Installation instructions

Cooktop and cutout dimensions

Clearances

* See section ‘Standards requirements’ following.

Before you start

Before starting to install the cooktop, make sure that:

• the cooktop has not been damaged during transport. In case of doubt after unpacking and checking it, contact the retailer
• the local distribution conditions (nature of gas and pressure) and the adjustment of the cooktop (as detailed on the appliance data label and in the ‘Gas rate and injector size table’ further below) are compatible
• the cooktop will be connected to a 220-240 V 50 Hz power supply and earthed via the power supply cable
• there is an earthed power outlet within the reach of the cooktop’s power supply cable (within 900 mm from the rear right of the cooktop, see dimension G in ‘Clearances’)
• the power outlet will be accessible after installation
• the power supply cable will not touch any hot metal parts
• a suitable isolating switch providing full disconnection from the mains power supply is incorporated in the permanent wiring, mounted and positioned to comply with local wiring rules and regulations. The isolating switch must be of an approved type and provide a 3 mm air gap contact separation in all poles (or in all active [phase] conductors if the local wiring rules allow for this variation of the requirements)
• the isolating switch will be accessible after installation
• the benchtop is made of a heat-resistant material
• exposed bare edges of the cutout are sealed with an oil-based paint or moistureproof polyurethane to prevent possible damage from moisture creeping between the cooktop trim and the benchtop.

Standards requirements

Temperature of nearby surfaces. Australian and New Zealand Gas Installation Standards (AS5601, NZS5261) require a cooktop to be installed so that the surface temperature of any nearby combustible surface will not exceed 65oC above ambient. This is typically achieved by:

• having the cooktop spaced away from the wall (see dimensions A, B, and C in ‘Clearances’)
• OR
• protecting the wall to a height of at least 150 mm along its length (see dimension D in ‘Clearances’) with non-combustible surface materials such as:

- 5 mm-thick ceramic tiles—these alone are adequate
- tempered glass or sheetmetal (minimum thickness 0.4 mm)—acceptable when used in front of a fire resistant material
- F&P splashback (not available in Australia) when used with a 10 mm clearance from the rear edge of the cooktop to the front of the splashback (SB90 and SB1216 splashback models only).

These cooktops have been tested by an independent testing lab and meet standards requirements when installed to the dimensions in these instructions.

 Fastening the cooktop to the bench

This cooktop is suppled with fastening brackets (and screws) that will cope with a bench thickness of 20-50 mm. For benches thicker than 50 mm, recess the underside to a thickness of 20-50 mm.

Fig. 1 Fastening the cooktop to the bench

Connecting the cooktop to the gas supply

This cooktop is supplied factory-set for Natural Gas, but is suitable for installation with either Natural Gas or LPG, provided the injectors appropriate for the gas type are installed. Refer to the ‘Gas rate and injector size table’ for nominal ratings and appropriate injector sizes, and to section ‘Converting to a different gas type’. The gas connection must be carried out by a suitably qualified person according to the relevant standards.

• For Natural Gas, connect the gas supply to the gas pressure regulator supplied with the cooktop. Adjust the regulator to obtain a test point pressure of 1 kPa (4”W.C.) with the three largest burners operating at the highest setting.
• For LPG, connect the the gas supply to the test point adaptor supplied with the cooktop. Ensure that the supply pressure is regulated to 2.75 kPa (11” W.C.) See section ‘Converting to a different gas type’.
• Make sure the connection point will be accessible with the cooktop installed.
• To enable the gas supply to be readily shut off, make sure the connection is fitted with an isolating valve close to the cooktop.
• Attach the duplicate appliance data label on a surface adjacent to the cooktop, so that it will be easily read with the cooktop installed.
• For instructions on converting the cooktop for use with a different gas type, see section ‘Converting to a different gas type’.

Special requirements for CG604 and CG905DWFC models

• Gas connection to these cooktops MUST use the elbow supplied. The regulator will not seal if installed without it.

• Ensure the fibre washer (supplied) is located between the elbow (supplied) and cooktop gas inlet (Fig.2). Failure to use this washer will cause the connection to leak. Tighten the floating nut to firm finger tight, plus an additional 1⁄4 turn (90o).

Gas connection with a flexible hose

• If the gas is connected with a flexible hose, the connector on the wall should be between 800- 850 mm above the floor and to a distance of at least 250 mm outside the width of the cooktop. The connector should be accessible with the cooktop installed.
• Flexible hose assemblies should be AS/NZS 1869 Class B or Class D certified. The thread connection shall be Rp 1⁄2” (ISO 7-1) female (for CG604 and CG905DWFC models) or male (for CG905DWAC models). See Figs. 2 and 3.
• The hose assembly must be as short as practicable and comply with relevant AS 5601/NZS 5261 requirements.
• The hose must not be kinked, subjected to abrasion or permanently deformed.
• The hose must not be near or in contact with any hot surfaces (eg base of metal hotplate, flue or chassis of underbench oven etc).

Leak-testing and flame-testing the cooktop

The operation of the cooktop, including the ignition system, must be tested before installation is complete. If, after following the instructions below, satisfactory performance cannot be obtained, contact the local gas authority or your local Authorised Repairer for advice and assistance.

Checking the connections for leaks

After installation and making all connections, check thoroughly for possible leaks and make sure all connections are gas-tight.

1. Turn all control dials to O (OFF).
2. Open the valve on the gas supply.
3. Check each connection one at a time by brushing a soap and water solution or a suitable leak detection fluid over it.

Do not use any naked flames to check for leaks. The presence of bubbles indicates a leak. Tighten or replace connections as appropriate, then leak-test all connections again. For CG604 and CG905DWFC models, ensure the fibre washer (supplied) is located between the elbow and the cooktop’s gas inlet.

Checking the burner flames

1. Light each burner.

2. Check for a well-defined blue flame without any yellow tipping. See Fig.4.

• If any abnormality is evident, check that:
  - the burner cap is located properly
  - the injector nipple is correctly aligned
  - the correct size injectors are installed.

Fig. 4 Incorrect and good flame patterns

Converting to a different gas type

Gas conversion may only be carried out by a suitably qualified person.

• To convert from one gas type to another, you need to replace the injectors and adjust the minimum burner setting.
• To replace the injectors, you will need a 7 mm box spanner (and a 10 mm ring spanner for CG905DWAC models). These are not supplied.

1. Switch the power supply to the cooktop off at at the wall.

Disconnect cooktop from the power supply before continuing.

2. Make sure each control dial is turned to O (OFF).

3. Remove all the pan supports and burner heads.

4. Pull off the control dials.

5. Using a 7 mm box spanner, remove the injectors and replace them with the correct ones

   (size numbers are stamped on the inside, eg 70=0.70 mm). Hold on to the card housing the replacement injectors for later use.

Adjusting the minimum burner setting

• This has been adjusted at the factory for Natural Gas but may need adjusting for local conditions.

• When converting to LPG, the minimum setting MUST be re-adjusted for each burner.

• To adjust the minimum setting, you will need a Ø 2.5 x 45 mm screwdriver.

1. Light the burner and set the control dial to its minimum.
2. Remove the dial.
3. Slowly turn the adjustment screw inside the valve shaft until a minimum regular flame is achieved.

The flame will diminish when the screw is turned clockwise, and increase when turned anti-clockwise. The brass wok burner in the centre of CG905DWAC models may require progressive venturi adjustment (Fig. 6) until a good flame (Fig.4) is achieved: - If the flame is ‘lifting off’ the burner, move the venturi closer to the injector. - If there is yellow tipping, move the venturi away from the injector.

4. Refit the dial.
5. Check the minimum burner setting: quickly turn the dial from maximum to minimum. The flame must not go out. If it does, repeat the steps above.

Repeat the steps above for each burner.

Fig. 5 Adjusting the minimum burner setting

Fig. 6 Progressive venturi adjustment for the brass wok burner on CG905DWAC models

Gas rate and injector size table