Electrolux GP5BOEOOBO (583398) User manual

Brand: Electrolux

Model: GP5BOEOOBO (583398)

Type: User manual

This manual is also suitable for

Thermetic

TTILTING FRYING PANS, GAS HEATED

(GP........)

US SERVICE MANUAL

Gas heated

TILTING FRYING PANS

Doc. 62.9695.03

Edition 1

09.2006

62.9695.03 Page 1

CONTENTS

1. CONSTRUCTION/ FUNCTIONS......................................................................................... 3

2. TECHNICAL DATA ............................................................................................................. 3

3. ELECTRIC DIAGRAMS ...................................................................................................... 4

4. MAINTENANCE CHECK LIST............................................................................................ 5

5. ACCESS TO INSIDE........................................................................................................... 6

6. FUNCTIONAL COMPONENTS........................................................................................... 6

6.1 OPERATING FOIL ............................................................................................................................ 6

6.2 UNIVERSAL CONTROL................................................................................................................... 7

6.2.1 PARAMETER PROGRAMMING ....................................................................................................................... 7

6.2.2 MANUAL PARAMETER INPUT ........................................................................................................................ 7

6.2.3 PROGRAMMING SPECIFIC APPLIANCE AND USER DATA ........................................................................ 8

6.2.4 ADJUSTING OF TEMPERATURE MEASURING ........................................................................................... 10

6.2.5 TEST FUNCTIONS FOR SERVICE APPLICATION ....................................................................................... 10

6.2.6 TROUBLESHOOTING DISPLAY .................................................................................................................... 10

6.2.7 OPERATING BOARD (UP) ............................................................................................................................. 11

6.2.8 CONTROL SWITCH (S) .................................................................................................................................. 12

6.2.9 SAFETY THERMOSTAT (F1) ......................................................................................................................... 12

6.2.10 FOOD SENSOR (B1) ...................................................................................................................................... 13

6.2.11 BOTTOM SENSOR (B2) ................................................................................................................................. 13

6.2.12 END SWITCH (ES) .......................................................................................................................................... 13

6.2.13 TERMINALS .................................................................................................................................................... 13

6.2.14 CONTROL FUSE (X4) ..................................................................................................................................... 14

6.2.15 RELAY (K1) ..................................................................................................................................................... 14

6.2.16 HEATING RESISTOR (E11) ........................................................................................................................... 14

6.3 MOTOR TILTING ............................................................................................................................ 14

6.3.1 CONTROL SYSTEM (KS) ............................................................................................................................... 14

6.3.2 TILTING MOTOR (AN) .................................................................................................................................... 14

6.3.3 SWITCH (CK) .................................................................................................................................................. 15

6.4 BURNER SYSTEM ......................................................................................................................... 15

6.4.1 FLAME ............................................................................................................................................................ 15

6.4.2 AUTOMATIC GAS IGNITOR (A3) .................................................................................................................. 15

6.4.3 BURNER ......................................................................................................................................................... 16

6.4.4 GAS CONNECTION PRESSURE ................................................................................................................... 17

Page 2 62.9695.03

6.4.5 THERMAL LOAD .............................................................................................................................................17

6.4.6 DIFFUSOR (VU) and NOZZLE (DU) ...............................................................................................................17

6.4.7 ELECTRODES (ED) (EM) ................................................................................................................................18

6.4.8 SEALANTS ......................................................................................................................................................18

6.4.9 CONVERSION TO ANOTHER TYPE OF GAS ...............................................................................................18

6.4.10 GAS DATA TABLE ..........................................................................................................................................19

6.5 ROTATION LINK (DK) ....................................................................................................................20

6.6 FAUCET ..........................................................................................................................................21

6.7 LID (D) .............................................................................................................................................22

6.8 PAN .................................................................................................................................................23

6.8.1 BEARINGS, PIVOTS .......................................................................................................................................23

6.8.2 CASING (MN) ..................................................................................................................................................23

6.8.3 WASTE GAS FLUE (KI) ..................................................................................................................................23

6.9 APPENDIX

UNIVERSAL CONTROL DESCRIPTION OF PARAMETERS .....................................................24

62.9695.03 Page 3

VALIDITY

This document refers to the following tilting frying pan program

with the above mentioned functional components.

ADDITIONAL DOCUMENTS

Operating instructions 76.9694.01delivered with the appliance

Installation instructions76.9699 delivered with the appliance

Spare parts list 76.9694.02distributed by the service

department

Electrical diagrams according to model

delivered with the appliance

SERIAL NUMBER YWWXXXXX

The serial number of the appliance is marked on the type

plate. The 8 digits give following information:

Y last digit of the year of production

WW week of production

XXXXX running number

SAFETY MEASURES

• Maintenance work, adjustments, conversions and repairs

may only be carried out by an authorized technician. These

technicians must be instructed by the manufacturer and

carry out the work in accordance with specific national and

local regulations. Parts requiring replacement are only to

be replaced by original spares.

• Strictly follow the attention and warning label indications on

the appliances.

• Servicing work on the gas supply may only be carried out

by gas company personnel or by an authorized installation

contractor.

• Cleaning and maintenance may only be carried out when

the appliance is cold.

• In case a connection with a seal is opened, always a new

seal should be used when installing the connection.

• The manager is responsible for ensuring that all compo-

nents relevant for safety (jacket safety valve, drain valve,

pressure gauge, thermostat, excess-temperature thermo-

stat) are in perfect working order at all times. The operating

condition of these components must be examined by an

authorized technician at least once a year and any defects

remedied if required.

• Before beginning any servicing, all appliances must be dis-

connected from the power supply; the steam, condensate,

hot water and drinking water pipes must also be turned off

or closed. Disconnection from the power supply is effected

by switching off at the main switch or removing the fuses

fitted to the power supply.

• The internal wiring in the appliance as well as the earth

connections must be carried out in accordance with the

complete electrical schematic. Basically, all metal parts on

which electrical connections are located must be earthed.

• In case a connection with a sealing is opened, always a

new sealing should be used when installing the connection.

• Boiling pans of this design and operating function do not

require special acceptance tests. They are subjected to a

pressure and operating test which meets the regulations on

the manufacturer's premises. Recurrent pressure testing is

not compulsory. To ensure the complete operating effi-

ciency and safety of appliances, however, owners should

arrange for personnel authorized by the manufacturer to

check on all safety equipment and to conduct pressure

tests at regular intervals.

• All gas appliances are tested according to the standards

ANSI/NSF 4 - 2002 of Commercial Cooking, Rethermaliza-

tion, and Powered Hot Food Holding and Transport Equip-

ment and ANSI Z83.11-2002 and CSA 1.8-2002 of Gas

Food Service Equipment.

• After the appliance has been connected, the service agent

must carry out a test of all functions in the course of which

all the programs and operating states of all operating ele-

ments as laid down in the operating instructions are

checked.

• The conclusion of a maintenance agreement should be

recommended to the user.

MAINTENANCE INTERVAL

An obligatory service check is required annually.

1. CONSTRUCTION/ FUNCTIONS

The food is heated by the thick base of the pan under which a

poker burner system is located. The pans are equipped with

an electronic comfort control unit with regulation of the bottom

resp. food temperature with or without programming of the

cooking time and starting time. The control system is operated

via a membrane keyboard. The pan has a variable-speed tilt-

ing facility powered by an electric motor. All types can be fitted

with a mixing unit if required.

2. TECHNICAL DATA

Model Pan bottom made of steel or nickel-chrome

plated steel

Style of mounting Floor mounting with feet

Tilting Electric motor powered with variable

speed

Control system Electronic control of pan-base and cooking

temperature

Heating up times

Heating up of an empty pan from 77°F (25°C) to an average

bottom temperature of 446°F (230°C) in 13 minutes.

) Voltage for control unit and tilting 230V/1~N*, 50/60 Hz

Gas heated tilting

frying pan

GP.B......

060 l

GP.C......

80 l

GP.E......

100 l

Gas heated tilting frying pans

GP.B......

060

GP.C......

GP.E......

100

vessel capacity gal 15.9 21.1 26.4

Gas heating capacity

16 20 26

Gas heating capacity

btu/h

54590 68260 88760

Natural gas

consumption ft/min

1.02 1.28 1.66

Propan

consumption ft/min

0.39 0.49 0.64

El. power kW 0.2 0.2 0.2

Voltage ) 120V/1~N,

60Hz

120V/1~N,

60Hz

120V/1~N,

60Hz

Amperage A 0.7 0.7 0.7

Page 4 62.9695.03

3. ELECTRIC DIAGRAMS

Gas heated tilting frying pans 60 LT - 100 LT (15.9 gal - 26.4 gal),

120 V:

The precise specifications of the individual electric compo-

nents are given in the corresponding parts list. These must be

used in conjunction with the electrical schematic valid for the

appliance.

91.4018

A1 Control board

A2 Operating board

A3 Dungs gas ignitor

B1 Food temperature sensor

B2 Bottom temperature sensor

E1 Electrodes)

E10 Tilting control

E11 Heating resistor

F1 Safety thermostat against excess

temperature

K1 Contactor

K2 Contactor

M1 Tilting motor

S1 Control switch

S2 End switch for horizontal position of

the pan

S3 Potentiometer for tilting

X1 Terminals

X4 Control fuse

Y1 Deaeration valve

T1 Single-phase transformer (only for

voltage unequal 230V)

Y2 Gas valve (SIT 0830832 Tandem)

Fig. 1 Electric diagram, gas heated tilting frying pans 60 LT - 100 LT (15.9 gal - 26.4 gal), 120 V

62.9695.03 Page 5

4. MAINTENANCE CHECK LIST

S = Part is relevant for safety

If, during servicing, an increased number of failures is

noted for a part that is relevant for safety, a written report

must be sent to the „Aftersales“ office responsible without

delay

Measuring the temperature of the pan base

Precise measurement of the temperature of a pan base using

methods in which contact with the base takes place by touch-

ing it with a probe (thermocouple, thermometer, etc.) is very

unreliable and generally leads to deviations in the order of

minus 20°C to 40°C. The use of heat-conducting paste does

not result in any substantial improvements.

Correct results can be achieved by means of infrared meas-

urement using a pyrometer (e.g. Raytek's Raynger, series

ST2L). To prevent reflection from the pan base, a heat-resist-

ant, fibre-glass tape (e.g. Scotch Brand tape from 3M) must be

bonded to the area to be measured. A surface area of 5 x 5 cm

is enough for this purpose.

Check Fault B Remedy

Connections for protective

conductors

Connections for equipoten-

tiality

Check that all electric con-

nections and contacts to

terminals, coils, switches

and junctions are tight.

In case of loose contacts

B tighten contacts.

Check relays.

The contacts must move

freely without sticking or

jamming.

In case of defects or faults B

replace contactor or relay.

Check the burner output,

i.e. measure the preset

heating-up time and com-

pare this with the nominal

value.

If this comparison reveals a

deviation of more than 10%

B Clean and check the gas

system.

Clean the diffusor on the

burner. Check its position

and attachment.

If its position has changed

B Set the diffusor correctly.

Check that the nozzle

(number) is correct. Clean

the area around the nozzle.

If the nozzle is not the appro-

priate size ∅ Fit the correct

nozzle. If the nozzle is dam-

aged B Fit a new one.

Check the distance

between the burner and the

pan base.

If the actual measurement

deviates more than ± 1mm

from the nominal measure-

ment

B Set the burner distance

exactly.

Visual check of the flame

with a mirror.

Flame tips yellow, flame

corona transparent, flames

lift off, flame strikes back

B Clean and set the diffusor

exactly.

Check the condition, the

gap and the attachment

point of the ignition elec-

trode and the earthing

(grounding) electrode.

If scaling is found, the gap is

not right or the shape has

changed

B Replace.

Check that the gas valve is

not leaking and that it is set

correctly.

S If it is leaking

B Replace the valve.

If it is functioning incorrectly

B Readjust it.

Measure the ionization cur-

rent at the electrodes when

the appliance is at full

power.

If this is outside the recog-

nized tolerance

B Set the electrodes more

accurately.

Check the high-tension

cable for cracks or brittle-

ness.

If any faults are found

B Replace the cables.

Check the plug on the igni-

tion electrode.

If any faults or oxidation are

found

B Replace the high-tension

cables.

Measure the gas pressure

when the appliance is at full

power.

In the case of deviations that

are higher than the permissi-

ble tolerance

B Send a report to the user

and have the gas pressure

corrected on-site or adapt the

nozzle to the new pressure.

Check condition and leak-

age of rotation link.

If any faults are found

B replace the parts con-

cerned.

Check that the internal gas

pipes are not leaking.

If a leak is found

B Seal the leak.

Ensure that the main gas

tap (if fitted) operates

smoothly and correctly.

If the tap is hard to turn

B Regrease the tap or

replace it.

Inspect internal wiring. In case of defect cables

B replace cables.

Check condition of all oper-

ating foils.

Defective foils

B replace.

Optical inspection of the

whole control unit.

S Defective foils

B replace.

Test all operating functions

and check that the control

unit works correctly.

S If problems are encountered

B find reason and repair fail-

ure.

Check switches for easy

movement and correct func-

tion.

If the switch is hard to turn or

makes a noise

B replace.

Compare the bottom tem-

perature display with the

actual value.

If the deviation is

 1°

B Adjust the display again.

Compare the food temper-

ature display with the

actual value.

If the deviation is

 1°

B Adjust the display again.

Inspect fixation and condi-

tion of all temperature sen-

sors (jacket, food,

deaeration, excess temper-

ature) and check electrical

connections.

S If sensors, fixation, electrical

connections are found to be

faulty

B replace the parts con-

cerned.

Inspect condition and func-

tion of the safety thermo-

stat.

S If sensors, fixation, electrical

connections are found to be

faulty

B replace the parts con-

cerned.

Check the function of the

heating resistance.

If it is not warm

B replace it.

Check all elements of the

display on the control panel

with service test 1.

If any element of the display

fails

B exchange the whole oper-

ating print.

Inspect fixation and condi-

tion of all switches (power

isolator, control, tilting, stir-

rer) and check electrical

connections.

If defects to any fixation or

electrical connections are

discovered

B replace the parts con-

cerned.

Check function of acoustic

signals.

If the sound is off key or no

sound is heard

B exchange the whole con-

trol board.

Check the lid for correct

shape or damage.

If irreparably damaged

B replace the lid.

Check the lid hinges for

correct function.

If defective

B disassemble, clean,

grease, adjust the hinge.

Check function of mixing

unit for function. Check for

leaks of water connections.

If the tap drips or if any pipes

leak

B replace seals.

Check Fault B Remedy

Page 6 62.9695.03

5. ACCESS TO INSIDE

Sheeting of console, support, pan

6. FUNCTIONAL COMPONENTS

6.1 OPERATING FOIL

EXCHANGE

Removal

Operating foils (FO) are bonded to the sheet metal surfaces

(cover plates) with self-adhesive coatings. They are removed

with a spatula, a screwdriver or a knife.

Remove the connecting rail

(VS)

Loosen the front nuts M6 from

underneath. Bend the rail up

slightly at the front. Pull the rail

out of the appliance.

Switch panel (F) removal:

Unscrew the two screws at

location (1) underneath the

switch panel and the nuts (MH)

at location (2) on the top, pull

out the switch panel at the bot-

tom and then lift up and out of

the fixation. The panel is

turned up 90° like a door and

hung at the top on the console.

Cover (A) removal:

If there is a connecting rail

installed to the cover it has to

be removed first. (see 5.3.1.).

Remove the nuts (MU) (two on

a single console, four on a twin

console) at the relevant loca-

tion (2). Lift the cover at the

front and pull it out of its clip

attachment at the back (3). If a

mixing unit is fitted, this does

not need to be removed from

the cover.

Service panel (V) removal:

Remove the two external nuts

(6) at the front and pull the

panel from its rear attachment

points (5).

Floor mounting on plinth

Side wall (S) removal:

To remove this, the switch

panel (F) must be removed

first. Remove the nuts (4) and

(5) inside. The upper internal

wall (W) cannot be disassem-

bled. It must be removed and

refitted together with the pan.

The panels are refitted in the

reverse order to that described

above.

Cover (A). The height of the

cover can be levelled by fitting

more or fewer shims (BE) and

tightening the nuts (MH).

Hanging the operating panel

(F) on the console

Removing the pan base (BD).

Set the pan in the horizontal

position. Remove the screws

(SB) from underneath and take

out the base (BD) from under-

neath.

Fitting the base (BD).

Carefully clean any remains of

the old seal from the edge of

the base. Stick a new sealing

strip (DB) on the edge of the

base. Carefully position the

threaded clip (SM) on the

jacket (MK). Tighten the

screws (SB).

Pan jacket. The pan jacket is

not removed during normal

servicing work.

Removing the Front pan

cover (VA):

The front panel of the pan

cover can be removed as fol-

lows without removing the

base (BD): remove the front

screws (SB), pull off the panel

underneath the pan, draw the

panel down and out of the pan

flange.

Cleaning

The surfaces to which the foil is to be

applied must be clean and dry, i.e., free

from dust, grease, rust, paint, etc. Suita-

ble for cleaning: toluol or 3M article S-

152 stick remover.

Procedure: shake the can thoroughly and

spray evenly on the surface to be

cleaned. (Distance about 5.9 - 7.9“ / 15 -

20 cm.) Rub over with a clean lint-free

cloth. If surfaces are heavily soiled,

repeat the process.

Sticking on the foil

Remove the protective backing, taking

care not to touch the adhesive. After

positioning press down well. It is impor-

tant to apply firm, even pressure. The

ideal working temperature is approxi-

mately 77°F (25°C). Temperatures below

50°F (10°C) should be avoided since the

adhesive becomes too hard and instanta-

neous adhesion is reduced. Following

application, the foil has a working tem-

perature range from -40 to +248°F (-40°

to + 120°C) continuous temperature load

and 356°F (180°C) short-time tempera-

ture load.

62.9695.03 Page 7

6.2 UNIVERSAL CONTROL

The appliances are equipped with a precise state-of-the-art

electronic microprocessor control system with digital preselec-

tion of temperature, cooking time and starting time. The control

system can also be remotely controlled using a PC. For con-

trol-system operation, please refer to the Operating Instruc-

tions.

Temperature setting

Cooking

If the nominal temperature set on the display (AT) is equal or

lower than 230°F (110°C), control takes place via the food sen-

sor fitted to the external side wall of the pan. The appliance is

set to the "Cooking" operating mode. The nominal temperature

is reached during heating up and then kept at this value - but

not exceeded - by electronic control and energy is supplied as

and when required. If pressure cooking is not selected, a max-

imum setting of no more than 212°F (100°C) is recommended.

Frying

If the nominal temperature set on the display (AT) is higher

than 230°F (110°C), control takes place via the bottom sensor

fitted underneath the pan. The appliance is set to the "Frying"

operating mode. The nominal temperature is reached during

heating up and then kept at this value - but not exceeded - by

electronic control and energy is supplied as and when

required.

Power setting

Fixed power settings can also be preselected with the elec-

tronic controller. In such cases, the preselected power is given

after boiling point has been reached. Setting the controller to a

fixed setting is done in order to be able to enter the degree of

boiling in the food individually, i.e. in accordance with the food,

the amount of food, the position of the lid, etc. The following

fixed power settings can be set using the display (AT):

Setting Power Heating time during

(AT) (%) a period of 120 sec.

L1 12.5 15 sec

L2 12.5 15 sec

L3 25 30 sec

L4 37.5 45 sec

L5 50 60 sec

L6 62.5 75 sec

L7 75 90 sec

L8 87.5 105 sec

L9 100 120 sec

Displays

AT (3 digits) Temperatures (if all 3 digits light up as well as

the point after the third digit, then this means

that 0.5°F must be added on after the point).

Parameter number (PNo.).

Parameter value (if all 3 digits light up as well as

a decimal point, then the numeral must be multi-

plied by 1000. E.g. display = 3.99, value =

3990).

Software version.

AD (3 digits) Cooking time

AZ (4 digits) Clock time.

Starting time.

Delay time.

6.2.1 PARAMETER PROGRAMMING

General remarks

The same software is used for all appliances which are

equipped with this control system. To ensure that each appli-

ance operates as desired, specific parameters must be

entered. The control systems which are installed in the appli-

ances at the factory or are in stock, are equipped with the

microprocessors fitted including the software. The software

contains a default setting (GS) of the parameters (PNo.). The

default setting is selected in such a way that a minimum of

parameters have to be adjusted for the individual setting of the

different appliances. In principle, the corresponding parame-

ters have to be entered for each appliance.

Software version

The microprocessor bears an adhesive label stating the soft-

ware version and the date. Any change in the software usually

also involves a change in the parameters. Please always

ensure that the version of the parameter list used matches the

software version. The following general rule applies: if the soft-

ware version has a different number, the parameter list with

the same version must also be used. If the software version

has a different additional letter in the version number (e.g. ver-

sion 2.51A, version 2.51B, etc.), the parameter list does not

change. Only the number of the version without the additional

letter is important for the parameter list.

Microprocessor (MP)

2 IC insertion sockets are located on the control board. The

large insertion socket for 64 pins accepts the microprocessor.

The software program is located in the ROM (Read Only Mem-

ory) of the microprocessor chip. An OTP version (One Time

Programmable) microprocessor is used. This version can only

be written to once and cannot be erased. This means that any

program change also means the use of a new chip. The old

chip can no longer be used.

EEPROM (EP)

The small insertion socket for 8 pins is for the EEPROM (Elec-

trically Erasable Programmable Read Only Memory). The

parameters are stored in this IC. Once stored, the parameters

remain in this IC even when disconnected from the power sup-

ply until they are changed by reprogramming or erased.

Before the parameters are changed for the first time to suit an

appliance, the values for the default setting must be loaded

into the EEPROM. The parameters can be entered in 2 differ-

ent ways:

Manual input (the more frequent case) and PC input.

6.2.2 MANUAL PARAMETER INPUT

Default setting (GS) of the parameters

The default setting of the parameters is the same for all appli-

ances which are equipped with this control system. Dependent

on the type of appliance, more or fewer parameters are

required with values that differ from each other to some

degree.

3 of the 4 buttons on the membrane keyboard (Q, R, V and P)

are used for the programming of parameters. The 3 buttons

are located in the bottom row on the operating panel. Buttons

V and P are located under the membrane and are not visibly

marked.

TT Button, activation of settings

LT Lamp, cooking temperature

DT Button, cooking time

LD Lamp, cooking time expires

ZT Button, starting time

LZ Lamp, starting time

LR Lamp, soft settings

Q Button, acoustic signal

R Button, soft

LS Lamp, temperature

pre-setting

AT Display, cooking tempera-

ture

T Temperature selection knob

AD Display, remaining cooking

time

D Cooking time knob

AZ Display, time

Z Starting time knob

S Control switch

Page 8 62.9695.03

)

(*) Display (AT): After "def" is displayed for approx. 2 seconds,

the actual value of the current food temperature will appear.

Display (AZ): Clock time appears (only with process com-

fort control).

The control system program now contains all the default set-

tings for the software version of the microprocessor installed.

Important

If the default setting (GS) of the parameters of an appliance

which was already in operation is programmed for new, all

parameters which register running times are set to zero.

Parameter-setting (X) specific to each appliance

In order to change the numbers (PNo.) and the content (X) of

the parameters, the same buttons are used as those for enter-

ing the default setting.)

Display (AT): Parameter PNo... 1 appears

Display (AZ): None

The parameter numbers (PNo.) and the values (X) which devi-

ate from the standard setting can now be entered alternately

on the display (AT).

As the same display is used to show the numbers (PNo.) and

the content (X) of the parameters, the following difference is

made between the two figures:

Changing the parameter number (PNo.) and content (X))

Rate of change of the displays

Increases (button P) or reductions (button Q) can be done at

three different speeds:

• Press the button briefly changes in single steps

• Press the button longer

• at least 1 second the display changes slowly

• press for at least 5 seconds the display changes fast

End of parameter programming

If the content (X) of a parameter (PNo.) is changed, the

changed value is stored when the display (AT) is changed

from parameter content to parameter number using the button

R. The following applies for the last parameter content

changed or if only a parameter content has been changed.

Parameter programming can be finished in 2 ways dependent

on whether the changed value is to be stored or not.:

6.2.3 PROGRAMMING SPECIFIC APPLIANCE AND

USER DATA

Appliance-specific parameters are only set on the basis of the

type of appliance. User-specific parameters are dependent on

user order, user requirements, siting terms and are only appli-

ance-dependent to a certain degree.

The parameters are programmed at the factory to the default

setting (GS) if no specific information is given.

New appliance installation

In the case of new appliances, the control system is pro-

grammed at the factory to the appliance-specific setting.

Starting position: supply switched off (switch S at 0)

1st

combination

Press and hold

buttons

Waiting time between

the different combina-

tions is 3 seconds

maximum

Supply to be switched on (turn switch S to I) Press buttons continu-

ously until the 2nd

beep, then press the

2nd combination

2nd

combination

Press buttons

Press buttons continu-

ously until the 2nd

beep, then press the

3rd combination

3rd

combination

Press buttons

4th

hold

button R

Hold button R pressed

until the 2nd beep,

then release.

(*)

Starting position: supply switched off (switch S at 0)

1st

combination

Press and hold

buttons

Waiting time between

the different combina-

tions is 3 seconds

maximum

Supply to be switched on (turn switch S to I) Press buttons continu-

ously until the 2nd

beep, then press 2nd

combination (for the

first time only 1 beep)

2nd

Press button

Hold button R pressed

until the 2nd beep,

then release.

* *

⇓

* *

Kind of display (AT): Meaning of display:

with 3 decimal points (e.g.

1.0.3.)

Number of parameter PNo

without decimal points (e.g.

126)

Content (X) of parameter (e.g.

temperature)

Starting position: supply switched off (switch S at 0)

1st

Press button

Changing

the display

(AT) from:

parameter number

(PNo.) to

parameter content (X)

or vice versa

2nd

Press button

Increasing the display

entered under 1.

parameter number

(PNo.)

or parameter content

(X)

3rd

Press button

Reducing the display

(AT):

parameter number

(PNo.)

or parameter content

(X)

Finishing: Procedure:

Changed value

to be stored

• Display (AT) shows the parameter number

• Switch off control switch (S)

without decimal

points (e.g. 126)

• Display (AT) shows the parameter value

(X)

• Switch off control switch (S)

62.9695.03 Page 9

When the appliance is installed at its intended site, the fitter in

charge of installation must set or check the following parame-

ters on the control system. The parameter values are different

for each software version.

PARAMETER

SOFTWARE VERSION BPTH 5.06

PNr.

Parameter

number

Default

setting

Designation

Tilting

boiling pan,

gas

1 0 Temperature display 1

24 0 Kind of heating 1

29 1 Deaeration sensor of the jacket 0

31 0 HOLD function 1

32 0 HACCP function

without: 0

with: 1

49 0 Appliance code 3

50 1 Appliance type 2

54 4 Quantity of switching steps 1

78 30 Duration of periods of the power levels 120

79 25 Power level L1 12

83 50

Input of height above sea level of the installation site in 10 m (500 m above sea

level. = 50).

148 20 m of SDIRHOFF = SDIRH-(q+m*dT/dt) for food sensor 10

157 70 Maximum board temperature 80

161 40 m of SDIRHOFF = SDIRH-(q+m*dT/dt) for the bottom sensor 20

Page 10 62.9695.03

6.2.4 ADJUSTING OF TEMPERATURE MEASURING

Measurement accuracy of temperature sensors

In general, the measuring accuracy of the temperature sen-

sors is enough for them not to have to be trimmed. Adjusting

the temperature sensors can be done via parameter PNo.

1.0.0. for the food- or pan bottom sensor and via parameter

PNo. 1.0.1. for the jacket- or side sensor. Adjusting consists of

entering a certain correction temperature (Offset temperature).

Measuring errors inherent in the system

Every pan has at least one food sensor. Dependent on the

heating system, there is also a jacket sensor. The jacket and

deaeration sensor are not trimmed and corrected. If there is a

temperature difference between the measuring location

(where the sensor is located) and the food, measurement of

the food temperature must be adjusted. This adjusting is done

through software with the help of parameters. Two measuring

points per sensor are provided for adjusting. Adjusting can be

done at any test temperatures. As correction is a linear func-

tion, the temperature difference to be corrected can be con-

verted on a linear basis to the corresponding fixed

temperatures on the X-axis (212 resp. 122°F, 50° resp. 100

°C).

Trimming procedure for the food sensor

• Ascertain the magnitude of ΔT and direction ± of the tem-

perature deviation between the temperature display (AT)

and the food, measured directly with a thermometer in the

cooking space at any temperature. In order to minimize the

error, this measuring temperature should be as high as

possible.

• Convert the deviation measured ΔT to the food tempera-

ture 212 or 122°F (100 or 50°C). These two values are to

be used as corrections for the parameters PNo. 1.0.8. and

1.0.9.

• If the actual food temperature is higher than the tempera-

ture shown on the display (AT), the Y-values (PNo. 1.0.8.

and PNo. 1.0.9.) will have to be lowered accordingly.

• If the actual food temperature is lower than the tempera-

ture shown on the display (AT), the Y-values (PNo. 1.0.8.

and PNo. 1.0.9.) will have to be raised accordingly.

Example: Measured food temperature 176°F (80°C)

Display (AT) on control panel 172°F (78°C)

Difference 4°F (-2°C)

Translation to food

temperature of 212°F -4x(212:176) = -4.8°F

(temperature of 100°C -2x(100:80) = -2.5°C)

Translation to food

temperature of 122°F -2x(122:176) = -2.8°C

(temperature of 50°C -2x(50:80) = -1.25°C)

Correction for PNo. 1.0.8. = 122 - 2.8 = 119.2°C

(Correction for PNo. 1.0.8. = 50 - 1.25 = 48.75°C)

Correction for PNo. 1.0.9. = 212 - 4.8 = 207.2°C

(Correction for PNo. 1.0.9. = 100 - 2.5 = 97.5°C)

Sign: If the bottom temperature measured is lower than

the one displayed, the correction values are

increased (plus sign). If the food temperature mea-

sured is higher than the one displayed, the correc-

tion values are reduced (minus sign).

6.2.5 TEST FUNCTIONS FOR SERVICE APPLICATION

For servicing purposes, various values and operating states of

the control system can be shown on the existing displays with

the help of buttons on the operating panel. The buttons are

also used to reset the jacket refilling display. The cooking pro-

cess can be switched on or off. All 4 buttons (Q, R, V and P) on

the membrane keyboard are used for service test displays.

The buttons are located on the bottom row of the operating

panel. The buttons have to be held down for the button combi-

nation for the activation of the test displays and the reset. In

order to avoid incorrect functions, always press the Q button

down first before pressing the other buttons.

6.2.6 TROUBLESHOOTING DISPLAY

A fault in the appliance is registered by the electronic control

system and, dependent on the type of fault, is shown on the

display (AT) by the letters E (error) or A (alarm) combined

with a one- or two-digit number. At the same time as the fault

occurs, an intermittent warning tone will sound, the energy

supply is interrupted and the lamp is switched off. Press button

Q to acknowledge the error message (warning tones).

Starting position: supply switched off (switch S at I

1st test,

press buttons

and hold

First time:

check of

lamps

; the figure 8 is

shown on all displays,

also all points are dis-

played

2nd test,

press buttons

and hold

Second time: on dis-

play (AT) the tempera-

ture in °F of the

control board

and on

display (AZ) the

clock

time

are shown

3rd test;

press buttons

and hold

The display (AT) pro-

vides information on

the current

condition

of the heating sys-

tem

1. electric or gas

ON = switched on,

OFF = switched off

4th test,

press buttons

and hold

Display (AT) =

tem-

perature in °F of

food sensor

J15.

Display (AZ) =

clock

time

5th test,

press buttons

and hold

Display (AT) =

tem-

perature in °F

of bot-

tom sensor J16.

Display (AZ) = clock

time

6th test,

press buttons

and hold

Display (AT) =

tem-

perature in °F steam

condensation sen-

sor

J18.

Display (AZ) = clock

time(UET only)

7th test,

press buttons

and hold

Display (AT) = number

software version

(e.g. 2.62)

Display (AZ) =

clock

time

Display/

failure

code

Problem Action

E1 Defective food temperature sensor

(J15); appliance switches off

Reset the error message and alarm with

button (Q); repair cause of problem

(loose connector, broken sensor, short

circuit)

E2 Defective jacket temperature sensor

(J16); appliance switches off

Reset the error message and alarm with

button (Q); repair cause of problem

(loose connector, broken sensor, short

circuit)

E4 Defective steam condensation sen-

sor

Reset the error message and alarm with

button (Q); repair cause of problem

(loose connector, broken sensor, short

circuit)

* * *

* *

* * *

62.9695.03 Page 11

FAULTY ERROR MESSAGE

If a faulty error message appears, that is to say, a message

that is inappropriate for the appliance, the appliance's parame-

ters are incorrectly set. This situation can be remedied by cor-

recting the parameters for the appliance in question.

MULTIPLE FAULTS

Two faults may be reported at once, e.g. E7 and E10. The dis-

plays follow one another. If, for example, fault display E7 is

reset with button Q, E10 appears on the display (AT). The

appliance will only function perfectly again when the latter has

been remedied and reset.

PROBLEMS WITHOUT DISPLAY

Finding the cause of the fault is dependent on the technician's

skill.

The parts of the control system can be accessed by removing

the control panel (F) as described in chapter 5.

6.2.7 OPERATING BOARD (UP)

If a fault is identified, no repairs can be made to the board. It is

replaced as a complete unit.

Removal

Pull off the operating knobs (BK) on the front of the switch

panel. Then remove the control board (see below). Remove

the long spacing sleeves (HP1). Remove the 6 nuts (MP2) and

washers from the steel panel (ST). Remove the steel panel

and the short spacing sleeves (HP2). Remove the operating

board.

Installation

Proceed in the reverse order to removal. Plug the flat cable

(FL) connector firmly into the board. Make sure that the board

is centered in relation to the windows in the switch panel and

the nuts (MPx) are not tightened excessively to avoid damage

to the board. Replace the operating knobs firmly on the front

panel to ensure that the seals are in place.

When replacing the operating circuit board the jumper JP1 the

position of the jumper JP1 must be checked resp. corrected.

A Jumper JP1 in the upper position

clock time is activated and will be stored

B Jumper JP1 in the lower position

clock time will be not stored, the battery will not get

unloaded. Condition of the board when getting as spare

part (position of the jumper JP1 for prints on stock).

E5 Defective control board temperature

sensor

Reset the error message and alarm with

button (Q); replace control board

E6 Temperature of food sensor J15 is

too high

Reset the error message and alarm with

button (Q); repair cause of problem

(defective contactor)

E7 Temperature of jacket sensor J16 is

too high

Reset the error message and alarm with

button (Q); repair cause of problem

(defective contactor)

E9 Defective analogue/digital trans-

former

Reset the error message and alarm with

button (Q); replace control board

E10 Response of safety thermostat to

lack of water; lack of water in the

jacket

Reset the error message and alarm with

button (Q); find cause of lack of water;

leakage at welds/ seals/ safety valve,

check valve; defective control unit; refill

jacket with demineralized water; reset

safety thermostat (F1) by pressing the

red button

E21 HACCP Master Personal Computer

is not connected.

Discharge fault display and signal by

pressing button (Q).

E22 HACCP Interface COP485.1 is not

connected.

Discharge fault display and signal by

pressing button (Q).

E23 HACCP configuration; EEPROM

COP485.1 (memory chip) has found

a reading fault.

Discharge fault display and signal by

pressing button (Q) and repair fault.

E24 HACCP configuration; EEPROM

COP485.1 (memory chip) has found

a spelling fault.

Discharge fault display and signal by

pressing button (Q) and repair fault.

Alarm Problem Action

A02 Error when the burner is ignited. Acknowledge the error message by

pressing the button (Q) and restart by

pressing the button (TT). Wait for the

delay time of 30 to 60 seconds.

Problem Reasons

Displays do not light up when

the appliance is switched on

Control fuse (X4) is faulty

Only the lamp (LS) lights up

when the control switch (S) is

switched on. Other functions

cannot be activated.

- Water on the printed circuit

board. Blow it off and dry

the board.

- Microprocessor is not pro-

grammed

The operating displays go

crazy

- Water on the control- and/or

operating board

- The flat cable between the

control- and operating board

is faulty or there is a poor

connection somewhere.

Display/

failure

code

Problem Action

Page 12 62.9695.03

Handling electronic boards

Electrostatic discharges (ESD) on circuit boards can cause

damage. Even voltages that are imperceptible to human

beings can partially or totally destroy components. Partial

destruction is frequently not noticeable at once and can lead to

early failure. The chain of protection from ESD must not be

interrupted, i.e. the following points must be observed where

electronic components are concerned:

• Transport should only take place in conductive boxes or

antistatic packaging to the place where the boards are to

be fitted.

• Do not reload the boards in non-conductive containers.

• Work on disassembled switch panels (changing boards or

ICs) must be carried out on surfaces of electrically conduc-

tive rubber. Servicemen carrying out work of this type must

wear ESD armbands which are connected to the ground

connection on the appliance.

• Do not touch the conductors when handling a board.

Always hold them between your finger and thumb.

• ICs (microprocessor, EEPROM) may only be placed and

stored on conductive foam or in specially designed contain-

ers.

• Never hold an IC with your bare hands - only do this when

you are wearing a grounded armband.

The same arrangements and measures also apply to faulty

boards that are returned for repair (warranty claims).

6.2.8 CONTROL SWITCH (S)

Removal

Set the control switch to Position 0. Remove the switch panel

(F) in accordance with § 5. Disconnect the electrical cables

from the contact emitter (KG). Twist the contact emitter coun-

terclockwise slightly by hand until it separates from the front

switch part. Unscrew the nuts (MS) and take out the handle

part at the front. (See picture Operating board UP).

Installation

Proceed as described under "Removal" but in the reverse

order. Make sure that the seal between the switch panel (F)

and the handle part is correctly installed and undamaged. The

cam on the handle part must also engage with the aperture in

the switch panel.

6.2.9 SAFETY THERMOSTAT (F1)

The purpose of the safety thermostat is to protect the electric

heating from overheating if there is an inadequate amount of

water in the jacket. It switches the heating off when a tempera-

ture of 356 +0/-50°F (180 +0/-28°C) is attained.

Resetting:

If the thermostat responds, the red button (RF1) will jump out

and the heating will cut out. After the cause of this response

has been remedied, the red button is pressed in again and the

appliance is then ready for use again.

Removal:

Remove the cover (A) from the right-hand console (see § 1.5).

The thermostat (F1) is fitted to a plate below the terminal strip

(see figure FG4 Automatic ignitor). Disconnect the electrical

connections from the thermostat. Remove the two attachment

screws (HF).

BK operating knobs

HP spacing sleeves

MP nuts and washers

ST steel panel

FL flat cable

JP1 bridge

Fig. 2 Operating board

Control board faults

Reason: Total failure

Water damage

Change over to a new software version

Damage to the control board, but

not to the ICs

Exchange: Entire control board Microprocessor (MP) and EEP-

ROM (EP) on the control board

Action: - First request the parameter values of

all sensors and note them down

- Enter the default setting (GS) of the

parameters

- Enter the correction settings for the

software version used

- Enter the appliance-specific setting of

certain parameters

- Enter the user-specific settings

- Enter the sensor corrections noted

above resp. new trimming of the tem-

perature measurement.

No settings required

Problem Reasons

The safety thermostat (F1) responds. Possible causes:

• Control fault

Capillary tube fitted to (F1) is broken

Food temperature sensor (B1) or the

bottom temperature sensor (B2) is not

fitted correctly (no contact)

Contactor is jammed

Attachment and local position of the

sensor (F1) has changed.

Identify and remedy the cause or replace the

relevant part.

If the capillary tube of the safety thermostat is

defective, the function of the boiling pan is

blocked.

Replace the thermostat.

If the ambient temperature of the thermostat

decreases under 14°F (-10°C) (transport or

stocking in winter) the thermostat switches off

and the function of the boiling pan is blocked.

Reset the thermostat at room temperature.

KF1 capillary tube sensor

PP baseplate

ME nuts

HM retaining clip

Fig. 3 Safety thermostat

62.9695.03 Page 13

The capillary tube sensor (KF1) is located on the front of the

pan and is attached to the baseplate (PP). The front wall of the

pan cladding (VA) has to be dismantled to remove the capillary

tube sensor (see § 1.5). Open up the insulation a little in the

area of the sensor. Loosen the two nuts (ME) and pull the sen-

sor out of the retaining clip (HM). Tie a strong cord to the sen-

sor. Pull the capillary tube sensor out of the appliance through

the pan pivot. Untie the cord from the sensor and leave it in the

appliance.

Installation

Tie the cord tightly to the new sensor and pull it back through

the appliance. Proceed as described under "Removal" but in

the reverse order. When fitting the retaining clip (HM), make

sure that the sensor (KF1) is in close contact with the base of

the pan.

6.2.10 FOOD SENSOR (B1)

The food sensor (B1) is located on the front wall of the pan

where the vertical wall meets the base. The active part of the

sensor is pressed against the outer jacket of the inner pan by a

retaining plate.

Test

Disconnect the sensor cable from the control board. Measure

the resistance with an ohmmeter at the ends of the cables.

They should show a resistance of 1097Ω at 77°F (25°C).

Removal

Remove the front wall of the pan cladding (see § 5). Open up

the insulation a little in the area of the sensor. Remove the

attachment owner HA and the nut (MQ) and take the sensor off

the retaining stud. Dismantle the switch panel (F) on the right-

hand console as described in § 5. Detach the sensor cable

from the J15 push-on connections on the control board (SP).

Firmly attach a strong cord to the cable end. Draw the cable

out of the appliance through the pan pivot. Remove the cord

from the cable and leave in the appliance.

Installation

Firmly attach the cord at the cable end of the new sensor and

draw the cable back through the appliance. Follow procedure

as described under "Removal" but in the reverse order. Note,

in particular, that the flat side of the sensor is pressed firmly

against the pan with heat-conductive paste (Rüeger/Crissier

RTP/II).

After replacement of the sensor it has to be trimmed again as

described in chapter "Adjusting".

6.2.11 BOTTOM SENSOR (B2)

The bottom sensor is installed in the middle of the pan bottom

(see figure "Burner").

Test

Disconnect the sensor cable from the control board. Measure

the resistance with an ohmmeter at the cable ends. At 77°F

(25°C), resistance should be 1097Ω.

Removal

Remove the bottom of the pan cladding and the cover of the

mixing tube (see § 5). Remove the guard (EN) of the bottom

sensor (B2) by taking off the nuts (ER). Unscrew the bottom

sensor (B2) nut (MB). Remove the switch panel (F) on the

right-hand console as described in § 5. Disconnect the sensor

cable (with a woven metal jacket) at the J16 push-on connec-

tions on the control print (SP). Attach a strong cord to the end

of the cable. Pull the cable out of the appliance through the

pan pivot. Take the cord off the cable and leave it in the appli-

ance.

Installation

Firmly attach the cord at the cable end of the new sensor and

draw the cable back through the appliance. Follow procedure

as described under "Removal" but in the reverse order. During

installation, make sure that: the threaded hole is cleaned; dirt

and traces of old heat conductive paste are removed; the sen-

sor is cleaned; a small amount of fresh heat conductive paste

(WP) (Rüeger/Crissier RTP/II) is applied to the tip of the sen-

sor; the sensor nut is screwed in but not tightened excessively.

Adjust and/or bend the front metal-clad part of the sensor

cable to suit the geometry of the combustion chamber.

Following replacement, the sensor must be retrimmed as

described in chapter "Adjusting".

6.2.12 END SWITCH (ES)

The end switch is located in the right-hand console and serves

to switch off the heating when the pan is tilted from its horizon-

tal position. On the tilting pivot, there is a protruding screw

which operates the end switch.

Setting

Insert the screw (SZ) into the pivot (KA) and secure it with a

lock nut. Fix the end switch (ES) securely to the holder (EH)

with the two screws (SX). Set the pan horizontal. Slide the

holder (EH) vertically until the lever (EB) trips the switch. The

switching action is clearly audible. Tighten the two screws (SE)

firmly in this position. The end switch must switch off when a

tilting angle of 10 degrees is reached.

Removal/Installation

Remove the screws (ES). Resetting is necessary after replac-

ing the switch.

6.2.13 TERMINALS

Removal and installation

The terminal rail is located in the right-hand console and can

be accessed from above after removing the cover. Normal ter-

minals are only clipped into the rail and can be released with

the help of a screwdriver. The earth terminal is also attached

by a central screw which has to be released during removal.

B1 sensor

HA attachment owner

MQ nut

Fig. 4 Food sensor

WP sensor

BT attachment owner

MB nut

B2 nut

Fig. 5 Food sensor

Fig. 6 End switch

Page 14 62.9695.03

6.2.14 CONTROL FUSE (X4)

Removal and installation

The fuse (either one or two may be fitted) for the pan control

board is located in the right-hand console on the terminal

assembly. Take off the cover (A) as described in § 5. Open the

cover of the fuse clip by flipping it open on one side. Take out

the fuse sideways and insert a new one. The fuse is located

loosely in the holder. Close the terminal cover.

6.2.15 RELAY (K1)

The purpose of the relay is to transmit the error signal of the

automatic igniter to the appliance's control electronics.

Removal

The relay is located in the right console on a plate (see BT4

figure Automatic gas ignitor) and can be accessed after the

cover has been removed. Remove the upper active part from

the base. If it is also necessary to remove the base: disconnect

the cables, release from the spring catch in the middle of the

foot with a screwdriver and remove it at an angle on one side.

Installation

Proceed as described under "Removal" but in the reverse

order.

6.2.16 HEATING RESISTOR (E11)

This resister is used for protecting the control system against

condensing water. It is always switched on when the appliance

is connected to the supply.

Removal and installation

The heating resistor is mounted to the console behind the con-

trol panel. Remove the control panel (F) and the cover (A) as

described in §5. Detach the electrical connections. Pull the

heating out of the two clamps.

6.3 MOTOR TILTING

All parts of the tilting mechanism (control system, tilting motor,

tilting switch) are located in the left-hand console.

6.3.1 CONTROL SYSTEM (KS)

This consists of the power supply unit (SE) and the control

board (QK). The control board (QK) is also new and has 10

contacts (no. 10 stays empty). All parts are compactly

mounted on a sheet metal support.

Removal:

Remove the cover (A), the front panel (F) and, if possible, the

sidewall (S) as described in § 1.5. Remove the guard which is

positioned above the controls to keep water off them by undo-

ing the screw (SS) and withdrawing the plate on the right from

the mounting. Disconnect the electrical leads. Take away the

two screws (SU). Pull the entire sheet metal support (BS) out

of the right-hand mounting (HS) and take the controls out from

the top.

Installation:

Proceed as described under "Removal" but in the reverse

order.

6.3.2 TILTING MOTOR (AN)

Removal

Remove the cover (A), the front panel (F) and, if possible, the

sidewall (S) as described in § 5. Set the pan in the horizontal

position. Prepare a piece of timber that is approx. 0.8“ (2 cm)

longer than the distance from the floor to the lower edge of the

pan cladding. Tilt the pan a little, stand the timber at the rear by

the edge of the cladding and tip the pan into the horizontal

position until the edge rests on the timber. This releases the

tilting motor spindle from any torque from the pan. Remove the

two plate nuts (MA) and the bolt (BA) from the motor spindle.

Power the motor spindle into the fully retracted position. Dis-

connect the motor leads from the board.

Remove the screw (SN) and its washer. Remove the plate

(PM). Raise the tilting motor at the back and take it out of the

console. Also remove the bolt (BB) and the spacer (DC) by

removing the nuts (MC). Dismantle the tilting handle (KH) from

the tilting shaft (KA) by undoing the screw (SA) and pulling the

handle from the shaft.

Installation

Proceed as described under "Removal" but in the reverse

order.

Adjustment

it is only possible to adjust the horizontal position of the pan

precisely by varying the packing (UM).

Problem Reasons

Tilting drive refuses to operate - Control fuse is faulty

- Water in the controls (general)

- Fault on the board

- Potentiometer on the switch is discon-

nected or faulty

- Tilting motor (gearbox, shaft) is faulty

- Tilting control is not being released by the

pan controls. The parameter PNo. .1.6.

programmed into the pan controls must be

correctly set at 1.

Fig. 7 Motor tilting

Fig. 8 Motor tilting removal

62.9695.03 Page 15

Procedure

Remove the cover (A) as described in § 5. The entire drive

must be fully assembled. Set the pan in the horizontal position.

Release the two screws (SW). The moment of force on the pan

will draw the mounting (HK) away from its attachment point.

This allows the thickness of the packet of packing (UM) to be

changed. The packing pieces have slots, which allows them to

be inserted or removed from the side. Adding additional pieces

(UM) will increase the tilting angle to the back while removing

packing pieces (UM) will increase the tilting angle to the front.

Adjustment is correct when the pan is exactly horizontal when

the motor spindle is fully extended. After setting, the screws

(SW) with the washers must be retightened firmly.

For large boiling pans (200 LT¸ 300 LT) after adjustment of the

horizontal kettle position the screw (KX) must be screwed

against the tilting handle (KH) and secured with the counter-

nut (KZ). This screw holds the torque of the kettle and unloads

the tilting motor.

6.3.3 SWITCH (CK)

From the neutral position 0, the switch can be turned to the

right or to the left for the two tilting directions. When the switch

is released, it is returned to the 0 position by a spring.

No repairs should be made to the switch itself.

Removal

Pull the tilting switch knob (GK) off the panel front. Remove the

front (F) as described in § 5. Detach the electrical connections

(EK) from the potentiometer (PK).

Take off the support plate (TB) by removing 4 nuts from the

front. Take off the complete switch (CK) by removing the 2

nuts (CM) and screws (CS) resp 2 screws (CA) from the sup-

port plate.

Installation

Proceed as described under "Removal" but in the reverse

order. Ensure that the electrical connections are made as

shown. The switch knob must be pressed firmly against the

front panel to ensure that the seal bears evenly all round. The

flat part of the shaft must be positioned downwards.

6.4 BURNER SYSTEM

6.4.1 FLAME

In a visual control, the flames must be dark blue without any

upper yellow or orange tips; they must be stable and soot-free

and stick firmly to the outlets. If there is a lack of primary air,

the flame has yellow streaks and tips; if there is too much pri-

mary air, the flame is short, transparent and tends to lift off the

burner. When the flame is correctly adjusted, it must not lift off

or strike back when the burner is cold as well as warm.

The flame will strike back into the burner when the speed of

the gas-air mixture through the burner outlets is too low, partic-

ularly when the air passages are dirty

The different ignition processes must also take place without

any delays. This concerns the lighting of the ignition burner,

cross ignition from the ignition burner to the main burner and

the spread of ignition or the flame to the whole area of the

main burner.

If the flame tested fails to meet all of the criteria listed above, it

must be readjusted or reset.

6.4.2 AUTOMATIC GAS IGNITOR (A3)

DUNGS DGAI.73

The purpose of the automatic igniter is to ignite the burner with

the electrodes at the start of operation and then to monitor the

flame using the ionization principle. As soon as the flame is

extinguished or fails to burn correctly, the automatic igniter

closes the gas valve thereby preventing the continuing flow of

any gas.

Flame control using ionization current

The principle of flame control using ionization current is that

the gas molecules are transformed by the high temperature in

the flame into electrical charge carriers. To exploit this effect

so that it serves as a cut-out, the electric circuit is interrupted

at the point where the flame from a burner is formed so that, in

operation, the circuit is closed by the conductivity of the burn-

ing gas and air mixture.

Fig. 9 Tilting motor, switch

Fault Cause

Burner refuses to burn No gas, nozzle is blocked, ignition system is

faulty

Burner fails to burn correctly Nozzle is blocked, diffusor is dirty

Ignition system fails to ignite the gas High-tension cable is faulty, high-tension plug

has a bad contact, Dungs electronics are

faulty

Ignition system triggers but the burner fails to

light

No gas

Electrodes are poorly located

Ignition system and burner only work initially

for a short time. The burner is then reextin-

guished.

Dungs electronics are faulty, ignition monitor-

ing is poor.Remedy by swapping the phase

and the neutral conductor on the appliance's

electrical connection.

Yellow flames, the burner creates soot, heat-

ing power is reduced

Nozzle is blocked, diffusor is dirty, burner filter

is dirty

Burner flame is uneven Burner holes are dirty

Fig. 10 Automatic gas

ignitor

Page 16 62.9695.03

The only fault source is that of a simulated flame due to a short

circuit or a creepage path, parallel to the ionization path,

resulting from dampness, scaling or suchlike. To preclude this

fault, it is possible to exploit the rectifier effect of the flame by

applying an alternating voltage between the electrodes. A

small current with d.c. components (ionization current) then

flows. The level of the ionization current varies between differ-

ent burning zones of the flame, but generally it increases as

the flame temperature and the thermal value of the gas

increase.

An ionization flame control system has the disadvantage of

possible wear, particularly of the electrodes, since these com-

ponents are subjected to high thermal loads. The advantage of

the system is the relatively short response time, i.e., less than

1 second.

Ignition procedure

When the appliance is switched on, the gas valve opens and is

ignited at the electrodes after about 5 seconds by the ignition

system which operates for about 5 seconds. The flame on the

burner should then be burning of its own accord and extend to

the entire burner.

If the flame fails to burn after starting, the automatic control

system reports a fault. Display AT on the operating panel will

indicate message A2.

Restarting: acknowledge the error message by pressing button

Q on the operating panel. Restart by pressing button TT. The

automatic start will only be initiated after a delay time of 30 to

60 seconds.

Fault

If the burner fails to ignite after several attempted starts, fur-

ther checks or work are necessary:

• Geometrical adjustment of the electrodes (see "Elec-

trodes")

• Electrode check (see "Electrodes")

• Phase and neutral conductor are transposed and the auto-

matic igniter is not operating correctly. This may happen

with a new installation. This fault can be remedied by

swapping the conductors over at the input terminals.

• Ionization current check.

• Remove the operating panel (P) and the hood as

described in section 5.

• Remove the cable bridge on terminals 9-10 on the

automatic igniter.

• Connect a DC microammeter (range 0 - 50μA) in series

to terminals 9 - 10. To prevent the instrument from

being damaged, the microammeter should be bridged

with a conductor before igniting or a 100μF capacitor

should be interconnected.

• In normal operation, the ionization current should not

fall below 3μA. The voltage is 230V.

• If the ionization current is less than 3μA, the electrodes

must be better aligned in the flame or in relation to each

other.

• After measuring work has been completed, the cable

bridge must be refitted to terminals 9 - 10 on the auto-

matic igniter.

The automatic igniter is set at the works. No attempt must be

made to make any alterations to the igniter.

Removal

The automatic gas ignitor (A3) is located in the right console

on a plate. Remove the cover (A) as described in §5. Remove

nut (MX), lift the sheet with all electrical parts up and hang the

sheet on the console. Disconnect the cables from the auto

matic igniter. Take out the two screws (FS). Slide the auto-

matic igniter on the attachment plate until the fixed screw head

(FF) releases it.

Installation

Proceed as described under "Removal" but in the reverse

order.

6.4.3 BURNER

The burner is located underneath the pan and consists of sev-

eral poker-shaped burners (BF), a distribution pipe (BG) with

an elbow (BK), a mixing tube (MB) with an integral diffusor

(VU) and a holder (HB) with the nozzle (DU). The common dis-

tribution pipe (BG) has a longitudinal slot to ignite the flame to

the individual poker burners. The flame is visible through a

window in the front cladding of the pan

Removal

Take off the pan bottom (BD) and the mixing tube cladding

(VM) in accordance with § 5. Remove the guard (EN) of the

bottom sensor (B2) by taking off the nuts (ER). Unscrew the

bottom sensor (B2) nut. Unscrew the gas supply from the

thread (US) of the nozzle holder (HB). Pull off the electrode

(ED) plug and take off the earth (ground) electrode (EM) cable

screw connection. Take off the two nuts (BM) as well as the

screws (BN). The burner can now be removed.

Installation

Proceed as described under "Removal" but in the reverse

order. When installing the bottom sensor (B2), make sure that:

the threaded hole is cleaned; dirt and traces of old heat con-

ductive paste are removed; the sensor is cleaned; a small

amount of fresh heat conductive paste (Rüeger/Crissier

RTP/II) is applied to the tip of the sensor; the sensor nut is

screwed in but not tightened excessively. When connecting

the gas supply up, make sure that the seal is not damaged. Fit

a new seal if required.

The burner is located centrally under the casing of the pan and

consists of a circular burner (BR), a mixing tube (MB) and a

holder (HB) for the nozzle. If the burner is damaged, it is only

necessary to replace the burner part as a whole.

Fig. 11 Ionization cur-

rent check

BM nuts

B2 bottom sensor

BN screws

EN sensor support

BD pan bottom

Fig.12 Burner

Burner faults Remedy

Flames burn unevenly on the pokers Poker holes are dirty. Clean the pokers.

Unscrew the cover plates (AG) by undoing

the screws (BR). Clean the holes (4 rows with

two sizes) using the appropriate pricker.

Individual pokers fail to burn The distribution pipe (BG) has failed to ignite.

Clean the ignition parts. Unscrew the plates

(UT) by undoing the screws (UV). Clean the

holes using the appropriate pricker.

Surface is heavily scaled, rusty, corroded Exchange the complete burner.

62.9695.03 Page 17

6.4.4 GAS CONNECTION PRESSURE

The current gas pressure must be measured at the measuring

nipple (M) with a liquid U - tube manometer (scale at least 0.1

mbar = 1 mm water column).

GAS VALVE SIT 0830.065 Tandem

The connection point for pressure measurement is located on

the gas valve (GV). Connecting the pressure gauge:

D Remove the screws (5) on the inlet side and (6) on the out-

let side of the gas valve.

D Connect the gauge by pushing a piece of flexible tubing

onto the connection.

Adjustment:

D Turn the pressure regulation and slow pressure regulations

screws clockwise as far as their stop.

D Then turn the screws counter-clockwise by "Z" turns in

accordance with the information in the settings table

76.9793.01 column „Pressure Regulation“ and „Slow pres-

sure regulation“

Contact the gas company if the gas pressure recorded is not

within the limits given. If the pressure is permanently outside

the tolerance figures, the appliance must be readjusted as

described in the section "Gas conversion".

6.4.5 THERMAL LOAD

If the thermal load has to be checked, this can be done by the

volumetric method. The thermal load is checked with the help

of a gas meter and a stopwatch. The correct volume V, which

must be supplied per time unit is calculated as follows:

Thermal load in kW x 1000

V = -------------------------------------------- (lt/min).

Heat value in kWh/m3 x 60

6.4.6 DIFFUSOR (VU) and NOZZLE (DU)

The diffusor (VU) is located in the mixing tube (MB) and serves

to develop pressure within the head of the burner.

Cleaning

The diffusor can become very dirty as a result of drawing in pri-

mary air. It should be disassembled for cleaning.

Removal

D Turn the pan 180° by disconnecting the tilting motor

(according to § 6.3) and support it at the front in this posi-

tion.

D Remove the screws (SB, § 5.) from underneath and take

out the base (BD) from underneath

D Remove the screw connection (US) on the gas pipe.

D Release the screw (SH) and wing nut (FM) and push the

diffusor (VU) into the mixing tube (MB) as far as possible or

screw the diffusor into the mixing tube.

D Unscrew the holder (HB) from the mixing tube (MB).

D Take the diffusor out of the mixing tube.

Unscrew the nozzle (DU) from the holder.

Installation

Proceed as described under "Removal" but in the reverse

order.

Please refer to the settings table 76.9793.01 columns „Main

flame“ for the correct nozzle.

D Remove any traces of old sealer from the nozzle thread

and reseal it with Loctite 572 before refitting it.

Adjustment

The position of the diffusor (gap X) determines the setting of

the primary air for combustion.

Please refer to the settings table 76.9793.01 column „Air

adjustment“.

D The diffusor is adjusted in the mixing tube either by slack-

ening the wing nut (FM) or

D by turning in the screw connection in the mixing tube.

Procedure:

D Close the main gas cock.

D Remove the service cladding (V)

on the left-hand console

SIT 0830 832 Tandem

Fig.13 Gas Valve

Gas pressure variation tolerances are as follows: mbar

Gas type Normal

pressure

Min.

pressure

Max.

pressure

inch

water g.

mbar inch

water g.

mbar inch

water g.

mbar

Natural gas A 7 17.4

USA

Liquid gas E 11 27.4

Propane

USA

BF Burner

BG Distribution pipe

BK Angle

DU Nozzle

FM Wing nut

HB Holder

MB Mixing tube

SH Screw

VU Diffusor

Xgap

US Screw connection

Fig.14 Diffusor

Page 18 62.9695.03

6.4.7 ELECTRODES (ED) (EM)

The electrodes handle the task of igniting and monitoring the

flame. One electrode (ED) is connected to the automatic igni-

ter (A3) by a high-tension cable. The earthing (grounding)

electrode (EM) is connected to the frame of the appliance by a

yellow-green lead.

Check

Check whether the ceramic bodies of the electrodes have:

• any cracks

• no more glaze

• any deposits such as soot, dirt, damp or grease.

If any of the above-mentioned faults are present, the electro-

des may fail to work in which case they must be replaced.The

electrodes must not be cooled off with water when they are hot

as this might cause the ceramic bodies to crack.

The ignition system will only operate perfectly if the electrodes

and the cables are not wet or damp.

Removal

Proceed as described under "Burner removal". By means of

the corresponding notches, the two electrodes are held in the

correct position by the tab (BA). The electrodes can be remo-

ved from the holder after the screw (SA) has been released.

Installation

Proceed as described under "Removal" but in the reverse

order.

Adjustment

The electrodes are best adjusted after the burner has been

removed from the appliance. The position of the electrode tips

to each other (2.5 - 3.5 mm) as well as the distances from the

burner must be adhered to. Restraightening of the electrodes

is only possible when new or after heating to red heat. An M3

screw can be used as a gauge to measure the gap.

The electrodes are positioned by means of slotted holes in the

attachment tabs. The vertical position is adjusted by releasing

the 2 screws (SD) and relocating the plate (BD). The horizontal

position is changed by releasing the 2 screws (SC) and reloca-

ting the plate (BC). The position of the pair of electrodes must

be exactly centred over a flame aperture of the burner.

6.4.8 SEALANTS

for parts containing gas

Loctite 572 white (liquid PTFE) For sealing gas pipes,

gas valve screw connections,

nozzles

Loctite 620 green For high-strength joints,

burner attachment,

burner pipes and

bends

6.4.9 CONVERSION TO ANOTHER TYPE OF GAS

Caution:

The gas supply shall be shut off prior to disconnecting the

electrical power, before proceeding with the conversion.

GAS TYPES

The appliances are equipped and adjusted at the factory to run

with:

If there is a change in the gas type or gas pressure, the follo-

wing parts must be checked, exchanged or converted:

• Nozzle (DU)

• Distance of diffusor (X)

• Readjustment of the gas valve

If there is a change in the gas type or gas pressure, the follo-

wing parts must be checked, exchanged or converted:

• Nozzle (DU)

• Distance of diffusor (X)

• Readjustment of the gas valve

Identification marking

A new type identification plate corresponding to the new gas

type setting must be fixed to the appliance, specifying the gas

type, gas pressure, gas category, etc.:

Fig.15 Electrodes

Natural gas category A,

nominal pressure 7 inch water gauche (17.4 mbar).

The appliances are arranged for a conversion to:

Propane gas category E,

nominal pressure 11 inch water gauche (27.4 mbar).

This appliance was converted on

(day-month-year): ...........................

to Propane Gas (LP) with

Kit No.: ............

Orifice No.: ............

by (name and address of organization making this conver-

sion):

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

which accepts the responsibility that this conversion has

been properly made.

PNC: ...........................

Series No.: ...........................

Type: ...........................

Gas Type: LP Propane

Gas Pressure: 11 inch Water Gauche (27.4 mbar)

Gas Rating: ...........................

62.9695.03 Page 19

6.4.10 GAS DATA TABLE

76.9793.01 - Gas heated Tilting Frying Pans 60 -100 lt

Model Gas type Category Nominal

pressure

Pressure

Regulator

Slow opening

regulation

Main flame Air

adjustment

Burner

distance

mbar Inch Water

Guage

mbar Setting after

turning completely

clockwise to close

mm No. Distance X Front

Back

GP5B…. FET 060 Natural gas USA A 17.4 6.02 15 2 turns anti-clockwise 3.15 71.4160.315 15mm 78mm 70mm

GP5B…. FET 060 Propane gas USA E 27.4 10.04 25 2 turns anti-clockwise 2.20 71.4160.220 10mm 78mm 70mm

GP5C…. FET 080 Natural gas USA A 17.4 6.02 15 2 turns anti-clockwise 3.60 71.4160.360 16mm 78mm 70mm

GP5C…. FET 080 Propane gas USA E 27.4 10.04 25 2 turns anti-clockwise 2.50 71.4160.x250 12mm 78mm 70mm

GP5E…. FET 100 Natural gas USA A 17.4 6.02 15 2 turns anti-clockwise 4.00 71.4160.400 16mm 78mm 70mm

GP5E…. FET 100 Propane gas USA E 27.4 10.04 25 2 turns anti-clockwise 2.80 71.4160.280 12mm 78mm 70mm

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