Stanley Alpha 120 Servicing Instructions Download Page 1 | Manualshive

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06/10 EINS 514810

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 Waterford Stanley.

PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE

Alpha

120/150K

Servicing Instructions

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Summary of Contents for Alpha 120

Page 1: ...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 Waterford Stanley PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE Alpha 120 150K Servicing Instructions ...

Page 2: ...TY 13 VENT OIL PUMP 13 ADJUST OIL PRESSURE 13 SET COMBUSTION AIR 14 CHECK SMOKE 14 REPLACEMENT OF FAN MOTOR 15 PARTS BURNER CHECK SMOKE 15 IGNITOR 16 RELAY 16 SOLENOID COIL 16 CONTROL BOX 17 PEC 17 PUMP ACCESS 17 REPLACEMENT OF ELECTRICAL COMPONENT ACCESS 18 19 PARTS ELECTRICAL TO FIT NEW BOILER CONTROL THERMOSTAT 20 CONTROLS TO FIT NEW BOILER PUMP OVERRUN THERMOSTAT 20 TO FIT NEW COOKER SAFETY OV...

Page 3: ...h hands 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 an...

Page 4: ...r head seals MUST BE CHANGED Flexible oil lines must be changed every 2 years WIRING Ensure there is no damage or loose connections 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 insulation fibre burner chambers BURNER SERVICING OIL PUMP SERVICING Cleaning of fuel line st...

Page 5: ... pipe However if the filters are 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 SEE FIG 1 1 Open up the bottom burner access door Remove door and put in a safe place 2 Remove 2 inner panel securing screws and remove panel 5 PREPARATION BURNER ACCESS Burner Removal FIG 1 DESN 5148...

Page 6: ...aw burner head SEE FIG 3 3 Place a sheet on the floor in front of the cooker to act as a working area 4 Disconnect the 12 pin plug from above the burner 5 Disconnect air intake SEE FIG 4 6 Slacken 2 M6 fixings and remove flue safety thermostat 7 Withdraw burner unit 6 BURNER REMOVAL FIG 2 FIG 3 FIG 4 DESN 514814 DESN 514847 DESN 514815 Burner Removal BURNER HEAD REMOVAL ...

Page 7: ... stacks it maybe necessary to slightly lift the top stack of baffles and withdraw bottom baffle stack first then withdraw the second stack of baffles Each heat exchanger has 3 rows of baffles 5 Ensure baffles and flueways are clear of debris and re fit baffle stacks as illustrated in Fig 8 NOTE One baffle configuration for all three models 6 Carefully vacuum any debris that has fallen into the bur...

Page 8: ...emove rear and base access doors use hex driver 3 Thoroughly clean top side and base flueways through access apertures with brush 4 Remove all debris with vacuum cleaner 5 Replace rear and base access doors Secure in position using hex driver 6 Brush and clean in between hotplate ribs on underside 7 Examine soft rope seal located around hotplate aperture in top plate and rope seal on hotspot Repla...

Page 9: ...he components from the two burners mixed up The correct combination of burner blast tubes are shown To remove blast tube slacken two grub screws pull forward 120K 150K INTRODUCTION FIG 12 FIG 13B FIG 13A DESN 512005 COOKER 10 VANES COOKER 10 VANES BOILER 10 VANES 5mm HOLES 10 LARGE SLOTS BOILER 10 VANES 5mm HOLES 20 LARGE SLOTS ...

Page 10: ...emove head assembly complete 4 Remove ignitor assembly by removing countersunk screw and clamp 5 Fit new ignition electrode assembly re assemble in reverse order 6 Check electrode gap and re set if necessary SEE FIG 15 1 Replace nozzle by 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 nozzle 4 Typically fi...

Page 11: ...stortion or cracking replacement will be necessary See PEC Replacement Page 17 SEE FIG 17 1 Remove pozi screws pull off fan case inlet 2 Clean between the blades of the fan impellor with a small brush and remove any residue Re assemble the burner in reverse order NOTE Burner head gaskets should be renewed at each service 11 Burner Servicing PHOTO ELECTRIC CELL PEC CLEANING FIG 17 DESN 514824 FIG 1...

Page 12: ...ng 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 petrol or paraffin 4 Re assemble in reverse order NOTE Flexible fuel hose s must be replaced every 2 years INTRODUCTION Oil Pump Servicing 12 FIG 18 DESN 512002 OIL PUMP STRAINER ...

Page 13: ...ing in the burner locking out This will be shown by the burner stopping and the reset button will be illuminated in the control box IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the reset button to restart See Fig 21 SEE FIG 19 Whilst the burner is running vent air from the pump by slackening the pressure gauge port sufficient to allow air to bleed out When bubble free oil seeps out re tighten...

Page 14: ... using the same hole for flue sampling insert the sensing end of a Baccarach Smoke Pump and check that the smoke in the boiler flueways does not exceed No 2 on the scale Replace the plugging screw Switch off the boiler burner COOKER BURNER SEE FIG 23 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...

Page 15: ... pozi drive screws remove fan case inlet 4 Undo grub screw remove fan 5 Remove 4 fixings withdraw motor 6 Re assemble in reverse order NOTE Ensure that gaskets and seals are in place and in good condition 15 FAN MOTOR Replacement of parts Burner FIG 24 DESN 514828 ...

Page 16: ... 2 Lift and withdraw control panel and turn over 3 Remove push on connectors noting position of each connector 4 Remove 2 relay fixing screws 5 Fit new relay 6 Re assemble in reverse order SEE FIG 27 Follow instructions in sections BURNER ACCESS Steps 1 to 2 BURNER REMOVAL Steps 1 to 5 1 Slacken solenoid plug securing screw 2 Remove plug 3 Remove solenoid securing nut and washer 4 Remove solenoid ...

Page 17: ...it new PEC 4 Re insert PEC taking care to insert the correct way round SEE FIG 30 Follow instructions in section BURNER ACCESS Steps 1 to 2 and BURNER REMOVAL Steps 1 to 5 1 Isolate fuel supply 2 Disconnect flexible hose This must be replaced every 2 years 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 pu...

Page 18: ...e 2 cover panel fixing screws 4 Disconnect cover panel It will be necessary to disconnect the push on tags from the selector switch and cooker ON neon SEE FIG 33 5 Lift control panel chassis and withdraw from aperture 6 To fully access the rear of the control chassis the thermostat capillaries should be removed from their pocket 18 ELECTRICAL COMPONENT ACCESS Replacement of parts Electrical contro...

Page 19: ...Replacement of parts Electrical controls FIG 34 DESN 514830 19 ...

Page 20: ...IG 36 Follow instructions in section ELECTRICAL COMPONENT ACCESS Steps 1 to 6 1 Undo the two screws on the front of the chassis which hold the thermostat in place 2 Remove the three push on connectors from back of thermostat 3 Replace thermostat The thermostat should be mounted with tag P at the left hand side Take care to push on thermostat phial correctly into the pocket provided 4 Re connect pu...

Page 21: ...ned in the same position as removed To complete follow instructions in section RE ASSEMBLE Steps 1 to 6 SEE FIG 38 Follow instructions in section ELECTRICAL COMPONENT ACCESS Steps 1 to 6 1 Undo the central hexagon nut on the front of the chassis which holds the thermostat in place 2 Remove the push on connectors from back of thermostat 3 Replace thermostat Take care to push thermostat phial correc...

Page 22: ...al in same position as removed 6 Re connect push on connector The VIOLET to P2 PINK to P and BLACK to P1 NOTE Ensure phials do not make contact with oven castings To complete follow instructions in RE ASSEMBLE Steps 1 to 6 SEE FIG 40 Follow instructions in section ELECTRICAL COMPONENT ACCESS Steps 1 to 4 1 To remove switch from the cover panel press the two toggles at top and bottom of switch push...

Page 23: ...the selector switch through the aperture and connect them onto the rear of the selector switch fitted in the outer panel Connect the VIOLET and BLUE wires to the COOKER ON neon Connect the ORANGE wire on 1 and the PURPLE wire on 2 4 Refix the outer panel in position and secure with the 2 screws 5 Replace the thermostat knobs 6 Replace the controls door Replacement of parts Electrical controls 23 F...

Page 24: ...R This thermostat is a safety cut out device which is intended to operate if the other controls fail This control will lock out and switches everything off except for the programmer clock and the Pump Overrun facility This thermostat has to be manually reset once the temperature has cooled down COOKER This thermostat is a safety cut out device which operates if the control thermostat fails This th...

Page 25: ...CONNECTED DIRECTLY TO THIS SUPPLY EXTERNAL PROGRAMMER NEUTRAL PUMP SUPPLY LIVE THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY PUMP SUPPLY NEUTRAL THE CIRCULATING PUMP MUST BE CONNECTED DIRECTLY TO THIS SUPPLY 3 AMP PERMANENT SUPPLY NOTE The 3 channel programmer LIVE must be connected directly to the programmer LIVE supply from the cooker TERMINAL STRIP CONNECTIONS BOILER SWITCHED L...

Page 26: ...26 FIG 43 Fault Finding ...

Page 27: ... for wiring continuity checks refer to Figs 37 and 38 for detailed and schematic 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 3 Unscrew the 2 screws holding the inner panel in place and re...

Page 28: ...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 distinguished FIG 44 ...

Page 29: ...d of the pre purge time for the duration as mentioned in the table of timings Low voltage protection at 220 240V nominal voltage 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 monitored in the start up phase but also permanently during operation If the voltage drops below 160Veff 80Veff during start up or run time...

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

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

Page 32: ...32 Fault Finding ...

Page 33: ...33 Fault Finding ...

Page 34: ...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...

Page 35: ...35 ...

Page 36: ...olicy of continuous product improvement the Company reserves the right to change specifications and make modifications to the appliance described at any time Supplied by Waterford Stanley Ltd Unit 210 IDA Industrial Estate Cork Road Waterford Ireland Tel 051 302300 Fax 051 302315 www waterfordstanley com ...

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