Instructions for Use Installation and Servicing To be left with the user CSI 85 AAA (T) 780 SERIES HIGH EFFINCENCY CONDENSING COMBINATION BOILER Natural Gas (G20) I2H - II2H3+ LPG (G30-G31) I3+ - II2H3+ Technical and illustrative data are not binding and can be modified without prior notice. The descriptions and illustrations in the present booklet are for guideline purposes only. RAVENHEAT MANUFACTURING LTD, CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET TEL. 0044( 0)113 252 7007 FAX: 0044 (0)113 238 0229 Website : www.ravenheat.co.uk - E-mail : firstname.lastname@example.org CONDENSING SYSTEM INNOVATION AUTOMATIC MODULATING BOILER FOR CENTRAL HEATING AND DOMESTIC HOT WATER This new high efficient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at super high efficiency. POSITION The appliance is extremely versatile as it can be fitted in almost any room. The appliance is room sealed, there is no contact between the combustion chamber and living accommodation. This guarantees maximum safety and efficiency. Indeed, our depression/combustion front cover has been designed to fit, achieving maximum air tight seal using screw down fasteners every 15 cm . This should not hinder service of the appliance, but does ensure maximum efficiency and safety - something which Ravenheat takes great pride in. Each boiler has been designed and manufactured in our modern plant to exacting ISO 9001 discipline and all boilers carry full CE marking of approval. Technical sales and commercial service are available throughout the UK. This product is guaranteed by Ravenheat Manufacturing, Chartists Way, Morley, LEEDS, LS27 9ET. Telephone No (0113) 252 7007. BASIC COMPONENTS - (See figure 1) Guarantee is valid for 12 months from date of purchase providing the appliance has been fitted in accordance with these instructions and relevant codes of practice. MAJOR COMPONENTS - Gas valve with flame modulator. Variable head pump suitable for any type of central heating system. Burner with flame stabiliser designed to operate under all thermal conditions. Primary heat exchanger constructed from copper. Unique patented condensing heat exchanger for high thermal flue transfer gases to water. Stainless steel plate heat exchanger for super high heat transfer to domestic hot water. Highly reliable diverter valve with ethylene propylene diaphragm permitting primary flow circulation in the boiler during domestic hot water supply. Built in frost protection. Printed circuit board designed to connect to room stat and/or timer/frost stat. Aesthetically pleasing panels and controls. On/Off ball valves for shutting off gas central heating and domestic hot water circuit Safety relief valve (for safety discharge). Programmable 7 day module with digital display (optional model). All front panel controls infrequently used have been hidden. This achieves simplicity of operation with easy to clean panels. NOTE: Due to the high efficiency of this boiler a plume of water vapour will form at the flue terminal during operation. COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH IMPORTANT This appliance contains materials that are indicated below. It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is-worn when handling, where applicable. The pertinent parts that contain any materials that could be interpreted as being injurious to health and safety. WARNING When installing the appliance, care should be taken to avoid any possibility of injury when handling sheet metal parts. GENERAL INFORMATION: GLUES AND SEALANTS - exercise caution - if these are still in liquid form. INSULATION PADS, CERAMIC FIBRE - may be harmful if inhaled, may be irritating to skin, eyes, nose and throat. When handling keep dust generation to a minimum, avoid inhaling and contact with skin or eyes. When disposing of the product keep dust generation to a minimum and ensure that parts are securely wrapped. When servicing avoid inhalation by using a vacuum cleaner in conjunction with other tools. After handling wash hands and other exposed parts. RAVENHEAT use only high quality material for production of this product, in an effort to protect the environment components should be re-cycled. 3 SECTIONS 1 2 3 4 5 6 7 8 9 10 11 12 TABLE OF CONTENTS PAGE INTRODUCTION DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION TECHNICAL DATA GENERAL REQUIREMENTS INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS FAULT FINDING ELECTRICAL SYSTEM DIAGRAM INSTALLATION INSTRUCTIONS FOR TWIN FLUE PIPE EXPLODED PARTS DIAGRAM LIST OF SPARE PARTS 6 6 8 10 15 25 30 40 42 43 46 46 47 Fig. 1 KEY 1 - Heat exchanger 2 - Sensing electrode 3 - Burner 4 - Expansion tank 5 - Modulating gas valve 6 - Condensing trap 7 - C.H. outlet 8 - Drain point 9 - Safety relief system 10 - D.H.W. outlet 4 11 - D.H.W. sensor 12 - D.H.W. heat exchanger 13 - D.H.W switch 14 - D.H.W inlet 15 - Diverter valve motor 16 - Low water pressure switch 17 - Circulation pump 18 - Overheat cut off thermostat 19 - C.H. sensor 20 - Spark electrode 21 - Combustion chamber 22 - Frame 23 - Sealed chamber 24 - Air pressure switch 25 - Auto air vent 26 - Fan 27 - Flue restriction ring 28 - Condensing heat exchanger 29 - Flue gas exhaust hood 30 - Temperature flue sensor Fig. 2 KEY 1 - Heat exchanger 2 - Sensing electrode 3 - Burner 4 - Expansion tank 5 - Modulating gas valve 6 - Condensing trap 7 - C.H. outlet 8 - Drain point 9 - Safety relief system 10 - D.H.W. outlet 12 - D.H.W. heat exchanger 15 - Diverter valve motor 16 - Water pressure sensor 17 - Circulation pump 18 - Overheat cut off thermostat 20 - Spark electrode 24 - Pressure switch 25 - Auto air vent 26 - Fan 27 - Flue restriction ring 28 - Condensing heat exchanger 29 - Compresson ball valves 30 - Temperature flue sensor 31 - Water pressure switch 32 - Water pressure gauge 33 - Automatic by-pass 34 - Gas service cock 5 SECTION 1 INTRODUCTION 1.1 The Ravenheat boiler is for the use of central heating and domestic hot water combined in one unit. It is fitted with an automatic domestic hot water priority valve. A / (winter/summer) selector switch is fitted to the left hand side of control panel.With the only (summer) position being for domestic hot water. position being for central heating with domestic hot water priority. The boiler is equipped with a front cover which can be removed for servicing. The data badge with technical data is placed on the lower right hand side of the frame. 1.2 Fig.1. Illustrates the general layout of components. Fig. 2. Illustrates the operating scheme described in section 2. the heating circuit fully pressurized so as to operate the low water sensor device the boiler will start in the same way in domestic hot water mode but with slightly differing time delay. In that it will start on minimum and remain at this level for about 1 minute. After which the flame will lift to its maximum setting as governed by a potentiometer which range rates the heating circuit between maximum and minimum power. As the heating sensor reaches temperature the gas burner power modulates down, the fan speed will also reduce to minimum fan speed. When starting, the fan will always start at maximum speed. 2.2.8 On the control panel are mounted two potentiometers (thermostats) these control the temperature. One is for domestic hot water and the other for heating. 2.2.9 The boiler is fitted with an anti-cycling device on the control board. This delays the boiler from re-firing over a 2/5 minute period when in heating mode. The domestic hot water will always take priority and is unaffected by the anti-cycling device. SECTION 2 2.1 DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION 2.2 Domestic hot water mode When the appliance is in rest mode with the mains neon switch on. Switch the summer/winter switch tap position, with the heating circuit charged with water (above 1 bar). If the domestic hot water tap is turned on, the boiler will function in the following sequence: 2.2.1 2.2.2 The spark ignition system is powered which in turn commences the spark igniter to operate and light the burner. At this point the ignition board opens the gas valve to light the burner. 2.2.3 When the electrode/sensor senses the signal of the burner, the spark igniter stops. 2.2.4 From the minimum gas rate setting the boiler increases to the maximum permissible pressure over a period of 3 to 4 seconds and will remain at its maximum required power until it reaches maximum regulated temperature. 2.2.5 2.2.6 2.2.7 6 The pump starts. The control board sensors. The fan operates via the pressure switch and sends a signal back to the ignition board that the fan is running at maximum speed. When the domestic hot water tap is closed the diverter valve goes back into rest mode, the main burner is shut down along with the pump and fan which are also switched off. The pressure switch returns to its rest mode Central heating mode If the switch is positioned on with a demand for heat to supply radiators, with GENERAL FUNCTION 2.3 Central Heating Mode 2.3.1 A potentiometer installed on the electric circuit board permits regulation of the boiler to partial heating requirements, between maximum and minimum settings. 2.3.2 Air is drawn by the fan for combustion. 2.3.3 The fan also forces exhaust gas through the flue to the outside, this creates a lesser pressure in the sealed combustion chamber, thus sucking in combustion air, through the inlet duct. 2.3.4 The boiler water temperature is automatically controlled by a built in thermostat 2.3.5 Interior space temperature is set by the room thermostat to be installed in the heating system. The boiler already carries connection terminals for this thermostat, as well as for a timeclock. The burner continues to operate until it is stopped by the timer or one of the thermostats 2.3.6 When the internal C.H. temperature sensor intervenes the main burner shuts down. The fan stops but the pump continues to operate. 2.3.7 When the room thermostats intervene the main burner shuts down. The fan stops and the pump turns off. 2.3.8 The condensate trap is fitted with a blockage safety sensor. This prevents the boiler operating should there be a blockage in the condensate discharge trap. 2.4 Domestic hot water mode 2.4.1 The heat exchanger in the D.H.W. circuit is built into the main heat exchanger, and domestic hot water is heated by converting the water in the central heating circuit. The transference of heat is very high because the two fluids move in a counter direction flow to each other. 2.4.2 2.4.3 Select (fig. 35) the winter position. When a hot water tap is turned on a diaphragm diverter valve excludes the central heating circuit, the boiler automatically modulates to maintain the domestic hot water at a constant temperature. Water temperature can be regulated using the D.H.W. thermostat located on the front control panel. When domestic hot water is being drawn the main burner and pump perform as they do during central heating except that the burner is commanded by the D.H.W. thermostat. 2.4.4 When D.H.W. is no longer called for the boiler automatically returns to the central heating mode. 2.4.5 Select (fig. 35) the summer position the boiler functions like an automatic gas hot water heater. When D.H.W. is no longer required the main burner fan and pump immediately turn off. This also takes place with the summer/ winter switch if there is no demand for heat to the central heating system or until the room thermostat/time clock demands from the central heating circuit the main burner fan and pump turn off immediately. . 2.5 SAFETY DEVICE In both central heating and domestic hot water mode safe operating is ensured by: 2.5.1 A differential pressure switch which shuts off the main burner if the fan stops or the flue or combustion air intake duct is obstructed. An overheat cut off thermostat set slightly higher than the high limit thermostat acts to turn of the burner to resetable “lockout” (Fig. 35) item 3. OVERALL DIMENSION 2.5.2 A safety valve is fitted on the central heating circuit set at 43 psi (3 bar). 2.5.3 A heating circuit (low water) pressure switch is set at 0.4 bar. Fig. 3 7 SECTION 3 TECHNICAL DATA CSI 85 AAA (T) - 780 Series TABLE 1 NATURAL GAS (G 20) І2H - П2H3+ NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET 22.6 kW 11.6 kW NOMINAL HEAT OUTPUT NOMINAL HEAT OUTPUT CONDENSING MINIMUM HEAT OUTPUT MINIMUM HEAT OUTPUT CONDENSING 22.3 kW 23.9 kW 11.4 kW 12.3 kW GAS RATE AFTER 10 MINUTES max min INLET PRESSURE 20 mbar BURNER PRESSURE C.H. max min MAIN BURNER INJECTORS ELECTRICAL SUPPLY POWER CONSUMPTION EXTERNAL FUSE RATING INTERNAL FUSE Nr. 13 x 1.25 230 V ~ 50 HZ 150 W 3A 2A DRY WEIGHT WATER CONTENT C.H. WATER CONTENT 46 kg 2.1 litre 0.5 litre 2.3 m3/h 1.2 m3/h 10.5 mbar 2.0 mbar (20 mm to BS 4265) GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W. 15 mm copper pipe SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 bar MINIMUM WORKING PRESSURE 0.5 bar 7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar CENTRAL HEATING OPERATING TEMPERATURE MAX 85°C MIN 45°C DESIGN FLOW RATE 1102 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/min D.H.W. FLOW RATE 30 °C rise 12.3 l/min D.H.W. FLOW RATE 35 °C rise 10.5 l/min D.H.W. FLOW RATE 40 °C rise 9.2 l/min D.H.W. TEMPERATURE max 65 °C min 35 °C BURNER PRESSURE D.H.W. max 11.2 mbar min 2.0 mbar Qmw Input Net max 26 kW min 11.6 kW D.H.W. PRESSURE max 10 bar (147 p.s.i.) D.H.W. PRESSURE PMW min 0.8 bar (118 p.s.i.) To obtain heat input 1.2 bar D.H.W. MINIMUM FLOW RATE 3 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers DESTINATION: AT, DK, Fl, SE, CATEGORY I2H DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+ FLUE TYPE - C12 - C32 - C52 NOX 4 8 SECTION 3 TECHNICAL DATA CSI 85 AAA (T) - 780 Series TABLE 1/A LPG (G 30 - G 31) І3+ - П2H3+ NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET 22.6 kW 11.6 kW NOMINAL HEAT OUTPUT NOMINAL HEAT OUTPUT CONDENSING MINIMUM HEAT OUTPUT MINIMUM HEAT OUTPUT CONDENSING 22.3 kW 23.9 kW 11.4 kW 12.3 kW GAS RATE AFTER 10 MINUTES max min INLET PRESSURE G31 37mbar BURNER PRESSURE C.H. max min G31 0.9 m3/h 0.4 m3/h G30 0.7 m3/h 0.3 m3/h G30 28-30 mbar G31 35.4mbar 7.3 mbar MAIN BURNER INJECTORS ELECTRICAL SUPPLY POWER CONSUMPTION EXTERNAL FUSE RATING INTERNAL FUSE Nr 13 x 0.75 230 V ~ 50 HZ 150 W 3A 2A DRY WEIGHT WATER CONTENT C.H. WATER CONTENT 46 kg 2.1 litre 0.5 litre GAS SUPPLY CONNECTION FLOW CONNECTION C.H. RETURN CONNECTION C.H. INLET CONNECTION D.H.W. OUTLET CONNECTION D.H.W. SAFETY DISCHARGE C.H. CONDENSATION DRAIN 15 mm compression isolating valve 22 mm compression isolating valve 22 mm compression isolating valve 15 mm compression isolating valve 15 mm compression 15 mm copper pipe 3/4” (21.5 mm) push fit over flow G30 27.3 mbar 7.0 mbar (20 mm to BS 4265) MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS MINIMUM WORKING PRESSURE 6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE CENTRAL HEATING OPERATING TEMPERATURE MAX 85°C 2.5 bar 0.5 bar 0.5 bar MIN 35°C DESIGN FLOW RATE 1102 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/min D.H.W. FLOW RATE 30 °C rise 12.3 l/min D.H.W. FLOW RATE 35 °C rise 10.5 l/min D.H.W. FLOW RATE 40 °C rise 9.2 l/min 10°C inlet temperature D.H.W. TEMPERATURE max 65 °C min 35 °C BURNER PRESSURE D.H.W. MAX G31 35.4 - G30 27.3 mbar MIN G31 7.3 - G30 7.0 mbar Qmw Imput Net MAX 22.6 Kw - MIN 11.6 Kw D.H.W. PRESSURE max 10 bar (147 p.s.i.) D.H.W. PRESSURE PMW min 0.8 bar (11.8 p.s.i.) To obtain heat input 1.2 bar D.H.W. MINIMUM FLOW RATE 3 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers DESTINATION: BE, FR CATEGORY I2H+ DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+ FLUE TYPE - C12 - C32 - C52 NOX 4 9 SECTION 4 4.1 4.1.1 The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations. GENERAL REQUIREMENTS SAFETY Gas Safety (Installation and Use). Regulations. It is law that all gas appliances are installed and serviced by a registered installer in accordance with the above regulations and these installation instructions. All registered installers carry a I.D. card and have a registration number. Both should be recorded in your boiler log book. You can check your installer in the gas safe register. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with. The installation of the boiler MUST be in accordance with the latest I.E.E. (BS 7671) Wiring Regulations, local building regulations, bye-laws of the local water authority, the building regulations and the Building Standards (Scotland) and any relevant requirements of the local authority. GENERAL INFORMATION Both the user and the manufacturer rely heavily on the installer, whose job it is to install the combination boiler and connect it to a correctly designed heating system. Acquaint yourself with the British Standards concerning installation requirements. If you need advice on any points your Ravenheat Technical Services Office would be pleased to help. It is recommended that tools suitable for brass fittings are used, and have a capability to accomodate hexagon sizes up to 50 mm. IMPORTANT: These appliances are CE certificated for safety and performance. It is, therefore, important that no external control devices e.g. flue dampers, economisers etc. are directly connected to this appliance unless covered by these Installation and Service Instructions or as otherwise recommended by Ravenheat in writing. If in doubt please enquire. Any direct connection of a control device not approved by Ravenheat could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety regulations and the above regulations. NOTE: The Ravenheat CSI 85 AAA - 780Sseries combination boiler has been tested and examined by ADVANTICA, and is certified to comply with PrEN 483 and BS EN 625. 4.2 LOCATION OF BOILER 4.2.1 Siting of the Ravenheat CSI 85 AAA - 780 series Combi Boiler must be as follows. The position of installation should be within the building, unless otherwise protected by a suitable enclosure. Adequate space for installation, servicing and air circulation around boiler must be allowed for. The Ravenheat CSI 85 AAA - 780 Series Combi Boiler must be fitted on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance may be installed on a combustible wall subject to the requirements of the Local Authority and Building Regulations. CODES OF PRACTICE/Ref: Documents Detailed recommendations are contained in the following British Standard Codes of Practice: BS.6891 Low pressure installation pipes. BS.6798 Installation of gas fired hot water boilers of rated input not exceeding 60 kW. BS.5449 Forced circulation hot water systems. BS.5546 Installation of gas hot water supplies domestic purposes (2nd Family Gases). BS.5440: 1 Flues (for gas appliances of rated input not exceeding 60 kW). BS.5440: 2 Ventilation (for gas appliances of rated input not exceeding 60 kW). DD 189: 1990 Discharge of condensate. Health & Safety Document No.635 The Electricity at Work Regulations, 1989. 10 LPG versions of this appliance shall not be installed in cellars or basements. 4.3 CLEARANCES AROUND THE APPLIANCE 4.3.1 The following minimum free spaces, required for installation inspection and servicing, must be left around the boiler 18 inches (450 mm) in front 5 inches (125 mm) above 6 inches (150 mm) below 0.2 inches (5 mm) on each side 1 inch (25 mm) in front when installed in a cupboard. 4.4 IMPORTANT NOTICE 4.4.1 If the combination boiler is to be fitted in a timber framed building it should be fitted in accordance with the British Gas Publication Guide for Gas Installations in Timber Frame Housing Reference DM2, If in doubt advice must be sought from the local gas supplier. The combination boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and in Scotland the electrical provisions of the Building Regulations applicable in Scotland. With respect to the installation of the combnation boiler in a room or internal space containing a bath or shower. Where a room sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control, utilising mains electricity should be so situated that it cannot be touched by a person using a bath or shower. A compartment used to enclose the combination boiler MUST be designed and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified accordingly Samples of the CSI combination boiler have been examined by B.G. Technology Notified Body, and is certified to comply with the essential requirements of the Gas Appliance, Directive 90/396/EEC, the Low Voltage, Directive 72/23/EEC and shows compliance with the Electro Magnetic Compatibility, Directive 89/336/EEC and are therefore permitted to carry the CE Mark. The appliance has been tested and approved by the WRc as meeting the requirements of G3 and L of the Building regulations and water Bylaws Scheme - Approved Products. 4.5 GAS SUPPLY 4.5.1 A gas meter is connected to the service pipe by the Local Gas Region or the Local Gas Region contractor. An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves. Installation pipes should be fitted in accordance with BS 6891. Pipework from the meter to the boiler must be of adequate size (22 mm) min To within at least 3 metre of the boiler (15 mm) min can then be used for remaining pipe work to the appliance. A smaller size than the boiler inlet gas connection should not be used. The complete installation must be tested for soundness as described in the above Code. N.B. if the gas supply for the boiler serves other appliances ensure an adequate supply is available both to the boiler and the other appliances when they are in use at the same time. 4.6 FLUE SYSTEM 4.6.1 The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discolouration that might occur to building products in the vicinity (see fig. 5). The terminal must not be located in a place where it is likely to cause a nuisance. In cold and/or humid weather water vapour may condense on leaving the flue terminal, the effect of such steaming must be considered The terminal must not be closer than 25 mm (1 in) to any combustible material For protection of combustibles, refer to BS 5440.1. Where a flue terminal is installed less than 1000 mm. from a plastic, or painted gutter; or 500 mm from painted eaves, an aluminium shield 1000 mm long, should be fitted to the underside of the gutter or painted surface. Pluming will occur at the terminal so, where possible, terminal positions which could cause a nuisance should be avoided. The flue must be installed in accordance with the recommendations of BS 5440: Part 1. IMPORTANT NOTES For greater flue lengths see twin flue instructions. Flue must be positioned in a place not likely to cause a nuisance. IMPORTANT: The following notes are intended for general guidance. The boiler MUST be installed so that the terminal is exposed to external air. It is important that the position of the terminal allows the free passage of air across it at all tirnes. Minimum acceptable spacing from the terminal to obstructions and ventilation opening are specified in Fig. 5. Note positions: Due to the terminal design, installation is possible with clearances less than those specified in BS 5440, Part 1. 11 Fig. 6 Terminal position for fan assisted boiler (minimum distance) ABCDEFGHIJKLMNP- Directly below an open window or other opening (e.g. air brick) From a vertical structure on the roof Below eaves Below balconies or car port roof From a vertical drain pipes and soil pipes From an internal or external corner Above ground or below balcony level From a surface facing a terminal From a terminal facing the terminal From an opening in the car port (e.g. door window) into dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the same wall Above an opening, air brick, opening windows etc... Below gutters, soil pipes or drain pipes Above intersection with roof NOTE: The flue must be terminated in a place not likely to cause a nuisance. 4.6.2 A concentric vertical flue kit is available for flueing applications up to a maximum height of 4 metres. For further details see vertical flue installation instructions. 4.7 AIR SUPPLY 4.7.1 The following notes are intended for general guidance. The room sealed fan flued boiler does not require a permanent air vent for combustion air supply. When installed in a cupboard or compartment ventilation is not required. 4.8 WATER CIRCULATION (central heating) 4.8.1 Detailed recommendations are given in BS 6798:1987/5449:1990 (for smallbore and microbore central heating systems). The following notes are given for general guidance. 12 mm 300 150 200 200 150 100 300 600 1200 1200 1500 300 300 75 300 4.8.2 Pipework Copper tubing to BS 2871 1.1.1971 is recommended for water pipes. Jointing should be either with capillary soldered or with compression fittings. Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps. It should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air except where providing useful heat, pipes should be insulated to prevent heat loss and to avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors. 4.8.3 An automatic system by-pass is included within the boiler. The boiler is suitable for use in system with thermostatic radiator valves and additional by-pass is required. 4.8.4 Draining tap These must be located in accessible positions to permit the draining of the whole system. The taps must be at least 15 mm nominal size and manufactured in accordance with BS 2870 1980. 4.8.5 Air release points These must be fitted at all high points where air will naturally collect, and must be sited to facilitate complete filling of the system. 4.8.6 The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated. It can accept up to 6 Its of expansion water. If the appliance is connected to a system with an unusually high water content, calculate the total expansion and add additional sealed expansion capacity as appropriate (Fig. 7). In general, modern systems will present no problem. 4.8.7 Mains water feed: central heating There must be no direct connection to the mains water supply, even through a non return valve, without the approval of the Local Water Authority. Fig. 7 PERMISSIBLE METHOD OF FILLING Figure 8 depicts the requirements of Diagram R24.2a of the Water Supply (Water Fittings) regulations 1999. Fig. 8 13 SIZING OF ADDITIONAL EXPANSION VESSEL: TABLE 3 Deduct from the value given in the table the 7 litre vessel supplied. Safety valve setting (bar) 3.0 Vessel charge pressure (bar) 0.5 Initial system pressure (bar) 0.5 1.0 1.0 1.5 Total water content of system 2.0 1.0 1.5 1.5 2.0 1.5 2.0 EXPANSION VESSEL VOLUME (LITRES) Litres 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 For system volumes other than those given above, multiply the system volume by the factor across 2.1 4.2 6.3 8.3 10.4 12.5 14.6 16.7 18.7 20. 8 22.9 25.0 27.0 29. 1 31 .2 33.3 35. 4 37.5 39.6 41.6 3.5 7.0 10.5 14.0 17.5 21.0 24.5 28.0 31 .5 35.0 38.5 42.0 45.5 49.0 52.5 56.0 59.5 63.0 66.5 70.0 6.5 12.9 19.4 25.9 32.4 38.8 45.3 51 .8 58.3 64.7 71 .2 77.7 84.1 90.6 97 .1 103.6 110.1 116.5 123.0 125.9 13.7 27.5 41.3 55.1 68.9 82.6 96.4 110.2 124.0 137.7 151 .5 165.3 179 .1 192.8 206.6 220.4 239.2 247.9 261 .7 275.5 2.7 5.4 8.2 10.9 13.6 16.3 19.1 21.8 24.5 27.2 30.0 32.7 35.7 38 .1 40.9 43.6 46.3 49.0 51 .8 54.5 4.7 9.5 14.2 19.0 23.7 28.5 33.2 38.0 42.7 47.5 52..2 57.0 61 .7 66.5 71 .2 76.0 80.7 85.5 90.2 95.0 10.3 20.6 30.9 41.2 51.5 61.8 72.1 82.4 92.7 103.0 113.3 123.6 133.9 144.2 154.5 164.8 175.1 185.4 195.7 206.0 0.0833 0.140 0.259 0.551 0 .109 0.190 0.412 3.9 7.8 11.7 15.6 19.5 23.4 27 .3 31.2 35 .1 39.0 42.9 46.8 50.7 54.6 58.5 62.4 66.3 70.2 74.1 78.0 0.156 8.3 16.5 24.8 33.1 41.3 49.6 57.9 66.2 74.5 82.7 91.0 99.3 107.6 115.8 124.1 132.4 140.7 148.9 157.2 165.5 0.331 Note: This pressure can be increased up to 1.5 bar to suit high static head situations, see item 10, other appliance components in the SERVICING INSTRUCTIONS. B) Where fitting of a make up vessel would be difficult, RE-PRESSURING of the system can be done. See section on FILLING. If the capacity of the central heating system should exceed 110 Litres, an additional vessel should be installed on the return to the combination boiler from the heating system (Fig. 7). Guidance on vessel sizing is given in (Table 3). Reference should be made to British Gas Publications, «Material and Installation Specifications for Domestic Central Heating and Hot Water». Draining taps should be at least 1/2” in BSP nominal size and be in accordance with BS 2879. 4.8.8 14 Installation to an existing central heating system. The combination boiler is designed to operate on a sealed system only. Therefore if the existing system is of the open water type it will have to be modified to comply with BS 5376 Part 2. Before installing a new combination boiler to an existing system, flush out the old system with a recommended descaling agent. It is important that the correct concentration of the water treatment product is maintained in accordance with the manufacturers’ instructions. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS 7593:1992 details the steps necessary to clean domestic central heating system. Also check pipework and renew any corroded pipework or fittings. Valve glands must be repacked or replaced wherever necessary and any defective controls exchanged. 4.8.9 WATER TREATMENT This boiler has a secondary ALUMINIUM alloy heat exchanger Ravenheat recommended only the use of FERNOX- COPAL or SENTINEL X100 water treatment products, which must be used in accordance with the manufacturers instructions. For further information contact: Fernox Manufacturing Co. Ltd. Tel 01799 550811 Sentinel Division Betz Dearborn Ltd. Tel. (0151) 424 5351 SALAMANDER CURROSION GUARD Salamander (Eng) Ltd Tel: (0121) 3780952 /4508 4.8.10 Hard water areas. If the area of installation is recognized as hard water, it is recommended that a suitable water treatment device is installed in the mains. The water hardness can be determined by using the standard test paper or by referring to local water authority. 4.9 DOMESTIC WATER 4.9.1 The domestic hot water must be in accordance with the relevant recommendations of BS 5546. Copper tubing to BS 2871 1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water. 4.10 ELECTRICAL SUPPLY Warning: this appliance must be earthed 4.10.1 External wiring to the appliance must be carried out by a qualified person and be in accordance with the current I.E.E. Regulations and local regulations which apply. The Ravenheat boiler is supplied for connection to a 230 V ~ 50 Hz single phase supply. The supply must be fused at 3 A. NOTE. The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance, by the use of a fused, double pole isolator, having a contact separation of at least 3 mm in all poles. The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except, where the appliance is installed in a bathroom, this MUST be sited outside the bathroom. SECTION 5 INSTALLATION 5.1 WARNING 5.1.1 It is MOST IMPORTANT that this appliance is installed in a VERTICAL POSITION, with the flue air duct passing through the wall. Make sure flue slopes 2.5° down towards the boiler that is 45 mm/m fall per metre of flue length (Fig. 23). Fig. 9 15 5.2 DELIVERY 5.2.1 The appliance carton containing (fig 9): Horizontal CSI flue kit (sold separate) Fig. 10. a) boiler fully assembled b) installation instructions and user instructions c) white paper template. 57 - Flue bend assembly 59 - Rubber seal Ø 60 60 - Air intake duct 61 - Flue exhaust duct 62 - Terminal 65 - Pipe centering spring 66 - Flue gas sample point 127 - Terminal Rubber. Polythene bag containing a) 2-22 mm compression ball valve complete with 3/4” washers. b) 1-15 mm compression ball valve complete with 1/2” washers. c) 1-15 mm compression ball valve. d) 2 coach bolts and wall plugs. e) screws and dowels WARNING Maximum allowable flue length 2.5 m horizontal maximum No 2x1000 mm. Flue duct extension used with standard flue. Fig. 10 OPTIONAL EXTRAS: Small carton containing (fig. 11): 57 - Straight header supplied as an extra cost only when requested 59 - Rubber seal Ø 60 66 - Flue gas sample point FLUE EXTENSION BOX CONTAINING (fig. 12): 1000 mm flue extension duct as an extra cost only when requested for side and vertical flue applications 59 - Rubber seal Ø 60 63 - Air intake duct extension 64 - Flue exhaust duct extension 65 - Pipe centering spring 16 Fig. 11 Fig. 12 5.3 UNPACKING. 5.3.1 Open the top of the carton (fig. 9). 5.3.2 Rest the carton on the floor ( keeping the flaps open). 5.3.3 Turn the carton over, with the boiler inside and then pull the carton. 5.3.4 Rest the boiler on the floor and remove the polystyrene guards (fig. 13). Fig. 13 5.4 POSITIONING OF THE BOILER. 5.4.1 Remove the 2 screws that secure the upper bottom part of the casing. 5.4.2 Unscrew the 4 screws that fasten the lower grating on the casing and remove it from the sides of the casing (Fig. 14). 5.4.3 Carefully slide the casing forward to lift off (fig. 15). Fig. 14 Fig. 15 5.5 INSTALLING THE APPLIANCE FOR REAR FLUE OUTLET Use the adhesive tape to attach the template to the wall, making sure that the centre line is vertical. - Mark the two holes to fix the hanging bracket onto the wall as well as the centre of the flue duct. - Detach the template from the wall. - Use a 10 mm. dia drill to make the 2 holes. Insert the plastic expansion plugs. - Cut or core drill a 105 mm. dia hole for inserting the flue duct. - Locate the wall hanging bracket and fix with the two coach bolts. Fit the elbow header, positioning it towards the required direction (Fig 16). IMPORTANT: Make sure that the elbow’s dia. 60 mm duct is inserted into the fan, the rubber seal and orifice plate have been correctly fitted. Fig. 16 17 5.5.2 Locate the rubber Ø 60 into the flue elbow header (fig 17). 5.5.3 If the standard flue is too long (the wall to go through is less than 680 mm thick) it can be shortened as follows: - Cut the inner flue duct (60 mm) at right angles to a length equal to W + 264 mm. Insert from cut and reassemble the two tubes. Insert centering spring 65 (must be deburred). - Reassemble together inner and outer flue duct - Remove the centering spring 65, the flue terminal to disengage inner flue duct - Measure the thickness W of the wall. - Cut the outer flue duct at right angles to a length equal to W + 152 mm Must be de-burred. Orifice plate CSI 79 concentric flue system. Fig. 17 Fig. 18 INTAKE AND EXHAUST TERMINAL COMPONENTS. Fig. 19 Fig. 20 KEY 56 - Straight header 57 - Elbow header 58 - Header gasket 59 - Rubber seal Ø 60 18 60 - STD air intake duct 61 - STD flue exhaust duct 62 - Terminal 63 - Air intake duct extension 64 - Flue exhaust duct extension 65 - Pipe centering spring 66 - Sample point 127 - Terminal rubber 5.5.4 Insert the flue assembly into the wall, being careful to make sure that the outer air duct comes flush to the inner surface of the wall. 5.5.5 Lift the boiler on to the wall, locating onto the fixing jig wall bracket. 5.5.6 Working above the boiler pull the flue exhaust duct towards the boiler in order to engage tube 61 into its header 57 (Fig. 19-20). Position flue into elbow header and push to locate inner and outer flue correctly ensuring a good seal is made with or rubber seal. 5.5.7 Fit terminal cover plate (fig. 22). 5.5.8 Extensions kits are available to order for flue extension of up to 2.5 metres total length. Fig. 21 Fig. 22 19 5.5.9 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of two extensions. The pipe length can be established using the instructions in section 5.5 for rear flue outlets and section 5.7 for side flue outlets. Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal. Extensions must be joined together with the standard terminal pipe, and inserted in each other as far as they can go. If an extension must be shortened, this must be done from the straight end, and not from the widened or tapered end. To measure the pipe properly all components must be assembled and total length measured before cutting. The straight end of the extension connects to the boiler. The flue output pipe fits into the boiler header until it stops. The air intake pipe should be located approximately 2 mm. from the boiler header (fig. 19). When cutting both inner and outer ducts of the extension, always ensure that the reduced end (male) of the inner duct is longer than the outer duct. All joints must be sealed with the rubber seals supplied. It is important to put the centering spacer, supplied with the unit, inside between the two pipes, from the side opposite the extension’s straight end. 5.7 INSTALLING THE APPLIANCE FOR SIDE FLUE OUTLET (Fig. 20). 5.7.1 - Attach the template to the wall with adhesive tape, making sure that the centre line is vertical and that the distance from the centre line to the nearest side wall is not less than measurement in Fig. 25. - Mark the two fixing bracket securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it is horizontal. - Make sure flue slopes 2.5° down towards the boiler that is 45 mm/m fall per metre of the flue length. Fig. 23 - Trace the centre of the flue duct hole measure distance (275 mm) from the corner of the wall and measure the distance (200 mm) to the centre of flue duct hole to the corner. Detach the template from wall. - Use a dia. 10 mm. drill to make the 2 holes for securing hanging bracket fixing. Insert the plastic expansion plugs. Core drill a 105 mm dia. hole in the side wall for inserting the flue duct. NOTE: a suitable support bracket is available from Ravenheat Manufacturing and should be used to support flue length at least every 1.8 metre preferably at each joint this bracket should be secured to wall and flue duct. 5.5.10 IN FLUE BEND Measure the distance between the flue bends or the flue/terminal assembly. The measurements should be taken from the outer edge of the flue and bend (fig. 26). IMPORTANT: inline flue bend - 1680 mm must be deducted from overall length for each 90°bend. Obtuse flue bend - 1680 mm must be deducted from overall length for each 135° bend (fig. 26). Fig. 25 5.6 COMPLETING BOILER INSTALLATION 5.6.1 Reassemble the outer casing proceeding in this order 1) Refit the instrument panel. 2) Fit the casing. 3) Refit the lower grating. 20 (sect 5.4) 5.7.2 Positioning the elbow towards the required direction (fig. 17). 5.7.3 Locate the Ø 60 into the elbow (fig. 17). 5.7.4 If the standard flue is too long (if the position of the boiler from the wall to go through as illustrated in the drawing and the wall thicknesses is less than specified above) it can be shortened as follows: fig.18. Fig. 26 KEY 59 - Rubber seal diam. 60 63 - Air intake duct extension - Remove the centering spring 65, pull the flue terminal, disengage inner flue duct. - Measure the thickness W of the wall. - Cut the outer air duct (100 mm. dia.) at right angles and to a length equal to W+Y - 47 mm. (fig. 18). - Cut the inner flue duct (60 mm dia.) at right angles and to a length equal to W+Y + 65 mm. - Outer air duct and inner flue duct must be de-burred. - Reassemble the two tubes. Insert centering spring 65. 5.7.5 64 - Flue exhaust extension 65 - Pipe centering spring 128 - In line bend 5.7.6 Lift the boiler on to the wall. Locate onto the top coach bolts. Fit the lower coach bolts and tighten all four securing bolts. 5.7.7 Working above the boiler pull the flue duct towards the elbow in order to engage tube into its header (Fig. 21). Position flue into straight header and push to locate inner and outer flue correctly. Ensuring good seal is made with o.rings. 5.7.8 Extension kits are available to order for flue extension of up to 2.5 metres total length (Fig. 19). For further details see sect 5.5.9. Insert the flue assembly into the wall, making sure it will not interfere when fixing the boiler on the wall. VERTICAL FLUE INSTRUCTIONS ONLY L + L = 3.25 m MAX Fig. 27 21 5.7.9 VERTICAL FLUE INSTRUCTION ONLY. IN LINE FLUE BEND - 1680 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90° BEND OBTUSE FLUE BEND - 1680 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135° BEND The vertical flue kit is intended for use where a horizontal flue outlet is not possible or desired The vertical flue can be used either with a flat roof or a pitched roof (maximum pitch 60°) Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 135°/90° flue bend (Fig. 27 - 28). Fig. 28 Use adhesive tape to attach the template to the wall, making sure that the centre line is vertical and that the flue centre line is vertically below the point at which the flue will exit the roof. Fig. 29 - Ensure that the maximum permissible flue length is not exceeded (fig. 29). - Mark the four boiler fastening holes on the wall. - Detach the template from the wall. MIN. DISTANCE mm - Use a 10 mm dia. drill to make the 4 boiler securing holes. Insert plastic expansion plugs (fig. 16). N above roof level (to base of terminal) 300 P from adjacent wall to flue 300 Q from internal corner to flue 300 S from facing terminal 1,200 M horizontally from a vertical terminal to a wall 300 - Screw in the two upper coach bolts leaving them about 10 mm out from the wall to enable the boiler to be located on the wall. POSITION Before proceeding with installation check the contents of the RAVENHEAT VERTICAL FLUE KIT, comprising of the following pieces: - 1 RAVENHEAT VERTICAL FLUE complete with terminal assembly (for vertical flue application). - Additional 1000 mm (approx) Flue Extension pieces as necessary, each extension is provided with flue centering bracket. - One box containing straight header with inlet and outlet sealing rings. Proceed with installation as detailed in section 5, of the main Installation and Servicing Instruction, ignoring all references to horizontal flue installations. 22 - Position the straight header on the top of the appliance (fig. 31) item 6, and ensure that the gasket is correctly fitted. Important: Make sure that the flue header dia 60 mm duct is inserted fully into the fan spigot. Starting at the appliance end, assemble the extension duct sections, making each inner and outer (flue) joint by inserting the spigot end into the socket end of the next tube, making sure the seal rings are correctly located (Fig. 30). Make sure that the entire flue is adequately supported. Use at least one bracket for each extension used. Ensure that all inner flue connections have a good fit/seal, and that the space clips in each extension are correctly positioned. Fig. 30 23467- 5.8 REASSEMBLE BOILER AS PER (sect. 5.6). 5.8.1 Fitting valve pack Remove plastic caps from boiler connection and fit valves as per fig. 32 using washers provided. 5.9 GAS CONNECTION (fig. 32). 5.9.1 A minimum working gas pressure of 20 mbar (8 in w.g.) must be available at the boiler inlet at full flow rate (37 mbar for propane, 29 mbar for butane). 5.9.2 Fit gas service cock to the boiler via the union nut and connect gas pipe. Do not overtighten and use another spanner as a counter force to avoid straining internal connections. Important consult (sect 4.5.1). 5.10 CENTRAL HEATING CONNECTION (fig. 32). Fig. 31 Cut a 105 mm diameter hole through the ceiling and/or roof, at the point previously marked. Fit a roof flashing sleeve (fig. 31 item 7) to the roof, available from Ravenheat Manufacturing. Insert the Vertical Flue terminal assembly through the flashing plate from the outside. Fix the appliance to the wall, locating onto the hanging bracket. Measure the vertical distance between the top of the flue (Fig. 29) and the bottom of the flue terminal assembly (Fig. 28). The measurements should be taken from the outer diameter of the flue. NOTE: Where this length does not match any standard combination of the extensions, they can be cut to the required length (Fig. 30). When cutting both inner and outer ducts of the extension, always cut on spigot side, and they must be de-burred. Elbow bend Elbow bend Flue extension Straight header Roof flashing 5.10.1 Before any central heating connections are made to the boiler all system valves should be opened and the system thoroughly flushed out with cold water. - Connect the central heating return pipe to the isolating cock. - Connect the central heating flow pipe to the isolating cock marked CHF. - Pipe dimensions and positions are marked on template supplied. 5.11 DOMESTIC HOT WATER (fig. 32) 5.11.1 The domestic hot water circuit does not need a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar. If in doubt it is advisable to install a pressure reducing valve. The minimum pressure needed to operate the domestic hot water system is 0.5 bar with a flow of approx 3 Its per min. - Connect the 15 mm. cold water pipe to the stop cock to the appliance inlet. - Connect the 15 mm. hot water pipe with a suitable connection. 23 5.12 SAFETY VALVE DISCHARGE AND CONDENSATE DRAIN CONNECTION. 5.12.1 The safety valve is located on the flow manifold, and discharge pipe is located between DHW cold inlet and DHW hot outlet. The discharge should terminate facing downward exterior to the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, in a easily visible position, not to cause damage to electrical components or wiring. The discharge must not be over an entrance or a window or any other type of access. 5.12.2 The condensate drain connection is on the left of Gas service cock (Fig.32). A 25 mm plastic overflow pipe is fitted on the condensing trap and should be used to fit on the drain connection, if required, to discharge condensate to a drain. The drain pipe should have a fall of a least 2.5° away from the boiler. Condensate should, if possible be discharged into the household internal drainage system. If this is not practicable, discharge can be allowed into the external household drains or a purpose designed soak away. It is recommended that any external condensate drain pipe is insulated and also preferably of 32 mm diameter, to prevent freezing in adverse weather conditions. The condensate is discharged periodically in “ slugs” by siphonic action. It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a 125mm high trap inside the boiler. Fitting an extra trap may cause the boiler siphon to work incorrectly. Refer to BS5546 or BS6798 for advice on disposal of boiler condensate. Fig. 32 5.13 ELECTRICAL CONNECTIONS 5.13.1 IMPORTANT: Electricity supply must be as specified in clause (sect. 4.10) - When controls external to the appliance are required, design of the external electrical circuits should be undertaken by a competent person. In accordance with the IEE wiring regulations. It is essential that all external controls must be volt free. Factory fitted internal wiring must not be disturbed when wiring external controls. - To gain access to the electrical box remove the front panel of the case as described in clauses (sect. 5.4). - The terminals are easily visible on the side of the control electronic box (fig. 59). - Heat resistant flexible cable is fitted between the isolator and the terminal block A 3 core cable of 0.75 mm 2 (24x0,2 mm) to BS 6500. Make sure all wires to the appliance are routed away from sharp edges and hot surfaces. The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carrying conductors becomes taut before the earthing conductor. Securely tighten all terminal screws and arrange the cable with slack between the cord anchorage and the terminal block. WARNING: If the supply cord is damaged, it must be replaced by a service engineer (supply cord available from Ravenheat Manufacturing Ltd). Fig. 33 24 5.14 PROGRAMMABLE TIMECLOCK Instructions for use User’s Guide. SECTION 6 COMMISSIONING 6.1 Each boiler has been through a rigorous operational procedure at our factory and should not require any further adjustment If in the unlikely event of the appliance not operating correctly, please turn to the Fault Finding and Logic Sequence Charts. 6.2 GAS SUPPLY INSTALLATION 6.2.1 Inspect the entire installation including the gas meter, test for soundness and purge, all as described in BS 6891. 6.3 ELECTRICAL INSTALLATION Preliminary electrical systems checks to ensure electrical safety shall be carried out by a competent person (earth continuity, polarity, resistance to earth). Those checks are outlined in the «Instructions for British Gas Multimeter» Booklet. If a fault has occurred on the appliance the fault finding procedure should be followed as specified under the servicing section of this document. 6.4 INITIAL FILLING OF THE SYSTEM Open central heating flow and return valves Unscrew the cap on automatic air release valve one full turn (leave open permanently). - Close all air release taps on the central heating system. - Gradually open stopcock at the filling point connection to the central heating system until water is heard to flow. - Starting with the lowest radiator open each air release tap in turn. Close it only when clear and free of bubbles, flowing out in the water is the same way release air from any high points in the pipework. - Continue filling the system until 1.5 bar register on gauge. Then turn off the filling points stopcock. - Inspect the system for water soundness and remedy any leaks discovered. 6.5 SETTING THE SYSTEM DESIGN PRESSURE The design pressure must be a min. 1 bar and max. 1.5 bar. These figures are read off the pressure gauge. - The actual reading should ideally be 1 bar + the height in metres to the highest point of the system above the base of the appliance (up to max of 1,5 bar). N.B.: The safety valve is set to lift a 3 bar. - To lower the system pressure to the required value remove drain point (fig. 45) or drain on the heating circuit. 6.6 FILLING THE HOT WATER SYSTEM Close all hot water draw-off taps. Open the cold water inlet cock. Slowly open each draw-off tap until clear water is discharged. 6.7 LIGHTING THE BOILER Before lighting the main burner make sure that the heating circuit flow and return valves are open and also that the cold water input cock is open. - If external controls are installed (e.g timeclock and thermostat) make sure that they call for heat. - Turn main switch (fig. 35 item 1A) to winter. Fig. 34 25 INSTRUMENT PANEL Fig. 35 GAS VALVE KEY 77 - Upstream pressure inlet 81 - Downstream pressure outlet 104 - Gas valve modulator 110 - Max. regulator nut 111 - Min. regulator nut 114 - Electrical connections modulator 115 - Electrical connections Fig. 36 26 - Turn control thermostat 4 up to its maximum setting. - Now the main burner should turn on. With leak detection fluid test for gas soundness of all gas components and joints. - See paragraph 6.13 for regulating the heating circuit thermostat. Check gas mains pressure (fig. 37). Fit a gas pressure gauge on pressure inlet 77 (fig. 36) on the gas valve, after releasing the seal screw. Check the gas mains pressure with the boiler operating. Check with the Local Gas supplier if the pressure differs significantly from 20 mbar (natural gas), 37 mbar (G 31) and 29 mbar (G 30). 6.8 CHECK THE GAS PRESSURE AT THE BURNER Now check if the maximum gas pressure at the burner is equal to 10.5 ± 0.5 mbar (4.2 ± 0.2 in w.g.) for CSI 85 - CSI 85T. – LPG check gas pressure inlet (37 mbar propane - 29 mbar butane). To do this proceed as follows: - Turn off main switch 1 (fig. 35) - Set main switch 1 on - Set control thermostat 5 at it maximum setting. - Fit a pressure gauge, using a hose, to pressure test point 81 (fig. 36), after first loosening its close-off screw. - Open one or more hot water taps so that at least 10-12 litre of water flows per minute. - The pressure indicated on the pressure gauge is the maximum operating gas pressure. - Check that the minimum pressure corresponds to 2 mbar (0.8 in w.g.) for G 20 as is set at the factory. - LPG 7.3 mbar for G 31 and 7.0 mbar for G 30. This is set and sealed at the factory and cannot be adjusted. Detach one of the wires going to modulator 104 (Fig. 51) and make the boiler operate as done for checking the maximum pressure. 6.9 ADJUSTING MINIMUM AND MAXIMUM PRESSURE (fig. 36) SIT-HONEYWELL-DUNGS GAS VALVE - Remove cap covering modulator to gas valve. - Detach one of the cables connected to the modulator 114. - With the boiler operating use a screw driver (HONEYWELL 9 mm spanner) to turn the nut 111 clockwise to increase pressure and anti-clockwise to decrease pressure. NOTE: LPG ONLY The minimum pressure is factory set and sealed, and cannot be adjusted. 6.10 RECONNECT THE DETACHED CABLE Use a screw-driver to hold nut 111 (HONEYWELL 9 mm spanner) and use a 10 mm spanner (HONEYWELL 7 mm spanner) wrench to rotate the nut 110 clockwise to increase the pressure and counter-clockwise to decrease it. After adjustment turnoff D.H.W. Taps. 6.11 SETTING CENTRAL HEATING GAS PRESSURE THE BOILER COMES SET AT MID POSITION RATING FOR USE ON C.H. (table1) When the boiler operates in the C.H. mode the gas pressure at the burner can be set between the min and max values. This permits capacity to be adjusted to suit system demand. If adjustment is required proceed as follows: - Remove the front panel and the panel instrument as described (sect. 5.4). - Unscrew the two screws holding the control box cover and lift off. - Select summer/winter switch in winter position (Fig. 35). - Turn CH control knob to maximum setting (fig. 35 item 4). - Check all external controls are on and calling for heat, ensure all D.H W. taps are off. - With boiler operating use a screwdriver to turn potentiometer (fig. 34) clockwise to increase pressure and anti-clockwise to decrease pressure. - To obtain the desired heat value establish pressure as per (fig. 37). - Replace the protective cover. - Once this pressure is established, mark it up on data badge with, adhesive red label/arrow burner pressure setting so that this can be referred to and checked during future servicing. 27 6.12 CHECKING THE FLUE SYSTEM 6.12.1 The flue system should be visually checked for soundness check all connections and fixings are secure and tight. Fig. 37 6.13 CHECKING THE HEATING THERMOSTAT 6.13.1 Allow the system to warm up and then turn the C.H thermostat to ensure the main burner modulates from “high” to “low” and “low” to “off” and vice versa (scale range covers approx 45° C - 85° C). 6.14 TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW 6.14.1 Put the appliance in operation with the (summer/winter) switch in summer position (Fig. 35). - Open a domestic hot water tap (preferably the bath tap). Ensure cold water inlet stopcock is open and the D.H.W. control knob is set at maximum (Fig. 35 item 5). - If the burner does not light check that the water flow rate is above the min. required to operate at 2.8 l/min. The temperature of the water will depend on the rate at which it flows. If, due to high water pressure, the flow rate is too high (and thus the temperature too low for practical use) the flow rate may be adjusted. It is better to set for the lowest acceptable temperature, preferably at the bath tap since the user can gain higher temperatures at other restricted flow taps (table 1 pag. 8). N.B.: If the cold supply is subject to large fluctuations or is above the permitted max water pressure, a suitable pressure/flow regulator should be fitted in the cold water supply to the appliance. - Select summer/winter switch on summer position (Fig. 35). Slowly close the draw off tap to reduce the flow rate to above the min (approx. 2.8 l/min). - Rotate the D.H.W. control knob to ensure it operates at its various setting (Fig. 35). - Close the draw-off tap still further. The burner should stop when the rate falls below about 2.8 l/min. Fig. 38 Once the process of commissioning the boiler is complete, the commissioning engineer MUST complete his section in the Benchmark log book. 28 Fig. 39 KEY 2 - Plenum chamber cover 6 - Combustion chamber 7 - Flue restriction ring 8 - Flue gas exhaust hood 15 - Connection pipe 18 - Heat exchanger 24 - Burner 27 - Auto air vent valve 28 - Pressure switch 29 - Seal 31 - Seal 42 - Sight glass 44 - Fan 46 - Header gasket 50 - Flue gas exhaust hood cover 53 - Connection tube 54 - Connection tube 58 - Ceramic insulation 61 - Condensing heat exchanger 80 - Plenum chamber 83 - Burner centering pin 84 - Seal 29 6.15 HANDING OVER TO THE USER 6.15.1 After completion of installation and commissioning of the system, the installer should hand over to the Householder by taking the following actions: - Hand the “User’s Instructions” to the Householder and explain His/Her responsibilities under the “Gas Safety Regulations 2000”. - Explain and demonstrate the lighting and shutting down procedures. - The operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder. This then ensures the greatest possible fuel economy consistent with household requirements of both heating and hot water consumptions. Advise the User of the precautions necessary to prevent damage to the system, and to the building, in the event of the system remaining inoperative during frost conditions. - Explain the function and the use of the summer/Winter and mains switch (Fig. 35). - Explain and demonstrate the function of time and temperature controls, neon lights radiator valves etc for the economic use of the system. - If an optional time clock is fitted, then draw attention to the time clock User’s Instructions and hand them to the Householder. - Stress the importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR. - Fill in the Benchmark log book and leave completed with the customer. SECTION 7 Data badge position-lower left hand side of casing. - The following notes apply to the appliance and its controls but it should be remembered that attention must also be paid to the heating and hot water circuits with special attention to radiator valves, thermostats, clocks, leaking hot water taps etc. - Where it is necessary to replace a gasket that relies on adhesive for securing - this adhesive will be supplied with the gasket as a spare item. - In all cases prior to servicing, remove the outer case (sect. 5.4). Operate the appliance by turning the hot water services on to a high water flow, and observe the main burner. - Check that the flame covers all the flame ports and is of a light blue colour. Yellow flames and excessive lifting of flames indicate poor combustion. - IMPORTANT: After completing any servicing or replacement of gas carrying components it is essential that a test for gas soundness is always carried out along with functional checks in operation. 7.2 TO INSPECT AND CLEAN THE APPLIANCE 7.2.1 Before carrying out cleaning operation, cover the electrical control panel with a piece of waterproof material to protect it from debris. 7.2.2 Inspect the heat exchanger for any blockage. Deposits of any material should be brushed away using a soft brush. SERVICING INSTRUCTIONS Ravenheat are a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage in the regular servicing of all central heating systems to ensure safety and efficiency. 7.1 SERVICING 7.1.1 To ensure continued efficient operation of the appliance it is necessary to carry out servicing and cleaning at regular intervals. The frequency of cleaning will depend upon the particular installation conditions and usage but in general, once gear should be adequate. 30 WARNING Before the start of any servicing or replacement of components always isolate electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock. NOTE: Do not use brushes with metallic bristles. 7.2.3 Examine internal pipe-work connections and automatic air vent for any water leaks. Rectify if necessary. 7.2.4 Examine the combustion chamber insulating material and renew if damaged (fig. 39). 7.2.5 Remove and examine the burner injector clean or renew, as necessary (fig. 35). 7.2.6 Inspect the burner and remove any deposit with a soft brush Check the electrodes for damage or deterioration, clean or renew as necessary. Ensure that the spark gaps are correct to dimensions specified in fig. 38. 7.2.7 7.2.8 7.2.9 Inspect the secondary condensate heat exchanger. Deposits can be cleared by removing and flushing out the exchanger. Inspect the siphonic condensate trap for a blockage. Any deposits should be flushed out (fig. 55). exchanger then from the appliance. Place in a safe place until required Reassemble in reverse order. Ensure wires are connected correctly. 7.6 To remove condensate trap (sect. 5.4). Pull forward the trap (fig. 55). Unscrew the earth wire, and the sensor. Replace in reverse order. TO REMOVE/REPLACE CONDENSING HEAT EXCHANGER (fig. 41). Remove front casing (sect. 7.3). Remove combustion chamber front cover as in (sect 7.4). Examine the fan for any mechanical damage, check to ensure free running of the fan wheel. Clean the wheel if necessary with a soft brush. Check sealing gasket and renew if damaged. 7.6.2 Close the ON/OFF valves for the heating. Drain the heating system from the drain point mounted system (fig. 45). 7.6.3 Remove the fan. 7.2.10 Examine flue duct and flue hood and ensure that there is no obstruction. Examine the gasket at the entry into the flue duct. 7.6.4 Disconnect 4 unions for the heating water pipelines (fig. 41) and remove the two short pipes. 7.2.11 It is essential that a good seal is made at the outlet to the fan, renew this gasket if there is any sign of damage or deterioration. 7.6.5 Remove screw holding the heat exchanger to chamber. Disconnect condensing discharge pipe by pulling off the pushfit connector at top rear of boiler (fig. 41). 7.3 TO REMOVE/REPLACE THE CASING. 7.6.6 7.3.1 Remove the 2 screws that secure the upper part and the 4 screws that fasten the lower grating on the casing. Carefully slide the casing forward to lift off. Pull the heat exchanger down and slightly forward until it comes out of the connection from chamber. 7.6.7 Replace in reverse order. Taking care to refit discharge pipe at rear. 7.4 TO REMOVE/REPLACE THE COMBUSTION CHAMBER COVER 7.4.1 Remove the front casing panel (sect. 7.3). 7.4.2 Unscrew all the screws that fasten the cover to the chamber body and put them into a container so that they don’t get lost. 7.4.3 Detach the cover, being careful not to damage the seal. 7.4.4 Reassemble in reverse order. Ensure good seal of cover when replacing. 7.5 TO REMOVE/REPLACE THE FAN ASSEMBLY. 7.5.1 Remove front casing (sect. 7.3). Remove combustion chamber front cover (sect. 7.4). 7.5.2 Disconnect the electrical connections from the fan motor. 7.5.3 Support the fan and remove the two fixing screws and bracket from the front of the flue hood. Carefully withdraw from condensing heat. IMPORTANT: When replacing exchanger new seals must be used. heat Fig. 40 31 7.7 TO REMOVE/REPLACE HOOD. THE FLUE 7.7.1 Remove front casing (sect. 7.3). Remove combustion chamber front cover as in (sect. 7.4). 7.7.2 Remove the fan (sect. 7.5). 7.7.3 Remove condensing heat exchanger (sect. 7.6). 7.7.4 Remove the three screws on the front that fasten the hood to the combustion chamber. 7.7.5 Remove the two screws at the rear of hood. 7.7.6 Replace in reverse order 7.8 TO REMOVE THE HEAT EXCHANGER (fIG. 47-48). 7.8.2 Remove the two sides of the casing by slightly lifting them and sliding them towards the top of the appliance, to release them from their upper suspension hooks. 7.8.3 Remove the fan (sect. 7.5). 7.8.4 Remove condensing heat exchanger. 7.9 TO REMOVE/REPLACE COMBUSTION CHAMBER INSULATION PANELS. 7.9.1 Remove casing front panel (sect. 7.3). Remove combustion chamber front cover (sect. 7.4). 7.9.2 Remove fan (sect. 7.5). 7.9.3 Remove condensing heat exchanger (sect. 7.6). 7.9.4 Remove the flue hood (sect. 7.7). 7.9.5 Remove main burner (fig. 51). Remove top insulation pieces at sides. Remove 2 screws securing combustion chamber to rear of boiler. Lower chamber carefully remove all insulation panels. 7.9.6 Replace in reverse order. 7.10 TO REPLACE THE ELECTRODE (fig.49). 7.10.1 Remove front casing (sect 7.3). Remove combustion chamber from cover (sect 7.4). 7.10.2 Detach the wire from electrode and then unscrew the nut that secures it to the pilot burner assembly and remove. 7.10.3 Replace with new electrode in reverse order. Fig. 41 7.8.5 Remove the flue hood (sect. 7.6). 7.8.6 Remove the automatic air vent (Fig. 92). 7.8.7 Disconnect unions for two heating (right side of boiler) water pipelines. 7.8.8 Unscrew the rings that fasten the heat exchanger to the combustion chamber. 7.8.9 Remove the two side insulation panels at top of heat exchanger. 7.8.10 Pull the heat exchanger up until its flow connections come out from the combustion chamber and then remove it (fig. 48). 7.8.11 Replace in reverse order. Ensure correct wire position. IMPORTANT: When replacing a exchanger new seals must be used. 32 heat Fig. 42 Fig. 43 Fig. 45 Fig. 44 33 7.11 7.11.1 7.11.2 7.11.4 TO REMOVE/REPLACE THE INJECTORS ( fig. 50). Remove the front casing and the depression chamber front cover (sect.7.3 - 7.4). 7.14.4 Replace in reverse order. Unscrew the union and the 4 screws securing the manifold at the burner. 7.15 Pull the manifold up and out from the combustion chamber. 7.15.1 Remove front casing (sect. 7.3). 7.15.2 Remove the wires that connect the sensors. 7.15.3 For C.H. thermistor remove the retaining clip from the pipe. Replace in reverse order. 7.15.4 For D.H.W. sensor close the on/off valves for the domestic inlet water circuit and open domestic hot water tap. Unscrew the sensor and replace in reverse order with new seal (fig. 46). 7.11.5 Unscrew and replace the injectors and their seals. 7.11.6 Replace in reverse order. 7.11.7 Relocate the grommet, sealing the gas supply pipe to the casing taking care not to damage it. Replace if necessary. 7.12 7.14.3 Remove the switch out from the instrument panel by pressing the clamp springs. TO REMOVE/REPLACE THE BURNER TO REMOVE/REPLACE THE HEATING AND/ OR HOT WATER CONTROL SENSOR. 7.12.1 Remove front casing (sect.7.3) and the combustion chamber front cover (sect.7.4). 7.16 7.12.2 Remove the injectors manifold as described in sect. 7.11. TO REMOVE/REPLACE THE OVERHEAT THERMOSTAT. 7.16.1 Remove front casing (sect. 7.3). 7.12.3 Remove the two screws securing the main burner to the combustion chamber (Fig 74). 7.16.2 Remove the two wires that connect to the overheat thermostat. 7.12.4 Pull the burner forward and remove (fig. 49). 7.12.5 Replace in reverse order. IMPORTANT: When refitting the burner make sure that the pins at the rear of the combustion chamber locate into the slots made on the rear of the burner. 7.13 7.16.3 Remove the two screws securing the thermostat to the pipe and pull it out. 7.16.4 Replace in reverse order (Fig.46). TO REMOVE/REPLACE THE GAS VALVE (fig. 36). 7.13.1 Remove front casing (sect.7.3) and the combustion chamber front cover (sect.7.4). 7.13.2 Unscrew the union. 7.13.3 Remove the 2 screws to the gas pipeline. 7.13.4 Remove the eight screws (four per side) that connect the gas valve to the gas pipelines and then remove it from its seat. 7.13.5 Replace in reverse order, always using new seals. 7.14 TO REMOVE/REPLACE THE MAIN SWITCH (fig. 35). 7.14.1 Remove front casing (sect. 7.3) and remove the panel instrument. Fig. 46 7.14.2 Detach the wires that connect to the switch. 34 Fig. 47 Fig. 48 Fig. 49 Fig. 50 Fig. 51 35 7.17 TO REMOVE/REPLACE THE DIFFERENTIAL PRESSURE SWITCH (fig. 52). 7.17.1 Remove front casing (sect. 7.3). 7.17.2 Detach the wire connector plug from the pressure switch, make sure that the wire connector plug are later reconnected. 7.17.3 Unscrew the two screws that fasten the pressure switch to the back of the combustion chamber. 7.19 TO REMOVE/REPLACE THE ELECTRIC CONTROL AND IGNITION BOARD. 7.19.1 Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel . 7.19.2 Unscrew the 2 screws holding the control box box cover and remove. Disconnect mains cables and any other connections (room thermostat). 7.19.3 Detach the connectors from the board. 7.17.4 Remove the two silicone tubes. 7.17.5 Ensure tubes are connected correctly (Fig. 52) avoiding kinks. 7.19.4 Replace in reverse order (ensure all electrical connections are made correctly). 7.17.6 Replace in reverse order ensuring that the “–” tapping is connected to the tube terminating inside the case and the “+” tapping is connected to the tube terminating at the flue ring. Fig. 53 Fig. 52 7.18 TO REMOVE/REPLACE THE WATER PRESSURE GAUGE (Fig. 54). 7.18.1 Remove front casing (sect 7.3). 7.18.2 Close the on/off valves for the heating circuit and drain the water at the drain point (fig. 45). 7.18.3 Unscrew the fitting that secures the pressure gauge probe. 7.18.4 Remove the pressure gauge from the instrument panel by pressing its fastening springs. 7.18.5 Replace in reverse order. New seal must be used. Fig. 54 36 7.22.7 Unscrew the nuts that fasten the pump to the ch pipe and diverter valve pump manifold. Remove the pump. Remove the casing (sect 7.3) and lower the instrument panel . 7.22.8 Remove the securing clip and pull out the plastic pipe that connect the condensing trap at the heat exchanger. Replace in reverse order. NOTE : Alway use new seals when re-fitting the new pump. 7.23 TO REMOVE/REPLACE C.H. DIVERTER VALVE (fig. 57). Unscrew the nut that fasten the condensing trap to the backframe and remove it. 7.23.1 Remove front and bottom of the casing (sect 7.3). Replace in reverse order. 7.23.2 Close the on/off valves for the CH and DHW circuit and drain the water at drain point (fig. 45) and open the domestic hot water tap. 7.23.3 Remove diverter valve switch. 7.23.4 Unscrew the C.H.diverter valve from the backframe. 7.23.5 Replace in reverse order. NOTE: Always use new o-rings. 7.23.6 Fill the boiler as described in sect.6.4 and check for leaks. 7.20 TO REMOVE/REPLACE CONDENSING TRAP (fig.55). 7.20.1 7.20.2 7.20.3 7.20.4 7.21 TO REMOVE/REPLACE DIVERTER VALVE SWITCH . 7.21.1 Remove front casing (sect 7.3). 7.21.2 Detach the electrical plug and remove the retaining clip (Fig.57). 7.21.3 7.22 Replace in reverse order. TO REMOVE/REPLACE PUMP (fig. 56). 7.22.1 Remove front casing (sect 8.1). Fig. 56 Fig. 55 Fig. 57 37 7.24.1 TO REMOVE/REPLACE DHW DIVERTER VALVE (fig. 57). 126.96.36.199 Remove front and bottom of the casing (sect 7.3). 7.24.2 Close the on/off valve for the DHW circuit and drain the boiler. 7.24.3 Remove the flow detector. 7.24.4 Unscrew the DHW diverter valve. 7.24.5 Replace in reverse order. NOTE: Always use new o-rings. 7.25 7.25.12 Remove the expansion vessel. 7.25.13 Replace all the components in reverse order using new seals. 7.25.14 Fill the system as described in the sect. 6 and check for leaks. TO REMOVE/REPLACE THE CENTRAL HEATING EXPANSION VESSEL (fig. 58). In the unlikely event of failure of the central heating expansion vessel it is recommended a suitable expansion vessel be fitted external to the boiler. It should be positioned on the return pipe and as close to the boiler as possible. However, if it is necessary to replace the central heating expansion vessel the boiler must be removed from the wall as follows. 7.25.1 Remove the casing (sect. 7.3) and lower the instrument panel and remove the control box cover. 7.25.2 Close the on/off valve on the domestic cold water, central heating and gas supply. 7.25.3 Drain domestic water from the lowest hot water tap and drain point on DHW inlet cock (Fig. 45). 7.25.4 Drain the boiler. 7.25.5 Disconnect all pipework connected to boiler. 7.28.7 Disconnect mains cables and any other connections (room thermostat, programming clock). 7.25.8 Remove the duct. 7.25.9 Remove the 2 the boiler by lifting from the wall bracket. 7.25.10 Unscrew the nut that connects the expansion vessel and remove it. 7.25.11 Remove the screw and the bracket supporting expansion vassel. 7.28.11 Replce in reverse order. 38 Fig. 58 7.26 TO REMOVE / REPLACE D.H.W. HEAT EXCHANGER. 7.26.1 Remove the front panel from the outer casing and lower the instrument panel (sect. 7.3). 7.26.2 Close the on/off valves for the heating circuit and the hot water circuit. Drain the boiler (Fig. 45) and drain hot water from the lowest hot water tap and drain point on DHW inlet cock. 7.26.4 Unscrew the two screws that connect the DHW heat exchanger and pull it out from boiler. 7.26.5 Replace in reverse order always use new seals. 7.26.6 Fill the boilers as described in (sect. 6.4 and 6.5) and check for leaks. 7.27 TO REMOVE/REPLACE TIMECLOCK (Fig.88/A). 7.27.1 Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel. 7.27.2 Remove control box cover (Sect. 7.19). 7.27.3 Remove control board (Sect. 7.19) from panel. 7.27.4 Remove two clips securing the timer. 7.27.5 Carefully remove the four wires connecting timer by pulling spade connectors from the timer. 7.27.6 Replace in reverse order (ensure all electrical connections are made correctly) (Fig. 59). 7.28 EXTERNAL HEATING CONTROLS (Fig.59). 7.28.1 Remove front and bottom of the casing (sect7.3). 7.28.2 Remove the external wire link on the PCB box. 7.27.3 Replace with external wire controls. Fig. 59 39 SECTION 8 FAULT FINDING CENTRAL HEATING Before trying to operate the boiler make sure that: - All gas supply cocks are open and the gas supply has been purge of air. - The heating system pressure is at least 1 bar min to 1.5 bar Max. - Main Switch on and power indicator light is on - Select “Winter” (Fig.35 item 1A) - Central Heating control knob to maximum (Fig.35 item 4) - Ensure external controls calling for heat (Room stat/Timeclock/TRV) Does power indicator light illuminate? Is 230 at L- N connections on control board No Yes Yes Replace On/Off Switch Is low pressure in the system No Does the pump run Check/Replace external Fuse and supply No Check/Replace pump if necessary Yes Is 230V at pump No No Re-pressure the system Yes Is there continuity at summer/winter switch No Replace summer/winter switch No Yes Check\Replace Low water Pressure Switch Is the fan running at Maximum speed No Is 230 V at Fan No Check /Replace Timeclock if OK Replace control board Yes Is the flow temperature less than 95° No Yes Is there 230 V on the Gas Valve Check/Replace Air flow pressure switch if ok Check/Repalce control board fuse Check/Replce Fan Yes Yes Yes Is the fan Oscillating on-off Yes Check\replace fan modulating board Is there spark ignition Check\Replace Gas Valve No Yes No Does burner light? Is there a gas supply for the applianced No Check Gas supply No Yes Yes Check\Replace condensing trap and\or condensing sensor Yes Check \Replace control board fuse Yes Is the burner on - off Yes Yes Check\Replace Gas Valve FAILED FLUE TEMPERATURE - Check operating system Does the gas pressure remain at min for few minutes and than increase to the set level Yes Is the burner shut down by overheat stat Yes Is the flue temperature less than 95°C No Yes - END CENTRAL HEATING TEST 40 Check \Replace Spark electrode - Check / Replace heating sensor - Check / Replace the overheat thermostat FAULT FINDING DOMESTIC HOT WATER Before continuing it may be necessary to see Central Heating Fault Finding (Sect.8) - All gas supply cocks are open and the gas supply has been purge of air. - The heating system pressure is at least 1 bar min to 1.5 bar Max. - Main Switch on and power indicator light is on - Select “Summer” (Fig.35 item 1A) - Domestic Hot Water control knob to maximum (Fig.35 item 5) - Open Domestic hot tap close to the appliance Ensure Domestic Hot Water flow is min. of 3 l/min No Check and replace the diverter valve motor Check filters are clean Yes Yes Does main burner light? Is low pressure in the system No No Does the flow detector light? Yes Check/Replace DHW diverter valve No Yes Re-pressure the system No FAILED DHW SENSOR - Check /Replace DHW sensor and cables FAILED HEATING SENSOR - Check / Replace heating sensor No No FAILED LOW WATER PRESSURE SWITCH - Check /Replace Low water pressure switch - Check system pressure No FAILED FLUE TEMPERATURE - Check operating system RESET THE BOILER - Push the Reset button on Digital Display and check LCD if illuminate Yes Does the DHW temperature stabilise at set point ? No Check / Replace DHW potentiometer No Check / Replace DHW sensor Yes END OF DOMESTIC HOT WATER TEST 41 SECTION 9 ELECTRICAL SYSTEM DIAGRAM. Fig. 60 42 SECTION 10 INSTALLATION INSTRUCTION FOR TWIN FLUE PIPE (ECCENTRIC FLUE DUCT SYSTEM). Fig. 62 Fig. 61 10.1 IMPORTANT. These instructions must be read in conjunction with the installation and servicing instructions. As with all flues the kits must be installed taking due account of the current issue of BS 5440 parts 1 & 2 and timber frame housing REF DM2. Also note that the requirements will vary depending upon the kit being installed. Guidance is provided but unless otherwise stated, always comply with the recommendations of the relevant codes of practice. 10.2 TWIN FLUE INSTRUCTIONS. This part of the installation manual covers the installation and fixing instructions of the twin flue eccentric flue duct systems only. When ordering twin flue it must be stated for CSI 85 AAA (T) - 780 series range. Typical installation procedures are illustrated by drawings. IMPORTANT Correct F1 orifice must be fitted. 10 - air intake bend 90° 13 - 45° flue exhaust bend 10 - flue exhaust bend 90° 14 - flue exhaust duct 11 - air inlet terminal 14 - air intake duct 12 - flue exhaust terminal 15 - two-way flue gas header 13- 45° air intake bend duct 16 - vertical eccentric flue exhaust duct Supplied with the CSI 85 AAA (T) 780 series twin flue header is a F1 orifice plate along with supplementary depression seal. Before fixing the twin flue system the existing orifice plate must be replaced with F1 also ensuring supplementary seal has been fitted. Remove the 13 screws securing the depression front panel item 2 figure 39 to expose front edge of depression chamber (Twin flue instructions figure 1 adjacent). Using adhesive sponge supplied with CSI twin flue header, carefully attach to depression chamber so as to create a softer seal. Taking care not to damage the new seal, carefully re-fit the depression chamber front cover in reverse order. Take out the 4 temporarily fitted securing screws, lifting out the gasket and orifice plate disconnecting it from the venturi tube. Discard this orifice plate and re-fit the F1 orifice plate ensuring that the venturi tube has been re-fitted, making sure this is securely located into the locating peg. 43 Locate the sealing washer fixing the twin flue header as illustrated making sure that the inner aluminium exhaust locates firmly in the outlet spigot make sure that the screws are satisfactorily located through the gasket seal. Locate the 2 x 80 mm ‘O’ rings in the twin flue header. Figures show the versatility of this flue system. Measurements and bends must be calculated correctly so as not to oversize maximum flue lenght. All located ‘O’ rings must be lubricated with a silicone grease to ensure easy, snug fit. NOTE: Exhaust flue must slope 2° down towards the boiler 35 mm fall per metre. Spacing Clips Spacing Clips are available on request should they be required. NOTE: for eccentric vertical flue a 125 mm (5 in) diameter flashing plate will be required. Fig. 63 Fig. 64 E = EXHAUST I = INLET T= TERMINAL Exhaust/suction system with concentric pipes for flat or sloping roofs. Extensions with two separate pipes. Maximum distance = I + E + T = 2 Metre + 2 Metre + 1 Metre = 12 Metre maximum (pipe + terminal). Minimum distance D = T = 2 metre. Exhaust terminal must not be cut. NOTE- The pressure loss for each elbow fitted is: 90° slow bend less 3 metre of pipe for each one fitted. 135° bend less 1.5 metre of pipe for each one fitted. NOTE: If bends are used in the exhaust flue then horizontal sections must be avoided and there must be a 2° slope towards the boiler 35 mm fall per metre. IMPORTANT: See Fig. 29 for terminal clearances. 44 Exhaust/suction system with two separate rated 80 dia. Pipes - exhaust on flat or sloping roof, suction from vertical wall. Maximum distance D = I + E + T = Total exhaust/inlet pipe = 20 metre. Exhaust terminal must not be cut. Min inlet pipe distance = 0.5 metre. NOTE: The pressure loss for each elbow is: 90° slow bend less 3 metre of pipe for each one fitted 45° bend less 1.5 metre of pipe for each one fitted Minimum total length = 2 metre Fig. 65 NOTE: Exhaust flue must slope 2° down towards the boiler 35 mm fall per metre. IMPORTANT: see Fig. 6 and 29 for terminal clearances. Exhaust/suction system with two separate pipes through a single vertical wall. Maximum distance D = I + E = Total exhaust/inlet pipe 18 metre. Minimum distance D = I + E = 1.5 metre. Min inlet pipe distance 0.5 metre. Min distance between pipe 50 mm. NOTE. The pressure loss for each elbow fitted is: Fig. 66 90° slow bend less 3 metre of pipe for each one fitted. 45° bend less 1.5 metre of pipe for each one fitted. IMPORTANT: inlet and exhaust terminals must never be installed on opposite walls of the building (PrEN 483). ITEM 1 2 3 4 5 6 7 8 9 10 DESCRIPTION CSI flue adaptor gasket and screws Straight pipe Eccentric vertical terminal 90º slow bend 45º bend Air inlet terminal (plastic) 80 mm Exhaust terminal (stainless steel) 80 mm Pitch roof slate Flat roof slate Twin flue pipe socket seal 60 mm PART NO 30005 30001 30003 30009 30011 30007 IMPORTANT NOTICE: If the flue terminates less than 2 m. above a balcony, above the ground, or above a flat roof to which people have access, then a suitable terminal guard must be fitted. Fit only recommended flue terminal guard by securing concetrically around terminal with screws. Available on request from: RAVENHEAT MANUFACTURING LTD Chartist Way Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. (0113) 252 7007 IMPORTANT: see Fig. 6 and 29 for terminal clearances. 45 SECTION 11 50 79 100 83 27 118 39 18 4 14 3 16 9 15 1 17 12 8 5 105 22 2 11 46 SECTION 12 RAVENHEAT CSI 85 AAA (T) - 780 series CONDENSING FANNED COMBI BOILER SHORT LIST OF SPARE PARTS Ravenheat G.C. Pos. Part. No. Part. No. 1 0014PAN06010/0 2 0012INT11005/0 3 0011GRU06005/0 4 0012POT05010/0 5 0007TER08010/0 6 0001CAM06005/0 E23-732 Combustion chamber 7 0001DIA06005/0 E23-730 Flue restriction ring 79CSI (F2) 8 0006IDR09007/0 372842 9 0007TER05005/0 E23-715 10 0014SPI09005/0 Sight glass 11 0007TER11015/0 C.H. Sensor 12 0011GRU11005/0 Flow manifold 13 0001CAP06005/0 14 0012RIV11005/0 Flow detector 15 0012CIR06010/0 Fan Control Board 15.1 0012CIR06011/0 Fan Control Board red 16 0012CIR06025/0 Printed ignition control board red 17 0014MAN11005/0 Knob 18 0012MOT11005/0 Diverter valve switch 21 0001C0P01010/0 Combustion chamber cover 22 0008VAL09015/0 Dungs valve gas 22.1 0008VAL06007/0 Honeywell valve gas 26 0002SCA06010/1 Heat exchanger 27 0014RAC11005/0 Condensing trap 28 0014REGO1005/0 29 0010TUB06050/2 Connecting pipe to air purge 30 0008VAL01010/0 Air purge valve 31 5018025 33 0012VEN03005/1 36 5018046 378864 Gasket 30 x 22 x 2 37 1015PAN06005/0 E23-737 Insulation pads set 39 0012FUS05015/0 E23-720 Internal fuse 2A 46 0014GUA01020/0 371277 Flue gasket Description Instrument panel E23-712 Switch Flow return E23-729 D.H.W. / C.H. Potentiometer Overheat thermostat E23-733 371271 372851 Water gauge D.H.W. Sensor Flue gas exhaust hood Water flow regulator Gasket 18.5 x 11.6 x 2 Fan 47 Ravenheat G.C. Pos. Part. No. Part. No. 47 0001CAM06012/0 Depression chamber 50 0012CAN09005/2 Ignition-sensing electrode 51 0012CAV08020/0 Cable for spark-sensing electrode 61 0002SCA06006/0 Condensing heat exchanger 62 0003UGE03005/0 371297 Nozzle Ø 1,25 for natural gas 62.1 0003UGE01011/0 E23-755 Nozzle DM 0.75 LPG 64 0001TEL06015/0 Frame right 64.1 0001TEL06020/0 Frame left 68 0003BRU06016/1 Burner natural gas 68.1 0003BRU06017/1 Burner LPG 79 0005PRE11010/1 Low water pressure switch 80 0009CIR06005/0 Circulation pump 83 0008VAL01018/1 Safety relief valve (3 bar) 87 0014TUB01005/1 White nylon tubes from pres. switch 87.1 0014TUB01006/1 Red nylon tubes from pres. switch 89 0005PRE06006/0 Pressure switch 93 0019CUR06005/1 Elbow header 95 0019PR005005/0 Flue extension duct complete 97 0019TER06005/1 Flue duct and terminal complete 100 0004VAS09010/0 Expansion tank 105 0012ORO01010/0 371258 Digital Timer 106 0019TER06010/0 E23-753 Vertical Flue Terminal Complete 114 0014GUA06010/0 Flue gasket dm 100 115 0014GUA06005/0 Flue gasket dm 60 116 0014GUA06015/0 Flue gasket dm 80 117 0019SDO06005/0 Twin header 118 0002SCA11025/0 Heat exchanger for D.H.W. water 48 Description 49 COD 0017LIB06006/2 - 06/2009 The code of practice for the installation, commissioning & servicing of gas central heating Installation, Commissioning and Service Record Log Book CUSTOMER DETAILS NAME ADDRESS TEL No. IMPORTANT 1. Please keep the Log Book in a safe place for future reference. 2. This Log Book is to be completed in full by the competent person(s) who commissioned the boiler and associated equipment and then handed to the customer. When this is done, the Log Book is a commissioning certificate that can be accepted as evidence of compliance with the appropriate Building Regulations. 3. Failure to install and commission this appliance to the manufacturer’s instructions may invalidate the warranty.The above does not affect your statutory rights. INSTALLER & COMMISSIONING ENGINEER DETAILS INSTALLER DETAILS COMPANY NAME INSTALLATION DATE ADDRESS TEL No. INSTALLER’S NAME CORGI REGISTRATION DETAILS REG No. CORGI ID SERIAL No. COMMISSIONING ENGINEER (IF DIFFERENT) NAME COMMISSIONING DATE ADDRESS TEL No. CORGI REGISTRATION DETAILS REG No. CORGI ID SERIAL No. BOILER MAKE AND MODEL APPLIANCE SERIAL No. SEDBUK No. LOCATION LOCATION NEW SISTEM %% or REPLACEMENT BOILER CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes. REQUIREMENT MEASURES PROVIDED 1. TIME AND TEMPERATURE CONTROL TO HEATING ROOM STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT 2. TIME AND TEMPERATURE CONTROL TO HOT WATER CYLINDER STAT & PROGRAMMER/TIMER COMBI BOILER 3. HEATING ZONE VALVES FITTED NOT REQUIRED 4. THERMOSTATIC RADIATOR VALVES FITTED 5. AUTOMATIC BYPASS TO SYSTEM FITTED 6. BOILER INTERLOCK PROVIDED NOT REQUIRED PLEASE FOLLOW THE INSTALLATION AND COMMISSIONING INSTRUCTIONS IN THE INSTALLATION MANUAL SUPPLIED WITH THE EQUIPMENT FOR ALL BOILERS HAS THE SYSTEM BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS? YES NO WHAT WAS THE CLEANSER USED? HAS AN INHIBITOR BEEN USED? YES NO WHICH INHIBITOR WAS USED? For the central heating mode, measure and record: kW HEAT INPUT BURNER OPERATING PRESSURE mbar CENTRAL HEATING FLOW TEMPERATURE °C CENTRAL HEATING RETURN TEMPERATURE °C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED? YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED? Benchmark is supported by The content of this Log Book has been produced in consultation with © CENTRAL HEATING INFORMATION COUNCIL 51 For the domestic hot water mode, measure and record: HEAT INPUT kW MAXIMUM BURNER OPERATING PRESSURE mbar MAXIMUM OPERATING WATER PRESSURE bar COLD WATER INLET TEMPERATURE °C HOT WATER OUTLET TEMPERATURE °C WATER FLOW RATE AT MAXIMUM SETTING Its/min FOR CONDENSING BOILERS ONLY HAS THE CONDENSATE DRAIN BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS? YES NO FOR ALL INSTALLATION DOES THE HEATING AND HOT WATER SYSTEM COMPLY WITH THE APPROPRIATE BUILDING REGULATIONS? YES HAS APPLIANCE AND ASSOCIATED EQUIPMENT BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS? YES HAVE YOU DEMONSTRATED THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS TO THE CUSTOMER? YES HAVE YOU LEFT ALL THE MANUFACTURER’S LITERATURE WITH THE CUSTOMER? YES COMPETENT PERSON’S SIGNATURE CUSTOMER’S SIGNATURE (To confirm demonstrations of equipment and receipt of appliance instructions) SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that your service engineer completes the appropriate Service Interval Record below. SERVICE PROVIDER SERVICE 1 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SERVICE 2 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SERVICE 4 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SERVICE 6 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SERVICE 8 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SERVICE 10 DATE: ENGINEER NAME COMPANY NAME TEL No. CORGI ID SERIAL No. COMMENTS SIGNATURE SIGNATURE When all of the above services have been completed, please contact your Service Engineer for an additional service interval record sheet. 52 GBLB Second Edition 01.03.02 Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions and in compliance with The Gas Safety Regulations. Always use the appliance manufacturer’s specified spare part when replacing gas controls.