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ICI Caldaie RIO 140 Installation And Servicing Manual

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

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  • Page 1: Installation And Servicing

    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...

  • Page 2: Table Of Contents

    LIST OF CONTENTS Section Subject Page Technical information......General boiler information....... Boiler installation........14 Fill and vent the system......17 Commissioning ........, 18 Information for the user......20 Boiler servicing ........21 Draining the boiler........23 Replacement of components....24 10 Wiring diagrams........11 Sequence of operation charts....

  • Page 3: Technical Information

    TECHNICAL INFORMATION 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, 2.3 bar hot (set when cold) Minimum heating system pressure (cold)......0.8 bar Maximum heating system volume........
  • Page 4 TECHNICAL INFORMATION NOMINAL BOILER RATINGS - Natural gas (G20) 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 residual pump head available 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.
  • Page 5 TECHNICAL INFORMATION BOILER SCHEMATIC 1 Automatic air vent 11 Ignition spark electrode 21 Anode 2 Co-axial duct 12 Ignition earth electrode 22 Storage cylinder 3 Air pressure 13 Flame detection electrode 23 Heating coil switch 14 Safety valve (3 bar) 24 Flow switch 4 Sealed chamber 15 Gas valve...

  • Page 6: General Boiler Information

    GENERAL BOILER INFORMATION 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 heating system. See section 2.11.
  • Page 7 GENERAL BOILER INFORMATION 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 house.
  • Page 8 GENERAL BOILER INFORMATION Fig. 1 Terminal position Min. distance Directly below an opening, air brick, window, etc. 300 mm Below gutters, soil pipes or drain pipes 75 mm Below eaves 200 mm Below balconies or car port roof 200 mm From a vertical drain pipe or soil pipe 75 mm From an internal or external corner...
  • Page 9 GENERAL BOILER INFORMATION 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 isolating valves (22 mm for central heating flow/return, 15 mm for mains water inlet and 22 mm [15 mm outlet] for gas).
  • Page 10 GENERAL BOILER INFORMATION 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 designing the system, especially at the maximum output (28.40 kW) the pump head, expansion vessel size, radiator mean temperature, etc.
  • Page 11 (hot) flushing and is maintained in service. For further information concerning inhibitors contact ICI Caldaie (UK) Limited. Fig. 5 2.12 DOMESTIC HOT WATER SYSTEM Refer to section 2.13 for unvented domestic hot water storage system 1 The boiler is set to provide a nominal output of 28.40 kW for domestic hot water.
  • Page 12 GENERAL BOILER INFORMATION 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 reducing valve, check valve and expansion relief valve, supplied in the water fittings pack, must be fitted before the mains water connection point of the boiler and there must be no isolating valves between these and the boiler.
  • Page 13 GENERAL BOILER INFORMATION 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 Domestic Hot Water and Central Heating mode.

  • Page 14: Boiler Installation

    BOILER INSTALLATION 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 from the pallet.
  • Page 15 BOILER INSTALLATION 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 connections first.
  • Page 16 BOILER INSTALLATION 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 assembly (or outer duct only) into the wall and carefully push it towards the boiler.

  • Page 17: Fill And Vent The System

    FILL AND VENT THE SYSTEM 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 not pressurise the vessel above 1.5 bar.

  • Page 18: Commissioning

    (section 5.1). If the boiler does not light after several attempts, contact ICI Caldaie UK Ltd. 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.
  • Page 19 4 Refill, vent and re-pressurise the system as described in section 4.2, adding a suitable inhibitor. For further information concerning inhibitors contact ICI Caldaie (UK) Limited. FINAL ASSEMBLY 1 If the boiler is to be left in service with the User, set the controls, timer (see Users Operating manual) and room thermostat (if fitted) to the User's requirements then refer to section 6.

  • Page 20: Information For The User

    INFORMATION FOR THE USER 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, in the event of the boiler not being used during frost conditions.

  • Page 21: Boiler Servicing

    BOILER SERVICING 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 the law that any service work must be carried out by CORGI registered personnel.
  • Page 22 BOILER SERVICING 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 carefully with a soft brush).

  • Page 23: Draining The Boiler

    DRAINING THE BOILER 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, then close the central heating flow and return valves.

  • Page 24: Replacement Of Components

    REPLACEMENT OF COMPONENTS 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.
  • Page 25 REPLACEMENT OF COMPONENTS 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 ignition control unit.
  • Page 26 REPLACEMENT OF COMPONENTS 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 load.
  • Page 27 REPLACEMENT OF COMPONENTS 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 box.
  • Page 28 REPLACEMENT OF COMPONENTS 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.
  • Page 29 REPLACEMENT OF COMPONENTS 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 supply has been isolated.
  • Page 30 REPLACEMENT OF COMPONENTS 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 in section 8.
  • Page 31 REPLACEMENT OF COMPONENTS 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 order using new sealing washers.
  • Page 32 REPLACEMENT OF COMPONENTS 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 pressure) as described in section 4.2, paragraphs 2 to 7.

  • Page 33: Wiring Diagrams

    WIRING DIAGRAMS 10.1 ILLUSTRATED WIRING DIAGRAM...
  • Page 34 WIRING DIAGRAMS 10.2 FUNCTIONAL FLOW WIRING DIAGRAM...

  • Page 35: Sequence Of Operation Charts

    SEQUENCE OF OPERATION CHARTS 11.1 AUTOMATIC IGNITION SEQUENCE...
  • Page 36 SEQUENCE OF OPERATION CHARTS 11.2 OPERATION IN CENTRAL HEATING MODE...
  • Page 37 SEQUENCE OF OPERATION CHARTS 11.3 OPERATION IN DOMESTIC HOT WATER MODE...

  • Page 38: Fault Finding

    FAULT FINDING 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 electrical checks must be repeated. Preliminary check of mains voltage and switches –...
  • Page 39 FAULT FINDING BURNER LIGHTS AND THEN GOES TO LOCK-OUT Possible cause Remedy Flame not detected Check position of electrode and adjust as necessary Check sensing lead connections, rectify as necessary Check sensing lead continuity, replace if necessary Ignition module faulty - replace Polarity of electrical supply reversed Check and rectify as necessary BURNER WILL NOT LIGHT FOR HOT WATER...

  • Page 40: Exploded Views And Parts Lists

    EXPLODED VIEWS AND PARTS LISTS 13.1 CASING AND ELECTRICS P. No. Description P. No. Description 18010150 Panel clip 50000895 Primary water overheat thermostat 60000400 Lower side panel 18040021 Temperature/pressure gauge (CH) 60000410 Upper side panel 16080050 Temperature gauge (DHW) 60000420 Lower front panel 14000504 On/off switch...
  • Page 41 EXPLODED VIEWS AND PARTS LISTS 13.2 GAS COMPONENTS N. P. No. Description N. P. No. Description 18030310 Locking nut 3/4" BSP 18 18011510 Flame detection electrode 18022084 Flame detection electrode lead (blue) 19 18022083 Ignition electrode lead (white) 50000613 Gas valve inlet manifold 20 51000704 Combustion chamber panel - front 50000630...
  • Page 42 EXPLODED VIEWS AND PARTS LISTS 13.3 SEALED COMBUSTION CHAMBER P. No. Description 51000046 Sealed chamber front cover 50000377 mtr. Sealed chamber seal 40000960 Pressure switch sensing tube (right/clear) 40000963 Pressure switch sensing tube (left/pink) 40000923 Pressure switch cover 51000031 Sealed chamber base/sides 51000036 Sealed chamber top panel 18010712...

  • Page 43: Water Components

    EXPLODED VIEWS AND PARTS LISTS 13.4 WATER COMPONENTS P. No. Q Description P. No. Q Description 60000150 CH expansion vessel (10 ltr) 60000615 Hot water inlet pipe 60000510 DHW expansion vessel (4 ltr) 60000670 Hot water expansion vessel pipe 18020190 Safety valve (3 bar) 40000215 Hot water overheat thermostat sensor...
  • Page 44 EXPLODED VIEWS AND PARTS LISTS 13.5 HORIZONTAL FLUE (CO-AXIAL) P.No. Description FH004 Outer wall seal FH002 Concentric flue pipe 100/80 mm FHV005 Inner wall seal (optional) FHV008 Flue clamp - Elbow to pipe FHV009 Stepped flue seal - elbow to pipe FHV007 'O' ring 80 mm - inner flue seal FHV006...

  • Page 45: Packing Lists

    PACKING LISTS 14.1 BOILER PACK Containing: Qty. Part No. Rio 140 boiler complete with timer (NG) 80090145 Rio 140 boiler complete with timer (LPG) 80090155 Installation and Servicing manual 18000170 Users Operating manual 18000180 Guarantee card 18000110 Flue restrictor (standard co-axial flue) 51000756 14.2 BOILER FITTINGS PACK...

  • Page 46: Information For Propane Boilers

    INFORMATION FOR PROPANE (G31) BOILERS 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 Burner pressure Gas rate...
  • Page 47 NOTE...
  • Page 48 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 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 competent person in accordance with the Gas Safety (Installation and Use) Regulations.
  • Page 50 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 fitted within the boiler, the need for external hot and cold water storage is eliminated.
  • Page 51 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 a hot tap depends on a lot of variables, such as mains pressure, distance of the tap from the boiler and the flow rate of the water leaving the tap.

  • Page 52: Electricity Supply

    GENERAL NOTES AND CARE OF YOUR SYSTEM 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. 'Summer/Winter' switch - This switch (switch push button in for winter, out for summer) allows you to switch off the central heating in the summer.
  • Page 53 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 display. The digital electronic display (24 hr.
  • Page 54 ELECTRONIC TIMER – Description of controls (see Figs. 3 and 4)
  • Page 55 PROGRAMMING THE ELECTRONIC TIMER...
  • Page 56 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.

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