Rayburn Heatranger 480D, Servicing Instructions

Page 1: ...WARNING This information is a copy of an original archive therefore Aga cannot be held responsible for its continued accuracy ...

Page 2: ...n GB and IE Servicing Instructions Heatranger 480D At the Heart of your Home P A T A P P 2 2 8 0 7 4 7 A N D O T H E R G B I E P A T E N T S P E N D I N G DESN 510517 PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE ...

Page 3: ...s Glass Yarn Mineral Wool Insulation Pads Ceramic Fibre May be harmful if inhaled May be irritating to skin eyes nose and throat When handling avoid contact with skin or eyes Use disposable gloves face masks and eye protection After handling wash hands and other exposed parts When disposing of the product reduce dust with water spray ensure that parts are securely wrapped Kerosene Gas Oil fuels mi...

Page 4: ... Rayburn cannot be serviced whilst hot so both oven and boiler thermostats should be turned off on the evening before the service visit BURNER REMOVAL for cleaning and inspection CLEANING Boiler heat exchanger flueways oven and hotplate flueways together with ceramic fibre burner chambers BURNER SERVICING OIL PUMP SERVICING Cleaning of fuel line strainer RE COMMISSIONING REPLACEMENT PARTS Addition...

Page 5: ...re 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 SEE FIG 1 1 Open up the bottom burner access door Remove door and put in a safe place 2 Remove the 4 inner panel securing screws and remove panel 3 Remove the 3 plinth securing screws and remove plinth 4 PREPARATION BURNER ACCESS ...

Page 6: ...et on the floor in front of the cooker to act as a working area 2 Disconnect the 5 pin plug underneath the burner SEE FIG 3 3 Undo the burner central locking nut 4 Remove 2 fan mounting plate nuts SEE FIG 4 5 Withdraw the burner unit 5 BURNER REMOVAL FIG 2 FIG 3 FIG 4 DESN 511238 DESN 511239 DESN 511240 Burner Removal ...

Page 7: ... top plate enamelled cover panel behind the L H insulating cover remove insulation pad A and sealing plate 5 Clean the boiler outlet flueway by inserting the flexible brush through top plate 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 ...

Page 8: ...ccess doors Secure in position using hex driver NOTE Further access to base flueway is available if diverter baffle is removed replace baffle if removed 6 Brush and clean in between hotplate ribs on underside 7 Examine soft rope seal located around hotplate aperture in top plate Replace if frayed or damaged 8 Replace hotplate ensuring the underside ribs lie over the oven and that it seals to the t...

Page 9: ...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 This prevents the possibility of contact between the diffusers and the electrodes in the event of diffuser distortion and will also ensure that the PEC sensing hole aligns with the PEC in the burner head of the boiler burner 8 INTRODUCTION Burner Ser...

Page 10: ...aking care not to wipe the nozzle tip itself 7 Check electrode gap and reset if necessary 1 Remove diffuser by slackening bolt note orientation of diffuser in relation to the ignitor assembly ensuring that the short vane is aligned vertically between the electrodes during re assembly This will also ensure that the PEC sensing hole aligns with the PEC in the boiler burner 2 Remove ignitor assembly ...

Page 11: ...an between the blades of the fan impeller with a small brush and tip upside down to remove any residue 2 Spin the motor to make sure that it turns easily Re assemble the burner in reverse order making sure that the fixing screws for the nozzle assembly are correctly lined up with the respective holes in the body 10 Burner Servicing FAN CLEANING PHOTO ELECTRIC CELL PEC CLEANING RE ASSEMBLE BURNER F...

Page 12: ... 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 3 Wash filter thoroughly in clean petrol or paraffin 4 Re assemble filter in reverse order of removal 11 INTRODUCTION OIL LINE FILTER CLEANING Oil Pump Servicing ...

Page 13: ...ility resulting in the burner locking out This will be shown by the burner stopping and the illumination of the signal light in the reset button of the control box see Fig 14 IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the re set button to restart SEE FIG 13 Whilst the burner is running vent air from the pump by slackening the pressure gauge port sufficient to allow air to bleed out When bub...

Page 14: ...e ways does not exceed No 2 on the scale Replace the plugging screw insulation pad and cover panel Switch off the boiler burner COOKER BURNER SEE FIG 15 Switch on cooker burner After 15 minutes of the cooker burner running Repeat the above procedures for the cooker burner To sample the flue gases from the cooker burner lift up the R H insulating cover and remove the countersunk headed screw in the...

Page 15: ... cover panel fixing screws 4 Remove cover panel It will be necessary to disconnect the push on tags from the selector switch SEE FIG 17 5 Remove the four control panel fixing screws 6 Tilt the chassis forwards from the top and lift out To fully access the rear of the control chassis the thermostat capillaries should be removed from their pockets 14 ELECTRICAL COMPONENT ACCESS Replacement of parts ...

Page 16: ...15 FIG 18 DESN 511140 Replacement of parts Electrical controls ...

Page 17: ...ostat The thermostat should be mounted with tag P at the right hand side looking from back Take care to push thermostat phial correctly into the pocket provided 4 Re connect push on connector wires The WHITE wire from the pump PL to P the other WHITE wire to 2 and the RED to 1 To complete follow instructions in section RE ASSEMBLE Steps 1 to 6 SEE FIG 21 Follow instructions in section ELECTRICAL C...

Page 18: ...ary which pass into the oven at the top left hand front corner The thermostat phial is located in a slot at the top front of the oven 4 Slacken the single screw where the phial passes through the roasting oven side and rotate the cover plate to open up the access hole 5 Slack the two screws in the top of the roasting oven at the front and rotate the two retaining clips 6 Allow the thermostat phial...

Page 19: ...grammer inserting the top base with the bottom clip 6 Refix the mounting brackets to the control chassis To complete follow instructions in section RE ASSEMBLE Steps 3 to 6 SEE FIG 25 Follow instructions in section ELECTRICAL COMPONENT ACCESS Steps 1 to 4 1 To remove switch of the cover panel press the two toggles at top and bottom of switch simultaneously and push switch through panel 2 Push repl...

Page 20: ...s backwards into position and secure with the four screws 3 Thread the two wires for the selector switch through the aperture and connect them onto the rear of the selector switch fitted in the outer panel Connect the YELLOW wire on 1 and the PURPLE wire on 2 4 Refix the outer panel in position and secure with the 2 screws 5 Replace the thermostat knobs 6 Replace the controls door 19 Replacement o...

Page 21: ... the short vane is aligned vertically between the electrodes during re assembly This will also ensure that the PEC sensing hole aligns with the PEC in the boiler burner 2 Remove ignition electrode assembly by removing nut 3 Fit new ignition electrode assembly re assemble in reverse order 4 Check electrode gap and reset if necessary SEE FIG 28 Follow instructions in sections BURNER ACCESS Steps 1 t...

Page 22: ...URNERS Steps 1 to 3 1 Remove push on connections noting position of each connection 2 Slacken inner securing screw remove outer securing screw 3 Remove relay 4 Fit new relay re assemble in reverse order SEE FIG 31 Follow instructions in sections BURNER ACCESS Steps 1 to 3 BURNER REMOVAL Steps 1 to 5 and DISMANTLE BURNERS Steps 1 to 3 1 Slacken solenoid plug securing screw 2 Remove plug 3 Remove so...

Page 23: ...le in reverse order SEE FIG 33 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 control box as detailed above 2 Unplug PEC 3 Undo wire connections 11 12 noting colour polarity 4 Withdraw PEC cable 5 Slacken and remove PEC clip note orientation of clip 6 Transfer and secure clip to new PEC 7 Fit new PEC re assemble in...

Page 24: ...nnect flexible hose 3 Disconnect pump supply tube from burner assembly 4 Remove pump from base 2 screws and washers SEE FIG 34 1 Remove 2 pump plate securing screws and remove plate 2 Remove filter 3 Fit new filter 4 Re assemble in reverse order 23 Replacement of parts Burner PUMP ACCESS PUMP FILTER REPLACEMENT FIG 34 DESN 511251 ...

Page 25: ...e 65 C then the pump overrun thermostat operates and switches on the pump until the overrun thermostat switches back BOILER This thermostat is a safety cut out device which is intended to operate if the other controls fail This control will lock out and switches everything off except for the programmer clock and the Pump Overrun facility This thermostat has to be manually reset once the temperatur...

Page 26: ... VALVE S ETC IF FITTED PUMP SUPPLY THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY PUMP SUPPLY THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY 3 AMP PERMANENT SUPPLY NOTE If no Hot Water System Controls are used a link MUST be fitted between H W ON and SW L BOILER If no Central Heating System Controls are used a link MUST be fitted between HTG ON and SW L BOILER If a ...

Page 27: ...26 Electrical Controls CONTROL CIRCUIT BOILER FIG 35 ...

Page 28: ...27 Electrical Controls CONTROL CIRCUIT COOKER FIG 36 ...

Page 29: ...28 Fault Finding WIRING DIAGRAM BURNER ONLY FIG 37 ...

Page 30: ...29 Fault Finding WIRING DIAGRAM APPLIANCE FIG 38 ...

Page 31: ...tinuity checks refer to Figs 35 36 37 and 38 for detailed and schematic wiring layouts To check out the electrical wiring at the burners you will first have to have access to the burner chamber Use the following procedure 1 Isolate the electrical power supply 2 Open up the bottom burner access door Remove door and put in a safe place 3 Unscrew the 4 screws holding the inner panel in place and remo...

Page 32: ...OSTAT ACTIVATED IS THERE 230V BETWEEN COOKER OVERHEAT STAT AND NEUTRAL REPLACE COOKER OVERHEAT STAT RESET OVERHEAT THERMOSTAT THERMOSTAT OR WIRING FAULT YES NO NO YES NO YES CHANGE CIRCULATING PUMP IS CIRCULATING PUMP OPERATING SATISFACTORILY CHECK BALANCE CH DHW SYSTEM CHANGE PUMP OVERRUN THERMOSTAT NO YES IS THE PUMP OVERRUN OPERATING AT A WATER TEMP OF 65 C NO YES ...

Page 33: ...GHT CHECK WITH GAUGE OIL SOAKED HEARTH BURNER FAULT OIL LEAKS AT PIPE FITTINGS TAKE APART AND REMAKE AS REQUIRED LEAKS AT TUBING CONNECTORS ENSURE END OF TUBING SQUARE NUMEROUS LOCK OUTS CURE THE LOCK OUT CONDITION ODOURS IN KITCHEN OIL PRESSURE INCORRECT ADJUST TO RECOMMENDED SETTINGS INCORRECT COMPONENTS USED ON COMBUSTION HEAD SEE SERVICING INSTRUCTIONS INTERNAL INSULATION PANELS INCORRECTLY PO...

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