XD-9006A GA-SWC-HB 04/09/2012 XLT Gas Oven & AVI Hood Parts & Service Manual CAUTION This appliance is for professional use by qualified personnel. This appliance must be installed by qualified persons in accordance with the regulations in force. This appliance must be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of substances harmful to health in the room in which it is installed.
WARNING & SAFETY INFORMATION SAFETY DEPENDS ON YOU Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or death. Read the installation, operating and maintenance instructions thoroughly before installing, using, or servicing this equipment. WARNING Post in a prominent location instructions to be followed in the event you smell gas. This information can be obtained by consulting your local gas supplier.
WARNING & SAFETY INFORMATION 3 Definitions & Symbols A safety instruction (message) includes a “Safety Alert Symbol” & a signal word or phrase such as WARNING or CAUTION. Each signal word has the following meaning: HIGH VOLTAGE This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you & other persons operating this equipment. Read the message & follow the instructions carefully.
WARRANTY - US & Canada XLT warrants gas ovens manufactured after April 1, 2009 utilizing quietFIRE™ burners and all electric ovens manufactured after April 1, 2011 to be free from any defect in material and workmanship under normal use for five (5) years from the date of original purchase by the end user, and further warrants main fan blades, conveyor shafts, and conveyor bearings for ten (10) years.
LIMITED WARRANTY - INTERNATIONAL 5 XLT warrants gas ovens manufactured after January 1, 2011 utilizing quietFIRE™ burners and all electric ovens manufactured after April 1, 2011 to be free from any defect in material and workmanship under normal use for two (2) years from the date of original purchase by the end user. XLT warrants AVI hoods to be free from any defect in material and workmanship under normal use for one (1) year from the date of original purchase by the end user.
GENERAL This manual, which contains an illustrated parts breakdown, has been prepared as an aid in understanding how the unit operates, how to diagnose problems, and order parts for the equipment. All of the parts, listed in the parts breakdown, are manufactured with the same precision as the original equipment. XLT parts and service providers are available worldwide. There are authorized service providers located in the principle cities of the United States.
TABLE OF CONTENTS 7 Warning & Safety Information..................................................................................................... 2 Warranty ....................................................................................................................................... 4 General ......................................................................................................................................... 6 Oven Theory of Operation ......................................
1. 2. 3. 4. 5. 6. GAS OVEN THEORY OF OPERATION When the Main Switch (S1) is turned on; The Oven Fan Motor (M1) located in the Back Wall will run. The Fan (M3) located on the Control Panel will run. The Temperature Control (TC) should display both the actual and set-point temperatures. The Conveyor Control (CC) should display the belt time. The burner will ignite. The conveyor belt should move.
GAS OVEN THEORY OF OPERATION 9 BC - The Burner Control (BC) is powered by 24 VAC from the Transformer (XFMR). Incoming power will be interrupted by the Temperature Control (TC) when the actual temperature rises above the Maximum Operating Temperature (see Specification Sheet). When the BC receives power, it initiates a pre-purge lighting sequence. A red LED will blink once after about 2-3 seconds to give notification that the lighting sequence has started.
GAS OVEN THEORY OF OPERATION FS/SI - The Flame Sensor/Spark Igniter consists of a copper-clad metal mounting plate, a ground electrode, and two additional electrodes encapsulated in ceramic insulators. One of the insulated electrodes has a 1/4” male spade welded to it while the other insulated electrode has a 3/16” male spade welded to it. The rod with the 1/4” spade connects to the Spark Terminal on the Burner Control (BC) via a spark wire.
GAS OVEN THEORY OF OPERATION 11 M4 - (Australia ovens only) - The Burner Blower Motor is a dual-voltage, shaded pole motor that supplies air for combustion. A Centrifugal Switch (S4) is physically mounted internally to prove rotation. PS - The Power Supply rectifies line voltage to 24 VDC, and supplies power to the Conveyor Control (CC). A 4 amp fuse is used to provide over current protection, which is mounted on the PS itself. There are no other fuses used anywhere else.
GAS OVEN THEORY OF OPERATION S1 - The Main Switch is a SPST normally open switch, mounted on the front of the Control Box. Activating this switch applies voltage to Terminal T6 of the Cool-Down Timer (R1) and to the primary side of the Transformer (XFMR). When used with the optional AVI Hood System, a remote switch mounted in the front of the AVI Hood replaces it. S2 - This Switch is a SPDT centrifugal switch physically mounted inside the Main Motor (M1).
GAS OVEN THEORY OF OPERATION 13 V1-V2 & V3- The Multi-Valve assembly has three (3) Gas Valves. The Main Valves (V1-V2) operate in series, and are wired in series via the Rectifier Plug. The Rectifier Plug rectifies 24 VAC from the Burner Control (BC) to 22 VDC. V1-V2 are solenoid valves and are open continuously during burner operation, regardless of either actual or set-point temperature values. V3 is a modulating valve, and is controlled by a variable electrical signal from the Signal Conditioner (SC).
HOOD THEORY OF OPERATION When any one of, or all of, the Hood Operator Switches (S2, S3, & S4) are turned on; 1. The Exhaust Fan Motor (M1) located on the roof will run. 2. The Variable Frequency Drive (VFD) will display a set value. The values are preset from the factory and can be referenced in the I&O manual. 3. The ovens associated with the corresponding switches will turn on.
HOOD THEORY OF OPERATION 15 CS - The Current Sensor is a device that detects electrical current in a wire, and then generates a signal proportional to it. It drives an LED indicator lamp (L3) to indicate that the VFD is drawing current and operating. A minimum of 1.5 AAC is required. L1 & L2 - These are standard incandescent light bulbs, and should illuminate when the contacts of S1 are closed.
HOOD THEORY OF OPERATION S1 - This SPST (NO) switch is located on the front of the hood and controls the lights. S2, 3, & 4 - These DPST (NO) switches are located on the front of the hood and control the ovens, as well as initiating and sequencing the operation of the VFD and damper circuits. Line voltage is continuously applied to pin 1 of REC 4, 5, & 6, which is connected by a wire to a contact in S2, 3, & 4. This is shown on the schematic as the lower RH connection point of S2, 3, & 4.
OVEN TROUBLESHOOTING 17 Mechanical Function If your oven does not function properly, please verify the following conditions: 1. Verify that the power cord to the oven is connected and/or plugged in if equipped with a plug and receptacle. 2. Check to see that the circuit breakers in the building electrical service panel have not been tripped or turned off. 3. Check all circuit breakers on the oven control panel to ensure they have not been tripped. 4.
HOOD TROUBLESHOOTING Before troubleshooting the hood: 1. Make sure that the RUN lamp and POWER lamp are lit. 2. Check to see that the breaker in the service panel is not tripped. 3. Check to see that the breaker on the hood electrical box is not tripped. 4. Make sure the Switch Relocation Cords (SRC) are properly installed to the oven(s). 5. Check to see that the grease filters are clean & installed properly. 6. Check to see if the exhaust fan is rotating in the correct rotation.
HOOD TROUBLESHOOTING 19 VFD Control Box - Standard Terminal Strip (TS1) Grounding Block Terminal Strip (TS2) Manual Mode Relay (R5) MUA Damper Relay (R1) Manual Mode Relay (R6) MUA Damper Relay (R2) Manual Mode Relay (R7) MUA Damper Relay (R3) Fire Suppression Relay (R8) Fire Suppression Relay (R4) Circuit Breaker VFD Controller Manual Mode Switch #1 Manual Mode Switch #2 Oven/hood interface VFD Control Box (Cover removed) Technical Support US: 888-443-2751 Technical Support INTL: 316-943
OVEN SERVICE PROCEDURES Conveyor Control Programming Procedure Read the entire instruction before programming. Configuration Key Functions = Behind the in XLT is a hidden button. This is used along with the up and down button to access the programming mode. Use this after each step to advance to the next parameter when programming. UP = Increases the setting of the selected parameter. Down = Decrease the setting of the selected parameter. 1.
OVEN SERVICE PROCEDURES Temperature Control Programming Procedure Read the entire instruction before programming. Configuration Key Functions = The new setting of the selected parameter is stored and the display advances to the next parameter. This is required between each parameter. = Increases the setting of the selected parameter. = Decrease the setting of the selected parameter. 1. Open V101 switch for Basic/advanced Configurations (Figure 1) 2.
OVEN SERVICE PROCEDURES Multi-Valve Adjustment Procedure Check Incoming Pressure: Loosen screw 1 full turn counter clockwise (Figure 1) Hook up Manometer to this test port Turn main switch to the on position Document incoming pressure on startup checklist.
OVEN SERVICE PROCEDURES Multi-Valve Adjustment Procedure Hook up Manometer: Loosen screw 1 full turn counter-clockwise (Figure 3) Hook up Manometer to this test port Turn main switch to the on position Figure 3 Check High Bias Pressure: Turn main switch to the on position After 30 seconds of pre-purge the oven will light Using a 8mm socket turn the High Flame Bias screw (Figure 4) until desired setting is achieved. Use chart on next page (Figure 5) for correct valve settings.
OVEN SERVICE PROCEDURES Multi-Valve Adjustment Procedure All Oven Models Natural Gas W/C mbar kPa W/C LP Gas mbar kPa High Flame Bias 3.5 8.75 0.875 10 25 2.5 Low Flame Bias 0.2 0.49 0.049 0.2 0.49 0.049 Figure 5 Check Low Bias Pressure: Pull one of the two blue wires going into the modulating valve.
OVEN SERVICE PROCEDURES Multi-Valve Adjustment Procedure Remove the Manometer : Turn main switch to the off position Remove the manometer and re tighten the screw (Figure 7) (Note: Do not over tighten the screw only snug is needed) Figure 7 Air Shutter Settings Primary Secondary Burner Shutter Settings All Oven Models Natural Gas Closed Primary 1.5 Secondary Technical Support US: 888-443-2751 LP Gas Closed 1.
HOOD SERVICE PROCEDURES Hitachi X200 Restoring Factory Defaults Access program parameters by pressing the key one time and using the up and down arrow keys to navigate to the appropriate parameter press the key again to make adjustments to that parameter by using the up and down arrows. To store the new settings press the button one time. B031 = 01 B084 = 01 After pressing the key Press and hold the down arrow key and key all at the same time.
HOOD SERVICE PROCEDURES VFD Controller Settings Switches On 1832, 1855 & 2440 3240, 3255 & 3270 3855 & 3870 Top Middle Bottom Single X 20 Hz 25 Hz 30Hz X 20 Hz 25 Hz 30Hz Double X 35 Hz 40 Hz 45 Hz X X 35 Hz 40 Hz 45 Hz X 20 Hz 25 Hz 30Hz X 30 Hz 35 Hz 40 Hz X 40 Hz 45 Hz 50 Hz Triple X X 30 Hz 35 Hz 40 Hz X X 40 Hz 45 Hz 50 Hz X X 40 Hz 45 Hz 50 Hz X X X 45 Hz 50 Hz 55 Hz Fire Suppression 60 Hz Figure 1 For operation instructions of manual mode see the I&O Manual at www.xltovens.
PARTS How to order Parts Have all information ready when calling XLT. Below is a list of information that is required for all orders. At the bottom of the BOM on the following parts overview pages are additional requirements needed depending on your parts order.
Technical Support US: 888-443-2751 Front Panel Front Panel Knob Crumb Tray Conveyor Sandwich Door Oven Lid Product Stop Chain Guard Back Wall Control Panel Main Switch Data Plate OVEN PARTS-OVERVIEW 29 Technical Support INTL: 316-943-2751
OVEN PARTS-FRONT PANEL 4 5 3 6 1 2 Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN PARTS-FRONT PANEL ITEM 1 2 3 4 5 6 FRONT PANEL QTY PART NUMBER DESCRIPTION 1 XA 6500 Front Panel Assembly 4 XA 6505 Front Panel Knob 1 XA 6600 Sandwich Door 4 XF 126-2 Screw 10-24 1 XM 6703 Door Retainer Left 1 XM 6704 Door Retainer Right Front Panel information required: Size of Oven Short or Long Window Stainless or Wood Handle 3” or 5” Window Opening Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 31
OVEN PARTS-BACK WALL 2 1 3 Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN PARTS-BACK WALL ITEM 1 2 3 BACK WALL QTY PART NUMBER DESCRIPTION 1 XA 50 Back Wall Assembly 1 XA 5009 Fan Motor w/ Mount 1 XA 5200 Fan Blade Back Wall information required: Size of Oven Voltage Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 33
OVEN PARTS-CONVEYOR 2 3 9 7 1 5 4 6 Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN PARTS-CONVEYOR ITEM 1 2 3 4 5 6 7 8 9 CONVEYOR QTY PART NUMBER DESCRIPTION 1 XA 7000 Conveyor Assembly 4 XA 7200 Conveyor Bearing Assembly 1 XM 7301 Conveyor Shaft Idle 1 XM 7302 Conveyor Shaft Drive 6 XM 7403 Conveyor Roll Notched 6 XM 7404 Conveyor Roll Plain 1 XP 9503 Conveyor Sprocket Driven 15 1 XP 9504 Conveyor Drive Chain 1 XP 9506 Conveyor Belt Conveyor information required: Split Belt or Standard Belt Which part is required and how many? Technical Support US: 888-443-2751 Technical Supp
OVEN PARTS-BASE 5 1 2 3 4 6 Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN PARTS-BASE BASE ITEM 1 2 3 4 5 6 QTY 1 4 2 2 1 4 PART NUMBER XA 1000 XM 1003 XM 1006 XM 1007 XM 1010 XP 1004 DESCRIPTION Base Assembly Base Leg Side Leg Angle Front/Back Leg Angle Oven Lid Caster Base information required: Size of Oven Single, Double, or Triple Stack Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 37
OVEN PARTS-FINGER GROUP 3 4 1 5 2 Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN PARTS-FINGER GROUP ITEM 1 2 3 4 5 FINGERS QTY PART NUMBER DESCRIPTION 1 XA 8Xxxxx Finger Group Assembly 4 XA 8001-B Finger Body Bottom 4 XA 8001-T Finger Body Top 2 XM 8009 Finger Block Off Plate 1 XM 8xxx Finger Outer Plate Finger information required: Size of Oven Customer name Part number on front of finger outer Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 39
OVEN PARTS-CONTROL BOX Service Position Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN PARTS-CONTROL BOX 3 4 5 2 6 ITEM 1 2 3 4 5 6 QTY 1.00 1.00 1.00 1.00 1.00 1.
OVEN PARTS-CONTROL BOX 1 4 2 3 ITEM 1 2 3 4 QTY 1.00 1.00 1.00 1.00 CONTROL BOX FRONT PART NUMBER DESCRIPTION XA 4117-12.5 RPM STD Conv Motor Assy 12.
OVEN PARTS-CONTROL BOX 4 7 5 2 8 3 9 1 ITEM 1 2 3 4 5 6 7 8 9 10 11 6 CONTROL BOX BACK QTY PART NUMBER DESCRIPTION 1.00 XA 4235 Rectifier Plug Assy 1.00 XP 4704 Cool Down Timer 120/230 Volt R1 1.00 XP 4705-DI Ignition Control DI RO & SQ 1.00 XP 4706 Transformer 24V 60VA 1.00 XP 4710-DI Signal Conditioner Elan 1.00 XP 4716 Power Supply PS 1.00 XP 5012 Capacitor Boot 1.00 XP 5014-30 Capacitor Baldor 3/4 HP 30uF 1.00 XP 4207-DI Multi-Valve V1 & V2 1.
OVEN PARTS-CONTROL BOX 1 ITEM 1 QTY PART NUMBER 1.
OVEN PARTS-CONTROL BOX Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 45
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HOOD PARTS-HOOD Main Canopy VFD Exhaust Fan Controller Front Shroud Panel End Shroud Panel (size specific) Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 47
HOOD ELECTRICAL DESCRIPTION VFD Control Box - Standard Terminal Strip (TS1) Grounding Block Terminal Strip (TS2) Manual Mode Relay (R5) MUA Damper Relay (R1) Manual Mode Relay (R6) MUA Damper Relay (R2) Manual Mode Relay (R7) MUA Damper Relay (R3) Fire Suppression Relay (R8) Fire Suppression Relay (R4) Circuit Breaker VFD Controller Manual Mode Switch #1 Manual Mode Switch #2 Oven/hood interface VFD Control Box (Cover removed) Technical Support US: 888-443-2751 Technical Support INTL: 3
HOOD PARTS-HOOD VFD ITEM 1 2 3 4 5 6 7 8 9 10 11 QTY 4.00 1.00 3.00 4.00 4.00 2.00 1.00 1.00 1.00 1.00 2.
OVEN ACCESSORIES PN XA 9521-18 XA 9521-24 XA 9521-32 XA 9521-38 Description Conveyor Shelf Conveyor Shelf Conveyor Shelf Conveyor Shelf PN Description XA 9400-xx32-2 Fire Suppression Kit, Double Stack XA 9400-xx40-2 Fire Suppression Kit, Double Stack XA 9400-xx55-2 Fire Suppression Kit, Double Stack XA 9400-xx70-2 Fire Suppression Kit, Double Stack Single & Triple Stack kits available. Contact factory for details.
HOOD ACCESSORIES PN Description HA 4000-3255 Hood Valance Assy HA 4000-3270 Hood Valance Assy Other sizes available. Contact factory for details.
SERVICE ACCESSORIES PN XS 0300 Description Lifting Jacks, PAIR PN XS 0306-1832 XS 0306-2440 XS 0306-32xx XS 0306-3870 Description Lifting Plates, PAIR Lifting Plates, PAIR Lifting Plates, PAIR Lifting Plates, PAIR PN XS 0310 PN XS 0200 Technical Support US: 888-443-2751 Description Lifting Pipe Description Cart Assy w/Straps Technical Support INTL: 316-943-2751
OVEN SCHEMATIC - STANDARD 1832-3855 Standard Single Box Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 53
OVEN SCHEMATIC - STANDARD 3270-3870 Standard Dual Box LH Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN SCHEMATIC - STANDARD 3270-3870 Standard Dual Box LH Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 55
OVEN SCHEMATIC - STANDARD 1832-3855 World Single Box Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
OVEN SCHEMATIC - STANDARD 3270-3870 World Dual Box LH Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 57
OVEN SCHEMATIC - WORLD 3270-3870 World Dual Box RH Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
HOOD SCHEMATIC - STANDARD w/VFD Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 59
HOOD SCHEMATIC - WORLD w/VFD Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
HOOD SCHEMATIC w/o VFD Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751 61
US: 888-443-2751 XLT Ovens PO Box 9090 Wichita, Kansas 67277 FAX: 316-943-2769 INTL: 316-943-2751 WEB: www.xltovens.
