Ravenheat Flue Boiler Installation And Servicing Instructions Download Page 32

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Supplied By www.heating spares.co Tel. 0161 620 6677

7.8.4

7.8.5

Remove the fan (sect. 7.6).

Fig. 54

Remove condensing heat exchanger

(sect. 7.6.5).

7.8.6

7.8.8

7.8.9

Remove the flue hood (sect. 7.7).

Remove the automatic air vent (Fig. 92).

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.

7.8.11

Remove the two side insulation panels at

top of heat exchanger (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 chamber front cover
(sect. 7.4).

7.9.2

7.9.3

Remove fan (sect. 7.6).

Remove condensing heat exchanger (sect.

7.6.5).

7.9.4

7.9.5

Remove the flue hood (sect. 7.7).

Remove main burner (sect. 7.15).
Remove top insulation pieces at sides.

Remove 2 screws securing combustion

chamber to rear of boiler.
Lower chamber carefully remove all insula-
tion panels.

7.9.6

Replace in reverse order.

Fig. 55

Summary of Contents for Flue Boiler

Page 1: ...m Water Fitting Byelaws Scheme WITH TIMER NATURAL GAS G 20 I2H G C NO 47 581 02 CSI LPG G 30 G 31 I3 G C N O 47 581 04 CSI INSTALLATION AND SERVICING INSTRUCTIONS TO BE LEFT WITH USER Technical and illustrative data are not binding and can be modified without prior notice The descriptions and illustrations in the present booklet are for guideline purposes only RAVENHEAT MANUFACTURING LTD CHARTISTS...

Page 2: ...t exchanger for high thermal flue transfer gases to water Built in frost protection Printed circuit board designed to connect to room stat cylinder stat and or timer frost stat Aesthetically pleasing panels and controls On Off ball valves for shutting off gas and central heating Safety relief valve for safety discharge Programmable 7 day module with digital display optional All front panel control...

Page 3: ...tion pilot burner 5 Interface board 6 Condensing heat exchanger 7 Ignition board 9 Ignition electrode 11 Frame 12 Modulating gas valve 15 Heating control 16 D H W control 17 D H W sensor 18 Pressure switch heating circuit 22 Overheat cut off thermostat 23 Safety relief system 26 Auto air vent valve 28 Air pressure switch 29 Circulation pump 30 Water pressure gauge 33 Main switch PAGE 5 5 7 8 9 14 ...

Page 4: ...5 Flue restriction ring 16 Hot water control potentiometer 6 Condensing heat exchanger 17 Water pressure switch 7 Electronic ignition 18 Overheat cut off thermostat 8 Condensing trap 20 Gas service cock 9 Ignition electrode 21 Compression ball valves 23 Safety relief system 26 Auto air vent valve 28 Air pressure switch 29 Circulating pump 30 Water pressure gauge 36 Fan 37 Expansion tank 38 Sealed ...

Page 5: ... At this point the ignition board opens the first step of the gas valve to light the pilot burner 2 2 4 2 2 5 2 2 6 Central heating mode 2 2 7 If the main neon switch is on with a demand for heat to supply radiators etc with the heating circuit fully charged so as to opera te the low water sensor device the boiler will start but with a slightly differing time delay in that it will start on minimum...

Page 6: ...o operate 2 3 7 When the room thermostats and or timer in tervene the main burner shuts down The fan stops and the pump turns off via the pump overrun 2 3 6 The condensate trap is fitted with a block age safety sensor This prevents the boiler operating should there be a blockage in the condensate discharge trap 3 1 SAFETY DEVICE 3 1 2 An overheat cut off thermostat set slightly higher than the hig...

Page 7: ...UPPLY CONNECTION 1 2 RC FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve 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 SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 8 LITRES EXPANSION VESSEL PRE CHARG...

Page 8: ...1 HOLE ELECTRICAL SUPPLY 2 3 0 V 5 0 H Z POWER CONSUMPTION 160W EXTERNAL FUSE RATING 3A INTERNAL FUSE 315 mA 2A 4A 20 mm to BS 4265 DRY WEIGHT kg 46 WATER CONTENT C H litre 1 O GAS SUPPLY CONNECTION 1 2 RC FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over ...

Page 9: ...ng 60 kW DD 189 1990 Discharge of condensate Health Safety Document No 635 The Electricity at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to th...

Page 10: ...nstal lation pipes should be fitted in accordance with BS 6891 Pipework from the meter to the boiler must be of adequate size 22 mm min To within at least 3 metre of the boiler 15 mm min can then be used for remain ing pipe work to the appliance A smaller size than the boiler inlet gas connection should not be used The complete installa tion must be tested for soundness as described in the above C...

Page 11: ...s Where possible pipes should have a gradi ent to ensure air is carried naturally to air release points and water flows naturally to drain taps It should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air Except where providing useful heat pipes should be insulated to prevent heat loss and to avoid freezing Particular attention should be paid ...

Page 12: ...systems will present no problem 4 8 7 Mains water feed central heating There must be no direct connection to the mains water supply even through a non return valve without the approval of the Local Water Authority 4 8 8 Permissible methods of filling Cistern method Fig 8 The system may be filled by one of the fol lowing methods Through a cistern used for no other purpose via a ballvalve perma nent...

Page 13: ...e factor across 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 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 A combined ...

Page 14: ...ger Ravenheat recom mended only the use of FERNOX COPAL SENTINEL Xl00 or SALAMANDER CUR ROSION GUARD water treatment products which 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 Salamander Eng Ltd Tel 0121 3780952 4508 4 10 ELECTRICAL SUPPLY Warning th...

Page 15: ...d copper tails complete with 3 4 brass nuts and washers Box 2 of 2 containing Fig 12 Horizontal CSI flue kit 57 Flue bend assembly 58 Header gasket 59 Rubber seal 0 60 60 Air intake duct 61 Flue exhaust duct 62 Terminal Fig 13 65 Pipe centering spring 66 Flue gas sample point 127 Terminal rubber Contained in the carton Fig 1O Fig 12 OPTIONAL EXTRAS Small carton containing Fig 13 57 Straight header...

Page 16: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 17: ...top of the appliance to release them from their upper suspension hooks Fig 26 27 Make sure the casing and screws are put to one side in a safe place INSTALLINGTHE APPLIANCE FOR REAR FLUE OUTLET 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 template ...

Page 18: ...ter flue duct 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 Fig 32 KEY 56 Straight header 57 Elbow header 56 Header gasket 59 Rubber seal 0 60 60 ...

Page 19: ...ur secur i n g b o l t s 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 Fig 33 5 5 8 Fit terminal cover plate and terminal guard Fig 36 37 5 5 9 Extension kits are available on order for flue ext...

Page 20: ...acket 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 5 5 11 INLINE 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 398 IMPORTANT inline flue bend...

Page 21: ...boiler on the wall Locate onto the top coach bolts Fit the lower coach bolts and tighten all four securing bolts Remove the centering spring 65 pull the flue terminal disengage inner flue duct 5 7 8 Working above the boiler pull the flue duct towards the elbow in order to engage tube into its header Fig 35 Position flue into straight header and push so as to locate inner and outer flue correctly E...

Page 22: ...e roof Fig 42 POSITION MIN DISTANCE mm N above roof level to base of terminal 300 P from adjacent wall to flue 300 Q from internal corner to flue 300 S from facing terminal 1 200 M horizontally from a vertical terminal to a wall 300 Ensure that the maximum permissible flue length is not exceeded Fig 42 Mark the four boiler fastening holes on the wall Detach the template from the wall Use a 10 mm d...

Page 23: ...ure the seal 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 6 5 6 1 5 9 5 9 1 5 9 2 5 10 5 10 1 REASSEMBLE BOILER AS PER sect 5 6 1 Fitting valve pack Remove plastic caps from bo...

Page 24: ...Supplied By www heating spares co Tel 0161 620 6677 Fig 48A Fig 48B Schematic Y plan Schematic S plan Fig 49A POSlTlONlNG OF WATER AND GAS CONNECTIONS 24 ...

Page 25: ...ernal wiring must not be disturbed when wiring external controls 5 13 3 To gain access to external zone valve and cylinder stat connection box remove the 2 screws on the side of the plastic cover just behind the control panel see Fig 48a or Fig 48b Heat resistant flexible cable is fitted between the isolator and the terminal block A 3 core cable of 0 75 mm 24 x 0 2 mm to BS6500 Make sure all wires...

Page 26: ...Supplied By www heating spares co Tel 0161 620 6677 2 6 ...

Page 27: ...pressure to the required value remove drain point Fig 93 or drain on the heating circuit LIGHTING THE BOILER Fig 50 Before lighting the main burner make sure that the heating circuit flow and return val ves are open If external controls are installed e g timeclock and thermostat make sure that they call for heat Turn on main switch 1 Fig 50 Turn control thermostat 4 up to its maxi mum setting Now ...

Page 28: ...d sect 5 4 3 Unscrew the two screws holding the control box cover and lift off Fig 78 Turn on main switch 1 Fig 50 Turn control thermostat 4 to maximum setting Fig 50 Check all external controls are on and calling for heat With boiler operating use a screwdriver to turn potentiometer Fig 48 clockwise to increase pressure and anti clockwise to decrease pressure Once the process of commissioning the...

Page 29: ... gas exhaust hood 15 Connection pipe 18 Heat exchanger 24 Main burner 25 Pilot burner 27 Auto air vent valve 28 Pressure switch 29 Seal 31 Seal 37 Window seal 42 Window clamp ring 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: ...sage but in general once per year should be adequate WARNING Before the start of any servicing or replace ment of components always isolate electric 7 2 7 2 1 7 2 2 7 2 3 7 2 4 7 2 5 7 2 5 1 7 2 6 ity supply to the appliance and always turn off the appliance gas supply at the gas ser vice cock Data badge position lower left hand sub frame The following notes apply to the appli ance and its control...

Page 31: ...ical connections from the fan motor 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 Reas semble in reverse order Ensure wires are connected correctly Fig 94 7 7 4 7 7 6 7 8 7 8 1 7 8 2 TO REMOVE REPLACE CONDENSING HEAT EXCHANGER FIG 54 55 Remov...

Page 32: ...low 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 chamber front cover sect 7 4 7 9 2 7 9 3 Remove fan sect 7 6 Re...

Page 33: ...Supplied By www heating spares co Tel 0161 620 6677 7 10 TO REPLACE THE ELECTRODE Fig 66 7 10 1 Remove front casing sect 7 3 Remove combustion chamber front cover sect 7 4 Fig 56 Fig 60 Fig 62 ...

Page 34: ... and the combustion chamber front cover sect 7 3 7 41 Remove the lower sect 5 4 2 Fig 21 Release the fitting that secures pilot pipe at the gas valve Remove electrode sect 7 10 Unscrew pilot connection from pilot burner Pull the aluminium tube downwards and the injector should come out by itself Replace in reverse order TO REPLACETHE PILOT BURNER Remove the front panel of the casing and the combus...

Page 35: ...t 7 3 4 Remove the pilot burner assembly as described in sect 7 13 Unscrew the union Fig 70 Unscrew the 4 screws securing the injector manifold to the burner Fig 71 Pull the manifold up and out from the com bustion chamber Fig 72 Unscrew and replace the injectors and their seals Fig 73 Replace in reverse order Reocate the grommet sealing the gas sup ply pipe to the casing taking care not to damage...

Page 36: ...THE GAS VALVE Fig 51 Remove front casing panel sect 7 3 Push the 2 clips that fasten the instrument panel Fig 23 Lift the instrument panel to detach it from the sides and lower it down by rotating it on its own hinges Fig 25 Pull the 2 wires from the Modulator Remove the electronic ignition board 7 32 2 3 Remove the lower grating sect 5 4 2 Unscrew the pilot burner tube connection Remove the eight...

Page 37: ...rheat thermostat making sure that these wires will subsequently be reconnect ed to the same poles Fig 94 7 25 1 7 25 2 7 22 5 Remove the split pin and pull the thermo stat sensor from its pocket 7 22 7 Replace in reverse order 7 25 3 TO REMOVE REPLACE THE ELECTRIC CONTROL BOARD PCB Remove the front panel from the outer cas ing sect 7 3 and lower the instrument panel sect 1 16 2 3 Unscrew the 2 scr...

Page 38: ...nd cover ensuring that con nection wire br L and bl N 7 25 10 Refill the heating system as described in the sect 6 4 5 and check for leaks 7 27 TO REMOVE REPLACE THE CENTRAL HEATING AND OR HOT WATER CONTROLTHERMISTOR 7 27 1 Remove the front panel from the outer cas ing sect 7 3 and lower the instrument panel sect 7 16 2 7 27 2 7 27 3 Remove left right side of casing sect 5 4 Remove the wires that ...

Page 39: ...ower coach bolts and release 2 top coach bolts then remove boil er from the wall 7 28 10 Unscrew the nut that connects the expan sion vessel and remove it Fig 91 7 28 11 Remove the screw supporting expansion vessel Fig 91 7 28 12 Remove the expansion vessel 7 28 13 Replace all the components in reverse order using new seals 7 28 14 Fill the system as described in the sect 6 and check for leaks 7 2...

Page 40: ...from p a n e l 7 31 4 Remove two clips securing the timer 7 31 5 Carefully remove the four wires connecting timer by pulling spade connectors from timer 7 31 6 Replace in reverse order ensure all electri cal connections are made correctly Fig 88 A 7 32 TO REMOVE REPLACE THE IGNITION BOARD 7 32 1 Remove front casing sect 7 3 lower the instrument panel sect 7 16 2 3 7 32 2 Remove the screw from the ...

Page 41: ...Supplied By www heating spares co Tel 0161 620 6677 Fig 90 Fig 91 Fig 93 41 ...

Page 42: ...Supplied By www heating spares co Tel 0161 620 6677 SECTION 8 FAULT FINDING CENTRAL HEATING Switch on Stat to maximum Ensure external controls calling for heat Room Stat Time Clock TRV DHW Stat 42 ...

Page 43: ...upplied By www heating spares co Tel 0161 620 6677 BOILER NOT OPERATIONAL ON TIMER INTEGRAL Switchon Select Winter CentralHeating Stat to Maximum Ensure External control calling for heat Room Stat TRV 43 ...

Page 44: ...Supplied By www heating spares co Tel 0161 620 6677 SECTION 9 ELECTRICAL SYSTEM DIAGRAM Fig 94 44 ...

Page 45: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 46: ...re illustrated by drawings IMPORTANT Correct F1 orifice must be fitted Supplied with the CSI twin flue header is a F1 orifice plate along 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 depression front panel item 2 figure 53A to expose front ...

Page 47: ...red NOTE for eccentric vertical flue a 125 mm 5 in diameter flashing plate will be required 90o M F bend consisting of 90o elbow with 0 ring side F 80 mm dia 0 ring 135 M F bend consisting of 135 elbow with 0 ring side F 80 mm dia 0 ring Vertical eccentric flue exhaust duct Exhaust suction system with concentric pipes for flat or sloping roofs Extensions with two separate pipes Maximum distance I ...

Page 48: ...NOTE The pressure loss for each elbow fitted is 90o slow bend less 3 metre of pipe for each one fitted 45o bend less 1 5 metre of pipe for each one fitted IMPORTANT inlet and exhaust terminals must never be installed on opposite walls of the building PrEN 483 ITEM DESCRIPTION IMPORTANT NOTICE If the flue terminates less than 2 M above a balcony above the PART NO ground or above a flat roof to whic...

Page 49: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 50: ...art No Part No E23 711 E23 712 E23 729 371267 E23 732 E23 730 372842 E23 715 371268 E23 716 E23 733 372845 E23 718 E24 630 372849 173100 372 866 372894 E23 731 E23 735 372888 372851 372867 173101 E23 737 E23 738 E23 726 372855 371277 Description Instrument panel TIMER MODEL Main switch D H W C H Potentiometer Overheat thermostat Combustion chamber Flue restriction ring 79CSI F2 Water gauge D H W C...

Page 51: ...80 5009080 372896 Circulation pump 81 0013GUA01045 0 371274 Gasket 48 x 42 x 1 82 5003283 372874 Brass manifold 83 5015010 372897 Safety relief valve 3 bar 85 0012FUS05020 0 E23 724 Internal fuse 4A 87 5021312 372875 Nylon tubes from pressure switch 89 0005PRE05015 0 E24 629 Pressure switch 93 0019CUR06005 0 E23 750 Elbow header 95 0019PR006005 0 E23 751 Flue extension duct complete 97 0019TER0600...

Page 52: ...Supplied By www heating spares co Tel 0161 620 6677 Chartists Way Morley Leeds LS27 9ET Telephone 0113 252 7007 Tfax 0113 238 0229 ...

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