Ravenheat Flue Boiler User guide

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CONDENSING FANNED FLUE BOILER
CSI SYSTEM
WITHOUT TIMER
NATURAL GAS (G20) (I 2H ) G.C.No47 581 01 - CSI
LPG (G30-G31) (I 3+ ) G.C.N
o
47 581 03 - CSI
Tested, certified and
service listed
Listed by The United Kingdom Water
Fitting Byelaws Scheme
WITH TIMER
NATURAL GAS (G 20) (I 2H ) G.C. NO47 581 02 - CSI
LPG (G 30 - G 31) (I 3+ ) G.C.N
O
47 581 04 - CSI
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE LEFT WITH USER
Technical and illustrative data are not binding and can be modified without prior notice.
The descriptions and illustrations in the present booklet are for guideline purposes only.
RAVENHEAT MANUFACTURING LTD., CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET. -TELEPHONE [phone]

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CONDENSING SYSTEM INNOVATION AUTOMATIC MODULATING
CENTRAL HEATING BOILER
This new super high efficient turbo-modulating boiler is designed to meet heating requirements at
super high efficiency, unheard of only a few years ago.
POSITION
The appliance is extremely versatile as it can be fitted in almost any room. The appliance is room
sealed, there is no contact between combustion chamber and living accommodation. This guarantees
maximum safety and efficiency. Indeed, our depression/combustion front cover has been designed to
fit, achieving maximum air tight seal using screw down fasteners at 15 cm. This should not hinder
service of the appliance, but does ensure maximum efficiency and safety - something which
Ravenheat take great pride in.
Each boiler has been designed and manufactured in our modern plant to exacting IS0 9001 discipline,
all boilers carry full CE marking of approval. Technical sales and commercial service are available
throughout the UK-This product is guaranteed by Ravenheat Manufacturing, Chartists Way, Morley,
LEEDS, LS27 9ET. Telephone No [phone].
BASIC COMPONENTS - (See figure 1)
Guarantee is a full 12 months from date of purchase providing the appliance has been fitted in
accordance with these instructions and relevant codes of practice.
MAJOR COMPONENTS
Gas valve with flame modulator.
Variable head pump suitable for any type of central heating system.
Main burner with flame stabiliser designed to operate under all thermal conditions.
Primary heat exchanger constructed from copper.
Unique patented condensing heat exchanger for high thermal flue transfer gases to water.
Built in frost protection.
Printed circuit board designed to connect to room stat cylinder stat, and/or timer/frost stat.
Aesthetically pleasing panels and controls.
On/Off ball valves for shutting off gas and central heating.
Safety relief valve (for safety discharge).
Programmable 7 day module with digital display (optional).
All front panel controls not often used have been hidden. This achieves simplicity of operation with
easy to clean panels.
NOTE: Due to the high efficiency of this boiler a plume of water vapour will form at the flue
terminal during operation.
COSHH - CONTROL OF SUBSTANCES HARMFULTO HEALTH
IMPORTANT
This appliance contains materials that are indicated below.
It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is
worn when handling, where applicable, the pertinent parts that contain any materials that could be
interpreted as being injurious to health and safety.
WARNING When installing the appliance, care should be taken to avoid any possibility of injury when
handling sheet metal parts.
GENERAL INFORMATION:
GLUES AND SEALANTS - exercise caution - if these are still in liquid form.
INSULATION PADS, CERAMIC FIBRE - may be harmful if inhaled, may be irritating to skin, eyes,
nose and throat.
When handling keep dust generation to a minimum, avoid inhaling and contact with skin or eyes.
When disposing of the product keep dust generation to a minimum and ensure that parts are securely
wrapped.
When servicing avoid inhalation by using a vacuum cleaner or in conjunction with other tools.
After handling wash hands and other exposed parts.
RAVENHEAT use only high quality material for production of this product, in an effort to protect the
environment components should be re-cycled.
2

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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
GENERAL LAYOUT
KEY
1 - Heat exchanger
3 Burner
4 - Ignition pilot burner
5 - Interface board
6 Condensing heat exchanger
7 - Ignition board
9 - Ignition electrode
11 - Frame
12 Modulating gas valve
15 - Heating control
16 - D.H.W. control
17 - D.H.W. sensor
18 - Pressure switch (heating circuit)
22 - Overheat cut off thermostat
23 - Safety relief system
26 - Auto air vent valve
28 -Air pressure switch
29 - Circulation pump
30 -Water pressure gauge
33 - Main switch
PAGE:
5
5
7-8
9
14
27
30
42
44
49
50
34 - C.H. sensor
35 - Condensing trap
36 - Fan
37 - Expansion tank
38 Sealed chamber
45 Combustion chamber
50 - Flue gas exhaust hood
105 - Timer
106 Flue restriction ring
3
.::

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OPERATING SCHEME
Fig. 2
KEY
1 - Heat exchanger 10 - Condensate sensor
3 - Burner 12 - Modulating gas valve
4 - Ignition pilot burner 15 - Heating control potentiometer
5 - Flue restriction ring 16 - Hot water control potentiometer
6 - Condensing heat exchanger 17 -Water pressure switch
7 - Electronic ignition 18 - Overheat cut-off thermostat
8 - Condensing trap 20 - Gas service cock
9 - Ignition electrode 21 - Compression ball valves
23 - Safety relief system
26 - Auto air vent valve
28 - Air pressure switch
29 - Circulating pump
30 -Water pressure gauge
36 - Fan
37 - Expansion tank
38 - Sealed chamber
4

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SECTION 1 INTRODUCTION 2.2.3
1.1
The Ravenheat CSI System boiler is a cen-
tral heating system boiler which incorpora-
tes a circulating pump, expansion vessel,
safety valve, pressure gauge and electronic
ignition. The boiler is equipped with a front
cover which can be removed for servicing.
The data badge is placed on the lower left
hand side of the frame.
1.1.1
The Ravenheat CSI System boiler has
been carefully developed to utilise best use
of energy for super high efficiency, it can be
used as a condensing system heating only
boiler or can be used in the design of a ‘Y’
or ‘s” plan heating system incorporating a
hot water cylinder, this makes best use of
the built in energy management system to
control all modes of operation.
1.1.2
The boiler comes with a built in single cha-
nel 7 day digital timer, this can be utilised to
control domestic hot water timed require-
ments and if a separate timer for heating is
required then it is recommended to fit a
room thermostat/timer is available from Ra-
venheat Manufacturing.
1.1.3
This appliance is designed for use with a
seal system only.
1.1.4
The provision of stored domestic hot water
is possible by the addition of an indirect cy-
linder with ‘Y’ or ‘S’ plan controls.
1.2
Fig. 1 illustrates the general layout of com-
ponents.
Fig. 2 illustrates the operating principles de-
scribed in section 2.
SECTION 2
2.1 DESCRIPTION OF CONTROL SYSTEM
AND SEQUENCE OF OPERATION
2.2
Domestic hot water mode (if installed)
When the appliance mains neon is switched
on with the heating circuit charged with wa-
ter above 1 bar with a demand from the ti-
mer and cylinder stat for hot water the boiler
will function in the following sequence.
2.2.1 The pump starts.
The control board sensors.
The fan operates via the pressure switch
and sends a signal back to the ignition
board that the fan is running at maximum
speed.
2.2.2 The spark ignition system is powered which
in turn commences the spark igniter to ope-
rate and light the burner.
At this point the ignition board opens the
first step of the gas valve to light the
pilot/burner.
2.2.4
2.2.5
2.2.6
Central heating mode
2.2.7
If the main neon switch is on with a demand
for heat to supply radiators, etc., with the
heating circuit fully charged so as to opera-
te the low water sensor device the boiler will
start but with a slightly differing time delay
in that it will start on minimum and remain at
this level for about 1 minute after which the
flame will lift to its maximum setting as go-
verned by a potentiometer range rate the
heating circuit between maximum and mini-
mum power.
2.2.8
2.2.9
2.3
2.3.1
Central Heating Mode
A potentiometer installed on the electric cir-
cuit board permits regulation of the boiler to
partial heating requirements, between the
factory settings.
2.3.2
Air is drawn by the fan for combustion
2.3.3
The fan also forces exhaust gas through the
flue to the outside, this creates a lesser
pressure in the sealed combustion cham-
ber, thus sucking in combustion air, through
the inlet duct.
When the electrode/sensor senses the si-
gnal of the pilot/burner, it opens the second
stage of the gas valve via the ignition board
on minimum power. Upon the second valve
opening the spark igniter stops.
From the minimum gas rate setting the boi-
ler increases to a maximum permissible
pressure and will remain at its maximum re-
quired power until its maximum regulated
temperature.
When the cylinder stat and or the DHW timer
is satisfied the boiler will go to rest mode the
main burner is shut down and the pressure
switch will return back to its rest mode. The
pump overrun will operate the pump for
about 1 minute after that the pump will stop.
Note
However, if there is a demand for heating
the boiler continue to operate to satisfy this
demand, rather than shut down, see 2.2.6.
On the control panel this potentiometer
(thermostat) controls the temperature. One
is for domestic hot water and the other for
heating.
The boiler is fitted with an anti-cycling devi-
ce on the control board. This delays the boi-
ler from re-firing over a 2.5 minute period
when in heating mode. The domestic hot
water will always take priority and is unaf-
fected by the anti-cycling device.
GENERAL FUNCTION
5

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2.3.4
The boiler water temperature is automati-
cally controlled by a built in thermostat.
2.3.5
Interior space temperature is set by the
room thermostat to be installed in the heat-
ing system. The boiler already carries con-
nection terminals for this thermostat, as
well as for a timeclock. The burner contin-
ues to operate until it is stopped by the
timer or one of the thermostats.
2.3.6
When the internal C.H. temperature sensor
intervene the main burner shuts down. The
fan stops but the pump continues to operate.
2.3.7
When the room thermostats and or timer in-
tervene the main burner shuts down. The
fan stops and the pump turns off via the
pump overrun.
2.3.6
The condensate trap is fitted with a block-
age safety sensor. This prevents the boiler
operating should there be a blockage in the
condensate discharge trap.
3.1 SAFETY DEVICE
3.1.2
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.
OVERALL DIMENSION
Fig. 3
IMPORTANT:
Terminal guard
must be fitted.
AVAILABLE PUMP HEAD PRESSURE DROP ACROSS APPLIANCE
Fig. 4 Fig. 5
6

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SECTION 3 TECHNICAL DATA
TABLE 1
NATURAL GAS (G 20) I 2H
NOMINAL HEAT INPUT NET 24.8 kW
MINIMUM HEAT INPUT NET
13.0 kW
NOMINAL HEAT OUTPUT 23.8 kW
NOMINAL HEAT OUTPUT CONDENSING 25.6 kW
MINIMUM HEAT OUTPUT
11.7 kW
MINIMUM HEAT OUTPUT CONDENSING 13.4 kW
GAS RATE max 2.5 m
3
S/h
AFTER 10 MINUTES
min
1.3 m
3
S/h
INLET PRESSURE 20 mbar (8.0 in w.g.)
BURNERPRESSURE
max 10.5 mbar
min
2.0 mbar
MAIN BURNER INJECTORS Nr. 13 x 1.25
PILOT BURNER INJECTOR 0.27 x 2 HOLES
ELECTRICAL SUPPLY
230V-50HZ
POWER CONSUMPTION
16OW
EXTERNAL FUSE RATING 3A
INTERNAL FUSE
315 mA - 2A - 4A (20 mm to BS 4265)
DRY WEIGHT kg 46
WATER CONTENT C.H. litre 1.O
GAS SUPPLY CONNECTION
1/2" RC
FLOW CONNECTION C.H.
22 mm compression isolating valve
RETURN CONNECTION C.H.
22 mm compression isolating valve
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION DRAIN
3/4" (21.5 mm) push fit over flow
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL
SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS 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
MIN 45 oC
DESIGN FLOW RATE 1023 l/h (225 gals/h) 20 oC RISE
MINIMUM FLOW RATE C.H. 503 I/h (111 gals/h)
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: AT. CH. DK. ES. FI. GB. IE. IT. PT. SE.
FLUE TYPE - C 12 - C 32 - C 52
CATEGORY I 2H
NOX 2
(84,500 Btu/h)
(44,500 Btu/h)
(81,200 Btu/h)
(87,200 Btu/h)
(40,100 Btu/h)
(45,700 Btu/h)
(88.25 ft3/h)
(45.9 ft3/h)
(4.2 in w.g.)
(0.8 in w.g.)
110 LITRE
(35.6 p.s.i.)
(7.35 p.s.i.)
(7.35 p.s.i.)
7
:

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SECTION 3 TECHNICAL DATA
TABLE 1/A
LPG (G 30 - G 31) I 3+
NOMINAL HEAT INPUT NET 24.8 kW
MINIMUM HEAT INPUT NET
13.0 kW
(84,500 Btu/h)
(44.500 Btu/h)
NOMINAL HEAT OUTPUT
NOMINAL HEAT OUTPUT CONDENSING
MINIMUM HEAT OUTPUT
MINIMUM HEAT OUTPUT CONDENSING
24.1 kW
25.6 kW
11.7 kW
13.4 kW
(82,100 Btu/h)
(87,200 Btu/h)
(40,100 Btu/h)
(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 ft
3
/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 w.g.)
G 30
27.3 mbar (10.9 in wg.)
PRESSURE
min
7.3 mbar (2.92 in w.g.) 7.0 mbar (2.8 in w.g.)
MAIN BURNER INJECTORS Nr. 13 x 0.75
PILOT INJECTOR 0.22 x 1 HOLE
ELECTRICAL SUPPLY 230V-50HZ
POWER CONSUMPTION 160W
EXTERNAL FUSE RATING
3A
INTERNAL FUSE 315 mA - 2A - 4A (20 mm to BS 4265)
DRY WEIGHT kg 46
WATER CONTENT C.H.
litre 1 .O
GAS SUPPLY CONNECTION 1/2" RC
FLOW CONNECTION C.H. 22 mm compression isolating valve
RETURN CONNECTION C.H. 22 mm compression isolating valve
SAFETY DISCHARGE C.H. 15 mm copper pipe
CONDENSATION DRAIN 3/4" (21.5 mm) push fit over flow
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRES
SEALED WATER SYSTEM C.H.
MAX PRESSURE PMS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85 oC
MIN 45 oC
(35.6 p.s.i.)
(7.35 p.s.i.)
(7.35 p.s.i.)
DESIGN FLOW RATE 1023 I/h (225 gals/h) 20 oC RISE
MINIMUM FLOW RATE C.H./503 Lts/h (111 gals/h)
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: BE. CH. ES. FR. GB. IE. IT. PT.
FLUE TYPE - C 12 - C 32 - C 52
CATEGORY l3+ NOX 2
8

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SECTION 4
GENERAL REQUIREMENTS
4.0
SAFETY
Gas Safety (Installation and
USE)
Regulations, 1994, and amendments 1996.
It is law that all gas appliances are installed
and serviced by a Corgi registered installer
(identified by in accordance with the
above regulations. Failure to install applian-
ces correctly could lead to prosecution, It is
in your own interest, and that of safety, to
ensure the law is complied with. Check the
boiler and flue is the correct type for
installation.
The installation of the boiler MUST also be
in accordance with the latest I.E.E (BS
7671) Wiring Regulations, local building
regulationsbye-laws of the local water
authority, the building regulations and the
Building standards (Scotland) and any
relevant requirements of the local authority.
4.1
GENERAL INFORMATION
Both the user and the manufacturer rely
heavily on the installer, whose job it is to in-
stall the combination boiler and connect it to a
correctly designed heating system. Acquaint
yourself with the British Standards concerning
installation requirements. If you need advice
on any points your Ravenheat Technical
Services Office would be pleased to help. It is
recommended that tools suitable for brass
fittings are used, and have a capability to
accomodate hexagon sizes up to 50 mms.
CODES OF PRACTICE/Ret Documents
Detailed recommendations are contained
in the following British Standard Codes of
Practice:
BS. 6891 Low pressure installation pipes.
BS. 6798
Installation of gas fired hot
water boilers of rated input not
exceeding 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. 544O:2 Ventilation (for gas appliances of
rated input not exceeding 60 kW).
DD 189:1990 Discharge of condensate
Health & Safety Document No. 635
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be
taken, in any way, as overriding statutory
obligations.
IMPORTANT. These appliances are CE
certificated for safety and performance. It
is, therefore, important that no external
control devices e.g. flue dampers,
economisers etc., are directly connected to
this appliance unless covered by these
Installation and Service Instructions or as
otherwise recommended 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 warranty. It could also infringe
the Gas Safety regulations and the above
regulations.
NOTE: The Ravenheat CSI combination
boiler has been tested and examined by
BG, and is certified to comply with PrEN
483 and BS EN 625.
Manufacturers instructions must NOT be
taken in any way as overriding statutory
obligations.
If in doubt on any point please consult
Ravenheat Manufacturing Ltd.
LOCATION OF BOILER
Siting of Ravenheat CSI System Combi
Boiler must be as follows. The position of
installation should be within the building,
unless otherwise protected by suitable
enclosure.
Adequate space for installation, servicing
and air circulation around boiler must be
allowed for.
The Ravenheat CSI System Combi Boiler
must be fitted on a flat and vertical wall
capable of adequately supporting the
weight of the boiler and any ancillary
equipment.
The appliance may be installed on a
combustible
wall
subject to the
requirements of the Local Authority and
Building Regulations.
LPG versions of this appliance shall not
be installed in cellars or basements.
4.3 CLEARANCES AROUNDTHE APPLIANCE
4.3.1
The following minimum free spaces, re-
quired for installation inspection and
servicing, must be left around the boiler
18 inches (450 mm) in front
5 inches (125 mm) above
6 inches (150 mm) below
0.2 inches (5 mm) on each side
1 inch (25 mm) in front when installed in a
cupboard.

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4.4 IMPORTANT NOTICE
4.4.1
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 DM2. If in doubt advice
must be sought from the local gas supplier.
The combination boiler may be installed in
any room or internal space, although partic-
ular attention is drawn to the requirements
of the current I.E.E. Wiring Regulations, and
in Scotland the electrical provisions of the
Building Regulations applicable in Scot-
land, with respect to the installation of the
combination boiler in a room or internal
space containing a bath or shower.
Where a room sealed appliance is installed
in a room containing a bath or shower, any
electrical switch or appliance control, utilis-
ing mains electricity should be so situated
that it cannot be touched by a person using
a bath or shower.
A compartment used to enclose the combi-
nation boiler MUST be designed and con-
structed specifically for this purpose. An
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 Appli-
ance 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.
4.5 GAS SUPPLY
4.5.1
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 ade-
quate to deal with the rate of gas supply
required for all appliances it serves. Instal-
lation pipes should be fitted in accordance
with BS 6891. Pipework from the meter to
the boiler must be of adequate size (22 mm)
min. To within at least 3 metre of the boiler
(15 mm) min. can then be used for remain-
ing pipe work to the appliance. A smaller
size than the boiler inlet gas connection
should not be used. The complete installa-
tion 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 con-
sidered.
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
surface.
Pluming will occur at the terminal so, where
possible, terminal positions which could
cause a nuisance should be avoided.
The flue must be installed in accordance with
the recommendations of BS 5440: Part 1.
IMPORTANT NOTES
For greater flue lengths see twin flue
instructions.
Flue must be positioned in a place not likely
to cause a nuisance.
IMPORTANT: The following notes are
intended for general guidance.
The boiler MUST be installed so that the
terminal is exposed to external air.
It is important that the position of the 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 BS 5440, Part 1.

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NOTE:
4.6.2
4.7
4.7.1
Fig. 6A
The flue must be terminated in a place not
likely to cause a nuisance.
A concentric vertical flue kit is available, for
flueing applications up to a maximun height
of 4.0 metres.
For further details see vertical flue installa-
tion instructions.
AIR SUPPLY
The following notes are intended for gener-
al guidance.
The room sealed fan flued boiler does not
require a permanent air vent for combustion
air supply.
Where installed in a cupboard or compart-
ment ventilation is not required.
4.8
4.8.1
WATER CIRCULATION (central heating)
Detailed recommendations are given in BS
6798 5449.1.1977 (for smallbore and
microbore central heating systems). The fol-
lowing notes are given for general guid-
ance.
4.8.2
Pipework
Copper tubing to BS 2871 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.
4.8.2.1 SYSTEM DESIGN
CONDENSATE DRAIN
A condensate drain is provided on the boil-
er. This drain must be connected to a
drainage point. All pipework and fittings in
the condensate drainage system MUST be
made of plastic - no other materials may be
used.
Discharge of condensate DD 189:1990.
The drain outlet on the boiler is standard
3/4" (21.5 mm) push fit overflow pipe.
NOTE: Condensate drain pipework must
never be less than 15 mm.
Important: any external runs must be car-
ried out in 1 1/4 (32 mm) wastepipe.
A fall of 2.5o(45 mm/m) all runs must have.
Fig. 6A illustrates typical heating only lay-
out. Figs. 6B and 6C illustrate typical layout
with ‘Y’ or ‘S’ plan system.
11

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Fig. 6C
Schematic ‘S’ plan
4.8.3
The water through the appliance heat
exchanger circuit must exceed the min.
1.84 gals/min. (503 It/h) when the burner is
firing. It is important to ensure that this rate
is achieved when sections of the system
are shut off either manually or by automatic
controls. Therefore a by-pass must be fit-
ted to the system (15 mm min.) (Fig. 6A).
If the volume of circulating water is too low,
the boiler water temperature will rise too
rapidly. This could cause noise in the system
or even cause the safety thermostat to trip.
4.0.4 Draining tap
These must be located in accessible posi-
tions to permit the draining of the whole
system. The taps must be at least 15 mm
nominal size and manufactured in accor-
dance with BS 2870 1960.
4.8.5 Air release points
These must be fitted at all high points where
air will naturally collect, and must be sited to
facilitate complete fitting of the system.
4.8.6 The appliance has an integral sealed
expansion vessel to accomodate the
increase of water volume when the system
is heated, It can accept up to 1.5 gal (7 Its)
of expansion water. If the appliance is con-
nected to a system with an unusually high
water content, calculate the total expansion
and add additional sealed expansion
capacity as appropriate (Fig. 7).
In general modern systems will present no
problem.
4.8.7
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.
4.8.8
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 sta-
tic 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. 6).
The system may be filled through a self
contained unit comprising of a cistern pres-
sure booster pump if required and if neces-
sary 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 con-
nected to the heating system to provide lim-
ited 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. 6

Supplied By www.heating spares.co Tel. [phone]
SIZING OF ADDITIONAL EXPANSION VESSELS: TABLE 3
Deduct from the value given in the table the 7 litre vessel supplied.
Safety
valve setting (bar)
Vessel charge
pressure (bar)
3.0
0.5 1.0 1.5
Initial system
(bar) pressure
Total water
content 01 system
Litres
0.5
1.0 1.5 2.0 1.0 1.5
2.0 1.5 2.0
EXPANSION VESSEL VOLUME (LITRES)
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
2.1
4.2
6.3
8.3
10.4
12.5
14.6
16.7
20.8
22.9
25.0
27.0
29.1
31.2
33.3
35.4
37.5
3.5
7.0
10.5
14.0
17.5
21.0
24.5
28.0
31.5
35.0
38.5
42.0
45.5
49.0
52.5
56.0
59.5
63.0
6.5
12.9
19.4
25.9
32.4
38.8
45.3
51.8
58.3
64.7
71.2
77.7
84.1
90.6
97.1
103.6
110.1
116.5
13.7
27.5
41.3
55.1
68.9
82.6
96.4
110.2
124.0
137.7
151.5
165.3
179.1
192.8
206.6
220.4
239.2
247.9
2.7
5.4
8.2
10.9
13.6
16.3
19.1
21.8
24.5
27.2
30.0
32.7
35.7
38.1
40.9
43.6
46.3
49.0
4.7
9.5
14.2
19.0
23.7
28.5
33.2
38.0
42.7
47.5
52.2
57.0
61.7
66.5
71.2
76.0
80.7
85.5
10.3
20.6
30.9
41.2
51.5
61.8
72.1
82.4
92.7
103.0
113.3
123.6
133.9
144.2
154.5
164.8
175.1
185.4
3.9
7.8
11.7
15.6
19.5
23.4
27.3
31.2
35.1
39.0
42.9
46.8
50.7
54.6
58.5
62.4
66.3
70.2
6.3
16.5
24.8
33.1
41.3
49.6
57.9
66.2
74.5
82.7
91 .0
99.3
107.6
115.8
124.1
132.4
140.7
148.9
For system volumes
other than those given
above, multiply the
0.0833 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) 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.
A combined double check valve shall be
installed upstream of the draw-off point,
through a temporary hose connection from
a tap supplied from the mains, where the
mains pressure is excessive a pressure
reducing valve shall be used to make filling
easier. The following fittings shall form a
permanent part of the system and shall be
fitted in the order stated.
a) A stop valve complying with the require-
ments of BS 1010 Part 2 (the temporary
hose from the draw off tap shall be con-
nected to this fitting).
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.
B) Where fitting a make up vessel would be
difficult re - pressurisation of the system can
be done. See section on FILLING.
If the capacity of the central heating system
should exceed 110 litres, an additional vessel
should be installed on the return to the combi-
nation boiler from the heating system (Fig. 7).
Guidance on vessel sizing is given in (Table 3).

Supplied By www.heating spares.co Tel. [phone]
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.
4.8.9
Installation to an existing central heating
system
The System boiler is designed to operate
on a sealed system only. Therefore if the
existing system is of the open water type it
will have to be modified to comply with BS
5376 Part 2.
Before installing a new System boiler to an
existing system, flush out the old system
with a recommended descaling agent.
It is most important that the correct concen-
tration of the water treatment product is
maintained in accordance with the manu-
facturers’ 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 neces-
sary and any defective controls exchanged.
WATER TREATMENT
This boiler has a secondary ALUMINIUM
alloy heat exchanger Ravenheat recom-
mended only the use of FERNOX-COPAL,
SENTINEL Xl00 or SALAMANDER CUR-
ROSION GUARD water treatment products,
which must be used in accordance with the
manufacturers instructions. For further
information contact:
Fernox Manufacturing Co. Ltd.
Tel. [phone]
Sentinel Division Betz Dearborn Ltd.
Tel. [phone]
Salamander (Eng) Ltd
Tel. [phone]
4.10
ELECTRICAL SUPPLY
Warning: this appliance must be earthed
4.10.1
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
supply. The supply must be fused at 3 A.
NOTE: The method of connection to the
electricity supply MUST facilitate complete
electrical isolation of the appliance, by the
use of a fused, double pole isolator, having
a contact separation of at least 3 mm in all
poles. The point of connection to the 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. 10
Fig. 11

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5.2
DELIVERY
WARNING:
5.2.1
The appliance will arrive on site in two
cartons
Maximum allowable flue length 2.5 m.
maximum No. 2x1000 mm.
Flue duct extension used with standard flue
Box 1 of 2 containing (Fig. 10 - 11):
a) boiler fully assembled
b) installation instructions and
user Instructions
c) white paper template
d) terminal cover plate (Fig. 12)
e) - 4 coach bolts and wall plugs
- screws and dowels
Polythene bag containing
a) 2-22 mm compression ball valves
b) 1-1/2" BSP Union gas cock
c) 2 22 mm flanged copper tails complete
with 3/4" brass nuts and washers
Box 2 of 2 containing (Fig. 12):
Horizontal CSI flue kit
57 - Flue bend assembly
58 Header gasket
59 - Rubber seal 0 60
60 - Air intake duct
61 - Flue exhaust duct
62 -Terminal
Fig. 13
65 - Pipe centering spring
66 Flue gas sample point
127 -Terminal rubber
(Contained in the carton Fig. 1O)
Fig. 12
OPTIONAL EXTRAS:
Small carton containing: (Fig. 13)
57 Straight header supplied as an extra cost only
when requested
59 - Rubber seal 0 60
66 - Flue gas sample point
FLUE EXTENSION BOX CONTAINING (Fig. 14)
1000 mm flue extension duct as an extra cost only
when requested for side and vertical flue applications
59 Rubber seal 0 60
63 - Air intake duct extension
64 - Flue exhaust duct extension
65 - Pipe centering spring
15

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

Supplied By www.heating spares.co Tel. [phone]
5.4
54.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.5
5.5.1
POSITIONING OF THE BOILER
- 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 milli-
metres up towards the top of the
appliance until it is free from its slot, and
then lift off (Fig. 20).
Unscrew the 2 screws that fasten the lower
grating on the casing and remove it from the
sides of the casing (Fig. 22).
Push down the 2 plastic clips that fasten the
instrument panel (Fig. 23).
Lower the instrument panel down by rota-
ting it on its own hinges (Fig. 25).
Unscrew the two screws fastening panels
(Fig. 21).
Remove the two sides of the casing by sligh-
tly lifting them and carefully sliding towards
the top of the appliance, to release them from
their upper suspension hooks (Fig. 26-27).
Make sure the casing and screws are put to
one side in a safe place.
INSTALLINGTHE APPLIANCE FOR
REAR FLUE OUTLET
Use adhesive tape to attach the template to
the wall, making sure that the centre line is
vertical.
- Mark the four boiler fastening holes on the
wall as well as the centre of the flue duct.
- Detach the template from the wall.
- Use a 10 mm. dia drill to make the 4 boi-
ler securing holes. Insert the plastic
expansion plugs.
- Cut or core drill a 105 mm. dia hole for
inserting the flue duct.
- Screw in the two upper coach bolts leaving
them about 10 mm. out from the wall to
enable the boiler to be located on the wall.
Fit the elbow header positioning it towards
the required direction (Fig. 30).
IMPORTANT: Make sure that the elbow’s
dia. 60 mm duct is inserted into the fan, the
rubber seal and orifice (F2) have been cor-
rectly fitted.
Fig. 21
Fig. 22
Fig. 23
Fig. 25
Fig. 26
Fig. 27
Fiq. 26-29

Supplied By www.heating spares.co Tel. [phone]
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 boil-
er is too long (the wall to go through is less
than 680 mm. thick) it can be shortened as
follows:
- Remove the centering spring 65, the flue
terminal to disengage inner flue duct.
- Measure the thickness W of the wall.
- Cut the outer flue duct at right angles to a
length equal to W + 152 mm.
Must be de-burred.
- Cut the inner flue duct (60 mm) at right
angles to a length equal to W + 264 mm.
Insert from cut end. Reassemble the two
tubes. Insert centering spring 65.
Must be de-burred.
- Reassemble together inner and outer
flue duct insert centering spring.
Fig. 32
KEY
56 -
Straight header
57 -
Elbow header
56 -
Header gasket
59 -
Rubber seal 0 60
60 - STD air intake duct 64 - Flue exhaust duct extension
61 - STD flue exhaust duct 65 - Pipe centering spring
62 - Teriminal
66 - Sample point
63 - Air intake duct extension
. 127 -Terminal cover plate
18

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5.5.4 Insert the flue assembly into the wall, being
careful to make sure that the outer air duct
comes flush to the inner surface of the wall.
5.5.5 Lift the boiler on to the wall (Fig. 34), locat-
ing onto the top coach bolts. Fit the two
lower coach bolts and tighten all four secur-
ing bolts.
5.5.6 Working above the boiler pull the flue
exhaust duct towards the boiler in order to
engage tube 61 into its header 57A.
Position flue into elbow header and push so
as to locate inner and outer flue correctly
ensuring good seal is made with o rings.
Fig. 33
5.5.8
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. 36
Fig. 34
Make good inside and outside wall around the air duct

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5.5.10 Each extension length extends the pipe by
approximately 1000 mm long up to a
maximum of two extensions.
Pipeline length can be established using
the instructions in section 5.5 for rear flue
outlets and section 5.7 for side flue outlets.
Extensions must be installed with the
widened end of the air intake pipe and the
tapered end of the flue pipe aimed towards
the exhaust terminal. Extensions must be
joined together with the standard terminal
pipe, and inserted in each other as far as
they can go.
If an extension must be shortened, this
must be done from the straight end, and
not from the widened or tapered end. To
measure the 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.
5.5.11
INLINE FLUE BEND
Measure the distance between the flue
bends or the flue/terminal assembly. The
measurements should be taken from the
outer edge of the flue and bend (Fig. 398).
IMPORTANT: inline flue bend - 1680 mm
must be deducted from overall length for
each 90” bend. Obtuse flue bend - 1680
mm must be deducted from overall length
for each 135” bend (Fig. 398).
5.6 COMPLETING BOILER INSTALLATION
5.6.1
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
adhesive tape, making sure that the
centre line is vertical and that the
distance from the centre line to the
nearest side wall is not less than
measurement in table 6.
-Mark the four boiler securing holes on
the wall and extend the axis of the flue
duct hole to the side wall ensuring it is
horizontal.
-Trace the centre of the flue duct hole
measure distance F (table 6). From the
corner of the wall (Fig. 38), measure the
distance Y between the centre of flue
duct hole to the corner. Detach the
template from wall.
-Use a dia. 10 mm. drill to make the 4
holes for securing the boiler. Insert the
plastic expansion plugs. Core drill a 105
mm dia. hole in the side wall for inserting
the flue duct.
TABLE 6
20