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Ravenheat Flue Boiler Installation And Servicing Instructions

Condensing fanned flue boiler
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CONDENSING FANNED FLUE BOILER
WITHOUT TIMER
NATURAL GAS (G20) (I
2H
LPG (G30-G31) (I
) G.C.N
3+
Tested, certified and
service listed
Listed by The United Kingdom Water
Fitting Byelaws Scheme
WITH TIMER
NATURAL GAS (G 20) (I
2H
LPG (G 30 - G 31) (I
) G.C.N
3+

INSTALLATION AND SERVICING INSTRUCTIONS

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 (0113) 252 7007
Supplied By www.heating spares.co Tel. 0161 620 6677
CSI SYSTEM
o
) G.C.N
47 581 01 - CSI
o
47 581 03 - CSI
O
) G.C. N
47 581 02 - CSI
O
47 581 04 - CSI
TO BE LEFT WITH USER

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Summary of Contents for Ravenheat Flue Boiler

  • Page 1: Installation And Servicing Instructions

    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 (0113) 252 7007 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 2 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.
  • Page 3 TABLE OF CONTENTS PAGE: SECTIONS: INTRODUCTION DESIGN PRINCIPLES AND OPERATING SEQUENCE 7 - 8 TECHNICAL DATA GENERAL REQUIREMENTS INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS FAULT FINDING ELECTRICAL SYSTEM DIAGRAM EXPLODED PARTS DIAGRAM LIST OF SPARE PARTS GENERAL LAYOUT 16 - D.H.W. control 34 - C.H.
  • Page 4 OPERATING SCHEME Fig. 2 10 - Condensate sensor 1 - Heat exchanger 23 - Safety relief system 12 - Modulating gas valve 26 - Auto air vent valve 3 - Burner 15 - Heating control potentiometer 4 - Ignition pilot burner 28 - Air pressure switch 16 - Hot water control potentiometer 5 - Flue restriction ring...
  • Page 5 SECTION gnal of the pilot/burner, it opens the second stage of the gas valve via the ignition board The Ravenheat CSI System boiler is a cen- on minimum power. Upon the second valve tral heating system boiler which incorpora- tes a circulating pump, expansion vessel, opening the spark igniter stops.
  • Page 6 2.3.4 The boiler water temperature is automati- 2.3.6 The condensate trap is fitted with a block- cally controlled by a built in thermostat. age safety sensor. This prevents the boiler operating should there be a blockage in the 2.3.5 condensate discharge trap. Interior space temperature is set by the room thermostat to be installed in the heat- ing system.
  • Page 7 3 TECHNICAL DATA SECTION TABLE 1 NATURAL GAS (G 20) I NOMINAL HEAT INPUT NET 24.8 kW (84,500 Btu/h) MINIMUM HEAT INPUT NET 13.0 kW (44,500 Btu/h) NOMINAL HEAT OUTPUT 23.8 kW (81,200 Btu/h) NOMINAL HEAT OUTPUT CONDENSING 25.6 kW (87,200 Btu/h) MINIMUM HEAT OUTPUT 11.7 kW...
  • Page 8 3 TECHNICAL DATA SECTION TABLE 1/A LPG (G 30 - G 31) I NOMINAL HEAT INPUT NET 24.8 kW (84,500 Btu/h) MINIMUM HEAT INPUT NET 13.0 kW (44.500 Btu/h) NOMINAL HEAT OUTPUT 24.1 kW (82,100 Btu/h) NOMINAL HEAT OUTPUT CONDENSING 25.6 kW (87,200 Btu/h) MINIMUM HEAT OUTPUT...
  • Page 9 British Standards concerning obligations. installation requirements. If you need advice If in doubt on any point please consult on any points your Ravenheat Technical Ravenheat Manufacturing Ltd. Services Office would be pleased to help. It is LOCATION OF BOILER...
  • Page 10 IMPORTANT NOTICE other appliances when they are in use at the same time. 4.4.1 If the combination boiler is to be fitted in a timber framed building it should be fitted in FLUE SYSTEM accordance with the British Gas Publication 4.6.1 Guide for Gas Installations in Timber Frame The terminal should be located where dis-...
  • Page 11 CONDENSATE DRAIN A condensate drain is provided on the boil- er. This drain must be connected to a drainage point. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other materials may be used.
  • Page 12 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.
  • Page 13 A test clock. c) Double check valve of an accepted type. d) A non return valve of an accepted type. We recommend use of a Ravenheat Filling Loop designed for this method of filling the system. Available from your supplier.
  • Page 14 Fig. 11 accordance with the current I.E.E. Regula- tions and local regulations which apply. The Ravenheat boiler is supplied for con- nection to a 230 V - 50 Hz single phase supply. The supply must be fused at 3 A.
  • Page 15 DELIVERY WARNING: Maximum allowable flue length 2.5 m. 5.2.1 The appliance will arrive on site in two maximum No. 2x1000 mm. cartons Flue duct extension used with standard flue Box 1 of 2 containing (Fig. 10 - 11): a) boiler fully assembled b) installation instructions and user Instructions Fig.
  • Page 16 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 17 POSITIONING OF THE BOILER Fig. 22 - Remove the 2 screws that secure the 54.1 upper part of the front panel of the casing (Fig. 19). Carefully slide the front panel a few milli- metres up towards the top of the appliance until it is free from its slot, and then lift off (Fig.
  • Page 18 5.5.2 Locate the rubber 0 60 into the flue elbow - Cut the inner flue duct (60 mm) at right header (Fig. 30). angles to a length equal to W + 264 mm. Insert from cut end. Reassemble the two 5.5.3 If the standard duct furnished with the boil- tubes.
  • Page 19 5.5.4 Insert the flue assembly into the wall, being 5.5.8 Fit terminal cover plate and terminal guard careful to make sure that the outer air duct (Fig. 36-37). comes flush to the inner surface of the wall. 5.5.9 Extension kits are available on order for flue 5.5.5 Lift the boiler on to the wall (Fig.
  • Page 20 NOTE: a suitable support bracket is availa- ble from Ravenheat Manufacturing and should be used to support flue length at least every 1.8 metre preferably at each joint this bracket should be secured to wall and flue duct.
  • Page 21 Fig. 39B 63 - Air intake duct extension 56 - Sample point 64 - Flue Exhaust duct extension 57 - Elbow Header 65 - Pipe centering spring 59 Rubber seal 0 60 128 In Line Bend Positioning the elbow towards the required - Reassemble the two tubes.
  • Page 22 (Fig. 29) Before proceeding with installation check the -Screw in the two upper coach bolts contents of the RAVENHEAT VERTICAL FLUE KIT, leaving them about 10 mm out from the comprising of the following pieces: wall to enable the boiler to be located on the wall.
  • Page 23 29 mbar for butane). Fit a roof flashing sleeve (7 Fig. 43) to the roof, 5.9.2 available from Ravenheat Manufacturing. Fit gas service cock to the boiler via the union nut and connect gas pipe. Insert the Vertical Flue terminal assembly through Do not overtighten and use another the flashing plate from the outside.
  • Page 24 Fig. 48A Fig. 48B Schematic ‘Y’ plan Schematic ‘S’ plan Fig. 49A POSlTlONlNG OF WATER AND GAS CONNECTIONS Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 25 (if required see Fig. 48). As an alternative The discharge must not be over an entrance Ravenheat recommend a room stat with or a window or any other type of access. built in timer for control of heating using boiler timer for DHW time settings.
  • Page 26 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 27 6 COMMISSIONING - If external controls are installed (e.g. SECTION timeclock and thermostat) make sure Each boiler has been through a rigorous that they call for heat. operational procedure at our factory and - Turn on main switch 1 (Fig. 50). should not require any further adjustment.
  • Page 28 - With the boiler operating use a screw Fig. 52B driver (HONEYWELL 9 mm spanner) to turn the nut 111 clockwise to increase pressure anti-clockwise to decrease pressure. NOTE: LPG ONLY The minimum pressure is factory set and sealed, and cannot be adjusted. 6.11 RECONNECTTHE DETACHED CABLE Use a screw-driver to hold nut 111...
  • Page 29 EXPLODED DIAGRAM OF BOILER BODY 1 -Window 27 - Auto air vent valve 53 - Connection tube 2 Plenum chamber cover 28 - Pressure switch 54 Connection tube 6 Combustion chamber 29 - Seal 58 Ceramic insulation 7 - Flue restriction ring 31 - Seal 61 Condensing heat exchanger 8 - Flue gas exhaust hood...
  • Page 30 NOTE: Do not use brushes with metallic bristles. 7.2.3 Examine internal pipe-work connections Ravenheat are a member of the Benchmark and automatic air vent for any water leaks. initiative and fully supports the aims of the Rectify if necessary. programme. Benchmark has instructed to improve the standards of installation and commissioning of 7.2.4...
  • Page 31 7.6.5 TO REMOVE/REPLACE CONDENSING removing and flushing out the exchanger. HEAT EXCHANGER FIG. 54-55 Inspect the siphonic condensate trap for a blockage. Any deposits should be flushed out (Fig. 90). 7.6.5.1, Remove front casing (sect. 7.3). Remove combustion chamber front cover as in (sect 7.2.6.1 To remove condensate trap (sect.
  • Page 32 7.8.4 Remove the fan (sect. 7.6). Fig. 54 7.8.5 Remove condensing heat exchanger (sect. 7.6.5). 7.8.6 Remove the flue hood (sect. 7.7). 7.8.8 Remove the automatic air vent (Fig. 92). 7.8.9 Disconnect unions for two heating (right side of boiler) water pipelines (Fig. 62). 7.8.10 Unscrew the rings that fasten the heat exchanger to the combustion chamber.
  • Page 33 7.10 TO REPLACE THE ELECTRODE Fig. 60 (Fig. 66) 7.10.1 Remove front casing (sect. 7.3). Remove combustion chamber front cover (sect. 7.4). Fig. 56 Fig. 62 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 34 Fig. 66 Fig. 63 7.10.2 Detach the wire from electrode and then unscrew the nut that secures it to the pilot burner assembly and remove. 7.10.3 Replace with new electrode in reverse order. 7.12 TO REPLACETHE PILOT INJECTOR (Fig. 68) Fig.
  • Page 35 7.14 TO REMOVE/REPLACE THE MAIN INJEC- Fig. 69 TORS 7.14.1 Remove the front panel of the casing and the combustion chamber front cover (sect. 7.3 & 4). Remove the pilot burner assembly as described in sect. 7.13. 7.14.2 Unscrew the union (Fig. 70). 7.14.3 Unscrew the 4 screws securing the injector manifold to the burner (Fig.
  • Page 36 7.15 TO REMOVE/REPLACE THE MAIN Fig. 72 BURNER 7.15.1 Remove the front panel of the casing and the combustion chamber front cover (sect. 7.3 & 7.4). 7.15.2 Remove the pilot burner assembly as described in sect. 7.13. 7.15.4 Remove the injectors manifold as described in sect.
  • Page 37 7.19.6 Replace in reverse order. 7.23 TO REMOVE/REPLACE THE ELECTRIC CONTROL BOARD (PCB) 7.20 TO REMOVE/REPLACE THE MAIN SWITCH (Fig. 82). 7.23.1 Remove the front panel from the outer cas- ing (sect. 7.3) and lower the instrument 7.20.1 Remove the front panel from the outer cas- panel (sect.
  • Page 38 IMPORTANT: 7.25.4 Remove the terminal covers and detach the 7.258 Make sure that the arrow that indicates the supply wires (Fig. 88). direction of flow aims from the bottom upwards. Unscrew the two hexagonal nuts that fasten 7.25.5 the pump to its pipes and remove the pump. 7.25.9 Replace wires and cover ensuring that con- nection wire br=L and bl=N.
  • Page 39 Fig. 83 7.28.7 Disconnect mains cables and any other connections (room thermostat, program- ming clock). 7.28.8 Remove the duct proceeding in reverse order as described in (sect. 5.5 or 5.7). 7.28.9 Remove the 2 lower coach bolts and release 2 top coach bolts then remove boil- er from the wall.
  • Page 40 7.31.6 Replace in reverse order (ensure all electri- 7.30.3 Unscrew the screw from its body, clean or cal connections are made correctly) (Fig. replace. Replace in reverse order. 88/A). Fill the system as described in the 7.30.4 TO REMOVE/REPLACE THE IGNITION 7.32 (sect.
  • Page 41 Fig. 90 Fig. 93 Fig. 91 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 42 SECTION 8 FAULT FINDING CENTRAL HEATING Switch on Stat to maximum Ensure external controls calling for heat (Room Stat/Time Clock/TRV) DHW Stat Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 43 BOILER NOT OPERATIONAL ON TIMER (INTEGRAL) Switch on/Select “Winter”/Central Heating Stat to Maximum/Ensure External control calling for heat (Room Stat/TRV) Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 44 Fig. 94 9 ELECTRICAL SYSTEM DIAGRAM SECTION Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 45 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 46 INSTALLATION INSTRUCTIONS FOR TWIN FLUE PIPE (ECCENTRIC FLUE DUCT SYSTEM) Fig. 1.8 IMPORTANT Supplied with the CSI twin flue header is a These instructions must be read in conjunc- F1 orifice plate along with supplementary tion with the main installation and servicing depression seal.
  • Page 47 flue header as illustrated making sure that M/F bend consisting of, the inner aluminium exhaust locates firmly in the outlet spigot. Make sure that the elbow with ‘0’ ring side F screws are satisfactorily located through 80 mm dia ‘0’ ring the gasket seal.
  • Page 48 Eccentric vertical terminal screws. 30001 90” slow bend Available on request from: 30003 45” bend RAVENHEAT MANUFACTURING LTD 3 0 0 0 9 Air inlet terminal (plastic) 80 mm Chartists Way 30011 Morley, Leeds, West Yorkshire Exhaust terminal (stainless steel) 80 mm ENGLAND LS27 9ET - U.K.
  • Page 49 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 50 RAVENHEAT CSI SYSTEM CONDENSING FANNED FLUE BOILER SHORT LIST OF SPARE PARTS Ravenheat G.C. Part. No. Description Pos. Part. No. E23-711 Instrument panel - TIMER MODEL 0014FRO06005/0 E23-712 Main switch 0012COM06005/0 D.H.W. / C.H. Potentiometer E23-729 0012POT05010/0 371267 Overheat thermostat...
  • Page 51 G.C. Ravenheat Part. No. Pos. Part. No. Description 5012096 372856 Nozzle 0,27 for natural gas 48.1 0003UGE01005/0 E02-129 Nozzle DM 0.22 x 1 LPG 5 0 2 1 0 5 0 372892 Ignition electrode E23-739 Cable for electrode 0012CAV06005/0 0002SCA06005/0...
  • Page 52 Chartists Way, Morley, Leeds, LS27 9ET. Telephone: (0113) 252 7007 Tfax: (0113) 238 0229 Supplied By www.heating spares.co Tel. 0161 620 6677...

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