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72

MICROWAVE SYSTEM

Microwave Seals and Gaskets

The oven equipped with seals and gaskets to eliminate excessive microwave exposure. These seals
need to be inspected at the time of service by the field technician for proper functionality.

Proper leak testing is performed with a quality test meter designed to sense at 2.45Ghz frequency. A
higher quality meter with an analog dial or digital display is highly recommended to reduce any false
readings. Lees expensive meters with only an audible alarm are not recommended. The meter needs
to register readings of less than 1.0mW/cm2 and greater than 5.0mW/cm2 for proper documentation
by the field technician.

The Copa Express oven utilizes a door choke design to efficiently seal the microwaves in the oven
cavity. The technician needs to inspect the door surfaces for debris build up and remove any build up
that may have accumulated between the door and the oven cavity surfaces.

The slots or openings of door choke must also be open and free of any food debris to operate at top
performance.

Door Choke Design

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Summary of Contents for Copa Express

Page 1: ...Pratica Products Inc USA 675 Town Square Boulevard Suite 200 2018 Pratica Products Inc USA Garland TX 75040 December 2018 For the Copa Express Oven Service Manual ...

Page 2: ...MENSIONS 7 INSTALLATION INSTRUCTIONS 7 UNPACKING INSTRUCTIONS 7 INSTALLATION WARNINGS PLEASE READ BEFORE LIFTING OVEN TO PREVENT INJURY 8 GENERAL INSTRUCTIONS 9 PRECAUTIONS TO AVOID POSSIBLE EXPOSURE TO EXCESSIVE MICROWAVE ENERGY 9 DAILY CLEANING QUARTERLY MAINTENANCE 11 DAILY CLEANING 12 QUARTERLY MAINTENANCE 15 THEORY OF OPERATION 19 COPA EXPRESS TECHNOLOGY 20 CHARACTERISTICS OF MICROWAVES 21 OV...

Page 3: ...MANUFACTURE INFORMATION 43 TECH SUPPORT 43 RESTORE FACTORY SETTINGS 43 MANUFACTURE SETTINGS 45 ACCESSING MANUFACTURE SETTINGS 46 ELECTRICAL LOAD TEST 47 READ INPUTS 47 CHANGE PASSWORD 47 CURRENT SENSOR 48 COUNTERS 48 OVEN DATA 48 ENGINE CONTROL 49 PREHEATING SPEED 49 VOLTAGE 49 ALERTS ERRORS 51 ALERTS AND ERRORS POSSIBLE SOLUTIONS 52 ALERTS 52 ERRORS 53 ALERTS ERRORS TABLE 53 MICROWAVE SYSTEM 55 T...

Page 4: ...ER TROUBLESHOOTING 78 HIGH LIMIT THERMOSTAT 81 TESTING HIGH LIMIT THERMOSTAT 81 CONVECTION HEATER 82 TESTING CONVECTION HEATER 82 IR ELEMENT 83 TESTING IR ELEMENT 83 CC IR TEMPERATURE SENSORS 84 TESTING TEMPERATURE SENSORS 84 CONTROL SYSTEM 87 MAIN CONTROL BOARD DISPLAY 88 TESTING POWER MODULE BOARD 89 SPEAKER 90 TESTING THE SPEAKER 90 POWER COMPONENTS 91 EMI FILTER 92 TESTING EMI FILTER 92 12VDC ...

Page 5: ...OOLING FAN SCHEMATIC 105 MICROWAVE CIRCUIT SCHEMATIC 106 PICTORIAL DIAGRAM 107 EXPLODED VIEW PARTS LIST 109 ASSEMBLY LEVEL 1 110 ASSEMBLY DOOR 111 ASSEMBLY PANEL 112 INVERTER 113 ASSEMBLY LEVEL 2 114 DOOR HINGE ASSEMBLY RHS 115 DOOR HINGE ASSEMBLY LHS 116 ASSEMBLY LEVEL 3 117 ASSEMBLY MOTOR 118 ELECTRIC PANEL ASSEMBLY 119 ASSEMBLY LEVEL 4 120 GEARMOTOR ASSEMBLY 121 HIGH VOLTAGE ASSEMBLY 122 ...

Page 6: ...vi INDEX ...

Page 7: ...1 SAFETY INSTRUCTIONS ...

Page 8: ...electrical shock Warning lease refrain from heating liquids or other foods in a sealed container since the package may explode Do not use metal lids or aluminum foil while cooking in this oven Please refrain from spraying any water or liquid on power cord and do not submerge in water Do not operate the oven in the power cord or outlet is damaged oven has been dropped or physically damaged or oven ...

Page 9: ...d electrician for assistance WARNING To reduce the risk of electrical shock the unit must be properly grounded Power Cord Replacement If the power cord is damaged in any way is must be replaced by the manufacturer Pratica Inc an authorized service agent or qualified personnel Fire Risk Reduction Please remove all content from inside the oven before applying power e g utensils paper food particles ...

Page 10: ...of hinges and latches 5 evidence of dropping or abuse c Before turning on microwave power for any service test or inspection within the microwave generating compartments check the magnetron wave guide or transmission line and cavity for proper alignment integrity and connections d Any defective or misadjusted components in the interlock monitor door seal and microwave generation and transmission s...

Page 11: ...5 SPECIFICATIONS INSTALLATION ...

Page 12: ...6 SPECIFICATIONS INSTALLATIONS Spec Sheet ...

Page 13: ...epth footprint 21 4 544mm Depth 30 7 780mm Volume 0 61 cu ft 17 5 Liters Installation Instructions Please read the following instructions carefully Install this unit in accordance with the instructions below Unpacking Instructions 1 Remove the unit from the packaging 2 Check the packaging and oven cavity thoroughly for accessories and literature 3 Discard any packaging inside the cavity e g cardbo...

Page 14: ...n up by the door handle Doing so may cause the door to misalign or cause damage to door hinges which will not be covered by warranty WARNING Never lift the unit from the removable front panel under the door as it may get Damaged or may come loose while lifting WARNING This unit is not meant to be stacked Please contact Pratica Inc for further details WARNING This unit is not meant to be installed ...

Page 15: ...ith the safety interlocks b Do not place any object between the oven front face and the door or allow soil or cleaner residue to accumulate on sealing surfaces c Do not operate the oven if it damaged It is particularly important that the oven door close properly and that there is no damage to the 1 Door bent 2 hinges and latches broken or loosened 3 door seals and sealing surfaces d The oven shoul...

Page 16: ...10 DAILY CLEANING QUARTERLY MAINTENANCE ...

Page 17: ...11 DAILY CLEANING QUARTERLY MAINTENANCE ...

Page 18: ...allowed to cool down properly Turn unit off by pressing the power button on panel Open oven door slightly to allow heat to disperse quicker Allow the unit to cool for approximately 30 40 minutes prior to cleaning Step 2 Cleaning the Wire Rack The rack is held in place by 2 metal hooks that act as security tabs to prevent the rack from coming loose Pull up on back part of rack and then pull towards...

Page 19: ...her instructions Step 5 Cleaning Air Filter WARNING Filter must be installed during oven use Only remove to clean when oven is not in use The air filter is located under the removable front panel under the door Locate the tab on the filter and pull towards the front of the unit Rinse the filter in hot water to remove any buildup and allow the filter to dry prior to reinstalling Step 6 Removing Foo...

Page 20: ...towel to remove as much left over cleaner and debris as possible Step 9 Cleaning the Oven Door Spray the cleaner on a nylon scrub pad or cloth to clean oven door If buildup occurs you may spray the cleaner directly on the affected area Dry down using a dry cloth or towel Step 10 Apply Oven Guard Apply the oven guard to a dry cloth or towel Wipe all surfaces of the cavity avoiding the IR element Th...

Page 21: ...ust mask and a pipe cleaner Step 1 Cool Down Oven and Unplug Turn the oven off by pressing the power button on panel Please look at daily cleaning for further instructions on how to clean the cavity Once oven is cooled down carefully unplug the power cord from the outlet Step 2 Remove Air Filter Remove bottom panel under door Locate the tab on the filter and pull towards front of unit Clean or rep...

Page 22: ...ing Clean the housing cover and verify that the vent slots are not blocked WARNING Do not attempt to clean the catalyst or spray any cleaner directly on it Step 6 Cleaning the Exhaust Pipe Visually look into the exhaust pipe to make sure that it is clean with no blockage You may use a pipe cleaner to break up any buildup id necessary Make sure the exhaust pipe lines up with the vent housing for pr...

Page 23: ...e the rear panel completely to gain access to both cooling fans You may use a clean damp cloth to clean the cooling fan blades Reinstall the rear panel and verify the vent tube goes into the rear catalyst housing Step 9 Install Air Filter Reinstall air filter and make sure all Phillips screws are secure The oven is ready to be turned on Step 8 Step 9 ...

Page 24: ...18 THEORY OF OPERATION ...

Page 25: ...19 THEORY OF OPERATION ...

Page 26: ... works by creating thermal energy that heats up the water molecules inside the product cooking it from the inside out 2 The top heater transfers thermal energy to the circulation air created by the blower motor located in rear of unit 3 The Stirrer distributes the microwaves evenly 4 The IR element assist in maintaining the temperature inside the cook cavity and cooking the bottom of the product T...

Page 27: ...those that do not need a medium to spread they can spread through a vacuum or certain kind of materials A fewer examples of electromagnetic waves are sunlight radio waves microwaves x rays and many others The waves may be represented by a solenoid similar like the picture below The wave changes from positive to negative and returns to neutral performing a complete cycle The number of times this cy...

Page 28: ...a low frequency As we move down the spectrum the length of the waves become smaller and the frequency becomes higher ex X Rays and Gamma Ray We also observe that the microwaves fit among the TV transmission waves and the infrared levels The microwaves utilized for microwave ovens have approximately 12 cm of length with a frequency of 2 45GHz In other words they complete 2 450 000 000 cycles per se...

Page 29: ...ce in a depth that ranges from two to seven centimeters heating the molecules of water fat and sugar by making them vibrate The heat is transmitted to the interior of the food by thermal conduction demystifying the idea that the microwaves cook food from the inside out These are three characteristics of the microwaves which are important Microwaves are reflected by the metals and can NOT pass thro...

Page 30: ... each other so when a food is exposed to an electromagnetic field the molecules are all aligned so that their charges point at the same direction When the electromagnetic field inverts the polarity the molecules also have their directions inverted As the microwaves invert their polarity 2 billion and 450 million times per second the molecules will also vibrate at the same frequency hitting one ano...

Page 31: ... walls shelves and finally the food In both cases the heat begins to cook the outside of the food first then slowly begins to cook the middle or center When product is cooked in a microwave oven the microwaves will start to penetrate the food The penetration of the microwaves in the food depends on the density of the food For example bread will be penetrated easier the meat because of its density ...

Page 32: ...26 OVEN CONTROLS AND COOKING ...

Page 33: ...27 OVEN CONTROLS AND COOKING ...

Page 34: ... when the CURRENT temperature is next to the PROGRAMMED that occurs so that the oven temperature enters in uniformity throughout the chamber Executing a Recipe After the preheating activate the desired GROUP To access the next group page utilize the paging arrows The RECIPES of the selected group will be displayed press on the recipe you wish To return to the Groups screen push the icon To access ...

Page 35: ...ter and of the bottom heather pressing the icon In case you wish to cancel the execution of a recipe push the icon If the equipment door is opened the operation will be paused however it is resumed when the door is closed If the programmer of the recipes adds information in one of the steps for examples ADD THE TOMATOES the recipe will be paused and the description of the information will be prese...

Page 36: ...e user In Heat Brown More Brown More and Heat More the time will be defined at the moment of creating the recipe Accessing the Options To access the settings at any time touch on the icon found in the fixed menu bar In the Options Screen there will be information such as Current Temperature in the Chamber Current Temperature in the Heater Test Mode Favorites Daily Cleaning Guide and Settings Touch...

Page 37: ...e conclusion of the operation the Copy Parameters icon will be enable Copy Parameters enables the user to transport the parameters defined is test Mode for the Edition of Groups and Recipes that is when click on the icon it will be necessary to inform the user s access password to the settings After informing the user s password choose between creating a new group or allocating the transported par...

Page 38: ...re critical when setting the total cook time The following information is critical when creating a new recipe The initial temperature of the product will change the desired results if not considered e g frozen cold or room temperature The size and or weight variation of the portion of product will also play a big role in determining the correct settings Only use containers approved for a microwave...

Page 39: ... the screen carefully 1st Open the oven door and wait for the temperature to drop until 65 C Proceed clicking on the arrow 2nd Remove the cook rack bottom jet and place in the sink Proceed clicking on the arrow 3rd Apply the Cleaner to the cooking rack and jet plate allow to stand Proceed clicking on the arrow 4th apply the Oven Cleaner to cavity walls and door let stand for 5 minutes Proceed clic...

Page 40: ...l removing cleaner and debris Proceed clicking on the arrow 7th Dry the oven cavity with a towel Proceed clicking on the arrow 8th Use a non abrasive scrub pad to loosen any stubborn stains on the cook rack and jet plate if necessary Proceed clicking on the arrow 9th Rinse dry and plate re install them into the oven cavity Proceed clicking on the arrow 10th Cleaning complete ...

Page 41: ...35 USER SETTINGS ...

Page 42: ...ptions Screen click on the icon Will be presented the screen User Password The standard password for the settings is 456789 The password may be changed The User Settings screen is composed by thirteen items Use the arrows to access the next options screen ...

Page 43: ...een groups The available choosing between editing or creating a group will be Edit Name changes the group s name you may use letters numbers or special characters Edit Image changes the image group icon takes Delete Recipes deletes the previously selected recipes Delete Group deletes all the information of the selected group including the recipes Order orders the location in which the group appear...

Page 44: ...e Edit Name changes the name of the recipe you may use letters numbers or special characters Edit Image changes the image the recipe icon takes Edit Steps accesses the options for edition of the steps of the selected recipe Delete Recipe deletes all the information of the selected recipe including the steps Order orders the location in which the recipe appears among the other recipes of the group ...

Page 45: ...ctor by lifting and pulling forward Press the icon The function available in USB are Import Export and Update System When selecting one of the functions the message Insert the flash drive and wait for recognition will appear After the recognition the user will be taken to the function options previously chosen Import All Group or Settings Export All Group or Settings System Update In case of error...

Page 46: ...ure The Current Temperature screen is only informative In it its possible to verify the temperature of both heaters the chamber and bottom heater Date Time Adjustment It is possible to adjust the Date Time and format it must be presented to the user respecting the following standards European dd mm yyyy American mm dd yyyy ISO yyyy mm dd Time 24h Format 12h Format ...

Page 47: ...osite screen will be displayed Choose the date and time format and click on to confirm and return to the options Celsius Fahrenheit Change the temperature format displayed in the oven between Celsius and Fahrenheit click on the icon among the User s Settings and define the temperature format you wish ...

Page 48: ...unction in which you may block functions which the operators have access For example If you wish that the Favorites and Test Mode functions are never accessed by the operators just click on both of them which will turn dark gray indicating that they are locked until the moment you wish to unlock them To unlock just click in the desired functions once more ...

Page 49: ... data to contact to clear out doubts request repairs or technical visits Restore Factory Settings ATTENTION The Restore Factory Settings option will delete all the Groups Recipes and their Steps decides the Settings defined by the user Make sure to create a backup through USB before proceeding After inserting the password and touching OK IT IS NOT POSSIBLE TO RECOVER THE INFORMATION ...

Page 50: ...44 MANUFACTURE SETTINGS ...

Page 51: ...45 MANUFACTURE SETTINGS ...

Page 52: ...ide the Options Screen click on the icon Will be presented the screen User Password The standard password for the settings is 459381 The password may be changed The User Settings screen is composed by nine items Use the arrows to access the next options screen ...

Page 53: ...t is possible to check some component s operation like buzzer microwaves general contact chamber heating bottom heating and inverter Read Inputs Show the status of the microswitches Change Password Let the costumer s and manufacturer s passwords be changed ...

Page 54: ...le to read the electric current in the microwave system Counters Show the data counting like faults recipes filter cleaning Oven Data Let the insert and data consults of the manufacturer like serial number manufacture date and oven generation G4 Rocket Express G5 Copa Express ...

Page 55: ...lect each model of inverter will control the motor Weg or Honeywell Preheating Speed Adjust the air speed that will be used during the preheating Voltage Select the voltage supply of the high tension circuit 208V 220V 240V ...

Page 56: ...50 ALERTS ERRORS ...

Page 57: ...51 ALERTS ERRORS ...

Page 58: ...n the Options icon The Options screen will bring instead of the Chamber and Bottom Heater temperatures a description of the alert For example ALERT SENSOR TURN OFF AND TURN ON THE OVEN Follow the orientation as described in the screen In this case turn off and turn on the oven using the panel button When turning the oven back on the screen that must be displayed is Just wait for the system to rese...

Page 59: ...rts Errors Table Component Becomes alert when Becomes error when Inverter more than ten reset attempts CLMG Low Magnetron Current thirty seconds without reaching the current Can Network Communication cables disconnected or faulty Chamber Sensor and IR only one inactive both inactive Panel Temperature From 65 C to 80 C exceeding 80 C for 10 minutes ...

Page 60: ...54 MICROWAVE SYSTEM ...

Page 61: ...55 MICROWAVE SYSTEM ...

Page 62: ... the positive half cycle of the alternate current voltage and charges the capacitor In this half cycle the diode works as a short circuit allowing the entire current pass through it In the negative half cycle the voltage of the capacitor and the 2000 volts are added resulting in a 4000V system In this half cycle the diode works as bridge allowing the current to flow to the Magnetron that generates...

Page 63: ...int does not allow for any adjustments to the sealing surfaces However the adjustments to the door and the sealing surface are made by loosening the 9 security screws around the perimeter After loosening the inner door choke assembly is free to move closer to the oven cavity as necessary Retighten screws to secure the adjustment Refer to page 74 for proper microwave leak testing procedures An RF l...

Page 64: ...wave can be energized The Monitor switches is locked on the left side of the oven and is used to act as a fail safe if both the Primary and the Secondary switches were to fail This switch is wired in series with a separate relay Interlock Relay used to open a fuse and disable the circuit This dead short condition will occur if the Monitor switch opens before either the Primary or Secondary switch ...

Page 65: ...sa The control board identifies the LED s as SW1 Primary and SW2 Secondary The LED s will illuminate when the over power is connected and the door is opened The oven does not need to be in the ON position to test the switch positions Care should be taken when servicing the oven with the power connected Observe the LED s from a safe distance The PPI team will post this information Similar to Rocket...

Page 66: ...ated per a round post with a step machined into one side The proper distance to adjust the Monitor switch is 0 0mm This switch is to be adjusted fully closed to support the Primary and Secondary switch contacts opening first Primary and Secondary switch adjustment steps 1 Open and close the door to verify the door moves freely and fully closes The door springs must be pulling the door closed to th...

Page 67: ...thermostats are self re setting When the temperature in the Magnetron exceeds 302 F 150 C the thermostat will open its contacts cutting power to the microwave circuit When the magnetron cools the contacts will reset and close Magnetron Thermostat Test 1 Unplug the oven and remove both side and top panels 2 Disconnect the thermostat wires and measure the continuity between the terminals of the ther...

Page 68: ...gized and this monitor switch opens a dead short will occur blowing the 20 amp fuses and disabling the oven for safety This is the third method to prevent microwave energy from leaving the cavity during an open door condition Voltage Relay The voltage relay is responsible for applying the correct voltage to the microwave high voltage transformers The control board determines the voltage based on t...

Page 69: ...een the COM1 terminal and the NO3 terminal of the SW1 SW2 and SW3 switches 4 If the door switch terminals have no continuity move on to the next test If the door switch read continuity the door switch is bad and needs to be replaced 5 Close the oven door and verify the continuity between the COM1 and NO3 terminals on all switches If the terminals have continuity while the switch is closed move on ...

Page 70: ...th primary wires to the HV transformer Never attempt to isolate by removing the secondary wires due to high voltage 1 Remove both the right side panel of the unit 2 Locate the CT that is connected around the wire number 36 of the power distribution bar 3 Inside the Option Screens click on the icon Settings and insert the password from manufacturer 459381 4 Go to menu Electrical Loads Test 5 Place ...

Page 71: ...ron by heating the cathode The magnetron will fully energize when the 2000V are applied from the secondary high voltage winding causing the emission of electrons that start to produce the microwave radiation The two longer wires of the transformer are the secondary low voltage wires 3 6V and the wire grounded to the transformer chassis belongs to the secondary high voltage side 2000V as seen in th...

Page 72: ...o discharge or discharge manually by grounding each capacitor terminal 3 Unplug all the wires from the HV transformer terminals 4 With the ohmmeter measure the resistance across the filament wires as shown in the picture on the right 5 The measured resistance value should be 0 0 ohms or a very low reading If the ohm reading is open or very high replace the transformer Testing Secondary HV Winding ...

Page 73: ... before commencing repair To perform the capacitor test a multimeter will be necessary 1 Unplug the oven and wait 5 minutes for the high voltage capacitor to discharge or discharge manually by grounding each capacitor terminal 2 Remove the rear panel of the unit 3 Unplug all wires and manually discharge capacitor 4 With the multimeter adjusted to the highest resistance scale measure the ohms betwe...

Page 74: ...est a multimeter and an extra 9V battery will be necessary 1 Remove the rear panel of the unit 2 Unplug the oven and discharge the capacitor manually by grounding each capacitor terminal 3 Disconnect the cables from the diode and manually discharge the capacitors 4 Connect the voltage meter in series with high voltage diode 5 Using a multimeter set to DC voltage connect one meter lead to one side ...

Page 75: ...en number of flaps pointing to the filament The antenna is connected to the anode flaps The filament cathode is located in the center of the Magnetron The cathode in the Magnetron is a filament that is supplied by the low voltage secondary 3 6 V of the transformer which emits electrons when heated These negatively charged electrons are attracted by the anode which is positively charged when the 4 ...

Page 76: ...ow As the electrons pass by the cavities the cavities begin to resonate and emit microwave radiation The microwave radiation that is produced by the cavities is captured by the antenna and funneled into the waveguide which will guide the microwave radiation into the cook cavity The microwave then gets attracted to the food product s due to the moisture MAGNET MAGNET ANTENNA ANODE FILAMENT CATHODE ...

Page 77: ...er set to lowest resistance scale measure the continuity between both magnetron terminals as shown in the picture below If the resistance measure zero ohms as shown in picture below move on to step 6 If the reading shows high resistance or open the magnetron is faulty and will need to be replaced 6 With the multimeter set to the highest resistance scale measure the continuity between each terminal...

Page 78: ...ce any false readings Lees expensive meters with only an audible alarm are not recommended The meter needs to register readings of less than 1 0mW cm2 and greater than 5 0mW cm2 for proper documentation by the field technician The Copa Express oven utilizes a door choke design to efficiently seal the microwaves in the oven cavity The technician needs to inspect the door surfaces for debris build u...

Page 79: ...he cook cavity through the waveguides These waveguides are attached to the cook cavity sides with a special stainless steel gasket between the two surfaces This gasket is held in place by the compression of the mounting hardware High temperature silicone must not be used to seal the gasket to the waveguide because the gasket needs an electrical connection to the waveguide The silicone is transpare...

Page 80: ...ve ample time to move the probe around the entire perimeter of the door 5 Star the cook cycle and measure the microwave emission with the meter positioning it perpendicular to the surface that is being measured Make sure to move the meter at 1 0 in per second while doing the test 6 While performing the leakage test note any meter spike areas that come close to 5mW cm2 for later re measurement 7 Re...

Page 81: ...75 IMPINGEMENT SYSTEM ...

Page 82: ...rs before continuing repairs Please follow the instructions below to test the blower motor 1 Unplug the oven and discharge the capacitors for safety purposes 2 Remove the rear panel from the unit 3 Unplug all 3 wires from the blower motor labeled V W U 4 Check continuity across all 3 windings in different combinations Each combination should have around 5 6 ohms ex V to W V to U W to U If no conti...

Page 83: ...utilizes a data communication protocol called MODBUS to communicate with the main control board The picture below shows the connections of the frequency inverter Note The ground cable must be properly grounded to the oven chassis IMPORTANT The switches on the side of the Frequency Inverter should always be in the ON position ...

Page 84: ...will continue with regular functioning If the communication is not immediately restored the main control board will attempt to reset the inverter ten times before an error message on the screen as shown below Frequency inverter errors The main control board will keep a counting log of the failures that occur in the inverter To know this information follow the steps below 1 Inside the Option Screen...

Page 85: ...voltage and will not accept the enabling command 3 FAULT The inverter will flash the fault code on the screen when there is a problem 4 NOT USED Without indication 5 CONFIGURATION Indicates the inverter has an incompatible program for the parameter After pressing the key it will keep showing an arrow until the incorrect setting is corrected as shown in the figure When a failure occurs the frequenc...

Page 86: ... are per the supply source network and the P296 parameter Input voltage too low Missing input phase Failure in preload circuit F022 Overvoltage in CC bus Overvoltage failure in intermediate circuit Wrong supply voltage Supply voltage is very high Load inertia very high or very fast deceleration ramp Very high P151 adjustment F051 Overtemperature in IGBT s Power module sensor over temp Temperature ...

Page 87: ...er The high limit thermostat protects the oven against overheating When the oven temperature rises above 752 F 400 C the contacts open and shuts off power to the heaters The high limit will reset automatically and usually happens within 5 minutes Testing High Limit Thermostat 1 Unplug the oven 2 Remove the right side panel of the unit 3 Unplug the wires and test or continuity If continuity is pres...

Page 88: ... physical damage to the heater or wires If any damage is seen remember to unplug the unit before continuing 3 Locate the top heater solid state switch on top of unit to get amp draw 4 Place amp clamp around top heater wire cable number 2 and turn unit on The amp draw should be between 14 16 amps on the cable 2 If there is no amp draw verify the heater solid state switch is not damage If the solid ...

Page 89: ...r any physical damage to the heater elements or wires If any damage is seen remember to unplug the unit before continuing 3 Locate the bottom heater solid state switch on top of unit to get amp draw 4 Place amp clamp around bottom heater wire cable number 1 and turn unit on The amp draw should be between 14 15 amps on the cable 1 If there is no amp draw verify the heater solid state switch is not ...

Page 90: ...elaying the information to the main control board Testing Temperature Sensors If one of the sensors has a problem the oven continues to work however in the display appear the fault message ALERT SENSOR TURN OFF AND ON THE OVEN When an error in both sensors occurs the board will stop the operation of the oven and will display the following fault message on the screen ERROR SENSORS CALL THE TECHNICA...

Page 91: ...be placed on the control board terminals where the temperature sensor wires were installed Once the jumper wire is installed the board should register room temperature on the temperature sensor verification screen WARNING Make sure to unplug the unit before installing jumper wire 6 Once the jumper wire is installed plug the unit back in and in the Options Screen verify If the sensor is reading the...

Page 92: ...86 CONTROL SYSTEM ...

Page 93: ...87 CONTROL SYSTEM ...

Page 94: ...ule board has connected a current sensor which measures the amp draw of the microwave circuit through the brown CT wire looping through it The current sensor is what determines if the microwave circuit is working correctly by communicating the registered amp draw to the board The current sensor is connected around the wire number 36 of the power distribution bar on the right side of the oven ...

Page 95: ...hows all the wires connected to the control board and which component they belong to Always verify for physical damage or loose connections before continuing to check continuity voltage etc If physical damage is observed replace the component or repair the wire if needed The PPI team will post this information Similar to Rocket Express ...

Page 96: ... will not power on and the incoming 12V DC from the power supply has been verified the control board is faulty and will need to be replaced Speaker The speaker provides audible feedback to the oven operator for example when a cook cycle is completed Testing the Speaker If the speaker is no longer audible check the speaker wires to make sure they are secure the terminals If wires are secure check t...

Page 97: ...91 POWER COMPONENTS ...

Page 98: ...esting EMI Filter To test the EMI Filter test across both terminals for incoming and outgoing AC voltage to verify that the voltage is passing through correctly 1 Remove rear panel from unit 2 Measure voltage across both input terminals should be 208 or 240V 3 Measure voltage across both output terminals if the voltage is the same as input the EMI Filter is good If the voltage is different by a la...

Page 99: ...er reads correct line voltage move on to step 3 If the multimeter does not read line voltage verify the wires are secure the store breaker is not tripped and correct voltage is getting to the unit or oven fuse is not blown 3 Measure the DC voltage in the bottom two terminals labeled V and V as shown in the picture If the multimeter registers 12V DC then power supply is good If the multimeter regis...

Page 100: ...y purposes manually discharge capacitors before troubleshooting cooling fans due to proximity 1 Unplug the unit and remove the rear panel 2 Manually verify the cooling fan spins freely and not seized If cooling fan is seized not spinning replace the cooling fan 3 Disconnect the cooling fan cables from the connectors and check for continuity If the meter registers continuity then the cooling fan is...

Page 101: ...ug the oven and remove the right side panel 2 With a flathead screwdriver locate the tab on the bottom and push down with the screwdriver At this point the fuse and holder will release allowing you access to open the side tab where the fuse is located 3 Remove the fuse and check for continuity If the fuse reads open replace the fuse ...

Page 102: ...96 FILTERING SYSTEM ...

Page 103: ...97 FILTERING SYSTEM ...

Page 104: ...other components The filter is located on the bottom of the unit and can be removed by pulling the filter and tray out towards the front of the oven The filter can be rinsed off with water and reinstalled allow filter to air dry before reinstalling in oven This filter does require regular maintenance and occasional replacement if damage The filter must be kept clean to ensure proper ventilation of...

Page 105: ... 246 C CAUNTION The catalyst can only be cleaned by approved non caustic oven cleaner provided by Pratica Inc and rinsed with distilled water The catalytic converter can become seriously damaged if cleaned with any other product Vent Catalyst In addition to the main catalytic converter the oven contains a secondary catalyst in the vent tube path This catalyst further assists in the breakdown of gr...

Page 106: ...100 COPA EXPRESS SCHEMATICS ...

Page 107: ...101 COPA EXPRESS SCHEMATICS ...

Page 108: ...102 COPA EXPRESS SCHEMATICS HMI Board Schematic ...

Page 109: ...103 Control Board Schematic ...

Page 110: ...104 COPA EXPRESS SCHEMATICS Heater Schematic ...

Page 111: ...105 Blower Motor cooling Fan Schematic ...

Page 112: ...106 COPA EXPRESS SCHEMATICS Microwave Circuit Schematic ...

Page 113: ...107 Pictorial Diagram The PPI team will post this information Similar to Rocket Express ...

Page 114: ...108 EXPLODED VIEW PARTS LIST ...

Page 115: ...109 EXPLODED VIEW PARTS LIST ...

Page 116: ...110 EXPLODED VIEW PARTS LIST Assembly Level 1 ...

Page 117: ...111 Assembly Door ...

Page 118: ...112 EXPLODED VIEW PARTS LIST Assembly Panel ...

Page 119: ...113 Inverter ...

Page 120: ...114 EXPLODED VIEW PARTS LIST Assembly Level 2 ...

Page 121: ...115 Door Hinge Assembly RHS ...

Page 122: ...116 EXPLODED VIEW PARTS LIST Door Hinge Assembly LHS ...

Page 123: ...117 Assembly Level 3 ...

Page 124: ...118 EXPLODED VIEW PARTS LIST Assembly Motor ...

Page 125: ...119 Electric Panel Assembly ...

Page 126: ...120 EXPLODED VIEW PARTS LIST Assembly Level 4 ...

Page 127: ...121 Gearmotor Assembly ...

Page 128: ...122 EXPLODED VIEW PARTS LIST High Voltage Assembly ...

Page 129: ......

Page 130: ...n Square Boulevard Suite 200 2018 Pratica Products Inc USA Garland TX 75040 For service or information Pratica Products Inc USA 675 Town Square Boulevard Suite 200 Garland TX 75040 1 214 299 7726 info praticausa com www praticausa com ...

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