Ravenheat CSI 85 User guide

ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER
CONDENSING FANNED COMBI
CSI 85 - CSI 85T
WITHOUT TIMER
NATURAL GAS (G 20) (I 2H ) G.C. N
0
47 581 19
LPG (G 30 - G 31) (I 3+ ) G.C. N
0
47 581 23
British Gas
Tested, certified and
service listed
Listed by The United Kingdom Water
Fitting Byelaws Scheme
WITH TIMER
NATURAL GAS (G 20) (I 2H ) G.C. N
0
47 581 20
LPG (G 30 - G 31) (I 3+ ) G.C. N
0
47 581 24
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE LEFT WITH USER
Technical and illustrative data are not binding and can be modified without prior notice.
The descriptions and illustrations in the present booklet are for guideline purposes only.
RAVENHEAT MANUFACTURING LTD., CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET. -TELEPHONE [phone]

CONDENSING SYSTEM INNOVATION AUTOMATIC MODULATING BOILER
FOR CENTRAL HEATING AND DOMESTIC HOT WATER
This new super high efficient turbo-modulating boiler is designed to meet domestic hot water and
central heating requirements at super high efficiency, unheard of only a few years ago.
POSITION
The appliance is extremely versatile as it can be fitted in almost any room. The appliance is room sealed,
there is no contact between combustion chamber and living accommodation. This guarantees maximum
safety and efficiency.. Indeed, our depression/combustion front cover has been designed to fit, achieving
maximum air tight seal using screw down fasteners at 15 cm. This should not hinder service of the appliance,
but does ensure maximum efficiency and safety - something which Ravenheat take great pride in.
Each boiler has been designed and manufactured in our modern plant to exacting IS0 9001 discipline,
all boilers carry full CE marking of approval. Technical sales and commercial service are available
throughout the UK. This product is guaranteed by Ravenheat Manufacturing, Chartists Way, Morley,
LEEDS, LS27 9ET. Telephone No [phone].
BASIC COMPONENTS - (See figure 1)
Guarantee is a full 12 months from date of purchase providing the appliance has been fitted in
accordance with these instructions and relevant codes of practice.
MAJOR COMPONENTS
Gas valve with flame modulator.
Variable head pump suitable for any type of central heating system.
Main burner with flame stabiliser designed to operate under all thermal conditions.
Primary heat exchanger constructed from copper.
Unique patented condensing heat exchanger for high thermal flue transfer gases to water.
Stainless steel plate heat exchanger for super high heat transfer to domestic hot water,
Highly reliable diverter valve with ethylene propylene diaphragm permitting primary flow
circulation 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 easy
to clean panels.
NOTE: Due to the high efficiency of this boiler a plume of water vapour will form at the flue
terminal during operation.
COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH
IMPORTANT
This appliance contains materials that are indicated below.
It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn
when handling, where applicable, the pertinent parts that contain any materials that could be interpreted
as being injurious to health and safety.
WARNING When installing the appliance, care should be taken to avoid any possibility of injury when
handling sheet metal parts.
GENERAL INFORMATION:
GLUES AND SEALANTS - exercise caution - if these are still in liquid form.
INSULATION PADS, CERAMIC FIBRE - may be harmful if inhaled, may be irritating to skin, eyes, nose
and throat.
When handling keep dust generation to a minimum, avoid inhaling and contact with skin or eyes,
When disposing of the product keep dust generation to a minimum and ensure that parts are securely
wrapped.
When servicing avoid inhalation by using a vacuum cleaner or in conjunction with other tools.
After handling wash hands and other exposed parts.
RAVENHEAT use only high quality material for production of this product, in an effort to protect the
environment components should be re-cycled.
3

SECTIONS:
1
2
3
4
5
6
7
8
9
10
11
TABLE OF CONTENTS
INTRODUCTION
DESIGN PRINCIPLES AND
OPERATING SEQUENCE
TECHNICAL DATA
GENERAL REQUIREMENTS
INSTALLATION
COMMISSIONING
SERVICING INSTRUCTIONS
FAULT FINDING
ELECTRICAL SYSTEM DIAGRAM
EXPLODED PARTS DIAGRAM
LIST OF SPARE PARTS
PAGE:
6
6
8-9-10
11
16
25
30
43
45
47
48
GENERAL LAYOUT
Fig.1
KEY
1 - Heat exchanger
2 - Heat exchanger for D.H.W. water
3 - Burner
4 - Ignition pilot burner
6 - Condensing heat exchanger
7 - Ignition board
9 - ignition electrode
11 - Frame
12 - Modulating gas valve
15 - Heating control
16 - Hot water control
17 - D.H.W. sensor
18 - Water pressure switch (heating circuit)
22 - Overheat cut of thermostat
23 - Safety relief system
24 - Three way valve
26 - Auto air vent valve
28 - Pressure switch
29 - Circulation
pump
30 - Water pressure gauge
33 - Main Switch
34 - C.H. sensor
35 - Condensing trap
36 - Fan
37 - Expansion tank
38 - Sealed chamber
45 - Combustion chamber
50 - Flue gas exhaust hood
105 - Timer
106 - Flue restriction ring

KEY
1 - Heat exchanger
2 - Heat exchanger for D.H.W. water
3 - Burner
4 - Ignition pilot burner
5 - Flue restriction ring
6 - Condensing heat exchanger
7 - Electronic ignition
8 - Condensing Trap
9 - Ignition electrode
10 - Condensate sensor
12 - Modulating gas valve 26 Auto air vent valve
15 - Heating control potentiometer
16 - Hot water control potentiometer
27 Pressure switch giving priority
28 - Pressure switch
17 - Water pressure switch
18 - Overheat cut-off thermostat
29 - Circulating pump
20 - Gas service cock
30 - Water pressure gauge
36 - Fan
21 - Compression ball valves
23 - Safety relief system
24 - Three way valve
25 - Flow regulator
37 - Expansion tank
38 - Sealed chamber

SECTION 1 INTRODUCTION
2.2.6 Central heating mode
1.1 The Ravenheat boiler is for the use of 2.2.7 If the switch is positioned on with a
central and domestic hot water combined in
‘demand for heat to supply radiators, etc., with
one unit. heating circuit fully charged so as to operate
It is fitted with an automatic domestic hot the low water sensor device the boiler will
water priority valve. start in the same way as domestic hot water
A (winter/summer) selector mode but with slightly differing time delay in
switch is fitted to the left hand side of control
that it will start on minimum and remain at this
panel. With the only (summer) position
level for about 1 minute, after which the flame
being for domestic hot water. will lift to its maximum setting as governed by
position being for central heating
a potentiometer range rates the heating circuit
with domestic hot water priority. The boiler
between maximum and minimum power.
is equipped with a front cover which can be
removed for servicing. The data badge with 2.2.6 On the control panel are mounted two
technical data is placed on the lower right
hand side of the frame.
potentiometers (thermostats) these control
the temperature. One is for domestic hot
water and the other for heating.
1.2 Fig. 1 Illustrates the general layout of
components. 2.2.9 The boiler is fitted with an anti-cycling
Fig. 2 Illustrates the operating principles device on the control board. This delays the
described in section 2. boiler from re-firing over a 2.5 minute period
when in heating mode. The domestic hot
SECTION 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 Mode
When the appliance is in rest mode with the
mains neon and switch on. Switch the summer/
2.3.1
A potentiometer installed on the electric
winter switch tap position, with the heating circuit board permits regulation of the boiler
circuit charged with water (above 1 bar). If the
to partial heating requirements, between
domestic 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 the
The fan operates via the pressure switch flue to the outside, this creates a lesser
and sends a signal back to the ignition board pressure in the sealed combustion
that 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 automatically
operate and light the burner.
controlled by a built in thermostat.
At this point the ignition board opens the first
step of the gas valve to light the pilot/burner. 2.3.5 Interior space temperature is set by the
2.2.3
room thermostat to be installed in the
When the electrode/sensor senses the heating system. The boiler already carries
signal of the pilot/burner, it opens the second connection terminals for this thermostat, as
stage of the gas valve via the ignition board well as for a timeclock. The burner
on minimum power. Upon the second valve continues to operate until it is stopped by
opening 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 sensor
increases to the maximum permissible intervenes the main burner shuts down. The
pressure over a period of 3 to 4 seconds and
fan stops but the pump continues to operate.
will remain at its maximum required power
until its maximum regulated temperature.
2.3.7 When the room thermostats intervene the
main burner shuts down. The fan stops and
2.2.5 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 a
pilot/burner. The pump and fan are also blockage safety sensor. This prevents the
switched off, the pressure switch returning boiler operating should there be a blockage
to 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 is
built 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 two
fluids move in a counter direction flow to
each other.
Switch 33 in the (winter) position,
When a hot water tap is turned on a di-
aphragm diverter valve excludes the central
heating circuit, the boiler automatically mod-
ulates to maintain the domestic hot water at
a constant temperature.
Water temperature can be regulated using
the D.H.W. thermostat located on the front
control panel.
When domestic hot water is being drawn the
main burner and pump perform as they do
during central heating except that the burner
is commanded by the D.H.W. thermostat.
2.4.5
3.1
OVERALL DIMENSION
3.1.2
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. The
boiler functions like an automatic gas hot
water 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 until
the room thermostat/time clock demands for
central heating circuit.
SAFETY DEVICE
In both central heating and domestic hot
water mode safe operating is ensured by:
- A differential pressure switch shuts off the
main burner if the fan stops or the flue or
combustion air intake duct is obstructed.
An overheat cut off thermostat set slightly
higher than the high limit thermostat acts to
turn off the burner to resetable “lockout”
(Fig. 50) 3.
3.1.3 A safety valve is fitted on
the central heating circuit
set at 43 psi (3 bar).
3.2.1 A heating circuit (low water)
pressure switch is set at 0.4
bar.

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 m
3
S/h (88.25 ft
3
/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 1.25
PILOT BURNER INJECTOR 0.27 x 2 HOLES
ELECTRICAL SUPPLY 230V-50HZ
POWER CONSUMPTION 160W
EXTERNAL FUSE RATING
3A
INTERNAL FUSE 315mA-2A-4A (20 mm to BS 4265)
DRY WEIGHT 51 kg
WATER CONTENT C.H.
2.1 litre
WATER CONTENT 0.5 litre
GAS SUPPLY CONNECTION
112" RC
FLOW CONNECTION C.H. 22 mm compression isolating valve
RETURN CONNECTION C.H. 22 mm compression isolating valve
INLET CONNECTION D.H.W. 15 mm compression isolating valve
OUTLET CONNECTION D.H.W. 15 mm copper pipe
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION 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 oC
MIN 45oC
DESIGN FLOW RATE 1073 I/h (236 gals/h) 20 oC RISE
MINIMUM 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
o
C 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 - C 12 - C 32 - C 52
Nox 2
CATEGORY I2H
8

SECTION 3 TECHNICAL DATA
TABLE 1/A
LPG (G 30 - G 31) I 3+
NOMINAL HEAT INPUT NET
MINIMUM HEAT INPUT NET
NOMINAL HEAT OUTPUT
NOMINAL HEAT OUTPUT CONDENSING
24.8 kW
13.0 kW
24.1 kW
25.6 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/h
MINIMUM HEAT OUTPUT CONDENSING 13.4 kW (45,700 Btu/h)
GAS RATE max G 31 0.95 m
3
S/h (33.53 ft/
3
h) 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 0.75
PILOT INJECTOR
0.22 x 1 HOLE
ELECTRICAL SUPPLY 230V-50HZ
POWER CONSUMPTION
16OW
EXTERNAL FUSE RATING
3A
INTERNAL FUSE 315mA-2A-4A
DRY WEIGHT 51 kg
(20 mm to BS 4265)
WATER CONTENT C.H. 2.1 litre
WATER CONTENT 0.5 litre
GAS SUPPLY CONNECTION
FLOW CONNECTION C.H.
RETURN CONNECTION C.H.
INLET CONNECTION D.H.W.
OUTLET CONNECTION D.H.W.
112” RC
22 mm compression isolating valve
22 mm compression isolating valve
15 mm compression isolating valve
15 mm copper pipe
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION DRAIN 3/4" (21.5 mm) push fit over flow
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 litres
SEALED WATER SYSTEM C.H.
MAX PRESSURE PMS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
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 RISE
MINIMUM 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
o
C rise
9.9 I/min (2.2 gals/min)
D.H.W. FLOW RATE 40
o
C rise
8.7 I/min (1.9 gals/min) 10 oC inlet temperature
D.H.W. TEMPERATURE max 65 oC
min 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 - C 12 - C 32 - C 52
CATEGORY I3+ NOX 2
9

SECTION 4 GENERAL REQUIREMENTS
4.0
SAFETY
Gas Safety (Installation and Use).
Regulations, 1994 and amended 2000.
It is law that all gas appliances are installed
and serviced by a CORGI registered in-
staller in accordance with the above regula-
tions and these installation instructions. All
CORGI registered installers carry a CORGI
I.D. card and have a registration number.
Both should be recorded in your boiler log
book. You can check your installer by calling
CORGI direct on: 01256 732300. Failure to
install appliances correctly could lead to
prosecution. It is in your own interest, and
that of safety, to ensure the law is complied
with. Check the boiler and flue is the correct
type 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 Building
Standards (Scotland) and any relevant re-
quirements of the local authority.
4.1
GENERAL INFORMATION
Both the user and the manufacturer rely heavi-
ly on the installer, whose job it is to install the
combination boiler and connect it to a correctly
designed heating system. Acquaint yourself
with the British Standards concerning installa-
tion requirements. If you need advice on any
points 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 hexagon
sizes up to 50 mms.
CODES OF PRACTICE/Ref: Documents
Detailed recommendations are contained in
the following British Standard Codes of
Practice:
BS. 6891
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 water
systems.
BS. 5546 Installation of gas hot water
supplies domestic purposes
(2nd Family Gases).
BS. 544O:1 Flues (for gas appliances of rated
input not exceeding 60 kW).
BS. 5440:2 Ventilation (for gas appliances of
rated input not exceeding 60 kW).
DD 189:1990 Discharge of condensate
Health & Safety Document No. 635
The Electricity at Work Regulations, 1989.
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 control
devices e.g. flue dampers, economisers
etc., are directly connected to this appliance
unless covered by these Installation and
Service Instructions or as otherwise recom-
mended by Ravenheat in writing. If in doubt
please enquire.
Any direct connection of a control device not
approved by Ravenheat could invalidate the
certification and the normal appliance war-
ranty. It could also infringe the Gas Safety
regulations and the above regulations.
NOTE: The Ravenheat CSI combination
boiler has been tested and examined by BG,
and is certified to comply with PrEN 483 and
BS EN 625.
Manufacturers instructions must NOT be
taken in any way as overriding statutory
obligations.
If in doubt on any point please consult
Ravenheat Manufacturing Ltd.
4.2 LOCATION OF BOILER
4.2.1
Siting of Ravenheat CSI 85 Combi Boiler
must be as follows. The position of installa-
tion should be within the building, unless
otherwise protected by suitable enclosure.
Adequate space for installation, servicing
and air circulation around boiler must be al-
lowed for.
The Ravenheat CSI 85 Combi Boiler must
be fitted on a flat and vertical wall capable of
adequately 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 of
the Local Authority and Building Regula-
tions.
LPG versions of this appliance shall not
be 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 boiler
18 inches (450 mm) in front
5 inches (125 mm) above
6 inches (150 mm) below
0.2 inches (5 mm) on each side
1 inch (25 mm) in front when installed in a
cupboard.
10

4.4
4.4.1
IMPORTANT NOTICE
4.5
4.5.1
If the combination boiler is to be fitted in a
timber framed building it should be fitted in
accordance with the British Gas Publication
Guide for Gas Installations in Timber Frame
Housing Reference DMZ. If in doubt advice
must be sought from the local gas supplier.
The combination boiler may be installed in
any room or internal space, although partic-
ular attention is drawn to the requirements
of the current I.E.E. Wiring Regulations, and
in Scotland the electrical provisions of the
Building Regulations applicable in Scotland,
with respect to the installation of the combi-
nation boiler in a room or internal space
containing a bath or shower,
Where a room sealed appliance is installed
in a room containing a bath or shower, any
electrical switch or appliance control, utilis-
ing mains electricity should be so situated
that it cannot be touched by a person using
a bath or shower.
A compartment used to enclose the combi-
nation boiler MUST be designed and con-
structed specifically for this purpose. An
existing cupboard, or compartment, may be
used provided it is modified accordingly.
Samples of the CSI combination boiler have
been examined by B.G. Technology Notified
Body, and is certified to comply with the
essential requirements of the Gas Appliance
Directive 90/396/EEC, the Low Voltage
Directive 72/23/EEC and shows compliance
with the Electro Magnetic Compatibility
Directive 89/336/EEC and are therefore per-
mitted to carry the CE Mark.
The appliance has been tested and
approved by the WRc as meeting the
requirements of G3 and L of the Building
regulations and water Bylaws Scheme -
Approved Products,
GAS SUPPLY
A gas meter is connected to the service pipe
by the Local Gas Region or the Local Gas
Region contractor. An existing meter should
be checked preferably by the Gas Region to
ensure that the meter is adequate to deal
with the rate of gas supply required for all
appliances it serves. Installation pipes
should be fitted in accordance with BS
6891. Pipework from the meter to the boiler
must be of adequate size (22 mm) min. To
within at least 3 metre of the boiler (15 mm)
min. can then be used for remaining pipe
work to the appliance. A smaller size than
the boiler inlet gas connection should not be
used. The complete installation must be
tested for soundness as described in the
above Code.
N.B. if the gas supply for the boiler serves
other appliances ensure an adequate sup-
ply is available both to the boiler and the
other appliances when they are in use at the
same time.
4.6 FLUE SYSTEM
4.6.1
The terminal should be located where dis-
persal of combustion products is not imped-
ed and with due regard for the damage or
discolouration that might occur to building
products in the vicinity (see fig. 6).
The terminal must not be located in a place
where it is likely to cause a nuisance.
In cold and/or humid weather water vapour
may condense on leaving the flue terminal.
The effect of such steaming must be consid-
ered.
The terminal must not be closer than 25
mm. (1 in) to any combustible material. For
protection of combustibles, refer to BS
5440.1.
Where a flue terminal is installed less than
1000 mm. from a plastic, or painted gutter;
or 500 mm from painted eaves. an alumini-
um shield 1000 mm. long, should be fitted to
the underside of the gutter or painted sur-
face.
Pluming will occur at the terminal so, where
possible, terminal positions which could
cause a nuisance should be avoided.
The flue must be installed in accordance with
the recommendations of BS 5440: Part 1.
Flue must be positioned in a place not like-
ly to cause a nuisance.
IMPORTANT: The following notes are
intended 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 at
all 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 less
than 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 pipes
C - Below eaves
D - Below balconies or car port roof
E - From vertical drain pipes and soil pipes
F - From internal or external corners
mm
300
25 4.8
25
25
25
25
4.8.1
G - Above ground or below balcony level 300
H - From a surface facing a terminal 600
I From a terminal facing a terminal
1200 4.82
J - From an opening in the car port (e.g. door
window) into dwelling. 1200
K - Vertically from a terminal on the same wall 1500
L Horizontally from a terminal on the same wall 300
NOTE: The flue must be terminated in a place not
likely to cause a nuisance.
4.6.2 A concentric vertical flue kit is available, for
flueing applications up to a maximum height
of 4.0 metres.
For further details see vertical flue installa-
tion instructions.
4.7
4.7.1
AIR SUPPLY
The following notes are intended for general 4.8.3
guidance.
The room sealed fan flued boiler does not
require a permanent air vent for combustion
air supply.
Where installed in a cupboard or compart-
ment ventilation is not required.
CONDENSATE DRAIN
Acondensate drain is provided on the boiler.
This drain must be connected to a drainage
point. 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 standard
3/4" (21.5 mm) push fit overflow pipe.
NOTE: Condensate drain pipework must
never be less than 15 mm.
Important: any external runs must be 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 BS
6798 5449.1.1977 (for smallbore and micro-
bore central heating systems). The following
notes are given for general guidance.
Pipework
Copper tubing to BS 2671 1.1.1971 is rec-
ommended for water pipes. Jointing should
be either with capillary soldered or with
compression fittings.
Where possible pipes should have a gradi-
ent to ensure air is carried naturally to air
release points and water flows naturally to
drain taps. It should be ensured as far as
possible that the appliance heat exchanger
is not a natural collecting point for air.
Except where providing useful heat, pipes
should be insulated to prevent heat loss and
to avoid freezing. Particular attention should
be paid to pipes passing through ventilated
spaces in roofs and under floors.
The water through the appliance heat
exchanger circuit must exceed the min. 1.84
gals/min. (503 It/h) when the burner is firing. It
is important to ensure that this rate is achieved
when sections of the system are shut off either
manually or by automatic controls. Therefore
a by-pass must be fitted to the system (15
mm min.) (Fig. 6A).
If the volume of circulating water is too low,
the boiler water temperature will rise too
rapidly. This could cause noise in the system
or even cause the safety thermostat to trip.
12

4.8.4
4.8.5
4.6.6
Draining tap
These 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 accordance
with ES 2870 1980.
Air release points
These must be fitted at all high points where
air will naturally collect, and must be sited to
facilitate complete fitting of the system.
The appliance has an integral sealed expan-
sion vessel to accomodate the increase of
water volume when the system is heated. It
can accept up to 1.5 gal (7 Its) of expansion
water. If the appliance is 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 no
problem.
4.6.7
4.8.8
Mains water feed: central heating
There must be no direct connection to the
mains water supply, even through a non-
return valve, without the approval of the
Local Water Authority.
Permissible methods of filling
Cistern method (Fig. 8).
The system may be filled by one of the fol-
lowing methods. Through a cistern used for
no other purpose, via a ballvalve perma-
nently connected directly to a service pipe
and/or cold water distributing pipe. The stat-
ic head available from the cistern should be
adequate to provide the initial system
design pressure.
The cold feed pipe from the cistern should
include a non-return valve, and a stop-valve
with an automatic air vent connected be-
tween them, with the stop valve being locat-
ed, between the cistern and the automatic
air vent. The stop valve may remain open
during normal operation of the system, if
automatic water make-up is required.
Booster pump method (Fig. 8).
The system may be filled through a self con-
tained unit comprising of a cistern pressure
booster pump if required and if necessary
an automatic pressure reducing valve or
flow restrictor. The cistern should be sup-
plied through a temporary connection from a
service pipe or cold water distributing pipe.
The unit may remain permanently connect-
ed to the heating system to provide limited
automatic water make up.
Mains topping up method (Fig. 9).
Here the temporary connection is supplied
from a service pipe, or distributing pipe,
which also supplies other draw-off points at
a lower level.
Fig. 9
MAINS WATER
SUPPLY
(SERVICE PIPE)
A combined double check valve shall be
installed upstream of the draw-off point,
through a temporary hose connection from
a tap supplied from the mains, where the
mains pressure is excessive a pressure
reducing valve shall be used to make filling
easier. The following fittings shall form a per-
manent part of the system and shall be fitted
in the order stated.
a) A stop valve complying with the require-
ments of BS 1010 Part 2 (the temporary
hose from the draw off tap shall be con-
nected to this fitting).
b) A test clock.
c) Double check valve of an accepted type.
d) A non return valve of an accepted type.
We recommend use of a Ravenheat
Filling Loop designed for this method of
filling the system. Available from your
supplier.
PROVISIONS FOR MAKE UP WATER
(Fig. 7)
Provision can be made for replacing water
loss from the system either.
A) from a manually filled made up bottle with
a readily visible water level. The bottle
should be mounted at least 150 mm (6 in)
above the highest point of the system and
be connected through a non return valve to
the return side of the heating system.

SIZING OF ADDITIONAL EXPANSION VESSELS: TABLE 3
Deduct from the value given in the table the 7 litre vessel supplied.
Safety
valve setting (bar)
3.0
Vessel charge
pressure (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 water
content Of system EXPANSION VESSEL VOLUME (LITRES)
Litres
25 2.1
3.5 6.5 13.7 2.7
4.7 10.3 3.9 6.3
50 4.2 7.0 12.9 27.5 5.4
9.5 20.6 7.6 16.5
75 6.3 10.5 19.4
41.3 6.2
14.2 30.9 11.7 24.6
19.0 41.2
100 6.3 14.0
25.9 55.1 10.9 15.6
33.1
125 10.4 17.5 32.4
66.9 13.6
23.7 51.5 19.5 41.3
150 12.5
21.0 36.6 62.6 16.3
26.5 61.6 23.4 49.6
175 14.6
24.5 45.3 96.4 19.1
33.2 72.1 27.3 57.9
200 16.7
26.0 51.6 110.2 21.6
36.0 62.4 31.2 66.2
225 16.7 31.5
56.3 124.0 24.5
42.7 92.7 35.1 74.5
250
20.6 35.0 64.7
137.7 27.2
47.5 103.0 39.0 62.7
275 22.9 36.5 71.2
151.5 30.0
52.2 113.3 42.9 91.0
300 26.0 42.0
77.7 165.3 32.7
57.0 123.6 46.6 99.3
325
27.0 45.5
64.1 179.1 35.7
61.7 133.9 50.7 107.6
350
29.1
49.0 90.6 192.6 36.1
66.5 144.2 54.6 115.6
375 31.2
52.5 97.1 206.6 40.9
71.2 154.5 56.5 124.1
400 33.3
56.0 103.6 220.4 43.6
76.0 164.6 62.4 132.4
425
35.4
59.5 110.1 239.2 46.3
80.7 175.1 66.3 140.7
450
37.5 63.0
116.5 247.9 49.0
65.5 165.4 70.2 146.9
475 39.6
66.5 123.0 261.7 51.6
90.2 195.7 74.1 157.2
500
41.6 70.0
125.9 275.5 54.5
95.0 206.0 76.0 165.5
For system volumes
other than those given
above, multiply the 0.0633 0.140 0.259
0.551 0.109
0.190 0.412 0.156 0.331
system volume by
the factor across
Note: This pressure can be increased up to 1.5 bar to suit high static head situations, see item 10, other appliance components in the
SERVICING INSTRUCTIONS.
B) Where fitting a make up vessel would be
difficult re pressurisation of the system can
be done. See section on FILLING.
If the capacity of the central heating system
should exceed 110 litres, an additional ves-
sel should be installed on the return to the
combination boiler from the heating system
(Fig. 7). Guidance on vessel sizing is given
in (Table 3).
Reference should be made to British Gas
Publications <<Material and Installation
Specifications for Domestic Central Heating
and Hot Water>>,. Draining taps should be at
least 1/2" in BSP nominal size and be in
accordance with BS 2879.
It is most important that the correct concen-
tration of the water treatment product is
maintained in accordance with the manufac-
turers’ instructions.
If the boiler is installed in an existing system
any unsuitable additives MUST be removed
by thorough cleansing.
BS 7593:1992 details the steps necessary
to clean domestic central heating system.
Also check pipework and renew any corrod-
ed pipework or fittings. Valve glands must be
repacked or replaced wherever necessary
and any defective controls exchanged.
WATER TREATMENT
This 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 the
existing system is of the open water type it
will have to be modified to comply with BS
5376 Part
2.
Before installing a new combination boiler to
an existing system, flush out the old system
with a recommended descaling agent.
alloy heat exchanger Ravenheat recom-
mended only the use of FERNOX-COPAL or
SENTINEL Xl00 water treatment products,
which must be used in accordance with the
manufacturers instructions. For further infor-
mation contact:
Fernox Manufacturing
Co. Ltd.
Tel. [phone]
Sentinel Division Betz Dearborn Ltd.
Tel. [phone]
14

SALAMANDER CURROSION GUARD Fig. 10
Salamander (Eng) Ltd
Tel: [phone]
4.8.10 Hard water areas
If the area of-installation is recognized as
hard water, it is recommended that a suit-
able water treatment device is installed in
the mains.
The water hardness can be determined by
using the standard test paper or by referring
to 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 of
BS 5546. Copper tubing to BS 2871. 1 is
recommended for water carrying pipework
and MUST be used for pipework carrying
potable water.
ELECTRICAL SUPPLY
Warning: this appliance must be earthed
External wiring to the appliance must be
carried out by a competent person and be in
accordance with the current I.E.E. 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 the
electricity supply MUST facilitate complete
electrical isolation of the appliance, by the
use of a fused, double pole isolator, having a
contact separation of at least 3 mm in all
poles. The point of connection to the elec-
tricity supply must be readily accessible and
adjacent to the appliance except, where the
appliance is installed in a bathroom, this
MUST be sited outside the bathroom.
SECTION 5 INSTALLATION
5.1 WARNING
5.1 .1
It is MOST IMPORTANT that this appliance
is installed in a VERTICAL POSITION, with
the flue air duct passing through the wall.
Make sure flue slopes 2.5odown towards
the boiler that is 45 mm/m fall per metre
of flue length.
Fig. 11
15

5.2
DELIVERY WARNING:
5.2.1
The appliance will arrive on site in two
cartons
Box 1 of 2 containing (Fig. 11):
a) boiler fully assembled
b) installation instructions and
user instructions
c) white paper template
d) terminal cover plate (Fig. 12)
e) - 4 coach bolts and wall plugs
- screws and dowels
Polythene bag containing:
a) 2-22 mm compression ball valves
(heating)
b) 1-15 mm compression ball valve
(with drain screw for domestic cold
water 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 cock
d) - 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 kit
56 - Flue gas sample point
57 - Flue bend assembly
59 - Rubber seal 0 60
60 - Air intake duct
61 - Flue exhaust duct
62 -Terminal
65 - Pipe centering spring
66 - Flue gas sample point
127 -Terminal rubber
(Contained in the carton Fig. 10)
Fig. 12
OPTIONAL EXTRAS:
Small carton containing: (Fig. 13)
57 - Straight header supplied as an extra cost only
when requested
59 - Rubber seal 0 60
66 - Flue gas sample point
63 - Air intake duct extension
64 - Flue exhaust duct extension
65 - Pipe centering spring
FLUE EXTENSION BOX CONTAINING (Fig. 14)
1000 mm flue extension duct as an extra cost Only
when requested for side and vertical flue applications
59 - Rubber seal 0 60
16

5.3
Fig. 15
1) Open the top
of the carton
Fig. 16
2) Rest the carton on
the floor (keeping the flaps open)
Fig. 18
4) Rest the boiler on the floor and remove
the polystyrene guards
Fig. 19
17

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 the
upper part of the front panel of the
casing (Fig. 19).
- Carefully slide the front panel a few
millimetres up towards the top of the
appliance-until it is free from its slot, and
then lift off (Fig. 20).
Unscrew the 2 screws that fasten the lower
grating on the casing and remove it from the
sides of the casing (Fig. 22).
Fig. 23
Push down the 2 plastic clips that fasten the
instrument panel (Fig. 23).
Lower the instrument panel down by
rotating it on its own hinges (Fig. 25).
Unscrew the two screws fastening panels
(Fig. 21).
Remove the two sides of the casing by slightly
lifting them and carefully sliding towards the
top of the appliance, to release them from
their upper suspension hooks (Fig. 26-27).
Fig. 25
Make sure the casing and screws are put to
one side in a safe place.
INSTALLING THE APPLIANCE FOR
REAR FLUE OUTLET
Fig. 26
Use adhesive tape to attach the template to
the wall, making sure that the centre line is
vertical.
- Mark the four boiler fastening holes on the
wall as well as the centre of the flue duct.
- Detach the template from the wall.
- Use a 10 mm. dia drill to make the 4
boiler securing holes. Insert the plastic
expansion plugs.
- Cut or cork drill a 105 mm. dia hole for
inserting the flue duct.
- Screw in the two upper coach bolts leaving
them about 10 mm. out from the wall to
enable the boiler to be located on the wall.
Fit the elbow header positioning it towards
the required direction (Fig. 30).
IMPORTANT: Make sure that the elbow’s
dia. 60 mm duct is inserted into the fan, the
rubber seal and orifice (F2) have been
correctly fitted.
Fig. 21
18

5.5.2 Locate the rubber 0 60 into the flue elbow
header (Fig. 30).
5.5.3 If the standard duct furnished with the boiler
is too long (the wall to go through is less
than 680 mm. thick) it can be shortened as
follows:
- Remove the centering spring 65, the flue
terminal to disengage inner flue duct.
- Measure the thickness W of the wall.
- Cut the outer flue duct at right angles to a
length equal to W + 152 mm.
Must be de-burred.
- Cut the inner flue duct (60 mm) at right
angles to a length equal to W + 264 mm.
Insert from cut end. Reassemble the two
tubes. Insert centering spring 65.
Must be de-burred.
- Reassemble together inner and outer
flue duct insert centering spring.
INTAKE AND EXHAUSTTERMINAL COMPONENTS
KEY
56 - Straight header
57 - Elbow header
58 - Header gasket
59 - Rubber seal 0 60
60 - STD air intake duct
61 - STD flue exhaust duct
62 -Terminal
63 -Air intake duct extension
64 - Flue exhaust duct extension
65 - Pipe centering spring
66 - Sample point
127 - Terminal cover plate
19

5.5.4
5.5.5
5.5.6
Fig. 33
Insert the flue assembly into the wall, being
careful to make sure that the outer air duct
comes flush to the inner surface of the wall.
Lift the boiler on to the wall (Fig. 34),
locating onto the top coach bolts. Fit the
two lower coach bolts and tighten all four
securing bolts.
Working above the boiler pull the flue
exhaust duct towards the boiler in order to
engage tube 61 into its header 57A.
Position flue into elbow header and push so
as to locate inner and outer flue correctly
ensuring good seal is made with o rings.
5.5.6 Fit terminal cover plate and terminal guard
(Fig. 36-37).
5.5.9 Extension kits are available on order for
flue extension of up to 2.5 metres total
length (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 by
approximately 1000 mm’ long up to a
maximum of two extensions.
Pipeline length can be established using
the instructions in section 5.5 for rear flue
outlets and section 5.7 for side flue outlets.
Extensions must be installed with the
widened end of the air intake pipe and the
tapered end of the flue pipe aimed towards
the exhaust terminal. Extensions must be
joined together with the standard terminal
pipe, and inserted in each other as far as
they can go.
If an extension must be shortened, this
must be done from the straight end, and
not from the widened or tapered end. To
measure the pipeline properly all
components must be assembled and total
length measured before cutting. The
straight end of the extension connects to
the boiler. The flue output pipe fits into the
boiler header until it stops. The air intake
pipe should be located approximately 2
mm. from the boiler header (Fig. 31).
When cutting both inner and outer ducts of
the extension, always ensure that the
reduced end (male) of the inner duct is
longer than the outer duct.
All joints must be sealed with the rubber
seals supplied.
It is important to put the centering spacer,
supplied with the unit, inside between the
two pipes, from the side opposite the
extension’s straight end.
NOTE: a suitable support bracket is availa-
ble from Ravenheat Manufacturing and
should be used to support flue length at
least every 1.8 metre preferably at each
joint this bracket should be secured to wall
and flue duct.
INLINE FLUE BEND
Measure the distance between the flue
bends or the flue/terminal assembly. The
measurements should be taken from the
outer edge of the flue and bend (Fig. 398).
IMPORTANT: inline flue bend - 1680 mm
must be deducted from overall length for
each 90obend. Obtuse flue bend - 1680
mm must be deducted from overall length
for each 135obend (Fig. 398).
COMPLETING BOILER INSTALLATION
Reassemble the outer casing (sect 5.4)
proceeding in this order
1) Fit the two sides.
2) Refit the instrument panel in reverse ord-
er as in sect. 5.4.4.
3) Refit the lower grating (sect. 5.4).
5.7 INSTALLING THE APPLIANCE FOR SIDE
FLUE OUTLET (Fig. 39)
5.7.1
-Attach the template to the wall with adhe-
sive tape, making sure that the centre line
is vertical and that the distance from the
centre line to the nearest side wall is not
less than measurement in table 6.
- Mark the four boiler securing holes on the
wall and extend the axis of the flue duct
hole to the side wall ensuring it is
horizontal.
-Trace the centre of the flue duct hole
measure distance F (table 6). From the
corner of the wall (Fig. 38), measure the
distance Y between. the centre of flue
duct hole to the corner. Detach the
template from wall.
-Use a dia. 10 mm. drill to make the 4
holes for securing the boiler. Insert the
plastic expansion plugs. Core drill a 105
mm dia. hole in the side wall for inserting
the flue duct.
TABLE 6
Fig. 39
21