Transcript
CONVEYOR OVEN
TYPE: PS 540
Installation and Operation Manual
S/N:
Rev.: 2.0
2.6.2005
Rev. 2.0
Dear Customer, Congratulations on deciding to choose a Metos appliance for your kitchen activities. You made an excellent choice. We will do our best to make you a satisfied Metos customer like thousands of customers we have around the world. Please read this manual carefully. You will learn correct, safe and efficient working methods in order to get the best possible benefit from the appliance. The instructions and hints in this manual will give you a quick and easy start, and you will soon note how nice it is to use the Metos equipment. All rights are reserved for technical changes. You will find the main technical data on the rating plate fixed to the equipment. When you need service or technical help, please let us know the serial number shown on the rating plate. This will make it easier to provide you with correct service. For your convenience, space is provided below for you to record your local Metos service contact information. METOS TEAM
Metos service phone number:............................................................................................... Contact person:....................................................................................................................
1
2.6.2005
2
Rev. 2.0
2.6.2005
Rev.
1. General .......................................................................................................... 1 1.1 Symbols used in the manual .......................................................................................... 1 1.2 Symbols used on the appliance ...................................................................................... 1 1.3 Checking the relation of the appliance and the manual ................................................. 1
2. Safety .............................................................................................................. 2 2.1 Safe use of the appliance ............................................................................................... 2 2.2 Safety instructions in case of malfunction ..................................................................... 2 2.3 Disposal of the appliance ............................................................................................... 2
3. Functional description .................................................................................. 3 3.1 General .......................................................................................................................... 3 3.2 Principle of air flow ....................................................................................................... 4 3.2.1 Heat transfer and how it works ............................................................................. 5 3.2.2 Air fingers .............................................................................................................. 5 3.3 Oven components ......................................................................................................... 6 3.3.1 Conveyor motor and conveyor belt ....................................................................... 7 3.3.2 Blower fan .............................................................................................................. 7 3.3.3 Electric heaters ....................................................................................................... 8 3.3.4 Window .................................................................................................................. 8 3.3.5 Cooling fan ............................................................................................................ 8 3.3.6 Air fingers and blank plates ................................................................................... 9 3.4 Control functions ........................................................................................................... 9 3.4.1 Door safety switch ............................................................................................... 10 3.4.2 Blower switch ...................................................................................................... 10 3.4.3 Heat switch .......................................................................................................... 10 3.4.4 Temperature controller ........................................................................................ 11 3.4.5 Conveyor speed digital control ............................................................................ 11 3.5 Control panel ............................................................................................................... 13
4. Operation instructions ............................................................................... 15 4.1 Operation procedures ................................................................................................... 4.1.1 Daily start-up procedure ...................................................................................... 4.1.2 Daily shutdown procedure ................................................................................... 4.2 Cleaning and maintenance ........................................................................................... 4.2.1 Daily cleaning and maintenance .......................................................................... 4.2.2 Monthly cleaning and maintenance .....................................................................
15 15 16 16 17 19
5. Installation ................................................................................................... 35 5.1 General ........................................................................................................................ 35
1
2.6.2005
5.2 Ventilation guidelines .................................................................................................. 5.3 Positioning the ovens ................................................................................................... 5.4 Ventilation hood .......................................................................................................... 5.5 Ventilation capture test ................................................................................................ 5.6 Conveyor rear stop and end stop installation .............................................................. 5.7 Electric connection ......................................................................................................
Rev.
35 36 36 37 37 38
6. Troubleshooting .......................................................................................... 39 8. Technical specifications .............................................................................. 63
2
2.6.2005
Rev. 2.0
General
1. General Carefully read the instructions in this manual as they contain important information regarding proper, efficient and safe installation, use and maintenance of the appliance. Keep this manual in a safe place for eventual use by other operators of the appliance. The installation of this appliance must be carried out in accordance with the manufacturer’s instructions and following local regulations. The connection of the appliance to the electric and water supply must be carried out by qualified persons only. Persons using this appliance should be specifically trained in its operation. Switch off the appliance in the case of failure or malfunction. The periodical function checks requested in the manual must be carried out according to the instructions. Have the appliance serviced by a technically qualified person authorized by the manufacturer and using original spare parts. Not complying with the above may put the safety of the appliance in danger.
1.1
Symbols used in the manual This symbol informs about a situation where a safety risk might be at hand. Given instructions are mandatory in order to prevent injury. This symbol informs about the right way to perform in order to prevent bad results, appliance damages or hazardous situations. This symbol informs about recommendations and hints that help to get the best performance out of the appliance.
1.2
Symbols used on the appliance This symbol on a part informs about electrical terminals behind the part. The removal of the part must be carried out by qualified persons only.
1.3 Checking the relation of the appliance and the manual The rating plate of the appliance indicates the serial number of the appliance. If the manuals are missing, it is possible to order new ones from the manufacturer or the local representative. When ordering new manuals it is essential to quote the serial number shown on the rating plate.
1
2.6.2005
Rev. 2.0
Safety
2. Safety 2.1 Safe use of the appliance The oven has to be used by trained personnel only. Do not store any combustible materials or flammable liquids anywhere near the appliance. Never disassemble or clean the oven with the blower switch or any other oven control turned “ON” or “I”. Turn “OFF” or “O” and lockout all electric power to the oven before attempting to clean or service this oven. Never use a water hose or pressurized steam cleaning equipment when cleaning the oven. Do not use any abrasive cleaning materials or a caustic cleaner when cleaning the oven. Do not operate oven if the cooling fan is not running or vent grille is plugged. Crumb pan is extremely hot while oven is operating. Allow oven to cool before removing crumb pan.
2.2
Safety instructions in case of malfunction If the oven doesn’t work properly or in case of malfunction, turn off the power and call for service. In emergency turn off the power with the general cut out switch.
2.3
Disposal of the appliance The destroying of the appliance when its economical lifetime has been reached may be harmful to the environment if not properly handled. Utilization of materials that are reusable is best done by professional personnel specialized in recycling.
2
2.6.2005
Rev. 2.0
Functional description
3. Functional description 3.1 General The PS 540 ovens can be used to bake and/or cook a wide variety of food products, such as pizza, pizza-type products, cookies, sandwiches, fish, steaks, chicken and others. The PS 540 ovens may be used either as a single oven or stacked for use as double or triple ovens. The major difference between the ovens is the width of the conveyor.
A single PS 540 oven is mounted on a base pad with legs and casters.
A double oven consists of two stacked single ovens.
3
2.6.2005
Rev. 2.0
Functional description
A triple oven consists of three stacked single ovens. The lower oven is mounted on a base pad with short legs and casters. On a double or triple oven, the ovens operate independently. All ovens use identical controls and components. One oven can be cleaned or serviced, while the others are operating.
3.2
Principle of air flow The fan-style blower draws air into the oven plenum where it is heated. The blower then pushes the hot air through the air fingers into the baking chamber. Each air finger contains an inner plate and outer plate that form the hot air into jets, distributing it across conveyor belt on which the food product rides. Air is then pulled back into the blower and the process continues. The curving, black arrows of the figure below, show this air flow.
5PPER !IR &INGERS
#ONVEYOR "ELTS
7INDOW
,OWER !IR &INGERS
4
2.6.2005
Rev. 2.0
Functional description
3.2.1
Heat transfer and how it works 1. Heat constantly moves from a warm object to a cold object. Heat moves using three different paths: conduction, radiation and convection. Conduction: This path utilizes surface-to-surface contact. The pizza dough in contact with pan is a good example of conduction. Radiation: This path has to do with objects radiating heat.Dark objects absorb heat whereas light or shiny objects reflect more heat. This is the reason that the inside of PS 540 ovens is light in colour-to reflect more heat back on the food product. Convection: This path has to do with moving a volume of air. It explains why hot air rises and cooler air replaces hot air. An industrial application of this principle is to incorporate a fan to force the hot air movement, which in turn increases the heat transfer to the food product. Each PS 540 oven has a large fan-style blower to move the hot air through the air fingers and onto the product to cook/bake the product most efficiently. 2. Temperature is the intensity of heat at the point where it is sensed. As discussed above, heat flows by conduction, radiation and convection. The speed at which the heat flows is determined by the temperature difference between the oven and the food product. The larger the difference, the faster the heat flows to the item that is being baked.
3.2.2
Air fingers The PS 540 ovens are conveyorized ovens that employ vertical jets of hot air streaming from air fingers (see fig.below) to give uniform, intense heating. The vertical streams of hot air provide an exceptional heat transfer rate and generally bake faster and at lower temperatures than convection hot air or infrared heating ovens.
-ANIFOLD !IR &LOW &ROM 0LENUM
-ANIFOLD "AFFLE
/UTER 0LATE
)NNER 0LATE
(IGH 6ELOCITY #OLUMNS OF !IR ON &OOD 0RODUCT
!IR &LOW &ROM 0LENUM
-ANIFOLD "AFFLE
)NNER 0LATE /UTER 0LATE -ANIFOLD
5
2.6.2005
Rev. 2.0
Functional description A PS 540 oven can accommodate up to four bottom and four top air fingers. Some PS 540 ovens used to bake pizza have four bottom fingers and two top fingers. For special product baking requirements, a number of other styles of fingers and finger arrangements are available from the factory.
3.3
6
Oven components
2.6.2005
Rev. 2.0
Functional description
3.3.1 Conveyor motor and conveyor belt
The conveyor belt is driven by a variable-speed electric motor operating through a gear reducer. The motor speed is controlled by a digital control. The stainless steel wire belt can travel in either direction at variable rates ranging from 3 minutes to 30 minutes. This is the time that a product can take to pass through the oven.
3.3.2 Blower fan
7
2.6.2005
Rev. 2.0
Functional description The blower fan is located at the rear of the oven. These blowers force heated air through the air fingers. The blower switch must be set to “ON” or “I” for oven warm-up and baking.
3.3.3
Electric heaters There are six heater elements mounted on the inside of the rear panel. Each element is connected to an electrical control which is energized by the temperature controller.
3.3.4
Window A window on the front of the oven permits viewing the items being baked and provide access to the oven for items that do not require full baking time, such as sandwiches, cookies, small items or cheese-melting processes.
3.3.5 Cooling fan
#OOLING &AN 'RILLE
#OOLING &AN
The cooling fans are located in the back of the oven. These cooling fans draw air through its grille, blowing it through the blower motor compartment and the control compartments into the oven top and exhausted out the front louvres.
8
2.6.2005
Rev. 2.0
Functional description
3.3.6
Air fingers and blank plates
(ALF "LANK 0LATE /UTER 0LATE
"LANK 0LATE
)NNER 0LATE
&INGER -ANIFOLD !SSEMBLY
"AFFLE
An air finger assembly is made up of three parts: 1.Outer plate is the removable covering with tapered holes, which direct the air stream onto the product being baked. 2.Inner plate - the perforated inner plate is vital in forming the unique air jets. It must be assembled into manifold with its holes aligned with the holes of the outer plate. Blank plates are available to install on the plenum where an air finger is not required.
3.4
Control functions
9
2.6.2005
Rev. 2.0
Functional description
3.4.1 Door safety switch The door safety switch is located at the lower right side of control panel opening. Opening the control panel door permits this switch to open, disconnecting power to all electrical controls. Do not touch the wires going to this safety switch. Current is always present.
3.4.2
Blower switch The blower switch has two positions. The switch must be “ON” or “I” for the main blowers to come on and permit the oven to run. The fan circulates the air throughout the oven and must stay on during baking and during the cool down cycle above 93°C to prevent blower bearing damage. To protect the blower motor and bearings a thermostatic override is built into the oven. If the temperature inside the oven is over 82°C, the main blower will continue to run after the blower switch is turned to the “OFF” or “O” position. An air pressure switch monitors the air flow from the blower, acting as a safety interlock for the heater. The heaters will not function if the air switch does not sense air from off the main blower fan.
3.4.3
Heat switch Turning the HEAT switch to “ON” or “I” will energize the electric heating system. The switch is in series with the blower fan motor and high temperature override switch. Both switches must be closed before the heating elements can be energized.
10
2.6.2005
Rev. 2.0
Functional description
3.4.4 Temperature controller The temperature controller is a solid state PID type to maintain the operator-set temperature. The temperature controller continuously monitors the oven temperature and turns on the modulating solid state relay controller. The heat is on for the time required to main tain a constant oven temperature. The temperature controller contains a low-limit switch which allows the oven to cool down to 93°C before shutting off the blower. A high-limit indication (ALM1) will appear on the display if the oven reaches 343°C.
3.4.5
Conveyor speed digital control
The on-off switch for the conveyor motor is on the control panel. Also on the control panel is the digital conveyor speed control. The digital control can be adjusted from 3 min. to 30 min. bake time (conveyor speed). Conveyor speed is measured by the amount of time it takes for an item to go through the bake chamber of the oven.
11
2.6.2005
Rev. 2.0
Functional description
0RODUCT AT ENTRANCE END OF BAKING CHAMBER
0RODUCT AT EXIT END OF BAKING CHAMBER
To check conveyor speed, place a product item at the entrance end of baking chamber as shown in the picture above. Time how long it takes for the leading edge of the item to go from the entrance end of baking chamber to the exit end. this should be the conveyor speed shown on the conveyor speed digital control.
12
2.6.2005
Rev. 2.0
Functional description
3.5
Control panel
13
2.6.2005
Rev. 2.0
Functional description
$ISPLAY
(%!4 /. ,IGHT 3%4 04 SETPOINT ,IGHT
30 ,/#+ ,IGHT
!#45!, 4%-0 ,IGHT
/6%24%-0 ,IGHT
3ERVICE +EY
4EMPERATURE +EY
5NLOCK +EY 3ET 0OINT +EY 5P !RROW AND $OWN !RROW +EYS
• • • • • • •
• • • •
14
Display shows the set point or the actual temperature in degrees (Fahrenheit or Celsius). “HEAT ON” lights when the burner is in operation. “SET PT” lights when the set point is shown in the display. “ACTUAL TEMP” lights when the actual temperature is shown in the display. SERVICE KEY - service use only. SET POINT KEY - press this key together with the Unlock Key to allow the Set Point to be changed. Changes can only be made for 60 seconds. UP ARROW and DOWN ARROW KEYS - press these keys to adjust the Set Point up or down. If the Set Point will not change, refer to Set Point Key and Unlock Key in this section. UNLOCK KEY- press this key together with the Set Point Key to allow the Set Point to be changed. Changes can only be made for 60 seconds. TEMPERATURE KEY - press this key once to view the Actual Temperature in the Display. OVERTEMP lights when the oven temperature is greater than 343°C. Refer to Quick Reference: Troubleshooting. SP LOCK lights when the set point is locked from changes. This setting can only be changed by service personnel.
2.6.2005
Rev. 2.0
Operation instructions
4. Operation instructions 4.1 Operation procedures 4.1.1
Daily start-up procedure Check that the circuit breaker/fused disconnect switch is in the ON position. Check that the oven window (if so equipped) is closed. 1.
Turn the “BLOWER” switch to the “ON” (“I”) position. This starts the main blower fan and cooling fans. The blower circulates air through the air fingers and must stay on during the cooking or baking process. Check if the cooling fans are operating when the blower switch is turned “ON” or “I” position.
2.
Turn the “CONVEYOR” switch to the “ON” (“I”) position. Set the conveyor speed for the desired baking time.
3.
If necessary, adjust the conveyor speed setting by pressing the “up arrow” or “down arrow” push buttons on the conveyor speed controller to change the displayed bake time.
4.
Adjust the temperature controller to a desired set temperature if necessary.
• •
Press the Set Point and Unlock keys at the same time. Wait for for the “SET PT” light to turn on. Press the Up Arrow and Down Arrow keys as necessary to adjust the set point.
WAIT FOR
OR
15
2.6.2005
Rev. 2.0
Operation instructions 5.
Turn the “HEAT” switch to the “ON” (“I”) position and wait for the “HEAT ON” light to turn on.
WAIT FOR
6.
Wait for the oven to heat to the set point temperature. Higher set point temperature will require a longer wait. The oven can reach a temperature of 232ºC in approximately 15 minutes.
7.
(Optional) Press the Temperature key to show the Actual temperature in the display and wait for the “ACTUAL TEMP” light to turn on. This allows you to monitor the oven temperature as it rises to the setpoint.
8.
WAIT FOR
Allow the oven to preheat for 10 minutes after it has reached the set point temperature
4.1.2 Daily shutdown procedure 1.
Turn the “Blower” and “HEAT” switches to the “OFF” (“O”) position. Note that the blowers will remain in operation until the oven has cooled to below 93ºC.
2.
Make certain that there are no products left on the conveyor inside the oven. Turn the “CONVEYOR” switch to the “OFF” (“O”) position.
3.
After the oven has cooled and the blowers are off, switch the circuit breaker/fuse disconnect to the off position.
In case of power failure, turn all switches to the “OFF” (“O”) position, open the oven window and remove the products. After the power has been restored, perform the normal start-up procedure. If the oven was switched off for less than 5 minutes, wait for at least five minutes before restarting the oven.
4.2
Cleaning and maintenance Before any cleaning or maintenance operations, perform the following procedure. • •
Switch off the oven and allow it to cool. Do not clean or service while it is warm Turn off the electric supply circuit breakers) and disconnect the electric supply to the oven
Never use a water hose, water jet or pressurized steam-cleaning equipment when cleaning this oven. Do not use excessive amounts of water to avoid saturating the oven insulation.
16
2.6.2005
Rev. 2.0
Operation instructions Do not use a caustic oven cleaner, which can damage the aluminized finger manifold surfaces. When cleaning your oven, first remove all heavy debris with a vacuum cleaner. Use a damp cloth for light cleaning. For heavier cleaning of baked on grease and carbon deposits use a non-caustic cleaner that will not react with the aluminized finger manifold surfaces.
4.2.1
Daily cleaning and maintenance A. Exterior Everyday you should clean the outside of the oven with a soft cloth and mild detergent.
B. Cooling fan
6ENT 'RILLE
#OOLING &AN 'RILLE
Four cooling fan grilles at the rear of each oven control compartment must be cleaned daily. Clean grilles with a stiff nylon type brush. Check the air intake of the cooling fan daily. The best time to check is right after starting the oven. Clean control compartment vent grille using a stiff nylon brush. If a fan blade is not rotating, broken or fan assembly is missing from main blower motor shaft, do not operate the oven. Replace cooling fan blade before operating the oven. Serious damage could be done to the burner blower motor and/or solid-state electrical components if oven is operated while cooling fan is not running or vent grille is plugged.
17
2.6.2005
Rev. 2.0
Operation instructions
C. Conveyor belt and crumb pans
#ONVEYOR BELT AND #RUMB PAN CLEANING
Everyday, just after starting the oven, stand at the unloading end of the conveyor and with a brush remove food particles (crumbs etc.) clinging to the conveyor belt, brushing them into the crumb pan. When the oven is cool, remove and clean the crumb pan at each end of the oven. Each crumb pan can be removed by sliding it out, as shown in the picture above. Reinstall the crumb pans after cleaning.
D. Window The window can be cleaned daily while it is in place.
18
2.6.2005
Rev. 2.0
Operation instructions
4.2.2 Monthly cleaning and maintenance The oven interior may require cleaning more than once a month depending on the volume of baking. To clean the interior you have to disassemble some parts of the oven.
A. Removing conveyor from oven for cleaning 1. Remove crumb pans. 2. Remove upper and lower end plugs from each end of oven by removing the two wing screws from each end plug. 3. Remove the conveyor end stop and rear stop.
19
2.6.2005
Rev. 2.0
Operation instructions 4. Remove conveyor drive chain cover as shown below.
5. Remove tension from drive chain by lifting and pushing the conveyor slightly into the oven. Remove drive chain from conveyor drive sprocket (see fig.below).
20
2.6.2005
Rev. 2.0
Operation instructions 6. Remove the split belt conveyor assembly as shown. The split belt conveyor assembly can only be removed from the drive end of the oven.
7. Begin sliding conveyor out of the oven as shown.
8. Continue sliding the conveyor completely out of the oven, fold it in half and then place it to the side for cleaning.
21
2.6.2005
Rev. 2.0
Operation instructions Be careful not to bump the drive sprocket while handling the conveyor to avoid damaging the drive shaft.
B. Air fingers disassembly for cleaning 1. As the air fingers are removed, use a felt pen to mark all parts of the fingers. This includes the finger manifold, inner plate and the outer plate. If a blank or choke plate is used, mark that plate also. fingers are marked in the order shown, as viewed from the front of the oven. The marks for an upper oven should be preceded with a “U”, example UB1, UT2, etc.
4
4
4
"
"
"
4 "
3TANDARD &INGERS 2. Slide blank plates straight out (see fig. below).
22
2.6.2005
Rev. 2.0
Operation instructions 3. Remove the air fingers, pull the finger at the back side - pull straight out as shown. It is highly recommended that each finger be marked before removing so it is placed in exactly the same position when reassembled.
4. With air fingers out, place them in an upright position to remove the outer plate. 5. Gently step on the lip of the finger and pull the outer plate off.
23
2.6.2005
Rev. 2.0
Operation instructions 6. To remove the inner plate, pull the plate out and then up.
7. The outer finger plate is stainless and may be cleaned by either soaking in a hot, strong detergent solution or using a caustic cleaner. The conveyor belt can also be cleaned in the same way.
3TANDARD 5PPER &INGER
3TANDARD ,OWER &INGER
C. Cleaning the window The window can be cleaned in place. If it needs a thorough cleaning it may have to be removed.
24
2.6.2005
Rev. 2.0
Operation instructions 1. Remove the window by opening the window and unscrewing the window knobs from each end.
2. Push the window all the way inside the oven, making sure it is clear of the frame. Now, turn the window sideways while inside the oven and then remove it. This will avoid breaking the window.
D. Reassembly of air fingers 1. Air fingers are made of one inner plate, one outer plate and the finger housing manifold. Be sure to match up the markings (T1,T2,T3 etc.) on all parts of the air fingers as you are reassembling.
25
2.6.2005
Rev. 2.0
Operation instructions 2. Reassemble the inner plate. keep your fingers clear so you won’t pinch them. The innerplate of a finger will only go in one way because of its design. 3. Replace the outer plate by placing your hands flat on the top of the plate and pushing down.
4. Replace the air fingers by pushing in at the back side. Remember to replace them according to the numbers marked on them when they were removed. They must go back in the same way they came out.
5. When inserting fingers, the tab on the outer plate must be in the groove as shown below. There is a blocking tab on the outside of the groove which will prevent inserting the finger in the groove if the outer plate is moved away from the flange of the finger manifold. Install fingers and blank plates correctly with edges interlocked and no space between edges (see figures below). Only M6 fingers fit in the bottom row. All M3 and M1 finger cover plates have extended lips at front. This extended lip will not allow these fingers to be installed in the bottom row.
26
2.6.2005
Rev. 2.0
Operation instructions
%XTENDED ,IP
4AB ON /UTER 0LATE
&LANGE OF &INGER -ANIFOLD
4AB ON /UTER 0LATE
4OP &INGER
)NCORRECT 4OO -UCH 3PACE
"LANK 0LATE
4AB ON /UTER 0LATE OF &INGER ,OCATED IN 'ROOVE
4OP &INGER
#ORRECT %DGES /VERLAP #OMPLETELY "LANK 0LATE
4AB ON /UTER 0LATE OF &INGER ,OCATED IN 'ROOVE
27
2.6.2005
Rev. 2.0
Operation instructions
E. Reinstall end plugs 1. Reinstall lower end plug. Be sure to tighten the wing screw on the end plug.
2. Reinstall conveyor. 3. Reinstall upper end plug. Be sure to tighten two wing screws on the end plug.
F. Conveyor reassembly into oven 1. Lift conveyor and position it in the oven as shown. Conveyor assembly may be inserted into either end of oven. If it is to be installed from the non-drive end of the oven, the drive sprocket assembly must be removed as shown in conveyor disassembly section. Split belt conveyors can only be inserted from the drive end of the oven.
28
2.6.2005
Rev. 2.0
Operation instructions 2. Reinstall the conveyor rear stop. Reinstall the conveyor end stop.
#ONVEYOR 2EAR 3TOP
-I D D L E B Y -A R S H A L L
#ONVEYOR %ND 3TOP
G. Checking conveyor belt tension Oven conveyor belt must be cool when adjusting belt. Do not adjust belt if HOT. 1. With the conveyor assembly in the oven, stand at one end of conveyor and check tension by lifting the conveyor belt at centre of the oven chamber opening. The belt should not lift higher that 75mm to 102mm. Adjust conveyor belt tension screws (located on left end of oven) for the 75mm to 102mm deflection as shown in the figure below.
2. If conveyor belt is still not under proper tension, an entire link must be removed. Use the procedure “H.Conveyor belt link removal” to remove a link.
29
2.6.2005
Rev. 2.0
Operation instructions
H. Conveyor belt link removal 1. Using long nose pliers, an entire link can be removed with the conveyor assembly either in or out of the oven. Position master links at end of conveyor as shown in the figure below.
-ASTER ,INKS
2. Using long nose pliers, unhook master links at left end of conveyor as shown.
30
2.6.2005
Rev. 2.0
Operation instructions 3. Remove the outside master links on the right and left sides of the conveyor belt as shown.
4. Unhook the link to be removed. 5. Pull on the belt link section and remove. Do not discard the link removed as it may be used for making spare master links. If a section of the conveyor belt is being replaced, it should be done now. Remove the links that need replacing and use the section of conveyor belt furnished in your installation kit to replace them.
31
2.6.2005
Rev. 2.0
Operation instructions 6. Before connecting the inside master links, notice that these links have a correct position (see fig.below). The link at the right is in correct (horns up) position for inserting into the conveyor belt. The horns facing down are in the incorrect position.
#ORRECT 0OSITION )NCORRECT 0OSITION
7. Reconnect the inside master links (see fig.below).
8. Reconnect the outside master links. The outside master links have right and left sides to them. The right edge master link has an open hook facing you as shown in the figure below. This will match up with the outer edges if the conveyor belt. Remember this hook travels backwards on the conveyor.
$IRECTION OF TRAVEL
32
2.6.2005
Rev. 2.0
Operation instructions 9. Replace all parts removed from the oven.
I. Replacing conveyor belt If a section of the conveyor belt needs replacing, it can be done with conveyor assembly either in or out of the oven. The section of the conveyor belt furnished with oven in the installation kit may then be used to replace a section.
J. Attaching drive chain 1. If drive sprocket assembly was removed, reassemble it into the conveyor drive shaft. Be sure flat on end of drive shaft aligns with set screw in conveyor shaft collar. Once in place tighten 3/32” set screw. 2. Lift conveyor and install drive chain to conveyor drive sprocket and motor sprocket.
3. The angle plate located on the underside of the conveyor must be against the lower end plug. This is true on both sides of the oven.
#RUMB 0AN -OUNTING "RACKET ,OWER %ND 0LUG
33
2.6.2005
Rev. 2.0
Operation instructions 4. Reassemble conveyor drive chain cover and then reassemble the bottom cover to the drive chain cover.
5. Install both upper and end plugs.
34
2.6.2005
Rev. 2.0
Installation
5. Installation 5.1 General The oven must be installed on an even (level) non-flammable flooring and any adjacent walls must be non-flammable. It is required that the oven be placed under a ventilation hood for adequate air supply and ventilation. Do not obstruct the flow of ventilation air to and from your oven. Do not obstruct the ventilation holes in the control panel On ovens with the machinery drive compartment located at the right end, a minimum clearance of 0 mm to a left side wall, 459 mm to a right side wall and 153 mm from a back wall to air openings at the rear of the oven must be maintained. On ovens with the machinery drive compartment located at the left end, a minimum clearance of 0 mm to a right side wall, 459 mm to a left side wall and 153 mm from a back wall to air openings at the rear of the oven must be maintained. There must be adequate clearance between the oven and any combustible construction. For servicing and cleaning, a minimum of 459 mm clearance from all walls is recommended. An electrical wiring diagram for the oven is located inside the machinery compartment
5.2 Ventilation guidelines A mechanically driven ventilation system is required for the PS 540 conveyorized electric ovens. Proper ventilation is the oven owner’s responsibility. Improper ventilation can inhibit oven performance. It is recommended that the ventilation and duct work be checked out every three months. Grease filters in the intake of the hood may be required by local codes.
35
2.6.2005
Rev. 2.0
Installation
5.3 Positioning the ovens Only suggested dimensions are shown. Utility code requirements supersede any factors shown.
/.
/& &
4 O / V E N
MM /.
/& &
4 O / V E N
MM
5.4
Ventilation hood The rate of air flow exhausted through the ventilation system is generally between 40 and 70 m3/min., but may vary depending on the oven configuration and hood design. To avoid a negative pressure condition in the kitchen area, return air must be brought back to replenish the air that was exhausted. A negative pressure in the kitchen can cause heat related problems to the oven components as if there were no ventilation at all. The best way of supplying return air is through the heating, ventilation and air conditioning system. Through those systems, the air can be temperature controlled for summer and winter. Return air can be brought in directly from outside the building, but detrimental affects can result from either extreme seasonal hot and cold temperature from the outdoors.
MM MINIMUM 4O ALLOW STACKING OF OVENS MM MINIMUM MM MINIMUM
36
MM MINIMUM
MM MINIMUM
2.6.2005
Rev. 2.0
Installation Return air from fan driven system within the hood must not blow at opening of bake chamber or poor oven baking performance will result.
5.5 Ventilation capture test It is recommended that a 30 second smoke candle test be performed on your ventilation hood system. Follow the steps below to complete the ventilation smoke test. All tests are to be done on a single ovens or lower units of a double or triple oven. It is recommended to wear protective gloves when performing this test. At no time should food be present when the smoke test is being conducted. Also check that no fire suppression system will be activated by the smoke. 1. Turn ventilation system on. 2. Turn oven(s) on and allow it heat up to customers normal operating temperature, or at minimum of 248°C. 3. Turn conveyor off. Place a 30 second smoke candle in a pie or cake pan which is no higher than 76 mm. 4. Open the front oven window. Next, light the smoke candle in the pan and then slide the pan into the centre of the bake chamber on the conveyor belt and close the window. 5. The ventilation hood should capture 90% to 100% of the smoke produced by the candle.
5.6
Conveyor rear stop and end stop installation Locate the conveyor rear stop and end stop in the installation kit. Install them at the exit end of the oven. (See fig. below).
#ONVEYOR 2EAR 3TOP
-I D D L E B Y -A R S H A L L
#ONVEYOR %ND 3TOP
37
2.6.2005
Rev. 2.0
Installation
5.7 Electric connection The connection of the appliance to the electric supply must be carried out by qualified persons only. A fused disconnect switch or a main circuit breaker (customer furnished) MUST be installed in the electric supply line for each oven. It is recommended that this switch/circuit breaker have lockout/tagout capability. Copper is the recommended material for the electrical supply conductors. Power requirements for electrically heated ovens are usually 240VAC,380VAC and 480 VAC. Do not use conduit for ground. A 51 mm dia. cutout /hole in the back of the machinery compartment provides access to the electrical supply connections. The actual wiring connections are made at the terminal block located in the electrical junction box. 240VAC units have a cord and plug Using flexible cables for the electric power supply conductors requires a 51mm strain-relief fitting (not furnished) to enable safe access to the terminal block from which oven power is distributed. The electric current rating for each conductor supplying PS 540-series ovens ranges from a minimum of 95 amperes to a maximum of 100 amperes. The 240VAC oven uses two legs of the supplied power to provide 240VAC power for the oven control circuitry.
%LECTRICAL *UNCTION #OVER 0LATE
*UNCTION #ONNECTION "OX
38
2.6.2005
Rev. 2.0
Troubleshooting
6. Troubleshooting
PROBLEM Product are overcooked or undercooked
Possible cause The controls may be set incorrectly.
Oven does not heat.
The controls may be set incorrectly.
Blower motor is running, yet little or no air blows from air fingers.
Air fingers may have been reassembled incorrectly after cleaning.
Oven blower and conveyor operate, yet the oven is not heating
Conveyor will not hold proper speed or will not move at all.
Conveyor may be jammed on an object in the oven or conveyor belt or drive chain tension may be incorrect.
Oven does not turn on when its switches are turned on.
Electric power may not be reaching the oven, or the controls may be set incorrectly.
OVERTEMP light is lit, food product is undercooked
The oven temperature exceeded 343°C and the burner was automatically shut down. The oven did not reach 93°C within 15 minutes of start-up, and the oven has stopped heating.
This image appears on display, oven is not heating.
Measures • Check for correct setting of conveyor speed control. • Check for correct setting on temperature controller. • Verify the food preparation process. • Check if both BLOWER switch and HEAT switch are in the “ON” or “I” position. • Assemble air fingers correctly. • Refer to maintenance procedure. • Reset the temperature controller to a new setting (above 93°C) after turning the BLOWER switch to OFF for 30 seconds. • Start the oven again. • Turn off the oven to the “OFF” or “O” position and allow it to cool. Disconnect power to the oven. • Check if the conveyor is blocked by an object inside the oven. • Check for proper tension of the conveyor drive chain and belt. • Check that the conveyor drive sprocket is tight. • Check that all electric supply switches are set to the “ON” or “I” position. • Start the oven. • Follow the Daily shutdown procedure. • Contact your service technician. •
• •
Turn the HEAT, BLOWER and CONVEYOR switches to the “OFF” or “O” position. Wait for AT LEAST FIVE MINUTES before restarting the oven. Repeat the Daily start-up procedure.
If these steps fail to resolve the problem, call for service.
39
2.6.2005
Troubleshooting
40
Rev. 2.0
2.6.2005
Rev. 2.0
Technical specifications
8.
Technical specifications
Wiring diagram 380V PS540 Wiring diagram 380-480V PS540 Installation drawing PS540 single oven Installation drawing PS540 double oven Installation drawing PS540 triple oven Installation drawing Restraint cable
63
Wiring diagram 380V PS540
Wiring diagram 380-480V PS540
#ONDUIT FOR %LECTRICAL #ONNECTIONS
2%#/--%.$%$ -).)-5- #,%!2!.#%3 2EAR OF /VEN TO 7ALL MM .ON CONTROL %ND OF /VEN TO 7ALL MM #ONTROL %ND OF /VEN TO 7ALL MM
Installation drawing PS540 single oven
#ONDUIT FOR %LECTRICAL #ONNECTIONS
2%#/--%.$%$ -).)-5- #,%!2!.#%3 2EAR OF /VEN TO 7ALL MM
.ON CONTROL %ND OF /VEN TO 7ALL MM #ONTROL %ND OF /VEN TO 7ALL MM
Installation drawing PS540 double oven
#ONDUIT FOR %LECTRICAL #ONNECTIONS
2%#/--%.$%$ -).)-5- #,%!2!.#%3 2EAR OF /VEN TO 7ALL MM .ON CONTROL %ND OF /VEN TO 7ALL MM #ONTROL %ND OF /VEN TO 7ALL MM
Installation drawing PS540 triple oven
Installation drawing Restraint cable
2.6.2005
Technical specifications
Item
Type
Specification
Conveyor belt width
PS540
813 mm
Heating zone length
PS540
1028 mm
Baking area squire feet
PS540
0.84 sq.m
Standard single oven w/legs LxWxH
PS540
2032x1557x1202 mm
Double oven LxWxH
PS540
2032x1557x1548 mm
Triple oven LxWxH
PS540
2032x1557x1969 mm
Weight of single oven
PS540
419 kg
Shipping weight
PS540
498.3 kg
Shipping cube
PS540
3.74 m3
Operating range
PS540
27 kW/hr
Maximum operating temperature
PS540
287°C
Warm-up time
PS540
15 min.
Recirculating air fan
PS540
One fan at 2300 RPM
Air velocity
PS540
1524 cm/sec (average)
Bake time
PS540
3 min. minimum bake time; 30 min. max. bake time
Main blower&elements voltage
PS540
240V; 380V; 480V
Control circuit voltage
PS540
208-240V
Phase
PS540
3Ph
Frequency
PS540
50/60Hz
Amperage draw
PS540
100 Amp; 50 Amp
Poles
PS540
4 pole
Wires
PS540
4 wire (3 hot, 1 grd.); 5 wire (3 hot, 1 neut. 1 grd)
PS540=PS 540
70
Rev. 2.0
