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]

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

5.4

POSITIONING OF THE BOILER

Fig. 22

54.1

5.4.2

5.4.3

5.4.4

5.4.5

5.4.6

- Remove the 2 screws that secure the
upper part of the front panel of the
casing (Fig. 19).

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

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

Push down the 2 plastic clips that fasten the

instrument panel (Fig. 23).

Lower the instrument panel down by rota-

ting it on its own hinges (Fig. 25).

Unscrew the two screws fastening panels

(Fig. 21).

Remove the two sides of the casing by sligh­tly lifting them and carefully sliding towards

the top of the appliance, to release them from

their upper suspension hooks (Fig. 26-27).

Make sure the casing and screws are put to

one side in a safe place.

Fig. 23

Fig. 25

5.5

5.5.1

Fig. 21

INSTALLINGTHE APPLIANCE FOR

REAR FLUE OUTLET

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 boi-

ler 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

rectly fitted.

orifice (F2) have been cor-

Fig. 26

Fig. 27

Fiq. 26-29

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

5.5.2

5.5.3

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

If the standard duct furnished with the boil-

er is too long (the wall to go through is less
than 680 mm. thick) it can be shortened as
follows:

- Remove the centering spring 65, the flue

terminal to disengage inner flue duct.

- Measure the thickness W of the wall.

- Cut the outer flue duct at right angles to a
length equal to W + 152 mm.
Must be de-burred.

- Cut the inner flue duct (60 mm) at right
angles to a length equal to W + 264 mm.

Insert from cut end. Reassemble the two

tubes. Insert centering spring 65.

Must be de-burred.

- Reassemble together inner and outer
flue duct insert centering spring.

Fig. 32

KEY

56

-

Straight header

57

-

Elbow header

56

-

Header gasket

59

-

Rubber seal 0 60

18

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

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

.

127 -Terminal cover plate

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

5.5.4

5.5.5

Insert the flue assembly into the wall, being
careful to make sure that the outer air duct
comes flush to the inner surface of the wall.

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

5.5.8

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.

Fig. 36

Fig. 34

Make good inside and outside wall around the air duct

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

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
components must be assembled and total

length measured before cutting. The
straight end of the extension connects to
the boiler. The flue output pipe fits into the

boiler header until it stops. The air intake
pipe should be located approximately 2

mm. from the boiler header (Fig. 31).
When cutting both inner and outer ducts of
the extension, always ensure that the

reduced end (male) of the inner duct is
longer than the outer duct.
All joints must be sealed with the rubber

seals supplied.

It is important to put the centering spacer,

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

pipeline

properly

all

5.7

5.7.1

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. 398).

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” 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).

20

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

Fig. 39B

5.7.2

5.7.3

5.7.5

KEY

56 - Sample point
57 - Elbow Header 65 - Pipe centering spring
59 Rubber seal 0 60 128 In Line Bend

Positioning the elbow towards the required - Reassemble the two tubes.

direction (Fig. 30).

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

- If the standard duct furnished with the
boiler is too long (position of the boiler

from the wall to go through as illustrated

in the drawing and wall thicknesses less

than what was specified above) it can

be shortened as follows: Fig.28-29-31-

32.

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

- Measure the thickness W of the wall.

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

- Cut the inner flue duct (60 mm. dia.) at
right angles and to a length equal to
W+Y + 65 mm.

- Outer air duct and inner flue duct must
be de-burred.

5.7.6

5.7.7

5.7.8

5.7.10 IMPORTANT: Terminal rubber must be

5.7.11

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.

fitted (Fig. 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.

63 - Air intake duct extension
64 - Flue Exhaust duct extension

Insert centering spring 65.

5.7.12 VERTICAL FLUE INSTRUCTIONS ONLY

Fig. P

Fig. 40

Fig. M

21

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

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 - 16130 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

o

). Where a straight

vertical flue is not possible or

desired, an offset vertical flue
can be used in conjunction
with a side horizontal flue
extension piece and an inline

o

/90o flue bend (Fig. 41).

135

IMPORTANT NOTES

For greater flue lengths see

twin flue leaflet

Fig. 41

Fig. R

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.

Fig. S

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 mastic
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.

22

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

Fig. 43

Fig. 44

Starting at the appliance end, assemble the
extension duct sections, making each inner and
outer (flue) joint by inserting the spigot end into the

socket end of the next tube, making sure the seal

rings are correctly located (Fig. 44). Make sure that
the entire flue is adequately supported. Use at least
one bracket for each extension used.

Ensure that all inner flue connections have a good

fit/seal, and that the space clips in each extension

are correctly positioned.

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

Fit a roof flashing sleeve (7 Fig. 43) to the roof,
available from Ravenheat Manufacturing.

Insert the Vertical Flue terminal assembly through
the flashing plate from the outside.

Fix the appliance to the wall, locating onto the top
coach bolts. Fit the two lower coach bolts and
tighten all four securing bolts,

Measure the vertical distance between the top of the
flue (Fig. 42) and the bottom of the flue terminal
assembly (Fig. 41). The measurements should be
taken from the outer diameter of the flue.
NOTE: Where this length does not match any
standard combination of the extensions, extension
can be cut to the required length (Fig. 44).

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

5.6

5.6.1

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

connection and fit flanged copper tail and

valves as per Fig. 46 using washers

provided.

GAS CONNECTION (Fig. 46)

A minimum working gas pressure of 20
mbar (8 in wg.) must be available at the
boiler inlet at full flow rate (37 mbar for
propane, 29 mbar for butane).

Fit gas service cock to the boiler via the
union nut and connect gas pipe.
Do not overtighten and use another
spanner as a counter force to avoid
straining internal connections.
Important consult (sect 4.5.1).

CENTRAL HEATING CONNECTION
(Fig. 46)

Before any central heating connections are
made to the boiler all system valves should
be opened and the system thoroughly

flushed out with cold water.

- Connect the central heating return pipe
to the isolating cock marked CHR.

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

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

plastic

caps

from

boiler

23

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

Fig. 48A Fig. 48B
Schematic ‘Y’ plan

Fig. 49A

Schematic ‘S’ plan

POSlTlONlNG OF WATER AND GAS CONNECTIONS

24

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

5.132 There are 2 electrical boxes, to gain access
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 panel board (Fig. 48).

5.12

5.12.1

5.13

5.13.1

SAFETY VALVE DISCHARGE

The safety valve is located near the pump. It

has a threaded outlet RC 1/2" (to 15 mm
copper) to permit a discharge pipe to be
connected. When connecting ensure the
discharge pipe does not restrict access.
The discharge should terminate facing down­ward exterior to the building in a position
where discharging (possibly boiling water &
steam) will not create danger or nuisance, in
easily visible position, and not to cause dam­age to electrical components or wiring.
The discharge must not be over an entrance
or a window or any other type of access.

ELECTRICAL CONNECTIONS

IMPORTANT: Electricity supply must be as

specified in clause (sect. 4.10).

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

It is essential that all external controls
must be volt free.
Factory fitted internal wiring must not be

disturbed when wiring external controls.

5.13.3

5.13.4 PROGRAMMABLETIME CLOCK

5.13.5

5.14

To gain access to external zone valve and

cylinder stat connection box remove the 2
screws on the side of the plastic cover just
behind the control panel (see Fig. 48a or
Fig. 48b).
Heat resistant flexible cable is fitted
between the isolator and the terminal block.
A 3 core cable of 0.75 mm (24 x 0.2 mm) to
BS6500.
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 cur-

rent 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.

A single channel 7 day digital programma­ble time clock is fitted as standard in the
boiler. When used with a ‘Y’ or ‘S’ plan sys­tem it will control DHW and/or heating only

(if required see Fig. 48). As an alternative

Ravenheat recommend a room stat with

built in timer for control of heating using

boiler timer for DHW time settings.

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).

PROGRAMMABLE TIME CLOCK

Instructions for use consult User’s Guide.

25

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

26

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

SECTION

6.1

6.2

6.2.1

6.3

6.4

6.5

6.7

6 COMMISSIONING

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.

GAS SUPPLY INSTALLATION

Inspect the entire installation including the
gas meter, test for soundness and purge,
all as described in BS 6891.

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 <<lnstructions 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

Open central heating flow and return
valves.

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

- Close all air release taps on the central

heating system.

- Gradually open stopcock at the filling

point connection to the central heating
system until water is heard to flow.

- Starting with the lowest radiator open

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

- Continue filling the syStem until 1.5 bar

registers on gauge. Then turn off the fil­ling points stopcock.

- Inspect the system for water soundness

and remedy any leaks discovered.

SETTlNG THE SYSTEM DESIGN

PRESSURE

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

- The actual reading should ideally be 1

bar + the height in metres to the highest
point of the system above the base of
the appliance (up to a max of 1,5 bar).
N.B.: The safety valve is set to lift a 3
bars (30 mt/42.5 psig).

- To lower the system pressure to the

required value remove drain point (Fig.

93) or drain on the heating circuit.

LIGHTING THE BOILER (Fig. 50)

Before lighting the main burner make sure
that the heating circuit flow and return val-

ves are open.

6.9

6.10

- 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 4 up to its maxi­mum setting.

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

- See paragraph 6.14 for regulating the
heating circuit thermostat.
Check gas mains pressure (Fig. 52). Fit

a gas pressure gauge on pressure inlet

77 (Fig. 51) on the gas valve, after

releasing the seal screw.
Check the gas mains pressure with boil-

er operating.

Check with the Local Gas supplier if the
pressure differs significantly from 20
mbar (natural gas), 37 mbar (G 31) and

29 mbar (G 30).

CHECK THE GAS PRESSURE AT THE
BURNER

Now check if the maximum gas pressure at
the burner is equal to 10.5 + 0.5 mbar (4.2

0.2 in wg.) for CSI 85 CSI 85T.

- LPG check gas pressure inlet (37 mbar

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

- Turn off main switch 1 (Fig. 50)

-Set main switch 1 on

-Set control thermostat 5 at its
maximum setting.

-Fit a pressure gauge, using a hose, to
pressure test point 81, (Fig. 51), after
first loosening its close-off screw.

-Open one or more hot water taps so
that at least 10 -12 litre of water flows
per minute.

- The pressure indicated on the pressure
gauge is the maximum operating gas
pressure.

- Check that the minimum pressure
corresponds to 2 mbar (0.8 in wg.) for

G 20 as is set at the factory.

- LPG 7.3 mbar for G 31 and 7.0 mbar for

G 30. This is set and sealed at the

factory and cannot be adjusted.

Detach one of the wires going to
modulator 104 (Fig. 51) and make the
boiler operate just as was done for

checking the maximum pressure.

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

the spark electrode tip.

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

- Remove cap covering modulator to gas
valve.

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

27

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

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

NOTE: LPG ONLY
The minimum pressure is factory set and
sealed, and cannot be adjusted.

and

anti-clockwise to

Fig. 52B

6.11

6.12

RECONNECTTHE DETACHED CABLE

Use a screw-driver to hold nut 111
(HONEYWELL 9 mm spanner) and use a 10
mm spanner (HONEYWELL 7 mm spanner)
wrench to rotate the nut 110 clockwise to
increase the pressure and counter-clock­wise to decrease it.
After adjustment turn off D.H.W. Taps.

SETTING CENTRAL HEATING GAS
PRESSURETHE BOILER COMES SET AT

MID POSITION RATING FOR USE ON C.H.
(table1)
When the boiler operates in the C.H. mode
the gas pressure at the burner can be set
between the min. and max. values.
This permits capacity to be adjusted to suit
system demand. If adjustment is required
proceed as follows:

- Remove the front panel and the panel

instrument as described in clauses
(sect. 5.4.1 and sect 5.4.3)

- Unscrew the two screws holding the

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

- Turn on main switch 1 (Fig. 50).

- Turn control thermostat 4 to maximum

setting. (Fig. 50)

- Check all external controls are on and

calling for heat.

- With boiler operating use a screwdriver

to turn potentiometer (Fig. 48) clockwise
to increase pressure and anti-clockwise
to decrease pressure.

- To obtain the desired heat value estab-

lish pressure as per (Fig. 52).

- Replace the protective cover.

- Once this pressure is established, mark
it up on data badge with adhesive red
label/arrow burner pressure setting so

that this can be referred to and checked
during future servicing.

RATIO BETWEEN BURNER PRESSURE

AND OUTPUT

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

6.13

6.13.1

6.14

6.14.1

CHECKINGTHE FLUE SYSTEM

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

CHECKINGTHE HEATINGTHERMOSTAT

Allow the system to warm up and then turn

the C.H. thermostat to ensure the main

burner modulates from ‘“high” to “low” and
“low” to “off” and vice versa (scale range
covers approx. 45

o

C - 85o C).

28

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

EXPLODED DIAGRAM OF BOILER BODY

KEY

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

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

24 - Main burner
25 Pilot burner

27 - Auto air vent valve
28 - Pressure switch
29 - Seal
31 - Seal
37 -Window seal
42 -Window clamp ring
44 - Fan
46 - Header gasket
50 - Flue gas exhaust hood cover

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

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

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 con-

trols 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.
Fill in the Benchmark log book and leave

completed with the customer.

7.2

7.2.1

ity supply to the appliance and always turn
off the appliance gas supply at the gas ser­vice cock.

Data badge position - lower left hand sub

frame.

- The following notes apply to the appli­ance and its controls but it should be
remembered that attention must also be
paid to the heating and hot water circuits

with special attention to radiator valves,
thermostats, clocks, leaking hot water
taps etc.

- Where it is necessary to replace a gas
ket 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,

SECTION 7 SERVICING INSTRUCTIONS

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 replace-

ment of components always isolate electric-

7.2.2

7.2.3

7.2.4

7.2.5

7.2.5.1

7.2.6

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.

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 heat
exchanger. Deposits can be cleared by

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

7.2.6.1

7.2.7

7.2.8

7.2.9

7.3

removing and flushing out the exchanger.

Inspect the siphonic condensate trap for a
blockage. Any deposits should be flushed
out (Fig. 90).

To remove condensate trap (sect. 5.4).

Pull forward the trap (Fig. 90).

Unscrew the earth wire, and the sensor.

Replace in reverse order. 7.6.5.2

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.

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 REMOVEIREPLACETHE FRONT

PANEL OFTHE CASING (Fig. 19 & 20)

7.6.5

7.6.5.1,

7.6.5.3

7.6.5.4

7.6.5.5

7.6.5.6

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

Remove front casing (sect. 7.3). Remove

combustion chamber front cover as in (sect

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

Close the ON/OFF valves for the heating.

Drain the heating system from the drain

point mounted system (Fig. 93).

Remove the fan (sect.7.6).

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).

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

7.3.1

7.4

7.4.1

7.4.2

7.4.3

7.4.4

7.6

7.6.1

Remove the 2 screws that secure the upper
part of the front panel of the casing.
Lift the front panel few millimeters to the

top, until it is free from the slot and remove

panel.

TO REMOVE/REPLACETHE

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 dam-

age the seal.

Reassemble in reverse order.
Ensure good seal of cover when replacing.

TO REMOVE/REPLACETHE FAN
ASSEMBLY (Fig. 58)

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

7.6.5.7

7.7

7.7.1

7.7.2

7.8.11

7.7.3

7.7.4

7.7.6

7.8

Replace in reverse order. Taking care to refit

discharge pipe at rear.

IMPORTANT: When replacing
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. 7.65)

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.

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

heat

7.6.2

7.6.4

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).

7.8.1

7.8.2

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.

31

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

7.8.4

Remove the fan (sect. 7.6).

Fig. 54

7.8.5

7.8.6

7.8.8

7.8.9

7.8.10

7.8.11

7.8.12

7.8.13

7.9

Remove condensing heat exchanger
(sect. 7.6.5).

Remove the flue hood (sect. 7.7).

Remove the automatic air vent (Fig. 92).

Disconnect unions for two heating (right

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

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).

7.9.1

7.9.2

7.9.3

7.9.4

7.9.5

7.9.6

Remove casing front panel (sect. 7.3).

Remove combustion chamber front cover
(sect. 7.4).

Remove fan (sect. 7.6).

Fig. 55

Remove condensing heat exchanger (sect.

7.6.5).

Remove the flue hood (sect. 7.7).

Remove main burner (sect. 7.15).
Remove top insulation pieces at sides.
Remove 2 screws securing combustion
chamber to rear of boiler.
Lower chamber carefully remove all insula­tion panels.

Replace in reverse order.

32

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

7.10

TO REPLACE THE ELECTRODE

(Fig. 66)

Fig. 60

7.10.1

Fig. 56

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

Fig. 62

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

Fig. 63

Fig. 66

Fig. 64

7.10.2

7.10.3

7.12

7.12.1

7.12.2

7.12.3

7.12.4

7.12.5

7.12.6

7.13

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

Replace with new electrode in reverse order.

TO REPLACETHE PILOT INJECTOR
(Fig. 68)

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

7.3 & 7.41.

Remove the lower sect. 5.4.2 (Fig. 21)

Release the fitting that secures pilot pipe at
the gas valve.

Remove electrode (sect. 7.10).

Unscrew pilot connection from pilot burner.

Pull the aluminium tube downwards and the
injector should come out by itself.

Replace in reverse order.

TO REPLACETHE PILOT BURNER

34

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.

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

7.14

TO REMOVE/REPLACE THE MAIN INJEC­TORS

Fig. 69

7.14.1

7.14.2

7.14.3

7.14.4

7.14.5

7.14.6

7.14.7

Remove the front panel of the casing and

the combustion chamber front cover (sect.

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

Unscrew the union (Fig. 70).

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

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

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

Replace in reverse order.

Reocate 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

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

7.15

TO REMOVE/REPLACE THE MAIN
BURNER

Fig. 72

7.15.1

7.15.2

7.15.4

7.15.5

7.15.6

7.15.7

7.16

7.16.1

7.16.2

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).

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

7.16.3

7.16.4

7.16.5

7.16.6

7.16.7

7.16.6

7.19

7.19.1

7.19.2

Lift the instrument panel to detach it from

the sides, and lower it down by rotating it on

its own hinges (Fig. 25).

Pull the 2 wires from the Modulator. Remove

the electronic ignition board (7.32.2/3).

Remove the lower grating (sect. 5.4.2).

Unscrew the pilot burner tube connection.

Remove the eight screws (four per side)

that connect the gas valve to the gas

pipelines and then remove it from its seat.

Replace in reverse order, always using new

seals.

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

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

control box cover (7.31.2/3).

Pull off the thermostat knobs (Fig. 78) and

unscrew lock nuts.

Fig. 74

Fig. 75

7.19.3

36

Detach all the connectors from PCB board.
Detach the PCB from its base by unscrew-

ing the 6 screws.

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

7.19.6

7.20

7.20.1

7.20.2

7.20.3

Replace in reverse order.

TO REMOVE/REPLACE THE MAIN

SWITCH (Fig. 82).

Remove the front panel from the outer cas­ing (sect. 7.3) and lower the instrument
panel (sect. 7.16.2 & 3), and remove the
control box coyer (7.31.213).

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

Detach the wires that connect to the switch

-

make sure that these wires are later

reconnected to the same poles (Fig. 94).

7.23

7.23.1

7.23.2

7.23.3

7.23.4

TO REMOVE/REPLACE THE ELECTRIC
CONTROL BOARD (PCB)

Remove the front panel from the outer cas­ing (sect. 7.3) and lower the instrument
panel (sect. 1 .16.2 & 3).

Unscrew the 2 screws holding the control

box cover and remove.

Disconnect mains cables and any other
connections (room thermostat and frost
thermostat if fitted).

Detach the connectors from the board

Detach the PCB board from its base by

unscrewing the six screws.

7.20.4

7.21

7.21 .1

7.21.2 Close the heating system on/off valves and

7.21.3

7.21.4 Remove the gauge from the instrument

7.21.5

7.22

7.22.1

7.22.2

7.22.3 Unscrew the plastic cover and locknut that

Replace in reverse order. 7.23.5

TO REMOVE/REPLACE THE WATER

PRESSURE GAUGE (Fig. 83). 7.23.6

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

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

Unscrew the fitting that secures the pres­sure gauge probe.

panel by pressing its fastening springs.

Replace in reverse order.

TO REMOVE/REPLACE THE OVERHEAT

THERMOSTAT

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

Remove lower grill and right side of the cas-

ing (sect. 5.4.2 & 5).

fastens the overheat thermostat and

remove it.

7.24

7.24.1

7.24.2

7.24.3

7.24.4

7.24.5

7.24.6

7.25

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

Having replaced PCB recommission boiler

on heating mode (sect. 6.15).

TO REMOVE/REPLACE THE

DIFFERENTIAL PRESSURE SWITCH

(Fig. 87).

Remove the front panel from the outer cas-

ing 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 termi-

nating inside the case and the + tapping is

connected to the tube terminating at flue

ring (Fig. 87 and 94).

TO REMOVE/REPLACE THE PUMP

(Fig. 88)

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

7.22.5

7.22.7

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

Replace in reverse order. 7.25.3

7.25.1

7.25.2

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

Remove lower grill right side of the casing
(sect. 5.4.2 & 5), lower the electric box
(sect. 7.16.2 & 3).

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

37

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

7.25.4

7.25.5

7.25.6

7.25.7

Remove the terminal covers and detach the

supply wires (Fig. 88).

Unscrew the two hexagonal nuts that fasten

the pump to its pipes and remove the pump.

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

Always use new seals when re-fitting the

new pump.

Replace in reverse order.

7.258

7.25.9

7.25.10

7.27

IMPORTANT:

Make sure that the arrow that indicates the
direction of flow aims from the bottom
upwards.

Replace wires and cover ensuring that con-

nection wire br=L and bl=N.

Refill the heating system as described in

the sect. 6.4 & 5 and check for leaks.

TO REMOVE/REPLACE THE CENTRAL

HEATING AND/OR HOT WATER

CONTROLTHERMISTOR

Fig. 78

Fig. 79

7.27.1

7.27.2

7.27.3

7.27.4

7.27.5

7.27.6

Fig. 82

Remove the front panel from the outer cas-

ing (sect. 7.3) and ‘lower the instrument

panel (sect. 7.16.2).

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

Remove the wires that connect the thermis-

tor (Fig. 81).

Close the on/off valves for the heating cir-

cuit and the hot water circuit. Drain the boil-

er at drain point (Fig. 93) and drain hot

water from the lowest hot water tap and

drain point on DHW inlet cock (Fig. 46).

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

Replace in reverse order.

Fig. 81

38

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

Fig. 83

7.28.7

7.28.8 Remove the duct proceeding in reverse

7.28.9 Remove the 2 lower coach bolts and

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

order as described in (sect. 5.5 or 5.7).

release 2 top coach bolts then remove boil-

er from the wall.

7.28

TO REMOVE/REPLACE THE CENTRAL

HEATING EXPANSION VESSEL

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

7.28.10 Unscrew the nut that connects the expan-

7.28.11 Remove the screw supporting expansion

7.28.12 Remove the expansion vessel.

7.28.13 Replace all the components in reverse

7.28.14 Fill the system as described in the sect. 6

7.29

7.29.1

7.29.2

7.29.3

7.29.4

7.29.5

7.29.6

sion vessel and remove it (Fig. 91).

vessel (Fig. 91).

order using new seals.

and check for leaks.

TO REMOVE/REPLACE THE AUTOMATIC

AIR VENT (Fig. 92)

Remove the front panel from the outer cas­ing and the combustion chamber front

cover (sect. 7.3 & 4).

Remove the lower grating (sect. 54.2).

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

Close the on/off valves for the central heat­ing circuit and drain the water from the boil-

er drain point (Fig. 93).

Unscrew and remove the plastic cap that

protects the valve vent hole.

Disconnect the unions 1 (Fig. 92) slightly

turn and remove auto air vent.

7.28.1

7.28.2

7.28.3

7.28.4

7.28.5

Remove the front panel from the outer cas­ing (sect. 7.3) and lower the instrument
panel (sect. 7.16.2 & 3) and remove the
control box cover (sect. 7.31.2/3).

Remove the lower grating (sect. 5.4.2).
Remove the two sides of the casing (sect.

5.4.5).

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

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

Drain the boiler (Fig. 93)

Disconnect all pipework connected to
boiler.

7.29.7

7.29.8

7.30

7.30.1

7.30.2 Close the on/off valves for the heating sys-

Replace in reverse order, using new seals.

Fill the system as described in the

sect. 6.4 & 5 and check for leaks.

TO REMOVE/REPLACE THE PRESSURE

RELIEFVALVE (Fig. 93)

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

casing, lower the instrument panel (sect:

7.16.2 & 3).

Remove right side of the casing (sect.

5.4.5).

tem and drain the water from the drain point

(Fig. 93).

39

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

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

7.30.4

7.31

7.31.1

Fill the system as described in the

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

TO REMOVE/REPLACE TIME CLOCK
(Fig. 88/A)

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

7.31.6

7.32

7.32.1

7.32.2

Replace in reverse order (ensure all electri-

cal connections are made correctly) (Fig.

88/A).

TO REMOVE/REPLACE THE IGNITION

BOARD

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

Remove the screw from the ignition box
cover.

7.31.2

7.31.3

7.31.4

7.31.5

Fig. 87

Remove control box cover (Sect. 7.23.2)

Remove control board (Sect. 7.23.2) from
panel.

Remove two clips securing the timer

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

7.32.3

7.32.4

7.32.5

Fig. 88/A

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

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

Replace in reverse order (ensure all electri-

cal) connections are made correctly.

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

Fig. 90

Fig. 91

Fig. 93

41

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

SECTION 8 FAULT FINDING CENTRAL HEATING

Switch on
Stat to maximum

Ensure external controls calling for heat (Room Stat/Time Clock/TRV) DHW Stat

42

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

BOILER NOT OPERATIONAL ON TIMER (INTEGRAL)

Switch on/Select “Winter”/Central Heating
Stat to Maximum/Ensure External control calling for heat (Room Stat/TRV)

43

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

SECTION

9 ELECTRICAL SYSTEM DIAGRAM

Fig. 94

44

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

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

8.0

INSTALLATION INSTRUCTIONS FOR

TWIN FLUE PIPE (ECCENTRIC FLUE

DUCT SYSTEM)

Fig. 1.8

8.1

IMPORTANT

These instructions must be read in conjunc-

tion 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 hous-

ing REF DMZ.
Also note that the requirements will vary
depending upon the kit being installed.

Guidance is provided but unless otherwise

stated, always comply with the recommen-

dations of the relevant codes of practice.

TWIN FLUE INSTRUCTIONS

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

IMPORTANT

Correct F1 orifice must be fitted.

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 depres-

sion chamber so as to create a softer seal.
Taking care not to damage the new Seat,
carefully re-fit the depression chamber front
cover in reverse order.

Take out the 4 temporarily fitted securing

screws, lifting our the gasket and orifice

plate disconnecting it from the venturi tube.

Discard this orifice plate and re-fit the F1

orifice plate ensuring that the venturi tube

has been re-fitted, making sure this is

securely located into the locating peg.

Locate the sealing washer fixing the twin

46

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

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..

o

M/F bend consisting of,

90

o

elbow with ‘0’ ring side F

90
80 mm dia ‘0’ ring

Figures show the versatility of this flueing
system. Measurements and bends must be
calculated correctly so as not to oversize
maximum flue lengths.

All located ‘0’ rings must be lubricated with
a silicone grease to ensure easy, snug fit.

o

NOTE: Exhaust flue must slope 2

down

towards the boiler 35 mm fall per metre.

Spacing Clips
Spacing clips are available on request
should they be required.

NOTE: for eccentric vertical flue a 125 mm
(5 in) diameter flashing plate will be
required.

135” M/F bend consisting of.

135” elbow with ‘0’ ring side F

80 mm dia ‘0’ ring

Vertical eccentric flue exhaust duct

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

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

Exhaust terminal must not be cut.

NOTE: The pressure loss for each elbow fitted is:

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

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

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

IMPORTANT: See Fig. 42 for terminal clearances

47

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

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

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

pipe = 20 metre.

Exhaust terminal must not be cut.

Min inlet pipe distance = 0.5 metre.

NOTE:The pressure loss for each elbow is:

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

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

Minimum total length = 2 metre.

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

IMPORTANT:

see Fig. 6 and 42 for terminal clearances

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

Fig. 4.8

ITEM DESCRIPTION

1

CSI flue adaptor gasket and screws
Straight pipe

2

Eccentric vertical terminal

3
4

90” slow bend

5

45” bend
Air inlet terminal (plastic) 80 mm

6
7

Exhaust terminal (stainless steel) 80 mm

Pitch roof slate

8
9

Flat roof slate
Twin flue pipe socket seal 60 mm

10

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

Minimum distance D = I + E = 1.5 metre.

Min inlet pipe distance 0.5 metre.

Min distance between pipe 50 mm.

NOTE: The pressure loss for each elbow fitted is:

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

45o 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.

30005

30001
30003

30009

30011

30007

ground, or above a flat roof to which people
have access, then a suitable terminal guard
must be fitted.

Fit only recommended flue terminal guard by

securing concentrically around terminal with

screws.

Available on request from:
RAVENHEAT MANUFACTURING LTD

Chartists Way

Morley, Leeds, West Yorkshire
ENGLAND LS27 9ET - U.K.

Tel. [phone]

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

48

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

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

RAVENHEAT CSI SYSTEM CONDENSING FANNED FLUE BOILER

SHORT LIST OF SPARE PARTS

Ravenheat

Pos.

1
2
4

5
6
7
8
9

10
11
13
15
16
17
18

18.1
21
22

22.1
24
25

25.1
26

27
29

30

31

32
33 0012VEN03005/0
37
38 001OTUB0606010
39 0012FUSO5015/0
45
46

47

Part. No.

0014FRO06005/0

0012COM06005/0
0012POT05010/0

0007TER03010/0

0001 CAM06005/0
0001 DIA06005/0
5027055
0007TER05005/0
0014VET01005/0
0010TUB05040/0
0001CAP06005/0
5021103
0012CIR05005/1

0014MAN06015/0
0012GEN05005/0
0012GEN05010/0

5003066

0008VAL03005/0
0008VALO5005/0

0003BRU06015/0

5012114
0003PIL05010/0
0002SCA0601010

0014RAC06005/0

001 0TUB06010/0
5015015

5018025

5018030

1015PAN06005/0

5023020

0014GUA01020/0

0001 CAM0601 O/O

G.C.
Part. No.

E23-711
E23-712
E23-729

371267

E23-732
E23-730
372842
E23-715

371268

E23-716
E23-733

372845

E23-718

E24-630

372849

173100

372-866
372894

E23-731
E23-735

372888
372851
372867
173101
E23-737
E23-738
E23-726
372855
371277

Description

Instrument panel - TIMER MODEL
Main switch

D.H.W. / C.H. Potentiometer
Overheat thermostat
Combustion chamber

Flue restriction ring 79CSI (F2)
Water gauge
D.H.W. / C.H. Sensor
Sight glass

Depression chamber gas pipe

Flue gas exhaust hood

Fuse 315 mA

Printed control board

Knob
Printed ignition board

Honeywell printed ignition board
Combustion chamber cover
Gas valve
Honeywell gas valve

Main burner

Pilot burner

Pilot burner for Honeywell gas valve

Heat exchanger
Condensing trap
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

Internal fuse 2A
Depression chamber pilot seal

Flue gasket

Depression chamber

50

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

Pos.

Ravenheat
Part. No.

G.C.

Part. No.

Description

48

48.1

50
51
61
62

62.1
64 0001TEL06005/0
65

68

68.1
70
79
80
81
82
83
85
87

89
93
95
97

100 0004VASO6010/0
105
106
110 0001 MAN05005/0
111
112

113
114

115
116
117

5012096 372856
0003UGE01005/0 E02-129
5021050 372892 Ignition electrode

0012CAV06005/0
0002SCA06005/0
0003UGE03005/0
0003UGE0l011/0 E23-755 Nozzle DM 0.75 LPG

5018046 372864 Seal

0003BRU06015/0 Main burner natural gas

0003BRU06002/0 Main burner LPG
0013GUA03035/0
0005PRE03010/0
5009080
0013GUA01045/0
5003283
5015010

0012FUS05020/0
5021312 372875
0005PRE05015/0 E24-629 Pressure switch

0019CUR06005/0
0019PR006005/0
0019TER06005/0

TM61 92

0019TER06010/0 E23-753 Vertical Flue Terminal Complete

0011RIV06006/0 Earth electrode
0011 RIV06005/0 Condensate blockage
0012CAV06015/0
0014GUA06010/0 Flue gasket dm 100
0014GUA06005/0 Flue gasket dm 60

0014GUA06015/0 Flue gasket dm 80

0019SD006005/0

Nozzle 0,27 for natural gas
Nozzle DM 0.22 x 1 LPG

E23-739 Cable for electrode
E23-740

371297

371273
371310
372896 Circulation pump
371274
372874 Brass manifold
372897

E23-724 Internal fuse 4A

E23-750 Elbow header
E23-751
E23-752

371258 Digital Timer

E23-754 Bottom panel

Condensing heat exchanger
Nozzle 1,25 for natural gas

Frame

Gasket 32 x 32 x 2 gas valve
Low water pressure switch

Gasket 48 x 42 x 1

Safety relief valve (3 bar)

Nylon tubes from pressure switch

Flue extension duct complete
Flue duct and terminal complete
Expansion tank

Earth wire

Twin header

51

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

Chartists Way, Morley, Leeds, LS27 9ET.

Telephone: [phone]

Tfax: [phone]