Keston Qudos 37, Qudos 37P User's Installation Manual

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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. [phone] Fax. [phone]

email : [e-mail] web : www.keston.co.uk

COMPLIANT WITH BUILDING REGULATION PART L1 & L2

SEDBUK A RATED

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
& Use) Regulations

Section Description
0 HANDLING INSTRUCTIONS

0.1 List of contents

0.2 Recommended handling procedure

1 USER INSTRUCTIONS

1.1 Introduction

1.2 Maintenance

1.3 Boiler Setup and Operation

1.4 Safety Information

2 GENERAL INSTRUCTION

2.1 Description

2.2 Boiler Schematic

2.3 Related Documents

2.4 Physical Data

2.5 Optional Accessories

2.6 Performance Data Q37 and Q37P

3 BOILER LOCATION

3.1 Dimensions & Minimum Clearances

3.2 Service Connections

3.3 Position

3.4 Electrical

3.5 Boiler Size Selection

3.6 Gas Supply

3.7 Water Systems

3.8 Flue System

3.9 Air Supply

3.10 Compartment Installation

3.11 Condensate Drainage

4 INSTALLATION OF THE BOILER

4.1 Wall Mounting Bracket

4.2 Mounting The Boiler

4.3 Assembly Practice

4.4 Installing Flue And Air Pipes

4.5 Condensate Drainage

4.6 Water System

4.7 Gas Supply

4.8 Electrical Supply

4.9 Exchanging A Boiler

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5 COMMISSIONING OF THE BOILER

5.1 Initial Flushing

5.2 Gas Supply

5.3 Electrical Installation

5.4 LP Gas

5.5 Initial Firing

5.6 Hot Flushing

5.7 Combustion Testing

5.8 Checking The Gas Pressure

5.9 Timing The Gas Meter

5.10 Handing Over To The User

6 FAULT FINDING

6.1 Electrical Control Sequence

6.2 Normal Operation

6.3 Fault Modes

6.4 Functional Flow Wiring Diagram

6.5 Electrical Wiring Diagram

6.6 Illustrated Wiring Diagram

6.7 Exploded Assembly Diagrams

7 SERVICING

7.1 Pre Service Checks

7.2 Recommended Routine Service

8 REPLACEMENT OF PARTS

8.0 General

8.1 Precautions

8.2 Access

8.3 Replacement Procedure

8.4 Electrical Components

8.5 Spark Ignition/Flame Detection Electrode

8.6 Burner

8.7 Heat Exchanger

8.8 Condensate Trap

8.9 Pump

9 SPARE PARTS LISTINGS
10 GAS BOILER COMMISSIONING CHECKLIST

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Page : ii

0. HANDLING INSTRUCTIONS

0.1 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. The following is a list of components
and their location in the boiler cabinet

Equipment List
Item Quantity Location

Wall Bracket Rawl Plugs 6 Inside accessories bag
Wall Bracket Wall Fixing Screws 6 Inside accessories bag
Wall Mounting Bracket 1 Secured to inside right

hand side of boiler case
Wall Mounting Bracket Nuts 2 Inside accessories bag.
Wall Mounting Bracket Washers 2+2 Inside accessories bag
50 mm muPVC Air/Flue Terminals 2 Inside accessories bag
Gas Isolating Cock 1 Inside accessories bag
50 mm muPVC Pipe 2 Inside boiler case
50 mm muPVC Elbow 2 Inside boiler case
Outside Temperature Sensor 1 Inside boiler case

Document List
Item Quantity Location

Registration of Purchase 1 In A4 envelope
2 Year Warranty Plan 1 In A4 envelope
Installation Template 1 In document bag

Remove the cabinet shell by removing the two retaining screws in the top of the cabinet and
the two retaining screws in the bottom of the cabinet.

0.2 RECOMMENDED HANDLING PROCEDURE

NB : The following lift operation exceeds the recommended weight for a one-man lift as
specified in the Manual Handling Operations 1992 Regulations.

For the carriage of carton it is recommended at least two people perform any lift. Clear the
carriage route of the carton from point of delivery to point of installation. Take care to avoid trip
hazards, slippery or wet surfaces and when climbing steps and stairs. Always use assistance
if required. If a sack truck is used it is recommended the carton is strapped to the truck.

For the unpacking of the appliance from the carton, it is recommended at least two people
perform any lift. It is recommended to cut the base end of carton and open the carton flaps.
Ensure the protective packing over the boiler tappings at the base of the boiler is kept in place,
then tilt the boiler forwards from its back onto its base and remove carton by sliding up over
the boiler. When lifting this appliance the back should be kept straight at all times. Avoid
twisting at the waist - reposition the feet instead. Avoid upper body bending when holding the
appliance and keep the boiler as close to the body as possible.

Before hanging the appliance on the wall it is best to store the appliance laid on its back with
the casing on. When ready to hang the boiler on the wall remove the casing and place to one
side. At this stage it is assumed that the wall bracket is correctly positioned and secured on
the wall face.

WD500 The Keston Q37 & Q37P Boilers

Page : iii

a) 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.

b) 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. Always
use assistance if required.

c) Lift the boiler by gripping at the four corners of the boiler back plate. When lifting this

appliance the back should be kept straight at all times. Avoid twisting at the waist ­reposition the feet instead. Avoid upper body bending when holding the appliance and

keep the boiler as close to the body as possible.
d) Lift the boiler and locate onto the two studs of the wall mounting bracket.
e) Place the wall mounting bracket washers over the bracket stud protruding through the

back plate of the boiler.
f) Secure the boiler onto the wall bracket by fixing the wall mounting bracket nuts onto the

wall bracket studs. This must be tightened well.
Safety footwear and gloves are recommended PPE when lifting this appliance - to protect

against sharp edges and ensure good grip.
The Q37 and Q37P boilers can be fitted in compartments with very small clearances required

around the appliance (refer to Section 3.1). Due consideration should therefore be given to
access within the compartment for lifting and positioning.

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Page : iv

1. USER INSTRUCTIONS

1.1 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.

These user instructions should be read carefully to ensure safe and economical use of your
Q37 or Q37P. The Q37 model is for use with natural gas only, the Q37P model is for use with
LPG only.

1.2 MAINTENANCE
Servicing

To ensure continual safe and efficient operation and to maintain product warranties it is a
requirement that the appliance is checked and serviced at least once per year. It is the law
that any servicing must be carried out by a competent person. Removal of the appliance

cabinet by anyone other than a competent person will automatically invalidate the
appliance warranty.

Clearances

If fixtures are to be positioned close to the boiler, the following minimum clearances must be
observed: Top 150mm, Left 5mm, Right 5mm, Base 100mm, Front 10mm. Extended
clearance is required to the front for servicing (300mm).

Cleaning

Normal case cleaning only requires dusting with a dry cloth. To remove more stubborn marks
wipe with a damp cloth and finish with a dry cloth.

1.3 BOILER SETUP & OPERATION

Check that the gas supply from the gas meter is turned on. Switch on the electrical supply to
the boiler. The display will now run through a self check procedure. Set any controls to call for
heat.

To light the boiler

The Q37 features separate two temperature controls to allow different settings depending on
the source of the demand, i.e. heating or hot water. To set these press the “+” or “-” buttons
associated with the 1st stat or 2nd stat temperature and set the required temperature. After a
few seconds the display stop flashing and will change back to show the actual boiler
temperature.
If the actual temperature
is less than the desired
temperature the boiler will
fire and, after a few
seconds, a “.” will appear
in the lower right hand
corner of the display to
show that the boiler is
alight.
In summer you can switch
the boiler to hot water only
by pressing the “2nd
STAT ONLY” button to
that the green lamp above
it is illuminated. In this
mode the boiler will not
respond to any demand
for 1st stat. Press the

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Installation & Servicing Instructions Page : 1

“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 “.” in the lower right corner of the display when the burner is alight. If the green lamp
near the “1st STAT” or “2nd STAT” +/- keys is illuminated the boiler is receiving a demand for
that function. If the green lamp is flashing the boiler is either up to temperature or shutting
down following removal of the “1st STAT” or “2nd STAT” demand.

Fault Modes

In the event that the boiler detects a situation which it considers to be a fault the display will
change to show a flashing fault code starting with an “E” and then a two digit number. The
table below explains these codes and the action you should take.

Water pressure too high - You have put too much water pressure in your systemE40

Water pressure error - You must top up the water pressure for your systemE37

Mains supply frequency incorrect - There may be a problem with your power supply.E35

Mains supply voltage < 180V - There may be a problem with your power supplyE34

Flame drop out - Check for obstruction of the flue and/or air terminals,
blockage/freezing of the drain pipe or a low gas supply (LPG).

E26

Water pressure losses - You have topped up the water pressure more than 4 times in
24 hours. You may have a leak on the system..

E24

Boiler overheat - Check that any valves to the heating circuit have not been shut down,
that there is no air in the system and that the water pressure is correct..

E03

False flame - There is possibly a problem with the power supply.E02

Ignition failure - the boiler has attempted to light five times and not succeeded - check
the gas supply is on.

E01

Description of faultDisplay

The above is an abbreviate list of possible error codes. If the code is not in the list above
consult a GAS SAFE REGISTER registered engineer. A full list of codes can be found in
Chapter 6 of this manual. If a code appears and you feel the original cause has been rectified,
press the “Reset” button to resume boiler operation. If the code persists consult a GAS SAFE
REGISTER registered engineer.
When topping up the water pressure you can observe the actual pressure by pressing the
“Installer” button repeatedly until the number “5” appears. After a few seconds the display with
then change to show the system water pressure in bar. Set the water pressure to between 1.0
and 2.0 bar.

Precautions

Care must be taken at all times to ensure that no blockage or obstruction is present in the
condensate drainage line. In addition, the air intake and flue exhaust terminals must be free
from obstruction at all times.

Frost Protection

The Q37 has an integral frost protection function. However, care should also be taken that any
exposed pipework is adequately insulated to prevent freezing.

1.4 SAFETY INFORMATION
IF YOU SUSPECT A GAS LEAK TURN OFF THE APPLIANCE IMMEDIATELY, TURN OFF

THE GAS TAP TO THE APPLIANCE (LOCATED UNDERNEATH) AND CONTACT YOUR
LOCAL GAS REGION WITHOUT DELAY.

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Installation & Servicing Instructions Page : 2

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. The details of the Checklist will be
required in the event of any warranty work being required. There is also Service Interval

Record (Chapter 10) to be completed after each annual service visit.
These forms (Chapter 10) should be kept in a safe place for the life of the boiler.

The boiler should be installed and serviced only by GAS SAFE REGISTER registered
operatives. All GAS SAFE REGISTER registered Installers carry a GAS SAFE REGISTER ID
card and have a registration number. Both should be recorded in your boiler manual
(Chapter 10: GAS BOILER COMMISSIONING CHECKLIST). You can check your installer by
calling GAS SAFE REGISTER direct on 0800 408 5500.

IMPORTANT
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 to ensure that they do not play with the appliance.

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Installation & Servicing Instructions Page : 3

2. GENERAL INSTRUCTION

2.1 DESCRIPTION

The KESTON Q37 and Q37P boilers utilize the latest in condensing technology to
produce a high efficiency boiler with SEDBUK A rated efficiency plus advanced controls to
maximize operational efficiency.

The Q37 is unique in concept and design. It comprises a high efficiency stainless steel

heat exchanger coupled with a low emissions burner to deliver ultra high efficiency

condensing mode operation within a compact wall hung cabinet. The unit automatically

adjusts gas and air rate according to demand to give a heating input in the range of 9.2kW

to 38.0kW (GCV). The integral pump assembly, in the Q37, is automatically speed

controlled to best match water flow rate to heat output & further increase appliance

efficiency.

In addition, the boiler feature a connection for an optional outside sensor to enable the

boilers inbuilt weather compensation option which delivers enhanced user comfort levels

with peak operating efficiency due to the lower flow temperatures involved. The boiler also

features an “Opentherm” connection point for the Keston Room Control module which

provides further advanced user control for room temperature compensation and optimum

start. The boiler fascia provides separate user controls for 2 stats (e.g. central heating and

domestic hot water temperatures). The boilers have the added advantage of very high

efficiency, and small diameter muPVC plastic flue which can be extended up to 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. The ignition is direct spark and fully automatic.

The boiler housing is not waterproof and should be installed in a position where it will

always be dry. Combustion air is drawn from the cabinet which is connected to outside

atmosphere via a small diameter plastic intake pipe. The cabinet therefore remains under

negative pressure at all times the boiler is operating.

The boiler is suitable for connection to open vented or, preferably, sealed systems. The

pump is fitted within the boiler.

The boiler heat exchanger is made from highly corrosion resistant stainless steel in

corrugated pipe form which provides massive surface area within a compact dimension.

The hot combustion gases from the down firing burner pass around the stainless steel

pipes imparting heat into the system water. The integral variable speed pump within the

appliance cabinet ensures the heat exchanger receives correct water flow when firing.

The Q37 is not a high water content boiler and does not contain the metal mass, or water

volume, of a cast iron or steel boiler. This boiler is of low mass and low water content and

therefore responds faster when there is a call for heat. The Q37 features full user

diagnostics, integral frost protection function, automatic pump and fan exercise in periods

of inactivity, anti cycle control and dry fire protection.

2.2 BOILER SCHEMATIC

Air is drawn into the boiler through a 50 mm muPVC (BS5255 and/or BSEN1566-1 and

BSEN1329) plastic pipe or, alternatively, via a 75mm Keston composite plastic pipe. Gas

is mixed with combustion air at the inlet to the fan. The gas flow is automatically regulated

by the gas valve according to the air flow generated by the fan. The gas and air are

thoroughly mixed in the blower and fed into the burner located at the top end of the heat

exchanger module. The gas and air mixture is ignited by a direct spark ignition control

system and burns with a blue flame just off the surface of the burner. As the hot products

of combustion pass downwards, they are cooled by exchanging heat with the circulating

water which enters the heat exchanger at the bottom of the heat exchanger. The optimum

heat input is detected by monitoring flow and return temperatures and is adjusted by

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Installation & Servicing Instructions Page : 4

controlling the speed of
the fan. The optimum
pump speed is also
detected and
automatically selected
by the boiler.

When the return water
temperature is below
55oC, part of the water
vapour in the
combustion products
will condense inside
the heat exchanger,
thus increasing the
boiler efficiency further
by releasing the latent
heat of condensation.
This condensate falls
to the bottom of the
heat exchanger where
it is separated from the
flue gases and exits from the boiler through the condensate drain. Any condensate
formed in the flue runs back down the flueway and is drained at the base of the flue
connection to the heat exchanger or drain points within the flue.

The condensate is very
slightly acidic (about the
same acidity as vinegar)
and should be piped in a
plastic pipe. It is not harmful
to the waste disposal
system and may be
disposed of as normal
waste water.

The flue gases are piped in
a 50 mm muPVC (BS5255
and/or BSEN1566-1 and
BSEN1329) plastic or,
alternatively, 75mm Keston
composite plastic pipe to
outside. The temperature of
the flue gases are usually
around 5oC to 10oC above
the temperature of the
return water. The flue pipe
should be terminated
outside the building from
where they cannot re-enter
the building or any other
adjacent building.

The heating level may be
controlled by room
thermostats, programmer
time clocks and compatible
energy management
systems. An optional
Keston room controller can

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Installation & Servicing Instructions Page : 5

be connected which will provide enhanced controls such as room compensation to further

increase efficiency and comfort levels on heating only systems. Once the controls are set

the boiler operates automatically. Further, a Keston outside sensor can be connected to

the boiler which will automatically invoke weather compensated heating which further

boosts user comfort and boiler efficiency.

In the event of the boiler overheating the safety devices will cause a safety shutdown.

The Q37 features an integral frost protection function which will operate the pump,

regardless of the external controls, should the boiler temperature fall below 10oC. In the

event the boiler temperature falls below 5oC the boiler will also fire. This is to avoid

damage to the boiler through freezing of boiler water. The boiler will turn off when the flow

temperature exceeds 15oC.

The Q37 features an integral pump exercise function which will run the pump, without

firing the boiler, for 10 seconds in the event the boiler is on standby for in excess of 24

hours without firing. This is to help prevent seizing of the pump due to long periods of

inactivity.

2.3 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. It is the law that ALL gas appliances

are installed by a competent person in accordance with the above regulations.

In addition, due account must be taken to the following Codes Of Practice:

BS 6891 : Low Pressure Installation Pipes
BS 6798 : Installation of Gas Fired Hot Water Boilers of

Rated Input Not Exceeding 70kW
BS 5449 : Installation Pumped Central Heating
BS 5546 : Installation of Gas Hot Water Supplies for

Domestic Purposes (2nd family gases)
BS 5440.1 : Flues (for gas appliances of rated input not

exceeding 70kW)
BS 5440.2 : Air Supply (for gas appliances of rated input not

exceeding 70kW)
BS 5482.1 : Domestic Propane and Butane Burning

Installations
BS 7074.1 : Expansion Vessels
BS 7593 : Treatment of Water in Hot Water Central Heating

Systems
BS 7671 : Requirements for Electrical Installations. IEE

Wiring Regulations 16th Edition.

BSEN 12828:2003 : Heating Systems in Buildings: Design for water

based heating systems
BSEN 12831:2003 : Heating Systems in Buildings: Method for

calculation of design heat load
BSEN 14336:2004 : Heating Systems in Buildings: Installation and

commissioning of water based heating systems
For Timber Framed Buildings, British Gas Publications DM2. Also British Gas
Publications 'Guidance Notes For The Installation Of Domestic Gas Condensing
Boilers' and 'Specification For Domestic Wet Central Heating Systems'.

In IE, the installation must be carried out by a competent person and installed in
accordance with the current edition of IS813 “Domestic Gas Installations”, the current
Building Regulation and reference should be made to the current ETC1 rules for electrical
installations.

WD500 Chapter 2 : General Instruction The Keston Q37 & Q37P Boilers

Installation & Servicing Instructions Page : 6

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.

2.4 PHYSICAL DATA - Q37 & Q37P

Cabinet Height mm 780
Cabinet Width mm 500
Cabinet Depth mm 304

Top Clearance mm 150
Side Clearance mm 5
Base Clearance mm 100
Front Clearance (for servicing) mm 300

Weight - Full kg / (lbs) 46/(101)
Weight - Empty kg / (lbs) 41/(90)

Flow and Return Connection 28mm pipe
Gas Connection 22mm pipe
Condensate Connection overflow 22mm plastic

IP Rating IP20 (IPX0)
Flue and Air Intake Material 50mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329)

Flue Pipe Size (nominal bore) mm / (in) 50 / (2)
Air Intake Pipe Size (nominal bore) mm / (in) 50 / (2)
Max. Air Intake Length m 39
Max. Flue Outlet Length m 20*
Max. Total Flue Outlet and Air Intake Length m 40
* Flue lengths between 16 and 20m will create a 1% reduction in output.
Flue and Air Intake Material 75mm Keston Composite
Flue Pipe Size (nominal bore) mm / (in) 75 / (3)
Air Intake Pipe Size (nominal bore) mm / (in) 75 / (3)
Max. Air Intake Length m 117
Max. Flue Outlet Length m 60**
Max. Total Flue Outlet and Air Intake Length m 120
** Flue lengths between 48 and 60m will create a 1% reduction in output

2.5 OPTIONAL ACCESSORIES

A range of accessories are available from Keston Boilers Ltd to compliment an installation.
Terminal wall sealing collars are available to make good the external all face whilst working from
the inside of the building using 50mm muPVC (BS5255 and/or BSEN1566-1 and BSEN1329)
pipe. Stand-off frame is available to leave a 50mm gap behind the boiler to allow routing of pipes
behind the boiler.

Description Part Number

Flue Terminal Wall Sealing Collar (50mm) C.08.0.00.07.0
Air Terminal Wall Sealing Collar (50mm) C.08.0.00.07.0
50/75mm Flue Adapter C.17.2.00.60.0
Flue Outlet Terminal (75mm) C.17.2.26.00.0
Air Inlet Terminal (75mm) C.17.2.26.00.0
Keston Chronotherm Room Controller C.17.4.21.00.0

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Installation & Servicing Instructions Page : 7

2.6 PERFORMANCE DATA - Q37 & Q37P

Seasonal Efficiency (SEDBUK) = 90.4 (Q37) & 92.4 (Q37P)
This value is used in the UK Government's Standard Assessment Procedure (SAP) for
energy rating of dwellings. 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.

The Q37 is intended for domestic and commercial EMC environments and on a governed
G20 meter supply.

The Q37P is intended for domestic and commercial EMC environments and on a governed
G31 supply.

WD500 Chapter 2 : General Instruction The Keston Q37 & Q37P Boilers

Installation & Servicing Instructions Page : 8

Q37 Q37P
NG (G20) LPG (G31)

Min. Input (Gross CV) kW/(Btu/h) 9.2/(31,400) 9.0/(30,700)
Max. Input (Gross CV) kW/(Btu/h) 38.0/(129,700) 37.0/(126,300)

Max. Output To Water

(80/60oC Flow/Return) kW/(Btu/h) 33.6/(114,700) 33.6/(114,700)
(50/30oC Flow/Return) kW/(Btu/h) 37.0/(126,300) 37.0/(126,300)

Min. Output To Water

(80/60oC Flow/Return) kW/(Btu/h) 8.1/(27,600) 7.4(25,250)
(50/30oC Flow/Return) kW/(Btu/h) 9.0/(30,700) 8.1/(27,600)

Max. Burner Press.-Hot

(Factory Preset)

mbar/(in w.g) 0/(0) 0/(0)
Max. Gas Cons. After 10 mins l/s / (Ft3/hr) 1.00/(127) 0.38/(49)
Max. Operating Flow Temp.

o

C 82 82

Max. Press. (Sealed System) bar 2.50 2.50
Inlet Gas Pressure mbar/(in w.g) 20.0 / (8.0) 37.0/(14.8)

Recommended Temp Diff.

o

C 8 to 20 8 to 20

Electrical Supply 230V 50Hz 230V 50Hz
Power Consumption (Max) W 198 198
Power Consumption (Standby) W 4 4

Type of Gas G20 Natural Gas G31 LPG
Optimum Flue Gas CO2 Level (at max CH rate, case on) 9.1±0.2 10.5±0.2

Expected CO/CO2 Ratio (at max CH rate, case on) 0.0006 0.001
Destination Countries GB/IE GB/IE

SEDBUK Efficiency 90.4 92.4
NOx Class 5 5
Heating System Minimum Press. bar / (lbf/sq in) 0.7 / ( 10.1)

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.

IMPORTANT
This product contains ceramic fibre boards, which although not regarded as a risk, contain
ceramic fibre which may cause temporary irritation to eyes, skin and respiratory tract. The
fibres are held in place by inorganic binders. Therefore as long as the boards are not
disturbed they will not be released. Since the boards are non-serviceable parts there
should be no risk. Under no circumstances should the user interfere with any sealed parts.

To ensure that the release of fibres from these RCF articles is kept to a minimum, during
installation and servicing we recommend that you use a HEPA filtered vacuum to remove
any dust accumulated in and around the appliance before and after working on the appli­ance. When replacing these articles we recommend that the replaced items are not broken
up, but are sealed within heavy duty polythene bags, and clearly labelled as RCF waste.
RCF waste is classed as a stable, non-reactive hazardous waste and may be disposed at a
landfill licensed to accept such waste. Protective clothing is not required when handling
these articles, but we recommend you follow the normal hygiene rules of not smoking,
eating or drinking in the work area and always wash your hands before eating or drinking.

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. The details of the Checklist will be required in
the event of any warranty work being required. There is also Service Interval Record (Chapter

10) to be completed after each annual service visit.
These forms (Chapter 10) should be kept in a safe place for the life of the boiler.

The boiler should be installed and serviced only by GAS SAFE REGISTER registered operatives.
All GAS SAFE REGISTER registered Installers carry a GAS SAFE REGISTER ID card and have a
registration number. Both should be recorded in your boiler manual (Chapter 10: GAS
BOILER COMMISSIONING CHECKLIST). You can check your installer by calling GAS SAFE
REGISTER direct on 0800 408 5500.

WD500 Chapter 2 : General Instruction The Keston Q37 & Q37P Boilers

Installation & Servicing Instructions Page : 9

3. BOILER LOCATION

3.1 DIMENSIONS AND MINIMUM
CLEARANCES

The boiler must be installed in minimum
clearances shown to allow subsequent
servicing, and safe operation. However, larger
clearances may be required during installation.

3.2 SERVICE CONNECTIONS

Gas, water, air and flue pipe, condensation,

and electrical connections are as shown. Gas
: 22mm pipe. Flow/Return 28mm pipe.

The Q37 is equipped with both top and bottom
outlet connections for flow and return. The
outlet connection which is not used should be
capped.

An optional stand-off frame is also available
which mounts behind the boiler to leave a
50mm deep space behind the boiler. This is
to permit pipe routing behind the boiler if
required. See Section 2.5 - Optional
Accessories.

3.3 POSITION

The Q37 and Q37P are not suitable for
external installation. The boiler may be
installed in any room or internal space,
although particular attention is drawn to the
requirements of the current IEE Wiring
Regulations and, in Scotland, the electrical
provisions of the Building Regulations
applicable in Scotland, with respect to the
installation of the boiler in a room or internal
space containing a bath or shower.

Where a room-sealed appliance is installed in
a room containing a bath or shower, any

electrical switch or appliance control, utilising

WD500 Chapter 3 - Boiler Location The Keston Q37 & Q37P Boilers

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All dimensions in mm.

150

300 When servicing appliance

100

Figure 3.1.1

Minimum Clearances

55

10 When appliance is operating

All dimensions in mm.

500

3

0

4

Figure 3.1.2
Dimensions

Flue

Air Intake

780

mm

mains electricity, should be so situated that it cannot be touched by a person using the
bath or shower. The Q37 and Q37P are classified as IP20 (IPX0) and are therefore
suitable for installation in Zone 3 areas, unless subject to hose down.

Compartment installation is permitted - such compartments must be constructed in
accordance with BS 6798.
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. Before locating the boiler near a living
space consider whether the sounds generated by the boiler will be objectionable. The
boiler may be located within a cupboard enclosure to reduce noise levels if located within
a living space. LPG boilers must not be installed in a cellar.

3.4 ELECTRICAL

3.4.1 Electrical Connections

The boiler must be connected to a permanent 230V ~ 50Hz supply, fused at 3A.

The boiler can be wired to a single switched live 230VAC input. However,
the boiler has TWO thermostats, and will therefore accept up to TWO
switched live 230VAC signal inputs, such as heating and hot water or
radiators and underfloor heating zones. 2nd STAT demand will always take
priority over a 1st STAT demand. Alternatively, a Keston Room Controller
can be connected directly, via two core low voltage cable, to the terminals
marked “OT”. The Keston Room Controller will then provide fully room
compensated control to ensure the boiler output is matched to the rooms
requirements at optimum boiler efficiency. This is only recommended for
heating only applications. Wiring external to the boiler must be in accordance

with current I.E.E wiring regulations and local regulations.

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Chimneys not used for
venting any other

appliance may be used.

Figure 3.3

Secure air & flue pipes at
chimney outlet.

[NB: Refer to
Section 3.8.3]

The method of connection to the mains electricity supply must facilitate complete
electrical isolation of the boiler, preferably by the use of a fused, unswitched three
pin plug and a shuttered socket-outlet, both complying with the requirements of
BS 1363. There must be only one common method of isolation for the boiler and
its control system.
The appliance must be connected to the 3A supply via a fused double-pole switch
having at least 3 mm (1/8 inch) contact separation in both poles, serving only the
boiler and the system controls.
The connection point to the mains supply should be readily accessible and
adjacent to the boiler, except for rooms containing a bath or a shower. Refer to
section 3.3 Position.

3.4.2 External Wiring & Controls

1. The boiler is designed so that all control wiring is external to the boiler.

2. Heating control signal inputs must the 230VAC "switched live" type unless
using a Keston Room Controller (see below)

3.4.2.1 Enhanced Control Options

Room Compensation (Opentherm)
A Keston Room Controller may be used to provide room compensated
control to ensure the boiler output is matched to the rooms requirements
at optimum boiler efficiency. This is only recommended for heating only
applications.

Weather Compensation
A Keston outside temperature sensor may be connected as an option.
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.

3.5 BOILER SIZE SELECTION

The Q37 will automatically adjust heat output and pump speed to match the system
requirements at any given time. Efficiency and combustion levels are maintained at
optimum levels throughout the possible output range. The Q37 is therefore suitable for all
systems with a total heat load within the maximum range of the boiler.

3.6 GAS SUPPLY

A gas meter should be connected to the service pipe by the local gas region or their
contractor. An existing meter should be checked preferably by the gas region to ensure
that the meter is adequate to deal with the rate of gas supply required. Installation pipes
should be fitted in accordance with BS 6891.

Minimum/Maximum Gas Pressure:

Natural gas pressure before the gas valve must be maintained at between 18 mbar (7.2 in
WG) and 22 mbar (8.8 in) while the boiler is running

.

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Live
Neutral
Earth

Mains Supply
230V

Fused @ 3A

Room Thermostat
T6360B1028

1
2
3

KESTON

Qudos 37

L
N
E

SL1

Alarm

SL2

3.4.2 Wiring Example

OTC
OTC

To Keston
Ext. Sensor
[Optional]

OT
OT

To Keston
Room Controller
[Optional - instead of room thermostat]

LPG pressure must be maintained between 31.5 mbar (12.4 in w.g) and 37.6 mbar (14.8
in w.g) while the boiler is running.
Gas pressures above or below these levels will lead to problems associated with the gas
valve's internal pressure regulator.

Supply pipes to the boiler must not be sized less than the boiler inlet connection
(22mm). Due consideration must be given to the supply pressure to other gas
appliances in the premises. Reduction in dynamic gas supply pressure will result in
intermittent ignition failures. Ensure gas supply pipe work is adequately sized for
the length of run from the meter to the boiler at a supply rate of 38kW (i.e. a natural

gas supply should be considered to be a minimum of 22mm diameter. If gas runs greater
than 14m, including the allowance for bends, are involved the pipe size should be
increased further).

3.7 WATER SYSTEMS

All piping must be installed in accordance with all applicable local and Water Supply
Bylaws for forced hot water heating systems.
Consideration must be given to pipe capabilities and pressure drop through the piping
when selecting pipe sizes. The primary pipe connections to the boiler must be sized
according to the system load, not dictated by the boiler connection sizes.
Water treatment must be carried out to BS 7593 : Treatment of Water in Hot Water
Central Heating Systems.
In IE the requirements given in the current edition of IS813 and the current Building
Regulations must be followed.

a The Q37 is suitable for use on open, vented water systems with combined feed

and vent fitted to the boiler return.

b It is preferable for use on sealed water systems, provided the appropriate

components required (see Section 3.7.2 Sealed Systems) are included in the
system.

c Any system must be thoroughly flushed clean of grease, dirt and debris, prior to

connection with the boiler. A trap may be installed in the flow line to collect any
solder, or other debris, from the installation.

d All water systems must be constructed to comply with requirements of the Local

Water Authority.
e Always use a system complying with the requirements of BS 5449 and BS 6798.
f System design must ensure an open circuit is always available to ensure

circulation when the pump overrun function is operating after boiler shutdown.
f Isolation valves must be fitted on the flow and the return to enable isolation when

maintaining the boiler.
g Copper tubing to BS 2871 Part 1 or barrier plastic pipe suitable to 110 oC, such as

Unipipe, is recommended.
h Jointing should be either with capillary, threaded or compression fittings. Pipes

should have a gradient to ensure air is passed easily to vent points and water

flows readily to drain points.
i Draining taps must be located in accessible positions which permit the draining of

the boiler and hot water storage vessel. Draining taps should be at least 22 mm in

nominal size and be in accordance with BS 2879.

AIR VENT POINTS
j These must be fitted at all high points where air will naturally collect and must be

sited to allow complete draining of the system.
k. 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.

3.7.1 Open Vented Systems

A typical system is shown in Figure 3.7.1 which includes a combined feed and

vent. Note that the combined feed and vent must be fitted to the primary

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