Ravenheat CSI 120/150 Low Nox (T) INSTRUCTIONS FOR USE INSTALLATION AND SERVICING (GBLB Second Edition 01.03.02)

CSI 120 (T) Low Nox

CSI 150 (T) Low Nox

Instructions for Use

Installation and Servicing

To be left with the user

HIGH EFFINCENCY - LOW NOX

COMBINATION BOILER

CSI 120 (T) Low Nox

Natural Gas (G20) I

LPG (G30-G31)

CONDENSING

- II

G.C. No. 47-581-39

I

3+

G.C. No. 47-581-41

2H

- II

2H3+

CSI 150 (T) Low Nox

Natural Gas (G20) I

G.C. No. 47-581-40

LPG (G30-G31) I G.C. No. 47-581-42

3+

2H

- II

2H3+

86

Technical and illustative data are not binding and can be modiﬁ ed 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

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist.

Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page

Make and model .....................................................8/9

Appliance serial no. on data badge ....... Front Cover

Controls

Time and temperature control to heating ............. 3

Time and temperature control to hot water .......... 39

Heating zone valves .............................................. n/a

TRV's ........................................................................

Auto bypass .............................................................13

Boiler interlock .........................................................13

For all boilers

Flushing to BS.7593 .............................................. 14

Inhibitor .................................................................. 14

Central heating mode

Heat input ................................................to be calculated

13

9

Burner operating pressure .................................... n/a

Central heating flow temp. ...... measure and record

Central heating return temp. ... measure and record

For combination boilers only

Scale reducer .......................................................... 11

Hot water mode

Heat input .......................................... to be calculated

Max. operating burner pressure ........measure & record

Max. operating water pressure ........... measure & record

Cold water inlet temp ..................... measure & record

Hot water outlet temp. .................... measure & record

Water flow rate at max. setting ............ measure & record

For condensing boilers only

Condensate drain .................................................. 24

For all boilers: complete, sign & hand over to customer

Page

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

For assistance see Ravenheat thechnical helpline: telephone: (01 13) 252 7007 fax: (01 13) 238 0229 e-mail: sales@ravenheat.co.uk

HIGH EFFICENCY CONDENSING SYSTEM INNOV ATION AUTOMATIC MODULATING BOILER

FOR CENTRAL HEA TING AND DOMESTIC HOT WATER

This new super high efﬁ cient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at super high efﬁ ciency, unheard of only a few years ago.

POSITION

The appliance is extremely versatile as it can be ﬁ tted in almost any room. The appliance is room sealed, there is no contact between combustion chamber and living accommodation. This guarantees maximum safety and efﬁ ciency. Indeed, our depression/combustion front cover has been designed to ﬁ t, achieving maximum air tight seal using screw down fasteners at 15 cm. This should not hinder service of the appliance, but does ensure maximum efﬁ ciency and safety - something which we at Ravenheat take great pride in. 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 service are available throughout the UK. This product is guaranteed by Ravenheat Manufacturing, Chartists Way, Morley, LEEDS, LS27 9ET. Telephone No (01 13) 252 7007.

BASIC COMPONENTS - (See ﬁ gure 1).

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.

MAJOR COMPONENTS

- 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.

- Primary heat exchanger constructed from stainless steel.

- Unique patented condensing heat exchanger for high thermal ﬂ ue 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 ﬂ ow 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 not often used have been hidden. This achieves simplicity of operation with easy to clean panels.

NOTE: Due to the high efﬁ ciency of this boiler a plume of water vapour will form at the ﬂ ue

terminal during operation.

COSHH - CONTROL OF SUBST ANCES HARMFUL T O HEALTH

IMPORT ANT

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 or 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

TABLE OF CONTENTS

PAGE

1 2 3 4 5 6 7 8

9 10 11 12

GENERAL LAYOUT

INTRODUCTION DESCRIPTION AND SEQUENCE TECHNICAL DATA GENERAL REQUIREMENTS INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS REPLACEMENT OF PARTS FAULT FINDING ELECTRICAL SYSTEM DIAGRAM ALTERNATIVE FLUE SYSTEM SP ARE PARTS

6 6

8 12 17 27 29 31 40 42 43 46

KEY

1 - Condensing trap 2 - DC Fan Supply 3 - Spark igniter 4 - Fan 5 - Ignition electrode

6 - Sight glass 7 - Main heat exchanger 8 - Temperature ﬂ ue sensor 9 - Circulation pump 10 - Auto air vent valve 11 - Gas Valve

4

12 - Overheat cut off thermostat 13 - Retaining clips 14 - Expansion vessel

Sensing electrode

15 16 - Pressure test point 17 - Gas inlet 18 - C.H. outlet

19 - D.H.W. sensor

20 - Condensate drain 21 - D.H.W. outlet 22 - D.H.W. Heat exchanger 23 - D.H.W. inlet

Fig. 1

24 - Drain point 25 - C.H. Return

26 - Safety relief system

27 - Burner manifold 28 - C.H. sensor 29 - Burner assembly 30 - Water pressure sensor 31 - D.H.W. Switch 32 - Insulation 33 - Rear insulation 34 - Diverter valve Motor 35 - Manual air vent valve

OPERATING SCHEME

Fig. 2

KEY

1 - Heat exchanger 2 - Heat exchanger for D.H.W. 3 - Burner 4 - Sensing electrode 8 - Condensing trap 9 - Ignition electrode

12 - Gas valve

15 - Temperature ﬂ ue sensor 17 - Low water pressure switch 18 - Overheat cut-off thermostat 20 - Gas service cock

21 - Compression ball valves

23 - Safety relief system

24 - Diverter valve

26 - Auto air vent valve 28 - Pressure switch 29 - Circulating pump 30 - Water pressure gauge 36 - Fan 37 - Expansion tank 38 - Diverter valve Motor 39 - Differential water pressure switch

5

SECTION 1 INTRODUCTION

1.1 The Ravenheat boiler is for the production

of central and domestic hot water combined in one unit.

It is ﬁ tted with an automatic domestic hot

water priority valve.

A Summer/winter switch is ﬁ tted to the left

hand side of the control panel.

With the Summer only switch position being

for domestic hot water.

The summer/winter 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 part of the left hand side panel.

1.2 Fig.1 Illustrates the general layout of components. Fig.2 Illustrates the operating principles described in section 2.

SECTION 2

etc , with heating circuit fully charged so as to

operate the low water sensor device the boiler

will start in the same way as domestic hot water mode. As the heating sensor reaches temperature

the fan speed modulates down. When starting, the fan will always start at the

set-point 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 ﬁ tted with an anti-cycling device

on the control board. This delays the boiler

from re-ﬁ ring over a 10 minute. 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.

GENERAL FUNCTION

2.1 DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERA TION

2.2 Domestic hot water mode

When the appliance is in rest mode with

the mains neon and switch on. Switch the summer/winter switch to Summer 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 The pump starts. The fan starts and sends a signal back to the

ignition board that the fan is running .

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 fan speed setting 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.

2.2.5 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.

2.2.6 Central heating mode

2.2.7 If the switch is positioned on winter

with a demand for heat to supply radiators,

2.3 Central Heating Mode

2.3.1 A potentiometer installed on the panel

instruments 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 ﬂ ue

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 burner shuts down. The fan stops but the pump continues to operate.

2.3.7 When the room thermostats intervene the burner shuts down. The fan stops and the pump after 3 minutes turns off.

2.3.8 In summer position an anti-block of the pump is included. Every day the pump is powered for a period of 2 minutes. The boiler also incorporates an anti-block system which powers the pump every 24 hours, allowing it 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.

6

2.4 Domestic hot water mode

2.4.1 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 transference of heat is very high because the two ﬂ uids move in a counter direction ﬂ ow to each other.

2.4.2 Select summer/winter switch (Fig.27) in 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.

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 summer/winter switch (Fig.27) in summer position. The boiler functions like an automatic gas hot water heater When D.H.W. is no longer required the burner and fan immediately turn off.

This also takes place when switch 1a is on Winter if there is no demand for

heat to the central heating system or until the room thermostat/time clock demands for central heating circuit.

2.5 SAFETY DEVICE

In both central heating and domestic hot

water mode safe operating is ensured by a

control board shuts off the main burner if the

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

2.4.3 When domestic hot water is being drawn the burner and pump perform as they do during central heating except that the burner is

OVERALL DIMENSION

Fig. 3

2.5.1 An overheat cut off thermostat acts to turn of the burner to resetable “lockout” (Fig. 27).

2.5.2 A safety valve is ﬁ tted on the central heating

circuit set at 3 bar.

2.5.3 A low water pressure switch set at 0.4 bar is ﬁ tted on heating circuit.

AVAILABLE PUMP HEAD

Fig.4

PRESSURE DROP ACROSS APPLIANCE

Fig.5

7

SECTION 3 TECHNICAL DATA

CSI 120 (T) Low Nox

TABLE 1

NATURAL GAS (G 20) І2H - П2H3+

NOMINAL HEAT INPUT NET QMS 26.0 kW MINIMUM HEAT INPUT NET 5.78 kW

NOMINAL HEAT OUTPUT 25.7 kW NOMINAL HEAT OUTPUT CONDENSING 28.8 kW MINIMUM HEAT OUTPUT 5.72 kW MINIMUM HEAT OUTPUT CONDENSING 6.41 kW

GAS RATE max 2.7 m AFTER 10 MINUTES min 0.6 m

INLET PRESSURE 20 mbar FAN SPEED C.H. Max 5250 rpm Combustion % CO2 : G20 - 9.0 (+ 0.2 / - 0.5)

min 140 rpm with the Case OFF BURNER INJECTORS Nr. 1 x 5.6

ELECTRICAL SUPPLY 230 V ~ 50 HZ POWER CONSUMPTION 160 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

3

/h

3

/h

DRY WEIGHT 40 kg WATER CONTENT C.H. 2.0 litre WATER CONTENT 0.5 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 85°C min 40°C DESIGN FLOW RATE 1383 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/min D.H.W. FLOW RATE 30 °C rise 15.4 l/min D.H.W. FLOW RATE 35 °C rise 13.2 l/min D.H.W. FLOW RATE 40 °C rise 11.5 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 40 °C FAN SPEED D.H.W. Max 6150 rpm min 1410 rpm

Qmw Input Net Max 32.5 kW min 5.78 kW D.H.W. PRESSURE PMW 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 (If required) DESTINATION: AT, DK, Fl, SE CATEGORY I

2H

DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+ FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A

8

SECTION 3 TECHNICAL DATA

CSI 120 (T) Low Nox

TABLE 1/A

LPG (G 30 - G 31) І3+ - П2H3+

NOMINAL HEAT INPUT NET QMS 26.0 kW MINIMUM HEAT INPUT NET 5.78 kW

NOMINAL HEAT OUTPUT 25.7 kW NOMINAL HEAT OUTPUT CONDENSING 28.8 kW MINIMUM HEAT OUTPUT 5.72 kW MINIMUM HEAT OUTPUT CONDENSING 6.41 kW

GAS RATE max G31 0.9 m AFTER 10 MINUTES min 0.4 m

INLET PRESSURE G31 37 mbar G30 28-30 mbar FAN SPEED C.H. Max 4800 rpm Combusiton % CO2 : G31 - 10.2 (+ 0.2 / - 0.5)

min 1320 rpm with the Case OFF G30 - 11.0 (+ 0.2 / - 0.5) BURNER INJECTORS Nr. 1 x 5.6

ELECTRICAL SUPPLY 230 V ~ 50 HZ POWER CONSUMPTION 160 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

3

/h G30 0.7 m3/h

3

/h 0.3 m3/h

DRY WEIGHT 40 kg WATER CONTENT C.H. 2.0 litre WATER CONTENT 0.5 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 85°C min 40°C DESIGN FLOW RATE 1383 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/min D.H.W. FLOW RATE 30 °C rise 15.4 l/min D.H.W. FLOW RATE 35 °C rise 13.2 l/min D.H.W. FLOW RATE 40 °C rise 11.5 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 40 °C FAN SPEED D.H.W. Max 5700 rpm min 1320 rpm

Qmw Input Net Max 32.5 kW min 5.78 kW D.H.W. PRESSURE PMW 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 (If required) DESTINATION: BE, FR CATEGORY I

3+

DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+ FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A

9

SECTION 3 TECHNICAL DATA

CSI 150 (T) Low Nox

TABLE 1

NATURAL GAS (G 20) І2H - П2H3+

NOMINAL HEAT INPUT NET QMS 32.0 kW MINIMUM HEAT INPUT NET 8.0 kW

NOMINAL HEAT OUTPUT 31.7 kW NOMINAL HEAT OUTPUT CONDENSING 34.9 kW MINIMUM HEAT OUTPUT 7.93 kW MINIMUM HEAT OUTPUT CONDENSING 8.73 kW

GAS RATE max 3.4 m AFTER 10 MINUTES min 0.85 m

INLET PRESSURE 20 mbar

3

/h

3

/h

FAN SPEED C.H. Max 5400 rpm Combustion % CO

: G20 - 9.0 (+ 0.2 / - 0.5)

2

min 1590 rpm with the Case OFF BURNER INJECTORS Nr. 1 x 6

ELECTRICAL SUPPLY 230 V ~ 50 HZ POWER CONSUMPTION 160 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 42 kg WATER CONTENT C.H. 2.0 litre WATER CONTENT 0.5 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 85°C min 40°C DESIGN FLOW RATE 1811 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/min D.H.W. FLOW RATE 30 °C rise 20.1 l/min D.H.W. FLOW RATE 35 °C rise 17.3 l/min D.H.W. FLOW RATE 40 °C rise 15.1 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 40 °C FAN SPEED D.H.W. Max 6300 rpm min 1590 rpm

Qmw Input Net Max 42.5 kW min 8.0 kW D.H.W. PRESSURE PMW 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 (If required) DESTINATION: AT, DK, Fl, SE CATEGORY I

2H

DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+ FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A

10

SECTION 3 TECHNICAL DATA

CSI 150 (T) Low Nox

TABLE 1/A

LPG (G 30 - G 31) І3+ - П2H3+

NOMINAL HEAT INPUT NET QMS 32.0 kW MINIMUM HEAT INPUT NET 8.0 kW

NOMINAL HEAT OUTPUT 31.7 kW NOMINAL HEAT OUTPUT CONDENSING 34.9 kW MINIMUM HEAT OUTPUT 7.93 kW MINIMUM HEAT OUTPUT CONDENSING 9.06 kW

GAS RATE max G31 1.3 m AFTER 10 MINUTES min 0.3 m3/h 0.25 m3/h

INLET PRESSURE G31 37 mbar G30 28-30 mbar FAN SPEED C.H. Max 4650 rpm Combusiton % CO2 : G31 - 10.2 (+ 0.2 / - 0.5)

min 1440 rpm with the Case OFF G30 - 11.0 (+ 0.2 / - 0.5) BURNER INJECTORS Nr. 1 x 6

ELECTRICAL SUPPLY 230 V ~ 50 HZ POWER CONSUMPTION 160 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

3

/h G30 0.99 m3/h

DRY WEIGHT 42 kg WATER CONTENT C.H. 2.0 litre WATER CONTENT 0.5 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 85°C min 40°C DESIGN FLOW RATE 1811 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 503 I/min D.H.W. FLOW RATE 30 °C rise 20.1 l/min D.H.W. FLOW RATE 35 °C rise 17.3 l/min D.H.W. FLOW RATE 40 °C rise 15.1 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 40 °C FAN SPEED D.H.W. Max 5850 rpm min 1440 rpm

Qmw Input Net Max 42.5 kW min 8.0 kW D.H.W. PRESSURE PMW 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 (If required) DESTINATION: AT, DK, Fl, SE CATEGORY I

2H

DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+ FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A

11

SECTION 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 boiler log book. You can check your installer by 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. Check the boiler and flue is the correct type for installation.

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.

4.1.1 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. CODES OF PRACTICE/Ref: Documents. Detailed recommendations are contained in the

following British Standard Codes of Practice:

BS6891: Low pressure installation pipes.

BS6798: Installation of gas fired hot water

boilers of rated input not exceeding

70 kW. BSEN12828 BSEN12831 BSEN14336 BS5546: Installation of gas hot water supplies domestic purposes (2ndFamily Gases).

BS5440: 1 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.

Health & Safety Document No.635 The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be

taken, in any way, as overriding statutory obligations.

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 120/150 Low Nox

combination boiler has been tested and examined by BSI, and is certified to comply with PrEN 483 and BS EN 625.

Manufactures instructions must NOT be taken

in any way as overriding statutory obligations.

If in doubt on any point please consult

Ravenheat Manufacturing Ltd.

4.2 LOCATION OF BOILER

4.2.1 Siting of Ravenheat CSI 120/150 Low Nox

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 120/150 Low Nox 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.

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.

12

4.4 IMPORTANT NOTICE

4.6 FLUE SYSTEM

4.4.1 For installation into timber framed buildings,

please refer to the Institute of Gas Engineers

Document IGE/UP/7. 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 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 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 120/150 Low Nox 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.

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. 6).

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

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.

IMPORTANT NOTICE: If the ﬂ ue terminates less a balcony, above the ground, or above a ﬂ at roof to which people have access, then a suitable terminal guard must be ﬁ tted 0001PRO11010/0. Fit only recommended FLUE TERMINAL GUARD by securing concentrically around terminal with screws. Available on request from:

RAVENHEAT Manufacturing Ltd Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - UK

Tel.0044(0)113 252 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 tirnes.

Minimum acceptable spacing from the terminal to obstructions and ventnation opening are speciﬁ ed in Fig. 6.

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

13

Fig.5

Terminal position for fan assisted boiler

(minimum distance) mm

A - Directly below an open window or other 300 opening (e.g. air brick) B - Below gutters, soil pipes or drain pipes 75 C - Below eaves 150 D - Below balconies or car port roof 200 E - From vertical drain pipes and soil pipes 150 F - From internal or external corners 300 G - Above ground or below balcony level 300 H - From a surface facing a terminal 600 I - From a terminal facing a terminal 1200 J - From an opening in the car port (e.g. door window) into dwelling. 1200 K - Vertically from a terminal on the same wall 1500 L - Horizontally from a terminal on the same wall 300 M - From adjacent wall to flue 300

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.

Where installed in a cupboard or compartment

ventilation is not required.

4.8 WATER CIRCULATION (central heating)

4.8.1 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.

4.8.2 Pipework

Copper tubing to BSEN 1057:1 2006,

BSEN 1172, BSEN 1652 and BSEN 1653, 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 The water through the appliance heat exchanger circuit must exceed the min. 2.38 gals/min. (650 It/h) when the burner is firing. It is important to ensure that this rate is achieved when sections of the system are shut off either manually or by automatic controls.

Therefore a by-pass must be fitted to the

system (15 mm min.) (Fig. 6).

If the volume of circulating water is too low, the

boiler water temperature will rise too rapidly. This could cause noise in the system or even cause the safety thermostat to trip.

14

Fig.6

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.

Fig.7

4.8.7 Mains water feed: central heating There must be no direct connection to the

mains water supply, even through a nonreturn valve, without the approval of the Local Water Authority.

4.8.8 Permissible methods of filling

Fig.8

Figure depicts the requirements of Diagram R24.2a of the Water Supply (Water Fittings) regulations 1999.

15

SIZING OF ADDITIONAL EXPANSION VESSEL: TABLE 3

Deduct from the value given in the table the 7 litre vessel supplied.

Safety

valve setting (bar)

Vessel charge

pressure (bar)

Initial system

pressure (bar)

T otal water

content of system

Litres

25 50

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500

3.0

0.5 1.0 1.5

0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0

EXPANSION VESSEL VOLUME (LITRES)

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

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

107.6

115.8

124.1

132.4

140.7

148.9

157.2

165.5

8.3

16.5

24.8

33.1

41.3

49.6

57.9

66.2

74.5

82.7

91.0

99.3

For system volumes other than those given above, multiply the system volume by the factor across

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 pressurisation 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

0.0833 0.140 0.259 0.551 0 .109 0.190 0.412 0.156 0.331

If the boiler is installed in an existing system

any unsuitable additives MUST be removed by thorough cleaning.

BS 7593:2006 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.

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.

WATER TREATMENT This boiler has a stainless steel heat

exchanger Ravenheat recommended only the use of FERNOX- COPAL or SENTINEL X100 water treatment products, which must be

4.8.9 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

Fernox Manufacturing Co. Ltd. Tel 01799 550811 Sentinel Division Betz Dearborn Ltd. Tel. (0151) 424 5351

used in accordance with the manufacturers instructions. For further information contact:

Part 2.

Before installing a new combination boiler to

an existing system, flush out the old system with a recommended descaling agent.

16

SALAMANDER CORROSION GUARD

5.2 DELIVERY

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 competent 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 readly 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

5.2.1 The appliance carton containing

a) boiler fully assembled with ﬂ ue adaptor

b) installation instructions, user instructions and Benchmark log book c) white paper template d) hanging bracket e) guarantee card f ) Polythene bag containing

- 2-22 mm compression ball valves complete with 3/4” washers

- 1-15 mm compression ball valves complete with 1/2” washers

- 1- 15 mm compression ball valve

- 2 coach bolts and wall plugs

- screws and dowels.

5.3 UNPACKING OF BOILER

5.3.1 IMPORTANT: With regards to the Manual

Handling Operations, 1992 Regulations,

the following lift operation exceeds the recommended weight for a one man lift.

5.3.2 - Stand the boiler carton upright.

- Open the top of the carton.

- Rest the carton on the ﬂ oor (keeping the ﬂ aps open).

- Turn the carton over with the boiler inside and then pull tha carton.

- Rest the boiler on the ﬂ oor and remove the polystyrene guards.

5.4 POSITIONING OF THE BOILER

5.4.1 Remove the 2 lower and the 2 upper

screws that secure of the front panel, and then lift off.

5.4.2 Unscrew the 4 screws that fasten the lower grating on the casing and remove it from the bottom of the casing.

5.4.3 Make sure the casing and screws are put to one side in a safe place.

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 inclined 2.5° down towards

the boiler that is 45 mm/m fall per metre of flue length (Fig.9).

IMPORTANT NOTES :

This appliance will produce a plume of

condensation in cool weather. This is due to the High Efﬁ cency and hence low ﬂ ue gas temperature of the boiler. See Optional extras (Fig.12).

Fig.9

17

OPTIONAL EXTRAS: (See Table 7)

HORIZONTAL FLUE KIT BOX CONTAINING (Fig 10):

57 - Flue bend assembly 59 - Rubber seal Ø 60 60 - Sample paint 61 - Flue exhaust duct 62 - Air intake duct 127 - Terminal Rubber wall seal

Fig 10

IMPORTANT :Please, lubricate the internal part of the seals before being fitted.

Generally speaking,oils and greases are not suitable for the “peroxide -EPDM”, therefore we suggest a correct lubrication using silicon-substances, for instance “Silikon Spray“ (Arexons)or the same product from the company “Soltecno s.r.l.”.

WARNING: with horizontal concentric ﬂ ue

FLUE EXTENSION BOX CONTAINING (Fig. 11): 1000 mm ﬂ ue extension duct as an extra cost only when requested for side and vertical ﬂ ue applications.

59 - Rubber seal Ø 60 63 - Air intake duct extension

64 - Flue exhaust duct extension

Fig 11

Maximum allowable ﬂ ue length 8 m maximum,

ﬂ ue duct extension used with standard ﬂ ue.

TYPE OF FLUE SYSTEM (All models) TABLE 6

Flue type C

13

C33 C

53

1

Flue Diameter 60/100 80/125 60/100 80/125 80mm (concentric) (concentric) (concentric) (concentric) single pipe

Minimum length (m) 0.3 0.3 1.0 1.0 0.5 (vertical length) (vertical length) Maximum length (m) 8.0 23.0 13.0 26.0 43.0

Equivalent length of 45° bend (m) 0.5 1.25 0.5 1.25 1.25 Equivalent length of 90° bend (m) 1.0 2.5 1.0 2.5 2.5

18

OPTIONAL EXTRAS:

PLUME MANAGEMENT KIT (Fig 12)

Max 6000 mm ﬂ ue extension duct as an extra cost only when requested to reduce pluming nuisance of condensation from 60/100 horizontal concentric ﬂ ue.

Plume Management Kit

Maximum Length (mm) 6000 minimum length (mm) 500

Equivalent length of 45° bend (mm) 500 Equivalent length of 90° bend (mm) 1000

The Maximum permitted ﬂ ue length is measured from the centre line of the ﬂ ue terminal to the top of the outlet terminal

IMPORTANT : Max ﬂ ue length must not exceed 6 m with a horizontal concentric 60/100 ﬂ ue of 3m ( L )

Plume Management Kit Part No Part. No Description

0019PRO11035/0 Flue Extension 60 L1000 Plume 0019CUR11035/0 90° Elbow bend 60 Plume 0019CUR11040/0 45° Elbow bend 60 Plume 0019TER11025/0 Horizontal terminal 60/100 Plume 0019GRI11020/0 Horizontal elbow header 60 Plume

IMPORTANT :Please, lubricate the internal part of the seals before being fitted.

ACCESSORIES CONCENTRIC FLUE 60/100 EXTRAS:

Part. No Description

TABLE 7

0019PRO11005/0 Flue Extension 60/100 L500 0019PRO11010/0 Flue Extension 60/100 L1000 0019CUR11005/0 45° Elbow bend 60/100 0019CUR11010/0 90° Elbow bend 60/100 0019TER11005/0 Horizontal terminal 60/100 0019GRI11015/0 Horizontal terminal header 60/100 0019TER11010/0 Vertical ﬂ ue Terminal

Fig. 12

19

5.5 INSTALLING THE APPLIANCE FOR

REAR FLUE OUTLET (Fig. 13-14-15-16)

5.5.1 Use adhesive tape to attach the template to

the wall, making sure that the centre line is vertical.

- Mark the two holes for to fix the hanging

bracket on 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 braket and fix by the two coach bolts. Fit the elbow header positioning it towards the required direction (Fig 13).

5.5.2 Make sure that the rubber Ø 60 is locate into

the flue elbow header.

5.5.3 If using horizontal flue duct and it is too long

it can be shortened . Shoud it be necessary to cut the flue, always cut equal amounts from both inner and outer pipes. Always cut the end furthest from the terminal. cut end must de-burred. NOTE : Add 30mm to overall flue length to allow for cover plate. (Fig.10 - item 127).

Fig 13

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 (Fig.13), 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.

Position flue into elbow header and push so as

to locate inner and outer flue correctly ensuring good seal is made with o rings.

5.5.7 Fit terminal cover plate and if necessary terminal guard.

5.5.8 Extensions kits are available to order for flue extension of up to 7 metres total length(Fig.16A).

5.5.9 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of seven extensions.

Pipeline 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 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 pipeline 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 and air intake pipes fits into the boiler header until it stops. (Fig. 16- Fig. 16A).

When cutting both inner and outer ducts of the

extension, always ensure that the reduced end (male) of the inner and outer duct are square and to the same length.

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.

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.

20

5.5.10 IN LINE 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. 18).

IMPORTANT: inline flue bend - 1000 mm

must be deducted from overall length for each 90°bend. Obtuse flue bend - 500 mm must be deducted from overall length for each 135° bend (Table 6).

Fig 14

5.6 COMPLETING BOILER INSTALLATION

5.6.1 Reassemble the outer casing (sect 5.4) in

reverse order.

Fig.15

INTAKE AND EXHAUST TERMINAL COMPONENTS

Fig.16

KEY

56 - Flue adapter 58 - Header gasket 59 - Rubber seal Ø 60 60 - Sample point

61 - STD ﬂ ue exhaust duct 62 - Terminal 63 - Flue extension 64 - Flue exhaust duct extension

IMPORTANT :Please, lubricate the internal part of the seals before being fitted.

Fig.16a

65 - Flue manifold rubber seal 66 - Securing screw 67 - Flue temperature sensor 127 - Terminal Rubber wall seal

128 - Elbow header

21

5.7 INSTALLING THE APPLIANCE FOR SIDE

FLUE OUTLET (Fig. 29)

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.17.

- 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.

- Trace the centre of the flue duct hole measure distance . From the corner of the wall

(Fig. 17), measure the distance (127mm)

between 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.

5.7.2 Positioning the elbow towards the required

direction.

5.7.5 Insert the flue assembly into the wall, making sure it will not interfere when fixing the boiler on the wall.

5.7.6 Lift the boiler on the wall. Locate onto the

wall fixing bracket.

5.7.7 Working above the boiler pull the flue duct

towards the elbow in order to engage tube into its header (Fig.10). Position flue into straight header and push so as to locate inner and outer flue correctly. Ensuring good seal is made with “o” rings.

5.7.8 IMPORTANT: Terminal rubber must be fitted

(Fig. 10).

5.7.9 Extension kits are available see table 6.

5.7.3 Make sure that rubber seal Ø 60 is locate

into the elbow.

5.7.4 If using horizontal flue duct and it is too long it can be shortened. Should it be necessary to cut the flue always.Cut equal amounts from both inner

and outer pipes.

Note : add 30mm to overall flue length to

allow for cover plate.( Fig.10 item127). .

- Remove the centering spring, 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. 15).

- 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.

IN LINE FLUE BEND AND FLUE EXTENSION

Fig. 17

Fig.18

IMPORTANT :Please, lubricate the internal part of the seals before being fitted.

22

128 - In line Flue Bend 59 - Rubber seal Ø 60 63 - Air intake duct extension 64 - Flue exhaust duct extension

5.7.10 VERTICAL FLUE INSTRUCTION ONLY (Fig.19-20-21)

IN LINE FLUE BEND - 1000 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90° BEND OBTUSE FLUE BEND -500 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. 19).

IMPORTANT NOTES : For greater flue length see twin flue or concentric 80/125 flue instructions

Proceed with installation as detailed in section 5 up to 5.5.8., of the main Installation and Servicing Instruction, ignoring all references to horizontal flue installations. 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 virtually below the point at which the flue will exit the roof.

Fig. 19

L + L = 8m Max

Fig. 20

Fig. 21

Straight Flue Straight Flue Offset Flue Offset Flue L = 12.0 m Max L = 12.0 m Max L = 2.0 m Max L = 2.0 m Max plus Terminal plus Terminal (10 Bend 90° Max) (20 Bend 45° Max) plus Terminal plus Terminal

- Ensure that the maximum permissible flue length is not exceeded (Fig. 21).

- Mark the two wall fixing bracket securing

holes on the wall.

- Detach the template from the wall.

- Use a 10 mm dia. drill to make the 2 holes securing fixing hanging bracket.

Insert plastic expansion plugs (Fig. 17).

- Screw in the two coach bolts.

- Position the flue extension and fix the securing screw on the flue adaptor appliance (Fig. 23) item 66, and ensure

that the gasket is correctly fitted. Important: Make sure that the flue

extension dia 60 mm duct is inserted fully

into the flue manifold, and the flue manifold rubber seal is correctly fitted.

23

Fig.23

Fig.24

Fig. 22

Cut a 105 mm diameter hole through the ceiling and/or roof, at the point previously marked. Fit a roof flashing sleeve ( Fig. 23) 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 wall fixing bracket. Measure the vertical distance between the top of the flue (Fig. 22) and the bottom of the flue terminal assembly (Fig. 19). 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, extension can be cut to the required length (Fig. 24). When cutting both inner and outer ducts of the extension, always cut on spigot side, and they must be de-burred.

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. 24). 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.

- Position the flue extension and fix the securing screw on the flue adaptor on the appliance (Fig. 23 item 66), and ensure that the gasket is correctly fitted. Important: Make sure that the flue extension dia 60 mm duct is inserted fully into the flue manifold, and the flue manifold rubber seal is correctly fitted.

24

IMPORTANT :Please, lubricate the internal part of the seals before the assembling.

5.8 REASSEMBLE BOILER AS PER (sect. 5.6.1)

5.8.1 Fitting valve pack

Remove plastic caps from boiler connection and fit valves as per Fig. 25 using washers provided.

5.9 GAS CONNECTION (Fig. 25)

5.13 ELECTRICAL CONNECTIONS

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. 25)

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 and fig. 26.

5.11 DOMESTIC HOT WATER (Fig. 25)

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 Lts per min. Flush out all foreign matter from the supply pipe before connecting to the appliance.

- Connect the 15 mm. cold water pipe to the stop cock to the appliance inlet.

- Connect the 15 mm. hot water pipe to the cock to the appliance inlet.

5.12 SAFETY VALVE DISCHARGE

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 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. 8 (Fig.33), remove the two securing screws on the supporting bracket and lower down, unclip the four plastic tabs and lift off the electrical box cover (Fig.46).

- The terminals are easily visible on the front of the electronic control board (Fig. 48).

- Heat resistant flexible cable is fitted between the isolator and the terminal block

2

A 3 core cable of 0.75 mm

(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 become 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.25

5.12.1 The safety valve is located near the pump. It has a 15 mm copper to permit a discharge pipe to be connected. When connecting ensure the discharge pipe does not restrict access. 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 easily visible position, and 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.

25

5.14 PROGRAMMABLE TIMECLOCK

Instructions for use consult User ’s Guide.

5.15 CONDENSATE DRAIN CONNECTION

5.15.1 The condensate drain connection is between

Gas service cock and Central Heating Flow valve connections (Fig.26). An 25mm

plastic overflow pipe is fitted on the

condensing trap and must 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.

POSITION OF WATER AND GAS CONNECTIONS

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

freelzing 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 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. 26

INSTRUMENT PANEL

Fig. 27

26

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.

- 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.: They safety valve is seat to lift a 3 bars (30 mt/42.5 psing).

- To lower the system pressure to the required value remove drain point (Fig. 29) 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.

6.4 INITIAL FILLING OF THE SYSTEM

Open central heating flow and return valves

Unscrew the cap on automatic air release valve positioned on the top of the pump housing 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 water, free of bubbles, flows out. In the same way release air from any high points in the pipework.

GAS VALVE

Fig. 28

6.7 LIGHTING THE BOILER

Before lighting the boiler 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.

- Push Summer/Winter switch Fig.27 to Winter.

IMPORTANT: Before switching on the boiler

POWER SWITCH FOR THE FIRST TIME when commissioning, turn the heating control knob (Fig.27) DOWN TO ITS MINIMUM setting leaving it at minimum for approx 5 mins to purge air saffely from the boiler heat exchanger.

Fig. 29

27

- Turn control knob (Fig.27) down to its minimum setting.

- Push the power main switch to on (Fig.27)

- The digital display will show water set point temperature in central heating.

- The fan start and after a few second the digital led display will show that the ignition commence.

- NOTES : It maybe necessary to reset the Digital Timer on boiler (if fitted) to start. Put the timer to on position (Fig.27).

-The ignition control will automatically have three attempts , but initially this may be due to air in the gas supply line.If the burner fails to light, the digital led display and fan will stop, and the display will show the lockout code.

-If necessary push the boiler Reset button (Fig.27) and the boiler will restart automatically.

- After the boiler has light, allow to warm at minimum temperature setting to purge any air from the system.

- Once the system has been purged of air turn the control knob (Fig.27) to the desired position. With leak detection fluid test for gas soundness of all gas components and joints.See paragraph 6.14 for regulating the heating circuit control knob.

6.8 CHECK THE GAS PRESSURE

Check the gas mains pressure at the gas valve

test nipple UPSTREAM ( Fig.28 ) with boiler

operating. Check with the Local Gas supplier if the pressure differ significabntly from 20 mbar G20 (natural gas), 37 mbar G31 (propane) and 29 mbar G30 (butane).

IMPORTANT : Any adjustement to the gas valve should only be carried out by a qualified person.

Refer to table 6.10 adjust the maximum level

of CO

by turning the Throttle on the gas

2

valve (Fig.28). Anti-clockwise to increase CO Clockwise to decrease CO

.

2

2.

After any new regulation wait to stabilise

about one minute.

- Replace the sample point screw on the flue manifold ( Fig.1 item 8).

- Replace the front panel of the case.

RATIO BETWEEN FAN SPEED AND HEAT INPUT

Fig. 30

ELECTRODES POSITION

IMPORTANT :The Gas Valve Throttle

adjuster is required to be sealed with tamper proof paint after adiustment.

6.9 COMBUSTION CHECK If a gas carrying components has been

replaced, the combustion of the appliance

should be checked as follows. Remove the front panel of the case. Ensure the boiler and external controls are

calling for heat. Turn on electrical supply. Open the Hot water tap at maximum flow rate.

Wait at least five minutes or until the unit has

reached its operating temperature. Unscrew the test sample screw on the boiler

elbow band (Fig.10 ). Measured the level of

. Check the reading against the

CO

2

corresponding value in sect.3 TECHNICAL

DATA. If adjustment proves necessary then proceed as follows.

28

Fig. 31

Once the process of commissioning the boiler is complete, the commissioning engineer MUST complete his section in the Benchmark log book.

6.10 CHECKING THE FLUE SYSTEM

6.10.1 The flue system should be visually checked for

soundness. Check all connections and fixings are secure and tight.

6.11 CHECKING THE HEATING THERMISTOR

6.11.1 Allow the system to warm up and then turn

the C.H thermistor 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).

6.12 TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW

6.12.1 Put the appliance in summer position with

the (summer/winter) switch (Fig.27).

- Open a domestic hot water tap (preferably

the bath tap). Ensure cold water inlet stopcock is open and the D.H.W. control knob (Fig.27) is set at maximum.

- Digital display show water temperature in demand ( led on).

- If the boiler does not light check that the water flow rate is above the min. required to operate the differential pressure 2 8 Lts./ min. (0.61 gals/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 use 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.

- 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.

- Slowly close the draw off tap to reduce the flow rate to above the min (approx. 2.8 litre/ min).

- Rotate the D.H.W. control knob to ensure it operates at its various setting.

- Close the draw-off tap still further. The burner should stop when the rate falls below about 2.8 litres/min (0.61 gals/min).

6.13 HANDING OVER TO THE USER

6.13.1 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

boiler switch Summer/ Winter and ON/OFF switch,reset and digit display .

- Explain and demonstrate the function of

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 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 SERVICING INSTRUCTIONS

Ravenheat are a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has 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.

Range Rating regulation of Central Heating

Maximum Setting

C.H. Regulations

minimum Setting

Heat Input Fan speed

kW rpm

CSI150 CSI120 CSI150 CSI120

Maximum Setting 32.0 26.0 5400 5250 minimum Setting 8.0 5.78 1590 140

29

7.1 SERVICE FUNCTION

When the jumper JP16 is inserted, “Co” (Control) is visualised on the digital display (fig. 27), no summer and winter leds are ON, only the yellow led is ON when boiler is running. In summer position, with sanitary request, it’ s possible to set the minimun power by R10 trimmer (fig. 50). In winter position, with heating request, it’ s possible to set the maximun CH power by R9 trimmer, while with sanitary request, it’ s possible to set the maximun DHW power by R19 trimmer. Moving the knob of a trimmer the fan speed is visualised flashing for 10 seconds on the digital display (see Technical data section 3).

7.2 ALARM HISTORY

It’ s possible to see the last 10 alarms or anomalies visualised on digital display by pushing the reset button for a least 10 seconds. In this case, when the functionalityis enabled the 3 leds on the panel start flashing. Pushing again the reset button it is possible to view the others errors. After the tenth, pushing again the reset button the first error is visualised. The exit from alarm history is automatic after 10 seconds from last pushing. The writer of the error in the memory locations starts after 1 hours of first continuous power on the board.

- 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.

7.4 TO INSPECT AND CLEAN THE APPLIANCE

7.4.1 Before carrying out cleaning operation,

cover the electrical control panel with a piece of waterproof material to protect it from debris.

Fig.32

7.3 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 year should be adequate.

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.

Data badge position-lower left hand front panel.

- 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 front panel of the case.Operate the appliance by turning the hot water services on to a high water flow, measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point.

7.4.2 Drop down the control panel into the service position.

Unscrew the gas valve from gas pipe

inlet. Disconnect the gas valve electrical plug at the gas valve.

Disconnect the electrical plug leads from

the fan.

Disconnect the electrode leads from the

electrodes.

Remove the five combustion chamber

retaining nuts and gently remove the fan,gas control valve, electrodes and

burner assembly from the combustion

chamber.(Fig.32).

7.4.3 Inspect the heat exchanger for any blockage. Deposits of any material should be brushed away using a soft brush.

NOTE: Do not use brushes with metallic

bristles.

30

7.4.4 Examine internal pipe-work connections and automatic air vent for any water leaks Rectify if necessary.

7.4.5 Examine and remove loose debris from combustion chamber using a soft brush and vacuum cleaner. Carefully flush by spraying water any remaining debris through the condensate trap.(Ensure the water is kept away from electrical components).

7.4.6 Inspect the siphonic condensate trap for

a blockage. Remove the cap at the base of the

condensate trap.

Remove any solid found. Remove the float to clean it.

SECTION 8 REPLACEMENT OF PARTS

8.1 GENERAL

8.1.1 Replacement of parts must be carried out by a competent person.

8.1.2 Before replacing any parts the boiler

should be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler.

8.1.3 After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls.

Any deposits should be flushed out. Reassemble and refit the condensing

trap.

When refitting the cap ensure that a

watertight seal is achieved, but do not

use excessive force.

7.4.7 Examine the spark and sensing electrodes for any mechanical damage, Clean away any debris and check the spark and sensing gap. See Fig.31.

7.4.8 Examine flue duct and flue manifold and ensure that there is no obstruction. Examine the gasket at the entry into the flue manifold.

7.4.9 It is essential that a good seal is made at the outlet to the flue manifold, renew this gasket if there is any sign of damage or deterioration.

7.5 CONVERTING THE APPLIANCE TO DIFFERENT GAS TYPES

7.5.1 Boilers are factory set to work for use with

Natural gas or LPG gas.This is clearly marked on the packing and boiler data badge.

To convert a boiler from one gas to another this operation must be carried out by a qualified competent person, with all necessary equipment.

It will also be necessary to obtain a

data badge conversion kit directly from Ravenheat Manufacturing Ltd.

1- Remove the case. 2 - Check gas mains pressure at the gas valve test nipple upstream (Fig.28) with boiler operating.Sect.6.8. 3 - Adjust Fan Speed as Sect.3 (technical data). 4 - Measure the level of CO2 as Sect.6.9 and adjust to correct data settings information. 5 - Affix new data badge. 6 - Replace in reverse order.

8.1.4 For replacement of parts, the front,side and bottom panel panels of the boiler will need to be removed.

To remove the front panel unscrew the two

screws upper and the two screws lower that securing the front panel to the boiler and lift off.

To remove the bottom panel unscrew the four screws and lift off. To remove the side panels, remove the

front and bottom panels, unscrews the screw below and lift off. (Fig.33) .

Fig.33

31

8.2 TO REMOVE/REPLACE IGNITION CONTROL BOARD

8.2.1 Remove the front casing panel

(sect. 8.1.4).

8.2.2 Detach all the connectors from the ingition control board.

8.2.3 Remove the 2 screws that secure the Ignition control board to the depression chamber, and remove.

8.2.4 Replace in reverse order.

8.3 TO REMOVE/ REPLACE THE

ELECTRODES (Fig.34)

8.3.1 Remove the front casing panel (sect. 8.1.4).

Fig.34

8.4 TO REMOVE/REPLACE THE FAN (Fig. 35-36)

8.3.2 Remove the ignition and/or sensing lead

plug .

8.3.3 Unscrew the two securing screws and put them into a container so that they don’t get lost.

Withdraw the Spark electrode and /or Sensing electrode carefully from the

combustion chamber cover being

careful not to damage the seal.

8.3.4 Replace with new electrode in reverse order. Ensure gap is correct and there

is a good seal when replaced.

8.4.1 Remove front and left hand side panel of the case (sect. 8.1.4).

8.4.2 Unplug plastic plug from the DC fan supply.

8.4.3 Unscrews the four screws that securing fan

to the gas manifold, check the gasket and replace if necessary.

8.4.4 Reassemble in reverse order. Ensure wires are connected correctly.

32

Fig.36

Fig.35

8.5 TO REMOVE/REPLACE THE BURNER (FIG.37)

8.5.1 Remove front casing (sect. 8.1.4).

8.5.2 Unscrew and Gently Remove combustion

chamber cover assembly with gas valve, fan, burner and electrodes from combustion chamber.as in sect. 7.2.2.

8.5.3 Remove the four screws that secure the gas manifold and carefully pull out the burner.

IMPORTANT: THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED.

8.5.4 Replace in reverse order.

8.6.7 Loosen the three heat exchanger securing

screws and clamps remove the heat exchanger.

CAUTION : There will be water in the heat

exchanger.

8.6.8 Carefully ease heat exchanger out. Replace in reverse order, always use a new

oring seals.

Fig.37

8.6 TO REMOVE/REPLACE THE HEAT EXCHANGER.

8.6.1 Remove front casing (sect 8.1.4).

8.6.2 Unscrew and Gently Remove combustion

chamber cover assembly with gas valve, fan, burner and electrodes from combustion chamber as in sect. 7.2.2.

8.6.3 Drain the boiler CH circuit and drain the DHW circuit.

8.6.4 Remove the clip securing the condense pipe out of the bottom of the heat exchanger and pull for to remove the pipe.

8.6.5 Remove the clips securing the flow and return pipes at the heat exchanger.

8.6.6 Unscrews the two nuts that fix the pipes at diverter valve and pump and move away from the heat exchanger.

8.7 TO REMOVE/REPLACE THE IGNITION

CONTROL BOX.

8.7.1 Remove front casing (sect 8.1.4).

8.7.2 Remove ignition and sensing leads and

electrical connections.

8.7.3 Remove the two fixing screws that fasten the ignition control box at the depression chamber.

8.7.4 Replace in reverse order.

Ensure correct wire position.

33

8.8 TO REMOVE/REPLACE GAS CONTROL VALVE AND OR VENTURI PLATE . (Fig.38).

8.8.1 Remove front casing (sect 8.1.4).

8.8.5 Unscrew and gently remove combustion

chamber cover assembly with gas valve, fan, burner and electrodes from combustion chamber.as in sect. 7.2.2.

8.8.2 Drop down the control panel into the service position.

8.8.3 Unplug plastic plug from the DC fan supply and unscrew the gas valve from gas pipe inlet.

8.8.4 Remove the electrical plug from the gas control valve.

Check the position of the gas valve on the

fan.

Fig.38

8.8.6 Remove the three screws, which fix the gas valve and venturi plate at the fan.

8.8.7 Remove the gas valve.

8.8.8 Replace in reverse order.

8.8.9 IMPORTANT : When gas control valve will be re -fitting, check combustion

and adjusted if necessary

CO

see section 6.10.

2

8.9 TO REMOVE/REPLACE COMBUSTION CHAMBER FRONT INSULATION (Fig.60).

8.9.1 Remove front casing (sect 8.1.4).

8.9.2 Remove fan,gas valve and burner

assembly as in sect.7.2.2.

8.9.3 Remove burner and spark/sensing electrodes and replace in reverse order NOTE: THE BURNER WILL REQUIRE A NEW GASKET.

8.10 TO REMOVE/REPLACE COMBUSTION CHAMBER REAR INSULATION.

8.10.1 Remove front casing (sect 8.1.4).

8.10.2 Remove fan,gas valve and burner

assembly as in sect.7.2.2.

34

8.10.3 Remove securing screw and washer in the center of the insulation and withdraw insulation.

8.10.4 Reassemble in reverse order.

8.11 TO REMOVE/REPLACE VIEWING GLASS. (Fig.61).

8.11.1 For access ref. sect. 8.9 (fig.40).

8.11.2 Remove the two screw that securing view

glass bracket.

8.11.3 Remove view glass. .

8.11.4 Remove gasket .

8.11.5 Replace in reverse order.

8.12 TO REMOVE/REPLACE EXPANSION VESSEL (Fig.39).

8.12.1 Remove front casing (sect 8.1.4).

8.12.2 Drain the CH circuit.

8.12.3 Remove at the front the securing bracket.

8.12.4 Unscrew the nut that fix the expasion

vessel, and carefully lift the vessel up and remove.

8.12.5 Replace in reverse order.

NOTE: Always use new gasket and “O”rings.

8.13 TO REMOVE/REPLACE PLATE TO PLATE HEAT EXCHANGER.

8.13.1 Remove front casing (sect 8.1.4).

8.13.2 Close off on/off valves for CH circuit and

DHW circuit and drain the boiler and drain hot water from the lowest hot water tap. .

8.13.3 Unscrews the two screws that connect the DHW heat exchanger and pull it out from the boiler.

8.13.4 If necessary the pipes from the flow manifold may have to be remove for easier access.

8.13.5 Replace in reverse order.

NOTE: Always use new “O”rings.

Fig.39

Fig.40

Fig.41

35

8.14 TO REMOVE/REPLACE FLUE MANIFOLD.

8.14.1 Remove front casing (sect 8.1).

8.14.2 Unscrew and Gently Remove combustion

8.14.3 Remove the heat exchanger as sect. 8.6.

8.14.4 Remove the two securing screws and pull to

8.14.5 Replace in reverse order.

NOTE: Always check the flue oring seal.

8.15 TO REMOVE/REPLACE DIVERTER VALVE

8.15.1 Remove front casing (sect 8.1).

chamber cover assembly with gas valve, fan, burner and electrodes from combustion chamber.as in sect. 7.2.2.

remove the flue manifold.

SWITCH.

8.17.4 Unscrew the C.H.diverter valve as in fig.48.

8.17.5 Replace in reverse order.

NOTE: Always use new o-rings.

8.17.6 Fill the boiler as described in sect.6.4 and check for leasks.

8.17.1 TO REMOVE/REPLACE DHW

DIVERTER VALVE.

8.17.1.1 Remove front and bottom of the casing

(sect 8.1).

8.17.1.2 Close the on/off valve for the DHW circuit and drain the boiler.

8.17.1.3 Remove the flow detector as fig.48.

8.17.1.4 Unscrew the DHW diverter valve as in

fig.68.

8.15.2 Detach the electrical plug and remove the retaining clip.

8.16 TO REMOVE/REPLACE PUMP (Fig.42/43).

8.16.1 Remove front casing (sect 8.1).

8.16.2 Remove lower grill of the casing and lower

the instrument panel with the electrical box.

8.16.3 Detach the supply wire connector from the pump.

8.16.4 Remove the securing clip at the pump manifold.

8.16.5 Remove the securing clip the fastens

the pressure gauge.

8.16.6 Unscrew the nut that fastens the pump

to the CH pipe and remove the pump.

8.16.7 Replace in reverse order.

NOTE : Alway use new seals when re-fitting new pump.

8.17 TO REMOVE/REPLACE C.H.

DIVERTER VALVE.

8.17.1.5 Replace in reverse order.

NOTE: Always use new o-rings.

Fig.42

8.17.1 Remove front and bottom of the casing (sect 8.1).

8.17.2 Close the on/off valves for the heating circuit and drain the water at drain point Fig.29.

8.17.3 Remove diverter valve switch (sect.8.15).

36

Fig.43

..

8.18 TO REMOVE/REPLACE THE CENTRAL HEATING AND/OR DOMESTIC HOT WATER THERMISTOR (Fig.44).

8.18.1 Remove front casing (sect 8.1)and lower the

instrument panel.

8.18.2 Remove the wires that connect the thermistor.

8.18.3 Remove the retainig clip from the pipe.

NOTE: When reconneting the polarity of the wiring to thermistor is unimportant.

8.22 TO REMOVE/REPLACE SAFETY DISCHARGE VALVE.

8.22.1 Remove front casing (sect 8.1).

8.22.2 Close the on/off valves for central Heating

circuit and drain the water from the boiler.

8.22.3 Unscrew the screw below the valve.

8.22.4 Remove the securing clip and remove the

pipe. Detach the valve.

8.18.4 Replace in reverse order.

8.19 TO REMOVE/REPLACE OVERHEAT THERMOSTAT (Fig.44).

8.19.1 Remove front casing (sect 8.1.4).

8.19.2 Remove the two wires that connect to the

overheat thermostat.

8.19.3 Remove the two screws securing the thermostat to the pipe and pull it out.

8.19.4 Replace in reverse order.

8.20 TO REMOVE/REPLACE AUTOMATIC

AIR VENT (Fig.43).

8.20.1 For access ,remove front casing (sect 8.1.4).

8.20.2 Close the on/off valves for C.H. circuit and

drain the water from at drain point. Fig.29.

8.22.3 Replace in reverse order, use a fill the system as described in sect.6.4 and check

for leaks.

8.20.3 Remove the pump see sect.8.16.

8.20.4 Remove the retainig clip.

8.20.5 Pull the automatic air vent from the pump.

8.20.6 Replace in reverse order and check for leak.

NOTE: Fit a new “O” ring.

8.21 TO REMOVE/REPLACE LOW WATER OR DIFFERENTIAL PRESSURE SWITCH -

( Fig. 2 - 45).

8.21.1 Remove front casing (sect 8.1.4).

8.21.2 Close the on/off valves for central Heating

circuit and drain the water from the boiler.

8.21.3 Pull wires off and unscrew the low water pressure switch from pump manifold.

8.21.4 Unscrew the nut at the flow water pressure switch, detach the faston and remove it.

8.21.4 Replace in reverse order, fill the system as described in sect.6.4 and check for leaks.

Fig.44

Fig.45

37

8.23 TO REMOVE/REPLACE TIMECLOCK.

8.23.1 Remove front casing (sect 8.1.4)

and lower the instrument panel.

8.23.2 Remove control board box cover.

8.25.4 Detach the Digital Display board from

panel instruments by unscrewing the four securing screws.

8.25.5 Replace in reverse order.

8.23.3 Pull the two securing clip that fasten the

timeclock to the panel instrument, and pull it out.

8.23.4 Carefully remove the four wires connecting timer by pulling spade connectors from timer.

8.23.5 Replace in reverse order.

NOTE: Ensure all electrical connections

are made correctly.

8.26 TO REMOVE/REPLACE CONDENSING TRAP (Fig.47).

8.26.1 Remove the casing (sect 8.1.4) and

lower the instrument panel.

8.26.2 Remove the securing clip and pull out the plastic pipe that connect the condensing trap at the heat exchanger.

8.26.3 Unscrew the nut that fasten the condensing trap to the depression chamber and remove it.

8.26.4 Replace in reverse order.

8.27 TO REMOVE/REPLACE THE MAIN

SWITCH (Fig. 49).

8.27.1 Remove front casing (sect 8.1.4) and

lower the instrument panel.

8.27.2 Remove the control box cover.

Fig.46

8.24 TO REMOVE/REPLACE CONTROL BOARD (Fig.46).

8.24.1 Remove front casing (sect 8.1.4)

and lower the instrument panel.

8.24.2 Remove control board box cover. (sect.8.13.1).

8.24.3 Detach the connectors from the board.

8.24.4 Detach the PCB board from its base by

unscrewing the four securing screws.

8.24.5 Replace in reverse order.

NOTE: When refitting the control panel

ensure the leads are not trapped.

8.25 TO REMOVE/REPLACE DIGITAL DISPLAY BOARD (Fig.46).

8.25.1 Remove front casing (sect 8.1.4)

and lower the instrument panel.

8.25.2 Remove control board box cover.

8.27.3 Pull off the switch knob. Remove

the switch out from the instrument panel by pressing the clamp springs.

8.27.4 Detach the wires that connect to the switch, make sure that these wires are later reconnected to the same poles.

8.27.5 Replace in reverse order.

8.28 TO REMOVE/REPLACE THE WATER PRESSURE GAUGE (Fig. 49).

8.28.1 Remove front casing (sect 8.1.4) lower

the instrument panel and remove lower panel of the case.

8.28.2 Close the on/off valves for the heating circuit and drain the water at the drain point Fig.51A. Remove the retaining clip.

8.28.3 Remove the pressure gauge from the instrument panel by pressing its fastening springs.

8.28.4 Replace in reverse order.

8.25.3 Detach the connectors from the board.

38

8.29 TO REMOVE/REPLACE FLUE TEMPERATURE SENSOR (Fig. 1).

C.H.Diverter valve switch

8.29.1 Remove front casing (sect 8.1.4).

8.29.2 Detach the electrical plug and unscrew

the sensor.

8.29.3 Replace in reverse order.

Flow detector switch

DHW Diverter valve

Fig.47

C.H.Diverter valve

Fig.48

8.30 TO REMOVE/REPLACE TEMPERATURE FLUE SENSOR (Fig. 1).

8.30.1 Remove front casing (sect 8.1.4).

8.30.2 Pull wire off an unscrew the sensor.

8.30.3 Replace in reverse order.

8.31 TO REMOVE/REPLACE MANUAL AIR VENT (Fig. 1).

8.31.1 Remove front casing (sect 8.1.4).

8.31.2 Unscrew the manual air vent and

replace in reverse order.

8.32 EXTERNAL HEATING CONTROLS (Fig.49/A).

8.32.1 Remove front and bottom of the casing

(sect7.3).

8.32.2 Remove the external wire link on the PCB box.

8.32.3 Replace with external wire controls.

Fig.49

Fig.49/A

39

SECTION 9

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.

- Select “Winter”.

- Central Heating control knob to maximum.

- Ensure external controls calling for heat (Room stat/Timeclock/TRV).

Does heating LCD on digital display illuminate

Yes

Does the pump run

Yes

Is the burner LCD illuminate on digital display

Yes

No

Is 230 at L-N connections on control board

Yes

Is low pressure in the system

Yes

Re-pressure the system

Is

17 displayed

No

Is 01 displayed

No

Is 28 displayed

No

Is 12 displayed

No

Is 04 displayed

No

Check/Replace

No

Replace On/Off Switch

Is 230V at pump

No

Is there continuity at summer/winter switch

Yes

external Fuse and supply

No

Yes

FAILED FAN SEQUENCE

- Check Fan Voltage

FAILED IGNITION SEQUENCE

- Check condensate drain if is not blocked

- Check gas valve operation

- Check the fan starts

- Check Ignition control board and cables

FAILED LOW WATER /DIFFERENTIAL

PRESSURE SWITCH OR PUMP

- Check /Replace Low water pressure switch

- Check pump

- Check system pressure

FAILED HEATING SENSOR

- Check / Replace heating sensor

FAILED OVERHEAT

- Check the overheat thermostat

Yes

No

Check/Replace pump if necessary

Replace summer/winter switch

Check /Replace Timeclock if OK Replace control board

Does boiler go off before set point

No

40

Is 30 displayed

Is 31 displayed

Is 02 displayed

Yes

- Check Domestic Hot Water

- Check if the system has been purge of air

- Check / Replace Automatic air vent

No

Yes

FAILED FLUE TEMPERATURE

- Check operating system

FAILED FLUE TEMPERATURE

- Check / Replace ﬂ ue sensor

FAILED TEMPERATURE

Reset the boiler

RESET THE BOILER

- Push the Reset button on Digital Display and check LCD if illuminate

NOTE : See Section 10 for LED DISPLAY CODE

FAULT FINDING DOMESTIC HOT WATER

Before continuing it may be necessary to see Central Heating Fault Finding (Sect.9):

- 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.

- Select “Summer” (Fig.50 item 1A).

- Domestic Hot Water control knob to maximum.

- Open Domestic hot tap close to the appliance.

Ensure Domestic Hot Water ﬂ ow is min. of 3 l/min

Yes

Does DHW LCD on digital display illuminate

Yes

Does the burner

LCD illuminate on

digital display

No

Check ﬁ lters are clean

Is low pressure in the system

Yes

Re-pressure the system

06 displayed

Is

No

Is

12 displayed

No

Is 28 displayed

No

Is

30 displayed

No

Yes

Check Microswitch on shunt valve being operate mechanically

No

Check/Replace diverter valve

FAILED DHW SENSOR

- Check /Replace DHW sensor and cables

FAILED HEATING SENSOR

- Check / Replace heating sensor

FAILED LOW WATER PRESSURE SWITCH

- Check /Replace Low water pressure switch

- Check system pressure

FAILED FLUE TEMPERATURE

- Check operating system

Yes

Check/Replace diverter valve

Yes

Does the DHW temperature stabilise at set point

Yes

END OF DOMESTIC HOT WATER TEST

No

Is 31 displayed

No

Is 02 displayed

Check / Replace DHW potentiometer

Yes

NOTE : See Section 10 for LED DISPLAY CODE

FAILED FLUE TEMPERATURE

- Check / Replace ﬂ ue sensor

FAILED TEMPERATURE

Reset the boiler

RESET THE BOILER

- Push the Reset button on Digital Display and check LCD if illuminate

No

Check / Replace DHW sensor

41

SECTION 10 ELECTRICAL SYSTEM DIAGRAM

42

Fig. 50

SECTION 11 INSTALLATION INSTRUCTIONS FOR ALTERNATIVE FLUE SYSTEM

11.1 INSTALLATION INSTRUCTIONS FOR TWIN FLUE PIPE (ECCENTRIC FLUE DUCT SYSTEM)

Part. No Description 0019SDO11005/0 Twin ﬂ ue header F80/F80

0019PRO11020/0 Straight pipe L.1000 d80 0019CUR11015/0 90° Elbow d80 0019CUR11020/0 45° Elbow d80 0019GRI11005/0 Air inlet terminal d80 0019GRI11010/0 Exhaust terminal d80 0019TER06011/0 Vertical eccentric ﬂ ue Terminal

11.1.1 TWIN FLUE INSTRUCTIONS This part of the installation manual covers the

installation and ﬁ xing instructions of the twin

Fig. 51

IMPORTANT :Please, lubricate the internal part of the seals before being fitted.

IMPORTANT These instructions must be read in

conjunction with the main installation and servicing instructions. As with all ﬂ ues the kits must be installed taking due account of the current issue of BS 5440 parts 1 & 2 and timber frame housing DM2 is referenced to the Institute of Gas Engineers Document IGE/UP/7. 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.

ﬂ ue eccentric ﬂ ue duct systems only. When ordering twin ﬂ ue it must be stated for CSI 120/150 Low Nox range. Typical installation procedures are illustrated by drawings.

Before ﬁ xing the twin ﬂ ue system the existing Remove the front panel of the case(sect.8.1). Unscrew the screw (Fig.16 item 66) on the Flue adapter.

Make sure that the Flue manifold rubber seal is locate into the ﬂ ue manifold, and lubricate the internal part of the seal before assembly (see sect. 4.6). Locate the header gasket on the twin ﬂ ue header and push into the ﬂ ue adaptor (Fig.16 item 56) making sure that the inner plastic exhaust locates ﬁ rmly in the outlet spigot of the ﬂ ue manifold, and screw the securing screw that secure the twin ﬂ ue header on the

boiler. Locate the 2 x 80 mm ‘O’ rings in the twin flue header and lubricate the internal part of the seal before assembly to ensure easy snug ﬁ t.(see sect. 4.6)

Figures show the versatility of this flueing

system. Measurements and bends must be

calculated correctly so as not to oversize

maximum flue lengths.

All located ‘O’ rings must be lubricated with

a silicone grease to ensure easy, snug fit.

NOTE: Exhaust flue must slope 2.5° down

towards the boiler 45 mm/m fall per metre of

flue length.

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.

43

IMPORTANT:

- See Fig. 6 and 42 for terminal clearances.

- The pressure loss see table 6.

IMPORTANT NOTICE:

- inlet and exhaust terminals must never be installed on opposite walls of the building (PrEN 483).

- If the ﬂ ue terminates less than 2 m above a balcony, above

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

- Fit only recommended ﬂ ue terminal guard by securing concentrically around terminal with screws.

11.1.2

11.1.3

11.1.4

Fig. 52

Exhaust/suction system with two separate rated 80 dia. Pipes - exhaust on ﬂ at or sloping roof, suction from vertical wall ( Fig.52). .

Maximum distance D = L + L1 = 40.5 metre + Terminal Minimum total length = 2 metre NOTE: Exhaust ﬂ ue must slope 2° down towards the boiler 35 mm fall per metre.

Exhaust/suction system with concentric pipes for ﬂ at or sloping roofs. Extensions with two separate pipes ( Fig.51 ).

Maximum distance : T= L = 21+21 = 42 metre+Terminal Minimum distance : L = 0.5+0.5=1metre + Terminal

Exhaust terminal must not be cut.

NOTE:

- If bends are used in the exhaust ﬂ ue then horizontal

- sections must be avoided and there must be a 2° slope

- towards the boiler 35 mm fall per metre.

Exhaust/suction system with two separate pipes through a single vertical wall ( Fig.53 ).

Maximum distance : D = L + L1 = 37 metre Minimum distance : D = L + L1 = 1 metre Min distance between pipe 50 mm.

Fig. 53

IMPORTANT: Please, lubricate the internal part of the seals before being fitted.

Available on request from: RAVENHEAT MANUFACTURING LTD Chartist Way,Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0044(0) 113 252 7007

44

11.2 INSTALLATION INSTRUCTIONS FOR CONCENTRIC 80/125 FLUE SYSTEM

11.2.1 The vertical 80/125flue kit is intended for use

where a horizontal 60/100 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. 54).

IMPORTANT:

- See Fig. 54 and 55 for terminal clearances.

- The pressure loss see table 6.

IMPORTANT NOTICE:

- When using our vertical ﬂ ue kit the 125mm x 100 reducer is supplied complete with the vertical terminal simply remove this and ﬁ x it into the ﬂ ue adaptor on the top of the boiler.

Fig. 55

Fig. 54

L + L = 23.5m Max

Straight Flue Straight Flue 90° Offset Flue 135° Offset Flue L = 25 m Max L = 25 m Max L = 21.0 m Max L = 22.5 m Max plus Terminal plus Terminal plus Terminal plus Terminal

NOTE : If using Flue arrangement in Fig.54 then the 125x100 Flue reducer must be purchased separately.

IMPORTANT: Please,

Part No Description 0019PRO11030/0 Flue Extension 80/125 L1000

lubricate the internal part of the seals before being fitted.

0019PRO11025/0 Flue Extension 80/125 L500 0019RID11005/0 125/80 to 100/60 Flue reducer 0019CUR11025/0 45° Flue bend 80/125 0019CUR11030/0 90° Flue bend 80/125 0019TER01005/0 Horizontal Flue Terminal 80/125 0019TER11010/0 Vertical Flue Terminal 80/125

Available on request from: RAVENHEAT MANUFACTURING LTD Chartist Way,Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0044(0) 113 252 7007

0019TEG06005/0 Flashing sleave

45

SECTION 12

SPARE PARTS

46

4

RAVENHEAT CSI 120/150 (T) LOW NOX

HIGHT EFFINCENCY CONDENSING COMBINATION BOILER

SHORT LIST OF SPARE PARTS

Pos. Ravenheat

G.C.

Description

Part. No.

1 0014PAN11020/0 Instrument panel 2 0012INT11005/1 Main - Summer/Winter switch 3 0012POT11005/0 DHW / CH Potentiometer assembly 4 0006IDR11005/0 Overheat thermostat 5 0012ORO01010/0 Digital timer 6 0012CIR11030/0 Digital display 7 00PAN11020/0 Instrument panel 8 0012FUS01015/0 Internal fuse 3.15 A

9 10

11 0004VAS13005/0 Expansion vassel 12 0002COL11005/0 Flue gas exhaust manifold 13 0007TER11035/0 Temperature ﬂ ue sensor 14 0003BRU11005/0 CSI120 burner

14.1 0003BRU11010/0 CSI150 burner 15 0002COP11005/0 Heat exvhanger cover assembly

15.1 0012CAN11005/0 Spark electrode

15.2 0012CAN11010/0 Sensing electrode 16 0007TER08010/0 Overheat thermostat 17 0007TER05006/0 C.H. sensor 18 0012GEN11010/0 Spark igniter 19 0014RAC11005/0 Condensing trap 20 0012VEN11015/0 CSI120 fan

20.1 0012VEN11010/0 CSI150 fan 21 0008VAL1005/0 CSI120 valve gas

21.1 0008VAL11015/0 CSI150 valve gas 22 0002SCA11035/0 D.H.W. heat exchanger 23 0011GRU11005/0 Flow manifold 24 0008VAL01018/1 Safety relief valve 25 0007TER05005/0 D.H.W. sensor 26 0012RIV11005/0 Flow detector 27 0012MOT11005/0 Diverter valve switch

0012CIR11025/0 Control board 0009CIR13005/0 Circulation pump

Part. No.

47

Pos. Ravenheat

Part. No.

28 0011OTT11005/0 By-pass 29 0005PRE05010/1 Low water pressure switch 30 0005PRE11015/0 Differential pressure switch 31 0011GRU11010/1 Return manifold 32 0013ORI11045/0 DHW Heat exchanger O”ring” 33 0013ORI11005/0 Valv. gas / Mixer O”ring” 34 0013ORI11035/0 Pump / Manifold O”ring” 35 0013ORI11015/0 Pump / press.gauge O”ring” 36 0013ORI11025/0 Pipe O”ring” 37 0012CAV11012/0

G.C. Part. No.

Description

Spark

cable

48

Chartists Way, Morley, Leeds, LS27 9ET

Telephone : 0044(0)113 252 7007 Tfax : 0044(0)113 238 0229 Website : www.ravenheat.co.uk E-mail : sales@ravenheat.co.uk

Ravenheat reserves the right to make changes and

improvements in our products which may affect the accuracy

of the information contained in thi leaﬂ et.

COD 0017LIB11010/2 - 01/2011

50

INSTALLER NOTIFICATION GUIDELINES

A change to Building Regulations (England and Wales) requires the installer to notify

when installing a heating appliance, as from 1st April 2005.

Install and commission

this appliance to

manufacturers' instructions

Complete the

Benchmark Checklist

Competent Person's

SELF CERTIFICATION SCHEME

If you notify via

Gas Safe Register they will

then notify the relevant Local Authority Building Control (LABC) scheme

on members behalf

Gas Safe Register Engineers

log on to the engineers section

of the website at

www.gassaferegister.co.uk

or telephone

0800 408 5577

You must ensure that the

notification number issued by

Gas Safe Register is written

onto the Benchmark Checklist

Gas Safe Register will record the

data and will send a certificate

of compliance to the property

Choose

Buildings Regulations

notification route

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

BUILDING CONTROL

Contact your relevant

Local Authority

Building Control (LABC) who

will arrange an inspection

or contact a government

approved inspector

LABC will record the data

and will issue a

certificate of compliance

51

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

The code of practice for the installation, commissioning & servicing of gas central heating

Installation, Commissioning and Service Record Log Book

CUSTOMER DETAILS

NAME ADDRESS

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 certiﬁ cate 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 ADDRESS INSTALLER’S NAME

CORGI REGISTRATION DETAILS

NAME ADDRESS

CORGI REGISTRATION DETAILS

REG No.

COMMISSIONING ENGINEER

REG No.

(IF DIFFERENT)

TEL No.

INSTALLATION DATE

TEL No.

CORGI ID SERIAL No.

COMMISSIONING DATE

TEL No.

CORGI ID SERIAL No.

BOILER

MAKE AND MODEL APPLIANCE SERIAL No.

LOCATION

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

If yes, and if required by the manufacturer, has a water scale reducer been ﬁtted?

4. THERMOSTATIC RADIATOR VALVES FITTED

5. AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

6. BOILER INTERLOCK PROVIDED

PLEASE FOLLOW THE INSTALLATION AND COMMISSIONING INSTRUCTIONS IN THE INSTALLATION MANUAL SUPPLIED WITH THE EQUIPMENT

NEW SISTEM

SEDBUK No. %

or REPLACEMENT BOILER

FOR ALL BOILERS

HAS THE SYSTEM BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS?

CONDENSING BOILERS ONLY

HAS AN INHIBITOR BEEN USED?

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

WHICH INHIBITOR WAS USED?

If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation ﬁtted? Yes

For the central heating mode, measure and record:

HEAT INPUT BURNER OPERATING PRESSURE

CENTRAL HEATING FLOW TEMPERATURE

CENTRAL HEATING RETURN TEMPERATURE

YES

NO

WHAT WAS THE CLEANSER USED?

YES

NO

kW

°C

mbar

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

YES NO

%

The content of this Log Book has been produced in

consultation with

Benchmark is supported by

For the domestic hot water mode, measure and record:

HEAT INPUT MAXIMUM BURNER OPERATING PRESSURE

MAXIMUM OPERATING WATER PRESSURE bar COLD WATER INLET TEMPERATURE HOT WATER OUTLET TEMPERATURE WATER FLOW RATE AT MAXIMUM SETTING

kW

mbar

°C °C

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 conﬁ rm demonstrations of equipment and receipt of appliance instructions)

It is recommended that your heating system is serviced regularly and that your service

engineer completes the appropriate Service Interval Record below.

Before completing the appropriate Service Interval Record below, please ensure

you have carried out the service as described in the boiler manufacturer’s instructions

Always use the appliance manufacturer’s speciﬁ ed spare part when replacing gas controls.

SERVICE 1 DATE: