AGA Rayburn G7 NP installation and servicing manual Owner's manual

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Rayburn G7 NP Installation & Servicing Manual | Manualzz
WARNING
This information is a copy of an original archive,
therefore Aga-Rangemaster cannot be held
responsible for its continued accuracy or relevance
Installation and Servicing
Instructions for Rayburn
Royal G7 Gas-Fired Cooker
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
examined before despatch.
IMPORTANT NOTICE: Any alteration that is not approved by
Rayburn, could invalidate the approval of the appliance, the
warranty and could also infringe the current issue of the
statutory requirements.
Control of Substances - Health and Safety
Important:
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, Fuel beds, 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 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.
“INTRODUCTION
The Rayburn Royal G7 Gas Cooker is a combined
cooker and domestic hot water heater.
It is available in Open Flue form only, operating on
natural draught, the boiler being designed for use on an
open vented water system only, operating with gravity
D.H.W. primaries. Ней
The appliance is available with Right hand oven and
Right hand flue outlet only. |
These appliances are suitable for either Natural or
L.P.G. gases dependant upon model type, an
Independently controlled gas burner provides heat to
the cooker and domestic hot water only.
TECHNICAL DETAILS
Boiler Water Connections
Flow Rp 1 (1in BSP Int)
Return Rp 1 (1in BSP Int)
Both connections are located towards the rear edge of
the appliance L.H. side panel.
Gas Connections
Flue Outlet Dia.
Min Working
Hydraulic pressure
of boiler |
Max Working =
Hydraulic pressure —
of boiler
Weight of —
Appliance ==
RPX% (%in BSP Int)
102mm (4in Int)
0.23 bar (3.4 psi)
1.75 bars (25.75psi)
318kg (7001b)
‘Cooker Cooker
LOW HIGH
Heat Input | KW 2.8 8.3
Btu/h 9,500 28,500
Heat Output | KW 0.73 2.6
Water Btu/h 2,500 9,000
Burner Nat | mbars — 13.5
Pressure Gas Tp —_ 54
PG | Mbars — 37.0
In w.g — 14.8
Burner Nat. Gas 2.37mm (0.0935in)
Injector Size LPG 1.498mm | (0.0595in)
INSTALLATION INSTRUCTIONS
The installation of the appliance must be in accordance
with the relevant requirements of the current Gas Safety
(Installation and Use) Regulations, Building Regulations,
Building Standards (Scotland) Regulations, Current |.E.E.
Wiring regulations and the bylaws of the local Water
Undertaking.
The installation should also be in accordance with any
relevant requirements of the local Gas Region and Local
Authority and the relevant recommendations of the
following current British Codes of Practice:-
BS6891 Installation of pipes and meters and low pressure
installation pipes.
BS5376 Selection and installation of gas space heating.
Part 2. Boilers of rated input not exceeding
6OkW. |
BS5546 Code of Practice for installation of gas hot water
supplies for domestic purposes (2nd family
gases).
BS5440 Flues and air supply for gas appliances of rated
input not exceeding 60k.
Part 1. Flues. Part 2. Air Supply.
BS6172 Code of Practice for installation of domestic
cooking appliances.
WP 1/93 EINS 33704
1 BSP.
FLOW
1 BSP
Fig. 1 RETURN CON ‘
mm Ins
A 840 33
B 848 335/16
G 820 327/4
D 1245 49
E 455 18
F 510 20
G 65 25/8
H 95 23/4
J 95 33/4
K 32 11/4
L 180 7
M 90 31/2
N 55 21/4
P 320 125/8
R 305 12
S 995 391/4
ke
E 4" B.S.P. FEMALE GAS CON.
Appliance - Hearth
The appliance must be installed on a solid level floor or
hase of incombustible material which is capable of
supporting the total weight.
Location
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 air circulation around
the appliance. See "Installation of Appliance”
General.
GAS SUPPLY
Meters
New gas meters should be connected to the service
pipe by the local Gas Region or a local Gas Region
contractor.
An existing meter should be checked, preferably by the
Gas Region, to ensure that the meter 1s adequate to
deal with the total rate of gas supply required.
Installation Pipes
Installation pipes should be fitted in accordance with
BS6891. Pipework from the meter or tank to the
appliance must be of adequate size. Do not use pipes
of a smaller size than the appliance gas connection.
The complete installation must be tested for soundness
and purged as described in the above Standard.
FLUE SYSTEM:
Detailed recommendations for fluing are given in BS
5440:1.
The following notes are intended to give general
guidance:
The cross-sectional area of the flue must be not less
than the area of the flue outlet of the cooker. The
height of the flue must be at least 3m (10ft) high from
the floor level. If flue pipe is used it must be not less
than 102mm (4in) internal diameter.
Flue pipes and fittings should be constructed from one
of the following materials:-
(a) Cement to BS 576.
(b) Aluminium or stainless steel BS 715.
(c) Cast iron mild steel to BS 41 acid resistant vitreous
enamel lined. |
Ensure that any intended chimney is swept and is free
of obstruction.
The flue should terminate in accordance with the
relevant recommendations given in BS 5440:1 Table 4.
The point of termination must not be within 600mm
(2ft) of an operable window, air vent or any other
ventilation opening.
Air Supply
Detailed recommendations for air supply are given in
BS 5440:2.
The following notes are intended to give general guidance :-
Kitchen or Internal Space Air Supply
Wherever an open flue appliance is to be installed it
must have a permanent air vent. This vent must be
either direct to outside air or to an adjacent room or
internal space which must itself have a permanent air
vent of at least the same size direct to outside air.
The minimum effective area of the permanent air vent
In the outside wall must be 37cm? (5.8In%).
Effect of an Extract Fan
If an extractor fan is fitted in the same room as an open
flue appliance there is a possibility that if adequate air
inlet area from outside is not provided, spillage of the
oroducts from the appliance flue could occur when the
extract fan is in operation. Where such installations
occur, a spillage test as detailed in BS 5440:1 must be
carried out as follows: By holding a smoke match so
that the flame is approximately 3mm (4") up the inside
the lower edge of the draught diverter.
Spillage is indicated by the smoke being displaced
outwards from the draught diverter. Any necessary
remedial action must be taken.
WATER CIRCULATION SYSTEM
Detailed recommendations for the water circulation
system are given in BS 6700:1987.
The following notes are of particular importance:-
1. Pipework should be insulated to help prevent heat
loss and possible freezing, particularly where pipes are
run through roof space and ventilated under floor
spaces. Cisterns situated in areas which may be
exposed to freezing conditions should also be
Insulated.
2. Draining taps must be located in accessible positions
to permit the draining of the whole system. Including
the appliance and hot water storage vessel. Draining
taps should be at least 4in BSP nominal size and be in
accordance with BS 2879.
3.The appliance boiler section should be connected to a
cistern water supply, subject to a maximum head of
18.25m (60ft), and water carrying copper tubes should
be to BS 2871:1.
4. The hot water storage vessel should be insulated,
preferably, with not less than 75mm (3in) thick mineral
fibre, or its equivalent.
The cast iron boiler can be supplied, vitreous enamelled
internally for use in some soft water areas. Vitreous
lined boilers can be used in conjunction with a direct cylinder.
The use of horizontal pipe runs should be avoided
wherever possible in order to prevent the collection of
air in the system. If horizontal runs are unavoidable, the
pipes should rise upwards in the direction away from
the appliance.
Hot Water Storage Vessel
It is recommended that an indirect 140 litre (30 gallon)
hot water storage cylinder of the double feed type
complying with BS 1566 Part1: DF Type 8, should be
lagged and fixed vertically as near as possible to the
appliance.
The water draw-off pipes to the taps must be dead leg
connection from the vent/expansion pipe. A drain tap
must be fitted at the lowest point of the system.
FLAT FACE TO
BE FACING REAR
| ADJUSTMENT SCREWS MUST BE
FITTED AS SHOWN AT ALL TIMES
~~] TO ENSURE SAFE OPERATION OF
THE COOKER.
TEST HOLE
TO BE FACING
FRONTWARDS
22mm OPEN VENT
EXPANSION
OVERFLOW |
OVERFLOW Е
OPEN VENT
COLD WATER
CISTERN
CISTERN NC DRAW OFF
и
!
|
!
!
uy
FE
= 225 COLD FEED
x
CYLINDER fe
DRAIN COCK
18mm COLD FEED 28mm FLOW & RETURN
FLOW
RETURN |‘
Fig.3 - Typical Gravity System
INSTALLATION OF APPLIANCE |
General
The appliance is floor-mounted and the space in which
the minimum clearances for servicing/instaliation must
have the following:
Between wall and L.H. side of appliance
150mm (бп)
Between wall and R.H. side of appliance
25mm (Min)
Above the raised insulating cover handle
75mm (3in).
Fig.4 - Clearance Between
Cooker and Combustible Wal
Ve COMBUSTIBLE WALL LINE
BRACKETS SCREWED TO
BACK EDGE OF BOTH SIDE
PLATES WHEN COMBUSTIBLE
WALL IS UTILIZED ON
INSTALLATION
INSTALLATION 1
150mm (6")
115mm и FLUE LINERS - TO BE NOT
(45) TTT LESS THAN 100mm (4") DIA IF
| 1. SMOOTH BORE OR 125mm
(5') DIA IF CORRUGATED TYPE |
REGISTER PLATE
SEALED TO BRICKWORK
CAST IRON SEALING
COLLAR WITH
FIBRE ROPE SEAL
> Cl FLUE PIPE
L 100mm (4) I/DIA |
RAR ия SS
25mm (1") MIN THICKNESS
OF NON-COMBUSTIBLE
MATERIAL BEHIND APPLIANCE
150mm (6") MIN FOR
ACCESS TO GAS SUPPLY
Fig.5
INSTALLATION 2
1" (25mm)
CLEARANCE
INSTALLATION 3
FLEXIBLE LINER 115mm 115mm
SEALED TOCIPIPE (4.5) (4.5)
125mm (5") DIA Tr
25mm (1") NON-
N— COMBUSTIBLE MATERIAL
FLUE LINERS TO BE NOT LESS
THAN 100mm (4") DIA SMOOTH
BORE OR 125mm (5") DIA IF
CORRUGATED TYPE
REGISTER PLATE
SEALED TO
BRICKWORK
~ 600mm
OF STRAIGHT
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 (lin) to combustible materials and where
passing through a combustible partition sleeve
providing an air space of at least 25mm (1in).
Spaces around the flue pipes passing through walls or
floors should be sealed against the passage of smoke
and flame.
Preliminary Installation
The appliance is delivered in a fully assembled condition
with the exception of the following items which are
supplied separately packed and require assembly.
1. Draught Diverter Assembly - See Fig 2.
2. Appliance Rear Distance Bracket - (For use when
appliance is installed 25mm (1in) away from a rear wall
of combustible material.) See Fig 4.
3. Insulating Covers.
4. Handrail & Brackets.
Wherever possible, it is recommended that 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 air gap.
(Combustible walls excepted).
Site Location
1. Remove the appliance assembly from its 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 crowbar) and insert a 1in BSP x
Tm 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 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 corner of the appliance
base plate, take the weight of the appliance on the
crowbar and remove the rear roller tube, followed by
similar action on the front tube.
NOTE: IF THE REAR WALL IS OF COMBUSTIBLE
MATERIAL, THERE MUST BE AN AIR GAP OF 25mm
(1in) BETWEEN THE WALL AND REAR OF
APPLIANCE. FIT REAR DISTANCE BRACKET AS
SHOWN IN FIG .4.
2. Assemble and locate the flue draught diverter
assembly on the top plate. See Fig.2.
3. Fit a 600mm (24in) minimum vertical height of flue
pipe into the draught diverter flue socket, sealing joint
with fire cement.
NOTE: IT IS RECOMMENDED THAT THE VERTICAL
FLUE PIPE, FITTED INTO THE DRAUGHT DIVERTER
SOCKET, HAS AN INTEGRAL CLEANING COVER
FITTED, TO FACILITATE CLEANING OF THE FLUE
PIPE.
4. Connect an terminate the flue system in accordance
with standard practice. See Fig.b.
5. Insulating covers are placed in position and their
chrome hinge spindle inserted and held in position with
the circlips provided.
6. 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 into the brackets, positioning them correctly,
and tighten the locating bolts.
Boiler Inspection
Remove the hotplate and ensure the internal face of
the boiler has been sealed to the combustion chamber
with fire cement.
Gas Installation
1. Connect the gas supply to the integral union gas
service cock on the appliance.
2. Test the whole of the gas installation, including the
meter for soundness and purge in accordance with the
recommendations in BS.6891.
Water Connections
The two Rp1 (1in BSP int) flow and return connections are
located towards the rear edge of the appliance left hand
side panel, and pipe connections should be made with R1
(Min BSP ext) x 28mm dia copper compression fittings.
Gravity Domestic Hot Water
The 28mm O.D. primary flow pipe must rise
continuously from the boiler section to the cylinder to
ensure good gravity circulation and extended to provide
an open vent. The 28mm O.D. primary flow and return
pipes must not exceed 10m (30ft) in length. Pipe runs
In excess of bm (15ft) must be lagged.
COMMISSIONING AND TESTING
Water Circulating System
The boiler/cylinder system should be thoroughly
flushed out with cold water and checked for water
soundness. Refill system and check that all air locks are
cleared.
The whole gas installation must be inspected and
tested for soundness and purged up to the appliance
gas cock in accordance with the recommendations of
BS 6891.
Commissioning and Lighting the Cooker
1. Turn oven control knob A to the OFF position.
2. Open outer burner door B and lift off inner
combustion chamber C.
3. After ensuring gas is available to the appliance, undo
the union at the appliance gas service cock D, open the
cock D and purge any air within the supply pipe.
WARNING: NO SMOKING OR NAKED LIGHTS
Close the appliance gas service cock D and remake the
union, turn gas service cock D to ON, and test for gas
soundness, using suitable leak detection fluid eg. a
soap solution and sense of smell to locate any gas
leaks.
A procedural check is necessary on the appliance to
ensure that all gas joints have remained in contact after
despatch from works and installation as follows:-
4. (a) Turn gas service cock D OFF.
(b) Disconnect the main burner inlet connection and
pilot union connection at the front of the burner
chamber.
(c) Lift up front of burner and draw forward carefully to
disengage support foot from baseplate location.
Withdraw the burner until flame failure device probe is
accessible in pilot light assembly.
(d) Carefully prise open, the keyhole slot at the rear end
of the bracket, disengage rope and remove burner.
(e) Lift out combustion chamber base plate to expose
gas controls.
(f) Plug or blank the end of the pilot light H feed tube,
then turn the gas service cock D ON.
(g) Test for gas soundness at all incoming joints to
flame failure device via gas governor, using suitable
leak detection fluid eg. soap solution and sense of
smell to locate any gas leaks.
(h) Without fitting the combustion chamber baseplate,
remove pilot plug and refit the main burner and pilot in
reverse order of removal.
(1) Light the pilot light only and confirm gas soundness
at pilot inlet connection and inlet of gas control tap A.
(1) Turn the gas control tap to HIGH and confirm gas
soundness at outlet of gas control tap A and inlet of
main burner K. |
(k) Turn gas service cock D and control tap A to OFF,
disconnect main burner K and re-locate the combustion
chamber base plate. Re-assemble gas burner in reverse
order of removal.
Cooker Control
1(a) Ensure appliance gas service cock D is ON with its
squarehead slot in line with the pipework. See Fig.6.
Gas will now flow to the pilot light.
(b) Light pilot H with a match or lighted taper.
NOTE: SOME AIR MAY BE PRESENT IN PILOT
SUPPLY TUBE. PURGE BY SLACKENING OFF PILOT
BURNER TUBE NUT 1 (fig.6) AT PILOT BURNER, AND
THEN RE-TIGHTEN.
(c) Inspect pilot flame which should envelope probe tip
J (for about 20mm flame length) of the flame failure
device, until it glows a dull red.
(d) Push in and turn cooker control knob A from OFF to
LOW.
The main burner K should cross-light smoothly from the
pilot light.
(e) Turn cooker control knob A from LOW to HIGH
observing the change in flame pattern and main burner
flame height, then test for gas soundness at all joints
above the combustion chamber base. Use suitable leak
detection fluid, eg. soap solution and sense of smell
where possible to locate gas leaks.
Fig.6
. COOKER CONTROL KNOB
. OUTER BURNER DOOR
. INNER COMBUSTION DOOR
. SERVICE COCK
. PILOT BURNER
THERMOCOUPLE
. BURNER
. TEST NIPPLE
. ADJUSTMENT SCREW
. FLAME FAILURE BUTTON
DESN 510191
<= Гот ОР в
Z
(f) Turn cooker control knob A to the OFF position and
turn appliance gas service cock D to OFF with head slot
across the pipework.
(g) Replace inner combustion chamber door C.
LIGHTING INSTRUCTIONS
Before lighting, ensure cooker control knob A is in the
OFF position.
Lighting Main and Pilot Burner
1. Open outer burner door B, lift off door C and turn
slotted head of appliance gas service cock D until slot is
positioned in line with pipework. (open)
2. Push in and hold red flame failure button 'N" and light
the pilot 'H' with a taper, continue to hold red button
for at least 15 seconds. Pilot should remain alight when
released. If it does not WAIT 3 MINUTES and repeat
sequence.
3.Remove sealing screw from main burner test nipple
L, fit gas pressure gauge.
4. Push in and turn cooker control knob A from OFF to
LOW. The main burner K should cross-light from pilot
light.
Replace combustion chamber door C.
5. Turn control knob A from LOW to HIGH, and after 10
minutes, check that the gas pressure conforms to the
pressure as indicated on the data plate.
6. Check that the main burner gas pressure Is
maintained and unaffected when other gas appliances
are used.
NOTE: IF FOR ANY REASON A GAS RATE CHECK IS
REQUIRED, TURN OFF ALL OTHER GAS
APPLIANCES, AND USING THE GAS METER TEST
DIAL AND WATCH TIMER, CHECK THAT THE
MAXIMUM GAS INPUT TO THE APPLIANCE IS AS
INDICATED ON THE DATA PLATE. (BS 6798:1987
GIVES FULL DETAILS CF THE METHOD).
7. Any adjustment of gas pressure can be obtained by
the removal of the blanking piug covering the
adjustment screw M (fig.6) on the appliance gas
governor below the combustion chamber.
8. Check that there is no spillage of combustion
products from the appliance down-draugnt diverter by
carrying out a spillage test as detailed in BS 5440:1. ie.
By holding a smoke match so that the flame is
approximately 3mm (%) up inside lower edge of the
draught diverter. Spillage is indicated by the smoke
being displaced outward from the draught diverter.
Inspect flame pattern and appearance of burner at high
fire to establish that there is adequate air for combustion.
9. Turn the control knob A to OFF and remove the
pressure gauge from the burner test nipple, then
replace the sealing screw.
10. Replace inner combustion chamber door C and
close outer burner door B.
HOW TO OPERATE COOKER CONTROL
Overnight and when not required for cooking, leave
cooker control knob A to LOW position. To increase the
temperature of the oven or hotplate, turn the cooker
control knob A to required temperature. Reduce knob
setting gradually in order to maintain required
temperature.
Turning Off
Ensure the cooker control knob A is at LOW setting.
Press and hold in cooker knob A simultaneously turning
it clockwise to OFF whereupon the main cooker burner
K will extinguish, leaving the pilot H alight.
To extinguish the pilot, turn slot of gas service cock D
until the slot is positioned across the pipework.
Check the operation of the flame failure device on
burner to ensure it shuts down in 60 seconds by
turning OFF service cock D with slot across the
pipework. The appliance should be at working
temperature.
INSTRUCT USER
(a) 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 remaining
inoperative during frost conditions.
(b) Advice the User that, for continued efficient and
safe operation of the appliance, It 1s important that
adequate servicing is carried out at regular intervals
recommended by the local Gas Region.
(c) Hand the Operating Instructions to the User and
demonstrate the correct operation of the appliance and
system controls.
NOTE: LEAVE THESE INSTRUCTIONS WITH THE
USER OR ADJACENT TO THE GAS METER.
LEAVE THESE INSTRUCTIONS WITH
THE USER.
METHOD OF APPLIANCE CONTROL
The cooker burner provides heat for the two ovens,
hotplate and domestic hot water.
A main gas service cock is incorporated at the LH side
of the cooker.
Operation
The burner K has a permanent pilot light H protected
by a flame failure valve "N"
Turning ON the main gas service cock D to allow gas
to the flame failure device "N"
Gas will pass to the pilot light H which must be lit
manually.
When the pilot heats the flame failure probe J
correctly, gas 1s allowed to pass through the flame
failure device to the cooker control knob A on the LH
side of the cooker.
Depressing the cooker control knob A and turning to
LOW, allows the gas to the main burner K which
cross-lights from the pilot burner.
LOW is the minimum (and idling) gas rate and setting
to position HIGH will provide a gas rate to provide an
oven temperature up to 260°C (500°F). When the oven
temperature is attained, manually turn the control knob
down to maintain oven temperature.
When not in use, reset knob A to LOW.
- SERVICING INSTRUCTIONS
Annual Servicing
It is important that servicing be carried out by a
competent service engineer, and it is recommended
that a contract be made with the local Gas Region
or a CORGI registered installer.
With normal use, a cooker flueway clean and burner
service should be carried out once per annum. An
additional flueway clean, half yearly, may be necessary
in some cases.
The householder should be advised to turn OFF the
cooker control knob the night preceding the day of
service, so that the appliance will have cooled down by
the following morning, in readiness for servicing.
Before commencing any servicing, turn OFF the gas
supply at the appliance gas service cock (bottom LH
side).
Standard Annual Service Schedule
a. Service clean of heat exchanger over flueways and
hotplate. Section 3.
b. Service clean of burner withe main injector. Section 2
с. Service clean of pilot burner assembly with injector.
Section 2.
d. Service maintenance of cooker control tap. Sections
7 and 8. |
1. To Obtain Servicing Access - Fig.1.
To obtain servicing access to main gas burner, gas
control and heat exchanger, process as follows:-
a. Lift out the hotplate.
b. Open the outer burner door and inner combustion
chamber door.
2. To Remove Main Burner
a. Ensure the appliance service cock A is turned OFF.
b. Disconnect main burner inlet union and pilot union
connection at the front of the burner chamber.
c. Lift up the front of the burner and draw forward
carefully to disengage support foot from baseplate
location.. Withdraw the burner until flame failure device
sensing probe is accessible. Slacken pilot bracket
hexagon clamping screw, disengage probe and remove
burner.
d. Gently brush the top face of the burner and examine
the flame ports. Remove and lint/fluff from injector,
burner venturi and tip downwards to remove debris.
e. Remove main injector and check it is free of deposit
with a tooth brush bristle or similar if necessary.
DO NOT USE OVERSIZE WIRE TO CLEAN INJECTOR
ORIFICE.
3. To Service Pilot Burner
a. Disconnect hexagon nut securing pilot feed pipe to
pilot burner.
b. Remove pilot injector and check to see if it is free of
deposit with a tooth brush bristle or similar if
necessary.
DO NOT USE WIRE TO CLEAN INJECTOR ORIFICE.
c. Examine probe end of flame failure device and
replace flame failure device if probe end is badly pitted,
corroded or malfunctioning.
4. To Clean the Heat Exchanger and Flueways
a. Remove the main and pilot burner assembly as
previously described.
b. Place a layer of paper on combustion chamber
baseplate.
c. Thoroughly brush vertical rear boiler flueway, cooker
flueway in an upward and downward direction. Brush
underside of baffle plate above the main burner and
also across the oven top.
d. Remove layer of paper with fallen debris.
e. Brush and clean in between hotplate ribs on
underside.
f. Examine soft rope seal locate on underside of
hotplate baffle plate. Replace if worn or frayed.
Fig.1
. COOKER CONTROL KNOB
. OUTER BURNER DOOR
. INNER COMBUSTION DOOR
. SERVICE COCK
PILOT BURNER
THERMOCOUPLE
. BURNER
. TEST NIPPLE
. ADJUSTMENT SCREW
. FLAME FAILURE BUTTON
Г ое PD
Z
DESN 510191
g. Examine soft rope seal located around hotplate
aperture in top plate. Replace if frayed or damaged.
h. Re-fit the main and pilot burner assembly in reverse
order of assembly.
Test all disconnected joints for gas soundness.
|. Replace hotplate ensuring that the underside ribs lie
over the combustion chamber.
|. Turn ON appliance service cock on outside of
appliance, light pilot and turn oven control knob to
confirm the burner lights satisfactorily.
5. To Remove Pilot Filter
a. Remove main and pilot burner assembly together
with combustion chamber baseplate as previously
described.
b. Disconnect piiot union elbow Joint o outlet of filter.
Unscrew complete filter and replace.
c. Re-assemble components in reverse order of
dismantling. |
6. To Remove Gas Governor - N.G.Only
a. Remove main and pilot burner assembly together
with combustion chamber baseplate as previously
described. |
b. Disconnect incoming union elbow and both feed
tubes at bulkhead. Remove gas control assembly.
c. Disconnect incoming/outgoing connections on gas
governor. |
d. Transfer fittings to new governor and replace. Re-
assemble in reverse order to dismantling and test for
gas soundness.
7. To Remove Flame Failure Valve
a. Remove main burner, pilot burner and gas control
assemblies together with combustion chamber
baseplate as previously described.
b. Disconnect all incoming/outgoing connections and
sensing probe from flame failure valve.
c. Transfer fittings to new valve and replace.
Re-assemble in reverse order to dismantling and test
for gas soundness.
8. Maintenance of Cooker Control Tap
a. Remove control knob and detach cover panel on side
of the appliance.
b. Hold spindle cover plate to tap body with finger
pressure and remove two retaining screws.
The cover plate is spring loaded, and the plate should
be carefully removed from tap body with the spring.
c. Withdraw tap plug from housing and lightly smear on
plug face, an approved grease sealant (such as
MOLYKOTE 1102), taking care not to block any of the
gasways.
d. Insert tap plug and spring into position, so that the
housing spindle ‘dog’ locates in a slot of the tap plug
spindle.
NOTE: THE SPINDLE COVER CANNOT BE RE-
ASSEMBLED IF THE 'DOG' LOCATION IS
INCORRECTLY ASSEMBLED.
e. Holding the spindle cover plate to the body, resecure
with screws removed.
Check assembly is correct by turning operating spindle.
9. To Remove Cooker Control Tap
a. Remove control knob and detach cover panel on side
of the appliance.
b. Disconnect inlet/outlet unions of control tap.
c. Disconnect mounting bracket via fixing screws from
Internal side of appliance.
d. Slacken off locknut and remove elbow from tap.
e. Transfer new tap via locknut, bracket and elbow
assembly.
Re-assemble in reverse order of dis-mantling.
10. To Remove Oven Temperature Indicator
a. Open main oven door fully and remove four screws
securing inner lining panel to outer door.
b. Remove inner lining panel and slagwool insulation.
c. Unscrew two hexagon nuts securing indicator to
outer door and remove indicator.
d. Fit replacement indicator in reverse order of
dismantling.
LEAVE THESE INSTRUCTIONS WITH
THE USER.
With Rayburn s policy of continuous product improvement,
the Company reserves the right to change specifications and
make Modifications to the appliance described and illustrated at
any time.
Glynwed Consumer Products Ltd.
Э Rayburn PO Box 30 Ketley Telford Shropshire TF1 4DD
A Telephone (0952) 642000 Telex 35196 Fax (0952) 641961
Installation and Servicing
Instructions for Rayburn
Royal G7 Gas—Fired Cooker
Home on the Range.
AMENDMENT SHEET
REF. PAGES DELETE SECTION &. To Remove Cooker Control Tap
REPLACE WITH
ia, er
=
1.Tum off gas supply at the gas service cock.
2.Remove control knob and detach caver panel (4
SCrews).
3.Disconnect unions of control tap.
4. Remove control tap mounting bracket screws and
remove tap.
5.Connect new control top to inlet and outlet gas
pipes.
6.Tum on gas supply at the service cock and light
cooker pilot.
7.Check for gas soundness at control tap inlet
union. |
8. Turn control tap to low position and check for gas
soundness at control tap outlet union.
9.Fit new cover plate ensuring that the tap spindie
and fixing boss penetrate through the welded fix-
ture on the cover plate.
10.Secure tap to cover plate using the single fixing
nut.
11.Refit knob.
1/95 EINS 510825
A EEE EEE EEE” A >

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Key Features

  • Combined cooker & water heater
  • Natural or LPG gas
  • Open flue
  • Detailed installation instructions
  • Comprehensive servicing guide
  • Safety instructions

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Frequently Answers and Questions

What type of gas does the Rayburn Royal G7 Gas Cooker use?
It can use either natural or LPG gas, depending on the model.
What are the minimum clearances required for installing the cooker?
The manual specifies minimum clearances between the cooker and walls, as well as for servicing/installation.
How often should the cooker be serviced?
A service clean of the flueways and burner should be carried out annually, with an additional flueway clean potentially needed every six months.

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