Ravenheat 780 Series, Instructions For Use Installation And Servicing

Page 1: ...llustrations in the present booklet are for guideline purposes only RAVENHEAT MANUFACTURING LTD CHARTISTS WAY MORLEY LEEDS LS27 9ET TEL 0044 0 113 252 7007 FAX 0044 0 113 238 0229 Website www ravenheat co uk E mail sales ravenheat co uk HIGH EFFINCENCY CONDENSING FANNED FLUE BOILER Natural Gas G20 I2H II2H3 LPG G30 G31 I3 II2H3 CSI SYSTEM AAA T CSI SYSTEM AAA T 780 SERIES 780 SERIES ...

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Page 3: ...per high heat transfer to domestic hot water Built in frost protection Printed circuit board designed to connect to room stat and or timer frost stat Aesthetically pleasing panels and controls On Off ball valves for shutting off gas central heating and domestic hot water circuit Safety relief valve for safety discharge Safety relief valve for safety discharge Programmable 7 day module with digital...

Page 4: ... 10 15 26 31 40 42 43 46 47 4 KEY 1 Heat exchanger 2 Sensing electrode 3 Burner 4 Expansion tank 5 Modulating gas valve 6 Condensing trap 7 C H outlet 8 Terminalboard 9 Safetyreliefsystem 10 Drain point 11 C H inlet 12 Circulationpump 13 Lowwaterpressureswitch 14 C H sensor 15 D H W sensor 16 Overheat cut off thermostat 17 Spark electrode 18 Combustion chamber 19 Frame 20 Sealed chamber 21 Air pre...

Page 5: ...irculationpump 6 Overheatcutoffthermostat 7 Expansiontank 8 Sparkelectrode 9 Heatexchanger 10 Fan 12 Air pressure switch 13 Fluerestrictionring 14 Temperaturefluesensor 15 Condensingheatexchanger 16 Ignitionelectrode 17 Condensingtrap 18 Burner 19 Modulating gas valve 20 DHW sensor 21 CH sensor Fig 2 ...

Page 6: ...st mode the main burner is shut down along with the pump and fan which are also switched off The pressure switch returns to its rest mode 2 2 6 Central heating mode 2 2 7 If the switch is positioned on with a demand for heat to supply radiators with the heating circuit fully pressurized so as to operate the low water sensor device the boiler will start in the same way in domestic hot water mode bu...

Page 7: ...7 Fig 3 OVERALL DIMENSION ...

Page 8: ...NECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 7 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CEN...

Page 9: ...4265 DRY WEIGHT 46 kg WATER CONTENT C H 2 1 litre WATER CONTENT 0 5 litre 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 SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE S...

Page 10: ...talled in a cupboard SECTION 4 GENERAL REQUIREMENTS 4 1 SAFETY Gas Safety Installation and Use Regulations It is law that all gas appliances are installed and serviced by a registered installer in accordance with the above regulations and these installation instructions All registered installers carry a I D card and have a registration number Both should be recorded in your boiler log book You can...

Page 11: ...s 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 ...

Page 12: ...atural 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 4 8 3 An automatic system by pass is included within the boiler The boiler is suitable for use in system with thermostatic radiator valves and additional by pa...

Page 13: ...ease of water volume when the system is heated It can accept up to 6 Its of expansion water If the appliance is connected to a system with an unusually high water content calculate the total expansion and add additional sealed expansion capacity as appropriate Fig 7 In general modern systems will present no problem 4 8 8 Mains water feed central heating There must be no direct connection to the ma...

Page 14: ... which must be used in accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co Ltd Tel 01799 550811 Sentinel Division Betz Dearborn Ltd Tel 0151 424 5351 Safety valve setting bar 3 0 Vessel charge pressure bar 0 5 1 0 1 5 Initial system pressure bar 0 5 1 0 1 5 2 0 1 0 1 5 2 0 1 5 2 0 Total water content of system EXPANSION VESSELVOLUME LITRES Litres ...

Page 15: ... a qualified person and be in accordance with the current I E E Regulations and local regulations which apply The Ravenheat boiler is supplied for connection to a 230 V 50 Hz single phase supply The supply must be fused at 3 A NOTE The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance by the use of a fused double pole isolator having a co...

Page 16: ...der supplied as an extra cost only when requested 59 Rubber seal Ø 60 66 Flue gas sample point 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 Ø 60 63 Air intake duct extension 64 Flue exhaust duct extension 65 Pipe centering spring WARNING Maximum allowable flue length 2 5 m horizontal max...

Page 17: ...off fig 17 Fig 15 Fig 16 Fig 17 5 5 INSTALLING THE APPLIANCE FOR REAR FLUE OUTLET Use the adhesive tape to attach the template to the wall making sure that the centre line is vertical Mark the two holes to fix the hanging bracket onto 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 2 holes Insert the plastic expansion plugs Cut or...

Page 18: ...er flue duct 60 mm at right angles to a length equal to W 264 mm Insert from cut and reassemble the two tubes Insert centering spring 65 must be de burred Reassemble together inner and outer flue duct insert centering spring fig 19 KEY 56 Straight header 57 Elbow header 58 Header gasket 59 Rubber seal Ø 60 60 STD air intake duct 61 STD flue exhaust duct 62 Terminal 63 Air intake duct extension 64 ...

Page 19: ... pull the flue exhaust duct towards the boiler in order to engage tube 61 into its header 57 Fig 21 22 Position flue into elbow header and push to locate inner and outer flue correctly ensuring a good seal is made with or rubber seal 5 5 7 Fit terminal cover plate fig 23 5 5 8 Extensions kits are available to order for flue extension of up to 2 5 metres total length Make sure flue slopes 2 5 down ...

Page 20: ...asure the distance between the flue bends or the flue terminal assembly The measurements should be taken from the outer edge of the flue and bend fig 28 IMPORTANT inline flue bend 1680 mm must be deducted from overall length for each 90 bend Obtuse flue bend 1680 mm must be deducted from overall length for each 135 bend fig 28 5 6 COMPLETING BOILER INSTALLATION 5 6 1 Reassemble the outer casing se...

Page 21: ...t centering spring 65 5 7 5 Insert the flue assembly into the wall making sure it will not interfere when fixing the boiler on the wall 5 7 6 Lift the boiler on to the wall Locate onto the top coach bolts Fit the lower coach bolts and tighten all four securing bolts 5 7 7 Working above the boiler pull the flue duct towards the elbow in order to engage tube into its header Fig 23 Position flue into...

Page 22: ...ng rings Proceed with installation as detailed in section 5 of the main Installation and Servicing Instruction ignoring all references to horizontal flue installations Use adhesive tape to attach the template to the wall making sure that the centre line is vertical and that the flue centre line is vertically below the point at which the flue will exit the roof Ensure that the maximum permissible f...

Page 23: ...ion always cut on spigot side and they must be de burred 5 8 REASSEMBLE BOILER AS PER sect 5 6 5 8 1 Fitting valve pack Remove plastic caps from boiler connection and fit valves as per fig 33 using washers provided 5 9 GAS CONNECTION fig 33 5 9 1 A minimum working gas pressure of 20 mbar 8 in w g must be available at the boiler inlet at full flow rate 37 mbar for propane 29 mbar for butane 5 9 2 F...

Page 24: ...nd 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 becomes 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 engi...

Page 25: ...n the boiler When used with a Y or S plan system it will control DHW and or heating only if required see fig 36 As an alternative Ravenheat recommend a room stat with built in timer for control of heating using boiler timer for DHW time settings 5 13 1 PROGRAMMABLE TIMECLOCK Instructions for use User s Guide Fig 36 ...

Page 26: ...s been through a rigorous operational procedure at our factory and should not require any further adjustment If in the unlikely event of the appliance not operating correctly please turn to the Fault Finding and Logic Sequence Charts 6 2 GAS SUPPLY INSTALLATION 6 2 1 Inspect the entire installation including the gas meter test for soundness and purge all as described in BS 6891 6 3 ELECTRICAL INST...

Page 27: ...ssure inlet 81 Downstream pressure outlet 104 Gas valve modulator 110 Max regulator nut 111 Min regulator nut 114 Electrical connections modulator 115 Electrical connections INSTRUMENT PANEL GAS VALVE 27 27 Fig 37 Fig 38 ...

Page 28: ... PRESSURE fig 36 SIT HONEYWELL DUNGS GAS VALVE Remove cap covering modulator to gas valve Detach one of the cables connected to the modulator 114 With the boiler operating use a screw driver HONEYWELL 9 mm spanner to turn the nut 111 clockwise to increase pressure and anti clockwise to decrease pressure NOTE LPG ONLY The minimum pressure is factory set and sealed and cannot be adjusted 6 10 RECONN...

Page 29: ...TING THERMOSTAT 6 13 1 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 Fig 39 Fig 40 6 12 CHECKING THE FLUE SYSTEM 6 12 1 The flue system should be visually checked for soundness check all connections and fixings are secure and tight ...

Page 30: ...ction pipe 18 Heat exchanger 24 Burner 27 Auto air vent valve 28 Pressure switch 29 Seal 31 Seal 42 Sight glass 44 Fan 46 Header gasket 50 Flue gas exhaust hood cover 53 Connection tube 54 Connection tube 58 Ceramic insulation 61 Condensing heat exchanger 80 Plenum chamber 83 Burner centering pin 84 Seal Fig 41 ...

Page 31: ...requency of cleaning will depend upon the particular installation conditions and usage but in general once gear should be adequate WARNING Before the start of any servicing or replacement of components always isolate electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock Data badge position lower left hand side of casing The following notes apply t...

Page 32: ...and put them into a container so that they don t get lost 7 4 3 Detach the cover being careful not to damage the seal 7 4 4 Reassemble in reverse order Ensure good seal of cover when replacing 7 5 TO REMOVE REPLACE THE FAN ASSEMBLY fig 42 7 5 1 Remove front casing sect 7 3 Remove combustion chamber front cover sect 7 4 7 5 2 Disconnect the electrical connections from the fan motor 7 5 3 Support th...

Page 33: ...t exchanger new seals must be used 7 9 TO REMOVE REPLACE COMBUSTION CHAMBER INSULATION PANELS 7 9 1 Remove casing front panel sect 7 3 Remove combustion chamber front cover sect 7 4 7 9 2 Remove fan sect 7 5 7 9 3 Remove condensing heat exchanger sect 7 6 7 9 4 Remove the flue hood sect 7 7 7 9 5 Remove the burner Remove top insulation pieces at sides Remove 2 screws securing combustion chamber to...

Page 34: ...34 Fig 45 Fig 44 Fig 46 ...

Page 35: ...en 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 13 TO REMOVE REPLACE THE GAS VALVE 7 13 1 Remove front casing sect 7 3 and the combustion chamber front cover sect 7 4 7 13 2 Unscrew the union 7 13 3 Remove the 2 screws to the gas pipeline 7 13 4 Remove the eight screws four per side that connect the gas va...

Page 36: ...36 Fig 48 Fig 47 Fig 49 Fig 50 Fig 51 ...

Page 37: ...nect mains cables and any other connections room thermostat 7 19 3 Detach the connectors from the board 7 19 4 Replace in reverse order ensure all electrical connections are made correctly 7 17 TO REMOVE REPLACE THE DIFFERENTIAL PRESSURE SWITCH fig 52 7 17 1 Remove front casing sect 7 3 7 17 2 Detach the wire connector plug from the pressure switch make sure that the wire connector plug are later ...

Page 38: ...rew the nut that fasten the condensing trap to the backframe and remove it 7 20 4 Replace in reverse order 38 7 21 TO REMOVE REPLACE PUMP fig 56 7 21 1 Remove front casing sect 8 1 7 21 3 Detach the supply wire connector from the pump 7 21 4 Remove the securing clip at the pump manifold the pressure gauge and the expansion vessel pipe 7 21 5 Unscrew the nut to the CH pipe and remove the pump 7 21 ...

Page 39: ...ach bolts then remove the boiler by lifting from the wall bracket 7 22 6 Unscrew the nut that connects the expansion vessel and remove it 7 22 7 Remove the screw and the bracket supporting expansion vassel 7 22 8 Replce in reverse order 7 22 9 Remove the expansion vessel 7 22 10 Replace all the components in reverse order using new seals 7 22 11 Fill the system as described in the sect 6 and check...

Page 40: ...trol board No Yes No Is the fan running at Maximum speed Yes No Is 230 V at Fan No Is the flow temperature less than 95 Yes Check Replce Fan Check replace fan modulating board Is there a gas supply for the applianced Is the flue temperature less than 95 C Yes Check Gas supply Check Replace heating sensor Check Replace the overheat thermostat No Yes No END CENTRAL HEATING TEST FAILED FLUE TEMPERATU...

Page 41: ...Timer set to AUTO Does neon on Timer illuminate Are L and N connections to points 1 and 2 Yes Is there 230V across point 1 and 2 Are L and N correctly Electrical fault within boiler No TIMER FAULT With leads disconnected is there continuity across leads to 3 and 5 Enter correct programme as per instructions provided Recheck No With leads connected is there continuity across leads to 3 and 5 No Is ...

Page 42: ...Fig 59 42 SECTION 9 ELECTRICAL SYSTEM DIAGRAM ...

Page 43: ...uct systems only When ordering twin flue it must be stated for CSI SYSTEM 780 series range Typical installation procedures are illustrated by drawings IMPORTANT Correct F1 orifice must be fitted Supplied with the CSI twin flue header is a F1 orifice plate along with supplementary depression seal Before fixing the twin flue system the existing orifice plate must be replaced with F1 also ensuring su...

Page 44: ... 35 mm fall per metre Spacing Clips Spacing Clips are available on request should they be required NOTE for eccentric vertical flue a 125 mm 5 in diameter flashing plate will be required Exhaust suction system with concentric pipes for flat or sloping roofs Extensions with two separate pipes Maximum distance I E T 2 Metre 2 Metre 1 Metre 12 Metre maximum pipe terminal Minimum distance D T 2 metre ...

Page 45: ...fall per metre IMPORTANT see Fig 6 and 31 for terminal clearances Exhaust suction system with two separate pipes through a single vertical wall Maximum distance D I E Total exhaust inlet pipe 18 metre Minimum distance D I E 1 5 metre Min inlet pipe distance 0 5 metre Min distance between pipe 50 mm NOTE The pressure loss for each elbow fitted is 90 slow bend less 3 metre of pipe for each one fitte...

Page 46: ...79 83 105 46 50 27 16 39 17 2 22 100 1 4 5 11 8 SECTION 11 ...

Page 47: ...0P01010 0 Combustion chamber cover 22 0008VAL09015 0 Dungs valve gas 22 1 0008VAL06007 0 Honeywell valve gas 26 0002SCA06010 1 Heat exchanger 27 0014RAC11005 0 Condensing trap 29 0010TUB06050 2 Connecting pipe to air purge 30 0008VAL01010 0 Air purge valve 31 5018025 372851 Gasket 18 5 x 11 6 x 2 33 0012VEN03005 1 Fan 36 5018046 378864 Gasket 30 x 22 x 2 37 1015PAN06005 0 E23 737 Insulation pads s...

Page 48: ...h 87 1 0014TUB01006 1 Red nylon tubes from pres switch 89 0005PRE06006 0 Pressure switch 93 0019CUR06005 1 Elbow header 95 0019PR005005 0 Flue extension duct complete 97 0019TER06005 1 Flue duct and terminal complete 100 0004VAS09010 0 Expansion tank 105 0012ORO01010 0 371258 Digital Timer 106 0019TER06010 0 E23 753 Vertical Flue Terminal Complete 114 0014GUA06010 0 Flue gasket dm 100 115 0014GUA0...

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Page 50: ...COD 0017LIB06010 2 03 2010 ...

Page 51: ...ES NO CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes REQUIREMENT MEASURES PROVIDED 1 TIME AND TEMPERATURE CONTROL TO HEATING ROOM STAT PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT 2 TIME AND TEMPERATURE CONTROL TO HOT WATER CYLINDER STAT PROGRAMMER TIMER COMBI BOILER 3 HEATING ZONE VALVES FITTED NOT REQUIRED 4 THERMOSTATIC RADIATOR VALVES FITT...

Page 52: ...Y NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regular...