British Gas RD 628 Installation And Servicing Instructions

Text of British Gas RD 628 User Guide:

• 8 K H H A G C D,E. J N Q F P Q B I L N N M M Q I TERMINAL POSITION MIN. DISTANCE A a – Directly below an opening, air brick, opening windows etc. 300 mm B– Above an opening, air brick, opening windows etc. 300mm C–Horizontally to an opening, air brick, opening windows etc. 300mm D–Below gutters, soil pipes or drain pipes. 75mm E– Below eaves. 200 mm F�

• British Gas RD 628, PERFORMANCE SPECIFICATIONS PRIMARY WATER CAPACITY litres 2.0 IP RATING (WHOLE OF BOILER) - WITH/WITHOUT PROGRAMMER FITTED IP 20 MAXIMUM MAINS INLET PRESSURE bar 10 MINIMUM MAINS INLET PRESSURE (WORKING) FOR MAXIMUM FLOW bar 1.0 MINIMUM MAINS INLET PR

• British Gas RD 628, This booklet is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the inter- ests of continued improvement. All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application. PUBLICATION 8 716 106 034b 09/03 Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. Technical Helpline 08705 266241. ROOM SEALED FLUE TERMINAL KIT For use on the Danesmoor Front Service Room Sealed Oil Appliances INSTALLATION INSTRUCTIONS The appliance/

• British Gas RD 628, OPERATION OF CONTROLS 8 The appliance is fitted with the following controls: OPERATING SWITCH In the ‘0’ position there is no mains electricity to the control board. In the ‘I’ position mains electricity is connected to the control board. CENTRAL HEATING TEMPERATURE CONTROL The position of this knob will determine the temperature of the water delivered to the radiators between fully clockwise and anti- clockwise to the mark. When the knob is turned anti-clockwise past the position towards the ‘’(Summer Position), then the appliance will operate in

• British Gas RD 628, Contents 1. Installation Regulations Page 1 2. General Information Page 1 3. Flue Lengths, Bends & Extensions Page 1 4. Measurement of Ducts Page 1 5. Siting of Flue Terminal Page 4 6. Installation Page 4 7. Accessory/Spare Parts List Page 7 1. Installation Regulations 1.1. The appliance/flue system should be installed by a competent person. The person installing the appliance/flue system should be aware of the Health and Safety at Work Act and take appropriate action to ensure the regulations are adhered to. In order to give optimum efficiency and trouble free operation the appliance/flue system must be commissioned by an OFTEC registered engineer, as required by the

• 15.9 Inlet Water Filter Remove the flow switch as described in 15.8 preceding. Taking care, remove flow restrictor assembly from the flow turbine. Carefully clean wire mesh by back flushing with water or replace assembly if necessary. Refer to Fig 61. 15.10 Control Board Remove the clip-on facia cover, cabinet and the connections cover. Carefully disconnect all the electrical con

• British Gas RD 628, an extension is fitted. 6.35. Using the flue as a guide, mark the position of the hole required to accept the flue terminal or meas- ure the flue centre position as shown in figs 1 and 2. 6.36. Measure and note the distance from the rear of the boiler to the wall for rear exit flues, or from the appliance cabinet side to the wall for left/right exit flues. This will be used to calculate the flue length “L”. 6.37. Pull the boiler forward to allow fitting of the flue terminal. 6.38. Cut a round hole in the wall of minimum diame- ter 150 mm.

• British Gas RD 628, 6.13. Check that the telescopic flue slides freely. Fasten together the flue terminal and any extension sections intended to pass through the wall, in a simi- lar manner to 6.6. Do not fix the telescopic length at this stage! 6.14. Push fit the flue terminal assembly onto the last flue section of the air box/flue assembly and drill the two securing holes. Do not screw together at this stage! Consideration must be given to the position of these securing screws on the section which will be fed back through the hole in the wall. Where access to a fixing screw will not be possible when the flue is installed, drill a new securing hole position, at the same

• British Gas RD 628, 12 Fig. 13. Functional flow diagram. On/Off switch ST2 (LS) ST2 (L R) ST2 (N S) ST1 centre pin ST15 right pin Pump Fan ST2 Pin N Optional link Room thermostat Transformer Fuse F2 (1.25A Slow) Fuse F1 (2A Slow) N N ST2 Pin L LIVE IN Electronics Electronics Inputs Outputs Spark Indicators Settings Regulator valve Spark electrodes Error indicator/reset Red Main valve Flow sensor CH sensor DHW sensor Air pressure switch Flame sense Overheat cut-off 24V programmer (if applicable) Gas valve mode switch CH Control knob DHW control knob Convert AC to low voltage electronics Electronics/ microprocessor (Safe

• 11 If ignition lockout has occurred, the fault indicator will flash slowly (approximately once per second). The appliance can be reset by pressing the reset button and holding in for 5 seconds. Check that the gas supply has not been interrupted. If this condition continues to occur, then call a service engineer. AIR FLOW DEVICE The appliance will enter a lockout conditi

• British Gas RD 628, Room thermostat and/or mains programmer (or link) On facia programmer (if fitted) On CH control knob On 35 17. Operational Flow Diagrams MAIN SWITCH ON CENTRAL HEATING DEMAND Pump on. Fan ON/ ignition sequence. Burner Light On. Three minute wait Gas valve Off. Burner light off. (Pump still On) Over tempera- ture shut- down if flow temperature 5°C above set value Fifteen second minimum burner pressure then ramp up pressure over next one minute Modulate gas to maintain flow temperature set by control knob (50-82°C) DEMAND END Overrun function (see overleaf) CENTRAL HEATING FUNCTION AND AND DOMESTIC HOT WATER FUNCTION MAIN SWITCH ON Flow senso

• British Gas RD 628, 44 Boiler is running in “Autofrost stat” mode. See Section 17. Replace control board. Note: A damp board could cause this fault. Is the boiler in a very cold environment (less than 5°C)? TEST G No Yes Is the CH limit potentiometer (concealed behind facia bottom panel) set to maximum? Does the problem occur in CH mode only? Water flow temperature very low (with all knobs set at maximum). TEST I No Yes It is not possible to easily isolate the fault. The most likely causes are control board (fail), heat exchanger (blocked) or gas valve (sticking). Hot water temperature always too hot during a demand (not regulating). TEST H Hot water sensor could b

• British Gas RD 628, 40 Is the boiler fully water pressurised and is all air vented? Rectify fault. No No No Reset and restart the boiler in CH mode. Does the pump run? Yes Test resistance across contacts 1 and 2 (blue wires). Is the reading below 100 ohms? Repair or replace harness. Remove front panel. Reset and restart the boiler. Can a flame be seen through the spy glass? Remove blue connector from gas valve. Is there continuity from blue wires to multiway connector? Replace gas valve Remove inner cover. Reset and restart the boiler. Does a spark occur across the electrodes?

• British Gas RD 628, If Z is greater than 725mm then two extension duct assemblies will be required, the first assembly being cut to length as plain tubes. If more than two extension ducts are needed in any section to achieve the required length then the final section of the assembly must not be less than 275mm without cutting the terminal assembly. NOTE: The flue duct of the final extension must be 30mm longer than the air duct. Each section must be connected to the previous section of the flue bend by fixing the flue ducts together and then similarly f

• British Gas RD 628, FILLING LOOP ASSEMBLY CONNECTION The filling loop assembly is packed in a box with the installation instructions and screw pack. Parts list of pack: Charging Link Assembly.............................................8 716 104 592 Charging Key Assembly..............................................8 716 104 591 Filter 3 / 8 " Thimble........................................................8 716 104 618 4 x Socket Head Cap Screw M4x 6mm.................2 910 141 116 4 x M4 Lock Washer........................................

• 4 Hot Water Mode: When a demand is made for hot water by opening a tap or shower, the flow turbine will energise the boiler. The burner will light at its maximum setting and hot water will be delivered to the tap or shower. When hot water is no longer required the appliance pump or fan may continue to operate to dissipate the excess heat within the boiler. Fig. 1. System Diagram. A

• British Gas RD 628, Control Board 11 Fig. 12. Wiring diagram. Fan Flame sense electrode Spark electrode Spark Generator Mains in Link CH sensor (front of heat exchanger) Flow turbine ST16 2 blue green 2 brown brown blue blue brown green red yellow ST2 ST15 ST1 Pump Gas valve black white black Overheat cut-off device DHW sensor Air Pressure Switch 2 green white black Code Plug Regulator & Solenoid Valve Main Solenoid Valve red black blue green/yellow black blue black red black red white ST5 Diagnostic Module

• British Gas RD 628, This manual is to be used in conjunction with the variant part number of the bar code below: Manufactured exclusively for British Gas by Worcester Heat Systems Limited ( Bosch Group), Cotswold Way, Warndon, Worcester WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. PUBLICATION 8 716 105 430a 05/03

• 7 USE IN HARD WATER AREAS Normally there is no need for scale protection. However, in areas of exceptionally hard water supply it is recommended that an In-Line scale inhibitor be fitted. Installation should be strictly in accordance with the requirements of the local Water Company. An isolating valve to facilitate servicing should be incorporated. The water hardness may be de

• British Gas RD 628, 22 Air pressure Switch Squeeze and push down the two plastic lugs and remove the pressure switch from under the bracket. See Fig 68. Remove the fixing clip (see Fig 68) and fit to the new air pressure switch insuring that the orientation of the clip to the air connec- tions is the same. Remove the electrical connections to the old switch and fit to the new switch in the same position. Place the replacement switch under the mounting bracket and locate the plastic lugs in the two holes in the bracket and push up until the lugs are fully home. Connect the RED tube to the +ve connector and the WHITE tube to the -ve connector. 23 Sight Glass Remove and replace th

• British Gas RD 628, an extension is fitted. 6.35. Using the flue as a guide, mark the position of the hole required to accept the flue terminal or meas- ure the flue centre position as shown in figs 1 and 2. 6.36. Measure and note the distance from the rear of the boiler to the wall for rear exit flues, or from the appliance cabinet side to the wall for left/right exit flues. This will be used to calculate the flue length “L”. 6.37. Pull the boiler forward to allow fitting of the flue terminal. 6.38. Cut a round hole in the wall of minimum diame- ter 150 mm. 6.39. Measure and note the wall thickness through the hole. This will be used to calculate the f

• British Gas RD 628, 38 Is there a 230V AC live supply across Terminal ST2 pins L and N? Switch off electrical power. Has fuse F1 blown? Caused by mains 230V parts external to the control board ie. (wiring to or faults within): pump, fan, transformer or other external controls connected to ST2 (including Diagnostic Module, although this failure is unlikely). Check all these parts for malfunction. Repair/replace part, replace fuse F1 and run the boiler. Note: Tracks on board may have also been damaged. Replace board if necessary. Check electrical supply to boiler. Has fuse F2 blown? TEST A No Yes Yes No likely to be caused by control board internal fault, low voltage wiring

• British Gas RD 628, RD 628 WALL MOUNTED COMBINATION BOILERS FOR CENTRAL HEATING AND MAINS FED DOMESTIC HOT WATER INSTALLATION AND SERVICING INSTRUCTIONS This appliance is for use with Natural Gas GC NUMBER 47 108 14 (N.G.) GB APPLIANCE OUTPUTS Domestic Central Heating Hot Water Minimum 8.1 kW 8.1 kW Maximum 28 kW 28 kW IMPORTANT: THESE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE LEFT WITH THE USER OR AT THE GAS METER Read the instructions before starting work - they have been written to make the installation easier and prevent hold-ups.

• British Gas RD 628, Hand over the User Booklet. Explain how to operate the appliance safely and efficiently. Tell the user what to do if the appliance is not to be used in very cold conditions. Tell the user what to do if the system pressure falls. Explain that regular servicing will maintain the safe and efficient operation and extend the life of the appliance. Tell the user that any work on the appliance must only be carried-out by a competent, CORGI registered, person. 14.1 To ensure the continued efficient operation of the appliance it must be checked at regular intervals. The frequency of servicing will depend up

• British Gas RD 628, tion and screwing through with the self tapping screws provided. 6.2. The following guide explains two possible meth- ods of assembly. The boiler can be fixed in position and the flue fed back through the wall (Method 1), or the flue can be assembled onto the boiler and the boiler /flue then pushed back against the wall to feed the flue through the wall (Method 2). In both cases the telescopic flue must be securely fastened at the required length using the two self tapping screws provided. Method 1. 6.3. Remove the 4 inch (103mm) conventional flue spigot and gasket from the flue outlet plate by undo- ing the three screws. Not

• British Gas RD 628, Fig. 4. Appliance casing dimensions and required clearances (side view). All dimensions in mm Fig. 6. Side flue opening A CH Flow = 75 B DHW Flow = 140 C Gas = 205 D Cold Water Inlet = 270 E CH Return = 335 F Relief Valve Discharge = 395 Fig. 3. Appliance casing dimensions and required clearances for installation/servicing All dimensions in mm 30 150 10 10 6 B C D E 190 (A, B, C, D,) 20 A B C D E F View of underside of appliance showing connections Valves shown closed. Fig. 7. Pipework connections All dimensions in mm 114 600 740 230 360 200 200 F All dimensions in mm 114 Fig. 5

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