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Rayburn Heatranger 480GB Servicing Instructions

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Summary of Contents for Rayburn Heatranger 480GB

  • Page 1 WARNING This information is a copy of an original archive, therefore Aga cannot be held responsible for its continued accuracy.
  • Page 2 Servicing Instructions At the Heart of your Home. Heatranger 480GB For use in GB and IE DESN 511653 PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE 10/99 EINS 511382...
  • Page 3 To this end, our products are thoroughly tested and examined before despatch. IMPORTANT NOTICE: Any alteration that is not approved by Aga-Rayburn could invalidate the approval of the appliance, operation of the warranty and could affect your statutory rights.

  • Page 4: Service Schedule

    INTRODUCTION SERVICE SCHEDULE To ensure the best performance from your Rayburn, it Annual Service should be serviced once a year, preferably at the start of the heating season by a registered heat installer. BURNER REMOVAL - for cleaning and inspection.

  • Page 5: Burner Access

    Burner Removal BURNER ACCESS WARNING: BEFORE REMOVING SERVICE ACCESS COVERS BEFORE ENSURE THAT ALL ELECTRICAL SUPPLIES APPLIANCE HAVE BEEN ISOLATED. SEE FIG. 1 1. Open up burner access door. Remove door and put in a safe place. 2. Remove the 4 inner panel securing screws and remove panel.
  • Page 6 Burner Removal BURNER REMOVAL IMPORTANT: DURING BURNER REMOVAL CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 2 1. Turn off gas cock. 2. Break gas cock union connection. 3. Disconnect the 5-pin plug underneath the burner. FIG.
  • Page 7 Cleaning HEAT EXCHANGER AND HOTPLATE FLUEWAY 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.

  • Page 8: Burner Head Cleaning

    Burner Servicing INTRODUCTION It is recommended that each burner is serviced individually so as not to get the components from the two burners mixed up. BURNER HEAD CLEANING 1. Clean heads with soft brush and inspect for damage or wear. FAN CLEANING 1.
  • Page 9 Re-commissioning TEST BURNERS ON DRY RUN (NO GAS) SEE FIG. 8 Switch on electricity supply BOILER BURNER Set boiler burner clock to continuous and turn the boiler thermostat to max. allowing the burner to start, the burner should go to lockout after the expiry of the ignition safety time.

  • Page 10: Set Combustion Air

    Re-commissioning SET COMBUSTION AIR SEE FIG. 9 Turn on the boiler burner. 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 11: Fan Motor

    Replacement of parts (Burner) FAN MOTOR SEE FIG. 10 Follow instructions in sections BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL, Steps 1 to 5. COOKER FAN 1. Carefully remove 2 push on connectors (noting terminals) and earth connection. 2.
  • Page 12 Replacement of parts (Burner) IGNITOR ELECTRODE SEE FIG 13 & 15 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL, Steps 1 to 6 and DISMANTLE BURNERS, Steps 1 to 2. 1. Remove securing nut and disconnect H.T. lead from ignition electrode.

  • Page 13: Gas Valve Replacement

    Replacement of parts (Burner) IGNITOR SEE FIG. 15 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL, Steps 1 to 6 and DISMANTLE BURNERS, Steps 1 to 2. 1. Remove securing nut and disconnect H.T. lead from ignition electrode.

  • Page 14: Electrical Component Access

    Replacement of parts (Electrical) ELECTRICAL COMPONENT ACCESS BEFORE REMOVING SERVICE ACCESS COVERS ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN TURNED OFF (SWITCH OFF AND REMOVE PLUG). SEE FIG. 18 1. Remove the controls door and place in a safe position. 2.
  • Page 15 Replacement of parts (Electrical) FIG. 20 DESN 511140...

  • Page 16: To Fit New Boiler Control Thermostat

    Replacement of parts (Electrical) TO FIT NEW BOILER CONTROL THERMOSTAT SEE FIG. 21 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 17: To Fit New Boiler Safety Overheat Thermostat

    Replacement of parts (Electrical) TO FIT NEW BOILER SAFETY OVERHEAT THERMOSTAT SEE FIG. 24 Follow instructions in 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 18: To Fit New Programmer

    Replacement of parts (Electrical) TO FIT NEW PROGRAMMER SEE FIG. 26 Follow instructions section ELECTRICAL COMPONENT ACCESS, Steps 1 to 4. 1. Remove the two screw holding the mounting bracket in the control chassis. 2. Pull the programmer forward to access the rear casing.

  • Page 19: Vent Fan

    Replacement of parts (Vent Fan) VENT FAN BEFORE REMOVING SERVICE ACCESS COVERS ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN TURNED OFF (SWITCH OFF AND REMOVE PLUG). SEE FIG. 28 1. Remove (2) fan cover securing screws, remove cover. 2.
  • Page 20 Replacement of parts (Electrical) RE-ASSEMBLE 1. Locate thermostat phials into boiler pockets, the pump overrun and boiler stats into the LH pocket and the overheat stat into the RH pocket. 2. Locate the base of the control chassis into the bottom of the doorway aperture, tilt the chassis backwards into position with the four screws.

  • Page 21: 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 22: Control Circuit-External

    Electrical Controls CONTROL CIRCUIT-EXTERNAL TERMINAL STRIP CONNECTIONS OVEN VENT FAN SPARE NEUTRAL TERMINAL SWITCH LIVE TO OPERATE BOILER FROM ROOM STAT SW/L BOILER OR CYLINDER STAT VIA ZONE VALVES IF FITTED HTG ON TO ROOM STAT/ZONE VALVE(S) ETC ( IF FITTED) FROST STAT (SEE NOTE BELOW) H/W OFF H/W ON...

  • Page 23: Control Circuit-Boiler

    Electrical Controls CONTROL CIRCUIT-BOILER FIG. 30...

  • Page 24: Control Circuit-Cooker

    Electrical Controls CONTROL CIRCUIT-COOKER FIG. 31...
  • Page 25 Electrical Controls WIRING DIAGRAM - BURNER ONLY FIG. 32...

  • Page 26: Wiring Diagram - Appliance

    Electrical Controls WIRING DIAGRAM - APPLIANCE FIG. 33...

  • Page 27: 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 or insulation cracked, spark generator faulty. ❏ No gas supply. ❏ Poor combustion. ❏...
  • Page 28 Fault Finding PROGRAMMER SLIDERS SET TO “CONT’ & THERMOSTATS TO MAXIMUM IS THERE 230V AT CONTROL BOX TERMINALS 2 & 1 ? IS THERE 230V SEE TROUBLE BETWEEN COOKER SHOOTING BURNER OVERHEAT STAT AND SECTION NEUTRAL HAS OVERHEAT REPLACE COOKER THERMOSTAT OVERHEAT STAT ACTIVATED...
  • Page 29 Fault Finding TROUBLESHOOTING-BURNER BURNER WILL NOT START Check that external wiring is correct. Check for 230V supply on terminal 1 at control box base, this will also determine if the thermostats are calling for heat. Check that incoming Neutral conductor is correctly wired onto terminal 2. Press reset button to ensure that the control box has not gone to lockout.

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