Rayburn Royal User manual

WARNING
This information is a copy of an original
archive, therefore Aga cannot be held
responsible for its continued accuracy.

Consumer Protection Act 1987
As
manufacturers and
suppliers
of cooking and
heating products, in compliance with Section
10
of
the Consumer Protection Act 1987
.
We take every
care to ensure, as far
as is
reasonably practicable,
that these products are so designed and constructed
as
to meet
the general safety requirement when properly used and installed .
To
this end,
our
products are thoroughly tested and
examinpd before despatch .

,
I

IMPORTANT NOTICE
:
Any
alteration that is not approved by
Rayburn, could invalidate the approval of the appliance, the
Varranty and
could
also infringe the current issue of the
l a .utory requirements
. .

.
~Control of Substances - Health and Safety
Important :
Note : Rayburn Royal and Regent Cookers are
delivered as self~corrtained units ready for installation .
Instructions for the preparation of the site and for the
assembly and connection of the boiler are included .
The Hot Wq,1 ;,q ;,System
With normal usage in 24 hours continuous burning the
Rayburn Royal has an approximate output of 100,000
Btu's
and,
the Rayburn Regent has an approximate
Installation Instructions for
Rayburn Royal and Regent
Cookers - Solid Fuel
Models
This appliance could contain any of the materials that are indicated
below . 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, Fuelbeds . Artificial Fuel-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
inhaling
and contact with skin or eyes . Use
disposable gloves, face masks andeye 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 .

'
output of 90,000 Btu's . To provide 2 or 3 hot baths at
intervals and normal household requirements ; the .
following mustbe . fulfilled :-
1 .The capacity of the storage cylinder may not exceed
35 gallons . The recommended capacity is 30 gallons
(direct or indirect) .
2 .The cylinder to be effectively lagged and fixed
vertically .
3 .The cylinder should be as near
as possible to
the cooker . In no
case may 1' flow and return
pipes exceed 30' each in .
length .
1 A' pipes may not
exceed
24' .
4 .1'
flow and
return pipes
exceeding 1F
each
in length
must be lagged-1~
.
pipes
exceeding 1-X
m

be lagged .
5 .The draw-off
pipe to the taps
must Ire a
'dead-leg`- .,, - . : .

. .
connection ftom theexpansion
pip e ;

. ~
6 .A towel raiVof not
more than 6
sq . ft . heatiiryg surface 'may
be
heated provided
the flow and
return . pip,,
are not more than-
15' each ih'
length, atnd : ,

.

,
providedlf e cylinder
and them"
pipes to the
cylinder and towel
rail are lagged .
When the hot
water storage
c'ylinder l4ery
closely,, ;couplecLto the
ba
towel
rail in advisable as m eat
leak and lagging should not be
applied .
A radiator is not permitted
To obtain
the
about-mentioned
outputs
the fire must
baleft
in
`overnight,
and
the cooker used
for cooking .
WP 10/91 EINS
3358 4

Important Note :
These instructions
must be
strictly
observed . If they
ire disregarded (e .g . anunlagged or over-size
cylinder), consumption of fuel maybe excessive, and
the cooker damaged by overfiring .
PREPARATION OF THE SITE
The hearth, walls adjacent to the cooker, and the
chimney must conform to the current building
regulations . The position of the flue outlet is
indicated in
the dimensioned drawings . Alternative flue layouts are
illustrated
.
The flue chamber is adaptable to
give either a
top or back outlet . The back outlet is used when there is
a brick flue immediately behind
the cooker, the top
outlet when the cooker is connected to the main flue by
means of cast iron flue pipe .
When the cooker is installed in a recess,
it
must
be
'free
standing' and not built - in solid at the sides . Adequate
space at the boiler side must
be
allowed for withdrawal
of the boiler for cleaning, if necessary .
NB : When a Rayburn cooker is supplied with a
platerack, an optional extra, the overall height from
the hearth level to the top of the platerack is 54 :x"
(1395) .
The
recess should be at least 6"
higher than
these overall heights to accommodate dinner plates .
THE BOILER
Unscrew the sheet metal cover plate on the side of the
cooker and remove
the
insulating material from behind
it . Joint the flow and return connections to the boiler,
replace the insulating material and screw on the cover
plate and collars .
The
boiler is now ready for connection to the hot water
cylinder . Make sure that there are no dips in the flow
pipe
between the boiler and cylinder . It is advisable to fit
a drain-off cock on the return pipe close to the cooker .
Important : Lift out the hotplate and cement seal the
joint
between the boiler face and its locating face on
the firebox sides with the fire cement provided .
Renew any brickwork cemented joints that may
have opened up in transit .
THE HOT PLATE
Lift off the surface ground hot plate and check that the
joints
between the underside of the hob, and the top of
the cooker are intact . Any joints which have opened up
should
be made good
with
the fire cement provided .
Replace hot plate making sure that it is seating properly
on the asbestos rope . It should be approximately Xe'
proud of the enamelled hob with an equal
space
all
round
.
When lighting the fire for the first time,
allow the cooker
to heat up gradually .
FIREBRICK REPLACEMENT
The firebricks fitted to Rayburn Cookers are of first
quality manufacture,
and providing the cooker has been
installed
and
used correctly will have a reasonable life .
They are, however, expendable
items and in time will
require renewal .
`~Rayburn
Note : All Sockets must be facing upwards
XCUwA'r
.r
Vary
.
s~l
P . .a .o .w .M Pw .L . .R .
r wry vas rwrr
CONDIN "n
COLIICTU10 vuu
The renewal of firebricks is not a major operation and
can be
carried
out by the
average handyman .
Replacement bricks either in sets or singly can be
obtained from your Rayburn distributor
.
FLUE LAYOUTS
In Fig .1 the Rayburn is installed in an existing recess .

f
There mustbe a clearance of not less than 6' between
the top of the flue pipe and any overhanging
brickwork .
Any cavities or pockets above the register plate should
as far as possible be filled and if necessary the flue
pipe
should be extended into the throat of the chimney and a
soot door provided for chimney sweeping .
In Fig .2 the Rayburn is connected direct to a brick flue .
In Fig .3 the Rayburn is connected to an existing brick
flue with
a
length of flue
pipe . Square
bends and
horizontal runs must not be used . There must be a
cleaning door at every bend .
Note : Whatever method of installation
is
employed
air must not be allowed to enter the chimney except
through the cooker . All joints
must be
air-tight .
Provision must always be made for sweeping the
chimney
.
Important : Asbestos cement pipes
and
fittings
should not beused within 6' of the cooker .
Chimneys of plain pipe
are
not
recommended
but
certain proprietary makers of insulated chimneys arl,
suitable .
Glynwed Consumer & Building Products
Ltd
PO
Box 30 Ketley Telford Shropshire
TF14DD
Telephone [phone] Telex 35196 Fax
[phone]
With
Rayburn's policy of continuous product improvement, the Company reserves the right to change specifications and
make
mnrlifirntinnc to thn nnnlinnrc rlccrriharl and ills ictritorl nt qnv timo

Rayburn Royal &
Regent
Solid
Fuel Cookers
OPERATING
INSTRUCTIONS
FUEL AND REFUELLING
LIGHTING THE FIRE
RIDDLING
TheRecommended Solid Fuels are : Manufactured - Sunbrite
Sh~gles, Sunbrite Doubles, Coallte, Phurnacite, Rexco and
Royal .
Natural - Anthracite Large Nuts, WdshDry Steam
Coal (Large
Nots), Housecoal (TrebkstLarge Nuts a Doubles/Nuts) .
Overdzu fad lumps should be broken down to size . Stone and
other foreign bodies should be removed when fuelling .
Fuel should be stored under coves, particularly manufactured

_
fuels which must be kept dry . Wet kitchen refuse should not

~~
FIG . t
be burned .
Before fuelling, open the chimney damper to its ruji extent . Fill the firebox to
the recommended level, not above the bottom of the fire door opening . It is not
necessary to keep the fuel constantly at this level, but if the fire is allowed to
bum very low there will be a time lag after refuelling before the heat reaches the
oven, hotplate and boiler .
When burning coal or anthracite, time should be allowed for a fresh charge
to ignite before the damper is closed .
open
the chimney damper, fire door and ashpit door . Kindle with paper and
sticks in the ordinary way . Leave the doors open until the fire is well alight .
Then
close both doors, and keep them closed . Push chimney damper back to
the
position which has been found from experience to give the best results .
A
gas poker may be employed instead of paper and sticks . The gas poker
can be inserted
through the ashpit immediately above the round grate .
Note : If there
is dead fuel in the grate, drop the bottom grate to remove
the
fuel when there is no gas poker .
Open
the chimney
damper to its full extent, engage the
operating tool on the
knob on
the riddler and
shake the bottom grate by a back and forth motion of

the riddler at the side of the ashpit door . Keep fire door and ashpit door closed .
Remove ash from ashpit at regular intervals .
If
ash is allowed to accumulate until
it touches the underside of the bottom
grate,
the bottom grate will quickly burn
out . Use the tool as an ashpan lifting handle . Reset the chimney damper after
riddling .
CONTROL
The fire is controlled by using the spin wheel on the ashpit door to govern the
air supply . The chimney damper in the flue chamber is for reducing the chimney
draught, and the more the damper can be closed the easier the cooker is to
control
.
It is marked to enable you to repeat the best setting you find suits your
chimney . No . 1 is closed position and No . 6 when fully open .
Do not try to obtain a quick increase in temperature by opening the chimney
damper to its full extent . This results in most of the heat being wasted up the
chimney .
Avoid excessive fire temperatures - they are not necessary and may do serious
harm m the cooker . The ~ sign that the cooler is being overheated is the
formation
of clinker (melted ash), and clinker
will
damage the fns bricks . Damaged
tire bricks
should be repaired with fire cement or if necessary replaced as soon
as possible .
Keep the ashpit door
securely closed with catch provided
.
THE ROASTING OVEN
The correct adjustment of the spin wheel and chimney damper
to obtain
the
oven temperature required varies with the chimney draught, and can be found
only by experiment . The following is a suggested method only, and may need
modification to suit local conditions .
i
S
ppose an oven temperature for roasting is desired, and that the cooler is
Thoroughly de-ash the fire as described in the 'Riddling' paragraph, and refuel .
Set the chimney damper
to No . 3 setting and
open the spin wheel
five complete
turns . As soon as the
fire
has
become nicely
red all through,
close
the
chimney
damper . Do not allow the fire
to become white
hot .
The temperajure of - the oven should now rise steadily . When it reaches a
point about 50 below that required, close the spin wheel to two turns open .
Thereafter control the temperature of the oven by adjusting the spin wheel .
Note : This method should prove successful in almost all cases, but if closing
the
chimney damper causes the fire to smoke, it should be opened gradually till
the
smoking stops .
To reduce top heat in the oven, place the sheet metal shelf on the top pair of
runners :
The oven may be cleaned with
a
stiff
wire
brush waken it is
very hot b
OVEN TEbTPEJLATURES
:-

Hot 400 - 500 . Moderate 300 - 4060 .
Slow 200° - 300 .
THE HOTPLATE
The best results can only be obtained by using machined base utensils
.
The
hottest part of the hot-plate is immediately above the fire ; the other end is for
simmering .
Fig . 5
The plug in the hotplate at the flue chamber end is for flue cleaning and
should
not be removed for cooking .
Keep the hotplate clean with a wire brush .
HOT
WATER SERVICE
The
supply of hot water is automatic and special manipulation of the spin wheel
and
chimney damper is not necessary, as it depends upon the cooker being
used
for cooking .
With
a normal day's cooking, two or three baths and hot water sufficient for
normal
household requirements can be obtained . To provide this quantity of
hot
water
the
cooker should be kept in overnight and the hot water system
must conform with the
installation instructions . In particular, the cylinder must
be lagged .
OVERNIGHT BURNING
The cooker is designed for continuous burning and the best results will only be
obtained if it is allowed to burn overnight . It is no more expensive in fuel .
Last thing at night open the chimney damper, riddle the fire, empty the
ashpan
and refuel . Do not overload . See that the ashpit door is securely closed .
close the
spin wheel and reopen it a quarter of a turn .
The
best position for the chimney damper can be found only by experiment,
but for a start try closing
it to No . 1 setting
.
In the morning
open
the
spin
wheel and damper
and riddle the fire . When it
is burning brightly, close
damper .
If
the
hotplate
is required immediately, do
not refuel before use .
GRATE REMOVAL AND REPLACEMENT
The bottom gate and support can be removed through the ashpit . Engage the
curved end of the dumping tool with the groove in the centre of the
bottom
gate support, raise slightly and draw the support forward
over
the
supporting
lugs . Lower the front of the gate and complete withdrawal (see Fig . 2) . Reverse
this procedure when replacing the gate making sure that the support rests on the
four
legs
of the ashpit sides .

FLUECLEANING
COOKER
When burn,

coke, anthracite or other smokeless fuel, the flue should be cleaned
once a month . The use of coal may call fqr weekly cleaning . The procedure is
illustrated in Figs . 3,4and 5 .
Allow the fire to bum out, or it may be done with slow fire
.
Open
the
chimney
damper to its maximum . Remove the
flue
chamber cleaninS door . Brush
the
soot
from
the flue pipe,
letting it fail onto
the
top of the
oven
.
Remove
the phg from
the hot plate, rake the soot forward, and push it
into
the firebox (Fig . 5) . Replace
parts removed .
Riddle the bottom grate thoroughly, dear the aahpit sad redght the fire .
CHIMNEY
Ensure the chimney flues are thoroughly swept
at
12 monthly intervals . inspect
any soot box at the base of the chimney every
3
months
sad
remove any
accumulation of
deposit
.
CLEANING THE ENAMEL
Surface blemishes caused by spillage are easier to remove when the cooker is Cool,
and a damp cloth is usually
all
that is necessary . This should not be done whilst
the cooker is hot .
THE WARMING OVEN (Royal only)
This oven is primarily intended for heating plates and keeping food wart .
NOTE
Take care when dosing the oven and fire doors to lift them on to the catch . The
doors should not be slammed shut, or this will wear away the metal retainer
catches
REMOVAL OF BOILER FOR CLEANING
(Instructions for Heating Engineers)
Turn dff the water from the main and drain the system . Disconnect
flow and
return pipes, and withdraw boiler through side of the cooker inspection panel,
and take out the insulating material on top and behind boiler . After replacing
boiler, repack the insulating material above and behind the boiler . Make good
with fire cement the joints between boiler and fire bricks . Re-make all pipe joints .
FIREBRICK REPLACEMENT
The firebricks fitted to 'Rayburn' Royal and Regent Cookers are of first quality
manufacture, and providing the cooker has been installed and used correctly
will have
a
reasonable life . They
are,
however, expendable items and in time will
require renewal .
The renewal of firebricks is not a major operation and can be carried out by
the average handyman . Replacement bricks either in sets or singly can be
obtained from your 'Rayburn' distributor . The bottom three bricks can be
removed and replaced without disturbing the remainder of the set . Always
quote the manufacturing number .
The Manufactureing number,
which will be found on a brass plate inside the
Roasting Oven, should be quoted if
any question arises in connection with the
Rayburn Cooker .
With Rayburn's policy of continuous product Improvement . the Company reserves the right to change
epeellkatione and make modtlcatbne to the appliance deeabed and Illustrated at any time .
PO Box 30 Kefley Telford Shropshire TF14DD
Telephone [phone] Telex 35196 Fax
[phone]
RLFIA 8189 (3) EWKO 33594