ravenheat Little Star LS 100 G.C.N LPG User guide

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ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER

WITHOUT TIMER LS 80 G.C. No4758129 (NAT.) - 4758131 (LPG) LS 100 G.C. N

NATURAL GAS (G20) -I

Listed by The United Kingdom Water

4758133 (NAT.) - 4758135 (LPG)

2H - II2H3+

LPG (G30 - G31) - I

Fitting Byelaws Scheme

3+-II2H3+

Fanned Combination Boiler

WITH TIMER

LS 80T G.C. No4758130 (NAT.) - 4758132 (LPG)

LS 1OOT G.C. N

NATURAL GAS (G20) - I

LPG (G30 - G31) - I

4758134 (NAT.) - 4758136 (LPG)

2H3+

3+-II2H3+

INSTALLATION AND SERVICING INSTRUCTIONS

TO BE LEFT WITH USER

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

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

THE LITTLE STAR - AUTOMATIC MODULATING BOILER

FOR CENTRAL HEATING AND DOMESTIC HOT WATER

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

POSITION

The appliance is extremely versatile as it can be fitted in almost any room. The appliance is room sealed, there is no contact between combustion chamber and living accommodation. This guarantees maximum safety and efficiency. Indeed, our depression/combustion front cover has been designed to fit achieving maximum air tight seal which ensures 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 and Europe. This product is guaranteed by Ravenheat Manufacturing, Chartists Way, Morley, LEEDS, LS27 9ET. Telephone No (0113) 252 7007.

BASIC COMPONENTS - (See figure 1)

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

MAJOR COMPONENTS

- Gas valve with flame modulator.

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

- Main burner with flame stabiliser designed to operate under all thermal conditions.

- Primary heat exchanger constructed from copper.

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

- High reliability diverter valve with ethylene propylene diaphragm permitting primary flow circu lation in the boiler during domestic hot water supply.

- Built in frost protection.

- Printed circuit board designed to connect to room stat and/or timer/frost stat.

- Aesthetically pleasing panels and controls.

- On/Off ball valves for shutting off gas central heating and domestic hot water circuits.

- Safety relief valve (for safety discharge).

- Programmable 7 day module with digital display (optional model). All front panel controls not often used have been hidden behind a lift up flap. This means neat design and easy clean panels.

COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH

IMPORTANT

This appliance contains materials that are indicated below.

It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn

when handling, where applicable, the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety.

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

handling sheet metal parts.

GENERAL INFORMATION:

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

When servicing avoid inhalation by using a vacuum cleaner or in conjunction with other tools,

After handling wash hands and other exposed parts,

RAVENHEAT use only high quality material for production of this product, in an effort to protect the environment components should be re-cycled,

SECTIONS:

3 4 5 6 7 8

9 10 11

GENERAL LAYOUT

Fig. 1

TABLE OF CONTENTS

INTRODUCTION DESIGN PRINCIPLES AND

OPERATING SEQUENCE TECHNICAL DATA GENERAL REQUIREMENTS

INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS

FAULT FINDING

ELECTRICAL SYSTEM DIAGRAM

EXPLODED PARTS DIAGRAM

LIST OF SPARE PARTS

PAGE:

8-9-10

11 16 25 30 43 45 47

KEY

1 - Heat exchanger 3 - Burner 4 - Ignition electrode 5 - Flue restriction ring 7 - Ignition board 9 - Detection electrode

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

16 - Hot water control 17 - D.H.W. sensor 18 - Water pressure switch (heating circuit) 22 - Overheat cut off thermostat 23 - Safety relief systems 24 - Three way valve 26 - Auto air vent valve 28 - Air pressure switch 29 - Circulation pump

30 - Water pressure gauge 33 - Main switch 34 - C.H. Sensor 36 - Fan 37 - Expansion tank 38 - Sealed chamber 45 - Combustion chamber 50 - Flue gas exhaust hood

105 - Timer

OPERATING

Fig. 2

SCHEME

KEY

1 - Heat exchanger

2 - Heat exchanger for D.H.W. water 3 - Burner 4 - Ignition electrode 5 - Flue restriction ring 6 - Elbow header 7 - Electronic ignition

8 - Twin header

9 - Detection electrode

10 - Straight header 12 - Modulating gas valve 15 - Heating control potentiometer 16 - Hot water control potentiometer 17 - Water pressure switch 18 - Overheat cut-off thermostat 20 - Gas service cock 21 - Compression ball valves 23 - Safety relief system

24 -Three way valve 26 - Auto air vent valve 28 - Pressure switch 29 - Circulating pump 30 - Water pressure gauge

36 - Fan 37 - Expansion tank 38 - Sealed chamber

SECTION 1 INTRODUCTION

2.2.6

Central heating mode

1.1

The Ravenheat boiler is for the use of cen-

tral and domestic hot water combined in one unit.

It is fitted with an automatic domestic hot water priority valve. A winter/summer selector switch is fitted to the left hand side of control panel. With the only summer position being for domestic hot water. Winter position being for central heating with domestic hot water priority. The boiler

is equipped with a front cover which can be

removed for servicing. The data badge with technical data is placed on front cover.

1.2 Fig. 1 Illustrates the general layout of

components.

Fig. 2 Illustrates the operating principles described in section 2.

SECTION 2

2.1

2.2

DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION

Domestic hot water mode

When the appliance is in rest mode with the

mains neon switch on. Switch the sum-

mer/winter switch in the summer Position,

making sure the heating circuit is charged with water (above 1 bar). When the domestic hot water tap is turned on, the boiler will function in the following sequence:

2.2.7

2.2.8

2.2.9

2.3

2.3.1

If the switch is positioned on winter with a demand for heat to supply radiators, etc. With heating circuit fully charged so as to operate the low water sensor device the

boiler will start in the same way as domestic hot water mode but with slightly differing time delay in that it will start on minimum and remain at this level for about 1 minute, after which the flame will lift to its maximum setting as governed by a potentiometer range rates the heating circuit between maximum and minimum power.

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

The boiler is fitted with an anti-cycling device on the control board. This delays the boiler from re-firing over a 2.5 minute period when in heating mode. The domestic hot water will always take priority and is unaffected by the anti-cycling device.

GENERAL FUNCTION

Central Heating Mode

A potentiometer is installed on the electric circuit board permits regulation of the boiler to partial heating requirements, between the factory setting.

2.2.1

2.2.2

2.2.3

2.2.4

2.2.5

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 gas valve to light the burner.

When the electrode/sensor senses the sig-

nal the burner the spark igniter stops.

From the minimum gas rate setting the boiler increases to the maximum permissible

pressure over a period of 3 to 4 seconds and will remain at its maximum required power

until its maximum regulated temperature.

When the domestic hot water tap is closed the diverter valve goes back into rest mode,

the main burner is shut down. The pump

and fan are also switched off, the pressure

switch returning to its rest mode.

2.3.2

2.3.3

2.3.4

2.3.5

2.3.6

2.3.7

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.

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

Interior space temperature is set by the

room thermostat to be installed in the heat-

ing system. The boiler already carries con-

nection terminals for this thermostat, as

well as for a timeclock. The burner will con-

tinue to operate until it is stopped by the

timer or one of the thermostats.

When the internal C.H. temperature sensor intervenes the main burner shuts down. The fan stops but the pump continues to operate.

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

2.4

2.4.1

2.4.2

2.4.3

Domestic hot water mode,

The heat exchanger in the D.H.W. circuit is a stainless steel plate heat exchanger water to water, and domestic water is heated by converting the water in the central heating circuit. The transference of heat is very high because the two fluids move in a counter direction flow to each other. Switch la Fig. 50 in the winter position. When a hot water tap is turned on a diaphragm diverter valve excludes the cen-

tral heating circuit, the boiler automatically until the room thermostat/time clock

modulates to maintain the domestic hot water at a constant temperature. Water temperature can be regulated using the D.H.W. thermostat located on the front control panel. When domestic hot water is being drawn the main burner and pump perform as they do during central heating except that the

burner is commanded by the D.H.W. ther-

mostat.

OVERALL DIMENSION

2.4.4

2.4.5

3.1

3.1.2

When D.H.W. is no longer called for the boiler automatically returns to the central heating mode. Switch la Fig. 50 in the summer position. The boiler functions like an automatic gas hot water heater. When D.H.W. is no longer

required the main burner fan and pump immediately turn off. This also takes place when switch

la Fig. 50 is on winter if there is no demand for heat to the central heating system or

demands for heat to the central heating circuit.

SAFETY DEVICE

In both central heating and domestic hot water mode safe operating is ensured by:

- A differential pressure switch which shuts off the main burner if the fan stops or the flue or combustion air intake duct is obstructed. An overheat cut off thermostat set slightly

higher than the high limit thermostat acts to turn off the burner to resetable “lockout“

(Fig. 50) item 3.

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

SECTION 3 TECHNICAL DATA

TABLE 1

NATURAL GAS (G 20)

NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET

NOMINAL HEAT OUTPUT MINIMUM HEAT OUTPUT

GAS RATE AFTER 10 MINUTES

max min

INLET PRESSURE 20 mbar

BURNER PRESSURE C.H.

max min

MAIN BURNER INJECTORS Nr. 13 x 1.35

ELECTRICAL SUPPLY

230 V - 50 HZ POWER CONSUMPTION 150w EXTERNAL FUSE RATING 3 A INTERNAL FUSE

DRY WEIGHT

WATER CONTENT C.H. WATER CONTENT

250 mA 2 A

39.3 kg

1.5 litre

0.5 litre

GAS SUPPLY CONNECTION

FLOW CONNECTION C.H. RETURN CONNECTION C.H. INLET CONNECTION D.H.W.

OUTLET CONNECTION D.H.W.

SAFETY DISCHARGE C.H.

26.1 kW

13.5 kW

24.1 kW

11.6 kW

2.6 m

1.3 m3/h

8.1 mbar

1.5 mbar

(20 mm to BS 4265)

15 mm compression isolating valve 22 mm compression isolating valve 22 mm compression isolating valve 15 mm compression isolating valve 15 mm copper pipe 15 mm copper pipe

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

6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar

CENTRAL HEATING OPERATING TEMPERATURE MAX 85 °C

MIN 45 °C

DESIGN FLOW RATE 1033 l/h 20 °C RISE MINIMUM FLOW RATE C.H. 650 l/h

D.H.W. FLOW RATE 30 °C rise 11.5 l/min D.H.W. FLOW RATE 35 °C rise 9.9 l/min D.H.W. FLOW RATE 40 °C rise

D.H.W.TEMPERATURE

8.6 l/min (2.0 gals/min)

max 65°C min 35°C

BURNER PRESSURE D.H.W. max 8.1 mbar

Input Net

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

max 26.1 kW

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

10 °C inlet temperature

min 1.5 mbar min 13.5 kW

D.H.W. MINIMUM FLOW RATE3 l/min (0.66 gals/min)

FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers

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

FLUE TYPE - C

CATEGORY I

SEDBUK RATING

12 C 32 C 52

79.61 %

NOX 2

BAND D

C 12 C 32 = ORIFICE PLATE DM 77 C52=

ORIFICE PLATE DM 75

85 LITRE

SECTION

3 TECHNICAL DATA

TABLE 1/A

NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET

NOMINAL HEAT OUTPUT MINIMUM HEAT OUTPUT

GAS RATE max G 31

AFTER 10 MINUTES min

INLET PRESSURE 37 mbar G 31

BURNER

PRESSURE

MAIN

ELECTRICAL SUPPLY 230 V POWER CONSUMPTION EXTERNAL FUSE RATING INTERNAL FUSE

DRY WEIGHT WATER CONTENT C.H. WATER CONTENT OHW

GAS SUPPLY CONNECTION

FLOW CONNECTION C.H.

RETURN CONNECTION C.H.

INLET CONNECTION D.H.W. OUTLET CONNECTION D.H.W.

SAFETY DISCHARGE C.H.

BURNER INJECTORS Nr. 13 x

max min

G 31

150 W 3A 250 mA - 2 A

39.3 kg

1.5 litre

0.5 litre

LPG (G 30 - G 31) I

26.1 kW

13.5 kW

24.1 kW

11.6 kW

0.95

m3/h

0.5

m3/h

35.4 mbar

9.6 mbar

0.75

50 HZ

(20 mm to

15 mm compression isolating valve 22 mm compression isolating valve 22 mm compression isolating valve

15 mm compression isolating valve 15 mm copper pipe

15 mm copper pipe

mbar

BS 4265)

0.79

0.4

27.3

6.6

m3/h

mbar mbar

MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL

SEALED WATER SYSTEM C.H.

2.5

MAX PRESSURE PMS MINIMUM WORKING PRESSURE 6

LITRES

CENTRAL HEATING OPERATING TEMPERATURE MAX 85 °C

DESIGN FLOW RATE DHW 1033 I/h 20 °C RISE MINIMUM FLOW RATE C.H./650 Lts/h (111 gals/h)

D.H.W. FLOW RATE 30 °C rise D 11.5 I/min D.H.W. FLOW RATE 35 °C rise

D.H.W. FLOW RATE 40 °C rise

D.H.W.TEMPERATURE

BURNER PRESSURE QMW Input Net

D.H.W. PRESSURE D.H.W. PRESSURE PMW D.H.W. MINIMUM FLOW RATE3 l/min

FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers

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

FLUE TYPE C12 - C32 - C52

CATEGORY l

SEDBUK RATING

C12 C32 ORIFICE PLATE DM 76 C52 =

EXPANSION

ORIFICE PLATE DM 74

VESSEL

D.H.W. max 8.1 mbar

PRE-CHARGE-PRESSURE

MIN 45 °C

9.9 I/min

8.6 I/min

max 65 °C min 35 °C

max 26.1 kW

max 10 bar min 0.8 bar

81.88 %

BAND D

bar

0.5 bar

10 °C inlet temperature

min 1.5 mbar min 13.5 kW

NOX 2

85 LITRES

SECTION 3 TECHNICAL DATA

TABLE 3

LS 100 (T)

NATURAL GAS (G 20) I 2H - II 2H3+

NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET

NOMINAL HEAT OUTPUT MINIMUM HEAT OUTPUT

GAS RATE

max

AFTER 10 MINUTES min

31.4 kW

13.0 kW

29.0 kW

11.2 kW

3.2 m

1.25 m3/h

INLET PRESSURE 20 mbar

BURNER PRESSURE C.H.

MAIN BURNER INJECTORS Nr. 15 x 1.25

ELECTRICAL SUPPLY POWER CONSUMPTION EXTERNAL FUSE RATING

max min

230V-50HZ 150w 3A

12.5 mbar

1.4 mbar

INTERNAL FUSE 250 mA 2 A (20 mm to BS 4265)

DRY WEIGHT

41.akg WATER CONTENT C.H. 1.7 litre WATER CONTENT

0.5 litre

GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W.

15 mm copper pipe

SAFETY DISCHARGE C.H. 15 mm copper pipe

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

6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar

CENTRAL HEATING OPERATING TEMPERATURE MAX 85

C MIN 45 oC

DESIGN FLOW RATE D.H.W. 1247 l/h 20°C

MINIMUM FLOW RATE C.H. 650 I/h

D.H.W. FLOW RATE 30oC rise 13.9 l/min D.H.W. FLOW RATE 35 D.H.W. FLOW RATE 40

D.H.W.TEMPERATURE max 65

BURNER PRESSURE D.H.W. max 12.5 mbar Q

Input Net

D.H.W. PRESSURE

C rise 11.9 l/min

C rise

10.4 l/min (2.0 gals/min) 10oC inlet temperature

C min 35oC

max 31.4 kW

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

min 1.4 mbar min 13.0 kW

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

3 l/min

FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers

DESTINATION: AT. DK. FI. SE.

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

CATEGORY I

CATEGORY II

2H3+

FLUE TYPE - C12 - C32 - C52

SEDBUK RATING

79.61 %

BAND D

C12 C32 ORIFICE PLATE DM 79 c52 =

ORIFICE PLATE DM 78

85 LITRE

NOX4

SECTION 3 TECHNICAL DATA

TABLE 4

LS 100 (T)

LPG (G 30 - G 31) II 2H3+ -I 3+

NOMINAL HEAT INPUT NET QMS MINIMUM HEAT lNPUT NET

NOMINAL HEAT OUTPUT

GAS

RATE

After 10 minutes

max

min

INLET PRESSURE

BURNER PRESSURE

C.H.

max min

MAIN BURNER INJECTORS Nr. 15 x 0.75

ELECTRICAL SUPPLY

POWER CONSUMPTION

EXTERNAL FUSE RATING

INTERNAL FUSE

DRY WEIGHT WATER CONTENT C.H. WATER CONTENT OHW

230V-50HZ

150w 3A 250 mA - 2 A

41.8 kg 1 .7 litre

0.5 litre

GAS SUPPLY CONNECTION FLOW CONNECTION C.H. RETURN CONNECTION C.H. INLET CONNECTION D.H.W.

OUTLET CONNECTION D.H.W.

SAFETY DISCHARGE C.H.

31.4 kW

13.0 kW

29.0 kW

37 mbar G

1.24

m3/h G

0.53 m3/h

28 30 mbar G 30

35.4 mbar

6.1 mbar

(20 mm to BS 4265)

15 mm compression isolating valve 22 mm compression isolating valve 22 mm compression isolating valve

15 mm compression isolating valve

15 mm copper pipe

0.95

m3/h

0.40 m3/h

27.2

mbar

4.7 mbar

MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL

SEALED WATER SYSTEM C.H.

MAX PRESSURE PMS 2.5 bar MINIMUM WORKING PRESSURE 0.5 bar

6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar

CENTRAL HEATING OPERATING TEMPERATURE

DESIGN FLOW RATE DHW 1247 I/h 20

C RISE

MAX 85

MIN 45°C

MINIMUM FLOW RATE C.H. 650 L/h

D.H.W. FLOW RATE 30oC rise 13.9 l/min D.H.W. FLOW RATE 35 D.H.W. FLOW RATE 40

D.H.W. TEMPERATURE

BURNER PRESSURE D.H.W.

QMW Input Net

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

C rise 11.9 I/min

C rise 10.4 l/min

max 65 oC

max mln

max 31.4 kW

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

10oC inlet temperature

min 35

G 31

35.4 mbar

6.1 mbar

min 13.0 kW

D.H.W. MINIMUM FLOW RATE 3 I/min

FLUE OUTLET NOM. DIAMETER 100 mm

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

DESTINATION: BE. FR.

specially supplied with boilers

CATEGORY ll

CATEGORY l

2H3+

FLUE TYPE C12 C32 C52

SEDBUK RATING

81.88 %

BAND D NOX 4

C12 - C32 = ORIFICE PLATE DM 78 c52 =

ORIFICE PLATE DM 77

G 31

85 LITRES

27.2 mbar

4.7 mbar

SECTION 4

4.0

SAFETY

Gas Safety (Installation and Use) Regulations, 1994 and amended 2000.

It is law that all gas appliances are installed and serviced by a CORGI registered in-

staller in accordance with the above regulations and these installation instructions. All CORGI registered installers carry a CORGI

I.D. card and have a registration number.

Both should be recorded in your boiler log recommended by Ravenheat in writing. If in book. You can check your installer by calling CORGI direct on: 01256 732300. Failure to

install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied the certification and the normal appliance with. Check the boiler and flue is the correct warranty. It could also infringe the Gas type for Installation. Safety regulations and the above regulaThe installation of the boiler MUST be in ac- tions. cordance with the latest I.E.E. (BS 7671) Wiring Regulations, local building regula- NOTE: The Ravenheat LITTLE STAR comtions, bye-laws of the local water authority, bination boiler has been tested and examthe building regulations and the Building ined by Advantica Technologies Ltd, and is Standards (Scotland) and any relevant re- certified to comply with PrEN 483 and quirements of the local authority.

4.1

GENERAL INFORMATION taken in any way as overriding statutory

Both the user and the manufacturer rely heav-

ily on the installer, whose job it is to install the combination boiler and connect it to a correct-

ly 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 recom-

mended that tools suitable for brass fittings tion should be within the building, unless

are used, and have a capability to accomo- otherwise protected by a suitable enclosure.

date hexagon sizes up to 50 mms.

CODES OF PRACTICE/Ref: Documents

Detailed recommendations are contained in the following British Standard Codes of

Practice:

BS. 6891

BS. 6798

BS. 5449

BS. 5546

BS. 5440:1

BS. 5440:2 Ventilation (for gas appliances of

GENERAL REQUIREMENTS

Low pressure installation pipes.

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

Forced circulation hot water systems.

Installation of gas hot water

supplies domestic purposes

(2nd Family Gases).

Flues (for gas appliances of rated

input not exceeding 60 kW).

rated input not exceeding 60 kW).

DD 189:1990 Discharge of condensate

The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.

IMPORTANT.These appliances are CE certificated for safety and performance. It is, therefore, important that no external control devices e.g. flue dampers, economisers etc., are directly connected to this appliance unless covered by these Installation and Service Instructions or as otherwise

doubt please enquire.

Any direct connection of a control device not approved by Ravenheat could invalidate

BS EN 625. Manufacturers instructions must NOT be

obligations. If in doubt on any point please consult Ravenheat Manufacturing Ltd.

4.2 LOCATION OF BOILER

4.2.1

Siting of Ravenheat Little Star Combi Boiler must be as follows. The position of installa-

Adequate space for installation, servicing and air circulation around boiler must be allowed for. The Ravenheat LS 80 (T) and LS 100 (T) Combi Boiler must be fitted on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance may be installed on a combustible wall subject to the requirements of the Local Authority and Building Regulations.

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

4.3

4.3.1

CLEARANCES AROUNDTHE APPLIANCE

LS 80 (T) - LS 100 (T)

Above 125 mm

Below 100 mm

Front 450 mm

Side 5 mm

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

5 mm in front when installed in a cupboard

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 partic-

ular attention is drawn to the requirements of the current I.E.E. Wiring Regulations, and

in Scotland the electrical provisions of the

Building Regulations applicable in Scot-

land, 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, utilis-

ing mains electricity should be so situated

that it cannot be touched by a person using

a bath or shower.

A compartment used to enclose the combi-

nation boiler MUST be designed and con-

structed specifically for this purpose. An ex-

isting cupboard, or compartment, may be

used provided it is modified accordingly.

Samples of the LITTLE STAR combination

boiler have been examined by Advantica

Technologies Ltd, and is certified to comply

with the essential requirements of the Gas

Appliance Directive 90/396/EEC, the Low

Voltage Directive 72/23/EEC and shows

compliance with the Electro Magnetic Com-

patibility Directive 89/336/EEC and are

therefore permitted to carry the CE Mark.

other appliances when they are in use at

the same time.

4.6

4.6.1 The terminal should be located where dis-

FLUE SYSTEM

persal 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 con-

sidered.sidered.

The terminal must not be closer than 25The terminal must not be closer than 25

mm. (1 in) to any combustible material. Formm. (1 in) to any combustible material. For protection of combustibles. refer to BSorotection of combustibles. refer to BS

5440.1. Where a flue terminal is installed less than

1000 mm. from a plastic, or painted gutter;

or 500 mm from painted eaves, an alumini-

um shield 1000 mm. long, should be fitted to the underside of the gutter or painted surface.

4.5

4.5.1

The appliance has been tested and approved by the WRc as meeting the require-

ments of G3 and L of the Building regula-

tions and water Bylaws Scheme -Approved

Products.

GAS SUPPLY

A gas meter is connected to the service

pipe by the Local Gas Region or the Local Gas Region contractor. An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves. Installation pipes should be fitted in accordance with BS 6891. Pipework from the meter to the boiler must be of adequate size (22 mm)

min. To within at least 3 metre of the boiler (15 mm) min. can then be used for remain-

ing 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 de-

scribed in the above Code.

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

other appliances ensure an adequate sup-

ply is available both to the boiler and the

IMPORTANT: The following notes are in-

tended 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:

installation is possible with clearances less than those specified in BS 5440, Part 1.

Due to the terminal design,

4.8

WATER CIRCULATION (central heating)

NOTE:

4.6.2

4.7

4.7.1

Fig. 6A

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 maximum

height of 4 metres. For further details see vertical flue installa-

tion instructions.

SUPPLY

AIR

The following notes are intended for gener-

al guidance.

The room sealed fan flued boiler does not

require a permanent air vent for combustion air supply. Where installed in a cupboard or compartment ventilation is not required.

4.8.1

4.8.2

4.8.3

Detailed recommendations are given in BS 6798:1987/5449:1990 (for. smallbore and microbore central heating systems). The following notes are given for general guidance.

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 16 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.

The water through the appliance heat

exchanger circuit must exceed the min.

2.38 gals/min. (650 It/h) when the burner is firing. It is important to ensure that this rate

is achieved when sections of the system

are shut off either manually or by automatic controls.

ted to the system (15 mm min.) (Fig. 6A).

Therefore a by-pass must be fit-

If the volume of circulating water IS too low,

the boiler water temperature will rise too

rapidly. This could cause noise in the system or even cause the safety thermostat to trip.

4.8.4

Draining tap

These must 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 accor-

dance with BS 2870 1980

Fig. 7

4.8.5

4.8.6

4.8.8

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.

The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated. It can accept up to 6 lts of expansion water. If the appliance is connetted to a system with an unusually high water content, calculate the total expansion and add additional sealed expansion capacity as appropriate (Fig. 7).

In general modern systems will present no

problem.

Permissible methods of dilling

Primary flow and

return pipes

4.8.7

Mains water feed: central heating

There must be no direct connection to the

mains water supply, even through a nonreturn valve, without the approval of the Local Water Authority.

Figure 1 depicts the requirements of Diagram R24.2a of he Water Supply (Water Fittings) Regulations 1999.

SIZING OF ADDITIONAL EXPANSION VESSELS: TABLE 3 Deduct from the value given in the table the 7 litre vessel supplied.

Note: This pressure can be increased up to 1.5 bar to suit static head situations, see item 10, other appliance instructions in the

SERVICING INSTRUCTIONS

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 85 litres, an additional vessel should be installed on the return to the combination boiler from the heating system (Fig. 7). Guidance on vessel sizing is given in (Table 3).

Reference should be made to British Gas

Publications

<<Material and Installation Specifications for Domestic Central Heating and Hot Water >>. Draining taps should be at

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.

least 1/2" in BSP nominal size and be in

accordance with BS 2879.

4.8.9

Installation to an existing central heating system

The combination boiler is designed to oper-

ate on a sealed system only. Therefore if the existing system is of the open water type it will have to be modified to comply

with BS 5376 Part 2.

Before, installing a new combination boiler to an existing system, flush out the old system with a recommended descaling agent.

4.8.10

4.9

4.9.1

4.10

4.10.1

Hard water areas

If the. area of installation is recognised as hard water, it is recommended that a suit-

able water treatment device is installed in the mains. The water hardness can be determined by

using the standard test paper or by referring Local water authority.

DOMESTIC WATER

The domestic hot water must be in accor-

dance with the relevant recommendations

of BS 5546. Copper tubing to BS 2871. 1 is

recommended for water carrying pipework

and MUST be used for pipework carrying

potable water.

ELECTRICAL SUPPLY

Warning: this appliance must be earthed

External wiring to the appliance must be

carried out by a competent person and be

in accordance with the current I.E.E. Regulations and local regulations which

apply.

The Ravenheat boiler is supplied for con-

nection to a 230 V - 50 Hz single phase

supply.

The supply must be fused at 3 A.

NOTE: The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance, by the

use of a fused, double pole isolator, having a contact separation of at least 3 mm in all poles. The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except, where the appliance is installed in a bathroom, this

MUST be sited outside the bathroom.

5.2

5.2.1

DELIVERY

The appliance will arrive on site in two

cartons: Boiler carton containing:

a) boiler fully assembled

b) installation instructions and

user instructions c) white paper template d) terminal cover plate (Fig. 12) g) - 4 coach bolts and wall plugs

- screws and dowels

Valve pack (poly bag):

a) 2-22 mm compression ball valves

(heating)

b) l-15 mm compression ball valve

main in boiler box obtaining c) l-15 mm compression d) l-15 mm compression outlet

2 15 fibrie washers 2 22 fibrie washers

Flue box containing (Fig. 12):

Standard Flue Assembly

58 Elbow Header 59 - Flue bend (Fig. 10) item 9 60 -Air intake duct 61 - Flue exhaust duct 62 -Terminal 65 - Pipe centering spring 66 Flue gas sample point

127 -Terminal Cover Plate

Fig.

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 in a HORIZONTAL PLANE. A minor deviation from the horizontal is acceptable, provided that this results in a downward slope of the flue/air duct away from the combination boiler.

Fig. 12

For vertical flue

system see sect. 5.7.12

(Minimum vertical 1100 mm)

5.4

POSITIONING OF THE BOILER

5.4.1

5.4.2

5.4.3

Fig. 19

Unscrew the 2 screws that fasten the lower grating on the casing and remove it the casing (Fig. 20).

Remove the 4 screws that secure in the

top, 2 in the bottom the casing (Fig. 19).

- Carefully slide the casing forward to lift off.

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

Fig. 21

5.5

INSTALLINGTHE APPLIANCE FOR REAR FLUE OUTLET

5.5.1

Use adhesive tape to attach the template

to the wall, making sure that the centre line

is vertical.

- Mark the two 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 2 boil-

er securing holes. Insert the plastic expansion plugs.

- Cut or core drill a 105 mm. dia hole for inserting the flue duct.

- Screw in the two upper coach bolts leaving them about 10 mm. out from the wall to enable the boiler to be located on the wall.

Fit the elbow header positioning it towards

the required direction (Fig. 30).

IMPORTANT: Make sure that the elbow’s dia. 60 mm duct is inserted into the fan, the rubber seal and orifice are been correctly located.

Fig. 29

Fig. 28

5.5.3

If the standard duct furnished with the boiler is too long it can be shortened.

Note: Should it be necessary to cut the flue, always cut equal amounts from both inner and outer pipes. Always cut the end furthest from the terminal. Cut end must de-burred.

Fig. 30

Orifice plate concentric flue system:

LS 80 (T)=77 mm (NAT. GAS) - 76 mm (LPG) LS 100 (T)=79 mm (NAT. GAS) - 78 mm (LPG)

Fig. 32

INTAKE AND EXHAUST TERMINAL COMPONENTS

Fig. 31

KEY

56 - Straight header 57 - Elbow header 58 - Header gasket

- Rubber seal 0 60

- STD air intake duct

- STD flue exhaust duct

- Terminal

- Air intake duct extension

- Flue exhaust duct extension

- Pipe centering spring

- Sample point

127

- Terminal cover plate

128

- Screw

5.5.4

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.

Fig. 35

5.5.5

5.5.6

Fig. 33

Fig. 34

Lift the boiler on to the wall (Fig. 34), locat-

ing onto the top coach bolts, and tighten all two securing bolts.

Working above the boiler pull the flue

exhaust duct towards the boiler in order to

engage tube 61 into its header 57

(Fig. 31).

Position flue into elbow header and push so

as to locate inner and outer flue correctly.

5.5.10

Each extension length extends the pipe by approximately 1000 mm long up to a maximum of three 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 ta-

pered end of the flue pipe aimed towards the

exhaust terminal. Extensions must be joined together with the standard terminal pipe, inserted in each other as far as they can go.

If an extension must be shortened, this

must be done from the straight end, and

not from the widened or tapered end. To

measure the pipeline properly all compo-

nents 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. (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.

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 rigidly secured

to wall and flue duct.

5.5.8

5.5.9

Fit terminal cover plate if required.

Extension kits are available on order

5.5.11

IN LINE FLUE BEND

Measure the distance between the flue bends or the flue/terminal assembly. The

measurement should be taken from the outer edge of the flue and bend (Fig. 39B).

IMPORTANT: in line flue bend 750 mm

must be deducted from overall length for each 90” bend. Obtuse flue bend - 375 mm

must be deducted from overall length for each 135” bend (Fig. 39 B).

Fig. 37

-Screw in the two upper coach bolts leaving them about 10 mm out from the wall in order to enable the boiler to be located.

5.6

5.6.1

5.7

5.7.1

COMPLETING BOILER INSTALLATION

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

1) Fit the casing.

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

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 two 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. 28), 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 2 holes for securing the boiler. Insert the plastic expansion plugs. Core drill 105 mm dia. hole In the side wall for inserting the flue duct.

5.7.2

5.7.5

Fig. 39

Positioning the elbow towards the required

direction (Fig. 30).

If the standard duct furnished with the

boiler is too long it can be shortened.

Note: Should it be necessary to cut the flue, always cut equal amounts from both inner and outer pipes. Always cut the end furthest from the terminal. Cut end must de-burred.

Fig. 39B

KEY

63 -Air intake duct extension

56 - Sample point (if required) 64 - Flue Exhaust duct extension 57 - Elbow Header 59 - Rubber seal 0 60

65 - Pipe centering spring

128 - In Line Bend (45” and/or 90”)

5.7.6

5.7.7

5.7.8

Insert the flue assembly into the wall, mak-

ing 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 two 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.ring.

5.7.12.1 VERTICAL FLUE OPTIONS

The vertical flue kit IS intended for use where a horizontal flue outlet is not Possible or desired. The vertical flue can be used either with a flat roof or a pitched roof (maximum pitch 60”). Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 135190” flue bend (Fig. 41).

5.7.10

57.11

Fit terminal cover plate if required (Fig. 37).

Extension kits are available on order for flue extension of up to 3.5 metres total length

(Fig. 31-39B). For further

details see sect 5.5.10.

Fig.P

5.7.12

VERTICAL FLUE INSTRUCTION ONLY

INLINE FLUE BEND 750 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90” BEND

OBTUSE FLUE BEND - 375 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135” BEND

Fig. 41

Fig. R Fig. S

Important: Make sure that the flue header dia 60 mm

duct is inserted fully onto the fan spigot.

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 flue centering bracket.

- One box containing straight header.

Model

LS 80 (T) LS 100 (T)

Max no of flue extensions length

4 4

Overall

Distance to

max flue centre of flue

from back wall

5.3 metre 157 mm

5.3 metre

157 mm

Proceed with installation as detailed in section 5 up to 5.5.1., ignoring all references to horizontal flue installations.

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

- Ensure that the maximum permissible flue length is not exceeded (Fig. 42).

- Mark the four boiler fastening holes on the wall.

- Detach the template from the wall.

- Use a 10 mm dia. drill to make the 4 boiler securing holes. Insert plastic expansion plugs (Fig. 29).

- Screw in the two upper coach bolts leav-

ing 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 is correctly fitted.

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

Fit a roof flashing sleeve (43 Fig. item 7) 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 and the bottom of the flue terminal assembly. The measurements should be taken from the outer

diameter of the flue (Fig. 41).

NOTE: Where this length does not match any stan-

dard combination of the extensions, extension can

be cut to the required length (Fig. 44).

When cutting both inner and outer ducts of the

extension, always cut on spigot side, and they must

be de-burred.

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. 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.

5.8

REASSEMBLE BOILER AS PER

(sect. 5.6.1)

5.8.1

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

5.9

5.9.1

GAS CONNECTION (Fig. 46)

A minimum gas pressure of 20 mbar (G20), 37 mbar (G31) and 28-30 (G30) must be available at the boiler inlet at full flow rate.

5.9.2

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

5.10

CENTRAL HEATING CONNECTION (Fig. 46)

5.10.1

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 dimension’s and position are marked

on template supplied and Fig. 49A

5.11

5.11 .1

DOMESTIC HOT WATER (Fig. 46)

The domestic hot water circuit does not

need a safety valve but it is essential to ensure ‘hat the pressure of the cold water supply does not exceed 10 bar. If in doubt it is advisable to install a pressure reducing

valve. The minimum pressure needed to

operate the domestic hot water system is

0.5 bar with a flow of approx 3 Lts. per min. Flush out all foreign matter from the supply

pipe before connecting to the appliance.

- Connect the 15 mm. cold water pipe to the stop cock to the appliance inlet marked DCW.

- Connect the 15 mm. hot water pipe with a suitable connection.

5.12

5.12.1

SAFETY VALVE DISCHARGE

The safety valve is located near the pump.

It has a threaded outlet RC l/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

downwards exterior to the building in a position where discharging (possibly boil-

ing water & steam) will not create danger or nuisance, but in easily visible position, and not to cause damage to electrical components or wiring. The discharge must not be over an

entrance or & window or any other type of

access.

complete, the commissioning engineer MUST complete his section in the Benchmark log book.

5.13 ELECTRICAL CONNECTlONS

SECT ION 6 COMMISSIONING

5.13.1

The electricity supply must be as specified in clause (sect. 4.10).

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

It is essential that all external controls must be

volt free.

Factory fitted internal wiring must not be

disturbed when wiring external controls.

- To gain access to the electrical box

remove the front panel of the case

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

- The terminals are easily visible on the front of the electronic control board (Fig.

48).

- Heat resistant flexible cable is fitted

between the isolator and the terminal block. It is a 3 core cable of 0.75 mm

(24x0,2 mm) to BS 6500. Make sure all wires to the appliance are

routed away from sharp edges and hot surfaces. The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carrying conductor does

not become taut before the earthing conductor.

Securely tighten all terminal screws and

arrange the cable with slack between the cord anchorage and the terminal

block.

WARNING: If the supply cord is dam-

aged, it must be replaced by a service

engineer (supply cord available from

Ravenheat Manufacturing Ltd).

PROGRAMMABLE TIME CLOCK

Instructions for use Consult User’s Guide.

6.1

Each boiler has been through a rigorous

operational procedure at our factory and

should not require any further adjustment. If in the unlikely event of the appliance not

operating correctly, please turn to the Fault

Finding and Logic Sequence charts.

6.2

6.2.1

GAS SUPPLY INSTALLATION

Inspect the entire installation including the gas meter, test for soundness and purge,

all as described in BS 6891.

6.3

ELECTRICAL lNSTALLATlON

Preliminary electrical system 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.

6.4

INITIAL FILLING OF THE SYSTEM

Open central heating flow and return valves.

Unscrew the cap on automatic air release

valve one full turn (leave open permanently).

- Close all air release taps on the central heating system.

- Gradually open stopcock at the filling

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

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

- Continue filling the system until at least

1.5 bar registers on gauge. Then turn off

the filling points stopcock.

- Inspect the system for water soundness

and remedy any leaks discovered.

6.5

SETTING THE SYSTEM DESIGN PRESSURE

The design pressure must be a min. 1 bar

and max. 1.5 bar. These figures are read off the pressure gauge.

- The actual reading should ideally be 1 bar + the height in metres to the highest

point of the system above the base of the appliance (up to a max of 1.5 bar).

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

bars (30 mt/42.5 psig).

- To lower the system pressure to the required value remove drain point (Fig.

93) or drain on the heating circuit.

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

- Press summer/winter selector switch la

Fig. 50 to winter.

Fig. 46

6.6

6.7

ELECTRICAL CONNECTION

Fig. 48

FILLING THE HOT WATER SYSTEM Close all hot water draw-off taps. Open the cold water inlet cock. Slowly open each draw-off tap until clear water is discharged.

LIGHTING THE BOILER (Fig. 50) Before lighting the main burner make sure

that the heating circuit flow and return

valves are open and also that the cold

water input cock is also open.

INSTRUMENT

PANEL

Fig. 50

6.9.1

6.10

Detach one of the wires going to modu- 6.12 lator 104 (Fig. 51) and make the boiler operate just as was done for checking

the maximum pressure.

Observe electrode. It should be about 3-4

from the burner (Fig. 52B).

CHECK THE GAS PRESSURE AT THE BURNER LPG (G 31) - (G30)

Now check if the maximum gas pressure at

the burner is equal to 35,4 (G31) 0.5

mbar or 27.3 (G30) 0.5 mbar.

To do this proceed as follows: Turn off main switch 1 (Fig. 50)

- Set summer/winter switch 1 on summer

- 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 if the minimum pressure corresponds to 9.6 mbar (G31), 6.6 mbar (G30) for LS 80 (T) or 6.1 mbar (G31), 4.7 mbar (G30) for LS 100 (T) as is set at the factory. Detach one of the wires going to modula-

tor 104 (Fig. 51) and make the boiler oper-

ate just as was done for checking the maximum pressure.

ADJUSTING MINIMUM AND MAXIMUM

PRESSURE (Fig. 51) HONEYWELL GAS VALVE

- Remove cap covering modulator to gas

valve.

- Detach one of the cables connected to

the modulator 114.

- With the boiler operating use a 9 mm

spanner to turn the nut 111 clockwise to

increase pressure and anti-clockwise to

decrease pressure.

SETTING CENTRAL HEATING GAS PRESSURE THE BOILER COMES SET AT MID POSITION RATING FOR USE ON C.H. (table 1/2/3/4)

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 casing. Unscrew the two screws holding the control box and lift off the cover.

- Switch summer/winter switch to winter position.

- Turn control thermostat 4 to maximum setting (Fig. 50).

- Check all external controls are on and calling for heat ensure all D.H.W. taps are off.

- With boiler operating use a screwdriver to turn potentiometer (Fig. 48) clockwise to increase pressure and anticlockwise to decrease pressure.

- To obtain the desired heat value establish pressure as per (Fig. 52).

- Replace the protective cover.

- Once this pressure is established, mark it up on data badge with adhesive red

label/arrow burner pressure setting so that this can be referred to and checked during future servicing.

RATIO BETWEEN BURNER PRESSURE AND OUTPUT NATURAL GAS (G 20) LPG (G30 - G31)

6.11

Fig. 52B

RECONNECTTHE DETACHED CABLE

Use a screw-driver to hold nut 111 firm a 9 mm spanner and use a 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.

IGNITION ELECTRODE

BURNER

SENSOR

ELECTRODE

BURNER

6.16

HANDING OVER TO THE USER

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

6.13 CHECKING THE FLUE SYSTEM

6.13.1

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

6.14

6.14.1

CHECKING THE HEATING THERMOSTAT

Allow the system to warm up and then turn the C.H. thermostat to ensure the main burner modulates from “high” to “low” and “low” to “off” and vice versa (scale range covers approx. 45” C 85” C).

6.15

TESTING AND REGULATINGTHE DOMESTIC HOT WATER SYSTEM FLOW

6.15.1

To put the appliance in operation with the (summer/winter) switch in winter position.

- Open a domestic hot water tap (preferably the bath tap). Ensure cold water inlet stopcock is open and the D.H.W. thermostat 5 (Fig. 50) is set at maximum.

- If the burner does not light check that the water flow rate is above the min. required to operate the differential pressure 2.8 Lts./min. (0.61 gals/min).

- The temperature of the water will depend on the rate at which it flows. If, due to high water pressure, the flow rate

IS too high (and thus the temperature

too low for practical use) the flow rate may be adjusted. It is better to set for

the lowest acceptable temperature

preferably at the bath tap since the user can gain higher temperatures at other restricted flow taps (Table 112).

- N.B.: If the cold supply is subject to large fluctuations or is above the permit-

ted max. water pressure, a suitable

pressure/flow regulator should be fitted in the cold water supply to the appliance.

- Turn the appliance mode selector switch 1 (Fig. 50) to the summer position . Slowly close the draw off tap to reduce

the flow rate to above the min. (approx.

2.8 litre/min - 0.61 gals/min.). Rotate the D.H.W. control thermostat to ensure it operates at its various setting.

- Close the draw-off tap still further. The burner should stop when the rate falls below about 2.8 litres/min (0.61 gals/min.).

6.16.1

After completion of installation and commissioning of the system, the installer should hand over to the Householder by taking the following actions:

- Hand the “User’s Instructions” to the Householder and explain His/Her responsibilities under the “Gas Safety Regulations 1996”.

- Explain and demonstrate the lighting and shutting down procedures.

- The operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder. This then ensures the greatest possible fuel economy consis-

tent with household requirements of both heating and hot water consumptions. Advise the User of the precautions necessary to prevent damage to the system, and to the building, in the event of the system remaining Inoperative during frost conditions.

- Explain the function and the use of the boiler (Summer/Winter) and ON/OFF switch.

- Explain and demonstrate the function of time and temperature controls neon lights radiator valves etc. for the economic use of the system.

- If an optional time clock is fitted, then draw attention to the time clock User’s Instructions and hand them to the Householder.

- Stress importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR.

Fill in the Benchmark log book and leave completed with the customer.

KEY

6 -

Main burner

11-

Chamber cover 10- Combustion chamber 12-

Air restriction ring

13-

Flue gas exhaust hood

17-

Heat exchanger

19-

Air pressure switch

Main burner

24 27 - Auto air vent valve

31-

Seal 37- Gasket 48 x 42 x 1 38- Connection pipe 42- Window clamp ring 44-

Fan

46 -

Header gasket

58 -

Ceramic insulation

84-

Depression chamber

85 -

Fan fastening bracket

87-

Nylos tuber from pressure

switch

SECTION 7 SERVICING INSTRUCTIONS

7.1

SERVICING

7.2.2

Inspect the heat exchanger for any blockage. Deposits of any material should be brushed always using a soft brush. NOTE: Do not use brushes with metallic bristles.

7.1.1

7.2

7.2.1

Ravenheat are a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

To ensure continued efficient operation of the appliance it is necessary to carry out servic-

ing and cleaning at regular intervals. The frequency of cleaning will depend upon the particular installation conditions and usage but

in general. once year should be adequate. WARNING

Before

replacement of components always iso-

late electricity supply to the appliance

and always turn off the appliance gas

supply at the gas service cock.

the start of any servicing or

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 hot water services on to a high water flow, and observe the main burner.

- Check that the flame covers all the flame ports and is of a light blue colour. Yellow flames and excessive lifting of flames indicate poor combustion.

IMPORTANT: After completion any servicing or replacement of gas carrying components it is essential that a test for gas soundness is always carried 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.

7.2.3

7.2.4

7.2.5

7.2.6

7.2.7

7.2.6

7.2.9

7.3

7.3.1

7.4

7.4.1

7.4.2

7.4.3

7.4.4

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 clean or renew as necessary (sec.

7.12 & 7.14).

Inspect the main burner and remove any deposit with a soft brush. Check the electrodes for damage or deterioration, clean

or renew as necessary. Ensure that the

spark gaps are correct to dimensions spec-

ified in Fig. 52.

Examine the fan for any mechanical dam-

age, 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 REMOVE/REPLACE THE FRONT

PANEL OF THE CASING (Fig. 19 & 20)

Unscrew the 2 screws that fasten the lower

grating on the casing and remove it from it

(Fig. 22)

Remove the 4 screws that secure the top

and bottom of the casing. (Fig. 19). Careful-

Iv side forward to lift off. Make sure the cas-

ing and screws are put to one side in a

safe place.

TO REMOVE/REPLACE THE COMBUS-

TION CHAMBER COVER

Remove the casing panel (sect. 7.3).

Unscrew 6 the screws that fasten the cover

to the chamber body and put them into a

container so that they don’t get lost.

Pull the cover forward to lift off.

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

7.6

TO REMOVE/REPLACE THE FAN ASSEMBLY (Fig. 58)

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

7.6.1

7.6.2

7.6.4

7.7

7.7.1

7.7.2

7.7.3

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

as in (sect. 7.4).

Disconnect the electrical connections from

the fan motor:

Support the fan and remove the two fixing screws and bracket from the front of the flue hood. Push down and carefully withdraw it from the appliance. Place in a safe place until required. Reassemble in reverse order. Ensure wires are connected correctly (Fig. 94).

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 the three screws on the front that fasten hood to the combustion chamber.

7.9

7.9.1

7.9.2

Fig. 58

TO REMOVE/REPLACE COMBUSTION CHAMBER INSULATION PANELS (Fig. 64).

Remove casing (sect. 7.3). Remove combustion chamber front cover (sect. 7.4). Remove fan assembly and flue hood (sect.

7.6 & 7.7). Remove main burner (sect. 7.15). Remove top insulation pieces at sides. Remove 2 screws securing combustion chamber.

To rear of boiler and power chamber care-

fully remove all insulation panels.

Replace in reverse order.

7.7.4

7.7.5

7.7.6

7.8

7.8.1

7.8.2

7.8.4

7.8.5

7.8.8

7.8.9

Remove the two screws at the rear of hood.

Pull the flue hood upwards and then

remove by tilting forward (Fig. 61).

Replace in reverse order.

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

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

Close the on/off valves for the heating. Drain the heating system from the drain point mounted on the system (Fig. 93).

Remove the fan (sect. 7.6).

Remove the flue hood (sect. 7.7).

Remove the automatic air vent (Fig. 92).

Disconnect unions for the hot water and heating water pipelines (Fig. 62).

7.8.11

7.8.12

7.8.13

Remove the two side insulation panels at

top of heat exchanger (Fig. 63).

Pull the heat exchanger up until its connections come out from the combustion chamber and then remove it (Fig. 64).

Replace in reverse order.

Ensure correct wire position (Fig. 94).

Fig. 60

Fig. 63

7.10

7.10.1

Fig. 61

Fig. 64

TO REPLACETHE ELECTRODES (Fig. 66)

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

7.10.2

7.10.3

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

Replace with new electrode in reverse

order

7.14

TO REMOVE/REPLACE THE MAIN

INJECTORS

7.14.1

Remove the front panel of the casing and

the combustion chamber front cover (sect.

7.3 & 4).

7.14.2

Unscrew the union (Fig. 70)

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

7.14.4

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

7.14.5

Unscrew and replace the injectors and

their seals. (Fig. 73).

7.14.6

Replace in reverse order.

Fig. 71

Fig. 70

7.15

TO REMOVE/REPLACE THE MAIN BURNER

Fig. 73

7.15.1

7.15.4

7.15.5

7.15.6

7.15.7

7.16

7.16.1

7.16.4

Remove the front panel of the casing and

the combustion chamber front cover (sect.

7.3 & 7.4).

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)

Pull the 2 wires from the Modulator. Remove

the electronic ignition board (7.32.2/3).

Fig. 74

7.16.7 Remove the eight screws (four per side) that connect the gas valve to the gas

pipelines and then remove it from its seat.

7.16.8

Replace in reverse order, always using new

seals.

Fig. 72

Fig. 75

7.19

7.19.1

7.19.2

7.19.3

TO REMOVE/REPLACE THE HEATING

CONTROL AND DOMESTIC HOT WATER CONTROL

Remove the casing (sect. 7.3) lower the instrument panel by unscrew the 2 screws holding up the instrument panel and con-

trol box and lower it down on its awn

hinges.

Remove the top of the control box cover by unclipplng it from its 4 locating clips (2 each side).

Remove the instrument panel from the control box by unclipping it from its 4 locating pins (2 each side).

7.22.3

7.22.4

7.22.5

7.22.6

7.22.7

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

Unscrew the plastic cover and locknut that fastens the overheat thermostat and

remove It.

Remove the split pin and pull the thermostat sensor from its pocket complete with case sealing grommet.

Remove case sealing grommet from the old thermostat and fit to new one.

Replace in reverse order.

7.19.4

7.19.5

7.19.6

7.20

7.20.1

7.20.2

7.20.3

7.20.4

7.21

7.21 .1

Detach the wires by unclipping the connector

from the control board (Fig. 79).

Unscrew the lock nut which fastens the potentiometer to the instrument panel (Fig. 78).

Replace in reverse order.

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

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

(sect. 7.19. 113).

Detach the wires that connect to the switch make sure that these wires are later recon-

nected to the same poles (Fig. 94).

Pull the switch out from the instrument

panel by pressing the clamp springs.

Replace in reverse order.

TO REMOVE/REPLACE THE WATER

PRESSURE GAUGE (Fig. 83).

Remove the casing (sect. 7.3) and lower

the instrument panel (sect. 7.19. 1/3).

7.23

7.23.1

7.23.2

7.23.3

7.23.4

7.23.5

7.23.6

7.24

7.24.1

7.24.2

TO REMOVE/REPLACE THE ELECTRIC CONTROL BOARD (PCB)

Remove the casing (sect. 7.3) and lower the instrument panel.

(sect. 7.19.1)

Detach the connectors from the board.

Detach the PCB board from its base by

unscrewing the 4 screws.

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

Having replaced PCB recommission boiler on heating mode (sect. 6.15).

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

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

Detach the wires that connect to the pres-

sure switch, make sure that these wires are

later reconnected to the same poles

(Fig. 94).

7.21.2

7.21.3

7.21.4

7.21.5

7.22

7.22.1

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

Unscrew the fitting that secures the pressure gauge probe.

Remove the gauge from the instrument

panel by pressing its fastening springs.

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.

7.24.3

7.24.4

7.24.5

7.24.6

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

Remove the two silicone tubes.

Ensure tubes are connected correctly (Fig.

87) avoiding kinks.

Replace in reverse order ensuring that the

- tapping is connected to the tube terminating inside the case and the + tapping is

connected to the tube terminating at flue

ring (Fig. 87 and 94).

7.25

TO REMOVE/REPLACE THE PUMP (Fig. 88)

Fig. 81

7.25.1

7.25.2

7.254

7.25.5

7.25.6

7.25.7

Fig. 78

Remove the casing (sect. 7.3) and lower

the instrument panel (sect. 7.19.1).

Remove lower grill of the casing (sect.

5.4.2 & 5), lower the electric box (sect.

7.16.2 & 3).

Detach the supply wire.

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 new

pump.

Replace in reverse order.

7.25.10 Refill as described in the sect. 6.4 & 5 and check for leaks (see 7.26.2).

Fig. 79

7.26

7.26.1

7.26.2

7.26.4

7.26.5

7.26.7

7.26.8

TO REMOVE/REPLACE THE DIVERTER

VALVE (Fig. 89)

Remove the casing and lower the instrument panel (sect. 7.3 & 7.19.1).

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).

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

Pull off circlip securing microswitches to

diverter valve.

Detach the wires that are connected to this. Remember that they must subsequently be reconnected to the same termi-

nals (Fig. 94).

Replace in reverse order. Always use new

seals.

7.26.9

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

and check for leaks.

7.27

7.27.1

7.27.3

7.27.4

7.27.5

7.27.6

TO REMOVE/REPLACE THE CENTRAL HEATING AND/OR HOT WATER CONTROL THERMISTOR

Remove the casing (sect. 7.3) and lower the instrument panel (sect. 7.19.1 for DHW).

Remove the wires that connect the thermistor (Fig. 81).

Close the on/off valves for the heating circuit and the hot water circuit. Drain the boiler at drain point (Fig. 93) and drain hot water from the lowest hot water tap and drain point on DHW inlet cock (Fig. 46).

Undo the nut and withdraw the sensor (Fig.

81) from its pocket.

Replace in reverse order,

7.28

7.28.1

7.28.2

7.28.3

7.28.4

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,

Remove the casing (sect. 7.3).

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

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

Drain the boiler (Fig. 93).

Fig. 82

Fig. 83

7.28.5

Disconnect all pipework connected to

boiler.

7.28.7

Disconnect mains cables and any other

connections (room thermostat, program-

ming clock).

7.28.8

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

7.28.9

Remove the 2 top coach bolts then remove

boiler from the wall.

7.28.10 Remove the top bracket, and unscrew the nut that connects the expansion vessel and remove it (Fig. 91).

7.28.12 Remove the expansion vessel.

7.28.13 Replace all the components in reverse

order using new seals.

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

7.29 TO REMOVE/REPLACE THE AIR

AUTOMATIC VENT (Fig. 92)

7.29.1

Remove the casing and the combustion

chamber front cover (sect. 7.3 & 4).

7.29.4

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

7.29.6

7.29.7

7.29.8

7.30

7.30.1

7.30.2

7.30.3

7.30.4

7.31

7.31.1

7.31.2

7.31.3

7.31.4

7.31.5

7.31.6

Disconnect the unions 1 and 2 (Fig. 92) slightly turn and remove pipe and auto air vent.

Replace in reverse order, using new seals.

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

TO REMOVE/REPLACE THE PRESSURE RELIEF VALVE (Fig. 93)

Remove the casing (sect. 7.3).

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

Undo the valve from its body, clean or replace. Replace in reverse order.

Fill the system as described in (sect. 6.4 &

6.5) and check for leaks.

TO REMOVE/REPLACE TIME CLOCK

(Fig. 88/A)

Remove the casing (sect. 7.3) and lower the instrument panel (sect. 7.19.1/.3).

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.

Replace in reverse order (ensure all electrical

connections are made correctly) (Fig. 88/A).

Fig. 88

7.32.4

7.32.5

7.33

7.33.1

7.33.3

7.33.4

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

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

TO REMOVE/REPLACE LOW WATER CUT-OFF SWITCH

Remove the casing (sect. 7.3) and lower the instrument panel (sect 7.19.1).

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

point (sect. 5.4.5).

Pull wire off and unscrew the sensor from its body. Replace in reverse order.

7.32

7.32.1

7.32.2

7.32.3

TO REMOVE/REPLACE THE IGNITION

BOARD

Remove casing (sect. 7.3).

Remove the screw from the ignition box cover.

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

7.33.5

Fill the system as described in the (sect. 6.4 & 6.5) and check for leaks.

EXTERNAL WIRING

Fig. 89

Fig. 92

Fig. 91

Fig. 93

Section 8 FAULT FINDING CENTRAL HEATING

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

FAULT FINDING DOMESTIC HOT WATER

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

Open Domestic hot tap close to appliance.

BOILER NOT OPERATIONAL ON TIMER (INTEGRAL)

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

SECTION 9 ELECTRICAL SYSTEM DIAGRAM

Fig. 94

SECTlON 10

10.0 INSTALLATION TWIN FLUE PIPE (ECCENTRIC FLUE

DUCT SYSTEM)

IMPORTANT: CORRECT LS 80 (T) 75 mm (NAT. GAS) - 74 mm (LPG), LS 100 (T) 78 mm (NAT. GAS) - 77 mm (LPG) MUST BE FITTED.

INSTRUCTIONS

FOR

IMPORTANT

As with all flues the kits must be installed taking due account of the current issue of

BS 5440 parts 1 & 2 and timber frame housing FIEF IGE/UP/7/1998.

Also note that the requirements will vary

depending upon the kit being installed. Guidance is provided but unless otherwise stated, always comply with the recommendations of the relevant codes of practice.

Fig. 1.9

10.1

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

LS 80 range. Typical installation procedures are illustrated by drawings.

10.2

Supplied with the twin flue header is an 75 mm diameter orifice plate. Before fixing the twin flue system the existing 77 LS 80 (T) - 80 LS 100 (T) orifice plate must be removed.

10.3

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 75 mm orifice plate ensuring that the venturi tube has been refitted, making sure this is securely located into the locating peg.

10.5 Locate the ceiling washer fixing the twin

flue header as illustrated making sure that the inner aluminium exhaust locates firmly on the fan outlet spigot. Make sure that the screws are satisfactorily located through the gasket seal.

10.6 Locate the two 80 mm ‘0’ rings in the twin

flue header.

90” M/F bend consisting of:

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

Figures 2.8, 3.8 and 4.8 show the versatility of this

flue system. Measurements and bends must be cal-

culated correctly so as not to oversize maximum flue

lengths. All spigot ends that are cut must be de-burred with a file.

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

Fig. 2.8

135” M/F bend consisting of:

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

Vertical eccentric flue exhaust duct

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.

Sampling point

Sampling point is positioned on the outlet of the twin flue header for the use of sampling gas combustion

products.

Condensing trap

To drain the exhaust pipe only with a greater distance of over 6 metres, a condensating trap must be fitted, or as an alternative to this the sampling point

may also be used as a condensating drain should this be required.

E = EXHAUST I = INLET

T = TERMINAL

D = DISTANCE (TOTAL)

Exhaust/suction system with concentric pipes for flat

or sloping roofs. Extensions with two separate pipes.

Maximum distance D = I + E + T = 14,5 metre + 14,5

metre + 1 metre = 30 metre maximum (pipe + terminal).

Exhaust terminal must not be cut.

NOTE: The pressure loss for each elbow fitted is:

90” elbow less 3 metre of pipe length for each one

fitted.

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

For exhaust pipe with a distance of over 6 metre a

condensing trap must be fitted.

Fig. 3.8

Exhaust/suction system with two separate rated 80 diam pipes - exhaust on flat or sloping roof,

suction from vertical wall.

Maximum distance D = I + E + T = Total

exhaust/inlet pipe = 27 metre.

Exhaust terminal must not be cut.

Min inlet pipe distance = 0.1 metre.

NOTE: The pressure loss for each elbow is:

90” elbow less 3 metre of pipe length for each one fit-

ted.

45” elbow less 1.5 metre d pipe for each one fitted.

For exhaust pipe with a distance of over 6 metre a

condensing trap must be fitted.

Fig. 4.8

Exhaust/suction system with two separate pipes

through a single vertical wall.

Maximum distance D = I + E = Total exhaust/inlet pipe 24 metre.

Min inlet pipe distance 0.1 metre.

Min exhaust pipe distance 0.1 metre.

NOTE: The pressure loss for each elbow fitted is:

90” elbow less 3 metre of pipe length for each one fit-

ted.

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

For exhaust pipe with a distance of over 6 metre a

condensing trap must be fitted.

SECTION 1 EXPLODED PARTS DIAGRAM

SECTION 12

RAVENHEAT SHORT LIST OF SPARE PARTS

Pos.

LS 80 (T)

Part. No.

0014PAN09005/0

00121NT0900510

OOl2POT05005/0

0007TER0301010

0001 CAM09005/0

0014MAN06015/0

00061DR0900510

0007TER05005/0

0014VET01005/0

0001 C0P09010/0

0001 DIA09005/0

0001 CAP09005/0

5021103

0012CIR0900510

G.C. LS 100 (T)

Part. No.

371267

371268

372645 372845

Part. No.

0014PAN09005/0

0012lNT09005/0

0012POT05005/0

0007TER03010/0

0001CAM10005/0

0014MAN06015/0

0006lDR09005/0

0007TER05005/0

0014VET01005/0

0001COP1001/0

0001 DIA09005/0

0001CAP10005/O

5021103

0012CIR09005/0

G.C.

Part. No

371267

371268

Description

INSTRUMENT PANEL

MAIN SWITCH

D.H.W/C.H. POTENTIMETER

OVERHEATTHERMOSTAT

COMBUSTION CHAMBER

THERMOSTAT KNOB

WATER GAUGE

D.H.W/C.H. SENSOR

SIGHT GLASS

CHAMBER COVER

AIR RESTRICTION RING

FLUE GAS EXHAUST HOOD

F2 FUSE 315 mA

PRINTED CONTROL BOARD

24.1

25.1

27 5015015

0002SCA0900510

0012GEN0901010

0005PRE09005/0

0004VASO9010/0

0009CIR0901110

0008vAL0900510

0002SCA0901510

0003BRU09005/0

0003BRU09010/0

0012lNT09010/0

0012PUL09005/0

000VAL01018/0

0014REGOI005/0

0013GUA0303510

5018025

5018030

0002SCA10005/0

0012GEN09010/0

0005PRE09005/0

0004VAS0901010

0009CIR09011/O

173100

372888 372888

371273

372851

372867 5018030

0008VAL09005/0

0002SCA09015/0

0003BRU10005/0

0003BRU10010/0

0012lNT09010/0

0012PuL09005/0

0008VAL01018/0

5015015

0013GUA03035/0 371273

5016025

173100

372851

372867

HEAT EXCHANGER

PRINTED IGNITION BOARD

AIR PRESSURE SWITCH

6 LT EXPANSION VESSEL

5 METRE PUMP

GAS VALVE

DHW HEAT EXCHANGER

MAIN BURNER NATURAL GAS (G 20)

MAIN BURNER LPG (G 31) - (G30)

SUMMER/WINTER SWITCH

FLAME FAILURE SWITCH

SAFETY VALVE 3 BAR

AUTO AIR VENT

WATER FLOW REGULATOR

GASKET 32X32X2 GAS VALVE

GASKET 18.5X11.5X2

GASKET 24X15X2

RAVENHEAT SHORT LIST OF SPARE PARTS CONTINUED

POS.

60.1

60.2

LS 80 (T) Part. No.

5018046

0013GUA01045/0

0010TVB009055/0

0012FUSO5015/0

0012CAN09005/0

0012VEN09005/0

0014GUA01020/0

0012CAVO9010/0

1015PAN09005/0

001ZCAV09005/0

5212210

0003UGE01011/0

5012125

G.C.

Part. No.

378864

371274

371279

E02130

372862

372861

LS 100 (T)

Part. No.

5018046

0013GUAO1045/0

0010TVB009055/0

0012FUS05015/0

0012CAN09005/0

0012VEN09005/0

0014GUA0102010

0012CAVO901 O/O

1015PAN10005/0

0012CAV09005/0

0003UGE01011/O

0003UGE03005/0

5012125

G.C.

Part. No

378864

371279

371297

372861

Description

GASKET 30X22X2

GASKET 48X42X1

PIPE TO AIR PURGE

F1 INTERNAL FUSE 2 A

IGNITION SENSING ELECTRODE

FAN LS 80

FLUE GASKET

CABLE FOR SPARK ELECTRODE

INSULATION PADS SET

CABLE FOR SENSING ELECTRODE

NOZZLE 1.35 FOR NAT GAS

NOZZLE 0.75 FOR LP GAS

NOZZLE 1.25 FOR NAT GAS

SEAL FOR NOZZLE

105

5018015

0008VAL09010/0

0005PRE03010/0

0011C0L09005/0

5021312

TM61 92

372865

371298

371310

372675

371256

5018015

0008VAL09010/0

0005PRE03010/0

0011C0L09005/0

5021312

TM61 92

372865

371298

371310

372875

371258

GASKET llX5X2

3 WAY VALVE

LOW WATER PRESS/SWITCH

BRASS MANIFOLD

NYLON TUBES FROM

PRESSURE SWITCH

DIGITALTIMER

Chartists Way, Morley, Leeds, LS27 9ET.

Telephone: (0113) 252 7007

Tfax: (0113) 238 0229

ravenheat Little Star LS 100 G.C.N LPG User guide

Specifications and Main Features

Frequently Asked Questions

User Manual