Keston qSpa Solar User's Manual
Contents
1. Br BI Br Bi Pd Anti Gravity Check Valve Dual Thermostat TWO PORT ZONE VALVE Not L supplied P A Solar Coil Ed This valve must be fitted on the return to the solar panels and be suitable for higher temperatures operation Standard 10 way wiring junction box Not supplied 230 VAC 5 amp Mains Supply 18 qSpa Installation and Servicing INSTALLATION S PLAN WIRING DIAGRAM WITH TWO 2 PORT VALVES AND BOILER CONTROLLED PUMP OVERRUN OPTION Central Heating Control HW Danfoss WB12 Wiring Centre Br BI GY Gr or V4043A TWO PORT ZONE VALVE L NEO Mains Supply Fed Via Double Pole Isolator 230 VAC 5 Amps Typical schematic wiring diagram for an unvented installation Y PLAN WIRING DIAGRAM WITH 3 PORT VALVE 2 PORT SAFETY VALVE AND BOILER CONTROLLED PUMP OVERRUN OPTION Room Thermostat Dual Aqau Stat Overheat Stat Control Stat WIRE COLOUR LEGEND R Red B Black Or Green Yellow L P connection on the boiler shown dotted and remove the boiler pump link ifthe boiler has an independant pump output V4043A TWO PORT ZONE VALVE The electrical installation must comply with IEE requirements For electrical installation refer to BS7671 Blue core used from standard 3 core flex please ensure you use brown sleeving at both terminating ends to identify core potential Note Do not attempt t2. 176755 qSpa Installation and Servicing qSpa Installation and Servicing 25 MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer Name Telephone Number Address Cylinder Make and Model Cylinder Seria Number _ ttt ttt ti ttt tT tT ttt ete te ee et et ttt Commissioned by print name Registered Operative ID Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable ALL SYSTEMS PRIMARY SETTINGS indirect heating only Is the primary circuit a sealed or open vented system Sealed Open w What is the maximum primary flow temperature C ALL SYSTEMS What is the incoming static cold water pressure at the inlet to the system bar Has a strainer been cleaned of installation debris if fitted Yes N
3. It is not acceptable to discharge straight The tundish should b icai edi into a soil pipe N Trapped gully e tundish snou e vertical located In the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device e g the temperature relief valve Worked Example The example below is for G1 2 temperature relief valve with a discharge pipe D2 having 4 elbows and length of 7m from the tundish to the point of discharge The discharge pipe D2 from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge be of metal and From the table below a Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i e discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device between 18 and 27m at least 3 sizes larger and so on Bends must be taken into account in calculating the flow resistance Refer to the table and the worked example Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from a G1 2 temperature relief valve is 9m subtract the resistance for 4 x 22mm elbows at 0 8m each 3 2m Therefore the maximum permitted length equates to 5 8m 5 8mis less than the actual len
4. qSpa amp qSpa Solar Installation and Servicing Instructions 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 December 2011 UIN 208118 AO1 MANUAL HANDLING OF APPLIANCE PRODUCTS Description Manual handling means any transporting or supporting of a load including lifting putting down pushing pulling carrying or moving by hand or bodily force Scope This assessment will coverthe largest unit within each product range manufactured by Ideal Heating For specific weights and dimensions please refer to technical data section Main Hazards Vision may not be clear due to the size of the products Adopting an incorrect method of lifting may cause injury attempting to lift these products will require help from others Team lifts Control Measures Manual lifting procedure The lift key factors in safe lifting are a Balance b Position of back c Positioning of the arms and body d The hold e Taking the lead for team lifts a Balance Since balance depends essentially upon the position of the feet they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension In taking up this position lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back b
5. and check that water is discharged from the valves and runs freely through the tundish and out at the discharge point Ensure that the valves re seat satisfactorily Note the water may be very hot Itis important to check that the discharge pipework is carrying the water away adequately Check for blockages etc if it is not Turn the mains water off and remove and clean the strainer element in the Pressure Reducing Valve Check the charge pressure in the expansion vessel and repressurise if required Re fill the system and ensure that all relief valves have re seated The Benchmark Service Record should be updated at each service Check the water pressure downstream of the combination valve is 3 bar in static condition Check and if necessary descale the heat exchanger in hard water areas ie above 200ppm mg l co 10000 N Notes The cylinder is factory fitted with a temperature amp pressure relief valve that must not be used for any other purpose or removed The cylinder is factory fitted with immersion heaters with thermal cut outs Immersions without thermal cut outs must not be fitted qSpa Installation and Servicing 5 GENERAL DESIGN qSpa is a range of INDindirect unvented hot water storage cylinders manufactured in the latest high quality duplex stainless steel They are designed to provide mains pressure hot water and are supplied as a package which complies with Section G3 of the Building Regulations The
6. Energy cut out W Solar Controller IE Expansion Vessel Motorised Valve Solar Pumping Station Energy cut out Not supplied All components in a solar primary system must be marked or identifiable in such a way that their design pressure and temperature can be readily determined A safety device pressure relief valve to control the risk of over pressure in system components should be fitted A termination from a safety pressure device should minimise the risk of damage to persons or materials Suitable locations are a high temperature receptacle an internal gully or else issue externally at ground level High level termination from walls or on roofs could cause injury to people or animals below if the valve were to release scalding water and steam The pipe leading to the safety device and the collector should be of rigid and non deformable construction without any possibility of restriction or disclosure by any other fitted component A more detailed diagram of our recommended arrangement for a typical solar system is shown on page 18 This provides all the necessary controls and safety devices necessary for the solar system i e the two port zone valve is wired as an energy cut out and the pump valve will only allow heat transfer as required under control of the solar controller The solar pocket provided accommodates an 8mm diameter sensor which with the sensor located
7. Position of back Straight not necessary vertical The spine must be kept rigid this coupled with a bent knee position allows the centre line of gravity of the body to be over the weight so reducing strain c Positioning of arms and body The further arms are away from the side the greater the strain on the shoulders chest and back Keep elbows close to the body arms should be straight d The hold Before lifting ensure you have a good hold e Taking the lead for team lifts As more than one person is required for these products ensure that one person is taking the lead This may be you so ensure that each person that is helping is made aware of the weight and of the items listed within this assessment Make sure you and any others helping know the route you intend to take that it is clear of any obstructions Never jerk the load as this will add a little extra force and can cause severe strain to the arms back and shoulders If there are steps involved decide on where you will stop and take a rest period Move smoothly and in unison taking care to look and listen to others helping with the lift Where possible use a sack truck to move the product over long flat distances only lift the products when necessary If in doubt stop and get more help Individual capability Individual capability plays an important part in handling these products Persons above average build and strength will find it easier and should be in goo
8. Signature SERVICE 6 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 7 Date Engineer Name SERVICE 8 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 9 Date Engineer Name SERVICE 10 Date Engineer Name Company Name Company Name Telephone Number Comments Telephone Number Comments Signature Signature Keston Heating PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 44 0 1482 443005 Fax 44 0 1482 467133 www keston co uk Keston pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice
9. domestic dwelling ie in an apartment block or student flats etc the hot and cold water system will need to be disinfected in accordance with BS6700 and the Water Regulations Because the qSpa appliance is stainless steel the use of chlorine as the disinfection agent can cause damage unless the appliance is adequately flushed and refilled with the mains water immediately on completion of the disinfection procedure Damage caused through a failure to do this adequately will not be covered by the warranty For the above reasons we recommend the use of a non chlorine based disinfectant such as Fernox LP Sterox as manufactured by Cookson Electronics when carrying out disinfection of systems incorporating these appliances IMPORTANT DRAIN DOWN PROCEDURE Switch off both the boiler and the immersion heater Open the nearest hot tap and run all hot water until cold then close it Close the incoming cold main at the stop tap Hold open the pressure and temperature relief valve until water stops discharging into the tundish and leave it open Open all the taps in the property Open the drain cock and ensure the pressure and temperature relief valve is held open until the cylinder is empty Remove the filter from the combination inlet group clean and replace Refill the system and open all hot taps until there is no air in the pipe work ENSURE CYLINDER IS DRAINED PRIOR TO CHECKING OR REMOVING FILTER FROM THE COMBINATION INLET GROUP 20 Allo
10. in the solar collector or in the flow pipe immediately adjacent to the collector will provide the information required by the solar controller Note If the motorised valve is not used then any factory built hydraulic station for solar use MUST be fitted with suitable non return valves in both flow and return pipes to prevent gravity circulation when the pump is not running If there is a possibility of the solar controller that you install causing the cylinder temperature to exceed 80 C under normal working conditions then a Solar tempering valve must be fitted to the domestic hot water outlet of the cylinder This must limit the hot water temperature to a maximum of 60 C ref building regulations part G3 3 63 Suitable plumbing configurations for installing this valve are shown on page 17 of this manual NB Any fitted overheat thermostats may require resetting in the winter months to enable backup heat sources to heat the cylinder qSpa Installation and Servicing INSTALLATION Figure 1 Cold port of the blending valve connected to mains supply NOT ALLOWED Mixed HW out Mains CW in Figure 2 Cold port of the blending valve connected to balanced cold supply NON RETURN VALVE MUST BE FITTED Mixed HW out Non Return Valve must be fitted Mains CW in Figure 3 Cold port of the blending valve connected to mains supply to the vessel after the inlet control group Mixed HW out Mains CW in qSpa Insta
11. of our products unless specifically requested to do so in writing All goods are sold subject to our Conditions of Sale which are set out at the rear of this specification In the interest of continuously improving the qSpa range Keston Heating reserve the right to modify the product without notice and in these circumstances this booklet which is accurate at the time of printing should be disregarded An updated set of Instructions will be produced and supplied with new appliances and will be made available for other appliances on request A KIWA product approved to comply with all relevant parts of the Building Regulations and Water Supply Water Fittings Regulations Visit www kiwa co uk for more information qSpa is produced under an ISO 9001 2008 Quality Management System approved by BSI jenchmar THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturers instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are requi
12. see table 1 Recovery times based on Primary Coil I H duty ie assumes the boiler output is adequate All connections are supplied with compression fittings for direct connection to copper pipework The heat up times shown for the D400 model indicate the times when 1 or 2 immersions are connected The diagrams shown are generic For exact product specification refer to the table eg the number of immersion heaters varies depending on model Heat up and recover times based on 0 25 l s primary flow rate and at 82 C flow temperature OO PBON o qSpa Installation and Servicing 9 INSTALLATION 10 INSTALLATION Combination Valve If two qSpas are coupled together the secondary inlet and outlet pipes must be balanced The units must be fitted on the same level Note No valves must be fitted between the expansion vessel and the storage cylinder s Model Selection Guide Max number Max hot water demand of bed spaces Bedrooms imeem seem 90 _ 3 bathrooms 2 separate showers rooms 9 6 3 bathrooms 3 separate showers rooms 9 6 Solar Model Selection Guide movere a oem ammem 1 weense shewerroom 6s Os 29 recom shewerroom ea va resent 2showerrooms n3 24 esters stewereom 3189 es Indirect litres General Design Considerations The cupboard footprint needs to be at least 650mm square for standard units up to 300 litres 73
13. 0mm for 400 litre The base chosen for the cylinder should be level and capable of supporting the weight of the unit when full of water as shown in General Data The discharge pipework for the safety valves must have a minimum fall of 1 200 from the unit to a safe discharge point All exposed pipework should be insulated and the unit should NOT be fixed in a location where the contents could freeze The pipe connecting the boiler flow to the appliance must not be less than 22mm copper or equivalent Mains Water Supply Existing properties with a 15mm supply will be satisfactory provided the local mains pressure is good but should be confined to single bathroom properties For new properties where simultaneous demand is required to more than one bathroom or a bathroom and one or more en suites the communication and service pipe into the dwelling should be a minimum of 22mm usually in the form of a 25mm MDPE supply The optimum performance is achieved if the inlet pressure is 3 bar dynamic However the qSpa will function with lower inlet pressures but this will reduce the performance There should be a flow of at least 30 litres per minute or above available into the property Normally qSpa provides well in excess of 40 litres min in most conditions Flow rates for ALL mains pressure Systems are subject to district pressures and system dynamic loss Particularly on larger properties with more than one bathroom the pipe sizes sho
14. Boiler Earth Los s O Boiler Switch Live Demand DRN DATE APPROVED N Fursman 07 12 10 ISSUE No 4 19 INSTALLATION INSTALLATION INSTALLATION COMMISSIONING Connections can come loose in transit and all should be checked before installation Ensure that the immersion heater setting is 60 C and that the wiring is in accordance with the diagram Check the pressure on the air side of the expansion vessel 3 bar This must be done when the volume in the cylinder is cold Check that the drain cock is closed and open all the cold and hot water taps and other terminal fittings Allow the system to fill with water and to run until there is no air left in the system Close the taps and inspect the system closely for leaks Manually open the Relief Valves one by one and check that water is discharged and run freely through the tundish and out at the discharge point The pipework should accept full bore discharge without overflowing at the tundish and the valve should seat satisfactorily In line with good plumbing practice use with exessive flux should be avoided When soldering above the cylinder ensure flux solder does not contaminate the cylinder below since this can cause corrosion Allow the cylinder to heat to normal working temperature then thoroughly flush the domestic hot and cold water pipework through each tap NOTE If this appliance is to be installed in other than a single
15. Poor Water Flow at Hot Taps FAULT Water Discharge Into Tundish START s Is pressure downstream of pressure reducing valve correct YES Is valve seal and seat clean amp undamaged YES Is incoming mains supply flow pressure adequate YES t Is in line strainer in combination valve clean YES p Is pressure reducing valve Water service check by supply company required Clean or replace strainer Clean or replace as appropriate as required Recommission in combination valve working Service replace PRV as appropriate YES p Is system free from restrictions blockages Clear obstructions YES END qSpa Installation and Servicing Is heater operating at less than 60 C Is expansion vessel charge pressure correct expansion vessel pressure NO YES v Re set temperature Replace ERV TPRV Is ERV TPRV discharging Is Replace PRV __ END 23 0 Z D L 3 x LL 0 Z D LL i x LL 0 Z D LL r x L 0 Z D L i d L 0 Z D E L n d LL 24 LIST OF PARTS SPARE PARTS LIST Description 4 flexible hose 9 24 litre expansion vessel T Quantity Stock Code No
16. appliance is extremely well insulated using high density HCFC free foam insulation with an ozone depleting potential ODP of zero and a global warming potential GWP of 1 Itis fitted with all necessary safety devices and supplied with all the necessary control devices to make installation on site as easy as possible qSpa is available in two basic variants 1 qSpa For use with gas or oil boilers Unvented cylinders must not be used with solid fuel boilers or steam as the energy source 2 qSpa Solar For providing hot water by solar gains and gas or oil boilers Unvented cylinders must not be used with solid fuel boilers or steam as the energy source qSpa qSpa Solar qSpa indirect is an unvented hot water storage cylinder qSpa Solar indirect is an unvented hot water storage cylinder and is provided with a high efficiency internal primary andis provided with a high efficiency internal primary coil which coil which is designed for use with a gas or oil boiler and is designed for use with a gas or oil boiler and is suitable for is suitable for both open vented and sealed pumped both open vented and sealed pumped primary systems primary systems i When used with a sealed heating system the boiler must When used with a sealed heating system the boiler must incorporate its own energy cut out overheat thermostat incorporate its own energy cut out overheat thermostat M M A high efficiency second solar coil is positioned below the qSpa indi
17. as etc are acceptable providing that where children play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility Discharges at a high level e g into metal hopper and metal down pipe with the end of the discharge pipe clearly visible tundish visible or not or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering systems that would collect such discharges Where a single pipe serves a number of discharges such as in blocks of flats the number served should be limited to not more than 6 systems so that any installation can be traced reasonably easily The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected If unvented hot water storage systems are installed where discharges form safety devices may not be apparent i e in dwellings occupied by blind infirm or disabled people consideration should be given to the installation of an electronically operated device to warn when discharge takes place Safety The safety devices supplied or fitted on a qSpa are selected for their suitability for the temperatures and pressures involved They must not be changed removed or by passed and it is essential that only genuine replacement parts supplied or approved by Keston Heating are used This includes the immersion heaters which must i
18. clude the following Check and clean filter Manually check the operation of the temperature relief valve Manually check the operation of the expansion relief valve Check discharge pipes from temperature and expansion relief valves are free from obstruction and blockage and are not passing any water Check the condition and if necessary descale the heat exchangers in hard water areas Check that water pressure downstream of pressure reducing valve is within the manufacturers limits Check operation of motorised valve Check the pressure on the air side of the expansion vessel This must be done when the volume in the cylinders is cold Check and advise the householder not to place any clothing or other combustible materials against or on top of this appliance 10 On completion of the work fill in the Benchmark Service Record towards the back of this manual IMPORTANT NOTE When draining down the appliance for any reason the instructions provided in the Commissioning Section MUST be followed to prevent potential damage to the cylinder qSpa Installation and Servicing 21 SEFVKVICINCS FAULT FINDING FAULT FINDING Scale In hard water areas it is recommended that an in line scale inhibitor is fitted Reducing the temperature of the stored water will reduce the rate at which scale forms If the recovery rate is badly affected this is an indication that scaling may have occurred In this event foll
19. d health Persons below average build and strength may require more rest periods during the handling process Pregnant women should not carry out this operation Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation Residual risk Following the guidelines given above will reduce any risk to injury All persons carrying out this operation must be fully trained and copies of the specific risk assessment made available for inspection and use in their training process Further guidance on Manual Handling can be obtained from the Health and Safety Executive Manual Handling Operations Regulations 1992 qSpa Installation and Servicing CONTENTS Benchmark Commissiong Checklist qSpa amp qSpa Solar Commissioning Destination Country GB IE Design Fault Finding General Data Table General Information Installation Manual Handling Schematics Servicing amp Maintenance Short List of Parts Wiring Diagrams qSpa Installation and Servicing 3 GENERAL These instructions should be read in conjunction with the installation servicing instructions issued by the manufacturer of the heat source being used Any installation must be in accordance with the relevant requirements of the Gas Safety Regulations Building Regulations LE E Wiring Regulations and the Water Fitting Regulations England and Wales or Water Byelaws Scot
20. d must be fitted with an over temperature cut out Unvented primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary Gate Valve connection is removed after use Not supplied Motorised Valve Energy cut out BPa Alternatively a CA device can be used which will allow the system to be permanently connected to the cold mains supply The primary system Morna NETE can then be topped up when required in the Not supplied same way as an open vented system fitted with 4 l LUI an F amp E Cistern Safety Valve Gate Valve All our cylinders are tested to BS EN 12897 at 15 l min at which they exceed the minimum requirements for heat up performance and re heat in less time than the maximum re heat times In extreme situations where excessive flow rates above 25 l min are present then a gate valve on the return from the cylinder to the boiler before it joins the central heating return may be required to reduce excessive flow rates and therefore any potential noise problems qSpa Installation and Servicing 15 INSTALLATION INSTALLATION 16 INSTALLATION Schematic Solar Indirect System Solar Panel Motorised Valve ps
21. e balance cold supply is provided with its own pressure reducing valve and is not taken from the balanced cold connection on the combination valve In this case it will also be necessary to fit a small expansion vessel on the balanced cold water system to accommodate the pressure rise caused by the increase in temperature of the balanced cold water Check the performance requirements of the terminal fittings with regard to flow pressure are suitable In relation to potable water systems expansion vessels shall be installed in a vertical orientation and located so that the length of the connecting pipe work is kept to a minimum Shower Fittings Aerated taps are recommended to prevent splashing Any type of shower mixing Pipe Layout In all mains pressure installations it is important to remember that the incoming cold supply must be shared between all terminal fittings It is important that a 22mm supply is brought to the appliance and a 22mm take off is continued at least to the bath If there are two baths 28mm pipework should be considered One metre of smaller diameter pipework or flow restrictors should be provided on the final connection to all outlets so as to balance the water available In any event the distribution pipework should generally be in accordance with EN806 1 Plastic Pipework This appliance is suitable for use with plastic pipework as long as the material is recommended for the purpose by the manufacture
22. e combination valve 11 INSTALLATION INSTALLATION PRESSURE amp TEMPERATURE EXPANSION RELIEF VALVE PIPEWORK The relief valve should be installed to Typical Discharge Pipe Arrangement discharge in accordance with G3 of Expansi n the Approved Document of the Building CU le E Regulations and should be piped to where it 4 o RS is visible but will not cause danger to persons or damage to materials The following information is taken from 500 mm max le Approved Document G3 of the Building cal L Regulations and is provided to assist with Dotted line showing the design and installation of the discharge alternative route with pipework However the information is not single tundish being used d exhaustive and reference should always be made to Approved Document G3 of the Building Regulations The final decision regarding any arrangements rests with Building Control and it is recommended Discharge below that their advice is sought if you have 22 mm metal pipe with continuous fixed grating any concerns regarding this aspect of the fall up to 9m equivalent length D2 installation NOTES The discharge will consist of scalding The two safety valves will only discharge waterand steam Asphalt roofing felt water under fault conditions When operating and non metallic rainwater goods may E i edm estt se EC Ee normally water will not be discharged N Fixed Grating
23. e if an approved non return valve is fitted otherwise during the heating cycle the water will expand back into the mains supply as the regulating valve must not be relied upon to act as a check valve under all operating conditions depending upon the characteristics of the blending valve hot water may also flow from the balanced cold water taps Figure 3 shows the cold port of the blending valve connected to the cold water supply to the vessel after the inlet control group This should be the preferred method It is recommended that the installer should ensure that there is no gravity circulation in the pipework connected to the cold port If necessary this can be achieved by fitting a non return valve or using a thermal trap 17 INSTALLATION INSTALLATION INSTALLATION Schematic Showing Solar Wiring Requirements S1 R Red B Bue B Black No isolation valve should be installed White between the solar Green Yellow circuit and the safety valve pressure relief valve Solar Controller Pressure Relief Valve Solar Thermstore Unvented Cylinder Anti Gravity Solar Check Valve Pumping Station
24. educe the likelihood of contaminants fouling the valve seat Following installation this line strainer must be cleaned and replaced This needs to be carried out on a regular basis as part of the annual maintenance service check Tundish This is to allow the discharge from any Relief Valve to be seen It must be fitted away from any electrical devices See page 12 for discharge pipework details Safety The immersion heaters must be earthed and they must be isolated from the mains before the cover is removed on every occasion Replacement immersion heaters should be obtained from Keston Heating Control overheat Dual Thermostats Care must be taken to ensure that the solar probes are fully inserted into the pockets provided Anti Vacuum Valve Important failure to follow the drain down procedure will invalidate the waranty see page 20 NEVER drain the cylinder of hot water and then close all cylinder inlets and outlets REASON as the air remaining in the cylinder cools the pressure inside the cylinder will fall below atmospheric and cause the cylinder to implode NEVER close the cold main and drain the cylinder via any tap connected to it REASON asthe water drains the pressure inside the cylinder may decrease below atmospheric and this will cause the cylinder to implode To stop the possibility of this occurring by accident an ANTI VACUUM VALVE should be fitted in the hot water take off pipe This will balance the cylinder s interna
25. ers supplied with the unit In any situation where the volume of heated pipework eg secondary circulation pipes or manifold pipework for multiple units exceeds 10 litres then an additional expansion vessel must be fitted to accommodate the extra expansion volume Handling Before Installation qSpa must be handled with care and stored the correct way up in a dry place Any manual handling lifting operations will need to comply with the requirements of the Manual Handling Operations Regulations issued by the H S E The appliance can be moved using a sack truck on the rear face although care should be taken and the route should be even In apartment buildings containing a number of storeys we would recommend that the appliances are moved vertically in a mechanical lift If it is proposed to use a crane expert advice should be obtained regarding the need for slings lifting beams etc A specific manual handling assessment is shown on page 2 of this manual MAINTENANCE Modifications should not be made to this product Replacement parts including immersion heaters should be purchased from Keston heating or agents approved by them Unvented hot water storage vessels need regular routine checks and these are detailed below It is for this reason that this manual must always be left with the qSpa It is essential that these checks be carried out at the time of boiler maintenance by a qualified installer 1 Manually open the relief valves in turn
26. gth of 7m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28mm pipe D2 from a G1 2 temperature relief valve equates to 14m As the actual length is 7m a 28mm D2 copper pipe will be satisfactory Sizing of copper discharge pipe D2 for a temperature relief valve An alternative approach for sizing with a G1 2 outlet size as supplied discharge pipes would be to follow BS6700 Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages Deduct the figure Maximum length of below from the straight pipe maximum length for no bends or elbows each bend or elbow in the discharge pipe b Have a vertical section of pipe at least Up to 9m 300mm long below the tundish before Up to 27m c Be installed with a continuous fall continued Size of discharge pipework 12 qSpa Installation and Servicing INSTALLATION d It is preferable for the discharge to be visible at both the tundish and the final point of discharge but where this is not possible or practically difficult there should be clear visibility at one or other of these locations Examples of acceptable discharge arrangements are 1 Ideally below the fixed grating and above the water seal in a trapped gulley 2 Downward discharges at a low level i e up to 100mm above external surfaces such as car parks hard standings grassed are
27. he electrical work unless you are competent to carry outto the above standard GAS BOILER Boiler Switch Live Demand eL ot dpolBei tos o OlBoiler Permanent Live Boiler Pump DRN DATE APPROVED N Fursman 07 12 10 ISSUE No 5 Central Heating Control HW ELECTRONICS Room Thermostat Spade connectors required Overheat Stat for earth connections R Supplied with stat Dual Cylinder Stat Control Stat WIRE COLOUR LEGEND Green Yellow core cable Provide extra core from terminal 12 to LP connection on the boiler shown dotted and remove V4073A MID POSITION ZONE VALVE L N Mains Supply Fed Via Double Pole Isolator 230 VAC 5 Amps Typical schematic wiring diagram for an unvented installation qSpa Installation and Servicing the boiler pump link ifthe boiler has an independant pump output Brf Bl iv or er V4043A TWO PORT ZONE VALVE The electrical installation must comply with IEE requirements For electrical installation refer to BS7671 Blue core used from standard 3 core flex please ensure you use brown sleeving at both terminating ends to identify core potential Note Do not attempt the electrical work unless you are competent to carry out to the above standard GAS BOILER Boiler Permanent Live Boiler Controlled Pump OjBoiler Neutral Ot dpoO
28. l and atmospheric pressures and eliminate this risk Available from Keston Heating qSpa Installation and Servicing INSTALLATION Heating primary Systems Schematic Open Vented Primary System The boiler and primary heating systems should be sized and installed in accordance with BS 5449 Warming Overflow Pipe Safet y qSpa is fitted with a Combined Temperature Qa HERE Pressure Relief Valve to cope with any increase O in system temperature and pressure above the design limitations when used with boilers up to Motorised Valve 45kW output which is the maximum allowed Minimum Energy cut out by section G3 of the Building Regulations The distance as primary water temperatures should be controlled dete as outlined below boiler Gate Valve manufacturers Not supplied instructions Primary Circuit It is essential that the circuit between the boiler Motorised Valve and the qSpa is pumped The motorised zone Not supplied valve supplied should be fitted adjacent to the i 3 unit and controlled by the cylinder thermostat supplied The thermostat and motorised valve pig 150mm max must be wired so that they both switch off should an overheat situation develop It is important to follow the wiring diagram in the Wiring Section of these instructions Sealed Primary Circuit Schematic Sealed Primary System Any boiler use
29. land It should be read in accordance with the relevant recommendations of the following BS 6798 BS 5549 BS 5546 BS 5440 1 BS 5440 2 CP 331 3 BS 6700 BS 5258 and BS 7593 1992 qSpa is covered by Section G3 of the Building Regulations England and Wales Technical Standard P3 Scotland and Building Regulation P5 Northern Ireland Compliance can be achieved via a Competent Person Self Certification Scheme or notificaton of installation to the Local Authority Building Control Department It must be installed by a competent person as defined by the relevant regulations Manufacturers notes must NOT be taken as over riding statutory obligations 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 at all times to ensure they do not play with the appliance This information is provided to assist generally in the selection of equipment Responsibility for selection and specification of our equipment must however remain that of our customer and any experts or consultants concerned with the installation s Please note that we do not therefore accept any responsibility for matters of design selection or specification for the effectiveness of an installation or system containing one
30. llation and Servicing Fitting Blending Valves To The Unvented qSpa Appliances When fitting a blending valve to the unvented appliances it is important that the installation does not contravene the G3 WRC and Health and Safety directives or the manufacturers recommendations If this is the case then the warranty should be null amp void The key requirements to comply with these regulations are 1 Any fitting or material in contact with potable water e g a blending valve must be approved by WRC or an equivalent body Connections or wiring arrangements must not bypass any safety devices Any expansion due to heating must not be allowed to expand back into the cold mains The settings of any safety devices must not be tampered with or adjusted The diagrams opposite shows how the blending valve can be piped onsite Figure 1 shows the cold water port of the blending valve connected to the mains cold water supply before the inlet control group This arrangement is completely unacceptable and illegal because the water is allowed to expand in to mains cold water supply the vessel will be charged to the incoming mains supply which may be considerably higher than the working pressure of the vessel If this arrangement is used then the Gledhill warrant will not be valid Figure 2 shows the cold water port of the blending valve connected to the balanced cold water outlet This arrangement will only be acceptabl
31. ncorporate an energy cut out All parts are available to approved installers from Keston Heating Schematic Diagram Hot Outlet Secondary Return Circuit P amp T Relief Valve Tundish Pump Non Return Valve Expansion Balanced Vessel Cold Outlets To Drain Immersion Heater Boiler 2 Port Valve Flow Kitchen Boil Cold oiler Tap Return Combination Valve qSpa Installation and Servicing Combination Inlet Group Combines elements 1 2 and 3 below 1 Pressure Reducing Valve This must be fixed near the cylinder The cold water supply to any mixer taps showers must be taken from the cold water tapping of this valve to ensure balanced hot and cold pressures This valve is factory set to ensure the correct operating pressure for the qSpa Non Return Valve This is integral with the pressure reducing valve to prevent backflow of hot water towards cold water draw off points Cold Water Expansion Relief Valve This safety device is preset at the factory and will relieve excess cold water pressure resulting from a fault condition 13 INSTALLATION INSTALLATION 14 INSTALLATION Pressure amp Temperature Relief Valve This safety device is also pre set at the factory and relieves before the temperature reaches 100 C It is also a Pressure Relief Valve and is pre set to 6 bar Immersion Heaters These are 3kW 240V AC heaters and incorporate a thermostat and a manually reset ene
32. o Go Weight Empty Weight Full Capacity Total Volume Al N loo me Co NIN gt oj 7 1 1 zs as Pressure Regulator 3 bar inlet group c w balance cold supply expansion vessel connection and expansion valve set at 4 75 bar Expansion Vessel size Pre charged to 3 bar Overall Height Overall Diameter wlelslN oo gislo zx EN ER 2 2lm B NI N olnm gt f 3 3 E f 3 3 Ala oja o o J Pressure amp Temperature Relief Valve 6bar 95 C 22mm Secondary Return Tapping 3 3 E s le i 3 w a x On Peak Immersion Heater High Level TR N A N R N Cold Feed 22mm Compression Connection m I 3 3 w o ES eo wo 5 wo o o AS o A CO Aaj A Aj A NIL O N O Off Peak Immersion Heater Low Level Volume of On Peak Water Heated Dual Control amp Overheat Stat 577 677 na ma e JEDE oa oS o e eo Litres N co NIO a co o N c GO R wo eo zx e c Co Go o A A o J A A kar A oo N Extra Stat Pocket For Boiler Use H mm If Required 22mm Primary Return l mm 223 223 223 Compression Connection 28mm tails for 400 litre model w NIN 2 E D zx e 51 wo LL i 1002 1115 1026 223 22mm Primary Flow Compression Connection 28mm tails for 400 litre model 22mm Solar Return Compression Connection T 3 2 2 D N Q2 co
33. o a Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes Ez No a What type of scale reducer has been fitted What is the hot water thermostat set temperature C What is the maximum hot water flow rate at set thermostat temperature measured at high flow outlet l min Time and temperature controls have been fitted in compliance with Part L of the Building Regulations Yes Type of control system if applicable Y Plan S Plan Other L Is the cylinder solar or other renewable compatible Yes L No What is the hot water temperature at the nearest outlet C All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes UNVENTED SYSTEMS ONLY Where is the pressure reducing valve situated if fitted What is the pressure reducing valve setting bar Has a combined temperature and pressure relief valve and expansion valve been fitted and discharge tested Yes No The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes Nol vol Are all energy sources fitted with a cut out device Yes ma Has the expansion vessel or internal air space been checked Yes THERMAL STORES ONLY What store temperature is achievable C What is the maximum hot water temperature C ALL INSTALLATIONS The hot
34. oa A Co 22mm Solar Flow Compression Connection Dual Control amp Overheat Stat n a n a TY vlees w N o A a o o a Oo N IN o e 9 o m vc S e BR N 3 R a Solar Pocket 5 vjz 3 3 3 3 3 2 LI 2 Solar Pocket p 3 3 2 D 2 D Second Off Peak Immersion Heater Low Level N o S di Go wo Ol e op ops mee di ojojo i 1 223 E m Dual Control amp Overheat Stat M ma SolarPocket_ wa n SoerPoeket i EE pes HERR 21 A co EN Ed a 0 97 0 97 kW Rating of Primary Coil e a N N o a Surface Area of Primary Heater Coil Pressure Loss Across Primary Heater Coil o o a o o o N o eo N o o N A o N A o w o o x o oa 2 2 LI Surface Area of Solar Heater Coil ojo lo Co o Pressure Loss Across Solar Heater Coil Heat Up Time from 15 C to 60 C applies to Primary Heat Source only AEIEIE TEk a m m 7 Recovery Time after 70 Draw Off applies to Primary Heat Source only Standing Losses kWhr 24hr Dedicated Solar Volume EN E ae io N co x N w sjal 8 m N A o 9 gt EE x E e 3 I o o o 2 slel of S SIE l ale eo e orn w wo dil Zlo 2 N N o o co Litres n a n a 8 qSpa Installation and Servicing GENERAL qSpa qSpa Solar NOTES Not all models
35. ow the procedures as recommended by a reputable Water Treatment Company General No water at the tap Check that the mains water supply is turned ON Check the line strainer is not blocked Check that the combination valve has been fitted so that water is flowing in the correct direction If the water at the tap is cold ensure that the boiler has been Switched ON and is working correctly Check that there are no air locks in the primary system ISOLATE THE UNIT AT THE MAINS ELECTRIC SUPPLY AND THEN CHECK THE FOLLOWING i The cylinder thermostat ii The thermal cut out which can be re set by pushing the red button iii The motorised valve iv The boiler thermostat v The boiler thermostat cut out if fitted ANY ENERGY CUT OUT MUST NEVER BE BY PASSED UNDER ANY CIRCUMSTANCES If the units are not getting hot and the heat source is electrical ensure that the immersion heaters are isolated from the mains before re setting the energy cut out If the immersion heater s need replacing this should be done with the units supplied from Keston Heating Discharge From Relief Valves If cold water is discharging from the expansion relief valve into the tundish check the pressure on the expansion vessel when cold and recharge if necessary If the fault continues and the problem cannot be stopped by operating the easing control a few times then either the Pressure Reducing Valve or the Relief Valve may be at fault If the cold water pre
36. r and is installed fully in accordance with their recommendations Secondary Hot Water Circulation Some models are fitted with a secondary return tapping as standard see tables 1 and 2 for details If fitted an extra expansion INSTALLATION valve can be used as long as both the hot and cold supplies are mains fed However all mains pressure systems are subject to dynamic changes particularly when other hot and cold taps showers are opened and closed which will cause changes in the water temperature at mixed water outlets such as showers For this reason and because these are now no more expensive than a manual shower we strongly recommend the use of thermostatic showers with this appliance These must be used in 3 storey properties where the impact on pressure temperature of opening another tap in the system is greater than normal The shower head provided must also be suitable for mains pressure supplies vessel may be necessary A non return valve MUST be FITTED near the return connection No valve or terminal fitting should be installed between the non return valve and the cylinder See schematic arrangement on page 13 WM or DWM EXTERNAL DC DCV HH WATER SOFTENER IF NECESSARY INCOMING COLD SUPPLY qSpa Installation and Servicing Note Cold supplies to single taps must be taken from the mains cold water system Cold supplies to mixer taps must be taken from the balanced cold water connection on th
37. rect models are listed on Table 1 page 8 primary coil to ensure maximum benefit of solar gain energy qSpa Solar indirect models are listed in Table 1 page 8 Note The cold supply elbow c w drain tapping must be fitted as shown above A flexible hose can then be connected to the drain tapping and providing the hose runs below the lowest level of the cylinder then all the water contents can be drained out by syphonic action The cold feed pipe dips internally to the base of the cylinder 6 qSpa Installation and Servicing GENERAL DESIGN 3 4 7 8 6 10 qSpa Basic Appliance Hot water draw off 22mm compression Temperature amp pressure relief valve 95 6 bar Hot water secondary return 22mm not fitted to smaller sizes see table 2 Immersion heater 1 BSP 3kW 22mm cold supply compression Immersion heater 1 BSP 3kW Dual control overheat stat pocket 22mm Boiler control sensor pocket spare Primary return 22mm 28mm tails for 400 litre models Primary flow 22mm 28mm tails for 400 litre models Component kit supplied separately A moo W m Combination inlet group incorporating pressure reducing valve strainer check valve balance cold take off point expansion relief valve and expansion vessel connection points Potable expansion vessels c w flexible hose and wall bracket Tundish Dual control thermostat and combined overheat the
38. red to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot Water Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information qSpa Installation and Servicing GENERAL MANUFACTURER KESTON HEATING Maximum inlet pressure to pressure reducing valve 12 bar Operating pressure PRV setting 3 bar Expansion vessel charge pressure 3 bar Expansion relief valve setting 4 75 bar Opening pressure of P amp T Relief Valve 6 bar Opening temperature of P amp T Relief Valve 95 C Energy cut out thermostat setting 80 C Max Working pressure Primary heat exchanger Indirect models 6 bar Max Working pressure Solar heat exchanger Solar models 10 bar Immersion heater rating 3kW 240V AC All cylinders are manufactured in accordance with the requirements of BS EN 12897 The tundish must be positioned so that it is visible to the occupant and is away from electrical devices Components supplied with qSpa Cold water inlet PRV combination valve expansion relief Pressure and temperature relief valve Control thermostat Energy cut out thermostat Energy cut out motorised valve indirects only Tundish 3kW Immersion heater Expansion vessel mounting bracket flexible hose Technical user product literature Note Please refer to Table 1 on page 8 to confirm the quantity of immersion heat
39. rgy cut out which operates at 80 C They have incalloy elements to prolong their life expectancy in aggressive water conditions Please refer to tables 1 and 2 to clarify how many off peak and on peak immersions are included with the unit you require Where it is intended that units are fitted to offpeak circuits then suitable controllers such as the Horstmann off peak electric time controller will be required External wiring to the immersion heaters must be in accordance with the relevant IEE Wiring Regulations and the circuit must be protected by a suitable fuse and a A EA Immersion Heater Wiring double pole isolating switch The correct method of terminating the wiring to the immersion heater is shown opposite Usage of the product in non domestic commercial applications can be extremely intensive and stressful to various components We recommend that titanium immersion heaters are fitted in such situations rather than the incology heater supplied as standard Titanium immersion heaters offer superior strength weight and a smoother finish which enable them to better withstand the extreme stress and temperature fluctuation often encountered within non domestic environments and situations where water quality is poor ensuring improved performance and extended operational life This can be purchased as a spare part from Ideal Heating see short list of parts page 24 Line Strainer This is integral within the combination inlet group to r
40. rmostat Two port 22mm zone valve for primary circuit Wiring junction box for primary system qSpa Installation and Servicing qSpa Solar Basic Appliance 1 Hot water draw off 22mm compression 2 Temperature amp pressure relief valve 95 6 bar 3 Hot water secondary return 22mm not fitted to smaller sizes see table 2 Immersion heater 124 BSP 3kW 22mm cold supply Dual control Overheat stat pocket Primary return 22mm 28mm tails for 400 litre models Primary flow 22mm 28mm tails for 400 litre models 9 Dual control Overheat stat pocket 10 Solar coil return to panel collector 22mm compression 11 Solar coil flow from panel 22mm compression 12 Solar thermostat pocket nons Oo Component kit supplied separately A Combination inlet group incorporating pressure reducing valve strainer check valve balance cold take off point expansion relief valve and expansion vessel connection points B Potable expansion vessels c w flexible hose and wall bracket C Tundish D Dual control thermostat and combined overheat thermostat x2 E Two port 22mm zone valve for primary circuit F Wiring junction box for primary system GENERAL TABLE 1 GENERAL DATA REFER TO DIAGRAMS ON PAGE 9 qSpa Solar aso soo a00 180 210 250 300 200 Faso s00 400 Be ULL Bal lion fd id lal a 83 1733 2040 1241 1491 1777 1792 OLIE 1155 1129 T N w
41. ssure is too high this would suggest that the Pressure Reducing Valve is at fault and the Keston Heating approved replacement should be fitted If the pressure is correct then the Relief Valve will require replacing with an Keston Heating approved component See Commissioning for drain down procedure If there is an overheat fault and very hot water is being discharged turn off the heat source but not the water supply When the supply is cool check thermostats and energy cut outs in the boiler and immersion heaters and replace the faulty component with a unit supplied by Keston Heating and check that it works correctly before returning the system to full operation 0 Z D LL 3 d LL 0 D Z LL T d IE 0 D Z IN J d LL 0 D Z IN J 2 0 Z a IE J 2 22 qSpa Installation and Servicing FAULT FINDING FAULT FINDING FAULT No Hot Water Indirect START YES Is boiler on YES Is hot water programmer in on position YES k Is zone valve in correct position YES Is control temperature set at 55 C 60 C YES Switch on Set programmer Re set check wiring amp plumbing is correct nmn Is all wiring to th Has high limit cut out RT nd 0 De controls ok YES YES Re set Replace thermostat FAULT
42. uld be calculated in accordance with BS6700 Model Selection Where selecting a solar model it is important to check the dedicated solar volume shown in tables 1 amp 2 is suitable for the total floor area of the dwelling to ensure compliance with Building Regulations The maximum floor area of the dwelling permitted for the models is shown opposite The suggested model sizes are based on typical hot water usage For high specification dwellings an increase of one model size should be considered qSpa Installation and Servicing INSTALLATION General Restrictions The highest hot or cold water draw off point should not exceed 10 metres above the Pressure Reducing Valve An ascending spray type bidet or any other appliance with a Class 1 back syphonage risk requiring a type A air gap should not be used qSpa should not be used where steam is the primary heating medium or in a situation where maintenance is likely to be neglected Unvented cylinders are not suitable for use with solid fuel boilers If the supply to the mixer fittings other than a dual outlet type is not taken from the balanced supply the system will become over pressurized and cause the pressure relief valve to discharge Over time this could also cause the premature failure of the appliance itself which will not be covered by the warranty In larger properties with a number of bathrooms en suites and long pipe runs we would recommend that th
43. w the cylinder to heat to normal working temperature with whatever heat source is to be used and check again for leaks The pressure relief valve or the P amp T valve should not operate during the heating cycle If the P amp T valve operates before the pressure relief valve due to high pressure check that the inlet control group is fitted correctly The boiler heating systems should be filled and commissioned in accordance with good practice following the guidance in BS 5449 the boiler manufacturers instructions This includes adequately flushing the system to remove any debris that may have been introduced during installation maintenance NOTE This appliance is covered by BENCHMARK and the service record must be completed after commissioning and after every maintenance service visit qSpa Installation and Servicing SERVICING SERVICING amp MAINTENANCE The Registered Installer is responsible for the safe installation and operation of the system The installer must also make his customer aware that periodic maintenance of the equipment is essential for safety Maintenance periods will vary for many reasons Keston Heating recommend a maximum of 12 months to coincide with boiler maintenance Experience of local water conditions may indicate that more frequent maintenance is desirable eg when water is particularly hard scale forming or where the water supply contains a high proportion of solids eg sand Maintenance must in
44. water system complies with the appropriate Building Regulations Yes The system has been installed and commissioned in accordance with the manufacturer s instructions Yes The system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer benchiman THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE 1 Date Engineer Name SERVICE 2 Date Engineer Name Company Name Company Name Telephone Number Telephone Number Comments Comments Signature Signature SERVICE 3 Date Engineer Name SERVICE 4 Date Engineer Name Company Name Telephone Number Company Name Telephone Number Comments Comments Signature SERVICE 5 Date Engineer Name
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