Vulcan ABC7G User Manual

SERVICE MANUAL

ABC Combi Gas Oven

ABC7G ML-137715

- NOTICE -

This Manual is prepared for the use of trained Vulcan 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 Vulcan 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 Vulcan Service Technician.

The reproduction, transfer, sale or other use of this Manual, without the express written consent of Vulcan, 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.

A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222

F45491 (0714)

ABC Combi Gas Oven

TABLE OF CONTENTS

GENERAL .................................................................................................. 4

INTRODUCTION ....................................................................................... 4

OPERATION, CLEANING AND MAINTENANCE ........................................................ 4

TOOLS ................................................................................................. 4

LUBRICATION ......................................................................................... 4

WATER QUALITY STATEMENT ........................................................................ 4

SPECIFICATIONS ...................................................................................... 5

REMOVAL AND REPLACEMENT OF PARTS ............................................................... 6

PANELS ............................................................................................... 6

INNER DOOR .......................................................................................... 7

INNER DOOR LATCH .................................................................................. 7

DOOR LAMP ........................................................................................... 8

DOOR LATCH .......................................................................................... 8

DOOR SWITCH ........................................................................................ 9

CONVECTION FAN MOTOR .......................................................................... 10

CONVECTION FAN BAFFLE .......................................................................... 11

MAIN CONTROL BOARD ............................................................................. 11

OXYGEN SENSOR ................................................................................... 12

OXYGEN SENSOR BOARD ........................................................................... 13

FERRITE ............................................................................................. 13

MOTOR CONTROL BOARD ........................................................................... 14

CONTROL PANEL .................................................................................... 14

ON / OFF SWITCH .................................................................................... 15

DISPLAY BOARD ..................................................................................... 16

CONTROL PANEL COOLING FAN .................................................................... 17

CONTROL BOX COOLING FAN ....................................................................... 18

REAR COOLING FAN ................................................................................. 18

KNOB & ENCODER ................................................................................... 19

HI-LIMIT THERMOSTAT .............................................................................. 19

CAVITY INTAKE TUBE ASSEMBLY ................................................................... 20

CAVITY VENT MOTOR ............................................................................... 21

CAVITY VENT SWITCHES ............................................................................ 21

GAS VALVE .......................................................................................... 22

IGNITOR .............................................................................................. 22

FLAME SENSOR ...................................................................................... 23

BURNER .............................................................................................. 24

INDUCER BLOWER ................................................................................... 24

HEAT EXCHANGER ASSEMBLY ...................................................................... 25

DRAFT INDUCER PRESSURE SWITCH ............................................................... 26

IGNITION MODULE ................................................................................... 26

TRANSFORMER ...................................................................................... 27

TEMPERATURE SENSOR (RTD1) .................................................................... 28

DRAIN WATER CONDENSATE VALVE ................................................................ 29

DRAIN WATER THERMOCOUPLE .................................................................... 29

HUMIDITY VALVE .................................................................................... 30

SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 32

CONFIGURATION MODE (1972) ...................................................................... 32

LOG INTO CONFIGURATION MODE 1972 ........................................................ 32

TO REVIEW / CHANGE CONFIGURATION MODE 1972 SETTINGS ............................... 32

LOGGING OUT OF CONFIGURATION MODE 1972 ............................................... 38

CALIBRATING OXYGEN SENSOR BOARD ........................................................... 38

GAS VALVE PRESSURE CHECK AND ADJUSTMENT ................................................ 39

TEMPERATURE CALIBRATION ....................................................................... 40

TEMPERATURE SENSOR (RTD1) TEST .............................................................. 41

COMBUSTION ANALYSIS ............................................................................ 41

F45491 (0714) Page 2 of 83

ABC Combi Gas Oven

CAVITY VENT SWITCH TEST AND ADJUSTMENT .................................................... 41

FLAME SENSE VOLTAGE TEST (FENWAL SERIES 35-61) ............................................ 43

DRAFT INDUCER TEST .............................................................................. 43

DOOR SWITCH ADJUSTMENT ....................................................................... 44

ELECTRICAL OPERATION ................................................................................ 46

COMPONENT FUNCTION ............................................................................ 46

ELECTRICAL PANEL COMPONENT LOCATION ...................................................... 48

SEQUENCE OF OPERATION ............................................................................. 49

CONDITIONS ......................................................................................... 49

ON/OFF SWITCH (SW4) TURNED ON, (NO CALL FOR HEAT) ........................................ 50

ON/OFF SWITCH (SW4) ON & WITH CALL FOR HEAT ................................................ 51

ON/OFF SWITCH (SW4) ON & WITH CALL FOR HEAT & CALL FOR HUMIDITY ....................... 52

OTHER SEQUENCES ................................................................................. 53

CIRCUIT BOARD LAYOUTS .............................................................................. 54

MAIN BOARD CONNECTIONS ........................................................................ 54

MOTOR BOARD ...................................................................................... 57

IGNITION MODULE ................................................................................... 58

WIRING DIAGRAMS ...................................................................................... 59

TERMINAL BLOCKS AND TRANSFORMER ........................................................... 60

MAIN BOARD ......................................................................................... 61

MOTOR BOARD ...................................................................................... 62

IGNITION MODULE ................................................................................... 63

COOLING FANS ...................................................................................... 64

DIAGNOSTICS / TROUBLESHOOTING ................................................................... 65

SERVICE MODE (1963) ............................................................................... 65

ERROR CODES ...................................................................................... 71

OVEN TROUBLESHOOTING .......................................................................... 74

QUICK OVER ALL CHECK ........................................................................ 74

TROUBLESHOOTING USING ERROR CODES .................................................... 74

TROUBLESHOOTING BY SYMPTOM ............................................................. 79

IGNITION CONTROL MODULE TROUBLESHOOTING .................................................... 83

IGNITION CONTROL MODULE TROUBLESHOOTING ................................................ 83

Page 3 of 83 F45491 (0714)

ABC Combi Gas Oven - GENERAL

GENERAL

INTRODUCTION

General

This manual is for ABC7 Combi ovens. Ovens feature a powered vent damper, advanced digital control panel with digital display for setting cook TEMPERATURE, TIME, and HUMIDITY.

Heating

The ABC Combi oven reaches baking temperature of 350°F at 0% humidity in approximately 5 ½ to 6 minutes; however, a 20 minute preheat is recommended.

Combi Ovens

Combi ovens provide convection heat, steam heat or a combination of both in a single compartment cooking chamber. Humidification is provided by water injection into oven cavity. Water is injected by means of an internal nozzle, it vaporizes on contact with hot interior surfaces.

Steam System

All combi ovens come with a boiler less flash steaming system which provides a quick response time as well as excellent cooking results.

All information, illustrations and specifications contained in this manual are based on latest product information available at time of release.

OPERATION, CLEANING AND

MAINTENANCE

Refer to Installation & Operation Manual (F47110) for specific operating instructions.

TOOLS

Standard

1. Standard set of hand tools.

2. Metric set of hand tools.

3. VOM with measuring micro amp current tester. (Any VOM with a sensitivity of at least 20,000 ohms per volt can be used.)

4. Inclined manometer - Dwyer Cat #1227 or equivalent.

5. 1/4" T with 1/4" tubing.

7. Field service grounding kit.

Special

1. Combustion analyzer.

2. M6 socket head cap screw 3" long (hardened black oxide finish) for removing convection fan from motor shaft.

3. Gear puller to remove CONVECTION FAN MOTOR.

LUBRICATION

1. Ovens have self-lubricating composite bearings. No lubrication required.

2. Anti seizing compound.

WATER QUALITY STATEMENT

The fact that a water supply is potable is no guarantee that it is suitable for steam generation. Proper water quality can improve the taste of the food prepared in the oven, reduce scale build-up or corrosion, and extend equipment life. Local water conditions vary from one location to another and can change throughout the year. The recommended water treatment for effective and efficient use of this equipment will vary depending on the local water conditions. Your water supply must be within the general guidelines outlined in the chart below at all times during use of this machine or service issues not covered under warranty may result.

Water hardness should be treated by removing the impurities (water softener with carbon block or dechlorinator and/or in-line water treatment). Low water hardness may also require a water treatment system to reduce potential corrosion. Water treatment has been shown to reduce costs associated with machine cleaning, reduce deliming and reduce corrosion of metallic surfaces.

Daily washing and rinsing of the cavity is required. In some cases it may be needed more than once a day to prevent compounding of contaminants deposited inside cavity even with acceptable filtration. Failure to wash and rinse down the cavity daily could result in damage of the oven cavity and interior parts. A Reverse Osmosis water treatment system can be installed to eliminate chlorides or other contaminates from the water if needed.

6. Temperature tester (thermocouple type).

F45491 (0714) Page 4 of 83

ABC Combi Gas Oven - GENERAL

NOTE: Failure to properly maintain water quality or preventative procedures for water can lead to issues not covered under warranty.

WATER SUPPLY GENERAL GUIDELINES

Supply Pressure (dynamic flow)

30-60 psig

less than 3 grains (17.1

Hardness

ppm = 1 grain of hardness)

Silica less than 13 ppm

Chloramines

Chlorides

Total Chlorine

zero

less than 30 ppm

zero

PH range 7-8

Un-Dissolved Solids less than 5 microns

Testing of water is always done AFTER water filter or water treatment used. Water quality does change with usage and should be checked after idle times to see if the condition worsens .

A carbon block filter system should always be used to remove Chlorine and Chloramine. If a water softener is used, a carbon block is still required. Check with your local water treatment specialist for proper sizing and replacement intervals for the carbon block cartridge.

If the Chlorides exceed 30 ppm and the oven is used more than 8 hours during the day in steam or combination mode the cavity will require rinsing every 8 hours. Failure to do so will result in corrosion and rusting of the oven cavity and interior parts. A Reverse Osmosis water treatment system can be installed to eliminate chlorides from the water and reduce the hardness. Preventative washing and rinsing may be needed more than once a day to prevent compounding of contaminants inside cavity.

Total Chlorine of 4.0 ppm is the max limit for the building water supply. A carbon block filter must still be used to remove all Chlorine and Chloramines from the water. Failure to do so will result in corrosion and rust in the cooking cavity which is not covered under warranty.

SPECIFICATIONS

Data

Appliances equipped with a flexible

electric supply cord are provided with a three prong grounding plug. It is imperative that this plug be connected into a properly grounded three prong receptacle. If the receptacle is not the proper grounding type, contact an electrician. Do not remove grounding prong from this plug.

Electrical and grounding

connections must comply with the applicable portions of the National Electrical Code and / or other local electrical codes.

NOTE: Do not use GFI outlets. The spark ignition can cause electrical noise that can false trigger the GFI detection.

Supply Voltage

Volts Amps Hertz Phase

120 5.0 60 1

Supply Gas Pressure Input

Natural Propane BTU/HR

5" - 14" w.c. 11" - 14" w.c. 80,000

Water Supply

A cold water supply with a flow pressure of 30 to 60 psi is required.

There is a 3/4" garden hose fitting located on rear of machine labeled FILTERED. This inlet must be connected to approved filter system. Failure to connect oven to approved filter system will void warranty.

There is also a 3/4" garden hose fitting located on rear of machine labeled NON-FILTER.

Plumbing Connections

Plumbing connections must comply

with the applicable sanitary, safety and plumbing codes.

Drain Connection

The drain connection must be plumbed with a minimum of 1" air gap. Drain water can not be greater than 140°F, upon discharge. There is a 1" NPT male port for drain. Drain plumbing, not supplied, should have a constant slope towards floor drain. Do not connect solidly to floor or other drains.

Page 5 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

PANELS

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Right Panel

1. Remove four right panel screws.

2. Lift right panel up and back using handles.

Fig. 2

4. On the right side, remove the screw in the upper right hand corner.

Fig. 1

3. Reverse procedure to install.

Rear Panel

1. Remove Right Panel.

2. Remove two fan screws.

3. Remove six utility panel screws.

NOTE: Bottom 2 utility screws only support utility panel and can be left assembled.

F45491 (0714) Page 6 of 83

NOTE: Gas Unit shown.

5. Remove four rear panel screws.

NOTE: Hold onto one panel handle to prevent rear panel from falling.

6. Lift with handles to remove.

7. Reverse procedure to install.

Left Panel

1. Remove Right Panel.

2. Remove Rear Panel.

3. On the left side, remove the screw in the upper

4. Lift left panel up and back towards the rear of the

Fig. 3

left hand corner.

unit.

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 4

5. Reverse procedure to install.

INNER DOOR

1. Open oven door.

2. Unlatch inner door using inner door latch.

Fig. 5

Fig. 6

4. Place inner door in a secure location to prevent damage.

5. Reverse procedure to install.

INNER DOOR LATCH

1. Remove upper door stiffener screws and remove upper door stiffener.

3. Lift inner door up off door hinge.

Fig. 7

2. Remove inner door latch screws.

Page 7 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 8

3. Reverse procedure to install.

4. Check for proper operation.

DOOR LAMP

Do not touch the Halogen lamp with bare

hands. If lamp is exposed to oil from skin, life of the Halogen lamp will be reduced. Skin oil may be removed with alcohol while lamp is cold.

NOTE: Use a clean rag or paper towel to handle replacement lamp. Ensure lamp is free from oil and dirt before replacing.

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove

2. Insert screwdriver in slot just above the screw.

INNER DOOR.

Fig. 9

Fig. 10

5. Reverse procedure to install.

DOOR LATCH

The oven and its parts are hot. Use

care when operating, cleaning or servicing the oven. The cooking compartment contains live steam. Stay clear when opening door.

Door Cam

1. Open door and remove

2. Remove door lock cover.

INNER DOOR.

3. Push in tab to free the glass cover from lamp holder

4. Grasp lamp using cloth and remove from lamp socket.

3. Remove cam screw and washer.

F45491 (0714) Page 8 of 83

Fig. 11

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

4. Press torsion springs ends together to unlatch from the door lock clamp bracket.

Fig. 12

5. Press latch into door to remove cam.

6. Reverse procedures to install.

7. Check for proper operation.

Latch Assembly

1. Remove Door Cam.

2. Remove retaining ring, shim, and ball bearing.

NOTE: Press in latch for better access to retaining ring.

DOOR SWITCH

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove CONTROL PANEL.

Do not place control panel on knobs.

Doing so will damage encoders. Lift one side of control panel up to prevent knobs from touching surface.

Fig. 14

2. Remove back control panel.

3. Remove lock nuts.

Fig. 13

3. Remove hex socket screws (x4).

4. Latch spring and wear latch plate are now accessible for replacement.

5. Reverse procedure to install.

6. Check for proper operation.

Fig. 15

4. Slide reed switch out from control switch bracket.

5. Remove reed switch screws.

6. Reverse procedures to install.

7. Check for proper operation.

Page 9 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

CONVECTION FAN MOTOR

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.

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

NOTE: When using gear puller to remove convection fan, do not use factory stainless steel cap screw or damage to the screw head may occur. Use a spare M6 cap screw as listed under

Convection Fan

1. Remove Right Panel.

2. Remove Rear Panel.

3. Remove humidity hose clamp.

Convection Fan Motor

4. Remove CONVECTION FAN BAFFLE.

5. Remove humidity cavity nozzle nuts to remove humidity cavity nozzle.

NOTE: Replace nozzle gasket if necessary.

Tools.

Fig. 17

NOTE: Gas Unit shown.

6. Remove socket head cap screw.

Fig. 18

NOTE: Gas Unit shown.

7. Remove atomizer bolt.

NOTE: Atomizer bolt is a left handed bolt. Turn clockwise to remove.

8. Remove water atomizer.

9. Thread atomizer bolt by hand into convection fan motor shaft. Leave approximately 1/8" space between hex head on left hand thread atomizer bolt and convection fan hub.

10. Insert spare M6 cap screw into convection fan motor shaft. Hand tighten only.

F45491 (0714) Page 10 of 83

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 19

11. Install gear puller.

12. Tighten gear puller to separate convection fan from the motor shaft.

NOTE: Applying heat uniformly to groove in convection fan will assist with separation of convection fan and motor shaft.

5. Lift baffle up off baffle hangers.

NOTE: Verify convection fan baffle is lifted over bottom and top rack guide supports.

Fig. 20

6. Pull towards front of oven to remove.

7. Reverse procedures to install.

13. Disconnect motor wires from convection fan terminal block.

Convection Fan Terminal Block (TB2)

Connection Call-outs

A TB Block Number

White 10

Blue 9

Black 8

Red 7

Brown 6

Brown 5

14. Remove convection motor shroud bolts. Refer to graphic 24710 Convection Fan Motor.

NOTE: Apply anti seizing compound to bolts.

15. Reverse procedure to install.

16. Check for proper operation.

CONVECTION FAN BAFFLE

The oven and its parts are hot. Use

care when operating, cleaning or servicing the oven.

1. Remove all oven racks.

NOTE: Verify convection fan baffle is hooked on top baffle hangers and supported behind the bottom baffle support guides.

Fig. 21

NOTE: Gas Unit shown.

MAIN CONTROL BOARD

Certain components in this system are

2. Remove left and right oven rack holders.

3. Lift baffle up off bottom baffle supports.

4. Lift baffle over bottom rack guides.

1. Check customer's current parameter settings.

Document customers parameter settings.

Page 11 of 83 F45491 (0714)

CONFIGURATION MODE (1972) for

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

NOTE: This step can only be accomplished if main control board is still operational.

NOTE: Oven hour counter (P18), water counter values (P19, P20), and error log will start new, with replacement main control board.

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

2. Remove Right Panel.

3. Remove electrical connections from main control board and oxygen sensor board.

4. Remove main control board.

6. Refer to CALIBRATING OXYGEN SENSOR BOARD.

7. Check for proper operation.

OXYGEN SENSOR

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Oxygen sensor is very HOT. Use

care when servicing oxygen sensor.

NOTE: Remove power from unit before replacing oxygen sensor. Having power to board when installing sensor, will cause damage oxygen sensor.

NOTE: Sensor can be damaged by water. Do not get wet.

1. Remove

2. Remove Rear Panel.

Right Panel.

Fig. 22

NOTE: Squeeze nylon standoffs to release board.

5. Remove OXYGEN SENSOR BOARD from main control board.

Installation of Replacement Control Board

1. Install OXYGEN SENSOR BOARD onto replacement main control board.

NOTE: Oxygen sensor board is easier to install onto main control board before installing main control board.

2. Line up holes on new main control board with nylon standoffs (x10).

3. Press board onto standoffs.

3. Disconnect oxygen sensor cable at plug.

NOTE: Do NOT disconnect cable from Oxygen Sensor Board.

Allow Oxygen Sensor to cool

completely before removing. Sensor, when powered and operating, is very HOT.

4. Remove all wire ties from oxygen sensor cable.

5. After oxygen sensor has cooled, loosen hex and carefully remove sensor from fitting.

4. Follow diagram Main Control Board Connections to rewire replacement board.

5. Configure board to customer's preferred parameter settings, noted prior to removing main control board. See CONFIGURATION MODE (1972) for configuration settings.

F45491 (0714) Page 12 of 83

6. Reverse procedures to install.

7. When installing, wire tie oxygen sensor cable as

Fig. 23

previously installed.

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Oxygen Sensor cable can not lay on the

bottom of the oven.

Oxygen Sensor cables are sensitive to

electrical noise and must be routed away from other wires.

8. Power unit on.

9. CALIBRATING OXYGEN SENSOR BOARD.

10. Check for proper operation.

OXYGEN SENSOR BOARD

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Certain components in this system are

1. Verify oxygen sensor board holes line up with the main control board holes.

NOTE: Connect 9 pin connection on back side of oxygen board header to 9 pins located on main control board oxygen board header.

Fig. 25

2. Secure using screws from replaced board.

3. Power on unit.

4. CALIBRATING OXYGEN SENSOR BOARD.

1. Remove Right Panel.

2. Remove electrical connections from oxygen sensor board.

NOTE: Note locations of wires.

3. Remove oxygen sensor board screws. Retain screws for installation of replacement oxygen sensor board.

5. Check for proper operation.

FERRITE

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove

2. Lift ferrite clip with flat screw driver (2 places).

Right Panel.

Fig. 24

Oxygen sensor board must be installed

while unit is unplugged. Failure to Do so will cause permanent damage to oxygen sensor board.

Installation of Oxygen Sensor Board.

Fig. 26

3. Reverse procedures to install.

Page 13 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

NOTE: When installing, place ferrite approximately 3 inches from oxygen sensor board.

NOTE: Loop ferrite wires around the ferrite to keep ferrite in place.

Fig. 28

5. Replace motor control board.

6. Reverse procedure to install.

Fig. 27

MOTOR CONTROL BOARD

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Certain components in this system are

1. Remove

2. Document wire locations.

3. Remove electrical connections from board.

4. Remove motor control board. (4 Nylon screws)

Right Panel.

7. Check for proper operation.

CONTROL PANEL

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Certain components in this system are

Control Panel

1. Remove Right Panel.

2. Disconnect multi pin connectors.

3. Disconnect control board ribbon cable.

F45491 (0714) Page 14 of 83

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 29

4. Remove ribbon cable wire tie.

NOTE: Replace wire tie on install.

7. Place control panel on a clean, flat surface.

8. Place in a secure location.

Do NOT place control panel flat on knobs.

Doing so will cause damage to encoders.

Fig. 32

9. Reverse procedures to install.

NOTE: The motor control board ribbon cable will fit in J1 as well as J8, make sure it gets plugged in to J1 on Main board.

Fig. 30

5. Remove 6 recessed control panel screws.

10. Verify proper operation.

ON / OFF SWITCH

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

On / Off Switch

1. Remove

2. Place control panel in a secure location on a clean, flat surface.

NOTE: Do NOT place control panel flat on knobs. Doing so will cause damage to encoders.

CONTROL PANEL from unit.

Fig. 31

6. Lift control panel up off hooks.

NOTE: Carefully pull connector and ribbon cable through hole when removing control panel.

Fig. 33

3. Remove screws from back of control base panel.

Page 15 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 34

NOTE: Use care when removing back of control panel

cover. Wires are attached.

Certain components in this system are

4. Unplug wires from back of On/Off switch

DISPLAY BOARD

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Certain components in this system are

Display Board

1. Remove

2. Place control panel in a secure location on a clean, flat surface.

NOTE: Do NOT place control panel flat on knobs. Doing so will cause damage to encoders.

CONTROL PANEL from unit.

Fig. 35

5. Using a pair of channel locks, squeeze in the sides and press the switch out the front of the panel.

6. Reverse procedures to install.

7. Check for proper operation.

Fig. 36

3. Remove screws from back of control base panel.

Fig. 37

NOTE: Use care when removing back of control panel

cover. Wires are attached.

F45491 (0714) Page 16 of 83

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Certain components in this system are

4. Remove display board ribbon cable.

5. Remove encoder ribbon cables.

6. Remove display board nuts.

CONTROL PANEL COOLING FAN

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Certain components in this system are

Display Board Fan

1. Remove

2. Place control panel in a secure location.

NOTE: Do NOT place control panel flat on knobs. Doing so will cause damage to encoders.

CONTROL PANEL from unit.

Fig. 38

7. On the new display board, make sure that jumper J5 on the back of the display board is installed and on the correct two pins. (The two closest to the edge of the board.)

Fig. 39

8. Reverse procedures to install.

9. Check for proper operation.

Fig. 40

3. Remove screws from back of control base panel.

Fig. 41

4. Disconnect cooling fan wire connection.

5. Remove cooling fan nuts.

Page 17 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 42

6. When installing fan, verify arrows are facing the correct direction.

Fig. 44

REAR COOLING FAN

NOTE: Air to exhaust out of control panel.

Fig. 43

7. Reverse procedure to install.

8. Check for proper operation.

CONTROL BOX COOLING FAN

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove

2. Remove two wires going to fan.

3. Remove nuts securing fan to frame.

4. Reverse procedure to install.

5. Check for proper air flow.

Rear Panel.

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove Right Panel.

2. Unplug two wires going to fan.

3. Remove two screws securing fan to frame.

4. Reverse procedure to install.

5. Check for proper air flow.

F45491 (0714) Page 18 of 83

Fig. 45

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

KNOB & ENCODER

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Certain components in this system are

Control Knob & Encoder

1. Remove

2. Place control panel in a secure location.

NOTE: Do NOT place control panel flat on knobs. Doing so will cause damage to encoders.

3. Remove control base panel.

4. Disconnect encoder ribbon cables.

CONTROL PANEL.

Fig. 46

Fig. 48

6. Remove encoder nut to remove encoder.

7. Reverse procedures to install.

NOTE: Tapped hole needs to be aligned with flat part of encoder.

8. Check for proper operation.

HI-LIMIT THERMOSTAT

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove hi-limit thermostat screws.

Fig. 47

5. Loosen set screw in tapped hole on knob.

Fig. 49

NOTE: Gas Unit shown.

2. Remove hi-limit thermostat probe.

NOTE: Hi-limit thermostat probe is located on top of unit, under insulation.

Page 19 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

NOTE: Turn Probe Mounting Screw quarter turn to loosen. Do not remove probe mounting screw and bracket.

Fig. 52

NOTE: Gas Unit shown.

Fig. 50

3. Reverse procedures to install.

NOTE: When installing hi-limit thermostat verify hilimit shaft is turned clockwise until it stops.

Fig. 51

4. Check for proper operation.

3. Cut cable ties as needed to free wiring harness back to vent motor and switches.

NOTE: Be sure to keep track of the routing of the wiring harness and cable ties.

4. Remove (4) nuts securing intake vent tube assembly to back of cavity.

CAVITY INTAKE TUBE ASSEMBLY

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove Rear Panel.

2. On right side of unit, disconnect plug P3.

F45491 (0714) Page 20 of 83

5. Replace parts as needed.

6. Reverse procedure to install.

NOTE: There is a gasket between cavity intake tube and the cavity. This gasket should be replaced .

Fig. 53

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

CAVITY VENT MOTOR

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove Rear Panel

2. Remove CAVITY INTAKE TUBE ASSEMBLY.

3. Rotate damper camshaft until set screw faces the rear of the cavity intake tube assembly.

NOTE: A small straight blade screwdriver (Jeweler screwdriver) is needed.

NOTE: If a small screwdriver is not available, cutting the wires and using a standard wire nut is acceptable.

8. Reverse procedure to install.

NOTE: When inserting the new motor, insure the flat side of the motor shaft faces the set screw.

9. Check CAVITY VENT SWITCH TEST AND ADJUSTMENT.

10. Check for proper operation.

CAVITY VENT SWITCHES

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove Rear Panel.

2. Remove wires going to cavity vent switches.

Fig. 54

4. Loosen set screw.

5. Remove two screws securing the vent motor to the frame.

6. Pull motor free from assembly.

7. Insert blade of small screwdriver into wire nuts to release motor wires.

Fig. 56

3. Remove bottom screw securing switches to frame.

Fig. 55

Page 21 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 57

4. Loosen top screw and remove switches from frame.

5. Replace switch or switches as needed.

6. Reverse procedure to install.

3. Remove gas line from gas valve.

4. Remove high voltage ignitor cable from ignitor.

5. Remove flame sensor wire from flame sensor.

6. Remove manifold screws from burner.

7. Remove gas valve from manifold.

7. Attach wires to switches.

Fig. 58

8. Perform CAVITY VENT SWITCH TEST AND ADJUSTMENT .

GAS VALVE

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Fig. 59

8. Reverse procedures to install.

NOTE: Make sure the switch on the gas valve is turned on.

Fig. 60

9. Check for proper operation.

IGNITOR

Certain components in this system are

1. Remove Right Panel.

2. Remove wires from gas valve.

F45491 (0714) Page 22 of 83

Ignitor Removal

1. Remove

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Right Panel .

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

2. Disconnect high voltage cable from ignitor.

Fig. 61

3. Remove ignitor screw.

4. Pull ignitor to remove.

5. Reverse procedures to install.

NOTE: Make sure to keep the high voltage cable routed separately from flame sensor cable (wire 206) and the ground wire (wire 205).

FLAME SENSOR

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

Flame Sensor Removal

1. Remove Rear Panel .

2. Disconnect flame sensor cable (wire 206) from flame sensor.

3. Remove flame sensor screw.

4. Pull flame sensor to remove.

Fig. 62

6. Check for proper operation.

Fig. 63

5. Reverse procedures to install.

NOTE: Make sure to keep high voltage cable routed separately from flame sensor cable (wire 206) and the ground wire (wire 205).

Page 23 of 83 F45491 (0714)

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

3. Remove burner ground screw from burner.

4. Remove burner screws to remove burner.

5. Remove burner seal.

NOTE: A scraper can be used to remove burner seal.

Fig. 64

6. Check for proper operation.

BURNER

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove manifold screws.

2. Gas valve, gas line, and manifold can be place aside.

NOTE: It is not necessary to remove gas line. Gas line can be used to hold gas valve and manifold assembly.

Fig. 66

6. Reverse procedures to install.

7. Check for proper operation.

INDUCER BLOWER

Disconnect the

electrical power to the machine and follow lockout / tagout procedures.

1. Remove

2. Remove Rear Panel .

3. Disconnect inducer blower wires.

INDUCER BLOWER

BLACK 211 (Black)

WHITE 213 (White)

RED 212 (Red)

Right Panel.

WIRE HARNESS

4. Remove motor shroud screws.

5. Lift up and towards front of unit to remove.

Fig. 65

F45491 (0714) Page 24 of 83

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

HEAT EXCHANGER ASSEMBLY

electrical power to the machine and follow lockout / tagout procedures.

1. Remove Right Panel.

2. Remove Rear Panel.

3. Remove INDUCER BLOWER.

4. Remove insulation above inducer blower.

5. Remove insulation to left of inducer blower.

NOTE: Retain insulation to reinstall after repairs.

6. Insert 2x4 board between heat exchanger and bottom of cavity.

Disconnect the

Fig. 67

6. Remove air pressure hose.

7. Remove gas flue screws.

8. Remove gas flue from rear of unit.

9. Lift up and back to remove.

10. Remove inducer blower screws.

Fig. 68

11. Pull to remove inducer blower.

Fig. 69

7. Support gas valve / burner assembly with a block of wood.

12. Remove any excess inducer blower seal before replacing seal.

13. Reverse procedures to install.

14. Check for proper operation.

Page 25 of 83 F45491 (0714)

Fig. 70

8. Remove mounting plate nuts.

9. Remove burner assembly nuts.

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