AGA RANGEMASTER eR7 Quick start guide

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Aga eR7 Field Service Manual USA and Canada
The information detailed in this guide applies to the Aga eR7 electric cooker, at all times the service
technician MUST apply their competencies and ensure the appliance is left safe for continued use,
should the appliance fail any test then engineering judgement must be applied as to whether the
appliance can be left operational.

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Contents
Product overview....................................................................................................................................3
Cooking zones ......................................................................................................................................... 4
The capacitance touch control panel......................................................................................................5
General information and power sharing ................................................................................................6
Power sharing around the cooking zones...............................................................................................6
Power supply connections ......................................................................................................................7
Essential tools .........................................................................................................................................8
Torque screwdriver settings ...................................................................................................................8
Fault diagnostics overview...................................................................................................................... 9
Connecting the TEK Vision software..................................................................................................... 10
Fault diagnostics ...................................................................................................................................11
TEK Vision opening screen with laptop connected...............................................................................12
TEK Vision diagnostics screen with no errors present..........................................................................13
TEK Vision diagnostics screen with errors present...............................................................................14
Explanation of error codes and advice what action to take .................................................................16
To reset the PCB after a fault condition................................................................................................18
TEK Vision software ..............................................................................................................................18
The logging screen tab ..........................................................................................................................19
The Firmware screen tab ......................................................................................................................19
The graph screen tab ............................................................................................................................20
Engineer’s diagnostic handset - (AE4M280323) ...................................................................................21
Using the engineers hand set: ..........................................................................................................21
Removal and replacement of major components ............................................................................22
Main PCB:..........................................................................................................................................22
Boiling plate and Simmer plate:........................................................................................................23
Customers Touch Control: ................................................................................................................24
Front Plate:........................................................................................................................................24
Oven doors:.......................................................................................................................................25
Touch control unit and thermocouples: ...........................................................................................26
Oven elements:.................................................................................................................................27
AGA Hotcupboard eR7 150 ...................................................................................................................28
Essential Parts List................................................................................................................................. 28
Wiring schematic. (North America) ......................................................................................................29
AGA Hotcupboard .............................................................................................................................30
AGA INSULATING LID HINGE ASSEMBLY (Introduced 2005).................................................................34

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Product overview
The Aga Er7 is an all-electric cooker that replaces the Aga Total Control it offers new enhanced
features with everyday radiant heat and has independently controlled hotplates and ovens, features
include:
•Capacitance touch-screen control panel with LED lighting.
•Electronic temperature control of the cooking zones to give accurate temperature control.
•LED heat indicators for a clear indication of when the cooker is heating up and has reached
the required temperature.
•The Boiling plate 330°C (626°F) and the Simmer plate 200°C (392°F) are pre- programmed to
get to their respective temperatures.
•The Roast Oven has five temperature settings R9, R8, R7, R6 and B4.
•The Baking Oven has four temperature settings B1, B2, B3 and B4.
•The Simmer Oven has one pre-set temperature.

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Cooking zones
Below is a picture showing the different cooking zones on the Aga eR7 100. All ovens and both
hotplates are independently controllable using the control panel located behind the top left hand
control door.
Aga eR7 150
The Aga er7 150 has a hotcupboard attached to the parent Aga, the hotcupboard does not use the
electronic controls that the eR7 utilises and is supplied either with a warming plate or a single zone
induction hob on the top.

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The capacitance touch control panel
Like the classic Aga cooker design the Aga eR7 has a Boiling plate and a Simmer plate. Each hotplate
is individually temperature controlled and pre –programmed within the main PCB
Each of the three ovens have their own pre-set temperature settings. When using the roasting and
baking ovens, different temperatures can be selected to suit the customer’s needs.
The customers control panel is located behind the top left hand door, we recommend engineers
familiarise themselves with the users instructions on the operational modes of the cooker so they
understand how the cooker works.

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General information and power sharing
The Aga eR7 does not need to be regularly serviced.
DO NOT ALTER or MODIFY the appliance.
The appliance warranty does not cover commercial use.
Please refer to the Aga eR7 cooker installation instructions for specific information regarding
appliance dimensions, clearances, electrical requirements and oven venting etc.
Installation instructions and videos are available to view at www.agaliving.com/
*Important Note*
BEFORE CARRYING OUT WORK ON THE APPLIANCE, THE POWER SUPPLY MUST
BE ISOLATED AND TESTED FOR SAFE ELECTRICAL ISOLATION.
The main cooker assembly is electrically tested before leaving the factory.
The cooker is controlled by a PCB which is located in the base of the cooker.
Always inspect the cooker before any work is carried and notify the customer of any existing
damage.
The customer’s capacitance touch user panel is connected to the main PCB by a communication
cable which is routed within the cooker.
The cooker has 5 cooking zones: Boiling plate, Simmer plate, Roast oven, Baking oven and Simmer
oven.
The boiling and simmer plate use the same 2.5kw circular element and the ovens have the same
rectangular 2.5kw element, the roasting and baking oven have 2 elements one in the top and one in
the base whereas the simmer oven has only one element in the base.
All element resistances will be approximately 18-22 ohms.
Power sharing around the cooking zones.
The PCB within the eR7 is programmed to share the power supply around the different cooking
zones. This means that despite the zones totalling around 17.5kW, which would have an approx.
current draw of 76amps only a 30amp supply is required. This is achieved by the programme only
allowing three elements to be active at any time.
The programme works in a priority order meaning that if all zones are turned on together the boiling
and simmering plates will always achieve 100% power initially, with the roasting oven’s two
elements alternating on / off to achieve the desired temperature. This means that at any one time
there are only three elements on at the same time.
Once a zone reaches temperature the power is then shared to another zone with a lower set
temperature. This varies automatically depending on the chosen settings.

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Power supply connections
The range must be supplied with a 240V 60Hz power supply and connected to an individual, properly
grounded branch circuit protected by a circuit breaker, at 240V it has a maximum load of 30 amps.
The electric connection must be done by a licensed electrician.
The Aga Er7 cooker leaves the factory set up for connection to a power supply, the power cable and
standard four (4) prong type 14-50p plug are pre connected at the factory.
The picture below shows the power cable (not connected) and the main PCB pulled out of its
position within the cooker showing the electrical connections

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Essential tools
Before carrying out work on the appliance, the power supply MUST be
isolated and tested for safe electrical isolation.
Always protect the cooker and work area before carrying out any work on the appliance, and always
inspect the cooker for any existing damage before starting work.
When undertaking maintenance work on this appliance, the engineer should ensure the following
tools are available
•Multi meter
•Clamp meter
•Insulation resistance tester
•Tool kit
•Torque driver with screwdriver bits
•Laptop with the TEK Vision software installed.
•TEK Vision connection key - (AE4M280824)
•Torque setting chart
•Hob support bars - (AE4M280399)
The electrical connections on the Aga Er7 must be tightened by the use of a torque screwdriver,
please see the table on the next page for the relevant settings.
Torque screwdriver settings
Torque Setting NM Product AREA
2 Er7 Oven element sub assembly
0.8 (80 cNm) Initial connection.
0.6 (60 cNm) Retighten. Er7 14 way terminal block connection on both PCB and
element sides
2 Er7 Mains supply cable to trident ( NUT)
2 Er7 Trident onto mains terminal block
0.6 (60 cNm) Er7 Vent fan terminal block
0.65 ( 65cNm ) Er7 Cable clamps
1.0 + 0.2 / - 0.0 Er7 Hotplate
0.8 Er7 150 Terminal Connections

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Fault diagnostics overview
The Aga Er7 control system is capable of detecting a range of conditions that have been pre-
determined as fault conditions .Error codes are generated when an error condition is detected, the
code signifies the type of error and the zone(s) affected, the codes are stored in the main PCB and
can be reviewed at any time after the error has occurred. The codes are stored in two locations, a
permanent fault count accessed via the PC interface and a temporary fault log which can be
accessed via the PC interface or via the digital display on the main PCB. The PC interface requires the
Field engineers test software referred to as TEK Vision and a TEK Vision Interface Key.
The temporary fault log is cleared each time the PCB is manually reset via the reset button on the
main PCB, The permanent fault count cannot be cleared. Ensure temporary error codes are
accounted for before resetting the PCB.
Errors are grouped into two categories Blocking and locking errors, both Locking and blocking errors
will disable the output to a zone showing an error condition.
The five heat zones are, Hotspot (Boiling plate), Simmer plate, Roast oven, Bake oven and Simmer
oven.
Blocking Errors: Certain error codes when recognised within the control system will block, a
reassessment of the fault condition will be conducted periodically, and if the error is still present
after the fourth assessment the controls will lock and permanently disable that zone and will require
a repair and a manual reset to clear the error status. If a blocking error occurs four times in a 24hr
period it will lock and disable the zone.
Locking Errors: Some error conditions will go straight to locked on the first detection of the error
condition. These error codes also cannot be cleared without external intervention.
To clear the error condition the reset button has to be used, cycling the power will not reset the
controls and does not clear the locked condition.
Error codes can be further sub divided into types and these are listed below:
Zone overheat errors, Thermocouple differential errors, Thermocouple open circuit errors, Triac
errors, Relay errors, Open channel errors, Full power time out errors, User panel overheat errors.
The full fault code list can be read further on in this document.

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Connecting the TEK Vision software
The below picture shows how the laptop is connected to the Tek PCB , the USB end fits into the
laptop and the other end is connected to the GSM port on the PCB, this connector has a spring type
clip on the end which will need to be pushed to release and remove.

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Fault diagnostics
The eR7 AGA’s electronic system has a built in diagnostic programme which will advise if an issue has
been detected. Most faults will be shown either by the zone display lights rapid flashing or an error
code either being displayed on the cookers display screen /customers handset screen.
When a customer reports a new issue, the error code must be obtained before any action is taken.
This will assist with a first time resolution wherever possible.
The customers handset error codes give an initial indication of the issue being experienced and can
be used to assist with a first time resolution. They should be requested at the time the fault is
reported by the customer
If the customer’s user panel display shows an error code it will be one of the three below:
•Error code FE: Touch panel microcontroller unresponsive or malfunctioned. A reboot may
resolve the issue, if the fault is still visible after the reboot, the panel will need to be
investigated and possibly replaced.
•Error code VE: Main controller firmware version incompatible. PCB with 6.1 or higher softer
is required, change the PCB.
•Error code CE: No response from main controller. Check the connection and condition of the
COMS cable and the sockets on the PCB and facia.
Should the customer report an error code on their eR7 AGA and you are required to visit site to
investigate, then the Tek vision software must be connected using the connection key and your
laptop. This software will give you full visibility of any faults which have occurred previously and also
which are currently present, aiding the correct fault diagnosis.

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TEK Vision opening screen with laptop connected
When using the Tek Vision software ensure the cooker power on /off button is on.
Below is a step by step guide to navigating the tek vision software. With the cookers PCB connected
to your laptop using the appropriate connection key, double click the Tek Vision icon, Tek Vision will
open and the below will be shown on your laptop screen , the default screen is the set up screen.
To start using the diagnostics first click the ‘serial port’ option and select ‘open port’ as shown
below.
This will then open the set up screen which shows the correct pre-set temperatures for each cooking
zone. This is shown in the picture below. This will be the set up tab on the screen

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TEK Vision diagnostics screen with no errors present
Below is the temperature tab which shows the cooker working in real time and you will see that
each zone shows the current temperatures recorded by the internal thermocouples and also in red it
shows if any errors are currently present. Below is a picture showing the screen with no errors
present and all zones are turned off.
To view the full error log, press the 'view/save error count log' button on the bottom right corner of
the screen. This will then open a pop up window which will show all the error codes along with the
time and date and the number of times the fault has occurred . This box will clear when the PCB is
reset.

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TEK Vision diagnostics screen with errors present
Below is an example of the screen with a fault showing in red. This is showing a 130 error code on
the hotspot.
By pressing the 'view/save error count log' button this time, you can now see the number of times
the 130 error code has occurred (4 times) along with any other previous errors.This box is the error
code history of the PCB and will not change when the PCB is reset.
You will see above the fault count pop up box gives you the option to save the fault count to file.
This must be saved and kept safe on every occasion a fault is found. This may be required as any
fault diagnostic discussion with AGA.

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To save the file, click the yes button and follow the instructions to save the file directly onto your
laptop as shown below.
Once the fault is cleared and with all zones on you should be able to see the below sceen on the
laptop showing that all zones are turned on and the cooker is heating up normally and power
sharing, it also gives information on,thermocouple temperatures,power being used and the user
panel temperature.

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Explanation of error codes and advice what action to take
Error Code
Zone Affected
Description
Action
002 All Com WD Fault
Reset and log, if recurring then PCB may be
required
003 All Com WD Fault
Check communication cable connections and
continuity of cable, reconnect, reset and test
004
N/A
N/A
Not used
005
N/A
N/A
Not used
006 All WD WDT Fault
Reset and log, If recurring then PCB may be
required.
007 All TC Ref Fault
Reset and log. If recurring then TCU may be
required
010-014 All
Full power time
out
Customer education, check position of
thermocouple.
020 - 024 All
T/Couple
Differential Exchange Thermocouple
060 – 100 All
T/Couple open
circuit Exchange Thermocouple
110 – 116 All Relay Short circuit
Reset and log. If recurring then PCB may be
required
120 – 124 All
Cooking Zone
Overheat Error Thermocouple cross connected on user control
130 – 136 All Triac Fault
Check connections of element, check resistance
of element (18-20Ω) If element open circuit
replace element. If element resistance correct
and software correct version then replace main
PCB.
139 All
User Panel
Overheat
Excessive temperatures recorded, check door
seals, doors left open lack of insulation etc.
140 All
Configuration Key
Fault
No Key fitted, wrong key in relation to phase of
electrical supply.
150 – 156 All Relay Open circuit
Reset and Log. If recurring then PCB may be
required
159 Handset RF Fault
Fault with receiver not communicating with
PCB

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*Important Note*
Please refer to the notes below to assist you with your diagnosis of any error codes recorded.
007:Error 7 will occur if the user panel PCB is unable to process thermocouple measurements
requiring the user panel to be replaced.
010 - 014: Full power time out - A full power time out is a safety feature implemented to show the
cooking zone is taking too long to reach it’s expected temperature.
Full power time out errors may be caused by the way the cooker is being operated. The following
can be causes, however this list is not exhaustive:
•Heat up time not allowed before use
•Doors left open
•Oversized pans
•Overly full pans
•Cold plain shelf left in the simmer oven while heating up
020 – 024: T/Couple differential - Use engineers handset / laptop software to monitor temperature
of thermocouples.
060 – 100: T/Couple open circuit - Check the thermocouple with a multimeter. Please remember
duplex thermocouples are used, so there are 4 wires on the plug, each thermocouple has a one
green and one white conductor , so test across the green and white conductor with the multimeter
probes. If open circuit exchange thermocouple. Check thermocouples are plugged fully in to user
control panel.
**Note**
Instances of Thermocouples returned for testing have shown they test ok at
room temp but drift apart or go open circuit at higher temperatures. Please
ensure you rule this out.
110 - 116: Relay short circuit - Reset PCB and Log. If recurring then PCB may be required.
120 - 124: Cooking Zone Overheat Error - Check thermocouples are not cross connected on back of
user control panel, visual Identification of where the thermocouples plug into are behind user
control panel.
130 - 136: Triac Fault - Check connections of element circuit showing a triac error at element
terminals, check resistance of element (18 – 20 Ω) if the element is open Circuit, replace the
element. If the element resistance is correct and software version is correct then replace main PCB.
User Panel Overheat - Excessive temperatures can be caused by baking oven door left open or not
fitting correctly , door seal defective ( leaking heat ).Plugs missing in thermocouple conduits. Towels
etc. being draped over the control panel door.
Configuration Key Fault - No configuration key fitted to board or wrong key in relation to the phase
of electrical supply the cooker is connected to. In addition, when controls are in standby it is
possible to see a display of the configuration key compared to the connected phase (s) supply. See
TB 30.01.14.
150 - 156: Relay Open Circuit - Reset and Log. If recurring then PCB may be required.

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To reset the PCB after a fault condition
Press and hold the reset button located on the front left hand side of the PCB.
Customers should not be instructed on how to reset the PCB.
The main PCB screen will first display “clearing locks” it’s important to keep pressing the reset
button until the screen displays “system reset.”
The screen will then display FW (Firmware) version followed by Stand- by.
The reset procedure is now complete, the controls will have gone into stand – by and all error codes
in the temporary fault log will be cleared, the permanent fault log will not be cleared by a reset.
Note: Occasionally the reset procedure may not clear an error on the first attempt so a second or
third attempt may be necessary.
TEK Vision software
There are 3other screens within the TEK Vision Software that are useful to a field technician. The
communication tab is not used by service technicians.

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The logging screen tab
The TEK Vision software has an in built data logger, which gives information on all temperatures
within the various zones, % of power the various channels are receiving and any fault codes that
appear, the log updates around every 5 seconds, as soon as the Tek vision software is opened the
system starts to log, if the system has to be reset the log will restart when this has been carried out.
The Firmware screen tab
The firmware screen tab gives information on what version of firmware the PCB’s are running, just
select the screen and press the refresh button and the values will appear.

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The graph screen tab
The graph screen tab gives temperature information for all of the cooking zones and the user panel
by using a graph, each zone has a different colour and time and temperature is recorded, individual
zones can be recorded on their own if required.