Ravenheat CSI 85, CSI 85T User Manual

CONDENSING SYSTEM INNOVATION AUTOMATIC MODULATING BOILER

FOR CENTRAL HEATING AND DOMESTIC HOT WATER

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

POSITION

The appliance is extremely versatile as it can be fitted in almost any room. The appliance is room sealed, there is no contact

between combustion chamber and living accommodation. This guarantees maximum safety and efficiency. Indeed, our
depression/combustion front cover has been designed to fit, achieving maximum air tight seal using screw down fasteners at
15 cm. This should not hinder service of the appliance, but does ensure maximum efficiency and safety - something which
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 [phone].

BASIC COMPONENTS - (See figure 1)

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

and relevant codes of practice.

- Gas valve with flame modulator.

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

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

- Primary heat exchanger constructed from copper.

- Unique patented condensing heat exchanger for high thermal flue transfer gases to water.

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

- Highly reliable diverter valve with ethylene propylene diaphragm permitting primary flow circulation
in the boiler during domestic hot water supply.

- Built in frost protection.

- Printed circuit board designed to connect to room stat and/or timer/frost stat. Aesthetically pleasing
panels and controls.

- On/Off ball valves for shutting off gas central heating and domestic hot water circuit Safety relief
valve (for safety discharge).

Programmable 7 day module with digital display (optional model).
All front panel controls not often used have been hidden. This achieves simplicity of operation with easy to clean

panels.

MAJOR COMPONENTS

NOTE: Due to the high efficiency of this boiler a plume of water vapour will form at the flue

terminal during operation.

COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH

IMPORTANT

This appliance contains materials that are indicated below.
It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is-worn when han­dling, where applicable, the pertinent parts that contain any materials that cót3ld 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

1
2

3
4
5
6
7
8

9
10
11

TABLE OF CONTENTS

INTRODUCTION
DESIGN PRINCIPLES AND
OPERATING SEQUENCE
TECNICAL DATA
GENERAL REQUIREMENTS
INSTALLATION
COMMISSIONING
SERVICING INSTRUCTIONS
FAUL FINDING
ELECTRICAL SYSTEM DIAGRAM
EXPLODED PARTS DIAGRAM
LIST OF SPARE PARTS

PAGE

6

6

8-9

6
15
26
30
39
40
45
46

KEY

1 - Heat exchanger
2 - Heat exchanger for D.H.W water
3 - Burner
4 - Sensing electrode
6 - Condensing heat exchanger

9 - Ignition electrode
11 - Frame
12 - Modulating gas valve
15 - Heating control
22 - Overheat cut off thermostat

4

16 - Hot water control
17 - D.H.W. sensor
18 - Water pressure switch (heating circuit)
23 - Safety relief system
24 - Three way valve
26 - Auto air vent valve
28 - Pressure switch
29 - Circulation pump
30 - Water pressure gauge
33 - Main switch

34 - C.H. sensor
35 - Condensing trap
36 - Fan
37 - Expansion tank
38 - Sealed chamber
45 - Combustion chamber

50 - Flue gas exhaust hood
105 - Timer
106 - Flue restriction ring

KEY

1 - Heat exchanger
2 - Heat exchanger for D.H.W water
3 - Burner
4 - Sensing electrode
5 - Flue restriction ring
6 - Condensing heat exchanger
8 - Condensing trap
9 - Ignition electrode

10 - Condensate sensor

12 - Modulating gas valve
15 - Heating control potentiometer
16 - Hot water control potentiometer
17 - Water pressure switch
18 - Overheat cut-off thermostat
20 - Gas service cock
21 - Compression ball valves
23 - Safety relief system
24 - Three way valve
25 - Flow regulator

26 - Auto air vent valve
27 - Pressure switch giving priority
28 - Pressure switch
29 - Circulating pump
30 - Water pressure gauge
36 - Fan
37 - Expansion tank
38 - Sealed chamber

5

SECT ION 1 INTRODUCTION

1.1 The Ravenheat boiler is for the use of central

and domestic hot water combined in one unit.

It is fitted with an automatic domestic hot

water priority valve.

A am / (winter/summer)selector

switch is fitted to the left hand side of control
panel.With the only (summer) position
being for domestic hot water.

position being for central heating

with domestic hot water priority. The boiler
is equipped with a front cover which can be
removed for servicing The data badge with
technical data is placed on the lower right
hand side of the frame

1.2 Fig . 1 I l lustrates the g eneral layout of
com p o nents.

Fig . 2 Illust r a tes the op erating

pri n c iples de s c ribed in s e ction 2.

SECT ION 2

2.1 DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION

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 but with slightly differing
time delay in that it will start on minimum
and remain at this level for about 1 minute,
after which the flame will lift to its maximum
setting as governed by a potentiometer
range rates the heating circuit between
maximum and minimum power. As the
heating sensor reaches temperature the
gas burner power modulates down, the fan
speed when always start at maximum speed.

2.2.8 On the control panel are mounted two
potentiometers (thermostats) these control
the temperature. One is for domestic hot
water and the other for heating

2.2.9 The boiler is fitted with an anti-cycling device
on the control board. This delays the boiler
from re-firing over a 2 5 minute period when
in heating mode. The domestic hot water will
always take priority and is unaffected by the
anti-cycling device

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 tap position,
with the heating circuit charged with water
(above 1 bar). If the domestic hot water
tap is turned on, the boiler will function in
the following sequence:

2.2.1 The pump starts.
The control board sensors.
The fan operates via the pressure switch and

sends a signal back to the ignition board that the
fan is running at maximum speed

2.2.2 The spark ignition system is powered which in
turn commences the spark igniter to operate
and light the burner.

At this point the ignition board opens the gas

valve to light the burner.

2.2.3 When the electrode/sensor senses the signal
of the burner, the spark igniter stops.

2.2.4 From the minimum gas rate setting the
boiler increases to the maximum permissible
pressure over a period of 3 to 4 seconds and
will remain at its maximum required power
until its maximum regulated temperature.

2.2.5 When the domestic hot water tap is closed the
diverter valve goes back into rest mode, the
main burner is shut down along with the pump
and fan whitch are also switched off.

The pressure switch returns to its rest mode

2.2.6 Central heating mode

2.2.7 If the switch is positioned on am

with a demand for heat to supply radiators,

GENERAL FUNCTION

2.3 Central Heating Mode

2.3.1 A potentiometer installed on the electric circuit

board permits regulation of the boiler to partial
heating requirements, between maximum and
minimum settings.

2.3.2 Air is drawn by the fan for combustion

2.3.3 The fan also forces exhaust gas through the flue

to the outside, this creates a lesser pressure in
the sealed combustion chamber, thus sucking
in combustion air, through the inlet duct.

2.3.4 The boiler water temperature is automatically
controlled by a built in thermostat

2.3.5 Interior space temperature is set by the room
thermostat to be installed in the heating
system. The boiler already carries connection
terminals for this thermostat, as well as for a
timeclock The burner continues to operate
until it is stopped by the timer or one of the
thermostats

2.3.6 When the internal C.H temperature sensor
intervenes the main burner shuts down. The
fan stops but the pump continues to operate.

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

2.3.8 The condensate trap is fitted with a blockage
safety sensor. This prevents the boiler
operating should there be a blockage in the
condensate discharge trap.

6

2.4 Domestic hot water mode

2.4.1 The heat exchanger in the D.H.W. circuit

is built into the main heat exchanger, and
domestic water is heated by converting
the water in the central heating circuit The
transference of heat is very high because the
two fluids move in a counter direction flow to
each other.

2.4.2 Switch 33 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.

2.4.3 When domestic hot water is being drawn the
main burner and pump perform as they do
during central heating except that the burner
is commanded by the D.H.W. thermostat.

2.4.4 When D.H.W. is no longer called for the boiler
automatically returns to the central heating
mode

2.4.5 Switch 33 in the (summer) position The
boiler functions like an automatic gas hot water
heater When D H.W. is no longer required the
main burner fan and pump immediately turn
off.

This also takes place when switch 33 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.

3.1 SAFETY DEVICE

In both central heating and domestic hot

water mode safe operating is ensured by:

A differential pressure switch shuts off the

main burner if the fan stops or the flue or
combustion air intake duct is obstructed

3.1.2 An overheat cut off thermostat set slightly
higher than the high limit thermostat acts
to turn of the burner to resetable “lockout”
(Fig. 50) item 3.

3.1.3 A safety valve is fitted on the
central heating circuit set at
43 psi (3 bar)

3.2.1 A heating circuit (low water)
pressure switch is set at 0 4
bar

7

SECTION 3 TECHNICAL DATA

CSI 85 - CSI 85T

TABLE 1

NATURAL GAS (G 20) І2H - П2H3+

NOMINAL HEAT INPUT NET QMS 22.6 kW
MINIMUM HEAT INPUT NET 11.6 kW

NOMINAL HEAT OUTPUT 22.3 kW
NOMINAL HEAT OUTPUT CONDENSING 23.9 kW
MINIMUM HEAT OUTPUT 11.4 kW
MINUMUM HEAT OUTPUT CONDENSING 12.3 kW

GAS RATE max 2.3 m3/h
AFTER 10 MINUTES min 1.2 m3/h

INLET PRESSURE 20 mbar

BURNER PRESSURE C.H. max 10.5 mbar

min 2.0 mbar

MAIN BURNER INJECTORS Nr. 13 x 1.25
ELECTRICAL SUPPLY 230 V ~ 50 HZ
POWER CONSUMPTION 150 W
EXTERNAL FUSE RATING 3A
INTERNAL FUSE 2 A (20 mm to BS 4265)

DRY WEIGHT 51 kg
WATER CONTENTC.H. 2.1 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 copper pipe
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION DRAIN 3/4” (21.5 mm) push fit over flow
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE
SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85°C MIN 45°C
DESIGN FLOW RATE 1073 I/h 20 °C RISE
MINIMUM FLOW RATE C.H. 503 I/min
D.H.W. FLOW RATE 30 °C rise 12.3 l/min
D.H.W. FLOW RATE 35 °C rise 10.5 l/min
D.H.W. FLOW RATE 40 °C rise 9.2 l/min

D.H.W. TEMPERATURE max 65 °C min 35 °C
BURNER PRESSURE D.H.W max 11.2 mbar min 2.0 mbar

QMw Input Net max 26 kW min 11.6 kW
D.H.W. PRESSURE max 10 bar (147 p.s.i.)
D.H.W. PRESSURE PMW min 0.8 bar (118 p.s.i.) To obtain heat input 1.2 bar
D.H.W. MINIMUM FLOW RATE 3 I/min
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: AT, DK, Fl, SE, CATEGORY I2H
DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+
FLUE TYPE - C12 - C32 - C52 NOX 4

8

SECTION 3 TECHNICAL DATA

CSI 85 - CSI 85T

TABLE 1/A

LPG (G 30 - G 31) І3+ - П2H3+

NOMINAL HEAT INPUT NET QMS 22.6 kW
MINIMUM HEAT INPUT NET 11.6 kW

NOMINAL HEAT OUTPUT 22.3 kW
NOMINAL HEAT OUTPUT CONDENSING 23.9 kW
MINIMUM HEAT OUTPUT 11.4 kW
MINUMUM HEAT OUTPUT CONDENSING 12.3 kW

GAS RATE max G31 0.9 m3/h G30 0.7 m3/h
AFTER 10 MINUTES min 0.4 m3/h 0.3 m3/h

INTERNAL PRESSURE G31 37mbar G30 28-30 mbar

BURNER PRESSURE C.H. max G31 35.4mbar G30 27.3 mbar

min 7.3 mbar 7.0 mbar

MAIN BURNER INJECTORS Nr 13 x 0.75
ELECTRICAL SUPPLY 230 V ~ 50 HZ
POWER CONSUMPTION 150 W
EXTERNAL FUSE RATING 3A
INTERNAL FUSE 2 A (20 mm to BS 4265)

DRY WEIGHT 51 kg
WATER CONTENTC.H. 21 litre
WATER CONTENT 05 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
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION DRAIN 3/4” (21.5 mm) push fit over flow

MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE

SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS 25 bar
MINIMUM WORKING PRESSURE 05 bar
6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 05 bar

CENTRAL HEATING OPERATING TEMPERATURE MAX 85°C MIN 35°C

DESIGN FLOW RATE 1102 I/h 20 °C RISE
MINIMUM FLOW RATE C.H. 503 I/min
D.H.W. FLOW RATE 30 °C rise 12.3 l/min
D.H.W. FLOW RATE 35 °C rise 10.5 l/min
D.H.W. FLOW RATE 40 °C rise 9.2 l/min 10°C inlet temperature

D.H.W. TEMPERATURE max 65 °C min 35 °C
BURNER PRESSURE DH.W max 35.4 (G31) mbar min 7.3 (G31)-7 (G30)

Qmw Imput Net max 27.3 (G30) mbar min 11.6 kW
D.H.W. PRESSURE max 10 bar (147 p.s.i.)
D.H.W. PRESSURE PMW min 0.8 bar (11.8 p.s.i.) To obtain heat input 1.2 bar
D.H.W. MINIMUM FLOW RATE 3 I/min
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: BE, FR CATEGORY I2H+
DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+
FLUE TYPE - C12 - C32 - C52 NOX 4

9

SECTION 4 GENERAL REQUIREMENTS

4.0.1 SAFETY
Gas Safety (Installation and Use)

Regulations, 1994 and amended 2000.

It is law that all gas appliances are installed

and serviced by a CORGI registered installer
in accordance with the above regulations
and these installation instructions. All CORGI
registered installers carry a CORGI I.D. card
and have a registration number. Both should
be recorded in your boiler log book. You can
check your installer by calling CORGI direct
on: 01256 732300. 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 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 mms.

CODES OF PRACTICE/Ref: Documents

Detailed recommendations are contained in the

following British Standard Codes of Practice:

BS.6891 Low pressure installation pipes.

BS.6798 Installation of gas fired hot water
boilers of rated input not exceeding
60 kW.

BS.5449 Forced circulation hot water systems.

BS.5546 Installation of gas hot water supplies

domestic purposes (2ndFamily

Gases).

BS.5440: 1 Flues (for gas appliances of rated

input not exceeding 60 kW).

BS.5440: 2 Ventilatio(for gas appliances of

rated input not exceeding 60 kW).

DD 189: 1990 Discharge of condensate.

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

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 LITTLE STAR combination

boiler has been tested and examined by
Advantica Technologies Ltd, and is certified to
comply with PrEN 483 and BS EN 625.

Manufacturers instructions must NOT be taken

in any way as overriding statutory obligations.

If in doubt on any point please consult

Ravenheat Manufacturing Ltd.

4.2 LOCATION OF BOILER

4.2.1 Siting of Ravenheat Little Star 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 LS 80 (T) and LS 100 (T) Combi

Boiler must be fitted on a flat and vertical wall
capable of adequately supporting the weight of
the boiler and any ancillary equipment.

The appliance may be 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 aroundthe 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.

10

4.4 IMPORTANT NOTICE

4.4.1 If the combination boiler is to be fitted in a

timber framed building it should be fitted in
accordance with the British Gas Publication
Guide for Gas Installations in Timber Frame
Housing Reference DM2 If in doubt advice
must be sought from the local gas supplier The
combination boiler may be installed in any room
or internal space, although particular attention
is drawn to the requirements of the current
I.E.E. Wiring Regulations, and in Scotland the
electrical provisions of the Building Regulations
applicable in Scotland, with respect to the
installation of the 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 combination boiler have been
examined by B.G. Technology Notified Body,
and is certified to comply with the essential
requirements of the Gas Appliance Directive
90/396/EEC, the Low Voltage Directive 72/23/
EEC and shows compliance with the Electro
Magnetic Compatibility Directive 89/336/EEC
and are therefore permitted to carry the CE
Mark.

The appliance has been tested and approved

by the WRc as meeting the requirements of
G3 and L of the Building regulations and water
Bylaws Scheme - Approved Products.

other appliances when they are in use at the

same time.

4.6 FLUE SYSTEM

4.6.1 The terminal should be located where dispersal

of combustion products is not impeded and with
due regard for the damage or discolouration
that might occur to building products in the
vicinity (see fig. 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 flue lengths see twin flue instruc­tions.
Flue must be positioned in a place not likely
to cause a nuisance.

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

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 specified
in Fig. 6.

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

11

Terminal position fo r fan assisted boiler

(min imum distan ce) mm

A - Dir ectly below an open window or other 30 0
opening (e.g. air br ick)
B - Bel ow gutters, soil pipes or drain pipes 25
C - Below eaves 25
D - Below balconies or car port roof 25
E - Fro m vertical drain pipes and soil pipes 25
F - F rom interna l or extern al corners 25
G - Above g round or be low balcony level 300
H - From a surface f acing a ter minal 600
I - From a terminal facing a terminal 1200
J - From an op ening in th e car port
(e.g. door window) i nto dwellin g. 1200
K - Vertically f rom a termi nal on the same wall 1500

L - Horizontally from a terminal on the same wall 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

BS 6798:1987/5449:1990 (for smallbore
and microbore central heating systems).
The following notes are given for general
guidance.

4.8.2 Pipework

Copper tubing to BS 2871 1.1.1971 is

recommended for water pipes. Jointing should
be either with capillary soldered or with
compression fittings.

Where possible pipes should have a gradient

to ensure air is carried naturally to air release
points and water flows naturally to drain taps.
It should be ensured as far as possible that
the appliance heat exchanger is not a natural
collecting point for air except where providing
useful heat, pipes should be insulated to
prevent heat loss and to avoid freezing.
Particular attention should be paid to pipes
passing through ventilated spaces in roofs and
under floors.

4.8.3 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. 6A).

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.

12

4.8.4 Draining tap
These must be located in accessible positions

to permit the draining of the whole system.
The taps must be at least 15 mm nominal size
and manufactured in accordance with BS 2870

1980.

4.8.5 Air release points
These must be fitted at all high points where

air will naturally collect, and must be sited to
facilitate complete filling of the system.

4.8.6 The appliance has an integral sealed expansion
vessel to accommodate the increase of water
volume when the system is heated.

It can accept up to 6 Its of expansion water.

If the appliance is connected to a system with
an unusually high water content, calculate
the total expansion and add additional sealed
expansion capacity as appropriate (Fig. 7).
In general, modern systems will present no
problem.

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

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

Figure 1 depicts the requirements of Diagram R24.2a
of the Water Supply (Water Fittings) regulations 1999.

13

SIZING OF ADDITIONAL EXPANSION VESSEL: TABLE 3

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

Safety

valve setting (bar)

Vessel charge

pressure (bar)

Initial system

pressure (bar)

Total 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
12 4.1
13 2.4
14 0.7
14 8 . 9
15 7 . 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 85
litres, an additional vessel should be installed
on the return to the combination boiler from the
heating system (Fig. 7). Guidance on vessel
sizing is given in Table 3.

Reference should be made to British Gas

Publications ,Material and Installation
Specifications for Domestic Central Heating
and Hot Water». Draining taps should be
at least 1/2” in BSP nominal size and be in

0.0833 0.140 0.259 0.551 0 .109 0.190 0.412 0.156 0.331

It is most important that the correct concentration

of the water treatment product is maintained
in accordance with the manufacturers’
instructions.

If the boiler is installed in an existing system

any unsuitable additives MUST be removed by
thorough cleansing.

BS 7593:1992 details the steps necessary

to clean domestic central heating system.
Also check pipework and renew any corroded
pipework or fittings. Valve glands must be
repacked or replaced wherever necessary and
any defective controls exchanged.

accordance with BS 2879.

WATER TREATMENT

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
Part 2.

Before installing a new combination boiler to

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

This boiler has a secondary ALUMINIUM alloy

heat exchanger Ravenheat recommended only
the use of FERNOX- COPAL or SENTINEL
X100 water treatment products, which must
be used in accordance with the manufacturers

instructions. For further information contact:
Fernox Manufacturing Co. Ltd.
Tel [phone]
Sentinel Division Betz Dearborn Ltd.
Tel. [phone]

14

SALAMANDER CURROSION GUARD

Salamander (Eng) Ltd
Tel: [phone]

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 readily accessible and adjacent to
the appliance except, where the appliance is
installed in a bathroom, this MUST be sited
outside the bathroom.

SECT ION 5 INSTALLATION

5.1 WARNING

5.1.1 It is MOST IMPORTANT that this appliance is

installed in a VERTICAL POSITION, with the
flue air duct passing through the wall.

Make sure flue slopes 2.5° down towards the

boiler that is 45 mm/m fall per metre of flue
length.

15

5.2 DELIVERY

5.2.1 The appliance carton containing (Fig 10)

a) boiler fully assembled
b) installation instructions and
user instructions
c) white paper template

Polythene bag containing
a) 2-22 mm flanged copper tails complete

with 3/4” brass nuts and washers

b) 1-15 mm compression ball valve

(with drain screw for domestic cold water inlet)

c) 1-1/2” BSP Union Gas Cock

d) - 2.15 mm flanged copper tails complete

with 1/2” brass nuts and washers

- 2.22 mm flanged copper tails complete
with 1/2” brass nuts and washers

e) - 4 coach bolts and wall plugs

- screws and dowels

Separate Box containing (Fig 12)

Horizontal CSI flue kit
56 - Flue gas assembly

57 - Flue bend assembly
59 - Rubber seal Ø 60
60 - Air intake duct
61 - Flue exhaust duct
62 - Terminal
65 - Pipe centering spring
66 - Flue gas sample point
127 - Terminal Cover Plate

WARNING
Maximum allowable flue length 2.5 m
maximum No 2x1000 mm
Flue duct extension used with standard flue

OPTIONAL EXTRAS:

Small carton containing: (Fig 13)

57 - Straight header supplied as an extra cost only
when requested
59 - Rubber seal 0 60
66 - Flue gas sample point

FLUE EXTENSION BOX CONTAINING (Fig. 14)
1000 mm flue extension duct as an extra cost only when
requested for side and vertical flue applications

59 - Rubber seal Ø 60
63 - Air intake duct extension
64 - Flue exhaust duct extension
65 - Pipe centering spring

16

17

5.4 POSITIONING OF THE BOILER

5.4.1 - Remove the 2 screws that secure the upper

part of the front panel of the casing (Fig 19).

- Carefully slide the front panel a few millimetres
up towards the top of the appliance until it is
free from its slot, and then lift off (Fig. 20).

5.4.2 Unscrew the 2 screws that fasten the lower
grating on the casing and remove it from the
sides of the casing (Fig. 22)

5.4.3 Push down the 2 plastic clips that fasten the
instrument panel (Fig. 23).

5.4.4 Lower the instrument panel down by rotating it
on its own hinges (Fig. 25)

Unscrew the two screws fastening panels (Fig.

21).

5.4.5 Remove the two sides of the casing by slightly
lifting them and carefully sliding towards the
top of the appliance, to release them from their
upper suspension hooks (Fig. 26-27)

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

5.5 INSTALLING THE APPLIANCE FOR REAR
FLUE OUTLET

5.5.1 Use adhesive tape to attach the template to

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

- Mark the four boiler fastening holes 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 4 boiler
securing holes. Insert the plastic expansion
plugs.

- Cut or core drill a 105 mm. dia hole for

inserting the flue duct

- Screw in the two upper coach bolts leaving
them about 10 mm. out from the wall to
enable the boiler to be located on the wall

Fit the elbow header positioning it towards
the
required direction (Fig 30).

IMPORTANT: Make sure that the elbow’s dia.
60 mm duct is inserted into the fan, the rubber
seal and orifice (F2) have been correctly

fitted.

18

5.5.2 Locate the rubber Ø 60 into the flue elbow
header (Fig 30).

5.5.3 If the standard duct furnished with the boiler is
too long (the wall to go through is less than
680 mm thick) it can be shortened as follows:

- Remove the centering spring 65, the flue
terminal to disengage inner flue duct

- Measure the thickness W of the wall.

- Cut the outer flue duct at right angles to a
length equal to W + 152 mm

Must be de-burred.

- Cut the inner flue duct (60 mm) at right angles
to a length equal to W + 264 mm Insert from
cut end Reassemble the two tubes Insert
centering spring 65 Must be de-burred

- Reassemble together inner and outer flue duct
insert centering spring

Fig 32

KEY

56 - Straight header
57 - Elbow header
58 - Header gasket
59 - Rubber seal Ø 60

60 - STD air intake duct
61 - STD fle exhaust duct
62 - Terminal
63 - Air intake duct extension

64 - Flue exhaust dct extension
65 - Pipe centering spring
66 - Sample point

127 - Terminal cover plate

19

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

5.5.4 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 34), locating
onto the top coach bolts Fit the two lower
coach bolts and tighten all four securing bolts.

5.5.6 Working above the boiler pull the flue exhaust
duct towards the boiler in order to engage
tube 61 into its header 57A. Position flue into
elbow header and push so as to locate inner
and outer flue correctly ensuring good seal is
made with o rings.

5.5.5 Lift the boiler on to the wall (Fig 34), locating
onto the top coach bolts Fit the two lower
coach bolts and tighten all four securing bolts.

20

5.5.10 Each extension length extends the pipe by
approximately 1000 mm long up to a maximum
of two 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 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 pipe fits into the boiler
header until it stops. The air intake pipe should
be located approximately 2 mm. from the boiler
header (Fig. 31).

When cutting both inner and outer ducts of the

extension, always ensure that the reduced end
(male) of the inner duct is longer than the outer
duct.

All joints must be sealed with the rubber seals

supplied.

It is important to put the centering spacer,

supplied with the unit, inside between the two
pipes, from the side opposite the extension’s
straight end.

5.7 INSTALLING THE APPLIANCE FOR SIDE
FLUE OUTLET (Fig. 39)

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 table 6.

- Mark the four boiler securing holes on the
walland extend the axis of the flue duct hole
to the side wall ensuring it is horizontal.

- Trace the centre of the flue duct hole measure
distance F (table 6). From the corner of
the wall (Fig. 28), measure the distance Y
between the centre of flue duct hole to the
corner Detach the template from wall.

- Use a dia. 10 mm. drill to make the 4 holes for
securing the boiler. Insert the plastic expansion
plugs. Core drill a 105 mm dia. hole in the
side wall for inserting the flue duct.

TABLE 6

CSI

F = 200 mm
G = 275 mm

NOTE: a suitable support bracket is available

from Ravenheat Manufacturing and should
be used to support flue length at least every

1.8 metre preferably at each joint this bracket
should be secured to wall and flue duct.

5.5.11 INLINE 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. 39B).

IMPORTANT: inline flue bend - 1680 mm must

be deducted from overall length for each 900
bend. Obtuse flue bend - 1680 mm must be
deducted from overall length for each 135°
bend (Fig. 39B).

5.6 COMPLETING BOILER INSTALLATION

5.6.1 Reasscmbte the outer casing (sect 5.4)

proceeding in this order

1)Fit the two sides.

2)Refit the instrument panel in reverse order
as insect. 5.4.4.

3)Refit the lower grating (sect. 5.4)

21

5.7.2 Positioning the elbow towards the required

direction (Fig. 30).

- Reassemble the two tubes.

Insert centering spring 65.

5.7.3 Locate the Ø 60 into the elbow (Fig. 30).

5.7.5 - If the standard duct furnished with the boiler

is too long (position of the boiler from
the wall to go through as illustrated in the
drawing and wall thicknesses less
than what was specified above) it can be
shortened as follows: Fig 28-29-31-32

- Remove the centering spring 65, pull the
flue terminal disengage inner flue duct.

- Measure the thickness W of the wall.

- Cut the outer air duct (100 mm. dia.) at right
angles and to a length equal to W+Y - 47
mm. (Fig. 32)

- 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.

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

5.7.7 Lift the boiler on the wall. Locate onto

the top coach bolts. Fit the lower coach
bolts and tighten all four securing bolts.

5.7.8 Working above the boiler pull the flue duct

towards the elbow in order to engage tube
into its header (Fig. 35). Position flue into
straight header and push so as to locate inner
and outer flue correctly. Ensuring good seal is
made with o.rings.

5.7.10 IMPORTANT: Terminal rubber must be fitted

(Fig. 37).

5.7.11 Extension kits are available on order for flue

extension of up to 2.5 metres total length (Fig.

31). For further details see sect 5.5.10.

22

5.7.12 VERTICAL FLUE INSTRUCTION ONLY

INLINE FLUE BEND - 1680 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90° BEND OBTUSE
FLUE BEND - 1680 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135° BEND

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. 41).

IMPORTANT NOTES

For greater flue lengths see

twin flue leaflet

POSITION MIN. DISTANCE mm

N above roof level (to base of terminal) 300
P from adjacent wall to flue 300
Q from internal corner to flue 300
S from facing terminal 1,200
M horizontally from a vertical terminal to a wall 300

Before proceeding with installation check the contents
of the RAVENHEAT VERTICAL FLUE KIT, comprising
of the following pieces:

- 1 RAVENHEAT VERTICAL FLUE complete
with terminal assembly (for vertical flue
application).

- Additional 1000 mm (approx) Flue Extension
pieces as necessary, each extension is
provided with flue centering bracket.

- One box containing straight header with inlet
and outlet sealing rings.

Proceed with installation as detailed in section 5 up
to 5.5.1., 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.

- Ensure that the maximum permissible flue
length is not exceeded (Fig. 42).

- Mark the four boiler fastening holes on the
wall.

- Detach the template from the wall.

- Use a 10 mm dia. drill to make the 4 boiler
securing holes. Insert plastic expansion
plugs (Fig. 29).

- Screw in the two upper coach bolts leaving
them about 10 mm out from the wall to
enable the boiler to be located on the wall.

- Position the straight header on the top of the
appliance (Fig. 43) item 6, and ensure that
the gasket is correctly fitted.

Important: Make sure that the flue header dia

60 mm duct is inserted.

23

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. 44).
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.

5.8 REASSEMBLE BOILER AS PER
(sect. 5.6.1)

5.8.1 Fitting valve pack

Remove plastic caps from boiler connection
and fit flanged copper tail and valves as per
Fig. 46 using washers provided.

5.9 GAS CONNECTION
(Fig. 46)

Cut a 105 mm diameter hole through the ceiling and/or
roof, at the point previously marked.

Fit a roof flashing sleeve (7 Fig. 43) 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 top
coach bolts. Fit the two lower coach bolts and tighten
all four securing bolts.

Measure the vertical distance between the top of
the flue (Fig. 42) and the bottom of the flue terminal
assembly (Fig. 41). 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. 44).

When cutting both inner and outer ducts of the
extension, always cut on spigot side, and they must
be de-burred.

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. 46)

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 marked CHR.

- Connect the central heating flow pipe to
the isolating cock marked CHF

- Pipe dimensions and positions are
marked on template supplied and fig. 45.

24

5.11 DOMESTIC HOT WATER (Fig. 46)

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 Us per min. The regulator screw on the
cold water outlet of the diverter valve may be
adjusted to prevent excess volume flow (Fig.
53 COMMISSIONING SECTION) 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 marked
DCW.

- Connect the 15 mm. hot water pipe with a
suitable connection.

5.12 SAFETY VALVE DISCHARGE

5.12.1 The safety valve is located near the pump.

It has a threaded outlet RC 1/2” (to 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

5.13 ELECTRICAL CONNECTIONS

5.13.1 IMPORTANT: Electricity supply must be as

specified in clause (sect. 4 10)

- When controls external to the appliance

are required, design of the external
electrical circuits should be undertaken by
a competent person. In accordance with the
IEE wiring regulations.

It is essential that all external controls must

be volt free.

Factory fitted internal wiring must not be

disturbed when wiring external controls

- To gain access to the electrical box remove
the front panel of the case as described in
clauses (sect. 5.4.1) and the instrument
panel as described in clauses (sect. 5.4.3).

- 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
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).

25

5.14 PROGRAMMABLE TIMECLOCK

Instructions for use consult User’s Guide.

SECT ION 6 COMMISSIONING

6.1 Each boiler has been through a rigorous

operational procedure at our factory and
should not require any further adjustment
If in the unlikely event of the appliance not
operating correctly, please turn to the Fault
Finding and Logic Sequence charts.

6.2 GAS SUPPLY INSTALLATION

6.2.1 Inspect the entire installation including the

gas meter, test for soundness and purge, all
as described in BS 6891.

6.3 ELECTRICAL INSTALLATION

Preliminary electrical systems checks to

ensure electrical safety shall be carried out
by a competent person (earth continuity,
polarity, resistance to earth). Those checks
are outlined in the «Instructions for British Gas
Multimeter» Booklet. If a fault has occurred
on the appliance the fault finding procedure
should be followed as specified under the
servicing section of this document.

6.4 INITIAL FILLING OF THE SYSTEM

Open central heating flow and return valves

Unscrew the cap on automatic air release
valve one full turn (leave open permanently).

- Close all air release taps on the central
heating system.

- Gradually open stopcock at the filling point
connection to the central heating system
until water is heard to flow.

- Starting with the lowest radiator open each
air release tap in turn. Close it only when
clear water, free of bubbles, flows out. In
the same way release air from any high
points in the pipework.

- Continue filling the system until 1.5 bar
register on gauge. Then turn off the filling
points stopcock

- Inspect the system for water soundness
and remedy any leaks discovered

6.5 SETIING 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 1bar
+ the height in metres to the highest point
of yhe 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 poin (Fig. 93)
or drain on the heating circuit.

6.6 FILLING THE HOT WATER SYSTEM
Close all hot water draw-off taps.

Open the cold water inlet cock.
Slowly open each draw-off tap until clear

water is discharged.

6.7 LIGHTING THE BOILER

Before lighting the main burner make sure

that thwe heating circuit flow and return
valves are open and also that the cold water
input cock is open.

- If external controls are installed (e.g
Timeclock and Thermostat) make sure
that they call for heat

- Turn main switch (1) to winter

26

KEY

77 - Upstream pressure inlet
81 - Downstream pressure outlet

104 - Gas valve modulator

110 - Max. regulator nut
111 - Min. regulator nut
114 - Electrical connections modulator
115 - Electrical connections

27

- Turn control thermostat 4 up to its maximum
setting

- Now the main burner should turn on With
leak detection fluid test for gas soundness
of all gas components and joints.

- See paragraph 6.14 for regulating the
heating circuit thermostat. Check gas
mains pressure (Fig. 52). Fit a gas pressure
gauge on pressure inlet 77 (Fig. 51) on the
gas valve, after releasing the seal screw.
Check the gas mains pressure with boiler
operating.

Check with the Local Gas supplier if the

pressure differs significantly from 20 mbar
(natural gas), 37 mbar (G 31) and 29 mbar
(G 30).

6.10 ADJUSTING MINIMUM AND MAXIMUM
PRESSURE (Fig. 51)

SIT-HONEYWELL-DUNGS GAS VALVE

- Remove cap covering modulator to gas
valve.

- Detach one of the cables connected to the
modulator 114.

- With the boiler operating use a screw
driver (HONEYWELL 9 mm spanner) to
turn the nut 111 clockwise to increase
pressure and anti-clockwise to decrease
pressure.

NOTE: LPG ONLY
The minimum pressure is factory set and

sealed, and cannot be adjusted.

6.9 CHECK THE GAS PRESSURE AT THE
BURNER

Now check if the maximum gas pressure at

the burner is equal to 10.5 ± 0.5 mbar (4.2
± 0.2 in w.g.) for CSI 85 - CSI 85T.

LPG check gas pressure inlet (37 mbar

propane - 29 mbar butane). To do this proceed
as follows:

- Turn off main switch 1 (Fig. 50)

- Set main switch 1 on

- Set control thermostat 5 at its
maximum setting.

- Fit a pressure gauge, using a hose, to

pressure test point 81, (Fig. 51), after
first loosening its close-off screw.

- Open one or more hot water taps so that at

least 10-12 litre of water flows per minute.

- The pressure indicated on the pressure

gauge is the maximum operating gas
pressure.

- Check that the minimum pressure

corresponds to 2 mbar (0.8 in w.g.) for G
20 as is set at the factory.

- LPG 7.3 mbar for G 31 and 7.0 mbar for G

30. This is set and sealed at the factory

and cannot be adjusted.

Detach one of the wires going to modulator

104 (Fig. 51) and make the boiler operate
just as was done for checking the maximum
pressure.

6.11 RECONNECT THE DETACHED CABLE

Use a screw-driver to hold nut 111

(HONEYWELL 9 mm spanner) and use a 10
mm spanner (HONEYWELL 7 mm spanner)
wrench to rotate the nut 110 clockwise to
increase the pressure and counter-clockwise
to decrease it. After adjustment turnoff D.H.W.
Taps.

6.12 SETTING CENTRAL HEATING GAS
PRESSURE THE BOILER COMES SET AT MID
POSITION RATING FOR USE ON C.H. (table1)

When the boiler operates in the C.H. mode

the gas pressure at the burner can be set
between the min. and max. values. This
permits capacity to be adjusted to suit system
demand. If adjustment is required proceed as
follows

- Remove the front panel and the panel
instrument as described in clauses

(sect. 5.4.1 and sect 5.4 3)

- Unscrew the two screws holding the

control box cover and lift off (Fig. 78).

- Select (winter) switch position

- Turn control thermostat 4 to maximum
setting. (Fig. 50)

- Check all external controls are on and
calling for heat, ensure all D.H W. taps are off.

- With boiler operating use a screwdriver to
turn potentiometer (Fig. 48) clockwise to
increase pressure and anti-clockwise to
decrease pressure

- To obtain the desired heat value establish
pressure as per (Fig. 52)

- Replace the protective cover.

- Once this pressure is established, mark
it up on data badge with, adhesive red
label/arrow burne pressure setting so that
this can be referred to and checked during
future servicing.

28

6.13 CHECKING THE FLUE SYSTEM

6.13.1 The flue system should be visually checked for

soundness Check all connections and fixings
are secure and tight

6.14 CHECKING THE HEATING THERMOSTAT

6.14.1 Allow the system to warm up and then turn

the C.H thermostat to ensure the main burner
modulates from “high” to “low” and “low” to
“off” and vice versa (scale range

covers approx. 45° C - 85° C).

6.15 TESTING AND REGULATING THE
DOMESTIC HOT WATER SYSTEM FLOW

6.15.1 Put the appliance in operation with the

(summer/winter) switch in summer position

- Open a domestic hot water tap (preferably
the bath tap). Ensure cold water inlet
stopcock is open and the D.H.W. thermostat
16 is set at maximum.

- If the burner 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 thus
the temperature too low for practical use)
the flow rate may be adjusted. It is better to
set for the lowest acceptable temperature,

preferably at the bath tap since the user
can gain higher temperatures at other

restricted flow taps (Table 1)

- To adjust the flow rate refer to (Fig 53)
side view and locate the adjustment screw
(Fig. 53). Turn the screw clockwise until the
required temperature is reached.

N.B.: If the cold supply is subject to large

fluctuations or is above the permitted max.
water pressure, a suitable pressure/flow
regulator should be fitted in the cold water
supply to the appliance.

- Turn the appliance mode selector switch
(Fig. 50) (1) to the summer position Slowly
close the draw off tap to reduce the flow
rate to above the min (approx. 2.8 litre/min

- 0 61 gals/min.). Rotate the D.H.W. control
thermostat 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 ).

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

29

KEY

2 - Plenum chamber cover
6 - Combustion chamber
7 - Flue restriction ring

8 - Flue gas exhaust hood
15 - Connection pipe
18 - Heat exchanger
24 - Burner

30

27 - Auto air vent valve
28 - Pressure switch
29 - Seal
31 - Seal
42- Sight glass
44 - Fan
46 - Header gasket
50 - Flue gas exhaust hood cover

53 - Connection tube
54 - Connection tube
58 - Ceramic insulation
61 - Condensing heat exchanger
80 - Plenum chamber
83 - Burner centering pin
84 - Seal

6.16 HANDING OVER TO THE USER

6.16.1 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 it only/ (Summer/Winter)

and ON/OFF switch.

- Explain and demonstrate the function of

time and temperature controls, neon lights
radiator valves etc for the economic use of
the system.

- If an optional time clock is fitted, then draw

attention to the time clock User’s Instructions
and hand them to the Householder

- Stress 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.

SECT ION 7 SERVICING INSTRUCTIONS

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 sub frame.

- The following notes apply to the appliance
and its controls but it should be remembered
that attention must also be paid to the
heating and hot water circuits with special
attention to radiator valves, thermostats,
clocks, leaking hot water taps etc.

- Where it is necessary to replace a gasket
that relies on adhesive for securing - this
adhesive will be supplied with the gasket as
a spare item.

- In all cases prior to servicing, remove the
outer case (sect. 5.4). Operate the appliance
by turning the hot water services on to a high
water flow, and observe the main burner.

- Check that the flame covers all the flame
ports and is of a light blue colour. Yellow
flames and excessive lifting of flames
indicate poor combustion.

- IMPORTANT: After completing any servicing
or replacement of gas carrying components
it is essential that a test for gas soundness
is always carried out along with functional
checks in operation

7.2 TO INSPECT AND CLEAN THE
APPLIANCE

7.2.1 Before carrying out cleaning operation,

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

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

NOTE: Do not use brushes with metallic

bristles

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.

7.1 SERVICING

7.1.1 To ensure continued efficient operation of the

appliance it is necessary to carry out servicing
and cleaning at regular intervals.

The frequency of cleaning will depend upon

the particular installation conditions and
usage but in general, once year should be
adequate.

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

7.2.4 Examine the combustion chamber insulating
material and renew if damaged (sect 7 9)

7.2.5 Remove and examine the burner injector
clean or renew, as necessary (sec. 7.12 &

7.14)

7.2.5.1 Inspect the burner and remove any deposit
with a soft brush Check the electrodes for
damage or deterioration, clean or renew
as necessary Ensure that the spark gaps
are correct to dimensions specified in sec.

7.15.

31

7.2.6 Inspect the secondary condensate
heat exchanger. Deposits can be
cleared by removing and flushing out
the exchanger Inspect the siphonic
condensate trap for a blockage Any
deposits should be flushed out (Fig. 90)

7.2.6.1 To remove condensate trap (sect. 5.4). Pull
forward the trap (Fig. 90)

Unscrew the earth wire, and the sensor.

Replace in reverse order.

7.2.7 Examine the fan for any mechanical
damage, check to ensure free running of
the fan wheel. Clean the wheel if necessary
with a soft brush. Check sealing gasket
and renew if damaged (sect. 7.6).

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

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

7.3 TO REMOVE/REPLACE THE FRONT
PANEL OF THE CASING (Fig. 19 & 20)

7.3.1 Remove the 2 screws that secure the upper

part of the front panel of the casing.

Lift the front panel few millimeters to the

top, until it is free from the slot and remove
panel

exchanger then from the appliance.
Place in a safe place until required
Reassemble in reverse order. Ensure wires
are connected correctly (Fig. 94)

7.6.5 TO REMOVE/REPLACE CONDENSING
HEAT EXCHANGER FIG. 54-55

7.6.5.1 Remove front casing (sect. 7.3).

Remove combustion chamber front cover

as in (sect 7.4). Remove lower grating by
unscrewing the two screws (Fig. 21).

7.6.5.2 Close the ON/OFF valves for the heating.
Drain the heating system from the drain
point mounted system (Fig. 93).

7.6.5.3 Remove the fan (sect.? 6)

7.6.5.4 Disconnect 4 unions for the heating water

pipelines (Fig. 54) and remove the two
short pipes.

7.6.5.5 Remove screw holding heat exchanger to
chamber. Disconnect condensing discharge
pipe by pulling off the pushfit connector at
top rear of boiler (Fig. 54).

7.6.5.6 Pull the heat exchanger down and slightly
forward until it comes out of the connection
from chamber (Fig. 55).

7.6.5.7 Replace in reverse order. Taking care to
refit discharge pipe at rear.

7.4 TO REMOVE/REPLACE THE
COMBUSTION CHAMBER COVER

7.4.1 Remove the front casing panel (sect. 7.3).

7.4.2 Unscrew all the screws that fasten the

cover to the chamber body and put them
into a container so that they don’t get lost.

7.4.3 Detach the cover, being careful not to
damage the seal.

7.4.4 Reassemble in reverse order.

Ensure good seal of cover when

replacing.

7.6 TO REMOVE/REPLACE THE FAN
ASSEMBLY (Fig. 58)

7.6.1 Remove front casing (sect. 7.3).

Remove combustion chamber front cover

as in (sect. 7.4).

7.6.2 Disconnect the electrical connections from
the fan motor.

7.6.4 Support the fan and remove the two fixing
screws and bracket from the front of the flue
hood. Carefully withdraw from condensing
heat

IMPORTANT: When replacing heat

exchanger new seals must be used.

7.7 TO REMOVE/REPLACE THE FLUE HOOD
(FIG. 60)

7.7.1 Remove front casing (sect. 7.3).

Remove combustion chamber front cover

as in (sect. 7.4).

7.7.2 Remove the fan (sect. 7.6)

7.8.11 Remove condensing heat exchanger (sect.

7.6.5)

7.7.3 Remove the three screws on the front that
fasten hood to the combustion chamber.

7.7.4 Remove the two screws at the rear of
hood.

7.7.6 Replace in reverse order

7.8 TO REMOVE THE HEAT EXCHANGER
(FIG. 62-63-64)

7.8.1 Remove front casing (sect 7.3).

Remove combustion chamber front cover

as in (sect. 7;4).

Remove the lower grating (sect.5.4.2)

Lower the instrument panel (sect. 5.4 3 & 4).

32

7.8.2 Remove the two sides of the casing by
slightly lifting them and sliding them
towards the top of the appliance, to release
them from their upper suspension hooks

7.8.4 Remove the fan (sect. 7.6).

7.8.5 Remove condensing heat exchanger (sect.

7.6.5).

7.8.6 Remove the flue hood (sect. 7.7).

7.8.8 Remove the automatic air vent (Fig. 92).

7.8.9 Disconnect unions for two heating (right

side of boiler) water pipelines (Fig. 62).

7.8.10 Unscrew the rings that fasten the heat
exchanger to the combustion chamber.

7.8.11 Remove the two side insulation panels at
top of heat exchanger (Fig. 63).

7.8.12 Pull the heat exchanger up until its flow
connections come out from the combustion
chamber and then remove it (Fig. 64).

7.8.13 Replace in reverse order.

Ensure correct wire position (Fig. 94).

IMPORTANT: When replacing a heat

exchanger new seals must be used.

7.9 TO REMOVE/REPLACE COMBUSTION

CHAMBER INSULATION PANELS

(Fig.63).

7.9.1 Remove casing front panel (sect. 7.3).

Remove combustion chamber front cover

(sect. 7.4).

7.9.2 Remove fan (sect. 7.6).

7.9.3 Remove condensing heat exchanger

(sect. 7.6.5).

7.9.4 Remove the flue hood (sect. 7.7).

7.9.5 Remove main burner (sect. 7.15).

Remove top insulation pieces at sides.

Remove 2 screws securing combustion
chamber to rear of boiler.

Lower chamber carefully remove all

insulation panels.

7.9.6 Replace in reverse order.

33

7.10 TO REPLACE THE ELECTRODE
(Fig.52B)

7.10.1 Remove front casing (sect 7.3)

Remove combustion chamber from cover

(sect 7.4)

34

7.10.2 Detach the wire from electrode and then
unscrew the nut that secures it to the pilot
burner assembly and remove

7.10.3 Replace with new electrode in reverse order.

35

7.14 TO REMOVE/REPLACE THE
INJECTORS

7.14.1 Remove the front panel of the casing and

the combustion chamber front cover (sect.

7.3 & 4).

7.14.2 Unscrew the union (Fig. 70).

7.14.3 Unscrew the 4 screw securing the injector

manifold to the burner (Fig. 71).

7.14.4 Pull the manifold up and out from the
combustion chamber (Fig. 72).

7.14.5 Unscrew and replace the injectors and
their seals (Fig. 73).

7.14.6 Replace in reverse order.

7.14.7 Relocate the grommet, sealing the gas

supply pipe to the casing taking care not to
damage it. Replace if necessary.

36

7.15 TO REMOVE/REPLACE THE BURNER

7.15.1 Remove the front panel of the casing and the

combustion chamber front cover
(sect 7.3 & 7.4).

7.15.4 Remove the injectors manifold as described
insect. 7.14.

7.15.5 Remove the two screws securing the main
burner to the combustion chamber (Fig 74).

7.15.6 Pull the burner forward and remove (Fig. 75).

7.15.7 Replace in reverse order.

IMPORTANT: When refitting the burner make

sure that the pins at the rear of the combustion
chamber locate into the slots made on the rear
of the burner.

7.16 TO REMOVE/REPLACE THE GAS VALVE
(Fig. 51)

7.16.1 Remove front casing panel (sect. 7 3).

7.16.2 Push the 2 clips that fasten the instrument

panel (Fig. 23).

7.16.3 Lift the instrument panel to detach it from the
sides, and lower it down by rotating it on its own
hinges (Fig. 25)

7.16.4 Pull the 2 wires from the Modulator.

7.16.5 Remove the lower grating (sect. 5.4.2) and the

gas valve.

7.16 Remove the eight screws (four per side) that
connect the gas valve to the gas pipelines and
then remove it from its seat.

7.16 Replace in reverse order, always using new seals.

7.19 TO REMOVE/REPLACE THE HEATING
CONTROL AND DOMESTIC HOT WATER
CONTROL

7.19.1 Remove the front panel from the outer casing

(sect. 7.3) and lower the instrument panel
(sect. 7.16.2 & 3), and remove the control box
cover (7.31.2/3).

7.19.2 Pull off the thermostat knobs (Fig. 78) and
unscrew lock nuts.

7.19.3 Detach all the connectors from PCB board.
Detach the PCB from its base by unscrewing
the 6 screws.

37

7.19.6 Replace in reverse order.

7.22.3 Replace in reverse order

7.20 TO REMOVE/REPLACE THE MAIN

SWITCH (Fig. 82).

7.20 Remove the front panel from the outer casing

(sect. 7.3) and lower the instrument panel
(sect. 7.16.2 & 3), and remove the control box
cover (7.31.2/3).

7.20.2 Pull off the switch knob. Remove the switch

out from the instrument panel by pressing the
clamp springs (Fig. 82).

7.20.3 Detach the wires that connect to the switc make

sure that these wires are later reconnected to
the same poles (Fig. 94)

7.20.4 Replace in reverse order

7.21 TO REMOVE/REPLACE THE WATER

PRESSURE GAUGE (Fig. 83).

7.21.1 Remove the front panel from the outer casing

(sect. 7.3) and lower the instrument panel
(sect. 7.16.2 & 3). Remove the lower grating
(sect. 5.4.2).

7.21.2 Close the heating system on/off valves and

drain the water from the drain point on the
heating system (Fig 93).

7.21.3 Unscrew the fitting that secures the pressure

gauge probe.

7.21.4 Remove the gauge from the instrument panel

by pressing its fastening springs.

7.21.5 Replace in reverse order.

7.22 TO REMOVE/REPLACE THE OVERHEAT

THERMOSTAT

7.22.1 Remove the front panel from the outer casing

(sect 7.3).

7.22.4 Remove the two wires that connect to the

overheat thermostat-making sure that these
wires will subsequently be reconnected to the
same poles (Fig. 94).

7.23 TO REMOVE/REPLACE THE ELECTRIC
CONTROL AND IGNITION BOARD

7.23.1 Remove the front panel from the outer

casing (sect. 7.3) and lower the instrument panel

(sect. 1.16.2 & 3)

7.23.2 Unscrew the 2 screws holding the control box
cover and remove.

Disconnect mains cables and any other

connections (room thermostat and frost
thermostat if fitted).

7.23.3 Detach the connectors from the board

7.23.5 Replace in reverse order (ensure all electrical

connections are made correctly)

7.24 TO REMOVE/REPLACE THE DIFFERENTIAL
PRESSURE SWITCH (Fig. 87).

7.24.1 Remove the front panel from the outer casing

and the combustion chamber front cover (sect.

7.3 & 4).

7.24.2 Detach the wires that connect to the pressure
switch, make sure that these wires are later
reconnected to the same poles (Fig. 94).

7.24.3 Unscrew the two screws that fasten the pressure

switch to the back of combustion chamber.

7.24.4 Remove the two silicone tubes.

7.24.5 Ensure tubes are connected correctly (Fig. 87)

avoiding kinks.

7.24.6 Replace in reverse order ensuring that the
tapping is connected to the tube terminating
inside the case and the + tapping is connected
to the tube terminating at flue ring

(Fig. 87 and 94)

7.25 TO REMOVE/REPLACE THE PUMP (Fig. 88)

7.25.1 Remove the front panel from the outer casing

(sect. 7.3) and lower the instrument panel

(sect. 7.16.2 & 3)

38

7.25.2 Remove lower grill right side of the casing
(sect. 5.4 2 & 5), lower the electric box

(sect. 7.16.2 & 3).

7.25.3 Close the on/off valves on the heating circuit
and drain at drain point water from the boiler
(Fig. 93).

7.25.4 Remove the wires that connect the pump (fig.

93).

7.25.5 Unscrew the two hexagonal nuts that fasten the
pump to its pipes and remove the pump.

NOTE: It may be necessary to loosen the flow

pipe at the heat exchanger to replace the pump
gaskets.

7.25.6 Always use new seals when re-fitting the new
pump.

7.25.7 Replace in reverse order

IMPORTANT:

7.25.8 Make sure that the arrow that indicates the

direction of flow aims from the bottom
upwards

7.25.10 Refill the heating system as described in the
sect. 6.4 & 5 and check for leaks

7.26 TO REMOVE/REPLACE THE DIVERTER
VALVE (Fig. 89)

7.26.1 Remove the front panel from the outer casing,

lower the instrument panel (sect. 7.16 2 & 3).

Remove lower grating (sect. 5.4.2).

7.26.2 Close the on/off valves for the heating circuit
and the hot water circuit. Drain the boiler at
drain point (Fig. 93) and drain hot water from
the lowest hot water tap and drain point on
DHW inlet cock (Fig. 46).

7.26.4 Unscrew the five nuts that connect the diverter

valve and pull it out from boiler being careful
not to damage the wires.

7.26.5 Pull off circlip securing microswitches to divert-

er valve

7.26.6 If replacing microswitch assembly use a screw-

driver to prise off the protective cover of the
microswitches.

7.26.7 Detach the wires that are connected to this.

Remember that they must subsequently be
reconnected to the same terminals (Fig. 94).

7.26.8 Replace in reverse order. Always use new
seals.

7.26.9 Fill the boiler as described in (sect. 6.4 & 5)
and check for leaks.

7.27 TO REMOVE/REPLACE THE CENTRAL
HEATING AND/OR HOT WATER CONTROL
THERMISTOR

7.27.1 Remove the front panel from theouter-cas-

ing (sect. 7.3) and lower the instrument panel
(sect. 7.16.2).

7.27.2 Remove left/right side of casing (sect. 5.4).

7.27.3 Remove the wires that connect the thermistor

(Fig. 81).

7.27.4 Close the on/off valves for the heating circuit

and the hot water circuit. Drain the boiler at
drain point (Fig. 93) and drain hot water from
the lowest hot water tap and drain point on
DHW inlet cock (Fig. 46).

39

7.27.5 Undo the nut and withdraw the sensor (Fig. 81)
from is pocket.)

7.27.6 Replace in reverse order.

7.28 TO REMOVE/REPLACE THE CENTRAL
HEATING EXPANSION VESSEL

In the unlikely event of failure of the central

heating expansion vessel it is recommended
a suitable expansion vessel be fitted exter­nal to the boiler. It should be positioned on
the return pipe and as close to the boiler as
possible (Fig. 7). However, if it is necessary to
replace the central heating expansion vessel
the boiler must be removed from the wall as
follows.

7.28.1 Remove the front panel from the outer
casing (sect. 7.3) and lower the instrument
panel (sect. 7.16.2 & 3) and remove the con­trol box cover (sect. 7.31.2/3). Remove the
lower grating (sect. 5.4.2). Remove the two
sides of the casing (sect. 5.4.5).

7.28.2 Close the on/off valve on the domestic cold
water, central heating and gas supply.

7.28.3 Drain domestic water from the lowest hot wa­ter tap and drain point on DHW inlet cock (Fig.

46).

7.28.4 Drain the boiler (Fig. 93).

7.28.5 Disconnect all pipework connected to boiler.

7.28.7 Disconnect mains cables and any other con-

nections (room thermostat, programming
clock).

7.28.8 Remove the duct proceeding in reverse order
as described in (sect. 5.5 or 5.7)

7.28.9 Remove the 2 lower coach bolts and release 2
top coach bolts then remove boiler from the wall.

7.28.10 Unscrew the nut that connects the expansion
vessel and remove it (Fig. 91)

7.28.11 Remove the screw supporting expansion ves
sel (Fig. 91).

7.28.12 Remove the expansion vessel.

7.28.13 Replace all the components in reverse order

using new seals.

7.28.14 Fill the system as described in the sect. 6 and
check for leaks.

40

7.29 TO REMOVE/REPLACE THE AUTOMATIC
AIR VENT (Fig. 92)

7.29.1 Remove the front panel from the outer cas-

ing and the combustion chamber front cover
(sect. 7.3 & 4).

7.29.2 Remove the lower grating (sect. 5.4.2)

7.29.3 Remove the fan assembly and the flue hood

(sect. 7.6 & 7 7).

7.29.4 Close the on/off valves for the central heating
circuit and drain the water from the boiler drain
point (Fig 93).

7.31.6 Replace in reverse order (ensure all electrical
connections are made correctly)

(Fig. 88/A)

7.29.5 Unscerw and remove the plastic cap that
protects the valve vent hole

7.29.6 Disconnect the unions 1 (Fig 92) slightly turn
and remove auto air vent

7.29.7 Replace in reverse order, using new seals.

7.29.8 Fill the system as described in the sec. 6.4&5
and check for leaks

7.30 TO REMOVE/REPLACE THE PRESSURE

RELIEF VALVE (Fig. 93)

7.30.1 Remove the front panel (sect. 7.3) and the

lower grating (sect. 5.4.2) from the outer
casing, lower the instrument panel (sect. 7.16.23)
Remove right side of the casing (sect. 5.4.5)

7.30.2 Close the on/off valves for the heating
system and drain the water from the drain
point

7.30.3 Unscrew the screw from its body, clean or
replace. Replace in reverse order

7.32 Replace in reverse order (ensure all electrical)
connections are made correctly.

7.30.4 Fill the system as described in the (sect. 6.4 & 6.5)

7.31 TO REMOVE TIME CLOCK

(Fig.88/A)

7.31.1 Remove the front panel from the outer casing

(sect. 7.16.2 and 3).

7.31.2 Remove control box cover (Sect. 7.23.2).

7.31.3 Remove control board (Sect. 7.23.2) from panel

7.31.4 Remove two clips securing the timer.

7.31.5 Carefully remove the four wires connecting

timer by pulling spade connectors from timer.

41

7.33 TO REMOVE / REPLACE D.H.W. HEAT
EXCHANGER

7.33.1 Remove the front panel from the outer casing

and lower the instrument panel (sect. 7.16.2 & 3)

7.33.2 Close the on/off valve may have to be remove
for easier acces.

7.33.4 Unscrew the four nuts that connect the DHW
heat exchanger and pull it out from boiler

7.33.5 If necessary the pipes from the diverter valve
may have to be remove for easier access.

7.33.6 Repleace in reverse order Always use new
seals.

7.33.7 Fill the boilers as described in (sect. 6.4 & 5)
and check for leaks.

42

43

Is fan Running at

Maximum speed

44

45

GERBER

PAGINA

DATA 06/05/2005

DURANTE

TAVOLA

CONTROLLATO

TARGA

CODICE IMP06006

DISEGNATO

MATERIALE SCALA

Tolleranze generali di lavorazione: UNI ISO 2768mk

DENOMINAZIONE

COLLEGAMENTO ELETTRICO CIRCUITO TECHNOSYSTEM

PER CALDAIA CSI85 MODULANTE

0012IMP06006/0

NOTE 0012IMP06006/0

E

D

A

B

C

RV DATA MODIFICA FIRMA

46

INSTALLATION iNSTRUCTION FOR TWIN
FLUE PIPE (ECCENTRIC FLUE DUCT SYSTEM)

IMPORTANT
These instructions must be read in

conjunction with the main installation and
servicing instructions

As with all flues the kits must be installed
taking due account of the current issue of BS
5440 parts 1 & 2 and timber frame housing
REF DM2
Also note that the requirements will vary
depending upon the kit being installed.
Guidance is provided but unless otherwise
stated, always comply with the
recommendations of the relevant codes of
practice

8.1 TWIN FLUE INSTRUCTIONS

This part of the installation manual covers the

installation and fixing instructions of the twin
flue eccentric flue duct systems only
When ordering twin flue it must be stated for
CSI range.
Typical installation procedures are illustrated
by drawings

IMPORTANT
Correct F1 orifice must be fitted.

10 - air intake bend 90°

10 - flue exhaust bend 90°

11 - air inlet terminal

12 - flue exhaust terminal

13- 45° air intake bend duct

Supplied with the CSI twin flue header is a
F1 orifice plate along with supplementary
depression seal
Before fixing the twin flue system the existing
orifice plate must be replaced with F1 also
ensuring supplementary seal has been fitted

Remove the 13 screws securing the depres­sion front panel item 2 figure 53A to expose
front edge of depression chamber (Twin flue
instructions figure 1 adjacent) Using adhesi­ve sponge supplied with CSI twin flue header,
carefully attach to depression chamber so as
to create a softer seal
Taking care not to damage the new seal,
carefully re-fit the depression chamber front
cover in reverse order

Take out the 4 temporarily fitted securing
screws, lifting our the gasket and orifice plate
disconnecting it from the venturi tube.
Discard this orifice plate and re-fit the F1 ori­fice plate ensuring that the venturi tube has
been re-fitted, making sure this is securely lo­cated into the locating peg.

13 - 45° flue exhaust bend

14 - flue exhaust duct

14 - air intake duct

15 - two-way flue gas header

16 - vertical eccentric flue exhaust duct

47

Locate the sealing washer fixing the twin flue
header as illustrated making sure that the ou­tlet spigot Make sure that the screws are satis­factorily located through the gasket seal.

Locate the 2 x 80 mm ‘O’ rings in the twin flue
header.

Figures show the versatility of this 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° down towards
the boiler 35 mm fall per metre.

Spacing Clips

Spacing Clips are available on request should
they be required.
NOTE: for eccentric vertical flue a 125 mm (5 in)
diameter flashing plate will be required.

E = EXHAUST
I = INLET
T= TERMINAL

Exhaust/suction system with concentric pipes for flat or
sloping roofs. Extensions with two separate pipes.

Maximum distance = I + E + T = 2 Metre + 2 Metre + 1
Metre = 12 Metre maximum (pipe + terminal).
Minimum distance D = T = 2 metre.

Exhaust terminal must not be cut

NOTE- The pressure loss for each elbow fitted is:

900 slow bend less 3 metre of pipe for each one fitted.
135° bend less 1.5 metre of pipe for each one fitted.

NOTE:
If bends are used in the exhaust flue then horizontal
sections must be avoided and there must be a 2° slope
towards the boiler 35 mm fall per metre.

48

IMPORTANT: See Fig. 42 for terminal clearances.

Exhaust/suction system with two separate rated 80 dia.
Pipes - exhaust on flat or sloping roof, suction from vertical
wall

Maximum distance D = I + E + T = Total exhaust/inlet pipe
= 20 metre

Exhaust terminal must not be cut.

Min inlet pipe distance = 0.5 metre.

NOTE: The pressure loss for each elbow is:

900 slow bend less 3 metre of pipe for each one fitted

45° bend less 1.5 metre of pipe for each one fitted

Minimum total length = 2 metre

NOTE: Exhaust flue must slope 2° down towards the boiler
35 mm fall per metre.

IMPORTANT:

see Fig. 6 and 42 for terminal clearances.

ITEM DESCRIPTION

1

CSI flue adaptor gasket and screws

2

Straight pipe

3

Eccentric vertical terminal

4

90º slow bend

5

45º bend

6

Air inlet terminal (plastic) 80 mm

7

Exhaust terminal (stainless steel) 80 mm

8

Pitch roof slate

9

Flat roof slate

10

Twin flue pipe socket seal 60 mm

Exhaust/suction system with two separate pipes through a
single vertical wall.

Maximum distance D = I + E = Totale exhaust/inlet pipe 18
metre.

Minimum distance D = I + E = 1.5 metre

Min inlet pipe distance 0 5 metre. Min distance between
pipe 50 mm.

NOTE. The pressure loss for each elbow fitted is:

90° slow bend less 3 metre of pipe for each one fitted.
450 bend less 1.5 metre of pipe for each one fitted.

IMPORTANT: inlet and exhaust terminals must ne­ver be installed on opposite walls of the buildin
(PrEN 483).

IMPORTANT NOTICE: If the flue terminares less

PART NO

30005

30001
30003
30009
30011

30007

than 2 M. above a balcony, above the ground, or
above a flat roof to which people have access,
then a suitable terminal guard must be fitted.
Fit only recommended flue terminal guard by
securing concetrically around terminal with screws.

Available on request from:
RAVENHEAT MANUFACTURING LTD
Chartist Way
Morley, Leeds, West Yorkshire
ENGLAND LS27 9ET - U.K.
Tel. [phone]

IMPORTANT:

see Fig. 6 and 42 for terminal clearances.

49

50

15

RAVENHEAT CSI 85 - CSI 85 CONDENSING FANNED COMBI BOILER

SHORT LIST OF SPARE PARTS

Ravenheat G.C.

Pos. Part. No. Part. No. Description

1 0014FR006005/2 Instrument panel - TIMER MODEL

2 0012COM06005/0 E23-712 Main switch

4 0012POT05010/0 E23-729 D.H.W. / C.H. Potentiometer

5 0007TER08010/0 Overheat thermostat

6 0001 CAM06005/0 E23-732 Combustion chamber

7 0001 DIA06005/0 E23-730 Flue restriction ring 79CSI (F2)

8 5027055 372842 Water gauge

9 0007TER05005/0 E23-715 D.H.W. Sensor

9.1 0007TER05006/0 CHSensor

10 0014SPI09005/0 SIight glass

11 0010TUB05041/0 Depression chamber gas pipe

13 0001 CAP06005/0 E23-733 Flue gas exhaust hood

15 0012CIR06010/0 FanControl Board

16 0012CIR05010/2 Printed ignition control board

17 0014MAN06015/0 E23-718 Knob

21 0001C0P01010/0 Combustion chamber cover

22 0008VAL09015/0 Dungs valve gas

26 0002SCA06010/0 E23-731 Heat exchanger

27 0014RAC06005/0 E23-735 Condensing trap

28 0014REGO1005/0 371271 Water flow regulator

29 0010TUB06050/1 Connecting pipe to air purge

30 0008VAL01011/0 Air purge valve

31 5018025 372851 Gasket 18.5 x 11.6 x 2

32 5018030 372867 Gasket 24 x 15 x 2

33 0012VEN03005/1 Fan

36 5018046 378864 Gasket 30 x 22 x 2

37 1015PAN06005/0 E23-737 Insulation pads set

39 0012FUS05015/0 E23-720 Internal fuse 2A

45 372855

46 0014GUA01020/0 371277 Flue gasket

51

Ravenheat G.C.

Pos. Part. No. Part. No. Description

47 0001 CAM06010/0 Depression chamber

50 0012CAN09005/2 Ignition-sensing electrode

51 001 2CAV08020/0 Cable for spark-sensing electrode

61 0002SCA06006/0 Condensing heat exchanger

62 0003UGE03005/0 371297 Nozzle Ø 1,25 for natural gas

62.1 0003UGE01011 /0 E23-755 Nozzle DM 0.75 LPG

64 0001TEL08005/0 Frame

65 5018046 372864 Seal

67 0010TUB06020/1 Connecting pipe D.H.W. outlet

24 0003BRU06016/0 Burner natural gas

24.1 0003BRU06017/0 Burner LPG

69 0008VAL06010/0 372-895 3-way valve

70 0013GUA03035/0 371273 Gasket 32 x 32 x 2 gas valve

79 0005PRE05010/0 371310 Low water pressure switch

80 0009CIR01011/1 Circulation pump

82 0011COL01005/2 Brass manifold

83 0008VAL01018/1 Safety relief valve (3 bar)

87 5021312 372875 Nylon tubes from pressure switch

89 0005PRE06006/0 Pressure switch

93 0019CUR06005/1 Elbow header

95 0019PR005005/0 Flue extension duct complete

97 0019TER06005/1 Flue duct and terminal complete

100 0004VAS06010/0 Expansion tank

105 TM6192 371258 Digital Timer

106 0019TER06010/0 E23-753 Vertical Flue Terminal Complete

110 0001 MAN05005/1 Bottom panel

112 0011RIV06007/0 Condensate blockage

113 0012CAV06015/0 Earth wire

114 0014GUA06010/0 Flue gasket dm 100

115 0014GUA06005/0 Flue gasket dm 60

116 0014GUA06015/0 Flue gasket dm 80

117 0019SDO06005/0 Twin header

118 0002SCA06015/1 Heat exchanger for D.H.W. water

02 5012051 371257 Diaphragm for 3-way valve

05 5012052 372899 Microswitch for 3-way valve

52

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

APPLIANCE & CONTROL DETAILS

COMISSIONING PROCEDURE INFORMATION

Installation, Commissioning and Service Record Log Book

CUSTOMER DETAILS

NAME

ADRESS

IMPORTANT

1. Please keep the Log Book in a safe place for future reference.

2. This Log Book is to be completed in full by the competent person(s) who commissioned the boiler and associated equipment and then handed to
the customer. When this is done, the Log Book is a commissioning certificate that can be accepted as evidence of compliance with the appropriate
Building Regulations.

3. Failure to install and commission this appliance to the manufacturer’s instructions may invalidate the warranty.The above does not affect your statutory rights.

INSTALLER & COMMISSIONING ENGINEER DETAILS

INSTALLER DETAILS

COMPANY NAME

ADRESS

INSTALLER’S NAME

CORGI REGISTRATION DETAILS

COMMISSIONING ENGINEER

NAME

ADRESS

CORGI REGISTRATION DETAILS

REG No.

(IF DIFFERENT)

REG 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 I ROOM STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT

TEL No.

INSTALLER DATE

TEL No.

CORGI ID SERIAL No.

COMMISSIONING DATE

TEL No.

CORGI ID SERIAL No.

NEW SISTEM

SEDBUK No. %

OR REPLACEMENT BOILER

%

2. TIME AND TEMPERATURE CONTROL TO HEATING CYLINDER STAT & PROGRAMMER/TIMER COMBI BOILER

3. HEATING ZONE VALVES FITTED NOT REQUIRED

4. THERMOSTATIC RADIATOR VALVES FITTED

5. AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

6. BOILERI INTERLOCK PROVIDED

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

FOR ALL BOILERS

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

WHAT WAS THE CLEANSER USED?

WHICH INHIBITOR WAS USED?

YES

NO

HAS AN INHIBITOR BEEN USED?

YES

NO

For the central heating mode, measure and record:

HEAT INPUT

BURNER OPERATING PRESSURE

CENTRAL HEATING FLOW TEMPERATURE

CENTRAL HEATING RETURN TEMPERATURE

kW

mbar

°C

°C

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

© CENTRAL HEATING INFORMATION COUNCIL

FOR ALL INSTALLATION

DOES THE HEATING AND HOT WATER SYSTEM COMPLY WITH THE APPROPRIATE BUILDING REGULATIONS?

HAS APPLIANCE AND ASSOCIATED EQUIPMENT BEEN INSTALLED AND
COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS?

HAVE YOU DEMONSTRATED THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS TO THE CUSTOMER?

HAVE YOU LEFT ALL THE MANUFACTURER’S LITERATURE WITH THE CUSTOMER?

COMPETENT PERSON’S SIGNATURE CUSTOMER’S SIGNATURE

(To confirm demonstrations of equipment and receipt of appliance instructions)

FOR CONDENSING BOILERS ONLY

HAS THE CONDENSATE DRAIN BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS?

YES NO

For the central hot water, 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

mbar

°C

°C

Its/min

kW

SERVICE 1 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 2 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 3 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

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

SERVICE INTERVAL RECORD

engineer completes the appropriate Service Interval Record below.

SERVICE PROVIDER

Before completing the appropriate Service Interval Record below, please ensure

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

and in compliance with The Gas Safety Regulations.

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

SERVICE 6 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 7 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 8 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 4 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 5 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

When all of the above services have been completed, please contact your Service Engineer for an additional service Interval record sheet.

SIGNATURE

SERVICE 9 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

SERVICE 10 DATE:

ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS

SIGNATURE

GBLB Second Edition 01.03.02

COD 0017LIB06006/0 - 06/2005