ICI Caldaie RIO 140 Installation And Servicing Manual - 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 Unscrew the gas inlet pressure test point screw (see Fig. 19). Ensure the gas supply is on and open the
boiler service cock (slot in operating spindle in line with valve body) to purge in accordance with BS 6891.
Check that the static gas supply pressure is at least 20 mbar.
3 Tighten the test point screw and test for gas soundness. Close the boiler service cock.
5.2
FIRST LIGHTING (Refer to Fig. 14 for boiler controls)
Ensure that the gas and electricity supplies to the boiler are off and that the central heating flow and return valves are open.
1 Temporarily replace the control panel fascia, secure it with one of its fixing screws.
2 Switch on the electricity supply to the boiler and set the timer for continuous operation - see Users
Operating manual.
3 Set the hot water temperature selector to maximum and central heating temperature selector to
maximum, and if a room thermostat is fitted, set it to maximum.
4 Press in the boiler on/off switch, (the green light indicates the switch is set to on). Ensure the summer/winter
switch is set to summer, i.e. hot water only, (the switch push button should be out and the green light out).
5 The boiler will attempt to heat the cold water in the storage cylinder, but as the gas supply is not yet
turned on the boiler will 'lock-out' and the red button on the control panel will light.
The hot water pump will still be working. Allow the pump to continue to run for a few minutes to vent the
internal primary circuit.
6 Turn on the gas supply at the boiler service cock and press the lock-out reset button (press and release
the button quickly - do not keep it pressed in).
After a few seconds the boiler should light - the burner flames can be seen through the inspection window
in the sealed chamber.
If the boiler does not light and goes to 'lock-out', press in the on/off switch to switch off the boiler and
check that the gas supply has been purged (section 5.1). If the boiler does not light after several attempts,
contact ICI Caldaie UK Ltd.
7 Allow the boiler to run until the water in the storage cylinder has reached the set temperature (20 to 25
minutes), when the boiler will turn off. Press in the summer/winter switch (the green light indicates the
switch is set to winter, i.e. heating and hot water), the boiler will light and operate in the heating central
mode. Allow the boiler to run for a few moments to circulate and vent air from the system.
5.3
CHECK THE BURNER PRESSURES
The maximum and minimum burner pressures can only be checked with a cold boiler/system. When
checking the maximum pressure you will only have two minutes before it modulates down.
The minimum and maximum pressures in the hot water mode (see section 1) must be established first,
before the pressure in the central heating can be checked or adjusted. With a cold store the boiler will
automatically be in the hot water mode, so there is no need to set the summer/winter switch to any
particular setting.
1 Press in the on/off switch to switch off the boiler. Isolated the gas supply at the service cock and press in the
boiler on/off switch, (the green light indicates the switch is set to on). The boiler will attempt to start, but as the gas
supply is not turned on the boiler will 'lock-out' and the red button on the control panel will light. The hot water
pump will still be working. Allow the pump to continue to run for a few minutes to cool the internal primary circuit.
Open a hot water tap to reduce the temperature of the stored water. Leave the tap running to remove
heat from the primary circuit, thereby increasing the time available to check the maximum pressure.
2 Switch off the electricity supply. Loosen the burner setting pressure test point screw on the gas valve (see
Fig. 19) and connect a pressure gauge. Disconnect one of the electrical leads to the modureg coil (see
Fig. 19) and open the boiler gas service cock.
3 Check minimum burner pressure
Switch on the electricity supply and after a few moments the boiler will light at the minimum burner
pressure.
The minimum pressure has been factory set and should not require adjusting. Check that the burner
pressure is 2.0 ± 0.1 mbar.
Refer to section 9.7.1, if any adjustment has to be made.
Switch off the electricity supply and reconnect the lead to the modureg coil.
4 Check maximum burner pressure
Switch on the electricity supply and after a moment or two the boiler will light at the maximum burner
pressure. Within two minutes the burner will reduce to the minimum pressure. Check that the burner
pressure is 11.9 ± 0.1 mbar.
Refer to section 9.7.1, if any adjustment has to be made.
Close the hot water tap.