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. 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.
CONTENTS SECTION CONTENTS PAGE 4 INSTALLATION SECTION TECHNICAL DATA 5 SITE REQUIREMENTS INTRODUCTION IMPORTANT GAS SUPPLY LOCATION VENT CONNECTION ELECTRICAL INSTALLATION REQUIREMENTS CLEARANCES PRELIMINARY INSTALLATION SITE LOCATION SETTING COMBUSTION 11 11 12 12 INSTALLATION INSTRUCTIONS BURNER ACCESS ELECTRICAL CONNECTION TERMINAL STRIP CONNECTIONS BURNER CONTROL ELECTRICAL CHECK COMBUSTION DISCHARGE SAFETY DEVICE ANCILLARY CONTROLS CHECK INSTRUCT THE USER 13 13 14 15 15 15 16 16 USERS GUID
SECTION CONTENTS BURNER COMBUSTION AIR TEST BURNER ON DRY RUN (NO GAS) 39 40 REPLACEMENT OF PARTS (BURNER) ELECTRODES CONTROL BOX 41 41 REPLACEMENT OF PARTS (ELECTRICAL CONTROLS) ELECTRICAL COMPONENT ACCESS TRANSFORMER FUSE TO FIT NEW FLUE SAFETY DEVICE TO FIT NEW COOKER SAFETY OVERHEAT THERMOSTAT AND OVEN CONTROL THERMOSTAT TO FIT NEW TIMER RE-ASSEMBLE 42 42 42 43 44 WIRING DIAGRAM - BURNER ONLY WIRING DIAGRAM - APPLIANCE BURNER DOES NOT START TROUBLESHOOTING - BURNER TROUBLESHOOTING CHART SERVI
Installation Section THE INSTALLATION OF THIS APPLIANCE MUST CONFORM WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES, WITH THE NATIONAL FUEL GAS CODE, ANSI Z223.1/NFPA 54 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.
PLEASE NOTE: IT IS ADVISABLE TO CHECK THE ACTUAL SIZE/WIDTH OF YOUR APPLIANCE BEFORE FINALLY FIXING ANY KITCHEN UNITS, SINCE ENAMELLED CAST IRON CAN VARY IN SIZE DIMENSIONS IN MM DESN 512448 TECHNICAL DATA Gas Inlet 1/2” NPT Electrical Supply 115 V Unpacked Appliance Weight - 326 Kg (719 lbs) 60 Hz Natural Gas Appliance Inlet Pressure (MAX.) Propane 10” w.g. 15” w.g. - 0.044 w.g. (± 0.012” w.g.) - 0.044 w.g. (± 0.012” w.g.) Burner Pressure (NEGATIVE) (non-adjustable) Max Flue Temp.
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. GAS SUPPLY Installation Pipes Pipework from the meter to the appliance must be of adequate size. Do not use pipes of a smaller size than the appliance gas connection.
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. The location must also provide adequate space for servicing and for air circulation around the appliance. See “Installation of the Appliance”.
Site requirements INSTALLATION CLEARANCES REAR DIM ‘A’ COMBUSTIBLE WALL NON-COMBUSTIBLE WALL 1” (25mm) 0” (0mm) DIM ‘B’ FLUE PIPE CLEARANCE TO COMBUSTIBLE WALL 2 1/4” (57 mm) NON-COMBUSTIBLE WALL 1” (25 mm) SIDES BELOW HOTPLATE 3/8” SIDES ABOVE HOTPLATE 2” (50 mm) WALL CABINET OVERHEAD 30” (762 mm) WALL CABINET OVERHEAD MAXIMUM DEPTH 13” (330 mm) WALL CABINET ALONGSIDE 30” (762 mm) FIG.
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. The gas vent proximity to combustion materials must be installed as recommended in ANSI/NFPA 211 and according to manufacturers instructions.
Site requirements VENT CONNECTION (continued) Chimneys and vents shall terminate above roof level and in accordance with the requirement of the current issue of the CAN/CGA - B149 Installation Code (Code W) (see Fig. 2) and be at least 1.53m (5ft) above the flue collar of the draft outlet. 1. If suitable, lined brick chimney is used it must be swept before connection and not less than 150mm (6in) internal diameter. 2. The top of the chimney should be fitted with an approved terminal. 3.
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. SIDE MUST BE INCREASED TO 50mm (2”) TO ALLOW REMOVAL OF OVEN SHELVES. SEE PAGE 4 - FIG. 1A.
Installation requirements SITE LOCATION SETTING COMBUSTION 1. Check that the hearth is level, then remove the appliance from its transit wooden pallet, and position it with its back against the wall and in its intended position for flue connection. 2. Locate and fit flue pipe into socket of flue pipe adaptor, seal joint with rope and fire cement. 3. Connect and terminate the flue system in accordance with the regulations in force.
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 FIG. 6 DESN 512568 ELECTRICAL CONNECTION - SEE FIG. 6 This appliance comes with a three-prong plug which should be connected to a proper receptacle. See page 10 (Electrical). This is fitted internally to the terminal strip shown in Fig. 6 and Fig. 7.
Installation Instructions TERMINAL STRIP CONNECTIONS FIG.
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. Providing there is gas to the burner, combustion should be established after approximately 30 seconds.
Installation Instructions ANCILLARY CONTROLS CHECK INSTRUCT THE USER Before leaving the site, check that the operation of cooker timer and thermostat are capable of controlling the burner correctly. Check the operation of burner control box. 1. Advise the User that, for continued efficient and safe operation of the appliance, it is important that adequate servicing is carried out annually. 2.
Users Guide 17
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. IMPORTANT NOTICE: PLEASE READ THE ACCOMPANYING WARRANTY.
SAFETY PRECAUTIONS AND HINTS 1. Do not store combustible materials, gasoline or other inflammable vapors and liquids near a range cooker. 2. Do not operate the appliance with the oven doors open, with the exception of loading and unloading the oven. 3. Ensure and maintain the continual free passage of air to the burner housing. Do not stand obstacles against a burner outer door. Loose hair from dogs or cats must not accumulate behind the outer burner door. 4.
FEATURES/ACCESSORIES Doors Fig. 9 To open the doors. Twist the handle slightly to disengage the door catch from the locking spindle and pull the door open. Thermodial See Fig. 10 FIG. 9 The thermodial positioned on the Roasting/Baking door is an approximate guide to the internal oven temperature. All thermodials vary slightly but the settings generally indicate the following temperatures.
FEATURES/ACCESSORIES (continued) PLAIN SOLID SHELF TOP RUNNER SHELF POSITION 1 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.
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.
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 1. 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. The time will increase/decrease from 12.
USING THE TIMER (continued) SETTING AN END TIME ONLY, AUTOMATICALLY 1. 2. 3. 4. 5. 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. When the cooking is finished, a bleep will sound and continue for 2 minutes unless cancelled manually AUTO symbols will flash.
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. Press the MINUTE TIMER plus + and minus - buttons. button the bell symbol will be displayed and 0.00. Set the required time by using the 2.
USING THE AUTOMATIC COOKING FUNCTION Using this function on the timer allows the user to select the amount of time the appliance is on and the finish/off time. HINTS ON THE USE OF THIS FEATURE * The AGA should be COLD before starting any automatic cooking where there is a delay in the start time.
MAIN OVEN OPERATION Note: care should be taken not to touch the hotplate, oven combustion chamber door and flue areas unless a insulated glove is used, as these areas are hot working surfaces and will burn unprotected skin. z z z z z z The oven is indirectly heated from the outside by hot gases from the heat source so that no flame or elements within the oven means full use can be made of the whole cooking area. The oven is hotter towards the top than the bottom.
COOKING WITH YOUR APPLIANCE Broiling The top of the oven is where broiling takes place. When the Roasting/Baking oven is hot, use the meat tin with a grill rack (used on the highest position) so that the fat can drip into the tray. Position the food on the rack and put into the oven on the highest runner. The heat from the cast iron roof of the oven will cook and color the food. Turn as necessary. Turn the grill rack over to the lowest position and it becomes a trivet for roasting meat and poultry.
COOKING WITH YOUR APPLIANCE COOKING CHART (ROASTING/BAKING OVEN) Setting Shelf Position SCONES 7 3 10-15 mins SMALL CAKES 5 4 20 mins (Turn the tray round halfway through cooking.
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 z z z z z z z It is not advisable to put wet clothes on the handrail: this may craze the enamel. To keep the vitreous enamelled surface bright and clean, wipe over daily with a soapy damp cloth, followed by a clean dry cloth. Wipe off any condensation streaks on the front plate as they occur or the vitreous enamel may be permanently discolored.
Servicing Instructions 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.
INTRODUCTION 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. A HOT APPLIANCE CANNOT BE SERVICED. DISCONNECT FROM ELECTRICITY SUPPLY BEFORE SERVICING. WHEN RE-WIRING ANY ELECTRICAL COMPONENTS, REFER TO CIRCUIT DIAGRAM FIG. 32 .
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. Remove the (4) inner panel securing screws and remove panel. 3. Remove the (3) base plate screws and remove base plate. BASE PLATE FIG.
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 1. Place a sheet on the floor in front of the cooker to act as a working area. 2. Turn off gas cock. 3. Break gas cock union connection. 4. Disconnect the terminal plug. (See Fig. 15) 5. Unscrew burner locking nuts (2). (See Fig. 16) 6. Remove burner by twisting clockwise and then remove. (See Fig. 17). TERMINAL STRIP GAS SUPPLY PIPE FIG.
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. 3. Thoroughly clean burner chamber flueway. 4.
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 always with the correct type. 4. Check that all electrical connections and cables are sound, undamaged and have not worked loose. 5. Clean the combustion air fan. 6. Refit all parts, ensuring they are correctly fitted. 7.
Electrical Controls CONTROL CIRCUIT-EXTERNAL TERMINAL STRIP CONNECTIONS 37
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.
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 CO2 (Carbon Dioxide) level. CO CO2 0 - 50 ppm 8.2% - 9.
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. Open the gas inlet cock, allowing the burner to restart. When the burner is in ‘run’ condition, close the inlet gas cock. When the flame is extinguished the gas valves solenoids on the burner should be de-energized almost immediately.
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. 3. Carefully replace the electrodes, ensuring the gasket is in place. Tighten screw. FIG. 23 DESN 512443 FIG. 24 DESN 512442 CONTROL BOX See Fig. 24 1. Turn off power to appliance. 2. Unplug 12-way connector. 3.
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 Remove the controls door and place in a safe position. Remove thermostat control knob. Remove the (2) cover panel fixing screws. Remove cover panel. It will be necessary to disconnect the push on tags from the timer, noting position of wiring. 5. Remove the (4) control panel fixing screws. 6.
Replacement of parts (Electrical Controls) THERMOSTAT FIG. 28 OVERHEAT THERMOSTAT COOKER TIMER DESN 511444 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. 1. Remove 2 screws securing flue safety device bracket. 2. Withdraw thermostat and remove (2) push on connectors. 3. Remove thermostat securing nut. 4. Remove phial guide bracket from tube. 5.
Replacement of parts (Electrical Controls) TO FIT NEW COOKER SAFETY OVERHEAT THERMOSTAT & OVEN CONTROL THERMOSTAT OVERHEAT THERMOSTAT SEE FIG. 30 Follow instructions in section COMPONENT ACCESS , Steps 1 to 6. ELECTRICAL 1. Undo the two screws on the front of the chassis which holds the thermostat in place. 2. Remove the (2) push on connectors from back of thermostat. 3. Open Roasting Oven door and, using a screwdriver, loosen the rear fixing screws and remove the front fixing screw of the inner L.H.
Fault Finding WIRING DIAGRAM - BURNER ONLY FIG.
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.
Trouble Shooting BURNER DOES NOT START Burner Check that the burner has not gone to lockout. Causes of lockout can be: z z z z z z 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. Live and Neutral connections reversed. Inadequate ground control with flame. General For access to individual controls refer to section on Replacement Parts.
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. Press reset button to ensure that the control box has not gone to lockout. 4. Check filter is clean on fan inlet. 5. If burner still refuses to start, change control box.
Trouble Shooting 49
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. OPERATING BY PRESSING WITH FINGER ONLY Please wait at least 10 seconds between resetting the lockout button. If resetting the lockout button does not light the burner immediately, it will be necessary to repeat the sequence.
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. AGA 1050 Fountain Street North Cambridge Ontario Canada N3H 4R7 Business: (519) 650-5775 Fax: (519) 650-3773 Toll-free Phone: 1-877-650-5775 Toll-free Fax: 1-800-327-5609 www.aga-heartland.
