Electrolux GU5HOEOOOO (583396) User manual

Brand: Electrolux

Model: GU5HOEOOOO (583396)

Type: User manual

This manual is also suitable for

Thermetic

TILTING BOILING PANS, ROUND, GAS

(GU........)

(KU........)

US SERVICE MANUAL

Gas heated

TILTING BOILING PANS

Doc. 62.9693.03

Edition 1

09.2006

62.9694.03 Page 1

CONTENTS

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

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

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

4. MAINTENANCE CHECK LIST............................................................................................ 6

5. ACCESS TO INSIDE........................................................................................................... 7

6. FUNCTIONAL COMPONENTS........................................................................................... 7

6.1 OPERATING FOIL .............................................................................................................................7

6.2 UNIVERSAL CONTROL ....................................................................................................................8

6.2.1 PARAMETER PROGRAMMING .........................................................................................................................8

6.2.2 MANUAL PARAMETER INPUT ..........................................................................................................................8

6.2.3 PROGRAMMING SPECIFIC APPLIANCE AND USER DATA ..........................................................................9

6.2.4 ADJUSTING OF TEMPERATURE MEASURING .............................................................................................11

6.2.5 TEST FUNCTIONS FOR SERVICE APPLICATION .........................................................................................11

6.2.6 TROUBLESHOOTING DISPLAY ......................................................................................................................12

6.2.7 OPERATING BOARD (UP) ...............................................................................................................................12

6.2.8 CONTROL BOARD (SP) ...................................................................................................................................13

6.2.9 CONTROL SWITCH (S) ....................................................................................................................................13

6.2.10 SAFETY THERMOSTAT (F1) ...........................................................................................................................13

6.2.11 FOOD SENSOR (B1) ........................................................................................................................................14

6.2.12 JACKET SENSOR (B2) ....................................................................................................................................14

6.2.13 DEAERATION SENSOR (B3) ...........................................................................................................................14

6.2.14 END SWITCH (ES) ............................................................................................................................................14

6.2.15 TERMINALS ......................................................................................................................................................15

6.2.16 CONTROL FUSE (X4) .......................................................................................................................................15

6.2.17 RELAY (K1) .......................................................................................................................................................15

6.2.18 HEATING RESISTOR (E11) .............................................................................................................................15

6.3 MOTOR TILTING ............................................................................................................................16

6.3.1 CONTROL SYSTEM (KS) .................................................................................................................................16

6.3.2 TILTING MOTOR (AN) ......................................................................................................................................16

6.3.3 SWITCH (CK) ....................................................................................................................................................16

6.4 BURNER SYSTEM ..........................................................................................................................17

6.4.1 FLAME ..............................................................................................................................................................17

6.4.2 AUTOMATIC GAS IGNITOR (A3) ....................................................................................................................17

Page 2 62.9694.03

6.4.3 BURNER ...........................................................................................................................................................18

6.4.4 SCREEN (BU) ...................................................................................................................................................18

6.4.5 GAS CONNECTION PRESSURE .....................................................................................................................18

6.4.6 THERMAL LOAD ..............................................................................................................................................19

6.4.7 DIFFUSOR (VU) and NOZZLE (DU) ................................................................................................................19

6.4.8 ELECTRODES (ED) (EM) .................................................................................................................................20

6.4.9 SEALANTS .......................................................................................................................................................20

6.4.10 CONVERSION TO ANOTHER TYPE OF GAS ................................................................................................20

6.4.11 GAS DATA TABLE ...........................................................................................................................................21

6.5 JACKET ..........................................................................................................................................22

6.5.1 SAFETY VALVE (SV) .......................................................................................................................................22

6.5.2 LEAKS / LACK OF WATER .............................................................................................................................23

6.5.3 DEAERATION SYSTEM ...................................................................................................................................24

6.5.4 DEAERATION VALVE (EV) .............................................................................................................................24

6.5.5 CHECK VALVE (RV) ........................................................................................................................................24

6.5.6 SIPHON (SP) ....................................................................................................................................................24

6.5.7 DATA PLATE, vessel (TY) ..............................................................................................................................25

6.5.8 INSULATION (see figure "Jacket") ................................................................................................................25

6.5.9 PAINT FINISH ...................................................................................................................................................25

6.5.10 JACKET PRESSURE TEST .............................................................................................................................25

6.6 ROTATION LINK (DK) .................................................................................................................... 25

6.7 FAUCET ..........................................................................................................................................27

6.8 LID (D), ............................................................................................................................................28

6.8.1 LID HINGE (DG) ...............................................................................................................................................28

6.9 PAN .................................................................................................................................................29

6.9.1 BEARINGS, PIVOTS ........................................................................................................................................29

6.9.2 CASING (MN) ...................................................................................................................................................29

6.9.3 WASTE GAS FLUE (KI) ...................................................................................................................................29

6.10 APPENDIX

UNIVERSAL CONTROL DESCRIPTION OF PARAMETERS ..................................................... 30

62.9693.03 Seite 3

VALIDITY

This document refers to the following tilting boiling pan pro-

gram:

ADDITIONAL DOCUMENTS

Operating instructions 76.9693.01delivered with the appliance

Installation instructions76.9699 delivered with the appliance

Spare parts list 76.9693.02distributed by the service

department

Electrical diagrams 91.4018, 91.4020

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 uniformly heated by steam by an external jacket.

The following sources of energy are used: electricity, saturated

steam and hot water. The pans are equipped with an elec-

tronic comfort control unit with regulation of the food tempera-

ture, with programming of the cooking time and with optional

programming of the starting time. The control system is oper-

ated via a membrane keyboard. The boiling pan has a vari-

able-speed tilting facility powered by an electric motor. All

models can be optionally equipped with a mixer unit.

2. TECHNICAL DATA

Tilting boiling pan with jacket heating system.

Electrically heated tilting boiling pans models have water-filled

jackets. Max. working conditions in the jacket: pressure 0.8 bar

(5.8 psi), temperature 244°F (118°C).

Heating-up time: time taken to heat the pan 100% full of water

from 68°F (20°C) to 194°F (90°C).

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

Gas heated tilting

boiling pan heated

.U.C......

080 E

.U.E......

100 E

.U.H......

150 E

.U.J......

200 E

.U.K......

300 E

Gas heated tilting boiling pans

.U.C......

080

.U.E......

100

.U.H......

150

.U.K......

300

vessel capacity gal 21.1 26.4 39.4 79.3

Gas heating capacity

18 21 27 43

Gas heating capacity

btu/h

61420 71650 92130 146720

Natural gas

consumption ft/min

1.15 1.34 1.66 2.87

Propan

consumption ft/min

0.44 0.51 0.64 1.1

El. power kW 0.2 0.2 0.2 0.2

Voltage ) 120V/1~N,

60Hz

120V/1~N,

60Hz

120V/1~N,

60Hz

120V/1~N,

60Hz

Amperage A 0.7 0.7 0.7 0.7

Jacket volume dm3 32 38 50 64

Jacket volume gal 8.5 10 13.2 16.9

Water filling lt 17 17 22 30

Water filling gal 3.7 3.7 5.8 7.9

Heating-up time min. 40 45 50 64

Seite 4 62.9693.03

3. ELECTRIC DIAGRAMS

Gas heated tilting boiling pans 80 LT - 150 LT (21.1 gal - 39.4 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.

91.4020

A1 Control board

A2 Operating board

A3 Dungs gas ignitor

B1 Food temperature sensor

B2 Jacket temperature sensor

E1 Electrodes)

E10 Tilting control

E11 Heating resistor

F1 Safety thermostat against lack of

water

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

T1 Single-phase transformer (only for

voltage unequal 230V)

Y1 Gas valve (SIT 080832 Tandem)

Fig.1 Electric diagram, gas heated tilting boiling pans 80 LT - 150 LT (21.1 gal - 39.4 gal), 120 V

62.9693.03 Seite 5

Gas heated tilting boiling pans 300 LT (79.3 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 Jacket temperature sensor

E1 Electrodes)

E10 Tilting control

E11 Heating resistor

F1 Safety thermostat against lack of

water

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

T1 Single-phase transformer (only for

voltage unequal 230V)

Y2 Gas valve (GS-4521-9993)

Fig.2 Electric diagram, gas heated tilting boiling pans 300 LT (79.3 gal), 120 V

Seite 6 62.9693.03

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

Check Fault D 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

D tighten contacts.

Check relays.

The contacts must move

freely without sticking or

jamming.

In case of defects or faults

D replace contactor or relay.

Check the burner output,

i.e. measure the preset hea-

ting-up time and compare

this with the nominal value.

If this comparison reveals a

deviation of more than 10%

D Clean and check the gas

system.

Clean the diffusor on the

burner. Check its position

and attachment.

If its position has changed

D 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 dama-

ged D Fit a new one.

Check the distance bet-

ween the burner and the

pan base.

If the actual measurement

deviates more than ± 1mm

from the nominal measure-

ment

D 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

D 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

D Replace.

Check that the gas valve is

not leaking and that it is set

correctly.

S If it is leaking

D Replace the valve.

If it is functioning incorrectly

D Readjust it.

Measure the ionization cur-

rent at the electrodes when

the appliance is at full

power.

If this is outside the recogni-

zed tolerance

D Set the electrodes more

accurately.

Check the high-tension

cable for cracks or brittlen-

ess.

If any faults are found

D Replace the cables.

Check the plug on the igni-

tion electrode.

If any faults or oxidation are

found

D 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

D 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 lea-

kage of rotation link.

If any faults are found

D replace the parts concer-

ned.

Check that the internal gas

pipes are not leaking.

If a leak is found

D Seal the leak.

Ensure that the main gas

tap (if fitted) operates

smoothly and correctly.

If the tap is hard to turn

D Regrease the tap or

replace it.

Inspect internal wiring. In case of defect cables

D replace cables.

Check condition of all ope-

rating foils.

Defective foils D replace.

Optical inspection of the

whole control unit.

Defective foils D replace.

Test all operating functions

and check that the control

unit works correctly.

S If problems are encountered

D find reason and repair

failure.

Check switches for easy

movement and correct

function.

If the switch is hard to turn or

makes a noise

D replace.

Compare the food tempe-

rature display with the

actual value.

If the deviation is

 1°

D Adjust the display again.

Inspect fixation and condi-

tion of all temperature sen-

sors (jacket, food,

deaeration, excess tempe-

rature) and check electrical

connections.

S If sensors, fixation, electrical

connections are found to be

faulty

D replace the parts concer-

ned.

Check the function of the

heating resistance.

If it is not warm D replace it.

Check all elements of the

display on the control panel

with service test 1.

If any element of the display

fails D exchange the whole

operating 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

D replace the parts concer-

ned.

Check function of acoustic

signals.

If the sound is off key or no

sound is heard

D exchange the whole con-

trol board.

Check the number of deae-

rations and thus the water

level in the jacket with para-

meter PNo. 1.6.5.

If the number of deaerations

is very high or there is too

little water in the jacket

D refill with demineralized

water and reset the value of

PNo. 1.6.5. to 0.

Check max. jacket pres-

sure (except on pans with

direct steam heating).

If it deviates from the max.

reference value

D reset the max. value with

PNo. 1.0.3.

Carry out a leak test of the

jacket (except on pans with

direct steam heating).

If there is a leak and high

water loss

D locate the leak and seal.

Check function of deaera-

tion valve.

If it is not tight during opera-

tion

D clean or replace the valve.

Inspect safety valve for

corrosion, damage and lea-

kage. Make function test

and maintenance.

S Clean the valve. If any inad-

missible properties are

encountered

D replace the whole valve.

Check the lid for correct

shape or damage.

If irreparably damaged

D replace the lid.

Check the lid hinges for

correct function.

If defective

D 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

D replace seals.

Check Fault D Remedy

62.9693.03 Seite 7

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 tur-

ned 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 jak-

ket (MK). Tighten the screws

(SB).

Pan jacket. The pan jacket is

not removed during normal

servicing work.

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 clea-

ned. (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

important 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 tempe-

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

+ 120°C) continuous temperature load

and 356°F (180°C) short-time tempera-

ture load.

Seite 8 62.9693.03

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

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

boiling point of water 207 - 212°F (97 - 100°C), this tempera-

ture will be reached during heating up and then maintained at

this value by the electronic control system and the careful sup-

ply of energy. The nominal temperature will not be exceeded

during this process.

When cooking certain products with poor heat conductivity

such as sugar solutions, nominal temperature settings

between 212 and 230°F (100° and 110°C) are required in

order to reach boiling point. The correct setting is largely a

matter of experience.

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).

Power settings.

Hold levels.

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).

Excess pressure in the jacket (test function).

State of the heating system or the valves (if all 3

digits light up as well as a decimal point, then

the numeral must be multiplied by 1000. E.g.

display = 12.3, value = 12300)

Software version.

AD (3 digits) Cooking time

AZ (4 digits) Clock time.

Starting time.

Excess pressure in the jacket (normal function).

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

62.9693.03 Seite 9

)

(*) 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

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 conti-

nuously until the 2nd

beep, then press the

2nd combination

2nd

combination

Press buttons

Press buttons conti-

nuously 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 conti-

nuously 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)

Seite 10 62.9693.03

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 SETTINGS

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

54 4 Quantity of switching steps 1

59 2 Regulator hysteresis for double jacket sensor 0.5

63 2 Double jacket sensor lower temperature band 1 1

64 4 Double jacket sensor lower temperature band 2 2

65 6 Double jacket sensor lower temperature band 3 3

66 4 Double jacket sensor upper temperature band 1 2

67 6 Double jacket sensor upper temperature band 2 3

68 8 Double jacket sensor upper temperature band 3 4

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).

85 80

Opening time of the deaeration valve

60 liter kettle:

80 - 150 liter kettle:

300 liter kettle:

120

99 170 Max. jacket pressure to release alarm 180

103 122 Double jacket sensor remappingy-high normal cooking 118

113 115 Double jacket sensor remappingy-high soft cooking 113

116 140 Max. pressure in double jacket 86

157 70 Maximum board temperature 80

62.9693.03 Seite 11

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 food temperature measured is lower than the

one displayed, the correction values are increased

(plus sign). If the food temperature measured is

higher than the one displayed, the correction 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.

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 action;

only if alarm

A31 is dis-

played;

refill jacket with

water

Following to test 1.

press buttons during 4

seconds until 2. beep;

this action serves to

automatically reset the

accumulated

amount

of deaerations

(PNo.

1.6.5.) at 0;after that

the alarm A31 disap-

pears from the display

(AT)

4th test,

press buttons

and hold

Display (AT)

jacket

pressure

in bar(e.g.

0.85 without the letter

P corresponding 0.85

bar (12.3 ) over pres-

sure; -.25 correspon-

ding 0.25 bar (3.6 psi)

vacuum pressure)

pressures lower than

0.40 bar (5.8 psi)

vacuum pressure are

not displayed

5th test,

press buttons

and hold

The display (AT) pro-

vides information on

the current

condition

of the heating

system

1. electric or gas

ON = switched on,

OFF = switched off

2. motor valve (steam

or hot water)

OP = opening, CL =

closing, OFF = stand-

still in any position bet-

ween full open resp.

closed

3. solenoid valve

(steam or hot water)

ON = open, OFF =

closed

6th test,

Presbyterians

and hold

Display (AT) =

tempe-

rature in °F of food

sensor J15.

Display (AZ) = clock

time

7th test,

press buttons

and hold

Display (AT) =

tempe-

rature in °F of jacket

sensor

J16.

Display (AZ) =

clock

time

8th test,

press buttons

and hold

Display (AT) =

tempe-

rature in °F of deae-

ration sensor

J17.

Display (AZ) =

clock

time

9th test,

press buttons

and hold

Display (AT) =

aper-

ture ratio of motor

valve

in % (100 = full

open)

Display (AZ) =

clock

time

10th test,

press buttons

and hold

Display (AT) = number

software version

(e.g. 2.62)Display (AZ)

clock time

* * *

* *

* * *

* *

* * *

Seite 12 62.9693.03

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).

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).

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)

E3 Defective deaeration temperature

sensor (J17); appliance switches off

Reset the error message and alarm with

button (Q); repair cause of problem

(loose connector, broken sensor, short

circuit)

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)

E8 Pressure in jacket is too high Reset the error message and alarm with

button (Q); repair cause of problem

(defective contactor)

E9 Defective analogue/digital transfor-

mer

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 jak-

ket

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

E11 Temperature of deaeration sensor

J17 is too high

Reset the error message and alarm with

button (Q)

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 pres-

sing the button (Q) and restart by pres-

sing the button (TT). Wait for the delay

time of 30 to 60 seconds.

A31 Lack of water in the jacket; alterna-

ting display (AT) of food temperature

and A31; this is an advance warning

to refill the jacket with water; the

deaeration valve has reached the

programmed max. amount of ope-

nings (8000) according to PNo..9.5.

Reset the error message and alarm with

button (Q); The appliance can continue

to be used normally. After starting each

time, error message A31 will be dis-

played.

To remedy the continuous message, add

demineralized water to the jacket. Reset

parameter PNo. 1.6.5. to 0 either by

changing the parameter content or by

button combination (as described in the

section "Test functions for service appli-

cation" action 3.)

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.

62.9693.03 Seite 13

6.2.8 CONTROL BOARD (SP)

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

replaced as a complete unit.

If a control board is replaced, it must be reprogrammed depen-

dent on the type of appliance and user-specific data (see sec-

tion Programming the control system). The number of the

software version is marked on the microprocessor.

Removal

Take off the switch panel (F) as described in § 5. Unplug all

electrical connectors from the board. Unplug the flat cable (FL)

connector and take it out of the guide, take off the 6 nuts

(MP1) and washers. Take the board off the steel panel (ST)

that is located between the control board and the operating

board and maintains a gap.

Installation

Place the long spacing sleeves (HP1) on the bolts (BP1) on

the steel panel (ST), position the board on the bolts and care-

fully tighten the nuts with their washers.

Reprogramming

The general test parameters are set in a new control pcb.

These settings do not correspond to any specific type of appli-

ance. After installing a new control pcb, the basic parameter

values must be programmed in first followed by the parame-

ters that are specific to the appliance (given in the parameter

list).

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).

6.2.9 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.

6.2.10 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.

BK operating knobs

HP spacing sleeves

MP nuts and washers

ST steel panel

FL flat cable

JP1 bridge

Fig.3 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

EEPROM (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

Seite 14 62.9693.03

Reset

When the thermostat responds, the red knob (RF1) jumps out

and heating is interrupted. After remedying the cause of this

response, the red knob is pressed in again and the appliance

is ready for use again.

Removal

Place the pan in its fully tilted position. Remove the base of the

jacket cladding (see § 5). The safety thermostat is attached to

a holder on the tube (RN) for the water level (see picture

Fig.15 Jacket). The capillary tube sensor (KF1) is inserted into

a tube at the highest point on the top rod heater (E1). Proce-

dure: take off the upper nut (MF) on the heating flange (HE).

Remove the guide (FF) and pull the capillary tube sensor

(KF1) out of the tube. Take off the two fixing screws (HF) on

the safety thermostat. If necessary, also take off the cable clip

above the thermostat. Take out the safety thermostat and with-

draw the capillary tube with the sensor.

Installation

Proceed as described under "Removal" but in the reverse

order. When fitting the guide (FF), make sure that the sensor

(KF1) is correctly installed and that the capillary tube (KR1) is

led upwards without touching the electrical contacts under any

circumstances.

6.2.11 FOOD SENSOR (B1)

The food sensor (B1) is located in a tube under the pan. 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 1097W at 77°F (25°C).

Removal

Remove the base of the jacket cladding (see § 5). Place the

pan in its fully tilted position. Slacken the locknut and the cap-

tive nut and withdraw the sensor from the retaining plate.

Remove the switch panel (F) 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".

6.2.12 JACKET SENSOR (B2)

The jacket sensor is installed on the face of a steam generator

(DE) on a tube flange. The active part of the sensor dips into

the water in the jacket. Test 7 is used to ascertain the temper-

ature of the jacket (see section Test functions).

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 base of the pan cladding (see § 5). Drain the

water out of the jacket as described in § 6.5. Set the pan in the

fully tilted position. Unscrew the nut (MB2) and pull the sensor

out of the heating flange. Remove the switch panel (F) as

described in § 5. Disconnect the sensor cable from the J16

push-on connections on the control board (SP). Firmly attach a

strong cord to the cable end. Draw the cable out of the appli-

ance 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 seal (DB2) is installed undamaged. Refill

the jacket with water when fitting work has been concluded.

6.2.13 DEAERATION SENSOR (B3)

The sensor is located in the lower part of the deaeration tube

(LE).

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 base of the pan cladding (see § 5). Set the pan in

the fully tilted position. Pull the clamp plate (KB) off the tube

(LE) (see picture Deaeration System). Remove the switch

panel (F) as described in § 5. Disconnect the sensor cable

from the J17 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 deaeration tube with the clamp plate with heat-con-

ductive paste (Rüeger/Crissier RTP/II).

6.2.14 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.

Problem Reasons

The safety thermostat (F1) responds after a

short operating period. The number of deae-

rations (query under parameter PNo. 1.6.5.) is

low.

Refer to 6.5 for possible causes. Section

Leaks/Lack of water. Identify and remedy the

cause or replace the part in question.

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.

62.9693.03 Seite 15

6.2.15 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.

6.2.16 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.

6.2.17 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.

6.2.18 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.

Fig.4 End switch

Seite 16 62.9693.03

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).

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).

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 disconnected

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.5 Motor tilting

Fig.6 Motor tilting removal

62.9693.03 Seite 17

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, parti-

cularly 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.

It must be noted that the measurement is taken in a steady-

state condition. The heat value (the lower heat value) must be

given by the gas supply company. If there are any deviations

of more than 5%, the use of the correct jets must be checked.

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 clo-

ses 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

burning gas and air mixture.

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

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

ting from dampness, scaling or suchlike. To preclude this fault,

it is possible to exploit the rectifier effect of the flame by app-

lying 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 different

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 tie, 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 "Electro-

des")

• 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 automa-

tic igniter.

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

Fig.7 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 reex-

tinguished.

Dungs electronics are faulty,

ignition monitoring is

poor.Remedy by swapping

the phase and the neutral

conductor on the

appliance's electrical con-

nection.

Yellow flames, the burner

creates soot, heating power is

reduced

Nozzle is blocked, diffusor is

dirty, burner filter is dirty

Burner flame is uneven Burner holes are dirty

Fig.8 Automatic gas

ignitor

Seite 18 62.9693.03

terminals 9 - 10. To prevent the instrument from being

damaged, the microammeter should be bridged with a

conductor before igniting or a 100mA capacitor should

be interconnected.

• In normal operation, the ionization current should not fall

below 3mA. The voltage is 230V.

• If the ionization current is less than 3mA, 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 automa-

tic igniter. Take out the two screws (FS). Slide the automatic

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 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.

Removal

Turn the pan 180° by disconnecting the tilting motor (according

to BT3) and support it at the front in this position. Remove the

base of the pan cladding (see § 5). Disconnect the cables from

the electrodes. Remove the screw connection (US) on the gas

pipe. Undo the lower central nut (ZM). Remove the 3 attach-

ment screws (BS). The burner can then be taken out with the 3

supports (SB) and the electrodes (ED) and (EM). The burner

can be further disassembled by removing the 3 screws (BC).

Installation

Proceed as described under "Removal" but in the reverse

order. The installation position, i.e. the gap (Y) between the

lower edge of the burner to the lowest point of the pan base

must be adhered to exactly. The vertical position of the burner

is set by adjusting the two nuts (ZM). The nuts then have to be

locked against each other.

Please refer to the pan settings table for gap Y.

6.4.4 SCREEN (BU)

Inside the head of the burner, there is a screen (BU) (cf. the

illustration of the electrodes) which prevents the flame from

striking back (brief, loud report) when the burner is switched

off. If the flames are yellow although all cleaning work has

been carried out (nozzle, diffusor, burner exit apertures) in

advance, the screen may be dirty. It can be cleaned after the

burner has been removed and dismantled.

6.4.5 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“

GAS VALVE Johnsons Controlsystems AND PRESSURE

REGULATOR Maxitrol RV48L (79.3 gal kettle)

Nominal Pressure Measure:

The current gas pressure must be measured at the measuring

nipple in the supply pipe with a liquid U - tube manometer

(scale at least 0.1 mbar = 1 mm water column)

D Close the main gas cock.

D Remove the service cladding (V) on the left-hand console

D Release the screw (1 turn) in the measuring nipple.

D Connecting the pressure gauge by pushing a piece of flexi-

ble tubing onto the nipple.

D Open the main gas cock.

D Run the burner on the appliance at full output.

D Check whether the permitted connection pressure range is

in fact so.

Fig.9 Ionization cur-

rent check

Fig.10 Burner

Procedure:

D Close the main gas cock.

D Remove the service cladding (V)

on the left-hand console

SIT 0830 832 Tandem

Fig.11 Gas Valve

62.9693.03 Seite 19

D When pressure measurement has been completed, refit

the screw to the valve and seal it. The other components

are reassembled in the reverse order to that described

above.

Regulated Pressure Measure:

The connection point for pressure measurement is located on

the gas valve (3). Connecting the pressure gauge:

D Remove the screw .

D Connect the gauge by pushing a piece of flexible tubing

onto the connection.

Adjustment:

D Remove cap (1) of the pressure regulator.

D Then turn the pressure regulation screw (2) of the pressure

regulator until the pressure coincides with the information

in the settings table 76.9793.02 column „Pressure Regula-

tion“.

D Turn the slow pressure regulations screw (4) of the gas

valve clockwise as far as their stop.

D Turn the screw (4) counter-clockwise by "Z" turns in

accordance with the information in the settings table

76.9793.02 column „Slow Opening 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".

6.4.6 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

6.4.7 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 BT3) 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.

D 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.

6.4.8 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.

Maxitrol RV48L

Johnsons

Control Sys-

tems

GS-4521-9993

Fig.12 Gas Valve and Pressure Regulator, 300 lt

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

DU Nozzle

FM Wing nut

HB Holder

MB Mixing tube

SH Screw

VU Diffusor

Xgap

US Screw connection

Fig. 13 Diffusor

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