Keston Qudos 37 User'S Installation Manual Download Page 1

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Qudos

udos

udos 3

Fan Powered High Efficiency

Modulating Domestic Condensing Gas Boiler

User, Installation and Servicing Instructions

ISSUE: 3/2010

Q37 & Q37P Models

CE/PI No : 87BQ006

Q37 - GC No : 41-930-23

Q37P - GC No : 41-930-24

These instructions must be left either with

the user or next to the site gas meter.

34 West Common Road

Hayes, Bromley, Kent BR2 7BX

Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459

email : [email protected] web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

WD500

The Keston Q37 & Q37P Boilers

Summary of Contents for Qudos 37

Page 1: ...Models CE PI No 87BQ006 Q37 GC No 41 930 23 Q37P GC No 41 930 24 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 4...

Page 2: ...cription 2 2 Boiler Schematic 2 3 Related Documents 2 4 Physical Data 2 5 Optional Accessories 2 6 Performance Data Q37 and Q37P 3 BOILER LOCATION 3 1 Dimensions Minimum Clearances 3 2 Service Connect...

Page 3: ...ult 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 Serv...

Page 4: ...MENDED 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 i...

Page 5: ...ppliance and keep the boiler as close to the body as possible d Lift the boiler and locate onto the two studs of the wall mounting bracket e Place the wall mounting bracket washers over the bracket st...

Page 6: ...learance is required to the front for servicing 300mm Cleaning Normal case cleaning only requires dusting with a dry cloth To remove more stubborn marks wipe with a damp cloth and finish with a dry cl...

Page 7: ...een shut down that there is no air in the system and that the water pressure is correct E03 False flame There is possibly a problem with the power supply E02 Ignition failure the boiler has attempted...

Page 8: ...ER 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 BOILE...

Page 9: ...to outside atmosphere via a small diameter plastic intake pipe The cabinet therefore remains under negative pressure at all times the boiler is operating The boiler is suitable for connection to open...

Page 10: ...ue 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...

Page 11: ...s appliances are installed by a competent person in accordance with the above regulations In addition due account must be taken to the following Codes Of Practice BS 6891 Low Pressure Installation Pip...

Page 12: ...e and Air Intake Material 75mm Keston Composite Flue Pipe Size nominal bore mm in 75 3 Air Intake Pipe Size nominal bore mm in 75 3 Max Air Intake Length m 117 Max Flue Outlet Length m 60 Max Total Fl...

Page 13: ...9 0 30 700 Max Input Gross CV kW Btu h 38 0 129 700 37 0 126 300 Max Output To Water 80 60o C Flow Return kW Btu h 33 6 114 700 33 6 114 700 50 30o C Flow Return kW Btu h 37 0 126 300 37 0 126 300 Mi...

Page 14: ...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 y...

Page 15: ...ction 2 5 Optional Accessories 3 3 POSITION The Q37 and Q37P are not suitable for external installation The boiler may be installed in any room or internal space although particular attention is drawn...

Page 16: ...a cellar 3 4 ELECTRICAL 3 4 1 Electrical Connections The boiler must be connected to a permanent 230V 50Hz supply fused at 3A The boiler can be wired to a single switched live 230VAC input However th...

Page 17: ...nnected as an option The boiler will automatically detect this connection and will operate on a weather compensation basis when receiving a heating demand signal from the SL1 terminal or from a Keston...

Page 18: ...are included in the system c 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 o...

Page 19: ...em is shown in Figure 2 7 2 It must include i A safety valve fitted on the flow adjacent to the boiler It must be non adjustable and preset to 3 bar A drain pipe must be attached at least as big as th...

Page 20: ...tres 39 0 27 2 20 8 250 litres 35 1 24 5 18 7 225 litres 31 2 21 8 16 7 200 litres 27 3 19 1 14 6 175 litres 23 4 16 3 12 5 150 litres 19 5 13 6 10 4 125 litres 15 6 10 9 8 3 100 litres 11 7 8 2 6 3 7...

Page 21: ...ions built in which enable modulated reheat of DHW Refer to Chapter 4 for more detail 3 7 5 Air Elimination In the initial charge of water to the boiler system and in all subsequent additions of water...

Page 22: ...ow the water pressure in bars Using the filling loop set the pressure to 1 0 to 2 0 bar WD500 Chapter 3 Boiler Location The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 17 Diagram...

Page 23: ...m 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 Boilers stockist Request part n...

Page 24: ...izontally 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...

Page 25: ...ipes 50 300 A Below above or beside openable window air brick etc Air Inlet Flue Terminal Dimensions mm The dimensions given in the table above may need to be increased to avoid wall staining and nuis...

Page 26: ...in 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...

Page 27: ...e the boiler in the studs protruding from the wall bracket b Fix the boiler on the bracket studs using the nuts and the washers supplied c Make the gas flow return and condensate connections to the sy...

Page 28: ...ced 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 co...

Page 29: ...pply wiring should be in PVC insulated cable not less than 0 75mm2 8 0mm dia to BS 6500 Table 16 material code H05VV F 3 The permanent live supply connection may be via a 3 amp fused double pole switc...

Page 30: ...l 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 with...

Page 31: ...and solder the system must be flushed 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 bo...

Page 32: ...that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should b...

Page 33: ...G TO STABILISE BEFORE TAKING A READING 4 Using the button for 1st STAT temperature control adjust the display to t00 minimum fan speed 5 Measure the CO2 reading in the flue gases The CO2 reading must...

Page 34: ...g is found to be incorrect when the boiler is firing at maximum rate contact Keston Boilers Ltd for further guidance 5 10 HANDING OVER TO THE USER It is important to fully explain the following a Proc...

Page 35: ...n 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 WD500 Chapter 5 Commissioning The Keston Q37 Q37P Boilers...

Page 36: ...ime 6 The burner will continue to operate until the gas valve interrupts the gas supply The gas valve will be closed by the control PCB if power is interrupted to the boiler by any external control or...

Page 37: ...5 N A 4 Actual CH return temperature maximum 72C NB Flow temperatures more than 20C above return temperature may lead to overheat and noise problems Check the pump performance and the system for bloc...

Page 38: ...gas supply air supply and flue E26 Control box errors possible faulty control box E25 Water pressure lost 4 times in 24 hours possible leak check system and boiler E24 Water filling error check water...

Page 39: ...6 4 FUNCTIONAL FLOW WIRING DIAGRAM WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 34...

Page 40: ...6 5 ELECTRICAL WIRING DIAGRAM WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 35...

Page 41: ...6 6 ILLUSTRATED WIRING DIAGRAM WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 36...

Page 42: ...6 7 Exploded Assembly Diagrams 6 7 1 Boiler Controls Assembly WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 37...

Page 43: ...6 7 2 Waterway Condensate Flue Assembly WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 38...

Page 44: ...6 7 3 Air Gas Assembly WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 39...

Page 45: ...6 7 4 Casing Assembly WD500 Chapter 6 Fault Finding The Keston Q37 Q37P Boilers Installation Servicing Instructions Page 40...

Page 46: ...C 10C 2 00 52 0 A 54 Spark Electrode C 17 2 29 00 0 A 73 Condensate Trap C 12 2 06 00 0 70 Flow Return Sensor C 12 2 05 00 0 71 Flue Sensor C 10C 2 11 00 0 65 Pressure Sensor C 10C 2 17 00 1 68 Pump C...

Page 47: ...e 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 f...

Page 48: ...onnect the gas air supply Ensure the flanged gas air supply joint is air tight h Turn on the electrical supply to the boiler and allow the boiler to reach operating temperature levels i Remove the com...

Page 49: ...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 cabinet 8 3 REPLACEMENT PROCEDURE i Always replace in...

Page 50: ...he return pipe from the heat exchanger v Remove the push on connectors from the pressure sensor taking note of the correct positions vi Unscrew the pressure sensor vii Reassemble Section 8 3 NB Use a...

Page 51: ...ove the combustion blower Section 8 4 7 iv Remove the four nuts fixing the burner to the top of the heat exchanger Fig 6 7 3 item 93 v Withdraw the burner from the top of the heat exchanger vi Reassem...

Page 52: ...ose to the base of the heat exchanger 8 9 PUMP Fig 6 7 2 item 68 i Isolate the appliance Section 8 1 ii Gain Access section 8 2 iii Isolate the waterways to the boiler using the system isolation valve...

Page 53: ...artDenomination 52 Burner 53 Burner Gasket 55 Ignitor Gasket 54 Ignitor Sensor Probe 70 Flow Return 71 Flue Thermistor Thermistors 65 Pressure Sensor 68 Pump WD500 Chapter 9 Spare Parts Listings The K...

Page 54: ...Q37 Gas Valve Mixer Assem 91 Fan Q37P Gas Valve Mixer Assem 111 Control Box 112 Fascia Panel WD500 Chapter 9 Spare Parts Listings The Keston Q37 Q37P Boilers Installation Servicing Instructions Page...

Page 55: ...55 Ignitor Gasket 70 Flow Return Thermistor 71 Flue Thermistor 65 Pressure Sensor 91 Fan 96 Gas Valve Mixer Air Gas Assembly NG Q37 96 Gas Valve Mixer Air Gas Assembly LPG Q37P 112 Control Panel 111 C...

Page 56: ...CENTRAL HEATING MODE 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...

Page 57: ...GAS SAFE REGISTER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME...

Page 58: ...itions 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 are at least 200mm apart Check tightness of all c...

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