Rayburn Heatranger 480GB, Installation Instructions Manual

Page 1: ...WARNING This information is a copy of an original archive therefore Aga cannot be held responsible for its continued accuracy ...

Page 2: ... 0 7 4 7 A N D O T H E R G B I E P A T E N T S P E N D I N G For use in GB and IE Installation Instructions Heatranger 480GB At the Heart of your Home PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THIS APPLIANCE 10 99 EINS511381 ...

Page 3: ...rious to health and safety see below for information Fire bricks 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 mask and disposable gloves Glass Yarn Mineral Wool Insulation Pads Ceramic Fibre May be harmful if inhaled May be irritating to skin eyes nose an...

Page 4: ...er Temp 82 C Water Capacity of 25 5 litres Boiler Max Operating 2 bar Pressure of Boiler Weight of Appliance 420kg Fuel NATURAL GAS G20 Cat I2H Terminal Requirements Wall Thickness 228mm 430mm Standard Kit Wall Thickness 430mm 660mm Standard Kit Extension Kit 3 GENERAL SPECIFICATIONS DESN 511263 DIMENSIONS IN MM NOTE IT IS ADVISABLE TO CHECK THE ACTUAL SIZE WIDTH OF YOUR APPLIANCE BEFORE FINALLY F...

Page 5: ...4 ...

Page 6: ...Technical Data 5 BOILER BURNER COOKER BURNER 20 16 x1 6mm 15 8 0 8 MAX 20 16 x 1 6mm 29 3 23 5 INLET PRESSURE mbar 12 12 BURNER PRESSURE mbar nominal INJECTOR HEAT INPUT kW BOILER OUTPUT kW 480GB ...

Page 7: ... 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 Appliance The space in which the appliance is to be fitted must have the following minimum dimensions Between wall and LH side of appliance 3mm Between wall and RH side of appliance 10mm Above the raised in...

Page 8: ...Site requirements 7 AIR REQUIREMENTS The appliance can only be installed in a room which meets ventilation regulations in force ...

Page 9: ...g or eaves Minimum siting dimensions for Balanced Flue terminals Position Minimum Spacing mm A Directly below an openable window air vent or an other ventilation opening 300 B Below gutter drain soil pipe 300 C Below eaves 300 D Below a balcony or car port roof 600 E From vertical drain and soil pipes 75 F From internal or external corners 600 G Above adjacent ground or balcony level 300 H From su...

Page 10: ...ater supply subject to a maximum heat of 2 bar 20m minimum of 0 1 bar 1m The heating system must be designed and adjusted if necessary to give a temperature differential across the boiler at full output of 10 C 14 C The use of horizontal pipe runs should be avoided wherever possible in order to prevent the collection of air in the system If horizontal runs are unavoidable the pipes should rise upw...

Page 11: ...is supplied for 230 Volt 50 Hz and 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...

Page 12: ...11 Site requirements FIG 4 ...

Page 13: ...ible 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 Whenever possible it 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...

Page 14: ...5 Remove the insulation pad B 6 Remove the 4 flue cleaning access door securing bolts and remove door 7 Check the position of the boiler flueway baffles 8 Replace door and refit bolts 9 Replace insulation pad B and the hotplate ensuring that it seals around the edges NOTE FOR THIS APPLIANCE USE ONLY 6 FLUEWAY BAFFLES Installation Instructions 13 SITE LOCATION FIG 7 FIG 8 DESN 510523 DESN 510524 ...

Page 15: ...PARATION SEE FIG 9 Mark and cut holes in wall for terminal duct and oven vent SEE FIG 10 Establish wall thickness A Establish distance between flue mounting plate when the cooker will be in final location and internal wall B FIG 9 DESN 511265 FIG 10 DESN511266 ...

Page 16: ...crew and washer Mark and cut exhaust duct A Wall thickness B internal spacing 20mm Position and tape exhaust duct insulation to exhaust duct Cut insulation back 40mm from end of duct 15 FIG 11 DESN 511267 FIG 12 DESN 511268 FIG 13 DESN511269 SECURE TAPE INSULATION WITH TAPE PROVIDED CUT BACK INSULATION FROM END OF DUCT LOCATE INSULATION TO DUCT 40mm ...

Page 17: ...andard Kit 228m 430mm WALL SLEEVE EE FIG 14 Mark and cut wall sleeve A Wall thickness B internal spacing 5mm SEE FIG 15 Locate and secure wall sleeve to flue mounting plate 1 gasket 8 screws 16 FIG 14 DESN 511270 FIG 15 DESN 511271 ...

Page 18: ...CTOR MUST BE LOCATED BEFORE THE APPLIANCE IS MOVED INTO POSITION Locate connector to vent fan Move appliance in intended position SEE FIG 17 Mark and cut vent pipe to length A wall thickness B internal spacing 40mm Locate vent pipe to appliance VENT PIPE 17 FIG 16 DESN 511272 FIG 17 DESN 511273 ...

Page 19: ...emove terminal Drill holes and locate rawlplugs Apply sealant to wall sleeve Locate terminal to wall sleeve Secure terminal to wall 4 screws SEE FIG 18 Apply sealant to exhaust duct Locate and secure insert tubes setting piece 1 gasket 6 screws 18 INSERT TUBES SETTING PIECE FIG 17 DESN 511275 FIG 18 DESN 511277 DESN 511274 DESN 511276 ...

Page 20: ... FIG 19 Locate and secure terminal baffle 4 screws SEE FIG 20 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 TERMINAL GUARD 19 FIG 19 DESN 511278 FIG 20 DESN 511279 ...

Page 21: ...ION SEE FIG 21 Mark and cut holes in wall for terminal duct and oven vent SEE FIG 22 Establish wall thickness A Establish distance between flue mounting plate when the cooker will be in final location and internal wall B 20 FIG 21 DESN 511265 FIG 22 DESN 511266 ...

Page 22: ...xhaust duct to the flue mounting plate 1 gasket 5 nuts and washers 1 screw and washer SEE FIG 24 Mark and cut exhaust duct extensions to length A wall thickness B internal spacing 430mm 21 FIG 23 DESN 511267 FIG 24 DESN 511280 CUT TO LENGTH A B 430mm NOTE EXCLUDE JOINTING PIECE FROM MEASUREMENT ...

Page 23: ...ust ducts and seal joint with tape SEE FIG 26 Position and tape exhaust duct insulation pieces to exhaust duct extension Cut insulation back 40mm from end of duct 22 FIG 25 DESN 511283 FIG 26 DESN 511269 DESN 511281 DESN511282 SECURE INSULATION WITH TAPE PROVIDED CUT BACK INSULATION FROM END OF DUCT LOCATE INSULATION TO DUCT 40mm ...

Page 24: ...ate and secure wall sleeve to the flue mounting plate 1 gasket 8 screws SEE FIG 28 Mark and cut wall sleeve extension to length A Wall thickness B internal spacing 455mm FIG 27 DESN 511271 FIG 28 DESN 511284 23 CUT TO LENGTH NOTE EXCLUDE JOINTING PIECE FROM MEASUREMENT A B 455mm ...

Page 25: ...lanced Flue Installation Extension Kit 430 660mm SEE FIG 29 Apply sealant to wall sleeve Locate wall sleeve extension to wall sleeve and seal joint with tape DESN 511285 DESN 511286 DESN 511287 FIG 29 24 ...

Page 26: ...LIANCE IS MOVED INTO POSITION Locate connector to vent fan Move appliance in intended position SEE FIG 31 Mark and cut vent pipe to length A wall thickness B internal spacing 40mm Locate vent pipe to appliance VENT PIPE 25 FIG 30 DESN 511271 FIG 31 DESN 511284 CUT TO LENGTH NOTE EXCLUDE JOINTING PIECE FROM MEASUREMENT A B 455mm ...

Page 27: ...remove terminal Drill holes and locate rawlplugs Apply sealant to wall sleeve Locate terminal to wall sleeve Secure terminal to wall 4 screws SEE FIG 33 Apply sealant to exhaust duct Locate and secure insert tube setting piece 1 gasket 6 screws INSERT TUBES SETTING PIECE 26 FIG 32 DESN 511275 FIG 33 DESN 511277 DESN 511274 DESN 511276 ...

Page 28: ... FIG 34 Locate and secure terminal baffle 4 screws SEE FIG 35 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 TERMINAL GUARD 27 FIG 34 DESN 511278 FIG 35 DESN 511279 ...

Page 29: ...in a safe place 2 Remove 4 inner panel securing screws and remove panel SEE FIG 37 1 Make electrical connections to terminal strip as wiring diagram see Fig 9 28 Commissioning Instructions BURNER ACCESS ELECTRICAL CONNECTION FIG 36 FIG 37 DESN 511119 DESN 511120 ...

Page 30: ...INDER 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...

Page 31: ...2 the burner will run The gas valves are a two stage design and although both solenoids open at the same time a low start facility initially operates and the gas will run at full rate after approximately 8 seconds SEE FIG 39 Checks to ensure electrical safety should be carried out by a competent person Check gas cock is in the on position Switch on the Electricity Set the boiler burner time clock ...

Page 32: ...ker Burner Switch off the boiler burner and repeat the above procedure with cooker burner To sample the flue gases from the cooker burner lift up the R H insulating cover and remove the countersunk headed screw in the hotplate The cooker burner should be set as specified as above Replace the countersunk headed screw on completion ensuring that it will not interfere with any pots and pans placed on...

Page 33: ...factory water temperature at each emitter 5 When the water system reaches working temperature check that the boiler thermostat operates satisfactorily 6 Examine the system for water soundness The system should then be turned off and rapidly drained whilst still hot The system should again be filled and cleared of all air locks Whilst refilling the system it is recommended that a suitable corrosion...

Page 34: ...33 ...

Page 35: ...34 ...

Page 36: ...35 ...

Page 37: ...36 ...