Vulcan-Hart ABC7E, ML-137716 Service Manual

SERVICE MANUAL

ABC Combi Electric Oven

ABC7E ML-137716

- 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

F45495 Rev. B (0515)

ABC Combi Electric Oven

TABLE OF CONTENTS

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

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

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

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

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

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

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

WATER QUALITY STATEMENT ........................................................................ 5

SPECIFICATIONS ...................................................................................... 6

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

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

FIRMWARE UPDATE PROCEDURE .................................................................... 8

USB ERROR MESSAGES .............................................................................. 9

REMOVAL AND REPLACEMENT OF PARTS .............................................................. 10

PANELS .............................................................................................. 10

INNER DOOR ......................................................................................... 11

INNER DOOR LATCH ................................................................................. 11

DOOR LAMP .......................................................................................... 12

DOOR LATCH ........................................................................................ 12

DOOR SWITCH ....................................................................................... 13

CONVECTION FAN MOTOR .......................................................................... 14

CONVECTION FAN BAFFLE .......................................................................... 15

MAIN CONTROL BOARD ............................................................................. 15

OXYGEN SENSOR ................................................................................... 16

OXYGEN SENSOR BOARD ........................................................................... 17

FERRITE ............................................................................................. 17

MOTOR CONTROL BOARD ........................................................................... 18

CONTROL PANEL .................................................................................... 18

ON / OFF SWITCH .................................................................................... 19

DISPLAY BOARD ..................................................................................... 20

CONTROL PANEL COOLING FAN .................................................................... 21

CONTROL BOX COOLING FAN ....................................................................... 22

REAR COOLING FAN ................................................................................. 22

KNOB & ENCODER ................................................................................... 23

HI-LIMIT THERMOSTAT .............................................................................. 23

CAVITY INTAKE TUBE ASSEMBLY ................................................................... 24

CAVITY VENT MOTOR ............................................................................... 25

CAVITY VENT SWITCHES ............................................................................ 25

TRANSFORMER ...................................................................................... 26

TEMPERATURE SENSOR (RTD1) .................................................................... 27

DRAIN WATER CONDENSATE VALVE ................................................................ 28

DRAIN WATER THERMOCOUPLE .................................................................... 28

HUMIDITY VALVE .................................................................................... 29

HEATING ELEMENTS ................................................................................ 30

CONTACTORS ....................................................................................... 31

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

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

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

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

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

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

TEMPERATURE SENSOR (RTD1) TEST .............................................................. 39

TEMPERATURE CALIBRATION ....................................................................... 39

F45495 Rev. B (0515) Page 2 of 77

ABC Combi Electric Oven

CAVITY VENT SWITCH TEST AND ADJUSTMENT .................................................... 40

DOOR SWITCH ADJUSTMENT ....................................................................... 41

HEATING ELEMENTS RESISTANCE CHECK ......................................................... 42

ELECTRICAL OPERATION ................................................................................ 43

COMPONENT FUNCTION ............................................................................ 43

CONTROL PANEL COMPONET LOCATIONS ......................................................... 45

SEQUENCE OF OPERATION ............................................................................. 46

CONDITIONS ......................................................................................... 46

ON/OFF SWITCH (SW4) TURNED ON, (NO CALL FOR HEAT) ........................................ 47

ON/OFF SWITCH (SW4) ON & WITH CALL FOR HEAT ................................................ 47

ON/OFF SWITCH (SW4) ON & WITH CALL FOR HEAT & CALL FOR HUMIDITY ....................... 49

OTHER SEQUENCES ................................................................................. 49

CIRCUIT BOARD LAYOUTS .............................................................................. 51

MAIN BOARD CONNECTIONS ........................................................................ 51

MOTOR BOARD ...................................................................................... 54

WIRING DIAGRAMS ...................................................................................... 55

TERMINAL BLOCKS .................................................................................. 55

T1 TRANSFORMER ................................................................................... 56

HEATING ELEMENTS ................................................................................ 57

MAIN BOARD ......................................................................................... 58

MOTOR BOARD ...................................................................................... 59

COOLING FANS ...................................................................................... 60

WIRING CHANGES FOR SINGLE PHASE ............................................................. 61

DIAGNOSTICS / TROUBLESHOOTING ................................................................... 62

SERVICE MODE (1963) ............................................................................... 62

ERROR CODES ...................................................................................... 67

OVEN TROUBLESHOOTING .......................................................................... 70

QUICK OVER ALL CHECK ........................................................................ 70

TROUBLESHOOTING USING ERROR CODES .................................................... 70

TROUBLESHOOTING BY SYMPTOM ............................................................. 74

Page 3 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - SERVICE UPDATES

SERVICE UPDATES

SERVICE UPDATES - ABC COMBI

ELECTRIC OVEN

January, 2015

1. New Heating Element Wiring Diagram - 05-20-15

2. New Software version - 08-11-14

A. FIRMWARE VERSION HISTORY

B. FIRMWARE UPDATE PROCEDURE

C. USB ERROR MESSAGES

F45495 Rev. B (0515) Page 4 of 77

ABC Combi Electric Oven - GENERAL

GENERAL

INTRODUCTION

General

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

Heating

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

Combi Ovens

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

Steam System

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

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

OPERATION, CLEANING AND

MAINTENANCE

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

TOOLS

Standard

1. Standard set of hand tools.

2. Metric set of hand tools.

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

4. Temperature tester (thermocouple type)

5. Field service grounding kit.

Special

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

2. Gear puller to remove convection fan.

3. USB Drive (Part # 00-443444)

LUBRICATION

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

2. Anti seizing compound.

WATER QUALITY STATEMENT

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

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

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

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

Page 5 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - GENERAL

WATER SUPPLY GENERAL GUIDELINES

Supply Pressure (dynamic flow)

30-60 psig

less than 3 grains (17.1

Hardness

ppm = 1 grain of hardness)

Silica less than 13 ppm

Chloramines

Chlorides

Total Chlorine

zero

less than 30 ppm

zero

PH range 7-8

Un-Dissolved Solids less than 5 microns

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

A carbon block filter system should always be used to remove Chlorine and Chloramine. If a

SPECIFICATIONS

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.

Data

Electrical and grounding connections must comply with the applicable portions of the National

Electrical Code and / or other local electrical codes.

Supply Voltage

208V 240V 480V

Model Phase

KW AMP KW AMP KW AMP

1 18 86.5 24 100 - -

ABC7E

3 18 50 24 57.8 24 28.9

NOTE: Single-phase blower motors are user on these ovens, so there is no need to check direction of motor rotation. The fan will rotate in the proper direction.

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.

Plumbing connections must comply

with the applicable sanitary, safety and plumbing codes.

Supply water requirements:

1. 2.0 to 6.0 grains of hardness per gal.

2. pH 7.0 to 8.0.

3. Chlorides less than 30 PPM.

Drain Connection

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

Plumbing Connections

F45495 Rev. B (0515) Page 6 of 77

ABC Combi Electric Oven - GENERAL

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

Page 7 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - UPGRADE ABC COMBI FIRMWARE

UPGRADE ABC COMBI FIRMWARE

FIRMWARE VERSION HISTORY

This section contains the history of the ABC7 Combi Oven Firmware. The release date of the Firmware is how it is identified. The table below will list the release date along with a short explanation of the features /

Firmware Version / (Release Date)

022514 (02-25-14) First production release.

081114 (08-11-14)

Comments

Fixed an issue with the E6 error. Motor current sense circuit would lock up and the oven could not sense current going to the convection fan motor, causing an E6 error.

Fixed an issue with the P4, P5 and P6 custom temperature settings. It fixes an issue with 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 the maximim 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.

fixes which were introduced with that particular version.

NOTE: The current version of firmware loaded in to the oven can be identifiied in Service Mode (1963) location P0.

Starting Serial Numbers

• 541074355 (480V)

• 541074349 (208V)

FIRMWARE UPDATE PROCEDURE

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

NOTE: The file must be loaded in the root directory of the thumb drive.

2. Remove the Right Panel.

3. Re-apply power to the oven and insure that the door is closed.

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

A. No Set Temperature.

B. Not in Service Test Mode (1963).

C. Not in Configuration Mode (1972).

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

Fig. 1

NOTE: The Convection Fan Motor may or may not

come on when the flash drive is inserted.

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

7. “Usb Flsh n_y” appears on the display.

F45495 Rev. B (0515) Page 8 of 77

ABC Combi Electric Oven - UPGRADE ABC COMBI FIRMWARE

• If something other than Usb Flsh n_y is

displayed, then refer to USB ERROR MESSAGES.

• If n is selected with the Humidy knob (turned

to the left, ccw), the oven will return to Idle Mode.

• 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

8. Enter Service Mode (1963),

(usually after only a few seconds), the Humidity display briefly shows Don. Don indicats the software flashed correctly. Oven returns to the Idle Mode (Temperature display ---)

• Verify that location P0 now shows 08-11-14 as the firmware revision code.

• Record (HRS) oven hour count.

• E6 error before the recorded oven hour

count can be ignored.

USB ERROR MESSAGES

Error Message Corrective Action

Usb Host Con

Usb Host Enu

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

Removing the USB drive, once the Temperature display returns to "---", reinsert the USB drive.

If error persists, use a different USB drive.

Removing the USB drive, once the Temperature display returns to "---", reinsert the USB drive.

If error persist, replace Main Control Board

Page 9 of 77 F45495 Rev. B (0515)

ABC Combi Electric 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. 3

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

Fig. 2

3. Reverse procedure to install.

Rear Panel

1. Remove Right Panel.

2. Remove two fan screws.

3. Remove six utility panel screws.

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

F45495 Rev. B (0515) Page 10 of 77

NOTE: Gas Unit shown.

5. Remove four rear panel screws.

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

6. Lift with handles to remove.

7. Reverse procedure to install.

Left Panel

1. Remove Right Panel.

2. Remove Rear Panel.

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

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

Fig. 4

left hand corner.

unit.

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 5

5. Reverse procedure to install.

INNER DOOR

1. Open oven door.

2. Unlatch inner door using inner door latch.

Fig. 6

Fig. 7

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

5. Reverse procedure to install.

INNER DOOR LATCH

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

3. Lift inner door up off door hinge.

Fig. 8

2. Remove inner door latch screws.

Page 11 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 9

3. Reverse procedure to install.

4. Check for proper operation.

DOOR LAMP

Do not touch the Halogen lamp with bare

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

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

Disconnect the

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

1. Remove

2. Insert screwdriver in slot just above the screw.

INNER DOOR.

Fig. 10

Fig. 11

5. Reverse procedure to install.

DOOR LATCH

The oven and its parts are hot. Use

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

Door Cam

1. Open door and remove

2. Remove door lock cover.

INNER DOOR.

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

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

3. Remove cam screw and washer.

F45495 Rev. B (0515) Page 12 of 77

Fig. 12

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

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

Fig. 13

5. Press latch into door to remove cam.

6. Reverse procedures to install.

7. Check for proper operation.

Latch Assembly

1. Remove Door Cam.

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

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

DOOR SWITCH

Disconnect the

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

1. Remove CONTROL PANEL.

Do not place control panel on knobs.

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

Fig. 15

2. Remove back control panel.

3. Remove lock nuts.

Fig. 14

3. Remove hex socket screws (x4).

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

5. Reverse procedure to install.

6. Check for proper operation.

Fig. 16

4. Slide reed switch out from control switch bracket.

5. Remove reed switch screws.

6. Reverse procedures to install.

7. Check for proper operation.

Page 13 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

CONVECTION FAN MOTOR

Certain components in this system are

subject to damage by electrostatic discharge during field repairs. A field service grounding kit is available to prevent damage. The field service kit must be used anytime the control board is handled.

Disconnect the

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

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

Convection Fan

1. Remove Right Panel.

2. Remove Rear Panel.

3. Remove humidity hose clamp.

Convection Fan Motor

4. Remove CONVECTION FAN BAFFLE.

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

NOTE: Replace nozzle gasket if necessary.

Tools.

Fig. 18

NOTE: Gas Unit shown.

6. Remove socket head cap screw.

Fig. 19

NOTE: Gas Unit shown.

7. Remove atomizer bolt.

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

8. Remove water atomizer.

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

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

F45495 Rev. B (0515) Page 14 of 77

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 20

11. Install gear puller.

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

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

5. Lift baffle up off baffle hangers.

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

Fig. 21

6. Pull towards front of oven to remove.

7. Reverse procedures to install.

13. Disconnect motor wires from convection fan terminal block.

Convection Fan Terminal Block (TB2)

Connection Call-outs

A TB Block Number

White 10

Blue 9

Black 8

Red 7

Brown 6

Brown 5

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

NOTE: Apply anti seizing compound to bolts.

15. Reverse procedure to install.

16. Check for proper operation.

CONVECTION FAN BAFFLE

The oven and its parts are hot. Use

care when operating, cleaning or servicing the oven.

1. Remove all oven racks.

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

Fig. 22

NOTE: Gas Unit shown.

MAIN CONTROL BOARD

Certain components in this system are

2. Remove left and right oven rack holders.

3. Lift baffle up off bottom baffle supports.

4. Lift baffle over bottom rack guides.

1. Check customer's current parameter settings.

Document customers parameter settings.

Page 15 of 77 F45495 Rev. B (0515)

CONFIGURATION MODE (1972) for

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

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

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

Disconnect the

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

2. Remove Right Panel.

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

4. Remove main control board.

6. Refer to OXYGEN SENSOR BOARD.

7. Check for proper operation.

OXYGEN SENSOR

Disconnect the

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

Oxygen sensor is very HOT. Use

care when servicing oxygen sensor.

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

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

1. Remove

2. Remove Rear Panel.

3. Disconnect oxygen sensor cable at plug.

Right Panel.

Fig. 23

NOTE: Squeeze nylon standoffs to release board.

5. Remove OXYGEN SENSOR BOARD from main control board.

Installation of Replacement Control Board

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

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

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

3. Press board onto standoffs.

NOTE: Do NOT disconnect cable from Oxygen Sensor Board.

Allow Oxygen Sensor to cool

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

4. Remove all wire ties from oxygen sensor cable.

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

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

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

F45495 Rev. B (0515) Page 16 of 77

6. Reverse procedures to install.

7. When installing, wire tie oxygen sensor cable as

Fig. 24

previously installed.

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Oxygen Sensor cable can not lay on the

bottom of the oven.

Oxygen Sensor cables are sensitive to

electrical noise and must be routed away from other wires.

8. Power unit on.

9. CALIBRATING OXYGEN SENSOR BOARD.

10. Check for proper operation.

OXYGEN SENSOR BOARD

Disconnect the

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

Certain components in this system are

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

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

Fig. 26

2. Secure using screws from replaced board.

3. Power on unit.

4. CALIBRATING OXYGEN SENSOR BOARD.

1. Remove Right Panel.

2. Remove electrical connections from oxygen sensor board.

NOTE: Note locations of wires.

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

5. Check for proper operation.

FERRITE

Disconnect the

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

1. Remove

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

Right Panel.

Fig. 25

Oxygen sensor board must be installed

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

Installation of Oxygen Sensor Board.

Fig. 27

3. Reverse procedures to install.

Page 17 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

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

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

Fig. 29

5. Replace motor control board.

6. Reverse procedure to install.

Fig. 28

MOTOR CONTROL BOARD

Disconnect the

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

Certain components in this system are

1. Remove

2. Document wire locations.

3. Remove electrical connections from board.

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

Right Panel.

7. Check for proper operation.

CONTROL PANEL

Disconnect the

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

Certain components in this system are

Control Panel

1. Remove Right Panel.

2. Disconnect multi pin connectors.

3. Disconnect control board ribbon cable.

F45495 Rev. B (0515) Page 18 of 77

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 30

4. Remove ribbon cable wire tie.

NOTE: Replace wire tie on install.

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

8. Place in a secure location.

Do NOT place control panel flat on knobs.

Doing so will cause damage to encoders.

Fig. 33

9. Reverse procedures to install.

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

Fig. 31

5. Remove 6 recessed control panel screws.

10. Verify proper operation.

ON / OFF SWITCH

Disconnect the

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

On / Off Switch

1. Remove

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

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

CONTROL PANEL from unit.

Fig. 32

6. Lift control panel up off hooks.

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

Fig. 34

3. Remove screws from back of control base panel.

Page 19 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 35

NOTE: Use care when removing back of control panel

cover. Wires are attached.

Certain components in this system are

4. Unplug wires from back of On/Off switch

DISPLAY BOARD

Disconnect the

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

Certain components in this system are

Display Board

1. Remove

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

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

CONTROL PANEL from unit.

Fig. 36

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

6. Reverse procedures to install.

7. Check for proper operation.

Fig. 37

3. Remove screws from back of control base panel.

Fig. 38

NOTE: Use care when removing back of control panel

cover. Wires are attached.

F45495 Rev. B (0515) Page 20 of 77

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Certain components in this system are

4. Remove display board ribbon cable.

5. Remove encoder ribbon cables.

6. Remove display board nuts.

CONTROL PANEL COOLING FAN

Disconnect the

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

Certain components in this system are

Display Board Fan

1. Remove

2. Place control panel in a secure location.

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

CONTROL PANEL from unit.

Fig. 39

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

Fig. 40

8. Reverse procedures to install.

9. Check for proper operation.

Fig. 41

3. Remove screws from back of control base panel.

Fig. 42

4. Disconnect cooling fan wire connection.

5. Remove cooling fan nuts.

Page 21 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

Fig. 43

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

Fig. 45

REAR COOLING FAN

NOTE: Air to exhaust out of control panel.

Fig. 44

7. Reverse procedure to install.

8. Check for proper operation.

CONTROL BOX COOLING FAN

Disconnect the

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

1. Remove

2. Remove two wires going to fan.

3. Remove nuts securing fan to frame.

4. Reverse procedure to install.

5. Check for proper air flow.

Rear Panel.

Disconnect the

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

1. Remove Right Panel.

2. Unplug two wires going to fan.

3. Remove two screws securing fan to frame.

4. Reverse procedure to install.

5. Check for proper air flow.

F45495 Rev. B (0515) Page 22 of 77

Fig. 46

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

KNOB & ENCODER

Disconnect the

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

Certain components in this system are

Control Knob & Encoder

1. Remove

2. Place control panel in a secure location.

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

3. Remove control base panel.

4. Disconnect encoder ribbon cables.

CONTROL PANEL.

Fig. 47

Fig. 49

6. Remove encoder nut to remove encoder.

7. Reverse procedures to install.

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

8. Check for proper operation.

HI-LIMIT THERMOSTAT

Disconnect the

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

1. Remove hi-limit thermostat screws.

Fig. 48

5. Loosen set screw in tapped hole on knob.

Fig. 50

NOTE: Gas Unit shown.

2. Remove hi-limit thermostat probe.

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

Page 23 of 77 F45495 Rev. B (0515)

ABC Combi Electric Oven - REMOVAL AND REPLACEMENT OF PARTS

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

Fig. 53

NOTE: Gas Unit shown.

Fig. 51

3. Reverse procedures to install.

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

Fig. 52

4. Check for proper operation.

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

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

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

CAVITY INTAKE TUBE ASSEMBLY

Disconnect the

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

1. Remove Rear Panel.

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

F45495 Rev. B (0515) Page 24 of 77

5. Replace parts as needed.

6. Reverse procedure to install.

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

Fig. 54

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