Ravenheat CSI85A Installation And Servicing Instructions Download

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CSI 85 A (T)

Summary of Contents for CSI85A

Page 2: ...eliable diverter valve with ethylene propylene diaphragm permitting primary flow circulation 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 circuit Safety relief valve for s...

Page 3: ...nger for D H W water 3 Burner 4 Sensing electrode 6 Condensing heat exchanger 9 Ignition electrode 11 Frame 12 Modulating gas valve 15 Heating control 22 Overheat cut off thermostat 16 Hotwatercontrol 17 D H W sensor 18 Waterpressureswitch heatingcircuit 23 Safetyreliefsystem 24 Threewayvalve 26 Autoairventvalve 28 Pressureswitch 29 Circulationpump 30 Waterpressuregauge 33 Main switch 34 C H senso...

Page 4: ... Modulatinggasvalve 15 Heatingcontrolpotentiometer 16 Hotwatercontrolpotentiometer 17 Waterpressureswitch 18 Overheatcut offthermostat 20 Gasservicecock 21 Compressionballvalves 23 Safetyreliefsystem 24 Threewayvalve 25 Flowregulator 26 Auto air vent valve 27 Pressure switch giving priority 28 Pressure switch 29 Circulating pump 30 Water pressure gauge 36 Fan 37 Expansion tank 38 Sealed chamber 5 ...

Page 5: ...upply radiators 6 etc with heating circuit fully so as to operate the low water sensor device the boiler will start in the same way as domestic 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...

Page 6: ...tat 2 4 4 When D H W is no longer called for the boiler automatically returns to the central heating mode 2 4 5 Switch 33 in the summer position The boilerfunctionslikeanautomaticgashotwater heater When D H W is no longer required the main burner fan and pump immediately turn off This also takes place when switch 33 is on winter if there is no demand for heat to the central heating system or until...

Page 7: ...GE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 7 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE MAX 85 C MIN 45 C DESIGN FLOW RATE 1102 I h 20 C RISE MINIMUM FLOW RATE C H 503 I...

Page 8: ...compression isolating valve OUTLET CONNECTION D H W 15 mm compression SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE 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 TEMPERATU...

Page 9: ...oard SECTION 4 GENERAL REQUIREMENTS 4 0 1 SAFETY Gas Safety Installation and Use Regulations 1994 and amended 2000 It is law that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the above regulations and these installation instructions All CORGI registered installers carry a CORGI I D card and have a registration number Both should be recorded in yo...

Page 10: ... be fitted in accordance with BS 6891 Pipework from the meter to the boiler must be of adequate size 22 mm min To within at least 3 metre of the boiler 15 mm min can then be used for remaining pipe work to the appliance A smaller size than the boiler inlet gas connection should not be used The complete installation must be tested for soundness as described in the above Code N B if the gas supply f...

Page 11: ...TION central heating 4 8 1 Detailed recommendations are given in BS 6798 1987 5449 1990 for smallbore and microbore central heating systems The following notes are given for general guidance 4 8 2 Pipework Copper tubing to BS 2871 1 1 1971 is recommended for water pipes Jointing should be either with capillary soldered or with compression fittings Where possible pipes should have a gradient to ens...

Page 12: ...l to accommodate the increase of water volume when the system is heated It can accept up to 6 Its of expansion water If the appliance is connected 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 di...

Page 13: ...hich must be used in accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co Ltd Tel 01799 550811 Sentinel Division Betz Dearborn Ltd Tel 0151 424 5351 Safety valve setting bar 3 0 Vessel charge pressure bar 0 5 1 0 1 5 Initial system pressure bar 0 5 1 0 1 5 2 0 1 0 1 5 2 0 1 5 2 0 Total water content of system EXPANSION VESSELVOLUME LITRES Litres 25...

Page 14: ... 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 connection 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 co...

Page 15: ...s Separate Box containing Fig 12 Horizontal CSI flue kit 56 Flue gas assembly 57 Flue bend assembly 59 Rubber seal Ø 60 60 Air intake duct 61 Flue exhaust duct 62 Terminal 65 Pipe centering spring 66 Flue gas sample point 127 Terminal Rubber OPTIONAL EXTRAS Small carton containing Fig 13 57 Straight header supplied as an extra cost only when requested 59 Rubber seal Ø 60 66 Flue gas sample point F...

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Page 17: ...iance to release them from their upper suspension hooks Fig 26 27 5 4 6 Make sure the casing and screws are put to one side in a safe place 5 5 INSTALLING THE APPLIANCE FOR REAR FLUE OUTLET 5 5 1 Use adhesive tape to attach the template to the wall making sure that the centre line is vertical Mark the four boiler fastening holes on the wall as well as the centre of the flue duct Detach the templat...

Page 18: ... at right angles to a length equal to W 152 mm Must be de burred Cut the inner flue duct 60 mm at right angles to a length equal to W 264 mm Insert from cut end Reassemble the two tubes Insert centering spring 65 Must be de burred Reassemble together inner and outer flue duct insert centering spring KEY 56 Straight header 57 Elbow header 58 Header gasket 59 Rubber seal Ø 60 60 STD air intake duct ...

Page 19: ...s and tighten all four securing bolts 5 5 6 Working above the boiler pull the flue exhaust duct towards the boiler in order to engage tube 61 into its header 57A Position flue into elbow header and push so as to locate inner and outer flue correctly ensuring good seal is made with o rings 5 5 8 Fit terminal cover plate and terminal guard Fig 36 37 5 5 9 Extensions kits are available on order for f...

Page 20: ...vailable from Ravenheat Manufacturing and should be used to support flue length at least every 1 8 metre preferably at each joint this bracket should be secured to wall and flue duct 5 5 11 IN LINE FLUE BEND Measure the distance between the flue bends or the flue terminal assembly The measurements should be taken from the outer edge of the flue and bend Fig 39B IMPORTANT inline flue bend 1680 mm m...

Page 21: ...and to a length equal to W Y 65 mm Outer air duct and inner flue duct must be de burred Reassemble the two tubes Insert centering spring 65 5 7 6 Insert the flue assembly into the wall making sure it will not interfere when fixing the boiler on the wall 5 7 7 Lift the boiler on the wall Locate onto the top coach bolts Fit the lower coach bolts and tighten all four securing bolts 5 7 8 Working abov...

Page 22: ... FLUE complete with terminal assembly for vertical flue application Additional 1000 mm approx Flue Extension pieces as necessary each extension is provided with flue centering bracket One box containing straight header with inlet and outlet sealing rings Proceed with installation as detailed in section 5 up to 5 5 8 of the main Installation and Servicing Instruction ignoring all references to hori...

Page 23: ...rings are correctly located Fig 44 Make sure that the entire flue is adequately supported Use at least one bracket for each extension used Ensure that all inner flue connections have a good fit seal and that the space clips in each extension are correctly positioned 5 8 REASSEMBLE BOILER AS PER sect 5 6 1 5 8 1 Fitting valve pack Remove plastic caps from boiler connection and fit valves as per Fig...

Page 24: ...The discharge must not be over an entrance or a window or any other type of access 5 13 ELECTRICAL CONNECTIONS 5 13 1 IMPORTANT Electricity supply must be as specified in clause sect 4 10 When controls external to the appliance are required design of the external electrical circuits should be undertaken by a competent person In accordance with the IEE wiring regulations It is essential that all ex...

Page 25: ...oint 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 water free of bubbles flows out In the same way release air from any high points in the pipework Continue filling the system until 1 5 bar register on gauge Then turn off the filling points stopcock Inspect the system for water soun...

Page 26: ...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 27 ...

Page 27: ...RESSURE Fig 51 SIT HONEYWELL DUNGS GAS VALVE Remove cap covering modulator to gas valve Detach one of the cables connected to the modulator 114 With the boiler operating use a screw driver HONEYWELL 9 mm spanner to turn the nut 111 clockwise to increase pressure and anti clockwise to decrease pressure NOTE LPG ONLY The minimum pressure is factory set and sealed and cannot be adjusted 6 11 RECONNEC...

Page 28: ...8 Lts min 0 61 gals min The temperature of the water will depend on the rate at which it flows If due to high water pressure the flow rate is too high and thus the temperature too low for practical use the flow rate may be adjusted It is better to set for the lowest acceptable temperature preferably at the bath tap since the user can gain higher temperatures at other restricted flow taps Table 1 T...

Page 29: ...nection pipe 18 Heat exchanger 24 Burner 27 Auto air vent valve 28 Pressure switch 29 Seal 31 Seal 42 Sight glass 44 Fan 46 Header gasket 50 Flue gas exhaust hood cover 53 Connection tube 54 Connection tube 58 Ceramic insulation 61 Condensing heat exchanger 80 Plenum chamber 83 Burner centering pin 84 Seal ...

Page 30: ... cleaning will depend upon the particular installation conditions and usage but in general once year should be adequate WARNING Before the start of any servicing or replacement of components always isolate electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock Data badge position lower left hand sub frame The following notes apply to the appliance ...

Page 31: ...rical connections from the fan motor 7 6 4 Support the fan and remove the two fixing screws and bracket from the front of the flue hood Carefully withdraw from condensing heat exchanger then from the appliance Place in a safe place until required Reassemble in reverse order Ensure wires are connected correctly Fig 94 7 6 5 TO REMOVE REPLACE CONDENSING HEAT EXCHANGER FIG 54 55 7 6 5 1 Remove front ...

Page 32: ...xchanger Fig 63 7 8 12 Pull the heat exchanger up until its flow connections come out from the combustion chamber and then remove it Fig 64 7 8 13 Replace in reverse order Ensure correct wire position Fig 94 IMPORTANT When replacing a heat exchanger new seals must be used 7 9 TO REMOVE REPLACE COMBUSTION CHAMBER INSULATION PANELS Fig 63 7 9 1 Remove casing front panel sect 7 3 Remove combustion ch...

Page 33: ...34 7 10 TO REPLACE THE ELECTRODE Fig 52B 7 10 1 Remove front casing sect 7 3 Remove combustion chamber from cover sect 7 4 ...

Page 34: ...35 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 ...

Page 35: ... 7 14 3 Unscrew the 4 screw securing the injector manifold to the burner Fig 71 7 14 4 Pull the manifold up and out from the combustion chamber Fig 72 7 14 5 Unscrew and replace the injectors and their seals Fig 73 7 14 6 Replace in reverse order 7 14 7 Relocate the grommet sealing the gas supply pipe to the casing taking care not to damage it Replace if necessary ...

Page 36: ...that fasten the instrument panel Fig 23 7 16 3 Lift the instrument panel to detach it from the sides and lower it down by rotating it on its own hinges Fig 25 7 16 4 Pull the 2 wires from the Modulator 7 16 5 Remove the lower grating sect 5 4 2 and the gas valve 7 16 Remove the eight screws four per side that connect the gas valve to the gas pipelines and then remove it from its seat 7 16 Replacei...

Page 37: ...me poles Fig 94 7 22 3 Replace in reverse order 7 23 TO REMOVE REPLACE THE ELECTRIC CONTROL AND IGNITION BOARD 7 23 1 Remove the front panel from the outer casing sect 7 3 and lower the instrument panel sect 1 16 2 3 7 23 2 Unscrew the 2 screws holding the control box cover and remove Disconnect mains cables and any other connections room thermostat and frost thermostat if fitted 7 23 3 Detach the...

Page 38: ...t water from the lowest hot water tap and drain point on DHW inlet cock Fig 46 7 26 4 Unscrew the five nuts that connect the diverter valve and pull it out from boiler being careful not to damage the wires 7 26 5 Pull off circlip securing microswitches to divert er valve 7 26 6 If replacing microswitch assembly use a screw driver to prise off the protective cover of the microswitches 7 26 7 Detach...

Page 39: ...as supply 7 28 3 Drain domestic water from the lowest hot wa ter tap and drain point on DHW inlet cock Fig 46 7 28 4 Drain the boiler Fig 93 7 28 5 Disconnect all pipework connected to boiler 7 28 7 Disconnect mains cables and any other con nections room thermostat programming 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 b...

Page 40: ...ing sect 5 4 5 7 30 2 Close the on off valves for the heating system and drain the water from the drain point 7 30 3 Unscrew the screw from its body clean or replace Replace in reverse order 7 30 4 Fillthesystemasdescribedinthe sect 6 4 6 5 7 31 TO REMOVE REPLACE TIME CLOCK Fig 88 A 7 31 1 Remove the front panel from the outer casing sect 7 16 2 and 3 and lower the instrument panel sect 7 16 2 and...

Page 41: ...ain the boiler Fig 93 and drain hot water from the lowest hot water tap and drain point on DHW inlet cock Fig 46 7 33 4 Unscrew the four nuts that connect the DHW heat exchanger and pull it out from boiler 7 33 5 If necessary the pipes from the diverter valve may have to be remove for easier access 7 33 6 Repleace in reverse order Always use new seals 7 33 7 Fill the boilers as described in sect 6...

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Page 43: ...Is fan Running at Maximum speed 44 ...

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Page 46: ... with supplementary depression seal Before fixing the twin flue system the existing orifice plate must be replaced with F1 also ensuring supplementary seal has been fitted Remove the 13 screws securing the depres sion front panel item 2 figure 53A to expose front edge of depression chamber Twin flue instructions figure 1 adjacent Using adhesi ve sponge supplied with CSI twin flue header carefully ...

Page 47: ...the boiler 35 mm fall per metre 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 Exhaust suction system with concentric pipes for flat or sloping roofs Extensions with two separate pipes Maximum distance I E T 2 Metre 2 Metre 1 Metre 12 Metre maximum pipe terminal Minimum distance D ...

Page 48: ... each elbow fitted is 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 inlet and exhaust terminals must ne ver be installed on opposite walls of the buildin PrEN 483 IMPORTANT NOTICE If the flue terminares less than 2 M above a balcony above the ground or above a flat roof to which people have access then a suitable terminal guard m...

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Page 50: ...23 733 Flue gas exhaust hood 15 0012CIR06010 0 Fan Control Board 15 1 0012CIR06011 0 Fan Control Board red 16 0012CIR05010 2 Printed ignition control board 16 1 0012CIR06012 0 Printed ignition control board red 17 0014MAN06015 0 E23 718 Knob 21 0001C0P01010 0 Combustion chamber cover 22 0008VAL09015 0 Dungs valve gas 26 0002SCA06010 0 E23 731 Heat exchanger 27 0014RAC06005 0 E23 735 Condensing tra...

Page 51: ... 80 0009CIR01011 1 Circulation pump 82 0011COL01005 2 Brass manifold 83 0008VAL01018 1 Safety relief valve 3 bar 87 5021312 372875 Nylon tubes from pressure switch 89 0005PRE06006 0 Pressure switch 93 0019CUR06005 1 Elbow header 95 0019PR005005 0 Flue extension duct complete 97 0019TER06005 1 Flue duct and terminal complete 100 0004VAS06010 0 Expansion tank 105 TM6192 371258 Digital Timer 106 0019...

Page 52: ...COD 0017LIB06006 0 06 2005 ...

Page 53: ...S NO 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 3 HEATING ZONE VALVES FITTED NOT REQUIRED 4 THERMOSTATIC RADIATOR VALVES FITTE...

Page 54: ...NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly...

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