Servicing Instructions XT - Oil (K/PF) For use in GB and IE DESN 514112 B Remember, when replacing a part on this appliance, use only spare parts that you can be assured conform the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by AGA. PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE raywarranty@aga-web.co.
Contents SECTION CONTENTS PAGE CONSUMER PROTECTION HEALTH & SAFETY 3 3 INTRODUCTION SERVICE SCHEDULE 4 4 OIL BURNER REMOVAL PREPARATION BURNER ACCESS BURNER REMOVAL 5 5 6 CLEANING BURNER CHAMBER OVEN & HOTPLATE FLUEWAY CLEANING 7 7 OIL BURNER SERVICING BURNER NOZZLE REMOVAL IGNITION ELECTRODE PHOTO ELECTRIC CELL (PEC) CLEANING FAN CLEANING OIL LINE FILTER CLEANING FLEXIBLE OIL LINES 8 8 9 9 - 10 10 10 RE-COMMISSIONING - OIL BLEED AIR FROM OIL SUPPLY FIT PRESSURE PAUGE SWITCH ON ELECTRICITY
Consumer Protection As responsible manufacturers we take care to make sure that are 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.
INTRODUCTION SERVICE SCHEDULE To ensure the best performance from your Rayburn it should be serviced once a year. Annual Service BURNER REMOVAL - for cleaning and inspection. CLEANING - Heat exchanger flueways, oven and hotplate flueways together with ceramic fibre burner chambers. BURNER SERVICING. OIL PUMP SERVICING - Cleaning of fuel line strainer. RE-COMMISSIONING. REPLACEMENT PARTS. This appliance must be commissioned by a competent engineer, such as OFTEC approved.
Oil Burner Removal PREPARATION WARNING: BEFORE REMOVING SERVICE ACCESS COVERS OR THE OIL BURNER ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN ISOLATED. The burner can be removed without disconnecting the oil supply pipe. However if the filter is 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. BURNER ACCESS SEE FIG. 1 1. Open up the bottom burner access door. 2.
Oil Burner Removal BURNER REMOVAL IMPORTANT: DURING BURNER REMOVAL CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 2 1. Place a sheet on the floor in front of the cooker to act as a working area 2. Disconnect the terminal strip plug. FIG. 2 DESN 511431 A BURNER LOCKING BOLTS SEE FIG. 3 3. Loosen the burner locking nuts (2). 4. Twist the burner. FIG. 3 DESN 511432 A FIG. 4 DESN 511433 B SEE FIG. 4 5. Withdraw the burner unit.
Cleaning BURNER CHAMBER IMPORTANT: DURING CLEANING CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 5 & 5A 1. TO REMOVE THE HOTPLATE: Remove the bolt and washers from inside the Roasting Oven (top left hand side) Lift insulating covers and remove 2 screws from the hotplate, then remove hotplate using lifting tool provided. 2. Clean the flueway by inserting the flexible brush through top plate aperture, directing it towards the flue outlet.
Oil Burner Servicing BURNER NOZZLE REMOVAL SLACKEN (2) HEX. SCREWS SEE FIG. 7 CHANGE THE NOZZLE AT THE ANNUAL SERVICE. 1. Remove blast tube by slackening two hex. screws. Thoroughly clean the blast tube. 2. Remove (2) screws securing access door. 3. Slacken (2) screws on either side of access door. 4. Open access door. 5. Remove push on electrode leads. 6. Slacken screws securing electrodes. 7. Pull out electrodes. 8. Using socket spanner unscrew nozzle.
Oil Burner Servicing PHOTO ELECTRIC CELL (PEC) CLEANING SEE FIG. 8 Withdraw Photo Electric Cell from the burner head. Clean PEC sensing end with a soft cloth taking care not to scratch the light sensitive body. Re-insert the PEC taking care to insert the correct way round. IF BADLY DISCOLOURED CHANGE IT. FIG. 8 DESN 511438 FAN CLEANING SEE FIG. 9 INSPECT AND CLEAN IF NECESSARY. 1. Remove (2) screws securing terminal strip/ transformer bracket. 2. Remove (2) push on electrode leads from transformer.
Oil Burner Servicing SEE FIG. 10 3. Remove (3) screws securing fan motor onto burner body. 4. Withdraw assembly from burner body. 5. Clean impeller with a soft brush. 6. Spin motor to check that it turns easily. FIG. 10 DESN 511441 FIG. 11 DESN 511442 SEE FIG. 11 7. Remove (1) screw and slacken (2) screws from air slider control. 8. Remove air slider and clean any fluff deposits. 9.
Re-commissioning - Oil BLEED AIR FROM OIL SUPPLY Disconnect the flexible oil pipe at the pump inlet, open the stop valve slowly and run off some of the oil into a receptacle to establish an air free supply to the pump. Remake the connection oil tight and leave valve open. FIT PRESSURE GAUGE SEE FIG. 12 Remove the bleed screw from the manifold and fit an oil pressure gauge with R1/8 connection to check the pump output pressure. SWITCH ON ELECTRICITY Set the thermostat to maximum.
Re-commissioning - Oil SET COMBUSTION AIR SEE FIG. 14 After 15 minutes of the burner running. To sample the flue gases from the cooker burner lift up the R.H. insulating cover and remove the countersunk headed screw and insert the sensing end of a portable analyser to check the CO2 (Carbon Dioxide) level in the hotplate. The cooker burner should be set to 11.0% CO2. IMPORTANT: Ensure that the bottom louvered plinth is in place during combustion setting procedures and the outer door is closed.
Fan Terminal (Cleaning) TERMINAL COVER REMOVAL 1. Disconnect power to appliance. 2. The terminal cover is secured using 4 screws. Unscrew the 4 screws and remove cover. (See Fig. 15). FIG. 15 DESN 513351 FIG. 16 DESN 513355 FIG. 16A DESN 513354 FAN REMOVAL 1. Disconnect the power to appliance. 2. Disconnect the 3 wires to the fan. 3. Unscrew (3) M5 fixings and withdraw, fan and mount assembly. 4. Clean fan with a soft brush. 5. Re-fit fan and mount assembly.
Electrical Controls OVERHEAT SAFETY THERMOSTAT IMPORTANT NOTE: This appliance is fitted with an overheat thermostat which has a manual reset button. If the overheat stat trips, the cooker will not operate, until the button has been pushed-in (reset). The engineer needs to follow ‘Fault Finding Guide’ to establish why the stat tripped. (The overheat thermostat and its sensing phial are located on the controls chassis rear). (See Fig. 25).
Electrical Controls PCB CONNECTIONS FIG.
Replacement of parts (Oil Burner) FAN MOTOR SEE FIG. 21 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, FAN CLEANING, Steps 1 to 4 and BURNER REMOVAL, Steps 1 to 5. 1. 2. 3. 4. Disconnect wires from terminal strip. Slacken (3) grub screws securing pump to fan body. Remove pump. Fit new fan motor and assemble in reverse order ensuring pump coupling is correctly located. FIG. 21 DESN 511447 FIG. 22 DESN 511448 PUMP ACCESS SEE FIG.
Replacement of parts (Oil Burner) SOLENOID COIL SEE FIG. 21 Follow instructions in sections BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL, Steps 1 to 5. 1. 2. 3. 4. Remove solenoid plug securing nut. Pull off electrical connection socket from solenoid. Remove solenoid coil. Fit new solenoid coil, re-assemble in reverse order. IGNITION TRANSFORMER Follow instructions in sections BURNER ACCESS, Steps 1 to 3. 1. 2. 3. 4. 5. Remove (4) screws securing transformer. Remove both H.T. leads from transformer.
Replacement of parts (Oil Burner) CONTROL BOX SEE FIG. 23 Follow instructions in sections ‘BURNER ACCESS’, Steps 1 to 3. 1. Insert flat bladed screwdriver in LH side of c.box, as diagram. 2. Repeat as above for RH side. 3. Gently pull control box away from mounting plate. 4. Fit new control box, re-assemble in reverse order. FIG. 23 PEC SEE FIG. 8 Follow instructions in sections BURNER ACCESS, Steps 1 to 3, BURNER REMOVAL, Steps 1 to 5. 1. 2. 3. 4. 5. 6. Unplug PEC.
Replacement of parts (Electrical controls) ELECTRICAL COMPONENT ACCESS BEFORE REMOVING SERVICE ACCESS COVERS ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN TURNED OFF. SEE FIG. 24 1. Open the controls door. 2. Remove thermostat control knob. 3. Remove 2 cover panel securing screws and remove cover panel. 4. Remove the four control panel fixing screws. 5. Tilt the chassis forwards from the top and lift out.
Replacement of parts (Electrical controls) FIG. 25 DESN 516745 TO FIT NEW FLUE SAFETY DEVICE ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN TURNED OFF. SEE FIG. 26 Follow instructions in section BURNER ACCESS, Steps 1 to 3. 1. 2. 3. 4. 5. 6. Remove PCB. Unscrew flue safety device. Remove bracket and unclip phial. Disconnect the two wires on the switch. Unscrew nut holding the stat body and remove. Replace in reverse order of removal. FIG.
Replacement of parts (Electrical controls) TO FIT NEW OVERHEAT THERMOSTAT SEE FIG. 25 Follow instructions in section COMPONENT ACCESS, Steps 1 to 5. ELECTRICAL 1. Undo the locknut, which holds the overheat thermostat to the bracket on the rear of the chassis. 2. Remove the 2 push on connectors from back of overheat thermostat. 3. Remove the phial from the 2 spring clips on the rear of the chassis. 4. Withdraw overheat thermostat from chassis. 5.
Fault Finding WIRING DIAGRAM - APPLIANCE FIG.
Fault Finding WIRING DIAGRAM - BURNER ONLY FIG.
Fault Finding Burner Check that the burner has not gone to lockout. Causes of lockout can be:l l l l l l l l No ignition, ignition electrode incorrectly positioned or insulation cracked, spark generator faulty, check for 230V at spark generator. No oil supply. Poor combustion. Photo electric cell incorrectly positioned, cracked or needs cleaning. Live and Neutral connections reversed. Oil valves not properly closed in shutdown position. Faulty control box. Faulty fire valve.
Fault Finding HIGH SMOKE NUMBERS NOZZLE FAULT REPLACE NOZZLE AIR INTAKE BLOCKED CHECK AIR INLET TO BURNER INCORRECT COMBUSTION SETTINGS RE-ADJUST TO INSTALLATION INSTRUCTIONS OIL PRESSURE INCORRECT ADJUST TO RECOMMENDED SETTINGS INCORRECT COMPONENTS USED ON COMBUSTION HEAD SEE SERVICING INSTRUCTIONS INTERNAL BURNER CHAMBER INSULATION PANELS INCORRECTLY POSITIONED OR FAULTY OIL SMELLS FUMES ON START UP DOWN DRAUGHT CHECK WITH GAUGE OIL SOAKED HEARTH NUMEROUS LOCK-OUTS ODOURS IN KITCHEN BURNER FAU
Fault Finding IMPORTANT NOTE: REFER TO OVERHEAT THERMOSTAT’, PAGE 14.
Fault Finding 27
Fault Finding 28
Fault Finding 29
For further advice or information contact your local distributor/stockist With AGA Rangemaster’s 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 Rangemaster Station Road Ketley Telford Shropshire TF1 5AQ England www.rayburn-web.co.uk www.agacookshop.co.
