Ravenheat CS 80 T, CS 90 T Instructions For Use Installation And Servicing

Technical and illustrative data are not binding and can be modiﬁ ed without prior notice. The descriptions and illustrations in the present booklet are for guidance purposes only.

RAVENHEAT MANUFACTURING LTD CHARTISTS WAY, MORLEY, LEEDS, U.K. LS27 9ET TEL.: 0113 252 7007 - FAX: 0113 238 0229

Website: www.ravenheat.co.uk - E-mail: sales@ravenheat.co.uk

Instructions for Use

Installation and Servicing

To be left with the user

CS 80 (T)

Natural Gas (G20) II

2H3P

G. C. No. 4758146

LPG (G31) II

2H3P

G.C. No. 4758147

CS 90 (T)

Natural Gas (G20) II

2H3P

G. C. No. 4758148

LPG (G31) II

2H3P

G.C. No. 4758149

1312

HIGH EFFICIENCY

CONDENSING

COMBINATION BOILER

2

3

HIGH

EFFICIENCY CONDENSING BOILER

FOR CENTRAL HEATING AN

FOR CENTRAL HEA TING AND DOMESTIC HOT W ATER

This new highly efﬁ cient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at super high efﬁ ciency.

POSITION

The appliance is extremely versatile as it can be ﬁ tted in almost any room. The appliance is room sealed so there is no contact

between the combustion chamber and living accommodation. This guarantees maximum safety and efﬁ ciency. Each boiler has been designed and manufactured in our modern plant to exacting ISO 9001 discipline, all boilers carry full CE marking of approval. Technical sales and commercial services are available throughout the UK Mainland. This product is guaranteed by Ravenheat manufacturing ltd, Chartists Way , Morley, LEEDS, LS27 9ET. T elephone No (0113) 252 7007.

Guarantee is a full 12 months from date of purchase providing the appliance has been ﬁ tted in accordance with these instructions

and relevant codes of practice.

-

Gas valve.

- Variable head pump suitable for any type of central heating system.

- Burner with ﬂ ame stabiliser designed to operate under all thermal conditions.

- Unique

condensing heat exchanger

for high thermal ﬂ ue transfer from gases to water.

- Stainless steel plate heat exchanger for super high heat transfer to domestic hot water supply.

- Built in frost protection.

- Printed circuit board designed to connect to room stat and/or timer.

- 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 (time clock version only).

NOTE: Due to the high

efﬁ ciency of thi

efﬁ ciency of this boiler a plume of water vapour will form at the ﬂ ue

terminal during operation.

COSHH - CONTROL OF SUBST ANCES

HAZARDOUS TO HEALTH

HAZARDOUS TO HEAL TH

IMPORTANT

It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn when handling this appliance, and where applicable the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety.

GENERAL INFORMATION: GLUES AND SEALANTS - exercise caution - if these are still in liquid form. RAVENHEAT use only high quality material for production of this product, in an effort to protect the environment wherever possible components should be recycled.

WARNING: when installing the appliance, care should be taken to avoid any possibility of injury when handling sheet metal parts.

MAJOR COMPONENTS

4

Users instructions

Sections Page Sections Page

1 Users guide 6 5 Installation 25

1.1 Introduction 6 5.1 Warning 25

1.2 Clearances around the appliance 6 5.2 Delivery 25

1.3 Operating safety checks to protect 6 5.3 Unpacking of boiler 25 your appliance (checking the system 5.4 Positioning of the boiler 25 pressure) 5.5 Optional extras 26

1.4 Appliance status indicators 7 5.6 Plume management kit 27

1.5 Digital display 8 5.7 Installing the appliance for rear flue 28

1.6 Boiler value 8 outlet

1.7 Time 8 5.8 Installing the appliance for side flue 28

1.8 Programming the heating times 9 outlet

1.9 Diagnostic 9 5.9 Completing horizontal flue installation 31

5.10 Intake and exhaust terminal 31 components

2 General layout 10 5.11 In-line flue bend and flue extension 31

2.1 Operating scheme 11 5.12 Vertical flue instructions 32

2.2 Introduction 12 5.13 Installation instructions for twin flue 34

2.3 Description of control system and 12 pipe sequence of operation 5.14 Twin flue instructions 34

2.4 Domestic hot water mode 12 5.15 Exhaust / suction system with 35

2.5 Central heating mode 12 concentric pipes for flat or sloping

2.6 General function 12 roofs.

2.7 Overall dimension 13 Extensions with two separate pipes

2.8 Safety device 13 5.16 Exhaust / suction system with two 35

2.9 Available pump head 13 separate rated 80 dia. pipes

2.10 Pressure drop across appliance 13 exhaust on flat or sloping roof, suction from vertical wall

3 Technical data WH 80(T) natural gas 14 5.17 Exhaust / suction system with two 35

3.1 Technical data WH 80(T) LPG 15 separate pipes through a single

3.2 Technical data WH 90(T) natural gas 16 vertical wall

3.3 Technical data WH 90(T) LPG 17 5.18 Installation instructions for 80/125 36 concentric flue system

4 General requirements 18 5.19 Assemble boiler 37

4.1 Safety 18 5.20 Fitting valve pack 37

Gas safety (Installation and use) 5.21 Gas connection 37

4.2 General information 18 5.22 Central heating connection 37

4.3 Location of boiler 19 5.23 Domestic hot water connection 37

4.4 Clearances around the appliance 19 5.24 Position of water/gas connections 37

4.5 Important notice 19 5.25 Safety valve discharge 38

4.6 Gas supply 19 5.26 Condensate drain connection 38

4.7 Flue system 20 5.27 Converting the appliance to different 39

4.8 Air supply 20 gas types

4.9 Water circulation (central heating) 20 5.28 Electrical connections 39

4.10 Flue terminal position 21 5.29 Outdoor sensor 39

4.11 Pipework 22

4.12 Boiler interlock control 22 6 Commissioning 40

4.13 Draining tap 22 6.1 Gas supply installation 40

4.14 Air release points 23 6.2 Electrical installation 40

4.15 Mains water feed: central heating 23 6.3 Initial filling of the system 40

4.16 Permissible methods of filling 23 6.4 Setting the heating system 40

4.17 Sizing of additional expansion vessel 24 design pressure

4.18 Installation to an existing central 24 6.5 Filling the hot water system 40

heating system 6.6 Lighting the boiler 40

4.19 Water treatment 25 6.8 Check the gas pressure 41

4.20 Hard water areas 25 6.9 Combustion check 41

4.21 Domestic water 25 6.10 Checking the flue system 42

4.22 Electrical supply 25

5

Sections Page Sections Page

6.11 Checking the heating thermostat 42 11 Spare parts 55

6.12 Testing/regulating the D.H.W flow 42

6.13 Keep hot 42 12 Benchmark commissioning 60

6.14 C.H. high/low temperature 42 checklist details

6.15 Range rating central heating or/and 43 12.1 Analyser check list 65 domestic hot water

6.16 Test mode 43

6.17 Instructing the user 43

7 Servicing instructions 44

7.1 Boiler frost protection 44

7.2 To inspect and clean the appliance 45

8 Replacements of parts 45

8.1 General 45

8.2 To remove front panel 45

8.3 To remove left and right panels 46

8.4 To remove/replace spark igniter box 46

8.5 To remove/replace fan 46

8.6 To remove/replace the electrodes 47

8.7 To remove/replace the burner 47

8.8 To remove/replace the heat 47 exchanger

8.9 To remove/replace expansion 48 vessel

8.10 To remove/replace gas valve 48

8.11 To remove/replace plate heat 48 exchanger

8.12 To remove/replace the water 48 pressure transducer

8.13 To remove/replace diverter valve 49 motor

8.14 To remove/replace C.H. diverter 49 valve

8.15 To remove/replace D.H.W. diverter 49 valve mechanism

8.16 To remove/replace pump 49

8.17 To remove/replace automatic air vent 49

8.18 To remove/replace safety relief valve 50

8.19 To remove/replace D.H.W. sensor 50

8.20 To remove/replace C.H. flow and 50 return sensors

8.21 To remove/replace flue sensor 50

8.22 To clean and remove/replace 50 condensing trap

8.23 To remove panel control box 51

8.24 To remove the instrument panel 51

8.25 To remove/replace control board 51

8.26 To remove/replace digital display 51 board

8.27 External control connection 51

9 Fault finding Central heating 52

9.1 Fault finding Domestic Hot Water 53

10 Electrical system diagram 54

6

It is the law that all gas appliances are installed by a competent person, in accordance with the gas safety installation and to the current Gas Safety (Installation and Use) Regulations B.S.5440:2-(2000).

All registered installers carry a Gas Safe Register ID card and have a registration number. Both should be recorded in your boiler Log book. You can check your installer’s registration at www.gassaferegister.co.uk.

ESCAPE OF GAS Should a gas leak be suspected, contact your gas supplier without delay .

GAS EMERGENCY NUMBER: 08001 11999

Do NOT search for gas leaks with a naked ﬂ ame.

WARNING: This appliance must be earthed.

1.1 INTRODUCTION Please carefully read the information given in this

booklet to help you gain maximum control from your appliance with minimum trouble and cost.

Y our Ravenheat Condensing Low Nox combination boiler has been designed to supply your Central Heating and Domestic Hot Water directly from one unit. When Central Heating is operating, the circulation will be interrupted when Domestic Hot Water is being drawn off (domestic hot water has priority). This will normally not affect the level of Heating.

PLEASE NOTE:

Due to the high efﬁ ciency of this appliance and resulting

low ﬂ ue gas exhaust temperature a white plume of condensation vapour (cool steam) will be emitted from the ﬂ ue outlet terminal, this is quite normal. It will be particularly evident during periods of low outdoor temperature or when the boiler is working at its optimum performance (Plume Management kits are available on request).

IMPORTANT: In the unlikely event of the exhaust ﬂ ue gases exceeding

the overheat temperature setting, the boiler operation will be stopped to prevent damage to the appliance.

1.2 CLEARANCES AROUND THE APPLIANCE

Side clearance:

The position of the appliance must provide a minimum clearance of only 5 mm as the side panels do not require removing for servicing.

However, if the option is preferred to remove the panels then a minimum clearance of 55 mm is required.

Top clearance:

The top clearance should be a minimum of 125 mm.

Bottom clearance:

A minimum bottom clearance of 80 mm is

required between the appliance

required between the appliance and any surface, though 150 mm is preferred whenever possible.

Front clearance: A minimum of 450 mm is required in front of the appliance for access during servicing, the front clearance can be reduced when installed in a cupboard to 25 mm from the access door.

USER CONTROLS

This appliance is designed to operate with the minimum

of ease for the user. All the controls are found on the

control panel on the front of the boiler.

1.3 OPERATING SAFETY CHECKS TO PROTECT

1.3 OPERATING SAFETY CHECKS T O PROTECT

YOUR APPLIANCE (CHECKING THE SYSTEM

PRESSURE)

Before lighting the appliance check that the Central

Heating system pressure is not less than 1 bar. If it

is below this it will be ecessary to re-pressurise the

system, between 1 and 1.5 bar to allow the boiler to

operate. To view the system pressure press the P button

once, this will display the current pressure

(if the

pressure is on nil or too low, then error code 08E is

displayed).

A ﬁ lling device (ﬁ lling loop) will have been ﬁ tted on the

system.

This is usually on the pipework near to the boiler. If you

are unsure of its position, or you cannot identify it, consult

the installer who ﬁ tted the boiler.

The ﬁ lling loop usually consists of two taps and a

separate silver coloured braided ﬂ exible pipe with

connection ﬁ ttings. Only when re-pressurising should the

braided ﬂ exible pipe be connected between the two taps,

ensure that the nuts or the pipe ends are tightened

onto the taps.

Fully open one of the taps ﬁ rst and then while monitoring

the water pressure on the digital display, carefully open

the second tap. When the water pressure is to a

maximum of 1.5 bar turn both taps off.

Disconnect the ﬂ exible pipe from the taps (a small

amount of water may be present).

Keep the pipe in a safe place for future use.

Press the P button once to return to the main screen.

In the event of an error, the appliance will show a

sequence code displayed on the digital display of the

control panel (ﬁ g. 1). By pressing the “RESET“

button it is possible to relight the boiler (see page 51

for list of error codes).

1 USERS GUIDE

7

1.4 APPLIANCE STATUS INDICATORS

Your boiler is equipped with a large LCD display that indicates the appliance operating status (ﬁ g. 1).

After a long period switched off (no power supply), the ﬁ rst switch on the internal backup circuit will charge in order to

maintain time

and update parameters. The screen will display

CLOW, after a few minutes of power su

CLOW, after a few minutes of power supply the display will be charged enough to allow all the functions.

Fig. 1

During the initial charge time, the display doesn’t allow the visualisation and/or modiﬁ cation function parameters. Instead other functions are working. When the appliance operates in rest mode, the display shows the boiler temperature and, for the time clock version only, the time. Alternatively the digital display also shows the water pressure.

KEY :

1 - ON/OFF button. Press to turn the boiler ON, “SUM” (hot water only) “WIN” (hot water and heating if set) and OFF. Press the button also to conﬁ rm selections.

2 - Press to reset the appliance if ever an error code is displayed.

3/4 - Temperature and function mode selectors. Press the arrow up or the arrow down to increase or decrease the heating or domestic hot water outlet temperature, when the digital display is in hot water or domestic set-point temperature. Press also to show the boiler values or to show the options program when the digital display is in menu setting.

5 - Press to set the Central Heating

Temperature required (when in winter mode).

Press the arrow up or the arrow down buttons to increase or decrease the temperature.

6 - Press to set the Domestic Hot Water

Temperature required. Press the arrow up or the arrow down buttons

to increase or decrease the temperature.

7 - TIMER MODE (time clock version only). Press to select “Auto” (heating times set), “Manual” (heating on all the time) and off (heating off).

8 - Press to show the boiler values. Use the arrow up and arrow down buttons to select

the following information: PBAR: water pressure

SFAN: speed fan (the display shows 3 digits (e.g. 500 = 5000 rpm) TFLOW: ﬂ ow temperature TRET: return temperature TDHW: domestic hot water temperature PWR: % power of modulation.

- Press for 3 seconds to enter into menu. Use the arrow up or arrow down buttons to select the following options:

- TIME (time clock version only): It is possible to set the time and the current day (Monday 1, Tuesday 2, Wednesday 3, Thursday 4, Friday 5, Saturday 6, Sunday 7), see section 1.7.

- PTMR (only time clock version): It is possible to set the timer, see section 1.8.

- BOIL: It is possible to set the boiler parameters C.H. max fan speed D.H.W. max fan speed Keep hot: “0” disabled and “1” enabled C.H. High/Low temperature: “1” high/“2” low.

8

1.6 BOILER VALUE

It is possible to show the boiler value. Press P button to show the boiler value.

Use the arrow up and the arrow down

buttons, (item 3 and

buttons, (item 3 and 4 ﬁ g. 1) to show the following info:

PBAR: water pressure SFAN: speed fan TFlow: ﬂ ow temperature TRet: return temperature TDHW: domestic hot water temperature PWR: % power of modulation.

1.7 TIME (

time clock

time clock version only)

SETTING THE TIME AND DAY

(time clock

version only):

1. Press and hold the P button for 4 seconds.

2. Press the up and down arrows to select “TIME” and then press the enter button.

3. Press the up and down arrows to select the current hour (24h). Then press the enter button.

4. Press the up and down arrows to select the current minute and then press the enter button.

5. Press the up and down arrows to select the current day (1=Mon, 2= Tue etc.) and then press the enter button. The time is now set.

KEY 1 - Day indicator:

(time clock version only)

1. Monday

2. Tuesday

3. Wednesday

4. Thursday

5. Friday

6. Saturday

7. Sunday

2 - Time (time clock version only).

3 - Central Heating: when the appliance

is in central heating mode icon 3 will be

ﬂ ashing.

4 - Auto (time clock version only): when the

digital clock is in automatic function icon 4

is displayed.

5 - Water pressure: Shows the current

pressure in the system.

6 - Manual: When the digital timer is set to

manual icon 6 is displayed, in this mode the

central heating is on permanently.

1.5 DIGITAL DISPLAY

Fig. 2

7 - ON/OFF: When the appliance is ON icon 7 is displayed. 8 - Modulation ﬂ ame level: When the burner is lit, 3 different levels on icon 8 are displayed. 9 - Day function (

time clock

time clock version only). 10 - Temperature. 11 - Anomaly - Lock - out - Test function. 12 - Domestic hot water: when the appliance is in domestic hot water mode the icon will ﬂ ash.

1.8 PROGRAMMING THE HEATING TIMES (

time clock vers

time clock version only)

The appliance incorporates a digital clock programmed with a default heating pattern (see table 1); however this can be modiﬁ ed to suit individual needs.

To change the programmed times:

1. Press and hold the P button for 3 seconds.

2. Press the up and down arrows to select “P TMR” and then press the enter button.

3. Press the up and down arrows to select the individual day you wish to set, or select the group of days (see table 2) then press the enter button.

4. Press the up and down arrows to select the ON1 time (ﬁ rst on time) and press the enter button.

5. Press the up and down arrows to set the OF1 time (ﬁ rst off) and press enter. Repeat this process for the remaining 3 settings. (Note: if not all 4 times are required then set the remaining on and off times to

24.00, this cancels the remaining on and off. For example see the weekend settings in (table 1.)

TABLE 1

TABLE 2

9

Once the times are set, press the P button and this will return to the main screen.

NB: If setting the times in a group, the days in the group will all be the same, however days not in this group will remain at the default time.

For example, setting Mon-Sat

For example, setting Mon-Sat will change all these days but Sunday will remain the same as table one unless changed individually.

The programmed times will only be activated when the boiler is in winter mode (section 1.4 key 1) and also set in auto mode (section 1.4 key 7). If you wish to override these times, press the timer mode button to select “MAN”, this puts the boiler in manual mode which overrides the timer on the boiler so the heating is on permanently (providing any external controls ﬁ tted are calling for heat). To turn the heating off, press the timer mode button to select off, this will now turn the heating off permanently until either auto or manual is selected.

1.9 DIAGNOSTIC

The display shows eventual error or faulty

message.

Stop boiler: The boiler stops the operating cycle

and waits for the disappearance of the cause of

the error in order to go back to be operating

mode.

Block boiler: The boiler requires a manual reset

to become operational again.

10

KEY

1 - Condensate trap 2 - Gas valve 3 - Gas inlet 4 - Drain point 5 - CH ﬂ ow 6 - Diverter valve motor

7 - DHW outlet 8 - DHW sensor 9 - DHW flow detector 10 - DHW inlet 11 - Safety pressure relief valve

12-Water pressure transducer 13 - CH return 14 - Control board 15 - Circulation pump 16 - Automatic air vent 17 - Condensate drain 18 - Expansion vessel 19 - Main heat exchanger 20 - Spark electrode 21 - Sensing electrode 22 - Flue temperature sensor

23 - Spark igniter 24 - Fan 25 - Burner 26 - Manual air vent 27 - Overheat cut off thermostat 28 - CH flow sensor 29 - CH return sensor

2.0 GENERAL LAYOUT (Fig. 3)

Fig. 3

11

KEY

1 - Flue exhaust manifold 2 - Condensate drain 3 - CH return 4 - CH return sensor 5 - Heat exchanger 6 - CH ﬂ ow 7 - Overheat cut off thermostat 8 - CH ﬂ ow sensor 9 - Manual air vent

10 - Burner 1 1 - Spark electrode 12 - Sensor electrode

13 - Fan 14 - Flue

temperature

temperature sensor 15 - Expansion vessel 16 - Automatic air vent 17 - Circulation pump 18 - Water pressure transducer

19 - Safety pressure relief valve 20 - Diverter valve motor 21 - Plate heat exchanger 22 - DHW sensor 23 - Gas valve 24 - Gas service cock 25 - CH compression ball valves 26 - DHW flow sensor 27 - DHW compression ball valves

2.1 OPERATING SCHEME (Fig. 4)

Fig. 4

As the heating sensor reaches temperature

the fan speed modulates to maintain the temperature set on the display panel. When starting, the fan will always start at the set-point speed.

The boiler is ﬁ tted with an anti-cycling device

on the control board. This delays the boiler

from re-ﬁ ring within 10 minutes. If the heating temperature goes 20 °C below the set point, the burner restarts immediately. The domestic hot water will always take

priority and is unaffected by the anti-cycling

device.

2.6 GENERAL FUNCTION The instrument panel permits regulation of the

boiler to partial heating requirements, between

maximum and minimum settings. Air and gas are drawn by the fan for

combustion. The fan also forces exhaust gas through

the ﬂ ue to the outside, this creates a lesser

pressure in the sealed combustion chamber,

thus sucking in combustion air, through the

inlet duct. The boiler water temperature is automatically

controlled by a built in thermostat. 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

external timer if required. The

external timer if required. The burner continues to operate until it is stopped by the digital clock or one of the thermostats.

When the internal C.H. temperature sensor or the room thermostat intervenes the burner

shuts down. The fan stops but the pump continues to operate for 3 minutes.

The boiler also incorporates an anti-block

system which powers the pump every 24 hours, allowing it to operate for 2 minutes if the boiler has not been in use. This operation may in some cases be heard for a short period when the pump has been activated.

The heat exchanger in the D.H.W. circuit is a stainless steel plate heat exchanger water

to water, and domestic water is heated by converting the water in the central heating circuit. The transfer of heat is very high because the two ﬂ uids move in a counter direction.

Select the winter position by summer/winter

button (item 1 ﬁ g. 1).

2.2 INTRODUCTION This boiler is designed for the production of

central heating and domestic hot water combined in one unit. It is ﬁ tted with an automatic domestic hot

water priority valve.

It is possible to select either a summer or

winter function.

With the summer position only being for

domestic hot water.

The winter position being for central heating

with domestic hot water priority.

2.3

DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION

AND SEQUENCE OF OPERA TION

2.4 Domestic hot water mode

When the appliance is in rest mode,

select the summer position by pressing

the ON/OFF button (item 1 fig. 1) please

ensure that the heating circuit is charged

with water (above 1 bar).

If the domestic hot water tap is turned

on the boiler will function in the

following sequence:

The pump starts. The fan starts and sends a signal back to the ignition board that the fan is running.

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.

When the electrode sensor senses the signal

that the burner is alight, the spark igniter stops.

The fan speed settings on the boiler increases

to the maximum permissible speed over

a period of 5 seconds and will remain at its

maximum required power until its maximum

regulated temperature is achieved and then

will modulate to maintain this.

When the domestic hot water tap is closed the

diverter valve goes back into rest mode, the

burner is shut down along with the fan which is

also switched off.

2.5 Central heating mode

If the appliance is in winter mode with a

demand for heat to supply radiators, etc. ,

with the heating circuit fully cha

with the heating circuit fully charged above 1 bar, so as to operate the low water sensor device the boiler will start in the same way as domestic hot water mode.

12

13

When a hot water tap is turned on the diverter

valve motor moves to exclude the central

heating circuit, the boiler automatically

modulates to maintain the domestic hot water

at a constant temperature.

The water temperature can be regulated by

the digital display.

When domestic hot water is being drawn off

the burner and pump perform as they do

during central heating except that the burner

is commanded by the D.H.W. thermostat.

When D.H.W. is no longer called for (tap is

turned off), the boiler will automatically return

to the central heating mode.

Select the summer position by pressing the

summer/winter button. The boiler functions

like an automatic gas hot water heater.

When D.H.W. is no longer required the

burner and pump and fan will immediately

turn off.

This also takes place when in winter mode, if there is no demand for heat to the central heating system or until the digital clock and room thermostat (if ﬁ tted) demands the central heating circuit.

2.8 SAFETY DEVICE In both central heating and domestic hot

water mode safe operation is ensured by a

control board which shuts off the main

burner, if the fan stops or the ﬂ ue or combustion air intake duct is obstructed.

An overheat cut off thermostat acts to turn

off the burner to resettable “lockout”.

A safety valve is ﬁ tted on the central heating circuit set at 3 bar. A low water pressure switch set at 0.4 bar is

ﬁ tted on heating circuit, to prevent the boiler operating below this boiler system pressure.

2.7 OVERALL DIMENSION (Fig. 5)

2.10 PRESSURE DROP ACROSS APPLIANCE (Fig. 7)

2.9 AVAILABLE PUMP HEAD (Fig. 6)

Fig. 5

NOMINAL HEAT INPUT NET QMS 20.0 kW MINIMUM HEAT INPUT NET 3.7 kW

NOMINAL HEAT OUTPUT 19.5 kW NOMINAL HEAT OUTPUT CONDENSING 21.4 kW MINIMUM HEAT OUTPUT 3.6 kW MINIMUM HEAT OUTPUT CONDENSING 4.0 kW

GAS RATE max 2.1 m

3

/h

AFTER 10 MINUTES min 0.4 m3/h INLET PRESSURE 20 mbar FAN SPEED Max 4200 rpm - 140 Hz Combustion % CO2 : 9.0 (+ 0.5 / - 0.5) Case ON

C.H. min 1300 rpm - 43 Hz 9.0 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 110 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 28 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

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 compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow 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 80 °C min 35 °C DESIGN FLOW RATE 1066 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 11.9 l/min D.H.W. FLOW RATE 35 °C rise 10.2 l/min D.H.W. FLOW RATE 40 °C rise 8.9 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 25.4 kW min 3.7 kW D.H.W. PRESSURE PMW Max 6.5 bar D.H.W. PRESSURE PMW min 0.5 bar D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE CATEGORY II

2H3P

FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A IP X4 D

3 TECHNICAL DATA

CS 80 (T)

TABLE 3/A

NATURAL GAS (G 20) П2H3P

14

3.1 TECHNICAL DATA

CS 80 (T)

TABLE 3/B

LPG ( G 31) П2H3P

NOMINAL HEAT INPUT NET QMS 20.0 kW MINIMUM HEAT INPUT NET 3.7 kW

NOMINAL HEAT OUTPUT 19.5 kW NOMINAL HEAT OUTPUT CONDENSING 21.4 kW MINIMUM HEAT OUTPUT 3.6 kW MINIMUM HEAT OUTPUT CONDENSING 4.0 kW

GAS RATE max G31 0.8 m

3

/h

AFTER 10 MINUTES min 0.15 m3/h INLET PRESSURE G31 37 mbar FAN SPEED C.H. Max 4200 rpm - 140 Hz

Combustion

Combustion % CO2 : 10.5 (+ 0.5 / - 0.5) Case ON

min 1300 rpm - 43 Hz 10.5 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 110 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 28 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

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 compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow 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 80 °C min 35 °C DESIGN FLOW RATE 1066 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 11.9 l/min D.H.W. FLOW RATE 35 °C rise 10.2 l/min D.H.W. FLOW RATE 40 °C rise 8.9 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 25.4 kW min 3.7 kW D.H.W. PRESSURE PMW Max 6.5 bar (147 p.s.i.) D.H.W. PRESSURE PMW min 0.5 bar (118 p.s.i.) D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE CATEGORY II

2H3P

FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A IP X4 D

15

16

NOMINAL HEAT INPUT NET QMS 24.5 kW MINIMUM HEAT INPUT NET 4.1 kW

NOMINAL HEAT OUTPUT 23.9 kW NOMINAL HEAT OUTPUT CONDENSING 26.4 kW MINIMUM HEAT OUTPUT 4.0 kW MINIMUM HEAT OUTPUT CONDENSING 4.4 kW

GAS RATE max 2.6 m

3

/h

AFTER 10 MINUTES min 0.4 m3/h INLET PRESSURE 20 mbar FAN SPEED Max 4200 rpm - 140 Hz Combustion % CO2 : 9.0 (+ 0.5 / - 0.5) Case ON

C.H. min 1300 rpm - 43 Hz 9.0 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 119 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 29 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

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 compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow 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 80 °C min 35 °C DESIGN FLOW RATE 1264 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 14.1 l/min D.H.W. FLOW RATE 35 °C rise 12.1 l/min D.H.W. FLOW RATE 40 °C rise 10.5 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 30.1 kW min 4.1 kW D.H.W. PRESSURE PMW Max 6.5 bar D.H.W. PRESSURE PMW min 0.5 bar D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE CATEGORY II

2H3P

FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A IP X4 D

3.2 TECHNICAL DATA

TABLE 3/C CS 90 (T)

NATURAL GAS (G 20) П2H3P

17

NOMINAL HEAT INPUT NET QMS 24.5 kW MINIMUM HEAT INPUT NET 4.1 kW

NOMINAL HEAT OUTPUT 23.9 kW NOMINAL HEAT OUTPUT CONDENSING 26.4 kW MINIMUM HEAT OUTPUT 4.0 kW MINIMUM HEAT OUTPUT CONDENSING 4.4 kW

GAS RATE max G31 1.0 m

3

/h

AFTER 10 MINUTES min 0.16 m3/h INLET PRESSURE G31 37 mbar G30 28-30 mbar FAN SPEED C.H. Max 4200 rpm - 140 Hz Combustion % CO2 : 10.5 (+ 0.5 / - 0.5) Case ON

min 1300 rpm - 43 Hz 10.5 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 119 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 29 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

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 compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow 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 80 °C min 35 °C DESIGN FLOW RATE 1264 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 14.1 l/min D.H.W. FLOW RATE 35 °C rise 12.1 l/min D.H.W. FLOW RATE 40 °C rise 10.5 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 30.1 kW min 4.1 kW D.H.W. PRESSURE PMW Max 6.5 bar D.H.W. PRESSURE PMW min 0.5 bar D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE CATEGORY II

2H3P

FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A IP X4 D

3.3 TECHNICAL DATA

TABLE 3/D CS 90 (T)

LPG (G 31) П2H3P

18

BS5546: Installation of gas hot water supplies domestic purposes

(2nd Family Gases).

BS5440: Flues (for gas appliances of rated

input not exceeding 70 kW).

BS5440: 2 Ventilation (for gas appliances of

rated input not exceeding 70 kW).

BSEN 677: 1998 Gas fired central heating boilers.

I.S. 813: Domestic gas Installations. The followings standards give

valuable

additional information:

additional information: BS 7074: Expansion vessels and ancillary

equipment

equipment for sealed water system. BS 7593: Treatment of water in domestic hot water and central heating system.

Health & Safety Document No.635

The Electricity at Work Regulations, 1989.

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 CS 80/90 (T) combi boiler has

been tested and examined by CERTIGAZ, and

is certified to comply with PrEN 483 and BS

EN 625.

Manufacturers instructions must NOT be taken

in any way as overriding statutory obligations.

If in doubt on any point please consult

Ravenheat.

4 GENERAL REQUIREMENTS

4.1 SAFETY

Gas Safety (Installation and Use).

Regulations.

It is law that all gas appliances are installed

and serviced by a Gas Safe registered installer in accordance with the above regulations and these installation instructions. All registered installers carry a Gas Safe I.D. card and have a registration number. Both should be recorded in your Benchmark commissioning checklist. You can check your installer on the Gas Safe register (www.gassaferegister.co.uk). Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of your safety, to ensure the law is complied with. Check the boiler and flue is the correct type for installation undertaken.

The installation of the boiler MUST be in

accordance with the latest I.E.E. (BS 7671)

Wiring Regulations, local building regulations,

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.

4.2 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 relevan

British Standards concerning installation

requirements. If you need further advice on

any points contact the Technical Services

Office on 0113 2527007 who would be

pleased to help. It is recommended that tools

suitable for brass fittings are used, and have

a capability to accommodate hexagon sizes

up to 50 mm.

APPLICABLE CODES OF PRACTICE Ref: Documents.

Detailed recommendations are contained in the

following British Standard Codes of Practice:

BS6891:2005: Low pressure installation

pipes. BS6798: Installation of gas fired hot water

boilers of rated input not exceeding 70 kW.

BSEN12828: Design for water based heating systems.

BSEN12831: Heating systems in buildings, Method for calculation of the design heat load.

BSEN14336: Installation & commissioning of water based heating systems.

19

4.3 LOCATION OF BOILER Siting of Ravenheat CS 80/90 (T) 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 the boiler must be allowed

for.

Ravenheat CS 80/90 (T) combi boiler m

Ravenheat CS 80/90 (T) 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 fitted on a combustible

wall insulation between the wall and the boiler is not necessary, unless required by the local

authority. For electrical safety reasons there must be no access available from the back of the boiler.

The boiler must not be fitted outside. LPG versions of this appliance shall not be

installed in cellars or basements.

4.4 CLEARANCES AROUND THE APPLIANCE

Side clearance:

The position of the appliance must provide minimum clearance of 5mm as the side panels.

Top clearance: The top clearance should be a minimum of 125 mm.

Bottom clearance: A bottom clearance of 80 mm is required

between the appliance and any surface. Though 150 mm is preferred whenever possible.

Front clearance: A minimum of 450 mm is required in front of the appliance for access during servicing, the front clearance can be reduced when installed in a cupboard, to 25 mm from the access door.

4.5 IMPORTANT NOTICE For installation into timber framed buildings,

please refer to the Institute of Gas Engineers

Document IGE/UP/7. The 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 combination 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 situated so that it cannot be touched by a person using a bath or shower. A compartment when 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 CS 80/90 (T) combi boiler have been examined by CERTIGAZ notification body, and are 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.

4.6 GAS SUPPLY 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 6891:2005. Pipework from

the meter to the boiler must be of adequate size

(22 mm) min to within at least one 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. It is the

responsibility of the Gas Installer

to size the gas installation pipework in

accordance with BS 6891:2005. Whilst the

principle of the 1:1 gas valve ensures t

principle of the 1:1 gas valve ensures the

Ravenheat range

Ravenheat range is able to deliver the full

output at an inlet pressures as low as 14

mbar, other gas appliances in the property

may not be as tolerant. When operating pressures are found to be

below the minimum meter outlet of 19 mbar

these should be checked to ensure this is

adequate for correct and safe operation.

20

Allowing for the acceptable pressure loss of 1

mbar across the installation pipework, it can be assumed that a minimum permitted operating pressure of 18 mbar (nat gas) will be delivered to the inlet of the appliance. (reference BS 6400-1 Clause 6.2 Pressure Absorption).

The external gas cock could further reduce the

operating pressure when measure

d at its

d at its test point. The pressure drop is relative to the heat input to the boiler (kW), refer to graph below.

4.7 FLUE SYSTEM 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 (section 4.10).

The terminal must not be l

ocated in a place

where it is likely to cause a nuisance in cold

and/or humid weather as water vapour may

condense on leaving the flue terminal.

The effect of such pluming must be

considered.

The terminal must not be closer than 25 mm

(1 inch) to any combustible material for

(1 inch) 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 ﬂ ue lengths see alternative ﬂ ue instructions. Flue must be positioned in a place not likely to cause a nuisance from pluming.

IMPORTANT NOTICE: If the ﬂ ue terminates

below a balcony, above the ground, above a ﬂ at roof to which people have access, then a suitable terminal guard must be ﬁ tted if

less than 2 metres high. The part number is

PRO110100.

Fit only recommended

FLUE TERMINAL

GUARD

GUARD bby securing concentrically around

terminal with screws. Available on request from:

Ravenheat Manufacturing ltd Chartists Way, Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - UK

Tel. 0113 252 7007

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

times.

times. Minimum acceptable spacing from the terminal to

obstructions and ventilation openings are speciﬁ ed in section 4.10.

Note positions: Due to the terminal design, installation is possible with clearances less than those speciﬁ ed in BS 5440, Part 1

NOTE: The flue must be terminated in a place not likely to cause a nuisance.

A concentric vertical flue kit is available for

longer flueing applications (see table 5 page

26).

For further details see vertical flue installation

instructions.

4.8 AIR SUPPLY 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.

Where installed in a cupboard or compartment

ventilation is not required.

4.9 WATER CIRCULATION (Central heating) Detailed recommendations are given in BS6798

2009/5449:1990 - BSEN12828 - BSEN12831

- BSEN14336 (for smallbore and microbore central heating systems). The following notes are given for general guidance.

21

4.10 FLUE TERMINAL POSITION

Ravenheat CS 80 T, CS 90 T Instructions For Use Installation And Servicing

Specifications and Main Features

Frequently Asked Questions

User Manual