Ravenheat CSI85A(T), CSI85A Installation And Servicing Instructions

CSI 85 A (T)

3

CONDENSING SYSTEM INNOV ATION AUT OMATIC MODULA TING BOILER

FOR CENTRAL HEA TING AND DOMESTIC HOT W ATER

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

POSITION

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

between combustion chamber and living accommodation. This guarantees maximum safety and effi ciency. Indeed, our
depression/combustion front cover has been designed to fi t, achieving maximum air tight seal using screw down fasteners at
15 cm. This should not hinder service of the appliance, but does ensure maximum effi ciency and safety - something which
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 fi gure 1)

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

and relevant codes of practice.

- Gas valve with fl ame modulator.

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

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

- Primary heat exchanger constructed from copper.

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

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

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

- Built in frost protection.

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

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

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

panels.

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

terminal during operation.

COSHH - CONTROL OF SUBST ANCES HARMFUL T O HEAL TH

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.

MAJOR COMPONENTS

TABLE OF CONTENTS

SECTIONS

1
2

3
4
5
6
7
8

9
10
11

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

PAGE

6
6

8-9

6
15
26
30
39
40
45
46

4

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

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

SECTION 1 INTRODUCTION

1.1 The Ravenheat boiler is for the use of central

and domestic hot water combined in one unit.

It is fi tted with an automatic domestic hot

water priority valve.

A / (winter/summer) selector

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

position being for central heating

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

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

SECTION 2

2.1 DESCRIPTION OF CONTROL SYSTEM
AND SEQUENCE OF OPERATION

2.2 Domestic hot water mode

When the appliance is in rest mode with

the mains neon 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 which 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 with

a demand for heat to supply radiators,

6

etc ,with heating circuit fully 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 fl ame 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 will also reduce to minimum fan speed.

When starting, the fan will always start at

maximum speed.

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

2.2.9 The boiler is fi tted with an anti-cycling device
on the control board. This delays the boiler
from re-fi ring 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.

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 fl ue

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

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

2.3.5 Interior space temperature is set by the room
thermostat to be installed in the heating
system. The boiler already carries connection
terminals for this thermostat, as well as for a
timeclock.

The burner continues to operate until it is

stopped by the timer or one of the thermostats

2.3.6 When the internal C.H. temperature sensor
intervenes the 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 fi tted with a blockage
safety sensor. This prevents the boiler
operating should there be a blockage in the
condensate discharge trap.

7

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 fl uids move in a counter direction fl ow 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 fl ue 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 fi tted 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.

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
MINIMUM HEAT OUTPUT CONDENSING 12.3 kW

GAS RATE max 2.3 m

3

/h

AFTER 10 MINUTES min 1.2 m

3

/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 CONTENT C.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 fi t over fl ow
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE
SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85°C MIN 45°C
DESIGN FLOW RATE 1102 I/h 20 °C RISE
MINIMUM FLOW RATE C.H. 503 I/min
D.H.W. FLOW RATE 30 °C rise 12.3 l/min
D.H.W. FLOW RATE 35 °C rise 10.5 l/min
D.H.W. FLOW RATE 40 °C rise 9.2 l/min

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

Qmw Input Net max 26 kW min 11.6 kW
D.H.W. PRESSURE max 10 bar (147 p.s.i.)
D.H.W. PRESSURE PMW min 0.8 bar (118 p.s.i.) To obtain heat input 1.2 bar
D.H.W. MINIMUM FLOW RATE 3 I/min
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: AT, DK, Fl, SE, CATEGORY I

2H

DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+
FLUE TYPE - C12 - C32 - C52 NOX 4

SECTION 3 TECHNICAL DATA

CSI 85 A (T)

TABLE 1

NATURAL GAS (G 20) І2H - П2H3+

8

SECTION 3 TECHNICAL DATA

CSI 85 A (T)

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

9

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

GAS RATE max G31 0.9 m

3

/h G30 0.7 m3/h

AFTER 10 MINUTES min 0.4 m

3

/h 0.3 m3/h
INLET 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 CONTENT C.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 compression
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION DRAIN 3/4” (21.5 mm) push fi t over fl ow

MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE
SEALED WATER SYSTEM C.H.

MAX PRESSURE PHS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 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 D.H.W. MAX G31 35.4 - G30 27.3 mbar

MIN G31 7.3 - G30 7.0 mbar
Qmw Imput Net MAX 22.6 Kw - MIN 11.6 Kw
D.H.W. PRESSURE max 10 bar (147 p.s.i.)
D.H.W. PRESSURE PMW min 0.8 bar (11.8 p.s.i.) To obtain heat input 1.2 bar
D.H.W. MINIMUM FLOW RATE 3 I/min
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: BE, FR CATEGORY I

2H+

DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+
FLUE TYPE - C12 - C32 - C52 NOX 4

10

The manufacturer’s notes must NOT be

taken, in any way, as overriding statutory
obligations.

IMPORTANT:
These appliances are CE certificated for

safety and performance. It is, therefore,
important that no external control devices e.g.
flue dampers, economisers etc., are directly
connected to this appliance unless covered by
these Installation and Service Instructions or
as otherwise recommended by Ravenheat in
writing. If in doubt please enquire.

Any direct connection of a control device

not approved by Ravenheat could invalidate
the certification and the normal appliance
warranty.

It could also infringe the Gas Safety regulations

and the above regulations.

NOTE:
The Ravenheat CSI 85 combination boiler

has been tested and examined by BG, and is
certified to comply with PrEN 483 and BS EN

625.

Manufactures instructions must NOT be taken

in any way as overriding statutory obligations.

If in doubt on any point please consult

Ravenheat Manufacturing Ltd.

4.2 LOCATION OF BOILER

4.2.1 Siting of Ravenheat CSI 85 Combi Boiler must

be as follows.

The position of installation should be within

the building, unless otherwise protected by a
suitable enclosure.

Adequate space for installation, servicing and

air circulation around boiler must be allowed
for.

The Ravenheat CSI 85 Combi Boiler must

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

The appliance may be installed on a combustible

wall subject to the requirements of the Local
Authority and Building Regulations.

LPG versions of this appliance shall not be

installed in cellars or basements.

4.3 CLEARANCES AROUND THE APPLIANCE

4.3.1 The following minimum free spaces, required

for installation inspection and servicing, must

be left around the boiler
18 inches (450 mm) in front
5 inches (125 mm) above
6 inches (150 mm) below

0.2 inches (5 mm) on each side
1 inch (25 mm) in front when installed in a

cupboard.

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 Ventilation (for gas appliances of

rated input not exceeding 60 kW).

DD 189: 1990 Discharge of condensate.

Health & Safety Document No.635

The Electricity at Work Regulations, 1989.

11

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.

4.5 GAS SUPPLY

4.5.1 A gas meter is connected to the service pipe

by the Local Gas Region or the Local Gas

Region contractor. An existing meter should

be checked preferably by the Gas Region to

ensure that the meter is adequate to deal with

the rate of gas supply required for all appliances

it serves. Installation pipes should be fitted in

accordance with BS 6891. Pipework from the

meter to the boiler must be of adequate size

(22 mm) min To within at least 3 metre of

the boiler (15 mm) min. can then be used for

remaining pipe work to the appliance. A smaller

size than the boiler inlet gas connection should

not be used The complete installation must be

tested for soundness as described in the above

Code
N.B. if the gas supply for the boiler serves

other appliances ensure an adequate

supply is available both to the boiler and the

other appliances when they are in use at the

same time.

4.6 FLUE SYSTEM

4.6.1 The terminal should be located where dispersal

of combustion products is not impeded and with
due regard for the damage or discolouration
that might occur to building products in the
vicinity (see fig. 6).

The terminal must not be located in a place

where it is likely to cause a nuisance In cold
and/or humid weather water vapour may
condense on leaving the flue terminal.

The effect of such steaming must be

considered

The terminal must not be closer than 25 mm (1

in) to any combustible material For protection
of combustibles, refer to BS 5440.1.

Where a flue terminal is installed less than

1000 mm. from a plastic, or painted gutter;
or 500 mm from painted eaves, an aluminium
shield 1000 mm. long, should be fitted to the
underside of the gutter or painted surface.

Pluming will occur at the terminal so, where

possible, terminal positions which could cause
a nuisance should be avoided.

The flue must be installed in accordance with

the recommendations of BS 5440: Part 1.

IMPORTANT NOTES

For greater fl ue lengths see twin fl ue instruc-
tions.
Flue must be positioned in a place not likely
to cause a nuisance.

IMPORTANT: The following notes are intended for

general guidance
The boiler MUST be installed so that the terminal

is exposed to external air.
It is important that the position of the terminal al-

lows the free passage of air across it at all tirnes.
Minimum acceptable spacing from the terminal to

obstructions and ventnation opening are specifi ed
in Fig. 6.

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

12

Terminal position for fan assisted boiler

(minimum distance) mm

A - Directly below an open window or other 300
opening (e.g. air brick)
B - Below gutters, soil pipes or drain pipes 25
C - Below eaves 25
D - Below balconies or car port roof 25
E - From vertical drain pipes and soil pipes 25
F - From internal or external corners 25
G - Above ground or below balcony level 300
H - From a surface facing a terminal 600
I - From a terminal facing a terminal 1200
J - From an opening in the car port
(e.g. door window) into dwelling. 1200
K - Vertically from a terminal on the same wall 1500

L - Horizontally from a terminal on the same wall 300

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.

13

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.

14

B) Where fitting of a make up vessel would be

difficult, re pressurisation of the system can be
done. See section on FILLING. If the capacity
of the central heating system should exceed
110 Litres, an additional vessel should be
installed on the return to the combination boiler
from the heating system (Fig. 7). Guidance on
vessel sizing is given in (Table 3).

Reference should be made to British Gas

Publications, «Material and Installation
Specifications for Domestic Central Heating
and Hot Water». Draining taps should be
at least 1/2” in BSP nominal size and be in
accordance with BS 2879.

4.8.9 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.

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.

WATER TREATMENT
This boiler has a secondary ALUMINIUM alloy

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

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

Safety

valve setting (bar)

3.0

Vessel charge

pressure (bar)

0.5 1.0 1.5

Initial system

pressure (bar)

0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0

T otal water

content of system

EXPANSION VESSEL VOLUME (LITRES)

Litres

25
50

75
100
125
150
175

200

225
250
275

300

325
350

375

400

425

450

475

500

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

8.3

16.5

24.8

33.1

41.3

49.6

57.9

66.2

74.5

82.7

91.0

99.3

107.6

115.8

124.1

132.4

140.7

148.9

157.2

165.5

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

0.0833 0.140 0.259 0.551 0 .109 0.190 0.412 0.156 0.331

SIZING OF ADDITIONAL EXPANSION VESSEL: TABLE 3

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

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.

15

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.

SECTION 5 INSTALLATION

5.1 WARNING

5.1.1 It is MOST IMPORTANT that this appliance is

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

Make sure flue slopes 2.5° down towards the

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

16

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 fl anged 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 fl anged copper tails complete

with 1/2” brass nuts and washers

- 2.22 mm fl anged 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 fl ue 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 Rubber

OPTIONAL EXTRAS:

Small carton containing: (Fig 13)

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

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

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

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

17

18

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.