Ravenheat Little Star LS 80 User guide

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ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER
WITHOUT TIMER
LS 80 G.C. N
o
4758129 (NAT.) - 4758131 (LPG)
LS 100 G.C. N
o
4758133 (NAT.) - 4758135 (LPG)
NATURAL GAS (G20) -I 2H - II 2H3+
LPG (G30 - G31) - I 3+- II 2H3+
Fanned Combination Boiler
Listed by The United Kingdom Water
Fitting Byelaws Scheme
WITH TIMER
LS 80T G.C. N
o
4758130 (NAT.) - 4758132 (LPG)
LS 1OOT G.C. N
o
4758134 (NAT.) - 4758136 (LPG)
NATURAL GAS (G20) - I 2H - II 2H3+
LPG (G30 - G31) - I 3+- II 2H3+
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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THE LITTLE STAR - AUTOMATIC MODULATING BOILER
FOR CENTRAL HEATING AND DOMESTIC HOT WATER
The new small super high efficiency turbo-modulating boiler is designed to meet domestic hot water
and central heating requirements at super high efficiency, unheard of only a few years ago.
POSITION
The appliance is extremely versatile as it can be fitted in almost any room. The appliance is room sealed,
there is no contact between combustion chamber and living accommodation. This guarantees maximum
safety and efficiency. Indeed, our depression/combustion front cover has been designed to fit achieving
maximum air tight seal which ensures maximum efficiency and safety - something which Ravenheat take
great pride in.
Each boiler has been designed and manufactured in our modern plant to exacting IS0 9001 discipline,
all boilers carry full CE marking of approval. Technical sales and commercial service are available
throughout the UK and Europe. This product is guaranteed by Ravenheat Manufacturing, Chartists
Way, Morley, LEEDS, LS27 9ET. Telephone No [phone].
BASIC COMPONENTS - (See figure 1)
.
Guarantee is a full 12 months from date of purchase providing the appliance has been fitted in accor-
dance with these instructions and relevant codes of practice.
MAJOR COMPONENTS
- Gas valve with flame modulator.
- Variable head pump suitable for any type of central heating system.
- Main burner with flame stabiliser designed to operate under all thermal conditions.
- Primary heat exchanger constructed from copper.
- Stainless steel plate heat exchanger for super high heat transfer to domestic hot water.
- High reliability diverter valve with ethylene propylene diaphragm permitting primary flow circu-
lation in the boiler during domestic hot water supply.
- Built in frost protection.
- Printed circuit board designed to connect to room stat and/or timer/frost stat.
- Aesthetically pleasing panels and controls.
- On/Off ball valves for shutting off gas central heating and domestic hot water circuits.
- Safety relief valve (for safety discharge).
- Programmable 7 day module with digital display (optional model).
All front panel controls not often used have been hidden behind a lift up flap. This means neat design
and easy clean panels.
COSHH - CONTROL OF SUBSTANCES HARMFUL TO HEALTH
IMPORTANT
This appliance contains materials that are indicated below.
It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn
when handling, where applicable, the pertinent parts that contain any materials that could be inter-
preted 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

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SECTIONS:
TABLE OF CONTENTS
INTRODUCTION
2
3
4
5
6
7
8
9
10
11
GENERAL LAYOUT
Fig. 1
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
.
KEY
1 - Heat exchanger
3 - Burner
4 - Ignition electrode
5 - Flue restriction ring
7 - Ignition board
9 - Detection electrode
11 - Frame
12 - Modulating gas valve
15 - Heating control
16 - Hot water control
30 - Water pressure gauge
17 - D.H.W. sensor
33 - Main switch
18 - Water pressure switch (heating circuit)
34 - C.H. Sensor
22 - Overheat cut off thermostat
36 - Fan
23 - Safety relief systems 37 - Expansion tank
24 - Three way valve
38 - Sealed chamber
26 - Auto air vent valve 45 - Combustion chamber
28 - Air pressure switch
50 - Flue gas exhaust hood
29 - Circulation pump
105 - Timer
4

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OPERATING
Fig. 2
SCHEME
KEY
1 - Heat exchanger
2 - Heat exchanger for D.H.W. water
3 - Burner
4 - Ignition electrode
5 - Flue restriction ring
6 - Elbow header
7 - Electronic ignition
8 - Twin header
9 - Detection electrode
10 - Straight header
12 - Modulating gas valve
15 - Heating control potentiometer
16 - Hot water control potentiometer
17 - Water pressure switch
18 - Overheat cut-off thermostat
20 - Gas service cock
21 - Compression ball valves
23 - Safety relief system
24 -Three way valve
26 - Auto air vent valve
28 - Pressure switch
29 - Circulating pump
30 - Water pressure gauge
36 - Fan
37 - Expansion tank
38 - Sealed chamber
5

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SECTION 1 INTRODUCTION
1.1 The Ravenheat boiler is for the use of cen-
tral and domestic hot water combined in
one unit.
It is fitted with an automatic domestic hot
water priority valve.
A winter/summer selector switch is fitted to
the left hand side of control panel. With the
only summer position being for domestic hot
water.
Winter position being for central heating
with domestic hot water priority. The boiler
is equipped with a front cover which can be
removed for servicing. The data badge with
technical data is placed on front cover.
1.2 Fig. 1 Illustrates the general layout of
components.
Fig. 2 Illustrates the operating principles
described in section 2.
SECTION 2
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
DESCRIPTION OF CONTROL SYSTEM
AND SEQUENCE OF OPERATION
Domestic hot water mode
When the appliance is in rest mode with the
mains neon switch on. Switch the sum-
mer/winter switch in the summer Position,
making sure the heating circuit is charged
with water (above 1 bar). When the domes-
tic hot water tap is turned on, the boiler will
function in the following sequence:
The pump starts.
The control board sensors.
The fan operates via the pressure switch and
sends a signal back to the ignition board that
the fan is running at maximum speed.
The spark ignition system is powered which
in turn commences the spark igniter to
operate and light the burner.
At this point the ignition board opens the gas
valve to light the burner.
When the electrode/sensor senses the sig-
nal the burner the spark igniter stops.
From the minimum gas rate setting the boil-
er increases to the maximum permissible
pressure over a period of 3 to 4 seconds and
will remain at its maximum required power
until its maximum regulated temperature.
When the domestic hot water tap is closed
the diverter valve goes back into rest mode,
the main burner is shut down. The pump
and fan are also switched off, the pressure
switch returning to its rest mode.
2.2.6
2.2.7
2.2.8
2.2.9
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
Central heating mode
If the switch is positioned on winter with a
demand for heat to supply radiators, etc.
With heating circuit fully charged so as to
operate the low water sensor device the
boiler will start in the same way as domes-
tic hot water mode but with slightly differing
time delay in that it will start on minimum
and remain at this level for about 1 minute,
after which the flame will lift to its maximum
setting as governed by a potentiometer
range rates the heating circuit between
maximum and minimum power.
On the control panel are mounted two
potentiometers (thermostats) these control
the temperature. One is for domestic hot
water and the other for heating.
The boiler is fitted with an anti-cycling
device on the control board. This delays the
boiler from re-firing over a 2.5 minute period
when in heating mode. The domestic hot
water will always take priority and is unaf-
fected by the anti-cycling device.
GENERAL FUNCTION
Central Heating Mode
A potentiometer is installed on the electric
circuit board permits regulation of the boiler
to partial heating requirements, between
the factory setting.
Air is drawn by the fan for combustion.
The fan also forces exhaust gas through the
flue to the outside, this creates a lesser
pressure in the sealed combustion cham-
ber, thus sucking in combustion air, through
the inlet duct.
The boiler water temperature is automati-
cally controlled by a built in thermostat.
Interior space temperature is set by the
room thermostat to be installed in the heat-
ing system. The boiler already carries con-
nection terminals for this thermostat, as
well as for a timeclock. The burner will con-
tinue to operate until it is stopped by the
timer or one of the thermostats.
When the internal C.H. temperature sensor
intervenes the main burner shuts down. The
fan stops but the pump continues to oper-
ate.
When the room thermostats intervene the
main burner shuts down. The fan stops and
the pump turns off.
6

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2.4
2.4.1
Domestic hot water mode,
The heat exchanger in the D.H.W. circuit is
a stainless steel plate heat exchanger water
2.4.4 When D.H.W. is no longer called for the boil-
er automatically returns to the central heat-
ing mode.
2.4.5
to water, and domestic water is heated by Switch la Fig. 50 in the summer position.
converting the water in the central heating The boiler functions like an automatic gas
circuit. The transference of heat is very high hot water heater. When D.H.W. is no longer
because the two fluids move in a counter required the main burner fan and pump
direction flow to each other. immediately turn off.
2.4.2 Switch la Fig. 50 in the winter position. This also takes place when switch
When a hot water tap is turned on a la Fig. 50 is on winter if there is no demand
diaphragm diverter valve excludes the cen- for heat to the central heating system or
tral heating circuit, the boiler automatically until the room thermostat/time clock
modulates to maintain the domestic hot demands for heat to the central heating cir-
water at a constant temperature.
cuit.
Water temperature can be regulated using
the D.H.W. thermostat located on the front
control panel.
3.1 SAFETY DEVICE
2.4.3 When domestic hot water is being drawn
the main burner and pump perform as they In both central heating and domestic hot
do during central heating except that the water mode safe operating is ensured by:
burner is commanded by the D.H.W. ther- - A differential pressure switch which shuts
mostat.
off the main burner if the fan stops or the
flue or combustion air intake duct is
obstructed.
OVERALL DIMENSION
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) item 3.
3.1.3 A safety valve fitted on the
central heating circuit set at
43 psi (3 bar).
A heating circuit (low water)
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SECTION 3 TECHNICAL DATA
TABLE 1
NATURAL GAS (G 20) I 2H
NOMINAL HEAT INPUT NET QMS
26.1 kW
MINIMUM HEAT INPUT NET
NOMINAL HEAT OUTPUT
MINIMUM HEAT OUTPUT
13.5 kW
24.1 kW
11.6 kW
GAS RATE max 2.6 m
3
/h
AFTER 10 MINUTES min
1.3 m3/h
INLET PRESSURE 20 mbar
BURNER PRESSURE C.H.
max 8.1 mbar
min 1.5 mbar
MAIN BURNER INJECTORS Nr. 13 x 1.35
ELECTRICAL SUPPLY 230 V - 50 HZ
POWER CONSUMPTION 150w
EXTERNAL FUSE RATING 3 A
INTERNAL FUSE 250 mA 2 A
(20 mm to BS 4265)
DRY WEIGHT
39.3 kg
WATER CONTENT C.H. 1.5 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.
SAFETY DISCHARGE C.H.
15 mm compression isolating valve
22 mm compression isolating valve
22 mm compression isolating valve
15 mm compression isolating valve
15 mm copper pipe
15 mm copper pipe
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL
SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85 °C
85 LITRE
MIN 45 °C
DESIGN FLOW RATE 1033 l/h 20 °C RISE
MINIMUM FLOW RATE C.H. 650 l/h
D.H.W. FLOW RATE 30 °C rise 11.5 l/min
D.H.W. FLOW RATE 35 °C rise 9.9 l/min
D.H.W. FLOW RATE 40 °C rise
8.6 l/min (2.0 gals/min) 10 °C inlet temperature
D.H.W.TEMPERATURE max 65°C min 35°C
BURNER PRESSURE D.H.W. max 8.1 mbar
min 1.5 mbar
Q
MW Input Net
max 26.1 kW
min 13.5 kW
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 RATE3 l/min (0.66 gals/min)
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: AT. CH. DK. ES. FI. GB. IE. IT. PT. SE.
FLUE TYPE - C 12 C32 C52
CATEGORY I 2H
NOX 2
SEDBUK RATING
79.61 %
BAND D
C12 C32 = ORIFICE PLATE DM 77
C 52 =
ORIFICE PLATE DM 75
8

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SECTION 3 TECHNICAL DATA
TABLE 1/A
LPG (G 30 - G 31) I 3+
NOMINAL HEAT INPUT NET QMS
26.1 kW
MINIMUM HEAT INPUT NET
13.5 kW
NOMINAL HEAT OUTPUT
24.1 kW
MINIMUM HEAT OUTPUT
11.6 kW
GAS RATE max G 31
0.95 m
3
/h
G 30 0.79
m
3
/h
AFTER 10 MINUTES min
0.5 m
3
/h
0.4
m
3
/h
INLET PRESSURE 37 mbar G 31
28 -
30 mbar
G 30
BURNER max
G 31
35.4 mbar
G 30 27.3
mbar
PRESSURE
min
9.6 mbar 6.6 mbar
MAIN
BURNER INJECTORS Nr. 13 x 0.75
ELECTRICAL SUPPLY 230 V - 50 HZ
POWER CONSUMPTION
150 W
EXTERNAL FUSE RATING
3A
INTERNAL FUSE 250 mA - 2 A
(20 mm to
DRY WEIGHT
39.3 kg
WATER CONTENT C.H.
1.5 litre
BS 4265)
WATER CONTENT OHW
0.5 litre
GAS SUPPLY CONNECTION 15 mm compression isolating valve
FLOW CONNECTION C.H. 22 mm compression isolating valve
RETURN CONNECTION C.H. 22 mm compression isolating valve
INLET CONNECTION D.H.W. 15 mm compression isolating valve
OUTLET CONNECTION D.H.W. 15 mm copper pipe
SAFETY DISCHARGE C.H. 15 mm copper pipe
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 85 LITRES
SEALED WATER SYSTEM C.H.
MAX PRESSURE PMS
2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
6 LITRES EXPANSION
VESSEL PRE-CHARGE-PRESSURE
0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85 °C
MIN 45 °C
DESIGN FLOW RATE DHW 1033 I/h 20 °C RISE
MINIMUM FLOW RATE C.H./650 Lts/h (111 gals/h)
D.H.W. FLOW RATE 30 °C rise D 11.5 I/min
D.H.W. FLOW RATE 35 °C rise
9.9 I/min
D.H.W. FLOW RATE 40 °C rise
8.6 I/min
D.H.W.TEMPERATURE
max 65 °C
min 35 °C
10 °C inlet temperature
BURNER PRESSURE D.H.W. max 8.1 mbar min 1.5 mbar
Q MW Input Net
max 26.1 kW
min 13.5 kW
D.H.W. PRESSURE
max 10 bar
D.H.W. PRESSURE PMW
min 0.8 bar
D.H.W. MINIMUM FLOW RATE3 l/min
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: BE. CH. ES. FR. GB. IE. IT. PT.
FLUE TYPE C12 - C32 - C52
CATEGORY l 3+ NOX 2
SEDBUK RATING 81.88 % BAND D
C12 C32 ORIFICE PLATE DM 76
C52 =
ORIFICE PLATE DM 74
9

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SECTION 3 TECHNICAL DATA LS 100 (T)
TABLE 3 NATURAL GAS (G 20) I 2H -II 2H3+
NOMINAL HEAT INPUT NET QMS
31.4 kW
MINIMUM HEAT INPUT NET
13.0 kW
NOMINAL HEAT OUTPUT
29.0 kW
MINIMUM HEAT OUTPUT
11.2 kW
GAS RATE max 3.2 m
3
/h
AFTER 10 MINUTES min
1.25 m
3
/h
INLET PRESSURE 20 mbar
BURNER PRESSURE C.H.
max 12.5 mbar
min
1.4 mbar
MAIN BURNER INJECTORS Nr. 15 x 1.25 ,
ELECTRICAL SUPPLY 230V-50HZ
POWER CONSUMPTION 150w
EXTERNAL FUSE RATING
3A
INTERNAL FUSE 250 mA 2 A (20 mm to BS 4265)
DRY WEIGHT 41 .a kg
WATER CONTENT C.H. 1.7 litre
WATER CONTENT
0.5 litre
GAS SUPPLY CONNECTION 15 mm compression isolating valve
FLOW CONNECTION C.H. 22 mm compression isolating valve
RETURN CONNECTION C.H. 22 mm compression isolating valve
INLET CONNECTION D.H.W. 15 mm compression isolating valve
OUTLET CONNECTION D.H.W.
15 mm copper pipe
SAFETY DISCHARGE C.H. 15 mm copper pipe
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL
SEALED WATER SYSTEM C.H.
MAX PRESSURE PHS
2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85 oC MIN 45 oC
DESIGN FLOW RATE D.H.W. 1247 l/h 20°C
MINIMUM FLOW RATE C.H. 650 I/h
D.H.W. FLOW RATE 30
o
C rise 13.9 l/min
D.H.W. FLOW RATE 35
o
C rise 11.9 l/min
D.H.W. FLOW RATE 40
o
C rise
10.4 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 12.5 mbar
min 1.4 mbar
Q
MW Input Net max 31.4 kW
min 13.0 kW
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 l/min
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers
DESTINATION: AT. DK. FI. SE.
CATEGORY I 2H
DESTINATION: GB. IE. CH. ES. IT. PT
CATEGORY II 2H3+
FLUE TYPE - C12 - C32 - C52
SEDBUK RATING
79.61 % BAND D NOX4
C12 C32 ORIFICE PLATE DM 79
c52 = ORIFICE PLATE DM 78
85 LITRE
10

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SECTION 3 TECHNICAL DATA LS 100 (T)
TABLE 4 LPG (G 30 - G 31) II 2H3+ -I 3+
NOMINAL HEAT INPUT NET QMS
31.4 kW
MINIMUM HEAT lNPUT NET
13.0 kW
NOMINAL HEAT OUTPUT
29.0 kW
GAS
RATE max G 31 1.24 m
3
/h G 30 0.95 m
3
/h
After 10 minutes
INLET PRESSURE 37 mbar G
BURNER PRESSURE
C.H. max G 31 35.4 mbar G 30 27.2 mbar
min
31
0.53 m3/h
0.40 m
3
/h
28 30 mbar G 30
min
6.1 mbar
4.7 mbar
MAIN BURNER INJECTORS Nr. 15 x 0.75
ELECTRICAL SUPPLY 230V-50HZ
POWER CONSUMPTION 150w
EXTERNAL FUSE RATING
3A
INTERNAL FUSE
DRY WEIGHT
WATER CONTENT C.H.
WATER CONTENT OHW
250 mA - 2 A
41.8 kg
1 .7 litre
0.5 litre
(20 mm to BS 4265)
GAS SUPPLY CONNECTION
FLOW CONNECTION C.H.
RETURN CONNECTION C.H.
INLET CONNECTION D.H.W.
OUTLET CONNECTION D.H.W.
SAFETY DISCHARGE C.H.
15 mm compression isolating valve
22 mm compression isolating valve
22 mm compression isolating valve
15 mm compression isolating valve
15 mm copper pipe
15 mm copper pipe
MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 85 LITRES
SEALED WATER SYSTEM C.H.
MAX PRESSURE PMS 2.5 bar
MINIMUM WORKING PRESSURE 0.5 bar
6 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar
CENTRAL HEATING OPERATING TEMPERATURE MAX 85 oCMIN 45°C
DESIGN FLOW RATE DHW 1247 I/h 20 oC RISE
MINIMUM FLOW RATE C.H. 650 L/h
D.H.W. FLOW RATE 30
o
C rise 13.9 l/min
D.H.W. FLOW RATE 35
o
C rise 11.9 I/min
D.H.W. FLOW RATE 40
o
C rise 10.4 l/min 10 oC inlet temperature
D.H.W. TEMPERATURE max 65 oCmin 35oC
BURNER PRESSURE D.H.W.
max
G 31 35.4 mbar
G 31
27.2 mbar
mln 6.1 mbar 4.7 mbar
Q MW Input Net
max 31.4 kW min 13.0 kW
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
FLUE OUTLET NOM. DIAMETER 100 mm
DESTINATION: GB. IE. CH. ES. IT. PT.
DESTINATION: BE. FR.
specially supplied with boilers
CATEGORY ll 2H3+
CATEGORY l 3+
FLUE TYPE C12 C32 C52
SEDBUK RATING 81.88 %
BAND D NOX 4
C12 - C32 = ORIFICE PLATE DM 78
c52 =
ORIFICE PLATE DM 77
11

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SECTION 4 GENERAL REQUIREMENTS The manufacturer’s notes must NOT be tak-
4.0
SAFETY
en, in any way, as overriding statutory oblig-
ations.
Gas Safety (Installation and Use)
Regulations, 1994 and amended 2000. IMPORTANT.These appliances are CE cer-
It is law that all gas appliances are installed tificated for safety and performance. It is,
and serviced by a CORGI registered in- therefore, important that no external control
staller in accordance with the above regula- devices e.g. flue dampers, economisers
tions and these installation instructions. All etc., are directly connected to this appli-
CORGI registered installers carry a CORGI ance unless covered by these Installation
I.D. card and have a registration number. and Service Instructions or as otherwise
Both should be recorded in your boiler log recommended by Ravenheat in writing. If in
book. You can check your installer by calling doubt please enquire.
CORGI direct on: 01256 732300. Failure to
install appliances correctly could lead to Any direct connection of a control device
prosecution. It is in your own interest, and not approved by Ravenheat could invalidate
that of safety, to ensure the law is complied the certification and the normal appliance
with. Check the boiler and flue is the correct warranty. It could also infringe the Gas
type for Installation. Safety regulations and the above regula-
The installation of the boiler MUST be in ac- tions.
cordance with the latest I.E.E. (BS 7671)
Wiring Regulations, local building regula- NOTE: The Ravenheat LITTLE STAR com-
tions, bye-laws of the local water authority, bination boiler has been tested and exam-
the building regulations and the Building ined by Advantica Technologies Ltd, and is
Standards (Scotland) and any relevant re- certified to comply with PrEN 483 and
quirements of the local authority. BS EN 625.
4.1
Manufacturers instructions must NOT be
GENERAL INFORMATION taken in any way as overriding statutory
Both the user and the manufacturer rely heav- obligations.
ily on the installer, whose job it is to install the If in doubt on any point please consult
combination boiler and connect it to a correct-
Ravenheat Manufacturing Ltd.
ly designed heating system. Acquaint yourself
with the British Standards concerning installa-
4.2 LOCATION OF BOILER
tion requirements. If you need advice on any
points your Ravenheat Technical Services Of-
4.2.1 Siting of Ravenheat Little Star Combi Boiler
fice would be pleased to help. It is recom- must be as follows. The position of installa-
mended that tools suitable for brass fittings tion should be within the building, unless
are used, and have a capability to accomo- otherwise protected by a suitable enclosure.
date hexagon sizes up to 50 mms.
Adequate space for installation, servicing
and air circulation around boiler must be al-
CODES OF PRACTICE/Ref: Documents
lowed for.
The Ravenheat LS 80 (T) and LS 100 (T)
Detailed recommendations are contained in
Combi Boiler must be fitted on a flat and ver-
the following British Standard Codes of tical wall capable of adequately supporting
Practice: the weight of the boiler and any ancillary
BS. 6891 Low pressure installation pipes.
equipment.
The appliance may be installed on a com-
BS. 6798
Installation of gas fired hot wa- bustible wall subject to the requirements of
ter boilers of rated input not ex-
the Local Authority and Building Regulations.
ceeding 60 kW.
BS. 5449 Forced circulation hot water LPG versions of this appliance shall not
be installed in cellars or basements.
systems.
BS. 5546
Installation of gas hot water
4.3
CLEARANCES AROUNDTHE APPLIANCE
supplies domestic purposes
(2nd Family Gases). 4.3.1 LS 80 (T) - LS 100 (T)
BS. 5440:1 Flues (for gas appliances of rated
input not exceeding 60 kW). Above 125 mm
BS. 5440:2 Ventilation (for gas appliances of
Below 100 mm
rated input not exceeding 60 kW).
Front 450 mm
DD 189:1990 Discharge of condensate Side 5 mm
Health & Safety Document No. 635
5 mm in front when installed in a cupboard
The Electricity at Work Regulations, 1989.
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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 ex-
isting cupboard, or compartment, may be
used provided it is modified accordingly.
Samples of the LITTLE STAR combination
boiler have been examined by Advantica
Technologies Ltd, and is certified to comply
with the essential requirements of the Gas
Appliance Directive 90/396/EEC, the Low
Voltage Directive 72/23/EEC and shows
compliance with the Electro Magnetic Com-
patibility Directive 89/336/EEC and are
therefore permitted to carry the CE Mark.
The appliance has been tested and ap-
proved by the WRc as meeting the require-
ments of G3 and L of the Building regula-
tions 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 re-
quired for all appliances it serves. Installa-
tion 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 de-
scribed in the above Code.
N.B. if the gas supply for the boiler serves
other appliances ensure an adequate sup-
ply is available both to the boiler and the
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.sidered.
The terminal must not be closer than 25The terminal must not be closer than 25
mm. (1 in) to any combustible material. Formm. (1 in) to any combustible material. For
protection of combustibles. refer to BSorotection of combustibles. refer to BS
5440.1.
Where a flue terminal is installed less than
1000 mm. from a plastic, or painted gutter;
or 500 mm from painted eaves, an alumini-
um shield 1000 mm. long, should be fitted
to the underside of the gutter or painted
surface.
IMPORTANT: The following notes are in-
tended for general guidance.
The boiler MUST be Installed so that the
terminal is exposed to external air.
It is important that the position of the 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 maximum
height of 4 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 combus-
tion 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
6798:1987/5449:1990 (for. smallbore and
microbore central heating systems). The fol-
lowing notes are given for general guidance.
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 16
drain taps. It should be ensured as far as
possible that the appliance heat exchanger
is not a natural collecting point for air
except where providing useful heat, pipes
should be insulated to prevent heat loss
and to avoid freezing. Particular attention
should be paid to pipes passing through
ventilated spaces in roofs and under floors.
4.8.3
The water through the appliance heat
exchanger circuit must exceed the min.
2.38 gals/min. (650 It/h) when the burner is
firing. It is important to ensure that this rate
is achieved when sections of the system
are shut off either manually or by automatic
controls. 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.
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4.8.4
4.8.5
4.8.6
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 1980
Fig. 7
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 sys-
tem.
The appliance has an integral sealed
expansion vessel to accommodate the
increase of water volume when the system
is heated. It can accept up to 6 lts of
expansion water. If the appliance is con-
netted 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 dilling
Primary flow and
return pipes
Figure 1 depicts the requirements of Diagram R24.2a of
he Water Supply (Water Fittings) Regulations 1999.
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SIZING OF ADDITIONAL EXPANSION VESSELS: TABLE 3
Deduct from the value given in the table the 7 litre vessel supplied.
Note: This pressure can be increased up to 1.5 bar to suit static head situations, see item 10, other appliance instructions in the
SERVICING INSTRUCTIONS
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.
B) Where fitting a make up vessel would be
difficult re - pressurisation of the system can
be done. See section on FILLING.
If the capacity of the central heating system
should exceed 85 litres, an additional 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.
4.8.9 Installation to an existing central heating
system
The combination boiler is designed to oper-
ate on a sealed system only. Therefore if
the existing system is of the open water
type it will have to be modified to comply
with BS 5376 Part 2.
Before, installing a new combination boiler to
an existing system, flush out the old system
with a recommended descaling agent. 16

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4.8.10
4.9
4.9.1
4.10
4.10.1
Hard water areas 5.2 DELIVERY
If the. area of installation is recognised as
hard water, it is recommended that a suit-
able water treatment device is installed in
the mains.
5.2.1 The appliance will arrive on site in two
cartons:
The water hardness can be determined by
using the standard test paper or by referring
Local water authority.
DOMESTIC WATER
The domestic hot water must be in accor-
dance with the relevant recommendations
of BS 5546. Copper tubing to BS 2871. 1 is
recommended for water carrying pipework
and MUST be used for pipework carrying
potable water.
Boiler carton containing:
a) boiler fully assembled
b) installation instructions and
user instructions
c) white paper template
d) terminal cover plate (Fig. 12)
g) - 4 coach bolts and wall plugs
- screws and dowels
Valve pack (poly bag):
a) 2-22 mm compression ball valves
(heating)
ELECTRICAL SUPPLY
Warning: this appliance must be earthed
b) l-15 mm compression ball valve
main in boiler box obtaining
c) l-15 mm compression
d) l-15 mm compression outlet
2 15 fibrie washers
2 22 fibrie washers
External wiring to the appliance must be
carried out by a competent person and be
in accordance with the current I.E.E.
Regulations and local regulations which
apply.
The Ravenheat boiler is supplied for con-
nection to a 230 V - 50 Hz single phase
supply. The supply must be fused at 3 A.
NOTE: The method of connection to the
electricity supply MUST facilitate complete
electrical isolation of the appliance, by the
use of a fused, double pole isolator, having
a contact separation of at least 3 mm in all
poles. The point of connection to the 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.
Flue box containing (Fig. 12):
Standard Flue Assembly
58 Elbow Header
59 - Flue bend (Fig. 10) item 9
60 -Air intake duct
61 - Flue exhaust duct
62 -Terminal
65 - Pipe centering spring
66 Flue gas sample point
127 -Terminal Cover Plate
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 in
a HORIZONTAL PLANE. A minor deviation
from the horizontal is acceptable, provided
that this results in a downward slope of the
flue/air duct away from the combination
boiler.
Fig.
For vertical flue
system see sect. 5.7.12
(Minimum vertical 1100 mm)
Fig. 12
10
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5.4
POSITIONING OF THE BOILER
5.4.1 Unscrew the 2 screws that fasten the lower
grating on the casing and remove it the
casing (Fig. 20).
5.4.2 -Remove the 4 screws that secure in the
top, 2 in the bottom the casing (Fig. 19).
- Carefully slide the casing forward to
lift off.
5.4.3
Make sure the casing and screws are put
to one side in a safe place.
Fig. 19
Fig. 21
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5.5
INSTALLINGTHE APPLIANCE FOR
REAR FLUE OUTLET
5.5.1
Use adhesive tape to attach the template
to the wall, making sure that the centre line
is vertical.
- Mark the two boiler fastening holes on
the wall as well as the centre of the flue
duct.
- Detach the template from the wall.
- Use a 10 mm. dia drill to make the 2 boil-
er securing holes. Insert the plastic
expansion plugs.
- Cut or core drill a 105 mm. dia hole for
inserting the flue duct.
- Screw in the two upper coach bolts leav-
ing them about 10 mm. out from the wall
to enable the boiler to be located on the
wall.
Fit the elbow header positioning it towards
the required direction (Fig. 30).
IMPORTANT: Make sure that the elbow’s
dia. 60 mm duct is inserted into the fan, the
rubber seal and orifice are been correctly
located.
Fig. 28
Fig. 29
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5.5.3
If the standard duct furnished with the boil-
er is too long it can be shortened.
Note: Should it be necessary to cut the flue,
always cut equal amounts from both inner
and outer pipes. Always cut the end
furthest from the terminal.
Cut end must de-burred.
Fig. 32
Fig. 30
Orifice plate concentric flue system:
LS 80 (T)=77 mm (NAT. GAS) - 76 mm (LPG)
LS 100 (T)=79 mm (NAT. GAS) - 78 mm (LPG)
INTAKE AND EXHAUST TERMINAL COMPONENTS
Fig. 31
KEY
56 - Straight header
57 - Elbow header
58 - Header gasket
59 - Rubber seal 0 60
64 - Flue exhaust duct extension
60 - STD air intake duct
65 - Pipe centering spring
61 - STD flue exhaust duct
66 - Sample point
62 - Terminal
127 - Terminal cover plate
63 - Air intake duct extension
128 - Screw
20

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5.5.4
5.5.5
5.5.6
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), locat-
ing onto the top coach bolts, and tighten all
two securing bolts.
Working above the boiler pull the flue
exhaust duct towards the boiler in order to
engage tube 61 into its header 57
(Fig. 31).
Position flue into elbow header and push so
as to locate inner and outer flue correctly.
5.5.10
Fig. 33
Fig. 34
5.5.11
5.5.8
Fit terminal cover plate if required.
5.5.9
Extension kits are available on order
Fig. 35
Each extension length extends the pipe by
approximately 1000 mm long up to a maxi-
mum of three extensions.
Pipeline length can be established using
the instructions in section 5.5 for rear flue
outlets and section 5.7 for side flue outlets.
Extensions must be installed with the
widened end of the air intake pipe and the ta-
pered end of the flue pipe aimed towards the
exhaust terminal. Extensions must be joined
together with the standard terminal pipe, in-
serted in each other as far as they can go.
If an extension must be shortened, this
must be done from the straight end, and
not from the widened or tapered end. To
measure the pipeline properly all compo-
nents must be assembled and total length
measured before cutting. The straight end
of the extension connects to the boiler. The
flue output pipe fits into the boiler header
until it stops. (Fig. 31)
When cutting both inner and outer ducts of
the extension, always ensure that the
reduced end (male) of the inner duct is
longer than the outer duct.
All joints must be sealed with the rubber
seals supplied.
It is important to put the centering spacer,
supplied with the unit, inside between the
two pipes, from the side opposite the
extension’s straight end.
NOTE: a suitable support bracket is 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 rigidly secured
to wall and flue duct.
IN LINE FLUE BEND
Measure the distance between the flue
bends or the flue/terminal assembly. The
measurement should be taken from the
outer edge of the flue and bend (Fig. 39B).
IMPORTANT: in line flue bend 750 mm
must be deducted from overall length for
each 90” bend. Obtuse flue bend - 375 mm
must be deducted from overall length for
each 135” bend (Fig. 39 B).
21