Manitowoc convotherm 4 Operating instructions

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Table of Contents
Repair Manual C4 1
Table of Contents
1General information 4
1.1Contact data 5
1.2Environmental protection 6
1.3Identifying your combi steamer 7
1.4Structure of the full set of documentation 8
1.5About this repair manual 9
2For your safety 11
3Replacing appliance parts to rectify problems 22
3.1Service hatches 26
3.1.1Removing and fitting the left side panel 27
3.1.2Removing and fitting the user interface board 29
3.1.3Removing and fitting the front cover 32
3.1.4Removing and fitting the floor hatch to the pump area 34
3.1.5Removing and fitting the floor hatch to the drain box 35
3.1.6Removing and fitting the access panel for the stacking-kit adapter 36
3.2Replacing cooking chamber components 37
3.2.1Removing and fitting the oven light 38
3.2.2Removing and fitting the halogen lamp 40
3.3Replacing parts of the appliance door 41
3.3.1Removing and fitting the disappearing door 42
3.3.2Removing and fitting the interior glass door 44
3.3.3Removing and fitting the door handle 46
3.3.4Removing and fitting the door gasket 48
3.3.5Removing and fitting the door drip tray 49
3.3.6Removing and fitting the door contact switch 50
3.3.7Removing and fitting the door catch block 51
3.4Replacing parts of the control electronics 53
3.4.1Removing and fitting the system interface board 54
3.4.2Removing and fitting the identification module (IDM) 57
3.4.3Removing and fitting the power supply module (PSM) 58
3.4.4Replacing parts of the UI board 59
►Preliminary tasks 60
►Removing and fitting the main switch 62
►Removing and fitting the USB port 63
►Removing and fitting the loudspeaker (easyTouch) 65

Table of Contents
Repair Manual C4 2
3.4.5Removing and fitting the fuses on the mounting plate 67
3.5Replacing components of the convection system 69
3.5.1Removing and fitting the motor / fan wheel 70
3.5.2Removing and fitting the cooking-chamber heating element 74
3.6Replacing parts of the boiler 77
3.6.1Cooling and emptying the boiler 78
3.6.2Removing and fitting the boiler 82
3.6.3Removing and fitting the boiler drainage pump 87
3.6.4Removing and fitting the water solenoid valve 89
3.6.5Removing and fitting the boiler heating element 91
3.6.6Removing and fitting the water-level probe (electrical appliance) 93
3.6.7Removing and fitting the water-level probe (gas appliance) 95
3.6.8Removing and fitting the dehumidifier valve 97
3.6.9Cleaning the dehumidifier valve 99
3.7Replacing the parts of the injection system 101
3.7.1Removing and fitting the injection unit 102
3.8Replacing the sensors 104
3.8.1Removing and fitting the drain probe 105
3.8.2Removing and fitting the bypass sensor 107
3.8.3Removing and fitting the convection safety thermostat (STB) 109
3.8.4Removing and fitting the core temperature probe 111
3.8.5Removing and fitting the boiler sensor 114
3.8.6Removing and fitting the boiler safety thermostat (STB) 116
3.8.7Removing and fitting the oven sensor 118
3.8.8Resetting the safety thermostat (STB) 119
3.9Replacing components of the waste water system 120
3.9.1Removing and fitting the CS-chamber drainage pump 121
3.9.2Removing and fitting the drain box 123
3.10Replacing components of the cleaning system 125
3.10.1Preliminary tasks for removing and fitting the cleaning system 126
3.10.2Removing and fitting the cleaning-fluid unit 128
3.10.3Removing and fitting the pressure switch 130
3.10.4Removing and fitting the cleaning-agent/rinse-aid dispensing pump 131
3.10.5Removing and fitting the circulation pump 133
3.10.6Removing and fitting the shower head 135
3.10.7Removing and fitting the recoil hand shower 136
3.10.8Removing and fitting the backflow preventer 138
3.11Replacing the solid-state relay 139
3.11.1Removing and fitting the solid-state relay 140
3.12Replacing the frequency converter 142
3.12.1Removing and fitting the frequency converter 143
3.13Replacing the flowmeter 148
3.13.1Removing and fitting the flowmeter 149
3.14Replacing the air-intake box 151
3.15Replacing the cooling fan 152
3.16Replacing parts in the gas system 153
3.16.1Removing and fitting the convection burner fan 154
3.16.2Removing and fitting the ignition and monitoring electrode 157
3.16.3Removing and fitting the heat exchanger 158
3.16.4Removing and fitting the boiler burner fan 159
3.16.5Removing and fitting the boiler burner 161
3.17Accessories 162
3.17.1Fitting the stacking kit 163
3.17.2Fitting the hood 173

Table of Contents
Repair Manual C4 3
3.17.3Fitting the fine particle filter 177
3.17.4Removing and fitting the fuses in the ON/OFF switch 179

1 General information
Repair Manual C4 4
1 General information
Purpose of this chapter
This chapter provides contact data, shows you how to identify your combi steamer and provides guid-
ance on using this manual.
Contents
This chapter contains the following topics:
Page
Contact data 5
Environmental protection 6
Identifying your combi steamer 7
Structure of the full set of documentation 8
About this repair manual 9

1 General information
Repair Manual C4 5
1.1 Contact data
Address
Convotherm Elektrogeräte GmbH,
Ovens & Advanced Cooking EMEA, Manitowoc Foodservice
Talstraße 35
82436 Eglfing
Germany
Contact information
Reception
Phone (head office) (+49) (0) 8847 67-0
Fax (+49) (0) 8847 414
Internet www.convotherm.com
www.manitowocfoodservice.com
Application support
Hotline (+49) (0) 8847 67-899
e-mail [e-mail]
con-dl-anwendungsberat[email protected]
Sales
e-mail, appliances/accessories con.[email protected]
e-mail, spare parts convot[email protected]
Customer service
Technical hotline (office hours) (+49) (0) 8847 67 541
Technical Hotline (outside office hours) (+49) (0) 175 405 41 09
e-mail [email protected]

1 General information
Repair Manual C4 6
1.2 Environmental protection
Statement of principles
Our customers' expectations, the legal regulations and standards and our company's own reputation set
the quality and service for all our products.
We have an environmental management policy that not only ensures compliance with all environmental
regulations and laws, but also commits us to continuous improvement of our green credentials.
We have developed a quality and environmental-management system in order to guarantee the con-
tinued manufacture of high-quality products, and to be sure of meeting our environmental targets.
This system satisfies the requirements of ISO 9001:2008 and ISO 14001:2004.
Environmental protection procedures
We observe the following procedures:
Use of residue-free compostable wadding materials
Use of RoHS-compliant products
REACH chemical law
Recommendation and use of bio-degradable cleaning fluids
Recycling of electronic waste
Environmentally friendly disposal of old appliances via the manufacturer
Join us in our commitment to protect the environment.

1 General information
Repair Manual C4 7
1.3 Identifying your combi steamer
Position of type plate
The type plate is located inside and on the left-hand side of the rear wall of the combi steamer.
Layout of the type plate
You can use the type plate to identify your combi steamer.
The type plate has the following layout on electric
appliances:
The type plate has the following layout on gas
appliances:
_
Item Meaning
1 Trade name
2 Part number
3 Name of appliance
combi steamer
4 Serial number including year of manufacture
Code making up the trade name
The code making up the trade name (item 1) identifies your appliance:
Elements of the trade
name Meaning
C4 Convotherm 4 appliance series
eT easyTouch controls
eD easyDial controls
numbers xx.yy Appliance size
EB Electrical appliance with boiler
ES Electrical appliance with water
injection
GB Gas appliance with boiler
GS Gas appliance with water injec-
tion

1 General information
Repair Manual C4 8
1.4 Structure of the full set of documentation
Contents of the documentation
The documentation for the combi steamer includes the following documents:
Training manual - Service
Training manual - Sales
Error message manual
Repair manual (this manual)
Installation manual
User manual
Structure of documentation
Topic Description See
Moving the appliance Moving the combi steamer Installation manual
Setting up the appliance Setup options
How to set up the combi steamer correctly
Installation manual
Installation Electrical connection
Gas supply
Water connection
Installation of the ConvoClean / ConvoClean+
automatic oven cleaning system
Installation manual
Preparing the appliance for use How to prepare the combi steamer for use Installation manual
Operation Describes the user interface
Working procedures and operating steps
User manual
Cleaning Cleaning instructions
Cleaning programs and cleaning tasks
User manual
Servicing Servicing schedule
Minor servicing tasks
User manual
Detailed servicing schedule
All servicing tasks
Training manual - Service
Software update Performing a software update Training manual
Service and Repairs Locating faults
Using software functions to rectify problems
Error message manual
Replacing appliance parts to rectify problems Repair manual
Taking out of operation How to take the combi steamer out of operation Installation manual
Technical data Shelf options
Maximum load
User manual
The complete technical specification for the combi
steamer
Installation manual
Dimensional drawings and
connection points
All dimensional drawings and connection points of
the combi steamer
Installation manual
Checklists Installation checklists Installation manual
Basic stock of spare parts Recommended basic stock of spare parts Training manual - Service

1 General information
Repair Manual C4 9
1.5 About this repair manual
Purpose
This repair manual is intended for all people who work with the combi steamer, and provides them with
the necessary information for identifying faults and for carrying out the necessary remedial actions
correctly and safely.
Target groups
Name of target group Tasks
Trained service engineers All servicing and repair work
Electrical fitter Installing and removing the electrical supply
All servicing and repair work
Gas fitter Installing and removing the gas connection
All servicing and repair work
Trainees Reference and training manual
Parts of this document that must be read without fail
If you do not follow the information in this document, you risk potentially fatal injury and prop-
erty damage.
To guarantee safety, all people who work with the combi steamer must have read and understood the
following parts of this document before starting any work:
the chapter 'For your safety'
the sections that describe the activity to be carried out
Layout of the repair manual
Chapter/section Purpose
General information Provides important contact data
Shows you how to identify your combi steamer
Provides guidance on using this repair manual
For your safety Describes the hazards posed by the combi steamer and suitable preventive
measures
You should read this chapter carefully in particular.
Replacing appliance parts to
rectify problems
Contains instructions for removing and fitting the appliance parts
Danger symbol
Danger symbol Meaning
Warns of potential injuries. Heed all the warning notices that appear after this
symbol to avoid potential injuries or death.

1 General information
Repair Manual C4 10
Form of warning notices
The warning notices are categorized according to the following hazard levels:
Hazard level Consequences Likelihood
Death / serious injury (irreversible) Immediate risk
Death / serious injury (irreversible) Potential risk
Minor injury (reversible) Potential risk
NOTICE Damage to property Potential risk

2 For your safety
Repair Manual C4 11
2 For your safety
Purpose of this chapter
This chapter provides you with all the information you need in order to use the combi steamer safely
without putting yourself or others at risk.
This is a particularly important chapter that you should read through carefully.
Contents
This chapter contains the following topics:
Page
Basic safety code 12
Warning signs on the combi steamer for table-top models with fixed supporting structure 13
Hazards and safety precautions when replacing appliance parts 14
Safety devices 18
Requirements to be met by personnel, working positions 20
Personal protective equipment 21

2 For your safety
Repair Manual C4 12
2.1 Basic safety code
Object of this safety code
This safety code aims to ensure that all persons who use the combi steamer have a thorough knowledge
of the hazards and safety precautions, and that they follow the safety instructions given in the user
manual and on the combi steamer. If you do not follow this safety code, you risk potentially fatal injury
and property damage.
Working with the combi steamer
Follow the instructions below:
Only those persons who satisfy the requirements stipulated in this user manual are permitted to use
the combi steamer.
Only use the combi steamer for the specified use. Never, under any circumstances, use the combi
steamer for other purposes that may suggest themselves.
Take all the safety precautions specified in this user manual and on the combi steamer. In particular,
use the prescribed personal protective equipment.
Only stand in the working positions specified.
Do not make any changes to the combi steamer, e.g. removing parts or fitting un-approved parts. In
particular, you must not disable any safety devices.
More on this ...
Related topics
>Safety devices 18
>Requirements to be met by personnel, working positions 20
>Personal protective equipment 21

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2 For your safety
Repair Manual C4 14
2.3 Hazards and safety precautions when replacing appliance
parts
Safety hazard: electrical power
Danger Where or in what situations does the
hazard arise? Preventive action
Risk of electric shock from
live parts
Under covers
Under the control panel
Work on the electrical system must only
be performed by qualified electricians
from an authorized customer service
company
Professional working
Before removing the covers:
Switch off all connections to the power
supply
Take protective measures at every
power switch to ensure that the power
cannot be switched on again.
Wait 15 minutes to allow the DC bus
capacitors to discharge
Make sure that the appliance is
de-energized
Make sure that the electrical connections
are intact and fixed securely before
plugging the appliance back into the
power supply.
On the appliance and on adjacent metal
parts
On the appliance and on adjacent
metallic accessories
Before putting the appliance back into
use, make sure that the appliance,
including all metallic accessories, is
connected to an equipotential bonding
system

2 For your safety
Repair Manual C4 15
Source of hazard: gas
Danger Where or in what situations does the
hazard arise? Preventive action
Risk of explosion from gas If gas pipes are leaking
If the gas tap is opened before the gas
has been connected fully
If the appliance is moved
The gas supply must be connected and
repaired solely by qualified gas engi-
neers from an authorized installation
company
Install gas shutoff device close to
appliance
Make sure that the appliance is secured
in place
Never move appliance during use
For wheeled appliances with a flexible
connection pipe:
Only move the appliance forward for
cleaning, servicing or repair purposes;
never move forward by more than 0.5
m
Before operating the appliance, always
engage the parking brake on the
wheels
Check that wheel brakes are on before
operation each day
On smelling gas:
Disconnect gas supply at the shut-off
devices
Ventilate room
Do not operate any electrical equip-
ment
Do not create naked flames
Get help
Risk of suffocation from
lack of air
Where appliance is installed Do not obstruct lower area of
equipment
Only operate appliance in a
draught-free environment
Ensure that a ventilation system is in
place, is working properly and is
running
Perform yearly servicing on the
appliance
Turn off the appliance when not in
use

2 For your safety
Repair Manual C4 16
Safety hazard: heat
Danger Where or in what situations does the
hazard arise? Preventive action
Risk of fire from heat given
off by the appliance
If flammable materials, gases or liquids
are stored near or on the appliance.
Do not store flammable materials, gases
or liquids beside or on top of the appli-
ance.
A risk of burns from hot
surfaces
Outside of appliance door Before starting servicing and repair work,
wait until the cooking chamber has
cooled to below 60°C or use the
Cool-Down function to cool the cooking
chamber
Wear specified protective clothing, in
particular protective gloves
Inside the entire cooking chamber,
including all parts that are inside during
cooking, such as
Racks
Suction panel
Core temperature probe
Shelf-grills etc.
On the inside of the appliance door
On the transport trolley
On the loading trolley
On the top of the appliance:
Air vent
Exhaust outlet
Ventilation port
Risk of scalding from hot
steam if water is sprayed
into the hot cooking
chamber
In the entire cooking chamber Before starting servicing and repair work,
wait until the cooking chamber has
cooled to below 60°C or use the
Cool-Down function to cool the cooking
chamber
Wear specified protective clothing, in
particular protective gloves

Safety hazard: mechanical parts of the appliance
Danger Where or in what situations does the
hazard arise? Preventive action
Risk of hand injuries from
rotating fans
In the cooking chamber behind the
suction panel
In wiring compartment
Disconnect power supply before re-
moving the suction panel
Disconnect power supply before re-
moving the cover
Risk of body parts being
crushed if the appliance tips
over or falls off
When the appliance is being moved e.g. to
gain better access to the connections
Always observe the requirements for the
supporting surface; see Requirements for
the installation site in the chapter ‘Setting
up the appliance’ in the Installation manual
Gefahr einer Schnittverlet-
zung durch scharfe Kanten
Beim Hantieren mit Blechteilen Bei diesen Tätigkeiten Vorsicht walten
lassen
Persönliche Schutzausrüstung tragen
Risk of hands being
pinched
When wheeling in transport trolleys or
loading trolleys
Always use the loading trolley handle
when moving transport trolleys or loading
trolleys

2 For your safety
Repair Manual C4 17
Safety hazard: cleaning agent
Danger Where or in what situations does the
hazard arise? Preventive action
Risk of chemical burns or
irritation to skin, eyes and
respiratory system from
contact with cleaning
agents and their fumes
When handling the cleaning-fluid canis-
ters
Wear personal protective equipment
When corrosive cleaning fluids are used Only use those cleaning fluids that are
specified under Cleaning fluids in the
‘Cleaning procedures’ chapter of the user
manual
Safety hazard: contamination of foodstuffs
Danger Where or in what situations does the
hazard arise? Preventive action
Risk of food contamination
by cleaning agents
From inadequate cleaning if
the caps have been swapped over on the
cleaning-agent and rinse-aid canisters to
which the supply tubes are connected
the canisters for cleaning agent and
rinse aid have been filled with the wrong
fluid
the bottles used for single-measure
dispensing have been swapped over
When replacing the canisters for clean-
ing agent and rinse aid, take care to fit
the correct tube to each canister.
When filling the canisters, make sure you
are adding the correct chemical for the
tube concerned.
When inserting the single-measure
dispensing bottles, make sure you fit the
correct bottle in the correct place.
Source of hazard: moving heavy weights
Hazard Where or in what situations does the
hazard arise? Preventive action
Risk of injury from over-
stressing your body
When moving the appliance Use a fork-lift truck or pallet truck to
place the appliance in its installation
position or to move the appliance into a
new position
Always use the correct number of
people and observe the limits specified
for lifting and carrying when shifting the
appliance
Observe the occupational safety
regulations that apply to the site of use
Personal protective equipment

2 For your safety
Repair Manual C4 18
2.4 Safety devices
Meaning
The combi steamer has a number of safety devices to protect the user from hazards. It is absolutely
essential that all safety devices are fitted and in working order when operating the combi steamer.
Position and function
The figure below shows a size 20.20 combi steamer as an example for all appliance sizes:
Item Safety device Function Check
1 Cover can only be re-
moved using tool
Prevents live parts from being
touched accidentally
Prevents access to the moving
fan from the wiring compartment
Check that the cover is in place
2 Operating panel can only
be removed using a tool
Prevents live parts from being
touched accidentally
Ensure that the operating panel is
in place
3 Appliance door Protects the user and outside
environment from hot steam
Check the door pane regularly for
scratches, cracks, indentations etc.
and replace it if any are found
4 On-latch position of
appliance door
Prevents scalding of user's face
and hands from escaping steam
When appliance is at low temper-
ature, check door positions as
described in 'Opening and closing
the appliance door safely' in the
user manual
5 Suction panel in cooking
chamber; can only be
removed using a tool
Prevents access to the moving fan
and ensures good heat distribution
See 'Removing and fitting the
suction panel' in the user manual
for further details
6 For floor-standing units:
built-in
preheat bridge in appli-
Prevents scalding from escaping
steam when the loading trolley is
not in the appliance during pre-