Rayburn 680KCD C User manual

12/15 E NS 516257
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THIS APPLIANCE
Installation
Instructions
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.
680 CD C/F
780 CD C/F
DESN 516260 DESN 516828

Contents
SECTION CONTENTS PAGE
CONSUMER PROTECT ON 3
HEALTH & SAFETY 3
APPL ANCE SPEC F CAT ON - 680KCD C/F 4
APPL ANCE SPEC F CAT ON - 780KCD C/F 5
TECHN CAL DATA 6
SITE REQUIREMENTS NTRODUCT ON 7
REGULAT ONS 7
LOCAT ON 8
O L P PE L NE 9
O L STORAGE 9
FLUE SYSTEM 10
TYP CAL CH MNEY NSTALLAT ON 11
TYP CAL EXTERNAL FLUE SYSTEM 12
A R SUPPLY 13
WATER C RCULAT ON SYSTEM 14
HEAT NG CONTROLS 14
ELECTR CAL SUPPLY 15
W R NG D AGRAM - NDEPENDENT SATRON C 16
BOXES
INSTALLATION CLEARANCES 17
REQUIREMENTS PREL M NARY NSTALLAT ON 17
S TE LOCAT ON 18
BAFFLES 19
O L CONNECT ON 20
COMMISSIONING BURNER ACCESS 21
INSTRUCTIONS ELECTR CAL CONNECT ON 21
O L PUMP 21
TERM NAL STR P CONNECT ONS 22
ELECTR CAL CHECK 22
F T PRESSURE GAUGE 23
VENT O L PUMP 23
ADJUST O L PRESSURE 23
SET COMBUST ON A R - BO LER 24
SET COMBUST ON A R - COOKER 25
ANC LLARY CONTROLS CHECK 26
BO LER CONTROL CHECK 26
NSTRUCT THE USER 26
SEALED SYSTEMS SEALED SYSTEM REQU REMENTS 27
COMM SS ON NG 27
TYP CAL OPEN VENTED SYSTEM 28
INSTALLATION CONDENSATE D SPOSAL 29
INSTRUCTIONS CONDENSATE TRAP 29
CONDENSATE SOAKAWAY 30
RECOMMENDED SCHIEDEL RITE-VENT SUPPLIERS 31
2

Consumer Protection
As responsible manufacturers we take care to make sure that our products are designed and
constructed to meet the required standards when properly installed and used.
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. t is the Users/ nstallers
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.
erosene 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 caused by cuts and abrasions.
3. ‘Oil acne’ is recognised by the presence of skin rashes. The arms are most often affected,
but may occur where there is contact with oil or oily clothing.
- Seek medical attention for any rash.
- Avoid skin contact with mineral oil or clothing contaminated with mineral oil.
4. nhalation of mineral oil vapours must be avoided. Never fire the burner in the open as
unburnt oil vapours are likely to occur.
5. Use a suitable barrier cream which will give protection against mineral oil, lanolin based hand
creams are usually very effective.
6. Never syphon mineral oil by use of the mouth. f accidentally swallowed, call a doctor, do not
induce vomiting.
NOTE: SMO E/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 lids to prevent staining the linings.
3

4
Boiler Water Connections
Flow (one) Rp 1 (1in. BSP nt)
Return (one) Rp 1 (1in. BSP nt)
Both connections are located towards the rear edge
of the appliance L.H. side panel.
Oil Inlet 10mm copper
To connect to the LH side
panel
Electrical Supply 230V~50Hz 270W
3 Amp Fused
Flue Outlet 125mm
CO2% - BO LER 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
ELECTR C
CONNECT ONS
FLUE
P PE
PLEASE NOTE: IT IS ADVISABLE TO CHEC THE ACTUAL
SIZE/WIDTH OF YOUR APPLIANCE BEFORE FINALLY
FIXING ANY ITCHEN 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
42
38
470
161
104
910 - TO TOP OF HOB
RETURN
P PE
FLOW
P PE
O L
CONNECT ON
FRONT VIEW LH SIDE
VIEW
RH SIDE
VIEW
PLAN VIEW
CONDENSE
OUTLET
RAYBURN 680 CD C/F ONLY

Boiler Water Connections
Flow (one) Rp 1 (1in. BSP nt)
Return (one) Rp 1 (1in. BSP nt)
Both connections are located towards the rear edge
of the appliance L.H. side panel.
Oil Inlet 10mm copper
To connect to the LH side
panel
Electrical Supply 230V~50Hz 270W
3 Amp Fused
Flue Outlet 125mm
CO2% - BO LER 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
ELECTR C
CONNECT ONS
PLEASE NOTE: IT IS ADVISABLE TO CHEC THE ACTUAL
SIZE/WIDTH OF YOUR APPLIANCE BEFORE FINALLY
FIXING ANY ITCHEN UNITS SINCE ENAMELLED CAST
IRON CAN VARY IN SIZE. DESN 516829
68
105
Fig. 1B
RH SIDE
VIEW
RAYBURN 780 CD C/F ONLY
5

Technical Data
6
BO LER 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
O L PRESSURE Bar (psi)
O L BURN NG RATE cc/m
HEAT NPUT kW
BO LER OUTPUT kW
680/780 CD C/F COOKER BURNER

The Rayburn is a floor standing combined cooker and
central heating boiler. t gives independent operation of
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 the programmer control if required.
The boiler is designed for use on a fully pumped low
pressure hot water circulation system with a pumped over
run facility or alternatively on a sealed system limited to 2
bar.
IMPORTANT
 This appliance must only be used with erosene
C2 to BS 2869.
 An Indirect Cylinder to BS 1566; Part 1 must be
fitted.
 If the heating circuits are controlled in such a way
that both heating and cylinder circuits can be
closed off at the same time then a BYPASS LOOP
should be fitted. (See Fig. 20).
 An OFTEC approved Fire Valve MUST be fitted in
the oil supply line.
 The supplied in line filter MUST be fitted.
 Permanent ventilation must be provided.
THIS APPLIANCE IS 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 WOR S.
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 in force and the bylaws of the local Water
Undertaking, it should also be in accordance with the
relevant current British Standard Codes of Practice.
BS5410 - nstallation of oil fired appliances for space
heating and hot water supply purpose. Part 1 Boiler of
rated output not exceeding 45kW.
BS5449 - Central Heating for domestic purposes, Part 1.
Forced circulation hot water system.
Building Regulations England and Wales. Part J. Heat
producing appliances.
Building Standards Scotland - Technical Standard Part
F. Heat producing appliances and storage of liquid and
gaseous fuel.
Building Regulations - Technical Booklet to Part L. Heat
producing appliances.
The Control of Oil Pollution (Oil) Regulations.
Site requirements
7
REGULATIONSINTRODUCTION

Fig. 2
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. However, this appliance must be installed on a
solid floor 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 for air circulation around
the appliance. See “ nstallation of Appliance”.
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 - 4mm
top plate
Between wall or unit and RH side of appliance - 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
n 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 such as ceiling or roof,
must be enclosed in a non-combustible sleeve providing
an air space of at least 25mm.
Space around the flue pipes passing through walls or
floors should be sealed against the passage of smoke
and flame. A fire stop valve and plate must be provided
where the flue passes through a ceiling.
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.
Site requirements
LOCATION
8

The oil supply connection between the storage tank and
the oil pipe should be run in copper pipe with a minimum
diameter of 10mm. Galvanised pipes and fittings should
not be used. Annealed copper pipe is preferred with a
flare type manipulative fittings. Capillary fittings with soft
solder should not be used. Steel pipes should be joined
using taper threads.
All pipework and fittings must be completely air tight. Only
oil resistant compounds and PTFE tape should be used
when making joints. Pipework must be protected against
damage whether fitted above or below ground.
The size and arrangement of pipework will depend upon
the distance and height of the oil storage tank in relation
to the oil pump inlet.
The oil line from the storage tank to the appliance
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 accessible position.
A flexible pipe connection, approximately 1000mm long,
is supplied to fit between the oil supply pipe and the oil
pump for ease of burner removal. This must be contained
within the appliance.
The minimum recommended oil tank size is 1400 litres
and the code of practice governing its installation are
covered by BS: 5420: Part 1. Mild Steel Tanks should be
to BS 799: Part 5 and plastic tanks to OFTEC Standard
OFS T100.
Site requirements
9
OIL PIPE LINE OIL STORAGE
GRAV TY S NGLE FEED
P PE SYSTEM
Fig. 3 - Rayburn 680KCD C/F shown DESN 516267 A

The flue system must be installed with the regulations in
force.
Maximum flue gas temperature 250°C
(Both burners on)
Minimum flue gas temperature 125°C
(Boiler burner on only)
Chimney Termination
All chimneys should terminate at least 600mm above the
roof level in accordance with current Building Regulations
and statutory requirements as outlined in BS 5410: Part 1,
BS 6461: Part 1 and BS 7566 Parts 1 to 4.
Chimney Cleaning
Ensure there are accessible airtight flue cleaning doors in
order to obtain cleaning access to the complete chimney.
Providing the appliance is operating correctly, an annual
chimney flue cleaning will suffice, but if in doubt arrange
for a half yearly clean, preferably at the beginning/end of
the heating season.
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
RO4M996246 R6089 ø125mm STRA GHT SECT ON BLACK LENGTH 950mm
RO4M996247 R6090 ø125mm STRA GHT SECT ON BLACK LENGTH 450mm
RO4M996248 R6091 ø125mm STRA GHT SECT ON BLACK LENGTH 200mm
*RO4M996249 R6092 * ø125mm x 500mm ADJUSTABLE NNER SECT ON -
BLACK
RO4M996252 R6093 LOCK NG BAND BLACK (ONE-OFF PER JO NT)
RO4M996253 R6094 V TON SEAL
BLAC PRIMA PLUS FLUE SYSTEM FROM AGA-RANGEMASTER
FOR TYPICAL FLUE INSTALLATIONS PLEASE SEE FIGS. 4 AND 5.
* PLEASE NOTE: The adjustable inner section requires a straight section (950, 450, 200 mm)
to provide adjustability.

11
Site requirements
TYPICAL CHIMNEY INSTALLATION
125 T/FLEX SCREW TYPE TERM NAL
PART NO. 4048125
BR CK CH MNEY
125 D A TECNOFLEX STA NLESS STEEL
FLEX P PE PART NO. TPBXX125
125 PR MA PLUS 125 T/FLEX
SCREW TYPE ADAPTOR
PART NO. S0E3125125
TECNO FLEX SYSTEM
ALL PARTS AVA LABLE
THROUGH RECOMMENDED
SCH EDEL R TE-VENT
STOCK STS
(SEE L ST OF APPROVED
STOCK STS N REAR OF
NSTRUCT ONS)
AVA LABLE D RECT FROM
AGA-RANGEMASTER. ALL
PARTS POWDER COATED
BLACK
OPT ONAL EXTENS ONS
950, 450,200mm LONG
(SUPPL ED W TH
V TON SEAL NG
GASKET)
45°
ELBOW
LOCK NG BAND
450mm LENGTH
W TH NSPECT ON
DOOR SUPPL ED
W TH COOKER
80- 400mm ADJ.
LENGTH
100.0 M N.
NSERT ON
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 NNER
SECT ON SUPPL ED W TH
V TON SEAL
*NOTE: TO PROV DE
ADJUSTAB L TY TH S PART
REQU RES E THER OF THE
FOLLOW NG STRA GHT
SECT ONS 900, 450, 200
(W TH L M TED ADJUSTMENT)
950, 450, 200MM STRA GHT
SECT ON

TYPICAL EXTERNAL FLUE SYSTEM
45° BEND
STRUCTURAL WALL
BAND W TH EXTENS ON
WALL BAND
TR M COLLAR
S NGLE TO TW N
WALL ADAPTER
FOR ‘ECO C D’
FLUE SYSTEM
STANDARD P PE
LENGTHS
WALL SLEEVE
450mm LENGTH
W TH NSPECT ON DOOR
SUPPL ED W TH
COOKER
COOKER N POS T ON
AGA NST WALL
ECO C D STA NLESS/STEEL
TW N WALL NSULATED
CH MNEY SYSTEM. ALL PARTS
AVA LABLE THROUGH
SCH EDEL R TE-VENT
STOCK STS (SEE
RECOMMENDED STOCK ST
L ST N BACK OF NSTRUCT ON
MANUAL)
12
Fig. 5 DESN 516269
Site requirements
NOTE: FOR PART NO’s FOR ECO ICID FLUE
SYSTEM GO TO www.schiedel.co.uk

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, see below:
IMPORTANT: THE LOUVERED AIR INTA E AT THE
BOTTOM FRONT OF THIS APPLIANCE MUST BE
EPT CLEAR OF ANY OBSTRUCTIONS.
Detailed recommendations for air supply are given in the
Building Regulations and in BS 5410: Part 1. The
following notes are intended to give general guidance.
1. Combustion and ventilation air supply to oil fired
appliance has to comply with the Building Regulations
and with BS 5410: Part 1. The air supply requirement
for oil fired appliance in 550mm2per kW of maximum
rated output above 5 kW. These requirements are
illustrated in OFTEC Technical Book No. 3.
2. The combustion air supply to open flued appliances
should normally be provided at high level into a room
where it will not cause discomfort by creating a cold
draught across the floor.
3. f combustion air is supplied through an under floor
duct the grilles at each end should be positioned in the
vertical plane to reduce the risk of blockage. Ducts
should be sized so as to reduce the resistance to air
flow.
4. The ventilation 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 change per
hour or by having ventilation openings of not less than
4000m2.
5. Extract fan should be positioned as far away from the
open flue as possible and should have a sufficient
dedicated air supply. To undertake a test the oil fired
appliance should be set in operation and the doors and
windows of the room containing it should be closed.
The extract fan should then be run at its maximum
setting. The oil fired heating appliance should be
observed to operate satisfactorily both before and after
the fan is switched on.
6. t is preferable for the air supply for an extract fan to be
located where it can serve the fan without the air
stream passing close to the oil fired appliance.
7. Oil fired appliances must not draw the combustion air
from a garage.
Carbon Monoxide Detector/Alarm
t is recommended that a Carbon Monoxide
Detector/Alarm should be fitted in the same area as the
cooker.
13
Site requirements
AIR SUPPLY
680KCD O/F
780KCD O/F 180cm2
MODEL M N. A R REQU REMENT

Flow and return pipework between cooker and zone
valves must be 28mm diameter minimum.
Space and water heating should be in accordance with
the relevant recommendations of BS 5410: Part 1.
n a combined central heating and domestic hot water
system, the hot water storage vessel must be of the
indirect cylinder type to BS 1566: Part 1. The hot water
storage vessel should be insulated with not less than
75mm thick mineral fibre or its equivalent.
Cisterns and pipework should not be situated in areas
which maybe exposed by freezing conditions.
Draining taps must be located in accessible positions
which permit the draining of the whole system, including
the heat storage vessel. Draining taps should be at least
1/2in BSP nominal size and be in accordance with BS
2879.
The appliance boiler section should be connected to a
cistern water supply, subject to a maximum head of
18.25m.
Alternatively a ‘sealed’ system may be used with an
appropriately sized expansion vessel and the pressure
relief valve is limited to 2 bar, See Page 27.
The heating 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
t 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
solating valves (preferably of the keyless type) must be
fitted to the inlet and outlet of the circulating pump to
facilitate service and replacement of pump without
draining the system.
Inhibitor
A corrosion inhibitor MUST be added to the heating
system to protect the heat exchanger and pipework.
nhibitor must also be replaced if the system is drained
after installation. As a precaution the heating system
MUST also be flushed out prior to the addition of the
inhibitor to ensure any flux, debris is removed.
ndependent temperature controls with time switch control
are recommended for providing temperature comfort from
radiators.
Typical controls can be motorised valves operated by
room thermostat and cylinder thermostat.
Thermostatic radiator valves may be fitted when required.
The boiler should be controlled so that it operates on
demand only.
Operation of the system under control of the boiler
thermostat only, does not produce the best efficiency.
Refer to the control equipment manufacturers literature
for information e.g. wiring.
Site requirements
14
WATER CIRCULATION SYSTEM HEATING CONTROLS

Wiring external to the appliance must be installed in
accordance with current National Wiring Regulations and
any local regulations which apply. The appliance is
supplied for 230 Volt ~ 50 Hz 270W a fuse rating of 3
amps. The method of connection to the mains supply
should facilitate complete isolation of the appliance, by
the use of a fused double pole switch having 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 be protected by a 30 mA Residual Current Circuit
Breaker (RCCB).
The minimum requirement 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.
n 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 diagrams.
The circulating pump must be connected to PL and PN on
the terminal block (See Fig. 6) and the cables clamped
and passed through the grommet in the right hand side
panel.
NOTE: The 3 amp fuse rating takes into account any
AUX L ARY components used. n most central heating
systems i.e. circulation pump, zone valves. AGA
recommend that only CE marked equipment is used in
conjunction with this appliance.
15
Site requirements
ELECTRICAL SUPPLY

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

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 - 4mm
top plate
Between wall or unit and RH side of appliance - 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
n addition adequate clearance must be available at the
front of the appliance to enable it to be operated and
serviced.
The appliance is delivered in a fully assembled condition
with the exception of the following items which are
supplied separately packed and require assembly:-
The appliance rear distance bracket
The cooker handrail
The oil filter
Appliance rear distance bracket: f 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 excepted).
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 TOP PLATE.
The handrail brackets are held on the front edges of the
cooker top-plate casting. Fit the handrail brackets
ensuring the fibre protecting washers are in position.
nsert the handrail into the brackets, positioning them
correctly, and tighten the grub screws and locating bolts.
Installation requirements
17
CLEARANCES
PRELIMINARY INSTALLATION
Fig. 7
Fig. 8
DESN 515909
DESN 515617
BRAC ETS SCREWED TO BAC
EDGE OF BOTH SIDE PLATES WHEN
COMBUSTIBLE WALL IS UNINSULATED
COMBUSTIBLE
WALL LINE
25mm

1. Check that the hearth is level, then remove the
appliance from its transit wooden pallet, and position it
with its back against the wall and in its intended
position for flue connection.
2. Locate and fit supplied flue pipe into socket of flue pipe
adaptor, as follows:-
a. Take flue collar silicone rubber trim and bend into
a circle.
b. Push trim into gap between flue pipe and flue
collar to create a neat seal.
c. Flue collar trim can be found in oven pack.
3. Fit trim seal, see Fig. 9.
4. Connect and terminate the flue system in accordance
with the regulations in force.
SEE F G. 10
1. Remove top LH door (Rayburn 680 CD 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 F G. 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 as shown in Fig. 12.
3. Check aluminium twisted baffles are in position and
there are 28 baffles, one in each recuperator tube.
NOTE: LH set of x 4 aluminium baffles are half length.
4. When replacing access door, tighten the 4 fixing
screws to a torque setting of 7.5 NM.
Installation requirements
18
SITE LOCATION
Fig. 10
Fig. 11
DESN 515949
DESN 515950
STEP 1
STEP 2
Fig. 9 DESN 515949

Installation requirements
19
Fig. 12
ALL BAFFLES MUST BE STAC ED IN
PLACE AS DIAGRAM ABOVE
DESN 515919

Installation requirements
IMPORTANT: DURING BURNER REMOVAL CARE
MUST BE TA EN NOT TO DAMAGE THE CERAMIC
FIBRE INSULATION.
SEE F GS. 13 & 14
COO ER BURNER - SEE FIG. 13
1. Unscrew jubilee clip and remove flexi air intake.
2. Using a 13mm spanner, unscrew top securing bolt
and remove burner by rotating clockwise and drawing
it away from the cooker.
BOILER BURNER - SEE FIG. 14
1. Place a sheet on the floor in front of the cooker to act
as a working area.
2. Remove lower LH door (Rayburn 680 CD 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 F G. 15
10mm copper pipe entering through LH side panel should
be routed through as Fig. 14 and fixed using clips
provided.
20
OIL CONNECTION
Fig. 13
Fig. 14
DESN 515961
DESN 515960
Fig. 15 DESN 516007 A