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Qudos 28s

User, Installation and Servicing

Instructions

FAN POWERED HIGH EFFICIENCY

MODULATING DOMESTIC CONDENSING

GAS SYSTEM BOILER

CE/PI No. 86-CM-43

Qudos 28s - GC No. 41-930-17

Qudos 28sP - GC No. 41-930-18

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 : [email protected] web :

www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

W D 4 2 0

i s s u e 7 - 2 0 1 1

Содержание 41-930-17

Страница 1: ...GC No 41 930 17 Qudos 28sP GC No 41 930 18 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 L2 SEDBUK A RATED WD 420 issue 7 2011 ...

Страница 2: ... Data 2 5 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 Systems 3 8 Flue System 3 9 Air Supply 3 10 Compartment Installation 3 11 Condensate Drainage 4 INSTALLATION OF THE BOILER 4 1 Wall Mounting Bracket 4 2 Mounting The Boiler 4 3 Assembly Practic...

Страница 3: ...ustrated 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 8 9 Pump 8 10 Expansion Vessel 9 SPARE PARTS LISTINGS 10 GAS BOILER C...

Страница 4: ...essories 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 c...

Страница 5: ...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 o...

Страница 6: ...ed to the front for servicing 300mm Cleaning Normal case cleaning only requires dusting with a dry cloth To remove more stubborn marks wipe with a damp cloth and finish with a dry cloth 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 self check procedure Set any controls to call fo...

Страница 7: ...ut the boiler has attempted to light five times and not succeeded check the gas supply is on E02 Description of fault Display 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 a...

Страница 8: ...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 IMPORT...

Страница 9: ...ontrols optional connection of a DHW thermistor to enable modulated reheat of DHW and optional legionella prevention function Further the Qudos 28s is developed with the concept that the gas boiler in the modern home is often supplemented by alternative or renewable energy sources As a result the Qudos 28s features optional connection of a solar thermal system pump panel and DHW sensor for direct ...

Страница 10: ...plastic pipe Gas is mixed with combustion air at the inlet to the fan The gas flow is automatically regulated by the gas valve according to the air flow generated by the fan The gas and air are thoroughly mixed in the blower and fed into the burner located at the top end of the heat exchanger module The gas and air mixture is ignited by a direct spark ignition control system and burns with a blue ...

Страница 11: ...d 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...

Страница 12: ...ic Propane and Butane Burning Installations BS 7074 1 Expansion Vessels BS 7593 Treatment of Water in Hot Water Central Heating Systems BS 7671 Requirements for Electrical Installations IEE Wiring Regulations 16th Edition BSEN 12828 2003 Heating Systems in Buildings Design for water based heating systems BSEN 12831 2003 Heating Systems in Buildings Method for calculation of design heat load BSEN 1...

Страница 13: ...x Flue Outlet Length m 60 Max Total Flue Outlet and Air Intake Length m 120 2 5 OPTIONAL ACCESSORIES A range of accessories are available from KESTON Heating to compliment an installation Terminal wall sealing collars are available to make good the external all face whilst working from the inside of the building using 50mm muPVC BS5255 and or BSEN1566 1 and BSEN1329 pipe Stand off frames are avail...

Страница 14: ... General Instruction The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 9 Qudos 28s Qudos 28sP Nat Gas G20 LPG G31 Min Input Gross CV kW Btu h 7 8 26 600 7 6 26 000 Max Input Gross CV kW Btu h 29 4 100 300 28 8 98 300 Max Output To Water 80 60o C Flow Return kW Btu h 26 4 90 500 26 4 90 500 50 30o C Flow Return kW Btu h 28 4 96 900 28 4 96 900 Min Output To Water 80 6...

Страница 15: ...mark initiative Qudos 28S 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 fo...

Страница 16: ...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 ...

Страница 17: ...l therefore accept up to TWO switched live 230VAC signal inputs such as heating and hot water or radiators and underfloor heating zones Alternatively a Keston Room Controller can be connected directly via two core low voltage cable to the terminals marked OT The Keston Room Controller will then provide fully room compensated control to ensure the boiler output is matched to the rooms requirements ...

Страница 18: ...nsation Ext Sensor A Keston outside temperature sensor may be connected as an option The boiler will automatically detect this connection and will operate on a weather compensation basis when receiving a heating demand signal from the SL terminal or from a Keston Room Controller Screened cable 80 density must be used to connect the outside temperature sensor Solar Control Where a solar thermal sys...

Страница 19: ...of 22mm diameter reducing to 15mm at the boiler If gas runs greater than 12m including the allowance for bends are involved the pipe size should be increased further 3 7 WATER SYSTEMS All piping must be installed in accordance with all applicable local and Water Supply Bylaws for forced hot water heating systems Consideration must be given to pipe capabilities and pressure drop through the piping ...

Страница 20: ...Volume Total Water Content of system in excess of 125 litres 1 0 bar Vessel charge initial system pressure 3 0 bar Safety Valve Setting k The boiler is supplied with an integral expansion vessel of 8l capacity This is suitable for systems of up to 125 litres system volume Table 3 7 Expansion Vessel Selection provides guidance for the correct additional expansion vessel size to use for systems with...

Страница 21: ...ce 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 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 of water to the boiler system and in all subsequent additions of water to the system some air will ...

Страница 22: ...for more detail 3 7 5 Filling The System The system should be filled using a G24 approved filling loop The system pressure should be set to between 1 0 and 2 0 bar To display the system water pressure press the T T T T button repeatedly until the water pressure is displayed indicated by the word bar to the right of the pressure reading Fill the system and monitor the pressure displayed When the pr...

Страница 23: ...VC flue and air pipework Air inlet uses two 92 5o sweep elbows Hence maximum length permissible i e a b in figure 3 8 2 39 0m 1 0m 1 0m 37 0m Flue outlet uses one 92 5o sweep elbow Hence maximum length permissible i e c d in figure 3 8 2 20 0m 1 0 m 19 0m 3 8 3 Slope Horizontal flue outlet pipework MUST slope at least 2 degrees 35 mm per metre run downwards towards the boiler Pipework can be verti...

Страница 24: ...cted terminal location does not cause nuisance 300 300 L Horizontally from terminal on same wall 1 500 1 500 K Vertically from terminal on same wall 100 1 200 J From opening in a car port not recommended 1 200 1 200 I From terminal facing a terminal 100 600 H From surface or boundary facing a terminal 100 200 G Above ground or balcony or roof 50 200 F From internal or external corner or to a bound...

Страница 25: ...e used for storage 3 11 CONDENSATE DRAINAGE Being a condensing boiler the Qudos 28S and Qudos 28SP are fitted with a condensate trap at the base of the heat exchanger and flue assembly with facility to connect to a drain point underneath the appliance The condensate trap is packed loose with the appliance and MUST be fitted BEFORE firing the appliance Secure it to the boiler frame and connect the ...

Страница 26: ... a Lift and locate the boiler onto the stud and the two locating pegs protruding from the wall bracket lift the boiler via the back frame only b Lower the boiler for hanging on the two pegs c Fix the boiler on the bracket stud using the nut and the washers supplied d Make the gas flow return condensate and PRV connections to the system Check all joints for tightness DO NOT FIRE THE BOILER UNTIL TH...

Страница 27: ... sealing collars are available to make good hole areas on the wall face part number C 08 0 00 07 0 g Support any pipes whose route could be displaced either of its own accord or by accident Any horizontal run over 1m or vertical runs of any length must always be supported Brackets should be placed at intervals of approximately 1m h Check all connections for security and re seal any joints using so...

Страница 28: ...lectrical 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 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 switch servin...

Страница 29: ...C 2 1 CH1 1 0 10V 0v 2 SENSOR 1 2 SENSOR 2 SENSOR 1 1 2 NO OPEN SOL DHW TS FLOW ANALOG DEMAND EXTERNAL SENSOR MAIN SUPPLY SOLAR PUMP CH DEMAND 1 N N SL1 SL2 E L LOCKOUT COM NO 2 C 10C 0 09 00 0 EXTERNAL SENSOR OPTIONAL TANK OPTIONAL DHW SENSOR SEPARATE CH DHW DEMAND WITH OPTIONAL DHW SENSOR CONTROL CONTROLS FROM DHW CONTROLS FROM CH GREY ORANGE BROWN BLUE M VALVE DHW ZONE VALVE CH ZONE BROWN GREY ...

Страница 30: ...lux or solder the system must be flushed cold again before proceeding Reduce the pressure to the Initial System Design Pressure Vent the system Gas Supply The complete gas installation up to the boiler gas control valve must be checked for soundness BS 6891 Electrical Installation Carry out preliminary electrical safety checks i e Earth continuity Polarity Resistance to Earth Short Circuit and ear...

Страница 31: ...as inlet pressure is satisfactory set the gas pressure check the gas input Full details of this procedure are given in Section 5 9 Timing The Gas Meter Combustion Testing It is advisable on all installations that the combustion quality is checked by measuring the carbon dioxide CO2 or oxygen O2 level This procedure is detailed in Section 5 7 Combustion Testing Badly tuned combustion will lead to r...

Страница 32: ... 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 checked for tightness BS 6891 5 3 ELECTRICAL INSTALLATION Carry out preliminary electrical safety checks i e Earth continuity Polarity Resistance to Earth Short Circuit using a suitable test meter 5 4 LP GAS The...

Страница 33: ...a quality water treatment such as Fernox MB1 or Sentinel X100 For sealed systems fill to the required Initial Design Pressure 5 7 COMBUSTION TESTING MANDATORY CHECK Competence to carry out the check of combustion performance PLEASE NOTE BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that y The person carrying out a com...

Страница 34: ...to 150 ppm for natural gas and 10 3 to 10 7 with a 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 4 Press the RESET butto...

Страница 35: ...s of the new metric digital type Model Time for 2 cu ft Time for 0 1 cu m Qudos 28s natural gas 71 to 78 seconds 125 to 138 seconds Qudos 28sP LPG 152 to 168 seconds 272 to 300 seconds If the meter timing is found to be incorrect when the boiler is firing at maximum rate contact KESTON Heating for further guidance 5 10 HANDING OVER TO THE USER It is important to fully explain the following a Proce...

Страница 36: ...st its power output and pump speed to best match the demands of the system at any time 6 The burner will continue to operate until the gas valve interrupts the gas supply The gas valve will be closed by the control PCB if power is interrupted to the boiler by any external control or the boiler exceeds the requested temperature If an interruption to the gas supply causes loss of the flame the contr...

Страница 37: ...outside temperature sensor is detected 7 System water pressure in bar Maximum 2 7 bar minimum 0 4 bar The boiler will shut down if the water pressure drops below 0 4 bar 6 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 5 Actual DHW temperature display indicates ...

Страница 38: ...ck the connections and wires to the return thermistor are intact and 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 wires to the flue thermistor are intact not short circuited E35 DHW thermistor closed circuit check the connections and wires to the ...

Страница 39: ...nter Purge 12 Lockout 8 Outside temperature 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 Maximum 2 7 bar minimum 0 4 bar The boiler will shut down if the water pressure drops below 0 4 bar 6 Actual Flue Temperature display indicates the flame and fan symbols NB Flue temperatures above 75C may cause re...

Страница 40: ...6 4 FUNCTIONAL FLOW WIRING DIAGRAM WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 35 ...

Страница 41: ...6 5 ELECTRICAL WIRING DIAGRAM WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 36 Ω ...

Страница 42: ...6 6 ILLUSTRATED WIRING DIAGRAM WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 37 ...

Страница 43: ...6 7 Exploded Assembly Diagrams 6 7 1 Boiler Controls Assembly WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 38 ...

Страница 44: ...6 7 2 Waterway Condensate Flue Assembly WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 39 ...

Страница 45: ... WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 40 ...

Страница 46: ...6 7 3 Air Gas Assembly WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 41 ...

Страница 47: ...6 7 4 Casing Assembly WD420 3 2007 Chapter 6 Fault Finding The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 42 ...

Страница 48: ...nitor Kit Q 10S 0 09 00 0 62 Condensate Trap Kit Q 10S 0 16 00 0 58 Flow Return Thermistor Q 10S 2 08 00 0 59 Flue Sensor Q 10S 2 09 00 0 101 Pressure Sensor C 10C 2 17 00 1 57 Flow Thermostat Q 10S 2 07 00 0 60 Pump Q 10S 2 10 00 0 Air Gas Assembly Fig 6 7 3 GC Number Code Description 111 Combustion Blower Q 10S 3 01 00 1 183 Q28s Gas Valve Mixer Air Gas Assembly Q 10S 3 04 00 0 183 Q28sP Gas Val...

Страница 49: ...gas rate as described in Section 5 9 y 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...

Страница 50: ...ting the gasket for damage and replacing if necessary and reconnect 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 combustion test point plug from the flue pipe This is situated on the flue spigot out of the cabinet j Carry the full procedure detailed in se...

Страница 51: ...ce service cock WARNING Parts of the boiler internal wiring will remain live even after setting the User Controls to Standby Shut off the power supply at the isolating switch before working on the appliance 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 the reverse order unless otherwise stated ii Electrical...

Страница 52: ...ions 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 8 4 5 Pressure Sensor Fig 6 7 2 2 2 item 101 i Isolate the appliance Section 8 1 ii Shut off t...

Страница 53: ... 2 item 57 i Isolate the appliance Section 8 1 ii Gain access Section 8 2 iii Remove the push on connector from the sensor taking note of the correct position iv Unscrew the bolts securing the stat Fig 6 7 2 1 2 item 77 v Reassemble Section 8 3 NB When fitting the new thermostat it is an advantage to smear a thin film of heat sink compound between the thermistor and pipe This combined with fitting...

Страница 54: ... 103 and 104 fixing the condensate trap to the base of the cabinet iii Disconnect the condense line from the projection of the condensate trap from the base of the cabinet iv Disconnect the airing hose from the small spigot on the top of the trap v Withdraw the condensate trap vi Mop up any spilled condensate vii Reassemble Section 8 3 NB When reassembling inspect the o ring Fig 6 7 2 2 2 item 69 ...

Страница 55: ...e pin Fig 6 7 4 item 37 and the EV bracket Fig 6 7 4 item 39 from the cabinet frame vii Remove the expansion vessel viii Reassemble Section 8 3 NB When reassembling inspect the gasket for damage and replace if necessary WD420 3 2007 Chapter 8 Replacement Of Parts The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 50 ...

Страница 56: ...52 Burner Kit 81 Burner Gasket 72 Ignitor Gasket 53 Ignitor Kit 58 Flow Return Thermistors 59 Flue Thermistor 57 Flow Overheat Thermostat 101 Pressure Sensor WD420 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 51 ...

Страница 57: ...n Q28sP Gas Valve Mixer Assem 132 Control Panel 131 Q28s Control PCB Q28sP Con PCB 60 Pump 98 Expansion Vessel WD420 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 52 ...

Страница 58: ... 59 Flue Thermistor 57 Flow Thermostat 101 Pressure Sensor 111 Fan 183 Gas Valve Mixer Air Gas Assembly NG Q28s 183 Gas Valve Mixer Air Gas Assembly LPG Q28sP 132 Control Panel 131 Control PCB NG Q28s 131 Control PCB LPG Q28sP 60 Pump 98 Expansion Vessel WD420 3 2007 Chapter 9 Spare Parts Listings The Keston Qudos 28s Qudos 28sP Boilers Installation Servicing Instructions Page 53 ...

Страница 59: ... 1 86 1 25 1 7 7 2 5 0 18 785 5 6 16758 7 216 7 6 67 0 1 5 86 7 1 725 86 FOR THE CENTRAL HEATING MODE MEASURE RECORD 6 5 7 P KU IW KU 851 5 23 5 7 1 35 6685 33 1 PEDU 175 7 1 2 7 03 5 785 2 175 7 1 5 7851 7 03 5 785 2 FOR COMBINATION BOILERS ONLY 6 7 5 6 5 8 5 1 77 6 12 7 7 3 2 6 5 8 5 6 1 77 FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD 6 5 7 P KU IW KU 0 080 851 5 23 5 7 1 35 6685 33 1 PEDU 2 7...

Страница 60: ...ME TEL No 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 TEL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No GAS SAFE REGISTER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER...

Страница 61: ...e that the exhaust pipe terminates away from windows or vents and is out of reach b Make sure that the air inlet and exhaust pipe outlets are at least 200mm apart b Check tightness of all connections in the boiler before firing b Ensure that the terminals supplied are fitted to both the exhaust and air inlet pipes b The system must be free from air before firing b If TRV s are installed on radiato...

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