AGA DUAL CONTROL
DC3G & DC5G
(POWER FLUE)
For use in GB & IE
PLEASE READ THESE INSTRUCTIONS BEFORE USING THIS APPLIANCE
AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
Burner Assembly & Flue System Upgrade
Instructions
REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the
safety and performance specication that we require.
DO NOT use reconditioned or copy parts that have not been clearly authorised by AGA.
09/16 LPRT 517434
1
9.
10.
7.
1.
2.
3.
4.
8.
5.
6.
1. Overview
Spare Upgrade Kit - AG9M996374 Power Flue Natural
Gas Burner Assembly & Flue System Kit
1. ‘Cold Start’ Thermostat AG4M212636
2. Flue Thermostat AG4M212363
3. Solenoid Thermostat AG4M212364
4. Sealing Ring AG4M410180
5. Thermostat Mounting Bracket AG2M212341
6. M4 x 6 mm LG Hex Head (x6) KHEX500684
7. Spacer Box Assembly AG1M212439 c/w 3 off Spring
Clips KCLP500683
8. Fan Wiring Harness AG4M212637
9. Burner Assembly AG1M212324
10. Instruction Sheet LPRT517434
Fig. 1.1
2
Fig. 1.6
Prior to installation ensure that power & gas
supplies are isolated.
1. Remove fan shroud Fig. 1.2
i. Remove retaining screw located through top vent
of fan shroud Fig. 1.2.
ii. Remove shroud.
2. Remove thermostat phials ‘A’ & ‘B’ from circlips
located at top of spacer box Fig. 1.3
Remove spacer box
i. Remove (2) screws ‘A’ xing spacer box to ue
nozzle Fig. 1.4.
ii. Remove (1) screw ‘B’ xing fan to spacer box Fig.
1.4.
iii. Slightly bend fan xing bracket in an upwardly
direction to allow spacer box removal Fig. 1.5.
iv. Slide the spacer box up to remove Fig. 1.6.
A
A B
Fig. 1.2
Fig. 1.3
A
B
A
Fig. 1.4
Fig. 1.5
3
A
Fig. 1.7
Vent fan removal
NOTE! Care must be taken when removing fan to
ensure terminals on motor windings do not get
damaged.
i. Rotate fan back & forth, pulling upwardly to
remove fan from ue elbow.
ii. Disconnect all wiring from fan unit. Place fan
aside.
Remove thermostat mounting
bracket
i. Remove (1) xing screw ‘A’ securing bracket to
chassis Fig. 1.7.
ii. Remove bracket c/w thermostats.
iii. Spacer box, thermostat brackets, stats & wiring
harness can now be discarded.
4
Re-fit
1. Prior to tting new thermostat mounting bracket pre-
wire thermostats. Secure the new bracket Fig. 1.1 in
position using (1) xing screw ‘A’ Fig. 1.8:
Route thermostat capillaries accordingly
• Cold start stat (blue capillary) to the right.
• Flue fan stat to the right.
• Solenoid stat to the left.
• Prior to re-fitting fan remove earth wire from harness
by cutting cable ties.
2. Re-connect earth wire to earth terminal located at
rear of chassis Fig. 1.9.
3. Position fan locally to ue elbow. Re-wire following
schematic wiring diagram Fig. 1.9.
4. Remove the old ‘O’ ring from vent fan spigot, and
replace with the new ‘O’ ring supplied with the kit.
5. Re-t fan to ue elbow.
CAUTION: Care must be taken when re-tting
fan to avoid damaging terminals on the motor
windings.
A
Fig. 1.8
5
DC3G shroud wiring connections – Inc AG4M212637
2
4
1
1
2
AG4M212364
1
4
2
AG4M212636
AG4M212363
L4
N1
H3
A
B
C
55°C
110°C
125°C
Cold Start
Thermostat
Flue Fan
Thermostat
Solenoid
Thermostat
Cold Start
Thermostat
Phial
Flue Fan
Thermostat
Phial
Solenoid
Thermostat
Phial
Aga
DC3 Gas
Power Flue
Cold Start
Issue 1 Sep 2016
bl
Existing
Harness
br
gr
g/y
br
r
gr
br
gr
br
or
y
r
g/y
g/y
bl
gr
gr
bk
black
br
brown
r
red
o
orange
y
yellow
v
violet
gr
grey
g/y
green
yellow
v
Fig. 1.9
Earth Chassis
6
A
B
A
A B
C
A
Fig. 1.10
Fig. 1.11
Fig. 1.12
Spacer box
1. Slide spacer box into position, secure in position (2)
screws ‘A’ Fig. 1.10.
Reposition fan securing bracket, secure to spacer box top
(1) screw ‘B’ Fig. 1.10.
2. Thermostat phials Fig. 1.11
i. Fit (3) thermostat phials as follows :
ii. Solenoid stat ‘A’ to top left-hand side of spacer
box
iii. Fan stat ‘B’ to top right-hand side of spacer box.
iv. Cold start stat ‘C’ to front centre of spacer box.
Route stat capillaries to sides of spacer box, ensuring fan
shroud will t without clashing.
3. Re-t shroud and secure in position Fig. 1.12.
7
A
B
A. Thermostat Capillary B. Thermodial Capillary
A
C
B
2. Burner assembly upgrade
1. Isolate mains gas & electricity supplies.
2. Remove fascia panel (4 mirror caps, 4 screws)
3. Turn gas cock to ‘OFF’ position.
4. Disconnect union joint to gas cock.
5. Disconnect wiring in left-hand side of burner housing
(2 off male/female molex connectors A & B) & earth
wire (C) located above control valve Fig. 2.1.
6. From inside top of roast oven remove phial mounting
plate & unclip phials from circlips.
7. Remove thermodial mounting bracket (2 screws)
c/w thermodial attached, taking care not to damage
capillary.
8. Withdraw thermodial & control valve capillaries
t h r o u g h g u i d e t u b e i n t o b u r n e r h o u s i n g .
Place thermodial & bracket aside.
9. Remove 4 screws securing burner assembly to
housing, and withdraw burner assembly from burner
chamber.
10. Fit new burner assembly. Re-connect ‘Molex’
connectors & earth wire to earth tag. Ensure wiring
is tucked behind front plate to LH side to prevent
entrapment of wires when re-tting fascia panel. Also
ensure control valve capillary is routed to RH side of
burner housing as shown in care notice.
11. Re-t thermodial & control valve capillaries through
guide tube into roast oven. Re-t to phial mounting
plate as shown in Fig. 2.2.
12. Re-t thermodial mounting bracket to housing (2
screws).
13. Turn gas cock to ‘ON’ position.
14. Restore gas & electric supply to appliance.
15. Check for gas tightness. Refer to page 25
installation instructions for inlet & burner pressure
testing.
16. Re-commission cooker. Refer to installation
instructions EINS516845.
NOTE! Vent fan will run at high speed from cold start for
approx 20 minutes.
Fig. 2.1
Fig. 2.2
8
Phial Wire
3. Care Notice
Fig. 3.1
Gas valve oven thermostat phial wire
Fig. 3.1
Following assembly of gas valve thermostat phial into
oven cavity, excess wire may cause an ‘Electrical
Shorting’ problem across simmering plate thermostat
terminals if routed loosely behind thermodial inside the
controls assembly.
To avoid this, phial wire should be routed towards the
right-hand side of the controls housing. Excess wire can
then be ‘coiled’ and positioned toward the bottom right-
hand corner of controls housing.
Similarly, the braided wire from the thermodial should also
be routed toward thr right-hand side of controls housing to
prevent similar problems occurring.
Notes
Notes
10
Notes
Notes
12
Notes
With AGA Rangemaster’s policy of continuous product
improvement, the Company reserves the right to
change specications and make modications to the
appliances described and illustrated at any time.
www.agaliving.com
www.agacookshop.co.uk
Manufactured By
AGA Rangemaster
Station Road
Ketley Telford
Shropshire TF1 5AQ
England
For further advice or information contact
your local AGA Specialist.
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AGA DC3 & DC5 Power Flue Burner Assembly and Flue System Upgrade Owner's manual
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