AGA RAYBURN benchmark 680KCD Servicing Instructions
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AGA RAYBURN benchmark 680KCD Servicing Instructions

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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.
PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE
680KCD
780KCD
DESN 515906
Servicing
Instructions
For use in GB & IE
Servicing
Instructions
DESN 516830
12/15 EINS 515872

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Summary of Contents for AGA RAYBURN benchmark 680KCD

  • Page 1 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. PLEASE READ THESE INSTRUCTIONS BEFORE SERVICING THIS APPLIANCE For use in GB &...

  • Page 2: Table Of Contents

    Contents SECTION CONTENTS PAGE CONSUMER PROTECTION HEALTH & SAFETY INTRODUCTION SERVICE SCHEDULE BURNER REMOVAL PREPARATION BURNER ACCESS BURNER REMOVAL CLEANING HEAT EXCHANGER CLEANING CONDENSATE TRAP CLEANING OVEN AND HOTPLATE FLUEYWAY CLEANING HOTPLATE REMOVAL OVEN VENT FAN BURNER SERVICING INTRODUCTION BURNER NOZZLE REMOVAL BURNER NOZZLE REPLACEMENT PHOTO ELECTRIC CELL (PEC) CLEANING FAN CLEANING...
  • Page 3 IMPORTANT NOTICE: PLEASE READ THE ACCOMPANYING WARRANTY Any alteration that is not approved by AGA could invalidate the approval of the appliance, operation of the warranty and could affect your statutory rights.
  • Page 4 INTRODUCTION SERVICE SCHEDULE To ensure the best performance from your Rayburn. It Annual Service should be serviced once a year, preferably at the start of the heating season. During annual service flexible oil lines, burner nozzles MUST BE CHANGED. This appliance must be commissioned by a competent WIRING: Ensure there is no damage or loose engineer, such as OFTEC approved.

  • Page 5: Burner Removal

    Burner Removal PREPARATION WARNING: BEFORE REMOVING SERVICE ACCESS COVERS OR THE OIL BURNER ENSURE THAT ALL ELECTRICAL AND OIL SUPPLIES TO THE APPLIANCE HAVE BEEN ISOLATED. The burners can be removed without disconnecting the oil supply 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.
  • Page 6 Burner Removal BURNER REMOVAL IMPORTANT: DURING BURNER REMOVAL CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIGS. 2, 3 & 4 COOKER BURNER - SEE FIG. 3 1. Unscrew jubilee clip and remove flexi air intake. 2.

  • Page 7: Cleaning

    Cleaning HEAT EXCHANGER CLEANING IMPORTANT: DURING CLEANING CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION. SEE FIG. 5 1. Remove top LH door (Rayburn 680KCD only) and facia glass. Remove 2 fixing screws from control panel chassis and hinge open. 2.
  • Page 8 Cleaning ALL BAFFLES MUST BE STACKED IN PLACE AS DIAGRAM ABOVE Fig. 7...
  • Page 9 Cleaning OVEN & HOTPLATE FLUEWAY CLEANING SEE FIG. 8 1. Remove top oven door and place in a safe position. (Rayburn 680KCD only) 2. Remove rear and base access doors use hex. driver. 3. Thoroughly clean top, side and base flueways through access apertures with brush.
  • Page 10 Cleaning OVEN VENT FAN Disconnect 4-pin plug, slacken 2 fixing screws, 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.

  • Page 11: Burner Servicing

    Burner Servicing INTRODUCTION SEE FIG. 11, 11A & 12 It is recommended that each side of the burner is serviced individually so as not to get the components from the two burners mixed up. The correct combination of burner blast tubes are shown. To remove blast tube, slacken two countersunk screws, pull forward.
  • Page 12 Burner Servicing BURNER NOZZLE REMOVAL SEE FIG. 13 1. Release two countersunk head screws and remove blast tube, carefully feeding the HT leads through the rear of the burner. 2. Remove two screws and slide out nozzle support cradle c/w ignitor assembly from burner head. 3.
  • Page 13 Burner Servicing COOKER FAN FAN CLEANING SEE FIG. 16 & 17 1. Remove two screws and air inlet snorkel. 2. Remove four screws and split fan case. 3. Clean between the blades of the fan impellor with a small brush and remove any residue. Fig.

  • Page 14: Oil Pump Servicing

    Oil Pump Servicing INTRODUCTION To carry out any servicing on the oil pump. Turn off the oil line isolating valve near to the appliance. SEAL STRAINER COVER OIL PUMP STRAINER CLEANING SEE FIG. 18 1. A container must be put under the pump to catch any oil when starting to clean the oil pump strainer.

  • Page 15: Re-Commissioning

    Re-commissioning BLEED AIR FROM OIL SUPPLY Disconnect the flexible oil pipe line at the pump inlet, open the stop valve slowly and run off some of the oil into a receptacle to establish an air free supply to the pump. Re-make the connection oil tight and leave valve open.

  • Page 16: Check Smoke

    Re-commissioning SEE FIG. 21 & 22 After 15 minutes of the boiler burner running. 1. Remove top LH door and store in a safe place. 2. Open control door. 3. Remove the plugging screw and insert the sensing end of a portable indicator to check the CO (Carbon Dioxide) level.

  • Page 17: Replacement Of Parts (Burner)

    Replacement of parts (Burner) FAN MOTOR SEE FIG. 25 Follow instructions in sections BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL. 1. Isolate electric supply. 2. Remove 3-pin plug. 3. Remove solenoid plug. 4. Disconnect oil pipe. FAN MOTOR 5.

  • Page 18: Solenoid Coil

    Replacement of parts (Burner) SOLENOID COIL SOLENOID SEE FIG. 27 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. Fig.

  • Page 19: Pump Access

    Replacement of parts (Burner) PUMP ACCESS SEE FIG. 30 Follow instructions in section BURNER ACCESS, Steps 1 to 3 and BURNER REMOVAL. 1. Isolate fuel supply. 2. Disconnect flexible hose (This must be replaced annually). 3. Remove solenoid plug. 4. Remove feed pipe. 5.

  • Page 20: Replacement Of Parts (Electrical Controls)

    Replacement of parts (Electrical controls) BEFORE REMOVING SERVICE ACCESS COVERS ENSURE THAT ALL ELECTRICAL ACCESS TO THE APPLIANCE HAS BEEN SWITCHED OFF (SWITCH OFF AND REMOVE PLUG). SEE FIG. 31 1. Remove the controls door and put in a safe position. (Rayburn 680KCD only).
  • Page 21 Replacement of parts (Electrical controls) Fig. 33 DESN 514774...
  • Page 22 Fault Finding 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 Fig.
  • Page 23 Fault Finding 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 Fig.

  • Page 24: Burner Does Not Start

    Fault Finding BURNER DOES NOT START Burners Check that the burner has not gone to lock-out. Causes of lock-out can be: No ignition, ignition electrode incorrectly positioned, insulation cracked, spark generator fault. No oil supply. Poor combustion. Photo electric cell incorrectly positioned, cracked or needs cleaning. Live and Neutral connections reversed.

  • Page 25: Error Table

    Fault Finding Error Table In the next tables a description of the different errors is given Errors can be divided in two groups. Blocking errors will disappear when error is gone, and non-volatile locking errors can only be reset by the reset button. A blocking error is indicated with an ‘E’...
  • Page 26 Fault Finding Cooker Burner (Control Box Type - DKO 970) Information system The information system communicates with the outside world using a LED (the used Flash-Code is similar to the Morse Code). The messages are optically transmitted by flashing appropriately a LED. Using an (optional) additional terminal the messages can be recorded and displayed in easily readable form.
  • Page 27 Fault Finding Cooker Burner (Control Box Type - DKO 970) In case of failure the LED is permanently illuminated. Every 10 seconds the illumination is interrupted by a flash code which indicates the cause of the error. Therefore the following sequence is performed which is repeated as long as the unit is not reset.
  • Page 28 Fault Finding Cooker Burner (Control Box Type DKO 970N) - Information system The information system is microprocessor based and reports on all aspects of burner control box operation and flame supervision. It informs continuously about the actual programming sequence the unit is just performing. Besides monitoring of the programming sequence it also allows to identify errors during start-up of operation without any additional testing devices.
  • Page 29 Fault Finding Fig. 37A DESN 516838...
  • Page 30 Fault Finding...
  • Page 31 Fault Finding...
  • Page 32 Fault Finding HIGH SMOKE NUMBERS INCORRECT INCORRECT INTERNAL COMPONENTS NOZZLE FAULT AIR INTAKE OIL PRESSURE COMBUSTION INSULATION USED ON BLOCKED SETTINGS INCORRECT PANELS COMBUSTION REPLACE INCORRECTLY RE-ADJUST ADJUST TO HEAD CHECK AIR POSITIONED NOZZLE RECOMMENDED SEE SERVICING INLET TO INSTALLATION SETTINGS INSTRUCTIONS FAULTY...
  • Page 40 For further advice or information contact your local distributor/stockist With AGA Rangemaster’s policy 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...

This manual is also suitable for:

Rayburn benchmark 780kcdDesn 515906Desn 516830

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