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Keston Qudos 37 User's Installation Manual

Fan powered high efficiency modulating domestic condensing gas boiler
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WD500
The Keston Q37 & Q37P Boilers
Q Q Q Q udos
udos 3 3 3 3 7 7 7 7
udos
udos
Fan Powered High Efficiency
Modulating Domestic Condensing Gas Boiler
User, Installation and Servicing Instructions
ISSUE:
3/2010
Q37 & Q37P Models
CE/PI No : 87BQ006
Q37 - GC No : 41-930-23
Q37P - GC No : 41-930-24
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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Summary of Contents for Keston Qudos 37

  • Page 1 WD500 The Keston Q37 & Q37P Boilers Q Q Q Q udos udos 3 3 3 3 7 7 7 7 udos udos Fan Powered High Efficiency Modulating Domestic Condensing Gas Boiler User, Installation and Servicing Instructions ISSUE: 3/2010 Q37 & Q37P Models...

  • Page 2: Table Of Contents

    WD500 The Keston Q37 & Q37P 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 WD500 The Keston Q37 & Q37P Boilers COMMISSIONING OF THE BOILER Initial Flushing Gas Supply Electrical Installation LP Gas Initial Firing Hot Flushing Combustion Testing Checking The Gas Pressure Timing The Gas Meter 5.10 Handing Over To The User FAULT FINDING...

  • Page 4: Handling Instructions

    0. HANDLING INSTRUCTIONS LIST OF CONTENTS The Keston Q37 and Q37P 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 WD500 The Keston Q37 & Q37P Boilers Have the wall bracket nuts and washers to hand so that they can be accessed whilst holding the boiler in position on its mounting bracket. The boiler has a dry weight of 41 kg (91 lbs) and will therefore require at least two people to lift without the use of lifting aids - ensure co-ordinated movements during lift.

  • Page 6: User Instructions

    1. USER INSTRUCTIONS INTRODUCTION Thank you for choosing this Keston Q37 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 Q37 and what to do in the unlikely event of a fault.

  • Page 7: Safety Information

    WD500 Chapter 1 : User Instructions The Keston Q37 & Q37P Boilers “2nd STAT ONLY” button again to extinguish the green light above and resume normal central heating operation. Normal Operation During normal operation the digital display will show the current boiler temperature and will show a “.”...
  • Page 8 WD500 Chapter 1 : User Instructions The Keston Q37 & Q37P Boilers Benchmark Initiative As part of the industry wide “Benchmark” initiative Q37 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 9: General Instruction

    20 metres horizontally or vertically. The Keston Q37 uses a variable speed combustion blower to deliver a premix of gas and air to a downward firing burner in a high efficiency, single pass heat exchanger. The flue system is room sealed and fan powered.
  • Page 10 WD500 Chapter 2 : General Instruction The Keston Q37 & Q37P Boilers controlling the speed of the fan. The optimum pump speed is also detected automatically selected by the boiler. When the return water temperature is below C, part of the water...

  • Page 11: Related Documents

    This is to help prevent seizing of the pump due to long periods of inactivity. RELATED DOCUMENTS The Keston Q37 and Q37P Condensing Boiler 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 12: Physical Data

    Chapter 2 : General Instruction The Keston Q37 & Q37P Boilers No alterations should be made to the boiler without written permission from Keston Boilers Ltd. Any unauthorised modification will invalidate the warranty and may affect the safe and efficient operation of the boiler.
  • Page 13 The test data from which it has been calculated have been certified by Advantica Technologies Ltd Keston Boilers Ltd declare that there are no substances harmful to health within the appliance or used during the production of the appliance.
  • Page 14 WD500 Chapter 2 : General Instruction The Keston Q37 & Q37P Boilers This boiler meets the requirements of SI 3083 The Boiler (Efficiency) Regulations and is therefore deemed to meet the requirements of Directive 92/42/EEC. The CE mark on the appliance shows compliance with Directives 90/396/EEC, 73/23/EEC and 89/336/EEC.

  • Page 15: Boiler Location

    WD500 Chapter 3 - Boiler Location The Keston Q37 & Q37P 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 16 The wall on which the boiler is mounted must be of suitable load bearing capacity and must be non-combustible. The Keston Q37 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 17: Boiler Size Selection

    The boiler will automatically detect this connection and will operate on a "weather compensation" basis when receiving a heating demand signal from the SL1 terminal or from a Keston Room Controller. Screened cable (80% density) must be used to connect the outside temperature sensor.

  • Page 18: Water Systems

    Where thermal stores are to be used the thermal store supplier should be consulted as to the compatibility of the thermal store with a Keston Q37. Thermal store units where the boiler directly heats an open vented thermal store are not suitable for use with the Q37.
  • Page 19 WD500 Chapter 3 - Boiler Location The Keston Q37 & Q37P Boilers RETURN. A safety valve is specified for the primary flow to ensure discharge path at all times in the event the feed/vent connection is isolated from the boiler flow [see 3.7.2(i)].
  • Page 20 WD500 Chapter 3 - Boiler Location The Keston Q37 & Q37P Boilers Air Vent Hose Union bib tap Keston Q37 Expansion Vessel RETURN By-pass HEATING CIRCUIT Hosepipe (disconnected FLOW after filling) Drain Cock Safety Valve Double BS 1010:2 Check Valve...
  • Page 21 1394. It is advisable to fit a locksheild valve on the cylinder return to enable balancing of the flow rate through the cylinder. The Keston qSpa range of stainless steel unvented cylinders are an ideal option for use with the Keston range. The Keston qSpa range combine exceptional recovery times with durable, long life stainless steel construction and all associated controls.
  • Page 22 WD500 Chapter 3 - Boiler Location The Keston Q37 & Q37P Boilers Diagram 3.7.6 Available Pump Head Graph 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 lit/min Figure 3.7.6 Additional System Pump...

  • Page 23: Flue System

    DO NOT USE ABS PIPE OR FITTINGS. 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 stockist for details). Keston Composite 75mm pipe MUST be painted where exposed to UV light.
  • Page 24 The Keston Q37 and Q37P, 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.
  • Page 25 WD500 Chapter 3 - Boiler Location The Keston Q37 & Q37P Boilers It is advisable for horizontal flue terminals to place a 45 elbow at the end of the flue to direct the condensate plume up and away from the property. If the air...

  • Page 26: Compartment Installation

    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 Q37 and Q37P are room sealed appliances and therefore do not require purpose provided ventilation to the boiler room for combustion air. 3.10...

  • Page 27: Installation Of The Boiler

    WD500 Chapter 4 : Installation The Keston Q37 & Q37P 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 28: Condensate Drainage

    WD500 Chapter 4 : Installation The Keston Q37 & Q37P Boilers Using the template supplied within the boiler packaging mark the positions of the two holes for the flue and air pipes on the wall(s) or ceiling. Drill the two holes in the wall/ceiling, preferably using a core drill.

  • Page 29: Gas Supply

    WD500 Chapter 4 : Installation The Keston Q37 & Q37P Boilers For optimum performance after installation, this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS7592:1992, "Treatment of water in domestic hot water central heating systems".
  • Page 30 It is essential that sludge or scale is removed from an existing system before fitting the boiler. The guarantee provided with the Keston Q37 and Q37P does not cover damage caused by system debris or sludge.

  • Page 31: Commissioning Of The Boiler

    INITIAL FLUSHING All waterways within the Keston Q37 and Q37P 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 32 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 33 3) IN THE EVENT THAT AN ACCEPTABLE COMBUSTION LEVEL CANNOT BE OBTAINED AT EITHER HIGH OR LOW RATE, CONTACT KESTON TECHNICAL SUPPORT ON 0208 462 0262. DO NOT LEAVE THE APPLIANCE RUNNING UNLESS ACCEPTABLE COMBUSTION LEVELS ARE ACHIEVED.
  • Page 34 Q37 (natural gas) Q37P (LPG) If the meter timing is found to be incorrect when the boiler is firing at maximum rate contact Keston Boilers Ltd for further guidance. 5.10 HANDING OVER TO THE USER It is important to fully explain the following: Procedure to light and turn off the boiler, including isolation of the electrical supply if necessary.
  • Page 35 WD500 Chapter 5 : Commissioning The Keston Q37 & Q37P Boilers Advise on the frost protection and pump/fan exercise feature. Advise the user that a plume of water vapour (steam) from the flue terminal is normal and that there is no need for concern.

  • Page 36: Fault Finding

    WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P 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 or SL2 (Switched Live) and N (Neutral) and the “1st STAT” or “2nd STAT”...
  • Page 37 (ie “1st STAT” or “2nd STAT”) is present. A demand is received by a 230V signal to SL1 or SL2 or via the Keston Room Control unit. If the lamp is lit the boiler is on, or is starting up, to serve the demand for that function. If the lamp is flashing the demand is still present but the burner is off because the unit exceeded the desired temperature and the forced anti-cycle delay has not elapsed.
  • Page 38 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P 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 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers FUNCTIONAL FLOW WIRING DIAGRAM Installation & Servicing Instructions Page : 34...
  • Page 40 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers ELECTRICAL WIRING DIAGRAM Installation & Servicing Instructions Page : 35...
  • Page 41 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers ILLUSTRATED WIRING DIAGRAM Installation & Servicing Instructions Page : 36...
  • Page 42 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers Exploded Assembly Diagrams 6.7.1 Boiler Controls Assembly Installation & Servicing Instructions Page : 37...
  • Page 43 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers 6.7.2 Waterway, Condensate & Flue Assembly Installation & Servicing Instructions Page : 38...
  • Page 44 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers 6.7.3 Air - Gas Assembly Installation & Servicing Instructions Page : 39...
  • Page 45 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers 6.7.4 Casing Assembly Installation & Servicing Instructions Page : 40...
  • Page 46 WD500 Chapter 6 : Fault Finding The Keston Q37 & Q37P Boilers 6.7.5 Exploded Diagrams Parts Reference List Boiler Controls Assembly (Fig. 6.7.1) GC Number Code Description Main Control Box (C.12.4.03.00.0) Control Panel (C.10C.4.04.00.0 A) Terminal Block HV (C.12.4.00.01.0) Terminal Block LV (C.12.4.00.03.0) E72-401 Thermal Fuse (C.08.4.21.00.0)
  • Page 47 WD500 Chapter 7 : Servicing The Keston Q37 & Q37P 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.
  • Page 48 WD500 Chapter 7 : Servicing The Keston Q37 & Q37P Boilers 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.

  • Page 49: Replacement Of Parts

    WD500 Chapter 8 : Replacement Of Parts The Keston Q37 & Q37P 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 FLUE THERMISTOR 8.4.5...
  • Page 50 WD500 Chapter 8 : Replacement Of Parts The Keston Q37 & Q37P Boilers Unclip the thermistor from the pipe. Reassemble (Section 8.3) When fitting the new thermistor it is an advantage to smear a thin film of heat sink compound between the thermistor and pipe. This, combined with fitting the new thermistor tightly to the pipe, ensures a good contact.
  • Page 51 WD500 Chapter 8 : Replacement Of Parts The Keston Q37 & Q37P Boilers Unscrew the bolts (Fig 6.7.3 - item 99 & 100) securing the gas inlet pipe to the gas control valve. Unscrew the bolts securing the gas valve (Fig 6.7.3 - item 95) to the inlet port of the combustion blower.
  • Page 52 WD500 Chapter 8 : Replacement Of Parts The Keston Q37 & Q37P Boilers Disconnect the condense line from the projection of the condensate trap from the base of the cabinet. Withdraw the condensate trap. Mop up any spilled condensate. vii) Reassemble (Section 8.3)

  • Page 53: Short Spare Parts List

    WD500 Chapter 9 : Spare Parts Listings The Keston Q37 & Q37P Boilers 9. SHORT SPARE PARTS LIST Item GC No Part Denomination Item GC No PartDenomination Burner Burner Gasket Ignitor Gasket Ignitor/Sensor Probe Flow/Return Flue Thermistor Thermistors Pressure Sensor Pump Installation &...
  • Page 54 WD500 Chapter 9 : Spare Parts Listings The Keston Q37 & Q37P Boilers Q37 Gas Valve - Mixer Assem. Q37P Gas Valve - Mixer Assem. Control Box Fascia Panel Installation & Servicing Instructions Page : 49...
  • Page 55 WD500 Chapter 9 : Spare Parts Listings The Keston Q37 & Q37P Boilers SHORT SPARE PARTS LIST FOR THE KESTON CONDENSING BOILER RANGE Item GC No Part Denomination Burner Burner Gasket Ignitor Ignitor Gasket Flow/Return Thermistor Flue Thermistor Pressure Sensor...
  • Page 56 WD500 Chapter 10 : Benchmark Checklist Final The Keston Q37 & Q37P 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 57: Service Interval Record

    WD500 Chapter 10 : Benchmark Checklist Final The Keston Q37 & Q37P 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 58 WD500 The Keston Q37 & Q37P Boilers KESTON CONDENSING BOILERS IMPORTANT Q37 and Q37P INSTALLATION KEY POINTS † Read Installation Manual Carefully † Ensure that ALL dust particles, filings , plastic chips etc. are removed from the inlet pipe. †...

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