Keston qSpa Solar, qSpa User Manual

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Installation and Servicing Instructions

qSpa & qSpa Solar

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.uk

December 2011

UIN 208118 A01

Description

Manual handling means any transporting or supporting of a load (including lifting, putting down, pushing, pulling, carrying or moving) by hand or bodily force.

Scope

This assessment will cover the largest unit within each product range manufactured by Ideal Heating.

For speciﬁc weights and dimensions please refer to technical data section.

Main Hazards

Vision may not be clear due to the size of the products. Adopting an incorrect method of lifting may cause injury, attempting to lift these products will require help from others. (Team lifts)

Control Measures

Manual lifting procedure

The lift, key factors in safe lifting are:

a. Balance b. Position of back c. Positioning of the arms and body d. The hold e. Taking the lead for team

lifts

a. Balance - Since balance depends essentially upon the position of the feet,

they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension. In taking up this position, lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back.

b. Position of back - Straight - not necessary vertical. The spine must be

kept rigid, this coupled with a bent knee position, allows the centre line of gravity of the body to be over the weight so reducing strain.

c. Positioning of arms and body - The further arms are away from the side,

the greater the strain on the shoulders, chest and back. Keep elbows

to the body arms should be straight.

d. The hold - Before lifting ensure you have a good hold.

e. Taking the lead for team lifts- As

more than one person is required for these products ensure that one person is taking the lead. This may be you so ensure that each person that is helping is made aware of the weight and of the items listed within this assessment. Make sure you and any others helping know the route you intend to take that it is clear of any obstructions. Never jerk the load as this will add a little extra force and can cause severe strain to the arms, back and shoulders. If there are steps involved decide on where you will stop and take a rest period. Move smoothly and in unison taking care to look and listen to others helping with the lift. Where possible use a sack tr

uck to move the product over long ﬂat distances, only lift the products when necessary. If in doubt stop and get more help.

Individual capability

Individual capability plays an important part in handling these products. Persons above average build and strength will ﬁnd it easier and should be in good health. Persons below average build and strength may require more rest periods during the handling process.

Pregnant women should not carry out this operation.

Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation.

Residual risk

Following the guidelines given above will reduce any risk to injury.

All persons carrying out this operation must be fully trained and copies of the speciﬁc risk assessment made av

ailable for inspection and use in their training process.

Further guidance on Manual Handling can be obtained from the Health and Safety Executive. Manual Handling Operations Regulations 1992.

MANUAL HANDLING OF APPLIANCE PRODUCTS

qSpa - Installation and Servicing

qSpa & qSpa Solar

Destination Country: GB, IE

CONTENTS

Benchmark Commissiong Checklist .................... 26,27

Commissioning ............................................................ 20

Design.......................................................................... 6,7

Fault Finding ........................................................... 22,23

General Data Table ..................................................... 8,9

General Information ................................................... 4,5

Installation ............................................................... 10-20

Manual Handling ............................................................ 2

Schematics.............................................................. 15-18

Servicing & Maintenance ............................................ 21

Short List of Parts ....................................................... 24

Wiring Diagrams .......................................................... 19

3qSpa - Installation and Servicing

GENERAL

These instructions should be read in conjunction with the installation/servicing instructions issued by the manufacturer of the heat source being used.

Any installation must be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, I.E.E. Wiring Regulations and the Water Fitting Regulations (England and Wales) or Water Byelaws (Scotland). It should be read in accordance with the relevant recommendations of the following:

BS 6798; BS 5549; BS 5546;

BS 5440:1; BS 5440:2; CP 331:3

BS 6700: BS 5258 and BS 7593: 1992

qSpa is covered by Section G3 of the Building Regulations (England and Wales) Technical Standard P3 (Scotland) and Building

Regulation P5 (Northern Ireland). Compliance can be achieved via a Competent Person Self Certication Scheme or noticaton of

installation to the Local Authority Building Control Department.

It must be installed by a competent person as dened by the relevant regulations. Manufacturers notes must NOT be taken as

over-riding statutory obligations.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person

responsible for their safety. Children should be supervised at all times to ensure they do not play with the appliance.

This information is provided to assist generally in the selection of equipment. Responsibility for selection and specication of our

equipment must however remain that of our customer and any experts or consultants concerned with the installation(s).

Please note: that we do not therefore accept any responsibility for matters of design selection or specication, for the effectiveness of an installation or system containing one of our products unless specically requested to do so in

writing.

All goods are sold subject to our Conditions of Sale which are set out at the rear of this specication. In the interest of

continuously improving the qSpa range, Keston Heating reserve the right to modify the product without notice, and in these

circumstances this booklet, which is accurate at the time of printing, should be disregarded. An updated set of Instructions will be

produced and supplied with new appliances and will be made available for other appliances on request.

A KIWA product approved to comply with all relevant parts of the Building Regulations and Water Supply (Water Fittings) Regulations. Visit www.kiwa.co.uk for more information.

qSpa is produced under an ISO 9001:2008 Quality Management System approved by BSI.

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the

correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturers instructions by

competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used

to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code

of Practice which is available from the Heating and Hot Water Industry Council who manage and promote the Scheme.

Visit www.centralheating.co.uk for more information.

qSpa - Installation and Servicing

GENERAL

MANUFACTURER: KESTON HEATING

Maximum inlet pressure to pressure reducing valve 12 bar Operating pressure (PRV setting) 3 bar

Expansion vessel charge pressure 3 bar Expansion relief valve setting 4.75 bar

Opening pressure of P & T Relief Valve 6 bar Opening temperature of P & T Relief Valve 95°C

Energy cut-out thermostat setting 80°C

Max. Working pressure - Primary heat exchanger (Indirect models) 6 bar Max. Working pressure - Solar heat exchanger (Solar models) 10 bar Immersion heater rating 3kW, 240V AC

All cylinders are manufactured in accordance with the requirements of BS EN 12897 The tundish must be positioned so that it is visible to the occupant and is away from electrical devices.

Components supplied with qSpa

• Cold water inlet PRV combination valve/expansion relief

• Pressure and temperature relief valve

• Control thermostat

• Energy cut-out thermostat

• Energy cut-out motorised valve (indirects only)

• Tundish

• 3kW Immersion heater

• Expansion vessel/mounting bracket/exible hose

• Technical/user product literature

(Note. Please refer to Table 1 on page 8 to conrm the quantity of immersion heaters supplied with the unit)

In any situation where the volume of heated pipework (eg. secondary circulation pipes or manifold pipework for multiple units)

exceeds 10 litres, then an additional expansion vessel must be tted to accommodate the extra expansion volume.

Handling Before Installation

qSpa must be handled with care and stored the correct way up in a dry place. Any manual handling/lifting operations will need to comply

with the requirements of the Manual Handling Operations Regulations issued by the H.S.E. The appliance can be moved using a sack truck on the rear face although care should be taken and the route should be even. In apartment buildings containing a number of storeys we

would recommend that the appliances are moved vertically in a mechanical lift. If it is proposed to use a crane, expert advice should be obtained regarding the need for slings, lifting beams etc.

A specic manual handling assessment is shown on page 2 of this manual.

MAINTENANCE

Modications should not be made to this product. Replacement parts, including immersion heaters, should be purchased from Keston heating, or agents approved by them. Unvented hot water storage vessels need regular routine checks, and these are detailed below. It is for this

reason that this manual must always be left with the qSpa.

It is essential that these checks be carried out at the time of boiler maintenance by a qualied installer:

1. Manually open the relief valves in turn, and check that water is discharged from the valves and runs freely through the tundish and out

at the discharge point. Ensure that the valves re-seat satisfactorily. (Note - the water may be very hot).

2. It is important to check that the discharge pipework is carrying the water away adequately. Check for blockages etc. if it is not.

3. Turn the mains water off and remove and clean the strainer element in the Pressure Reducing Valve.

4. Check the charge pressure in the expansion vessel and repressurise if required

5. Re-ll the system and ensure that all relief valves have re-seated.

6. The Benchmark Service Record should be updated at each service.

7. Check the water pressure downstream of the combination valve is 3 bar in static condition.

8. Check and if necessary, descale the heat exchanger in hard water areas ie. above 200ppm (mg/l).

Notes.

The cylinder is factory tted with a temperature & pressure relief valve that must not be used for any other purpose or removed. The cylinder is factory tted with immersion heaters with thermal cut outs. Immersions without thermal cut outs must not be tted.

5qSpa - Installation and Servicing

GENERAL

DESIGN

qSpa is a range of INDindirect unvented hot water storage cylinders, manufactured in the latest high quality duplex stainless steel.

They are designed to provide mains pressure hot water and are supplied as a package which complies with Section G3 of the Building

Regulations. The appliance is extremely well insulated using high density HCFC free foam insulation with an ozone depleting potential

(ODP) of zero and a global warming potential (GWP) of 1. It is tted with all necessary safety devices and supplied with all the necessary control devices to make installation on site as easy as possible.

qSpa is available in two basic variants:

1. qSpa - For use with gas or oil boilers. Unvented cylinders must not be used with solid fuel boilers or steam as the energy source.

2. qSpa Solar - For providing hot water by solar gains and gas or oil boilers. Unvented cylinders must not be used with solid fuel boilers or steam as the energy source.

qSpa

qSpa indirect is an unvented hot water storage cylinder

and is provided with a high efciency internal primary

coil which is designed for use with a gas or oil boiler and is suitable for both open vented and sealed pumped primary systems.

When used with a sealed heating system the boiler must incorporate its own energy cut-out overheat thermostat.

qSpa indirect models are listed on Table 1, page 8.

qSpa Solar

qSpa Solar indirect is an unvented hot water storage cylinder

and is provided with a high efciency internal primary coil which

is designed for use with a gas or oil boiler and is suitable for both open vented and sealed pumped primary systems.

When used with a sealed heating system the boiler must incorporate its own energy cut-out overheat thermostat.

A high efciency second solar coil is positioned below the primary coil to ensure maximum benet of solar gain energy.

qSpa Solar indirect models are listed in Table 1, page 8.

Note:

The cold supply elbow c/w drain tapping must be tted as shown above. A exible hose can then be connected to the drain

tapping and, providing the hose runs below the lowest level of the cylinder, then all the water contents can be drained out by syphonic action. (The cold feed pipe dips internally to the base of the cylinder.)

qSpa - Installation and Servicing

DESIGN

GENERAL

7 8 6

7 6

4 8

qSpa

Basic Appliance

1. Hot water draw off (22mm) compression

2. Temperature & pressure relief valve 95°/6 bar

3. Hot water secondary return 22mm

(not tted to smaller sizes, see table 2)

4. Immersion heater 1¾” BSP 3kW

5. 22mm cold supply compression

6. Immersion heater 1¾” BSP 3kW

7. Dual control/overheat stat pocket (22mm)

8. Boiler control sensor pocket (spare)

9. Primary return (22mm)

- (28mm tails for 400 litre models)

10. Primary ow (22mm)

- (28mm tails for 400 litre models)

Component kit supplied separately

A. Combination inlet group incorporating pressure reducing

valve, strainer, check valve, balance cold take off point,

expansion relief valve and expansion vessel connection points.

B. Potable expansion vessels c/w flexible hose and wall

bracket

C. Tundish D. Dual control thermostat and combined overheat thermostat E. Two port (22mm) zone valve for primary circuit F. Wiring junction box for primary system

qSpa Solar

Basic Appliance

1. Hot water draw off (22mm) compression

2. Temperature & pressure relief valve 95°/6 bar

3. Hot water secondary return 22mm

(not tted to smaller sizes, see table 2)

4. Immersion heater 1¾” BSP 3kW

5. 22mm cold supply

6. Dual control/Overheat stat pocket

7. Primary return (22mm)

- (28mm tails for 400 litre models)

8. Primary ow (22mm)

- (28mm tails for 400 litre models)

9. Dual control/Overheat stat pocket

10. Solar coil return to panel collector (22mm) compression

11.

Solar coil ow from panel (22mm) compression

12. Solar thermostat pocket

Component kit supplied separately

Combination inlet group incorporating pressure reducing

valve, strainer, check valve, balance cold take off point,

expansion relief valve and expansion vessel connection points.

B. Potable expansion vessels c/w exible hose and wall

bracket

C. Tundish D. Dual control thermostat and combined overheat

thermostat (x2) E. Two port (22mm) zone valve for primary circuit F. Wiring junction box for primary system

7qSpa - Installation and Servicing

GENERAL

TABLE 1 - GENERAL DATA (REFER TO DIAGRAMS ON PAGE 9)

Cylinder qSpa qSpa Solar

Model 90 120 150 180 210 250 300 400 180 210 250 300 400

Weight - Empty kg 19 22 26 28 33 38 44 55 30 35 40 46 59

Weight - Full kg 109 142 176 208 243 288 344 455 210 245 290 346 459

Capacity (Total Volume) Litres 90 120 150 180 210 250 300 400 180 210 250 300 400

Pressure Regulator 3 bar inlet group c/w balance cold supply, expansion vessel connection and expansion valve set at 4.75 bar

Expansion Vessel size. Precharged to 3 bar

Overall Height A=mm 732 920 1107 1295 1483 1733 2020 2040 1295 1483 1733 2020 2040

Overall Diameter mm 550 550 550 550 550 550 550 630 550 550 550 550 630

Pressure & Temperature Relief

Valve 6bar 95°C

22mm Secondary Return Tapping C=mm n/a n/a n/a n/a 1127 1377 1577 1577 n/a 1127 1377 1577 1592

On Peak Immersion Heater - High

Level

Cold Feed 22mm Compression Connection

Off Peak Immersion Heater - Low

Level

Volume of On Peak Water Heated Litres 40 67 92 116 145 109 130 180 80 95 115 140 190

Dual Control & Overheat Stat G=mm 367 367 407 447 482 577 677 668 747 867 994 1130 1053

Extra Stat Pocket For Boiler Use

If Required

22mm Primary Return Compression Connection (28mm tails for 400 litre model)

22mm Primary Flow Compression Connection (28mm tails for 400 litre model)

22mm Solar Return Compression Connection

22mm Solar Flow Compression Connection

Dual Control & Overheat Stat M=mm n/a n/a n/a n/a n/a n/a n/a n/a 419 419 539 539 651

Solar Pocket N=mm n/a n/a n/a n/a n/a n/a n/a n/a 882 1000 1180 1367 1383

Solar Pocket P=mm n/a n/a n/a n/a n/a n/a n/a n/a 218 233 294 300 357

Second Off Peak Immersion

Heater - Low Level

kW Rating of Primary Coil kW 16.5 18 18.5 19 20.5 21.5 25 30.5 18 18.5 19 20.5 22

Surface Area of Primary Heater Coil

Pressure Loss Across Primary Heater Coil

Surface Area of Solar Heater Coil m2n/a n/a n/a n/a n/a n/a n/a n/a 0.680 0.680 0.970 0.970 1.270

Pressure Loss Across Solar Heater Coil

Heat Up Time from 15°C to 60°C (applies to Primary Heat Source only)

Recovery Time after 70% Draw Off

(applies to Primary Heat Source only)

Standing Losses kWhr/24hr kWh 0.80 1.00 1.20 1.40 1.60 1.75 1.93 3.33 1.40 1.60 1.75 1.93 3.33

Dedicated Solar Volume Litres n/a n/a n/a n/a n/a n/a n/a n/a 96 101 107 125 165

bar 3 3 3 3 3 3 3 3 3 3 3 3 3

Litres 12 12 18 18 24 24 35 2x24 18 24 24 35 2x24

B=mm 490 678 865 1053 1241 1491 1777 1777 1053 1241 1491 1777 1792

D=mm 352 352 392 432 432 927 1099 1151 574 614 1042 1155 1129

E=mm 367 367 442 442 442 522 522 542 437 437 522 522 557

F=mm n/a n/a n/a n/a n/a 512 512 586 n/a n/a n/a n/a n/a

H=mm 367 367 407 447 482 577 677 668 n/a n/a n/a n/a 1053

I=mm 223 223 223 223 223 223 223 223 614 654 702 815 766

J=mm 312 312 392 392 392 472 522 533 834 914 1002 1115 1026

K=mm n/a n/a n/a n/a n/a n/a n/a n/a 223 223 223 223 238

L=mm n/a n/a n/a n/a n/a n/a n/a n/a 352 352 472 472 548

R=mm n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a

m20.59 0.59 0.68 0.78 0.78 0.97 0.97 1.27 0.59 0.68 0.78 0.78 0.97

bar 0.165 0.165 0.191 0.216 0.216 0.241 0.241 0.310 0.165 0.191 0.216 0.216 0.241

bar n/a n/a n/a n/a n/a n/a n/a n/a 0.191 0.191 0.241 0.241 0.310

min 21 27 28 33 41 44 48 55 28 35 38 41

min 16 19 19 21 26 30 32 36 16 16 19 20

continued . . . . .

qSpa - Installation and Servicing

GENERAL

qSpa qSpa Solar

,00º

00º

NOTES.

1. Not all models - see table 1.

2. Recovery times based on Primary Coil/I.H. duty (ie. assumes the boiler output is adequate).

3. All connections are supplied with compression ttings for direct connection to copper pipework.

4. The heat up times shown for the D400 model indicate the times when 1 or 2 immersions are connected.

5. The diagrams shown are generic. For exact product specication refer to the table eg. the number of immersion heaters varies

depending on model.

6. Heat up and recover times based on 0.25 l/s primary ow rate and at 82ºC ow temperature

9qSpa - Installation and Servicing

INSTALLATION

I.V.

Combination Valve

I.V.

INSTALLATION

If two qSpas are coupled together the secondary inlet and outlet pipes must be balanced. The units must be tted on the same level.

Note: No valves must be tted between the expansion vessel and the storage cylinder(s).

Model Selection Guide

Max hot water demand

1 shower room Bedsit (0) 90

1 bathroom 2 (2) 120

1 bathroom 4 (3) 120

1 bathroom + separate shower room 6 (4) 150

1 bathroom + 2 separate shower rooms

or 2 bathrooms

2 bathrooms + separate shower room 7 (5) 210

2 bathrooms + 2 separate shower rooms 7 (5) 250

3 bathrooms + 2 separate showers rooms 9 (6) 300

3 bathrooms + 3 separate showers rooms 9 (6) 400

Solar Model Selection Guide

Max hot water demand

1 shower room 44 Bedsit -

1 bathroom 44 1-3 180

1 bathroom 66 1-3

1 bathroom + 1 shower room 66 1-3 210

1 bathroom + 1 shower room 84 1-3 -

1 bathroom + 2 shower rooms 84 2-4 250

1 bathroom + 2 shower rooms 113 2-4 -

2 bathrooms + 1 shower room 113 3-4 300

2 bathrooms + 1 shower room 150 4-5 -

2 bathrooms + 2 shower rooms 150 4-5 400

Max oor

area (m2)

Max number

of bed spaces

(Bedrooms)

7 (5) 180

Bedrooms

Indirect

litres

Indirect

litres

General Design Considerations

The cupboard footprint needs to be at least 650mm square for standard units up to 300 litres, 730mm for 400 litre.

The base chosen for the cylinder should be level and capable of supporting the weight of the unit when full of water as shown in General Data.

The discharge pipework for the safety valves

must have a minimum fall of 1 : 200 from the unit

to a safe discharge point. All exposed pipework should be insulated and the unit should NOT be xed in a location where the contents could

freeze.

The pipe connecting the boiler ow to the

appliance must not be less than 22mm copper or equivalent.

Mains Water Supply

Existing properties with a 15mm supply will be satisfactory provided the local mains pressure is good, but should be confined to single bathroom properties. For new properties where simultaneous demand is required to more than one bathroom or a bathroom and one or more en-suites, the communication and service pipe into the dwelling should be a minimum of 22mm

(usually in the form of a 25mm MDPE supply).

The optimum performance is achieved if the inlet pressure is 3 bar dynamic. However, the qSpa will function with lower inlet pressures, but this will reduce the performance. There should be

a ow of at least 30 litres per minute or above

available into the property. Normally qSpa provides well in excess of 40 litres/min in most conditions. Flow rates for ALL mains pressure systems are subject to district pressures and system dynamic loss. Particularly on larger properties with more than one bathroom, the pipe sizes should be calculated in accordance with BS6700.

Model Selection

Where selecting a solar model, it is important

to check the dedicated solar volume (shown in tables 1 & 2) is suitable for the total oor area of

the dwelling to ensure compliance with Building

Regulations. The maximum oor area of the

dwelling permitted for the models is shown opposite.

The suggested model sizes are based on

typical hot water usage. For high specication

dwellings an increase of one model size should be considered.

qSpa - Installation and Servicing

INSTALLATION

General Restrictions

a. The highest hot or cold water draw off point should not exceed 10 metres above

the Pressure Reducing Valve.

b. An ascending spray type bidet or any other appliance with a Class 1 back-

syphonage risk requiring a type A air gap should not be used.

c. qSpa should not be used where steam is the primary heating medium, or in a

situation where maintenance is likely to be neglected.

d. Unvented cylinders are not suitable for use with solid fuel boilers. e. If the supply to the mixer ttings (other than a dual outlet type) is not taken

from the balanced supply the system will become over pressurized and cause the pressure relief valve to discharge. Over time this could also cause the premature failure of the appliance itself which will not be covered by the warranty.

f. In larger properties with a number of bathrooms/en-suites and long pipe runs we

would recommend that the balance cold supply is provided with its own pressure

reducing valve and is not taken from the balanced cold connection on the combination valve. In this case it will also be necessary to t a small expansion

vessel on the balanced cold water system to accommodate the pressure rise caused by the increase in temperature of the balanced cold water.

g. Check the performance requirements of the terminal ttings with regard to ow/

pressure are suitable.

h. In relation to potable water systems, expansion vessels shall be installed in a

vertical orientation and located so that the length of the connecting pipe work is kept to a minimum.

Shower Fittings

Aerated taps are recommended to prevent splashing. Any type of shower mixing valve can be used as long as both the hot and cold supplies are mains fed. However, all mains pressure systems are subject to dynamic changes particularly when other hot and cold taps/showers are opened and closed, which will cause changes in the water temperature at mixed water outlets such as showers. For this reason and because these are now no more expensive than a manual shower we strongly recommend the use of thermostatic showers with this appliance. These must be used in 3 storey properties where the impact on pressure/ temperature of opening another tap in the system is greater than normal. The shower head provided must also be suitable for mains pressure supplies.

Pipe Layout

In all mains pressure installations it is important to remember that the incoming cold supply must be shared between all

terminal ttings. It is important that a 22mm

supply is brought to the appliance and a

22mm take-off is continued at least to the bath. If there are two baths, 28mm pipework should be considered. One metre of smaller diameter pipework, or ow restrictors, should be provided on the nal connection to all

outlets so as to balance the water available.

In any event the distribution pipework should

generally be in accordance with EN806:1.

Plastic Pipework

This appliance is suitable for use with

plastic pipework as long as the material

is recommended for the purpose by the manufacturer and is installed fully in accordance with their recommendations.

Secondary Hot Water Circulation

Some models are tted with a secondary

return tapping as standard (see tables 1 and

2 for details). If tted, an extra expansion

vessel may be necessary. A non-return

valve MUST be FITTED near the return

connection. No valve or terminal fitting should be installed between the non return valve and the cylinder. (See schematic arrangement on page 13.)

INSTALLATION

P&T

TO EXTERNAL TAP

INCOMING COLD SUPPLY

qSpa - Installation and Servicing

DHW

ERV/NRV

PRV

SINK

SCV

WM or DWM

WATER SOFTENER (IF NECESSARY)

WHB

SCV

DCV

WC BATH

Note: Cold supplies to single taps must be

taken from the mains cold water system.

Cold supplies to mixer taps must be taken from the balanced cold water connection on the combination valve.

WHB

W.C.

INSTALLATION

PRESSURE & TEMPERATURE/EXPANSION RELIEF VALVE PIPEWORK

INSTALLATION

Typical Discharge Pipe Arrangement

15 mm discharge pipe

500 mm max.

P & T Relief Valve

300 mm

min.

22 mm metal pipe with continuous fall up to 9m equivalent length (D2).

NOTES:

The discharge will consist of scalding waterand steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges.

It is not acceptable to discharge straight into a soil pipe.

Worked Example

Expansion relief valve

Dotted line showing alternative route with single tundish being used

Discharge below fixed grating

Fixed Grating

Trapped gully

The relief valve should be installed to discharge in accordance with G3 of the Approved Document of the Building Regulations and should be piped to where it is visible, but will not cause danger to persons or damage to materials.

The following information is taken from

Approved Document G3 of the Building Regulations and is provided to assist with the design and installation of the discharge

pipework. However, the information is not

exhaustive and reference should always be made to Approved Document G3 of the Building Regulations. The final decision regarding any arrangements rests with Building Control and it is recommended that their advice is sought if you have any concerns regarding this aspect of the installation.

The two safety valves will only discharge water under fault conditions. When operating normally water will not be discharged.

The tundish should be vertical, located in the same space as the unvented hot water

storage system and be tted as close as

possible and within 500mm of the safety device e.g. the temperature relief valve.

The example below is for G1/2 temperature relief valve with a discharge pipe (D2) having 4 elbows and length of 7m from the tundish to the point of discharge.

From the table below:

Maximum resistance allowed for a straight length of 22mm copper discharge

pipe (D2) from a G1/2 temperature relief valve is: 9m subtract the resistance for 4 x 22mm elbows at 0.8m each = 3.2m.

Therefore the maximum permitted length equates to: 5.8m.

5.8m is less than the actual length of 7m therefore calculate the next largest size.

Maximum resistance allowed for a straight length of 28mm pipe (D2) from a

G1/2 temperature relief valve equates to: 14m.

As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

Sizing of copper discharge pipe ‘D2’ for a temperature relief valve

with a G1/2 outlet size (as supplied)

Deduct the gure

Size of discharge

pipework

Maximum length of

straight pipe

(no bends or elbows)

below from the

maximum length for

each bend or elbow in

the discharge pipe

22mm Up to 9m 0.8m

28mm Up to 18m 1m

35mm Up to 27m 1.4m

The discharge pipe (D2) from the tundish should terminate in a safe place where there

is no risk to persons in the vicinity of the

discharge, be of metal and:

a) Be at least one pipe size larger than the

nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger, and so on. Bends must be

taken into account in calculating the ow

resistance. Refer to the table and the

worked example.

An alternative approach for sizing

discharge pipes would be to follow BS6700 Specification for design installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

b) Have a vertical section of pipe at least

300mm long, below the tundish before

any elbows or bends in the pipe work.

c) Be installed with a continuous fall.

continued . . . . .

qSpa - Installation and Servicing

INSTALLATION

d) It is preferable for the discharge to be visible at both the tundish and the nal

point of discharge but where this is not possible or practically difcult there

should be clear visibility at one or other of these locations. Examples of acceptable discharge arrangements are:

1. Ideally below the xed grating and above the water seal in a trapped gulley.

2. Downward discharges at a low level; i.e. up to 100mm above external

surfaces such as car parks, hard standings, grassed areas etc are

acceptable providing that where children play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.

3. Discharges at a high level; e.g. into metal hopper and metal down pipe with the end of the discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering systems that would collect such discharges.

4. Where a single pipe serves a number of discharges, such as in blocks of ats, the number served should be limited to not more than 6 systems so

that any installation can be traced reasonably easily. The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected. If unvented hot water storage systems are installed where discharges form safety devices may not be

apparent i.e. in dwellings occupied by blind, inrm or disabled people,

consideration should be given to the installation of an electronically operated

device to warn when discharge takes place.

INSTALLATION

Safety

The safety devices supplied or tted on a qSpa are selected for their suitability for

the temperatures and pressures involved. They must not be changed, removed or by-passed and it is essential that only genuine replacement parts supplied or approved by Keston Heating are used. This includes the immersion heaters, which must incorporate an energy cut-out. All parts are available to approved installers from Keston Heating.

Schematic Diagram

Hot Outlet

Secondary

Return Circuit

P&T Relief Valve

Tundish

Expansion

Vessel

ERV

Balanced

Cold

Outlets

NRV

PRV

Combination

Valve

Stop Tap

Kitchen

Cold

Tap

Pump

Boiler

Flow

Boiler

Return

Non Return

Valve

To Drain

Immersion Heater

2 Port Valve

Combination Inlet Group

Combines elements 1, 2 and 3 below.

1. Pressure Reducing Valve - This must be

xed near the cylinder. The cold water

supply to any mixer taps/showers must

be taken from the cold water tapping of

this valve to ensure balanced hot and cold pressures. This valve is factory set to ensure the correct operating pressure for the qSpa.

2. Non Return Valve - This is integral with the pressure reducing valve to prevent

backow of hot water towards cold water

draw off points.

3. Cold Water Expansion Relief Valve - This safety device is preset at the factory and will relieve excess cold water pressure resulting from a fault condition.

qSpa - Installation and Servicing

INSTALLATION

Pressure & Temperature Relief Valve

This safety device is also pre-set at the factory and relieves before the temperature reaches 100°C. It is also a Pressure Relief Valve, and is pre-set to 6 bar.

Immersion Heaters

These are 3kW 240V AC heaters and incorporate a thermostat and a manually

reset energy cut-out which operates at 80°C. They have incalloy elements to prolong their life expectancy in aggressive water conditions.

Please refer to tables 1 and 2 to clarify how many off peak and on peak

immersions are included with the unit you require.

Where it is intended that units are tted to offpeak circuits, then suitable controllers such as the Horstmann off peak electric time controller will be required. External

wiring to the immersion heaters must be in accordance with the relevant IEE Wiring Regulations and the circuit must be protected by a suitable fuse and a double pole isolating switch.

The correct method of terminating the wiring to the immersion heater is shown opposite.

E L

Immersion Heater Wiring

Thermostat

Safety

Cut-out

Usage of the product in non-domestic commercial applications can be extremely intensive and stressful to various components.

We recommend that titanium immersion heaters are tted in such situations, rather than the incology heater supplied as standard. Titanium immersion heaters offer superior strength, weight and a smoother nish which enable them to better withstand the extreme stress and temperature uctuation often encountered within non-domestic environments and situations where water

quality is poor - ensuring improved performance and extended operational life. This can be purchased as a spare part from Ideal Heating (see short list of parts, page 24).

Line Strainer

This is integral within the combination inlet group to reduce the likelihood of contaminants fouling the valve seat. Following

installation this line strainer must be cleaned and replaced. This needs to be carried out on a regular basis. as part of the

annual maintenance/service check.

Tundish

This is to allow the discharge from any Relief Valve to be seen. It must be tted away from any electrical devices. See page 12 for discharge pipework details.

Safety

The immersion heaters must be earthed and they must be isolated from the mains before the cover is removed on every occasion. Replacement immersion heaters should be obtained from Keston Heating.

Control/overheat Dual Thermostats

Care must be taken to ensure that the solar probes are fully inserted into the pockets provided.

Anti Vacuum Valve

Important - failure to follow the drain down procedure will invalidate the waranty.(see page 20)

NEVER drain the cylinder of hot water and then close all cylinder inlets and outlets. REASON as the air remaining in the cylinder cools the pressure inside the cylinder will fall below atmospheric and cause the

cylinder to implode.

NEVER close the cold main and drain the cylinder via any tap connected to it. REASON as the water drains, the pressure inside the cylinder may decrease below atmospheric and this will cause the cylinder

to implode.

To stop the possibility of this occurring by accident an ANTI VACUUM VALVE should be tted in the hot water take off pipe. This will balance the cylinder’s internal and atmospheric pressures and eliminate this risk.

Available from Keston Heating.

qSpa - Installation and Servicing

INSTALLATION

Heating/primary Systems

Warming/Overflow

Pipe

Minimum

distance as

required by

boiler

manufacturers

instructions

Boiler

Safety Valve

Schematic Open Vented Primary System

F & E Cistern

Motorised Valve

(Energy cut-out)

Gate Valve

(Not supplied)

Motorised Valve

Pump

150mm max.

(Not supplied)

Schematic Sealed Primary System

Motorised Valve (Energy cut-out)

Gate Valve

(Not supplied)

Expansion

Vessel

Gauge

Motorised Valve

(Not supplied)

The boiler and primary/heating systems should be sized and installed in accordance with BS 5449.

Safety

qSpa is tted with a Combined Temperature/

Pressure Relief Valve to cope with any increase in system temperature and pressure above the design limitations, when used with boilers up to

45kW output, which is the maximum allowed

by section G3 of the Building Regulations. The primary water temperatures should be controlled as outlined below.

Primary Circuit

It is essential that the circuit between the boiler and the qSpa is pumped. The motorised zone

valve supplied should be tted adjacent to the

unit and controlled by the cylinder thermostat supplied. The thermostat and motorised valve must be wired so that they both switch off should an overheat situation develop. It is important to follow the wiring diagram in the Wiring Section of these instructions.

Sealed Primary Circuit

Any boiler used must be fitted with an over temperature cut-out. Unvented primary circuits may be filled or replenished by means of a temporary connection between the circuit and

a supply pipe provided a ‘Listed’ double check valve or some other no less effective backow

prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use.

Alternatively, a CA device can be used, which will allow the system to be permanently connected to the cold mains supply. The primary system can then be topped up, when required, in the

same way as an open vented system tted with an F&E Cistern.

INSTALLATION

Boiler

qSpa - Installation and Servicing

Pump

Gate Valve

All our cylinders are tested to BS EN 12897 at 15 l/min at which they exceed the minimum requirements for heat up performance and re-heat in less time than the maximum re-heat times.

In extreme situations where excessive ow rates,

above 25 l/min are present, then a gate valve on the return from the cylinder to the boiler, before it joins the central heating return, may be required

to reduce excessive ow rates and therefore any

potential noise problems.

INSTALLATION

Motorised Valve

Energy cut-out

(Not supplied)

Schematic Solar Indirect System

Motorised Valve

Energy cut-out

(Not supplied)

Solar Panel

Solar

Controller

Expansion

Vessel

Solar Pumping Station

All components in a solar primary system

must be marked or identiable in such a way

that their design pressure and temperature can be readily determined.

A safety device (pressure relief valve) to

control the risk of over-pressure in system components should be tted. A termination

from a safety pressure device should

minimise the risk of damage to persons

or materials. Suitable locations are a high temperature receptacle, an internal gully or else issue externally at ground level. High level termination from walls or on roofs could cause injury to people or animals below if the valve were to release scalding water and steam.

The pipe leading to the safety device and the collector should be of rigid and non-deformable construction, without any possibility of restriction or disclosure by any

other tted component.

A more detailed diagram of our recommended arrangement for a typical solar system is shown on page 18.

This provides all the necessary controls and safety devices necessary for the solar system i.e. the two port zone valve is wired as an energy cut out and the pump/valve will only allow heat transfer as required under control of the solar controller.

The solar pocket provided accommodates an

8mm diameter sensor which, with the sensor

located in the solar collector (or in the ow

pipe immediately adjacent to the collector), will provide the information required by the solar controller.

Note: If the motorised valve is not used then any factory built hydraulic station

for solar use MUST be tted with suitable non-return valves in both ow and return

pipes to prevent gravity circulation when the pump is not running.

If there is a possibility of the solar controller that you install causing the cylinder

temperature to exceed 80ºC, under normal working conditions, then a Solar tempering

valve must be fitted to the domestic hot water outlet of the cylinder. This must limit the hot water temperature to a maximum of

60ºC. (ref building regulations part G3 3.63). Suitable plumbing congurations for installing

this valve are shown on page 17 of this

manual. NB. Any tted overheat thermostats

may require resetting in the winter months

to enable backup heat sources to heat the

cylinder.

qSpa - Installation and Servicing

INSTALLATION

✗

Figure 1: Cold port of the blending valve connected to mains supply

NOT ALLOWED

Mixed HW out

Mains CW in

Figure 2: Cold port of the blending valve connected to balanced cold

supply - NON-RETURN VALVE MUST BE FITTED

Mixed HW out

Non-Return Valve (must be fitted)

Mains CW in

Fitting Blending Valves To The Unvented qSpa Appliances

When tting a blending valve to the unvented

appliances, it is important that the installation does not contravene the G3, WRC and Health and Safety directives or the manufacturers recommendations. If this is the case, then

the warranty should be null & void. The key requirements to comply with these

regulations are: -

1. Any fitting or material in contact with potable water (e.g. a blending valve) must be approved by WRC or an equivalent body.

2. Connections or wiring arrangements must not bypass any safety devices.

3. Any expansion due to heating must not

be allowed to expand back into the cold

mains.

4. The settings of any safety devices must not be tampered with or adjusted.

The diagrams opposite shows how the blending valve can be piped onsite.

Figure 1 shows the cold water port of the blending valve connected to the mains cold water supply before the inlet control group. This arrangement is completely unacceptable and illegal because: -

• the water is allowed to expand in to mains

cold water supply.

• the vessel will be charged to the incoming

mains supply which may be considerably

higher than the working pressure of the

vessel.

If this arrangement is used then the Gledhill warrant will not be valid.

INSTALLATION

Figure 3: Cold port of the blending valve connected to mains supply

qSpa - Installation and Servicing

to the vessel after the inlet control group

Mixed HW out

Mains CW in

Figure 2 shows the cold water port of the blending valve connected to the balanced cold water outlet. This arrangement will only be acceptable if an approved non-return

valve is tted, otherwise: -

• during the heating cycle, the water will expand back into the mains supply, as the

regulating valve must not be relied upon

to act as a check valve under all operating

conditions.

• depending upon the characteristics of the blending valve, hot water may also ow

from the balanced cold water taps.

Figure 3 shows the cold port of the blending valve connected to the cold water supply to the vessel after the inlet control group. This should be the preferred method. It is recommended that the installer should ensure that there is no gravity circulation in

the pipework connected to the cold port. If necessary, this can be achieved by tting

a non-return valve or using a thermal trap.

INSTALLATION

WIRE COLOUR LEGEND

Red BlueBl

BrownBr

Wh G/Y

Black

Orange

Yellow

White

Green / Yellow

Grey

Green

INSTALLATION

Schematic Showing Solar Wiring Requirements

No isolation valve should be installed between the solar circuit and the safety valve (pressure relief valve)

1 bar

Solar Controller

G G Br Bl Br Bl

+ C

1 2C1

Pressure Relief Valve

Solar Thermstore Unvented Cylinder

Solar

Anti Gravity

Check Valve

Pumping Station

Anti Gravity Check Valve

Dual Thermostat

+ C

G Br

TWO PORT

ZONE VALVE

Gr Or

(Not supplied)

Solar Coil

This valve must be fitted on

the return to the solar panels

and be suitable for higher

temperatures operation

Bl Bl Bl

G G

Br Br Br Br BrGr

1 98765432 10

L N

230 VAC 5 amp

BrBr

Br GBl

Mains Supply

GOr

Standard 10 way wiring junction box (Not supplied)

qSpa - Installation and Servicing

INSTALLATION

(S-PLAN) WIRING DIAGRAM WITH TWO 2 PORT VALVES AND BOILER CONTROLLED PUMP OVERRUN OPTION

ELECTRONICS

N L 1 2 3 4

Bl Br Br Br

Br Bl

Danfoss WB12 Wiring Centre

1 98765432 10

Br Bl G/Y Br Br Bl G/Y

5 Amps

L N

Mains Supply Fed Via Double Pole Isolator 230 VAC ~ 5 Amps

HW CH

OFF ON OFF ON

Room ThermostatCentral Heating Control

1 2 3 4

Br Bl B

G/Y

HTG VALVE

Br Bl G/Y

V4043A TWO PORT ZONE VALVE

*Br

HW VALVE

HTG

G/Y

OrGr

G/Y

Br Br B

4 core cable

Br Bl G/Y Or Gr

V4043A TWO PORT ZONE VALVE

DHW

Typical schematic wiring diagram for an unvented installation

Overheat Stat Control Stat

G/Y Br *Br

Provide extra core from terminal 12 to

L-P connection on the boiler (shown dotted) and remove the boiler pump link if the boiler has an independant pump output.

Br Bl G/Y

Dual Aqau Stat

3 core flex

Boiler Pump

DRN.

N. Fursman

* Blue core used from standard 3 core flex please ensure you use brown sleeving at both terminating ends to identify core potential.

DATE

WIRE COLOUR LEGEND

G/Y

The electrical installation must comply with IEE requirements.

For electrical installation

refer to BS7671

Note: Do not attempt

the electrical work unless

you are competent to carry

out to the above standard

GAS BOILER

Boiler Permanent Live

Boiler Neutral

Boiler Earth

Boiler Switch Live Demand

Boiler Controlled Pump

L_P

SL_B

ENN_P

Br Bl G/Y B Br Bl G/Y

07-12-10

APPROVED

ISSUE No : 5

Red BlueBl

BrownBr

Black

Orange

Yellow

White Green / Yellow

Grey

Green

E_P

INSTALLATION

(Y-PLAN) WIRING DIAGRAM WITH 3 PORT VALVE/2 PORT SAFETY VALVE AND BOILER CONTROLLED PUMP OVERRUN OPTION

WIRE COLOUR LEGEND

Wh G/Y

The electrical installation must comply with IEE requirements.

For electrical installation

refer to BS7671

Note: Do not attempt

the electrical work unless

you are competent to carry

out to the above standard

GAS BOILER

Boiler Permanent Live

Boiler Neutral

Br Bl G/Y B Br Bl G/Y

APPROVED

ISSUE No : 4

Red

BlueBl

BrownBr

Black

Orange

Yellow

White Green / Yellow

Grey

Green

Boiler Earth

Boiler Switch Live Demand

Boiler Controlled Pump

L_P

SL_B

ENN_P

E_P

ELECTRONICS

N L 1 2 3 4

Bl Br Br Br

Br Bl

1 98765432 10

Br Bl G/Y Wh Br BrBl G/Y

5 Amps

L N

Mains Supply Fed Via Double Pole Isolator 230 VAC ~ 5 Amps

HW CH

OFF ON OFF ON

Room ThermostatCentral Heating Control

1 2 3 4

Br Bl B

G/Y

HTG VALVE

*Br

HW VALVE

Wh Bl G/Y

V4073A

MID POSITION

ZONE VALVE

HTG

G/Y

OrGr

G/Y

Br Br B

4 core cable

Or B

Gr Gr

Br Bl G/Y Or Gr

TWO PORT

ZONE VALVE

DHW

Typical schematic wiring diagram for an unvented installation

V4043A

Spade

connectors

required for earth

connections

G/Y Br

Dual Cylinder Stat

Overheat Stat

R (Supplied with stat)

4 core cable

Provide extra core from terminal 12 to L-P connection on the boiler (shown dotted) and remove the boiler pump link if the boiler has an independant pump output.

Br Bl G/Y

Boiler Pump

DRN.

N. Fursman

Control Stat

DATE

07-12-10

*BrB

* Blue core used from standard 3 core flex please ensure you use brown sleeving at both terminating ends to identify core potential.

qSpa - Installation and Servicing

COMMISSIONING

INSTALLATION

Connections can come loose in transit, and all should be checked before

installation.

Ensure that the immersion heater setting is 60°C and that the wiring is in accordance with the diagram.

Check the pressure on the air side of the expansion vessel = 3 bar. This must

be done when the volume in the cylinder is cold.

Check that the drain cock is closed, and open all the cold and hot water taps and other terminal ttings. Allow the system to ll with water, and to run until there is no air left in the system. Close the taps and inspect the system closely for leaks.

INSTALLATION

Manually open the Relief Valves one by one and check that water is discharged and run freely through the tundish and out at the discharge point. The pipework should accept full bore discharge without overowing at the tundish, and the

valve should seat satisfactorily.

In line with good plumbing practice, use with exessive ux should be avoided.

When soldering above the cylinder, ensure ux/solder does not contaminate the

cylinder below, since this can cause corrosion.

Allow the cylinder to heat to normal working temperature, then thoroughly ush the domestic hot and cold water pipework through each tap.

NOTE: If this appliance is to be installed in other than a single domestic dwelling

ie. in an apartment block or student ats etc., the hot and cold water system will

need to be disinfected in accordance with BS6700 and the Water Regulations.

Allow the cylinder to heat to normal working

temperature with whatever heat source is

to be used, and check again for leaks. The pressure relief valve or the P&T valve should

not operate during the heating cycle. If the

P&T valve operates before the pressure relief valve due to high pressure, check that the inlet control group is tted correctly. The boiler/heating systems should be lled

and commissioned in accordance with good practice following the guidance in BS 5449/ the boiler manufacturers instructions. This includes adequately flushing the system to remove any debris that may have been introduced during installation/maintenance.

NOTE: This appliance is covered by

BENCHMARK and the service record must

be completed after commissioning and after every maintenance/service visit.

Because the qSpa appliance is stainless steel, the use of chlorine as the

disinfection agent can cause damage unless the appliance is adequately ushed and relled with the mains water immediately on completion of the disinfection

procedure. Damage caused through a failure to do this adequately will not be covered by the warranty.

For the above reasons we recommend the use of a non chlorine based

disinfectant such as Fernox LP Sterox as manufactured by Cookson Electronics

when carrying out disinfection of systems incorporating these appliances.

IMPORTANT - DRAIN DOWN PROCEDURE

1 Switch off both the boiler and the immersion heater

2 Open the nearest hot tap and run all hot water until cold, then close it

3 Close the incoming cold main at the stop tap

4 Hold open the pressure and temperature relief valve until water

stops discharging into the tundish and leave it open

5 Open all the taps in the property

6 Open the drain cock and ensure the pressure and temperature relief

valve is held open until the cylinder is empty

Remove the lter from the combination inlet group clean and replace. Rell the system and open all hot taps until there is no air in the pipe work. ENSURE

CYLINDER IS DRAINED PRIOR TO CHECKING OR REMOVING FILTER FROM THE COMBINATION INLET GROUP.

qSpa - Installation and Servicing

SERVICING

SERVICING & MAINTENANCE

The Registered Installer is responsible for the safe installation and operation

of the system. The installer must also make his customer aware that periodic

maintenance of the equipment is essential for safety.

Maintenance periods will vary for many reasons. Keston Heating recommend a

maximum of 12 months to coincide with boiler maintenance. Experience of local water conditions may indicate that more frequent maintenance is desirable, eg, when water is particularly hard, scale-forming or where the water supply contains

a high proportion of solids, eg, sand. Maintenance must include the following:

1. Check and clean lter

2. Manually check the operation of the temperature relief valve.

3. Manually check the operation of the expansion relief valve.

4. Check discharge pipes from temperature and expansion relief valves are free from obstruction and blockage and are not passing any water.

5. Check the condition and if necessary descale the heat exchangers in hard

water areas.

6. Check that water pressure downstream of pressure reducing valve is within

the manufacturers limits.

7. Check operation of motorised valve.

8. Check the pressure on the air side of the expansion vessel. This must be

done when the volume in the cylinders is cold.

9. Check and advise the householder not to place any clothing or other combustible materials against or on top of this appliance.

10. On completion of the work, ll in the Benchmark Service Record towards the back of this manual.

IMPORTANT NOTE

When draining down the appliance for any reason, the instructions provided in the Commissioning Section MUST be followed to prevent potential damage to the cylinder.

SERVICING

qSpa - Installation and Servicing

FAULT FINDING

Scale

In hard water areas it is recommended that an in-line scale inhibitor

is tted. Reducing the temperature of the stored water will reduce

the rate at which scale forms. If the recovery rate is badly affected, this is an indication that scaling may have occurred. In this event, follow the procedures as recommended by a reputable Water Treatment Company.

General

No water at the tap. Check that the mains water supply is turned ON. Check the line strainer is not blocked. Check that the combination valve has been tted so that water is owing in the

correct direction. If the water at the tap is cold, ensure that the boiler has been

switched ON and is working correctly. Check that there are no air locks in the primary system. ISOLATE THE UNIT AT THE MAINS ELECTRIC SUPPLY AND THEN CHECK THE FOLLOWING:

i. The cylinder thermostat ii. The thermal cut-out, which can be re-set by pushing the red button iii. The motorised valve iv. The boiler thermostat

v. The boiler thermostat cut-out (if tted)

ANY ENERGY CUT-OUT MUST NEVER BE BY-PASSED UNDER ANY CIRCUMSTANCES.

If the units are not getting hot and the heat source is electrical, ensure that the immersion heaters are isolated from the mains before re-setting the energy cut-out. If the immersion heater(s) need replacing this should be done with the units supplied from Keston Heating.

Discharge From Relief Valves

If cold water is discharging from the expansion relief valve into

the tundish check the pressure on the expansion vessel when

cold and recharge if necessary.

If the fault continues and the problem cannot be stopped by operating the easing control a few times then either the Pressure Reducing Valve or the Relief Valve may be at fault. If the cold water pressure is too high, this would suggest that the Pressure Reducing Valve is at fault and the Keston Heating approved

replacement should be tted. If the pressure is correct then

the Relief Valve will require replacing with an Keston Heating approved component.

See Commissioning for drain down procedure.

If there is an overheat fault and very hot water is being discharged, turn off the heat source, but not the water supply.

When the supply is cool, check thermostats and energy cut-outs in

the boiler and immersion heaters and replace the faulty component

with a unit supplied by Keston Heating and check that it works

correctly before returning the system to full operation.

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

qSpa - Installation and Servicing

FAULT FINDING

FAULT - No Hot Water (Indirect)

START

YES

Is boiler on?

YES

Is hot water programmer

in ‘on’ position?

YES

Is zone valve in

correct position?

YES

Is control temperature

set at 55ºC - 60ºC?

Switch on

Set programmer

Re-set, check wiring &

plumbing is correct

Re-set

YES

Has high limit cut out?

YES

Re-set

END

FAULT - Poor Water Flow at Hot Taps

START

YES

Is incoming mains supply flow/pressure adequate?

YES

Is in-line strainer

(in combination valve)

clean?

YES

Is pressure reducing valve

(in combination valve)

working?

YES

Is system free from

restrictions/blockages?

Water service check by

supply company required

Clean or replace strainer

as appropriate

Service /replace PRV

as appropriate

Clear obstructions

NO NO

Is all wiring to the

controls ok?

YES

Replace thermostat

FAULT - Water Discharge Into Tundish

START

Is pressure downstream

of pressure reducing valve

correct?

YES

Is valve seal and seat clean & undamaged?

YES

Is heater operating at

less than 60ºC?

Re-wire

YES

Clean or replace

as required

Is expansion vessel

charge pressure correct?

YES

Replace ERV/TPRV

YES

Recommission

expansion

vessel pressure

Is ERV/TPRV

discharging?

YES

END

qSpa - Installation and Servicing

Re-set temperature

Replace PRV END

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

LIST OF PARTS

SPARE PARTS LIST

Description Quantity Stock Code No.

1 3kW immersion element 1 176749

3 Pressure and temperature relief valve 6 bar 95°C 1 176748

4 Inlet group set at 3 bar c/w expansion relief valve set at 4.75 bar 1 176750

5 ¾” exible hose 1 176755

7 12 litre expansion vessel 1 176751

8 18 litre expansion vessel 1 176752

9 24 litre expansion vessel 1 176753

10 35 litre expansion vessel 1 176754

12 22mm 2 port valve (indirects only) 1 176758

13 Junction wiring box (12 way) 1 176759

14 Control and overheat limit thermostat 1 176757

15 15mm x 22mm tundish 1 176756

qSpa - Installation and Servicing

25qSpa - Installation and Servicing

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name Telephone Number

Address

Cylinder Make and Model

Cylinder Serial Number

Commissioned by (print name) Registered Operative ID Number

Company Name Telephone Number

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate

Building Regulations Notiﬁcation Number (if applicable)

ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)

Is the primary circuit a sealed or open vented system? Sealed

What is the maximum primary ﬂow temperature?

ALL SYSTEMS

What is the incoming static cold water pressure at the inlet to the system?

Has a strainer been cleaned of installation debris (if ﬁtted)? Ye s

Is the installation in a hard water area (above 200ppm)? Yes

If yes, has a water scale reducer been ﬁtted? Yes

What type of scale reducer has been ﬁtted?

What is the hot water thermostat set temperature?

What is the maximum hot water ﬂow rate at set thermostat temperature (measured at high ﬂow outlet)?

Time and temperature controls have been ﬁtted in compliance with Part L of the Building Regulations? Ye s

Type of control system (if applicable) Y Plan

Is the cylinder solar (or other renewable) compatible? Yes

What is the hot water temperature at the nearest outlet?

All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Ye s

Open

S Plan

Other

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l/min

°C

UNVENTED SYSTEMS ONLY

Where is the pressure reducing valve situated (if ﬁtted)?

What is the pressure reducing valve setting?

Has a combined temperature and pressure relief valve and expansion valve been ﬁtted and discharge tested? Yes

The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes

Are all energy sources ﬁtted with a cut out device? Yes

Has the expansion vessel or internal air space been checked? Yes

THERMAL STORES ONLY

What store temperature is achievable?

What is the maximum hot water temperature?

ALL INSTALLATIONS

The hot water system complies with the appropriate Building Regulations Yes

The system has been installed and commissioned in accordance with the manufacturer’s instructions Yes

The system controls have been demonstrated to and understood by the customer Yes

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm satisfactory demonstration and receipt of manufacturer’s literature)

All installations in England and Wales must be notiﬁed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.

A Building Regulations Compliance Certiﬁcate will then be issued to the customer.

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°C

qSpa - Installation and Servicing

SERVICE RECORD

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE 1 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 3 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 5 Date

Engineer Name

Company Name

Telephone Number

Comments

SERVICE 2 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 4 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 6 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 7 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 9 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 8 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

SERVICE 10 Date

Engineer Name

Company Name

Telephone Number

Comments

Signature

27qSpa - Installation and Servicing

Keston Heating, PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN Tel. +44 (0) 1482 443005 Fax. +44 (0) 1482 467133. www.keston.co.uk

Keston pursues a policy of continuing improvement in the design and performance of its products.

The right is therefore reserved to vary specication without notice.

qSpa - Installation and Servicing

Keston qSpa Solar, qSpa User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual