Welbilt Convotherm 4 easyTouch Installation guide

Combi steamer
Convotherm 4
Training manual - Original, ENG






Table of Contents
Training manual Convotherm 4 3
Table of Contents
1General information 5
1.1Contact data 6
1.2Environmental protection 7
1.3Identifying your combi steamer 8
1.4Structure of the full set of documentation 10
1.5About this training manual 11
2For your safety 13
2.1Basic safety code 14
2.2Warning signs on the combi steamer 15
2.3Hazards and safety precautions when replacing appliance parts 17
2.4Safety devices 21
2.5Requirements to be met by personnel, working positions 23
2.6Personal protective equipment 24
3Appliance construction / modules 25
3.1Service hatches 26
3.2Bottom frame 27
3.3Wiring compartment 28
3.3.1Electric appliances 28
3.3.2Gas appliances 29
3.4Drain box / collector 32
3.5Boiler 34
3.6Sensor positions / temperature measurement 35
3.7Knowledge test on appliance modules 36
3.7.1Electric appliances (knowledge test) 36
3.7.2Gas appliances (knowledge test) 38
4Operating principles 39
4.1Variable frequency drive / Motor / Fan 40
4.2Solid-state relay 41
4.3Flowmeter 42
4.4Water circuit 43
4.5Waste-water cooling 45
4.6Closed system (ACS+) 46
4.7Water treatment system / Filter Care 47
4.8Steam generation 48
4.9Steam measurement 49
4.10Cleaning system / pumps 50
4.11Crisp&Tasty 53
4.12Gas appliances / forced-air burner technology 54
5Service programs 58
5.1easyDial 59
5.1.1Running the Service program 59
5.1.2Service values 60
5.1.2.1Diagnostic-testing values 60
5.1.2.2Read values 62
5.1.2.3Control values (adjustable parameters) 64

Table of Contents
Training manual Convotherm 4 4
5.2easyTouch 67
5.2.1Running the Service program 67
5.2.2Service menu 70
5.2.2.1Settings tab 70
5.2.2.2I/O tab 71
5.2.2.3Status tab 73
5.2.2.4Gas tab 74
5.2.2.5Tools tab 76
6Troubleshooting 86
6.1The top 5 customer complains according to the Pareto Principle (80:20) 87
6.2Software error messages - summary 89
6.3Cooking programs that can be used in emergency mode - Summary 91
7Control electronics 94
7.1easyDial 95
7.2easyTouch 95
7.3System Interface Board (SI board) 96
7.4Controller layout diagram 105
8Software update 108
8.1easyDial software update 109
8.1.1Preliminary steps for updating the appliance software 109
8.1.2Software update 110
8.2easyTouch software update 112
8.2.1Preliminary steps for updating the appliance software 112
8.2.2Software update 113
8.3Importing cleaning files for easyDial appliances with fully automatic oven cleaning116
8.3.1Preparing for the import 116
8.3.2Importing cleaning files 116
9Servicing / Cleaning 117
9.1List of tools 118
9.2Multitool 120
9.3Recommended servicing tasks 136
9.3.1Cleaning the dehumidifier valve 137
9.3.2Testing steam-generation injection at the injection unit 139
9.3.3Adjusting the injection pressure 140
9.3.4Cleaning the injection nozzle 141
9.3.5Descaling the appliance 143
9.3.5.1Descaling the boiler 143
9.3.5.2Descaling the cooking chamber 148
9.3.6Adjustment 150
9.3.6.1Testing gas appliances before putting the appliance into use 150
9.4Check lists - Servicing 152

1 General information
Training manual Convotherm 4 5
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 6
Environmental protection 7
Identifying your combi steamer 8
Structure of the full set of documentation 10
About this training manual 11

1 General information
Training manual Convotherm 4 6
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]
Phone, spare parts (+49) (0) 8847 67 - 880
email, spare parts [email protected]
Service documents download centre
(spare-parts lists, circuit diagrams, Service
manuals)
www.convotherm.com
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
Training manual Convotherm 4 7
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 environmen-
tal 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 agents
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
Training manual Convotherm 4 8
1.3 Identifying your combi steamer
Position of type plate
The type plate is located on the left-hand side of the combi steamer.
Layout and structure of the type plate (electric appliances)
Item Name
1 Name of appliance
Combi Steamer
2 Trade name
Element Meaning
C4 Convotherm 4 appliance series
eT easyTouch controls
eD easyDial controls
numbers xx.yy Appliance size
EB Electrical unit with boiler
ES Electrical unit with water injection
-N for appliances with an NSK certificate
3 Electrical values
4 Serial number
Element Meaning
Heating method Electrical unit (X, V)
Steam generation method Injection (S)
Boiler (B)
Appliance size 6.10 (1)
6.20 (2)
10.10 (3)
10.20 (4)
12.20 (5)
20.10 (6)
20.20 (7)
Year of manufacture 2014 (14)
2015 (15)
...
Month of manufacture January (01)
February (02)
March (03)
...
Sequential number 4 digits
5 Part number

1 General information
Training manual Convotherm 4 9
Layout and structure of the type plate (gas appliances)
Type plate Additional plate Name
1 Name of appliance
Combi Steamer
2 Trade name
Element Meaning
C4 Convotherm 4 appliance
series
eT easyTouch controls
eD easyDial controls
numbers
xx.yy
Appliance size
GB Gas appliance with boiler
GS Gas appliance with water
injection
-N for appliances with an
NSK certificate
3 Electrical values
4 Serial number
Element Meaning
Heating
method
Gas appliance (Y, W)
Steam
generation
method
Injection (S)
Boiler (B)
Appliance
size
6.10 (1)
6.20 (2)
10.10 (3)
10.20 (4)
12.20 (5)
20.10 (6)
20.20 (7)
Year of
manufacture
2014 (14)
2015 (15)
...
Month of
manufacture
January (01)
February (02)
March (03)
...
Sequential
number
4 digits
5 Part number
6 Gas data
7 Country ID
8 Gas category
9 Gas setting for appliance

1 General information
Training manual Convotherm 4 10
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 - After-sales service (this manual)
Training manual - Sales
Error message manual
Repair 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

1 General information
Training manual Convotherm 4 11
1.5 About this training manual
Purpose
This training manual is intended for all people who service or repair the combi steamer, and provides
them with the necessary information on the design and construction of the appliance, the operating
principles, monitoring and control devices and on servicing and cleaning. This document also serves
as a training and reference manual for authorized and approved customer service engineers.
Who should read this manual
Name of target group Tasks
Trained service engineers All servicing and repair work
Electrical installation
engineer
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 training manual
Chapter/section Purpose
General information Provides important contact data
Shows you how to identify your combi steamer
Provides guidance on using this training manual
For your safety Describes the hazards posed by the combi steamer and appropriate preventive
measures.
You should read this chapter carefully in particular.
Appliance construc-
tion/modules
Describes the design and construction of the combi steamer, the modules it
contains and what they do.
Operating principles Explains how the combi steamer and its modules work.
Monitoring and safety
circuits
Describes the safety circuits in the appliance.
Troubleshooting Summarizes the software error messages
Summarizes the cooking programs that can be used in emergency mode
Control electronics Describes the controller software in a combi steamer.
TDs (Technical Documents) Contains information on Service updates and modifications to the appliance.
Servicing/cleaning Shows the tools needed for servicing work
Shows an example of the service contract
Shows an example of the servicing checklist
Explains the procedure for descaling the appliance

1 General information
Training manual Convotherm 4 12
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.
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
Training manual Convotherm 4 13
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 14
Warning signs on the combi steamer for table-top units with fixed supporting structure 15
Hazards and safety precautions when replacing appliance parts 17
Safety devices 21
Requirements to be met by personnel, working positions 23
Personal protective equipment 24

2 For your safety
Training manual Convotherm 4 14
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 warning notices 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 unapproved parts. In
particular, you must not disable any safety devices.

2 For your safety
Training manual Convotherm 4 15
2.2 Warning signs on the combi steamer
Warning signs and what they mean
The figure below shows a size 20.10 combi steamer as an example for all appliance sizes:
The following warning signs must be attached to the combi steamer so as to be easily visible at all
times. The labeled areas indicate where the warning signs may need to appear depending on the type
and design of the supporting structure.
Range Warning sign Description
1
Electric shock warning
There is a risk of electric shock from live parts if the protective cover is
opened.
2
3
Warning of hot liquids
Spillage of hot liquid foods can result in scalds if the upper shelf levels are
loaded with liquids or foods that produce liquid during cooking. Shelves that
lie above the sightline of the user must not be used for liquid foodstuffs or
food that will liquefy during cooking.
2 Warning of hot steam and vapour
There is a risk of scalding from hot steam and vapour escaping when the
appliance door is opened.

2 For your safety
Training manual Convotherm 4 16
If the supporting structure is designed to be mobile, the following additional warning signs must be
attached to the combi steamer so as to be easily visible. The labeled areas indicate where the warning
signs may need to appear depending on the type and design of the supporting structure.
Range Warning sign Description
2
3
Tipping or toppling warning for combi steamer
There is a risk of the combi steamer toppling over if it is placed on a wheeled
supporting structure. Always take great care when moving the combi steamer.
Toppling warning for loading trolley
There is a risk of the loading trolley toppling over if it hits an obstacle. Always
take great care when moving the loading trolley.
2 Damage or detachment warning for appliance connections
There is a risk of the appliance connections being damaged or pulled off if the
combi steamer is moved. Always ensure there is enough length in the con-
necting cables/pipes when moving the combi steamer. After moving, always
secure the combi steamer against rolling away.

2 For your safety
Training manual Convotherm 4 17
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 electri-
cians 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
Training manual Convotherm 4 18
Safety hazard: gas
Danger Where or in what situations does the
hazard arise?
Preventive action
Explosion hazard from gas If gas pipes are leaking
If the gas tap is opened before servic-
ing or repair work has finished
If the appliance is moved
After repairing or replacing any gas
components.
Always disconnect the gas supply before
starting work on the gas installation
For table-top units on a wheeled platform
and with a flexible connection pipe:
Do not move the appliance forward
beyond its range of movement in order
to carry out servicing or repair work.
The range of movement is set by the
retaining device used to secure the
appliance in place (typically 0.5 m).
Never strain the connecting cables or
pipes.
Secure the appliance by engaging the
parking brake on the wheels
Never move appliance during use
Connection of the gas supply must be
entrusted solely to qualified gas engi-
neers from an authorized installation
company
Always perform a gas leak test after any
repair to a gas component.
Risk of suffocation from
lack of breathable air
Where appliance is installed Check the exhaust gas readings and if
necessary get an authorized installa-
tion company to adjust the burner
Ensure that a ventilation system is in
place, is working properly and is run-
ning, and that the ventilation require-
ments stipulated by the installation
engineer are met
Do not obstruct lower area of equip-
ment
Only operate appliance in a
draught-free environment

2 For your safety
Training manual Convotherm 4 19
Safety hazard: heat
Danger Where or in what situations does the
hazard arise?
Preventive action
Fire hazard 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 or were 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
removing the suction panel
Disconnect power supply before
removing 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 Installa-
tion manual
Risk of cuts from sharp
edges
When handling sheet-metal parts Exercise caution when performing
these tasks
Wear personal protective equipment
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
Training manual Convotherm 4 20
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 working with cleaning agents Wear personal protective equipment
Observe the labels on the cleaning
agents and the relevant safety
datasheets before using the cleaning
agents
When corrosive cleaning agents are
used
Only use those cleaning agents that are
specified under 'Cleaning agents' 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 can-
isters 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
cleaning 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.
Safety hazard: moving heavy weights
Danger 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 forklift truck or pallet truck to
place the appliance in the installation
position or to move it to a new position
Always use the correct number of
persons and observe the limits speci-
fied for lifting and carrying when ad-
justing the appliance position
Observe the local occupational safety
regulations
Wear personal protective equipment