AGA 480KB Rayburn Heatranger Instruction Manual

AGA 480KB Rayburn Heatranger

Product Information

Specifications

• Product Name: Heatranger 440/460/480/499KB
• Model Number: DESN 511653 B
• Installation Instructions for use in GB and IE
• Manufacturer Warranty: Ray Warranty
• Contact Email: raywarranty@aga-web.co.uk

Product Usage Instructions

Section: Site Requirements

This section provides information on the installation requirements and commissioning instructions for the Heatranger appliance.

Balanced Flue Installation (Standard Kit 250mm-430mm)

Instructions for installing the balanced flue using the standard kit with a length range of 250mm to 430mm.

Balanced Flue Installation (Extension Kit 430mm-880mm)

Instructions for installing the balanced flue using the extension kit with a length range of 430mm to 880mm.

Section: Contents

This section provides a list of contents included with the Heatranger appliance.

Section: Consumer Protection

This section highlights that the Heatranger appliance is designed and constructed to meet required safety standards when properly installed and used. It also mentions that any unauthorized alteration could invalidate the warranty and affect statutory rights.

Section: Health & Safety

This section provides information on handling specific materials contained in the appliance and the necessary precautions to be taken to ensure health and safety. It includes instructions for handling firebricks, fuel beds, artificial fuels, fire cement, glues and sealants, glass yarn, mineral wool, insulation pads, and ceramic fiber.

FAQs

• Q: Can I use reconditioned or copy parts for replacement?
  • A: No, it is recommended to use only spare parts that conform to the safety and performance specifications required by AGA.
• Q: Where can I find the warranty information?
  • A: The warranty information can be found in the accompanying documentation or by contacting Ray Warranty via email at raywarranty@aga-web.co.uk.
• Q: Are there any specific requirements for handling certain materials in the appliance?
  • A: Yes, when handling materials such as fire cement, glues and sealants, glass yarn, mineral wool, insulation pads, and ceramic fiber, it is important to exercise caution and use appropriate protective clothing such as disposable gloves, face masks, and eye protection. After handling, wash hands and other exposed parts properly. When disposing of the product, reduce dust with water spray and ensure that parts are securely wrapped.

Heatranger 440/460/480/499KB

Installation Instructions

For use in GB and IE

DESN 511653 B

REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by AGA.

PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THIS APPLIANCE

raywarranty@aga-web.co.uk

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12/13 EINS 511641-E

SECTION SITE REQUIREMENTS
INSTALLATION REQUIREMENTS COMISSIONING INSTRUCTIONS
BALANCED FLUE INSTALLATION (STANDARD KIT 250mm-430mm) BALANCED FLUE INSTALLATION (EXTENSION KIT 430mm-880mm)

CONTENTS
CONSUMER PROTECTION HEALTH & SAFETY
GENERAL SPECIFICATIONS
TECHNICAL DATA
INTRODUCTION REGULATIONS LOCATION OIL PIPE LINE OIL STORAGE GRAVITY SINGLE FEED PIPE SYSTEM SUCTION LIFT TWO-PIPE SYSTEM FLUE SYSTEM WATER CIRCULATION SYSTEM HEATING CONTROLS TIMING CONTROLS EXTERNAL CONTROLS ELECTRICAL SUPPLY WIRING DIAGRAM
CLEARANCES PRELIMINARY INSTALLATION SITE LOCATION
BURNER ACCESS ELECTRICAL CONNECTION OIL PUMP TERMINAL STRIP CONNECTIONS ELECTRICAL CHECK FIT PRESSURE GAUGE VENT OIL PUMP ADJUST OIL PRESSURE SET COMBUSTION AIR SEALED SYSTEM REQUIREMENTS COMMISSIONING TYPICAL SEALED SYSTEM TYPICAL OPEN VENTED SYSTEM ANCILLARY CONTROLS CHECK BOILER CONTROL CHECK INSTRUCT THE USER
PREPARATION EXHAUST DUCT WALL SLEEVE LOCATE APPLIANCE VENT PIPE TERMINAL INSERT TUBES/SETTING PIECE TERMINAL BAFFLE TERMINAL GUARD
PREPARATION EXHAUST DUCT WALL SLEEVE LOCATE APPLIANCE VENT PIPE TERMINAL INSERT TUBES/SETTING PIECE TERMINAL BAFFLE TERMINAL GUARD

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Contents
PAGE
3 3
4
5
6 6 7 8 8 9 9 10-11 12 13 13 14 15 16
17 17 18-19
20 20 20 21 22 22 22 22 23 24 24 25 25 26 26 26
27 28 29 30 30 31 31 32 32
33 34-35 36-37 38 38 38 39 40 40

Consumer Protection

As responsible manufacturers we take care to make sure that our products are designed and constructed to meet the required safety standards when properly installed and used.
IMPORTANT NOTICE: PLEASE READ THE ACCOMPANYING WARRANTY Any alteration that is not approved by AGA could invalidate the approval of the appliance, operation of the warranty and could affect your statutory rights.
Health & Safety
This appliance may contain some of the materials that are indicated. 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 of the listed materials that could be interpreted as being injurious to health and safety, see below for information.
Firebricks, Fuel Beds, Artificial Fuels When handling use disposable gloves.
Fire cement When handling use disposable gloves.
Glues and Sealants Exercise caution – if these are still in liquid form use face masks and disposable gloves.
Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre May be harmful if inhaled. May be irritating to skin, eyes, nose and throat. When handling avoid contact with skin or eyes. Use disposable gloves, face-masks and eye protection. After handling wash hands and other exposed parts. When disposing of the product, reduce dust with water spray, ensure that parts are securely wrapped.
Kerosene & Gas Oil Fuels (mineral oils) 1. The effect of mineral oils on the skin vary according to the duration of exposure. 2. The lighter fractions also remove the protective grease normally present on the surface of the
skin. This renders the skin dry, liable to crack and more prone to damage caused by cuts and and abrasions. 3. `Oil acne’ is recognised by the presence of skin rashes. The arms are most often affected, but may occur where there is contact with oil or oily clothing. – Seek medical attention for any rash. – Avoid skin contact with mineral oil or clothing contaminated with mineral oil. 4. Inhalation of mineral oil vapours must be avoided. Never fire the burner in the open as unburnt oil vapours are likely to occur. 5. Use a suitable barrier cream which will give protection against mineral oil, lanolin based hand creams are usually very effective. 6. Never syphon mineral oils by use of the mouth. If accidentally swallowed, call a doctor, do not induce vomiting.
NOTE: SMOKE/SMELL EMITTED DURING INITIAL USAGE Some parts of the cooker have been coated with a light covering of protective oil. During initial operation of the cooker, this may cause smoke/smell to be emitted and is normal and not a fault with the appliance, it is therefore advisable to open doors and or windows to allow for ventilation. Lift the lids to prevent staining the linings.
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582

905

FLOW

65

CONNECTION

509 940

1355 910

278
RETURN CONNECTION

60 542
END ELEVATION

Fig. 1

PLEASE NOTE: IT IS ADVISABLE TO CHECK THE ACTUAL SIZE/WIDTH OF YOUR APPLIANCE BEFORE FINALLY FIXING ANY KITCHEN UNITS SINCE ENAMELLED CAST IRON CAN VARY IN SIZE.
GENERAL SPECIFICATIONS

ELECTRIC AND OIL CONNECTIONS
DESN 511654

Boiler Water Connections

Flow (one)

Rp 1 (1in.BSP Int)

Return (one)

Rp 1 (1in.BSP Int)

Both connections are located towards the rear edge of the appliance L.H. side panel.

Oil Inlet

10mm copper To connect to the R.H. side panel

Electrical Supply

230V ~ 50Hz 220/270W 3 Amp Fused

CO2%

– Boiler – Cooker

11.0-11.5 11.0-11.5

Water Capacity of Boiler

11.5 litres

Weight of Appliance 395kg

Max. Operating Pressure of Boiler

2 bar (20m)

Fuel

Kerosene C2

Terminal Requirements Wall Thickness – 250mm – 430mm – Standard Kit Wall Thickness – 430mm – 880mm – Standard + Extension Kit

Max. Water Temp.

82°C

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Technical Data

440KB
BURNER NOZZLE (US g/h) OIL PRESSURE Bar (psi) OIL BURNING RATE cc/m HEAT INPUT kW BOILER OUTPUT kW TOTAL OUTPUT kW
460KB
BURNER NOZZLE (US g/h) OIL PRESSURE Bar (psi) OIL BURNING RATE cc/m HEAT INPUT kW BOILER OUTPUT kW TOTAL OUTPUT kW
480KB
BURNER NOZZLE (US g/h) OIL PRESSURE Bar (psi) OIL BURNING RATE cc/m HEAT INPUT kW BOILER OUTPUT kW TOTAL OUTPUT kW
499KB
BURNER NOZZLE (US g/h) OIL PRESSURE Bar (psi) OIL BURNING RATE cc/m HEAT INPUT kW BOILER OUTPUT kW TOTAL OUTPUT kW

BOILER BURNER
0.35 @ 60°H 8.5 (120) 23.0 14.2 12.3 12.5
BOILER BURNER
0.55 @ 80°EH 10 (145) 38 21.7 17.5 18.2
BOILER BURNER
0.65 @ 80°EH 10 (145) 47.5
29.3
23.5 24.7
BOILER BURNER
0.85 @ 80° EH 10 (145) 58 35.2 29.3 29.5

COOKER BURNER
0.35 @ 80°S 8.5 (120) 23.0 14.2
3.1
COOKER BURNER
0.40 @ 80° EH 10 (145) 28.5 17.6
3.1
COOKER BURNER
0.40 @ 80° EH 10 (145) 28.5 17.6
3.1
COOKER BURNER
0.40 @ 80° EH 10 (145) 28.5 17.6
3.1

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INTRODUCTION

The Rayburn is a floor standing combined cooker and central heating boiler. It gives independent operation for space heating, domestic hot water and cooking. The appliance is fired by two independent pressure jet oil burners. Either burner can be independently operated under programmer control if required. The boiler is designed for use on a fully pumped low pressure hot water circulation system, with a pumped over run facility or alternatively on a sealed system limited to 2 bar.
IMPORTANT
This appliance must only be used with Kerosene C2 to BS 2869.
An Indirect Cylinder to BS1566: Part 1 must be fitted.
If the heating circuits are controlled in such a way that both heating and cylinder circuits can be closed off at the same time then a PERMANENTLY OPEN BYPASS LOOP should be provided.
An OFTEC approved Fire Valve MUST be fitted in the oil supply line.
The supplied in line filter MUST be fitted.

Site requirements
REGULATIONS
THE APPLIANCE IS A CONTROLLED SERVICE BY DEFINITION AND REQUIRES EITHER FITMENT UNDER THE REMIT OF BUILDING CONTROL OR INSTALLATION BY AN OFTEC REGISTERED 105 TECHNICIAN (CLASSED AS A COMPETENT PERSON) WHO CAN SELF-CERTIFY HIS OWN WORKS.
The appliance must be commissioned by a competent or OFTEC approved engineer.
The installation of the appliance must be in accordance with the relevant requirements of the current Building Regulations BS7671: 1992 (formerly IEE Wiring Regulations) and the bylaws of the local Water Undertaking. It should also be in accordance with the relevant recommendations of the following current British Standard Codes of Practice.
BS 5410 Installation of oil fired appliances for space heating and hot water purposes Part 1 Boilers of rate output not exceeding 45kW.
BS 5449 Central Heating for domestic purposes. Part 1, Forced circulation hot water system.
Building Regulations England & Wales, Part J, Heat producing appliances.
Building Standards Scotland – Technical Standard Part F. Heat producing appliances and storage of liquid and gaseous fuel.
Building Regulations Northern Ireland – Technical Booklet to Part L. Heat producing appliances.
The Control of Pollution (Oil Regulations).

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Site requirements

LOCATION

Appliance Hearth. The surface temperature of the floor below the appliance does not exceed 100°C. The constructional hearth described in Section J does not apply. This appliance must be installed on a solid floor or base of incombustible material which is capable of supporting the total weight.

Where the cooker is to stand in a recess or against a wall which is to be tiled, IN NO CIRCUMSTANCES SHOULD THE TILES OVERLAP THE COOKER TOP PLATE. (See Fig. 2).

The location chosen for the appliance must permit the installation and the provision of a satisfactory flue and an adequate air supply. The location must also provide adequate space for servicing and for air circulation around the appliance. See “Installation of the Appliance”.

The space in which the appliance is to be fitted must have the following minimum dimensions.

Between wall or unit and LH side of appliance – 10mm top plate Between wall or unit and RH side of appliance – 10mm top plate SHOULD THE WALL PROJECT BEYOND THE FRONT OF THE APPLIANCE, IT MUST BE INCREASED TO 50mm, SEE FIG. 3. To allow door to open enough to change oven and shelf position. Above the raised insulating cover handle – 60mm

*NOTE – Where oil pipe is required to turn at 90°, if pipe is taken straight out from appliance gap may be reduced to 10mm.

In addition, adequate clearance must be available at the front of the appliance to enable it to be operated and serviced. Flue pipes and fittings must not be closer than 25mm to combustible materials and where passing through a combustible partition, must be enclosed in a non-combustibler sleeve providing an air space of at least 25mm.

Fig. 2

10mm

DESN 516733 50mm

10mm

Fig. 3

WALL PROJECTING BEYOND THE FRONT OF THE APPLIANCE
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OIL PIPE LINE
The oil supply connection between the storage tank and the oil pipe should be run in copper or steel pipe with a minimum diameter of 10mm. Galvanised pipes and fittings should not be used. Annealed copper pipe is preferred with flare type manipulative fittings. Capillary fittings with soft solder should not be used. Steel pipes should be joined using taper threads.
All pipe work and fittings must be completely air tight. Only oil resistant compounds and PTFE tape should be used when making joints. Pipe work must be protected against damage whether fitted above or below ground.
The size and arrangement of pipe work will depend upon the distance and height of the oil storage tank in relation to the oil pump inlet.
The oil line from the storage tank to the appliance must be fitted with a remote acting OFTEC approved fire valve operating at 150°F, fitted with an appropriate length of capillary to enable the valve body to be located externally at the point where the oil line enters the building. The sensing bulb of the fire valve MUST be fitted to the clips located on the L.H. side of the appliance. See Fig. 5.
The 5-10 micron oil filter supplied with the appliance must be fitted on the oil pipe line and stop valve must be fitted, as close to the cooker as possible in an accessible position.
A flexible pipe connection, approximately 1000mm long, is supplied to fit between the oil supply pipe and the oil pump for ease of burner removal. This must be contained within the appliance case.
Where the oil pipe connection is taken at 90° from the cooker a special elbow fitting is supplied loose with the cooker.

Site requirements

OIL STORAGE

The minimum recommended oil tank size is 1400 litres, which must be installed in accordance with the relevant regulations in force and the code of practice governing its installation are covered by BS 5410 Part 1 Mild Steel Tanks should be to BS 799 Part 5 and plastic tanks to OFTEC standard OFS T100.

TWO PIPE SYSTEM KIT

A kit is available for a two pipe system (optional extra).

Part No.

RO9M 998550

CAT No.

R4613

The kit is made up of the following parts:

Bulkhead Fitting Flexi Hose Return Oil Nipple

Two Pipe System Fitting Instruction – EINS 512015

REMOVE HORSESHOE WASHER
Fig. 4 8
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DESN 511990

Site requirements
GRAVITY SINGLE FEED PIPE SYSTEM
DESN 511671 B SUCTION LIFT TWO-PIPE SYSTEM

DESN 511672 A

NOTE: SUCTION LIFT MAY ALSO BE ACHIEVED BY USE OF A SINGLE PIPE LIFT WITH A DEAERATION DEVICE

REFER TO INSTRUCTION SHEET FOR DETAILS ON FITTING TWO-PIPE SYSTEM.
Fig. 5

H METRES

MAXIMUM LENGTH (METRES)
9

10mm OD 12mm OD

0 0.5 1.0 1.5 2.0 2.5 3.0 35 30 25 20 15 8 6 100 100 100 90 70 30 20

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FLUE SYSTEM

SEE FIG. 6
The flue system must be installed in accordance with the regulations in force.
Terminal Position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in Fig. 6. Where the terminal is within 1m of any plastic material, such material should be protected from the effects of the combustion products of the flue.
Terminal Protection A terminal guard is supplied with the cooker and must be fitted. If the flue termination is less than 2 metres above ground level, if damage could occur to the terminal or if there is the possibility of accidental contact by persons.
Maximum Flue Gas Temperature 260ºC with both burners on.

Site requirements

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Site requirements

Fig. 6

A BELOW A GUTTER OR SANITARY PIPEWORK 600mm

B HORIZONTAL FROM OPENING, AIR BRICK, 600mm WINDOW ETC

C ABOVE GROUND OR BALCONY LEVEL

300mm

D BELOW EAVES OR BALCONY

600mm

E FROM AN INTERNAL OR EXTERNAL CORNER 300mm

F FROM A TERMINAL FACING A TERMINAL

1200mm

G FROM A SURFACE FACING A TERMINAL

600mm

H VERTICAL FROM TERMINALS ON THE SAME 1500mm WALL

I HORIZONTAL FROM TERMINALS ON THE SAME WALL

750mm

J BELOW AN OPENING, AIR BRICK, WINDOW ETC

600mm

K FROM VERTICAL SANITARY PIPEWORK

300mm

Where the terminal is within 1 metre of any plastic material, such material should be protected from the effects of combustion products of fuel.
There are additional general requirements in most Regulations and Standards that the flue must be positioned so that it does not cause a nuisance and permits the dispersal of combustion products.
Consideration must be given, as to the possible adverse affects of combustion noise on adjoining properties, inherent with this type of product.

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WATER CIRCULATION SYSTEM

Flow and return pipework between cooker diverter valves must be 28mm diameter minimum.
Space and water heating systems should be in accordance with the relevant recommendations of BS 5410: Part 1.
In a combined central heating and domestic hot water system, the hot water storage vessel must be of the indirect cylinder type to BS 1566: Part 1. The hot water storage vessel should be insulated with not less than 75mm thick mineral fibre or its equivalent.
Cisterns and pipework should not be situated in areas which may be exposed by freezing conditions and should be insulated.
Draining taps must be located in accessible positions which permit the draining of the whole system, including the heat storage vessel. Draining taps should be at least 1/2 in BSP nominal size and be in accordance with BS 2879.
The appliance boiler section should be connected to a cistern water supply, subject to a maximum head of 18.25m. The heating system must be designed (and adjusted if necessary) to give temperature differential across the boiler at full output of 10-14°C. When horizontal runs are used the pipes should rise upwards in the direction away from the appliance.
Circulating Pump It is recommended that the selected pump be sized to suit the boiler pressure loss and therefore adequate to give the required temperature differential between the flow and return.
The pump should be able to meet the requirements of the system design and fitted in a readily accessible position.
Isolating Valves Isolating valves (preferably of the keyless type) must be fitted to the inlet and outlet of the circulating pump to facilitate service and replacement of parts without draining the system.
Inhibitor A corrosion inhibitor MUST be added to the heating system to protect the heat exchanger and pipework. Inhibitor must also be replaced if the system is drained after installation. As a precaution the heating system MUST also be flushed out prior to the addition of the inhibitor to ensure any flux, debris removed.
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Site requirements

Site requirements
HEATING CONTROLS
Internal temperature and time controls are supplied These provide control of cooking and hot water temperatures. The cooker is supplied with 2-channel programmer:Channel 1 – Marked “COOKER” Channel 2 – Marked “BOILER”.
A separate switch in conjunction with the hot water channel gives priority to either the domestic hot water or the supply of hot water for central heating/DHW (if external controls are fitted).
It is recommended that independent temperature controls are provided for comfortable room temperatures, for economic operation and for control of the domestic hot water flow to the cylinder.
Consideration should be given to fitting a frost thermostat which should be set to operate at a temperature of approximately 4°C.
Consideration must be given when selecting 3 port midposition or 2 port zone valves. That they are capable of handling the heat output of the boiler side, of this range of appliance.
It is essential that the capacity of the individual valves is considered to enable the correct size to be chosen.
For this range of appliances, where Honeywell valves are selected, a guide to selection is as follows:-
Model:
440KB, 22mm (3/4″) 2 or 3 port
460KB, 22mm (3/4″): 2 or 3 port
480KB, 28mm (1″): 2 or 3 port
499KB, 28mm (1″): 2 port only
3 port mid-position valves are inappropriate for selection with the 499KB model.

TIMING CONTROLS
The latest publication of Part L of the Building Regulations states that “separate timing controls should be provided for space heating and water heating”.
The 400 Series cookers/boilers are fitted with a 2 channel programmer.
Channel 1 controls the cooking facility. Channel 2 controls the boiler facility which is space heating and water heating combined.
To meet the new Building Regulations, the space heating and water heating functions must have individual timing controls, therefore we recommend the fitting of an auxillary programmable room thermostat to control space heating timings and use channel 2 on the appliance to control the hot water.
WARNING: POWER TO THE APPLIANCE AND AUXILLARY CONTROLS i.e. PROGRAMMABLE ROOM STAT MUST BE VIA THE SAME ISOLATION SWITCH.

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Site requirements
440/460/480/499KB – EXTERNAL CONTROLS
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Site requirements
ELECTRICAL SUPPLY
Wiring external to the appliance must be installed by a Qualified Engineer in accordance with current National Wiring Regulations and any local regulations which apply. The appliance is supplied for 230 Volt ~ 50Hz 220/270W a fuse rating of 3 amps. The method of connection to the mains supply should facilitate complete electrical isolation of the appliance, by the use of a fused double pole switch having a contact separation of at least 3mm serving only the appliance. The point of connection to the mains should be readily accessible and adjacent to the appliance. The installation should be protected by a 30mA Residual Current Circuit Breaker (RCCB). The minimum requirement for the power cable is that it should be a 3 core PVC sheathed flexible cord (85°C min) at least 0.75mm2 (24 x 0.2mm) to the relevant standard. WARNING THIS APPLIANCE MUST BE EARTHED In the event of an electrical fault after installation of the appliance, preliminary electrical system checks must be carried out i.e. earth continuity, short circuit, polarity and resistance to earth. For wiring instructions see wiring diagrams. The circulating pump must be connected to PL and PN on the terminal block (See Fig. 7) and the cables clamped and passed through the grommet in the right hand side panel. NOTE: The 3 amp fuse rating takes into account any auxiliary components used. In most central heating systems i.e. circulation pump, zone valves, Aga recommend that only CE marked equipment is used in conjunction with this appliance.
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WIRING DIAGRAM 440/460/480/499 KB

Site requirements

Fig. 7

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Installation requirements

CLEARANCES
The appliance is floor mounted. The space in which the appliance is to be fitted must have the following minimum dimensions.
Between wall or unit and LH side of appliance – 10mm top plate Between wall or unit and RH side of appliance – 10mm top plate SHOULD THE WALL PROJECT BEYOND THE FRONT OF THE APPLIANCE, IT MUST BE INCREASED TO 50mm, SEE FIG. 3. To allow door to open enough to change oven and shelf position. Above the raised insulating cover handle – 60mm
In addition adequate clearance must be available at the front of the appliance to enable it to be operated and serviced.
PRELIMINARY INSTALLATION

The appliance is delivered in a fully assembled condition with the exception of the following items which are supplied separately packed and require assembly:-
The appliance rear distance bracket.
The cooker handrail.
The oil filter. The balanced flue terminal. The inlet elbow
Appliance rear distance bracket: if the rear wall is of combustible material, there must be an air gap of 25mm between the wall and the rear of the cooker. Fit the rear distance brackets as shown in Fig. 8. Whenever possible it is recommended that the skirting board is removed for the width of the appliance to enable the rear edge of the appliance top plate to make contact with the vertical wall and avoid a rear gap. (Combustible wall excepted).
Where the cooker is to stand in a recess or against a wall which is to be tiled, IN NO CIRCUMSTANCES SHOULD THE TILES OVERLAP THE TOP PLATE.
The handrail brackets are held on the front edges of the cooker top-plate casting. Remove the travel nuts and replace with the handrail brackets ensuring the fibre protecting washers are in position. Insert the handrail with fitted endcaps into the brackets, positioning them correctly, and tighten the locating bolts (Fig. 9).

Fig. 8

Fig. 9 17
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DESN 511264 DESN 510454 A

SITE LOCATION
SEE FIG. 10 & 11
1. Check that the hearth is level, then remove the appliance from its transit wooden pallet.
2. Lift up the insulating covers and remove the hotplate using lifting hooks provided.
3. Connect and terminate flue system in accordance with the regulations in force.
Refer to Section `BALANCED FLUE INSTALLATION’ for terminal kit installation details.

Installation requirements

Fig. 10

DESN 510523

4. Remove the 4 flue cleaning access door securing bolts and remove door.
   5. Check the position of the boiler flueway baffles. 6. Replace door and refit bolts. 7. Replace the hotplate ensuring that it seals around the
   edges.

NOTE

The baffles are assembled in alternate directions to allow the gases to flow front to back through the assembly.

Each heat exchanger has two rows of baffles .

Ensure that the baffles are having the top and bottom plates of the same width and marked TOP are fitted last. One at top of each flueway.

Total number of baffles fitted:-

440 = 6

(2 x 3)

460 = 6

(2 x 3)

480 = 8

(2 x 4)

499 = 10

(2 x 5)

Fig. 11

18

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DESN 512011

Installation requirements

Fig. 12

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BURNER ACCESS
SEE FIG. 13
1. Open the burner access door. Remove door and put in a safe place.
2. Remove 4 inner panel securing screws and remove panel.
3 Remove the 3 plinth securing screws and remove plinth.

Commissioning Instructions

Fig. 13
ELECTRICAL CONNECTION
SEE FIG. 16 1. Make electrical connections to terminal strip as wiring
diagram (See Fig. 14). 2. Always route cables from the external power supply
and control systems away from hot surfaces.

DESN 511998

Fig. 14
OIL PUMP
SEE FIG 15
1. Bring the sensing phial of the fire valve through the grommet in the right hand side panel and locate in the clips provided.
2. Before connecting the flexible oil pipe to the pump inlet, open the stop valve slowly and run off some of the oil into a receptacle to establish an air free supply and clean supply to the pump. Make the connection onto the oil pump tight and leave valve open.
3. Ensure that the fire valve is routed to allow free removal of the twin burner assembly.
Fig. 15 20
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TERMINAL STRIP DESN 511577
DESN 512000

Commissioning Instructions

TERMINAL STRIP CONNECTIONS

OVEN VENT FAN N
SW/L BOILER HTG ON H/W OFF H/W ON
PN NEUTRAL PL LIVE L LIVE
N NEUTRAL E EARTH

SPARE NEUTRAL TERMINAL
SWITCH LIVE TO OPERATE BOILER FROM ROOM STAT OR CYLINDER STAT VIA ZONE VALVES IF FITTED TO ROOM STAT/ZONE VALVE(S) ETC ( IF FITTED) FROST STAT (SEE NOTE BELOW)
TO CYLINDER STAT/ZONE VALVE(S) ETC (IF FITTED). PUMP SUPPLY (THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY) PUMP SUPPLY (THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY)
3 AMP PERMANENT SUPPLY

NOTE: If no Hot Water System Controls are used a link MUST be fitted between H/W ON and SW/L BOILER. If no Central Heating System Controls are used a link MUST be fitted between HTG ON and SW/L BOILER. If a Frost Thermostat is fitted it MUST be connected to SW/L BOILER and H/W OFF

Fig. 16

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Commissioning Instructions

ELECTRICAL CHECK

Checks to ensure electrical safety should be carried out by a competent person.
FIT PRESSURE GAUGE
SEE FIG. 17
Remove the bleed screw from the manifold and fit an oil pressure gauge with R1/8 connection to check the pump output pressure.
Switch on the Electricity
Set the boiler burner clock switch to continuous and turn the boiler thermostat to maximum. The boiler burner should run on pre-purge for 7 to 15 seconds, with the ignition spark energised. The oil solenoid valve should then open allowing the burner to fire. Until all the air from the oil pump is flushed out there may be some flame instability resulting in the burner locking out. This will be shown by the burner stopping and the illumination of the signal light in the reset button of the control box (see Fig. 17). In this event, wait at least one minute, then press the re-set button to restart.
VENT OIL PUMP

RESET BUTTONS
Fig. 17

PRESSURE PORT/ BLEED SCREW
DESN 511999

SEE FIG. 17
Whilst the burner is running, vent air from the pump by slackening the pressure gauge connection sufficient to allow air to bleed out. When bubble free oil seeps out retighten.
Alternatively, a pump/gauge manifold with venting port may also be used.

ADJUST OIL PRESSURE

Fig. 18

SEE FIG. 18

Whilst the burner is running check the oil pressure on the pressure gauge.

If the pressure gauge is not indicating the correct reading then adjust the pressure by turning the pressure regulator clockwise to increase or anti- clockwise to decrease the pressure until the pressure gauge reads 10 bar (145 Ibf/In2).

Switch off the burner, remove the pressure gauge and refit the gauge port plug.

NOTE: 440KB ONLY Increase/decrease the pressure until the pressure gauge reads 8 bar (120 psi).

NOTE: 499KB ONLY During initial start up, the pressure will indicate approximately 100 psi for 30 seconds then up to 10 bar (145Ib/in). Any adjustments must be made after this sequence has been completed.

Fig. 18A

22

OIL PRESSURE ADJUSTMENT

DESN 511997

DESN 512046

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Commissioning Instructions

SET COMBUSTION AIR
SEE FIG 19 & 20
The air controls of the burners are factory pre-set, however small adjustments may be necessary to suit the site conditions (See Fig. 19).
Turn boiler burner on.
After 15 minutes remove the enamelled top cover panel (behind the L.H. insulating cover) and remove the insulation pad. Remove the plugging screw and insert the sensing probe of a portable combustion analyser to check the CO2 (Carbon Dioxide) level. Adjust the boiler burner air intake until a reading of 11-11.5% CO2 is recorded on the indicator.
Check Smoke
Remove the CO2 sampling probe using the same hole for flue sampling insert the sensing end of a Baccarach Smoke Pump and check that the smoke in the boiler flue ways is 0-1 on the scale. Replace the plugging screw, insulation pad and cover panel.
Cooker Burner
Switch off the boiler burner and repeat the procedure with cooker burner. After 15 minutes running sample the flue gases from the cooker burner. Lift up the RH insulating cover and remove the countersunk headed screw in the hotplate. The cooker burner should be set to 11-11.5% CO2 with a smoke No. 0-1. Replace the countersunk headed screw on completion ensuring that it will not interfere with any pots and pans placed on the hotplate.
When satisfied with combustion check refit burner door inner panel.
Refit outer burner door.

Fig. 19
BOILER BURNER FLUE GAS SAMPLING
HOLE

DESN 512001
COOKER BURNER FLUE GAS SAMPLING
HOLE

Fig. 20 23
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DESN 511652

SEALED SYSTEM REQUIREMENTS

SEE FIG. 21
a. The installation must comply with the requirements of BS 6798 and BS 5449. Maximum water 82ºC temperature.
b. A safety valve set to operate at 2 bar (30Ibf/in2) shall be fitted in the flow pipe close to the boiler. There must not be any valve between the safety valve and the boiler. The valve should be positioned on a discharge pipe fitted to prevent any discharge creating a hazard to occupants or cause damage to electrical components and wiring.
c. A pressure gauge covering at least the range 0 to 4 bar (0 to 60 Ibf/in2) shall be fitted in the system, in a visible position.
d. A diaphragm type expansion vessel, to BS 4814, shall be connected at a point in the return pipe close to the boiler. The vessel must be chosen to suit the volume of water in the system and the system charge must not be less than static head at the point of connection. Further details can be obtained from “British Gas Specification for Domestic Wet Central Heating Systems Part 3 Sealed Systems”.

Safety Valve Setting
Vessel charge and initial system pressure
Multiplying Factor

2.0 bar

0.5 bar

1.0 bar

0.09

0.16

Expansion vessel

L

L

volume (litres)

Vs

Vs

= System volume Vs x

x

x

factor

0.09

0.16

Vs = System Volume Litres
e. The hot water cylinder shall be either the indirect coil type or a cylinder fitted with a calorifer which is suitable for the system pressure.
f. The Make-Up System Provision shall be made for replacing lost water from the system by either of the following methods:
a) From a make-up vessel or tank, and connected through a non-return valve to the system on the return side of the hot water cylinder or return side of all heat emitters or radiators.
b) Where access to a make up vessel would be difficult, by a remote automatic pressurisation and make up unit.

Sealed System
g. Mains Connection There shall be no connection to the mains water supply or to the water storage cistern supplying domestic hot water, even though a non- return valve may be fitted, without the approval of the local water authority.
h. The Filling Point The system shall be fitted with a filling point at low level, and be in accordance with the local water authority requirement, and shall generally have a stop valve to BS. 1010.
l. Commissioning – General The system shall be filled with water by a method acceptable to the Local Water Authority.
Check the operation of the safety valve manually.
Test the operation of the high limit cut-out according to the manufacturers instructions.
After flushing and refilling the system either:-
(a) If a make-up vessel is filled release water from the safety valve until the level in the make-up bottle falls visibly, then top up the make-up bottle.
(b) If there is no make-up vessel either release or introduce water until the designed cold water pressure level is reached.
Whilst refilling the system it is essential that a corrosion inhibitor is added to the feed water.
COMMISSIONING
Follow the commissioning instructions as for open vented systems. See Section Commissioning Instructions with the following additions:
Fill the system until the pressure gauge registers 1.5 bar (22Ibf/in2). Clear any airlocks and check for water soundness.
Check the operation of the safety valve, by allowing the water pressure to rise until the valve opens. The valve should open within +0.3 bar (+ 4.35 Ibf/in2) of the pre-set pressure. If this is not possible conduct a manual check and test.
Release cold water to initial filling pressure.
Any set pointer gauge should be set to coincide with the recommended filling pressure.

24
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Sealed System

Fig. 21

25
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ANCILLARY CONTROLS CHECK

Before leaving the site, check the operation of programmer, control thermostats are working correctly and are capable of controlling the burners correctly. Check the operation of both burner control boxes.
In the event of a flame failure the control boxes should cut off the oil supply by closing the solenoid valves. The reset buttons will then be illuminated.
WAIT 1 MINUTE BEFORE RESETTING THE CONTROL BOX.
BOILER CONTROL CHECK
Check that:-
1. The boiler system is full of water and all the valves are fully open.
2. The programmer is set to continuous heating and the heating switch set to heating.
3. Ensure that the electricity supply is ON, that the pump, is running and the boiler thermostat is ON.
The boiler and pump should be run until the system is hot and an inspection made for water leaks.
The system should then be turned off and rapidly drained whilst still hot, with all manual and automatic valves in the open position. The system should again be filled and cleared of all air locks. Whilst refilling the system it is essential that a corrosion inhibitor is added to the feed water.
When all air has been removed and the system is hot the by-pass should be adjusted to ensure a quiet operation and the radiators balanced.
4. Allow the pump adjuster to maintain a boiler “flow and return” temperature differential of 10°C – 14°C.
Checks must be made by the installer to see that this differential is obtained after the boiler `Flow’ temperature is stabilised.
The system should be balanced by regulating the water flow rate through individual heat emitters to ensure a satisfactory water temperature at each emitter.
5. When the water system reaches working temperature check that the boiler thermostat operates satisfactorily.

Commissioning Instructions
INSTRUCT THE USER
1. Advise the User of the precautions necessary to prevent damage to the heating system and to the building in the event of the heating system being inoperative during frost conditions.
2. Advise the User that, for continued efficient and safe operation of the appliance, it is important that adequate servicing is carried out at regular 12 monthly intervals.
3. Hand the Operating Instructions to the User and demonstrate the correct operation of the appliance and system controls.
4. Leave the Installation and Servicing Instructions with the User.

26
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Balanced Flue Installation (Standard Kit 250mm-430mm)
PREPARATION
Mark and cut holes in wall for terminal duct and oven vent.

Fig. 22
Establish wall thickness (A). Establish distance between flue mounting plate (when the cooker will be in final location) and internal wall (B).

DESN 511265

Fig. 23 27
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DESN 511266

Balanced Flue Installation (Standard Kit 250mm-430mm)
EXHAUST DUCT
Locate and secure exhaust duct to flue mounting plate, (1) gasket, (5 ) nuts and washers,(1) screw and washer.

Fig. 24
Mark and cut exhaust duct. A (Wall thickness) + B (internal spacing) + 20mm.

DESN 511267

Position and tape exhaust duct insulation to exhaust.duct.
Cut insulation back 40mm from end of duct.

Fig. 25

DESN 511268

SECURE INSULATION WITH TAPE PROVIDED CUT BACK INSULATION FROM END OF DUCT
40mm

Fig. 26 28
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LOCATE INSULATION TO DUCT
DESN 511269

Balanced Flue Installation (Standard Kit 250mm-430mm)
WALL SLEEVE
Mark and cut wall sleeve. A (Wall thickness) + B (internal spacing) – 5mm.

Fig. 27
Locate and secure wall sleeve to flue mounting plate, (1) gasket, (8) screws.

DESN 511270

Fig. 28 29
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DESN 511271

Balanced Flue Installation (Standard Kit 250mm-430mm)
LOCATE APPLIANCE
NOTE: THE CONNECTOR MUST BE LOCATED BEFORE THE APPLIANCE IS MOVED INTO POSITION.
Locate connector to vent fan. Move appliance in intended position.

VENT PIPE
Mark and cut vent pipe to length. A (Wall thickness) + B (internal spacing) + 40mm. Locate vent pipe to appliance.

Fig. 29

DESN 511272

Fig. 30 30
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DESN 511273

Balanced Flue Installation (Standard Kit 250mm-430mm)
TERMINAL
Locate terminal to wall sleeve, mark location of securing holes. remove terminal. Drill holes and locate rawlplugs. Apply sealant to wall sleeve. Locate terminal to wall sleeve. Secure terminal to wall (4) screws.

Fig. 31
INSERT TUBES/SETTING PIECE
Apply sealant to exhaust duct. Locate and secure insert tubes/setting piece, (1) gasket, (6) screws. NOTE: Inner tubes are of different lengths to assist in assembly.

DESN 511275

Fig. 32 31
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DESN 511277

Balanced Flue Installation (Standard Kit 250mm-430mm)
TERMINAL BAFFLE
Locate and secure terminal baffle, (4) screws.

Fig. 33
TERMINAL GUARD
Locate terminal guard to wall, mark location of securing holes, remove guard. Drill holes and fit rawlplugs. Locate and secure terminal guard to wall, (4) screws.
NOTE: The guard must be fitted where the terminal base is below 2m above the ground level or where the terminal can be touched either intentionally or accidentally eg. window cleaning or painting etc.

DESN 511278

Fig. 34 32
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DESN 511279

Balanced Flue Installation (Extension Kit 430mm-880mm)
PREPARATION
Mark and cut holes in wall for terminal duct and oven vent.

Fig. 35
Establish wall thickness (A). Establish distance between flue mounting plate (when the cooker will be in final location) and internal wall (B).

DESN 511265

Fig. 36 33
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DESN 511266

Balanced Flue Installation (Extension Kit 430mm-880mm)
EXHAUST DUCT
Locate and secure exhaust duct to flue mounting plate, (1) gasket, (5 ) nuts and washers,(1) screw and washer.

Fig. 37

Mark and cut exhaust duct extensions to length. A (Wall thickness) + B (internal spacing) – 430mm.

CUT TO LENGTH

DESN 511267

A + B – 430mm
NOTE: EXCLUDE JOINTING PIECE FROM MEASUREMENT

Fig. 38 34
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DESN 511280

Balanced Flue Installation (Extension Kit 430mm-880mm)
Apply sealant to exhaust ducts. Locate exhaust duct extensions to exhaust ducts and seal joint with tape.

Position and tape exhaust duct insulation pieces to exhaust.duct/extension.
Cut insulation back 40mm from end of duct.

Fig. 39

DESN 511283

SECURE INSULATION WITH TAPE PROVIDED CUT BACK INSULATION FROM END OF DUCT
40mm

Fig. 40 35
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LOCATE INSULATION TO DUCT
DESN 511269

Balanced Flue Installation (Extension Kit 430mm-880mm)
WALL SLEEVE
Locate and secure wall sleeve to flue mounting plate, (1) gasket, (8) screws.

Fig. 41

Mark and cut wall sleeve extension to length. A (Wall thickness) + B (internal spacing) – 455mm.

CUT TO LENGTH

DESN 511271

A + B – 455mm

NOTE: EXCLUDE JOINTING PIECE FROM MEASUREMENT

Fig. 42 36
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DESN 511284

Balanced Flue Installation (Extension Kit 430mm-880mm)
Apply sealant to wall sleeve. Locate wall sleeve extension to wall sleeve and seal joint with tape.

Fig. 43

DESN 511287

37
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Balanced Flue Installation (Extension Kit 430mm-880mm)
LOCATE APPLIANCE
NOTE: THE CONNECTOR MUST BE LOCATED BEFORE THE APPLIANCE IS MOVED INTO POSITION.
Locate connector to vent fan. Move appliance in intended position.

VENT PIPE
Mark and cut vent pipe to length. A (Wall thickness) + B (internal spacing) + 40mm. Locate vent pipe to appliance.

Fig. 44

DESN 511272

Fig. 45 38
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DESN 511273

Balanced Flue Installation (Extension Kit 430mm-880mm)
TERMINAL
Locate terminal to wall sleeve, mark location of securing holes. remove terminal. Drill holes and locate rawlplugs. Apply sealant to wall sleeve. Locate terminal to wall sleeve. Secure terminal to wall (4) screws.

Fig. 46
INSERT TUBES/SETTING PIECE
Apply sealant to exhaust duct. Locate and secure insert tubes/setting piece, (1) gasket, (6) screws.
NOTE: The inner tubes are of different lengths to assist in assembly.

DESN 511275

Fig. 47 39
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DESN 511277

Balanced Flue Installation (Extension Kit 430mm-880mm)
TERMINAL BAFFLE
Locate and secure terminal baffle, (4) screws.

Fig. 48
TERMINAL GUARD
Locate terminal guard to wall, mark location of securing holes, remove guard. Drill holes and fit rawlplugs. Locate and secure terminal guard to wall, (4) screws.
NOTE: The guard must be fitted where the terminal base is below 2m above ground level, or where the terminal can be touched either intentionally or accidentally eg. window cleaning or painting etc.

DESN 511278

Fig. 49 40
w

DESN 511279

41
w

42
w

43
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For further advice or information contact your local distributor/stockist
With AGA Rangemaster’s policy of continuous product improvement, the Company reserves the
right to change specifications and make modifications to the appliance described at any
time.
Manufactured by AGA Rangemaster
Station Road Ketley Telford Shropshire TF1 5AQ
England
www.rayburn-web.co.uk
www.agacookshop.co.uk

References

• AGA Cookshop | Official Online Shop
• Rayburn Cast Iron Central Heating Range Cookers | AGA Living
• Manual-Hub.com – Free PDF manuals!

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