mastro ABJ0001, ABA2002, ABJ0002, ABA2004 Maintenance Instructions

008_03

Installation, operating and
maintenance instructions

04/2006

GAS COOKER

ABJ0001 · ABJ0002

ABA2002
ABA2004

Models and dimensions page 3

Data of appliances 5

Technical data 5-6

Operating instructions 7

Construction, equipment installed

and safety devices 7

Cooking top (gas) 7

Electric oven (convection-heated) 7

Assembly 7

Location 7

Legal and technical requisites 7

Installation 7

Installation procedure 7

Connecting the gas supply 7

Gas venting 7

Wiring 7

Unipotential 7

Commissioning the appliance 8

Before commissioning the appliance 8

Start-up 8

Testing the power rating 8

Checking input pressure 8

Checking power rating using

the volumetric method 8

Checking power rating when using

LP gas 8

Checking the primary air 8

Checking the functions 8

Note for the installer 8

Running the appliance on other types

of gas 8

Replacing the nozzle on a burner 8

Adjusting the low flame

page

9

Maintenance 9

Replacing parts 9

Ignition plug 9

Gas tap 9

Thermocouple 9

Electric oven resistences 60 9

Electric oven resistences 90 9

Using the appliance 11

Start-up 11

Turning a burner on and

off (cooking top) 11

Turning the electric oven on and off 60 11

Turning the appliance off

in an emergency 11

Turning the electric oven on and off 90 11

What to do if something goes wrong or if

not using the appliance for a long time 12

Taking care of the appliance -

frequency of maintenance 12

WEEE Directive 12

Wiring 13-14

Warning 15

INDEX

008-03 - Gas cooker

2

008-03 - Gas cooker

3

Dimensions

Fig. 1 - A

A
G
T

Off-take
Gas connection
Data plate

Burner:

B Ø 70
C Ø 90

T

T

A

40 40

320

ABJ00001

G

C

655

B

""

400

80 ±1

G

13.5 ±1

35 ±2

G

130

300

220 50

30

40 40

A

720

130

300

80 ±1

220 50

G

30

ABJ00002

215

260

180

655

G

C

B

400 200200

800

B

C

13.5 ±1

35±2

G

260 215

180

37,5

125 1 25

55 40 55 55 40 55

A

725

ABA20002

G

655 ±1

37,5

T

130

220 50

C

875

465140

655

B

400 200200

800

G

B

C

13.5 ±1

35±2

G

260 215

180

008-03 - Gas cooker

4

Dimensions

125 125

875 210

27,5

83 8374

5540

55

725

C

55 5540

13,5 1

B

T

27,5

35 1

G

125 12525055 5540 55 55

40

55 554083 8374

T

220 50

875 210

465

650 G

140

52,5 52,5

1095

13,5 1

1095

220 50

465

650 G

140

ABA20004

250

280

700

B

C

B

35 2

G

250

280

700

B

200 400 200

800

C

170

C

200 400 200400

B

1200

C

170

G

Gas connection

T

Data plate

008-03 - Gas cooker

5

2 - DATA OF APPLIANCES

The instructions contained in this manual apply to our gas
cookers in the II2H3+ category (see table on page 6).
The data plate is located on the front of the appliance and

CAT/KAT GAS/GAZ G30 G31 G20 G25

II2H3B/P P mbar 30 30 20 -

II2H3+ P mbar 30 37 20--

II2H3+ P mbar 28 37 20 -

0051
TIPO/TYPE

MOD.

ART.

N.

N.

Qn kW

MOD.

V AC kW Hz

THE APPLIANCE MUST BE CONNECTED IN COMPLIANCE WITH THE LAWS IN FORCE
AND INSTALLED IN A WELL-VENTILATED ROOM. READ THE INSTRUCTION MANUALS
BEFORE INSTALLING AND USING THE APPLIANCE.
THE APPLIANCE MUST BE INSTALLED BY QUALIFIED PERSONNEL.

m3/h

II2ELL3B/P P mbar 50 50 20 20

II2E+3+ P mbar 28 37 20 25

II2H3B/P P mbar 50 50 20 -

I2E P mbar - - 20 -

II2H3+ P mbar 28 37 20 -

I3B/P P mbar 30 30

I3+ P mbar 28 37

Predisposto a gas: - Gas preset: - Prevu pour gaz:

Eingestelt für Gas: - Preparado para gas: -

on the control panel. It contains all necessary reference
data such as the name of the manufacturer, input pressu­re, gas type setting, etc.

--II2H3B/P P mbar 30 30

--

--

Geschuckt voor:

SE FI DK CZ SK SI

IT CH PT

ES IE GB GR

NL

25II2L3B/P P mbar 30 30

DE

FR BE

AT C H

LU

EE LV LT

EE LV LT

NO MT CY IS HU

CY

MADE IN ITALY

G30/G31 28/37 mbar

G20 20 mbar

Model

ABJ00001

ABJ00002

ABA20004

ABA20002

3 - TECHNICAL DATA

Version

Gas range 2 burners

Gas range 4 burners

Gas range 4 burners - electric convection oven 1/1 gn

Gas range 6 burners - electric convection oven 1/1 gn

Gas range 4 burners - electric convection oven 60

Dim.: LxWxH

400 x 650 x 300

800 x 650 x 300

800 x 650 x 875

1200 x 650 x 875

800 x 650 x 875

N.

51BQ2895

51BQ2895

51BQ2895

51BQ2895

51BQ2895

008-03 - Gas cooker

6

Model

TABLE 1

B

Ø 70

C
Ø 90

Category

Construction type

Air necessary for combustion

Nominal capacity

Minimum capacity

Overall capacity (Gas)

ABJ00001

ABJ00002

6.0

12.0

kW

kW

hour consumption

G20

m

0,63

1,27

12.0

kW

1,27

ABA20004

18.0

kW

1,90

ABA20002

12.0

kW

1,27

Input pressure

Natural gas 2H

LP gas 3+

G20

G30/G31

Gas connection values (consumption)

Natural gas 2H

LP gas 3+

(HuB = 9.45 kWh/m

(HuB = 12.87 kWh/kg) in kg/h

II2H3+

A

3

/h

m

kW

kW

G25

3

/h

m3/h

20 mbar

28/37 mbar

3

) in m3/h

-

-

-

-

-

G30/G31

kg/h

0,47

0,94

0,94

1,41

0,94

5

2.5

0.7

0.265

0.196

7

3.5

0.7

0.370

0.274

Nozzles Ø 1/100 mm.

G20
Main
burner

G30/31

N. nozzles pilot burner

Primary air distance "A"

Electrotechnical data

Power electric oven :

60 GN 1/1 - 2.56 kW

90 GN 1/1 - 2.56 kW

Nominal capacity

Low flame

Nominal capacity

Low flame

G20

G30/G31

Natural gas G20

LP gas G30/G31

120

adjustable

80

40

-

-

8

1

Voltage rating:

AC 230 50 Hz

145

adjustable

95

40

-

-

8

3

Lead wire / Section

3 x 1.5 mm2

008-03 - Gas cooker

7

Construction, equipment installed and
safety devices

Robust steel frame, with 4 legs (adjustable in height).
18/10 chrome-nickel steel outer panelling.

Cooking top (Gas)

- Each position has a burner with a flame distributor.

- Max-min safety gas taps.

- Thermocouple.

- Each position has independent piezo ignition.

- Enamelled cast-iron pan supports.

- Plastic control knobs.

Electric oven (convection-heated)

- Acid-proof enamelled sheet-steel muffle; steel grill
support pair, removable for cleaning.

- Acid-proof enamelled sheet-metal floor.

- Extractable chromium-plated steel grill.

- Heat-insulated double-thickness door with heat-proof
glass window; on sprung hinges; insulated handle.

- Door and muffle insulated with spun glass.

- Oven temperature adjustable from 50°C to 290°C (122°F
to 554°F) by means of a thermostat connected to a switch.

- The pilot lamps show whetherthe oven is on and/or
heated.

ASSEMBLY

Location

The appliance should be installed in a well ventilated room,
and if possible under a range hood.
The appliance can be installed on its own or alongside
other equipment.
If the appliance is to be installed near inflammable walls, a
minimum distance of 150 mm around the sides and back
should be allowed.
If this is impossible, take proper steps to ensure the
installation is safe, such as fitting tiles or heat-reflecting
material to the walls
Before connecting up the appliance to the gas supply,
check on the data plate that the appliance is fitted for the
type of gas available.
If not, consult paragraph “Running the appliance on other
types of gas”, page 8.

Legal and technical requisites

During assembly, the following legal and technical
requisites should be adhered to:

- relevant national legislation;

- local building and fire safety regulations;

- worksheet “Technical rules for installing gas”;

- worksheet “Technical rules for LP gas”;

- worksheet “Gas installations in industrial kitchens”;

- industrial injury legislation;

- local Gas Board regulations;

- current CEI regulations.

INSTALLATION

Assembly, installation and maintenance, i.e.:

- assembly, connecting the gas supply, checking power
rating, transforming or adapting the appliance to run on
other types of gas, and commissioning,

- connecting the appliance to the mains,

must all be done by contractors authorised by the local
Gas and Electricity Boards in accordance with local and
national legislation.
Before doing anything else, seek advice from your Gas
and Electricity Boards.

Installation procedure

To level the appliance correctly, adjust the height of the
four legs.

Connecting the gas supply

The R 1/2” gas off-take on the appliance can either be
permanently fixed to the mains or made detachable using
a standard adaptor.
If flexible hose is used, it must be in stainless steel and to
current regulations.
After completing connection, check for leaks using a
special leak-detector spray.

Gas venting

These appliances are A construction type, thus no gas
venting is required.
For advice on ventilating the premises where the
appliance is installed, observe current regulations.

Wiring

Before connecting the appliance to the electricity supply,
check the following:

- make sure the mains supply voltage matches the value
on the data plate;

- make sure the appliance is properly earthed.

- Make sure the shielding of the connections can stand
up to the nominal capacity.

Also an omnipolar switch with at least a 3 mm. contact
aperture should be installed upstream of the appliance, so
that it can be completely disconnected from the mains.
Compulsort automatic safety switches can be used for this
purpose.

Equipotential

The omnipolar switch must be located near the appliance
and easy to reach.
The connecting cable used for the appliance must be
suited in section to the particular version and to its
nominal capacity.
Use an H07-RN-F type cable.

OPERATING INSTRUCTIONS

008-03 - Gas cooker

8

Before commissioning the appliance

Before commissioning the appliance, remove the protective
wrapping.

Start-up

Before starting the appliance up, check that its specifica­tions (category and type of gas used) match those of the fa­mily and group of the gas available locally.
If not, adapt the appliance to the gas family or group requi­red (see paragraph “Running the appliance on other types
of gas”, page 8).
To start the appliance up, see the instructions for regular
use.

Testing the power rating

Use the specific nozzles for the nominal capacity on the ap­pliance.
Capacity can be of two types:

- nominal, as given on the data plate;

- minimum.

These nozzles are shown in “TECHNICAL DATA” table 1.
The following are the operating pressure tolerances to ob­tain the nominal power according to the agreed nozzles:

- from 15 to 22.5 mbar for gases of the second family

- from 25 to 45 mbar for gases of the third family
(Butane-Propane).

The appliance will not work outside the above pressure th­reshholds.
To adjust the capacity to its minimum value, use the data in
tables 1 “TECHNICAL DATA”.
If you wish to check the nominal capacity further, you may
do so using a gas meter according to the so-called ”volu­metric method”. It is normally enough, however, simply to
check that the nozzles are functioning correctly.

Checking input pressure (Fig. 2)

Input pressure should be measured using a gauge (e.g. a
gooseneck pipe, min. resolution 0.1 mbar).
Remove screw (F) from the pressure socket and connect
it to the tube on the gauge; after measuring, the screw
should be retightened absolutely airtight (F).

Checking power rating using the
volumetric method

Using a gas meter and a chronometer, you can read the
volume of gas output per time unit.
The correct volume will be the value of “E” expressed in li­tres per hour (It/hr) or litres per minute (It/min).
The following formula is used to calculate the value of “E”:

Capacity

Heat value

E =

Capacity should only be measured when the appliance is at
a standstill.
The heat value can be obtained from your local Gas Board.
To obtain the nominal and minimum capacities in relation to
the nominal pressure, consult “TECHNICAL DATA” table 1.

WARNING

It is not possible to adjust nominal capacity in advance.

Checking power rating when using LP
gas

Check that the type of nozzles used match manufacturer's
specifications. Check that the output pressure regulator in­stalled collaterally to the plant conforms to the specifica­tions laid down in paragraph "Checking input pressure", pa­ge 8 (see data plate or measure the pressure).

Checking the primary air

The primary air in the open burners can be adjusted.
Air volume flow is correct when there is sufficient protection
against the flame rising when the burner is cold or light­back when it is hot.

Checking the functions

- Start the appliance in accordance with the instructions;

- Check the gas tubes for leaks;

- Check that the flame on the main burner lights properly
and is correctly formed, even on low;

- Draw up a servicing and maintenance contract.

Note for the installer

- Explain and demonstrate to the user how the machine
works according to the instructions, and hand him this
manual.

- Remind the user that any structural alterations to the
room housing the appliance may affect the combustion
air supply. Once the alterations have been completed,
the appliance and its functions should be thoroughly
checked.

Running the appliance on other types of
gas

When changing to another type of gas, e.g. from natural to
LP, or to another gas group, consult the “TECHNICAL DA­TA” table 1 to make sure you use the appropriate nozzlzes
for the main burner. The nozzles for the cooking top burners
for different types of gas, marked in 100ths of mm, are in a
case supplied with the appliance.
When the appliance has been transformed or adapted, re­check its functions as described in paragraph "Checking
the functions", page 7.

Replacing the nozzle on a burner
(Fig. 2)

To change nozzle (C), remove the knobs and loosen the

COMMISSIONING THE APPLIANCE

control panel fixing screws.
Remove the control panel, disconnect the ignition lead and
unscrew the nozzle from the nozzle holder with a spanner.
Replace with a new nozzle (see “TECHNICAL DATA” table);
if necessary, to facilitate this operation push the air adjust­ment sleeve upwards loosening screw (G).
After fitting the nozzle, reset primary air distance “A” (see
“TECHNICAL DATA” table).

Adjusting the low flame (Fig. 2)

Referring to the “TECHNICAL DATA” table, set the low fla­me screw (D) as follows:

- if the appliance is to run on LP gas, tighten the low flame
screw as far as it will go;

- if the appliance is to run on natural gas, turn the low fla­me screw while simultaneously adjusting the primary air:

● read off the setting in It/min which corresponds to the

heat value (calculated by the “Volumetric Method”) in
the Gas Flow Setting Table (2);

● start the appliance up according to the instructions;

● after allowing the appliance to run for 45 minutes, turn

the knob to low and set minimum by turning screw (20)
(to the right = gas flow decreases; to the left = gas flow
increases).

Adjust the gas flow.

MAINTENANCE

The following maintenance programme should be carried
out at least once a year:

- Check that all the safety and setting devices are working
properly;

- Check that the burners are working properly with regard
to:

● ignition

● combustion safety;

- Check the functions of the appliance as described in pa­ragraph "Checking the functions".

If the main burner needs cleaning, proceed as follows:

a) remove the pan support, the flame distributor, the

crown and the burner supports;

b) clean the parts with water and detergent, rinse and dry;
c) when reassembling the parts, make sure you replace

them in the right order.

REPLACING PARTS

All parts must be replaced by authorised technicians
only!

To replace the following parts first remove all the control
knobs and the control panel (after loosening the fixing
screws), then disconnect the ignition lead.

Ignition plug (Fig. 2)

Remove the pan support, the flame distributor, the crown
and the the burner crown support, pull out the spring using
a pointed tool, remove the ignition plug from the bottom, di­sconnect the ignition lead and insert a new plug.

Gas tap (Fig. 2)

Loosen the gas piping and thermocouple fixing screws,
then loosen the screws fixing the gas supply to the gas
ramp and insert a new tap.

Thermocouple (Fig. 2)

Loosen the screws fixing the thermocouple to the gas tap
and the burner. Insert the new part. After replacing the
parts, fit the control panel back into place.

WARNING

Every time a replacement involving gas input parts is
made, recheck all functions and test for leakage.

Resistances electric oven 60

Disconnect the power supply!

Open the oven door; remove the protective shield covering
the back wall of the oven by loosening its fixing screws; the
resistance is held by 5 screws, two of which are on the flan­ge. Once these screws have been loosened, you can pull
the resistance forward. Disconnect the leads and fit a new
resistance.

Resistances electric oven 90

Disconnect the appliance from the mains. The bottom resi­stance is under the oven floor.
The top resistance is fixed to the roof of the cooking cham­ber.
To remove the resistances, loosen the screws fixing them
to the relative flange, pull the resistances and relative leads
forwards.
Disconnect the leads using a screwdriver and fit a new re­sistance following the above sequence in reverse order.

008-03 - Gas cooker

9

008-03 - Gas cooker

10

2

G

B

C

E

D

F

START-UP

Turning a burner on and off (cooking
top) (Fig. 2)

Press the knob (H) and turn to the left as far as .
Keep the knob pressed down while repeatedly pressing
the piezo ignition button (E) until the flame catches.
Keep the knob pressed down for another 15-20 seconds:
if the flame goes out after the knob is released, start
again.
To turn the burner off during normal operation,turn the
knob as far as (●).

Turning the electric oven on and off 60
(Fig. 3)

If you turn selector knob (I) to the right, first the oven light
will come on, followed immediately by the ventilator, but
the heating will stay OFF.
With the oven in this condition (air circulation without any
heating) it can be used to defreeze foodstuffs.
In this condition only the green pilot lamp (M) (appliance
on) stays on.
If you continue to turn the knob, you can set any
temperature required.
As soon as the heating comes on, yellow pilot lamp (L) will
come on, and go off as soon as the required temperature
is reached.
To turn the oven , turn the knob back to ● (OFF).

Turning the appliance off in an
emergency

In an emergency turn off the appliance according to the
instructions; close the gas supply tap or disconnect the
power supply.

Turning the electric oven on and off 90
(Fig. 6)

Select the type of heating required by turning knob 23,
bearing in mind that the indicator light 25 stays on in all
positions.

This symbol indicates that the two interior oven
lights are on without any type of heating selected
(optional).

Heating is both from above (ceiling element) and
below (floor element). This is the traditional
cooking mode.

The bottom heating element is switched on (floor
element).
Heat therefore rises from bottom to top.

Heating is from top to bottom, as the top element
is switched on (ceiling element).

In this position the "grill" element, placed at the
top of the oven over the ceiling element, is
switched on.

As in the previous position with the fan switched
on (convection).

In this position the ceiling element (above), the
floor element (below) and the fan are all switched
on (convection).

Convection cooking

In this position the heat is produced by a circular
element placed on the back of the oven around
the fan.

Defrosting mode

No heating element is in operation; only the fan is
switched on to quickly defrost frozen foods.

USING THE APPLIANCE

008-03 - Gas cooker

11

3

6

0

0

1

0

I

4

1

0

8

1

L
M

2

5

0

2

2

0

0

5

0

0

1

0

5

1

0

3

0

0

2

5

0

0

2

24 2623 25

008-03 - Gas cooker

12

The required temperature may be chosen by turning knob
24: warning light 26 comes on and goes out when the
elements are switched on. To turn off the oven, turn the
two knobs to position ● (zero).

What to do if something goes wrong or
if not using the appliance for a long
time

When the appliance is not to be used for a long time,
clean thoroughly and turn off both the gas and electric
supply. In the case of malfunctioning or failure, turn off
the gas supply and disconnect from the mains. Call the
service centre.

TAKING CARE OF THE APPLIANCE
FREQUENCY OF MAINTENANCE

Warning!

Never clean the appliance with jets of water, whether
direct or pressurised.
Allow the machine to cool down before cleaning

Giving the appliance a thorough clean every day (after
turning it off) will keep it in perfect working order and
make it last longer. All steel parts should be cleaned with
water and a detergent, using a damp cloth; do not use
abrasive substances or corroding detergents.
Do not use steel wool, which could leave traces of rust.
For the same reason, avoid touching the appliance with
anything made of iron.
Do not clean any parts of the appliance other than the
grilling plate with emery or sandpaper. If absolutely
necessary, you may use powdered pumice stone.
If the appliance is extremely dirty, use a synthetic sponge
such as Scotchbrite.
After cleaning the appliance, rinse with clean water and
dry with a clean cloth.
All maintenance work must be carried out by qualified
personnel only.
Have the appliance checked at least once a year; we
strongly recommend that you stipulate a servicing and
maintenance contract with your supplier.

THE 2002/96/EC DIRECTIVE (WEEE):
information to users

This informational note is meant only for owners
of equipment marked with the symbol shown in
Fig. A on the adhesive label featuring the tech­nical specifications applied on the actual pro-

duct (the label also giving the serial number).

This symbol indicates that the product is classified, ac­cording to the regulations in force, as an item of electrical
and electronic equipment and conforms to EU Directive
2002/96/EC (WEEE) meaning that, at the end of its service
life, it must be treated separately from domestic waste,
i.e. it must be handed in free of charge to a separate wa­ste electrical and electronic equipment collection centre
or returned to the reseller when buying a new equivalent
item of equipment.

The user is responsible for delivering the unit at the end of
its life to the appropriate collection facilities. Failure to do
so shall result in the user being subject to the penalties
prescribed by the legislation in force on waste.
Suitable separated collection so that the unit no longer
used can be sent off for environmentally compatible recy­cling, treatment and disposal helps avoid possible negati­ve effects on the environment and on health and facilita­tes the recycling of the product's component materials.

For more detailed information on available collection sy­stems, contact the local waste disposal service or the
shop you purchased the unit from.
Producers and importers fulfil their responsibility for envi­ronmentally compatible recycling, treatment and disposal
both directly and by joining a collective scheme.

008-03 - Gas cooker

13

Wiring diagrams

ABA20002

230 V 1 AC

L1 L2

mA

123

H1

P2 P1

B1

4312

F1

F2

R1

P3

H2

M

M1

~

H3

mA

Line input terminal board

B1

Commutator

F1

Thermostat

H1

Pilot lamp

H2

Pilot lamp (voltage)

R1

Oven resistance

F2

Safety thermostat

H3

Oven lighting

M1

Motorfan

Total capacity 2,5 kW

008-03 - Gas cooker

14

Wiring diagrams

ABA20004

RC

RG

MV

~

CR

P3

5

P4

6

P5

7

P6

G

P1

P2

2

1

3

4

T

21

A

Terminal board

C

Switch

R

Green indicator light

G

Yellow indicator light

RC

Ceiling element

RG

Grill element

RS

Floor element

RV

Fan element

MV

Fan motor

T

Thermostat.

Total capacity 2,5 kW

RV

RS

NL

A

008-03 - Gas cooker

15

WARNING

DUE TO ITS POLICY OF CONTINUAL PRODUCT IMPRO­VEMENT, THE MANUFACTURER RESERVES THE RIGHT
TO MAKE ANY CHANGES DEEMED NECESSARY.

THE MANUFACTURER CANNOT BE HELD RESPONSI­BLE IF THE INSTRUCTIONS CONTAINED IN THIS MA­NUAL ARE NOT OBSERVED.