Rayburn 600K User guide

05/14A E NS 515877
PLEASE READ THESE I STRUCTIO S BEFORE SERVICI G THIS APPLIA CE
600K/700K
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.

Contents
SECTIO CO TE TS PAGE
CONSUMER PROTECT ON 3
HEALTH & SAFETY 3
NTRODUCT ON 4
SERV CE SCHEDULE 4
BUR ER REMOVAL PREPARAT ON 5
BURNER ACCESS 5
BURNER REMOVAL 6
CLEA I G OVEN & HOTPLATE FLUEWAY CLEAN NG 7
BUR ER SERVICI G NTRODUCT ON 8
BURNER NOZZLE REMOVAL 8
BURNER NOZZLE REPLACEMENT 8
PHOTO ELECTR C CELL (PEC) CLEAN NG 9
FAN CLEAN NG 9
RE-ASSEMBLE BURNER 9
OIL PUMP SERVICI G NTRODUCT ON 10
O L PUMP STRA NER CLEAN NG 10
O L L NE F LTER CLEAN NG 10
RE-COMMISSIO I G BLEED A R FROM O L SUPPLY 11
F T PRESSURE GAUGE 11
SW TCH ON ELECTR C TY 11
VENT O L PUMP 11
ADJUST O L PRESSURE 11
SET COMBUST ON A R AND CHECK SMOKE 12
REPLACEME T OF PARTS FAN MOTOR 13
(BUR ER) GN T ON ELECTRODES 13
GN TOR 14
SOLENO D CO L 14
CONTROL BOX 15
PEC 15
PUMP ACCESS 16
REPLACEME T OF PARTS ELECTR CAL COMPONENT ACCESS 17
(ELECTRICAL CO TROLS) RE-ASSEMBLE 17
CONTROL C RCU T - EXTERNAL 17
FAULT FI DI G RAYBURN 600 W R NG - SELF CONTA NED CONTROL 19
RAYBURN 600 W R NG - SATRON C BOXES 20
BURNER DOES NOT START 21
ERROR TABLE 22
NFORMAT ON SYSTEM - COOKER BURNER 23-24
(CONTROL BOX TYPE DKO 970)
NFORMAT ON SYSTEM - COOKER BURNER 25-26
(CONTROL BOX TYPE DKO 970N)
FAULT F ND NG - COOKER 27
H GH SMOKE NUMBERS/O L SMELLS 28
2

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.
IMPORTA T OTICE: PLEASE READ THE ACCOMPA YI G WARRA TY
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.
Health & Safety
This appliance may contain some of the materials that are indicated. t is the Users/ nstallers
responsibility to ensure that the necessary personal protective clothing is worn when handling
where applicable. The pertinent parts that contain any of the listed materials that could be
interpreted as being injurious to health and safety, see below for information.
Firebricks, Fuel Beds, Artificial Fuels
When handling use disposable gloves.
Fire cement
When handling use disposable gloves.
Glues and Sealants
Exercise caution - if these are still in liquid form use face mask and disposable gloves.
Glass Yarn, Mineral Wool, Insulation Pads, Ceramic Fibre
Maybe harmful if inhaled. May be irritating to skin, eyes, nose and throat. When handling avoid
contact with skin or eyes. Use disposable gloves, face-masks and eye protection. After handling
wash hands 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 more prone to damage caused by cuts and
abrasions.
3. ‘Oil acne’ is recognised by the presence of skin rashes. The arms are most often affected,
but may occur where there is contact with oil or oily clothing.
- Seek medical attention for any rash.
- Avoid skin contact with mineral oil or clothing containing mineral oil.
4. nhalation of mineral oil vapours must be avoided. Never fire the burner in the open air as
unburnt oil vapours are likely to occur.
5. Use a suitable barrier cream which will give protection against mineral oil, lanolin based hand
cream are usually very effective.
6. Never syphon mineral oil by mouth. f accidentally swallowed, call a doctor, do not induce
vomiting.
OTE: SMOKE/SMELL EMITTED DURI G I ITIAL USAGE
Some parts of the cooker have been coated with a light covering of protective oil. During initial
operation of the cooker, this may cause smoke/smell to be emitted and is normal and not a fault
with the appliance, it is therefore advisable to open doors and or windows to allow for ventilation.
Lift the lids to prevent staining the linings.
3

To ensure the best performance from your Rayburn. t
should be serviced once a year; preferably at the start of
the heating season.
This appliance must be commissioned by a competent
engineer, such as OFTEC approved.
Failure to install and maintain the appliance correctly
could lead to prosecution.
An additional flueway and combustion chamber clean
halfway through the heating season may be necessary in
some cases.
The Rayburn cannot be serviced whilst hot, so the oven
thermostat should be turned off on the evening before the
service visit.
Annual Service
During annual service flexible oil line, burner nozzles and
burner head seals MUST BE CHA GED.
WIRI G: Ensure there is no damage or loose
connections. This should be carried out by a competent
engineer.
BURNER REMOVAL - for cleaning and inspection.
CLEAN NG - Flueways, oven and hotplate flueways
together with ceramic fibre burner chambers.
BURNER SERV C NG
O L PUMP SERV C NG - Cleaning of fuel line strainer.
RE-COMM SS ON NG
REPLACEMENT PARTS
Oven Door Fit - Both doors must be checked and
adjusted if necessary to ensure the alignment with the
door catch is correct, the keep is secure and the oven is
sealed when the door is closed.
This appliance MUST be serviced at regular 12 monthly
intervals to optimise its safety, efficiency and
performance.
4
I TRODUCTIO SERVICE SCHEDULE

WAR I G: BEFORE REMOVI G SERVICE ACCESS
COVERS OR THE OIL BUR ER E SURE THAT ALL
ELECTRICAL SUPPLIES TO THE APPLIA CE HAVE
BEE 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.
SEE F G. 1
1. Open up the bottom burner access door. Remove door
and put in a safe place. (Rayburn 600K only).
2. Remove 4 inner panel securing screws and remove
panel.
3. Remove the 3 plinth securing screws and remove
plinth.
5
PREPARATIO
BUR ER ACCESS
Burner Removal
Fig. 1 DESN 516793

IMPORTA T: DURI G BUR ER REMOVAL CARE
MUST BE TAKE OT TO DAMAGE THE CERAMIC
FIBRE I SULATIO .
SEE F GS 2 & 3
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. Withdraw burner body complete with flexi-head.
6
BUR ER REMOVAL
Fig. 2
Fig. 3
DESN 515886
DESN 515887
Burner Removal

SEE F G. 4 & 4A
1. Remove the top oven door and place in a safe
position. (Rayburn 600K only).
2. Remove side and base access doors (complete with
gaskets) 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 hotplate ribs on
underside.
8. Examine soft rope seal located around hotplate
aperture in top plate and two rope seals on hotspot.
Replace if frayed or damaged.
9. Replace hotplate ensuring the underside ribs are on
the LH side and that it seals to the top plate.
7
Cleaning
OVE & HOTPLATE FLUEWAY
CLEA I G
Fig. 4 DESN 515764
Fig. 4A DESN 515783

S
SEE F G. 5
To remove blast tube, slacken two grub screws, pull
forward.
SEE F G. 6
1. Remove two socket head screws.
2. Remove head assembly complete.
3. Disconnect ignition leads.
4. Remove ignitor assembly, by removing countersunk
screw and clamp.
5. Unscrew nozzle from its holder with a correctly fitting
tubular spanner to avoid damage to hexagon.
SEE F G. 7
1. Replace nozzle with a new one of the same make and
specification, 0.35 @ 80°S.
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 is
sufficient.
DO OT OVERTIGHTE .
5. Ensure electrode gaps are correct.
8
I TRODUCTIO
Burner Servicing
Fig. 5 DESN 515765
COOKER BUR ER
Fig. 6 DESN 515766
BUR ER OZZLE REMOVAL
Fig. 7 DESN 510538
3mm
BUR ER OZZLE REPLACEME T

SEE F G. 8
Withdraw Photo Electric Cell from the burner head. Clean
PEC sensing end with a soft brush taking care not to
scratch the light sensitive body. Re-insert PEC taking care
to insert the correct way round.
Should the cell show signs of distortion or cracking,
replacement will be necessary. See PEC replacement,
Page 15.
SEE F G. 9
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.
Re-assemble the burner in reverse order.
OTE: Burner head gaskets should be renewed at each
service.
9
Burner Servicing
FA CLEA I G
PHOTO ELECTRIC CELL (PEC)
CLEA I G
RE-ASSEMBLE BUR ER
Fig. 8
Fig. 9
DESN 515767
DESN 515768
P.E.C

To carry out servicing on the oil pump. Turn off the oil line
isolating valve near to the appliance.
SEE F G. 10
1. A container must be put under the pump to catch any
oil when starting to clean the oil pump strainer.
2. Remove 4 socket head screws.
3. Remove filter
4. Wash with clean kerosene.
5. Re-assemble in 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.
OTE: Flexible hose (s) must be replaced at each
service, ie. annually.
10
I TRODUCTIO
OIL PUMP STRAI ER CLEA I G
Oil Pump Servicing
OIL LI E FILTER CLEA I G
Fig. 10 DESN 512002
COVER
STRA NER
FUEL NLET
SEAL

SEE F G. 15
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.
Remove the bleed screw from the manifold and fit an oil
pressure gauge with R1/8 connection to check the pump
output pressure.
Until all the air from the oil pump is flushed out there may
be some flame instability, resulting in the burner locking
out. This will be shown by the burner stopping and the
illumination of the signal light in the reset button of the
control box (See Fig. 12). I THIS EVE T, WAIT AT
LEAST O E MI UTE, then press the re-set button to
restart.
SEE F G. 11
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, retighten.
SEE F G. 12
With the burner running check the oil pressure on the
pressure gauge.
f the pressure gauge is not indicating the correct reading,
then adjust the pressure by turning the pressure regulator
clockwise to increase or anti-clockwise to decrease the
pressure until the pressure gauge reads 10 bar
(145 bf/ n2).
11
BLEED AIR FROM OIL SUPPLY
FIT PRESSURE GAUGE
SWITCH O ELECTRICITY
VE T OIL PUMP
ADJUST OIL PRESSURE
Re-commissioning
Fig. 11
Fig. 12
DESN 515888
DESN 515769
PRESSURE PORT
BLEED SCREW
O L PRESSURE
ADJUSTMENT
COOKER BURNER
RESET BUTTON

SEE F G. 13 & 13A
Switch on cooker burner.
After 15 minutes of the cooker burner running, lift up the
RH insulating cover and remove the countersunk headed
screw in the hotplate. nsert the sensing end of a portable
indicator to check the CO2(Carbon Dioxide) level. Adjust
the cooker burner air intake until a reading of 11.0/11.5%
is recorded on the indicator.
Using the same hole for flue sampling, insert the sensing
end of a Baccarach Smoke Pump and check that the
smoke in the cooker flueways does not exceed No. 2 on
the scale.
Replace the countersunk headed screw on completion
ensuring that it will not interfere with any pots and pans
placed on the hotplate.
12
SET COMBUSTIO AIR A D
CHECK SMOKE
Re-commissioning
Fig. 13A
Fig. 13
DESN 515889
DESN 512001
COOKER FLUE
SAMPL NG HOLE

SEE F G. 14
Follow instructions in sections BURNER ACCESS, Steps
1-3 and BURNER REMOVAL.
1. solate electric supply.
2. Remove 3-pin plug.
3. Remove solenoid plug.
4. Disconnect oil pipe.
5. Undo 2 screws and remove snorkel.
6. Remove 4 countersunk screws from fan case and split
the case.
7. Remove grub screw and withdraw fan.
8. Remove 4 countersunk screws and remove fan motor
from case.
9. Remove 3 socket head screws and withdrawn pump.
10.Re-assemble in reverse order.
OTE: Ensure that gaskets and seals are in place and in
good condition.
Follow instructions in BURNER ACCESS, Steps 1 to 3
and BURNER NOZZLE REMOVAL.
SEE F G. 15
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.
13
FA MOTOR
Fig. 14 DESN 515768
Fig. 15 DESN 515766
IG ITIO ELECTRODES
Replacement of parts (Burner)

SEE F G. 16
Follow instructions in sections BURNER ACCESS, Steps
1 to 3 and BURNER REMOVAL.
1. Remove both HT leads from ignitor.
2. Remove mains plug from ignitor.
3. Remove earth screw.
4. Remove 2 ignitor securing screws.
5. Remove ignitor.
6. Fit new ignitor, re-assemble in reverse order.
SEE F G. 17
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.
14
Replacement of parts (Burner)
Fig. 16 DESN 515770
Fig. 17 DESN 515771
SOLE OID COIL
IG ITOR
EARTH
SCREW

SEE F G. 18
Follow instructions in section BURNER ACCESS, Steps 1
to 3.
1. Undo centre fixing screw.
2. Gently pull control box away from base.
3. Fit new control box, re-assemble in reverse order.
SEE F G. 19
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.
15
Replacement of parts (Burner)
PEC
CO TROL BOX
Fig. 18
Fig. 19
DESN 515772
DESN 515767

SEE F G. 20
Follow instructions in section BURNER ACCESS, Steps 1
to 3 and BURNER REMOVAL.
1. solate fuel 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. 20 DESN 511995
16

BEFORE REMOVI G SERVICE ACCESS COVERS
E SURE THAT ALL ELECTRICAL ACCESS TO THE
APPLIA CE HAS BEE SWITCHED OFF (SWITCH
OFF A D REMOVE PLUG).
SEE F G. 21
1. Remove the controls door and place in a safe position,
(Rayburn 600K only).
2. Remove thermostat control knob.
3. Remove the 2 cover panel fixing screws.
4. Remove glass cover panel and place in a 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 knob.
5. Replace the controls door, (Rayburn 600K only).
SEE F G. 22
17
ELECTRICAL COMPO E T
ACCESS
Replacement of parts (Electrical controls)
Fig. 21 DESN 515890
RE-ASSEMBLE
CO TROL CIRCUIT-EXTER AL
Fig. 22 DESN 515893

18
Fig. 23 DESN 515891
Replacement of parts (Electrical controls)

19
Fault Finding
Fig. 24
Rayburn 600/700K Wiring Diagram
111MB self contained control

20
Fault Finding
Fig. 25
RAYBUR 600/700K COOKER O LY WIRI G DIAGRAM
111MB FOR I DIVIDUAL SATRO IC BOXES