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Rayburn Heatranger 480AL (CF) - User Manual

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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
raywarranty@aga-web.co.uk
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
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Summary

INTRODUCTION

Consumer Protection

Manufacturer's commitment to safety standards for designed products.

Important Notice

Warning about unauthorized alterations invalidating warranty and statutory rights.

Important

Note on materials possibly injurious to health and safety requiring PPE.

REGULATIONS

SITE REQUIREMENTS

SPECIFICATIONS

Technical details including dimensions, gas types, and outputs.

LOCATION

Requirements for appliance placement, clearances, and floor base.

GAS SUPPLY

Guidelines for gas pipework size, testing, and purging.

ELECTRICAL SUPPLY

Requirements for correct earthing, polarization, and mains supply connection.

SPECIFICATIONS

NAT. GAS (G20)

Performance data for Natural Gas operation.

PROPANE (G31)

Performance data for Propane gas operation.

SITE REQUIREMENTS

LOCATION

Details on floor suitability, clearances around the appliance, and flue pipe proximity.

GAS SUPPLY

Pipework requirements, testing for soundness, and purging.

ELECTRICAL SUPPLY

Earthing, polarization, mains supply details, and connection methods.

CONTROLS

FLUE SYSTEM

Open Flue

Specific requirements for open flue systems including cross-sectional area and flue pipe size.

AIR REQUIREMENTS

Kitchen or Internal Space Air Supply

Need for permanent air vent to outside or adjacent space for open flue appliances.

Effect of an Extract Fan

How extract fans can affect appliance safety and the need for spillage tests.

WATER CIRCULATION SYSTEM

Circulating Pump

Guidance on selecting and sizing the circulating pump.

Isolating Valves

Requirement for keyless isolating valves for pump service.

Inhibitor

Importance of adding corrosion inhibitor and flushing the system.

Sealed System Requirements

INSTALLATION INSTRUCTIONS

CLEARANCES

Minimum space requirements around the appliance for installation and servicing.

PRELIMINARY INSTALLATION

Details on unpacking and assembling initial components like the draught diverter and handrail.

INSTALLATION INSTRUCTIONS

Site Location

Instructions for moving and positioning the appliance for flue connection.

INSTALLATION INSTRUCTIONS

GAS CONNECTION

Procedure for connecting the gas supply and testing.

WATER CONNECTIONS

Location of flow and return pipe connections.

SYSTEM SUITABILITY

Confirmation that the boiler is suitable for fully pumped systems with control systems.

COMBUSTION DISCHARGE SAFETY DEVICE

Explanation of the safety device and its reset procedure.

INSTALLATION INSTRUCTIONS

ELECTRICAL CONNECTIONS

Steps for connecting the electrical wiring, terminal strip, and cable clamps.

ELECTRICAL CHECKS

Recommendation for qualified engineer to check electrical safety.

COMMISSIONING

ELECTRICAL INSTALLATION

Checks for electrical safety by a competent person.

WATER CIRCULATION SYSTEM

Procedure for flushing, filling, and checking the water system.

COMMISSIONING THE COOKER AND BOILER

Steps for isolating power, checking gas, and gas soundness.

INSTRUCT THE USER

Advising the user on precautions, servicing, operation, and gas safety.

LIGHTING THE PILOT

Step-by-step guide for lighting the boiler and cooker pilot burners.

BOILER OUTPUT SETTING

How to adjust the boiler output and refer to specifications.

COMMISSIONING

MAIN BURNER LIGHTING

Procedure for lighting the main burners, including safety device check.

SPILLAGE TEST

Performing a spillage test on the draught diverter for safety.

SERVICING

ANNUAL SERVICING

Importance and timing of annual servicing by a competent person.

SERVICE SCHEDULE

A list of tasks to be performed during a service.

SERVICING

PRE-SERVICE CHECK

Operating the appliance and system to note faults before service.

HOTPLATE CLEANING

Instructions for cleaning the hotplate using lifting tools.

BURNER ACCESS

Steps to access the burner area by removing the plinth.

SERVICING

BURNER CLEANING (Boiler)

Detailed steps for cleaning the boiler burner assembly and injectors.

SERVICING

BURNER CLEANING (Cooker)

Detailed steps for cleaning the cooker burner assembly and injectors.

SERVICING

HEAT EXCHANGER

Procedure for cleaning the heat exchanger, caution with insulation.

COMBUSTION CHAMBER INSULATION

Checking the boiler burner insulation for damage and replacement.

FLUE CLEANING

Brushing flueways and checking the draught diverter assembly.

SERVICING

RE-ASSEMBLE THE APPLIANCE

Instructions for re-assembling the appliance in reverse order after servicing.

REPLACEMENT OF PARTS - COOKER

TO FIT NEW BURNER

Steps to replace the cooker burner assembly.

TO FIT NEW BURNER INJECTOR

Steps to replace the cooker burner injector.

REPLACEMENT OF PARTS - ELECTRICAL CONTROLS

ELECTRICAL COMPONENT ACCESS

Procedures for accessing electrical components, including removing covers and tilting the chassis.

REPLACEMENT OF PARTS - COOKER

TO FIT NEW OVEN CONTROL THERMOSTAT

Steps to replace the oven control thermostat and reposition phial.

TO FIT NEW COOKER OVERHEAT THERMOSTAT

Steps to replace the cooker overheat thermostat and reposition phial.

REPLACEMENT OF PARTS - BOILER

TO FIT NEW GAS VALVE

Steps to replace the boiler gas valve, including pipe transfer and pressure setting.

TO FIT NEW PILOT INJECTOR

Steps to replace the boiler pilot injector.

REPLACEMENT OF PARTS - BOILER

TO FIT NEW BURNER

Steps to replace the boiler burner assembly, including flange elbow connection.

TO FIT NEW BURNER INJECTOR

Steps to replace the boiler burner injector.

TO FIT NEW BOILER THERMOSTAT

Steps to replace the boiler thermostat and associated components.

REPLACEMENT OF PARTS - BOILER

TO FIT NEW BOILER OVERHEAT THERMOSTAT

Steps to replace the boiler overheat thermostat.

TO FIT COMBUSTION DISCHARGE SAFETY DEVICE

Steps to replace the combustion discharge safety device.

SEALED SYSTEM REQUIREMENTS

Safety Valve Setting

Requirement for safety valve setting and pressure range.

Expansion Vessel

Selection criteria for expansion vessel volume based on system water volume.

Make-Up Vessel

Methods for replacing lost water, e.g., make-up vessel or automatic pressurisation.

Commissioning - General

General commissioning steps for sealed systems, including filling and safety valve checks.

COMMISSIONING

COMMISSIONING

Specific commissioning procedures for sealed systems, including pressure filling and safety valve testing.

Rayburn Heatranger 480AL (CF) Specifications

General IconGeneral
TypeRange Cooker
Fuel TypeOil
Number of Ovens2
HotplateYes
Flue Size127mm

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