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 : sales@ravenheat.co.uk
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).
7.24.1.1
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.