AGA COOKMASTER R40G Owner's Manual
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AGA COOKMASTER R40G Owner's Manual

AGA COOKMASTER R40G Owner's Manual

Floor standing cooker
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WARNING: If the information in this manual is not followed exactly, a fire or
explosion may result causing property damage,personal injury or death.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT DO YOU DO IF YOU SMELL GAS
.
Do not try to light any appliance.
.
Do not touch any electrical switch
.
Do not use any phone in your building.
.
Immediately call your gas supplier from a neighbors phone.
Follow the gas suppliers instructions
.
If you can not reach your gas supplier call the fire department.
Installation and service must be performed by a qualified installer, service
agency or the gas supplier.
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
authorized by AGA.
PLEASE READ THESE INSTRUCTIONS BEFORE INSTALLING OR USING THIS APPLIANCE.
INSTALLER: LEAVE THESE INSTRUCTIONS WITH THE APPLIANCE.
CUSTOMER: KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE.
COOKMASTER R40G
OWNERS MANUAL
Installation, Servicing,
Users Instructions
& Cooking Guide
FOR USE IN USA/CANADA
11/09 EINS 512534

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Summary of Contents for AGA COOKMASTER R40G

  • Page 1 COOKMASTER R40G OWNERS MANUAL WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage,personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

  • Page 2: Table Of Contents

    USING THE TIMER 23-24 THE MINUTE TIMER USING THE AUTOMATIC COOKING FUNCTION MAIN OVEN OPERATION COOKING WITH YOUR APPLIANCE COOKING CHART (ROASTING/BAKING OVEN) CLEANING & CARING FOR YOUR AGA SERVICING INSTRUCTIONS INTRODUCTION SERVICE SCHEDULE PREPARATION BURNER REMOVAL BURNER ACCESS BURNER REMOVAL...
  • Page 3 SECTION CONTENTS PAGE COMBUSTION AIR BURNER TEST BURNER ON DRY RUN (NO GAS) ELECTRODES REPLACEMENT OF PARTS CONTROL BOX (BURNER) ELECTRICAL COMPONENT ACCESS REPLACEMENT OF PARTS TRANSFORMER (ELECTRICAL CONTROLS) FUSE TO FIT NEW FLUE SAFETY DEVICE TO FIT NEW COOKER SAFETY OVERHEAT THERMOSTAT 44 AND OVEN CONTROL THERMOSTAT TO FIT NEW TIMER RE-ASSEMBLE...
  • Page 4 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 authorized by AGA. CAUTION: THIS UNIT IS HEAVY.

  • Page 5: Technical Data

    PLEASE NOTE: IT IS ADVISABLE TO CHECK THE ACTUAL SIZE/WIDTH DIMENSIONS IN MM OF YOUR APPLIANCE BEFORE FINALLY FIXING ANY KITCHEN DESN 512448 UNITS, SINCE ENAMELLED CAST IRON CAN VARY IN SIZE TECHNICAL DATA 1/2” NPT Unpacked Appliance Weight - 326 Kg (719 lbs) Gas Inlet 115 V 60 Hz...

  • Page 6: Introduction

    Site requirements INTRODUCTION The AGA Cookmaster is a floor standing only cooker, fired by a gas burner. It is suitable for vertical flue outlet only. IMPORTANT The burner fitted to this appliance has been designed and constructed exclusively for use with the AGA Cookmaster and MUST not be used on any other appliances or any other uses.

  • Page 7: Location

    Site requirements LOCATION The appliance is floor mounted and must be installed on a solid floor or base of non-combustible material which is capable of supporting the total weight. The location chosen for the appliance must permit the installation and the provision of a satisfactory flue and an adequate air supply.
  • Page 8 Site requirements INSTALLATION CLEARANCES REAR DIM ‘A’ COMBUSTIBLE WALL 1” (25mm) NON-COMBUSTIBLE WALL 0” (0mm) DIM ‘B’ FLUE PIPE CLEARANCE TO ” (57 mm) COMBUSTIBLE WALL NON-COMBUSTIBLE WALL 1” (25 mm) SIDES BELOW HOTPLATE ” (10 mm) SIDES ABOVE HOTPLATE 2”...

  • Page 9: Vent Connection

    Site requirements VENT CONNECTION A 125 mm (5”) Type B Gas Vent must be used and fastened by screw to the draft hood flue collar. U.S. The gas vent must be connected to a chimney or independently and in accordance with Chapter 26, chimney Gas Vent and Fireplace Systems of the current issue of Equipment and Volume of the ASHRAE Handbook.

  • Page 10: Electrical

    Termination at the roofs eaves is unacceptable. 5. The AGA Distributor or local gas company should be advised if there is any doubt as to the suitability of the flue. 6. Approved factory made chimneys are acceptable with the appliance and should not be less than 10mm (4in) internal diameter.

  • Page 11: Clearances

    Installation requirements CLEARANCES The appliance is floor mounted. The space in which the appliance is to be fitted must have the following minimum dimensions. Between wall and LH side of appliance - 10mm (1/2”) Between wall and RH side of appliance - 10mm (1/2”) SHOULD THE WALL PROJECT BEYOND THE FRONT OF THE APPLIANCE, THEN THE GAP AT THE R.H.

  • Page 12: Site Location

    Installation requirements SITE LOCATION SETTING COMBUSTION Because this appliance uses a pre-mix burner, no setting 1. Check that the hearth is level, then remove the up of combustion is required; the burner automatically appliance from its transit wooden pallet, and position controls the air to gas rate ratio.

  • Page 13: Burner Access

    Installation Instructions BURNER ACCESS - SEE FIG. 5 1. Open the burner access door. 2. Remove (5) inner panel securing screws and remove panel. 3 Remove the (3) plinth securing screws and remove plinth. FIG. 5 DESN 511424 ELECTRICAL CONNECTION - SEE FIG.

  • Page 14: Terminal Strip Connections

    Installation Instructions TERMINAL STRIP CONNECTIONS FIG. 7...

  • Page 15: Burner Control

    Installation Instructions BURNER CONTROL When the thermostat is calling for heat, 230V is supplied to terminals 10 and 11 on the control box and tab 1 and 2 on the fan, energizing the fan. There will then be a short delay while the control box checks that the fan is running and pre-purges.

  • Page 16: Ancillary Controls Check

    Installation Instructions ANCILLARY CONTROLS CHECK INSTRUCT THE USER Before leaving the site, check that the operation of cooker 1. Advise the User that, for continued efficient and safe timer and thermostat are capable of controlling the burner operation of the appliance, it is important that adequate correctly.
  • Page 17 Users Guide...

  • Page 18: Introduction

    INTRODUCTION Thank you for buying an AGA appliance. To get the best from it, please read this leaflet and carefully follow the instructions before using your AGA for the first time. Consumer Protection As responsible manufacturers we take care to make sure that our products are designed and constructed to meet the required safety standards when properly installed and used.

  • Page 19: Safety Precautions & Hints

    SAFETY PRECAUTIONS AND HINTS Do not store combustible materials, gasoline or other inflammable vapors and liquids near a range cooker. Do not operate the appliance with the oven doors open, with the exception of loading and unloading the oven. Ensure and maintain the continual free passage of air to the burner housing. Do not stand obstacles against a burner outer door.

  • Page 20: Features/Accessories

    Do not worry, close the door and after a few minutes, the dial will have regained its FIG. 10 position. As an AGA user, you will soon become accustomed to your individual appliance. Oven Grid Shelves See Fig. 11 To ensure the correct operation of the oven grid shelves, they should be inserted as shown.

  • Page 21: Features/Accessories

    SHELF POSITION 2 SHELF POSITION 3 SHELF POSITION 4 SHELF POSITION 5 OVEN BASE FIG. 12 Further accessories, tins, grid shelves, solid shelves, saucepans, aprons and gauntlets, etc. are available from your AGA dealer. Control Settings and Temperature Equivalents APPROX MARK TEMP 250ºF (120ºC)

  • Page 22: Setting The Cooker For Use

    SETTING THE COOKER FOR USE FIG. 12A DESN 514596 Before you can use the appliance, it will be necessary to set the time of day.

  • Page 23: Using The Timer

    USING THE TIMER This is a 24 hour clock and when the power supply is initially switched on, or after an interruption in supply, the clock will show AUTO and 0.00 alternately. SETTING THE TIME OF DAY Press and hold the MINUTE TIMER and COOK TIME buttons at the same time, (the word AUTO flashes and the 0.00 is displayed steadily) press the plus + or minus - buttons until the required time of day is displayed.

  • Page 24: Using The Timer

    USING THE TIMER (continued) SETTING AN END TIME ONLY, AUTOMATICALLY Place the food on the correct shelves in the oven. Press the STOP button until the time at which the cooking is to end, appears on the display. Set the oven temperature control. Cooking will start immediately and the COOK TIME symbol will illuminate and remain throughout cooking.

  • Page 25: The Minute Timer

    THE MINUTE TIMER SEE FIG. 13 THE MINUTE TIMER The minute timer works separately from the time of day clock and can be set to time periods from 1 minute to 23.59 hours. Only a one handed operation is required. SETTING THE MINUTE TIMER 1.

  • Page 26: Using The Automatic Cooking Function

    The AGA should be COLD before starting any automatic cooking where there is a delay in the start time. Because the AGA is made from cast iron and will therefore retain the heat for a number of hours after it is turned off, food should NOT be loaded into the appliance for automatic cooking if the AGA has been used earlier in the day, or is slightly warm, even if it has been turned off for some hours.

  • Page 27: Main Oven Operation

    When left on L setting, your Roasting/Baking oven will maintain a low idling temperature suitable for slow cooking. As the AGA is made of cast iron, the time for the appliance to heat up and cool down is longer than with a conventional oven.

  • Page 28: Cooking With Your Appliance

    When cooking a casserole or meat dishes in the Simmering/Warming oven, always start off cooking somewhere else on the AGA first. (ie allow casseroles to come to a boil, and cook for 5-10 minutes on the hotplate or in the Roasting/Baking oven before being transferred to the Simmering/Warming oven).

  • Page 29: Cooking Chart (Roasting/Baking Oven)

    30-35 mins YORKSHIRE PUDDING 2 or 3 25-35 mins SLOW/FAST ROASTING SEE AGA Depending on Joint COOKBOOK FOR TIMES Shelf Positions are counted downwards (ie., top shelf is No. 1 position). (See Fig. 12) The positions are a guide only and can be altered.

  • Page 30: Cleaning & Caring For Your Aga

    CLEANING AND CARING FOR YOUR AGA REMEMBER: BE CAREFUL OF THE HOT APPLIANCE! DO NOT USE A STEAM CLEANER TO CLEAN THIS COOKER. Enamelled Top Plate and Front Plate It is not advisable to put wet clothes on the handrail: this may craze the enamel.
  • Page 31 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 authorized by AGA.

  • Page 32: Service Schedule

    For continued safe and efficient operation of the range, it is important that servicing is carried out annually as recommended by your AGA Distributor or local gas company. The Cookmaster should be turned OFF by the user the night preceding the day of servicing so that the range will have cooled down by the following morning.

  • Page 33: Preparation

    Burner Removal PREPARATION WARNING: BEFORE REMOVING SERVICE ACCESS COVERS, ENSURE THAT ALL ELECTRICAL POWER HAS BEEN DISCONNECTED. INNER PANEL (4 SCREWS) BURNER ACCESS SEE FIG. 14 1. Open up the bottom burner access door. Remove door and put in a safe place. 2.

  • Page 34: Burner Removal

    Burner Removal BURNER REMOVAL IMPORTANT: DURING BURNER REMOVAL CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBRE INSULATION INSIDE THE COMBUSTION CHAMBER. SEE FIG. 15 TERMINAL STRIP 1. Place a sheet on the floor in front of the cooker to act as a working area.

  • Page 35: Burner Chamber

    Burner Chamber/Servicing BURNER CHAMBER IMPORTANT DURING CLEANING CARE MUST BE TAKEN NOT TO DAMAGE THE CERAMIC FIBER INSULATION INSIDE THE COMBUSTION CHAMBER. SEE FIG. 18 1. Lift insulation covers and remove hotplate using lifting hooks provided. 2. Clean the flueway by inserting the flexible brush through top plate aperture, directing it towards the flue outlet, Scrape the deposits towards the burner chamber.

  • Page 36: Burner Head Cleaning

    Burner Servicing BURNER HEAD CLEANING 1. Check the burner head for any signs of damage or degrading. 2. Examine the condition of the electrodes and that they are not damaged or loose. Do they need cleaning? (See Fig. 20). 3. Inspect all gaskets. If necessary, replace them, but BURNER always with the correct type.

  • Page 37: Terminal Strip Connections

    Electrical Controls CONTROL CIRCUIT-EXTERNAL TERMINAL STRIP CONNECTIONS...

  • Page 38: Overheat Safety Thermostat

    Electrical Controls OVERHEAT SAFETY THERMOSTAT This thermostat is a safety cut-out device which operates if the control thermostat fails. This device automatically resets. See Fig. 28. FLUE SAFETY THERMOSTAT 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.

  • Page 39: Combustion Air

    Burner COMBUSTION AIR IMPORTANT: ENSURE THAT THE LOUVERED BASE PLATE IS IN POSITION DURING COMBUSTION TESTING AND SETTING PROCEDURES. ENSURE THE OUTER DOOR IS CLOSED. TURN THE BURNER ON After 15 minutes, lift up the R.H. insulating cover and remove the countersunk screw and insert the sensing end of a portable indicator to check the CO (Carbon Dioxide) level.

  • Page 40: Test Burner On Dry Run (No Gas)

    Burner TEST BURNER ON DRY RUN (NO GAS) SEE FIG. 22 Switch on the electricity supply. Set the time clock as stated in the Users Instructions. Turn the thermostat to max. allowing the burner to start. The burner should go to lockout Reset.

  • Page 41: Electrodes

    Replacement of parts (Burner) The only parts to be replaced are:- Electrodes Electrode Leads Control Box If any other parts fails then the whole burner is to be replaced. ELECTRODES See Fig. 23 1. Turn off power to appliance. 2. Unscrew the fixing screw and withdraw the electrodes.

  • Page 42: Electrical Component Access

    Replacement of parts (Electrical Controls) ELECTRICAL COMPONENT ACCESS BEFORE REMOVING SERVICE ACCESS COVERS ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN TURNED OFF. SEE FIG. 25 1. Remove the controls door and place in a safe position. 2. Remove thermostat control knob. 3.

  • Page 43: To Fit New Flue Safety Device

    Replacement of parts (Electrical Controls) THERMOSTAT OVERHEAT THERMOSTAT COOKER FIG. 28 DESN 511444 TIMER TO FIT NEW FLUE SAFETY DEVICE ENSURE THAT ALL ELECTRICAL SUPPLIES TO THE APPLIANCE HAVE BEEN TURNED OFF. SEE FIG. 28 Follow instructions in section BURNER ACCESS Steps 1 to 3.

  • Page 44: To Fit New Cooker Safety Overheat Thermostat

    Replacement of parts (Electrical Controls) TO FIT NEW COOKER SAFETY OVERHEAT OVERHEAT THERMOSTAT & OVEN CONTROL THERMOSTAT THERMOSTAT SEE FIG. 30 Follow instructions section ELECTRICAL COMPONENT ACCESS , Steps 1 to 6. 1. Undo the two screws on the front of the chassis which holds the thermostat in place.

  • Page 45: Wiring Diagram - Burner Only

    Fault Finding WIRING DIAGRAM - BURNER ONLY FIG. 31...

  • Page 46: Wiring Diagram -Appliance

    Fault Finding WIRING DIAGRAM -APPLIANCE CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. FIG. 32...

  • Page 47: Burner Does Not Start

    Trouble Shooting BURNER DOES NOT START Burner Check that the burner has not gone to lockout. Causes of lockout can be: No ignition. Electrode incorrectly positioned or insulation cracked, control box faulty. No gas supply. Poor combustion. Flame probe in contact with ground, moisture present on probe affecting insulation.

  • Page 48: Troubleshooting - Burner

    Trouble Shooting TROUBLESHOOTING - BURNER BURNER WILL NOT START 1 Check that the external wiring is correct. 2. Check the 230v supply on terminal 10 and 11 at control box base, this will also determine if the thermostats are calling for heat. (See Fig. 33). 3.
  • Page 49 Trouble Shooting...

  • Page 50: Servicing Or Fault

    Servicing or Fault BURNER RESET If a fault occurs on the burner, then it automatically shuts down and the red button on the front base plate will be illuminated. This can be reset, after 10 seconds by depressing the reset button. The reset button is located in the lower base panel.
  • Page 52 For further advice or information contact your local AGA distributor With AGA’s policy of continuous product improvement, the company reserves the right to change specifications and make modifications to the appliance described at any time. 1050 Fountain Street North Cambridge...

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