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  4. RIO 140
  5. Installation And Servicing Manual

ICI Caldaie RIO 140 Installation And Servicing Manual

Summary of RIO 140

  • Page 1

    Installation and servicing manual rio 140 floor standing combination boiler providing central heating and mains fed domestic hot water for use with natural gas (g20) - natural gas model only or propane (g31) - propane model only ec certificated for safety and performance it is important that the boi...

  • Page 2

    List of contents 2 section subject page 1 technical information.............................. 3 2 general boiler information....................... 6 3 boiler installation..................................... 14 4 fill and vent the system............................ 17 5 commissioning .................

  • Page 3

    1 technical information 3 1.1 technical specifications central heating maximum heating system water temperature .................... 90°c + 0 - 5°c minimum heating system water temperature..................... 30°c ± 2°c maximum heating system pressure................................... 1.5 bar cold...

  • Page 4

    1 technical information 4 1.2 nominal boiler ratings - natural gas (g20) 1.3 pump performance ∆t given above, is the temperature difference between the central heating flow and return connections. The recommended range of ∆t across the boiler is between 11 and 20°c. The pump head given above is the ...

  • Page 5

    1 technical information 5 1.5 boiler schematic 1 automatic air vent 2 co-axial duct 3 air pressure switch 4 sealed chamber 5 flue hood 6 fan 7 limit thermostat 8 heating sensor 9 heat exchanger 10 burner 11 ignition spark electrode 12 ignition earth electrode 13 flame detection electrode 14 safety v...

  • Page 6

    2 general boiler information 6 2. 1 boiler description the rio 140 is a room-sealed combination boiler using a small multi-directional fan-assisted balanced flue. The boiler, providing central heating and domestic hot water at mains pressure, has been designed for use with a sealed water central hea...

  • Page 7

    2 general boiler information 7 2.4 natural gas (g20) supply - refer to section 15 for propane (g31) the maximum natural gas requirement of the boiler is 3.27 m³/h. The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances in the...

  • Page 8

    2 general boiler information 8 fig. 1 terminal position min. Distance a directly below an opening, air brick, window, etc. 300 mm b below gutters, soil pipes or drain pipes 75 mm c below eaves 200 mm d below balconies or car port roof 200 mm e from a vertical drain pipe or soil pipe 75 mm f from an ...

  • Page 9

    2 general boiler information 9 2.9 water and gas connections (see fig. 2) the fittings pack includes three isolating valves and a gas service cock, together with all the necessary pipework and fittings to connect them. A 15 mm pipe stub is also supplied for the hot water outlet connection. The isola...

  • Page 10

    2 general boiler information 10 2.11 central heating system - sealed systems only (see fig. 4) 1 the boiler is only suitable for use with a sealed system complying with the requirements of bs 5449 and bs 6798. The maximum temperature of the central heating water is 90 +0 - 5°c. Design notes - when d...

  • Page 11

    2 general boiler information 11 10 to avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly cleaned in accordance with the procedure given in bs 7593. This involves the use of a cleanser, circulating it around the system for the required tim...

  • Page 12

    2 general boiler information 12 2.13 unvented domestic hot water storage the local authority must be notified of the intention to install an unvented hot water storage system, as the installation is subject to building regulations approval. To comply with the building regulations the pressure reduci...

  • Page 13

    2 general boiler information 13 fig. 7 2.14 method of operation the boiler operating mode is controlled by the 'heating' switch on the control panel. When set to hot water only, the boiler will only operate in the domestic hot water mode. When set to heating & hot water, it will operate in the domes...

  • Page 14

    3 boiler installation 14 3.1 unpack the boiler (see fig. 8) 1 dismantle the transit crate from around the boiler and carefully remove the boiler from the pallet. Note: take care not to damage the casing when dismantling the crate and not to damage the corners of the case when removing the boiler fro...

  • Page 15

    3 boiler installation 15 3.4 connect the pipework (see fig. 2 and section 14) having ensured that all the water pipework has been thoroughly flushed and that the gas supply is clear, the pipework can now be connected to the boiler - ensure that all the plastic caps are removed from the boiler connec...

  • Page 16

    3 boiler installation 16 7 insert the terminal end of the inner duct into the end of the outer duct just cut and push it fully home. If there is sufficient space around the boiler to fit the inner duct from inside the building, then do this in paragraph 9. 8 from outside the building insert the asse...

  • Page 17

    4 fill and vent the system 17 4.1 central heating expansion vessel pressure the expansion vessel fitted is supplied with a charge pressure of 1.0 bar (equivalent to a static head of 10.2 metres). The charge pressure must not be less than the static head at the point of connection (see fig. 4). Do no...

  • Page 18

    5 commissioning 18 5.1 test for gas soundness and purge the supply 1 with the boiler gas service cock closed (slot in operating spindle at right angle to valve body), pressure test the gas supply and inlet pipework connection to the boiler service cock for soundness in accordance with bs 6891. 2 uns...

  • Page 19

    5 commissioning 19 fig. 15 5 maximum burner pressure in central heating mode note: the maximum burner pressure in the central heating mode is adjusted by means of the potentiometer (see fig. 15) on the main driver board, the pressures given in section 1.2 can only be achieved if the burner minimum a...

  • Page 20

    6 information for the user 20 the user must be advised (and demonstrated if necessary) of the following important points:- 1 how to light and turn off the boiler and how to operate the system controls. 2 the precautions necessary to prevent damage to the central heating system and to the building, i...

  • Page 21

    7 boiler servicing 21 to ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate. It is ...

  • Page 22

    7 boiler servicing 22 7.3 cleaning the boiler 1 check the condition of the bottom of the heat exchanger, if it requires cleaning the flue hood should be removed as described in section 9.28, paragraphs 2 to 9. If the flue hood is removed, the condition of the fan impeller should be checked (clean ca...

  • Page 23

    8 draining the boiler 23 refer to figs. 2 and 19 press in the on/off switch (see fig. 14) to switch off the boiler (green light off) and isolate the electricity gas supplies. Open the upper front panel (hinges to the left) to gain access. Central heating circuit 1 make a note of the system pressure,...

  • Page 24

    9 replacement of components 24 it is the law that any service work must be carried out by corgi registered personnel. Warning: before servicing the boiler press in the on/off switch (see fig. 14) to switch off the boiler (green light off), isolate the electricity supply and close the boiler gas serv...

  • Page 25

    9 replacement of components 25 9.5 electrode lead(s) 1 ensure that the electricity supply has been isolated. 2 gain access to the electrode leads as described in section 7.2, paragraphs 1 to 3. 3 disconnect the electrode lead from the electrode (white ignition r/h, blue flame sensing l/h) and the ig...

  • Page 26

    9 replacement of components 26 9.7.1 set the burner pressures the minimum burner pressure is the same in both the central heating and hot water modes. The maximum burner pressure in the hot water mode is fixed, the maximum burner pressure in the central heating mode is adjustable to suit the heating...

  • Page 27

    9 replacement of components 27 9.11 lock-out reset switch 1 ensure that the electricity supply has been isolated. 2 open the upper front panel (hinges to the left) to gain access. 3 remove the four screws securing the control box top cover. Slide the cover back and up to remove it from the control b...

  • Page 28

    9 replacement of components 28 6 re-assemble in reverse order using a new board - refer to the wiring diagram, page 34, for electrical connections. Do not use excessive force when re-making the board connections and ensure all plugs and leads are correctly connected. Note: the burner pressure (in th...

  • Page 29

    9 replacement of components 29 7 re-assemble in reverse order, ensuring the front return edge of the control box top is located under the front panel return. 8 test the boiler as described in section 7.5, paragraphs 1,2 and 3. 9.18 system temperature/pressure gauge 1 ensure that the electricity supp...

  • Page 30

    9 replacement of components 30 9.21 automatic air vent the air vent is positioned at the back of the boiler on the upper left hand side and is accessible without opening the case. 1 ensure that the electricity supply has been isolated. 2 drain the central heating circuit of the boiler as described i...

  • Page 31

    9 replacement of components 31 water flow switch 1 ensure that the electricity supply has been isolated. 2 drain the central heating circuit of the boiler as described in section 8. 3 remove the microswitch as described above. 4 undo the unions and withdraw the flow switch. 5 re-assemble in reverse ...

  • Page 32

    9 replacement of components 32 5 fit a replacement sensor, using a small amount of thread sealant. 6 reconnect the electrical leads (polarity is not important) and re-assemble in reverse order. 7 fill the boiler and re-pressurise the system to between 0.8 and 1.5 bar (to match the original system pr...

  • Page 33

    10 wiring diagrams 33 10.1 illustrated wiring diagram.

  • Page 34

    10 wiring diagrams 34 10.2 functional flow wiring diagram.

  • Page 35

    11 sequence of operation charts 35 11.1 automatic ignition sequence.

  • Page 36

    11 sequence of operation charts 36 11.2 operation in central heating mode.

  • Page 37

    11 sequence of operation charts 37 11.3 operation in domestic hot water mode.

  • Page 38

    12 fault finding 38 during the fault finding procedure the first electrical checks to be carried out are:- short circuit, polarity, earth continuity and resistance to earth. After completing a service or fault finding task which has required the breaking and remaking of electrical connections, the e...

  • Page 39

    12 fault finding 39 burner lights and then goes to lock-out possible cause flame not detected polarity of electrical supply reversed remedy check position of electrode and adjust as necessary check sensing lead connections, rectify as necessary check sensing lead continuity, replace if necessary ign...

  • Page 40

    13 exploded views and parts lists 40 13.1 casing and electrics n. P. No. Q. Description 1 18010150 6 panel clip 2 60000400 2 lower side panel 3 60000410 2 upper side panel 4 60000420 1 lower front panel 5 60000430 1 lower back panel 6 60000440 1 lower base plate 7 60000570 1 lower top plate 8 100500...

  • Page 41

    13 exploded views and parts lists 41 13.2 gas components n. P. No. Q. Description 1 18030310 1 locking nut 3/4" bsp 2 18022084 1 flame detection electrode lead (blue) 3 50000613 1 gas valve inlet manifold 4 50000630 2 gas valve manifold gasket (ng) 5 50000730 1 gas valve (ng/lpg) 6 50000940 1 igniti...

  • Page 42

    13 exploded views and parts lists 42 13.3 sealed combustion chamber n. P. No. Q. Description 1 51000046 1 sealed chamber front cover 2 50000377 mtr. Sealed chamber seal 3 40000960 1 pressure switch sensing tube (right/clear) 4 40000963 1 pressure switch sensing tube (left/pink) 5 40000923 1 pressure...

  • Page 43

    13 exploded views and parts lists 43 13.4 water components n. P. No. Q description 1 60000150 1 ch expansion vessel (10 ltr) 2 60000510 1 dhw expansion vessel (4 ltr) 3 18020190 1 safety valve (3 bar) 4 18030050 2 connector 1/2" 5 18030320 2 locknut 1/2" 6 41000225 1 dhw expansion vessel (2ltr) 7 40...

  • Page 44

    13 exploded views and parts lists 44 13.5 horizontal flue (co-axial) n. P.No. Q description 1 fh004 1 outer wall seal 2 fh002 1 concentric flue pipe 100/80 mm 3 fhv005 1 inner wall seal (optional) 4 fhv008 1 flue clamp - elbow to pipe 5 fhv009 1 stepped flue seal - elbow to pipe 6 fhv007 2 'o' ring ...

  • Page 45

    14 packing lists 45 14.1 boiler pack containing: qty. Part no. Rio 140 boiler complete with timer (ng) 1 80090145 rio 140 boiler complete with timer (lpg) 1 80090155 installation and servicing manual 1 18000170 users operating manual 1 18000180 guarantee card 1 18000110 flue restrictor (standard co-...

  • Page 46

    15 information for propane (g31) boilers 46 the following instructions, specific to propane boilers, must be read in conjunction with the standard installation and servicing instructions in this manual. 15.1 nominal boiler ratings - propane (g31) propane (g31) at 37 mbar heat output heat input burne...

  • Page 47

    Note 47.

  • Page 48

    18000170 ed. 2-07/01 3 - st. 200 - 12/01 ici caldaie uk ltd unit 23, whaddon business park, whaddon salisbury, wiltshire, sp5 3hf telephone (01722) 711077 fax (01722) 711120 this manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appe...

  • Page 49: Rio 140

    Users operating manual rio 140 floor standing combination boiler providing central heating and mains fed domestic hot water for use with natural gas (g20) - natural gas model only or propane (g31) - propane model only ec certificated for safety and performance the boiler must be installed by a compe...

  • Page 50

    2 about your boiler the rio 140 is a combination boiler with an integral unvented hot water storage tank. It will supply domestic hot water at mains pressure and provide central heating. As all the basic components required for the central heating system and for providing domestic hot water are fitt...

  • Page 51

    3 domestic hot water system the boiler will supply domestic hot water whenever a hot tap is opened. The flow of water from the taps (hot or cold) depends upon the mains water pressure, and in some homes it may not be possible to use a number of taps at the same time. The temperature of water leaving...

  • Page 52

    4 general notes and care of your system 1 on/off switch - this switch (switch push button in for on, out for off) turns the boiler and the timer on and off. The green light on the switch indicates it is in the on position. 2 'summer/winter' switch - this switch (switch push button in for winter, out...

  • Page 53

    5 timer the timer (mechanical or electronic) fitted to your boiler allows you to control the times of your central heating periods only. Domestic hot water will always be available, provided the boiler is switched on. The mechanical timer has a 24 hr. Clock setting together with a 12 hr. Clock hands...

  • Page 54

    6 electronic timer – description of controls (see figs. 3 and 4).

  • Page 55

    7 programming the electronic timer.

  • Page 56

    18000180 ed. 2-07/01 3 - st. 200 - 12/01 terms of guarantee 1 the company shall mean ici caldaie uk ltd. 2 the boiler is guaranteed for a period of 12 months from the date of installation providing that any work undertaken is authorised by the company and carried out by an approved service agent. 3 ...