How it works
      Back to home
      1. Home
      2. Sapiens
      3. How it works

      Sapiens - Steam production

      STEAM PRODUCTION - DIRECT INJECTION

       

      All appliances are equipped with the S1 solenoid valve that enters softened water, through a nozzle, in the center of the fan to develop steam directly in the cooking cabinet

      A)

      The S1 solenoid valve, in boiler-free appliances, has always an additional direct outlet on which the water pressure switch is installed.

      S1 is controlled by output O35 (S O25) of the relays board

      B)

      On the output of the S1 valve a flow regulator must always be installed; the color change depending on the model and must be inserted into the valve as per picture

      C)

      The PA pressure switch, existing only in the direct steam unit, is connected to the body of the S2 solenoid valve to detect the water pressure (200÷500KPa).

      The PA pressure switch, if water supply is present, closes the inputs I11-12 (S I16–I17)

      If, during a cooking, there is a lack of pressure in the supply line the message A04 is immediately displayed and the cooking in progress suspended; the message will stay until the pressure is restored.

      		  

      D)

      Nozzle on the fan; this nozzle lets water reach the center of the fan and it is important to keep it clean trough an adequate water softening system. 

      E)

      The SC temperature probe, located in the chamber next to the fan, measures the air temperature. It’s protected by a small screen to be able to detect the real temperature of the air that recirculate in the cooking chamber.

      The F2 safety thermostat trips if the chamber temperature reaches 360°C and disables the C6, which disables the power to heating and auxiliaries, and generates the alarm message A02.

      		  

      F)

      The SD temperature probe, located in the ventilation pipe, measures the temperature in the drain system and determines the activation of the activation Solenoid valve S5

      G)

      The S5 solenoid valve feeds the two condensation nozzles and injects cold water to condense the steam into the drain.

      The solenoid valve is controlled by output O35 (S O24) of the relay board

      		  

      H)

      The condensation nozzle in the drain sprays, upon activation of the S5 solenoid valve, a water jet in the direction of the drain box.


      I)

      The condensation nozzle of the drain box sprays, upon activation of the S5 solenoid valve, a water jet in the direction of the chamber drain. 

      STEAM CONTROL - DIRECT INJECTION

       

      Operation

      The S1 solenoid valve is activated cyclically until saturation temperature is reached on the SD probe.

      The time of activation is based on several parameters that consider the model, the type of power supply, the temperature in chamber SC and the ventilation pipe SD; the duration of the cycle is normally 60 sec

      The system of steam generation is controlled by the relay board through the reading of the SD probe but are an active part of the system the solenoid valve with the flow regulators, the condensation solenoid valve S5 with the relative nozzles, and the fastdry system

       

      Operation

      The SD probe in addition to managing the adjustment of the activation frequency of the S1 solenoid valve, controls the activation of the condensation nozzles by powering S5.

      S5 is activated in Steam mode at 72°C; for Convection or Combi mode the temperature is 82°C.

       

      STEAM PRODUCTION - BOILER

       

      The principle of operation is similar to direct injection steam but in this case the steam is produced in a container (boiler) with its own heating elements; in this way the evaporation of water therefore does not subtract energy to the chamber heating system and the steam generated is more saturated

       

      A)

      In addition to S1 which replicates what just described for direct steam appliances, there is an S2 solenoid valve dedicated to the load of water in the boiler on the same body as the S1 (thanks to the calout system it is not necessary for the water to be softened).

      On the output to the S2 solenoid valve is installed an orange flow regulator that allows a precise evaluation of the amount of water charged according to the time and volume of the boiler

      		  

      B)

      The water inlet is on the upper side of the boiler, to prevent a possible reflux to the water network (EN61770).

      		  

      C)

      The L3 level sensor manages the S2 solenoid valve, if water is not detected the S2 solenoid valve is activated.

      The detection is continuous and based on the conductivity of water, which must be at least 50μS/cm.

      If the water is not detected within the set time (60 sec.) will be displayed the A04 alarm message; it is not necessarily a fault, it can be a momentary drop in pressure in the plant.

      Max time allowed to refill the boiler, from empty, is 300 seconds.

      		  

      D)

      The L2 Level sensor acts as an emergency sensor by immediately interrupting heating if water is not detected by this sensor.

      E)

      The Temperature probe SB manages the boiler preheating and (85°C) and activate the boiler flush in the morning if temperature is below 55°C

      		  

      F)

      The F3 safety thermostat trips if the boiler temperature reaches 150°C and disables the C6, which disables the power for the heating and the auxiliaries, and generates the alarm message A03.

      		  

      G)

      The heating elements are composed of triplet of heating elements

      H)

      The level sensor L1 manages the emptying of the boiler and PsB is activated for a set time (40 ÷ 60 sec.). At the end, if L1  continues to detect water system refills the boiler and checks the loading time.

      If the loading time is adequate (capacity stabilized at 8l/min.) then the system ignores the reading of L1 but if the load time is too short an alarm message will be generated . 

      		  

      I)

      Pump PsB empties the boiler when required or needed

      J)

      CalFree loading for the CalOut system is via the PB pump

       

       

      Warning:  In case of emergency, it is possible to turn off the boiler from the Service menu - Oven Model.

      It is also necessary to remember to turn off the water pressure switch or short-circuit the input on the board because the PA pressure switch does not exist in the unit with boiler.

      As a spare part the boiler is supplied as a single component complete with nut, fixing ring and level probes.

       

      Resistances must be ordered separately.

      In this way it is possible to manage only 3 boiler replacement codes for electric heating

       

      BOILER CONTROL BOARD NABOO 5.0

       

      Boiler Expansion PCB

      The boiler expansion board LA6530____ compatible with all Naboo units is powered and controlled through BUS connection (RJ45 - 15Vdc) and get the power for outputs through F3 with 230V.

      Here's the table that describes the expansion card terminals

      The system operates in a way analogous to the direct steam production system but in addition to the boiler itself, there is a Boiler Expansion Board that controls the boiler and the components connected to it.

      Activation from the S1, on direct injection, has been replaced by the activation of the boiler heating elements.

      Activation of the S5 is based on the Naboo B, on the Steam type: Ecovapor or Turbovapor.

       

      Boiler Expansion NABOO

      Boiler Expansion PCB

      The boiler expansion board LA65302520 compatible only with units produced up to October 2023 is powered via F3 with 230V and controlled via the BUS connection (RJ45).

      Here's the table that describes the expansion card terminals

       

      Boiler Expansion SAPIENS

      Boiler Expansion PCB

      The expansion boiler is powered via F3 with 230V and controlled via the serial connection.

      Here's the table that describes the expansion card terminals

      Preriscaldamento Boiler

       

      The preheating works with 50% of the energy until reaching 85° C on the SB probe; if Steam / Combination cooking is selected, 100% of the power is used.

      Boiler preheating

      When the device is on, the boiler is filled (L3), the automatic preheating of boiler is started to have steam immediately when necessary.

      During the boiler preheating, any manual/program/recipe cooking using a combi or steam phase is paused pending its completion.

      The boiler preheating remains active but if the device is left on standby for more than 60 min. or if the door is kept open, this function is inhibited until a new cooking is started or the door is closed.

      AUTOMATIC BOILER FLUSH

      The operation takes place automatically if:

      a) The date is changed (it's a new day)

      b) The unit is on

      c) The temperature measured by SB is less than 55°C

      Automatic boiler flush

      Evaporation and the simultaneous replenishment of evaporated water leads to increase water hardness, so it is essential to empty the boiler at least once a day. The operation takes place automatically through the PsB pump

       

      AUTOMATIC BOILER FLUSH

      1 2 3 4

       

      5

      Below are the phases of automatic boiler flush:

      1. The boiler is filled until L3 detects water
      2. The PSB pump starts and in order L3 does not detect water, so L2 does not detect and finally L1 does not detect water
      3. The S2 solenoid valve and the PsB pump are activated
      4. Activation of PSB only, to complete emptying
      5. Once the program is finished, the S2 solenoid valve is activated to refill the boiler and in sequence L1 detects water, then L2 and finally L3 detects water; at this point S2 is disabled.

      CALOUT

      The Calout System is based on a PB pump that draws the Calfree product from the tank and sends it to the boiler. The PB pump is located between the chamber and the bottom and is accessible via a panel that lowers.

      The Calout is managed by the I/O board where the meters and process logic are located, and by the Boiler expansion that controls the inputs and outputs to the pump and boiler

      The Calout is a function present in all the appliances with boiler, and the purpose of this function is to remove the thin layer of limescale that forms in boiler due to boiling, before it becomes too thick and is no longer removable other than with particularly aggressive products

       

      The Calout system is based on the actual heating time of the boiler heating element and warns the operator that it is time to start the process after 4 hours of heating the boiler (not of steaming).

       

      The customer can ignore the request but after an additional hour of heating will appear a yellow light asking to carry out the "Calout".

       

      It will be possible to ignore again and proceed for another 3 hours but at the end a red light will appear with the request "Calout NOW".

      Depending on the settings (calout block active/disabled) it will be possible to continue but a window will appear, with the warning that it will be necessary the intervention of a technician (the calout will be disabled and it will be necessary to make a Descaling to reactivate it)

      Warning: when you exceed the yellow traffic light (5 hours of heating) the time necessary to perform the Calout and the amount of product used is double.

      Furthermore, when you exceed 5 hours of heating, the system automatically ignoring the L1 level sensor because it is now probably covered with limescale. L1 will be automatically reactivated after phase 9 of the Calout program.

      Warning: the Calout function in the boiler menu of the Service level allows you to make a Calout cycle but not to reactivate the Calout in case it has disabled (Red alert).

      To reactivate the Calout, you must start the Descaling program available in the same menu, but that uses a different chemical.

       

      The Calout process involves the following phases:

      1. The boiler is refilled until the level is reached on L3
      2. The boiler is emptied and rinsed
      3. Pb pump is activated to pump CalFree into the boiler
      4. Water is added by activating S2 until the level is reached on L3
      5. The boiler is heated to activate the chemical reaction
      6. Pause to make the CalFree act and remove the limescale
      7. Steam phase
      8. The boiler is emptied and rinsed
      9. The boiler is refilled. If the accumulated time exceeds 5 hours (yellow light) return to phase 3
      10. Steam phase 110°C
      11. The boiler is rinsed and refilled

      At the end of Calout program (alone or in combination with a washing cycle) the heating time meter resets.

      Flowmeter

       

       

      On Boiler units with the option Chemical Detection System a flowmeter, controlled by the Auxiliary expansion board through the input Flux All, detect the chemical flow and warn in case of lack of chemical.

      Warning: The alert come only at the end of the cycle or in case that previous cycle was unsuccessful and nobody reset the tank counter.

      Flowmeter is located near the pump PB.

      Descaling

       

      In case of explicit request of the appliance, to reactivate the Calout function disabled by non-compliance with the system requests, or in the case of an excessive formation of limestone in the boiler, it is possible, only for qualified technicians, to access the boiler descaling function

      Prerequisites

      To use the guided descaling program you need

      - Combiboiler DS010

      - Pump for chemicals

      - Personal protective equipment (gloves, glasses)

      - Clean the cooking camera and cool the appliance.

      Access the function

      To access the descaling program

      A) Go to the Service level

      B) Select the menu boiler

      C) Select the boiler decaling program

      Descaling procedure

      A) The fully guided procedure begins with a boiler cooling and discharge phase.

      B) When prompted by message slowly introduce, through the inlet of the steam in cabinet, the

      indicated amount of Combiboiler using a pump for chemicals.

      C) Confirm continuing the program

      D) The phases will follow each other for about 70 minutes until the end of the process, which will

      end with a boiler drain.

      Recommendations

      - The procedure must be performed by a qualified technician.

      - Use only Combiboiler DS010.

      - Use an adequate pump for chemicals products

      - The product should be poured with caution; any leaks could damage the cooking camera.

      - Oversee the procedure, do not delegate the task to the end customer.

      - Do not interrupt the procedure because the product may damage the boiler or contaminate food.

      - In case of emergency the procedure can be interrupted with password; the boiler must be emptied and rinsed manually.

      - At the end is recommended at least a visual inspection of level probes.

      - Carry out a thorough rinsing of the camera from any residue of chemicals.