Installation Instructions for Aga Gas Fired Range Models: GC Open Flue Range (2 Oven) GC Direct Vent Range (2 Oven) GE Open Flue Range (4 Oven) GE Direct Vent Range (4 Oven) For U.S. and Canadian Markets NOTE: THESE INSTRUCTIONS SHOULD BE LEFT WITH THE APPLIANCE AND THE USER TO RETAIN FOR FUTURE REFERENCE. Aga Gas Fired ranges are delivered unassembled. Before installation can be made the site is inspected for suitability by an Authorised Aga Distributor and corrected where necessary to conform with local installation codes or in the absence of local codes with: In Canada: The CAN/CGA-B149 installation codes. In U.S.: The National Fuel Gas Code ANSI Z223. 1-latest edition. Assembly is undertaken on site by the same Aga Distributor to ensure correct performance and safety. The top face of the hearth must be of non-combustible material for a minimum thickness of 12mm (1/2in) and comply with current Building Regulations and National Fire Laws. OPEN FLUE RANGE MODELS GC AND GE The wall behind the cooker draft hood and flue connector must have a minimum air gap of 57mm (2 1/4"). Any openings in the wall behind the range or in the floor under the range must be sealed before appliance installation. Ensure the draft hood is securely bolted to the support spigot as shown in Fig. 2. NOTE: THIS IS NORMALLY FITTED AND SECURED BY THE FACTORY BEFORE DESPATCH. The wall behind the range must be the outside wall for DIRECT VENT RANGEMODELS GC AND GE the venting of flue products. Wall thickness between 150mm (6 in) and 355mm (14 in) can be catered for at the same time as site inspection. Alternatively, special lengths can be offered to order up to a maximum of 610mm (24 in) long. Open Flue - Models GC and GE BASE OR HEARTH It is essential that the base or hearth on which the range stands should be level and strong enough to support the weight of the range. Approximate weights:Models GC (Open Flue) and GC (Direct Vent) - 408kg (900lb) Models GE (Open Flue) and GC (Direct Vent) - 585kg (1290lb) 1 04/01 EINS 33644 diagrams) and be at least 1.53m (5ft) above the flue collar of the draft hood outlet. Part 7, Venting of Equipment, outlined in the current National Gas Code ANSI Z223 - latest edition gives detailed guidelines on all these aspects. Canada: The gas vent must be connected to a chimney or independently and in accordance with the CAN/CGA - B149 installation codes. The air gap between vent and combustible materials must be given for the following types of vent: (i) Type B Vent - 25mm (1in) minimum. (ii) Single wall vent connector - 150mm (6in) minimum. Listed connectors passing through combustible walls and partitions must be guarded by a ventilated metal thimble not less than 200mm (8in) diameter. Chimneys and vents shall terminate above roof level and in accordance with the requirement of the current issue of the CAN/CGA - B149 Installation Code (Code W) (see diagrams) and be at least 1.53m (5ft) above the flue collar of the draft outlet. 1. If suitable lined brick chimney is used it must be swept before connection and not less than 150mm (6in) internal diameter. 2. The top of the chimney should be fitted with an approved Terminal. 3. The flue route to the chimney should be as direct as possible. Resistance in the form of directional change should be kept to a minimum. Right angle bends and horizontal runs should be avoided. 4. The chimney terminal should terminate at the highest possible point, preferably in a freely exposed position. Termination at the roofs eaves is unacceptable. 5. The Aga Distributor or Local Gas Company should be advised where any doubt arises as to the suitability of the flue. 6. Approved factory made chimneys are acceptable with VENT CONNECTION A 100mm (4in) Type B Gas Vent must be used and fastened by screw to the draft hood flue collar. U.S. The gas vent must be connected to a chimney or independently and in accordance with Chapter 26, chimney, Gas Vent and Fireplace Systems of the current issue of Equipment and Volume of the ASHRAE Handbook. The gas vent proximity to combustible materials must be installed as recommended in ANSI/NFPA 211 and according to manufacturers instructions. Chimneys and vents shall terminate above roof level and in accordance with the requirements of the current issue of ANSI/NFPA 211 (see 2 the appliance and should not be less than (4in) internal diameter. 7. In the event of an extractor fan being fitted in the vicinity of the range, compensatory ventilation will be required to satisfy the demands of the fan without influencing combustion efficiency or chimney flue condition. Direct Vent - Models GC and GE The location chosen for the appliance must permit the provision of a satisfactory flue termination. The location must also provide adequate space for servicing and air circulation around the range. Should the installation of the appliance be in an unusual location or restricted space, special procedures may be necessary and the following current codes give detailed guide lines on this aspects: U.S.: The National Fuel Gas Code ANSI Z223. 1-latest edition. Canada: The CAN/CGA B -149 installation codes. The following notes are intended to give general guidance. 1. The range must be installed so that the flue terminal is exposed to the external air and terminal clearances comply with: In U.S.: The National Fuel Gas Codes ANSI Z223 1-latest edition Section 7.7. In Canada: CAN/CGA-B149 installation code. 2. Termination should be on a clear expanse of wall, the terminal being preferably not less than 355mm (14in) away from a corner, recess of projection. 3. A hole must be cut through an outside wall as indicated in Fig. 6 with the hole rising from inside to outside face of wall. DO NOT install the terminal:(a) Within 300mm (12in) measured vertically, from the bottom of an openable window, air vent or any other ventilating opening. (b) Within 300mm (12in) above adjacent ground level. (c) Within 600mm (24in) of any surface facing the terminal. (d) Within 355mm (14in) (U.S.) or 300mm (12in) (Canada) below eaves or balcony. The direct vent terminal must be protected by a terminal protective guard installed over the terminal to prevent unauthorised contact with hot terminal surfaces. See Fig. 8. 4. All jointing faces providing primary air and flue exhaust paths, must be sealed in an airtight fashion, with particular emphasis on the following locations: (a) Air intake tube joints to be sealed with silicone adhesive provided. (b) Combustion chamber top sealed with a fire-cemented gasket to the outer barrel. (c) Fire cement joints between underside contact faces of hotplates and simmering plate with cement provided. (d) Gasket between flue intake/exhaust manifold. Gasket provided. The air inlet/products outlet direct vent, and the terminal of the appliance must not be less than 300mm (12in) to combustible material. The terminal is suitable for walls of 150mm (6in) to 355mm (14in) overall thickness. For special lengths up to 610mm (24in), consult your local Aga Distributor. WALL TILING If 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 range top plate. NOTE: A GAS CONTROL VALVE MUST BE INSTALLED. GAS SUPPLY - U.S. PIPE THREADS IN THE GAS PIPELINE EXTERNALLY OF THE RANGE (NOT SUPPLIED). 9.5mm (3/8in) N.P.T. Male connection near the front of the range on the L.H. or R.H. side - Optional. ALL GAS CONTROLS MUST BE U.S. PIPE THREADS. Maximum Heat Input: 4.4 kw (15,000 Btu/h) 3 GC, GE Open Flue Models Maximum Heat Input: 4.4kw (15,000 (Btu/h) GC, GE Direct Vent Models The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5kPa). The appliance must be isolated from the gas supply piping system by closing the individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5kPa). LOCATION OF NAME PLATE The model and serial numbers for this appliance are found on the name plate. These numbers must be used when requesting advice from your Aga Distributor. The name plate is located on the inside face of the outer burner door. The maximum gas inlet pressure at the appliance must not exceed 12 inches w.g. (2.98kPa) for Natural Gas and 14 inches w.g. (3.48kPa) for L.P. Gas. The minimum gas inlet pressure at the appliance must be 4 inches w.g. (1kPa) Natural Gas and 10 inched w.g. (2.248kPa) L.P. Gas to enable the correct manifold pressure to be obtained. 4 INITIAL LIGHTING OF RANGE In a cold range, difficulty may be experienced in maintaining the main burner alight on initial light-up only. Should this occur, set the control knob to the position. Depress knob and light pilot. With the pilot flame established, rotate the gas valve control knob 2 anti-clockwise to its low fire position where upon the main burner will automatically light. Leave in the low fire position for at least 30 minutes. After 30 minutes rotate the control knob further anti-clockwise to the mid position in the green band for normal running. 5 NOTE: DO NOT ATTEMPT TO SERVICE THE RANGE YOURSELF. CONTACT YOUR LOCAL AGA DISTRIBUTOR STATING THE MODEL AND SERIAL NUMBER TOGETHER WITH YOUR NAME AND ADDRESS TECHNICAL SPECIFICATION Models Gas Type Range Model Main Burner Injector Pilot Burner Injector Combination Gas Valve Bypass Screw Gas Burner Pressure Combination Gas Valve Pilot Assembly GC and GE - Open Vent/GC and GE - Direct Vent Natural Gas GC/GE 400 L.P.G. GC/GE 180 REPLACEMENT PARTS In the event of a component failure which requires replacement, contact your local Aga Distributor who will advise and supply the necessary replacement. Expendable components that will require replacing at some time or other are listed as follows:Description 1. Pilot Thermocouple 2. Main Burner 3a. Pilot Burner Assembly N.G. 3b. Pilot Burner Assembly L.P.G. 4. Combination Gas Valve 5a. Pressure Regulator N.G. 5b. Pressure Regulator L.P.G. 6. Combustion Chamber Door Seal 4212 1.00mm or 1.20mm 4.0 inch w.c. S.I.T. EUROSIT 4208 0.60mm or 0.80mm 10.0 inch w.c. JOHNSONS 6 7 Installer Servicing Instructions for Aga Models GC and GE Open Flue Ranges and GC and GE Direct Vent Ranges It is recommended that the range be serviced at regular annual intervals. Arrange with the householder that the range has been turned OFF the night before to ensure it is cold upon arrival. ignitor cable to ensure the PTFE insulation remains intact and is firmly connected to the spark electrode. Clean any carbon away from the electrode. 7. Refit combustion chamber baffle. 8. DIRECT VENT MODEL ONLY - GC AND GE. Using a wire brush, lightly remove the old sealing cement on the contact under faces of the hotplate and simmering plates to the cooker, and lighly smear another cement sealing coat provided, before refitting of hotplates. 9. Refit gas burner assembly in reverse manner described in 2 and reconnect the gas supply at service gas valve union. On completion test the gas installation for soundness and purge. Leak testing of the appliance shall be conducted according to manufacturer's instructions. NOTE: USE SOAPY WATER SOLUTION ON NEW GAS CONNECTIONS TO ENSURE THERE ARE NO GAS LEAKS. 10. Turn on the gas supply and follow the procedure for lighting the burner. 11. Ensure that the pilot and main burner flames are burning evenly, the thermocouple is enveloped by the pilot flame. 12. Visually check main burner and pilot flame for correct flame pattern. An established main burner at high fire will be predominantly blue with yellow tippings on an even height flame strip and be about 150mm (6in) high. See Fig. 11. Ensure all flameports have cross-lit and that the pilot light flame is free from sooting. 13. The maximum depth of any cabinets installed above the top cooking surface of the range must not exceed 330mm (13in). YEARLY SERVICE The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1/2 psig (3.5kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1/2 psig (3.5kPa). 1. Isolate the gas supply by turning off the service gas valve beneath the combination gas valve. Break the hexagon union connection nut. 2. Detach inner burner door fixing screws and draw complete gas burner assembly clear of the combustion chamber resting it on the floor in front of the range. NOTE: THERE IS SUFFICIENT LENGTH OF THERMOSTAT CAPILLARY TUBE WITHOUT DETACHING THE SENSING END FROM THE TOP OF THE ROASTING OVEN. 3. Remove the boiling plate, combustion chamber baffle and simmering plate. 4. Check conditions of flueways and combustion chamber and clean if ...