ICI Caldaie RIO 140, Installation And Servicing Manual

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9 REPLACEMENT OF COMPONENTS
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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 service cock (see Fig. 2). Allow the boiler to
cool.
Important notes when removing or replacing components:-
1 Always test for gas soundness after replacing any gas carrying components or disturbing any gas
connections.
2 Always check the condition of the sealed chamber seals when removing/replacing the top or front
panels. Replace if necessary.
3 Always check the condition of sealing washers and 'O' rings. Replace if necessary.
4 Check the operation of the boiler, refer to section 2.14 if necessary.
5 Ensure that all the controls are returned to their original settings.
To replace any components in sections 9.1 to 9.17 does not require any draining of the boiler.
Refer to Figs. 16 and 18 for the position of the components.
9. 1 BURNER
1 Ensure that the electricity supply has been isolated.
2 Remove the burner as described in section 7.2, paragraphs 1 to 5.
3 From underneath the burner, remove the screws securing the electrodes and withdraw them. Transfer
them to the new burner. Ensure that the earth lead is connected and that the ignition electrodes are
positioned before fitting the flame sensing electrode. Check the electrode gaps. See Fig. 17.
5 Fit the burner, re-assemble in reverse order and test the boiler as described in section 7.5, paragraphs 1,
2 and 3.
9.2 BURNER INJECTORS
1 Ensure that the electricity supply has been isolated.
2 Remove the burner as described in section 7.2, paragraphs 1 to 5.
3 Remove the four screws securing the burner blade assembly to the injector bar and remove the blade
assembly.
4 Unscrew the damaged injector and screw in a replacement using a new sealing washer.
5 Refit the blade assembly to the injector bar and secure with the four screws previously removed. Use the
outer set of holes.
6 Replace the burner, re-assemble in reverse order and test the boiler as described in section 7.5,
paragraphs 1, 2 and 3.
9.3 FAN
1 Ensure that the electricity supply has been isolated.
2 Open the upper front panel (hinges to the left) to gain access.
3 Gain access to the fan as described in section 9.27, paragraphs 2 to 9.
4 Remove the four fixing screws securing the fan to the flue hood. Withdraw the assembly and disconnect
the electrical leads from the fan motor, noting their position.
Note : It may be necessary to disconnect the electrical leads from the central heating sensor, when
reconnecting the polarity is not important.
5 Connect the electrical leads to the new fan and secure it to the flue hood using the four screws previously
removed.
Reconnect the sensor electrical leads if they were removed. Connect the sensing tubes to the fan - right
(transparent) one to top connection, left (pink) one to bottom connection.
Note: Left and right refer to view when facing front of boiler.
7 Re-assemble in reverse order and test the boiler as described in section 7.5, paragraphs 1,2 and 3.
9.4 ELECTRODES
1 Ensure that the electricity supply has been isolated.
2 Remove the burner as described in section 7.2, paragraphs 1 to 5.
3 From underneath the burner, remove the screws securing the electrodes and remove from the burner.
4 When refitting the electrodes, the earth electrode is at the left and the ignition electrode/flame sensing
electrodes are at the right, secure in position with the screws previously removed. See Fig. 17.
Ensure the earth lead is connected by the L/H electrode fixing screw, the R/H ignition electrode bracket is
positioned first (white lead) then the flame sensing electrode (blue lead) bracket is positioned on top
before securing in position.
5 Check the electrode gaps and positions (see Fig. 17) ensuring that the ignition electrode tips are:-
a) Directly over a flame port, b) 4 mm apart, c) 5 mm above the burner blade.
Check that the flame sensing electrode tip is 6 mm above the burner blade.
6 Replace the burner, re-assemble in reverse order and test the boiler as described in section 7.5,
paragraphs 1,2 and 3.