SMART GENERATION CONVEYOR OVEN SERIES SERVICE AND REPAIR MANUAL BLODGETT OVEN COMPANY www.blodgett.com 50 Lakeside Avenue, Box 586, Burlington, Vermont 05402 USA Telephone, (802) 658Ć6600 Fax: (802)864Ć0183 PN M10306 Rev C (11/01) E 2001 - G.S.
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TABLE OF CONTENTS 1. INTRODUCTION Oven Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Specifications . . . . . . . . . . . . . . . . . . . .
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CHAPTER 1 INTRODUCTION
SMART GENERATION OVEN SPECIFICATIONS VENTILATION REQUIREMENTS inĆline tempering unit. Air supplied directly from outĆ side the building to the kitchen or oven area, nonĆ tempered, can be used as supply air but the design must accommodate potential operational and enviĆ ronmental drawbacks. A mechanically driven ventilation system is reĆ quired for the removal of excess heat and cooking vapors. For gas models, a ventilation system is also required for the removal of the products of gas combustion.
6" (15.2 cm) Minimum FIGURE 1 1-2 9" (22.7 cm) 20" (50.8 cm) 60" (152.4 cm) 6" (15 .2cm) Minimum Triple Stack - 6.5" (17 cm) Double Stack - 17.5" (44.5 cm) Single Stack - 23.5" (59.7 cm) SG2136 Series Shown 64" (162.5 cm) 3" (7.6 cm) Minimum 0" (0cm) if wall or 6" (15.
6" (15.2 cm) Minimum 77" (196 cm) SG3240 Series Shown 3" (7.6 cm) Minimum FIGURE 2 1-3 Triple Stack - 7" (17.8 cm) Double Stack - 17.25" (43.8 cm) Single Stack - 23.25" (59 cm) 14" (35.5 cm) 24" (61 cm) 72" (182 cm) 6" (15 .2cm) Minimum 0" (0cm) if wall or 6" (15.
INTRODUCTION ELECTRICAL SPECIFICATIONS SG2136G SG3240G The SG2136G requires a 5 Amp, 50/60HZ, 1 , 208Ć240VAC, 3 wire service consisting of L1, L2 and ground. Use 75_C rated cable. Size wire to NaĆ tional Electric or local codes. The SG3240G requires a 5 Amp, 50/60HZ, 1 , 208Ć240VAC, 3 wire service consisting of L1, L2 and ground. Wiring from the power source to these units must be a minimum of #16 AWG CU. stranded wire or larger. SG2136E SG3240E Use 75_C rated cable.
SMART GENERATION SG2136E Single Phase Power SG2136G and SG3240G L1 Supply L2 L1 208Ć240 Oven Supply Supply L2 L3 208Ć240 Oven SG2136E and SG3240E Wye Three Phase Power General Export Installations SG2136E and SG3240E Delta Three Phase Power U.S.
INTRODUCTION GAS SPECIFICATIONS GAS CONNECTIONS NOTE: For natural gas meter sizing, consult your local gas company to ensure that your meĆ ter will provide the proper supply. Domestic and General Export installations The gas line should be large enough to accommoĆ date the peak demand of all the gas appliances. TABLE 2 reflects a straight line, 50 foot run with no coupling restrictions and no other appliances drawing service.
SMART GENERATION SG3240G DOMESTIC AND GENERAL EXPORT Natural Gas Propane Gas Single 3/4" line 3/4" line Double 1Ć1/4" line 1" line Triple 1Ć1/4" line 1Ć1/4" line Orifice Size 4.80mm (0.189") diameter 2.82mm (0.111") diameter Gas Line Sizing Incoming Gas Pressure W.C. kPa mbar W.C. kPa mbar 7" 1.74 17.4 12.5" 3.11 31.1 5.5" 1.36 13.7 11" 2.73 27.4 3.5" 0.87 8.7 10" 2.50 25.
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CHAPTER 2 OPERATION
SMART GENERATION STANDARD MANUAL CONTROL MANUAL CONTROL DESCRIPTION 1. DIGITAL DISPLAY - two line display gives the time, temperature and other control related inĆ formation. 4. ARROW KEYS - press to change the set time and temperature in the display. 5. TIME KEY - press to change the cook time. 2. OVEN ON/OFF (ON/STANDBY) - controls power to the oven. 6. ENTER/RESET KEY - press to save new cook time or temperature. Also press to silence the alarm in case of a fault.
OPERATION OPERATION To change the cook time: NOTE: The following example is in _F. The display will read _C if programmed in celsius. 1. Press the TIME key (5). To turn the oven on: The display reads: 1. Press the OVEN ON/OFF key (2). The control defaults to the last time and temperature setĆ tings used. The display reads: 2. Press the ARROW keys (4) to scroll to the deĆ sired cook time. SET TEMP XXXF HEAT COOK TIME XX:XX 3. Press the ENTER key (6) to set the new cook time.
SMART GENERATION PROGRAMMABLE MENU CONTROL MENU CONTROL DESCRIPTION 1. DIGITAL DISPLAY - two line display gives the time, temperature and other control related inĆ formation. 4. MENU KEYS - programmable product keys. Up to four different time and temperature setĆ tings can be saved. 2. OVEN ON/OFF (ON/STANDBY) - controls power to the oven. 5. ENTER/RESET KEY - press to save settings while programming. Also press to silence the alarm in case of a fault.
OPERATION MENU PROGRAMMING OPERATION NOTE: The following example is in _F. The display will read _C if programmed in celsius. 1. Press the OVEN ON/OFF key (2). The control defaults to the last time and temperature setĆ tings used. To enter programming mode: 1. With the oven off, press and hold the UP ARĆ ROW key (3) and the ENTER/RESET key (5) siĆ multaneously for approximately three seconds.
SMART GENERATION OVEN ADJUSTMENTS FOR COOKING The combination of belt time, oven temperature, and air flow are important for achieving quality reĆ sults from your Blodgett conveyor oven. Use the following guidelines to adjust the belt time and oven temperature of your unit. For questions reĆ garding further oven adjustments, please contact your local Blodgett Sales Representative for assisĆ tance. Air flow adjustments may be necessary to fine tune the oven for your particular product.
OPERATION Air Slides BlockĆOff Plate Air Flow Plate Air Flow Plates SG2136 Series Shown FIGURE 3 Product Clearance Adjustment Plate BlockĆOff Plate Air Flow Plate SG3240 Series Shown FIGURE 4 2-6
SMART GENERATION SCHEMATICS SG2136G FIGURE 5 2-7
OPERATION SG2136E - 2 WIRE FIGURE 6 2-8
SMART GENERATION SG2136E - 3 WIRE FIGURE 7 2-9
OPERATION SG2136E - 4 WIRE FIGURE 8 2-10
SMART GENERATION SG3240G FIGURE 9 2-11
OPERATION SG3240E - 3 WIRE FIGURE 10 2-12
SMART GENERATION SG3240E - 4 WIRE FIGURE 11 2-13
CHAPTER 3 CALIBRATION AND ADJUSTMENT
SMART GENERATION CONTROL IDENTIFICATION AND REGISTRATION CONTROL REGISTRATION The following instructions are for both the standard manual and programmable menu PLC controls. See FIGURE 12 for control identification. NOTE: The following control registration proceĆ dure applies to installations in North AmeriĆ ca only. The installer may be required to obtain a registration number from the Blodgett Oven Service Department before the unit can be operated.
CALIBRATION AND ADJUSTMENT GAS PRESSURE ADJUSTMENTS REGULATED GAS PRESSURE NOTE: Gas models only. The incoming and manifold pressure should be meaĆ sured at the same time with two water manometers. The oven must be turned on and the main burner valve open. This method will reveal any obstructions in the pipe line or inadequate pipe size. 1. Let the oven heat to 510_F (266_C). 2.
SMART GENERATION PRIMARY AIR ADJUSTMENT COMBUSTION BLOWER PRESSURE SWITCH ADJUSTMENT NOTE: Gas models only. The adjustment of the pressure switches after installation is extremely important. The switch proves that the gas combustion air blower is operaĆ tional. If the pressure switch stays open, the oven will not heat.
CALIBRATION AND ADJUSTMENT Circulation Blowers' Pressure Switch (See View D) Blower 2 Relay View B SW4 Blower 1 Relay ENB 2 DIR 2 ENB 1 DIR 1 Switch 4 (See View B) Heat Relay Ignition Control Board (See View C) Interface Board (See View A) Interface Board - View A Combustion Blower Pressure Switch (See View D) Interface Slide Tray (SG3240G shown) Typical circulation blower pressure expected is .30" W.C. (SG3240) or .25" W.C.
SMART GENERATION CONVECTION BLOWERS MOTOR ROTATION OF CONVECTION BLOWERS CHECKING THE LOW LIMIT OF THE BLOWERS: The correct amp draw for most gas conveyor ovens is 1 amp when the oven is hot. 1. Turn the oven on. Let it heat to 200_F (93_C). Shut the oven off. The blowers should come back on in several seconds. If the amp draw is less than .5, remove the back of the oven and check for proper motor rotation direcĆ tion. See FIGURE 15. NOTE: Open the small front access door to speed cooling.
CALIBRATION AND ADJUSTMENT TEMPERATURE CALIBRATION To Calibrate the Cook Temperature: After the oven has been cycling at the normal temĆ perature for 60 minutes, place a temperature probe in the center of the oven to verify proper caliĆ bration. If the oven is not cycling to within 5_F (3_C) of the setpoint use the following calibration procedure. 1. The display reads: Use the arrow keys to toggle between TEMP and TIME. When the display reads TEMP, press the ENTER/RESET key.
SMART GENERATION 6. The display reads: To Exit Configuration and Calibration Mode: OVEN TEMP XXXF OFFSET +(-)XXXF 1. Press and hold the UP ARROW and ENTER/ RESET keys simultaneously for approximately three seconds. NOTE: The offset equals the setpoint minus the probe temperature. NOTE: The top line now displays the operating oven temperature including the offset. You can use the arrow keys to fine tune the offĆ set by scrolling to a desired offset value. Press the ENTER/RESET key to accept the offset.
CALIBRATION AND ADJUSTMENT BELT SPEED CALIBRATION To Calibrate the Belt Speed: Place an object on the belt. Time its passage from entrance to exit. If the actual speed is not within 5 seconds of the set time, check the calibration setĆ tings as follows. 1. The display reads: NOTE: Measure using the leading or the trailing edge. Do not use the leading edge in and the trailing edge out. Use the arrow keys to toggle between TEMP and TIME. When the display reads TIME, press the ENTER/RESET key.
SMART GENERATION 6. The display reads: To Exit Calibration Mode: SELECT MOTOR RATIO XX 1. Press and hold the UP ARROW and ENTER/ RESET keys simultaneously for approximately three seconds. Use the arrow keys to scroll to the correct moĆ tor ratio. Press the ENTER/RESET key to select the correct motor ratio value. 7.
CHAPTER 4 PARTS REPLACEMENT
SMART GENERATION PLC REPLACEMENT AND PROGRAMMING PLC REMOVAL AND REPLACEMENT PLC PROGRAMMING 1. Remove burner and control access cover. 1. With the oven off, press the UP ARROW key and the ENTER/RESET keys simultaneously for approximately 3 to 5 seconds. The display will read ACCESS CODE. 2. Disconnect the ribbon cables. 3. Disconnect power supplies from both the PLC and the RTD converter. 2.
PARTS REPLACEMENT INTERFACE BOARD NOTE: The interface board is sensitive to electroĆ static discharge. Proper grounding preĆ cautions are required before handling the interface board. BELT DIRECTION NOTE: If motor direction is changed the belt direcĆ tion must also be changed. REMOVAL AND REPLACEMENT 1. Locate the enable/disable switches and direcĆ tion switches on the IFB. 1. Remove the ribbon clable and other harnesses from the board. 2. Toggle the enable/disable switch to the off position. 2.
SMART GENERATION CIRCULATING FAN PRESSURE SWITCH REPLACEMENT NOTE: If a Blower Failure alarm occurs during heating, turn the adjustment screw on the circulation pressure switch clockĆ wise (-) about 1/4 turn; the switch should stay closed at a higher temperĆ ature now. Turn the oven OFF (into Standby) and then ON to continue heating. 1. If the oven contains pressure switch M9422 (see FIGURE 3), remove and discard. 2. Carefully remove and discard the jumper wires from the pressure switch lead wires.
PARTS REPLACEMENT See FIGURE 5 for Detail Circulation Pressure Switch Circulation Blower Relays FIGURE 4 Typical circulation blower pressure expected is .30" W.C. (SG3240) or .25" W.C.
SMART GENERATION COMBUSTION PRESSURE SWITCH ADJUSTMENT The adjustment of the pressure switches after installation is extremely important. The switch proves that the gas combustion air blower is operaĆ tional. If the pressure switch stays open, the oven will not heat. The operator will be given both audiĆ ble and visual alarms for a combustion blower failĆ ure: COMBUSTION BLWR FAIL" 2.
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CHAPTER 5 TROUBLESHOOTING
SMART GENERATION FAULT DISPLAY INDICATORS If a fault should occur, access the second level proĆ gramming and proceed to the hour meter menu. 2. Note the amount of time in the display on your invoice. To access second level programming: NOTE: The hour meter cannot be reset unless the PLC is replaced. 1. Hold the UP ARROW and ENTER/RESET keys simultaneously for approximately 3 seconds. The display will indicate the access mode. To return to user mode: 1.
TROUBLESHOOTING DC DRIVE SYSTEM DC Drive System Inoperative No Is oven on? Turn oven on. Yes Is motor feedback #1 lit? No Yes Is X-O on PLC Illuminated? No Replace PLC. Yes Is enable switch in the OFF position? No Toggle to the OFF position. No Remove wire from J7 Pin 4. Measure VDC on the end of the wire to ground. Yes Measure enable signal at J7 Pin 4. Is the signal approximately 5VDC? Yes Hz varies dependent on time. Is the voltage approximately 5VDC? Measure Hz at J7 Pin 1.
SMART GENERATION HEATING SYSTEM Heat Inoperative Is oven on? No Turn oven off. Let all indicator lights go off for at least 5 seconds. Yes Check power supply. No Are any indicator lights lit? Yes Is oven in cool down mode? Are all indicator lights off? No Yes Check blowers and pressure switch. No No Reference section on related indicator. Yes Is cir. pressure indicator lit? Yes Check PLC and interface board. No Are all other input LEDs out? Yes From C on last page of chart.
TROUBLESHOOTING A Is combustion blower ind. lit? No Yes No Is Y3 LED on PLC lit? Replace PLC. Yes Replace IEFB or ribbon cable. Is combustion pressure ind. lit? No Yes No Yes No Yes Verify 24VDC to motor. No Replace interface board or relay. Yes Replace combustion pressure switch. Clear or replace tubing. Wait ten seconds. Is pilot indicator lit? Is combustion motor rotating? No Is Y5 LED on PLC lit? Replace motor.
SMART GENERATION B Is ignition proof ind. lit? No Is pilot light lit? Yes Increase setpoint above ambient temperature. No Is pilot out when power off? Is there a heat demand? No Is PLC Y6 lit? Yes No Go back to C on first page of chart. Is heat indicator lit? Yes Replace interface board. Is K1 LED on interface board lit? No Replace K1 relay or interface board. Yes 24VDC to coil Is main valve energized? No Check and/or replace wire.
TROUBLESHOOTING Heat/K1 LED Blower 1 LED Heat Relay/K1 Blower 2 LED Blower 1 Relay Blower 2 Relay Circulation Blowers Pressure Switch Switch 4 (See View A) View A SW4 ENB 2 DIR 2 Relay Fault Reset Button K1 LED ENB 1 Relay Fault Indicator LED DIR 1 K1 LED FIGURE 3 5-6
SMART GENERATION CONVECTION SYSTEM Circulation blowers inoperative Is oven on or in Cool Down mode? No Turn oven on. Yes Are circulating blower indicators lit? Yes No Is Y2 on PLC lit? Yes Replace interface board and or ribbon cable. Are neon lights on interĆ face board lit? Yes No Is No current to blower between .4 and 1 amp per blower? Replace relay and/or interĆ face board. Replace blower. Yes Done FIGURE 4 5-7 No Replace PLC.
TROUBLESHOOTING REFERENCE TABLES HEATING ELEMENT RESISTANCE ELEMENT PROBE RESISTANCE VS TEMPERATURE RESISTANCE SG2136E/G and SG3240E/G SG1236E 208 volt 1 8.22-9.09 220 volt 1 9.20-10.17 240 volt 1 10.95-12.10 208 volt 3 5.48-6.06 240 volt 3 7.30-8.06 240/415 volt 3 + N 10.95-12.10 220/380 volt 3 + N 9.20-10.17 SG3240E 2.95-3.27 240 volt 3 3.94-4.35 220/380 volt 3 + N 4.96-5.48 230/400 volt 3 + N 5.42-5.
