Rayburn Cooktop 200SFW User Guide

Installation Instructions for  
Rayburn Cookmaster 200SFW  
and Rayburn Cookmaster  
Better than you ever imagined  
Plus 212SFW Solid Fuel Cooker  
Consumer Protection  
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.  
As responsible manufacturers we take care to make sure that our  
products are designed and constructed to meet the required safety  
standard when properly installed and used.  
Firebricks, Fuel beds, Artificial Fuels - when handling use  
IMPORTANT NOTICE: PLEASE READ THE ACCOMPANYING  
WARRANTY. Any alteration that is not approved by Aga could  
invalidate the approval of the appliance, operation of the warranty  
and could affect your statutory rights.  
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.  
All local regulations including those referring to National and  
European standards need to be complied with when installing  
the appliance.  
Glass Yarn, Mineral Wool, Insulation Pads, Kerosene/Gas Oil -  
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.  
Important  
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,  
WARNING  
PERFORMANCE  
THE ASHPIT DOOR AND FIREBOX DOORS MUST  
BE LOCKED CLOSED AT ALL TIMES DURING  
NORMAL USE, EXCEPT WHEN LIGHTING OR RE-  
FUELLING  
REMEMBER, when replacing a part on this  
appliance, use only spare parts that you can be  
assured conform to the safety and performance  
specification that we require. Do not use  
reconditioned or copy parts that have not been  
authorised by AGA.  
6 kW. This provides about 2 kW to hot water and 4 kW  
to the appliance. Other fuels may give a slightly  
different result.  
Weight of Rayburn Cookmaster Plus 212SFW - 300 Kgs.  
Weight of Rayburn Cookmaster 200SFW - 240 Kgs.  
The Rayburn Cookmaster 200SFW is intended to be  
used for cooking only. The Rayburn Cookmaster Plus  
212SFW is intended to supply heating for cooking and  
domestic hot water.  
There is no requirement for an electrical power supply.  
The mean flue gas temperature of the Rayburn  
Cookmaster 200SFW directly downstream of the flue  
spigot at nominal heat output is 131ºC.  
The Rayburn Cookmaster 200SFW has been tested  
using Taybrite manufactured smokeless fuel only. The  
nominal heat output of this appliance is 4.4 kW.  
The mean flue gas temperature of the Rayburn  
Cookmaster Plus 212SFW directly downstream of the  
flue spigot at nominal heat output is 210ºC.  
The Rayburn Cookmaster Plus 212SFW has been  
tested using Taybrite manufactured smokeless fuel and  
wood logs. The nominal heat output of this appliance is  
DESN 510179 D  
08/06 EINS 514406  
1
 
IMPORTANT: LIFT OUT THE HOTPLATE AND  
CEMENT SEAL THE JOINT BETWEEN THE BOILER  
FACE AND ITS LOCATING FACE ON THE FIREBOX  
SIDES WITH FIRE CEMENT. RENEW ANY  
BRICKWORK CEMENTED JOINTS THAT MAY HAVE  
AIR SUPPLY  
Rayburn Cookmaster 200SFW: There is no  
requirement for additional ventilation as this appliance  
is rated at less than 5kW. Should another appliance be  
used in the property and the total heat output is greater  
than 5 kW, additional ventilation must be provided in  
accordance with the Building Regulations.  
OPENED IN TRANSIT.  
PREPARATION OF SITE  
The non-combustible hearth must be solid and level  
and together with the walls adjacent to the cooker and  
chimney, conform to current Building Regulations.  
Rayburn Cookmaster Plus 212SFW: Provision must  
be made for additional ventilation. A permanent  
unobstructed air vent having a minimum effective area  
of 5.5 cm2 must communicate to outside air or an  
adjacent room which in turn has a permanent vent of at  
least the same size to outside air.  
The cooker and chimney flue installation should be in  
accordance with the relevant recommendations of  
BS8303, BS. 6461 Part 1 and BS. 7566 Parts 1 to 4.  
If a flue draught stabiliser is fitted in the flue this vent  
size must be increased to a minimum 23.5 cm2. If his  
appliance us used with an additional appliance of a  
similar type then the air supply must be adequate for  
both appliances in accordance with the Building  
Regulations.  
Rayburn Cookmaster Plus 212SFW - The boiler  
installation section must also be in accordance with the  
byelaws of the local Water Undertaking and any  
relevant requirements of the Local Authority.  
COOKER POSITION  
Any air inlet grilles must be positioned so that they are  
not liable to blockage.  
When the cooker is installed in a recess it must be  
‘freestanding’ and not built-in solid at the sides.  
It is not permissible to use an air extraction device in  
the same room as the appliance, unless additional  
ventilation is provided to prevent any adverse effect on  
the flue.  
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.  
Ensure that any combustible material e.g. kitchen  
furniture is spaced away from the cooker to the  
recommended distances. See Fig. 1. The work surface  
however, may be fitted to the top plate on both sides.  
Effect of Extractor Fan  
Avoid if possible the installation of an extractor fan in  
the same room as the appliance or the room where the  
permanent air vent is located.  
NOTE: SMOKE/SMELL EMITTED DURING INITIAL  
USAGE  
Compensating extra air inlets must be introduced  
equivalent to the capacity of the fan wheel when fitted.  
Some parts of the cooker have been coated with a light  
covering of protective oil, 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 insulating lids to  
prevent staining the linings.  
3
 
THE CHIMNEY  
The minimum chimney draught requirement for the  
200SFW at nominal total heat output is 2.5 Pa.  
The minimum chimney draught requirement for the  
212SFW at nominal total heat output is 12 Pa.  
The mean flue gas temperature of the Rayburn  
200SFW directly downstream of the flue spigot at  
nominal heat output is 131ºC.  
The mean flue gas temperature of the Rayburn  
212SFW directly downstream of the flue spigot at  
nominal heat output is 210ºC.  
The appliance is not suitable for installation in a shared  
flue system  
Checking Existing Chimney  
Fig. 2  
DESN 510181 C  
The internal and external location of the chimney should  
be checked before the appliance is installed and  
rectification made where necessary to prevent leakage  
or porosity. The soundness of the chimney which  
should have a minimum flue dimension of 150mm can  
be confirmed by smoke testing.  
Advice on the test method can be obtained from  
HETAS Ltd.  
When repairing or re-using existing chimneys it is  
recommended that the building control officer be  
consulted before the commencement of work with  
particular attention to the chimney height and its  
termination  
The chimney MUST be swept before installation.  
Erecting New Chimney  
The flue through the chimney should be formed with  
pre-cast moisture and acid resistant liners with a  
minimum internal diameter of 150mm diameter and all  
in accordance with the current Building Regulations  
(England and Wales) and in Scotland the Building  
Standards (Scotland) (Consolidation) Regulations and  
the Codes of Practice for chimneys and flues BS. 6461  
Part 1 and BS. 7566 Parts 1 to 4.  
Fig. 3  
DESN 510182 C  
Ensure the chimney liners are free of projecting internal  
building jointing composition before the appliance is  
installed.  
Factory-Made Insulated Chimneys  
It is recommended the chimney be ceramic lined and  
comply with BS. 4543: Part 2.  
The minimum diameter for a straight chimney is 150mm  
and there should be not more than two bends of 45º  
from vertical.  
Fig. 4  
DESN 510183 C  
4
 
IN ALL TYPE OF CHIMNEYS THE MINIMUM HEIGHT  
FOR CORRECT OPERATION OF THE CHIMNEY IS  
4.5m AND SHOULD TERMINATE ABOVE THE ROOF  
IN ACCORDANCE WITH REGIONAL STATUTORY  
REQUIREMENTS RECOMMENDED FLUE DRAUGHT  
- 12 pa MINIMUM. THE APPLIANCE SHOULD BE  
INSTALLED AND CONFORM TO THE CURRENT  
CODES OF PRACTICE FOR INSTALLATION OF  
DOMESTIC HEATING AND COOKING APPLIANCES  
BURNING SOLID FUEL - BS 8303.  
In Fig. 3 the cooker is connected direct to a brick flue.  
Horizontal pipe runs between cooker and brick flue  
must not be used.  
In Fig. 4 the cooker 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.  
ALWAYS ADVISE THE USER TO CLEAN THE  
COOKER FLUES IN ACCORDANCE WITH THE  
OPERATING INSTRUCTIONS AND TO HAVE THE  
CHIMNEY SWEPT AT A MINIMUM OF 12 MONTHLY  
INTERVALS  
COMMISSIONED.  
AFTER  
THE  
COOKER  
IS  
If the chimney is unlined, and there is any doubt about  
its condition, it should be lined in accordance with  
Current Building Regulations.  
COOKER FLUE CONNECTION  
PROVISION MUST ALWAYS BE MADE FOR  
SWEEPING THE CHIMNEY  
The position of available types of flue layouts are shown  
in Figs. 2, 3 and 4, the cooker flue chamber is  
adaptable to providing either top or back flue outlets, by  
means of the reversible loose socket.  
IMPORTANT: CEMENT TYPE PIPES AND FITTINGS  
MUST NOT BE USED WITHIN 2m OF COOKER.  
CHIMNEYS OF PLAIN PIPE ARE NOT  
RECOMMENDED BUT CERTAIN PROPRIETARY  
MAKES OF INSULATED CHIMNEY ARE SUITABLE.  
a) Rear Flue Outlet  
This must only be used where there is a brick flue  
immediately behind the cooker. Provision must be  
made for a condensate collecting vessel and  
cleaning door. See Fig. 3.  
EXTENDED HORIZONTAL FLUE PIPE CONNECTION  
IS ALLOWED UP TO A MAXIMUM OF 150mm IN  
LENGTH.  
NO BEND CONNECTIONS ARE ALLOWED.  
b) Top Flue Outlet  
The cooker should be connected to the main flue via  
a 125mm minimum diameter cast iron flue pipe or  
appropriately internally/externally vitreous enamelled  
mild steel pipe and be sealed to the cooker flue  
chamber with soft rope and fire cement. Any bends  
in the flue pipe must not be less than 135º (45º from  
vertical) and be complete with a cleaning door.  
FLUE LAYOUTS  
In Fig. 2 the cooker is installed in an existing recess.  
There must be a clearance of not less than 150mm  
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.  
If a flue liner or insulated chimney is used, the size  
should not be less than 150mm.  
5
 
HIGH UPDRAUGHTS  
Tall chimneys may develop excessively high  
updraughts which prevent the appliance operating  
correctly.  
It is recommended that a proprietary brand adjustable  
flue draught stabiliser having an openable cross  
sectional area of 126cm2 be fitted above the flue pipe  
connection, either in the brickwork or into a right angle  
‘T’ fitting in the flue pipe position that will not  
inconvenience appliance operation or maintenance.  
INSTALLATION  
Fig. 5  
DESN 513152  
Place the cooker in the intended position and lift out the  
surface ground hotplate, checking that the joint between  
the underside of the hob and the top of the cooker are  
intact.  
Fit the flue chamber which should be given a 1mm  
smear of fire cement on the underside then screwed to  
the cooker. Make sure there is a good seal between the  
flue chamber and the cooker top (if there is an ingress  
of air it can affect the flue draught and proper working of  
the cooker). Before the fire cement hardens remove any  
surplus with a damp cloth then polish with a dry cloth.  
If the appliance is installed near combustible material  
then as well as adhering to minimum clearances in Fig.  
1 additional non-combustible insulation must be fitted to  
the wall to protect the area around the flue and fluebox.  
The insulation must reach a minimum distance of  
150mm either side of the flue/flue box and follow the  
line of the flue. The minimum specification for this  
material is Superwool 607 LTI with a density of  
320kg/m3, a thickness of 10mm and a self finish. There  
must be a minimum 16mm air gap between the  
insulation board and an adjacent combustible wall  
surface. A higher specification material may be used  
but the air gap must be maintained.  
Open the firebox and ashpit doors and check that the  
bottomgrate is in position. Operate the riddling lever to  
ensure the bottomgrate operation.  
Failure to do so can result in the enamel surface being  
permanently marked.  
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 handrails  
with fitted endcaps into the brackets, positioning them  
correctly, and tighten the locating bolts (Fig. 8).  
The handrail brackets are held on the front end 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. (See Fig. 5).  
Any joints which have opened should be made good  
with fire cement provided.  
Replace the hotplate making sure that it is seating  
evenly on the soft rope and that it is approximately  
1.5mm proud of the enamelled top plate, with an equal  
space all round.  
Connect pipework to boiler flow and return tappings.  
6
 
TESTING AND COMMISSIONING  
After completing the installation, the Heating Contractor  
should demonstrate to the user, the operation of the  
appliance and the routine flue operating method.  
1. Check that the system is full of water and free  
from air pockets. (Rayburn Cookmaster Plus  
212SFW only).  
2. Select and install the appropriate burning grate  
as required by the customer (see Users  
Instructions for method).  
3. When lighting pull the flue chamber damper open  
to maximum.  
4. Add paper and sticks with a small quantity of fuel  
through the fuelling aperture onto bottomgrate  
and close the firebox door.  
5. Open ashpit door, ignite fuel and close ashpit door  
when fuel is well alight with spinwheel on ashpit  
door at required setting.  
(6. Allow the cooker to heat up gradually at first time  
lighting.  
NOTE: The water capacity of the boiler is 7 litres.  
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.  
The renewal of firebricks is not a major operation and  
can be carried out by the average person.  
Replacement bricks either in sets or singly can be  
obtained from your Rayburn distributor.  
LEAVE INSTRUCTIONS FOR FUTURE USE  
7
 
For further advice or information contact your  
local distributor/stockist  
With Aga’s policy of continuous product  
improvement, the Company reserves the right to  
change specifications and make modifications to  
the appliance described at any time.  
Manufactured by  
Aga  
Station Road  
Ketley Telford  
Shropshire TF1 5AQ  
England  
8
 

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