Rayburn Heatranger 440 User manual

12/13 EINS 511566-E[email protected]
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THIS APPLIANCE
For use in GB and IE
Installation
Instructions
Heatranger 440/460/480/499K
DESN 512012 A
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.

Contents
SECTION CONTENTS PAGE
CONSUMER PROTECTION 3
HEALTH & SAFETY 3
GENERAL SPECIFICATION 4
TECHNICAL DATA 5
SITE REQUIREMENTS INTRODUCTION 6
REGULATIONS 6
LOCATION 7
OIL PIPE LINE - ECOFLAM 8
OIL STORAGE - ECOFLAM 8
GRAVITY SINGLE FEED SYSTEM 9
SUCTION LIFT TWO-PIPE SYSTEM 9
FLUE SYSTEM 10
AIR SUPPLY 11
WATER CIRCULATION SYSTEM 12
HEATING CONTROLS 13
TIMING CONTROLS 13
EXTERNAL CONTROLS 14
ELECTRICAL SUPPLY 15
WIRING DIAGRAM - ECOFLAM 16
INSTALLATION CLEARANCES 17
REQUIREMENTS PRELIMINARY INSTALLATION 17
SITE LOCATION 18-19
COMMISSIONING BURNER ACCESS - ECOFLAM 20
INSTRUCTIONS ELECTRICAL CONNECTION - ECOFLAM 20
OIL PUMP - ECOFLAM 20
TERMINAL STRIP CONNECTIONS 21
ELECTRICAL CHECK - ECOFLAM 22
FIT PRESSURE GAUGE - ECOFLAM 22
VENT OIL PUMP - ECOFLAM 22
ADJUST OIL PRESSURE - ECOFLAM 22
SET COMBUSTION AIR - ECOFLAM 23
ANCILLARY CONTROLS CHECK 24
BOILER CONTROL CHECK 24
INSTRUCT THE USER 24
SEALED SYSTEM REQUIRMENTS 25
COMMISSIONING 25
TYPICAL SEALED SYSTEM 26
2

Consumer Protection
As responsible manufacturers we take care to make sure that our products are designed and
constructed to meet the required safety 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. 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
May be 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.
Kerosene and Gas Oil (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 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. Inhalation 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 oils by use of the mouth. If accidentally swallowed, call a doctor, do
not induce vomiting.
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 lids to prevent staining the linings.
3

4
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.
Oil Inlet 10mm copper
To connect to the R.H.
side panel.
Electrical Supply 230V ~ 50Hz 220/270 W
3 Amp Fused
Flue 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 2 bar (20m)
Pressure of Boiler
Fuel - Kerosene C2
GENERAL SPECIFICATIONS
ELECTRIC AND
OIL
CONNECTIONS
RETURN
CONNECTION
542
910
1355
65
582
110
91
125
905
509
940
278
60
FLOW
CONNECTION
END ELEVATION
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 512013
Fig. 2

Technical Data
5
BOILER BURNER
BURNER NOZZLE (US g/h) 0.55 @ 80º EH 0.40 @ 80º EH
10 (145)
28.5
17.6
10 (145)
38
21.7
17.5
OIL PRESSURE Bar (psi)
OIL BURNING RATE cc/m
HEAT INPUT kW
BOILER OUTPUT kW
460K COOKER BURNER
BOILER BURNER
BURNER NOZZLE (US g/h) 0.65 @ 80º EH 0.40 @ 80º EH
10 (145)
28.5
17.6
10 (145)
47.5
29.3
23.5
OIL PRESSURE Bar (psi)
OIL BURNING RATE cc/m
HEAT INPUT kW
BOILER OUTPUT kW
480K COOKER BURNER
TOTAL OUTPUT kW 18.2 3.1
TOTAL OUTPUT kW 24.7 3.1
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 @ 80º EH
BOILER BURNER
10 (145)
58
35.2
29.3
29.5
COOKER BURNER
0.40 @ 80º EH
10 (145)
28.5
17.6
3.1
499K
BOILER BURNER
BURNER NOZZLE (US g/h) 0.35 @ 60º H 0.35 @ 80º S
8.5 (120)
23.0
14.2
8.5 (120)
23.0
14.2
12.3
OIL PRESSURE Bar (psi)
OIL BURNING RATE cc/m
HEAT INPUT kW
BOILER OUTPUT kW
440K COOKER BURNER
TOTAL OUTPUT kW 12.5 3.1

The Rayburn is a floor standing combined cooker and
central heating boiler. It 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
lThis appliance must only be used with Kerosene
C2 to BS 2869.
lAn Indirect Cylinder to BS 1566: Part 1 must be
fitted.
lIf 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. 18)
lAn OFTEC approved Fire Valve MUST be fitted in
the oil supply line.
lThe supplied in line filter MUST be fitted.
lPermanent Ventilation must be provided.
THIS APPLIANCE IS A CONTROLLED SERVICE BY
DEFINITION AND REQUIRES EITHER FITEMENT
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 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 Installation of oil fired appliances for space
heating and hot water supply purposes. 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 & 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 Pollution (Oil) Regulations.
Site requirements
6
REGULATIONSINTRODUCTION

10mm
10mm
50mm
Fig. 3
WALL PROJECTING BEYOND THE
FRONT OF THE APPLIANCE
Appliance Hearth: The surface temperature of the floor
below the appliance does not exceed 100ºC. 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 “Installation of the 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 - 10mm
top plate
Between wall or unit and RH side of appliance - 10mm
top plate
SHOULD THE WALL PROJECT BEYOND THE FRONT
OF THE APPLIANCE, IT MUST BE INCREASED TO
50mm (SEE FIG. 1). To allow door to open enough to
change oven and shelf position.
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
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 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,
(See Fig. 2).
Site requirements
LOCATION
7
Fig. 2 DESN 516733

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 PFTE tape should be used
when making joints. Pipe work must be protected against
damage whether fitted above or below ground.
The size and arrangement of pipe work 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 150ºF, 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 sensing bulb of the
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 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.
Where the oil pipe connection is taken out at 90º from the
cooker a special elbow fitting is supplied loose with the
cooker.
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.
TWO PIPE SYSTEM KIT
A kit is available for a two pipe system (optional extra).
Part No: RO9M 998550
CAT No: R4613
The kit is made up of the following parts:
Bulkhead Fitting
Flexi Hose
Return Oil Nipple
Two Pipe System Fitting Instruction -
Site requirements
8
OIL PIPE LINE OIL STORAGE
DESN 511990Fig. 4
REMOVE
HORSESHOE WASHER

Site requirements
9
Fig. 5
MAXIMUM
LENGTH
(METRES)
H METRES
10mm OD
12mm OD
0
35 30 25 20 15 8 6
100 100 100 90 70 30 20
0.5 1.0 1.5 2.0 2.5 3.0
REFER TO INSTRUCTION
SHEET FOR DETAILS ON
FITTING TWO-PIPE
SYSTEM
GRAVITY SINGLE FEED
PIPE SYSTEM
SUCTION LIFT
TWO-PIPE SYSTEM

The flue system must be installed in accordance with the
regulations in force.
Information
Maximum flue gas temperature 260ºC
(Both burners on)
Minimum flue gas temperature 125ºC
(Boiler burner on only)
The appliance requires a minimum chimney draught of
1.0mm (0.04 WG) with both burners on.
Maximum chimney draught 6.0mm (0.23” WG) draughts
in excess of this figure will require a draught stabiliser,
fitted either in the chimney or flue pipe and in the same
compartment.
Flue gas mass flow (Both burners on) - 440K
460K-111.5 kgh-1
480K - 95.5 kgh-1
499K - 185 kgh-1
Detailed recommendations for flueing in England and
Wales are given in Part J of the Building Regulations. For
Scotland in Technical Standard F to the Building
Standards and in Northern Ireland in Technical Booklet L
to the Building Regulations. Guidance is also given in BS
5410: Part 1.
Due to the range in flue gas temperatures a brick chimney
should be fitted with a suitable stainless steel flexible
liner. Where it is necessary to avoid condensation, such
as an exposed end gable, the lining may be wrapped with
a proprietary insulating blanket.
NOTE: TO ACHIEVE THE OPTIMUM OPERATIONAL
SOUND LEVELS FROM THE APPLIANCE IT IS
RECOMMENDED THAT CAST IRON FLUE PIPE IS
USED WHERE POSSIBLE.
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.
Site requirements
10
FLUE SYSTEM
Fig. 6 DESN 510521’A’

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 INTAKE AT THE
BOTTOM FRONT OF THIS APPLIANCE MUST BE
KEPT 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 is 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. If 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 kitchens in Part F of
the Building Regulations (England & Wales) is for
mechanical extract at the rate of 60 litres per second or 30
litres per second 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
4000mm2.
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. It 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.
11
Site requirements
AIR SUPPLY
460K
440K 127 cm2
147 cm2
480K 180 cm2
MODEL MIN. AIR REQUIREMENT
499K 211 cm2
AIR SUPPLY

Flow and return pipework between cooker diverter valves
must be 28mm diameter minimum.
Space and water heating systems should be in
accordance with the relevant recommendations of BS
5410: Part 1.
In 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 may be exposed by freezing conditions should be
insulated.
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. 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
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 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.
Inhibitor 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.
Site requirements
12
WATER CIRCULATION SYSTEM

Site requirements
Internal temperature and time controls are supplied.
These provide control of cooking and hot water
temperatures. The cooker is supplied with 2-channel
programmer.
Channel 1 - Marked “COOKER”
Channel 2 - supplies hot water - Marked “BOILER”
A separate switch in conjunction with the hot water
channel gives priority to either the domestic hot water or
the supply of hot water for central heating/DHW (if
external controls are fitted).
It is recommended that independent temperature controls
are provided for comfortable room temperatures for
economic operation and for control of the domestic hot
water flow to the cylinder.
Consideration should be given to fitting a frost thermostat
switch should be set to operate at a temperature of
approximately 4°C.
Consideration must be given when selecting 3 port mid-
position or 2 port zone valves.
It is essential that the capacity of the individual valves is
considered to enable the correct size to be chosen.
For this range of appliance, where Honeywell valves are
selected, a guide to selection is as follows:-
Model:-
440K, 22mm (3/4”) 2 or 3 port
460K, 22mm (3/4”) 2 or 3 port
480K, 28mm (1”) 2 or 3 port
499K, 28mm (1”) 2 port only
3 Port Mid Position valves are inappropriate for selection
with the 499K model.
The latest publication of Part L of the Building Regulations
states that “separate timing controls should be provided
for space heating and water heating”.
The 400 Series cookers/boilers are fitted with a 2 channel
programmer.
Channel 1 controls the cooking facility.
Channel 2 controls the boiler facility which is space
heating and water heating combined.
To meet the new Building Regulations, the space heating
and water heating functions must have individual timing
controls, therefore we recommend the fitting of an
auxillary programmable room thermostat to control space
heating timings and use channel 2 on the appliance
programmer to control the hot water.
WARNING: POWER TO THE APPLIANCE AND
AUXILLARY CONTROLS i.e. PROGRAMMABLE
ROOM STAT MUST BE VIA THE SAME ISOLATION
SWITCH.
13
HEATING CONTROLS TIMING CONTROLS

Site requirements
14
440/460/480/499K - EXTERNAL 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 220/270W 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 a 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 30mA Residual Current Circuit
Breaker (RCCB).
The minimum requirement for the power cable is that it
should be a 3 core PVC sheathed flexible cord (85ºC 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 diagrams.
The circulating pump must be connected to PL and PN on
the terminal block (see Fig. 8) 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
auxiliary components used. In 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. 8
440/460/480/499 K

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 - 10mm
top plate
Between wall or unit and RH side of 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
In 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.
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. 9. 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 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. 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. (Fig. 10).
Installation requirements
17
CLEARANCES
PRELIMINARY INSTALLATION
Fig. 9
Fig. 10
DESN 510226
DESN 510454 A

SEE FIG. 11 & 12
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 flue pipe into socket of flue pipe
adaptor, sealing joint with fire cement.
3. Connect and terminate the flue system in accordance
with the regulations in force.
4. Lift up the insulating covers and remove the hotplate
using lifting hooks provided (See Fig. 11).
5. Remove the 4 flue cleaning access door securing
bolts and remove door.
6. Check the position of the boiler flueway baffles.
7. Replace door and refit bolts.
NOTE:
The baffles are assembled in alternate directions, to allow
gases to flow front to back through the assembly.
Each heat exchanger has two rows of baffles (See Fig.
12A).
Ensure that the baffles are having the top and bottom
plates of the same width and marked TOP are fitted last.
One at top of each flueway.
Total number of baffles fitted:-
440 = 6 (2 x 3)
460 = 6 (2 x 3)
480 = 8 (2 x 4)
499 = 10 (2 x 5)
Installation requirements
18
SITE LOCATION
Fig. 11
Fig. 12
DESN 510523
DESN 512011
FLUE CLEANING
ACCESS DOOR
BOILER FLUEWAY
BAFFLE

Installation requirements
19
Fig. 12A

20
SEE FIG. 13
1. Open the burner access door. Remove door and put
in a safe place.
2. Remove 4 inner panel securing screws and remove
panel.
3. Remove the 3 plinth securing screws and remove
plinth.
SEE FIG. 14
1. Make electrical connections to terminal strip as
wiring diagram (See Fig. 16).
SEE FIG. 15
1. Bring the sensing 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 and
clean supply to the pump. Make the connection onto
the oil pump tight and leave valve open.
3. Ensure that the fire valve is routed to allow free
removal of the twin burner assembly.
Commissioning Instructions
Fig. 13 DESN 511998
DESN 511577
DESN 512000
Fig. 14
Fig. 15
BURNER ACCESS
OIL PUMP
ELECTRICAL CONNECTION
TERMINAL STRIP