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 : info@keston.co.uk web : www.keston.co.
WD420/3/2007 The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 5.6 5.7 5.8 5.9 5.10 6 The Keston Qudos 28s & Qudos 28sP Boilers Hot Flushing Combustion Testing Checking the Gas Pressure Timing The Gas Meter Handing Over To The User 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 8.8 8.9 8.
WD420/3/2007 The Keston Qudos 28s & Qudos 28sP Boilers 0. HANDLING INSTRUCTIONS 0.1 LIST OF CONTENTS The Keston Qudos 28s and Qudos 28sP 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.
WD420/3/2007 The Keston Qudos 28s & Qudos 28sP Boilers 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 hang the boiler on the wall remove the casing and place to one side.
WD420/3/2007 Chapter 1 : User Instructions The Keston Qudos 28s & Qudos 28sP Boilers 1. USER INSTRUCTIONS 1.1 INTRODUCTION Thank you for choosing this Keston Qudos 28s 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 28s and what to do in the unlikely event of a fault.
WD420/3/2007 Chapter 1 : User Instructions The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 1.4 Chapter 1 : User Instructions The Keston Qudos 28s & Qudos 28sP 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).
WD420/3/2007 Chapter 2 : General Instruction The Keston Qudos 28s & Qudos 28sP Boilers 2. GENERAL INSTRUCTION 2.1 DESCRIPTION The KESTON Qudos 28s and Qudos 28sP boilers utilize the latest in condensing technology to produce a high efficiency boiler with SEDBUK A rated efficiency plus advance controls to maximize operational efficiency. The Qudos 28s is unique in concept and design.
WD420/3/2007 Chapter 2 : General Instruction ENTER The Keston Qudos 28s & Qudos 28sP Boilers RESET 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.
WD420/3/2007 Chapter 2 : General Instruction The Keston Qudos 28s & Qudos 28sP Boilers 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.
WD420/3/2007 Chapter 2 : General Instruction The Keston Qudos 28s & Qudos 28sP Boilers 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 pump due to long periods of inactivity. 2.
WD420/3/2007 2.
WD420/3/2007 2.6 Chapter 2 : General Instruction The Keston Qudos 28s & Qudos 28sP Boilers PERFORMANCE DATA - Qudos 28s & Qudos 28sP Qudos 28s Nat. Gas (G20) 7.8/(26,600) 29.4/(100,300) Qudos 28sP LPG (G31) 7.6/(26,000) 28.8/(98,300) Min. Input (Gross CV) kW/(Btu/h) Max. Input (Gross CV) kW/(Btu/h) Max. Output To Water (80/60oC Flow/Return) kW/(Btu/h) 26.4(90,500) 26.4/(90,500) (50/30oC Flow/Return) kW/(Btu/h) 28.4/(96,900) 28.4/(96,900) Min. Output To Water (80/60oC Flow/Return) kW/(Btu/h) 7.
WD420/3/2007 Chapter 2 : General Instruction The Keston Qudos 28s & Qudos 28sP Boilers 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.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP 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 28s can be located virtually anywhere desired provided that all regulations are complied with.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers BS 1363. There must be only one common method of isolation for the boiler and its control system. 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.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers 3.5 BOILER SIZE SELECTION The Qudos 28s will automatically adjust heat output and pump speed 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 28s is therefore suitable for all systems with a total heat load within the maximum range of the boiler. 3.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers Copper tubing to BS 2871 Part 1 or barrier plastic pipe suitable to 110 oC, such as Unipipe, is recommended. 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.
WD420/3/2007 m n Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers The installation must be designed to work with flow temperatures of up to 110 oC. All components of the system must be suitable for a working pressure of 3 bar and a temperature of 110 oC. Care should be taken in making all connections that the risk of leakage is minimised. The pipe from the safety discharge valve must not discharge above an entrance, window or any type of public access area.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers If an additional pump is required the selected pump must comply with BS 1394. Provision must be made in the system design for control of the additional pump. A connection point is available within the boiler to signal operation of the additional pump. However, this will need to drive the additional pump via a suitable relay.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers 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 stockist 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.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers 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.
WD420/3/2007 Chapter 3 : Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers 3.8.6 Distance Between Flue Outlet & 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 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.
WD420/3/2007 Chapter 4 : Installation The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Chapter 4 : Installation The Keston Qudos 28s & Qudos 28sP Boilers 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. Remember the flue pipe must slope downwards back towards the boiler and this is best achieved using 92.5o bends.
WD420/3/2007 4.6 Chapter 4 : Installation The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Chapter 4 : Installation 5.1 The Keston Qudos 28s & Qudos 28sP Boilers Twin Thermostat Operation with Weather Compensation ORANGE BLUE ( 3A FUSE ) N E 230V MAIN SUPPLY E N L L SL2 SL1 2 1 N NO COM CH DEMAND SOLAR PUMP Q28S BOILER LOCKOUT MAIN CONNECTOR MAIN SUPPLY SEPARATE CH & DHW DEMAND WITH ( OPTIONAL ) WEATHER COMPENSATION GREY M FROM CH CONTROLS BROWN CH ZONE VALVE ORANGE BLUE GREY M BROWN FROM DHW CONTROLS DHW ZONE VALVE C.10C.0.09.00.
WD420/3/2007 Chapter 4 : Installation 5.3 The Keston Qudos 28s & Qudos 28sP Boilers Solar Control SL2 SL1 ORANGE BLUE GREY M ORANGE BLUE GREY M TS DHW FLOW OPEN SENSOR SENSOR SENSOR SWITCH THERM 1 2 1 2 1 2 NO C 2 1 ANALOG DEMAND CH1 01 0V BROWN FROM DHW CONTROLS DHW ZONE VALVE LOW VOLTAGE CONNECTOR SOL. FROM CH CONTROLS BROWN CH ZONE VALVE SOLAR PUMP C.10C.0.09.00.
WD420/3/2007 Chapter 4 : Installation The Keston Qudos 28s & Qudos 28sP Boilers 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 (minimum 18 mbar required for Natural Gas and 31 mbar required for LP gas).
WD420/3/2007 Chapter 5 : Commissioning The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 f. g. Chapter 5 : Commissioning The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Chapter 5 : Commissioning The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 7) 5.8 NB: Chapter 5 : Commissioning The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers 6. FAULT FINDING 6.1 ELECTRICAL CONTROL SEQUENCE When the external control(s) are calling for heat, power will be fed to the boiler connection strip at terminal SL1 (Switched Live) and N (Neutral) and the radiator symbol with a “1” will appear in the top left of the display.
WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers QUICK REFERENCE 6.2 NORMAL OPERATION The Qudos 28s and Qudos 28sP 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 “T T” button repeatedly until the display shows “SHP” and then press the “ENTER” button, you will enter the installer information mode.
WD420/3/2007 6.3 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers ERROR HISTORY The Qudos 28s 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.
WD420/3/2007 6.
WD420/3/2007 The Keston Qudos 28s & Qudos 28sP Boilers ELECTRICAL WIRING DIAGRAM Ω 6.
WD420/3/2007 6.
WD420/3/2007 6.7 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers Exploded Assembly Diagrams 6.7.
WD420/3/2007 6.7.
WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers , Installation & Servicing Instructions Page : 40
WD420/3/2007 6.7.
WD420/3/2007 6.7.
WD420/3/2007 6.7.5 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code 131 131 E72-401 132 151 133 Description Q28s Main Control PCB (Q.10S.4.01.00.0 F) Q28sP 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 (Q.10S.4.03.00.0) Waterway, Condensate & Flue Assembly (Fig. 6.7.2) GC Number Code Description 51 Heat Exchanger Assy (Q.
WD420/3/2007 Chapter 7 : Servicing The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 c. d. e. f. g. h. i. j. k. l. m. n. Chapter 7 : Servicing The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 Boilers Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP 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 PRESSURE SENSOR 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.
WD420/3/2007 Boilers Chapter 8 : Replacement Of Parts v) vi) vii) The Keston Qudos 28s & Qudos 28sP Remove the Control Panel by removing the four retaining screws (Fig 6.7.1, item 160). Reassemble (Section 8.3) Check for correct operation of the Control Panel. 8.4.2 Boiler Flow and Return Thermistors (Fig. 6.7.2 - 1/2 & 2/2 item 58) 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.
WD420/3/2007 Boilers Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP 8.4.7 Combustion Blower (Fig. 6.7.3 item 111) i) Isolate the appliance (Section 8.1) ii) Gain access (Section 8.2) iii) Disconnect the connector block from the combustion blower. iv) Unscrew the bolts (Fig 6.7.3 item 114) securing the gas inlet pipe to the gas control valve. v) Remove the four nuts securing the combustion blower (fig. 6.7.3 item 120) outlet flange to the burner and remove the combustion blower.
WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP Boilers iv) Remove the 4 nuts fixing the burner to the top of the heat exchanger (Fig 6.7.3, item 120). v) Remove the spark ignition/flame detection electrode (Section 8.5) vi) Withdraw the burner from the top of the heat exchanger. vii) Reassemble (Section 8.3) NB: When reassembling inspect any gaskets for damage and replace if necessary. 8.7 HEAT EXCHANGER (Fig. 6.7.2 - 1/2 item 51) i) Isolate the appliance (Section 8.
WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP Boilers iv) Drain the system to below the level of the appliance. v) Disconnect the flexible hose (Fig. 6.7.2 - 2/2 item 95) from the expansion vessel. vi) Undo the 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 9 : Spare Parts Listings The Keston Qudos 28s & Qudos 28sP Boilers 9.
WD420/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28s & Qudos 28sP Boilers 183 Q28s Gas Valve - Mixer Assem. Q28sP Gas Valve - Mixer Assem. 119 Fan 132 Control Panel 131 Q28s Control PCB Q28sP Con.
WD420/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28s & Qudos 28sP Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No 52 81 53 72 58 59 57 101 111 183 183 132 131 131 60 98 Installation & Servicing Instructions Part Denomination Burner Kit Burner Gasket Ignitor Kit Ignitor Gasket Flow/Return Thermistor Flue Thermistor Flow Thermostat Pressure Sensor Fan Gas Valve - Mixer Air-Gas Assembly (NG-Q28s) Gas Valve - Mixer Air-Gas Assembly (LPG-Q28sP) Control Panel
WD420/3/2007 Chapter 10 : Benchmark Checklist Final The Keston Qudos 28s & Qudos 28sP Boilers 10. GAS BOILER COMMISSIONING CHECKLIST BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. ___________________ NOTIFICATION No.
WD420/3/2007 Chapter 10 : Benchmark Checklist Final The Keston Qudos 28s & Qudos 28sP 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.
WD420/3/2007 The Keston Qudos 28s & Qudos 28sP Boilers KESTON CONDENSING BOILERS IMPORTANT Qudos 28s and Qudos 28sP INSTALLATION KEY POINTS 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.
