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  5. Installation Instructions Manual

Rayburn Heatranger 440 Installation Instructions Manual

Manual is about: Burning Range Cooker

Summary of Heatranger 440

  • Page 1

    12/13 eins 511641-e raywarranty@aga-web.Co.Uk for use in gb and ie installation instructions heatranger 440/460/480/499kb desn 511653 b please read these instructions before installing this appliance remember, when replacing a part on this appliance, use only spare parts that you can be assured conf...

  • Page 2: Contents

    Contents section contents page consumer protection 3 health & safety 3 general specifications 4 technical data 5 site requirements introduction 6 regulations 6 location 7 oil pipe line 8 oil storage 8 gravity single feed pipe system 9 suction lift two-pipe system 9 flue system 10-11 water circulatio...

  • Page 3

    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 i...

  • Page 4

    4 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 co 2 % - boiler 11....

  • Page 5: Technical Data

    Technical data 5 boiler burner burner nozzle (us g/h) 0.55 @ 80°eh 0.40 @ 80° eh 10 (145) 28.5 17.6 10 (145) 38 21.7 17.5 oil pressure bar (psi) oil burning rate cc/m heat input kw boiler output kw 460kb 480kb cooker burner total output kw 18.2 3.1 boiler burner cooker burner burner nozzle (us g/h) ...

  • Page 6: Site Requirements

    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 re...

  • Page 7: Site Requirements

    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. The ...

  • Page 8: Site Requirements

    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 sh...

  • Page 9: Site Requirements

    Site requirements 9 fig. 5 maximum length (metres) h metres 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 refer to instruction sheet for details on fitting two-pipe system. Gravity single feed pipe system suction lift two-pipe system desn 511671 b desn 511672 a...

  • Page 10: Site Requirements

    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...

  • Page 11: Site Requirements

    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 ve...

  • Page 12: Site Requirements

    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 th...

  • Page 13: Site Requirements

    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 e...

  • Page 14: Site Requirements

    Site requirements 440/460/480/499kb - external controls 14.

  • Page 15: Site Requirements

    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...

  • Page 16: Site Requirements

    16 site requirements fig. 7 wiring diagram 440/460/480/499 kb.

  • Page 17: Installation Requirements

    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 th...

  • Page 18: Installation Requirements

    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 ‘bal...

  • Page 19: Installation Requirements

    Installation requirements fig. 12 19.

  • Page 20: Commissioning Instructions

    20 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. See fig. 16 1. Make electrical connections to terminal strip as wiring diagram (see fig. 14). 2. Alwa...

  • Page 21: Commissioning Instructions

    21 commissioning instructions fig. 16 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 (s...

  • Page 22: Commissioning Instructions

    22 checks to ensure electrical safety should be carried out by a competent person. 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...

  • Page 23: Commissioning Instructions

    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. Re...

  • Page 24: Sealed System

    Sealed system 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/in 2 ) shall be fitted in the flow pipe close to the boiler. There must not be any valve between the safety valve a...

  • Page 25: Sealed System

    Sealed system 25 fig. 21.

  • Page 26: Commissioning Instructions

    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...

  • Page 27: Balanced Flue Installation

    27 l mark and cut holes in wall for terminal duct and oven vent. L establish wall thickness ( a ). L establish distance between flue mounting plate (when the cooker will be in final location) and internal wall ( b ). Balanced flue installation (standard kit 250mm-430mm) preparation fig. 22 fig. 23 d...

  • Page 28: Balanced Flue Installation

    28 l locate and secure exhaust duct to flue mounting plate, (1) gasket, (5 ) nuts and washers,(1) screw and washer. L mark and cut exhaust duct. A (wall thickness) + b (internal spacing) + 20mm. L position and tape exhaust duct insulation to exhaust.Duct. L cut insulation back 40mm from end of duct....

  • Page 29: Balanced Flue Installation

    L mark and cut wall sleeve. A (wall thickness) + b (internal spacing) - 5mm. L locate and secure wall sleeve to flue mounting plate, (1) gasket, (8) screws. 29 wall sleeve fig. 27 fig. 28 desn 511270 desn 511271 balanced flue installation (standard kit 250mm-430mm).

  • Page 30: Balanced Flue Installation

    Note: the connector must be located before the appliance is moved into position. L locate connector to vent fan. L move appliance in intended position. L mark and cut vent pipe to length. A (wall thickness) + b (internal spacing) + 40mm. L locate vent pipe to appliance. 30 vent pipe locate appliance...

  • Page 31: Balanced Flue Installation

    L locate terminal to wall sleeve, mark location of securing holes. Remove terminal. L drill holes and locate rawlplugs. L apply sealant to wall sleeve. L locate terminal to wall sleeve. L secure terminal to wall (4) screws. L apply sealant to exhaust duct. L locate and secure insert tubes/setting pi...

  • Page 32: Balanced Flue Installation

    L locate and secure terminal baffle, (4) screws. L locate terminal guard to wall, mark location of securing holes, remove guard. L drill holes and fit rawlplugs. L locate and secure terminal guard to wall, (4) screws. Note: the guard must be fitted where the terminal base is below 2m above the groun...

  • Page 33: Balanced Flue Installation

    L mark and cut holes in wall for terminal duct and oven vent. L establish wall thickness ( a ). L establish distance between flue mounting plate (when the cooker will be in final location) and internal wall ( b ). 33 preparation fig. 35 fig. 36 desn 511265 desn 511266 balanced flue installation (ext...

  • Page 34: Balanced Flue Installation

    L locate and secure exhaust duct to flue mounting plate, (1) gasket, (5 ) nuts and washers,(1) screw and washer. L mark and cut exhaust duct extensions to length. A (wall thickness) + b (internal spacing) - 430mm. 34 exhaust duct fig. 37 fig. 38 desn 511267 desn 511280 balanced flue installation (ex...

  • Page 35: Balanced Flue Installation

    L apply sealant to exhaust ducts. L locate exhaust duct extensions to exhaust ducts and seal joint with tape. L position and tape exhaust duct insulation pieces to exhaust.Duct/extension. L cut insulation back 40mm from end of duct. 35 fig. 39 fig. 40 desn 511283 desn 511269 balanced flue installati...

  • Page 36: Balanced Flue Installation

    L locate and secure wall sleeve to flue mounting plate, (1) gasket, (8) screws. L mark and cut wall sleeve extension to length. A (wall thickness) + b (internal spacing) - 455mm. 36 wall sleeve fig. 41 fig. 42 desn 511271 desn 511284 balanced flue installation (extension kit 430mm-880mm) cut to leng...

  • Page 37: Balanced Flue Installation

    L apply sealant to wall sleeve. L locate wall sleeve extension to wall sleeve and seal joint with tape. 37 fig. 43 desn 511287 balanced flue installation (extension kit 430mm-880mm).

  • Page 38: Balanced Flue Installation

    Note: the connector must be located before the appliance is moved into position. L locate connector to vent fan. L move appliance in intended position. L mark and cut vent pipe to length. A (wall thickness) + b (internal spacing) + 40mm. L locate vent pipe to appliance. 38 vent pipe locate appliance...

  • Page 39: Balanced Flue Installation

    L locate terminal to wall sleeve, mark location of securing holes. Remove terminal. L drill holes and locate rawlplugs. L apply sealant to wall sleeve. L locate terminal to wall sleeve. L secure terminal to wall (4) screws. L apply sealant to exhaust duct. L locate and secure insert tubes/setting pi...

  • Page 40: Balanced Flue Installation

    L locate and secure terminal baffle, (4) screws. L locate terminal guard to wall, mark location of securing holes, remove guard. L drill holes and fit rawlplugs. L locate and secure terminal guard to wall, (4) screws. Note: the guard must be fitted where the terminal base is below 2m above ground le...

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  • Page 44

    44 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...