Ravenheat Flue Boiler, CSI System Installation And Servicing Instructions

Supplied By www.heating spares.co Tel. [phone]

CONDENSING FANNED FLUE BOILER

CSI SYSTEM

WITHOUT TIMER

NATURAL GAS (G20) (I

LPG (G30-G31) (I3+) G.C.No 47 581 03 - CSI

Tested, certified and

Listed by The United Kingdom Water

Fitting Byelaws Scheme

2H

) G.C.No 47 581 01 - CSI

service listed

WITH TIMER

NATURAL GAS (G 20) (I

LPG (G 30 - G 31) (I3+) G.C.NO 47 581 04 - CSI

2H

) G.C. NO 47 581 02 - 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 [phone]

Supplied By www.heating spares.co Tel. [phone]

CONDENSING SYSTEM INNOVATION AUTOMATIC MODULATING

CENTRAL HEATING BOILER

This new super high efficient turbo-modulating 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 [phone].

BASIC COMPONENTS - (See figure 1)

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

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.
Built in frost protection.
Printed circuit board designed to connect to room stat cylinder stat, and/or timer/frost stat.
Aesthetically pleasing panels and controls.
On/Off ball valves for shutting off gas and central heating.
Safety relief valve (for safety discharge).

Programmable 7 day module with digital display (optional).
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 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.

2

Supplied By www.heating spares.co Tel. [phone]

SECTIONS:

1

2

3
4
5
6
7

8

9
10
11

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:

5

5

7-8

9
14
27
30

42
44

49
50

KEY

1 - Heat exchanger
3 Burner
4 - Ignition pilot burner
5 - Interface board
6 Condensing heat exchanger
7 - Ignition board
9 - Ignition electrode

11 - Frame

12 Modulating gas valve
15 - Heating control

16 - D.H.W. control
17 - D.H.W. sensor
18 - Pressure switch (heating circuit)
22 - Overheat cut off thermostat
23 - Safety relief system
26 - Auto air vent valve
28 -Air 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

3

.::

Supplied By www.heating spares.co Tel. [phone]

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

4

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

Supplied By www.heating spares.co Tel. [phone]

SECTION

1.1

1 INTRODUCTION

The Ravenheat CSI System boiler is a cen­tral heating system boiler which incorpora­tes a circulating pump, expansion vessel,
safety valve, pressure gauge and electronic
ignition. The boiler is equipped with a front
cover which can be removed for servicing.
The data badge is placed on the lower left

hand side of the frame.

1.1.1

1.1.2

1.1.3

1.1.4

1.2

SECTION 2

The Ravenheat CSI System boiler has

been carefully developed to utilise best use
of energy for super high efficiency, it can be
used as a condensing system heating only
boiler or can be used in the design of a ‘Y’
or ‘s” plan heating system incorporating a
hot water cylinder, this makes best use of

the built in energy management system to

control all modes of operation.

The boiler comes with a built in single cha­nel 7 day digital timer, this can be utilised to
control domestic hot water timed require-

ments and if a separate timer for heating is
required then it is recommended to fit a
room thermostat/timer is available from Ra-

venheat Manufacturing.

This appliance is designed for use with a
seal system only.

The provision of stored domestic hot water

is possible by the addition of an indirect cy­linder with ‘Y’ or ‘S’ plan controls.

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

2.2.3

2.2.4

2.2.5

2.2.6

2.2.7

2.2.8

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.

From the minimum gas rate setting the boi­ler increases to a maximum permissible
pressure and will remain at its maximum re­quired power until its maximum regulated
temperature.

When the cylinder stat and or the DHW timer

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. The

pump overrun will operate the pump for

about 1 minute after that the pump will stop.

Note

However, if there is a demand for heating
the boiler continue to operate to satisfy this

demand, rather than shut down, see 2.2.6.

Central heating mode

If the main neon switch is on with a demand

for heat to supply radiators, etc., with the

heating circuit fully charged so as to opera-

te the low water sensor device the boiler will

start but with a 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 go-

verned by a potentiometer range rate the

heating circuit between maximum and mini-

mum power.

On the control panel this potentiometer

(thermostat) controls the temperature. One

is for domestic hot water and the other for

heating.

2.1

2.2

2.2.1

2.2.2

DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION

Domestic hot water mode (if installed)

When the appliance mains neon is switched
on with the heating circuit charged with wa-

ter above 1 bar with a demand from the ti-

mer and cylinder stat for hot water the boiler
will function in the following sequence.

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

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

The spark ignition system is powered which

in turn commences the spark igniter to ope­rate and light the burner.
At this point the ignition board opens the

first step of the gas valve to light the

pilot/burner.

2.2.9

2.3

2.3.1

2.3.2

2.3.3

The boiler is fitted with an anti-cycling devi-

ce on the control board. This delays the boi-

ler from re-firing over a 2.5 minute period

when in heating mode. The domestic hot

water will always take priority and is unaf-

fected by the anti-cycling device.

GENERAL FUNCTION

Central Heating Mode

A potentiometer installed on the electric cir-

cuit board permits regulation of the boiler to

partial heating requirements, between the

factory settings.

Air is drawn by the fan for combustion

The fan also forces exhaust gas through the

flue to the outside, this creates a lesser

pressure in the sealed combustion cham-

ber, thus sucking in combustion air, through

the inlet duct.

5

Supplied By www.heating spares.co Tel. [phone]

2.3.4

2.3.5

2.3.6

The boiler water temperature is automati-

cally 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 timeclock. The burner contin-

ues to operate until it is stopped by the

timer or one of the thermostats.

When the internal C.H. temperature sensor

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

2.3.6

3.1

3.1.2

3.1.3

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.

SAFETY DEVICE

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.

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

2.3.7

OVERALL DIMENSION

Fig. 3

IMPORTANT:

Terminal guard

must be fitted.

When the room thermostats and or timer in­tervene the main burner shuts down. The
fan stops and the pump turns off via the
pump overrun.

3.2.1

A heating circuit (low water) pressure
switch is set at 0.4 bar.

AVAILABLE PUMP HEAD PRESSURE DROP ACROSS APPLIANCE
Fig. 4

6

Fig. 5

Supplied By www.heating spares.co Tel. [phone]

SECTION

3 TECHNICAL DATA

TABLE 1

NATURAL GAS (G 20) I

2H

NOMINAL HEAT INPUT NET

MINIMUM HEAT INPUT NET

24.8 kW

13.0 kW

NOMINAL HEAT OUTPUT 23.8 kW

NOMINAL HEAT OUTPUT CONDENSING 25.6 kW

MINIMUM HEAT OUTPUT

MINIMUM HEAT OUTPUT CONDENSING

GAS RATE

AFTER 10 MINUTES

INLET PRESSURE

BURNERPRESSURE

max 2.5 m

min

20 mbar (8.0 in w.g.)

max 10.5 mbar

min

MAIN BURNER INJECTORS

PILOT BURNER INJECTOR

ELECTRICAL SUPPLY

POWER CONSUMPTION

EXTERNAL FUSE RATING

INTERNAL FUSE

DRY WEIGHT

Nr. 13 x 1.25

0.27 x 2 HOLES

230V-50HZ

16OW

3A

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

kg 46

11.7 kW

13.4 kW

3

1.3 m3S/h

2.0 mbar

WATER CONTENT C.H. litre 1.O

S/h

(84,500 Btu/h)

(44,500 Btu/h)

(81,200 Btu/h)

(87,200 Btu/h)

(40,100 Btu/h)

(45,700 Btu/h)

(88.25 ft3/h)

(45.9 ft

3

/h)

(4.2 in w.g.)

(0.8 in w.g.)

GAS SUPPLY CONNECTION

FLOW CONNECTION C.H.

RETURN CONNECTION C.H.

1/2" RC

22 mm compression isolating valve

22 mm compression isolating valve

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

SEALED WATER SYSTEM C.H.

MAX PRESSURE PHS

MINIMUM WORKING PRESSURE

2.5 bar

0.5 bar

8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar

o

CENTRAL HEATING OPERATING TEMPERATURE MAX 85

MIN 45

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

o

C RISE

C

o

C

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

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

2H

52

NOX 2

110 LITRE

(35.6 p.s.i.)

(7.35 p.s.i.)

(7.35 p.s.i.)

7

:

Supplied By www.heating spares.co Tel. [phone]

SECTION

3 TECHNICAL DATA

TABLE 1/A

LPG (G 30 - G 31) I

3+

NOMINAL HEAT INPUT NET 24.8 kW

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

G 31

min

37 mbar G 31

max

G 31

min

0.95 m3S/h (33.53 ft3/h)

0.5 m3S/h

35.4 mbar

7.3 mbar (2.92 in w.g.)

13.0 kW

24.1 kW

25.6 kW

11.7 kW

13.4 kW

(17.65 ft3/h)

28 - 30 mbar

(14.0 in w.g.)

MAIN BURNER INJECTORS Nr. 13 x 0.75

PILOT INJECTOR

ELECTRICAL SUPPLY

POWER CONSUMPTION

EXTERNAL FUSE RATING

INTERNAL FUSE

DRY WEIGHT

WATER CONTENT C.H.

0.22 x 1 HOLE

230V-50HZ

160W

3A

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

kg 46

litre 1 .O

(84,500 Btu/h)

(44.500 Btu/h)

(82,100 Btu/h)

(87,200 Btu/h)

(40,100 Btu/h)

(45.700 Btu/h)

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

0.4 m3/h (14.12 ft3/h)

G 30

G 30

27.3 mbar (10.9 in wg.)

7.0 mbar (2.8 in w.g.)

GAS SUPPLY CONNECTION

1/2" RC

FLOW CONNECTION C.H. 22 mm compression isolating valve

RETURN CONNECTION C.H. 22 mm compression isolating valve

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 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

o

CENTRAL HEATING OPERATING TEMPERATURE MAX 85

MIN 45

o

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

C RISE

C

o

C

(35.6 p.s.i.)

(7.35 p.s.i.)

(7.35 p.s.i.)

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

FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers

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

FLUE TYPE - C12 - C32 - C

52

CATEGORY l3+ NOX 2

8

Supplied By www.heating spares.co Tel. [phone]

SECTION 4

4.0

4.1

SAFETY
Gas Safety (Installation and
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

relevant requirements of the local authority.

GENERAL INFORMATION

Both the user and the manufacturer rely

heavily on the installer, whose job it is to in-

stall the combination boiler and connect it to a

correctly designed heating system. Acquaint
yourself with the British Standards concerning

installation requirements. If you need advice

on any points your Ravenheat Technical

Services Office would be pleased to help. It is

recommended that tools suitable for brass
fittings are used, and have a capability to

accomodate hexagon sizes up to 50 mms.

CODES OF PRACTICE/Ret Documents

Detailed recommendations are contained

in the following British Standard Codes of

BS. 6891

BS. 6798

BS. 5546

GENERAL REQUIREMENTS

Practice:

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.

Installation of gas hot water
supplies domestic purposes
(2nd Family Gases).

USE)

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
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
invalidate the certification and the normal
appliance warranty. 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 System 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
allowed for.
The Ravenheat CSI System Combi Boiler

must be fitted on a flat and vertical wall
capable of adequately supporting the
weight of the boiler and any ancillary
equipment.
The appliance may be installed on a
combustible

requirements of the Local Authority and

Building Regulations.

LPG versions of this appliance shall not
be installed in cellars or basements.

devices e.g. flue dampers,

approved

wall

Ravenheat could

by

subject to

the

BS. 544O:1 Flues (for gas appliances of rated

input not exceeding 60 kW).

BS. 544O:2 Ventilation (for gas appliances of

rated input not exceeding 60 kW).

DD 189:1990 Discharge of condensate

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

4.3

4.3.1

CLEARANCES AROUNDTHE APPLIANCE

The following minimum free spaces, re­quired for installation inspection and
servicing, must be left around the boiler

18 inches (450 mm) in front
5 inches (125 mm) above
6 inches (150 mm) below

0.2 inches (5 mm) on each side

1 inch (25 mm) in front when installed in a
cupboard.

Supplied By www.heating spares.co Tel. [phone]

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 DM2. If in doubt advice
must be sought from the local gas supplier.
The combination boiler may be installed in
any room or internal space, although partic­ular attention is drawn to the requirements
of the current I.E.E. Wiring Regulations, and
in Scotland the electrical provisions of the
Building Regulations applicable in Scot­land, with respect to the installation of the
combination boiler in a room or internal
space containing a bath or shower.
Where a room sealed appliance is installed
in a room containing a bath or shower, any
electrical switch or appliance control, utilis­ing mains electricity should be so situated
that it cannot be touched by a person using
a bath or shower.
A compartment used to enclose the combi­nation boiler MUST be designed and con­structed specifically for this purpose. An
existing cupboard, or compartment, may be
used provided it is modified accordingly.
Samples of the CSI combination boiler have
been examined by B.G. Technology Notified
Body, and is certified to comply with the
essential requirements of the Gas Appli­ance Directive 90/396/EEC, the Low Voltage
Directive 72/23/EEC and shows compliance
with the Electro Magnetic Compatibility
Directive 89/336/EEC and are therefore per­mitted to carry the CE Mark.

The appliance has been tested and
approved by the WRc as meeting the
requirements of G3 and L of the Building
regulations and water Bylaws Scheme ­Approved Products.

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

4.6

4.6.1

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 con­sidered.
The terminal must not be closer than 25
mm. (1 in) to any combustible material. For
protection of combustibles, refer to BS

5440.1.
Where a flue terminal is installed less than

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

Pluming will occur at the terminal so, where
possible, terminal positions which could
cause a nuisance should be avoided.
The flue must be installed in accordance with
the recommendations of BS 5440: Part 1.

IMPORTANT NOTES

For greater flue lengths see twin flue
instructions.
Flue must be positioned in a place not likely
to cause a nuisance.

4.5

4.5.1

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

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

installation is possible with clearances less

than those specified in BS 5440, Part 1.

to the

terminal

design,

Supplied By www.heating spares.co Tel. [phone]

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

o

(45 mm/m) all runs must have.

NOTE:

4.6.2

4.7

4.7.1

The flue must be terminated in a place not
likely to cause a nuisance.

A concentric vertical flue kit is available, for
flueing applications up to a maximun height
of 4.0 metres.

For further details see vertical flue installa-

tion instructions.

AIR SUPPLY

The following notes are intended for gener­al guidance.
The room sealed fan flued boiler does not
require a permanent air vent for combustion
air supply.
Where installed in a cupboard or compart­ment ventilation is not required.

4.8

4.8.1

4.8.2

4.8.2.1

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 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.

SYSTEM DESIGN

Fig. 6A illustrates typical heating only lay­out. Figs. 6B and 6C illustrate typical layout
with ‘Y’ or ‘S’ plan system.

Fig. 6A

11

Supplied By www.heating spares.co Tel. [phone]

capacity as appropriate (Fig. 7).

In general modern systems will present no

problem.

Fig. 6C

Schematic ‘S’ plan

4.8.3

4.0.4

4.8.5

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 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.

Draining tap

These must be located in accessible posi­tions to permit the draining of the whole
system. The taps must be at least 15 mm
nominal size and manufactured in accor­dance with BS 2870 1960.

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

4.8.8

Fig. 6

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 fol­lowing 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 sta­tic 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. 6).
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 con­nected 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.

4.8.6

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 con-

nected to a system with an unusually high
water content, calculate the total expansion
and add additional sealed expansion

Supplied By www.heating spares.co Tel. [phone]

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

content 01 system

(bar)

Total water

Litres

25
50

75
100
125
150
175
200
225

250
275
300
325
350
375
400
425

3.0

0.5 1.0

0.5

2.1

4.2

6.3

8.3

10.4

12.5

14.6

16.7

20.8

22.9

25.0

27.0

29.1

31.2

33.3

35.4

37.5

1.0 1.5

3.5

7.0

10.5

14.0

17.5

21.0

24.5

28.0

31.5

35.0

38.5

42.0

45.5

49.0

52.5

56.0

59.5

63.0

103.6

110.1

116.5

6.5

12.9

19.4

25.9

32.4

38.8

45.3

51.8

58.3

64.7

71.2

77.7

84.1

90.6

97.1

2.0

EXPANSION VESSEL VOLUME (LITRES)

13.7

27.5

41.3

55.1

68.9

82.6

96.4

110.2

124.0

137.7

151.5

165.3

179.1

192.8

206.6

220.4

239.2

247.9

1.0

2.7

5.4

8.2

10.9

13.6

16.3

19.1

21.8

24.5

27.2

30.0

32.7

35.7

38.1

40.9

43.6

46.3

49.0

1.5

4.7

9.5

14.2

19.0

23.7

28.5

33.2

38.0

42.7

47.5

52.2

57.0

61.7

66.5

71.2

76.0

80.7

85.5

2.0

10.3

20.6

30.9

41.2

51.5

61.8

72.1

82.4

92.7

103.0

113.3

123.6

133.9

144.2

154.5

164.8

175.1

185.4

1.5

1.5

3.9

7.8

11.7

15.6

19.5

23.4

27.3

31.2

35.1

39.0

42.9

46.8

50.7

54.6

58.5

62.4

66.3

70.2

2.0

6.3

16.5

24.8

33.1

41.3

49.6

57.9

66.2

74.5

82.7
91 .0

99.3

107.6

115.8

124.1

132.4

140.7

148.9

For system volumes
other than those given
above,

multiply

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

SERVICING INSTRUCTIONS.

the

0.0833

0.140 0.259

0.551

0.109 0.190 0.412 0.156

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

filling the system. Available from your
supplier.

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
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-

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

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

should exceed 110 litres, an additional vessel

should be installed on the return to the combi-

nation boiler from the heating system (Fig. 7).

Guidance on vessel sizing is given in (Table 3).

0.331

appliance components in the

for

this

method of

Supplied By www.heating spares.co Tel. [phone]

4.8.9

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 heating
system

The System boiler is designed to operate
on a sealed system only. Therefore if the
existing system is of the open water type it
will have to be modified to comply with BS
5376 Part 2.
Before installing a new System boiler to an
existing system, flush out the old system
with a recommended descaling agent.
It is most important that the correct concen­tration of the water treatment product is
maintained in accordance with the manu­facturers’ instructions.
If the boiler is installed in an existing system
any unsuitable additives MUST be removed
by thorough cleansing.
BS 7593:1992 details the steps necessary
to clean domestic central heating system.
Also check pipework and renew any corrod­ed pipework or fittings. Valve glands must
be repacked or replaced wherever neces­sary and any defective controls exchanged.

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 CUR­ROSION GUARD water treatment products,
which must be used in accordance with the
manufacturers instructions. For further
information contact:
Fernox Manufacturing Co. Ltd.
Tel. [phone]
Sentinel Division Betz Dearborn Ltd.

Tel. [phone]
Salamander (Eng) Ltd
Tel. [phone]

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 con­nection to a 230 V - 50 Hz single phase
supply. The supply must be fused at 3 A.

Fig. 11

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

Supplied By www.heating spares.co Tel. [phone]

5.2

5.2.1

DELIVERY

The appliance will arrive on site in two
cartons

Box 1 of 2 containing (Fig. 10 - 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
b) 1-1/2" BSP Union gas cock
c) 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 rubber

(Contained in the carton Fig. 1O)

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

15

Supplied By www.heating spares.co Tel. [phone]