ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER
FANNED COMBI RSF 82E - RSF 82ET
WITHOUT TIMER RSF 82E G.C. NNATURAL GAS (G 20)
Tested, certified and service listed
Listed by The United Kingdom Water Fitting Byelaws Scheme
WITH TIMER 0 RSF 82ET G.C. N 04 NATURAL GAS (G 20)
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 WAY, MORLEY, LEEDS, LS27 9ET. - TELEPHONE (0113) 252 7007
ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER. FOR CENTRAL HEATING AND DOMESTIC HOT WATER This new high efficient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at super high efficiency, unheard of only a few years ago. 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 combustion chamber and living accomodation. 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 at 15 cm. This should not hinder service of the appliance, but does ensure maximum efficiency and safety - something which Ravenheat take great pride in. Each boiler has been designed and manufactured in our modern plant to exacting ISdiscipline, 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, Chartist Way, Morley,. LEEDS, LS27 9ET. Telephone No 0113 2527007. BASIC COMPONENTS - (See figure 1) Guarantee is a full 12 months from date of purchase providing the appliance has been fitted in accordance with these instructions and relevant codes of practice. MAJOR COMPONENTS Gas valve with flame modulator. Variable head pump suitable for any type of central heating system. Main burner with flame stabiliser designed to operate under all thermal conditions. Double parallel heat exchanger which, for domestic hot water uses, the countercurrent system, offering high thermal exchange and durability. High reliability diverter valve with ethylene propylene diaphragm permitting primary fluid circulation in the boiler during D.H.W. supply. This gives maximum heat exchange, improved efficiency and exceptionally silent operation. 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 circuits. Safety relief valve (for safety discharge). Programmable 7 day module with digital display (optional model). All front panel controls not often used have been hidden. This achieves simplicity of operation with easy to clean panels. COSHH - CONTROL OF SUBSTANCES HARMFULTO HEALTH IMPORTANT This appliance contains materials that are indicated below. It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn when handling, where applicable, the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety. 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 or in conjunction with other tools, After handling wash hands and other exposed parts. RAVENHEAT use only high quality material for production of this product, in an effort to protect the environment components should be re-cycled.

TABLE OF CONTENTS SECTIONS: 5. INTRODUCTION DESIGN PRINCIPLES AND OPERATING SEQUENCE TECHNICAL DATA GENERAL REQUIREMENTS INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS FAULT FINDING ELECTRICAL SYSTEM DIAGRAM EXPLODED PARTS DIAGRAM LIST OF SPARE PARTS PAGE: 8-9-48

GENERAL LAYOUT

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 - DHW 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 SCHEME

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 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 29 - Circulating pump 30 -Water pressure gauge - F a n 37 - Expansion tank 38 - Sealed chamber 60 -Air intake duct 61 - Flue duct 62 -Terminal

SECTION 1

INTRODUCTION The Ravenheat boiler is for the use of central and domestic hot water combined in one unit. It is fitted with an automatic domestic hot water priority valve. A (winter/summer) selector switch is fitted to the left hand side of control panel. With the only (summer) position being for domestic hot water. position being for central heating with domestic hot water priority. The boiler is equipped with a front cover which can be removed for servicing. The data badge with technical data is placed on the lower left hand side of the frame. Fig. 1 Illustrates the general layout of components. Fig. 2 Illustrates the operating principles described in section 2. 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 this 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 intervene 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.

OVERALL DIMENSION

Fig. 3
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). 3.1.3 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.

SECTION

3 TECHNICAL DATA
TABLE 1 HEAT INPUT NET NOMINAL HEAT OUTPUT NOMINAL GAS RATE AFTER 10 minutes INLET PRESSURE BURNER PRESSURE

NATURAL GAS (G 20) I

max mid min max mid min max mid min 20 mbar ma* mid min SIT POLIDORO MOD/NP N. 13X1.35 POLIDORO PA525F 0.27x2 HOLES
GAS CONTROL VALVE MAIN BURNER MAIN BURNER INJECTORS PILOT BURNER PILOT INJECTOR ELECTRICAL SUPPLY 230V-50HZ POWER CONSUMPTION 160W EXTERNAL FUSE RATING 3A INTERNAL FUSE RATING 315 mA - 2A - 4A (20mm to BS4265) DRY WEIGHT 48 kg (106 Lbs\ WATER CONTENT D.H.W. 0.5 Lts. (0.9 pints) WATER CONTENT C.H. 3.0 Lts. (5.3 pints) GAS SUPPLY CONNECTION RC 112" 22 mm FLOW CONNECTION C.H. compression isolating valve 22 mm RETURN CONNECTION C.H. compression isolating valve INLET CONNECTION D.H.W. 15mm compression isolating valve OUTLET CONNECTION D.H.W. 15mm copper pipe MAXIMUM PERMISSIBLE COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRES SAFETY DISCHARGE PIPE 15mm 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 DESIGN FLOW RATE 1013 I/h (223 gals) 20 oC RISE MINIMUM FLOW RATE C.H./503 Lts/h (111 gals/h) D.H.W. FLOW RATE 30 oC rise 11.3 l/min (2.5 gals/min) D.H.W. FLOW RATE 35 oC rise 9.7 l/min (2.1 gals/min) D.H.W. FLOW RATE 40 oC rise 8.5 I/min (1.9 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 1.0 bar (14.5 psi.) 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: GB FLUE TYPE - C 12 - C 32 CATEGORY I 2H NOX 2
26.1 kW 18.9 kW 13.0 kW 23.6 kW 16.6 kW 10.3 kW 2.6 m3/h 2.1 m3/h 1.3 m3/h (8.0 in wg.) 8.1 mbar 4.1 mbar 1.5 mbar 837 TANDEM

BS. 5449 BS. 5546

BS. 544O:1 BS. 5440:2
Health &Safety Document No. 635 The Electricity at Work Regulations, 1989. The manufacturers 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 this appliance unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ravenheat in writing. If in doubt please enquire. Any direct connection of a control device not approved by Ravenheat could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety regulations and the above regulations.

4.5 4.5.1

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 supply is available both to the boiler and the other appliances when they are in use at the same time. FLUE SYSTEM The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discoloration 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. Pluming will occur at the terminal so, where possible, terminal positions which could cause a nuisance should be avoided. The flue must be installed in accordance with the recommendations of BS 5440: Part 1. IMPORTANT NOTICE: if a left or right side flue is required, then a 90 Degree Bend will be needed. (Not supplied as standard). Available on order. 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

valve setting (bar) Vessel charge pressure (bar) Initial system pressure (bar) Total water content Of system Litres For system volumes other than those given above, multiply the system volume by the factor across 2.1 4.2 6.3 6.3 10.4 12.5 14.6 16.7 18.7 20.8 22.9 25.0 27.0 29.1 31.2 33.3 35.4 37.5 39.6 41.6 3.5 7.0 10.5 14.0 17.5 21.0 24.5 28.0 31.5 35.0 38.5 42.0 45.5 49.0 52.5 56.0 59.5 63.0 66.5 70.1 6.5 I2.9 19.4 25.9 32.4 38.8 45.3 51.8 58.3 64.7 71.2 77.7 84.1 90.6 97.1 103.6 110.1 116.5 123.0 125.9 3.0 0.5 0.5 1.0 1.5 1.5 1.5 2.0 1.5 2.0

1.0 2.0 1.0

EXPANSION VESSEL VOLUME (LITRES)
13.7 27.5 41.3 55.1 68.9 82.6 96.4 110.2 124.0 137.7 151.5 165.3 179.1 192.8 206.6 220.4 239.2 247.9 261.7 275.5
2.7 5.4 8.2 10.9 13.6 16.3 19.1 21.8 24.5 27.2 30.0 32.7 35.7 38.1 40.9 43.6 46.3 49.0 51.8 54.5
4.7 9.5 14.2 19.0 23.7 28.5 33.2 38.0 42.7 47.5 52.2 57.0 61.7 66.5 71.2 76.0 80.7 85.5 90.2 95.0
10.3 20.6 30.9 41.2 51.5 61.8 72.1 82.4 92.7 103.0 113.3 123.6 133.9 144.2 154.5 164.8 175.1 185.4 195.7 206.0
3.9 7.8 11.7 15.6 19.5 23.4 27.3 31.2 35.1 39.0 42.9 46.8 50.7 54.6 58.5 62.4 66.3 70.2 74.1 78.0
8.3 16.5 24.8 33.1 41.3 49.6 57.9 66.2 74.5 82.7 91.0 99.3 107.6 115.8 124.1 132.4 140.7 148.9 157.2 165.5

0.0833

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 a make up vessel would be difficult re pressurisation of the system can be done. See section on FILLING. If the capacity of the central heating system should exceed 110 litres, an additional vessel may be installed if required on the return to the combination boiler from the heating system (Fig. 7). Guidance on vessel sizing is given in (Table 3). Reference should be made to British Gas Publications <<Material and Installation Specifications for Domestic Central Heating and Hot Water>>. Draining taps should be at least 1/2 in BSP nominal size and be in accordance with BS 2879. 4.8.9 Installation to an existing central heating system The combination boiler is designed to operate on a sealed system only. Therefore if the existing system is of the open water type it will have to be modified to comply with BS 5376 Part 2. Before installing a new combination boiler to an existing system flush out the
old system with a recommended descaling agent. Also check pipework and renew any corroded pipework or fittings. Valve glands must be repacked or replaced wherever necessary and any defective controls exchanged. 4.8.10 Hard water areas If the area of installation is recognized as a hard water, it is recommended that a suitable water treatment device is installed in the mains. The water hardness can be determined by using the standard test paper or by referring to local water authority. DOMESTIC WATER The domestic hot water must be in accordance with the relevant recommendations of BS 5546. Copper tubing to BS 2871. 1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water.

4.9 4.9.1

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 contact separation of at least 3 mm in all poles. The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except, where the appliance is installed in a bathroom, this MUST be sited outside the bathroom.

Fig. 10

5 INSTALLATION WARNING It is MOST IMPORTANT that this appliance is installed in a VERTICAL POSITION, with the flue air duct passing through the wall in a HORIZONTAL PLANE. A minor deviation from the horizontal is acceptable, provided that this results in a downward slope of the flue/air duct away from the combination boiler. DELIVERY The appliance will arrive on site in two cartons: Boiler carton containing (Fig. 10-l 1): a) boiler fully assembled b) installation instructions and user instructions c) white paper template d) terminal cover plate (Fig. 12) e) - 4 coach bolts and wall plugs - screws and dowels Polythene bag containing: a) 2-22 mm compression ball valves (heating) b) 1-15 mm compression ball valve (with drain screw for domestic cold water inlet) c) 1-1/2 BSP Union gas cock d) - mm flanged copper tails complete with 1/2 brass nuts and washers - mm flanged copper tails complete with 3/4" brass nuts and washers

5.1 5.1.1

5.2 5.2.1

Fig. 11

FLUE BOX CONTAINING (Fig. 12): Standard Flue Assembly 127 - Air intake duct - Flue exhaust duct -Terminal -Pipe centering spring -Terminal Cover Plate
(Contained in the carton Fig. 10)

Fig. 12

OPTIONAL EXTRAS: Flue bend carton containing: (Fig. 13) 57 Flue bend supplied as an extra cost only when requested 59 Rubber seal 0 60

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 WARNING: Maximum allowable flue length 3.5 m horizontal or 4.5 m vertical (Fig. 3) or page 21. maximum No. 3x800 mm vertical No. 4x800 mm. Flue duct extension used with standard flue

Fig. 14

UNPACKING

Fig. 18

4) Rest the boiler on the floor and remove the polystyrene guards

Fig. 19

2) Rest the carton on the floor (keeping the flaps open)

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). 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 2 screws that fasten the two side panels (Fig. 21). 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.

Fig. 22

Fig. 23

5.4.3 5.4.4 5.4.5

Fig. 25

5.4.6 5.5 5.5.1

Fig. 27

Fig. 21 Fig. 28-29

If the standard duct furnished with the boiler is too long (the wall to. go through is less than 680 mm. thick) it can be shortened as follows: - Remove the centering spring 65, turn the flue terminal clockwise and push to disengage inner flue duct. - Measure the thickness W of the wall. - Cut the outer flue duct at right angles to a length equal to W + 98 mm.
- Cut the inner flue duct (60 mm) at right angles to a length equal to W + 201 mm. Insert from cut end. Reassemble the two tubes turn the flue terminal anti clockwise to lock together. Insert centering spring 65. Must be de-burred. Fig. 32

Fig. 30

INTAKE AND EXHAUST TERMINAL COMPONENTS Fig. 31
KEY 56 - Straight header 57 - Elbow header 58 - Header gasket 59 - Rubber seal 0 60
- STD air intake duct - STD flue exhaust duct -Terminal -Air intake duct extension

127 128

- Flue exhaust duct extension - Pipe centering spring - Terminal cover plate - Screw
insert the flue assembly into the wall, being careful to make sure that the outer air duct comes flush to the inner surface of the wall. Lift the boiler on to the wall (Fig. 34), locating onto the top coach bolts. Fit the two lower coach bolts and tighten all four securing bolts. Working above the boiler pull the flue exhaust duct towards the boiler in order to engage tube 61 into its header 56A (Fig. 31-35).

5.5.8 5.5.9

Fit terminal cover plate if required. Extension kits are available on order for flue extension of up to 3.5 metres total length (Fig. 31).

Fig. 35

Fig. 33

Fig. 34

Fig. 37

5.5.10

Each extension length extends the pipe by approximately 1000 mm long up to a maximum of three extensions. Pipeline length can be established using the instructions in section 5.5 for rear flue outlets and section 5.7 for side flue outlets. Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal. Extensions must be joined together, with the standard terminal pipe, inserted in each other as far as they can go. If an extension must be shortened, this must be done from the straight end, and not from the tapered end. To measure the pipeline properly all components must be assembled and total length measured before cutting. The straight end of the extension connects to the boiler. The flue output pipe fits into the boiler header until it stops (Fig. 31). All joints must be sealed with a rubber collar, fastened with the pipe straps supplied. It is important to put the centering spacer, supplied with the unit, inside between the two pipes, from the side opposite the extensions straight end. NOTE: a suitable support bracket is available 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.

- 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 a 100 mm dia. hole in the side wall for inserting the flue duct. - 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.

Fig. 38

5.5.11
INLINE 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). COMPLETING BOILER INSTALLATION Reassemble 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. 38-39) -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 305 mm. -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 60 mm. from the corner of the wall (Fig. 38). Fig. 39

5.6 5.6.1

5.7 5.7.1

Fig. 398

KEY 56 - Sample point (if required) 57 - Elbow Header 59 - Rubber seal 0 60
63 -Air intake duct extension 64 - Flue Exhaust duct extension 65 - Pipe centering spring 128 - In Line Bend (45 and/or 90)
USING AN INLINE 135o OR 90o BEND & VERTICAL FLUE SECTION
Deducted from overall length for each 90 bend 750 mm 135 bend 375 mm VERTICAL FLUE OPTIONS The vertical flue kit is intended for use where a horizontal flue outlet is not possible or desired. The vertical flue can be used either with a flat roof or a pitched roof (maximum pitch 60). Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 90 flue bend.
Detach the straight header and replace it with the elbow header (supplied on request), positioning the elbow towards the required direction (Fig. 40). Important: make sure that the elbows dia. 60 mm. duct is inserted into the fan and that the rubber seal and orifice are been correctly fitted. Remove left or right flue duct door cover as appropriate (Fig. 42). - 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.31-32). - Remove the centering spring 65. turn the flue terminal clockwise and push to 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 - 94 mm. (Fig. 32). - Cut the inner flue duct (63 mm. dia.) at right angles and to a length equal to W+Y. - Reassemble the two tubes turn the flue terminal anti clockwise to lock together. Insert centering spring 65 must be deburred. Insert the flue assembly into the wall, making sure it will not interfere with the boiler body (Fig. 43) when mounting. 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 61 into its header 57A. Fit terminal cover plate if required (Fig. 37). Extension kits are available on order for flue extension of up to 3.5 metres total length (Fig. 31). For further details see sect 5.5.10. REASSEMBLE BOILER AS PER (sect. 5.6.1) Fitting valves pack Remove plastic caps from boiler connection and fit flanged copper tail and valves as per Fig. 46 using washers provided.

ELBOW HEADER

5.7.4 5.7.5

RUBBERSLEEVE

5.7.10 5.7.11

Fig. 42

5.8 5.6.1

Fig. 43

5.9 5.9.1
GAS CONNECTION (Fig. 46) A minimum gas pressure of 20 mbar (6 in w.g.) must be available at the boiler inlet at full flow rate. 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 CENTRAL HEATING CONNECTION (Fig. 46) Before any central heating connections are made to the boiler all system valves should be opened and the system thoroughly flushed out with cold water. - Connect the central heating return pipe to the isolating cock marked CHR. - Connect the central heating flow pipe to the isolating cock marked CHF. - Pipe dimensions and position are marked on template supplied and Fig. 49 A DOMESTIC HOT WATER (Fig. 46) The domestic hot water circuit does not need a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar. If in doubt it is advisable to install a pressure reducing valve. The minimum pressure needed to operate the domestic hot water system is 0.5 bar

Fig. 44

5.10 5.10.1

5.11 5.11.1

Fig. 45
with a flow of approx 3 Lts per min. The regulator screw on the cold water outlet of the diverter valve may be adjusted to prevent excess volume flow (Fig. 53 COMMISSIONING SECTION). Flush out all foreign matter from the supply pipe before connecting to the appliance. - Connect the 15 mm. cold water pipe to the stop cock to the appliance inlet marked DCW. - Connect the 15 mm. hot water pipe with a suitable connection.

Fig. 46

5.13 5.13.1
ELECTRICAL CONNECTIONS 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 external controls must be volt free. Factory fitted internal wiring must not be disturbed when wiring external controls. - To gain access to the electrical box remove the front panel of the case as described in clauses (sect. 5.4.1) and the instrument panel as described in clauses (sect. 5.4.3). - The terminals are easily visible on the front of the electronic control board (Fig. 48). - Heat resistant flexible cable is fitted between the isolator and the terminal block. It is a 3 core cable of 0.75 mm2 (24x0.2 mm) to BS 6500. Make sure all wires to the appliance are routed away from sharp edges and hot surfaces. The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carryIng conductors does not become taut before the earthing conductor. Securely tighten all terminal screws and arrange the cable with slack between the cord anchorage and the terminal block. WARNING: If the supply cord is damaged, it must be replaced by a service engineer (supply cord available from Ravenheat Manufacturing Ltd). PROGRAMMABLE TIMECLOCK Instructions for use Consult Users Guide.

Fig. 49

INSTRUMENT PANEL Fig. 50

GAS VALVE Fig. 51

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
LIGHTINGTHE BOILER (Fig. 50) Before lighting the main burner make sure that the heating circuit flow and return valves are open and also that the cold water input cock is also open. - If external controls are installed (e.g. timeclock and thermostat) make sure that they call for heat. - Turn summer/winter selector switch 1 to w i n t e r - Turn control thermostat 4 up to its maximum setting. - Now the main burner should turn on. With leak detection fluid test for gas soundness of all gas components and joints. - See paragraph 6.14 for regulating the heating circuit thermostat. Check gas mains pressure (Fig. 52). Fit a gas pressure gauge on pressure inlet 77 (Fig. 51) on the gas valve, after releasing the seal screw. Check the gas mains pressure with boiler operating. Check with the Local Gas Supplier if the pressure differs significantly from 20 mbar. CHECK THE GAS PRESSURE AT THE BURNER Now check if the maximum gas pressure at the burner is equal to 8.1 0.5 mbar (3.2 0.2 in w.g.) for RSF 82E - RSF 82ET. To do this proceed as follows: - Turn off main switch 1 (Fig. 50) -Set main switch on & -Set control thermostat 5 at its maximum setting. -Fit a pressure gauge, using a hose, to pressure test point 81, (Fig. 51), after first loosening its close-off screw. -Open one or more hot water taps so that at least 10 11.4 litre of water flows per minute. - The pressure indicated on the pressure gauge is the maximum operating gas pressure. - Check if the minimum pressure corresponds to 1.5 mbar (0.6 in w.g.) RSF 82E - RSF 82ET as is set at the factory. Detach one of the wires going to modulator 104 (Fig. 51) and make the boiler operate just as was done for checking the maximum pressure. Observe the pilot flame which will light a second before main burner. It should be about 20 mm long (Fig. 528) and envelop the spark electrode tip.
ADJUSTING MINIMUM AND MAXIMUM PRESSURE (Fig. 51) SIT-HONEYWELL 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. 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 adjustement turn off D.H.W.Taps. SETTING CENTRAL HEATING GAS PRESSURETHE BOILER COMES SET AT MID POSITION RATING FOR USE ON C.H. (table1) 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 controlsare 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 anti-clockwise to decrease pressure. - To obtain the desired heat value establish pressure as per (Fig. 52). - 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 Fig. 52

6.13 6.13.1

CHECKING THE 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. 45oC 85oC). TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW 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 galsimin). - 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). - To adjust the flow rate refer to (Fig. 53) side view and locate the adjustment screw (Fig. 53). 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 (Fig. 50) (1) 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 litreslmin (0.61 galslmin.).

6.14 6.14.1

6.15 6.15.1

THREE WAY VALVE Fig. 53

Once the process of commissioning the boiler is complete, the commissioning engineer MUST complete his section in the Benchmark log book.

HANDING OVER TO THE USER

6.16.1 A f t e r c o m p l e t i o n o f i n s t a l l a t i o n a n d commissioning of the system, the installer should hand over to the Householder by taking the following actions: - Hand the Users Instructions to the Householder and His/Her explain responsibilities under the Gas Safety Regulations 1996 (as amended). - Explain and demonstrate the lighting and shutting down procedures. - The operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder. This then ensures the greatest possible fuel economy consistent with household requirements of both heating and hot water consumptions. Advise the User of the precautions necessary to prevent damage to the system, and to the building, in the event of the system remaining inoperative during frost conditions. - Explain the function and the use of the boiler only/ (Summer/Winter) and ON/OFF switches. - Explain and demonstrate the function of time and temperature controls neon lights radiator valves etc. for the economic use of the system. - If an optional time clock is fitted, then draw attention to the time clock Users Instructions and hand them to the Householder. - Stress importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR. Fill in the Benchmark log book and leave completed with the customer.

7.22.2 7.22.3

7.22.4 7.22.5

7.25.2

7.22.6
7.25.3 Close the on/off valves on the heating circuit and drain at drain point water from the boiler (Fig. 93). 7.25.4 7.25.5 Remove the terminal covers and detach the supply wires (Fig. 88). Unscrew the-two hexagonal nuts that fasten the pump to its pipes and remove the pump. NOTE: It may be necessary to loosen the flow pipe at the heat exchanger to replace the pump gaskets. 7.25.6 7.25.7 Always use new seals when re-fitting new pump. Replace in reverse order
7.25.8 7.25.9 7.25.10 7.26 7.26.1
IMPORTANT: Make sure that the arrow that indicates the direction of flow aims from the bottom upwards. Replace wires and cover ensuring that connection wire br=L and bl=N. Refill the heating system as described in the sect. 6.4 & 5 and check for leaks TO REMOVE/REPLACE THE DIVERTER VALVE (Fig. 89) Remove the front panel from the outer casing, lower the instrument panel (sect. 7.16.2 & 3). Remove lower gratin; (sect. 5.42). Close the on/off valves for the heating circuit and the hot water circuit. Drain the boiler at drain point (Fig. 93) and drain hot water from the lowest hot water tap and drain point on DHW inlet cock (Fig. 46). Unscrew the five nuts that connect the diverter valve and pull it out from boiler being careful not to damage the wires. Pull off circlip securing microswitches to diverter valve. If replacing microswitch assembly use a screw-driver to prise off the protective cover of the microswitches. Detach the wires that are connected to this. Remember that they must subsequently be reconnected to the same terminals (Fig. 94). Replace in reverse order. Always use new seals. Fill the boiler as described in (sect. 6.4 & 5) and check for leaks. TO REMOVE/REPLACE THE CENTRAL HEATING AND/OR HOT WATER CONTROL THERMISTOR Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 7.162). Remove left/right side of casing (sect. 5.4). Remove the wires that connect the thermistor (Fig. 81). Close the on/off valves for the heating circuit and the hot water circuit. Drain the boiler at drain point (Fig. 93) and drain hot water from the lowest hot water tap and drain point on DHW inlet cock (Fig. 46). Undo the nut and withdraw the sensor (Fig. 81) from its pocket.

7.29.5 7.29.6

7.29.7 7.29.8 7.30 7.30.1

7.30.2

7.30.3 7.30.4 7.31 7.31.1
7.31.2 7.31.3 7.31.4 7.31.5

Fig. 87

Fig. 93

Fig. 91

Section 8 FAULT FINDING CENTRAL HEATING
Switch on Select Winter Central Heating Stat to maximum Ensure external controls calling for heat (Room Stat/Time Clock/TRV
FAULT FINDING DOMESTIC HOT WATER
Before continuing it may be necessary to see Central Heating Fault Finding. Select only (Summer) Domestic Hot Water. Open Domestic hot tap close to appliance.
9 ELECTRICAL SYSTEM DIAGRAM

Fig. 94

SECTlON IO

EXPLODED PARTS DIAGRAM

RAVENHEAT RSF 82 E - RSF 82 ET FANNED COMBI BOILER SHORT LIST OF SPARE PARTS

Ravenheat Part. No.

0014FR006005/0 0012COM06005/0 0012P0T05005/0 0007TER0301O/O 5027055. 0007TER05005/0 0014VETO1005/CAP05005/0012CIR05005/0 0014MAN06015/0 0012CIR05016/0 0012GEN0008VALO3005/0 0008VALO5005/0003PIL05010/0 0002SCA0501O/O 0014REGO1005/5018030 1012VEN01006/5095025 0012FUSO5015/0014GUA01020/0 0001CAM05010/0 5012096

18.22 22.25.48

G.C. Part. No.
E23-711 E23-712 E23-372842 E23-E23-E24-627 E23-718 E24-E23-E23-371277 372856

Description

Instrument panel - TIMER MODEL Main switch DHW / C.H. Potentiometer Overheat thermostat ! Water gauge D.H.W. / C.H. Sensor Sight glass Flue gas exhaust hood Fuse 315 mA Printed control board Knob Printed ignition board Honeywell printed ignition board Combustion chamber cover Gas valve Honeywell gas valve Pilot burner Pilot burner for Honeywell gas valve Heat exchanger Water flow regulator Connecting pipe to air purge Air purge valve Gasket 18.5 x 11.6 x 2 Gasket24x15x2 Fan 82 ET Gasket 30 x 22 x 2 Insulation pads set Internal fuse 2A Depression chamber pilot seal Flue gasket Depression chamber Nozzle 0,27 for natural gas

8 5012210

G.C. Part. No. 372892
372864 372-372874 E23-723 E23-E24-372880 E23-372899
Ignition electrode Cable for electrode Nozzle 1,35 for natural gas Frame. Seal Main burner 3-way valve Seal 32 x 32 x 2 gas valve Low water pressure switch Circulation pump Gasket 48 x 42 x 1 Brass manifold Safety relief valve (3 bar) Internal fuse 4A Nylon tubes from pressure switch Pressure switch Elbow header Flue extension duct complete Flue duct and terminal complete Expansion tank Air restriction ring dm 79 Digital timer Vertical flue terminal complete Diaphragm for 3-way valve Microswitch for 3-way valve

0001TEL05005/0 5018046

0003BRU05015/0 0008VALO3010/0 0013GUA03035/0 0005PRE03010/0013GUAOlO45/0008VAL01017/0 0012FUSO5020/0005PRE05015/DIA05005/0 Tmb5012051 5012052
Chartists Way, Morley, Leeds, LS27 9ET. Telephone: (0113) Tfax: (0113) 238 0229