Rayburn Heatranger 440 Installation Instructions Manual Download

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12/13 EINS 511641-E

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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 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.

Summary of Contents for Heatranger 440

Page 1: ...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 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 ...

Page 2: ...CTION 20 OIL PUMP 20 TERMINAL STRIP CONNECTIONS 21 ELECTRICAL CHECK 22 FIT PRESSURE GAUGE 22 VENT OIL PUMP 22 ADJUST OIL PRESSURE 22 SET COMBUSTION AIR 23 SEALED SYSTEM REQUIREMENTS 24 COMMISSIONING 24 TYPICAL SEALED SYSTEM 25 TYPICAL OPEN VENTED SYSTEM 25 ANCILLARY CONTROLS CHECK 26 BOILER CONTROL CHECK 26 INSTRUCT THE USER 26 BALANCED FLUE INSTALLATION PREPARATION 27 STANDARD KIT 250mm 430mm EXH...

Page 3: ... 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...

Page 4: ...ty of 11 5 litres Boiler Weight of Appliance 395kg Max Operating 2 bar 20m Pressure of Boiler Fuel Kerosene C2 Terminal Requirements Wall Thickness 250mm 430mm Standard Kit Wall Thickness 430mm 880mm Standard Extension Kit GENERAL SPECIFICATIONS DESN 511654 PLEASE NOTE IT IS ADVISABLE TO CHECK THE ACTUAL SIZE WIDTH OF YOUR APPLIANCE BEFORE FINALLY FIXING ANY KITCHEN UNITS SINCE ENAMELLED CAST IRON...

Page 5: ...PUT kW BOILER OUTPUT kW 0 65 80 EH 10 145 47 5 29 3 TOTAL OUTPUT kW 23 5 24 7 0 40 80 EH 10 145 28 5 17 6 3 1 499KB BOILER BURNER BURNER NOZZLE US g h OIL PRESSURE Bar psi OIL BURNING RATE cc m HEAT INPUT kW BOILER OUTPUT kW TOTAL OUTPUT kW 0 85 80 EH 10 145 58 35 2 29 3 29 5 COOKER BURNER 0 40 80 EH 28 5 17 6 10 145 3 1 BOILER BURNER BURNER NOZZLE US g h 0 35 60 H 0 35 80 S 8 5 120 23 0 14 2 8 5 ...

Page 6: ...ITHER 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...

Page 7: ...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...

Page 8: ...e 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 ...

Page 9: ... 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 NOTE SUCTION LIFT MAY ALSO BE ACHIEVED BY USE OF A SINGLE PIPE LIFT WITH A DEAERATION DEVICE ...

Page 10: ... 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 wi...

Page 11: ...L J BELOW AN OPENING AIR BRICK 600mm WINDOW ETC K FROM VERTICAL SANITARY PIPEWORK 300mm 11 Site requirements 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 an...

Page 12: ...eating 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 different...

Page 13: ...s 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 The latest publication of Part L of the Building Regulati...

Page 14: ...Site requirements 440 460 480 499KB EXTERNAL CONTROLS 14 ...

Page 15: ...equirement 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 ins...

Page 16: ...16 Site requirements Fig 7 WIRING DIAGRAM 440 460 480 499 KB ...

Page 17: ...inal 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...

Page 18: ...emove 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 ...

Page 19: ...Installation requirements Fig 12 19 ...

Page 20: ...nsing 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 ...

Page 21: ...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 22: ...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 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 clo...

Page 23: ...ke 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 sh...

Page 24: ...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...

Page 25: ...Sealed System 25 Fig 21 ...

Page 26: ...en 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 reg...

Page 27: ...d 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 DESN 511265 DESN 511266 ...

Page 28: ... internal spacing 20mm l Position and tape exhaust duct insulation to exhaust duct l Cut insulation back 40mm from end of duct Balanced Flue Installation Standard Kit 250mm 430mm Fig 24 DESN 511267 DESN 511268 DESN 511269 Fig 25 Fig 26 EXHAUST DUCT SECURE INSULATION WITH TAPE PROVIDED LOCATE INSULATION TO DUCT CUT BACK INSULATION FROM END OF DUCT 40mm ...

Page 29: ...leeve 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: ... 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 Fig 29 Fig 30 DESN 511272 DESN 511273 Balanced Flue Installation Standard Kit 250mm 430mm ...

Page 31: ...cate terminal to wall sleeve l Secure terminal to wall 4 screws l Apply sealant to exhaust duct l Locate and secure insert tubes setting piece 1 gasket 6 screws NOTE Inner tubes are of different lengths to assist in assembly TERMINAL Fig 31 Fig 32 DESN 511275 DESN 511277 INSERT TUBES SETTING PIECE Balanced Flue Installation Standard Kit 250mm 430mm 31 ...

Page 32: ...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 32 Fig 33 Fig 34 DESN 511278 DESN 511279 TERMINAL BAFFLE TERMINAL GUARD Balanced Flue Installation Standard Kit 250mm 430mm ...

Page 33: ...ven 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 Extension Kit 430mm 880mm ...

Page 34: ...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 Extension Kit 430mm 880mm CUT TO LENGTH NOTE EXCLUDE JOINTING PIECE FROM MEASUREMENT A B 430mm ...

Page 35: ...ition 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 Installation Extension Kit 430mm 880mm SECURE INSULATION WITH TAPE PROVIDED CUT BACK INSULATION FROM END OF DUCT LOCATE INSULATION TO DUCT 40mm ...

Page 36: ...crews 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 LENGTH A B 455mm NOTE EXCLUDE JOINTING PIECE FROM MEASUREMENT ...

Page 37: ...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: ... 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 Fig 44 Fig 45 DESN 511272 DESN 511273 Balanced Flue Installation Extension Kit 430mm 880mm ...

Page 39: ...e terminal to wall sleeve l Secure terminal to wall 4 screws l Apply sealant to exhaust duct l Locate and secure insert tubes setting piece 1 gasket 6 screws NOTE The inner tubes are of different lengths to assist in assembly 39 TERMINAL Fig 46 Fig 47 DESN 511275 DESN 511277 INSERT TUBES SETTING PIECE Balanced Flue Installation Extension Kit 430mm 880mm ...

Page 40: ...e 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 Fig 48 Fig 49 DESN 511278 DESN 511279 TERMINAL BAFFLE TERMINAL GUARD 40 Balanced Flue Installation Extension Kit 430mm 880mm ...

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Page 44: ...ter 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 ...

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