Rayburn Heatranger 460K User manual

This information refers to the following
products
Rayburn 460K, 480K,
499K
Open Flue MX models
Fitted with Nu-Way burners

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

12/00 EINS 511566-MX
[email protected]
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THIS APPLIANCE
For use in GB and IE
Installation
Instructions
Heatranger 460/480/499K
At the Heart of your Home
DESN 511593

Consumer Protection
As manufacturers and suppliers of cooking and heating products. We take every care to ensure,
as far as is reasonably practical, 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 examined before despatch.
IMPORTANT NOTICE: Any alteration that it is not approved by Aga-Rayburn 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.
2

3
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 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

Technical Data
4
BOILER BURNER
BURNER NOZZLE (US g/h) 0.55 @ 80˚EH 0.40 @ 80˚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 @ 80˚EH 0.40 @ 80˚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 @ 80˚EH
BOILER BURNER
10 (145)
58
35.2
29.3
29.5
COOKER BURNER
0.40 @ 80˚EH
10 (145)
28.5
17.6
3.1
499K

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
❐This appliance must only be used with
Kerosene 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
PERMANENTLY OPEN BYPASS LOOP should be
fitted.
❐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.
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 BS7671: 1992 (formerly IEE Wiring
Regulations), 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 Northern Ireland - Technical
Booklet to Part L. Heat producing appliances.
The Control of Pollution (Oil) Regulations.
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 “Installation of the Appliance”.
The space in which the appliance is to be fitted must have
the following minimum dimensions.
Between wall and LH side of appliance - 10mm
Between wall and RH side of appliance - 50mm
IF THE WALL PROJECTS BEYOND THE FRONT OF
THE APPLIANCE.
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.
Site requirements
5
REGULATIONS
LOCATIONINTRODUCTION

SEE FIG. 1
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 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. 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 150˚F, 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.
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.
Where the oil pipe connection is taken out at 90˚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 998422
CAT No: R3921
The kit is made up of the following parts:
Bulkhead Fitting
Flexi Hose
Return Oil Nipple
Bypass Screw
Two Pipe System Fitting Instruction - EINS 511614
Site requirements
6
OIL PIPE LINE OIL STORAGE
DESN 511613

Site requirements
7
FIG. 1
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
TWP-PIPE SYSTEM

SEE FIG. 2
The flue system must be installed with the regulations in
force.
Information
Maximum flue gas temperature 260˚C
(Both burners on)
Minimum flue gas temperature 125˚C
(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) - 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 multifuel
stainless steel flexible liner. Where it is necessary to
avoid condensation, such as an exposed end gable
insulation; such as vermiculite, should be back filled
between the flexible liner and the full length of the
brickwork.
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
8
FLUE SYSTEM
FIG. 2 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 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. 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 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.
9
Site requirements
AIR SUPPLY
460K 146.9 cm2
480K 179.2 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 (see Fig. 3) 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
10
WATER CIRCULATION SYSTEM
FIG. 3
Flow Litres (hour)
Pressure Drop (mb)
Hydraulic Pressure Loss Curve (MX)
●
●
●
99,000 Btu
(29kW)
80,000 Btu
(23.4kW)
60,000 Btu
(17.6kW)
227
2
2.5
3
3.5
4
4.5
453 680 755 1007 1246

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:-
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.
11
HEATING CONTROLS

Site requirements
12
Typical External Wiring with Honeywell 3 Port Mid Position Valve
For use with 460, 480K
Typical External Wiring with 2 Honeywell N.C. Motorised 2 Port Zone Valves
For use with models 460, 480, 499K
460/480/499K

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 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 (85˚C 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. 4) 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-Rayburn
recommend that only CE marked equipment is used in
conjunction with this appliance.
13
Site requirements
ELECTRICAL SUPPLY

14
Site requirements
FIG. 4
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 and LH side of appliance - 10mm
Between wall and RH side of appliance - 50mm
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. 5. 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. 6).
Installation requirements
15
CLEARANCES
PRELIMINARY INSTALLATION
FIG. 5
FIG. 6
DESN 510226
DESN 510454 A

SEE FIG 7 & 8
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. 7).
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:
Lowest baffles are stainless steel and must be kept in
this position. They 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.
8A).
Total number of baffles fitted:-
460 = 6 (2 x 3)
480 = 8 (2 x 4)
499 = 10 (2 x 5)
Installation requirements
16
SITE LOCATION
FIG. 7
FIG. 8
DESN 510523
DESN 511595

Installation requirements
17
FIG. 8A

18
SEE FIG. 9
1. Open the burner access door. Remove door and put
in a safe place.
2. Remove 2 inner panel securing screws and remove
panel.
3. Remove the 3 plinth securing screws and remove
plinth.
SEE FIG. 10
1. Make electrical connections to terminal strip as
wiring diagram (See Fig. 12).
SEE FIG. 11
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. 9 DESN 511578
DESN 511577
DESN 511611
FIG. 10
FIG. 11
BURNER ACCESS
OIL PUMP
ELECTRICAL CONNECTION
TERMINAL STRIP