-72-
Revision 5/F3528
W
IRIN
G
SCH
E
MATI
C F
O
R
IR
RE
-CONN
CT
IO
N
TO
REPLACEMENT IGNI
TION BOX AS
SEMBLY
IL
LUSTRATION OF FITTED
TI
ON
BOX
Page 1: ...SERVICE MANUAL G32 CONVECTION OVEN Revision 5 F3528 Manual P N M0MG32 January 2004 Applies to units from S N 40256...
Page 2: ...CTION PAGE NO 1 SPECIFICATIONS 5 2 INSTALLATION 7 3 OPERATION 11 3 1 Description of Controls 3 2 Explanation of Control System 4 MAINTENANCE 15 4 1 Cleaning 4 2 Routine Procedures 5 TROUBLE SHOOTING G...
Page 3: ...NS 57 11 PARTS DIAGRAM 58 11 1 Main Assembly 11 2 Control Panel Assembly 11 3 Ignition Electrode Assembly 11 4 Gas Piping Assembly 12 SERVICE CONTACTS 69 APPENDIX A Ignition Box Replacement Kits 71 AP...
Page 4: ...MODEL G32 LEGEND Electrical connection entry point Water entry BSP hose connection Gas connection entry point BSP female not USA Canada NPT female USA Canada only Dimensions shown in millimetres Dime...
Page 5: ...V AC 50 Hz 0 55A 1 Phase 220 240 V AC 60 Hz 0 7 A 1 Phase ELECTRICAL PLUG SPECIFICATION REQUIREMENTS Australia AS 2124 10 Amp 3 pin Canada NEMA 5 15 15 Amp 3 pin New Zealand AS 2124 10 Amp 3 pin Unit...
Page 6: ...n accordance with local codes BEFORE CONNECTION TO POWER AND GAS SUPPLY Unpack and check unit for damage and report any damage to the carrier and dealer Report any deficiencies to your dealer Fit the...
Page 7: ...nning Turning the screw clockwise increases the pressure whilst turning counter clockwise decreases the pressure WATER CONNECTION A cold water supply should be fitted to the water inlet BSP hose conne...
Page 8: ...itioned correctly over oven back Position flue duct on bottom unit so that it is positioned centrally in shroud back flue cut out and is flush with oven back Check that the oven vent is covered and ma...
Page 9: ...emaining 3 8 x 8 Phillips screws supplied Figure 2 4 Rating Plate Figure 2 6 Units manufactured up to July 2002 The rating plate for the G32 convection oven is located at the bottom right corner of th...
Page 10: ...e button is depressed 1 POWER Depress to switch power on or off switch illuminates when power is on 5 ROAST TIMER 3 Hour roast timer Indicator illuminates when time up 0 reached and product held at 75...
Page 11: ...ture is used to instantaneously add steam into the oven The temperature control of this oven is with a capillary type thermostat which can be set to a required cooking temperature The thermostat switc...
Page 12: ...ion attempt will be started automatically If this is unsuccess ful the ignition will go to lock out mode NOTE Different voltage and market models have different ignition sequence and re ignition speci...
Page 13: ...Roast n Hold selected and 3 Hour timer at zero position The factory preset hold thermostat can be adjusted as required to change the holding temperature if necessary Refer Service section for this pr...
Page 14: ...up and lift out SIDE RACKS To remove lift front top to disengage and slide rack forward To replace slide top rear slot in rack onto rear stud then engage front keyhole on front stud OVEN BASE TRAY Rem...
Page 15: ...S Check for deterioration 12 months DOOR PIVOT BUSHES Check for wear 12 months DOOR CATCH Ensure that catch is adjusted such that the door closes properly 12 months WATER NOZZLE Check for liming in wa...
Page 16: ...ition spark faulty Refer fault diagnosis 6 1 2 Burner flame not being sensed Refer fault diagnosis 6 1 2 Ignition transformer faulty 110V models only Refer fault diagnosis 6 1 2 Ignition burner contro...
Page 17: ...for obstructions Refer service section 6 3 22 Check for obstructions Check for obstructions Check injector alignment Refer service section 6 4 9 BURNER NOISY BURNER BLOWBACK BURNER BACKFIRE Oven not...
Page 18: ...zzle blocked Fault with water valve Refer fault diagnosis 6 1 7 Steam switch faulty Refer fault diagnosis 6 1 7 Turn water on at water supply Remove clean or replace Refer service section 6 3 13 Servi...
Page 19: ...n for correct setting procedure Clean Refer service section 6 3 21 Check appliance gas type NO THERMOSTAT HEATING INDICATOR Indicator faulty Refer fault diagnosis 6 1 13 Replace Refer service section...
Page 20: ...it correctly Refer installation section Adjust Refer service section 6 4 5 Replace Refer service section 6 3 26 DOOR SEAL LEAKS Door seal damaged Door seal incorrectly fitted Door catch setting incorr...
Page 21: ...Indicator 30 6 1 16 Holding Temperature Incorrect 30 6 2 ACCESS 31 6 2 1 Control Panel 31 6 2 2 Service Panel Side Panel 31 6 2 3 Service Panel Rear Panels 31 6 2 4 Burner Access Panel 31 6 2 5 Manual...
Page 22: ...Pivot Bushes 39 6 3 27 Stainless Steel Door Outer Glass 39 6 3 28 Stainless Steel Door Inner Glass 40 6 4 ADJUSTMENT CALIBRATION 40 6 4 1 Regulator Adjustment 40 6 4 2 Thermostat Calibration 40 6 4 3...
Page 23: ...park gap too large see the following section Cracked spark rod ceramic or carbon build up HT leads to spark electrode and earth broken deteriorated HT leads between ignition electrodes and ignition co...
Page 24: ...transformer terminal block pre serial number 203927 or at yellow and blue lead connections on ignition control box With thermostat on calling for heat voltage should be 24Vac 4Vac across yellow and b...
Page 25: ...rol boxes used on 220 240 volt model G32 s are operated from direct voltage supply from the thermostat hold thermostat circuit Correct ignition box operation should result in ignition box commencing s...
Page 26: ...but burner doesn t ignite or if burner ignites but doesn t stay alight firstly check correct electrode assembly operation Refer fault diagnosis 6 1 2 Burner Ignition Spark Not Working If all checks ar...
Page 27: ...inals with the light switch depressed 6 1 7 NO WATER INJECTION STEAM Steam switch faulty Check voltage to the bottom terminal of the switch If there is no voltage then check wiring With switch depress...
Page 28: ...ostat out of calibration Place an accurate digital thermometer probe in centre of oven Set thermostat to 180 C or 355 F Close the oven door and allow oven thermostat to cycle on and off twice Record o...
Page 29: ...heck wiring If relay is not latched ON when Roast n Hold switch illuminated then check the voltage across terminals 7 and 8 of relay coil fig 6 1 3 If the voltage is correct but the relay is in the of...
Page 30: ...RVICE REAR PANELS 2 Panel is now free to hinge at bottom When closing the panel ensure wires and capillary tube are clear of metal or other terminals Figure 6 2 1 2 Remove panel Figure 6 2 2 Figure 6...
Page 31: ...1 Hinge down control panel refer 6 2 1 2 Remove two screws holding microswitch to bracket 6 3 3 INDICATOR NEON LIGHT 1 With control panel open refer 6 2 1 remove the wires from the back of the neon 2...
Page 32: ...ithdraw and remove two screws holding buzzer to bracket 4 Transfer wires to new buzzer 5 Reassemble in reverse order Figure 6 3 5 Figure 6 3 6 2 From back push neon through front of panel rotating clo...
Page 33: ...3 Transfer wires to new thermostat 4 Open oven door remove racks and fan baffle rack Loosen two screws securing thermostat phial bracket 5 Withdraw old thermostat phial through side of oven Note posi...
Page 34: ...ar access panel refer 6 2 3 3 To remove or replace solenoid disconnect water solenoid from oven water tube behind water solenoid with a 1 2 13mm spanner 4 Remove water solenoid from oven by removing t...
Page 35: ...3 16 OVERTEMP THERMOSTAT UK UNITS ONLY 1 Open control panel refer 6 2 1 2 To reset firmly press reset button Figure 6 3 21 4 Remove wires from overtemp 5 Open oven door remove racks and fan baffle rac...
Page 36: ...line next to the manual gas valve 3 Transfer wires from old ignition box to the new one 4 Secure new ignition box to the oven with two screws 3 Disconnect wires earth at sensor flame sensor and spark...
Page 37: ...nnect the three leads from the gas control valve 7 Remove the gas valve and connected piping by drawing out through the side service panel 8 Replace and reassemble in reverse order Figure 6 3 29 Figur...
Page 38: ...ensuring that the silicone rubber seals cover the outer edges of the glass Refit the trim panels Figure 6 3 37 Figure 6 3 38 6 3 25 DOOR SEALS 1 Open oven door 2 To remove hold at their centre point...
Page 39: ...ss 6 3 28 STAINLESS STEEL DOOR INNER GLASS Figure 6 3 42 3 Replace with new glass and re assemble door 4 Refit door to the oven 6 4 1 REGULATOR ADJUSTMENT Figure 6 4 1 To change the gas type regulator...
Page 40: ...mostat Shaft Fan Switch Calibration Nut Thermostat Figure 6 4 2 6 4 4 DOOR MICROSWITCH ADJUSTMENT 1 Open oven door 2 Open control panel refer 6 2 1 3 With fingers bend actuator arm of microswitch so t...
Page 41: ...panel 2 Open control panel refer 6 2 1 Loosen two screws on control panel holding 60 minute timer Two Screws 3 The timer can now be rotated as required to ensure that the buzzer sounds at the zero pos...
Page 42: ...43 Revision 5 F3528 7 CIRCUIT SCHEMATICS 7 1 1 220 240V 50Hz UK ONLY FROM SERIAL NO 203927 For units pre serial number 203926 refer section 7 1 2...
Page 43: ...44 Revision 5 F3528 7 1 2 220 240V 50Hz UK ONLY TO SERIAL NO 203926 For units after serial number 203927 refer section 7 1 1...
Page 44: ...45 Revision 5 F3528 7 2 1 100 120V 60Hz USA CANADA FROM SERIAL NO 203927 For units pre serial number 203926 refer section 7 2 2...
Page 45: ...46 Revision 5 F3528 7 2 2 100 120V 60Hz USA CANADA TO SERIAL NO 203926 For units after serial number 203927 refer section 7 2 1...
Page 46: ...GAS WATER 3 8 inch GAS REGULATOR CONNECTIONS ELECTRICAL YELLOW BLUE GREEN BROWN NEUTRAL SPARK SENSOR WATER INJECTOR IGNITION BOX HEATING 6 1Hr TIMER 3 4 1 2 BUZZER B POWER 5 4 HOLD LIGHTS TIME UP 4 LI...
Page 47: ...48 Revision 5 F3528 7 3 2 220 240V 50Hz NOT UK TO SERIAL NO 203926 For units after serial number 203927 refer section 7 3 1...
Page 48: ...1 2 OVERTEMP 2 MAINS TERMINAL BLOCK EARTH NEUTRAL PHASE 44 50Hz 3 1 4 PART OF CONTROL PANEL SUB ASSEMBLY GROMMET POSITION OR FIT AT STAGE 2 8 6 5 5 3 3 9 15 16 21 23 24 41 27 52 52 51 51 LIGHT LIGHT W...
Page 49: ...50 Revision 5 F3528 8 1 2 220 240V 50Hz UK ONLY TO SERIAL NO 203926 For units after serial number 203927 refer section 8 1 1...
Page 50: ...51 Revision 5 F3528 8 2 1 100 120V 60Hz USA CANADA FROM SERIAL NO 203927 For units pre serial number 203926 refer section 8 2 2...
Page 51: ...52 Revision 5 F3528 8 2 2 100 120V 60Hz USA CANADA TO SERIAL NO 203926 For units after serial number 203927 refer section 8 2 1...
Page 52: ...10 T9 T15 T16 T12 T13 T14 49 53 26 26 44 30 23 45 50Hz 3 1 4 PART OF CONTROL PANEL SUB ASSEMBLY GROMMET POSITION OR FIT AT STAGE 2 8 6 5 5 3 3 9 15 16 21 23 24 41 27 52 52 51 51 LIGHT LIGHT WATER SOLE...
Page 53: ...54 Revision 5 F3528 8 3 2 220 240V 50Hz NOT UK TO SERIAL NO 203926 For units after serial number 203927 refer section 8 3 1...
Page 54: ...ld Timer 110V 021472 Roast n Hold Timer Knob 021474 Switch Steam Light 021534 Relay Roast n Hold 220 240V 021535 Relay Roast n Hold 110V 018223 Hold Thermostat 003004 Microswitch 003002 Oven Lamp Glas...
Page 55: ...rom S N 218596 Also used to replace 015316 spark earth electrodes 022901 Spark Earth Electrodes From S N 47875 to S N 218595 022909 Ignition Electrode Kit Up To Serial Number 218595 SA1021 Obsolete Co...
Page 56: ...sion 5 F3528 10 ACCESSORIES OVEN RACKS PART NO 015168 DOUBLE STACKING KIT PART NO 021545 COOKIE KIT SIX TRAY OPTION PART NOS 017156 017157 STAINLESS STEEL DOOR OPTION PART NO SA1060 A25 STAINLESS STEE...
Page 57: ...58 Revision 5 F3528 11 PARTS DIAGRAMS 11 1 MAIN ASSEMBLY...
Page 58: ...NG BOX 18 015947 MOTOR SPACER STUD 19 014727 SIDE INSULATION PANEL 20 013520 OVEN LIGHT ASSY 240V 019482 OVEN LIGHT ASSY 110V USA CANADA 013521 LAMP 40W 240V 015825 LAMP 40W 110V USA CANADA 003002 LIG...
Page 59: ...UBE WA PLATED 010990 ADJUSTABLE FOOT 64 015575 SIDE RACK L H 65 015168 OVEN RACK 66 015656 FAN BAFFLE 67 014031 OVEN BAFFLE STUD 019367 OVEN BAFFLE STUD UK ONLY 68 015930 BAFFLE LOCATING BRACKET 69 00...
Page 60: ...61 Revision 5 F3528 11 2 CONTROL PANEL ASSEMBLY Mounted on item 6 Main assembly...
Page 61: ...LABEL 8 018223 HOLD THERMOSTAT 9 011419 TIMER 3 Hr 240V 50 Hz 011983 TIMER 3 Hr 240V 60 Hz 015823 TIMER 3 Hr 110V USA CANADA ONLY 10 021442 TIMER MOUNTING PANEL 11 016579 HINGE 12 021474 LIGHT STEAM...
Page 62: ...ECTRODE ASSEMBLY COMPLETE 1 024105 IGNITION ELECTRODE BRACKET 2 024106 ELECTRODE MOUNTING BRACKET 3 024127 SPARK ELECTRODE 4 022902 FLAME ELECTRODE 5 041022 SCREW 6 045011 WASHER FLAT 7 044001 NUT 8 0...
Page 63: ...on 11 3 1 16 1 0 16 5 2 0 8mm 64 1 8 1 0 5 3mm 2 2 1 65mm ELECTRODE SETTINGS Pos Part No Description SA 1021 IGNITION ELECTRODE ASSEMBLY COMPLETE OBSOLETE REPLACE WITH 022909 ELECTRODE ASSEMBLY UPGRAD...
Page 64: ...15 IGNITION ELECTRODE ASSEMBLY COMPLETE OBSOLETE REPLACE WITH 022909 ELECTRODE ASSEMBLY UPGRADE KIT 1 015316 IGNITION SPARK ROD 2 016051 ELECTRODE EXTENSION 3 015315 FLAME SENSOR USE 022902 FLAME SENS...
Page 65: ...22909 ELECTRODE ASSEMBLY UPGRADE KIT 1 015315 FLAME SENSOR OBSOLETE REPLACE WITH 022902 2 018732 IGNITION ELECTRODE 3 018759 IGNITION ELECTRODE BRACKET 0 1 4mm 95mm 60mm 11mm ELECTRODE SETTINGS Pos Pa...
Page 66: ...67 Revision 5 F3528 11 4 GAS PIPING ASSEMBLY...
Page 67: ...FEMALE 11 032170 INJECTOR 1 70 mm LPG PROPANE GAS 032155 INJECTOR 1 55 mm G31 PROPANE GAS UK ONLY 032270 INJECTOR 2 70 mm NATURAL GAS 032260 INJECTOR 2 60 mm G20 NATURAL GAS UK ONLY 12 015313 MACK UN...
Page 68: ...on Rd Tel 08 8431 0522 Kent Town SA 5067 Spare Parts Free Call 1800 337 963 WESTERN AUSTRALIA MOFFAT PTY PO Box 689 Tel 08 9305 8855 Joondalup Business Centre WA 6027 Spare Parts Free Call 1800 337 96...
Page 69: ...l 0121 327 5575 Business Park Fax 0121 327 9711 Birmingham B7 5QU England UNITED STATES OF AMERICA MOFFAT INC 3765 Champion Blvd Winston Salem Tel 1 800 551 8795 NC27115 Fax 336 661 9546 NATIONAL COVE...
Page 70: ...2 3 4 5 1 5 4 3 2 a Turn off power and disconnect from electrical supply Open control panel b Remove ignition box mounting panel assembly 2 screws c Remove overtemp bracket c w overtemp d Cut all cabl...
Page 71: ...72 Revision 5 F3528 WIRING SCHEMATIC FOR WIRE RE CONNECTION TO REPLACEMENT IGNITION BOX ASSEMBLY ILLUSTRATION OF FITTED REPLACEMENT IGNITION BOX...
Page 72: ...load switch to the rear e Rewire ignition box as described below 1 Remove green wire 1 from old ignition box Remove terminal strip wire and connect to terminal block 2 Remove red wire 2 from ignition...
Page 73: ...74 Revision 5 F3528 ILLUSTRATION OF FITTED REPLACEMENT IGNITION BOX WIRING SCHEMATIC FOR WIRE RE CONNECTION TO REPLACEMENT IGNITION BOX ASSEMBLY...
Page 74: ...l Flashing light confirms lockout condition If light is on steady electrical fault exists Minimum Flame Current 1 A From serial number 203927 Make Fenwal Type 2460D 506 023 Case Colour Grey Voltage 24...
Page 75: ...spracontrols Type 33100211 33000211 Case Colour Blue Voltage 220 240 Vac Ignition Trial Period 7 Seconds Pre purge 0 seconds Ignition Retries None Re ignition Attempts None 33100211 1 33000211 Spark R...
