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Keston Qudos 28h User, Installation And Servicing Instructions

Fan powered high efficiency modulating domestic condensing gas heat only boiler
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WD440/3/2007
The Keston Qudos 28h & Qudos 28hP Boilers
Qudos 28h
Fan Powered High Efficiency
Modulating Domestic Condensing
Gas Heat Only Boiler
User, Installation And Servicing
Instructions
CE/PI No : 87BR36
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.
34 West Common Road
Hayes, Bromley, Kent BR2 7BX
Tel. +44 (0)20 8462 0262 Fax. +44 (0)20 8462 4459
email : info@keston.co.uk web : www.keston.co.uk
COMPLIANT WITH BUILDING REGULATION PART L1 & L2
SEDBUK A RATED

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  • Page 1 WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers Qudos 28h Fan Powered High Efficiency Modulating Domestic Condensing Gas Heat Only Boiler User, Installation And Servicing Instructions CE/PI No : 87BR36 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.

  • Page 2: Table Of Contents

    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 &...
  • Page 3 WD440/3/2007 The Keston Qudos 28h & Qudos 28hP Boilers Combustion Testing Checking The Gas Pressure Timing The Gas Meter 5.10 Handing Over To The User FAULT FINDING Electrical Control Sequence Normal Operation Fault Modes Functional Flow Wiring Diagram Electrical Wiring Diagram...

  • Page 4: List Of Contents

    0. HANDLING INSTRUCTIONS 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.
  • Page 5 Safety footwear and gloves are recommended PPE when lifting this appliance - to protect against sharp edges and ensure good grip. The Qudos 28h and Qudos 28hP boilers can be fitted in compartments with very small clearances required around the appliance (refer to Section 3.1). Due consideration should therefore be given to access within the compartment for lifting and positioning.

  • Page 6: Introduction

    These user instructions should be read carefully to ensure safe and economical use of your Qudos 28h or Qudos 28hP. The Qudos 28h model is for use with natural gas only, the Qudos 28hP model is for use with LPG only.
  • Page 7 Any indication of leakage from the boiler cabinet should be investigates by a CORGI engineer. Frost Protection The Qudos 28h has an integral frost protection function. However, care should also be taken that any exposed pipework is adequately insulated to prevent freezing.

  • Page 8: Safety Information

    WD440/3/2007 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.

  • Page 9: Description

    DHW thermistor to enable modulated reheat of DHW and optional legionella prevention function Further, the Qudos 28h 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...

  • Page 10: Boiler Schematic

    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. 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.

  • Page 11: Related Documents

    In the event of the boiler overheating the safety devices will cause a safety shutdown. The Qudos 28h features an integral frost protection function which will operate the system pump, regardless of the external controls, should the boiler temperature fall below 10 In the event the boiler temperature falls below 5 C the boiler will also fire.
  • Page 12 WD440/3/2007 Chapter 2 : General Instruction The Keston Qudos 28h & Qudos 28hP Boilers BS 6891 Gas Supplies BS 6798 Installation Central Heating Boilers BS 5449 Installation Pumped Central Heating BS 5546 Installation Domestic Hot Water BS 5440.1 Flues BS 5440.2 Air Supply BS 5482.1...

  • Page 13: Physical Data

    Max. Total Flue Outlet and Air Intake Length 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 face whilst working from the inside of the building using 50mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329) pipe.

  • Page 14: Performance Data

    Keston Boilers Ltd declare that there are no substances harmful to health within the appliance or used during the production of the appliance. The Qudos 28h is intended for domestic and commercial EMC environments and on a governed G20 meter supply.
  • Page 15 Benchmark Initiative As part of the industry wide “Benchmark” initiative Qudos 28h 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.

  • Page 16: Dimensions & Minimum Clearances

    WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 3. BOILER LOCATION All dimensions in mm. DIMENSIONS AND MINIMUM CLEARANCES The boiler must be installed in minimum clearances shown allow subsequent servicing, and safe operation. However, larger clearances may be required during installation.
  • Page 17 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. Because of the boiler's compact size and venting flexibility, the installation is not limited to a boiler room setting.
  • Page 18 However, the Qudos 28h features a wide range of OPTIONAL control features normally associated with commercial boilers installations at additional cost. These are provided as standard in the Qudos 28h and require low costs sensors to be added to activate them. The features provided are detailed below. Refer to Chapter 4.8 for further wiring detail.

  • Page 19: Boiler Size Selection

    This will provide full functionality normally accessed via the boiler fascia panel. 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.
  • Page 20 WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers Air Vent Hose Union bib tap KESTON Qudos 28h Expansion Vessel Safety Relief Valve RETURN By-pass HEATING CIRCUIT Hosepipe (disconnected FLOW after filling) Drain Cock Pump...
  • Page 21 WD440/3/2007 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.

  • Page 22: Flue System

    Contact Keston Boilers Ltd for information The Qudos 28h also has advance control options built in which enable modulated reheat of DHW and anti-legionella function. Refer to Chapter 4 for more detail.
  • Page 23 WD440/3/2007 Chapter 3 - Boiler Location The Keston Qudos 28h & Qudos 28hP Boilers 50mm 75mm Maximum Air Inlet Length 39.0m 117.0m Maximum Flue Outlet Length: 20.0m Maximum Total Flue and Air Intake Length : 40.0m 120.0m Example (assuming 50mm muPVC flue and...
  • Page 24 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) 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. Installation & Servicing Instructions...

  • Page 25: Compartment Installation

    3.11 CONDENSATE DRAINAGE Being a condensing boiler, the Qudos 28h and Qudos 28hP 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.

  • Page 26: Wall Mounting Bracket

    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.

  • Page 27: Condensate Drainage

    WD440/3/2007 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.

  • Page 28: Water System

    WD440/3/2007 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.
  • Page 29 The Keston Qudos 28h & Qudos 28hP Boilers Advanced Features Wiring The Qudos 28h features comprehensive and advance functionality as standard. Whilst these advances funtions are not mandatory, they will provide enhanced boiler operation performance and efficiency. Detailed below are suggested wiring methods to activate various functions.

  • Page 30: Exchanging A Boiler

    It is essential that sludge or scale is removed from an existing system before fitting the boiler. The guarantee provided with the Keston Qudos 28h and Qudos 28hP does not cover damage caused by system debris or sludge.
  • Page 31 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.

  • Page 32: Initial Flushing

    INITIAL FLUSHING All waterways within the Keston Qudos 28h and Qudos 28hP are either copper or high alloy stainless steel. As a result water treatment chemicals for central heating boilers such as Fernox MB1, Sentinel X100 or equivalent, are suitable.

  • Page 33: Hot Flushing

    50 ppm at low rate. If CO levels above these values are experienced, the combustion chamber and flue system should be investigated. The Qudos 28h is factory set for combustion and should need no adjustment. However, in the event adjustment is required.
  • Page 34 WD440/3/2007 Chapter 5 : Commissioning The Keston Qudos 28h & Qudos 28hP Boilers Set any controls to call for heat. Press “ ” button repeatedly until the display shows “SEr”, then press “ENTER”. Press the “ ” until the display shows “100%”.
  • Page 35 WD440/3/2007 Chapter 5 : Commissioning The Keston Qudos 28h & Qudos 28hP Boilers TIMING THE GAS METER After the boiler has been started, and with no other appliances using gas, time the gas meter to be certain that the unit is running at the proper gas input. Determine the cubic feet of gas passing through the meter and determine the input in Btu per hour.
  • Page 36 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 6. FAULT FINDING 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”...
  • Page 37 SL1 or SL2. Other methods of placing a demand on the boiler is via an Opentherm control, such as the Keston Room Controller, or a 0-10VDC input. Either alternative input is indicated by the inverted “T” symbol on the bottom row of the display.

  • Page 38: Fault Modes

    WD440/3/2007 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”...
  • Page 39 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 occuring. This is very useful for diagnosing the cause of an error lockout, particularly when the error is intermittant.
  • Page 40 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 35...
  • Page 41 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 36...
  • Page 42 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 37...
  • Page 43 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers Exploded Assembly Diagrams 6.7.1 Boiler Controls Assembly Installation & Servicing Instructions Page : 38...
  • Page 44 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 6.7.2 Waterway, Condensate & Flue Assembly Installation & Servicing Instructions Page : 39...
  • Page 45 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 6.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 40...
  • Page 46 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 6.7.4 Casing Assembly Installation & Servicing Instructions Page : 41...
  • Page 47 WD440/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28h & Qudos 28hP Boilers 6.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code Description Q28h Main Control PCB (Q.10S.4.01.00.0) Q28hP Main Control PCB (Q.10S.4.15.00.0) Control Panel (Q.10S.4.02.00.0) E72-401 Thermal Fuse (C.08.4.21.00.0)
  • Page 48 When servicing ensure that the gas and electrical supplies to the boiler are isolated before any work starts. Hazardous materials are not used in the construction of the Qudos 28h and Qudos 28hP. However, due care should be taken when handling boiler components.
  • Page 49 WD440/3/2007 Chapter 7 : Servicing The Keston Qudos 28h & Qudos 28hP Boilers Replace the burner head, inspecting the gasket for damage and replacing if necessary, and reconnect the gas/air supply. Ensure the flanged gas/air supply joint is air tight.
  • Page 50 WD440/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP Boilers 8. REPLACEMENT OF PARTS CONTENTS GENERAL PRECAUTIONS ACCESS REPLACEMENT PROCEDURE ELECTRICAL COMPONENTS 8.4.1 CONTROL PANEL 8.4.2 BOILER FLOW & RETURN THERMISTORS 8.4.3 CABINET TEMPERATURE SENSOR 8.4.4...
  • Page 51 WD440/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP Boilers 8.4.2 Boiler Flow and Return Thermistors (Fig. 6.7.2 item 48) Isolate the appliance (Section 8.1) Gain access (Section 8.2) iii) Remove the push on connectors from the thermistor taking note of the correct positions.
  • Page 52 WD440/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP Boilers 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.
  • Page 53 WD440/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28h & Qudos 28hP Boilers HEAT EXCHANGER (Fig. 6.7.2 item 41) Isolate the appliance (Section 8.1) Gain access (Section 8.2) iii) Shut off the water supply to the appliance. Remove the burner (Section 8.6) Drain the system to below the level of the appliance.
  • Page 54 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 PartDenomination Burner KIT 64 Burner Gasket Ignitor Gasket Ignitor KIT Flow/Return Thermistors...
  • Page 55 WD440/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28h & Qudos 28hP Boilers Q28h Gas Valve - Mixer Assem. Q28hP Gas Valve - Mixer Assem. Control Panel Q28h Control PCB Q28hP Con. PCB Installation & Servicing Instructions Page: 50...
  • Page 56 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 Part Denomination Burner KIT Burner Gasket Ignitor KIT Ignitor Gasket Flow/Return Thermistor...
  • Page 57 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. ____________________ CONTROLS To comply with the Building Regulation, each section must have a tick in one or other of the boxes TIME &...

  • Page 58: Service Interval Record

    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.
  • Page 59 KESTON CONDENSING BOILERS IMPORTANT Qudos 28h and Qudos 28hP INSTALLATION KEY POINTS † 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.
  • Page 60 The Keston Qudos 28s and Qudos 28h condensing boilers are supplied fabricated for Natural Gas combustion at a supply pressure of 20 mbar. These conversion instructions must be read in conjunction with the Keston Qudos 28s or Qudos 28h Installation & Servicing Instructions - WD420 and WD440.
  • Page 61 WD458/1/2008 To measure CO 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.
  • Page 62 The Keston Qudos 28sP and Qudos 28hP condensing boilers are supplied fabricated for LPG combustion at a supply pressure of 37 mbar. These conversion instructions must be read in conjunction with the Keston Qudos 28s or Qudos 28h Installation & Servicing Instructions - WD420 and WD440.
  • Page 63 Note the original appliance serial number band production date on the new data badge vii) Stick the new data badge Q.10S.1.00.04.0 ( for the Qudos 28s - Fig. 6.7.4 item 8) or Q.10H.1.00.03.0 (for the Qudos 28h - Fig. 6.7.4 item 7) into the appliance in place of the original NG database. viii) Reassemble (Section 8.3).
  • Page 64 In any event, the CO2 level at low rate must ALWAYS be less than CO2 levels at high rate. 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.
  • Page 65 Telephone KESTON BOILERS technical support (phone no. 0208 462 0262) 8) Press the “RESET” button twice to return to the normal operation mode and display.

This manual is also suitable for:

Qudos 28hp41-930-1941-930-20

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