Stanley DONARD 60K User manual

DONARD 60K GAS FIRED
To ensure safety, satisfaction and reliable service, this Cooker should be installed by a suitably qualified
and competent person. The provision of a Central Heating facility, requires that the hot water systems
involved, conform fully to good plumbing practice and established standards.
INSTALLATION AND OPERATING INSTRUCTIONS
TO BE LEFT WITH END USER
(SUPER STAR 60K GAS COOKER)

TABLE OF CONTENTS PAGE NO.
1. Introduction ....................................................................................................................................... 3.
2. Specification .......................................................................................................................................4
3. Technical Data .................................................................................................................................. 5.
4. Location ............................................................................................................................................ 6.
5. Electrical Supply ............................................................................................................................... 6.
6. Gas Pipes & Fittings ......................................................................................................................... 6.
7. Meters ............................................................................................................................................... 6.
8. Gas Pipe Size .................................................................................................................................... 6.
9. Hearth Construction .......................................................................................................................... 7.
10. Installation ......................................................................................................................................... 7.
11. Chimney’s .......................................................................................................................................... 7.
12. Pre-Installation Check........................................................................................................................ 7.
13. Sealing............................................................................................................................................... 7.
14. Flue Height..........................................................................................................................................8
15. Flues ................................................................................................................................................. 8.
16. Suitable Material ............................................................................................................................... 8.
17. Connections ...................................................................................................................................... 8.
18. Draught Requirements....................................................................................................................... 8.
19. Flue Cleaning..................................................................................................................................... 8.
20. Down Draughts ................................................................................................................................. 9.
21. Use of Existing Chimneys and Flues ................................................................................................ 9.
22 Factory Made Insulated Chimneys ................................................................................................... 9.
23. Flue Liner .......................................................................................................................................... 9.
24. Ventilation and Combustion Air Requirements ................................................................................ 10.
25. Outside Air Connection..................................................................................................................... 10.
26. Clearance to Combustibles .............................................................................................................. 11.
27. Gas Connection.................................................................................................................................12.
28. Heating .............................................................................................................................................12.
29 Water Pipe Fittings ............................................................................................................................13.
30. Plumbing Drawings............................................................................................................................13.
31. Safety Valve.......................................................................................................................................14.
32. S Plan Wiring Diagram......................................................................................................................14.
33. By Pass Loop ....................................................................................................................................15.
34. Airing Cupboard Layout.....................................................................................................................15.
35. Provision for Filling Sealed Systems.................................................................................................16.
36. Water Circuit Temperature.................................................................................................................16.
37. Pipe Thermostats ..............................................................................................................................16.
38. Care for your Central Heating System..............................................................................................16.
39. General Maintenance ........................................................................................................................17.
40. Servicing............................................................................................................................................17.
41. Draining..............................................................................................................................................17
42. Indirect Domestic Cylinder ................................................................................................................17.
43. Commissioning Procedures and Checks ..........................................................................................17.
44. Operation...........................................................................................................................................18.
45. Ovens................................................................................................................................................19.
46. Cental Heating...................................................................................................................................19.
47. Summer Setting.................................................................................................................................19.
48. Hotplate.............................................................................................................................................19.
49. Hotplate Insulating Covers ................................................................................................................19.
50. Cooking Utensils................................................................................................................................19.
51. Heating System Controls...................................................................................................................19.
52. Opening Cooker Door .......................................................................................................................20.
53. Cleaning ............................................................................................................................................20.
54. Mild Steel...........................................................................................................................................21.
55. External Automatic Time Switch........................................................................................................21.
1

2
PAGE NO.
56. Condensation ....................................................................................................................................21.
57. Ovens ................................................................................................................................................21.
58. Hotplate.............................................................................................................................................21.
59. Servicing & Cleaning of the Appliance..............................................................................................21.
60. Chimney Cleaning .............................................................................................................................22.
61. Burner Removal.................................................................................................................................22.
62. Wiring Diagram..................................................................................................................................23.
63. Wiring Diagram..................................................................................................................................24.
64. Trouble Shooting Guide.....................................................................................................................25.

Congratulations on purchasing this fine Irish made Gas-Fired Central Heating Cooker. It is built to exacting
standards and it will give you every satisfaction in use. We invite you to read carefully the operating and
installation instructions provided. This will enable you to familiarise yourself with this appliance.
In your own interest and that of safety, it is the law that all gas appliances are installed and commissioned by
competent persons in accordance with the Gas Safety Installation and Use Regulations 1998 (as amended).
Cookers can become very hot with use and retain their heat for a long period of time after use.
Children, aged or infirm persons should be supervised at all times and should not be allowed to touch
the hot surfaces or be in the vicinity when in use or until the appliance has cooled down after use.
This is a combination appliance capable of providing up to 17.6 kW (60,000 Btu’s/hr) to water. Space heating
to room in which the appliance is installed is 3.67 kW (12,000 Btu’s/hr) approximately.
The complete installation must be done in accordance with current Standards and Local Codes. It should be
noted that the requirements and these publications may be superseded during the life of this manual.
3
INTRODUCTION
1. Plate rack (to order)
2. Splash back (to order)
3. Hotplate Covers
4. 150mm (6”) 90° Bend
5. Bend Cleaning Plate
6. Hob
7. Towel Rail
8. Fire Door
9. Burner Door
10. Main Oven Door
11. Simmer Oven Door
12. Base Frame
13. Hotplate
14. Simmer and Cleaning Plate
15. Boiler Thermostat
16. Oven Thermostat
17. Green Neon Indicator Light
18. Reset Button / Limit stat
19. Red Lock Out Light
IMPORTANT - CONTROL OF SUBSTANCES HARMFUL TO HEALTH
It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn when
handling materials that could be interpreted as being injurious to health and safety.
When handling Firebricks & Fire Cement, use disposable gloves. Exercise caution and use disposable masks
and gloves when handling glues and sealants. When working with fibre glass, mineral wool, insulation
materials, ceramic blanket/board, avoid inhalation as it may be harmful. Avoid contact with skin, eyes, nose and
throat, use disposable protection. Installation should be carried out in a well ventilated area.
Note: These instructions are only valid if the country symbol appears on the appliance. If the symbol does not
appear on the appliance, it is necessary to refer to the technical instructions concerning modifications of the
appliance to the conditions of use of the country.
The manufacturers reserve the right to make alterations to design, materials or construction for manufacturing or other reasons subsequent to publication.
0063
U.K.: ALL GAS APPLIANCES MUST BY LAW BE
INSTALLED BY A COMPETENT PERSON, ONLY
USE A C.O.R.G.I REGISTERED ENGINEER.
IRELAND: ALL GAS APPLIANCES MUST BE
INSTALLED BY A COMPETENT PERSON AS
OUTLINED IN I.S. 813.

4
DIMENSIONS A B C D E F G H J K L M N
METRIC 915 920 530 560 300 1047 130 325 525 190 1475 1” BSP 150
(millimetre)
IMPERIAL 36 361/420 7/ 8 22 11 3/ 4 411/ 4 51/8 123/4205/8 71/258 1”BSP 6
(inches) Female
FEATURE METRIC IMPERIAL
HOT PLATE 555 x 325 22 x 13
ROASTING OVEN 400W x 320H x 410D 16W x 121/2H x 16D
SIMMERING OVEN 400W x 225H x 410D 16W x 9H x 16D
SPECIFICATION
This appliance has been tested and approved in accordance with the Gas Appliance Directive (90/396/EEC),
the Low Voltage Directive (72/23/EEC) and the Electromagnetic Compatibility Directive (89/336/EEC) as
amended.
Differential Pressure Across the Boiler
Note: Water temperature rise for above test recorded at 16°C.
Design flow rate through the boiler 23 Litres / min. (G.P.M)
Static differential across the boiler 52 mbar (21” W.G.)
Dynamic pressure differential across the boiler 6 mbar (2.41” W.G.)
Note: dimensions stated below may be subject to
a slight +/- variation

5
TECHNICAL DATA
FUELS: N.G. 2nd Family, Natural Gas.(I.E., G.B., F.R., A.T., D.K.,E.S.,
F.I., I.T., P.T. & S.E)
L.P.G. 3rd Family, L.P.G.(I.E., G.B., B.E., F.R., E.S., & P.T.)
PRODUCT IDENTIFICATION NO: 63AQ8500
COUNTRY OF DESIGNATION: I.E. & G.B., B.E., A.T., D.K., E.S., F.I., I.T., P.T., S.E., & F.R.
GAS TYPES: N.G. I2H, G20, 20 mbar & I2E+ (F.R. Only)
L.P.G. I3P, G31, 37 mbar
MAINS GAS PIPE: N.G. min.13mm 1/2” BSP capable of 90 ft3/hr from a domestic
regulator.
L.P.G. min. 13mm 1/2” coated copper capable of 45 ft3/hr from an
approved L.P.G. - Propane regulator.
MAINS CURRENT: 230V - 240V, 50 Hz, A.C.
SUPPLY FUSE RATING: 3A
IONISATION CURRENT: Minimum of 7µa.
IP PROTECTION DEGREE: IP 20.
ELECTRICAL INPUT: 90 watts.
MAINS GAS PRESSURE: N.G. 20 mbar 8” wg
GAS RATE: 2.3 m3/hr 81 ft.3/hr
L.P.G. 37 mbar 14” wg
FAN PRESSURE: 2.5 mbar 1” wg
MAXIMUM FLUE RESISTANCE: 0.8 mbar 0.32” wg
MANIFOLD PRESSURE: N.G. 14.9 mbar 6” wg
L.P.G. 7 mbar 2.8” wg
GROSS INPUT: 24.9 kW 85,000 Btu/hr
NET INPUT: N.G. 22.5 kW 76,811 Btu/hr
L.P.G. 23 kW 78,476 Btu/hr
BOILER OUTPUT: 17.6 kW 60,000 Btu/hr
SPACE HEATING: 3.67 kW 12,000 Btu/hr
BOILER CONSTRUCTION: 6mm & 4mm mild steel plate
BOILER TYPE: B23
MAX. BOILER WORKING PRESSURE: 1.9 Bar 27.3 P.S.I.
TEST PRESSURE OF BOILER: 2.7 Bar 40 P.S.I.
OPERATING TEMP. LIMIT IN BOILER: 96°C 205oF
BOILER CAPACITY: 9.1 Litres 2.5 Gallons
COOKER WEIGHT: 364kgs 800 lbs
Whilst the primary air and gas rate on this appliance have been set, combustion tests and the gas rating must
be undertaken, during commissioning and adjusted accordingly.
NOTE: This appliance shall be installed in accordance with the regulations in force and only used in a well
ventilated location. Read the technical instructions before installing this appliance. Read the user’s
instructions carefully before lighting this appliance.
As manufacturer’s and suppliers of cooking and heating appliances, we take every possible care to ensure, as reasonably practicable, that
these appliances are so designed and constructed as to meet the general safety requirement when properly used and installed.
United Kingdom Ireland
*Section 10 of the Consumer Protection Act. * Safety Health and Welfare at Work Act 1989.
*Gas Safety (Installation and Use) Regulations 1998 (as amended) * S.I. 101 of 1992 (as amended).
* Gas Appliance Safety Regulations (as amended). * S.I. 150 of 1995 (as amended).
*Health and Safety at Work Act. * I.S. 813 (as amended).
IMPORTANT NOTICE: Any alteration to this appliance that is not approved in writing by Waterford Stanley, will render the guarantee void.
The installation must comply with the following:
The Building Regulations: Part J England & Wales., Part F Section 5 Scotland, Part L Northern Ireland and Part J Ireland.
B.S. 5449: Forced circulation hot water central heating system for domestic installation.
B.S. 7671: Requirements for Electrical Regulations.
Safety Document 635: The Electricity at Work Regulations. I.S. 813 : Domestic Gas Installation
B.S. 7074 Part 1 & 2: Hot Water Supply. B.S. 5440 Parts 1 & 2 Installation & maintenance of flues and
B.S. 4814: Sealed Systems. ventilation
B.S. 6891 Gas Pipe Sizing B.S. 7593 Treatment of water in domestic hot water systems
PAS 33 : 1999: Product Assessment Specification for Design,
Installation & Commissioning of Gas Fired Central Heating
Systems in Domestic Premises.

6
LOCATION
Prior to installation, ensure that the local distribution
conditions (nature of the gas and gas pressure) and
adjustment conditions are compatible. The
adjustment conditions for this appliance are stated
on the data badge which is fitted inside the bottom
burner door.
When choosing a location for this appliance you
must have:
(a) Sufficient room for the installation (see
clearances), a satisfactory flue, and an
adequate air supply for correct combustion and
operation. (See Ventilation & Combustion Air
Requirements).
(b) Adequate space for maintenance and air
circulation.
(c) Solid floor or base of non-combustible material
which is capable of supporting the total weight
of the appliance. (see Technical Data).
ELECTRICAL SUPPLY
All wiring external to the appliance must conform to
the current BS 7671, B.S. 7462, Safety Document
635, ETC: Part 1 section 5.4.6. & The Electricity at
Work Regulations. The cooker requires a 230V -
240V, 50Hz supply. Connection of the appliance
and any system controls to the mains supply must
be through a moulded on plug top, (with a 5?Amp
fuse fitted), which is fitted to the appliance in
accordance with EN 60335, Consumer Protection, -
S.I. 1994 No. 1768, plug and sockets etc. (safety)
Regulations 1994.
Always install in accordance with current local
wiring regulations.
WARNING: THIS SUPPLY AND APPLIANCE
MUST BE EARTHED (Refer to B.S. 7430 Code
of Practice for Earthing)
Where a risk of low voltage can occur, a voltage
sensitive device should be fitted to prevent start up
of the burner so as not to endanger the installation.
(see fig. 30)
To isolate the appliance completely, unplug from the
mains socket. Always ensure that this socket is
easily accessible and close to the appliance.
Persons in charge of this appliance should be aware
of this socket outlet position.
GAS PIPES AND FITTINGS
Materials used for installation work should be fire
resistant and gas tight and should conform to the
following or their equivalent:
*B.S. 2871 Part 1 & pr EN 1057 - Copper Tubes.
*B.S. 219, EN 29453 & ISO 9453 - soft solders.
*B.S. 759 - Valves, gauges and other safety
equipment.
*B.S. 1387 - Steel tubes.
* B.S. 6362 & B.S. 4127 - Stainless steel tubes.
* B.S. 1552 - Manual Shut of valves.
*B.S. 1740 - Wrought steel pipes.
*B.S. 5295 & B.S. 6956 Jointing Materials.
* B.S. 4089 - LPG hoses and assemblies.
METERS
A suitable gas meter must be connected to the
service pipe either by a representative of the gas
board or by an appointed contractor. If using an
existing meter have it checked to ensure that the
meter is capable of dealing with the total rate of gas
supply needed. (See Technical Data).
GAS PIPE SIZE
It is important that the correct service pipe size be
used in order to ensure an adequate gas supply.
This depends on the distance between the supply
meter, the pressure drops caused by bends and the
expected pressure drop in the gas mains at peak
demand times.
NOTE: The Donard has an input rating of 24.9 kW
(85,300 Btu’s/hr) approximately. See BS 6891. (If
in doubt consult your gas supply company)
A3/4” gas shut off valve, which does not cause a
restriction in flow or a pressure drop when open,
must be fitted as close to the appliance as possible.
This tap should be accessible at all times.
Fig. 1
WARNING: To avoid pipe sealing compounds from
entering into the gas train, do not apply sealing
compound to the first two threads at the tip of the
gas connection.

HEARTH CONSTRUCTION
When a non-combustible floor surface is not available then we recommend that the cooker be placed on a slab
of pre-cast concrete 40mm (11/2”) deep or a slab of other insulating material. This hearth must extend (150mm)
6” to either side of the appliance and (225mm) 9” to the front. The cooker must stand on a flat surface.
INSTALLATION
Flue Liner greater than (150mm) 6” Diameter 150mm (6”) Salt Glazed Earthenware Flue &
Purposely Made Pre-cast Sealed Concrete
Chimney’s
CHIMNEYS
Generally the most effective chimney for gas is one
that is straight, avoid offsets and terminate an
approved low resistance flue terminal.
Fig.2
Fig.3
Fig.5 Fig.6
SEALING
This cooker and flue system operate under a
positive pressure, it is essential that all flue joints
are tightly sealed against flue gas leakage and
tested accordingly (see figs. above).
PRE-INSTALLATIONCHECK
Before installing your appliance, check
that the chimney is clean and clear of
obstructions. Cracked brick-work and
leaking joints should be made good.
IT IS RECOMMENDED TO CONNECT
TO A FLUE OF 150mm (6”).
Note: Fill voids and area around liner
with vermiculite or a comparable
approved material. (See figs. above).
7
Fig.4
Fig.6a Fig.6b
Vertical Flue
Adaptor (not
included)

8
The height of the chimney or flue serving this
appliance should not be less than 4m (13’)
measured vertically from the appliance outlet to the
top of the flue terminal, and having a diameter of
150mm (6”). The terminal position should be in
accordance with B.S. 5440 Part 1 and the Building
Regulations.
FLUES
The chimney and flue pipes intended for use with
this appliance should be mechanically robust,
resistant to internal and external corrosion, non-
combustible, and durable under the conditions to
which they are likely to be subjected.
Flues require a suitable external terminal which
should be designed to permit easy ingress of
combustion products whilst providing protection
against the entry of rain, birds and other foreign
matter into the system. Flue pipes and accessories
such as clips and stays should not be made of
unprotected mild steel or other material which is
likely to corrode.
Where flue piping passes through a closure plate
with a sliding door, ensure that the pipe continues up
and is ultimately connected to the flue liner and well
sealed with fire cement.
Do not connect to a chimney serving another
appliance. Always ensure that the connection is to
a chimney of the same size. Chimneys wholly
constructed of single skin pipe are not
recommended under any circumstances. Due to
their inability to retain heat such chimneys will
inevitably give rise to the formation of condensation.
(see figs 2,3,& 4).
SUITABLEMATERIAL
*Mineral Fibre cement pipes conforming to B.S.
7435.
*Sheet metal conforming to B.S. 715 & B.S. 4076.
*Insulated metal chimneys conforming to B.S.
4543 and B.S. 5440 (a galvanised finish is not
suitable).
* Clay flue linings conforming to B.S. 1181.
*Pre-cast concrete chimney blocks, incorporated
into the building structure. It is particularly
important that the correct connection block be
provided at the base of the flue. B.S. 3572. (see
fig 3)
*Cast iron or acid resistant vitreous enamel lined
mild steel to B.S. 41.
CONNECTIONS
This appliance can either be connected to an
approved masonry chimney or gas flue. This
appliance may be connected either direct vertical or
horizontal.
A cast iron 90° bend with cleaning door is provided
with the cooker. A vertical cast iron outlet pipe with
cleaning door is available to order. (See Figs. 5 & 6)
ALL FLUE CONNECTIONS MUST BE
THOROUGHLY SEALED. Blocked chimneys are
dangerous, keep chimneys and flueways clean; read
the operating instructions.
STANLEY CAST IRON PIPES AND BENDS ARE
HIGHLY RECOMMENDED FOR INTERIOR USE.
(see fig. 5 & 6)
NOTE: Maximum horizontal length should not be
more than 300mm (12”).
WHERE THE APPLIANCE SPIGOT OR FLUE PIPE
PROTRUDES INTO THE CHIMNEY, CARE
SHOULD BE TAKEN TO ENSURE THAT IT DOES
NOT BLOCK THE CHIMNEY.
DRAUGHT REQUIREMENTS
While inadequate draught can seriously effect the
efficient operation of the appliance, chimneys over
(5.4m) 18ft. or houses built on high ground can
experience excessive draught. The accepted
draught reading for satisfactory operation is 1.5mm
min. (06.” w.g.) 2.5mm max. (0.1” w.g.).
FLUE CLEANING
The flue pipe must be fitted with a cleaning plate,
the flue must be inspected annually and cleaned
when necessary.
Fig. 7
Note: Never connect to a chimney or flue
system serving another appliance.
FLUE HEIGHT
If it is necessary to offset the chimney, the
recommended angle is 60° to the horizontal and the
statutory minimum is 45°C.

9
DOWN DRAUGHTS
However well designed, constructed and positioned,
the satisfactory performance of the flue can be
adversely affected by down draught caused by
nearby hills, adjacent tall buildings or trees. These
can deflect wind to blow directly down the flue to
create a zone of high pressure over the terminal.
A suitable anti-down draught terminal or cowl will
usually effectively combat direct down blow but no
cowl is likely to prevent down draught due to a high
pressure zone. (see fig. 8) Ensure that any cowl
used will not restrict the flue exit, or cause excessive
back pressure, Refer to B.S. 5440: Part 1.
condition, and dimensions are acceptable. Flues
that have proved to be unsatisfactory, particularly
with regard to down draught, must not be considered
for this appliance until they have been examined and
any faults corrected. If there is any doubt about an
existing chimney a smoke test to B.S. 5440: Part 1
should be carried out.
Before connecting this appliance to a chimney or
flue pipe which has previously been used with
another fuel, the chimney or flue pipe must be
thoroughly swept and lined accordingly.
All register plates, restrictor plates, damper etc.
which could obstruct the flue at a future date must
be removed before connecting this appliance.
Where a chimney is not to be lined a suitable void
must be provided at the base to contain any debris
which might fall from the inside wall, so as to prevent
that debris from obstructing the appliance flue outlet.
(Removal of debris should be facilitated by the
provision of an access door). The void should have
a depth of not less than 250mm (10”) below the
appliance connection.
The combustion products from this appliance will
have a descaling effect on hardened soot deposits
left from burning solid fuels.
ALTHOUGH THE CHIMNEY MAY HAVE BEEN
CLEANED OF LOOSE SOOT PRIOR TO
INSTALLATION, IT IS IMPERATIVE THAT THE
CHIMNEY IS INSPECTED FOR SCALED SOOT
PARTICLES AFTER THE FIRST MONTH OF
OPERATION AND ANY LOOSE MATERIALS
REMOVED TO AVOID BLOCKAGE.
FACTORY-MADE INSULATED CHIMNEYS
Factory-made insulated chimneys should be
constructed and tested to meet the relevant
standards and recommendations given in:
*B.S. 7566 – Installation of factory-made chimneys
conforming to B.S. 4543 for domestic appliances.
Part 1: Method of specifying installations design
information.
Part 2: Specification for installation design.
Part 3: Specification for site installation.
Part 4: Recommendation for installation design
and installation.
FLUE LINERS
Chimney’s lined with salt glazed earthenware pipes
are acceptable if the pipes comply with BS 1181 and
must be 150mm (6”). When lining an existing
chimney, a liner approved to BS 715 & B.S. 4543
Parts 1, 2 & 3 should be used.
The liner should be secured at the top and bottom
using a closure/clamping plate, firmly sealed and
Fig.8
USE OF EXISTING CHIMNEYS AND FLUES
When connecting to an existing chimney it is
necessary to line the flue using either 150mm (6”)
rigid or flexible stainless steel liner. An existing flue
pipe or chimney that has proved to be satisfactory
when used for solid fuel can normally be used for
this appliance provided that its construction,