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THIS APPLIANCE MUST BE INSTALLED IN
ACCORDANCE WITH THE RULES IN FORCE AND
USED ONLY IN A SUFFICIENT VENTILATION SPACE.

USE ONLY ON FULLY PUMPED SYSTEMS

This Rayburn Gas combination appliance is combined
cooker and hot water boiler providing central heating and
domestic hot water in addition to special cooking
facilities. It is available in open flue form, operating on
natural draught, the boiler being designed for use in fully
pumped, open or sealed systems. Two separate
independent controlled gas burners provide heat. One

burner for central heating boiler section, providing heating
and hot water, whilst the other burner provides heat to
the cooker.

REMEMBER, when replacing a part on this appliance,
use only spare parts that we require. Do not use
reconditioned or copy parts that have not been
clearly authorised by Aga.

In the interests of safety all gas appliances should be
installed by competent persons, in accordance with the
regulations in force.

FOR USE IN GB & IE

INTRODUCTION

REGULATIONS

1

07/05 EINS 512112

[email protected]

Heatranger 480AG (CF)/480AL (CF)

Better than you ever imagined

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.

Important

This appliance may contain some of the materials that are indicated
It is the Users/Installers responsibility to ensure that the necessary
personal protective clothing is worn when handling where 

applicable, the pertinent parts that contain any of the listed materials
that could be interpreted as being injurious to health and safety, see
below for information.

Firebricks, Fuel beds, Artificial Fuels - 

when handling use

disposable gloves.

Fire cement - 

when handling use disposable gloves.

Glues and Sealants 

- exercise caution - if these are still in liquid form

use face mask and disposable gloves.

Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre,
Kerosene/Gas Oil -

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.

PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THE APPLIANCE

Installation

and

Servicing

Instructions

DESN 512129 

Summary of Contents for Heatranger 480AG (CF)

Page 1: ...ed 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 Important This appliance may contain some of the materials that are indicated It is the Users Instal...

Page 2: ...3 INSTRUCT THE USER 13 LIGHTING THE PILOT 13 BOILER OUTPUT SETTING 13 MAIN BURNER LIGHTING 14 SERVICING ANNUAL SERVICING 15 SERVICE SCHEDULE 15 PRE SERVICE CHECK 16 HOTPLATE CLEANING 16 BURNER ACCESS 16 BURNER CLEANING 17 18 HEAT EXCHANGER 19 COMBUSTION CHAMBER INSULATION 19 FLUE CLEANING 19 RE ASSEMBLE THE APPLIANCE 20 REPLACEMENT OF PARTS COOKER TO FIT NEW BURNER 21 TO FIT NEW BURNER INJECTOR 21...

Page 3: ...ssure BRAY CAT 28 600 Max Heat Inputs Gross Max Heat Inputs Net Inlet Pressure Marking Injector Size Max Boiler Output Min Boiler Output 480AG NAT GAS G20 17 6 kW at 20 5mbar burner pressure 23 4kW at 32 5mb burner pressure Max Boiler Output Min Boiler Output BOILER TOTAL MIN 34 8kW MAX MIN MAX COOKER 29 3kW 24 6kW 27 0kW 22 6kW 39 5kW 36 4kW 32 0kW 10 2kW 9 4kW 1 09m3 h 2103g h 37mbar 0 37m3 h 70...

Page 4: ...ere the cooker is to stand in a recess or against a wall which is to be tiled in no circumstances should the tiles overlap the cooker top plate NOTE SMOKE SMELL EMITTED DURING INITIAL USAGE Some parts of the cooker have been coated with a light covering of protective oil During initial operation of the cooker this may cause smoke smell to be emitted and is normal and not a fault with the appliance...

Page 5: ...CE MINIMUM GAP ON RIGHT HAND SIDE MINIMUM GAP ON LEFT HAND SIDE R 1 2 1 2 BSP GAS CONNECTION Fig 1A Fig 1B 5 10mm 50mm 10mm WATER CONNECTIONS INSTALLER MUST MAKE PROVISION TO GAIN ACCESS TO 22mm COPPER FLOW AND RETURN PIPE DURING INSTALLATION ...

Page 6: ...hould form the initial connection to lined chimneys Where a chimney is to be used which is not composed of or lined with a non porous acid resistant material it should be lined with a stainless steel flexible flue liner in accordance with relevant standards Before connecting the appliance to or inserting a liner into a flue that has been previously used the flue must be thoroughly swept clean of a...

Page 7: ... in the direction away from the appliance Circulating Pump It is recommended that the selected pump be sized to suit the boiler pressure loss see Fig 2 and therefore adequate to give the required temperature differential between the flow and return The pump should be able to meet the requirements of the system design and fitted in a readily accessible position Isolating Valves Isolating valves pre...

Page 8: ...arately packed and require assembly 1 Draught Diverter See Fig 3 Assembly 2 Appliance Rear for use when appliance is Distance Bracket installed 25mm away from a rear wall of combustible material See Fig 4 3 Hand Rail The handrail brackets are held on the front ends of the cooker top plate casting Remove the travel nuts and replace with the handrail brackets ensuring the fibre protecting washers ar...

Page 9: ...ppliance on the crowbar and remove the rear rolled tube followed by similar action on the front tube 2 Assemble and locate the flue draught diverter assembly on flue spigot as follows See Fig 6 1 Ensure baffle plate is located with front stamping towards front of cooker 2 Ensure C D S D is correctly located in C D S D in phial clip NOTE IT IS RECOMMENDED THAT A SLIP OR SPLIT ADAPTOR IS FITTED BETW...

Page 10: ...em under control of the boiler thermostat only does not produce the best efficiency Refer to the control equipment manufacturer s literature for information e g wiring The internal boiler cooker wiring is shown in Fig 10 For safety purposes a combustion discharge safety device is fitted This will only operate under adverse flue conditions If the switch has operated it should be pushed in to reset ...

Page 11: ...erminal marked BSL NOTE The link between terminals L1 and BSL MUST be removed to ensure correct operation of the time switch If the time switch is fitted to the cooker then the switched live MUST be connected to the terminal marked CSL NOTE The link terminals L1 and CSL MUST be removed to ensure correct operation of the time switch Refit the terminal cover plate WARNING THIS APPLIANCE MUST BE EART...

Page 12: ...Installation Instructions 12 FIG 10 ...

Page 13: ...11 This appliance is fitted with an automatic ignition unit that will light the main burner on demand Should button K see Fig 11 be illuminated press button this will allow the burner ignition to continue should the button illuminate again this will indicate a fault on the boiler burner Contact your local CORGI registered gas engineer to correct the fault Cooker see Fig 11 Press in and hold the co...

Page 14: ...he air has been removed from the water circuit the pump and radiators should be balanced to achieve the correct temperature to drop across the system Set any timer room temperature etc to suit the customer s requirements SPILLAGE TEST With cooker and boiler burners full on A spillage test must be carried out after 5 minutes as follows Light a smoke match and position into the draught diverter as s...

Page 15: ...vice so that the appliance will be cooled down by the following morning in readiness for servicing Before commencing any service isolate the electricity supply then turn OFF the gas supply at the gas service cocks 1 Carry out a pre service check noting any operational faults 2 Clean the hotplate 3 Clean the burners 4 Clean the burner and pilot injectors 5 Clean the heat exchanger 6 Check the condi...

Page 16: ...TER COMPLETING SERVICE ALWAYS CHECK FOR GAS SOUNDNESS AND CHECK THIS FUNCTION OF CONTROLS Lift out the hotplate using lifting tools provided Brush the fins with a wire brush to remove any deposits SEE FIG 7 1 Open up the bottom burner access door 2 Remove the 3 plinth securing screws and remove plinth 16 Servicing PRE SERVICE CHECK FIG 12 HOTPLATE CLEANING SEE FIG 12 BURNER ACCESS DESN 510145 A ...

Page 17: ...op and check the flame ports are clear Any deposits may be removed with a non metallic brush Remove three screws securing burner assembly to manifold A Remove two screws securing burner left handside support B Slide out burner element assembly Check the burner injectors check the orifices and remove any deposits from the injectors and burner venturi using a suitable non metallic brush Remove pilot...

Page 18: ...or bracket and remove controls away from burner door Brush burner venturi and remove any deposits from inside the burner venturi and tip downwards to discharge debris Remove the burner injector check the orifice and remove any deposits from the injector using a suitable non metallic brush Remove pilot injector Clean any deposits by rinsing in warm water or use a suitable non metallic brush DO NOT ...

Page 19: ...See Fig 17B Remove access plate R Using a suitable brush clean the heat exchanger from above and below NOTE The insulation used on the inside surface of the combustion chamber is delicate Great care must be taken when cleaning the heat exchanger not to abrade it No attempt should be made to clean the insulation Remove boiler burner assembly as previously described Check insulation for any signs of...

Page 20: ...nnect electronic ignition unit to the boiler gas valve Re connect ignitor lead to ignition unit Replace hotplate Test fully for gas soundness Test the Appliance and Installation Ensure that gas is turned on at both of the service cocks and electrical supply is ON Following the sequence in COMMISSIONING INSTRUCTIONS 20 Servicing RE ASSEMBLE THE APPLIANCE ...

Page 21: ... 3 Remove burner and transfer all ancillary items 4 Fit new burner 5 Re assemble in reverse order Follow instructions in section Burner Cleaning of Servicing Instructions and remove the cooker burner assembly 1 Refer to the above and remove the burner 2 Unscrew injector 3 Fit replacement 4 Re assemble in reverse order 21 Replacement of Parts Cooker TO FIT NEW BURNER TO FIT NEW BURNER INJECTOR ...

Page 22: ...osition 2 Remove both thermostat control knobs 3 Remove the 2 cover panel fixing screws 4 Remove cover panel SEE FIG 19 5 Remove the two control panel fixing screws 6 Tilt the chassis from the top and lift out taking care not to damage thermostat capillaries 7 Re assemble in reverse order 22 Replacement of Parts Electrical Controls ELECTRICAL COMPONENT ACCESS FIG 18 FIG 19 DESN 512150 DESN 512131 ...

Page 23: ...23 Replacement of Parts Electrical Controls FIG 20 DESN 512148 EARTH POST THERMOSTAT CAPILLARIES COOKER THERMOSTAT COOKER OVERHEAT THERMOSTAT CABLE CLAMP BOILER THERMOSTAT CAPILLARY BOILER THERMOSTAT ...

Page 24: ...CESS Steps 1 to 6 1 Undo the two screws on the front of the chassis which holds the thermostat in place 2 Remove the two push on connectors from back of thermostat 3 Open main oven door to access the thermostat phial and capillary which pass into the oven at the top left hand corner 4 Remove LH side plate Slacken screw front phial mounting bracket and rotate Note Both the oven control thermostat p...

Page 25: ...alve ensuring correct positioning 4 Refit gas valve to elbow flange ensuring correct positioning 5 Check for gas soundness and set burner pressure Follow instructions in section Burner Cleaning of Servicing Instructions and remove the boiler burner assembly 1 Release both ends of the pilot supply pipe 2 Remove injector 3 Fit replacement 4 Re assemble in reverse order 5 Check for gas soundness 25 R...

Page 26: ...manifold 2 Remove two screws securing burner left handside support 3 Slide out burner element assembly 4 Replace injectors 5 Re assemble following instructions as above Follow instructions in section ELECTRICAL COMPONENT ACCESS page 22 1 Remove four screws securing control box 2 Remove split pin securing thermostat phials in location 3 Remove phials from heat exchanger phial pocket 4 Remove electr...

Page 27: ...e bracket 4 Feed CDSD phial and capillary down tubing 5 Remove spindle lockout and electrical leads from CDSD extract CDSD See Fig 27 6 Fit replacement and re assemble in reverse order NOTE INCORRECT FITTING OF COMBUSTION DISCHARGE DEVICE COULD LEAD TO COMBUSTION PRODUCTS LEAKING INTO THE ROOM ONLY PARTS SUPPLIED BY RAYBURN MUST BE USED 27 Replacement of Parts Boiler TO FIT NEW BOILER OVERHEAT THE...

Page 28: ...r storage cistern supplying domestic hot water even though a non return valve may be fitted without the approval of the local water authority h The Filling Point The system shall be fitted with a filling point at a low level and be used in accordance with the local water authority requirement i Commissioning General The system shall be filled by water by a method acceptable to the Local Water Auth...

Page 29: ... TO THE RETURN THEN THE PRESSURE GAUGE AND EXPANSION VESSEL ARE FITTED ADJACENT TO THE SUCTION SIDE OF THE PUMP THE SAFETY VALVE REMAINS AS SHOWN ON THE FLOW PIPE Typical Open Vented System THIS BY PASS BALANCING VALVE SHOULD BE OF AN AUTOMATIC TYPE AND MUST HAVE AT LEAST 1 5 METRES OF 22mm PIPE EACH SIDE BETWEEN IT AND THE COOKER ALTERNATIVELY THE BYPASS LOOP CAN INCORPORATE A TOWEL RAIL CONTROLL...

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Page 31: ...31 ...

Page 32: ...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 ...

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