Blodgett COS-5HA Installation Manual

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COSĆ5HA

INSTALLATION AND OPERATION INSTRUCTIONS

FOR SHIPBOARD USE

FSCM 07695

BLODGETT COMBI

www.blodgett.com

44 Lakeside Avenue Burlington, Vermont 05401 USA Telephone (800) 331Ć5842, (802) 860Ć3700 Fax: (802)864Ć0183

PN R10303 Rev K (4/09)

E 2009 - Blodgett Corporation

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SAFETY SUMMARY

The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These recommend precautions that personnel must understand and apply during many phases of operation and mainteĆ nance.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must at all times observe all safety regulations. Do not replace comĆ ponents or make adjustments inside the equipment with the high voltage supply turned on. Under certain conditions, dangerous potentials may exist when the power control is in the off position, due to the charge retained in capacitors. To avoid casualties, always reĆ move power and discharge and ground a circuit before touching it.

DO NOT SERVICE OR ADJUST ALONE

Under no circumstances should any person reach into or enter the enclosure for the purĆ pose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering aid.

RESUSCITATION

Personnel working with or near high voltages should be familiar with modern methods of resuscitation.

The following appear in the text of this volume, and are repeated here for emphasis.

WARNING:

Before performing any mainteĆ nance or replacing any component on this unit, disconnect oven from electrical source.

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APPROVAL AND PROCUREMENT RECORD

APPROVAL DATA FOR: COSĆ5H

Electric Combination Oven

TITLE OF MANUAL: Technical Manual, COSĆ5H

Electric Combination Oven

APPROVAL AUTHORITY: Defense General Supply Center

Letter Dated ?? ??? ??

CONTRACT NO. NSN NO. OF UNITS APL

REMARKS

DATE: 5 Mar 98

CERTIFICATION:

It is hereby certified that the technical manual provided under contract number XXXĆXXXĆ XXĆXĆXXXX for COSĆ5H has been approved by the approval data shown above.

(Signed) _____________________________

Tim Thaler

(Title) Director of National Accountsą

Blodgett Combi 44 Lakeside Avenue Burlington, VT 05401 FSCM 07695

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COMMANDING OFFICER NAVAL SHIP WEAPON SYSTEMS ENGINEERING STATION NAVAL SEA DATA SUPPORT ACTIVITY (CODE 5B00) PORT HUENEME, CA 93043-5007

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IMPORTANT

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INĆ STALLATION, OPERATING AND MAINTENANCE INĆ STRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

The information contained in this manual is important for the proper installation, use, and maintenance of this oven. Adherence to these procedures and instructions will result in satisfactory baking results and long, trouble free service. Please read this manual carefully and retain it for future reference.

Errors: Descriptive, typographic or pictorial errors are subject to correcĆ

tion. Specifications are subject to change without notice.

A PERSONAL WORD

FROM BLODGETT COMBI

Congratulations on your purchase of the BLODGETT CombiĆOven/Steamer. We firmly believe that your choice has been a wise one, and trust you will reĆ ceive many years of excellent service from your new multiĆpurpose oven.

The CombiĆOven/Steamer concept offers completely new potential for cookĆ ing which minimizes shrinkage, while maintaining food's essential vitamins and valuable nutrients. In addition, you will find that cooking with the CombiĆ Oven/Steamer will save time, labor and extensive cleaning of both the kitchen and the appliance.

With the CombiĆOven/Steamer the quality, taste, consistency, and look of the food are improved, thus endorsing the policy to which we've always adhered: For Better Cooking!"

Once you've had a chance to use your multiĆpurpose oven, please tell us, your dealer and colleagues about any creative and interesting applications you have discovered; exchange ideas with other users. Be sure to advise us or your dealer immediately should any mechanical or technical problems be enĆ countered (...we're here to help!) and above all Enjoy Cooking the BLODGETT CombiĆOven/Steamer Way!

Your Service Agency's Address:

Model:

Serial Number:

Your oven was installed by:

Your oven's installation was checked by:

Introduction

The Blodgett CombiĆOven/Steamer

For quite some time, commercial cooking equipĆ ment has remained more or less unchanged. There are kettles, deck ovens, the good old range with its legion of pots āand āmany āother āextra āappliances. The result: time expenditure, excesĆ sive manual work, and countless cleaning proĆ cesses. The last āāāfew āāāyears āāhave āāpaved āāthe āāway āāfor āa revolution in the equipment of restaurant and inĆ stitutional kitchens.

The Blodgett CombiĆOven/Steamer offers a comĆ pletely new method of cooking. With the Oven/ Steamer you have the choice of two cooking proĆ cesses: Steam and Hot Air, either...

D Separately D Combined, or D In Sequence

And for easy operation you can choose from three modes:

Steam Hot Air

Combi

Steam &

Hot Air

In the Steam mode you can:

steam reheat reconstitute stew thaw simmer blanch preserve braise poach

In the Hot Air mode you can

roast bake grill gratinate broil

In the Combination Steam and Hot Air mode you can:

defrost roast rethermalize reheat bake forced steaming

Not āāonly āāthat, āāyou āācan āāuse āātwo āāor āthree functions in sequence during one cooking process. We call this:

D combiĆsteaming D combiĆroasting D combiĆbaking

The combination of circulating hot air and steam in the space saving, high performance CombiĆ Oven/Steamer leads to improvements in the folĆ lowing areas:

D increased productivity in the kitchen D a reduction in capital expenditures for multiple

equipment replacement

D a wider range of menu choices D a simplified cleaning process

The work process is simplified since products are prepared on or in steam table āpans āand trays. Food can be cooked, stored, and transported with āthe āsame āāpans. āSmall āamounts of product can be processed efficiently; preĆcooked and conveĆ nience foods can be reheated within minutes. āMany frozen foods can be processed without preĆ thawing. This flexibility in preparation reduces the need for kettles and steam tables since there is no need for large amounts of food to be kept warm for long periods of time.

Today the improvement of food quality is more imĆ portant than ever. Vegetables are cooked in the Blodgett CombiĆOven/Steamer without water at the optimal temperature of just under 212_F/100_C, maintaining valuable vitamins, minĆ erals, nutrients and trace elements.āā Cooking meat in the Combi results in less shrinkage and a firmer, juicier product. The Blodgett CombiĆOven/SteamĆ er is being used more and more for baking. Steam and Hot āAir āmodes āmake āit āa āgeneral āpurpose bakĆ ing appliance.

Introduction

Description of the CombiĆOven/Steamer

ABOUT THE OVEN/STEAMER

Blodgett CombiĆOven/Steamers are quality proĆ duced using highĆgrade stainless steel with first class workmanship.

The high performance fresh steam generator with its control system makes it possible to enjoy all of the advantages of a high quality steamer at the flick of a switch. Fresh steam enters the oven cavĆ ity without pressure and is circulated at high speed. This process enables quick and gentle cooking and ensures high quality food while proĆ viding convenient working methods. The steam generator is completely automatic and protected from running dry.

The exhaust system is effective in all cooking modes and results in better quality foods and no flavor transfer. The fan, which is guarded against accidental finger contact, is driven by a quiet and powerful motor. The condenser draws out excess steam from the appliance. Condensation and waste water, which result during steaming and cleaning, are continuously drained.

The use of high quality insulation impedes excesĆ sive heat radiation and saves energy.

OVEN/STEAMER OPERATION

Ease of operation is guaranteed through the simĆ ple arrangement of the controls. Graphic symbols make the appliance easy for even inexperienced kitchen staff to operate. Steam, Hot Air and Combi modes can be selected with one switch. A fourth function on the mode selection switch, the Cool Down mode, allows the oven cavity to cool down rapidly with the door opened or closed.

Cleaning is kept to a minimum. The interior is sprayed with a selfĆacting cleaning solution which interacts with steam to easily remove crusts and stains. The oven is designed for easy care and is welded water tight so that the internal cooking cavity may be rinsed with a hose after the steam cleaning process.

SPECIFICATIONS - COSĆ5HD/AB

Electrical

Specifications 440Ć480 VAC, 3 phase, 44 KW, 58 amps

Water Atmospheric Vented Drain

Water Pressure 40 PSI (276 kPa) minimum

50 PSI (345 kPa) maximum

Water Connection 3/4" NPT Female

Introduction

Oven Features

2 23

Standard Features

1 Control Panel

2 Oven Doors

3 Rotating Door Latch

4 Base Section

Figure 1

5 Deliming Port

6 Deliming Handle

7 Optional Meat Probe

8 Door Drip Pan

Installation

General Installation Information

The purpose of the installation section of this manual is to assist the designers and naval archiĆ tects engineering the installation of a Blodgett Combi COSĆ5HA Hatchable Combination Oven into a new or existing ship.

Blodgett Combi has developed the COSĆ5HA to fit in the same footprint as a Blodgett Mark V convecĆ tion Oven. The COSĆ5HA Combination oven can be used as a convection oven, steamer, or in a Combi" mode in which pulsed steam is comĆ bined with convection to provide faster cooking and increase the moisture content of cooked foods. Because of these features, the oven utilizes water for generating steam. The Combi is a multiĆ system cooking oven and is more complex than a convectional oven. Therefore, more attention has to be paid to the installation process than that of a convection oven.

The COSĆ5HA requires the following support sysĆ tems:

D Power 440 VAC, 3 phase, 60 amp service D Water Potable, 40 to 50 psi D Drain Atmospheric vented drain,

1" minimum diameter

D Hood Air venting required for steam

removal

THE INSTALLATION INSTRUCTIONS CONĆ TAINED HEREIN ARE FOR THE USE OF QUALIĆ FIED INSTALLATION AND SERVICE PERSONNEL ONLY. INSTALLATION OR SERVICE BY OTHER THAN QUALIFIED PERSONNEL MAY RESULT IN DAMAGE TO THE OVEN AND/OR INJURY TO THE OPERATOR.

Qualified installation personnel are individuals, a firm, a corporation, or a company which either in person or through a representative are engaged in, and are responsible for:

D The installation of electrical wiring from the elecĆ

tric meter, main control box or service outlet to the electric appliance.

Qualified installation personnel must be experiĆ enced in such work, be familiar with all precauĆ tions required and have complied with all requireĆ ments of state or local authorities having jurisdiction.

Reference: National Electrical Code, ANSI/NFPA

70-Latest Edition and/or Canadian Electrical Code CSA C22.1 as applicable.

This equipment is to be installed in compliance with the Basic Plumbing Code of the Building OffiĆ

cials and Code Administrators International Inc. (BOCA) and the Food Service Sanitation Manual of the Food and Drug Administration (FDA).

Appliance is to be installed with backflow prevenĆ tion in accordance with applicable federal, provĆ ince and local codes.

Installation

Delivery and Location

DELIVERY AND LOCATION

The COSĆ5HA hatchable combination oven is shipped fully assembled on a special vibration reĆ sistant pallet. In addition, the oven is mounted on two hardwood skids to facilitate removal from the pallet. These skids were designed to match the height of the separate installation base. This alĆ lows the assembled oven to be slid directly onto the base after the installation base is mounted in position and hard plumbed with potable water and electric power.

COSĆ5HA dimensions:

Height 62.25" with legs

68.25" with 6" legs 65" with base

Width 38.19"

Depth 44.13"

The following clearances are required for the COSĆ5HA:

Sides 0" Rear 6"

UNPACKING

1. Remove the protective cover around the oven. Inspect the unit for visible damage.

2. Remove the bolts that lock the 2Ć1/2" x 4" hardwood skids to the pallet base.

3. Use a forklift to raise the oven assembly off the pallet. The skids can be left in position to assist in moving an assembled oven onto the instalĆ lation base or discarded after the oven assemĆ bly is unbolted into separate components for passage through hatches.

ASSISTANCE

Blodgett Combi also provides engineering assisĆ tance when custom installation kits are required. Our goal is to ensure that each oven installation can be made in the most efficient and economical manner.

For further information, please contact the BlodĆ gett Combi Engineering Department:

D Phone 1Ć800Ć331Ć5842 D Fax 802Ć860Ć3702

Installation

Installation Base

There are two installation base configurations. If you do have a base with leg feet, (this configuraĆ tion is rarely used on board Navy vessels) proceed to the next page and continue the installation proĆ cedure.

The Blodgett Combi COSĆ5HA utilizes a stainless steel locking installation base. The base is availĆ able with or without legs. The installation base was designed to facilitate the installation process and to improve the access to the oven if and when maĆ jor service is required.

Since the COSĆ5HA is slightly narrower than the installation base, multiple bases can be installed side by side on the deck with no allowance for side clearance.

1. Secure the 2Ć1/2" high installation base using

one of the following methods: a.) Weld the base directly to the deck. b.) Bolt the base to the deck.

2. Seal the base with an NSF approved sealant.

1.44

INSTALLATION BASE

Figure 2

33.91

38.37

Installation

Installation Base

INSTALLATION BASE WITH OPTIONAL LEGS

Figure 3

1.44

33.91

38.37

Installation

Utility Connections

WATER CONNECTION

The oven requires access to potable water with an inlet pressure of approximately 40 to 50 PSI.

1. The water is connected to the rear of the instalĆ lation base at the 3/4" NPT female coupling.

Figure 4

2. The water is directed to the oven through an inĆline pressure regulator and a flexible interĆ nal hose which connects to a fitting in the front of the oven. (Set at 35 psi.)

DRAIN CONNECTION

The unit is provided with an optional wrotĆcopper soldered end tube fitting reducer 3" x 2" funnel that may be fixed to the installation base. For multiple oven installations, install a deck mounted sloping drain with individual funnels positioned to accept the drain outlets of the individual ovens.

The power requirement of the oven is 440 volt, 3 phase, 60 amp service.

1. The electrical service is brought into the oven through the seal tight connector located on the rear of the installation base.

2. The power leads are brought into a water proof terminal box located in the front of the installation base.

3. A grounding stud is supplied on the inside of the installation base. See Figure 6.

Connect

Hose Here

Figure 6

Figure 5

Installation

Oven Installation - No Dismantling Required

Use this procedure if the oven assembly does not have to be dismantled to bring it into the galley where the installation base has been fitted.

1. Slide the oven assembly on the shipping skids in front of the installation base.

2. Remove the two 1/2" bolts from the front of the installation base. See Figure 7.

1/2" Bolt

Figure 7

3. Unscrew the front panel from the oven base section. Leave the hoses connected to the front panel and the oven base section.

4. Remove the two bolts securing the skids to the front of the oven base section. See Figure 8.

1/2" Bolt

5. Remove the two bolts and angle plates securing the skids to the rear of the oven base section. See Figure 9.

Bolt & Plate

Figure 9

6. Move the oven assembly to the installation base as follows:

a.) Lubricate the top surface of the installaĆ

tion base with a little grease or silicone spray.

b.) Slide the oven assembly off the skids onto

the tracks of the installation base.

c.) The locking pins on the rear of the oven

base section will fit into and lock the base to the upright tabs attached to the installaĆ tion base.

7. Reinstall the two bolts that were removed in Step 2, from the installation base through the oven base section into the installation base. See Figure 8 for installation location.

8. Hook up water and electrical connections to the oven base section. Refer to Figure 4 and Figure 5 on page 9 for water connection locaĆ tions.

Bolt & Plate

Figure 8

Installation

Oven Installation - Some Dismantling Required

Use this procedure if the oven assembly will be dismantled to bring it into the galley where the installation base has been fitted.

The assembled oven consists of three sections:

D upper oven section D lower oven section D oven base section.

The oven base section consists of the major elecĆ trical components, steam generators, and the atĆ tachment components for mating the oven asĆ sembly to the installation base which is mounted directly to the deck. In order to dismantle the oven assembly, you will have to separate electrical wire harnesses and plumbing lines. We recommend that you tape both sides of each electrical and hose connection and mark them for easy identifiĆ cation during reassembly.

If you are installing more than one oven assembly, keep all hardware and panels associated with one oven assembly separate from the other oven asĆ semblies. If the oven assembly has to be disĆ mantled in order to fit through the hatches, use the following procedure:

OVEN DISMANTLING

1. Remove the racks from the inside of both the upper and lower oven sections. See Figure 10.

2. Remove the side support racks from the inĆ side of both the upper and lower oven secĆ tions. See Figure 11.

Figure 11

3. Remove the drip pan from the front of both ovens. See Figure 12.

Figure 10

Figure 12

Installation

Oven Installation - Some Dismantling Required

4. Remove the upper and lower screws holding the control panel cover. See Figure 13. Do this to both the upper oven and the lower oven.

Mounting Screw

Figure 13

5. Remove the control panel cover by sliding it forward. The upper and lower side edge must clear the front trim.

6. Remove the right side rear panel by sliding it forĆ ward about an inch and then lifting the entire paĆ nel to free the retaining springs. See Figure 15. Do this to both the upper oven and the lower oven.

Figure 14

Figure 15

Oven Installation - Some Dismantling Required

7. On the rear of the COSĆ5HA oven, loosen four hose clamps so you can remove the copper drain assembly. Loosen the two clamps closĆ est to the oven drains and the two clamps conĆ necting the drains to the top vent assembly. Remove the drain assembly. See Figure 16.

Hose Clamps

Installation

Figure 17

Hose Clamps

Figure 16

8. The oven base section has electrical and plumbing fittings connected to both upper and lower oven sections. To separate the three oven sections (base, upper & lower) you will need to disconnect these fittings. Refer to Figure 17. Disconnect the large black multiĆ pin wire connectors in each section.

9. Disconnect the white multiĆpin connectors in the upper and lower oven sections. See Figure 17.

10. Disconnect the three hot air electrical wires from the terminal blocks in both the upper and lower oven sections. Also remove the three wires in the small terminal block below the eleĆ ment wires. (Both sections) See Figure 18.

Figure 18

Installation

Oven Installation - Some Dismantling Required

11. Disconnect the two wires to the lower fan only. Remove the rear body panel on the lower oven section and the rear body panel on the base. Refer to Figure 19.

Figure 19

12. Refer to Figure 20. Remove the two screws holding the conduit bracket in place in the botĆ tom oven section. Slide the bracket out of the way and reinstall the two screws. This bracket needs to be loose so the wire harnesses can be routed out of the upper and lower oven secĆ tions to separate the three sections.

securing the bracket holding the 90_ brass fitĆ ting to the frame. See Figure 21. Repeat for other connector.

NOTE: Silver pipe insulation not shown for

clarity.

14. Remove the three bolts (1/2 inch diameter) that connect the top and lower oven sections together.

Two bolts are located in the rear upper left and right corners of the lower oven section. These bolts can be accessed from the back of the lower oven section. See Figure 23.

The third bolt is accessed from the right side of the lower oven section. It is located in the upper right hand corner. See Figure 24.

Figure 20

13. To the left of the lower oven drain is a 90_ brass

fitting. Disconnect the upper straight steam connect fitting with a wrench from both the 90_ brass fittings. Next remove the two bolts

Handle

Figure 21

Handle

Figure 22

Installation

Oven Installation - Some Dismantling Required

Bolt

Figure 23

15. Remove the upper oven section from on top of the lower oven section. Use care not to chafe any of the harnesses that come from the base section. Use gloves to protect hands from any sharp edges.

16. Unscrew the front panel from the oven base section by removing the perimeter screws only. Slide the tray forward approximately 12" by pulling on the two U" shaped handles. See Figure 22. Leave the hoses connected to the front panel and the oven base section.

17. Remove the four bolts (1/2 inch diameter) that connect the lower oven section and oven base section together.

Two bolts are located in the rear upper left and right corners of the oven base section. These bolts can be accessed from the back of the oven base section. See Figure 24 and Figure 25.

The third bolt is accessed from the right side of the oven base section. It is located in the upĆ per front right hand corner. See Figure 26.

The fourth bolt is accessed from the left side of the oven base section. It is located in the upĆ per front left hand corner. See Figure 27.

18. Remove the lower oven section from atop the oven base section. Use care not to chafe any of the harnesses that come from the base secĆ tion. Use gloves to protect hands from any sharp edges.

Figure 24

Figure 25

Figure 26

Figure 27

Installation

Oven Installation - Some Dismantling Required

OVEN REĆASSEMBLY

After the installation base has been secured in position, connect the potable water line and elecĆ trical wires to the base assembly. Insure that all utiĆ lities are OFF before beginning the reassembly of the COSĆ5HA oven. The power distribution box loĆ cated in the base must have a service loop such that it will reach the main input power terminal blocks located in the center, rear of the base oven section.

1. Remove the two 1/2" bolts from the front of the installation base. See Figure 28.

1/2" Bolt

Figure 28

2. Lubricate the top surface of the installation base with a little grease or silicone spray. PosiĆ tion the oven base section onto the flat track surface of the installation base approximately 4" to 5". Support the front of the oven base section with a piece of 2" pipe (2Ć3/8" OD approximately) by 39" (minimum) long.

3. Apply a 1/8 inch bead of clear silicone RTV to the perimeter of the top edge of the oven base section. Lift the lower oven section onto the oven base section. Use gloves to protect hands from any sharp edges.

1/2" Bolt

4. Install the four bolts (1/2 inch diameter) that connect the lower oven section and oven base section together.

Two nuts are located in the rear lower left and right corners of the lower oven section. These nuts can be accessed from the back of the oven base section. See Figure 24 and Figure 25 on page 15.

The third nut is accessed from the right side of the oven base section. It is located in the lower front right hand corner of the lower oven secĆ tion. See Figure 26 on page 15.

The fourth nut is accessed from the left side of the oven base section. It is located in the lower front left hand corner of the lower oven secĆ tion. See Figure 27 on page 15.

5. Carefully route the wires from the base oven section into the lower oven section. Resecure the conduit in place with the two screws. See Figure 20.

6. Apply a 1/8" bead of clear silicone RTV to the perimeter of the top edge of the lower oven section. Lift the upper oven section onto the lower oven section. Use gloves to protect hands from any sharp edges.

7. Install the three bolts (1/2 inch diameter) that connect the top and lower oven sections toĆ gether.

Two nuts are located in the rear lower left and right corners of the upper oven section. These nuts can be accessed from the back of the lower oven section. See Figure 29.

The third nut is accessed from the right side of the lower oven section. It is located in the upĆ per front right hand corner of the upper oven section. See Figure 30.

Oven Installation - Some Dismantling Required

Bolt

Figure 29

Bolt

Figure 30

8. Refer to Figure 31. To the left and right of the lower oven drain is a 90Ćdegree brass fitting. Refit the mounting bracket for the 90Ćdegree fitting in place and attach the two mounting bolts which secure it. Reconnect the upper straight steam connect fittings with a wrench to both of the 90 degree brass fittings.

Installation

9. Install the rear body panel to the lower oven, but leave the bottom row of screws off so you can install the rear body panel to the base secĆ tion later.

10. Reconnect the electrical wires in the upper and lower oven sections. Each section has a large black multiĆpin connector, two large white connectors, and three element wires. In the lower oven section reconnect the fan wires to the cool fan in the rear. Refer to previous FigĆ ures 16,17, & 18.

11. Install the funnel drain as follows: a.) Hold the funnel bracket and fasten the

wrap around bracket around the funnel using the 10Ć24 screws.

b.) Using the 1/4Ć20 screws, fasten the funnel

bracket to the bottom of the install base. Refer to Figure 32.

12. Review instructions in STEPS 1 thru 11 to enĆ sure that all connections have been made propĆ erly, hoses are not kinked, and all electrical wire harnesses are routed correctly to prevent chafe or damage.

13. Complete the attached checklist document.

Figure 31

Installation

Oven Installation - Some Dismantling Required

14. Slide the COSĆ5HA oven until it is about 1' from locking into the rear of the installation base. Insure that the potable water line from the base oven section is connected to the installation base. Refer to Figure 4 and Figure 5 on page 9 for water connection locations. Connect the electrical wire service loop to the base oven section in the center, rear where the power terminal block is located

15. Slide the oven assembly back onto the installaĆ tion base. The locking pins on the rear of the oĆ

Funnel

Wrap Around

Bracket

ven base section will fit into and lock the base to the upright tabs attached to the installation base. Install the two bolts (1/2 inch diameter) reĆ moved in STEP 1 (Figure 28), thru the oven base section and into the installation base.

16. Install the rear panel to the base oven section. Locate the copper drains. Reinstall the top and bottom copper drains. Tighten all hose clamps. See Figure 16 and Figure 32.

INSTALLATION COMPLETE. PROCEED WITH CHECKĆOUT PROCEDURE.

Wrap Around

Bracket

Figure 32

Funnel

Oven Installation - Some Dismantling Required

OVEN INSTALLATION CHECKLIST

j Installation base secured j Potable water connected j Electrical power connected j Removed bolts from install base j Lubricated install base, positioned oven j Siliconed top edge of oven base j Installed bolts to oven base and lower oven j Installed rear body panel j Siliconed top edge of lower oven j Installed bolts that connect lower oven to top

oven

Installation

j Installed rear body panel j Reconnected steam line j Reconnected electrical wire harnesses j Installed optional funnel drain, if applicable j Check for not kinks, no chance of chafing on

harness

j Replaced control panels j Slide oven back into place j Hooked water and electrical to base

Operation

Oven Startup and Shutdown

OVEN STARTĆUP

1. Turn the mode switch to the desired mode, Steam, Hot Air, Combi, Cool Down.

STEAM MODE

1. Turn the mode switch selector knob to the Steam Position. The green POWER" indicaĆ tor lamp illuminates on the front control panel.

2. Steam fills the cavity and is controlled by a nonĆaccessible internal thermostat.

Preheating for the STEAM mode

Before the first use of the appliance, daily or after the oven has been idle for 3 hours, preheat with the STEAM function until steam enters the oven cavity. The appliance can then be loaded.

HOT AIR MODE

1. Turn the mode selector switch to the Hot Air position. The green POWER" indicator lamp illuminates on the front control panel.

2. Set the Hot Air thermostat to the desired temĆ perature. The Thermostat lamp illuminates inĆ dicating the cavity temperature is below the desired set point.

3. When the cavity temperature reaches the deĆ sired set point, the temperature indicator lamp goes off.

Preheating for the HOT AIR mode

COMBI MODE

1. Turn the mode selector switch to the Combi position. The green POWER" indicator lamp illuminates on the front control panel.

2. Set the Hot Air thermostat to the desired temĆ perature.

3. The hot air thermostat lamp illuminates, indiĆ cating the cavity temperature is below the deĆ sired set point.

4. Once the cavity temperature reaches the deĆ sired set point, the temperature indicator lamp goes off.

5. The steam and hot air modes come on to satĆ isfy the thermostat set points.

Preheating for the COMBI mode

Always preheat the appliance prior to loading. Open the door and load the product quickly.

COOL DOWN

1. Turn the mode selector switch to the Cool Down mode.

2. The convection blower comes on with the door open or closed.

OVEN SHUT DOWN

1. Turn the mode selector switch to the off posiĆ tion.

Always preheat the appliance prior to loading. Open the door and load the product quickly.

Operation

Standard Controls

CONTROLS IDENTIFICATION SEE FIGURE 33

1. DON'T STEAM LIGHT

Indicates the unit is too hot to operate in the steam mode. Place the unit in the Cool Down mode until the temperature is below 230_F (110_C). This light does not inhibit steam proĆ

duction.

2. POWER ON LIGHT

Indicates the unit is in Steam, Hot Air or Combi.

3. MODE SELECTOR SWITCH

Turns power to the oven on or off. Allows seĆ lection of Steam, Hot Air, Combi or Cool Down Modes.

4. TEMPERATURE DIAL

Used to set desired cooking temperature.

5. HEATING INDICATOR LIGHT

Lights when the Hot Air heating is in operation.

6. TIMER DIAL

Used to set desired cooking time.

7. FAN SPEED SWITCH

Used to select low or high speed.

NOTE: When looking through the door the blower

rotation must be clockwise.

Figure 33

Operation

Standard Controls

OPERATION

1. Turn the MODE SELECTOR Switch (3) to the desired function.

The POWER ON Light (2) illuminates.

2. Set the TIMER (6) for the desired cooking time or set it to STAY ON. The buzzer sound and the unit shuts off when the time has expired.

3. For the HOT AIR and COMBI modes, set the TEMPERATURE Dial (4) to the desired cook temperature. The HEATING INDICATOR Light (5) illuminates and stays lit until the desired temperature is reaches.

4. The selected mode operates automatically. The temperature, time and mode can be alĆ tered at any time during the cooking process. The operation can be stopped by the use of the Mode Selector Switch or by opening the door.

5. At the end of the specified time period, the buzzer sounds and the appliance will shut off automatically. Move the TIMER (6) to the STAY ON position to stop the buzzer and restart the unit.

6. To cool down the oven cavity, switch the MODE SELECTOR Switch (3) to COOL DOWN. In the Cool Down mode neither the temperature dial or the timer will be operationĆ al. The blower will function with the door open or closed.

7. The mode selector switch is also the main power switch. In the OFF position the apĆ pliance is not operational.

NOTE: Always disconnect the power supply beĆ

fore servicing the unit.

Operation

Optional Meat Probe

CONTROLS IDENTIFICATION SEE FIGURE 34

1. MEAT PROBE SWITCH

Controls power to the meat probe.

2. MEAT PROBE CONTROL

Use to set the desired probe temperature. InĆ dicates the actual temperature of the product

3. MEAT PROBE CONNECTOR

Receptacle for the plug in meat probe.

NOTE: For sanitation it is recommended that

the meat probe remain plugged into the front panel receptacle at all times.

OPERATION

Measuring the product core temperatures during long roasting periods is very practical. It is espeĆ cially important for products such as Roast Beef to reach a specific internal temperature.

Place the probe through to the middle of the prodĆ uct's thickest section. Be sure the probe does not touch any bone and the tip is not in a fat pocket. These conditions can cause inaccurate readings.

1. Set the MODE SELECTOR Switch to the deĆ

sired function.

2. Turn the MEAT PROBE Switch (1) to ON.

3. To set the desired core temperature press the

blue SET BUTTON (4) on the MEAT PROBE CONTROL (2).

Use the up arrow key (6) to increase the setĆ point temperature. Use the down arrow key (5) to decrease the setpoint temperature.

Press the set button again to store the setĆ point.

4. Set the TIMER to STAY ON. The cooking proĆ

cess runs automatically. When the selected core temperature is reached,

the buzzer will sound and the appliance shuts off automatically.

The temperature and mode can be changed at any time during the process.

5. Shut the appliance off by setting all switches

to OFF.

NOTE: When setting the internal temperature, be

sure to allow for carryĆover cooking after the roast is removed from the oven

Figure 34

WATLOW

1 2 RDY

SET

4 5 6

Cooking Guide

The Hot Air Mode

INFORMATION ABOUT THE HOT AIR MODE

How cooking with hot air works

Hot air is circulated at high speed on all sides of the product, providing a concentrated cooking process. This function is extremely effective for inĆ tensive browning.

What can be cooked with hot air

Hot air can be used for all foods which need a short cooking time and intensive ābrowning. For examĆ ple: steaks, cutlets, fillets, breaded foods, and varĆ ious baked foods. This function may also be used for au gratin.

COOKING WITH THE HOT AIR MODE

Temperatures

For intensive browning and crispy crusts, preheat the oven to the maximum temperature of 500_F/260_C. This is especially important when searing.

Performance

The charts showing performance examples (See Cooking Guide) are based on full capacity. Better results may be obtained by reducing product quantities.

Cooking Times

Due to the constant hot air circulation, this apĆ pliance cooks faster than conventional grills and deck ovens.

Cooking times will vary according to the quality, weight, and height of the product.

Trays or Racks?

This is a question of individual choice. Racks have the advantage of browning food on all sides; the underside of tightly packed foods may be lighter when using trays.

TIPS AND PROCEDURES

Loading the Oven

Place like sized product together on one rack. āāIn order to ensure proper air circulation, racks āand ātrays āshould ānot āābe āācrowded.

Oiling

The quality of some foods, such as steaks and breaded meats, can be enhanced by coating with oil or a paprika oil mixture.

Breaded Foods

The degree of browning is dependent on the amount of raw material in the breading. Oil can be used to intensify the browning. Press the breading firmly but don't overload the oven. Flouring seared foods is not recommended.

Baking

For baking, the Mode selector switch may be set to HOT AIR, STEAM, COMBI or any combination according to the type of product. Steam added to the baking process opens up a wide range of posĆ sibilities: such as hard crusts and good shine on certain types of breads. Here are some tips for baking:

D Preheat oven to the baking temperature. D Baking ātemperatures ācan āgenerally āābe set

50Ć75_F/20Ć25_C lower than with a conventionĆ al baking or roasting oven. When in doubt, lowĆ er the temperature.

D Theā bakingā timeā canā be āshorterā than āwith conĆ

ventional methods.

D Slightly reduce your quantities of mixtures with

excessive moisture.

D Use ādeep trays for light mixtures in order to enĆ

sure undisturbed baking. Baking forms should not be higher than 3 inches.

D Cakeā āāformsā ā(āpans, āāātins,ā āāetc.), āāāshould be placed

on racks.

D Distributeāā foods āāevenly āwhenā āloading half loads. D Use āevery āsecond ātierā for baking bread,ā heavyāā

mixtures (yeast doughs, etc.) and well filled forms.

INFORMATION ABOUT THE STEAM MODE How steaming works

This mode gently cooks food using nonĆpressurĆ ized steam. Fresh steam is directed into the oven from the generator. It is not necessary to add water to foods during the cooking process.

What can be steamed

Vegetables, side dishes, fish, meat, poultry, diet foods, garnishes, dumplings, casseroles, meat loaf, fruits, desserts and eggs.

How to operate the Steam mode

Simply turn the Mode Selector Switch to the STEAM position and set the Timer.

The advantages of steaming

Steaming āis āa wellĆknown cooking process freĆ quently used in restaurant and institutional kitchĆ ens. With this appliance it is now possible to enjoy the many advantages of steaming, some of which are:

D Shorter Cooking Times

The continuous processing of large amounts of product is no problem and long cooking times are no longer necessary. Even with full loads, relatively shorter cooking time for food is needĆ ed.

Cooking Guide

The Steam Mode

D High Quality Foods

With ātheā useāāāofā steam,ā valuable taste and aroma are preserved since steamed foods retain their own natural taste. During the steaming process foods retain the nutrients and vitamins which are lost in water during boiling. Therefore, when compared, steamed foods have much āābetter color than foods that have been boiled. āAlso,ā by using shallow containers the product is not layĆ ered as deeply and mushing is avoided.

D Vitamin Retention

Vitamins are not destroyed. This is due to the shorter cooking times, the use of less or little water and the use of a low temperature; slightly less than 212_F/100_C.

D Firmness

With the use of steam, overcooking āisā notā a problem and firmness can be individually conĆ trolled.

D Simultaneously Steaming Different Foods

There is no flavor transfer when cookingā āwithā ātheā āSTEAM āāmode. For this reason, various types of food with different cooking times can be loaded or removed at any point during the cooking proĆ cess.

Cooking Guide

The Steam Mode

TIPS AND PROCEDURES

Containers

Both solid and perforated steam table pans of vaĆ rying sizes (full, half, and oneĆthird size) may be used in the appliance. Small pans may be placed on wire racks.

Stocks for Sauces

When trays are used for cooking there is usually enough stock collected for making sauces. When using perforated pans, insert a solid pan in the botĆ tom rack to collect the stock.

Seasoning

Since there is no liquid added during the steaming process, season using one of the following methĆ ods:

D Season before cooking: Sprinkle the spice

mixture evenly over the food prior to cooking.

D Oil seasoning after cooking: Stir the oil mixĆ

ture into the product. Steam again for two minĆ utes in some cases.

Blanching and Prep Work

Large amounts of product can be blanched in a short amount of time. Trays should not be filled higher than 3 inches.

The STEAM mode is excellent for preparing vegeĆ tables for peeling.

Canning and Preserving

The diameter of the containers must not exceed 4Ć5 inches when canning.

Thawing

Thawing time is much shorter when using steam and produces higher quality food.

Reheating

The use of steam creates an even distribution of heat, which gives food better taste and retention of nutrients.

Foods are reheated in the trays in which they were cooked. Reheating times vary according to the height and content of the containers.

SAMPLE DISHES

Vegetables

Fresh and frozen vegetables may be steamed toĆ gether. Frozen vegetables should be loosely scatĆ tered on the trays. Perforated trays shorten cookĆ ing time, although solid trays may be used.

Cooking times will vary depending on the quality of the vegetables. When āsteaming āfresh āvegetaĆ bles, āācheck the product 3/4 of the way through the āācooking āāperiod.

Steamed vegetables tend to soften after cooking. āāāSinceāāāthereāāāāisāāāāaāāāādelay between cooking and serving, it is best not to steam āvegetables too āsoft.ā Thisā āis āāespecially important for foods prepared for transĆ port.

Rice and Potatoes

Rice requires the addition of water for steaming. Remember that the rice continues to swell after cooking; plan your quantities accordingly.

Always cook potatoes in perforated pans. Steam can permeate the potatoes better if they are quarĆ tered through the width and not the length.

Eggs

Eggs are inserted onto wire racks, either in the cardboard container or placed into perforated trays (there is no need to puncture them). Cooking eggs with the STEAM function saves work and reĆ sults in less waste since steamed eggs do not break. Also, the degree of hardness ācan ābe āconĆ trolled āexactly. Begin timing when the oven winĆ dow is misted over.

Fish

Fish ācan ābe steamed āin āātrays āāwithout using extra stock. Use a 1 inch pan for fresh fish (Fillets). For larger or frozen pieces, use a 2 inch pan.

Poached fish can be prepared with aromatic herbs āand āvegetables āin āeither āsolid āor perforated pans. Steam without stock.

Shell fish can be steamed in perforated pans. Use a solid pan to catch drippings for stock.

Cooking Guide

The Combi Mode (Steam and Hot Air)

INFORMATION ABOUT THE COMBI (STEAM AND HOT AIR) MODE

How Combi Mode Works

With this function, the advantages of steam (short cooking time, less shrinkage) and hot air (intenĆ sive aroma, appetizing color) are combined. Steam and hot air circulate at high speeds, āenvelĆ oping āthe product āon all sides and providing an inĆ tensive cooking process.

What can be cooked in Combi mode?

All types of roasts, duckling, pork, beef, lamb, meat loaf, ground chuck foods, casseroles, poulĆ try, āstuffed vegetables, vegetables au gratin and yeast doughs.

The advantages of Combi mode?

D Productivity

Previously, several different appliances, and multiple procedures, were necessary to comĆ bine āāāheat andāāāsteam preparation. Now all of these āmethods āācan āābe āāused āāwithout ātime wastĆ ing interruptions, with one appliance.

D Less Shrinkage

The āāāusual āāāweight āāāloss āāāduring āāāāroasting āāāāin conĆ ventional appliances can be reduced by apĆ proximatelyā ā13%āāā āofāāā ātheāā āāoriginalāā weight.

D Juiciness and Crunchy Crusts

When used at the beginning of the cooking proĆ cedure, the searing action of steam instantly closes āall āpores. āThis āreduces āāthe āloss of protein āand āmeat ājuices. Therefore, products with long roasting times remain juicy. Foods retain their moisture and roasts develop a āpleasing ācolor āas āwell āāas āāan āāappetizing crust. āMeats āāhave āāa proĆ nounced āroasted taste and āāburning āāof āāthe āāsurĆ face āis āāalmost impossible.

COOKING IN THE COMBI MODE

The COMBI function can be used for āthe āentire cooking process or for any portion of the cooking procedure you desire.

What do CombiĆroasting, CombiĆsteaming and CombiĆbaking mean?

We have created these names since both modes, STEAM and HOT AIR, can be applied in any comĆ bination as follows:

D Together, as in the COMBI function. D In sequence

Example: first STEAM and then HOT AIR.

D Or in sequence and then in combination

Example: first HOT AIR and then COMBI Or conversely: first COMBI and then HOT AIR.

D Or all three functions in sequence

Example: first STEAM, then HOT AIR, then COMBI.

For additional tips on when to use each of these Combi Modes see the Summary of Functions" on the following page.

Cooking Guide

Summary of Functions

MODE SELECTION COOKING METHODS PRODUCTS

Steam

Hot Air

Combi

Steam Hot Air

Hot Air Combi

Steaming, defrosting, thawing, reĆ heatingĆreconstituting, blanching, preserving, poaching, simmering, braising, stewing.

Roasting, grilling, baking, au gratin.

CombiĆsteaming, CombiĆroasting, CombiĆbaking, defrostingĆthawing, reheatingĆreconstituting.

CombiĆsteaming, CombiĆbraising, CombiĆroasting, CombiĆbaking,

(Begin with steam, then with dry heat for crusting, browning, gratinating.)

CombiĆsteaming, CombiĆroasting, CombiĆbaking,

(Start with dry heat, switch over to Combi for slow but gentle even browning, switch back and forth as necessary.)

Convenience food, potatoes, rice, fresh or frozen vegetables, fresh or frozen fish, poultry, meat, fruit, eggs, puddings, casseroles.

Roast beef, pork, veal, lamb, chickĆ en, hamburger, fish, stuffed vegetaĆ bles, toast, lasagne, potatoes, pies, shortbread, puff pastry, Danish and French pastry, bread.

Prime rib, whole bone ham, goose, turkey, fish, mutton, beef, pork roast, French pastry, bread, rolls, puff pastry, Danish pastry, convenience food.

Stuffed peppers, gratinated vegetaĆ bles, fennel, broccoli, cauliflower, rack of lamb, pork

French pastry, puff pastry, yeast dough, turkey, duck, goose, lamb, stuffed vegetables.

Combi Hot Air

Steam Hot Air Combi

CombiĆbraising, CombiĆroasting, CombiĆbaking,

(Start with Combi, finish with dry heat for crusty, crisp, brown surface, switch back and forth as necessary.)

CombiĆsteaming, CombiĆroasting, CombiĆbaking,

(For meats: sear pores closed with steam, then brown with dry heat, then switch between Combi and dry heat. For stuffed vegetables: steam first and switch between dry heat and Combi during the rest of the cooking process.)

Whole bone ham, ham in bread dough (English Ham), whole fillets of beef, pastry dough, yeast dough (bread, rolls).

Veal, pork, beef, leg of lamb, goose, duck, turkey, prime rib, puddings, stuffed peppers; ideal for all prodĆ ucts which need a humid cooking process.

Cooking Guide

General Tips and Procedures

USING RACKS

Use racks for roasts needing a longer roasting time, large roasts (pork, veal, beef, venison, lamb), searing, toast, au gratin, (chicken, duck, goose, legs, chops), cooking in containers, thawĆ ing, baking in tins, etc. When cooking in racks it is important to turn food products.

USING PANS

D 1I Deep Steam Table Pan

For fried potatoes, hamburgers, au gratin, thawĆ ing, meat loaf, meat balls, fried, poached and steamed fish, baked goods, vegetable casseĆ roles, duck and goose.

D 2I Deep Steam Table Pan

For ācabbage ārolls, āstuffed āpeppers, āstews, ārice, āvegetables, āsauerkraut, āassorted āfruits āand ācompote. āAlso āfor ācollecting āāstock, preparing sauces, etc.

D 2½IDeep Perforated Steam Table Pan

For vegetables without stock, side dishes (breads) and products with shorter cooking times.

D 4IDeep Perforated Steam Table Pan

For vegetables (blanching spinach for examĆ ple), potatoes, shelled or unshelled eggs.

D 6IDeep Perforated Steam Table Pan

For potatoes.

LOADING THE OVEN

To ensure that the product will brown on all sides, do not āplace āfoods ātoo āclose togetherā. Place the grain of meats parallel to the air stream ā(left āāto āāright). āāThis āāensures āābetter āabsorption and shortĆ ens the cooking process. Place like sized pieces together on the same rack, smaller pieces cook more quickly.

Place the food in the appropriate pans/trays or disĆ tribute it on the racks. Insert racks and trays into the pan rack. It is recommended that the pan rack be loaded outside of the oven when processing large amounts of product. The pan rack for table models āis āwell āsuited āfor this purpose; it allows āfor a higher hourly production and an efficient work sequence.

REMOVING THE PRODUCT

Turn the Mode Selector Switch to OFF before opening the appliance door.

NOTE: Open the door slowly after steaming! Hot

Steam Will Be Present!

COOKING TIMES

The length of the cooking process depends on the quality, weight and thickness of the food product.

TEMPERATURES

Typically, the longer the cooking process, the lowĆ er the temperature.

Cooking Guide

Suggested Times and Temperatures

PRODUCT SUGGESTED CORE TEMPERATURE

Beef

Fillet of Beef

Roast Beef

Pot Roast

Veal

Saddle of Veal

Loin

Shoulder

Stuffed or Boned

Leg, TopĆside

Pork

Leg

Picnic Shoulder

Ham

Smoked Pork Chops

Ribs

Tongue

medium rare

well done

medium

well done

fricandeau

well done

juicy

well done

130_Ć140_F

170_F

160_F

165_Ć175_F

165_Ć170_F

172_F

185_F

155_F

158_F

150_F

195_F

54_Ć60_C

78_C

70_C

75_Ć80_C

75_Ć78_C

78_C

85_C

85_Ć80_C

68_C

70_C

90_C

Poultry

Chicken

Goose

Turkey, Duck

Lamb

When the meat is well done it has a core temperature between 173_Ć185_F (79_Ć85_C). The core has a slightly pink color and the juices are clear.

Saddle

Leg

Pâtés

Pâté 160_Ć165_F72_Ć74_C

NOTE: Actual temperatures may vary from those shown. Write in your proven temperatures for ready refĆ

erence.

well done

slightly pink

well done

slightly pink

well done

185_F

195_Ć198_F

175_Ć185_F

158_Ć165_F

175_F

165_Ć170_F

180_Ć185_F

85_C

90_Ć92_C

80_Ć85_C

70_Ć75_C

80_C

75_Ć78_C

82_Ć85_C

Cooking Guide

Notes

Maintenance

Cleaning and Preventive Maintenance

CLEANING THE INTERIOR

Daily cleaning of the appliance is essential for sanĆ itation, and to ensure against operational difficulĆ ties.

For difficult cleaning, allow the sprayĆon oven cleaner to work longer before rinsing.

1. Cool āāthe āoven down to 140_F/60_C or, if the

āāovenāā has āābeenā āidle, āāturnā the steam modeā onā foār 3 āto ā4ā minutesā inā order āāāto warm the oven surfaces.

2. Spray āāthe āinteriorā of āātheāā ovenā with a cleaning solution.

NOTE: Never spray water into the unit when

the temperature is above 212_F. NEVĆ ER SPRAY WATER IN THE UNIT AFTER USING THE HOT AIR OR COMBI MODES.

3. Let āthe ācleanerā āworkāā for āā10ā toā 20 minutes withāāāāā the āāāāovenā āāāāoff.āāā āForā āādifficult, baked on grease, etc. allow to work over night.

4. Set the timer for 15 to 20 minutes.

5. Set āātheā āmodeā āāselector switch to Steam. This will soften all burned on residue.

6. Rinseāā āātheāāā āovenāāāāā interiorā āāāwithāāāāā waterāā (a hose mayāā ābeāā āused,āā ābut āāātakeāā careā thatā only āātheā āoven'sā inĆ terior cavity is sprayed with water).

7. Setā āāātheā āāāmode āāāselectorāāā toā āāsteam āāāforā anotherā five minutes to flush out the oven interior and reĆ move all detergent residue.

NOTE: The āoven ācavity ā should ā never ā be scoured

or scraped.

On stainless interiors, deposits of baked on splatĆ ter, oil, grease or light discoloration āmay ābe āreĆ

moved āwith āa good non toxic industrial stainless steel cleaner. Apply cleaners when the oven is cold and always rub with the grain of the metal. The racks, rack supports and the blower wheel may be cleaned in the oven or by removing them from the āoven āand āsoaking āthem in a solution of ammonia and water.

NOTE: DO NOT use corrosive cleaners on the

Oven/Steamer.

CLEANING THE EXTERIOR

Oven exteriors may be cleaned and kept in good condition with a light oil. Saturate a cloth and wipe the oven when it is cold; wipe dry with a clean cloth.

WARNING!!

DO NOT spray the outside of the apĆ pliance with water.

PREVENTIVE MAINTENANCE

The best preventive maintenance measures are āāāthe āāāproper āāinitial āāinstallation āāof āāthe equipment and a program for cleaning the oven routinely. The Oven/Steamer requires no lubrication. Contact the factory, the factory representative or a local Blodgett Combi service company to perform maintenence and repairs should they be required.

WARNING!!

Disconnect appliance from power supply before servicing or cleaning.

Maintenance

Decalcification

The COSĆ5HA has a separate boiler for each unit. There are deliming ports and handles for each boiler located on the base unit. The left deliming port and handle is for the bottom unit. The right deliming port and handle is for the top oven. To save time the boilĆ ers should be delimed simultaneously.

The COSĆ5HA should be delimed on a monthly baĆ sis regardless of water quality or usage. Use the following procedure to delime the boilers.

WARNING!!

ALWAYS USE PROPER SAFETY EQUIPĆ MENT WHEN DELIMING. Gloves and eye safety equipment are recommended.

1. Set both mode selector switches to Steam

mode. Wait until steam is produced. This will ensure that the water in the steam generators is hot.

2. Turn the mode selector switches to OFF.

3. Remove both deliming port covers on the

base unit.

4. Add 10 ounces of deliming solution to the deĆ

liming bottle and then add 1Ć3/4 gallons of warm water.

NOTE: LimeĆaĆwayt or a generic equivalent

are recommended. The main active ingredient should be a deluted conĆ centration of phospheric acid.

5. Delime the boilers as follows:

a.) Connect the deliming hose to one of the

deliming ports on the base section.

b.) Turn the corresponding red deliming hanĆ

dle on the base unit so it is vertical. This

opens the deliming port. c.) Pump in all of the solution. d.) Close the deliming handle and remove

the deliming hose from the deliming port.

The handle is now horizontal.

6. Repeat STEPS 4 and 5 for the other oven.

7. Allow the ovens to sit with the deliming soluĆ tion in them for at least 1/2 hour.

NOTE: For heavy lime build up, allow to stand

for 1 hour.

8. Drain and flush the boilers as follows: a.) Connect a drain hose to one of the delimĆ

ing ports. Allow the boiler to drain comĆ pletely. The drain hose is not supplied.

b.) Carefully rinse out the deliming container

and fill it with 1Ć3/4+ gallons of fresh water only.

c.) Turn the oven to Steam and allow the boilĆ

er to fill. Wait at least 2 minutes.

d.) Connect the deliming pump to the same

deliming port on the base section.

e.) Turn the red deliming handle on the base

unit so it is vertical. This opens the delimĆ ing port.

f.) Pump in all of the water in the deliming

pump.

g.) Close the deliming handle and remove

the deliming hose from the deliming port. The handle is horizontal.

h.) Connect the drain hose to the same deĆ

liming port on the base section.

i.) Turn the red deliming handle on the base

unit so it is vertical. This opens the delimĆ

ing port. j.) Let all the water drain from the boiler. k.) Remove the drain hose and turn the hanĆ

dle to the horizontal position.

9. Repeat STEPS b. and 8 for the other boiler.

10. Reattatch the covers to the deliming ports.

Deliming

Deliming Port

Port

Figure 35

Maintenance

Troubleshooting Top Oven Section

HOW TO USE THIS TROUBLESHOOTING GUIDE

Always troubleshoot the circuit in the following sequence. Troubleshoot each oven section this way. Go from: 1) COOL DOWN 2) HOT AIR 3) STEAM 4) COMBI

If the oven shorts or trips the redundant contactor when selecting the mode switch to the COOL DOWN position, shut off the main breaker, turn the mode selector switch to COOL DOWN and then turn the main breaker back on.

COOL DOWN MODE

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Motor doesn't run in cool down.

NOTE: The COSĆ5H has a redundant contactor (K1 & K6) which are in series with the 440V operating

components (hot air & steam elements, motors). If a redundant contactor is tripped, the conĆ trol circuit lights will work (green OVEN ON (H6) and hot air (H5) but the motors and elements will not work until the fault is determined and the redundant contactor is reset.

S Main circuit breaker is OFF

S StepĆdown transformer (T1) is defective

S Mode selector switch (S1) is not closing beĆ

tween terminals 23 & 24

S Motor contactor K8 is not closing

S The motor overload (OL6) has tripped.

S The circuit overload (K6) has tripped.

S Verify the main breaker is not tagged out or the

breaker has tripped. If the main breaker is tripped, there is a high probability of a steam or hot air eleĆ ment short. Proceed to the appropriate trouble shooting section and review. Overload has tripped. Isolate which oven section is tripping the breaker.

S Verify 440V input to the transformer. Check the

transformer coils. Approximately 2.2 ohms priĆ mary / .7 ohms secondary. Output is 220VAC. Replace if needed.

S Verify switch is closing with meter. Replace if

needed.

S The contactor coil resistance is approximately

1.39K ohms. Verify voltage between the coil A1 and A2.

S Check windings of motor. Resistance of windĆ

ings is approximately 85 ohms. Running current is .5 plus amps. To reset the overload, lift the plastic cover and push in test reset. Verify the overload setting, .63. Review Convection Motor runs Intermittently" before replacing.

S See following circuit description

Maintenance

Troubleshooting Top Oven Section

Each oven section has a redundant contactor that will not allow the high voltage controls to work (hot air elements, steam elements, & convection moĆ tors) should a fault be detected. Review the followĆ ing fault probable causes. If you reset a fault, you must determine the route cause of the overload. When the circuit overload trips, it breaks all 3 inĆ coming legs to the hot air elements, steam eleĆ ments, and motor. It also has an auxiliary contact which breaks the return leg to the contactor coils in the low voltage control circuit to these associatĆ ed components.

1. The steam generator high limit (TAS1) has tripped. Proceed to Steam Mode" to deterĆ mine cause.

2. The motor overload (OL6) has tripped. Review motor overload has tripped in Cool Down".

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Convection motor runs intermittently.

S Thermal overload on motor (M1) is opening and

closing (automatically resets when cooled).

3. The steam overload (OL2) has tripped. ProĆ ceed to Steam Mode" to determine cause.

4. The hot air overload (OL4) has tripped. ProĆ ceed to Hot Air Mode" to determine cause.

NOTE: Overloads have an LED on them which

flashes when an overload is tripped.

5. Two consecutive flashes - indicates a current overload / probable element short

6. continuously ON" - indicates a phase fault: high / low / missing one or more legs

7. On / Off continuous flash - the overloads are smart" and will recognize if all the high voltĆ age legs are not wired in phase. This can hapĆ pen on initial start up if a leg is reversed (moĆ tors running backwards (clockwise) or a componant has been changed and not wired exactly as taken out).

S Check current draw. See if motor seal is out of

alignment. (Requires removal of blower wheel.) Adjust seal if needed. Evaluate motor. Replace if defective.

S Electrical compartment cooling fan is not running.

NOTE: The phrases boiler" or steam generator" are used interchangeably. The COSĆ5HA has an atmoĆ

spheric steam generator". The reason is for clarity and brevity.

S Check windings on fan (600+ ohms coil resistĆ

ance) if open, replace.

Maintenance

Troubleshooting Top Oven Section

HOT AIR MODE

NOTE: Confirm cool down works before proceeding with hot air.

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the hot air position but no control panel lights are on.

S Cavity high limit (F3) is open. (opens at 662_F)

S Oven has over temped. Hot air thermistor is out of

tolerance. Unplug from thermostat and check reĆ sistance. (Use ohm chart) Replace if needed.

S Defective hot air thermostat. Replace

S Cavity high limit is defective. Replace

S Power on light (H4) has 220V but is not lit.

S Mode selector switch (S1) is not closed between

terminals 9 & 10.

SYMPTOM: Hot air temperature light (H5) will not come on but power on light (H4) is lit.

S Oven is up to temperature.

S Door switch (S2) is not closing.

S Relay (R5) is open.

S Replace light (H5)

S Defective mode selector switch (S1). Replace

switch.

S Everything is OK.

S Proximity door switch (S2) is not engaging. ReĆ

move access plate & inspect. Replace if defective.

S Optional meat probe control has reached temĆ

perature and shut off oven by supplying 220V to terminals 7 & 8 on (R5).

S Relay (R5) is defective. Replace

S Timer (S4) has timed out to zero minute position.

S Reset timer to a timed position or fully into the stay

on position if continued operation is desired.

S Defective timer (S4).

S Replace timer (S4). Verify voltage 220V is presĆ

ent on terminals 6 & 7 before replacement.

Maintenance

Troubleshooting Top Oven Section

HOT AIR MODE (continued)

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Hot air temperature light (H5) will not come on but power on light (H4) is lit. (continued)

S Hot air thermostat (P5) is not getting 220V at

inputs L1 and C.

S Hot air thermostat (P5) is getting voltage 220V to

inputs but has no 220V to terminal NO" and common.

S Check wire connections.

S Hot air thermistor probe is bad or out of tolerĆ

ance. Refer to OHM chart. Replace if needed. 77 = 100,000 212 = 6,780 347 = 1,070.

S Defective hot air temperature control (P5). ReĆ

place.

SYMPTOM: No heat in Hot Air Mode but hot air (H5) and power light (H4) are both on.

S Motor is running and the centrifugal switch is

open.

S Hot air contactor (K5) does not pull in.

S Hot air contactor (K5) is energized 220V at coil

but no heat.

S OHM out switch (red wires in motor) while motor

is running, if it is open, remove motor and inspect centrifugal switch through access plate for loose or disconnected wires. Replace if defective. If you reĆ place a motor, always replace the motor seal.

S Verify 220V to coil, A1 & A2. The coil resistance

is approximately 400 ohms. Replace if needed.

S Verify settings on the Hot air overload (OL4) The

RC (A) should be set at 16 amps. The TIMER(S) should be set at 0" (This is a time delay function and is not used). The elements are wired such that there is a balance load. Use your meter, go between L1 to L2, L2 to L3, and L3 to L1 at the hot air contactor (K5) on the red wires that go to the elements. The resistance should be 45 to 49 ohms. If not, you have lost a hot air element. Individual elements ohm out at 66 ohms. Verify voltage on all 3 legs. If the hot air overload (OL4) LED is on or flashing review The circuit overload (K6) has tripped" in the COOL DOWN section for LED logic.

SYMPTOM: Oven appears to be working properly, but the bake pattern has changed or is uneven.

S One or more hot air elements are open. S Check continuity of elements. Replace as needed.

Maintenance

Troubleshooting Top Oven Section

STEAM MODE

NOTE: Confirm cool down and hot air modes work before continuing. By checking hot air mode first, you

have trouble shot all common components in both the hot air and steam mode up to and through the timer (S4).

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the steam mode position but power light is off.

S Mode selector switch (S1) is not closed between

terminals 3 & 4.

S Power on light (H4) is defective.

S High limits (F3) has tripped.

S Defective mode selector switch (S1). Replace

mode switch.

S Replace light.

S Return to Troubleshooting Hot Air Mode.

SYMPTOM: Steam generator overfills.

S FILL CIRCUIT LOGIC S Inside the steam generator is a ball float with a reed

switch. The reed switch is opened and closed by a magnet built into the float. The float reed switch is connected to the Y1 terminal on the float deĆ bounce timer (TMR3). If the float is closed for 2 secĆ onds (supplying power to the Y1 terminal) it changes the float debounce timer (TMR3) NC" terminal to open" and closes" the NO" terminal supplying power to fill solenoid (SOL2). Once full, power is resupplied to terminal NC", this terminal in turn is connected a Boiler Duty Cycle control (TMR4), terminal C". The Boiler Duty Cycle conĆ trol supplies power to the steam contactor (K3) on a duty cycle of 2.4 minutes ON" and 36 seconds OFF". Settings for the float controls are shown beĆ low. Visually inspect your timers to determine which ones you have.

BIOLER DUTY CYCLE CONTROL

TMR 2 & 4

Crouzet

TLR1

1Ć10 min

2.5

6Ć60 sec

Carlo Gavazzi

DHA51

60 sec

2.5

6 sec

FLOAT DEBOUNCE TIMER

TMR 1 & 3

Crouzet

TUR1

1Ć10 sec

Carlo Gavazzi

DCB61

No Settings

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Steam generator overfills.

Maintenance

Troubleshooting Top Oven Section

S Float assembly is hanging up.

S The Float Debounce timer has failed.

S Solenoid is staying open.

S Excessive water pressure to the solenoid.

SYMPTOM: TOO HOT FOR STEAM light is on.

S TOO HOT FOR STEAM light is an information

light only, if it is ON" it does not affect operation

SYMPTOM: Mode switch is in the steam mode, power on light is on, but no steam.

NOTE: If the water level is not maintained properly, a safety TAS2 (capillary type thermostat, opens

at 275F & must be manualy reset) Before continuing, review the sequence of operation to understand the float circuit / fill logic. (see previous page)

S Mode switch terminals 1 & 2 open

S Delime steam generator / remove float assembly

if needed and clean / move float assembly up / down, verify reed switch is opening & closing with VOM

S Replace as needed.

S Replace if needed, coil resistance is 1850 ohms

S Water regulator was not set to correct pressure,

adjust to 35psi.

S Open door and cool down cooking cavity if TOO

HOT FOR STEAM light comes on in the steam mode, P1 is defective.

S Use VOM to ohm out terminals, replace mode

switch in needed

S Mode switch terminals 5 & 6 open

S Boiler is not full of water due to:

Water solenoid (SOL2) is open

Water regulator is clogged or not working

S Use VOM to ohm out terminals, replace mode

switch in needed

S A quick way to see if you have water, is to open the

deliming port and see if water is present.

The resistance of the coil is about 560 ohms. Verify voltage to the coil.

Remove the regulator and inspect for water flow. Adjust regulator to proper pressure, 35 psi.

Maintenance

Troubleshooting Top Oven Section

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the steam mode, power on light is on, but no steam.

NOTE: If the water level is not maintained properly, a safety (TAS2) (capillary type thermostat, opens

at 275F & must be manualy reset) Before continuing, review the sequence of operation to understand the float circuit / fill logic.

S Redundant Contactor (K6) has tripped due to:

Boiler high limit (TAS2) has opened or tripped

An element has shorted.

Incoming power issue

S Continued resetting of the boiler high limit

(TAS2) will weaken the high limit and cause preĆ mature tripping.

Reset the (TAS2) high limit. Ball float (SW2) is hung up in the boiler and staying closed. A quick way to see if you have water, is to open the delimĆ ing port and see if water is present. Remove and inspect.

The Float debounce timer has failed such that NC" is staying closed all the time. Inspect to inĆ sure settings haven't been readjusted.

Verify settings on the Steam overload (OL2). The RC (A) should be set at 20 amps. The TIMER(S) should be set a 0". Use your meter, go between L1 to L2, L2 to L3, and L3 to L1. At the steam conĆ tactor (K3) on then blue wires that go to the eleĆ ments. The resistance should be 45 to 49 ohms. If not, you have lost a steam element. Individual elements ohm out at 115 ohms. Verify voltage on all 3 legs. If the Hot air overload LED is on or flashĆ ing review The circuit overload (K6) has tripped" in the COOL DOWN section for LED logic.

A lost leg or low voltage will trip the redundant contactor (K6).

S Coil for the fill solenoid (SOL2) is open / verify inĆ

put. Ohm out coil windings, should be approxiĆ mately 1850 ohms. Replace (SOL2) if needed.

Maintenance

Troubleshooting Top Oven Section

COMBI MODE

NOTE: Confirm cool down, hot air and steam modes work before continuing. By confirming previous

modes you have tested most of the components in Combi.

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the Combi position but no control panel lights are on.

S Mode selector switch (S1) terminals 21 & 22 are

open.

SYMPTOM: Power light (H4) is on, hot air heat light (H5) is on and off, but no steam.

S Mode selector switch (S1) terminals (15 & 16) or

(17 & 18) are open.

S Solid state combi timer is not operating. (no

steam in the combi mode only)

S Replace switch.

S Verify resister assembly (with adjusting knobs) is

plugged fully in

S Verify power in on terminals 2 & 3

S Verify output on terminal 1

S Verify timer knob settings (15 sec on" / 45 sec

off")

SYMPTOM: Power light (H4) is on, steam works, but no hot air.

S Mode selector switch (S1) terminals 19 & 20 are

open.

SYMPTOM: Not enough steam in the Combi mode.

S Cavity temperature is too high (over 400_F)

S Timing sequence needs adjusting to increase

steam.

S Replace switch.

S Reduce temperature.

S Left knob is time ON", right knob is time OFF"

Maintenance

Troubleshooting Top Oven Section

SEQUENCE OF OPERATION - COOL DOWN

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1,L2,L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer, (T1) 220V

4. Control circuit breaker (CB1)

5. Plug connector P3 terminal 9

6. Jack connector J3 terminal 9

7. Jack connector J9 terminal 21

8. Mode switch (S1) terminal 23 to 24

9. Jack connector J9 terminal 11

10. Jack connector J3 terminal 1

11. Plug connector P3 terminal 1

12. Motor contactor (K8) terminal A1 to A2

13. Terminal block L1,L2,L3 (440V/3ph)

14. Redundant contactor (K6) T1,T2,T3

15. Motor overload contactor (K8) L1,L2,L3

16. Motor overload protector (OL6) T1,T2,T3

17. Terminal block (TBĆ1,2,&3)

18. Convection motor

SEQUENCE OF OPERATION OVERLOAD SAFETY CIRCUIT

NOTE: Applies to all modes: Cool Down, Hot Air,

Steam and Combi

SEQUENCE OF OPERATION - COMBI

NOTE: Electricity flows through these components

in the order listed.

For the Combi mode both the HOT AIR and the STEAM MODE circuits are powered up. The steam circuit is cycled in at a timing interval of 15 seconds ON" and 45 seconds OFF". Refer to each circuit separately and substitute in the folĆ lowing sequence of operation.

Hot Air

10. Mode selector switch (S1) terminals 21 to 22

30. Mode selector switch (S1) terminals 19 to 20

Steam

10. Mode selector switch (S1) terminals 21 to 22

32. Mode selector switch (S1) terminals 15 to 16 Combi solid state timer 2 to 1 (ON" 15 seconds, OFF" 45 seconds)

33. SKIP

34. SKIP

35. SKIP

36. SKIP

37. Mode selector switch (S1) terminal 17 to 18

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1,L2,L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer (T1), 220V

4. Control circuit breaker

5. Boiler high limit (TAS2) terminal 11 to 1

6. Motor overload protector (OL6) terminal 95 to 96

7. Steam overload protector (OL2) terminal 95 to 96

8. Hot Air overload protector (OL4) terminal 95 to 96

9. Redundant contactor (K6) coil A1 to A2

SEQUENCE OF OPERATION - HOT AIR

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1, L2, L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down

440V to 220V)

3. Secondary coil of transformer (T1), 220V

4. Control circuit breaker (CB1)

5. Plug connector P3 terminal 9

6. Jack connector J3 terminal 9

7. Jack connector J9 terminal 21

8. Cavity high limit (F3) terminal 1 to 2

9. Jack connector J9 terminal 2

10. Mode switch (S1) terminal 9 to 10

11. Power ON light (H4)

12. Electrical compartment cooling fan (CF)

13. Jack connector J9 terminal 5

14. Door switch (S2)

15. Jack connector J9 terminal 13

16. Meat probe relay (R5) terminal 6 to 1

17. Timer (S4) terminals 4 to 6 or Timer (S4) termiĆ

nal 4 to 5, if timer is timed out

18. Buzzer (T1)

19. Jack connector J9 terminal 11

20. Power junction: to follow, motor operation.

Jump to step 30 to continue control circuit opĆ eration

21. Plug connector P3 terminal 1

Maintenance

Troubleshooting Top Oven Section

22. Motor contactor (K8) coil terminal A1 to A2

23. Auxiliary contact (K6ĆAUX) on Redundant conĆ tactor (K6)

24. Terminal block L1, L2, L3 (440V/3ph)

25. Redundant contactor (K6) terminals T1, T2, T3

26. Motor contactor (K8) terminals L1, L2, L3

27. Motor overload protector (OL6) terminals T1, T2, T3

28. Terminal block (TB2Ć1, 2, & 3)

29. Convection motor

30. Mode switch (S1) terminal 11 to 12

31. Hot air thermostat (P5) terminal C to L1

32. Hot air thermostat (P5) terminal COM to NO

33. Hot air light (H5)

34. Jack connector 9 terminal 10

35. Motor Centrifugal switch (CS1)

36. Jack connector J3 terminal 7

37. Plug connector P3 terminal 7

38. Hot air contactor (K5) terminal A1 to A2

39. Auxiliary contact (K6ĆAUX) on Redundant conĆ tactor (K6)

40. Terminal block L1, L2, L3 (440V/3ph)

41. Redundant contactor (K6) terminals T1, T2, T3

42. Hot air contactor (K5) terminals L1, L2, & L3

43. Hot air overload protector (OL4) T1, T2, & T3)

44. Terminal block (TB1Ć1 thru 6)

45. Hot air elements

Maintenance

Troubleshooting Top Oven Section

SEQUENCE OF OPERATION - STEAM

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1, L2, L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer (T1), 220V

4. Control circuit breaker (CB1)

5. Plug connector P3 terminal 9

6. Jack connector J3 terminal 9

7. Jack connector J9 terminal 21

8. Cavity high limit (F3) terminal 1 to 2

9. Jack connector J9 terminal 2

10. Mode switch (S1) terminal 3 to 4

11. Power junction: to follow, control circuit operaĆ tion. Jump to step 37 to go to fill circuit for boiler

12. Power ON light (H4)

13. Electrical compartment cooling fan (CF)

14. Jack connector J9 terminal 5

15. Door switch (S2)

16. Jack connector J9 terminal 13

17. Meat probe relay (R5) terminal 6 to 1

18. Timer (S4) terminals 4 to 6 or Timer (S4) termiĆ nal 4 to 5, if timer is timed out

19. Buzzer (T1)

20. Jack connector J9 terminal 11

21. Power junction: to follow, motor operation. Jump to step 32 to continue control circuit opĆ eration

22. Jack connector P3 terminal 1

23. Plug connector P3 terminal 1

24. Motor contactor (K8) coil terminal A1 to A2

25. Auxiliary contact (K6ĆAUX) on redundant conĆ tactor (K6)

26. Terminal block L1, L2, L3 (440V/3ph)

27. Redundant contactor (K6) terminals T1, T2, T3

28. Motor contactor (K8) terminals L1, L2, L3

29. Motor overload protector (OL6) terminals T1, T2,T3

30. Terminal block (TB2Ć1, 2, & 3)

31. Convection motor

32. Mode switch (S1) terminal 7 to 8

33. Jack connector J9 terminal 19

34. Too Hot to Steam thermostat (P1) terminal 31 to 34 (closes at 230F)

35. Jack connector J9 terminal 20

36. Don't steam light (H2)

37. Mode switch (S1) terminal 1 to 2

38. Jack connector J9 terminal 6

39. Jack connector J3 terminal 5

40. Boiler duty cycle control (TMR4) terminal A1 to A2

41. Mode switch (S1) terminal 5 to 6

42. Jack terminal J9 terminal 24

43. Jack terminal J3 terminal 10

44. Plug connector P3 terminal 10

45. Float debounce timer (TMR3) terminal A1 and C

46. Float (SW2) terminal 1 to 2

47. Float debounce timer (TMR3), if water level satisfied, Jump to step 43

48. Terminal C to NO if low water

49. Water solenoid (SOL2) terminal 1 to 2

50. Float dedounce timer (TMR3) terminal NC

51. Boiler duty cycle control (TMR4) terminal C to NO

52. Steam contactor (K3) coil terminal A1 to A2

46) Auxiliary contact (K6ĆAUX) on redundant contactor (K6)

53. Terminal block L1, L2, L3 (440V/3ph)

54. Redundant contactor (K6) terminals T1, T2, T3

55. Steam contactor (K3) terminals L1, L2, L3

56. Steam overload protector (OL2) terminals T1, T2, T3

57. Steam elements

Maintenance

Troubleshooting Bottom Oven Section

HOW TO USE THIS TROUBLE SHOOTING GUIDE

Always troubleshoot the circuit in the following sequence. Trouble shoot each oven section this way. Go from: 1) COOL DOWN 2) HOT AIR 3) STEAM 4) COMBI.

COOL DOWN MODE

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Motor doesn't run in cool down.

NOTE: The COSĆ5H has a redundant contactor (K1 & K6) which are in series with the 440V operating

components (hot air & steam elements, motors). If a redundant contactor is tripped, the conĆ trol circuit lights will work (green OVEN ON (H6) and hot air (H5), but the motors and eleĆ ments will not work until the fault is determined and the redundant contactor is reset.

S Main circuit breaker is OFF

S StepĆdown transformer (T1) is defective

S Mode selector switch (S1) is not closing beĆ

tween terminals 23 & 24

S Motor contactor K7 is not closing

S The motor overload (OL5) has tripped.

S The circuit overload (K6) has tripped

S Verify the main breaker is not tagged out or the

S Verify 440V input to the transformer. Check the

transformer coils. Approximately 2.2 ohms priĆ mary / .7 ohms secondary. Output is 220VAC. Replace if needed.

S Verify switch is closing with meter. Replace if

needed.

S The contactor coil resistance is approximately

1.39K ohms. Verify voltage between the coil A1 and A2.

S Check windings of motor. Resistance of windĆ

ings is approximately 85 ohms. Running current is .5 plus amps. To reset the overload, lift the plastic cover and push in ref test reset. Verify the overload setting, .63 review convection motor runs intermittently before replacing.

S See following circuit description

Maintenance

Troubleshooting Bottom Oven Section

Each oven section has a redundant contactor that will not allow the high voltage controls to work (hot air elements, steam elements, & convection moĆ tors) should a fault be detected. Review the followĆ ing fault probable causes. If you reset a fault, you must determine the route cause of the overload. When the circuit overload trips, it breaks all three incoming legs to the hot air elements, steam eleĆ ments, and motor. It also has an auxiliary contact which breaks the return leg to the contactor coils in the low voltage control circuit to these associatĆ ed components.

1. The steam generator high limit (TAS2) has tripped. Proceed to Steam Mode" to deterĆ mine cause.

2. The motor overload (OL5) has tripped. Review motor overload has tripped in Cool Down".

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Convection motor runs intermittently.

S Thermal overload on motor (M2) is opening and

closing (automatically resets when cooled).

3. The steam overload (OL1) has tripped. ProĆ ceed to Steam Mode" to determine cause.

4. The hot air overload (OL3) has tripped. ProĆ ceed to Hot Air Mode" to determine cause.

NOTE: Overloads have an LED on them which

flashes when an overload is tripped.

a.) Two consecutive flashes - indicates a

current overload / probable element short

b.) Continuously ON" - indicates a phase

fault : high / low / missing one or more legs

c.) On / Off continuous flash - the overloads

are smart" and will recognize if all the high voltage legs are not wired in phase. This can happen on initial start up if a leg is reĆ versed (motors running backwards (clockĆ wise)) or a component has been changed and not wired exactly as taken out.

S Check current draw. See if motor seal is out of

alignment. (Requires removal of blower wheel.) Adjust seal if needed. Evaluate motor. Replace if defective.

S Electrical compartment cooling fan is not running.

NOTE: The phrases boiler" or steam generator" are used interchangeably. The COSĆ5HA has an atmoĆ

spheric steam generator". The reason is for clarity and brevity.

S Check windings on fan (600+ ohms coil resistĆ

ance) if open, replace.

Maintenance

Troubleshooting Bottom Oven Section

HOT AIR MODE

NOTE: Confirm cool down works before proceeding with hot air.

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the hot air position but no control panel lights are on.

S Cavity high limit (F3) is open. (opens at 662_F)

S Oven has over temped. Hot air thermistor is out of

tolerance. Unplug from thermostat and check reĆ sistance. (Use ohm chart) Replace if needed.

S Defective hot air thermostat. Replace

S Cavity high limit is defective. Replace

S Power on light (H4) has 220V but is not lit.

S Mode selector switch (S1) is not closed between

terminals 9 & 10.

SYMPTOM: Hot air temperature light (H5) will not come on but power on light (H4) is lit.

S Oven is up to temperature.

S Door switch (S2) is not closing.

S Relay (R5) is open.

S Replace light (H5)

S Defective mode selector switch (S1). Replace

switch.

S Everything is OK.

S Proximity door switch (S2) is not engaging. ReĆ

move access plate & inspect. Replace if defective.

S Optional meat probe control has reached temĆ

perature and shut off oven by supplying 220V to terminals 7 & 8 on (R5).

S Relay (R5) is defective. Replace

S Timer (S4) has timed out to zero minute position.

S Reset timer to a timed position or fully into the stay

on position if continued operation is desired.

S Defective timer (S4).

S Replace timer (S4). Verify voltage 220V is presĆ

ent on terminals 6 & 7 before replacement.

Maintenance

Troubleshooting Bottom Oven Section

HOT AIR MODE (continued)

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Hot air temperature light (H5) will not come on but power on light (H4) is lit. (continued)

S Hot air thermostat (P5) is not getting 220V at

inputs L1 and C.

S Hot air thermostat (P5) is getting voltage 220V to

inputs but has no 220V to terminal NO" and common.

S Check wire connections.

S Hot air thermistor probe is bad or out of tolerĆ

ance. Refer to OHM chart. Replace if needed. 77 = 100,000 212 = 6,780 347 = 1,070.

S Defective hot air temperature control (P5). ReĆ

place.

SYMPTOM: No heat in Hot Air Mode but hot air (H5) and power light (H4) are both on.

S Motor is running and the centrifugal switch is

open.

S Hot air contactor (K4) does not pull in.

S Hot air contactor (K4) is energized 220V at coil

but no heat.

S OHM out switch (red wires in motor) while motor

S Verify 220V to coil, A1 & A2. The coil resistance

is approximately 400 ohms. Replace if needed.

Verify settings on the Hot air overload (OL4) The RC (A) should be set at 16 amps. The TIMER(S) should be set at 0" (This is a time delay function and is not used). The elements are wired such that there is a balance load. Use your meter, go between L1 to L2, L2 to L3, and L3 to L1 at the hot air contactor (K4) on the red wires that go to the elements the resistance should be 45 to 49 ohms. If not, you have lost a hot air element. IndiĆ vidual elements ohm out at 66 ohms. Verify voltĆ age on all three legs. If the hot air overload (OL3) LED is on or flashing review the circuit overload (K1) has tripped in the COOL DOWN section for LED logic.

SYMPTOM: Oven appears to be working properly, but the bake pattern has changed or is uneven.

S One or more hot air elements are open. S Check continuity of elements. Replace as needed.

Maintenance

Troubleshooting Bottom Oven Section

STEAM MODE

NOTE: Confirm cool down and hot air modes work before continuing. By checking hot air mode first, you

have trouble shot all common components in both the hot air and steam mode up to and through the timer (S4).

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the steam mode position but power light is off.

S Mode selector switch (S1) is not closed between

terminals 3 & 4.

S Power on light (H4) is defective.

S High limits F3 has tripped.

S Defective mode selector switch (S1). Replace

mode switch.

S Replace light.

S Return to Troubleshooting Hot Air Mode.

SYMPTOM: Steam generator overfills.

S FILL CIRCUIT LOGIC S Inside the steam generator is a ball float with a reed

switch. The reed switch is opened and closed by a magnet built into the float. The float reed switch is connected to the Y1 terminal on the float deĆ bounce timer (TMR1). If the float is closed for 2 secĆ onds (supplying power to the Y1 terminal) it changes the float debounce timer (TMR1) NC" terminal to open" and closes" the NO" terminal supplying power to fill solenoid (SOL2). Once full, power is resupplied to terminal NC", this terminal in turn is connected to Boiler Duty Cycle control (TMR2), terminal C". The Boiler Duty Cycle conĆ trol supplies power to the steam contactor (K2) on a duty cycle of 2.4 minutes ON" and 36 seconds OFF". Settings for the float controls are shown beĆ low. Visually inspect your timers to determine which ones you have.

BIOLER DUTY CYCLE CONTROL

TMR 2 & 4

Crouzet

TLR1

1Ć10 min

2.5

6Ć60 sec

Carlo Gavazzi

DHA51

60 sec

2.5

6 sec

FLOAT DEBOUNCE TIMER

TMR 1 & 43

Crouzet

TUR1

1Ć10 sec

Carlo Gavazzi

DCB61

No Settings

Maintenance

Troubleshooting Bottom Oven Section

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Steam generator overfills.

S Float assembly is hanging up.

S The Float Debounce timer has failed.

S Solenoid is staying open.

S Excessive water pressure to the solenoid.

SYMPTOM: TOO HOT FOR STEAM light is on.

S TOO HOT FOR STEAM light is an information

light only, if it is ON" it does not affect operation

SYMPTOM: Mode switch is in the steam mode, power on light is on, but no steam.

NOTE: If the water level is not maintained properly, a safety (TAS1) (caliary type thermostat, opens

at 275F & must be manualy reset) Before continuing, review the sequence of operation to understand the float circuit / fill logic.

S Mode switch terminals 1 & 2 open

S Delime steam generator / remove float assembly

if needed and clean / move float assembly up / down, verify reed switch is opening & closing with VOM

S Replace as needed.

S Replace if needed. Coil resistance is 1800 ohms.

S Water regulator was not set to correct pressure,

adjust to 35psi.

S Open door and cool down cooking cavity if TOO

HOT FOR STEAM light comes on in the steam mode, P1 is defective.

S Use VOM to ohm out terminals, replace mode

switch in needed

S Mode switch terminals 5 & 6 open

S Boiler is not full of water due to:

Water solenoid (SOL1) is open

Water regulator is clogged or not working

S Use VOM to ohm out terminals, replace mode

switch in needed

S A quick way to see if you have water, is to open

the deliming port and see if water is present.

The resistance of the coil is about 560 ohms. Verify voltage to the coil.

Remove the regulator and inspect for water flow. Adjust regulator to proper pressure, 35 psi.

Maintenance

Troubleshooting Bottom Oven Section

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the steam mode, power on light is on, but no steam.

NOTE: If the water level is not maintained properly, a safety (TAS1) (capillary type thermostat, opens

at 275F & must be manually reset) Before continuing, review the sequence of operation to understand the float circuit / fill logic.

S Redundant Contactor (K1) has tripped due to:

Boiler high limit (TAS1) has opened or tripped

An element has shorted.

Incoming power issue

S Continued resetting of the boiler high limit (TAS1)

will weaken the high limit and cause premature tripĆ ping.

Reset the (TAS1) high limit. Ball float (SW1) is hung up in the boiler and staying closed. A quick way to see if you have water, is to open the deliming port and see if water is present. Remove and inspect.

Verify settings on the Steam overload (OL 1). The RC (A) should be set at 20 amps. The TIMER(S) should be set at 0".Use your meter, go between L1 to L2, L2 to L3, and L3 to L1. At the steam contactor (K2) on then blue wires that go to the elements. The reĆ sistance should be 45 to 49 ohms. If not, you have lost a steam element. Individual elements ohm out at 115 ohms. Verify voltage on all three legs. If the Hot air overload LED is on or flashing review The cirĆ cuit overload (K6) has tripped" in the COOL DOWN section for LED logic.

A lost leg or low voltage will trip the redundant conĆ tactor (K1).

S Coil for the fill solenoid (SOL2) is open verify inĆ

put. Ohm out coild windings, should be approxiĆ mately 1850 ohms. Replace (SOL2) if needed.

Maintenance

Troubleshooting Bottom Oven Section

COMBI MODE

NOTE: Confirm cool down, hot air and steam modes work before continuing. By confirming previous

modes you have tested most of the components in Combi.

POSSIBLE CAUSE(S) SUGGESTED REMEDY

SYMPTOM: Mode switch is in the Combi position but no control panel lights are on.

S Mode selector switch (S1) terminals 21 & 22 are

open.

SYMPTOM: Power light (H4) is on, hot air heat light (H5) is on and off, but no steam.

S Mode selector switch (S1) terminals (15 & 16) or

(17 & 18) are open.

S Solid state combi timer is not operating. (no

steam in the combi mode only)

S Replace switch.

S Verify resister assembly (with adjusting knobs) is

plugged in fully

S Verity power in on terminals 2 & 3

S Verify output on terminal 1

S Verify timer knob settings (15 sec on" / 45 sec

off")

SYMPTOM: Power light (H4) is on, steam works, but no hot air.

S Mode selector switch (S1) terminals 19 & 20 are

open.

SYMPTOM: Not enough steam in the Combi mode.

S Cavity temperature is too high (over 400_F)

S Timing sequence needs adjusting to increase

steam.

S Replace switch.

S Reduce temperature.

S Left knob is time ON" /right knob is time OFF"

Maintenance

Troubleshooting Bottom Oven Section

SEQUENCE OF OPERATION - COOL DOWN

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1, L2, L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer (T1), 220V

4. Control circuit breaker (CB1)

5. Plug connector P4 terminal 9

6. Jack connector J4 terminal 9

7. Jack connector J9 terminal 21

8. Mode switch (S1) terminal 23 to 24

9. Jack connector J9 terminal 11

10. Jack connector J4 terminal 1

11. Plug connector P4 terminal 1

12. Motor contactor (K7) terminal A1 to A2

13. Terminal block L1, L2, L3 (440V/3ph)

14. Redundant contactor (K1) T1, T2, T3

15. Motor overload contactor (K7) L1, L2, L3

16. Motor overload protector (OL5) T1, T2, T3

17. Terminal block (TBĆ1,2,&3)

18. Convection motor

SEQUENCE OF OPERATION OVERLOAD SAFETY CIRCUIT

NOTE: Applies to all modes: Cool Down, Hot Air,

Steam and Combi

1. Terminal block L1, L2, L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer (T1), 220V

4. Control circuit breaker

5. Boiler high limit (TAS1) terminal 11 to 12

6. Motor overload protector (OL5) terminal 95 to 96

7. Steam overload protector (OL1) terminal 95 to 96

8. Hot Air overload protector (OL3) terminal 95 to 96

9. Redundant contactor (K1) coil A1 to A2

SEQUENCE OF OPERATION - COMBI

NOTE: Electricity flows through these components

in the order listed.

Hot Air

10. Mode selector switch (S1) terminals 21 to 22

30. Mode selector switch (S1) terminals 19 to 20

Steam

10. Mode selector switch (S1) terminals 21 to 22

32. Mode selector switch (S1) terminals 15 to 16 Combi solid state timer 2 to 1 (ON" 15 seconds, OFF" 45 seconds)

33. SKIP

34. SKIP

35. SKIP

36. SKIP

37. Mode selector switch (S1) terminal 17 to 18

Maintenance

Troubleshooting Bottom Oven Section

SEQUENCE OF OPERATION - HOT AIR

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1, L2, L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer, 220V

4. Control circuit breaker (CB1)

5. Plug connector P4 terminal 9

6. Jack connector J4 terminal 9

7. Jack connector J9 terminal 21

8. Cavity high limit (F3) terminal 1 to 2

9. Jack connector J9 terminal 2

10. Mode switch (S1) terminal 9 to 10

11. Power ON light (H4)

12. Electrical compartment cooling fan (CF)

13. Jack connector J9 terminal 5

14. Door switch (S2)

15. Jack connector J9 terminal 13

16. Meat probe relay (R5) terminal 6 to 1

17. Timer (S4) terminals 4 to 6 or Timer (S4) termiĆ nal 4 to 5, if timer is timed out

18. Buzzer (T1)

19. Jack connector J9 terminal 11

20. Power junction: to follow, motor operation. Jump to step 30 to continue control circuit opĆ eration

21. Plug connector P4 terminal 1

22. Motor contactor (K7) coil terminal A1 to A2

23. Auxiliary contact (K1ĆAUX) on redundant conĆ tactor (K1)

24. Terminal block L1, L2, L3 (440V/3ph)

25. Redundant contactor (K1) terminals T1, T2, T3

26. Motor contactor (K7) terminals L1, L2, L3

27. Motor overload protector (OL5) terminals T1, T2, T3

28. Terminal block (TB2Ć1, 2, & 3)

29. Convection motor

30. Mode switch (S1) terminal 11 to 12

31. Hot air thermostat (P5) terminal C to L1

32. Hot air thermostat (P5) terminal COM to NO

33. Hot air light (H5)

34. Jack connector 9 terminal 10

35. Motor Centrifugal switch (CS1)

36. Jack connector J4 terminal 7

37. Plug connector P4 terminal 7

38. Hot air contactor (K4) terminal A1 to A2

39. Auxiliary contact (K1ĆAUX) on redundant conĆ tactor (K1)

40. Terminal block L1, L2, L3 (440V/3ph)

41. Redundant contactor (K1) terminals T1, T2, T3

42. Hot air contactor (K4) terminals L1, L2, & L3

43. Hot air overload protector (OL3) T1, T2, & T3)

44. Terminal block (TB1 Ć1 thru 6)

45. Hot air elements

SEQUENCE OF OPERATION - STEAM

NOTE: Electricity flows through these components

in the order listed.

1. Terminal block L1, L2, L3 (440V/3ph)

2. Primary coil of transformer (T1) (step down 440V to 220V)

3. Secondary coil of transformer (T1) 220V

4. Control circuit breaker (CB1)

5. Plug connector P4 terminal 9

6. Jack connector J4 terminal 9

7. Jack connector J9 terminal 21

8. Cavity high limit (F3) terminal 1 to 2

9. Jack connector J9 terminal 2

10. Mode switch (S1) terminal 3 to 4

11. Power junction: to follow, control circuit operaĆ tion. Jump to step 37 to go to fill circuit for boiler

12. Power ON light (H4)

13. Electrical compartment cooling fan (CF)

14. Jack connector J9 terminal 5

15. Door switch (S2)

16. Jack connector J9 terminal 13

17. Meat probe relay (R5) terminal 6 to 1

18. Timer (S4) terminals 4 to 6 or Timer (S4) termiĆ nal 4 to 5, if timer is timed out

19. Buzzer (T1)

20. Jack connector J9 terminal 11

21. Power junction: to follow, motor operation. Jump to step 32 to continue control circuit opĆ eration

22. Jack connector J4 terminal 1

23. Plug connector P4 terminal 1

24. Motor contactor (K7) coil terminal A1 to A2

25. Auxiliary contact (K1ĆAUX) on redundant conĆ tactor (K1

26. Terminal block L1, L2, L3 (440V/3ph)

27. Redundant contactor (K1) terminals T1, T2, T3

28. Motor contactor (K7) terminals L1, L2, L3

Maintenance

Troubleshooting Bottom Oven Section

29. Motor overload protector (OL5) terminals T1, T2, T3

30. Terminal block (TB2Ć1, 2, & 3)

31. Convection motor

32. Mode switch (S1) terminal 7 to 8

33. Jack connector J9 terminal 19

34. Too Hot to Steam thermostat (P1) terminal 31 to 34 (closes at 230F)

35. Jack connector J9 terminal 20

36. Don't steam light (H2)

37. Mode switch (S1) terminal 1 to 2

38. Jack connector J9 terminal 6

39. Jack connector J4 terminal 5

40. Boiler duty cycle control (TMR1) terminal A1 to A2

41. Mode switch (S1) terminal 5 to 6

42. Jack terminal J9 terminal 24

43. Jack terminal J4 terminal 10

44. Plug connector P4 terminal 10

45. Float debounce timer (TMR1) terminal A1 and C

46. Float (SW1) terminal 1 to 2

47. Float debounce timer (TMR1), if water level satisfied, jump to step 43

48. Terminal C to NO if low water

49. Water solenoid (SOL1) terminal 1 to 2

50. Float dedounce timer (TMR1) terminal NC

51. Boiler duty cycle control (TMR2) terminal C to NO

52. Steam contactor (K2) coil terminal A1 to A2

53. Auxiliary contact (K1ĆAUX) on redundant conĆ tactor (K1)

54. Terminal block L1, L2, L3 (440V/3ph)

55. Redundant contactor (K1) terminals T1, T2, T3

56. Steam contactor (K2) terminals L1, L2, L3

57. Steam overload protector (OL1) terminals T1, T2, T3

58. Steam elements

Maintenance

Schematic - Top Oven

Figure 36

Maintenance

Schematic - Bottom Oven

Figure 37

Maintenance

Schematic - Oven Base Control

Figure 38

Maintenance

Schematic - Oven Base Power

Figure 39

Blodgett COS-5HA Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual