Duke 5/9 THE OVEN User manual

SERVICE MANUAL
This manual is Copyright © 2011 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
trademark of the Duke Manufacturing Co.
Duke Manufacturing Co.
2305 N. Broadway
St. Louis, MO 63102
Phone: [phone]
Toll Free: 1-800-735-3853
Fax: [phone]
www.dukemfg.com
P/N 153611B
Please read this manual completely before attempting to
install, operate or service this equipment
ELECTRIC
CONVECTION OVEN
MODELS
5/9 THE OVEN
5/9 SERIES OVENS
6/13 THE OVEN
E SERIES
59-E3C
59-E3P

Service Manual for Electric Convection Oven
2
IMPORTANT WARNING AND SAFETY INFORMATION
WARNING
READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR
PERFORMING MAINTENANCE ON THE EQUIPMENT.
WARNING
FAILURE TO FOLLOW INSTRUCTIONS IN THIS MANUAL CAN CAUSE PROPERTY
DAMAGE, INJURY OR DEATH.
WARNING
DO NOT USE OR STORE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN
THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WARNING
DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPERLY PLACING AND SECURING
ALL COVER AND ACCESS PANELS.
CAUTION
Observe the following:
• Provide and maintain adequate minimum clearances from all walls and combustible materials.
• Provide and maintain adequate clearance for air openings.
• Keep the equipment area free and clear of combustible material.
• Operate equipment only on the type of electricity indicated on the specication plate.
• Retain this manual for future reference.

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Service Manual for Electric Convection Oven
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................................................................6
GENERAL .....................................................................................................................................................................6
INSTALLATION .............................................................................................................................................................6
OPERATION .................................................................................................................................................................6
CLEANING ....................................................................................................................................................................6
TOOLS ..........................................................................................................................................................................6
Standard.................................................................................................................................................................6
ELECTRICAL SPECIFICATIONS ..................................................................................................................................6
COMPONENT REMOVAL AND REPLACEMENT ................................................................................................................7
Electrical LOCKOUT/TAGOUT Procedure ....................................................................................................................7
RIGHT SIDE PANEL (OVENS WITH DUAL DOORS) ...................................................................................................7
X CONTROL PANEL ASSEMBLY .................................................................................................................................8
Component Access Procedure...............................................................................................................................8
POWER Switch ......................................................................................................................................................8
X Controller ............................................................................................................................................................8
OVEN READY Light ...............................................................................................................................................8
Fan Switch .............................................................................................................................................................8
Fuse and Fuse Holder ...........................................................................................................................................8
LIGHT Switch .........................................................................................................................................................8
XX CONTROL PANEL ASSEMBLY ...............................................................................................................................9
Component Access Procedure...............................................................................................................................9
POWER Switch ......................................................................................................................................................9
XX Controller ..........................................................................................................................................................9
OVEN READY Light ...............................................................................................................................................9
Fan Switch .............................................................................................................................................................9
LIGHT Switch .........................................................................................................................................................9
Fuse and Fuse Holder ...........................................................................................................................................9
Z CONTROL PANEL ASSEMBLY .............................................................................................................................. 10
Component Access Procedure............................................................................................................................ 10
POWER Switch ................................................................................................................................................... 10
Z Controller ......................................................................................................................................................... 10
OVEN READY Light ............................................................................................................................................ 10
Fuse and Fuse Holder Light ................................................................................................................................ 10
LIGHT Switch ...................................................................................................................................................... 10
ZX CONTROL PANEL ASSEMBLY .............................................................................................................................11
Component Access Procedure.............................................................................................................................11
POWER Switch ....................................................................................................................................................11
ZX Controller ........................................................................................................................................................11
OVEN READY Light .............................................................................................................................................11
LIGHT Switch .......................................................................................................................................................11
Fuse and Fuse Holder Light .................................................................................................................................11
ZZ CONTROL PANEL ASSEMBLY ............................................................................................................................ 12
Component Access Procedure............................................................................................................................ 12
POWER Switch ................................................................................................................................................... 12
ZZ Oven Control.................................................................................................................................................. 12
Fuse and Fuse Holder Light ................................................................................................................................ 12
6/13 & 5/9 V CONTROLLER ASSEMBLY & “E”SERIES-ELECTRO MECHANICAL CONTROLLER ASSEMBLY... 13
Component Access Procedure............................................................................................................................ 13
POWER Switch ................................................................................................................................................... 13
TEMPERATURE Control ..................................................................................................................................... 13
1 - Hour TIMER ................................................................................................................................................... 13
OVEN READY Light ............................................................................................................................................ 13

Service Manual for Electric Convection Oven
4
Fan Switch .......................................................................................................................................................... 13
LIGHT Switch ...................................................................................................................................................... 13
Fuse and Fuse Holder Light ................................................................................................................................ 13
Buzzer ................................................................................................................................................................. 13
59-E3P OVEN CONTROLS ....................................................................................................................................... 14
Component Access Procedure............................................................................................................................ 14
POWER Switch ................................................................................................................................................... 14
Controller............................................................................................................................................................. 14
OVEN READY Light ............................................................................................................................................ 14
Fuse and Fuse Holder Light ................................................................................................................................ 14
Transformer ......................................................................................................................................................... 14
Contactor............................................................................................................................................................. 14
Terminal Block ..................................................................................................................................................... 14
CONTROL CIRCUIT BOARD REPLACEMENT ......................................................................................................... 15
CONTROL CIRCUIT BOARD JUMPER SETTINGS .................................................................................................. 15
Single Menu Jumper Setting (Churches or Popeye’s) ........................................................................................ 15
Seven Menu Jumper Settings (Popeye’s Chicken only) ..................................................................................... 16
MOTOR ...................................................................................................................................................................... 16
Side Mounted Motor ............................................................................................................................................ 16
Rear Mounted Motor ........................................................................................................................................... 17
STEP-DOWN TRANSFORMER ................................................................................................................................. 18
POWER TRANSFORMER ......................................................................................................................................... 18
3-RELAY PRINTED CIRCUIT BOARD (Relay Board) ............................................................................................... 18
RTD PROBE .............................................................................................................................................................. 19
THERMOSTAT ........................................................................................................................................................... 19
KX THERMOSTAT ..................................................................................................................................................... 20
BACKUP TOGGLE SWITCH...................................................................................................................................... 20
ELEMENTS ................................................................................................................................................................ 21
Side Mounted Elements ...................................................................................................................................... 21
Back Mounted Elements ..................................................................................................................................... 22
OVEN LIGHTS ........................................................................................................................................................... 23
DOORS ...................................................................................................................................................................... 23
Removal .............................................................................................................................................................. 23
Disassembly ........................................................................................................................................................ 23
Gasket Replacement........................................................................................................................................... 23
Roller Latch ......................................................................................................................................................... 24
Door Switch ......................................................................................................................................................... 24
Door Handle ........................................................................................................................................................ 24
Turnbuckle Assembly (2-door 6/13 Series only) ................................................................................................ 24
SERVICE PROCEDURES ................................................................................................................................................ 25
MAINTENANCE INSTRUCTIONS ............................................................................................................................. 25
Oven Door Adjustment ........................................................................................................................................ 25
6/13 Series Turnbuckle Adjustment..................................................................................................................... 25
Oven Door Switch Adjustment ............................................................................................................................ 25
OVEN DOOR SWITCH CHECK ................................................................................................................................. 26
THERMOSTAT CALIBRATION .................................................................................................................................. 26
Check Calibration ................................................................................................................................................ 26
To Calibrate the Thermostat ................................................................................................................................ 26
ELEMENT .................................................................................................................................................................. 27
RTD ............................................................................................................................................................................ 27
MOTOR CIRCUIT CHECK ......................................................................................................................................... 27

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Service Manual for Electric Convection Oven
ZZ CONTROLLER PROGRAMMING ........................................................................................................................ 28
System Programming .......................................................................................................................................... 28
Factory Programming .......................................................................................................................................... 29
TROUBLESHOOTING CHARTS ....................................................................................................................................... 30
6/13 V CONTROLLER AND E SERIES ELECTRO-MECHANICAL CONTROLLER ................................................. 30
5/9 OVEN WITH ZZ CONTROLLER .......................................................................................................................... 31
ALL SOLID STATE CONTROLLERS EXCEPT ZZ CONTROLLER .......................................................................... 32
5/9 CCSI CONTROL WITH BACKUP THERMOSTAT ............................................................................................... 33
SCHEMATIC DIAGRAMS
5/9 “V” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................... 34
6/13 “V” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................. 35
6/13 “V” OPTION PULSE PLUS 208/240 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 36
6/13 “V” OPTION 480 VAC. 50/60 HZ 1PH OR 3PH ......................................................................................................... 37
6/13 “V” OPTION PULSE PLUS 440/480 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 38
5/9 “X” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................... 39
6/13 “X” PULSE OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ..................................................................................... 40
6/13 “X” PULSE OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................... 41
6/13 “X” PULSE PLUS OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 42
S 6/13 “X” OPTION 440/480 VAC. 50/60 HZ 1PH OR 3PH .............................................................................................. 43
6/13 “X” PULSE OPTION 440/480 VAC. 50/60 HZ 1PH OR 3PH ..................................................................................... 44
6/13 “X” PULSE PLUS OPTION 440/480 VAC. 50/60 HZ 1PH OR 3PH .......................................................................... 45
5/9 “Z & ZX” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ........................................................................................... 46
6/13 “Z, ZX” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ........................................................................................... 47
6/13 “Z, ZX” OPTION 480 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................. 48
6/13 “ZZ” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ................................................................................................ 49
5/9 & 6/13 “ZZ” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH ...................................................................................... 50
5/9 “ZZ” OPTION 208/240 VAC. 50/60 HZ 1PH OR 3PH .................................................................................................. 51
5/9 THERMOSTAT 208/240 VAC. 50/60 HZ 1PH OR 3PH ............................................................................................... 52
WIRING DIAGRAMS
5/9 “V” 208/240 V .............................................................................................................................................................. 53
6/13 “V” 208/240 V ............................................................................................................................................................ 54
6/13 “V” OPTION 208/220 OR 230/240 VAC. 1PH OR 3PH ............................................................................................. 55
6/13 “V” PULSE PLUS 208/240 V ..................................................................................................................................... 56
6/13 “V” 440/480 V ............................................................................................................................................................ 57
6/13 “V” PULSE 440/480 V................................................................................................................................................ 58
6/13 “X” 208/240 V ............................................................................................................................................................ 59
6/13 “X” PULSE PLUS 208/240 V ..................................................................................................................................... 60
5/9 “X” COM6000 208/240 V ............................................................................................................................................. 61
6/13 “X” 440/480 V ............................................................................................................................................................ 62
6/13 “X” PULSE 440/480 V................................................................................................................................................ 63
6/13 “X” PULSE PLUS 440/480 V ..................................................................................................................................... 64
6/13 “X” PULSE PLUS 440/480 V ..................................................................................................................................... 65
6/13 “W” OPTION COM6000 208/240 VAC. 1PH OR 3PH ............................................................................................... 66
6/13 “Z” “ZX” 208/240 V..................................................................................................................................................... 67
5/9 “Z” “ZX” 208/240 V....................................................................................................................................................... 68
6/13 “Z” “ZX” 440/480 V..................................................................................................................................................... 69
6/13 “ZZ” W/BACKUP 208/240 V ...................................................................................................................................... 70
5/9 “ZZ” W/BACKUP 208/240 V ........................................................................................................................................ 71
5/9 CCSI BACKUP TSTAT 208/240 V ............................................................................................................................... 72
CUSTOMER ASSISTANCE ............................................................................................................................................... 75