Rayburn Heatranger 880K, 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: ...ver imagined DESN 514286 PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE 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: ...TCH ON ELECTRICITY 14 VENT OIL PUMP 14 ADJUST OIL PRESSURE 14 SET COMBUSTION AIR 15 CHECK SMOKE 15 REPLACEMENT OF PARTS FAN MOTOR 16 BURNER IGNITION ELECTRODES 16 IGNITOR 17 SOLENOID COIL 18 CONTROL BOX 18 PUMP ACCESS 19 REPLACEMENT OF PARTS ELECTRICAL COMPONENT ACCESS 20 ELECTRICAL CONTROLS TO FIT NEW BOILER CONTROL THERMOSTAT 21 TO FIT NEW BOILER PUMP OVERRUN THERMOSTAT 21 TO FIT NEW COOKER SAFE...

Page 4: ... and other exposed parts When disposing of the product reduce dust with water spray ensure that parts are securely wrapped Kerosene and Gas Oil fuels mineral oils 1 The effect of mineral oils on the skin vary according to the duration of exposure 2 The lighter fractions also remove the protective grease normally present on the surface of the skin This renders the skin dry liable to crack and more ...

Page 5: ...g before the service visit Annual Service During annual service burner nozzles and burner head seals MUST BE CHANGED Flexible oil lines must be changed every 2 years WIRING Ensure there is no damage or loose connections This should be carried out by a competent engineer BURNER REMOVAL for cleaning and inspection CLEANING Boiler heat exchanger flueways oven and hotplate flueways together with insul...

Page 6: ...y 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 SEE FIG 1 1 Open up the bottom burner access door Remove door and put in a safe place 2 Remove inner panel securing screw and remove panel 5 PREPARATION BURNER ACCESS Burner Removal FIG 1 DESN 514439...

Page 7: ...duct 7 Undo two burner retaining nuts lower burner and remove BOILER BURNER 8120 8150 ONLY SEE FIG 4 1 Place a sheet on the floor in front of the cooker to act as a working area 2 Disconnect air intake 3 Slacken retaining nut 4 Rotate burner to right and remove COOKER BURNER REMOVAL SEE FIG 2 1 Place a sheet on the floor in front of the cooker to act as a working area 2 Remove boiler burner as abo...

Page 8: ...r securing bolts and remove door 4 Remove the boiler flueway baffles from between boiler cross waterways The baffles are assembled in alternate directions to allow gases to flow front to back through the assembly Each heat exchanger has two rows of baffles Total number of baffles fitted are 800 6 2 x 3 8120 6 2 x 3 8150 6 2 x 3 7 HEAT EXCHANGER CLEANING Cleaning FIG 5 FIG 6 FIG 7 FIG 8 DESN 514438...

Page 9: ...0 11 1 Remove the top oven door and place in a safe position 2 Remove base access door using hex driver 3 Thoroughly clean top side and base flueways through access apertures with brush 4 Remove all debris with vacuum cleaner 5 Replace base access door Secure in position using hex driver 6 Brush and clean in between hotplate ribs on underside 7 Examine soft rope seal located around hotplate apertu...

Page 10: ...ally 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 8120 8150K 880K 9 INTRODUCTION Burner Servicing FIG 12 FIG 13 FIG 14 CESN 514452 DESN 514454 DESN 514453 ...

Page 11: ...ect ignition leads 5 Remove socket head screw from back of head assy Withdraw nozzle holder complete with ignitors 6 Remove ignitor assembly by removing countersunk screw and clamp 7 Unscrew nozzle from its holder with correct fitting tubular spanner to avoid damage to hexagon SEE FIG 18 1 Replace nozzle by a new one of the same make and specification 2 Ensure that mating faces are clean 3 Hold no...

Page 12: ... 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 11 Burner Servicing PHOTO ELECTRIC CELL PEC CLEANING FIG 21 DESN 514445 FIG 20 DESN 514460 FIG 19 DESN 514446 ...

Page 13: ... flange has 3 fixings to the fan case 2C BOILER BURNER 8120 8150 ONLY SEE FIG 23 Remove 4 pozi drive screws pull off fan case inlet 3 Withdraw assembly from burner body 4 Clean impellor with a soft brush 5 Spin motor to check that it burns easily Re assemble the burner in reverse order NOTE Burner head gaskets should be renewed at each service FAN CLEANING Burner Servicing 12 RE ASSEMBLE BURNER FI...

Page 14: ...ng 3 Wash filter thoroughly in clean petrol or paraffin 4 Re assemble in reverse order NOTE Flexible fuel hose s must be replaced every 2 years To carry out any servicing on the oil pump Turn off the oil line isolating valve near to the appliance 1 The oil pump strainer is situated on top of the pump 2 Remove the cartridge filter with a hex driver 3 Wash with clean petrol or paraffin 4 Re assemble...

Page 15: ...bility 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 IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the re set button to restart SEE FIG 26 OR 27 Whilst the burner is running vent air from the pump by slackening the pressure gauge port sufficient to allow air to bleed out When bubble ...

Page 16: ...ump and check that the smoke in the boiler flue 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 30 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 Remove the RH countersunk headed ...

Page 17: ...e 4 pozi drive screws remove fan case inlet 5 Undo grub screw remove fan 6 Remove 4 fixings withdraw motor 7 Re assemble in reverse order NOTE Ensure that gaskets and seals are in place and in good condition Follow instructions in BURNER ACCESS Steps 1 to 3 and BURNER NOZZLE REMOVAL Steps 1 to 5 SEE FIG 33 1 Disconnect ignition leads 2 Remove 2 socket head screws 3 Remove head assembly complete 4 ...

Page 18: ...0 ONLY SEE FIG 35 1 Undo 2 access door fixings 2 Remove both HT leads 3 Remove mains plug 4 Remove ignitor securing screws 5 Remove ignitor 6 Fit new ignitor re assemble in reverse order BOILER BURNER 8120 8150 ONLY SEE FIG 36 1 Undo 2 Philips head screws slide out mounting bracket 2 Remove both HT leads 3 Remove mains plug 4 Remove ignitor securing screws 5 Remove ignitor 6 Fit new ignitor re ass...

Page 19: ...verse order SEE FIG 38 Follow instructions in sections BURNER ACCESS Steps 1 to 3 BURNER REMOVAL Steps 1 to 2 1 Remove 2 control box mounting screws 2 Insert a flat bladed screwdriver in LH side of c box as diagram 3 Repeat as above for RH side 4 Gently pull c box away from base 5 Fit new c box re assemble in reverse order 18 Replacement of parts Burner CONTROL BOX FIG 38 DESN 514435 FIG 37 DESN 5...

Page 20: ...isconnect flexible hose This must be replaced every 2 years 3 Remove solenoid plug 4 Remove feed pipe 5 Slacken three securing screws and remove pump 6 Check drive replace if worn or damaged 7 Replace pump reassemble in reverse order Replacement of parts Burner PUMP ACCESS FIG 39 DESN 511995 PUMP DRIVE PUMP FIXING SCREWS 3 19 ...

Page 21: ...lace in a safe position 2 Remove the 4 panel fixing screws 3 Tilt assembly forward 4 Remove the four control panel fixing screws 5 Tilt the chassis forward from the top and lift out To fully access the rear of the control chassis the thermostat capillaries should be removed from their pockets 20 ELECTRICAL COMPONENT ACCESS Replacement of parts Electrical controls FIG 40 DESN 514455 ...

Page 22: ...on RE ASSEMBLE Steps 1 to 6 SEE FIG 41 Follow instructions in 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 Remove the three push on connectors from back of thermostat 3 Replace thermostat The thermostat should be mounted with tag P at the left hand side Take care to push on thermostat phial correctly into th...

Page 23: ...rmostat phial correctly into the pocket provided 4 Re connect push on connector wire as Fig To complete follow the instructions in section RE ASSEMBLE Steps 1 to 6 SEE FIG 44 Follow instructions in 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 Remove 2 push on connectors from back of thermostat 3 Open roasting ove...

Page 24: ...lacement switch into aperture and click into place The switch should be fitted with terminal 1 at the top To complete follow instructions in section RE ASSEMBLE Steps 3 to 6 1 Locate thermostat phials into boiler pocket 2 Refix the panel in position and secure with the 4 screws 3 Replace the controls door Replacement of parts Electrical controls 23 TO FIT NEW SELECTOR SWITCH FIG 45 DESN 510553 A R...

Page 25: ...R 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 temperature has cooled down COOKER This thermostat is a safety cut out device which operates if the control thermostat fails This th...

Page 26: ...CHED LIVE TO OPERATE COOKER FROM EXTERNAL PROGRAMMER SWITCHED LIVE TO OPERATE BOILER FROM ROOM STAT OR CYLINDER STAT VIA ZONE VALVES IF FITTED THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY TERMINAL STRIP CONNECTIONS Electrical Controls N N N 6 9 10 11 PUMP SUPPLY LIVE PUMP SUPPLY N PUMP SUPPLY E ...

Page 27: ...26 Fault Finding FIG 46 Appliance Control Panel Internal Wiring ...

Page 28: ...27 Fault Finding Burner Control Wiring FIG 47 ...

Page 29: ...the burner 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 remove panel 4 Unscrew the 3 screws holding the louvered plinth in place and remove plinth The external mains connections are made...

Page 30: ...hoto resistor Burner does not ignite Dirty ignition electrodes Fault at electrodes Electrodes installed wrongly Faulty ignition transformer Blocked nozzle Nozzle needs replacing Oil pressure to low Blocked oil filter Excessive combustion air for nozzle capacity Fault in control box Burner ignites and then stops Faulty nozzle Photo resistor does not see flame Excessive combustion air for nozzle cap...

Page 31: ...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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Page 33: ...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 Station Road Ketley Telford Shropshire TF1 5AQ England www aga web co uk www agacookshop co uk www agalinks com ...