ELECTRONIC IGNITION - AUTOMATIC MODULATING BOILER FANNED COMBI RSF 84E - RSF IOOE RSF 84ET - RSF IOOET WITHOUTTIMER o RSF 84E G.C. N 47 581 27A RSF 1OOE G.C. No 47 581 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 47 581 28A RSF 1OOET G.C. No 47 581 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 IS0 9001 discipline, 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. 3 TABLE OF CONTENTS SECTIONS: 1 2 3 4 5 6 7 8 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 6 6 8 12 17 27 33 44 46 50 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 4 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 29 30 36 37 38 60 61 62 - 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. 1.1 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. 1.2 2.2.8 SECTION 2 2.1 2.2 DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION Domestic hot water mode When the appliance is in rest mode with the mains neon switch on. Switch the summer/winter switch in the position, making sure the heating circuit is charged with water (above 1 bar). When the domestic hot water tap is turned on, the boiler will function in the following sequence: The pump starts. The control board sensors. The fan operates via the pressure switch and sends a signal back to the ignition board that the fan is running at maximum speed. The spark ignition system is powered which in turn commences the spark igniter to operate and light the burner. At this point the ignition board opens the first step of the gas valve to light the pilot/burner. When the electrode/sensor senses the signal of the pilot/burner, it opens the second stage of the gas valve via the ignition board on minimum power. Upon the second valve opening the spark igniter stops. From the minimum gas rate setting the boiler increases to the maximum permissible pressure over a period of 3 to 4 seconds and will remain at its maximum required power until its maximum regulated temperature. When the domestic hot water tap is closed the diverter valve goes back into rest mode, the main burner is shut down along with the pilot/burner. The pump and fan are also 2.2.9 2.2.1 2.3.2 2.3.3 2.2.2 2.3.4 2.3.5 2.2.3 2.2.4 2.3.6 2.2.5 2.3.7 6 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. 2.4.2 2.4.3 3.1.2 2.4.4 3.1.3 3.2.1 2.4.5 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 Lt ...