressure before the gas valve must be maintained at between 18 mbar 7 2 in WG and 22 mbar 8 8 in while the boiler is running LPG pressure must be maintained between 31 5 mbar 12 4 in w g and 37 6 mbar 14 8 in w g while the boiler is running Gas pressures above or below these levels will lead to problems associated with the gas valve s internal pressure regulator Supply pipes to the boiler must not be sized less than the boiler inlet connection 15 mm Due consideration must be given to the supply pressure to other gas appliances in the premises Reduction in dynamic gas supply pressure will result in intermittent ignition failures Ensure gas supply pipe work is adequately sized for the length of run from the met
41. RUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDE A CO CO RATIO READING N A O YES L C0 CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER Installation amp Servicing Instructions Page 54 WD420 3 2007 Chapter 10 Benchmark Checklist Final The Keston Qudos 28s amp Qudos 28sP Boilers SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 pate SERVICE 2 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No GAS SAFE REGISTER ID CARD SERIAL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE pate SERVICE 4 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No GAS SAFE REGISTER ID CARD SERIAL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNAT
42. URE SERVICE 5 pate SERVICE 6 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No GAS SAFE REGISTER ID CARD SERIAL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 pate SERVICE 8 pate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No GAS SAFE REGISTER ID CARD SERIAL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 pate SERVICE 10 bate ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No GAS SAFE REGISTER ID CARD SERIAL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE Installation amp Servicing Instructions 55 WD420 3 2007 The Keston Qudos 28s amp Qudos 28sP Boilers p i m KESTON CONDENSING BOILERS IMPORTANT Qudos 28s and Qudos 28sP INSTALLATION KEY POINTS 4 Read Installation Manual Carefully 4 Ensure that ALL dust particles filings plastic chips etc are removed from the inlet pipe Ifthe installation is a replacement the system must be flushed clean System should be drained hot then refilled then drained again until the water is clean 4 that th
43. ZONE VALVES FITTED L NOT REQUIRED HOT WATER ZONE VALVES FITTED L NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED L AUTOMATIC BYPASS TO SYSTEM FITTED L NOT REQUIRED LI FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE L mnr ft hr BURNER OPERATING PRESSURE IF APPLICABLE O N A mbar CENTRAL HEATING FLOW TEMPERATURE L c CENTRAL HEATING RETURN TEMPERATURE C ql FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES No D WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE L N A Imba COLD WATER INLET TEMPERATURE 1 HOT WATER OUTLET TEMPERATURE L IC WATER FLOW RATE Its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUIDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INST
44. a blocked air inlet Any breakage or damage to the burner mesh indicate the burner must be replaced Installation amp Servicing Instructions Page 44 WD420 3 2007 Chapter 7 Servicing The Keston Qudos 28s amp Qudos 28sP Boilers If necessary clean the burner with a mild household detergent and rinse under a hot running tap If necessary from visual inspection clean the heat exchanger using a suitable stiff plastic bristle brush vacuum out any large particles and flush the heat exchanger with fresh water until the water flowing from the condensate drain is clear Remove the condensate trap Section 8 8 and clean by flushing through with clean running water Check the electrode assembly mounted on the heat exchanger If the point is damaged or burnt replace it Check that the spark gap measures 4 mm Replace the burner head inspecting the gasket for damage and replacing if necessary and reconnect the gas air supply Ensure the flanged gas air supply joint is air tight Turn on the electrical supply to the boiler and allow the boiler to reach operating temperature levels Remove the combustion test point plug from the flue pipe This is situated on the flue spigot out of the cabinet Carry the full procedure detailed in section 5 7 COMBUSTION TESTING MANDATORY Replace the combustion test point plug Recheck the burner pressure by following the procedure detailed in Section 4 7 Check all joints for
45. all clearances required around the appliance refer to Section 3 1 Due consideration should therefore be given to access within the compartment for lifting and positioning Page iv WD420 3 2007 es 1 User Instructions The Keston Qudos 28s amp Qudos 28sP Boilers 1 1 1 2 1 3 1 USER INSTRUCTIONS INTRODUCTION Thank you for choosing this Keston Qudos 28s for your household heating The boiler is designed to be very straightforward to operate and has no user serviceable parts inside the cabinet The following instructions are to provide you with information on the operation and maintenance of your Qudos 28s and what to do in the unlikely event of a fault These user instructions should be read carefully to ensure safe and economical use of your Qudos 28s or Qudos 28sP The Qudos 28s model is for use with natural gas only the Qudos 28sP model is for use with LPG only MAINTENANCE Servicing To ensure continual safe and efficient operation and to maintain product warranties it is a requirement that the appliance is checked and serviced at least once per year It is the law that any servicing must be carried out by a competent person Removal of the appliance cabinet by anyone other than a competent person will automatically invalidate the appliance warranty Clearances If fixtures are to be positioned close to the boiler the following minimum clearances must be observed Top 150mm Left 5mm Right 5mm Base 200mm Front
46. ance and efficiency Detailed below are suggested wiring methods to activate various functions Installation amp Servicing Instructions Page 23 WD420 3 2007 Chapter 4 Installation The Keston Qudos 28s amp Qudos 28sP Boilers 5 1 Twin Thermostat Operation with Weather Compensation SEPARATE CH amp DHW DEMAND WITH OPTIONAL WEATHER COMPENSATION Er gt 11 t z ag 212 I N lt E Sw E sf si lt _ ORANGE d Grey E e n Q28S hr a BLUE BROWN FROM CH BOILER z255 CONTROLS D J 5 2 CH ZONE az VALVE 2 5 s orane 7 h GREY lt Bla BLUE BROWN FROM DHW J 88 ALES GO C 10C 0 09 00 0 8g LOW VOLTAGE CONNECTOR Be SENSOR SENSOR swch THERM DEMAND SENSOR HL 1 2 1 21 2 211 E 0v 1 2 E w i 5 2 Modulation of DHW generation SEPARATE CH amp DHW DEMAND WITH OPTIONAL DHW SENSOR CONTROL gt L o 22 T N z lt ul PS E gt 5 ORANGE GREY Q28S JBE BOILER z 53 conors 5 o
47. ance to Earth Short Circuit using a suitable test meter LP GAS The Keston Qudos 28s and Qudos 28sP are supplied preset for the gas designated on the boiler packing LPG installations must use Qudos 28sP model only INITIAL FIRING Important Checking the gas pressure to the pre mix burner requires a special procedure outlined below which must be carried out a Purge the gas supply in accordance with BS 6891 b Vent the water system Important The heat exchanger consists of corrugated tubes which can trap an air pocket Great care must be taken to ensure that water flow has been established through the heat exchanger and thus ensuring no air pockets remain in the heat exchanger and pipe work Firing the boiler while an air pocket exists in the heat exchanger could damage it Turn the gas service cock to ON Turn on the electrical supply setting any external controls to call for heat The radiator symbol should illuminate in the top left of the display along with a 1 to the left of the radiator symbol or a 2 to the right e Select the CH temperature using the W of the control panel set the CH temperature to 80C Press the ENTER button to store this setting and press the Installation amp Servicing Instructions Page 27 WD420 3 2007 Chapter 5 Commissioning The Keston Qudos 28s amp Qudos 28sP Boilers 5 6 5 7 RESET button so that the display reverts to show th
48. ary irritation to eyes skin and respiratory tract The fibres are held in place by inorganic binders Therefore as long as the boards are not Installation amp Servicing Instructions Page 9 WD42 2007 hapter 2 neral Instruction _ The Keston 2 28sP Boiler disturbed they will not be released Since the boards are non serviceable parts there should be no risk Under no circumstances should the user interfere with any sealed parts To ensure that the release of fibres from these RCF articles is kept to a minimum during installation and servicing we recommend that you use a HEPA filtered vacuum to remove any dust accumulated in and around the appliance before and after working on the appli ance When replacing these articles we recommend that the replaced items are not broken up but are sealed within heavy duty polythene bags and clearly labelled as RCF waste RCF waste is classed as a stable non reactive hazardous waste and may be disposed at a landfill licensed to accept such waste Protective clothing is not required when handling these articles but we recommend you follow the normal hygiene rules of not smoking eating or drinking in the work area and always wash your hands before eating or drinking p a benchmark gt Benchmark Initiative As part of the industry wide Benchmark initiative Qudos 28S boiler manual includes Gas Boiler Commissioning Checklist Chapter 10 This form should be completed by your installer
49. at max CH rate case on 0 0007 0 001 Destination Countries GB IE GB IE SEDBUK Efficiency 91 0 93 0 NOx Class 5 5 Safety Valve bar Ibf sq in 3 43 5 3 43 5 Expansion Vessel Capacity litre 8 8 SEDBUK Rating A 91 1 A 92 996 NB For larger systems an additional expansion vessel may be required Expansion Vessel Charge Pressure bar Ibf sq in 1 0 14 5 Heating System Minimum Pressure bar Ibf sq in 0 6 8 7 Seasonal Efficiency SEDBUK 91 1 Qudos 28s amp 92 9 Qudos 28sP This value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by Advantica Technologies Ltd KESTON Heating declare that there are no substances harmful to health within the appliance or used during the production of the appliance The Qudos 28s is intended for domestic and commercial EMC environments and on a governed G20 meter supply The Qudos 28sP is intended for domestic and commercial EMC environments and on a governed G31 supply This boiler meets the requirements of SI 3083 The Boiler Efficiency Regulations and is therefore deemed to meet the requirements of Directive 92 42 EEC The CE mark on the appliance shows compliance with Directives 90 396 EEC 73 23 EEC and 89 336 EEC IMPORTANT This product contains ceramic fibre boards which although not regarded as a risk contain ceramic fibre which may cause tempor
50. been fired for more than one hour since installation the CO levels should not exceed 150 ppm at high rate and DO NOT ADJUST THIS SCREW UNDER ANY 4 3 CIRCUMSTANCES 50 ppm at low rate If CO levels above these values are experienced the combustion chamber and flue system should be investigated The Qudos 28s is factory set for combustion and should need no adjustment However in the event adjustment is required Check combustion errors are not a result of incorrectly installed flue and or air system terminal location or damage or debris on the burner If all these factors are found to be in order precede as follows 1 2 Set any controls to call for heat Press the W button repeatedly until the display shows SEr then press ENTER Press the W until the display shows 100 Press ENTER and the boiler will be locked on at Maximum rate If no further buttons are pressed for 10 minutes the boiler will automatically revert to normal operation Measure the CO reading in the flue gases and adjust if necessary the adjustment screw pos 4 to produce a CO reading of 8 9 to 9 3 with a corresponding CO level of 50 to 150 ppm for natural gas and 10 3 to 10 7 witha corresponding CO level of 50 to 150 ppm for LPG NORMAL ADJUSTMENT IF REQUIRED SHOULD NEED NO MORE THAN HALF OF ONE ROTATION OF THE ADJUSTMENT SCREW pos 4 ADJUSTMENTS IF MADE SHOULD BE IN STEPS OF NO MORE THAN 1 8 OF A TURN YOU MUST WAIT
51. blockage or obstruction is present in the condensate drainage line In addition the air intake and flue exhaust terminals must be free from obstruction at all times Care should be taken not to damage the condensate trap protruding from the base of the boiler Any sign of leakage of this part should be reported to a GAS SAFE REGISTER registered engineer immediately If the part becomes broken the boiler should be turned off and a GAS SAFE REGISTER registered engineer contacted to make a repair Any indication of leakage from the boiler cabinet should be investigates by a GAS SAFE REGISTER engineer Frost Protection The Qudos 28s has an integral frost protection function However care should also be taken that any exposed pipework is adequately insulated to prevent freezing Installation amp Servicing Instructions Page 2 WD420 3 2007 Se 1 User Instructions The Keston Qudos 28s amp Qudos 28sP Boilers 1 4 SAFETY INFORMATION IF YOU SUSPECT A GAS LEAK TURN OFF THE APPLIANCE IMMEDIATELY TURN OFF THE GAS TAP TO THE APPLIANCE LOCATED UNDERNEATH AND CONTACT YOUR GAS SUPPLIER WITHOUT DELAY Benchmark Initiative e enchmark As part of the industry wide Benchmark initiative Qudos 28 boiler manual includes Gas Boiler Commissioning Checklist Chapter 10 This form should be completed by your installer at the end of the installation and commissioning process The details of the Checklist will be re
52. bove 75C may cause reduced boiler output Flue temperatures above 80C will cause boiler lockout 6 System water pressure in bar Maximum 2 7 bar minimum 0 4 bar The boiler will shut down if the water pressure drops below 0 4 bar 7 Outside temperature display indicates a small graph on the bottom row NB Only relevant if an outside temperature sensor is detected 8 Position in sequence 0 Initialise 1 Standby 4 Purge 6 Safety 7 Run 8 Postpurge 9 Inter Purge 12 Lockout 9 Time in hours since last error occurred Installation amp Servicing Instructions Page 34 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 4 FUNCTIONAL FLOW WIRING DIAGRAM x o x a tX EL 2 A ES Z Aa Z N Ll m lt N A z o
53. connection point is available within the boiler to signal operation of the additional pump However this will need to drive the additional pump via a suitable relay KESTON Q28s Expansion Vessel if required RETURN Permanently Open 28mm HEATING CIRCUIT KA By pass AD VE lt gt FLOW Drain s Cock lt Additional System if required 3 7 4 Hot Water System if applicable The hot water storage vessel must be of the indirect type certain direct cylinders can be used provided they are suitably adapted by fitting an immersion calorifier DIRECT CYLINDERS MUST NOT BE USED Further guidance is provided in BS 1394 It is advisable to fit a locksheild valve on the cylinder return to enable balancing of the flow rate through the cylinder The Keston Spa range of stainless steel unvented cylinders are an ideal option for use with the Keston range The Keston qSpa range combine exceptional recovery times with durable long life stainless steel construction and all associated controls Contact KESTON Heating for information The Qudos 28s also has advance control options built in which enable modulated reheat of DHW and anti legionella function Refer to Chapter 4 for more detail 3 7 5 Filling The System The system should be filled using a G24 approved filling loop The system pressure should be set to between 1 0 and 2 0 bar To display the system water pre
54. cription Cabinet Cover Assy Q 10S 0 08 00 0 A Databadge NG Q 10S 1 00 04 0 Databadge LPG Q 10S 1 00 04 1 Combustion Test Plug B 04 2 00 49 1 Page 43 WD420 3 2007 Chapter 7 Servicing The Keston Qudos 28s amp Qudos 28sP Boilers 7 ROUTINE ANNUAL SERVICING To ensure the continued safe and efficient operation of the boiler it is necessary to carry out routine servicing at regular intervals Servicing must be carried out at least once per year The frequency of the servicing will depend upon the particular operating conditions It is the law that any service work must be carried out by competent qualified persons NB When servicing ensure that the gas and electrical supplies to the boiler are isolated before any work starts Hazardous materials are not used in the construction of the Qudos 28s and Qudos 28sP However due care should be taken when handling boiler components All joints should be checked for tightness after servicing and before firing the appliance After servicing complete the Gas Boiler Commissioning Checklist Service Interval Record Chapter 10 These forms Chapter 10 should be kept in a safe place for the life of the boiler PLEASE NOTE During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the flue systems and flue joints as described in Section 4 4 The integrity of the boiler combustion circ
55. cy stainless steel heat exchanger coupled with a low emissions burner to deliver ultra high efficiency condensing mode operation within a compact wall hung cabinet The unit automatically adjusts gas and air rate according to demand to give a heating input in the range of 7 8kW to 29 4kW GCV The integral pump assembly in the Qudos 28s is automatically speed controlled to best match water flow rate to heat output amp further increase appliance efficiency The Qudos 28s has been developed to embrace the concept of advanced controls to ensure the ultra high performance burner and heat exchanger system is run to optimum performance levels whilst provided or exceeding the comfort levels demanded As a result the boilers feature a host of additional connections for an optional outside sensor to enable the boilers inbuilt weather compensation option which delivers enhanced user comfort levels with peak operating efficiency due to the lower flow temperatures involved an optional Opentherm connection point for the Keston Room Control module which provides further advanced user control for room temperature compensation and optimum start optional 0 10VDC input where temperature control is provided by external 3rd party intelligent controls optional connection of a DHW thermistor to enable modulated reheat of DHW and optional legionella prevention function Further the Qudos 28s is developed with the concept that the gas boiler in the
56. e symbol on the top row the display stops flashing and becomes constantly illuminated The boiler is now in its normal run condition 5 The boiler will automatically and continuously adjust its power output and pump speed to best match the demands of the system at any time 6 The burner will continue to operate until the gas valve interrupts the gas supply The gas valve will be closed by the control PCB if power is interrupted to the boiler by any external control or the boiler exceeds the requested temperature If an interruption to the gas supply causes loss of the flame the control box will pause for approximately 10 seconds and then attempt to re ignite the unit If this attempt fails i e due to continued lack of gas supply the boiler will make four further attempts to ignite at intervals of approximately 10 seconds and will then go to a lockout state the display shows E02 Once the gas supply has been resumed the boiler can be reset by pressing the Reset button 7 The boiler can also be shut down by the cabinet temperature sensor water pressure sensor or flue overheat sensor Any failure of the boiler to sequence in the above manner should be investigated using the following trouble shooting table Before attempting any electrical fault finding always carry out preliminary electrical system checks On completion of any service fault finding task which has required the breaking and remaking of electrical connections
57. e actual flow temperature of the boiler Once a heating demand is received the fan will start and the boiler will enter the pre purge phase During this phase the boiler pump will also start to run The pump and fan symbols should illuminate on the top line of the indicating they are both running After 5 seconds the boiler will start to spark indicated by a flashing flame symbol on the top row of the display and will energise the gas valve When ignition is achieved the flame symbol on the top row will stop flashing and remain steady If an air lock or other blockage is present the unit may go to overheat or water pressure lockout This will be indicated by the display flashing error code E12 or E67 If this occurs clear the blockage and or purge the air from the system and press the Reset button to restart the ignition sequence If ignition does not occur the boiler at approximately 20 second intervals will make four further attempts to light the burner If after five automatic attempts the boiler still fails to ignite the display will show the code E 02 indicating no ignition If after five manual attempts to allow for purging of any air in the gas line the boiler still fails to ignite refer to Section 6 3 Fault Modes f Check for gas tightness between the gas service cock and connection to the burner manifold g Check for soundness of the connection between the heat exchanger base and the conde
58. e pipe ensures a good contact Cabinet Temperature Sensor Fig 6 7 1 item 151 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the cabinet temperature sensor from the connector block by slackening the retaining screws iv Reassemble Section 8 3 Flue Thermistor Fig 6 7 2 1 2 item 59 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the push on connectors from the thermistor taking note of the correct positions iv Unscrew the retaining nuts and remove the thermistor v Reassemble Section 8 3 NB When fitting the new thermistor it is an advantage to smear a thin film of heat sink compound between the thermistor and plate This combined with fitting the new thermistor tightly to the plate ensures a good contact Pressure Sensor Fig 6 7 2 2 2 item 101 i Isolate the appliance Section 8 1 ii Shut off the water supply to the appliance iii Gain access Section 8 2 iv Drain the system to below the level of the appliance v Remove the push on connector from the pressure sensor vi Unscrew the pressure sensor vii Reassemble Section 8 3 NB Use a little jointing compound or PTFE tape on the thread viii Refill the system See Section 5 Commissioning NB When reassembling inspect the o ring Fig 6 7 2 2 2 item 100 for damage and replace if necessary Main Control PCB Fig 6 7 1 item 131 i Isolate the appliance
59. easing the boiler efficiency further by releasing the latent heat of condensation This condensate falls to the Installation amp Servicing Instructions Page 5 WD42 2007 hapter 2 neral Instruction The Keston 2 28sP Boiler bottom of the heat exchanger where it is separated from the flue gases and exits from the boiler through the condensate drain Any condensate formed in the flue runs back down the flueway and is drained at the base of the flue connection to the heat exchanger or drain points within the flue The condensate is very slightly acidic about the same acidity as vinegar and should be piped in a plastic pipe It is not harmful to the waste disposal system and may be disposed of as normal waste water The flue gases are piped a 50 mm muPVC BS5255 and or and BSEN1329 plastic or alternatively 75mm Keston composite plastic pipe to outside The temperature of the flue gases are uSually around 5 C to 10 C above the temperature of the return water The flue pipe should be terminated outside the building from where they cannot re enter the building or any other adjacent building It should also be terminated such that flue products cannot be drawn into the boiler air intake terminal The heating level may be controlled by room thermostats programmer time clocks and compatible energy management systems An optional Keston room controller can be connected which will provide enhanced controls such as room compensatio
60. er is heated the air is driven out of the solution and will collect in high spots in the system These air bubbles can interfere with pumping and heat transfer and must be eliminated 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 re venting in a day or so after all air has been driven out of solution 3 7 3 System Pump Selection if required The Qudos 28s features an integral circulating pump which has sufficient excess head to drive most domestic systems The available head is shown in the graph below If the system index circuit resistance is in excess of the available head from the integral pump an additional system pump will be required Q28s Available pump head Pump Head m The schematic below illustrates recommended approach to using an 1 additional system pump The additional system pump should be sized to overcome 5 10 5 20 si the index circuit resistance Flow Rate Ipm only as the boilers integral pump will overcome boiler resistance Installation amp Servicing Instructions Page 16 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers 3 8 If an additional pump is required the selected pump must comply with BS 1394 Provision must be made in the system design for control of the additional pump A
61. er made five unsuccessful attempts to ignite Check gas supply ignitor condition and spark gap Check flue and air system and condensate drainage for obstruction Check gas valve setting and operation E03 Spark gap too small OR Gas valve faulty check connections to gas valve and operation of gas valve solenoids E04 Flame lost 5 times in a single demand period check combustion setting high and low and ignitor condition E12 Flow overheat check water circulation is not blocked check pump operation and flow thermistor condition E20 Fan unable to reach ignition rate check fan and impeller restriction E24 Return exceed flow temperature by 10C check direction of water circulation and operation of flow and return thermistors E25 Flow temperature increased too quickly check water circulation and pump operation E26 Water pressure sensor is open circuit disconnected E28 Fan fault check connector to fan operation of fan E31 Flow thermistor closed circuit check the connections and wires to the flow thermistor are intact not short circuited E32 Return thermistor closed circuit check the connections and wires to the return thermistor are intact not short circuited E33 DHW thermistor closed circuit check the connections and wires to the DHW thermistor are intact not short circuited if present E35 Flue thermistor closed circuit check the connections and wires to the flue thermistor are intact not short circuited E36 Flow thermisto
62. er to the boiler at a supply rate of 28 4kW i e a natural gas supply should be considered to be a minimum of 22mm diameter reducing to 15mm at the boiler If gas runs greater than 12m including the allowance for bends are involved the pipe size should be increased further 3 7 WATER SYSTEMS All piping must be installed in accordance with all applicable local and Water Supply Bylaws for forced hot water heating systems Consideration must be given to pipe capabilities and pressure drop through the piping when selecting pipe sizes The primary pipe connections to the boiler must be sized according to the system load not dictated by the boiler connection sizes Water treatment must be carried out to BS 7593 Treatment of Water in Hot Water Central Heating Systems In IE the requirements given in the current edition of 15813 and the current Building Regulations must be followed a The Keston Qudos 28s is designed for installation on sealed water systems only With fully pumped water circulation The pump an 8l expansion vessel and associated safety devices are fitted within the boiler b Any system must be thoroughly flushed clean of grease dirt and debris prior to connection with the boiler A trap may be installed in the flow line to collect any solder or other debris from the installation C All water systems must be constructed to comply with requirements of the Local Water Authority d Always use a system complying with the re
63. ere is a proper electrical supply i e 230V fused at 3A for the permanent live E Take great care with pipe connections to ensure that no damage is done to the internal pipework 4 Ensure that the 22mm condensate pipe is not exposed to freezing conditions g sure that the exhaust pipe terminates away from windows or vents and is out of reach g sure that the air inlet and exhaust pipe outlets are at least 200mm apart Check tightness of all connections in the boiler before firing 4 Ensure that the terminals supplied are fitted to both the exhaust and air inlet pipes 7 The system must be free from air before firing f TRV s are installed on radiators ensure that a bypass is installed to maintain required flow Complete the Gas Boiler Commissioning Checklist Service Interval Record Chapter 10 Z Complete the combustion testing Section 5 7 using a calibrated flue gas analyser
64. es 5 4 75 litres 8 2 100 litres 10 9 125 litres 13 6 k The boiler is supplied with an integral expansion vessel of 8l capacity This is suitable for systems of up to 125 litres system volume Table 3 7 Expansion Vessel Selection provides guidance for the correct additional expansion vessel size to use for systems with a water content larger than 125 litres Any additional Air Vent Hose Union KESTON X bib tap Qudos 28s Additional Expansion E Vessel X US if required T a lt q RETURN By pass gt HEATING CIRCUIT pa m FLOW disconnected Drain after filling a KK gt lt 4 lt Dbl Check Valve BS 1010 2 N lt X Stop Tap Hose Test Connector Cock Figure 3 7 Sealed Systems Diagram vessel must be fitted on the boiler primary return l A filling point must be fitted requirements in accordance with local water authority Installation amp Servicing Instructions Page 15 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers E m The installation must be designed to work with flow temperatures of up to 110 C All components of the system must be suitable for a working pressure of 3 bar and a temperature of 110 C Care should be taken in making all connections that the risk of leakage is minimised n The pipe from the safety discharge valve must not discharge above an entrance window or any type of public access area The boiler
65. eston Room Controller Screened cable 80 density must be used to connect the outside temperature sensor Solar Control Where a solar thermal system is in use with a twin coil cylinder such as the Keston qSpa Twin the Qudos 28s will control operation of the solar pump in conjunction with the boiler The boiler requires connection to the solar tank sensor solar panel sensor and solar pump Modulating DHW Reheat The Qudos 28s can provide direct modulation to maximise the re heat performance of the DHW cylinder A DHW cylinder sensor can be connected directly to the Qudos 28 A DHW demand input can also be provided to control DHW reheat activity perhaps in conjunction with Solar Thermal With this facility connected an automatic anti legionnella facility can also be provided Analog Demand 0 10VDC Where external control panels are used in boiler room applications a 0 10VDC input can be connected to the boiler in place of the SL1 switched live demand The 0 10VDC signal will drive the first setpoint at 1VDC 10C setpoint NB 0 5VDC is off gt 8 0 VDC is 80C External Lockout Signal Where remote monitoring and or alarms are installed the boiler offers a volt free lockout signal output The boiler will provide a closed circuit across the two output points when the boiler is in lockout Installation amp Servicing Instructions Page 13 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28s
66. f the pump head taking note of the correct position vii Remove the four allen bolts securing the pump head to the hydroblock back body viii Remove the pump head ix Reassemble Section 8 3 EXPANSION VESSEL Fig 6 7 2 2 2 item 98 i Isolate the appliance Section 8 1 ii Gain Access section 8 2 iii Isolate the waterways to the pump using the system isolation valves Installation amp Servicing Instructions Page 49 WD420 3 2007 8 Replacement Of Parts The Keston Qudos 285 amp Qudos 28sP iv Drain the system to below the level of the appliance v Disconnect the flexible hose Fig 6 7 2 2 2 item 95 from the expansion vessel vi Undo the pin Fig 6 7 4 item 37 and the EV bracket Fig 6 7 4 item 39 from the cabinet frame vii Remove the expansion vessel viii Reassemble Section 8 3 NB When reassembling inspect the gasket for damage and replace if necessary Installation amp Servicing Instructions Page 50 WD420 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28s amp Qudos 28sP Boilers ee 9 SHORT SPARE PARTS LIST Item No Part Denomination Item GC No Part Denomination 52 Burner Kit 81 Burner Gasket 72 Ignitor Gasket 53 Ignitor Kit 58 Flow Return Thermistors 59 Flue Thermistor 57 Flow Overheat Thermostat 101 Pressure Sensor Installation amp Servicing Instructions Page 51 WD420 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 2
67. ig 6 7 2 2 2 item 85 from the heat exchanger xi Remove the two screws Fig 6 7 2 1 2 item 83 fixing the heat exchanger to the top xii Remove the heat exchanger xiii Reassemble Section 8 3 xiv Recommission Section 5 Commissioning CONDENSATE TRAP Fig 6 7 2 2 2 item 62 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 Remove the two screws and washers Fig 6 7 2 2 2 item 103 and 104 fixing the condensate trap to the base of the cabinet iii Disconnect the condense line from the projection of the condensate trap from the base of the cabinet iv Disconnect the airing hose from the small spigot on the top of the trap v Withdraw the condensate trap vi Mop up any spilled condensate vii Reassemble Section 8 3 NB When reassembling inspect the o ring Fig 6 7 2 2 2 item 69 for damage and replace if necessary When re fitting the condensate trap pour water until nearly full Then reconnect the condensate trap to the base of the heat exchanger and with the airing hose PUMP Fig 6 7 2 2 2 item 60 i Isolate the appliance Section 8 1 ii Gain Access section 8 2 iii Isolate the waterways to the boiler using the system isolation valves iv Drain the system to below the level of the appliance v Undo the screw Fig 6 7 1 item 144 to the panel support Fig 6 7 4 item 4 and rotate it on the right vi Disconnect the pump electrical cable from the connections box o
68. ll depend upon particular site conditions but in general it will be easiest and most accurate to install the boiler and then build up the flue outlet and air inlet pipes to the terminal this is the sequence described 4 1 a 4 2 4 3 4 4 WALL MOUNTING BRACKET All dimensions mm Place the bracket on the wall horizontally with the 156 pre drilled holes at the bottom and position as dictated by the template supplied within the boiler packaging Drill through the centre hole of the bracket plug the hole and fix in position Using a spirit level make sure the bracket is completely level and mark the position of the other screw holes Remove the bracket and drill the holes in the positions marked Plug these holes Screw the bracket to the wall using Screws of an appropriate size for the wall Figure 4 1 Wall Mounting Fixing Locations type No 12 x 2 inch wood screws normally suffice MOUNTING THE BOILER after system cleaning and testing a Lift and locate the boiler onto the stud and the two locating pegs protruding from the wall bracket lift the boiler via the back frame only b Lower the boiler for hanging on the two pegs c Fix the boiler on the bracket stud using the nut and the washers supplied d Make the gas flow return condensate and PRV connections to the system Check all joints for tightness DO NOT FIRE THE BOILER UNTIL THE CONDENSATE TRAP IS SECURED IN P
69. n the diagram below Gas 15mm compression Flow Return 0 75 inch BSP male Gas 0 5 inch BSP male PRV 15mm copper pipe and Condensate 21 3mm plastic pipe An optional stand off frame part number Q 288 0 01 00 0 is also available which mounts behind the boiler to leave a 50mm deep space behind the boiler This is to permit pipe routing behind the boiler if required See Section 2 5 Optional Accessories 3 3 POSITION The Qudos 28s and Qudos 28sP are not suitable for external installation The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the All dimensions in mm 150 When servicing erating Figure 3 1 1 200 Minimum Clearances Figure 3 1 2 Dimensi Flue Exhaust Air Intake ons All dimensions bath or shower The Qudos 28S and Qudos 28SP are classified as IP20 IPXO and are therefore suitable for installation in Zone 3 areas unless subjec
70. n to further increase efficiency and comfort levels However this is only recommended for heating only applications Once the controls are set the boiler operates automatically Further a Keston outside sensor can be connected to the boiler which will automatically invoke weather compensated heating which further boosts user comfort and boiler efficiency In the event of the boiler overheating the safety devices will cause a safety shutdown A safety discharge valve and discharge pipe is fitted to the boiler The Qudos 28s aR VENT features an integral S alee frost protection function which will operate the pump regardless of the external controls should the boiler f temperature fall below uc E 10 C In the event the VEN THERMISTOR 4 boiler temperature N BURNER MENTOR falls below 5 C the boiler will also fire This is to avoid n damage to the boiler THERMISTOR through freezing of boiler water The boiler will turn off TT when the flow f temperature exceeds SAFEN 15 we UMP qi ENDE The Qudos 28s T features an integral gt A pump exercise RETURN DISCHARGE FLOW CONDENS
71. nsate trap HOT FLUSHING a Allow the system to heat up checking for water soundness b Follow instructions provided with the cleaning agent i e Fernox Supafloc or equivalent Turn off the boiler and flush the water system while still hot Thoroughly flush the system with clear water C Refill the system using a quality water treatment such as Fernox MB1 or Sentinel X100 For sealed systems fill to the required Initial Design Pressure COMBUSTION TESTING MANDATORY CHECK Competence to carry out the check of combustion performance PLEASE NOTE BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements and Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Although the gas pressure is preset at the factory it is required to assure proper combustion by measuring gas input and the level of carbon dioxide or oxygen and carbon monoxide in the flue outlet from the boiler Over firing
72. o seal the air inlet with solvent cement as the flue outlet pipe joints 4 5 CONDENSATE DRAINAGE NB When installing the boiler consider Condensate Trap Assembly The condensate trap is fitted loose inside the cabinet i Fit the condensate trap through the hole in the base of the boiler frame ii Remove the cap fitted to the condensate drain spigot at the base of the heat exchanger iii Securely connect the condensate trap inlet to the heat exchanger drain Spigot Be carefully to the correct position of sealing O ring iv Secure the trap to the boiler frame using the fixing bolts supplied v Connect the airing hose to the top of the condensate trap Connect the condensate drainage system to the boiler It is advisable to use a detachable fitting at connection to the boiler to enable easy removal for servicing Fill the condensate trap by pouring water into the boiler flue until water is seen to flow freely from the condensate drainage system Make the final connection of flue pipe to the boiler Details are provided in Chapter 3 Section 3 11 Condensate Drainage Connection 22mm plastic pipe Installation amp Servicing Instructions Page 22 WD420 3 2007 Chapter 4 Installation The Keston Qudos 28s amp Qudos 28sP Boilers 4 6 4 7 4 8 WATER SYSTEM Connect the flow and return HEATING CIRCUIT system pipework to the boiler Details of system requirements are given in Chapter 3 Section 3 7 Water S
73. of any warranty work e Advise on the frost protection and pump fan exercise feature f Advise the user that a plume of water vapour steam from the flue terminal is normal and that there is no need for concern Installation amp Servicing Instructions Page 30 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s amp Qudos 28sP Boilers 6 FAULT FINDING 6 1 ELECTRICAL CONTROL SEQUENCE When the external control s are calling for heat power will be fed to the boiler connection strip at terminal SL1 Switched Live and N Neutral and the radiator symbol with a 1 will appear in the top left of the display If the user control setting of the CH temperature is to a temperature above the actual boiler flow temperature and provided all safety sensors are confirmed as OK the control PCB will initiate the following sequence 1 The fan and pump will start indicated by a pump and a fan symbol on the top row of the display 2 When the fan reaches running speed the control PCB will start the ignition sequence 3 After a pre purge period of about 5 seconds the gas valve will open to allow gas to mix with the air at the suction side of the fan and the ignition spark will occur at the main burner indicated by a flashing flame symbol on the top row of the display 4 When the burner ignites the flame is detected by the control PCB through the combined flame sensor ignitor and the ignition spark is stopped The flam
74. quired in the event of any warranty work being required There is also Service Interval Record Chapter 10 to be completed after each annual service visit These forms Chapter 10 should be kept in a safe place for the life of the boiler The boiler should be installed and serviced only by GAS SAFE REGISTER registered operatives All GAS SAFE REGISTER registered Installers carry a GAS SAFE REGISTER ID card and have a registration number Both should be recorded in your boiler manual Chapter 10 GAS BOILER COMMISSIONING CHECKLIST You can check your installer by calling GAS SAFE REGISTER direct on 0800 408 5500 IMPORTANT This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the appliance Installation amp Servicing Instructions Page 3 WD42 2007 hapter 2 neral Instruction The Keston Qu 2 28sP Boiler 2 GENERAL INSTRUCTION 2 1 DESCRIPTION The KESTON Qudos 28s and Qudos 28sP boilers utilize the latest in condensing technology to produce a high efficiency boiler with SEDBUK A rated efficiency plus advance controls to maximize operational efficiency The Qudos 28s is unique in concept and design It comprises a high efficien
75. quirements of BS 5449 and BS 6798 e System design must ensure an open circuit is always available to ensure circulation when the pump overrun function is operating after boiler shutdown f Isolation valves must be fitted on the flow and the return to enable isolation when maintaining the boiler Installation amp Servicing Instructions Page 14 WD420 3 2007 d 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers g Copper tubing to BS 2871 Part 1 or barrier plastic pipe suitable to 110 C such as Unipipe is recommended h Jointing should be either with capillary threaded or compression fittings Pipes should have a gradient to ensure air is passed easily to vent points and water flows readily to drain points i Draining taps must be located in accessible positions which permit the draining of the boiler Draining taps should be at least 22 mm in nominal size and be in accordance with BS 2879 AIR VENT POINTS j These must be fitted at all high points where air will naturally collect and must be sited to allow complete draining of the system Table 3 7 Additional Expansion Vessel Selection Safety Valve Setting 3 0 bar Vessel charge amp initial system 1 0 bar pressure Total Water Content of system in Vessel excess of 125 litres Volume 25 litres 2 7 50 litr
76. r open circuit not connected check the connections and wires to the flow thermistor are intact and connected E37 Return thermistor open circuit not connected check the connections and wires to the return thermistor are intact and connected E38 DHW thermistor open circuit not connected check the connections and wires to the DHW thermistor are intact and connected if present E40 Flue thermistor open circuit not connected check the connections and wires to the flue thermistor are intact and connected SERVICE RESET REQUIRED E52 Flue overheat check combustion and heat exchanger Reset required on main PCB SERVICE RESET REQUIRED E62 Water pressure is gt 2 7 bar check operation of expansion vessel or filling loop is left open E67 Water pressure is lt 0 4bar E70 Cabinet overheat thermal fuse will need replacing Check hot gasket joints and combustion for cause of overheat Reset required on main PCB SERVICE RESET REQUIRED E73 Code plug error check loom and connections to main pcb E74 Supply voltage lt 190V check mains supply condition E75 Supply voltage gt 270V check mains supply condition E76 Solar panel sensor closed circuit if present E77 Solar panel sensor open circuit if present E95 Solar tank sensor closed circuit if present E96 Solar tank sensor open circuit if present Installation amp Servicing Instructions Page 33 WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s
77. rewing the union fitting from the gas valve viii Reassemble Section 8 3 ix Check the gas rate and combustion See Section 5 Commissioning NB Always change the gas valve venturi assembly together This assembly is factory preset but must be checked using the procedure set out in Section 5 7 Combustion testing Flow Thermostat Fig 6 7 2 1 2 item 57 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the push on connector from the sensor taking note of the correct position iv Unscrew the bolts securing the stat Fig 6 7 2 1 2 item 77 v Reassemble Section 8 3 NB When fitting the new thermostat it is an advantage to smear a thin film of heat sink compound between the thermistor and pipe This combined with fitting the new thermistor tightly to the pipe ensures a good contact SPARK IGNITION FLAME DETECTION ELECTRODE Fig 6 7 2 1 2 item 53 i ii iii iv v Isolate the appliance Section 8 1 Gain access Section 8 2 Remove the pull off HT lead to the spark ignition electrode Undo the screws to the spark ignition electrode flange located on the heat exchanger top panel Fig 6 7 2 1 2 item 73 and withdraw the spark ignition electrode Reassemble Section 8 3 NB When reassembling inspect the gasket for damage and replace if necessary With the new spark ignition electrode in place it is essential to ensure the gap between the tip of the electrode and the
78. s All pipe work must be adequately supported All joints other than approved push on or plastic compression connectors must be made and sealed with solvent cement suitable for muPVC pipes and conforming to BS 6209 1982 Consideration must be given to Corgi 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 made good Rubber collars are available for flue and air terminals to finish the external wall face around the terminals Part No C 08 0 00 07 0 3 9 AIR SUPPLY The KESTON Qudos 28s and Qudos 28sP are room sealed appliances and therefore do not require purpose provided ventilation to the boiler room for combustion air 3 10 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 3 11 CONDENSATE DRAINAGE Being a condensing boiler the Qudos 28S and Qudos 28SP are fitted with a condensate trap at the base of the heat exchanger and flue assembly with facility to connect to a drain point underneath the appliance The condensate trap is packed loose with the appliance and MUST be fitted BEFORE firing the appliance Secure it to the boiler frame and connect the airing hose on the top Use only plastic piping and do not reduce belo
79. s BS 7593 Treatment of Water in Hot Water Central Heating Systems BS 7671 Requirements for Electrical Installations IEE Wiring Regulations 16th Edition BSEN 12828 2003 Heating Systems in Buildings Design for water based heating systems BSEN 12831 2003 Heating Systems in Buildings Method for calculation of design heat load BSEN 14336 2004 E Heating Systems in Buildings Installation and commissioning of water based heating systems For Timber Framed Buildings British Gas Publications DM2 Also British Gas Publications Guidance Notes For The Installation Of Domestic Gas Condensing Boilers and Specification For Domestic Wet Central Heating Systems In IE the installation must be carried out by a competent person and installed in accordance with the current edition of 15813 Domestic Gas Installations the current Building Regulation and reference should be made to the current ETC1 rules for electrical installations No alterations should be made to the boiler without written permission from KESTON Heating Any unauthorised modification will invalidate the warranty and may affect the safe and efficient operation of the boiler Installation amp Servicing Instructions Page 7 WD42 2007 hapter 2 neral Instruction _ The Keston 2 28sP Boiler 2 4 PHYSICAL DATA Qudos 28s amp Qudos 28sP Cabinet Height mm 700 Cabinet Width mm 435 Cabinet Depth mm 280 Top Clearance mm 150 Side Clearance mm 5 Base Clearance
80. safety discharge valve pipe must be extended using not less than 15mm pipe to discharge in a visible position outside the building facing downwards preferably over a drain The pipe must have a continuous fall and be routed to a position so that any discharge of water possibly boiling or steam cannot create any danger to persons damage to property or external electrical components or wiring To ease future servicing it is advisable to use a compression type fitting to extend the safety discharge valve pipe 3 7 1 Boiler By pass Piping Boiler water flows are critical to the operation of the boiler If flow cannot be maintained through the system piping to meet the minimums required by the boiler insufficient water flows through the boiler will cause the boiler to kettle or even produce steam which can damage the heat exchanger and will invalidate the heat exchanger warranty In addition an open circuit is required after boiler shutdown to permit circulation during the boilers 2 minute pump overrun sequence It is advisable to incorporate a boiler by pass in the system especially if thermostatic radiator valves are used The flow return differential should be 10 C to 20 C To comply with the Building Regulations Part L1 the bypass must of the automatic type 3 7 2 Air Elimination In the initial charge of water to the boiler system and in all subsequent additions of water to the system some air will be dissolved in the water As the wat
81. ssure press the q button repeatedly until the water pressure is displayed indicated by the word to the right of the pressure reading Fill the system and monitor the pressure displayed When the pressure is set press the RESET button until the normal display is resumed FLUE SYSTEM NB When installing a replacement boiler a new flue system must be used Do not re use the existing boiler flue installation 3 8 1 Design Individual air supply and flue outlet pipes are used The material used for the flue outlet and the air intake systems must be muPVC to BS 5255 In addition the flue outlet and air intake pipe work must be marked BSEN 1566 1 and the fittings must be marked BSEN 1329 Marley muPVC Solvent Weld Waste System 50 and Polypipe System 2000 muPVC Solvent Figure 3 3 1 Terminals Flue Outlet Air Inlet Terminals Weld Waste System 50mm are recommended DO NOT USE ABS PIPE OR FITTINGS Installation amp Servicing Instructions Page 17 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers Alternatively where flue or air intake lengths of up to 60m are require Keston Composite 75mm flue and air pipe can be used contact your KESTON Heating stockist for details Keston Composite 75mm pipe MUST be painted where exposed to UV light Both 50mm flue outlet terminal and 50mm air inlet terminal are supplied and are illustrated in Figure 3
82. t iron or steel boiler This boiler is of low mass and low water content and therefore responds faster when there is a call for heat The Qudos 28 features full user diagnostics integral frost protection function automatic pump and fan exercise in periods of inactivity anti cycle control and dry fire protection BOILER SCHEMATIC Air is drawn into the boiler through a 50 mm muPVC BS5255 and or BSEN1566 1 and BSEN1329 plastic pipe or alternatively via a 75mm Keston composite plastic pipe Gas is mixed with combustion air at the inlet to the fan The gas flow is automatically regulated by the gas valve according to the air flow generated by the fan The gas and air are thoroughly mixed in the blower and fed into the burner located at the top end of the heat exchanger module The gas and air mixture is ignited by a direct spark ignition control system and burns with a blue flame just off the surface of the burner As the hot products of combustion pass downwards they are cooled by exchanging heat with the circulating water which enters the heat exchanger at the bottom of the heat exchanger The optimum heat input is detected by monitoring flow and return temperatures and is adjusted by controlling the speed of the fan The optimum pump speed is also detected and automatically selected by the boiler When the return water temperature is below 55 C part of the water vapour in the combustion products will condense inside the heat exchanger thus incr
83. t to hose down TOP VIEW _ 284 Service Connection Locations JASE VIEW 405 1 M ERES All dimensions are in mtm Installation amp Servicing Instructions Page 11 WD420 3 2007 Chapter 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers EG Compartment installation is permitted such compartments must be constructed in accordance with BS 6798 The wall on which the boiler is mounted must be of suitable load bearing capacity and must be non combustible The Keston Qudos 28s can be located virtually anywhere desired provided that all regulations are complied with Because of the boiler s compact size and venting flexibility the installation is not limited to a boiler room setting Before locating the boiler near a living space consider whether the sounds generated by the boiler will be objectionable The boiler may be located within a cupboard enclosure to reduce noise levels if located within a living space LPG boilers must not be installed in a cellar Chimneys not used for venting any other appliance may be used Secure air flue pipes at chimney outlet NB Refer to Section 3 8 3 Figure 3 3 3 4 ELECTRICAL 3 4 1 Electrical Connections The boiler must be connected to a permanent 230V 50Hz supply fused at 3A
84. the cabinet shell by removing the two retaining screws in the top of the cabinet and the two retaining screws in the bottom of the cabinet RECOMMENDED HANDLING PROCEDURE NB The following lift operation exceeds the recommended weight for a one man lift as specified in the Manual Handling Operations 1992 Regulations For the carriage of carton it is recommended at least two people perform any lift Clear the carriage route of the carton from point of delivery to point of installation Take care to avoid trip hazards slippery or wet surfaces and when climbing steps and stairs Always use assistance if required If a sack truck is used it is recommended the carton is strapped to the truck For the unpacking of the appliance from the carton it is recommended at least two people perform any lift It is recommended to cut the base end of carton and open the carton flaps Ensure the protective packing over the boiler tappings at the base of the boiler is kept in place then tilt the boiler forwards from its back onto its base and remove carton by sliding up over the boiler When lifting this appliance the back should be kept straight at all times Avoid Page iii WD420 3 2007 The Keston Qudos 28s amp Qudos 28sP Boilers EAn OA EE twisting at the waist reposition the feet instead Avoid upper body bending when holding the appliance and keep the boiler as close to the body as possible Before hanging the appliance on the wall it is best to s
85. tightness up to the gas burner Complete the Gas Boiler Commissioning Checklist Service Interval Record Chapter 10 Installation amp Servicing Instructions Page 45 WD420 3 2007 duse 8 Replacement Of Parts The Keston Qudos 28s amp Qudos 28sP 8 0 8 1 8 2 8 3 8 4 8 REPLACEMENT OF PARTS CONTENTS 8 0 GENERAL 8 1 PRECAUTIONS 8 2 ACCESS 8 3 REPLACEMENT PROCEDURE 8 4 ELECTRICAL COMPONENTS 8 4 1 CONTROL PANEL 8 4 BOILER FLOW amp RETURN THERMISTORS 8 4 8 CABINET TEMPERATURE SENSOR 844 FLUE THERMISTOR 8 4 5 PRESSURE SENSOR 8 4 6 MAIN CONTROL PCB 8 4 7 COMBUSTION BLOWER 8 4 8 GAS CONTROL VALVE 8 4 9 FLOW THERMOSTAT 8 5 SPARK IGNITION FLAME DETECTION ELECTRODE 8 6 BURNER 8 7 HEAT EXCHANGER 8 8 CONDENSATE TRAP 8 9 PUMP 8 10 EXPANSION VESSEL GENERAL The following must always be carried out by a competent qualified person PRECAUTIONS i Always switch off the mains electricity supply and disconnect the plug at the isolating switch and socket If a switch only is used then remove the fuse ii Gain access to the appliance Section 8 2 and turn off the gas supply at the appliance service cock WARNING Parts of the boiler internal wiring will remain live even after setting the User Controls to Standby Shut off the power supply at the isolating switch before working on the appliance ACCESS i Remove the cabinet by removing the screws to the top and bottom of the cabinet REPLACEMENT PROCE
86. tore the appliance laid on its back with the casing on When ready to hang the boiler on the wall remove the casing and place to one side At this stage it is assumed that the wall bracket is correctly positioned and secured on the wall face a Have the wall bracket nut and washers to hand so that they can be accessed whilst holding the boiler in position on its mounting bracket b The boiler has a dry weight of 43 kg 95 Ibs and will therefore require at least two people to lift without the use of lifting aids ensure co ordinated movements during lift Always use assistance if required c Lift the boiler by gripping at the four corners of the boiler back plate When lifting this appliance the back should be kept straight at all times Avoid twisting at the waist reposition the feet instead Avoid upper body bending when holding the appliance and keep the boiler as close to the body as possible d Liftthe boiler and locate onto the stud and the two pegs of the wall mounting bracket e Place the wall mounting bracket washers over the bracket stud protruding through the back plate of the boiler Secure the boiler onto the wall bracket by fixing the wall mounting bracket nut onto the wall bracket stud This must be tightened well Safety footwear and gloves are recommended PPE when lifting this appliance to protect against sharp edges and ensure good grip The Qudos 28s and Qudos 28sP boilers can be fitted in compartments with very sm
87. ture may lead to overheat and noise problems Check the pump performance and the system for blockages 4 Actual DHW temperature display indicates a tap symbol NB Only relevant if the DHW sensor option is connected 5 Actual Flue Temperature display indicates the flame and fan symbols NB Flue temperatures above 75C may cause reduced boiler output Flue temperatures above 80C will cause boiler lockout 6 System water pressure in bar Maximum 2 7 bar minimum 0 4 bar The boiler will shut down if the water pressure drops below 0 4 bar 7 Outside temperature display indicates a small graph on the bottom row NB Only relevant if an outside temperature sensor is detected 8 DHW flow rate not relevant for this model 9 Current fan speed rpm display indicates a fan symbol 10 Active setpoint the temperature that the boiler is attempting to reach and maintain as determined by the user setting and or the outside temperature sensor advanced controls 11 The current boiler configuration not used for general diagnostics 12 The hours that the boiler has been connected to a power supply since manufacture of the PCB P nn is thousands of hours plus nnn is single hours i e 1345 hours would display as P 01 and 234 13 The hours days that the burner has been operated since manufacture of the PCB B nn is thousands of hours plus nnn is single hours i e 1345 hours would display as B 01 and 234
88. type 5 1 5 2 5 3 5 4 5 5 INITIAL FLUSHING All waterways within the Keston Qudos 28s and Qudos 28sP are either copper or high alloy stainless steel As a result water treatment chemicals for central heating boilers such as Fernox MB1 Sentinel X100 or equivalent are suitable In any event reference must be made to BS 7593 Treatment Of Water In Hot Water Central Heating Systems a Disconnect the boiler from the system at the flow and return connections and temporarily link the flow and return pipes on the system b Flush the entire system until clean water is discharged free from dirt flux solder etc The use of a flushing chemical is recommended e g Fernox Supafloc or equivalent Sludge and scale must be removed from an existing system Boiler failure due to System debris or sludge shall invalidate the guarantee Connect the system to the boiler and fill in accordance with Section 3 7 Water Systems At this stage fill to a pressure of about 2 5 bar d Check the complete system for water soundness If leaks need to be rectified using flux and solder the system must be flushed cold again before proceeding e Reduce the pressure to the Initial System Design Pressure Vent the system GAS SUPPLY The complete gas installation up to the boiler service cock must be checked for tightness BS 6891 ELECTRICAL INSTALLATION Carry out preliminary electrical safety checks i e Earth continuity Polarity Resist
89. uit and the relevant seals The operational working gas inlet pressure at maximum rate as described in Section 5 8 The gas rate as described in Section 5 9 The combustion performance as described in Section 5 7 7 1 Pre Service Checks It is recommended that an inspection should be carried out prior to shutting down the unit for servicing Remove the front cover by removing the screws retaining the top and bottom The following items should be observed a Smooth starting and running of the blower b Smooth lighting of the burner e Check for leakage of gas gas air or combustion products d Check all flexible joints and hoses for condition and soundness replace if necessary e Check for condensate leaks f Check for water soundness g Inspect the flue vent and air intake pipework Joints must be sound and all pipework well bracketed h Check that there is a steady fall back to the boiler from the flue pipe to allow condensate to run back into the boiler i With the boiler operating at a low return temperature i e less than 50 C check that the condensate flows freely from the condensate line 7 2 Recommended Routine Service a Remove the outer case by first removing the securing screws at the top and bottom of the appliance b Remove the burner head Section 8 6 and inspect the burner appearance Black markings or other discoloration s on the gauze indicate too much gas or a lack of air possibly due to
90. used Figure 2 8 3 Flue Condensate Drain Air inlet pipework can be truly horizontal or Point Example vertical or sloping in a downward direction towards the boiler but in this 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 To Terminal To Boiler Tee Fitting 6 in min Due the low temperature of the flue gases further condensate will form within the flue system Drain points with suitable traps must therefore be incorporated within the flue Installation amp Servicing Instructions Page 18 WD420 3 2007 LES 3 Boiler Location The Keston Qudos 28s amp Qudos 28sP Boilers system at the base of vertical flue sections in excess of 6m for 50mm muPVC pipe flue Systems These additional condensate drains must be run to discharge as detailed in section 3 11 Such drain points can be formed using standard muPVC fittings Refer to the example in Figure 3 8 3 3 8 4 Terminations Air inlet terminals must be facing horizontally or downwards to prevent entry of rain into the terminal and positioned to ensure only fresh air is drawn into the boiler The air terminal must be located outside of the building Flue and air terminals must be positioned so that flue products are not drawn into the air inlet Site specific wind conditions should be considered to achieve this Drawing of combustion air directly from a ventilated
91. w 15 mm internal diameter within the dwelling Condensate should preferably be drained into the sanitary waste system or alternatively the rainwater system of the property in most cases Ensure in all cases that the disposal of the condensate is in accordance with any local regulations in force Termination of the pipe must be either at a branch or stack internal to the house or externally at an open gully Alternatively discharge into a purpose made condensate soakaway can be considered Existing or purpose built drains must use suitable corrosion resistant material as condensate is mildly acidic The connection to the condensate drain of the boiler and the condensate drain pipework itself should be properly sealed to ensure there is no possibility of leakage into the dwelling A minimum slope downwards towards the drain of 1 in 20 is essential Freezing of the termination and pipework must be prevented Any drainage pipes outside the property must be at least 32 mm inside diameter Installation amp Servicing Instructions Page 20 WD420 3 2007 Chapter 4 Installation The Keston Qudos 28s amp Qudos 28sP Boilers 4 INSTALLATION OF THE BOILER Read Chapter 3 Boiler Location and decide upon the position of the boiler Installation of the boiler is straightforward but consideration must be given to access to allow flue and air pipes to be pushed through walls and ceilings The order in which the components are installed wi
92. ystems Connections 0 75 inch BSPM For optimum performance after installation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS7592 1992 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleaner such as Fernox Superfloc or BetzDearborn s Sentinel X300 or X400 Full instructions are supplied with the products but for immediate information please contact Fernox on 01799 550811 or BetzDearborn on 0151 420 9563 For long term protection against corrosion and scale after flushing it is recommended that an inhibitor such a Fernox MB1 or BetzDearborn s Sentinel X100 is dosed in accordance with the guidelines given in BS7593 1992 GAS SUPPLY Connect the gas supply to the appliance Details of gas supply requirements are given in Chapter 3 Section 3 6 Gas Supply Supply of adequate gas pressure with the boiler running is critical to ensure reliable operation of the boiler Connections 0 5 inch BSPM ELECTRICAL SUPPLY The entry point s for the electrical supply cable s is in the base of the appliance see Section 3 2 Service Connections fig 3 1 2 via a cord grip bush Feed the cable through the bush and route inside the cabinet to the connection strip located to the front bottom right area of the cabinet 1 The electrical supply must be as specified in Chapter 3 Section 3 4 Electrical Supply WAR

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