Ravenheat HE Primary AAA Operating manual

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Technical and illustative 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
TEL. [phone] - FAX: [phone]
Website : www.ravenheat.co.uk - E-mail : [e-mail]
Instructions for Use
Installation and Servicing
To be left with the user
HIGH EFFINCENCY
CONDENSING
PRIMARY BOILER
HE PrimaryAAA
HE PrimaryAAA
Natural Gas (G20) I2H - II2H3+
G.C. No. 47-581-
05
05
LPG (G30-G31) I3+ - II2H3+
G.C. No. 47-581-
06
06

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CONDENSING SYSTEM INNOVATION
CENTRAL HEATING BOILER
This new super high efficient 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 ISO 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
- Gas valve
- 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
- Aesthetically pleasing panels and controls
- On/Off ball valve for shutting off gas
- Programmable 7 day module with digital display (optional)
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.
MAJOR COMPONENTS
3

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TABLE OF CONTENTS
SECTIONS
1
2
3
4
5
6
7
8
9
10
11
INTRODUCTION
DESIGN PRINCIPLES AND
OPERATING SEQUENCE
TECNICAL DATA
GENERAL REQUIREMENTS
INSTALLATION
COMMISSIONING
SERVICING INSTRUCTIONS
FAUL FINDING
ELECTRICAL SYSTEM DIAGRAM
EXPLODED PARTS DIAGRAM
LIST OF SPARE PARTS
PAGE
6
6
8-9
6
15
26
30
37
38
42
43
GENERAL LAYOUT
Fig.1
KEY
1 - Heat exchanger
3 - Burner
4 - Sensing electrode
6 - Condensing heat exchanger
9 - Ignition electrode
11- Modulating Gas Valve
15-Heatcontrolthermostat
18- Frame
22-C.H.sensor
26-Heatingcontrol
28-AirPressure switch
35-Condensingtrap
36-Fan
38 - Overheat cut off thermostat
45 - Combustion chamber
50 - Flue gas exhaust hood
106 - Flue restriction ring

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OPERATING SCHEME
KEY
1 - Heat exchanger
3 - Burner
4 - Sensing electrode
5 - Flue restriction rin
6 - Condensing heat exchanger
8 - Condensing trap
9 - Ignition electrode
18 - Overheat cut-off thermostat
22- C.H. sensor
26 - Modulating Gas Valve
28 - Air Pressure switch
36 - Fan
38 - Sealed chamber
Fig.2

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6
SECTION 1 INTRODUCTION
1.1 The CSI Primary is a gas fired room sealed
fan assisted condensing heating boiler suit-
able for fully pumped open vented or sealed
system central heating and domestic hot
water systems.
1.2 The provision of stored domestic hot
water is possible by the addition of
an indirect cylinder with ‘Y’ or ‘S’ plan
controls The data badge is placed on the
front panel.
1.2.1 Fig 1 illustrates the general layout of
components.
Fig.2 illustrates the operating principals
described in section 2.
SECTION 2 DESCRIPTION OF CONTROL SYSTEM
AND SEQUENCE OF OPERATION
2.1 If the main neon is on with a demand for
heat to the system (radiators etc ) 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 The spark ignition system is powered which
in turn commences the spark ignitor to
operate and light the burner. At this point
the ignition board opens the gas valve to light
the burner.
2.2.1 When the electrode/sensor senses the signal
of the burner the spark ignition stops.
2.2.2 From the minimum gas rate setting
the boiler increases to the maximum
permissible pressure over a period
of 3 to 4 seconds and will remain at
its maximum required power until its
maximum regulated temperature.
2.2.3 When the boiler thermostat is satisfied the
boiler will go to rest mode, the burner is shut
down and the pressure switch will return
back to its rest mode.
2.2.4 As the heating sensor reaches temperature
the gas burner power modulates down,
the fan speed. When starting, the fan will
always start at maximum speed.
2.2.5 The boiler is fitted with an anti-cycling
device on the control board. This delays
the boiler from re-firing over a 2/5 minute
period.
2.3 GENERAL FUNCTION
2.3.1 The gas valve boiler output settings may
be adjusted to requirements other than
factory settings
2.3.2 Air is drawn by the fan for combustion
2.3.3 he fan also forces exhaust gas through the flue
to the outside, this creates a lesser pressure
in the sealed combustion chamber, thus
sucking in combustion air through the inlet duct
2.3.4 The boiler water temperature is automatically
controlled by a built in thermostat
2.3.5 Interior space temperature is set by the room
thermostat to be installed in the heating system The
boiler already carries connection terminals for this
thermostat, as well as for a timeclock The burner
continues to operate until it is stopped by the
timer or one of the thermostats
2.3.6 When the room thermostats and/or timer intervene
the burner shuts down The fan stops and the pump
off via the pump overrun.
2.3.7 The condensate trap is fitted with a blockage safety
sensor This prevents the boiler operating should there
be a blockage in the condensate discharge trap.
2.3.8 An overheat cut off thermostat set slightly higher
than the heat thermostat acts to turn off the burner to
resetable “lockout” (Fig 50) .
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 installer in
accordance with the above regulations and these
installation instructions. All CORGI registered
installers carry a CORGI I.D. card and have a
registration number. Both should be recorded in
your boiler log book. You can check your installer
by calling CORGI direct on: 01256 732300.
Failureto 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
theboilerandflueisthecorrecttypeforinstallation.
The installation of the boiler MUST be in
accordancewiththelatestI.E.E. (BS 7671) Wiring
Regulations, local building regulations, bye-laws
ofthelocalwaterauthority,thebuildingregulations
and the Building Standards (Scotland) and any
relevant requirements of the local authority.
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 install 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

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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 Regulations1989
The manufacturer’s notes must NOT
be taken, in any way, as overriding
statutory obligations
IMPORTANTTheseappliancesare CEcer-
tificated for safety and performance It
is, therefore, important that no external
control devices e g flue dampers,
economisers etc,are directly connected
tothisapplianceunlesscovered bythese
Installation and Service Instructions or
asotherwiserecommendedbyRavenheat
in writing If in doubt please enquire
Any directconnection ofa controldevice not
approvedbyRavenheatcouldinvalidatethe
certificationandthenormalappliancewar-
ranty It could also infringe the Gas Safety
regulations and the above regulations
NOTE The Ravenheat HE Primary boiler
has been tested and examined by BG,and
is certified to comply with PrEN 483
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 HE Primary Boiler
mustbeasfollowsThe position of installa-
tionshouldbewithinthe building,unless
otherwise protected by suitable enclosure
Adequate space for installation, servicing
and air circulation around boiler must
be allowed for.
The Ravenheat HE Primary must be fitted
on a flat and vertical wall capable of ade-
quately supporting the weight of the boiler
and any ancillary equipment
The appliance may be installed on a
combustible wall subject to the require-
ments of the Local Authority and Building
Regulations.
LPG versions ofthis appliance shallnot
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 ser-
vicing, must be left around the boiler.
for brass fittings are used, and have a capa-
bility to accomodate hexagon sizes up to 50
mm.
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 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 5440 1 Flues (for gas appliances
of rated input not exceeding
60 kW)
PRESSURE DROPACROSS APPLIANCE
Fig.5
OVERALL DIMENSION Fig.3

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SECTION 3 TECHNICAL DATA HE PRIMARY AAA
TABLE 1 NATURAL GAS (G 20) І2H - П2H3+
NOMINAL HEAT INPUT NET QMS 22.6 kW
MINIMUM HEAT INPUT NET 11.6 kW
NOMINAL HEAT OUTPUT 22.3 kW
MINIMUN HEAT OUTPUT CONDENSING 23.9 kW
NOMINAL HEAT OUTPUT 11.4 kW
MINIMUM HEAT OUTPUT CONDENSING 12.3 kW
GAS RATE Max 2.3 m3/h
AFTER 10 MINUTES min 1.2 m3/h
INLET PRESSURE 20 mbar
BURNER PRESSURE max 10.5 mbar
min 2.0 mbar
BURNER INJECTORS Nr. 13 x 1.25
ELECTRICAL SUPPLY 230V ~ 50 Hz
POWER CONSUMPTION 60 W
EXTERNAL FUSE RATING 3 A
INTERNAL FUSE 2 A
DRY WEIGHT 35 kg
WATER CONTENT C H 0.5 litre
GAS SUPPLY CONNECTION C H 15 mm
FLOW CONNECTION C H 22 mm
RETURN CONNECTION C H 22 mm
CONDENSATION DRAIN 3/4” (21.5 mm) push fit over flow
SEALED WATER SYSTEM C.H.
MAX PRESSURE PMS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX - 85 °C min - Off
FLUE OUTLET NOM. DIAMETER 60/100 mm specially supplied with boilers
DESTINATION : AT, DK, Fl, SE CATEGORY I2H
DESTINATION: GB, IE, CH, ES, IT, PT CATEGORY II2H3+
FLUE TYPE: C12 - C32 - C52 NOX 4

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HE PRIMARY AAA
TABLE 1/A LPG (G 30 - G 31) І3p - П2H3+
NOMINAL HEAT INPUT NET QMS 22.6 kW
MINIMUM HEAT INPUT NET 11.6 kW
NOMINAL HEAT OUTPUT 22.3 kW
MINIMUN HEAT OUTPUT CONDENSING 23.9 kW
NOMINAL HEAT OUTPUT 11.4 kW
MINIMUM HEAT OUTPUT CONDENSING 12.3 kW
GAS RATE Max G31 0.9 m3/h G30 0.7 m3/h
AFTER 10 MINUTES min 0.4 m3/h 0.3 m3/h
INLET PRESSURE G31 37 mbar G 30 28-30 mbar
BURNER PRESSURE Max G 31 35. 4 mbar G 30 27. 3 mbar
min 7. 3 mbar 7. 0 mbar
BURNER INJECTORS Nr. 13 x 0.75
ELECTRICAL SUPPLY 230V ~ 50 Hz
POWER CONSUMPTION 60 W
EXTERNAL FUSE RATING 3 A
INTERNAL FUSE 2 A
DRY WEIGHT 35 kg
WATER CONTENT C H 0.5 litre
GAS SUPPLY CONNECTION C H 15 mm
FLOW CONNECTION C H 22 mm
RETURN CONNECTION C H 22 mm
CONDENSATION DRAIN 3/4” (21.5 mm) push fit over flow
SEALED WATER SYSTEM C. H.
MAX PRESSURE PMS 2. 5 bar
MINIMUM WORKING PRESSURE 0. 5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX - 85 °C min - Off
FLUE OUTLET NOM. DIAMETER 60/100 mm specially supplied with boilers
DESTINATION : BE, FR CATEGORY I3p
DESTINATION : GB, IE, CH, ES, IT, PT CATEGORY II2H3+
FLUE TYPE : C12 - C32 - C52 NOX 4

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A smaller size than the boiler inlet
gas connection should not be used The
complete installation must be tested for
soundness as described in the above Code
N B: if the gas supply for the boiler serves
other appliances ensure an adequate
supply is available both to the boiler and the
other appliances when they are in use at
the same time.
4.6 FLUE SYSTEM
4.4.1 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 considered.
The terminal must not be closer than 25 mm (1
in) to any combustible material For protection
of combustibles, refer to BS 5440.1.
Where a flue terminal is installed less than
1000 mm from a plastic, or painted gutter, or
500 mm from painted eaves, an aluminium
shield 1000 mm long, should be fitted to the
underside of the gutter or painted surface
Pluming will occur at the terminal so, where
possible, terminal positions which could
cause a nuisance should be avoided The
flue must be installed in accordance with the
recommendations of BS 5440.Part 1.
IMPORTANT:Thefollowingnotesareintended
for general guidance.
The boiler MUST be installed so that the
terminal is exposed to external air.
It is important that the position of the terminal
allows the free passage of air across it at all
times.
Minimum acceptable spacing from the ter-
minal to obstructions and ventilation opening
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.
IMPORTANT NOTES
For greater flue lengths see twin flue
Instructions.
Flue must be positioned in a place not likely
to cause a nuisance.
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
4.4 IMPORTANT NOTICE
4.4.1 If the 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 boiler may be installed in any room
or internal space, although particular
attention is drawn to the requirements of
thecurrentI.E.EWiringRegulations,and
in Scotland the electrical provisions of-
the Building Regulations applicable in
Scotland, with respect to the installation
of the combination boiler in a room or
internalspacecontaining abathorshower
Where a room sealed appliance is
installed in a room containing a bath or
shower, any electrical switch or appliance
control, utilising mains electricity should
be so situated that it cannot be touched by
a person using a bath or shower.
Acompartmentusedtoenclosetheboiler
MUSTbedesignedandconstructedspecif-
icallyforthispurposeanexistingcupboard,
or compartment, may be used provided it
is modified accordingly. Samples of the
CSI boiler have been examined by BG
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
Electra Magnetic Compatibility Directive
89/336/EEC and are therefore permitted
to carry the CE Mark .
The appliance has been tested and
approved by the WRc as meeting
the requirements of G3 and L of the
Building regulations and water Bylaws
Scheme- Approved Products.
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 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.
10

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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 maximun height
of 40 metres.
For further details see vertical flue installation
instructions.
4.7 AIR SUPPLY
4.7.1 The following notes are intended for general
guidance.
The room sealed fan flued boiler does not re
quire a permanent air vent for combustion air
supply.
Where installed in a cupboard or compartment
ventilation is not required.
CONDENSATE DRAIN
A condensate drain is provided on the boiler
This drain must be connected to a drainage
pointAll pipework and fittings in the condesate
drainage system MUST be made of plastic-no
other materials may be used Discharge of
condensate DD X 189 1990 Y.
The drain outlet on the boiler is standard
3/4” (21 5 mm) push fit overflow pipe.
NOTE:Condensate drain pipework must
never be less than 15 mm.
Important: any external runs must be carried
out in 1 1/4 (32 mm) wastepipe .
A fall of 2 5° (45 mm/m) all runs must have.
4.8 WATER CIRCULATION (central heating)
4.81 Detailed recommendations are given in BS
6798:1897/ 5449 : 1990 (for smallbore
and microbore central heating systems).
The following notes are given for general
guidance.
4.8.2 Pipework
Copper tubing to BS 2871 1.1.1971 is reco-
mended for water pipes Jointing should be
either with capillary soldered or with
compression fittings.
Where possible pipes should have a gradient
to ensure air is carried naturally to air release
points and water flows naturally to drain taps,
It should be ensured as far as possible that
the appliance heat exchanger is not a natural
collecting point for air.
Except where providing useful heat, pipes
should be insulated to prevent heat loss and
to avoid freezing Particular attention should
be paid to pipes passing through ventilated
spaces in roofs and under floors.
Fig 6
Terminal position for fan assisted boiler
(minimum distance) mm
11
Fig.6A
A- Directly below an open window or other 300
opening (e.g. air brick)
B - Below gutters, soil pipes or drain pipes 75
C - Below eaves 150
D - Below balconies or car port roof 200
E - From vertical drain pipes and soil pipes 150
F - From internal or external corners 300
G - Above ground or below balcony level 300
H - From a surface facing a terminal 600
I - From a terminal facing a terminal 1200
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
M - From adjacent wall to flue 300

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WATER SYSTEM
4.8.2.1 WATER SYSTEM
For an open (vented) system the boiler
mustbesuppliedfromanunrestricted
watersupplytakenfromafeedandexpan-
sion tank (minimum 22 litre 5 gall)
capacity situated at a maximum
height of 27 5 metre (90ft) above
the boiler The cold feed supply must
be 15 mm minimum size It is impor-
tant that the relative positions of the
pump, cold feed and open vent See Fig
6D
4.8.2.2 CILINDER
The hot water cylinder must be a
double feed (fully indirect) type
4.8.2.3 SEALED WATER SYSTEMS
The installation should comply with
the appropriate requirements of BS5449
Part 1 and BS6798, see Fig 6EAll valves
and fittings must be suitable for use on
sealed systems
4.8.2.4 SAFETY VALVE
Thesafety valvemustbe fitted ina sealed
system The safety valve must conform
to BS6759 Part 1 and be fitted to the
requirements of BS6798
4.8.2.5 EXPANSION VESSEL
A diaphragm type expansion vessel,
conforming to BS4814 must be connected
at a point close to the inlet side of the
circulating pump, see Fig 6E or as laid
down by the manufacturer
The expansion vessel must suit the volume
of water in the system, seeBS5449 Part 1
clause 25 for details The charge pressure
must not be less than static head i e
the height of the highest point of the
system ABOVE the expansion vessel
The expansion vessel should have
sufficient capacity to accept the volume
change when the water is heated from 10
°C to 110 °C Refer to BS5449 Part 1
for specific details See Table 3
4.8.2.6 PRESSURE GAUGE
Apressure gauge with set pointer and cov-
ering at least the range 0 to 4 bar (0 to 60
lb/in2)shallbepermanentlyfittedtothesys-
temin aposition itcanbe seenwhen carry-
ing out the filling operation
4.8.2.7 SYSTEM DESIGN
Fig 6A illustrates typical heating only lay-
outFigs6Band 6Cillustrate typicallayout
with ‘Y’ or ‘S’ plan system
4.8.3 The water through the appliance heat
exchanger circuitmust exceed themin 184
gals min (503 It/h) when the burner is firing
Itis important toensurethat this rateis
achievedwhensectionsofthesystemare
shut off either manually or bu automatic

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The static head available from the
cistern should be adequate to provide
the initial system design pressure.
Thecoldfeedpipefromthecisternshould
includeanon-returnvalve,andastop-valve
withanautomaticairventconnectedbe-
tween them, with the stop valve being locat-
ed,betweenthecisternandtheautomatic
airventThestopvalvemayremainopen
during normal operation of the system,
if automatic water make-up is required
Booster pump method (Fig 8).
controls Therefore aby-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 evene cause the safety thermostat to trip
4.8.4. 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 accordance with BS 2870 1980.
4.8.5 Air release points
Thesemustbefitted atall highpoints where
air will naturally collect, and must be sited to
facilitate complete fitting of the system.
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
nootherpurpose, via a ballvalve perma-
nently connected directly to a service
pipe and/or cold water distributing pipe .

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The system may be filled through a self
containedunitcomprisingofacisternpres-
sureboosterpumpifrequiredandifneces-
saryan automaticpressure reducingvalve
orflowrestrictorThecisternshouldbesup-
pliedthroughatemporary connectionfrom
a service pipe or cold water distributing
pipeTheunitmayremainpermanentlycon-
nectedtotheheatingsystemtoprovidelim-
ited automatic water make up
Mains topping up method (Fig 9)
Herethetemporary connection is supplied
from a service pipe, or distributing pipe,
whichalsosuppliesotherdraw-offpointsat
a lower level
A combined double check valve shall be
installed upstream of the draw-off point,
throughatemporaryhoseconnectionfrom
a tap supplied from the mains, where the
mains pressure is excessive a pressure
reducingvalveshallbeusedtomakefilling
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
hosefromthedrawofftapshallbecon-
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 offillingthe systemAvailable
from your supplier
PROVISIONS FOR MAKE UP WATER
(Fig 7)
Provisioncanbemadefor replacingwater
loss from the system either
A) from a manually filled made up bottle
withareadilyvisible water levelThebottle
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
Ifthecapacityofthecentralheatingsystem
14
Safety
valve setting (bar) 30
Vessel charge
pressure (bar) 05 10 15
Initial system
pressure (bar) 05 10 15 20 10 15 20 15 20
Total water
content of system EXPANSION VESSELVOLUME (LITRES)
Litres
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
475
500
21
42
63
83
104
125
146
167
187
208
229
250
270
291
31 2
333
354
375
396
41 6
35
70
105
140
175
210
245
280
315
350
385
420
455
490
525
560
595
630
665
700
65
129
194
259
324
388
453
518
583
647
71 2
777
841
906
971
1036
1101
1165
1230
1259
137
275
413
551
689
826
964
1102
1240
1377
1515
1653
1791
1928
2066
2204
2392
2479
2617
2755
27
54
82
109
136
163
191
218
245
272
300
327
357
381
409
436
463
490
518
545
47
95
142
190
237
285
332
380
427
475
52.2
570
617
665
71 2
760
807
855
902
950
103
206
309
412
515
618
721
824
927
1030
1133
1236
1339
1442
1545
1648
1751
1854
1957
2060
39
78
117
156
195
234
273
312
351
390
429
468
507
546
585
624
663
702
741
780
83
165
248
331
413
496
579
662
745
827
910
993
1076
1158
1241
1324
1407
1489
1572
1655
For system volumes
other than those given
above, multiply the
system volume by
the factor across
00833 0140 0259 0551 0109 0190 0412 0156 0331
SIZING OF EXPANSION VESSEL TABLE 3
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

Supplied By www.heating spares.co Tel. [phone]
should exceed 110 litres, an additional
vessel should be installed on the return
to the combination boiler from the heating
system(Fig 7) Guidance on vessel sizing
is given in (Table 3).
Reference should be made to British
Gas Publications «Material and
Installation Specifications for Domestic
Central Heating and Hot Water» Draining
taps should be at least 1/2” in BSP
nominal size and be in accordance with
BS 2879.
4.8.9 Installation to an existing central heating
system
Before installing a new boiler to an existing
system, flush out the old system with a rec-
ommended descaling agent.
It is most important that the correct concen-
tration of the water treatment product
is maintained in accordance with the
manufacturers’ instructions .
If the boiler is installed in an existing system
anyunsuitable additives MUST beremoved
by thorough cleansing BS 7593 1992
details the steps necessary to clean
domestic central heating system Also
check pipework and renew any corroded
pipework or fittings Valve glands must be
repacked or replaced wherever neces-
saryandanydefectivecontrolsexchanged.
WATER TREATMENT
This boiler has a secondary
ALUMINIUM alloy heat exchanger.
Ravenheat recommended only the
use of FERNOX-COPAL SENTINEL
X100 or SALAMANDER CURROSION
GUARD water treatment products,
which must be used in accordance
with the manufacturers instructions
For further information contact
Fernox Manufacturing Co Ltd
Tel [phone]
Sentinel Division Betz Dearborn Ltd
Tel [phone]
Salamander (Eng)Ltd
Tel [phone]
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. Regulations and local
regulationswhichapplyTheRavenheat
boiler is supplied for connection
to a 230 V ~ 50 Hz single phase
supply The supply must be fused at 3A.
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
Thepointofconnectiontotheelectricity
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
applianceisinstalledin aVERTICAL
POSITION, with the flue air duct
passing through the wall Make sure
flue slopes 2.5° down towards
the boiler that is 45 mm/m fall per
metre of flue length.
15

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Fig. 12
Fig. 13
Fig. 14
16
OPTIONAL EXTRAS:
STRAIGHT HEADER Box containing (Fig 13) :
57 - Straight header
59 - Rubber seal Ø 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 Ø 60
63 - Air intake duct extension
64 - Flue exhaust duct extension
65 - Pipe centering spring
5.2 DELIVERY
5.2.1 The appliance carton containing (Fig.15)
a) boiler fully assembled
b) installation instructions and
user instructions
c) white paper template
d) terminal cover plate
Polythene bag containing
a) 1-1/2” BSP Union Gas Cock
b) 2-22 mm flanged copper tails complete
with 3/4” brass nuts and washers
c) 4 coach bolts and wall plugs
screws and dowels.
WARNING
Maximum allowable flue length 2.5 m
maximum No 2x1000 mm
Flue duct extension used with standard flue
Horizontal HE flue kit carton
containing (Optional) (Fig 12)
57- Flue bend assembly
58- Header gasket
59- Rubber seal Ø 60
60- Air intake duct
61- Flue exhaust duct
62- Terminal
65- Pipe centering spring
66- Flue gas sample point
127-Terminal Cover Plate

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17
Fig. 18

Supplied By www.heating spares.co Tel. [phone]
18
5.4 POSITIONING OF THE BOILER
5.41 Remove the 4 screws that secure the upper
and the lower part of the casing(Fig.19-20).
5.4.2 Unscrew the 4 screws that fasten the lower
grating on the casing and remove it from the
sides of the casing (Fig.20)
5.4.2.1 Carefully slide the casing forward to lift off.
(Fig 21).
5.4.2.2 Make sure that the casing and screws are put
to one side in a safe place.
5.4.3 Lifting instrument panel (not necessary
for installation).
- Unscrew the 2 screws that fasten the
instrument panel.
- Lift the instrument panel in order to
detach it from the sides, and lift it up
by rotating it on its own hinges.
Make sure the casing screws are put to
one side in a safe place.
Fig. 19
Fig. 20
Fig. 21
Fig. 28
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.
5.5 INSTALLING THE APPLIANCE FOR
REAR FLUE OUTLET
5.5.1 Use adhesive tape to attach the template to the
wall, making sure that the centre line is vertical
- Mark the 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 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).

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INTAKE AND EXHAUST TERMINAL COMPONENTS
19
5.5.2 Locate the rubber Ø 100 and Ø 60 into the flue
elbow header (Fig 30).
- 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.
KEY
56 - Straight header
57 - Elbow header
58- Header gasket
59 - Rubber seal Ø 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
Fig. 30
Fig. 32
Fig. 31
Fig. 29
IMPORTANT
CORRECT FLUE MUST BE USED .
Check Spigot Distance ( approx 35mm )
on STARTER HEADER.
Ensure Flue is fitted together correctly,
supported and firmly secured . (Fig.29).

Supplied By www.heating spares.co Tel. [phone]
Fig 37
20
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), locating
onto the top coach bolts Fit the two lower
coach bolts and tighten all four securing
bolts.
5.5.6 Working above the boiler pull the flue exhaust
duct towards the boiler in order to engage
tube item 61 into its header 57 ( Fig.31).
Position flue into elbow header and push so
as to locate inner and outer flue correctly
ensuring good seal is made with o-rings.
5.5.7 Fit terminal cover plate and terminal guard.
(Fig.37)
5.5.8 Extension kits are available on order for flue
extension of up to 2.5 metres total length
(Fig.31).
Fig 36
Fig.35
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.

Supplied By www.heating spares.co Tel. [phone]
21
5.5.9 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 towardstheexhaust 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
widenedortaperedend.Tomeasurethepipeline
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 available
from Ravenheat Manufacturing and should
be used to support flue length at least every
1.8 metre preferably at each joint this bracket
should be secured to wall and flue duct.
5.5.10 INLINE FLUE BEND
Measurethedistancebetweenthefluebendsor
theflue/terminalassembly.Themeasurements
should be taken from the outer edge of the flue
and bend(Fig.39). IMPORTANT: Inline flue
bend - 1680 mm must be deducted from
overall length for each 90° bend - 1680 mm
must be deducted from overall length for
each 135° bend (Fig 39).
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 order
as in sect. 5.4.3.
3) Refit the lower grating .
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. 28), measure the
distance Y between the centre of flue duct
hole to the corner Detach the template
from wall.
- Use a dia 10 mm drill to make the 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
CSI PRIMARY
F = 140 mm
G = 275 mm
5.7 INSTALLING THE APPLIANCE FOR SIDE
FLUE OUTLET (Fig. 28)