Rayburn 660, Service Manual

Page 1: ...Servicing Instructions DESN 515618 DESN 516825 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: ...AIR FROM OIL SUPPLY 14 FIT PRESSURE GAUGE 14 SWITCH ON ELECTRICITY 14 VENT OIL PUMP 14 ADJUST OIL PRESSURE 14 SET COMBUSTION AIR 15 CHECK SMOKE 15 REPLACEMENT OF PARTS FAN MOTOR 16 BURNER IGNITION ELECTRODES 16 IGNITOR 17 SOLENOID COIL 17 CONTROL BOX 18 PEC 18 PUMP ACCESS 19 REPLACEMENT OF PARTS ELECTRICAL COMPONENT ACCESS 20 21 ELECTRICAL CONTROLS RE ASSEMBLE 20 21 CONTROL CIRCUIT EXTERNAL 20 21 ...

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: ...aned 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 660 680 699K only 2 Remove 4 inner panel securing screws and remove panel 3 Remove the 3 plinth securing screws and remove plinth 6 PREPARATION BURN...

Page 7: ... and remove flexi air intake pipe from burner 4 Using a 5mm Allen key remove top securing bolt and remove burner by rotating it approximately 90 counterclockwise and drawing it away from the boiler COOKER BURNER FLEXIHEAD 1 Using a 13mm spanner unscrew top securing bolt and remove the horseshoe clamp 2 Withdraw the burner head BODY 1 Using a 10mm spanner remove 2 baseplate securing screws 2 Withdr...

Page 8: ...skets 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 replace gaskets if necessary Secure in position using hex driver 6 Remove hotplate by unscrewing 2 x countersunk hex screws insert lifting eyes and lift hotplate out with hooks provided 7 Brush and clean in between hot...

Page 9: ...Cleaning 9 Fig 7 ALL BAFFLES MUST BE STACKED IN PLACE AS DIAGRAM ABOVE 660 680 760 780 699 799 660 680 760 780 699 799 ...

Page 10: ...e shown To remove blast tube slacken two grub screws pull forward COOKER Grub screws in head BOILER Countersunk screws in tube 680K 780K 660K 760K 10 INTRODUCTION Burner Servicing Fig 8 Fig 9A Fig 9B DESN 515765 BOILER 8 VANES COOKER 10 VANES COOKER 10 VANES BOILER 10 VANES 3mm HOLES SMALL SLOTS Fig 8A COOKER BURNER BOILER BURNER 699K 799K Fig 9C COOKER 10 VANES BOILER 10 VANES 5mm HOLES 20 LARGE ...

Page 11: ...e out nozzle support cradle c w ignitor assembly from burner head 3 Unscrew nozzle from its holder with a correctly fitting tubular spanner to avoid damage to hexagon SEE FIG 11 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 nozzle 4 Typically finger tight plus 1 4 turn with spanner i...

Page 12: ...e necessary See PEC replacement Page 17 SEE FIG 13 13A 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 NOTE Burner head gaskets should be renewed at each service 12 Burner Servicing FAN CLEANING PHOTO ELECTRIC CELL PEC CLEANING RE ASSEMB...

Page 13: ...reverse 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 13 INTRODUCTION OIL PUMP ST...

Page 14: ... shown by the burner stopping and the illumination of the signal light in the reset button of the control box See Fig 16 IN THIS EVENT WAIT AT LEAST ONE MINUTE then press the re set button to restart SEE FIG 15 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 16 With th...

Page 15: ...xceed No 2 on the scale Replace the plugging screw and plug Switch off the boiler burner COOKER BURNER SEE FIG 17A 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 s...

Page 16: ...REMOVAL COOKER BURNER SEE FIG 19 1 Remove 2 socket head screws 2 Remove head assembly complete 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 necessary BOILER BURNER SEE FIG 19A 1 Release two countersunk head screws and remove blast tube 2 Remove two ...

Page 17: ...nitor See instruction in section burner removal boiler burner steps 1 to 4 SEE FIG 21 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 NOTE Boiler burner must be removed from appliance in order to gain access to solenoid coil See instructi...

Page 18: ...e in order to gain access to control box See instruction in section burner removal boiler burner steps 1 to 4 SEE FIG 23 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 PEC CONTROL BOX...

Page 19: ...l supply 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 24 DESN 511995 19 ...

Page 20: ...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 660 680 699K only SE...

Page 21: ...21 Fig 27 DESN 514774 Replacement of parts Electrical controls ...

Page 22: ...22 Fault Finding Fig 28 Rayburn 600 700 Wiring Diagram 111MB for Individual Satronic boxes ...

Page 23: ...23 Fault Finding Fig 29 Rayburn 600 700 Wiring Diagram 111MB self contained control ...

Page 24: ...ctions For access to individual controls refer to section Replacement Parts and for wiring continuity checks refer to Figs 28 29 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 660 68...

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 31A 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 ...