SERIES: 700 / 900 S.A.V MAINTENANCE & AFTER SALES WORK PPS-3WE711911CH
GENERAL Tools Every time you se this symbol it is vital that you have the tool indicated to ensure correct and compliant work is undertaken We accept no responsibility if our recommendations are not followed Safety Under no circumstances should you access the technical compartment (front facia removed) to change components without first isolating the unit electrically and turning the gas off Again we accept no responsibility if our recommendations are not followed After any work undertaken on the Gas supply a drop test should be performed to ensure there are no leaks. PPS-3WE711911CH 2
GAS VALVE ELECTRIC IGNITION UNIT PILOT SUB ASSEMBLY BURNER JETS THERMOSTAT SELECTOR SWITCH RADIANT HOBS ELEMENTS INDUCTION ELECTRIC FRYERS GAS FRYERS PT 100 PROBE CHECKING GAS BOILING KETTLES CONTENT PPS-3WE711911CH 3
GAS VALVE Standard gas valve Remove gas control knob and open the front facia Undo the supply pipe to the burner using a 19mm spanner, clamp the valve to stop it turning Undo the brass nut connecting the thermocouple Undo the connection between the valve and the gas ramp (19mm spanner) and uncouple the valve from the ramp Change the valve Fit the old bypass to the new valve. Gas valve with pilot Follow the above procedure but before disconnecting the valve from the gas ramp undo the connection to the pilot Change the valve Fit the old bypass to the new valve. Brass nut Pilot connection nut Supply pipe connection Gas ramp PPS-3WE711911CH 4
GAS VALVE Thermostatic gas valve (gas oven) Follow the procedure for removing a gas valve with thermocouple up to the point of removing it from the gas ramp Undo the connection to the pilot (10mm spanner) Open the oven door. Remove the oven base plate and the right hand runners Remove the cavity seal in the top right hand corner Lift the thermostat bulb from its housing in on the right hand side of the oven cavity Remove the valve and change it Attention: when fitting the new valve ensure the end of the capillary protection sleeve passes through the cavity seal channel Fit the old bypass to the new valve. If this bypass does not correspond to the gas being used (see table of jets) it will lead to the destruction of the thermostatic element of this valve Seal Bulb wire Supply pipe connection Protective sleeve Thermostat bulb PPS-3WE711911CH 5
GAS VALVE Gas valve with solenoid (Plancha) Undo the 2 supply connections above the valve Undo the pilot connection nut (10mm spanner) Undo the brass nut connecting the thermocouple (9mm spanner) Undo the connection between the valve and the gas ramp (19mm spanner) and uncouple the valve from the ramp Remove the valve and change it Fit the old bypass to the new valve. Thermocouple connection Burner supply connections Pilot connection PPS-3WE711911CH 6
ELECTRIC IGNITION UNIT Electric ignition (Tops and units) Open the facia panel Unclip the ignition unit from its support Disconnect the electrode wires Disconnect the ignition unit electrically Change it Electric ignition (boiling kettles) Open the lower facia panel Disconnect the ignition electrode wires Disconnect the ignition unit electrically Undo the two screws holding the electrical box Pull the box 2 to 3cms way from the side panel Squeeze the ignitor clip to release it from its support Change the ignition unit Electrode wires Ignition unit Screws Supply terminals Ignitor clip PPS-3WE711911CH 7
ELECTRIC IGNITION UNIT Connecting electrodes to the ignition unit One can use an ignition module with more points than necessary to replace the actual one in situ It is important to connect to the 2 or 3 coil points Example: I need one point: connect the electrode to point 1 connect point 2 to earth. I need 3 points: connect the electrodes to points 3, 4 and 5 (coil 2) It is pointless to connect points 1 and 2. 4 1 5 3 2 1 3 2 4 PPS-3WE711911CH 8
PILOT SUB ASSEMBLY Open burners Thermocouple (without optional pilot) Undo the brass nut connecting the thermocouple to the gas valve (see gas valve chapter) Remove the open burner pan support Undo the two screws holding the thermocouple support Remove the thermocouple and its support from the open burner well Undo the thermocouple fixing nut and remove the thermocouple Note: when fitting the new thermocouple do not forget to fit the retaining washer Pilot sub assembly Remove the open burner pan support Remove the pilot cover Undo the two screws holding the thermocouple support Lift the assembly upwards Screws Thermocouple Screw Retaining washer Pilot cover PPS-3WE711911CH 9
PILOT SUB ASSEMBLY Undo the fixing nut of the defective part For the electrode: disconnect the wires (round terminal) and change the electrode The silicone sleeve must be refitted to avoid the risk of arcing For the thermocouple: disconnect the thermocouple from the gas valve (see gas valve chapter) and change the thermocouple For the pilot jet: undo the pilots brass back nut and change the jet Ignition electrode Thermocouple Gas jet Pilot PPS-3WE711911CH 10
PILOT SUB ASSEMBLY Solid top Pilot sub assembly Undo the nuts holding the thermocouple and pilot to the gas valve (see gas valve chapter) Remove the pilot 400 solid top: Undo the two fixing bolts 800 solid top: Remove the bulls eye and the left hand solid top plate. Undo the pilot fixing screw Remove the pilot assembly (pilot copper tube electrode..) Undo the fixing nut of the defective part For the electrode: disconnect the wires (round terminal) and change it The silicone sleeve must be refitted to avoid the risk of arcing For the thermocouple: change the thermocouple For the pilot jet: undo the pilots supply pipe brass back nut and change the jet 400 solid top 800 solid top PPS-3WE711911CH 11 Bolts Screw
PILOT SUB ASSEMBLY Plancha Pilot sub assembly Undo the nuts holding the thermocouple and pilot to the gas valve (see gas valve chapter) Remove the pilot Undo the pilot support bracket fixing bolt with a flat 8mm spanner Remove the pilot assembly (pilot copper tube electrode..) Undo the fixing nut of the defective part For the electrode: disconnect the wires (round terminal) and change it The silicone sleeve must be refitted to avoid the risk of arcing For the thermocouple: change the thermocouple For the pilot jet: undo the pilots supply pipe brass back nut and change the jet Bolt PPS-3WE711911CH 12
PILOT SUB ASSEMBLY Gas oven Pilot sub assembly Open the oven door Remove the ovenware (grill, containers) Remove the base and right hand runners Undo the fixing nut of the defective part For the electrode: disconnect the wires (round terminal) and change it The silicone sleeve must be refitted to avoid the risk of arcing For the thermocouple: undo the connection to the gas valve (see gas valve chapter) and change the thermocouple For the pilot jet: undo the pilots supply pipe brass back nut and change the jet The ignition electrode must be removed before undoing the pilot tube nut so as not to break the electrode Check the position of the pilot relative to the burner. Electrode PPS-3WE711911CH 13 Pilot Thermocouple
BURNER JET Open burner Open the units facia panel Undo the supply pipe to the burner (19mm spanner), clamp the valve to stop it turning Remove the pin from the air adjuster Remove the assembly parallel to the venturi Undo the jet from its holder (13mm spanner) Remove the jet and change it Gas oven Open the oven door Remove any ovenware Remove the base Remove the pin from the air adjuster Remove the jet holder assembly from the venturi Undo the jet from its holder (13mm spanner) Remove the jet and change it R pin R pin Jet + jet holder PPS-3WE711911CH 14
THERMOSTAT Plancha Open the units facia panel Removing the thermostat from the facia Disconnect the electrical terminals Steel plate: Separate the thermostat from the switch by spreading the arms of the coupling Chrome plate: Remove the control knob Undo the two fixing bolts Withdrawing the thermostat bulb Remove the collection drawer Undo the 2 or 4 bolts (depending on the model) holding the protection plate and remove it There is a hole below the plate through which the capillary passes Disengage the capillary from the front and withdraw the bulb Change the thermostat When fitting a new thermostat pay attention to the radius of any bends in the capillary Terminals PPS-3WE711911CH 15 Bolts Coupling
THERMOSTAT Solid top / Radiant hob Open the units facia panel Removing the thermostat from the facia Disconnect the thermostats electrical supply terminals Remove the control knob Undo the two thermostat fixing screws Withdrawing the thermostat bulb Undo the two bolts holding the cross members under the hobs, the assembly drops down towards the front and is then pull it towards the front Prise the small tab to free the bulb Extract the bulb from its ceramic support: Attention its fragile Change the thermostat When refitting the hob supporting bars ensure they are located in the 2 rear slots Tab Bolts Screws Ceramic support Slots PPS-3WE711911CH 16
SELECTOR SWITCH Electric rings Remove the control knob Open the units facia panel Undo the two screws holding the switch Disconnect the electrical cabling from the switch Change the switch Screws PPS-3WE711911CH 17
RADIANT HOBS Solid top / Radiant hobs Open the facia panel Disconnect the defective hobs wires from the thermostat Follow the procedure for extracting a thermostat bulb in the procedure for changing a thermostat Lift the hob from its support and change the hob Electric rings Open the facia panel Undo nut under the cross member holding the defective ring Remove the plate from above the unit Disconnect the ring electrically Change the ring Nut Cabling PPS-3WE711911CH 18
ELEMENTS Plancha Open the facia panel Undo the two bolts holding the element support Withdraw the element support Disconnect the defective element(s) Change it or them The element support chassis is fixed at the front by two setscrews and fits into two slots at the rear. Bolts Vis Cabling PPS-3WE711911CH 19
INDUCTION Control Open the facia panel Undo the two screws on the label side of the facia Unplug the connectors Rear control on Control C Front control on Control B Change the component Generator Open the facia panel Undo the 2 bolts holding the generator Lift the assembly (to miss the caged nut on a table top unit) and pull the generator forward to get to the connections Disconnect the control, power and sensor wires Balance the generator on the front to disconnect the supply to the rear Change the generator Control Bolts Vis Control B Poti Lamps rt + gn + PwrMgmt + Control C Poti Lamps rt + gn + Power connection, Sensor control PwrMgmt + PPS-3WE711911CH 20
ELECTRIC FRYERS The potentiometer Open the facia panel Remove the control knob Unclip the potentiometer (prise the coupling apart) from the switch Remover the potentiometer from the coupling Disconnect the potentiometer wires from the control card Change the potentiometer taking care to fit the new one the right way round. ( Wires on the side the coupling fixes to) When connecting the potentiometer to the card the wires should face towards the relay card Screws Connection Coupling Potentiometer PPS-3WE711911CH 21
ELECTRIC FRYERS Control card Before changing the control card check the fuse is OK if not change the fuse Open the technical box cover (see access to technical components) Disconnect the 2 probe wires, the potentiometer and the two input and output wires Lift the card out Unclip the 4 stud clips Tip: Use 4-6mm copper pipe for the stud clips Change the card Note: The new card needs to be programmed to suit the type of fryer Energy: Gas or electric fryers Models: 140-180 or 80-180 C Fuse Probe wires Potentiometer wires Gas Electric 140-180 C 80-180 C PPS-3WE711911CH 22
Contactor Open the facia panel Undo the various contacts on the faulty unit Unclip the faulty contactor Look where the 2 holes are in the base of the contactor Push the contactor to unclip it Change the contactor Switch S4 Remove the cover of the element housing by undoing the 4 fixings (4 screws) Remove the switch Disconnect the switch electrically Undo the two fixing screws from the side of the housing Change the switch Isolate the white wire (normally closed contact) ELECTRIC FRYERS Contacts Screws PPS-3WE711911CH 23 Hole Switch Connection
Probe Open the facia panel Disconnect the 2 wires from the control card Lift the lid off the element housing. To do this undo the 4 fixing screws Cut the probe cable but leave it in place (this can be used to draw the new probes cable from its housing to the control card) Remove the probe Undo the split nut Undo the screw on the clamp that holds the point of the probe in place Change the probe Pass the wires through the cable gland Tighten the end in the clamp The end of the probe should protrude 10mm beyond the clamp ELECTRIC FRYERS Split nut Wires 10mm Probe wire to be cut Screws Vis Probe PPS-3WE711911CH 24
ELECTRIC FRYERS Attach the new probes wires to the old probes wires that were left in situ Draw the new wire through to the front of the unit This operation allows the probe wires to be drawn across the enclose and the top of the unit so they can be connected to the control card Note: when connecting the probe it is not polarised Wires Control card PPS-3WE711911CH 25
GAS FRYERS Access to the technical compartment Open the door Remove the protective cover Remove the drain valve handle (M10 nut) Undo and remove the 4 panhead screws Remove the cover Remove the technical box lid Undo and remove the 4 screws Potentiometer Remove the knob and open the facia panel Unclip the potentiometer (by opening the coupling) from the switch Unclip the potentiometer from the coupling Open the technical compartment cover (see access to the technical compartment) Disconnect the potentiometer wires from the control card Change the potentiometer taking care to fit the new one the right way round. ( Wires on the side the coupling fixes to) When connecting the potentiometer to the card the wires should face towards the relay card Handle Screws Vis Screws Connection Box lid Screws Vis Coupling Potentiometer PPS-3WE711911CH 26
GAS FRYERS Control probe Open the technical box cover (see access to the technical compartment) Disconnect the two wires from the control card Open the facia panel Remove the clip holding the insulation support plate in place Remove the plate and the insulation Remove the probe Holding the probe inside the tank Undo the external nut Withdraw the probe through the interior of the tank Change the probe We recommend that the seal is changed whenever a probe is changed Attention: The seal is inside the tank in the oil Probe Nut Tank exterior Wires Retaining clip Insulation support plate Seal Tank interior PPS-3WE711911CH 27
GAS FRYERS Control card Before changing the control card check the fuse is OK if not change the fuse Open the technical box cover (see access to technical components) Disconnect the 2 probe wires, the potentiometer and the two input and output wires Lift the card out Unclip the 4 stud clips Tip: Use 4-6mm copper pipe for the stud clips Change the card Note: The new card needs to be programmed to suit the type of fryer Energy: Gas or electric fryers Models: 140-180 or 80-180 C Fuse Probe wires Potentiometer wires Gas Electric 140-180 C 80-180 C PPS-3WE711911CH 28
GAS FRYERS Flame control box A2 (All models) Remove the protective cover (see access to the technical compartment Undo and remove the centre screw Withdraw the box from its support Unclip the box cover Disconnect the ignition and flame control electrode Disconnect the flat connector Change the box We recommend that the seal between the base of the valve and the box is changed whenever either item is replaced Fit the new box Attention: do not power up the fryer without tightening the blue box fixing screw, if you don t even the smallest movement could cause its failure Electrode wire Seal Control box Screw Flat connector PPS-3WE711911CH 29
GAS FRYERS Gas solenoid (standard fryers) Follow the procedure for removing the flame control box and take it out Undo the 3 part connection supplying gas to the solenoid Undo the two nuts holding the burner assembly and pull it forward to gain access to the flange connecting the solenoid Undo the four flange fixing screws Undo the pilot pipe coupling Remove the solenoid Adjust the new solenoid Remove the black blanking plug Turn the screw in the direction of «+» until you hear a click Fit the new solenoid We recommend changing the seals between the inlet and outlet of the solenoid and between the flame control box whenever a solenoid is changed. Connection Blanking plug Ecrou Nuts Pilot connection Screw Screws Vis PPS-3WE711911CH 30
GAS FRYERS Ignition and flame control electrode (standard fryer) Open the flame control box lid (see procedure for changing the box) Disconnect the ignition and flame control electrode Slacken the 3 piece connection on the solenoid gas supply pipe Undo the two nuts holding the burner assembly and pull it forward to gain access to the electrode Undo the fixing nut Remove the electrode and change it Attention: do not forget to refit the sleeve to the new electrode. This electrode serves two purposes, ignition (20kV) and flame control. It is imperative that it is sleeved in 9mm silicone tube to prevent any electromagnetic perturbations. Electrode connector Sleeve Connection Electrode Nut Ecrou Nuts PPS-3WE711911CH 31
PT 100 PROBE CHECK PT 100 probe components Temperature sensor comprises a resistance sensor with the value of 100 ohms for a temperature of 0 and 138.5 ohms for a temperature of 100 C. The variation of the resistance to temperature relationship is linear. The resistance reading is directly proportional to the measured temperature. The sensor is not polarised. The sensor can be extended using copper wire. PT100 How to read the table To find the resistance that corresponds to a temperature of 164 C. Find the intersection of the 160 C line and the 4 C column. The reading is thus 162.53 Ohms PPS-3WE711911CH 32
PT 100 PROBE CHECK Table Temperature in C relative to Resistance in Ω for PT100 sensor Correspondance Température en C Résistance en Ω pour Sonde PT100 C 0 1 2 3 4 5 6 7 8 9 0 100.00 100.39 100.78 101.17 101.56 101.95 102.34 102.73 103.12 103.51 10 103.90 104.29 104.68 105.07 105.46 105.85 106.24 106.63 107.02 107.4 20 107.79 108.18 108.57 108.96 109.35 109.73 110.12 110.51 110.90 111.28 30 111.67 112.06 112.45 112.83 113.22 113.61 113.99 114.38 114.77 115.15 40 115.54 115.93 116.31 116.70 117.08 117.47 117.85 118.24 118.62 119.01 50 119.40 119.78 120.16 120.55 120.93 121.32 121.70 122.09 122.47 122.86 60 123.24 123.62 124.01 124.39 124.77 125.16 125.54 125.92 126.31 126.69 70 127.07 127.45 127.84 128.22 128.60 128.98 129.37 129.75 130.13 130.51 80 130.89 131.27 131.66 132.04 132.42 132.80 133.18 133.56 133.94 134.32 90 134.70 135.08 135.46 135.84 136.22 136.60 136.98 137.36 137.74 138.12 100 138.50 138.88 139.26 139.64 140.02 140.39 140.77 141.15 141.53 141.91 110 142.29 142.66 143.04 143.42 143.80 144.17 144.55 144.93 145.31 145.68 120 146.06 146.44 146.81 147.19 147.57 147.94 148.32 148.70 149.07 149.45 130 149.82 150.20 150.57 150.95 151.33 151.70 152.08 152.45 152.83 153.20 140 153.58 153.95 154.32 154.70 155.07 155.45 155.82 156.19 156.57 156.94 150 157.31 157.69 158.06 158.43 158.81 159.18 159.55 159.93 160.30 160.67 160 161.04 161.42 161.79 162.16 162.53 162.90 163.27 163.65 164.02 164.39 170 164.76 165.13 165.50 165.87 166.24 166.61 166.98 167.35 167.72 168.09 180 168.46 168.83 169.20 169.57 169.94 170.31 170.68 171.05 171.42 171.79 190 172.16 172.53 172.90 173.26 173.63 174.00 174.37 174.74 175.10 175.47 200 175.84 176.21 176.57 176.94 177.31 177.68 178.04 178.41 178.78 179.14 210 179.51 179.88 180.24 180.61 180.97 181.34 181.71 182.07 182.44 182.80 220 183.17 183.53 183.90 184.26 184.63 184.99 185.36 185.72 186.09 186.45 PPS-3WE711911CH 33
PT 100 PROBE CHECK Check With an ohm meter set to 200 ohms the resistance of the probe (less than 107 ohms for 20 degrees). Check the probe insulation between one of the wires and the metal part with the meter set to 20 mega ohms (value over 10 mega ohms). Check the continuity between the armoured casing and the metallic part of the sensor. PT100 Ω mω PPS-3WE711911CH 34
GAS BOILING KETTLES Access to technical components Opening the control facia Remove the knob from the gas control Unscrew the two screws under the facia Withdraw the facia Note: There are lugs on the lower section allowing the facia panel to be clipped in the open position. Opening the lower facia panel Unscrew the two screws under the facia Withdraw the facia Pilot thermocouple On bain marie boiling kettles: before changing the thermocouple check that its connection with the water level control card is working by bridging the two output contacts. Open the control facia Undo the brass thermocouple connection to the gas valve (9mm spanner) Gas knob Connection Screws Vis Screws Vis PPS-3WE711911CH 35
Undo the brass thermocouple connection to the pilot light Change the thermocouple Note: There is a spacer in the pilot assembly to position the thermocouple in the pilot flame check it s present Note: the thermocouple circuit passes through the water level control card to ensure the safety of the unit. Ignition electrode Open the lower facia panel Undo the electrode connection to the pilot Disconnect the electrode cable Change the electrode It is vital that the silicone sleeve is refitted to avoid a short. Note: If the electrode is working but the gas doesn t light, check its position. The point of the electrode must be in the opposite corner of the pilot flame. The electric arc should be between the point of the electrode and the upper corner of the pilot. PPS-3WE711911CH GAS BOILING KETTLES Electrode Position of the electrode Thermocouple nut Silicone sleeve 36
GAS BOILING KETTLES Burners and components Open the lower facia panel Undo the burner gas supply connection Undo the pilot gas supply connection Undo the brass thermocouple connection to the pilot light (see paragraph pilot thermocouple) Withdraw the thermocouple from the pilot Undo the two burner fixing nuts (on top of the burner) Pull the burner towards you Change the burner or one of its components (air ring, jet.). Pilot connection Burner connection Ecrous Nuts Burner Air ring PPS-3WE711911CH Pilot Jet 37
GAS BOILING KETTLES Water level control; and safety card Open both the control and lower facia panels Only on 150 litre boiling kettles Undo the gas connection to the burner Undo the screw holding the incoming electrical connections and allow it to hang below the unit Disconnect the 2 wires (black & white) connecting to the back of the gas valve Undo the 2 screws holding the electrical box Pull the box forward Disconnect the electrical wires from the card and reconnect to the new card Note: do not forget to refit the resistor between terminals 7 and 8 on the new card. Gas connection Hatch screw Bolts Vis 2 wires PPS-3WE711911CH 38
GAS BOILING KETTLES Unclip the card from its support (4 clips) Note: use a piece of copper pipe 4 to 6mm Ø to unclip the card Change the card Clips Resistor Safety valve (indirect heating) Ensure the well is cool and not under pressure Remove the small right hand flue vent Unscrew the valve Note: 23mm hexagonal pipe spanner is required Reference 86-23, supplier SAM. It is vital the spanner fits over both hexagonal sections of the valve to avoid damaging it Change the valve PPS-3WE711911CH Flue vent Valve Hexagonal Parties hexagonales sections 39