Bakers Pride Oven DRG-40 User's Manual

Add to my manuals
40 Pages

advertisement

Bakers Pride Oven DRG-40 User's Manual | Manualzz

Gas Rotisserie Oven

MODEL DRG-40

Installation and Operation Manual

Serial Numbers 120170 and Higher

Warranty Information

LIMITED ONE YEAR WARRANTY

BKI (The "Company") warrants to the original purchaser that at time of shipment from the

Company factory, this equipment will be free from defect in materials and workmanship. Written notice of a claim under this warranty must be received by the Company within ONE YEAR from the date of installation, but no longer than ONE YEAR AND THREE MONTHS from date of shipment from the factory. Defective conditions caused by abnormal use or misuse, lack of or improper maintenance, damage by third parties, alterations by unauthorized personnel, acts of

God, failure to follow installation and/or operating instructions, or any other events beyond the reasonable control of the Company will NOT be covered under this warranty. The obligation of the Company under this warranty shall be limited to repairing or replacing (at the option of the

Company) any part, with the exception of lamps, fuses, and glass (which are not covered under warranty), which is found defective in the reasonable opinion of the Company. Any part found defective by the Company will be repaired or replaced without charge F.O.B. factory,

Simpsonville, South Carolina or F.O.B. authorized BKI Distributor. The Company and/or its authorized representatives will assume the normal replacement labor expense for the defective part for the period of the warranty as stated above, excluding travel and/or other expenses incidental to the replacement of the defective part, where replacement work is performed during standard business hours and not subject to overtime, holiday rates, and/or any additional fees. IN

NO EVENT SHALL THE COMPANY BE LIABLE FOR LOSS OF USE, LOSS OF REVENUE OR

LOSS OF PRODUCT OR PROFIT OR FOR INDIRECT OR CONSEQUENTIAL DAMAGES

INCLUDING BUT NOT LIMITED TO, FOOD SPOILAGE OR PRODUCT LOSS. WARRANTY

DOES NOT COVER GLASS BREAKAGE. THE ABOVE WARRANTY IS EXCLUSIVE AND ALL

OTHER WARRANTIES, EXPRESS OR IMPLIED, ARE EXCLUDED INCLUDING THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

REPLACEMENT PARTS

Any appliance replacement part, with the exception of lamps, fuses, and glass, which proves to be defective in material or workmanship within ninety (90) days of installation will be replaced without charge F.O.B. Factory, Simpsonville, SC or F.O.B. authorized BKI Distributor. The user shall have the responsibility and expense of removing and returning the defective part to the

Company as well as the cost of reinstalling the replacement or repaired part.

The purchaser must post, in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained by consulting the local gas supplier.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or servicing this equipment.

Gas Rotisserie Oven Table of Contents

Table of Contents

Table of Contents .................................................................................................................................................... 1

Introduction.............................................................................................................................................................. 2

Safety Precautions ................................................................................................................................................ 2

Safety Signs and Messages ............................................................................................................................. 2

Safe Work Practices ......................................................................................................................................... 3

Safety Labels .................................................................................................................................................... 6

Operation.................................................................................................................................................................. 8

Controls and Indicators ......................................................................................................................................... 8

Controller Operation ............................................................................................................................................ 10

Modes ............................................................................................................................................................. 10

Programming................................................................................................................................................... 11

Cooking ............................................................................................................................................................... 12

Power Failure During Cooking Cycle .................................................................................................................. 12

Probe (Thermocouple) Diagnostics..................................................................................................................... 13

Operation After Gas or Power Outage ................................................................................................................ 13

Normal Shutoff .................................................................................................................................................... 13

Installation.............................................................................................................................................................. 14

Inspection for Shipping Damage ......................................................................................................................... 14

Preparation.......................................................................................................................................................... 14

Location and Clearance ...................................................................................................................................... 15

Installation Procedure.......................................................................................................................................... 15

Gas Conversion Instructions ............................................................................................................................... 16

Maintenance ........................................................................................................................................................... 17

Scheduled Maintenance...................................................................................................................................... 17

Oven Cleaning ................................................................................................................................................ 17

Troubleshooting................................................................................................................................................... 24

Appendix A............................................................................................................................................................. 25

1

Gas Rotisserie Oven Introduction

Introduction

Your DRG-40 is a computer controlled gas fired rotisserie oven. It utilizes a double revolving rotor system to ensure even product cooking. The unit contains a single stage cook and hold computer with 5 customizable cook programs. Electrical controls are provided for powering the unit, turning on inside lights, igniting upper/lower burners, turning the rotors, filling the water bath and resetting the unit. A manual lever is supplied for draining water from the water bath. The rotor system is removable to allow for easy maintenance and cleaning.

The BKI name and trademark on this unit assures you of the finest in design and engineering -- that it has been built with care and dedication -- using the best materials available. Attention to the operating instructions regarding proper installation, operation, and maintenance will result in long lasting dependability to ensure the highest profitable return on your investment.

PLEASE READ THIS ENTIRE MANUAL BEFORE OPERATING THE UNIT. If you have any questions, please contact your BKI Distributor. If they are unable to answer your questions, contact the BKI Technical Service Department, toll free: 1-800-927-6887.

Outside the U.S., call 1-864-963-3471.

Safety Precautions

Always follow recommended safety precautions listed in this manual. Below is the safety alert symbol. When you see this symbol on your equipment, be alert to the potential for personal injury or property damage.

Safety Signs and Messages

The following Safety signs and messages are placed in this manual to provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Know and understand the meaning of these instructions, signs, and messages. Damage to the equipment, death or serious injury to you or other persons may result if these messages are not followed.

This message indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This message indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

This message indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

This message is used when special information, instructions or identification are required relating to procedures, equipment, tools, capacities and other special data.

2

Gas Rotisserie Oven Introduction

Safe Work Practices

Wear Safe Clothing Appropriate To Your Job

Always wear your insulated mitts when handling hot racks or touching any hot metal surface. If you lose or damage your mitts, you can buy new ones at your local restaurant equipment supply store or from your local BKI Distributor.

Always wear non-skid shoes when working around the oven or any other equipment.

Never wear loose clothing such as neckties or scarves while operating this equipment. Keep loose hair tied back or in a hair net while operating this equipment.

Always wear appropriate personal protection equipment during the cleaning process to guard against possible injury from hot cleaning solution.

Beware of High Voltage

This equipment uses high voltage. Serious injury can occur if you or any untrained or unauthorized person installs, services, or repairs this equipment. Always Use an

Authorized Service agent to Service Your Equipment.

Keep this manual with the Equipment

This manual is an important part of your equipment. Always keep it near for easy access. If you need to replace this manual, contact:

BKI

Technical Services Department

P.O. Box 80400

Simpsonville, S.C. 29680-0400

Or call toll free: 1-800-927-6887

Outside the U.S., call 864-963-3471

Protect Children

Keep children away from this equipment. Children may not understand that this equipment is dangerous for them and others.

NEVER allow children to play near or operate your equipment.

3

Gas Rotisserie Oven Introduction

Keep Safety Labels Clean and in Good Condition

Do not remove or cover any safety labels on your equipment. Keep all safety labels clean and in good condition. Replace any damaged or missing safety labels. Refer to the Safety Labels section for illustration and location of safety labels on this unit.

If you need a new safety label, obtain the number of the specific label illustrated on page 6, then contact:

BKI

Technical Services Department

P.O. Box 80400

Simpsonville, S.C. 29680-0400

Or call toll free: 1-800-927-6887

Outside the U.S., call 864-963-3471

Be Prepared for Emergencies

Be prepared for fires, injuries, or other emergencies.

Keep a first aid kit and a fire extinguisher near the equipment. You must use a 40pound Type BC fire extinguisher and keep it within 25 feet of your equipment.

Keep emergency numbers for doctors, ambulance services, hospitals, and the fire department near your telephone.

Know your responsibilities as an Employer

• Make certain your employees know how to operate the equipment.

• Make certain your employees are aware of the safety precautions on the equipment and in this manual.

• Make certain that you have thoroughly trained your employees about operating the equipment safely.

• Make certain the equipment is in proper working condition. If you make unauthorized modifications to the equipment, you will reduce the function and safety of the equipment.

Use Gas Safely-- Avoid Danger

Gas can be a dangerous fuel if not handled safely.

Make sure to ventilate the oven properly. If the oven is not properly ventilated, carbon monoxide can be released around the oven. Asphyxiation or suffocation can occur if gas is not ventilated properly.

Before using this appliance for the first time, contact your local gas supplier for instructions about what to do if you smell gas. Post those instructions somewhere near the oven, so that everyone who uses or works near the oven knows what to do if they smell gas.

Clearance to Combustibles

Observe proper clearance to combustibles as noted on the oven rating tag. Never place anything on top of the oven. The flues on top of the oven should be a minimum horizontal distance of 6 inches from any combustible material. Never place any combustible materials above the top of the oven. Never use any solvents near the oven. The open flame inside the oven could ignite solvent fumes, resulting in a fire or explosion.

4

Gas Rotisserie Oven Introduction

Do Not Smoke Near The Oven

This oven uses combustible fuels to operate. Smoking near this oven could possibly cause a fire. Do not allow anyone to smoke near this oven.

5

Gas Rotisserie Oven

Safety Labels

Introduction

6

Gas Rotisserie Oven Introduction

7

Gas Rotisserie Oven

Operation

Controls and Indicators

Refer to the figure and table below for an explanation of the oven’s controls and indicators.

Operation

8

Gas Rotisserie Oven

Item # Description

1

2

3

HEAT ON LED

TIME/TEMP Display

Program LEDs (1-5)

5 POWER ON/OFF Switch

6 HEAT ON/OFF Switch

7 LIGHTS ON/OFF Switch

8 ROTOR ON/OFF Switch

9 LOWER FLAME ON/OFF

Switch

10 PUSH TO RESET Switch

11 WATER FILL Switch

12

13

ROTOR JOG Switch

Drain Lever

Operation

Function

Illuminates to indicate that the top burners are on. It cuts off only when the temperature is reached.

Shows time/temperature and other messages during operation.

Illuminates to represent the program selected.

ITEM SELECT - This button is used to select the program. When this button is pressed, the controller advances to the next program and its associated LED illuminates.

START/STOP - This button is used to start and stop a cook or hold cycle.

UP AND DOWN ARROWS - These buttons are used for setting time/temperature by incrementing or decrementing to the desired value.

These buttons are used in conjunction with the COOK TEMP,

COOK TIME, HOLD TEMP, and HOLD TIME buttons.

COOK TEMP - This button is used to review and/or change the cook temperature for the individual program.

COOK TIME - This button is used to review and/or change the cook time for the individual program.

HOLD TEMP - This button is used to review and/or change the hold temperature for the individual program.

HOLD TIME - This button is used to review and/or change the hold time for the individual program.

REVIEW – This button is used to review and/or change a setting for any program.

Controls power to the entire unit.

Controls ignition of top burners if ROTOR and POWER switch are on and doors are shut.

Controls power to the lights inside oven.

Controls power to the motor that turns the rotors if the POWER switch is on.

Controls ignition of lower burner if the doors are closed and the ROTOR is on. This burner does not cycle on and off as does the top burner.

Pressing this switch resets power to the rotor motor when the motor experiences an overload condition.

Controls the flow of water into the bottom of the unit. Press and hold this switch to cause water to flow. Fill the pan to approximately ¼” (6.3 mm.) of water to assist cleaning of unit.

Controls power to the motor that turns the rotors when the doors are open, the ROTOR switch is on and the POWER switch is on. Press and hold this switch to cause the rotors to turn.

Controls the drain valve inside the unit. To open the valve, place the lever in the vertical position. To close the valve, place the lever in the horizontal position.

9

Gas Rotisserie Oven Operation

Controller Operation

The DRG-40 contains a single-stage cook and hold timer/temperature controller that has 5 cook programs and 5 modes of operation. This section explains the operating modes and programming of the controller.

Modes

Ready Mode

This mode is used to inform the operator that the oven temperature is at the initial temperature (Ready Range) for a particular program. Ready mode is entered following the initial warm-up period after power-up or when a new program is selected. In case of changing to a new program the oven may have to cool down or warm up to reach the initial oven temperature for the newly selected program. When the oven temperature enters the Ready Range for the current program, the display will flash “rEdy” and an audible alert will sound. At this time the display will alternate between the ready message and the current oven temperature. With the oven temperature in the Ready

Range, a cycle may be started by pressing the START/STOP button.

Stop Mode

To enter the stop mode while a timing cycle is not in progress, press and hold the START/STOP button for one

(1) second. The display will alternate between “STOP” and the oven temperature.

To enter the stop mode while a timing cycle is in progress, press and hold the START/STOP button for two (2) seconds. The controller will enter the ready mode after one (1) second. Continuing to hold the START/STOP button for an additional (1) second will put the controller in the stop mode.

To exit the stop mode, press the START/STOP button. If the oven temperature is in the Ready Range, the audible alert will sound. If the oven temperature is not in the Ready Range, the display will show the “too Hot” or

too CooL” message as applicable. When the oven temperature again reaches the Ready Range, the audible alert will sound and the oven will be in the ready mode.

Cook Mode

The cook mode may be entered at any time. Press the START/STOP button to begin a programmed timed cycle.

While timing the cooking cycle, the display will alternate between the time remaining and the actual temperature.

When the time remaining reaches zero, the controller will alarm and flash the message “donE”.

If hold mode is disabled for this program, the unit will continue to alarm until the START/STOP button is pressed, which will then cancel the current cycle and the controller will enter the stop mode.

If hold mode is enabled, the audible alert will sound for five (5) seconds or until a button is pressed. The unit will then go into hold mode.

To cancel a cycle in progress, press and hold the START/STOP button for one (1) second. To restart a cycle with the same programs, press the START/STOP button.

Hold Mode

When the unit enters hold mode, the display will show “HoLd” for one (1) second, the accumulated time for two

(2) seconds, and the oven temperature for one (1) second. The oven temperature will be regulated to the programmed hold temperature setting.

When the accumulated hold time reaches the hold time setting, the display will flash the message “HoLd donE” and alarm until a button is pressed. The control will now enter the stop mode. The hold cycle may be canceled by pressing the START/STOP button for one (1) second.

Review Mode

While a cycle is in progress, the operator may enter the review mode and review and/or change a setting for any program. This is done by momentarily pressing the REVIEW button, then pressing the ITEM SELECT button for the desired item program. The display will be blank, and the program LED will flash. The operator may then press the function button and review/change the setting. If a button is not pressed within five (5) seconds, the controller will exit review mode. The cycle will continue to count accordingly (up or down) while in review mode.

10

Gas Rotisserie Oven Operation

If a cycle is changed during a timed cook or hold cycle and the time is set for a value that is less than the elapsed time for the current cycle, the cycle will be completed when the review mode is exited.

If the cycle in progress goes into audible alert while in review mode, the controller will exit review mode and all changes will be canceled.

Programming

Setting a Program

2. Press and hold a function (COOK TEMP, COOK TIME, HOLD TEMP, OR HOLD TIME) button. The current setting will be displayed.

• The hold mode may be disabled on any program individually. The timed cook cycle may also be disabled, and the controller will operate as a holding timer. This is done by setting the cook or hold time to “OFF”.

• The controller may also operate with the cook and/or hold temperature set to “OFF”. When both the cook and hold temperature are set to “OFF”, the controller will not regulate the oven temperature.

This feature is intended for demonstration or display purposes.

Reviewing a Program

3. Press and hold the desired function button. The current setting will be displayed.

4. To change the setting, press the UP or DOWN button while holding the function button.

• If a button is not pressed within five (5) seconds, the controller will exit review mode and continue the cycle previously in progress.

• The cycle in progress will continue to count up or down accordingly while in the review mode.

• If a cycle is changed during a timed cook and/or hold cycle and the time is set for a value that is less than the elapsed time for the current cycle, the current cycle will be completed when the review mode is exited.

• If the cycle in progress goes into audible alert while in review mode, the controller will exit review mode and all changes will be canceled.

11

Gas Rotisserie Oven Operation

Cooking

position. The controller will automatically load the settings from the last program selected and begin regulating to the cook or hold temperature. Typically, the oven temperature is too cool upon power-up. If the oven temperature is below the programmed temperature, the display will alternately flash “too”,

CooL” until the oven temperature reaches the programmed temperature.

2. Select the desired program by pressing the ITEM SELECT button until the LED corresponding to the desired program is illuminated.

4. When the controller reaches the programmed temperature, the display will alternate between “rEdy” and the current oven temperature. The audible alert will also sound for five (5) seconds. The audible alert may be canceled early by pressing the START/STOP button. The display will continue to flash the ready message.

During the ready message, the operator may also change to a new program. Since each program may be set for a different temperature, the controller may require a warm-up or cool-down period for the oven to get in range. If the oven temperature is out of range from the new setting, the display will show either

too Hot-OPEn door” or “too CooL”, until the oven temperature comes within range of the new setting.

The ready message will again be displayed.

Once the display shows “rEdy”, if the oven temperature falls out of range again (due to the door opening to load product), the “too Hot or “too CooL message will not be displayed. The “too Hot or “too CooL messages are disabled during a cycle.

All burners are turned “OFF” when the doors are opened. Always allow a minimum of three (3) seconds before closing the doors again.

5. Open the oven doors and load the product. Use the ROTOR JOG switch on the front panel to operate the rotors during loading.

6. Once the product is loaded, close the doors.

7. When the display is flashing the ready message and you want to start the cook cycle, press the

START/STOP button.

8. When a cook cycle ends, do one of the following:

• If a hold time/temperature has not been programmed, an alarm will sound and the display will flash the message “donE” until a button is pressed. Press the START/STOP button to enter the stop mode.

• If a hold time/temperature has been programmed, the hold cycle will start. During the hold cycle the oven temperature will be regulated to the programmed hold temperature setting. When the accumulated hold time reaches the hold time setting, an alarm sounds and the display will flash the message “HoLd donE” until a button is pressed. Press the START/STOP button to enter the stop mode.

Power Failure During Cooking Cycle

The controller will suspend operation retaining programs and cycle times. When power is restored, operation will resume where left off when power failed.

12

Gas Rotisserie Oven Operation

Probe (Thermocouple) Diagnostics

If the probe (thermocouple inside the oven) stops working, the controller will cancel the cooking cycle, an audible alert will sound, and the display will show “PROB”.

Operation After Gas or Power Outage

The oven will shut off automatically if the gas supply is interrupted or the power goes out. If either of these conditions occur you should perform the following procedure:

For your safety, if the gas supply stops, or, if the power goes out, make sure to wait for at least five minutes before restarting your oven. This allows time for any unburned gas to dissipate. (LP gas may take longer than five minutes.) If you smell gas, do not start your oven. located on the front panel in the “OFF” position.

2. Wait at least five minutes to allow any gas that may have accumulated in the burner compartment to escape.

3. Follow normal operating procedures once the power or gas is restored.

Normal Shutoff

2. Wait at least five minutes to allow oven to cool.

3. Place the POWER switch and ROTOR switch in the “OFF” position.

13

Gas Rotisserie Oven Installation

Installation

Inspection for Shipping Damage

It is the owners’ responsibility to file all freight claims with the delivering truck line. Inspect all cartons and crates for damage as soon as they arrive. If damage to cartons or crates is found, or if a shortage is found, note this on the bill of lading (all copies) prior to signing.

If damage is found when the equipment is opened, immediately call the delivering truck line and follow up the call with a written report indicating concealed damage to your shipment. Ask for an immediate inspection of your concealed damage item. Packaging material MUST be retained to show the inspector from the truck line.

Preparation

There are several things the installer must know before installing the oven. These are listed below:

When using natural gas, the supply pressure must never drop below 7 inches of water column. If the supply pressure can exceed 14 inches of water column, a pressure regulator must be used. This regulator must be sized to ensure that the pressure never goes below 7 inches of water column while the unit is in operation.

• The oven installation must conform with city or county standards for gas appliances and gas piping. If your area does not have local codes, consult the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the

Natural Gas and Propane Installation Code, CSA B149.1. In Europe, city and country codes are enforced.

Do not attempt to test the gas pressure of your oven. Pressure testing should be done only by an authorized Service Agent.

• During any pressure testing of the gas supply system, the oven must be protected. The oven and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5 kPa). The oven must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa).

• The oven must be electrically grounded to conform with the local code of your city or county. If your area does not have local codes, consult the latest version of the National Electrical Code ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.2. In EUROPE, city and country codes are enforced.

• A schematic diagram of the unit is located inside the control cabinet.

• The Authorized Service Agent that installs your oven must connect the cord set at the rear of the oven to an electrical source with a voltage matching that stamped on the name and rating tag. Refer to the wiring diagrams in this manual.

• Make sure a connector is used that complies with the Standard for Connectors for Movable Gas

Appliances, ANSI Z21.69 • CSA 6.16.

• Make sure a quick-disconnect device is used that complies with the Standard for Quick-Disconnect

Devices for Use With Gas Fuel, ANSI Z21.41 • CSA 6.9.

• In Europe, the installer must supply the gas supply connector.

14

Gas Rotisserie Oven Installation

• Make sure a restraining device is used that complies with the Standard for Commercial Gas Ranges,

ANSI Z83.11/CGA 1.8 (such as BKI part number FT0279) to guard against transmission of strain to the connector.

• The drain on the DRG-40 is a ¾” ball valve. Under NO circumstances, should this valve be hard plumbed to a drain line. A short nipple may be used to direct the discharge into a 2” drain that should have a bell reducer (to act as a funnel) placed on the end of drain line. The best configuration is to place this bell reducer just below the valve. Using a ¾” line to come out from under the oven is not recommended, as it would be easy to plug up.

• Retain the manual for future reference.

Location and Clearance

Install your oven in a well-ventilated area. This will ensure that the gas burns properly and will help prevent any fires. When deciding on a location, remember the following:

• All gas-burning appliances need enough fresh air for combustion.

• Locate the oven where it can be vented into an adequate exhaust hood. Your local gas utility must approve your ventilation system. Consult a ventilation or heating company to help you design an adequate system that meets ventilation codes and standards for your city or county. In Europe, install according to local codes.

• Keep the oven away from any combustibles such as curtains, wood paneling, boxes, or towels. The flue riser at the top of the oven should also be kept away from any flammable material.

• Observe proper clearance to combustibles as noted on the oven rating tag. Never place anything on top of the oven. The flues on top of the oven should be a minimum horizontal distance of 6 inches from any combustible material. Never place any combustible materials above the top of the oven. Never use any solvents near the oven. The open flame inside the oven could ignite solvent fumes, resulting in a fire or explosion.

• Keep the work area around the oven free of objects that might block fresh air or that might cause a fire.

• Do not attach an extension to the exhaust stack. This may stop the burner from operating properly, cause the burner to go off, or, cause other dangerous malfunctions. It may also cause a strong draft in the room.

A draft can interfere with the burner.

• Do not locate the oven near strong drafts. Keep the oven away from doors that are opened and closed frequently.

Installation Procedure

Ensure that an authorized BKI service agent installs the oven. An authorized BKI service agent should be a qualified gas service technician and a licensed electrician.

Failure to restrain the oven could allow it to move, causing a possible break in the gas line resulting in an explosive condition.

1. Install an ANSI Z83.11/CGA 1.8 compliant restraining device (such as BKI part number FT0279) per the instructions below: a. Mount the wall attachment according the restraining device manufacturer instructions. b. If possible, loop one end of the restraining cable around one of the rear legs and attach the spring-loaded hook to the cable then attach the other spring-loaded hook to the wall attachment.

15

Gas Rotisserie Oven Installation

If you are unable to do this, drill a small ¼” hole through the back flange of the shelf, then follow the restraining device manufacturer instructions to finish the installation.

Use appliance connectors and quick-disconnect devices that are in compliance with the applicable ANSI and CSA standards.

2. Attach an appliance connector to the oven according to the instructions provided by the appliance connector manufacturer.

3. Connect the gas supply to the oven. In Europe, the gas supplier must provide the gas hookup connecting line.

4. Lock the casters so the oven does not move. Every time you use the oven, make sure the casters are locked so the oven cannot move. (In Canada: refer to caster codes CAN 1-6.10 M88 and CAN 1-6.9

M79.)

5. Turn on the gas at the gas supply valve.

6. Check for gas leaks from the gas supply to the oven gas valve using a soap and water solution. If a leak is detected, tighten the connection where the leak occurs.

7. Connect the three-prong (grounded) plug directly into a properly grounded three-prong receptacle.

8. Apply power to the oven.

9. Perform the following procedures provided in the Startup and Checkout section of the VR8105, VR8205,

and VR8305 Direct Ignition Combination Gas Controls Installation Instructions (69-1226-2). Refer to

Appendix A.

• Perform Gas Leak Test

• Turn On System

• Turn On Main Burner

• Check and Adjust Gas Input Burner Ignition (for Standard model Pressure Regulator)

10. Place the HEAT switch, LOWER FLAME switch, and LIGHTS switch in the “OFF” position.

11. Wait at least five minutes to allow oven to cool.

12. Place the POWER switch and ROTOR switch in the “OFF” position.

Gas Conversion Instructions

To convert the gas system from a Natural Gas to LP Gas application or vice versa, contact the BKI Technical

Service Department, toll free: 1-800-927-6887. Outside the U.S., call 1-864-963-3471.

16

Gas Rotisserie Oven Maintenance

Maintenance

The restraining device must always be connected when the appliance is in service.

Disconnect for movement, such as servicing or cleaning. Reconnect the restraint when oven has been returned to its normal position.

Failure to remove power from this unit before performing maintenance may cause severe electrical shock. This unit may have more than one disconnect switch.

Scheduled Maintenance

Use the following table to help manage scheduled maintenance activities.

Activity

Daily User Oven Clean the entire Oven and lubricate gears.

Oven Cleaning

Cleaning is not only necessary for sanitary reasons, but will increase sales appeal and maximize operating efficiency.

Failure to remove power from this unit may cause severe electrical shock. This unit may have more than one disconnect switch.

Using abrasive cleaners may damage the cabinet finish. Use only a mild soap and water solution.

DO NOT USE OVEN CLEANER on this machine. Caustic cleaners can cause damage to the machine.

NEVER USE A WATER HOSE OR A STEAM CLEANER TO WASH THIS UNIT.

Excess water can get into the interior of the cabinet and cause damage.

Always wear appropriate personal protection equipment during the cleaning process to guard against possible injury from hot fluid cleaning solution.

1. Make sure that the rotors hubs are positioned as shown below:

ROTOR

HUBS

17

Gas Rotisserie Oven Maintenance

2. Turn off all switches and controls and let the oven cool.

3. Drain and dispose of the renderings from bottom of oven.

4. Remove all food products from the unit. Remove V-spits, meat baskets and meat forks from the unit and place them in a large sink to soak in hot cleaning solution (BKI Cleaner).

5. Remove the Rotor System as described below:

• Loosen spinner hubs on both sides of the rotor shaft.

SPINNER

HUB

• Lift rotor shaft up and off of rotor hubs and out of unit.

A

18

Gas Rotisserie Oven

B

C

• Place the rotor shaft in a large sink.

Maintenance

19

Gas Rotisserie Oven

• If using a dual rotor shaft, loosen the center spinner hub.

CENTER

SPINNER

HUB

Remove the center rotor from the shaft and place in large sink.

A

Maintenance

B

20

Gas Rotisserie Oven Maintenance

• Pull drive rotor away from the oven wall to disengage drive hub (on rotor) from the drive shaft and place in sink.

A

B

C

21

Gas Rotisserie Oven Maintenance

• Pull passive rotor away from the oven wall to disengage drive hub (on rotor) from the drive shaft and place in sink.

A

B

C

22

Gas Rotisserie Oven Maintenance

6. Place the Rotor System components in a large sink to soak in hot cleaning solution. Clean the rotors with warm water, a sponge and BKI Cleaner. Wipe dry with a clean cloth.

7. Clean the outside and inside of the rotisserie oven with warm water, a sponge and an approved cleaner which is authorized for use on food surface areas.

8. Lubricate the rotor gears with Permatex® Super Lube® Synthetic Lubricant with Teflon® (L0200).

When reassembling a dual rotor shaft, ensure the countersunk holes of the center rotor face the long side of the shaft.

COUNTERSUNK

SIDE

9. Reassemble the oven.

23

Gas Rotisserie Oven Maintenance

Troubleshooting

Problem Cause

Unit will not turn on. Power to unit is not on. Problem with building power panel, circuit breaker or fuse.

Power cord may not be plugged into outlet.

Blown fuse.

Check circuit breaker or fuses at building power panel.

Plug cord into outlet.

Not rotating. Motor circuit breaker tripped.

Rotor switch not functioning.

ROTOR switch may not be activated.

Doors may not be closed.

Defective switch.

Oven does not heat at all. Doors may not be closed.

Gas supply valve may be closed.

ROTOR switch may not be activated.

HEAT switch may not be on.

Improper program settings.

Gas valve may be in safety lockout mode.

Burner does not ignite.

Hi Limit switch may be tripped.

Doors may not be closed.

Contact an authorized BKI service agent for corrective action.

Press the reset button. If problem persists, contact an authorized BKI service agent for corrective action.

Make sure the ROTOR switch is on.

Close the doors.

Contact an authorized BKI service agent for corrective action.

Close the doors.

Open gas supply valve.

Make sure the ROTOR switch is on.

Turn HEAT switch on.

Check program settings.

Turn off HEAT switch for one minute, then turn back on.

Contact an authorized BKI service agent for corrective action.

Contact an authorized BKI service agent for corrective action.

Close the doors. Lower burner is not working.

Lights are not working.

Gas supply valve may be closed.

HEAT and LOWER FLAME switch may not be on.

Gas valve may be in safety lockout mode.

Burner does not ignite.

Light switch may not be on.

Controller displays “PROB”. Thermocouple connection is loose

Water Fill is not working or thermocouple defective.

Water supply to oven may be off.

Defective oven water system.

Open gas supply valve.

Turn HEAT switch and LOWER FLAME switch on.

Turn off HEAT switch to allow gas fumes to clear, then turn back on.

Contact an authorized BKI service agent for corrective action.

Turn the LIGHTS switch on. If problem persists contact an authorized BKI service agent for corrective action.

Contact an authorized BKI service agent for corrective action.

Turn on water supply.

Contact an authorized BKI service agent for corrective action.

24

Gas Rotisserie Oven

Appendix A

Gas Control Valve Instructions

Appendix A

25

69-1226-2.fm Page 1 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, and VR8305

Direct Ignition Combination

Gas Controls

INSTALLATION INSTRUCTIONS

APPLICATION

These direct ignition gas controls are used in gas-fired appliances with up to 415 ft pressure drop (8.5 m 3

3 /hr. capacity at 1 in. wc

/hr at 0.25 kPa) on natural gas.

They include a manual valve, two automatic operators and a pressure regulator.

These gas controls are available in a range of valve capacities, see Table 1. (Table 2 provides gas capacity conversion factors.) The suffix letter indicates temperature range and regulator type, see Table 3.

Table 1. Valve Capacity a

Model

VR8105

VR8205

Size Inlet-

Outlet (in.)

1/2 x 1/2

AGA Certified

Capacity for Natural

Gas

85

150 ft 3 /hr

2.3

4.2

m 3 /hr

AGA Certified Minimum

Regulation for

Natural Gas ft 3 /hr

10 d

20 e

0.4

0.6

m 3 /hr

120

200

AGA Certified Maximum

Regulation for

Natural Gas ft 3 /hr m 3 /hr

3.4

5.7

30 f 0.8

340 9.6

370 10.5

VR8305 b,c

VR8305 b,c

VR8305 b,c

1/2 x 3/4

3/4 x 3/4

240

270

300

6.8

7.6

8.5

415 11.8

f a b c d e

Capacity based on 1000 Btu/ft 3 at 0.25 kPa pressure drop).

, 0.64 sp gr natural gas at 1 in. wc pressure drop (37.3 MJ/m 3 , 0.64 sp gr natural gas

Capacity is reduced by 5 percent when using an outlet screen.

Valves are guaranteed at only 77 percent of the rating.

Minimum regulation for LP gas is 15,000 Btuh.

Minimum regulation for LP gas is 40,000 Btuh.

Minimum regulation for LP gas is 50,000 Btuh.

Table 2. Gas Capacity Conversion Factor.

Gas

Specific

Gravity

Manufactured 0.60

Mixed

Propane

0.70

1.53

0.516

0.765

1.62

Multiply Listed

Capacity By

Table 3. Model Number Suffix Letter Designation.

H

K

M

P

Q

R

A

C

Model No.

Suffix

Letter

Ambient

Temperature

Range

0°F to 175°F

(-18°C to +79°C)

-40°F to +175°F

(-40°C to +79°C)

Pressure Regulator

Standard

Step-opening

Slow Opening

Standard

Type

Step-opening

Two-stage

Convertible

® U.S. Registered Trademark

Copyright © 1999 Honeywell Inc. • All Rights Reserved

69-1226-2

69-1226-2.fm Page 2 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

SPECIFICATIONS PLANNING THE INSTALLATION

Body Pattern: Straight through; see Table 1 for inlet and outlet size.

Electrical Ratings:

Voltage and Frequency: 24 Vac, 60 Hz.

Current Draw: 0.5A with both operators energized.

Capacity: See Table 1.

Conversion:

Use conversion factors in Table 2 to convert capacities for other gases.

Regulation Range: See Table 1.

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury, or death.

Follow these warnings exactly:

1. Plan the installation as outlined below.

2. Plan for frequent maintenance as described in the Maintenance section.

Heavy demands are made on the controls when direct ignition systems are used on central heating equipment in barns, greenhouses, and commercial properties and on heating appliances such as commercial cookers, agricultural equipment, industrial heating equipment and pool heaters.

Natural-LP Gas Conversion Kits: See Table 4.

Pipe Adapters:

Angle and straight adapters available for 3/8-, 1/2- and

3/4-in. pipe. See Table 5. Flange kits include one flange with attached O-ring, four mounting screws, a

9/64 in. hex wrench and instructions.

P

Q

R

Model No. Suffix Letter

H, K, M

Special steps may be required to prevent nuisance shutdowns and control failure due to frequent cycling, severe environmental conditions related to moisture, corrosive chemicals, dust or excessive heat. These applications require Honeywell Home and Building

Control Engineering review; contact your Honeywell

Sales Representative for assistance.

Approvals:

American Gas Association Design Certificate: L2025006.

Canadian Gas Association Design Certificate: L2025006.

Australian Gas Association Design Certificate: 4214.

Approved for Delta C applications.

European Community (CE) Certificate: Pending.

Review the following conditions that can apply to your specific installation and follow the precautions suggested.

Frequent Cycling

This control is designed for use on appliances that typically cycle three to four times an hour only during the heating season. In year-around applications with greater cycling rates, the control can wear out more quickly.

Perform a monthly checkout.

Table 4. Natural-LP Gas Conversion Kits

Kit to Convert Natural Gas to LP

393691

Kit to Convert LP to Natural Gas

394588

Not field convertible.

396021

Not required, convertible valve.

Not field convertible.

396025

Not required, convertible valve.

Table 5. Flange Adapter Part Numbers.

3/8

3/8

1/2

1/2

3/4

3/4

Inlet/Outlet

Pipe Size (in. NPT)

Straight

Elbow

Straight

Elbow

Straight

Elbow

Flange Type

393690-3

393690-4

393690-5

Part No.

a,b

Without Hex Wrench

393690-1

393690-2

393690-6

With Hex Wrench

393690-11

393690-12

393690-16

393690-13

393690-14

393690-15 a b

Flange kits include one flange, one O-ring and four mounting screws.

Do not use flanges on control models with 3/4 in. inlet and 3/4 in. outlet. On models with 1/2 in. inlet and 3/4 in. outlet, use flanges only on the 1/2 in. inlet side.

69-1226—2 2

69-1226-2.fm Page 3 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

Table 6 shows additional specifications for the CE-only models.

Specification

Main Valve Connection

Ambient Temperature Range

Maximum Inlet Pressure

Pressure Regulation

Regulator Adjustment

Ground Terminal

Pressure Taps

Valve Classification

Table 6. VR8205A,H/VR8305A,H CE Models.

VR8205A,H (CE Model Only)

1/2 in. ISO, 7/1 internal thread

(BSP.PL).

VR8305A,H (CE Model Only)

1/2 in., 3/4 in. ISO, 7/1 internal thread

(BSP.PL).

-20°C to +70°C (-4°F to +158°F)

60 mbar (24 in. wc).

Servo regulator with adjustable outlet pressure; in accordance with EN 88

Class C.

Natural gas: 9 mbar, typical; LP: 20 mbar, typical.

For natural gas, 7.5 mbar to 12.5 mbar field adjustable.

For LP gas, 20 mbar to 30 mbar field adjustable.

6.3 mm

9 mm OD

B+D C+D

CAUTION

Equipment Damage Hazard.

Improper use can damage equipment.

Read the instructions before use. This control must be installed in accordance with the rules in force.

appliance operates at very high temperatures, use insulation, shielding, and air circulation, as necessary, to protect the control. Proper insulation or shielding should be provided by the appliance manufacturer; verify proper air circulation is maintained when the appliance is installed.

INSTALLATION

Water or Steam Cleaning

If a control gets wet, replace it. If the appliance is likely to be cleaned with water or steam, protect (cover) the control and wiring from water or steam flow. Mount the control high enough above the bottom of the cabinet so it does not get wet during normal cleaning procedures.

High Humidity or Dripping Water

Dripping water can cause the control to fail. Never install an appliance where water can drip on the control. In addition, high ambient humidity can cause the control to corrode and fail. If the appliance is in a humid atmosphere, make sure air circulation around the control is adequate to prevent condensation. Also, regularly check out the system.

When Installing this Product…

1. Read these instructions carefully. Failure to follow them could damage the product or cause a hazardous condition.

2. Check the ratings given in the instructions and on the product to make sure the product is suitable for your application.

3. Installer must be a trained, experienced service technician.

4. After installation is complete, check out product operation as provided in these instructions.

Corrosive Chemicals

Corrosive chemicals can attack the control, eventually causing a failure. If chemicals are used for routine cleaning, avoid contact with the control. Where chemicals are suspended in air, as in some industrial or agricultural applications, protect the control with an enclosure.

Dust or Grease Accumulation

Heavy accumulations of dust or grease can cause the control to malfunction. Where dust or grease can be a problem, provide covers for the control to limit contamination.

Heat

Excessively high temperatures can damage the control.

Make sure the maximum ambient temperature at the control does not exceed the rating of the control. If the

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury or death.

Follow these warnings exactly:

1. Disconnect power supply before wiring to prevent electrical shock or equipment damage.

2. To avoid dangerous accumulation of fuel gas, turn off gas supply at the appliance service valve before starting installation, and perform

Gas Leak Test after installation is complete.

3. Always install a sediment trap in gas supply line to prevent contamination of gas control.

4. Do not force the gas control knob. Use only your hand to turn the gas control knob. Never use any tools. If the gas control knob does not operate by hand, the gas control should be replaced by a qualified service technician.

Force or attempted repair may result in fire or explosion.

3 69-1226—2

69-1226-2.fm Page 4 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

CAUTION

Equipment Damage.

Can burn out valve coil terminals.

Never apply a jumper across (or short) the valve coil terminals, even temporarily.

Follow the appliance manufacturers instructions if available; otherwise use these instructions as a guide.

IMPORTANT

These gas controls are shipped with protective seals over the inlet and outlet tappings. Do not remove the seals until ready to install adapters or connect the piping.

Converting Gas Control from Natural Gas to LP Gas (or LP Gas to Natural Gas)

WARNING

Fire Or Explosion Hazard.

Can cause property damage, severe injury or death.

1. Do not attempt to convert step-opening models

(suffix letter P).

2. Always change the main and pilot burner orifices when converting from natural to LP gas or from LP to natural gas. Carefully follow appliance manufacturer specifications and instructions to assure proper appliance conversion.

3. Gas controls are factory-set for natural (and manufactured) or LP gas. Do not attempt to use a gas control set for natural

(manufactured) gas on LP gas, or a gas control set for LP gas on natural (manufactured) gas.

Controls with standard, slow-opening, and two-stage regulators (model numbers with suffix H, K, M, or Q) can be converted from one gas to the other with a conversion kit (ordered separately). See Table 4 for the correct conversion kit.

Convertible Pressure Regulators

Controls with suffix letter R are convertible pressure regulator models. They can be converted from natural gas to LP gas or from LP gas to natural gas without a conversion kit.

Before converting the control from one gas to another, check the control label and the appliance manufacturer’s rating plate to determine if the pressure regulator setting

(factory set) will meet the appliance manifold requirements after conversion.

NOTE: Convertible pressure regulator models (suffix letter R) do not have field-adjustable regulators.

If the factory pressure regulator setting meets the appliance manifold requirement, convert the control as follows:

1. Remove the pressure regulator cap, Fig. 1.

2. Invert the cap so that the letters appear that represent the gas type appropriate for the appliance. NAT for natural manufactured gas, LP for liquid petroleum gas.

3. Replace the cap and tighten firmly.

PRESSURE

REGULATOR

CAP

A

T N

T

A

A

T N

T

A

OR

L

P

P

L

OTHER SIDE

OF CAP

M11678

Fig. 1. Top view of convertible pressure regulator cap.

Install Adapters To Control

If adapters are being installed on the control, mount them as follows:

Flanges

1. Choose the appropriate flange for your application.

2. Remove the seal over the ignition system control inlet or outlet.

3. Make sure that the O-ring is fitted in the groove of the flange. If the O-ring is not attached or is missing, do not use the flange.

4. With the O-ring facing the gas control, align the screw holes on the control with the holes in the flange. Insert and tighten the screws provided with the flange. See Fig. 2. Tighten the screws to 25 inch-pounds of torque to provide a gas-tight seal.

1

VALVE OUTLET

FLANGE

9/64 INCH HEX SCREWS (4)

1 DO NOT OVERTIGHTEN SCREWS. TIGHTEN TO

25 INCH-POUNDS.

M9046

Fig. 2. Firmly fasten flange to valve, but do not overtighten screws.

Bushings

1. Remove the seal over the control inlet or outlet.

2. Apply a moderate amount of good quality pipe compound to the bushing, leaving two end threads bare. On an LP installation, use compound that is resistant to LP gas. Do not use Teflon tape.

3. Insert the bushing in the control and carefully thread the pipe into the bushing until tight.

69-1226—2 4

69-1226-2.fm Page 5 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

Complete the instructions below for installing the piping, installing the control, connecting the pilot gas tubing and the wiring. Make sure the leak test you perform on the control after completing the installation includes leak testing the adapters and screws. If you use a wrench on the valve after the flanges are installed, use the wrench only on the flange, not on the control. See Fig. 5.

Location

The gas controls are mounted in the appliance vestibule on the gas manifold. If this is a replacement application, mount the gas control in the same location as the old control.

Locate the combination gas control where it cannot be affected by steam cleaning, high humidity, or dripping water, corrosive chemicals, dust or grease accumulation or excessive heat. To assure proper operation, follow these guidelines:

• Locate gas control in a well-ventilated area.

• Mount gas control high enough above cabinet bottom to avoid exposure to flooding or splashing water.

• Assure the ambient temperature does not exceed the ambient temperature ratings for each component.

• Cover gas control if appliance is cleaned with water, steam, or chemicals or to avoid dust and grease accumulation.

• Avoid locating gas control where exposure to corrosive chemical fumes or dripping water are likely.

Install Piping to Control

All piping must comply with local codes and ordinances or with the National Fuel Gas Code (ANSI Z223.1, NFPA

No. 54), whichever applies. Tubing installation must comply with approved standards and practices.

1. Use new, properly reamed pipe that is free from chips. If tubing is used, make sure the ends are square, deburred and clean. All tubing bends must be smooth and without deformation.

2. Run pipe or tubing to the control. If tubing is used, obtain a tube-to-pipe coupling to connect the tubing to the control.

3. Install a sediment trap in the supply line to the control. See Fig. 3.

Install Control

1. Mounted 0 to 90 degrees in any direction, including vertically, from the upright position of the gas control knob.

2. Mount so the gas flow is in the direction of the arrow on the bottom of the control.

3. Thread the pipe the amount shown in Table 6 for insertion into control or adapters. Do not thread pipe too far. Valve distortion or malfunction can result if the pipe is inserted too deeply.

3/8

1/2

3/4

Pipe

Size

Table 7. NPT Pipe Thread Length (in.).

Thread Pipe this Amount

9/16

3/4

13/16

Maximum Depth Pipe can be inserted into Control

3/8

1/2

3/4

DROP

HORIZONTAL

PIPED

GAS

SUPPLY

GAS

CONTROL

3 IN.

(76 MM)

MINIMUM

2

DROP

HORIZONTAL

1

TUBING

GAS

SUPPLY

RISER

3 IN.

(76 MM)

MINIMUM

2

RISER

PIPED

GAS

SUPPLY

1 ALL BENDS IN METALLIC TUBING SHOULD BE SMOOTH.

2 CAUTION: SHUT OFF THE MAIN GAS SUPPLY BEFORE REMOVING

END CAP TO PREVENT GAS FROM FILLING THE WORK AREA. TEST

FOR GAS LEAKAGE WHEN INSTALLATION IS COMPLETE.

M3077

Fig. 3. Sediment trap installation.

4. Apply a moderate amount of good quality pipe compound (do not use Teflon tape) only to the pipe, leaving two end threads bare. On LP installations, use a compound resistant to LP gas.

See Fig. 4.

5. Remove the seals over the control inlet and outlet if necessary.

6. Connect the pipe to the control inlet and outlet. Use a wrench on the square ends of the control. If a flange is used, place the wrench on the flange rather than on the control. Refer to Figs. 5 and 6.

TWO IMPERFECT

THREADS GAS CONTROL

PIPE

GAS

CONTROL

2

3 IN.

(76 MM)

MINIMUM

GAS

CONTROL

THREAD PIPE THE AMOUNT

SHOWN IN TABLE FOR

INSERTION INTO GAS CONTROL

APPLY A MODERATE AMOUNT OF

PIPE COMPOUND TO PIPE ONLY

(LEAVE TWO END THREADS BARE).

M3075B

Fig. 4. Use moderate amount of pipe compound.

5 69-1226—2

69-1226-2.fm Page 6 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

WHEN FLANGE IS NOT USED WHEN FLANGE IS USED

APPLY WRENCH

FROM TOP OR

BOTTOM OF GAS

CONTROL TO

EITHER SHADED AREA

APPLY WRENCH

TO FLANGE ONLY

M3084A

Fig. 5. Proper use of wrench on gas control with and without flanges.

HI-LO

ADJUSTMENT SCREWS

(UNDER CAP)

REGULATOR

VENT COVER

PRESSURE REGULATOR

ADJUSTMENT (UNDER

CAP SCREW)

INLET

PRESSURE TAP

WIRING

TERMINALS (2)

OUTLET

PRESSURE

TAP

LO

HI

OUTLET

TWO-STAGE

PRESSURE

REGULATOR

MODEL

INLET

INLET

GAS CONTROL KNOB

M10967A

Fig. 6. Top view of gas control.

Wiring

Follow the wiring instructions furnished by the appliance manufacturer, if available, or use the general instructions provided below. When these instructions differ from the appliance manufacturer, follow the appliance manufacturer instructions.

All wiring must comply with applicable electrical codes and ordinances.

Disconnect power supply before making wiring connections to prevent electrical shock or equipment damage.

1. Check the power supply rating on the gas control and make sure it matches the available supply.

Install a transformer and other controls as required.

2. Connect the control circuit to the gas control terminals. See Fig. 7 and 8.

3. Adjust thermostat heat anticipator to 0.50A rating stamped on valve operator.

69-1226—2 6

69-1226-2.fm Page 7 Thursday, November 13, 2003 12:50 PM

TEMPERATURE

CONTROLLER

2

S87 CONTROL MODULE

24V (GND)

24V

5

ALARM

VALVE

VALVE

GND

4

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

STARTUP AND CHECKOUT

L1

(HOT)

L2

1

ALARM, IF USED

MV

MV

DUAL VALVE

COMBINATION

GAS CONTROL

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury or death.

1. Do not force the gas control knob on the appliance. Use only your hand to turn the gas control knob. Never use any tools.

2. If the knob does not operate by hand, the control should be replaced by a qualified service technician.

3

IGNITER-SENSOR AND

BURNER GROUND

Q347 IGNITER-SENSOR

BURNER

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED.

2 ALTERNATE LIMIT CONTROLLER LOCATION.

3 MAXIMUM IGNITER-SENSOR CABLE LENGTH: 3 ft. [.9 m] OR LESS.

4 3 A REPLACEABLE FUSE.

5 ALARM TERMINAL PROVIDED ON SOME MODELS.

M9043

Fig. 7. Typical wiring connections for 24 volt control in S87 Direct Ignition System.

Gas Control Knob Settings

Gas control knob settings are as follows:

• OFF: Prevents pilot and main gas flow through the control.

• ON: Permits gas to flow into the control body. Under control of the thermostat and direct ignition module, gas can flow to the main burners.

NOTE: Controls are shipped with the gas control knob in the ON position.

Perform Gas Leak Test

DUAL VALVE

COMBINATION

GAS CONTROL

S89C,G,J/S890C,G,J

HOT SURFACE

IGNITION CONTROL

MV

MV

VALVE

VALVE (GND)

24V

TH-W

24V (GND)

GND (BURNER)

VENT

DAMPER PLUG

3

L2

HSI

L1

HSI

SEN

BURNER

GROUND

THERMOSTAT

OR CONTROLLER

2

WHITE

BLUE

BLACK

BLUE

HOT

SURFACE

IGNITER-

SENSOR

Q354 FLAME

SENSOR

LIMIT

CONTROLLER

L1

(HOT)

L2

1

1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD

PROTECTION AS REQUIRED. MAKE SURE L1 AND L2 ARE NOT

REVERSED; THIS WOULD PREVENT FLAME DETECTION.

2 ALTERNATE LIMIT CONTROLLER LOCATION.

3 SEN TERMINAL AND Q354 FLAME SENSOR ON D MODELS ONLY.

M9047

Fig. 8. Typical wiring connections with 24 volt control in S89 Direct Ignition System.

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury or death.

Perform Gas Leak Test every time work is done on a gas system.

IMPORTANT

Do not spray soap and water solution on the gas control. Do not use an excessive amount of soap and water solution to perform the gas leak test. These can damage the control.

Gas Leak Test

1. Paint pipe connections upstream of the gas control with rich soap and water solution. Bubbles indicate a gas leak.

2. If a leak is detected, tighten the pipe connections.

3. Light the main burner. Stand clear of the main burner while lighting to prevent injury caused from hidden leaks that could cause flashback in the appliance vestibule.

4. With the main burner in operation, paint the pipe joints (including adapters) and the control inlet and outlet with rich soap and water solution.

5. If another leak is detected, tighten the adapter screws, joints, and pipe connections.

6. Replace the part if a leak cannot be stopped.

Turn On System

Rotate the gas control knob counterclockwise

ON.

Turn On Main Burner

Follow appliance manufacturer instructions or turn thermostat up to call for heat.

to

7 69-1226—2

69-1226-2.fm Page 8 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

Check and Adjust Gas Input and Burner

Ignition

IMPORTANT

1. Do not exceed input rating stamped on appliance nameplate, or manufacturer’s recommended burner orifice pressure for size orifice(s) used. Make certain primary air supply to main burner is properly adjusted for complete combustion. Follow appliance manufacturer instructions.

2. IF CHECKING GAS INPUT BY CLOCKING

GAS METER: Make certain there is no gas flow through the meter other than to the appliance being checked. Other appliances must remain off with the pilots extinguished (or deduct their consumption from the meter reading). Convert flow rate to Btuh as described in form 70-2602,

Gas Controls Handbook, and compare to Btuh input rating on appliance nameplate.

3. IF CHECKING GAS INPUT WITH

MANOMETER: Make sure the gas control is in the OFF position before removing outlet pressure tap plug to connect manometer

(pressure gauge). Also move the gas control knob back to the OFF position when removing the gauge and replacing the plug. Before removing inlet pressure tap plug, shut off gas supply at the manual valve in the gas piping to the appliance or, for LP, at the tank. Also shut off gas supply before disconnecting manometer and replacing plug. Repeat Gas Leak Test at plug with main burner operating.

NOTE: Check the inlet pressure before adjusting the pressure regulator.

Standard and Slow-Opening (H, K and M)

Models

1. Carefully check the main burner lightoff. Make sure that the main burner lights smoothly and that all ports remain lit.

2. Check the full rate manifold pressure listed on the appliance nameplate. Gas control full rate outlet pressure should match this rating.

3. With main burner operating, check the control flow rate using the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on the control. See Fig. 6.

4. If necessary, adjust the pressure regulator to match the appliance rating. See Tables 8 and 9 for factory-set nominal outlet pressure and adjustment range.

a. Remove the pressure regulator adjustment cap screw.

Using a screwdriver, turn the inner adjustment screw

(Fig. 6) clockwise to increase or counterclockwise the burner.

to decrease the gas pressure to b. Always replace the cap screw and tighten firmly to prevent gas leakage.

5. If the desired outlet pressure or flow rate cannot be achieved by adjusting the gas control, check the gas control inlet pressure using a manometer at the inlet pressure tap of the gas control. If the inlet pressure is in the nominal range (see Tables 8 and 9), replace the gas control. Otherwise, take the necessary steps to provide proper gas pressure to the control.

NOTE: If the burner firing rate is above 150,000 Btuh on VR8305 models (see Table 1 for VR8305 capacities), it may not be possible to deliver the desired outlet pressure. This is an application issue, not a control failure. Take whatever steps are required to correct the situation.

Step-Opening (P) Models

Step-opening models require that you check and adjust the full-rate pressure first and then check the step pressure. The step pressure is not field adjustable.

1. Carefully check the main burner lightoff. Make sure that the main burner lights smoothly and that all ports remain lit.

2. Check the full rate manifold pressure listed on the appliance nameplate. Gas control full rate outlet pressure should match this rating.

3. With main burner operating, check the gas control flow rate using the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on the gas control. See Fig. 6.

4. If necessary, adjust the pressure regulator to match the appliance rating. See Tables 8 and 9 for factory-set nominal outlet pressure and adjustment range.

a. Remove the pressure regulator adjustment cap screw.

Using a screwdriver, turn the inner adjustment screw

(Fig. 6) clockwise counterclockwise

to increase or

to decrease the gas pressure to the burner.

b. Always replace the cap screw and tighten firmly to prevent gas leakage.

5. If the desired outlet pressure or flow rate cannot be achieved by adjusting the gas control, check the gas control inlet pressure using a manometer at the inlet pressure tap of the control. If the inlet pressure is in the nominal range (see Tables 8 and

9), replace the control. Otherwise, take the necessary steps to provide proper gas pressure to the control.

6. Carefully check the burner lightoff at step pressure.

Make sure the burner lights smoothly and without flashback to the orifice. Make sure all ports remain lit. Cycle the burner several times, allowing at least

60 seconds between cycles for the regulator to resume the step function. Repeat after allowing the burner to cool. Readjust the full rate outlet pressure, if necessary, to improve lightoff characteristics.

Two-Stage (Q) Models

Two-stage models require that you check and adjust both high and low pressure regulator settings. Two-stage appliance operating sequences vary. Consult the appliance manufacturer instructions for the specific operating sequence and regulator adjustment procedure for the appliance in which the control is installed.

1. Set appliance to operate on high.

2. Carefully check the main burner lightoff. Make sure that the main burner lights smoothly and that all ports remain lit.

3. Check the full rate (high) manifold pressure listed on the appliance nameplate for high pressure. The gas control full rate outlet pressure should match this rating.

69-1226—2 8

69-1226-2.fm Page 9 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

4. With main burner operating, check the gas control flow rate using the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on the gas control. See Fig. 6.

5. If necessary, adjust the high pressure regulator to match the appliance rating. See Tables 8 and 9 for factory-set nominal outlet pressure and adjustment range.

a. Remove the pressure regulator adjustment cap

(Fig. 6).

Using a screwdriver, turn the inner adjustment screw for

HI pressure clockwise to increase or counterclockwise to the burner.

to decrease the gas pressure

6. After high pressure has been checked, check low pressure regulation. Two-stage appliance a. Remove the pressure regulator adjustment cap

(Fig. 6).

Using a screwdriver, turn the inner adjustment screw for

LO pressure clockwise to increase or counterclockwise to the burner.

to decrease the gas pressure

10. Once high and low pressure have been checked and adjusted, replace pressure regulator adjustment cap. If the desired outlet pressure or flow rate cannot be achieved by adjusting the gas control, check the control inlet pressure using a manometer at the inlet pressure tap of the control.

If the inlet pressure is in the nominal range (see

Tables 8 and 9), replace the gas control.

Otherwise, take the necessary steps to provide proper gas pressure to the control.

operating sequences vary. Consult the appliance manufacturers instructions for the specific operating sequence and regulator adjustment procedure for the appliance in which the control is

Check Safety Lockout (Slow-Opening

Controls Only) installed and for instructions on how to prevent the control from moving to high stage while checking the low pressure regulator setting.

7. Check the low rate manifold pressure listed on the appliance nameplate. Gas control low rate outlet pressure should match this rating.

8. With main burner operating, check the gas control flow rate as before (using the meter clocking method or check pressure using a manometer connected to the outlet pressure tap on the control).

9. If necessary, adjust the low pressure regulator to match the appliance rating. See Tables 8 and 9 for factory-set nominal outlet pressure and adjustment range.

1. With the system power off and the thermostat set to call for heat, manually shut off the gas supply.

2. Energize ignition control and start timing safety lockout time. When spark ignition terminates, stop timing.

When using the VR8105H, VR8205H and

VR8305H step-opening control, the specified ignition control safety lockout time must exceed 8.5 seconds for the system to function properly.

3. After spark cutoff, manually reopen the gas control knob. No gas should flow to the main burner.

4. Reset the system by adjusting the thermostat below room temperature, wait 30 seconds, and then move the thermostat setting up to call for heat. Normal ignition should occur.

Table 8. Pressure Regulator Specification Pressures (in. wc).

Model Type

Standard,

Slow

Type of

Gas

NAT

Nominal Inlet

Pressure Range

5.0-7.0

Factory Set Nominal Outlet

Pressure

Step Full Rate

3.5

Step

Setting Range

Full Rate

3.0-5.0

Step

Two-stage

LP

NAT

LP

NAT

12.0-14.0

5.0-7.0

12.0-14.0

5.0-7.0

0.9

2.2

10.0

3.5

10.0

1.7 Low

3.5 High

None

None

LP 12.0-14.0

— 4.9 Low

10.0 High

— a

Low Fire setting range for VR8305Q 1/2 in. by 1/2 in. and 1/2 in. by 3/4 in. is 1.5 to 3.0 in. wc.

8.0-12.0

0.7-1.7

1.4-5.5

0.9-3.0 Low a

3.0-5.0 High

3.5-5.5 Low

8.0-11.0 High

9 69-1226—2

69-1226-2.fm Page 10 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

Table 9. Pressure Regulator Specification Pressures (kPa).

Model Type

Standard,

Slow

Step

Two-stage

Type of

NAT

LP

NAT

LP

NAT

LP

Gas

Nominal Inlet

Pressure Range

1.2-1.7

2.9-3.9

1.2-1.7

2.9-3.9

1.2-1.7

2.9-3.9

Factory Set Nominal Outlet

Pressure

0.2

0.5

Step Full Rate

0.9

2.5

0.9

2.5

0.48 Low

0.9 High

1.2 Low

2.5 High

None

None

Step

Setting Range

Full Rate

0.7-1.2

a Low Fire setting range for VR8305Q 1/2 in. by 1/2 in. and 1/2 in. by 3/4 in. is 0.37 to 0.75 kPa.

2.0-3.0

0.17-0.48

1.4-1.37

0.22-0.75 Low a

0.75-1.2 High

0.9-1.4 Low

2.0-2.5 High

Check Safety Shutdown Performance

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury or death.

Perform the safety shutdown test any time work is done on a gas system.

NOTE: Read steps 1 through 7 before starting, and compare to the safety shutdown or safety lockout tests recommended for the direct ignition (DI) module. Where different, use the procedure recommended for the module.

1. Turn off gas supply.

2. Set thermostat or controller above room temperature to call for heat.

3. Watch for ignition spark or for glow at hot surface igniter either immediately or following prepurge.

See DI module specifications.

4. Time the length of spark operation. See the DI module specifications.

5. After the module locks out, open the manual gas cock and make sure no gas is flowing to the main burner.

6. Set the thermostat below room temperature and wait one minute.

7. Operate system through one complete cycle to make sure all controls operate properly.

MAINTENANCE

• In many such applications, particularly commercial cooking, the equipment operates 100,000 to 200,000 cycles per year. Such heavy cycling can wear out the gas control in one to two years.

• Exposure to water, dirt, chemicals and heat can damage the gas control and shut down the control system.

The maintenance program should include regular checkout of the control as outlined in the Startup and

Checkout section, and the control system as described in the appliance manufacturer literature.

Maintenance frequency must be determined individually for each application. Some considerations are:

• Cycling frequency. Appliances that may cycle 20,000 times annually should be checked monthly.

• Intermittent use. Appliances that are used seasonally should be checked before shutdown and again before the next use.

• Consequence of unexpected shutdown. Where the cost of an unexpected shutdown would be high, the system should be checked more often.

• Dusty, wet, or corrosive environments. Since these environments can cause the gas control to deteriorate more rapidly, the system should be checked more often.

The system should be replaced if:

• It does not perform properly on checkout or troubleshooting.

• The gas control is likely to have operated for more than 200,000 cycles.

• The control is wet or looks as if it has been wet.

SERVICE

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury, or death.

Do not disassembly the gas control; it contains no replaceable components. Attempted disassembly, repair, or cleaning can damage the control, resulting in gas leakage.

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury or death.

Do not disassemble the gas control; it contains no replaceable components. Attempted disassembly, repair, or cleaning can damage the control, resulting in gas leakage.

Regular preventive maintenance is important in applications in the commercial cooking and agricultural and industrial industries that place a heavy load on system controls because:

69-1226—2 10

69-1226-2.fm Page 11 Thursday, November 13, 2003 12:50 PM

VR8105, VR8205, AND VR8305 DIRECT IGNITION COMBINATION GAS CONTROLS

CAUTION

Equipment Damage.

Can burn out valve coil terminals.

Never apply a jumper across (or short) the valve coil terminals, even temporarily.

After servicing, verify proper system operation.

If Main Burner Does Not Come On With

Call For Heat

1. Confirm the gas control knob is in the ON position.

2. Adjust thermostat several degrees above room temperature.

3. Using ac voltmeter, measure across MV terminals at gas control.

4. If voltage is incorrect or not present, check control circuit for proper operation.

5. If proper voltage is present, replace gas control.

INSTRUCTIONS TO THE

HOME-OWNER

WARNING

Fire or Explosion Hazard.

Can cause property damage, severe injury, or death.

Follow these warnings exactly:

1. Before lighting, smell around the appliance for gas. Be sure to smell next to the floor because

LP gas is heavier than air. If you smell gas:

(a) •Turn off the gas supply at the appliance service valve. On LP gas systems, turn off the gas supply at the gas tank.

(b) •Do not light any appliances in the house.

(c) •Do not touch electrical switches or use the phone.

(d) •Leave the building and use a neighbor’s phone to call your gas supplier.

(e) •If you cannot reach your gas supplier, call the fire department.

2. Replace the gas control in the event of any physical damage, tampering, bent terminals, missing or broken parts, stripped threads, or evidence of exposure to heat.

IMPORTANT

Follow the operating instructions provided by the heating appliance manufacturer. The information below describes a typical control application, but the specific controls used and the procedures outlined in your appliance manufacturer instructions can differ, requiring special instructions.

To Turn ON Appliance

STOP: Read the Warnings Above Before

Proceeding

1. The lighting sequence on this appliance is automatic; do not attempt to manually light the main burner.

2. If the furnace does not come on when the thermostat is set several degrees above room temperature, set the thermostat to its lowest setting to reset the safety control.

3. Remove the burner access panel if provided on your appliance.

Turn the gas control knob clockwise to OFF.

4. Wait five minutes to allow any gas in the combustion chamber to vent. Then if you smell gas, STOP! Follow Step 1 in the Warning above. If you do not smell gas, continue with the next step.

If you do not smell gas, turn knob on gas control counterclockwise to ON.

5. Replace the burner access panel.

6. Reset the thermostat to the desired temperature.

7. If the appliance does not turn on, turn the gas control knob to OFF and contact a qualified service technician for assistance.

Turning Off the Appliance

Vacation Shutdown

Set the thermostat to the desired room temperature while you are away.

Complete Shutdown

Turn off power to the appliance. Turn off the gas supply to the appliance. Turn gas control knob clockwise to OFF. Appliance will completely shut off.

Follow the procedure in the Instructions to the

Homeowner section above to resume normal operation.

11 69-1226—2

69-1226-2.fm Page 12 Thursday, November 13, 2003 12:50 PM

Automation and Control Solutions

Honeywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

Honeywell Limited-Honeywell Limitée

35 Dynamic Drive

Scarborough, Ontario

M1V 4Z9

69-1226—2 G.R. Rev. 11-99

Printed in U.S.A. on recycled paper containing at least 10% post-consumer paper fibers.

www.honeywell.com

P.O. Box 80400, Simpsonville, S.C. 29680-0400, USA http://www.bkideas.com

Made and printed in the U.S.A

LI0175/0807

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals