advice on oil fired rayburn 480k

[markproperjob]

I recently recieved a job to service a rayburn 480k cooker/boiler in my area.
i have serviced many 480k's, and am aware of the importance of using the correct sized stainless anti drip nozzles, and of the correct combustion settings.
i've worked exclusively on oil fired appliances for 20yrs.
this one has caused much head scratching.

on arrival at the property, i was told the history of the cooker, and that it had been serviced earlier in the year by a guy who had not inspired confidence, and that the cooker had deteriated since.
I proceeded to carry out a full and thorough service.
I ended up changing a severely worn oil pump, both nozzles that were of brass construction not stainless and of completely wrong sizes, one pair of burnt out electrodes and leads.
on inspecting the cooker burner, the entire blast tube had burnt away to grey metal chrystals, where matey had altered combustion wrongly and turned it into a cutting torch!
also, and this is my point for advice, the cooker combustion chamber heat protection plate,(heavy fluted cast iron plate bolted to side of top oven) has been totally deformed by excess heat, and has formed a funnel shape directing flame straight to side of the top oven. this is obviously unnaceptable, as it will crack or melt the oven eventually, causing fume ingress into the kitchen.

I have removed the 832 control box for the cooker burner, to prevent its use while awaiting repair, and have a new blast tube ready to fit, but regards the heat protection plate, this will have to be cut off as bolts are melted.

would it be acceptable to replace this damaged plate with a section of heat resistant ellis board /simular heat proof fire board, instead of buying a replacement cast iron plate? these are extremely expensive, and customer is elderly. i have seen inside a brand new rayburn last month, and it had fireproof board linings.
any experience in this would be appreciated.
mark

 

[Bartdude]

Hi Mark

It sounds like a Mark 1 480k. I'm afraid that this is terminal. The heat conduction plate that has warped cannot be replaced,it has a slot which extends under the oven,this means that you can't move the plate to the side to remove it without dismantling the whole cooker,if it's warped it's even more difficult to remove. I tried cutting one in place with an angle grinder to remove it and nearly lost a finger! It's not available as a spare item from Rayburn any longer,the only way would be to find a second hand one. But dismantling a Mk 1 480k and re-assembling is not a job I would want to undertake.

The Mk 1 and 2(with a pnuematic Tai San pump) have a few basic design flaws, the cooker combustion chamber being a major one.It is too small and as a result the burner head components have a short life expectancy. If you look through the sight glass when you turn the burner off the blast tube is usually glowing,the heat can't escape the chamber fast enough and the temperature rises causing all sorts of problems,including the warping of the conductor plate you described. This will happen to most of them in time and I doubt it's the fault of the previous engineer,even though it wasn't set up correctly.

I've has this discussion with Rayburn technical lots of times over the years and in the early days a they would be replaced with the far better MX model if the customer shouted loudly enough.A few were repaired but they were sent back to the factory for that,the parts are all specialist and you would need to have them to hand to carry out a boiler replacement. Now though a Mk 1 could be nearly 20 years old and unfortunately there's not a lot that can be done.

There is a similar thread here

http://www.ukplumbersforums.co.uk/central-heating-forum/15645-leaking-rayburn.html

 

[Gray0689]

I recently recieved a job to service a rayburn 480k cooker/boiler in my area.
i have serviced many 480k's, and am aware of the importance of using the correct sized stainless anti drip nozzles, and of the correct combustion settings.
i've worked exclusively on oil fired appliances for 20yrs.
this one has caused much head scratching.

on arrival at the property, i was told the history of the cooker, and that it had been serviced earlier in the year by a guy who had not inspired confidence, and that the cooker had deteriated since.
I proceeded to carry out a full and thorough service.
I ended up changing a severely worn oil pump, both nozzles that were of brass construction not stainless and of completely wrong sizes, one pair of burnt out electrodes and leads.
on inspecting the cooker burner, the entire blast tube had burnt away to grey metal chrystals, where matey had altered combustion wrongly and turned it into a cutting torch!
also, and this is my point for advice, the cooker combustion chamber heat protection plate,(heavy fluted cast iron plate bolted to side of top oven) has been totally deformed by excess heat, and has formed a funnel shape directing flame straight to side of the top oven. this is obviously unnaceptable, as it will crack or melt the oven eventually, causing fume ingress into the kitchen.

I have removed the 832 control box for the cooker burner, to prevent its use while awaiting repair, and have a new blast tube ready to fit, but regards the heat protection plate, this will have to be cut off as bolts are melted.

would it be acceptable to replace this damaged plate with a section of heat resistant ellis board /simular heat proof fire board, instead of buying a replacement cast iron plate? these are extremely expensive, and customer is elderly. i have seen inside a brand new rayburn last month, and it had fireproof board linings.
any experience in this would be appreciated.
mark

Think you would be best to ask Rayburn

 

[dontknowitall]

My Rayburn's knackered now with the same faults. I couldn't understand why I was having difficulties over the last 2-3 years but now know this is a problem with the Mark I.

I tried phoning Aga/Rayburn and they were useless! However, I did find someone who, although he gave me bad news, certainly knew what he was talking about.

Here's a link if you want to read more about it. Friendly chap who can talk the behind off a donkey but knows his stuff!!

Top of the Range Ltd - AGA and Rayburn 400 Series Specialists

 

[markproperjob]

cheers chap!
i'll call him dreckly.
i dont want to give the old dear bad news just yet as shes lost her hubby recently and losing her rayburn too wouldnt be nice!
if i can repair it at reasonable cost, but this sounds doubtful at moment from previous posters excellent knowlage, then i'll be a happy oil fitter.
thanks
mark

 

[Vintage Ranges]

I recently recieved a job to service a rayburn 480k cooker/boiler in my area.
i have serviced many 480k's, and am aware of the importance of using the correct sized stainless anti drip nozzles, and of the correct combustion settings.
i've worked exclusively on oil fired appliances for 20yrs.
this one has caused much head scratching.

on arrival at the property, i was told the history of the cooker, and that it had been serviced earlier in the year by a guy who had not inspired confidence, and that the cooker had deteriated since.
I proceeded to carry out a full and thorough service.
I ended up changing a severely worn oil pump, both nozzles that were of brass construction not stainless and of completely wrong sizes, one pair of burnt out electrodes and leads.
on inspecting the cooker burner, the entire blast tube had burnt away to grey metal chrystals, where matey had altered combustion wrongly and turned it into a cutting torch!
also, and this is my point for advice, the cooker combustion chamber heat protection plate,(heavy fluted cast iron plate bolted to side of top oven) has been totally deformed by excess heat, and has formed a funnel shape directing flame straight to side of the top oven. this is obviously unnaceptable, as it will crack or melt the oven eventually, causing fume ingress into the kitchen.

I have removed the 832 control box for the cooker burner, to prevent its use while awaiting repair, and have a new blast tube ready to fit, but regards the heat protection plate, this will have to be cut off as bolts are melted.

would it be acceptable to replace this damaged plate with a section of heat resistant ellis board /simular heat proof fire board, instead of buying a replacement cast iron plate? these are extremely expensive, and customer is elderly. i have seen inside a brand new rayburn last month, and it had fireproof board linings.
any experience in this would be appreciated.
mark

Hi Mark
Menheniot? You would then know Heritage. I designed and founded this brand. Several years ago I improved and up-dated my designs to produce www.vintageranges.com
I am not suggesting replacing the customer's terminal Rayburn with a Vintage (or heaven forbid a JW cooker!).
Nonetheless, you now know of a high quality alternative. If I can be of any help, please email me at [email protected]
Best Regards
John

 

[Vintage Ranges]

My Rayburn's knackered now with the same faults. I couldn't understand why I was having difficulties over the last 2-3 years but now know this is a problem with the Mark I.

I tried phoning Aga/Rayburn and they were useless! However, I did find someone who, although he gave me bad news, certainly knew what he was talking about.

Here's a link if you want to read more about it. Friendly chap who can talk the behind off a donkey but knows his stuff!!

Top of the Range Ltd - AGA and Rayburn 400 Series Specialists

Hi Dontknowitall
Sorry to hear about the Rayburn.
John

 

[markproperjob]

Thanks for reply john!
I'll bear that in mind.
My customer actually bought the 480 new from jim years ago, but its obviously well out of warranty now.
Shes not in a position to buy a new O/F range cooker due to the prices they command.
I'll have to consider stripping the 480 down and having a replacement plate fabricated locally.
Mark