Electrolux KU5KOEOOOO (583397) User manual

Type
User manual
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
kW
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.
S
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
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)
*
*
Ï
*
Ð
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
GS
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).
X
85 80
Opening time of the deaeration valve
60 liter kettle:
80 - 150 liter kettle:
300 liter kettle:
60
80
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
of
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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Electrolux KU5KOEOOOO (583397) User manual

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