xcelerate™ hi-speed oven service instructions · removing lipids, proteins and organic...

W164 N9221 Water Street • P.O. Box 450 • Menomonee Falls, Wisconsin 53052-0450 • U.S.A. PHONE: 262.251.3800 800.558.8744 U.S.A./CANADA FAX: 262.251.7067 800.329.8744 U.S.A. ONLY

www.alto-shaam.comD U E T O O N G O I N G P R O D U C T I M P R O V E M E N T , S P E C I F I C A T I O N S A R E S U B J E C T T O C H A N G E W I T H O U T N O T I C E .P R I N T E D I N U . S . A .

XL-300, XL-400

Xcelerate™ Hi-Speed Oven SERVICE INSTRUCTIONS

XLSERVICE• REV. 1 • 08/14

i

Cleaning ................................................................................................ 1Touch Screen Firmware Update ............................................................ 4How to Change the Door Switch .......................................................... 5How to Change the Motor ..................................................................... 9How to Change the PCB ..................................................................... 11How to Change the Speaker ............................................................... 14How to Check the Microwave ............................................................. 16How to Check Turning Direction of the T-Verter .................................. 21How to Connect the Transformer Safety Thermostat.......................... 22How to Improve Leakage Current - Disable EMI Filter ........................ 23Reset Overheat Protector .................................................................... 25

Xcelerate™ Hi-Speed Oven TABLE OF CONTENTS

XCELERATE SERVICE INSTRUCTIONS • XLSERVICE • 1.

w w w . a l t o - s h a a m . c o m | 8 0 0 - 5 5 8 - 8 7 4 4 | 2 6 2 - 2 5 1 - 3 8 0 0

The oven should be cleaned inside and outside on a daily basis. Outside cleaning: Never use steel wool or abrasive cleaning material to clean the exterior. Use a moist towel or recommended stainless steel cleaner.

• Switch off the oven and keep the door closed. The oven fans will cool down the oven automatically.

• Before starting to clean the oven wait at least 30 minutes to cool down.

• Be careful and make sure it is not hot before reaching into the oven. Wait until it is cool.

• Please remove the stone and the stone holder made of chrome nickel steel.

• For safety pull the plug before cleaning the oven.

• Do not use a water jet to clean the appliance. Sever damage or electrical hazard could result. The warranty becomes void if appliance is flooded.

• Use a damp clean cloth or sponge to clean the appliance. If the oven is heavily soiled a liquid detergent can also be used. After the application of liquid detergent the baking chamber must be wiped down with clean water.

• We recommend using a liquid detergent, which is certified for food industrial use and has capabilities of removing lipids, proteins and organic substances.

DAILY CLEANING

Wait for the oven to cool down completely. Wear safety gloves. Remove the stone holder and stone. You may want to clean the oven in the morning when the oven is cool - before food production begins.

Xcelerate™ Hi-Speed Oven CLEANINg

XCELERATE SERVICE INSTRUCTIONS • XLSERVICE • 2


Spray oven cleaner on the side and back walls of the baking chamber and on the bottom of the baking chamber.

Soak the wire cooking shelf with cleaning detergent to remove food residue. Wear safety gloves.

Wipe with a damp cloth. Afterwards rinse with fresh water. You may also use a scotch brite sponge or a plastic scouring pad to clean the wire cooking shelf.

Before cleaning the stone, be sure the stone has cooled completely to prevent cracking. To clean the stone use a damp towel or sponge and fresh water. Do not use a strong detergent. This can affect the taste of the food. Discolored marks on the stone are not a sanitation threat, but be sure to remove larger particles from the surface.

As the water soaks in, wipe off food residue from the door plate and rinse surface by wiping with a sponge and clean warm water.

Xcelerate™ Hi-Speed Oven CLEANINg



WEEKLY CLEANING

Regularly clean the back vents of the oven of dust and grease. Be sure the oven has cooled down and the fans are not running. Use a damp towel. If the cooling vents are blocked, the oven could malfunction.

Regularly check that the wall clearances are sufficient otherwise damage to the appliance and surroundings may occur. Do not store anything directly on the oven.

Keep at least 15 cm distances from heat sources, like a grill or other heating appliances. Keep at least 102mm space on the left and right sides, and 300mm clearance from the back. An optional Alto-Shaam heat shield can be used in the back to reduce the rear clearance requirement to 0mm.

Failing to do so will void warranty and cause premature failure of components. Please refer to the instruction manual.

Clean the front of the oven the same way. Be sure the contact area between door and oven front is always clean and free of debris. Build up of particles in this area can cause the oven to malfunction.

Wipe the inside of the baking chamber as the detergent has soaked in. Rinse surfaces by wiping with a sponge and clean warm water.

Xcelerate™ Hi-Speed Oven

CLEANINg



STEP 1: PREPARE FILE

Copy the firmware file named “AS420UI1.bin” to a good quality USB drive. The file name must always be the same. This means you have to make sure not to mix up different firmware files on your computer. After the update is finished, always check the version number on the start screen to be sure the right version is installed.

STEP 2: PREPARE OvEN

Connect the USB drive to the USB port of the oven and open the door. Disconnect the main power for 10 seconds. Alternatively turn off the main circuit breaker for 10 seconds.

STEP 3: PERFORm UPDATE

Reconnect the main power and wait for 20 seconds. The Update process starts instantly. The LED on the USB Drive flashes fast, then stops, then flashes fast again, then stops and flashes slowly (update finished).

During these 20 seconds: •DONOTinterruptpower! •DONOTremovetheUSBdrive!DONOTtouchany buttons/switches!

STEP 4: RESET

After 20 seconds, when the LED on the USB drive flashes slowly, remove the USB drive and close the door. Then disconnect the main power again for 10 seconds.

STEP 5: POWER ON AND vERIFY

Connect the main power again. Then power on the control panel. On the bottom of the start screen the current firmware version is displayed.

Xcelerate™ Hi-Speed Oven TOUCH SCREEN FIRmWARE UPDATE

• Carefully read the entire document before trying to update the firmware.• Not following these steps can damage the control board permanently.• The update should only be performed by qualified service personnel.



Xcelerate™ Hi-Speed Oven CHANgE DOOR SWITCH

First check that the door is closing properly. If debris builds up on the door it might not close properly and the door switches are not activated properly.

STEP 1

Unplug, or disconnect the main power of the oven (not onlythefuse!),thenopentheservicepanelontherightside of the oven. Remove the top of the oven. The door switch is located on the upper left corner of the electric board. Open the door.

STEP 2

Disconnect the cables of the PCB. Disconnect the cables of the door switch.




STEP 5

Reinstall the electric board with the six screws. Then reconnect the cables to the PCB (keypad cable black side up).

STEP 3

Unscrew the six mounting screws of the electric board (two at the bottom, two at the upper left, two at the upper right). Then carefully move the electric board towards you to gain access behind the electric board.

STEP 4

Now unscrew the four screws of the door switch assembly, remove it and assemble the new door switch assembly. Reassemble the four screws. But do not fully tighten the screws at this point, so the new door switch can move freely for later adjustment.




STEP 6

Connect the cables back to the new door switch assembly. The cables are marked S11, S12, etc. The first two letters indicate which switch to connect the cable to (S3 at the top, S1 at the bottom left, S2 at the bottom right). The third number indicates which contact of each switch. (1 upper contact COm, 2 middle contact NO, 3 lower contact NC). For example S11 has to be connected to the upper COm contact (1) of the Switch S1 at the bottom right.

STEP 7: ADjUSTING ThE DOOR SWITCh

With everything back in place, the four screws of the door switch have to be loose, otherwise the door switch assembly might be damaged when closing the door. Slowly close the door.

STEP 8

Push the upper switch towards the left until the trigger of the switch just touches the outside of the switch. Do not press so hard that the trigger bends over the housing of the switch. When you have the right position, fix the position with the screw. Repeat with the lower switches. Push the assembly to the right position where the trigger starts to touch the housing and tighten the screws.



STEP 9: ChECK ThE SWITChING SEqUENCE

Open and close the door very slowly, so you hear the ‘click’ noise of the switches three times. Also watch the switches.

STEP 8: CONTINUED


When closing the door S2 must ‘click’ first, after that S1 and S2 should ‘click’.

S2 is the safety switch. If S2 does not switch before S1 and S3 switch (‘click’), a short circuit will occur and circuit breaker F1 will trip. This mechanism is an international standard that disables microwave operation if there is a malfunction of a switch or the adjustment is not correct.

If this type of short circuit occurs more than two or three times, switch S2 is likely damaged and must be replaced again.

When you are sure the switch activation sequence is correct, you can apply power to the oven. Place a glass of water in the oven, start a cooking sequence that includes the use of microwave power and slowly open the door. If all works fine, open the door quickly. If the adjustment is correct the oven will work normally. If F1 trips while opening the door, checktheswitchesagain.Alwaysdisconnectthemainpowerplugwhenworkingonthedoorswitch!



Xcelerate™ Hi-Speed Oven CHANgE mOTOR

STEP 1

Dismantle three cables (black/blue/white) from Inverter

STEP 2

Use the tool to loosen 4 screws around the motor and then dismantle the isolation material

STEP 3

Loosen 2 screws from magnetron and dismantle the small stainless steel panel



STEP 4

Use a wrench tool to loosen 8 screws from motor. Afterwards, you can dismantle the motor from the machine.

ChECK ThE TURNING DIRECTION

When the frequency inverter has been connected start the oven then quickly open the door, to stop the fan.

Standing behind the oven you can observe the motor turning when it slows down (see green arrow).

The turning direction must be counter clockwise looking from behind the oven (see red arrow)

If the motor is turning in the wrong direction, swap the sequence of two of the motor cables, for example from white-blue-black change to blue-white-black.

Xcelerate™ Hi-Speed Oven CHANgE mOTOR



Xcelerate™ Hi-Speed Oven CHANgE PCB

STEP 1

Unplug the oven or disconnect the main power to the oven (notonlythefuse!),thenopentheservicepanelontheright. The PCB is located on the lower left of the electric board.

STEP 2

Disconnect the green plugs of the PCB.

STEP 3

Disconnect the gray display cable.

STEP 4

Disconnect the USB cable

STEP 5

Carefully disconnect the keypad cable at the bottom.

STEP 6

Now the control box at the front has to be removed. Unscrew the two screws at the bottom of the control box.



STEP 7

The control box then needs to be slid upwards.

STEP 8

Unplug the small white display cable. Now the control box can be removed.

STEP 9

Unscrew the four screws of the PCB on the electric board and remove it. Assemble the new PCB.

STEP 10

Reconnect the white cable of the display and reassemble the control box.




STEP 11

Reconnect all cables of the PCB. Caution: Ensure power to the PCB is connected correctly or damage to the PCB will occur.


All plugs have a clear direction, except the green-black keypad cable at the bottom. The black mesh must face upwards. Check that all pins are connected, that none are free or loose.

If connected wrong, the buttons of the keypad cannot work.

Reassemble the oven and test all functions:

• Display works?

• Temperature reading is correct?

• USB transfer can work?

• All keys work?

• Speaker works after end of baking time?



STEP 1

If the Alarm is not working first check in Service mode that Speaker Volume is not set to 0.

Check if the oven cooling fan is working and the ventilation is sufficient. If the oven overheats the speaker can be damaged.

If the speaker is still not working unplug the unit or disconnect the main power of the oven, then open the service panel on the right. The Speaker is located on the bottom next to the PCB.

STEP 2

Cut the white cable tie so the two cables of the speaker are free. Then unplug the double plug of the speaker from the PCB.


CHANgE SPEAKER




CHANgE SPEAKER

STEP 4

Install the new speaker and reconnect it to the PCB. A111 is the upper cable; A112 is the cable at the bottom of the plug.

If the new speaker does not work exchange the PCB (separate instruction).

STEP 3

Unscrew the two red cables A111 and A112 from the plug. Take the plug and attach it to the new speaker.

Unscrew the four screws of the old speaker and remove it from the oven.




CHECK mICROWAVE1. Water heating teSt 1 Liter, 2 MinuteS

a. 59°F (15°C) warmer: normalb. 32°F (0°C) warmer: likely mic Control problem, connection, capacitor or diode defectivec. 41°F (5°C) warmer: likely magnetron or Diode defective

2. MeaSure MiCroWave Current S32a. 6a-8a: normalb. 0A: Connection loose, microwave Control problem, Transformer short circuit, Door Switch problem, Diode defectivec. 3A: Likely Diode defective, exchanged. 4-5A: Likely Capacitor defective, exchange e. 12A: Likely magnetron defective, exchange

3. CheCk MiCroWave ControL (PCB, door SWitCh, MiCroWave ContaCtor)

4. CheCk tranSForMer

5. Change diode and CaPaCitor

6. Change Magnetron




CHECK mICROWAVESTEP 1: TEST hEATING FUNCTION

Cool down the oven and set “SET TEmP” in “SERVICE mODE” to 68°F (20°C) to deactivate convection heating.

STEP 4

When finished stir the water a bit and measure the temperature again. The water should be approximately 59°F (15°C) warmer than before. This value may vary depending on ambient temperature, line voltage and water container. If you have this temperature increase the microwave works properly.

If there is a problem with the microwave you will not have a temperature increase at all or only a minor increase of less than 41°F (5°C). In this case continue with amps measurement.

STEP 5: AmP mEASUREmENT

Disconnect the main power. Open the right side panel of the oven. Clamp your amp meter to the cable S32 near the door switch. (Do not measure near the transformer or microwave. The voltage, high frequency and magnetic fields can interfere and prevent getting an accurate reading).

STEP 2

Place a plastic bowl with about one liter of water into the baking chamber. measure and note the temperature.

STEP 3

go to “mANUAL mODE” and set the parameters

tiMe 2:00 minutes teMP 68°F (20°C) air 10% MiC 100%

then press “START”



STEP 6

Power the oven back on, place a cup of water inside the oven, then start the microwave. Normally there should be 6 to 8 Amps going through S32, and all microwave components are working properly. If the water still does not heat check if the antenna in the top of the baking chamber is installed properly.

If you measure a current higher closer to 12A the magnetron is likely faulty or broken. Alternatively, the transformer could also be damaged. Change the magnetron first then the transformer since the magnetron is most likely to fail.

If the measure is a lower current closer to 3A, it is likely the diode is damaged or broken.

If the measure is 4 – 5A, it is likely the capacitor is damaged or broken.

Finally if there is no current at all, please check for lose cable connection or that all door switches are properly closed.

These are the components most likely to be affected but are by no means the only components that may be affected.

STEP 7: ChECKING ThE CONTROL CIRCUIT

Disconnect the oven from the main power. Remove the cables T2L and T2N from the transformer and connect your volt meter.

STEP 8

Power the oven back on, close the door and start microwave operation. When you start you should measure line voltage at the cables T2L and T2N. Then the microwave circuit is supplied with power correctly and proceed with STEP 9.

If there is no voltage when the microwave function is started, check if the microwave output of the control PCB is active. If not, the door switch input of the PCB may not be active. Check K2 and S1, which produce the input signal. It is very unlikely the PCB itself has a problem, andthereusuallyisnoneedtochangethePCB!

Check if Relays/Contactor K1 is working.

Check the function and adjustment of the door switch assembly.


CHECK mICROWAVE



STEP 9: ChANGE ThE CAPACITOR

Disconnect the main power and wait two minutes. Remove the back cover. Unscrew the holding bracket of the capacitor, disconnect the three cables and replace with a new capacitor. Polarity does not matter.

Check amps and water heating to confirm that this solved the problem.

STEP 10: ChANGE ThE DIODE

Disconnect the main power and wait two minutes. Remove the back cover. Unscrew the two screws of the diode, disconnect the two cables and replace with a new diode. Polarity is important! The terminal with the larger hole is connected to earth “PE”. The terminal with the smaller hole is connected to high voltage cable “D”. Diode working direction is towards earth.


5000v! the following steps take place in the high voltage part of the microwave circuit. Be extremely careful to always unplug the appliance and disconnect the main power, then wait two minutes for the capacitors to discharge before touching anYthing!


CHECK mICROWAVE



STEP 11: ChANGE ThE mAGNETRON

Remove the top panel of the oven (two screws at the back, three screws at the front). Remove the four cables from the magnetron and the high temperature safety switch. Unscrew the four 8mm nuts, which hold the magnetron (8mm ratchet wrench works best).

CAREFULLY pull out the magnetron.

STEP 12

When assembling check that the four fingers of the pipe firmly hold the antenna of the magnetron and have good contact. If a finger is out of shape bend it back first. If electrical contact is not good the pipe can melt in this area later and the microwave will not work.

STEP 13

Check the antenna is assembled properly and the nuts of the magnetron are firmly tightened.



CHECK mICROWAVE5000v! the following steps take place in the high voltage part of the microwave circuit. Be extremely careful to always unplug the appliance and disconnect the main power, then wait two minutes for the capacitors to discharge before touching anYthing!




CHECK TURNINg DIRECTION OF THE T-VERTER

ChECK

When the frequency inverter has been connected start the oven, and shortly afterwards, open the door so the fan stops.

Stand behind the oven to observe the motor rotation when it slows down (green arrow).

The rotation direction must be counter clockwise when viewed from behind the oven (red arrow).

adjuSt

If direction is ok nothing has to be done.

If the motor is turning in the wrong direction either exchange two phases of the motor. Or move the direction jumper of the frequency inverter from contact3 (FWD) to contact4 (REV).



STEP 1

The transformer safety thermostat can be wired in series with the magnetron thermostat S5. Therefore, first remove the single cable between contactor K2A1 and S51 on the magnetron.


CONNECT THE TRANSFORmER SAFETY THERmOSTAT

STEP 2

Afterwards connect the cable from the transformer thermostat to contactor K2A1.

Two cables from transformer safety thermostat switch

Then, connect the other cable from the transformer thermostat to S51 on the magnetron.



STEP 3

On the right side there is the black switch to enable/disable the EmI filter.

Switch is in = enabled, which means higher leakage current, possibly causing RCD trips.

Switch is out = disabled, less leakage current.

Disabling the switch is not a problem for the EmI since Xcelerate has a dedicated separate filter. Newer models are disabled at the factory.

STEP 1

Disconnect the main power of the oven (not only the fuse!),thenopentheservicepanelontheright.Themotor control is located on the upper right corner of the electric board.

STEP 2

Use a screw driver and pry the top cover up carefully, then you can remove it.


DISABLE SECONDARY EmI FILTER



STEP 4

Use pliers to pull out the switch carefully (about 5mm). Now the filter is disabled.

SteP 5

Reinstall the top cover. First insert the rear hinge of the cover then push it down.

Reassemble the housing.


DISABLE SECONDARY EmI FILTER




RESET HIgH LImIT SWITCH

Xcelerate has a safety overheat protection switch, which reliably cuts the power to the heating element in case of overheating.

The mechanical construction of this part is very sensitive and can be triggered by vibration from transport. Vibration can also partially trigger the switch causing it to fully trigger after the first few days of operation.

When the high limit protection switch is tripped it can cause the oven to stop heating. A reset can easily be done.

STEP 1

Wait for the oven to cool down a few minutes. The overheat protection switch is located at the back on the bottom of the oven under a protection cover. Remove the cover.

STEP 3

Please reinstall the safety cover. The oven is now ready to use.

Over time, a dirty filter might be the cause of overheating. Should you have to reset the oven more often without obvious reason, please contact your service agent or Alto-Shaam.

STEP 2

Press the red reset button firmly. Quite a bit of strength is needed to push it correctly. The reset can be felt as a “click”.

xcelerate™ hi-speed oven service instructions · removing lipids, proteins and organic...

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