Rayburn Heatranger 480AG CF User guide

1
Heatranger 480AG (CF)/480AL (CF)
Installation and Servicing Instructions
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09/22 EINS 512112LPRT 512180
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, the warranty
and could also infringe the current issue of the statutory
requirements.
All local regulations including those referring to national
and European standards need to be complied with when
installing this appliance.
Control of Substances - Health & Safety Important
This appliance may contain of the materials that are
indicated below. 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, Articial 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 Oil - may be harmful if inhaled, may be irritating
to skin, eyes, nose and throat. When handling avoid inhaling
and 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.
Introduction
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 ue 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.
Regulations
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
DESN 512129
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING THE APPLIANCE

2
Contents
Specications 3
Site Requirements 4
Location 4
Gas supply 4
Electrical supply 4
Controls 6
Flue system 6
Air requirements 6
Water circulation system 7
Installation Instructions 8
Clearances 8
Preliminary installation 8
Site Location 9
Gas connection 10
Water connections 10
System suitability 10
Combustion discharge safety device 10
Electrical connections 11
Electrical checks 11
Commissioning 13
Electrical installation 13
Water circulation system 13
Commissioning the cooker and boiler 13
Instruct the user 13
Lighting the pilot 13
Boiler output setting 13
Main burner lighting 14
Spillage test 14
Servicing 15
Annual servicing 15
Service schedule 15
Pre-service check 15
Hotplate cleaning 15
Burner access 15
Burner cleaning 16
Heat exchanger 18
Combustion chamber insulation 18
Flue cleaning 18
Re-assemble the appliance 19
Replacement of Parts - Cooker 19
To t new burner 19
To t new burner injector 19
Electrical component access 20
To t new oven control thermostat 21
To t new cooker overheat 21
Replacement of Parts Boiler 22
To t new gas valve 22
To t new pilot injector 22
To t new burner 22
To t new burner injector 22
To t new boiler thermostat 23
To t new boiler overheat thermostat 23
To t combustion discharge safety device 23
Sealed System 24
Sealed system requirements 24
Commissioning 24

3
Specications
DESN 512130
905
118
125
1240
940
446
50
67
585
102
38
542
910
1355
R ½ (½”BSP TAPER)
NOTE: IT IS ADVISABLE TO CHECK THE ACTUAL
SIZE/WIDTH OF YOUR CUPBOARDS BEFORE
FINALLY FIXING ANY KITCHEN UNITS SINCE
ENAMELLED CAST IRON CAN VARY IN SIZE.
480AG NAT. GAS (G20) TOTAL BOILER COOKER
MIN. MAX. MIN. MAX.
Max. Heat Inputs - Gross 34kW 41.0kW 23.5kW 30.5kW 10.7 kW
Max. Heat Inputs - Net 30.5kW 37.0kW 21.0kW 27.5kW 9.6 kW
Inlet Pressure 20mbar 2.82m/h 1.02m/h
Marking - Injector Size - 1.17mm x 15 BRAY CAT 28/600
Max. Boiler Output 23.4kW at 13mbar burner pressure
Min. Boiler Output 17.6kW at 8mbar burner pressure
480AL PROPANE (G31) TOTAL BOILER COOKER
MIN. MAX. MIN. MAX.
Max. Heat Inputs - Gross 35.8kW 40.7kW 25.6kW 30.5kW 10.2kW
Max. Heat Inputs - Net 33.0kW 37.4kW 23.5kW 28kW 9.4kW
Inlet Pressure 37mbar 1.09m/h (2103g/h) 0.37m/h (700g/h)
Marking - Injector Size - 0.75mm x 15 4016
Max. Boiler Output 23.4kW at 32.5mb burner pressure
Min. Boiler Output 17.6 kW at 20.5mbar burner pressure
Gas Connection R½ (½” BSP TAPER) Appliance weight: 330Kg
Electrical Supply 230V~50Hz 3 amp Fused Boiler Connections: Flow 22mm O/D Copper Tube
Max. Working Pressure of Boiler: Return 22mm O/D Copper Tube
Open Vent System 3 bar (30m) Flue Outlet: 125mm
Sealed System 2.60 bar (26.0m)
Max. Water Temp. 82ÞC + 3ÞC
Water Capacity 0.6 litre

4
Location
The appliance must be installed on a solid level oor or base
of incombustible material which is capable of supporting the
total weight.
The location chosen for the appliance must permit
installation and the provision of a satisfactory ue and an
adequate air supply. The location must also provide space for
servicing and air circulation around the appliance.
Between wall and LH side of appliance 10mm Between
wall and RH side of appliance 10mm*
*SHOULD THE WALL PROJECT BEYOND THE FRONT OF
THE APPLIANCE, WHEN IT MUST BE INCREASED TO 50MM
(SEE FIG. Fig. 1.1, Fig. 1.2).*
Above the raised insulating cover handle 60mm
NOTE: GAS AND WATER CONNECTIONS ARE LOCATED
ON THE LH SIDE OF THE APPLIANCE. INSTALLERS MUST
MAKE PROVISION FOR ACCESS TO THESE CONNECTIONS
DURING INSTALLATION.
In addition, adequate clearance must be available at the
front of the appliance to enable it to be operated and
serviced. Flue pipes and ttings must not be closer than
25mm to combustible materials and where passing through
a combustible partition such as a ceiling or roof, must be
enclosed in a non-combustible sleeve providing an air space
of at least 25mm.
Spaces around ue pipes passing through walls or oors
should be sealed against the passage of smoke and ame.
Where 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, it is therefore
advisable to open doors and or windows to allow for
ventilation. Lift the insulating lids to prevent staining the
linings.
Gas supply
Pipework from the meter to the appliance must be of
adequate size. It is recommended that ø22mm minimum
diameter copper tubing is used. Do not use pipes of a smaller
size than the appliance gas connection. The complete
installation must be tested for soundness and purged in
accordance with the regulations in force.
Electrical supply
External wiring must be correctly earthed, polarised and
in accordance with current regulations. The main supply
required is 230V, 50Hz fused at 3A.
NOTE: The method of connection to the electricity supply
must facilitate complete electrical isolation of the appliance,
preferably by the use of a fused three pin plug and
unswitched shuttered outlet. Alternatively, connection may
be made by a via a fused double-pole isolator with a contact
separation of at least 3mm in all poles and serving the
appliance and system control only.
Site Requirements

5
DESN 512146
DESN 512134
WATER CONNECTIONS:
INSTALLER MUST MAKE
PROVISION TO GAIN
ACCESS TO 22mm COPPER
FLOW AND RETURN PIPE
DURING INSTALLATION.
R ½ (½”BSP TAPER)
10mm 10mm
50mm
MINIMUM GAP ON RIGHT HAND SIDE
MINIMUM GAP ON LEFT HAND SIDE
WALL PROJECTING THE FRONT OF THE APPLIANCE
Fig. 1.1
Fig. 1.2

6
Controls
Independent temperature controls with time switch control
are recommended for providing temperature comfort from
radiators.
Typical controls can be motorised valves operated by room
thermostat and cylinder thermostat.
Thermostatic radiator valves may be tted if required
and consideration should be given to tting a frost
thermostat which should set to operate at a temperature of
approximately 4ºC.
The boiler should be controlled so that it operates on
demand only.
Operation of the system under control of the boiler
thermostat only, does not produce the best eciency.
Refer to the control equipment manufacturer’s literature for
information e.g wiring.
The internal boiler/cooker wiring diagram is shown in Fig.
1.12on page 12.
Flue system
Open Flue
The following notes are intended to give general guidance.
The cross sectional area of the ue serving the cooker must
not be less than the area of the ue outlet of the cooker
(12,273mm). If ue pipe is to be used it must not be less than
125mm internal diameter.
A straight vertical section of the ue pipe of a length not
less than 600mm must be utilised immediately above the
draught diverter before any bends are used. Bends not
less than 135º must not be used. The equivalent height of
the ue must be a minimum of 3m in length.
Flue pipes and ttings should be constructed from one of the
following materials:-
a. Cement
b. Aluminium or stainless steel
c. Cast iron or mild steel acid resistant vitreous enamel
lined.
If a chimney is to be used, it should be one that is composed,
of or lined with, a non-porous acid resistant material.
A ue pipe constructed in (a) to (c) above, should 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 exible ue liner, in accordance
with relevant standards.
Before connecting the appliance to or inserting a liner
into a ue that has been previously used, the ue must be
thoroughly swept clean of any soot and loose materials. If a
bae plate, etc is tted in the ue it must be removed before
connecting the appliance to, or inserting a liner into the ue.
The ue should terminate in accordance with relevant
recommendations.
Flue Terminal
The total free area of the openings in the ue terminal must
be a minimum of 24,546mm = (cross sectional area of
125mm dia ue x 2) in the UK GC1 and GC2 terminals meet
this requirement.
Air requirements
The following notes are intended to give general guidance:-
Kitchen or Internal Space Air Supply
Wherever an open ue appliance is to be installed it must
have a permanent air vent. This vent must be either direct to
outside air or to an adjacent room or internal space which
itself must have a permanent air vent of at least the same size
direct to outside air.
The minimum eective area of the permanent air vent in the
outside wall must be 147cm.
Eect of an Extract Fan
It may be necessary to increase air vent by 50% or consult fan
manufacturers. If there is any type of extract fan tted in the
same room as an open ue appliance there is a possibility
that if adequate air inlet are from outside is not provided,
spillage of the products from the appliance ue could occur
when the extract fan is in operation. Where such installations
occur, a spillage test must be carried out and any necessary
remedial action taken.

7
Water circulation system
In a combined central heating and domestic hot water
system, the hot water storage vessel must be of the indirect
cylinder type. The hot water storage vessel should be
insulated with not less than 75mm thick mineral bre or its
equivalent.
Cisterns and pipework should not be situated in areas which
may be exposed by freezing conditions and should be
insulated.
Draining taps must be located in accessible positions which
permit the draining of the whole system, including the heat
storage vessel.
The appliance boiler section should be connected to cistern
water supply, subject to a maximum head of 3 bar (30m),
minimum of .1 bar (1m).
The heating system must be designed (and adjusted if
necessary) to give temperature dierential across the boiler
at full output of 10-14ºC.When horizontal runs are used the
pipes should rise upwards 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. 1.3) and therefore adequate
to give the required temperature dierential between the
ow and return.
The pump should be able to meet the requirements of the
system design and tted in a readily accessible position.
Isolating Valves
Isolating valves (preferably of the keyless type) must be tted
to the inlet and outlet of the circulating pump to facilitate
service and replacement of pump without draining the
system.
Inhibitor
A corrosion inhibitor MUST be added to the heating system
to protect the heat exchanger and pipework. Inhibitor must
also be replaced if the system is drained after installation. As
a precaution the heating system MUST also be ushed out
prior to the addition of the inhibitor to ensure any ux, debris
is removed.
300 600 900 1200 1500
Fig. 1.3 Pressure Loss Curve
Sealed System Requirements See on page 24 and on
page 25

8
Clearances
The appliance is oor mounted. The space in which the
appliance is to be tted must have the following minimum
dimensions:-
Between wall and LH side of appliance - 10mm Between wall
and RH side of appliance - 10mm*
*SHOULD THE WALL PROJECT BEYOND THE FRONT OF
THE APPLIANCE, WHEN IT MUST BE INCREASED TO 50MM
(SEE FIG. Fig. 1.1, Fig. 1.2).
Above the raised insulating cover handle - 60mm
In addition, adequate clearance must be available at the front
of the appliance to enable it to be operated and serviced
Preliminary installation
The appliance is delivered assembled with the exception of
the following items which are supplied separately packed
and require assembly.
1. Draught Diverter Assembly See Fig. 1.4.
2. Appliance Rear Distance Bracket: (for use when
appliance is installed (25mm) away from a rear wall of
combustible material). See Fig. 1.5.
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 bre protecting washers are in position. Insert
the handrail with tted endcaps in to the brackets,
positioning them correctly, and tighten the locating
bolts (Fig. 1.6).
Installation Instructions
Fig. 1.4
Fig. 1.5
Fig. 1.6
DESN 512141 A
DESN 512142
DESN 510454‘A’
25mm
COMBUSTIBLE
WALL LINE
BRACKETS
SCREWED TO BACK
EDGE OF BOTH
SIDE PLATES WHEN
COMBUSTIBLE WALL
IS UTILISED ON
INSTALLATION

9
Site Location
1. Remove the appliance assembly from the transit
wooden pallet by the temporary location of a sloping
ramp board between the pallet and the oor. With the
appliance on the oor, lift the front of the appliance
(manually or crowbar) and insert a 32mm x 1m long
tube between the front of the appliance base plate and
the oor.
Draw the tube balanced appliance forward until the
tube is at the rear of the appliance and then insert
a second similar tube at the front of the appliance,
between the base plate and the oor. The tube
supported appliance can now slowly be“rolled”across
the oor and positioned with its back against the wall,
and in its intended location for ue connection.
Using a crowbar at the rear of the appliance base plate,
take the weight of the appliance on the crowbar and
remove the rear rolled tube, followed by similar action
on the front tube.
2. Assemble and locate the ue draught diverter assembly
on ue spigot as follows (See Fig. 1.7):-
a. Ensure bae plate is located with‘front’stamping
towards front of cooker.
b. 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 BETWEEN THE DIVERTER FLUE
SOCKET AND FLUE PIPE TO FACILITATE POSSIBLE FLUE
DISCONNECTION AFTER COMMISSION.
Connect the ue system in accordance with standard
practice.
Fig. 1.7
DESN 512141 A
1
2
6
9
3
5
4
8
7
NOTE: INCORRECT FITTING OF COMBUSTION DISCHARGE
SAFETY DEVICE COULD ALLOW PRODUCTS TO LEAK INTO
THE ROOM UNDER ADVERSE CONDITIONS.
KEY
1. FLUE PIPE
2. HOOD
3. TOP SPACER - SHORT
4. BOTTOM SPACERS - LONG
5. BAFFLE
6. SPIGOT
7. COMBUSTION DISCHARGE SAFETY DEVICE (C.D.S.D.)
8. COMBUSTION DISCHARGE SAFETY DEVICE PHIAL
CLIP
9. CDSD PHIAL BRACKET

10
Gas connection
1. Connect the gas supply to the ½”BSP tapered
thread on the left hand side of the appliance (See
“Specications” page 3).
2. Test the whole of the gas installation including the
meter and purge in accordance with the relevant
recommendations.
Water connections
1. The two ow and return (22mm O/D Copper Tube)
connections are located towards the rear edge of the
appliance left hand side panel.
System suitability
THIS BOILER IS SUITABLE FOR FULLY PUMPED SYSTEMS
ONLY.
For optimum operating conditions the heating system into
which the boiler is installed, should include a control system.
Such a system will include a time switch and a room
thermostat and/or cylinder thermostat.
The boiler should be controlled so that it is operated on
demand only.
Operation of the system under control of the boiler
thermostat only does not produce the best eciency. Refer
to the control equipment manufacturer’s literature for
information e.g. wiring.
The internal boiler/cooker wiring is shown in Fig. 1.12.
Combustion discharge safety
device
For safety purposes a combustion discharge safety device is
tted. This will only operate under adverse ue conditions. If
the switch has operated, it should be pushed in to reset (Fig.
1.8). If this problem persists contact your local engineer to
determine and rectify the cause. It is important not to reset
more than once as this may indicate a ue blockage.
n WARNING: The combustion discharge safety device
must not be interfered with or rendered inoperative,
as this could interfere with the safe operation of the
appliance and invalidate the appliance warranty.
Fig. 1.8
CDSD RESET BUTTON
DESN 511788

11
Electrical connections
Supply cable:
PVC insulated three core 85ºC rated 300/500V .75mm.
To connect the electrical wiring to the appliance.
Make electrical connections to terminal strip as wiring
diagram.
Remove the plinth cover at the bottom of the appliance (See
Fig. 1.9 ).
Fit supply and pump cables to the terminals as shown in Fig.
1.11. Ensure that the appropriate cable clamp is used.
The permanent live MUST be connected to the terminal
marked L.
If a time switch is tted to the boiler then the system live
MUST be connected to the terminal 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 tted 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.
Ret the terminal cover plate.
n WARNING! THIS APPLIANCE MUST BE EARTHED,
EXTERNAL CONTROLS AND THE APPLIANCE MUST
BE SUPPLIED VIA THE SAME PLUG AND SOCKET OR
ISOLATOR.
Electrical checks
Check to ensure electrical safety should be carried out by a
qualied engineer.
Fig. 1.9
DESN 511767
DESN 511778
DESN 517924
Fig. 1.10
Fig. 1.11
Terminal Strip

12
CONTROL PANELS
BOILER STAT. AND
PUMP OVERRUN BOILER OVERHEAT
BOILER GAS VALVE
COMBUSTION DISCHARGE
SAFETY DEVICE
COOKER STAT
COOKER
OVERHEAT
COOKER
SOLENOID
PL
PN
L
L1
N
N
CSI
BSL
L2
L3
PUMP
PERMANENT SUPPLY
230V, 3A, 50Hz
LINK L1 TO CSL OR
PROVIDE TIMED LIVE
FOR COOKER BURNER
LINK L1 TO BSL OR PROVIDE
LIVE SUPPLY TO BOILER
FROM PROGRAMMER OR
AUXILIARY CONTROLS
G/Y
G/Y
G/Y
G/Y
WH
BL
Y
98
7
3
G
Y
BR
BR
BL
BR
BR
OR
OR
BL
BL
R
R
R
R
Y
KEY
BR - BROWN
BL - BLUE
R - RED
OR - ORANGE
WH - WHITE
G/Y - GREEN / YELLOW
THIS APPLIANCE IS NOT CALLING FOR HEAT.
I.E. THE USER THERMOSTATS ARE IN THE OFF POSITION SAFETY
STATS SHOWING NORMAL CONDITIONS
DESN 517926
Fig. 1.12

13
Electrical installation
Checks to ensure electrical safety should be carried out
by a competent person, ie. earth continuity, polarity and
resistance to earth.
Water circulation system
The whole of the system should be thoroughly ushed out
with cold water without the pump in position. Ensure that all
valves are open. With the pump tted, the system should be
lled.
Vent all heat emitters and check for water soundness.
Commissioning the cooker and
boiler
Isolate electricity at the wall socket. Turn the cooker and
boiler control knob to o.
After ensuring gas is available to the appliance, loosen joint
and purge any air from the supply pipe.
n WARNING: NO SMOKING OR NAKED LIGHTS.
Tighten joint and check gas service cocks are in the ON
position. Check for gas soundness up to the gas valves. (See
Fig. 1.14)
Instruct the user
1. Advise the User of the precautions necessary to prevent
damage to the heating system and to the building
in the event of the heating system being inoperative
during frost conditions.
2. Advise the User for continued ecient and safe
operation of the appliance, it is important that
adequate servicing is carried out at regular 12 monthly
intervals.
3. Hand the Operating Instructions to the User and
demonstrate the correct operation of the appliance and
system controls.
4. Leave the Installation, Servicing and Operating
Instructions with the User.
5. Gas Safety - Show the user the procedure for isolating
the appliance from the gas and electric supply. As
referred to in the Operating Instructions - Ref Gas Leak
or Appliance Fault.
Lighting the pilot
Boiler (see Fig. 1.14)
This appliance is tted with an automatic ignition unit that
will light the main burner on demand. Should button K(see
Fig. 1.14) 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 Gas Safe Registered engineer to correct the fault.
Cooker (see Fig. 1.14).
Press in and hold the cooker ame failure override button C
allowing a few seconds for the gas to reach the cooker pilot.
Press the piezo ignitor button Dand the pilot burner will
light.
Continue to hold the button in for 15 seconds after the pilot
has been lit so that when the button is released, the pilot
should remain alight.
If it does not, WAIT 3 MINUTES then repeat the procedure.
Boiler output setting
480AG & 480AL REFER TO PAGE 3 ‘SPECIFICATIONS’.
The boiler side of the appliance is preset to give a maximum
heat output of 23.4 kW.
The multifunctional burner control valve can be reset to
decrease this output to 17.6kW.
To decrease the boiler output to 17.6kW connect the
pressure gauge to the burner test nipple Jand turn on the
boiler burner.
Remove cap screw to expose pressure regulator adjustment
screw H.
Slowly turn adjustment screw with a small screwdriver until
the burner pressure required is recorded on the pressure
gauge. Turn adjustment screw counter-clockwise to decrease
or clockwise to increase gas pressure to the burner. See heat
output table below.
Replace pressure regulator cap screw
Boiler burner burner setting must be indicated by ticking
correct box at top of lighting instruction plate, on the inside
of the burner door.
MAX. MIN.
HEAT OUTPUT 23.4 kW 17.6 kW
NAT. GAS 13mb 8mb
PROPANE 32.5mb 20.5mb
Commissioning

14
Main burner lighting see Fig. 1.14
This appliance is tted with a combustion discharge safety
device which will switch o both main burners in adverse
ue conditions. Before turning on main burners ensure that
the manual reset button, which is located on the right hand
side of the plinth is depressed (Fig. 1.8).
Ensure the electricity supply is turned ON and set any
external controls to the ON position.
Turn the boiler thermostat knob to MAX., and the boiler will
ignite.
Turn the cooker thermostat to H, and the cooker burner will
go to full rate.
Check for gas soundness of all leaks with leak detection uid.
Turn o both burners.
Turn the thermostat knob to the required setting.
The boiler and pump should be run until the system is hot.
Check for water leaks, then ush the system with all manual/
automatic valves open. Upon relling check the system for
leaks. When all the 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 shown in Fig. 1.13. If smoke does not spill back into the
room then the installation is satisfactory. If smoke is drawn
back into the room leave burners on for further 10 minutes
and check again.
n WARNING: IF THE SMOKE SPILLS BACK INTO THE
ROOM, DISCONNECT THE APPLIANCE AND SEEK
EXPERT ADVICE.
Commissioning
DESN 517111
DESN 512964
Fig. 1.14
Fig. 1.13
KEY
C - COOKER FLAME FAILURE OVERRIDE BUTTON
D - PIEZO IGNITION BUTTON - COOKER
E - GAS COCK - COOKER
G - GAS COCK - BOILER
H - BOILER BURNER PRESSURE REGULATOR ADJUSTMENT
SCREW
I - PRESSURE TEST NIPPLE INLET
J - PRESSURE TEST NIPPLE - BOILER BURNER
K - BOILER BURNER RESET
DESN 512965

15
Annual servicing
It is important for the correct operation of the appliance that
servicing be carried out annually by a competent person in
accordance with gas safety regulations.
With normal use, a boiler/cooker service should be carried
out immediately after the end of the heating season. The
householder should be advised to turn o both boiler and
cooker control knobs the night preceding the day of the
service, 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.
Service schedule
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 condition of the boiler combustion chamber
insulation.
7. Check that the ueway is unobstructed and that the
draught diverter unit is correctly assembled.
8. Oven Door Fit - Both doors must be checked and
adjusted if necessary to ensure the alignment with the
door catch is correct, the keep is secure and the oven is
sealed when the door is closed.
Pre-service check
Operate the appliance and system, noting any faults which
may need to be corrected during service.
n WARNING: ISOLATE UNIT FROM ELECTRICITY
SUPPLY AND TURN OFF GAS AT SERVICE COCKS
BEFORE SERVICING. AFTER COMPLETING SERVICE
ALWAYS CHECK FOR GAS SOUNDNESS AND CHECK
THIS FUNCTION OF CONTROLS.
Hotplate cleaning see Fig. 1.15
Lift out the hotplate using lifting tools provided. Brush the
ns with a wire brush to remove any deposits.
Burner access
SEE Fig. 1.9
1. Open up the bottom burner access door.
2. Remove the 3 plinth securing screws and remove plinth.
Servicing
DESN 510145 A
Fig. 1.15

16
Burner cleaning
Boiler (See Fig. 1.16 and Fig. 1.17)
Ensure isolation of electricity and gas supply. Remove plinth
3 screws (See Fig. 1.9).
Disconnect ignitor lead Cand ame detector lead D from the
electronic ignition unit.
Lift up electronic ignition unit J to release unit from gas valve.
Undo union nut K. Undo four screws L.
Allow burner assembly to drop down and slide forwards on
rails, then lift and remove burner assembly from unit.
See Fig. 1.18
Brush the boiler burner top and check the ame 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 orices and remove
any deposits from the injectors and burner venturi using a
suitable non-metallic brush.
Remove pilot injector. Clean any deposits by rinsing in warm
water or use a suitable brush. DO NOT attempt to push a
wire through the orice.
DESN 512961
DESN 512962
DESN 512137 v 11-21
Fig. 1.16
Fig. 1.17
Fig. 1.18
B

17
Cooker (see Fig. 1.19 and Fig. 1.20)
Remove solenoid connector plug M.
Undo union nut N.
Undo two screws P.
Remove the burner, complete with controls, from the unit
(See Fig. 1.20).
Brush the cooker burner top and check ame ports are clear.
(See Fig. 1.21)
Remove two screws from pilot bracket.
Remove two screws from burner door, securing injector
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 orice 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 attempt
to push a wire through the orice.
DESN 512132
DESN 512966
DESN 512133
Fig. 1.19
Fig. 1.21
Fig. 1.20
M
P
N

18
Heat exchanger Fig. 1.22 & Fig. 1.23
BEFORE REMOVING SERVICE ACCESS COVERS ENSURE
THAT ALL ELECTRICAL ACCESS TO THE APPLIANCE HAS
BEEN SWITCHED OFF (SWITCH OFF AND REMOVE PLUG).
SEE Fig. 1.22 & Fig. 1.23
1. Remove the controls door and place in a safe position.
2. Remove both thermostat controls knobs.
3. Remove the 2 cover panel xing screws.
4. Remove 4 screws securing control box.
5. With bracket on rear of control box, hang the controls
box on the bottom edge of control aperture.
6. Remove 4 wingnuts securing access plate. (See Fig.
1.24).
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.
Combustion chamber insulation
Remove boiler burner assembly as previously described.
Check insulation for any signs of deterioration or physical
damage and replace if necessary.
Flue cleaning
Brush out cooker and boiler ueways with a suitable brush.
Check the assembly of the draught diverter.
DESN 512150
DESN 512144
DESN 512145
Fig. 1.22
Fig. 1.23
Fig. 1.24
REMOVE 4 SCREWS

19
Re-assemble the appliance
Re-assemble the appliance in reverse order. Ret boiler and
cooker burner assemblies.
Re-connect solenoid electrical supply to cooker burner
assembly.
Re-connect 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.
To fit new burner
Follow instructions in section Burner Cleaning of Servicing
Instructions and remove the cooker burner assembly.
1. Remove two pilot assembly screws.
2. Remove two screws securing injector bracket. a
3. Remove burner and transfer all ancillary items.
4. Fit new burner.
5. Re-assemble in reverse order.
To fit new burner injector
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.
Replacement of Parts - Cooker

20
Electrical component access
BEFORE REMOVING SERVICE ACCESS COVERS ENSURE
THAT ALL ELECTRICAL ACCESS TO THE APPLIANCE HAS
BEEN SWITCHED OFF (SWITCH OFF AND REMOVE PLUG).
SEE Fig. 1.25
1. Remove the controls door and place in a safe position.
2. Remove both thermostat control knobs.
3. Remove the 2 cover panel xing screws.
4. Remove cover panel.
SEE Fig. 1.26
5. Remove the two control panel xing screws.
6. Tilt the chassis from the top and lift out taking care not
to damage thermostat capillaries.
7. Re-assemble in reverse order.
DESN 512150
DESN 512131
Fig. 1.25
Fig. 1.26
Fig. 1.27
BOILER
THERMOSTAT
CAPILLARY
BOILER
THERMOSTAT
CABLE CLAMP
COOKER OVERHEAT
THERMOSTAT
THERMOSTAT
CAPILLARIES
EARTH POST
COOKER
THERMOSTAT