SERVICE MANUAL
KA SERIES ELECTRIC ROTARY
OVENS
Information in this manual superceedes TSB 1406.
KA7E ML-137701 SELF-CLEAN, GLASS BACK
ML-137709 SELF-CLEAN, SOLID BACK
KA7EM ML-137710 MANUAL-CLEAN, GLASS
BACK WITH GREASE ASSIST
ML-137711 MANUAL-CLEAN, GLASS
BACK WITHOUT GREASE
ASSIST
ML-137713 MANUAL-CLEAN, SOLID BACK
WITH GREASE ASSIST
ML-137714 MANUAL-CLEAN, SOLID BACK
WITHOUT GREASE ASSIST
KA7E WITH STAND ACCESSORY SHOWN
This Manual is prepared for the use of trained Hobart Service
Technicians and should not be used by those not properly
qualified.
This manual is not intended to be all encompassing. If you have
not attended a Hobart Service School for this product, you should
read, in its entirety, the repair procedure you wish to perform to
determine if you have the necessary tools, instruments and skills
required to perform the procedure. Procedures for which you do
not have the necessary tools, instruments and skills should be
performed by a trained Hobart Service Technician.
The reproduction, transfer, sale or other use of this Manual,
without the express written consent of Hobart, is prohibited.
This manual has been provided to you by ITW Food Equipment
Group LLC ("ITW FEG") without charge and remains the property
of ITW FEG, and by accepting this manual you agree that you will
return it to ITW FEG promptly upon its request for such return at
any time in the future.
- NOTICE -
A product of Hobart Service 701 S. Ridge Ave Troy, OH 45374
F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS
TABLE OF CONTENTS
GENERAL .................................................................................................. 4
REFERENCE INFORMATION .......................................................................... 4
TSB'S & TSI'S ...................................................................................... 4
INSTRUCTIONS & SPECIFICATIONS .............................................................. 4
INTRODUCTION ....................................................................................... 4
ELECTRICAL SPECIFICATIONS ....................................................................... 5
WATER SUPPLY REQUIREMENTS (KA7E ONLY) ...................................................... 5
TOOLS ................................................................................................. 5
ACCESSORY STAND INSTRUCTIONS ................................................................. 5
KA7E SELF-CLEAN (ML-137701, ML-137709) ...................................................... 5
KA7EM WITH GREASE ASSIST (ML-137710, ML-137713) .......................................... 7
KA7EM WITHOUT GREASE ASSIST (ML-137711, ML-137714) ..................................... 8
TETHER BRACKET AND OVEN MOUNTING TO STAND (KA7E, KA7EM) ........................... 9
REMOVAL AND REPLACEMENT OF PARTS .............................................................. 10
COVERS .............................................................................................. 10
PUMP COVER .................................................................................... 10
RIGHT SIDE COVER .............................................................................. 10
LEFT SIDE COVER ............................................................................... 10
TOP COVER (CONTROL PANEL) ................................................................. 10
TOP COVER ...................................................................................... 10
FAN COVER ...................................................................................... 11
DOOR ................................................................................................ 11
DOOR ADJUSTMENT ............................................................................. 12
DOOR SWITCH ADJUSTMENT (KA7E ONLY; IF REQUIRED) ..................................... 12
DOOR SWITCH MAGNET (KA7E ONLY) .............................................................. 13
OUTER DOOR GLASS ................................................................................ 13
WASH ARM, STRAINER PANS, STRAIN PAN SUPPORT, DRAIN SHROUD (KA7E ONLY) ............. 13
LAMP ................................................................................................. 14
FAN MOTORS ASSEMBLY ............................................................................ 15
HEATING ELEMENTS ................................................................................ 17
HIGH LIMIT THERMOSTAT ........................................................................... 18
TEMPERATURE SENSOR ............................................................................ 18
CONTACTORS ....................................................................................... 19
POWER SWITCH AND MOMENTARY SWITCHES .................................................... 19
DISPLAY BOARD AND KEYPAD ...................................................................... 20
ROTOR STOP/START SWITCH ....................................................................... 21
MEAT PROBE MINI JACK ............................................................................. 22
CAPACITORS ........................................................................................ 22
WATER LEVEL CONTROL BOARD (KA7E ONLY) ..................................................... 23
WATER LEVEL SENSOR (KA7E ONLY) ............................................................... 24
CHEMICAL SENSOR (KA7E ONLY) ................................................................... 24
WASH PUMP RELAY (KA7E ONLY) ................................................................... 24
TRANSFORMER ...................................................................................... 25
CPU BOARD .......................................................................................... 25
PERISTALTIC PUMPS ................................................................................ 26
PUMP REMOVAL ................................................................................. 26
PROCEDURE TO REPLACE PUMP HOSE ........................................................ 26
WATER FILL VALVE (KA7E ONLY) .................................................................... 28
WASH PUMP (KA7E ONLY) ........................................................................... 28
DRAIN PUMP (KA7E ONLY) ........................................................................... 29
DRIVE MOTOR ASSEMBLY ........................................................................... 29
DRIVE MOTOR ADJUSTMENT .................................................................... 31
DRIVE MOTOR, SPEED REDUCER AND GEARBOX .................................................. 33
SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 36
SERVICE MODE - PROGRAMMING AND DIAGNOSTICS ............................................. 36
F25294 Rev. A (0412) Page 2 of 72
KA SERIES ELECTRIC ROTARY OVENS
PROCEDURE TO ENTER SERVICE MODE ....................................................... 36
PROCEDURE TO TOGGLE BETWEEN NO ID AND OPERATOR ID MODE ........................ 36
PROCEDURE TO TOGGLE BETWEEN 9 AND 99 PROGRAMS .................................... 36
SERVICE MODE PARAMETERS .................................................................. 36
DEMO MODE (KA7E ONLY) ........................................................................... 41
RETURN TO NORMAL MODE ..................................................................... 43
TEMPERATURE SENSOR TEST ...................................................................... 43
HEATING ELEMENT TEST ............................................................................ 44
PUMP, K3 RELAY COIL TESTS ....................................................................... 44
CONTROLS CALIBRATION ........................................................................... 44
CALIBRATION PROCEDURE ..................................................................... 44
ELECTRICAL OPERATION ................................................................................ 46
COMPONENT FUNCTION ............................................................................ 46
SEQUENCE OF OPERATION ......................................................................... 46
PROGRAMMED COOKING ....................................................................... 46
WASHING CYCLE SEQUENCE OF OPERATIONS ................................................ 47
USER PRESSES CLEAN BUTTON ................................................................ 47
CONTROLS EXPLANATION .......................................................................... 48
MODEL KA7E ..................................................................................... 48
MODEL KA7EM ................................................................................... 49
COMPONENT LOCATIONS ........................................................................... 50
MODEL KA7E ..................................................................................... 50
MODEL KA7EM ................................................................................... 52
WIRING DIAGRAMS .................................................................................. 54
KA7E - COMPONENT CONNECTIONS ............................................................ 54
KA7EM - COMPONENT CONNECTIONS .......................................................... 55
POWER CONNECTION ........................................................................... 56
SCHEMATIC DIAGRAMS ............................................................................. 57
MODEL KA7E ..................................................................................... 57
MODEL KA7EM ................................................................................... 59
PLUMBING DIAGRAMS (KA7E ONLY) ................................................................ 62
TROUBLESHOOTING ..................................................................................... 64
TROUBLESHOOTING ................................................................................. 64
TROUBLESHOOT ROTOR COMPONENTS ........................................................... 67
APPENDIX ................................................................................................ 69
REVERSING CONTROLS ............................................................................. 69
© HOBART SERVICE 2012
Page 3 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - GENERAL
GENERAL
Oven cleaners are corrosive and can cause chemical burns. Rubber gloves, goggles and protective
clothing are required. Read and follow the instructions for the oven cleaner.
Safety standards require that, when the rotary oven’s electric supply line is properly connected to the
electrical power supply, an adequate means must be provided to limit movement of the oven without applying stress
to the electrical conduit. This means that, as part of the installation, the oven must be secured to either the wall or
the floor to limit movement of the oven and, thus, preventing damage to the flexible electrical conduit during cleaning,
maintenance and service operations.
REFERENCE INFORMATION
TSB'S & TSI'S
NOTE: Links or references to the TSB's are provided
here and in the appropriate sections of service
manual.
TSB 1381 KA7E ROTARY OVEN SCRAMBLED VFD DISPLAY.
TSB 1383
TSB 1400 KA7E - LEAKS AT DRIVE ARM GASKET DURING WASH CYCLE.
TSB 1417 KA7E - CLOGGING AT INPUT AND OUTPUT OF PERISTALTIC PUMPS.
TSI
Instructions & Specifications
KA7E F-40182 F-35521
KA7EM F-40287 F-45111
ROTISSERIE OVENS HR5E, HR7E AND KA7E NEW DRIVE MOTOR
ASSEMBLIES.
HR7E AND KA7E ROTISSERIE OVEN ROTOR CRANK ARM DISENGAGING
FROM ROTOR.
Model Specifications Instructions Manual
INTRODUCTION
• Electronic control with message center, time,
temperature and program display features.
See Multimedia
section in TIS.
See Multimedia
section in TIS.
See Multimedia
section in TIS.
All pictures and illustrations shown are of a KA7E
unless otherwise specified. When specific model
number designations are needed for clarity, they are
added to the procedure or picture.
General
• Capacity of the KA series seven spit oven is 21
to 35 chickens.
• Stacking kit available to stack ovens.
• Refer to the Specifications sheet for oven
Installation details and Instructions manual for
operating and cleaning instructions.
KA7E - Model Description
• Rotisserie oven with automatic clean cycle.
F25294 Rev. A (0412) Page 4 of 72
• Pass through controls on the unload side to
• Equipped with grease assist and chemical
• Pump for automatic draining.
KA7EM - Model Description
• Rotisserie oven without automatic clean cycle
• Electronic control with time, temperature and
• Manual drain valve.
snooze cook cycle, silence beeper and stop cook
cycle.
cleaner peristaltic pumps.
features (manual cleaning).
program display features.
KA SERIES ELECTRIC ROTARY OVENS - GENERAL
• Equipped with grease assist and chemical
cleaner peristaltic pumps.
• Available with a grease assist peristaltic pump to
remove grease during a cook cycle (optional).
ELECTRICAL SPECIFICATIONS
KA7E AND KA7EM
VOLTS PHASE WATTAGE AMPERAGE
208 1 9,300 42.8
208 3 9,300 24.7
240 1 9,300 37.7
240 3 9,300 21.8
NOTE: Separate power supplies must be used when
stacking two ovens.
INSTALLATION NOTE:
Before putting oven into service, check to ensure
incoming power terminal block TB6 wire retaining
screws are tight.
• VOM with AC current tester (Any VOM with a
sensitivity of at least 20,000 ohms per volt can be
used.)
• Temperature Tester
• Field Service Grounding Kit
• Torque wrench capable of measuring up to 45 inlbs.
• Jewelers screwdriver
• Power switch and momentary switch removal
tool (two required) made locally to dimensions in
graphic below
NOTE: Material for tool can be aluminum, hard plastic
or any other hard material which can be easily
fabricated to dimensions.
Ovens mounted on casters or installed on stands with
casters must be provided with an adequate restraining
means to guard against transmission of strain to the
electric supply line. Instructions for tethering are
included in stacking kit instructions and with optional
oven stand. Disconnect the flexible electrical
conduit(s) before disconnecting the restraint.
WATER SUPPLY REQUIREMENTS
(KA7E ONLY)
NOTE: For proper operation, use only HOT water
supply. For installations at the end of a long hot water
line, a second pre-rinse may be required to be
programmed to prime the line.
Hot water supply:
• 3/4" hose bib fitting.
• 0.5 GPM @ 25-50 PSI.
• 120°F - 140°F.
• Recommended hardness, 4 - 6 grains.
• Minimum conductivity required, 30
MICROMHOS/CM.
Fig. 1
ACCESSORY STAND
INSTRUCTIONS
NOTE: Separate units can be lifted by means of a
forklift. To do this, open both doors. Remove fan
cover. Slide forks all of the way thru top of oven. Make
sure forks rest on the frame member and are spread
as far apart as possible. Stacked units must not be
lifted in this manner.
KA7E Self-Clean (ML-137701, ML-137709)
1. Remove Right Side Cover.
2. With oven lifted, remove drain plug and save it.
Drain hose is connected here and routed down
thru base.
3. Remove electric power cord blank and install
proper restraining fitting for power cord.
TOOLS
• Standard set of hand tools
Page 5 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - GENERAL
BOTTOM VIEW SHOWN
4. Remove screws securing water fill valve to utility
plate.
5. Remove screws securing drain manifold to utility
plate and utility plate to frame.
PREVIOUS CONSTRUCTION
6. Current construction - Remove strain relief nuts
securing chemical-in and grease-out hoses.
A. Remove hoses from strain relief fittings (pull
hoses through fittings but leave connected
to machine).
CURRENT CONSTRUCTION
7. Previous construction - Remove chemical-in and
grease-out hoses from 45 degree strain relief
fittings.
Fig. 5
8. Discard original utility plate, saving screws.
9. Slide mounting bracket off water fill valve.
10. Reinstall mounting bracket to water fill valve
F25294 Rev. A (0412) Page 6 of 72
Fig. 6
(rotated as shown).
KA SERIES ELECTRIC ROTARY OVENS - GENERAL
15. Route water supply through the bottom of the
stand and connect. (Fittings mate to ¾ inch male
hose bib, not supplied.)
Fig. 9
Fig. 7
11. Install water valve onto bracket on new utility
plate (supplied with stand).
Fig. 8
12. Install new utility plate onto oven using screws
removed earlier.
13. Install drain plug removed earlier.
16. Route water drain through the bottom of the
stand and connect. (Fittings mate to 1 inch
female NPT, not supplied.)
17. Route chemical-in and grease-out hoses down
through bottom of machine into stand. Connect
hoses to grease vessel and chemical container.
18. Route power cord thru base into oven and
connect to terminal block.
19. Proceed to Tether Bracket and Oven Mounting to
Stand (KA7E, KA7EM).
KA7EM with Grease Assist (ML-137710,
ML-137713)
1. Remove Right Side Cover.
2. Remove electric power cord blank. Install power
cord restraining fitting (not supplied) in the proper
hole E1.
14. Install new hoses supplied with oven and route
down into base.
Fig. 10
Page 7 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - GENERAL
3. Remove screws and valve bracket from factory
standard utility plate.
4. Save screws and bracket. Discard original
factory standard utility plate.
5. Remove grease-out hose from 45 degree strain
relief fitting.
Fig. 12
3. Remove screws from factory standard utility
plate.
Fig. 11
6. Install valve bracket from old plate onto new utility
plate (supplied with stand).
7. Install new utility plate assembly onto oven using
screws removed earlier.
8. Install ¾" MNPT to ¾" ID, 90 deg, Barb Hose
Fitting (not supplied) into P1 drain connection.
NOTE: P1 drain connection cannot drop through into
stand and must exit out the right side of the oven.
9. Route grease-out hose down through bottom of
machine into stand.
10. Route power cord through stand up into oven and
connect to terminal block.
11. Proceed to Tether Bracket and Oven Mounting to
Stand (KA7E, KA7EM).
KA7EM without Grease Assist (ML-137711,
ML-137714)
1. Remove Right Side Cover.
2. Remove electric power cord blank. Install power
cord restraining fitting (not supplied) in the proper
hole E1.
Fig. 13
4. Install ¾" MNPT to ¾" ID, 90 deg, Barb Hose
Fitting (not supplied) into P1 drain connection.
5. Install new utility plate (supplied with stand)
assembly onto oven using screws removed
earlier.
6. Install Plug Button (supplied with stand
accessory) into new utility plate.
F25294 Rev. A (0412) Page 8 of 72
KA SERIES ELECTRIC ROTARY OVENS - GENERAL
Fig. 14
7. Route power cord through stand up into oven and
connect to terminal block.
2. Using holes in oven's caster mounting plate,
secure oven to stand using 4 screws and 4
washers provided with stand accessory. Install
washers such that bolt does not slip through.
8. Proceed to Tether Bracket and Oven Mounting to
Stand (KA7E, KA7EM).
Tether Bracket and Oven Mounting to Stand
(KA7E, KA7EM)
1. Ensure that tether bracket is installed.
A. The bracket must be installed along with
one of the swivel casters to a corner as
shown using the caster hardware provided.
The remaining open hole in the center of the
tether bracket is to be used to secure one
end of the tether (locally supplied chain,
cable, etc.). The other end of the tether is to
be secured to an anchoring point in the wall
or floor when oven installation is complete.
Make sure that during oven movement, no
stress is applied to the flexible electrical
conduit(s).
Fig. 16
3. Install all removed covers.
4. Continue with installation per Instructions
Manual.
Fig. 15
Page 9 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
REMOVAL AND REPLACEMENT OF PARTS
Due to use of chemical detergents, all interior replacement hardware must be stainless steel hardware
as listed in the parts catalog.
COVERS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Pump Cover
1. Remove two thumbscrews securing pump cover
and lift cover off.
2. Reverse procedure to install.
NOTE: Anytime service is performed requiring the
right side cover to be removed, check to ensure
incoming power terminal block wire retaining screws
are tight.
Right Side Cover
1. Remove Pump Cover.
2. Remove twelve screws securing right side cover
to frame.
Left Side Cover
1. Remove ten screws securing left side cover to
frame.
2. Loosen one screw securing top center of cover.
3. Loosen one screw securing top center of cover.
Fig. 17
4. Remove cover.
Fig. 18
3. Remove cover.
4. Reverse procedure to install.
Top Cover (Control Panel)
1. Remove screws securing top cover over controls
area.
2. Remove cover.
3. Reverse procedure to install.
Top Cover
1. Remove screws securing Top Cover (Control
Panel).
2. Remove cover.
3. Remove remaining screws securing top cover
and lift cover off.
5. Reverse procedure to install.
F25294 Rev. A (0412) Page 10 of 72
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 19
4. Reverse procedure to install.
DOOR
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Left Side Cover.
2. Open oven door and pull inner oven door to
overcome magnet hold to main door.
Fan Cover
1. Open door.
2. Remove nut securing fan cover to top of cavity.
3. Grab deflector edge and pivot edge toward you
to disengage cover from studs.
4. Slide cover off studs at opposite side and remove
cover.
NOTE: Fan cover can be removed thru either door in
the same manner.
Fig. 21
3. Lift inner door hinge pins out of hinge bushings
and lay door on a flat padded surface.
VIEW - AS LOOKING THROUGH DOOR GLASS
5. Reverse procedure to install.
NOTE: Make sure all six studs are engaged properly
and that the cover does not hang down.
Page 11 of 72 F25294 Rev. A (0412)
Fig. 22
4. Remove screws securing facade to oven.
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
8. Reverse procedure to install but leave nuts
securing hinge plate loose. Perform Door
Adjustment.
Door Adjustment
1. With top hinge plate mounting nuts loose, use an
object to shim handle end of door to make bottom
of door parallel to the sump facade.
Fig. 23
5. Close door.
6. Remove nuts securing top hinge to cabinet.
Fig. 24
7. Carefully remove hinge plate while supporting
hinge backing plate and lift door off lower hinge
pin.
Fig. 26
2. Tighten hinge plate nuts and check door
operation. Make sure there is no interference or
rubbing when door is operated. Door must not
contact sump facade when opening or closing.
3. Check Door Switch Adjustment (KA7E only; if
required). LED at CPU board input X22 should
be on when both doors are closed and both door
switches are closed.
Door Switch Adjustment (KA7E only; if required)
1. With oven top facade removed to access door
switch, loosen switch mounting screws and
adjust switch as required. LED at CPU board
input X22 should be on when both doors are
closed and both door switches are closed.
2. Install all covers and check for proper operation.
Fig. 25
F25294 Rev. A (0412) Page 12 of 72
Fig. 27
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
DOOR SWITCH MAGNET (KA7E
ONLY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Open oven door and pull inner oven door to
overcome magnet hold to main door.
OUTER DOOR GLASS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove door as outlined under DOOR.
2. Lay door on a flat padded surface.
3. Remove screws securing glass and remove
glass.
4. Install new glass in same orientation as old glass.
NOTE: Avoid contact such as bumping or hitting, or
abrasion of glass edges.
5. Install in reverse order and adjust door as
outlined under Door Adjustment.
WASH ARM, STRAINER PANS,
STRAIN PAN SUPPORT, DRAIN
SHROUD (KA7E ONLY)
Fig. 28
2. Remove screws securing magnet housing and
remove magnet.
Fig. 29
3. Reverse procedure to install and check Door
Switch Adjustment (KA7E only; if required).
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Open oven door.
2. Use strainer pan handle and lift pan out of oven.
NOTE: Pan positions are not interchangeable.
Fig. 30
3. To remove wash arm, unscrew knurled part of
wash arm.
Page 13 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 31
4. To remove strain pan support, lift end and
disengage other end from stud.
LAMP
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Do not touch the glass portion of the lamp
with your hands. The oil from your hands could affect
the operation of the lamp. Skin oil may be removed
with alcohol while the lamp is cold.
NOTE: Use a clean rag or paper towel to handle
replacement lamp.
1. Open door.
2. Remove screws securing facade to oven.
Fig. 32
5. To remove drain shroud, remove nuts and
washers securing shroud and lift shroud out of
oven.
Fig. 33
6. Reverse procedures to install.
Fig. 34
3. Remove two nuts securing lamp assembly to top
of oven.
Fig. 35
4. Lift lamp assembly out of oven and support it.
5. Loosen screws in terminal block securing lamp
wires and pull wires out of block.
F25294 Rev. A (0412) Page 14 of 72
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 36
6. Work lamp with wires out of lamp brackets. Wires
can not be removed from lamp.
Fig. 37
7. Install and tighten insulators evenly to prevent
damage.
8. Reverse procedure to install.
FAN MOTORS ASSEMBLY
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Fig. 38
4. Remove washer from both shafts.
Fig. 39
5. Remove C clip from both shafts.
1. Remove
2. Remove wing nut securing each fan blade. Nut is
left hand thread, turn clockwise to remove.
3. Remove both fan blades.
Right Side Cover and Fan Cover.
Page 15 of 72 F25294 Rev. A (0412)
Fig. 40
6. Unscrew both fan mounting nuts.
NOTE: Check condition of o-ring on fan mounting nut
and replace if necessary.
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
C. Work pipe out of oven.
Fig. 41
7. KA7E only:
Fig. 42
A. Loosen hose clamp and remove hose from
control side nozzle and pipe assembly.
B. Remove screws and nuts securing control
side nozzle pipe assembly to top of oven.
NOTE: Check condition of o-rings on screw heads
and replace if necessary.
Fig. 44
8. Insert two large screwdrivers or similar objects
that can lift fan motor assembly enough for motor
shafts to clear inside ceiling.
Fig. 45
9. Identify and disconnect motor wires.
10. Carefully slide fan motor assembly out of cavity.
11. Remove screws securing fan motor assembly
and lift out.
Fig. 43
F25294 Rev. A (0412) Page 16 of 72
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
2. Disconnect lead wires from element being
replaced.
Fig. 46
12. Remove o-ring from old fan motor shaft and
install on new fan motor. If not in good condition,
install new o-ring.
Fig. 47
13. Reverse procedure to install.
14. After installing the fan blade, verify that it does
not rub the top of the cavity. If required, remove
fan blade and tighten fan mounting nut (shown in
Step 6 above).
Fig. 48
3. Use a wrench on element inside oven while
removing and installing mounting nut.
Fig. 49
4. Remove nuts securing element being replaced.
NOTE: If mounting nuts will not slide over wire lead
backup nuts, loosen them or remove them.
HEATING ELEMENTS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover and Fan Cover.
Fig. 50
5. Remove screws securing element support
bracket to ceiling and remove bracket.
Page 17 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 51
6. Slide element out of wall.
7. Clean off old gasket that may stick to wall or
washer and replace with new gasket (not
included with element).
Fig. 53
3. Disconnect wires from high limit thermostat.
4. Remove screws securing high limit to frame.
Fig. 52
8. Reverse procedure to install.
9. Torque element mounting nuts to 45in-lbs. Use
backup wrench on element inside oven to
prevent twisting and damage to element.
10. Torque nuts securing wires onto element to 1420in-lbs. Use a backup wrench on back nut to
prevent twisting and damage to element.
HIGH LIMIT THERMOSTAT
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Pull high limit probe out of hole located in top right
hand corner.
Fig. 54
5. Reverse procedure to install.
NOTE: Set the high limit thermostat to its maximum
clockwise position.
TEMPERATURE SENSOR
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Remove screw and nut securing temperature
sensor to mounting bracket.
F25294 Rev. A (0412) Page 18 of 72
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
POWER SWITCH AND
MOMENTARY SWITCHES
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
NOTE: Momentary switches on KA7E only.
Fig. 55
3. Disconnect wires from temperature sensor.
4. Pull temperature sensor out thru the opening in
oven wall.
5. Reverse procedure to install.
CONTACTORS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove
2. Disconnect lead wires from contactor being
replaced.
3. Push down on top of contactor and pull bottom of
contactor out then up to remove it from the din
rail.
Right Side Cover.
1. Remove
2. Disconnect wires from switch.
NOTE: There are four tabs (two at each end) that
must be depressed in order for switch to slide out of
bezel.
SWITCH DISASSEMBLED FOR VIEW
3. Use recommended tools to release locking tabs
at both top and bottom of switch body.
Right Side Cover.
PARTS REMOVED FOR VIEW
4. Reverse procedure to install.
NOTE: Picture below shows parts not installed in
oven for illustration purposes. It is recommended that
you fully insert tools and gently spread tool ends apart
as shown. Then gently pull switch out of bezel. Some
gentle prying may be necessary to start switch out of
bezel.
Page 19 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
2. Unplug ribbon cable from display board.
A. Spread retaining clips to extract plug from
socket.
Fig. 58
Fig. 60
3. Remove six nuts securing display panel with
display board attached and lift out of oven.
Fig. 59
4. Push switch out of bezel.
5. Reverse procedure to install.
DISPLAY BOARD AND KEYPAD
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Certain components in this system are
subject to damage by electrostatic discharge during
field repairs. A field service grounding kit is available
to prevent damage. The field service grounding kit
must be used anytime the control board is handled.
TSB 1381 KA7E ROTARY OVEN SCRAMBLED VFD
DISPLAY.
1. Remove
F25294 Rev. A (0412) Page 20 of 72
Right Side Cover.
Fig. 61
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
ROTOR STOP/START SWITCH
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Unscrew black knob and remove from switch.
Fig. 62
4. Unplug keypad cable from display board.
5. Remove eight nuts and washers securing board
to panel and lift board off studs.
Fig. 63
6. Remove spacers from studs on display panel.
Fig. 65
3. Unscrew mounting nut.
Fig. 66
Fig. 64
7. Reverse procedure to install.
4. Pull switch out of hole.
5. Identify and disconnect wires.
6. Reverse procedure to install.
Page 21 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
MEAT PROBE MINI JACK
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Mini jack is located under power switch.
Fig. 68
4. Identify and disconnect wires from mini jack
terminals.
Fig. 67
3. Use a small screwdriver or similar object to
carefully pry tabs out and work retainer clip off
jack.
NOTE: Jack shown removed from oven for view. Also
notice that wires are polarity sensitive and must be
connected properly for correct operation.
5. Reverse procedure to install.
CAPACITORS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove
2. Disconnect wires from capacitor being replaced.
3. Remove hardware securing capacitor being
replaced and remove capacitor.
Right Side Cover.
F25294 Rev. A (0412) Page 22 of 72
Fig. 69
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
4. Identify and disconnect wires.
Fig. 70
4. Reverse procedure to install.
WATER LEVEL CONTROL BOARD
(KA7E ONLY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Certain components in this system are
subject to damage by electrostatic discharge during
field repairs. A field service grounding kit is available
to prevent damage. The field service kit must be used
anytime the control board is handled.
1. Remove Right Side Cover.
2. Remove four screws securing divider wall that
water level control board is fastened to.
Fig. 72
5. Use needle nose pliers to squeeze tabs on five
board supports. Work board off supports.
Fig. 71
3. Pivot divider wall to access water level control
board.
Fig. 73
6. Reverse procedure to install.
Page 23 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
WATER LEVEL SENSOR (KA7E
ONLY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove
2. Remove wire attached to sensor.
3. Unscrew sensor and remove from oven.
4. Reverse procedure to install.
Right Side Cover.
PARTS REMOVED FOR VIEW
CHEMICAL SENSOR (KA7E ONLY)
Fig. 75
4. Reverse procedure to install.
WASH PUMP RELAY (KA7E ONLY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Use small screwdriver to pry out release tab, lift
front of relay and disengage rear of relay from din
rail.
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Oven cleaners are corrosive and
can cause chemical burns. Rubber gloves, goggles
and protective clothing are required. Read and follow
the instructions for the oven cleaner.
1. Remove Right Side Cover.
2. Remove wire attached to sensor.
3. Loosen hose clamps and work hoses off sensor.
F25294 Rev. A (0412) Page 24 of 72
3. Identify and disconnect wires.
4. Reverse procedure to install.
Fig. 76
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
TRANSFORMER
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Remove two screws and nuts securing
transformer.
Fig. 77
CPU BOARD
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Certain components in this system are
subject to damage by electrostatic discharge during
field repairs. A field service grounding kit is available
to prevent damage. The field service kit must be used
anytime the control board is handled.
1. Remove
2. Carefully identify and disconnect all wires from
CPU board.
Right Side Cover.
3. Identify and disconnect wires to transformer.
4. Unscrew nut and remove mounting bracket.
Fig. 78
5. Reverse procedure to install.
Fig. 79
3. Squeeze tabs on one support at a time and pull
board off supports.
Fig. 80
4. Reverse procedure to install.
Page 25 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
PERISTALTIC PUMPS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Oven cleaners are corrosive and
can cause chemical burns. Rubber gloves, goggles
and protective clothing are required. Read and follow
the instructions for the oven cleaner.
NOTE: Procedure applies to KA7E; and the KA7EM
with grease assist only.
NOTE: KA7E rotisserie ovens previously were
produced with 3 peristaltic pumps - a gray water/sump
pump, grease pump, and chemical pump. The gray
water/sump pump is no longer required in current
production beginning with Serial No. 46300096. The
pump system parameters have changed so that the
main drain pump (not pictured) removes any lingering
gray water from the sump. Refer to
- PROGRAMMING AND DIAGNOSTICS for
Programming parameters
SERVICE MODE
Pump Removal
1. Remove Right Side Cover.
2. Disconnect wires for pump to be removed.
3. Disconnect hoses for pump to be removed.
4. Remove screws securing pump to frame.
Fig. 82
5. Rotate pump slightly counterclockwise to line up
with cutout in frame and withdraw pump out of
frame.
6. Reverse procedure to install.
Procedure to Replace Pump Hose
NOTE: Only use recommended replacement hose
found in the parts catalog.
Fig. 81
TSB 1417 KA7E - CLOGGING AT INPUT AND
OUTPUT OF PERISTALTIC PUMPS. See Multimedia
section in TIS.
F25294 Rev. A (0412) Page 26 of 72
1. Remove three screws securing face plate and
Fig. 83
pull face plate off.
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
KA7E PREVIOUS CONSTRUCTION WITH GREY
WATER/SUMP PERISTALTIC SHOWN ON LEFT
2. Disconnect hose ends and work hose out of
pump.
Fig. 87
5. Install new hose. Work hose around cavity and
manually turn rollers as hose is positioned. Make
sure hose clamp is in cutout to hold hose in
position.
Fig. 85
3. If rollers need to be removed, use a screwdriver
and release both sides of retaining clamp.
Fig. 86
4. Pull roller assembly off shaft.
Page 27 of 72 F25294 Rev. A (0412)
Fig. 88
6. Install face plate.
7. Install hose clamps and connect hoses. Trim
discharge hose length if needed for proper fit.
8. Complete reversing procedure to install.
9. Verify that pump is working properly as outlined
under SERVICE MODE - PROGRAMMING AND
DIAGNOSTICS.
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
WATER FILL VALVE (KA7E ONLY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Shut off water supply to oven.
3. Disconnect water hose into oven water fill valve.
4. Disconnect wires to water fill valve.
5. Remove screws securing water valve to utility
plate.
KA7E - CURRENT CONSTRUCTION
6. Disconnect hose connected to outlet of water
valve.
7. Reverse procedure to install.
WASH PUMP (KA7E ONLY)
KA7E - PREVIOUS CONSTRUCTION
3. Remove screws securing pump to bracket.
4. Loosen both hose clamps.
Fig. 91
5. Pivot pump and pull out of oven.
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Disconnect wires from wash pump.
6. Reverse procedure to install.
F25294 Rev. A (0412) Page 28 of 72
Fig. 92
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
DRAIN PUMP (KA7E ONLY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove Right Side Cover.
2. Remove WASH PUMP (KA7E ONLY).
3. Disconnect wires from drain pump.
4. Remove screws securing pump to bracket.
5. Loosen both hose clamps.
DRIVE MOTOR ASSEMBLY
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
TSB1400 KA7E - LEAKS AT DRIVE ARM GASKET
DURING WASH CYCLE.
TSB 1383 ROTISSERIE OVENS HR5E, HR7E AND
KA7E NEW DRIVE MOTOR ASSEMBLIES. See
Multimedia section in TIS.
TSI HR7E AND KA7E ROTISSERIE OVEN ROTOR
CRANK ARM DISENGAGING FROM ROTOR. See
Multimedia section in TIS.
1. Check that crank arm is stopped pointing to the
side that has the interior light (or pointing away
from motor). If it is not, apply power to unit and
use the rotate switch to start and stop drive motor
when crank arm is in the proper position. Then
disconnect power.
NOTE: If there is a motor malfunction and you cannot
position the crank arm, you will be able to manually
put the crank arm in the proper position after you
remove the motor and speed reducer. Refer to DRIVE
MOTOR, SPEED REDUCER AND GEARBOX.
Fig. 93
6. Pivot pump and pull out of oven.
Fig. 94
7. Reverse procedure to install.
Fig. 95
2. Remove Right Side Cover.
3. Remove screws securing gasket bracket and
gasket.
NOTE: Replace washers and gasket with new ones
on reassembly.
Page 29 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 96
NOTE: Gasket bracket may not be able to be
removed until gear box mounting screws are
removed.
4. Identify and remove motor wires from terminal
block.
A. Insert jeweler screwdriver or similar small
tool into holes to release spring tension and
pull wires out.
NOTE: The following picture shows the terminal block
disassembled to illustrate how the tool is inserted to
release the wire.
KA7E - PREVIOUS CONSTRUCTION SHOWN
6. Remove four screws, washers and nuts securing
assembly to motor support.
Fig. 99
7. Pivot motor away from oven and work crank arm
out of hole in side wall.
Fig. 97
5. Remove four screws securing pump mounting
box and allow box to slide down for access to
motor support screws.
F25294 Rev. A (0412) Page 30 of 72
8. Remove gasket bracket and gasket if not already
Fig. 100
removed.
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 101
9. If replacing any individual piece, remove four
screws securing motor and speed reducer to
gearbox. Torque screws to 22 inch lbs. on
reassembly.
3. Place non-driven side of rotor shaft onto upper
notch of support bearing.
NOTE: Ensure rotor is slid as far as possible on
bearing support toward non-drive side.
Fig. 103
MOTOR ALREADY REMOVED
10. Install in reverse order.
11. Snug but do not tighten screws securing gasket
bracket at this time. Bracket and gasket must be
loose during the drive motor adjustment
procedure.
12. Continue to Drive Motor Adjustment.
Drive Motor Adjustment
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
4. Place drive end of rotor shaft on crank arm
support notch.
Fig. 104
5. Loosen screws securing rotor drive motor to
support bracket.
NOTE: Some pictures show different model oven
parts. They are used for view and adjustment is
identical.
1. Remove Right Side Cover.
2. Install rotor.
Fig. 105
6. Use a square or similar tool to make gearbox
square to motor support.
Page 31 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
Fig. 106
Fig. 108
8. Rotate rotor to align crank arm pins with slots on
rotor.
Fig. 107
7. Slide gearbox in or out, while keeping it square
to motor support, until there is sufficient
clearance for rotor shaft to be lifted off and on the
support notch without the end of shaft contacting
crank arm.
Fig. 109
9. Slide rotor toward crank arm to engage pins.
F25294 Rev. A (0412) Page 32 of 72
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
17. Check for proper removal and installation of
rotor.
18. Tighten gasket bracket screws.
19. Continue reassembly and check oven for proper
operation.
DRIVE MOTOR, SPEED REDUCER
AND GEARBOX
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Fig. 110
10. Apply power to oven and carefully jog motor to
place crank pointing toward side with interior
light. Ensure crank arm is parallel with oven wall.
Position motor as necessary while maintaining
adjustment in previous step.
11. Jog motor to point crank arm to opposite side of
oven. Ensure crank arm is parallel with oven wall.
Position motor as necessary while maintaining
adjustment in previous steps.
12. Repeat steps 6 thru 11 as necessary until
conditions are met.
13. Jog motor to put crank arm pointing down.
14. Disconnect power to oven.
15. Tighten gear case mounting screws.
NOTE: Non-drive end rotor shaft should seat itself in
lower notch of support bearing. This is normal
operating position.
1. Remove the rotor.
2. Remove
3. Identify and remove motor wires from terminal
block.
A. Insert jeweler screwdriver or similar small
NOTE: The following picture shows the terminal block
disassembled to illustrate how the tool is inserted to
release the wire.
Right Side Cover.
tool into holes to release spring tension and
pull wires out.
Fig. 111
16. Lift rotor out of oven.
Fig. 112
4. Remove four screws securing pump mounting
box and allow box to slide down for access to
motor screws.
Page 33 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
KA7E - PREVIOUS CONSTRUCTION SHOWN
5. Remove four screws securing motor and speed
reducer to gearbox. Torque screws to 22 inch lbs.
on reassembly.
Fig. 114
6. Pull motor away from speed reducer and lay it
aside.
Fig. 116
8. To remove gearbox, manually rotate worm gear
to position crank arm to point toward the side with
the interior light (or away from the motor).
Fig. 117
9. Remove screws securing gasket bracket and
gasket.
NOTE: Replace washers and gasket with new ones
on reassembly.
Fig. 115
7. Pull speed reducer away from gearbox and lay it
aside.
F25294 Rev. A (0412) Page 34 of 72
NOTE: Gasket bracket may not be able to be
removed until gear box mounting screws are
removed.
Fig. 118
KA SERIES ELECTRIC ROTARY OVENS - REMOVAL AND REPLACEMENT OF PARTS
10. Remove four screws, washers and nuts securing
gearbox to motor support.
11. Pivot gearbox away from oven and work crank
arm out of hole in side wall.
12. Remove gasket bracket and gasket if not already
removed.
Fig. 119
13. Install in reverse order.
14. Snug but do not tighten screws securing gasket
bracket at this time. It must be loose during the
drive motor adjustment procedure.
15. Continue to Drive Motor Adjustment.
Page 35 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
SERVICE PROCEDURES AND ADJUSTMENTS
SERVICE MODE - PROGRAMMING
AND DIAGNOSTICS
NOTE: Service Mode allows access to the
programming parameters and diagnostic tests to
check the oven settings and the electrical component
functionality. Additionally, on KA7E machines a
DEMO MODE can be utilized as a continuation of the
diagnostic tests that allow the technician to manually
step through and verify clean cycle operation without
having to run an actual clean cycle.
NOTE: The P key is used to toggle the minus sign on
and off. Use this key if a negative value must be
entered. Entering an invalid number results in the time
display being set to 0 and a beep-beep will sound
indicating you should key in a new value.
Procedure to Enter Service Mode
1. Turn power switch off.
2. Press and hold keys CLOCK, 7, and 8 at the
same time while turning power switch on.
3. Displays shows flashing P in temperature
window which indicates you are in service mode.
2. Press and hold keys 1, 2, and 3 at the same time
while turning power switch on.
3. Display shows ID in the temperature window and
ON or OFF in the time window.
4. Turn power switch off and then back on to return
to operator mode.
5. Repeat steps 1 thru 4 to toggle back.
Procedure to Toggle Between 9 and 99 Programs
1. Turn power switch off.
2. Press and hold keys PROBE, ENTER, and 2 at
the same time while turning power switch on.
3. Display shows 9 or 99 in temperature window
and PROG in the time window.
4. Turn power switch off and then back on to return
to operator mode.
5. Repeat steps 1 thru 4 to toggle back.
4. Press number key(s) to enter Parameter Number
according to the chart below, then press ENTER
key.
A. Time display will flash showing current value
of the parameter.
5. Either accept this value by pressing ENTER key
or key in new value and then press ENTER key
to accept it.
A. P will flash in temperature window indicating
a new parameter number can be entered.
6. To save parameter settings and exit service
mode, turn the power switch to off. The unit will
remember the changes. After the power is turned
off, power can be disconnected from unit if
necessary to complete repairs.
Procedure to Toggle Between No ID and Operator
ID Mode
1. Turn power switch off.
PROGRAMMING, ALL SOFTWARE VERSIONS
Parameter
Number
0 Time display will show software version (Read Only). X X
Description KA7E KA7EM
Service Mode Parameters
KA7E DISPLAY SHOWN
F25294 Rev. A (0412) Page 36 of 72
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
Parameter
Number
1
PROGRAMMING, ALL SOFTWARE VERSIONS
Description KA7E KA7EM
0 = Fahrenheit. F 0 will display in Time window. Default = 0
1 = Celsius. C 1 will display in Time window.
FC will display in Program window.
If the temperature display option is changed, you will see a slight pause as all
stored cook programs are converted to new units.
0 = AM/PM. AP 0 will display in Time window. Default = 0
X X
2
3
4
5
NOTE: In the table below, an asterisk (*) beside
Parameter Number indicates a Service Only
parameter that must be unlocked to verify or edit the
setting as outlined in the following procedure. After the
unlock code is entered, any of the Service Only
parameters are viewable.
1. Press 72 and select ENTER (parameter to unlock
service only parameters.
2. Press 1972 and select ENTER (code to unlock
service only parameters) (1 beep).
Parameter
Number
31 43
1 = 24 hour clock. 24 1 will display in Time window.
CL will display in Program window.
Future use - To be used when connected to remote computer.
0 = ASCII serial protocol. 0 will display in Time window. Default = 0
1 = Binary serial protocol. 1 will display in Time window.
SP will display in Program window.
Future use - To be used when connected to remote computer.
Oven ID number Range = 0 to 31. The number entered will display in Time window.
Default = 0
ID will display in Program window.
Temperature offset. Difference between sensor temperature and displayed
temperature value; used to correct for the difference between sensor and cooking
chamber temperature if any.
Range = +30 to -30. The number entered will display in Time window. Default = 0
C or F depends on unit selected.
OS will display in Program window.
PROGRAMMING CONTINUED, CURRENT SOFTWARE VERSION C027
Setting Description KA7E KA7EM
Chemical pump ON time in seconds (default = 43). Time required may
vary for type of chemical used.
CP will display in Program window.
X X
X X
X X
X X
3. Enter desired Parameter Number containing an
asterisk (*) and verify or edit the setting as
necessary.
4. After all desired Parameter Numbers are
checked, press 0 (zero) and select ENTER.
Normal programming can continue.
5. Verify the remaining Parameter numbers as
necessary.
X ---
Page 37 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
Parameter
Number
*32 10
*33 2
34 120
35 2
*36 2
PROGRAMMING CONTINUED, CURRENT SOFTWARE VERSION C027
Setting Description KA7E KA7EM
Preheat time in minutes (default = 10)
X X
PH will display in Program window.
Main Drain pump ON time in minutes (default = 2)
X ---
SP will display in Program window.
Chemical wash time in minutes (default = 120)
X ---
Ct will display in Program window.
Number of rinse cycles (default = 2)
X ---
nr will display in Program window.
Rinse time in minutes (default = 2)
X ---
Rt will display in Program window.
Number of pre-rinses (default = 1).
37 1
38 0
39 0
*40 5
*41 150
*42 150
*43 200
44 0
nP will displayed in Program window.
Increase pre-rinse number if initial fill is not hot enough.
Leave setting at 0 and advance to next program number.
Ft will display in Program window.
Leave setting at 0 and advance to next program number.
LC will display in Program window.
Water fill time limit in minutes (default = 5)
FL will display in Program window.
Add time as necessary if water pressure is low.
Cool down temperature in Fahrenheit (default = 150)
Ct will display in Program window.
Oven must cool to this temperature before next operation can start.
Preheat temperature in Fahrenheit (default = 150)
CP will display in Program window.
Drying temperature in Fahrenheit (default = 200)
Cd will display in Program window.
Demo Mode. Leave setting at 0 (zero) and continue to the next
Program Number. See DEMO MODE in the next section.
dE will display in Program window.
X ---
X ---
X ---
X ---
X X
X X
X ---
X ---
*45 15
Additional fill time in seconds (default = 10)
0F will display in Program window.
Wash pump ON time during cleaning (default = 4)
48 4
Pr is display in Program window.
Wash pump OFF time during cleaning (default = 4)
49 4
SO will display in Program window.
F25294 Rev. A (0412) Page 38 of 72
X ---
X ---
X ---
Parameter
Number
93 ---
Parameter
Number
31 80
34 120
37 2
48 4
49 4
93 ---
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
PROGRAMMING CONTINUED, CURRENT SOFTWARE VERSION C027
Setting Description KA7E KA7EM
0 (zero) will display in time window as the initial value. Used to set
all parameters to default and clear all recipes.
Set value to 73 and press Enter. Machine is set to factory default
settings.
PROGRAMMING CONTINUED, PREVIOUS SOFTWARE VERSION dA09
Setting Description KA7E ---
Chemical pump ON time in seconds (default = 80). Time required may
vary for type of chemical used.
CP will displayed in Program window.
Chemical wash time in minutes (default = 120)
Ct will displayed in Program window.
Number of pre-rinses (default = 1). Increase if initial fill is not hot
enough.
nP will displayed in Program window.
Wash pump ON time during cleaning (default = 1)
Pr will displayed in Program window.
Wash pump OFF time during cleaning (default = 7)
SO will displayed in Program window.
0 (zero) will display in time window as the initial value. Used to set
all parameters to default and clear all recipes.
Set value to 73 and press Enter. Machine is set to factory default
settings.
X X
X ---
X ---
X ---
X ---
X ---
x x
DIAGNOSTICS, ALL SOFTWARE VERSIONS
Parameter
Number
Display Test
20
21
22 Relay Test, components should function KA7E KA7EM
All segments and LEDs are cycled to check operation.
When complete, oven will beep and be ready for the next Parameter Number
entry.
Keypad Test
When keys are pressed one at a time, the time display will indicate which one.
When no keys are pressed, the display should be blank. If not blank, indicates
a stuck key. Exit service mode by turning power switch off and then on again.
Enter service mode again if necessary.
Press 1 - Operates CR1 "Lights" at terminal X1 X X
Press 2 - Operates CR2 "Fans" at terminal X2 X X
Description KA7E KA7EM
X
X X
Page 39 of 72 F25294 Rev. A (0412)
X
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
Parameter
Number
DIAGNOSTICS, ALL SOFTWARE VERSIONS
Description KA7E KA7EM
Press 3 - Operates CR3 "Rotate Motor" at terminal X3 X X
Press 4 - Operates CR4 "Contactor K1" at terminal X4
X X
NOTE: Contactor K2 is already energized thru power switch & high limit.
Press 5 - Operates CR5 "Sump/ Main Drain Motor" at terminal X5 X ---
Press 6 - Operates CR6 "Wash Pump" at terminal X6 (door(s) must be closed) X ---
Press 7 - Operates CR7 "Chemical Pump" at terminal X7 X ---
Press 8 - Operates CR8 "Sump Fill Valve" at terminal X8 X ---
Press 9 - Operates CR9 "Grease drain" at terminal X9.
X X
NOTE: KA7EM with grease assist option only.
Press 0 - Operates CR10 "Gray water/sump peristaltic" at terminal X10.
23
Press ENTER to exit this test.
NOTE: Gray water/sump peristaltic removed from ovens with Serial No.
46300096 and higher.
CPU Board Input Test, display indicates function KA7E KA7E
This tests for 24VAC input on X16 thru X24 to the CPU board. Uses one of
the 9 digits on the front display for each of the inputs (digit 8 & 9 future use).
The digits are arranged on the display in the pattern shown in the picture at
the end of this section.
- If an input is OFF, the digit displays a dash ( - ).
- If the input is ON, the digit displays a 1.
Included in the picture are display examples for the KA7E input test "Fill Me"
(digit 2) and "Door Position" (digit 7). The tests show a "1" for both the inputs
indicating 24VAC is present (water fill valve energized and doors closed).
NOTE: KA7EM will always display one "1" in digit 2 position and a dash in all
the other digit positions.
Digit 1 - Press rotate switch to test input to CPU board (X16). X X
Digit 2 - Fill Me input to CPU board ( X17 ). Ground the probe to a metal surface
on machine to test (approximately 3 second time delay).
Digit 3 - Low Level Input (X18). Ground the chemical probe sensor to a metal
surface on machine to test (approximately 3 second time delay).
Digit 4 - Press stop switch at rear of machine to test input to CPU board(X19). X ---
Digit 5 - Press silence switch at rear of machine to test input (X20). X ---
X ---
X ---
X ---
X ---
Digit 6 - Press snooze switch at rear of machine to test input (X21). X ---
Digit 7 - Open door(s) to test. The input to CPU board is removed from (X22).
Close door(s) and input is back ON.
Digit 8 & 9 - Future Use. X ---
Press ENTER to exit this test. X ---
F25294 Rev. A (0412) Page 40 of 72
X ---
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
A. Press 0 and select ENTER to verify software
version.
B. Press ENTER to return to parameter
selection screen.
2. If current software version C027, continue to step
4.
3. If previous software version, press 72 and select
ENTER (parameter to unlock service only
parameters.
A. Press 1972 and select ENTER (code to
unlock service only parameters) (1 beep).
DIAGNOSTIC DISPLAY EXAMPLES
DEMO MODE (KA7E ONLY)
NOTE: Diagnostic tests in SERVICE MODE -
PROGRAMMING AND DIAGNOSTICS should be
performed prior to entering DEMO MODE. The DEMO
MODE is a continuation of the diagnostic tests for
verifying clean cycle operation on KA7E machines.
After verifying clean cycle operation, the machine
must be returned to NORMAL MODE as outlined in
the procedure.
NOTE: Remove tube from chemical cleaner bottle
before starting procedure to keep excess chemical
from entering machine during test.
NOTE: The grey water/sump peristaltic pump was
removed from machines with Serial No. 46300096
and higher.
1. Enter SERVICE MODE - PROGRAMMING AND
DIAGNOSTICS. Use the keypad to enter
parameter numbers.
Operation
VFD Display - Current
Software Version (C027)
VFD Display - Previous
Software Version (dA09)
4. Press 44 and select ENTER (allows selection of
DEMO/NORMAL Mode parameter).
5. Press 1 and select ENTER (sets machine to
DEMO MODE).
6. Turn power switch OFF (save settings and exit
service mode).
7. Turn power switch ON. Oven is now operating in
demo mode and is idle. Door should remain
closed.
A. Press CLEAN key to enter clean mode.
Disregard error messages.
B. Cavity light should be ON to indicate the
oven is in demo mode. If light is not on,
repeat procedure to enter DEMO MODE.
NOTE: As you press ENTER to advance through the
clean cycle operation, there may be short delays
before the cycle begins. You can pause the cycle at
any time by pressing the rotate switch or opening the
door.
Verify Functionality
• Cavity light ON
8
9
10
NORMAL WASH MODE
PREHEATING
NORMAL WASH MODE
DRAINING GREASE
NORMAL WASH MODE
WATER FILL
CLEANING
PREHEATING
CLEANING
DRAINING GREASE
CLEANING
WATER FILL
Page 41 of 72 F25294 Rev. A (0412)
• Rotor turning
• Heaters ON
If correct, press ENTER.
• Grease pump ON
• Rotor stops
• Heaters OFF
If correct, press ENTER.
If correct, allow water to fill up to the
water level probe. When water level is
satisfied, it will automatically roll to the
next step.
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
Operation
11
12
13 ---
14
15
16
17
18 ---
19
20
21
22 ---
23
VFD Display - Current
Software Version (C027)
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
ADDING DETERGENT
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
NORMAL WASH MODE
VFD Display - Previous
Software Version (dA09)
CLEANING
DEGREASE #1
WATER DRAIN
WATER FILL
WASHING CLEANING
SOAKING
WATER DRAIN
WATER FILL
RINSE #1
WATER DRAIN
WATER FILL
DEGREASE #1
CLEANING
WATER DRAIN
CLEANING
WATER DRAIN
CLEANING
WATER FILL
CLEANING
ADDING DETERGENT
WASHING
CLEANING
WATER DRAIN
CLEANING
WATER DRAIN
CLEANING
WATER FILL
CLEANING
RINSE #1
CLEANING
WATER DRAIN
CLEANING
WATER DRAIN
CLEANING
WATER FILL
Verify Functionality
If the machine is washing (wash arm
spinning), press ENTER.
If the machine is draining water, press
ENTER.
If installed, the grey water/sump
peristaltic pump should be running.
If correct, press ENTER.
If correct, allow water to fill up to water
level probe. When satisfied it will
automatically roll to the next step.
• Chemical pump ON
• Verify pump is pulling chemical.
See Clean Cycle Troubleshooting
(KA7E Only) as necessary.
If correct, press ENTER.
If the machine is washing (wash arm
spinning), press ENTER.
NOTE: Total cycle time is 2 hrs (timer
counts down). Washing/ soaking
alternates every 4 min during the cycle.
• Drain pump ON
• Rotor stop
If correct, press ENTER.
If installed, the grey water/sump
peristaltic pump should be running.
If correct, press ENTER.
If correct, allow water to fill up to water
level probe. When satisfied it will
automatically roll to the next step.
• Wash arm spraying
• Rotor turning
If correct, press ENTER.
• Drain pump ON
• Rotor stop
If correct, press ENTER.
If installed, the grey water/sump
peristaltic pump should be running.
If correct, press ENTER.
If correct, allow water to fill up to water
level probe. When satisfied it will
automatically roll to the next step.
F25294 Rev. A (0412) Page 42 of 72
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
Operation
24
25
26 ---
27
28
Return to Normal Mode
1. Enter SERVICE MODE - PROGRAMMING AND
DIAGNOSTICS. Use the keypad to enter
parameter numbers.
2. If current software version C027, continue to step
4.
3. If previous software version dA09, press 72 and
select ENTER (parameter to unlock service only
parameters.
A. Press 1972 and select ENTER (code to
4. Press 44 and select ENTER (allows selection of
DEMO/NORMAL Mode parameter).
5. Press 0 and select ENTER (sets machine to
NORMAL MODE).
6. Turn power switch OFF (save settings and exit
service mode).
7. Turn power switch ON. Oven is now operating in
normal mode and is idle.
A. Cavity light should be OFF to indicate the
B. Install tube back into chemical cleaner
VFD Display - Current
Software Version (C027)
NORMAL WASH MODE
RINSE #2
NORMAL WASH MODE
WATER DRAIN
NORMAL WASH MODE
DRYING
PRESS START OR CLEAN
CLEAN CYCLE
COMPLETE
Select program 0-9
unlock service only parameters) (1 beep).
oven is in normal mode. If light is not off,
repeat procedure to enter NORMAL MODE.
bottle.
VFD Display - Previous
Software Version (dA09)
WATER DRAIN
WATER DRAIN
CLEAN CYCLE
CLEANING
RINSE #2
CLEANING
CLEANING
CLEANING
DRYING
COMPLETE
1. Remove Right Side Cover.
2. Remove the probe lead wires from the CPU
3. Test the probe with an ohmmeter.
60 530
70 541
80 552
90 563
100 573
125 600
150 627
200 680
250 732
300 785
Verify Functionality
• Wash arm spraying
• Rotor turning
If correct, press ENTER.
If correct, allow the water to drain
completely from the machine. It will
automatically roll to the next step.
If installed, the grey water/sump
peristaltic pump should be running.
Allow the pump to remove the water. It
will automatically roll to the next step
after 2 minutes.
• Heaters ON
• Rotor turning
If correct, press ENTER.
Done. The machine will automatically
exit CLEANING and go to IDLE.
TEMPERATURE SENSOR TEST
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
board.
TEMPERATURE in °F RESISTANCE ±5 OHMS
Page 43 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
TEMPERATURE in °F RESISTANCE ±5 OHMS
350 836
400 887
450 938
HEATING ELEMENT TEST
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
MODEL
KA7E,
KA7EM
*Tolerance +5 / -10 %.
WATTAGE/
RESISTANCE*
VOLTAGE
2500/208 18
2500/240 24
3000/208 16
3000/240 21
PUMP, K3 RELAY COIL TESTS
3. Record the temperature tester readout for an
additional 3 cycles. It should cycle around a set
point.
4. Calculate the amplitude. Amplitude = (Turn Off Turn On). An amplitude of more than 40 degrees
may indicate a failed element. See heating
element test.
5. Calculate the average. Actual average = (Turn
On + Turn Off ) divided by 2. Variance (between
actual average and programmed set point) of
greater than 5 degrees indicates that adjustment
is needed.
6. To adjust:
A. Enter SERVICE MODE - PROGRAMMING
AND DIAGNOSTICS, enter parameter
number 5 Temperature Offset.
NOTE: The P key is used to toggle the minus sign on
and off. Use this key if a negative value must be
entered.
B. If the actual average temperature is higher
than the programmed set point, then enter
a positive offset value of the same amount.
(For example if the oven is cycling around
an actual average of 360 degrees, adjust by
entering an offset of +10.)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
MODEL PUMP RESISTANCE ±5 OHMS
KA7E Drain 87
KA7E Wash 32
KA7E,
KA7EM*
KA7E K3 190
*Models with grease assist option only.
Grease
Peristaltic
14
CONTROLS CALIBRATION
Calibration Procedure
NOTE: See Table 12 at the end of this procedure.
1. Place temperature tester probe in the geometric
center of oven cavity.
2. Program a set point of 350 degrees. Allow oven
temperature to cycle 3 times. Oven display
temperature reading should equal the set point of
350 degrees.
C. If the actual average temperature is lower
than the programmed set point, then enter
a negative offset value of the same amount.
(For example if the oven is cycling around
an actual average of 340 degrees, adjust by
entering an offset of -10.)
1) The offset can be adjusted + or - 30 deg
F, but is only functional within the
operating limits of the oven. Factory
setting is 0.
7. To save the setting, press the enter key.
8. Turn the power switch to off and then on again.
The oven will remember the changes.
9. To recall the offset value, enter SERVICE MODE
- PROGRAMMING AND DIAGNOSTICS, enter
parameter number 5 Temperature Offset. Verify
that the value you set is visible on the time
display.
F25294 Rev. A (0412) Page 44 of 72
KA SERIES ELECTRIC ROTARY OVENS - SERVICE PROCEDURES AND ADJUSTMENTS
Temperature Data Recording Table
Temperature Tester
Heater Turn on
________ ________ ________
________ ________ ________
________ ________ ________
Actual Average
Temperature Tester
(Turn On + Turn Off)
Heater Turn off
divide by 2
Page 45 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
ELECTRICAL OPERATION
COMPONENT FUNCTION
Power Switch ......... Controls power to control circuits.
High Limit Thermostat ...Prevents oven from exceeding 482°F ±12 °F if controls malfunction.
Wash Pump M1
(KA7E) ................
Drain Pump M2 ....... Empties water from oven when turned on.
Rotisserie Motor M3 ... Turns the rotisserie.
Blower Motors M4, M5 ...Circulates air inside oven cavity.
Grey Water/Sump
Pump M6 (KA7E) .....
Grease Pump M7 ..... Empties grease accumulated in sump prior to wash cycle. KA7EM models with grease
Chemical Pump M8
(KA7E) ................
Water Fill Valve S1
(KA7E) ................
Water Level Control
Board (KA7E) .........
CPU Board ............ Allows input from keypad, controls oven functions.
Contactor K1 ......... Power to oven heat elements. Controlled by CPU board.
Contactor K2 ......... Supplies power to oven heat elements and controlled by power switch and by high limit
Circulates water and detergent during wash cycle.
Empties remaining water from sump area. Removed from ovens with Serial No.
46300096 and higher
assist only.
Dispenses predetermined amount of detergent for wash cycle.
Is turned on to fill oven with fresh water for wash and rinse cycles.
Monitors input from water level sensor and chemical sensor.
thermostat.
Relay K3 (KA7E) ...... Monitors door interlock switches and provides power to wash pump.
Light (internal) ........ Provides light for inside oven.
Temperature Sensor ... Senses temperature of oven cavity for the CPU control.
Display Board ........ Shows time and temperature; also contains keypad for programming CPU board.
Rotisserie Motor
Capacitor C1 ..........
Blower Motor
Capacitors C2, C3 ....
SEQUENCE OF OPERATION
Refer to Model KA7E Schematic Sheet 1 and Sheet 2
for the electrical sequence of operation. The letter "P"
followed by a 2 digit number refers to the Program
Item Number in SERVICE MODE - PROGRAMMING
AND DIAGNOSTICS.
Programmed Cooking
1. Conditions
F25294 Rev. A (0412) Page 46 of 72
Start capacitor for rotisserie motor.
Run capacitors for blower motors M2, M3.
A. Oven connected to correct supply voltage
and is properly grounded.
B. Control board is powered and LED on board
is flashing to indicate power is applied.
NOTE: Control board is powered and neutral is
applied to the oven component circuitry when supply
voltage is connected to the oven. The power switch
controls power for the oven to operate, not power to
the oven.
C. Power switch is off.
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
D. High limit thermostat is set to maximum and
contacts are closed.
E. Oven cavity is at room temperature.
2. Power switch is turned on.
A. Power switch indicator light on.
B. Power supplied to K2 coil thru power switch
contacts and high limit thermostat contacts.
1) K2 contacts close.
C. Display shows time and the last operated
program number.
D. Step LEDs may be on if a program is
selected.
E. Oven is in idle mode.
3. Select a saved cook program (press numbered
keys 1 thru 9).
A. Any programed step LEDs for the selected
program are illuminated.
4. Press Start to run cook cycle.
A. Power applied to rotisserie motor (M3) thru
internal relay CR3 on CPU board.
B. Power applied to blower motors M4 and M5
thru internal relay CR2 on CPU board.
6. Cavity reaches programmed set temperature.
A. CPU board internal relay CR4 opens.
1) Power removed from K1 contactor coil.
a. Power removed from heater
elements E1, E2 and E3.
7. Oven continues to cycle until time expires and
beeper sounds; or add 5 min button is pressed;
or stop button is pressed.
A. Press beeper silence button to silence
beeper.
8. At the end of cook cycle, all power is removed
from M3, M4, M5, E1, E2, and E3.
9. Press Start to run the selected program again, or
select a different program to run.
Washing Cycle Sequence of Operations
NOTE: Auto clean oven's - the grease pump cycles
on/off depending on the times entered in service
mode.
NOTE: The grey water/sump peristaltic pump was
removed from machines with Serial No. 46300096
and higher.
Criteria for starting wash cycle:
1. Power switch must be ON.
C. Power applied to light thru internal relay
CR1 on CPU board.
D. Power applied to heat element contactor K1
coil thru internal relay CR4 on CPU board
and power switch contacts.
1) K1 contacts close.
2) Power applied to heat elements E1,
E2, and E3 thru K1 closed contacts and
K2 closed contacts.
E. Display shows the number of the program
running.
F. Step LED for the cook step in progress will
blink.
G. Cook temperature for the cook step in
progress will display.
H. Total combined cook time for all steps in
the selected program will be displayed and
will count down.
5. Temperature sensor senses oven cavity
temperature.
NOTE: High limit thermostat must be set to maximum
otherwise thermostat could regulate cavity
temperature.
2. Machine must be in idle mode (not in a cooking
mode).
3. Cavity temperature must be less than the
programmed setting P41. Factory default is set
at 250°F (recommended).
A. If the temperature is above this setting when
the clean button is pressed, the unit goes
into cool down mode until temp goes down
to programmed setting P41or below.
4. All spits and accessories are removed from
interior of cavity.
5. No soft metals (i.e. Aluminum foil) are inside the
machine.
User Presses CLEAN Button
1. Preheat mode: Oven goes into pre-heat cooking
mode with a temperature programmed set point
in P42. The machine remains in preheat mode for
the number of minutes programmed in P32.
2. Drain Grease: The grease pump comes ON for
the number of minutes programmed in P30.
3. Pre-rinse: Factory default is 1 pre-rinse.
However, multiple pre-rinses are programmable
in P37.
Page 47 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
4. Water is injected into the sump until level reaches
probe. This "fill time" will then be used for all
subsequent fill cycles.
5. Once water is sensed at the probe, the wash
pump turns ON and rinsing begins. This normally
lasts for 2 minutes. (can be programmed by P36)
6. After rinsing is complete, the drain pump turns
ON for 3 minutes. (can be programmed by P33)
7. After drain pump is complete, the drain peristaltic
turns ON for 3 minutes (if installed on machine).
8. Cycle now complete.
9. Wash: Now the machine is ready to wash.
10. Fill sump with water based on "fill time"
determined during Pre-Rinse.
11. Chemical injected for 40 seconds. (can be
reprogrammed in P31)
12. Begin washing. Wash pump ON for 4 minutes
(can be reprogrammed in P48) and OFF for 4
minutes (can be reprogrammed in P49).
13. Washing lasts for 120 minutes. (can be
reprogrammed in P34)
14. After washing is complete, the drain pump turns
ON for 3 minutes. (can be programmed in P33)
15. After drain pump is complete, the drain peristaltic
turns ON for 3 minutes (if installed on machine).
(can be programmed in P33)
16. Wash cycle complete.
17. Post-rinse: The number of post-rinse cycles is
factory set at 2. (can be programmed in P35)
18. Fill sump with water based on "fill time"
determined by Pre-Rinse.
19. After filling with water, the wash pump turns ON
and washing begins. This normally lasts for 2
minutes.
20. After rinsing is complete, the drain pump turns
ON for 3 minutes.
21. After drain pump is complete, the drain peristaltic
turns ON for 3 minutes (if installed on machine).
22. Cycle now complete.
23. Drying Mode: After the post rinse cycles are
complete, the software enters the Drying Mode
for 10 minutes.
24. The machine heats to 250°F (can be
programmed by P43). If drying time is set to 0,
the drying mode is skipped.
25. Cleaning is complete.
CONTROLS EXPLANATION
Model KA7E
F25294 Rev. A (0412) Page 48 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Model KA7EM
Fig. 122
Page 49 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 123
COMPONENT LOCATIONS
Model KA7E
F25294 Rev. A (0412) Page 50 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 124
KA7E - Component Name
A ...................... Fan, motors and blade assembly M4 and M5
B ...................... Heat elements (two 3000W E1 and E3, one 2500W E2)
C ...................... Temperature sensor
D ...................... TB3 terminal block
E ...................... TB2 terminal block
F ...................... Capacitor C1 for drive motor M3
G ...................... Water level control board
H ...................... Capacitors C2 and C3 for fan motors M4 and M5
I ....................... CPU board
J ...................... Heat element contactors K1 and K2
Page 51 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
K ...................... Transformer supplies 24V to CPU board
L ...................... K3 door interlock relay
M ..................... TB1 terminal strip
N ...................... High limit thermostat
O ...................... TB6 power in terminal block
P ...................... Drive motor assembly M3
Q ...................... Grey Water/Sump pump M6. Removed from ovens with Serial No. 46300096 and higher.
NOTE: TB4 terminal strip located above and behind pumps.
R ...................... Grease pump M7
S ...................... Chemical pump M8
T ...................... Chemical sensor (not shown)
U ...................... Water fill S1
V ...................... Utility plate
W ..................... Wash pump M1
X ...................... Drain manifold
Y ...................... Drain pump M2
1 ...................... Snooze switch
2 ...................... Silence buzzer switch
3 ...................... Stop switch
4 ..................... Rotate switches
5 ..................... Overlay with switch instructions
6 ...................... Keypad and display board assembly
7 ...................... Power switch
8 ...................... Meat probe mini jack
Model KA7EM
F25294 Rev. A (0412) Page 52 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 125
KA7EM - Component Name
A ...................... Fan, motors and blade assembly M4 and M5
B ...................... Heat elements (two 3000W E1 and E3, one 2500W E2)
C ...................... Temperature sensor
D ...................... Capacitor C1 for drive motor M3
E ...................... Capacitors C2 and C3 for fan motors M4 and M5
F ...................... CPU board
G ...................... Heat element contactors K1 and K2
H ...................... Transformer supplies 24V to CPU board
I ....................... TB1 terminal strip
J ...................... High limit thermostat
Page 53 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
K ...................... TB2 power in terminal block
L ...................... Drive motor assembly M3
M ..................... Utility plate (for grease assist option)
N ...................... Electrical Connection (E1)
O ...................... Grease Assist, Pumped Drain (P2)
P ...................... Drain (main & sump) (P1)
Q ...................... TB3 terminal strip located above and behind pump.
R ...................... Grease Pump - Models with grease assist only.
S ...................... Sump Drain Level, Manual
1 ...................... Keypad and display board assembly
2 ...................... Rotate switches
3 ...................... Power switch
4 ...................... Meat probe mini jack
WIRING DIAGRAMS
KA7E - Component Connections
F25294 Rev. A (0412) Page 54 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
KA7EM - Component Connections
Fig. 126
Page 55 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 127
Power Connection
F25294 Rev. A (0412) Page 56 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
SCHEMATIC DIAGRAMS
Model KA7E
Fig. 128
Page 57 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 129
F25294 Rev. A (0412) Page 58 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Model KA7EM
Fig. 130
Page 59 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 131
F25294 Rev. A (0412) Page 60 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 132
Page 61 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
PLUMBING DIAGRAMS (KA7E
ONLY)
Fig. 133
F25294 Rev. A (0412) Page 62 of 72
KA SERIES ELECTRIC ROTARY OVENS - ELECTRICAL OPERATION
Fig. 134
Page 63 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - TROUBLESHOOTING
TROUBLESHOOTING
Troubleshooting
Before performing any of the troubleshooting checks
listed below, use the SERVICE MODE PROGRAMMING AND DIAGNOSTICS to assist in
diagnosing the problem. By utilizing the oven controls
General Troubleshooting (KA7E & KA7EM)
SYMPTOM POSSIBLE CAUSES
Clogging at input and output of peristaltic pumps (KA7E
and KA7EM with grease assist only)
Scrambled VFD display (KA7E only)
Power switch internal indicator light not on but oven
operates.
No power to oven controls.
diagnostic tests the service technician can quickly and
easily determine if a component is functioning
properly or in need of repair.
NOTE: Ensure wiring and board connections are tight
and secure; and board connectors are inserted
properly (not misaligned).
TSB 1417 KA7E - CLOGGING AT INPUT AND OUTPUT
OF PERISTALTIC PUMPS. See Multimedia section in
TIS.
TSB 1381 KA7E ROTARY OVEN SCRAMBLED VFD
DISPLAY.
1. Wired incorrectly.
2. Power switch malfunction.
1. Main breaker open.
2. Power switch malfunction.
3. Wired incorrectly.
1. Oven wired incorrectly.
Main breaker will trip.
Rotor does not turn.
TSI: HR7E AND KA7E ROTISSERIE OVEN ROTOR
CRANK ARM DISENGAGING FROM ROTOR. See
Multimedia section in TIS.
Blower motor does not run when cooking.
Oven temperature does not reach desired temperature
or takes a longer time to heat-up and recover.
2. Heat element shorted.
3. Wiring shorted.
1. See TROUBLESHOOT ROTOR COMPONENTS.
2. Control board malfunction. Test in P22.
3. Crank arm pins sheared.
1. Blower motor malfunction. Test in P22.
2. Blower motor capacitor malfunction.
3. Control board malfunction.
1. Incorrect line voltage.
2. Heat element malfunction.
3. High limit thermostat not set to maximum position.
4. Blower motors malfunction. Test in P22.
5. Blower motor capacitor malfunction.
6. Temperature sensor malfunction.
7. Oven out of calibration.
8. Control board malfunction.
F25294 Rev. A (0412) Page 64 of 72
KA SERIES ELECTRIC ROTARY OVENS - TROUBLESHOOTING
General Troubleshooting (KA7E & KA7EM)
SYMPTOM POSSIBLE CAUSES
1. High limit thermostat open.
No heat, but blowers, rotor and customer lamp do
operate when oven cavity is below set temperature.
No display and/or keypad does not function.
Slow cooking.
Clean Cycle Troubleshooting (KA7E Only)
NOTE: Durning a cleaning cycle, pauses of several seconds may occur as the oven cycles from one mode of
cleaning to another mode. This is normal and should not be considered a problem.
SYMPTOM POSSIBLE CAUSES
Leaks into control area at drive arm.
Water is not spraying during wash cycle.
Wash arm is not turning.
Nothing seems to be happening after CLEAN is pressed.
2. K1 contactor malfunction.
3. K2 contactor malfunction.
4. Control board malfunction.
1. Display cable connection loose.
2. Keypad connection at display circuit board loose.
3. Bad ribbon cable.
4. Keypad malfunction.
5. Display circuit board malfunction.
6. Control board malfunction.
1. Fan cover not installed correctly.
2. Clean oven fans.
3. Blower motor(s) malfunction. Test in P22.
TSB1400 KA7E - LEAKS AT DRIVE ARM GASKET
DURING WASH CYCLE.
1. Wash cycle is in soak mode. Display shows
Soaking.
1. Strainer pans are not installed correctly and are
interfering with wash arm motion.
1. Oven is cooling down or preheating to the optimum
temperature for cleaning.
1. Chemical bottle may be empty.
Oven is not clean enough after clean cycle is complete.
Too much foam or white residue left after clean cycle.
Page 65 of 72 F25294 Rev. A (0412)
2. Ensure tubing is cut at an angle and that standpipe
is in place to prevent tube from curling inside
chemical bottle.
3. Water not hot enough.
4. May need additional pre-rinse programmed (P37).
1. Water not hot enough.
2. Add second pre-rinse to prime hot water line (P37).
3. Make sure washer arm is not plugged. Remove all
debris if necessary.
4. Increase wash pump duty cycle (P48).
5. Increase amount of chemical being used (P31).
KA SERIES ELECTRIC ROTARY OVENS - TROUBLESHOOTING
Clean Cycle Troubleshooting (KA7E Only)
Nothing seems to be happening in clean mode.
Oven uses too much chemical.
Grease or liquids running outside of oven. 1. Pump tubing needs to be replaced.
1. Time delays are programmed between steps during
clean cycle. This is normal operation.
1. Typical usage is approximately 1/2 gallon per day.
Contact Product Service.
1. Chemical bottle may be empty.
2. Ensure tubing is cut at an angle and that standpipe
is in place to prevent tube from curling inside
chemical bottle.
Chemical pump not pulling chemical cleaner.
Clean Cycle Troubleshooting - Error Messages (KA7E Only)
Display Shows When Displayed Cause
ERROR 1
CHECK DETERGENT
OR
CHECK DETERGENT
CHECK DETER PUMP
ERROR 2
When cleaning agent flow from
container into sump is not detected by
sensor.
3. Check chemical pump ON time (P31).
4. Clog inside hose inlet or outlet.
5. Hose leaking or air gaps at connections.
6. Pump not receiving power or malfunction.
7. Control board malfunction.
1. Insufficient liquid level in
cleaning agent bottle.
2. Pick up tube not submerged in
cleaner. Ensure tubing is cut at
an angle and that standpipe is in
place to prevent tube from
curling inside chemical bottle.
3. Defective hose (broken,
squeezed closed).
4. Chemical pump or control not
working. Test in P22.
PRESS STOP
OR
ATTEMPTING TO
DRAIN SUMP
DRAIN FAIL
CHECK DRAIN, PUMP
F25294 Rev. A (0412) Page 66 of 72
When there is water in the sump at
the start of a clean cycle.
1. Oven drain plugged/not flowing.
2. Drain pump plugged.
3. Drain pump fails to operate or
control not working. Test in P22.
KA SERIES ELECTRIC ROTARY OVENS - TROUBLESHOOTING
Clean Cycle Troubleshooting - Error Messages (KA7E Only)
Display Shows When Displayed Cause
ERROR 3
PRESS STOP
OR
CANNOT CONTINUE
CLEANING CYCLE
WATER FAIL
CHECK SUPPLY
DOOR IS OPEN
CLOSE THE DOOR
NORMAL WASH MODE
OR
CLEANING
CYCLE PAUSED
CYCLE
STOPPED
WASH MODE
CANCELLED
OR
CLEANING
CANCELLED
INTERRUPTED
CLEAN CYCLE
When no or insufficient water is
coming into oven.
When door needs closed during
certain steps of the program.
Displays when Pause (Rotate) button
is pressed during cleaning cycle.
Returns to and displays step of cycle
that was paused when Pause button
is pressed and released, or when
door is closed or opened and closed.
Displays for 5 seconds when STOP
key pressed during clean cycle up to
and through DRAINING GREASE, or
when STOP key is pressed during a
cook time.
Displays when STOP key is pressed
during cleaning cycle including and
after the CLEANING WATER FILL
step for the pre-rinse. Please wait
while oven cycles through two rinse
cycles and the drying cycle.
Displays when clean cycle
interrupted by cycling power off and
back on. Please wait while oven
cycles through two rinse cycles and
the drying cycle.
TROUBLESHOOT ROTOR
COMPONENTS
1. If drive hub on gear box does not turn:
A. Remove four screws securing rotor drive
motor and speed reducer to gearbox.
B. Lift motor off speed reducer and support it.
C. Press the rotate switch.
1. Main water supply turned off.
2. Supply hose disconnected or
kinked.
3. Water pressure too low.
4. Oven fill valve or control not
working. Test in P22.
5. Unit draining as it fills. Test in
P22.
1. Door left open when it should be
closed.
2. Door closed position sensor or
control not working. Test in P23.
---
---
---
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1) Verify motor shaft rotation as viewed
from end of shaft. Rotation must be
clockwise. If rotation is
counterclockwise, replace capacitor. If
motor shaft rotates correctly, continue
to step D.
2) If motor does not operate.
a. Does relay on control board
operate?
Yes = replace motor and/or motor
capacitor.
Page 67 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - TROUBLESHOOTING
No = replace control board.
b. Assemble oven and check
operation.
D. Lift speed reducer off gearbox.
E. Insert at least two motor mounting screws
into motor flange and mate speed reducer
to motor. Hold the assembly while pressing
the rotate switch.
1) If output shaft on speed reducer
rotates, continue to step F.
2) If output shaft on speed reducer does
not rotate and motor is running, replace
speed reducer. Assemble oven and
check operation.
F. Manually rotate gearbox shaft which mates
with speed reducer to verify gearbox
function.
1) If crank arm does not rotate or worm
gear cannot be rotated, replace
gearbox. Assemble oven and check
operation.
2) If crank arm does rotate, recheck
previous steps to identify malfunction.
F25294 Rev. A (0412) Page 68 of 72
KA SERIES ELECTRIC ROTARY OVENS - APPENDIX
APPENDIX
REVERSING CONTROLS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
NOTE: Rotor on/off switch position does not get
changed.
1. Remove Right Side Cover.
2. Disconnect wires from power switch.
3. Squeeze tabs on bezel and pull switch and bezel
out of hole.
Fig. 135
4. Unplug ribbon cable from display board.
Fig. 136
5. Remove six nuts securing display panel with
display board attached and lift out of oven.
A. Spread retaining clips to extract plug from
socket.
Fig. 137
Page 69 of 72 F25294 Rev. A (0412)
KA SERIES ELECTRIC ROTARY OVENS - APPENDIX
Fig. 138
6. Remove mini jack from front panel.
A. Use a small screwdriver or similar object to
carefully pry tabs out and work retainer clip
off jack.
Fig. 140
7. Identify and disconnect wires from mini jack
terminals.
8. KA7E only:
A. On opposite side of oven, identify and
remove wires from momentary switches.
B. Remove six nuts securing momentary
switch plate and work the plate from the
oven.
Fig. 139
NOTE: Jack shown removed from oven for view. Also
notice that wires are polarity sensitive and must be
connected properly for correct operation.
C. Remove two nuts securing the auto clean
overlay plate and its retaining plate.
D. Install momentary switch plate and auto
clean overlay plate on the opposite side of
oven.
F25294 Rev. A (0412) Page 70 of 72
KA SERIES ELECTRIC ROTARY OVENS - APPENDIX
Fig. 141
9. KA7EM only:
A. On the opposite side of oven, remove six
nuts securing the blank switch cover plate
and work the plate from oven.
B. Remove two nuts securing blank overlay
cover plate and its retaining plate.
C. Install the blank switch cover plate and
blank overlay cover plate on the opposite
side of where removed.
MODEL KA7EM
D. From front of oven, remove drain handle
from the drain control linkage assembly
(manual grease/sump drain).
E. Remove drain control linkage assembly
from drain valve and work from oven.
1) Remove drain control lever from
linkage assembly.
2) Re-install drain control lever near the
end of linkage assembly. See picture
23921 below.
3) Remove bushing from the front of
oven.
Page 71 of 72 F25294 Rev. A (0412)
Fig. 143
KA SERIES ELECTRIC ROTARY OVENS - APPENDIX
F. From rear of oven, remove plug and re-
install on the opposite side of where
removed.
1) Install bushing in-place of plug.
Fig. 144
Fig. 145
10. Install power switch on the opposite side of where
removed.
11. Install display panel with display board on the
opposite side of where removed.
12. Cut cable ties as necessary and route wires to
their appropriate parts then reconnect.
13. Route ribbon cable to display board and
reconnect.
14. Install new cable ties as needed to neatly dress
wires out of the way.
15. Install covers and check for proper operation.
2) Insert threaded end of drain control
linkage assembly through bushing.
3) Install drain control lever to drain valve.
Secure with mounting nut.
F25294 Rev. A (0412) Page 72 of 72
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