Fri-Jado BS3i User manual

WWW.FRIJADO.COM Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
Bake Star intelligent
- NOTICE -
This manual is prepared for the use of trained Service Technicians and should
not be used by those not properly qualified. If you have attended a training
for this product, you may be qualified to perform all the procedures in this
manual.
This manual is not intended to be all encompassing. If you have not attended a
training for this product, you should read, in its entirety, the repair procedure
you wish to perform to determine if you have the necessary tools, instru-
ments and skills required to perform the procedure. Procedures for which you
do not have the necessary tools, instruments and skills should be performed
by a trained technician.
Reproduction or other use of this Manual, without the express written consent of
Fri-Jado, is prohibited.
SERVICE MANUAL
MODELS
BS3i
BS5i
BS8i
BS10i
Model BS5i

Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
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TABLE OF CONTENTS
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Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013 Page 3
TABLE OF CONTENTS
Versions
Version Issue date
dd/mm/yy
Remarks
0705 01/05/2007 First release BSi with i-control
0808 01/08/2008 A few errors removed from the partslist.
1301 31/01/2013 Extension with service procedures
Extension with electrical tests
Expansion of the exploded views. Fasteners included.
Included exploded view of extraction hoods.
Included exploded view of stands.
Included exploded view of drive-in trolley.
Included exploded view of stacking kit.
1306 12/06/2013 Parts added on pages 51 (stacking) and 60 (loctite)

Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
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TABLE OF CONTENTS
INDEX
Index .......................................................................................................................................................... 4
General technical data.............................................................................................................................. 6
Technical Data ....................................................................................................................................... 6
Programming instructions........................................................................................................................ 8
Overview of the control panel.............................................................................................................. 8
The I-control menu’s.............................................................................................................................. 8
The cooking proces................................................................................................................................ 9
The automatic cook correction........................................................................................................... 10
Programming (adding or editing a program)................................................................................... 11
Programming (delete, test or sort program(s))................................................................................. 13
Entering the service menu .................................................................................................................. 13
Default parameters BSi sv 4.30 (since January 2013)........................................................................ 14
Cleaning program BS-i......................................................................................................................... 15
Service procedures.................................................................................................................................. 16
Adjusting the door .............................................................................................................................. 16
Mounting the doorlock....................................................................................................................... 17
Placing the doorgasket........................................................................................................................ 18
Mounting of the glass ......................................................................................................................... 19
Trouble shooting door and lock. ........................................................................................................ 20
Mounting of the fans .......................................................................................................................... 21
Mounting of the shaft seal and turbine............................................................................................. 22
Electrical tests.......................................................................................................................................... 23
Measuring on the heating system ...................................................................................................... 23
Measuring on the PT1000 sensor........................................................................................................ 24
Measuring on the blower system ....................................................................................................... 25
Measuring on the illumination transformer ...................................................................................... 29
The electric doorlock .......................................................................................................................... 30
Measuring on the steam and water system ....................................................................................... 31
Measuring on the vent motor............................................................................................................. 31
Trouble shooting ..................................................................................................................................... 32
Overview of error codes...................................................................................................................... 32
Trouble shooting by symptom. ........................................................................................................... 33
Trouble shooting by part / function. .................................................................................................. 35
Exploded views and partslists ............................................................................................................... 40
Electrical parts...................................................................................................................................... 40
Door parts ............................................................................................................................................ 42
Heat, Steam and Drain parts............................................................................................................... 44
Sheet metal .......................................................................................................................................... 46
Hoods.................................................................................................................................................... 48
Stacking kit........................................................................................................................................... 50
Design Stand ........................................................................................................................................ 52
Welded Stand....................................................................................................................................... 54
Drive-in Trolley..................................................................................................................................... 56
Overview of heaters and capacitors ................................................................................................... 58
Fasteners............................................................................................................................................... 59
Miscellaneous....................................................................................................................................... 60
Electrical diagrams ................................................................................................................................. 62
Circuit diagram BS3-i ........................................................................................................................... 62
Wiring diagram BS3-i........................................................................................................................... 63
Circuit diagram BS5-i ........................................................................................................................... 64
Wiring diagram BS5-i........................................................................................................................... 65
Circuit diagram BS8-i ........................................................................................................................... 66

Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013 Page 5
TABLE OF CONTENTS
Wiring diagram BS8-i........................................................................................................................... 67
Circuit diagram BS10-i ......................................................................................................................... 68
Wiring diagram BS10-i......................................................................................................................... 69
Circuit diagram BS5-i 9,75kW............................................................................................................ 70
Wiring diagram BS5-i 9,75kW........................................................................................................... 71
Circuit diagram BS8-i 14,6kW........................................................................................................... 72
Wiring diagram BS8-i 14,6kW............................................................................................................ 73
Circuit diagram BS10-i 18,8kW.......................................................................................................... 74
Wiring diagram BS10-i 18,8kW......................................................................................................... 75
Circuit diagram BS3-i 200V 60Hz ...................................................................................................... 76
Wiring diagram BS3-i 200V 60Hz....................................................................................................... 77
Circuit diagram BS5-i 200V 60Hz ...................................................................................................... 78
Wiring diagram BS5-i 200V 60Hz....................................................................................................... 79
Circuit diagram BS8-i 200V 60Hz ...................................................................................................... 80
Wiring diagram BS8-i 200V 60Hz....................................................................................................... 81
Circuit diagram BS10-i 200V 60Hz .................................................................................................... 82
Wiring diagram BS10-i 200V 60Hz..................................................................................................... 83
Electric diagram BSi hood in stacked units ....................................................................................... 84

Page 6 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
TECHNICAL DATA
STANDARD MODELS BS3i BS5i BS8i BS10i
Power 7880W 12750W 19100W 23300W
Fuses needed with power connec-
tion400V 3N~50…60Hz ( 3 phases with
neutral)
3x 16A 3x 20A 3x 32 3x 35
Fuses needed with power connection
230V 3~50…60Hz (3 Phases without
neutral)
3x 30A 3x 35A 3x 50A 3x 63A
Standard plug from factory
(According to IEC 60309 and CEE-form)
16A
3P+N+E
5 pole
32A
3P+N+E
5 pole
32A
3P+N+E
5 pole
63A
3P+N+E
5 pole
Default cable 5x2,5 mm² 5x4 mm² 5x4 mm² 5x6 mm²
Net weight 108 kg 136 kg 181 kg 212 kg
Gross weight 125 kg 155 kg 203 kg 234 kg
Hight 650 mm 850 mm 1150 mm 1350 mm
Width 910 mm 910 mm 910 mm 910 mm
Depth 740 mm 740 mm 740 mm 740 mm
SPECIAL MODELS 200V 3~ 50...60Hz BS3i BS5i BS8i BS10i
Power 7400W 12000W 17600W 21600W
Maximum current 28A 35A 54A 65A
Default cable 4 mm² 6 mm² 6 mm² 6 mm²
Tools
• Standard set of tools.
• Metric wrenches, sockets and hex socket key wrenches.
• Multi-meter and AC current clamp meter.
• Temperature tester.
• Insulation value tester (Megger).
• Field Service Grounding Kit.
• Puller.
This manual covers the Bake Star intelligent series bake-off ovens. The Bake Star intelligent comes in various
sizes with 3, 5 8 or 10 baking levels for standard 40x60 cm baking trays. The ovens are also available in stacked
versions of 3+3 3+5 and 5+5.
Special versions with lower connectionpower are available for the 5, 8 and 10 layer version.
• BS3i – Bake-off oven with 3 levels
• BS5i – Bake-off oven with 5 levels
• BS3i – Bake-off oven with 8 levels
• BS10i – Bake-off oven with 10 levels
All of the information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of printing.
GENERAL TECHNICAL DATA

GENERAL TECHNICAL DATA
Page 7
Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013

Page 8 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
PROGRAMMING INSTRUCTIONS
THE I-CONTROL MENU’S
OVERVIEW OF THE CONTROL PANEL
This controller has menu’s for:
• The operator. see tab “operate”.
• The store (department) manager. see tab “program”.
• The service engineer. see tab “settings”.
See overview of choices in the menu’s below.
Operate Program (for manager) Settings (manager and service)
Program 1 Add program Information --> shows software version and last error
Program 3 Edit program Manager --> Manager settings, including password
Program ..... Delete program Service --> Service settings and I/O test screens
Test program
Timer:
Cleaning
Manual
The operator has the following possibilities:
• Running cooking programs or the cleaning program.
• Setting the timer to auto start the unit. (Only if the manager parameter “Auto recipe
start” is enabled.)
• Use of the manual program. (Only if the service parameter “manual operation” is enab-
led.)
The manager controls the “program” menu and the manager settings in the settings menu.
In case the manager decided to activate the manager password, the operator does not
have access to the program tab and the manager parameters under the settings tab.
The service engineer has access to all menu’s. The password for the service settings is 4878.
In case the manager has set a manager password, this will be shown in one of the service
settings.
Choosing and run-
ning programs
Programming
cooking programs
-Information
-Parameter settings
-I/O test
Start / pause of
program
Switching ON
Press for 3 seconds
-Press 6 seconds
for key test.
Combination of dial and
up - down - left - right keys
Stop / cancel
of program
-Rotor key for positioning
rotor
-Door open key in BSi
Confirmation or ente-
ring of choice.
Switching OFF
Press both keys for
3 seconds.
Refer to the service manual “I-control”!

PROGRAMMING INSTRUCTIONS
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Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
The cooking program can consist of:
• Preheat function
• Cooking process
• Boost function
• Cook correction
Preheat function.
• Preheat can be enabled in the manager settings menu. This means that in case it is enab-
led, preheat will be active in all cooking programs. It is disabled by default.
• The BSi units have the possibility to have the preheat choice in each cooking program.
Cooking proces.
• The cooking proces can consist of maximum 9 cooking steps.
• A cooking step ends when the time elapses.
• In BSi, the first step can be programmed as preheat step.
• A “hold” function can be programmed as a last (continuous) step.
• By default the automatic cook correction facility will add or deduct time at the end of the
proces for equal results with different load quantity.
The cooking proces step by step.
Action Message on the display Comment
1 Choose program Summary of Program names Start here in case the program has a preheat step.
2 Press <OK> Please wait. Do not load
oven!
Oven is preheating
3 Preheat ready.
Press ok to stop alarm.
The alarm sounds. The preheat temperature is
reached.
4 Press <OK> Please load oven and press
Start
The alarm stops. Follow on screen instructions.
5 Open door Door open Start here in case the program has no preheat step
6 Load products Door open
7 Close door Ready in .... minutes
press power for extra time
The program starts after closing.
In case the program has no preheat step, the right
program has to be chosen now.
8 Press <Start> Ready in .... minutes
press power for extra time
It is during the proces already possible to add extra
time by pushing <Power>
9 Ready
press power for extra time
The alarm sounds
10 Press <OK> Ready
press power for extra time
The alarm stops.
It is now possible to open the door and check the
products or push <Stop/Cancel>
--If the products are not good, then proceed at #11
(adjust the time and push <OK>
--If good, then proceed at #15 (unload the oven).
11 Press <Power> ......minutes
12 adjust time
13 Press <OK> Ready in .... minutes
press power for extra time
14 Press <OK> Ready
press power for extra time
This is the same as #9
15 Open the door
and/or push
<Stop/cancel>
Summary of Program names End of program
THE COOKING PROCES

PROGRAMMING INSTRUCTIONS
Page 10 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
Boost function.
• This function can be activated during the cooking proces. (in the bottom line of the
display it says “Press power for extra time”). See in the above diagram from #11-#14.
• Even after opening and closing the door, it is still possible to give in extra cooking time.
The program calculates the surface from the
diagram below the curved line. (tempera-
ture * time). The result is the so called heat
number. This heat number is stored into
the cooking program.
All further cooking programs will try to get
the same heat number.
The second diagram shows an example with
full load. It takes more time for the unit to
reach the programmed cooking tempera-
ture. See dashed line. The surface above
the dashed line represents the missing part
of the heat number. The cook correction
will put this missing part behind the nor-
mal cooking time. Therefore extra time is
added in order to reach the desired heat
number.
It is also possible that time is deducted in case
a smaller load has been put into the oven.
Time will be added in case of:
A bigger load.
A colder load. (straight from the freezer)
A lower mains voltage.
Somebody opened the door.
Time will be deducted in case of:
A smaller load.
A warmer load. (defrosted)
Higher mains voltage.
Note that:
In case the time or temperature will be
changed in the cooking program, the heat
number will be adapted with this amount.
THE AUTOMATIC COOK CORRECTION
°C
°C
Extra time
Cooking time
Temparature curve
with half load
The automatic cook correction facility will automaticly add or deduct time to the pro-
grammed cooking time in order to have constant cooking quality.
After programming a new program, the first cooking process will be the “learning” process.
It is recommended to do the first cook with a half load.
The heat number is stored in the cooking
program. In case such a program is cop-
ied with FIPS (see additional software),
the heat number goes with it.
It is possible that in case the program has
changed a lot, the cook correction is not
able to perform well anymore. In that
case the program has to be deleted and
reprogrammed with the good param-
eters.
It is possible to disable this auto cook cor-
rection feature in the service parameters.
See “parameter listings” -> “auto correct.

PROGRAMMING INSTRUCTIONS
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Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
Method of working:
1. Select a cell to edit with the arrow keys. The cell will turn .
2. Activate the cell with <OK>. The cell will turn .
3. Edit the cell with the dial, or up and down keys. --> xxx
4. Confirm with <OK>. --> xxx
5. Select the next cell. -->
6. Finish programming when all necessary cells are edited, by using the <down> key towards
“save program”.
7. Push <OK> to leave the screen.
Additional information about the cooking parameters:
Time.
In the first line (step), time is adjustable from 1 untill 240 minutes and it has also a preheat
possibility. “PRE” is shown in that case.
In the second step, there is also a possibility to put the time on “HOLD”. The program will
run untill the <Stop> key is being pushed.
PROGRAMMING (ADDING OR EDITING A PROGRAM)
Press <program>.
Select “add program” or “edit program” with the dial.
Confirm with <OK>
Make a name.
Select a character with the dial.
Next character with arrow or OK.
Finally confirm with <OK> twice.
In case of editing, just repeat <OK>.
The following screen will appear.
The screen shows a diagram with 9 lines. These are
the 9 possible cooking steps of which a cooking
proces can consists of.
The top line will be the first cooking step, or it can
be the preheat fase (advised).
The 6 columns represent respectively the time, tem-
perature, fan speed, steam mode, steam quantity
and vent position (open or closed).

PROGRAMMING INSTRUCTIONS
Page 12 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
2 minutes
2 minutes
2 minutes
0,1 second
0,1 second
5 seconds
3 seconds
Mode 0
Mode 1
Mode 2
0,1 second
Temperature.
The temperature is adjustable from 0 untill 250°C (482°F).
Fan speed.
The Bake Star has 5 speeds 1 - 5 and a special speed “s”. This is a very low speed.
Steam.
The BSi has various steam possibilities. 60 different quantities in 3 modes. It will be ex-
plained below.
Vent. (exhaust valve)
This valve can be closed or opened in each step.
The BSi has also a third possibility named “5”. This will open the vent the last 5 minutes of
the cooking step.
Explanation of the steam system.
Steam is made by dripping water on the blower turbines. The turbines throw the water on
the heaters and then it evaporates into steam.
The water quantity is controlled by one or more solenoïd valves. By shortly (0,1 second)
opening the solenoïd valve, small amounts of water come through. Shortly opening the
solenoïd valve is called a (steam) pulse.
Programming steam in the BSi.
The steam quantity in the cooking program can be adjusted from 1 untill 60 (pulses)in steps
of 1. This can be done in 3 different modes.
The diagrams show examples of cooking steps of 2 minutes with a steam setting of 5 in the 3
different modes. (5 pulses in mode 0, 1 and 2)
Mode 0.
This mode is meant for Bake off products. Only a
small amount of steam is used at the beginning of
the baking step.
The 5 pulses come at the beginning of the step with
an interval of 3 seconds. The Pulse width and inter-
val are adjustable in the service parameter settings
Mode 1.
This mode is used in case a cooking step is needed
with a certain humidity during this step.
In this case the 5 pulses come per minute.
Mode 2.
This mode is the same as mode 1. Except for the first
pulse. This pulse is much larger.
This mode is used for very delicate products to ensu-
re that the oven cavity is filled up with steam in the
first seconds of the cooking process.

PROGRAMMING INSTRUCTIONS
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Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
PROGRAMMING (DELETE, TEST OR SORT PROGRAM(S))
Deleting a program.
Choose the “delete program”option.
Choose the program to be deleted with the dial or the
up / down keys.
Confirm with <OK>.
Choose “Yes”
Confirm with <OK>
Note that in the service menu, there is a possibily to delete
all programs!
Test a program.
Choose the “test program” option.
Choose the program to be tested with the dial or the up /
down keys.
Confirm with <OK>.
The program starts as normal, but now there is a possibi-
lity to change the program during the cooking proces by
pushing <OK>.
Alphabetic sort the programs.
Choose the “alphabetic sort” option.
Choose “Yes”
Confirm with <OK>
Note that in case the program names are numbers, and
there are more than 10 cooking programs, these numbers
need to have a leading “0”. For example 01, 02 ...9, 10,
11. When more then 100 programs it should be like 001,
002..........099, 100, 101. Otherwise it will not sort in the
right order.
Press <program>.
ENTERING THE SERVICE MENU
Press <settings>.
Select “manager” or “service” with the dial.
Confirm with <OK>
“Manager”contains a limited number of parameters.
“Service” contains system parameters, only to be adjusted
by qualified and trained people.
Pass words:
Manager: in case the password setting is “0000”, no pass-
word will be asked when entering the “program” tab or
the manager settings under the “settings”tab. In case it is
lost, it can be found in the service parameters.
Service: Password 4878.

PROGRAMMING INSTRUCTIONS
Page 14 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
Level 1 Level 2 Level 3 Default Possibilities
Informa-
tion
4.29 software version
Manager
Change Pin
code
0000 0000 - 9999
Light on on - off
Temperature °C °C - °F
Set time Local time
Set date Actual date
Set contrast 80 35 - 105
Time format 24 hr 24 hr - AM/PM
Date format DMY DMY - MDY
Alarm signal yes no - yes
Preheat mode no no - 1x - yes
Preheat delta 30 -50°C to + 50°C or -90°F to +90°F
autom. Door
open
no no - timed - yes
Open for
cooling
no no - yes
Auto recipe
start
yes no - yes
Buzzer set 0 0-4
key beep yes no - yes
water capa-
city
3000 50 - 30000
Lime filter remaining capacity of lime filter
Lime filter
replaced
no no - yes
Clear error no no - yes
Service 4878
device type BSI STGi, Multi, M-Bake, BSi, STOi, ACR,
RC8, TDRi
auto-correct time no - time
set language englisch englisch - deutsch - francais - neder-
lands - espanol - japanese - danish -
italiano
IrDA interface no no - yes
IP network IP address 192.168.0.40 192.168.0.10 - 192.168.0.249
IP netmask 255.255.255.0 none
IP gateway 192.168.0.250 none
auto IP / DHCP off on
NAFEM op-
tion
no no - “password”
alarm delays alarm T4 3 sec. 1 - 60
alarm T5 5 min. 1 - 60
auto open T6 3 sec. 1 - 120
DEFAULT PARAMETERS BSI SV 4.30 (SINCE JANUARY 2013)
Refer to the service manual “i-control” for the software description!!

PROGRAMMING INSTRUCTIONS
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Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
Level 1 Level 2 Level 3 Default Possibilities
Pulse timing t1 5 sec. 0,1 - 120
T2 3 sec. 1 - 10
T3 0,1 sec.
(Japan 0,2
sec)
0,1 - 1
fan values Fan speed right T9 45 sec. 10 - 90
Fan speed left T10 45 sec. 10 - 90
Fan Pause T11 3 sec. 1 - 90
Fan cool speed 3 1 - 5
fan S times Fan S speed right T12 10 10 - 90
Fan S speed left T13 10 10 - 90
Fan S pause T14 15 10 - 90
Fan S speed 3 1 - 5
manual ope-
ration
no yes - no
correct-factor 3x 1x - 10x
debug rs232 no no - yes
demo mode no no - yes
auto off 60 no or 10 - 240
pin code **** read out of the manager pin code
Sensor offset 0 °C -5°C - 5°C
complete
cleaning
yes no - yes
delete all
programs
no - yes
edit clean
prog
special see table below
PID factors P 100 0 - 100
I 5 0 - 100
D 100 0 - 500
iMax 100 10 - 300
Relay actions: 80 16 - 160
Energy Volts 230 1 - 260
Model BS-I5 BS-I3 - BS-I5 - BS-I8 - BS-I10
Pressure no no - yes
I/O test read the inputs and set the outputs
Ignore errors no no - yes
Cleaning program
step time temp blower steam exhaust
1 5 50 1 1 10 closed
2 30 70 1 1 30 closed
3 5 40 5 3 | closed
4 5 60 5 0 - closed
5 - 0 - 0 - closed
6 - 0 - 0 - closed
7 - 0 - 0 - closed
8 - 0 - 0 - closed
9 - 0 - 0 - closed
CLEANING PROGRAM BS-I
The cleaning program is adjustable
in the service menu!
Enter parameter “edit clean prog”

Page 16 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
SERVICE PROCEDURES
WARNING: Disconnect the electrical power to the machine
at the main circuit box. Place a tag on the circuit box indica-
ting the circuit is being serviced.
Adjustment of the door.
By means of the upper hinge it is possible
to “rotate” the door a few mm, through
which both catch forks can be adjusted in
height as it were.
The glass of the outside door is glued with
double sided tape, to the metal hinge.
Therefore it is not adjustable. For the
same reason, the glass can only be delive-
red as an assembly with the hinges.
The lower hinge is not adjustable. The cur-
rent hinges are locked with a M6 nut at
the bottom side.
It is however possible to put an extra washer
under the hinge, or remove one.
There is some margin on the holes in the
doorpost and the glass to make it possible
to align the catch forks. The screws of the
door handle go through these holes.
To prevent the bolts from the doorhandle
from coming loose, the spacers from the
handle are nowadays made out of solid
stainless steel and a thick washer is app-
lied under the bolthead.
At the same time the screw thread in the
handles is strenghtened.
The screws need to be fixed with thread loc-
ker, like Loctite 620
ADJUSTING THE DOOR

SERVICE PROCEDURES
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Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
MOUNTING THE DOORLOCK
Mounting the doorlock.
It is important that the plastic housing will
be mounted on a distance from the metal
front plate of the oven. This is to keep the
lock as cool as possible.
Fiber spacers are used for this purpose. It is
practical to glue the spacer on the hou-
sing with “seconds glue” before moun-
ting the door lock.
Use as less as possible!! The glue must not
penetrate into the lock!!!
The lock is fixed with screws M4x10.
Use the locking agent “Loctite 620” or similar
to prevent the screws from coming loose.
More details can be found in the chapter
electrical tests!
It is difficult to reach the lock from behind
during (dis)mounting. To ease the job, the
shown tool can be made.
The shown numbers are pos. numbers in the
exploded views.
The door catch “fork” (see picture) is moun-
ted with a lock washer without the use of
a locking agent.
Adjustment of the door lock (catch).
A number of aspects have to be taken into account.
a) The “catch fork” has to go through the middle of the hole into the lock and during mo-
tion never touching the plastic housing. The only audible and perceptible may be the me-
tal roll, ticking and rolling against the metal “grabber” from the lock. With the first BS
ovens (untill serialnummer 100019498 ,febr. 2003), whereby the frontplate is NOT consi-
sting of one plate in its entirety, this can be a problem. Especially when the oven is moved
regularly and the floor is not even (smooth). The door can start “hanging” in such a case.
b) Check the adjustment of the door when the oven is standing (back) on its position. The
reason is explained above!
c) The door motion must be “blocked” by the door gasket. Just before the door comes to
a stand still, the lock has to catch the door. The fact is that the lock is NOT capable to
“block” the closing door without having damage from it.
d) In cold situation, the gasket pushes with less force to the door than in hot position.
112 927 926 892

SERVICE PROCEDURES
Page 18 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
e) A new gasket will have “set” itself after a few weeks, after which the door will close a lit-
tle easier. It is therefore recommended to adjust the door a little tighter with a new gas-
ket and inform the customer about it.
Some guidelines.
a) When it is possible, in cold situation, to close each lock separately without worth mentio-
ning force, then the adjustment is to light. In this case the door will probably not even
open when the switch is being pushed, because the gasket is not pushing hard enough
against the door.
b) When it is difficult to close the door at 200°C (only one lock “catches” for example), then
the adjustment is too hard.
c) Take care of a proper mounting with the above mentioned distance bushes.
d) In case there are tracks of moisture on the old lock, then probably the sealant in the cor-
ner behind the gasket is leaking. Take the gasket (in the corner) out of the rebate and
close the holes with sealant.
The Bake Star door gasket consists of one piece. Because there is a cavity in the profile, the
straight pieces are more flexible than the vulcanized corners. There the gasket is massive.
In principle the gasket is not being glued (sealant) in the gasket channel. Therefore the old
gasket can simply be pulled out.
After that, the channel needs to be checked on unevenness’s like remainders of the old gas-
ket.
Start in the corners when placing the new gasket. Then divide the gasket as good as possible
over the length so that the gasket lies flat in the channel.
Some guidelines.
a) The gasket needs to be pushed fully to the bottom of the
channel. All three little ribs
will be disappeared in the channel.
b) In case the gasket goes too deep in the channel, than there
are filling strips available to solve this. It is advised to fix
the fillingstrips with sealant. Try to keep the front side free
of sealant so that the new gasket will not be
glued.
In extreme situations the 3500101 gasket (of the
Memory Excellent) can be used. It is 2mm higher. This comes however per meter and has
no vulcanized corners.
c) In the corners behind the door gasket there are gaps by
reason of sheet metal engineering. These gaps are in the
factory closed with sealant, to prevent from steam and wa-
ter leakage to the inside of the oven. Check and/or repair
this seal.
On the picture, the application of a filling strip is shown as
well as the gap that came into existence after removing
the gasket.
PLACING THE DOORGASKET
3704626

SERVICE PROCEDURES
Page 19Page 19
Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
As mentioned before, the hinge and outer
glass are glued together with tape. All
other strips and posts on the inner and
outer glass are screwed.
It is very important that metal parts do not
touch the glass. In case it does touch, the
glass will burst eventually!!!.
Take care that during mounting a new glass,
that no splinter of the old glass remains
between the post and the new glass. Also
then, the new glass will burst.
Nowadays the glass is clamped in between
2 ptfe flanged bushes. The “bush part”
which goes into the hole in the glass,
is 2mm or 3mm high. By placing such a
flange bush on either side, the hole has to
be filled up completely.
The inner glass is 5mm thick. See Note! The-
refore a 2mm and a 3mm bush is used in
each hole.
The outer glass is 6mm thick. There, two bu-
shes of 3mm will be used in each hole.
At the same time, thick washers are used un-
der the different bolt heads and nuts.
6mm 5mm
Outer glass Inner glass
2x
3mm bush
1x 3mm bush
1x 2mm bush
MOUNTING OF THE GLASS
Note!!!!
The BS10 units from serial number 100054521
(week 36 2011) have inner glass of 6mm
thickness. These need to be mounted with
3 mm bushes on both sides.

SERVICE PROCEDURES
Page 20 Service Manual Bake Star intelligentPKII form 9123665 rev. 06/2013
• The door opens and closes normally, but the blowers keep on turning when the door is
opened.
The microswitch came loose or is defect. The CPU does not “see” then, that the door
has opened. In case of a BSp or a BSi (2006 model) it is even so that at the end of the
baking program it is not possible anymore to control the keyboard because the CPU
is waiting for the “door open” signal. Then the customer’s only possibility is to pull the
plug after which he can bake another session.
-->Replace the door lock.
• The door does not open.
` The gasket is not pushing hard enough against the door.
-->Adjust the door lock and/or exchange the gasket. (See below)
The door lock misses. Do the following test: Firmly pull the door and activate the
“door open” key. When the lock misses, than it is broken.
Replace the door lock and adjust it properly.
Loose wiring or a defect printed circuit board.
-->Check the wiring and/or exchange the printed circuit board.
• The door does not close.
The adjustment of the door is too hard. The gasket pushes too firm.
Adjust the door.
The doorlock is defect.
Replace the doorlock and adjust properly.
The manual opening feature is adjusted too taut.
-->Proper adjust the manual opening feature.
• The door opens automatically (during baking).
The manual opening feature is adjusted too taut.
-->Proper adjust the manual opening feature.
TROUBLE SHOOTING DOOR AND LOCK.