Blodgett DFG-100 XCEL User Manual

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DFG-100 XCEL

convection oven INSTALLATION - OPERATION - MAINTENANCE

BLODGETT OVEN COMPANY

www.blodgett.com

44 Lakeside Avenue, Burlington, Vermont 05401 USA Telephone: (802) 658-6600 Fax: (802)864-0183

PN 36434 Rev U (3/14)

© 2014 - G.S. Blodgett Corporation

Your Service Agency’s Address:

Model

Serial number

Oven installed by

Installation checked by

IMPORTANT

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

INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE USER SMELLS GAS MUST BE POSTED IN A PROMINENT LOCATION. This information may be obtained by contacting your 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.

The information contained in this manual is important for the proper installation, use, and maintenance of this oven. Adherence to these procedures and instructions will result in satisfactory baking results and long, trouble free service. Please read this manual carefully and retain it for future reference.

ERRORS: Descriptive, typographic or pictorial errors are subject to correction. Specifications are subject to change without notice.

TABLE OF CONTENTS

INSTALLATION

Oven Description and Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Delivery and Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oven Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Sanitation Bolts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Leg Attachment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Caster Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Double Section Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ventilation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Utility Connections - Standards and Codes.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Gas Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Electrical Connection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Initial Startup.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

OPERATION

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SSI-M Solid State Infinite Control with Manual Timer.. . . . . . . . . . . . . . . . . . . . . . . 16 SSD - Solid State Digital Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SmartTouch Touchscreen Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 How Cook & Hold Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 General Guidelines for Operating Personnel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Suggested Times and Temperatures.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

MAINTENANCE

Cleaning and Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation

Oven Description and Specifications

Cooking in a convection oven differs from cooking in a conventional deck or range oven since heated air is constantly recirculated over the product by a fan in an enclosed chamber. The moving air continually strips away the layer of cool air surrounding the product, quickly allowing the heat to penetrate. The result is a high quality product, cooked at a lower temperature in a shorter amount of time.

Blodgett convection ovens represent the latest advancement in energy efficiency, reliability, and ease of operation. Heat normally lost, is recirculated within the cooking chamber before being vented from the oven: resulting in substantial reductions in energy consumption and enhanced oven performance.

Air Flow Pattern for DFG-100 XCEL

Figure 1

GAS SPECIFICATIONS - DFG1XL/AA

U.S., Canada and General Export

 

Natural Gas

Propane Gas

 

US Units

SI Units

US Units

SI Units

Heating Value

1000 BTU/cu.ft.

37.3 MJ/m3

2550 BTU/cu. ft.

95.0 MJ/m3

Specific Gravity (air=1.0)

0.63

0.63

1.53

1.53

Oven Input

 

 

 

 

Standard rate

60,000 BTU/hr

17.6 kW

60,000 BTU/hr

17.6 kW

High rate

80,000 BTU/hr

23.5 kW

80,000 BTU/hr

23.5 kW

Manifold Pressure

 

 

 

 

Standard rate

2.0” W.C.

.50 kPa

5.5” W.C.

1.43 kPa

High rate

3.5” W.C.

.87 kPa

10.0” W.C.

2.5 kPa

Main Burner Orifice Size

2.1 mm

2.1 mm

55 MTD

1.3 mm

Australia

 

 

 

 

Oven Input

 

 

 

 

Standard rate

0.5 kPa

63 MJ/h

1.44 kPa

63 MJ/h

High rate

0.875 kPa

84 MJ/h

2.5 kPa

84 MJ/h

Main Burner Orifice Size

2.1 mm

2.1 mm

55 MTD

1.3 mm

NOTE: * - Multiple Twist Drill

 

 

 

 

2

Installation

Delivery and inspection

All Blodgett ovens are shipped in containers to prevent damage. Upon delivery of your new oven:

Inspect the shipping container for external damage. Any evidence of damage should be noted on the delivery receipt which must be signed by the driver.

Uncrate the oven and check for internal damage. Carriers will accept claims for concealed damage if notified within fifteen days of delivery and the shipping container is retained for inspection.

The Blodgett Oven Company cannot assume responsibility for loss or damage suffered in transit. The carrier assumed full responsibility for delivery in good order when the shipment was accepted. We are, however, prepared to assist you if filing a claim is necessary.

oven location

The well planned and proper placement of your oven will result in long term operator convenience and satisfactory performance.

The following clearances must be maintained between the oven and any combustible or non-combustible construction.

DFG100 XCEL

Oven body right side - 0” (0cm)

Oven body left side - 0” (0cm)

Oven body back - 0” (0cm)

Oven body bottom - 6” (15cm)

Delivery and Inspection

The following clearances must be available for servicing.

Oven body sides - 12” (30cm)

Oven body back - 12” (30cm)

NOTE: On gas models, routine servicing can usually be accomplished within the limited movement provided by the gas hose restraint. If the oven needs to be moved further from the wall, the gas must first be turned off and disconnected from the oven before removing the restraint. Reconnect the restraint after the oven has been returned to its normal position.

It is essential that an adequate air supply to the oven be maintained to provide a sufficient flow of combustion and ventilation air.

Place the oven in an area that is free of drafts.

Keep the oven area free and clear of all combustibles such as paper, cardboard, and flammable liquids and solvents.

A clearance of 6” is required on the bottom and sides of the unit for cleaning. Do not place the oven on a curb base or seal to a wall.

The location must provide adequate clearance for the air opening into the combustion chamber.

Before making any utility connections to this oven, check the rating plate to be sure the oven specifications are compatible with the gas and electrical services supplied for the oven.

1.Pull out control panel. The rating plate attached to the inside of the control compartment.

3

Installation

Oven Assembly

Sanitation Bolts

These bolts are required to block any exposed hole on the back of an oven. This includes:

any unit, single or stacked, without a back panel.

any holes in stacked units not used for mounting stacking brackets.

1.Locate the 5/16” bolts that were shipped with the oven.

2.Install the bolts as shown in Figure 2.

Double Stacked Units

Units without Back Panels

Figure 2

4

Installation

Leg Attachment

1.Push the oven onto a lift with the bottom of the oven down.

2.Align the threaded stud in each leg with the nut located inside each bottom corner of the oven frame. Turn the legs clockwise and tighten to the nearest full turn.

3.Align the two leg plate holes in each leg with those in the oven bottom. Secure each leg using two 1/2” bolts.

NOTE: If using casters see CASTER ASSEMBLY before proceeding.

4.Level the oven by screwing the adjustable leg feet in or out as necessary.

6” (15 cm) Legs Shown

Figure 3

Oven Assembly

Caster Assembly

NOTE: Install the locking casters on the front of the oven. Install the non-locking casters on the back of the oven.

NOTE: Use a gas hose restraint on all units with casters.

Casters for Single and Double Stacked Ovens:

1.Attach the legs as described.

2.Pry the adjustable feet out of the legs.

3.Insert one caster into each leg as shown. Tighten the lock nuts to secure the casters.

Adjustable

Leg Foot

Gas Hose

Restraint Bracket

Caster Assembly

Figure 4

Low Profile Casters for Double Stacked Ovens:

1.Align the three holes in each caster assembly plate with those in the oven bottom. Secure each caster using three 1/2” bolts.

Gas Hose Restraint Bracket

Figure 5

5

Installation

Oven Assembly

Double Section Assembly

1.Secure the short legs to the bottom sections as described.

2.Attach lower flue box to lower oven.

3.Place the upper section in position on top of the lower oven.

4.Attach the stacking brackets using the remaining 5/16” bolts shipped with the ovens.

5.Install flue riser and attach upper flue box to upper oven.

WARNING!!

When stacking ovens be sure to remove the single oven flue boxes prior to attaching upper and lower boxes and riser.

Oven Leveling

After assembly, the oven should be leveled and moved to the operating location.

1.The oven can be leveled by adjusting the feet or casters located on the bottom of each leg.

Flue

Boxes

Flue Riser

Figure 6

6

Installation

On gas models the installation of a proper ventilation system cannot be over emphasized. This system removes unwanted vapors and products of combustion from the operating area.

This oven may be vented using either:

A mechanically driven, canopy type, exhaust hood, or

A direct flue arrangement.

U.S. and Canadian installations

Refer to your local ventilation codes. In the absence of local codes, refer to the National ventilation code titled,

“Standard for the Installation of Equipment for the Removal of Smoke and Grease Laden Vapors from Commercial Cooking Equipment”, NFPA-96-Latest Edition.

Australia and general export installations

Installation must conform with Local and National installation standards. Local installation codes and/or requirements may vary. If you have any questions regarding the proper installation and/or operation of your Blodgett oven, please contact your local distributor. If you do not have a local distributor, please call the Blodgett Oven Company at 0011-802-658-6600.

WARNING:

Failure to properly vent the oven can be hazardous to the health of the operator and may result in operational problems, unsatisfactory baking and possible damage to the equipment.

Damage sustained as a direct result of improper ventilation will not be

Ventilation

Canopy Type Exhaust Hood

A mechanically driven, canopy type exhaust hood is the preferred method of ventilation.

The hood should be sized to completely cover the equipment plus an overhang of at least 6” (15 cm) on all sides not adjacent to a wall. The distance from the floor to the lower edge of the hood should not exceed 7’ (2.1m).

The total makeup and exhaust air requirements for hood capacity should be approximately 30 CFM (.85 m3) for each oven section.

Installing the canopy hood draft diverter

Ovens ordered for hood venting are supplied with a draft diverter. Install the draft diverter as follows:

1.Place the diverter over the flue connector with the open area facing the front of the oven. See Figure 7.

2.Secure both ends with the sheet metal screws provided.

Draft

Diverter

Front of Oven

Figure 7

7

Installation

Ventilation

Direct Flue Arrangement

When the installation of a mechanically driven exhaust hood is impractical the oven may be vented by a direct flue arrangement.

WARNING!!

It is essential that the direct flue be installed as follows. Incorrect installation will result in unsatisfactory baking and oven damage.

The flue must be class B or better with a diameter of 6”

(15 cm) for single ovens and 8” (20 cm) for double stacked ovens. The height of the flue should rise 6-8 ft (2-2.5 m) above the roof of the building or any proximate structure.

Never direct vent the oven into a hood. The flue should be capped with a UL Listed type vent cap to isolate the unit from external environmental conditions.

The direct vent cannot replace air consumed and vented by the oven. Provisions must be made to supply the room with sufficient make-up air. Total make-up air requirements for each oven section should be approximately 30 CFM (.85 m3) per section. To increase the supply air entering the room, a ventilation expert should be consulted.

Installing the draft hood

Ovens ordered for direct venting are supplied with a draft hood. Install the draft hood as follows:

1.Place the draft hood over the flue connector.

2.Secure both ends with the sheet metal screws provided.

Flue

Drafthood

Front of

Oven

Figure 8

8

Installation

Utility Connections - Standards and Codes

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:

the installation or replacement of gas piping and the connection, installation, repair or servicing of equipment.

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.

U.S. and Canadian installations

The installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1, as applicable.

Installation must conform with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70-Latest Edition and/or Canadian National Electric Code C22.1 as applicable.

Appliance is to be installed with backflow prevention in accordance with applicable federal, province and local codes.

Australia and general export installations

Instllation must conform with Local and National installation standards. Local installation codes and/or requirements may vary. If you have any questions regarding the proper installation and/or operation of your Blodgett oven, please contact your local distributor. If you do not have a local distributor, please call the Blodgett Oven Company at 0011-802-658-6600.

9

Installation

Gas Connection

gas piping

A properly sized gas supply system is essential for maximum oven performance. Piping should be sized to provide a supply of gas sufficient to meet the maximum demand of all appliances on the line without loss of pressure at the equipment.

Example:

NOTE: BTU values in the following example are for natural gas.

You purchase a DFG-100 XCEL convection oven to add to your existing cook line.

1. Add the BTU rating of your current appliances.

Pitco Fryer

120,000 BTU

6 Burner Range

60,000 BTU

Deck Oven

50,000 BTU

Total

230,000 BTU

2. Add the BTU rating of the new oven to the total.

Previous Total

230,000 BTU

DFG-100 XCEL (high rate) 80,000 BTU

New Total

310,000 BTU

3.Measure the distance from the gas meter to the cook line. This is the pipe length. Let’s say the pipe length is 40’ (12.2 m) and the pipe size is 1” (2.54 cm).

4.Use the appropriate table to determine the total capacity of your current gas piping.

The total capacity for this example is 320,000 BTU. Since the total required gas pressure, 310,000 BTU is less than

320,000 BTU, the current gas piping will not have to be increased.

NOTE: The BTU capacities given in the tables are for straight pipe lengths only. Any elbows or other fittings will decrease pipe capacities. Contact your local gas supplier if you have any questions.

Maximum Capacity of Iron Pipe in Cubic Feet of

Natural Gas Per Hour

(Pressure drop of 0.5 Inch W.C.)

Pipe

 

Nominal Size, Inches

 

Length (ft)

3/4”

 

1”

1-1/4”

1-1/2”

 

2”

10

360

 

680

1400

2100

 

3950

20

250

 

465

950

1460

 

2750

30

200

 

375

770

1180

 

2200

40

170

 

320

660

990

 

1900

50

151

 

285

580

900

 

1680

60

138

 

260

530

810

 

1520

70

125

 

240

490

750

 

1400

80

118

 

220

460

690

 

1300

90

110

 

205

430

650

 

1220

100

103

 

195

400

620

 

1150

From the National Fuel Gas Code Part 10 Table 10-2

Maximum Capacity of Pipe in Thousands of BTU/hr of Undiluted L.P. Gas at 11” W.C.

(Pressure drop of 0.5 Inch W.C.)

Pipe

Outside Diameter, Inches

Length (ft)

3/4”

1”

1-1/2”

10

608

1146

3525

20

418

788

2423

30

336

632

1946

40

287

541

1665

50

255

480

1476

60

231

435

1337

70

215

404

1241

80

198

372

1144

90

187

351

1079

100

175

330

1014

From the National Fuel Gas Code Part 10 Table 10-15

10

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