Southbend 4365A, 4601DD-2RR User Manual

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SERVICE

WARNING

ADJUSTMENTS AND SERVICE WORK MAY BE PERFORMED ONLY BY A QUALIFIED TECHNICIAN WHO IS EXPERIENCED IN, AND KNOWLEDGEABLE WITH, THE OPERATION OF COMMERCIAL COOKING EQUIPMENT. TO ASSURE YOUR CONFIDENCE, CONTACT YOUR AUTHORIZED SERVICE AGENCY FOR RELIABLE SERVICE, DEPENDABLE ADVICE OR OTHER ASSISTANCE, AND FOR GENUINE FACTORY PARTS.

NOTICE

INSTALLATION OF OTHER THAN GENUINE SOUTHBEND PARTS WILL VOID THE WARRANTY ON THIS EQUIPMENT.

The serial plate are located on the right side of the range (see Figure 1 on page 3).

Replacement parts (including parts not listed in this manual) may be ordered either through a Southbend Authorized Parts Distributor or a Southbend Authorized Service Agency.

When ordering parts, please supply the Model Number, Serial Number, Part Number, and Part Description.

In case of problems in operation at initial installation, check type of gas and manifold pressure and compare with information listed on the serial plate.

This section contains troubleshooting flowcharts, procedures, and electric schematics to assist a qualified service technician in the servicing of a Southbend Ultimate Restaurant Range.

TROUBLESHOOTINGFLOWCHARTS, PROCEDURES, ANDWIRINGDIAGRAMS

Find the symptom below that corresponds to the malfunction, then turn to the corresponding page. Follow the flowchart on that page until the problem is solved.

Troubleshooting Flowchart, Procedure, or Wiring Diagram

Page

 

 

 

Troubleshooting Open-TopBurners

22

 

 

 

 

Troubleshooting Base Oven

23

 

 

 

 

Troubleshooting Convection-OvenBlower

24

 

 

 

 

Adjustment of Gas Pressure Regulator

26

 

 

 

 

Adjustment of Open-TopPilots

27

 

 

 

 

Adjustment of Open-TopBurners

27

 

 

 

 

Adjustment of Oven Standing Pilot

27

 

 

 

 

Adjustment of Oven Burner

27

 

 

 

 

Adjustment of Charbroiler, Standard-Griddle,and UniformHot-TopBurners and Pilots

27

 

 

 

 

Calibration of Oven Thermostat

28

 

 

 

 

Adjustment of Thermostatic Griddle Bypass Flame Level

28

 

 

 

 

Calibration of Thermostatic Griddle Thermostat

28

 

 

 

 

Conversion from One Type of Gas to Another

29

 

 

 

 

Wiring Diagram for Gas Oven

30

 

 

 

 

Wiring Diagram for Infrared Broiler in Gas Oven Cavity

31

 

 

 

 

Wiring Diagram for Electric Standard Oven

32

 

 

 

 

Wiring Diagram for Electric Convection Oven

33

 

 

 

 

OWNERS MANUAL 1190820 REV 3 (11/10)

PAGE21 OF48

SERVICE

ULTIMATERESTAURANTRANGES

TROUBLESHOOTINGOPEN-TOPBURNERS

Each open-topburner should have a steady blue flame on each port of the burner. Propane burners may have a small amount of yellow tipping, and may make a slight popping noise when turned off.

If the flame is rising up off of the ports, adjust the burner shutter so it is more closed. If the flame is long and yellow adjust the burner shutter so it is more open.

Consult the following table and the flowchart on this page.

Problem

Look for -

 

 

No burners or pilots in the range will turn on.

– Main gas supply to range is OFF.

 

 

Spark electrode does not spark (to light pilot).

– Battery (inside corresponding spark module on rear of

 

of range) needs replacement.

 

 

All burners produce excessive carbon deposits.

– Incorrect gas type supplied to range.

 

– Incorrect supply pressure.

 

 

Only some burners in a range produce excessive carbon

– Incorrect orifices or orifice alignment.

deposits.

– Primary air not adjusted properly.

 

 

Only some pilots produce excessive carbon deposits.

– Pilot gas not adjusted properly.

 

– Incorrect pilot orifice.

 

 

Top burner will not come on, but oven will come on.

– Control knob for top burner is in OFF position.

 

– Pilot out.

 

 

Open-topburner pilot will not stay ignited.

– Pilot gas not adjusted properly.

 

– Clogged orifice.

 

– Draft condition.

 

– Improper ventilation system.

 

– Air in gas line.

 

– Thermocouple bad.

 

 

Figure 7

Troubleshooting Open-TopBurners

Open-topburners are not working correctly.

Check that the burners are set level in their support brackets.

Check that the burners are clean and that their ports are clear.

Remove each burner and check that the venturi is clean and free of buildup and debris. Also check that the orifice size is correct and that it is clean and free of buildup and debris.

Remove the burner control knobs and carefully lower the control panel. CAUTION! Convection oven models have wiring attached behind the panel.

Check that each burner valve and orifice is in alignment with the corresponding burner.

Check the pressure of the gas supply with all the gas appliances connected to the supply turned fully on. The inlet pressure (before entering the pressure regulator for the range) must be a minimum 7" W.C. for natural gas, or a minimum 11" W.C. for propane but no more than 14” H2O for either gas typ. Adjust the pressure and/or capacity of the gas supply, if necessary.

Check the pressure of the gas manifold of the range (after the gas leaves the pressure regulator for the range). See page 26.

PAGE22 OF48

OWNERS MANUAL 1190820 REV 3 (11/10)

TROUBLESHOOTINGBASEOVEN

CAUTION

Proper and efficient operation of oven is dependent on correct installation and function of components. Always verify that components are in place and functioning as intended.

Consult the following table and the flowchart that begins on the following page.

Problem

Look for -

 

 

Oven will not come on.

– Oven pilot is out.

 

 

Oven pilot will not stay ignited

– Pilot gas not adjusted properly.

 

– Bad thermopile.

 

– Bad thermopile connections at safety valve.

 

– Bad safety valve.

 

– Clogged orifice.

 

– Dirty pilot

 

– Draft condition.

 

– Improper ventilation system.

 

– Air in gas line.

 

 

Figure 8

Troubleshooting Oven Pilot

Oven pilot does not work.

Check whether the pilot flame is lit by looking through the hole in the bottom of the oven. Leave the oven door open for five minutes to allow gas fumes to clear.

If the pilot is not lit, attempt to light the pilot by raising the kick panel slightly and rotating its top edge outward. Press and hold the button on the oven safety valve and put a flame to the pilot.

No

Does the pilot light?

Yes

 

 

 

Check that the oven pilot adjustment on the manifold is open.

If the pilot still will not light, do the following: Remove the oven bottom. Loosen the pilot nut on the burner bracket. Remove the pilot tube from the safety valve. Remove the pilot orifice from the pilot or end of the tube and check for debris.

Re-installthe pilot orifice and tubing.

Continue to hold the button for 30 seconds. The pilot should remain lit after the button is released. If it does not, wait five minutes and try again.

If the pilot will not remain lit, do the following: Remove the thermocouple from the safety valve. Install a thermocouple adapter between the safety valve and the thermocouple to measure the direct-currentmillivoltage produced by the thermocouple. While holding the button, light the pilot and measure the voltage produced by the thermocouple. If the voltage does not rise above 10 millivolts, adjust the pilot valve and retest. If the voltage still does not quickly rise above 10 millivolts, replace the thermocouple.

If instead the thermocouple is working properly, replace the safety valve.

OWNERS MANUAL 1190820 REV 3 (11/10)

PAGE23 OF48

SERVICE

ULTIMATERESTAURANTRANGES

TROUBLESHOOTINGCONVECTION-OVENBLOWER

WARNING

Before attempting to service or replace any electrical component, make sure power source has been disconnected.

CAUTION

When changing motor or servicing range, always verify that blower wheel rotation is clockwise when looking into the oven cavity.

If the blower does not run at all, consult the flowchart that begins on the next page. If the blower runs intermittently, consult the flowchart on this page.

The appropriate wiring diagram for the oven can be found on the rear of the oven (as well as at the end of this section of this manual).

Figure 9

Convection-OvenBlower Runs Intermittently

 

Convection-ovenblower runs intermittently.

 

 

Does the problem

 

No

Yes

occur only when the oven

 

is hot?

 

 

 

DISCONNECT POWER AT CIRCUIT BREAKER.

Check all wiring for loose connections or breaks.

Remove the cover from the junction box on the back of the range. Disconnect the black wire and place an ammeter in the circuit.

CAUTION: Check that the ammeter is rated for at least 40 amperes! Reconnect the power to the range and turn on the blower switch while watching the ammeter. The reading should surge and then return to the rated current of the motor when running at high speed. If the measured current exceeds the motor rating, replace the blower motor.

Check that there are no air-flowobstructions around the range.

Check that the blower motor is not pressing against the wall behind the range.

Check that the blower motor air vents are not obstructed.

Check for excessive grease and dust buildup on the motor.

Check for sources of excessive heat behind the range.

Check for hot-airleaks around the motor pocket.

With the blower turned ON, turn the oven thermostat to OFF and allow the oven to cool. If the blower motor runs continuously when the oven is cool, turn the oven thermostat to the highest setting. If the blower motor shuts off when the oven becomes hot, and if there are no sources of excessive heat around the blower motor, replace the blower motor.

PAGE24 OF48

OWNERS MANUAL 1190820 REV 3 (11/10)

Figure 10

Convection-OvenBlower Does Not Run

Convection-ovenblower does not run.

DISCONNECT POWER AT CIRCUIT BREAKER.

Remove the control knobs from the front of the range. Remove the screws that secure the top of the control panel and carefully tilt the panel forward to expose the back of the blower switch that is mounted in the front panel. CAUTION: Be careful not to damage the wiring behind the control panel. Remove the protective cover from the blower control switch.

Check that the switch wires and terminals are secure.

Use a multimeter to check the continuity across the terminals of blower-switchwires 1 and 3 (refer to the appropriate wiring diagram in this manual or on the range). With the switch in the ON position, there should be continuity.

No

Is there continuity?

Yes

 

 

 

Replace the blower control switch.

Reconnect the power supply. Use a voltmeter to measure the voltage across the center terminals of switch wires 1 and 2.

 

Does the measured

 

Yes

No

voltage match the rated voltage

 

of the range?

 

 

 

Re-assemblethe switch cover and control panel. Turn on theblower-controlswitch and open the oven door.

Check power supply to range.

 

Does the blower

 

No

Yes

run with the oven door

 

open?

 

 

 

DISCONNECT POWER AT CIRCUIT BREAKER.

Open the kick panel below the oven door by raising it slightly and tilting the top edge outward. Locate the door switch and check for continuity across the wired switch terminals while pressing the switch actuator lever.

No

Is there continuity?

Yes

 

 

 

DISCONNECT POWER AT CIRCUIT BREAKER.

Open the kick panel below the oven door by raising it slightly and tilting the top edge outward. Locate the door switch and check that one wire is connected to the common (90°bottom) terminal of the switch. Move the other wire to the normally open (lower leg) terminal on the side of the door switch.

Replace door switch.

 

Close the oven door (which should

 

 

 

 

 

 

 

 

press the door-switchactuator lever).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there continuity?

 

 

 

 

 

No

 

 

 

Yes

 

Continue on next page.

 

 

 

 

 

 

 

 

 

Loosen the two screws on the door switch bracket and adjust it so that the door switch is pressed when the oven door is closed.

OWNERS MANUAL 1190820 REV 3 (11/10)

PAGE25 OF48

SERVICE

ULTIMATERESTAURANTRANGES

Figure 11

Convection-OvenBlower Does Not Run, Continued

(Continuing from previous page.)

CHECK THAT POWER IS DISCONNECTED

AT CIRCUIT BREAKER.

Remove the wire terminal cover from the blower motor.

Check that the red wire is capped off.

Remove the wire nuts from the black and the white wires. Check that in each case the wires are twisted together securely.

Check that the common wire is connected to the motor black wire.

Check that the neutral wire is connected to the white wire.

Reconnect the power supply and turn on blower-controlswitch. Use a voltmeter to measure the voltage between the black wire and the white wire.

No

Is there voltage?

Yes

 

 

 

DISCONNECT POWER AT CIRCUIT BREAKER.

Check all wiring for loose terminals or breaks.

DISCONNECT POWER AT CIRCUIT BREAKER.

Remove the wire nuts from the red, white, and black wires. Check that the resistance across the white and black wires is approximately 1.9 ohms. Check that the resistance across the white and red wires is also approximately 1.9 ohms. If either resistance is incorrect, replace the blower motor.

ADJUSTMENT OFGASPRESSUREREGULATOR

The pressure regulator is factory set at 4" W.C. (0.99 kPa) for natural gas and 10" W.C. (2.48 kPa) for propane gas. To check the manifold pressure:

1.Turn all thermostats and burner control knobs to OFF position.

2.Turn main gas valve to entire range off.

3.Remove control panel and locate the small plug in the manifold.

4.Remove plug and install a fitting appropriate to connect a manometer.

5.Turn on main gas to range and light pilots.

6.Turn all burners and ovens to full ON position and read manometer.

7.If manometer does not read 4" W.C. (0.99 kPa) for natural gas, or 10" W.C. (2.48 kPa) for propane gas, adjust regulator (if gas pressure is correct go to Step 10).

8.Remove cap from top of regulator.

9.With a screwdriver rotate regulator adjustment screw clockwise to increase, or counterclockwise to decrease, pressure until manometer shows correct reading.

10.Repeat steps 1 and 2.

11.Remove manometer fitting and replace plug in manifold.

12.Turn on main gas to range and light pilots.

13.Replace control panel.

PAGE26 OF48

OWNERS MANUAL 1190820 REV 3 (11/10)

ADJUSTMENT OFOPEN-TOPPILOTS

The open-toppilots are thenon-aerated(yellow-tippedflame) type. One is located beside eachopen-topburner.

Pilot outage is often caused by an unstable flame due to over-adjustmentto the point where the flame is leaving its port, or “blowing off.” Often, in an effort to improve ignition, the pilots are increased too much and result in this unstable condition.

The pilots are adjusted by inserting the blade of a screwdriver into the slot on the small valve, located on the manifold. The maximum flame size is approximately 3/4" (19 mm) with a slight yellow tip. The first indication of over-adjustmentis evident when the yellow tip begins to stream into black streaks and generate carbon. Continuedover-adjustmentleads to the unstable lifting and blowing condition.

ADJUSTMENT OFOPEN-TOPBURNERS

All open-topburners are primarily adjusted by means of an air shutter on the mixer face.

To adjust a burner, loosen the screw that holds the air shutter in position and rotate the mixer cap until a clear, stable blue flame is obtained. The flame should not be yellow tipped nor should it blow off the burner ports.

All orifice sizes and burner rate are properly set at the factory and should not be altered.

Over-ratedburners cause poor burner and pilot performance, resulting in less heat, and wasted gas.

ADJUSTMENT OFGASOVENSTANDINGPILOT

The standing oven pilot flame can be adjusted by turning the adjusting screw on the pilot line valve with a screwdriver. The pilot line valve is located behind the kick panel below the oven door. Remove the kick panel to gain access. The pilot flame is properly adjusted when it is just large enough to maintain a glowing red color of the thermopile capillary bulb.

ADJUSTMENT OFGASOVENBURNER

The oven burner orifice is of the fixed type, sized for the specified gas supply. The burner flame characteristics are controlled by varying the primary air mixer cap. There should be a clear blue flame with a distinct inner cone at each port. Excessive primary air can result in “blowing” or the flames leaving the ports. Lack of primary air causes soft or yellow tipped flame.

ADJUSTMENT OFCHARBROILER, STANDARD-GRIDDLE, ANDUNIFORMHOT-TOPBURNERS

AND PILOTS

The burner valves are not adjustable. The burner orifice is of the fixed type, sized for the type of gas and the operating altitude. To adjust the burner air-gasmixture, loosen the screw that secures the air shutter on the mixer face and rotate the mixer cap to obtain a clear, stable blue flame with a distinct inner cone at each port. Excessive primary air causes “blowing” (the flames leaving the ports), while insufficient primary air causes a soft or yellow tipped flame.

The pilots are near the front of the burners, and are held in position by brackets. To adjust a pilot flame, insert a screwdriver through the opening in the valve panel between the control knobs and turn the appropriate pilot adjustment screw counterclockwise to increase the size of the pilot flame, or clockwise to decrease the size of the pilot flame. The maximum flame size is approximately 3/4" with a slight yellow tip. The first indication of overadjustment is when the flame tip becomes more yellow and begins to generate carbon, which appears as rising black streaks. Continued over-adjustmentleads to unstable lifting and a blowing condition.

OWNERS MANUAL 1190820 REV 3 (11/10)

PAGE27 OF48

SERVICE

ULTIMATERESTAURANTRANGES

CALIBRATION OFGASOVENTHERMOSTAT

The oven thermostat control is carefully calibrated at the factory so that its dial settings closely match actual oven temperatures. Field recalibration is seldom necessary, and should not be resorted to unless considerable experience with unexpected cooking results definitely proves that the control is not maintaining the temperatures to which the dial is set.

When checking the oven temperature, use a test instrument or a reliable mercury thermometer positioned in the center of the oven. The oven bottom must be in place. For convection ovens, the blower baffle must be in place.

Proceed as follows:

1.Light the oven pilot, set the oven thermostat to 350°F, and, if the oven is a convection oven, turn on the fan.

2.After burner has been on about 15 minutes, check the oven temperature. The oven door should be open for as short a time as possible. Use a flashlight, if necessary, to see the thermometer clearly.

3.Continue to check temperature noting the minimum and maximum "swing" variation in temperature until two successive readings are within 5 degrees of each other. The oven temperature is the midpoint of the "swing" range.

The control should be recalibrated if your reading is not within 20 degrees of the dial setting (350°F). If calibration is required, the additional steps to be taken are these:

4.Insert a flat screwdriver through the center of the thermostat stem and then turn the adjustment screw clockwise to decrease the oven temperature and counterclockwise to increase the oven temperature. Do not allow the stem to turn. Turn the adjustment screw only 5 degrees of rotation in the appropriate direction, then repeat Steps 2 and 3 to check the temperature. Repeat until the temperature is within 10 degrees of 350°F.

5.Set the oven thermostat to 400°F. Check oven temperature again, as instructed in Steps 2 and 3. If the oven temperature is not within 20 degrees of the dial setting (400°F) it means that the sensing element is inoperative and the control should be replaced.

ADJUSTMENT OFTHERMOSTATICGRIDDLEBYPASSFLAMELEVEL

When the griddle reaches the temperature at which the dial is set, the control cuts down the flow of gas to the amount required to keep the griddle at that temperature. Always, however, the control must bypass enough gas to keep the entire burner lit. To maintain this minimum flame, the bypass must be set carefully and accurately, as follows (see Figure 12 on page 29):

1.Light the burner, then turn dial FULL ON.

2.After 5 minutes, turn dial clockwise to point slightly beyond first mark on dial.

3.Remove dial and bezel.

4.With a screwdriver, turn Bypass Adjustor (counterclockwise to increase the flame, clockwise to decrease it) until there is a minimum flame over the entire burner.

5.Replace bezel and dial, turning the dial clockwise until it locks in the OFF position.

CALIBRATION OFTHERMOSTATICGRIDDLETHERMOSTAT

The griddle temperature control is carefully calibrated at the factory—thatis, it is so adjusted that dial settings match actual temperatures. Field recalibration is seldom necessary, and should not be resorted to unless considerable experience with cooking results definitely proves that the control is not maintaining the temperatures to which the dial is set.

Recalibration should not be undertaken, however, until the griddle bypass flame has been adjusted (see previous subsection).

To check temperatures when recalibrating, use a test instrument with a DISC type thermocouple for surface temperature checking. Drop a couple of drops of oil on griddle surface plate and place thermocouple disc flat into the oil.

Proceed as follows (see Figure 12 below):

1.Remove dial and push out metal insert.

2.Replace dial, turn to 350°F (175°C) mark, and light burner.

3.After burner has been on about 15 minutes check temperature.

PAGE28 OF48

OWNERS MANUAL 1190820 REV 3 (11/10)

4.Continue to check temperature, at 5-minuteintervals, until two successive readings are within 5°F (3°C) of each other.

The control should be recalibrated if your reading is not within 20°F (11°C) of the dial setting (350°F or 175°C). If calibration is required, the additional steps to be taken are these:

5.Hold dial firmly, insert screwdriver through center of dial, and push calibration stem inward. DO NOT TURN THIS STEM.

6.While holding calibration stem in firmly with screwdriver, turn dial until it is set at the actual oven temperature as shown by your test instrument. Release pressure on calibration stem. Replace dial insert.

7.Set dial at 400°F (205°C) mark. Check temperature again, as instructed in steps 3 and 4. If the temperature is not within 20°F (11°C) of the dial setting (400°F or 205°C), it means that the sensing element is inoperative and the control should be replaced.

Figure 12

 

Thermostat Calibration and Bypass Flame Adjustment

 

 

Bypass Adjuster

 

Calibration Stem

Dial Insert

Bezel

 

Dial

 

CONVERSION FROMONETYPE OFGAS TOANOTHER

Each range is shipped adjusted and equipped for a specific type of gas (either natural gas or propane). To convert a range from one type of gas to another, do the following:

1.Refer to service procedures to access all burner orifices.

2.Refer to instructions included with conversion kit.

3.Follow all steps as indicated in the conversion kit.

4.Check for leaks and proper manifold pressure (the procedure is on page 26).

5.Re-lightall pilots and check for proper operation.

Note: A kit for conversion to a different type of gas may be purchased from Southbend.

OWNERS MANUAL 1190820 REV 3 (11/10)

PAGE29 OF48

SERVICE

ULTIMATERESTAURANTRANGES

Figure 13

Wiring Diagram for Gas Oven

PAGE30 OF48

OWNERS MANUAL 1190820 REV 3 (11/10)