Rayburn 660 User manual

05/14A E NS 515601
PLEASE READ THESE I STRUCTIO S BEFORE SERVICI G THIS APPLIA CE
660/680/699K
760/780/799K
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
BENCHMARK SCHEME 4
NTRODUCT ON 5
SERV CE SCHEDULE 5
BUR ER REMOVAL PREPARAT ON 6
BURNER ACCESS 6
BURNER REMOVAL 7
CLEA I G HEAT EXCHANGER CLEAN NG 8 - 9
OVEN AND HOTPLATE FLUEWAY CLEAN NG 8 - 9
BUR ER SERVICI G NTRODUCT ON 10
BURNER NOZZLE REMOVAL 11
BURNER NOZZLE REPLACEMENT 11
PHOTO ELECTR C CELL (PEC) CLEAN NG 12
FAN CLEAN NG 12
RE-ASSEMBLE BURNER 12
OIL PUMP SERVICI G NTRODUCT ON 13
O L PUMP STRA NER CLEAN NG 13
O L L NE F LTER CLEAN NG 13
RE-COMMISSIO I G BLEED A R FROM O L SUPPLY 14
F T PRESSURE GAUGE 14
SW TCH ON ELECTR C TY 14
VENT O L PUMP 14
ADJUST O L PRESSURE 14
SET COMBUST ON A R 15
CHECK SMOKE 15
REPLACEME T OF PARTS FAN MOTOR 16
(BUR ER) GN T ON ELECTRODES 16
GN TOR 17
SOLENO D CO L 17
CONTROL BOX 18
PEC 18
PUMP ACCESS 19
REPLACEME T OF PARTS ELECTR CAL COMPONENT ACCESS 20 - 21
(ELECTRICAL CO TROLS) RE-ASSEMBLE 20 - 21
CONTROL C RCU T - EXTERNAL 20 - 21
FAULT FI DI G W R NG D AGRAM - SATRON C BOXES 22
W R NG D AGRAM - SELF CONTA NED CONTROL 23
BURNER DOES NOT START 24
ERROR TABLE 25
NFORMAT ON SYSTEM - COOKER BURNER 26 - 27
(CONTROL BOX TYPE DKO 970)
NFORMAT ON SYSTEM - COOKER BURNER 28-29
(CONTROL BOX TYPE DKO 970N)
FAULT F ND NG - BO LER 30
FAULT F ND NG - COOKER 31
H GH SMOKE NUMBERS/ O L SMELLS 32
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 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 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

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are
provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the
manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be
provided to the customer for future reference.
nstallers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code
of Practice which is available from the Heating and Hotwater ndustry Council who manage and promote the scheme. Visit
www.centralheating.co.uk for more information.
THE BE CHMARK SCHEME
4

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 both oven
and boiler thermostats 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 - Boiler heat exchanger, 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.
Additional Flueway Clean
t may be necessary in some installations to give the
boiler flueways a clean out at the end of the heating
season.
This appliance MUST be serviced at regular 12 monthly
intervals to optimise its safety, efficiency and
performance.
After servicing, complete the relevant Service nterval
Record section of the Benchmark Checklist (provided
separately).
5
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 660/680/699K
only).
2. Remove 4 inner panel securing screws and remove
panel.
3. Remove the 3 plinth securing screws and remove
plinth.
6
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 & 4
BOILER BUR ER
1. Place a sheet on the floor in front of the cooker to act
as a working area.
2. Remove lower LH door (Rayburn 660/680/699K only)
and burner aperture cover and store in a safe place.
3. Unscrew jubilee clip and remove flexi air intake pipe
from burner.
4. Using a 5mm Allen key, remove top securing bolt and
remove burner by rotating it approximately 90°
counterclockwise and drawing it away from the boiler.
COOKER BUR ER
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.
7
BUR ER REMOVAL
Fig. 2
Fig. 3
Fig. 4
DESN 515761
DESN 515762
DESN 515763
Burner Removal

IMPORTA T: DURI G CLEA I G CARE MUST BE
TAKE OT TO DAMAGE THE CERAMIC FIBRE
I SULATIO .
SEE F G. 5
1. Remove top LH door (Rayburn 660/680/699K only)
and facia glass and store in a safe place.
2. Open control door and disconnect 3-pin plug. Remove
boiler access door complete with gasket and insulation
pad.
3. Remove baffles from boiler
Each heat exchanger has two rows of baffles. (See Fig. 7)
Total number of baffles fitted:-
660/680/760/780 = 4 (2 x 2)
699/799 = 4 (2 x 2)
SEE F G. 6 & 6A
1. Remove the top oven door (Rayburn 660/680/699K
only) and place in a safe position.
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.
8
HEAT EXCHA GER CLEA I G
Cleaning
Fig. 5 - Rayburn 660/680/699K shown DESN 515619
OVE & HOTPLATE FLUEWAY
CLEA I G
Fig. 6 DESN 515764
Fig. 6A DESN 515783

Cleaning
9
Fig. 7
ALL BAFFLES MUST BE STACKED I
PLACE AS DIAGRAM ABOVE
660/680
760/780
699
799
660/680
760/780
699
799

SEE F G. 8, 8A, 9A, 9B & 9C
t 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 grub screws, pull
forward.
COOKER = Grub screws in head
BO LER = Countersunk screws in tube
680K/780K
660K/760K
10
I TRODUCTIO
Burner Servicing
Fig. 8
Fig. 9A
Fig. 9B
DESN 515765
BO LER 8 VANES
COOKER 10
VANES
COOKER 10
VANES
BO LER 10 VANES
3mm HOLES
SMALL SLOTS
Fig. 8A
COOKER BUR ER
BOILER BUR ER
699K/799K
Fig. 9C
COOKER 10
VANES
BO LER 10 VANES
5mm HOLES
20 LARGE SLOTS

COOKER
SEE F G. 10
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.
BOILER
SEE F G. 10A
1. Release two countersunk head screws and remove
blast tube.
2. Remove two screws and slide out nozzle support
cradle c/w ignitor assembly from burner head.
3. Unscrew nozzle from its holder with a correctly fitting
tubular spanner to avoid damage to hexagon.
SEE F G. 11
1. Replace nozzle with a new one of the same make and
specification.
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.
11
Burner Servicing
BUR ER OZZLE REMOVAL
BUR ER OZZLE REPLACEME T
Fig. 11
Fig. 10
DESN 510538
DESN 515766
3mm
Fig. 10A

SEE F G. 12
Withdraw Photo Electric Cell from the burner head. Clean
PEC sensing end with a soft cloth 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 17.
SEE F G. 13 & 13A
1. Remove two screws and air inlet snorkel.
2. Remove four screws and split fan case.
3. Clean between the blades of the fan impeller 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.
12
Burner Servicing
FA CLEA I G
PHOTO ELECTRIC CELL (PEC)
CLEA I G
RE-ASSEMBLE BUR ER
Fig. 12
Fig. 13
DESN 515767
DESN 515768
P.E.C
Fig. 13A
COOKER FA
BOILER FA

To carry out any servicing on the oil pump. Turn off the oil
line isolating valve near to the appliance.
SEE F G. 14
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 paraffin.
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 fuel hose (s) must be replaced at each
service, ie annually.-
13
I TRODUCTIO
OIL PUMP STRAI ER CLEA I G
Oil Pump Servicing
OIL LI E FILTER CLEA I G
Fig. 14 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.
SEE F G. 15
Remove the bleed screw from the manifold and fit an oil
pressure gauge with R1/8 connection to check the pump
output pressure.
Set the boiler burner time clock to continuous and turn the
boiler thermostat to maximum. The boiler burner should
run on pre-purge for 7-15 seconds. With the ignition spark
energised. The oil solenoid valve should open allowing
the burner to fire.
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. 16). I THIS EVE T, WAIT AT
LEAST O E MI UTE, then press the re-set button to
restart.
SEE F G. 15
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, re-tighten.
SEE F G. 16
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).
14
BLEED AIR FROM OIL SUPPLY
FIT PRESSURE GAUGE
SWITCH O ELECTRICITY
VE T OIL PUMP
ADJUST OIL PRESSURE
Re-commissioning
Fig. 15
Fig. 16
DESN 515775
DESN 515769
BO LER BURNER
RESET BUTTON
PRESSURE PORT
BLEED SCREW
O L PRESSURE
ADJUSTMENT
COOKER BURNER
RESET BUTTON

SEE F G. 17 & 17A
After 15 minutes of the boiler burner running.
Remove the plug located behind the LH dome lid.
Remove the plugging screw and insert the sensing end of
a portable indicator to check the CO2(Carbon Dioxide)
level. Adjust the boiler burner air intake until a reading of
11.0/11.5% is recorded on the indicator.
SEE F G. 17A
Remove the CO2sampling tube and using the same hole
for flue sampling, insert the sensing end of a Baccarach
Smoke Pump and check that the smoke in the boiler
flueways does not exceed No.2 on the scale.
Replace the plugging screw and plug.
Switch off the boiler burner.
COOKER BURNER - SEE F G. 17A
Switch on cooker burner.
After 15 minutes of the cooker burner running.
Repeat the above procedures for the cooker burner. To
sample the flue gases from the cooker burner lift up the
RH insulating cover and remove the countersunk headed
screw in the hotplate. The cooker burner should be set to
11.0/11.5% maximum Smoke No.2.
Replace the countersunk headed screw on completion
ensuring that it will not interfere with any pots and pans
placed on the hotplate.
15
SET COMBUSTIO AIR
CHECK SMOKE
Re-commissioning
Fig. 17A
Fig. 17
DESN 515637
DESN 512001
COOKER FLUE
SAMPL NG HOLE
BO LER FLUE
SAMPL NG HOLE

SEE F G. 18
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 withdraw 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.
COOKER BUR ER
SEE F G. 19
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.
BOILER BUR ER
SEE F G. 19A
1. Release two countersunk head screws and remove
blast tube.
2. Remove two screws and slide out nozzle support
cradle c/w ignitor assembly from burner head.
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.
16
FA MOTOR
Fig. 18 DESN 515768
Fig. 19 DESN 515766
IG ITIO ELECTRODES
Replacement of parts (Burner)
Fig. 19A

SEE F G. 20
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.
OTE: Boiler burner must be removed from appliance in
order to gain access to ignitor. See instruction in section
burner removal, boiler burner, steps 1 to 4.
SEE F G. 21
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.
OTE: Boiler burner must be removed from appliance in
order to gain access to solenoid coil. See instruction in
section burner removal, boiler burner, steps 1 to 4.
17
Replacement of parts (Burner)
Fig. 20 DESN 515770
Fig. 21 DESN 515771
SOLE OID COIL
IG ITOR
EARTH
SCREW

SEE F G. 22
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.
OTE: Boiler burner must be removed from appliance in
order to gain access to control box. See instruction in
section burner removal, boiler burner, steps 1 to 4.
SEE F G. 23
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.
18
Replacement of parts (Burner)
PEC
CO TROL BOX
Fig. 22
Fig. 23
DESN 515772
DESN 515767

SEE F G. 24
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. 24 DESN 511995
19

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. 25
1. Remove the controls door (Rayburn 660/680/699K
only) and place in a safe position.
2. Remove both thermostat control knobs.
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 knobs.
5. Replace the controls door (Rayburn 660/680.699K
only).
SEE F G. 26
20
ELECTRICAL COMPO E T
ACCESS
Replacement of parts (Electrical controls)
Fig. 25 DESN 515773
RE-ASSEMBLE
CO TROL CIRCUIT-EXTER AL
Fig. 26 DESN 514865