CONDENSING FANNED FLUE BOILER
CSI PRIMARY
NATURAL GAS (G 20) (I 2H)
G.C.
LPG
G.C.
Listed by The United Kingdom Water
No41
(G 30
No41
Tested, certified and
service listed
Fitting Byelaws Scheme
581 05
- G 31)
581 06
CSI
(I3+)
CSI
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
CONDENSING SYSTEM INNOVATION
CENTRAL HEATING BOILER
This new super high efficient boiler is designed to meet 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.
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
Aesthetically pleasing panels and controls.
On/Off ball valve for shutting off gas.
Programmable 7 day module with digital display (optional).
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 HARMFULTO 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.
3
SECTIONS:
1
2
3
4
5
6
7
8
9
10
11
GENERAL LAYOUT
TABLE OF CONTENTS
PAGE:
INTRODUCTION
6
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
6
8-9
6
15
26
30
39
40
45
46
KEY
1
- Heat exchanger
3
-Burner
4
- Ignition pilot burner
6
- Condensing heat exchanger
9
- Ignition electrode
11
- Frame
4
15 - Heat control thermostat
22 - Overheat cut off thermostat
26 -Auto air vent valve
28 - Pressure switch
35 - Condensing trap
36 - Fan
38 - Sealed chamber
45 - Combustion chamber
50 - Flue gas exhaust hood
106 - Flue restriction ring
OPERATING SCHEME
Fig. 2
KEY
1 - Heat exchanger
3 - Burner
4 - Ignition pilot burner
5 Flue restriction ring
6 - Condensing heat exchanger
7 - Electronic ignition
8 Condensing trap
9 - Ignition electrode
12 - Gas valve
15 - Heat control thermostat
18 - Overheat cut-off thermostat
26 - Auto air vent valve
28 - Pressure switch
36 Fan
38 - Sealed chamber
SECTION
1 INTRODUCTION
1.1
The CSI Primary is a gas fired room sealed
fan assisted condensing heating boiler suitable for fully pumped open vented or sealed
system central heating and domestic hot
water systems.
1.2
The provision of stored domestic hot water
is possible by the addition of an indirect
cylinder with ‘Y’ or ‘S’ plan controls. The
data badge is placed on the front panel.
1.2.1
Fig. 1 illustrates the general layout of components.
Fig. 2 illustrates the operating principals
described in section 2.
SECTION
2 DESCRIPTION OF CONTROL SYSTEM
AND SEQUENCE OF OPERATION
2.1
If the main neon is on with a demand for
heat to the system (radiators etc.) the fan
operates via the pressure switch and sends
a signal back to the ignition board that the
fan is running at maximum speed.
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
The fan also forces exhaust gas through the
flue to the outside, this creates a lesser
pressure in the sealed combustion chamber, thus sucking in combustion air through
the inlet duct.
The boiler water temperature is automatically controlled by a built in thermostat.
Interior space temperature is set by the
room thermostat to be installed in the heating system. The boiler already carries connection terminals for this thermostat, as
well as for a time clock. The burner contin-
ues to operate until it is stopped by the
timer or one of the thermostats.
When the room thermostats and/or timer
intervene the main burner shuts down. The
fan stops and the pump off via the pump
overrun.
The condensate trap is fitted with a block-
age safety sensor. This prevents the boiler
operating should there be a blockage in the
condensate discharge trap.
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.3
2.3.1
The spark ignition system is powered which
in turn commences the spark ignitor to
operate and light the burner. At this point
the ignition board opens the gas valve to
light the pilot/burner.
When the electrode/senor sensors the sig-
nal 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 ignition stops.
From the minimum gas rate setting and
after a few seconds the gas gradually starts
to increase to maximum set required power
until it’s maximum regulated temperature.
When the boiler thermostat is satisfied the
boiler will go to rest mode, the main burner
is shut down and the pressure switch will
return back to its rest mode.
A pump overrun will operate the pump for
about 1 minute if the temperature of water
in the boiler is above 78
o
C, after this water
is dispersed the pump will stop.
The boiler is fitted with a thermostatic anti-
cycle device, this delays the boiler from
refiring until the return water temperature is
reduced.
GENERAL FUNCTION
The gas valve boiler output settings may be
adjusted to requirements other than factory
settings.
3.2.1
An overheat cut off thermostat set slightly
higher than the heat thermostat acts to
turn off the burner to resetable “lockout”
(Fig. 50) 3.
SECTION
4 GENERAL REQUIREMENTS
4.0
SAFETY
Gas Safety (Installation and USE) Regulations, 1994, and amendments 1996.
It is law that all gas appliances are installed
and serviced by a Corgi registered installer
(identified by ) in accordance with the
above regulations. 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 also be
in accordance with the latest I.E.E (BS
7671) Wiring Regulations, local building
regulationsbye-laws of the local water
authority, the building regulations and the
Building standards (Scotland) and any rele-
vant requirements of the local authority.
4.1
GENERAL INFORMATION
Both the user and the manufacturer rely
heavily on the installer, whose job it is to install the combination boiler and connect it to
a correctly designed heating system. Acquaint yourself with the British Standards
concerning installation requirements. If you
need advice on any points your Ravenheat
Technical Services Office would be pleased
to help. It is recommended that tools suitable
2.3.2
6
Air is drawn by the fan for combustion.
OVERALL DIMENSION
Fig. 3
PRESSURE DROP ACROSS APPLIANCE
Fig.
5
BS. 5440:2 Ventilation (for gas appliances
DD 189:1 1990 Discharge of condensate
Health & Safety Document No. 635
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be
taken, in any way, as overriding statutory
obligations.
IMPORTANT. These appliances are CE certificated for safety and performance. It is,
therefore, important that no external control
devices e.g. flue dampers, economisers
etc., are directly connected to this appliance unless covered by these Installation
and Service Instructions or as otherwise
recommended by Ravenheat in writing. If in
doubt please enquire.
Any direct connection of a control device not
approved by Ravenheat could invalidate the
certification and the normal appliance war-
ranty. It could also infringe the Gas Safety
regulations and the above regulations.
of rated input not exceeding
60
kW).
for brass fittings are used, and have a capability to accomodate hexagon sizes up to 50
mms.
CODES OF PRACTICE/Fief: Documents
Detailed recommendations are contained in
the following British Standard Codes of
Practice:
BS. 6891
BS. 6798
BS. 5449
BS. 5546
Low pressure installation pipes.
Installation of gas fired hot
water boilers of rated input not
exceeding 60 kW.
Forced circulation hot water
systems.
Installation of gas hot water
supplies domestic purposes
(2nd Family Gases).
4.2
4.2.1
4.3
NOTE: The Ravenheat CSI Primary boiler
has been tested and examined by BG, and
is certified to comply with PrEN 483.
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 Primary 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
allowed for.
The Ravenheat CSI Primary must be fitted
on a flat and vertical wall capable of ade-
quately supporting the weight of the boiler
and any ancillary equipment.
The appliance may be installed on a
combustible wall subject to the require-
ments of the Local Authority and Building
Regulations.
LPG versions of this appliance shall not
be installed in cellars or basements.
CLEARANCES AROUND THE
APPLIANCE
BS. 5440:
1 Flues (for gas appliances of
rated input not exceeding
60
kW).
4.3.1
The following minimum free spaces, re-
quired for installation inspection and servic-
ing, must be left around the boiler:
7
SECTION 3 TECHNICAL DATA
TABLE 1
NATURAL GAS (G 20) I
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 20 mbar
BURNERPRESSURE
MAIN BURNER INJECTORS
PILOT BURNER INJECTOR
ELECTRICAL SUPPLY
min
max
min
Nr. 13 x 1.25
0.27 x 2 HOLES
230V-50HZ
2H
24.8 kW
13.0 kW
(84,500 Btu/h)
(44,500 Btu/h)
23.8 kW (81,200 Btu/h)
25.6 kW
11.7 kW
13.4 kW
3
S/h
2.5 m
3
1.3 m
S/h
(87,200 Btu/h)
(40,100 Btu/h)
(45,700 Btu/h)
(88.25 ft3/h)
(45.9 ft3/h)
(8.0 in w.g.)
10.5 mbar
2.0 mbar
(4.2 in w.g.)
(0.8 in w.g.)
POWER CONSUMPTION
EXTERNAL FUSE RATING
INTERNAL FUSE 4 A
DRY WEIGHT
WATER CONTENT C.H.
GAS SUPPLY CONNECTION
FLOW CONNECTION C.H.
RETURN CONNECTION C.H.
CONDENSATION DRAIN
6OW
3A
(20 mm to BS 4265)
kg 35
litre 0.5
1/2" RC
22 mm
22 mm
3/4" (21.5 mm) push fit over flow
SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS
MINIMUM WORKING PRESSURE
CENTRAL HEATING OPERATING TEMPERATURE MAX 85
2.5 bar
0.5 bar
o
C
MIN 62°C
o
DESIGN FLOW RATE 1023 I/h (225 gals/h) 20
C RISE
MINIMUM FLOW RATE C.H. 503 I/h (111 gals/h)
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
(35.6 p.s.i.)
(7.35 p.s.i.)
DESTINATION: AT. CH. DK. ES. FI. GB. IE. IT. PT. SE.
FLUE TYPE - C12 - C32 - C
CATEGORY
I
2H
52
8
NOX 2
SECTION 3 TECHNICAL DATA
TABLE l/A
LPG (G 30 - G 31) I
NOMINAL HEAT INPUT NET
MINIMUM HEAT INPUT NET
NOMINAL HEAT OUTPUT
NOMINAL HEAT OUTPUT CONDENSING
MINIMUM HEAT OUTPUT
MINIMUM HEAT OUTPUT CONDENSING
GAS RATE
AFTER 10 MINUTES
INLET PRESSURE
BURNER
PRESSURE
max
min
37 mbarG31
max
min
MAIN BURNER INJECTORS
PILOT INJECTOR
ELECTRICAL SUPPLY
G
31
G 31
Nr. 13 x 0.75
0.22 x 1 HOLE
230V-50HZ
3+
24.8 kW
13.0 kW
24.1 kW
11.7 kW
13.4 kW
G
30
0.95
m3S/h
(33.53 ft3/h)
0.79
0.5 m3S/h (17.65 ft3/h) 0.4 m3/h (14.12 ft3/h)
G
28 - 30 mbar
35.4 mbar (14.0 in w.g.)
7.3 mbar (2.92 in w.g.)
30
G 30
27.3 mbar (10.9 in wg.)
7.0 mbar (2.8 in w.g.)
m3/h
(84,500 Btulh)
(44,500 Btulh)
(82,100 Btulh)
(87,200 Btu/h)
(40,100 Btulh)
(45,700 Btu/h)
(27.89
ft3/h)
POWER CONSUMPTION
EXTERNAL FUSE RATING
6OW
3A
INTERNAL FUSE 4 A (20 mm to BS 4265)
DRY WEIGHT kg 35
WATER CONTENT C.H. litre 0.5
GAS SUPPLY CONNECTION
FLOW CONNECTION C.H.
RETURN CONNECTION C.H.
CONDENSATION DRAIN
1/2" RC
22 mm
22 mm
3/4" (21.5 mm) push fit over flow
SEALED WATER SYSTEM C.H.
MAX PRESSURE PMS
2.5 bar (35.6 p.s.i.)
MINIMUM WORKING PRESSURE 0.5 bar
O
CENTRAL HEATING OPERATING TEMPERATURE MAX 85
C
MIN 62°C
O
DESIGN FLOW RATE 1023 I/h (225 gals/h) 20
C RISE
MINIMUM FLOW RATE C.H./503 Lts/h (111 gals/h)
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
(7.35 p.s.i.)
DESTINATION: BE. CH. ES. FR. GB. IE. IT. PT.
FLUE TYPE - C52 - C32 - C
52
CATEGORY l3+
NOX 2
9
4.4
4.4.1
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.
IMPORTANT NOTICE
If the boiler is to be fitted in a timber framed
building it should be fitted in accordance
with the British Gas Publication Guide for
Gas Installations in Timber Frame Housing
Reference DM2. If in doubt advice must be
sought from the local gas supplier.
The boiler may be installed in any room
internal space, although particular attention
is drawn to the requirements of the current
I.E.E. Wiring Regulations, and in Scotland
the electrical provisions of the Building
Regulations applicable in Scotland, with
respect to the installation of the
tion 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,
electrical switch or appliance control,
ing mains electricity should be so situated
that it cannot be touched by a person
a bath or shower.
A compartment used to enclose the boiler
MUST be designed and constructed
ically for this purpose. An existing cupboard,
or compartment, may be used provided it
modified accordingly. Samples of the CSI
boiler have been examined by B.G.Technol-
ogy 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 Com-
patibility Directive 89/336/EEC and are
therefore permitted to carry the CE Mark.
The appliance has been tested and
approved by the WRc as meeting the
requirements of G3 and L of the Building
regulations and water Bylaws Scheme -
Approved Products.
combina-
any
utilis-
using
specif-
or
tion 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 sup-
ply is available both to the boiler and the
other appliances when they are in use at
the same time.
4.6 FLUE SYSTEM
4.6.1
is
The terminal should be located where dis-
persal of combustion products is not imped-
ed 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 con-
sidered.
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
surface.
Pluming will occur at the terminal so, where
possible, terminal positions which could
cause a nuisance should be avoided.
The flue must be installed in accordance with
the recommendations of BS 5440: Part 1.
IMPORTANT NOTES
For greater flue lengths see twin flue
instructions.
Flue must be positioned in a place not likely
to cause a nuisance.
4.5
4.5.1
10
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
ing pipe work to the appliance. A smaller
size than the boiler inlet gas connection
should not be used. The complete installa-
be used for remain-
IMPORTANT: The following notes are
intended for general guidance.
The boiler MUST be installed so that the
terminal is exposed to external air.
It is important that the position of the terminal allows the free passage of air across it
at all times.
Minimum acceptable spacing from the terminal to obstructions and ventilation opening are specified in Fig. 6.
Note positions: Due to the terminal design,
installation is
than those specified in BS 5440, Part 1.
possible with clearances less
NOTE:
The flue must be terminated in a place not
likely to cause a nuisance:
Fig. 6
4.6.2
4.7
4.7.1
4.8
4.8.1
Fig. 6A
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.
AIR SUPPLY
The following notes are intended for gener-
al 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.
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.
Important: any external runs must be carried 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.
Terminal position for fan assisted boiler
(minimum
A
B
C Below eaves
D
E From vertical drain pipes and soil pipes
F
G - Above ground or below balcony level
H
I
J From an opening in the car port (e.g. door
K
L
4.8.2
distance)
- Directly below an open window or other
opening (e.g. air brick)
Below gutters, soil pipes or drain pipes
Below balconies or car port roof
From internal or external corners
- From a surface facing a terminal
From a terminal facing a terminal
window) into dwelling.
Vertically from a terminal on the same wall
- Horizontally from a terminal on the same wall
Pipework
Copper tubing to BS 2871 1.1 .1971 is recommended for water pipes. Jointing should
be either with capillary soldered or with
compression fittings.
Where possible pipes should have a gradient to ensure air is carried naturally to air
release points and water flows naturally to
drain taps. It should be ensured as far as
possible that the appliance heat exchanger
is not a natural collecting point for air.
Except where providing useful heat, pipes
should be insulated to prevent heat loss
and to avoid freezing. Particular attention
should be paid to pipes passing through
ventilated spaces in roofs and under floors.
11
WATER SYSTEM
4.8.2.1
4.8.2.2
4.8.2.3
4.8.2.4
WATER SYSTEM
For an open (vented) system the boiler
must be supplied from an unrestricted
water supply taken from a feed and expansion tank (minimum 22 litre 5 gall) capacity
situated at a maximum height of 27.5 metre
(90ft) above the boiler. The cold feed supply
must be 15 mm minimum size. It is important that the relative positions of the pump,
cold feed and open vent. See Fig. 6D.
CYLINDER
The hot water cylinder must be a double
feed (fully indirect) type.
SEALED WATER SYSTEMS
The installalation should comply with the
appropriate requirements of BS5449 Part 1
and BS6798, see Fig. GE. All valves and fittings must be suitable for use on sealed
systems.
SAFETY VALVE
The safety valve must be fitted in a sealed
system. The safety valve must Conform to
BS6759 Part 1 and be fitted to the require-
ments of BS6798.
4.8.2.5
4.8.2.6
4.8.2.7
EXPANSION VESSEL
A diaphragm type expansion vessel, conforming to BS4814 must be connected at a
point close to the inlet side of the circulating
pump, see Fig. 6E or as laid down by the
manufacturer.
The expansion vessel must suit the volume
of water in the system, see BS5449 Part 1
clause 25 for details. The charge pressure
must not be less than static head i.e. the
height of the highest point of the system
ABOVE the expansion vessel.
The expansion vessel should have sufficient capacity to accept the volume change
when the water is heated from 10
o
C. Refer to BS5449 Part 1 for specific
o
C to 110
details. See Table 3.
PRESSURE GAUGE
A pressure gauge with set pointer and covering at least the range 0 to 4 bar (0 to 60
2
) shall be permanently fitted to the sys-
Ib/in
tem in a position it can be seen when carry-
ing out the filling operation.
SYSTEM DESIGN
Fig. 6A illustrates typical heating only layout, Figs 6B and 6C illustrate typical layout
with ‘Y’ or ‘S’ plan system.
Fig. 6D
Open (vented) system pipework requirements
4.8.3
12
The waler through the appliance heat
exchanger circuit must exceed the mm 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 of: either manually or bu automatic
controls. Therefore a by-pass must be fit-
ted 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.
4.8.4. Draining tap
These must he located in accessible positions to permit the draining of the whole
system. The taps must be at least 15 mm
nominal size and manufactured in accordance with BS 2870 1980.
4.8.5
Air release points
These must be fitted at all high points where
air will naturally collect, and must be sited to
facilitate complete fitting of the system.
4.8.7 Mains water feed: central heating
There must be no direct connection to the
mains waler supply, even through a nonreturn valve, without the approval of the
Local Water Authority.
4.8.8 Permissible methods of filling
Cistern method (Fig. 8).
The system may be filled by one of the following methods. Through a cistern used for
no other purpose. via a hallvalve permanently connected directly to a service pipe
and/or cold water distributing pipe. The static head available from the cistern should
be adequate 10 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).
Fig. 8
13
SIZING OF EXPANSION VESSELS: TABLE 3
Safety
valve setting (bar)
Vessel charge
pressure (bar)
Initial system
pressure (bar)
Total water
content Of system
Litres
25 2.1 3.5 6.5 13.7 2.7 4.7 10.3 3.9 8.3
50 4.2 7.0 12.9 27.5 5.4 9.5 20.6 7.8 16.5
75 6.3 10.5 19.4 41.3 8.2 14.2 30.9 11.7 24.8
100 8.3 14.0 25.9 55.1 10.9 19.0 41.2 15.6 33.1
125 10.4 17.5 32.4 68.9 13.6 23.7 51.5 19.5 41.3
150 12.5 21 .0 38.8 82.6 16.3 28.5 61.8 23.4 49.6
175 14.6 24.5 45.3 96.4 19.1 33.2 72.1 27.3 57.9
200 16.7 28.0 51.8 110.2 21.8 38.0 82.4 31.2 66.2
225 18.7 31.5 58.3 124.0 24.5 42.7 92.7 35.1 74.5
250 20.8 35.0 64.7 137.7 27.2 47.5 103.0 39.0 82.7
275 22.9 38.5 71.2 151.5 30.0 52.2 113.3 42.9 91.0
300 25.0 42.0 77.7 165.3 32.7 57.0 123.6 46.8 99.3
325 27.0 45.5 84.1 179.1 35.7 61.7 133.9 50. 7 107.6
350 29.1 49.0 90.6 192.8 38.1 66.5 144.2 54.6 115.8
375 31.2 52.5 97.1 206.6 40.9 71.2 154.5 58.5 124.1
400 33.3 56.0 103.6 220.4 43.6 76.0 164.8 62.4 132.4
42 5 3 5.4 5 9. 5 110.1 239.2 46.3 80.7 175.1 66.3 140.7
450 37.5 63.0 116.5 247.9 49.0 85.5 185.4 70.2 148.9
475 39.6 66.5 123.0 261.7 51.8 90.2 195.7 74.1 157.2
500 41.6 70.0 125.9 275.5 54.5 95.0 206.0 78.0 165.5
For system volumes
other than those given
above, multiply the 0.0833 0.140 0.259 0.551 0.109 0.190 0.412 0.156 0.331
system volume by
the factor across
3.0
0.5
0.5
1.0
1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0
EXPANSION VESSEL VOLUME (LITRES)
1.5
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.
The system may be filled through a self
contained unit comprising of a cistern pressure booster pump if required and if neces-
sary 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 connected to the heating system to provide limited automatic water make up.
ments of BS 1010 Part 2 (the temporary
hose from the draw off tap shall be con-
nected to this fitting).
b) A test clock.
c) Double check valve of an accepted type.
d) A non return valve of an accepted type.
We recommend use of a Ravenheat
Filling Loop designed for this method of
filling the system. Available from your
supplier.
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.
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-
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.
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
14
4.8.9
should exceed 110 litres, an additional ves-
sel 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 l/2" in BSP nominal size and be in
accordance with BS 2879.
Installation to an existing central heating
system
Before installing a new boiler to an existing
system, flush out the old system with a recommended descaling agent.
It is most important that the correct concentration of the water treatment product is
maintained in accordance with the manufacturers’ instructions.
If the boiler is installed in an existing system
any unsuitable additives MUST be removed
by thorough cleansing.
BS 7593:1992 details the steps necessary
to clean domestic central heating svstem.
Also check pipework and renew any corroded pipework or fittings. Valve glands must
be repacked or replaced wherever neces-
sary and any defective controls exchanged.
adjacent to the appliance except, where the
appliance is installed in a bathroom, this
MUST be sited outside the bathroom.
SECTION 5 INSTALLATION
5.1
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.
Fig. 10
o
down towards
4.10
4.10.1
WATER TREATMENT
This boiler has a secondary ALUMINIUM
alloy heat exchanger Ravenheat recommended only the use of FERNOX-COPAL
SENTINEL Xl00 or SALAMANDER COR-
ROSION GUARD water treatment products,
which must be used in accordance with the
manufacturers instructions. For further
information contact:
Fernox Manufacturing Co. Ltd.
Tel. 01799 550811
Sentinel Division Betz Dearborn Ltd.
Tel. (0151) 424 5351
Salamander (Eng) Ltd
Tel. (0121) 3780952/4508
ELECTRICAL SUPPLY
Warning: this appliance must be earthed
Fig. 11
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
supply. The supply must be fused at 3 A.
NOTE: The method of connection to the
electricity supply MUST facilitate complete
electrical isolation of the appliance, by the
use of a fused, double pole isolator, having
a contact separation of at least 3 mm in all
poles. The point of connection to the elec-
tricity supply must be readily accessible and
15
5.2
5.2.1
DELIVERY
The appliance will arrive on site in two
cartons
Box 1 of 2 containing (Fig. 1O):
a) boiler fully assembled
b) installation instructions and
user instructions
c) white paper template
d) terminal cover plate (Fig. 12)
e) - 4 conch bolts and wall plugs
-screws and dowels
Polythene bag containing (Fig. 11):
a) l-112” BSP Union Gas Cock
d) 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
57 - Flue bend assembly
58 - Header gasket
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 Cover Plate
(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 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
Fig. 14
59 - Rubber seal 60
63 - Air intake duct extension
64 - Flue exhaust duct extension
65 - Pipe centering spring
16
17
5.4
POSITIONING OF THE BOILER
Fig. 22
5.4.1
54.2
5.4.2.1
5.4.2.2
5.4.3
5.5
Remove the 4 screws that secure the upper
part of the front panel of the casing (Fig.
19). Carefully 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).
Remove the two sides of the casing bu sli-
ghtly lifting them and carefully sliding
towards the too of the appliance to release
them from their upper suspension hooks
(Fig. 26-27).
Make sure that the casing and screws are
put to one side in a safe place.
Lowering instrument panel (not necessary
for installation).
- Unscrew the 2 screws that fasten the
instrument panel (Fig. 23).
-
Lift the instrument panel in order to detach it from the sides. and lower it down by
rotating it on its own hinges (Fig. 24-25).
Make Sure the casing screws are put to one
side in a safe place.
INSTALLINGTHE APPLIANCE FOR
REAR FLUE OUTLET
Fig. 23
Fig. 25
5.5.1
Fig. 21
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 boiIer securing holes. Insert the plastic
expansion plugs.
-
Cut or core drill a 105 mm dia hole for
inserting the flue duct.
-
Screw in the two upper coach bolts leaving
them about 10 mm out from the wall to
enable the boiler to be located on the wall.
Fit the elbow header positioning it towards
the required direction (Fig. 30).
IMPORTANT: Make sure that the elbow’s
dia. 60 mm duct is inserted into the fan, the
rubber Seal and orifice (F2) have been cor-
rectly fitted.
18
5.5.2
5.5.3
Locate the rubber 0 100 and 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.
Fig. 32
INTAKE AND EXHAUSTTERMINAL COMPONENTS
Fig. 31
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
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), locat-
ing onto the top coach bolts. Fit the two
lower coach bolts and tighten all four secur-
ing bolts.
5.5.6
5.5.9
Fig. 35
Fit terminal cover plate and terminal guard
(Fig. 36-37).
Extension kits are available on order for flue
extension of up to 2.5 metres total length
(Fig. 31).
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.
5.5.10
Each extension length extends the pipe by
approximately 1000 mm long up to a maximum of two extensions.
Pipeline length can be established using
the instructions in section 5.5 for rear flue
outlets and section 5.7 for side flue outlets.
Extensions must be installed with the
widened end of the air intake pipe and the
tapered end of the flue pipe aimed towards
the exhaust terminal. Extensions must be
joined together with the standard terminal
pipe, and inserted in each other as far as
they can go.
If an extension must be shortened, this
must be done from the straight end, and not
from the widened or tapered end. To measure the pipeline properly all components
must be assembled and total length measured before cutting. The straight end of the
extension connects to the boiler. The flue
output pipe fits into the boiler header until it
stops. The air intake pipe should be located
approximately 2 mm. from the boiler header
(Fig. 31).
When cutting both inner and outer ducts of
the extension, always ensure that the
reduced end (male) of the inner duct is
longer than the outer duct.
All joints must be sealed with the rubber
seals supplied.
It is important to put the centering spacer,
supplied with the unit, inside between the
two pipes, from the side opposite the exten-
sion’s straight end.
5.7
INSTALLING THE APPLIANCE FOR SIDE
FLUE OUTLET (Fig. 39)
-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. 39B).
IMPORTANT: 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
o
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 ord-
er as in sect. 5.4.4.
3) Refit the lower grating (sect. 5.4).
Fig. 39
21
Fig. 39B
5.7.2
5.7.3
5.75
KEY
56
-
Sample point
57
-
Elbow Header
59
-
Rubber seal 0
Positioning the elbow towards the required
direction (Fig. 30).
Locate the rubber 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.
60
5.7.6
5.7.7
5.7.8
5.7.10
5.7.11
63 - Air intake duct extension
64 - Flue Exhaust duct extension
65 - Pipe centering spring
128 - In Line Bend
- Reassemble the two tubes.
Insert centering spring 65.
Insert the flue assembly into the wall,
making sure it will not interfere when fixing
the boiler on the wall.
Lift the boiler on the wall. Locate onto the
top coach bolts. Fit the lower coach bolts
and tighten all four securing bolts.
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.
IMPORTANT: Terminal rubber must be
fitted (Fig. 36-37).
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.
5.7.12
VERTICAL FLUE INSTRUCTIONS ONLY
5.7.12
VERTICAL FLUE INSTRUCTION ONLY
INLINE FLUE BEND - 1680 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90” BEND
OBTUSE FLUE BEND - 1680 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135” BEND
The vertical flue kit is intended
for use where a horizontal flue
outlet is not possible or
desired. The vertical flue can
be used either with a flat roof
or a pitched roof (maximum
pitch 60”). Where a straight
vertical flue is not possible or
desired, an offset vertical flue
can be used in conjunctioncan be used in conjunction
with a side horizontal fluewith a side horizontal flue
extension piece and an inlineextension piece and an inline
135o190o flue bend (Fig. 41).
1
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
MIN. DISTANCE mm
300
300
300
1,200
M horizontally from a vertical terminal to a wall 300
Before proceeding with installation check the
contents of the RAVENHEAT VERTICAL FLUE KIT,
comprising of the following pieces:
- 1 RAVENHEAT VERTICAL FLUE
complete with terminal assembly (for
vertical flue application).
-Additional 1000 mm (approx) Flue
Extension pieces as necessary, each
extension is provided with 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.
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 stan-
dard 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 (6 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
marked CHR.
- Connect the central heating flow pipe
marked CHF.
-
Pipe dimensions and positions are marked
on template supplied and fig. 49/A.
24
5.13
ELECTRICAL CONNECTIONS
Fig. 46
5.13.1
IMPORTANT: Electricity supply must be as
specified in clause (sect. 4.10).
-
When controls external to the appliance
are required, design of the external elec-
trical circuits should be undertaken by a
competent person. In accordance with
the IEE wiring regulations.
Factory fitted internal wiring must not be
disturbed when wiring external controls.
- To gain access to the electrical box
remove the front panel of the case as
described in clauses (sect. 5.4.1) and
the instrument panel as described in
clauses (sect. 5.4.3).
The terminals are easily visible on the front
of the electronic control board (Fig. 48).
- Heat resistant flexible cable is fitted
between the isolator and the terminal
block. A 3 core cable of 0.75 mm
(24x0.2 mm) to BS 6500.
Make sure all wires to the appliance are
routed away from sharp edges and hot
surfaces.
The cable must be fastened with its cord
anchorage and connected so that should
the cable slip from the anchorage the
current carrying conductors become taut
before the earthing conductor.
Securely tighten all terminal screws and
arrange the cable with slack between the
cord anchorage and the terminal block.
WARNING: If the supply cord is dam-
aged, it must be replaced by a service
engineer (supply cord available from
Ravenheat Manufacturing Ltd).
2
cable of 0.75 mm (24 x 0.2 mm) to BS6500.
Make sure all wires to the appliance are
routed away from the 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.
5.13.2
5.13.3
To gain access to the electrical connection
remove the front panel of the case as
described in clauses (sect. 5.4.1).
Unscrew the 2 screws that fasten the instrument panel (Fig. 23).
Lift the instrument panel in order to detach
it from the sides, and lower it down by rotating it on its own hinges (Fig. 24-25). Make
sure the casing and screws are put to one
side in a safe place.
The terminal box is easily visible on the
front of the control panel. Pull the electrical
cover off to expose connection (Fig. 48).
Heat resistant flexible cable is fitted between
the isolator and the terminal block. A 3 core
5.13.4 The pump must be connected directly to the
boiler terminal’s marked pump supply (Fig.
48). Any external controls must not interrupt
this electrical connection.
5.13.5
To fit timer/programmer remove white link
wire - 230 volts.
5.13.6
Check the electrical installation for earth
continuity, short circuits, resistance to
earth, correct polarity and fuse failure.
WARNING: if supply cord is damaged it
must be replaced by a service engineer
(supply cord available from Ravenheat
Manufacturing Ltd).
25
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 INSTALLATION
Inspect the entire installation including the
gas meter, test for soundness and purge, all
as described in BS 6891.
6.5
SETTING THE SYSTEM DESIGN
PRESSURE
The design pressure must be a min 1 bar
and max 1.5 bar. These figures are read off
the pressure gauge.
- The actual reading should ideally be 1
bar + the height in metres to the highest
point of the system above the base of
the appliance (up to 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.
6.3
6.4
Fig. 48
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.
INITIAL FILLING OF THE SYSTEM
Unscrew the cap on automatic air release
valve one full turn (leave open permanently).
- Close all air release taps on the heating
system.
- Gradually fill the 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.
- Inspect the system for water soundness
and remedy any leaks discovered.
6.7
6.7.1
LIGHTING THE BOILER (Fig. 50)
Before lighting the main burner make sure
that the heating circuit flow and return
valves are open.
- If external controls are installed (e.g.
timeclock and thermostat) make sure
that they call for heat.
- Turn on main switch 1 (Fig. 50).
LIGHTING THE BOILER (Fig. 50)
Before lighting the main burner make sure
that any heating circuit flow and return
valves are open.
- If external controls are installed (e.g.
timeclock and thermostat) make sure
that they call for heat.
- Turn on main switch 1 (Fig. 50).
- Turn control thermostat up to its maxi-
mum 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. 51)
Fit a gas pressure gauge on pressure inlet
77 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 (G31) and 29 mbar
(G30).
26
6.8
CHECK THE GAS PRESSURE AT THE
BURNER
Now check the gas pressure at the burner is
equal to 10.5 0.5 mbar (4.2 + 0.2 in wg.)
for CSI.
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 control thermostat at its maximum
setting.
- Fit a pressure gauge, using hose to
pressure test point 81, (Fig. 51). After
first loosening its close-off screw.
- Turn on mains switch 1 (Fig. 50). Switch
on timer and any external controls.
- The pressure indicated after a few seconds on the pressure gauge is the maximum operating gas pressure.
Observe the pre light flame which will light a
second before main burner. It should be
about 20 mm long (Fig. 52B) end envelop
the spark electrode tip.
Fig. 52B
6.10
Fig. 52
ADJUSTING BURNER SETTlNG
PRESSURE
- With the boiler operating use a spanner
(Honeywell a screw driver) to turn the
nut 110 clockwise to increase pressure
and anticlockwise to decrease pressure.
- To obtain the desired heat value estab-
lish pressure as per (Fig. 52).
- Once the 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.
RATIO BETWEEN BURNER
PRESSURE AND OUTPUT
Once the process of commissioning the boiler is
complete,
complete his section in the Benchmark log book.
6.14
6.14.1
the commissioning engineer MUST
CHECKING THE HEATING THERMOSTAT
Allow the system to warm up and then turn
the C.H. thermostat to ensure the main burn
er modulates from “high” to off and vice versa
(scale range covers approx. 62” C - 85” C).
6.13
6.13.1
28
CHECKINGTHE FLUE SYSTEM
The flue system should be visually checked
for soundness. Check all connections and
fixings are secure and tight.
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
42
53 - Connection tube
54 - Connection tube
58 - Ceramic insulation
61 - Condensing heat exchanger
80 - Plenum chamber
83 - Burner centering pin
84 - Seal
29
6.16
6.16.1
HANDING OVER TO THE USER
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 1996”.
- 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 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.
SECTION
7 SERVICING INSTRUCTIONS
7.2
7.2.1
7.2.2
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 boiler thermostat up
and down 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 per year should be adequate.
WARNING
Before the start of any servicing or replacement of components always isolate electricity supply to the appliance and always turn
off the appliance gas supply at the gas
service cock.
30
7.2.3
7.2.4
7.2.5
7.2.5.1
7.2.6
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 elec-
trodes for damage or deterioration, clean or
renew as necessary. Ensure that the spark
gaps are correct to dimensions specified in
sec. 7.15.
Inspect the secondary condensate heal
exchanger. Deposits can be cleared by
removing and flushing out the exchanger.
Inspect the siphonic condensate trap for a
blockage. Any deposits should be flushed
out (Fig. 90).
7.2.6.1
7.2.7
7.2.8
To remove condensate 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).
Examine flue duct and flue hood and
ensure that there is no obstruction. Exam-
ine the gasket at the entry into the flue duct.
7.6.5.2
7.6.5.3
7.6.5.4
7.6.5.5
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).
Disconnect 4 unions for the heating water
pipelines (Fig. 54) and remove the two short
pipes.
Remove screw holding heat exchanger to
chamber. Disconnect condensing discharge
pipe by pulling off the pushfit connector at
top rear of boiler (Fig. 54).
7.2.9
7.3
7.3.1
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.6
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 4 screws that secure the upper
part of the front panel of the casing and
carefully remove.
TO REMOVE/REPLACE THE
COMBUSTION 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.
TO REMOVE/REPLACE THE FAN
ASSEMBLY (Fig. 58)
7.6.5.6
7.6.5.7
7.7.2
7.7.2.1
7.7.4
7.7.6
Pull the heat exchanger down and slightly
forward until it comes out of the connection
from chamber (Fig. 55).
Replace in reverse order. Taking care to refit
discharge pipe at rear.
IMPORTANT: When replacing heat
exchanger new seals must be used.
TO REMOVE/REPLACE THE FLUE HOOD
(FIG. 60)
Remove front casing (sect. 7.3). Remove
combustion chamber front cover as in
(sect. 7.4).
Remove the fan (sect. 7.6).
Remove condensing heat exchanger
(sect. 7.6.5)
Remove the three screws on the front that
fasten hood to the combustion chamber.
Remove the two screws at the rear of hood.
Replace in reverse order.
7.6.1
7.6.2
7.6.4
7.6.5
7.6.5.1. Remove front casing (sect. 7.3). Remove
Remove front casing (sect. 7.3).
Remove combustion chamber front cover
as in (sect. 7.4).
Disconnect the electrical connections 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
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
combustion chamber front cover as in (sect
7.4). Remove lower grating by unscrewing
the two screws (Fig. 21).
7.8
7.8.1
7.8.2
7.8.6
7.8.8
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).
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.
Remove the fan (sect. 7.6).
Remove condensing heat exchanger
(sect. 7.6.5).
Remove the flue hood (sect. 7.7).
Remove the automatic air vent (Fig. 92).
31
7.8.9
Disconnect unions for two heating (right
side of boiler) water pipelines (Fig. 62).
Fig. 55
7.8.10
7.8.11
7.8.12
7.8.13
7.9
7.9.1
7.9.2
7.9.3
Unscrew the rings that fasten the heat
exchanger to the combustion chamber.
Remove the two side insulation panels at
top of heat exchanger (Fig. 63).
Pull the heat exchanger up until its flow
connections come out from the combustion
chamber and then remove it (Fig. 64).
Replace in reverse order.
Ensure correct wire position (Fig. 94)
IMPORTANT: When replacing a heat
exchanger new seals must be used.
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).
7.9.4
Remove the flue hood (sect. 7.7)
7.9.5
7.9.6
7.10
7.10.1
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 insula-
tion panels.
Replace in reverse order.
TO REPLACETHE ELECTRODE
(Fig. 66)
Remove front casing (sect. 7.3).
Remove combustion chamber front cover
(sect. 7.4).
32
Fig. 58
Fig. 60
Fig. 62
UNSCREW
33
Fig. 63
Fig. 66
Fig. 64
7.10.2
Detach the wire from electrode and then
unscrew the nut that secures it to the pilot
burner assembly and remove.
7.10.3 Replace with new electrode in reverse order.
7.12
TO REPLACE THE PILOT INJECTOR
(Fig. 68)
7.12.1
Remove the front panel of the casing and
the combustion chamber front cover (sect.
7.3 & 7.4).
Remove the lower sect. 5.4.2 (Fig. 21).
7.12.2
Release the fitting that secures pilot pipe at
the gas valve.
7.12.3
7.12.4
7.12.5
Remove electrode (sect. 7.10).
Unscrew pilot connection from pilot burner
Pull the aluminium tube downwards and the
injector should come out by itself.
7.12.6
7.13
Replace in reverse order
TO REPLACE THE 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.
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 com-
bustion 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
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 injectors manifold as 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).
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
Remove the 2 screws 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).
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
CONTROLTHERMOSTAT
Fig. 78, 79, 81
Remove the front panel from the outer casing (sect. 7.3) and lower the instrument
panel (sect. 7.16.2 & 3).
Fig. 75
7.19.2
7.19.3
36
Pull off the thermostat knob.
Detach the wires that connect to the thermostat - make sure that these wires reconnect to the same poles.
7.19.4
Unscrew the two screws that fasten the
thermostat to the instrument panel.
Fig. 76
7.19.5
7.19.6
7.22
7.22.1
7.22.2
7.22.3
7.22.4
7.22.5
7.22.7
Remove the split pin and pull the thermostat from its pocket (Fig. El).
Replace in reverse order.
TO REMOVE/REPLACE THE OVERHEAT
THERMOSTAT (Fig. 78,79)
Remove the front panel from the outer
casing (sect. 7.3) and lower the instrument
panel (sect. 7.16.2 & 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 subsequently be reconnected to the same poles.
Remove the split pin and pull the thermostat sensor from its pocket.
Replace in reverse order.
Fig. 79
7.24
7.24.1
7.24.2
7.24.3
7.24.4
7.24.5
7.24.6
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).
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 is
connected to the tube terminating at flue
ring (Fig. 87 and 94).
Fig. 81
37
7.27.5
Undo the nut and withdraw the sensor
(Fig. 81) from its pocket.
7.32
TO REMOVE/REPLACE
THE IGNITION BOARD
7.27.6
7.29
Replace in reverse order.
TO REMOVE/REPLACE THE
AUTOMATIC AIR VENT (Fig. 92)
7.29.1
Remove the front panel from the outer casing and the combustion chamber front cover (sect. 7.3 & 4).
7.29.2
Remove the lower grating (sect. 5.4.2).
7.29.3 Remove the fan assembly and the flue hood
(sect. 7.6 & 7.7).
Fig. 87
7.32.1
7.32.2
7.32.3
7.32.4
7.32.5
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.
SECTION
8 FAULT FINDING
Stat to maximum
Ensure external controls calling for heat (Room Stat/Time Clock/TRV
SECTION
9 ELECTRICAL SYSTEM DIAGRAM
Fig. 94
40
41
8.0
INSTALLATION INSTRUCTIONS FOR
TWIN FLUE PIPE (ECCENTRIC FLUE
DUCT SYSTEM)
Fig.
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
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
procedures are illustrated by drawings.
with
installation
the
Supplied with the CSI twin flue header is a
F1 orifice plate along with supplementary
depression seal.
Before fixing the twin flue system the
existing orifice plate must be replaced with
F1 also ensuring supplementary seal has
been fitted.
Remove the 13 screws securing the
depression front panel item 2 figure 53A to
expose front edge of depression chamber.
(Twin flue instructions figure 1 adjacent).
Using adhesive sponge supplied with CSI
twin flue header, carefully attach to
depression chamber so as to create a
softer seal. Taking care not to damage the
new seal, carefully re-fit the depression
chamber front cover in reverse order.
Take out the 4 temporarily fitted securing
screws, lifting our the gasket and orifice
plate disconnecting it from the venturi tube.
42
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.
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.
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.
90o M/F bend consisting of.
90” elbow with ‘0’ ring side F
80 mm dia ‘0’ ring
135” M/F bend consisting of.
135” elbow with ‘0’ ring side F
80 mm dia ‘0’ ring
Exhaust/suction system with concentric pipes for flat
sloping roofs. Extensions with two separate
or
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:
o
slow bend less 3 metre of pipe for each one
90
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.
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
o
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.
Fig. 4.6
ITEM DESCRIPTION
1
CSI flue adaptor gasket and screws
2
Straight pipe
Eccentric vertical terminal
3
4
90” slow bend
5
45” bend
6
Air inlet terminal (plastic) 60 mm
7
Exhaust terminal (stainless steel) 80 mm
8
Pitch roof slate
9
Flat roof slate
10
Twin flue pipe socket seal 60 mm
Maximum distance D = I + E = Total exhaust/inlet
pipe 18 metre.
Minimum distance D = I + E = 1.5 metre.
Min inlet pipe distance 0.5 metre.
Min distance between pipe 50 mm.
NOTE: The pressure loss for each elbow fitted is:
90” slow bend less 3 metre of pipe for each one fitted.
45” 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
PART NO.
ground, or above a flat roof to which people
have access, then a suitable terminal guard
must be fitted.
30005
Fit only recommended flue terminal guard by
securing concentrically around terminal with
screws.
30001
30003
30009
30011
Available on request from:
RAVENHEAT MANUFACTURING LTD
Chartists Way
Morley, Leeds, West Yorkshire
ENGLAND LS27 9ET - U.K.
Tel. (0113) 252 007
30007
IMPORTANT:
see Fig. 6 and 42 for terminal clearances.
44
RAVENHEAT CSI PRIMARY CONDENSING FANNED COMBI BOILER
SHORT LIST OF SPARE PARTS
Pos.
1
4
5
6
7
10
11
13
17
18
21
22
Ravenheat
Part. No.
0001 PAN06005/0
0007TER06005/0
0007TER03010/0
0001 CAM06005/0
0001 DIA06005/0
0014VET01005/0
001 0TUB05040/0
0001 CAP06005/0
0014MAN06015/0
0012GEN05005/0
5003066
0008VAL06005/0
G.C.
Part. No.
371267
E23-732
E23-730
371268
E23-716
E23-733
E23-718
E24-630
372849
Description
Instrument panel
Boiler thermostat
Overheat thermostat
Combustion chamber
Flue restriction ring 79CSI (F2)
Sight glass
Depression chamber gas pipe
Flue gas exhaust hood
Knob
Printed ignition board
Combustion chamber cover
Sit gas valve
22.1
24 0003BRU06015/0
25
26
27
29
30
31
32
33
37
38
45
46
0008VAL06006/0
5012114
0002SCA06010/0
0014RAC06005/0
001 OTUB0601 O/O
5015015
5018025
5018030
0012VEN03005/0
1015PAN06005/0
0010TUB06060/0
5023020
0014GUA01020/0
372-866
372894
E23-731
E23-735
372888
37285 1
372867
173101
E23-737
E23-738
372855
371277
Honeywell gas valve
Main burner
Pilot burner
Heat exchanger
Condensing trap
Connecting pipe to air purge
Air purge valve
Gasket 18.5 x 11.6 x 2
Gasket 24 x 15 x 2
Fan
Insulation pads set
Pipe to air purge
Depression chamber pilot seal
Flue gasket
47
48
48.1
46
0001 CAM0601 O/O
5012096
0003UGE01005/0
372856
E02-129
Depression chamber
Nozzle 0,27 for natural gas
Nozzle DM 0.22 x 1 LPG
Pos.
Ravenheat
Part. No.
G.C.
Part. No.
Description
50
51
61
62
62.1
64
68
68.1
70
81
85
87
89
93
5021050
0012CAVO6005/0
0002SCA06005/0
0003UGE03005/0
0003UGE01011/0
0001TEL06010/0
0003BRU06015/0
0003BRU06002/0
0013GUA03035/0
0013GUA01045/0
0012FUS05020/0
5021312
0005PRE05015/0
0019CUR06005/0
372892
E23-739
E23-740
371297
E23-755
371273
371274
E23-724
372875
E24-629
E23-750
Ignition electrode
Cable for electrode
Condensing heat exchanger
Nozzle 1,25 for natural gas
Nozzle DM 0.75 LPG
Frame
Main burner natural gas
Main burner LPG
Gasket 32 x 32 x 2 gas valve
Gasket 48 x 42 x 1
Internal fuse 4A
Nylon tubes from pressure switch
Pressure switch
Elbow header
95
97
106
110
111
112
113
114
115
116
117
0019PRO06005/0
0019TER06005/0
0019TER06010/0
0001 MAN06005/0
0011RIV06006/0
0011RIV06005/0
0012CAVO6015/0
0014GUA06010/0
0014GUA06005/0
0014GUA06015/0
0019SDO06005/0
E23-751
E23-752
E23-753
Flue extension duct complete
Flue duct and terminal complete
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
47
Chartists Way, Morley, Leeds, LS27 9ET.
Telephone: (0113) 252 7007
Tfax: (0113) 238 0229
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