electric conveyor oven - Star-Mfg

electric conveyor oven - Star-Mfg
®
ELECTRIC
CONVEYOR OVEN
®
MODEL
UM1833A-208V
UM1833A-240V
UM1850A-208V
UM1850A-240V
Installation and
Operation
Instructions
®
2M-Z9844 Rev. B 2/9/07
®
UM1850A
SAFETY SYMBOL
These symbols are intended to alert the user to the presence of
important operating and maintenance instructions in the manual
accompanying the appliance.
RETAIN THIS MANUAL FOR FUTURE REFERENCE
NOTICE
Using any part other than genuine Star factory supplied parts relieves the
manufacturer of all liability.
Star reserves the right to change specifications and product design without
notice. Such revisions do not entitle the buyer to corresponding changes,
improvements, additions or replacements for previously purchased
equipment.
Due to periodic changes in designs, methods, procedures, policies and
regulations, the specifications contained in this sheet are subject to change
without notice. While Star Manufacturing exercises good faith efforts to provide
information that is accurate, we are not responsible for errors or omissions
in information provided or conclusions reached as a result of using the
specifications. By using the information provided, the user assumes all risks in
connection with such use.
MAINTENANCE AND REPAIRS
Contact your local authorized service agent for service or required maintenance. Please record the model
number, serial number, voltage and purchase date in the area below and have it ready when you call to
ensure a faster service.
Model No.
Authorized Service Agent
Reference the listing provided with the unit
or
Serial No.
Voltage
Purchase Date
for an updated listing go to:
Website:
E-mail
Telephone:
www.star-mfg.com
Service@star-mfg.com
(800) 807-9054 Local (314) 781-2777
The Star Service Help Desk
Business
Hours:
8:00 am to 4:30 p.m. Central Standard Time
Telephone:
(800) 807-9054 Local (314) 781-2777
Fax:
(800) 396-2677 Local (314) 781-2714
E-mail
Parts@star-mfg.com
Service@star-mfg.com
Warranty@star-mfg.com
Website:
www.star-mfg.com
Mailing Address: Star Manufacturing International Inc.
10 Sunnen Drive
St. Louis, MO 63143
U.S.A
2
SPECIFICATIONS
UM1833A-208V, UM1833A-240V
Rating/Connection:
6,400 Watts (6,000 element), 32/29 Amps at 208/240V
NEMA 6-50 plus with six foot oil-resistant cord
Electrical Supply:
Separate 50 Amp 208/240VAC, single phase, 50/60 Hz service per Oven
Approximate Weight (1833 Oven with Legs): Installed - 180 Lbs (81.8 kg), Shipping - 210 Lbs (95.5 kg)
Dimensions: Width: 51.2" (130.0 cm) - Oven with Shelves
Depth: 30.4" (77.2 cm)
Height: 20.0" (50.8 cm) - Single Oven with Legs
36.0" (91.4 cm) - Double Oven with Legs
Recommended Minimum Clearances:
Rear of Oven to Wall
0" (0 cm)
Conveyor Extensions to Wall
6" (15.2 cm)
UM1850A-208V, UM1850A-240V
Rating/Connection:
6,400 Watts (6,000 element), 32/29 Amps at 208/240V
NEMA 6-50 plus with six foot oil-resistant cord
Electrical Supply:
Separate 50 Amp 208/240VAC, single phase, 50/60 Hz service per Oven
Approximate Weight (1850 Oven with Legs): Installed - 210 Lbs (95.5 kg), Shipping - 240 Lbs (109.1 kg)
Dimensions: Width: 50.0" (127.0 cm)
Depth: 30.4" (77.2 cm)
Height: 20.0" (50.8 cm) - Single Oven with Legs
36.0" (91.4 cm) - Double Oven with Legs
Recommended Minimum Clearances:
Rear of Oven to Wall
0" (0 cm)
Conveyor Extensions to Wall
6" (15.2 cm)
UM1833 WITH
INFEED/EXIT SHELVES
A
A2
24.1 [612]
TOP VIEW
1833 W\OUT
SHELVES SHOWN
0
C
A = 51.2 (1300)
A1= 50.0 (1270)
A2= 33.0 (838)
B = 30.4 (772)
C = 16.0 (406)
C1= 20.0 (508)
STACKED DIMENSION
= C + C1
UM1850
A1
11.4 [291]
2.0 [51]
14.5 [369]
CONTROL BOX
DOOR OPEN
8.2
[208]
B
0
0
C1
10.6 [269]
21.0 [533]
22.0 [559]
FRONT VIEWS
END VIEW
2
14.5
[369]
GENERAL INFORMATION
This equipment is designed and sold for commercial use only by personnel trained and
experienced in its operation and is not sold for consumer use in and around the home nor for
use directly by the general public in food service locations.
First and foremost, each crate should be examined before signing the Bill of Lading to report
any visible damage by the trucker in transit and to account for the proper number of crates.
If there is apparent damage, arrangements should be made to file a claim against the carrier.
Interstate Commerce Regulations require that the claim must be initiated by the consignee.
Proper and secure storage facilities should be arranged for the oven(s) if necessary to protect
it from outdoor or damp conditions at all times before installation.
-IMPORTANTWhen you have all the crates unloaded, open the crates and remove all plastic covers. Inspect
at once for concealed damage. If anything appears to be damaged, contact the appropriate
persons immediately to file a damage claim. After completing this inspection, finish unpacking
the oven. Be sure to remove all paper protection and packing material from the unit
prior to heating.
CAUTION
FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE
VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
INSTALLATION
The ovens are equipped for the voltage indicated on the nameplate mounted on the rear of
the control box. They will operate on alternating current (AC) only. A cord is provided with a
NEMA 6-50 plug. A matching receptacle with 50A supply must be provided.
WARNING
DO NOT CONNECT TO DIRECT CURRENT (DC).
The installation of the electric oven should conform to the:
NATIONAL ELECTRIC CODE AND ALL LOCAL ELECTRIC CODES AND
ORDINANCES AND THE LOCAL ELECTRIC COMPANY RULES AND
REGULATIONS.
PURCHASER'S RESPONSIBILITY
It is the responsibility of the purchaser:
1. To see that the electric services for the oven are installed on site in accordance with the
manufacturer's specifications.
2. To unload, uncrate, and install the oven in its proper location and in accordance with this
installation operation manual.
3. To see that electric services are connected properly by a qualified installer of your choice.
All such connections must be in accordance with applicable code requirements.
4. To arrange for inspection and operation check-out by an authorized service technician.
The warranty becomes effective upon verification of proper installation.
4
IMPORTANT SAFETY INFORMATION
Do not attempt to operate the oven until connection of utility service has been fully inspected
by an authorized service technician or a Star Service Representative. This service is required
by Star in order to assist the purchaser in proper start-up of the oven on site. Please note the
specific details on the Warranty and make certain that service connections are made to proper
utility services.
The warranty shall not apply if the oven is started up and operated prior to the utilities and oven
being inspected and check-out made by an authorized service technician or a Star Service
Representative.
CAUTION
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR
MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ
ALL INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS
EQUIPMENT.
CAUTION
Minimum clearances must be maintained from all walls and combustible materials. Minimum
clearances for this unit should be 0 inches from the rear (rear bumpers provided must be in place)
and 6 inches from both sides. Keep the oven free and clear of all combustible material.
CAUTION
Do not obstruct the ventilation holes in the control panels as these provide cooling air for the
controls.
WARNING
The oven is to be operated only on the type of electricity shown on the specification plate.
INSTALLATION INFORMATION
THE INSTALLATION INSTRUCTIONS CONTAINED HEREIN ARE FOR THE USE OF
QUALIFIED INSTALLATION AND SERVICE PERSONNEL ONLY. INSTALLATION OR
SERVICE BY OTHER THAN QUALIFIED PERSONNEL MAY RESULT IN DAMAGE
TO THE OVEN AND/OR INJURY TO THE OPERATOR.
Qualified installation personnel are individuals, a firm, a corporation, or a company which either
in person or through a representative are engaged in and responsible for:
1. The installation of electrical wiring from the electric meter, main control box, or service outlet
to the electric appliance.
Qualified installation personnel must be experienced in such work, familiar with all precautions
required, and have complied with all requirements of state or local authorities having
jurisdiction.
LOCATION
The well-planned and proper placement of your oven will result in long-term operator convenience
and satisfactory performance.
It is essential that an adequate air supply to the oven be maintained to provide a sufficient flow
of ventilation air. Follow these guidelines:
1. Place the oven in an area that is free of drafts.
2. Keep the oven area free and clear of all combustibles such as paper, cardboard, flammable
liquids, and solvents.
3. Do not place the oven on a curb base or seal to a wall. This will restrict the flow of air and
prevent proper ventilation to the blower motors. This condition must be corrected to prevent
permanent damage to the oven.
4. On all models, tripping of the blower motor's thermal overload device indicates an excessive
ambient temperature at the back of the oven. This condition must be corrected to avoid
permanent damage to the oven.
5
This appliance must be installed on a sturdy
counter or stand using the feet provided
for cleaning clearance. As a minimum, 24"
of clearance on the discharge end of the
oven should be allowed for removal of the
conveyor assembly if the oven is not on a
mobile cart. Also allow room for a service
technician to access the control box door
and the fan motor cover over the rear of the
oven if the oven is not movable.
CAUTION
Any surface the oven is mounted on should have a raised area around the
perimeter to prevent the oven from accidentally sliding off the edge. Serious
injury or death could occur if the oven falls on a person.
CAUTION
Any cart that the oven is mounted on must be deep and wide enough to provide
a stable platform. A cart with a narrow stance could allow the oven to tip over,
causing property damage or serious harm to people.
VENTILATION
Local codes prevail. These are the "authority having jurisdiction" as stated by the National
Fire Protection Association, Inc. in NFPA 96-Latest Edition. For further ventilation information
see below.
A ventilation hood may be required to remove heat and cooking odors. The hood and HVAC
installation must meet local codes to gain approval by the authority having jurisdiction.
Requirements may vary throughout the country depending on the location by city, county, and
state. Obtain information from the authority having jurisdiction to determine the requirements
for your installation. Obtain information and review copies of codes or documents that will
be used to inspect and approve your installation. Your ventilation hood supplier and HVAC
contractor should be contacted to provide guidance.
CAUTION
Prevent airflow through the cooking tunnel. Air must NOT be directed onto the
oven's front or rear or to the sides of the cooking area. This can cause incomplete
or uneven baking and increased energy consumption.
ELECTRICAL CONNECTION
Before making any electrical connections to this unit, check that the power supply is adequate
for the voltage, amperage, and phase requirements stated on the rating plate. A wiring diagram
is included herewith.
When installed, this appliance must be electrically grounded and its installation must comply with
the National Electric Code, ANSI-NFPA 70, latest version, manufacturer's installation instructions,
and applicable local municipal building codes. In Canada, all electrical connections are to be
in accordance with CSA C22.1 - Canadian Electrical Code Part 1 and/or local codes.
WARNING
This appliance is equpped with a three-prong (grounding) plug for your protection
against shock hazard and should be plugged directly into a properly grounded threeprong receptacle. Do not cut or remove the grounding prong from this plug.
6
STACKING INSTRUCTIONS
The following instructions should be followed when stacking more
than one unit.
Single Oven (or Bottom) Cart Install:
1.
2.
3.
4.
5.
Remove door, conveyor, and finger assemblies.
Unbolt unit from shipping crate (4 bolts).
Turn unit on front as shown.
Thread the four legs into the bottom of the oven.
CAREFULLY lift oven upright.
Stacked Oven Install Preparation:
1.
2.
3.
4.
Remove door, conveyor, and finger assemblies.
Unbolt unit from shipping crate (4 bolts).
Turn unit on front as shown.
Remove top of lower oven (4 screws total, 2 each front and rear)
and bolt to stacked oven base using 3/8 - 16 bolts.
5. Place top oven on lower unit and re-attach with screws for top of
lower oven.
OPERATING INSTRUCTIONS
DO NOT ATTEMPT TO OPERATE THE OVEN until connection of utility
service and installation has been fully inspected (start-up check-out)
by an authorized service technician or a Star Service Technician in
order to assure the oven is properly installed and in working order.
The warranty becomes effective upon verification of proper
installation.
CAUTION
DO NOT WORK AROUND THE CONVEYOR
BELT WITH LONG HAIR, LOOSE CLOTHING, OR
DANGLING JEWELRY. GETTING CAUGHT IN THE
BELT COULD RESULT IN DISMEMBERMENT OR
FATAL INJURY.
Unless specified otherwise, conveyor travel is factory set for left to right operation when facing
the front of the oven. If a direction change is required, refer to "DISPLAY INFORMATION,"
section 3 for instructions on how to program the controller for a direction change. In addition,
the conveyor belt must be changed to travel in the new direction.
SAFETY OPERATING INSTRUCTIONS
The information contained in this section is provided for the use of qualified operating personnel.
Qualified operating personnel are those who have carefully read the information contained in
this manual, are familiar with the functions of the oven and/or have had previous experience
with the operation of the equipment described. Adherence to the procedures recommended
herein will assure the achievement of optimum performance and long, trouble-free service.
7
Please take time to read the following safety operating instructions. They are
the key to the successful operation of your Ultra-Max Conveyor Oven.
General Safety Tips:
SAFETY TIPS
For your safety, read before operating.
If you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switches.
3. Use an exterior phone to call your gas
supplier immediately.
4. If you cannot reach your gas supplier, call
the fire department.
In the event of a power failure:
1. Turn all switches off.
2. DO NOT attempt to operate the oven until
the power is restored.
1. If the oven needs to be moved for any
reason, the power must be disconnected
from the unit before doing so.
2. DO NOT remove the control box cover
unless the oven is unplugged.
OPERATION
To turn the oven on:
1. Push the power switch to "ON."
2. After the fan begins to build pressure,
the pressure switch will provide power to
the control board to engage the heating
element contactor. You should hear an
initial "click" from the contactor as it begins
to heat.
To adjust the time and temperature:
1. Press the DOWN and UP arrows
) at the same time. Hold for four
(
seconds until the TIME display goes
blank.
"HEAT" LIGHT
2. Press the ENTER button ( ) to switch
between TIME and TEMPERATURE.
ON
3. Press the UP arrow ( ) to increase or the
DOWN arrow ( ) to decrease the TIME
or TEMPERATURE. Hold either button
down for faster display changes.
4. After five seconds, the new numbers will
be saved and the oven will display the new
settings.
OFF
To Start:
Push power switch "ON".
To turn the oven off:
If burner does not lght in one minute push the power
switch to the"OFF" position and wait five minutes.
1. Push the power switch to "OFF." The
oven is equipped with a cool-down feature
for motor shaft and bearing protection.
This enables the blower motor(s) to run
regardless of the controller status. The
blower(s) continue to run until the oven
cools to a safe temperature.
After five minutes, retry.
Adjusting TIME and TEMPERATURE:
1) Press the up and down buttons ( uv ) at the same time,
hold for four seconds until TIME display goes blank.
2) Press the enter button (
and TEMPERATURE.
) to switch between TIME
3) Press the up button ( u) to increase or the down button ( v ) to
decrease TIME or TEMPERATURE. Hold button down for
faster display changes.
4) After five seconds, the new numbers will be saved and the oven
will display new settings.
®
8
DISPLAY INFORMATION
When operating the oven, there are three levels of access:
1. Store Level - General employees would know these functions and how to change them.
)
While the oven is running, enter this mode by holding the DOWN and UP arrows (
simultaneously for four seconds. The TIME display goes blank and the TEMP setpoint is
displayed. Adjust with the DOWN or UP arrows. The ENTER button ( ) toggles between
TIME and TEMP. The parameter that can be adjusted is displayed, the other is blank.
When TIME and TEMP are adjusted as needed, wait five seconds and SAVE is displayed.
The values are accepted and the controller begins controlling to these new values. The
conveyor continues to operate at the same speed until a new value is accepted. The
temperature control output should be OFF during changes.
2. Manager Level - This is a lock so that TIME and TEMP cannot be changed even at the Store
Level. While the oven is running, enter this mode by holding the DOWN and UP arrows
simultaneously for 4 seconds. The TIME display goes blank and the TEMP setpoint is
displayed. Release the UP arrow and continue to hold the DOWN arrow for an additional
4 seconds. The TEMP display shows LOC as the TIME display shows nO, which indicates
that the TIME/TEMP parameters can be changed after reaching the STORE level. yES
indicates that the parameters cannot be changed even after entering the STORE level.
The LOC setting can be toggled using the ENTER button ( ).
ADDITIONAL FUNCTIONS
The conveyor belt direction and the temperature display can be changed on the conveyor
oven by a qualified technician. To change the belt direction, the technician must reverse the
motor direction and rotate the conveyor belt for proper oven function. A technician can also
change the temperature display from Fahrenheit to Celsius. These changes can be made by
the technician during the start-up/check-out or at a later date.
ERROR CODES
Error codes will display as flashing text messages for diagnostic purposes. Any temperature
or thermocouple error should turn the temperature output OFF and leave the conveyor running
at the same speed. The belt error should turn the temperature output OFF. The speed error
should display when the motor is unable to settle at the chosen speed. This might occur if a
fast speed is chosen that the motor is unable to spin fast enough to achieve. The speed signal
output will remain the same but the display will flash the error message.
9
BAKE TIME VERSUS TEMPERATURE
1. Bake time is actually conveyor speed and is defined as the time the product is actually in
the oven. This is measured by noting the time when the leading edge of the product enters
the oven and the time the leading edge of the product leaves the oven. This is adjusted
by using the conveyor speed controller.
2. Bake temperature is adjusted by changing the setpoint of the temperature controller to the
desired bake temperature. When the oven reaches the desired temperature, the red dot
in the lower right corner of the temperature display will turn off and on as the controller
maintains the temperature.
3. When establishing a bake time and temperature for a given product, the general rule shall
be as the bake time increases the bake temperature decreases and the reverse is also true;
increase temperature, decrease time. However, there are limits to the above rule. Going
to extremes will result in a burnt exterior and raw interior or it will result in a very light color
but over-baked product.
4. Once a good bake has been established, the fine adjustments should be made by holding
either the bake time or bake temperature constant, then varying the other.
CONVEYOR SPEED
Bake Time (Conveyor Speed) - As stated previously, bake time (conveyor speed) is defined as
the amount of time elapsed between the time the leading edge of the product enters the oven
and the leading edge of the product exits the oven. Bake time is controlled by adjusting the
digital speed controller. The setting on the control panel indicates the actual bake time.
Bake time will be the same for any size product.
TIME OF DELIVERY
The time of delivery is the amount of elapsed time between the period when the leading edge
of the product enters the oven and the trailing edge of the product is fully discharged and is
ready to be delivered to the customer.
40 (DELIVERY)
32 (DELIVERY)
∅=8
Time of delivery
changes if the product
size changes.
24 (BAKE)
∅=16
Tip: Train yourself not to
pull the product out of the
oven when the leading edge
comes out. Always wait
until the entire product has
passed under the air nozzle
holes - the product needs
this time to fully bake.
6:00 (BAKE)
8:00 (DELIVERY)
10:00 (DELIVERY)
BAKE vs. DELIVERY TIME
Time to Delivery changes with product
but Bake Time remains constant
at a steady conveyor speed.
10
CLEANING INSTRUCTIONS
Follow this recommended cleaning schedule for proper oven performance:
CAUTION
DISCONNECT THE POWER SUPPLY BEFORE SERVICING OR CLEANING THIS OVEN.
SAFEGUARD THE POWER SO IT CANNOT BE ACCIDENTALLY RESTORED. FAILURE
TO DO SO COULD RESULT IN DISMEMBERMENT, ELECTROCUTION, OR FATAL INJURY.
THERE IS MORE THAN ONE POWER SUPPLY CONNECTION POINT WHEN OVENS ARE
STACKED, SO MAKE SURE THAT ALL SWITCHES ARE IN THE OFF POSITION BEFORE
CLEANING OR MAINTENANCE.
No electrical components should be subjected to moisture. It is therefore important that the
oven is wiped down carefully. NEVER throw buckets of water over the oven or subject it to
pressure washing from a hose or a pressure spray. If water or other liquid is spilled on the
oven, make sure that none of it has entered the control box area before switching the oven
ON. If in doubt, call your service company.
CAUTION
Adhere to the following warnings when cleaning or maintaining your conveyor oven:
1. The oven must be cool. Do not use power cleaning equipment, steel wool, or wire brushes
on stainless steel surfaces.
2. Do not use a caustic or an alkaline base cleaner on the interior of the oven.
This will ruin the aluminized finish of the oven interior.
3. When using cleaning solutions, be sure they meet local and national health standards.
DAILY
1. Clean the conveyor belt using a nylon brush. Allow any foreign material to drop into the
crumb pans.
2. Empty and clean the crumb pans. Use a hot water and detergent mix.
Rinse with clean water.
EVERY MONTH
1.
2.
3.
4.
5.
6.
7.
8.
9.
Brush and clean the guard on the motor cooling fan.
Unplug the oven.
Remove the crumb pans.
Remove the conveyor assembly.
Unlatch and remove the front door. First remove all Baffles then Finger Assemblies.
See instructions next page.
Clean the oven interior with an appropriate oven cleaner.
Clean the conveyor assembly, crumb pans, and other removable components.
Wash in a hot water, detergent mix and rinse with clean water. For difficult cleaning
areas, use a heavy-duty de-greaser or oven cleaner.
Move the oven and clean under it. Be careful not to damage the oven's electrical cord or
plug when moving.
Reassemble the oven, being certain to include all Finger Assemblies and the Upper &
Lower Baffles.
Be certian the Lower Baffle Flange is properly positioned behind the Rear Oven Wall, as
well as the Upper Baffle is in position against the Upper Baffle Seat, as shown.
EVERY TWELVE MONTHS
A factory authorized service person should:
1. Open and clean the inside of the control box.
2. Check and tighten all electrical components.
If maintenance is required, contact your local service company, a factory
representative, or Star Manufacturing.
11
Removing Finger Assemblies
1.
2.
3.
4.
Once cooled, REMOVE conveyor assembly and door.
Life up and remove Upper & Lower Baffles as shown in Step 1.
Slide Finger Assembly out of unit as shown in Step 2.
Lift Assembly apart as shown in Step 3. and wash in a hot water, detergent mix and rinse
with clean water. For difficult cleaning areas, use a heavy-duty de-greaser or oven cleaner.
Reassemble Finger Assemblies
1. Reassemble finger assemblies and install in unit.
2. Properly install Baffles as shown in Step 4.
CAUTION
BE CERTAIN THE LOWER BAFFLE IS PROPERLY INSTALLED BEHIND THE REAR
PANEL SO NOT TO INTERFERE OR DAMAGE CONVEYOR ASSEMBLY.
3. Reinstall conveyor & door assembly, and test unit for proper operation.
1
2
3
IL1190
4
UPPER BAFFLE
LOWER BAFFLE
Baffle & Finger Removal / Installation
12
CONVEYOR BELT TENSION
The conveyor belt of the Ultra-Max Conveyor Oven does
not have a tension adjustment. If the belt becomes too
loose, a link will have to be removed to tighten. A belt
that is too tight will also cause operational problems due
to excessive drag. We suggest that you have a qualified
service technician perform this adjustment.
CAUTION
Careful consideration should be exercised prior
to removing a belt link because a belt that is
too tight will impede the smooth operation of
the conveyor.
Remove the outside master links on the right and left
sides of the conveyor belt. Remove the center splice
clips next.
CONVEYOR BELT LINK REMOVAL
An entire link can be removed with the conveyor assembly
either in or out of the oven. This may be necessary as
the belt stretches after continuous use. Following are
the necessary steps for removing links:
1. Move the splice clips to either end of the oven for
easy access.
2. Unhook the splice clips using long nose pliers.
3. Unhook the full link to be removed and slide it out.
Do not discard the link removed as it may be used
for making spare splice clips.
Unhook the end loop and pull up on the link section.
Save this link as it may be used for making splice
clips.
4. Reconnect the inside splice clips.
5. Reconnect the outside splice clips.
6. Replace all parts removed from the oven.
7. Straighten any bent wires to ensure smooth sprocket
engagement.
Check the orientation of the splice clips (the hooks
should be up). The belt shown is the top section,
ready for left-to-right travel.
13
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