Escolar Documentos
Profissional Documentos
Cultura Documentos
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.
This new high efficient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at
super high efficiency.
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 the 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
every 15 cm . This should not hinder service of the appliance, but does ensure maximum efficiency and safety - something
which Ravenheat takes great pride in.
Each boiler has been designed and manufactured in our modern plant to exacting ISO 9001 discipline and 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 (0113) 252 7007.
BASIC COMPONENTS - (See figure 1)
Guarantee is valid for 12 months from date of purchase providing the appliance has been fitted in accordance with these
instructions and relevant codes of practice.
MAJOR COMPONENTS
NOTE: Due to the high efficiency of this boiler a plume of water vapour will form at the flue
terminal during operation.
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 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
SECTIONS TABLE OF CONTENTS PAGE
1 INTRODUCTION 6
2 DESCRIPTION OF CONTROL 6
3 SYSTEM AND SEQUENCE OF OPERATION 8
4 TECHNICAL DATA 10
5 GENERAL REQUIREMENTS 15
6 INSTALLATION 25
7 COMMISSIONING 30
8 SERVICING INSTRUCTIONS 40
9 FAULT FINDING 42
10 ELECTRICAL SYSTEM DIAGRAM 43
INSTALLATION INSTRUCTIONS FOR 46
TWIN FLUE PIPE 46
11 EXPLODED PARTS DIAGRAM 47
12 LIST OF SPARE PARTS
Fig. 1
KEY
1 - Heat exchanger 11 - D.H.W. sensor 21 - Combustion chamber
2 - Sensing electrode 12 - D.H.W. heat exchanger 22 - Frame
3 - Burner 13 - D.H.W switch 23 - Sealed chamber
4 - Expansion tank 14 - D.H.W inlet 24 - Air pressure switch
5 - Modulating gas valve 15 - Diverter valve motor 25 - Auto air vent
6 - Condensing trap 16 - Low water pressure switch 26 - Fan
7 - C.H. outlet 17 - Circulation pump 27 - Flue restriction ring
8 - Drain point 18 - Overheat cut off thermostat 28 - Condensing heat exchanger
9 - Safety relief system 19 - C.H. sensor 29 - Flue gas exhaust hood
10 - D.H.W. outlet 20 - Spark electrode 30 - Temperature flue sensor
4
Fig. 2
KEY
1 - Heat exchanger 15 - Diverter valve motor 30 - Temperature flue sensor
2 - Sensing electrode 16 - Water pressure sensor 31 - Water pressure switch
3 - Burner 17 - Circulation pump 32 - Water pressure gauge
4 - Expansion tank 18 - Overheat cut off thermostat 33 - Automatic by-pass
5 - Modulating gas valve 20 - Spark electrode 34 - Gas service cock
6 - Condensing trap 24 - Pressure switch
7 - C.H. outlet 25 - Auto air vent
8 - Drain point 26 - Fan
9 - Safety relief system 27 - Flue restriction ring
10 - D.H.W. outlet 28 - Condensing heat exchanger
12 - D.H.W. heat exchanger 29 - Compresson ball valves
5
SECTION 1 INTRODUCTION the heating circuit fully pressurized so as
to operate the low water sensor device the
1.1 The Ravenheat boiler is for the use of central boiler will start in the same way in domestic
heating and domestic hot water combined hot water mode but with slightly differing time
in one unit. It is fitted with an automatic delay. In that it will start on minimum and
domestic hot water priority valve. remain at this level for about 1 minute. After
A / (winter/summer) selector which the flame will lift to its maximum setting
switch is fitted to the left hand side of control as governed by a potentiometer which range
panel.With the only (summer) position rates the heating circuit between maximum
being for domestic hot water. and minimum power. As the heating sensor
position being for central heating reaches temperature the gas burner
with domestic hot water priority. The boiler power modulates down, the fan speed
is equipped with a front cover which can be will also reduce to minimum fan speed.
removed for servicing. The data badge with When starting, the fan will always start at
technical data is placed on the lower right maximum speed.
hand side of the frame.
2.2.8 On the control panel are mounted two
1.2 Fig.1. potentiometers (thermostats) these control
Illustrates the general layout of components. the temperature. One is for domestic hot
Fig. 2. water and the other for heating.
Illustrates the operating scheme described
in section 2. 2.2.9 The boiler is fitted with an anti-cycling device
SECTION 2 on the control board. This delays the boiler
from re-firing over a 2/5 minute period when
2.1 DESCRIPTION OF CONTROL SYSTEM in heating mode. The domestic hot water will
AND SEQUENCE OF OPERATION always take priority and is unaffected by the
anti-cycling device.
2.2 Domestic hot water mode
When the appliance is in rest mode with GENERAL FUNCTION
the mains neon switch on.
Switch the summer/winter switch tap 2.3 Central Heating Mode
position, with the heating circuit charged
with water (above 1 bar). If the domestic 2.3.1 A potentiometer installed on the electric circuit
hot water tap is turned on, the boiler will board permits regulation of the boiler to partial
function in the following sequence: heating requirements, between maximum and
minimum settings.
2.2.1 The pump starts.
The control board sensors. 2.3.2 Air is drawn by the fan for combustion.
The fan operates via the pressure switch and
sends a signal back to the ignition board that the 2.3.3 The fan also forces exhaust gas through the flue
fan is running at maximum speed. to the outside, this creates a lesser pressure in
the sealed combustion chamber, thus sucking
2.2.2 The spark ignition system is powered which in in combustion air, through the inlet duct.
turn commences the spark igniter to operate
and light the burner. 2.3.4 The boiler water temperature is automatically
At this point the ignition board opens the gas controlled by a built in thermostat
valve to light the burner.
2.3.5 Interior space temperature is set by the room
2.2.3 When the electrode/sensor senses the signal thermostat to be installed in the heating
of the burner, the spark igniter stops. system. The boiler already carries connection
terminals for this thermostat, as well as for a
2.2.4 From the minimum gas rate setting the timeclock.
boiler increases to the maximum permissible The burner continues to operate until it is
pressure over a period of 3 to 4 seconds and stopped by the timer or one of the thermostats
will remain at its maximum required power until
it reaches maximum regulated temperature. 2.3.6 When the internal C.H. temperature sensor
intervenes the main burner shuts down. The
2.2.5 When the domestic hot water tap is closed the fan stops but the pump continues to operate.
diverter valve goes back into rest mode, the
main burner is shut down along with the pump 2.3.7 When the room thermostats intervene the
main burner shuts down. The fan stops and
and fan which are also switched off.
the pump turns off.
The pressure switch returns to its rest mode
2.3.8 The condensate trap is fitted with a blockage
2.2.6 Central heating mode safety sensor. This prevents the boiler
2.2.7 If the switch is positioned on with operating should there be a blockage in the
a demand for heat to supply radiators, with condensate discharge trap.
6
2.4.4 When D.H.W. is no longer called for the boiler
2.4 Domestic hot water mode
automatically returns to the central heating
mode.
2.4.1 The heat exchanger in the D.H.W. circuit
is built into the main heat exchanger, and
2.4.5 Select (fig. 35) the summer position the
domestic hot water is heated by converting
boiler functions like an automatic gas hot
the water in the central heating circuit. The
water heater. When D.H.W. is no longer
transference of heat is very high because the
required the main burner fan and pump
two fluids move in a counter direction flow to
immediately turn off.
each other.
This also takes place with the summer/
winter switch if there is no demand for
2.4.2 Select (fig. 35) the winter position.
heat to the central heating system or
When a hot water tap is turned on a diaphragm
until the room thermostat/time clock
diverter valve excludes the central heating
demands from the central heating circuit
circuit, the boiler automatically modulates to
the main burner fan and pump turn off
maintain the domestic hot water at a constant
immediately. .
temperature.
Water temperature can be regulated using
2.5 SAFETY DEVICE
the D.H.W. thermostat located on the front
control panel.
In both central heating and domestic hot
water mode safe operating is ensured by:
2.4.3 When domestic hot water is being drawn the
main burner and pump perform as they do
2.5.1 A differential pressure switch which shuts off
during central heating except that the burner
the main burner if the fan stops or the flue or
is commanded by the D.H.W. thermostat.
combustion air intake duct is obstructed.
An overheat cut off thermostat set slightly
higher than the high limit thermostat acts
to turn of the burner to resetable “lockout”
(Fig. 35) item 3.
OVERALL DIMENSION
Fig. 3
7
SECTION 3 TECHNICAL DATA
CSI 85 AAA (T) - 780 Series
TABLE 1
8
SECTION 3 TECHNICAL DATA
CSI 85 AAA (T) - 780 Series
TABLE 1/A
BS.6798 Installation of gas fired hot water LPG versions of this appliance shall not be
boilers of rated input not exceeding installed in cellars or basements.
60 kW.
4.3 CLEARANCES AROUND THE APPLIANCE
BS.5449 Forced circulation hot water systems.
4.3.1 The following minimum free spaces, required
BS.5546 Installation of gas hot water supplies
for installation inspection and servicing, must
domestic purposes (2nd Family
be left around the boiler
Gases).
18 inches (450 mm) in front
BS.5440: 1 Flues (for gas appliances of rated 5 inches (125 mm) above
input not exceeding 60 kW). 6 inches (150 mm) below
0.2 inches (5 mm) on each side
BS.5440: 2 Ventilation (for gas appliances of 1 inch (25 mm) in front when installed in a
rated input not exceeding 60 kW). cupboard.
10
4.4 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 4.6 FLUE SYSTEM
accordance with the British Gas Publication
Guide for Gas Installations in Timber Frame 4.6.1 The terminal should be located where dispersal
Housing Reference DM2, If in doubt advice of combustion products is not impeded and with
must be sought from the local gas supplier. The due regard for the damage or discolouration
combination boiler may be installed in any room that might occur to building products in the
or internal space, although particular attention vicinity (see fig. 5).
is drawn to the requirements of the current The terminal must not be located in a place
I.E.E. Wiring Regulations, and in Scotland the where it is likely to cause a nuisance. In cold
electrical provisions of the Building Regulations and/or humid weather water vapour may
applicable in Scotland. With respect to the condense on leaving the flue terminal, the
installation of the combnation boiler in a room effect of such steaming must be considered
or internal space containing a bath or shower. The terminal must not be closer than 25 mm
Where a room sealed appliance is installed (1 in) to any combustible material For protection
in a room containing a bath or shower, any of combustibles, refer to BS 5440.1.
electrical switch or appliance control, utilising Where a flue terminal is installed less than
mains electricity should be so situated that it 1000 mm. from a plastic, or painted gutter;
cannot be touched by a person using a bath or or 500 mm from painted eaves, an aluminium
shower. shield 1000 mm long, should be fitted to the
A compartment used to enclose the combination underside of the gutter or painted surface.
boiler MUST be designed and constructed
specifically for this purpose. An existing Pluming will occur at the terminal so, where
cupboard, or compartment, may be used possible, terminal positions which could cause
provided it is modified accordingly Samples a nuisance should be avoided.
of the CSI combination boiler have been The flue must be installed in accordance with
examined by B.G. Technology Notified Body, the recommendations of BS 5440: Part 1.
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 IMPORTANT NOTES
with the Electro Magnetic Compatibility,
Directive 89/336/EEC and are therefore For greater flue lengths see twin flue
permitted to carry the CE Mark. instructions.
Flue must be positioned in a place not
The appliance has been tested and approved likely to cause a nuisance.
by the WRc as meeting the requirements of
G3 and L of the Building regulations and water
Bylaws Scheme - Approved Products.
11
Fig. 6
A- Directly below an open window or other opening (e.g. air brick) 300
B- From a vertical structure on the roof 150
C- Below eaves 200
D- Below balconies or car port roof 200
E- From a vertical drain pipes and soil pipes 150
F- From an internal or external corner 100
G- Above ground or below balcony level 300
H- From a surface facing a terminal 600
I- From a terminal facing the 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- Above an opening, air brick, opening windows etc... 300
N- Below gutters, soil pipes or drain pipes 75
P- Above intersection with roof 300
12
4.8.4 Draining tap 4.8.6 The appliance has an integral sealed expansion
These must be located in accessible positions vessel to accommodate the increase of water
to permit the draining of the whole system. volume when the system is heated.
The taps must be at least 15 mm nominal size It can accept up to 6 Its of expansion water.
and manufactured in accordance with BS 2870 If the appliance is connected to a system with
1980. an unusually high water content, calculate
the total expansion and add additional sealed
4.8.5 Air release points expansion capacity as appropriate (Fig. 7).
These must be fitted at all high points where In general, modern systems will present no
air will naturally collect, and must be sited to problem.
facilitate complete filling 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.
Fig. 7
Fig. 8
13
SIZING OF ADDITIONAL EXPANSION VESSEL: TABLE 3
Deduct from the value given in the table the 7 litre vessel supplied.
Safety
3.0
valve setting (bar)
Vessel charge
0.5 1.0 1.5
pressure (bar)
Initial system
0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0
pressure (bar)
Total water
EXPANSION VESSEL VOLUME (LITRES)
content of system
Litres
Note: This pressure can be increased up to 1.5 bar to suit high static head situations, see item 10, other appliance components in the
SERVICING INSTRUCTIONS.
B) Where fitting of a make up vessel would It is important that the correct concentration
be difficult, RE-PRESSURING of the system of the water treatment product is maintained
can be done. See section on FILLING. If the in accordance with the manufacturers’
capacity of the central heating system should instructions.
exceed 110 Litres, an additional vessel should If the boiler is installed in an existing system
be installed on the return to the combination any unsuitable additives MUST be removed by
boiler from the heating system (Fig. 7). thorough cleansing.
Guidance on vessel sizing is given in (Table BS 7593:1992 details the steps necessary
3). to clean domestic central heating system.
Reference should be made to British Gas Also check pipework and renew any corroded
Publications, «Material and Installation pipework or fittings. Valve glands must be
Specifications for Domestic Central Heating repacked or replaced wherever necessary and
and Hot Water». Draining taps should be any defective controls exchanged.
at least 1/2” in BSP nominal size and be in
accordance with BS 2879. 4.8.9 WATER TREATMENT
This boiler has a secondary ALUMINIUM alloy
4.8.8 Installation to an existing central heating heat exchanger Ravenheat recommended only
system. the use of FERNOX- COPAL or SENTINEL
The combination boiler is designed to operate X100 water treatment products, which must
on a sealed system only. Therefore if the be used in accordance with the manufacturers
existing system is of the open water type it will instructions. For further information contact:
have to be modified to comply with BS 5376 Fernox Manufacturing Co. Ltd.
Part 2. Tel 01799 550811
Before installing a new combination boiler to Sentinel Division Betz Dearborn Ltd.
an existing system, flush out the old system Tel. (0151) 424 5351
with a recommended descaling agent.
14
SALAMANDER CURROSION GUARD
SECTION 5 INSTALLATION
5.1 WARNING
Fig. 9
15
5.2 DELIVERY
Fig. 10
OPTIONAL EXTRAS:
Small carton containing (fig. 11):
59 - Rubber seal Ø 60
63 - Air intake duct extension
64 - Flue exhaust duct extension Fig. 12
65 - Pipe centering spring
16
5.3 UNPACKING.
Fig. 14
Fig. 15
17
5.5.2 Locate the rubber Ø 60 into the flue elbow - Cut the inner flue duct (60 mm) at right angles
header (fig 17). to a length equal to W + 264 mm.
Insert from cut and reassemble the two
5.5.3 If the standard flue is too long (the wall to tubes. Insert centering spring 65 (must be de-
go through is less than 680 mm thick) it can burred).
be shortened as follows: - Reassemble together inner and outer flue duct
Fig. 17
Fig. 18
Fig. 19
Fig. 20
KEY
56 - Straight header 60 - STD air intake duct 64 - Flue exhaust duct extension
57 - Elbow header 61 - STD flue exhaust duct 65 - Pipe centering spring
58 - Header gasket 62 - Terminal 66 - Sample point
59 - Rubber seal Ø 60 63 - Air intake duct extension 127 - Terminal rubber
18
5.5.4 Insert the flue assembly into the wall, being 5.5.7 Fit terminal cover plate (fig. 22).
careful to make sure that the outer air duct
comes flush to the inner surface of the wall. 5.5.8 Extensions kits are available to order for flue
extension of up to 2.5 metres total length.
5.5.5 Lift the boiler on to the wall, locating onto the
fixing jig wall bracket.
Fig. 21
Fig. 22
19
5.5.9 Each extension length extends the pipe by 5.7 INSTALLING THE APPLIANCE FOR SIDE
approximately 1000 mm long up to a maximum FLUE OUTLET (Fig. 20).
of two extensions.
The pipe length can be established using the 5.7.1 - Attach the template to the wall with adhesive
instructions in section 5.5 for rear flue outlets tape, making sure that the centre line is
and section 5.7 for side flue outlets. Extensions vertical and that the distance from the centre
must be installed with the widened end of the line to the nearest side wall is not less than
air intake pipe and the tapered end of the measurement in Fig. 25.
flue pipe aimed towards the exhaust terminal. - Mark the two fixing bracket securing holes on
Extensions must be joined together with the the wall and extend the axis of the flue duct
standard terminal pipe, and inserted in each hole to the side wall ensuring it is horizontal.
other as far as they can go. - Make sure flue slopes 2.5° down
If an extension must be shortened, this must towards the boiler that is 45 mm/m
be done from the straight end, and not from the fall per metre of the flue length.
widened or tapered end. To measure the pipe Fig. 23
properly all components must be assembled - Trace the centre of the flue duct hole measure
and total length measured before cutting. The distance (275 mm) from the corner of the wall
straight end of the extension connects to the and measure the distance (200 mm) to the
boiler. The flue output pipe fits into the boiler centre of flue duct hole to the corner.
header until it stops. The air intake pipe should Detach the template from wall.
be located approximately 2 mm. from the boiler - Use a dia. 10 mm. drill to make the 2 holes for
header (fig. 19). securing hanging bracket fixing. Insert the
When cutting both inner and outer ducts of the plastic expansion plugs. Core drill a 105 mm
extension, always ensure that the reduced end dia. hole in the side wall for inserting the flue
(male) of the inner duct is longer than the outer duct.
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.
20
Fig. 26
KEY
59 - Rubber seal diam. 60 64 - Flue exhaust extension
63 - Air intake duct extension 65 - Pipe centering spring
128 - In line bend
- Remove the centering spring 65, pull the 5.7.6 Lift the boiler on to the wall. Locate onto
flue terminal, disengage inner flue duct. the top coach bolts. Fit the lower coach
- Measure the thickness W of the wall. bolts and tighten all four securing bolts.
- Cut the outer air duct (100 mm. dia.) at right
angles and to a length equal to W+Y - 47 5.7.7 Working above the boiler pull the flue duct
mm. (fig. 18). towards the elbow in order to engage tube into
- Cut the inner flue duct (60 mm dia.) at right its header (Fig. 21). Position flue into straight
angles and to a length equal to W+Y + 65 mm. header and push to locate inner and outer
- Outer air duct and inner flue duct must be flue correctly. Ensuring good seal is made
de-burred. with o.rings.
- Reassemble the two tubes.
Insert centering spring 65. 5.7.8 Extension kits are available to order for flue
extension of up to 2.5 metres total length
5.7.5 Insert the flue assembly into the wall, making (Fig. 19). For further details see sect 5.5.9.
sure it will not interfere when fixing the boiler
on the wall.
L + L = 3.25 m MAX
Fig. 27
21
5.7.9 VERTICAL FLUE INSTRUCTION ONLY.
IN LINE FLUE BEND - 1680 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90° BEND
OBTUSE FLUE BEND - 1680 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135° BEND
Fig. 28
22
Fig. 30
2- Elbow bend
3- Elbow bend
4- Flue extension
6- Straight header
7- Roof flashing
5.9.2 Fit gas service cock to the boiler via the union
nut and connect gas pipe. Do not overtighten
and use another spanner as a counter force to
avoid straining internal connections.
Important consult (sect 4.5.1).
Measure the vertical distance between the top of 5.11 DOMESTIC HOT WATER (fig. 32)
the flue (Fig. 29) and the bottom of the flue terminal
assembly (Fig. 28). The measurements should be 5.11.1 The domestic hot water circuit does not need
taken from the outer diameter of the flue. a safety valve but it is essential to ensure that
NOTE: Where this length does not match any the pressure of the cold water supply does
standard combination of the extensions, they can not exceed 10 bar. If in doubt it is advisable
be cut to the required length (Fig. 30). to install a pressure reducing valve. The
minimum pressure needed to operate the
When cutting both inner and outer ducts of the domestic hot water system is 0.5 bar with a
extension, always cut on spigot side, and they must flow of approx 3 Its per min.
be de-burred. - Connect the 15 mm. cold water pipe to the
stop cock to the appliance inlet.
- Connect the 15 mm. hot water pipe with a
suitable connection.
23
5.12 SAFETY VALVE DISCHARGE AND
CONDENSATE DRAIN CONNECTION.
Fig. 33
24
5.14 PROGRAMMABLE TIMECLOCK - Continue filling the system until 1.5 bar
Instructions for use User’s Guide. register on gauge. Then turn off the filling
points stopcock.
SECTION 6 COMMISSIONING - Inspect the system for water soundness and
remedy any leaks discovered.
6.1 Each boiler has been through a rigorous
operational procedure at our factory and 6.5 SETTING THE SYSTEM DESIGN PRESSURE
should not require any further adjustment The design pressure must be a min. 1 bar and
If in the unlikely event of the appliance not max. 1.5 bar. These figures are read off the
operating correctly, please turn to the Fault pressure gauge.
Finding and Logic Sequence Charts. - The actual reading should ideally be 1
bar + the height in metres to the highest
6.2 GAS SUPPLY INSTALLATION point of the system above the base of the
appliance (up to max of 1,5 bar).
6.2.1 Inspect the entire installation including the N.B.: The safety valve is set to lift a 3 bar.
gas meter, test for soundness and purge, all - To lower the system pressure to the
as described in BS 6891. required value remove drain point (fig. 45)
or drain on the heating circuit.
6.3 ELECTRICAL INSTALLATION
Preliminary electrical systems checks to 6.6 FILLING THE HOT WATER SYSTEM
ensure electrical safety shall be carried out Close all hot water draw-off taps.
by a competent person (earth continuity, Open the cold water inlet cock.
polarity, resistance to earth). Those checks Slowly open each draw-off tap until clear water
are outlined in the «Instructions for British Gas is discharged.
Multimeter» Booklet. If a fault has occurred
on the appliance the fault finding procedure 6.7 LIGHTING THE BOILER
should be followed as specified under the Before lighting the main burner make sure that
servicing section of this document. the heating circuit flow and return valves are
open and also that the cold water input cock is
6.4 INITIAL FILLING OF THE SYSTEM open.
Open central heating flow and return valves - If external controls are installed (e.g
Unscrew the cap on automatic air release timeclock and thermostat) make sure that
valve one full turn (leave open permanently). they call for heat.
- Close all air release taps on the central - Turn main switch (fig. 35 item 1A) to winter.
heating system.
- Gradually open stopcock at the filling point
connection to the central heating system
until water is heard to flow.
- Starting with the lowest radiator open each
air release tap in turn. Close it only when
clear and free of bubbles, flowing out in
the water is the same way release air from
any high points in the pipework.
Fig. 34
25
INSTRUMENT PANEL
Fig. 35
GAS VALVE
KEY
77 - Upstream pressure inlet
81 - Downstream pressure outlet
104 - Gas valve modulator
110 - Max. regulator nut
111 - Min. regulator nut
114 - Electrical connections modulator
115 - Electrical connections
Fig. 36
26
- Turn control thermostat 4 up to its maximum 6.9 ADJUSTING MINIMUM AND MAXIMUM
setting. PRESSURE (fig. 36)
- Now the main burner should turn on. With SIT-HONEYWELL-DUNGS GAS VALVE
leak detection fluid test for gas soundness - Remove cap covering modulator to gas
of all gas components and joints. valve.
- See paragraph 6.13 for regulating the - Detach one of the cables connected to the
heating circuit thermostat. modulator 114.
Check gas mains pressure (fig. 37). Fit a - With the boiler operating use a screw
gas pressure gauge on pressure inlet 77 driver (HONEYWELL 9 mm spanner) to
(fig. 36) on the gas valve, after releasing turn the nut 111 clockwise to increase
the seal screw. pressure and anti-clockwise to decrease
Check the gas mains pressure with the pressure.
boiler operating.
Check with the Local Gas supplier if the NOTE: LPG ONLY
pressure differs significantly from 20 mbar The minimum pressure is factory set and
(natural gas), 37 mbar (G 31) and 29 mbar sealed, and cannot be adjusted.
(G 30).
6.10 RECONNECT THE DETACHED CABLE
6.8 CHECK THE GAS PRESSURE AT THE Use a screw-driver to hold nut 111
BURNER (HONEYWELL 9 mm spanner) and use a 10
Now check if the maximum gas pressure at mm spanner (HONEYWELL 7 mm spanner)
the burner is equal to 10.5 ± 0.5 mbar (4.2 wrench to rotate the nut 110 clockwise to
± 0.2 in w.g.) for CSI 85 - CSI 85T. increase the pressure and counter-clockwise
– LPG check gas pressure inlet (37 mbar to decrease it. After adjustment turnoff D.H.W.
propane - 29 mbar butane). To do this proceed Taps.
as follows:
- Turn off main switch 1 (fig. 35) 6.11 SETTING CENTRAL HEATING GAS
- Set main switch 1 on PRESSURE THE BOILER COMES SET
- Set control thermostat 5 at it maximum AT MID POSITION RATING FOR USE ON
setting. C.H. (table1)
- Fit a pressure gauge, using a hose, to When the boiler operates in the C.H. mode
pressure test point 81 (fig. 36), after the gas pressure at the burner can be set
first loosening its close-off screw. between the min and max values. This
- Open one or more hot water taps so that at permits capacity to be adjusted to suit system
least 10-12 litre of water flows per minute. demand. If adjustment is required proceed as
- The pressure indicated on the pressure follows:
gauge is the maximum operating gas - Remove the front panel and the panel
pressure. instrument as described (sect. 5.4).
- Check that the minimum pressure - Unscrew the two screws holding the
corresponds to 2 mbar (0.8 in w.g.) for G control box cover and lift off.
20 as is set at the factory. - Select summer/winter switch in winter
- LPG 7.3 mbar for G 31 and 7.0 mbar for G position (Fig. 35).
30. This is set and sealed at the factory - Turn CH control knob to maximum
and cannot be adjusted. setting (fig. 35 item 4).
Detach one of the wires going to modulator - Check all external controls are on and
104 (Fig. 51) and make the boiler operate as calling for heat, ensure all D.H W. taps are off.
done for checking the maximum pressure. - With boiler operating use a screwdriver to
turn potentiometer (fig. 34) clockwise to
increase pressure and anti-clockwise to
decrease pressure.
- To obtain the desired heat value establish
pressure as per (fig. 37).
- Replace the protective cover.
- Once this pressure is established, mark
it up on data badge with, adhesive red
label/arrow burner pressure setting so that
this can be referred to and checked during
future servicing.
27
6.12 CHECKING THE FLUE SYSTEM
Fig. 37
6.13 CHECKING THE HEATING THERMOSTAT - Select summer/winter switch on summer position
(Fig. 35).
6.13.1 Allow the system to warm up and then turn Slowly close the draw off tap to reduce the flow
the C.H thermostat to ensure the main burner rate to above the min (approx. 2.8 l/min).
modulates from “high” to “low” and “low” to “off” - Rotate the D.H.W. control knob to ensure it
and vice versa (scale range covers approx operates at its various setting (Fig. 35).
45° C - 85° C). - Close the draw-off tap still further. The burner
should stop when the rate falls below about
6.14 TESTING AND REGULATING THE 2.8 l/min.
DOMESTIC HOT WATER SYSTEM FLOW
28
Fig. 39
KEY
2 - Plenum chamber cover 27 - Auto air vent valve 53 - Connection tube
6 - Combustion chamber 28 - Pressure switch 54 - Connection tube
7 - Flue restriction ring 29 - Seal 58 - Ceramic insulation
8 - Flue gas exhaust hood 31 - Seal 61 - Condensing heat exchanger
15 - Connection pipe 42 - Sight glass 80 - Plenum chamber
18 - Heat exchanger 44 - Fan 83 - Burner centering pin
24 - Burner 46 - Header gasket 84 - Seal
50 - Flue gas exhaust hood cover
29
6.15 HANDING OVER TO THE USER WARNING
Before the start of any servicing or
6.15.1 After completion of installation and replacement of components always
commissioning of the system, the installer isolate electricity supply to the appliance
should hand over to the Householder by taking and always turn off the appliance gas
the following actions: supply at the gas service cock.
- Hand the “User’s Instructions” to
the Householder and explain His/Her Data badge position-lower left hand side of
responsibilities under the “Gas Safety casing.
Regulations 2000”.
- Explain and demonstrate the lighting and - The following notes apply to the appliance
shutting down procedures. and its controls but it should be remembered
- The operation of the boiler including the use that attention must also be paid to the
and adjustment of ALL system controls which heating and hot water circuits with special
should be fully explained to the Householder. attention to radiator valves, thermostats,
This then ensures the greatest possible clocks, leaking hot water taps etc.
fuel economy consistent with household - Where it is necessary to replace a gasket
requirements of both heating and hot water that relies on adhesive for securing - this
consumptions. adhesive will be supplied with the gasket as
Advise the User of the precautions necessary a spare item.
to prevent damage to the system, and to the - In all cases prior to servicing, remove the
building, in the event of the system remaining outer case (sect. 5.4). Operate the appliance
inoperative during frost conditions. by turning the hot water services on to a high
- Explain the function and the use of the water flow, and observe the main burner.
summer/Winter and mains switch (Fig. 35). - Check that the flame covers all the flame
- Explain and demonstrate the function of ports and is of a light blue colour. Yellow
time and temperature controls, neon lights flames and excessive lifting of flames
radiator valves etc for the economic use of indicate poor combustion.
the system.
- If an optional time clock is fitted, then draw - IMPORTANT: After completing any servicing
attention to the time clock User’s Instructions or replacement of gas carrying components
and hand them to the Householder. it is essential that a test for gas soundness
- Stress the importance of regular servicing is always carried out along with functional
by a qualified Heating Engineer and that a checks in operation.
comprehensive service should be carried out
AT LEAST ONCE A YEAR. 7.2 TO INSPECT AND CLEAN THE
- Fill in the Benchmark log book and leave APPLIANCE
completed with the customer.
7.2.1 Before carrying out cleaning operation,
SECTION 7 SERVICING INSTRUCTIONS cover the electrical control panel with a
piece of waterproof material to protect it
from debris.
30
7.2.7 Inspect the secondary condensate exchanger then from the appliance.
heat exchanger. Deposits can be Place in a safe place until required
cleared by removing and flushing out Reassemble in reverse order. Ensure wires
the exchanger. Inspect the siphonic are connected correctly.
condensate trap for a blockage. Any
deposits should be flushed out (fig. 55). 7.6 TO REMOVE/REPLACE CONDENSING
HEAT EXCHANGER (fig. 41).
7.2.8 To remove condensate trap (sect. 5.4). Pull
forward the trap (fig. 55). Remove front casing (sect. 7.3).
Unscrew the earth wire, and the sensor. Remove combustion chamber front cover
Replace in reverse order. as in (sect 7.4).
7.2.9 Examine the fan for any mechanical 7.6.2 Close the ON/OFF valves for the heating.
damage, check to ensure free running of Drain the heating system from the drain
the fan wheel. Clean the wheel if necessary point mounted system (fig. 45).
with a soft brush. Check sealing gasket and
renew if damaged. 7.6.3 Remove the fan.
7.2.10 Examine flue duct and flue hood and ensure 7.6.4 Disconnect 4 unions for the heating water
that there is no obstruction. Examine the pipelines (fig. 41) and remove the two short
gasket at the entry into the flue duct. pipes.
7.2.11 It is essential that a good seal is made at the 7.6.5 Remove screw holding the heat exchanger
outlet to the fan, renew this gasket if there is to chamber. Disconnect condensing
any sign of damage or deterioration. discharge pipe by pulling off the pushfit
connector at top rear of boiler (fig. 41).
7.3 TO REMOVE/REPLACE THE CASING.
7.6.6 Pull the heat exchanger down and slightly
7.3.1 Remove the 2 screws that secure the upper forward until it comes out of the connection
part and the 4 screws that fasten the lower from chamber.
grating on the casing.
Carefully slide the casing forward to lift off. 7.6.7 Replace in reverse order. Taking care to
refit discharge pipe at rear.
7.4 TO REMOVE/REPLACE THE
COMBUSTION CHAMBER COVER IMPORTANT: When replacing heat
exchanger new seals must be used.
7.4.1 Remove the front casing panel (sect. 7.3).
31
7.9 TO REMOVE/REPLACE COMBUSTION
7.7 TO REMOVE/REPLACE THE FLUE
CHAMBER INSULATION PANELS.
HOOD.
7.9.1 Remove casing front panel (sect. 7.3).
7.7.1 Remove front casing (sect. 7.3).
Remove combustion chamber front cover
Remove combustion chamber front cover
(sect. 7.4).
as in (sect. 7.4).
7.9.2 Remove fan (sect. 7.5).
7.7.2 Remove the fan (sect. 7.5).
7.9.3 Remove condensing heat exchanger
7.7.3 Remove condensing heat exchanger (sect.
(sect. 7.6).
7.6).
7.9.4 Remove the flue hood (sect. 7.7).
7.7.4 Remove the three screws on the front
that fasten the hood to the combustion
7.9.5 Remove main burner (fig. 51).
chamber.
Remove top insulation pieces at sides.
Remove 2 screws securing combustion
7.7.5 Remove the two screws at the rear of
chamber to rear of boiler.
hood.
Lower chamber carefully remove all
insulation panels.
7.7.6 Replace in reverse order
7.9.6 Replace in reverse order.
7.8 TO REMOVE THE HEAT EXCHANGER
(fIG. 47-48).
Fig. 41
32
Fig. 42
Fig. 43
Fig. 45
Fig. 44
33
7.11 TO REMOVE/REPLACE THE INJECTORS
( fig. 50). 7.14.3 Remove the switch out from the instrument
panel by pressing the clamp springs.
7.11.1 Remove the front casing and the depression
chamber front cover (sect.7.3 - 7.4). 7.14.4 Replace in reverse order.
7.11.5 Unscrew and replace the injectors and their 7.15.2 Remove the wires that connect the sensors.
seals.
7.15.3 For C.H. thermistor remove the retaining clip
7.11.6 Replace in reverse order. from the pipe.
Replace in reverse order.
7.11.7 Relocate the grommet, sealing the gas supply
pipe to the casing taking care not to damage 7.15.4 For D.H.W. sensor close the on/off valves for
it. Replace if necessary. the domestic inlet water circuit and open do-
mestic hot water tap.
7.12 TO REMOVE/REPLACE THE BURNER Unscrew the sensor and replace in reverse
order with new seal (fig. 46).
7.12.1 Remove front casing (sect.7.3) and the
combustion chamber front cover (sect.7.4).
7.16 TO REMOVE/REPLACE THE OVERHEAT
7.12.2 Remove the injectors manifold as described THERMOSTAT.
in sect. 7.11.
7.16.1 Remove front casing (sect. 7.3).
7.12.3 Remove the two screws securing the main
burner to the combustion chamber (Fig 74). 7.16.2 Remove the two wires that connect to the
overheat thermostat.
7.12.4 Pull the burner forward and remove (fig. 49).
7.16.3 Remove the two screws securing the thermostat to
7.12.5 Replace in reverse order. the pipe and pull it out.
IMPORTANT: When refitting the burner make 7.16.4 Replace in reverse order (Fig.46).
sure that the pins at the rear of the combustion
chamber locate into the slots made on the rear
of the burner.
34
Fig. 47 Fig. 48
Fig. 49
Fig. 50
Fig. 51
35
7.17 TO REMOVE/REPLACE THE DIFFERENTIAL 7.19 TO REMOVE/REPLACE THE ELECTRIC
PRESSURE SWITCH (fig. 52). CONTROL AND IGNITION BOARD.
7.17.1 Remove front casing (sect. 7.3). 7.19.1 Remove the front panel from the outer
casing (sect. 7.3) and lower the instrument
7.17.2 Detach the wire connector plug from the panel .
pressure switch, make sure that the wire con-
nector plug are later reconnected. 7.19.2 Unscrew the 2 screws holding the control box
box cover and remove.
7.17.3 Unscrew the two screws that fasten the pressure Disconnect mains cables and any other
switch to the back of the combustion cham- connections (room thermostat).
ber.
7.19.3 Detach the connectors from the board.
7.17.4 Remove the two silicone tubes.
7.19.4 Replace in reverse order (ensure all electrical
7.17.5 Ensure tubes are connected correctly (Fig. 52) connections are made correctly).
avoiding kinks.
Fig. 53
Fig. 52
36
7.20 TO REMOVE/REPLACE CONDENSING 7.22.7 Unscrew the nuts that fasten the pump to the
TRAP (fig.55). ch pipe and diverter valve pump manifold.
Remove the pump.
7.20.1 Remove the casing (sect 7.3) and lower
the instrument panel . 7.22.8 Replace in reverse order.
NOTE : Alway use new seals when re-fitting
7.20.2 Remove the securing clip and pull the new pump.
out the plastic pipe that connect the
condensing trap at the heat exchanger. 7.23 TO REMOVE/REPLACE C.H.
DIVERTER VALVE (fig. 57).
7.20.3 Unscrew the nut that fasten the
condensing trap to the backframe and 7.23.1 Remove front and bottom of the casing (sect
remove it. 7.3).
7.20.4 Replace in reverse order. 7.23.2 Close the on/off valves for the CH and DHW
circuit and drain the water at drain point
(fig. 45) and open the domestic hot water tap.
7.21 TO REMOVE/REPLACE DIVERTER
VALVE SWITCH . 7.23.3 Remove diverter valve switch.
Fig. 56
Fig. 55
Fig. 57
37
7.25.12 Remove the expansion vessel.
7.24.1 TO REMOVE/REPLACE DHW
DIVERTER VALVE (fig. 57). 7.25.13 Replace all the components in reverse order
7.24.1.1 Remove front and bottom of the casing using new seals.
(sect 7.3).
7.25.14 Fill the system as described in the sect. 6 and
7.24.2 Close the on/off valve for the DHW circuit check for leaks.
and drain the boiler.
38
7.27 TO REMOVE/REPLACE TIMECLOCK
(Fig.88/A).
7.27.1 Remove the front panel from the outer casing (sect.
7.3) and lower the instrument panel.
Fig. 59
39
SECTION 8 FAULT FINDING CENTRAL HEATING
No
Check\Replace Low
water Pressure Switch Check /Replace Timeclock
Yes if OK Replace control board
Is the fan Oscillating on-off Yes Check\replace fan modulating board Is there spark ignition No Check \Replace
Spark electrode
Yes
No
Does burner light? No Is there a gas supply for the applianced Yes
Check\Replace condensing
No Check Gas supply Yes
trap and\or condensing sensor
Yes
Yes Check \Replace control board fuse
Yes
Is the burner shut down by overheat stat Yes Is the flue temperature less than 95°C
40
FAULT FINDING DOMESTIC HOT WATER
Before continuing it may be necessary to see Central Heating Fault Finding (Sect.8)
- All gas supply cocks are open and the gas supply has been purge of air.
- The heating system pressure is at least 1 bar min to 1.5 bar Max.
- Main Switch on and power indicator light is on
- Select “Summer” (Fig.35 item 1A)
- Domestic Hot Water control knob to maximum (Fig.35 item 5)
- Open Domestic hot tap close to the appliance
Yes
Yes
Check/Replace
Is low pressure Does the flow No
Does main burner No DHW diverter
No in the system detector light?
light? valve
Yes No
No
Does the DHW No Check / Replace DHW potentiometer No Check / Replace DHW sensor
temperature
stabilise at set point ?
Yes
41
SECTION 9 ELECTRICAL SYSTEM DIAGRAM.
Fig. 60
42
SECTION 10 INSTALLATION INSTRUCTION FOR
TWIN FLUE PIPE (ECCENTRIC FLUE DUCT SYSTEM).
Fig. 61 Fig. 62
These instructions must be read in 13- 45° air intake bend duct 16 - vertical eccentric flue exhaust duct
conjunction with the installation and Supplied with the CSI 85 AAA (T) 780
servicing instructions. series twin flue header is a F1
orifice plate along with supplementary
As with all flues the kits must be installed depression seal.
taking due account of the current issue of BS Before fixing the twin flue system the existing
5440 parts 1 & 2 and timber frame housing orifice plate must be replaced with F1 also
REF DM2. ensuring supplementary seal has been fitted.
Also note that the requirements will vary
depending upon the kit being installed. Remove the 13 screws securing the
Guidance is provided but unless otherwise depression front panel item 2 figure 39 to
stated, always comply with the expose front edge of depression chamber
recommendations of the relevant codes of (Twin flue instructions figure 1 adjacent).
practice. Using adhesive sponge supplied with CSI
twin flue header, carefully attach to
10.2 TWIN FLUE INSTRUCTIONS. depression chamber so as to create a softer
seal.
This part of the installation manual covers the Taking care not to damage the new seal,
installation and fixing instructions of the twin carefully re-fit the depression
flue eccentric flue duct systems only. chamber front cover in reverse order.
When ordering twin flue it must be stated for
CSI 85 AAA (T) - 780 series range. Take out the 4 temporarily fitted securing
Typical installation procedures are illustrated screws, lifting out the gasket and orifice plate
by drawings. disconnecting it from the venturi tube.
Discard this orifice plate and re-fit the F1
IMPORTANT orifice plate ensuring that the venturi tube has
Correct F1 orifice must be fitted. been re-fitted, making sure this is securely
located into the locating peg.
43
Locate the sealing washer fixing the twin flue
header as illustrated making sure that the
inner aluminium exhaust locates firmly in the
outlet spigot make sure that the screws are
satisfactorily located through the gasket seal.
Spacing Clips
Spacing Clips are available on request should
they be required.
NOTE: for eccentric vertical flue a 125 mm (5 in)
diameter flashing plate will be required.
Fig. 63
Fig. 64
E = EXHAUST
I = INLET
T= TERMINAL
90° slow bend less 3 metre of pipe for each one fitted.
135° bend less 1.5 metre of pipe for each one fitted.
NOTE:
If bends are used in the exhaust flue then horizontal
sections must be avoided and there must be a 2° slope
towards the boiler 35 mm fall per metre.
44
Exhaust/suction system with two separate rated 80 dia.
Pipes - exhaust on flat or sloping roof, suction from vertical
wall.
90° slow bend less 3 metre of pipe for each one fitted
45° bend less 1.5 metre of pipe for each one fitted
IMPORTANT:
see Fig. 6 and 29 for terminal clearances.
90° slow bend less 3 metre of pipe for each one fitted.
45° bend less 1.5 metre of pipe for each one fitted.
Fig. 66
IMPORTANT: inlet and exhaust terminals must
never be installed on opposite walls of the building
(PrEN 483).
IMPORTANT:
see Fig. 6 and 29 for terminal clearances.
45
SECTION 11
50
79
100
27 83
118 39
18
4
14
16
3 9 15
1
17 8
12 5
105
2
22
11
46
SECTION 12 RAVENHEAT CSI 85 AAA (T) - 780 series CONDENSING FANNED COMBI
BOILER
Ravenheat G.C.
Pos. Part. No. Part. No. Description
47
Ravenheat G.C.
Pos. Part. No. Part. No. Description
48
49
COD 0017LIB06006/2 - 06/2009
The code of practice for the installation, commissioning & servicing of gas central heating
Installation, Commissioning and Service Record Log Book
CUSTOMER DETAILS
NAME
ADDRESS TEL No.
IMPORTANT
1. Please keep the Log Book in a safe place for future reference.
2. This Log Book is to be completed in full by the competent person(s) who commissioned the boiler and associated equipment and then handed to
the customer. When this is done, the Log Book is a commissioning certificate that can be accepted as evidence of compliance with the appropriate
Building Regulations.
3. Failure to install and commission this appliance to the manufacturer’s instructions may invalidate the warranty.The above does not affect your statutory rights.
INSTALLER & COMMISSIONING ENGINEER DETAILS
INSTALLER DETAILS
COMPANY NAME INSTALLATION DATE
ADDRESS TEL No.
INSTALLER’S NAME
BOILER
MAKE AND MODEL
APPLIANCE SERIAL No. SEDBUK No. %%
LOCATION
LOCATION NEW SISTEM or REPLACEMENT BOILER
CONTROLS
To comply with the Building Regulations, each section must have a tick in one or other of the boxes.
REQUIREMENT MEASURES PROVIDED
1. TIME AND TEMPERATURE CONTROL TO HEATING ROOM STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT
2. TIME AND TEMPERATURE CONTROL TO HOT WATER CYLINDER STAT & PROGRAMMER/TIMER COMBI BOILER
PLEASE FOLLOW THE INSTALLATION AND COMMISSIONING INSTRUCTIONS IN THE INSTALLATION MANUAL SUPPLIED WITH THE EQUIPMENT
Benchmark is supported by
The content of this Log Book has been produced in
consultation with
© CENTRAL HEATING INFORMATION COUNCIL
51
For the domestic hot water mode, measure and record:
HEAT INPUT kW
HAVE YOU LEFT ALL THE MANUFACTURER’S LITERATURE WITH THE CUSTOMER? YES
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
When all of the above services have been completed, please contact your Service Engineer for an additional service interval record sheet.
52