Blodgett XCEL-50EC Service Manual

Service Manual

Model - XL50EC

Grilled Chicken Oven with

Semi-automatic Cleaning System

Blodgett Oven Co. ~ 44 Lakeside Ave., Burlington, VT 05401 ~ 800-331-5842 ~ www.blodgett.com ~ 12/1/08

44 Lakeside Avenue, Burlington Vermont 05401 U.S.A.

Telephone: 1-(800)331-5842 (802)860-3700 D Fax:(802)652-2814

XCEL-50EC KFC OVEN STARTUP/ACTIVATION CHECKLIST

Return form to BLODGETT when job is complete. Submit one form with each unit installed.

SERIAL NO.

STORE ID

ADDRESS

CITY________________________ STATE_______ ZIP

PHONE:(______)

ELECTRIC: V VOLTAGE_____________ PHASE

MODEL_______________DATE OF INSTALLATION

SERVICE AGENCY

ADDRESS

CITY________________________ STATE_______ ZIP

PHONE:(______)______________ MECHANIC

The rating plate is located on the back of the oven.

OPERATIONAL START-UP/ACTIVATION PROCEDURE

Information can be found in the Startup Guide or by contacting the factory. Write in N/A if not applicable.

1. Flush Water inlet hose for 30 seconds to remove all debris in the water line before attaching the water hose to oven. Verify water is cold. Yes No

2. Is the oven level? If no, level the unit. Yes No

3. Drain pipe and drain actuator are installed? Yes No

4. Does drain hose reach open drain? Cut to length as needed. Attach the 90_ pvc fitting to the end of the hose.

5. Is the cleaning solution tray installed? Be sure there are no kinks in the chemical line.

6. COMPONENT FUNCTION TESTS: In “Diag Input” mode, check the operation of the following;

_____ 1. Door Strike Switch _____ 2. Door Proximity Switch

7. COMPONENT FUNCTION TESTS: In “Diag Output” mode, check the operation of the following;

_____ 1. Heat On (Light on the S S Relay) _____ 8. Quench Solenoid

Yes No

_____ 2. Fan High _____ 9. Chem Pump

_____ 3. Fan Low _____ 10. Recirc Pump

_____ 4. Fan Forward _____ 11. Door Lock

_____ 5. Fan Reverse _____ 12. Contactor

_____ 6. Cooling Fan _____ 13. Water Solenoid

_____ 7. Drain Valve (look down drain) _____ 14. Recirc Valve

8. Set the water pressure to 20-PSI flowing. Test 2 quarts in 50 seconds. Yes No

9. Verify there are no water leaks from the connector to the cavity. Yes No

10. Verify blower wheel wing screw is tight. Yes No

11. Verify all metal edges are deburred. Yes No

12. Verify the baffle and racks a re installed properly. Yes No

13. Verify incoming voltage matches Data Tag of oven. Yes No

14. Applied voltage between L1 to L2 ______ L2 to L3______ L1 to L3 ______

15. Amp draw at terminal block L1_____ L2 _____ L3 _____

16. Turn oven on. Allow heat to cycle 3 times. Shut oven off. Yes No

17. Apply your company sticker on “Door Lock” cover. Y es No

18. Remove all protective vinyl from exterior sheet metal. Yes No

Fax completed form to Blodgett at 802-652-2814.

This appliancemay be equipped with proprietaryfeatures and/or components which are for the exclusiveuseofthecustomerindicated above. Further, there may be procedures and/or methods being utilized in preparing this customer’s productwhichmay be proprietary. I hereby certify that this information will be held in confidence and not disclosed to any third party for whom it is not intended.

I hereby certify that the above indicated Blodgett XCEL-50EC KFC oven has been installed, a ctivated and is in good working order.

Service Agent’s Signature

FORM/Serv.27

(White Copy To Blodgett Warranty Department, Yellow Copy To Customer, Pink Copy To Service Agency)

Store Manager’s Signature

P/N 52246 Rev A

FAST ~ VVC for XL-50EC Oven

Second Level Programming

(The oven needs to be in the “ON” position)

Press and hold the (P) Button

for 3 seconds

Press the (P) Button Enter Service Code “2222”

Press the (P) Button Scroll to “Diag Input”

Strike Switch Press button 1, open closed door

Hinge Switch (Proximity) Press button 2, open closed door

Press the (P) Button Scroll to “Diag Output”

Press the (P) Button

Press and hold # button to test Component Function Test:

1 S/S Heat Relay 2Fan High

Scroll to “Programming”

3 Fan Low 4 Fan Forward (CCW) 5 Fan Reverse (CW) 6 Cooling Fan (Blows in) 7 Drain Valve Actuator (N.C.) 8 Quench Solenoid

9 Chemical Pump 10 Recirc Pump 11 Door Lock Motor 12 Mechanical Contactor (N.C.) 13 Water Fill Solenoid 14 Recirc Solenoid

Press the (P) Button

Scroll to exit

FAST ~ VVC for XL-50EC Oven

Second Level programming

Press and hold the

(P) Button for 3 seconds

Press the (P) Button Code 2222

Press the (P) Button Scroll to “Clean Cycle”

Press the (P) Button

Corresponding Name Press ▼ to scroll through times

Pre-Rinse Time 3:00

Fill Time 1:45

Chemical Time 3:45

Wash Time 45:00 Rinse Time 5:00

Pump Fill Time 2:30

Purge Time 2:00

Scroll to programming

Final Rinse Time 10:00

Flush Time 2:00

Drain Time 3:00

Set Temp 180F

Fan Speed Very High

Fan Reverse Time 3:00

Soil Shield NO

Full Bottle Time 17:12

To exit programming Press ▼ to “EXIT”

Press the (P) Button

NOTE: Fill times are based on 20 PSI inlet flow pressure

J6-Pin #1

J2-

Pin #1

XL-50EC Relay Board – Rear View

Call outs of “J” connectors and #1 pin location

J3-Pin #1

J20-Pin #1

J14-Pin #1

J1-Pin #1

J18-Pin #1

J7-Pin #1

J19-Pin #1

J11-Pin #1

J41-Pin #1

Voltage

XL-50EC - Trouble shooting test points

Test Points on Relay Board

~ Using the control diagnostic outputs ~

Key # Output Components

1 6 7 8

9 13 12

10

14

S/S Heat Relay

Cooling Fan

Drain Actuator

Quench Solenoid

Chemical Pump

Fill (Spritzer) Solenoid

*** Mech. Contactor

Recirc Pump

Recirc Solenoid

Connector J18-Pin #5(Empty) Connector J20-Pin #2-OR Connector J18-Pin #5(Empty) Connector J3-Pin#11-GY Connector J18-Pin #5(Empty) Connector J18-Pin #7-OR Connector J18-Pin #5(Empty) Connector J2-Pin #6-OR Connector J18-Pin #5(Empty) Connector J2-Pin #8-V Connector J18-Pin #5(Empty) Connector J18- Pin#3-BL Connector J18-Pin #5(Empty) Connector J6-Pin #5-OR

Terminal #12, 7+8-WH on rear

Black lead Red Lead

24 volt transformer

Connector J6- Pin #8-V

Connector J3-Pin #6-Y

*** NOTE: Component is normally energized, de-energizes during testing

AC + DC

24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC

24 VAC

Key # Motor Inverter Drive

Fan High Speed (75Hz)

2

Fan Low Speed (60Hz)

3

4

5

Fan Forward (45Hz)

Fan Reverse (45Hz) Connector

Connector J11-Pin #1-BK

Connector

Black lead Red Lead

Connector J2-Pin#9-GY

Connector J2-Pin#10-GY

Connector J2-Pin#9-GY

Connector J2-Pin#10-GY

Connector J2-Pin#9-GY

J11-Pin #1-BK

Connector J2-Pin#10-GY Connector J2-Pin#11-GY Connector J2-Pin#12-GY

Connector J2-Pin#9-GY Connector J2-Pin#10-GY Connector J2-Pin#11-GY Connector J2-Pin#12-GY

AC + DC

23 VDC

0.0 VDC

0.0 VDC 23 VDC 23 VDC 23 VDC

0.0 VDC 23 VDC 23 VDC 23 VDC 23 VDC

0.0 VDC

NOTE: Logic for motor control connects return circuit. "0" volts means circuit completed

Control Transformer

Convection Motor Windings

Connection Motor Windings

Component Resistance Readings

Part Name Ohms Part Name Ohms

24VDC Power Supply, Across +V & -V

(Unwired DC Voltage)

24VDC Power Supply, Across L & N

(Unwired Line Voltage)

Chemical Pump Motor 23.9 Cooling Fan 3.7

Component Transformer- Jumper

Removed Primary contacts 1 & 2

Component Transformer- Jumper

Removed Primary contacts 6 & 5

Component Transformer- with Jumper

Primary contacts 6 & 1

Component Transformer with Jumper

Secondary contacts 7 & 12

Element, 208V (Single element) 10.8 Liquid Detection Sensor 20

326

0.6

6.4 Door Lock Motor 6

5.5 Hitachi (Brown to Blue) 2.5

11.4 Hitachi (Brown to Black) 27.65

0.3 Hitachi (Blue to Black) 27.65

(Primary)

(Secondary)

62.2

1.2

Element, 240V (Single element) 14.5 Mechanical Contactor Coil 73.4

Quench Solenoid Valve 178

Re-Circ Solenoid Valve 2.3

Recirculation Pump 1.5

Water Solenoid Valve 178 Solid State Heat Relay (SSR) 5.12

Note: Readings may vary some based on meter capability and accuracy

Blue to Black

Brown to Black

Brown to Blue

6.2

FAST ~ VVC for XL-50EC Oven

Error State Controller Message Error Cause

The controller cannot detect the input

Fan Error Detection "FAN ERROR"

Fan Error Detection

in clean/delime

cycles

Clean/Delime Error

“WARNING-DO NOT OPEN

DOOR” “DO NOT USE OVEN”

"FAN ERROR"

“CALL FOR SERVICE”

signal from the "at speed" relay for

15sec, indicating the fan is in fact ON. VFD has sensed fan issues. Most

likely the drain has malfunctioned and cavity is full of water and chemical.

If a second fan errors occur during the clean/delime cycle.

Strike Switch Error

SSR Heat Sink

Error

Fan Drive Error

Detection

High Limit Error "HIGH LIMIT ERROR"

Door Lock Error

In clean/Delime

cycles

High Limit Temp

Error-Cavity

High Temp Error-

Cavity

Inverter Drive

Probe Error

Cavity Probe Error

Cook Heat Fail

Detection

"HEAT SINK ERROR"

"FAN DRIVE ERROR"

"ERROR-DOOR NOT LOCKED"

In Idle: "HI LIMIT TEMP"

In Cook: "FAIL-HI LIMIT TEMP"

In Cook: "FAIL-HI TEMP"

"BAD DRIVE PROBECALL FOR SERVICE"

In Idle: "PROBE OPEN/SHORT"

In Cook: "FAIL-PROBE

"ERROR“

“STRIKE SWITCH"

In Idle: "HI TEMP"

OPEN/SHORT"

"FAIL-COOK HEAT"

If the "Hinge" switch is open, but the "Strike" switch remains closed.

The controller cannot detect the input signal from the SSR thermal switch.

The controller cannot detect the Fan Drive input for 10 seconds.

If the controller sees an input from the

mech contactor for more than 2 sec.

Controller cannot detect the door lock input for 5 seconds while in the CLEAN or DELIME mode. Top microswitch on door lock not fully engaged or bad.

If the cavity temperature (from the cavity probe) is greater than 565°F.

If the cavity temp (from the cavity probe) is greater than the set temp of the first profile selected +150°F.

If the probe in the heat sink of the VFDrive (Hitachi Drive Probe) opens or shorted.

If the cavity probe is open or shorted.

If the cavity temperature doesn't rise 2°F within 5 min.

Communication

Error

Recovery Detection

NOTE: Faults that occur during clean or delime cycles must be cleared with the “HELP” code, or 4357.

In Idle: "COMM ERROR

CALL FOR SERVICE"

In Cook: "FAIL-COMM ERROR"

"HEAT ERROR

CALL FOR SERVICE"

\\bgtstore\public1\Service\Customers\K F C\Grill Chicken Program\Self-Cleaning Ovens\Round 2 Ovens\Technical Info\Error Codes KFC Oven.doc

If the controller looses communication with the relay board.

If the cavity temp doesn't make it from 150°F to 300°F within 5 mins.

BLODGETT XL50EC - KFC - Motor Drive Parameters

PRESS PRESS

FUNC d001 STR to save b005

DISPLAY DISPLAY

▼ keep pushing until A--- ▲ once b012

FUNC once A001 FUNC once FUNC once

▼ keep pushing until 4. 0 0

▲ once 02 STR to save b012

STR to save A001

▲ once b022

▲ once A002 FUNC once

FUNC once

▼ keep pushing until 3. 6 0

▲ keep pushing until 01 STR to save b022

STR once A002

▲ once b083

▲ keep pushing until A020 FUNC once

FUNC once

▲ keep pushing until 10.0

▲ push + hold until 45.0 STR to save b083

STR to save A020

▲ keep pushing until C001

▲ once A021 FUNC once

FUNC once

▼ keep pushing until 00

▲ push + hold until 60.0 STR to save C001

STR to save A021

▲ once C002

▲ once A022 FUNC once

FUNC once

▼ keep pushing until 01

▲ push + hold until 75.0 STR once C002

STR to save A022

▲ once C003

▲ once A023 FUNC once

FUNC once

▲ keep pushing until 02

▲ push + hold until 95.0 STR once C003

STR to save A023

▲ once C004

▲ keep pushing until A051 FUNC once

FUNC once

▲ keep pushing until 03

▲ once 01 STR to save C004

STR to save A051

▲ once C005

▲ once A052 FUNC once

FUNC once

▼ keep pushing until 12

▲ push + hold until 40.0 STR to save C005

STR to save A052

▲ keep pushing until C015

▲ twice A054 FUNC once

FUNC once

▼ keep pushing until 01

▲ push + hold until 60 STR once C015

STR to save A054

▲ keep pushing until C022

▲ once A055 FUNC once

FUNC once

▼ keep pushing until 05

▲ push + hold until 5. 0 STR once C022

STR to save A055

▲ push + hold until b01 FUNC

FUNC once

▲ twice 02 STR

STR to save b001

▲ once b002 FUNC

FUNC once

▲ push + hold until 25.0 STR

STR to save b002

▲ keep pushing until b005 FUNC

FUNC once STR to save 0. 0

▲ keep pushing until F002

once

▼ keep pushing until 2. 0 0

▲

once once once

F002 F003

▼ keep pushing until 5. 0 0

once

F003

▲ keep pushing until d001

Programming Complete

0. 0

▼ keep pushing until 01

BLODGETT XL50EC - KFC - Motor Drive Parameters

Checking last three stored error codes

FUNC d001

▲ keep pushing until d081

FUNC once FUNC once d081

▲ keep pushing until d082

FUNC once FUNC once d082

▲ keep pushing until d083

FUNC once FUNC once d083

▼ keep pushing until d001

FUNC

Normal operation

Clearing stored error codes

FUNC d001

▼ keep pushing until b---

FUNC

▲ keep pushing until b084

FUNC FUNC

Press "STOP", "FUNC", ▲ and ▼ keys and continue to hold all 4 for three seconds. Display will show "D000", then "HC", then screen will scroll and stop at "d001"

FUNC 0. 0

STR

once b001

once 00 once b084

to save

Last error code will be displayed

2nd to last error code will be displayed

3rd to last error code will be displayed

0. 0

Motor Inverter Error Codes

E_01 Over current event while at constant speed E_02 Over current event during deceleration E_03 Over current event during acceleration E_04 Over current event during other conditions E_05 Overload protection E_07 Over-voltage protection E_08 EEPROM error E_09 Under-voltage error E_11 CPU error E_22 CPU error E_12 External trip E_13 USP E_14 Groung Fault E_15 Input over-voltage E_21 Inverter thermal trip E_35 Thermistor

Sequence of Operation for KFC, XL-50EC oven

Mode Switch in the “OFF” position

You will have AC voltage at:

• The 50 AMP Fuse Holder

• The Line Side of the (K1) Mech. Contactor

• Circuit Breaker (CB1) on the front control panel

• 24 VDC power supply power light on

• The large transformer (T2) on the left hand side in the back of the oven

• The small transformer (T1) on the left hand side in the front of the oven

• The Relay board Input J7-1 & 3 24 VAC Voltage

• The Relay board Input J19-2 & 3 24 VAC Voltage

• The VFD Computer Control Input 15 pin connector J1-1 & 3 24 VAC

Voltage

• Mode Switch pins 1 & 3 Line Voltage

You will have DC voltage at:

• Positive Red DC voltage (+24VDC) on the following;

• Relay board J-19-1

• TB-4 on back panel 9 down from top right RD 24

• Proximity Switch

• Door Switch (SW1)

• SSR Heat Sink

• Mode Switch, in on pin 6, out of pin 5 to the relay board J1-8 (closed in

the OFF position)

• Door Lock Control Board

• Auxiliary contactor mech. (K1 aux.) in A-1 out A-2 to Relay Board J11-3

• Negative Black DC voltage (-24VDC RTN)

• Relay Board J19-4

• Relay Board J11-1

• Door Lock Control Board

• A-2 Coil of the Mechanical Contactor

• The Drain Actuator

• With your Meter Leads:

• Black on J18-6 and Red on J18-7

• You will have Negative -24vdc in the Closed position

• You will have Positive +24vdc in the Open position

Sequence of Operation for KFC, XL-50EC oven

Mode Switch in the “ON” position

• The Relay Board Verifies the Following with DC voltage:

• The Mode Switch contacts opens between 5 & 6 DC voltage is

removed from the Relay Board J11-8

• The Door Switch (SW1) is closed sending DC voltage to J11-5

• The Proximity Switch is closed sending DC voltage to J11-2

• With the Door Lock Switch Open there is no DC voltage present from

the Door Lock Control to the Relay Board on J11-7

• The SSR Heat-Sink is Closed sending DC voltage to J11-6

• Dc voltage supplied out of the RELAY BOARD J6-5 through the CAVITY

HIGH LIMIT (SW4) to the COIL OF THE MECHANICAL CONTACTOR (K1)

• The Contacts of the Mechanical Contactor (K1) close and opens the contacts of the Auxiliary contactor mech. (K1 aux.) removing DC voltage from the Relay Board J11-3

• The contacts 1 & 2 and 3 & 4 close on the Mode Switch and send AC voltage to L-1 and L-3 of the Hitachi Motor Inverter Drive.

• The Relay Board sends DC voltage out J-2 pins 9 & 10 to the Hitachi

Inverter pins 3 & 4

• The Hitachi Inverter speeds up to 75 Hertz

• The Hitachi Inverter Verifies DC voltage from pins 11 & L back to the

Relay Board on J11- 4 & 1 Showing the motor is running

• The Relay Board sends DC voltage out of J20-2 & 3 to the Control Circuit of the SSR powering the Elements

• The controller displays “Preheat” and starts to heat up to 450 degrees

• When the oven reach’s a temp of 450 degrees the display will count

down from 30 minutes to heat soak the cavity.

• When the 30 minute heat soak counts down the display will read “Load”

Set Program:

• The Relay Board sends DC voltage from J2- 9 & 10 to the Hitachi Inverter 3 & 4 and the motors speeds up to 95 Hertz

• The motor will reverse directions every 7 minutes by switching DC voltage from the Relay Board J2-11 To Pin 1 on the Hitachi for forward and J2-12 to pin 2 on the Hitachi for reverse

Sequence of Operation for KFC, XL-50EC oven

Clean Cycle

• Steam Cycle

• +24vdc is powered out of J18-3 through the TB4-1 on the backpack

to the water Spritzer solenoid

• The water will cycle 1 second ON every 20 seconds from 450 deg to

300 deg

• Then the water will cycle 2 seconds ON every 20 seconds from 300

deg to 200 deg

• Prerinse 3:00

• Drain Opens

• +24vdc is powered out of J18-3 through the TB4-1 on the backpack

to the water Spritzer solenoid

• +24vdc is powered out of J2-6 through the TB4-2 on the backpack to

the quench solenoid

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

• Fill Time 1:45

• Drain Closed

• +24vdc is powered out of J18-3 through the TB4-1 on the backpack

to the water Spritzer solenoid

• Chemical Time 3:45

• Drain Closed

• +24vdc is powered out of J2-8 through the TB5-5 on the backpack to

the chemical pump

• Wash Time 45:00

• Drain Closed

• +24AC is powered out of J6-8 through the TB5-1 on the backpack to

the re-circulation pump

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

Sequence of Operation for KFC, XL-50EC oven

• Rinse Time 5:00

• Drain Open

• +24vdc is powered out of J18-3 through the TB4-1 on the backpack

to the water Spritzer solenoid

• +24vdc is powered out of J2-6 through the TB4-2 on the backpack to

the quench solenoid

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

• Pump Fill Time 2:30

• Drain Closed

• +24vdc is powered out of J18-3 through the TB4-1 on the backpack

to the water Spritzer solenoid

• +24vdc is powered out of J2-6 through the TB4-2 on the backpack to

the quench solenoid

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

• Purge Time 2:00

• Drain Closed

• +24AC is powered out of J6-8 through the TB5-1 on the backpack to

the re-circulation pump

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

• Final Rinse 10:00

• Drain Open

• +24vdc is powered out of J18-3 through the TB4-1 on the backpack

to the water Spritzer solenoid

• +24vdc is powered out of J2-6 through the TB4-2 on the backpack to

the quench solenoid

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

Sequence of Operation for KFC, XL-50EC oven

• Flush Time 2:00

• Drain Open

• +24vdc is powered out of J2-6 through the TB4-2 on the backpack to

the quench solenoid

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

• Final Drain Time 3:00

• Drain Open

• +24vdc is powered out of J2-6 through the TB4-2 on the backpack to

the quench solenoid

• +24AC is powered out of J3-6 through the TB5-3 on the backpack to

the re-circulation solenoid

FAST ~ VVC for XL-50EC Oven

Clean Cycle Programming

Press the clean Button “Clean”

Press the (P) Button “Is the Cavity clear of Debris” Press the (P) Button “Is the Drain Hose Connected” Press the (P) Button “Steam Cycle”

Water Spritz for 1 second every 20 seconds From 450°F to 300°F Water Spritz for 2 second every 20 seconds From 300°F to 200°F

Sequence Time Count Down Time

Pre-Rinse Time 3:00 1:20

Fill Time 1:45 1:17

Chemical Time 3:45 1:16

Wash Time 45:00 1:12 Rinse Time 5:00 0:25

Pump Fill Time 2:30 0:20

Purge Time 2:00 0:17

Final Rinse Time 10:00 0:15

Flush Time 2:00 0:05

Drain Time 3:00 0:03

Maintains Set Temp 180F

Turn Oven Off Wipe Cavity Clean

NOTE: Fill times are based on 20 PSI inlet flow pressure

NOTES: ___________________________________________________________________

___________________________________________________________________________

Blodgett XCEL-50EC Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual