ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER
FANNED COMBI RSF 84E - RSF IOOE RSF 84ET - RSF IOOET
WITHOUTTIMER o RSF 84E G.C. N 27A RSF 1OOE G.C. No 25A NATURAL GAS (G 20) AND PROPANE (G 31)
Tested, certified and service listed
Listed by The United Kingdom Water Fitting Byelaws Scheme
WITH TIMER RSF 84ET G.C. No 28A RSF 1OOET G.C. No 26A NATURAL GAS (G 20) AND PROPANE (G 31)
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 accommodation. This guarantees maximum safety and efficiency. Indeed, our depression/combustion front cover has been designed to fit achieving maximum air tight seal using screw down fasteners 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 HARMFUL TO 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: 9 1O 11. 12 GENERAL LAYOUT PAGE INTRODUCTION DESIGN PRINCIPLES AND OPERATING SEQUENCE TECHNICAL DATA GENERAL REQUIREMENTS INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS FAULT FINDING ELECTRICAL SYSTEM DIAGRAM INSTALLATION INSTRUCTIONS FOR TWIN FLUE EXPLODED PARTS DIAGRAM LIST OF SPARE PARTS 53 54
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.

2.4 2.4.1

Domestic hot water mode The heat exchanger in the D.H.W. circuit is built into the main heat exchanger, and domestic water is heated by converting the water in the central heating circuit. The transference of heat is very high because the two fluids-move in a counter direction flow to each other. Switch 33 in the (winter) position. When a hot water tap is turned on a diaphragm diverter valve excludes the central heating circuit, the boiler automatically modulates to maintain the domestic hot water at a constant temperature. Water temperature can be regulated using the D.H.W. thermostat located on the front control panel. When domestic hot water is being drawn the main burner and pump perform as they do during central heating except that the burner is commanded by the D.H.W. thermostat. When D.H.W. is no longer called for the boiler automatically returns to the central heating mode. Switch 33 in the (summer) position. The boiler functions like an automatic gas hot
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.

(4.9 in w.g.) (1.96 in w.g.) (0.56 in w.g.)

90.47% NET 89.4% NET

TECHNICAL DATA TABLE 3 HEAT INPUT NET NOMINAL
RSF 84E(T) PROPANE GAS (G 31) I
(91,800 Btu/h) 26.9 kW max (68,200 Btu/h) mid 20.0 kW (46,000 Btu/h) min 13.5 kW (83,880 Btu/h) 24.58 kW max H E A T O U T P U T 17.6 kW (60,060 Btu/h) mid NOMINAL 10.7 kW (36,506 Btu/h) min (37,07 ft3/h) 1.05 m 3 /h max GAS RATE 3 (28,95 ft3/h) 0.82 m /h mid AFTER 10 minutes (18,36 ft3/h) 0.52 m3/h min (14.85 in w.g.) 37 mbar INLET PRESSURE (8.23 in wg.) 20.5 mbar max BURNER PRESSURE (5.94 in w.g.) 14.8 mbar mid (1.77 in w.g.) 4.4 mbar min 837 TANDEM SIT GAS CONTROL VALVE POLIDORO MOD/NP MAIN BURNER MAIN BURNER INJECTORS N. 13X0.85 POLIDORO PA525F PILOT BURNER (MARKING) 1 HOLE PILOT INJECTOR 0.22 230V-50HZ ELECTRICAL SUPPLY 160W POWER CONSUMPTION 3A EXTERNAL FUSE RATING 315mA-2A-4A (20mmtoBS4265) 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. MAXIMUM PERMISSIBLE COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRES 15 mm copper pipe SAFETY DISCHARGE 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 ooC MIN 45 C o DESIGN FLOW RATE 1057 l/h (236 gals) 20 C RISE MINIMUM FLOW RATE C.H. 494 Lts/h (109 gals/h) D.H.W. FLOW RATE 30 oC rise 11.7 l/min (2.6 galslmin) D.H.W. FLOW RATE 35 oC rise 10.1 l/min (2.24 gals/min) D.H.W. FLOW RATE 40 oC rise 8.8 l/min (1.96 gals/min) 10 oC inlet temperature max 65 o C D.H.W. TEMPERATURE min 35C max 10 bar (147 p.s.i.) D.H.W. PRESSURE min 0.8 bar (11.8 p.s.i.) To obtain 95% heat input 1.0 bar (14.5 p.S.i.) D.H.W. MINIMUM FLOW RATE 3 l/m (0.66 galS/min) FLUE OUTLET NOM. DIA. 100 m/m specially supplied with boilers Nominal Efficiency DESTINATION: BE - FR - IE - PT - ES - GB - CH FLUE TYPE - C12 - C32 - C52 CATEGORY I3P 10 Efficiency at 30% Load NOX 2
TECHNICAL DATA TABLE 4 HEAT INPUT NET NOMINAL
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

BS. 5449 BS. 5546

RSF 84E (T) Above 125 mm Below 100 mm Front 450 mm Side 75 mm
RSF 1OOE (T) Above 150 mm Below 100 mm Front 450 mm Side 5 mm
BS. 544O:1 Flues (for gas appliances of rated input not exceeding 60 kW). BS. 5440:2 Ventilation (for gas appliances of rated input not exceeding 60 kW). Health & Safety Document No. 635
25 mm in front when installed in a cupboard The Electricity at Work Regulations, 1989.

4.4 4.4.1

IMPORTANT NOTICE If the combination boiler is to be fitted in a timber framed building it should be fitted in accordance with the British Gas Publication Guide for Gas installations in Timber Frame Housing Reference IGE/UP/7/1998. If in doubt advice must be sought from the local gas supplier. The combination boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space containing a bath or shower. Where a room sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using a bath or shower. A compartment used to enclose the combination boiler MUST be designed and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified accordingly. Samples of the RSF 84E/84ET - RSF 1OOE/1OOET combination boilers have been examined by B.G.Technology Notified Body, and are certified to comply with the essential requirements of the Gas Appliance Directive 90/396/EEC, the Low Voltage Directive 72/23/EEC and shows compliance with the Electro Magnetic Compatibility Directive 89/336/EEC and are therefore permitted to carry the CE Mark. The appliance has been tested and approved by the WRc as meeting the requirements of G3 and L of the Building regulations and water Bylaws Scheme Approved Products.
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.

Fig. 10

SECTION 5 INSTALLATION 5.1 5.1.1 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.
Flue box containing (Fig. 12): Standard Flue Assembly 57 - Flue bend assembly 59 - Rubber seal 60 - Air intake duct 61 - Flue exhaust duct 62 - Terminal 65 - Pipe centering spring 66 - Flue sample point
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

Fig. 35

Fig. 33

Fig. 34

Each extension length extends the pipe by approximately 1000 mm long up to a maximum of two 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 widened or 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. The air intake pipe should be located approximately 2 mm from the boiler header (Fig. 31). When cutting both inner and outer ducts of the extension, always ensure that the reduced end (male) of the inner duct is longer than the outer duct. All joints must be sealed with the rubber seals supplied. It is important to put the centering spacer, supplied with the unit, inside between the two pipes, from the side opposite the 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 rigidly secured to wall and flue duct.

5.5.11

IN LINE FLUE BEND Measure the distance between the flue bends or the flue/terminal assembly. The 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.

6.2 6.2.1

INITIAL FILLING OF THE SYSTEM Open central heating flow and return valves. Unscrew the cap on automatic air release valve one full turn (leave open permanently). - Close all air release taps on the central heating system. - Gradually open stopcock at the filling point connection to the central heating system until water is heard to flow. - Starting with the lowest radiator open each air release tap in turn. Close it only when clear water, free of bubbles, flows out. In the same way release air from any high points in the pipework. - Continue filling the system until at least 1.5 bar registers on gauge. Then turn off. the filling points stopcock. - Inspect the system for water soundness and remedy any leaks discovered.
PROGRAMMABLE TIME CLOCK Instructions for use Consult Users Guide

Fig. 49/A

SETTINGTHE SYSTEM DESIGN PRESSURE The design pressure must be a min. 1 bar and max. 1.5 bar. These figures are read off the pressure gauge. - The actual reading should ideally be 1 bar + the height in metres to the highest point of the system above the base of the appliance (up to a max of 1,5 bar). N.B.: The safety valve is set to lift a 3 bars (30 mt/42.5 psig. - To lower the system pressure to the required value remove drain point (Fig. 93) or drain on the heating circuit. FILLING THE HOT WATER SYSTEM Close all hot water draw-off taps. Open the cold water inlet cock. Slowly open each draw-off tap until clear water is discharged. LIGHTING THE 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 winter Fig. 46

ELECTRICAL CONNECTION

INSTRUMENT PANEL Fig. 50
GAS VALVE Fig. 51 - 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. - Turn control thermostat 4 up to its maximum setting. - 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. 6.9 CHECK THE GAS PRESSURE AT THE BURNER NATURAL GAS (G 20) Now check if the maximum gas pressure at the burner is equal to 8.1 0.5 mbar (3.2 f 0.2 in w.g.) for RSF 84E or 12.5 0.5 mbar (4.9 f 0.2 in w.g.) for RSF 100E. To do this proceed as follows: - Turn off main switch 1 (Fig. 50) -Set main switch 1 on -Set control thermostat 5 at its maximum setting.

6.15 6.15.1

Fig. 528 F Y

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.
EXPLODED DIAGRAM OF BOILER BODY Fig. 54
KEY 1 - Window 2 - Plenum chamber cover 6 - Combustion chamber 7 - Air restriction ring 8 - Flue gas exhaust hood 15 - Connection pipe 18 - Heat exchanger 19 - Air pressure switch 42 44. - Main burner - Pilot burner - Auto air vent valve - Seal - Seal - Window seal - Window clamp ring - Fan 46 - Header gasket 58 - Ceramic insulation 80 - Plenum chamber 81 - Connection tube 82 - Connection tube + 83 - Burner centering pin 84 - Seal 85 - Fan fastening bracket

6.16 6.16.1

HANDING OVER TO THE USER After completion of installation and 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 explain His/Her responsibilities under the Gas Safety Regulations 1996. - 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 switch. - 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. 7.2.2
WARNING Before the start of any servicing or replacement of components always isolate electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock. Data badge position - lower left hand sub frame. - The following notes apply to the appliance and its controls but it should be remembered that attention must also be paid to the heating and hot water circuits with special attention to radiator valves, thermostats, clocks, leaking hot water taps etc. - Where it is necessary to replace a gasket that relies on adhesive for securing this adhesive will be supplied with the gasket as a spare item. - In all cases prior to servicing, remove the outer case (sect. 5.4). Operate the appliance by turning the hot water services on to a high water flow, and observe the main burner. - Check that the flame covers all the flame ports and is of a light blue colour. Yellow flames and excessive lifting of flames indicate poor combustion. - IMPORTANT: After completing any servicing or replacement of gas carrying components it is essential that a test for gas soundness is always carried along with functional checks in operation. 7.2 7.2.1 TO INSPECT AND CLEAN THE APPLIANCE Before carrying out cleaning operation, cover the electrical control panel with a piece of waterproof material to protect it from debris. Inspect the heat exchanger for any blockage. Deposits of any material should be brushed always using a soft brush. NOTE: Do not use brushes with metallic bristles. Examine internal pipe-work connections and automatic air vent for any water leaks. Rectify if necessary. Examine the combustion chamber insulating material and renew if damaged (sect. 7.9). Remove and examine the main burner injector and pilot injector clean or renew, as necessary (sec. 7.12 & 7.14). Inspect the main burner and remove any deposit with a soft brush. Check the electrodes for damage or deterioration, clean or renew as necessary. Ensure that the spark gaps are correct to dimensions specified in Fig. 52B.

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,

7.19.1

7.22.4 7.19.2 Pull off the thermostat knob (Fig. 78). Remove the lock nut and remove the control board (PCB) 7.22.5 7.19.3 7.19.4 7.19.5 7.20 7.20.1 Detach the wires by unclipping the connector from the control board (Fig. 79). Unscrew the lock nut which fastens the potentiometer to the instrument panel (Fig. 78). Replace in reverse order. TO REMOVE/REPLACE THE MAIN SWITCH (Fig. 82). Remove the front panel from the outer casing (sect. 7.3), lower the instrument panel (sect. 7.16.2 & 3), remove the control box cover (7.31.2/3) and remove the control knob. Detach the wires that connect to the switch - make sure that these wires are later reconnected to the same poles (Fig. 94). Pull the switch out from the instrument panel by pressing the clamp springs. Replace in reverse order. TO REMOVE/REPLACE THE WATER PRESSURE GAUGE (Fig. 83). Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 7.16.2 & 3). Remove the lower grating (sect. 54.2). Close the heating system on/off valves and drain the water from the drain point on the heating system (Fig. 93). Unscrew the fitting that secures the pressure gauge probe. Remove the gauge from the instrument panel by pressing its fastening springs. Replace in reverse order. TO REMOVE/REPLACE THE OVERHEAT THERMOSTAT 7.24.4 7.22.1 Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 7.1.6.2 & 3) and remove the control box cover (sect. 7.31.2/3). 7.24.5 7.24.3 7.23.5 7.23.6 7.24 7.24.1 7.23.3 7.23.4 7.20.4 7.21 7.21.1 7.22.6 7.22.7 7.23, 7.23.1

TO REMOVE/REPLACE THE CENTRAL HEATING EXPANSION VESSEL In the unlikely event of failure of the central heating expansion vessel it is recommended a suitable expansion vessel be fitted external to the boiler. It should be positioned on the return pipe and as close to the boiler as possible (Fig. 7). However, if it is necessary to replace the central heating expansion vessel the boiler must be removed from the wall as follows.

7.27.1

7.27.2 7.27.3 7.27.4

7.27.5 7.27.6

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 (sect. 7.31.2/3). Remove the lower grating (sect. 5.4.2). Remove the two sides of the casing (sect. 5.4.5). Close the on/off valve on the domestic cold water, central heating and gas supply. Drain domestic water from the lowest hot water tap and drain point on DHW inlet cock (Fig. 46). Drain the boiler (Fig. 93). Disconnect all pipework connected to boiler. Disconnect mains cables and any other connections (room thermostat, programming clock). Remove the duct proceeding in reverse order as described in (sect. 5.5 or 5.7). Remove the 2 lower coach bolts and release 2 top coach bolts then remove boiler from the wall.
7.292 Replace in reverse order 7.29.3 Fig. 82 7.29.4 7.28.5 7.28.7

7.28.8 7.28.9

Fig. 83
7.28.10 Unscrew the nut that connects the expansion vessel and remove it (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. 7.29 7.29.1 TO REMOVE/REPLACE THE AIR AUTOMATIC VENT (Fig. 92) Remove the front panel from the outer casing and the combustion chamber front cover (sect. 7.3 & 4). Remove the lower grating (sect. 5.4.2). Remove the fan assembly and the flue hood (sect. 7.6 & 7.7).

7.29.2 7.29.3

7.29.4
Close the on/off valves for the central heating circuit and drain the water from the boiler drain point (Fig. 93). Unscrew and remove the plastic cap that protects the valve vent hole (Fig. 92). Disconnect the unions 1 and 2 (Fig. 92) slightly turn and remove pipe and auto air vent. Replace in reverse order, using new seals. Fig. 88 Fill the system as described in the sect. 6.4 & 5 and check for leaks. TO REMOVE/REPLACE THE PRESSURE RELIEF VALVE (Fig. 93) Remove the front panel (sect. 7.3) and the lower grating (sect. 5.4.2) from the outer casing, lower the intstrument panel (sect. 7.16.2& 3). Remove right side of the casing (sect. 5.4.5). Close the on/off valves for the heating system and drain the water from the drain point (Fig. 93). Unscrew the valve from its body, clean or replace. Replace in reverse order. Fill the system as described in (sect. 6.4 & 6.5) and check for leaks. TO REMOVE/REPLACE TIME CLOCK (Fig. 88/A) Remove the front panel from the outer casing (sect. 7.3) and lower the instrument panel (sect. 7.16.2 and 3). Remove control box cover (sect. 7.23.2). Remove control board (sect. 7.23.2) from panel. Remove two clips securing the timer. 7.33.4 Carefully remove the four wires connecting timer by pulling spade connectors from timer. Replace in reverse order (ensure all electrical connections are made correctly) (Fig. WA). TO REMOVE/REPLACE THE IGNITION BOARD Remove front casing (sect. 7.3) lower the instrument panel (sect. 7.16.2 & 3). Remove the screw from the ignition box cover. Detach the ignition box from its base on the gas valve. Pull wire off and unscrew the sensor from its body. Replace in reverse order. Fill the system as described in the (sect. 6.4 & 6.5) and check for leaks. 7.32.4 7.32.5 7.33 7.33.1 7.33.2 Remove the PCB cover and detach the connectors from the board. Replace in reverse order ensure all electrical connections are made correctly. TO REMOVE/REPLACE LOW WATER CUT-OFF SWITCH Remove the front panel from the outer casing (sect. 7.3 & 4). Remove the lower grating (sect. 5.4.2).

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.