Duke 59-BS Service Manual

ELECTRIC CONVECTION OVEN

MODELS

5/9 THE OVEN 5/9 SERIES OVENS 6/13 THE OVEN E SERIES 59-E3C 59-E3P

SERVICE MANUAL

Please read this manual completely before attempting to

install, operate or service this equipment

Reproduction without written permission is prohibited. Duke is a registered

trademark of the Duke Manufacturing Co.

Duke Manufacturing Co.

2305 N. Broadway

St. Louis, MO 63102

Phone: 314-231-1130

Toll Free: 1-800-735-3853

Fax: 314-231-5074

www.dukemfg.com

P/N 153611B

Service Manual for Electric Convection Oven

IMPORTANT WARNING AND SAFETY INFORMATION

WARNING

READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR

PERFORMING MAINTENANCE ON THE EQUIPMENT.

WARNING

FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY

DAMAGE, INJURY OR DEATH.

WARNING

DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN

THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING

DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING

ALL COVER AND ACCESS PANELS.

CAUTION

Observe the following:

• Provide and maintain adequate minimum clearances from all walls and combustible materials.

• Provide and maintain adequate clearance for air openings.

• Keep the equipment area free and clear of combustible material.

• Operate equipment only on the type of electricity indicated on the specication plate.

• Retain this manual for future reference.

Service Manual for Electric Convection Oven

TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................................................................6

GENERAL .....................................................................................................................................................................6

INSTALLATION .............................................................................................................................................................6

OPERATION .................................................................................................................................................................6

CLEANING ....................................................................................................................................................................6

TOOLS ..........................................................................................................................................................................6

Standard.................................................................................................................................................................6

ELECTRICAL SPECIFICATIONS ..................................................................................................................................6

COMPONENT REMOVAL AND REPLACEMENT ................................................................................................................7

Electrical LOCKOUT/TAGOUT Procedure ....................................................................................................................7

RIGHT SIDE PANEL (OVENS WITH DUAL DOORS) ...................................................................................................7

X CONTROL PANEL ASSEMBLY .................................................................................................................................8

Component Access Procedure...............................................................................................................................8

POWER Switch ......................................................................................................................................................8

X Controller ............................................................................................................................................................8

OVEN READY Light ...............................................................................................................................................8

Fan Switch .............................................................................................................................................................8

Fuse and Fuse Holder ...........................................................................................................................................8

LIGHT Switch .........................................................................................................................................................8

XX CONTROL PANEL ASSEMBLY ...............................................................................................................................9

Component Access Procedure...............................................................................................................................9

POWER Switch ......................................................................................................................................................9

XX Controller ..........................................................................................................................................................9

OVEN READY Light ...............................................................................................................................................9

Fan Switch .............................................................................................................................................................9

LIGHT Switch .........................................................................................................................................................9

Fuse and Fuse Holder ...........................................................................................................................................9

Z CONTROL PANEL ASSEMBLY .............................................................................................................................. 10

Component Access Procedure............................................................................................................................ 10

POWER Switch ................................................................................................................................................... 10

Z Controller ......................................................................................................................................................... 10

OVEN READY Light ............................................................................................................................................ 10

Fuse and Fuse Holder Light ................................................................................................................................ 10

LIGHT Switch ...................................................................................................................................................... 10

ZX CONTROL PANEL ASSEMBLY .............................................................................................................................11

Component Access Procedure.............................................................................................................................11

POWER Switch ....................................................................................................................................................11

ZX Controller ........................................................................................................................................................11

OVEN READY Light .............................................................................................................................................11

LIGHT Switch .......................................................................................................................................................11

Fuse and Fuse Holder Light .................................................................................................................................11

ZZ CONTROL PANEL ASSEMBLY ............................................................................................................................ 12

Component Access Procedure............................................................................................................................ 12

POWER Switch ................................................................................................................................................... 12

ZZ Oven Control.................................................................................................................................................. 12

Fuse and Fuse Holder Light ................................................................................................................................ 12

6/13 & 5/9 V CONTROLLER ASSEMBLY & “E”SERIES-ELECTRO MECHANICAL CONTROLLER ASSEMBLY... 13

Component Access Procedure............................................................................................................................ 13

POWER Switch ................................................................................................................................................... 13

TEMPERATURE Control ..................................................................................................................................... 13

1 - Hour TIMER ................................................................................................................................................... 13

OVEN READY Light ............................................................................................................................................ 13

Service Manual for Electric Convection Oven

Fan Switch .......................................................................................................................................................... 13

LIGHT Switch ...................................................................................................................................................... 13

Fuse and Fuse Holder Light ................................................................................................................................ 13

Buzzer ................................................................................................................................................................. 13

59-E3P OVEN CONTROLS ....................................................................................................................................... 14

Component Access Procedure............................................................................................................................ 14

POWER Switch ................................................................................................................................................... 14

Controller............................................................................................................................................................. 14

OVEN READY Light ............................................................................................................................................ 14

Fuse and Fuse Holder Light ................................................................................................................................ 14

Transformer ......................................................................................................................................................... 14

Contactor............................................................................................................................................................. 14

Terminal Block ..................................................................................................................................................... 14

CONTROL CIRCUIT BOARD REPLACEMENT ......................................................................................................... 15

CONTROL CIRCUIT BOARD JUMPER SETTINGS .................................................................................................. 15

Single Menu Jumper Setting (Churches or Popeye’s) ........................................................................................ 15

Seven Menu Jumper Settings (Popeye’s Chicken only) ..................................................................................... 16

MOTOR ...................................................................................................................................................................... 16

Side Mounted Motor ............................................................................................................................................ 16

Rear Mounted Motor ........................................................................................................................................... 17

STEP-DOWN TRANSFORMER ................................................................................................................................. 18

POWER TRANSFORMER ......................................................................................................................................... 18

3-RELAY PRINTED CIRCUIT BOARD (Relay Board) ............................................................................................... 18

RTD PROBE .............................................................................................................................................................. 19

THERMOSTAT ........................................................................................................................................................... 19

KX THERMOSTAT ..................................................................................................................................................... 20

BACKUP TOGGLE SWITCH...................................................................................................................................... 20

ELEMENTS ................................................................................................................................................................ 21

Side Mounted Elements ...................................................................................................................................... 21

Back Mounted Elements ..................................................................................................................................... 22

OVEN LIGHTS ........................................................................................................................................................... 23

DOORS ...................................................................................................................................................................... 23

Removal .............................................................................................................................................................. 23

Disassembly ........................................................................................................................................................ 23

Gasket Replacement........................................................................................................................................... 23

Roller Latch ......................................................................................................................................................... 24

Door Switch ......................................................................................................................................................... 24

Door Handle ........................................................................................................................................................ 24

Turnbuckle Assembly (2-door 6/13 Series only) ................................................................................................ 24

SERVICE PROCEDURES ................................................................................................................................................ 25

MAINTENANCE INSTRUCTIONS ............................................................................................................................. 25

Oven Door Adjustment ........................................................................................................................................ 25

6/13 Series Turnbuckle Adjustment..................................................................................................................... 25

Oven Door Switch Adjustment ............................................................................................................................ 25

OVEN DOOR SWITCH CHECK ................................................................................................................................. 26

THERMOSTAT CALIBRATION .................................................................................................................................. 26

Check Calibration ................................................................................................................................................ 26

To Calibrate the Thermostat ................................................................................................................................ 26

ELEMENT .................................................................................................................................................................. 27

RTD ............................................................................................................................................................................ 27

MOTOR CIRCUIT CHECK ......................................................................................................................................... 27

Service Manual for Electric Convection Oven

ZZ CONTROLLER PROGRAMMING ........................................................................................................................ 28

System Programming .......................................................................................................................................... 28

Factory Programming .......................................................................................................................................... 29

TROUBLESHOOTING CHARTS ....................................................................................................................................... 30

6/13 V CONTROLLER AND E SERIES ELECTRO-MECHANICAL CONTROLLER ................................................. 30

5/9 OVEN WITH ZZ CONTROLLER .......................................................................................................................... 31

ALL SOLID STATE CONTROLLERS EXCEPT ZZ CONTROLLER .......................................................................... 32

5/9 CCSI CONTROL WITH BACKUP THERMOSTAT ............................................................................................... 33

SCHEMATIC DIAGRAMS

5/9 “V” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................... 34

6/13 “V” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................. 35

6/13 “V” OPTION PULSE PLUS 208/240 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 36

6/13 “V” OPTION 480 VAC. 50/60 HZ 1PH OR 3PH ......................................................................................................... 37

6/13 “V” OPTION PULSE PLUS 440/480 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 38

5/9 “X” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................... 39

6/13 “X” PULSE OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ..................................................................................... 40

6/13 “X” PULSE OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................... 41

6/13 “X” PULSE PLUS OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 42

S 6/13 “X” OPTION 440/480 VAC. 50/60 HZ 1PH OR 3PH .............................................................................................. 43

6/13 “X” PULSE OPTION 440/480 VAC. 50/60 HZ 1PH OR 3PH ..................................................................................... 44

6/13 “X” PULSE PLUS OPTION 440/480 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 45

5/9 “Z & ZX” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ........................................................................................... 46

6/13 “Z, ZX” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ........................................................................................... 47

6/13 “Z, ZX” OPTION 480 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................. 48

6/13 “ZZ” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ................................................................................................ 49

5/9 & 6/13 “ZZ” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ...................................................................................... 50

5/9 “ZZ” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................. 51

5/9 THERMOSTAT 208/240 VAC. 50/60 HZ 1PH OR 3PH ............................................................................................... 52

WIRING DIAGRAMS

5/9 “V” 208/240 V .............................................................................................................................................................. 53

6/13 “V” 208/240 V ............................................................................................................................................................ 54

6/13 “V” OPTION 208/220 OR 230/240 VAC. 1PH OR 3PH ............................................................................................. 55

6/13 “V” PULSE PLUS 208/240 V ..................................................................................................................................... 56

6/13 “V” 440/480 V ............................................................................................................................................................ 57

6/13 “V” PULSE 440/480 V................................................................................................................................................ 58

6/13 “X” 208/240 V ............................................................................................................................................................ 59

6/13 “X” PULSE PLUS 208/240 V ..................................................................................................................................... 60

5/9 “X” COM6000 208/240 V ............................................................................................................................................. 61

6/13 “X” 440/480 V ............................................................................................................................................................ 62

6/13 “X” PULSE 440/480 V................................................................................................................................................ 63

6/13 “X” PULSE PLUS 440/480 V ..................................................................................................................................... 64

6/13 “X” PULSE PLUS 440/480 V ..................................................................................................................................... 65

6/13 “W” OPTION COM6000 208/240 VAC. 1PH OR 3PH ............................................................................................... 66

6/13 “Z” “ZX” 208/240 V..................................................................................................................................................... 67

5/9 “Z” “ZX” 208/240 V....................................................................................................................................................... 68

6/13 “Z” “ZX” 440/480 V..................................................................................................................................................... 69

6/13 “ZZ” W/BACKUP 208/240 V ...................................................................................................................................... 70

5/9 “ZZ” W/BACKUP 208/240 V ........................................................................................................................................ 71

5/9 CCSI BACKUP TSTAT 208/240 V ............................................................................................................................... 72

CUSTOMER ASSISTANCE ............................................................................................................................................... 75

Service Manual for Electric Convection Oven

INTRODUCTION

GENERAL

Illustrations used in this manual may show any model unless the information is specic to a particular model. All procedures are applicable to all models unless specically indicated.

INSTALLATION

For detailed installation instructions, refer to the Installation and Operation Manual.

OPERATION

For specific operating instructions, refer to the Installation and Operation Manual.

ELECTRICAL SPECIFICATIONS

6/13 and “E” CONVECTION OVEN

TOTAL

VOLTS 1 PHASE 3 PHASE

CLEANING

For specic cleaning instructions, refer to the Installation and Operation Manual.

TOOLS

Standard

• Standard set of hand tools.

• VOM with A.C. current tester (Any quality VOM with a sensitivity of at lease 20,000 ohms per volt can be used).

• Pyrometer

10 208 53 Amps 31 amps

10 240 46 Amps 27 amps

10 220/380 20 amps

10 240/415 18 amps

10 480 14 amps

5/9 THE OVEN

TOTAL

10 208 53 Amps 31 amps

10 240 46 Amps 27 amps

VOLTS 1 PHASE 3 PHASE

5/9, 59-E3C, 59-53P OVENS

TOTAL

8 208 41 Amps 24 amps

8 240 36 Amps 21 amps

VOLTS 1 PHASE 3 PHASE

Service Manual for Electric Convection Oven

WARNING

Screw

Control

Panel

Lower

Trim

Piece

Insert Panel

Right

Side

Panel

COMPONENT REMOVAL AND REPLACEMENT

Electrical LOCKOUT/TAGOUT

Procedure

WARNING: BEFORE PERFORMING ANY

SERVICE THAT INVOLVES ELECTRICAL CONNECTION OR DISCONNECTION AND/OR EXPOSURE TO ELECTRICAL COMPONENTS, ALWAYS FOLLOW THE ELECTRICAL LOCKOUT/TAGOUT PROCEDURE. DISCONNECT ALL CIRCUITS. FAILURE TO COMPLY CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH.

The Electrical LOCKOUT/TAGOUT Procedure is used to protect personnel working on an electrical appliance. Before performing any maintenance or service that requires exposure to electrical components, follow these steps:

1. In electrical box, place appliance circuit breaker into OFF position.

RIGHT SIDE PANEL (OVENS WITH DUAL DOORS)

2. Place a lock or other device on electrical box cover to prevent someone from placing circuit breaker ON.

3. Place a tag on electrical box cover to indicate that appliance has been disconnected for service and power should not be restored until tag is removed by maintenance personnel.

4. Disconnect appliance power cord from electrical outlet.

5. Place a tag on the cord to indicate that unit has been disconnected for service and power should not be restored until tag is removed by maintenance personnel.

1. Remove the screw at the top of the Control Panel.

2. Rotate the panel down about 90° being careful not to damage wiring, RTD or Thermocouple tube.

3. Loosen the four screws that hold the front lower Trim Panel in place.

4. Slide the Trim Panel forward, and remove it.

Before the large side panel can be removed the

stainless steel insert panel behind the control compartment must rst be removed.

5. Remove the two screws that hold the small stainless steel insert panel in place.

6. Slide the panel forward and out of the oven.

7. To remove the large side panel remove the six screws on the front and rear anges of the panel.

8. Pull the panel free from bottom and remove it.

Service Manual for Electric Convection Oven

WARNING

Power

Switch

Nut

X Controller

Temperature

Probe

Screw

Knob

Oven

Ready

Light

Knob

Fan

Switch

Fuse Holder &

Fuse (10 amp delay)

Control

Panel

Mylar

X CONTROL PANEL ASSEMBLY

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of X Control Panel assembly and slide Control Panel out to allow access to Control Panel components.

X Controller

1. Perform Component Access Procedure.

2. Tag and disconnect wires from Controller.

3. Remove knobs from front of Control Panel.

4. Remove four nuts securing Controller to Control Panel.

5. Remove Controller from rear of Control Panel.

6. Reverse procedure to install a new Controller.

OVEN READY Light

1. Perform Component Access Procedure.

2. Tag and disconnect wires to OVEN READY Light.

3. Remove OVEN READY Light from front of Control Panel.

4. Reverse procedure to install a new OVEN READY Light.

Fan Switch

POWER Switch

1. Perform Component Access Procedure.

2. Loosen setscrews and remove knob from POWER Switch.

3. Tag and disconnect wires from POWER Switch.

4. Remove nut securing POWER Switch.

5. Remove POWER Switch from rear of panel.

6. Reverse procedure to install POWER Switch.

1. Perform Component Access Procedure.

2. Tag and disconnect wires from Fan Switch.

3. Remove Fan Switch from front of Control Panel.

4. Reverse procedure to install a new Fan Switch.

Fuse and Fuse Holder

1. Perform Component Access Procedure.

2. Remove screw (1) to access back of Control Panel to replace Fuse Holder.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Control Panel.

6. Reverse procedure to install Fuse Holder.

LIGHT Switch

NOTE: LIGHT Switch is only on the 6/13 Oven.

1. Perform Component Access Procedure.

2. Tag and disconnect wires from LIGHT Switch.

3. Remove LIGHT Switch from front of Control Panel.

4. Reverse procedure to install a new LIGHT Switch.

Service Manual for Electric Convection Oven

Power

Switch

Nut

Controller

Temperature

Probe

Screw

Knob

Oven

Ready

Light

Fan

Switch

Fuse Holder &

Fuse (10 amp delay)

WARNING

Mylar

Control

Panel

XX CONTROL PANEL ASSEMBLY

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of XX Control Panel assembly and slide Control Panel out to allow access to Control Panel components.

XX Controller

1. Perform Component Access Procedure

2. Tag and disconnect wires from Controller.

3. Remove knobs from front of Control Panel.

4. Remove nuts securing Controller to Control Panel.

5. Remove Controller from rear of Control Panel.

6. Reverse procedure to install Controller.

OVEN READY Light

1. Perform Component Access Procedure.

2. Tag and disconnect wires to OVEN READY Light.

3. Remove OVEN READY Light from front of Control Panel.

4. Reverse procedure to install OVEN READY Light.

Fan Switch

1. Perform Component Access Procedure.

POWER Switch

1. Perform Component Access Procedure.

2. Loosen setscrews and remove knob from POWER Switch.

3. Tag and disconnect wires from POWER Switch..

4. Remove nut securing POWER Switch.

5. Remove POWER Switch from rear of Control Panel.

6. Reverse procedure to install POWER Switch.

2. Tag and disconnect wires from Fan Switch.

3. Remove Fan Switch from front of Control Panel.

4. Reverse procedure to install Fan Switch.

LIGHT Switch

NOTE: LIGHT Switch is only on the 6/13 Oven.

1. Perform Component Access Procedure.

2. Tag and disconnect wires from LIGHT Switch.

3. Remove LIGHT Switch from front of Control Panel.

4. Reverse procedure to install LIGHT Switch.

Fuse and Fuse Holder

1. Remove Fuse Cap to replace Fuse.

2. Perform Component Access Procedure.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Control Panel.

6. Reverse procedure to install a new Fuse Holder.

Service Manual for Electric Convection Oven

Power

Switch

Nut

Temperature

Probe

Screw

Knob

Oven

Ready

Light

Fuse Holder &

Fuse (10 amp delay)

WARNING

Lexan

Control

Panel

Knob

Digital

Control

Panel

Controller

Z CONTROL PANEL ASSEMBLY

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of Z Control Panel assembly and slide control panel out to allow access to Control Panel components.

Z Controller

1. Perform Component Access Procedure.

2. Tag and disconnect wires from Controller.

3. Remove two knobs from front of Control Panel.

4. Remove four nuts securing Controller to Control Panel.

5. Remove Controller from rear of Control Panel.

6. Reverse procedure to install a new Controller.

OVEN READY Light

1. Perform Component Access Procedure.

2. Tag and disconnect wires to OVEN READY Light.

3. Remove OVEN READY Light from front of panel.

4. Reverse procedure to install a new OVEN READY Light.

Fuse and Fuse Holder Light

POWER Switch

1. Perform Component Access Procedure.

2. Loosen setscrew and remove knob from POWER Switch.

3. Tag and disconnect wires from POWER Switch.

4. Remove nut securing POWER Switch.

5. Reverse procedure to install POWER Switch.

1. Remove Fuse Holder cap to replace Fuse.

2. Perform Component Access Procedure.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Control Panel.

6. Reverse procedure to install a new Fuse Holder.

LIGHT Switch

NOTE: LIGHT Switch is only on the 6/13 Oven.

1. Perform Component Access procedure.

2. Tag and disconnect wires from LIGHT Switch.

3. Remove LIGHT Switch from front of Control Panel.

4. Reverse procedure to install a new LIGHT Switch.

Service Manual for Electric Convection Oven

Power

Switch

Nut

Temperature

Probe

Screw

Knob

Oven

Ready

Light

Fuse Holder &

Fuse (10 amp delay)

WARNING

Lexan

Control

Panel

Knob

Digital

Control

Panel

Controller

ZX CONTROL PANEL ASSEMBLY

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of ZX Control Panel assembly and slide control panel out to allow access to Control Panel components.

ZX Controller

1. Perform Component Access Procedure.

2. Tag and disconnect wires from ZX Controller, & tag wires.

3. Remove two knobs from front of Digital Control Panel.

4. Remove four nuts securing ZX Controller to back of Digital Control Panel.

5. Remove Controller from rear of Digital Control Panel.

6. Reverse procedure to install ZX Controller.

OVEN READY Light

1. Perform Component Access Procedure.

2. Tag and disconnect wires to OVEN READY Light.

3. Remove OVEN READY Light from front of Digital Control Panel.

POWER Switch

1. Perform Component Access Procedure.

2. Loosen set screw and remove knob from POWER Switch.

3. Tag and disconnect wires from POWER Switch, & tag wires.

4. Remove nut securing POWER Switch.

5. Reverse procedure to install a new POWER Switch.

4. Reverse procedure to install a new OVEN READY Light.

LIGHT Switch

NOTE: LIGHT Switch is only on the 6/13 Oven.

1. Perform Component Access Procedure.

2. Tag and disconnect wires from LIGHT Switch.

3. Remove LIGHT Switch from front of Digital Control Panel.

4. Reverse procedure to install a new LIGHT Switch.

Fuse and Fuse Holder Light

1. Remove Fuse Holder Cap to replace Fuse.

2. Perform Component Access Procedure.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Digital Control Panel.

6. Reverse procedure to install a new Fuse Holder.

Service Manual for Electric Convection Oven

Temperature

Probe

Screw

Control

Panel

Relay

Board

Transformer

208/240V

WARNING

POWER

Oven

Control

Power

Switch

Fuse Holder &

Fuse (10 amp delay)

ZZ CONTROL PANEL ASSEMBLY

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of ZZ Control Panel assembly and slide Control Panel assembly out to allow access to Control Panel components.

ZZ Oven Control

1. Perform Component Access Procedure.

2. Tag and disconnect wires from ZZ Oven Control.

3. Remove two screws securing ZZ Oven Control to Control Panel and remove Oven Control.

4. Reverse procedure to install a new ZZ Oven Control.

Fuse and Fuse Holder Light

1. Remove Fuse Holder Cap to replace Fuse.

2. Perform Component Access Procedure.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Control Panel.

6. Reverse procedure to install a new Fuse Holder.

POWER Switch

1. Perform Component Access Procedure.

2. Tag and disconnect wires from POWER Switch.

3. Disengage POWER Switch from retainer and

4. Reverse procedure to install a new POWER Switch.

remove through front of Control Panel.

Service Manual for Electric Convection Oven

Power

Switch

Buzzer

1-Hour

Timer

Knob

Oven

Ready

Light

2-speed

Fan

Switch

Fuse Holder & Fuse

(10 amp delay)

Thermostat

Interior Light

Switch

Mylar,

Electric

Cook/Timer

Control Panel

Screw

6/13 & 5/9 V CONTROLLER ASSEMBLY & “E”SERIES-ELECTRO MECHANICAL CONTROLLER ASSEMBLY

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of Control Panel assembly and slide Control Panel assembly out to allow access to Control Panel components.

1 - Hour TIMER

1. Perform Component Access Procedure.

2. Loosen set screw and remove 1 - Hour TIMER.

3. Remove nut securing 1 - Hour TIMER and remove timer.

4. Reverse procedure to install 1 - Hour TIMER.

OVEN READY Light

1. Perform Component Access Procedure.

2. Tag and disconnect wires to OVEN READY Light.

3. Remove OVEN READY Light from front of Control Panel.

4. Reverse procedure to install OVEN READY Light.

Fan Switch

1. Perform Component Access Procedure.

2. Tag and disconnect wires from Fan Switch.

3. Remove Fan Switch from front of Control Panel.

4. Reverse procedure to install Fan Switch.

POWER Switch

1. Perform Component Access Procedure.

2. Loosen set screws and remove knob from POWER Switch.

3. Tag and disconnect wires from POWER Switch.

4. Remove nut securing POWER Switch and remove POWER Switch.

5. Reverse procedure to install POWER Switch.

TEMPERATURE Control

Refer to THERMOSTAT in this section.

LIGHT Switch

NOTE: LIGHT Switch is only on the 6/13 Oven.

1. Perform Component Access Procedure.

2. Tag and disconnect wires from LIGHT Switch.

3. Remove LIGHT Switch from front of Control Panel.

4. Reverse procedure to install LIGHT Switch.

Fuse and Fuse Holder Light

1. Remove Fuse Holder Cap to replace Fuse.

2. Perform Component Access Procedure.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Control Panel.

6. Reverse procedure to install Fuse Holder.

Buzzer

1. Perform Component Access Procedure.

2. Tag and disconnect wires from Buzzer.

3. Remove screw securing Buzzer to back of Control Panel and remove Buzzer.

4. Reverse procedure to install Buzzer.

Service Manual for Electric Convection Oven

Power

Switch

Temperature

Probe

Knob

Oven

Ready

Light

Fuse Holder &

Fuse (10 amp delay)

WARNING

Mylar Panel

Digital

Control

Panel

Screw

Transformer

Contactor

Terminal

Block

E3P

Controller

59-E3P OVEN CONTROLS

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Component Access Procedure

Remove screw at top center of 59-E3P Control Panel assembly and slide Control Panel assembly out to allow access to Control Panel components.

Controller

1. Perform Component Access Procedure.

2. Tag and disconnect wires from Controller.

3. Remove nuts securing Controller to Control Panel.

4. Remove Controller from rear of Control Panel.

5. Reverse procedure to install a new Controller.

OVEN READY Light

1. Perform Component Access procedure.

2. Tag and disconnect wires to OVEN READY Light.

3. Remove OVEN READY Light from front of panel.

4. Reverse procedure to install a new OVEN READY Light.

NOTE: Transformer, Contactor, and Terminal Block are

mounted on a panel behind the Oven Control.

Fuse and Fuse Holder Light

POWER Switch

1. Perform Component Access Procedure.

2. Loosen set screws and remove knob from POWER Switch.

3. Tag and disconnect wires from POWER Switch.

4. Remove nut securing POWER Switch and remove POWER Switch.

1. Remove Fuse Holder Cap to replace Fuse.

2. Perform Component Access Procedure.

3. Tag and disconnect wires to Fuse Holder.

4. Remove nut securing Fuse Holder.

5. Remove Fuse Holder from front of Control Panel.

6. Reverse procedure to install a new Fuse Holder.

Transformer

Refer to TRANSFORMER in this section.

Contactor

1. Perform Component Access Procedure.

2. Tag and disconnect wires to Contactor.

3. Remove four nuts and remove Contactor.

4. Reverse procedure to install a new Contactor.

Terminal Block

5. Reverse procedure to install a new POWER Switch.

1. Perform Component Access Procedure.

2. Tag and disconnect wires to Terminal Block.

3. Remove four nuts and remove Terminal Block.

4. Reverse procedure to install a new Terminal Block.

Service Manual for Electric Convection Oven

CONTROL

CIRCUIT

BOARD

PROBE

TRANS.

RELAY

COM

Blue Wire (Existing)

Purple Wire

(Existing)

Wire Nut

#2 White Wire (New)

#1 Blue Wire

(New)

#32 Black Wire

(Exisiting)

#3 Black Wire (New)

NO NC

CONTROL CIRCUIT BOARD REPLACEMENT

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

The Control Circuit Board is used only in 5/9 convection ovens used by Popeye’s Chicken or Churches Chicken.

1. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the Control Circuit Board.

2. Remove the two and four wire connectors from the Control Circuit Board.

3. Remove the Probe connector from the Control Circuit Board.

4. Remove the defective Control Circuit Board.

5. Install the replacement Control Circuit Board.

6. Attach the two and four wire connectors.

7. Attach the Probe connector.

8. Mount the Relay to the Control Panel below the Control Circuit Board. DO NOT MOUNT THE RELAY ON THE CONTROL CIRCUIT BOARD.

9. Attach the new wires #1, #2 and # 3 to the relay, refer to the gure above for details.

10. Remove the wire nut that secures the 3 black and 1 purple wire, separate the purple wire from the bundle.

11. Referring to the gure above connect the #3 black wire from the relay to the bundle black wires that contained the purple wire removed in the previous step and reattach the wire nut.

12. Referring to the gure above connect the purple wire removed in step 10 to the blue wire and attach a wire nut.

13. Referring to the gure above disconnect the #32 black wire from the blue wire.

14. Connect the #32 black wire to the common terminal on the relay.

15. Connect the #2 white wire to the blue wire coming from the relay and attach a wire nut.

16. Close the Control Panel and reattach its mounting screw.

17. Proceed to the Control Circuit Board Jumper Setting Instructions.

CONTROL CIRCUIT BOARD JUMPER SETTINGS

The Control Circuit Board is shipped with the jumper in position 3. Position 1 loads Churches Chicken’s default settings. Position 2 loads Popeye’s Chicken’s default settings.

Single Menu Jumper Setting (Churches or Popeye’s)

1. Turn the power off to the unit.

2. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the Control Circuit Board.

3. Place the jumper in the #3 position, see the diagram below.

Service Manual for Electric Convection Oven

Screws

Rack

Shelf

Right Inside Panel

Screws

JUMPER

MOTOR

The motor is attached to the right side of the oven in the following models:

• 5/9 Series Oven

• 5/9 The Oven

• 59-E3C Oven

• 59-E3P Oven

JUMP ER

JUMPER

POSITIONS

View of Back of Control Board

4. Reattach the Control Panel.

5. Turn the oven on and check the parameter settings.

6. Refer to the Operation & Installation Manual for programming instructions.

Seven Menu Jumper Settings (Popeye’s Chicken only)

1. Turn the power off to the unit.

The motor is attached to the back of the oven in the following models:

• 6/13 The Oven

• “E” Series Oven

Side Mounted Motor

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

2. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the Control Circuit Board.

3. Place the jumper in the #4 position; see the diagram above for jumper location.

4. Reattach the Control Panel.

5. Turn the oven on and check for parameter settings.

6. Refer to the Operation & Installation Manual for programming instructions.

1. Open Oven Doors.

2. Remove shelves.

3. Remove two side racks.

4. Remove four screws attaching right inside panel and remove panel to gain access to Motor Terminals.

Service Manual for Electric Convection Oven

Inside back panel

Fan

Set Screws

Nut

Mounting

Plate

Motor

Junction

Box

Rack

Back Panel

Light Bulb Panel

ShelfFan

Rear Mounted Motor

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

1. Open Oven Doors.

2. Remove shelves.

3. Remove two side racks.

4. Remove four screws attaching back plate and remove back plate to access Motor.

5. Inside the Oven, loosen setscrews on Blower (Fan) and remove Fan from Motor Shaft.

6. Remove right side access panel.

7. At right side of oven, label and disconnect motor wires at Motor Junction Box.

8. Remove four nuts securing Motor to Mounting Plate and remove Motor.

9. Reverse procedure to install Motor.

5. Loosen setscrews on Blower (Fan) and remove Fan from Motor Shaft.

6. At rear of oven, label and disconnect Motor wires at Motor Junction Box.

7. Remove four nuts securing Motor to Mounting Plate and remove Motor.

8. Reverse procedure to install Motor.

Service Manual for Electric Convection Oven

Nut

Mounting

Plate

Motor

Junction

Box

Motor

Relay

Board

Step-down

Transformer

Power

Transformer

STEP-DOWN TRANSFORMER

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

NOTE: Used on the 59-E3C and 59E3P oven.

Transformer is located behind Control Panel.

1. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the Step-Down Transformer.

2. Label and disconnect wires from Step-Down Transformer.

3. Re m o v e two screws securing Step-Dow n Transformer to panel and remove Step-Down Transformer.

4. Reverse p r oc e d u re t o i n sta l l Step-Dow n Transformer.

POWER TRANSFORMER

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

NOTE: Used on ovens with the Model 59-ZZ controller

or 5/9 ZZ Controller. Power Transformer is located behind Control Panel.

1. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to The Power Transformer.

2. Label a n d disconne c t w i res from Po w e r Transformer.

3. Remove four screws attaching Power Transformer to panel and remove Power Transformer.

4. Reverse procedure to install Power Transformer.

3-RELAY PRINTED CIRCUIT BOARD (Relay Board)

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

NOTE: Used on ovens with the Model 59-ZZ Controller

or 5/9 ZZ Controller. PCB is located behind Control Panel.

1. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the Relay Board.

2. Label and disconnect wires to Relay Board.

3. Remove four screws attaching Relay Board assembly and remove Relay Board.

4. Reverse procedure to install a new Relay Board.

Service Manual for Electric Convection Oven

To RTD probe

in oven

Typical board connection

Bracket Thermostat

Probe

RTD PROBE

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

The RTD Probe is located parallel to the oven door at the front of the oven cavity for the following ovens:

5/9 The Oven

X Controller

XX Controller

Z and ZX Controller

ZZ Controller

The RTD Probe is located at the top center of the right wall for the following ovens:

6/13 The Oven

X Controller

XX Controller

Z and ZX Controller

THERMOSTAT

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

The Thermostat is located on the V Controller and the Thermostat Probe is located in the upper right of oven. The Thermostat Probe provides temperature information back to the Thermostat. The capillary tube from the Thermostat to the Thermostat Probe is covered with a berglass sleeve.

The RTD Probe is mounted on the top right center wall for the following ovens:

59-E3C and 59-E3P ovens

CCSI Controller

1. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the RTD Probe connection on the Relay Board.

2. Disconnect RTD Probe connector from Control Board.

3. Remove RTD Probe from inside of the oven and pull connector through side of oven to remove.

NOTE: When removing the Thermostat be careful not

to bend the capillary tube at a sharp angle to prevent kinking.

1. Remove screw at top center of Control Panel assembly and slide Control Panel out to allow access to the Thermostat Probe capillary tube.

2. Open Oven Door and carefully remove Thermostat Probe from bracket at upper right side of the oven.

2. Pull Thermostat Probe through the oven sidewall.

3. Remove Thermostat knob from front of V Controller assembly.

4. Tag and disconnect wires from back of Thermostat.

5. Remove nut securing the Thermostat to front of V Controller assembly.

4. Reverse procedure to install a new RTD Probe.

6. Pull Thermostat off rear of V Controller assembly.

7. Reverse procedure to install a new Thermostat. Be sure berglass insulation is on capillary tube to Thermostat Probe.

Service Manual for Electric Convection Oven

Thermostat

Probe

Thermostat

Probe

Oven

Sidewall

Bracket

Backup

Toggle Switch

Mounting

Bracket

Temperature

Plate

Thermostat

Probe

Side

Access

Panel

Knob

Screw

Thermostat

KX THERMOSTAT

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

The KX (Back up)Thermostat is used on the 59-E3C and 59-E3P Ovens as an Oven Backup Thermostat. This Thermostat is located behind the right access panel, next to the Motor. The Thermostat Probe is located inside the oven parallel to the Oven Door on the top of the open cavity.

NOTE: When removing the KX Thermostat be careful

not to bend the capillary tube at a sharp angle to prevent kinking.

1. Open Oven Door and carefully remove Thermostat Probe from upper right front of the Oven.

2. Pull Thermostat Probe through the oven sidewall.

3. Remove two screws then remove side access panel.

4. Remove two screws and remove mounting bracket.

5. Tag and disconnect wires from KX Thermostat.

6. Remove knob from KX Thermostat.

7. Remove nut securing KX Thermostat,

8. Pull KX Thermostat off mounting bracket.

9. Reverse procedure to install a new KX Thermostat. Be sure berglass insulation is on capillary tube to Temperature Probe.

BACKUP TOGGLE SWITCH

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

1. Remove two screws then remove side access panel.

2. Remove two screws and remove mounting bracket.

3. Tag and disconnect wires to Backup Toggle Switch.

4. Remove nut securing Backup Toggle Switch.

5. Pull Backup Toggle Switch off mounting bracket.

6. Reverse procedure to install a new Backup Toggle Switch.

Service Manual for Electric Convection Oven

Screws

Rack

Shelf

Right Inside Panel

Screws

Disconnect wires

Brackets

Inner

Element

Center

Element

Outer

Element

ELEMENTS

The Elements are attached inside of the oven on the right side in the following models:

5/9 Series Oven 59-E3C Oven 5/9 The Oven 59-E3P Oven

The Elements are attached inside the oven on the back in the following models.

6/13 The Oven “E” Series Oven

For both the side and back mounted locations, the Elements consists of an inner Element, a center Element and an outer Element. When replacing Elements be sure to use the correct Element.

Side Mounted Elements

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

1. Inside oven, remove shelves and racks.

3. Remove right side panel as described in RIGHT SIDE PANEL REMOVAL to gain access to the Element connections.

4. Remove screws securing cover over heater wire terminals on right side of oven.

5. Tag and disconnect Element wires at the terminals.

6. Remove the four screws securing the terminal plate.

7. Open Oven Door.

2. Remove four screws securing right side panel inside oven and remove panel. This allows access to the Blower and the Elements.

8. Remove the two brackets securing the Elements around the Blower.

9. Slide Element out through inside of oven.

10. Reverse procedure to install an Element.

NOTE: Element lead wires should be torqued to

30 inch pounds.

Service Manual for Electric Convection Oven

Rack

Back Panel

Light Bulb Panel

ShelfFan

Fan

Terminals

Outside back panel

Inside back panel

Bracket

Screws

Terminal Plate

Inner

Element

Center

Element

Outer

Element

Bracket

Back Mounted Elements

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

1. Inside oven, remove shelves and racks.

2. Remove four screws securing Back Panel inside oven and remove panel. This allows access to the Blower and the Elements.

5. Open oven door.

3. Remove screws securing cover over heater wire terminals on back of oven on the upper left.

4. Tag and disconnect Element wires at the terminals.

6. Remove the four screws securing the terminal plate to the oven interior.

7. Remove the two clamps securing the Elements around the Blower.

8. Slide Element assembly out through inside of oven.

9. Reverse procedure to install Elements.

NOTE: Element lead wires should be torqued to 30

inch pounds.

OVEN LIGHTS

Rack

Back Panel

Light Bulb Panel

ShelfFan

Right Side

Rack

Light

Access

Panel

Light

Bulbs

Screws

Oven lights are located on the right side of the oven. The light bulbs are replaced from inside the oven. The light sockets are replaced by removing the right side panel.

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

1. Open Oven Door.

2. Remove shelves and right side rack to access Light Bulbs.

Service Manual for Electric Convection Oven

DOORS

3. Remove four screws securing light bulb panel over light bulbs and remove the panel.

4. Remove the faulty light bulb.

5. Reverse procedure to install a new light bulb.

The doors on all ovens are constructed similarly, except the 6/13 oven has a turnbuckle assembly that causes both the left and the right doors to open together. The left hand doors are shown disassembled in the two illustrations.

WARNING: DISCONNECT OVEN FROM POWER

SOURCE BEFORE PERFORMING ANY SERVICE.

Removal

1. Open oven door(s).

2. Remove Top Finish Piece.

3. Loosen setscrew on top and bottom Door Bearings.

4. Slide oven door off the hinges.

5. Reverse procedure to install Oven Door.

Disassembly

The oven door can be disassembled as necessary to replace the handle, door glass, micro switch, bearing, roller latch, door catch, and gaskets. On the 6/13 Dual Door Ovens a turnbuckle assembly can also be replaced.

Gasket Replacement

The Gaskets are not attached to the oven door. These gaskets are attached to the oven frame. The four gaskets can be individually replaced.

NOTE: There are four separate Gaskets for the top,

bottom, and two sides. Each Gasket is replaced independently.

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