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Keston 41-930-19, User, Installation And Servicing Instructions

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Keston 41-930-19 User, Installation And Servicing Instructions Download Page 20

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WD440/3/2007 

        

Chapter 3 - Boiler Location 

The Keston Qudos 28h & Qudos 28hP Boilers

Installation & Servicing Instructions

Page  :  15

Pump

Valve

Safety
Relief

Valve

bib tap

Hose Union

Hose

Stop Tap

BS 1010:2

RETURN

HEATING CIRCUIT

FLOW

Cock

Test

Connector

after filling)

(disconnected

Hosepipe

Vessel

Expansion

KESTON

Qudos 28h

Dbl Check

By-pass

Cock

Drain

Figure 3.7.1:  Sealed Systems Diagram

L/S

Air Vent

RETURN

Rad. 2

Rad. 1

FLOW

Expansion
Pipe

Valve

L/S

Minimum
8ft Height

Minimum

22mm

Tank

Expansion

Cylinder

KESTON

Qudos 28h

Pump

Figure 3.7.2 :  Open Vented Systems Diagram

Valve

By-pass

3-Way
Valve

Summary of Contents for 41-930-19

Page 1: ...1 930 19 Qudos 28hP GC No 41 930 20 These instructions must be left either with the user or next to the site gas meter 34 West Common Road Hayes Bromley Kent BR2 7BX Tel 44 0 20 8462 0262 Fax 44 0 20...

Page 2: ...Optional Accessories 2 6 Performance Data 3 BOILER LOCATION 3 1 Dimensions Minimum Clearances 3 2 Service Connections 3 3 Position 3 4 Electrical 3 5 Boiler Size Selection 3 6 Gas Supply 3 7 Water Sys...

Page 3: ...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 Replac...

Page 4: ...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 50 mm muPVC Pipe...

Page 5: ...ts durring 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 A...

Page 6: ...cloth and finish with a dry cloth 1 3 BOILER SETUP 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...

Page 7: ...f fault Display The above is an abbreviated list of possible error codes If the code is not in the list above consult a CORGI registered engineer A full list of codes can be found in Chapter 6 of this...

Page 8: ...red 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 pl...

Page 9: ...s As a result the Qudos 28h features optional connection of a solar thermal system pump panel and DHW sensor for direct control of solar thermal system from the boiler Other additional energy source s...

Page 10: ...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...

Page 11: ...t protection function which will operate the system pump regardless of the external controls should the boiler temperature fall below 10o C In the event the boiler temperature falls below 5o C the boi...

Page 12: ...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 acc...

Page 13: ...ngth m 120 2 5 OPTIONAL ACCESSORIES A range of accessories are available from Keston Boilers Ltd to compliment an installation Terminal wall sealing collars are available to make good the external all...

Page 14: ...hould 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 servic...

Page 15: ...d 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 co...

Page 16: ...m 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...

Page 17: ...hed live 230VAC signal inputs such as heating and hot water Alternatively a Keston Room Controller can be connected directly via two core low voltage cable to the terminals marked OT The Keston Room C...

Page 18: ...applications Weather Compensation Ext Sensor A Keston outside temperature sensor may be connected as an option The boiler will automatically detect this connection and will operate on a weather compe...

Page 19: ...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...

Page 20: ...0 2 RETURN HEATING CIRCUIT FLOW Cock Test Connector after filling disconnected Hosepipe Vessel Expansion KESTON Qudos 28h Dbl Check By pass Cock Drain Figure 3 7 1 Sealed Systems Diagram L S Air Vent...

Page 21: ...valves are used The flow return differential should be 10o C to 20o 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...

Page 22: ...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...

Page 23: ...n 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 hori...

Page 24: ...ust not terminate at a level above that of the flue If either the air inlet or flue outlet terminate at a height of less than 2 1m above ground level the terminal must be protected by a suitable guard...

Page 25: ...roperty 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...

Page 26: ...MOUNTING THE BOILER after system cleaning and testing a Lift and locate the boiler onto the stud and the two locating pegs protruding from the wall bracket lift the boiler via the back frame only b Lo...

Page 27: ...complete the two terminations See Section 3 8 Flue System and make good all holes wall sealing collars are available to make good hole areas on the wall face part number C 08 0 00 07 0 g Support any...

Page 28: ...ection 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...

Page 29: ...VALVE DHW ZONE VALVE CH ZONE BROWN GREY BLUE ORANGE M 3A FUSE 230V MAIN SUPPLY E N L BOILER MAIN CONNECTOR LOW VOLTAGE CONNECTOR Q28H E THERM SWITCH C 2 1 CH1 1 0 10V 0v 2 SENSOR 1 2 SENSOR 2 SENSOR...

Page 30: ...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...

Page 31: ...ng The Gas Meter Combustion Testing It is advisable on all installations that the combustion quality is checked by measuring the carbon dioxide CO2 or oxygen O2 level This procedure is detailed in Sec...

Page 32: ...ushed cold again before proceeding e Reduce the pressure to the Initial System Design Pressure Vent the system 5 2 GAS SUPPLY The complete gas installation up to the boiler service cock must be checke...

Page 33: ...lthough 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 fro...

Page 34: ...til 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 r e p e a t the process again from...

Page 35: ...cal 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 re...

Page 36: ...al 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...

Page 37: ...levant if an outside temperature sensor is detected 7 System water pressure in bar Minimum 0 2 bar The boiler will shut down if the water pressure drops below 0 bar 6 Actual Flue Temperature display i...

Page 38: ...connected E37 Flow thermistor open circuit not connected check the connections and wires to the flow thermistor are intact and connected E36 Flue thermistor closed circuit check the connections and wi...

Page 39: ...e 12 Lockout 8 Outside temperaure display indicates a small graph on the bottom row NB Only relevant if an outside temperature sensor is detected 7 System water pressure in bar Minimum 0 2 bar The boi...

Page 40: ...6 4 FUNCTIONAL FLOW WIRING DIAGRAM WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 35...

Page 41: ...6 5 ELECTRICAL WIRING DIAGRAM WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 36...

Page 42: ...6 6 ILLUSTRATED WIRING DIAGRAM WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 37...

Page 43: ...6 7 Exploded Assembly Diagrams 6 7 1 Boiler Controls Assembly WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 38...

Page 44: ...6 7 2 Waterway Condensate Flue Assembly WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 39...

Page 45: ...6 7 3 Air Gas Assembly WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 40...

Page 46: ...6 7 4 Casing Assembly WD440 3 2007 Chapter 6 Fault Finding The Keston Qudos 28h Qudos 28hP Boilers Installation Servicing Instructions Page 41...

Page 47: ...9 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 Q 10S...

Page 48: ...ess 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 ther...

Page 49: ...e flue pipe This is situated on the flue spigot out of the cabinet j Carry the full procedure detailed in section 5 7 COMBUSTION TESTING MANDATORY k Replace the combustion test point plug l Recheck th...

Page 50: ...the User Controls to Standby Shut off the power supply at the isolating switch before working on the appliance 8 2 ACCESS i Remove the cabinet by removing the screws to the top and bottom of the cabi...

Page 51: ...ilm of heat sink compound between the thermistor and plate This combined with fitting the new thermistor tightly to the plate ensures a good contact 8 4 5 Water Pressure Switch Fig 6 7 2 item 74 i Iso...

Page 52: ...n 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...

Page 53: ...he top xii Remove the heat exchanger xiii Reassemble Section 8 3 xiv Recommission Section 5 Commissioning 8 8 CONDENSATE TRAP Fig 6 7 2 item 51 i Isolate the appliance Section 8 1 ii Gain access Secti...

Page 54: ...Burner KIT 64 Burner Gasket 55 Ignitor Gasket 43 Ignitor KIT 48 Flow Return Thermistors 49 Flue Thermistor 47 Flow Overheat Thermostat 74 Water Press Switch WD440 3 2007 Chapter 9 Spare Parts Listings...

Page 55: ...r Assem 91 Fan Q28hP Gas Valve Mixer Assem 112 Control Panel 111 Q28h Control PCB Q28hP Con PCB WD440 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28h Qudos 28hP Boilers Installation Servici...

Page 56: ...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 Cont...

Page 57: ...E MEASURE RECORD GAS RATE m3 hr ft3 hr BURNER OPERATING PRESSURE IF APPLICABLE N A mbar CENTRAL HEATING FLOW TEMPERATURE O C CENTRAL HEATING RETURN TEMPERATURE O C FOR COMBINATION BOILERS ONLY HAS A W...

Page 58: ...GNATURE SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE...

Page 59: ...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 Make sure that the air inlet and exhaust pipe outlets a...

Page 60: ...00 0 with the LPG gas valve venturi assembly part number Q 10S 3 05 00 0 according to section 8 4 8 v Check the gas rate and combustion MANDATORY Although the gas pressure is preset at the factory it...

Page 61: ...produce a CO2 reading of 10 3 10 7 with a corresponding CO level of 50 150 ppm 4 Press the RESET button once and then press the ENTER button Use the button until the display shows 32 30 for LPG Press...

Page 62: ...0 with the NG gas valve venturi assembly part number Q 10S 3 04 00 0 according to section 8 4 8 v Check the gas rate and combustion MANDATORY Although the gas pressure is preset at the factory it is r...

Page 63: ...t if necessary the adjustment screw pos 4 to produce a CO2 reading of 8 9 9 3 with a corresponding CO level of 50 150 ppm 4 Press the RESET button once and then press the ENTER button Use the button u...

Page 64: ...s Carbon dioxide and carbon monoxide are colorless odorless gases produced by all combustion processes When the Keston condensing boiler is operating properly carbon dioxide CO2 levels will be between...

Page 65: ...will be locked on at Minimum rate If no further buttons are pressed for 10 minutes the boiler will automatically revert to normal operation 5 Measure the CO2 reading in the flue gases The CO2 reading...

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