Rayburn 680KCD Servicing Instructions Download

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12/15 EINS 515872

PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE

Servicing

Instructions

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.

680KCD

780KCD

DESN 515906

DESN 516830

Summary of Contents for 680KCD

Page 1: ...ns 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 680KCD 780KCD DESN 515906 DESN 516830 ...

Page 2: ... 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 FAN MOTOR 17 PARTS BURNER IGNITION ELECTRODES 17 IGNITOR 17 SOLENOID COIL 18 CONTROL BOX 18 PEC 18 PUMP ACCESS 19 REPLACEMENT OF ELECTRICAL COMPONENT ACCESS 20 21 PARTS ELECTRICAL RE ASSEMBLE 20 CONTROLS CONTROL CIRCUIT EXTERNAL 20...

Page 3: ...nd 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 more pr...

Page 4: ...ce visit Annual Service During annual service flexible oil lines burner nozzles MUST BE CHANGED 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 ceramic fibre burner chambers BURNER SERVICING OIL PUMP SERVICING Cleaning ...

Page 5: ...ing 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 Rayburn 680KCD only 2 Remove 4 inner panel securing screws and remove panel 3 Remove the 3 plinth securing screws and remove plinth 5 PREPARATION BUR...

Page 6: ...m the cooker BOILER BURNER SEE FIG 4 1 Place a sheet on the floor in the front of the cooker to act as a working area 2 Remove lower LH door and burner aperture cover and store in a 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...

Page 7: ...raw access door from below through burner aperture 2 Remove stack of 5 sheet metal baffles check assembly and replace as shown in Fig 7 3 Check aluminium twisted baffles are in position and there are 28 baffles one in each recuperator tube NOTE LH set of x 4 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 cond...

Page 8: ...Cleaning 8 Fig 7 ALL BAFFLES MUST BE STACKED IN PLACE AS DIAGRAM ABOVE ...

Page 9: ...soft rope seal located around hotplate aperture in top plate and rope seal on hotspot Replace if frayed or damaged 8 Replace hotplate SEE FIG 9 1 Lift up two insulating lids on the top of the cooker 2 Using a 7mm allen key unscrew 2 countersunk retaining bolts 3 Insert M12 eye hooks into hotplate See Fig 8 4 Using lifting hooks lift hotplate vertically and withdraw 5 Re assemble in reverse order n...

Page 10: ...s slide forward and lift off keyhole slots See Fig 10 Clean in between fan blades using soft brush removing any debris Re assemble in reverse order NOTE Burners must be removed to access oven vent fan 10 OVEN VENT FAN Cleaning Fig 10 DESN 515962 ...

Page 11: ... the two burners mixed up The correct combination of burner blast tubes are shown To remove blast tube slacken two countersunk screws pull forward COOKER AND BOILER Countersunk screws in tube Fig 12 DESN 515964 COOKER BURNER BOILER BURNER 11 INTRODUCTION Burner Servicing 4 VANES Fig 11 DESN 515963 Fig 11A DESN 515977 10 VANES ...

Page 12: ... nozzle holder with correct spanner when tightening nozzle 4 Typically finger tight plus 1 4 turn is sufficient DO NOT OVERTIGHTEN 5 Ensure electrode gaps are correct SEE FIG 15 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 PEC taking care to insert the correct way round Should the cell show s...

Page 13: ...ews and split fan case 3 Clean between the blades of the fan impellor with a small brush and remove any residue Re assemble the burner in reverse order 13 Burner Servicing FAN CLEANING RE ASSEMBLE BURNER Fig 16 DESN 515967 Fig 17 COOKER FAN BOILER FAN DESN 515968 FAN FAN FAN ...

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 paraffin 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: ... some flame instability resulting in the burner locking out This will be shown by the burner stopping and the illumination of the signal light in the reset button of the control box See Fig 19 IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the re set button to restart SEE FIG 19 Whilst the burner is running vent air from the pump by slackening the pressure gauge port sufficiently to allow air t...

Page 16: ...e scale Replace the plugging screw and plug Switch off the boiler burner COOKER BURNER SEE FIG 24 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 hotplate The cooker burner should be set to 11 0 11 5 m...

Page 17: ...to 3 and BURNER NOZZLE REMOVAL SEE FIG 26 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 ignition electrode assembly re assemble in reverse order 6 Check electrode gap and reset if necessar...

Page 18: ...ntral fixing screw 2 Gently pull control box away from base 3 Fit new control box re assemble in reverse order SEE FIG 29 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 18 Replacement of parts Burner Fig 27 DESN 51...

Page 19: ...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 30 DESN 515976 19 PUMP ...

Page 20: ...afe 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 only SEE FIG 3...

Page 21: ...21 Fig 33 DESN 514774 Replacement of parts Electrical controls ...

Page 22: ...22 Fault Finding Fig 34 Rayburn 680 780K CD Wiring 111MB for independent Satronic boxes KEY APPLIANCE G Y GREEN YELLOW BL BLUE OR ORANGE BR BROWN W WHITE R RED BK BLACK PL PURPLE GR GREY Y YELLOW ...

Page 23: ...23 Fault Finding Fig 35 Rayburn 680 780K CD Wiring Diagram 111MB Self Contained Control KEY APPLIANCE W WHITE BR BROWN BL BLUE G Y GREEN YELLOW R RED BK BLACK OR ORANGE Y YELLOW GR GREY P PINK PL PURPLE ...

Page 24: ...tions For access to individual controls refer to section Replacement Parts and for wiring continuity checks refer to Figs 34 and 35 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 680...

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: ...itted 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 distinguished Fault ...

Page 29: ...Fault Finding Fig 37A 29 DESN 516838 ...

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

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

Page 32: ... 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 POSITIONED OR FAULTY ...

Page 33: ...33 ...

Page 34: ...34 ...

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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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