Rayburn Cookmaster 300K Release note

10/05 EINS 511985
Better than you ever imagined
Installation & Servicing Instructions
for Rayburn Cook aster 300K and
Rayburn Cook aster Plus 308K
Oil-Fired Cooker
Consumer Protection Act 1987
As responsible anufacturers we take care to ake sure that our products are designed and constructed to eet
the required safety standards when properly installed and used.
IMPORTANT NOTIC : Any alteration that is not approved by Aga-Rayburn, could invalidate the approval of the
appliance, operation of the warranty and could also affect your statutory rights.
Control of Substances - Health and Safety Important
This appliance ay contain so e of the aterials that are indicated. It is the Users/Installers responsibility to
ensure that the necessary personal protective clothing is worn whenhandling, where applicable, the pertinent
parts that contain any of the listed aterials that could be interpreted as being injurious to health and safety, see
below for infor ation.
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 for use face ask and disposable gloves.
Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre, Kerosene/Gas Oil - ay be har ful if inhaled
,
ay be irritating to skin, eyes, nose and throat. When handling avoid inhaling and contact with skin or eyes. Use
disposable gloves, face- asks 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.
INTRODUCTION
The Rayburn Cook aster Plus 308K is a cooker providing do estic hot water and cooking facilities. It is available
with
a vertical flue and outlet only, with the oil burner operating on natural draught.
The boiler is designed for use in an open vented water syste only, with gravity D.H.W. pri aries.
Page
1
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

The heat exchanger is anufactured fro a high quality stainless steel and where per itted by local water
authorities ay be used on direct hot water syste s, although it is preferable to use the indirect syste .
Alternatively, the Rayburn Cook aster 300K is a non-boiler odel. However with this odel the IDLING
T MP RATUR MAY B HIGH R.
These appliances ust only be used with Co ercial Kerosene current issue to BS 2869: Class C2 suitable
for
vapourising burners.
IMPORTANT: IN ORD R TO ACHI V TH OPTIMUM P RFORMANC FROM THIS APPLIANC , IT IS
SS NTIAL THAT TH INITIAL COMMISSIONING OF TH APPLIANC IS UND RTAK N BY S L CT D
,
TRAIN D INSTALLING S RVIC NGIN RS (SUCH AS OFT C APPROV D).
YOUR RAYBURN STOCKIST WILL PROVID ADVIC ON TH LOCATION OF TH N AR ST INSTALLING
NGIN R. W ALSO R COMM ND YOU CONTRACT OUT TH P RIODIC S RVICING OF TH
APPLIANC TO THIS INSTALLING S RVICING NGIN R.
THIS APPLIANC IS A CONTROLL D S RVIC BY D FINITION AND R QUIR S ITH R FITM NT UND R
TH R MIT OF BUILDING CONTROL OR INSTALLATION BY AN OFT C R GIST R D 105 T CHNICIAN
(CLASS D AS A COMP T NT P RSON) WHO CAN S LF C RTIFY HIS OWN WORKS.
R M MB R, 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.
[e-mail]
Boiler Model - 308K Non-Boiler Model 300K
Cooker Cooker Cooker Cooker
LOW HIGH LOW HIGH
Heat Input
kW
Btu/h
2.78
9,497
7.42
25,321
2.16
7,386
5.48
18,700
Heat Output Water
kW
Btu/h
0.59
2,000
2.34
8,000
Oil Input cc/ inute 4.5 12.0 3.5 8.5 - 9.0
Boiler Water Connections Weight of Appliance 300Kg
Flow (one) Rp 1 (1in BSP Int)
Overall Di ensions
Height: 995
Width: 940
Depth: 655
Return (one) Rp1 (1in BSP Int)
Both connections are located towards the rear
edge of the appliance L.H. side panel. FUEL - COMMERCIALKEROSENE current issue to
BS.2869: Class C2 suitable for vapourising burners
Oil Valve Inlet Rp¼(¼in BSP Int)
Flue Outlet Dia. 102
Page
2
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

DESN 511031
PLEASE NOTE: IT IS ADVISABLE TO CHECK THE WIDTH OF YOUR APPLIANCE BEFORE FINALLY FIXING
ANY KITCHEN UNITS SINCE ENAMELLED CAST IRON CAN VARY IN SIZE
Fig.1 Oil Storage tank and pipeline details DESN 510210
INSTALLATION INSTRUCTIONS
The installation of the appliance ust be in accordance with the relevant require ents of the current Building
Regulations, current I.E.E. Wiring Regulations and the byelaws of the local Water Authority.
Page
3
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

It should be in accordance also with any relevant require ents of the Local Authority and the relevant
reco endations of the following current British Codes of Practice:
BS.5410 Installation of oil fired space heating and hot water supply purposes. Boilers of rated output
not exceeding 44kW.
Building Regulations
J/1/2/3 Provision for introduction of air supply and discharge of products of co bustion for
appliances.
BS.4543 Specification for chi ney for oil fired appliances. Part 3.
Building Regulations
J/1/2/3 Provision for protection against fire and heat.
LOCATION
Appliance Hearth
This appliance ust be installed on a solid level floor or base of inco bustible aterial which is a capable
of
supporting the total weight.
The location chosen for the appliance ust per it installation and the provision of a satisfactory flue and an
adequate air supply. The location ust also provide adequate space for servicing and air circulation around the
appliance. See "Installation of Appliance".
Where the cooker is to stand in a recess or against a wall, in no circumstances should the tiles overlap
the cooker top plate.
OIL STORAG - See fig.1
The ini u reco ended oil tank size is 1400 litres (300 gallons) and the Codes of Practice governing its
installation are covered by BS.5410.
The require ents for ild steel tanks should be to BS.799 Part 5. Plastic Oil Tanks to OFTEC Standard OFS
T100. The oil storage tank ust be positioned with the botto of the tank not less than 630 , and the top not
ore than 3.2 above the base of the cooker.
Oil Pipe Line
The oil line fro the storage tank to the appliance ust be fitted with a re ote acting fire valve (such as a
Teddington KBB-66°C) located outside the building, or where the supply enters the wall on the inside of the
building and with the heat sensing phial of the fire valve, located as near as practicable on the L.H. side of the
cooker.
A 5-10 icron oil filter should also be fitted in the oil line, and the ini u size of the copper oil pipe line should
not be less than 10 dia eter.
A stop valve ust be fitted near the appliance, in an accessible position.
We also reco end an additional re ote acting fire valve be fitted close to the oil control valve, with its heat
sensing phial located in the burner housing, but not touching, the inner burner door.
Page
4
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

FLU SYST M - See Fig.2
Detailed reco endations for fluing are given in the current Building Regulations J/1/2/3.
The following notes are intended to give a general guidance:-The cross sectional area of the flue serving the
appliance ust not be less than the area of the flue outlet of the appliance and be at least 4.5 high.
The flue pipe to be used ust not be less than 102 internal dia eter. Flue pipes and fittings should be
constructed fro one of the following aterials:-
a) Mild Steel with a wall thickness of 3 ini u .
b) Stainless Steel to BS.1449. Part 2.
c) Cast Iron to BS.41.
d) Mild Steel, acid resistant vitreous ena el lined to BS.1344. Part 2
Chimneys
Chi neys should be built of asonry or be asse bled fro factory- ade insulated co ponents.
Masonry chi neys ay be built of any asonry aterial, with a lining, of if flue blocks., without a lining.
The chi ney lining should be 125 ini u dia eter and be for ed of oisture and acid resistant liners to
BS.1181 with rebated or socketed joints upper ost. Alternatively, linings ay be i perforate clay flue pipes as
described in BS.65 or flue blocks to BS.1289 and installed to BS.6461.
A 125 ini u dia eter factory- ade, insulated chi ney, co plying to BS. 4543 ay be fitted and installed
to BS.7566.
Use of older existing chimneys
Older chi neys ust be swept thoroughly, and a suitable flexi liner fitted.
Chimney Terminations
All chi neys should ter inate above the highest roof ridge level in accordance with current Building Regulations
and statutory require ents as outlined in BS.6461 Part 1 and BS.7566 Parts 1 to 4.
However well-designed, constructed and positioned, the satisfactory perfor ance of a flue can be adversely
affected by the down-draught caused by adjacent tall buildings and trees or even nearby hills. These deflect the
wind
creating a zone of high pressure over the ter inal causing it to blow directly down the chi ney flue.
A suitable anti-downdraught ter inal such as the Marcone will usually effectively co bat low pressure down-blow
but no known cowl is likely to prevent down-draught due to a high pressure zone.
Chimney Cleaning
Ensure there are accessible airtight flue cleaning doors in order to obtain cleaning access to the co plete
chi ney. Providing the appliance is operating correctly, an annual chi ney flue clean will suffice, but if in doubt,
arrange for a half yearly clean, preferably at the beginning/end of the central heating season.
Flue Draught
For correct perfor ance of the appliance, it is reco ended that the flue pull be a ini u of 1 H
2
O
.
Page
5
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

High Chimney Draughts
A well sealed, tall exposed chi ney on a hill, is an instance where generated draughts could be excessive and
ust be controlled.
Page
6
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

Fig.2 Flue Layouts
Should this occur, a flue stabilizer ust be fitted either in the flue pipe or chi ney, but in the sa e roo as the
appliance.
Flue
Gas
Temperature
Page
7
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

Typical flue gas te perature under nor al operating conditions are 200 - 250°C.
Maxi u flue gas te perature typically 330°C (308K at axi u setting).
UND R NO CIRCUMSTANC S SHOULD 90° B NDS B US D IN TH FLU SYST M
AIR SUPPLY
Detailed reco endations for air supply are given in the current Building Regulations J/1/2/3.
The following notes are intended to give general guidance:-
Kitchen or Internal Space Air Supply
Wherever a flued appliance is to be installed, it ust have a per anent air vent. This vent ust be either direct to
outside air or to an adjacent roo or internal space which ust itself have a per anent air vent of at least the
sa e size direct to outside air. The ini u effective area of the per anent air vent in the outside wall ust be
30.5c
2
(4.75in
2
).
ffect of xtractor Fan
Avoid if possible the installation of an extractor fan in the sa e roo as the appliance or the roo where the
per anent vent is located. Additional air inlets ust be fitted to introduce co pensating air, equivalent to the
capacity of the fan when fitted.
HOT WAT R SYST M
Hot water syste s should be in accordance with the relevant reco endations given in BS.6700.
The following notes are of particular i portance:-
1. In do estic hot water syste s the hot water storage vessel should preferably be of the indirect cylinder of
calorific type.
2. The hot water storage vessel should be insulated, preferably, with not less than 75 thick ineral fibre
,
or its equivalent.
3. Pipework should be insulated to help prevent heat loss and possible freezing, particularly where pipes are
run through roof spaces. Cisterns situated in area which ay be exposed to freezing conditions should
also be insulated.
4. Draining taps ust be located in accessible positions which per it the draining of the appliance and hot
water storage vessel. Draining taps should be at least
1/2
in BSP no inal size and be in accordance with
BS.2879.
5. The appliance boiler section should be connected to a cistern water supply, subject to a axi u head
of
18.25 (1.8 Bar).
6. Water carrying copper tubes should be to BS.2871, Part 1.
7. Hot water syste s should be in accordance with the relevant reco endations given in BS.6700.
8. The use of horizontal pipe runs should be avoided wherever possible in order to prevent the collection of
air in the syste . If horizontal runs are unavoidable the pipes should rise upwards in the direction away
fro the appliance.
Hot Water Storage Vessel
It is reco ended that an indirect 140 litre (30 gallon) hot water storage cylinder of the double feed type e.g.
Page
8
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

(Manufactured by Albion Cylinders) co plying with the BS.1566, should be insulated, preferably with not less
than 75 thick ineral fibre or its equivalent, and fixed vertically as near as possible to the appliance. The
water
draw-off pipes to the taps ust be dead leg connection fro the vent expansion pipe. A drain tap ust be
fitted at the lowest point of the syste .
A towel rail of not ore than 0.55
2
heating surface ay be heated providing the flow and return pipes are not
ore than 5 each in length, and provided the cylinder and pipes to the cylinder are insulated.
NOT : The appliance MUST NOT be operated if the water syste is out of operation or has been drained.
Fig.3 Typical Gravity Syste DESN 511035
Corrosion Inhibitor
A corrosion inhibitor can be used when installing this appliance to an Indirect hot water cylinder only.
If the cylinder is very close to the cooker, a towel rail is advisable as a heat leak and lagging should not be
applied.
Appliance Boiler
The appliance boiler is of stainless steel construction.
INSTALLATION
OF
APPLIANC
G N RAL
Page
9
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...

The co bined appliance is floor- ounted and the space in which the appliance is to be fitted ust have the
following ini u di ensions:-
Between wall and L.H. side of appliance 150
Between wall and R.H. side of appliance 10 ,
OR IF THE WALL PROJECTS BEYOND THE FRONT OF THE APPLIANCE - 50 (See Fig. 4 )
Above the raised insulating cover handle 75
Fig. 4
In addition, adequate clearance ust be available at the front of the appliance to enable it to be operated and
serviced.
Flue pipes and fitting ust not be closer than 25 to co bustible aterials and where passing through a
co bustible partition such as a ceiling or roof, ust be enclosed in non-co bustible sleeve providing an air space
of at least 25 .
Spaces around the flue pipes passing through walls or floors should be sealed against the passage of s oke and
fla e.
PR LIMINARY INSTALLATION
The appliance is delivered in a fully asse bled condition with the exception of the following ite s which are
supplied separately packed and require asse bly.
1. Co plete, but dis-asse bled oil burner with spare set of wicks.
2. Oil Constant Level Valve and Support Bracket.
3. Flue Outlet Asse bly.
4. Handrail Tube.
5. Appliance rear distance bracket - For use when the appliance is installed near a rear wall or co bustible
aterial - See Fig.6.
6. Boiler sealing ce ent.
7. 8 dia copper oil feed tube.
8. Boiler pipe Collars-Boiler Model Only.
Wherever possible, it is reco ended that skirting board is re oved for the width of the appliance to enable the
rear edge of the appliance top plate to ake contact with the vertical wall, and avoid a rear air gap. (Co bustible
walls
excepted).
Page
10
of
23
EINS 511985
26/10/2006
file://\\server1\docs\NetC s\Aga%20Product%20Information%20Spares%20and%20Tec
...