ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER

CONDENSING FANNED COMBICSI 85 - CSI 85T

WITHOUT TIMERNATURAL GAS (G 20) (I2H) G.C. N0 47 581 19LPG (G 30 - G 31) (I3+) G.C. N0 47 581 23

Tested, certified andservice listed

Listed by The United Kingdom WaterFitting Byelaws Scheme

WITH TIMERNATURAL GAS (G 20) (I2H) G.C. N0 47 581 20LPG (G 30 - G 31) (I3+) G.C. N0 47 581 24

INSTALLATION AND SERVICING INSTRUCTIONSTO BE LEFT WITH USER

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

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

CONDENSING SYSTEM INNOVATION AUTOMATIC MODULATING BOILERFOR CENTRAL HEATING AND DOMESTIC HOT WATER

This new super high efficient turbo-modulating boiler is designed to meet domestic hot water andcentral heating requirements at super high efficiency, unheard of only a few years ago.

POSITIONThe 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 maximumsafety and efficiency.. Indeed, our depression/combustion front cover has been designed to fit, achievingmaximum 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 availablethroughout the UK. This product is guaranteed by Ravenheat Manufacturing, Chartists Way, Morley,LEEDS, LS27 9ET. Telephone No (0113) 252 7007.

BASIC COMPONENTS - (See figure 1)Guarantee is a full 12 months from date of purchase providing the appliance has been fitted inaccordance with these instructions and relevant codes of practice.

MAJOR COMPONENTS

Gas valve with flame modulator.Variable head pump suitable for any type of central heating system.Main burner with flame stabiliser designed to operate under all thermal conditions.Primary heat exchanger constructed from copper.Unique patented condensing heat exchanger for high thermal flue transfer gases to water.Stainless steel plate heat exchanger for super high heat transfer to domestic hot water,Highly reliable diverter valve with ethylene propylene diaphragm permitting primary flowcirculation in the boiler during domestic hot water supply.Built in frost protection.Printed circuit board designed to connect to room stat and/or timer/frost stat.Aesthetically pleasing panels and controls.On/Off ball valves for shutting off gas central heating and domestic hot water circuit.Safety relief valve (for safety discharge).Programmable 7 day module with digital display (optional model).

All front panel controls not often used have been hidden. This achieves simplicity of operation with easyto clean panels.

NOTE: Due to the high efficiency of this boiler a plume of water vapour will form at the flueterminal during operation.

COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH

IMPORTANT

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

WARNING When installing the appliance, care should be taken to avoid any possibility of injury whenhandling 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, noseand 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 securelywrapped.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 theenvironment components should be re-cycled.

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SECTIONS:

12

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4567891011

TABLE OF CONTENTS

INTRODUCTIONDESIGN PRINCIPLES ANDOPERATING SEQUENCETECHNICAL DATA

GENERAL REQUIREMENTSINSTALLATIONCOMMISSIONINGSERVICING INSTRUCTIONSFAULT FINDINGELECTRICAL SYSTEM DIAGRAMEXPLODED PARTS DIAGRAMLIST OF SPARE PARTS

PAGE:6

68 - 9 - 1 0

1116253043454748

GENERAL LAYOUT

F i g . 1

KEY1 - Heat exchanger2 - Heat exchanger for D.H.W. water3 - Burner4 - Ignition pilot burner6 - Condensing heat exchanger7 - Ignition board9 - ignition electrode

11 - Frame12 - Modulating gas valve15 - Heating control

16 - Hot water control17 - D.H.W. sensor18 - Water pressure switch (heating circuit)22 - Overheat cut of thermostat23 - Safety relief system24 - Three way valve26 - Auto air vent valve28 - Pressure switch29 - Circulation pump30 - Water pressure gauge

33 - Main Switch34 - C.H. sensor35 - Condensing trap36 - Fan37 - Expansion tank38 - Sealed chamber45 - Combustion chamber50 - Flue gas exhaust hood105 - Timer106 - Flue restriction ring

KEY1 - Heat exchanger2 - Heat exchanger for D.H.W. water3 - Burner4 - Ignition pilot burner5 - Flue restriction ring6 - Condensing heat exchanger7 - Electronic ignition8 - Condensing Trap9 - Ignition electrode10 - Condensate sensor

12 - Modulating gas valve 26 Auto air vent valve15 - Heating control potentiometer16 - Hot water control potentiometer

27 Pressure switch giving priority28 - Pressure switch

17 - Water pressure switch18 - Overheat cut-off thermostat

29 - Circulating pump

20 - Gas service cock30 - Water pressure gauge36 - Fan

21 - Compression ball valves23 - Safety relief system24 - Three way valve25 - Flow regulator

37 - Expansion tank38 - Sealed chamber

SECTION 1 INTRODUCTION 2.2.6 Central heating mode

1.1 The Ravenheat boiler is for the use of 2.2.7 If the switch is positioned on with acentral and domestic hot water combined in ‘demand for heat to supply radiators, etc., withone unit. heating circuit fully charged so as to operateIt is fitted with an automatic domestic hot the low water sensor device the boiler willwater priority valve. start in the same way as domestic hot waterA (winter/summer) selector mode but with slightly differing time delay inswitch is fitted to the left hand side of control that it will start on minimum and remain at thispanel. With the only (summer) position level for about 1 minute, after which the flamebeing for domestic hot water. will lift to its maximum setting as governed by

position being for central heating a potentiometer range rates the heating circuitwith domestic hot water priority. The boiler between maximum and minimum power.is equipped with a front cover which can beremoved for servicing. The data badge with 2.2.6 On the control panel are mounted twotechnical data is placed on the lower righthand side of the frame.

potentiometers (thermostats) these controlthe temperature. One is for domestic hotwater and the other for heating.

1.2 Fig. 1 Illustrates the general layout ofcomponents. 2.2.9 The boiler is fitted with an anti-cyclingFig. 2 Illustrates the operating principles device on the control board. This delays thedescribed in section 2. boiler from re-firing over a 2.5 minute period

when in heating mode. The domestic hotSECTION 2 water will always take priority and is

unaffected by the anti-cycling device.2.1 DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION GENERAL FUNCTION

2.2 Domestic hot water mode 2.3 Central Heating ModeWhen the appliance is in rest mode with themains neon and switch on. Switch the summer/ 2.3.1 A potentiometer installed on the electricwinter switch tap position, with the heating circuit board permits regulation of the boilercircuit charged with water (above 1 bar). If the to partial heating requirements, betweendomestic hot water tap is turned on, the boiler maximum and minimum settings.will function in the following sequence:

2.3.2 Air is drawn by the fan for combustion.2.2.1 The pump starts.

The control board sensors. 2.3.3 The fan also forces exhaust gas through theThe fan operates via the pressure switch flue to the outside, this creates a lesserand sends a signal back to the ignition board pressure in the sealed combust ionthat the fan is running at maximum speed. chamber, thus sucking in combustion air,

through the inlet duct.2.2.2 The spark ignition system is powered which

in turn commences the spark igniter to 2.3.4 The boiler water temperature is automaticallyoperate and light the burner. controlled by a built in thermostat.At this point the ignition board opens the firststep of the gas valve to light the pilot/burner. 2.3.5 Interior space temperature is set by the

2.2.3room thermostat to be installed in the

When the electrode/sensor senses the heating system. The boiler already carriessignal of the pilot/burner, it opens the second connection terminals for this thermostat, asstage of the gas valve via the ignition board w e l l a s f o r a t i m e c l o c k . T h e b u r n e ron minimum power. Upon the second valve continues to operate until it is stopped byopening the spark igniter stops. the timer or one of the thermostats.

2.2.4 From the minimum gas rate setting the boiler 2.3.6 When the internal C.H. temperature sensorincreases to the maximum permissible intervenes the main burner shuts down. Thepressure over a period of 3 to 4 seconds and fan stops but the pump continues to operate.will remain at its maximum required poweruntil its maximum regulated temperature. 2.3.7 When the room thermostats intervene the

main burner shuts down. The fan stops and2.2.5 When the domestic hot water tap is closed the pump turns off.

the diverter valve goes back into rest mode,the main burner is shut down along with the 2.3.6 The condensate trap is fitted with apilot/burner. The pump and fan are also blockage safety sensor. This prevents theswitched off, the pressure switch returning boiler operating should there be a blockageto its rest mode. in the condensate discharge trap.

6

2.4

2.4.1

2.4.2

2.4.3

Domestic hot water mode 2.4.4

The heat exchanger in the D.H.W. circuit isbuilt into the main heat exchanger, and do-mestic water is heated by converting the wa-ter in the central heating circuit. The trans-ference of heat is very high because the twofluids move in a counter direction flow toeach other.Switch 33 in the (winter) position,When a hot water tap is turned on a di-aphragm diverter valve excludes the centralheating circuit, the boiler automatically mod-ulates to maintain the domestic hot water ata constant temperature.Water temperature can be regulated usingthe D.H.W. thermostat located on the frontcontrol panel.When domestic hot water is being drawn themain burner and pump perform as they doduring central heating except that the burneris commanded by the D.H.W. thermostat.

2.4.5

3.1

OVERALL DIMENSION3.1.2

When D.H.W. is no longer called for the boil-er automatically returns to the central heat-ing mode.Switch 33 in the (summer) position. Theboiler functions like an automatic gas hotwater heater. When D.H.W. is no longer re-quired the main burner fan and pump imme-diately turn off.This also takes place when switch 33 is on (winter) if there is no demand for

heat to the central heating system or untilthe room thermostat/time clock demands forcentral heating circuit.

SAFETY DEVICE

In both central heating and domestic hotwater mode safe operating is ensured by:- A differential pressure switch shuts off themain burner if the fan stops or the flue orcombustion air intake duct is obstructed.

An overheat cut off thermostat set slightlyhigher than the high limit thermostat acts toturn off the burner to resetable “lockout”(Fig. 50) 3.

3.1.3 A safety valve is fitted onthe central heating circuitset at 43 psi (3 bar).

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

SECTION 3 TECHNICAL DATA

TABLE 1 NATURAL GAS (G 20) I2H

NOMINAL HEAT INPUT NET 24.0 kW (84,500 Btu/h)MINIMUM HEAT INPUT NET 13.0 kW (44.500 Btu/h)

NOMINAL HEAT OUTPUT 23.8 kW (81,200 Btu/h)NOMINAL HEAT OUTPUT CONDENSING 25.6 kW (87,200 Btu/h)MINIMUM HEAT OUTPUT 11.7 kW (40,100 Btu/h)MINIMUM HEAT OUTPUT CONDENSING 13.4 kW (45,700 Btu/h)

GAS RATE max 2.5 m3S/h (88.25 ft3/h)AFTER 10 MINUTES min 1.3 m3S/h (45.9 ft3/h)

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

BURNER PRESSURE C.H. max 10.5 mbar (4.2 in w.g.)min 2.0 mbar (0.8 in w.g.)

MAIN BURNER INJECTORS Nr. 13 x 1.25PILOT BURNER INJECTOR 0.27 x 2 HOLES

ELECTRICAL SUPPLY 2 3 0 V - 5 0 H ZPOWER CONSUMPTION 160WEXTERNAL FUSE RATING 3AINTERNAL FUSE 3 1 5 m A - 2 A - 4 A (20 mm to BS 4265)

DRY WEIGHT 51 kgWATER CONTENT C.H. 2.1 litreWATER CONTENT 0.5 litre

GAS SUPPLY CONNECTION 112" RCFLOW CONNECTION C.H. 22 mm compression isolating valveRETURN CONNECTION C.H. 22 mm compression isolating valveINLET CONNECTION D.H.W. 15 mm compression isolating valveOUTLET CONNECTION D.H.W. 15 mm copper pipeSAFETY DISCHARGE C.H. 15 mm copper pipeCONDENSATION DRAIN 3/4" (21.5 mm) push fit over flow

MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE

SEALED WATER SYSTEM C.H.MAX PRESSURE PHS 2.5 bar (35.6 p.s.i.)MINIMUM WORKING PRESSURE 0.5 bar (7.35 p.s.i.)8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar (7.35 psi.)

CENTRAL HEATING OPERATING TEMPERATURE MAX 85 oCMIN 45oC

DESIGN FLOW RATE 1073 I/h (236 gals/h) 20 oC RISEMINIMUM FLOW RATE C.H. 503 l/h (111 gals/h)

D.H.W. FLOW RATE 30 oC rise 12.2 l/min (2.7 gals/min)D.H.W. FLOW RATE 35 oC rise 10.3 l/min (2.3 gals/min)D.H.W. FLOW RATE 40 oC rise 9.0 l/min (2.0 gals/min) 10 oC inlet temperature

D.H.W. TEMPERATURE max 65 oC min 35 oC

BURNER PRESSURE D.H.W. max 11,2 mbar (4.5 in w.g.) min 2.0 mbar (0.8 in w.g.)QMw Input Net max 26 kW (88,600 Btu/h) min 13 kW (44,500 Btu/h)

D.H.W. PRESSURE max 10 bar (147 p.s.i.)D.H.W. PRESSURE PMW min 0.8 bar (11.8 p.s.i.) To obtain heat input 1.2 bar (17.1 p.s.i.)D.H.W. MINIMUM FLOW RATE 3 l/min (0.66 gals/min)

FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers

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

FLUE TYPE - C12 - C32 - C52

Nox 2CATEGORY I2H

8

SECTION 3 TECHNICAL DATA

TABLE 1/A LPG (G 30 - G 31) I3+

NOMINAL HEAT INPUT NETMINIMUM HEAT INPUT NET

NOMINAL HEAT OUTPUTNOMINAL HEAT OUTPUT CONDENSING

24.8 kW13.0 kW

24.1 kW25.6 kW

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

(82,100 Btu/h)(87,200 Btu/h)

MINIMUM HEAT OUTPUT 11.7 kW (4O,1OO Btu/hMINIMUM HEAT OUTPUT CONDENSING 13.4 kW (45,700 Btu/h)

GAS RATE max G 31 0.95 m3S/h (33.53 ft/3h) G 30 0.79 m3/h (27.89 ft3/h)AFTER 10 MINUTES min 0.5 m3S/h (17.65 ft3/h) 0.4 m3/h (14.12 ft3/h)

INLET PRESSURE 37 mbar G 31 28 - 30 mbar G 30

BURNER max G 31 35.4 mbar (14.0 in wg.) G 30 27.3 mbar (10.9 in wg.)PRESSURE min 7.3 mbar (2.92 in wg.) 7.0 mbar (2.8 in wg.)

MAIN BURNER INJECTORS Nr. 13 x 0.75PILOT INJECTOR 0.22 x 1 HOLE

ELECTRICAL SUPPLY 2 3 0 V - 5 0 H ZPOWER CONSUMPTION 16OWEXTERNAL FUSE RATING 3AINTERNAL FUSE 3 1 5 m A - 2 A - 4 A

DRY WEIGHT 51 kg

(20 mm to BS 4265)

WATER CONTENT C.H. 2.1 litreWATER CONTENT 0.5 litre

GAS SUPPLY CONNECTIONFLOW CONNECTION C.H.RETURN CONNECTION C.H.INLET CONNECTION D.H.W.OUTLET CONNECTION D.H.W.

112” RC22 mm compression isolating valve22 mm compression isolating valve15 mm compression isolating valve15 mm copper pipe

SAFETY DISCHARGE C.H. 15 mm copper pipeCONDENSATION 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 barMINIMUM WORKING PRESSURE 0.5 bar8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar

CENTRAL HEATING OPERATING TEMPERATURE MAX 85 oC

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

MIN 45°C

DESIGN FLOW RATE 1023 l/h (225 gals/h) 20 oC RISEMINIMUM FLOW RATE C.H./503 Lts/h (111 gals/h)

D.H.W. FLOW RATE 30 oC rise D 11.7 l/min (2.6 gals/min)D.H.W. FLOW RATE 35 oC rise 9.9 I/min (2.2 gals/min)D.H.W. FLOW RATE 40 oC rise 8.7 I/min (1.9 gals/min) 10 oC inlet temperature

D.H.W. TEMPERATURE max 65 oCmin 35 oC

D.H.W. PRESSURE max 10 bar (147 p.s.i.)D.H.W. PRESSURE PMW min 0.8 bar (11.8 p.s.i.)D.H.W. MINIMUM FLOW RATE 3 I/min (0.66 gals/min)

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

FLUE OUTLET NOM. DIAM

DESTINATI

ETER 100 mm specially supplied with boilers

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

FLUE TYPE - C12 - C32 - C52

CATEGORY I3+ NOX 2

9

SECTION 4 GENERAL REQUIREMENTS

4.0 SAFETYGas Safety (Installation and Use).Regulations, 1994 and amended 2000.It is law that all gas appliances are installedand serviced by a CORGI registered in-staller in accordance with the above regula-tions and these installation instructions. AllCORGI registered installers carry a CORGII.D. card and have a registration number.Both should be recorded in your boiler logbook. You can check your installer by callingCORGI direct on: 01256 732300. Failure toinstall appliances correctly could lead toprosecution. It is in your own interest, andthat of safety, to ensure the law is compliedwith. Check the boiler and flue is the correcttype for installation.The installation of the boiler MUST be in ac-cordance with the latest I.E.E. (BS 7671)Wiring Regulations, local building regula-tions, bye-laws of the local water authority,the building regulations and the BuildingStandards (Scotland) and any relevant re-quirements of the local authority.

4.1 GENERAL INFORMATIONBoth the user and the manufacturer rely heavi-ly on the installer, whose job it is to install thecombination boiler and connect it to a correctlydesigned heating system. Acquaint yourselfwith the British Standards concerning installa-tion requirements. If you need advice on anypoints your Ravenheat Technical Services Of-fice would be pleased to help. It is recommend-ed that tools suitable for brass fittings are used,and have a capability to accomodate hexagonsizes up to 50 mms.

CODES OF PRACTICE/Ref: Documents

Detailed recommendations are contained inthe following British Standard Codes ofPractice:

BS. 6891 Low pressure installation pipes.

BS. 6798 Installation of gas fired hot wa-ter boilers of rated input not ex-ceeding 60 kW.

BS. 5449 Forced circulation hot watersystems.

BS. 5546 Installation of gas hot watersupplies domestic purposes(2nd Family Gases).

BS. 544O:1 Flues (for gas appliances of ratedinput not exceeding 60 kW).

BS. 5440:2 Ventilation (for gas appliances ofrated input not exceeding 60 kW).

DD 189:1990 Discharge of condensate

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be tak-en, in any way, as overriding statutory oblig-ations

IMPORTANT. These appliances are CE cer-tificated for safety and performance. It is,therefore, important that no external controldevices e.g. flue dampers, economisersetc., are directly connected to this applianceunless covered by these Installation andService Instructions or as otherwise recom-mended by Ravenheat in writing. If in doubtplease enquire.

Any direct connection of a control device notapproved by Ravenheat could invalidate thecertification and the normal appliance war-ranty. It could also infringe the Gas Safetyregulations and the above regulations.

NOTE: The Ravenheat CSI combinationboiler has been tested and examined by BG,and is certified to comply with PrEN 483 andBS EN 625.Manufacturers instructions must NOT betaken in any way as overriding statutoryobligations.If in doubt on any point please consultRavenheat Manufacturing Ltd.

4.2 LOCATION OF BOILER

4.2.1 Siting of Ravenheat CSI 85 Combi Boilermust be as follows. The position of installa-tion should be within the building, unlessotherwise protected by suitable enclosure.Adequate space for installation, servicingand air circulation around boiler must be al-lowed for.The Ravenheat CSI 85 Combi Boiler mustbe fitted on a flat and vertical wall capable ofadequately supporting the weight of the boil-er and any ancillary equipment.The appliance may be installed on a com-bustible wall subject to the requirements ofthe Local Authority and Building Regula-tions.

LPG versions of this appliance shall notbe installed in cellars or basements.

4.3 CLEARANCES AROUND THE APPLIANCE

4.3.1 The following minimum free spaces, re-quired for installation inspection and servic-ing, must be left around the boiler18 inches (450 mm) in front5 inches (125 mm) above6 inches (150 mm) below0.2 inches (5 mm) on each side1 inch (25 mm) in front when installed in acupboard.

10

4.4

4.4.1

IMPORTANT NOTICE

4.5

4.5.1

If the combination boiler is to be fitted in atimber framed building it should be fitted inaccordance with the British Gas PublicationGuide for Gas Installations in Timber FrameHousing Reference DMZ. If in doubt advicemust be sought from the local gas supplier.The combination boiler may be installed inany room or internal space, although partic-ular attention is drawn to the requirementsof the current I.E.E. Wiring Regulations, andin Scotland the electrical provisions of theBuilding Regulations applicable in Scotland,with respect to the installation of the combi-nation boiler in a room or internal spacecontaining a bath or shower,Where a room sealed appliance is installedin a room containing a bath or shower, anyelectrical switch or appliance control, utilis-ing mains electricity should be so situatedthat it cannot be touched by a person usinga bath or shower.A compartment used to enclose the combi-nation boiler MUST be designed and con-structed specifically for this purpose. Anexisting cupboard, or compartment, may beused provided it is modified accordingly.Samples of the CSI combination boiler havebeen examined by B.G. Technology NotifiedBody, and is certified to comply with theessential requirements of the Gas ApplianceDirective 90/396/EEC, the Low VoltageDirective 72/23/EEC and shows compliancewith the Electro Magnetic CompatibilityDirective 89/336/EEC and are therefore per-mitted to carry the CE Mark.

The appl iance has been tested andapproved by the WRc as meeting therequirements of G3 and L of the Buildingregulations and water Bylaws Scheme -Approved Products,

GAS SUPPLY

A gas meter is connected to the service pipeby the Local Gas Region or the Local GasRegion contractor. An existing meter shouldbe checked preferably by the Gas Region toensure that the meter is adequate to dealwith the rate of gas supply required for allappliances it serves. Installation pipesshould be fitted in accordance with BS6891. Pipework from the meter to the boilermust be of adequate size (22 mm) min. Towithin at least 3 metre of the boiler (15 mm)min. can then be used for remaining pipework to the appliance. A smaller size thanthe boiler inlet gas connection should not beused. The complete installation must betested for soundness as described in theabove Code.N.B. if the gas supply for the boiler servesother appliances ensure an adequate sup-ply is available both to the boiler and the

other appliances when they are in use at thesame time.

4.6 FLUE SYSTEM

4.6.1 The terminal should be located where dis-persal of combustion products is not imped-ed and with due regard for the damage ordiscolouration that might occur to buildingproducts in the vicinity (see fig. 6).The terminal must not be located in a placewhere it is likely to cause a nuisance.In cold and/or humid weather water vapourmay condense on leaving the flue terminal.The effect of such steaming must be consid-ered.The terminal must not be closer than 25mm. (1 in) to any combustible material. Forprotection of combustibles, refer to BS5440.1.Where a flue terminal is installed less than1000 mm. from a plastic, or painted gutter;or 500 mm from painted eaves. an alumini-um shield 1000 mm. long, should be fitted tothe underside of the gutter or painted sur-face.

Pluming will occur at the terminal so, wherepossible, terminal positions which couldcause a nuisance should be avoided.The flue must be installed in accordance withthe recommendations of BS 5440: Part 1.

Flue must be positioned in a place not like-ly to cause a nuisance.

IMPORTANT: The following notes areintended for general guidance.

The boiler MUST be installed so that the ter-minal is exposed to external air.

It is important that the position of the termi-nal allows the free passage of air across it atall times.

Minimum acceptable spacing from the ter-minal to obstructions and ventilation open-ing are specified in Fig. 6.

Note positions: Due to the terminal design,installation is possible with clearances lessthan those specified in ES 5440, Part 1.

11

Fig. 6

Terminal position for fan assisted boiler(minimum distance)A - Directly below an open window or other

opening (e.g. air brick)B - Below gutters, soil pipes or drain pipesC - Below eavesD - Below balconies or car port roofE - From vertical drain pipes and soil pipesF - From internal or external corners

mm300

25 4.825252525

4.8.1

G - Above ground or below balcony level 300H - From a surface facing a terminal 600I From a terminal facing a terminal 1200 4.82J - From an opening in the car port (e.g. door

window) into dwelling. 1200K - Vertically from a terminal on the same wall 1500L Horizontally from a terminal on the same wall 300

NOTE: The flue must be terminated in a place notlikely to cause a nuisance.

4.6.2 A concentric vertical flue kit is available, forflueing applications up to a maximum heightof 4.0 metres.For further details see vertical flue installa-tion instructions.

4.7

4.7.1

AIR SUPPLY

The following notes are intended for general 4.8.3guidance.The room sealed fan flued boiler does notrequire a permanent air vent for combustionair supply.Where installed in a cupboard or compart-ment ventilation is not required.

CONDENSATE DRAIN

A condensate drain is provided on the boiler.This drain must be connected to a drainagepoint. All pipework and fittings in the conden-sate drainage system MUST be made of plas-tic - no other materials may be used.Discharge of condensate DD 189:1990.

The drain outlet on the boiler is standard3/4" (21.5 mm) push fit overflow pipe.NOTE: Condensate drain pipework mustnever be less than 15 mm.

Important: any external runs must be car-ried out in 1 1/4 (32 mm) wastepipe.A fall of 2.5” (45 mm/m) all runs must have.

WATER CIRCULATION (central heating)

Detailed recommendations are given in BS6798 5449.1.1977 (for smallbore and micro-bore central heating systems). The followingnotes are given for general guidance.

PipeworkCopper tubing to BS 2671 1.1.1971 is rec-ommended for water pipes. Jointing shouldbe either with capillary soldered or withcompression fittings.Where possible pipes should have a gradi-ent to ensure air is carried naturally to airrelease points and water flows naturally todrain taps. It should be ensured as far aspossible that the appliance heat exchangeris not a natural collecting point for air.Except where providing useful heat, pipesshould be insulated to prevent heat loss andto avoid freezing. Particular attention shouldbe paid to pipes passing through ventilatedspaces in roofs and under floors.

The water through the appliance heatexchanger circuit must exceed the min. 1.84gals/min. (503 It/h) when the burner is firing. Itis important to ensure that this rate is achievedwhen sections of the system are shut off eithermanually or by automatic controls. Thereforea by-pass must be fitted to the system (15mm min.) (Fig. 6A).If the volume of circulating water is too low,the boiler water temperature will rise toorapidly. This could cause noise in the systemor even cause the safety thermostat to trip.

12

4.8.4

4.8.5

4.6.6

Draining tapThese must be located in accessible posi-tions to permit the draining of the whole sys-tem. The taps must be at least 15 mm nomi-nal size and manufactured in accordancewith ES 2870 1980.

Air release pointsThese must be fitted at all high points whereair will naturally collect, and must be sited tofacilitate complete fitting of the system.

The appliance has an integral sealed expan-sion vessel to accomodate the increase ofwater volume when the system is heated. Itcan accept up to 1.5 gal (7 Its) of expansionwater. If the appliance is connected to a sys-tem with an unusually high water content,calculate the total expansion and add addi-tional sealed expansion capacity as appro-priate (Fig. 7).In general modern systems will present noproblem.

4.6.7

4.8.8

Mains water feed: central heatingThere must be no direct connection to themains water supply, even through a non-return valve, without the approval of theLocal Water Authority.

Permissible methods of fillingCistern method (Fig. 8).The system may be filled by one of the fol-lowing methods. Through a cistern used forno other purpose, via a ballvalve perma-nently connected directly to a service pipeand/or cold water distributing pipe. The stat-ic head available from the cistern should beadequate to provide the initial systemdesign pressure.The cold feed pipe from the cistern shouldinclude a non-return valve, and a stop-valvewith an automatic air vent connected be-tween them, with the stop valve being locat-ed, between the cistern and the automaticair vent. The stop valve may remain openduring normal operation of the system, ifautomatic water make-up is required.Booster pump method (Fig. 8).The system may be filled through a self con-tained unit comprising of a cistern pressurebooster pump if required and if necessaryan automatic pressure reducing valve orflow restrictor. The cistern should be sup-plied through a temporary connection from aservice pipe or cold water distributing pipe.The unit may remain permanently connect-

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

F i g . 9MAINS WATER

SUPPLY(SERVICE PIPE)

A combined double check valve shall beinstalled upstream of the draw-off point,through a temporary hose connection froma tap supplied from the mains, where themains pressure is excessive a pressurereducing valve shall be used to make fillingeasier. The following fittings shall form a per-manent part of the system and shall be fittedin the order stated.a) A stop valve complying with the require-

ments of BS 1010 Part 2 (the temporaryhose from the draw off tap shall be con-nected to this fitting).

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

We recommend use of a RavenheatFilling Loop designed for this method offilling the system. Available from yoursupplier.

PROVISIONS FOR MAKE UP WATER(Fig. 7)Provision can be made for replacing waterloss from the system either.A) from a manually filled made up bottle witha readily visible water level. The bottleshould be mounted at least 150 mm (6 in)above the highest point of the system andbe connected through a non return valve tothe return side of the heating system.

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

Safetyvalve setting (bar) 3.0

Vessel chargepressure (bar)

0.5 1.0 1.5

Initial System .pressure (bar)

0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0

Total watercontent Of system

EXPANSION VESSEL VOLUME (LITRES)

Litres2 5 2.1 3.5 6.5 13.7 2.7 4.7 10.3 3.9 6.350 4.2 7.0 12.9 27.5 5.4 9.5 20.6 7.6 16.575 6.3 10.5 19.4 41.3 6.2 14.2 30.9 11.7 24.6

19.0 41.2100 6.3 14.0 25.9 55.1 10.9 15.6 33.1125 10.4 17.5 32.4 66.9 13.6 23.7 51.5 19.5 41.3150 12.5 21.0 36.6 62.6 16.3 26.5 61.6 23.4 49.6175 14.6 24.5 45.3 96.4 19.1 33.2 72.1 27.3 57.9200 16.7 26.0 51.6 110.2 21.6 36.0 62.4 31.2 66.2225 16.7 31.5 56.3 124.0 24.5 42.7 92.7 35.1 74.5250 20.6 35.0 64.7 137.7 27.2 47.5 103.0 39.0 62.7275 22.9 36.5 71.2 151.5 30.0 52.2 113.3 42.9 91.0300 26.0 42.0 77.7 165.3 32.7 57.0 123.6 46.6 99.3325 27.0 45.5 64.1 179.1 35.7 61.7 133.9 50.7 107.6350 29.1 49.0 90.6 192.6 36.1 66.5 144.2 54.6 115.6375 31.2 52.5 97.1 206.6 40.9 71.2 154.5 56.5 124.1400 33.3 56.0 103.6 220.4 43.6 76.0 164.6 62.4 132.4425 35.4 59.5 110.1 239.2 46.3 80.7 175.1 66.3 140.7450 37.5 63.0 116.5 247.9 49.0 65.5 165.4 70.2 146.9475 39.6 66.5 123.0 261.7 51.6 90.2 195.7 74.1 157.2500 41.6 70.0 125.9 275.5 54.5 95.0 206.0 76.0 165.5

For system volumesother than those givenabove, multiply the 0.0633 0.140 0.259 0.551 0.109 0.190 0.412 0.156 0.331system volume bythe factor across

Note: This pressure can be increased up to 1.5 bar to suit high static head situations, see item 10, other appliance components in theSERVICING INSTRUCTIONS.

B) Where fitting a make up vessel would bedifficult re pressurisation of the system canbe done. See section on FILLING.If the capacity of the central heating systemshould exceed 110 litres, an additional ves-sel should be installed on the return to thecombination boiler from the heating system(Fig. 7). Guidance on vessel sizing is givenin (Table 3).Reference should be made to British GasPublications <<Material and InstallationSpecifications for Domestic Central Heatingand Hot Water>>,. Draining taps should be atleast 1/2" in BSP nominal size and be inaccordance with BS 2879.

It is most important that the correct concen-tration of the water treatment product ismaintained in accordance with the manufac-turers’ instructions.If the boiler is installed in an existing systemany unsuitable additives MUST be removedby thorough cleansing.BS 7593:1992 details the steps necessaryto clean domestic central heating system.Also check pipework and renew any corrod-ed pipework or fittings. Valve glands must berepacked or replaced wherever necessaryand any defective controls exchanged.

WATER TREATMENTThis boiler has a secondary ALUMINIUM

4.6.9 Installation to an existing central heat-ing system

The combination boiler is designed to oper-ate on a sealed system only. Therefore if theexisting system is of the open water type itwill have to be modified to comply with BS5376 Part 2.

Before installing a new combination boiler toan existing system, flush out the old systemwith a recommended descaling agent.

alloy heat exchanger Ravenheat recom-mended only the use of FERNOX-COPAL orSENTINEL Xl00 water treatment products,which must be used in accordance with themanufacturers instructions. For further infor-mation contact:Fernox Manufacturing Co. Ltd.Tel. 01799 550811Sentinel Division Betz Dearborn Ltd.Tel. (0151) 424 5351

14

SALAMANDER CURROSION GUARD Fig. 10

Salamander (Eng) LtdTel: (0121) 3780952/4508

4.8.10 Hard water areasIf the area of-installation is recognized ashard water, it is recommended that a suit-able water treatment device is installed inthe mains.The water hardness can be determined byusing the standard test paper or by referringto local water authority.

4.9

4.9.1

4.10

4.10.1

DOMESTIC WATER

The domestic hot water must be in accor-dance with the relevant recommendations ofBS 5546. Copper tubing to BS 2871. 1 isrecommended for water carrying pipeworkand MUST be used for pipework carryingpotable water.

ELECTRICAL SUPPLY

Warning: this appliance must be earthed

External wiring to the appliance must becarried out by a competent person and be inaccordance with the current I.E.E. Regula-tions and local regulations which apply.The Ravenheat boiler is supplied for con-nection to a 230 V - 50 Hz single phase sup-ply. The supply must be fused at 3 A.

NOTE: The method of connection to theelectricity supply MUST facilitate completeelectrical isolation of the appliance, by theuse of a fused, double pole isolator, having acontact separation of at least 3 mm in allpoles. The point of connection to the elec-tricity supply must be readily accessible andadjacent to the appliance except, where theappliance is installed in a bathroom, thisMUST be sited outside the bathroom.

SECTION 5 INSTALLATION

5.1 WARNING

5.1 .1 It is MOST IMPORTANT that this applianceis installed in a VERTICAL POSITION, withthe flue air duct passing through the wall.Make sure flue slopes 2.5o down towardsthe boiler that is 45 mm/m fall per metreof flue length.

Fig. 11

15

5.2 DELIVERY WARNING:

5.2.1 The appliance will arrive on site in twocartonsBox 1 of 2 containing (Fig. 11):a) boiler fully assembledb) installation instructions and

user instructionsc) white paper templated) terminal cover plate (Fig. 12)e) - 4 coach bolts and wall plugs

- screws and dowels

Polythene bag containing:a) 2-22 mm compression ball valves

(heating)b) 1-15 mm compression ball valve

(with drain screw for domestic coldwater inlet)

Maximum allowable flue length 2.5 m.maximum No. 2x1000 mm.Flue duct extension used with standard flue

Fig. 13

c) 1-1/2" BSP Union gas cockd) - 2 15 mm flanged copper tails complete

with 1/2" brass nuts and washers- 2 22 mm flanged copper tails complete

with 3/4" brass nuts and washers

Box 2 of 2 containing (Fig. 12):Horizontal CSI flue kit56 - Flue gas sample point57 - Flue bend assembly59 - Rubber seal 0 6060 - Air intake duct61 - Flue exhaust duct62 -Terminal65 - Pipe centering spring66 - Flue gas sample point

127 -Terminal rubber(Contained in the carton Fig. 10)

Fig. 12

OPTIONAL EXTRAS:Small carton containing: (Fig. 13)

57 - Straight header supplied as an extra cost onlywhen requested

59 - Rubber seal 0 6066 - Flue gas sample point

63 - Air intake duct extension64 - Flue exhaust duct extension65 - Pipe centering spring

FLUE EXTENSION BOX CONTAINING (Fig. 14)1000 mm flue extension duct as an extra cost Onlywhen requested for side and vertical flue applications

59 - Rubber seal 0 60

1 6

5.3

Fig. 15

1) Open the topof the carton

Fig. 16

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

Fig. 18

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

Fig. 19

1 7

5.4

5.4.1

5.4.2

5.4.3

5.4.4

5.4.5

5.4.6

5.5

5.5.1

POSITIONING OF THE BOILER Fig. 22

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

- Carefully slide the front panel a fewmillimetres up towards the top of theappliance-until it is free from its slot, andthen lift off (Fig. 20).

Unscrew the 2 screws that fasten the lowergrating on the casing and remove it from thesides of the casing (Fig. 22).

Fig. 23

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

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

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

Remove the two sides of the casing by slightlylifting them and carefully sliding towards thetop of the appliance, to release them fromtheir upper suspension hooks (Fig. 26-27).

Fig. 25

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

INSTALLING THE APPLIANCE FORREAR FLUE OUTLET

Fig. 26Use adhesive tape to attach the template tothe wall, making sure that the centre line isvertical.- Mark the four boiler fastening holes on the

wall as well as the centre of the flue duct.- Detach the template from the wall.- Use a 10 mm. dia drill to make the 4

boiler securing holes. Insert the plasticexpansion plugs.

- Cut or cork drill a 105 mm. dia hole forinserting the flue duct.

- Screw in the two upper coach bolts leavingthem about 10 mm. out from the wall to

enable the boiler to be located on the wall.Fit the elbow header positioning it towardsthe required direction (Fig. 30).

IMPORTANT: Make sure that the elbow’sdia. 60 mm duct is inserted into the fan, therubber seal and orifice (F2) have beencorrectly fitted.

Fig. 21

1 8

5.5.2 Locate the rubber 0 60 into the flue elbowheader (Fig. 30).

5.5.3 If the standard duct furnished with the boileris too long (the wall to go through is lessthan 680 mm. thick) it can be shortened asfollows:- 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 rightangles to a length equal to W + 264 mm.Insert from cut end. Reassemble the twotubes. Insert centering spring 65.Must be de-burred.

- Reassemble together inner and outerflue duct insert centering spring.

INTAKE AND EXHAUSTTERMINAL COMPONENTS

KEY56 - Straight header57 - Elbow header58 - Header gasket59 - Rubber seal 0 60

60 - STD air intake duct61 - STD flue exhaust duct62 -Terminal63 -Air intake duct extension

64 - Flue exhaust duct extension65 - Pipe centering spring66 - Sample point

127 - Terminal cover plate

19

5.5.4

5.5.5

5.5.6

Fig. 33

Insert the flue assembly into the wall, beingcareful to make sure that the outer air ductcomes flush to the inner surface of the wall.

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

Working above the boiler pull the flueexhaust duct towards the boiler in order toengage tube 61 into its header 57A.Position flue into elbow header and push soas to locate inner and outer flue correctlyensuring good seal is made with o rings.

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

5.5.9 Extension kits are available on order forflue extension of up to 2.5 metres totallength (Fig. 31).

Fig. 35

Fig. 34

Make good inside and outside wall around the air duct

20

5.5.10

5.5.11

5.6

5.6.1

Each extension length extends the pipe byapproximately 1000 mm’ long up to amaximum of two extensions.Pipeline length can be established usingthe instructions in section 5.5 for rear flueoutlets and section 5.7 for side flue outlets.Extensions must be installed with thewidened end of the air intake pipe and thetapered end of the flue pipe aimed towardsthe exhaust terminal. Extensions must bejoined together with the standard terminalpipe, and inserted in each other as far asthey can go.If an extension must be shortened, thismust be done from the straight end, andnot from the widened or tapered end. Tomeasure the pipeline properly allcomponents must be assembled and totallength measured before cutting. Thestraight end of the extension connects tothe boiler. The flue output pipe fits into theboiler header until it stops. The air intakepipe should be located approximately 2mm. from the boiler header (Fig. 31).When cutting both inner and outer ducts ofthe extension, always ensure that thereduced end (male) of the inner duct islonger than the outer duct.All joints must be sealed with the rubberseals supplied.It is important to put the centering spacer,supplied with the unit, inside between thetwo pipes, from the side opposite theextension’s straight end.

NOTE: a suitable support bracket is availa-ble from Ravenheat Manufacturing andshould be used to support flue length atleast every 1.8 metre preferably at eachjoint this bracket should be secured to walland flue duct.

INLINE FLUE BENDMeasure the distance between the fluebends or the flue/terminal assembly. Themeasurements should be taken from theouter edge of the flue and bend (Fig. 398).IMPORTANT: inline flue bend - 1680 mmmust be deducted from overall length foreach 90o bend. Obtuse flue bend - 1680mm must be deducted from overall lengthfor each 135o bend (Fig. 398).

COMPLETING BOILER INSTALLATION

Reassemble the outer casing (sect 5.4)proceeding in this order1) 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).

5.7 INSTALLING THE APPLIANCE FOR SIDEFLUE OUTLET (Fig. 39)

5.7.1 -Attach the template to the wall with adhe-sive tape, making sure that the centre lineis vertical and that the distance from thecentre line to the nearest side wall is notless than measurement in table 6.

- Mark the four boiler securing holes on thewall and extend the axis of the flue ducthole to the side wall ensuring it ishorizontal.

-Trace the centre of the flue duct holemeasure distance F (table 6). From thecorner of the wall (Fig. 38), measure thedistance Y between. the centre of flueduct hole to the corner. Detach thetemplate from wall.

-Use a dia. 10 mm. drill to make the 4holes for securing the boiler. Insert theplastic expansion plugs. Core drill a 105mm dia. hole in the side wall for insertingthe flue duct.

TABLE 6

Fig. 39

21

65KEY 63 -Air intake duct extension56 - Sample point 64 - Flue Exhaust duct extension57 - Elbow Header 65 - Pipe centering spring59 - Rubber seal 0 60 128 - In Line Bend

5.7.2 Positioning the elbow towards the required - Reassemble the two tubes.direction (Fig. 30). Insert centering spring 65.

5.7.3

5.7.5

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

- If the standard duct furnished with theboiler is too long (position of the boilerfrom the wall to go through as illustratedin the drawing and wall thicknesses lessthan what was specified above) it can beshortened as follows: Fig.28-29-31-32.

- Remove the centering spring 65, pullthe flue terminal disengage inner flueduct.

- Measure the thickness W of the wall.- Cut the outer air duct (100 mm. dia.) at

right angles and to a length equal toW+Y - 47 mm. (Fig. 32).

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

- Outer air duct and inner flue duct mustbe de-burred.

5.7.12 VERTICAL FLUE INSTRUCTIONS ONLY

6.7.6 Insert the flue assembly into the wall,making sure it will not interfere when fixingthe boiler on the wall.

5.7.7 Lift the boiler on the wall. Locate onto thetop coach bolts. Fit the lower coach boltsand tighten all four securing bolts.

5.7.8 Working above the boiler pull the flue ducttowards the elbow in order to engage tubeinto its header (Fig. 35).Position flue into straight header and pushso as to locate inner and outer flue correctly.Ensuring good seal is made with o.rings.

5.7.10 IMPORTANT: Terminal rubber must befitted (Fig. 37).

5.7.11 Extension kits are available on order forflue extension of up to 2.5 metres totallength (Fig. 31). For further details see sect5.5.10.

Fig. 40

Fig. M

22

57.12 VERTICAL FLUE INSTRUCTION ONLY

INLINE FLUE BEND - 1680 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90” BENDOBTUSE FLUE BEND - 1680 MM MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135” BEND

The vertical flue kit is intendedfor use where a horizontal flueoutlet is not possible ordesired. The vertical flue canbe used either with a fiat roofor a pitched roof (maximumpitch 60o). Where a straightvertical flue is not possible ordesired, an offset vertical fluecan be used in conjunctionwith a side horizontal flueextension piece and an inline135o/90o flue bend (Fig. 41).

Fig. 42

POSITION MIN. DISTANCE mm

N above roof level (to base of terminal) 300P from adjacent wall to flue 300Q from internal corner to flue 300S from facing terminal 1,200M horizontally from a vertical terminal to a wall 300

Before proceeding with installation check thecontents of the RAVENHEAT VERTICAL FLUE KIT,comprising of the following pieces:

- 1 RAVENHEAT VERTICAL FLUEcomplete with terminal assembly (forvertical flue application).

-Addi t ional 1000 mm (approx) FlueExtension pieces as necessary, eachextension is provided with inlet and outletsealing rings and flue centering bracket.

-One box containing straight header withinlet and outlet sealing rings.

Proceed with installation as detailed in section 5 upto 5.4.8., of the main Installation and ServicingInstruction, ignoring all references to horizontal flueinstallations,

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

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

-Mark the four boiler fastening holes onthe wall.

- Detach the template from the wall.

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

-Screw in the two upper coach boltsleaving them about 10 mm out from thewall to enable the boiler to be located onthe wall.

- Position the straight header on the top ofthe appliance (Fig. 43) Item 6, andensure that the gasket and sealing ringsare correctly fitted.

Important: Make sure that the flue header dia 60 mmduct is inserted fully into the fan spigot.

23

Cut a 105 mm diameter hole through the ceilingand/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 throughthe flashing plate from the outside.

Fix the appliance to the wall, locating onto the topcoach bolts. Fit the two lower coach bolts and tightenall four securing bolts.

Measure the vertical distance between the top of theflue (Fig. 42) and the bottom of the flue terminalassembly (Fig. 41). The measurements should betaken from the outer diameter of the flue.NOTE: Where this length does not match anystandard combination of the extensions, extensioncan be cut to the required length (Fig. 44).

When cutting both inner and outer ducts of theextension, always cut on spigot side, and they mustbe de-burred.

Starting at the appliance end, assemble theextension duct sections, making each inner andouter (flue) joint by inserting the spigot end into thesocket end of the next tube, making sure the sealrings are correctly located (Fig. 44). Make sure thatthe entire flue is adequately supported. Use at leastone bracket for each extension used.

Ensure that all inner flue connections have a good.fit/seal, and that the space clips in each extensionare correctly positioned

5.8

5.8.1

5.9

5.9.1

5.9.2

5.10

5.10.1

REASSEMBLE BOILER AS PER(sect. 5.6.1)

Fitting valve packRemove plastic caps from boiler connectionand fit flanged copper tail and valves as perFig. 46 using washers provided.

GAS CONNECTION (Fig. 46)

A minimum working gas pressure of 20mbar (8 in w.g.) must be available at theboiler inlet at full flow rate (37 mbar forpropane, 29 mbar for butane).

Fit gas service cock to the boiler via theunion nut and connect gas pipe.Do not overtighten and use anotherspanner as a counter force to avoidstraining internal connections.Important consult (sect 4.5.1).

CENTRAL HEATING CONNECTION(Fig. 46)

Before any central heating connections aremade to the boiler all system valves shouldbe opened and the system thoroughlyflushed 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.

24

5.11

5.11 .1

5.12

5.12.1

5.13

5.13.1

DOMESTIC HOT WATER (Fig. 46) Fig. 46

The domestic hot water circuit does not needa safety valve but it is essential to ensure thatthe pressure of the cold water supply does notexceed 10 bar. If in doubt it is advisable toinstall a pressure reducing valve. The mini-mum pressure needed to operate the domes-tic hot water system is 0.5 bar with a flow ofapprox 3 Lts per min. The regulator screw onthe cold water outlet of the diverter valvemay be adjusted to prevent excess volumeflow (Fig. 53 COMMISSIONING SECTION).Flush out all foreign matter from the supplypipe before connecting to the appliance.- Connect the 15 mm. cold water pipe to

the stop cock to the appliance inletmarked DCW.

- Connect the 15 mm. hot water pipe witha suitable connection.

SAFETY VALVE DISCHARGE

The safety valve is located near the pump. Ithas a threaded outlet RC 1/2" (to 15 mmcopper) to permit a discharge pipe to beconnected. When connecting ensure thedischarge pipe does not restrict access.The discharge should terminate facingdownward exterior to the building in a posi-tion where discharging (possibly boilingwater & steam) will not create danger or nui-sance, in easily visible position, and not tocause damage to electrical components orwiring.The discharge must not be over an entranceor a window or any other type of access.

ELECTRICAL CONNECTIONS

IMPORTANT: Electricity supply must be asspecified in clause (sect. 4.10).- When controls external to the appliance

are required, design of the external elec-trical circuits should be undertaken by acompetent person. In accordance withthe IEE wiring regulations.It is essential that all external controlsmust be volt free.Factory fitted internal wiring must not bedisturbed when wiring external controls.

- To gain access to the electrical boxremove the front panel of the case asdescribed in clauses (sect. 5.4.1) and theinstrument panel as described in clauses(sect. 5.4.3).

- The terminals are easily visible on the frontof the electronic control board (Fig. 46).

- Heat resistant flexible cable is fittedbetween the isolator and the terminalblock. A 3 core cable of 0.75 mm2(24x0,2mm) to BS 6500.Make sure all wires to the appliance arerouted away from sharp edges and hotsurfaces.The cable must be fastened with its cordanchorage and connected so that shouldthe cable slip from the anchorage the cur-rent carrying conductors become tautbefore the earthing conductor.Securely tighten all terminal screws andarrange the cable with slack between thecord anchorage and the terminal block.

WARNING: If the supply cord is dam-aged, it must be replaced by a serviceengineer (supply cord available fromRavenheat Manufacturing Ltd).

Fig. 49A

25

5.14 PROGRAMMABLE TIME CLOCKInstructions for use consult User’s Guide

SECTION 6 COMMISSIONING

6.1

6.2

6.2.1

6.3

6.4

Each boiler has been through a rigorousoperational procedure at our factory andshould not require any further adjustment. Ifin the unlikely event of the appliance notoperating correctly, please turn to the FaultFinding and Logic Sequence charts.

GAS SUPPLY INSTALLATlON

Inspect the entire installation including thegas meter, test for soundness and purge, allas described in BS 6891.

ELECTRICAL INSTALLATIONPreliminary electrical systems checks toensure electrical safety shall be carried outby a competent person (earth continuity,polarity, resistance to earth). Those checksare outlined in the <<Instructions for BritishGas Multimeter,>> Booklet. If a fault hasoccurred on the appliance the fault findingprocedure should be followed as specifiedunder the serv ic ing sec t ion o f th isdocument.

INITIAL FILLING OF THE SYSTEMOpen central heating flow and return valves,Unscrew the cap on automatic air releasevalve 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 heatingsystem until water is heard to flow.

- Starting with the lowest radiator openeach air release tap in turn. Close it onlywhen clear water, free of bubbles, flowsout. In the same way release air fromany high points in the pipework.

- Continue filling the system until 1.5 barregisters on gauge. Then turn off thefilling points stopcock.

- Inspect the system for water soundnessand remedy any leaks discovered.

6.5 SETTlNG THE SYSTEM DESIGNPRESSUREThe design pressure must be a min. 1 barand max. 1.5 bar. These figures are read offthe pressure gauge.- The actual reading should ideally be 1

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

- To lower the system pressure to therequired value remove drain point (Fig.93) or drain on the heating circuit.

6.6 FILLING THE HOT WATER SYSTEMClose all hot water draw-off taps,Open the cold water inlet cock.Slowly open each draw-off tap until clearwater is discharged.

6.7 LIGHTING THE BOILER (Fig. 50)Before lighting the main burner make surethat the heating circuit flow and returnvalves are open and also that the cold waterinput cock is open.- If external controls are installed (e.g.

timeclock and thermostat) make surethat they call for heat.

- Turn main switch (1) to winter

26

27

- Turn control thermostat 4 up to itsm a x i m u m s e t t i n g .

- Now the main burner should turn on.With leak detection fluid test for gassoundness of all gas components andjoints.

- - See paragraph 6.14 for regulating theheating circuit thermostat.Check gas mains pressure (Fig. 52). Fita gas pressure gauge on pressure inlet77 (Fig. 51) on the gas valve, afterreleasing the seal screw.Check the gas mains pressure withboiler operating.Check with the Local Gas supplier if thepressure differs significantly from 20mbar (natural gas), 37 mbar (G 31) and29 mbar (G 30).

6.9 CHECK THE GAS PRESSURE AT THEBURNERNow check if the maximum gas pressure atthe 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 mbarpropane - 29 mbar butane).To do this proceed as follows:- Turn off main switch 1 (Fig. 50)

-Set main switch 1 on-Set con t ro l thermosta t 5 a t i t smaximum setting.- Fit a pressure gauge, using a hose, to

pressure test point 81. (Fig. 51) afterfirst loosening its close-off screw.

-Open one or more hot water taps sothat at least IO-12 litre of water flowsper minute.

- The pressure indicated on the pressuregauge is the maximum operating gaspressure.

- Check that the minimum pressurecorresponds to 2 mbar (0.8 in wg.) forG 20 as is set at the factory.

- LPG 7.3 mbar for G 31 and 7.0 mbar forG 30. This is set and sealed at thefactory and cannot be adjusted.Detach one of the wires going tomodulator 104 (Fig. 51) and make theboiler operate just as was done forchecking the maximum pressure.

Observe the pilot flame which will light asecond before main burner. It should beabout 20 mm long (Fig. 528) and envelopthe spark electrode tip.

6.10

6.11

6.12

ADJUSTING MINIMUM AND MAXIMUMPRESSURE (Fig. 51) SIT-HONEYWELLGAS VALVE- Remove cap covering modulator to gas

valve.- Detach one of the cables connected to

the modulator 114.- With the boiler operating use a screw

driver (HONEYWELL 9 mm spanner) toturn the nut 111 clockwise to increasepressure and anti-clockwise to decreasepressure.

NOTE: LPG ONLYThe minimum pressure is factory set andsealed, and cannot be adjusted.

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

SETTlNG CENTRAL HEATING GASPRESSURE THE BOILER COMES SETAT MID POSITION RATING FOR USE ONC.H. (table1)When the boiler operates in the C.H. modethe gas pressure at the burner can be setbetween the min. and max. values.This permits capacity to be adjusted to suitsystem demand. If adjustment is requiredproceed 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 thecontrol box cover and lift off (Fig. 78).

- Select (winter) switch position- Turn control thermostat 4 to maximum

setting. (Fig. 50)- Check all external controls are on and

calling for heat, ensure all D.H.W. tapsare off.

- With boiler operating use a screwdriverto turn potentiometer (Fig. 48) clockwiseto increase pressure and anti-clockwiseto decrease pressure.

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

- Replace the protective cover.- Once this pressure is established, mark

it up on data badge with adhesive redlabel/arrow burner pressure setting sothat this can be referred to and checkedduring future servicing.

RATIO BETWEEN BURNERPRESSURE AND OUTPUT

Fig. 52

Once the process of commissioning the boiler iscomplete, the commissioning engineer MUSTcomplete his section in the Benchmark log book.

6.13 CHECKING THE FLUE SYSTEM

6.13.1 The flue system should be visually checkedfor soundness. Check all connections andfixings are secure and tight.

6.14 CHECKING THE HEATING THERMOSTAT

6.14.1 Allow the system to warm up and then turnthe C.H. thermostat to ensure the mainburner modulates from ‘“high” to “low” and“low” to “off” and vice versa (scale rangecovers approx. 45o C 85o C).

6.15 TESTING AND REGULATING THEDOMESTIC HOT WATER SYSTEM FLOW

6.15.1 Put the appliance in operation with the(summer/winter) switch in summer position.- Open a domestic hot water tap

(preferably the bath tap). Ensure coldwater inlet stopcock is open and theD.H.W. thermostat 16 is set at maximum.

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

- The temperature of the water wi l ldepend on the rate at which it flows. If,due to high water pressure, the flow rateis too high (and thus the temperaturetoo low for practical use) the flow ratemay be adjusted. It is better to set forthe lowest acceptable temperature,preferably at the bath tap since the usercan gain higher temperatures at otherrestricted flow taps (Table 1).

- To adjust the flow rate refer to (Fig. 53)side view and locate the adjustmentscrew (Fig. 53). Turn the screwclockwise until the required temperatureis reached.N.B.: If the cold supply is subject tolarge fluctuations or is above thepermitted max. water pressure, asuitable pressure/flow regulator shouldbe fitted in the cold water supply to theappliance.

- Turn the appliance mode selector switch(Fig. 50) (1) to the summer position.Slowly close the draw off tap to reducethe flow rate to above the min. (approx.2.8 litre/min 0.61 gals/min.). Rotate theD.H.W. control thermostat to ensure itoperates at its various setting.

- Close the draw-off tap still further. Theburner should stop when the rate fallsbelow about 2.8 l i t res/min (0.61gals/min.).

29

EXPLODED DIAGRAM OF BOILER BODY

KEY1 - Window2 - Plenum chamber cover6 - Combustion chamber7 - Flue restriction ring8 - Flue gas exhaust hood

15 - Connection pipe18 - Heat exchanger24 - Main burner25 - Pilot burner

27 - Auto air vent valve28 - Pressure switch29 - Seal31 - Seal37 -Window seal42 -Window clamp ring44 - Fan46 - Header gasket50 - Flue gas exhaust hood cover

53 - Connection tube54 - Connection tube58 - Ceramic insulation61 - Condensing heat exchanger80 - Plenum chamber83 - Burner centering pin84 - Seal

30

6.16 HANDING OVER TO THE USER

6.16.1 After complet ion of instal lat ion andcommissioning of the system’, the installershould hand over to the Householder bytaking the following actions:- Hand the “User’s instructions” to the

Householder and explain His/Herresponsibilities under the “Gas SafetyRegulations 2000”.

- Explain and demonstrate the lightingand shutting down procedures.

- The operation of the boiler including theuse and adjustment of ALL systemcontrols which should be fully explainedto the Householder. This then ensuresthe greatest possible fuel economyconsistent with household requirementso f bo th hea t ing a n d h o t w a t e rconsumptions.Advise the User of the precautionsnecessary to prevent damage to thesystem, and to the building, in the eventof the system remaining inoperativeduring frost conditions,

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

- Explain and demonstrate the function oftime and temperature controls, neonl ights radiator valves etc. for theeconomic use of the system.

- If an optional time clock is fitted, thendraw attention to the time clock User’sInstructions and hand them to theHouseholder.

- Stress importance of regular servicingby a qualified Heating Engineer and thata comprehensive service should becarried out AT LEAST ONCE A YEAR.

- Fill in the Benchmark log book andleave completed with the customer.

SECTION 7 SERVICING INSTRUCTIONS

Ravenheat are a member of the Benchmark initiativeand fully supports the aims of the programme.Benchmark has instructed to improve the standardsof installation and commissioning of central heatingsystems in the UK and to encourage in the regularservicing of all central heating systems to ensuresafety and efficiency.

7.1 SERVICING

7.1.1 To ensure continued efficient operation of theappliance it is necessary to carry out servicingand cleaning at regular intervals. Thefrequency of cleaning will depend upon theparticular installation conditions and usage butin general, once year should be adequate.

7.2

7.2.1

7.2.2

7.2.3

7.2.4

7.2.5

7.2.5.1

Before the start of any servicing orreplacement of components alwaysisolate electricity supply to the applianceand always turn off the appliance gassupply at the gas service cock.Data badge position lower left hand subframe.- The following notes apply to the

appliance and its controls but it shouldbe remembered that attention must alsobe paid to the heating and hot watercircuits with special attention to radiatorvalves, thermostats, clocks, leaking hotwater taps etc.

- Where it is necessary to replace a gasketthat relies on adhesive for securing - thisadhesive will be supplied with the gasketas a spare item.

- In all cases prior to servicing, remove theouter case (sect. 5.4). Operate theappliance by turning the hot waterservices on to a high water flow, andobserve the main burner.

- Check that the flame covers all the flameports and is of a light blue colour. Yellowflames and excessive lifting of flamesindicate poor combustion,

- IMPORTANT: After completing anyservicing or replacement of gas carryingcomponents it is essential that a test forgas soundness is always carried outalong with functional checks in operation.

TO INSPECT AND CLEAN THEAPPLIANCE

Before carrying out cleaning operation,cover the electrical control panel with apiece of waterproof material to protect itfrom debris.

Inspect the heat exchanger for anyblockage. Deposits of any material shouldbe brushed away using a soft brush.NOTE: Do not use brushes with metallicbristles.

Examine internal pipe-work connections andautomatic air vent for any water leaks.Rectify if necessary.

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

Remove and examine the main burnerinjector and pilot injector clean or renew, asnecessary (sec. 7.12 & 7.14).

Inspect the main burner and remove anydeposit with a soft brush. Check theelectrodes for damage or deterioration,clean or renew as necessary. Ensure thatthe spark gaps are correct to dimensionsspecified in sec. 7.15.

31

7.2.6

7.2.6.1

7.2.7

7.2.8

7.2.9

7.3

7.3.1

7.4

7.4.1

7.4.2

7.4.3

7.4.4

7 . 6

7.6.4

Inspect the secondary condensate heatexchanger. Deposits can be cleared byremoving and flushing out the exchanger.Inspect the siphonic condensate trap for ablockage. Any deposits should be flushedout (Fig. 90).

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

Examine the fan for any mechanicaldamage, check to ensure free running ofthe fan wheel. Clean the wheel if necessarywith a soft brush. Check sealing gasket andrenew if damaged (sect. 7.6).

Examine flue duct and flue hood andensure that there is no obstruct ion.Examine the gasket at the entry into theflue duct.

It is essential that a good seal is made atthe outlet to the fan, renew this gasket ifthere is any sign of damage ordeterioration.

TO REMOVE/REPLACE THE FRONTPANEL OF THE CASING (Fig. 19 & 20)

Remove the 2 screws that secure the upperpart of the front panel of the casing.Lift the front panel few millimeters to thetop, until it is free from the slot and removepanel.

TO REMOVE/REPLACE THE COMBUS-TION CHAMBER COVER

Remove the front casing panel (sect. 7.3).

Unscrew all the screws that fasten thecover to the chamber body and put theminto a container so that they don’t get lost.

Detach the cover, being careful not todamage the seal.

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

TO REMOVE/REPLACE THE FAN

nt cover

the fan motor.from

Support the fan and remove the two fixingscrews and bracket from the front of theflue hood.Carefully withdraw from condensing heat

7.6.5 TO REMOVE/REPLACE CONDENSINGHEAT EXCHANGER FIG. 54-55

7.6.5.1.

7.6.5.2

Remove front casing (sect. 7.3). Removecombustion chamber front cover as in (sect7.4). Remove lower grating by unscrewingthe two screws (Fig. 21).Close the ON/OFF valves for the heating.Drain the heating system from the drainpoint mounted system (Fig. 93).

7.6.5.3

7.6.5.4

Remove the fan (sect.7.6).

Disconnect 4 unions for the heating waterpipelines (Fig. 54) and remove the twoshort pipes.

7.6.5.5 Remove screw holding heat exchanger tochamber. Disconnect condensing dischargepipe by pulling off the pushfit connector attop rear of boiler (Fig. 54).

7.6.5.6 Pull the heat exchanger down and slightlyforward until it comes out of the connectionfrom chamber (Fig. 55).

7.6.5.7 Replace in reverse order. Taking care torefit discharge pipe at rear.

IMPORTANT: When replacing heatexchanger new seals must be used.

7.7 TO REMOVE/REPLACETHE FLUE HOOD(FIG. 60)

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

7.7.2 Remove the fan (sect. 7.6)

7.8.11 Remove condensing heat exchanger(sect. 7.6.5)

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

7.8.1 Remove front casing (sect 7.3). Removecombustion 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).

exchanger then from the appliance.Place in a safe place until required. Reas-semble in reverse order. Ensure wires areconnected correctly (Fig. 94).

3 2

7.82 Remove the two sides of the casing byslightly lifting them and sliding themtowards the top of the appliance, to releasethem from their upper suspension hooks.

7.84

7.8.5

Remove the fan (sect, 7.6).

Remove condensing heat exchanger(sect. 7.65). .

7.8.6

7.8.6

7.8.9

Remove the flue hood (sect, 7.7).

Remove the automatic air vent (Fig. 92).

Disconnect unions for two heating (rightside of boiler) water pipelines (Fig. 62).

7.8.10 Unscrew the rings that fasten the heatexchanger to the combustion chamber.

7.8.11 Remove the two side insulation panels attop of heat exchanger (Fig. 63).

7.812 Pull the heat exchanger up until its flowconnections come out from the combustionchamber and then remove it (Fig. 64).

7.8.13 Replace in reverse order.Ensure correct wire position (Fig. 94).

IMPORTANT: When replacing a heatexchanger new seals must be used.

7.9 TO REMOVE/REPLACE COMBUSTIONCHAMBER INSULATION PANELS (Fig.63).

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

7.9.2

7.9.3

Remove fan (sect. 7.6).

Remove condensing heat exchanger (sect.7.6.5).

7.9.4

7.9.5

Remove the flue hood (sect. 7.7).

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

7.9.6 Replace in reverse order.

Fig. 54

Fig. 55

33

7.10

7.10.1

TO REPLACE THE ELECTRODE(Fig. 66)

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

Fig. 56

Fig. 60

TAKE OFF

Fig. 62

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

7.13.1

7.13.2

7.13.4

7.13.5

Detach the wire from electrode and thenunscrew the nut that secures it to the pilotburner assembly and remove.

Replace with new electrode in reverse order.

TO REPLACETHE PILOT INJECTOR(Fig. 68)

Remove the front panel of the casing andthe combustion chamber front cover (sect.7.3 & 7.4).Remove the lower grating sect. 5.4.2 (Fig. 21).

Release the fitting that secures pilot pipe atthe gas valve.

Remove electrode (sect:7.10).

Unscrew pilot connection from pilot burner.

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

Replace in reverse order,

TO REPLACETHE PILOT BURNER

Remove the front panel of the casing andthe 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 pilotburner to main burner (Fig. 69).

Replace in reverse order.

35

7.14

7.14.1

7.14.2

7.14.3

7.14.4

7.14.5

7.14.6

7.14.7

Fig. 68

TO REMOVE/REPLACE THE MAIN Fig. 69INJECTORS

Remove the front panel of the casing andthe combustion chamber front cover (sect.7.3 & 4). Remove the pilot burner assemblyas described in sect. 7.13.

Unscrew the union (Fig. 70).

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

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

Unscrew and replace the injectors and theirseals (Fig. 73).

Replace in reverse order.

Relocate the grommet, sealing the gassupply pipe to the casing taking care not todamage it. Replace if necessary. Fig. 70

Fig. 71

36

7.15

7.15.1

TO REMOVE/REPLACE THE MAIN BURNER

Remove the front panel of the casing andthe combustion chamber front cover (sect.7.3 & 7.4).

7.15.2

7.15.4

7.15.5

Remove the pilot burner assembly asdescribed in sect. 7.13.

Remove the injectors mani fo ld asdescribed in sect. 7.14.

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

7.15.6 Pull the burner forward and remove( F i g . 7 5 ) .

7.15.7 Replace in reverse order.

IMPORTANT: When refitting the burnermake sure that the pins at the rear of thecombustion chamber locate into the slotsmade on the rear of the burner.

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

7.16.1

7.16.2

7.16.3

Remove front casing panel (sect. 7.3).

Push the 2 clips that fasten the instrumentpanel (Fig. 23).

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

7.16.4 Pull the 2 wires from the Modulator. Removethe electronic ignition board (7.32.2/3).

7.16.5

7.16.6

7.16.7

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 gaspipelines and then remove it from its seat.

7.16.6

7.19

7.19.1

7.19.2

7.19.3

Replace in reverse order, always using newseals.

TO REMOVE/REPLACE THE HEATINGCONTROL AND DOMESTIC HOT WATERCONTROL

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect. 7.16.2 & 3), and remove thecontrol box cover (7.31.2/3).

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

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

Fig. 75

37

7.19.6

7.20

7.20.1

7.20.2

7.20.3

7.20.4

7.21

7.21 .1

7.21.2

7.21.3

7.21.4

7.21.5

7.22

7.22.1

7.22.2

7.22.3

7.22.4

7.22.5

Replace in reverse order.

TO REMOVE/REPLACE THE MAINSWITCH (Fig. 82).

7.22.7

7.23

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect.-7.16.2 & 3), and remove thecontrol box cover (7.31.2/3).

7.23.1

7.23.2Pull off the switch knob. Remove the switchout from the instrument panel by pressingthe clamp springs (Fig. 82).

Detach the wires that connect to the switch- make sure that these wires are laterreconnected to the same poles (Fig. 94).

7.23.3

7.23.4Replace in reverse order.

TO REMOVE/REPLACE THE WATERPRESSURE GAUGE (Fig. 83).

7.23.5

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect. 7.16.2 & 3).Remove the lower grating (sect. 5.4.2).

7.23.6

7.24

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

7.24.1

Unscrew the fitting that secures thepressure gauge probe. 7.24.2

Remove the gauge from the instrumentpanel by pressing its fastening springs.

Replace in reverse order. 7.24.3

TO REMOVE/REPLACE THE OVERHEATTHERMOSTAT

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect. 7.16.2 & 3), and remove thecontrol box cover (7.31.2/3).

7.24.4

7.24.5

7.24.6Remove lower grill and right side of thecasing (sect. 5.4.2 & 5).

Unscrew the plastic cover and locknut thatfastens the overheat thermostat and remove it.

7.25Remove the three wires that connect to theoverheat thermostat - making sure thatthese wires will subsequently bereconnected to the same poles (Fig. 94).

7.25.1

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

Replace in reverse order.

TO REMOVE/REPLACE THE ELECTRICCONTROL BOARD (PCB)

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect. 1.16.2 & 3).

Unscrew the 2 screws holding the controlbox cover and remove.Disconnect mains cables and any otherconnections (room thermostat and frostthermostat if fitted).

Detach the connectors from the board.

Detach the PCB board from its base byunscrewing the six screws.

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

Having replaced PCB recommission boileron heating mode (sect. 6.15).

TO REMOVE/REPLACE THE DIFFEREN-TIAL PRESSURE SWITCH (Fig. 87).

Remove the front panel from the outercasing and the combustion chamber frontcover (sect. 7.3 & 4).

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

Unscrew the two screws that fasten thepressure switch to the back of combustionchamber.

Remove the two silicone tubes.

Ensure tubes are connected correctly (Fig.87) avoiding kinks.

Replace in reverse order ensuring that the- tapp ing i s connec ted to the tubeterminating inside the case and the +tapping is connected to the tubeterminating at flue ring (Fig. 87 and 94).

TO REMOVE/REPLACE THE PUMP(Fig. 88)

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (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).

38

7.25.3 Close the on/off valves on the heatingcircuit and drain at drain point water fromthe boiler (Fig. 93).

7.25.4 Remove the terminal covers and detach thesupply wires (Fig. 88).

7.25.5 Unscrew the two hexagonal nuts that fastenthe pump to its pipes and remove thepump.

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

7.25.6 Always use new seals when re-fitting thenew pump. .

7.25.7 Replace in reverse order

Fig. 78-

Fig. 79 7.26.7

Fig. 81

7.25.8

7.25.9

7.25.10

7.26

7.26.1

7.26.2

7.26.4

7.26.5

7.26.6

7.26.8

7.26.9

7.27

7.27.1

7.27.2

7.27.3

7.27.4

IMPORTANT:Make sure that the arrow that indicates thedirection of flow aims from the bottomupwards.

Replace wires and cover ensuring thatconnection wire br=L and bl=N.

Refill the heating system as described inthe sect. 6.4 & 5 and check for leaks.

TO REMOVE/REPLACE THE DIVERTERVALVE (Fig. 89)

Remove the front panel from the outercasing, lower the instrument panel (sect,7.16.2 & 3).Remove lower grating (sect. 5.4.2).

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

Unscrew the five nuts that connect thediverter valve and pull it out from boilerbeing careful not to damage the wires.

Pull off circlip securing microswitches todiverter valve.

If replacing microswitch assembly use ascrew-driver to prise off the protectivecover of the microswitches.

Detach the wires that are connected to this.Remember that they must subsequently bereconnected to the same terminals (Fig.94).

Replace in reverse order. Always use newseals.

Fill the boiler as described in (sect. 6.4 & 5)and check for leaks.

TO REMOVE/REPLACE THE CENTRALHEATING AND/OR HOT WATER CONTROLTHERMISTOR

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect. 7.16.2).

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

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

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

39

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

7.27.6 Replace in reverse order.

Fig. 82

Fig. 83

7.28

7.28.1

7.28.2

7.28.3

7.28.4

7.28.5

7.28.7

7.28.8

7.28.9

7.28.10

7.28.11

7.28.12

7.28.13

7.28.14

7.29

7.29.1

7.29.2

7.29.3

TO REMOVE/REPLACE THE CENTRALHEATING EXPANSION VESSELIn the unlikely event of failure of the centralheating expansion vessel i t i srecommended a suitable expansion vesselbe fitted external to the boiler. It should bepositioned on the return pipe and as closeto the boiler as possible (Fig. 7).However, if it is necessary to replace thecentral heating expansion vessel the boilermust be removed from the wall as follows,

Remove the front panel from the outercasing (sect. 7.3) and lower the instrumentpanel (sect. 7.16.2 & 3) and remove thecontrol 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 coldwater, central heating and gas supply.

Drain domestic water from the lowest hotwater tap and drain point on DHW inletcock (Fig. 46).

Drain the boiler (Fig. 93).

Disconnect all pipework connected toboiler.

Disconnect mains cables and any otherconnections (room thermostat, programmingclock).

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

Remove the 2 lower coach bolts andrelease 2 top coach bolts then removeboiler from the wall.

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

Remove the screw supporting expansionvessel (Fig. 91).

Remove the expansion vessel.

Replace all the components in reverseorder using new seals,

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

TO REMOVE/REPLACE THE AUTOMATICAIR VENT (Fig. 92)

Remove the front panel from the outercasing and the combustion chamber frontcover (sect. 7.3 & 4).

Remove the lower grating (sect, 5.4.2).

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

40

7.29.4

7.29.5

7.29.6

7.29.7

7.29.8

7.30

7.30.1

7.30.2

7.30.3

7.30.4

7.31

7.31 .1

7.31.2

7.31.3

7.31.4

7.31.5

Close the on/off valves for the centralheating circuit and drain the water from theboiler drain point (Fig. 93).

Unscrew and remove the plastic cap thatprotects the valve vent hole.

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

Replace in reverse order, using new seals.

Fi l l the system as ‘descr ibed in thesect. 6.4 & 5 and check for leaks.

TO REMOVE/REPLACE THE PRESSURERELIEF VALVE (Fig. 93)

Remove the front panel (sect. 7.3) and thelower grating (sect. 5.4.2) from the outercasing, lower the instrument panel (sect.7.16.2 & 3).Remove right side of the casing (sect.5.4.5).

Close the on/off valves for the heatingsystem and drain the water from the drainpoint (Fig. 93).

Unscrew the screw from its body, clean orreplace. Replace in reverse order.

Fi l l the system as descr ibed 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 outercasing (sect. 7.3) and lower the instrumentpanel (sect. 7.16.2 and 3).

Remove control box cover (Sect. 7.23.2).

Remove control board (Sect. 7.23.2) frompanel.

Remove two clips securing the timer.

Carefully remove the four wires connectingtimer by pulling spade connectors fromtimer.,

Fig. 88

7.31.6

7.32

7.32.1

7.32.2

7.32.3

7.32.4

7.32.5

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

TO REMOVE/REPLACE THE IGNITIONBOARD

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

Remove the screw from the ignition boxcover.

Detach the ignition box from its base on thegas valve.

Remove the PCB cover and detach theconnectors from the board.

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

TO REMOVE / REPLACE D.H.W. HEATEXCHANGER

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

Close the on/off valves for the heating circuitand the hot water circuit, Drain the boiler(Fig. 93) and drain hot water from the lowesthot water tap and drain point on DHW inletcock (Fig. 46).

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

If necessary the pipes from the divertervalve may have to be remove for easieraccess.

Replace in reverse order. Always use newseals.

Fill the boiler as described in (sect. 6.4 & 5)and check for leaks. Fig. 69

7.33

7.33.1

7.33.2

7.33.4

7.33.5

7.33.6

7.33.7

42

Section 8 FAULT FINDING CENTRAL HEATINGSwitch onSelect “Winter”Central HeatingStat to maximumEnsure external controls calling for heat (Room Stat/Time Clock/TRV)

FAULT FINDING DOMESTIC HOT WATERBefore continuing it may be necessary to see Central Heating Fault FindingSelect only (Summer) Domestic Hot Water.Open Domestic hot tap close to appliance.

45

SECTION 9 ELECTRICAL SYSTEM DIAGRAM Fig. 94

46

47

49

8.0 INSTALLATION INSTRUCTIONS FORTWIN FLUE PIPE (ECCENTRIC FLUEDUCT SYSTEM)

IMPORTANTThese instruct ions must be read inconjunction with the main installation andservicing instructions.

As with all flues the kits must be installedtaking due account of the current issue ofBS 5440 parts 1 & 2 and timber framehousing REF DM2.Also note that the requirements will varydepending upon the kit being installed.Guidance is provided but unless otherwisestated, always comply with therecommendations of the relevant codes ofpractice.

8.1 TWIN FLUE INSTRUCTIONS

This part of the installation manual coversthe installation and fixing instructions of thetwin flue eccentric flue duct systems only.When ordering twin flue it must be statedfor CSI range. Typical installationprocedures are illustrated by drawings.

IMPORTANTCorrect F1 orifice must be fitted.

10 - air intake bend 90o 13 - 45o flue exhaust bendIO - flue exhaust bend 90o 14 - flue exhaust duct11 - air inlet terminal 14 - air intake duct12 - flue exhaust terminal 15 - two-way flue gas header13 - 45o air intake bend 16 - vertical eccentric flue exhaust duct

Supplied with the CSI twin flue header is aF1 orifice plate along with supplementarydepression seal.Before fixing the twin flue system the existingorifice plate must be replaced with F1 alsoensuring supplementary seal has been fitted.

Remove the 13 screws securing thedepression front panel item 2 figure 53A toexpose front edge of depression chamber.(Twin flue instructions figure 1 adjacent).Using adhesive sponge supplied with CSItwin flue header, carefully attach todepression chamber so as to create asofter seal. Taking care not to damage thenew seal, carefully m-fit the depressionchamber front cover in reverse order.

Take out the 4 temporarily fitted securingscrews, lifting our the gasket and orificeplate disconnecting it from the venturi tube.Discard this orifice plate and re-fit the F1orifice plate ensuring that the venturi tubehas been re-fitted, making sure this issecurely located into the locating peg.

50

Locate the sealing washer fixing the twin flueheader as illustrated making sure that theinner aluminium exhaust locates firmly in theoutlet spigot. Make sure that the screws aresatisfactorily located through the gasket seal.

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

90” M/F bend consisting of.

90” elbow with ‘0’ ring side F80 mm dia ‘0’ ring

f l ue header .

Figures show the versatility of this flueingsystem. Measurements and bends must becalculated correctly so as not to oversizemaximum flue lengths.

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

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

Spacing ClipsSpacing clips are available on requestshould they be required.NOTE: for eccentric vertical flue a 125 mm(5 in) diameter flashing plate will berequired.

135” M/F bend consisting of.

135” elbow with ‘0’ ring side F80 mm dia ‘0’ ring

Vertical eccentric flue exhaust duct

E = EXHAUSTI = INLETT = TERMlNAL

Exhaust/suction system with concentric pipes for flator 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 onefitted.

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

NOTE:If bends are used in the exhaust flue then horizontalsections 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.

51

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

Maximum distance D = I + E + T = Total exhaust/inletpipe = 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 theboiler 35 mm fall per metre.

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

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

Maximum distance D = I + E = Totale exhaust/inletpipe 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 mustnever be installed on opposite walls of thebuilding (PrEN 483).

IMPORTANT NOTICE: If the flue terminatesless than 2 M. above a balcony, above theground, or above a flat roof to which peoplehave access, then a suitable terminal guardmust be fitted.Fit only recommended flue terminal guard bysecuring concentrically around terminal withscrews.

Available on request from:RAVENHEAT MANUFACTURING LTDChartists WayMorley, Leeds. West YorkshireENGLAND LS27 9ET - U.K.Tel. (0113) 252 007

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

52

RAVENHEAT CSI 85 - CSI 85T CONDENSING FANNED COMBI BOILER

SHORT LIST OF SPARE PARTS

Pos

1 0014FRO06005/02 0012COM06005/04 0012POT05010/05 0007TER03010/06 0001CAM06005/07 0001DIA06005/08 50270559 0007TER05005/010 0014VET01005/011 001 0TUB05040/013 0001CAP06005/015 5021103

16 0012CIR05005/217 0014MAN06015/018 0012GEN05005/018.1 0012GEN05010/021 500306622 0008VAL03005/022.1 0008VAL05005/024 0003BRU06015/025 501211425.1 0003PIL05010/026 0002SCA06010/027 0014RAC06005/028 0014REG01005/029 0010TUB06010/030 501501531 501802532 501803033 0012VEN03005/036 501804637 1015PAN06005/038 0010TUB06060/039 0012FUS05015/045 502302046 0014GUA01020/0

Ravenheat G.C.Part. No. Part. No.

E23-711E23-712E23-729

371267E23-732E23-730372842E23-715371268E23-716E23-733372845

E23-718E24-630

372849173100

372-866372894

E23-731E23-735371271

372888372851372867

173101378864E23-737E23-738E23-720

372855371277

Description

Instrument panel - TIMER MODELMain switch

D.H.W. / C.H. PotentiometerOverheat thermostatCombustion chamberFlue restriction ring 79CSI (F2)

Water gaugeD.H.W. / C.H. SensorSight glassDepression chamber gas pipeFlue gas exhaust hood

Fuse 315 mAPrinted control boardKnobPrinted ignition board

Honeywell printed ignition boardCombustion chamber coverGas valveHoneywell gas valveMain burnerPilot burner

Pilot burner for Honeywell gas valveHeat exchangerCondensing trapWater flow regulatorConnecting pipe to air purgeAir purge valveGasket 18.5 x 11.6 x 2

Gasket 24 x15 x 2Fan

Gasket 30 x 22 x 2Insulation pads setPipe to air purgeInternal fuse 2A

Depression chamber pilot sealFlue gasket

54

Pos.

47

4848.1

5051616262.164

65676868.16970798081828385878993

9597100105106110111

112

113114

115116117118

0205

Ravenheat G.C.Part. No. Part. No.

0001CAM06010/0

50120960003UGE01605/050210500012CAV06005/00002SCA06005/00003UGE03005/00003UGE01011/0

0001TEL06005/050180460010TUB06020/00003BRU06015/00003BRU06002/00002VAL06005/00013GUA03035/00005PRE03010/05009080

0013GUA01045/0500328350150100012FUS05020/05021312

0005PRE05015/00019CUR06005/00019PR006005/00019TER06005/00004VASO6010/0TM61920019TER06010100001MAN05005/00011RIV06006/00011RIV06005/0

0012CAV06015/00014GUA06010/0

0014GUA06005/00014GUA06015/00019SD006005/0

0002SCA06015/050120515012052

372856E02-129

372892E23-739E23-740371297E23-755

372864E23-742

372-895371273

371310372896371274372874

372897E23-724

372875E24-629

E23-750E23-751E23-752

Description

Depression chamberNozzle 0,27 for natural gasNozzle DM 0.22x1 LPGIgnition electrodeCable for electrodeCondensing heat exchangerNozzle 1,25 for natural gasNozzle DM 0.75 LPG.

FrameSealConnecting pipe D.H.W. outletMain burner natural gasMain burner LPG3-way valveGasket 32 x 32 x 2 gas valveLow water pressure switchCirculation pump

Gasket 48 x 42 x 1Brass manifold

Safety relief valve (3 bar)Internal fuse 4A

Nylon tubes from pressure switchPressure switch

Elbow headerFlue extension duct completeFlue duct and terminal completeExpansion tankDigital TimerVertical Flue Terminal CompleteBottom panelEarth electrode

Condensate blockageEarth wireFlue gasket dm 100

Flue gasket dm 60Flue gasket dm 80Twin header

Heat exchanger for D.H.W. waterDiaphragm for 3-way valveMicroswitch for 3-way valve

371258E23-752E23-754

3 7 1 2 5 73 7 2 8 9 9

55

Chartists Way, Morley, Leeds, LS27 9ET.

Telephone: (0113) 252 7007

Tfax: (0113) 238 0229