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British Gas 4100 & 4125 RD2 -

Installation & Servicing

SHORT LIST OF PARTS

66 SHORT PARTS

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Summary of Contents for British Gas 4100 RD2

Page 1: ...INSTALLATION MANUAL British Scottish Gas RD2 the floor standing boiler Floor standing gas fired fanned flue boiler 4100 4125 RD2 Installers guide to central heating boilers SERVICING ...

Page 2: ...he system demands Complete range There are 7 models in the range All models include an overheat thermostat and a Flue Directional kit for side and top outlet installations Full system suitability All 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 They can also be used o...

Page 3: ...oiler Output to Water kW Btu h 29 3 100 000 36 6 125 000 Burner Setting Pressure hot mbar in w g 11 6 4 6 12 7 5 1 Seasonal Effiiciency SEDBUK Band D 78 8 78 5 Table 2 Performance Data Note Gas consumption is calculated using a calorific value of 38 7 MJ m3 1038 Btu ft3 gross or 34 9 MJ m3 935 Btu ft3 nett To obtain the gas consumption at a different calorific value a For l s divide the gross heat...

Page 4: ... is required to receive and transmit data from the boiler Without this facility the boiler operates as standard fanned flued boiler OPTIONAL EXTRA KITS Extension Duct kit To extend standard flue 90 o Flue Elbow Kit CONTENTS Air Supply 7 Boiler Assembly Exploded view 12 Boiler Clearances 6 Electrical Connections 23 Electrical Diagrams 23 26 Electrical Supply 8 Extension Ducts Fitting 21 Fault Findi...

Page 5: ... any way as overriding statutory obligations IMPORTANT These appliances are certificated by the BG Technology Certification Services for safety and performance It is important therefore that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or otherwise recommended by British Gas i...

Page 6: ... for servicing An existing cupboard or compartment may be used providing it is modified for the purpose In both cases details of essential features of cupboards compartment design including airing cupboard installation are to conform to the following z z z z z BS 6798 z z z z z The position selected for installation MUST allow adequate space for servicing in front of the boiler and for air circula...

Page 7: ...n BS 5440 1 2000 IMPORTANT It is absolutely ESSENTIAL to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors other sources of natural air infiltration or forced ventilation air conditioning If this should occur the appliance MUST be turned OFF labelled unsafe and corrective action...

Page 8: ...as RD2 incorporates a cast iron heat exchanger As part of the installation the central heating system should be thoroughly flushed with appropriate water treatment in order to comply with BS7593 1992 British Gas recommend the use of Fernox or Betz Dearborn water treatment products which must be used in accordance with the manufacturers instructions For further information contact Fernox Manufactur...

Page 9: ...e between the top of the boiler and the base of the cylinder 3 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 3 The circulating pump is positioned on the FLOW and the vertical distance between the p...

Page 10: ...ssure gauge covering at least the range 0 4 bar 0 60 lb in2 must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel 4 Expansion Vessel a A diaphragm type expansion vessel must be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal si...

Page 11: ...initial system design pressure The cold feed pipe from the cistern should include a non return 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 cist...

Page 12: ...urner manifold 28 Gas cock 38 Pressure switch 41 Air inlet duct 42 Turret access cover assy 46 Boiler base plate 47 Baseplate heat shield 49 Flue baffle 65 Control box 92 Thermostat bush LEGEND 1 Heat exchanger assembly 2 Front section 3 Centre section 4 Section alignment rings and O rings 5 Back section 6 Flow thermistor sensor pocket 6A Return thermistor sensor pocket 6B O heat thermostat sensor...

Page 13: ...abs from under the top panel BOILER HARDWARE PACK z 1 BSP plugs 3 off z Distributor tube 1 off z 28mm x 1 BSP male straight adapter compression fitting 3 off For connection to the boiler PUMPED GRAVITY flow return tappings z Flow sensor pocket 1 off z Return sensor pocket kit comprising Hexagon bush 1 off Sensor pocket 1 off O ring 1 off Heyco bush 1 off M5 x 10mm Pozi screw 3 off Washers 3 off z ...

Page 14: ... top panel forward and lift it off the boiler 9 Remove the 2 screws securing the LH side panel to the turret front panel and baseplate 10 Pull the panel forward disengaging from the collector hood tab lift it clear of the locating peg and remove 11 Repeat steps 9 and 10 to remove the RH panel 12 The boiler is held to the packaging base by 4 M6 hex head screws Remove the front screws slacken the re...

Page 15: ...p Bottom Bottom LH LH LH LH RH LH RH LH RH LH RH RH RH RH LH RH LH RH LH RH 1 Screw the distributor tube supplied with a 1 BSP x 28mm copper adaptor into the selected heating return tapping using an appropriate jointing material IMPORTANT It is IMPERATIVE that the index mark on the distributor tube bush is in alignment with the mark on the section boss as shown in Frame 3 DO NOT disturb it when co...

Page 16: ...e cardboard support provided 4 5 3 2 1 Mex 1843 6 10 9 8 7 15 TOP FLUE OUTLET ASSEMBLY 100 ONLY Exploded view IMPORTANT The maximum total equivalent horizontal flue length is 2m for 100 model 5 Mex 1844 1 6 3 2 4 7 LEGEND 1 Terminal 2 Weather seal 3 Flue assembly 4 Boiler sealing ring 5 Flue extension tube 6 Elbow 7 Flue connector 8 Turret access cover Notes For lengths greater than 600mm see Fram...

Page 17: ...ces immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the 2 wall faces 4 Remove the template from the wall Note If the terminal is to be sited within 25 40mm of a corner or vertical pipe refer to Table 3 then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided The t...

Page 18: ...e the position for the foam seal measure the wall thickness and mark it onto the flue measuring from the groove near the terminal 2 Wrap the self adhesive foam strip round the flue ensuring that the foam is on the terminal side of the line This seals the gap between the flue and the wall 20 FITTING THE FOAM SEAL 21 FITTING THE FLUE ASSEMBLY A Inside fitting If the flue assembly cannot be fitted fr...

Page 19: ... M4 screw Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal is correctly aligned 24 CONNECTING THE FLUE TO THE BOILER Side 22 LOCATING THE BOILER Rear and Side flue A If the flue assembly can be fitted from the outside proceed as follows 1 Move the boiler into position ensuring that the flue outlet is in line with the wall opening 2 Insert th...

Page 20: ...ine 2 Fit the 2 halves of the side outlet plate to the wall ensuring they are behind the boiler sealing ring 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 2 Secure the flue to the boiler using the 2 M4 x 16mm screws previously removed 25 CONNECTING THE FLUE TO THE BOILER Top...

Page 21: ...0 308 600 to 1000 B 1 off D 1 off B 1 off D 1 off 150 308 152132 600 to 1550 B 1 off D 1 off N A 150 308 152132 1 off 1550 to 2000 B 1 off D 2 off N A 150 308 152132 2 off Top outlet flue length A B Elbow allowance 90 o Elbow 1m 45 o Elbow 0 7m 29 FITTING THE KIT 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto the inner flue du...

Page 22: ...d a gas supply pipe NOT LESS THAN 15mm 1 2 OD to the boiler and connect to the gas cock situated at the front LH side of the boiler 3 Test the gas installation for soundness and purge in accordance with BS 6891 1988 Refer to Servicing instructions Boiler Dimension A 100 473 18 5 8 125 546 21 1 2 30 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal Its u...

Page 23: ...ation must be accessible to the user after installation Notes 1 If a programmer is fitted refer to the instructions provided and Frame 35 2 For gravity DHW applications the pump MUST be wired through the programmer 1 Remove the securing screw and lift off the mains terminal box cover 2 Route the mains cable from the LH rear of the boiler along the front of the baseplate to the terminal box Note Le...

Page 24: ...rom the RH rear of the boiler and across the top of the control box Refer to Frame 33 Leave sufficient length of cable to enable it to be routed as shown once the casing has been fitted and secure to the casing with the ties provided 3 Controls that override an on off control e g frost thermostat must be wired in parallel with the control s to be overridden Refer to Frame 40 4 If a proprietary sys...

Page 25: ...umbering of 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 NOT the orange wire MUST be the one connected to permanent L 39 HONEYWELL C PLAN IMPORTANT The pump must not be wired directly to the boiler Notes 1 Some earth wires are omitted for clarity En...

Page 26: ...l using the screws previously removed 12 Relocate the Burner on neon in the lens holder at the back of the control panel 13 Fit the control thermostat to the rear of the control panel using the 2 screws provided Fit the correct way up as shown T 14 Fit the control thermostat knob 15 Secure the wiring harnesses in the edge clips on the RH side panel 16 Secure all other internal wiring IMPORTANT Wir...

Page 27: ...hermostat F is OFF 3 Slacken the screw in the burner pressure test point B and connect a gas pressure gauge via a flexible tube 4 Switch the electricity supply ON and check that all external controls are calling for heat 5 Press the reset button J and the overheat thermostat reset button H 6 Set the boiler thermostat knob F to position 6 The fan will start After the fan has run for a few seconds t...

Page 28: ...lities under the current Gas Safety Installation and Use Regulations or the rules in force 2 Draw attention to the lighting instruction label affixed to the inside of the controls door 3 Explain and demonstrate the lighting and shutting down procedures 4 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest...

Page 29: ...that the flue terminal is unobstructed and that the flue system is sealed correctly h If the appliance has been installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 47 to 52 and MUST be carried out in sequence Note In order to carry out either servicing or replacement of some components the boiler casing must removed Refer ...

Page 30: ...d 1 Brush off any deposits that may have fallen onto the burner heads ensuring that the flame ports are unobstructed and remove any debris that may have collected 2 Remove the main burner injectors Check clean or replace as required 3 Refit the injectors using an approved jointing compound 4 Inspect the ignition detection electrodes ensure they are clear and in good condition Check that a The HSI ...

Page 31: ... Any Re assemble the boiler in the following order 1 Refit the flue baffles 2 Inspect the collector hood rope gasket and replace if necessary ensuring that the self adhesive rope is fitted centrally on to the lip of the collector hood fan assembly The boiler efficiency will be adversely affected if incorrectly fitted Refit the collector hood cover with the 4 screws Tighten the screws Ensure that t...

Page 32: ...hat the position of the HSI relative to the burner is correct 7 Check the operation of the boiler 1 Remove the lower front panel and grille assembly Refer to Frame 47 2 Remove the control box cover 3 Unplug the potentiometer lead from the PCB and withdraw it from the control box 4 Disengage the lead from the retaining clips 5 Pull off the thermostat knob 6 Remove the 2 screws securing the potentio...

Page 33: ...trols assembly a Remove the control box cover b Unplug the HSI lead from the PCB and withdraw it from the box c Disconnect the detection lead from the electrode d Remove the screw securing the control box to the baseplate slide to the left to release and place to one side e Disconnect the electrical leads from the gas valve f Undo the gas service cock union g Remove the 4 wing nuts and withdraw th...

Page 34: ...g compound and re assemble in reverse order 6 Check the operation of the boiler 59 MAIN BURNER INJECTOR 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 Withdraw the burner 4 Fit the new burner and re assemble in reverse order t...

Page 35: ...he sealing O ring supplied with the valve is correctly fitted at the outlet flange c An approved jointing compound is used when reconnecting the gas inlet pipe 6 Reassemble in reverse order 7 Check the operation of the boiler 60 GAS VALVE REPLACEMENT 1 Remove the lower front panel control panel and top panel Refer to Frame 47 2 Remove the silicon rubber tube from the fan pressure sensing point 3 D...

Page 36: ...boiler Fuse To change the fuse prise the top off the holder and disengage the fuse Refer to Frame 34 for location 64 THERMISTOR SENSOR LEAD HARNESS REPLACEMENT 1 Remove the lower front panel and grille assembly Refer to Frame 47 2 Remove the control box cover Refer to Frame 63 3 Unplug the 7 way Molex connector carrying 6 wires from the top of the PCB 4 Withdraw the leads from the control box and ...

Page 37: ... the sensor from the pocket 3 Remove the control box cover 4 Unfasten the overheat thermostat retaining nut disconnect the electrical leads and withdraw the thermostat from the control box 5 Fit the new thermostat and reassemble in reverse order 6 Check that the reset button on the new thermostat is pressed in 7 Check the operation of boiler Thermostat pocket Hook plate Sensor end 2 Mex 1861 Mex 1...

Page 38: ...cure If no fault found change PCB Check pressure switch sensing pipes for blockages bad connections and reversed connection Is pressure difference at switch greater than 0 9 mbar Change fan Is fault corrected YES NO Change pressure switch Is fault corrected 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 block...

Page 39: ... harness 1 152 800 38 Pressure switch HONEYWELL C6065F1373 1 155 412 49 E26 419 Flue baffle kit 4100 6 079 890 E26 420 4125 4 079 891 67 308 557 Thermostat knob 1 139 296 83 E26 452 Overheat thermostat 1 153 727 89 Potentiometer with harness 1 154 443 90 Thermistor sensor harness CROSSLANDS 1 154 439 The following are parts commonly required as replacement components due to damage or expendability...

Page 40: ...40 British Gas 4100 4125 RD2 Installation Servicing SHORT LIST OF PARTS 66 SHORT PARTS ...

Page 41: ...lation Servicing LIST OF PARTS Legend 63 Control panel complete assembly 67 Control potentiometer knob 71 Control front panel door 72 Magnetic strip 89 Control potentiometer 67 BOILER CONTROL PANEL Exploded View 68 BOILER CASING ASSEMBLY ...

Page 42: ...Exploded View Legend 16 Burner assembly complete 18 Burner manifold 20 Main burner 21 Main burner injector 24 Gas valve 25 Gas valve O ring 26 Detection electrode 26A Hot surface igniter 28 Gas cock 70 BURNER ASSEMBLY Legend 29 Control box 30 PCB 34 PCB standoff 37 Control box cover ...

Page 43: ...43 British Gas 4100 4125 RD2 Installation Servicing NOTES ...

Page 44: ...cepted by BSI 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 publication British Gas S...

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