Blodgett MG3270 Installation Manual

BLODGETT CONVEYOR

STARTUP AND CALIBRATION GUIDE

BLODGETT OVEN COMPANY

www.blodgettcorp.com

50 Lakeside Avenue, Box 586, Burlington, Vermont 05402 USA Telephone (800) 331-5842, (802) 860-3700 Fax: (802)864-0183

PN M9437 Rev E (6/01)

E 2000 --- G.S. Blodgett Corporation

Table o f C o n t e nts

Introduction

Pre-Startup Requirements 2.........................................

Manual Control Startup

Control Identification 3..............................................

Gas Pressure Adjustments 4........................................

Temperature Control Configuration 5.................................

Temperature Calibration 6...........................................

Motor Control Board Adjustment 7...................................

Belt Speed Calibration 8............................................

Closed Loop --- Dart Microd rive MDP 8............................

Open Loop 9...................................................

Convection Blowers and Ventilation 10.................................

Computer Control Startup

Control Identification 11..............................................

Gas Pressure Adjustments 12........................................

Convection Blowers 13..............................................

Computer Configuration 14..........................................

Temperature Calibration 15...........................................

Belt Speed Calibration 16............................................

Closed Loop Single Belt 16.......................................

Open Loop Twin Belt 17..........................................

Ventilation 17.......................................................

Motor Control Board Adjustment 18...................................

PLC Control Startup

Control Identification and Registration 19..............................

Gas Pressure Adjustments 20........................................

Convection Blowers 23..............................................

Temperature Calibration 24...........................................

Belt Speed Calibration 26............................................

Introduction

Pre-Startup Requirements

OWNER’S RESPONSIBILITIES

A minimum of 5 to 7 working days are needed to schedule a start-up procedure.

Before a factory representative, or a factory trained representative, arrives to perform a start up procedure, the owner MUST ALREADY have satisfied the following requirements:

1. Gas Models: Installation of an adequate mechanically driven ventilation system for the unit. The ventilation system should replace 80% of the exhaust volume with fresh make up air. The table below can be used as a guideline.

2. Electric supplies installed by a certified professional.

NOTE: Refer to the Owner’s manual provided

with the oven for electrical specifications.

3. Gas Models: Gassuppliesinstalledbyacertified professional.

NOTE: Refer to the Owner’s manual provided

with the oven for gas specifications.

Be sure to size the meter for all gas models as follows:

U.S. installations

a.) Add the total BTU’s/hr of all the gas ap-

pliances on the line.

b.) Convert BTU’s to cubic ft/hr using the for-

mula Cu Ft/Hr = 1000 BTU/Hr.

c.) Size the meter accordingly.

General export and Canadian installations

a.) Add the total M

on the line.

b.) Sizethemeteraccordingly.

NOTE: Refer to the Owner’s manual provided with

the oven for additional information on utility installation requirements.

SERVICE AGENCY’S RESPONSIBILITIES

Before performing a start-up procedure, the service agency MUST ALREADY have satisfied the following requirements:

1. Assembly of the oven(s).

NOTE: Refer to the Owner’s manual provided

with the oven for assembly.

2. Conversion of ovens to other types of gas when required.

/min of all the appliances

Oven

Model

MT1828G 400-500

SG2136G or MT2136G

SG3240G or MT3240G

MT3255G 1000-1400

MT3270 1200-1650

MG3270 1200-1650

MT3855 1000-1400

MT3870 1200-1650

Exhaust Volume -- CFM (M3/min) Supply Requirements -- CFM (M3/min)

Single Double Trip le Single Double Trip le

(14-17)

400-500

(14-17)

800-1000

(23-28)

(28-40)

(34-47)

(28-40)

(34-47)

800-1000

(23-28)

800-1000

(23-28)

1200-1600

(34-46)

2000-2800

(57-79)

2400-3300

(68-93)

2400-3300

(68-93)

2400-3300

(68-93)

2400-3300

(68-93)

1200-1500

(34-43)

1200-1500

(34-43)

2000-2400

(57-68)

3000-4100

(85-116)

3600-5000

(102-142)

3600-5000

(102-142)

3600-5000

(102-142)

3600-5000

(102-142)

320-400

(12-14)

320-400

(12-14)

640-800

(18-23)

800-1120

(23-32)

960-1320

(27-37)

960-1320

(27-37)

800-1120

(23-32)

960-1320

(27-37)

640-800

(18-23)

640-800

(18-23)

960-1280

(27-36)

1600-2240

(46-64)

1920-2640

(54-75)

1920-2640

(54-75)

1920-2640

(54-75)

1920-2640

(54-75)

960-1200

(27-34)

960-1200

(27-34)

1600-1920

(46-54)

2400-3300

(68-93)

2880-4000

(82-113)

2880-4000

(82-113)

2880-4000

(82-113)

2880-4000

(82-113)

Manual Control Startup

Control Identification

The following instructions are for the standard manual control. See Figure 1 for control identification.

COOK TIME

ON OFF

CONVEYOR

ACTUAL SETPOINT HEAT

TEMPERATURE

Figure 1

ON OFF

HEAT

ON OFF

BLOWER

Manual Control Startup

Gas Pressure Adjustments

THE FOLLOWING STARTUP PROCEDURES MUST BE PERFORMED BY A QUALIFIED TECHNICIAN ONLY.

REGULATED GAS PRESSURE

NOTE: Gas models only.

Incoming static gas pressure to the unit, with all the gas appliances drawing from the supply, should be a minimum of 5.5” W .C. (13.7 mbar) for natural gas and 11” W .C. (28 mbar) for propane gas.

The manifold pressure, if measured after the regulator located inside the control box, must be 3.5” W.C. (9 mbar) for natural gas and 10” W.C. (25 mbar) for propane gas.

The pressure can be checked at the tap on either the dual regulated gas valve or the solenoid valve.

Turn the adjusting screw on the left front side of the dual regulated valve to adjust the gas pressure. Turn the screw clockwise to raise the gas pressure and counter-clockwise to lower it.

PRIMARY AIR ADJUSTMENT

NOTE: Gas models only.

The air shutter disc on the burner blower motor, located inside the control box at the top of the assembly, is factory adjusted to provide the most efficient blue flame possible at sea level.

1. Visually examine the quality of the flame.

2. If it needs adjusting, increase or decrease the air mixture to attain the best flame quality.

Pressure Tap

Regulator

Cap

Regulator Adjustment

Figure 2

Manual Control Startup

Temperature Control Configuration

CONFIGURATION PROCEDURES

NOTE: Follow these configuration procedures to

change the factory settings.

To enter the Configuration Menus

1. Press and hold the actual temperature key for approximately 10 seconds. When the menu system has been accessed, the display toggles between dEF and either SP or Act.

Setting the Default Display

The default display determines whether the controller displays the actual or setpoint temperature.

1. Use the arrow keys to select the desired display default.

NOTE: We recommend using the setpoint

display default.

2. Press the actual temperature k ey to enter the selected display default. The display toggles between HYS and a numerical value.

Setting the Control Hysteresis

The control hysteresis, or burner cycle is used to prevent rapid cycling around the setpoint. The hysteresis is adjustable from 2_F to 252_F(1_Cto 122_C).

1. Use the arrow keys to select the desired control hysteresis.

NOTE: We recommend 5_F(3_C) initially.

2. Press the actual temperature k ey to enter the selected hysteresis value. The display toggles between OFF and a numerical value.

Setting the Display Offset

Setting the Deviation Band Alarm

The deviation band alarm causes the display to flash when the actual temperature varies (in either direction) from the setpoint. The deviation band alarm is adjustable to off or values from 1_Fto 252_F (0.5_C to 122_C).

1. Use the arrow keys to select the desired deviation band alarm.

NOTE: We recommend 20_F(11_C).

2. Press the actual temperature k ey to enter the selected alarm value.

To exit the Configuration Menus

1. Push and hold the actual temperature key for approximately 3 seconds.

NOTE: The unit exits the configuration menus if

the controller is not touched for 1 minute at any time during programming.

SETTING THE DISPLAY UNITS

1. Press and hold the actual temperature key for approximately 10 seconds until the display reads unt and flashes F or c.Presstheupor down arrow key to toggle between _Fand_C.

2. Press and hold the actual temperature key until the control exits the programming mode.

The display offset adjusts the displayed t emperature if the actual temperature differs from the temperature seen by the thermocouple. If the actual temperature is lower a positive offset is needed. If the actual temperature is higher a negative offset is needed. The display offset is adjustable from

-126_F to +126_F(-87_Cto+52_C).

1. Use the arrow keys to select the desired display offset.

2. Press the actual temperature k ey to enter the selected offset value. The display toggles between ALr and a numerical value.

ACTUAL SETPOINT HEAT

Figure 3

Manual Control Startup

Temperature Calibration

Low Limit Adjustment

1. Bring the oven to 200_F(93_C).

2. Turn the blower and heat switches to OFF. The blower should continue to run.

3. Monitor the digital temperature control display. The blower motors should shut off within the range of 170-135_F(77-57_C).

4. To adjust the temperature, turn the low-limit potentiometer. A clockwise rotation increases the setting, counter-clockwise decreases it. SeeFigure4.

INCREASE

INCREASEDECREASE

DECREASE LOW LIMITP2HI LIMIT

INCREASE

DECREASE

High Limit Adjustment

NOTE: Refer to the wiring diagram shipped with

the oven for terminal locations.

1. Remove the wires from the common and N.O. terminals. Touch the wires together to energize the heat circuit. This enables the oven to heat above the highest temperature allowed by the controller.

2. When the display reads 600_F (316_C), the burner blower motor should shut off. If the temperature rises above 600_F (316_C), adjust the hi-limit pot (Figure 4) so the burner shuts off at 600_F (316_C). A clockwise rotation of the high-limit pot increases the temperature, counter-clockwise decreases it.

910

T/C

RED

ACTUAL SETPOINT HEAT

INCREASE

HI LIMIT

1 2 3 4 5 6 7 8

230 115 NC C NO NO C

United Electric Board

DECREASE

LOW LIMIT

ZYTRON

SERIES 300

13 265

230

NO C NC

115

OUTPUT 1

Zytron Board

Figure 4

Athena Temperature Controller

478

NO C

OUTPUT 2

Manual Control Startup

Motor Control Board Adjustment

High/low speed motor control board adjustment for 180 and 130 VDC motors

NOTE: This procedure does not apply to Dart Mi-

crodrive systems or cooking computers.

NOTE: The motor control board is located on the

slide out control panel.

High Speed Motor Adjustment:

1. Turn the cook time control knob on the front panel fully clockwise to decrease the cook time and turn the conveyor belt on.

2. With the motor connected (make no open circuit voltage readings) measure the voltage at the motor leads (A1 & A2 in Figure 5) on the DC control board. If the voltage is not within 3 VDC of the specified voltage continue with step 3.

3. Turn the MAX trim pot counter-clockwise to lower and clockwise to raise the voltage until it is within 3 VDC of the specified voltage.

Minimum Speed Pot

Maximum Speed Pot

Low Speed Motor Adjustment:

1. Turn the cook time control knob on the front panel fully counter-clockwise to increase the cook time.

2. With the motor connected (make no open circuit voltage readings) measure the voltage at the motor leads on the DC control board (A1 & A2 in Figure 5). If the voltage is not within 1 VDC of the specified voltage, continue with step 3.

3. Turn the MIN SPEED pot clockwise to lower the voltage and counter-clockwise to raise the voltage.

130 Volt System 180 Volt System

Model Low High Low High

MT2136 20 130 26 180

MT3255 26 130 26 180

MT3270 26 130 26 180

MG3270 26 130 N/A N/A

Torque (current) limiting adjustment (DO NOT ADJUST)

Yellow or Violet (pin 12)

Orange or Gray (pin 10)

Blue (pin 8)

Gray

Blue

Violet

Speed Pot

Line Hot (VAC)

Line Neutral (VAC)

REMOVE RED PLUG FROM TOP OF DC MOTOR PRIOR TO OPERATING!

Warning: Circuit components are not at ground potential! Use only a non-metallic or insulated adjustment tool.

Shock hazards may occur with conducting tools!

ACC MAX MIN TORQ

TB1

L N A1 A2

PM Motor Armature

TP1

TP2

Barrier Terminal Block TB1

Power Line and Motor Ground

REG

Figure 5

Manual Control Startup

Belt Speed Calibration

CLOSED LOOP -- DART MICRODRIVE MDP

1. Remove the top cover. The internal dip switch is located next to the transformer.

Dip Switch Detail

123456 78

Figure 6

PROGRAMMING THE MDP CONTROL

NOTE: Anyvariable can be changed WITHOUT re-

setting the others.

To En t e r t h e Pr o g r a m M o d e

1. Set DIP switches 1, 2, 3, 4, 5, 6 and 8 to OFF. Set DIP switch 7 to ON. The motor stops.

2. The display reads PROG.

NOTE: In rate mode the current decimal point

is also displayed.

Time or Rate Mode (Displayed Decimal Place)

This allows settings to be made in the proper units.

1. Set DIP switch 4 to ON.

2. The current decimal point (if any) will be lit. The display gives the current value of the decimal place variable. To change press the up or down arrow keys. Use 0-4 for the rate mode. Use5forthetimemode.

NOTE: The decimal point will not be lit if the

unit is currently in the time mode.

3. When finished, flip DIP switch 4 to OFF.

4. The display reads PROG.

KConstant

1. Flip DIP sw itch 1 to ON.

2. The display gives the current value for the constant. To change press the up or down arrow keys.

NOTE: For ovens with a 70” (178 cm) tunnel

the preset constant is 5:20. For ovens with a 55” (140 cm) tunnel the preset constant is 4:08.

3. When finished, set DIP switch 1 to OFF.

4. The display reads PROG.

NOTE: If you change the constant, the display set-

ting will be set to the slowest speed when you exit the programming mode.

Minimum Setting

1. Flip DIP sw itch 2 to ON.

2. The display gives the current value for the low er limit. To change press the up or down arrow keys.

3. When finished flip DIP sw itch 2 to OFF.

4. The display reads PROG.

Maximum Setting

1. Flip DIP sw itch 3 to ON.

2. The display gives the current value for the upperlimit.Tochangepresstheupordownarrow keys.

3. When finished flip DIP sw itch 3 to OFF.

4. The display reads PROG.

To Ex i t th e P ro g r a m M o d e

1. Make sure DIP switch 5 (Master/Follower Mode select) is in the desired position (ON = Follower; OFF= Master).

NOTE: In most cases DIP switch 5 should be

set to the master position (OFF).

2. Set DIP switches 1, 2, 3, 4, 6 and 8 to OFF.

3. If satisfied with programming values, set DIP switch 7 to OFF. The control operates using the new programmed variables.

CHECKING THE BELT SPEED CALIBRATION

Placeapanonthebeltandstarttheconveyor.

1. Begin timing the belt’s speed when the trailing edge of the pan enters the oven.

2. End the timing cycle when the trailing edge of the pan exits the oven.

3. If the displayed time differs from the actual more than 5 seconds, reprogram the K constant.

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