Vulcan-Hart ABC Service Manual

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SERVICE MANUAL

ABC Combi Gas Oven

ABC7G NAT / ML-137715

NATP / ML-137717

- 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 Rev. B (0518)

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ABC Combi Gas Oven

TABLE OF CONTENTS

SERVICE UPDATES ....................................................................................... 4

SERVICE UPDATES - ABC COMBI GAS OVEN ......................................................... 4

GENERAL .................................................................................................. 5

INTRODUCTION ....................................................................................... 5

OPERATION, CLEANING AND MAINTENANCE ........................................................ 5

TOOLS ................................................................................................. 5

LUBRICATION ......................................................................................... 5

WATER QUALITY STATEMENT ........................................................................ 6

SPECIFICATIONS ...................................................................................... 7

UPGRADE ABC COMBI FIRMWARE ....................................................................... 8

FIRMWARE VERSION HISTORY ....................................................................... 8

FIRMWARE UPDATE PROCEDURE .................................................................. 10

USB ERROR MESSAGES ............................................................................. 11

REMOVAL AND REPLACEMENT OF PARTS .............................................................. 13

PANELS .............................................................................................. 13

INNER DOOR ......................................................................................... 14

INNER DOOR LATCH ................................................................................. 14

DOOR LAMP .......................................................................................... 15

DOOR LATCH ........................................................................................ 15

DOOR SWITCH ....................................................................................... 17

MAIN CONTROL BOARD ............................................................................. 18

OXYGEN SENSOR ................................................................................... 18

OXYGEN SENSOR BOARD ........................................................................... 19

FERRITE ............................................................................................. 20

MOTOR CONTROL BOARD ........................................................................... 21

CONTROL BOX COOLING FAN ....................................................................... 21

CONTROL PANEL .................................................................................... 22

CONTROL PANEL COOLING FAN .................................................................... 23

ON / OFF SWITCH .................................................................................... 24

KNOB & ENCODER ................................................................................... 25

DISPLAY BOARD ..................................................................................... 25

MEAT PROBE SOCKET ............................................................................... 26

REAR COOLING FAN ................................................................................. 27

HIGH-LIMIT THERMOSTAT ........................................................................... 28

CAVITY INTAKE TUBE ASSEMBLY ................................................................... 29

CAVITY VENT MOTOR ............................................................................... 30

CAVITY VENT SWITCHES ............................................................................ 31

TRANSFORMER ...................................................................................... 31

TEMPERATURE SENSOR (RTD1) .................................................................... 33

DRAIN WATER CONDENSATE VALVE ................................................................ 34

DRAIN WATER THERMOCOUPLE .................................................................... 34

HUMIDITY VALVE .................................................................................... 35

CONVECTION FAN BAFFLE .......................................................................... 36

CONVECTION FAN MOTOR .......................................................................... 37

GAS VALVE .......................................................................................... 39

IGNITOR .............................................................................................. 39

FLAME SENSOR ...................................................................................... 40

INDUCER BLOWER ................................................................................... 40

HEAT EXCHANGER ASSEMBLY ...................................................................... 42

DRAFT INDUCER PRESSURE SWITCH ............................................................... 44

IGNITION MODULE ................................................................................... 44

SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 46

CONFIGURATION MODE (1972) - GAS ............................................................... 46

F45491 Rev. B (0518) Page 2 of 119

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ABC Combi Gas Oven

CALIBRATING OXYGEN SENSOR BOARD ........................................................... 53

CHECK OXYGEN SENSOR DATE CODE (REPLACEMENT SENSORS) ............................... 54

TEMPERATURE SENSOR (RTD1) TEST .............................................................. 55

TEMPERATURE CALIBRATION ....................................................................... 55

EXTERNAL MEAT PROBE THERMOCOUPLE CALIBRATION ......................................... 56

CAVITY VENT SWITCH TEST AND ADJUSTMENT .................................................... 56

DOOR TO CONTROL PANEL ALIGNMENT ............................................................ 58

DOOR SWITCH ADJUSTMENT ....................................................................... 61

TRANSFORMER RESISTANCE CHECK ............................................................... 61

MOTOR RESISTANCE CHECK ....................................................................... 63

GAS VALVE PRESSURE CHECK AND ADJUSTMENT ................................................ 64

FLAME SENSE VOLTAGE TEST (FENWAL SERIES 35-61) ............................................ 65

DRAFT INDUCER TEST .............................................................................. 66

COMBUSTION ANALYSIS ............................................................................ 66

ELECTRICAL OPERATION ................................................................................ 68

COMPONENT FUNCTION ............................................................................ 68

ELECTRICAL PANEL COMPONENT LOCATION ...................................................... 71

SEQUENCE OF OPERATION ............................................................................. 72

CONDITIONS ......................................................................................... 72

ON/OFF SWITCH (SW4) TURNED ON, (NO CALL FOR HEAT) ........................................ 73

ON/OFF SWITCH (SW4) ON & WITH CALL FOR HEAT ................................................ 74

ON/OFF SWITCH (SW4) ON & WITH CALL FOR HEAT & CALL FOR HUMIDITY ....................... 75

OTHER SEQUENCES ................................................................................. 76

CIRCUIT BOARD LAYOUTS .............................................................................. 79

MAIN BOARD CONNECTIONS ........................................................................ 79

MOTOR BOARD ...................................................................................... 82

IGNITION MODULE ................................................................................... 83

WIRING DIAGRAMS ...................................................................................... 84

TERMINAL BLOCKS AND TRANSFORMER ........................................................... 85

MAIN BOARD ......................................................................................... 86

MOTOR BOARD ...................................................................................... 87

IGNITION MODULE ................................................................................... 88

COOLING FANS ...................................................................................... 89

DIAGNOSTICS / TROUBLESHOOTING ................................................................... 90

SERVICE MODE (1963) ............................................................................... 90

ERROR CODES ...................................................................................... 96

OVEN TROUBLESHOOTING ........................................................................ 102

IGNITION CONTROL MODULE TROUBLESHOOTING ................................................... 119

IGNITION CONTROL MODULE TROUBLESHOOTING ............................................... 119

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ABC Combi Gas Oven - SERVICE UPDATES

SERVICE UPDATES

SERVICE UPDATES - ABC COMBI

GAS OVEN

May 2018

1. Updated all chapters due to firmware update in this service manual.

NOTE: Upgrade ABC Combi Firmware 04-24-17.

2. FIRMWARE VERSION HISTORY .

3. FIRMWARE UPDATE PROCEDURE .

4. MEAT PROBE SOCKET .

F45491 Rev. B (0518) Page 4 of 119

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ABC Combi Gas Oven - GENERAL

GENERAL

INTRODUCTION

General

This manual is for ABC7 Combi ovens. Ovens feature a powered vent damper, and an 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 5½ to 6 minutes; however, a 20minute 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, and vaporizes on contact with hot interior surfaces.

Steam System

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

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

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

6. Temperature tester (thermocouple type).

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.

4. USB Drive (Part # 00-443444).

5. No-Go / Go Gauges for DOOR TO CONTROL PANEL ALIGNMENT.

A. No-Go Gauge - .200"

• Use .032", .030", .028", .025", .022", . 020", .018", .015", and .010" feeler gauges to make a .200" No-Go gauge.

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 minimum of NFPA-70E CAT III 600V, UL/CSA/TUV listed. Sensitivity of at least 20,000 ohms per volt. Meter leads must also be rated at CAT III 600V. Clamp on type amp meter with minimum of NFPA-70E CAT III 600V, UL/CSA/ TUV listed.

Fig. 1

B. Go gauge - .119"

• Use .032", .030", .028", .025" and .004" feeler gauges to make a .119" Go gauge.

LUBRICATION

NOTE: Ovens have self-lubricating composite

bearings. No lubrication required.

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ABC Combi Gas Oven - GENERAL

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.

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

Plumbing connections must comply with the applicable sanitary, safety and plumbing codes.

WATER SUPPLY GENERAL GUIDELINES

Supply Pressure (dynamic flow) 30-60 psig

Hardness less than 3 grains (17.1 ppm = 1 grain of hardness)

Silica less than 13 ppm

Chloramines

Chlorides

Total Chlorine

zero

less than 30 ppm

zero

PH range 7-8

Undissolved 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.

F45491 Rev. B (0518) Page 6 of 119

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ABC Combi Gas Oven - GENERAL

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: The spark ignition in this appliance can cause

electrical noise that can false trigger the GFCI detection. Some GFCI’s are more sensitive than others. The use of a higher trip tolerance GFCI will reduce nuisance tripping. Contact Technical Support for more information.

The drain connection must be plumbed with a minimum of 1" air gap. Drain water cannot 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.

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

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ABC Combi Gas Oven - UPGRADE ABC COMBI FIRMWARE

UPGRADE ABC COMBI FIRMWARE

FIRMWARE VERSION HISTORY

This section contains history of ABC7 Combi Oven Firmware. The release date of Firmware is how it is identified. The table below lists release date and a short explanation of features / fixes which were introduced with that particular version.

NOTE: Current version of firmware loaded into oven can be identified with Parameter P0 in Service Mode (1963) or Configuration Mode (1972). The current version of in-application program (IAP) shows briefly on the Timer display when USB is inserted.

Firmware Version / (Release Date)

022514 (02-25-14)

Comments

• First production release FIRMWARE.

• IAP6.15 (in-application program) loaded to read USB port.

• Rev 11 oxygen board code.

081114 (08-11-14)

• Main board identified with ‘red wire’ on T1, (256k flash, STM32F207VCT6, 01/14-08/16, #266-#1185).

• IAP6.15 (in-application program) loaded to read USB port.

• Rev 11 oxygen board code.

• Main board identified with ‘red wire’ on T1, (256k flash, STM32F207VCT6, 01/14-08/16, #266-#1185).

• Main board identified with ‘red wire’ on T1, (1024k flash, STM32F207VGT6, 10/16, #1224-#1316).

Serial Numbers

• 541074335 (-NAT)

• 541074349 (-208V)

• 541075058 (-240v)

• 541074355 (-480v)

Combi Changes

Fixed a motor board hardware issue with the E6 error. Motor current sense circuit would lock up and the oven sensed a “false positive” current going to the convection motor, causing an E6 motor.

Fixed an issue with the P4, P5 and P6 custom temperature settings. It fixes an issue with the custom temps feature, in which initial lowest temp value when turning up from standby could be out of P15/16 range, if the only enabled custom temps are above/below P15/16.

In Configuration Mode (1972), increases maximum temperature setting in parameter P15 to 482F.

NOTE: Ovens with Serial Numbers prior to 541073334 must have their High Limit Thermostat changed before the setting of the maximum temperature can be set above 450F.

F45491 Rev. B (0518) Page 8 of 119

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ABC Combi Gas Oven - UPGRADE ABC COMBI FIRMWARE

Firmware Version / (Release Date)

Comments

• IAP6.21 (in-application program) loaded to read USB port with Rev 12 oxygen board code.

• Main Board identified with ‘green wire’ on T1, (1024k flash, STM32F207VGT6, 01/17+, #1317+).

• Oxygen Sensor, Revision C, August 2016.

Starting Serial numbers FIRMWARE

• 541083050 (-NATP) or 541083053 (-208P, -240P, -480P)

• 541083068 (-NAT) or 541083068 (-208, -240, -480)

Backward Compatibility

The 4-24-17 firmware is backward compatible to ovens with 8-11-14 or 2-25-14. It is highly recommended that the upgrade to IAP 6.21 and Rev 12 oxygen board software be completed at the same time. However, if the IAP and oxy boards are not also upgraded, the oven will still work but without benefit of the E14 and E28 diagnostics and new functionality thereof.

IAP Changes

Work-around for damaged USB port on Main board. If proper operation of USB port on main board is not properly detected in 1 second, the USB port is ignored. Fixed rare issue with USB_HOST_CONN shown on display interrupting normal oven operation. Pairs with Combi firmware addition of E14 error.

042417 (04-24-17)

Combi Changes

• Changed Service Test Mode (1963).

• Added additional oxygen sensor tests: o5, o6, o7, Pb.

• Added error codes: E14 (USB-requires IAP 6.21), E21 (motor speed), E29 (rtd).

• Removed error code E16 removed & replaced with E22, E23, E24, E25, E26, E27,

E28 (E28 Requires Revision 12 oxygen board firmware).

• Changed Configuration Mode (1972).

• Changed P12 (motor speed). Added P21 (probe calibration), P29 (cook 2 probe UI),

P34 (humidification method).

• Changed defaults P25 and P26 for drain water tempering for new style drain with

bent tube assembly, current production for starting s/n’s:

541082447 (-NAT)

541082442 (-208)

541082482 (-240)

541082425 (-480)

• Added P76 (factory only) to calibrate TC1 & TC2 thermocouple based on TC2

external meat probe thermocouple analog offset (after 2-minute temperature stabilization). Turning Timer knob switches Timer display to show uncalibrated probe temp (TC2 with P76 analog offset applied) for ease of calibration.

• Changed User Interface.

Page 9 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - UPGRADE ABC COMBI FIRMWARE

Firmware Version / (Release Date)

Comments

• Additional functionality of Cook-to-Probe and Fan Speed Control with push button

encoder. Added fan speed to the time and humidity “recalled’ settings when the on/ off switch is turned on. (If oven is equipped: ABCx-xxxP devices only. Pairs with P29, P12, P21.)

• Changed Operate Mode.

• Removed the temperature augmentation to 220F, at temperature setpoints of

212-220F for enhanced steaming.

• Removed sensor based valve/vent operation at the 100% humidity setpoint case

and replaced with continual flow of Y9 low hum water valve while vent remains closed. Defaults to sensor based humidification at humidity setpoints of <100%. Pairs with configuration setting P34 (default=dis) for enhanced steaming.

• Modified transfer function and calculations for additional accuracy on TC2

thermocouple reading for the cook-to-probe feature. Applies to all thermocouples. Pairs with Main board hardware modifications to the probe circuit as indicated by the “green” wire on T1.

• Removed all audible “error beeps” for all non-critical errors.

• Fixed a rare issue with the timer expiring/alarming when not previously set. Or which

“no” or “HEAT” could show for a split second after closing the door.

• General Fixes:

• Change project target was STM32F207IGH6, 1M flash, now STM32F207VGT6, 1M

flash corresponds to hardware change on Main board.

• Update to stm32 2.28 support package. Double the heap and stack size. (Software

maintenance.)

FIRMWARE UPDATE PROCEDURE

1. Obtain a copy of ABCombi.bin file and the IAP.bin file from the Hobart Service Resource Center and load it onto a USB flash drive (thumb drive).

NOTE: The file must be loaded in the root directory in the USB flash drive.

2. Remove RIGHT PANEL.

3. Re-apply power to oven and ensure door is closed.

4. Review and record oven's unique information.

NOTE: The oven's internal memory is reconfigured, and set to factory default when updating from 8-11-14 to 4-24-17. It is necessary to record any unique information.

B. Review (or Error Download to USB Flash

Drive) the Error Log and Counter data in 1963 Service Test Mode for your records or analysis.

NOTE: Oven memory will not be overwritten when upgrading from 4-24-17 to future revisions.

5. Place the Oven in Idle Mode (Temperature display - - -).

• No Set Temperature.

• Not in service test mode (1963).

• Not in configuration mode (1972).

6. Insert the USB flash drive into the oven’s USB-A port.

NOTE: The convection fan motor may or may not come on when the USB flash drive is inserted.

A. Write down any custom settings in

Configuration Mode (1972) Parameters P4, P5, P6. These settings must be reconfigured after firmware update.

F45491 Rev. B (0518) Page 10 of 119

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ABC Combi Gas Oven - UPGRADE ABC COMBI FIRMWARE

Fig. 2

7. View the LED displays on the front of the oven.

• The oven briefly flashes the in-application program version IAP 6.21 on the timer display.

8. "Usb Flsh n_y” appears on the display.

• If something other than "Usb Flsh n_y" is displayed, then refer to USB ERROR MESSAGES.

• If "n" is selected with the humidity knob (turned to the left, ccw), the oven will return to Idle mode. Firmware not updated.

• If "y" is selected (turned to the right, cw), the humidity display briefly changes to show "yes", then "del" as the necessary flash is deleted, then begins showing a percentage complete from 0-100 as the software image is flashed. When flashing is complete (usually after a few seconds), the humidity display briefly shows "don", which indicates the software flashed correctly. Oven returns to the Idle Mode (Temperature display - - -). Firmware is updated.

9. Enter Configuration Mode (1972),

• Verify that parameter P0 now shows 4-24-17 as the firmware revision code.

• Enter oven hour count, found in parameter P18 on the service ticket.

NOTE: Updating the IAP is highly recommended when updating firmware from 8-11-14 to 4-24-17 or later versions. Required for proper operation of the E14 error and “USB HOST COnn” fix.

NOTE: When updating firmware from 4-24-17 to later versions skip to step 11.

A. Continue in configuration mode (1972), with

the USB flash drive remaining inserted.

B. Turn temperature knob clockwise to P72.

“2000” shows on timer display.

C. Turn timer knob counterclockwise to enter

password “1972” allowing access. "Eng" shows on timer display.

D. Turn temperature knob counterclockwise to

P65. Display will show “FIAP no”.

E. Turn humidity knob clockwise to select “yes”

to request IAP firmware update. Display will show “IAP FLSH n_y”.

NOTE: If oven does not respond, select “yes” again.

F. Turn humidity knob counterclockwise to

select “y” and initiate IAP download. Selecting "n" will cancel back to P65.

• Display will show “USb flsh don”.

• Display will briefly show “IAP 6.21” (watch for this to verify the IAP updated correctly).

• Display will show “IAP FLSH n_y”, asking to re-flash the oven firmware (not IAP firmware) again. Select "n", but you can select either “y” or “n” without issue.

• Oven exits configuration mode, and returns to Idle Mode (Temperature display - - - ).

11. Remove USB flash drive.

Updating the Oxygen Sensor Board Firmware

Oxygen sensor board firmware cannot be updated remotely and must be replaced to get the current revision. Contact your local Hobart Service office for the latest replacement part.

10. Update the In-Application Program (IAP).

USB ERROR MESSAGES

Page 11 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - UPGRADE ABC COMBI FIRMWARE

Error Message Corrective Action

Usb Host Con

Usb Host Enu

Usb No Fil: The ABCombi.bin file was not found on USB drive. Reload ABCombi.bin file.

USB Fail < 1, 2 or 3 > USB drive needs to be formatted in FAT32 format. If this fails use a different USB drive.

USB Fail < 4-5, 7-8 or 15-18 >

USB Fail < 9-14>

Remove USB drive. When temperature display returns to "---", reinsert USB drive.

If error persists, use a different USB drive.

Remove USB drive. When temperature display returns to "---", reinsert USB drive.

If error persist, replace Main Control Board

F45491 Rev. B (0518) Page 12 of 119

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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. 4

Fig. 3

3. Reverse procedure to install.

Rear Panel

1. Remove RIGHT PANEL.

2. Remove two fan screws (1, Fig. 4).

3. Remove six utility panel screws (2, Fig. 4).

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

4. Remove screw in the upper right hand corner on right side of oven.

Fig. 5

5. Remove four rear panel screws (3, Fig. 4).

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

6. Lift with handles (4, Fig. 4) to remove.

7. Reverse procedure to install.

Left Panel

1. Remove RIGHT PANEL.

2. Remove REAR PANEL.

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

3. Remove screw in the upper left hand corner on left side of oven.

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

Fig. 8

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

Fig. 6

5. Reverse procedure to install.

INNER DOOR

1. Open oven door.

2. Unlatch inner door using inner door latch.

Fig. 7

5. Reverse procedure to install.

INNER DOOR LATCH

1. Remove INNER DOOR.

2. Remove upper door stiffener screws from both ends and remove upper door stiffener.

Fig. 9

3. Remove inner door latch screws.

3. Lift inner door up off door hinge.

F45491 Rev. B (0518) Page 14 of 119

Fig. 10

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

4. Reverse procedure to install.

Apply Blue Loctite 243 to inner door latch screws and inside stiffener screws.

Apply Purple Loctite 222 to the upper door stiffener screws.

Tighten screws to 24 in. lb.; do not overtighten.

5. Check for proper operation.

DOOR LAMP

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

Do not touch 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.

NOTE: Previous production ovens had three 5W lamps. Current production ovens have one 10W lamp.

1. Remove INNER DOOR.

2. Insert screwdriver in slot just above screw.

Fig. 11

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

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

Fig. 12

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 INNER DOOR.

2. Remove door lock cover.

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 15

Fig. 13

3. Remove cam screw (1, Fig. 14) and washer.

Latch Assembly

1. Remove DOOR CAM.

2. Remove four allen screws (1-4 in Fig. 16) on plunger mechanism.

Fig. 16

3. Reverse procedure to install.

NOTE: When installing new plunger, tighten allen screws in crisscross pattern as numbered in Fig. 16 torque to 24 in. lbs.

4. Check for proper operation.

Apply pressure to door latch to verify smooth

Fig. 14

4. Release torsion spring from lower slot (2, Fig.

14) in clamp bracket, then release top spring.

5. Press latch (1, Fig. 15) into door to remove cam (2, Fig. 15).

F45491 Rev. B (0518) Page 16 of 119

movement.

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

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. 17

2. Remove back control panel.

3. Remove two lock nuts (1, Fig. 18).

Fig. 19

6. Reconnect wires to connector.

7. Install switch into bracket. Must measure 3 ½" from bottom of control box and 1-3/16" as shown in Fig. 20.

Measurements for switch placement are critical to door switch operation.

Fig. 20

Fig. 18

4. Remove two screws (2, Fig. 18) to release switch from bracket.

5. Insert screwdriver into switch wire connector and push down on lower side to release wires.

Page 17 of 119 F45491 Rev. B (0518)

8. Install control panel back cover.

9. Install control panel to oven.

The door operation (latch, handle and sealing) can be negatively affected any time the control panel has been moved for servicing. Verify door latch alignment with door by opening and closing door when Control Panel is loosely mounted AND when securely mounted. If door is not operational, perform DOOR TO CONTROL PANEL ALIGNMENT.

10. Verify door switch operation.

Page 18

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

MAIN CONTROL BOARD

Certain components in this system are subject to damage by electrostatic discharge (ESD) during field repairs. An ESD kit is required to prevent damage. The ESD kit must be used anytime the circuit board is handled.

1. Check CONFIGURATION MODE (1972) - GAS for customer's current parameter settings.

Document customer's parameter settings.

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. Note and disconnect electrical connections from main control board and oxygen sensor 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.

4. Follow diagram MAIN BOARD CONNECTIONS to rewire replacement board.

5. Configure board to customer's preferred parameter settings for P25, P26, and P29 in configuration version. Refer to CONFIGURATION MODE (1972) - GAS for configuration settings.

6. Refer to CALIBRATE OXYGEN SENSOR BOARD if oxygen board is being replaced.

7. Check for proper operation.

OXYGEN SENSOR

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

4. Squeeze nylon standoffs to release and remove main control board.

Fig. 21

5. Remove OXYGEN SENSOR BOARD from main control board.

Installation of Replacement Control Board

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

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 it wet.

1. Remove RIGHT PANEL.

2. Remove REAR PANEL.

3. Disconnect main board TC cable plug (1, Fig.

22) from oxygen sensor cable at plug (2, Fig.

22).

NOTE: Do NOT disconnect cable from Oxygen Sensor Board.

F45491 Rev. B (0518) Page 18 of 119

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 22

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.

9. Check for proper operation.

OXYGEN SENSOR BOARD

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

1. Remove RIGHT SIDE PANEL.

2. Note wire locations and remove connections from oxygen sensor board.

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

Fig. 23

6. Reverse procedures to install.

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

7. When installing, route oxygen sensor cable as previously installed.

NOTE: Inspect oxygen sensor extension cable for damage and replace if necessary.

Oxygen sensor cables are sensitive to electrical noise and must be routed away from other wires.

8. Power unit on.

Page 19 of 119 F45491 Rev. B (0518)

Fig. 24

Page 20

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

2. Secure using screws from replaced board.

Oxygen sensor board must be installed while unit is

unplugged. Failure to install while unit is unplugged will cause permanent damage to oxygen

sensor board.

Installation of Oxygen Sensor Board.

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

Verify electrical connection between main board and oxygen board is secure by connecting 10-pin female header on back side of oxygen board to 10-pin male header located on main control board.

3. Power on unit.

4. Do not CALIBRATE OXYGEN SENSOR BOARD except at high altitude.

5. Check for proper operation.

Refer to SERVICE MODE (1963) and perform oxygen sensor test o1 through o5.

FERRITE

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

1. Remove RIGHT PANEL.

2. Lift ferrite clip with flat screwdriver (two places).

Fig. 25

Fig. 27

3. Reverse procedures to install.

NOTE: Install ferrite approximately 3 inches from oxygen sensor board.

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

Fig. 26

F45491 Rev. B (0518) Page 20 of 119

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 28

MOTOR CONTROL BOARD

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

1. Remove RIGHT PANEL.

2. Note and disconnect electrical connections from board.

3. Remove motor control board nylon screws.

Fig. 29

4. Reverse procedure to install.

5. Check for proper operation.

CONTROL BOX COOLING FAN

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 screws securing fan to frame.

4. Check for proper air flow.

5. Reverse procedure to install.

Page 21 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 30

CONTROL PANEL

Fig. 32

4. Remove ribbon cable wire ties.

NOTE: Replace wire ties on install.

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

Control Panel

1. Remove RIGHT PANEL.

2. Disconnect P1 connector.

Fig. 33

5. Remove recessed control panel screws.

Fig. 34

6. Lift control panel up off hooks.

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

Fig. 31

3. Disconnect motor and control board ribbon cables.

F45491 Rev. B (0518) Page 22 of 119

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

NOTE: Motor control board ribbon cable will fit in J1 as well as J8, make sure it gets plugged into P1 on Main board.

10. Verify proper operation.

CONTROL PANEL COOLING FAN

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

DOOR TO

Fig. 35

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

8. Place in secure location.

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

Fig. 36

9. Reverse procedures to install.

Display Board Fan

1. Remove CONTROL PANEL from unit.

2. Place control panel in a secure location.

3. Remove screws from back of control base panel.

Fig. 37

4. Disconnect cooling fan wire connection.

5. Remove cooling fan nuts.

Previous Production Shown

Page 23 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 38

6. Verify arrows are facing the correct direction when installed.

NOTE: Air to exhaust out of control panel.

ON / OFF SWITCH

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

On / Off Switch

1. Remove CONTROL PANEL from unit.

2. Remove screws from back of control base panel.

Previous Production Shown

Fig. 39

7. Reverse procedure to install.

8. Check for proper operation.

Fig. 40

NOTE: Use care when removing back of control panel

cover. Wires are attached.

3. Disconnect On/Off switch wires.

F45491 Rev. B (0518) Page 24 of 119

Fig. 41

Page 25

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

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

5. Reverse procedures to install.

6. Check for proper operation.

KNOB & ENCODER

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

Control Knob & Encoder

1. Remove CONTROL PANEL.

2. Place control panel in a secure location.

3. Disconnect encoder ribbon cables.

Fig. 43

5. Remove encoder nut (3, encoder.

6. Reverse procedures to install.

NOTE: Tapped hole needs to be aligned with flat part (2,

Fig. 43) of encoder. Align tab in control panel hole

needs to align with groove in encoder.

7. Check for proper operation.

NOTE: Verify push button feature (ABCx-xxxxP devices only) is operable after knob is installed.

Fig. 43) to remove

DISPLAY BOARD

Fig. 42

4. Loosen set screw (1, Fig. 43) in tapped hole on knob.

Page 25 of 119 F45491 Rev. B (0518)

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

Display Board

Page 26

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

1. Remove CONTROL PANEL.

2. Remove screws from back of control base panel.

Fig. 44

Use care when removing back of control panel cover. Wires are attached.

3. Remove display board ribbon cable.

4. Remove encoder ribbon cables.

5. Remove display board nuts.

Fig. 46

7. Reverse procedures to install.

8. Check for proper operation.

MEAT PROBE SOCKET

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

1. Remove RIGHT SIDE PANEL.

2. Disconnect probe socket from control board at

Fig. 45

6. On new display board, verify jumper J5 on back of display board is installed and on the correct two pins. Two closest to edge of the board.)

F45491 Rev. B (0518) Page 26 of 119

TC2 connection (1, Fig. 47).

Page 27

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 47

3. Remove CONTROL PANEL.

4. Remove screws (1, Fig. 48), nuts (from behind), and probe socket from control panel.

Fig. 49

7. Check for proper operation.

Fig. 48

5. Reverse procedure to install.

6. Align prongs (2, Fig. 48) as shown so meat probe (1, Fig. 49) plugs in with cord down.

REAR COOLING FAN

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

1. Remove RIGHT PANEL and REAR PANEL.

2. Remove two wires going to fan.

3. Remove nuts securing fan to frame.

Current Production Shown

Page 27 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

HIGH-LIMIT THERMOSTAT

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

1. Remove High-limit thermostat screws.

Fig. 50

4. Check for proper air flow.

5. Reverse procedure to install.

Fig. 51

Fig. 52

2. Remove High-limit thermostat probe.

Fig. 53

NOTE: Top panel removed in photo (Fig. 54) for

clarity. High-limit thermostat probe is located on top of unit, under insulation.

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

F45491 Rev. B (0518) Page 28 of 119

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 54

3. Reverse procedures to install.

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

Fig. 55

4. Check for proper operation.

CAVITY INTAKE TUBE ASSEMBLY

Fig. 56

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

NOTE: Note location of cable ties and wire routing. Vent motor and switch cables have a strain relief.

4. Remove motor shroud (1, Fig. 57).

Fig. 57

5. Remove four nuts securing intake vent tube assembly to back of cavity.

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

1. Remove RIGHT PANEL and REAR PANEL.

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

PREVIOUS GENERATION GAS OVEN

Page 29 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 59

Fig. 58

6. Replace parts as needed.

7. Reverse procedure to install.

Torque caity intake nuts to 24 in. lbs.

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

8. Check for proper operation.

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.

4. Loosen set screw.

5. Remove two screws securing 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. 60

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

F45491 Rev. B (0518) Page 30 of 119

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.

When inserting new motor, ensure flat side of motor shaft faces the set screw.

NOTE: Note location of cable ties and wire routing. Vent motor and switch cables have a strain relief.

9. Check CAVITY VENT SWITCH TEST AND ADJUSTMENT.

Page 31

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

10. Check for proper operation.

CAVITY VENT SWITCHES

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

1. Remove RIGHT PANEL and REAR PANEL.

2. Remove wires going to cavity vent switches.

Fig. 63

8. Perform CAVITY VENT SWITCH TEST AND ADJUSTMENT.

TRANSFORMER

Fig. 61

3. Remove screws securing switches to frame.

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

1. Remove RIGHT PANEL and REAR PANEL.

2. Disconnect plugs P7 (1, Fig. 64) and P8 (2, Fig.

64) going to transformer (3, Fig. 64).

Fig. 62

4. Remove top screw and remove switches from frame.

5. Replace switch or switches as needed.

6. Reverse procedure to install.

7. Attach wires to switches.

NOTE: Note location of cable ties and wire routing. Vent motor and switch cables have a strain relief.

Page 31 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 66

Transformer weighs 12.5 pounds and has a strong magnetic pull to the frame of oven.

5. Slide transformer off studs and down to the bottom of the oven.

Fig. 64

3. Remove two nuts on left hand side of transformer bracket.

Fig. 65

4. Remove nut on the right hand side of transformer bracket.

Fig. 67

6. Remove transformer and bracket from oven.

7. Remove nut and both washers securing transformer to bracket.

F45491 Rev. B (0518) Page 32 of 119

Fig. 68

Page 33

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

8. Replace transformer.

9. Tighten nyloc nut to 75 in. lbs. to ensure transformer does not rotate loose.

10. Reverse procedure to install.

TEMPERATURE SENSOR (RTD1)

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

1. Remove RIGHT PANEL.

2. Remove REAR PANEL.

3. Remove all RTD wire ties.

4. Remove black wire from TB2-3 and red wire from TB2-4.

NOTE: Insert small screwdriver in square next to the wire to release the wire from terminal block.

B. Pull upper insulation clip out and slide over

out of the way.

C. Spin square insulation clip holding outer

layer.

D. Carefully remove outer layer of insulation

and set aside for reinstalling.

E. Cut inner layer of insulation.

F. Spin square insulation clip holding inner

layer.

G. Carefully remove inner layer of insulation

and set aside for reinstalling.

7. Remove both RTD nuts.

Fig. 69

5. Remove OXYGEN SENSOR.

6. Remove insulation.

Fig. 70

A. Cut outer layer of insulation.

Fig. 71

8. Remove temperature sensor RTD1 and gasket from unit.

9. Clean mounting surface.

10. Reverse procedure to install.

RTD wiring should exit straight out of insulation through special slot cut out in insulation and not pressed against oven cavity. Do not wire tie.

Verify insulation is tucked underneath upper insulation clip. Must replace insulation to prevent oven from overheating.

NOTE: Torque probe nuts at 10 in. lbs.

11. Check for proper operation.

Page 33 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

DRAIN WATER CONDENSATE

VALVE

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

1. Remove RIGHT PANEL and REAR PANEL.

2. Remove two screws securing valve to utility panel.

7. Check for proper operation.

DRAIN WATER THERMOCOUPLE

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

1. Remove RIGHT PANEL.

2. Loosen screws for terminal TC1 and remove wires.

Fig. 72

3. Remove two wires going to valve.

4. Loosen hose clamp and pull valve free of hose.

Fig. 73

5. Replace valve.

Fig. 74

3. Cut cable ties securing wires going to drain water thermocouple.

4. Loosen fitting that goes to drain.

1st Generation Production

Fig. 75

2nd Generation Production

6. Reverse procedure to install.

F45491 Rev. B (0518) Page 34 of 119

Page 35

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

8. Refer to CONFIGURATION MODE (1972) GAS to check parameter P25, P26. based on drain type.

HUMIDITY VALVE

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

1. Remove RIGHT PANEL and REAR PANEL.

Fig. 76

5. Pull thermocouple from housing.

Fig. 77

6. Replace thermocouple ensuring the thermpcouple is set to .800.

Thermocouple shown outside machine for clarity. Dimension of .800 should be met when thermocouple is installed.

2. Remove screws securing humidity valve to utility panel.

Fig. 79

NOTE: The humidity valve is a double valve.

3. Remove two wires going to drain water condensate valve.

NOTE: This makes it easier to pull the humidity valve out from behind the utility panel.

Fig. 78

7. Reverse procedure to install.

4. Remove the four wires going to humidity valve.

NOTE: Make sure to note which wire goes to which terminal.

Page 35 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 80

5. Loosen the two hose clamps securing the valve and free the valve from the two hoses.

Fig. 82

2. Remove left and right rack guides (1, Fig. 83).

Fig. 81

6. Replace valve.

Correct valve orientation prevents a water "stuck on" condition. Verify water valve tubes are on top and electrical connections are on bottom when installing.

7. Reverse procedure to install.

CONVECTION FAN BAFFLE

The oven and its parts are hot. Use care when operating, cleaning or servicing the oven.

1. Remove all oven racks (1, Fig. 82).

Fig. 83

3. Lift baffle (1, Fig. 84) up off bottom baffle support guides (Fig. 85).

4. Lift baffle over bottom rack guide hangers (2, Fig.

84).

5. Lift baffle up off top baffle hangers (Fig. 85).

Fig. 84

F45491 Rev. B (0518) Page 36 of 119

Page 37

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

6. Pull towards front of oven to remove.

7. Reverse procedures to install.

Verify convection fan baffle is hooked on top panel and supported behind bottom baffle support guides.

Fig. 85

CONVECTION FAN MOTOR

Fig. 86

4. Note and disconnect motor wires (1, Fig. 86).

Convection Fan Terminal Block (TB2)

Connection Call-outs

A TB Block Number

White 10

Blue 9

Black 8

Red 7

Brown 6

Brown 5

Any wire ties removed during removal must be replaced during installation.

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 TOOLS.

Convection Fan

1. Remove RIGHT PANEL.

2. Remove REAR PANEL.

3. Remove humidity hose clamp (3, Fig. 86).

NOTE: Insulation removed from for clarity.

Page 37 of 119 F45491 Rev. B (0518)

5. Remove nuts, shroud and spacers if they exist (2, Fig. 86).

Do not remove motor mounting nuts at this time.

6. Remove CONVECTION FAN BAFFLE.

7. Remove humidity cavity nozzle nuts (Fig. 87) to rotate nozzle for clearance.

NOTE: Replace nozzle gasket if necessary.

Page 38

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 87

8. Remove socket head cap screw.

NOTE: May need to apply heat for removal.

Fig. 88

9. Remove atomizer bolt (Fig. 88).

NOTE: Atomizer bolt is a left-handed bolt.

NOTE: May need to apply heat for removal.

Fig. 89

13. Install gear puller.

14. Tighten gear puller to separate convection fan from motor shaft.

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

15. Remove motor mounting nuts.

16. Reverse procedure to install.

NOTE: Verify motor wire orientation before installing.

10. Remove water atomizer.

11. Thread atomizer bolt into fan motor shaft. Leave approximately 1/8" space between hex head on atomizer bolt and fan hub.

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

Apply Loctite™ 272 to all torqued threads.

17. Set specific torques when installing.

F45491 Rev. B (0518) Page 38 of 119

Fig. 90

Page 39

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

• Torque motor mount nuts to 240 in. lbs.

• Torque atomizer bolt to 350 in. lbs.

• Torque atomizer socket head cap screw to

75 in. lbs.

• Verify atomizer nozzle is aligned with center

of atomizer blade locking screw and torque nuts to 75 in. lbs.

NOTE: Tighten atomizer nozzle clamp after baffle, rack guides and racks are installed.

18. Check for proper operation.

GAS VALVE

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

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

Fig. 92

9. Check for proper operation.

IGNITOR

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

1. Remove RIGHT PANEL.

2. Remove wires from gas valve.

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.

Fig. 91

Ignitor Removal

1. Remove RIGHT PANEL.

2. Disconnect high voltage cable from ignitor.

Fig. 93

3. Remove ignitor screw.

4. Pull ignitor to remove.

5. Reverse procedures to install.

8. Reverse procedures to install.

Page 39 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

NOTE: Verify high voltage cable is routed separately from flame sensor cable (wire 206) and ground wire (wire 205).

Fig. 95

5. Reverse procedures to install.

NOTE: Verify high voltage cable is routed separately from flame sensor cable (wire 206) and ground wire (wire 205).

Fig. 94

6. Check for proper operation.

FLAME SENSOR

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

Flame Sensor Removal

1. Remove RIGHT PANEL.

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

3. Remove flame sensor screw.

4. Pull flame sensor to remove.

Fig. 96

6. Check for proper operation.

INDUCER BLOWER

1. Remove RIGHT PANEL.

F45491 Rev. B (0518) Page 40 of 119

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

Page 41

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

2. Remove REAR PANEL.

3. Disconnect inducer blower wires.

INDUCER BLOWER

BLACK 211 (Black)

WHITE 213 (White)

RED 212 (Red)

4. Remove motor shroud screws.

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

WIRE HARNESS

Fig. 99

8. Push gas flue (1, Fig. 100) back.

Fig. 97

6. Remove air pressure hose.

Fig. 98

Fig. 100

9. Remove inducer blower assembly mounting nuts.

7. Remove gas flue screws (1, Fig. 99).

Fig. 101

Page 41 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

10. Pull to remove inducer blower assembly.

11. Remove any excess inducer blower seal and clean surface before replacing seal.

12. Reverse procedures to install.

13. Check for proper operation.

HEAT EXCHANGER ASSEMBLY

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

1. Remove RIGHT PANEL.

2. Remove REAR PANEL.

3. Remove gas flue screws (1, Fig. 102) from blower.

Fig. 102

4. Push gas flue (1, Fig. 103) back.

Fig. 104

6. Remove gas valve assembly mounting nuts.

Fig. 105

7. Remove inducer blower assembly mounting nuts.

Fig. 103

5. Remove ignitor wire, flame sense wire, and air pressure hose (Fig. 104).

F45491 Rev. B (0518) Page 42 of 119

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ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 108

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

Fig. 106

8. Remove burner assembly mounting nuts.

Right Side

Fig. 107

Left Side

Fig. 109

10. Remove mounting plate nuts.

Fig. 110

11. Pull to remove heat exchanger from inside oven cavity. Remove any remaining gasket and clean surface.

NOTE: Check heat exchanger gasket for proper sealing.

12. Replace heat exchanger gasket.

13. Reverse procedure to install.

Page 43 of 119 F45491 Rev. B (0518)

Page 44

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

14. Torque nuts to 75 in. lbs.

15. Check for proper operation.

DRAFT INDUCER PRESSURE

SWITCH

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

1. Remove RIGHT PANEL.

2. Remove leads from pressure switch.

Fig. 112

3. Remove wires.

Fig. 111

3. Remove tube from pressure switch.

4. Remove screws and nuts securing pressure switch.

5. Reverse procedure to install.

IGNITION MODULE

Ignition Module

S1 Remote Flame Sensor 206

GND System Ground 205

V2 Valve Ground 207

24VAC 24 VAC Supply 209

L1 120 VAC Input (hot) 203

IND Inducer Blower (output) 204

V1 Valve Power (Output) 208

PSW Pressure Switch Input 201

TH / W Thermostat Input 200

FC+

FC-

4. Remove ignition module screws and nuts.

5. Reverse procedure to install.

Description

Alarm (normally closed

contact)

Flame Current Test

Pins

Wire

Number

225

None

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

1. Remove RIGHT PANEL.

2. Remove high voltage cable.

F45491 Rev. B (0518) Page 44 of 119

Page 45

ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 113

NOTE: Verify high voltage cable is routed separately

from flame sensor cable (wire 206) and ground wire (wire 205).

Fig. 114

6. Check for proper operation.

Page 45 of 119 F45491 Rev. B (0518)

Page 46

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

SERVICE PROCEDURES AND ADJUSTMENTS

Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times and follow Arc Flash procedures. If test points are not easily accessible, disconnect power and follow Lockout/Tagout procedures, attach test equipment and reapply power to test.

CONFIGURATION MODE (1972) - GAS

Log Into Configuration Mode 1972

1. Check with customer to verify settings have not been altered from factory settings.

2. Turn unit on.

NOTE: Oven must have no temp set to enter configuration.

3. Turn Timer knob counterclockwise until Timer display shows "set".

4. Turn Humidity knob counterclockwise until Humidity display shows "PAS".

A. Timer display will show "2000".

5. Turn Timer display counterclockwise to 1972.

A. Timer display will flash "1972".

B. Timer and Humidity display will flash twice.

C. Humidity display changes from "PAS" to "CFg" when logging into Configuration Mode.

D. Temperature Display will go to P0, which is the first configuration setting.

To review / change Configuration Mode 1972 settings

1. Turn the Temperature knob clockwise one step at a time, to go to the next configuration setting.

NOTE: Currently addresses P22, P30, and P31 are blank.

2. Presently P35 is the last address, the counter will continue to go higher, but the Time display and the Humidity display will be blank.

3. Turn the Humidity Knob to change the values as needed.

4. Refer to: "Configuration Mode (1972) Settings" chart below for options.

Logging out of Configuration Mode 1972

1. Turn Temperature knob counterclockwise until "---" displayed.

F45491 Rev. B (0518) Page 46 of 119

Page 47

Temp.

Display

("---")

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Time Display

Description

("----")

Humidity Display

("---")

P0 Current firmware code revision (Month, day, year).

P1 Set temperature to Fahrenheit or Celsius. UnIt F or C

Temperature knob increments.

Temperature increment can be adjusted by 1, 5, or 10 degrees.

Humidity knob increments.

Humidity can be adjusted by 1 or 10 percent increments.

Custom Operator Interface

Factory Default UI Setting FACt

Custom UI Setting CUSt

NOTE: Operator can flip between P4 FACt and P4 CUSt. Custom settings will be remembered.

NOTE: Only when P4 is set to custom can settings in P5 and P6 be configured.

Define Temperature Selection in UI

NOTE: Only when P4 is set to custom can settings in P5

and P6 be configured.

(Month: 04, Day: 24)

(Indicates customer

settings are currently

0424

tInC 1, 5, 10, 25

HInC 1 and 10

FACt

CUSt

loaded.)

(Year: 2017)

Letter after number. =

Revision within a

date.

Turn Hum knob

between Factory

(FACt) and Custom

(CUSt)

SEt

Turn knob to edit

custom settings.

TIP: Select “ALL on”

ALL

Page 47 of 119 F45491 Rev. B (0518)

to begin customizing

if minimal changes

needed to FACt

settings.

Page 48

Temp.

Display

("---")

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Time Display

Description

("----")

Humidity Display

("---")

oFF

80 (min)

... 482 (max)

Turn Timer knob

through temperature

choices.

Define Humidity Selection in UI

NOTE: Only when P4 is set to custom can settings in P5

and P6 be configured.

80 (F)

482(F)

Turn Timer knob

through temperature

choices.

NOTE: The following is an example of customizing the P4 through P6 settings.

P4 set to CUSt Example

1. Toggle Hum knob to select CUSt settings.

2. Turn Temperature knob to P5.

3. Toggle Hum knob oFF.

4. Scroll timer knob to temperature of 212.

5. Toggle humidity knob to on.

6. Scroll timer knob to 325.

7. Toggle humidity knob to on.

8. Turn Temperature knob to P6.

9. Scroll timer knob to 325.

212(F) on

325(F) on

212(F)

ALL

FACt

CUSt

ALL oFF

TIP: Select “ALL oFF” if you want to start customizing from scratch.

oFF / on

Hum knob can be toggled to change

individual

temperature on or off.

90 (% humidity)

0 (%)

Hum knob can be

used to change

humidity mapping to

selected

temperature.

100(%)

10. Toggle knob to 0%

F45491 Rev. B (0518) Page 48 of 119

325(F)

0(%)

Page 49

Temp.

Display

("---")

11. At completion, user interface is customized so user can only select 212F @ 100% or 325F @ 0%

End of example.

Allows users to manual adjust humidity settings during operation.

Oven Buzzer

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Time Display

Description

("----")

HAdJ on / oFF

Humidity Display

("---")

P10

P11

P12

ON - Buzzer stops after 5 seconds.

OFF - Buzzer turns on until door is opened or timer is turned off.

Door Lights

ON - Door lights flash at end of timer countdown.

OFF - Door lights do not flash at end of countdown.

Batch Timer.

Timer recalls last operated value when door is open and closed after buzzer. User does not need to reset timer.

For example, User removes a batch of fries from oven and puts in a second batch of fries.

Clean reminder.

"CLn good bYE" shown when on/off switch is toggled off.

Convection Fan Speed.

• Non-adjustable: units without probe

or units 8-11-14 FIRMWARE and prior.

• Units with Probe only (adjustable).

• 1400+ RPMs

b 5 on / oFF

FLSH on / oFF

trCL on / oFF

CLn on / oFF

F3 7

Turn Timer Knob

F2 4-6

Turn Timer Knob

• 700-900-1250 RPMs

• 525-700-900 RPMs

NOTE: Speed selected for F1 must always be below F2.

P13 Convection Fan Breaking Speed. (not adjustable) F br 5

Reversing fan timing.

P14

P15

Number of minutes cavity fan turns before breaking and turning in opposite direction.

Define maximum temperature knob setting in UI.

Maximum temperature that can be set by user. Minimum setting limited by P16.

Page 49 of 119 F45491 Rev. B (0518)

F1 3-5

FrEU Off, 2, 3, 4, 5

80 thru 482

t_HI

increments of 1,

(450default).

Page 50

Temp.

Display

("---")

P16

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Description

Define minimum temperature knob setting in UI.

Minimum temperature that can be set by user. Maximum setting limited by P15.

NOTE: Must be less than P15.

NOTE: Settings at P15 and P16 are only in effect if P4

is set to FACt.

Cavity Automatic Steam Reduction: Reduces the cavity's steam build up before end of timed cook. Vent intake is opened "selected" seconds before end of timer countdown.

Time Display

("----")

t_Lo

Humidity Display

("---")

80 thru 482

increments of 1.

P17

P18

P19

P20

NOTE: Steam reduction is not engaged mid-cook or during a "non-timed" cook when door opened.

Example: P17 = 30 seconds (default). As the cook time counts down, the vent opens allowing the steam to dissipate.

Oven hour counter. Total hours oven has been cooking.

Example: Timer: 0009, Humidity: 999 = 9,999 hours.

NOTE: Counters will zero when Main I/O board is replaced.

Humidity water counter. Total amount of water used to humidity oven in gallons.

Example: Timer: 0009, Humidity: 999 = 9,999 gallons.

NOTE: Counters will zero when Main I/O board is replaced.

NOTE: Add P19 & P20 for total water usage.

Condensate tempering water counter. Total amount of water used to cool drain water in gallons.

NOTE: Counters will zero when Main I/O board is replaced.

AUto oFF, 30, 60, 90

oVEn / 0009 HrS / 999

HUn / 0009 gAL / 999

Cond / 000 gAL / 00

NOTE: Add P19 & P20 for total water usage.

External Meat Probe Thermocouple Calibration (temperature offset).

P21

Refer to EXTERNAL MEAT PROBE THERMOCUPLE TEMPERATURE CALIBRATION.

F45491 Rev. B (0518) Page 50 of 119

PCAL

Turn Timer knob to

view current

calculated probe

temp TC2 with P21

applied for ease of

calibration.

Example: 170(F)

Turn Humidity knob

clockwise for positive

offset or

counterclockwise for

negative offset.

-10°F thru +10°F increments of 1

Default 0

Page 51

Temp.

Display

("---")

P23

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Description

Demo Mode

Used for sales. All functions operable except for heat.

Disables critical errors.

NOTE: Display will show "ABC trY it" after on/off switch is turned off.

Time Display

("----")

dEno on

Humidity Display

Turn humidity knob

clockwise for positive

("---")

offset, to lower

overall cavity temperature.

P24

P25

Temperature calibration (Temperature Offset)

Refer to Temperature Calibration in Service Procedures and Adjustments.

Condensate drain sensor activate temp.

Temperature at which to run cooling water into drain trap to achieve the proper exit temperature of the drain water.

NOTE: P25 and P26 are interdependent. The system requires P26 setting less than P25.

Important: This parameter needs to be set based on drain type, not based on firmware revision.

oCAL

dron

Turn humidity knob

counter clockwise for

negative offset, to

raise overall cavity

temperature.

-15 thru 15

increments of 1.

Default 0

Tc1 =120 through

160 Increments of 1.

140 (old drain,

regardless of

firmware revision)

160 (new drain,

regardless of

firmware revision)

Fig. 115

Page 51 of 119 F45491 Rev. B (0518)

Page 52

Temp.

Display

("---")

P26

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Description

Condensate drain sensor deactivate temp.

Temperature at which to stop cooling water into the drain trap to achieve proper exit temperature of drain water.

NOTE: P25 and P26 are interdependent. The system requires P26 setting less than P25.

Important: This parameter needs to be set based on drain type, not based on firmware revision.

Time Display

("----")

droF

Humidity Display

("---")

tC1 = 115 thru 155

increments of 1.

130 (old drain,

regardless of

firmware revision)

155 (new drain,

regardless of

firmware revision)

P27

P28

P29

P32

Fig. 116

Condensate tempering probe.

Enabled: Tempering of drain water based on condensate probe temperature (Energy efficient). See P25 & P26.

Disabled: Continuous time based tempering when in steam mode. (Less energy efficient.)

Additional Humidity knob operator interface.

Enabled: Customer has option to turn humidity knob below 0, to a "---" setpoint. In this mode, vent is forced closed and no humidity water valve operation.

Disabled: Humidity knob choices are set between 0 to 100%.

User Interface (Push button functions) Cook-to-Probe & Fan Speed Control separately enabled/disabled.

Oxygen board calibrate / zero.

(Only recommended for high altitudes.)

Oxygen Sensor Data

StPr EnA / d15

AStn EnA / d15

P_UI EnA/dIS

Scroll Timer knob to

F_UI EnA/dIS

ZEro

51 .2

Turning knob to "yes" indicates a multi-step

procedure.

Shown in % of Absolute Humidity. This value will not match the % Relative Humidity value shown on User

P33

F45491 Rev. B (0518) Page 52 of 119

Interface at oven cavity temperatures < 212°F.

ONLY USED WHEN CALIBRATING OXYGEN SENSOR. (Refer to calibrating oxygen sensor board in

service manual.)

NOTE: Combine the two numbers to get

51.2%.

Page 53

Temp.

Display

("---")

P34

P35

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Configuration Mode (1972) Settings

Description

Humidification method (not adjustable).

Disabled (default) allows for oxygen sensor based humidification at all humidity setpoints <100%.

Enabled (future) employs a non-oxygen sensor based humidification method.

Reset parameters to factory default values.

To reset values to factory default:

1. Turn humidity knob clockwise to YES. Timer display flashes "----".

2. Turn timer knob clockwise to spell "rSET", one letter at a time.

NOTE: Humidity display will read don, when the parameters have been reset.

Time Display

("----")

drIP EnA/dIS

rSET

Humidity Display

("---")

no / YES

don

NOTE: This will reset P4,5,6 Custom settings.

CALIBRATING OXYGEN SENSOR

BOARD

Oxygen sensor board needs to be calibrated when oven is installed at high altitude, otherwise do not calibrate.

1. Check oven temperature to verify oven temperature is below 100°F.

2. Open cavity door and keep open.

3. Towel dry cavity floor to ensure no standing water or steam in cavity.

NOTE: May need to remove racks to dry cavity floor.

4. Turn oven on and wait at least 3 minutes for sensor to warm up.

5. Log into Configuration Mode (1972).

6. Turn temperature knob clockwise to "P33".

• Timer display should read between 0 and

24.

• Humidity display should read between .00

and .99.

7. Turn temperature knob counterclockwise to P32.

• Timer displays "ZEro".

• Humidity displays "no".

8. Turn humidity knob clockwise to "yes" with cavity door open, to initiate the calibration process.

NOTE: Timer display will toggle between "OPEN" and "DOOR", and beeps if door is closed. Timer displays "dry", humidity displays "no", after confirming cavity is dry.

9. Turn humidity knob to "yes" to confirm cavity is dry.

• Convection fan will turn on.

• Timer display flashes "---" when conditions

are ready for calibration.

NOTE: Oven cavity temperature must be below 100°F. If temperature not less than 100°F / 38°C, timer display toggles cool/xxx°F (xxx°F / xxx°C = current temperature), until temperature is below 100°F / 38°C.

NOTE: If conditions are not met: ("P33" less than or equal to 24, cavity temperature less than 100°F / 38°C, with door open, and convection fan up to speed), the system will not allow user to enter 0000 in the timer and will beep.

NOTE: If timer displays "----" when viewing P33, oxygen sensor is warming. Wait 3 minutes. When ready, Timer / Humidity display will change to a numeric value.

NOTE: To exit out of calibrating oxygen sensor board before calibrating, turn Humidity knob to "no" or turn Temperature knob to exit.

Page 53 of 119 F45491 Rev. B (0518)

Page 54

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

10. Turn timer knob clockwise to "0000", one digit at a time to calibrate the sensor.

• Timer displays "donE" and Humidity

displays "yes" when complete.

• Convection fan turns off.

11. Check oxygen sensor board.

A. Turn temperature knob clockwise to "P33".

• Timer display should read between 0 and 2.

NOTE: This value should be near 0%. For example, timer = 2, humidity = .99, represents 2.99%.

• Humidity display should read between . 00 and .99.

B. Turn temperature knob counterclockwise

until "---" displayed to exit out of configuration mode 1972.

CHECK OXYGEN SENSOR DATE CODE (REPLACEMENT SENSORS)

• Use only replacement sensors with date code August 2016 and higher.

• Date code is indicated on sensor by first 3 numbers in the location shown by the red box as shown in Fig.

117.

• Replacement sensors require revision 12 oxygen sensor board firmware.

• Refer to Service Mode 1963 to check oxygen sensor board firmware revision (See Test O2).

Fig. 117

F45491 Rev. B (0518) Page 54 of 119

Page 55

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

TEMPERATURE SENSOR (RTD1)

TEST

1. Remove RIGHT PANEL.

2. Remove probe lead wires from Main I/O board.

3. Test probe with an ohmmeter.

4. If out of range, remove remove wires from terminal block TB2 and test again.

TEMPERATURE in °F RESISTANCE ±5 OHMS

60 530

70 541

80 552

90 563

100 573

125 600

150 627

200 680

250 732

300 785

350 836

400 887

450 938

REAR PANEL, then

TEMPERATURE CALIBRATION

1. Place temperature tester probe in geometric center of oven cavity.

2. Program a setpoint of 350°F. Allow oven temperature to cycle 3 times.

NOTE: Oven's temperature display shows setpoint. To view actual cavity temperature as it cycles around

setpoint, slightly turn temperature knob clockwise one notch or counterclockwise one notch and actual cavity temperature will blink three times.

NOTE: Turning temperature knob more than one notch will change temperature setpoint.

3. Record temperature tester readout for an additional 3 cycles. It should cycle around setpoint.

Temperature Data Recording Table

Actual

Temperature

Tester

Heater Turn On

________ ________ ________

4. Calculate amplitude. Amplitude = (Turn Off - Turn On). An amplitude of more than 40°F may indicate a problem with heat source. For example, poor combustion, see combustion analysis.

5. Calculate average. Actual average = (Turn On + Turn Off) divided by 2. Variance (between actual average and programmed setpoint) of greater than 5 degrees indicates that adjustment is needed.

6. To adjust:

A. Enter CONFIGURATION MODE (1972) -

GAS, scroll temperature knob to P24. Turn humidity knob to enter offset.

NOTE: Turn humidity knob clockwise for positive offset, to lower overall cavity temperature.

NOTE: Turn humidity knob counterclockwise for negative offset, to raise overall cavity temperature.

B. If actual average temperature is higher than

programmed setpoint, enter a positive offset value of same amount. (For example, if oven is cycling around an actual average of 360°F, adjust by entering an offset of +10°F.)

C. If the actual average temperature is lower

than programmed setpoint, enter a negative offset value of the same amount. (For example, if oven is cycling around an actual average of 340°F, adjust by entering an offset of -10°F.)

Average

(Turn On +

Turn Off)

divide by 2

Temperature

Tester

Heater Turn off

Page 55 of 119 F45491 Rev. B (0518)

Page 56

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

1) The offset can be adjusted ±30 degrees, but is only functional within the operating limits of the oven. Factory setting is 0.

7. To save setting, exit configuration mode by turning temperature knob back to "---" (idle mode) and listen for beep.

8. To recall offset value, enter CONFIGURATION MODE (1972) - GAS, turn temperature knob to P24. Verify the value set is visible in humidity.

EXTERNAL MEAT PROBE

THERMOCOUPLE CALIBRATION

NOTE: ABCx-xxxP devices only.

1. Place end of probe into slurry of ice and water.

2. Insert probe into socket on front panel of oven.

3. Log into CONFIGURATION MODE (1972) GAS.

4. Check probe temperature by turning temperature knob clockwise to P21.

• Timer display should read PCAL.

• Humidity display should read 0, (default

zero offset).

encountered, vent switches and vent motor are operating properly.

1. Go into SERVICE MODE (1963).

2. Turn temperature knob until Y10 comes on display.

3. Turn humidity knob one step clockwise.

NOTE: Test will take about 15 seconds.

NOTE: Timer display will go from (VEnt / CLSd, to

SPin / = 5, to VEnt / oPEn) or (VEnt / oPEn, to SPin / = 5, to VEnt / CLSd).

4. If test ran successfully, turn humidity knob one detent clockwise to run test again. Complete test eight times.

If an error occurs:

• Timer display showing "Err" means vent switches are in an error state and need adjusted or replaced.

• Timer display showing "=Err" means vent motor did not draw current.

• After 75 seconds, if vent switches do not indicate a ¼ turn has been made, the humidity display will show "Err".

CAVITY SHAFT SET SCREW ADJUSTMENT

5. Calibrate probe (P21).

A. Turn timer knob clockwise to view current

calculated probe temperature.

NOTE: Calculated probe temperature is TC2 input with P21 applied.

B. Turn humidity knob clockwise or

counterclockwise to adjust offset (-10 through +10) until timer display matches the input.

NOTE: Timer display reads 32 with ice water input.

C. Exit out of configuration mode 1972.

CAVITY VENT SWITCH TEST AND

ADJUSTMENT

Y10 TEST

Y10 test measures motor current, conditions of two vent switches and time it takes for the two switches, to indicate a change for the vent. Each time the test runs, the motor should turn ¼ of a turn. A ¼ turn is what it takes to make the vent to go from fully closed to fully open, or from fully open to fully closed. It is recommended this test be run eight times so the motor will go through 2 full cycles. If no errors are

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

1. Turn damper camshaft by hand.

• If damper camshaft is loose, continue to

next step.

• If unable to turn by hand, refer to VENT

SWITCH ADJUSTMENT; cavity shaft does not need adjusted.

2. Remove CAVITY VENT MOTOR.

Removing motor allows you to locate the flat on the shaft to tighten set screw on.

3. Spin shaft to locate flat.

4. Install motor.

5. Rotate shaft to locate set screw over the flat on shaft.

6. Tighten set screw.

7. Perform Y10 test in Service Mode.

F45491 Rev. B (0518) Page 56 of 119

Page 57

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

VENT SWITCH ADJUSTMENT

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

1. Loosen screws securing vent to the frame (by 1/4 turn) to allow top of switches to be adjusted in or out.

Fig. 118

2. Remove wires 44, 45, 46, and 47 from vent switches

Fig. 119

3. Rotate damper camshaft (using a pair of channel locks) until indicator on the end of the camshaft is at diagonal (Fig. 120).

Fig. 120

4. Connect a meter set to check resistance to the common terminal and N.C. contact of switch 1.

NOTE: If meter reading indicates an open, pull top of switch away from camshaft. If meter reading indicates continuity, continue to next step.

5. Press top side of switches towards camshaft until meter indicates an open.

6. Tighten screws securing switches.

7. Use meter to check the common terminal and N.C. contact of both switches. Both switches at this point should read open.

8. Perform a quick check.

A. Connect a meter set to check resistance to

the common terminal and N.C. contact of switch 1.

B. Rotate damper camshaft through one

revolution using channel locks.

C. During one revolution of the Cam shaft, the

meter should indicate continuity at two different spots. These two spots should be 180° from each other.

D. Repeat this check for switch 2.

9. Reconnect wires to both vent switches.

10. Reattach panels.

Page 57 of 119 F45491 Rev. B (0518)

Page 58

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

DOOR TO CONTROL PANEL

ALIGNMENT

Alignment Checks

1. Visually check to see if control panel (1, Fig.

122) is flush with the frame (2, Fig. 122) of the oven along the top (Fig. 121) and side. Not with the top trim (3, Fig. 122).

Front/Top View

2. Verify door alignment to control panel with straight edge.

Fig. 123

3. Verify door spacing is correct.

A. Insert the Go gauge (.119") above and

below plunger within the black handle bezel area.

Side View

Fig. 121

Fig. 124

B. Insert No-Go gauge (.200" ) above and

below plunger within the black handle bezel area.

4. If oven failed any alignment checks, do the following adjustments.

• Visual alignment check of the control panel

failed, perform Control Panel Adjustment.

• Visual alignment check of the door failed,

perform Door Adjustment.

• Go/No-Go gauge check failed, perform

Door Adjustment.

Fig. 122

F45491 Rev. B (0518) Page 58 of 119

Page 59

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

All three alignment checks must pass before checking door operation.

5. Verify door operates correctly.

A. Check that the door comes to about an inch

from closing before it compresses gasket.

B. Verify door closes without slamming.

C. Handle should turn smoothly with little effort

to unlatch.

Control Panel Adjustment

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

1. Remove right panel.

A. Remove four right panel screws.

B. Lift right panel up and back using handles.

Fig. 126

NOTE: Only loosen screw enough that the alignment

of the control panel can be adjusted with some effort.

3. Adjust the control panel (1, Fig. 128) until it is flush with the frame (2, Fig. 128) of the oven along the top (Fig. 127) and side. Not with the top trim (3, Fig. 128).

Front/Top View

Fig. 125

2. Slightly loosen six screws securing control panel.

Page 59 of 119 F45491 Rev. B (0518)

Fig. 127

Side View

Page 60

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Fig. 128

4. Tighten screws securing control panel at 24 in. lbs.

5. Repeat all three Alignment Checks.

Door Adjustment

1. Loosen top and bottom hinge screws slightly to allow door to move.

Fig. 129

2. Adjust door (1, Fig. 130) so top is flush with control panel (2, Fig. 130).

NOTE: Keep in mind you must keep the proper distance between the door and control panel (3, Fig.

130) for Go/No-Go gauge to pass.

F45491 Rev. B (0518) Page 60 of 119

Page 61

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Fig. 130

3. Tighten door hinge screws at 75 in. lbs.

4. Repeat all three Alignment Checks.

C. Loosen screws and nuts to adjust and

obtain dimensions as shown in Fig. 131.

Fig. 131

D. Verify wire location as shown in Fig. 132.

DOOR SWITCH ADJUSTMENT

1. In SERVICE MODE (1963), run (Y6) Door test.

NOTE: If the door test reports that the door is open when it is closed it may be because the door reed switch is not lined up with the magnet in the door.

To adjust the door reed switch:

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

A. Remove RIGHT PANEL.

B. Remove CONTROL PANEL.

TRANSFORMER RESISTANCE CHECK

Fig. 132

Page 61 of 119 F45491 Rev. B (0518)

Page 62

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

1. Unplug both primary and secondary side of transformer.

2. Measure resistance at both plug connections.

3. Verify resistance is ± 10% for each reading. Refer to Fig. 134.

Fig. 133

There are two types of transformers, one with a wire harness sleeve and one without. Use the proper diagram for the transformer you are servicing in

Fig. 134.

F45491 Rev. B (0518) Page 62 of 119

Page 63

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

MOTOR RESISTANCE CHECK

1. Remove REAR PANEL.

2. Note and disconnect motor wires (1, Fig. 135) at TB2.

Fig. 134

Fig. 135

3. Measure resistance.

Page 63 of 119 F45491 Rev. B (0518)

Page 64

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Fig. 137

2. Test inlet manifold pressure.

A. Open inlet pressure tap by turning screw 1

to 2 turns counterclockwise.

B. Attach manometer hose to inlet pressure

tap.

Fig. 136

4. Reconnect motor wires to TB2.

5. Install REAR PANEL.

6. Verify proper operation.

GAS VALVE PRESSURE CHECK

AND ADJUSTMENT

Disconnect the electrical power to the machine and follow lockout / tagout procedures. There may be multiple circuits. Be sure all circuits are disconnected.

Shut off the gas before servicing the unit and follow lockout / tagout procedures.

1. Remove RIGHT PANEL.

Fig. 138

C. Reconnect power and turn gas supply on.

D. If static line pressure exceeds 14" W.C. (½

psig) the customer must supply and install a pressure reducing valve to reduce the pressure below the maximum allowable for the valve.

E. Close inlet pressure tap by turning screw

CW. until tight.

3. Test outlet and adjust manifold pressure.

A. Open outlet pressure tap by turning screw 1

to 2 turns CCW.

B. Remove the pressure regulator adjustment

cap from the main gas valve to access the adjustment screw.

F45491 Rev. B (0518) Page 64 of 119

Page 65

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

C. Attach manometer hose to outlet pressure

tap.

Fig. 139

D. Reconnect power and turn gas supply on.

E. Set Temperature knob to call for heat.

NOTE: Accurate gas pressure adjustment can only be made with the burner on.

5. Verify operation.

FLAME SENSE VOLTAGE TEST

(FENWAL SERIES 35-61)

NOTE: The minimum flame voltage necessary to

keep the system from lockout is .7 Volts.

1. Connect a DC voltmeter to FC-FC+ terminals.

NOTE: Turn adjustment screw clockwise to increase the pressure. Turn adjustment screw counterclockwise to decrease pressure.

F. Set Manifold pressure to 3.5" W.C.

NOTE: Always replace the adjustment cap after adjustment and securely tighten to ensure proper operation.

G. Close outlet pressure tap by turning screw

CW until tight.

Orifice Sizes

Altitudes Natural Gas L.P. Gas

0 - 1999 ft. # 40 #53

2000 - 2999 ft. # 41 # 54

3000 - 5999 ft. # 42 # 54

6000 - 7999 ft. #43 # 54

8000 - 9999 ft. # 44 # 55

Above 10,000 ft. # 45 # 55

Natural Gas L.P. Gas

Static Line Pressure

Manifold Pressure

BTU / Hr 80,000 80,000

Min. Max. Min. Max.

5" 14" 11" 14"

3.5" W.C. 10" W.C.

Fig. 140

2. Meter should read .7 volts or higher.

NOTE: If reading is below "0" volts, reverse meter leads and take another reading.

3. Disconnect power and reconnect leads for proper polarity.

4. Check for proper operation.

4. Install right panel.

Page 65 of 119 F45491 Rev. B (0518)

Page 66

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

DRAFT INDUCER TEST

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

1. Using two 1/4" hoses and a T-connector, connect an incline manometer inline between the inducer fan and pressure switch.

• Reading on manometer should be approx. 3" WC of negative pressure.

3. Exit service mode.

A. Turn temperature knob counter clockwise

until "---" is displayed.

4. Use temperature knob to make setpoint 300°F.

A. With burner ignited, reading on manometer

should settle approx. 1.6" WC of negative pressure.

5. Turn temperature knob counterclockwise until "---" is displayed.

6. Log into SERVICE MODE (1963).

A. Turn timer knob counterclockwise until timer

display shows "SEt".

B. Turn humidity knob counterclockwise until

Humidity display shows "PAS".

1) Timer display will show "2000".

C. Turn timer display counterclockwise to

1963.

Fig. 141

2. Log Into SERVICE MODE (1963).

A. Turn unit on.

B. Turn timer knob counterclockwise until timer

display shows "SEt".

C. Turn humidity knob counterclockwise until

humidity display shows "PAS".

1) Timer display will show "2000".

D. Turn timer display counterclockwise to

1963.

1) Timer display will flash "1963".

2) Timer and humidity display will flash twice.

3) Humidity display changes from "PAs" to "tst" when logging into service mode.

E. Use the temperature knob to advance to

Y16 (Blower /Air Pressure Switch test).

F. Use humidity knob to start draft inducer fan.

• Oven should pass the test.

NOTE: Pressure switch requires a minimum of 1" W.C. negative pressure to operate.

1) Timer display will flash "1963".

2) Timer and humidity display will flash twice.

3) Humidity display changes from "PAs" to "tst" when logging into service mode.

D. Use temperature knob to advance to Y16

(Blower / Air Pressure Switch test).

E. Use humidity knob to start draft inducer fan.

• Oven should pass the test.

• With heat exchanger being at 300°F, reading on manometer should be approx. 2" WC of negative pressure.

7. Exit service mode.

A. Turn temperature knob counterclockwise

until "---" is displayed.

COMBUSTION ANALYSIS

1. Verify manifold pressure. Refer to GAS VALVE PRESSURE CHECK AND ADJUSTMENT.

2. Insert combustion analyzer meter 8" into air sampling tube at approximately (300°F +/- 50°F) (149°C +/- 25°C) for combustion tests.

F45491 Rev. B (0518) Page 66 of 119

Page 67

ABC Combi Gas Oven - SERVICE PROCEDURES AND ADJUSTMENTS

Fig. 142

3. Set oven temperature to 450°F (230°C) with a burner flame established, take combustion measurements O2 and CO readings.

If correct combustion reading cannot be obtained, verify orifice size is correct for gas type. Refer to ABC Combi Oven Gas / Elevation Conversion Kit for proper orifice size.

• O2: Range 4% to 10%

• CO: Not to exceed 0.04% (400 PPM)

NOTE: If correct combustion readings cannot be obtained, contact Cooking Support.

Page 67 of 119 F45491 Rev. B (0518)

Page 68

ABC Combi Gas Oven - ELECTRICAL OPERATION

ELECTRICAL OPERATION

COMPONENT FUNCTION

Main Board ........... Manages all input/output functions of oven as required for combi cook operation. Monitors

oven temp RTD probe, and outputs call for heat to ignition module. Monitors oxygen sensor board and outputs to humidity valves. Monitors condensate tempering thermocouple probe and outputs to condensate valve, monitors door switch and controls cavity lights. Outputs to motor control board to control speed and direction of Convection Fan motor. Rotates the cavity vent intake damper from open/closed using the cavity vent motor output and two cavity vent switch inputs. Monitors on/off switch to change operator interface from sleep/wake mode. Enables cooling fans. Monitors the display board for customer input from knobs, and sends time, temperature, and humidity information to display board. Also monitors ignition module NC output, pressure switch NC contact for ignition errors. Monitors N.O. relay contacts for high limit errors and monitors oxygen board and motor board for oxygen sensor and convection fan motor errors.

Display Board ........ Processes signals from each encoder mounted to each of the three control knobs. Then

sends signal to Main board. Processes input signals from Main board to refresh displays with Time Temperature and Humidity cooking information.

Motor Control

Board .................

Oxygen Sensor

Board .................

Oxygen Sensor

(SW5) .................

Door Switch (SW3) ... Magnetic reed switch. It senses the presence of the magnet in the door and closes.

ON / OFF Switch

(SW4) .................

Encoders (SW7, SW8,

SW9) ..................

Low voltage portion of the board processes drive signal (amber LED) and reverse signal (green LED) from the Main board to control an on board reversing relay and external solid state relay. The reversing relay contacts on the high voltage side of the board reverses voltage phases to change the motor rotation direction; the solid state relay wired to the motor board, and power the convection fan motor. The motor neutral phase is daisy chained with convection fan motor’s thermal fuse and F7 motor current protection fuse at the motor board. The motor board’s current sense circuit monitors the current through the fuses and sends a low voltage signal back to the main board (viewed on the RED LED) on the low voltage side. The current sense circuit is also responsible for detecting E1 and E6 errors.

Heats and controls the oxygen sensor, and reports back oven cavity humidity information to the Main board. Also receives calibration command from Main board.

Measures the amount of humidity in the oven cooking cavity, and is controlled by oxygen sensor board.

Monitored by the main board, which starts stops the cook cycle and activates the lights based on the state of the door switch.

Is a toggle switch that is monitored by main board to put unit from sleep to cooking idle mode. It provides 230 VAC to the following relays on the main board: cavity vent motor, high and low humidity valve, condensate tempering valve, cooling fans.

Optically coupled rotary encoder switch that is mounted behind the control knob and sends signal to display board as knob is turned in any direction or pushed.

Transformer (T1) ..... Transformer, with 120 VAC input. Multiple secondary voltages are as follows: 230 VAC

to motor board and convection fan motor, vent motor, all water solenoids and cooling fans, 12 VAC oxygen board and oxygen sensor, 12 VAC cavity lamps, 24 VAC main board, motor board (low voltage portion) , vent switches, door switches, high limit sensing contacts, 24 VAC to ignition module and gas valves.

Terminal Block

(TB1) ..................

Terminal Block

(TB2) ..................

F45491 Rev. B (0518) Page 68 of 119

Incoming voltage supply connection. Transformer to 230 VAC connections.

Convection Fan Motor (MTR1) and Oven sensor (RTD1) connection.

Page 69

ABC Combi Gas Oven - ELECTRICAL OPERATION

Terminal Block

(TB4) ..................

Fuse (F1) ............. 4A - Protects Oxygen Sensor Board.

Fuse (F2) ............. 4A - Protects Cavity Light circuit.

Fuse (F3) ............. 4A - Protects main board, motor board (low voltage portion), vent switches, door switches,

Fuse (F4) ............. 4A - Protects Ignition Module circuit and Relay R4.

Fuse (F7) ............. 6.25A - motor current protection fuse. F7 protects from a malfunction of the motor board’s

Fuse (F8) ............. 5 A - Protects Oxygen Sensor Board. (Mounted on Oxygen Sensor Board.)

Oven Door Lights (L1,

L2, L3) ................

Cavity Vent Motor

(Mtr2) .................

Cavity Vent

Open(SW1) ...........

Cavity Vent Closed

(SW2) .................

Humidity Valve Cavity

(Low Flow) (Sol2) .....

Low voltage outputs from transformer connection.

high limit sensing contacts

on-board reversing relay.

Provides light for the oven cavity (located in door frame). Voltage to light circuit. (12 Volt, 5 Watt Bulbs).

Controls the oven cavity vent intake damper inside the Cavity Vent Intake Tube.

Reports the position (open/closed/spin) of the cavity vent intake damper. Works in conjunction with SW2.

Reports the position (open/closed/spin) of the cavity vent intake damper. Works in conjunction with SW1.

Admits water into the injection nozzle (in a slow stream) that drips onto water atomizer to vaporize the water droplets and provide steam for combi mode or cool the oven temperature.

Humidity Valve Cavity

(High Flow) (Sol3) ....

Cooling Fans (CF1,

CF2, CF3) .............

Convection Fan Motor

(Mtr1) .................

Oven Sensor Input

(RTD1) ................

Air Pressure Switch

(SW6) .................

High Limit (TS1) ...... Removes power from ignition module if oven overheats. The state of the high limit is

Spark Electrode ...... Ignites the gas.

Flame Sense Probe ... Senses the presence of a flame.

Cavity Gas Valve

(V1) ...................

Ignition Module ....... Controls the inducer blower and gas valve. Generates the spark for burner ignition,

Admits water into the injection nozzle (in a slow stream) that drips onto water atomizer to vaporize the water droplets and provide steam for combi mode or cool the oven temperature.

Circulate air through the oven control panel, display panel, and convection fan motor area for component cooling.

Circulates air through the oven cavity. Is driven by Motor Control Board through capacitor C1. Reverses direction at programed intervals.

Senses oven cavity temperature and is monitored by the Main board.

Monitors VACuum created by the draft inducer motor. Prevents burner ignition if a vacuum of 1" W.C. is not present.

sensed by relay R5 which signals Vulcan Main I/O board to display error code.

Controls the gas flow.

monitors the pressure switch and the presence of a flame and controls the No ignition light.

Inducer Blower Motor

(MTR3) ................

Cold Water

Condensate (Sol1) ....

When energized, drives fan to generate draft required for proper oven operation, and exhausts combustion products out of flue.

Admits water to p-trap on power up to seal oven cavity. And admits water ptrap to mix with drain water to cool drain discharge water to 140°F before exiting oven.

Page 69 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - ELECTRICAL OPERATION

Drain Water Sensor

Input (TC1) ............

External Meat Probe Thermocouple Input

(TC2) ..................

Motor Interlock Relay

(R1) ...................

Heat Interlock Relay

(R2) ...................

Oxygen Board Interlock Relay

(R3) ...................

Inducer Blower Relay

(R4) ...................

High Limit Sense Relay

(R5) ...................

Fan Motor Relay

(R6) ...................

Ferrite ................ Passive electric component used to suppress high frequency noise from the oxygen

Monitors drain water temperature and is monitored by the Main board.

Monitors food product temperature, and is monitored by the main board when external probe is plugged into socket on front panel then inserted into food product (units with probe).

Removes power to the motor control board when On/Off switch is Off.

Is used to disable the call for heat signal from the main board to the ignition module when the On/Off switch is Off.

Removes power to the oxygen board and sensor when the On/Off switch is Off.

Used to disable the ignition module and to supply power to the combustion blower in the test mode.

Is used to report the condition of the High Limit Switch to Main Board.

Solid State Relay used to drive the convection fan motor. Is controlled by the motor control board.

sensor board.

........................

F45491 Rev. B (0518) Page 70 of 119

Page 71

ABC Combi Gas Oven - ELECTRICAL OPERATION

ELECTRICAL PANEL COMPONENT LOCATION

Fig. 143

Page 71 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - SEQUENCE OF OPERATION

SEQUENCE OF OPERATION

NOTE: Refer to schematic diagram for the electrical sequence of operation.

Conditions

1. Unit plugged into 120 VAC incoming power supply and is properly grounded.

2. ON/OFF switch (SW4) off.

3. Door switch closed (SW3).

4. High limit switch (TS1) closed.

5. 120 VAC

A. 120 VAC to TB1-9C to:

1) Blower test relay’s COM contact (R4.2).

2) L1 (blower relay) on ignition module.

B. 120 VAC (Com) to TB1-8A to:

1) Inducer blower COM.

C. 120 VAC to Transformer T1 (TB1-9, TB1-8)

for correct oven voltage on primary input of T1.

1) Transformer step up from 120 VAC to 230 VAC providing voltage for oven components (solenoid valves, motor board (convection fan motor), vent intake motor, and cooling fans.

2) Transformer steps down from 120 VAC to 24 VAC on two secondaries, 24 VAC and 24 VAC (IM).

a. 24 VAC (IM) providing voltage for

relay coils R4, R5, for high limit switch, and for ignition module and gas valve, call for heat relays.

b. 24 VAC providing voltage for main

board, motor board, vent switches, door switch.

3) Transformer steps down 120 VAC to 12 VAC on two secondaries, 12 VAC (Lite) and 12 VAC (Oxy).

a. 12 VAC (Lite) Light providing

voltage for the cavity door lights.

b. 12 VAC (Oxy) providing voltage

for oxygen sensor board and oxygen sensor.

6. 230 VAC

A. 230 VAC from transformer through TB1-6

to:

1) On/Off Switch (SW4).

2) Motor Interlock Relay (R1.2) Common contact.

B. 230 VAC (Com) from transformer through

TB1-3, TB1-4 and TB1-5 to:

1) Cavity Vent (M2).

2) V2 Main Board.

3) Oxygen Interlock Relay coil (R3-B).

4) Heat Interlock Relay coil (R2-B).

5) Motor Interlock Relay coil (R1-B).

6) Motor Interlock Relay Common Contact (R1.1).

7) Cold Water Condensate Solenoid 1 (SOL1).

8) Humidity Valve Cavity (Low Flow) Solenoid 2 (SOL2).

9) Humidity Valve Cavity (Hi Flow) Solenoid 3 (SOL3).

10) Cooling Fans (CF1, CF2, and CF3).

7. 24 VAC (IM)

A. 24 VAC (IM) from transformer to TB4-14

through 4A fuse (F4) to:

1) High Limit Switch (TS1).

2) High Limit Sense Relay Coil (R5-A) through TS1.

3) V6 on Main I/O board.

4) V5 on Main I/O board.

B. 24VAC (IM) (Com) from transformer to

TB4-1, TB4-2, and TB4-3 to:

1) High Limit Sense Relay Coil COM (R5B).

2) Gas Valve (V1) COM.

3) V1 (24V COM supply) Ignition Module.

4) V4 (call_ for_ heat common) Main I/O board.

5) V11 (fault detect common) Main I/O board.

F45491 Rev. B (0518) Page 72 of 119

Page 73

ABC Combi Gas Oven - SEQUENCE OF OPERATION

6) Blower Test Relay Coil COM (R4-B).

8. 24 VAC

A. 24 VAC from transformer to TB4-16 through

4A fuse (F3) to:

1) Cavity Vent Switch (SW1-COM).

2) Cavity Vent Switch (SW2-COM).

3) Hi Limit Sense Relay (R5.1-COM).

4) Door Switch (SW3).

5) V9 connection on Main I/O Board.

6) P21 connection on Motor Control/ Reversing Board.

B. 24VAC (Com) from transformer to TB4-5

and TB4-6 to:

1) P22 connection on Motor Control/ Reversing Board.

2) V8 connection on Main I/O Board.

9. 12 VAC (oxy)

A. 12 VAC (oxy) from transformer to TB4

thought 4A fuse F1 to:

1) Oxygen board interlock relay COM contact (R3.1).

B. 12 VAC (oxy) COM from transformer to TB4

to:

1) Oxygen board interlock relay COM contact (R3.2).

10. 12 VAC (lite)

A. 12 VAC (lite) from transformer to TB4

through 4A fuse (F2) to:

1) V3 (Lamp) on Main board.

B. 12 VAC (lite) COM from transformer to TB4

to:

1) Cavity Lamps (L1, L2, and L3) COM (Previous Production Models).

2) Cavity Lamps (L1) COM (Current Production Models).

ON/OFF Switch (SW4) turned ON,

(No Call for Heat)

1. Motor Interlock relay coil (R1) energizes.

A. Provides 230 VAC across P1 (wire 106) and

P20 (wire 107) on Motor Board.

2. Heat Interlock relay coil (R2) energizes.

A. R2.1 closes, providing 24 VAC (IM) to

Ignition Module, (through R4.1 normally closed contacts).

B. Ignition Module performs a self-check.

Ignition Module light flashes once and enters a thermostat scan state.

C. R2.2 closes allowing the Call_For_Heat

signal input from the Main board to pass to both Ignition module and XH2 pressure switch. (Which is not asserted at this point.)

3. R3 oxygen sensor board interlock relay coil (R3) energizes.

A. Providing 12 VAC (Oxy) to Oxygen Board

across J1 (wire 42) and J2 (wire 43).

B. Rev. 11 FIRMWARE (as seen in SERVICE

MODE (1963) o2 test).

1) D3 (amber), D4 (red), D5 (green) LEDs energized for 2 seconds.

2) D3 (amber) LED energized for 3 seconds confirming calibration of electronics on board.

3) D4 (red) LED energized for 1-3 minutes while the oxygen board is heating up the oxygen sensor.

4) D5 (green) LED blinks indicating transmission of Humidity data from Oxygen sensor board through piggyback connection to Main board.

NOTE: Rev. 11 - Once in regulation, only the green LED blinks. However, due to sporadic electrical noise, the red LED may intermittently come on indicating undershoot or overshoot of the oxygen sensor’s heater function (hysteresis). If this condition lasts longer than 60 seconds, condition is logged, E16.

C. Rev. 12 FIRMWARE (as seen in SERVICE

MODE (1963) o2 test).

1) D3 (amber), D4 (red), D5 (green) LEDs energized for 2 seconds.

2) D5 (green) LED energized for 3 seconds confirming calibration of electronics on board.

3) D3 (amber) LED (Rev. 12 firmware energized for 1-3 minutes while the oxygen board is heating up the oxygen sensor.

B. Convection fan motor (M1) energizes.

Page 73 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - SEQUENCE OF OPERATION

4) D5 (green) LED blinks indicating transmission of Humidity data from Oxygen sensor board through piggyback connection to Main board.

NOTE: Rev. 12 - Once in regulation, only the green LED blinks. However, due to sporadic electrical noise, the amber LED or the red LED may intermittently come on indicating undershoot or overshoot of the oxygen sensor’s heater function (hysteresis). If this condition lasts longer than 60 seconds, the condition is logged, E22-28.

4. 230 VAC to V1 on Main board.

A. Main board sends Control signals through

the ribbon cable to display board and illuminates the Temp (---) Time (--:--) and humidity (---) displays (---).

B. Y6 energizes the 3 cooling fans (CF1, CF2,

and CF3).

C. Y9 energizes the cold water condensate

Valve (Sol 1) to fill the Ptrap for 6 seconds so cold air does not get sucked up into the cooking cavity through the drain.

D. Y10 Cavity Vent Intake motor (Mtr2)

energizes to close the vent (if previously open).

E. Main I/O board monitor SW1 and SW2 for

the closed position, and de-energizes Y10, cavity vent intake motor.

F. Y13 energizes turning on the cavity lamp(s).

NOTE: Newer construction energizes one 10W lamp (L1). Older construction energizes three each of 5 Watt lamps (L1, L2, L3).

3. Green colored LED indicates the direction of the

NOTE: The state of the onboard reversing relay changes every two minutes (as indicated by the green led). This reverses the phases of the motor to reverse the direction of the motor.

4. Red LED indicates the presence of current in the

5. The Solid State Relay (R6) energizes continually

NOTE: Default convection motor fan speed is: F3, maximum.

6. Convection Fan Motor (Mtr1) energizes.

Ignition Module (blower test relay R4 off)

1. Y14 call_for_heat relay energizes.

NOTE: On the initial call for heat, a software counter begins to measure "call_for_heat" on time (see OVERSHOOT FEATURE).

2. Main I/O board reads back the call for heat

3. Main I/O board monitors the NC fault output from

4. 24 VAC (IM) is supplied to the TH/W thermostat

5. Ignition Module checks pressure switch at PSW

6. Ignition Module energizes IND output and the

ON/OFF Switch (SW4) ON & with

Call for Heat

1. Temperature knob turned, to enter Temperature setpoint. Sending signal from SW7 encoder to Main I/O board through the ribbon cable (for example 350°F).

NOTE: Timer (SW8 input) has no effect on the call for heat. no timed cooking.

Motor Control Board

1. Main I/O board sends controls signals through the ribbon cable to the motor board.

2. Amber colored LED turns on to indicate that a drive signal is being sent to the external solid state relay.

F45491 Rev. B (0518) Page 74 of 119

7. Ignition Module checks pressure switch at PSW

NOTE: Main momentary signal on Xh2 is now gone and the main board knows the pressure switch has been made.

8. Ignition Module combustion blower pre-purge

9. Ignition Module energizes the gas valve (V1).

10. Ignition Module sparks electrode for 1st trial

11. Ignition Module detects flame and shuts off spark

motor and toggles its state from on to off (or off to on) every 2 minutes during a cooking cycle.

convection fan motor, and signals the main I/O board through the ribbon cable.

at default fan speed.

(momentarily) on XH2 as part of the Error checking routine.

the ignition module as part of the Error checking routine.

input on the ignition module.

input for normally open contacts.

Combustion blower (MTR3) energizes.

input for closed contacts.

delay begins, and combustion blower removes residual gas from combustion chamber.

ignition.

electrode.

A. If flame is not established after the spark

period.

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ABC Combi Gas Oven - SEQUENCE OF OPERATION

1) 2nd pre-purge period.

2) 2nd spark.

B. If flame is not established after the 2nd

spark period.

1) 3rd pre-purge period.

2) 3rd spark.

C. If flame is not established after the 3rd spark

period, the module will go into a lock out, and the red LED on the ignition module will blink, and NO Heat will show in the Timer display on the oven.

D. Main I/O board detects the Ignition Module

lock out and will reset the ignition module one time by de-asserting and reasserting the call for heat Y14.

E. The Ignition Module will repeat the ignition

sequence up to 3 times again, and if a flame is not detected after this second set of 3 tries, the ignition module will lock out a second time, and the red LED on the ignition module will blink. NO HEAT will show in the timer display.

3) This must be the “first call for heat cycle”.

The “first call for heat cycle” is defined as the first time the control board calls for heat after:

a. First time a temperature setpoint

is entered in cook mode.

a) When temperature is set

from "---".

b) When On/Off switch is

toggled and temperature is automatically recalled.

b. When the temperature setpoint is

changed.

c. When it is detected that the door

goes from being opened to closed in cook mode.

15. Y14 call_for_heat relay de-energizes.

16. Ignition Module de-energizes Gas valve (V1).

17. Ignition Module de-energizes Combustion blower (MTR3).

F. To reset the Ignition Module, turn the On/Off

(SW4) off and back on again.

12. Ignition Module continues to energize the Gas valve and combustion blower.

13. Ignition Module continues to monitor the flame sense.

14. Cavity temperature RTD1 monitored by Main I/O board at XA1 & XA2, and turns off the call for heat when cavity temperature is satisfied.

Overshoot Feature

A. When trays of frozen product are placed in

the oven, and the oven is recovering up to setpoint, the temperature in the center of the oven and the temperature in the upper corner where the temperature probe is, are going to be different. To make up for this, the first time the oven tries to reach setpoint, the control board will keep calling for heat until the temperature at the cavity temperature probe is 50°F higher than the setpoint (“augmented setpoint”). This feature automatically kicks in if the following conditions exist.

1) The temperature setpoint is higher than 250°F.

2) It takes longer than 8 minutes to reach setpoint.

ON/OFF Switch (SW4) ON & with

Call for Heat & Call for Humidity

Humidification Sequence

1. Humidity knob automatically changes to the mapped humidity for that setting, or humidity knob can be changed by the user (SW9 input).

2. Humidity knob sending signal from SW9 encoder to Main I/O board through the ribbon cable (for example 70%).

3. After Main I/O board senses the cavity temperature on RTD1 is within 50°F of setpoint.

4. Y8 Low humidity water valve, SOL2, energizes.

5. For Humidity Setpoint = 100%, firmware 4-24-17 and later.

A. Y8 Low humidity water valve remains

energized continually without regulation, as long as cavity temperature does not fall below 50°F of setpoint, or does not fall below 50°F of augmented setpoint. See overshoot feature.

6. For Humidity Setpoints 0- 99%, firmware 4-24-17 and later (or for Humidity Setpoints 0-100%, firmware 8-11-14, 2-25-14).

Page 75 of 119 F45491 Rev. B (0518)

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ABC Combi Gas Oven - SEQUENCE OF OPERATION

NOTE: All humidity setpoints between 90% and 99% are treated as 90%.

NOTE: If the oxygen sensor is not functioning (error codes E16, E22-E23, E25-E28), oven will enter a “limp along mode” and will steam in an inefficient open loop mode at setpoints between 212°F and 220°F, and / or humidity setpoints of 100% and will steam with both water valves (Y8, SOL2 & Y5, SOL3) energized continually without regulation.

A. Y5 High humidity water valve, SOL3

energizes.

B. Main I/O board monitors oven humidity

oxygen sensor, SW5. Then when humidity is satisfied, SW5=setpoint.

C. Y5 Humidity high water valve off.

D. Y8 Low humidity water valve off.

Regulation

1) When oven humidity sensor,

SW5 < setpoint – 10%. Y8 Low humidity water valve, SOL2, reenergizes.

2) And if oven humidity

sensor<setpoint -20%. Y5 High humidity water valve, SOL3 reenergizes.

3) Y5 Humidity high water valve off.

4) Y8 Low humidity water valve off.

Hysteresis - Cavity vent intake motor (during cook cycle).

NOTE: Humidity Setpoints = 100%, firmware 4-24-17

and later, or Humidity setpoint = “---“ if so programmed in P28 CONFIGURATION MODE (1972).

1. Y10 energizes to close vent (until Main I/O board detects SW1, SW2 closed position).

2. Y10 de-energizes and vent remains closed during cook.

NOTE: Humidity Setpoints 0 - 99%, with firmware 4-24-17 and later ((or Humidity Setpoints 0-100%), with firmware 8-11-14, 2-25-14).

1. Main I/O board monitor oven humidity oxygen sensor, SW5, and compares it to humidity setpoint.

2. Y10 energizes to open the vent (until Main I/O board detects SW1, SW2 open position) when oxygen sensor, SW5 > Setpoint +10%.

Example

If Setpoint=70%, if actual humidity is 80%, then open vent.

3. Y10 energizes to close the vent (until Main I/O board detects SW1, SW2 closed position) when oxygen sensor SW5 <= Setpoint.

Example

If Setpoint=70%, if actual humidity is 70%, then close vent.

Automatic Venting

1. When Timer counts down to 30 seconds (defined in P17), then the vent will be opened to release steam in the cavity prior to the presumed opening of the door when the timer expires.

2. Y5 Humidity high water valve off.

3. Y8 Low humidity water valve off.

4. Y10 Cavity Vent Intake motor (MTR2) energizes.

5. Main I/O board monitors SW1 and SW2 for the open position, and de-energizes Y10, cavity vent intake motor.

OTHER SEQUENCES

Timer Expires (All ABC devices) AND Cook to Probe Temperature satisfied (ABCx-xxxP devices only)

1. Timer sends a signal from SW8 encoder to Main I/O board through the ribbon cable to

2. Main I/O Board either:

• Counts down the time.

NOTE: Timer does not count down when door is open.

• Monitors temperature on external meat

probe thermocouple (TC2).

3. Main I/O board turns off humidity water valves Y5 and Y8 (turns off steam) typically 30 seconds before timer expires (programmed by P17 in CONFIGURATION MODE 1972).

4. Main I/O board energizes on board buzzer for 5 seconds (or continuously if so programmed in P8 in CONFIGURATION MODE (1972)). Display lights flash.

A. Buzzer stops when additional time/cook-to-

temperature is added (turn timer knob right).

B. Buzzer function is muted when the knob is

turned left with door shut. Display lights will still flash.

F45491 Rev. B (0518) Page 76 of 119

Page 77

ABC Combi Gas Oven - SEQUENCE OF OPERATION

C. Opening the door stops the time and buzzer

function.

5. Timer function (or cook-to-probe function) does not control or affect heating. Oven will continue to heat, (without humidity) after timer expires (or after cook to probe) temperature has been reached.

6. Humidity Function not re-enabled until timer is reset and/or door is opened and closed.

Door Open (SW3 open)

1. Y14 call_for_heat_low is off.

2. Y5 Humidity high water valve off.

3. Y8 Low humidity water valve off.

NOTE: At any time during operation, if door is opened, the cook timer pauses.

Electronic Motor Break (When door opens)

A. Main board sends controls signals through

ribbon cable to motor board.

B. Amber (L1) and red (L3) LEDs turn off.

C. The Solid State Relay (R6) de-energizes.

D. Green colored LED (L2) indicates direction

of motor and toggles its state from on to off, or off to on.

E. Amber colored LED (L1) pulses (faint glow)

to indicate that a break signal is being sent to the external solid state relay.

F. Solid state relay (R6) pulses.

G. Convection fan motor (MTR1),

electronically breaks.

H. Amber (L1) and red (L3) LED’s off.

2. When water temperature inside drain assembly is above (P25 parameter) 160°F (new bent tube drain), or 140°F (old NPT pipe drain), cold water condensate valve (SOL1) is energized. This allows cold water to mix in to achieve the proper exit temperature of drain water.

3. When water temperature inside drain assembly is below (P26 parameter) 155°F (new bent tube drain), or 130°F (old NPT pipe drain), cold water condensate valve (SOL1) is de-energized.

4. Every two hours, cold water condensate valve (SOL1) is energized for 6 seconds to ensure ptrap remains full of water. This prevents cold air being sucked into drain and into cooking cavity.

NOTE: Parameter P25 and P26 are set based on drain type, not firmware revision.

Rapid Cool Feature

1. Temperature setpoint is turned down by operator, so RDT1 temperature is now 70°F higher than the temperature setpoint.

A. Main board checks status of SW1 and SW2

(Cavity Vent switches).

1) If switches indicate vent is closed, the cavity vent intake motor is energized.

2) When switches indicate vent is fully opened, the cavity vent intake motor is de-energized.

B. Humidity (high flow) water valve (SOL3) is

energized.

C. Humidity (low flow) water valve (SOL2) is

energized.

2. When RDT1 temperature drops to within 70°F of the temperature setting:

I. The solid state relay (R6) OFF.

J. Convection fan motor (MTR1) energizes.

Cold Water Condensate

NOTE: TC1 does not monitor water as it exits the

oven, rather it monitors water as it exits the oven cavity. Inside the bent drain tube assembly, it mixes cooling water in as necessary to achieve proper exit temperature of the water.

1. Water inside drain assembly is monitored by Main I/O board using drain water sensor TC1.

Page 77 of 119 F45491 Rev. B (0518)

A. Humidity (high flow) water valve (SOL3) is

de-energized.

B. Humidity (low flow) water valve (SOL2) is

de-energized.

Motor Control Board

1. Main I/O board sends signals through the ribbon cable to motor board.

2. Amber colored LED turns on to indicate that a drive signal or a brake signal.

3. Green colored LED indicates direction of the motor and toggles its state from on to off (or off to on) every 2 minutes during a cooking cycle.

NOTE: State of the onboard reversing relay changes every two minutes (indicated by LED). This reverses phases of the motor to reverse motor direction.

Page 78

ABC Combi Gas Oven - SEQUENCE OF OPERATION

4. Red LED indicates presence of current in convection fan motor, and signals the main I/O board through ribbon cable.

5. Solid State Relay (R6) energizes, at a delayed on time (as programmed in P12 CONFIGURATION MODE (1972)) every 60 hertz cycle to control motor speed (fire angle control).

6. Convection fan motor (MTR1) energizes (at low, medium or high speed setting).

F45491 Rev. B (0518) Page 78 of 119

Page 79

ABC Combi Gas Oven - CIRCUIT BOARD LAYOUTS

CIRCUIT BOARD LAYOUTS

MAIN BOARD CONNECTIONS

Meter readings for different settings on unit.

NOTE: Temperature knob presets to best set humidity. However, humidity can be adjusted.

Main Control Board Connections

Oxygen Board Connections (Function)

Designation

J1 Wire 42 12 VAC (OXY) input

J2 Wire 43 12 VAC (OXY) (COM)

J3 Cable Wire harness connected to Oxygen sensor (SW5)

Designation Reference Point ON/OFF Switch (OFF) ON/OFF Switch (ON)

J1 J2 O V 12 VAC

Designation

J1 Ribbon Cable Ribbon cable connection for Motor Board.

Wire number connected

MAIN I/O BOARD CONNECTIONS (FUNCTION)

Wire number connected

Function

Oxygen Board voltage readings

Function

Page 79 of 119 F45491 Rev. B (0518)

Page 80

ABC Combi Gas Oven - CIRCUIT BOARD LAYOUTS

MAIN I/O BOARD CONNECTIONS (FUNCTION)

Designation

J2 Ribbon Cable Ribbon cable connection for Display Board.

TC1+ White wire Condensate tempering probe input.

TC1- Red wire Condensate tempering probe input.

TC2+ White wire External Meat probe thermocouple.

TC2- Red wire External Meat probe thermocouple.

V1 Wire 28 230 VAC input (from On/Off switch.)

V2 Wire 27 230 VAC (COM) input.

V3 Wire 23 12 VAC (Lite) input.

V4 Wire 228 24 VAC (IM) (COM) input.

V5 Wire 224 24 VAC (IM) input (call for heat relay supply voltage)

V6 Wire 16 24 VAC (IM) input (blower test relaysupply voltage)

V7 Wire 13 Chassis Ground input.

V8 Wire 12 24 VAC (COM) input (main board power supply)

V9 Wire 11 24 VAC input (main board power supply)

V11 Wire 8 24 VAC (IM) (COM) input.

XA1 Wire 41 Oven Sensor RDT1 input.

XA2 Wire 40 Oven Sensor RDT1 input.

X3 Wire 3 Cavity Vent Switch (SW1) input.

X4 Wire 4 Cavity Vent Switch (SW2) input.

X5 Wire 5 Hi Limit Sense Switch input.

X6 Wire 6 Door Switch input.

X7 Wire 225 Ignition Module Fault detect input.

XH2 Wire 226 Air Pressure Switch input.

Y5 Wire 33 Output for Humidity fill valve (high) relay.

Y6 Wire 34 Output for Cooling Fans (CF1, CF2 and CF3) relay.

Y8 Wire 36 Output for Humidity fill valve (low) relay.

Y9 Wire 37 Output for Condensate tempering valve relay.

Y10 Wire 26 Output for Cavity Vent Intake Motor relay.

Y13 Wire 22 Output for Cavity Light relay.

Y14 Wire 227 Output for Heat relay.

Y16 Wire 17 Output for Service Mode blower test relay.

Wire number connected

Function

F45491 Rev. B (0518) Page 80 of 119

Page 81

ABC Combi Gas Oven - CIRCUIT BOARD LAYOUTS

Main Board Connection Points (Output Voltage readings)

ON/OFF Switch (ON)

Designation

Y5 V2 0 VAC 0 VAC

Y6 V2 0 VAC 230 VAC 230 VAC 230 VAC

Y8 V2 0 VAC 0 VAC

Y9 V2 0 VAC

Y10 V2 0 VAC

Y13 TB4-9 0 VAC

Y14 V4 0 VAC 0 VAC

Y16 V4 0 VAC 0 VAC 0 VAC 24 VAC

Reference

Point

ON/OFF Switch

(OFF)

Temperature Knob

Set to

"---" (0°F)

230 VAC for 6 seconds when on/off switch turned on.

230 VAC for 15 seconds when on/off switch turned on to close vent.

12 VAC when door is open.

Temperature Knob >

80°F

230 VAC as needed

Controlled by temp or humidity settings.

230 VAC as needed when temp is within 50° of setpoint.

Controlled by oxygen sensor and humidity setting.

230 VAC for 6 seconds every 2 hours to fill ptrap, and if Drain Water Sensor Input calls for cold water.

230 VAC for 15 seconds controlled by oxygen sensor and humidity setting.

12 VAC when door is open.

24 VAC when call for heat is needed.

Service Tests

Mode

230 VAC

230 VAC for 15 seconds.

12 VAC when door is open.

24 VAC during Y17 test.

Page 81 of 119 F45491 Rev. B (0518)

Page 82

ABC Combi Gas Oven - CIRCUIT BOARD LAYOUTS

MOTOR BOARD

Fig. 145

F45491 Rev. B (0518) Page 82 of 119

Page 83

ABC Combi Gas Oven - CIRCUIT BOARD LAYOUTS

IGNITION MODULE

Fig. 146

Ignition Module Description Wire Number

S1 Remote Flame Sensor 206

GND System Ground 205

V2 Valve Ground 207

24VAC 24 VAC Supply 209

L1 120/240 VAC Input (hot) 203

IND Inducer Blower (output) 204

NC Alarm (normally closed contact) 225

V1 Valve Power (Output) 208

PSW Pressure Switch Input 201

TH / W Thermostat Input 200

FC+

FC-

Flame Current Test Pins None

Page 83 of 119 F45491 Rev. B (0518)

Page 84

ABC Combi Gas Oven - WIRING DIAGRAMS

WIRING DIAGRAMS

F45491 Rev. B (0518) Page 84 of 119

Page 85

ABC Combi Gas Oven - WIRING DIAGRAMS

TERMINAL BLOCKS and TRANSFORMER

Fig. 147

Page 85 of 119 F45491 Rev. B (0518)

Page 86

ABC Combi Gas Oven - WIRING DIAGRAMS

MAIN BOARD

Fig. 148

F45491 Rev. B (0518) Page 86 of 119

Page 87

ABC Combi Gas Oven - WIRING DIAGRAMS

MOTOR BOARD

Fig. 149

Page 87 of 119 F45491 Rev. B (0518)

Page 88

ABC Combi Gas Oven - WIRING DIAGRAMS

IGNITION MODULE

Fig. 150

F45491 Rev. B (0518) Page 88 of 119

Page 89

ABC Combi Gas Oven - WIRING DIAGRAMS

COOLING FANS

Fig. 151

Page 89 of 119 F45491 Rev. B (0518)

Page 90

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

DIAGNOSTICS / TROUBLESHOOTING

SERVICE MODE (1963)

Logging into Service Mode 1963

1. Turn unit on.

NOTE: Oven must have no temperature set to enter Service Mode.

2. Turn Timer knob counterclockwise until Timer display shows "SEt".

3. Turn Humidity knob counterclockwise until Humidity display shows "PAS".

A. Timer display will show "2000".

4. Turn Timer display counterclockwise to 1963.

A. Timer display will flash "1963".

B. Timer and Humidity display will flash twice.

C. Humidity display changes from "PAs" to "tst" when logging into Service Mode.

NOTE: Humidity knob used to advance.

NOTE: Tests function with door open or closed.

NOTE: For some tests (Y5 - Y13), time display toggles between test number and data reading such as current or

temperature.

NOTE: To view TC1, see Y9 test. To view TC2, see P21 Calibration in CONFIGURATION MODE (1972) - GAS.

Temp.

Display

("---")

Current firmware code revision

S5 High limit thermostat status. HILt

S10

S11

(Month, day, year). Time and Humidity show example.

State of Door Switch.

Open / Close door to test switch.

State of O/I Switch.

Toggle front panel switch to test.

Electric vs Gas.

Auto detects if oven is gas or electric.

Description Timer Display ("--:--") Humidity Display ("---")

0424

(Month: 04, Date: 24)

HI / CLS (Switch closed)

LO / oPn (Switch open)

HI / CLS (Switch closed)

door

Lo / oPn (Switch open)

AC on / off

tyPE Lo / gAS

(current oven temp)

(Year: 2017)

rd1 Oven Cavity Temperature.

E2 indicates readings out of range.

556F indicates open circuit.

<40F indicates short circuit.

F45491 Rev. B (0518) Page 90 of 119

oVn

Page 91

Temp.

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Display

("---")

o 1

Description Timer Display ("--:--") Humidity Display ("---")

Oxygen sensor power.

Verifies 12VAC is supplied to Oxygen Sensor Board.

Oxygen sensor board revision number.

o2Pr

orREV

on/Err

on - Oxygen board is powered.

Err - Oxygen board is not powered.

example: 012

(If no revision number seen -

power off / on to recognize revision

date.)

NOTE: Revision 12 is backward

compatible to ovens s/n

541083068 and before and is a

required upgrade when changing a

sensor.

O0 / -

• Oxygen board not transmitting a status.

• Check connections.

O1 / HT

• Oxygen board is heating the oxygen sensor.

o 3

Oxygen Board /Oxygen Sensor status.

NOTE: Reported as a pair.

02bd

• Wait 3 minutes for warming after power is applied.

02 / rdY

• Oxygen board is ready and transmitting humidity data from sensor.

O3 / Cal

• Oxygen board can't calibrate itself.

• Damaged Oxygen board.

O4 / Cur (Current error)

• Oxygen board can't sense current in oxygen sensor heater.

• Check for disconnected sensor.

Page 91 of 119 F45491 Rev. B (0518)

Page 92

Temp.

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Display

("---")

o 4

Description Timer Display ("--:--") Humidity Display ("---")

Oxygen sensor data.

Shown in % of Absolute Humidity. This value will not match the % Relative Humidity value shown on User interface at oven cavity temperatures less than 212°F.

Same value as P33 in CONFIGURATION MODE (1972) - GAS.

NOTE: Combine the numbers in the two displays to get the complete percentage.

Reports duty cycle of oxygen sensor heater regulation.

Reports ramp input given to oxygen board.

Reports condensation time phase input given to oxygen board.

Convection fan Test.

051 .2

Combine the two numbers to get

51.2 %

duty Example: 33

rAanP/0005

PHAS/0001

1. Checks fan speeds 3 through

Visually check for change in fan speed.

2. Checks current sensing of motor.

Visually check for display to change from IoFF to Ion in Timer display.

3. Checks breaking of motor.

Visually check for convection fan breaking to a stop and not coasting to a stop.

SPd / Ion

SPd / IoFF

oFF, 3, 4, 5, 6, 7

F45491 Rev. B (0518) Page 92 of 119

Page 93

Temp.

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Display

("---")

Description Timer Display ("--:--") Humidity Display ("---")

Convection Fan Reverse Test.

Turn humidity knob to initiate test. Note direction of fan. For example, clockwise.

Turn humidity knob to reverse motor. Note direction of fan has changed. For example, counterclockwise.

NOTE: Turning humidity knob too quickly during breaking sequence, will cause oven to beep.

Humidity High flow Water Valve.

When turned on, water will flow out of water atomizer.

NOTE: Valve flow rate = 15 liters / hour (.25 liter / min).

rEV

Ion / IoFF

H2HI

When on, Timer display toggles

between H2H1 and a value to

indicate solenoid is energized.

Expected value = 6 ± 1

NOTE: Wait 10 seconds for

proper value reading in timer

display.

HI / Lo

on / oFF

Cooling fans.

Fan 1 (control panel), fan 2 (display panel), fan 3 (oven rear).

Humidity Low flow Water Valve.

When turned on, water will flow out of water atomizer.

NOTE: Valve flow rate = 15 liters / hour (.25 liter / min).

NOTE: When Timer displays

"=Err", indicates that the valve is

not drawing the proper current.

CFAn / (Current Sense value)

When on, Timer display toggles

between CFan and a value to

indicate fans are energized.

Expected value = approximately

99 for 3 fans, 66 for 2 fans.

NOTE: When Timer displays

"=Err", indicates that the fans are

not drawing the proper current.

H2Lo

When on, Timer display toggles

between H2Lo and a value to

indicate solenoid is energized.

Expected value = 6 ± 1

NOTE: Wait 10 seconds for

proper value reading in timer

display.

on / oFF

NOTE: When Timer displays

"=Err", indicates that the valve is

not drawing the proper current.

Page 93 of 119 F45491 Rev. B (0518)

Page 94

Temp.

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Display

("---")

Y10

Description Timer Display ("--:--") Humidity Display ("---")

Water drain Condensate valve.

When turned on, water will flow out drain.

NOTE: Valve flow rate = 300 liters / hour (5 liters / min).

Cavity Vent Intake.

Current sense and Vent operation test.

1. Checks state of vent switches.

2. Checks rotation of vent motor, quarter turn at a time.

NOTE: Properly check cavity vent intake by turning humidity knob between oPn and CLS a minimum of 4 times to get full rotation.

3. Times rotation of quarter turn, to verify vent switches seat properly on shaft.

4. Checks for current feedback to verify motor is energized.

H2dr / Drain Temp

When on, Timer display toggles between three things. H2dr which is the name of the test, a value to

indicate solenoid is energized

(settles at a value of 6 ±1 and the

drain tempering probe's (TC1)

temperature).

NOTE: When Timer displays

"=Err", indicates that the valve is

not drawing the proper current.

VEnt / CLSd

SPIn / =5

Display toggles. SPIn indicates

switches are in spinning state. "=5"

is an approximate number which

indicates motor is energized

properly.

When complete: VEnt / oPEn

NOTE: "Err/=5", switches are in

an error state, see ERROR

CODES .

NOTE: When timer display "=Err" indicates that the vent motor is not

drawing the proper current.

LItE

on / oFF

Humidity display shows CLS.

CLS, turn humidity knob to initiate

test.

Display counts up to 15 seconds, if

operating properly.

When complete: Humidity knob

will read oPEn

NOTE: Counts past 15 indicate switches have not seated properly, Err displays after 75 seconds, Test

continues to run.

when on, Timer display toggles

between LItE and a value to

indicate lights are energized.

Y13 Oven cavity door light.

Blower test / Air Pressure Switch.

(Timer display will initially read

Y16

F45491 Rev. B (0518) Page 94 of 119

"FAIL", until blower has successfully turned on and up to speed and pressure switch has been opened. Timer display will then read "PASS".)

Expected values:

75 for 3 lights

50 for 2 lights

25 for 1 light

0 for no lights on

blo

FAIL / PASS

on / oFF

Page 95

Temp.

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Display

("---")

Y17

HUn gAL

Cnd gAL

Description Timer Display ("--:--") Humidity Display ("---")

Ignition sequence test (gas only). on / oFF

IGn oFF

test.

tst

to turn test off.

--- (not pressed)

oFF / on

Example: 999

Resets ignition module faults.

Tests ignition module gas valve pressure switch, induction blower, and spark ignitor.

Heat test rate of temperature rise.

NOTE: If cavity temperature is above 400°F, oven will beep and turn off test. Turn Humidity knob to turn off beep.

NOTE: If test fails, for example, gas turned off to unit, test will stop, and error code will be shown. If error codes generate, refer to ERROR CODES (1963).

Reports the press of the push button encoder. (ABCx-xxxP devices only)

Display

Test - assure led light segments operate.

Humidity Water Counter.

NOTE: Same value as P19 in CONFIGURATION MODE (1972) - GAS.

Condensate Tempering Water Counter.

NOTE: Same value as P20 in CONFIGURATION MODE (1972) - GAS.

blo0 to blo9

rSt0 to rSt9

trY

NOTE: trY1 is the spark from

spark ignitor.

NOTE: If trY does not display, wait

approximately 30 seconds for

error codes to generate. If error

codes generate, refer to ERROR

CODES (1963).

102F / Heat

115F / PASS

Example: Err Example: E11

--- (not pressed)

PUSH (Timer pressed)

Temperature, Timer, Humidity

displays sequence thru dots and

digits 0 - 9.

(Example: ..., 000, 111, etc.)

Example: 0009

Turn humidity knob on to initiate

When heat test passes, turn

Humidity knob counter clockwise

PUSH (Hum pressed)

Example: Total gallons: 9,999.

Page 95 of 119 F45491 Rev. B (0518)

Page 96

Temp.

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Display

("---")

Cooking Hours.

NOTE: Same value as P18 in

HRS

LOg (Refer to ERROR CODES.)

E0 thru E21

Logging out of Service Mode 1963

1. Turn Temperature knob counterclockwise until "---" displayed.

CONFIGURATION MODE (1972) - GAS.

(Hour counter does not increment in idle mode.)

(Refer to ERROR CODES.)

Description Timer Display ("--:--") Humidity Display ("---")

Example: 999

Example: 0009

Example: Total hours: 9,999.

ERROR CODES

In cook mode, the oven always checks for errors. The oven does not check for errors in idle mode, (all displays show ----). All errors are stored into a log in SERVICE MODE (1963). Some errors are considered critical, that the oven cannot operate and if detected, everything is shut down, error number is displayed, and oven beeps continually.

NOTE: E6 error is the exception to the rule, and is the only error logged during idle time.

To turn off continuous beep, toggle on/off switch. If condition still exists, error will reappear immediately. If error beep turns back on, turn Timer knob counterclockwise, back to idle mode "---".

ERRORS 0 - 2 below are "critical" errors. Oven will not function in this condition. All processes are stopped and oven is shut down.

Some errors are considered non-critical, where something requires service, but oven can still cook. Some of these errors are displayed in operator interface, so customer knows to call for service. Other non-critical errors are logged as a diagnostics tool for service.

When an error code is logged, the hour that the error occurred is recorded. The hours in the log are cooking hours. Cooking hours are the number of hours the oven has been in use. Cooking hours do not increase during idle time (all displays show ----). So if a school uses an oven 6 hours a day, 5 days a week, the cooking hours will increase 30 hours a week.

F45491 Rev. B (0518) Page 96 of 119

Page 97

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

Logging into Service Mode 1963

1. Turn unit on.

2. Turn Timer knob counterclockwise until Timer display shows "SEt".

3. Turn Humidity knob counterclockwise until Humidity display shows "PAS".

A. Timer display will show "2000".

4. Turn Timer display counterclockwise to 1963.

A. Timer display will flash "1963".

B. Timer and Humidity display will flash twice.

C. Humidity display changes from "PAs" to "tst" when logging into Service Mode.

5. Turn Temperature knob clockwise through all tests in service mode, until "HRS" is displayed in the Temperature display.

This displays the current number of cooking hours in the Timer and Humidity displays. Make a note of the hour listed. This is important so that you can tell how long it has been since the error has occurred.

To read the current number of hours

A. With HRS displayed in the temperature display.

B. 0009 in the Timer display.

C. 999 in the humidity display.

D. The oven would have 9,999 cooking hours.

6. Turn Timer knob clockwise one more click, then "LOg" is displayed in the Temperature display.

Page 97 of 119 F45491 Rev. B (0518)

Page 98

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

There are two ways error codes are stored, sequential log and error bucket.

Sequential log: A quick timed ordered list on errors recorded.

Error buckets: Each bucket, E0...E21, displays an individual error and every hour that the error occurred.

How to read sequential Log

When Log is shown in Temperature display, sequential error log is being displayed. The last stored error is shown in the Timer display. Then the Timer display, in conjunction with the Humidity display toggles the hour count when error occurred.

Sequential Log

1. With Log displayed in the temperature display.

2. Timer Display toggles between E1 and 0009.

3. Humidity display flashing 999

4. Means that an E1 error occurred at cooking hour 9,999.

This is a sequential log. To view the next error recorded, turn Timer knob clockwise. If no more errors have been recorded, Timer displays "ErrS" and Humidity displays "End". If multiple errors have been recorded, "--]" will be displayed in Temperature display when Timer knob is turned. The next error in the sequential log is shown in the Timer display. Then the Timer display in conjunction with the humidity display toggles between error code and hour in which the error occurred.

NOTE: As the sequential log stores multiple error logs, only view the last few error codes to know what errors have occurred to prevent oven from working properly.

How to Read Error Buckets

To view bucket list, turn Temperature knob clockwise to start error buckets, starting at E0. If no errors have been recorded for E0, then Temperature displays "E0 (error code)", Timer displays "ErrS", Humidity displays "End". If no errors are displayed in error bucket, turn Temperature knob clockwise to next error.

If errors are recorded in error bucket, Temperature displays "E0 (error code)", Timer and humidity displays oven hour count the error last occurred. If multiple errors have been recorded, "--]" will be displayed in Temperature display when Timer knob is turned clockwise, the oven will display each recorded event and associated hour count. The next hour count is shown in Timer and Humidity displays. To view multiple hours recorded, continue turning Timer knob clockwise. Timer knob will show "ErrS" and Humidity display will show "End" when all recorded hours have been displayed.

NOTE: Multiple errors can be recorded during the same hour. Turning the Humidity knob clockwise will skip hour by hour, not displaying each individual recorded event.

E0 ..................... High Limit Error (Critical Error): Oven overheats, tripping high limit thermostat, and

removes voltage from ignition module.

E1 ..................... Convection Fan Motor Error (Critical Error): Motor Board does not sense current to motor.

Possible causes: 1) Convection fan has overheated and fan's thermal fuse has tripped, or 2) motor board's 6-1/4 fuse amp has been blown.

E2 ..................... RTD Probe Error (Critical Error): Probe RTD readings are out of range indicating a main

board problem.

E3 ..................... (Future Use.)

E4 ..................... Controls Compartment Ambient Error: Operating temperature of controls has exceeded

recommenced temperature limits for more than 15 minutes.

E5 ..................... Drain Tempering Probe Error: Drain tempering probe readings are out of the 32°F to

250°F range.

F45491 Rev. B (0518) Page 98 of 119

Page 99

ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

E6 ..................... Convection Fan Current Error: Control board reads current to convection fan motor, when

convection fan should be off.

Error E6 is the only error that can be logged during idle mode.

E7 ..................... Auto Electric or Gas Detection Error: Control board cannot auto detect type of unit or

state of auto detect pin has changed.

E8 ..................... Ignition Error: Ignition Module Error Checking Problem.

1. Ignition module inoperable.

2. Improper sensing of X7 (fault) and XH2 (pressure switch) input to main board.

• Oven "may" heat in this condition, but Combi's Main board cannot sense ignition faults.

E9 ..................... Ignition Error: Ignition Module, flame sensed before call for heat.

• Pre-ignition error.

• Fenwal Module red light ‘2’ flash.

E10 ................... Ignition Error: Ignition Module Lock Out Fault.

• Pre-ignition. Failure to ignite gas after 3 sparks.

• Fenwal Module red light ‘3’ flash.

E11 ................... Ignition Error: Air flow fault 1.

Blower or AP switch problem.

• Pre-ignition air pressure not up to speed.

• Fenwal Module red light ‘1’ flash.

E12 ................... Ignition Error: Air flow fault 1 or Control Fault.

1. Blower or AP switch problem.

• Post ignition air pressure drops out while burning.

• Fenwal Module Red light ‘1’ flash.

2. Internal control fault inside to Fenwal ignition module.

• Pre-ignition

• Fenwal Module Red Light Steady ‘on'.

E13 ................... Ignition Error: Flame dropout Detection.

Fenwal re-ignites after gas supply restored.

No fault ‘flash’ but oven is not heating in this condition.

• Post ignition flame drops out before controller set temperature is satisfied.

E14 ................... Logs an E14 error if USB is not functioning on main board. (Requires IAP 6.21.)

E15 ................... Vent Error: Either vent motor has a problem and cannot rotate, or the vent switches are

out of adjustment and cannot tell vent motor when to stop its rotation at the open or closed position. This means the system cannot humidify efficiently. Although switches should seat into position within 15 seconds for a quarter turn, error will not be logged until vent motor runs 75 seconds without completing.

E16 ................... For 4-24-17 firmware revisions and above: E16 inactive, replaced with E22 – E28.

For 8-11-14, 2-25-14 firmware revisions: In cook mode, where oxygen sensor/ oxygen sensor board has fallen out of its ready status.

1. Stuck in warming.

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ABC Combi Gas Oven - DIAGNOSTICS / TROUBLESHOOTING

2. Communication error.

3. Internal oxygen board heating or calibration error.

E17 ................... (Future Use.)

E18 ................... In cook mode, where oxygen sensor board has lost 12V supply.

E19 ................... (Future Use.)

E20 ................... Cooling Fan Dropout: Current not sensed in one or more of the cooling fans. Check

cooling fans to ensure fans are functioning properly.

E21 ................... Logs an error when part of the motor speed control zero cross circuit on either the motor

board or main board is inoperable. (Logs error when 60 seconds has passed without seeing a 60Hz zero cross signal.)

E22 ................... Log event created when condition persists for more than 60 seconds for "no COMM".

Communication dropout between oxygen & main boards. Indicates board error (if together with no power, an E18 is logged instead).

E23 ................... Log event created when condition persists for more than 60 seconds for "bad COMM".

Communication unrecognized status received from oxy board. Indicates board error.

E24 ................... Log event created when condition persists for more than 60 seconds for "bad reading",

“stuck” at 100% absolute humidity, for more than 60 seconds. Indicates damaged oxygen sensor.

E25 ................... Log event created when condition persists for more than 60 seconds for "under heating":

• Undershoot of the sensor’s heater regulation. Status 01 is returned for more than 60 seconds after first o.k. status (after warm-up complete) indicating intermittent electrical noise interference. (Rev. 12 amber LED, Rev. 11, red LED, comes back on for more than 60 seconds after warm-up complete.)

• Stuck in warming. Status 01 is returned for more than 3 minutes before the first o.k. status when the board is reset or following a COMM error. (Rev. 12 amber LED, Rev. 11 red LED, never turns off after power up.)

E26 ................... Log event created when condition persists for more than 60 seconds for "damaged

oxygen board". Status 03 returned from the oxy board indicating on board IC’s cannot calibrate themselves.

E27 ................... Log event created when condition persists for more than 60 seconds for "cannot heat

sensor". Status 04 returned from the oxy board indicating no heater current and possibly an open sensor, unplugged sensor or intermittent connection.

E28 ................... Log event created when condition persists for more than 60 seconds for "Over-heating".

• Overshoot of the sensor’s heater regulation. Status 05 returned from the oxy board for more than 60 seconds indicating intermittent electrical noise interference. (Rev. 12 oxygen board’s red LED comes on for more than 60 seconds, after warm-up complete.)

NOTE: E28 error requires Rev. 12 oxygen sensor board. When using Rev. 11 oxygen sensor board, the overheating condition is logged as E25.

E29 ................... Logs E29 error when RTD reads abnormally low <40F indicating a damaged sensor.

Logging out of Service Mode 1963

1. Turn Temperature knob counterclockwise until "---" displayed.

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