Ravenheat Energycatcher Installation instructions

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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
TEL. [phone] - FAX: [phone]
Website : www.ravenheat.co.uk - E-mail : [e-mail]
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE LEFT WITH THE USER
ENERGYCATCHER
ENERGYCATCHER
This is an energy saving product
SAP RECOGNISED
CERT ACCREDITATION

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Thank you for purchasing Energycatcher combiplus or combistore
patented energy saving system which when used in conjunction with the
arrangement listed below will save substantial amounts of energy along with
meaningful carbon reductions.

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GENERAL INFORMATION
All Ravenheat appliances have been designed and manufactured to the highest quality and standards to be both
reliable and to save on operating costs.
The Energycatcher must be installed in accordance with the manufacturer’s guidelines. Failure to do so could negate
the warranty supplied with this unit.
Energycatcher must be installed and serviced by a competent person in accordance with the following
recommendations:
- Current Gas Safety (Installation and Use) regulations
- All current Building Regulations issued by the department for the Enviroment i.e. Approved Document L1.
- Building Standards (Scotland) (Consolidation) Regulations issued by the Scottish Development Department.
- UK Water Regulations/Bylaws (Scotland)
The installation should also be in accordance with the following British Standards Codes of practice:
- BS 5440:1:2000 Flues
- BS 5449:1990 Forced Circulation Hot Water System
- BS 5546:2000 Installation of Hot Water Supplies for Domestic Use
- BS 6700:1997 Design, Installation, Testing & Maintenance of Suppling Water
- BS 6798:2000 Installation of Gas Fired Hot Water Boilers
- BS 6891:1998 Gas Installation
- BS 7593:1992 Code of practice for treatment of Water In Heating System
- BS 7671:2001 Requirements for electrical Installation, IEE Wiring Regulations
Energycatcher is designed to be used on water systems not exceeding 6.0 bar static pressure. If the pressure is
greater than this, a 6.0 bar limited pressure reducing valve must be fitted prior to the Energycatcher pipework
(item 11 page 20).
Note:
Energycatcher is designed to fit Ravenheat 120/150 models only. It can be fitted to any Band A condensing combi
though the installer must have written approval from manufacturer of the boiler and the manufacturer of
Energycatcher.
IMPORTANT :
2.5 bar pressure reducing valve (supplied) must be fitted on mains
inlet supply before the Energycatcher or boiler see fig. 11 - 12 - 13.

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SECTIONS
1
2
3
4
5
6
7
8
9
10
11
12
13
INTRODUCTION
GENERAL LAYOUT
TECHNICAL DATA
OPERATING
DELIVERY
INSTALLATION
ENERGYCATCHER FIXING
WATER CONNECTIONS
ENERGYCATCHER WITH REMOTE TANK
STORE ENERGYCATCHER PIPEWORK
SERVICING
ALTERNATIVE ENERGYCATCHER
SYSTEMS
LIST OF SPARE PARTS
PAGE
6
7
8
8
9
10
13
14
14
14
18
18
20
TABLE OF CONTENTS
COMBIPLUS COMBISTORE
PFGHRD FGHRS
PFGHRD : Passive Flue Gas Heat Recovery Device
FGHRS : Flue Gas Heat Recovery System
A0-1
System B1-1 System

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Section 1 INTRODUCTION
Energycatcher is an ingenious patented unit which
requires no electrical connection, has no running costs,
and no maintenance costs.
All Ravenheat boilers conform to SEDBUK bandA, they
are over 91 % efficient in converting gas to heat. When
Energycatcher is fitted to a boiler, it adds up to 7 % to
the boiler efficiency and thereby an overall 7% saving
on gas per year. Which, apart from the costs of buying
the unit delivers FREE domestic hot water. This saving
is good news for the householder’s gas bill, and the
environment.
In addition, the flue exhaust temperature, or plume, is
also considerably cooler with Energycatcher.
UK building Regulations demand that this plume is
exhausted from the house so as not to affect either the
home’ s fabric or people. Tests by Ravenheat show
that the plume temperature is reduced by up to 45 °C,
making it far safer and resulting in much less heat being
pumped into the atmosphere.
When Energycatcher is attached to a condensing boiler,
thelowtemperatureofthisexhaustresultsinthepolluting
gasescondensingto thedrain,ratherthan goinginto the
atmosphere;
1.1
Summary savings using Energycatcher:
- Energy neutral (free energy).
- The Energycatcher is efficient at extracting heat to
water.
- Extra heat is extracted from outlet fumes reducing
them
to as low 23°C.
- When the boiler is working in hot water mode the
outlet
flue fume temperatures are no greater than 3-5 °C
higher
than the incoming cold feed.
- Extra boiler efficiency whenever the boiler is operating
(DHW or CH). This efficiency is stored as thermal
gain.
- Saves on gas bills.
- Helps the environment.
1.2
Summary of benefits of Energycatcher:
- Fuel bills reduced.
- CO2 saving
- Pluming is almost eliminated due to operation
(thermal gain).
Outlet fumes are too low to support water vapour.
- Less cold water usage.
- Instant hot water delivery.
- Payback of initial outlay around 2 to 3 years.
- Delivers substantial heat savings (twice that of solar)
when there are no thermal gains due to poor
weather.
- Compatible to work with solar system in conjunction
with Energycatcher for all year round savings.
- Uses no power to recover heat.
- No electrical power connections.

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Section 2 GENERAL LAYOUT
Fig. 1

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Section 4 OPERATING
4.1
The boiler’s flue gases, instead of going
straight outside at around 60 °C, the flue gases
are fed into the Energycatcher, where they flow
over a heat exchanger. This otherwise wasted
heat is transferred to the water in the heat
exchanger, which moves under convection into
Energycatcher and/or a storage tank. The tank
can be of any size to suit the need for example,
after the central heating has run for a short
period the store will be heated, giving a good
supply of preheated hot water. The exhaust
gases, now considerably cooler, then vent to
the atmosphere.
If the householder runs the central heating
system in the early morning, so the house is
warmed for breakfast time. All the time the
boiler is running, the waste heat in the flue
is being transferred to the water in the heat
exchanger, which then passes to the storage
tank. This water can reach between 40 and 50
°C within 20 mins - to a max of 60 °C.
When the householder runs the hot tap, either
for a wash, shower or bath etc....
Section 3 TECHNICAL DATA
The preheated hot water runs directly from
Energycatcher and/or storage tank through
the boiler (combi type) to the tap, this
preheated water is supplied totally free of
charge, it is cycled through the boiler where
the higher than normal inlet temperature is
sensed, and only sufficient heat applied,
bringing the water up to the normal
preselected outlet temperature set on the
boiler. Far less gas is used to supply this
“piping hot” water.
Either way, the householder saves money;
Ravenheat estimates that over the year, a
typical average gas bill will be cut by up to
7% over and above a 91% efficient Sedbuk
band A condensing boiler (over 50% saving
by replacing non-condensing appliances
with a Ravenheat condensing boiler and
Energycatcher).
In addition, hot water flows from the tap
quicker than normal (less cold water is
used).
D.H.W. pressure max 6,0 (bar)
Dry weigh
t
12,3 (Kg)
Water content 1,6 (Litre)
Water inlet pipe 3/4 " BSP
Water outlet pipe 3/4" BSP
Suitable for use with Ravenheat boiler model
s
Ravenheat 120/150 Low Nox boile
r
Other boiler manufacture Any band A SEDBUK gas boiler , of whatever type or
make, can be fitted with a Ravenheat Energycatcher
subject to all round consent.
Flue resistance 1,5 m length for 60/100 flue
Deduct from overall boiler flue length 1,0 m length for 80/125 flue
Boiler flue length See boiler manual and overall maximum flue length
then deduct value in flue resistance as above

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Section 5 DELIVERY
5.1
The appliance will be delivered in two cartons:
(1) Large rectangular box contains:
a) Energycatcher main unit.
5.2
(2) Long rectangular box containing accessories:
a) stand off wall bracket for boiler and Energycatcher consisting of 1 left and 1 right hand painted side
bracket.
b) 1 upper cross member and 1 lower T shaped cross member.
c) 1 paper template
d) 1 polythene bag containing:
2 22 mm flanged angle valves and fibre washers.
1 15 mm angled valve (blue) and washer.
1 angled bend and washer.
1 bag of 4 fixing bolts and dowels.
1 15 mm drained down valve.
1 condensing trap.
e) 1 polythene bag containing:
4 Energycatcher / boiler fixing bolts and nuts.
1 pipe clamping clip.
1 dual lock strip (condensing trap fixing)
8 screws and washers (back frame assembly screws).
f) 2 Data ID label for Energycatcher (affix correct one to boiler).

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6.3
Attach the template to the wall making sure that
the centre line is vertical using adhesive tape.
- mark the holes for the side fixing brackets to
the wall as well as the centre flue duct, detach
the template from the wall.
- use a 10 mm drill to make the 4 holes. Insert
the plastic expansion plugs.
- cut or core drill the 105 mm diameter hole for
inserting the flue duct (rear left, right or
vertical).
Fix the 4 coach bolts provided, leaving them a
couple of mm proud of the wall.
- locate the boiler fixing stand off bracket over
the 4 bolts and tighten it to the wall, taking care
not to over twist or distort the frame if the wall
is uneven.
6.1
WHEN INSTALLING ENERGYCATCHER
IT MUST BE FITTED IN CONJUNCTION
WITH RAVENHEAT 120/150
CONDENSING BOILER THEREFORE ITS
IMPORTANT TO FAMILIARISE
YOURSELF WITH THE BOILER MANUAL
IN CONJUNCTION WITH INSTALLATION
OF ENERGYCATCHER.
6.2
Assembling backframe.
Select the left and right hand side stand off
bracket, placing them face down with the fixing
studs facing upwards and screw holes cross
referencing, take the 8 screws fix the top and
bottom cross members on the inner side of the
side stand off brackets. Fig. 2
Note:
It is important to ensure screw holes line up
correct as these have been deliberately offset
to avoid incorrect positioning of cross members
within the backframe assembly. Fig. 4.
Fix 4-15mm clips provided ( pointing clips to the
wall ) in the backframe cross members. Fig. 5
Fig. 2
Fig. 3
Section 6 INSTALLATION

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6.4
Locate the 4 boiler/Energycatcher fixing bolts and
nuts into the upper studs of the secured backframe,
leave them slightly loose of the frame.
Fig. 4
6.5.1
You may wish to run cold feed/preheat pipes into the
backframe.
It is best to use 15 mm plastic pipe as this should
bend when located in plastic clips, otherwise put
offset bends on feed pipes.

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6.5.2
Take out from the Energycatcher valve pack the blue
isolation valve and connect it to a 15 mm pipework
(not supplied) making sure compression connection
is water tightened. length of pipe approx 120 cm.
- Clip the pipe into backframe right side clips.
- Connect cold mains inlet and locate in clips leaving
more than 100 mm above top backframe so this
can be connected to the cold inlet later.
Note:
It may be necessary to slacken backrame from the
wall to locate pipes in clips.
6.6
Unpack and prepare the selected boiler for
installation as set out in the main boiler manual.
6.7
Remove the straight exhaust white header and
gasket from the top of the boiler by removing the 4
screws located on the top of the boiler itself.
Fig. 6.
Fig. 7
6.8
Lift up the boiler onto the 2 lower backframe bolts
and locate tighten them to secure boiler to
backframe.
Fig. 4.
6.9
Remove boiler front cover by removing lower 2
screws on bottom of cover slide up the front panel
to dislocate it from studs.
Fig. 7.
Fig. 6
Fig. 5

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Section 7 ENERGYCATCHER FIXING
7.1
Before fitting remove the front cover of
Energycatcher by removing the 2 screws located on
the top of the front panel.
7.2
Slide up the front panel to dislocate it from fixing
studs and remove.
Fig. 8.
Fig. 9
Fig. 8
7.3
IMPORTANT
Make sure the black rubber 60 mm
seal is located into the boiler top flue
exhaust manifold.
7.4
Before offering Energycatcher up to
the boiler it is important to lubricate
the inlet and outlet manifold on
Energycatcher and boiler.
IMPORTANT
Generally speaking oils and greases
are not suitable for the “peroxide-
EPDM“, therefore we suggest a correct
lubrication using silicone-substances,
for instance “ silikon spray” (Arexons)
or similar product.
7.5
Taking Energycatcher, lift it up on the top of the
boiler while at the same time ensuring that the 2
flexible pipes ( condensing outlet pipe and drain
down braided hose) drop down the backframe
so that they can be connected later. Lift
Energycatcher onto the 2 fixing bolts at the
upper top of the stand off backframe while
at the same time locating the Energycatcher
flue inlet manifold into the boiler black rubber
washer.
7.6
Tighten Energycatcher fixing bolts.
Fig. 10
7.7
Fit desired flue as set out in main boiler installation
manual.
Note : If the flue from Energycatcher is
vertical then the flue connection must
start with a header sampling point. Part.
no. PR5094110A.
Fig. 10.
7.8
Flue resistance.
It is important to deduct appropriate flue length to
allow for Energycatcher’s increased flue resistance.
Details of which are set out in section 3.

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Section 8 WATER CONNECTIONS
Note:
Energycatcher comes with its own extended valve
pack water connections, change these with ones
supplied in boiler box. Use 2 of the angled water
boiler connection valves to correct Energycatcher
inlet and outlet. Fig. 9.
Energycatcher external pipework ( not provided) can
be installed in 15 mm plastic or copper.
8.1
The boiler water connections are as set out in the
main manual.
Cold mains inlet feed must be taken immediately to
Energycatcher up through the backframe.
Fig.4a.
8.2
The outlet pipe (preheat) from Energycatcher outlet
to be taken down the backframe and connected to
the boiler cold water inlet (use the blue angled valve
provided) in Energycatcher accessory box.
Fig. 10 ( section 6.5.1).
8.3
All other water and gas connections along with
electricity supply to the boiler are all as set out in the
boiler instruction manual.
8.4
Fix the straight 1/2” / 15mm isolating drain using the
fibre washer provided to the 1/2” BSP outlet from the
braided pipe , this will act as a drain down discharge
point if this is required.
Ensure this is correctly closed and capped where
necessary to prevent this being opened accidently
( cap not provided )
8.5
Fix the condensate trap to the flexible discharge
pipe from Energycatcher ensuring that this trap is
fixed to the Energycatcher (not the boiler discharge
pipe as this is already trapped within the boiler).
By teeing these together ensure that the condensate
discharge is disposed of safely as set out in the
main installation manual.
Also ensuring that condensate trap is securely
secured.
Section 9 ENERGYCATCHER WITH REMOTE
TANK
9.1
The tank pipework should not exceed 5 m total length.
Positioning of the tank must be above the
Energycatcher, or at the left or right hand side. When
fitting at the side use the hose which can be taken
through the side of backframe.
Fig. 12-13.
Important : if using the flexible hose to the tank
connection you must cap off the 3/4” preheat outlet on
the top right of energycatcher.
9.2
If you are to use Energycatcher with an additional 15ltr
cylinder continue as follows:
9.3
Offer the cylinder up to the wall and fix with bracket
provided, taking care not to exceed measurements.
9.4
It is important that both pipes connected to
Energycatcher from the cylinder must have a slight fall
back to Energycatcher.
Section 10 STORE ENERGYCATCHER
PIPEWORK
10.1
- Take cold mains inlet supply up through back of the
boiler.
- Immediately above energycatcher fix a 15 mm T with
the junction pointing horizontally forward and
connect to Energycatcher inlet. Immediately above
tee fit reversing valve with arrow pointing down
(valve is sold separately).
- Immediately after the valve fit a further T.
- Take the pipework back down on to the boiler
cold water inlet.
- Take the upper T connecting to the top of the
cylinder.
Fig. 12-13.
Connect the return pipe from the tank to either top
of energycatcher outlet or use flexible connector.
Connecting through the hole in the side bracket fixing
a draincock within the connection (not supplied).
10.2
Filling the system
It is important that the system is fully filled prior to the
commissioning of the boiler otherwise the boiler could
be damaged in the process of filling and charging the
cylinder.
Make sure all air is removed by opening outlet taps.
Check that the water is adequately running through the
hot water supply and taps prior to commissioning.
When replacing front panel refit boiler front panel first
then Energycatcher panel.
10.3
Fix the Energycatcher ID label to boiler. See page 5.

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10.4
ENERGYCATCHER STAND ALONE UNIT
Fig. 11

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10.5
WITH REMOTE STORAGE TANK
Fig. 12

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Fig. 13

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Section 11 SERVICING
Energycatcher is a simple designed unit, no maintenance
is required. The unit contains no mechanical, electrical or
serviceable parts.
It is recommended that the Energycatcher should be
subjected to a general condition and flue inspection with
boiler maintenance by a competent person.
Ravenheat are a member of the Benchmark initiative and
fully supports the aims of the programme, to improve the
standards of installation and commissioning of central
heating systems in the UK and to encourage in the
regular servicing of all central heating system to ensure
safety and efficiency.
11.1
All routine boiler servicing requirements can be achieved
by the removal of the Energycatcher front panel.
To remove the boiler front panel see boiler manual.
For further information contact:
Ravenheat Ltd
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Website: www.ravenheat.co.uk

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12.1
Energycatcher can be installed to work in
conjunction with solar panels; the panels produce
a boost to water temperatures when the sun
shines, while the Energycatcher comes into its
own whenever the boiler is used to heat the
home or provide DHW. Energycatcher is a good
investment to install in conjunction with solar
panels, and offers immediate returns.
There are other systems designs which are
available:
12.2
Increased energy saving with larger stores.
12.3
Increased domestic hot water flow rates.
12.4
Management system to decrease flue pluming
even further.
For details of our design service please contact
us with your requirements via email.
[e-mail]
Section 12 ALTERNATIVE ENERGYCATCHER
SYSTEMS

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Pos. Ravenheat part nr. G.C. part nr. Description
1 1002SCA12010/0 Heat exchanger
2 0019PRO12005/0 Flue extension
3 0010TUB12015/0 Flow pipe
4 0010TUB12005/0 Return pipe
5 0019ATT12005/0 Flue adapter
6 0014GUA11020/0 Flue gasket
7 0014RAC06005/0 Condensing trap
8 0013GUA01025/0 Gasket 24x15x2
9 0010TUB12010/1 Flex hose
10 0013GUA01020/0 Gasket 18.5x11.5x2
11 0008RID12010/0 Limited pressure valve (optional)
Section 13 LIST OF SPARE PARTS