VERTICAL COOKING S.A.V. PRECISIO/ PRECIJET OVENS MAINTENANCE AND REPAIR 27/03/2012 PPS-3BEFM10PC
GENERAL Tools Every time this symbol appears, it is imperative to have the appropriate tool in order to ensure compliance and correct installation We accept no responsibility if you do not follow our recommendations Safety Under no circumstances should you access the technical compartment (right hand side panel) to change a component without having first isolated the electrical supply and turned off the gas We accept no responsibility if you do not follow our recommendations PPS-3BEFM10PC 2
PORTHOLE LIGHT FANS MOTORS ELEMENTS GAS BURNERS CAVITY VENT VALVE STEAM GENERATOR CLEANING SYSTEM 6 & 10 LEVEL DOORS 20 LEVEL DOOR DOOR ADJUSTMENT OTHER COMPONENTS RELAY CARD CONTROL PANEL PREVENTIVE MAINTENANCE TOOLS CONTENTS PPS-3BEFM10PC 3
PORTHOLE LIGHT Seal Open the oven door Remove the right hand runners, the cooking module or trolley Undo the 4 screws holding the stainless collar and lift it out with the glass and seal Separate the seal from the glass Glass Follow the same procedure Bulb Follow the same procedure up to the point of removing the seal Put gloves on This is a halogen bulb and must not come into contact with your fingers Remove and replace the bulb PPS-3BEFM10PC 4
FANS Fan Open the oven door Remove the cooking module or trolley Open (or lift out) the ventilation duct Protect the base of the oven cavity in case the fan impellor falls whist being removed Undo the screw holding the water injection pipe Remove the pipe (be aware of the O rings) Undo the screw holding the injection washer Remove the injection and flat washers Refit the injection washer retaining screw to avoid damaging the motors drive shaft thread Locate the medium puller With one hand hold the fan and puller with the other tighten the puller with an adjustable spanner until the fan is free. Remove the fan and the puller Medium puller Oven cavity protection Injection washer O rings PPS-3BEFM10PC 5
MOTOR Motor shaft seal Follow the same procedure to remove the fan Remove the motor shaft seal and it wear ring If replacing a shaft seal do not forget to replace the wear ring as well Lubricate the shaft with high temperature food standard grease such as BIOLUB Motor Same procedure as required to change a drive shaft seal Remove the right hand and rear oven panels Disconnect the motor electrically Undo the 4 fixing screws. When refitting torque to 14 Nm. For the top and central motors on a 20 level oven the boiler needs to be displaced Disconnect the boiler drain from the connection Tee Undo and remove the two boiler fixing screws Remove the motor Clean Boiler support Seal + ring PPS-3BEFM10PC 6
ELEMENTS Elements Remove the cooking module or trolley Open (or lift out) the ventilation duct Protect the base of the oven cavity in case the element falls or any tools are dropped Undo the bottom retaining screw then the top 3 screws Gently pull the element towards you Disconnect electrically using two flat spanners Remove the element and replace it, do not forget to ensure the new element is bridged in the same way as the original When refitting elements torque the fixing screws to: M4: 2.2 Nm / M5: 4 Nm / M6: 5 Nm We recommend that the seal is always changed when an element is changed and during the annual maintenance Element seal Follow the procedure for changing an element to the point it can be removed Remove the seal, fit a new one and refit the element Fixing screws Bridging example Seal PPS-3BEFM10PC 7
Filter Undo the 3 screws holding the grill in place Remove the grill Withdraw the filter We recommend that the filter is always changed if a fan is replaced and at least once per year GAS BURNER Grill Filter Ventilator (fan) Disconnect the fan electrically Remove the two supply cables Remove the fan Withdraw the burner cover Undo and remove the central screw and those on each side If the burner is fitted with a pressostat see the Pressostat paragraph Remove the cover Fan Cover Screws PPS-3BEFM10PC 8
GAS BURNER Undo the 4 screws that fix the fan onto the burner Withdraw the burner Don t forget to remove the filter housing to fit it to the new fan Flame control box(es) Disconnect the 3 electrode wires from the flame control box Undo the 2 fixing screws Screw holding cover to box (right hand one) Screw holding box to valve (left hand one) Lift the cover from the blue box Unhook the connector Withdraw the flame control box by lifting it upwards Fan Connector Screws PPS-3BEFM10PC 9
Gas valve(s) Remove the silicone tube from the gas valve Remove the flame control box Undo the screw fixing it to the valve (left hand screw under the box) Undo the gas valve exit nut and withdraw the copper tube Undo the 4 screws holding the gas entry elbow and withdraw it from the valve Remove the valve We recommend that the seals on the entry and exit from the valve are always changed if the valve is changed Remove the jet support from the gas valve Undo the jet support Change the seal Fit to the support and jet to the new valve GAS BURNER Gas elbow Jet Screw PPS-3BEFM10PC 10
GAS BURNER Electrodes Disconnect the 3 electrode wires from the flame control box Disconnect the silicone hose from the gas valve Cut the cable ties holding the electrode wires to the gas supply pipe work Undo the nut holding the supply pipe to the burner and disconnect the pipe Undo the 4 nuts and lock nuts holding the burner Withdraw the burner On the burner undo the electrode fixing screws Remove the electrode(s) The electrodes are shaped to make them easier to get out they can be dressed slightly if necessary. Electrode wires Gas burner Hose Electrode PPS-3BEFM10PC 11
GAS BURNER Refit the new electrode(s) exactly as they were Width: extremity at 13mm from the edge Height: extremity at 3mm from the burner crown Distance between them: 3mm minimum Crown / burner head crown Follow the procedure for changing electrodes up to the point of removing them. Undo the screws (1 on each side) Withdraw the crown and its head and change them. When refitting ensure each element is properly seated in the burner head. The crown should be inset by 1mm 13mm 3mm 1mm 3mm Crown PPS-3BEFM10PC 12
GAS BURNER Pressostat Electrical disconnection Disconnect the 3 supply cables Hydraulic disconnection Slide the pressostat silicone tube off Remove the pressostat Undo the screw fixing the support bracket to the burner cover Withdraw the pressostat with its bracket Unclip the pressostat from its support Pressostat PPS-3BEFM10PC 13
OVEN CAVITY Seal Pinch the seal along one edge and pull it towards you Unclip it from the whole surround and remove it The door closure must be readjusted if the door seal is changed (see slide on doors) Probe Electrical disconnection Unclip the connector Disconnect the two supply wires feeding the connector Remove the probe Lift the clips Remove the probe and its seal The probe seal must always be changed if the probe is replaced or checked. Clips Cavity seal Seal Probe wires PPS-3BEFM10PC 14
VENT VALVE Valve motor Disconnect the electrical supply to the motor Unscrew several turns the screw connecting the motor to the tie rod It is preferable not to remove the screw as it holds the tie rod in position Undo the 2 screws holding the motor to its support Withdraw the motor Valve seal Withdraw the valve Unclip the seal Remove the seal and replace it It is advisable to put a spot of mastic on the seal when putting it onto its support Connecting screw Seal Valve PPS-3BEFM10PC 15
STEAM GENERATOR Probe: Water level control Electrically disconnect the probe Undo the nut holding the supply cable Withdraw the nut, the washers and the cable Withdraw the probe Undo the probe Withdraw the probe When fitting a probe it must be glued in using Loctite 5331 Drain valve Check that the drain valve is in the CLOSED position This isn t vital. If not it will suffice to pivot the block top to bottom Disconnect the supply cables from the connector block Withdraw the drive unit: Undo the fixing screw Pivot the block towards the interior of the oven and withdraw it Probe All the way round PPS-3BEFM10PC 16 glue Electric block
STEAM GENERATOR Drain valve (cont) Removing the mechanical valve: If the electric drive unit is working we recommend that the boiler is drained before removing the valve (see SAV section of operating instructions) Remove (cut) the cable tie holding the hose in place Work the hose off the valve Unscrew the valve from the boiler exit Unscrew the smooth extension section from the valve When fitting a valve it must be glued at both ends using Loctite 5331 Immersion heater Before intervening on the element or the probe the boiler must be drained (see SAV section of operating instructions) If its the element and the probe refer to the probe section for its disconnection Smooth extension Valve PPS-3BEFM10PC 17
STEAM GENERATOR Immersion heater (cont) Disconnect the immersion heater element Depending on the model unclip or unscrew the nuts holding the supply cable ends in place Withdraw the cables (Note Label the cables) Withdraw the immersion heater element Undo the 3 fixing screws Withdraw the element and replace it with a new one. Do not forget to check the bridging is the same When refitting elements torque the fixing screws to: M4: 2.2 Nm / M5: 4 Nm / M6: 5 Nm We recommend that the seal is always changed when an element is removed or changed Element seal Follow the procedure for changing an element to the point it can be removed Remove the seal, fit a new one and refit the element Immersion element with probe Bridging bars PPS-3BEFM10PC 18 Seal
STEAM GENERATOR Temperature probe (Electric boiler) Electrically disconnect the probe Undo the probe to relay card connector Remove the cables from the connector Withdraw the probe Follow the procedure for changing an immersion heater element up to the point it is withdrawn Undo the hose clamp and slacken the probe cable gland Withdraw the probe with its seals and change them Probe seals must always be changed when a probe is changed or checked Locate the new probe on the element as per the guidelines. In the case of a 20 level oven do not for get to seat the probe as far in as possible (330mm) Stainless clamp Probe wires 400 mm 280 mm 330 mm 10 mm 10 mm Seals 6/10 level ovens 20 level ovens PPS-3BEFM10PC 19
STEAM GENERATOR Temperature probe (Gas boiler) Electrically disconnect the probe Undo the probe to relay card connector Remove the cables from the connector Withdraw the probe Unscrew and withdraw the probe The probe seal must always be changed when a probe is changed or checked Probe wires Seal PPS-3BEFM10PC 20
CLEANING SYSTEM Wash pump Electrical disconnection Disconnect the supply and earth wires from the pump Disconnect from the condenser Hydraulic disconnection Slacken the stainless hose clamp holding the hose in place Work the return hose off Withdraw the pump Undo the two screws and washers Pull the pump upwards and lift out with its seal The pump seal must always be changed when it is changed or checked Before refitting the new pump fit the stainless spacer recovered from the old pump and the new seal Earth cable end Screw Condenser Stainless spacer PPS-3BEFM10PC 21 Seal
CLEANING SYSTEM Descaler pump (Precisio) Electrical disconnection Disconnect the electrical supply to the pump Hydraulic disconnection Undo the two nuts on the entry and exit from the pump Work off the chemical hoses Attention: When removing the hoses be aware of chemicals remaining in them. Refer to the Maintenance manual for how to purge these hoses. Withdraw the pump Undo the two nuts Withdraw the pump When refitting a new pump in place of the old one be careful about its orientation, the distributor should be at the front Fixing nut Pump Supply to pump Outlet nut PPS-3BEFM10PC 22
CLEANING SYSTEM Detergent pump Electrical disconnection Disconnect the electrical supply to the pump Hydraulic disconnection Cut the two hose clamps Work off the chemical hoses Withdraw the pump Undo the two lock nuts Pull the pump towards you When refitting a new pump in place of the old one be careful about its orientation, the distributor should be to the right Connection Cable tie Distributor to the right PPS-3BEFM10PC 23
6 & 10 LEVEL DOORS Door closure system Removing the handle Undo the grub screw Pull the handle towards you Access to the closure system Open the inner door Undo the 3 Torx screws on the external edge of the door on the closure side Unscrew the 2 pan heads on the inside of the door + the 2 screws holding the top and bottom spring brackets, remove the brackets and cross bars Withdraw the closure system support Change the defective pieces Torx screw Pan head screw Grub screw Spring plate Closure system PPS-3BEFM10PC 24
6 & 10 LEVEL DOORS Door axis ring Withdraw the door ring by drifting it towards the interior Replace the ring Wear ring PPS-3BEFM10PC 25
20 LEVEL DOORS Door closure system Removing the handle Undo the two Allen screws Pull the handle towards you Note when refitting, the first screw is pointed the second flat faced Access to the closure system Undo the 6 Torx screws on the external edge of the door on the closure side Open the inner door Unscrew the 8 pan heads (6 on the inside of the door and 2 below) + the 2 screws holding the top spring brackets, remove the bracket and cross bar Withdraw the closure system support Change the defective pieces Torx screw Pan head screw Closure system Grub screws Spring plate PPS-3BEFM10PC 26
20 LEVEL DOORS Door axis ring Remove the pin with a pin punch Withdraw the wear ring and change it Door handle adjustment Adjustment is required when refitting the door handle if it is not in line with the axis of the door itself Undo the Allen screw holding the back of the door handle Position the handle in line with the door edge Move the screw to bring the back plate against the handle Retighten the Allen screw Axe Wear ring Back plate screw PPS-3BEFM10PC 27
DOOR ADJUSTMENT Adjusting the door Check that the oven cavity is level, if not refer to the Installation manual. Note: The entry heights are different for different models of oven Levelling the door right to left Slacken the three hinge fixing screws Place a spirit level on top of the door Adjust the door to level it Tighten the three screws To seal the door Open the right hand side panel Remove the cover and slacken the Allen screw holding the door axis Open the door Top hinge PPS-3BEFM10PC 28
DOOR ADJUSTMENT Remove the door catch and its packing spacer shim 20 level oven: 2 screws (grip the nuts that are inside the technical compartment) 6 or 10 level oven: 1 Allen screw Replace the spacer with a thicker one Refit the door catch For 20 level oven put the trolley inside Close the door Start the oven in steam mode Press gently on the hinge side to stop air escaping Tighten the Allen screw that holds the door axis Check for leaks If there are leaks repeat the procedure but with a thinner spacer shim until the door seals correctly Switch the oven to convection at 200 C Check the door opens and closed easily. 20 level oven 6 & 10 level oven Press gently PPS-3BEFM10PC 29
OTHER COMPONENTS Technical compartment fan Electrically disconnect the fan Cut the cable ties holding the supply cables in place Disconnect the two wires from the fan Remove the fan Undo the 4 fixing screws Remove the fan Condenser nozzle Remove (cut) the cable tie holding the hose Work the hose off the nozzle Unscrew the nozzle support from the condenser Unscrew the nozzle from its support Change the nozzle and its seal We recommend the seal is always changed if the nozzle is changed Nozzle support Nozzle Seal PPS-3BEFM10PC 30
OTHER COMPONENTS Klixon Disconnect the two supply cables Remove the klixon relay and its seal by unscrewing it from its support We recommend the seal is always changed if the klixon is changed Safety thermostat Electrically disconnect the thermostat Disconnect the two supply cables Remove the bulb Pull it towards you Remove the thermostat Undo the fixing screw Remove the thermostat and replace it When fitting the new bulb put a dab of mastic on the end of the sleeve Thermostat Bulb PPS-3BEFM10PC 31
RELAY CARD Relay card Electrically disconnect the relay card Card output connectors Card input connectors The RJ45 plug Remove the card Undo the two fixing screws Remove the card by pulling it towards the front of the oven Fuses Follow the procedure for changing the card up to the point of removal Remove the fuse or fuses and change them Input connector RJ45 plug Output connector Relay card Nuts PPS-3BEFM10PC 32
CONTROL PANEL Removing the facia Electrically disconnect the card Disconnect the RJ45 plug from the relay card Disconnect the wires from the core probe connector from the relay card Undo the fixing screw below the facia panel. On 20 level ovens open the door hatch Remove the facia Buzzer Undo the 3 fixing screws holding the facia card protection cover Open the cover Disconnect the buzzer from the facia card Unscrew the 2 lock nuts holding the buzzer (not fully tightened) Remove the buzzer and change it Note: when refitting the buzzer do not fully tighten the fixing screws, they need to be slightly loose for the buzzer to work properly Probe wires connector RJ45 plug Buzzer connection PPS-3BEFM10PC 33
CONTROL PANEL Removing the card Follow the procedure for changing the buzzer up to the point of removing it if the buzzer isn t supplied with the card Electrically disconnect the card The two supply cables from the stop start button The RJ45 plug The USB connection The coder connection Removing the card Undo the 4 nuts Remove the card and change it When the new card is fitted do not forget the braided anti-parasite connections to the two card locating studs Nuts Coder connection USB connection RJ45 plug Stop start cables Anti-parasite braiding PPS-3BEFM10PC 34
CONTROL PANEL Coder Disconnect the coder from the facia card (see removing the facia card) Carefully remove the black dial by pulling it vertically Undo the central screw Remove the coder and change it When refitting the dial position it gently and check that there is enough clearance to allow it to validate correctly. If it doesn t change the dial. Stop/Start button Electrically disconnect the button Unclip the contact Unscrew the button head Withdraw the assembly and change it Coder Nut Contact Button head 2 screws PPS-3BEFM10PC 35
PREVENTIVE MAINTENANCE The customer will be automatically informed when service is needed The service counter is calculated function of the frequency of the oven use and of the number of hours between 2 services. Theses values must be entered by the technician when installing the oven and must be verified after every maintenance operation Checking points : Every Every year 6 month Checking and cleaning of the vents (air intake grid + fan) x Visual check of leaks (leaks from hydraulic circuit) x Visual check of seals (door seal, oura, lighting porthole) x Checking of control, regulation and security actuators x Checking and cleaning of the condenser (injection nozzle and temperature sensor) x Cleaning of water inlet filter x Checking of gaz pressure x Checking the status of clamping screw terminals and contactors x Checking the cooking cavity x Checking the water hardness and adjustment of parameters x Checking the scaling of steam generator and parameters adjustment. x Forced descaling if needed Checking the status of chemical inlet hoses for cleaning and descaling product x Checking the status of the facia lexan (stick, tears,...) x Checking of water inlet electro valves (cf maintenance screen) x Systematic Replacement : Every Every year 6 month Motor shaft seal x Inlet hoses for cleaning and descaling product x Internal hose of peristaltic pumps for descaling product x Gas burner filter x PPS-3BEFM10PC 36
TOOLS Tools required: Spanners, adjustables Sockets set. Screwdrivers Pin punch Spirit level Latex gloves Medium puller Medium puller PPS-3BEFM10PC 37