Rayburn 410K, Servicing Instructions

Page 1: ...WARNING This information is a copy of an original archive therefore Aga cannot be held responsible for its continued accuracy ...

Page 2: ...9 99 EINS 511897 MX For use in GB and IE Servicing Instructions 410K DESN 511420 PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE ...

Page 3: ...E 11 ELECTRICAL CONTROLS OVERHEAT SAFETY THERMOSTAT 12 FLUE SAFETY DEVICE 12 CONTROL CIRCUIT EXTERNAL 13 RE COMMISSIONING SET COMBUSTION AIR 14 CHECK SMOKE 14 REPLACEMENT OF PARTS BURNER FAN MOTOR 15 PUMP ACCESS 15 PUMP FILTER REPLACEMENT 15 SOLENOID COIL 16 IGNITION TRANSFORMER 16 IGNITION ELECTRODES 16 CONTROL BOX 17 P E C 17 REPLACEMENT OF PARTS ELECTRICAL ELECTRICAL COMPONENT ACCESS 18 CONTROL...

Page 4: ...s Glass Yarn Mineral Wool Insulation Pads Ceramic Fibre May be harmful if inhaled May be irritating to skin eyes nose and throat When handling avoid contact with skin or eyes Use disposable gloves face masks and eye protection After handling wash hands and other exposed parts When disposing of the product reduce dust with water spray ensure that parts are securely wrapped Kerosene Gas Oil fuels mi...

Page 5: ...nnot be serviced whilst hot so the thermostat should be turned off on the evening before the service visit 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 IMPORTANT FLEXIBLE OIL LINE M...

Page 6: ...ned 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 the 4 inner panel securing screws and remove panel 3 Remove the 3 plinth securing screws and remove plinth 5 PREPARATION BURNER ACCESS Burner Remova...

Page 7: ...heet on the floor in front of the cooker to act as a working area 2 Disconnect the terminal strip plug SEE FIG 3 3 Loosen the burner locking nuts 2 4 Twist the burner SEE FIG 4 5 Withdraw the burner unit 6 BURNER REMOVAL FIG 2 FIG 3 FIG 4 DESN 511431 A DESN 511432 A DESN 511433 A Burner Removal BURNER LOCKING BOLTS ...

Page 8: ...and place in a safe position 2 Remove side and base access doors using hex driver 3 Thoroughly clean top side and base flueways through access apertures with brush 4 Remove all debris with vacuum cleaner 5 Replace side 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 pl...

Page 9: ...er unscrew nozzle Ensuring hexagon is held to stop nozzle holder turning 9 Remove nozzle and check filter for debris Replace with one of same specified make and pattern 10 Refit nozzle taking care not to overtighten 11 Re assemble in reverse order NOTE Do not touch the face of nozzle to avoid blocking of fine drilling SEE FIG 7 and PAGE 15 Inspect the ignition electrodes for crazing in the porcela...

Page 10: ...nsing 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 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 DESN 511439 DESN 511440 FIG 9 ...

Page 11: ...OFF the line isolating valve fitted prior to the oil line filter 2 Dismantle filter by unscrewing bolt at base of bowl 3 Make arrangements to catch kerosene 4 Wash filter thoroughly in clean kerosene 5 Re assemble filter in reverse order of removal REMEMBER Do not kink hoses Do not pass hoses through side casing panels Always flush oil through before final connection Check hose for signs of discol...

Page 12: ...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 13 IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the re set button to restart SEE FIG 12 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 SEE FIG ...

Page 13: ...h operates if the control thermostat fails This device automatically resets This thermostat is a safety cut out device which will operate under adverse wind or a blocked flue condition It is a manually reset device which can be reset by pressing in the centre BURNER RESET BUTTON FLUE SAFETY DEVICE DESN 511742 FIG 14 ...

Page 14: ...NEUTRAL 3 AMP PERMANENT SUPPLY PROGRAMMER EARTH PROGRAMMER NEUTRAL PIPE FLOW THERMOSTAT PROGRAMMER LIVE TERMINAL STRIP CONNECTIONS Electrical Controls SWITCH LIVE FROM PROG IF AN OPTIONAL EXTERNAL PROGRAMMER IS TO BE INSTALLED CONNECT WIRING AS SHOWN AND REMOVE LINK FROM PL L2 ...

Page 15: ...T Ensure that the bottom louvred plinth is in place during combustion setting procedures and the outer door is closed Remove the CO2 sampling tube and using the same hole for flue sampling insert the sensing end of a Baccarach Smoke Pump and check that the smoke in the flue ways does not exceed 0 1 on the scale Replace the countersunk headed screw on completion ensuring that it will not interfere ...

Page 16: ...ectly located SEE FIG 16 Follow instructions in section BURNER ACCESS Steps 1 to 3 and BURNER REMOVAL Steps 1 to 5 1 Isolate fuel supply 2 Disconnect flexible hose 3 Disconnect pump outlet supply tube 4 Remove solenoid securing nut 5 Remove solenoid 6 Slacken 3 grub screws on pump flange 7 Remove pump 8 When re fitting pump inspect pump coupling for signs of wear or cracking replace if necessary a...

Page 17: ...curing transformer 2 Remove both H T leads from transformer 3 Disconnect the wires from the terminal strip 4 Remove transformer 5 Fit new transformer re assemble in reverse order SEE FIG 7 Follow instructions in sections BURNER ACCESS Steps 1 to 3 BURNER REMOVAL Steps 1 to 5 and BURNER NOZZLE REMOVAL Steps 2 to 7 1 Remove ignition electrode assembly 2 Fit new ignition electrode assembly in reverse...

Page 18: ... new control box re assemble in reverse order SEE FIG 8 Follow instructions in sections BURNER ACCESS Steps 1 to 3 BURNER REMOVAL Steps 1 to 5 1 Unplug PEC 2 Undo wire connections from terminal strip 3 Withdraw PEC cable 4 Slacken and remove PEC clip note orientation of clip 5 Transfer and secure clip to new PEC 6 Fit new PEC re assemble in reverse order 17 Replacement of parts Burner PEC CONTROL ...

Page 19: ... It will be necessary to disconnect the push on tags from the timer noting position of wiring 5 Remove the four control panel fixing screws 6 Tilt the chassis forwards from the top and lift out To fully access the rear of the control chassis the oven thermostat capillary should be removed from the oven Follow instructions in section TO FIT NEW OVEN CONTROL thermostat Steps 3 to 6 18 ELECTRICAL COM...

Page 20: ...rmostat securing nut 4 Remove phial guide bracket from tube 5 Pull phial from securing clips and withdraw 6 Fit replacement device and assemble in reverse order of removal ensuring the phial is correctly located within the tube and guide bracket is located under the safety device fixing bracket 19 FIG 20 FIG 21 DESN 511737 DESN 511736 Replacement of parts Electrical controls COOKER TIMER OVEN THER...

Page 21: ...s in section ELECTRICAL ASSEMBLY Steps 1 to 5 Follow instructions in section ELECTRICAL COMPONENT ACCESS Steps 1 to 4 1 Remove timer by depressing retaining clips 2 Fit new timer ensuring correct location To complete follow instructions in section ELECTRICAL COMPONENT ACCESS Steps 2 to 5 1 Locate the base of the control chassis into the bottom of the doorway aperture tilt the chassis backwards int...

Page 22: ...21 WIRING DIAGRAM APPLIANCE Fault Finding FIG 23 FLOW PIPE THERMOSTAT ...

Page 23: ...Fault Finding WIRING DIAGRAM BURNER ONLY 22 FIG 24 410K ...

Page 24: ...er you will first have to have access to 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 4 screws holding the inner panel in place and remove panel 4 Unscrew the 3 screws holding the louvered plinth in place and remove plinth The external mains connections are made to a te...

Page 25: ...K 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 BURNER CHAMBER INSULATION PANELS INCORRE...

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