INSTALLATION INSTRUCTIONSINCLUDING
SERVICING & COMMISSIONINGFOR
AGA COOKERSMODELS
OC,OCB,OE ,GC,GCB
ISSUE No. 1
DATE: 30th JUNE 20006
Supplied by: Snughome Cookers Ltd. 2 Cromwell Road, Shaw, Newbury, RG14 2HL
Tel.No. 01635 846787 Fax. No. 01635 846787
THIS IS A NEW PRODUCT SO PLEASE READ THESE INSTRUCTIONS CAREFULLY, ANDIMPLEMENT THEM, DO NOT TRY AND CUT CORNERS AS THIS COULD ENDANGER THECONSUMER.
Compliance with EN 50165 & EN 60335Compliance with current legislation regarding Oil tanks and the siting thereof as directed by the BuildingRegulations Parts J & L.
The fitting of safety Fire Valves as directed by the Building Regulations and by Snughome Ltd.This Equipment must be earthed.This Equipment is only suitable for the appliance for which it has been designed..
Installation of this Equipment must be carried out by a suitably OFTEC qualified/ trained personnel, Thathave also received training from Snughome in this type of conversion.
This equipment should be wired from a double pole switched fused spur having a minimum contact gap of3 mm, rated at 5 amps
GENERAL INFORMATIONThis is a pressure jet conversion, and unlike the vaporising sleeve burner, which relies fully on a negativeflue pull throughout the appliance, in this case there are sections within the appliance, which can have apositive pressure. This means that all the joints and seals in the appliance must be gas tight. Failure to dothis could mean combustion gases escaping into the room, with potentially serious effects. Various extragaskets and sealants are provided with the kit to avoid this situation
This Snughome Conversion Kit for the Aga Cooker has been designed and manufactured by ourengineers who have many year’s experience in the Conversion field and incorporates many advancesin technology and design. Currently it is ideally suited to the Conversion and Refurbishment Market,where the appliance can be easily modified as required. With the steady deterioration in the qualityof Domestic Fuel Oil and in order to increase the overall market. This Pressure Jet conversion has beendeveloped in conjunction with one of the top burner manufacturers.
How it WorksThe burner is controlled electrically by (a) the inbuilt timer (b) the oven thermostatWhen switched ON from cold, the burner WILL NOT FIRE for around 3 minutes. This is because the pre-heateris warming the oil so that it combusts efficiently. Also the in built timer is SET to run the burner for 3 minutes ONand 3 minutes OFF .It always starts from the OFF position.The purpose of the timer is to moderate the heat build up in the cast iron ash pit and barrel of the Aga- if it wereto run continuously there is a danger that the casting might be damaged.So the burner will fire one the timer goes to an ON period and the fan / pump operates Please note that thepurging / bleeding of the oil pump can only occur when the burner is in firing mode and the pump is electric- andit should be bled both at the top (high pressure test point) and at the bottom ( low pressure input) .When settingpressures etc its easy to simply switch off the power supply at the mains to put the timer into the “next mode” –rather than adjust the timer – so you can bleed / set pressure without interruption. Don’t be tempted to reset thetimer to a different timing period – we have carried out exhaustive tests to confirm this timing mode!The burner will continue to switch on /off every 3 minutes until the oven heat required is reached, as set by thecontrol knob. The burner will then stay off until the oven calls for heat. Only use components supplied by SNUGHOME Ltd. as these have been specifically designed forthis purpose. NO LIABILITY WILL BE ACCEPTED IF OTHER THAN SNUGHOME PARTS AREFITTED. It has been designed to use most common fuel oils. All components are manufactured from well-proven materials and should give reliable service with improved economy. Noise has always been aproblem with pressure jets but in this case care has been taken to reduce this to a minimum.The sale of the Conversion is also backed up with an experienced Technical Team that is always willing togive help and advice. This advice is also available on a Help Line. It is the Company’s policy to give theCustomer and Installer the best Product and Service available.At present these instructions refer to vertically flued appliances and not low level discharge flues.
Technical Data :
This appliance is an oil fired pulse pressure jet 1stage. This should give a good performance and highefficiency, and be more economic than previous vapourising burners.
The Fuel suitable for this burner are as follows:
1. Class C2 Kerosene ( Otherwise known as 28sec Heating Fuel.)( 1-2 mm2/sec) - (No pre-heater is needed)2. Low Sulphur Diesel – ( 32 Sec Fuel).)( 2– 4.5mm2/sec)3. Red Diesel — ( 1.5 - 5.5 mm2/sec)4. Gas Oil ( 1.5 - 5.5 mm2/sec)5. Mazout ( 8 mm2/sec)
(A n oil Pre-heater is fitted to these burners as standard and therefore suitable for the above fuelswith only a pressure change to the burner)
The Burner:1. Power Suppl y — 5 amp. 220 - 230V ac (a 24V dc version may be possible)2. Burner nozzle - Danfoss – 0.30 US gph. 600 EH3. Burner Pressure 90 psi. (6 bar )
Site Vetting; Before any decision to convert any appliance the site and the appliance must beinspected. Failure to do this will generally lead to a poor installation and a dissatisfied Customer.On arrival at the site have a look up at the chimneys and if possible check from a couple ofdirections. See if there is any soot stain down the sides of the chimney pots. Have a look at the surroundings of the chimney particularly angled close roofs, over hanging branchesand trees ,geographical position (i.e. anti down draught).
COOKER POSITION -- Although this cooker can be turned off and on as required it shouldbe considered as normally constant running it will get hot. Therefore a minimum clearanceof 100 mm should be left on either side of the appliance when combustible materials areplaced close to it, for example kitchen units. Any other surfaces adjacent to the cookershould be of non-combustible materials.This conversion does not need free area around the sides of the cooker for air supply as it re-ceives combustion air through the front of the cooker.
AIR SUPPLY - See Building Regulations “J”. L1 & L2 ( 1st April 2002).
1. This is a fan assisted burner and runs at 59,000 Btu/hr maximum when burning, the air requirementsfor this must be taken into account when determining the necessary ventilation.2. Extractor fans when fitted should be positioned as far away from the flue as possible and shouldhave a sufficient dedicated air supply. To undertake a test, the oil fired appliance should be set in operationat maximum setting and the doors and windows closed. The extractor fan should then be run at its maximumsetting. The oil fired heating appliance should be observed to operate satisfactorily both before and after the fan is switched on.2. It is preferable that the air supply for the extractor fan should be located where it can serve the fanwithout the air stream passing close to the oil fired appliance.3. It is necessary that both round ducts from the side panels to the front trunking box are fit-ted as these are the only air intakes for the burner. As a result it is essential that these are not blockedor covered.
Oil fired appliances MUST NOT draw combustion air from a garage.
FLUES & CHIMNEY TERMINATIONBuilding Regulations “J”. L1 & L2The new approved documents J, and the “Competent Persons legislation both came into force on the 1st
April 2002.All installations, chimneys, flue’s , building work etc, must comply with the new legislation.Suitable Flues and liners should be used in accordance with Building Regulations Document Jpages 18 - 21, and page 52An Anti Down Draught Cowl (that conforms to British Standards) SHOULD BE FITTED.Possibly the best one on the market today is the O.H. COWL. Down draught will not go away it has to beeliminated.The chimney is a vital component in the appliance in order to achieve a combustion free from dis-turbances. The evacuation of the exhaust gases are dependent on the weight of the hot gasesrelative to the ambient air.
If the chimney is cooled by lack of insulation the difference in weight will also decrease the naturaldraught. The cooling of the chimney can vary a lot, amongst other things depending on the wind.
A bad chimney can create the following effects:
1. Pressure fluctuations at start up that create overpressure in the combustion chamber andpossibly exhaust gases and soot in the room and top oven.
2. A smoky flame during the time necessary to heat the chimney until the natural draught hasstabilised.
3. Deterioration of the chimney due to condensation af the water vapour into water and acid com-ponents.
4. Noise and heat transferring to adjacent rooms.5. Soot deposits near the chimney and poor distribution of the exhaust gases due to low velocity
(too cool gases in too large a chimney area.
FOR SPECIALIST HELP ON CHIMNEYS OR FLUE PROBLEMS CONTACT THE O.H.HELP-LINE. GOOD SOUND TECHNICAL ADVICE ON CHIMNEY’S AND FLUES CAN ALSO BEOBTAINED FROM YOUR N.A.C.S. CHIMNEY-SWEEPING TECHNICIAN
OIL STORAGE & SUPPLYFor this appliance the oil tank can be mounted at ground level. Also it can be fitted with the lowest oil
level in the tank 1.3m below the level of the oil pump, over 1.3m a circulator or lift pump is required. Themild steel oil storage tank should be manufactured to BS 799 Part 5. Plastic oil tanks are covered byOFTEC standard OFST100. The minimum recommended oil tank size is 1400 litres (300 gallons). Codes ofpractice governing installation are covered by BS5410 Part 1.Should a lift pump be required with the new building regulations and current trends in health and safety it isrecommended that the oil lifter is mounted external to the building.
1. Oil pipe, fittings, filter etc should comply with the relevant standards.2. The pipe line MUST be of a suitable size (10 mm diameter is usually sufficient) to ensure that maximum flow can be achieved (any other appliance should be accounted for).3. A manual isolator valve and oil filter must be fitted directly on the outlet from the oil tank.4. A 5-10 micron oil filter is fitted in control assembly to prevent small particles entering the burner assembly.
Fire valves should also be fitted, one according to the instructions to protect the appliance and asecond mounted external to the building to comply with the new Building Regulations.
It is recommended that a manual shut off valve be fitted in the same room as the appliance.On page 12, a diagram of a layout is shown which would comply with the new regulations and provide a
suitable oil supply to the appliance.
Fitting the Snugburner in the Aga Deluxe OC , OCB, OE cooker
Preliminaries.
Tools required.Electric drill. ¼” Whitworth tapps (our part no TD001) & 6mm tap5.1mm& 5.5 mm drill bit to tap out the holes to ¼” Whitworth.6/8mm box spanner, ideally also 5/16 Whit box spanner or long socket & drive.Tube of siliconeOil joint sealant / PFTE tape.Electrical screwdriver.Powerful inspection light / strong torch.
Model OC / OCB/ OEAs above please grind off the stat mounting lugs. Please make sure that the cast iron spacer is thecorrect type as the earlier one WILL NOT ACCEPT THE BURNER. It has the left side corner cutout just where we need the pump!
The lugs have been ground off
If LEFT side housing, our burner WILL NOT FIT. Contact us for a different housing.
Wiring needs.The cooker requires a dedicated power point, with or without a time clock to control firing.The cooker MUST be earthed .A twin core & earth heat resistant flex of 1 mm or larger is required.
Oil Pipe. The cooker requires a 10mm oil line or smaller, with gravity feed from the tank or a liftpump, to be terminated with a fire stop valve at the side of the cooker.
Cleaning out the cookerLift off hot spot, remove baffle, strip out vaporizing burner, feed pipe and power supply. Removesimmering hob, vacuum all passages .Empty flue box, remove diverter plate.You may leave the KBB sensor in place (if fitted). Make sure the chimney is clean and the liner iseither checked or replaced.
x
Fitting the burner.Take the mounting plate and position squarely over the door, with the cut out in line with the dooropening. Mark through the 4 fixing hole positions centrally with a felt tip or similar.(a) Center punch the marked spot and drill the 4 holes. Tap them with the ¼” tap n and attach the mounting plate loosely to confirm fit, Then remove it.(b) Take the burner assembly and position onto the studs, to check access and note tt he position for the oil inlet pipe access under the burner.(c) Remove the burner once you are sure it will fit over the mounting studs.
Oil pipe & Flex Its easy to fit the oil pipe at this stage and bend it so that the tube curves in a 180degree bend inside the Aga , with enough on a horizontal level to make the connection to the oilpump once the burner is in place. Leave the external length sticking out from under the Aga baseplate – it’s easier to move it from there. Gently bend the tube out of the way do it doesn’t interferewith fitting the burner. Also introduce the flex and leave in place in the void under the burner.
.
Fitting the CeramicsThese are brittle and should be handled carefully – especially No 2 and No 7. Whilst we and themanufacturers have worked hard to ensure a good fit you may need to carefully reduce sizes , oncorners so that the blocks lock together. We also supply some mastic which when set “makes” aceramic seal .
Looking DOWN onto the ceramics – right side is rear of Aga.
These are numbered to ease fitting and should be installedas followsNo 1.Rear block, fit through front and push gently to rear ofash pit
The Mounting plate in place – the 4 x pennywashers with countersunk ¼” Whitworth screw-driver slotted panel pins are the ones you havedrilled & tapped the holes for
Next fit No 2, the front block with the blast tube cut out inthe upper section.Note this is best fitted THROUGH THE FRONT, tilt andslide in. Once in placePull it to the front so it butts up against the front plate, asper photo
Next fit the plates 3 & 4 which but up to each side ofthe ash pit, through the top
Plate 5 fits into the gap, again through the top, andcovers the bottom of the burner chamber.
Plate 6, the angled section, fits at the back andpushes up to the rear block
The next ceramic, the thick square blanketmarked 7 simply lays over the floor of theburner chamber, and up over the Ceramicnumber 6 , to form a heatproof shield on top ofthe ceramics
Next fit your free mastic gloves and insert the ceramic rope (supplied) all around the top of theceramics, filling the gap between them and the underside of the outer barrel. Tuck in tightly then“wodge” the ceramic mastic (supplied in a tub) over the entire joint to seal it all in place.This material sets rock hard .
Finally take the ceramic ring marked 8 and lower itnarrow side down into the outer barrel. It should fittightly into the base area – if too big file gently until itdoes, push it so it’s in contact with the lower ceramics.
Now you can simply refit the baffle plate but we leave it out & the circular baffle ring.until we havefired the unit & checked combustion.
Fitting the ceramic spacer behind the burner.Attach it with silicone to the rear face of the burnermounting plate
I.Fit the ceramic heat shield part 9 to the Agabetween the No 2 ceramic and the rear section ofthe carrier plate. It should be gently pushed intoplace 9
Next fit the mounting plate and bolt up with the4 x Whitworth screwdriver headed bolts withwashers on.
It’s a good idea now to locate the oven stat in the top oven. An easy way to get the probe in placeis to push a length of solder through the entry hole, and tape the end of the new probe to it, thencarefully pull it back into the oven. Drill and screw in place the 2 clips, in the roof of the oven tun-nel slide the ceramic bullets in place over the stat probe.You may attach the probe stat to theouter cover now or later.
Fitting the Burner.Slide the burner onto the 3 studs, making sure the bundy oil tube doesn’t foul the burner.Gently position it so that the blast tube enters the ceramic tunnel, then push firmly home & tightenthe mounting nuts evenly.
Connecting the oil pipe.Hold the end of the 6mm bundy tube and gently pull up and across to connect to the oil pump, us-ing jointing compound and tightly securely. Note – because the pump is flexibly mounted makesure the joint is TIGHT and also that the bundy tube doesn’t reverberate against the fan housingwhich would create noise. Trim and bend the other end of the pipe and make into the oil filter us-ing the fitting supplied.
Wiring. Connect the terminal block to the feed flex and prepare for switching on.
Bleeding the oil pipe. There is a small bleed fitting on the pump- see photo-
50mm to left of oil pipe connection with thumb nut. Connect 1/8* diameter bleed tube supplied andfeed into a jar. Connect oil pressure test gauge by removing knurled nut (with recessed Allen keyhead at top of pump) .Bleed oil through from line. Its important to bleed both sides of the pump asair can get trapped in the pump and create noise.
Once bled, shut off thumb nut.
Top oven flue vent.
Each Aga may require a slightly different solution here. If fitting a HIGH LEVEL DISCHARGE weare offering a small flexible tube to fit into the oven vent and this is to be run into the flue manifoldand into the flue pipe. If a normal flue no vent may be required. We suggest the flexible vent tubeis fitted and sealed in place with fireclay.Test the draw through the oven by using a smoke match in the oven – make sure the flue is warmand that the smoke is drawn to the vent
Flue box.
You have removed the original baffle plate . Fit the 2” stainless steel vent up into the flue pipe andsecure in place by pushing the supplied metal pin into the holes about 7mm up from the bottomblanking steel plate ( supplied) so that only 7mm of the tube protrudes into the flue manifold area.Pack the entire flue box around this with the ceramic blanket to baffle the gases noise and makeairtight. If originally solid fuel refit the flue box door prior to fitting the flue box shroud.
Firing the burner.Advise the client you are about to fire the burner and ensure ventilation is adequate!Switch on the burner. It will take up to 4 minutes before the burner will fie from switching on,this is the time the pre-heater takes to warm up and send power to the control box.It may go to LOCK OUT initially as the oil pump is full of air. Bleed until oil is constant, note thelock out button stays RED for around 2 minutes after it locks ot. Note also that the burner isTIMED and will NOT FIRE initially until it has done its “3 minutes off cycle” .You can speed up theoff period initially by switching the power off to the burner, then on again – this fools the burnerinto an ON period!Set pressure to 90 psi – subject to fuel type you are using.KERODIESELMAZOUT -- 100psi
Thumb Wing Nut
Bleed Pipe Pressure Setting Screw
Pressure Setting ScrewLock Nut
High PressureBleed Nipple &Pressure Test Point
You are looking for a short bluey / yellow flame about 2-3” out of the blast tube, steady not to longor sooty.
Burner air adjustment. This is obtained by moving the lever next to where the bundy oil fed pipedescends into the void under the fan unit. Move IT UP to increase the air and DOWN to decreasethe air)
Once you are happy with the flame, fit baffle plate No 7, cast iron baffle and lower gently in theouter barrel.
Current legislation insists that burners are set up using Combustion Testing Equipment.In order to obtain the best performance from the burner and cooker these units must alsobe set up using testing equipment.As there is no ideal testing point in or on the cooker it is necessary to do this in the flue above theFlue Box. Therefore drill a hole in the flue suitable for the test probe. Before firing the burner totest the combustion put a plug in the vent hole in the top oven. This is to ensure that there is noflue gas dilution due to air getting in, as this would upset any readings and give false results.Which could lead to bad combustion as the cooker gets hot.Start the burner.. After the burner has fired allow approximately 10 minutes for it to settle down.Then check the combustion. It should approximately read as follows:
COLD COMBUSTION FIGURESWith the cover plate in positionCo --- -- -- -- 30 – 100 ppmCO2 -- -- -- -- - 8.8 – 9.0% This will change when hotCo/CO2 -- -- -- 0.0003 – 0.0008
It may be necessary to adjust the combustion to these figures by setting the air lever as detailedabove.
When the cooker is hot and up to temperature this should give:
HOT COMBUSTION FIGURESWith the cover plate in positionCo --- -- -- -- 30 – 100 ppmCO2 -- -- -- -- - 9.5 – 9.7 %Co/CO2 -- -- -- 0.0003 – 0.0008If not it may be necessary to adjust accordingly.
After Setting the combustion REMEMBER TO REMOVE THE PLUG FROM THE OVEN VENTor you will get condensation coming from the oven, also ensure that the combustion testhole in the flue is closed.Remember to leave the customer with the test results.
Servicing.The annual service consists of the following
(a) Remove burner and visually check baffles/ ceramics. Repair ceramics if required withceramic material (we can supply) ,replace any too badly damaged.
(b) Clean out burner blast area, removing any debris that may have fallen in.(c) Remove nozzle and replace with new. Check and replace blast tube if any cracking at end .(d) Remove fan unit and make sure the fan is clean – removing any build up on the blades and
around the air intake.(e) Check and clean the oil filter supplied – burner will lock out if starved of fuel .
(f) Refit everything, test fire, set combustion and make sure customer happy.
Suggested Layout for KBB’S
KBB 65 S
ENS
OR
FITTED
AB
OVE
APP
LIAN
CE
KBB 90 S
ENS
OR
OIL C
ON
TRO
LM
AN
UAL
SH
UTO
FF VALV
E
INTE
RN
AL FIR
E VALV
E KBB
90 OR
SIM
ILAR
TO P
ROTE
CT AP
PLIA
NC
EFITTR
D TO
MA
NUFA
CTU
RE
RSIN
STR
UC
TION
S
5/10 Micron
FILTE
RE
XTER
NA
L FIRE VA
LVE KBB
65O
R S
IMILA
R TO
COM
PLY
WITH
PA
RT J O
F THE
NEW B
UILD
ING
RE
GU
LATIO
NS
FILTER
/STR
AIN
ER
TAN
K ISO
LATO
RV
ALVE
OIL TA
NK P
LINTH
TOP
OU
TLET O
IL TANK
BM
LIFT PUM
P OR S
IMILA
R TO
ALLO
W TH
E OIL TO
GRAV
ITY FEE
DIN
TO TH
E O
IL CO
NTR
OL
THE
HE
IGH
T OF TH
E O
IL LEVE
L IN TH
E PU
MP
SH
OU
LD BE BE
-TW
EEN
1.5 TO 3.0 M
ETE
RS AB
OV
E THE
OIL LEVE
L LINE O
N THE
OIL
CO
NTR
OL A
ND S
HO
ULD B
E POS
ITION
ED
EXTE
RN
AL TO
THE
BU
ILDIN
G. TH
IS M
EA
NS THA
T IT SH
OU
LD BE
EN
CLO
SE
D IN A
WEA
THE
R-P
RO
OF E
NC
LOS
URE
DIAG
RA
M O
F OIL LIN
E REQ
UIR
EM
ENTS IF A TO
P OU
TLET OIL TAN
K IS U
SED.
FILTER:- A strainer/filter should be fitted to the tank. An additional 5/10 m
icron filter (supplied with kit) is fitted just before the oil control on the appliance.
FIRE VALVES:- In order to comply with current legislation, a fire valve KBB 65 0r sim
ilar Type (available from
OILW
ARM
but not supplied as part of the kit) ,m
ust be fitted at the point where the fuel line enters the
property.It’s sensor being inside the property to isolate the fuel in the event of a property fire.
Normally this would be situated above the appliance not at floor level.
Under no circumstances should a
KB
B/E
be used on this type of installation as it is self re-setting, and can allow oil to run into a hot burner.
A second fire valve, KBB 90 or similar type (set at 90
oC) supplied with the kit, is fitted next to the oil control with it’s sensor located inside the burner housing
(ashpit area), and fitted in accordance with the OILW
ARM
instructions supplied.;
KBB 90s are used to protect the Appliance andM
UST N
OT be used to p
rotect the property, this is carried out by the KB
B 65s.
