KEY 1 - Heat exchanger 3 - Burner 4 - Pilot burner 7 - Ignition board 9 - Ignition electrode 11 - Frame 12 - Modulating gas valve 15 - Heating control 16 - Hot water control
17- D.H.W. sensor 18- Water pressure switch (heating circuit) 22 - Overheat cut off thermostat 23 - Safety relief systems 24 - Three way valve 26 - Auto air vent valve 28 - Air pressure switch 29 - Circulation pump 30 - Water pressure gauge
33 - Main switch 34 - C.H. Sensor 36 - Fan 37 - Expansion tank 38 - Sealed chamber 45 - Combustion chamber 50 - Flue gas exhaust hood 105 -Timer 106 - Air restriction ring

OPERATING

Fig. 2
KEY 1 - Heat exchanger 2 - Heat exchanger for D.H.W. water 3 - Burner 4 - Pilot burner 5 - Air restriction ring 7 - Electronic ignition 9 - Ignition electrode 12 - Modulating gas valve 15 - Heating control 16 - Hot water control
17 - Low water pressure switch 18 - Overheat cut-off thermostat 20 - Gas service cock 21 - Compression ball valves 23 - Safety relief system 24 - Three way valve 25 - Flow regulator 26 - Auto air vent valve 27 - D.H.W. pressure switch giving priority 28 - Air pressure switch
- Circulating pump - Water pressure gauge - Fan - Expansion tank - Sealed chamber - Elbow header - Twin header - Straight header

SE C T I O N 1

I NTRODUCTION 2.2.6 2.2.7
switched off, the pressure switch returning to its rest mode. Central heating mode If the switch is positioned on with a demand for heat to supply radiators, etc. With heating circuit fully charged 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 maximum and minimum power. On the control panel are mounted two potentiometers (thermostats) these control the temperature. One is for domestic hot water and the other for heating. The boiler is fitted with an anti-cycling device on the control board. This delays the boiler from re-firing over a 2.5 minute period when in heating mode. The domestic hot water will always take priority and is unaffected by the anti-cycling device. GENERAL FUNCTION 2.3 2.3.1 Central Heating Mode A potentiometer is installed on the electric circuit board permits regulation of the boiler to partial heating requirements, between the factory setting. Air is drawn by the fan for combustion. The fan also forces exhaust gas through the flue to the outside, this creates a lesser pressure in the sealed combustion chamber, thus sucking in combustion air, through the inlet duct. The boiler water temperature is automatically controlled by a built in thermostat. Interior space temperature is set by the room thermostat to be installed in the heating system. The boiler already carries connection terminals for this thermostat, as well as for a timeclock. The burner will continue to operate until it is stopped by the timer or one of the thermostats. When the internal C.H. temperature sensor intervenes the main burner shuts down. The fan stops but the pump continues to operate. When the room thermostats intervene the main burner shuts down. The fan stops and the pump turns off.

water 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 the room thermostat/time clock demands for heat to the central heating circuit. 3.1 SAFETY DEVICE In both central heating and domestic hot water mode safe operating is ensured by: - A differential pressure switch which shuts off the main burner if the fan stops or the flue or combustion air intake duct is obstructed. An overheat cut off thermostat set slightly higher than the high limit thermostat acts to turn off the burner to resetable lockout (Fig. 50) item 3. A safety valve fitted on the central heating circuit set at 43 psi (3 bar). A heating circuit (low water) pressure switch is set at 0.4 bar.

3.1.3 3.2.1

OVERALL DIMENSION

DIMENSIONS (mm)

AVAILABLE PUMP HEAD
PRESSUREDROP ACROSS APPLIANCE

Fig. 5

SECTION

3 TECHNICAL DATA

TABLE 1 HEAT INPUT NET NOMINAL
RSF 84E(T) NATURAL GAS (G 20) I2H
(91,800 Btu/h) (68,250 Btu/h) (49,800 Btu/h) (83,880 Btu/h) (60,060 Btu/h) (39,250 Btu/h) (91.8 ft3/h) (67.1 ft3/h) (45.9 ft3/h) (3.2 in w.g.) (1.6 in wg.) (0.6 in w.g.)
26.9 kW max mid 20.0 kW min 14.6 kW max 24.58 kW HEAT OUTPUT 17.6 kW mid NOMINAL 11.5 kW min 2.6 m3/h max GAS RATE 1.9 m3/h mid AFTER 10 minutes 1.3 m3/h min (8.0 in w.g.) 20 mbar INLET PRESSURE 8.1 mbar max BURNER PRESSURE 4.0 mbar mid 1.5 mbar min 837 TANDEM SIT GAS CONTROL VALVE POLIDORO MOD/NP MAIN BURNER MAIN BURNER INJECTORS N. 13X1.35 POLIDORO PA525F PILOT BURNER (MARKING) 2 HOLES PILOT INJECTOR 0.27 230V-50HZ ELECTRICAL SUPPLY 160W POWER CONSUMPTION 3A EXTERNAL FUSE RATING 315mA - 2A - 4A (20mm to BS4265) INTERNAL FUSE RATING 48 kg (106 Lbs) DRY WEIGHT 0.5 Lts. (0.9 pints) WATER CONTENT D.H.W. 3.0 Lts. (5.3 pints) WATER CONTENT C.H. 15 mm compression isolating valve GAS SUPPLY CONNECTION 22 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 15 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression OUTLET CONNECTION D.H.W.

RSF lOOE(T) PROPANE GAS (G 31) I
32.82 kW (112,000 Btu/h) max 21.39 kW mid (73,000 Btu/h) 14.00 kW min (47,800 Btu/h) 29.66 kW HEAT OUTPUT (101,221 Btu/h) max 19.1 kW NOMINAL mid (65,170 Btu/h) 11.2 kW min (38,220 Btu/h) 1.3 m3/h GAS RATE (45.9 ft3/h) max AFTER 10 minutes 0.8 m3/h mid (28.2 ft3/h) 0.6 m3/h min (21.2 ft3/h) INLET PRESSURE (14.85 in w.g.) 37 mbar 23.5 mbar BURNERPRESSURE max (9.43 in w.g.) 9.3 mbar mid (3.73 in w.g.) 3.7 mbar min (1.48 in w.g.) GAS CONTROL VALVE 837 TANDEM SIT MAIN BURNER POLIDORO MOD/NP MAIN BURNER INJECTORS N. 15X0.85 PILOT BURNER POLIDORO PA525F PILOT INJECTOR 0.22 (MARKING) 1 HOLE ELECTRICAL SUPPLY 230V-50HZ POWER CONSUMPTION 160W EXTERNAL FUSE RATING 3A INTERNAL FUSE RATING 315mA-2A-4A (20mmtoBS4265) DRY WEIGHT 53 kg (116.6 Lbs) WATER CONTENT D.H.W. 0.7 Lts. (1.2 pints) WATER CONTENT C.H. 3.5 Lts. (5.2 pints) GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W. 15 mm compression MAXIMUM PERMISSIBLE COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRES SAFETY DISCHARGE PIPE 15 mm copper pipe SEALED WATER SYSTEM C.H. SYSTEM MAX PRESSURE 2.5 bar (35.6 p.s.i.) MINIMUM WORKING PRESSURE 0.5 bar (7.35 p.s.i.) 8 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar (7.35 p.s.i.) CENTRAL HEATING OPERATING TEMPERATURE MAX 85 oC MIN 45 oC o DESIGN FLOW RATE 1275 I/h (283 gals) 20 C RISE MINIMUM FLOW RATE C.H. 481 Lts/h (106 gals/h) D.H.W. FLOW RATE 30 oC rise 14.2 l/min (3.16 gals/min) D.H.W. FLOW RATE 35 oC rise 12.2 I/min (2.7 gals/min) D.H.W. FLOW RATE 40 oC rise 10.6 l/min (2.4 gals/min) 10 oC inlet temperature D.H.W.TEMPERATURE max 65 oC min 35C D.H.W. PRESSURE max 10 bar (147 p.s.i.) min 0.8 bar (11.8 p.s.i.) To obtain 95% heat input 1.7 bar (24.7 p.s.i.) D.H.W. MINIMUM FLOW RATE 3 I/m (0.66 gals/min) FLUE OUTLET NOM. DIA. 100 m/m specially supplied with boilers DESTINATION: BE - FR - IE - PT - ES - GB - CH Nominal Efficiency FLUE TYPE C12 - C32 - C52 Efficiency at 30% Load CATEGORY I 3P NOX 2

GENERAL REQUlREMENTS

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 your boiler log book. You can check your installer by calling CORGI direct on: 01256 732300. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with. Check the boiler and flue is the correct type for installation. The installation of the boiler MUST be in accordance with the latest I.E.E. (BS 7671) Wiring Regulations, local building regulations, bye-laws of the local water authority, the building regulations and the Building Standards (Scotland) and any relevant requirements of the local authority. GENERAL INFORMATION Both the user and the manufacturer rely heavily on the installer, whose job it is to install the combination boiler and connect it to a correctly designed heating system. Acquaint yourself with the British Standards concerning installation requirements. If you need advice on any points your Ravenheat Technical Services Office would be pleased to help. It is recommended that tools suitable for brass fittings are used, and have a capability to accommodate hexagon sizes up to 50 mms. CODES OF PRACTICE/Ref: Documents Detailed recommendations are contained in the following British Standard Codes of Practice: BS. 6891 BS. 6798 Low pressure installation pipes Installation of gas fired hot water boilers of rated input not exceeding 60 kW. Forced circulation hot water systems. Installation of gas hot water supplies domestic purposes (2nd Family Gases). 4.3 4.3.1 4.2 4.2.1

ply is available both to the boiler and the other appliances when they are in use at the same time. 4.6 4.6.1 FLUE SYSTEM The terminal should be located where dispersal of combustion products is not impeded, and with due regard for the damage or discolouration that might occur to building products in the vicinity (see fig. 6). The terminal must not be located in a place where it is likely to cause a nuisance. The terminal must not be closer than 25 mm. (1 in) to any combustible material. For protection of combustibles, refer to BS 5440.1. Where a flue terminal is installed less than 1000 mm. from a plastic, or painted gutter; or 500 mm from painted eaves, an aluminium shield 1000 mm. long, should be fitted to the underside of the gutter or painted surface. The flue must be installed in accordance with the recommendations of BS 5440: Part 1.
IMPORTANT NOTICE: if the flue terminates 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 must be fitted. Fit only recommended flue terminal guard by securing concentrically around terminal with screws. Available on request from: RAVENHEAT Manufacturing Ltd Chartists Way Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 7007 IMPORTANT: The following notes are intended for general guidance. The boiler MUST be installed so that the terminal is exposed to external air. It is important that the position of the terminal allows the free passage of air across it at all times. Minimum acceptable spacing from the terminal to obstructions and ventilation opening are specified in Fig. 6. Note positions: Due to the terminal design, installation is possible with clearances less than those specified in BS 5440, Part 1.

4.5 4.51

GAS SUPPLY A gas meter is connected to the service pipe by the Local Gas Supplier or a contractor. An existing meter should be checked preferably by the gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves. Installation 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 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 for the boiler serves other appliances ensure an adequate sup-

Fig. 6

A twin flue system is also available. For further details see twin flue installation instruction (sect. 10). A I R S U P P L Y

4.7 4.7.1

The following notes are intended for general guidance. The room sealed fan flued boiler does not require a permanent air vent for combustion air supply. Where installed in a cupboard or compartment ventilation is not required. WATER CIRCULATION (central heating) Detailed recommendation are given in BS 6798:1987/5449:1990 (for smallbore and microbore central heating systems). The following notes are given for general guidance. 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 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 to pipes passing through ventilated spaces in roofs and under floors. The water through the appliance heat exchanger circuit must exceed the min. 2.38 gals/min. (650 It/h) when the burner is firing. It is important to ensure that this rate is achieved when sections of the system are shut off either manually or by automatic controls. Therefore a by-pass must be fitted to the system (15 mm min.) (Fig. 6A).
4.8 Terminal position for fan assisted boiler (minimum distance) A Directly below an open window or other opening (e.g. air brick) B - Below gutters, soil pipes or drain pipes C - Below eaves D - Below balconies or car port roof E - From vertical drain pipes and soil pipes F - From internal or external corners G - Above ground or below balcony level H - From a surface facing a terminal I - From a terminal facing a terminal J From an opening in the car port (e.g. door window) into dwelling. 4.8.1
The flue must be terminated in a place not likely to cause a nuisance. FLUE ALTERNATIVES 4.8.3
A concentric vertical flue kit is available for flueing applications up to a maximum height of 4 metres vertically. For further details see vertical flue installation instructions (sect. 5.7.12).

Fig. 6A

If the volume of circulating water is too low, the boiler water temperature will rise too rapidly. This could cause noise in the system or even cause the overheat cut off to lockout. 4.8.4 Draining tap These must be located in accessible positions to permit the draining of the whole system. The taps must be at least 15 mm nominal size and manufactured in accordance with BS 2870 1980. Air release points These must be fitted at all high points where air will naturally collect, and must be sited to facilitate complete fitting of the system. The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated. It can accept up to 1.5 gal (7 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.

For vertical flue system see sect. 5.7.12 (Minimum vertical 1100 mm)

Fig. 12

OPTIONAL EXTRAS: a) Straight header (Fig. 10) item 3. b) 1000 mm flue extension. c) Concentric 90 in-line bend (Fig. 10) item 2. d) Concentric vertical flue (Fig. 10) item 1. e) Concentric 45 in-line bend (Fig. 10) i t e m 1 0.

Fig. 13

FLUE EXTENSION BOX CONTAINING (Fig. 14): 1000 mm flue extension duct as an extra cost only when requested for side and vertical flue applications 59 - Rubber seal 63 Air intake duct extension 64 - Flue exhaust duct extension 65 - Pipe centering spring STRAIGHT HEADER BOX CONTAINING (Fig. 13): 55 - Rubber seal 57 - Straight header supplied as an extra cost Only when requested 59 Rubber seal 66 - Flue gas sample point 5.3 UNPACKING

Fig. 14

Fig. 17 3) Turn the carton over, with the boiler inside and then pull the carton
Fig. 15 1) Open the top of the carton

Fig. 18

2) Rest the carton on the floor (keeping the flaps open)
4) Rest the boiler on the floor and remove the polystyrene guards

5.4 5.4.1

POSITIONING OF THE BOILER - Remove the 2 screws that secure the upper part of the front panel of the casing (Fig. 19). - Carefully slide the front panel a few millimetres up towards the top of the appliance until it is free from its slot, and then lift off Fig. 20). Unscrew the 2 screws that fasten the lower grating on the casing and remove it from the sides of the casing (Fig. 22).

Fig. 22

Fig. 19

Fig. 23

Fig. 25

Fig. 21

TABLE 6

5.4.3 5.4.4 5.4.5

Push down the 2 plastic clips that fasten the instrument panel (Fig. 23). Lower the instrument panel down by rotating it on its own hinges (Fig. 25). Unscrew the two screws that fasten the two side panels. Remove the two sides of the casing by slightly lifting them and carefully sliding towards the 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. INSTALLING THE 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 from the wall. - Use a 10 mm. dia drill to make the 4 boiler securing holes. Insert the plastic expansion plugs. - Cut or core drill a 105 mm. dia hole for inserting the flue duct. - Screw in the two upper coach bolts leaving them about 10 mm. out from the wall to enable the boiler to be located on the wall. Fit the elbow header positioning it towards the required direction (Fig. 30). IMPORTANT: Make sure that the elbows dia. 60 mm duct is inserted into the fan, the rubber seal and orifice are been correctly fitted.

5.5.11

IN LINE FLUE BEND Measure the distance between the flue bends or the flue/terminal assembly. The measurement should be taken from the outer edge of the flue and bend (Fig. 398). IMPORTANT: in line flue bend - 750 mm must be deducted from overall length for each 90o bend. Obtuse flue bend - 375 mm must be deducted from overall length for each 135 bend (Fig. 39 B).

5.5.6 5.5.9

Fit terminal cover plate if required. Extension kits are available on order.

Fig. 37

- Screw in the two upper coach bolts leaving them about 10 mm out from the wall in order to enable the boiler to be located. 5.7.2 Positioning the elbow towards the required direction (Fig. 30).

5.6 5.6.1

COMPLETING BOILER INSTALLATION Reassembles the outer casing (sect 5.4) proceeding in this order 1) Fit the two sides. 2) Refit the instrument panel in reverse order as in (sect. 5.4.4). 3) Refit the lower grating (sect. 5.4). INSTALLING THE APPLIANCE FOR SIDE FLUE OUTLET (Fig. 39) -Attach the template to the wall with adhesive tape, making sure that the centre line is vertical and that the distance from the centre line to the nearest side wall is not less than MEASUREMENT IN TABLE 6. -Mark the four boiler securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it is horizontal. -Trace the centre of the flue duct hole measure distance F (table 6). From the corner of the wall (Fig. 28), measure the distance y between the centre of flue duct hole to the corner. Detach the template from wall. -Use a dia. 10 mm. drill to make the 4 holes for securing the boiler. Insert the plastic expansion plugs. Core drill 105 mm dia. hole in the side wall for inserting the flue duct.

5.7 5.7.1

- If the standard duct furnished with the boiler is too long (position of the boiler from the wall to go through as illustrated in the drawing and wall thicknesses less than what was specified above) it can be shortened as follows: Fig. 28-29-31-32. - Remove the centering spring 65, pull the flue terminal disengage inner flue duct. - Measure the thickness W of the wall. - Cut the outer air duct (100 mm dia.) at right angles and to a length equal to W+Y - 47 mm. (Fig. 32). - Cut the inner flue duct (60 mm dia.) at right angles and to a length equal to W+Y + 65 mtn. - Outer air duct and inner flue duct must be de-burred. - Reassemble the two tubes. Insert centering spring 65 (Fig. 31).

Fig. 39

Fig. 39B 56 I 128 I
IN LINE FLUE BEND AND FLUE EXTENSION
KEY 56 - Sample point (if required) 57 - Elbow Header 59 - Rubber seal 0 60

65 128

Air intake duct extension - Flue Exhaust duct extension - Pipe centering spring - In Line Bend (45 and/or 90)
Insert the flue assembly into the wall, making sure it will not interfere when fixing the boiler on the wall. Lift the boiler on the wall. Locate onto the top coach bolts. Fit the lower coach bolts and tighten all four securing bolts. 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. Ensuring good seal is made with o.rings. Fit terminal cover plate if required (Fig. 37). Extension kits are available on order for flue extension of up to 2.5 metres total length (Fig. 31-39B). For further details see sect 5.5.10.

driver (HONEYWELL 9 mm spanner) to turn the nut 111 clockwise to increase anti-clockwise to and pressure decrease pressure. 6.RECONNECTTHE DETACHED CABLE Use a screw-driver to hold nut 111 firm (HONEYWELL 9 mm spanner) and use a 10 mm spanner (HONEYWELL 7 mm spanner) wrench to rotate the nut 110 clockwise to increase the pressure and counter-clock-wise to decrease it. After adjustment turn off D.H.W. Taps. SETTING CENTRAL HEATING GAS PRESSURE THE BOILER COMES SET AT MID POSITION RATING FOR USE ON C.H. (table 1/2/3/4) When the boiler operates in the C.H. mode the gas pressure at the burner can be set between the min. and max. values. This permits capacity to be adjusted to suit system demand. If adjustment is required proceed as follows: - Remove the front panel and the panel instrument as described in clauses (sect. 5.4.1 and sect 5.4.3). Unscrew the two screws holding the control box cover and lift off (Fig. 78). - Select (winter) switch position - Turn control thermostat 4 to maximum setting (Fig. 50). - Check all external controls are on and calling for heat ensure all D.H.W. taps are off. - With boiler operating use a screwdriver to turn potentiometer (Fig. 48) clockwise to increase pressure and anticlockwise to decrease pressure. - To obtain the desired heat value establish pressure as per (Fig. 52 or Fig. 52A). - 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. RATIO BETWEEN BURNER PRESSURE AND OUTPUT NATURAL GAS (G 20)
RATIO BETWEEN BURNER, PRESSURE AND OUTPUT LPG (G 31)

6.13 6.13.1

CHECKINGTHE FLUE SYSTEM The flue system should be visually checked for soundness. Check all clamps and fixings are secure and tight. CHECKING THE HEATING THERMOSTAT Allow the system to warm up and then turn the C.H. thermostat to ensure the main burner modulates from high to low and "low to off and vice versa (scale range covers approx. 45 C - 85 C). TESTING AND REGULATINGTHE DOMESTIC HOT WATER SYSTEM FLOW To put the appliance in operation with the (summer/winter) switch in winter position. - Open a domestic hot water tap (preferably the bath tap). Ensure cold water inlet stopcock is open and the D.H.W. thermostat 5 (Fig. 50) is set at maximum. - If the burner does not light check that the water flow rate is above the min. required to operate the differential pressure 2.8 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 1/2). - To adjust the flow rate refer to (Fig. 53) rear view and locate the adjustment screw (Fig. 2). Turn the screw clockwise until the required temperature is reached. N.B.: If the cold supply is subject to large fluctuations or is above the permitted max. water pressure, a suitable pressure/flow regulator should be fitted in the cold water supply to the appliance. - Turn the appliance mode selector switch 1 (Fig. 50) to the summer position. Slowly close the draw off tap to reduce the flow rate to above the min. (approx. 2.8 litre/min - 0.61 gals/min). Rotate the D.H.W. control thermostat to ensure it operates at its various setting. - Close the draw-off tap still further. The burner should stop when the rate falls below about 2.8 litres/min (0.61 gals/min.).

7 SERVICING INSTRUCTIONS

7.2.3 Ravenheat are a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark has been instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency. 7.1 7.1.1 SERVICING To ensure continued efficient operation of the appliance it is necessary to carry out servicing and cleaning at regular intervals. The frequency of cleaning will depend upon the particular installation conditions and usage but in general, once year should be adequate.

7.2.4 7.2.5

Examine the fan for any mechanical damage, check to ensure free running of the fan wheel. Clean the wheel if necessary with a soft brush. Check sealing gasket and renew if damaged (sect. 7.6). Examine flue duct and flue hood and ensure that there is no obstruction. Examine the gasket at the entry into the flue duct. It is essential that a good seal is made at the outlet to the fan, renew this gasket if there is any sign of damage or deterioration. TO REMOVE/REPLACE THE FRONT PANEL OF THE CASING (Fig. 19 & 20) Remove the 2 screws that secure the upper part of the front panel of the casing. Lift the front panel few millimeters to the top, until it is free from the slot and remove panel. TO REMOVE/REPLACE THE COMBUSTION CHAMBER COVER

7.7.3 7.7.4 7.7.5

Remove the three screws on the front that fasten hood to the combustion chamber. Remove the two screws at the rear of hood. Pull the flue hood upwards and then remove by tilting forward (Fig. 61). Replace in reverse order. TO REMOVE THE HEAT EXCHANGER (Fig. 62-63-64) Remove front casing (sect. 7.3). Remove combustion chamber front cover as in (sect. 7.4). Unscrew the two screws that fasten the two sides panel (sect. 5.4.5). Remove the lower grating (sect. 54.2). Lower the instrument panel (sect. 5.4.3 & 4). Remove the two sides of the casing by slightly lifting them and sliding them towards the top of the appliance, to release them from their upper suspension hooks. Close the on/off valves for the heating and the hot water circuits. Drain the heating system from the drain point mounted on the system (Fig. 93) and drain the hot water from the lowest tap on its pipeline system and drain point on D.H.W. inlet cock (Fig. 46). Remove the fan (sect. 7.6). Remove the flue hood (sect. 7.7) Remove the automatic air vent (Fig. 92) Disconnect unions for the hot water and heating water pipelines (Fig. 62). Unscrew the rings that fasten the heat exchanger to the combustion chamber (Fig. 62). Remove the two side insulation panels at top of heat exchanger (Fig. 63). Pull the heat exchanger up until its connections come out from the combustion chamber and then remove it (Fig. 64). Replace in reverse order. Ensure correct wire position (Fig. 94). IMPORTANT: When replacing a heat exchanger new seals must be used.

7.7.6 7.8

7.3 7.3.1

7.4 7.4.1 7.4.2

7.8.3 Remove the front casing panel (sect. 7.3). Unscrew all the screws that fasten the cover to the chamber body and put them into a container so that they dont get lost. Detach the cover, being careful not to damage the seal. Reassemble in reverse order. Ensure good seal of cover when replacing. TO REMOVE/REPLACE THE FAN ASSEMBLY (Fig. 58) Remove front casing (sect. 7.3). Remove combustion chamber front cover as in (sect. 7.4). Disconnect the electrical connections from the fan motor. Support the fan and remove the two fixing screws and bracket from the front of the flue hood. Push down and carefully withdraw it from the appliance. Place in a safe place until required. Reassemble in reverse order. Ensure wires are connected correctly (Fig. 94). TO REMOVE/REPLACE THE FLUE HOOD (Fig. 60) Remove front casing (sect. 7.3). Remove combustion chamber front cover as in (sect. 7.4). Remove the fan (sect. 7.6) 7.8.4 7.8.5 7.4.4 7.6 7.6.1 7.8.8 7.8.9 7.8.10

7.6.2 7.6.4

7.8.11 7.8.12

7.8.13

7.7 7.7.1
TO REMOVE/REPLACE COMBUSTION CHAMBER INSULATION PANELS (Fig. 64). Remove casing front panel (sect. 7.3). Remove combustion chamber front cover (sect. 7.4).
Remove fan assembly and flue hood (sect. 7.6 & 7.7). Remove main burner (sect. 7.15). Remove top insulation pieces at sides. Remove 2 screws securing combustion chamber. To rear of boiler and lower chamber carefully remove all insulation panels. 7.9.2 Replace in reverse order.

7.10 7.10.1

TO REPLACETHE ELECTRODE (Fig. 66) Remove front casing (sect. 7.3). Remove combustion chamber front cover (sect. 7.4)

Fig. 61

Fig. 58

Fig. 62

Fig. 60

Fig. 63

Fig. 66

7.10.2

Detach the wire from electrode and then unscrew the nut that secures it to the pilot burner assembly and remove. Replace with new electrode in reverse order. TO REPLACETHE PILOT INJECTOR (Fig. 68) Remove the front panel of the casing and the combustion chamber front cover (sect. 7.3 & 7.4). Remove the lower grating (sect. 5.4.2). 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 combustion chamber front cover (sect. 7.3 & 7.4). Remove the electrode and pilot injector (sect. 7.10 and sect. 7.12). Remove the two screws securing pilot burner to main burner (Fig. 69). Replace in reverse order.

7.10.3 7.12 Fig. 64 7.12.1
7.12.2 7.12.3 7.12.4 7.12.5 7.12.6 7.13 7.13.1

7.13.2 7.13.4 7.13.5

7.14 7.14.1
TO REMOVE/REPLACE THE MAIN INJECTORS 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. 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 combustion chamber (Fig. 72). Unscrew and replace the injectors and their seals (Fig. 73). Relocate the grommet, sealing the gas supply pipe to the casing taking care not to damage it. Replace if necessary. Replace in reverse order. Fig. 70
7.14.2 7.14.3 7.14.4 7.14.5 7.14.6

7.14.7

Fig. 68

Fig. 71

7.15 7.15.1
TO REMOVE/REPLACE THE MAIN BURNER Remove the front panel of the casing and the combustion chamber front cover (sect. 7.3 & 7.4). Remove the pilot burner assembly as described in sect. 7.13. RSF 100 ONLY Remove the two screws holding the lower plate to the burner and remove the plate. Remove the injectors manifold as described in sect. 7.14. Remove the two screws securing the main burner to the combustion chamber (Fig. 74). Fig. 73 Pull the burner forward and remove (Fig. 75). Replace in reverse order. IMPORTANT: When refitting the burner make sure that the pins at the rear of the combustion chamber locate into the slots made on the rear of the burner.

7.15.2 7.15.3

7.15.4 7.15.5 7.15.6 7.15.7
7.16 7.16.1 7.16.2 7.16.3
TO REMOVE/REPLACE THE GAS VALVE (Fig. 51) Remove front casing panel (sect. 7.3). Push the 2 plastic 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 screws (four per side) that connect the gas valve to the gas pipelines and then remove it from its seat. Replace in reverse order, always using new seals. Fig. 74
7.16.4 7.16.5 7.16.6 7.16.7

7.16.8

TO REMOVE/REPLACE THE HEATING CONTROL AND DOMESTIC HOT WATER CONTROL Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 7.16.2 & 3) and remove the control box cover (7.31.2/3).

7.22.2 7.22.3

Remove lower grill and right side of the casing (sect. 5.4.2 & 5). Remove the three wires that connect to the overheat thermostat making sure that these wires will subsequently be reconnected to the same poles (Fig. 94). Unscrew the plastic cover and locknut that fastens the overheat thermostat and remove it. Remove the split pin and pull the thermostat sensor from its pocket complete with case sealing grommet. Remove case sealing grommet from the old thermostat and fit to new one. Replace in reverse order. TO REMOVE/REPLACE THE ELECTRIC CONTROL BOARD (PCB) Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 1.16.2 & 3). 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). Detach the connectors from the board. Detach the PCB board from its base by unscrewing the six screws. Replace in reverse order (ensure all electrical connections are made correctly). Having replaced PCB recommission boiler on heating mode (sect. 6.15). TO REMOVE/REPLACE THE DIFFERENTIAL PRESSURE SWITCH (Fig. 87). Remove the front panel from the outer casing and the combustion chamber front cover (sect. 7.3 & 4). Detach the wires that connect to the pressure switch, make sure that these wires are later reconnected to the same poles (Fig. 94). Unscrew the two screws that fasten the pressure switch to the back of combustion chamber. Remove the two silicone tubes. Ensure tubes are connected correctly (Fig. 87) avoiding kinks,

10 - air intake bend 90o 10 - flue exhaust bend - air inlet terminal 12 - flue exhaust terminal 13 45o air intake bend 13 - 45o flue exhaust bend 14 - flue exhaust duct 14 air intake duct 15 - two-way flue gas header 16 - vertical eccentric flue exhaust duct

Fig. 1.9

NOTE: on all models RSF 84E must be replaced with 80 mm type supplied with twin flue header.
90 M/F bend consisting of: 90 elbow with 0 ring side F 80 mm dia 0 ring
Figures 2.8, 3.8 and 4.8 show the versatility of this flue system. Measurements and bends must be calculated correctly so as not to oversize maximum flue lengths. All spigot ends that are cut must be de-burred with a file. All located 0 rings must be lubricated with a silicone grease to ensure easy, snug fit.
135 M/F bend consisting of: 135 elbow with 0 ring side F 80 mm dia 0 ring
NOTE: Exhaust flue must slope 2 down towards the boiler 35 mm fall per metre. Spacing Clips Spacing clips are available on request should they be required. Sampling point Sampling point is positioned on the outlet of the twin flue header for the use of sampling gas combustion products.
Vertical eccentric flue exhaust duct
Condensing trap To drain the exhaust pipe only with a greater distance of over 6 metres, a condensating trap must be fitted, or as an alternative to this the sampling point may also be used as a condensating drain should this be required.
Exhaust/suction system with concentric pipes for flat or sloping roofs. Extensions with two separate pipes. Maximum distance D = I + E + T = 14 metre + 14 metre + 1 metre = 29 metre maximum (pipe + terminal). Exhaust terminal must not be cut. NOTE: The pressure loss for each elbow fitted is: 90 elbow less 4 metre of pipe length for each one fitted. 45 elbow less 1.5 metre of pipe for each one fitted. For exhaust pipe with a distance of over 6 metre a condensing trap must be fitted.

Fig. 3.8

Exhaust/suction system with two separate rated 80 diam pipes - exhaust on flat or sloping roof, suction from vertical wall. Maximum distance D = I + E + T = Total exhaust/inlet pipe = 26 metre. Exhaust terminal must not be cut. Min inlet pipe distance = 0.1 metre. NOTE: The pressure loss for each elbow is: 90 elbow less 4 metre of pipe length for each one fitted. 45 elbow less 1.5 metre of pipe for each one fitted. For exhaust pipe with a distance of over 6 metre a condensing trap must be fitted.

Exhaust/suction system with two separate pipes through a single vertical wall. Maximum distance D = I + E = Total exhaust/inlet pipe 24 metre. Min inlet pipe distance 0.1 metre. Min exhaust pipe distance 0.1 metre. Fig. 4.8 NOTE: The pressure loss for each elbow fitted is: 90 elbow less 4 metre of pipe length for each one fitted. 45 elbow less 1.5 metre of pipe for each one fitted. For exhaust pipe with a distance of over 6 metre a condensing trap must be fitted.

EXPLODED PARTS DIAGRAM

SECTION 12
RAVENHEAT SHORT LIST OF SPARE PARTS
Pos. 18.22 22.24.1 24.25.1 25.2 26
RSF IOOE (T) Part. No. 0014FR007005/0 0012COM06005/0 0012POTO5005/0 0007TER0301O/O 0001CAM03005/0 0014MAN06015/0007TER05005/0 0014VET01005/COP03010/DIA05005/0 0001CAP3005/0012CIR05010/0 0002SCA01010/1 0012CIR05016/0 0012GEN05010/0 0005PRE05005/5009080 0008VAL03005/0 0008VALO5005/0 0003BRU07005/0 0003BRU0701O/O 0003PIL0501/0003PIL01005/0 0003PIL05015/0 0008VAL01017/0

G.C. Part. No.

RSF 84E (T) Part. No. 0014FR006005/0 0012COM06005/0 0012POT05005/0
Description INSTRUMENT PANEL MAIN SWITCH D.H.W/C.H. POTENTIOMETER

371267

0007TER0301O/O 0001CAM01005/O 0014MAN06015/0
OVERHEATTHERMOSTAT COMBUSTION CHAMBER THERMOSTAT KNOB

372642

5027055 0007TER05005/0

372842

WATER GAUGE D.H.W/C.H. SENSOR

371268

0014VET01005/0001DIA04005/0

372845

SIGHT GLASS CHAMBER COVER AIR RESTRICTION RING FLUE GAS EXHAUST HOOD F2 FUSE 315 mA PRINTED CONTROL BOARD HEAT EXCHANGER PRINTED IGNITION BOARD HONEYWELL PRINTED IGNITION BOARD AIR PRESSURE SWITCH

371292 372845

0001CAP04005/00l2ClR05010/0 0002SCA05005/0 0012CIR05016/0 0012GEN0501010 0005PRE05005/0

173100

0008VALO3005/0 0008VALO5005/0 0003BRU05015/0 0003BRU08005/0 0003PIL05010/0
8 LT EXPANSION VESSEL 5 METRE PUMP GAS VALVE HONEYWELL GAS VALVE MAIN BURNER NATURAL GAS (G 20) MAIN BURNER LPG (G 31) PILOT BURNER FOR HONEYWELL GAS VALVE G 20

372894

5012114 0003PIL01005/0 0003PIL05015/0 0008VAL01017/0
PILOT BURNER NATURAL GAS (G 20) PILOT BURNER LPG (G 31) PILOT BURNER FOR HONEYWELL GAS VALVE G 31 SAFETY VALVE 3 BAR
RAVENHEAT SHORT LIST OF SPARE PARTS CONTINUED
RSF 1OOE (T): Part. No. 48.60 60.87 0003UGE01012/5018015 0008VAL0301O/O 0005PRE03010/5023020 0012FUS05020/0013GUA03005/0 0013GUA03035/0013GUA01045/0 0010TUB03050/0 0012FUS05015/1012VEN07006/0 0014GUA0l020/0003UGE01005/0 0012CAV03005/0 1015PAN03005/0 0003UGE03005/0 5015015