ICI Caldaie RIO 140 Installation And Servicing Manual Download

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EXPLODED VIEWS AND PARTS LISTS

13.4

WATER COMPONENTS

P. No.

Q Description

60000150

CH expansion vessel (10 ltr)

60000510

DHW expansion vessel (4 ltr)

18020190

Safety valve (3 bar)

18030050

Connector 1/2"

18030320

Locknut 1/2"

41000225

DHW expansion vessel (2ltr)

40000405

Adaptor 1/2” x 3/8"

60000170

Adaptor 3/8" x 1/8"

50000365

Blanking cap 3/8"

10 40000065

Water inlet nut

11 40000060

Water inlet fitting

12 40000100

'O' ring

13 MG-140-UK

Cylinder

14 16041016

Washer

15 18040299

DHW Pump

16 18050125

Pump sealing washer

17 13080033

Non return valve

18 60000210

Nut

19 60000220

Connector

20 60000625

Cold water outlet pipe

21 60000630

Heating return pipe

22 60000640

Air separator

23 60000650

Pump to flow switch pipe

24 18040010

Primary water flow switch

25 18021033

Primary water flow switch microswitch

26 60000655

Primary water flow switch to boiler pipe

P. No.

Q Description

27 60000615

Hot water inlet pipe

28 60000670

Hot water expansion vessel pipe

29 40000215

Hot water overheat thermostat sensor

30 18020150

Automatic air vent

31 60000540

Drain cock 1/4"

32 40000917

Hot water sensor

33 60000590

Flow connection pipe

34 18050045

Sealing washer Ø 1/2"

35 18050020

Sealing washer Ø 3/4"

36 18050130

Sealing washer Ø 1"

37 50000465

Sealing washer Ø 3/8"

38 18050090

Olive 3/4"

39 18050080

Olive 1/2"

40 60000140

CH expansion vessel mounting bracket

41 40000320

Connector 3/4"

42 18030310

Locknut 3/4"

43 60000605

Sensor pocket

44 16010010

Anode

45 18022810

Drain cock 1/2"

46 07020151

Connector 1/2”

47 07040003

Tee 1/2”

48 40000415

Blanking plug 3/8"

49 60000730

Temperature/pressure relief valve

50 16080050

Temperature gauge sensor

51 60000635

Temperature/pressure relief valve pipe

52 60000750

Air separator bracket

53 18040300

CH Pump

Summary of Contents for RIO 140

Page 1: ... 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 boiler is installed and serviced as described in these instructions After installing the boiler leave these instructions with the User ...

Page 2: ...re of the product are cured and present no known hazards when used in the manner for which they are intended The following material is also present in the product Insulation material Material Type Ceramic fibre board Description Rigid board Known Hazards May cause temporary irritation or rash to skin High dust levels may irritate eyes and upper respiratory system Precautions Avoid unnecessary or r...

Page 3: ...d at 3 5 bar Hot water storage capacity 140 litre Temperature pressure relief valve setting 90 95 C 7 bar Expansion relief valve setting 6 0 bar Mains water inlet pressure reducing valve setting 3 5 bar GENERAL Burner injector Natural gas marked 125 No off 15 Electrode gap 4 mm Type of ignition Direct burner ignition Primary water content 9 0 litre Weight installed and including water 307 kg Lifti...

Page 4: ...e for the heating system Note When designing the heating system especially at the higher output 28 40 kW the pump head expansion vessel size radiator mean temperature etc must all be taken into account 1 4 FLUE LIMITATIONS Co axial flue size 100 60 mm Twin pipe flue size 80 80 mm Co axial flue maximum length 4 m 3 m with one elbow Reduction per elbow 0 8 m 45 and 90 Twin pipe maximum length 20 m t...

Page 5: ...electrode 13 Flame detection electrode 14 Safety valve 3 bar 15 Gas valve 16 Pressure gauge 17 Heating expansion vessel 18 Hot water expansion vessels 19 Cold water inlet to storage cylinder 20 Hot water outlet from storage cylinder 21 Anode 22 Storage cylinder 23 Heating coil 24 Flow switch 25 Hot water non return valve 26 Heating non return valve 27 Hot water pump 28 Heating pump 29 Storage cyli...

Page 6: ...A temperature pressure relief valve to vent the hot water store in the event of overheating 90 95 C 7 bar A built in frost protection control that will switch the boiler on if the primary water temperature falls below 5 C 2 2 REGULATIONS TO COMPLY WITH It is the law that all gas appliances are installed by competent persons such as British Gas or other CORGI registered personnel in accordance with...

Page 7: ...th air vents must be into the same room or be on the same wall to the outside air The minimum free area for each vent is 306 cm this may be halved if the ventilation is directly to the outside air 3 If installed in a cupboard or compartment with a door allow at least 75 mm clearance between the front of the boiler and the door for air movement 5 mm should be allowed at each side of the boiler 2 7 ...

Page 8: ...publication Guide for Gas Installation in Timber Framed Housing reference DM2 4 Installation may be in any room although particular attention is drawn to the requirements of the current IEE Wiring Regulations and in Scotland the electrical provision of the Building Regulations applicable in Scotland with respect to the installation of a boiler in a room containing a bath or shower Where a room sea...

Page 9: ...o supplied are a pressure reducing valve check valve expansion relief valve and a tundish See section 2 13 All nuts and olives supplied with the fittings are suitable for use with copper tubing to BS 2871 The water connections have been temporarily sealed with plastic caps to prevent any residual water from factory testing leaking from the boiler during transit All the plastic caps must be removed...

Page 10: ...hanger If the boiler is used on a small system below 12 21 kW and thermostatic radiator valves are used throughout then an external by pass is required Automatic air vent an automatic air vent fitted externally allows the boiler to be installed and vented without disturbing the room sealed inner case 3 Using the expansion vessel as supplied and an initial system pressure cold of between 0 8 and 1 ...

Page 11: ... be insulated to reduce heat loss 7 All taps and mixing valves used with the hot water system must be suitable for operating at a mains pressure of up to 8 bar 8 A shower may be used with the boilers if required It is recommended that thermostatically controlled shower valves are used to protect against a flow of water at too high a temperature If a fixed head type shower is used no anti syphonage...

Page 12: ...long directly below the tundish before any bends or elbows in the pipe iii Be installed with a continuous fall iv Have no valves or taps Where a single pipe serves a number of discharges such as in a block of flats the number served should be limited to not more than six systems so that any installation can be traced reasonably easily The single common discharge pipe should be at least one pipe si...

Page 13: ... output is then automatically adjusted to match the system demand When the temperature of the primary water is equal to the pre set temperature minus 10 C the burner output is automatically reduced When the set water temperature is reached the burner is turned off The pump continues to run circulating water around the system for as long as both the timer and room thermostat if fitted are calling f...

Page 14: ...tion Refer to section 2 7 2 Mark the centre lines of the flue on the wall behind the boiler as shown in Fig 9 If side exit flue is to be used continue the horizontal centre line of the flue across the wall to the side wall then along the side wall 221 mm Note This will give the position of the centre of the hole for the flue The figure of 221 mm assumes the boiler is to be positioned against the w...

Page 15: ...e is closed when the slot in the operating spindle is at right angles to the valve 3 5 FIT THE STANDARD HORIZONTAL FLUE See Figs 10 and 11 Alternative flue options are described in our seperate flue brochure Note To avoid rain or possible condensation running into the boiler the flue must not slope down towards the boiler The following procedure applies to both rear or side exit flue The only diff...

Page 16: ...and tighten to secure the outer duct to the elbow 17 Make good the inside wall and also the outside wall behind the outer sealing collar 18 Fit a terminal guard if necessary See section 2 7 3 5 1 FIT A FLUE EXTENSION TO A HORIZONTAL FLUE See Fig 12 1 Withdraw the inner flue duct from the outer air duct of the standard flue supplied with the boiler 2 Position the flared end of the extension inner d...

Page 17: ...alves are open before pressurising the system the system could be over pressurised as the safety valve is within the boiler and would not protect the system if the valves were closed Gradually open the fill point valve in the heating system until water is heard to flow 4 Vent each radiator in turn starting with the lowest in the system to remove the air 5 It is important that the pumps are properl...

Page 18: ...r 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 burn...

Page 19: ...n the on off switch green light off to turn off the boiler Disconnect the pressure gauge and tighten the test point screw Press in the on off switch green light on to light the boiler and test for gas soundness around the test point screw 7 Replace the control box cover ensuring the front return edge is located under the front panel return and secure with four screws 5 4 FINAL COMMISSIONING 1 Allo...

Page 20: ...registered personnel 5 Ensure that the boiler controls and room thermostat if fitted are set to the User s requirements 6 Tell the User the sealed system pressure 7 Show the User the position of the safety valve discharge pipe and tundish 8 Explain to the User that if the boiler should ever lock out the reset button should be pressed in and released quickly and that if it cannot be reset a Service...

Page 21: ...ning 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 The data label is positioned inside the upper front panel Always test for gas soundness after servicing any gas carrying components 7 2 DISMANTLING PRIOR TO SERVICING See Fig 16 1 Open...

Page 22: ...T THE BOILER 1 Perform Earth Continuity test and Resistance to Earth test 2 Turn on electricity and gas supplies to the boiler 3 Check the general operation of boiler and controls 4 Lower the system pressure and check reset the pressure in the primary water expansion vessel as necessary Reset the system pressure 5 Check and adjust gas settings hot water minimum maximum and heating maximum 6 Carry ...

Page 23: ... in the central heating flow pipe just to the left of the gas valve Open the drain cock and drain the boiler Note When refilling ensure the system is adequately protected by a suitable anti corrosion inhibitor Hot water circuit 1 Close the mains water supply valve and ensure all hot taps are closed 2 Remove the lower front panel of the boiler pulls off Connect a suitable hose pipe to the drain coc...

Page 24: ...s 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 sec...

Page 25: ... the bottom of the sealed chamber 8 Carefully pass the new thermostat bulb through the grommet in the back of the control box through the grommet in the bottom of the sealed chamber and secure it to the heat exchanger using the clip previously removed Secure the new thermostat to the control box and reconnect the electrical leads to terminals C and 1 the polarity is not important Ensure the earth ...

Page 26: ...stic enclosure 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 screw securing the ignition control unit to the gas valve Carefully prise open the wiring cover clips on the top and right hand side of the cover and remove the cover Disconnect the wiring connector and withdraw the ignition control unit away from the ga...

Page 27: ... the leads refer to the wiring diagram page 34 for electrical connections 6 Replace the control box cover ensuring the front return edge is located under the front panel return and secure with four screws 7 Test the boiler as described in section 7 5 paragraphs 1 2 and 3 9 13 SWITCHES The same procedure applies to both the on off and summer winter switches the switches are not the same 1 Ensure th...

Page 28: ... the control box cover ensuring the front return edge is located under the front panel return and secure with four screws 9 Test the boiler as described in section 7 5 paragraphs 1 2 and 3 9 16 AIR PRESSURE SWITCH The air pressure switch is positioned on the back of the boiler at the top and is accessible without opening the case 1 Ensure that the electricity supply has been isolated 2 Remove the ...

Page 29: ...er as described in section 8 3 Disconnect the discharge pipe from the safety valve 4 Remove the union nut securing the pressure sensor to the front of the safety valve and withdraw the sensor 5 Unscrew the safety valve from the central heating flow pipe 6 Re assemble in reverse order using a new valve 7 Fill the boiler and re pressurise the system to between 0 8 and 1 5 bar to match the original s...

Page 30: ...ure as described in section 4 2 paragraphs 2 to 7 8 Test the boiler as described in section 7 5 paragraphs 1 2 and 3 9 23 HOT WATER EXPANSION VESSELS 4 litre white 2 litre silver The boiler is fitted with two hot water expansion vessels see Fig 19 The 4 litre expansion vessel is positioned on the back of the boiler at the right hand side and is accessible from the top The 2 litre vessel is positio...

Page 31: ...ws Remove the four screws securing the control box top cover Slide the cover back and up to remove it from the control box From inside the control box remove the four screws securing the box to the boiler Fig 21 9 26 DOMESTIC HOT WATER TEMPERATURE PRESSURE RELIEF VALVE The DHW temperature pressure relief valve is positioned in the left hand connection point on top of the hot water storage cylinder...

Page 32: ...o clear the inlet pipe then withdraw it from the outlet pipe 13 Transfer the central heating sensor and overheat thermostat bulb clip from the old heat exchanger to the new one 14 Re assemble in reverse order using new O rings on the heat exchanger connections ensuring the grub screws are correctly located and not over tightened Also replace the flue seals and the seals to the boiler top cover if ...

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: ...h continuity replace if necessary Check 230V output from ignition board pins 8 9 on ignition PCB Check electrical connections to fan Check continuity of wiring to fan Check 230V at fan replace fan if necessary Check electrical connections to switch Check continuity N C contact replace if necessary Check control replace if necessary Pump and fan operating followed by boiler lock out Possible cause ...

Page 39: ...k timer setting and reset as necessary Check electrical connections rectify as necessary Check switch continuity replace if necessary Check setting of thermostat and reset as necessary Check wiring and connections rectify as necessary Check switch continuity replace if necessary Check and rectify as necessary Check electrical connections rectify as necessary Check sensor see note below replace if ...

Page 40: ...690 1 Control box body 14 60000360 1 Control box top panel 15 60000375 1 Control box fascia panel N P No Q Description 16 50000895 1 Primary water overheat thermostat 17 18040021 1 Temperature pressure gauge CH 18 16080050 1 Temperature gauge DHW 19 14000504 1 On off switch 20 14000505 1 Summer winter 21 60000380 2 Control knob 22 60000530 1 Reset switch 23 40000790 1 Main driver board 24 40000455...

Page 41: ...00705 1 Thermostat phial retaining clip 16 18011515 1 Ignition earth electrode 17 18011511 1 Ignition spark electrode N P No Q Description 18 18011510 1 Flame detection electrode 19 18022083 1 Ignition electrode lead white 20 51000704 1 Combustion chamber panel front 21 51000536 1 Combustion chamber panel side rear 22 50000895 1 Primary water overheat thermostat 23 51000172 1 Insulation panel fron...

Page 42: ...g tube right clear 4 40000963 1 Pressure switch sensing tube left pink 5 40000923 1 Pressure switch cover 6 51000031 1 Sealed chamber base sides 7 51000036 1 Sealed chamber top panel 8 18010712 1 Viewing window 9 60000560 1 Chassis 10 18052115 6 Grommet small 11 18052119 2 Grommet large 12 41000921 1 Fan assembly 13 41000926 1 Pressure switch 2 68 mbar 14 50000518 1 Pressure switch mounting bracke...

Page 43: ...3 1 Primary water flow switch microswitch 26 60000655 1 Primary water flow switch to boiler pipe N P No Q Description 27 60000615 1 Hot water inlet pipe 28 60000670 1 Hot water expansion vessel pipe 29 40000215 1 Hot water overheat thermostat sensor 30 18020150 1 Automatic air vent 31 60000540 1 Drain cock 1 4 32 40000917 1 Hot water sensor 33 60000590 1 Flow connection pipe 34 18050045 5 Sealing ...

Page 44: ...entric 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 80 mm inner flue seal 7 FHV006 1 Gasket flue elbow to boiler 8 FHV010 6 Screw pan hd pozi No 8 x 11 9 FH003 1 90 flue elbow 10 FHV031 1 Screw pan hd pozi M3 x 10 optional ...

Page 45: ...below 2 90020092 15 mm pipe connector for cold and hot water see below 2 90020093 15 mm pipe connector for gas see below 1 90020094 3 4 in fibre washer flow return connections 2 18050020 1 2 in fibre washer hot cold water connections 2 18050045 Tundish 1 41000275 Check valve 1 41000245 Pressure reducing valve 1 41000235 Expansion relief valve 1 41000240 14 3 STANDARD FLUE KIT Containing Qty Part N...

Page 46: ...er is 1 26 m h The gas storage vessel and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances in the house A 22 mm supply pipe will be necessary for the majority of installations but reference should be made to BS 5482 1994 for detailed guidance on gas pipe sizing The regulator should ensure a dynamic pressure of 37 mbar at the inlet ...

Page 47: ...NOTE 47 ...

Page 48: ...t the date of printing but will be superseded and should be disregarded if specifications and or appearances are changed in the interests of continued product improvement All goods sold are subject to our official Conditions of Sale a copy of which may be obtained on application ICI Caldaie UK Ltd 1998 No part of this manual may be reproduced by any means without prior written consent ...

Page 49: ...Natural Gas model only or Propane G31 Propane model only EC Certificated for Safety and Performance The boiler must be installed by a competent person in accordance with the Gas Safety Installation and Use Regulations Servicing and replacement of parts must only be carried out by competent persons such as British Gas or other CORGI registered personnel ...

Page 50: ...urned off and the pump continues to run As the heating system water cools the temperature drop is detected by the control system and the burner is automatically restarted for the cycle to continue until either the timer or room thermostat stops calling for heat The burner is then turned off if it is operating at the time and the pump runs on for about 2 minutes Domestic Hot Water Mode When a deman...

Page 51: ...fitted is set at the desired setting and the timer is correctly set refer to the relevant Timer section 2 Turn both the Hot Water and Heating temperature selectors fully clockwise to their maximum setting 3 Switch on the electricity supply to the boiler 4 Press in the On Off switch the green light on the switch indicates the switch is set to on 5 The boiler is now ready to light automatically If t...

Page 52: ...ged from the end of theses pipes switch off the boiler and contact your Service Engineer Your installer should have informed you where these pipes terminate 8 Clearances and ventilation Always ensure that the boiler has the following minimum clearances for safety and servicing Top 300 mm Front 600 mm Sides 5 mm If the boiler is installed in a compartment your Installer will have provided ventilati...

Page 53: ...central heating A typical timer setting for a working family could be as follows The groups of tappets between 6 00 and 8 00 and 16 00 and 22 00 set outwards as shown in Fig 2 This would provide two on periods for central heating from 6 am to 8 am then again from 4 pm to 10 pm To set the timer to the correct time of day turn the dial outer tappet ring clockwise until the time of day is against the...

Page 54: ...6 ELECTRONIC TIMER Description of controls see Figs 3 and 4 ...

Page 55: ...7 PROGRAMMING THE ELECTRONIC TIMER ...

Page 56: ...de prompt service in the unlikely event of a problem occurring but cannot be held responsible for any consequence of delay however caused 7 We strongly recommend that you complete and return the Guarantee Registration Card but failure to do so does not affect your statutory rights DO NOT NEGLECT YOUR GAS COMBINATION BOILER THE COMPANY RECOMMENDS YOU TAKE OUT AN ANNUAL SERVICE CONTRACT WITH AN APPR...

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