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Rayburn Heatranger 480D Servicing Instructions

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WARNING
This information is a copy of an original
archive, therefore Aga cannot be held
responsible for its continued accuracy.

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Summary of Contents for Rayburn Heatranger 480D

  • 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

    Servicing Instructions At the Heart of your Home Heatranger 480D For use in GB and IE DESN 510517 PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE 10/99 EINS 511231...

  • Page 3: Consumer Protection

    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

    Additional Flueway Clean It may be necessary in some installations to give the The Rayburn cannot be serviced whilst hot, so both oven boiler flueways a clean out at the end of the heating and boiler thermostats should be turned off on the season.

  • Page 5: Burner Removal

    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 6 Burner Removal BURNER REMOVAL IMPORTANT: DURING BURNER REMOVAL CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 2 1. Place a sheet on the floor in front of the cooker to act as a working area 2.

  • Page 7: Heat Exchanger Cleaning

    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 insulation pad B, remove the 4 flue cleaning access door securing bolts and remove door.
  • Page 8 Cleaning OVEN & HOTPLATE FLUEWAY CLEANING SEE FIG. 8 1. Remove the top oven door and place in a safe position. 2. Remove side and base access doors using hex. driver. 3. Thoroughly clean top, side and base flueways through access apertures with brush.

  • Page 9: Burner Servicing

    Burner Servicing INTRODUCTION SEE FIG. 9 It is recommended that each burner is serviced individually so as not to get the components from the two burners mixed up. The correct combination of burner blast tubes and diffusers are shown. When removing the diffusers it is important to note the orientation of the diffuser in relation to the ignitor assembly (see Fig.10), to ensure correct alignment during re-assembly.

  • Page 10: Burner Nozzle Removal

    Burner Servicing BURNER NOZZLE REMOVAL SEE FIG. 10 1. Disconnect oil feed nut. 2. Slacken the grub screw. 3. Disconnect the two ignition leads from ignitor and gently tap the centre oil inlet boss. 4. The complete nozzle assembly should now move through the Burner sleeve.

  • Page 11: Photo Electric Cell (Pec) Cleaning

    Burner Servicing PHOTO ELECTRIC CELL (PEC) CLEANING SEE FIG. 11 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. FIG.

  • Page 12: Oil Pump Servicing

    Oil Pump Servicing INTRODUCTION Turn OFF the oil line isolating valve near to the appliance. OIL LINE FILTER CLEANING 1. Turn OFF the line isolating valve fitted prior to the oil line filter. 2. Follow manufacturer’s instructions to remove filter element from the housing, taking care to collect oil residue from the filter housing.
  • Page 13 Re-commissioning BLEED AIR FROM OIL SUPPLY SEE FIG. 13 Disconnect the flexible oil pipe 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 14: Set Combustion Air

    Re-commissioning SET COMBUSTION AIR SEE FIG. 15 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 15: Replacement Of Parts

    Replacement of parts (Electrical controls) 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. 16 1. Remove the controls door and place in a safe position. 2.
  • Page 16 Replacement of parts (Electrical controls) FIG. 18 DESN 511140...

  • Page 17: To Fit New Boiler Control Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW BOILER CONTROL THERMOSTAT SEE FIG. 19 Follow instructions in section 5.1 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 18: To Fit New Boiler Safety Overheat Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW BOILER SAFETY OVERHEAT THERMOSTAT SEE FIG. 22 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 19: To Fit New Programmer

    Replacement of parts (Electrical controls) TO FIT NEW PROGRAMMER SEE FIG. 24 Follow instructions in section ELECTRICAL COMPONENT ACCESS, Steps 1 to 4. 1. Remove the two screws holding the mounting bracket to the control chassis. 2. Pull the programmer forward to access the rear casing.
  • Page 20 Replacement of parts (Electrical controls) 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 and secure with the four screws.

  • Page 21: Fan Motor

    Replacement of parts (Burner) FAN MOTOR SEE FIG. 26 Follow instructions in sections BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL, Steps 1 to 5. 1. Carefully remove 2 push on connectors (noting terminals) and earth connection. 2. Remove 4 securing screws. 3.

  • Page 22: Solenoid Coil

    Replacement of parts (Burner) IGNITOR SEE FIG. 29 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL, Steps 1 to 5 and DISMANTLE BURNERS Steps 1 to 3. 1. Remove both HT leads from ignitor. 2. Remove mains plug from ignitor. 3.

  • Page 23: Control Box

    Replacement of parts (Burner) CONTROL BOX SEE FIG. 32 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL, Steps 1 to 5 and DISMANTLE BURNERS Steps 1 to 3. 1. Insert flat bladed screwdriver in LH side of c.box, as diagram.

  • Page 24: Pump Access

    Replacement of parts (Burner) PUMP ACCESS SEE FIG. 34 Follow instructions in section BURNER ACCESS, steps 1 to 3 and BURNER REMOVAL, steps 1 to 5. 1. Isolate fuel supply 2. Disconnect flexible hose. 3. Disconnect pump supply tube from burner assembly. 4.

  • Page 25: Electrical Controls

    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 26: Control Circuit-External

    Electrical Controls CONTROL CIRCUIT-EXTERNAL TERMINAL STRIP CONNECTIONS OVEN VENT FAN 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) FROST STAT (SEE NOTE BELOW) H/W OFF H/W ON...

  • Page 27: Control Circuit-Boiler

    Electrical Controls CONTROL CIRCUIT-BOILER FIG. 35...

  • Page 28: Control Circuit-Cooker

    Electrical Controls CONTROL CIRCUIT-COOKER FIG. 36...

  • Page 29: Fault Finding

    Fault Finding WIRING DIAGRAM - BURNER ONLY FIG. 37...

  • Page 30: Wiring Diagram - Appliance

    Fault Finding WIRING DIAGRAM - APPLIANCE FIG. 38...

  • Page 31: Burner Does Not Start

    Fault Finding BURNER DOES NOT START Burners Check that the burners have not gone to lock-out. Causes of lockout can be- ❏ No ignition, ignition electrode incorrectly positioned or insulation cracked, spark generator faulty, check for 230v at spark generator. ❏...
  • Page 32 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 SECTION AND NEUTRAL HAS OVERHEAT REPLACE COOKER THERMOSTAT OVERHEAT STAT ACTIVATED...

  • Page 33: Oil Smells

    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 POSITIONED NOZZLE CHECK AIR INLET RECOMMENDED SEE SERVICING INSTALLATION TO BURNER SETTINGS INSTRUCTIONS FAULTY...

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