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 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.
WD440/3/2007 The Keston Qudos 28h & 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 & Use) Regulations. Section Description 0 0.1 0.2 HANDLING INSTRUCTIONS List of contents Recommended handling procedure 1.1 1.2 1.3 1.4 USER INSTRUCTIONS Introduction Maintenance Boiler Setup and Operation Safety Information 2.1 2.2 2.3 2.
WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers 5.7 Combustion Testing 5.8 5.9 5.10 Checking The Gas Pressure Timing The Gas Meter Handing Over To The User 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 FAULT FINDING Electrical Control Sequence Normal Operation Fault Modes Functional Flow Wiring Diagram Electrical Wiring Diagram Illustrated Wiring Diagram Exploded Assembly Diagrams 7.1 7.2 SERVICING Pre Service Checks Recommended Routine Service 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.
WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers 0. HANDLING INSTRUCTIONS 0.1 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 flue kit. All additional components are packed inside the boiler cabinet itself.
WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 1 : User Instructions The Keston Qudos 28h & Qudos 28hP Boilers 1. USER INSTRUCTIONS 1.1 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.
WD440/3/2007 Chapter 1 : User Instructions The Keston Qudos 28h & Qudos 28hP Boilers Normal 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 “]” symbol is shown on the display the boiler is receiving a demand for that function.
WD440/3/2007 1.4 Chapter 1 : User Instructions The Keston Qudos 28h & Qudos 28hP Boilers 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 boiler manual includes Gas Boiler Commissioning Checklist (Chapter 10).
WD440/3/2007 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers ENTER RESET function, automatic pump and fan exercise in periods of inactivity, anti cycle control and dry fire protection. 2.2 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.
WD440/3/2007 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers The flue gases are piped in a 50 mm muPVC (BS5255 and/or and BSEN1329) plastic or, alternatively, 75mm Keston composite plastic pipe to outside. The temperature of the flue gases are usually around 5oC to 10oC 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.
WD440/3/2007 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers BS 6891 BS 6798 : : Low Pressure Installation Pipes Installation of Gas Fired Hot Water Boilers of Rated Input Not Exceeding 70kW BS 5449 : Installation Pumped Central Heating BS 5546 : Installation of Gas Hot Water Supplies for Domestic Purposes (2nd family gases) BS 5440.1 : Flues (for gas appliances of rated input not exceeding 70kW) BS 5440.
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WD440/3/2007 2.6 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers PERFORMANCE DATA - Qudos 28h & Qudos 28hP Min. Input (Gross CV) kW/(Btu/h) Max. CH Input (Gross CV) kW/(Btu/h) Max. CH Output To Water (80/60oC Flow/Return) kW/(Btu/h) (50/30oC Flow/Return) kW/(Btu/h) Min. CH Output To Water (80/60oC Flow/Return) kW/(Btu/h) (50/30oC Flow/Return) kW/(Btu/h) Max. Burner Press.-Hot (Factory Preset) mbar/(in w.g) Max. Gas Cons. After 10 mins (DHW) l/s / (Ft3/hr) o Max.
WD440/3/2007 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 3. BOILER LOCATION $OO GLPHQVLRQV LQ PP DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown to allow subsequent servicing, and safe operation. However, larger clearances may be required during installation. 3.2 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & 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 boiler 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 3.5 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. 3.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers $LU 9HQW +RVH 8QLRQ ELE WDS KESTON Qudos 28h Safety Relief Valve Expansion Vessel / 6 RETURN HEATING CIRCUIT By-pass FLOW Drain Cock +RVHSLSH GLVFRQQHFWHG DIWHU ILOOLQJ Pump Dbl Check Valve 7HVW &RFN Figure 3.7.1: Sealed Systems Diagram %6 6WRS 7DS +RVH &RQQHFWRU . Figure 3.7.
WD440/3/2007 h i j k m Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 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. 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers A 92.5o sweep elbow is equivalent to 1.0m straight length. A 45o 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) )/8( Air inlet uses two 92.5o sweep elbows. Hence, maximum length permissible (i.e. a+b in figure 3.8.2) = 39.0m - 1.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 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) 3.9 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. 3.
WD440/3/2007 Chapter 4 : Installation The Keston Qudos 28h & 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.
WD440/3/2007 NB: Chapter 4 : Installation The Keston Qudos 28h & 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 the spigot to the internal flue pipe using the flexible couple and fastening clips. Ensure the clips are properly secured and no leakage can occur.
WD440/3/2007 4.6 Chapter 4 : Installation The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 4 : Installation 4.9 The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 4 : Installation 4.9.3 The Keston Qudos 28h & Qudos 28hP Boilers Solar Control 1 2 TS 1 DHW 2 1 2 FLOW NO C OPEN 2 1 ANALOG DEMAND CH1 0-1 0V ORANGE BLUE ( 3A FUSE ) N E 230V MAIN SUPPLY E N L LOW VOLTAGE CONNECTOR SOL.
WD440/3/2007 Chapter 4 : Installation The Keston Qudos 28h & 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 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.
WD440/3/2007 Chapter 5 : Commissioning The Keston Qudos 28h & 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.
WD440/3/2007 f. g. Chapter 5 : Commissioning The Keston Qudos 28h & Qudos 28hP Boilers “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.
WD440/3/2007 Chapter 5 : Commissioning The Keston Qudos 28h & Qudos 28hP Boilers To measure CO2 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.
WD440/3/2007 7) 5.8 NB: Chapter 5 : Commissioning The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 6. FAULT FINDING 6.1 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 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.
WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 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 also be used to show other information about the operation of the boiler. Press the “S S” button repeatedly until the display shows “SHP” (“Show Parameters) and then press the “ENTER” button, you will enter the installer information mode.
WD440/3/2007 6.3 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 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.
WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 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.
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WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers ELECTRICAL WIRING DIAGRAM Ω 6.
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WD440/3/2007 6.7 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers Exploded Assembly Diagrams 6.7.
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WD440/3/2007 6.7.5 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code 111 111 E72-401 112 132 113 Description Q28h Main Control PCB (Q.10S.4.01.00.0 F) Q28hP Main Control PCB (Q.10S.4.15.00.0 F) Control Panel (Q.10S.4.02.00.0) Thermal Fuse (C.08.4.21.00.0) Ignitor Cable (C.17.4.19.00.0) Waterway, Condensate & Flue Assembly (Fig. 6.7.2) GC Number Code Description 41 Heat Exchanger Assy(Q.10S.
WD440/3/2007 Chapter 7 : Servicing The Keston Qudos 28h & 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.
WD440/3/2007 c. d. e. f. g. h. i. j. k. l. m. n. Chapter 7 : Servicing The Keston Qudos 28h & 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.
WD440/3/2007 Boilers Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP 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 & RETURN THERMISTORS 8.4.3 CABINET TEMPERATURE SENSOR 8.4.4 FLUE THERMISTOR 8.4.5 WATER PRESSURE SWITCH 8.4.6 MAIN CONTROL PCB 8.4.7 COMBUSTION BLOWER 8.4.8 GAS CONTROL VALVE 8.4.9 FLOW THERMOSTAT 8.5 SPARK IGNITION/FLAME DETECTION ELECTRODE 8.6 BURNER 8.
WD440/3/2007 Boilers Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP 8.4.2 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 of the correct positions. iv) Unclip the thermistor from the pipe. v) Reassemble (Section 8.
WD440/3/2007 Boilers Chapter 8 : Replacement Of Parts iv) v) vi) 8.5 8.6 The Keston Qudos 28h & Qudos 28hP Unscrew the bolts (Fig 6.7.3 item 94) securing the gas inlet pipe to the gas control valve. Remove the four nuts securing the combustion blower (fig. 6.7.3 item 100) outlet flange to the burner and remove the combustion blower. Reassemble (Section 8.3) NB: When reassembling inspect any gaskets for damage and replace if necessary. 8.4.8 Gas Control Valve /Venturi Assembly (Fig. 6.7.
WD440/3/2007 Boilers Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP 8.7 HEAT EXCHANGER (Fig. 6.7.2 item 41) i) Isolate the appliance (Section 8.1) ii) Gain access (Section 8.2) iii) Shut off the water supply to the appliance. iv) Remove the burner (Section 8.6) v) Drain the system to below the level of the appliance. vi) Remove the flue thermistor (Section 8.4.4) vii) Remove the spark ignition/flame detection electrode (Section 8.
WD440/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28h & Qudos 28hP Boilers 9. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No Part Denomination 42 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.
WD440/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28h & Qudos 28hP Boilers 163 Q28h Gas Valve - Mixer Assem. Q28hP Gas Valve - Mixer Assem. 91 Fan 112 Control Panel 111 Q28h Control PCB Q28hP Con.
WD440/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28h & Qudos 28hP Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No 42 64 43 55 48 49 47 74 91 163 163 112 111 111 Installation & Servicing Instructions Part Denomination Burner KIT Burner Gasket Ignitor KIT Ignitor Gasket Flow/Return Thermistor Flue Thermistor Flow Thermostat Water Pressure Switch Fan Gas Valve - Mixer Air-Gas Assembly (NG-Q28s) Gas Valve - Mixer Air-Gas Assembly (LPG-Q28sP) Control Panel C
WD440/3/2007 Chapter 10 : Benchmark Checklist Final The Keston Qudos 28h & Qudos 28hP Boilers 10. GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. ___________________ NOTIFICATION No.
WD440/3/2007 Chapter 10 : Benchmark Checklist Final The Keston Qudos 28h & 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.
WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers KESTON CONDENSING BOILERS IMPORTANT Qudos 28h and Qudos 28hP INSTALLATION KEY POINTS b b b b b b b b b b b b b b b Read Installation Manual Carefully Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe. If the 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.
