Rayburn Heatranger 440 Servicing Instructions
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Rayburn Heatranger 440 Servicing Instructions

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See also: Instructions for Using , Instruction and Installation Manual
Servicing
Instructions
Heatranger 440/460/480/499K
For use in GB and IE
DESN 512012 A
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 clearly
authorised by AGA.
PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE
05/14 EINS 511567-E
raywarranty@aga-web.co.uk

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Summary of Contents for Rayburn Heatranger 440

  • Page 1 Servicing Instructions Heatranger 440/460/480/499K For use in GB and IE DESN 512012 A 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 clearly authorised by AGA.

  • Page 2: Table Of Contents

    Contents SECTION CONTENTS PAGE CONSUMER PROTECTION HEALTH & SAFETY INTRODUCTION SERVICE SCHEDULE BURNER REMOVAL PREPARATION BURNER ACCESS BURNER REMOVAL CLEANING HEAT EXCHANGER CLEANING 8-10 OVEN & HOTPLATE FLUEWAY CLEANING BURNER SERVICING INTRODUCTION BURNER NOZZLE REMOVAL BURNER NOZZLE REPLACEMENT PHOTO ELECTRIC CELL (PEC) CLEANING FAN CLEANING RE-ASSEMBLE BURNER OIL PUMP SERVICING...
  • Page 3 Contents SECTION CONTENTS PAGE FAULT FINDING WIRING DIAGRAM - APPLIANCE BURNER DOES NOT START INFORMATION SYSTEM COOKER BURNER 34-35 (CONTROL BOX TYPE DKO 970) INFORMATION SYSTEM COOKER BURNER 36-37 (CONTROL BOX TYPE DKO 970N) FAULT FINDING - BOILER 38-39 FAULT FINDING - COOKER 40-41 HIGH SMOKE NUMBERS/OIL SMELLS...

  • Page 4: Consumer Protection

    Consumer Protection As responsible manufacturers we take care to make sure that our products are designed and constructed to meet the required safety standards when properly installed and used. 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.
  • Page 5 BURNER SERVICING. The Rayburn cannot be serviced whilst hot, so both oven OIL PUMP SERVICING - Cleaning of fuel line strainer. and boiler thermostats should be turned off on the RE-COMMISSIONING evening before the service visit.
  • Page 6 Burner Removal PREPARATION WARNING: BEFORE REMOVING SERVICE ACCESS COVERS OR THE OIL BURNERS ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN ISOLATED. The burners can be removed without disconnecting the oil supply pipe. However if the filters are being cleaned or a pressure gauge fitted to the pump then the oil supply should be turned OFF and arrangements made to catch any oil which will leak from the oil pump.
  • Page 7 Burner Removal BURNER REMOVAL IMPORTANT: DURING BURNER REMOVAL CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 2, 3 & 4 1. Place a sheet on the floor in front of the cooker to act as a working area. 2.
  • Page 8 Cleaning HEAT EXCHANGER CLEANING IMPORTANT: DURING CLEANING CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 5 1. Lift insulation covers and remove hotplate using lifting hooks provided. Fig. 5 DESN 510523 SEE FIG. 6 2. Remove the 4 flue cleaning access door securing bolts and remove door.
  • Page 9 Cleaning Fig. 6A...

  • Page 10: Oven & Hotplate Flueway Cleaning

    Cleaning SEE FIG. 7 4. Lift top plate enamelled cover panel (behind LH insulating cover) remove insulation pad and sealing plate. 5. Clean the boiler outlet flueway by inserting the flexible brush through the top plate aperture, directing it towards the flue outlet. Scrape the deposits towards the heat exchanger.

  • Page 11: Introduction

    Burner Servicing INTRODUCTION BOILER 8 VANES SEE FIG 9, 10A, 10B & 10C It is recommended that each side of the burner is serviced individually so as not to get the components from the two burners mixed up. The correct combination of burner blast tubes are shown. To remove blast tube, slacken two grub screws, pull forward.

  • Page 12: Burner Nozzle Removal

    Burner Servicing BURNER NOZZLE REMOVAL SEE FIG. 11 1. Disconnect ignition leads. 2. Remove two socket head screws. 3. Remove head assembly complete. 4. Remove ignitor assembly, by removing countersunk screw and clamp. 5. Unscrew nozzle from its holder with a correctly fitting tubular spanner to avoid damage to hexagon.

  • Page 13: Fan Cleaning

    Burner Servicing PHOTO ELECTRIC CELL (PEC) CLEANING SEE FIG. 13 Withdraw Photo Electric Cell from the burner head. Clean PEC sensing end with a soft cloth taking care not to scratch the light sensitive body. Re-insert PEC taking care to insert the correct way round. Should the cell show signs of distortion or cracking, replacement will be necessary.

  • Page 14: Introduction

    Oil Pump Servicing INTRODUCTION To carry out any servicing on the oil pump. Turn off the oil line isolating valve near to the appliance. SEAL STRAINER COVER OIL PUMP STRAINER CLEANING SEE FIG. 15 1. Remove 4 socket head screws. 2.

  • Page 15: Bleed Air From Oil Supply

    Re-commissioning BLEED AIR FROM OIL SUPPLY SEE FIG. 17A Disconnect the flexible oil pipe line at the pump inlet, open the stop valve slowly and run off some of the oil into a receptacle to establish an air free supply to the pump. Remake the connection oil tight and leave valve open.

  • Page 16: Set Combustion Air

    Re-commissioning SET COMBUSTION AIR SEE FIG. 18 & 18A After 15 minutes of the boiler burner running. Remove the enamelled top cover panel and the insulation pad. Remove the plugging screw and insert the sensing end of a portable indicator to check the CO (Carbon Dioxide) level.

  • Page 17: Ignition Electrodes

    Replacement of parts (Burner) FAN MOTOR 440/460K ONLY SEE FIG. 19 & 19A Follow instructions in sections BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL, Steps 1 to 6. 1. Remove 3-pin plug. 2. Remove solenoid plug (499K ONLY). 3.

  • Page 18: Ignitor

    Replacement of parts (Burner) IGNITOR REMOVE SEE FIG. 19 EARTH SCREW Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL Step 4. 1. Remove both HT leads from ignitor, 2. Remove mains plug from ignitor. 3. Remove earth screw. 4.

  • Page 19: Control Box

    Replacement of parts (Burner) CONTROL BOX SEE FIG. 22 Follow instructions in section BURNER ACCESS, Steps 1 to 3. 1. Undo centre fixing screw. 2. Gently pull control box away from base. 3. Fit new control box, re-assemble in reverse order. Fig.

  • Page 20: Pump Access

    Replacement of parts (Burner) PUMP ACCESS SEE FIG. 24 Follow instructions in section BURNER ACCESS, Steps 1 PUMP FIXING to 3 and BURNER REMOVAL, Steps 1 to 5. PUMP SCREWS (3) DRIVE Isolate fuel supply. Disconnect flexible hose. (This must be replaced annually).
  • Page 21 Replacement of parts (Electrical controls) ELECTRICAL COMPONENT ACCESS BEFORE REMOVING SERVICE ACCESS COVERS ENSURE THAT ALL ELECTRICAL ACCESS TO THE APPLIANCE HAVE BEEN SWITCHED OFF (SWITCH OFF AND REMOVE PLUG). SEE FIG. 26 1. Remove the controls door and place in a safe position. 2.
  • Page 22 Replacement of parts (Electrical controls) Fig. 28 DESN 513150...

  • Page 23: To Fit New Boiler Control Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW BOILER CONTROL THERMOSTAT SEE FIG. 29 Follow instructions section ELECTRICAL COMPONENT ACCESS, Steps 1 to 6. 1. Undo the two screws on the front of the chassis which hold the thermostat in place. 2.

  • Page 24: To Fit New Cooker Safety Overheat Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW COOKER SAFETY OVERHEAT THERMOSTAT SEE FIG. 31 Follow instructions section ELECTRICAL BLACK COMPONENT ACCESS, Steps 1 to 6. 1. Undo the two screws on the front of the chassis which holds the thermostat in place. 2.

  • Page 25: To Fit New Boiler Safety Overheat Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW BOILER SAFETY OVERHEAT THERMOSTAT SEE FIG. 32 Follow instructions section ELECTRICAL COMPONENT ACCESS, Steps 1 to 6. 1. Undo the central hexagon nut on the front of the chassis which holds the thermostat in place. 2.

  • Page 26: To Fit New Programmer

    Replacement of parts (Electrical controls) TO FIT NEW PROGRAMMER SEE FIG. 34 Follow instructions section ELECTRICAL COMPONENT ACCESS, Steps 1 to 4. 1. Slacken two screws at bottom of programmer. 2. Pull the bottom of the programmer forward and lift. 3.

  • Page 27: Re-Assemble

    Replacement of parts (Electrical controls) RE-ASSEMBLE 1. Locate thermostat phials into boiler pocket. 2. Locate the base of the control chassis into the bottom of the door way aperture, tilt the chassis backwards into position and secure with the four screws. 3.

  • Page 28: Pump Overrun Facility

    Electrical Controls PUMP OVERRUN OVERHEAT SAFETY FACILITY THERMOSTATS When the programmer switches off the BOILER channel BOILER then the water circulating pump will be switched off. If during the period shortly after this the residual heat in the This thermostat is a safety cut-out device which is appliance causes the water temperature in the boiler to intended to operate if the other controls fail.

  • Page 29: Control Circuit-External

    Electrical Controls CONTROL CIRCUIT-EXTERNAL TERMINAL STRIP CONNECTIONS OVEN VENT FAN DO NOT USE SPARE NEUTRAL TERMINAL SW/L BOILER SWITCH LIVE TO OPERATE BOILER FROM ROOM STAT OR CYLINDER STAT VIA ZONE VALVES IF FITTED HTG ON TO ROOM STAT/ZONE VALVE(S) ETC ( IF FITTED) H/W OFF FROST STAT (SEE NOTE BELOW) H/W ON...

  • Page 30: Control Circuit-Boiler

    Electrical Controls CONTROL CIRCUIT-BOILER Fig. 37...

  • Page 31: Control Circuit-Cooker

    Electrical Controls CONTROL CIRCUIT-COOKER (KB MODEL ONLY) Fig. 38...

  • Page 32: Fault Finding Wiring Diagram - Appliance

    Fault Finding WIRING DIAGRAM APPLIANCE - 440/460/480K/499K Fig. 39...

  • Page 33: Burner Does Not Start

    Fault Finding BURNER DOES NOT START Burners Check that the burners have not gone to lock-out. Causes of lock-out can be:- No ignition, ignition electrode incorrectly positioned, insulation cracked, spark generator fault. No oil supply. Poor combustion. Photo electric cell incorrectly positioned, cracked or needs cleaning. Live and Neutral connections reversed.
  • Page 34 Fault Finding Cooker Burner (Control Box Type - DKO 970) Information system The information system communicates with the outside world using a LED (the used Flash-Code is similar to the Morse Code). The messages are optically transmitted by flashing appropriately a LED. Using an (optional) additional terminal the messages can be recorded and displayed in easily readable form.
  • Page 35 Fault Finding Cooker Burner (Control Box Type - DKO 970) In case of failure the LED is permanently illuminated. Every 10 seconds the illumination is interrupted by a flash code which indicates the cause of the error. Therefore the following sequence is performed which is repeated as long as the unit is not reset.

  • Page 36: Control Box Type Dko 970

    Fault Finding Cooker Burner (Control Box Type DKO 970N) - Information system The information system is microprocessor based and reports on all aspects of burner control box operation and flame supervision. It informs continuously about the actual programming sequence the unit is just performing. Besides monitoring of the programming sequence it also allows to identify errors during start-up of operation without any additional testing devices.
  • Page 37 Fault Finding Fig. 41A DESN 516838...
  • Page 38 Fault Finding...
  • Page 39 Fault Finding...
  • Page 40 Fault Finding...
  • Page 41 Fault Finding...
  • Page 42 Fault Finding HIGH SMOKE NUMBERS INCORRECT INCORRECT INTERNAL COMPONENTS NOZZLE FAULT AIR INTAKE OIL PRESSURE COMBUSTION INSULATION USED ON BLOCKED SETTINGS INCORRECT PANELS COMBUSTION REPLACE INCORRECTLY RE-ADJUST ADJUST TO HEAD CHECK AIR POSITIONED NOZZLE RECOMMENDED SEE SERVICING INLET TO INSTALLATION SETTINGS INSTRUCTIONS FAULTY...
  • Page 44 With AGA Rangemaster’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 Rangemaster Station Road Ketley Telford Shropshire TF1 5AQ England www.rayburn-web.co.uk www.agacookshop.co.uk...

This manual is also suitable for:

Heatranger 460Heatranger 499kHeatranger 480

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