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Rayburn 680KCD C, Service Manual, Page: 1 / 36

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Rayburn 680KCD C Service Manual Download Page 1

05/14A EINS 516258

PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE

680KCD C/F

780KCD C/F

Servicing

Instructions

DESN 516260

DESN 516828

For use in GB & IE

REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the

safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly

authorised by AGA.

Summary of Contents for 680KCD C

Page 1: ...rvicing Instructions DESN 516260 DESN 516828 For use in GB IE REMEMBER when replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by AGA ...

Page 2: ...NG 14 RE COMMISSIONING BLEED AIR FROM OIL SUPPLY 15 FIT PRESSURE GAUGE 15 SWITCH ON ELECTRICITY 15 VENT OIL PUMP 15 ADJUST OIL PRESSURE 15 SET COMBUSTION AIR 16 CHECK SMOKE 16 REPLACEMENT OF PARTS FAN MOTOR 17 BURNER IGNITION ELECTRODES 17 IGNITOR 18 SOLENOID COIL 18 CONTROL BOX 19 PEC 19 PUMP ACCESS 20 REPLACEMENT OF PARTS ELECTRICAL COMPONENT ACCESS 21 22 ELECTRICAL CONTROLS RE ASSEMBLE 21 22 CO...

Page 3: ...ds and other exposed parts When disposing of the product reduce dust with water spray ensure that parts are securely wrapped Kerosene and Gas Oil fuels mineral oils 1 The effect of mineral oils on the skin vary according to the duration of exposure 2 The lighter fractions also remove the protective grease normally present on the surface of the skin This renders the skin dry liable to crack and mor...

Page 4: ... requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council...

Page 5: ...ections This should be carried out by a competent engineer BURNER REMOVAL for cleaning and inspection CLEANING Boiler 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 Oven Door Fit Both doors must be checked and adjusted if necessary to ensure the alig...

Page 6: ...eaned 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 SEE FIG 1 1 Open up the bottom burner access door Remove door and put in a safe place Rayburn 680KCD C F only 2 Remove 4 inner panel securing screws and remove panel 3 Remove the 3 plinth securing screws and remove plinth 6 PREPARATION BURNE...

Page 7: ... safe place 3 Unscrew jubilee clip and remove flexi air intake pipe from burner 4 Using a 13mm spanner remove top securing bolt and remove burner by rotating it approximately 90 counterclockwise and drawing it away from the boiler COOKER BURNER 1 Unscrew jubilee clip and remove flexi air intake 2 Using a 13mm spanner unscrew top securing bolt and remove burner by rotating clockwise and drawing awa...

Page 8: ...hdraw access door from below through burner aperture 2 Remove stack of 5 sheet metal baffles check assembly and replace as shown in Fig 8 3 Check aluminium twisted baffles are in position and there are 28 baffles one in each recuperator tube NOTE LH set of 4 x aluminium twisted baffles are half length 4 When replacing access door tighten the 4 fixing screws to a torque setting of 7 5 NM 5 Check co...

Page 9: ...Cleaning 9 Fig 6 ALL BAFFLES MUST BE STACKED IN PLACE AS DIAGRAM ABOVE ...

Page 10: ...ing hex driver 6 TO REMOVE THE HOTPLATE Remove nut and washer from inside the roasting oven top left hand side Unscrew 2 countersunk hex screws insert lifting eyes and lift hotplate out with hooks provided 7 Brush and clean in between hotplate ribs on underside 8 Examine soft rope seal located around hotplate aperture in top plate and two rope seals on hotspot Replace if frayed or damaged 9 Replac...

Page 11: ...om the two burners mixed up The correct combination of burner blast tubes are shown To remove blast tube slacken two grub screws pull forward COOKER BOILER Countersunk screws in tube COOKER BURNER 11 INTRODUCTION Burner Servicing Fig 10 10 VANES Fig 9 COOKER BOILER BURNER BOILER BURNER Fig 11 4 VANES DESN 515977 DESN 515963 ...

Page 12: ... Remove two screws and slide out nozzle support cradle complete with ignitor assembly from burner head 3 Unscrew nozzle from its holder with a correctly fitting tubular spanner to avoid damage to hexagon SEE FIG 14 1 Replace nozzle with a new one of the same make and specification 2 Ensure that mating faces are clean 3 Hold nozzle holder with correct spanner when tightening the nozzle 4 Typically ...

Page 13: ...ns of distortion or cracking replacement will be necessary See PEC Replacement Page 19 SEE FIG 16 1 Remove two screws and air inlet snorkel 2 Remove four screws and split fan case 3 Clean between the blades of the fan impeller with a small brush and remove any residue Re assemble the burner in reverse order 13 Burner Servicing FAN CLEANING PHOTO ELECTRIC CELL PEC CLEANING RE ASSEMBLE BURNER Fig 15...

Page 14: ...everse order 1 Turn OFF the line isolating valve fitted prior to the oil line filter 2 Follow manufacturers instructions to remove filter element from the housing taking care to collect kerosene residue from the filter housing 3 Wash filter thoroughly in clean kerosene 4 Re assemble in reverse order NOTE Flexible fuel hose s must be replaced at each service ie annually 14 INTRODUCTION OIL PUMP STR...

Page 15: ...illumination of the signal light in the reset button of the control box See Fig 18 IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the re set button to restart SEE FIG 18 Whilst the burner is running vent air from the pump by slackening the pressure gauge port sufficiently to allow air to bleed out When bubble free oil seeps out re tighten SEE FIG 19 With the burner running check the oil pressur...

Page 16: ...oke in the boiler flueways does not exceed No 2 on the scale Replace the plugging screw and plug Switch off the boiler burner COOKER BURNER SEE FIG 21 Switch on cooker burner After 15 minutes of the cooker burner running Repeat the above procedures for the cooker burner To sample the flue gases from the cooker burner lift up the RH insulating cover and remove the countersunk headed screw in the ho...

Page 17: ...ad screws and withdraw pump 10 Re assemble in reverse order NOTE Ensure that gaskets and seals are in place and in good condition SEE FIG 23 1 Release two countersunk head screws and remove blast tube 2 Remove two screws and slide out nozzle support cradle c w ignitor assembly from burner head 3 Disconnect ignition leads 4 Remove ignitor assembly by removing countersunk screw and clamp 5 Fit new i...

Page 18: ...rews 4 Remove ignitor 5 Fit new ignitor re assemble in reverse order SEE FIG 25 Follow instructions in sections BURNER ACCESS Steps 1 to 3 and BURNER REMOVAL 1 Remove plug 2 Remove solenoid securing nut and washer 3 Remove solenoid coil 4 Fit new solenoid coil re assemble in reverse order 18 Replacement of parts Burner Fig 24 DESN 516265 SOLENOID COIL IGNITOR Fig 25 DESN 515972 SOLENOID ...

Page 19: ...ble in reverse order SEE FIG 27 Follow instructions in section BURNER ACCESS Steps 1 to 3 1 Withdraw PEC from burner head 2 Push in retaining clip and remove PEC from plug 3 Fit new PEC 4 Re attach plug and re insert PEC taking care to insert the correct way round 19 Replacement of parts Burner PEC CONTROL BOX Fig 26 Fig 27 DESN 515973 DESN 515974 PHOTO ELECTRIC CELL ...

Page 20: ...upply 2 Disconnect flexible hose This must be replaced annually 3 Remove solenoid plug 4 Remove feed pipe 5 Slacken three securing screws and remove pump 6 Check drive replace if worn or damaged 7 Replace pump re assemble in reverse order Replacement of parts Burner PUMP ACCESS Fig 28 DESN 515976 20 PUMP ...

Page 21: ...safe position 5 Remove the two control panel fixing screws 6 Pull open facia controls chassis hinged on RH side and remove 3 pin plug from rear of control board 1 Re attach the 3 pin plug 2 Close facia controls chassis and secure with the 2 screws 3 Refit the outer panel in position and secure with the 2 screws 4 Replace the thermostat knobs 5 Replace the controls door Rayburn 680KCD C F only SEE ...

Page 22: ...22 Fig 31 DESN 514774 Replacement of parts Electrical controls ...

Page 23: ...23 Fault Finding Fig 32 Rayburn 600 700 Wiring Diagram 111MB for Individual Satronic boxes ...

Page 24: ...nnections For access to individual controls refer to section Replacement Parts and for wiring continuity checks refer to Fig 32 wiring diagrams To check out the electrical wiring at the burners you will first have to access the burner chamber Use the following procedure 1 Isolate the electrical power supply 2 Open up the bottom burner access door Remove door and put in a safe place Rayburn 680KCD ...

Page 25: ...r flow sensor Heater_T1 was above 95 C 4 17 7 16 Overheat error detected on cooker Cooker temperature was above 270 C with the burner on 5 Sensor difference detected on cooker or heater Cooker sensors deviated more than 20 C for a period of 10 minutes Heater sensors deviated more than 10 C for a period of 1 minute 6 n a n a 7 n a Spare error number n a 8 10 E2prom version incorrect Parameter setti...

Page 26: ...ally transmitted by flashing appropriately a LED Using an optional additional terminal the messages can be recorded and displayed in easily readable form Programming sequence display The built in microprocessor controls not only the programming sequence but the information system too The individual phases of the programming sequence are displayed as Flash Code The following messages can be disting...

Page 27: ...pre purge timer for the duration as mentioned in the table of timings Low voltage protection at 220 240V 110 120V nominal usage The mains voltage has to be more than 187Veff 94Veff in order to allow the unit to perform a start up The mains voltage is not only mentioned in the start up phase but also permanently during operation If the voltage drops below 160Veff 80Veff during start up or run time ...

Page 28: ... optically transmitted by flashing apprioriately a LED Using an optional additional terminal the messages can be recorded and displayed in easy readable form Programming sequence display The built in microprocessor controls not only the programming sequence but the information system too The individual phases of the programming sequence are displayed as Flash Code The following messages can be dis...

Page 29: ...Fault Finding 29 Fig 34A DESN 516838 ...

Page 30: ...30 Fault Finding ...

Page 31: ...31 Fault Finding ...

Page 32: ...GHT CHECK WITH GAUGE OIL SOAKED HEARTH BURNER FAULT OIL LEAKS AT PIPE FITTINGS TAKE APART AND REMAKE AS REQUIRED LEAKS AT TUBING CONNECTORS ENSURE END OF TUBING SQUARE NUMEROUS LOCK OUTS CURE THE LOCK OUT CONDITION ODOURS IN KITCHEN OIL PRESSURE INCORRECT ADJUST TO RECOMMENDED SETTINGS INCORRECT COMPONENTS USED ON COMBUSTION HEAD SEE SERVICING INSTRUCTIONS INTERNAL INSULATION PANELS INCORRECTLY PO...

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Page 36: ... 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 Tel 0845 815 2020 www rayburn web co uk www agacookshop co uk 36 ...

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