Ideal Boilers British Gas 3100 RD1 Installation & Servicing Manual Download

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INSTALLATION

M A N U A L

British/Scottish

Gas RD1

the wall hung boiler

Wall hung, gas fired

fanned flue boiler

Installers guide to central heating boilers

& SERVICING

330 - 3100 RD1

Summary of Contents for British Gas 3100 RD1

Page 1: ...INSTALLATION M A N U A L British Scottish Gas RD1 the wall hung boiler Wall hung gas fired fanned flue boiler Installers guide to central heating boilers SERVICING 330 3100 RD1 ...

Page 2: ...s Complete range There are 7 models in the range All models include a Downward Routing Pipe Kit and an overheat thermostat Full system suitability Most models are suitable for connection to pumped open vent central heating systems pumped central heating combined with pumped or gravity indirect domestic hot water supply systems Note the 3100 model is not suitable for gravity installations They can ...

Page 3: ...0 45 1 5 Electrical supply 230 V 50 Hz Boiler power consumption 150W Fuse rating External 3A Internal F2A to BS 4265 Water content litre gal 2 7 0 6 3 65 0 8 4 65 1 0 4 65 1 0 Dry Weight kg lb 40 9 90 3 46 6 102 8 52 6 116 0 52 6 116 Maximum installation weight kg lb 31 4 69 3 37 4 82 5 43 1 95 43 1 95 Boiler size Height mm in 700 27 5 Width mm in 380 15 0 Depth mm in 300 11 8 Flue duct diameter m...

Page 4: ... this case are concentric The fan is down stream of the combustion chamber I2H An appliance designed for use on 2nd Family gas Group H only B G Certified P I No 87 BL 27 Destination Countries GB Natural Gas only Appliance type C12 C32 Data Badge Top of Controls Support Models G C Appliance No 330 RD1 41 392 13 340 RD1 41 392 16 350 RD1 41 392 17 360 RD1 41 392 20 370 RD1 41 392 21 380 RD1 41 392 2...

Page 5: ...ot water boilers of rated input not exceeding 60 kW BS 5449 Forced circulation hot water systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 7593 Treatment of water in domestic hot water central heating systems BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 k...

Page 6: ...g the space in which the boiler is to be installed must be at least wide enough to accommodate the tool c If using the Complete Sealed System Unit then refer to the instructions packed with the unit for the necessary clearances Pelmet restrictions If the ability to fit or remove the casing during installation and subsequent servicing is impaired by pelmets etc this operation can be made easier by ...

Page 7: ...ng Installation pipes MUST be fitted in accordance with BS 6891 Pipework from the meter to the boiler MUST be of an adequate size 3100 models should be piped in 22mm minimum The final 1 metre may be run in 15mm if it is visible The complete installation MUST be tested for gas soundness and purged as described in the above code FLUE INSTALLATION Pluming may occur at the terminal so terminal positio...

Page 8: ...ising mains electricity should be so situated that it cannot be touched by a person using the bath or shower See Frame 31 for details the cupboard compartment at both high and low levels The air vents must either communicate with room internal space or be direct to outside air The minimum effective areas of the permanent air vents required in the cupboard compartment are specified in Table 4 and a...

Page 9: ... a domestic circulator capable of providing an 11 C 20 F temperature differential e g Grundfos UPS 15 50 or equivalent The vertical distance between the pump and feed expansion cistern MUST comply with the pump manufacturers minimum requirements to avoid cavitation Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Briti...

Page 10: ...ust be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal size and not incorporating valves of any sort b The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 o C 230 o F c The charge pressure must not be less than the static water head above the vessel The pressure attained in the system ...

Page 11: ... valve and a stop valve with an automatic air vent connected between them the stop valve being located between the system and the automatic air vent The stop valve may remain open during normal operation of the system if automatic water make up is required b Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve an...

Page 12: ...Gravity horizontal pipes should be ABOVE ceiling level and as SHORT as possible A MINIMUM inclination of 25mm per 3m run 1 per 10 is required to avoid air locks If these conditions cannot be met pumped primaries MUST be used The 3100 is not suitable for gravity circulation The graph assumes 8 elbows in the gravity circuit For each elbow in excess of 8 R must be reduced by 300 mm 12 in or H increas...

Page 13: ...sted below Wall mounting template Wall mounting plate Side outlet terminal mounting plate Flue extension tube Boiler sealing ring Flue elbow Downward routing pipe kit Boiler Hardware Pack Contents 50mm x No 14 wood screw 4 off 50mm x No 10 wood screw 8 off Wall plug 12 off M8 washer 1 off Sealing plate 1 off M5 wing nut 3 off M8 x 12 Hx Hd screw 1 off British Gas Logo 1 off Scottish Gas Logo 1 off...

Page 14: ... applicable the extension flue box es 10 PACKAGING AND CASING REMOVAL 11 DOWNWARD ROUTING PIPE KIT Product Qty Downward pipe routing bracket 2 off M8 Spacing pillar 1 off M5 Spacing pillar 1 off Panel rear assembly 1 off M5 x 10 Pozi hex hd 2 off Cla 1379 1 If it is intended to route the flow and return pipe work downwards between the back of the boiler and the wall the Downward Pipe Routing Kit m...

Page 15: ...et with the support bracket It is MOST IMPORTANT that the boiler is installed in a vertical position Flue length mm Accessories Product No Up to 600 B Pack 1 off 150 308 600 to 1550 B Pack 1 off D Pack 1 off 150308 152132 1550 to 2500 B Pack 1 off D Pack 2 off 150308 152132 2 off 2500 to 3000 B Pack 1 off D Pack 3 off 150308 152132 3 off Note Vertex and Roof Flue Kits are available as optional ext...

Page 16: ...ed in a separate kit must be used These brackets are secured to the wall mounting plate and it is essential to use only those holes as shown on the wall mounting template 1 An optional flue duct extension kit is required for lengths distance from the outside wall to the relevant side of the boiler casing greater than 600mm 23 1 2 Refer to Frame 12 2 When cutting the ducts always use the cardboard ...

Page 17: ...7 Flue extension ducts 1 Cut the flue hole preferably with a 125mm 5 core boring tool ensuring that the hole is square to the wall If the hole has been accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue However both wall faces immediately around the cut hole should be flat make good if necessary For less accurate holes make g...

Page 18: ...he outer flue duct This ensures correct alignment of the flue terminal 4 Stick the self adhesive foam strip provided in the hardware pack onto the flue immediately behind the boiler sealing ring 21 FITTING THE SIDE OUTLET PLATES Side outlet flues only Note If the boiler is fitted closer than 25mm to the side wall the side outlet plate must be fitted now 1 Split the side outlet plate into 2 down th...

Page 19: ...e blanking plate from the direction required and use this to blank off the rear outlet Side and rear flue 2 Lift the boiler onto the wall mounting plate hooks as shown Do not use the burner controls for lifting 3 Fit the M8 screw washer and rectangular plate to retain the boiler Notes a Have ready to hand the M8 screw washer and rectangular plate supplied in the hardware pack Before fully tighteni...

Page 20: ...550 B Pack 1 off D Pack 1 off see Frame 12 1550 to 2500 B Pack 1 off D Pack 2 off see Frame 12 2500 to 3000 B Pack 1 off D Pack 3 off see Frame 12 Note Side flue shown 26 FLUE EXTENSION DUCTS For flue lengths greater than 600mm Not for 3100 model 25 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 duct...

Page 21: ... Hz is required All external controls and wiring must be suitable for mains voltage Wiring should be in 3 core PVC insulated sheathed cable not less than 0 75mm2 24 x 0 2mm to BS 6500 Table 16 Wiring Regulations and local regulations Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both pole...

Page 22: ...be wired in parallel with the control s to be overridden Refer to Frame 38 4 If a proprietary system is used follow the instructions supplied by the manufacturer Advice on required modifications to the wiring may be obtained from the component manufacturers Volt Free Contacts If switched live is connected here EC1 leave other terminal without connection If programmer is used here EC1 the switched ...

Page 23: ...b w or or r b b r r w w b br y y y g y g y g pky w pk y r r r w y g 34 PICTORIAL WIRING IMPORTANT No system controls to be wired in this mains supply 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 4 Switc...

Page 24: ... terminals on thermostats see the manufacturer s literature 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Smiths valves are similar but note that the GREY wire not the orange wire MUST be the one connected to permanent L 36 TWO SPRING CLOSED VALVE Pumped only w white y g yellow green gy grey or orange v violet pk pink LEGEND b blue bk black br brown r red ...

Page 25: ...h should suffice for all systems which do not use the OFF terminals of the programmer Diagram B shows a change over frost stat which will cover most systems which do use CH OFF If however on such a system the HW pipework is in an isolated part of the house a second frost stat may be used to protect it If in doubt ask your installer for advice Clock with volt free contacts should be used 39 COMMISS...

Page 26: ...Swing the control box back into its working position 6 Switch the electricity supply ON and check that all external controls are calling for heat 7 Press the boiler reset switch H and the overheat thermostat reset button J 8 Set the boiler control knob D to maximum The fan will start After the fan has run for a few seconds the gas valve should open and the ignition commence The main burner will th...

Page 27: ...e service contract yourself or alternatively offer to the customer the benefits of the British Gas Services details of which are outlined in the household pack supplied with this boiler After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 43 HANDING OVER 42 GENERAL CHECKS Make the following checks for correct o...

Page 28: ...l the burner downwards to disengage the retention tab Remove the burner to a safe place for inspection and cleaning 2 Remove the fixing screws and swing the control box down into the servicing position Refer to Frame 53 3 Remove the hot surface igniter securing screw and disengage from the combustion chamber 1 If the Sealed System Unit is fitted lift off the casing 2 Open the controls support door...

Page 29: ...flue elbow and flue connector Disconnect the flue connector from the elbow and slide into the flue Remove the flue elbow 5 Disconnect the silicon rubber tube from the rear of the collector hood 6 Slacken the two M5 nuts on the front tie rods releasing the tie rods from the combustion chamber 7 Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood fan assemb...

Page 30: ...detailed in Frame 48 and ensuring that there is an inlet pressure of 20 mbar available the pilot does not light then contact British Gas Services Relight in accordance with Initial Lighting Frame 40 52 SIGHTGLASS REPLACEMENT 1 Refer to Frame 51 2 Unfasten the 2 nuts and washers holding the sightglass assembly to the casing front panel 3 When fixing the new assembly ensure that the parts are in the...

Page 31: ... of the switch 12 Press in the 2 side retaining clips and remove the switch 13 Replace and reassemble in reverse order 14 Check the operation of the boiler 54 CONTROL POTENTIOMETER THERMISTOR SENSOR LEADS and RESET SWITCH REPLACEMENT 55 PILOT BURNER REPLACEMENT 1 Refer to Frame 51 2 Remove the burner and air box assembly Refer to Frame 46 3 Remove the electrode retaining nut and remove the pilot s...

Page 32: ...the burner 4 At this stage the main burner injector can be removed checked cleaned or replaced as required Ensure that an approved jointing compound is used sparingly 5 Fit the new burner ensuring that the retention tab is correctly located in the air box slot and re assembly in reverse order 6 Check the burner for cross lighting and flame stability 58 MAIN BURNER AND MAIN BURNER INJECTOR REPLACEM...

Page 33: ...thdraw from the control box 6 Fit the new PCB and reassemble in reverse order 7 Check the operation of the boiler Fuse To change the fuse prise the top off the holder and disengage the fuse Refer to Frame 32 for fuse location 1 Refer to Frame 51 2 Remove the APS fixing screw 3 Remove both sensing tubes from the APS 4 Remove the 3 electrical connections from the APS 5 Fit the new APS and reassemble...

Page 34: ...46 3 Drain the system 4 Disconnect the water connections If compression fittings are used then cut the pipes both above and below the fittings in order to allow the heat exchanger assembly to be removed Remove the heat exchanger drain plug and drain the residual water into a suitable receptacle 5 Remove the fan collector hood assembly Refer to Frame 47 6 Remove the combustion chamber Refer to Fram...

Page 35: ...ES NO Change pressure switch Is fault corrected Is the boiler casing correctly fitted Does the main burner light NO YES YES Does the hot surface igniter turn off NO Is there a gas supply to the boiler Is the pilot injector blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve Expect 230 V AC YES NO YES NO NO Is there a supply on the fan connector at PCB Expect 230 V AC ...

Page 36: ...171 441 18 308 317 Detection electrode complete with lead and backnut 410 mm lg 1 171 442 18 1 Hot surface igniter 330 340 1 171 973 18 2 Hot surface igniter 350 380 3100 1 171 490 19 E58 681 Control box assembly including PCB 1 171 894 21A E58 714 Boiler thermostat potentiometer 1 171 875 23 386 149 Automatic ignition PCB with modem c w gas valve harness 1 171 451 26 308 283 Thermostat knob 1 171...

Page 37: ...PARTS LEGEND Numbers up to 51 relate to the B G spares list 10 Burner manifold 11 Air box and pilot assembly 12 Main burner 13 Main burner injector 67 BURNER ASSEMBLY Exploded View 16 Pilot shield 17 Gas control valve 42 Gas service cock 66 SHORT PARTS LIST ...

Page 38: ... LIST OF PARTS LED 1 LED 2 LED 3 LED 4 23A Fuse 21A Cla 2710 58A 26 LEGEND 19 Control box 21A Thermostat potentiometer 26 Thermostat knob 23A Printed circuit board 58A Lockout reset switch 68 CONTROL BOX Exploded View 69 BOILER CASING ASSEMBLY ...

Page 39: ...British Gas RD1 Installation Servicing 39 NOTES ...

Page 40: ...r British Gas by Ideal Boilers British Gas Services Limited Registered in England No 3141243 Registered Office Millstream Maidenhead Road Windsor Berkshire SL4 5GD British Gas Services Ltd has made every effort to ensure that the information contained in this leaflet is accurate However not all the information is within the control of British Gas Services Ltd and it may have changed since publicat...

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