OPTIMUM / ADVANCIA S.A.V. MAINTENANCE & AFTER SALES WORK PPS-3BE711911CH
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 that there are no leaks. PPS-3BE711911CH 2
CONTENTS 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 THERMOCOUPLE J PROBE CHECKING GAS BOILING KETTLES ADVANCIA PLUS BRATT PAN ADVANCIA PLUS BOILING KETTLES PPS-3BE711911CH 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-3BE711911CH 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 thermostats bulb from its housing 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-3BE711911CH 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-3BE711911CH 6
ELECTRIC IGNITION UNIT Electric ignition unit Open the facia panel Unclip the ignition unit from its support Disconnect the electrode wires Disconnect the ignition unit electrically Change it Reconnect the supply cables. 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 igniter clip to release it from its support Change the ignition unit Electrode wires Ignition unit Screws Supply terminals Igniter clip PPS-3BE711911CH 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 4 2 3 PPS-3BE711911CH 8
PILOT SUB ASSEMBLY OPEN BURNERS (Optimum & Advancia) 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-3BE711911CH 9
PILOT SUB ASSEMBLY Undo the defective parts fixing nut. 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-3BE711911CH 10
PILOT SUB ASSEMBLY OPEN BURNER (Advancia plus) Pilot sub assembly Remove the open burner pan support Remove the pilot cover Slacken the fixing bolt without removing it (8mm spanner) Slide the cover forward to get it off 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 The ignition electrode must be removed before undoing the pilot tube nut so as not to break the electrode Electrode Thermocouple Pilot cover Bolt PPS-3BE711911CH 11
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 defective parts fixing nut 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 Bolts Screw PPS-3BE711911CH 12
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 defective parts fixing nut 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-3BE711911CH 13
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 defective parts fixing nut 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 Pilot Thermocouple PPS-3BE711911CH 14
BURNER JET OPEN BURNERS 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-3BE711911CH 15
THERMOSTAT PLANCHA (Optimum / Advancia) 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-3BE711911CH 16 Bolts Coupling
THERMOSTAT PLANCHA (Advancia Plus) 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 nuts on each side of the plate Tighten the central bolt (17mm spanner) to raise the plate to its high position Remove the bulb by pulling it towards the front Change the thermostat Push the end of the bulb into its location using a small screwdriver Lower the plate to its original position Keep an eye on the capillary whilst lowering the plate to ensure it isn t crushed. On a gas unit ensure it passes through the cut out in the combustion chamber Terminals Screws Plate lifting bolt PPS-3BE711911CH 17 Bulb Vis Nuts Cut out
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 Screw Screw Ceramic support Slots PPS-3BE711911CH 18
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-3BE711911CH 19
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 it 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-3BE711911CH 20
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 bolts and fits into two slots at the rear. Bolts Vis Cabling PPS-3BE711911CH 21
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 or A and B or A and C (depending on model) Front control on Control B or B and D or C and D (depending on model) 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 PPS-3BE711911CH 22 Poti Lamps rt + gn + PwrMgmt + Control C Poti Lamps rt + gn + Power connection, Sensor control PwrMgmt +
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 Vis Connection Coupling Potentiometer PPS-3BE711911CH 23
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-3BE711911CH 24
ELECTRIC FRYERS 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 (2 screws + 2 bolts) 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) Contacts Screws Bolts PPS-3BE711911CH 25 Hole Switch Connection
ELECTRIC FRYERS 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 Split nut Wires 5 to 10mm Probe wire to be cut Screws Vis Probe PPS-3BE711911CH 26
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-3BE711911CH 27
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 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 Vis Connection Box lid Screws Vis Coupling Potentiometer PPS-3BE711911CH 28
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-3BE711911CH 29
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-3BE711911CH 30
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-3BE711911CH 31
GAS FRYERS Flame control box A3 Only on high performance fryers Remove the protective cover (see access to the technical compartment Unclip the transparent protective film Follow the same procedure and recommendations as for the A2 flame control box Relay card Only on high performance fryers Remove the A3 flame control box as per the procedure above Disconnect the card connectors Undo the two screws holding it to its support Change the card Attention: do not forget to refit the transparent film. It serves two functions: protecting the card from liquid ingress and it is an electrical insulator. Control box A2 Card Control box A3 Transparent film Connectors Screws Vis PPS-3BE711911CH 32
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-3BE711911CH 33
GAS FRYERS Gas solenoid (high performance fryer) Follow the procedure for removing the flame control box and remove it Undo the 3 part connection from the solenoid Undo the pilot pipe coupling Undo the four flange fixing screws 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 3 part connection Flange Pilot connection Screws Vis Screws Vis Blanking plug Screw PPS-3BE711911CH 34
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 screws 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 Ecrou Nuts Electrode Nut PPS-3BE711911CH 35
GAS FRYERS Ignition and flame control electrode (high performance fryer) The fryer has 2 electrodes, one for each burner Open the flame control box lid for the defective electrode (see procedure for changing the box) Disconnect the ignition and flame control electrode Open the lid of the technical box (see access to the technical compartment Remove the technical box Undo the 4 screws (2 on each side) Rest the box on the floor Remove the copper pipe feeding the pilots Undo the connection to the gas valve Undo the two connections to the pilots Electrode connector Screws Pilot pipe PPS-3BE711911CH 36
GAS FRYERS Remove the pipe supplying the burners Undo the connection to the gas valve Undo the 2 connections to the burners Remove the protective screen and insulation from the burners Undo the 3 fixing nuts Pull the burner forward to gain access to the faulty electrode Undo the screw, nut and washer holding the electrode Withdraw 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. Sleeve Burner Ecrous Nuts Burner pipe Electrode Screw PPS-3BE711911CH 37
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-3BE711911CH 38
Table PT 100 PROBE CHECK Correspondance Temperature in Température C relative to en Resistance C Résistance in Ωen for Ω pour PT100 Sonde sensor 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-3BE711911CH 39
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-3BE711911CH 40
J THERMOCOUPLE PROBE CHECK J Thermocouple probe components FER 99.9% CONSTANTAN Cu55 Ni45 Temperature probes consist of two metals. They deliver a constant voltage that is a function of the difference in temperature between the two ends of the sensor, 0 mv for a difference of 0 degrees and 5.27 mv for a difference of 100 degrees. Measuring the voltage doesn t directly give us the temperature. The sensor is polarised be careful when connecting it. The same is true for any extension cable. Corresponding Temperature in C for Voltage in mv for J Thermocouple C 0 10 20 30 40 50 60 70 80 90 0 0 0.51 1.02 1.54 2.06 2.58 3.11 3.65 4.19 4.72 100 5.27 5.81 6.36 6.91 7.46 8.01 8.56 9.11 9.67 10.22 200 10.78 11.33 11.89 12.44 13.00 13.55 14.11 14.66 15.22 15.77 How to read the chart: So to find the voltage corresponding to a temperature of 140 C. Take the intersection of the 100 C line and the 40 C column. Giving a reading of 7.46 mv. PPS-3BE711911CH 41
J THERMOCOUPLE PROBE CHECK Check J - Ω mv mω Checking: the resistance of the probe with a multi meter set to 200ohms (less than 20 ohms). the voltage on the probe terminals on a 200mV direct current setting. (Cold probe 0 mv, probe in a lighter flame at least 30mv) the insulation between each wire and the metal or armoured section with an ohmmeter calibrated at 20 mega ohms (value should be over 15 mega ohms). for continuity between the armoured section and the metallic part of the sensor. Determining the polarity of the sensor If the labelling is missing proceed as follows to determine the polarity. PPS-3BE711911CH 42
J THERMOCOUPLE PROBE CHECK 1) use a magnet The magnetic wire is the + wire. 2) use a multi meter Starting with a cold thermocouple connect a digital multi meter (set to 200mV d.c.) heat the probe. If the display is positive the wire is connected to COM on the multi meter. If the display starts negative the + wire is connected to COM. 3) using the digital display With a cold thermocouple read the value displayed, heat the thermocouple and check that the reading increases, if it does not reverse the connections, if it does it is wired correctly. PPS-3BE711911CH 43
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. - the water level probe is working. Open the control facia Undo the brass thermocouple connection to the gas valve (9mm spanner) Gas knob Connection Screws Vis Screws Vis PPS-3BE711911CH 44
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 any risk of arcing. 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-3BE711911CH GAS BOILING KETTLES Electrode Position of the electrode Thermocouple nut Silicone sleeve 45
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-3BE711911CH Pilot Jet 46
GAS BOILING KETTLE Simmerstat (bain marie 110/150 litres) Open the control facia Disconnect the electrical supply to the simmerstat Remove the control knob Unscrew the two fixing screws Change the simmerstat It is imperative that the two metal pieces are refitted to the front of the simmerstat. If not the time taken to light and extinguish the burner will not comply with European regulations. Gas solenoid (bain marie 110/150 litres) A functioning solenoid coil has a resistance value of around 1k Ohm. Open the control facia Undo the connector screw and remove it Unscrew the coil retaining screw and remove the coil Undo the piston The gas solenoid is supplied with a piston, the complete assembly must be changed. The brass block is permanently fixed to the gas valve. Simmerstat connections Coil screw Piston Pièces Pieces Connector screw PPS-3BE711911CH 47
GAS BOILING KETTLES Change the solenoid Note: the screw holding the piston in position should only be moderately tightened. Water level control; and safety card Open both the control & 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. PPS-3BE711911CH 2 wires Gas connection Hatch screw Bolts Vis 48
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 and the protection tube 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 and and the plastic metal seal PPS-3BE711911CH Flue vent Protection tube Valve Hexagonal Parties sections hexago 49
ADVANCIA PLUS BRATT PAN Access to technical components Lid Baskets Basket lift bar Left facia Lower left facia - Water solenoid - Volumetric doser - Basket lift ram Well facia - Elements - Gas burner, pilot - J thermocouple probe,.. Right control facia Lower right arm facia panel - Technical boxes - Tilt ram - Ram supply box PPS-3BE711911CH 50
ADVANCIA PLUS BRATT PAN Open the control facia Undo the 2 screws under the facia and remove it Note: On the lower edge there are tabs allowing the panel to be clipped into the facia whilst open. Open the lower facia panels Undo the 2 screws under the facia Remove the facia Cantilevered units: undo the hatch under the arm Undo the 2 screws underneath at the front Pull the hatch towards you to disengage the 2 tabs at the rear Free standing units: remove the right hand panel If the bratt pan is fixed to another unit on the right it must be pulled out, unless the flexible connections are long enough the services (water, gas and electrics) will need to be disconnected Opening the well facia Undo the 4 screws under the front edge Undo 2 screws below the facia Remove the facia tilting it to disengage the upper fold Control facia Lower facias Screws Screws Screws Vis PPS-3BE711911CH 51
ADVANCIA PLUS BRATT PAN Facia card Open the control facia Disconnect the ribbon cable connecting the facia and relay cards Put the facia on a flat surface to remove the card Undo the 4 nuts holding the cover Unscrew the studs supporting the card Remove the facia card Configure the new cards switches Switch TF or TC TF: Temperature in Fahrenheit TC: Temperature in Celsius Switch EL or GA EL: Electric GA: Gas Switch 5 or 8 Always in position 5 Refit the new facia card Note: There is a foam seal between the facia and the protective cover check it is in good condition and replace it if necessary. Cover Ecrous Nuts Open side of cover faces downwards Switches PPS-3BE711911CH 52
ADVANCIA PLUS BRATT PAN Relay card Open the lower facia and pull the technical drawer towards you Disconnect the ribbon cable between the facia and relay cards Disconnect all the cards connections Note: all the connectors are foolproof so cannot be reconnected incorrectly Remove the card Unclip from the 4 plastic pins Advice: Use a 4-6mm copper pipe on the clips Change the card Remove the Prom from the old relay card and fit it to the new one Lift the Prom gently from both edges using two screwdrivers if you do not have an specific clamp If changing the Prom fit it to the new relay card Check before fitting it that the two notches (one on the card the other on the Prom) are aligned. Connector Connectors Connecteur Relay Card Colonnettes Plastic pins Prom Notches PPS-3BE711911CH 53
ADVANCIA PLUS BRATT PAN Additional gas card Open the lower facia and pull the technical drawer towards you Disconnect each wire one by one and reconnect them onto the new card as you go Advice: to avoid pulling the wires out use a screwdriver to lift the connector shields Remove the card Unclip from the 4 plastic pins Advice: Use a 4-6mm copper pipe on the clips Change the card Fit the new card Relay Well tilt (electric bratt pan), heat (gas bratt pan), basket lift. Open the lower facia and pull the technical drawer towards you Undo the screw holding the relay Disconnect the defective relay and connect up the new one at the same time Put the new relay in place Relay Shields Electric bratt pan Connector shields Additional gas card Colonnettes Plastic pins Screw Gas bratt pan Relay PPS-3BE711911CH 54
HORIZONTAL COOKING ADVANCIA PLUS BRATT PAN Jack plug Ram supply box The well tilt ram supply box This box is fixed to the inside of the top part of the right arm Open the lower facia and pull the technical drawer towards you Disconnect the supply wires to the box from the terminals in the technical drawer Disconnect the two jack plugs Remove the ram supply box Undo the fixing screw Pull the box to the left Change the box Basket lift ram box The box is at the back of the right hand side Follow the same procedure as for the well tilt ram supply box Pull the box to the left PPS-3BE711911CH Ram wires Jack plug Well tilt ram enclosure Screw Basket lift ram enclosure Screw 55
ADVANCIA PLUS BRATT PAN Elements (electric bratt pans) Lower the well to the normal heating position Open the well facia (See access to technical components) Undo the front screws on the connection box Slacken the electric cable gland Tilt the well into the drain position Isolate the electrical supply Undo the other connection box fixing screws Pull the box downwards Disconnect the defective element(s) Change the element(s) Remove the element locators Disengage the enclosure with its insulation Unscrew the M8 blind nuts Undo the nuts holding the retaining comb in place to free the defective elements When replacing it grease the studs holding the comb in place with high temperature grease Connection box Elements Screws Vis Cable gland Comb PPS-3BE711911CH 56 Nut
ADVANCIA PLUS BRATT PAN Burner and its components (gas bratt pan) Remove the gas ramp Lower the well to the normal heating position Switch off the electrical supply Open the well facia (See access to technical components) Undo the 2 screws holding the gas ramp Undo the supply connection to the gas ramp Lift the gas ramp out You have access to the gas jets Pilot Undo the gas supply connection to the pilot Unscrew the two pilot support fixing screws Lift out the pilot and its support Ramp Connector Screw Ramp Connector Screws Vis Pilot support PPS-3BE711911CH 57
ADVANCIA PLUS BRATT PAN Ignition electrode Follow the procedure for removing the pilot Undo the electrode connection from the pilot Disconnect the electrode wire (round coupling) Change the electrode It is imperative that the silicone sleeve be refitted to avoid arcing. Gas burner Follow the procedure for removing the pilot Undo the nuts on the front burner cover. Remove the cover Attention: Do not damage/strain the probe wires. Undo the left and right hand burner fixing screws Remove the burner downwards and pull it towards you. Silicone sleeve Probe wires Nuts Electrode Front burner cover Screw PPS-3BE711911CH 58
ADVANCIA PLUS BRATT PAN J thermocouple probe Before changing a probe check which one of the two is defective, see the procedure for checking a J thermocouple. Follow either the procedure for accessing the elements for an electric bratt pan or for the gas burner for a gas unit Disconnect the two probes from the relay card terminals. Once the defective probe is identified attach the wires of the new probe to those of the old one Pull the probe wire through the underside of the bratt pan This operation allows the probe wire to pass through the axis of rotation and into the technical box for connection to the control card Probe wires PPS-3BE711911CH 59
ADVANCIA PLUS BRATT PAN Remove the probe Undo the nut holding the guide support and remove the guide Undo the two nuts holding the probes protective cover and remove the cover and probe flange Remove the defective probe Fit the new probe This probe should not be damaged or scratched it is a jacketed J thermocouple which is relatively fragile Put contact grease into the hole where the new probe is to be located. Slide the point of the probe into the hole and bend it slightly to be sure that the end is all the way in When refitting the protective cover this should press slightly on the curvature of the probe Gas bratt pan Electric bratt pan Guide support Protective cover Guide support PPS-3BE711911CH 60
ADVANCIA PLUS BRATT PAN Well tilt ram Open the control facia panel (2 screws below panel) and lift it off Disconnect the ribbon cable between the relay and facia card Open the lower facia panel (2 screws underneath it) Cantilevered unit: remove the hatch under the arm Undo the two front screws Pull the hatch forward to disengage the rear lugs Free standing units: remove the right side If the bratt pan is fixed to another unit on its right the bratt pan will have to be pulled out. This means disconnecting services (water gas and electricity) unless the flexibles are long enough Pull the technical drawer towards you and lift it out Disconnect the jack plug from the rams transformer Technical drawer Façade Control de commande facia Façade Lower inférieure facia Jack plug PPS-3BE711911CH 61
ADVANCIA PLUS BRATT PAN Remove the technical drawers top runner Undo the front screw Unhook the runner from the rear panel This runner needs to be removed to free up enough space to remove the tilt ram Undo the pressure screw which adjusts the ram operational movement Undo the two lock nuts holding the head of the ram (17mm spanner) Remove the M10 nut holding the dowel peg Remove the dowel peg, the base of the ram is disengaged Lift the ram assembly out Screw Pressure screw Lock nuts Runner Dowel peg M10 nut PPS-3BE711911CH 62
ADVANCIA PLUS BRATT PAN Strip the ram down, the stainless head and the heat cut off switch with its bracket Refit the switch and its bracket to the new ram Extend the new rams arm completely Fix the switch and its bracket to the plastic part of the arm Move the arm back in The stainless section and the second part (plastic) need to go in the switch will locate itself Check that the switch is working Check with an ohm meter that the contact is closed between the black and the white wires (arm retracted) Fit the stainless head to the new ram using the dowel peg Head of ram Stainless dowel Head of ram Switch Dowel and circlip PPS-3BE711911CH 63
ADVANCIA PLUS BRATT PAN Refit the ram to the bratt pan but do not tighten the two lock nuts Reconnect the transformer jack plug Level the well by adjusting the pressure screw (tightening: the back of the well sinks, slackening: the rear rises) See the procedure for adjustment / leveling the well in the maintenance manual Refit the technical drawers top runner Reconnect the ribbon cable between the relay and facia cards Switch the power back on Tilt the well and check the well is level and that the power cut off switch works Tighten the two lock nuts Pressure screw Lock nuts PPS-3BE711911CH 64
ADVANCIA PLUS BRATT PAN Basket lift ram (optional) Remove the baskets and the basket lift bar Open the left hand facia Open the lower facia on the left arm Tilt the well into the draining position Isolate the services electric, gas and water Disconnect the supply cables to the ram Remove the access hatch located inside the chassis of the bratt pan Undo the two fixing screws Lift the hatch cover then move it towards the chassis interior Undo the nut holding the rams pin and remove the pin, the base of the ram is disengaged Undo the nut holding the pin at the other end of the ram and remove the pin, the ram is now free PPS-3BE711911CH 65 Ram Nut Supply cables Pin View through the hatch Nut Hatch View from the facia
ADVANCIA PLUS BRATT PAN Remove the ram assembly Fit the new ram to the unit Connect the supply cables Refit the hatch cover Switch the power back on Tilt the well back to horizontal Fit the basket lift bar. Hook at least one basket onto the bar Lower the basket into the well (bar fully down) Switch off with the bar still lowered Isolate all the services Slacken the 2 nuts holding the housing to the support Slacken the lock nut on the headless adjustment screw Use this screw to adjust the position of the basket lift bar (approximately 5mm below the baskets hook with the basket resting in the well) Retighten the lock nut Retighten the 2 housing fixing screws Lift bar Housing fixing nuts Adjustment screw 5 mm PPS-3BE711911CH 66
ADVANCIA PLUS BOILING KETTLES Access to technical components Lid Rear tank panel - Pressure valve - Water level probe - Lid reed switch - Volumetric water doser Left hand arm facia Right hand facia or controls Left hand lower facia - Water solenoid - Non return valve Front tank panel - Immersion heater - PT 100 probe - Water gauge Right hand lower facia - Technical box (relay card) - Tilt ram - Frequency inverter PPS-3BE711911CH 67
ADVANCIA PLUS BOILING KETTLES Open the control facia Undo the two screws under the facia Remove the facia panel Note: There are lugs at low level to locate the facia in the open position Open the lower facia panels Undo the two screws under the facia Remove the facia panel Note: The procedure for removing the facia panels is the same for right or left hand panels Free standing units: remove the right side If the boiling kettle is fixed to another unit on its right the boiling kettle will have to be pulled out. This means disconnecting services (water gas and electricity) unless the flexibles are long enough Remove the tanks front panel Undo the 4 screws underneath Remove the panel by pulling it downwards Screws Vis Screws Vis Tank front panel Screws Vis PPS-3BE711911CH 68
ADVANCIA PLUS BOILING KETTLES Opening the tank s rear panel Open the lid Tilt the tank into the drain position Remove the tank base panel Undo the fixing screws» 2 on each side» 2 on the rear Remove the panel Undo the rear panel fixing screws 1 on each side Remove the panel by pulling it towards the rear Screw Rear panel Screws Vis Screws Vis Tank base panel PPS-3BE711911CH 69
ADVANCIA PLUS BOILING KETTLES Draining the double jacket Remove the tank s base panel Follow the procedure for removing the rear panel up until the base is removed Tilt the tank back to the horizontal position Using a screwdriver open the quarter turn valve Attention: the double jacket should be cold during this operation Wait until the double jacket is empty Close the drain valve Drain valve pipe Valve PPS-3BE711911CH 70
ADVANCIA PLUS BOILING KETTLES Facia card Open the control facia panel Unclip the supply connector from the facia card Place the facia on a flat surface to remove the facia card Undo the 2 nuts holding the angle bracket. Remove the bracket Undo the 6 holding the cover and card onto the facia panel. Attention: do not loose the flat washers when removing the nuts Remove the facia card and its cover Refit the new facia card and cover assembly Note: there is a foam seal on the protective cover check it is good condition. Connector Foam seal Ecrous Nuts Angle bracket Ecrous Nuts Facia card PPS-3BE711911CH 71
ADVANCIA PLUS BOILING KETTLES Relay card Before changing this card check that the fuse hasn t blown, if it has replace it. Open the lower panel on the right hand arm and pull the technical drawer out Undo the 4 screws holding the card and its support onto the technical enclosure Remove the card and support assembly Unclip all the connectors from the relay card Note: all the connectors are fool proof so cannot be reconnected incorrectly Remove the card from its support Undo the 4 fixing screws Attention: do not loose the relay cards locating sleeves Technical drawer Relay card Jumper Screws Vis Fuse PPS-3BE711911CH 72
ADVANCIA PLUS BOILING KETTLES Change the card Attention: it is vital that the new card is programmed according to the type of: Boiling kettle: Red connectors Energy: Electric or steam: Jumper Electric: Position 2 and 3 Fit the new card If the relay card is changed the water dosing system will need to be recalibrated Calibrating the water dosing system Move the switch to the calibrating position Switch the boiling kettle on Open the water supply Measure exactly 5 litres of water into a measuring jug Close the water supply Move the switch back to the normal position Restart the boiling kettle Jumper PPS-3BE711911CH 73
ADVANCIA PLUS BOILING KETTLES Double jacket water level probe Follow the procedure for removing the rear panel Undo the connector fixing screw Disconnect the probe Undo the probe using a 24mm ratchet spanner Change the probe Fitting the new probe Identify with a marker on the nut the probes open position The probes contact is open if there is water. Mark the nut on the opening side Insert the probe into its housing Attention: put PTFE tape on the new probes thread Note: Once the probe is tightened the marking should be towards the top of the boiling kettle. If the float is fitted incorrectly the unit will heat continuously because the contact will be open as though water is detected. Risking the elements(s) and/or the probe. Screw Probe connector Contact open Marking Marking towards the top of the unit PPS-3BE711911CH 74
ADVANCIA PLUS BOILING KETTLES Product temperature probe Follow the procedure for removing the front panel Cut the probe wires at the push connectors Open the access to the probe by unsticking the aluminium covering Undo the probe support fixing screw and remove the support Remove the probe Change the probe Note: the probe has an adhesive support do not forget to remove the covering from the adhesive before fitting the probe Attention: It is imperative that the wires are reconnected with sleeved push connections Push connections Product probe Double jacket probe Product probe Screw PPS-3BE711911CH 75
ADVANCIA PLUS BOILING KETTLES Double jacket temperature probe Drain the double jacket Follow the procedure for draining the jacket Follow the procedure for removing the tank s front panel Cut the probe wires at the push connectors Undo the probe fixing nut Remove the probe Change the probe Attention: put PTFE tape on the new probes thread Attention: It is imperative that the wires are reconnected with sleeved push connections Product probe Double jacket probe Nut Push connections PPS-3BE711911CH 76
ADVANCIA PLUS BOILING KETTLES Immersion heaters Attention: It is vital that the immersion heater seals are changed annually and whenever they are removed Drain the double jacket Follow the procedure for draining the jacket Remove the front panel Follow the procedure for removing the tank s front panel Disconnect the immersion heater electrically Undo the 3 terminal screws Withdraw the immersion heaters wires Remove the immersion heater Undo the 3 fixing nuts Pull the element towards you Terminal screw PPS-3BE711911CH 77 Nut
ADVANCIA PLUS BOILING KETTLES Remove the terminal connection and fit it to the new immersion heater element using the identical cabling Fit a new seal to the new heater element Remember: It is imperative that a new seal is fitted if an immersion heater element is changed Fit and connect the new element Check the wiring with and amp-metre Note: the 3 elements should have the same amperage Terminal Seal PPS-3BE711911CH 78
ADVANCIA PLUS BOILING KETTLES Frequency inverter Attention: Only on boiling kettles fitted with a mixer arm Follow the procedure for removing the control facia Follow the procedure for removing the lower right hand panel and pull the technical drawer towards you Undo the 2 nuts holding the inverters support to the right hand side panelling Remove the assembly Disconnect the inverter electrically Remove the inverter from its support Undo the 4 fixing screws Change the frequency inverter Attention: Check that the new inverter has an EPROM Inverter Ecrous Nuts Vis Screws EPROM PPS-3BE711911CH 79
ADVANCIA PLUS BOILING KETTLES Tank tilting ram Follow the procedure for removing the control facia, the lower right hand arm panel and pull out the technical drawer Remove the right hand panel Undo the two nuts to slacken the rams support Undo the pin fixing screw before removing it Remove the pin, the base of the ram is disengaged Undo the screw holding the rear pin and remove it Remove the pin, the ram is disengaged Disconnect the supply to the ram Disconnect the 2 wires (brown and blue) from their terminals Lift the ram assembly out Pin Screw Pin Ecrous Nuts Screw Fils Wires PPS-3BE711911CH 80
ADVANCIA PLUS BOILING KETTLES Refit a ram without tightening the two nuts that hold the head of the ram securely Slacken the lock nut on the limit screw and tighten it so it is no longer in contact with the tilt connecting arm. Reconnect the ram electrically Level the tank using the adjustment screw (tightening: the rear of the tank lifts, slackening: it descends) Tighten the two ram support nuts. Bring the limit screw back into contact with the tilt connecting arm. Tighten the limit screws lock nut Adjustment screw Ecrous Nuts Lock nut and limit screw PPS-3BE711911CH 81
ADVANCIA PLUS BOILING KETTLES Preventative maintenance The need for preventative maintenance is signalled automatically when the message "SEr" appears on the control panel display. The service indicator is programmed for 500 hours use between each service. Operations required: Every 500 hours Every year Visual check for leaks (integrity of the hydraulic circuits) x x Check the control and safety mechanisms x x Test the pressure valve (see procedure below) x x Check and clean the double jacket float x x Check that the supply and contactor electrical connections are tight x x Check the state of the well x x Check for hard water and parameter adjustments x x Check & adjust the calibrations (water dosing, pressure stat ) x x Check the double jacket for lime scale, descale if necessary x x Check the state of the control panel (watertight, readable...) x x Check and adjust the detectors (lid, well...) x x Check the well tilt motor x x Check and adjust the heating system (emersion heaters, relay card, wiring ) x x Immersion heater descaling - x Check test and adjust the mixer arm and its mechanism x x Ensure the water supply solenoids operate correctly x x Oil the moving parts (tilt axis, roller bearings on the mixer arm) x x Double jacket draining x x Replacement operations: Every Every year 500 hours Immersion heater seal - x PPS-3BE711911CH 82
ADVANCIA PLUS BOILING KETTLES Pressure valve (checking) Follow the procedure for removing the front and back panels Follow the procedure for removing the lower right hand arm panel and pull out the technical drawer Switch the heating on at the maximum set temperature of 125 C. Fill the tank three quarters full with water Test the valve to ensure it isn t blocked Hold in the K1 contactor located in the technical drawer Check that the safety valve opens when the pressure indicated on the gauge exceeds 1.5 bar. If not change the safety valve Pressure gauge 1.5 bar Contactor K1 PPS-3BE711911CH 83
ADVANCIA PLUS BOILING KETTLES Other. Follow the procedure for removing the tank s rear panel Volumetric doser Lid position reed switches Non return valve Safety pressure stat Air purge valve Non return valve Capteurs Reed switches (Reed) Volumetric doser Mixer arm motor Safety pressure stat Air purge valve PPS-3BE711911CH 84