Ravenheat CSI 85 - CSI 85T INSTALLATION AND SERVICING INSTRUCTIONS (03/2021)

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Page 1

ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER

CONDENSING FANNED COMBI

CSI 85 - CSI 85T

WITHOUT TIMER

NATURAL GAS (G 20) (I2H) G.C. N0 47 581 19

LPG (G 30 - G 31) (I3+) G.C. N0 47 581 23

Tested, certified and

service listed

Listed by The United Kingdom Water

Fitting Byelaws Scheme

WITH TIMER

NATURAL GAS (G 20) (I2H) G.C. N0 47 581 20

LPG (G 30 - G 31) (I3+) G.C. N0 47 581 24

INSTALLATION AND SERVICING INSTRUCTIONS

TO BE LEFT WITH USER

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

RAVENHEAT MANUFACTURING LTD., CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET. -TELEPHONE (0113) 252 7007

Page 2

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 IS0 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 (0113) 252 7007.

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.

MAJOR COMPONENTS

Gas valve with flame modulator. Variable head pump suitable for any type of central heating system. Main 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.

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

terminal during operation.

COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH

IMPORTANT

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

WARNING When installing the appliance, care should be taken to avoid any possibility of injury when

handling sheet metal parts.

GENERAL INFORMATION: GLUES AND SEALANTS - exercise caution - if these are still in liquid form. INSULATION PADS, CERAMIC FIBRE - may be harmful if inhaled, may be irritating to skin, eyes, nose and throat. When handling keep dust generation to a minimum, avoid inhaling and contact with skin or eyes, When disposing of the product keep dust generation to a minimum and ensure that parts are securely wrapped. When servicing avoid inhalation by using a vacuum cleaner 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.

Page 3

SECTIONS:

4 5 6 7 8

9 10

GENERAL LAYOUT

TABLE OF CONTENTS

INTRODUCTION DESIGN PRINCIPLES AND

OPERATING SEQUENCE TECHNICAL DATA

GENERAL REQUIREMENTS

INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS

FAULT FINDING

ELECTRICAL SYSTEM DIAGRAM

EXPLODED PARTS DIAGRAM

LIST OF SPARE PARTS

PAGE:

8-9-10

16 25 30 43 45 47

Fig.1

KEY

1 - Heat exchanger 2 - Heat exchanger for D.H.W. water 3 - Burner 4 - Ignition pilot burner 6 - Condensing heat exchanger 7 - Ignition board 9 - ignition electrode

11 - Frame 12 - Modulating gas valve 15 - Heating control

16 - Hot water control 17 - D.H.W. sensor 18 - Water pressure switch (heating circuit) 22 - Overheat cut of thermostat 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

Page 4

KEY

1 - Heat exchanger

2 - Heat exchanger for D.H.W. water 3 - Burner 4 - Ignition pilot burner 5 - Flue restriction ring 6 - Condensing heat exchanger 7 - Electronic ignition 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

Page 5

SECTION

1 INTRODUCTION

2.2.6 Central heating mode

1.1

The Ravenheat boiler is for the use of

2.2.7

central and domestic hot water combined in one unit.

It is fitted with an automatic domestic hot

water priority valve.

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

position being for central heating

with domestic hot water priority. The boiler is equipped with a front cover which can be removed for servicing. The data badge with 2.2.6 On the control panel are mounted two

technical data is placed on the lower right

hand side of the frame.

1.2

Fig. 1 Illustrates the general layout of

components.

2.2.9 The boiler is fitted with an anti-cycling

Fig. 2 Illustrates the operating principles

described in section 2.

SECTION 2

2.1

DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION

2.2 Domestic hot water mode 2.3

When the appliance is in rest mode with the mains neon and switch on. Switch the summer/

2.3.1

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:

2.3.2 Air is drawn by the fan for combustion.

2.2.1

The pump starts. The control board sensors. 2.3.3 The fan operates via the pressure switch and sends a signal back to the ignition board pressure 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

2.3.4

operate and light the burner. At this point the ignition board opens the first

2.3.5 Interior space temperature is set by the

2.2.3

step of the gas valve to light the pilot/burner.

When the electrode/sensor senses the signal of the pilot/burner, it opens the second

stage of the gas valve via the ignition board

on minimum power. Upon the second valve

opening the spark igniter stops.

If the switch is positioned on with a

‘demand for heat to supply radiators, 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.

potentiometers (thermostats) these control the temperature. One is for domestic hot water and the other for heating.

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.

GENERAL FUNCTION

Central Heating Mode

A potentiometer installed on the electric circuit board permits regulation of the boiler

to partial heating requirements, between

maximum and minimum settings.

The fan also forces exhaust gas through the

flue to the outside, this creates a lesser

in the sealed combustion

chamber, thus sucking in combustion air,

through the inlet duct.

The boiler water temperature is automatically

controlled by a built in thermostat.

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.

2.2.4 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 pilot/burner. The pump and fan are also switched off, the pressure switch returning to its rest mode.

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.

2.3.6 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.

Page 6

2.4

2.4.1

2.4.2

2.4.3

Domestic hot water mode

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. 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. 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

2.4.5

3.1

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

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.

OVERALL DIMENSION

3.1.2

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

Page 7

SECTION

3 TECHNICAL DATA

TABLE 1

NOMINAL HEAT INPUT NET 24.0 kW MINIMUM HEAT INPUT NET

NOMINAL HEAT OUTPUT NOMINAL HEAT OUTPUT CONDENSING MINIMUM HEAT OUTPUT MINIMUM HEAT OUTPUT CONDENSING

NATURAL GAS (G 20) I2H

13.0 kW (44.500 Btu/h)

23.8 kW

25.6 kW

11.7 kW

13.4 kW

(84,500 Btu/h)

(81,200 Btu/h) (87,200 Btu/h) (40,100 Btu/h) (45,700 Btu/h)

GAS RATE max 2.5 m3S/h (88.25 ft3/h) AFTER 10 MINUTES

min

1.3 m3S/h (45.9 ft3/h)

INLET PRESSURE 20 mbar (8.0 in w.g.)

BURNER PRESSURE C.H. max 10.5 mbar

min

2.0 mbar (0.8 in w.g.)

(4.2 in w.g.)

MAIN BURNER INJECTORS Nr. 13 x 1.25

PILOT BURNER INJECTOR 0.27 x 2 HOLES

ELECTRICAL SUPPLY POWER CONSUMPTION EXTERNAL FUSE RATING

230V-50HZ

160W

INTERNAL FUSE 315mA-2A-4A (20 mm to BS 4265)

DRY WEIGHT WATER CONTENT C.H. WATER CONTENT

GAS SUPPLY CONNECTION

51 kg

2.1 litre

0.5 litre

112" RC FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W.

OUTLET CONNECTION D.H.W.

15 mm compression isolating valve

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

(35.6 p.s.i.) MINIMUM WORKING PRESSURE 0.5 bar (7.35 p.s.i.) 8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar (7.35 psi.)

CENTRAL HEATING OPERATING TEMPERATURE MAX 85

MIN 45

DESIGN FLOW RATE 1073 I/h (236 gals/h) 20

C RISE

MINIMUM FLOW RATE C.H. 503 l/h (111 gals/h)

D.H.W. FLOW RATE 30 D.H.W. FLOW RATE 35 D.H.W. FLOW RATE 40oC rise

D.H.W. TEMPERATURE

C rise 12.2 l/min (2.7 gals/min)

C rise 10.3 l/min (2.3 gals/min)

9.0 l/min (2.0 gals/min)

max 65oC min 35oC

C inlet temperature

BURNER PRESSURE D.H.W. max 11,2 mbar (4.5 in w.g.) min 2.0 mbar (0.8 in w.g.) QMw Input Net

D.H.W. PRESSURE

max 26 kW (88,600 Btu/h)

max 10 bar (147 p.s.i.)

D.H.W. PRESSURE PMW min 0.8 bar (11.8 p.s.i.)

min 13 kW (44,500 Btu/h)

To obtain heat input 1.2 bar (17.1 p.s.i.)

D.H.W. MINIMUM FLOW RATE 3 l/min (0.66 gals/min)

FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers

DESTINATION: AT. CH. DK. ES. FI. GB. IE. IT. PT. SE.

FLUE TYPE - C12 - C32 - C

CATEGORY I

Nox 2

Page 8

SECTION

3 TECHNICAL DATA

TABLE 1/A

NOMINAL HEAT INPUT NET MINIMUM HEAT INPUT NET

NOMINAL HEAT OUTPUT NOMINAL HEAT OUTPUT CONDENSING MINIMUM HEAT OUTPUT MINIMUM HEAT OUTPUT CONDENSING

GAS RATE max AFTER 10 MINUTES

INLET PRESSURE

min

37 mbar G 31

BURNER max PRESSURE

MAIN BURNER INJECTORS PILOT INJECTOR

min

Nr. 13 x 0.75

0.22 x 1 HOLE

LPG (G 30 - G 31) I

G 31

0.95 m3S/h (33.53 ft/3h)

0.5 m3S/h (17.65 ft3/h) 0.4 m3/h (14.12 ft3/h)

28 - 30 mbar

35.4 mbar (14.0 in wg.)

7.3 mbar

(2.92 in wg.) 7.0 mbar (2.8 in wg.)

24.8 kW

13.0 kW

24.1 kW

25.6 kW

11.7 kW

13.4 kW

G 30 0.79 m3/h (27.89 ft3/h)

G 30

27.3 mbar (10.9 in wg.)

ELECTRICAL SUPPLY 230V-50HZ POWER CONSUMPTION EXTERNAL FUSE RATING INTERNAL FUSE 315mA-2A-4A

16OW

(20 mm to BS 4265)

DRY WEIGHT 51 kg WATER CONTENT C.H. WATER CONTENT

GAS SUPPLY CONNECTION FLOW CONNECTION C.H. RETURN CONNECTION C.H. INLET CONNECTION D.H.W. OUTLET CONNECTION D.H.W. SAFETY DISCHARGE C.H.

2.1 litre

0.5 litre

112” RC 22 mm compression isolating valve 22 mm compression isolating valve

15 mm compression isolating valve

15 mm copper pipe

CONDENSATION DRAIN 3/4" (21.5 mm) push fit over flow

MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 litres

SEALED WATER SYSTEM C.H. MAX PRESSURE PMS 2.5 bar MINIMUM WORKING PRESSURE

0.5 bar

8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar

CENTRAL HEATING OPERATING TEMPERATURE MAX 85

MIN 45°C

DESIGN FLOW RATE 1023 l/h (225 gals/h) 20

C RISE

MINIMUM FLOW RATE C.H./503 Lts/h (111 gals/h)

D.H.W. FLOW RATE 30

D.H.W. FLOW RATE 35oC rise D.H.W. FLOW RATE 40oC rise

D.H.W. TEMPERATURE

D.H.W. PRESSURE D.H.W. PRESSURE PMW

C rise D 11.7 l/min (2.6 gals/min)

9.9 I/min (2.2 gals/min)

8.7 I/min (1.9 gals/min) 10oC inlet temperature

max 65 oC min 35

max 10 bar (147 p.s.i.) min 0.8 bar (11.8 p.s.i.)

D.H.W. MINIMUM FLOW RATE 3 I/min (0.66 gals/min)

To obtain heat input 1.2 bar (17.1 p.s.i.)

FLUE OUTLET NOM. DIAM

DESTINATI

ON: BE. CH. ES. FR. GB. IE. IT. PT.

FLUE TYPE - C12 - C32 - C

CATEGORY I3+

ETER 100 mm specially supplied with boilers

NOX 2

(84,500 Btu/h) (44,500 Btu/h)

(82,100 Btu/h) (87,200 Btu/h) (4O,1OO Btu/h (45,700 Btu/h)

(35.6 p.s.i.) (7.35 p.s.i.) (7.35 p.s.i.)

Page 9

SECTION 4 GENERAL REQUIREMENTS

4.0

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 re-

quirements of the local authority.

4.1

GENERAL INFORMATION

Both the user and the manufacturer rely heavi-

ly 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 recommend-

ed 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

BS. 6798

Low pressure installation pipes.

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

BS. 5449

Forced circulation hot water systems.

BS. 5546

Installation of gas hot water supplies domestic purposes

(2nd Family Gases).

BS. 544O: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

4.2

4.2.1

4.3

4.3.1

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 recom-

mended 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 war-

ranty. It could also infringe the Gas Safety

regulations and the above regulations.

NOTE: The Ravenheat CSI combination

boiler has been tested and examined by BG,

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.

LOCATION OF BOILER

Siting of Ravenheat CSI 85 Combi Boiler

must be as follows. The position of installation should be within the building, unless

otherwise protected by suitable enclosure.

Adequate space for installation, servicing

and air circulation around boiler must be al-

lowed for. The Ravenheat CSI 85 Combi Boiler must

be fitted on a flat and vertical wall capable of

adequately supporting the weight of the boil-

er and any ancillary equipment. The appliance may be installed on a com-

bustible 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.

CLEARANCES AROUND THE APPLIANCE

The following minimum free spaces, re-

quired for installation inspection and servic-

ing, 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.

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

Page 10

4.4

4.4.1

IMPORTANT NOTICE

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 DMZ. 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 partic-

ular 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 combi-

nation 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, utilis-

ing 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 combi-

nation 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 per-

mitted to carry the CE Mark.

4.6

4.6.1

other appliances when they are in use at the same time.

FLUE SYSTEM

The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or

discolouration that might occur to building

products in the vicinity (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 consid-

ered.

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 alumini-

um shield 1000 mm. long, should be fitted to

the underside of the gutter or painted sur-

face.

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.

4.5

4.5.1

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,

GAS SUPPLY

A gas meter is connected to the service pipe by the Local Gas Region or the Local Gas Region contractor. An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves. Installation pipes should be fitted in accordance with BS

6891. 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

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 ter-

minal is exposed to external air.

It is important that the position of the termi-

nal allows the free passage of air across it at

all times.

Minimum acceptable spacing from the ter-

minal to obstructions and ventilation open-

ing are specified in Fig. 6.

Note positions: Due to the terminal

design,

installation is possible with clearances less

than those specified in ES 5440, Part 1.

Page 11

Fig. 6

CONDENSATE DRAIN

A condensate drain is provided on the boiler.

This drain must be connected to a drainage point. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other materials may be used.

Discharge of condensate DD 189:1990.

The drain outlet on the boiler is standard 3/4" (21.5 mm) push fit overflow pipe.

NOTE: Condensate drain pipework must never be less than 15 mm.

Terminal

(minimum distance) A - Directly below an open window or other

B C - Below eaves D E F G H I J

K L

NOTE:

position for fan assisted boiler

opening (e.g. air brick)

- Below gutters, soil pipes or drain pipes

- Below balconies or car port roof

- From vertical drain pipes and soil pipes

- From internal or external corners

- Above ground or below balcony level

- From a surface facing a terminal From a terminal facing a terminal

- From an opening in the car port (e.g. door window) into dwelling.

- Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

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 4.0 metres.

For further details see vertical flue installa-

tion instructions.

4.7

AIR SUPPLY

mm 300

25 25 25 25

25 300 600

1200

1200 1500

300

4.8

4.8.1

4.82

Important: any external runs must be car-

ried out in 1 1/4 (32 mm) wastepipe.

A fall of 2.5” (45 mm/m) all runs must have.

WATER CIRCULATION (central heating)

Detailed recommendations are given in BS 6798 5449.1.1977 (for smallbore and microbore central heating systems). The following notes are given for general guidance.

Pipework

Copper tubing to BS 2671 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.

4.7.1

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 compart-

ment ventilation is not required.

4.8.3

The water through the appliance heat exchanger circuit must exceed the min. 1.84 gals/min. (503 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.

Page 12

4.8.4

4.8.5

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 ES 2870 1980.

Air release points

These must be fitted at all high points where air will naturally collect, and must be sited to facilitate complete fitting of the system.

ed to the heating system to provide limited automatic water make up. Mains topping up method (Fig. 9). Here the temporary connection is supplied from a service pipe, or distributing pipe, which also supplies other draw-off points at a lower level.

4.6.6

4.6.7

4.8.8

The appliance has an integral sealed expansion vessel to accomodate the increase of water volume when the system is heated. It can accept up to 1.5 gal (7 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.

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.

Permissible methods of filling

Cistern method (Fig. 8).

The system may be filled by one of the fol-

lowing methods. Through a cistern used for no other purpose, via a ballvalve permanently connected directly to a service pipe and/or cold water distributing pipe. The stat-

ic head available from the cistern should be adequate to provide the initial system design pressure. The cold feed pipe from the cistern should

include a non-return valve, and a stop-valve with an automatic air vent connected between them, with the stop valve being located, between the cistern and the automatic air vent. The stop valve may remain open

during normal operation of the system, if automatic water make-up is required.

Booster pump method (Fig. 8). The system may be filled through a self contained unit comprising of a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve or flow restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe. The unit may remain permanently connect-

Fig. 9

A combined double check valve shall be

installed upstream of the draw-off point, through a temporary hose connection from a tap supplied from the mains, where the

mains pressure is excessive a pressure

reducing valve shall be used to make filling easier. The following fittings shall form a permanent part of the system and shall be fitted in the order stated. a) A stop valve complying with the require-

b) A test clock. c) Double check valve of an accepted type. d) A non return valve of an accepted type.

PROVISIONS FOR MAKE UP WATER (Fig. 7) Provision can be made for replacing water loss from the system either.

A) from a manually filled made up bottle with

a readily visible water level. The bottle should be mounted at least 150 mm (6 in) above the highest point of the system and be connected through a non return valve to

the return side of the heating system.

MAINS WATER

SUPPLY

(SERVICE PIPE)

ments of BS 1010 Part 2 (the temporary hose from the draw off tap shall be connected to this fitting).

We recommend use of a Ravenheat Filling Loop designed for this method of

filling the system. Available from your supplier.

Page 13

SIZING OF ADDITIONAL EXPANSION VESSELS: 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 2.1 50 4.2

75 6.3 100 6.3 125 10.4 150 12.5 175 14.6

200 16.7 225 16.7 250 275 300 325 350 375 400 425 450 475 39.6

500

For system volumes other than those given

above, multiply the 0.0633 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.

3.0

0.5

20.6

22.9

26.0

27.0

29.1

31.2

33.3

35.4

37.5

41.6

1.0 1.5

3.5 6.5 13.7

7.0 12.9 27.5 5.4

10.5 19.4

14.0

17.5 32.4

21.0

24.5 45.3

26.0

31.5

35.0 64.7

36.5 71.2

42.0

45.5

49.0

52.5

56.0 103.6 220.4

59.5

63.0

66.5

70.0

0.140 0.259

25.9

36.6

51.6 110.2

56.3

77.7 165.3

64.1

90.6 192.6

97.1

110.1

116.5 247.9

123.0 261.7 51.6

125.9 275.5 54.5

2.0

EXPANSION VESSEL VOLUME (LITRES)

41.3

55.1 10.9

66.9

62.6

96.4

124.0

137.7

151.5 30.0

179.1

206.6

239.2

0.551 0.109

27.2

32.7

35.7

36.1

40.9

43.6

46.3

49.0

1.0

2.7

6.2

13.6

16.3

19.1

21.6

24.5

1.5

4.7 10.3

9.5 20.6

14.2 30.9

19.0 41.2

23.7 51.5

26.5 61.6

33.2 72.1

36.0 62.4

42.7 92.7

47.5 103.0

52.2 113.3

57.0 123.6

61.7 133.9

66.5 144.2

71.2 154.5

76.0 164.6

80.7 175.1

65.5 165.4

90.2 195.7

95.0 206.0

0.190 0.412

2.0

1.5

3.9 6.3

7.6 16.5

11.7 24.6

15.6

19.5

23.4 49.6

27.3

31.2

35.1

39.0 62.7

42.9

46.6

50.7

54.6 115.6

56.5

62.4 132.4

66.3 140.7

70.2 146.9

74.1

76.0

0.156

2.0

33.1

41.3

57.9

66.2

74.5

91.0

99.3

107.6

124.1

157.2

165.5

0.331

4.6.9

B) Where fitting 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.

Installation to an existing central heat-

ing system

The combination boiler is designed to oper-

ate 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

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 concen-

tration of the water treatment product is

maintained in accordance with the manufac-

turers’ 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 Xl00 water treatment products, which must be used in accordance with the manufacturers instructions. For further information contact: Fernox Manufacturing

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

Co. Ltd.

Page 14

SALAMANDER CURROSION GUARD

Salamander (Eng) Ltd Tel: (0121) 3780952/4508

4.8.10 Hard water areas

If the area of-installation is recognized as hard water, it is recommended that a suitable water treatment device is installed in the mains.

The water hardness can be determined by

using the standard test paper or by referring to local water authority.

Fig. 10

4.9

4.9.1

4.10

4.10.1

DOMESTIC WATER

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.

ELECTRICAL SUPPLY

Warning: this appliance must be earthed

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 con-

nection to a 230 V - 50 Hz single phase sup-

ply. 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.

Fig. 11

SECTION 5 INSTALLATION

5.1

5.1 .1

WARNING

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 the boiler that is 45 mm/m fall per metre

of flue length.

down towards

Page 15

5.2

5.2.1

DELIVERY

The appliance will arrive on site in two

cartons

Box 1 of 2 containing (Fig. 11):

a) boiler fully assembled

b) installation instructions and

user instructions

c) white paper template

d) terminal cover plate (Fig. 12)

e) - 4 coach bolts and wall plugs

- screws and dowels

Polythene bag containing:

a) 2-22 mm compression ball valves

(heating)

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 3/4" brass nuts and washers

Box 2 of 2 containing (Fig. 12):

Horizontal CSI flue kit

56 - Flue gas sample point

57 - Flue bend assembly 59 - Rubber seal 0 60 60 - Air intake duct 61 - Flue exhaust duct 62 -Terminal 65 - Pipe centering spring 66 - Flue gas sample point

127 -Terminal rubber

(Contained in the carton Fig. 10)

WARNING: Maximum allowable flue length 2.5 m. maximum No. 2x1000 mm.

Flue duct extension used with standard flue

Fig. 13

Fig. 12

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 0 60 63 - Air intake duct extension 64 - Flue exhaust duct extension 65 - Pipe centering spring

Page 16

5.3

Fig. 15

1) Open the top of the carton

Fig. 18

4) Rest the boiler on the floor and remove the polystyrene guards

Fig. 16

2) Rest the carton on the floor (keeping the flaps open)

Fig. 19

Page 17

5.4

POSITIONING OF THE BOILER

Fig. 22

5.4.1

5.4.2

5.4.3

5.4.4

5.4.5

5.4.6

- 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).

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

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

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

Unscrew the two screws fastening panels (Fig. 21).

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).

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

Fig. 23

Fig. 25

5.5

5.5.1

Fig. 21

INSTALLING THE APPLIANCE FOR

REAR FLUE OUTLET

Fig. 26

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 cork 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.

Page 18

5.5.2

5.5.3

Locate the rubber 0 60 into the flue elbow header (Fig. 30).

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.

INTAKE AND EXHAUSTTERMINAL COMPONENTS

KEY 56-Straight header 57-Elbow header 58-Header gasket 59-Rubber seal 0 60

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

64 -

Flue

exhaust duct extension 65 - Pipe centering spring 66 - Sample point

127 - Terminal cover plate

Page 19

5.5.4

5.5.5

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.

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 Fit terminal cover plate and terminal guard (Fig. 36-37).

5.5.9

Extension kits are available on order for

flue extension of up to 2.5 metres total

length (Fig. 31).

Fig. 35

5.5.6

Fig. 33

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.

Fig. 34

Make good inside and outside wall around the air duct

Page 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 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.

all

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 wall and 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. 38), 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

5.5.11

5.6

5.6.1

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.

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. 398). IMPORTANT: inline flue bend - 1680 mm must be deducted from overall length for each 90 mm must be deducted from overall length

for each 135

bend. Obtuse flue bend - 1680

bend (Fig. 398).

COMPLETING BOILER INSTALLATION

Reassemble the outer casing (sect 5.4) proceeding in this order

1) Fit the two sides.

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

3) Refit the lower grating (sect. 5.4).

Fig. 39

Page 21

KEY

63 -Air intake duct extension 56-Sample point 64 - Flue Exhaust duct extension 57-Elbow Header 65 - Pipe centering spring 59-Rubber seal 0

128 - In Line Bend

5.7.2

Positioning the elbow towards the required direction (Fig. 30).

5.7.3

5.7.5

Locate the 0 60 into the elbow (Fig. 30).

- 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.

5.7.12 VERTICAL FLUE INSTRUCTIONS ONLY

- Reassemble the two tubes. Insert centering spring 65.

6.7.6

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.

Fig. 40

Fig. M

Page 22

57.12 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 fiat 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

/90o flue bend (Fig. 41).

Fig. 42

POSITION

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

MIN. DISTANCE mm

300 300 300

1,200

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 inlet and outlet sealing rings and flue centering bracket.

-One box containing straight header with

inlet and outlet sealing rings.

Proceed with installation as detailed in section 5 up to 5.4.8., of the main Installation and Servicing Instruction, ignoring all references to horizontal flue installations,

Use adhesive tape to attach the template to the wall, making sure that the centre line is vertical and that the flue centre line is virtually below the point at which the flue will exit the roof.

-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 and sealing rings are correctly fitted.

Important: Make sure that the flue header dia 60 mm

duct is inserted fully into the fan spigot.

Page 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

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.

5.8

5.8.1

5.9

5.9.1

5.9.2

5.10

5.10.1

REASSEMBLE BOILER AS PER

(sect. 5.6.1)

Fitting valve pack

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

GAS CONNECTION (Fig. 46)

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).

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).

CENTRAL HEATING CONNECTION

(Fig. 46)

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.

Page 24

5.11

DOMESTIC HOT WATER (Fig. 46)

Fig. 46

5.11 .1

5.12

5.12.1

5.13

5.13.1

The domestic hot water circuit does not need a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar. If in doubt it is advisable to install a pressure reducing valve. The minimum pressure needed to operate the domestic hot water system is 0.5 bar with a flow of approx 3 Lts per min. 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.

SAFETY VALVE DISCHARGE

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.

ELECTRICAL CONNECTIONS

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. 46).

- Heat resistant flexible cable is fitted between the isolator and the terminal block. A 3 core cable of 0.75 mm2(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 dam-

aged, it must be replaced by a service engineer (supply cord available from Ravenheat Manufacturing Ltd).

Fig. 49A

Page 25

5.14

PROGRAMMABLE TIME CLOCK

Instructions for use consult User’s Guide

SECTION 6 COMMISSIONING

6.1

Each boiler has been through a rigorous operational procedure at our factory and should not require any further adjustment. If

in the unlikely event of the appliance not operating correctly, please turn to the Fault

Finding and Logic Sequence charts.

6.2

6.2.1

GAS SUPPLY INSTALLATlON

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 registers on gauge. Then turn off the

filling points stopcock.

- Inspect the system for water soundness

and remedy any leaks discovered.

6.5

SETTlNG THE SYSTEM DESIGN PRESSURE

The design pressure must be a min. 1 bar and max. 1.5 bar. These figures are read off the pressure gauge.

- The actual reading should ideally be 1 bar + the height in metres to the highest point of the system above the base of

the appliance (up to a max of 1,5 bar).

N.B.: The safety valve is set to lift a 3

bars (30 mt/42.5 psig).

- To lower the system pressure to the required value remove drain point (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 (Fig. 50) Before lighting the main burner make sure

that the heating circuit flow and return

valves are open and also that the cold water input cock is open.

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

- Turn main switch (1) to winter

Page 26

Page 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).

6.9 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 wg.) 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 IO-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 wg.) 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.

Observe the pilot flame which will light a second before main burner. It should be about 20 mm long (Fig. 528) and envelop the spark electrode tip.

6.10

6.11

6.12

ADJUSTING MINIMUM AND MAXIMUM PRESSURE (Fig. 51) SIT-HONEYWELL 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.

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 turn off D.H.W.Taps.

SETTlNG 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 burner pressure setting so

that this can be referred to and checked

during future servicing.

Page 28

RATIO BETWEEN BURNER PRESSURE AND OUTPUT

6.13

6.13.1

CHECKING THE FLUE SYSTEM

The flue system should be visually checked for soundness. Check all connections and fixings are secure and tight.

Fig. 52

6.14

6.14.1

6.15

6.15.1

CHECKING THE HEATING THERMOSTAT

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 85o C).

TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW

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.

Page 29

EXPLODED DIAGRAM OF BOILER BODY

KEY

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

8 - Flue gas exhaust hood 15 - Connection pipe 18 - Heat exchanger 24 - Main burner 25 - Pilot burner

27 - Auto air vent valve 28 - Pressure switch 29 - Seal 31 - Seal 37 -Window seal 42 -Window clamp ring 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

Page 30

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 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.

SECTION

7 SERVICING INSTRUCTIONS

7.2

7.2.1

7.2.2

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.

TO INSPECT AND CLEAN THE APPLIANCE

Before carrying out cleaning operation, cover the electrical control panel with a piece of waterproof material to protect it from debris.

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

7.1.1

SERVICING

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

7.2.4

7.2.5

7.2.5.1

Examine internal

pipe-work connections and

automatic air vent for any water leaks.

Rectify if necessary.

Examine the combustion chamber insulating material and renew if damaged (sect. 7.9).

Remove and examine the main burner injector and pilot injector clean or renew, as necessary (sec. 7.12 & 7.14).

Inspect the main 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.

Page 31

7.2.6

7.2.6.1

7.2.7

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).

To removecondensate trap (sect. 5.4). Pull forward the trap (Fig. 90). Unscrew the earth wire, and the sensor. Replace in reverse order.

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).

7.6.5

7.6.5.1.

7.6.5.2

7.6.5.3

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

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

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). Close the ON/OFF valves for the heating.

Drain the heating system from the drain point mounted system (Fig. 93).

Remove the fan (sect.7.6).

7.2.8

7.2.9

7.3

7.3.1

7.4

7.4.1

7.4.2

7.4.3

7.4.4

Examine flue duct and flue hood and ensure that there is no obstruction.

Examine the gasket at the entry into the

flue duct.

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.

TO REMOVE/REPLACE THE FRONT

PANEL OF THE CASING (Fig. 19 & 20)

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.

TO REMOVE/REPLACE THE COMBUS-

TION CHAMBER COVER

Remove the front casing panel (sect. 7.3).

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.

Detach the cover, being careful not to

damage the seal.

Reassemble in reverse order.

Ensure good seal of cover when replacing.

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.

IMPORTANT:

exchanger new seals must be used.

7.7

TO REMOVE/REPLACETHE 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 (sect. 7.6.5)

When

condensing

replacing

heat

heat exchanger

7.6

7.6.4

TO REMOVE/REPLACE THE FAN

nt cover

from

the fan motor.

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

7.8

7.8.1

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

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).

Page 32

7.82

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.

7.84

7.8.5

7.8.6

7.8.9

7.8.10 Unscrew the rings that fasten the heat

7.8.11

7.812 Pull the heat exchanger up until its flow

7.8.13 Replace in reverse order.

Remove the fan (sect, 7.6).

Remove

(sect. 7.65). .

Remove the flue hood (sect, 7.7).

Remove the automatic air vent (Fig. 92).

Disconnect unions for two heating (right

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

exchanger to the combustion chamber.

Remove the two side insulation panels at

top of heat exchanger (Fig. 63).

connections come out from the combustion

chamber and then remove it (Fig. 64).

Ensure correct wire position (Fig. 94).

IMPORTANT: When replacing a heat exchanger new seals must be used.

condensing heat exchanger

Fig. 54

7.9

7.9.1

7.9.2

7.9.3

7.9.4

7.9.5

7.9.6

TO REMOVE/REPLACE COMBUSTION

CHAMBER INSULATION PANELS (Fig.

63).

Remove casing front panel (sect. 7.3). Remove combustion chamber front cover (sect. 7.4).

Remove fan (sect. 7.6).

Remove condensing heat exchanger (sect.

7.6.5).

Remove the flue hood (sect. 7.7).

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.

Replace in reverse order.

Fig. 55

Page 33

7.10

TO REPLACE THE ELECTRODE (Fig. 66)

Fig. 60

7.10.1

Fig. 56

Remove front casing (sect. 7.3). Remove combustion chamber front cover

(sect. 7.4).

TAKE OFF

Fig. 62

Page 34

Fig. 63

Fig. 66

Fig. 64

7.10.2

7.10.3

7.12

7.12.1

7.12.2

7.12.3

7.12.4

7.12.5

7.12.6

7.13

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

Replace with new electrode in reverse order.

TO REPLACETHE PILOT INJECTOR (Fig. 68)

Remove the front panel of the casing and the combustion chamber front cover (sect.

7.3 & 7.4). Remove the lower grating sect. 5.4.2 (Fig. 21).

Release the fitting that secures pilot pipe at

the gas valve.

Remove electrode (sect:7.10).

Unscrew pilot connection from pilot burner.

Pull the aluminium tube downwards and the

injector should come out by itself.

Replace in reverse order,

TO REPLACETHE PILOT BURNER

7.13.1

7.13.2

7.13.4

7.13.5

Remove the front panel of the casing and

the combustion chamber front cover (sect.

7.3 & 7.4).

Remove the electrode and pilot injector (sect. 7.10 and sect. 7.12).

Remove the two screws securing pilot

burner to main burner (Fig. 69).

Replace in reverse order.

Page 35

7.14

TO REMOVE/REPLACE THE MAIN INJECTORS

Fig. 69

7.14.1

7.14.2

7.14.3

7.14.4

7.14.5

7.14.6

7.14.7

Remove the front panel of the casing and

the combustion chamber front cover (sect.

7.3 & 4). Remove the pilot burner assembly as described in sect. 7.13.

Unscrew the union (Fig. 70).

Unscrew the 4 screws securing the injector manifold to the burner (Fig. 71).

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

Unscrew and replace the injectors and their

seals (Fig. 73).

Replace in reverse order.

Relocate the grommet, sealing the gas supply pipe to the casing taking care not to damage it. Replace if necessary.

Fig. 70

Fig. 68

Fig. 71

Page 36

7.15

TO REMOVE/REPLACE THE MAIN BURNER

7.15.1

7.15.2

7.15.4

7.15.5

7.15.6

7.15.7

7.16

7.16.1

Remove the front panel of the casing and

the combustion chamber front cover (sect.

7.3 & 7.4).

Remove the pilot burner assembly as

described in sect. 7.13.

Remove the

described in sect. 7.14.

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

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

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.

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

Remove front casing panel (sect. 7.3).

injectors

manifold as

7.16.2

7.16.3

7.16.4

7.16.5

7.16.6

7.16.7

7.16.6

7.19

7.19.1

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

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

Pull the 2 wires from the Modulator. Remove

the electronic ignition board (7.32.2/3).

Remove the lower grating (sect. 5.4.2).

Unscrew the pilot burner tube connection.

Remove the eight screws (four per side)

that connect the gas valve to the gas

pipelines and then remove it from its seat.

Replace in reverse order, always using new

seals.

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

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).

Fig. 75

7.19.2

7.19.3

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

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

Page 37

7.19.6

Replace in reverse order.

7.22.7

Replace in reverse order.

7.20

7.20.1

7.20.2

7.20.3

7.20.4

7.21

7.21.2

7.21.3

7.21.4

TO REMOVE/REPLACE THE MAIN SWITCH (Fig. 82).

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).

Pull off the switch knob. Remove the switch out from the instrument panel by pressing the clamp springs (Fig. 82).

Detach the wires that connect to the switch

- make sure that these wires are later

reconnected to the same poles (Fig. 94).

Replace in reverse order.

TO REMOVE/REPLACE THE WATER

PRESSURE GAUGE (Fig. 83).

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).

Close the heating system on/off valves and

drain the water from the drain point on the

heating system (Fig. 93).

Unscrew the fitting that secures the

pressure gauge probe.

Remove the gauge from the instrument

panel by pressing its fastening springs.

7.23

7.23.1

7.23.2

7.23.3

7.23.4

7.23.5

7.23.6

7.24

7.24.1

7.24.2

TO REMOVE/REPLACE THE ELECTRIC

CONTROL BOARD (PCB)

Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 1.16.2 & 3).

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).

Detach the connectors from the board.

Detach the PCB board from its base by

unscrewing the six screws.

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

Having replaced PCB recommission boiler

on heating mode (sect. 6.15).

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

Remove the front panel from the outer casing and the combustion chamber front cover (sect. 7.3 & 4).

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

7.21.5

7.22

7.22.1

7.22.2

7.22.3

7.22.4

7.22.5

Replace in reverse order. 7.24.3

TO REMOVE/REPLACE THE OVERHEAT THERMOSTAT

7.24.4 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).

Remove lower grill and right side of the

casing (sect. 5.4.2 & 5).

Unscrew the plastic cover and locknut that fastens the overheat thermostat and remove it.

Remove the three wires that connect to the overheat thermostat - making sure that these wires will reconnected to the same poles (Fig. 94).

Remove the split pin and pull the thermostat sensor from its pocket 7.25.2

subsequently be

7.24.5

7.24.6

7.25

7.25.1

Unscrew the two screws that fasten the pressure switch to the back of combustion chamber.

Remove the two silicone tubes.

Ensure tubes are connected correctly (Fig.

87) avoiding kinks.

Replace in reverse order ensuring that the

- tapping is connected to the tube terminating inside the case and the + tapping terminating at flue ring (Fig. 87 and 94).

TO REMOVE/REPLACE THE PUMP (Fig. 88)

Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 7.16.2 & 3).

Remove lower grill right side of the casing

(sect. 5.4.2 & 5) lower the electric box

(sect. 7.16.2 & 3).

connected to the tube

Page 38

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

7.25.5

Remove the terminal covers and detach the

supply wires (Fig. 88).

Unscrew the two hexagonal nuts that fasten

the pump to its pipes and remove the

pump.

7.25.8

7.25.9

7.25.10

IMPORTANT:

Make sure that the arrow that indicates the

direction of flow aims from the bottom

upwards.

Replace wires and cover ensuring that

connection wire br=L and bl=N.

Refill the heating system as described in

the sect. 6.4 & 5 and check for leaks.

7.25.6

7.25.7

Fig. 78

Fig. 79

NOTE: It may be necessary to loosen the flow pipe at the heat exchanger to replace the pump gaskets.

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

Replace in reverse order

7.26

7.26.1

7.26.2

7.26.4

7.26.5

7.26.6

7.26.7

TO REMOVE/REPLACE THE DIVERTER

VALVE (Fig. 89)

Remove the front panel from the outer casing, lower the instrument panel (sect,

7.16.2 & 3). Remove lower grating (sect. 5.4.2).

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).

Unscrew the five nuts that connect the diverter valve and pull it out from boiler being careful not to damage the wires.

Pull off circlip securing microswitches to diverter valve.

If replacing microswitch assembly use a screw-driver to prise off the protective cover of the microswitches.

Detach the wires that are connected to this.

Remember that they must subsequently be

reconnected to the same terminals (Fig.

94).

Fig. 81

7.26.8

7.26.9

7.27

7.27.1

7.27.2

7.27.3

7.27.4

Replace in reverse order. Always use new

seals.

Fill the boiler as described in (sect. 6.4 & 5)

and check for leaks.

TO REMOVE/REPLACE THE CENTRAL

HEATING AND/OR HOT WATER CONTROL

THERMISTOR

Remove the front panel from the outer

casing (sect. 7.3) and lower the instrument

panel (sect. 7.16.2).

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

Remove the wires that connect the

thermistor (Fig. 81).

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).

Page 39

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

7.27.6 Replace in reverse order.

Fig. 82

7.28

TO REMOVE/REPLACE THE CENTRAL

HEATING EXPANSION VESSEL

In the unlikely event of failure of the central heating 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,

expansion vessel

it is

Fig. 83

7.28.1

7.28.2

7.28.3

7.28.4

7.28.5

7.28.7

7.28.8

7.28.9

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).

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

Drain domestic water from the lowest hot water tap and drain point on DHW inlet cock (Fig. 46).

Drain the boiler (Fig. 93).

Disconnect all pipework connected to

boiler.

Disconnect mains cables and any other connections (room thermostat, programming clock).

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

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

7.28.10

7.28.11

7.28.12

7.28.13

7.28.14

7.29

7.29.1

7.29.2

7.29.3

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

Remove the screw supporting expansion vessel (Fig. 91).

Remove the expansion vessel.

Replace all the components in reverse order using new seals,

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

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

Remove the front panel from the outer casing and the combustion chamber front cover (sect. 7.3 & 4).

Remove the lower grating (sect, 5.4.2).

Remove the fan assembly and the flue hood (sect. 7.6 & 7.7).

Page 40

7.29.4

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

Fig. 88

7.29.5

7.29.6

7.29.7

7.29.8

7.30

7.30.1

7.30.2

7.30.3

7.30.4

7.31

7.31 .1

7.31.2

7.31.3

Unscrew and remove the plastic cap that protects the valve vent hole.

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

Replace in reverse order, using new seals.

Fill the system as ‘described in the sect. 6.4 & 5 and check for leaks.

TO REMOVE/REPLACE THE PRESSURE

RELIEF VALVE (Fig. 93)

Remove the front panel (sect. 7.3) and the lower grating (sect. 5.4.2) from the outer casing, lower the instrument panel (sect.

7.16.2 & 3).

Remove right side of the casing (sect.

5.4.5).

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

point (Fig. 93).

Unscrew the screw from its body, clean or

replace. Replace in reverse order.

Fill the system as described in the

(sect. 6.4 & 6.5) and check for leaks.

TO REMOVE/REPLACE TIME CLOCK

, (Fig. 88/A)

Remove the front panel from the outer

casing (sect. 7.3) and lower the instrument

panel (sect. 7.16.2 and 3).

Remove control box cover (Sect. 7.23.2).

Remove control board (Sect. 7.23.2) from

panel.

7.31.6

7.32

7.32.1

7.32.2

7.32.3

7.32.4

7.32.5

Replace in reverse order (ensure all electrical connections are made correctly) (Fig. 88/A).

TO REMOVE/REPLACE THE IGNITION BOARD

Remove front casing (sect. 7.3) lower the instrument panel (sect. 7.16.2 & 3),.

Remove the screw from the ignition box cover.

Detach the ignition box from its base on the gas valve.

Remove the PCB cover and detach the connectors from the board.

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

7.31.4

7.31.5

Remove two clips securing the timer.

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

Page 41

7.33

TO REMOVE / REPLACE D.H.W. HEAT

EXCHANGER

7.33.1

7.33.2

7.33.4

7.33.5

7.33.6

7.33.7

Remove the front panel from the outer casing and lower the instrument panel (sect. 7.16.2 & 3).

Close the on/off valves for the heating circuit

and the hot water circuit, Drain the boiler

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

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

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

Replace in reverse order. Always use new

seals.

Fill the boiler as described in (sect. 6.4 & 5)

and check for leaks.

Fig. 69

Page 42

Page 43

Section 8 FAULT FINDING CENTRAL HEATING

Switch on Select “Winter” Central Heating Stat to maximum Ensure external controls calling for heat (Room Stat/Time Clock/TRV)

Page 44

FAULT FINDING DOMESTIC HOT WATER

Before continuing it may be necessary to see Central Heating Fault Finding Select only (Summer) Domestic Hot Water.

Open Domestic hot tap close to appliance.

Page 45

SECTION 9 ELECTRICAL SYSTEM DIAGRAM

Fig. 94

Page 46

Page 47

Page 48

Page 49

8.0

INSTALLATION INSTRUCTIONS FOR

TWIN FLUE PIPE (ECCENTRIC FLUE

DUCT SYSTEM)

8.1

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.

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 IO - flue exhaust bend 90 11 - air inlet terminal 12 - flue exhaust terminal 15 - two-way flue gas header

13 - 45

air intake bend

13 - 45o flue exhaust bend

14 - flue exhaust duct 14 - air intake duct

16 - vertical eccentric flue exhaust 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 m-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.

Page 50

Locate the sealing washer fixing the twin flue header as illustrated making sure that the inner aluminium exhaust locates firmly in the

outlet spigot. Make sure that the screws are

satisfactorily located through the gasket seal.

Locate the 2 x 80 mm ‘0’ rings in the twin

flue header.

90” M/F bend consisting of.

90” elbow with ‘0’ ring side F 80 mm dia ‘0’ ring

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 ‘0’ 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.

135” M/F bend consisting of.

135” elbow with ‘0’ ring side F

80 mm dia ‘0’ ring

Vertical eccentric flue exhaust duct

E = EXHAUST I = INLET

T = TERMlNAL

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

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

Exhaust terminal must not be cut.

NOTE: The pressure loss for each elbow fitted is:

90” slow bend less 3 metre of pipe for each one

fitted.

135” bend less 1.5 metre of pipe for each one fitted

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

IMPORTANT: See Fig. 42 for terminal clearances.

Page 51

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

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

Exhaust terminal must not be cut.

Min inlet pipe distance = 0.5 metre.

NOTE: The pressure loss for each elbow is:

90” slow bend less 3 metre of pipe for each one fitted.

45” bend less 1.5 metre of pipe for each one fitted.

Minimum total length = 2 metre.

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

IMPORTANT:

see Fig. 6 and 42 for terminal clearances.

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:

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

bend less 1.5 metre of pipe for each one fitted.

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

IMPORTANT NOTICE: If the flue terminates

less than 2 M. above a balcony, above the

ground, or above a flat roof to which people

have access, then a suitable terminal guard must be fitted.

Fit only recommended flue terminal guard by securing concentrically around terminal with

screws.

Available on request from:

RAVENHEAT MANUFACTURING LTD Chartists Way Morley, Leeds. West Yorkshire ENGLAND LS27 9ET - U.K.

Tel. (0113) 252 007

IMPORTANT: see Fig. 6 and 42 for terminal clearances.

Page 52

Page 53

RAVENHEAT CSI 85 - CSI 85T CONDENSING FANNED COMBI BOILER

SHORT LIST OF SPARE PARTS

Ravenheat

Pos

1 2 4

5 6 7

8 9

18.1 21 22

22.1 24

25.1

28 29 30 5015015 31 32

33 36 37 38 39

45 46

Part. No.

0014FRO06005/0 0012COM06005/0

0012POT05010/0

0007TER03010/0

0001CAM06005/0 0001DIA06005/0 5027055 0007TER05005/0 0014VET01005/0 001 0TUB05040/0 0001CAP06005/0 5021103

0012CIR05005/2

0014MAN06015/0 0012GEN05005/0

0012GEN05010/0

5003066

0008VAL03005/0

0008VAL05005/0 0003BRU06015/0

5012114

0003PIL05010/0

0002SCA06010/0 0014RAC06005/0 0014REG01005/0 0010TUB06010/0

5018025

5018030

0012VEN03005/0 5018046

1015PAN06005/0 0010TUB06060/0 0012FUS05015/0 5023020 0014GUA01020/0

G.C. Part. No.

E23-711 E23-712 E23-729

371267 E23-732 E23-730 372842

E23-715

371268

E23-716 E23-733

372845

E23-718 E24-630

372849

173100

372-866 372894

E23-731 E23-735 371271

372888

372851

372867

173101 378864 E23-737 E23-738

E23-720

372855 371277

Description

Instrument panel - TIMER MODEL Main switch

D.H.W. / C.H. Potentiometer Overheat thermostat Combustion chamber Flue restriction ring 79CSI (F2)

Water gauge D.H.W. / C.H. Sensor Sight glass

Depression chamber gas pipe Flue gas exhaust hood

Fuse 315 mA

Printed control board Knob Printed ignition board

Honeywell printed ignition board Combustion chamber cover Gas valve

Honeywell gas valve Main burner

Pilot burner

Pilot burner for Honeywell gas valve

Heat exchanger Condensing trap Water flow regulator Connecting pipe to air purge Air purge valve

Gasket 18.5 x 11.6 x 2

Gasket 24 x15 x 2

Fan

Gasket 30 x 22 x 2

Insulation pads set

Pipe to air purge

Internal fuse 2A

Depression chamber pilot seal

Flue gasket

Page 54

Pos.

Ravenheat Part. No.

G.C.

Part. No.

Description

48.1

50 51

61 62

62.1 64

65 67 68

68.1 69 70 79

80 81 82 83 85 87 89 93

95 97 100 105 106 110 111

112

113 114

115 116

117 118

02 05

0001CAM06010/0

5012096

0003UGE01605/0 5021050 0012CAV06005/0 0002SCA06005/0 0003UGE03005/0 0003UGE01011/0

0001TEL06005/0

5018046 0010TUB06020/0 0003BRU06015/0

0003BRU06002/0

0002VAL06005/0

0013GUA03035/0

0005PRE03010/0

5009080

0013GUA01045/0

5003283

5015010

0012FUS05020/0

5021312

0005PRE05015/0

0019CUR06005/0

0019PR006005/0

0019TER06005/0

0004VASO6010/0

TM6192

0019TER0601010

0001MAN05005/0

0011RIV06006/0 0011RIV06005/0

0012CAV06015/0

0014GUA06010/0

0014GUA06005/0 0014GUA06015/0 0019SD006005/0

0002SCA06015/0 5012051 5012052

372856

E02-129

372892

E23-739

E23-740

371297

E23-755

372864

E23-742

372-895

371273

371310 372896 371274 372874

372897

E23-724

372875

E24-629

E23-750 E23-751 E23-752

371258 E23-752

E23-754

371257 372899

Depression chamber Nozzle 0,27 for natural gas Nozzle DM 0.22x1 LPG

Ignition electrode Cable for electrode Condensing heat exchanger

Nozzle 1,25 for natural gas

Nozzle DM 0.75 LPG.

Frame

Seal

Connecting pipe D.H.W. outlet

Main burner natural gas

Main burner LPG

3-way valve

Gasket 32 x 32 x 2 gas valve

Low water pressure switch Circulation pump

Gasket 48 x 42 x 1

Brass manifold

Safety relief valve (3 bar)

Internal fuse 4A

Nylon tubes from pressure switch

Pressure switch

Elbow header

Flue extension duct complete

Flue duct and terminal complete

Expansion tank Digital Timer Vertical Flue Terminal Complete Bottom panel Earth electrode

Condensate blockage

Earth wire Flue gasket dm 100

Flue gasket dm 60 Flue gasket dm 80 Twin header

Heat exchanger for D.H.W. water Diaphragm for 3-way valve Microswitch for 3-way valve

Page 55

Chartists Way, Morley, Leeds, LS27 9ET.

Telephone: (0113) 252 7007

Tfax: (0113) 238 0229

Ravenheat CSI 85 - CSI 85T INSTALLATION AND SERVICING INSTRUCTIONS (03/2021)

Specifications and Main Features

Frequently Asked Questions

User Manual