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IDEAL British Gas 100 RD2 Installation And Servicing Manual

Floor standing, gas fired fanned flue boiler
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Summary of Contents for IDEAL British Gas 100 RD2

  • Page 2 The British Gas RD2 is a range of cast iron floor standing gas central heating boilers. A complete range of natural gas models is available. The ideal replacement boiler... Easy to install, easy to operate and easy to service. The British Gas RD2 really is the ultimate replacement floor standing range - you can depend on it.
  • Page 3 GENERAL Table 1 - General Data Boiler Size Gas Supply Connection in. BSP Rc 1/2 (1/2) Number of Boiler Sections Flow and Return Connections Rc 1 (1" BSP) MAXIMUM Static Water Head m (ft.) 30.5 (100) (3 bar) MINIMUM Static Water Head m (ft.) 1.0 (3.3) Electrical Supply...

  • Page 4: Table Of Contents

    GENERAL British Gas RD2 CONTENTS 100 RD2 G.C. No. 41 387 58 Air Supply..............7 125 RD2 G.C. No. 41 387 59 Boiler Assembly - Exploded view ......12 Natural Gas only Appliance type: C Boiler Clearances ............6 Certified - P.I.

  • Page 5: Gas Safety Regulations

    GENERAL GAS SAFETY IMPORTANT. These appliances are certificated by the BG Technology Certification Services for safety and performance. Current Gas Safety (Installation and Use) It is important, therefore, that no external control devices, e.g. Regulations, or the rules in force. flue dampers, economisers etc., are directly connected to It is law that all gas appliances are installed by a CORGI these appliances unless covered by these Installation and...

  • Page 6: Boiler Clearances

    GENERAL An existing cupboard or compartment may be used, providing it Bathrooms is modified for the purpose. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the In both cases details of essential features of cupboards/ current I.E.E.

  • Page 7: Air Supply

    GENERAL GAS SUPPLY 4. Where the lowest part of the terminal is fitted less than 2m (6'6") above a balcony, above ground or above a flat roof to The local gas supplier should be consulted, at the installation which people have access then the terminal MUST be planning stage, in order to establish the availability of an protected by a purpose designed guard.

  • Page 8: Electrical Supply

    GENERAL WATER CIRCULATION SYSTEM WATER TREATMENT The boiler must NOT be used for direct hot water supply or for The British Gas RD2 incorporates a cast iron heat sealed systems. The boiler is suitable for connection to pumped exchanger. As part of the installation the central heating open vent central heating systems, pumped central heating system should be thoroughly flushed with appropriate combined with pumped or gravity indirect domestic hot water...
  • Page 9 GENERAL MINIMUM REQUIREMENTS Fully pumped systems 1. Open vent and cold feed connections must be made to the boiler flow and return tappings according to the options shown in Frame 12. 2. The boiler is assumed to be the highest point of the circulating system.
  • Page 10 GENERAL SEALED SYSTEM REQUIREMENTS Make-up vessel Hose (max. capacity union 3 litres Air vent Non-return valve Water supply Safety valve Pressure gauge Automatic air vent Drain cock HEATING CIRCUIT Hosepipe (disconnect after filling) Pump Expansion Double check valve BOILER vessel BS.1010:2 stop tap Test cock...
  • Page 11 GENERAL SEALED SYSTEM REQUIREMENTS - continued 7. Mains Connection c. Through a temporary hose connection from a draw-off tap supplied from a service pipe under mains pressure. Where There must be no direct connection to the mains water supply the mains pressure is excessive a pressure-reducing valve or to the water storage tank supplying domestic water, even shall be used to facilitate filling.

  • Page 12: Boiler Assembly - Exploded View

    INSTALLATION 7 BOILER ASSEMBLY - Exploded View 100 shown with casing removed . Fan sensor Flow sensor Overheat sensor Return sensor Tie rod Data badge LEGEND 16. Front plate assy. 1. Heat exchanger assembly. 18. Burner manifold. 2. Front section. 28.
  • Page 13 INSTALLATION UNPACKING BOILER HARDWARE PACK The boiler is supplied fully assembled in 1" BSP plugs - 3 off. Pack A, together with a standard flue Distributor tube - 1 off. assembly for lengths up to 600mm (23 1/2") 28mm x 1"BSP male straight rear or side flue outlet in Pack B.

  • Page 14: Determining The Flue Length

    INSTALLATION 10 BOILER CASING REMOVAL - continued 6. Release the screw securing the control box to the baseplate and slide to the left to release the box. 7. Remove the 2 screws securing the top panel to the sides. 8. Draw the top panel forward and lift it off the boiler. 9.

  • Page 15: Preparing The Boiler

    INSTALLATION 12 PREPARING THE BOILER 1. Screw the distributor tube (supplied with a 1" BSP x 28mm copper adaptor) into the selected heating return tapping, Table 7 - Fully Pumped Systems using an appropriate jointing material. Connections Sensor Position IMPORTANT. (as viewed at front) It is IMPERATIVE that the index mark on the distributor tube bush is in alignment with the mark on the section boss, as...
  • Page 16 INSTALLATION 14 SIDE FLUE ASSEMBLY - Exploded view - For wall thickness 114mm to 600mm Note. For lengths greater than 600mm see Frame 11. 4. Fit the outlet elbow pointing in the desired direction. Rotate 1. The boiler turret assembly is factory built for rear flue in the bayonet slot and secure with the M4 screw.

  • Page 17: Preparing The Wall

    INSTALLATION 16 PREPARING THE WALL 1. Tape the template into the selected position. 2. Mark onto the wall the position of the flue duct hole. Note. IMPORTANT. Ensure that, during the cutting If the terminal is to be operation, masonry falling outside of the building sited within 25-40mm does not cause damage or personal injury.

  • Page 18: Fitting The Flue Assembly

    INSTALLATION 19 FITTING BOILER SEALING RING TO THE FLUE - Top (100 only) 1. Fit the boiler sealing ring inside the appropriate length (A) of outer flue duct (refer to Frame 11). Ensure the boiler sealing ring is fully engaged. 2.

  • Page 19: Locating The Boiler

    INSTALLATION 22 LOCATING THE BOILER B. If the flue assembly has been fitted from the inside Rear and Side flue proceed as follows: A. If the flue assembly can be fitted from the outside, 1. Move the boiler into position ensuring that the flue proceed as follows: slides into the flue extension tube and the 3 sealing ring studs locate into the boiler back...
  • Page 20 INSTALLATION 25 CONNECTING THE FLUE TO THE BOILER - Top (100 only) 1. Connect the flue terminal to the boiler, using the length (A) of flue duct previously cut and ensuring that the inner flue locates into the kit extension tube (without ring).
  • Page 21 SERVICING 27 FLUE EXTENSION DUCTS 28 FLUE EXTENSION DUCTS - continued Top outlet flue length = A + B + Elbow allowance Elbow = 1m Elbow = 0.7m FLUE KITS Pack B: supplied as standard. Pack D: optional extension kit for side flue, top or rear flue outlet. Refer to Frame 27. 1.

  • Page 22: Gas Connection

    INSTALLATION 30 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal. Its use is not essential if the flue hole and flue ducts have been accurately cut and the outside wall face is flat. 1.

  • Page 23: Electrical Connections

    INSTALLATION 33 ELECTRICAL CONNECTIONS 1. Remove the securing screw and lift off the mains terminal box cover. WARNING. The appliance must be efficiently earthed. 2. Route the mains cable from the LH rear of the boiler, along A mains supply of 230 V ~ 50 Hz is required. the front of the baseplate to the terminal box.

  • Page 24: External Controls

    SERVICING 35 EXTERNAL CONTROLS IMPORTANT. A link wire between terminal EC1and EC2 is not acceptable. The wiring diagrams illustrated in Frames 35-37 cover the Note. Route the cable to terminals EC1 & EC2 from the RH systems most likely to be fitted to this appliance. rear of the boiler and across the top of the control box.
  • Page 25 SERVICING 37 MID POSITION VALVE Pumped only Notes. 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring. 2. For numbering of terminals on thermostats see the manufacturer's literature. 3. This is a fully controlled system - set the boiler thermostat to maximum.

  • Page 26: Frost Protection

    SERVICING Clock with volt free contacts should be used. 40 FROST PROTECTION Central heating systems fitted wholly inside the house do not normally require frost protection as the house acts as a 'storage heater' and can normally be left at least 24 hrs.

  • Page 27: Initial Lighting

    SERVICING 42 COMMISSIONING AND TESTING GAS INSTALLATION 1. The whole of the gas installation, including the meter, ELECTRICAL INSTALLATION MUST be inspected and tested for soundness, and purged 1. Checks to ensure electrical safety should be carried in accordance with the recommendations of BS. 6891. out by a competent person.

  • Page 28: Handing Over

    SERVICING 44 GENERAL CHECKS Make the following checks for correct operation: Thermostat Flow Temperature Knob Setting 1. Turn the boiler thermostat OFF and ON to check that the main burner is extinguished and relit in response. 2. Set the boiler thermostat knob to position 6 and operate the mains on/off switch.
  • Page 29 SERVICING 46 SCHEDULE WARNING. d. Clean the main burner. Refer to Frame 49. BEFORE SERVICING always turn OFF the gas supply at the e. Clean the heat exchanger. Refer to Frame 50. gas service cock and switch OFF and DISCONNECT the electrical supply to the appliance.

  • Page 30: Burner And Controls Assembly Removal

    SERVICING 48 BURNER AND CONTROLS ASSEMBLY REMOVAL 1. Remove the control box cover. 2. Unplug the HSI lead from the PCB and withdraw it from the box. 3. Disconnect the detection lead from the electrode. 4. Remove the screw securing the control box to the baseplate, slide to the left to release and place to one side.

  • Page 31: Gas Pressure Adjustment

    SERVICING 51 RE-ASSEMBLY Re-assemble the boiler in the following order: 4. Refit the thermistor sensor and secure with the M4 screw. 1. Refit the flue baffles. 5. Refit the burner assembly. 2. Inspect the collector hood rope gasket and replace, if necessary, ensuring that the self adhesive rope is fitted 6.
  • Page 32 SERVICING 54 HOT SURFACE IGNITER (HSI) REPLACEMENT 1. Remove the lower front panel and grille assembly. Refer to Frame 47. 2. Remove the securing screw and lift off the control box cover. 3. Unplug the HSI lead from the PCB and withdraw it from the control box.

  • Page 33: Controls Panel Replacement

    SERVICING 56 CONTROLS PANEL REPLACEMENT 1. Remove the lower front panel/grille assembly and control 4. Fit the new control panel and re-assemble in reverse panel. Refer to Frame 47. order. 2. Remove the control thermostat potentiometer. Refer to 5. Check the operation of the boiler. Frame 55.

  • Page 34: Main Burner Replacement

    NOTES 58 MAIN BURNER REPLACEMENT 1. Remove the lower front panel/grille assembly. Refer to Frame 47. 2. Remove the burner and controls assembly. Refer to Frame 57. 3. Remove the 2 nuts and washers securing the burner to the front plate and manifold.

  • Page 35: Gas Valve Replacement

    NOTES 60 GAS VALVE REPLACEMENT 1. Remove the lower front panel and grille assembly. Refer to Frame 47. 2. Remove the burner and controls assembly. Refer to Frame 57. 3. Unscrew the gas inlet pipe from the valve. 4. Remove the 4 securing screws and withdraw the valve from the burner manifold.
  • Page 36 GENERAL 63 PRINTED CIRCUIT BOARD (PCB) REPLACEMENT IMPORTANT. Overheat thermostat Any failure indicating a PCB fault should be confirmed reset button before replacing the PCB by ensuring that all Reset button electrical connections are correctly made (Check pin alignment) and secure. 1.
  • Page 37 GENERAL 65 THERMOSTAT REPLACEMENT Hook plate Thermostat pocket 1. Remove the lower front panel and grille assembly. Refer to Frame47 2. Undo the overheat thermostat sensor retaining screw and withdraw the sensor from the pocket. 3. Remove the control box cover. 4.

  • Page 38: Fault Finding

    FAULT FINDING Before attempting any electrical fault finding ALWAYS carry out Detailed instructions on the cleaning and adjustment or preliminary electrical system checks, i.e. earth continuity, replacement of faulty components are contained in the polarity and resistance to earth using a suitable meter. 'Servicing' section of this publication.

  • Page 39: Short List Of Parts

    SHORT LIST OF PARTS When ordering spares please quote: The following are parts commonly required as replacement components, due to damage or expendability. Their failure or 1. Boiler model absence is likely to affect safety or performance of this 2. Appliance G.C. number appliance.
  • Page 40 SHORT LIST OF PARTS 66 SHORT PARTS British Gas 100 & 125 RD2 - Installation & Servicing...
  • Page 41 LIST OF PARTS 67 BOILER CONTROL PANEL - Exploded View Legend 63. Control panel complete assembly. 67. Control potentiometer knob. 71. Control front panel (door). 72. Magnetic strip. 89. Control potentiometer. 68 BOILER CASING ASSEMBLY British Gas 100 & 125 RD2 - Installation &...

  • Page 42: Burner Assembly

    LIST OF PARTS 69 CONTROL BOX - Exploded View Legend 29. Control box. 30. PCB . 34. PCB standoff. 37. Control box cover. Mex 1851 70 BURNER ASSEMBLY Legend 16. Burner assembly complete. 18. Burner manifold. 20. Main burner. 21. Main burner injector. 24.
  • Page 43 NOTES British Gas 100 & 125 RD2 - Installation & Servicing...
  • Page 44 This boiler is exclusively manufactured for British Gas by Ideal Boilers Ltd. THIS SYMBOL IS YOUR ASSURANCE OF QUALITY These appliances are designed for use with Natural Gas only. They have been tested and conform with the provisions of BS. 6332 and BS. 5258.

This manual is also suitable for:

British gas 125 rd2British gas 40 rd2British gas 80 rd2British gas 50 rd2British gas 60 rd2British gas 70 rd2

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