Bubble Mk 2 PJ. CONVERSION Rayburn MF 19-12-05 Service manual

1
Mk 2 PJ. CONVERSION ©
Rayburn MF 19-12-05
INSTALLATION INFORMATION ©
http://www.oilstoves.co.uk/

2
C ntents
1-8. See Separate Document. ____________________________________ 4
11. Fitting The it._____________________________________________ 4
1. Rem ving The Firebricks. ______________________________________ 4
1a. Rem ve The Thick Fr nt Firebrick Beneath The Fuel-L ading D r. ______ 5
2. Rem ve The Oven Side Bricks. __________________________________ 5
3. Rem ve The Opp site Oven Firebricks. ____________________________ 5
4. Rem ve Fuel L ading D r Inner Cast Ir n Pr tective Plate. ____________ 6
5. Rem ve The Ash pan. _________________________________________ 6
6. Rem ve the grate carrier. _____________________________________ 6
7 Rem ve The Riddling Grate Bars. _________________________________ 6
8. Rem ve The Riddling Grate Supp rt Frame._________________________ 7
9. Rem ve The Sec ndary Air Chamber Casting. _______________________ 7
10. Rem ve the sec ndary air chamber fasteners. ______________________ 7
11. Check The H t Plate Seal. _____________________________________ 8
12.Rem ve The Flue B x Damper Plate. ______________________________ 8
13. L ck The Air Valve Open. _____________________________________ 8
12. Fitting The Boards And Burner Components._______________________ 8
4. Start Fitting The First B ards. _________________________________ 9
5. Fit The Cl sure Plate._________________________________________ 9
6. Fit Opp site Oven Over Cl sure Plate B ard._______________________ 10
7. Fit Primary Cl sure Plate B ard And Primary Fr nt B ard. _____________ 10
8. Fit Sec ndary Fr nt B ard. ___________________________________ 10
10. Fit The Fuel L ading D r Access C ver Plate. _____________________ 10
11. Fit Burner Base Plate. _______________________________________ 11
12. Fit C mbusti n Head. _______________________________________ 11
13. Fit The Air H se T The C mbusti n Head. _______________________ 11
14. Fit The Fuel Pump. _________________________________________ 12
15. Tighten The Fuel H se. ______________________________________ 12
16. Fit The C ntr l M dule. _____________________________________ 12
12b. Services Into The Burner. __________________________________ 13
1. Oil Feed. _________________________________________________ 13
2. Oil Is lati n Valve.__________________________________________ 14
3. Oil Pipew rk T Pressure Jet Burners. ___________________________ 14
4. P wer In._________________________________________________ 14
5. Fit the baffle kit. __________________________________________ 14
6. Fit ver ven baffle _________________________________________ 14
13. Commissioning._____________________________________________ 15

3
1. Setting the Burner Up. _______________________________________ 15
2. Heat Balancing the System. ___________________________________ 15
3. Lighting. _________________________________________________ 15
3.1. T Bleed The Pump. ________________________________________ 15
3.2. Set The C ntr l Stat. ______________________________________ 15
3.3. Set The Time Cl ck. _______________________________________ 15
3.4. Check The Burner Air Shutter. _______________________________ 16
3.6. Ignite The Burner. ________________________________________ 16
3.7. Fit The Baffle B x. ________________________________________ 16
3.9. T Set F r G d C mbusti n._________________________________ 16
3.10. C mbusti n Air. __________________________________________ 16
3.11. T Adjust The Pump Pressure. _______________________________ 17
4. Final Checks. ______________________________________________ 17
4.1. Fuel Tank. _______________________________________________ 17
4.2. Fuel. ___________________________________________________ 17
4.3. Filter.__________________________________________________ 17
4.4. Site Glass r Tank Gauge. ___________________________________ 17
4.5. Oil line._________________________________________________ 17
4.6. Fire valves. ______________________________________________ 17
4.7. Thr ugh Wall Sleeving. _____________________________________ 17
4.8. Is lati n valve. ___________________________________________ 17
4.9. Electrical. _______________________________________________ 17
4.10. Ventilati n. _____________________________________________ 17
4.11. Chimney System. _________________________________________ 18
4.12. Check c ntr ls Functi n. ___________________________________ 18
4.14. Vent the Ashpan D r. _____________________________________ 18
14. Warranty . _______________________________________________ 18
1. Items N t C vered Under the Warranty __________________________ 19
2. Lab ur. __________________________________________________ 19
3. Travelling time. ____________________________________________ 19
4. C nsequential l ss r damage. __________________________________ 19
5. N zzles. _________________________________________________ 19
6. Baffle kits and Insulati n B ards._______________________________ 19
7. Damage t the Fuel Pump._____________________________________ 19
15. Fault Finding. _____________________________________________ 19
16. Servicing. ________________________________________________ 19
18. Illustrations ______________________________________________ 19
1. Secti nal Details ___________________________________________ 20
2. B ard Details______________________________________________ 20

4
3. Ventilate Ashpit D r _______________________________________ 21
4. Opti nal Oven Stat Details____________________________________ 22
5. Oven stat sensing p siti n. ____________________________________ 23
6. Wiring and c ntr l lay ut _____________________________________ 23
7. Wiring Diagrams (All stat details)_______________________________ 24
8. Chimney terminal details. _____________________________________ 25
19. Parts and packing list _______________________________________ 26
1
1- -8 8. . S S
E
EE E
S
S
E
EP PA AR RA AT TE E
D
D
O
OC CU UM ME EN NT T
.
.
T ls Required
1. 60mm h le saw
2. High temp silic ne adhesive
3. M10 nut driver r suitable s cket
1
11 1. . F F
I
IT TT TI IN NG G
T
T
H
HE E
I
IT T
.
.
Bef re starting any w rk, check ff
the c ntents f the packing list with
the kit c ntents and make sure that
everything is c mplete.
Clean chimney, check and adjust the
chimney vacuum (0.02" - 0.06" w.g.)
and pr vide a cleaning access (min
diameter 5" f r linings.)
If applicable, check ut the existing
h t water system.
Install fuel tank and run a fuel line up
t the fireb x side f the appliance.
If necessary, m dify the electrical
supply.
Fit suitable ventilati n int the
appliance site.
Rem ve the h t plate
1
1. . R R
E
EM MO OV VI IN NG G
T
T
H
HE E
F
F
I
IR RE EB BR RI IC C S S
.
.
Fig 1 Sh ws the internals f a typical,
left hand ven MF, the pp site ven
fire bricks are still in situ and the
ven side casting is badly damaged.
This appliance is typical f the degree
f damage which can be inflicted by
inc rrect use and lack f adequate
maintenance.
This appliance was used f r
ph t graphic purp ses nly and was
n t in a g d en ugh c nditi n t be
rec mmissi ned.
Fig 1

5
1
1
A
A
.
. R R
E
EM MO OV VE E
T
T
H
HE E
T
T
H
HI IC C
F
F
R
RO ON NT T
F
F
I
IR RE EB BR RI IC C
B
B
E
EN NE EA AT TH H
T
T
H
HE E
F
F
U
UE EL L
-
-L L
O
OA AD DI IN NG G
D
D
O
OO OR R
.
.
(This is a time c nsuming j b, d n't
rush and take care n t t apply t
much pressure as the fr nt casting f
the appliance is nly thin and can be
easily br ken.)
2
2. . R R
E
EM MO OV VE E
T
T
H
HE E
O
O
V
VE EN N
S
S
I
ID DE E
B
B
R
RI IC C S S
.
.
Damaged pp site ven firebrick
Fig 2
3
3. . R R
E
EM MO OV VE E
T
T
H
HE E
O
O
P
PP PO OS SI IT TE E
O
O
V
VE EN N
F
F
I
IR RE EB BR RI IC C S S
.
.
These firebricks sh uld be fitted f r
summer time c king nly and
rem ved in wintertime t all w m re
heat fr m the fire t the water
heating.
Many users are unaware f this and
leave the firebricks permanently in
situ.
Scale build up behind them and makes
the rem val very time c nsuming and
difficult, if y u enc unter this
situati n, take great care n t t
damage the b iler during the rem val
pr cess.
Typical Damaged and scaled up,
pp site ven firebrick.
Fig 3
Damaged ven side casting
Fig 4

6
4
4. . R R
E
EM MO OV VE E
F
F
U
UE EL L
L
L
O
OA AD DI IN NG G
D
D
O
OO OR R
I
I
N
NN NE ER R
C
C
A
AS ST T
I
I
R
RO ON N
P
P
R
RO OT TE EC CT TI IV VE E
P
P
L
LA AT TE E
.
.
Fig 5
Rem ve the fuel-l ading d r and
rem ve the cast ir n pr tecti n plate
attached t it.
(N te it may be necessary t drill the
head ff the ld fastener and use
stills ns n the stub t rem ve it.)
Clean the d r inner surface and paint
it with heat resistant matt black
paint.
5
5. . R R
E
EM MO OV VE E
T
T
H
HE E
A
A
S
SH H P PA AN N
.
.
6
6. . R R
E
EM MO OV VE E T TH HE E G GR RA AT TE E C CA AR RR RI IE ER R
.
.
View thr ugh ash pit d r sh wing
damaged grate assembly in p siti n
Fig 6
7
7 R R
E
EM MO OV VE E
T
T
H
HE E
R
R
I
ID DD DL LI IN NG G
G
G
R
RA AT TE E
B
B
A
AR RS S
.
.
Fig 7.

7
Fig 8. Rem ve the grate bars by
lifting them up fr m the back supp rt.
8
8. . R R
E
EM MO OV VE E
T
T
H
HE E
R
R
I
ID DD DL LI IN NG G
G
G
R
RA AT TE E
S
S
U
UP PP PO OR RT T
F
F
R
RA AM ME E
.
.
Fig 9.
9
9. . R R
E
EM MO OV VE E
T
T
H
HE E
S
S
E
EC CO ON ND DA AR RY Y
A
A
I
IR R
C
C
H
HA AM MB BE ER R
C
C
A
AS ST TI IN NG G
.
.
Fig 10.
View thr ash pit d r sh wing
sec ndary air casting attached t
fr nt plate.
1
10 0. . R R
E
EM MO OV VE E T TH HE E S SE EC CO ON ND DA AR RY Y A AI IR R
C
CH HA AM MB BE ER R F FA AS ST TE EN NE ER RS S
.
.
There are tw fasteners, ne at the
ven side and ne at the pp site ven
side.
If it is n t p ssible t unscrew them,
it may be necessary t grind the
heads ff.
Fig 11.

8
Fig 12. Sec ndary air chamber casting
rem ved.
Vac The Debris Out.
Th r ughly vacuum ut all the dust
and debris fr m the appliance and the
ash pan area.
Fig 13. Rem ve the ash pit base plate
casting.
1
11 1. . C C
H
HE EC C
T
T
H
HE E
H
H
O
OT T
P
P
L
LA AT TE E
S
S
E
EA AL L
.
.
Make sure that the ceramic r pe seal,
n t which the h tplate sits, is in
g d c nditi n and n t ver
c mpressed, if it is n t f rming a
g d airtight seal with the cl sure
plate, renew it.
1
12 2. .R R
E
EM MO OV VE E
T
T
H
HE E
F
F
L
LU UE E
B
B
O
OX X
D
D
A
AM MP PE ER R
P
P
L
LA AT TE E
.
.
Rem ve the sliding damper in the flue
b x and seal the pening left by the
sliding damper with fire cement.
Check that there are n p tential f r
air leaks in r ar und the flue b x.
Check the rear utlet c ver plate, as
these are pr ne t leaking.
1
13 3. . L L
O
OC C
T
T
H
HE E
A
A
I
IR R
V
V
A
AL LV VE E
O
O
P
PE EN N
.
.
It is essential that as much c ling
and c mbusti n air as p ssible be
all wed t circulate ar und the
burner.
A permanent free air supply must be
established, as the burner cann t
functi n c rrectly with ut it.
T achieve this it is necessary t fully
pen the spin valve which is l cated in
the ash pan access d r and l ck it
permanently in this p siti n by use f
either a l ck nut, r a (suitably
p siti ned) drilled h le and split pin.
1
12 2. . F F
I
IT TT TI IN NG G
T
T
H
HE E
B
B
O
OA AR RD DS S
A
A
N
ND D
B
B
U
UR RN NE ER R
C
C
O
OM MP PO ON NE EN NT TS S
.
.
Bef re permanently fitting the
b ards, try a dummy run, t make sure
everything fits bef re final
permanent fitting and fire cementing.
It will be necessary t trim the ashpit
side lining b ards, the fr nt b ards
and the pp site ven under and ver
cl sure plate b ards t fit.
(The b ards can be cut and shaped
with w d w rking equipment.)
Start fitting the b ards as per Fig 4

9
1. Ash pit Base Oven Side Lining
B ards x 2.
2. Opp site ven cl sure plate supp rt
b ard.
3. The ven side b ard.
These b ards will have t be cut
trimmed t fit flush up t the side f
the ashpit castings and will f rm the
ven side supp rt t the cl sure plate.
4
4. . S S
T
TA AR RT T
F
F
I
IT TT TI IN NG G
T
T
H
HE E
F
F
I
IR RS ST T
B
B
O
OA AR RD DS S
.
.
Fig 4
Use silic ne t attach the b ards t
the side castings.
The b ards as sh wn in Fig 4 are held
in place by the angle brackets n the
underside f the cl sure plate.
5
5. . F F
I
IT T
T
T
H
HE E
C
C
L
LO OS SU UR RE E
P
P
L
LA AT TE E
.
.
The cl sure plate is fitted with the
angles d wn.
Fig 6
The cl sure plate has retaining angles
attached t the underside; these are
used t h ld the side supp rt b ards
in situ.
View fr m ab ve sh wing cl sure plate
fitted.
Fig 7

10
6
6. . F F
I
IT T
O
O
P
PP PO OS SI IT TE E
O
O
V
VE EN N
O
O
V
VE ER R
C
C
L
LO OS SU UR RE E
P
P
L
LA AT TE E
B
B
O
OA AR RD D
.
.
Fig 8
Fig 8a
7
7. . F F
I
IT T
P
P
R
RI IM MA AR RY Y
C
C
L
LO OS SU UR RE E
P
P
L
LA AT TE E
B
B
O
OA AR RD D
A
A
N
ND D
P
P
R
RI IM MA AR RY Y
F
F
R
RO ON NT T
B
B
O
OA AR RD D
.
.
Fig 8b
8
8. . F F
I
IT T
S
S
E
EC CO ON ND DA AR RY Y
F
F
R
RO ON NT T
B
B
O
OA AR RD D
.
.
Fig 8c
Sec ndary fr nt b ard in place.
9. When the sec ndary fr nt b ard is
fitted, fix it t the fr nt b ard by
the use f 4 x 35mm w d screws.
Screw thr ugh fr m the fr nt b ard
int the sec ndary b ard.
1
10 0. . F F
I
IT T
T
T
H
HE E
F
F
U
UE EL L
L
L
O
OA AD DI IN NG G
D
D
O
OO OR R
A
A
C
CC CE ES SS S
C
C
O
OV VE ER R
P
P
L
LA AT TE E
.
.
and use it as a template t mark the
centre f the viewing p rt.
Fig 14
Rem ve the plate and drill thr ugh
with a 60mm diameter h le saw.
Using the viewing glass as a template,
mark a further c ncentric circle
ar und the 60mm h le.