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SERVICE MANUAL

1. 50 MODEL KAZEM isprate Sn 52 WIRING DIAGRAMS ecd A EPER 54 COMPONENT CONNECTIONS 2 90 eene nhe nennen 54 KA7EM COMPONENT CONNECTIONS 2 0 0 nens 55 POWER CONNECTION dct tence aaah Maece MER 56 SCHEMATIC DIAGRAMS ont eis Mite crates 57 2255 2 624 te 57 42552 cc da P M o AL MM KL M LU LL LE 59 PLUMBING DIAGRAMS ONLY 3 2 99222 1 62 TROUBLESHOOTING 0 o pde 64 TROUBLESHOOTING deme 64 TROUBLESHOOT ROTOR COMPONENTS 42 2 2 2 22 2 2 0 022222 67 Meet rH 69 REVERSING CONTROLS uae ie Mac dui a e M Ae Ada 69 HOBART SERVICE 2012 30 77 F25294 Rev A 0412 KA SERIES ELECTRIC OVENS GENERA
2. beer 18 TEMPERATURE SENSOR d Pd 18 CONTACTORS oro tee duis wads tad asd 19 POWER SWITCH AND MOMENTARY SWITCHES 4 2 19 DISPLAY BOARD AND KEYPAD 2 7 4 20 ROTORSSTOP START SWITGH ere chad theres d 21 eei Rer ub uoo as 22 CAPACITORS a epe Reb Uhr bet eei e nb kata eed d rto ga 22 WATER LEVEL CONTROL BOARD ONLY 23 WATER LEVEL SENSOR ONLY 4 7 2 24 CHEMICAL SENSOR ONLY 2 2 1 42 4 27 72 24 WASH PUMP RELAY ONLY 24 TRANSFORMER 2 5 teg teat acuta etel rre hatin a Re cod d dt 25 CPU BOARD noh eA me pea ace rds t nine adenine BC o dt 25 PERISTAETIGC PUMBS tto tc sede ict echte MIROR RA RO
3. 6 of 72 KA SERIES ELECTRIC OVENS GENERAL INSTALL GREASE OUT HOSEBICHEMICAL IN 19422 Fig 9 15 Route water supply through the bottom of the stand and connect Fittings mate to 4 inch male PARTS REMOVED FOR VIEW hese pb notrsuppliedy Fig 7 16 Route water drain through the bottom of the stand and connect Fittings mate to 1 inch female NPT not supplied 11 Install water valve onto bracket on new utility plate supplied with stand 17 Route chemical in and grease out hoses down through bottom of machine into stand Connect hoses to grease vessel and chemical container 18 Route power cord thru base into oven and connect to terminal block 19 Proceed to Tether Bracket and Oven Mounting to Stand KA7E KA7EM KA7EM with Grease Assist ML 137710 ML 137713 1 Remove Right Side Cover 2 Remove electric power cord blank Install power cord restraining fitting not supplied in the proper PARTS REMOVED FOR VIEW hole E1 Fig 8 12 Install new utility plate onto oven using screws removed earlier 13 Install drain plug removed earlier 14 Install new hoses supplied with oven and route down into base GREASE HOSE P2 ELECTRICAL 23923 E1 Fig 10 Page 7 of 72 25294 0412 KA SERIES ELECTRIC OVENS GENERAL 3 Remove screws and valve bracket from factory standard utility plate
4. 5 REMOVAL AND REPLACEMENT OF PARTS DOOR aN A WARNING Disconnect the amp IX S electrical power to the machine and follow lockout tagout procedures e 4 COVER 1 Remove Left Side Cover 2 Open oven door and pull inner oven door to overcome magnet hold to main door INNER DOOR A1 2120 Fig 19 4 Reverse procedure to install Fan Cover 1 Open door 2 Remove nut securing fan cover to top of cavity 3 Grab deflector edge and pivot edge toward you to disengage cover from studs 7 4 Slide cover off studs at opposite side and remove ik ELT cover L 5 NOTE Fan cover can be removed thru either door in 19300 the same manner Fig 21 3 Lift inner door hinge pins out of hinge bushings and lay door on a flat padded surface oun x HINGE BUSHING ZPIVOT EDGE TOWARDS YOU oun Ww Ae REMOVE NUT VIEW AS LOOKING THROUGH DOOR GLASS 19301 5 Reverse procedure to install Fig 22 4 Remove screws securing facade to oven NOTE Make sure all six studs are engaged properly and that the cover does not hang down Page 11 of 72 F25294 Rev 0412 KA SERIES ELECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS yy yov Fig 23 5 Close door 6 Remove nuts securing top hinge to cabinet Fig 24 7 Carefully remove
5. OVENS SERVICE PROCEDURES AND ADJUSTMENTS PROGRAMMING ALL SOFTWARE VERSIONS Parameter Description Number E 0 Fahrenheit F will display in Time window Default 0 1 Celsius C 1 will display in Time window FC will display in Program window If the temperature display option is changed you will see a slight pause as all stored cook programs are converted to new units 0 AM PM AP 0 will display in Time window Default 0 1 24 hour clock 24 1 will display in Time window CL will display in Program window Future use To be used when connected to remote computer 0 ASCII serial protocol 0 will display in Time window Default 0 1 Binary serial protocol 1 will display in Time window SP will display in Program window Future use To be used when connected to remote computer Oven ID number Range 0 to 31 The number entered will display in Time window Default 0 ID will display in Program window Temperature offset Difference between sensor temperature and displayed temperature value used to correct for the difference between sensor and cooking chamber temperature if any Range 30 to 30 The number entered will display in Time window Default 0 C or F depends on unit selected OS will display in Program window NOTE In the table below an asterisk beside 3 Enter desired Parameter Number containing an Parameter Number indicates a Service Only asterisk and verify o
6. reassembly 19388 MOTOR ALREADY REMOVED Install in reverse order Snug but do not tighten screws securing gasket bracket at this time Bracket and gasket must be loose during the drive motor adjustment procedure Continue to Drive Motor Adjustment Drive Motor Adjustment WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures NOTE Some pictures show different model oven parts They are used for view and adjustment is identical 1 2 Remove Right Side Cover Install rotor Page 31 of 72 Place non driven side of rotor shaft onto upper notch of support bearing NOTE Ensure rotor is slid as far as possible on bearing support toward non drive side UPPER NOTCH ON SUPPORT BEARING Fig 103 Place drive end of rotor shaft on crank arm support notch CRANK ARM SUPPORT NOTCH 10170 Fig 104 Loosen screws securing rotor drive motor to support bracket Fig 105 Use a square or similar tool to make gearbox square to motor support F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS SUPPORT NOTCH Fig 108 8 Rotate rotor to align crank arm pins with slots on rotor Fig 107 7 Slide gearbox in or out while keeping it square to motor support until there is sufficient clearance for rotor shaft to be lifted off and on the support notch without the end of shaft contacting cr
7. OVENS 137701 137709 137710 ML 137711 ML 137713 ML 137714 19298 KA7E WITH STAND ACCESSORY SHOWN NOTICE SERVICE MANUAL KA SERIES ELECTRIC ROTARY Information in this manual superceedes TSB 1406 SELF CLEAN GLASS BACK SELF CLEAN SOLID BACK MANUAL CLEAN GLASS BACK WITH GREASE ASSIST MANUAL CLEAN GLASS BACK WITHOUT GREASE ASSIST MANUAL CLEAN SOLID BACK WITH GREASE ASSIST MANUAL CLEAN SOLID BACK WITHOUT GREASE ASSIST A product of Hobart Service This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified This manual is not intended to be all encompassing If you have not attended a Hobart Service School for this product you should read in its entirety the repair procedure you wish to perform to determine if you have the necessary tools instruments 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 Hobart Service Technician The reproduction transfer sale or other use of this Manual without the express written consent of Hobart is prohibited This manual has been provided to you by ITW Food Equipment Group LLC ITW FEG without charge and remains the property of ITW FEG and by accepting this manual you agree that you will return it to ITW FEG promptly upon its request for s
8. 3 Remove both fan blades 19318 Fig 40 6 Unscrew both fan mounting nuts NOTE Check condition of o ring on fan mounting nut and replace if necessary Page 15 of 72 Tn n F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS C Work pipe out of oven 19320 Fig 41 7 KATE only Fig 44 8 Insert two large screwdrivers or similar objects that can lift fan motor assembly enough for motor shafts to clear inside ceiling m 55 SS Fig 42 Loosen hose clamp and remove hose from Fig 45 control side nozzle and pipe assembly 9 Identify and disconnect motor wires B Remove screws and nuts securing control side nozzle pipe assembly to top of oven 10 Carefully slide fan motor assembly out of cavity NOTE Check condition of o rings on screw heads 11 Remove screws securing fan motor assembly and replace if necessary and lift out VS 77 25294 Rev 0412 TI _ Page 16 of 72 KA SERIES ELECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS Fig 46 12 Remove o ring from old fan motor shaft and install on new fan motor If not in good condition install new o ring Fig 47 13 Reverse procedure to install 14 After installing the fan blade verify that it does not rub the top of the cavity If required remove fan blade and tighten fan mounting nut shown in Step 6 above HEATING EL
9. 4 Save screws and bracket Discard original factory standard utility plate 5 Remove grease out hose from 45 degree strain relief fitting VALVE BRACKET ORIGIONAL UTILITY PLATE GREASE OUT HOSE 23924 Fig 11 6 Install valve bracket from old plate onto new utility plate supplied with stand 7 Install new utility plate assembly onto oven using screws removed earlier 8 Install 34 MNPT to 34 ID 90 deg Barb Hose Fitting not supplied into P1 drain connection NOTE P1 drain connection cannot drop through into stand and must exit out the right side of the oven 9 Route grease out hose down through bottom of machine into stand 10 Route power cord through stand up into oven and connect to terminal block 11 Proceed to Tether Bracket and Oven Mounting to Stand KA7E KA7EM without Grease Assist ML 137711 ML 137714 1 Remove Right Side Cover 2 Remove electric power cord blank Install power cord restraining fitting not supplied in the proper hole E1 F25294 Rev A 0412 H ELECTRICAL E1 23925 Fig 12 3 Remove screws from factory standard utility plate LS ad ORIGIONAL UTILITY PLATE Fig 13 4 Install 34 MNPT to 34 ID 90 deg Barb Hose Fitting not supplied into P1 drain connection 23926 5 Install new utility plate supplied with stand assembly onto oven using screws removed earlier 6 Install Pl
10. 5 Either accept this value by pressing ENTER key or key in new value and then press ENTER key to accept it A Pwillflash in temperature window indicating a new parameter number can be entered 6 To save parameter settings and exit service mode turn the power switch to off The unit will remember the changes After the power is turned off power can be disconnected from unit if necessary to complete repairs Procedure to Toggle Between No ID and Operator ID Mode 1 Turn power switch off N Press and hold keys 1 2 and 3 at the same time while turning power switch on 3 Display shows ID in the temperature window and ON or OFF in the time window 4 Turn power switch off and then back on to return to operator mode 5 Repeat steps 1 thru 4 to toggle back Procedure to Toggle Between 9 and 99 Programs 1 Turn power switch off 2 Press and hold keys PROBE ENTER and 2 at the same time while turning power switch on 3 Display shows 9 or 99 in temperature window and PROG in the time window 4 Turn power switch off and then back on to return to operator mode 5 Repeat steps 1 thru 4 to toggle back TIME OAM OPM TEM PERATURE Qc PROGRAM STEP 123 4 OOOO 23930 KA7E DISPLAY SHOWN Service Mode Parameters PROGRAMMING ALL SOFTWARE VERSIONS Parameter T Time display will show software version Read Only F25294 Rev A 0412 x Page 36 of 72 KA SERIES ELECTRIC
11. KA SERIES ELECTRIC OVENS ELECTRICAL OPERATION m the uA TB2 power in terminal block lE Drive motor assembly M3 Utility plate for grease assist option s Electrical Connection E1 o Grease Assist Pumped Drain P2 Posse eise ec etes Drain main amp sump P1 Dos edt TB3 terminal strip located above and behind pump Renee eU Grease Pump Models with grease assist only S Sump Drain Level Manual d vo EA ERA Vas Keypad and display board assembly 2 ut Rotate switches etta Power switch d estos bubo Meat probe mini jack WIRING DIAGRAMS Component Connections F25294 Rev A 0412 54 of 72 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION t HEATING ELEMENTS LIGHT 12 5 6 13 14 15 16 POWER SWITCH 7 2T T5 3 6 SNOOZE SILENCE BUZZER ROTATE SWITCH ROTATE SWITCH DRIVE MOTOR mn WATER FILL i 1 1 GREY WATER SUMP GREASE CHEMICAL Removed from ovens with Serial No 46300096 and higher WATER GROUND GROUND CHEMICAL LEVEL LEVEL Al 33
12. REMOVAL AND REPLACEMENT OF PARTS NOTICE Due to use of chemical detergents all interior replacement hardware must be stainless steel hardware as listed in the parts catalog COVERS WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Pump Cover 1 Remove two thumbscrews securing pump cover and lift cover off 2 Reverse procedure to install NOTE Anytime service is performed requiring the right side cover to be removed check to ensure incoming power terminal block wire retaining screws are tight Right Side Cover 1 Remove Pump Cover 2 Remove twelve screws securing right side cover to frame 3 Loosen one screw securing top center of cover LOOSEN SCREW RIGHT SIDE COVER Fig 17 4 Remove cover 5 Reverse procedure to install F25294 Rev A 0412 Left Side Cover 1 Remove ten screws securing left side cover to frame 2 Loosen one screw securing top center of cover LOOSEN SCREW LEFT SIDE COVER Fig 18 3 Remove cover 4 Reverse procedure to install Top Cover Control Panel 1 Remove screws securing top cover over controls area 2 Remove cover 3 Reverse procedure to install Top Cover 1 Remove screws securing Top Cover Control Panel 2 Remove cover 3 Remove remaining screws securing top cover and lift cover off Page 10 of 72 KA SERIES ELECTRIC
13. of the 9 digits on the front display for each of the inputs digit 8 amp 9 future use The digits are arranged on the display in the pattern shown in the picture at the end of this section If an input is OFF the digit displays a dash If the input is ON the digit displays a 1 Included in the picture are display examples for the input test Fill Me digit 2 and Door Position digit 7 The tests show a 1 for both the inputs indicating 24VAC is present water fill valve energized and doors closed NOTE will always display one 1 in digit 2 position and a dash in all the other digit positions Digit 1 Press rotate switch to test input to CPU board X16 Digit 2 Fill Me input to CPU board X17 Ground the probe to a metal surface on machine to test approximately 3 second time delay Digit 3 Low Level Input X18 Ground the chemical probe sensor to a metal surface on machine to test approximately 3 second time delay Digit 4 Press stop switch at rear of machine to test input to CPU board X19 Digit 5 Press silence switch at rear of machine to test input X20 Digit 6 Press snooze switch at rear of machine to test input X21 Digit 7 Open door s to test The input to CPU board is removed from X22 Close door s and input is back ON Digit 8 amp 9 Future Use Press ENTER to exit this test F25294 Rev A 0412 40 of 7
14. 5 5 m 4 2 g Z 808 c z 5 5 m 1 1 19 gt d 208 240V B F25294 Rev A 0412 1 2 TB1 3 e al WATER LEVEL CONTROL Removed from ovens with Serial No 46300096 and higher KA7E SCHEMATIC SHEET 1 Al 3357 Fig 129 Page 58 of 72 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION RS485 2 RIBBON a SERIAL DISPLAY X24 os PT500 RTD i Oven Temp X22 J4 Type J Sump Temp x J3 J Meat Probe 4 X20 X35 12VDC X19 X36 gt Beeper L3 x18 seH 12VDC LIGHT 9 ADD 5 MINUTES Lc X17 x16 X6 yate PUMP TETS WASH 4 X32 eol X id GA 24 DRAIN PUMP X5 X5 DRAIN 2 6 3 HEATERS TB1 2 L amp xao f81 12 1109 BLACK 101 1 6 C1 RED C2 Harpo PRONT 815 4 X10 BLUE BLACK TB15 4 X2 gt B1 13 M FANS BLUE Cw M CK 1 5 x8 O BROWN x B1 12 TB1 6 LIGHT Xie AL TB5 1 _ 52 1 5 o 2x 9 5 a gt o m X15 X14 x X pO Hood Auto Off NO d T Timing Trigger ai 1 5 lt Hood Oven A H 3 Hood Oven 6B Interlock Hood Auto Off 8112 81 12 Ng Timing Tri
15. Fig 119 Install in reverse order Snug but do not tighten screws securing gasket bracket at this time It must be loose during the drive motor adjustment procedure Continue to Drive Motor Adjustment Page 35 of 72 F25294 Rev A 0412 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS SERVICE MODE PROGRAMMING AND DIAGNOSTICS NOTE Service Mode allows access to the programming parameters and diagnostic tests to check the oven settings and the electrical component functionality Additionally on KA7E machines a DEMO MODE can be utilized as a continuation of the diagnostic tests that allow the technician to manually step through and verify clean cycle operation without having to run an actual clean cycle NOTE The P key is used to toggle the minus sign on and off Use this key if a negative value must be entered Entering an invalid number results in the time display being set to 0 and a beep beep will sound indicating you should key in a new value Procedure to Enter Service Mode 1 Turn power switch off 2 Press and hold keys CLOCK 7 and 8 at the same time while turning power switch on 3 Displays shows flashing P in temperature window which indicates you are in service mode 4 Press number key s to enter Parameter Number according to the chart below then press ENTER key A Time display will flash showing current value of the parameter
16. Oven temperature does not reach desired temperature 4 Blower motors malfunction Test in P22 or takes a longer time to heat up and recover Blower motor capacitor malfunction Temperature sensor malfunction Oven out of calibration Control board malfunction F25294 Rev A 0412 64 of 72 KA SERIES ELECTRIC OVENS TROUBLESHOOTING General Troubleshooting KA7E amp KA7EM SYMPTOM POSSIBLE CAUSES High limit thermostat open No heat but blowers rotor and customer lamp do _K1 contactor malfunction operate when oven cavity is below set temperature 222 K2 contactor malfunction Control board malfunction Display cable connection loose Keypad connection at display circuit board loose No display and or keypad does not function Keypad malfunction Display circuit board malfunction Control board malfunction Fan cover not installed correctly Slow cooking Clean oven fans Blower motor s malfunction Test in P22 Clean Cycle Troubleshooting KA7E Only NOTE Durning a cleaning cycle pauses of several seconds may occur as the oven cycles from one mode of cleaning to another mode This is normal and should not be considered a problem SYMPTOM POSSIBLE CAUSES Leake intoconttolareaatdnvearii TSB1400 LEAKS AT DRIVE ARM GASKET DURING WASH CYCLE Water is not spraying during wash cycle 1 Wash cycle is in soak mode Display shows
17. Soaking 1 Strainer pans are not installed correctly and are Wash arm is not turning interfering with wash arm motion 1 Oven is cooling down or preheating to the optimum Nothing seems to be happening after CLEAN is pressed temperature for cleaning 1 Chemical bottle may be empty Ensure tubing is cut at an angle and that standpipe is in place to prevent tube from curling inside Oven is not clean enough after clean cycle is complete chemical bottle Water not hot enough May need additional pre rinse programmed P37 Water not hot enough Add second pre rinse to prime hot water line P37 Make sure washer arm is not plugged Remove all Too much foam or white residue left after clean cycle debris if necessary Increase wash pump duty cycle 48 Increase amount of chemical being used P31 Page 650f72 25294 0412 KA SERIES ELECTRIC ROTARY OVENS TROUBLESHOOTING Clean Cycle Troubleshooting KA7E Only 1 Time delays are programmed between steps during clean cycle This is normal operation Cyan ses too mbeh chenestl 1 Typical usage is approximately 1 2 gallon per day Contact Product Service Grease or liquids running outside of oven 1 Pump tubing needs to be replaced Chemical bottle may be empty Nothing seems to be happening in clean mode Ensure tubing is cut at an angle and that standpipe is in place to prevent tube from curling inside chemical bott
18. add 10 minutes to cook time Press to silence buzzer and enter hold mode Press to end cook cycle Al 2130 Fig 122 Model KA7EM Page 49 of 72 F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION HOB ABT ADD 5 Adds 5 minutes to a program step each VHOBART time it is pressed T PROBE Displays temperature external meat probe e X not printed Service use only Hidden key when pressed TEMPERATURE po on keypad oven cavity current temperature will display o X O 1 23 Enter numeric value s PROGRAMS CLEAR Clears time or temperature entry gt 2 gt H et MANUAL 0 Enter a MANUAL Program ENTER Accepts time or temperature entry START Begins cooking cycle PROGRAM Enters program mode to modify a cook program press P for 3 seconds STOP Stops cycle SILENCE Silences beeper CLOCK Sets the clock for time of day P STOP coc AUX Toggles grease assist pump On Off ROTATE Rotor on off pauses cooking and cleaning cycle MAIN Turns oven and controls on or off POWER SWITCH PROBE External temperature probe plugs in here Pulling lever assembly away from machine opens the sump valve Sump disposal port is on right side of machine Pushing lever assembly toward machine Al 3354 closes the sump valve Fig 123 COMPONENT LOCATIO
19. cable ties as needed to neatly dress wires out of the way 15 Install covers and check for proper operation 2 Insert threaded end of drain control linkage assembly through bushing 3 Install drain control lever to drain valve Secure with mounting nut F25294 Rev A 0412 gt Page 72 of 72
20. hinge plate while supporting hinge backing plate and lift door off lower hinge pin F25294 Rev A 0412 8 Reverse procedure to install but leave nuts securing hinge plate loose Perform Door Adjustment Door Adjustment 1 With top hinge plate mounting nuts loose use an object to shim handle end of door to make bottom of door parallel to the sump facade Fig 26 2 Tighten hinge plate nuts and check door operation Make sure there is no interference or rubbing when door is operated Door must not contact sump facade when opening or closing 3 Check Door Switch Adjustment only if required LED at CPU board input X22 should be on when both doors are closed and both door switches are closed Door Switch Adjustment only if required 1 With oven top facade removed to access door Switch loosen switch mounting screws and adjust switch as required LED at CPU board input X22 should be on when both doors are closed and both door switches are closed 2 Install all covers and check for proper operation Page 12 of 72 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS DOOR SWITCH MAGNET ONLY ky WARNING Disconnect the S electrical power to the machine and SY follow lockout tagout procedures 1 oven door and pull inner oven door to overcome magnet hold to main door INNER DOOR 19300 Fig 28 2 Remove screws secur
21. is positioned Make sure hose clamp is in cutout to hold hose in position Fig 85 3 frollers need to be removed use a screwdriver and release both sides of retaining clamp ou 2668 a 19428 Fig 88 6 Install face plate 7 Install hose clamps and connect hoses Trim discharge hose length if needed for proper fit 8 Complete reversing procedure to install 9 Verify that pump is working properly as outlined under SERVICE MODE PROGRAMMING AND DIAGNOSTICS Fig 86 4 Pull roller assembly off shaft Page 27 of 72 n F25294 Rev A 0412 KA SERIES ELECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS WATER FILL VALVE KA7E ONLY WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Remove Right Side Cover Shut off water supply to oven 1 2 3 Disconnect water hose into oven water fill valve 4 Disconnect wires to water fill valve 5 Remove screws securing water valve to utility 19367 CURRENT CONSTRUCTION 6 Disconnect hose connected to outlet of water valve 7T Reverse procedure to install WASH PUMP KA7E ONLY WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove Right Side Cover 2 Disconnect wires from wash pump F25294 Rev A 0412 gt Page 28 of 72 KA7E PREVIOUS CONSTRUCTION Remove screws s
22. operating in normal mode and is idle A Cavity light should be OFF to indicate the oven is in normal mode If light is not off repeat procedure to enter NORMAL MODE B Install tube back into chemical cleaner bottle Page 43 of 72 CLEAN CYCLE COMPLETE 3 e Wash arm spraying Rotor turning If correct press ENTER If correct allow the water to drain completely from the machine It will automatically roll to the next step If installed the grey water sump peristaltic pump should be running Allow the pump to remove the water It will automatically roll to the next step after 2 minutes Rotor turning If correct press ENTER Done The machine will automatically exit CLEANING and to IDLE TEMPERATURE SENSOR TEST WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Remove Right Side Cover Remove the probe lead wires from the CPU board Test the probe with an ohmmeter TEMPERATURE in F RESISTANCE 5 OHMS 85 25294 0412 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS TEMPERATURE in F RESISTANCE 5 OHMS 350 836 WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures WATTAGE MODEL RESISTANCE VOLTAGE KATE Tolerance 5 10 96 PUMP K3 RELAY COIL TESTS WARNING D
23. putting oven into service check to ensure incoming power terminal block TB6 wire retaining screws are tight Ovens mounted on casters or installed on stands with casters must be provided with an adequate restraining means to guard against transmission of strain to the electric supply line Instructions for tethering are included in stacking kit instructions and with optional oven stand Disconnect the flexible electrical conduit s before disconnecting the restraint WATER SUPPLY REQUIREMENTS KA7E ONLY NOTE For proper operation use only HOT water supply For installations at the end of a long hot water line a second pre rinse may be required to be programmed to prime the line Hot water supply e 3 4 hose bib fitting e 0 5 25 50 PSI e 120 F 140 F Recommended hardness 4 6 grains Minimum conductivity required 30 MICROMHOS CM TOOLS Standard set of hand tools Page 5 of 72 VOM with AC current tester Any VOM with a sensitivity of atleast 20 000 ohms per volt can be used Temperature Tester e Field Service Grounding Kit Torque wrench capable of measuring up to 45 in Ibs Jewelers screwdriver Power switch and momentary switch removal tool two required made locally to dimensions in graphic below NOTE Material for tool can be aluminum hard plastic or any other hard material which can be easily fabricated to dimensions 118 THICK Fig 1 ACCESSORY
24. switch and bezel out of hole Fig 136 RELEASE TABS 2 5 Remove six nuts securing display panel with T S display board attached and lift out of oven OTHER THREE NUTS NOT VISIBLE Fig 135 4 Unplug ribbon cable from display board A Spread retaining clips to extract plug from Fig 137 socket Page 69 of 72 c F25294 Rev A 0412 SERIES ELECTRIC ROTARY OVENS APPENDIX O t DISPLAY BOARD NUTS O Ci DISPLAY 19345 PANEL Fig 140 Cc 7 Identify and disconnect wires from mini jack 0 4 49338 terminals Fig 136 8 KATE only 95 Remeveimintjacketon Mont panel A opposite side of oven identify and A Usea small screwdriver or similar object to remove wires from momentary switches carefully pry tabs out and work retainer clip B Remove six nuts securing momentary off jack switch plate and work the plate from the oven C Remove two nuts securing the auto clean overlay plate and its retaining plate D Install momentary switch plate and auto clean overlay plate on the opposite side of oven Fig 139 NOTE Jack shown removed from oven for view Also notice that wires are polarity sensitive and must be connected properly for correct operation F25294 Rev A 0412 Page 70 of 72 KA SERIES ELECTRIC ROTARY OVENS APPENDIX FRONT BACK VIEW VIEW O REMOVE 3CO NEN SIX NUTS p HOBART BACK VIEW O RE
25. window Number of pre rinses default 1 will displayed Program window Increase pre rinse number if initial fill is not hot enough Leave setting at 0 and advance to next program number Leave setting at 0 and advance to next program number Water fill time limit in minutes default 5 X X a m o FL will display in Program window Add time as necessary if water pressure is low Cool down temperature in Fahrenheit default 150 Ct will display Program window Oven must cool to this temperature before next operation can start Preheat temperature in Fahrenheit default 150 N CP will display in Program window Drying temperature in Fahrenheit default 200 N Cd will display in Program window Demo Mode Leave setting at zero and continue to the next Program Number See DEMO MODE in the next section dE will display in Program window Additional fill time in seconds default lt 10 OF will display in Program window Wash pump ON time during cleaning default 4 Pr is display in Program window Wash pump OFF time during cleaning default 4 AB SO will display Program window B m 25294 0412 Page 38 of 72 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS PROGRAMMING CONTINUED CUR
26. 2 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS ERES 9 digit display Input Test KA7EM Input Test board input test Fill Me amp Door Fill Me is ON amp all Position are ON others are OFF 23929 DIAGNOSTIC DISPLAY EXAMPLES DEMO MODE KA7E ONLY NOTE Diagnostic tests in SERVICE MODE PROGRAMMING AND DIAGNOSTICS should be performed prior to entering DEMO MODE The DEMO MODE is a continuation of the diagnostic tests for verifying clean cycle operation on KA7E machines After verifying clean cycle operation the machine must be returned to NORMAL MODE as outlined in the procedure NOTE Remove tube from chemical cleaner bottle before starting procedure to keep excess chemical from entering machine during test NOTE The grey water sump peristaltic pump was removed from machines with Serial No 46300096 and higher 1 Enter SERVICE MODE PROGRAMMING AND DIAGNOSTICS Use the keypad to enter parameter numbers A Press 0 and select ENTER to verify software version B Press ENTER to return to parameter selection screen 2 If current software version C027 continue to step 4 3 If previous software version press 72 and select ENTER parameter to unlock service only parameters A Press 1972 and select ENTER code to unlock service only parameters 1 beep 4 Press 44 and select ENTER allows selection of DEMO NORMAL Mode pa
27. 2 2 2 2 2 27 4 10 ee tq 10 PUMP COVER ee eee RA ur alt d dob dores 10 RIGHT SIDE COVER turre o ern e tod de De eal d t aee ie netu pa E 10 EEFT SIDE COMER himins rette ne teca eei detta A eli b eb DNE eh nr wing deen eae 10 COVER CONTROL PANEL irre etra T c a 10 TOP eui AP 10 FAN COVER gp Errem 11 DOOR qc EE 11 DOOR ADJUSTMENT ntt rettet eet et eee ed c Ce Ioa eden 12 DOOR SWITCH ADJUSTMENT ONLY IF REQUIRED 12 DOOR SWITCH MAGNET ONLY 4 2 2 2 2 13 OUTER DOOR GLASS neuere Soi aa uoti tia Rod i ee rae trt od e Hd doa ta 13 WASH ARM STRAINER PANS STRAIN PAN SUPPORT DRAIN SHROUD ONLY 13 Aad dat tto ante ou tnos a e be S IDA LA aH d ok c seni ied ded Natta 14 EFAN MOTORS ASSEMBDY A gei dieta se 15 HEATING ELEMENTS et Redit thee comedian ide netta epis 17 HIGH LIMIT THERMOSTAT
28. 5 SE 4 H H H H H Hood Auto Off Timing Trigger Notes 1 Remove wire 42 on the top rotisserie Add wires 91 92 93 94 as shown 2 If rotisseries are stacked remove wire 42 on the bottom machine and add wires 95 96 97 98 as shown 3 If rotisserie is on a stand discard wires 95 96 97 and 98 DERIVED FROM 00 891572 Label Rev B KA7EM SCHEMATIC SHEET 2 AI 2914 Fig 132 Page 61 of 72 Tn n F25294 Rev A 0412 KA SERIES ELECTRIC OVENS ELECTRICAL OPERATION PLUMBING DIAGRAMS ONLY FROM FILL SOLENOID VALVE TO UPPER NOZZLE TO UPPER NOZZLE WASH PUMP DRAIN MANIFOLD 2140 25294 0412 222 Page 62 of 72 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION GREY WATER GREASE CHEMICAL SUMP PUMP PUMP I 1 I 1 1 I CHEMICAL PUMP OUT GREASE PUMP INLET l 2 gt n 2 o 72 a gt o GREASE CHEMICAL IN OUT REMOVED FROM OVENS WITH 46300096 SERIAL NO AND HIGHER DRAIN MANIFOLD 3359 Fig 134 Page 63 of 72 2 25294 0412 KA SERIES ELECTRIC ROTARY OVENS TROUBLESHOOTING TROUBLESHOOTING diagnostic tests the service technician can quickly and easily determine if a component is functioning properly or in need of repair T
29. 56 Fig 126 Component Connections Page 55 of 72 Tn n F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION o LE z o z lt I POWER SWITCH MODELS WITH GREASE ASSIST OPTION DRIVE MOTOR Fig 127 Power Connection Page 56 of 72 F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION SINGLE PHASE THREE PHASE L1 L1 112131415161718 9 4 4 1121314 516 7 9 10 11 12 Al 2142 Fig 128 SCHEMATIC DIAGRAMS Model KA7E Page 57 of 72 2 25294 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION NOTE 1 FILL ME relay located on water level control board Wire X17 attached to Common of H L Relay Wire 26 attached to NO of H L Relay 2 CHEMICAL SENSE relay located on water level control board Wire X18 attached to Common of LLCO relay Wire 26 attached to NO of LLCO relay 819 120 183 2070 7832 19 7821 1822 8 DOOR DOOR 25 ae D I SILENCE BUZZER x0 DOOR l snooze etes CHEMICAL SENSE NOTE 2 n NOTE 1 TETO o 129 18 16 H ROTATE SWITCHES 1 10 BACK GREY WATER SUMP PUMP POWER SWITCH z 9 4 2 9 gt 2 ox 5 O lt a z
30. 95 2 Remove Right Side Cover 3 Remove screws securing gasket bracket and gasket 7 Reverse procedure to install NOTE Replace washers and gasket with new ones on reassembly Page 29 of 72 n F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS TEFLON WASHER TEFLON GASKET Fig 96 6 Remove four screws washers and nuts securing removed until gear box mounting screws are removed es 4 Identify and remove motor wires from terminal block A Insert jeweler screwdriver or similar small tool into holes to release spring tension and IIT T pull wires out e 2 7 auum 5385 Fig 99 7 Pivot motor away from oven and work crank arm out of hole in side wall NOTE The following picture shows the terminal block ull disassembled to illustrate how the tool is inserted to release the wire 3 jg Fig 97 5 Remove four screws securing pump mounting Fig 100 box and allow box to slide down for access to 8 Remove gasket bracket and gasket if not already motor support screws removed F25294 Rev A 0412 30 of 72 10 11 12 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS 19387 Fig 101 If replacing any individual piece remove four Screws securing motor and speed reducer to gearbox Torque screws to 22 inch Ibs
31. ECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS WATER LEVEL SENSOR ONLY ky A WARNING Disconnect the S electrical power to the machine and follow lockout tagout procedures 1 Remove Right Side Cover 2 Remove wire attached to sensor 3 Unscrew sensor and remove from oven PARTS REMOVED FOR VIEW 4 Reverse procedure to install CHEMICAL SENSOR ONLY WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures WARNING Oven cleaners are corrosive and can cause chemical burns Rubber gloves goggles and protective clothing are required Read and follow the instructions for the oven cleaner 1 Remove Right Side Cover 2 Remove wire attached to sensor 3 Loosen hose clamps and work hoses off sensor F25294 Rev A 0412 Fig 75 4 Reverse procedure to install WASH PUMP RELAY KA7E ONLY WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove Right Side Cover 2 Use small screwdriver to pry out release tab lift front of relay and disengage rear of relay from din rail Fig 76 3 Identify and disconnect wires 4 Reverse procedure to install Page 24 of 72 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS TRANSFORMER 1 Remove Right Side Cover 2 Remove two screws and nuts securing transfo
32. EMENTS WARNING the electrical power to the machine and follow lockout tagout procedures 1 Remove Right Side Cover and Fan Cover Page 17 of 72 2 Disconnect lead wires from element being replaced 19327 Fig 48 3 Usea wrench on element inside oven while removing and installing mounting nut 19328 Fig 49 4 Remove nuts securing element being replaced NOTE If mounting nuts will not slide over wire lead backup nuts loosen them or remove them REPLACE GASKE BEHIND WASHERS Fig 50 5 Remove screws securing element support bracket to ceiling and remove bracket F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS Fig 53 3 Disconnect wires from high limit thermostat Fig 51 4 Remove screws securing high limit to frame 6 Slide element out of wall Clean off old gasket that may stick to wall or washer and replace with new gasket not included with element GASKET 22819333 Fig 54 Fig 52 5 Reverse procedure to install Reverse procedure to install NOTE Set the high limit thermostat to its maximum 9 Torque element mounting nuts to 45in lbs Use clockwise position backup wrench on element inside oven to prevent twisting and damage to element TEMPERATURE SENSOR 10 Torque nuts securing wires onto element to 14 20in lbs Use a backup wrench on back nut to prev
33. L GENERAL WARNING Oven cleaners are corrosive and can cause chemical burns Rubber gloves goggles and protective clothing are required Read and follow the instructions for the oven cleaner Safety standards require that when the rotary oven s electric supply line is properly connected to the electrical power supply an adequate means must be provided to limit movement of the oven without applying stress to the electrical conduit This means that as part of the installation the oven must be secured to either the wall or the floor to limit movement of the oven and thus preventing damage to the flexible electrical conduit during cleaning maintenance and service operations REFERENCE INFORMATION TSB S amp TSI S NOTE Links or references to the TSB s are provided here and in the appropriate sections of service manual TSB 1381 KA7E ROTARY OVEN SCRAMBLED VFD DISPLAY ROTISSERIE OVENS HR7E AND KA7E NEW DRIVE MOTOR See Multimedia TSB 1383 ASSEMBLIES section in TIS TSB 1400 LEAKS AT DRIVE ARM GASKET DURING WASH CYCLE See Multimedia section in TIS HR7E AND ROTISSERIE OVEN ROTOR CRANK ARM DISENGAGING See Multimedia FROM ROTOR section in TIS TSB 1417 CLOGGING AT INPUT AND OUTPUT OF PERISTALTIC PUMPS TSI Instructions amp Specifications Specifications Instructions Manual 40182 35521 KA7EM F 40287 F 45111 INTRODUCTION Electronic co
34. MOVE 3O SIX NUTS C DRAIN HANDLE 13364 MODEL KA7EM D From front of oven remove drain handle from the drain control linkage assembly manual grease sump drain Al 2137 Fig 141 9 only A opposite side of oven remove six nuts securing the blank switch cover plate and work the plate from oven B Remove two nuts securing blank overlay cover plate and its retaining plate E Remove drain control linkage assembly from drain valve and work from oven C Install the blank switch cover plate and blank overlay cover plate on the opposite side of where removed 1 Remove drain control lever from linkage assembly 2 Re install drain control lever near the end of linkage assembly See picture 23921 below 3 Remove bushing from the front of oven Page 71 of 72 Tn n F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS APPENDIX DRAIN CONTROL LINKAGE ASSEMBLY OVEN USE DRAIN CONTROL LEVER Fig 143 F From rear of oven remove plug and re install on the opposite side of where Fig 145 removed 10 Install power switch on the opposite side of where 1 Install bushing in place of plug removed ew o INSTALLED 12 y Cut cable ties as necessary and route wires to their appropriate parts then reconnect 13 Route ribbon cable to display board and reconnect 14 Install new
35. NS Model KA7E F25294 Rev A 0412 Page500f72 KA SERIES ELECTRIC OVENS ELECTRICAL OPERATION 3355 Fig 124 Component Name Jl IEEE Fan motors and blade assembly M4 and M5 Heat elements two 3000W 2500W 2 Temperature sensor Dae TB3 terminal block ES Sets TB2 terminal block E iiid Capacitor C1 for drive motor M3 cp Water level control board Hie Capacitors C2 and C3 for fan motors M4 and M5 ER MEME CPU board Jio enirn Heat element contactors K1 and K2 Page 51 of 72 2 25294 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION XR Transformer supplies 24V to CPU board lx K3 door interlock relay TB1 terminal strip Nono ie win High limit thermostat or TB6 power in terminal block Posse E etas Drive motor assembly M3 cp Grey Water Sump pump M6 Removed from ovens with Serial No 46300096 and higher NOTE 4 terminal strip located above and behind pumps Rosse oE Grease pump M7 occa duh Chemic
36. NUTS NOT VISIBLE Page 20 of 72 KA SERIES ELECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS DISPLAY BOARD DISPLAY PANEL O Cj 19338 Fig 62 4 Unplug keypad cable from display board 5 Remove eight nuts and washers securing board to panel and lift board off studs y y X KEYPAD CABLE A A A A 19340 Fig 63 6 Remove spacers from studs on display panel Fig 64 7 Reverse procedure to install ROTOR STOP START SWITCH 3 4 5 6 Page 21 of 72 x WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Remove Right Side Cover Unscrew black knob and remove from switch 19342 Fig 65 Unscrew mounting nut 19343 Fig 66 Pull switch out of hole Identify and disconnect wires Reverse procedure to install F25294 Rev A 0412 KA SERIES ELECTRIC 5 REMOVAL AND REPLACEMENT OF PARTS MEAT PROBE MINI JACK x WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove Right Side Cover 2 Mini jack is located under power switch 19345 Fig 68 Identify and disconnect wires from mini jack terminals gt 5 Reverse procedure to install CAPACITORS A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Fig 67 3 Use a small sc
37. RENT SOFTWARE VERSION C027 0 zero will display in time window as the initial value Used to set all parameters to default and clear all recipes Parameter Number Set value to 73 and press Enter Machine is set to factory default settings PROGRAMMING CONTINUED PREVIOUS SOFTWARE VERSION dA09 Chemical pump ON time in seconds default 80 Time required may vary for type of chemical used Parameter Number gt CP will displayed Program window Chemical wash time in minutes default 120 Co Ct will displayed Program window Number of pre rinses default 1 Increase if initial fill is not hot enough nP will displayed in Program window Wash pump ON time during cleaning default 1 AB Pr will displayed in Program window Wash pump OFF time during cleaning default 7 AR SO will displayed in Program window 0 zero will display in time window as the initial value Used to set all parameters to default and clear all recipes Set value to 73 and press Enter Machine is to factory default settings NEN BE DIAGNOSTICS ALL SOFTWARE VERSIONS Parameter Description KA7E Number Display Test All segments and LEDs are cycled to check operation X X When complete oven will beep and be ready for the next Parameter Number entry Keypad Test When keys are pressed one at a time the time display will indicate whi
38. RMASENVSSEUNMODE CLEANING If the machine is draining water press WATER DRAIN WATER DRAIN ENTER T NORMAL WASH MODE WATER FILL NORMAL WASH MODE ADDING DETERGENT NORMAL WASH MODE WASHING NORMAL WASH MODE SOAKING is NORMAL WASH MODE WATER DRAIN NORMAL WASH MODE WATER FILL 28 NORMAL WASH MODE RINSE 1 54 NORMAL WASH MODE WATER DRAIN 95 NORMAL WASH MODE WATER FILL F25294 Rev A 0412 CLEANING WATER DRAIN CLEANING WATER FILL CLEANING ADDING DETERGENT CLEANING WASHING CLEANING WATER DRAIN CLEANING WATER DRAIN CLEANING WATER FILL CLEANING RINSE 1 CLEANING WATER DRAIN CLEANING WATER DRAIN CLEANING WATER FILL Page 42 of 72 If installed the grey water sump peristaltic pump should be running If correct press ENTER If correct allow water to fill up to water level probe When satisfied it will automatically roll to the next step Chemical pump ON Verify pump is pulling chemical See Clean Cycle Troubleshooting KA7E Only as necessary If correct press ENTER If the machine is washing wash arm spinning press ENTER NOTE Total cycle time is 2 hrs timer counts down Washing soaking alternates every 4 min during the cycle Drain pump ON e Rotor stop If correct press ENTER If installed the grey water sump peristaltic pump should be running If correct press ENTER If correct allow water to fill up to water level probe When satisf
39. STAND INSTRUCTIONS NOTE Separate units can be lifted by means of a forklift To do this open both doors Remove fan cover Slide forks all of the way thru top of oven Make sure forks rest on the frame member and are spread as far apart as possible Stacked units must not be lifted in this manner Self Clean ML 137701 ML 137709 1 Remove Right Side Cover 2 With oven lifted remove drain plug and save it Drain hose is connected here and routed down thru base 3 Remove electric power cord blank and install proper restraining fitting for power cord F25294 Rev A 0412 SERIES ELECTRIC OVENS GENERAL DRAIN PLUG e BOTTOM VIEW SHOWN 4 Remove screws securing water fill valve to utility plate 5 Remove screws securing drain manifold to utility plate and utility plate to frame 6 Current construction Remove strain relief nuts securing chemical in and grease out hoses A Remove hoses from strain relief fittings pull hoses through fittings but leave connected to machine Fig 5 8 Discard original utility plate saving screws 9 Slide mounting bracket off water fill valve SLIDE MOUNTING BRACKET OFF CURRENT CONSTRUCTION T Previous construction Remove chemical in and grease out hoses from 45 degree strain relief fittings PARTS REMOVED FOR VIEW Fig 6 10 Reinstall mounting bracket to water fill valve rotated as shown F25294 Rev A 0412
40. al pump M8 Teese iet trit Chemical sensor not shown Usi Water fill 51 M retos deep Utility plate W calc denen Wash pump M1 XK EET Drain manifold ed Drain pump M2 Snooze switch 2 ws eS Silence buzzer switch gei E ta Stop switch Rotate switches D Gs dicebat pi RAS Overlay with switch instructions Keypad and display board assembly peu Power switch Bios ee hae Meat probe mini jack Model KA7EM F25294 Rev A 0412 520472 KA SERIES ELECTRIC OVENS ELECTRICAL OPERATION 956626 inre unii Oia as tet Fig 125 Fan motors and blade assembly 4 and 5 Boo e sus Heat elements two 3000W 1 one 2500W 2 Temperature sensor D teed cu AR Capacitor C1 for drive motor M3 Esso ead du atr Capacitors C2 and C3 for fan motors M4 and M5 FE vui VES CPU board Heat element contactors K1 and K2 oo edges Transformer supplies 24V to CPU board 1 terminal strip ga High limit thermostat Page 53 of 72 1 2910 F25294 Rev A 0412
41. ank arm Fig 109 9 Slide rotor toward crank arm to engage pins F25294 Rev A 0412 gt Page 32 of 72 KA SERIES ELECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS Fig 110 10 Apply power to oven and carefully jog motor to place crank pointing toward side with interior light Ensure crank arm is parallel with oven wall Position motor as necessary while maintaining adjustment in previous step 11 Jog motor to point crank arm to opposite side of oven Ensure crank arm is parallel with oven wall Position motor as necessary while maintaining adjustment in previous steps 12 Repeat steps 6 thru 11 as necessary until conditions are met 13 Jog motor to put crank arm pointing down 14 Disconnect power to oven 15 Tighten gear case mounting screws NOTE Non drive end rotor shaft should seat itself in lower notch of support bearing This is normal operating position UPPER NOTCH LOWER NOTCH ROTOR SHAFT Fig 111 16 Lift rotor out of oven Page 33 of 72 17 Check for proper removal and installation of rotor 18 Tighten gasket bracket screws 19 Continue reassembly and check oven for proper operation DRIVE MOTOR SPEED REDUCER AND GEARBOX WARNING Disconnect the electrical power to the machine SS N follow lockout tagout procedures 1 Remove the rotor 2 Remove Right Side Cover 3 Identify and remove motor wires from terminal bl
42. atates den tus 41 RETURN NORMAL MODE ume A Sale t e DA M dE 43 TEMPERATURE SENSOR FEST sen esses eti estos 43 HEATING ELEMENT ii sad CA up 44 PUMP K3 RELAY COIL TESTS 44 CONTROLS CALIBRATION s cce Le 44 CALIBRATION PROCEDURE su Ce 44 ELECTRICAL OPERATION 22544n13iueacusoi nid o Ub a eH e set deacon 46 COMPONENT FUNCTION iut gt 46 SEQUENCE OF OPERATION 2 2 2 222 0 0 0 009002202000002022 46 PROGRAMMED COOKING 2 2 2 ni n ne nnne nsns 46 WASHING CYCLE SEQUENCE OF OPERATIONS 2 40002 2 2 47 USER PRESSES CLEAN BUTTON 0 2 47 CONTROLS EXPLANATION sce snc UOI MEER 48 MODEL KATE Base i teet 48 MODEL KATEMi lt ieg tia pase decies tis nes dn UL dE E 49 COMPONENT LOCATIONS I 50 inc
43. ch one When no keys are pressed the display should be blank If not blank indicates X X a stuck key Exit service mode by turning power switch off and then on again Enter service mode again if necessary Relay Test components should function KA7EM Press 1 Operates CR1 Lights at terminal X1 Press 2 Operates CR2 Fans at terminal X2 Page 39 of 72 F25294 Rev A 0412 e KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS DIAGNOSTICS ALL SOFTWARE VERSIONS Parameter NEE Description KA7E Press 3 Operates CR3 Rotate Motor at terminal X3 Press 4 Operates CR4 Contactor K1 at terminal X4 5 N m NOTE Contactor 2 is already energized thru power switch amp high limit Press 5 Operates CR5 Sump Main Drain Motor at terminal X5 Press 6 Operates CR6 Wash Pump at terminal X6 door s must be closed Press 7 Operates CR7 Chemical Pump at terminal X7 Press 8 Operates CR8 Sump Fill Valve at terminal X8 Press 9 Operates 9 Grease drain at terminal X9 NOTE KA7EM with grease assist option only Press 0 Operates CR10 Gray water sump peristaltic at terminal X10 Press ENTER to exit this test NOTE Gray water sump peristaltic removed from ovens with Serial No 46300096 and higher 23 CPU Board Input Test display indicates function This tests for 24 input on X16 thru X24 to the CPU board Uses
44. ches and provides power to wash pump Provides light for inside oven Senses temperature of oven cavity for the CPU control Shows time and temperature also contains keypad for programming CPU board Start capacitor for rotisserie motor Run capacitors for blower motors M2 M3 A Oven connected to correct supply voltage and is properly grounded Control board is powered and LED on board is flashing to indicate power is applied NOTE Control board is powered and neutral is AND DIAGNOSTICS Programmed Cooking 1 Conditions F25294 Rev A 0412 applied to the oven component circuitry when supply voltage is connected to the oven The power switch controls power for the oven to operate not power to the oven C Power switch is off Page 46 of 72 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION D High limit thermostat is set to maximum and contacts are closed E Oven cavity is at room temperature 2 Power switch is turned on A Power switch indicator light on B Power supplied to K2 coil thru power switch contacts and high limit thermostat contacts 1 K2 contacts close C Display shows time and the last operated program number D Step LEDs may be on if a program is selected E Oven is in idle mode 3 Select a saved cook program press numbered keys 1 thru 9 A programed step LEDs for the selected program are illuminated 4 Press Start to run cook cycle A Po
45. different program to run Washing Cycle Sequence of Operations NOTE Auto clean oven s the grease pump cycles on off depending on the times entered in service mode NOTE The grey water sump peristaltic pump was removed from machines with Serial No 46300096 and higher Criteria for starting wash cycle 1 Power switch must be ON 2 Machine must be in idle mode not in a cooking mode 3 Cavity temperature must be less than the programmed setting P41 Factory default is set at 250 F recommended A Ifthe temperature is above this setting when the clean button is pressed the unit goes into cool down mode until temp goes down to programmed setting 41 below 4 All spits and accessories are removed from interior of cavity 5 No soft metals i e Aluminum foil are inside the machine User Presses CLEAN Button 1 Preheat mode Oven goes into pre heat cooking mode with a temperature programmed set point in P42 The machine remains in preheat mode for the number of minutes programmed in P32 2 Drain Grease The grease pump comes ON for the number of minutes programmed in P30 3 Pre rinse Factory default is 1 pre rinse However multiple pre rinses are programmable in P37 F25294 Rev A 0412 11 12 13 14 15 25294 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION Water is injected into the sump until level reaches probe This fill time will then be
46. ecuring pump to bracket Loosen both hose clamps Fig 91 Fig 92 Reverse procedure to install KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS DRAIN PUMP ONLY DRIVE MOTOR ASSEMBLY W WARNING Disconnect the Re e WARNING Disconnect the electrical power to the machine and m i electrical power to the machine and follow lockout tagout procedures NY AS follow lockout tagout procedures Remove Right Side Cover TSB1400 LEAKS AT DRIVE GASKET Remove WASH PUMP KA7E ONLY DURING WASH CYGLE TSB 1383 ROTISSERIE OVENS HR7E AND KA7E NEW DRIVE MOTOR ASSEMBLIES See Remove screws securing pump to bracket Multimedia section in TIS 1 2 3 Disconnect wires from drain pump 4 5 Loosen both hose clamps TSI HR7E AND KA7E ROTISSERIE OVEN ROTOR CRANK ARM DISENGAGING FROM ROTOR See Multimedia section in TIS 1 Check that crank arm is stopped pointing to the side that has the interior light or pointing away from motor If it is not apply power to unit and use the rotate switch to start and stop drive motor when crank arm is in the proper position Then disconnect power NOTE If there is a motor malfunction and you cannot position the crank arm you will be able to manually put the crank arm in the proper position after you remove the motor and speed reducer Refer to DRIVE MOTOR SPEED REDUCER AND GEARBOX Fig 93 Fig
47. egrees adjust by entering an offset of 10 C Ifthe actual average temperature is lower than the programmed set point then enter a negative offset value of the same amount For example if the oven is cycling around an actual average of 340 degrees adjust by entering an offset of 10 1 Theoffset can be adjusted or 30 deg F but is only functional within the operating limits of the oven Factory setting is 0 7 save the setting press the enter key 8 Turn power switch to off and then on again The oven will remember the changes 9 To recall the offset value enter SERVICE MODE PROGRAMMING AND DIAGNOSTICS enter parameter number 5 Temperature Offset Verify that the value you set is visible on the time display Page 44 of 72 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS Temperature Data Recording Table NENNEN Actual Average Temperature Tester Temperature Tester Turn Turn Off Heater Turn on Heater Turn off divide by 2 Page 450f72 F25294 Rev A 0412 KA SERIES ELECTRIC OVENS ELECTRICAL OPERATION Power Switch High Limit Thermostat Wash Pump M1 7 2 Rotisserie Motor Blower Motors M4 5 Grey Water Sump Pump M6 Grease Pump M7 Chemical Pump M8 7 Water Fill Valve 81 Wate
48. ent twisting and damage to element HIGH LIMIT THERMOSTAT A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures H gt WARNING Disconnect the Right side Cover electrical power to the machine and 2 Remove screw and nut securing temperature follow lockout tagout procedures sensor to mounting bracket 1 Remove Right Side Cover 2 Pull high limit probe out of hole located in top right hand corner F25294 Rev A 0412 gt Page 18 of 72 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS Fig 55 Disconnect wires from temperature sensor Pull temperature sensor out thru the opening in oven wall 5 Reverse procedure to install CONTACTORS WARNING Disconnect the SS electrical power to the machine and AS follow lockout tagout procedures 1 Remove Right Side Cover 2 Disconnect lead wires from contactor being replaced 3 Push down on top of contactor and pull bottom of contactor out then up to remove it from the din rail PARTS REMOVED FOR VIEW 4 Reverse procedure to install Page 19 of 72 POWER SWITCH AND MOMENTARY SWITCHES electrical power to the machine and follow lockout tagout procedures NOTE Momentary switches on KA7E only 1 Remove Right Side Cover 2 Disconnect wires from switch NOTE There are four tabs two at each end that must be depressed in orde
49. gger o Maur REG SCHEMATIC SH EET 2 1 Remove wire 42 on the top rotisserie Add wires 91 92 93 94 as shown 2 If rotisseries are stacked remove wire 42 on the bottom machine and add wires 95 96 97 98 as shown DERIVED FROM 00 891443 Label Rev B amp C 13358 2 frotisserie is on a stand discard wires 95 96 97 and 98 Fig 130 Model KA7EM Page 59 of 72 F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION Tie this high for manual machines ROTATE SWITCH Power Switch KA7EM SCHEMATIC SHEET 1 Al 2913 Fig 131 F25294 Rev A 0412 60 of 72 SPARE INPUT SPARE INPUT SPARE INPUT X16 J X32 X31 52 xe KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION ms RIBBON E SERIAL CABLE TO DISPLAY 26 c 3x25 c 3x24 Se X33 Oven Temp c x23 e x22 Extra TC Input e 3 oe Meot Probe x21 X35c 3 20 Optional External Buzzer c 3x19 c 3xi8 c x7 x16 ew T 2 lI Soy Xm A HEAT X31 Xx30 x10 c x10 RS c 3x10 x10 X al a 5 132 1 1 340 Hood Auto Off o iming Tri TOP oven Timing Trigger os mH Hood Oven Interlock Hood Oven Interlock Bottom Oven 14
50. ied it will automatically roll to the next step Wash arm spraying Rotor turning If correct press ENTER Drain pump ON Rotor stop If correct press ENTER If installed the grey water sump peristaltic pump should be running If correct press ENTER If correct allow water to fill up to water level probe When satisfied it will automatically roll to the next step KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS VFD Display Current VFD Display Previous 2 Software Version C027 Software Version dA09 Funcnonality NORMAL WASH MODE RINSE 2 NORMAL WASH MODE WATER DRAIN NORMAL WASH MODE DRYING CLEANING RINSE 2 CLEANING WATER DRAIN CLEANING WATER DRAIN CLEANING DRYING PRESS START OR CLEAN CLEAN CYCLE COMPLETE Select program 0 9 Return to Normal Mode 1 Enter SERVICE MODE PROGRAMMING AND DIAGNOSTICS Use the keypad to enter parameter numbers If current software version C027 continue to step 4 If previous software version 09 press 72 select ENTER parameter to unlock service only parameters A Press 1972 and select ENTER code to unlock service only parameters 1 beep Press 44 and select ENTER allows selection of DEMO NORMAL Mode parameter Press 0 and select ENTER sets machine to NORMAL MODE Turn power switch OFF save settings and exit service mode Turn power switch ON Oven is now
51. ing magnet housing and remove magnet Fig 29 3 Reverse procedure to install and check Door Switch Adjustment KA7E only if required Page 13 of 72 OUTER DOOR GLASS 4 WARNING Disconnect the v at 45 s S electrical power to the machine and follow lockout tagout procedures 1 Remove door as outlined under DOOR 2 Lay door on a flat padded surface 3 Remove screws securing glass and remove glass 4 Install new glass in same orientation as old glass NOTE Avoid contact such as bumping or hitting or abrasion of glass edges 5 Install in reverse order and adjust door as outlined under Door Adjustment WASH ARM STRAINER PANS STRAIN PAN SUPPORT DRAIN SHROUD ONLY 4 MCN N WARNING Disconnect the v at 45 s S electrical power to the machine and follow lockout tagout procedures Uy 1 Open oven door 2 Use strainer pan handle and lift pan out of oven NOTE Pan positions are not interchangeable STRAINER PAN NON DRIVE SIDE STRAINER PAN TNT DRIVE SIDE 3t Fig 30 3 remove wash arm unscrew knurled part of wash arm F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS LAMP WARNING the electrical power to the machine and follow lockout tagout procedures NOTICE Do not touch the glass portion of the lamp gt 3 with your hands The oil f
52. isconnect the electrical power to the machine and follow lockout tagout procedures PUMP RESISTANCE 5 OHMS Grease Peristaltic 7 2 14 Models with grease assist option only CONTROLS CALIBRATION Calibration Procedure NOTE See Table 12 at the end of this procedure 1 Place temperature tester probe in the geometric center of oven cavity 2 Program a set point of 350 degrees Allow oven temperature to cycle 3 times Oven display temperature reading should equal the set point of 350 degrees F25294 Rev A 0412 3 Record the temperature tester readout for an additional 3 cycles It should cycle around a set point 4 Calculate the amplitude Amplitude Turn Off Turn On An amplitude of more than 40 degrees may indicate a failed element See heating element test 5 Calculate the average Actual average Turn On Off divided by 2 Variance between actual average and programmed set point of greater than 5 degrees indicates that adjustment is needed 6 To adjust A Enter SERVICE MODE PROGRAMMING AND DIAGNOSTICS enter parameter number 5 Temperature Offset NOTE The P key is used to toggle the minus sign on and off Use this key if a negative value must be entered B Ifthe actual average temperature is higher than the programmed set point then enter a positive offset value of the same amount For example if the oven is cycling around an actual average of 360 d
53. le Chemical pump not pulling chemical cleaner Chock chemical pump On liners Clog inside hose inlet or outlet Hose leaking or air gaps at connections Pump not receiving power or malfunction Control board malfunction Clean Cycle Insufficient liquid level in cleaning agent bottle ERROR 1 Pick up tube not submerged in cleaner Ensure tubing is cut at CHECK DETERGENT When cleaning agent flow from an angle and that standpipe is in OR container into sump is not detected by place to prevent tube from sensor curling inside chemical bottle CHECK DETERGENT Defective hose broken CHECK DETER PUMP squeezed closed Chemical pump or control not working Test in P22 ERROR 2 PRESS STOP OR Oven drain plugged not flowing ATTEMPTING TO When there is water the sump at 2 Drain pump plugged the start of a clean cycle DRAIN SUMP 3 Drain pump fails to operate or control not working Test in P22 DRAIN FAIL CHECK DRAIN PUMP F25294 Rev A 0412 66 of 72 KA SERIES ELECTRIC OVENS TROUBLESHOOTING Clean Cycle Troubleshooting Error Messages KA7E Only ERROR 3 Main water supply turned off PRESS STOP Supply hose disconnected OR kinked CANNOT CONTINUE When no or insufficient water is 3 Water pressure too low coming into oven CLEANING CYCLE Oven fill valve or control not working Test i
54. n P22 WATER FAIL Unit draining as it fills Test in CHECK SUPPLY P22 Door left open when it should be DOOR IS OPEN When door needs closed during closed CLOSE THE DOOR certain steps of the program Door closed position sensor or control not working Test in P23 NORMAL WASH MODE Displays when Pause Rotate button is pressed during cleaning cycle OR Returns to and displays step of cycle CLEANING that was paused when Pause button is pressed and released or when CYCLE PAUSED door is closed or opened and closed Displays for 5 seconds when STOP CYCLE key pressed during clean cycle up to and through DRAINING GREASE or STOPPED when STOP key is pressed during a cook time WASRMUDE Displays when STOP key is pressed CANCELLED during cleaning cycle including and after the CLEANING WATER FILL OR step for the pre rinse Please wait CLEANING while oven cycles through two rinse CANCELLED cycles and the drying cycle Displays when clean cycle INTERRUPTED interrupted by cycling power off and back on Please wait while oven CLEAN CYCLE cycles through two rinse cycles and the drying cycle 1 Verify motor shaft rotation as viewed TROUBLESHOOT ROTOR from end of shaft Rotation must be COMPONENTS clockwise If rotation is counterclockwise replace capacitor If 1 If drive hub on gear box does not turn motor shaft rotates correctly continue 3 to step D A Remove four screws securing rotor drive motor and speed reduce
55. ntrol with message center time temperature and program display features All pictures and illustrations shown are of a e Pass through controls on the unload side to unless otherwise specified When specific model snooze cook cycle silence beeper and stop cook number designations are needed for clarity they are cycle added to the procedure or picture e Equipped with grease assist and chemical General cleaner peristaltic pumps e Capacity of the KA series seven spit oven is 21 gt Pump for automatic draining to 35 chickens Model Description Stacking kit available to stack ovens e Rotisserie oven without automatic clean cycle e Referto the Specifications sheet for oven features manual cleaning Installation details and Instructions manual for 5 Electronic control with time temperature and operating and cleaning instructions program display features KATE Model Description Manual drain valve Rotisserie oven with automatic clean cycle F25294 Rev A 0412 4 of 72 KA SERIES ELECTRIC ROTARY OVENS GENERAL Equipped with grease assist and chemical cleaner peristaltic pumps Available with a grease assist peristaltic pump to remove grease during a cook cycle optional ELECTRICAL SPECIFICATIONS KA7E AND KA7EM VOLTS PHASE WATTAGE AMPERAGE NOTE Separate power supplies must be used when stacking two ovens INSTALLATION NOTE Before
56. ock A Insert jeweler screwdriver or similar small tool into holes to release spring tension and pull wires out NOTE The following picture shows the terminal block disassembled to illustrate how the tool is inserted to release the wire Fig 112 4 Remove four screws securing pump mounting box and allow box to slide down for access to motor screws F25294 Rev A 0412 KA SERIES ELECTRIC OVENS REMOVAL AND REPLACEMENT OF PARTS 5 Remove four screws securing motor and speed Fig 116 reducer to gearbox Torque screws to 22 inch lbs on reassembly 8 Toremove gearbox manually rotate worm gear to position crank arm to point toward the side with the interior light or away from the motor 6 motor away from speed reducer and lay it aside 9 Remove screws securing gasket bracket and gasket NOTE Replace washers and gasket with new ones on reassembly Fig 115 T Pull speed reducer away from gearbox and lay it NOTE Gasket bracket may not be able to be aside removed until gear box mounting screws are removed F25294 Rev A 0412 gt Page 34 of 72 10 11 12 13 14 15 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS Remove four screws washers and nuts securing gearbox to motor support Pivot gearbox away from oven and work crank arm out of hole in side wall Remove gasket bracket and gasket if not already removed 19387
57. quired in current production beginning with Serial No 46300096 The pump system parameters have changed so that the main drain pump not pictured removes any lingering gray water from the sump Refer to SERVICE MODE PROGRAMMING AND DIAGNOSTICS for Programming parameters GREASE CHEMICAL PUMP PUMP A ccm 2 CURRENT CONSTRUCTION GRAY WATER GREASE CHEMICAL SUMP PUMP PUMP PUMP PREVIOUS CONSTRUCTION 13278 Fig 81 TSB 1417 CLOGGING AT INPUT AND OUTPUT OF PERISTALTIC PUMPS See Multimedia section in TIS F25294 Rev A 0412 Pump Removal 1 Remove Right Side Cover Disconnect wires for pump to be removed Disconnect hoses for pump to be removed Eu dr UNS Remove screws securing pump to frame Fig 82 5 Rotate pump slightly counterclockwise to line up with cutout in frame and withdraw pump out of frame Fig 83 6 Reverse procedure to install Procedure to Replace Pump Hose NOTE Only use recommended replacement hose found in the parts catalog 1 Remove three screws securing face plate and pull face plate off Page 26 of 72 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS 19424 PREVIOUS CONSTRUCTION WITH GREY WATER SUMP PERISTALTIC SHOWN ON LEFT 2 Disconnect hose ends and work hose out of Pap Fig 87 5 Install new hose Work hose around cavity and manually turn rollers as hose
58. r Level Control Board KATE CPU Board Contactor 1 Contactor 2 Relay KATE Light internal Temperature Sensor Display Board Rotisserie Motor Capacitor C1 Blower Motor Capacitors C2 SEQUENCE OF OPERATION Refer to Model KA7E Schematic Sheet 1 and Sheet 2 B for the electrical sequence of operation The letter P followed by a 2 digit number refers to the Program Item Number in SERVICE MODE PROGRAMMING ELECTRICAL OPERATION COMPONENT FUNCTION Controls power to control circuits Prevents oven from exceeding 482 12 F if controls malfunction Circulates water and detergent during wash cycle Empties water from oven when turned on Turns the rotisserie Circulates air inside oven cavity Empties remaining water from sump area Removed from ovens with Serial No 46300096 and higher Empties grease accumulated in sump prior to wash cycle KA7EM models with grease assist only Dispenses predetermined amount of detergent for wash cycle Is turned on to fill oven with fresh water for wash and rinse cycles Monitors input from water level sensor and chemical sensor Allows input from keypad controls oven functions Power to oven heat elements Controlled by CPU board Supplies power to oven heat elements and controlled by power switch and by high limit thermostat Monitors door interlock swit
59. r edit the setting as parameter that must be unlocked to verify or edit the necessary setting as outlined in the following procedure After the unlock code is entered any of the Service Only parameters are viewable 4 After all desired Parameter Numbers are checked press 0 zero and select ENTER Normal programming can continue 1 Press 72and select ENTER parameter to unlock service only parameters 2 Press 1972 and select ENTER code to unlock service only parameters 1 beep 5 Verify the remaining Parameter numbers as necessary PROGRAMMING CONTINUED CURRENT SOFTWARE VERSION C027 Parameter Description KA7E KA7EM Number Chemical pump ON time in seconds default 43 Time required may vary for type of chemical used CP will display in Program window Page 370f72 F25294 Rev A 0412 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS PROGRAMMING CONTINUED CURRENT SOFTWARE VERSION C027 Preheat time in minutes default lt 10 Parameter Number KA _ 32 X PH will display in Program window Main Drain pump ON time in minutes default 2 SP will display Program window Chemical wash time in minutes default 120 Co Ct will display Program window Number of rinse cycles default 2 nr will display in Program window Rinse time in minutes default 2 Rt will display in Program
60. r for switch to slide out of bezel TABS SWITCH DISASSEMBLED FOR VIEW 3 Use recommended tools to release locking tabs at both top and bottom of switch body NOTE Picture below shows parts not installed in oven for illustration purposes It is recommended that you fully insert tools and gently spread tool ends apart as shown Then gently pull switch out of bezel Some gentle prying may be necessary to start switch out of bezel F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS TOOLS FULLY INSERTED GENTLY PRY OUT 4 10191 Fig 58 INSERT TOOL TO RELEASE TABS f Fig 59 4 Push switch out of bezel 5 Reverse procedure to install DISPLAY BOARD AND KEYPAD WARNING Disconnect the SS SS electrical power to the machine and follow lockout tagout procedures NOTICE Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service grounding kit must be used anytime the control board is handled TSB 1381 KA7E ROTARY OVEN SCRAMBLED VFD DISPLAY 1 Remove Right Side Cover F25294 Rev A 0412 2 Unplug ribbon cable from display board A Spread retaining clips to extract plug from socket Fig 60 3 Remove six nuts securing display panel with display board attached and lift out of oven OTHER THREE
61. r to gearbox 2 If motor does not operate B Lift motor off speed reducer and support it a Does relay on control board operate C Press the rotate switch Yes replace motor and or motor capacitor Page 67 of 72 F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS TROUBLESHOOTING No replace control board b Assemble oven and check operation Lift speed reducer off gearbox E Insert at least two motor mounting screws into motor flange and mate speed reducer to motor Hold the assembly while pressing the rotate switch 1 If output shaft on speed reducer rotates continue to step F 2 If output shaft on speed reducer does not rotate and motor is running replace speed reducer Assemble oven and check operation F Manually rotate gearbox shaft which mates with speed reducer to verify gearbox function 1 If crank arm does not rotate or worm gear cannot be rotated replace gearbox Assemble oven and check operation 2 If crank arm does rotate recheck previous steps to identify malfunction F25294 Rev A 0412 68 72 KA SERIES ELECTRIC ROTARY OVENS APPENDIX APPENDIX REVERSING CONTROLS WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures NOTE Rotor on off switch position does not get changed 1 Remove Right Side Cover 2 Disconnect wires from power switch 3 Squeeze tabs on bezel and pull
62. rameter 5 Press 1 and select ENTER sets machine to DEMO MODE 6 Turn power switch OFF save settings and exit service mode 7 Turn power switch ON Oven is now operating in demo mode and is idle Door should remain closed A Press CLEAN key to enter clean mode Disregard error messages B Cavity light should be ON to indicate the oven is in demo mode If light is not on repeat procedure to enter DEMO MODE NOTE As you press ENTER to advance through the clean cycle operation there may be short delays before the cycle begins You can pause the cycle at any time by pressing the rotate switch or opening the door Cavity light ON CLEANING Rotor turning PREHEATING e Heaters If correct press ENTER Grease pump ON NORMAL WASH MODE PREHEATING CLEANING Rotor stops DRAINING GREASE Heaters OFF If correct press ENTER If correct allow water to fill up to the water level probe When water level is satisfied it will automatically roll to the next step NORMAL WASH MODE WATER FILL CLEANING WATER FILL NORMAL WASH MODE DRAINING GREASE Page 41 of 72 F25294 Rev A 0412 KA SERIES ELECTRIC OVENS SERVICE PROCEDURES AND ADJUSTMENTS VFD Display Current VFD Display Previous Software Version C027 Software Version dA09 NORMAL WASH MODE CLEANING DEGREASE 1 DEGREASE 1 If the machine is washing wash arm spinning press ENTER 12 NO
63. rat e bct E etu 26 PUMPR REMOVAL RP ES etit ea uestre we state 26 PROCEDURE REPLACE PUMP HOSE 7 26 WATER FILL VALVE ONLY 2 2 2 2 2 2 7 28 WASELUPUMP KATE ONLY y orb ee ade ea ete ecd 28 DRAIN PUMP emassa cet n eie crine a d Rat 29 DRIVEMOTOR ASSEMBLY http ere quede ceat ace teen dl AR Rec edo Rubi Re 29 DRIVE MOTOR ADJUSTMENT ee mee emeret 31 DRIVE MOTOR SPEED REDUCER AND GEARBOX 33 SERVICE PROCEDURES AND ADJUSTMENTS es 36 SERVICE MODE PROGRAMMING AND DIAGNOSTICS 36 F25294 Rev A 0412 _ Page 2 of 72 KA SERIES ELECTRIC 5 PROCEDURE TO ENTER SERVICE MODE 2 2002 70 36 PROCEDURE TO TOGGLE BETWEEN NO ID AND OPERATOR ID MODE 36 PROCEDURE TO TOGGLE BETWEEN 9 AND 99 PROGRAMS 36 SERVICE MODE PARAMETERS 2 36 DEMO KAZE ONLY ctor ashore cutee ne edu a MeG
64. rewdriver or similar object to carefully pry tabs out and work retainer clip off 1 Remove Right Side Cover jack 2 Disconnect wires from capacitor being replaced NOTE Jack shown removed from oven for view Also 3 Remove hardware securing capacitor being notice that wires are polarity sensitive and must be replaced and remove capacitor connected properly for correct operation F25294 Rev A 0412 22 of 72 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS Identify and disconnect wires Fig 70 4 Reverse procedure to install Fig 72 5 Use needle nose pliers to squeeze tabs on five WATER LEVEL CONTROL BOARD board supports Work board off supports KA7E ONLY ARROWS INDICATE WARNING Disconnect the BOARD electrical power to the machine and SUPPORTS follow lockout tagout procedures gout p ex NOTICE Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service kit must be used anytime the control board is handled 1 Remove Right Side Cover 2 Remove four screws securing divider wall that water level control board is fastened to Fig 73 6 Reverse procedure to install Fig 71 3 Pivot divider wall to access water level control board Page 23 of 72 c F25294 Rev A 0412 KA SERIES EL
65. rmer Fig 77 3 Identify and disconnect wires to transformer 4 Unscrew nut and remove mounting bracket Fig 78 5 Reverse procedure to install Page 25 of 72 CPU BOARD WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service kit must be used anytime the control board is handled 1 Remove Right Side Cover 2 Carefully identify and disconnect all wires from CPU board Fig 79 3 Squeeze tabs on one support at a time and pull board off supports ARROWS INDICATE Pss Y 2000000 o olllttitil tol EE 19364 Fig 80 4 Reverse procedure to install F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS PERISTALTIC PUMPS WARNING Oven cleaners are corrosive and can cause chemical burns Rubber gloves goggles and protective clothing are required Read and follow the instructions for the oven cleaner NOTE Procedure applies to KA7E and the KA7EM with grease assist only NOTE KATE rotisserie ovens previously were produced with 3 peristaltic pumps a gray water sump pump grease pump and chemical pump The gray water sump pump is no longer re
66. rom your hands could affect a 19309 the operation of the lamp Skin oil may be removed Fig 31 with alcohol while the lamp is cold 4 remove strain pan support lift end and NOTE Use a clean rag or paper towel to handle disengage other end from stud replacement lamp 1 Open door 2 Remove screws securing facade to oven yy Yo Fig 34 e 3 Remove two nuts securing lamp assembly to top Fig 32 of oven 5 drain shroud remove nuts washers securing shroud and lift shroud out of oven 4 Lift lamp assembly out of oven and support it 5 Loosen screws in terminal block securing lamp wires and pull wires out of block Fig 33 6 Reverse procedures to install F25294 Rev A 0412 14 of 72 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS 19314 22 4 Fig 36 Fig 38 6 Work lamp with wires out of lamp brackets Wires 4 Remove washer from both shafts can not be removed from lamp Fig 37 7 Install and tighten insulators evenly to prevent damage 8 Reverse procedure to install 19317 FAN MOTORS ASSEMBLY rds 5 Remove C clip from both shafts x WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove Right Side Cover and Fan Cover 2 Remove wing nut securing each fan blade Nut is left hand thread turn clockwise to remove
67. roubleshooting Before performing any of the troubleshooting checks listed below use the SERVICE MODE NOTE Ensure wiring and board connections are tight PROGRAMMING AND DIAGNOSTICS to assist in and secure and board connectors are inserted diagnosing the problem By utilizing the oven controls properly not misaligned General Troubleshooting KA7E amp KA7EM SYMPTOM POSSIBLE CAUSES TSB 1417 KATE CLOGGING AT INPUT AND OUTPUT OF PERISTALTIC PUMPS See Multimedia section in TIS Scrambled VFD display KA7E only ROTARY OVEN SCRAMBLED VFD Power switch internal indicator light not on but oven 1 Wired incorrectly operates 2 Power switch malfunction Main breaker open Clogging at input and output of peristaltic pumps KA7E and KA7EM with grease assist only No power to oven controls Power switch malfunction Wired incorrectly Oven wired incorrectly Main breaker will trip Heat element shorted Wiring shorted Rotor does not turn See TROUBLESHOOT ROTOR COMPONENTS TSI HR7E AND KA7E ROTISSERIE OVEN ROTOR Control board malfunction Test in P22 CRANK ARM DISENGAGING FROM ROTOR See Multimedia section in TIS Crank arm pins sheared Blower motor malfunction Test in P22 Blower motor does not run when cooking Blower motor capacitor malfunction Control board malfunction Incorrect line voltage Heat element malfunction High limit thermostat not set to maximum position
68. s if installed on machine 22 Cycle now complete 23 Drying Mode After the post rinse cycles are complete the software enters the Drying Mode for 10 minutes 24 The machine heats to 250 F can be programmed by P43 If drying time is set to O the drying mode is skipped 25 Cleaning is complete CONTROLS EXPLANATION Model KA7E Page 48 of 72 KA SERIES ELECTRIC ROTARY OVENS ELECTRICAL OPERATION MAIN POWER SWITCH Turns oven and controls on or off Service use only Hidden key when pressed X not printed oven cavity current temperature will display on keypad 1 8 gt S Ow PROGRAMS HDC Nai Hees MESSAGE CENTER PROGRAM CLOCK PROBE ADD 5 START STOP SILENCE CLEAR ENTER Provides instructions to operator Enters program mode to modify a cook program press P for 3 seconds Sets the clock for time of day Displays temperature external meat probe Adds 5 minutes to a program step each time it is pressed Begins cooking cycle Stops cycle Silences beeper Clears time or temperature entry Accepts time or temperature entry CLEAN Begins cleaning cycle 0 9 Enter numeric value s Manual 0 Enter a manual program e ROTATE Rotor on off pauses cooking and cleaning cycle REAR OF OVEN PASS THROUGH CONTROLS Press to silence buzzer and
69. uch return at any time in the future 701 S Ridge Ave Troy OH 45374 F25294 Rev A 0412 KA SERIES ELECTRIC 5 TABLE OF CONTENTS GENERAL deae enne E eee lade dro edu td eit E tata 4 REFERENCE INFORMATION ted rettet eerie rep d a te dra eer a sea dae ere 4 ALIM EI 4 INSTRUCTIONS amp SPECIFICATIONS 4 2 2 1 4 INTRODUCTION eese Dieu 4 2 vie db 5 WATER SUPPLY REQUIREMENTS ONLY 2 2 2 2 2 5 sep o 5 ACCESSORY STAND INSTRUCTIONS 2 2 2 2 2 1 1 2 0 2 2042308 22 2 5 SELF CLEAN ML 137701 ML 137709 5 KA7EM WITH GREASE ASSIST ML 137710 ML 137713 7 KA7EM WITHOUT GREASE ASSIST ML 137711 ML 137714 8 TETHER BRACKET AND OVEN MOUNTING TO STAND KATE KA7EM 9 REMOVAL AND REPLACEMENT OF PARTS 4 2 2
70. ug Button supplied with stand accessory into new utility plate Page 8 of 72 KA SERIES ELECTRIC OVENS GENERAL UNUSED jc HOSE BARB FITTING P1 NEW UTILITY PLATE PLUG BUTTON Fig 14 7 Route power cord through stand up into oven and connect to terminal block 8 Proceedto Tether Bracket and Oven Mounting to Stand KA7E KA7EM Tether Bracket and Oven Mounting to Stand KA7E KA7EM 1 Ensure that tether bracket is installed A bracket must be installed along with one of the swivel casters to a corner as shown using the caster hardware provided The remaining open hole in the center of the tether bracket is to be used to secure one end of the tether locally supplied chain cable etc The other end of the tether is to be secured to an anchoring point in the wall or floor when oven installation is complete Make sure that during oven movement no stress is applied to the flexible electrical conduit s 19431 Fig 15 Page 9 of 72 2 Using holes in oven s caster mounting plate Secure oven to stand using 4 screws and 4 washers provided with stand accessory Install washers such that bolt does not slip through SECURE OVEN TO STAND 4 PLACES Nu Ac Fig 16 Install all removed covers Continue with installation per Instructions Manual F25294 Rev A 0412 KA SERIES ELECTRIC ROTARY OVENS REMOVAL AND REPLACEMENT OF PARTS
71. used for all subsequent fill cycles Once water is sensed at the probe the wash pump turns ON and rinsing begins This normally lasts for 2 minutes can be programmed by P36 After rinsing is complete the drain pump turns ON for 3 minutes can be programmed by P33 After drain pump is complete the drain peristaltic turns ON for 3 minutes if installed on machine Cycle now complete Wash Now the machine is ready to wash Fill sump with water based on fill time determined during Pre Rinse Chemical injected for 40 seconds can be reprogrammed in P31 Begin washing Wash pump ON for 4 minutes can be reprogrammed in P48 and OFF for 4 minutes can be reprogrammed in 49 Washing lasts for 120 minutes can be reprogrammed in P34 After washing is complete the drain pump turns ON for 3 minutes can be programmed in P33 After drain pump is complete the drain peristaltic turns ON for 3 minutes if installed on machine can be programmed in P33 16 17 18 19 20 Wash cycle complete Post rinse The number of post rinse cycles is factory set at 2 can be programmed in P35 Fill sump with water based on fill time determined by Pre Rinse After filling with water the wash pump turns ON and washing begins This normally lasts for 2 minutes After rinsing is complete the drain pump turns ON for 3 minutes 21 After drain pump is complete the drain peristaltic turns ON for 3 minute
72. wer applied to rotisserie motor M3 thru internal relay CR3 on CPU board B Power applied to blower motors M4 and M5 thru internal relay CR2 on CPU board C Power applied to light thru internal relay CR1 on CPU board D Power applied to heat element contactor K1 coil thru internal relay CR4 on CPU board and power switch contacts 1 contacts close 2 Power applied to heat elements E1 E2 thru K1 closed contacts and K2 closed contacts E Display shows the number of the program running F Step LED for the cook step in progress will blink Cook temperature for the cook step in progress will display H Total combined cook time for all steps in the selected program will be displayed and will count down 5 Temperature sensor senses oven cavity temperature NOTE High limit thermostat must be set to maximum otherwise thermostat could regulate cavity temperature Page 47 of 72 6 reaches programmed set temperature A CPU board internal relay CR4 opens 1 Powerremoved from K1 contactor coil a Power removed from heater elements E1 E2 and E3 7 Oven continues to cycle until time expires and beeper sounds or add 5 min button is pressed or stop button is pressed A Press beeper silence button to silence beeper 8 Atthe end of cook cycle all power is removed from 4 5 E2 9 Press Startto run the selected program again or select a

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