Rayburn 208G User manual

For use in GB and IE
01/10 EINS 511342[email protected]
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THIS APPLIANCE
Installation
Instructions
208G/L
THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS
AND THE REGULATIONS IN FORCE AND ONLY USED IN A SUITABLY VENTILATED LOCATION.
REMEMBER, when replacing a part on tbis 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.

Consumer Protection
As manufacturers and suppliers of cooking and heating products. We take every care to ensure,
as far as is reasonably practical, that these products are so designed and constructed as to meet
the general safety requirement when properly used and installed. To this end, our products are
thoroughly tested and examined before despatch.
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 mask and disposable gloves.
Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre
Maybe 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.
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 insulating lids to prevent staining the linings
2

GENERAL SPECIFICATIONS
DESN 511371
DIMENSIONS IN MM
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.
Gas Inlet Rp 1/4 (1/4” BSP Int )
Flue Outlet Dia. 100mm
Min. Operating 0.23 bar
Pressure of Boiler
Max. Operating 1.75 bar
Pressure of Boiler
Weight of Appliance 318kg
PROP. GAS (G31) Cat I3P
NAT. GAS (G20) Cat I2H 37.020.0 1.553.0 42084212
INLET PRESSURE mbar
BURNER MARKING - Injector size
PILOT MARKING
COOKER LOW
COOKER HIGH 1.88.0 0.362.2
HEAT INPUT kW
HEAT OUTPUT WATER kW
3
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.

The Rayburn 208G/L Gas Cooker is a combined cooker
and domestic hot water heater.
It is available in Open Flue form only, operating on natural
draught, the boiler being designed for use on an open
vented indirect hot water system only, operating with
gravity D.H.W. primaries.
The appliance is available with Right hand oven and Right
hand flue outlet only.
A single gas burner provides heat to both hot water and
cooker and is controlled by a manually operated 5
position gas tap.
In the interests of safety all gas appliances should be
installed by competent persons in accordance with the
regulations in force.
INTRODUCTION REGULATIONS
4

Installation Pipes
Do not use pipes of a smaller size than the appliance gas
connection.
The complete installation must be tested for soundness
and purged.
The appliance must be installed on a solid level floor or
base of incombustible material which is capable of
supporting the total weight.
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 air circulation around
the appliance.
The appliance is floor-mounted and the space in which
the minimum clearances for servicing/installation must
have the following:
Between wall and L.H. side of appliance
150mm
Between wall and R.H. side of appliance
25mm
Above the raised insulating cover handle
75mm
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 sleeve providing an air space of at
least 25mm.
Spaces around the flue pipes passing through walls or
floors should be sealed against the passage of smoke and
flame.
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.
If a shelf is to be fitted above the appliance, the depth of
the shelf must be no greater than 330mm with a minimum
clearance of 760mm between the top of the appliance and
the underside of the shelf.
5
LOCATION
GAS SUPPLY

SEE FIG. 1
The following notes are intended to give general
guidance. The cross sectional area of the flue serving the
cooker must not be less than the area of the flue outlet of
the cooker. If flue pipe is to be used it must not be less
than 100mm internal diameter.
A straight vertical section of cast iron flue pipe of a
length not less than 600mm MUST be utilised
immediately above the flue spigot before any bends
are used.
In any event the minimum flue length MUST not be
less than 3m.
Flue pipes and fitting should be constructed from one of
the following materials:-
(a)Cement
(b)Aluminium or stainless steel
(c) Cast iron or mild steel acid resistant vitreous enamel
lined.
If a chimney is to be used, it preferably should be one that
is composed of or lined with a non-porous acid resistant
material.
A flue pipe constructed in cast iron, should form the initial
connection to lined chimneys.
Where a chimney is to be used which is not composed of
or lined with a non-porous acid resistant material it should
be lined with a stainless steel flexible flue liner in
accordance with the relevant standards.
Before connecting the appliance to or inserting a liner into
a flue that has been previously used, the flue MUST be
thoroughly swept clean of any soot and loose materials. If
a baffle plate, etc. is fitted in the flue it must be removed
before connecting the appliance to, or inserting a liner into
the flue.
The flue should terminate in accordance with the
regulations in force.
The appliance can only be installed in a room which
meets the ventilation regulations in force. But, in any
event the room must have a permanent vent of minimum
free air area of 37cm2.
Effect of an Extractor Fan
If there is any type of extract fan fitted in the same room
as an appliance, there is a possibility that if adequate air
inlet from outside is not provided, spillage of the products
from the appliance flue could occur when the extract fan
is in operation.
Where such installations occur, a spillage test must be
carried out.
6
FLUE SYSTEM AIR REQUIREMENTS
FIG. 1

The following notes are of particular importance:-
Pipework should be insulated to help prevent heat loss
and possible freezing, particularly where pipes are run
through roof space and ventilated under floor spaces.
Cisterns situated in areas which may be exposed to
freezing conditions should also be insulated.
Draining taps must be located in accessible positions to
permit the draining of the whole system. Including the
appliance and hot water storage vessel.
The appliance boiler section should be connected to a
cistern water supply, subject to a maximum head of
18.0m.
The hot water storage vessel should be insulated,
preferably, with not less than 75mm thick mineral fibre, or
its equivalent.
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 upwards in the direction away from the
appliance.
Hot Water Storage Vessel
It is recommended that an indirect 140 litre hot water
storage cylinder of the double feed type should be lagged
and fixed vertically as near as possible to the appliance.
The water draw-off pipes to the taps must be dead leg
connection from the vent/expansion pipe.Adrain tap must
be fitted t the lowest point of the system.
Note: The appliance MUST not be operated if the
water system is put out of operation or has been
drained.
Water Connections
The two Rp1 (1in BSP int) flow and return connections are
located towards the rear edge of the appliance left hand
side panel, and pipe connections should be made with R1
(1in BSP ext) x 28mm dia copper compression fittings.
Gravity Domestic Hot Water
The 28mm O.D. primary flow and return pipe must rise
continuously from the boiler section to the cylinder to
ensure good gravity circulation and extended to provide
an open vent. The 28mm O.D. primary flow and return
pipes must not exceed 10m in length. Pipe runs in excess
of 5m must be lagged.
7
WATER CIRCULATION SYSTEM

The appliance is delivered in a fully assembled condition
with the exception of the following items which are
supplied separately packed and require assembly.
1. Draught Diverter Assembly - See Fig. 3.
2. Appliance Rear Distance Bracket - (For use when
appliance is installed 25mm away from a rear wall of
combustible material). See Fig. 4.
3. Handrail & Brackets. See Fig. 5.
1. Remove the appliance assembly from its transit
wooden pallet by the temporary location of a sloping
ramp board between the pallet and the floor.
With the appliance on the floor, lift the front of the
appliance (manually or crowbar) and insert a 1in BSP
x 1m long tube between the front of the appliance
base plate and the floor. Draw the tube balanced
appliance forward until the tube is at the rear of the
appliance and then insert a second similar tube at the
front of the appliance, between the base plate and
floor. The tube supported appliance can now be slowly
“rolled” across the floor and positioned with its back
against the wall, and in its intended position for flue
connection.
Using a crowbar at the rear corner of the appliance
base plate, take the weight of the appliance on the
crowbar and remove the rear roller tube, followed by
similar action on the front tube.
NOTE: IF THE REAR WALL IS OF COMBUSTIBLE
MATERIAL, THERE MUST BE AN AIR GAP OF
25mm BETWEEN THE WALL AND REAR OF
APPLIANCE. FIT REAR DISTANCE BRACKET AS
SHOWN IN FIG. 4.
Wherever possible, it is recommended that 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 air
gap (Combustible walls excepted).
2. Assemble and locate the flue draught diverter
assembly on the top plate. See Fig. 3.
3. Fit a 600mm minimum vertical height of flue pipe into
the draught diverter flue socket before any bends,
sealing joint with fire cement.
4. Connect and terminate the flue system in accordance
with standard practice. See Fig. 1.
5. The handrail brackets are held on the front ends 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. See Fig. 5.
8
PRELIMINARY INSTALLATION
SITE LOCATION
FIG. 3
FIG. 4
FIG. 5 DESN510454 ‘A’

Gas Installation
Connect the gas supply to the integral union gas service
cock on the left hand side of the appliance.
Test the whole of the gas installation, including the meter
for soundness and purge in accordance with the
regulations in force.
9

SEE FIG. 6
Water Circulating System
The boiler/cylinder system should be thoroughly flushed
out with cold water and checked for water soundness.
Refill system and check that all air locks are cleared.
Gas Circuit
The whole gas installation must be inspected and tested
for soundness and purged up to the appliance gas cock in
accordance with the regulations in force.
Lighting Main and Pilot Burner
This appliance is fitted with a combustion discharge safety
device (CDSD) which will switch off the appliance in
adverse flue conditions.
Before turning on the main burners ensure that the
manual reset button Pis depressed.
Before lighting ensure cooker control knob Ais in the z
position.
1. Open outer burner door B, lift off door Cand turn
slotted head of appliance gas service cock Duntil slot
is positioned in line with pipework. (open).
2. Push in and hold red flame failure button Nand light
the pilot Hwith a taper, continue to hold red button for
at least 15 seconds. Pilot should remain alight when
released. If it does not WAIT 3 MINUTES and repeat
sequence.
3. Remove sealing screw from gas inlet pressure test
nipple L, fit gas pressure gauge.
4. Push in and turn cooker control knob Afrom zto 4.
The main burner Kshould cross-light from pilot light.
5. Replace combustion chamber door C.
6. Turn the control knob Ato 1and allow the cooker to
warm up for 10 minutes.
7. Turn control knob Ato 4, check that the main inlet gas
pressure is as indicated on the data plate and
unaffected when other gas appliances are used.
8. Check that there is no spillage of combustion products
from the appliance down-draught diverter by carrying
out a spillage test.
Inspect flame pattern and appearance of burner at full
fire to establish that there is adequate air for
combustion.
9. Close outer burner door B.
10.If there is any type of extract fan in the same room as
an appliance, there is a possibility that if adequate air
inlet area from outside is not provided, spillage of the
products from the appliance flue could occur when the
extract fan is in operation.
Where such installations occur, a spillage test must be
carried out.
Overnight and when not required for cooking, leave
cooker control knob Ato Lposition. To increase the
temperature of the oven or hotplate, turn the cooker
control knob Ato required temperature. Reduce knob
setting gradually in order to maintain required
temperature.
Turning Off
Press and hold in cooker knob Asimultaneously turning it
clockwise zwhereupon the main cooker burner Kwill
extinguish, leaving the pilot Halight.
To extinguish the pilot, turn slot of gas service cock Duntil
the slot is positioned across the pipework.
COMMISSIONING AND TESTING
10
HOW TO OPERATE COOKER
CONTROL

11
FIG. 6

Advise the Use of the precautions necessary to prevent
damage to the heating system and to the building in the
event of the heating system remaining inoperative during
frost conditions.
Advise the User that, care should be taken not to touch
the hotplate, oven, combustion chamber, door and flue
areas unless a insulated glove is used as these areas are
hot working surfaces and will burn unprotected skin.
Advise the User that, for continued efficient and safe
operation of the appliance, it is important that adequate
servicing is carried out at regular intervals recommended
by the Local Gas Authority, or a competent service
engineer.
Hand the User Instructions to the User and demonstrate
the correct operation of the appliance and system
controls.
SEE FIG. 6
NOTE: LEAVE THESE INSTRUCTIONS WITH THE
USER OR ADJACENT TO THE GAS METER.
Annual Servicing
It is important that servicing be carried out by a
competent service engineer, and it is recommended
that a contract be made with the local Gas Authority
or a competent service engineer.
With normal use, a cooker flueway clean and burner
service should be carried out once per annum.
The householder should be advised to turn OFF the
cooker control knob the night preceding the day of
service, so that the appliance, will have cooled down by
the following morning, in readiness for servicing. Before
commencing any servicing, turn OFF the gas supply at
the appliance gas service cock (bottom LH side).
Oven Door Fit - Both doors must be checked and
adjusted if necessary to ensure the alignment with the
door catch is correct, the keep is secure and the oven is
sealed when the door is closed.
Standard Annual Service Schedule
a. Service clean of heat exchanger over flueways and
hotplate.
b. Service clean of burner main injector.
c. Service clean of pilot burner assembly with injector.
1. To Obtain Servicing Access
To obtain servicing access to main gas burner, gas
control and heat exchanger, proceed as follows:-
a. Lift out the hotplate.
b. Open the outer burner door and remove inner
combustion chamber door.
2. To Remove Main Burner
a. Ensure the appliance service cock Dis turned OFF.
b. Disconnect main burner inlet union and pilot union
connection at the front of the burner chamber.
c. Remove two screws securing burner to baseplate, lift
up the front of the burner and draw forward carefully
to disengage support foot from baseplate location.
Withdraw the burner unit until Pilot assembly is
accessible, unscrew thermocouple and remove
burner.
d. Gently brush the top face of the burner and examine
the flame ports. Remove any lint/fluff from injector,
burner venturi and tip downwards to remove debris.
e. Remove main injector and check it is free of deposits.
12
INSTRUCT USER SERVICING INSTRUCTIONS

3. To Service Pilot Burner
a. Remove main burner assembly as previously
described.
b. Unscrew thermocouple fixing nut.
c. Disconnect hexagon nut securing pilot feed pipe to
pilot burner.
d. Remove pilot injector and check to see if it is free of
deposits.
e. Examine probe end of thermocouple Jand replace if
probe end is badly pitted, corroded or malfunctioning.
4. To Clean the Heat Exchanger and Flueways
a. Remove the main and pilot burner assembly as
previously described.
b. Place a layer of paper on combustion chamber
baseplate.
c. Thoroughly brush vertical rear boiler flueway, cooker
flueway in an upward and downward direction. Brush
underside of baffle plate above the main burner and
also across the oven top.
d. Remove layer of paper with fallen debris.
e. Brush and clean in between hotplate ribs on
underside.
f. Examine soft rope seal locate on underside of hotplate
baffle plate. Replace if worn or frayed.
g. Examine soft rope seal located around hotplate
aperture in top plate. Replace if frayed or damaged.
h. Re-fit the main and pilot burner assembly in reverse
order of assembly.
Test all disconnected joints for gas soundness.
i. Replace hotplate ensuring that the underside ribs lie
over the combustion chamber.
j. Turn ON appliance service cock D, light pilot and turn
oven control knob to confirm the burner lights
satisfactorily.
5. To Replace Cooker Control Tap
a. Turn OFF gas supply at the gas service cock D.
b. Remove control knob and detach cover panel (4
screws).
c. Disconnect unions of control tap and tap fixing
bracket.
d. Fit new control tap and connect inlet and outlet gas
pipes.
e. Turn ON gas supply at the service cock Dand light
cooker pilot.
f. Check for gas soundness at control tap inlet unions.
g. Turn control tap Ato position 4 and check for gas
soundness at control tap outlet unions.
h. Fit cover plate.
i. Refit knob.
6. To Remove Oven Temperature Indicator
a. Open main oven door fully and remove four screws
securing inner lining panel to outer door.
b. Remove inner lining panel sealing washer and
slagwool insulation.
c. Unscrew two hexagon nuts securing indicator to outer
door and remove indicator.
d. Fit replacement indicator in reverse order of
dismantling.
7. To Remove FSD
a. Remove gas inlet cover plate.
b. Disconnect gas inlet union at gas cock.
c. Disconnect outlet and pilot feed pipe from FSD.
d. Unscrew FSD fixing bracket and withdraw FSD from
bracket until thermocouple and interrupter wires are
accessible, remove wires and unscrew thermocouple.
e. Remove elbows and bracket from FSD.
f. Re-assemble in reverse order.
g. Check joints for gas soundness.
h. Replace cover.
8. To Remove Combustion Discharge Safety Device
a. Remove control knob.
b. Remove screws securing control panel and remove
panel.
c. Remove screws securing gas inlet cover and remove
cover.
d. Remove spindle locknut and wire leads from C.D.S.D.
e. Remove C.D.S.D. phial from spring clip in down
draught diverter hood Fig. 3.
f. Withdraw C.D.S.D. and fit replacement in reverse
order.
IMPORTANT: INCORRECT FITTING OF COMBUSTION
DISCHARGE DEVICE COULD LEAD TO COMBUSTION
PRODUCTS LEAKING INTO THE ROOM.
NOTE: ONLY APPROVED RAYBURN COMBUSTION
SAFETY DEVICES MUST BE FITTED TO THIS
APPLIANCE.
13

14

15

With AGA's policy of continuous product
improvement, the Company reserves the right to
change specifications and make modifications to
the appliance described and illustrated at any time.
Manufactured By
AGA
Station Road
Ketley Telford
Shropshire TF1 5AQ
England
For further advice or information contact
your local distributor/stockist
16
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