Rayburn 660 Installation Instructions Manual Download

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Contents

SECTION

CONTENTS

PAGE

CONSUMER PROTECTION

HEALTH & SAFETY

APPLIANCE SPECIFICATION - 680KCD C/F

APPLIANCE SPECIFICATION - 780KCD C/F

TECHNICAL DATA

SITE REQUIREMENTS

INTRODUCTION

REGULATIONS

LOCATION

OIL PIPE LINE

OIL STORAGE

FLUE SYSTEM

TYPICAL CHIMNEY INSTALLATION

TYPICAL EXTERNAL FLUE SYSTEM

AIR SUPPLY

WATER CIRCULATION SYSTEM

HEATING CONTROLS

ELECTRICAL SUPPLY

WIRING DIAGRAM - INDEPENDENT SATRONIC

BOXES

INSTALLATION

CLEARANCES

REQUIREMENTS

PRELIMINARY INSTALLATION

SITE LOCATION

BAFFLES

OIL CONNECTION

COMMISSIONING

BURNER ACCESS

INSTRUCTIONS

ELECTRICAL CONNECTION

OIL PUMP

TERMINAL STRIP CONNECTIONS

ELECTRICAL CHECK

FIT PRESSURE GAUGE

VENT OIL PUMP

ADJUST OIL PRESSURE

SET COMBUSTION AIR - BOILER

SET COMBUSTION AIR - COOKER

ANCILLARY CONTROLS CHECK

BOILER CONTROL CHECK

INSTRUCT THE USER

SEALED SYSTEMS

SEALED SYSTEM REQUIREMENTS

COMMISSIONING

TYPICAL OPEN VENTED SYSTEM

INSTALLATION

CONDENSATE DISPOSAL

INSTRUCTIONS

CONDENSATE TRAP

CONDENSATE SOAKAWAY

RECOMMENDED SCHIEDEL RITE-VENT SUPPLIERS

Summary of Contents for 660

Page 1: ... For use in GB IE 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 680KCD C F 780KCD C F DESN 516260 DESN 516828 ...

Page 2: ...LLATION CLEARANCES 17 REQUIREMENTS PRELIMINARY INSTALLATION 17 SITE LOCATION 18 BAFFLES 19 OIL CONNECTION 20 COMMISSIONING BURNER ACCESS 21 INSTRUCTIONS ELECTRICAL CONNECTION 21 OIL PUMP 21 TERMINAL STRIP CONNECTIONS 22 ELECTRICAL CHECK 22 FIT PRESSURE GAUGE 23 VENT OIL PUMP 23 ADJUST OIL PRESSURE 23 SET COMBUSTION AIR BOILER 24 SET COMBUSTION AIR COOKER 25 ANCILLARY CONTROLS CHECK 26 BOILER CONTR...

Page 3: ...s and other exposed parts When disposing of the product reduce dust with water spray ensure that parts are securely wrapped Kerosene and Gas Oil Mineral Oils 1 The effect of mineral oils on the skin vary according to the duration of the exposure 2 The lighter fractions also remove the protective grease normally present on the surface of the skin This renders the skin dry and more prone to damage c...

Page 4: ...11 5 litres Boiler Weight of Appliance 395kg Max Operating Pressure 2 bar 20m of Boiler Fuel Kerosene C2 GENERAL SPECIFICATIONS ELECTRIC CONNECTIONS FLUE PIPE 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 DESN 516266 995 68 105 Fig 1A 126 125 940 TO HOB SPLASHBACK 644 985 1395 162 529 ...

Page 5: ...ue Outlet 125mm CO2 BOILER 11 0 11 5 COOKER 11 0 11 5 Max Water Temp 82 C Water Capacity of 11 5 litres Boiler Weight of Appliance 395kg Max Operating Pressure 2 bar 20m of Boiler Fuel Kerosene C2 GENERAL SPECIFICATIONS ELECTRIC CONNECTIONS 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...

Page 6: ...nical Data 6 BOILER BURNER BURNER NOZZLE US g h 0 65 80 EH 0 35 80 S 10 145 24 15 0 8 5 125 42 5 25 24 OIL PRESSURE Bar psi OIL BURNING RATE cc m HEAT INPUT kW BOILER OUTPUT kW 680 780KCD C F COOKER BURNER ...

Page 7: ... A CONTROLLED SERVICE BY DEFINITION AND REQUIRES EITHER FITMENT UNDER THE REMIT OF BUILDING CONTROL OR INSTALLATION OF 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 Bu...

Page 8: ...ance 4mm top plate SHOULD THE WALL PROJECT BEYOND THE FRONT OF THE APPLIANCE IT MUST BE INCREASED TO 50mm SEE FIG 2 To allow oven door to open enough to change oven and shelf positions 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 Flue pipes and fittings must not be closer than 2...

Page 9: ...ance must be fitted with a remote acting OFTEC approved fire valve operating at 150 F 65 C 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 5 10 micron oil filter supplied with the appliance must be fitted in the oil pipe and stop valve must be fitted as close to the cooker as possible in an acc...

Page 10: ...The appliance must only be connected to approved flue systems Off the appliance using Schiedel Ritevent Prima Plus available in black from AGA Rangemaster and then either ECO ICID or Tecno Turbo Flex System For further information on Schiedel Ritevent Flue Systems go to www schiedel co uk Site requirements 10 FLUE SYSTEM PART No SHORT CODE DESCRIPTION RO4M996245 R6088 45 ø125mm ELBOW BLACK RO4M996...

Page 11: ...LABLE DIRECT FROM AGA RANGEMASTER ALL PARTS POWDER COATED BLACK OPTIONAL EXTENSIONS 950 450 200mm LONG SUPPLIED WITH VITON SEALING GASKET 45 ELBOW LOCKING BAND 450mm LENGTH WITH INSPECTION DOOR SUPPLIED WITH COOKER 80 400mm ADJ LENGTH 100 0 MIN INSERTION Fig 4 DESN 516268 Site requirements 125 T FLEX LW TOP PLATE PART NO 4002125 125 T FLEX LW TOP CLAMP PART NO 4003125 500mm ADJUSTABLE INNER SECTIO...

Page 12: ...LEEVE 450mm LENGTH WITH INSPECTION DOOR SUPPLIED WITH COOKER COOKER IN POSITION AGAINST WALL ECO ICID STAINLESS STEEL TWIN WALL INSULATED CHIMNEY SYSTEM ALL PARTS AVAILABLE THROUGH SCHIEDEL RITE VENT STOCKISTS SEE RECOMMENDED STOCKIST LIST IN BACK OF INSTRUCTION MANUAL 12 Fig 5 DESN 516269 Site requirements NOTE FOR PART NO s FOR ECO ICID FLUE SYSTEM GO TO www schiedel co uk ...

Page 13: ...on requirement for kitchen in Part F of the Building Regulations England Wales is for mechanical extract at the rate of 60 litres per second or 30 litres if the fan is incorporated in a cooker hood The amount can be reduced if the spillage of flue gases might be caused by the outflow of air from the room Background ventilation is also required either by producing a constant extract rate of one air...

Page 14: ...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 ...

Page 15: ...r 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 polarity and resistance to earth For wiring instructions see wiring diagra...

Page 16: ...16 Site requirements Fig 6 680KCD C F 780KCD C F Rayburn 600 700 Wiring 111MB for independent Satronic boxes ...

Page 17: ...acket 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 bracket as shown in Fig 7 Wherever possible it is recommended that the skirting board is removed for the width of the appliance to enable the rear edge of the appliance to make contact with the vertical wall and avoid a rear gap Combustible wall excep...

Page 18: ... Remove top LH door Rayburn 680KCD C F only and facia glass Remove 2 fixing screws from control panel chassis and hinge open 2 Remove lower bolt from control panel fixing bracket and pivot bracket upwards away from boiler access door SEE FIG 11 1 Remove four securing nuts and withdraw access door from below through burner aperture 2 Remove stack of 5 sheet metal baffles check assembly and replace ...

Page 19: ...Installation requirements 19 Fig 12 ALL BAFFLES MUST BE STACKED IN PLACE AS DIAGRAM ABOVE DESN 515919 ...

Page 20: ... on the floor in front of the cooker to act as a working area 2 Remove lower LH door Rayburn 680KCD C F only and burner aperture cover and store in a safe place 3 Unscrew jubilee clip and remove flexi air intake pipe from burner 4 Using a 13mm spanner remove top securing bolt and remove burner by rotating it approximately 90 counter clockwise drawing it away from the burner SEE FIG 15 10mm copper ...

Page 21: ...ake electrical connections to terminal strip as wiring diagram See Fig 6 1 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 and clean supply to the pump Make the connection onto the oil pump tight and leave valve open Commissioning Instructions Fig 16 Rayburn 680KCD C F shown DESN 516261 DESN...

Page 22: ...r or room stat The system pump and mains should be connected as shown in Fig 18 Checks to ensure electrical safety should be carried out by a competent person 22 Commissioning Instructions TERMINAL STRIP CONNECTIONS Fig 18 DESN 514865 ELECTRICAL CHECK ...

Page 23: ... least one minute then press the re set button to restart 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 re tighten SEE FIG 20 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 pressu...

Page 24: ...w and insert the sensing end of a portable indicator 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 CO2 sampling tube for flue sampling insert the sensing end of a Baccarach Smoke Pump and check that the smoke in the boiler flueways do not exceed No 2 on the scale Replace the plugging screw an...

Page 25: ...top plate plug 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 screws right hand side in the hotplate The cooker burner should be set to 11 0 11 5 CO2 with a maximum smoke No 2 Replace the countersunk headed screw on completi...

Page 26: ... all air locks have 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 flow and return differential temperature of 10 14 C Checks must be made by the installer to see that the differential is obtained after the boiler Flow temperature is stabilised The system should be balanced by regulati...

Page 27: ...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 a low level and be used in accordance with the local water authority requirement and shall generally have a stop valve to BS 1010 i Commissioning General The system shall be filled by water by a method acc...

Page 28: ...D MUST HAVE AT LEAST 2 5 METRES OF 28mm PIPE EACH SIDE BETWEEN IT AND THE COOKER THE BY PASS LOOP MUST NOT BE INSULATED SHOULD THE PUMP BE FITTED TO THE RETURN SIDE THEN THE PRESSURE GAUGE AND EXPANSION VESSEL ARE FITTED ADJACENT TO THE SUCTION SIDE OF THE PUMP THE SAFETY VALVE REMAINS AS SHOWN ON THE FLOW PIPE ...

Page 29: ...to a minimum to reduce the risk of trapping condensate Condensate disposal pipes MUST be fitted with a trap whether they are connected internally or externally Rayburn boilers are supplied with a condensate trap to provide the required 75mm water seal in the condensate discharge pipe from the boiler This trap incorporates a float which will create a seal when the trap is empty and an overflow warn...

Page 30: ...is clear and able to operate SEE FIG 27 To keep external pipework to a minimum locate the soakaway as close as possible to the boiler whilst ensuring it is located clear of building foundations and other services e g gas electricity etc The soakway should be located at least 500mm from any adjacent building Ensure that the drainage holes in the soakaway tube face away from the building Only use a ...

Page 31: ... 1SW TEL 0140443267 BES LTD UNIT 3 JUNCTION 6 INDUSTRIAL PARK ELECTRIC AVENUE BIRMINGHAM WEST MIDLANDS B6 7JA TEL 0121 322 6432 WHITESIDE CHIMNEYS 75 77 AQUEDUCT STREET PRESTON LANCASHIRE PR1 7RE TEL 01772 202508 GEORGE CHRISITIE SONS 17 SALAMANDER YARDS EDINBURGH SCOTLAND EH6 7HB TEL 0131 554 6116 NEW VENT SOLUTIONS UNIT B6 DENMARK STREET POSSILPARK GLASGOW LANARKSHIRE G22 6DB TEL 0141 336 7742 C...

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Page 36: ... 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 Tel 0845 815 2020 www rayburn web co uk www agacookshop co uk 36 ...

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Rayburn 660, Installation Instructions Manual

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