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Rayburn Heatranger 880K 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 880K

  • 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 Better than you ever imagined Heatranger 880/8120/8150K For use in GB and IE DESN 514286 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 3: 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 7 - 8 OVEN AND HOTPLATE FLUEWAY CLEANING BURNER SERVICING INTRODUCTION BURNER NOZZLE REMOVAL BURNER NOZZLE REPLACEMENT PHOTO ELECTRIC CELL (PEC) CLEANING FAN CLEANING RE-ASSEMBLE BURNER...
  • Page 4 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 The Rayburn cannot be serviced whilst hot, so both oven BURNER SERVICING. and boiler thermostats should be turned off on the OIL PUMP SERVICING - Cleaning of fuel line strainer.
  • 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 FIBRE INSULATION. THE BOILER BURNER NEEDS TO BE REMOVED FIRST. BOILER BURNER - 880 ONLY (SEE FIG. 3) 1. Place a sheet on the floor in front of the cooker to act as a working area.
  • Page 8 Cleaning HEAT EXCHANGER CLEANING IMPORTANT: DURING CLEANING CARE MUST BE TAKEN NOT TO DAMAGE THE FIBRE INSULATION. SEE FIG. 5 1. Lift insulation covers and remove 4 fixing screws. 2. Using lifting hooks provided, remove hotplate. FIG. 6 DESN 514434 FIG.
  • Page 9 Cleaning SEE FIG. 9 5. Clean the boiler outlet flueway by inserting the flexible brush through the rear aperture, directing it towards the flue outlet. Scrape the deposits towards the heat exchanger. 6. Thoroughly clean boiler heat exchanger flueway. 7. Carefully vacuum any debris that has fallen down into the burner chamber.
  • Page 10 Burner Servicing INTRODUCTION SEE FIG 12, 13 & 14 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 11 Burner Servicing BURNER NOZZLE REMOVAL BOILER BURNER REMOVAL (880 ONLY) (SEE FIG. 15) 1. Slacken 2 grub screws, pull tube forward. 2. Unscrew nozzle from its holder with a correct fitting tubular spanner. BOILER BURNER REMOVAL (8120/8150 ONLY) (SEE FIG. 16) 1.
  • Page 12 Burner Servicing PHOTO ELECTRIC CELL (PEC) SEE FIG. 13 CLEANING SEE FIG. 19 - 21 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.
  • Page 13 SEE FIG. 14 Burner Servicing FAN CLEANING Clean between the blades of the fan impeller with a small brush and remove any residue. 2A. COOKER BURNER ONLY (SEE FIG. 22) The fan motor flange has 3 fixings to the fan case. 2B.
  • Page 14 Oil Pump Servicing INTRODUCTION - BOILER BURNER SEAL To carry out any servicing on the oil pump. Turn off the oil STRAINER line isolating valve near to the appliance. COVER OIL PUMP STRAINER CLEANING SEE FIG. 24 1. Remove 4 socket head screws. 2.
  • Page 15 Re-commissioning BLEED AIR FROM OIL SUPPLY SEE FIG. 26 OR 27 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 Re-commissioning SET COMBUSTION AIR SEE FIG. 28 After 15 minutes of the boiler burner running. Remove the enamelled centre shroud Remove the left hand plugging screw and insert the sensing end of a portable indicator to check the CO (Carbon Dioxide) level. Adjust the boiler burner air intake until a reading of 11.0/11.5% is recorded on the indicator.
  • Page 17 Replacement of parts (Burner) FAN MOTOR Follow instructions in sections BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL, Steps 1 to 6. COOKER BURNER AND BOILER BURNER - 880K ONLY - SEE FIG. 31 1. Remove 3-pin plug. 2. Remove solenoid plug. 3.
  • Page 18 Replacement of parts (Burner) IGNITOR Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL Step 4. COOKER BURNER ONLY (SEE FIG. 34) 1. Remove both HT leads from ignitor, 2. Remove mains plug from ignitor. 3. Remove earth screw. 4.
  • Page 19 Replacement of parts (Burner) SOLENOID COIL SEE FIG. 37 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL, Steps 1 to 5 . 1. Remove plug. 2. Remove solenoid securing nut and washer. 3. Remove solenoid coil. 4.
  • Page 20 Replacement of parts (Burner) PUMP ACCESS SEE FIG. 39 PUMP FIXING Follow instructions in section BURNER ACCESS, Steps 1 PUMP SCREWS (3) to 3 and BURNER REMOVAL, Steps 1 to 5. DRIVE Isolate fuel supply. Disconnect flexible hose. (This must be replaced every 2 years).

  • Page 21: Electrical Component Access

    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. 40 1. Remove the controls door and place in a safe position. 2.

  • Page 22: To Fit New Boiler Control Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW BOILER CONTROL THERMOSTAT SEE FIG. 41 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 23: To Fit New Cooker Safety Overheat Thermostat

    Replacement of parts (Electrical controls) TO FIT NEW COOKER SAFETY OVERHEAT THERMOSTAT SEE FIG. 42 Follow instructions section ELECTRICAL COMPONENT ACCESS, Steps 1 to 6. 1. Undo 2 screws on the front of the chassis which holds the thermostat in place. 2.

  • Page 24: To Fit New Selector Switch

    Replacement of parts (Electrical controls) TO FIT NEW SELECTOR SWITCH SEE FIG. 45 Follow instructions section ELECTRICAL COMPONENT ACCESS, Steps 1 to 4. 1. To remove switch from the cover panel press the two toggles at top and bottom of switch, push switch through panel.

  • Page 25: 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 26: Terminal Strip Connections

    Electrical Controls CONTROL CIRCUIT-EXTERNAL TERMINAL STRIP CONNECTIONS 5 AMP PERMANENT SUPPLY PERMANENT PROGRAMMER - LIVE PERMANENT PROGRAMMER - NEUTRAL SWITCHED LIVE TO OPERATE COOKER FROM EXTERNAL PROGRAMMER SWITCHED LIVE TO OPERATE BOILER FROM ROOM STAT OR CYLINDER STAT VIA ZONE VALVES IF FITTED PUMP SUPPLY - LIVE THE CIRCULATING PUMP MUST BE...

  • Page 27: Appliance Control Panel Internal Wiring

    Fault Finding Appliance Control Panel Internal Wiring FIG. 46...

  • Page 28: Burner Control Wiring

    Fault Finding Burner Control Wiring FIG. 47...
  • Page 29 Fault Finding Burner Check that the burner has not gone to lockout. Causes of lockout can be:- No ignition, ignition electrode incorrectly positioned or insulation cracked, spark generator faulty, check for 230V at spark generator. No oil supply. Poor combustion. Photo electric cell incorrectly positioned, cracked or needs cleaning.

  • Page 30: Burner Fault Finding

    Fault Finding Burner Fault Finding Burner does not start up Mains switch not on. Blown fuse. Boiler thermostats not made. Fault in control box. Burner pre-purges and stops Fault in control box. Burner does not ignite during cycle - Fault in control box. and stops Fault in photo-resistor.
  • Page 31 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 33 For further advice or information contact your local distributor/stockist With Aga’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 Station Road Ketley Telford Shropshire TF1 5AQ England www.aga-web.co.uk...

This manual is also suitable for:

Heatranger 8120kHeatranger 8150k

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