Vulcan-Hart ABC Service Manual
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)
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
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
© VULCAN 2018
Page 3 of 119 F45491 Rev. B (0518)
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
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.
Page 5 of 119 F45491 Rev. B (0518)
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
1
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
2
Total Chlorine
2
4
zero
less than 30 ppm
zero
3
PH range 7-8
Undissolved Solids less than 5 microns
1
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.
2
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.
3
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.
4
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
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
Page 7 of 119 F45491 Rev. B (0518)
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
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)
OR
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)
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
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)
ABC Combi Gas Oven - UPGRADE ABC COMBI FIRMWARE
Error Message Corrective Action
Usb Host Con
or
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.
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
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.
Page 13 of 119 F45491 Rev. B (0518)
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
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.
Page 15 of 119 F45491 Rev. B (0518)
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.
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.
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
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.
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. 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
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
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.
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. 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)
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.
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.
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
ABC Combi Gas Oven - REMOVAL AND REPLACEMENT OF PARTS
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
CONTROL PANEL ALIGNMENT.
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.
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.
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)
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.
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.
Fig. 40
NOTE: Use care when removing back of control panel
cover. Wires are attached.
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.
3. Disconnect On/Off switch wires.
F45491 Rev. B (0518) Page 24 of 119
Fig. 41
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.
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.
6. Check for proper operation.
KNOB & ENCODER
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
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.
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.
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.
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.
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.
Display Board
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.
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.
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.
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.
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).
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.
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.
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)
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
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)
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.
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