Keston Qudos 28s User, Installation And Servicing Instructions
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Keston Qudos 28s User, Installation And Servicing Instructions

Fan powered high efficiency modulating domestic condensing gas system boiler
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WD420/3/2007
The Keston Qudos 28s & Qudos 28sP Boilers
Qudos 28s
Fan Powered High Efficiency
Modulating Domestic Condensing
Gas System Boiler
User, Installation And Servicing
Instructions
CE/PI No : 87BR36
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.
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 WD420/3/2007 The Keston Qudos 28s & Qudos 28sP Boilers Qudos 28s Fan Powered High Efficiency Modulating Domestic Condensing Gas System Boiler User, Installation And Servicing Instructions CE/PI No : 87BR36 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.

  • Page 2: Table Of Contents

    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 &...
  • Page 3 WD420/3/2007 The Keston Qudos 28s & Qudos 28sP Boilers Hot Flushing 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...

  • Page 4: List Of Contents

    0. HANDLING INSTRUCTIONS 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.
  • Page 5 Safety footwear and gloves are recommended PPE when lifting this appliance - to protect against sharp edges and ensure good grip. The Qudos 28s and Qudos 28sP 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 28s or Qudos 28sP. The Qudos 28s model is for use with natural gas only, the Qudos 28sP 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 28s 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

    WD420/3/2007 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.

  • Page 9: Description

    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...

  • Page 10: Boiler Schematic

    The Qudos 28s is not a high water content boiler and does not contain the metal mass, or water volume, of a cast iron or steel boiler. This boiler is of low mass and low water content and therefore responds faster when there is a call for heat.
  • Page 11 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 5 C to 10 C above the temperature of the return water.

  • Page 12: Related Documents

    This is to help prevent seizing of the pump due to long periods of inactivity. RELATED DOCUMENTS The Keston Qudos 28s and Qudos 28sP Condensing Boilers must be installed in accordance with the current issue of the Gas Safety (Installation and Use) Regulations 1996, current IEE Wiring Regulations, Building Regulations, Building Standards (Scotland) Consolidation, and the Bye Laws of the local Water Undertaking.

  • 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 28s 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 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.

  • Page 16: Dimensions & Minimum Clearances

    The Qudos 28S and Qudos 28SP are classified as IP20 (IPX0) and are therefore suitable for installation in Zone 3 areas, unless subject to hose down.
  • 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 28s 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 28s 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 28s 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

    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.
  • Page 20 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 C, 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.
  • Page 21 WD420/3/2007 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 All components of the system must be suitable for a working pressure of 3 bar and a temperature of 110 C.

  • Page 22: Flue System

    Contact Keston Boilers Ltd for information The Qudos 28s 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 Chapter 3 - Boiler Location The Keston Qudos 28s & Qudos 28sP Boilers air pipe can be used (contact your Keston 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.
  • Page 24 The two terminals are subject to the requirements of BS 5440 Pt 1 for clearances from features of the building although some can be decreased to the values indicated. The Keston Qudos 28s and Qudos 28sP, as with any condensing boiler, will generate a condensate “plume” from the flue terminal in all weather conditions.

  • Page 25: Compartment Installation

    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.

  • Page 26: Wall Mounting Bracket

    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.

  • Page 27: Condensate Drainage

    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.

  • Page 28: Water System

    Advanced Features Wiring The Qudos 28s 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 29 WD420/3/2007 Chapter 4 : Installation The Keston Qudos 28s & Qudos 28sP Boilers Twin Thermostat Operation with Weather Compensation SEPARATE CH & DHW DEMAND WITH ( OPTIONAL ) WEATHER COMPENSATION ORANGE GREY Q28S BLUE BROWN FROM CH BOILER CONTROLS CH ZONE...

  • 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 28s and Qudos 28sP does not cover damage caused by system debris or sludge.
  • Page 31 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).

  • Page 32: Initial Flushing

    INITIAL FLUSHING All waterways within the Keston Qudos 28s and Qudos 28sP 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 50 ppm at low rate. If CO levels above these values are experienced, the combustion chamber and flue system should be investigated. The Qudos 28s is factory set for combustion and should need no adjustment. However, in the event adjustment is required.
  • Page 34 If following the above procedure, combustion levels described above at both high and low rate could not be obtained, please turn off the appliance and isolate the gas to the appliance. Telephone KESTON BOILERS technical support (phone no. 0208 462 0262) Press the “RESET”...
  • Page 35 WD420/3/2007 Chapter 5 : Commissioning The Keston Qudos 28s & Qudos 28sP 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 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers 6. FAULT FINDING 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.
  • 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

    WD420/3/2007 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”...
  • Page 39 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 occuring. This is very useful for diagnosing the cause of an error lockout, particularly when the error is intermittant.
  • Page 40 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 35...
  • Page 41 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 36...
  • Page 42 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 37...
  • Page 43 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers Exploded Assembly Diagrams 6.7.1 Boiler Controls Assembly Installation & Servicing Instructions Page : 38...
  • Page 44 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers 6.7.2 Waterway, Condensate & Flue Assembly Installation & Servicing Instructions Page : 39...
  • Page 45 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers Installation & Servicing Instructions Page : 40...
  • Page 46 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers 6.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 41...
  • Page 47 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers 6.7.4 Casing Assembly Installation & Servicing Instructions Page : 42...
  • Page 48 WD420/3/2007 Chapter 6 : Fault Finding The Keston Qudos 28s & Qudos 28sP Boilers 6.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code Description Q28s Main Control PCB (Q.10S.4.01.00.0) Q28sP 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 49 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 28s and Qudos 28sP. However, due care should be taken when handling boiler components.
  • Page 50 WD420/3/2007 Chapter 7 : Servicing The Keston Qudos 28s & Qudos 28sP 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 51 WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP 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 52 WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP Boilers Remove the Control Panel by removing the four retaining screws (Fig 6.7.1, item 160). Reassemble (Section 8.3) vii) Check for correct operation of the Control Panel.
  • Page 53 WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP Boilers 8.4.7 Combustion Blower (Fig. 6.7.3 item 111) Isolate the appliance (Section 8.1) Gain access (Section 8.2) iii) Disconnect the connector block from the combustion blower.
  • Page 54 WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP Boilers Remove the 4 nuts fixing the burner to the top of the heat exchanger (Fig 6.7.3, item 120). Remove the spark ignition/flame detection electrode (Section 8.5) Withdraw the burner from the top of the heat exchanger.
  • Page 55 WD420/3/2007 Chapter 8 : Replacement Of Parts The Keston Qudos 28s & Qudos 28sP Boilers Disconnect the flexible hose (Fig. 6.7.2 - 2/2 item 95) from the expansion vessel. Undo the pin (Fig. 6.7.4 - item 37) and the EV bracket (Fig. 6.7.4 - item 39) from the cabinet frame.
  • Page 56 WD420/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28s & Qudos 28sP Boilers 9. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No PartDenomination Burner Kit Burner Gasket Ignitor Gasket Ignitor Kit Flow/Return Thermistors Flue Thermistor...
  • Page 57 WD420/3/2007 Chapter 9 : Spare Parts Listings The Keston Qudos 28s & Qudos 28sP Boilers Q28s Gas Valve - Mixer Assem. Q28sP Gas Valve - Mixer Assem. Control Panel Q28s Control PCB Q28sP Con. PCB Pump Expansion Vessel Installation & Servicing Instructions...
  • Page 58 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 Part Denomination Burner Kit Burner Gasket Ignitor Kit Ignitor Gasket Flow/Return Thermistor...
  • Page 59 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. ____________________ CONTROLS To comply with the Building Regulation, each section must have a tick in one or other of the boxes TIME &...

  • Page 60: Service Interval Record

    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.
  • Page 61 KESTON CONDENSING BOILERS IMPORTANT Qudos 28s and Qudos 28sP 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 62 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 63 If CO levels above these values are experienced, the combustion chamber and flue system should be investigated. The Qudos 28s is factory set for combustion and should need no adjustment. However, in the event adjustment is required. Check combustion errors are not a result of incorrectly installed flue and/or air system, terminal location or damage or debris on the burner.
  • Page 64 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 65 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.
  • Page 66 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 67 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 28sp

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