Keston qSpa Solar, qSpa User Manual
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
close
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
2
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 Certication Scheme or noticaton of
installation to the Local Authority Building Control Department.
It must be installed by a competent person as dened 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 specication 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 specication, for
the effectiveness of an installation or system containing one of our products unless specically 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 specication. 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.
4
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 conrm 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 specic manual handling assessment is shown on page 2 of this manual.
MAINTENANCE
Modications 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 qualied 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 efciency 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 efciency 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 efciency second solar coil is positioned below the
primary coil to ensure maximum benet 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.)
6
qSpa - Installation and Servicing
DESIGN
GENERAL
10
1
2
3
4
7
8
6
5
9
3
12
9
7
6
11
12
1
2
4
8
5
10
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
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 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
45
24
continued . . . . .
8
qSpa - Installation and Servicing
GENERAL
qSpa qSpa Solar
A
C
D
H
F
J
B
G
E
I
C
N
G
M
L
P
I
E
K
A
B
D
J
º
0
0
,
5
1
2
5
,
0
0
º
4
0
,
0
0
º
,00º
5
3
00º
,
5
4
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 specication 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
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