INSTALLATION SERVICE AND MAINTENANCE MANUAL GAS ML COMBINATION OVEN/STEAMER W 1 6 4 N 9 2 2 1 W a t e r S t r e e t • P. O . B o x 4 5 0 • M e n o m o n e e F a l l s , W i s c o n s i n 5 3 0 5 2 - 0 4 5 0 PHONE: 262.251.3800 800.558-8744 PRINTED IN U.S.A. USA/CANADA FAX: 262.251.7067 • 800.329.8744 U.S.A. 262.251.1907 INTERNATIONAL ONLY USA WEBSITE: www.alto-shaam.com #6011ML 10/11/2004 Gas INSTALLATION, SERVICE AND MAINTENANCE MANUAL MANUEL D'INSTALLATION, DE MISE EN ROUTE ET D'ENTRETIEN MODELES : COMBITHERM GAS MODELS 6•10ML, 7•14ML, 10•10ML, 10•20ML, 12•18ML & 20•20ML COMBITHERM FOUR/CONVECTION VAPEUR 6•10 ML , 7•14 ML , 10•10 ML , 10•20 ML , 12•18 ML & 20•20 ML GAS SAFETY: Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. ADVERTISSEMENT Ne pas entreposer ni utiliser de l'essence ni d'autres vapeurs ou liquides inflammables dans le voisinage de cet appareil, ni de tout autre appareil. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment. NOTE: Instructions obtained from the local gas supplier, indicating procedures to be followed in the event that the user smells gas, must be posted In a prominent location. The information contained in this manual is important for the proper installation, use and maintenance of this oven. Please read carefully and retain for future reference. Improper connection of this appliance will nullify all warranties. ADVERTISSEMENT Une installation, un ajustement, une altération, un service ou un entretien non conforme aux normes peut causer des dommages a'la propriété, des blessures ou la mort. Lisez attentivement les directives d'installation, d'opération et d'entretien avant de faire l'enstallation ou l'entretiende cet équipement. NOTE: En dernier reours, les instructions provenant du fournisseur local de gas doivent être mises en evidence de maniere a indiquer les procedures à suivre au cas ou l'utilizateur sentirait le gaz. MIES EN GARDE MISE EN Les informations contenues dans ce manuel sont importantes pour l'installation l'utilisation et l'entretien de ce four. S'il vous plait lisez-le tres attentivement et GARDE conservez-le. La non-application de ces consignes annule toutes garanties. ALTO-SHAAM, INC.® P.O. BOX 450, W164 N9221 WATER STREET MENOMONEE FALLS, WI 53052-0450, USA The Alto-Shaam Gas Combitherm oven/steamer has a specification plate affixed to the left-hand side panel of the oven. The plate includes electrical and gas connection specifications and should be reviewed prior to service. MODEL GAS TYPE SERIAL NO. MANIFOLD GAS PRESSURE INPUT RATE ELECTRICAL: 110-120V, 60 Hz, 1 PH IN. W.C. BTU/HR AMP WATTS MINIMUM CLEARANCES FOR COMBUSTIBLE AND NON-COMBUSTIBLES CONSTRUCTION: LEFT= 4 INCHES / RIGHT = 1 INCH / REAR = 1 INCH FOR USE ONLY ON NON-COMBUSTIBLE FLOORS DOIT ETRE UTILISE SEULEMENT SUR DES PLANCHERS INCOMBUSTIBLES FOR INSTALLATION UNDER VENTILATION HOOD ONLY POUR UNE INSTALLATION SOUS UNE HOTTE D'EVACUATION SEULEMENT INTENDED FOR OTHER THAN HOUSEHOLD USE DESTINE A UN USAGE AUTRE QUE DOMESTIQUE ANS Z83.11-CSA 1.8-2002 ANSI/NSF4 Contact the factory if any servicing assistance is required. Remember to provide the model number and serial number of the oven which can be found on on this oven nameplate. Gas TABLE OF CONTENTS 2.0 CONTROL PANEL IDENTIFICATION . . .15 1.0 INSTALLATION 1.1 Receiving & Transportation . . . . . . .1 1.2 Basic Installation Site Requirements . . .1 1.3 Ventilation Requirements . . . . . . . . .2 1.4 Positioning On Site . . . . . . . . . . . . .2 1.5 Installation Codes & Standards . . . .2 1.6 Installation Requirements . . . . . . . .3 2.4.1 Cleaning Instructions . . . . . . . .19 1.7 Air Supply Requirements . . . . . . . . .4 2.4.2 Automatic Cleaning Program . . .20 1.8 1.9 Assembly Requirements . . . . . . . 1.8.1 Exhaust Gas Flue Diverter . 1.8.2 Sound Absorber . . . . . . . . . 1.8.3 Hand Shower Holder . . . . . 1.8.4 Drip Tray . . . . . . . . . . . . . . 1.8.5 Roll-In Cart (TROLLEY) Guide Rails . . .4 . . .4 . . .4 . . .4 . . .4 . . . .5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 2.1 Safety Precautions . . . . . . . . . . . . .17 2.2 Preventive Maintenance . . . . . . . . .18 2.3 Routine Cleaning Requirements . . .18 2.4 Daily Oven Cleaning 2.5 Monthly Cleaning 2.5.1 Water Intake Filter Cleaning . . . .21 2.5.2 Drain Pipe Cleaning . . . . . . . . . . .21 2.5.3 Flue Outlet Cleaning . . . . . . . . . .21 2.5.4 Fan Cleaning . . . . . . . . . . . . . . . . .22 Electrical Connection . . . . . . . . . . . .5 1.10 Water Supply . . . . . . . . . . . . . . . . . .6 2.6 Roll-In Cart/Food Trolley Cleaning . .23 1.11 Water Drainage . . . . . . . . . . . . . . . .6 2.7 Daily Gasket Cleaning . . . . . . . . . .23 1.12 Gas Connection Requirements . . . . .7 3.0 SERVICE SECTION 1.13 Gas Type and Pressure . . . . . . . . . . .7 3.1 Combitherm Service Record . . . . . .24 1.14 Gas Connection . . . . . . . . . . . . . . . .7 3.2 Combitherm Gas 1.15 Leak Testing 3.2.1 Exterior Component Identification . .25 . . . . . . . . . . . . . . . . . .8 . . . . . . . . . . .8 3.2.2 Operating Schematic . . . . . . . . . .25 1.17 Gas Exhaust . . . . . . . . . . . . . . . . . . .8 3.2.3 Plumbing System . . . . . . . . . . . .25 1.16 Fuel Interlock System 1.18 Gas Pressure Chart . . . . . . . . . . . . .9 3.3 Service Views — LEFT- SIDE PANEL 1.19 Gas Flame Patterns . . . . . . . . . . . . .9 Models 6•10, 7•14, 10•10, 10•20, 12•18 . . .26 1.20 Burner Pilot Adjustment Control, Bypass, Water . . . . . . . .10 1.20.1 Checking Pressure . . . . . . . . .10 1.20.2 Adjust Pilot Burner . . . . . . . . . . . . . . .27 Optional Grease Collection System . . . .28 . . . . . . . .10 1.20.3 Manifold Pressure Adjustment . . .10 3.4 1.20.4 Ignition & Burner Check . . . . .10 Troubleshooting . . . . . . . . . . . . . . . . . . . . .29-30 Control Reset . . . . . . . . . . . . . . . . . . . . . . . . . .30 1.20.5 Verify Sequence of Operation . . . .10 1.21 Sequence of Operation . . . . . . . . . .11 1.22 Stacking Combitherm Connections .12 1.23 Post Installation Check List . . . . . .13 1.24 Emergency Operation . . . . . . . . . . .14 3.6 Combitherm Gas Parts List . . . . . . . . . . . .31-33 Wiring Diagrams . . . . . . . . . . . . . . . . . . . .34-36 Transportation & Damage Claims . . . .37 Limited Warranty . . . . . . . . . . . . . . . .37 COMBITHERM GAS INSTALLATION ® 1.1 RECEIVING & TRANSPORTATION Upon receipt of the Combitherm combination oven/ steamer, check the exterior of the shipping carton for any physical damage that could result in damage to the contents. If the oven was not received from the carrier in an upright position, there is a stronger possibility of concealed damage. Remove the carton or uncrate the unit carefully and inspect for any transit damage. Immediately report any damage to the delivering freight carrier. ® The oven must remain on the pallet while being moved to the installation site by fork lift or pallet lift truck. Note the dimensions required for doorways and aisles for access of the oven and pallet to the installation site.Transport the oven in an upright and level position only. Do not tilt the oven. ATTENTION ATTENTION With the oven on the original MODEL pallet, remove the carton and all 6•10MLGAS packaging materials. Open the oven door and remove all 10•10MLGAS documents and other materials 7•14MLGAS from the oven interior. Remove 10•20MLGAS the roll-in cart if so equipped. PA L L E T I Z E D D I M E N S I O N S WIDTH DEPTH HEIGHT W / PALLET 42" (1067mm) 35" (889mm) 42" (1067mm) 42" (1067mm) 35" (889mm) 48" (1219mm) 45" (1143mm) 51" (1295mm) 68" (1727mm) 51" (1295mm) 49" (1245mm) 65" (1651mm) 12•18MLGAS 51" (1295mm) 49" (1245mm) 65" (1651mm) 20•20MLGAS 58" (1473mm) 44" (1118mm) 85" (2159mm) 1.2 BASIC INSTALLATION SITE REQUIREMENTS H O O D I N S TA L L AT I O N I S R E Q U I R E D • Installation surface must be level. • Do not install adjacent to flammable surfaces. • Deep fat fryers or similar heat producing equipment must not be installed in the immediate vicinity of the hand shower. • The installation surface must be non-combustible (unable to burn). The oven must remain on the pallet while being moved to the installation site with fork lift or pallet lift truck. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 1 C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.3 VENTILATION REQUIREMENTS A steam ventilation hood is mandatory for the operation of the oven. The ventilation hood must be installed in accordance with local building codes for steam exhaust and must protrude 12-inches to 20-inches (300mm to 500mm) over the front side of the oven. A grease filter must be located in the protruding area of the hood. Grease filters should be thoroughly cleaned on a regular basis following manufacturer's instructions. Ventilation hoods must ensure an adequate amount of incoming air during operation and must be operated whenever the combination oven/steamer is used in order to avoid the accumulation of condensation in the hood area. See the section titled Gas Exhaust. 1.4 POSITIONING ON SITE Lift the oven from the pallet with a fork lift or pallet lift truck positioned at the front of the oven. For damage protection, the use of two wooden boards, placed between the bottom of the oven and the lifting forks, is strongly recommended. Stand the oven in a level position. Use the adjustable feet to overcome an uneven floor and ensure that the unit is level. It is strongly recommended that table top models be mounted on a factory supplied stand or a stand that is stable, open, level, and non-combustible. Recommended height is 23-inches (584mm). Adjust the height of floor models for smooth access of the trolley or cart. Ensure that the unit is level, right-to-left and back-to-front. When positioning the oven, observe the minimum space allocation requirements shown. OBSERVE ATTENTION LABEL ON OVEN FOR A R E A T O AV O I D WITH LIFTING FORK. To insure proper operation, the installation of this oven must be completed by qualified technicians in accordance with the instructions provided in this manual. Failure to follow the instructions provided may result in damage to the oven, building, or cause personal injury to personnel. MODEL NET WEIGHT 6•10MLGAS 377 lb (171 kg) 10•10MLGAS 490 lb (222 kg) 7•14MLGAS 528 lb (239 kg) 10•20MLGAS 573 lb (260 kg) 12•18MLGAS 666 lb (302 kg) 20•20MLGAS 838 lb (380 kg) 1.5 INSTALLATION CODES & STANDARDS The following codes and standards are required for installation of this oven: AIR SUPPLY, ELECTRICAL CONNECTIONS, WATER CONNECTIONS, GAS CONNECTIONS, GAS EXHAUST, AND WASTE WATER DISCHARGE. Installation must comply with local codes required for gas appliances. In the absence of local codes, installation must comply with the National Fuel Gas Code, ANSI Z223.1 (latest edition). In Canada, the appropriate code is the Natural Gas Installation Code, CAN/CGA-B149.1 or the Propane Installation Code, CAN/CGA-B. Adherence to code by a qualified installer is essential for the following: Gas Plumbing, Gas Appliance Installation, Commercial Cooking Ventilation, Water and Plumbing, and OSHA Regulations. The installation surface must be heat resistant and noncombustible (unable to burn). See your local codes or the National Fuel Gas Code for the definition of combustible and non-combustible construction. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 2 — 6011ML C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.6 INSTALLATION REQUIREMENTS The installation surface must be non-combustible (unable to burn). 4" (102mm) ➡ Do not install oven adjacent to flammable surfaces. Strictly observe all local fire safety regulations. ➡ In order to ensure proper ventilation, a minimum distance of at least 6-inches (152mm) must be kept from the control panel side [ LEFT ] of the oven and any adjoining surfaces. 18" (46cm) In addition to ventilation requirements, additional clearance is needed for service access. A minimum distance of 18-inches (457mm) is strongly recommended. If adequate service clearance is not provided, it will be necessary to disconnect the gas, water, and drain to move the oven with a fork lift for service access. Charges in connection with inadequate service access is not covered under warranty. ➡ Allow a minimum of 4-inches (102mm) from the right side of the oven to allow the door to open to at least a 90° angle. Fully opened, the door will extend up to a 225° angle. If the oven is furnished with the retractable door option, allow a minimum clearance of 6-1/2-inches (16cm). 4" (102mm) RETRACTABLE DOOR OPTION: 6-1/2" (165mm) 20" (50cm) MINIMUM 20" (50cm) ➡ Allow a minimum clearance of 4-inches (102mm) from the back of the oven for plumbing connections. ➡ Allow a 20-inch (50cm) clearance at the top of the oven for free air movement and for the steam vent(s) located at the top [ LEFT- REAR ]. ➡ Do not install the oven adjacent to heat producing equipment such as fryers, broilers, etc. Heat from such appliances may cause damage to the controls of the Combitherm. Minimum clearance recommended: 20-inches (50cm). Place the Combitherm oven on a stable, noncombustible L E V E L horizontal surface. For countertop models, the oven stand must be level. In addition, the overall height of the oven should be positioned so the operating controls and shelves may be conveniently reached from the front. A L L I N S TA L L AT I O N I N S T RU C T I O N S AND REQUIREMENTS MUST BE S T R I C T LY O B S E RV E D. IMPROPER CONNECTION OF THIS APPLIANCE NULLIFIES ALL WARRANTIES. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 3 C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.7 AIR SUPPLY REQUIREMENTS Installation of this oven must include a provision for an adequate flow of fresh air for gas combustion. This requirement must be observed by the installer as well as the operator. The bottom of the oven provides air supply access for gas combustion and must be kept clear at all times. O P E R ATO R C AU T I O N Make certain the area around the bottom of the oven is kept clear of obstructions to allow a continuous supply of fresh air for gas combustion. Make certain the oven installation maintains adequate air ventilation to provide cooling for electrical and gas components. The area around the oven should be clear of any obstructions which might retard the flow of cooling air. Failure to observe this caution may result in damage to the control components and will void the warranty. 1.8 ASSEMBLY REQUIREMENTS 1.8.1 EXHAUST GAS FLUE DIVERTER Install the diverter as shown on the drawing. Make certain the wire screen is in place before attaching with the screws provided with the diverter. 1.8.2 SOUND ABSORBER Screw the sound absorber on the threaded nipple located at the top of the oven on the back, lefthand side. 1.8.3 HAND SHOWER HOLDER Fasten the hand shower holder in the holes provided on the oven using the three (3) screws packaged with the holder. O P E R ATO R C AU T I O N Do not use circulating fans on the floor. Floor fans will cause the loss of pilot flame and will affect burner operation. Local and the National Fuel Gas Code provide rules for determining the amount of fresh air necessary for combustion and ventilation of commercial cooking appliances. The codes will help determine if additional outside air may be necessary to meet health and safety regulations. 1.8.4 DRIP TRAY Hang the drip tray at the front of the oven as indicated on the drawing. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 4 FRONT OF OVEN — 6011ML C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.8 ASSEMBLY REQUIREMENTS 1.8.5 ROLL-IN CART (TROLLEY) GUIDE RAILS ( ON CART EQUIPPED MODELS ) Mount REAR SUPPORT on the bottom of the oven toward the back. Fasten each end of the REAR SUPPORT with a WASHER , LOCK WASHER , and BOLT . Align each GUIDE RAIL with the slotted holes located at the front of the REAR SUPPORT . Loosely fasten each GUIDE RAIL from the back of the REAR SUPPORT with a WASHER , LOCK WASHER , and NUT . Do not tighten GUIDE RAIL fasteners. Attach the front end of each GUIDE RAIL to the oven base with a WASHER , LOCK WASHER , and BOLT . Push the roll-in cart (trolley) into the oven, center the cart right-to-left, and close the oven door. From the rear of the oven, slide both guide rails toward the center of the oven until they make contact with the roll-in cart. Lock the GUIDE RAILS into position by tightening both NUTS at the back of the REAR SUPPORT . At the front of the oven, make certain contact has been made between the oven and the cart along the total width of the oven to create a complete seal. When a full seal has been determined, recheck each connection to make certain it has been fully tightened. 1.9 ELECTRICAL CONNECTION Ensure the power supply matches the electrical specification located on the oven data plate. Gas models shipped within the United States and Canada are typically rated 110-120V, 60Hz, 1Ph and include an electrical cord. Fuses are located behind the left side panel. Installation of electrical connections and wiring must be made by a licensed electrical contractor. The oven must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 (latest edition). In Canada, electrical connections must comply with the Canadian Electrical Code, CSA C22.1. ACCESSING CONTROL AREA Access the electrical control system through the left side panel of the oven. MAKE CERTAIN TO DISCONNECT POWER AND ENSURE THE GAS SUPPLY IS SHUT OFF BEFORE REMOVING THE LEFT SIDE PANEL. An electrical diagram is affixed inside the left-hand side control area. A copy of the electrical diagram is also located at the back of this manual. Service or changes must be done by a licensed electrical contractor and in accordance with local codes and regulations. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 5 C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.10 WATER SUPPLY CONNECT TO POTABLE ( DRINKABLE ) COLD WATER ONLY WATER PRESSURE REQUIREMENTS: M I N I M U M 40 PSI (3 BAR) MAXIMUM 90 PSI (6 BAR) Flush the water line at the installation site before connecting the oven to the water supply. A shut-off valve and approved back-flow preventer must be installed when connecting the oven to the cold water intake. The water supply line must be a minimum of 3/4-inch (NPT) (19mm). A hose connector is supplied for flexible hose connection to the COLD water source. A water conditioning system is recommended if the water supply is between 6 and 8 grains of hardness. If water tests over 14 grains of hardness, the installation of a water softener is strongly recommended. THE MAIN WATER SUPPLY SHUT-OFF VALVE MUST BE IN THE OPEN POSITION WHEN THE OVEN IS BEING USED. PIPE SEALING TAPE ( TEFLON ®) MUST BE USED AT ALL CONNECTION POINTS. The use of a pipe sealing compound is not recommended. The hand shower spray hose is installed adjacent to the cold water intake connection. A ball valve is installed on the oven for hose connection to the COLD water source. Assemble the washer and the flexible hose on the ball valve and hang the spray handle on the holder previously installed on the oven. ELBOW 1.11 WATER DRAINAGE AVERAGE DRAIN WATER TEMPERATURE The oven must discharge through an indirect waste pipe by means of an air gap. The drain thread is 1-1/2-inch (38,1mm) NPT. A union is required. Install a 1-1/2-inch (38,1mm) diameter drain line. The drain line must always be a positive gradient away from the oven and not more than 12-inches (305mm) before an air gap. NOTE: In the U.S.A., this equipment is to be installed to comply with the Basic Plumbing Code of the Building Officials and Code Administrators International, Inc. [BOCA], and the Food Service Sanitation Manual of the Food & Drug Administration [FDA]. If several units are to be connected to one drain pipe, the dimensions of the pipe must be sufficient to allow an unobstructed water drain system. 149°F (65°C) NOTE: Install with the use of the elbow and washers provided with the gas Combitherm oven. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 6 — 6011ML C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.12 GAS CONNECTION REQUIREMENTS Installation of this oven must be completed by a qualified installer familiar with the local codes and regulations governing the installation of commercial gas appliances. Installation must be in accordance with local codes, and in the absence of local codes, with the National Fuel Gas Code ANSI Z223.1 (latest edition). In Canada, the appropriate code is the Natural Gas Installation Code, CAN/CGA-B149.1 or the Propane Installation Code, CAN/CGA-B. 1.13 GAS TYPE AND PRESSURE Check the oven nameplate information to determine if the oven was manufactured for use with natural or propane gas. Make certain the gas supply matches the nameplate information. Check the oven nameplate to determine the gas manifold pressure for the oven. The minimum supply pressure to the oven must exceed this value by at least 1" w.c. It is recommended that the supply pressure be between 5" w.c. and 14" w.c. for natural gas, and 11" w.c. and 14" w.c. for propane. An alternate gas supply inlet may be required for installation sites with elevations at 3,000 feet (914m) above sea level. Please check with the factory. Should conversion to the opposite fuel be desired, conversion parts must be ordered from the factory. Conversion must be completed by a qualified service Always remember to reflect the person only. conversion on the oven's nameplate. 1.14 GAS CONNECTION The minimum size requirement for gas piping or a flexible connector is 3/4 - inch (19mm). For long runs of gas piping, the pipe diameter must conform to the tables in the National Fuel Gas Code, ANSI/NFPA Z223.1. A listed gas shut-off valve must be installed upstream of the appliance to shut off the gas supply during servicing. The shut-off valve should be accessible with the appliance in the normal installation position. If the oven or the oven stand is supplied with casters, gas connection must be made with a flexible connector that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69; or in Canada, Connectors for Movable Gas Appliances, CAN/CGA-6.16-M87. When using a flexible connector, a quick disconnect device must be used to comply with the Standard for QuickDisconnect Devices for Gas Fuels, ANSI Z21.41; or in Canada, Quick Disconnect Devices for Use with Gas Fuels, CAN1-6.9. The other end of the cable should be permanently attached to the rear frame of the oven. The cable should be of sufficient length so that no strain is ever placed on the flexible gas connector in the event of accidental movement of the oven without properly disconnecting the gas connector. The flexible connector should be routed to form a downward "U" loop between the building gas supply and the permanent attachment at the rear of the oven. The routing of the flexible connector must not be made under the oven. Oven temperatures achieved during operation are too hot for safe operation. Gas piping should be installed from the point of gas connection at the bottom, front of the oven to the back of the oven where the flexible connector may be safely used. See the illustration for the recommended placement. When a quick disconnect device and flexible connector are used, a restraining device must be installed to limit the movement of the appliance and prevent damage to the connector or quick disconnect. An example of a restraining device would consist of a 2000 pound test, stainless steel cable, attached to a structural member of the kitchen wall behind the oven. The means of attachment should consist of a quick connect snap so that the oven can be disconnected when the appliance must be moved away from the wall. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L CAUTION OVERHEATING DANGER Gas piping must never be installed to run under the burner. — 6011ML PG. 7 C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.15 LEAK TESTING If a pressure leak test above 1/2 psi is to be performed on the building supply gas piping, the shut-off gas valve and oven inlet gas supply line must be disconnected from the building supply piping before conducting the pressure test. Failure to do so may result in damage to the manual gas valve, gas components in the oven, or both. If any gas leak tests are to be conducted at pressures equal to or below 1/2 psi, the manual gas shut-off valve upstream of the oven must be turned off before conducting the tests. Leak testing of the internal oven piping system was conducted before shipping the oven from the factory. If additional testing is needed, it should only be conducted at normal gas supply pressures. If the testing is performed using combustible gas in the piping, the leak checking should be done with a soap solution (bubble checking). The use of an electronic combustible gas leak detector is helpful, however, this type of detector can be oversensitive. Electronic detectors may indicate false leaks from other sources which would not be detected when checking with a liquid solution to verify a no-hazard gas connection. NEVER CHECK FOR LEAKS USING AN OPEN FLAME. When starting the oven after initial installation, the gas lines must be free of air. It may take up to 30 minutes to eliminate all air from the lines. If, after this time there is no pilot, call for factory assistance. 1.16 FUEL INTERLOCK SYSTEM Local codes may require the fuel supply to the oven be interlocked to the ventilation hood. If that is the case, a separate, electrically operated gas valve must be installed in the gas line. Valve selection is at the discretion of the installer, however, the valve must be recognized by the authority which has jurisdiction. 1.17 GAS EXHAUST The oven is not designed for direct connection to a chimney vent system or for direct connection to a horizontal exhaust system. The oven must be installed under a ventilation hood listed to ANSI/UL 705 (latest edition), and the installation must be c o m p l e t e d i n a c c o r d a n c e w i t h t h e A N S I / N F PA 9 6 - 1 9 8 7 , S t a n d a r d f o r Ve n t i l a t i o n C o n t r o l a n d F i r e P r o t e c t i o n o f Commercial Cooking Operations. The oven is supplied with a flue diverter which must be installed on the oven prior to installation. See Assembly Requirements toward the front of this manual. Oven operators should be instructed with regard to the hazards of placing any material on top of the oven that would obstruct the flow of flue products out the opening of the flue diverter. Operators should also be instructed with regard to the hazards of hot flue gases and that any material or items placed on top of, or in front of the flue defector could be damaged or cause a fire hazard. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 8 — 6011ML C O M B I T H E R M G A S I N S TA L L AT I O N ® 1 . 1 8 G A S P R E S S U R E C H A RT The gas valve, pilot burner and nozzles for the main burner have been fitted according to the gas type specified on the name plate. Technical specifications for the gas system are as follows: Combitherm Gas Model 6•10 7•14 10•10 7 in. W.C. 5 in. W.C. 14 in. W.C. — 220 3.5 in. W.C. 45 cu.ft/hr 45,500 Btu/hr 7 in. W.C. 5 in. W.C. 14 in. W.C. — 320 3.5 in. W.C. 81.9 cu.ft/hr 82,000 Btu/hr in. W.C. in. W.C. in. W.C. — 280 3.5 in. W.C. 67 cu.ft/hr 68,000 Btu/hr 11 in. W.C. 11 in. W.C. 14 in. W.C. 11 in. W.C. 11 in. W.C. 14 in. W.C. 11 11 14 — 135 10 in. W.C. 17.7 cu.ft/hr 45,500 Btu/hr — 190 10 in. W.C. 32.9 cu.ft/hr 82,000 Btu/hr — 170 10 in. W.C. 26.5 cu.ft/hr 68,000 Btu/hr 10•20 12•18 ML 20•20 Natural Gas Connected pressure rating Min. connected pressure Max. connected pressure Nozzle pilot burner Nozzle burner Manifold pressure Gas Consumption Gross thermal output 7 5 14 7 5 14 in. W.C. in. W.C. in. W.C. — 400 3.5 in. W.C. 112 cu.ft/hr 113,000 Btu/hr 7 5 14 in. W.C. in. W.C. in. W.C. — 400 3.5 in. W.C. 168.1 cu.ft/hr 170,000 Btu/hr Propane Gas Connected pressure rating Min. connected pressure Max. connected pressure Nozzle pilot burner Nozzle burner Manifold pressure Gas Consumption Gross thermal output in. W.C. in. W.C. in. W.C. 11 11 14 in. W.C. in. W.C. in. W.C. — 220 10 in. W.C. 44.1 cu.ft/hr 113,000 Btu/hr 11 11 14 in. W.C. in. W.C. in. W.C. — 220 10 in. W.C. 66.5 cu.ft/hr 170,000 Btu/hr 1.19 GAS FLAME PATTERNS When starting the oven after initial installation, the gas lines must be free of air. It may take up to 30 minutes to eliminate all air from the lines. If, after this time there is no pilot, call for factory assistance. After the installation is complete, the oven must be test fired to ensure that the system is operating properly. Follow the operating instructions located in the cooking guide furnished with the oven. Under most circumstances, initial operation will be the only installer check necessary. The flame pattern under both hot and cold conditions should be stable on all burner ports. There should be no lifting or blowing after 15 seconds of operation. Gas Combitherm ovens are not equipped with air shutter adjustment on the burners. If the flame pattern does not match correct pattern shown, contact the factory for further directions. Make certain the electric igniter lights the pilot burner quickly. The main burner should light within 4 seconds, without problems and should light smoothly with no harsh noise. When the oven is COLD, cycle the oven ON and OFF five times to verify proper operation. Allow the oven to heat for 5 minutes and repeat the process. Check the flame pattern on the burners. The flames should be blue in color with little or no yellow in the flame. Some yellow tipping is normal with propane gas models, however, there should be no indication any yellow tipping will produce soot on the combustion chamber walls, pilot, or main burner. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 9 C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.20 BURNER PILOT ADJUSTMENTS Combitherm gas ovens are equipped with intermittent pilotbased operation and are fitted with a Honeywell gas valve. The gas valve has a built-in pressure regulator and a hot surface intermittent pilot ignition control for safe operation. The valve has a step open feature (standard) for natural gas operation. For propane, a full open feature is standard. Explanation of the gas valve is shown in the illustration. NOTE: If this procedure is not clearly understood, DO NOT perform any changes. Call the factory for assistance. 1.20.1 CHECKING PRESSURE A. Turn gas connection OFF. Open gas inlet pressure connection cap and unscrew the tap. Connect pressure gauge at pressure tap. Read pressure. B. If pressure measured is higher or lower than that specified in the Pressure Table located in this manual, DO NOT PROCEED WITH INITIAL OPERATION . C. Remove pressure gauge, screw in the tap, and close with protective cap. 1.20.2 ADJUST PILOT BURNER The pilot burner assembly installed in the oven is tested prior to shipment and does not require any adjustment. If adjustment is desired, the following instructions are to be completed by a qualified technician only. A. Turn main power switch ON and switch the ignition control switch on the gas valve to the ON position. B. Set temperature and timer and press the START/STOP key. Follow oven operational instructions. C. The pilot flame should be lit and blue in color with very little or no yellow tipping. 1.20.3 MANIFOLD PRESSURE ADJUSTMENT The gas valve has a built-in pressure regulator and regulates the manifold pressure according to specifications presented in the Pressure Table in this manual. The valve requires no adjustment; however, if adjustment is desired, a qualified technician only should follow the instructions shown below. A. Turn power and gas supply OFF. B. Remove protective cap from outlet gas/manifold gas tap. Unscrew, connect pressure gauge. 1.20.4 IGNITION & BURNER CHECK After the installation is complete the oven needs to be test fired to ensure that the system is operating properly. Follow the operating instructions located in the cooking guide furnished with the oven. Under most circumstances, initial operation will be the only installer check necessary. The flame pattern under both hot and cold conditions should be stable on all burner ports. There should be no lifting or blowing after 15 seconds of operation. Gas Combitherm ovens are not equipped with air shutter adjustment on the burners. If the flame pattern does not match correct pattern shown, contact the factory for further directions. Make certain the electric igniter lights the pilot burner quickly. The main burner should light within 4 seconds, without problems and should light smoothly with no harsh noise. When the oven is COLD, cycle the oven ON and OFF five times to verify proper operation. Allow the oven to heat for 5 minutes and repeat the process. D. Select a program, set temperature and timer, and press the START/STOP key. Follow the oven operational instructions. Check the flame pattern on the burners. The flames should be blue in color with little or no yellow in the flame. Some yellow tipping is normal with propane gas models, however, there should be no indication any yellow tipping will produce soot on the combustion chamber walls, pilot, or main burner. E. The gas valve will open and the main burner flame should be established. 1.20.5 VERIFY SEQUENCE OF OPERATION C. Turn main power switch ON, and switch the ignition control switch on the gas valve to ON position. F. Measure manifold pressure. If it requires adjustment, open the cap on the pressure regulator and adjust the screw for increased or decreased gas pressure. DO NOT SET THE REGULATOR TO ANY OTHER SETTING OT H E R T H A N TO T H E DATA S P E C I F I E D I N T H E PRESSURE CHART IN THIS MANUAL. G. Turn the gas valve OFF or to the PILOT position. H. Close pressure regulator and manifold/outlet gas tap with protective caps. The Gas Combitherm is fitted with an intermittent pilot and a Honeywell gas valve, which provides automatic pilot ignition and main burner ignition. The ignition control system will routinely undergo three ignition trials (for pilot burner ignition) before identifying an ignition failure to timeout. The normal sequence of operation is illustrated on the following page of this manual. When starting the oven after initial installation, the gas lines must be free of air. It may take up to 30 minutes to do this. If, after this time there is no pilot, call for factory assistance. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 10 — 6011ML C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.21 SEQUENCE OF OPERATION Honeywell SmartValve ™ System Start Apply 24 VAC to Appliance Thermostat Calls for Heat Five Minute Retry Delay Flame Signal Detected! YES • Pilot Valve/Ignition Off • Wait for Flame Signal to Disappear NO NO Internal Check Okay? Trial for Ignition • Pilot Valve Opens • Igniter Powered Three Second Flame Failure Recycle Delay Pilot Lights and Flame is sensed during Trial for Ignition? YES Main Burner Operation NO • Pilot Valve Closes • Igniter Off YES • Main and Pilot Valves Close • EFT Output De-energizes 1 • Igniter Off • Main Valve Opens Electronic Fan Timer (EFT) Output Energizes Flame Signal Lost? NO Thermostat Call for Heat Ends Flame Lost More than Five Times in One Call for Heat? NO YES End • Main and Pilot Valves Close • EFT Output De-energizes 1 Igniter will turn off about 30 seconds into the trial for ignition if the pilot flame has not lit. It will turn back on for the final 30 seconds of the 90 second trial for ignition. The pilot valve will be energized during the entire trial for ignition. This is normal operation for this gas ignition system. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 11 C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.22 STACKING COMBITHERM CONNECTIONS Stacking Combitherm requirements: • Two (2) water supply connections • Two (2) water drain connections • Two (2) gas connections I F L O C A L C O D E A L L OW S , the gas, water, and drain may be manifolded as long as the size of the water inlet is increased to 1-inch (25,4mm) and the drains include an external vent. The drawing illustrates one suggested method of a manifold installation. 1" (25,4mm) UNION Intake 1" (25,4mm) 3/4" (19mm) UNION 15" (381mm) VENT GAS UNION Intake 1" (25,4mm) 3/4" (19mm) 1-1/4" (32mm) UNION WATER C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 12 DRAIN — 6011ML 1-1/2" (38mm) 1" (25,4mm) C O M B I T H E R M G A S I N S TA L L AT I O N ® 1.23 POST-INSTALLATION CHECK LIST In order for this oven to operate properly, installation must conform with the instructions provided in this manual. Following full installation the following list is provided as a final check to help assure conformance. INSTALLER REQUIREMENTS INITIALS / DATE ■ Bottom of oven has been checked for damage due to improper positioning on site. ■ Proper clearances have been allowed at the top of the oven and from all adjacent surfaces with allowance of free air access to all vents. ■ Clearance has been provided at the left of the oven for service access. ■ A minimum distance of 20-inches (1/2 meter) has been provided between the oven and any heat producing equipment such as fryers, broilers, etc. ■ The oven has been leveled on a stable surface. ■ The oven has been connected to COLD water on a single water connection. ■ Incoming water pressure is between a minimum of 40 PSI (3 BAR) and a maximum of 90 PSI (6 BAR). ■ A water conditioner is highly recommended, especially if the water grains of hardness is NOT within the range of pH5 and 9. Contact factory for assistance. ■ Installation of drain is at a minimum of 1-1/2" (38,1mm) with a positive descending slope. ■ 2" (51mm) air gap at drain is free of obstructions. INSTRUCTIONS TO OWNER/OPERATOR INITIALS / DATE ■ Owner/operator has been instructed on the importance of cleaning the oven along with ■ Owner/operator has been advised to use authorized Combitherm oven cleaner only. ■ Owner/operator has been informed of the safety warnings located in the operation guide proper cleaning procedures, and daily cleaning of the interior. including the warning not to handle pans containing liquid or semi liquid products positioned above eye level of the operator. Damage directly attributed to improper set up, installation, or cleaning can invalidate warranty claims. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011 PG. 13 1.24 E M E R G E N C Y O P E R AT I O N In the event of an error code, operation of the Combitherm can be continued on a limited basis for a short duration. Cooking times may be longer than normal operation and close monitoring of the cooking process is recommended. Contact an authorized service agency immediately if the problem cannot be rectified with simple steps in the troubleshooting guidelines located in this manual. Error conditions under which continued operation can be conducted are indicated by YES in the chart shown below. When the oven malfunctions, an error code will appear in the display. PRESS THE START/STOP KEY TO ACKNOWLEDGE THE ERROR. The keys for the usable operational modes will begin to flash and can be operated normally. SELECT AND PRESS ONE OF THE COOKING MODES INDICATED. The oven control will only respond to the oven mode keys flashing. SET THE OVEN CONTROLS AS IF OPERATING UNDER NORMAL CIRCUMSTANCES. Depending on the error code involved, oven function, such as temperature range, may be limited. PRESS THE START/STOP KEY TO BEGIN THE COOKING PROCESS. PRESS THE START/STOP KEY WHEN THE TIMER EXPIRES. WHEN THE OVEN FAULT IS CORRECTED, THE COMBITHERM WILL RETURN TO NORMAL OPERATION. ERROR DISPLAY MESSAGE GAS ELECTRIC CODE E01 Low water pressure YES YES 1 SUPERHEATED CONVECTION RETHERM DELTA - T MODE STEAM MODE MODE MODE MODE NO NO up to 356°F NO YES STEAM (180°C) E02 EL-temperature too high YES YES YES CONTROL COMPARTMENT TEMP E03 Fan Fault NO YES EL-fan fault Up to 284°F Up to 284°F Up to 284°F (140°C) (140°C) (140°C) (140°C) NO NO NO NO Up to 284°F Up to 284°F Up to 284°F Up to 284°F (140°C) (140°C) (140°C) (140°C) (100°C) BLOWER FAN E04 Up to 212°F Up to 284°F NO YES YES CONTROL COOLING FAN E05 Gas fault YES NO YES YES YES YES YES E15 Drain temperature YES YES NO NO Up to 356°F NO YES (180°C) HIGH DRAIN TEMP E21 Oven probe error NO YES CTC error E24 Bypass probe error TEMPERATURE PROBE NO NO NO NO (100°C) TEMPERATURE PROBE E22 212°F only YES YES YES YES YES YES YES NO YES Up to 210°F NO YES NO YES (99°C) E25 Drain probe error NO B3 YES YES PROBE 2 Up to 356°F 2 Up to 356°F 2 Up to 356°F (180°C) (180°C) (180°C) 2 2 YES E81 Program memory error YES YES YES YES YES YES YES E83 Algorithm error YES YES YES YES YES YES YES E89 12C error YES YES YES YES YES YES YES 1 Cooking time increases significantly. Food on the upper shelves is finished first 2 Water injection into the condenser is activated for the entire cooking mode (high water consumption). 3 When error codes E23 and E26 appear simultaneously, steam generator does not preheat. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 14 2 . 0 C O N T R O L PA N E L I D E N T I F I C AT I O N POWER ON/OFF KEY STEAM MODE KEY RETHERM MODE KEY CONVECTION MODE KEY PROGRAM INSTALL/EDIT KEY START / STOP KEY SUPERHEATED STEAM AND CONVECTION MODE KEY PROGRAMMED MENU KEY DELUXE MODELS ONLY DELUXE MODELS ONLY CHEF FUNCTION KEY FUNCTION & OPERATING INDICATORS COOKING TEMPERATURE KEY CONTROL PANEL DISPLAY CORE TEMPERATURE KEY UP ARROW KEY QUICK PROGRAM KEYS TIME KEY DOWN ARROW KEY ADJUSTMENT KNOB DELUXE MODELS ONLY MOISTURE VENT KEY ELECTRIC MODELS ONLY C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011 PG. 15 2 . 0 C O N T R O L PA N E L I D E N T I F I C AT I O N POWER ON/OFF KEY Activates power to the oven. STEAM MODE KEY The oven will operate in the steam mode at a temperature range of 86°F to 248°F (30°C to 120°C). • Automatic steaming at 212°F (100°C). FACTORY- SET DEFAULT . • Quick steaming between 213°F and 248°F (101°C and 120°C). • Low Temperature Steaming between 86°F and 211°F (30°C and 99°C). START/STOP KEY Initiates all cooking mode functions and programmed procedures stored in memory. Stops an activated cooking mode or programmed procedure currently in progress, and exits Chef function key. SUPERHEATED STEAM AND CONVECTION MODE KEY Selection key for the combination steam and convection cooking mode which can be set within a temperature range of 212°F to 482°F (100°C and 250°C). ADJUSTMENT KNOB Serves the same function as the up and down arrow keys to increase or decrease the displayed cook temperature , time , or core temperature . MOISTURE VENT KEY ELECTRIC MODELS ONLY Immediately vents steam and condensate from the oven compartment while cooking in the Convection mode or in the Superheated Steam and Convection mode . RETHERM MODE KEY Food rethermalization or reheating mode will operate with automatic steam injection at a temperature range of 248°F and 320°F (120°C and 160°C). CONVECTION MODE KEY Selection key for convection cooking without steam at a temperature range of 86°F to 482°F (30°C and 250°C). PROGRAM INSTALL AND EDIT KEY Used to create, change, duplicate, and delete programmed menus. DELUXE MODELS ONLY . FUNCTION & OPERATING INDICATORS PROGRAMMED MENU KEY Shows a list menu in display of all stored cooking programs and is also used to exit the list menu display. DELUXE MODELS ONLY . CHEF FUNCTION KEY Used to select programmed menu functions, various auxiliary functions, and several chef help instructions. COOKING TEMPERATURE KEY Used to set the required cooking temperature, to recall the set cooking temperature, or to check the actual oven temperature in conjunction with the down arrow key , the up arrow key or the adjustment knob . TIME KEY Used to set the required cooking time or recall the set cooking time in conjunction with the down arrow key , the up arrow key or the adjustment knob . DOWN ARROW KEY Used to decrease displayed cook temperature , time , or core temperature and as a scrolling key for programming functions. Reduced Power Key Lock Reduced Fan Speed Moisture Vent Confirmation of Oven Operation Peak Power Use Energy Protection CONTROL PANEL DISPLAY CORE TEMPERATURE KEY Used to set the required internal product temperature, to recall the internal product temperature set by the operator, or to display the current internal temperature of the product in conjunction with the down arrow key , the up arrow key or the adjustment knob . UP ARROW KEY Used to increase displayed cook temperature , time , or core temperature and as a scrolling key for programming functions. QUICK PROGRAM KEYS Immediate access to frequently used operator set programs including cooking modes, cleaning, and other oven functions. DELUXE MODELS ONLY . C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 16 2 . 1 I M P O R TA N T S A F E T Y P R E C A U T I O N S For safe release of the cooking compartment steam, initially open the door approximately 2" (50mm) only. Stand behind the door as the hot STEAM steam is released. DO NOT USE THE ATTACHED HAND-HELD HOSE TO SPRAY ANYTHING OTHER THAN THE INTERIOR OF THE COMBITHERM OVEN COMPARTMENT. AT NO TIME SHOULD THE EXTERIOR OF THE OVEN BE STEAM CLEANED, HOSED-DOWN WITH THE HAND-SPRAYER, FLOODED WITH WATER, OR FLOODED WITH LIQUID SOLUTION OF ANY KIND. DO NOT USE THE SPRAY HOSE IN A HOT COOKING COMPARTMENT. ALLOW THE OVEN TO COOL TO A MINIMUM OF 150°F (66°C). DO NOT USE HIGH PRESSURE WATER CLEANING METHODS ON THE INTERIOR OR EXTERIOR OF THE COMBITHERM OVEN. DO NOT HANDLE PANS CONTAINING LIQUID OR SEMI LIQUID PRODUCTS POSITIONED ABOVE EYE LEVEL OF THE OPERATOR. SUCH PRODUCTS CAN SCALD AND CAUSE SERIOUS INJURY. U S E A U T H O R I Z E D C O M B I T H E R M L I Q U I D O V E N C L E A N E R O N LY. UNAUTHORIZED CLEANING AGENTS MAY DISCOLOR OR HARM INTERIOR SURFACES OF THE OVEN. READ AND UNDERSTAND LABEL AND M AT E R I A L S A F E T Y D ATA S H E E T B E F O R E USING THE OVEN CLEANER. F O R O P E R AT O R S A F E T Y NOTE AND OBSERVE ALL SAFETY PRECAUTIONS LOCATED THROUGHOUT THIS MANUAL. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011 PG. 17 COMBITHERM CLEANING & MAINTENANCE ® 2.2 Preventive Maintenance In addition to the routine cleaning and maintenance procedures, there are several additional steps to be taken for both sanitation purposes and to keep the oven running at top operating efficiency. These additional safeguards will help prevent inconvenient down time and costly repairs. ● DO NOT DISPOSE OF GREASE, FAT, OR SOLID WASTE DOWN THE OVEN DRAIN. Fats and solids will eventually coagulate in the drain system, causing blockage. ● MAKE CERTAIN THE DRAIN SCREEN IS ALWAYS IN PLACE. REMOVE ANY SOLID WASTE MATERIAL FROM THE DRAIN SCREEN BEFORE IT ENTERS THE DRAIN SYSTEM. The routine removal of solids from the drain screen will help prevent blockage. ● USE THE AUTHORIZED COMBITHERM OVEN CLEANER ONLY. The use of unauthorized cleaning agents may discolor or harm the interior surfaces of the oven. ● TO PROLONG THE LIFE OF THE DOOR GASKET, REMOVE AND CLEAN THIS ITEM DAILY. The acids and related compounds found in fat, particularly chicken fat, will considerably weaken the composition of the gasket unless cleaned on a daily basis. ● TO ADDITIONALLY PROTECT GASKET LIFE, ALLOW OVEN DOOR TO REMAIN SLIGHTLY OPEN AT THE END OF THE PRODUCTION DAY. An open door will relieve the pressure on the door gasket. ● ROUTINELY CLEAN DOOR HINGES. Open oven door to relieve tension. Clean all parts of the hinge. 2.3 Routine Cleaning Requirements DAILY OVEN CLEANING To be performed at the end of each production day or between production shifts. M O N T H LY C L E A N I N G W AT E R I N TA K E F I LT E R DRAIN PIPE FLUE OUTLET FA N D A I LY G A S K E T C L E A N I N G It is important to prolong the life of the oven gasket by cleaning this item on a daily basis. Routine cleaning will help protect the composition of the gasket from deterioration caused by acidic foods. After allowing the oven to cool, remove pull-out gasket and wash in hot, soapy water. Do not place in the dishwasher. Always replace the gasket before cleaning the oven interior or operating the oven. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 18 COMBITHERM CLEANING & MAINTENANCE ® RUBBER GLOVES AND PROTECTIVE EYE WEAR MUST BE WORN WHEN USING THE OVEN CLEANER. USE AUTHORIZED COMBITHERM LIQUID OVEN CLEANER ONLY. Unauthorized cleaning agents may discolor or harm interior surfaces of the oven. Read and understand label and material safety data sheet before using the oven cleaner. Causes severe burns. Do not get in eyes, on skin, or on clothing. Do not wear contacts. Harmful or fatal if swallowed. Do not breathe mist. Use in well ventilated area. Keep out of reach of children. Do not use on aluminum. Do not mix with anything but water. THOROUGHLY RINSE EMPTY CONTAINER WITH WATER AND SAFELY DISCARD. 2 . 4 D A I LY O V E N C L E A N I N G D O N O T S P R AY C L E A N E R I N T O A H O T O V E N . ALLOW THE OVEN TO COOL TO 150°F (66°C). 2.4.1 The temperature in the display indicates the air temperature inside the oven compartment and not the interior walls of the oven. Always make certain to allow the oven walls to cool to a minimum of 150 ° F (60 ° C) before spraying the compartment with oven cleaner. cleaner. 1. Remove all food scraps and residue from the oven drain . 2. Wearing safety glasses and rubber gloves, remove the drain screen and spray Combitherm liquid oven cleaner directly into the drain pipe . Replace the drain screen. 3. GAS EXHAUST FLUE DIVERTER HIGH PRESSURE RELIEF PORT OVEN LIGHT FAN Generously spray the interior oven surfaces with an even coat of Combitherm Liquid Oven Cleaner. Spray all built-in components, shelves, side racks, and pans. FAN GUARD COVER PLATE OVEN DRAIN 4. Once a week, loosen the thumb screw(s) and swing Fan Guard Cover Plate toward the back of the oven. Spray the back of the Fan Guard Cover Plate, the oven fan, and the left-hand side of the oven. Close the swing out Cover Plate . Lock the cover into place and tighten thumb screw(s). 5. Insert the Combitherm Liquid Oven Cleaner spray nozzle directly into the High Pressure Relief Port and spray several times. 6. Securely close the oven door. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011 PG. 19 COMBITHERM CLEANING & MAINTENANCE ® 2.4.2 A U T O M AT I C C L E A N I N G P R O G R A M The Combitherm automatic cleaning function selects the proper temperature for each step of the cleaning process. With the oven power on: PRESS THE CHEF FUNCTION KEY. ➡ Rotate the adjustment knob until the clean symbol is highlighted in the display. PRESS THE CHEF FUNCTION KEY. ➡ Press the up Clean and down arrow keys or rotate the adjustment knob to select YES for the automatic cleaning function. PRESS THE CHEF FUNCTION KEY TO CONFIRM THE SETTING AND START THE CLEANING PROGRAM. THE OVEN WILL BEGIN A 20 MINUTE, 2-STEP CLEANING CYCLE. • 10 minutes at 86°F (30°C) to allow the cleaning agent to work • 10 minutes at full steam temperature of 212°F (100°C) to clean the oven FOR DELUXE OVENS WITH A PROGRAMMED MENU KEY FOLLOW STEPS 1 THROUGH 6 ON THE PRECEDING PAGE. With the oven power on: PRESS THE PROGRAMMED MENU KEY. ➡ Rotate the adjustment knob to program 250 = CLEAN. PRESS THE START KEY. DELUXE MODELS CAN ALSO BE CLEANED AS SHOWN IN THE PREVIOUS INSTRUCTIONS. 7. When the buzzer signals the end of the cleaning process, press the start/stop key deactivate the audible signal or open the oven door. 8. With the door open, use the hand held hose and direct a stream of water into the High Pressure Relief Port to rinse away oven cleaner residue. 9. Rinse the interior and all sprayed components with the hand-held hose. Make certain to thoroughly rinse all surfaces to remove any cleaning solution residue. Use a non-abrasive cleaning pad for any problem areas. 10. Loosen the thumb screw(s) and swing Fan Guard Cover Plate toward the back of the oven. Thoroughly rinse the back of the Fan Guard Cover Plate, the oven fan, and the left-hand side of the oven. Close the swing out Cover Plate . Lock the cover into place and tighten thumb screw(s). L E AV E D O O R S L I G H T LY O P E N A F T E R C L E A N I N G C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 20 — 6011ML to COMBITHERM CLEANING & MAINTENANCE ® 2.5 Monthly Cleaning — GAS Perform once a month in addition to the daily oven cleaning procedure. 2 . 5 . 1 W AT E R I N TA K E F I LT E R C L E A N I N G Monthly cleaning of the filter at the front of the water intake connection will prevent the water injection system from becoming blocked. 1. Press the oven power switch to the OFF position. 2. Disconnect the water intake connection located below the oven. 3. Remove the line filter and clean thoroughly. 4. Replace the line filter and reconnect the water. 5. Press the oven power switch to the ON position and check to make certain the water intake connection does not leak. 2.5.2 CLEANING THE DRAIN PIPE Fats and solids will eventually coagulate in the drain system, causing blockage. Consequently, water will back-up into the interior oven compartment, resulting in an oven that is inoperable. Monthly cleaning of the oven drain will prevent the drain from becoming blocked. ELBOW 1. Press the oven power switch to the OFF position. 2. Locate the drain outlet below the oven and remove the drain plug with a wrench. 3. Thoroughly dislodge and remove the accumulated deposits through the drain plug outlet or through the drain opening at the bottom of the oven interior. Rinse out the open drain with the hand-held hose. 4. Replace the drain plug and tighten securely with a wrench. 5. Press the oven power switch to the ON position and check to make certain the drain does not leak. 2.5.3 CLEANING THE FLUE OUTLET Inspect the flue diverter assembly located on the top of the oven on a monthly basis. Remove accumulated dirt and debris. KEEP THE OVEN EXHAUST OUTLET CLEAR OF ALL OBJECTS THAT COULD OBSTRUCT THE FLOW OF COMBUSTION GASES. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011 PG. 21 COMBITHERM CLEANING & MAINTENANCE Monthly Cleaning ® Thoroughly clean the fan at a minimum of once every six months. This procedure will remove the heavy build-up of grease which will accumulate on the oven fan. 2 . 5 . 4 FA N C L E A N I N G A Fan Service Tool is included with each Combitherm shipment. This tool must be used for both disassembling and reassembling the fan whenever a thorough cleaning is required. 1. Press the oven power switch to the OFF position. 2. Remove the oven shelves and side rack shelf supports. 3. Loosen the fasteners holding the fan guard door and swing the door to the fully open position. 4. While holding the fan wheel in place, insert the shaft attachment of the Fan Service Tool through the hole in the ball-shaped water diffuser and rotate counter-clockwise to completely remove the diffuser. 5. Loosen the two hexagon socket bolts located on either side of the central wheel hub with the allen-wrench attachment of the Fan Service Tool. 6. Insert the bolt attachment of the Fan Service Tool into the central wheel hub and turn clockwise until the wheel is completely disengaged from the mounting shaft. 7. Place the fan and the ball-shaped water diffuser in the bottom of the oven compartment. Wearing safety glasses and rubber gloves, spray these items, the walls of the heat exchanger compartment, the pipes and the back side of the fan-guard door with Combitherm liquid oven cleaner and let stand for approximately 5 minutes. 8. Thoroughly rinse all sprayed components with the hand-held hose to remove all detergent residue. 9. Dry the fan mounting shaft. Place the fan wheel on the mounting shaft and lightly tap into place. 10. Tighten the two hexagon socket bolts located on either side of the central wheel hub with the allen-wrench attachment of the Fan Service Tool. 11. Screw the ball-shaped water diffuser into the central wheel hub and firmly tighten by hand. 12. Attach the fan guard door with the four screws and replace the side rack shelf supports and the oven shelves. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 22 — 6011ML COMBITHERM CLEANING & MAINTENANCE ® 2 . 6 R O L L - I N C A RT / F O O D T R O L L E Y C L E A N I N G ( O N EQUIPPED MODELS ) 1. Move food trolley to a cart wash area. Trolleys may be cleaned using any mild cleaning detergent and warm water. 2. Hand wipe all framing, slides, drip pan, and base. Thoroughly clean debris from the casters. A spray hose can be used for easier cart cleaning. 3. Remove detergent solution with warm water. 4. Wipe or spray with a sanitizing solution designed for use on metal and vinyl food contact surfaces. 5. Allow trolley to air dry. As an alternative, trolleys can be sprayed with Combitherm liquid oven cleaner while inside the oven. Allow the trolley to remain in the oven through the normal cleaning cycle, followed by steps 2 through 5 above. 2 . 7 D A I LY G A S K E T C L E A N I N G It is important to prolong the life of the oven gasket by cleaning this item on a daily basis. Routine cleaning will help protect the composition of the gasket from deterioration caused by acidic foods. After allowing the oven to cool, remove pull-out gasket and wash in hot, soapy water. Do not place in the dishwasher. Always replace the gasket before cleaning the oven interior or operating the oven. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 23 3 . 0 C O M B I T H E R M G A S S E RV I C E S E C T I O N ® 3.1 COMBITHERM SERVICE Alto-Shaam urges the user to maintain a record of service performed on the Combitherm Gas Oven/Steamer. Model: ______________________ Serial No: ______________________ Gas Type: ______________________ D AT E PROBLEM DETECTED CORRECTION PERFORMED C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 24 — 6011ML C O M B I T H E R M G A S S E RV I C E S E C T I O N ® 3.2 COMBITHERM GAS Sound Absorber (EXHAUST SILENCER) 3.2.1 EXTERIOR COMPONENTS Food Probe 3.2.2 OPERATING SCHEMATIC Electrical Cord Door Latch Gas Valve Access Burner Tubes below Door Handle Cold water is used for generating steam and for cooling the drain water. The water is sprayed over the hottest area of the oven and is converted into steam. Steam is blown into the oven by means of a fan wheel. 3.2.3 PLUMBING SYSTEM C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 25 C O M B I T H E R M G A S S E RV I C E S E C T I O N ® 3.3 SERVICE VIEW: Left Side Panel Components Combitherm Gas Models 6•10ML, 7•14ML, 10•10ML, 10•20ML and 12•18ML Fuses Transformer Motor Capacitors Water Cooling Line Motor Contactor Motor Protection Switch Pressure Gauge Pressure Switch Terminals Fuse — Holder C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 26 — 6011ML Motor Water Nozzle C O M B I T H E R M G A S S E RV I C E S E C T I O N ® 3.3 SERVICE VIEW: Control, Bypass & Water Combitherm Gas Models 6•10ML, 7•14ML, 10•10ML, 10•20ML and 12•18ML BYPASS Cooling Fan Relay Board Bypass Probe Control Board (behind housing) Communication Cable Power Supply Board High Limit Closed System Board (behind housing) Water Solenoid Valve Water Pressure Regulator Water Inlet Gas Valve Shower Hose Attachment C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L Electrical Cord — 6011ML PG. 27 C O M B I T H E R M G A S S E RV I C E S E C T I O N ® 3.3 SERVICE VIEW: Grease Collection System (option) Combitherm Gas Models 7•14ML Front of unit Grease Drain C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L PG. 28 — 6011ML 3.4 TROUBLESHOOTING In the event of a Combitherm malfunction during operation, an error code and message will appear in the display to assist in finding a rapid solution to the problem. The following is a list of all error codes which includes the cause along with a possible solution. ERROR CODE DESCRIPTION OF ERROR POSSIBLE CAUSE/REMEDY E01 Low water. Water supply is off. Low water pressure. Filter in solenoid valve or water connection is clogged. Pressure regulator (located under the solenoid valve) needs to be increased to 40psi. Clockwise rotation increases pressure, counter-clockwise decreases pressure. Seal with acrylic nail polish. Water pressure switch is defective or clogged. E02 Excessive temperature in control service area: The error message will occur at a service area temperature of 176°F (80°C). Auxiliary fan is defective. Ventilation vents are blocked due to inefficient distance from wall at installation site. Minimum distance to equipment such as fryers, grills, kettles, etc. has not been maintained. E03 Convection Fan malfunction. Motor Protection trip circuit, F52 has been set too low. Set amp dial at a higher setting. Fuse, F10 is blown. Improper main power supply wire to unit is causing a high amp draw. Fan wheel is obstructed. Motor Protection Switch, F52 is defective. Fan Motor is defective. E04 Cooling Fan malfunction. Cooling fan is obstructed. Cooling fan is defective. E05 Gas or flame is not detected. Gas line is not connected. Air is present in the gas line. Pilot does not ignite. Pilot assembly is defective. Incoming power lines are reversed — L1 Black and L2 White. E11 Oven probe (N6 thermocouple) measures a temperature in excess of 572°F (300°C). Oven Temperature Probe, N6 is defective. Motor Protection Switch, F52 is tripped. E15 Drain probe (B3 thermocouple) measures a temperature in excess of 212°F (100°C). Water supply is off. Oven is connected to warm water supply. Inlet filter on solenoid valve is dirty. Solenoid valve or solenoid valve coil on Y2 is defective. Thermocouple B3 is defective. C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011 PG. 29 3.4 TROUBLESHOOTING ERROR CODE E21 DESCRIPTION OF ERROR Oven Temperature Probe N6. POSSIBLE CAUSE/REMEDY Oven Temperature Probe connection is bad at X6 on the control module. Oven Temperature Probe, N6 is defective. E22 Core Temperature Probe B10. Core Temperature Probe connection is bad at X6 on the control module. Core Temperature Probe, B10 is defective. E29 Probe short to ground. Check all thermocouple probes to ground. No ground should be present. E80 ID (identity) error. The electronic control cannot differentiate between gas or electric operation and disconnects all circuit connections. Contact problem on X3 connection. Bridge missing at X3, Gas pin 2 to 7. E81 Cooking procedure-programming error. Unit has been changed from Fahrenheit to Celsius. E82 WP error in cookbook. Preset program or cleaning program corrupt. The sequence must be deleted and reprogrammed. E83 E96 Non-compatible software between the display board and Press and hold the Chef function key while in the OFF mode relay board. and verify both the BM and SM software versions. Software and hardware error. Communication cable is lose between relay board and display board. Communications cable defective. 3.4.1 CONTROL RESET There is a remote possibility in the day-today operation of the Combitherm that the control could lock or freeze. If this occurs, the control is easy to reset. Press and hold the Power Key for a period of 5 seconds. Release the Power Key. The control will reset itself within approximately 15 seconds. WHEN RESET, THE DISPLAY WILL INDICATE THE TIME AND DATE AND THE CONTROLS WILL BE FULLY FUNCTIONAL . Alto-Shaam has established a twenty-four hour emergency service call center to offer immediate customer access to a local authorized service agency outside of standard business hours. The emergency service access is provided exclusively for Alto-Shaam equipment and is available throughout the United States through the use of Alto-Shaam's toll-free number. Emergency service access is available seven days a week including holidays . C O M B I T H E R M G A S I N S TA L L AT I O N A N D M A I N T E N A N C E M A N UA L — 6011ML PG. 30 TR ANS P O RTAT I O N DAMAGE and CLAIMS LIMITED WARRANTY All Alto-Shaam equipment is sold F.O.B. shipping point, and when accepted by the carrier, such shipments become the property of the consignee. Should damage occur in shipment, it is a matter between the carrier and the consignee. In such cases, the carrier is assumed to be responsible for the safe delivery of the merchandise, unless negligence can be established on the part of the shipper. 1. Make an immediate inspection while the equipment is still in the truck or immediately after it is moved to the receiving area. Do not wait until after the material is moved to a storage area. Alto-Shaam, Inc. warrants to the original purchaser that any original part that is found to be defective in material or workmanship will, at our option, subject to provisions hereinafter stated, be replaced with a new or rebuilt part. The labor warranty remains in effect one (1) year from installation or fifteen (15) months from the shipping date, whichever occurs first. The parts warranty remains in effect one (1) year from installation or fifteen (15) months from the shipping date, whichever occurs first. Exceptions to the one year part warranty period are as listed: A. Halo Heat cook/hold ovens include a five (5) year parts warranty on the heating element. Labor will be covered under the terms of the standard warranty period of one (1) year or fifteen (15) months. B. Alto-Shaam Quickchillers include a five (5) year parts warranty on the refrigeration compressor. Labor will be covered under the terms of the standard warranty period of one (1) year or fifteen (15) months. 2. Do not sign a delivery receipt or a freight bill until you have made a proper count and inspection of all merchandise received. This warranty does not apply to: 1. Calibration. 3. Note all damage to packages directly on the carrier ’s delivery receipt. 2. Replacement of light bulbs and/or the replacement of display case glass due to damage of any kind. 4. Make certain the driver signs this receipt. If he refuses to sign, make a notation of this refusal on the receipt. 3. Equipment damage caused by accident, shipping, improper installation or alteration. 4. Equipment used under conditions of abuse, misuse, carelessness or abnormal conditions. 5. Any losses or damage resulting from malfunction, including loss of product or consequential or incidental damages of any kind. 6. Equipment modified in any manner from original model, substitution of parts other than factory authorized parts, removal of any parts including legs, or addition of any parts. 5. If the driver refuses to allow inspection, write the following on the delivery receipt: Driver refuses to allow inspection of containers for visible damage. 6. Telephone the carrier ’s office immediately upon finding damage and request an inspection. Mail a written confirmation of the time, date, and the person called. 7. Save any packages and packing material for further inspection by the carrier. 8. Promptly file a written claim with the carrier and attach copies of all supporting paperwork. We will continue our policy of assisting our customers in collecting claims which have been properly filed and actively pursued. We cannot, however, file any damage claims for you, assume the responsibility of any claims, nor accept deductions in payment for such claims. This warranty is exclusive and is in lieu of all other warranties, expressed or implied, including the implied warranties of merchantability and fitness for purpose. In no event shall the Company be liable for loss of use, loss of revenue, or loss of product or profit, or for indirect or consequential damages. This warranty is in lieu of all other warranties expressed or implied and Alto-Shaam, Inc. neither assumes or authorizes any persons to assume for it any other obligation or liability in connection with Alto-Shaam equipment. A LTO - S H A A M , I N C . Wa r r a n t y e f f e c t i v e J a n u a r y 1 , 2 0 0 0 RECORD THE MODEL AND SERIAL NUMBER OF THE OVEN FOR EASY REFERENCE. ALWAYS REFER TO BOTH MODEL AND SERIAL NUMBER IN ANY CONTACT WITH ALTO-SHAAM REGARDING THE OVEN. Model Number: _____________________________________ Date Installed: _____________________________________ Voltage: ____________________________________________ Purchased From: ____________________________________ Serial Number: ______________________________________ ____________________________________________________ W164 N9221 Water Street PHONE: ● 262.251.3800 800.558.8744 P. O . B o x 4 5 0 FA X : U. S . A . / C A N A DA ● Menomonee Falls, Wisconsin 53052-0450 262.251.7067 ● 262.251.1907 I N T E R N AT I O N A L 800.329.8744 U. S . A . / C A N A DA ● U.S.A. WEBSITE: W W W. a l t o - s h a a m . c o m PRINTED IN U.S.A.
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