Ideal Boilers British Gas 440 RD2, Installation & Servicing Manual

Page 1: ...INSTALLATION MANUAL British Scottish Gas RD2 the floor standing boiler Floor standing gas fired fanned flue boiler 440 480 RD2 Installers guide to central heating boilers SERVICING ...

Page 2: ...e 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 on...

Page 3: ...59 4 0 56 71 3 0 65 83 1 0 75 95 0 Boiler Output to Water kW Btu h 11 7 40 000 14 7 50 000 17 6 60 000 20 5 70 000 23 4 80 000 Burner Setting Pressure hot mbar in w g 10 3 4 4 11 8 4 7 12 2 4 9 10 6 4 3 13 2 5 3 Seasonal Efficiency SEDBUK Band D 78 2 78 9 79 0 80 5 79 8 Key to symbols GB United Kingdom Countries of destination PMS Maximum operating pressure of water C12 A room sealed appliance des...

Page 4: ...iler 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 25 Electrical Supply 8 Extension Ducts Fitting 21 Fault Finding 38 Flue Fitting 15 21 Flue Installation 7 Gas Safe...

Page 5: ...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 Services i...

Page 6: ... of the space in which the boiler is to operate and to facilitate servicing are as shown in the table below Additional space will be required for installation depending upon site conditions IMPORTANT In order to facilitate gas connection a clearance of at least 100 mm 4 must be available at either the left hand side or the right hand side DURING installation Refer to Frame 31 In addition a MINIMUM...

Page 7: ...y 5 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible material are given in 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 thr...

Page 8: ...upply such as a double pole switch having a 3mm 1 8 contact separation in both poles or a plug and socket serving only the boiler and system controls The means of isolation must be accessible to the user after installation For bathroom installations the point of connection to the mains must be situated outside the bathroom FLOW RATE gals hr PRESSURE LOSS mbar FLOW RATE l min PRESSURE LOSS ft water...

Page 9: ... 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 pu...

Page 10: ...A pressure 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 nomin...

Page 11: ...nitial 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 ciste...

Page 12: ...Front plate assy 18 Burner manifold 28 Gas cock 38 Pressure switch 41 Air inlet duct 42 Turret access cover assy 46 Boiler base plate 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 poc...

Page 13: ... pocket 1 off 1 2 square bar 1 off Cable tie 4 off Control thermostat knob 1 off M3 x 6mm Pozi pan screw 1 off Self tapping screw 2 off British Gas Logo 1 off Scottish Gas Logo 1 off To install the boiler the casing MUST be removed 1 Undo the 2 screws and lift off the lower front panel 2 Remove the 2 screws and lift off the grille assembly 3 Release the Burner On neon from the rear of the control ...

Page 14: ...ides 8 Draw the 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...

Page 15: ...Tables 6 and 7 6 Fit 28mm x 1 BSP adapter pipe fittings to the appropriate rear tappings for DHW if required and plug any unused tappings Connections Sensor Position as viewed at front Back Section Front Section CH DHW Flow Return O heat Flow Return Flow Return Top Bottom Bottom LH LH RH RH LH LH RH LH RH RH LH LH RH LH RH RH LH LH RH RH LH RH LH LH RH RH LH RH Table 7 Gravity Dom Hot Water Pumped...

Page 16: ... 6 When cutting the ducts always use the cardboard support provided 4 5 3 2 1 Mex 1843 6 10 9 8 7 15 TOP FLUE OUTLET ASSEMBLY Exploded view Note For lengths greater than 600mm see Frame 11 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 1 The boiler turret assembly is factory built fo...

Page 17: ...ediately 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 terminal...

Page 18: ...on 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 from the outsi...

Page 19: ...ew 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 the flue ...

Page 20: ...he split line 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 ...

Page 21: ... 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 duct 3 Fit the outer flue extension duct onto the outer air duct 4 Drill 3 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screws provided to fix the air duct in position 6 Repe...

Page 22: ...the boiler inlet with the boiler operating 2 Extend 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 440 327 12 7 8 450 480 400 15 3 4 30 TERMINAL WALL PLATE This plate allows neat con...

Page 23: ...olation 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 ...

Page 24: ...ontacts If switched live is connected here EC1 leave other terminal without connection If programmer is used here EC1 and the switched live MUST BE FUSED at 2A Max IMPORTANT A link wire between terminal EC1 and EC2 is not acceptable Note Route the cable to terminals EC1 EC2 from the RH rear of the boiler and across the top of the control box Refer to Frame 33 Leave sufficient length of cable to en...

Page 25: ...mbering 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 Gravity HW Pumped CH IMPORTANT The pump must not be wired directly to the boiler Notes 1 Some earth wires are om...

Page 26: ...stat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost stat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal disturbance to other wiring of the programmer Designation of the terminal...

Page 27: ...ermostat 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 th...

Page 28: ...ossible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 5 Explain the function and the use of the boiler thermostat and external controls 45 HANDING OVER After completing the installa...

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 components the boiler casing must removed Refer to Fr...

Page 30: ...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 5 Undo the gas service cock union 6 Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 7 Place on a convenient working surface 1 Remove the silicon rubb...

Page 31: ...the rated output with the related burner pressure and heat input Reassemble 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 ho...

Page 32: ...at 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 potentiom...

Page 33: ...ols 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 the ...

Page 34: ...g compound and reassemble 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 reassemble in reverse order tak...

Page 35: ... rubber tube from the fan pressure sensing point 3 Disconnect the fan leads 4 Remove the securing screw and withdraw the fan thermistor sensor from the scroll 5 Disconnect the silicon rubber tube from the top of the collector hood 6 Remove the 4 M4 screws on the top of the collector hood and by sliding it forwards remove collector hood fan assembly 7 Remove the three M4 screws retaining the fan to...

Page 36: ... boiler Fuse To change the fuse prise the top off the holder and disengage the fuse Refer to Frame 34 for the 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...

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 Mex 1861 Mex 186...

Page 38: ...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 NO YES Does the hot surface igniter turn off NO Is there a gas supply to the boiler Is the pilot injector blocked YE...

Page 39: ... No 43 gas valve neon harness 1 152 800 38 Pressure switch HONEYWELL C6065F1373 1 155 412 49 E26 419 Flue baffle kit 440 2 079890 E26 420 450 460 4 079891 E26 419 470 480 4 079890 67 E00 054 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 replace...

Page 40: ...40 British Gas 440 480 RD2 Installation Servicing SHORT LIST OF PARTS 66 SHORT PARTS ...

Page 41: ... 71 Control front panel door 72 Magnetic strip 89 Control potentiometer 67 BOILER CONTROL PANEL Exploded View 68 BOILER CASING ASSEMBLY Legend 46 Baseplate 63 Control panel complete assembly 64 Control panel complete 71 Control front panel door 73 L H Side panel 74 RH Side panel 75 Casing front panel 76 Casing top panel 77 Grille panel ...

Page 42: ...ed View Legend 29 Control box 30 PCB 34 PCB standoff not shown 37 Control box cover 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 ...

Page 43: ...NOTES 43 British Gas 440 480 RD2 Installation Servicing ...

Page 44: ...ccepted by BSI Priority Helpline 08459 500 400 This boiler is exclusively manufactured for 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...