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Jan12_Q28h Manual 8-2011

1. Installation amp Servicing Instructions Page 38 The Keston Qudos 28h amp Qudos 28hP Boilers WD440 3 2007 Chapter 6 Fault Finding 6 7 2 Waterway Condensate amp Flue Assembly J Page 39 Installation amp Servicing Instructions WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers pS E yyy 6 7 3 Aird Gas Assembly Installation 8 Servicing Instr
2. A 4 a az z 3 W S Dl R 315 DE Sp CONTROLS Z sa EP 8 al ia EZ SUMP z 3 lt o Q28H 3 ORANGE ee _ GREY BOILER IN BLUE AM BROWN FROM DHW M CONTROLS E 515 go H y E AN HE gt 7 312 iN j E g t gt esis a E E p TANK o Sh paan ae gt Pi Poi u is 7 Senso TS SENSOR EXTERNAL SENSOR OPTIONAL i LOW VOLTAGE CONNECTOR lal g SOL TS DHW FLOW OPEN ANQUQG EXTERNAL k GL arial SENSOR SENSOR SENSOR SWITCH HERM Hi SENSOR Nt e P 112111 2 1 1 FeJov 4 12 JE e e ah y SOLAR PANEL E al 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 28h and Qudos 28hP 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 28h and
3. 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 5 pate SERVICE 6 bare 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 Date SERVICE 8 bare 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 Dare 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 Page 53 WD440 3 2007 The Keston Qudos 28h amp Qudos 28hP Boilers R KESTON CONDENSING BOILERS IMPORTANT Qudos 28h and Qudos 28hP INSTALLATION KEY POINTS g Read Installation Manual Carefully Ensure that ALL dust particles filings plastic chips etc are removed from the inlet p
4. 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 WARNING 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 Ear
5. Qudos 28h User Installation and Servicing Instructions FAN POWERED HIGH EFFICIENCY MODULATING DOMESTIC CONDENSING GAS HEAT ONLY BOILER CE PI No 86 CM 43 Qudos 28h GC No 41 930 19 Qudos 28hP GC No 41 930 20 CE 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 440 issue 8 2011 WD440 3 2007 The Keston Qudos 28h amp Qudos 28hP 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 INSTALLAT
6. NE pu 5 a FON i Y SIISNIS a Z HT Ha PT 005 E ansas SL w u a0sNas a 3 05 wus m 3 105 3 EF RE gu a S ul gt H a E 2 za a 1 g u05 SUNYH3d de 2 8 E a o 5 SNIVA XJWADASNYAL T o 10X207 v m 5 Tutu g g Z 353 aoc ucz ag a lt a 27 Le a h 8 2 l l J x a Z t al gt ol Ey gt aa m iy ty 5 SE pea loca dq al a A Al e NN Swi 59 y IS DEMAND SL Installation 8 Servicing Instructions Page 36 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers 6 6 ILLUSTRATED WIRING DIAGRAM SNIVIN Installation 8 Servicing Instructions Page 37 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers A ee 6 7 Exploded Assembly Diagrams 6 7 1 Boiler Controls Assembly
7. 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 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 8 6 BURNER Fig 6 7 2 items 42 i ii iii iv v vi vii Isolate the appliance Section 8 1 Gain access Section 8 2 Remove the combustion blower Section 8 4 7 Remove the 4 nuts fixing the burner to the top of the heat exchanger Fig 6 7 3 item 100 Remove the spark ignition flame detection electrode Section 8 5 Withdraw the burner from the top of the heat exchanger Reassemble Section 8 3 NB When reassembling inspect any gaskets for damage and replace if necessary Installation amp Servicing Instructions Page 47 WD440 3 2007 ee 8 Replacement Of Parts _ The Keston Qudos 28h amp Qudos 28hP 8 7 HEAT EXCHANGER Fig 6 7 2 item 41 i ii ii iv xi xii xiii xiv Isolate the appliance Section 8 1 Gain access Section 8 2 Shut off the water supply to the appliance Remove the burner Section 8 6 Drain the system to below the level of the appliance Remove the flue thermistor Section 8 4 4 Remove the spark ignition flame detection electrode Section 8 5 Remove the flue connection
8. 4 gt Valve Valve FLOW a Ne LIV Rad 2 Rad 1 Installation amp Servicing Instructions Page 15 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers AAA 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 k A filling point must be fitted in accordance with local water authority requirements 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 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 hea
9. 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 temporary irritation to eyes skin and respiratory tract The fibres are held in place by inorganic binders Therefore as long as the boards are not 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 Installation amp Servicing Instructions Page 9 WD44 2007 hapter 2 neral Instruction The Keston 28h 28hP Boiler appliance 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 OPERE benchmark Benchmark Initiati
10. N BLUE BROWN Cones 2130 i 2 hiz ae z 2 Q28H ge ____ ORANGE a a GREY BOILER gt A BLUE BROWN FROM DHW INTRI 2 3 3 EE o 3 2 2 A z gt b gt a LU __ SYSTEM PUMP acre SENEOR OPTIONAL LOW VOLTAGE CONNECTOR al Ta sensor SENSOR OR swiren enw BEMAND SENSOR NS l Pa T 2 1 2 14 2 NO C 2 1 0v 1 2 E ann y gt i 4 9 2 Modulation of DHW generation SEPARATE CH amp DHW DEMAND WITH OPTIONAL DHW SENSOR CONTROL gt JE L z au z z N E E y ju _ p eJi O fafs ORANGE as __ GREY 9132 S wu BLUE AM _ BROWN FROM CH zZ 239 d M a CONTROLS z o O CHZONE O a z VALVE z 3 Q28H g 3 bal ORANGE M e a GREY a z z BOILER lz te a aroun CONTROLS 2 9 e 3 2 az gt p gt amp Lu lt 40 0 09 00 0 SYSTEM PUMP EXTERNAL SENSOR LOW VOLTAGE CONNECTOR ere ra SOL TS DHW FLOW OPEN ANALOG EXTERNAL GLA PA 7 DHW SENSOR SENSOR SENSOR SENSOR SWITCH THERM CHi SENSOR Mee Pt N 11211 2 NO C 2 1 PP 04 1 2 E Ny OPTIONAL AN vy TANK L__ Bett 4 i Installation amp Servicing Instructions Page 24 WD440 3 2007 Chapter 4 Installation The Keston Qudos 28h amp Qudos 28hP Boilers 4 10 4 9 3 Solar Control SOLAR CONTROL WITH DHW SENSOR INPUT al _ ORANGE p GREY BLUE M __ BROWN FROM CH 230V MAIN SUPPLY 3A FUSE
11. 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 1 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 E25 The boiler temperature is rising too fast ask your Service Engineer to check for system blockage or pump failure E26 The system water pressure is too low Check the system has water in and for sealed 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
12. Qudos 28hP 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 if on a sealed system 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 if on a sealed system 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 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 Installation amp Servicing Instructions Page 25 WD440 3 2007 Chapter 4 Installation The Keston Qudos 28h amp Qudos 28hP Boilers 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 Met
13. 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 e The integrity of the boiler combustion circuit and the relevant seals e 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 C 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
14. 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 Input must be within plus or minus 5 of the rated input Time in seconds the time taken to pass 2 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 28h natural gas 71 to 78 seconds 125 to 138 seconds Qudos 28hP 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
15. and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that e 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 e 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 e 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 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 CO 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 COz levels will be between 9 5 8 9 9 low rate and 10 3 amp 10 7 high rate an
16. and safe operation However larger clearances may be required during installation SERVICE CONNECTIONS Gas water air and flue pipe condensation and electrical connections are as shown in 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 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 POSITION The Qudos 28h and Qudos 28hP Combi 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 bath or shower The Qudos 28h and Qudos All dimensions in mm 300 When servicing appliance Figure 3 1 1 200 Minimum Clearances Figure 3 1 2 Dimensions All dimensions i Flue Exhaust Air
17. 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 and secured 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 below 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 WD440 3 2007 Chapter 4 Installat
18. condition E12 Flow overheat check water circulation is not blocked check system 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 system 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 SERVICE RESET REQUIRED E36 Flow thermistor 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 pres
19. constructed to comply with requirements of the Local Water Authority d Always use a system complying with the requirements 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 g Copper tubing to BS 2871 Part 1 or barrier plastic pipe suitable to 110 C such as Unipipe is recommended Installation amp Servicing Instructions Page 14 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers Air Vent L Hose Union KESTON X bibtap Qudos 28h Expansion Safety eee Relief 8 ale Valve x L S sA a T f V7 LJ lt I RETURN 1 By pass X HEATING CIRCUIT pe ZA Hosepipe DK gt FLOW disconnected after filling i K D lt e Dbl Check BS 1010 2 l 2 Valve X Stop Tap Hose Test Connector Cock Figure 3 7 1 Sealed Systems Diagram Figure 3 7 2 Open Vented Systems Diagram Expansion webct Pipe Expansion Tank Minimum 8ft Height KESTON Qudos 28h Cylinder 22mm Minimum X L S T Valve RETURN L Pump 3 By pass 3 Way AD
20. 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 Flue Terminal Wall Sealing Collar 50mm Air Terminal Wall Sealing Collar 50mm 50 75mm Flue Adapter Flue Outlet Terminal 75mm Air Inlet Terminal 75mm Stand Off Back Plate Keston Chronotherm Room Controller DHW Tank Sensor Solar Sensors Kit Panel sensor and 2 x DHW Tank Sensors Part Number C 08 0 00 07 0 C 08 0 00 07 0 C 17 2 00 60 0 C 17 2 26 00 0 C 17 2 26 00 0 Q 10H 0 01 00 0 C 17 4 21 00 0 Q 10S 0 04 00 0 Q 10S 0 05 00 0 Installation amp Servicing Instructions Page 8 WD440 3 2007 2 6 PERFORMANCE DATA Qudos 28h amp Qudos 28hP Chapter 2 General Instruction The Keston Qudos 28h amp Qudos 28hP Boilers ee Qudos 28h Qudos 28hP Nat Gas G20 LPG G31 Min Input Gross CV kW Btu h 7 8 26 600 7 6 26 000 Max CH Input Gross CV kW Btu h 29 4 100 300 28 8 98 300 Max CH Output To Water 80 60 C Flow Return kW Btu h 26 4 90 500 26 4 90 500 50 30 C Flow Return kW Btu h 28 4 96 900 28 4 96 900 Min CH Output To Water 80 60 C Flow Return kW Btu h 7 0 24 900 7 0 24 900 50 30 C 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 h
21. 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 C Advise that a reduction in the water pressure reading on 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 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 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers 6 1 6 FAULT FINDING ELECTRICAL CONTROL SEQUENCE When the main external control s are calling for heat power will be fed to the boiler connection strip at terminal SL1 Switched Live and N Neutral or
22. lockout 6 System water pressure in bar Minimum 0 2 bar The boiler will shut down if the water pressure drops below 0 2 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 external 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 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 i
23. mass and low water content and therefore responds faster when there is a call for heat The Qudos 28h features full user diagnostics integral frost protection Installation amp Servicing Instructions Page 4 WD440 3 2007 Chapter 2 General Instruction The Keston Qudos 28h amp Qudos 28hP Boilers 2 2 16 Return Connection 17 Control PCB 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
24. 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 instructions 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 Installation amp Servicing Instructions Page 19 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers 3 9 3 10 3 11 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 AIR SUPPLY The KESTON Qudos 28h and Qudos 28hP are room sealed appliances and therefore do not require purpose provided ventilation to the boiler room for combustion air 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 CONDENSATE DRAINAGE Being a condensing boiler the Qudos 28h and Qudos 28hP are fitted with a
25. the wall bracket lift the boiler via the back frame only Lower the boiler for hanging on the two pegs Fix the boiler on the bracket stud using the nut and the washers supplied Fit the condensate trap and secure in position 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 POSITION AND THE AIRING HOSE IS CONNECTED ON THE TOP 000 ta 4 3 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 4 4 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 Installation amp Servicing Instructions Page 21 WD440 3 2007 NB Note Chapter 4 Installation The Keston Qudos 28h amp Qudos 28hP Boilers When installing the boiler consider Flue Spigot Assembly The flue spigot 50mm muPVC is inside the accessory bag Put the flue spigot assembled with the test plug on the cabinet frame and secure it by fastening the two M6 screws Couple th
26. 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 to 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 a
27. 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 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 compensation 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 The Qudos 28h features an integral frost protection function which will operate the system pump regardless of the external controls should the boiler temperature fall below 10 C In the event the boiler temperature falls below 5 C the boiler will also fire This is to avoid damage to the boiler through freezing of boiler water The boiler will turn off when the flow temperature exceeds 15 C The Qudos 28h features a system pump exercise function which wil
28. El 3 E SSA al Ly JOSNIS ane SE YANNIS yal NY 4 7100 Joel Ios Ws or SABE AIMO pA ZHOS Avec z ii 92 40 gt vy e4 E gt Be Bi eo e Mia Lo a og ties ee pel ma Na AS a AR SS A E A 7 100 gt N p gt m E m fe W Z n ms ao Spa p VESTA ra E n dWNd avs JAVA SYD 1H 3 5 Y0 33194310 E pI 4o3 uoz g uo i 5 O WSLNOD 133453 43IMDd a did av 10S ps 1 Ly 30d kan I A 70 at 4aMOd NOIL93130 SWV14 p ni CNY NOILINSI ag gt AOLINOI AAWA SVI NIVA 35 Page Installation amp Servicing Instructions WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers RC yy 6 5 ELECTRICAL WIRING DIAGRAM SENSOR FLUE LEGEND f D a a ansyas 1x3 T anywad Smee rue wazh NID A i UU HOLEAS RV T
29. ION 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 Hot Flushing Page i WD440 3 2007 The Keston Qudos 28h amp Qudos 28hP Boilers E 5 7 Combustion Testing 5 8 Checking The Gas Pressure 5 9 Timing The Gas Meter 5 10 Handing Over To The User 6 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 7 SERVICING 7 1 Pre Service Checks 7 2 Recommended Routine Service 8 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 9 SPARE PARTS LISTINGS 10 GAS BOILER COMMISSIONING CHECKLIST Page ii WD440 3 2007 The Keston Qudos 28h amp Qudos 28hP Boilers AAA A 0 1 0 2 0 HANDLING INSTRUCTIONS LIST OF CONTENTS The Keston Qudos 28h and Qudos 28hP 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 intake systems The boiler is packed in a single box without additional fl
30. Intake 680 28hP are classified as IP20 IPXO and are therefore suitable for installation in Zone 3 areas unless subject to hose down TOP VIEW WM MMMM a 284 Je T Vdd E Installation amp Servicing Instructions WD440 3 2007 AAA 3 4 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers 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 28h 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 NB Refer to Section 3 8 3 Chimneys not used for venting any other appliance may be used Secure air flue pipes at chimney outlet Figure 3 3 ELECTRICAL 3 4 1 Electrical Connections The boiler mu
31. ONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS O THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS O IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDE A CO CO RATIO READING C0 CO YES LT amO 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 52 WD440 3 2007 Chapter 10 Benchmark Checklist Final The Keston Qudos 28h amp Qudos 28hP 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 bate 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 3 Date SERVICE 4 pate ENGINEER NAME ENGINEER NAME
32. alternatively demand may be conveyed to the boiler via the Opentherm or 0 10VDC input options and the radiator symbol with a 1 will appear in the top left of the display If the required 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 will start and the system pump will be energised 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 8 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 flame 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 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 an
33. ation of Gas Fired Hot Water Boilers of Rated Input Not Exceeding 70kW BS 5449 Z Installation Pumped Central Heating BS 5546 E Installation of Gas Hot Water Supplies for Domestic Purposes 2nd family gases BS 5440 1 E Flues for gas appliances of rated input not exceeding 70kW BS 5440 2 E Air Supply for gas appliances of rated input not exceeding 70kW BS 5482 1 Domestic Propane and Butane Burning Installations BS 7074 1 E Expansion Vessels BS 7593 E Treatment of Water in Hot Water Central Heating Systems BS 7671 k Requirements for Electrical Installations IEE Wiring Regulations 16th Edition BSEN 12828 2003 i Heating Systems in Buildings Design for water based heating systems BSEN 12831 2003 E Heating Systems in Buildings Method for calculation of design heat load BSEN 14336 2004 2 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
34. ature 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 tightness up to the gas burner Complete the Gas Boiler Commissioning Checklist Service Interval Record Chapter 10 Installation amp Servicing Instructions Page 44 WD440 3 2007 ee 8 Replacement Of Parts The Keston Qudos 28h amp Qudos 28hP 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 2 BOILER FLOW 8 RETURN THERMISTORS 8 4 3 CABINET TEMPERATURE SENSOR 8 44 FLUE THERMISTOR 8 45 WATER PRESSURE SWITCH 8 4 6 MAIN CONTROL PCB 8 4 7 COMBUSTION BLOWER 8 48 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 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 servic
35. binet 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 Page iii WD440 3 2007 The Keston Qudos 28h amp Qudos 28hP Boilers PA E a 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 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 store the appliance laid on its back with the casing on When ready to ha
36. by slackening the retaining strap and pulling the flue off the heat exchanger spigot Remove the condensate trap Section 8 8 Disconnect the flow and return pipe union nuts Fig 6 7 2 item 68 from the heat exchanger Remove the two screws Fig 6 7 2 item 66 fixing the heat exchanger to the top Remove the heat exchanger Reassemble Section 8 3 Recommission Section 5 Commissioning 8 8 CONDENSATE TRAP Fig 6 7 2 item 51 i i ii iv v vi vii Isolate the appliance Section 8 1 Gain access Section 8 2 Remove the two screws and washers Fig 6 7 2 items 76 and 77 fixing the condensate trap to the base of the cabinet Disconnect the condense line from the projection of the condensate trap from the base of the cabinet Disconnect the airing hose from the small spigot on the top of the trap Withdraw the condensate trap Mop up any spilled condensate Reassemble Section 8 3 NB When reassembling inspect the O ring Fig 6 7 2 item 73 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 Installation amp Servicing Instructions Page 48 WD440 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28h amp Qudos 28hP Boilers A 51 yyy 9 SHORT SPARE PARTS LIST Item GCNo Part Denomination Item GCNo Part Denomination 42 Burner KIT 64 Burner Gaske
37. d flue pipes can be passed Figure 3 8 2 Flue amp Air Maximum Length Example outside the building through only one wall or through two different walls 3 8 3 Slope Horizontal flue outlet pipework MUST slope at least 2 degrees 35mm per metre run downwards towards the boiler Pipework can be vertical Only swept elbows can be used Figure 2 8 3 Flue Condensate Drain Point Example To Terminal gt Air inlet pipework can be truly horizontal or 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 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 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 te
38. d 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 WD440 3 2007 Chapter 5 Commissioning The Keston Qudos 28h amp Qudos 28hP 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 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 28h 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 p
39. 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 28h 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 WD440 3 2007 Se 1 User Instructions The Keston Qudos 28h amp Qudos 28hP 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 As part of the industry wide Benchmark initiative Qudos 28 a boiler manual includes Gas Boiler Commissioning Checklist q enchma K 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 required in the event of any warranty work being requ
40. e 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 PROCEDURE 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 112 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 125 and item 124 iv Disconnect the Control Panel by unplugging the cable connector v Remove the Control Panel by removing the four retaining screws Fig 6 7 1 item 141 vi Reassemble Section 8 3 vii Check for correct operation of the Control Panel Installation amp Servicing Instructions Page 45 WD440 3 2007 ee 8 Replacement Of Parts The Keston Qudos 28h amp Qudos 28hP 8 4 2 8 4 3 8 4 4 8 4 5 8 4 6 8 4 7 Boiler Flow and Return Thermistors Fig 6 7 2 item 48 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the push on connectors from the thermistor taking note
41. e 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 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
42. e two output points when the boiler is in lockout Installation amp Servicing Instructions Page 13 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers 3 5 3 6 3 7 BOILER SIZE SELECTION The Qudos 28h will automatically adjust heat output 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 28h is therefore suitable for all systems with a total heat load within the maximum range of the boiler 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 app
43. eaning 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 28h 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 y 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 WD440 3 2007 Sen 1 User Instructions The Keston Qudos 28h amp Qudos 28hP Boilers Normal
44. ed 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 29 Installation amp Servicing Instructions Page 27 WD440 3 2007 Chapter 5 Commissioning The Keston Qudos 28h amp Qudos 28hP Boilers 5 6 5 7 RESET button so that the display reverts to show the 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 over
45. ent 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 E67 Water pressure is lt 0 2bar 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 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers pa 5 yyy ERROR HISTORY The Qudos 28h 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 Show Errors and then press the ENTER button you will en
46. er Combustion Testing It is advisable on all installations that the combustion quality is checked by measuring the carbon dioxide CO2 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 WD440 3 2007 Chapter 5 Commissioning The Keston Qudos 28h amp Qudos 28hP 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 type 5 1 5 2 5 3 5 4 5 5 INITIAL FLUSHING All waterways within the Keston Qudos 28h and Qudos 28hP 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 dir
47. ermal 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 28h 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 or open vented water central heating system with fully pumped circulation 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 The Qudos 28h is not a high water content boiler and does not contain the metal mass or water volume of a cast iron or steel boiler This boiler is of low
48. 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 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 increasing the boiler efficiency further by releasing the latent heat of condensation This condensate falls to the 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 Installation amp Servicing Instructions Page 5 WD44 2007 hapter 2 neral Instruction The Keston 28h 28hP Boiler The flue gases are piped in a 50 mm muPVC BS5255 and or and
49. 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 a blocked air inlet Any breakage or damage to the burner mesh indicates the burner must be replaced Installation amp Servicing Instructions Page 43 WD440 3 2007 So Chapter 7 Servicing The Keston Qudos 28h amp Qudos 28hP 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 temper
50. gas inlet pipe to the gas control valve v Unscrew the bolts securing the gas valve Fig 6 7 3 item 106 to the inlet port of the combustion blower vi Remove the gas valve venturi assembly as a complete unit vii Unscrewing 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 Overheat Thermostat Fig 6 7 2 item 47 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 item 60 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 8 5 SPARK IGNITION FLAME DETECTION ELECTRODE Fig 6 7 2 item 43 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 item 56 and withdraw the spark ignition electrode Reassemble
51. he cylinder The Keston qSpa 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 28h 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 sealed systems only 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 3 8 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 f 5255 In addition the flue outlet and air intake Flue Outlet Air Inlet Terminals pipe work must be marked BSEN 1566 1 and Figure 3 8 1 Terminals the fittings must be marked BSEN 1329 Marley muPVC Solvent Weld Waste System 50mm and Polypipe System 2000 muPVC Solvent Weld Waste System 50mm are recommended DO NOT USE ABS PIPE OR FITTINGS 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 stockis
52. heat 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 lf 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 condensate 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 Cs 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
53. iler and the system controls 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 Controls 1 The boiler is designed so that all control wiring is external to the boiler 2 Heating control signal inputs must the 230VAC switched live type unless using a Keston Room Controller see below or 0 10VDC input 3 The system pump must also be wired back to the boiler to enable the boiler to provide pump overrun and pump exercise function 3 4 2 1 Enhanced Control Options The Qudos 28h can be wired into a conventional heating installation using only permanent and switched live connections and pump connection However the Qudos 28h 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 28h 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 a
54. ion The Keston Qudos 28h amp Qudos 28hP 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 will 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 WALL MOUNTING BRACKET a Place the bracket on the wall horizontally with the All dimensions in mm pre drilled holes at the bottom and position as 4593 dictated by the template lt O O O O O O supplied within the boiler packaging b Drill through the centre hole of the bracket plug the hole and fix in position Cc Using a spirit level make sure the bracket is completely level and mark the position of the other screw holes d Remove the bracket and drill the holes in the positions marked Plug these holes e Screw the bracket to the wall using screws of an appropriate size for the wall type No 12 x 2 inch wood Figure 4 1 Wall Mounting Fixing Locations screws normally suffice N 4 2 MOUNTING THE BOILER after system cleaning and testing a Lift and locate the boiler onto the stud and the two locating pegs protruding from
55. ipe 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 Ensure that there is a proper electrical supply i e 230V fused at 3A for the permanent live g Ensure that the system pump is wired back to the System Pump connections in the boiler J Take great care with pipe connections to ensure that no damage is done to the internal pipework M Ensure that the 22mm condensate pipe is not exposed to freezing conditions Make sure that the exhaust pipe terminates away from windows or vents and is out of reach A Make sure that the air inlet and exhaust pipe outlets are at least 200mm apart Check tightness of all connections in the boiler before firing Ensure that the terminals supplied are fitted to both the exhaust and air inlet pipes r The system must be free from air before firing If TRV s are installed on radiators ensure that a bypass is installed to maintain required flow g Complete the Gas Boiler Commissioning Checklist Service Interval Record Chapter 10 id Complete the combustion testing Section 5 7 using a calibrated flue gas analyser
56. ired 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 WD44 2007 hapter 2 neral Instruction The Keston 28h 28hP Boiler 2 GENERAL INSTRUCTION 2 1 DESCRIPTION The KESTON Qudos 28h and Qudos 28hP boilers utilise the latest in condensing technology to produce a high efficiency boilers with SEDBUK A rated efficiency plus advance controls to maximise operational efficiency The Qudos 28h is unique in concept and design It comprises a high efficiency stainless steel heat exchanger coupled with a low em
57. issions 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 Qudos 28h 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 28h is developed with the concept that the gas boiler in the modern home is often supplemented by alternative or renewable energy sources As a result the Qudos 28h features optional connection of a solar thermal system pump panel and DHW sensor for direct control of solar th
58. ith 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 100 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 8 Servicing Instructions Page 29 WD440 3 2007 Chapter 5 Commissioning The Keston Qudos 28h amp Qudos 28hP 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
59. l run the pump without 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 system pump due to long periods of inactivity FLUE AR EXHAUST INLET A TESTING POINT THERMAL FUSE 2 3 RELATED DOCUMENTS y The Keston Qudos 28h a p and Qudos 28hP Wmo AR VENT Condensing Boilers must be installed in accordance with the current issue of the Gas Safety Installation and Use Regulations 1996 current IEE Wiring Regulations BURNER N CNITOR Building Regulations FLUE MER Building Standards biien A Scotland Consolidation A and the Bye Laws of the local Water Undertaking 5 It is the law that ALL gas REUN appliances are installed by in a competent person in accordance with the above regulations C N In addition due account must be taken to the following Codes Of CONDENSATE Practice J gt gt a FLOW CONDENSATE GAS RETURN Installation amp Servicing Instructions Page 6 WD440 3 2007 Chapter 2 General Instruction The Keston Qudos 28h amp Qudos 28hP Boilers A yyy BS 6891 Low Pressure Installation Pipes BS 6798 Z Install
60. liances 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 meter 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 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 1S813 and the current Building Regulations must be followed a The Keston Qudos 28h is designed for installation on sealed or open vented water systems With fully pumped water circulation 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
61. n 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 Keston 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 28h 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 28h 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 Analogue 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 lt 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 th
62. ng 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 35 kg 77 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 Lift the 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 f 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 28h and Qudos 28hP boilers can be fitted in compartments with very small clearances required around the appliance refer to Section 3 1 D
63. 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 the pipe ensures a good contact Cabinet Temperature Sensor Fig 6 7 1 item 132 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 item 49 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 Water Pressure Switch Fig 6 7 2 item 74 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 connectors from the pressure switch vi Unscrew the pressure switch vii Reassemble Section 8 3 NB Use a li
64. oint 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 1 200 100 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 terminates 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 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
65. r 0 76 96 6 0 35 45 0 Max Operating Flow Temp C 82 82 Max Press Sealed System bar 2 70 2 50 Min Press Head Open System bar 0 25 8 feet 0 25 8 feet 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 80 80 Power Consumption Standby W 8 5 8 5 Type of Gas G20 Natural Gas G31 LPG Optimum Flue Gas CO Level at max CH rate case on 9 1 0 2 10 5 0 2 Expected CO CO2 Ratio at max CH rate case on 0 0007 0 001 Destination Countries GB IE GB IE SEDBUK Efficiency 91 1 93 1 NOx Class 5 5 Seasonal Efficiency SEDBUK 91 1 Qudos 28h amp 93 1 Qudos 28hP 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 28h is intended for domestic and commercial EMC environments and on a governed G20 meter supply The Qudos 28hP 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
66. r of the boxes TIME amp TEMPERATURE CONTROL TO ROOM T STAT amp PROGRAMMABLE ROOMSTAT C HEATING PROGRAMMER TIMER H TIME amp TEMPERATURE CONTROL TO HOT CYLINDER T STAT amp WATER PROGRAMMER TIMER H COMBI BOILER L HEATING ZONE VALVES FITTED LI NOT REQUIRED LJ HOT WATER ZONE VALVES FITTED CJ NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED LJ AUTOMATIC BYPASS TO SYSTEM FITTED LI NOT REQUIRED LI FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS O THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE E Co f BURNER OPERATING PRESSURE IF APPLICABLE Ls mbr CENTRAL HEATING FLOW TEMPERATURE Ld C CENTRAL HEATING RETURN TEMPERATURE Ld C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES NO O WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE O 7 mr EE f MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE L Imba COLD WATER INLET TEMPERATURE pb JC HOT WATER OUTLET TEMPERATURE E WATER FLOW RATE LJ its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES LI FOR ALL INSTALLATIONS C
67. re provided in Chapter 3 Section 3 11 Condensate Drainage Connection 22mm plastic pipe Installation amp Servicing Instructions Page 22 WD440 3 2007 Chapter 4 Installation The Keston Qudos 28h amp Qudos 28hP 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 Systems 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
68. recede as follows 1 2 3 4 5 6 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 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 8 with a corresponding CO level of 5 to 20 ppm for natural gas and 9 5 to 9 9 w
69. required flow x rate for the boiler against the pressure 1 4 losses contributed by the boiler A Osa bo The Keston Qudos 28h condensing 0 10 20 30 40 50 60 boiler offers a hydraulic resistance of lit min 2 9m 9ft water at the required flow rate of 36 l m 7 9 gpm See graph opposite If a single pump is to be used for the entire installation the boiler resistance must be added to the pressure loss caused by the rest of the system and a pump selected that is Installation amp Servicing Instructions Page 16 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers eee capable of meeting the flow rate required at the total pressure loss generated by the boiler and the rest of the system The selected pump must comply with BS 1394 It is important to note that the minimum flow rate must be maintained whenever the boiler is firing Systems using zone valves must be specifically designed to only fire the boiler when the pump is running and the minimum flow rate can be achieved 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 t
70. restoration of water pressure indicates a system leak which should be investigated 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 or the open vent 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 is not 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 For sealed systems raise up the system pressure until error 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 blockage or obstruction is present in the condensate
71. rminals 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 boiler room invalidates the heat exchanger warranty Installation amp Servicing Instructions Page 18 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers ee 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 28h and Qudos 28hP 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 p
72. s Assembly Fig 6 7 3 Q 108 2 07 00 0 GC Number Code Description 91 Combustion Blower Q 10S 3 01 00 1 163 Q28h Gas Valve Mixer Air Gas Assembly Q 10S 3 04 00 0 163 Q28hP Gas Valve Mixer Air Gas Casing Assembly Fig 6 7 4 Assembly Q 10S 3 05 00 0 GC Number Code Description 2 Cabinet Cover Assy Q 10H 0 04 00 0 A 7 Databadge NG Q 10H 1 00 03 0 7 Databadge LPG Q 10H 1 00 03 1 E73 355 16 Combustion Test Plug B 04 2 00 49 1 Installation amp Servicing Instructions Page 42 WD440 3 2007 Chapter 7 Servicing The Keston Qudos 28h amp Qudos 28hP 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 28h and Qudos 28hP 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
73. s indicated by the inverted T symbol on the bottom row of the display Installation amp Servicing Instructions Page 32 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP 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 required 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 Boiler 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
74. so be used to show other information about the operation of the boiler Press the A button repeatedly until the display shows SHP Show Parameters 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 Seq No Meaning 1 The flame current in micro amps detected from the burner should be lt 1 when off and gt 2 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 temperature may lead to overheat and noise problems Check the system 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
75. st be connected to a permanent 230V 50Hz supply fused at 3A 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 waiter 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 Further the boiler can be driven by an external 0 10VDC input Wiring external to the boiler must be in accordance with current 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 BS 1363 There must be only one common method of isolation for the boiler and its control system Installation amp Servicing Instructions Page 12 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers 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 bo
76. t 55 Ignitor Gasket 43 Ignitor KIT 48 Flow Return Thermistors 49 Flue Thermistor 47 Flow Overheat Thermostat 74 Water Press Switch Installation amp Servicing Instructions Page 49 WD440 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28h amp Qudos 28hP Boilers 163 Q28h Gas Valve Mixer Assem 91 Fan Q28hP Gas Valve Mixer Assem 112 Control Panel 111 Q28h Control PCB Q28hP Con PCB Installation amp Servicing Instructions Page 50 WD440 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28h amp Qudos 28hP Boilers yyy SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination 42 Burner KIT 64 Burner Gasket 43 Ignitor KIT 55 Ignitor Gasket 48 Flow Return Thermistor 49 Flue Thermistor 47 Flow Thermostat 74 Water Pressure Switch 91 Fan 163 Gas Valve Mixer Air Gas Assembly NG Q28s 163 Gas Valve Mixer Air Gas Assembly LPG Q28sP 112 Control Panel 111 Control PCB NG Q28h 111 Control PCB LPG Q28hP Installation amp Servicing Instructions Page 51 WD440 3 2007 Chapter 10 Benchmark Checklist Final The Keston Qudos 28h amp Qudos 28hP Boilers 10 GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No henchman 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 othe
77. t 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 e Earth continuity Polarity Resistance to Earth Short Circuit using a suitable test meter LP GAS The Keston Qudos 28h and Qudos 28hP are supplied preset for the gas designated on the boiler packing LPG installations must use Q28hP models 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 establish
78. t 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 water 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 Q28h hydraulic resistance elimination when filling the system and A will allow re venting in a day or so after 7 all air has been driven out of solution 3 7 3 Pump Selection gt i The Keston Qudos 28h and Qudos 28hP 5 boilers have low water content heat exchangers with a high resistance to flow when compared with cast iron heat Q 4 exchanger boilers As a result selection 7 of the correct pump is essential in order 3 s to avoid localised boiling within the heat Z exchanger The selected pump must be 2 x capable of maintaining the
79. t 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 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 Installation amp Servicing Instructions Page 17 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers AAA 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 KESTON Qudos 28h Flue outlet uses one 92 5 sweep elbow Hence maximum length permissible i e c d in figure 3 8 2 20 0m 1 0 m 19 0m NB The air an
80. ter 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 Seq 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 system 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 Minimum 0 2 bar The boiler will shut down if the water pressure drops below O 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 R
81. th CH Demand SL1 230V Switched Live i e Room Thermostat System Pump L Brown wire Live to system pump System Pump N Blue wire Neutral to system pump System Pump E Yellow Green wire Earth to system pump Ensure connection is made such that if the cable slips in its anchorage the current carrying conductors become taut before the earthing conductor Installation amp Servicing Instructions Page 23 WD440 3 2007 Chapter 4 Installation The Keston Qudos 28h amp Qudos 28hP Boilers 4 9 Advanced Features Wiring The Qudos 28h features comprehensive and advance functionality as standard Whilst these advances functions are not mandatory they will provide enhanced boiler operation performance and efficiency Detailed below are suggested wiring methods to activate various functions 4 9 1 Twin Thermostat Operation with Weather Compensation SEPARATE CH amp DHW DEMAND WITH OPTIONAL WEATHER COMPENSATION gt gt L L ay gt z5 z a N 3 E y i i Eji O ae ORANGE f F gt rev 53d 4 5 A 2 Ww a
82. ttle jointing compound or PTFE tape on the thread viii Refill the system See Section 5 Commissioning Main Control PCB Fig 6 7 1 item 111 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Pull off the multi pin connectors and HT lead away from the board lv Remove the box by removing the retaining screw Fig 6 7 4 item 10 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 Combustion Blower Fig 6 7 3 item 91 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Disconnect the connector block from the combustion blower Installation amp Servicing Instructions Page 46 WD440 3 2007 8 4 8 8 4 9 Chapter 8 Replacement Of Parts _ The Keston Qudos 28h amp Qudos 28hP iv Unscrew the bolts Fig 6 7 3 item 94 securing the gas inlet pipe to the gas control valve v Remove the four nuts securing the combustion blower fig 6 7 3 item 100 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 163 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 94 securing the
83. uctions Page 40 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers ee 6 7 4 Casing Assembly Installation amp Servicing Instructions Page 41 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers A yyy 6 7 5 Exploded Diagrams Parts Reference List Boiler Controls Assembly Fig 6 7 1 GC Number Code Description 111 Q28h Main Control PCB Q 10S 4 01 00 0 F 111 Q28hP Main Control PCB Q 10S 4 15 00 0 F 112 Control Panel Q 10S 4 02 00 0 E72 401 132 Thermal Fuse C 08 4 21 00 0 113 Ignitor Cable C 17 4 19 00 0 Waterway Condensate amp Flue Assembly Fig 6 7 2 GC Number Code Description 41 Heat Exchanger Assy Q 10S 0 11 00 0 42 Burner Kit Q 10S 0 10 00 0 64 Burner Head Gasket C 10C 2 00 45 0 A 55 Ignitor Gasket C 10C 2 00 52 0 A 43 Ignitor Kit Q 10S 0 09 00 0 51 Condensate Trap Kit Q 10H 0 06 00 0 48 Flow Return Thermistor Q 10S 2 08 00 0 49 Flue Sensor Q 10S 2 09 00 0 114 045 74 Water Pressure Switch B 04 2 23 00 0 47 Flow Overheat Thermostat Air Ga
84. ue consideration should therefore be given to access within the compartment for lifting and positioning Page iv WD440 3 2007 Se 1 User Instructions The Keston Qudos 28h amp Qudos 28hP Boilers 1 1 1 2 1 3 1 USER INSTRUCTIONS INTRODUCTION Thank you for choosing this Keston Qudos 28h 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 28h 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 28h or Qudos 28hP The Qudos 28h model is for use with natural gas only the Qudos 28hP 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 305mm Extended clearance is required to the front for servicing Cl
85. ue 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 the cabinet shell by removing the two retaining screws in the top of the ca
86. un 8 Postpurge 9 Inter Purge 12 Lockout 9 Time in hours since last error occurred Installation amp Servicing Instructions Page 34 The Keston Qudos 28h amp Qudos 28hP Boilers Chapter 6 Fault Finding WD440 3 2007 FUNCTIONAL FLOW WIRING DIAGRAM 6 4 y 5 al J aici IV a me am o 2 z So ge 23 25 83 Bg T a 28 2 92 80 6 ar z z 318 2 8 aosnas moy A Irm ay JOSN3S Nanay 4 gt y AVY IdSId s ro A 202X mms EM om eros 7 a aida y CICA YAS SRS 30OSN3S 30713 cml A alle o a EMS SAS i d _ a a Ma HT 3 IO s 3409 WAIT ans IRS B l yyy Y Y y y 5 8 THD OWA m Wa3H1 o g a i daad SXOSNIS ONG S1ivis AVLS ao7 N340 a io 4 12 uon gt uon 02 od 11 uoa ET uoo uon 402 e uo gt a f
87. ve As part of the industry wide Benchmark initiative Qudos 28h 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 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 WD440 3 2007 Chapter 3 Boiler Location The Keston Qudos 28h amp Qudos 28hP Boilers 3 1 3 2 3 3 3 BOILER LOCATION DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown to allow subsequent servicing
88. 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 WD44 2007 hapter 2 neral Instruction The Keston 2 4 PHYSICAL DATA Qudos 28h amp Qudos 28hP Cabinet Height Cabinet Width Cabinet Depth Top Clearance Side Clearance Base Clearance Front Clearance for servicing Weight Full Weight Empty Flow and Return Connection Gas Connection Condensate Connection overflow IP Rating 28h 28hP Boiler 680 390 280 150 5 200 300 39 86 35 77 G3 4 G1 2 22mm plastic IP20 IPX0 Flue and Air Intake Material 50mm muPVC BS5255 and or BSEN1566 1 and BSEN1329 Flue Pipe Size nominal bore mm in Air Intake Pipe Size nominal bore mm in Max Air Intake Length m Max Flue Outlet Length m Max Total Flue Outlet and Air Intake Length m 50 2 50 2 39 20 40 Flue and Air Intake Material 75mm Keston Composite Flue Pipe Size nominal bore mm in Air Intake Pipe Size nominal bore mm in Max Air Intake Length Max Flue Outlet Length Max Total Flue Outlet and Air Intake Length 2 5 OPTIONAL ACCESSORIES 75 3 75 3 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
89. y 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 the checks earth continuity polarity short circuit resistance to earth must be repeated Installation amp Servicing Instructions Page 31 WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h amp Qudos 28hP Boilers A yyy oa QUICK REFERENCE 6 2 NORMAL OPERATION The Qudos 28h and Qudos 28hP boilers feature a user display which shows actual flow temperature However the display can al

Jan12_Q28h Manual 8-2011

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