Moffat E35GN-26 Service Manual

E35 CONVECTION OVEN

SERVICE

MANUAL

E35 Turbofan Ovens

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WARNING: ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY.

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CONTENTS

This manual is designed to take a more in depth look at the E35 convection oven for the purpose of making the unit more understandable to service people.

There are settings explained in this manual that should never require to be adjusted, but for completeness and those special cases where these settings are required to change, this manual gives a full explanation as to how, and what effects will result.

SECTION PAGE NO.

1. SPECIFICATIONS .............................................................................................................................. 5

2. INSTALLATION .................................................................................................................................. 10

3. OPERATION ....................................................................................................................................... 12

3.1 Description of Controls (up to Lot No. 0817999).

3.2 Description of Controls (from Lot No. 0818001).

3.3 Explanation of Control System

4. MAINTENANCE .................................................................................................................................. 19

4.1 Cleaning

4.2 Routine Procedures

5. TROUBLE SHOOTING GUIDE........................................................................................................... 21

6. SERVICE PROCEDURES .................................................................................................................. 24

6.2 Access

6.3 Replacement

6.4 Adjustment / Calibration

7. ELECTRICAL SCHEMATICS ............................................................................................................. 47

8. ELECTRICAL WIRING DIAGRAMS................................................................................................... 54

9. ACCESSORIES / OPTIONS ............................................................................................................... 68

IMPORTANT: MAKING ALTERATIONS MAY VOID WARRANTIES AND APPROVALS.

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10. PARTS DIAGRAMS............................................................................................................................ 69

11.1 Oven Main Assembly.

11.2 Control Panel Assembly.

11.3 Gear Plate Assembly.

11.4 Door Assembly.

11. SERVICE CONTACTS........................................................................................................................ 92

APPENDIX A. STACKING KIT INSTRUCTIONS........................................................................................ 94

APPENDIX B. STAND MOUNTING INSTRUCTIONS ................................................................................ 97

APPENDIX C. MOTOR CONTROL AND STEAM TIMER ADJUSTMENT GUIDE .................................... 98

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MODEL: E35-26

1. SPECIFICATIONS

FRONT

880

720

15/16”

MWS

ELECTRICAL ENTRY

WATER ENTRY

155

165

MWS

665

1 4

5 8

880

800

SIDE

VENT Ø 76 O.D.

PLAN

MWS

(1.6)

LEGEND

630

- Electrical connection entry point

- Water entry - 3/4” BSP hose connection

Dimensions shown in millimetres and inches

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MODEL: E35-30

FRONT

880

720

15/16”

MWS

ELECTRICAL ENTRY

WATER ENTRY

155

" 2

165

MWS

665

38.6

980

800

SIDE

VENT Ø 76 O.D.

PLAN

MWS

(1.6)

LEGEND

630

- Electrical connection entry point

- Water entry - 3/4” BSP hose connection

Dimensions shown in millimetres and inches

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MODEL: E35GN-26

970

810

FRONT

MWS

WATER ENTRY

165

ELECTRICAL ENTRY

880

165

800

MWS

66548

SIDE

VENT Ø 76 O.D.

PLAN

LEGEND

- Electrical connection entry point

- Water entry - 3/4” BSP hose connection

Dimensions shown in millimetres. Dimensions in inches shown in brackets.

630

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MODEL: E35GN-26 DOUBLE STACK

970

998

955

MWS

165

MWS

2030

790 80075

335

LEGEND

FRONT

MWS

VENT Ø 76 O.D.

720

PLAN

- Electrical connection entry point

- Water entry - 3/4” BSP hose connection

SIDE

Dimensions shown in millimetres. Dimensions in inches shown in brackets.

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LOCATION

To ensure correct ventilation for the motor and controls the following minimum installation clearances are to be adhered to:

Rear 0mm / 0“. Left-hand side 0mm / 0”. Right-hand side 75mm / 3.0”.

OVEN INTERNAL DIMENSIONS E35-26

Width 465mm / 18

/4”. Height 685mm / 27”. Depth 760mm / 30”. Oven Volume 0.24m³ / 8.5ft³.

E35-30

Width 465mm / 18

/4”. Height 685mm / 27”. Depth 860mm / 34”. Oven Volume 0.27m³ / 9.7ft³.

E35GN-26

Width 555mm / 21

/5” Height 685mm / 27” Depth 760mm / 30” Oven Volume 0.29m³ / 10.2ft³

OVEN RACK SIZE E35-26

Width 460mm / 18” or 405mm / 16” (Adjustable shelf width) Depth 660mm / 26”

E35-30

Width 460mm / 18” or 405mm / 16” (Adjustable shelf width) Depth 760mm / 30”

E35GN-26

Width 530mm Depth 660mm Standard 2/1 GN Pan or 2 x 1/1 GN Pan

OVEN RACK SPACING

6 Tray (standard) 105 mm / 4

/8”

8 Tray (option) 78 mm / 3“

ELECTRICAL SUPPLY SPECIFICATION OPTIONS

208V, 60Hz, 1P+N+E, 53.7A, 11.2 kW. 220V, 50Hz, 1P+N+E, 56.8A, 12.5 kW. 220-240V, 60Hz, 1P+N+E, 52.0A, 12.5 kW. 230-240V, 50Hz, 1P+N+E, 52.0A, 12.5 kW. 208V, 60Hz, 3P+E, 31A/Ph, 11.2 kW. 220V, 50Hz, 3P+E, 33A/Ph, 12.5 kW. 220-240V, 60Hz, 3P+E, 50.7A/Ph, 12.5 kW. 220V, 60Hz, 3P+E, 32.8A/Ph, 12.5kW. 380V, 60Hz, 3P+N+E, 18.9A/Ph, 12.5kW. 380V, 50Hz, 3P+N+E, 18.9A/Ph, 12.5 kW. 400-415V, 50Hz, 3P+N+E, 17.4A/Ph, 12.5 kW. 400-415V, 50Hz, 3P+N+E, 11A/Ph, 8kW.

ELECTRICAL CONNECTION WIRE CONDUCTOR SIZES

1P+N+E/Gnd 6AWG/10mm² Copper T75 min. 3P+E/Gnd 10AWG/6mm² Copper T75 min. 3P+N+E/Gnd 12AWG/4mm² Copper T75 min.

WATER SUPPLY CONNECTION Max Pressure 550 kPa / 5.5 bar / 80 psi. Min Pressure 100 kPa / 1.0 bar / 15 psi.

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2. INSTALLATION

WARNING: THIS APPLIANCE MUST BE GROUNDED.

WARNING: ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY.

It is most important that the oven is installed correctly and that the operation is correct before use. Installation shall comply with local electrical, health and safety requirements.

BEFORE CONNECTION TO POWER SUPPLY

Unpack and check unit for damage and report any damage to the carrier and dealer. Report any deficiencies to your dealer. Fit the feet which are packed inside the oven. Check that the available power supply is correct to that shown on the rating plate located on the right-hand side panel.

208V, 60Hz, 1P+N+E, 53.7A, 11.2 kW 220V, 50Hz, 1P+N+E, 56.8A, 12.5 kW 220-240V, 60Hz, 1P+N+E, 52.0A, 12.5 kW 230-240V, 50Hz, 1P+N+E, 52.0A, 12.5 kW 208V, 60Hz, 3P+E, 31A/Ph, 11.2 kW 220V, 50Hz, 3P+E, 33A/Ph, 12.5 kW 220-240V, 60Hz, 3P+E, 50.7A/Ph, 12.5 kW 220V, 60HZ, 3P+E, 32.8A/Ph, 12.5kW 380V, 60Hz, 3P+N+E, 18.9A/Ph, 12.5kW 380V, 50Hz, 3P+N+E, 18.9A/Ph, 12.5 kW 400-415V, 50Hz, 3P+N+E, 17.4A/Ph, 12.5 kW 400-415V, 50Hz, 3P+N+E, 11A/Ph, 8kW

LOCATION

To ensure correct ventilation for the motor and controls the following minimum installation clearances are to be adhered to:

Rear 0mm / 0“ Left-hand side 0mm / 0” Right-hand side 75mm / 3.0”

Position the oven in its allocated working position. Use a spirit level to ensure the oven is level from side to side and front to back. (If this is not carried out, uneven cooking could occur). The feet/legs used with bench or floor mounting or provided with stands are adjustable and will require adjusting in levelling the unit. It should be positioned so the operating panel and oven shelves are easily reachable for loading and unloading.

Bench Mounting

For bench mounted applications the oven must be fitted with 100mm / 4 inch feet.

Floor Mounting

For floor mounted applications the oven must be fitted with 150mm / 6 inch legs.

Four 100mm/4 inch or 150mm / 6 inch

Note: adjustable legs are available separately from your E35 dealer as an optional extra.

Stand Mounting

Ovens that are to be mounted on stands do not require feet or legs. Refer to Appendix B for stand mounting instructions.

Avoid having heat producing equipment such as fryers or steamers adjacent to the right-hand side of oven.

BEFORE USE

Operate the oven for about 1 hour at 200°C (400°F) to remove any fumes or odours which may be present.

ELECTRICAL CONNECTION

Remove side cover panel to allow access to the terminal block and strain relief cable clamp. The cable can be fitted through the entry grommet and secured from strain by tightening the fitted strain relief bushing. Connect cable to the terminals as marked. Refit cover panel.

IMPORTANT: FIXED WIRING INSTALLATIONS MUST INCLUDE AN ALL-POLE DISCONNECTION SWITCH.

Refer to specifications section for wire connections required, and supply connection conductor sizes.

IMPORTANT: THE OVEN VENT LOCATED ON THE CABINET TOP MUST NEVER BE OBSTRUCTED.

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WATER CONNECTION

A cold water supply should be fitted to the water

/4” BSP hose connection) which is located

inlet ( on the rear of the right hand side of the unit.

Alternately, a connection elbow and sealing washer is supplied with this unit for direct connection of a

/2” ID hose, which is

recommended for easy installation and service.

Connect water supply - Max inlet pressure 80psi / 550kPa.

Turn on water supply to check for leaks.

IMPORTANT: MAXIMUM INLET WATER

PRESSURE IS 550 kPa / 80 psi.

DOUBLE STACKING UNITS

When it is desired to mount an E35 Turbofan oven on an E85 prover, a double stacking kit must be used. Available from your dealer or Turbofan distributor. (see Spare Parts).

When mounting one oven on top of another, a double stacking kit is also required.

For stacking kit assembly instructions, refer to Appendix A.

RACK WIDTH POSITIONS

The E35 models have an adjustable rack width setting. This allows for the racking to be configured for 405mm / 16” or 460mm / 18” wide baking sheets / pans or racks.

Position the side racks in their innermost position for 16” trays and in their outermost position for 18” trays.

Removal of Side Racks (as illustrated)

1) Lift the side rack off the bottom locating pins.

2) Move bottom of rack toward centre of oven.

3) Lower rack to clear top locating pins, and

remove.

Replacement of Side Racks

1) Insert rack into the oven, placing the appropriate holes over the top locating pins.

2) Lift the side rack over the bottom locating pins.

3) Lower rack with appropriate holes over bottom locating pins.

RATING PLATE LOCATION

The rating plate for the E35 convection oven is located at the bottom left corner of the RH side panel. An internal rating plate is also located behind the RH side panel on the vertical dividing panel behind the electrical contactors. (Units manufactured from July 2002).

Internal Rating Plate

Figure 2.3

Rating Plate

Locating Stud

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Figure 2.2

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3. OPERATION

NOTE: A full user’s operation manual is supplied with the product and can be used for further

referencing of installation, operation and service.

3.1 DESCRIPTION OF CONTROLS (Up to Lot No. 0817999)

1. VENT

Oven vent closed (incorporates over-

pressure relief when closed).

Oven vent open (light illuminates).

2. THERMOSTAT

Temperature range 60 - 280°C / 100 - 550°F. (Light illuminates when elements are cycling ON to maintain set temperature).

3. TIMER

1 Hour bake timer. (Light illuminates when “time up” (0) reached, and buzzer sounds).

4. STEAM BUTTON

Push button to activate automatic steam dose into oven chamber. (Light illuminates when button activated for duration of steam cycle).

5. FAN SPEED

HI Full fan speed (Star point connection on

motor).

LO Half fan speed (Delta point connection

on motor).

6. POWER

O UNIT IS OFF

I UNIT IS ON (Light illuminates when

switched to this position). Oven lights operate continuously. Fan starts after 10 seconds when door

closed.

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NOTE: A full user’s operation manual is supplied with the product and can be used for further

referencing of installation, operation and service.

3.2 DESCRIPTION OF CONTROLS (from Lot No. 0818001)

1. VENT

°C

280

220

200

180

100

120

140

160

Oven vent closed (incorporates over-

pressure relief when closed).

Oven vent open.

2. THERMOSTAT Temperature range 60 - 280°C / 100 - 550°F. (Light illuminates when elements are cycling ON to maintain set temperature).

3. TIMER 1 Hour bake timer. (Light illuminates when “time up” (0) reached, and buzzer sounds).

4. STEAM BUTTON Push button to activate steam dose into oven chamber.

NOTE: Press steam button for 10 seconds

will give you 10 seconds of steam.

5. FAN SPEED

HI Full fan speed (Star point connection on

motor). LO Half fan speed (Delta point connection

on motor).

6. POWER O UNIT IS OFF

I UNIT IS ON (Light illuminates when

switched to this position). Oven lights operate continuously. Fan starts after 10 seconds when door

closed.

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3.3 EXPLANATION OF CONTROL SYSTEM

The E35 Turbofan convection oven features multi-function operator controls, and a combined fan motor and steam control system.

A correct understanding of their operation is required before carrying out any service or fault repair work. The control device functions are explained as follows:

Circuit Protection

All models are fitted with a 3 pole circuit breaker, from which a control circuit is taken from L1 circuit breaker, and this control circuit is fitted with a 6A circuit breaker. The 3 pole main circuit breakers are rated 25A/pole for 3P+N+E/GND and 1P+N+E/GND supply models, and 40A/pole for 3P+E/GND (no neutral) models. These provide control circuit protection via the 6A circuit breaker, and load circuit protection via the 3 pole circuit breakers.

Additionally, the 3 pole circuit breaker is mechanically connected to a Shunt Trip breaker, which in the event of the oven fan motor overheating will trip the 3 pole circuit breakers to isolate power from the unit. The Shunt Trip is directly connected to thermal limit switches in the motor windings, and the supply Neutral (or L3 on 3 phase, no neutral models). A supply from the 6A control circuit breaker is connected to the motor thermal switches. Should any of the motor windings overheat, the thermal switches close and supply power to the Shunt Trip, which in turn trips (triggers) and mechanically trips the 3 pole circuit breaker.

Accordingly, causes of circuit breakers tripping can be ascertained with the above knowledge, and this is covered in more detail in the Fault Diagnosis section.

Power ‘On’ / ‘Off’

A Power switch on the control panel isolates power to the operator controls of the oven. With the power switch OFF all functions of the oven are inoperable.

An integral cooling fan, behind the control panel used to keep the electrical controls of the oven cool, is on continuously whenever the power supply to the oven is on. Switching the oven control panel Power switch off will leave the cooling fan running.

With the Power switch ON (illuminated neon indicator), power is supplied to all operator controls.

Oven Lamps

Up to Lot No. 0817999.

The two oven lamps (12 volt halogen) are on whenever the Power switch is on. The oven lamps are supplied with 12 volts from an electronic lamp transformer fitted on the oven’s control switchgear assembly.

From Lot No. 0818001.

The two oven lamps (208 / 240 volt halogen) are on whenever the Power switch is on. The oven lamps are supplied with mains voltage.

Bake Timer

The 60 minute bake timer is a mechanical timer and can therefore be operated with the oven’s power ON or OFF. However only with the oven’s power switch On and the oven door closed will the timer turn on the time-up buzzer and time-up indicator neon on the control panel. The buzzer and time-up indicator provide indication that the time setting has run down to zero and at this point will remain on continuously until the 60 minute timer has been manually set back to the Off (vertical) position. The 60 minute timer does not control any other part of the oven’s operating system as the timer is independent of the temperature control, heating, fan, or steam system.

Oven Vent

Up to Lot No. 0817999.

The oven vent is a manual operation by way of the Vent knob on the control panel.

The vent knob directly rotates the vent shaft through 90 degrees to open and close the vent. The vent shaft passes through a rotary switch mounted behind the control panel and this switch is used to switch ‘On’ or ‘Off’ the vent indicating neon. In the vent ‘Open’ position, the indicator is illuminated. The oven vent restricts venting of the oven when in the closed position, however the vent flap is fitted with a spring loaded overpressure flap which relieves excess pressure created during oven steaming. This avoids steam pressure escaping out of door seals etc, if the oven is steamed with the vent closed. The spring pressure on the over-pressure vent flap ensures that only excess steam is lost out of the vent.

From Lot No. 0818001.

The oven vent is a manual operation by way of the Vent knob on the control panel.

The vent shaft passes through the control panel and directly rotates the vent shaft to manually open and close the vent. The oven vent restricts venting of the oven when in the closed position,

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however the vent flap is fitted with a spring loaded over-pressure flap which relieves excess pressure created during oven steaming. This avoids steam pressure escaping out of door seals etc, if the oven is steamed with the vent closed. The spring pressure on the over-pressure vent flap ensures that only excess steam is lost out of the vent.

Door Switch

The oven has a mechanical door, micro-switch located below the oven opening, which breaks the power supply to the oven fan and temperature control circuits when the door is opened. Additionally, opening the oven door will remove power from the Bake Timer buzzer and indicator. This allows only the oven lights to be operational if the oven door is opened.

Thermostat Control

Heating of the oven is controlled by an electronic thermostat control, comprising of a potentiometer dial and knob on the control panel, a temperature sensing probe (thermistor type) in the oven chamber, and the thermostat control board behind the control panel. Power to the electronic thermostat is supplied through an over-temperature/hi limit thermostat. Accordingly a failure of the electronic thermostat control causing a temperature over-run will result in the over-temperature thermostat switching and removing power from the heating control circuit. The over-temperature thermostat is able to be manually reset, however a serviceman is required to perform this function, as removal of the R/H service panel is required to access this safety protection device.

The electronic thermostat when set to a temperature will illuminate the heating neon indicator on the control panel whenever the oven heating elements are on. When the indicator neon goes out, the oven is up to the set temperature.

Heating / Elements

The electronic thermostat when requiring heating of the oven, switches power to the heating contactor (referred to as C1 contactor on models prior to Lot no 0817999, and C3 on models from Lot no 0818001).

The heating contactor closes to supply power through to the heating elements in the oven. In all ovens all 3 poles of the contactor are used to supply L1, L2, and L3 phase circuits to the 3 heating elements on each side of the oven fan motor.

On 3 Phase + Neutral supply models, all 6 elements are looped to neutral, and the 3 Phase power to the elements is to each set of three elements in parallel connection. Hence each of the elements is supplied with the Phase to Neutral voltage.

On 3 Phase supply models (no neutral), the set of three elements each of the fan motor are connected in Delta configuration, which each element being supplied the Phase to Phase voltage.

On 1 Phase + Neutral supply models, all 6 elements are looped to neutral, and the 1 Phase power to the elements is split into three poles at the main circuit breakers on the oven, then feed through the three poles of the heating contactor, from where each pole is connected to two of the six elements in parallel. Hence each of the elements is supplied with the Phase to Neutral voltage.

The heating elements are rated at 2000 Watts each, therefore providing a total of 12000 Watts or 12kW of heating.

In some cases special heating kilowatts may be supplied to special request, so always check rating plate information on the unit if in doubt.

The heating contactor cycles ON / OFF as controlled by the thermostat to maintain set oven temperature.

Fan / Motor

The E35 Turbofan ovens use a dual speed, bi-directional oven fan circulation system, in order to provide even heat distribution through the oven, and fan speed control to suit different product types.

To provide both dual fan speed and bi-direction, a motor of 4 pole / 8 pole configuration is used.

Fan / Motor Direction

The direction change is made by swapping two phases to the motor through the motor contactors. On models to Lot no 0817999 these are referred to as C2 and C3 contactors. On models from Lot no 0818001 these are referred to as C1 and C2 contactors.

In one direction L1, L2, and L3 are switched through the first motor direction contactor with the second motor direction contactor open. In the alternate direction, the second contactor closes and the first contactor opens. L1 and L2 are reversed on the second contactor connections. The motor contactors are mechanically interlocked (interlock fitted to rear of contactors) to prevent any switching overlap.

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Motor direction change is automatic, and the duration of the direction cycle is factory set. Additionally, a dwell period between at each change of direction occurs to allow the motor to restart in the opposite direction only after the motor rotation has slowed down. This is necessary to avoid motor overheating due to the high current load that would be required to change direction instantaneously.

Each direction cycle is 90 seconds long, at the beginning of which is a preset 10 second dwell / delay. As the dwell is at the beginning of the cycle, the fan always has a 10 second start delay when the oven is first turned on, or when the door is closed after opening.

Up to Lot No. 0817999.

The direction control timing is provided by three electronic timers mounted below the motor contactors on the electrical switchgear panel of the oven. Timer T1 controls the direction cycle time, timer T3 controls the dwell for one direction and timer T5 controls the dwell for the opposite direction.

When the door is closed and power is ON, cycle timer T1 will switch power to dwell timer T3 for 90 seconds. Timer T3 will then switch power through to motor direction contactor C2 after the preset 10 second delay. The motor will then run for the remainder of the 90 second cycle.

At the completion of the 90 second cycle, cycle timer T1 will switch the power from T3 dwell timer to T5 dwell timer. This dwell timer will then switch power through to contactor C3 after the preset 10 s

econd delay, and the motor will run in the opposite direction for the remainder of that 90 second cycle. At the completion of that cycle the cycle timer T1 switches power back to the other dwell timer, and this continues until the oven door is opened, or the power is turned off.

From Lot No. 0818001.

The direction control timing is provided by a single Motor Direction Cam Timer mounted below the motor speed contactors C4, C5 and C6 on the electrical switchgear panel of the oven.

The circulation fan on the E35 oven reverses direction every 90 seconds for a 50Hz supply (every 75 seconds for 60Hz). Prior to a change of direction the fan motor is switched off for 10 seconds (8½ seconds for 60Hz) to allow the motor / fan to slow down. Cycling of the fan motor is controlled by a continuous cam timer with electric motor. The timer has two cams and switches which supply power alternately to one of two motor supply contactors, causing the motor to alternate direction. During the fan motor slow down periods, both cam switches are open and

power is not supplied to either of the motor supply contactors. When the oven door is opened or the power is switched off the cams will stop. When the oven door is closed or the power switched back on the cam timer will resume its cycle from the point where it stopped.

Fan / Motor Speed

For HI speed operation the motor is run as a 4 pole motor. (1420 rpm 50Hz / 1750 rpm / 60Hz) For LO speed operation the motor is run as an 8 pole motor. (715 rpm 50Hz/850 rpm / 60Hz)

Selection of the pole configuration for run speed is made though the motor contactors C4, C5 and C6.

In HI speed setting the motor contactors C4 and C6 close, C4 switching power to the motor on the 4 pole connection leads, and C6 binding 4 of the 8 motor poles to allow motor to run as a 4 pole motor.

In LO speed setting the motor contactor C5 closes to switch power to the motor on the 8 pole connections leads, with contactors C4 and C6 remaining open.

Motor contactors C5 and C6 are mechanically interlocked (interlock fitted to rear of contactors) to prevent any switching overlap between LO and HI speed changes.

The motor speed control is by manual operation of the Fan Speed switch on the control panel. This rotary switch simply supplies power to either motor contactors C4 and C6 for HI speed, or C5 for LO speed. The contactors stay closed in the selected setting unless the oven door is opened. Closing the oven door allows the contactors to switch on again.

Fan / Motor - Single Phase Models

The operation of the fan motor on single phase E35 models is the same as other three phase models for two speed and bi-direction operation, except for the electrical circuit required.

On single phase models the same motor is used as on three phase models, but with capacitors in the motor circuit to create an artificial phase lag, that is normally part of the three phase supply on three phase models. Use of the three phase motor is required to retain the bi-direction operation.

On single phase models the L1 supply to the motor connects to the normal L1 connection of the motor, and the Neutral supply connects to the normal L2 (as connected on three phase models) connection of the motor. A capacitor is then connected to the normal L3 (as connected on the three phase models) connection of the motor, and

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this capacitor is supplied power from the L1/ Phase supply. This capacitor is referred to as the Run capacitor as it is permanently in the circuit during motor operation. Each motor on single phase models has two run capacitors, one for the LO speed operation (lower capacitance) and one for the HI speed operation (higher capacitance). Each Run capacitor is only used when the motor is running at that speed setting.

Additionally a Start capacitor is also fitted on single phase models, and is used for starting the motor rotation at the beginning of each direction change when in HI speed setting only. This capacitor is switched on for approximately 7 seconds only at the beginning of each motor start up, with a contactor C7 switching the Start capacitor on and off, and with a timer T6 controlling the timing of the contactor C7.

Fan direction change in single phase models is still controlled by motor contactors C2 and C3. However unlike three phase models where C2 and C3 swap phases over to change motor start rotation / direction, single phase models use C2 and C3 to switch the run capacitor form the L1 supply to the Neutral supply for direction change.

Control of the motor cycle timing and dwell timing is the same as three phase models.

Motor Protection

Refer Circuit Protection at start of section.

Steam System

Up to Lot No. 0817999.

The E35 Turbofan ovens feature an automatically timed oven chamber steaming system, that allows operators to inject a 10 second period of steam into the oven at any stage. The steam is generated when a solenoid valve opens and supplies mains water to a calibrated wide spray angle nozzle in the oven that discharges the water as a fine spray into the oven fan. The fine spray at a wide angle is then immediately thrown by the fan circulation across the oven heating elements either side of the fan. The fine spray instantaneously turns to steam on the hot elements, which is supported by the hot air of the oven also turning the water droplets into steam.

The steam is initiated by depressing the Steam switch on the control panel. When depressed the steam switch provides power one of two Steam timers which are preset to 10 seconds steam cycle duration. These Steam timers are T2 and T4.

T2 is associated with fan dwell timer T3 and is used when steam is required during the fan direction cycle that uses the T3 dwell timer.

T4 is associated with fan dwell timer T5 and is used when steam is required during the fan direction cycle that uses the T5 dwell timer.

This ensures that steam can be used in either fan direction cycle, and additionally allows the fan to be turned on as soon as steam is activated, even if the fan was in a direction change dwell. Ensuring that the fan is running when steam is required is necessary to atomise the water droplets by the mechanical action of the fan, and by the fan throwing the water across the elements.

The Steam switch on the control panel only needs to be depressed momentarily as the duration of the steam injection is automatically timed by the steam timers. The Steam switch will illuminate for the duration of the steam injection to provide a visual confirmation of the steaming process. The light in the steam switch is independent of the switch contacts and is powered by the electrical circuit to the water solenoid valve. Therefore the switch is illuminated for as long as the water solenoid is open: 10 seconds.

Steam System

From Lot No. 0818001.

The E35 Turbofan ovens feature a manually operated oven chamber steaming system, that allows operators to inject a shot of steam into the oven at any stage. The steam is generated when a solenoid valve opens and supplies mains water to a calibrated wide spray angle nozzle in the oven that discharges the water as a fine spray into the oven fan. The fine spray at a wide angle is then immediately thrown by the fan circulation across the oven heating elements either side of the fan. The fine spray instantaneously turns to steam on the hot elements, which is supported by the hot air of the oven also turning the water droplets into steam.

The steam is initiated by depressing the Steam switch on the control panel. When depressed, the steam switch provides power to the water solenoid. Pressing the Steam switch for one second will provide one second of steam, pressing the steam switch for 5 seconds will provide 5 seconds of steam.

The Steam switch will not illuminate as with pre-Lot No. 0818001 Ovens.

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Summary of Components

Up to Lot No. 0817999.

The electrical switchgear (not user controls) components are summarised as follows:

C1 Heating contactor Switches elements ON / OFF.

C2 Motor direction contactor Phases switched in line.

C3 Motor direction contactor Phases L1 and L2 swapped on 3 phase

models.

Run capacitor swapped from L1 to

Neutral on 1 phase models.

C4 Motor speed contactor HI speed.

C5 Motor speed contactor LO speed.

C6 Motor speed contactor HI speed (changes motor from 8 pole

to 4 pole).

T1 Fan cycle timer Direction cycle.

T2 Steam timer For T3 dwell direction.

T3 Fan dwell timer Alternate direction (always initial

direction dwell).

T4 Steam timer For T5 dwell direction.

T5 Fan dwell timer Alternate direction (always 2

direction

dwell).

C7 Motor start capacitor contactor. (Single phase models only).

T6 Motor start capacitor timer (Single phase models only).

Motor contactor interlocks fitted to C2+C3 (mounted on rear on contactors).

Motor contactor interlocks fitted to C5+C6 (mounted on rear on contactors).

Summary of Components

From Lot No. 0818001.

The electrical switchgear (not user controls) components are summarised as follows:

C1 Motor direction contactor Phases switched in line.

C2 Motor direction contactor Phases L1 and L2 swapped on 3 phase

models.

Run capacitor swapped from L1 to

Neutral on 1 phase models.

C3 Heating contactor Switches elements ON / OFF.

C4 Motor speed contactor HI speed.

C5 Motor speed contactor LO speed.

C6 Motor speed contactor HI speed (changes motor from 8 pole

to 4 pole).

C7 Motor start capacitor contactor. (Single phase models only).

T1 Motor start capacitor timer (Single phase models only).

Motor contactor interlocks fitted to C1+C2 (mounted on rear on contactors).

Motor contactor interlocks fitted to C5+C6 (mounted on rear on contactors).

E35 Turbofan Ovens

Revision 12

-18-

4. MAINTENANCE

WARNING: ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY.

4.1 CLEANING

WARNING: ALWAYS TURN THE

POWER SUPPLY OFF BEFORE CLEANING.

IMPORTANT: THIS UNIT IS NOT

WATER PROOF. DO NOT USE A WATER JET SPRAY TO CLEAN INTERIOR OR EXTERIOR OF THIS UNIT.

EXTERIOR

Clean with a good quality stainless steel cleaning compound. Harsh abrasive cleaners may damage the surface.

INTERIOR

Ensure that the oven chamber is cool. Do not use wire brushes, steel wool or other abrasive materials. Clean the oven regularly with a good quality oven cleaner. Take care not to damage the fan or the tube at the right side of the oven which controls the thermostat.

SIDE RACKS

To remove, follow instructions given in the installation section.

OVEN DOOR (HINGED GLASS)

Outer surfaces: Clean with conventional glass

cleaners

Inner surfaces: To clean between the inner and outer door glasses, firstly ensure the door is locked shut. With a screwdriver, coin, or other suitable device,

/4 turn the outer glass locks to release the outer glass and allow it to be hinged open for cleaning access (refer to figure 4.1 for correct procedure).

IMPORTANT: ALWAYS ENSURE THAT THE OUTER GLASS IS HINGED CLOSED AND LOCKED INTO POSITION BEFORE OPENING DOOR.

TOP

LOCKED

UN-LOCKED

LOCKED

BOTTOM

Figure 4.1

OVEN DOOR (HINGED GLASS)

Outer surfaces: Clean stainless steel with quality

stainless steel cleaner.

Inner surfaces: Clean stainless steel with quality stainless steel cleaner.

Door glass: Clean with conventional glass cleaners.

OVEN SEALS

To remove, pull out the seal starting at each corner. The seal may be washed in the sink, but take care not to cut or damage it. To replace, fit the seal in at the corners first, then push in the rest of the seal.

E35 Turbofan Ovens

Revision 12

-19-

Figure 4.2

4.2 ROUTINE PROCEDURES

PROCEDURE INTERVAL

DOOR SEALS Check for deterioration. 12 months

DOOR PIVOT BUSHES Check for wear. 12 months

DOOR CATCH Ensure that catch is adjusted such that the door closes

12 months

properly.

ELEMENT Check that element resistance is correct to it’s rating (refer

12 months

6.3.12).

WATER NOZZLE Check for lime build-up in water nozzle. 12 months

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Revision 12

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5. TROUBLE SHOOTING

WARNING: ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY.

The following Troubleshooting Guide should be used to identify any incorrect oven operation. On correct identification of the operating fault the Troubleshooting guide will make reference to the corrective action required, or refer to the Fault Diagnosis section and / or Service section to assist in correction of the fault.

FAULT POSSIBLE CAUSE REMEDY

THE OVEN DOES NOT OPERATE / START

The mains isolating switch on the wall, circuit breaker or fuses are “off” at the power board.

The power switch on the oven is off (‘0’).

Incorrect electrical supply.

Oven circuit breaker tripped.

Power switch on unit faulty.

FAN DOESN’T OPERATE Door not closed.

(Fan only operates when the door is closed).

Door microswitch out of adjustment.

Door microswitch faulty.

Fan motor faulty.

Fan timers / Contactors faulty.

Turn on.

Turn switch to ‘I’ position.

Ensure electrical supply correct.

Identify fault. Reset circuit breaker.

Replace.

(Refer service section 6.3.1).

Close door.

Adjust.

(Refer service section 6.4.1).

Replace.

(Refer service section 6.3.3).

Replace.

(Refer service section 6.3.21).

Replace. (Refer service section 6.3.10).

STEAM LIGHT DOES NOT ILLUMINATE

Up to Lot No. 0817999 Only.

NO STEAM

(continued next page)

E35 Turbofan Ovens

Revision 12

Blown bulb. Replace bulb.

Water not turned on.

Blocked filter in water solenoid.

Nozzle blocked.

Check valve blocked / corroded.

-21-

Turn water on at isolating valve.

Clean filter.

Remove, clean or replace. (Refer service section 6.3.15).

Remove check valve.

(Refer service section 6.3.15).

FAULT POSSIBLE CAUSE REMEDY

NO STEAM

(continued)

Steam tube blocked.

Faulty solenoid coil.

Steam switch faulty.

Timer faulty.

Up to Lot No. 0817999.

STEAMS ONLY SOMETIMES

Steam timer faulty. Replace.

Up to Lot No. 0817999.

SLOW RECOVERY Faulty contactor.

Element(s) blown.

NO HEAT IN OVEN Faulty door microswitch.

Faulty heating contactor.

Over-temperature control tripped.

Faulty thermostat controls.

Remove, clean or replace.

Replace. (Refer service section 6.3.16).

Replace. (Refer service section 6.3.13).

Adjust / Replace.

(Refer service section 6.3.10).

Replace. (Refer service section 6.3.10).

Replace. (Refer service section 6.3.11).

Adjust or replace. (Refer service section 6.3.3).

Replace. (Refer service section 6.3.10).

Reset.

Replace. (Refer service section 6.3.7).

OVER-TEMPERATURE CONTROL TRIPS / OVEN OVERHEATS

Oven too hot, thermostat out of calibration.

Over-temp out of calibration.

TIMER WILL NOT TIME DOWN Faulty timer.

NO TIME UP ALARM INDICATION

Faulty timer.

Faulty buzzer.

NO HIGH FAN SPEED

NO LOW FAN SPEED

Fan selector switch faulty.

Replace.

(Refer service section 6.3.8).

Replace. (Refer service section 6.3.12).

Replace. (Refer service section 6.3.18).

Replace.

(Refer service section 6.3.18).

Replace. (Refer service section 6.3.19).

Replace.

(Refer service section 6.3.22).

Replace. (Refer service section 6.3.22).

E35 Turbofan Ovens

Revision 12

-22-

FAULT POSSIBLE CAUSE REMEDY

OVEN LIGHTS NOT ILLUMINATING

Blown bulb(s).

Faulty lighting transformer. (Up to Lot No. 0817999 Only).

NOTE:

If both light bulbs have blown then there will be no output from the lighting transformer.

OVEN VENT INDICATOR NOT ILLUMINATING WHEN IN ‘OPEN’ POSITION.

Up to Lot No. 0817999.

OVER-PRESSURE VENT NOT OPERATING DURING STEAM CYCLE

Indicator faulty.

Switch faulty.

Vent blocked.

Over-pressure vent mechanism restricted.

DOOR DOES NOT CLOSE Tray in way of door.

Door seal obstruction.

Door handle in wrong position.

Up to Lot No. 0817999.

Door setting incorrect.

Replace.

(Refer service section 6.3.4).

Replace.

(Refer service section 6.3.6).

Replace.

(Refer service section 6.3.2).

Replace. (Refer service section 6.3.23).

Remove and clean blockage.

Remove and clean. (Refer service section 6.3.24).

Correctly position tray in rack.

Correctly install door seal. (Refer maintenance section).

Reposition door handle.

(Refer service section 6.3.28a /

6.3.29).

Adjust.

(Refer service sections 6.4.3 /

6.4.4 / 6.4.5).

DOOR SEAL LEAKS Door seal damaged.

Door seal incorrectly fitted.

Replace.

(Refer Section 4, Maintenance).

Correctly install door seal.

(Refer Section 4, Maintenance).

RACKS DO NOT FIT Incorrect pin location. Relocate on correct pin.

E35 Turbofan Ovens

Revision 12

-23-

6. SERVICE PROCEDURES

WARNING: ENSURE POWER SUPPLY IS SWITCHED OFF BEFORE SERVICING.

WARNING: ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY.

SECTION PAGE NO.

6.2 ACCESS.............................................................................................................................................. 26

6.2.1 Control Panel ...................................................................................................................... 26

6.2.2 Service Panel (RH Side Panel)........................................................................................... 26

6.2.3 Baffle ................................................................................................................................... 26

6.2.4 Side Panel (LH Side)........................................................................................................... 26

6.2.5a Control Panel Rear (Up to Lot No.0817099)....................................................................... 26

6.2.5b Control Panel Rear (From Lot No.0818001)....................................................................... 27

6.3 REPLACEMENT ................................................................................................................................. 28

6.3.1 Power Switch ...................................................................................................................... 28

6.3.2 Indicator Lights.................................................................................................................... 28

6.3.3 Door Microswitch................................................................................................................. 28

6.3.4 Light Bulb / Glass ................................................................................................................ 29

6.3.5 Light Fitting.......................................................................................................................... 29

6.3.6 Lighting Transformer (Up to Lot No.0817099) .................................................................... 29

6.3.7 Thermostat Dial................................................................................................................... 29

6.3.8 Thermostat Board ............................................................................................................... 30

6.3.9 Thermostat Probe ............................................................................................................... 30

6.3.10 Contactors / Timers etc ...................................................................................................... 31

6.3.11 Elements ............................................................................................................................. 31

6.3.12 Over Temp Thermostat ....................................................................................................... 31

6.3.13a Steam Switch (Up to Lot No.0817099) ............................................................................... 32

6.3.13b Steam Switch (From Lot No.0818001)................................................................................ 32

6.3.14 Spray Nozzle....................................................................................................................... 32

6.3.15 Check Valve (Up to Ser. No.261984).................................................................................. 33

6.3.16 Water Solenoid.................................................................................................................... 33

6.3.17 Cooling Fan......................................................................................................................... 33

6.3.18 Bake Timer .......................................................................................................................... 34

6.3.19a Buzzer (Up to Lot No.0817099) .......................................................................................... 34

6.3.19b Buzzer (From Lot No.0818001)........................................................................................... 34

6.3.20 Oven Fan............................................................................................................................. 34

6.3.21 Fan Motor..............................................................................................................

6.3.22 Fan Speed Selector Switch................................................................................................. 36

6.3.23 Vent Switch (Up to Lot No.0817099) .................................................................................. 36

6.3.24a Vent / ‘Over Pressure’ Vent (Up to Lot No.0817099).......................................................... 36

6.3.24b Vent / ‘Over Pressure’ Vent (From Lot No.0818001) .......................................................... 36

6.3.25 Door Outer Glass ................................................................................................................ 37

6.3.26 Door Inner Glass ................................................................................................................. 37

6.3.27a Door Catches (Up to Lot No.0817099) ............................................................................... 37

6.3.27b Door Catches (From Lot No.0818001)................................................................................ 38

6.3.28a Door Handle (Up to Lot No.0817099) ................................................................................. 38

6.3.28b Door Handle (From Lot No.0818001) ................................................................................. 38

6.3.29 Door Catch Mechanism (Up to Lot No.0817099)................................................................ 39

.............. 35

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Revision 12

-24-

6.4 ADJUSTMENT / CALIBRATION ........................................................................................................ 40

6.4.1 Door Microswitch Adjustment.............................................................................................. 40

6.4.2 60 Minute Timer Zero Position Adjustment......................................................................... 40

6.4.3a Door Setting / Adjustment (Up to Lot No.0817099) ............................................................ 40

6.4.3b Door Setting / Adjustment (From Lot No.0818001)............................................................. 40

6.4.4 Door Seal Adjustment (From Lot No.0818001)................................................................... 41

6.4.5 Door Latch Adjustment (From Lot No.0818001)................................................................. 41

6.4.6a Reversing the Door (Up to Lot No.0817099) ...................................................................... 42

6.4.6a Reversing the Door (From Lot No.0818001)....................................................................... 43

6.4.7 Fan and Steam Timer Operation / Adjustment ................................................................... 45

6.4.8 Fan / Steam Flow Chart (From Lot No.0818001)................................................................ 46

E35 Turbofan Ovens

Revision 12

-25-

6.2 ACCESS

6.2.4 SIDE PANEL (LH SIDE)

6.2.1 CONTROL PANEL

1) Remove vent knob by pulling straight off.

2) Remove screw above vent shaft.

One Screw

Pre Lot No.0818001

Post Lot No.0818001

Figure 6.2.1

3) Panel is now free to hinge at bottom, take

care not to drop panel or pull wires out. (support panel while working with panel open).

6.2.2 SERVICE (RH SIDE) PANEL

1) Undo the 4 screws holding panel.

2) Remove panel.

6.2.5a CONTROL PANEL—REAR (Up to Lot No.0817099)

Vent Indicator

Heating Indicator

Thermostat

Bake Time Up Indicator

Four Screws

Figure 6.2.2

2) Remove panel.

6.2.3 BAFFLE

1) Remove racks, trays and RH side rack.

2) Undo the 4 nuts holding the baffle.

3) Pull panel off studs, pull bottom into middle of oven and remove panel.

Four Nuts

Bake Timer

Steam Switch

Fan Speed Selector Switch

Power Indicator

Power Switch

Figure 6.2.5a

E35 Turbofan Ovens

Revision 12

Figure 6.2.3

-26-

6.2.5b CONTROL PANEL—REAR

(From Lot No.0818001)

Heating Indicator

Thermostat

Bake Time Up Indicator

Bake Timer

Figure 6.2.5b

Steam Switch

Thermostat PC Board

Fan Speed Selector Switch

Power Indicator

Power Switch

Time Up Buzzer

E35 Turbofan Ovens

Revision 12

-27-

6.3 REPLACEMENT

6.3.1 POWER SWITCH

1) Pull knob off front of switch.

2) Open control panel (refer 6.2.1) and undo 2 screws securing switch.

Two Screws

Figure 6.3.1

3) Transfer wires to new switch.

4) Withdraw old switch and insert new switch, securing with screws.

6.3.3 DOOR MICROSWITCH

1) Open oven door.

2) Remove nut on front of micro-switch.

Microswitch Nut

Figure 6.3.3a

3) Remove 3 screws holding microswitch cover panel and drop panel down.

6.3.2 INDICATOR LIGHTS

1) With control panel open (refer 6.2.1) remove wires from the back of the indicator light.

Indicator Wires

Figure 6.3.2

2) From back push indicator through front of panel rotating clockwise.

3) Push new indicator in from front of panel, and re-connect wires.

Three Screws

Figure 6.3.3b

4) Remove 2nd nut on front of micro-switch, to free micro-switch. (Loosen / remove 2 bolts holding micro-switch bracket as required).

2nd Microswitch Nut

Figure 6.3.3c

5) Transfer wires to new the new switch and reassemble.

Common

E35 Turbofan Ovens

Revision 12

Normally Open

Normally Closed

(Not used)

Figure 6.3.3d

6) Adjust micro-switch (refer 6.4.1).

-28-

6.3.4 LIGHT BULB / GLASS

1) Remove LH side rack from oven.

2) Undo the four screws holding light face surround on and remove the glass and surround. Check the seal and replace if necessary.

Four Screws

6.3.6 LIGHTING TRANSFORMER (Up to Lot No.0817099)

1) With R/H service panel removed (refer 6.2.2) transfer wires to new transformer with the aid of a screw-driver.

2) Remove one screw and loosen the second screw securing the transformer.

Two Screws

Figure 6.3.6

Figure 6.3.4

3) Pull bulb straight out of fitting, towards back of oven (taking care not to break glass). Replace bulb.

NOTE

The bulb is a halogen lamp, so do not touch the glass of the bulb while pushing straight into light fitting (use an oil free cloth or paper towel).

4) Replace seal, glass and surround, securing with the screws (do not over tighten).

6.3.5 LIGHT FITTING

1) Remove glass and surround (refer 6.3.4).

2) Remove LH side panel (refer 6.2.).

2) Disconnect wires at connector block (inside LH side panel).

Top Light Connector

Block

3) Remove the old transformer and secure the new transformer with the screws.

6.3.7 THERMOSTAT DIAL

1) Pull knob off front of thermostat.

2) Open control panel (refer 6.2.1) and undo two screws securing thermostat bracket.

Two Screws

Figure 6.3.7a

3) Transfer wires to new thermostat.

4) Undo nut holding thermostat to bracket

Thermostat Nut

Bottom Light Connector

Block

Figure 6.3.5

3) Open fibreglass to expose lamp fitting.

4) Push in tabs at back of light fitting from outside oven, pivot into oven and remove.

5) Re-assemble in reverse order.

E35 Turbofan Ovens

Revision 12

-29-

Figure 6.3.7b

5) Withdraw old thermostat and insert new thermostat, securing with nut.

6) Re-assemble in reverse order.

6.3.9 THERMOSTAT PROBE

1) Remove R/H service panel (refer 6.2.1) and oven fan baffle (refer 6.2.3).

2) Remove bracket on steam line inside oven cavity by undoing the two screws.

Bracket

Thermostat Dial

Thermostat Board

Figure 6.3.7c

Thermostat Dial Resistances

NOTE

Dial must be dis-connected from board for testing.

O is orange wire, P is purple wire, Y is yellow

wire.

Resistance Between Dial Position O-P P-Y O-Y Off 900 Ω 900 Ω 0 Ω Halfway 900 Ω 450 Ω 450 Ω Maximum 900 Ω 0 Ω 900 Ω

6.3.8 THERMOSTAT BOARD

1) With control panel open (refer 6.2.1) transfer wires to new board.

2) Squeeze legs together on plastic clips holding board and extract.

3) Push new board onto clips.

Thermostat

Board

Two Screws

Figure 6.3.9

3) Undo the 2 bolts on the flange where the probe enters the oven (inside oven).

NOTE

Removal of probe and its mounting plate will require breaking of the silicone sealant.

Two Bolts

Figure 6.3.10

4) With control panel open (6.2.1) remove wires from thermostat board (2 fine brown wires at bottom left of board - refer figure 6.3.8).

5) Remove probe by drawing wires into oven.

6) Install the new probe in the reverse order.

NOTE

Ensure probe mounting plate has RTV silicone sealant applied to sealing face to ensure a leak proof assembly. Remove excess sealant after tightening securing screws.

Thermostat Probe Resistances

NOTE

Probe must be disconnected from board for testing.

Pre Lot No.0818001

E35 Turbofan Ovens

Revision 12

Figure 6.3.8

Post Lot No.0818001

-30-

Temperature Resistance (kΩ)

0°C (32°F) 288

37°C (99°F) 56

100°C (212°F) 6.1

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