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Convotherm 4 Assembly Instructions Manual

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Stacking kit
Convotherm 4
UL, USA Assembly Instructions – Original, ENG

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Summary of Contents for Convotherm 4

  • Page 1 Stacking kit Convotherm 4 UL, USA Assembly Instructions – Original, ENG...
  • Page 3 TION, AND BE FULLY UNDERSTOOD BY ALL USERS OF THIS EQUIPMENT. THIS INFORMA‐ TION NEED TO BE OBTAINED FROM YOUR LOCAL GAS SUPPLIER. ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CONVOTHERM AUTHORIZED TECHNI‐ CIAN. KEEP AREA FREE AND CLEAR OF COMBUSTIBLES.

  • Page 5: Table Of Contents

    Table of Contents Table of Contents General Environmental Protection About These Assembly Instructions For Your Safety Basic Safety Instructions Your Stacking Kit’s Intended Use Additional Hazards and Safety Measures During Transport and Setup Additional Hazards and Safety Measures During Installation, Placement into Operation, Maintenance, and Removal from Service Additional Hazards and Safety Measures During Operation and Cleaning Staff and Work Area Requirements...

  • Page 6: General

    1 General 1  General Purpose of this section This section explains how to use these assembly instructions. 1.1  Environmental Protection Policy statement Our customers' expectations, the legal regulations and standards we have to follow, and our compa‐ ny's reputation are what drives the quality and service behind all our products. Our environmental management policy is not only designed to ensure that we are always in full com‐...

  • Page 7: About These Assembly Instructions

    1 General 1.2  About These Assembly Instructions Purpose These assembly instructions provide answers to the following questions: What kinds of things are important to keep in mind when installing a stacking kit? ■ Customer documentation structure The customer documentation is made up of the following: Installation manual ■...

  • Page 8: For Your Safety

    2 For Your Safety 2  For Your Safety Purpose of this section The purpose of this section is to provide you with all the information on hazards and safety measures that you will need (in addition to the unit safety information found in the operating and installation man‐ uals) in order to safely work with and on the stacking kit without putting yourself and others at risk.

  • Page 9: Additional Hazards And Safety Measures During Transport And Setup

    2 For Your Safety 2.3    Additional Hazards and Safety Measures During Transport and Setup Transportation and setup When transporting and setting up the combi oven, keep the following hazards in mind and take the actions required in order to eliminate and/or minimize these hazards: Risk / hazard Where and in which situations will What to do / safety equipment...
  • Page 10 2 For Your Safety Risk / hazard Where and in which situations will What to do / safety equipment the risk/hazard exist? Risk of burns posed by On the air vent Let the unit cool down before mak‐ ■ ■ hot surfaces ing changes On the exhaust ducts...

  • Page 11: Additional Hazards And Safety Measures During Installation, Placement Into

    2 For Your Safety 2.4    Additional Hazards and Safety Measures During Installation, Placement into Operation, Maintenance, and Removal from Service Installation, placement into operation, maintenance, and removal from service When installing and maintaining the combi oven, as well as when placing it into operation or removing...
  • Page 12 2 For Your Safety Risk / hazard Where and in which situations will What to do / safety equipment the risk/hazard exist? Crush hazard if the unit Whenever moving the units across Secure the units so that they can‐ ■ ■...

  • Page 13: Additional Hazards And Safety Measures During Operation And Cleaning

    2 For Your Safety 2.5    Additional Hazards and Safety Measures During Operation and Cleaning Operation and cleaning When operating and cleaning the combi oven, keep the following hazards in mind and take the actions required in order to eliminate and/or minimize these hazards: Risk / hazard Where and in which situations will What to do...
  • Page 14 2 For Your Safety Risk / hazard Where and in which situations will the What to do risk/hazard exist? Pinch point hazard (for When units are being moved on a Do not pull the base with rollers ■ multiple body parts) base with rollers forward unless you are cleaning the combi oven case or the floor/...
  • Page 15 2 For Your Safety Risk / hazard Where and in which situations will What to do the risk/hazard exist? Pinch point hazard When units are being moved on a Keep the unit doors shut (hand and foot hazard) base with rollers Risk of scalding posed When units are being moved on a Let the units cool down...

  • Page 16: Staff And Work Area Requirements

    2 For Your Safety 2.6    Staff and Work Area Requirements Staff requirements The table below specifies the qualifications needed for each role. Provided that they have the required qualifications, a single person can take over more than one role if necessary. Role Required qualifications Tasks...
  • Page 17 2 For Your Safety Role Required qualifications Tasks Water and waste‐ Qualified staff from an authorized Connecting the unit to the water ■ ■ water installer service company connection at the facilities Has relevant training Uninstalling water connections ■ ■ Connecting the unit to the drain ■...

  • Page 18: Stacking Kit Version Layouts And Components

    6.10 on 10.10 with 6.10 on 6.10 with 6.10 on 10.10 with 6.10 on 6.10 rollers, rollers, with 6” base height base height of 4”/6” base height 4”/6” base height 12” base height 6" 6" ■ ■ 6”/8” (marine 6”/8” (marine mod‐...

  • Page 19: Versions And Components

    6.20 on 6.20 door) 6.20 on 10.20 3455862 6.10 on 6.10 6.10 on 10.10 Stacking kit with rollers, ES/EB 4” base height 3455865 6.20 on 6.20 6.20 on 10.20 3462275 6.10 on 6.10 6.10 on 10.10 Stacking kit with rollers, ES/EB 6”...
  • Page 20 3 Stacking kit version layouts and components Item number Version Unit type For the following units Optional 3416730 Wastewater installation kit Two units 3423745 Single water connection kit Two units 3423747 Double water connection kit Two units (if there is soft water and hard water) 3455859 Wall anchoring kit for stacking One unit...

  • Page 21: Center Adapter For Electrical Units

    Qty. Left side cover Baffle DIN 53085 M5 x 10 A2 serrated flange screw M4 A4 serrated face nut Closed moisture removal box 1.6” – 2.4” hose clamp 2 (for 10.10/10.20) Sleeve 1 (for 10.10/10.20) Intake duct 1 (for 10.10/10.20) DN 50 gland grommet 1 (for 6.10/10.10)
  • Page 22 3 Stacking kit version layouts and components Designation Qty. Right side cover DIN 933 M8x40 screw DIN 7982 8 x 25 counter‐ sunk screw (depending on the unit version) M5 x 25 A2 countersunk screw Front cover...

  • Page 23: Center Adapter For Gas Units

    3 Stacking kit version layouts and components 3.4  Center Adapter for Gas Units Stacking kit parts: Center Adapter for Gas Units The figure below shows a size 6.20 center adapter for gas units used as an example representing all unit sizes: Designation Qty.
  • Page 24 3 Stacking kit version layouts and components Designation Qty. M4 x 10 A2 pan head screw Heat shield Air vent 2 (for 6.20/10.20) 1 (for 6.10/10.10) Rear cover Right side cover DIN 933 M8x40 screw DIN 7982 8 x 25 countersunk screw (depending on the unit version) M5 x 25 A2 countersunk screw...

  • Page 25: 6" Base

    Base Adjustable foot e S8 A2 P2 P3 serrated washer DIN 931 M8 x 70 A2 P4 hex screw DIN 7976 4.8 x 80 A2 P4 hex washer head self-tapping screw DIN 931 M5 x 75 A2 P4 hex screw...

  • Page 26: 12" Base

    Base Adjustable foot e S8 A2 P2 P3 serrated washer DIN 931 M8 x 70 A2 P4 hex screw DIN 7976 4.8 x 80 A2 P4 hex washer head self-tapping screw DIN 931 M5 x 75 A2 P4 hex screw...

  • Page 27: Base With Rollers

    S8 A2 P2 P3 serrated washer DIN 931 M8 x 70 A2 P4 hex screw DIN 7976 4.8 x 90 A2 P4 hex washer head self-tapping screw DIN 931 M5 x 75 A2 P4 hex screw Front roller (4” or 6” base height)

  • Page 28: Marine Model Base

    Marine Model Base Adjustable foot e S8 A2 P2 P3 serrated washer DIN 931 M8 x 70 A2 P4 hex screw DIN 7976 4.8 x 80 A2 P4 hex washer head self-tapping screw DIN 931 M5 x 75 A2 P4 hex screw...

  • Page 29: Planning For Setup And Assembly

    4 Planning for Setup and Assembly 4  Planning for Setup and Assembly Purpose of this section This section provides information on the requirements that apply when setting up a stacking kit. It includes the basic installation steps involved, as well as information regarding the tools and materials you will need.

  • Page 30: Required Tools And Materials

    4 Planning for Setup and Assembly Stacking kit weights Depending on the specific size and version, the stacking kit will weigh between 66 and 110 lbs (not including any units or accessories). Stacking kit combinations featuring electrical and gas units...

  • Page 31: Basic Installation Procedure

    They are used as an example representing all unit sizes and unit models: 1. Install the exhaust extension (if necessary) 2. The bottom combi oven is mounted on the base 3. Install the center adapter 4. The top combi oven is installed 5. The flue is installed...

  • Page 32: Assembly

    5 Assembly 5  Assembly Purpose of this section This section provides detailed information on the assembly steps required for the stacking kit. This section is intended exclusively for installers and authorized customer service companies. Prerequisites The following prerequisites must be met: You have read and understood the 'For Your Safety' section.
  • Page 33 5 Assembly Installing the exhaust duct extension Clean the inside of the exhaust duct as far as you will be inserting the exhaust duct extension. Clean the outside of the exhaust duct extension. Apply a bead of high heat silicone all around the bottom of the exhaust duct extension.
  • Page 34 5 Assembly Slide the exhaust duct extension as far as it will go into the exhaust duct. Wipe off the excess silicone. Check to make sure that the gap between the exhaust duct extension and the exhaust duct is completely filled with silicone.

  • Page 35: The Bottom Combi Oven Is Mounted On The Base

    5 Assembly 5.2  The bottom combi oven is mounted on the base The figures below show a stacking kit for gas units. They are used as an example representing all unit sizes and unit models. Preparing the bottom unit Make sure that the bottom unit’s oven cavity is empty (re‐ move the racks, suction panel, sheet pans, etc.).
  • Page 36 Stacking kit with rollers (4” or 6” base height) Use the nuts included with the installation kit to install the rollers on the stacking kit’s base (long rollers (1) in the back, short rollers (2) in the front).
  • Page 37 5 Assembly Before starting to fasten the base, remove the two retain‐ ing screws for the left side panel at the bottom of the unit. Install the water distributor, hoses, tubes, gas angle bracket, and cleaning agent lines as applicable. Fastening the base Stacking kit with 6”...
  • Page 38 5 Assembly Use an open-end wrench with a width across flats of 13 mm and the four enclosed hex screws and the serrated washers to fasten the base with the rollers (rollers with lock in the front). Use a socket wrench with a width across flats of 8 mm to lock the brakes.

  • Page 39: Installing The Center Adapter

    5 Assembly 5.3  Installing the Center Adapter The figures below show a stacking kit for gas units. They are used as an example representing all unit sizes and unit models. Preparation steps Remove the two long screws on the left side of the base. Remove the left side panel.
  • Page 40 5 Assembly Pull the dry air intake down. Dispose of the pipe that is cut at an angle. You will not be needing it anymore. Turn the venting valve back to its original position. Make sure that the gasket is in its correct end position. Apply a bit of lubricant (e.g., soap) to the air vent(s).
  • Page 41 5 Assembly Side covers: Disengage the left and right side covers from the tabs in the front and back. Rear cover: Use a Phillips screwdriver to unscrew the seven pan head screws. Remove the rear center adapter cover. Use a Phillips screwdriver to remove the five screws at the top of the unit.
  • Page 42 5 Assembly Fastening the center adapter Before inserting the screws, squeeze silicone into the dril‐ led holes. Use the five enclosed countersunk screws to screw the center adapter in place. Use silicone with all five countersunk screws in order to secure the joint, make it water tight, and prevent water from penetrating the bottom unit.
  • Page 43 5 Assembly Insert the bottom end of the intake duct into the dehumidi‐ fier valve’s gasket and slide the second hose clamp onto the sleeve. Connect the grounding cable to the intake duct’s spade terminal. Apply lubricant to the moisture removal box’s pipe sec‐ tion.
  • Page 44 5 Assembly Use the sleeve and the hose clamp to connect the intake duct and the bottom end of the moisture removal box. Make sure that the gaskets and the sleeve are in their correct position and have a proper fit. 6.10/6.20: Insert the bottom end of the moisture removal box into the dehumidifier valve’s gasket.
  • Page 45 5 Assembly Use the serrated face nuts (M4) to secure the exhaust gas flue box. Install the rear cover. Notice: Depending on the specific stacking kit version, it may be necessary to open holes on the rear cover.

  • Page 46: Installing The Top Unit

    5 Assembly 5.4  Installing the Top Unit The figures below show an electrical stacking kit for stacking a size 6.10 unit on a size 6.10 unit. They are used as an example representing all unit sizes and unit models: Preparing the top unit Make sure that the top unit’s oven cavity is empty (re‐...
  • Page 47 5 Assembly Remove the feet from the left unit side. Make sure that the grease filter (if any) has been re‐ moved. Secure the bend. Remove the two upper foam blocks on the left unit side and lower the unit. Setting up the unit on top Suggestion for installation with a lifting device: Align both units in front of each other.
  • Page 48 5 Assembly Place four groups of two foam blocks (enclosed with the packaging) on the center adapter – one in each corner. Move the top unit over the foam blocks and align it with the bottom unit. Make sure that in each foam block group, the two foam blocks are perfectly aligned with each other.
  • Page 49 5 Assembly Carefully lower the unit. 10.b Use a piece of lumber (1) to slightly lift the unit careful‐ 11.a Remove the remaining foam blocks. Position the unit on the pins (2) on both sides. Make sure that the four pins on the center adapter are 11.b in the correct position inside the corresponding holes at the bottom of the unit.
  • Page 50 5 Assembly Making the electrical connection Remove the top unit’s left side panel. In the top unit’s electrical wiring compartment, on the left side, knock out the lower perforated opening for the grom‐ met. Slit the grommet. Push the grommet into the opening. Route the cable for the cooling fan.
  • Page 51 5 Assembly Connect the stacking kit’s fan cable to the supply mod‐ ule’s 12 V terminals (+ and -). Caution: 12 VDC! Make sure to route the cable properly inside the wiring compartment and to use the correct polarity when making the connections: Stacking kit cable Power supply module...
  • Page 52 5 Assembly Grease the grommet. Install the long air vent(s).
  • Page 53 5 Assembly For gas units only: Installing the exhaust duct Place the exhaust duct on the studs intended for this pur‐ pose and use the four enclosed serrated face nuts (M4) to secure it. Use the three enclosed serrated face nuts (M4) to fasten the heat shield onto the exhaust duct cover.
  • Page 54 5 Assembly Installing the connections Route the water and cleaning agent connections, all ca‐ bles, and the gas connection (in the case of gas units) through the opening on the rear panel. Make sure to install them correctly as specified in the in‐ stallation manual for your combi oven.
  • Page 55 5 Assembly Make sure that the baffle’s bent edge is at the top. Mount the left cover on the center adapter using the mag‐ net/tab mechanism. Mount the right cover on the center adapter using the magnet/tab mechanism. On the top unit, bend the the door contact switch holding plate 90°...
  • Page 56 5 Assembly Knock out the appropriate perforated section on the front cover as required for the unit combination door being used. Right-hinged door on 1 and 2 bottom Right-hinged door on Disappearing door on bottom Disappearing door on Disappearing door on bottom Right-hinged door on Right-hinged door on...

  • Page 57: Wall Anchoring (Optional) / Marine Model / Retaining Element

    5 Assembly 5.5  Wall Anchoring (Optional) / Marine Model / Retaining Element Wall anchoring In order to minimize the risk of the stacking kit toppling over, the stacking kit can be secured to the wall using the enclosed wall anchoring kit for stacking kits (optional). Attach the wall bracket.

  • Page 58: Affixing Warning Labels

    5 Assembly 5.6  Affixing Warning Labels Location of warning labels on the combi oven The figure below shows a stacking kit used as an example representing all unit sizes: Type and location of the warning labels that need to be affixed (if not affixed already) The following warning labels need to be affixed at the defined locations on the combi oven.

  • Page 59: Additional Work

    5 Assembly 5.7  Additional Work Overview of additional work required For information on the following tasks and details, please refer to the installation manual for the combi oven: Connecting the combi oven ■ Placing into operation and disposal ■ Special equipment and accessories ■...

  • Page 60: Placing Into Operation

    6 Placing into operation 6  Placing into operation Purpose of this section This section goes over how to place your combi ovens into operation once they are on the stacking kit. 6.1  Procedure for Placing the Unit into Operation Meaning This section is intended to provide commissioning staff with an overview of the prerequisites that must be met before placing the combi ovens into operation, as well as with information on how to place them into operation.

  • Page 61: Cleaning And Maintenance

    7 Cleaning and maintenance 7  Cleaning and maintenance Purpose of this section This section provides information on the cleaning and maintenance schedules and explains how to clean and maintain your unit. 7.1  Cleaning Work Prerequisites Before performing any cleaning work, check to make sure that the following prerequisites are met: You must have already read and understood how to perform the work described in “Cleaning In‐...

  • Page 62: Removing From Service

    8 Removing from service 8  Removing from service Purpose of this section This section goes over how to remove your combi ovens from service if you are using them with a stacking kit. 8.1  Procedure for Removing the Unit from Service Prerequisites The following prerequisites must be met: You must have familiarized yourself with the work listed in the combi oven’s installation manual ■...
  • Page 64 Additional technical documentation can be found in the download center at : www.convotherm.com Welbilt off ers fully-integrated kitchen systems and our products are ® backed by KitchenCare aftermarket parts and service. Welbilt’s portfolio of award-winning brands includes Cleveland™, Convotherm , Delfi eld ® ® fi tkitchen , Frymaster ®...