Rayburn Heatranger 480CD User manual

12/15 EINS 514710[email protected]
For use in GB and IE
Installation
Instructions
Heatranger 480CD
DESN 514712
PLEASE READ THESE INSTRUCTIONS BEFORE USING 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 required. Do not use reconditioned or copy
parts thay have not been clearly authorised by AGA.

Contents
2
SECTION CONTENTS PAGE
CONSUMER PROTECTION 3
HEALTH AND SAFETY 3
SPECIFICATIONS 4
SITE REQUIREMENTS INTRODUCTION 5
REGULATIONS 5
LOCATION 5
GAS SUPPLY 5
ELECTRIC SUPPLY 5
CONTROLS 7
BALANCED FLUE SYSTEM 7
AIR SUPPLY 7
WATER CIRCULATION SYSTEM 9
INSTALLATION INSTRUCTIONS SITE LOCATION 10
CLEARANCES 10
PRELIMINARY INSTALLATION 10
GAS CONNECTION 11
WATER CONNECTIONS 11
SYSTEM SUITABILITY 11
ELECTRICAL CONNECTIONS 12
ELECTRICAL CHECKS 12
WIRING DIAGRAM 13
CONDENSATE TRAP 14
CONDENSATE PIPE 14
BALANCED FLUE INSTALLATION EXHAUST DUCT 15
TERMINAL GUARD 15
VENT PIPE 16
VENT PIPE GUARD 16
SEALED SYSTEM SEALED SYSTEM REQUIREMENTS 17 - 18
OPEN SYSTEM REQUIREMENTS 17 - 18
COMMISSIONING 17 - 18
COMMISSIONING ELECTRICAL INSTALLATION 19
WATER CIRCULATION SYSTEM 19
COMMISSIONING THE COOKER AND BOILER 19
INSTRUCT THE USER 19
LIGHTING THE BOILER BURNER 19
BOILER OUTPUT SETTING 19
BOILER COMBUSTION 19 - 20
COOKER BURNER LIGHTING 20
COOKER OUTPUT 20
COMBUSTION 20

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.
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 lids to prevent staining the linings.
3

23.4 kW
Specifications
4
Gas Connection R1/2 (1/2” BSP TAPER) Water Capacity 0.6 litre
22mm Copper Pipe must be used to within 1metre of the Appliance weight 330Kg
appliance Boiler Connections: Flow 22mm O/D Copper Tube
Electrical Supply 230V~50Hz 3 amp Fused Return 22mm O/D Copper Tube
Max. Working Pressure of Boiler: Flue Outlet - Concentric Flue 100mm/60mm (x2)
Open Vent System 3 bar (30m) Max. Length 514mm
Sealed System 3 bar (30m) With Optional Extension1000mm
Max. Water Temp. 82°C + 3°C
BOILERTOTAL COOKER
20 mbar
41.3 kW 26.7 kW 14.6 kW
23.4 kW
Max. Heat Inputs - Gross
Inlet Pressure
Max. Boiler Output (80°/60°C) net
Min. Boiler Output (80°/60°C) net
480CD NAT. GAS (G20)
NOTE: IT IS ADVISABLE TO CHECK
THE ACTUAL SIZE/WIDTH OF YOUR
CUPBOARDS BEFORE FINALLY
FIXING ANY KITCHEN UNITS SINCE
ENAMELLED CAST IRON CAN VARY
IN SIZE.
DESN 514853Fig. 1
6.9 kW
CO2% @ Max. Rate
CO2% @ Min. Rate
8.8 - 10.2%
8.8 - 10.2%
8.8 - 10.2%
-
CO (PPM) Max. Rate 0 - 50 0 - 100
CO (PPM) Min. Rate 0 - 50 -

THIS APPLIANCE MUST BE INSTALLED IN
ACCORDANCE WITH THE RULES IN FORCE AND
USED ONLY IN A SUFFICIENT VENTILATION SPACE.
This Rayburn Gas combination appliance is a combined
cooker and hot water boiler providing central heating
and domestic hot water, in addition to special cooking
facilities.
The boiler has been designed for use in fully pumped
systems. Two separate independent controlled gas
burners provide heat, one to the boiler section, providing
heat and domestic hot water, whilst the other provides
heat to the cooker.
In the interests of safety, all gas appliances should be
installed by competent persons, in accordance with the
regulations in force.
The appliance must be installed in 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
installation and provision of a satisfactory flue. The
location must also provide space for servicing, including
access to the flue for combustion setting/checking, and
air circulation around the appliance.
Between wall and LH side of appliance 150mm
Between wall and RH side of appliance 10mm*
*SHOULD THE WALL PROJECT BEYOND THE
FRONT OF THE APPLIANCE. THEN IT MUST BE
INCREASED to 50mm (SEE FIG. 2A, 2B & 2C).*
Above the raised insulating cover handle
60mm
NOTE: Worktops may extend up to the side of the
appliance, also an infill can butt up to LH side of
the appliance, provided it can easily be removed for
servicing the appliance.
In addition, adequate clearance must be available at the
front of the appliance to enable it to be operated and
serviced.
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.
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.
CHECK THAT THE GAS SUPPLY IS COMPATIBLE
WITH THE INFORMATION ON THE DATA PLATE.
Pipework from the meter to the appliance must be of
adequate size. It is recommended that a minimum of
ø22mm copper tubing is used. Do not use pipes of a
smaller size than the appliance gas connection. The
complete installation must be tested for soundness and
purged in accordance with the regulations in force.
THIS APPLIANCE MUST BE EARTHED.
External wiring must be correctly earthed, polarised and
in accordance with current regulations. The main supply
required is 230V, 50Hz fused at 3A.
NOTE: The method of connection to the electricity
supply must facilitate complete electrical isolation of
the appliance, preferably by the use of a fused three
pin plug and unswitched shuttered outlet. Alternatively,
connection may be made by a via a fused double pole
isolator with a contact separation of at least 3mm in all
poles and serving the appliance and system control only.
Site Requirements
INTRODUCTION
GAS SUPPLY
ELECTRICAL SUPPLY
5
REGULATIONS
LOCATION

Fig. 2A
Fig. 2B
6
Fig. 2C
MINIMUM GAP ON RIGHT HAND SIDE
GAP REQUIRED FOR SERVICING ON LEFT HAND SIDE
WALL PROJECTING BEYOND THE FRONT OF THE
APPLIANCE

CONTROLS
Independent temperature controls with time switch
control are recommended ferature 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.
The internal boiler/cooker wiring is shown in Fig. 9.
BALANCED FLUE SYSTEM
FLUE INSTALLATION
Pluming will occur at the terminal so terminal positions
where this could cause a nuisance should be avoided.
The flue must be installed in accordance with the
recommendations of BS 5440-1: 2000. In IE refer to I.S.
813: 2002.
The following notes are intended for general guidance:
1. The appliance MUST be installed so that the terminal
is exposed to external air.
2. It is important that the position of the terminal allows
the free passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specied in
Fig. 5.
3a. Ensure the two flues are cut to size using Fig
13, the boiler flue requires a 3° incline so that any
condensate formed in the flue drops back into the
heat exchanger. This is achieved by the design of the
appliance, the boiler flue should be angled when simply
pushed into place. This should result in the boiler flue
being inclined and the cooker flue perfectly horizontal.
4. Ensure that the guard is tted centrally. (See Fig. 16).
5. The ue assembly shall be placed or shielded as to
prevent ignition or damage to any part of the building.
6. The air inlet/products outlet duct and the terminal of
the boiler MUST NOT be closer than 25mm (1”) to
combustible material. Detailed recommendations on
the protection of combustible material are given in
BS. 5440-1:2000.
IMPORTANT: It is absolutely essential to ensure, in
practice, that products of combustion discharging
from the terminal cannot re-enter the building or any
other adjacent building through ventilators, windows,
doors and any other sources of natural air infiltration,
or forced ventilation/air conditioning.
If this should occur the appliance MUST be turned OFF,
labelled as ‘unsafe’ until corrective action can be taken.
7. A hole must be drilled for the vent pipe, the location
of which can be seen on Fig. 1. which shows the
appliances overall dimensions.
8. The oven vent terminal guard must also be fitted to
prevent the copper outlet being touched. (See Fig.
17).
AIR SUPPLY
It is NOT necessary to have a purpose provided air vent
in the room or internal space in which the appliance is
installed.
Site Requirements
7

Site Requirements
8
A BELOW A GUTTER OR SANITARY PIPEWORK 600mm
B HORIZONTAL FROM OPENING, AIR BRICK, 600mm
WINDOW ETC
C ABOVE GROUND OR BALCONY LEVEL
300mm
D BELOW EAVES OR BALCONY
600mm
E FROM AN INTERNAL OR EXTERNAL CORNER 300mm
F FROM A TERMINAL FACING A TERMINAL
1200mm
G FROM A SURFACE FACING A TERMINAL
600mm
H VERTICAL FROM TERMINALS ON THE SAME 1500mm
WALL
I HORIZONTAL FROM TERMINALS ON THE 750mm
SAME WALL
J BELOW AN OPENING, AIR BRICK,
600mm
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 and permits the dispersal of combustion products.
Consideration must be given, as to the possible adverse affects of combustion noise on adjoining properties,
inherent with this type of product.
Fig. 3
SEE FIG. 3
The flue system must be installed in accordance with the regulations in force.
Terminal Position
The minimum acceptable spacings from the terminal to obstructions and ventilations openings are shown in Fig. 5.
Where the terminal is within 1m of 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 2 metres above ground
level, if damage could occur to the terminal or if there is the possibility of accidental damage by persons.
Maximum Flue Gas Temperature 260°C with the cooker burner on.

Site Requirements
9
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 and 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
1/2 in BSP nominal size and be in accordance with BS
2879.
The appliance boiler section should be connected to
cistern water supply, subject to a maximum head of 3 bar
(30m), minimum of .1 bar (1m).
The heating system must be designed (and adjusted if
necessary) to give temperature differential across the
boiler at full output of 10-14°C. Where 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. (See Fig. 4).
The pump should be able to meet the requirements of the
system design and fit 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.
Sealed System Requirements
See Pages 18 and 19.
WATER CIRCULATION SYSTEM
Fig. 4
Pressure Loss Curve

SITE LOCATION
1. Remove the appliance assembly from the 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 with a crowbar) and insert a 32mm 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 the 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 of the appliance base plate,
take the weight of the appliance on the crowbar and
remove the rolled tube, followed by similar action
on the front tube.
The appliance is floor mounted. The space in which
the appliance is to be fitted must have the following
minimum dimensions:
Between wall and LH side of appliance - 150mm
Between wall and RH side of appliance - 10mm*
*SHOULD THE WALL PROJECT BEYOND THE
FRONT OF THE APPLIANCE, WHEN IT MUST BE
INCREASED TO 50mm (SEE FIG. 2A, 2B & 2c)*
Above the raised insulating cover handle - 60mm
In addition the adequate clearance must be available at
the front of the appliance to enable it to be operated and
serviced.
The appliance is delivered assembled with the exception
of the following items, which are supplied separately
packed and require assembly.
1. Air Inlet Spigots/Concentric Balance Flue Kit
2. Appliance Rear Distance Bracket - (for use when
appliance is installed (25mm) away from a rear
wall of combustible material). See Fig. 5.
3. Handrail - 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 in to the brackets,
positioning them correctly, and tighten the locating bolts.
(See Fig. 6).
Installation Instructions
10
CLEARANCES
PRELIMINARY INSTALLATION
Fig. 5 DESN 512553
Fig. 6 DESN 510454 A

GAS CONNECTION
1. Connect the gas supply to the 1/2” BSP tapered
thread on the left hand side of the appliance. (22mm
copper pipe must be used to within 1 metre of the
appliance.
2. Test the hole of the gas installation including the
meter and purge in accordance with the relevant
recommendations.
WATER CONNECTIONS
The two 22mm flow and return connections are located
towards the rear edge of the appliance left hand side
panel.
SYSTEM SUITABILITY
THIS BOILER IS SUITABLE FOR FULLY PUMPED
SYSTEMS ONLY.
For optimum operating conditions the heating system
into which the boiler is installed, should include a control
system.
Such a system will include a time switch and a room
thermostat and/or cylinder thermostat.
The boiler should be controlled so that it is operated 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.
The internal boiler/cooker wiring is shown in Fig. 9.
Installation Instructions
11
Fig. 7 DESN 514864

ELECTRICAL CONNECTIONS
The switch LIVE must be connected to the programmer
or room stat.
The system pump and mains should be connected as
shown in Fig. 8.
ELECTRICAL CHECKS
Checks to ensure electrical safety should be carried out
by a qualified engineer.
Installation Instructions
12
Fig. 8 DESN 514865

Installation Instructions
13
Fig. 9

CONDENSATE TRAP
This appliance has a built-in condensate trap, which
eliminates the need for any external traps. The flexible
drain hose is located on the underside of the boiler. This
should be routed through the cutout in the side or back
of the appliance. Connect to the flexible and extend the
pipe run away from the appliance with a continuous fall
of 21/2° (or 20mm in every metre).
Once the pipe has been positioned, ensure that the pipe
is still connected fully to the outlet of the trap.
Before initial firing of the boiler, the condensate trap
must be filled with water to prevent the escape of flue
gases. On the underside of the boiler, unscrew the
transparent glass of the drain connection, fill the trap to
halfway with water, before re-assembling.
CONDENSATE PIPE
The condensate pipe may terminate into any four areas:-
1. Into an internal waste system, with the end of the
pipe into a gully below ground level, but above the water
line.
2. Into an external waste system, with the end of the
pipe into a gully below ground level, but above the water
line.
3. Into an internal soil and vent stack.
4. Into an external purpose-made soakaway.
As external condensate pipe runs may be susceptible
to freezing during very cold weather, it is advisable to
terminate the pipe into an internal waste system where
possible.
1. The pipework should be insulated with the weather-
proof material to prevent the condensation from
freezing.
2. The pipe run should turn the shortest practical route.
3. The pipe should terminate as close as is possible to
the ground/drain, while still allowing for the safe
dispersal of the condensation.
4. All pipework and fittings in the condensate drain
system must be made of plastic. No other materials
may be used.
When insufficient head is available a proprietary
condense lift pump may be used.
Installation Instructions
14
Fig. 10 DESN 514866

EXHAUST DUCT
THIS APPLIANCE MUST BE INSTALLED WITH THE
DUCTS AND TERMINALS SUPPLIED.
lIt is recommended to fit the spigots to the appliance
before putting it into position for ease of fitting.
l Locate and secure 100mm air inlet spigots, 1 gasket
and 4 screws. (See Fig. 11). It is advisable to stick the
gaskets to the appliance using a sealant to ease the
fitting.
l Screw in tap tight screws to secure spigots.
lUsing Fig. 12, measure from the outside of the wall to
the end of the recess on the 100mm spigot, this will
be the same for both the cooker and boiler flues, then
cut the 100mm tube to this length. Then cut the 60mm
pipe to 120mm. (See Fig. 13).
Once both flues have been cut to size, file any burrs away
and chamfer the 60mm pipe ends to allow easier fitting
into the couplings.
N.B. It may also be possible to use a high temperature
grease to allow easier fitting.
To ensure the boiler flue has been fitted correctly into
the boiler flue outlet, remove the glass control facia and
brackets behind. The boiler elbow can then be adjusted if
required and a correct fitting can also be checked of the
flue. The covering plate supplied can then be mounted on
the wall.
TERMINAL GUARD
l Locate terminal guard to wall, mark location of
securing holes, remove guard.
l Drill holes and fit rawlplugs.
l Locate and secure terminal guard to wall (4 screws).
NOTE: The guard must be fitted where the terminal is
below 2m above the ground level or where the terminal
can be touched either intentionally or accidentally eg.
window cleaning or painting.
15
Balanced Flue Installation
Fig. 11 DESN 514867
Fig. 12 DESN 514868
Fig. 13 DESN 514869 A
Fig. 14 DESN 514870

If the house wall is thicker than 500mm, an extension
kit wil be needed (to be ordered separately). The two
extensions supplied are the same size, one will fit into
the boiler without cutting. The cooker flue will need
the 60mm diameter pipe reducing to 120mm. The two
standard flues will now fit into the extensions.
VENT PIPE
l Mark and cut pipe to length.
A (Wall thickness) + B (internal spacing) + 90mm
lLocate vent pipe to appliance
VENT PIPE GUARD
A vent pipeguard is supplied with the cooker and must
be fitted if the vent termination is less than 2 metres
above ground level, or subject to damage.
When fitted, it must be positioned to provide a minimum
of 50mm clearance from any part of the terminal and be
central over the terminal.
16
Balanced Flue Installation
Fig. 15 DESN 514871
Fig. 16 DESN 514991
Fig. 17 DESN 511273

SEALED SYSTEM REQUIREMENTS
See Fig. 19
a. The installation must comply with the requirements
of BS 6798 and BS 5449. Maximum water 82°C
temperature.
b. A safety valve set to operate at 2 bar (30Ibf/In2)
shall be fitted in the flow pipe close to the boiler. There
must not be any valve between the safety valve and the
boiler. The valve should be positioned on a discharge
pipe fitted to prevent any discharge or creating a hazard
to occupants or cause damage to electrical components
and wiring.
c. A pressure gauge covering at least the range 0 to
4 bar (0 to 60 Ibf/In2) shall be fitted in the system, in a
visible position.
d. A diaphragm type expansion vessel to BS 4814 shall
be connected at a point in the return pipe close to the
boiler. The vessel must be chosen to suit the volume
of water in the cistern and the system charge must not
be less than the static head at the point of connection.
Further details can be obtained from ‘British Gas
Specification for Domestic Wet Central Heating Systems
Part 3 Sealed Systems’.
Vs = System Volume Litres
e. The hot water cylinder shall be either the indirect coil
type or a cylinder fitted with a calorifer which is suitable
for the system pressure.
f. The Make-Up System
Provision shall be made for replacing the lost water from
the system by either of the following methods:
a) From a make-up vessel or tank, and connected
through a non-return valve to the system on the return
side of the hot water cylinder or return side of all heat
emitters or radiators.
b) Where access to a make-up vessel would be difficult,
by a remote automatic pressurisation and make-up unit.
OPEN SYSTEM REQUIREMENTS
If you are using an open system, the pressure sensor
on the flow pipe needs to be wired out of the system.
This is achieved by removing the RED link wire which
connects between the pressure sensor and the overheat
sensor. The remaining wire on the pressure sensor
should now be moved onto the spare terminal on the
overheat sensor.
N.B. It is very common on initial filling and
commissioning that air locks will cause the overheat
sensor to trigger a fault (A3). It is advisable to
temporarily connect the pump to the permanent Live and
Neutral so that it is continually running to vent the air.
To re-set the A3 fault, press the REPEAT button, once
the flow temperature drops below 60°C the boiler vents
all the air. You MUST re-connect the Pump Live and
Neutral into the correct terminals.
COMMISSIONING
Follow the commissioning instructions as for open
vented systems. See Section Commissioning
Instructions with the following additions:-
Fill the system until the pressure gauge registers 1.5
bar (22 Ibf/In2). Clear any airlocks and check for water
soundness.
Check the operation of the safety valve, by allowing the
water pressure to rise until the valve opens. The valve
should open with ±0.3 bar (±4.35 Ibf/In2) of the pre-set
pressure. If this is not possible conduct a manual check
and test.
Release cold water for initial filling pressure.
Any set pointer gauge should be set to coincide with the
recommended filling pressure.
Safety Valve Setting 2.0 bar
Vessel charge and
initial system pressure 0.5 bar 1.0 bar
0.16
L
Vs
x
0.16
0.09
L
Vs
x
0.09
Multiplying Factor
Expansion Vessel
volume (litres)
= System volume Vs x
factor
17
Sealed System
Fig. 18 DESN 514999

Sealed System
Fig. 19
18

Commissioning
ELECTRICAL INSTALLATION
WATER CIRCULATION SYSTEM
COMMISSIONING THE COOKER
AND BOILER
INSTRUCT THE USER
LIGHTING THE BOILER BURNER
BOILER OUTPUT SETTING
BOILER COMBUSTION
Fig. 20 DESN 514873
19
Checks to ensure electrical safety should be carried out
by a competent person i.e. earth continuity, polarity and
resistance to earth.
The whole of the system should be thoroughly flushed
out with cold water without the pump in position. Ensure
that all valves are open. With the pump fitted, the system
should be filled.
Vent all heat emissions and check for water soundness.
Insert condensate trap.
Isolate electricity supply at the wall socket. Turn the
cooker and boiler control knob to off.
After ensuring gas is available to the appliance, loosen
joint and purge any air from the supply pipe.
WARNING: NO SMOKE OR NAKED LIGHTS.
Tighten joint and check gas service cocks are in the ON
position. Check for gas soundness up to the gas valves.
1. Advise the User of the precautions necessary to
prevent damage to the heating system and to the
building in the event of the heating system being
inoperative during frost conditions.
2. Advise the User for continued efficient and safe
operation of the appliance. It is important that
adequate servicing is carried out at regular 12
monthly intervals.
3. Hand the Users Instructions to the User and
demonstrate the correct operation of the appliance
and system controls.
4. Leave the Installation, Servicing and Users
instructions with the User.
5. Gas Safety - Show the user the procedure for
isolating the appliance from the gas and electric
supply. As referred to in the Users Instructions - Ref.
Gas Leak or Appliance Fault.
To light the burner - turn the boiler thermostat to maximum
and create a demand on the room thermostat.
Check the gas consumption and ensure it is ±5% of the
nominal, 26.7 kW.
Connect a suitable analyser to the flue outlet of the boiler.
(See Fig. 20).
Although the appliance is pre-set check that the CO2/CO
levels are within tolerances.
CO28.8 - 10.2%
CO 0-50ppm
To check the levels at full rate, turn the boiler knob fully
clockwise.
To check the levels at the low rate, turn the boiler knob to
the first segment of the dial.
If these levels are within the tolerance, no further action is
required with the boiler.
If levels are not within tolerance check for possible causes
e.g. blocked flue, faulty fan etc. If non other fault can be
detected, the gas valve needs to be adjusted manually.
To do this, turn the boiler knob fully clockwise to create
the highest possible demand.
Turn the gas valve regulator A (See Fig. 21) in the
appropriate direction. Turning clockwise will decrease the
CO2turning anti-clockwise will increase the CO2. Please
note that due to the sensitivity of the screw, only small
adjustments will be necessary.

20
Commissioning
COOKER OUTPUT
COOKER BURNER LIGHTING
COMBUSTION
Once adjustment has been made, wait until CO2level
stabilises and recheck the combustion. Repeat the above
steps as necessary.
Check that CO2levels are within stated levels at minimum
rate, turn knob to first segment on the display.
Using the method detailed above, run the boiler at its
minimum output. Wait for the boiler to stabilise and
perform the combustion analysis, check the results.
If found to be inconsistent, turn the gas valve regulator
B (See Fig. 21) in the appropriate direction. Turning
clockwise will increase the CO2turning anti-clockwise will
decrease the CO2. Please note that due to the sensitivity
of the screw, only small adjustments will be necessary
(1/8 of a turn).
Once adjustment has been made, wait until the CO2level
stabilises and recheck combustion. Repeat the above
steps as necessary.
After completion of calibration, recheck the CO2, at
maximum output.
Fig. 21 DESN 515016
Turn the cooker burner to mark H and ensure programmer
is set to MANUAL, the burner should light within 60
seconds.
Check within 5 minutes that the gas consumption is ±5%
of the stated heat input. 14.6 kW.
Connect a suitable gas analyser to the sample point on
the hob or flue outlet. Ensure the CO/CO2content is:
CO28.8 - 10.2%
CO 0 - 100ppm
If these levels cannot be obtained, check gas rate and
adjust the throttle screw if required and allow readings to
stabilise. (See Fig. 22).
Fig. 22 DESN 514881