Hobart OV500G2 ML- 132498, OV500E2 ML- 132499, OV500E1 ML- 132501, OV500G1 ML- 132500 User Manual

SERVICE MANUAL

BAXTER OV500 SERIES

RACK OVEN

OV500G2 MODEL SHOWN

This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified.

This manual is not intended to be all encompassing. If you have not attended a Hobart Service School for this product, you should read, in its entirety, the repair procedure you wish to perform to determine if you have the necessary tools, instruments and skills required to perform the procedure. Procedures for which you do not have the necessary tools, instruments and skills should be performed by a trained Hobart Service Technician.

OV500G1

OV500G2

OV500E1

OV500E2

ML- 132500

ML- 132498

ML- 132501

ML- 132499

The reproduction, transfer, sale or other use of this Manual, without the express written consent of Hobart, is prohibited.

This manual has been provided to you by ITW Food Equipment Group LLC ("ITW FEG") without charge and remains the property of ITW FEG, and by accepting this manual you agree that you will return it to ITW FEG promptly upon its request at any time in the future.

A product of BAXTER ORTING, WA 98360-9236

F25361 (January 2010)

OV500 SERIES RACK OVEN

TABLE OF CONTENTS

GENERAL ................................................................................3

Introduction ............................................................................ 3

Location .............................................................................. 3

Operation ............................................................................. 3

Cleaning .............................................................................. 3

Lubrication ............................................................................ 3

Control Location ........................................................................ 4

Tools................................................................................. 4

OV500G1 Gas Oven Specifications ......................................................... 5

OV500G2 Gas Oven Specifications ......................................................... 7

OV500E1 Electric Oven Specifications ...................................................... 9

OV500E2 Electric Oven Specifications ..................................................... 11

REMOVAL AND REPLACEMENT OF PARTS ................................................... 13

Steam Panel .......................................................................... 13

Rack Rotator Assembly ................................................................. 13

Rotator Motor ......................................................................... 15

Actuator ............................................................................. 16

Convection Blower/motor ................................................................ 17

Gas Valve ............................................................................ 18

Gas Manifold / Orifices .................................................................. 18

Heat Exchanger .......................................................................19

Ignition Module ........................................................................ 21

Controller ............................................................................21

High Limit Switch ...................................................................... 22

Draft Inducer Motor ..................................................................... 23

Pressure Switches ..................................................................... 24

Oven Cavity Vent Motor ................................................................. 24

Oven Cavity Vent Switch ................................................................ 25

Thermostat (Back Up System Only) ........................................................ 25

Temperature Probe .................................................................... 26

Eprom Replacement .................................................................... 27

Door Swing Change .................................................................... 27

SERVICE PROCEDURES AND ADJUSTMENTS................................................. 28

Controller Input/output Status Diagnostic .................................................... 28

Ignition Module Self Diagnostics .......................................................... 29

Temperature Probe Test ................................................................ 29

Controller Temperature Calibration ........................................................ 29

Controller Settings ..................................................................... 29

Burner Adjustments .................................................................... 34

Flame Sense Location .................................................................. 38

Flame Sense Current Test ............................................................... 38

Combustion Analysis ................................................................... 38

F25361 (January 2010)

Page 2 of 60

OV500 SERIES RACK OVEN

Draft Inducer Test ...................................................................... 39

Hood Vent Draft Pressure Test ........................................................... 40

Door Adjustment ....................................................................... 41

Door Switch Adjustment ................................................................. 41

Rack Position Switch Adjustment .......................................................... 42

Rack Position Adjustment................................................................ 42

Rack Height Adjustment .................................................................42

Actuator Lubrication .................................................................... 44

Air and Angle Shutter Adjustments ......................................................... 45

ELECTRICAL OPERATION .................................................................. 47

Component Function ................................................................... 47

Oven Sequence of Operation ............................................................. 49

Burner Sequence of Operation ............................................................ 50

Component Location ................................................................... 52

Wiring Diagrams .......................................................................53

OVEN TROUBLESHOOTING ................................................................ 56

IGNITION MODULE TROUBLESHOOTING ..................................................... 58

BURNER TROUBLESHOOTING .............................................................. 59

Page 3 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - GENERAL

GENERAL

INTRODUCTION

General

OV500G1 & OV500E1 rack ovens hold one single rack and OV500G2 & OV500E2 rack ovens hold two single racks or one double rack.

Oven features:

• Powered rack lift with high temperature bearings and a clutch rotating system designed to stop the rack in the event of a jam without damage to the rotation motor or losing rack alignment.

• Digital programmable controller with optional backup control, flush flooring, and field reversible bake chamber door.

All of the information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing.

Heating

The rack oven reaches baking temperatures of 350EF in approximately 20 minutes; however, a 30 minute preheat is recommended to fully heat the steam generator.

composite bearings on power rack lift shaft - no lubrication required.

CONTROL LOCATION

Steaming System

Standard on all rack ovens, is a self-contained spherical cast steam system providing excellent steaming conditions.

LOCATION

Refer to the Installation Instructions for specific location requirements.

OPERATION

Refer to the Operation Manual for specific operating instructions.

CLEANING

Refer to the Operation Manual for specific cleaning instructions.

LUBRICATION

• Circulation motor upper and lower bearings, rotator chain, and lift motor spherical bearing lubricate with high temperature grease every 6 months.

• Lift actuator.

• Oven has high temperature self-lubricating

TOOLS

• Standard set of hand tools

• Oven pressure panel feeler gauge Part No. 011M5689-1 Do not discard feeler gauge

• Multi-Meter that measures 200 micro amps Grainger No. 6MR09

• Clamp meter Part No. 00-541069 Grainger No. 1ND81 or equivalent

• Temperature tester (thermocouple type) with 10' probe

• Inclined manometer - Dwyer Cat. #1227 or equivalent

• Manometer U tube Part No. TL-84908 or equivalent

• Grounding kit - Static Control Kit Grainger No. 4KK44

• Jeweler's screw driver set - Sears No. 00930448000 or equivalent

• Combustion analyzer Bacharach Fyrite Pro 125 Bacharach model# 24-8105 or Fyrite "Insight" Model 24-8251(Order from Bakery Support)

• BACHARACH gas leak detector (Order from Bakery Support)

F25361 (January 2010)

Page 4 of 60

OV500 SERIES RACK OVEN - GENERAL

OV500G1 GAS OVEN

SPECIFICATIONS

â WATER:

1/2" NPT, 30-75 PSI cold water required, customer to install in-line filter, shut off valve and line strainer.

Ï DRAIN:

6 1/4" (front) or 7" (rear) connection A.F.F. (See notes). Route to air-gap drain. Do not slope drain upwards. Plug the drain connection that is not in use.

Rear Drain: 1/2" NPTF Front Drain: 1/2" NPTF

Ð POWER:

Two supplies required. 120/60/1 20 AMP dedicated circuit required and one

of the following voltage options.

Voltage Full Load AMPS

208 - 240/60/1 8.8 - 7.6 AMPS 208 - 240/60/3 5.0 - 4.4 AMPS 440 - 480/60/3 2.4 - 2.2 AMPS

Ñ GAS:

Natural Gas (N.G.) 3/4" NPT, W.C.N.G. (N.G. rated 1025 BTU/CU. FT.

SP. GR. 1.00) Liquified Propane Gas (L.P.G.) 3/4" NPT, W.C.L.P.G. (L.P.G. rated 2440

BTU/CU.FT., SP. GR. 1.52)

Natural Gas Liquified Propane Gas

BTU/HR 180,000 180,000

W.C. 5.0" - 10.0" 12.0" - 14.0"

Ò HOOD VENT:

8" DIA connection collar. Customer to supply duct and ventilator fan per state and local codes. Air proving switch factory installed & integrated with burner system operation. Oven provided relay with max. 10 amp 1/2 H.P. @ 120V output for fan operation. If larger, use oven relay to control additional separately powered contactor / relay for hood fan. Chamber vents are factory ducted to this integral hood. 690 CFM required, 0.6" W.C. static pressure drop through hood. Hood is UL710 Listed when grease filters are installed. Type B gas vent can be used except when bake products are grease laden.

NOTES:

1. A.F.F.: Above finished floor.

2. Customer responsible to finish and install all utilities to and from oven.

3. All services must comply with all Federal, State and Local codes.

4. To reduce the risk of fire, the appliance is to be installed on non-combustible surface only, with no combustible material within 18 inches above the appliance. The appliance is to be mounted on floors of non-combustible construction with noncombustible flooring and surface finish and with no combustible material against the underside, or on non-combustible slabs or arches having no combustible material against the underside. Such construction shall in all cases extend not less than 12 inches beyond the equipment on all sides.

5. The floor must be of non-combustible material, and must be level with surrounding area with a maximum slope of 1/8" per foot up to 3/4" maximum in all directions. Floor anchors require a minimum 1" thick solid floor substrate.

6. Oven is UL/C-UL classified and CSA (AGA/CGA) approved for 0" clearance on the side and rear walls. Unit requires 1" to 4" clearance for rear drain connection.

7. Top of oven requires a minimum of 24" for service accessibility.

8. Customer responsible to install flue piping. Flue must be vented outside of building.

9. Manufacturer reserves the right to make changes in sizes and specifications.

Export Ratings

â WATER:

1/2" NPT, 2.1-5.2 Bar cold water required, customer to install in-line filter, shut off valve and line strainer. Flow rate of 8 l/min..

Ð POWER:

Single supply connection provided: 200V/50-60HZ/3PH/5.3A OR 380415V/50HZ/3PH/2.8-2.5 circuit required.

1 kVA transformer supplied for control circuit operation voltage of 110V. This is a multifunction transformer, so output voltage should be verified before operation. Some wiring may be required to obtain proper output voltage.

Oven fan (1.1kW) 200V/50-60Hz/3ph/5.3A or 380415V/50Hz/3ph/ 2.8 - 2.5A.

ÑGAS:

Natural Gas (N.G.) 3/4" NPT (N.G. Rated 38.2Mj/m3 or 9120 Kcal/m3

SP Gr 1.00) Liquefied Propane Gas (LPG) 3/4" NPT (LPG Rated 90.9Mj/m3 or 21710 Kcal/m3

SP Gr 1.52)

Natural Gas Liquified Propane Gas

kCAL/HR 45,400 45,400

cm W.C. 12.7 - 25.4 30.5 - 35.6

Mj/HR 190 190

kPa 1.25 - 2.50 3.00 - 3.50

NOTE: Pressure not to exceed 35.6 cm W.C. or 3.5 kPa

Ò HOOD VENT:

20.3 cm DIA. Connection collar. Customer is to supply duct and ventilator fan per federal and/or local codes. Chamber vent (steam) and combustion exhaust are discharged into the hood. An air proving switch is factory installed and integrated with burner system operation. If proper ventilation is not provided, burner will not operate. Oven provides a relay to activate a customer supplied and powered contactor/relay, so that when oven is powered up external fan will operate. The hood requires a minimum of 19.5 m

3

/min for safe operation. For fan calculation purposes you should assume 0.15 kPa resistance through the hood. Grease filters (optional) may be installed in the hood instead of standard baffle.

F25361 (January 2010)Page 5 of 60

OV500 SERIES RACK OVEN - GENERAL

F25361 (January 2010) Page 6 of 60

OV500 SERIES RACK OVEN - GENERAL

OV500G2 GAS OVEN

SPECIFICATIONS

â WATER:

1/2" NPT, 30-75 PSI cold water required, customer to install in-line filter, shut off valve and line strainer.

Ï DRAIN:

2 3/4" (front) or 5 1/2" (rear) connection A.F.F. (See notes). Route to air-gap drain. Do not slope drain upwards. Plug the drain connection that is not in use. Kit provided to extend drain to either side of oven. Rear Drain: 3/4" NPTF Front Drain: 3/8" NPTF

Ð POWER:

Two supplies required. 120/60/1 20 AMP dedicated circuit required and one of the following voltage options.

Voltage Full Load AMPS

208 - 240/60/1 8.8 - 7.6 AMPS

208-240/60/3 5.0 - 4.4 AMPS

440 - 480/60/3 2.4 - 2.2 AMPS

Ñ GAS:

Natural Gas (N.G.) 1 1/4" NPT, W.C.N.G. (N.G. rated 1025 BTU/CU. FT. SP. GR. 1.00) Liquified Propane Gas (L.P.G.) 1 1/4" NPT, W.C.L.P.G. (L.P.G. rated 2440 BTU/CU.FT., SP. GR. 1.52)

Natural Gas Liquified Propane Gas

BTU/HR 300,000 350,000 300,000 350,000

W.C. 5.0 -14.0" 6.0 - 14.0" 10.0" - 14.0" 12.0 - 14.0"

Ò HOOD VENT:

10" DIA connection collar. Air proving switch factory installed & integrated with burner system operation. Oven provided rely with max. 10 amp 1/2 H.P. @ 120V output for fan operation. If larger, use oven relay to control additional separately powered contactor / relay for hood fan. Customer to supply duct and ventilator fan per state and local codes. Chamber vents are factory ducted to this integral hood. 900 CFM required, 0.6" W.C. static pressure drop through hood. Hood is UL710 Listed when grease filters are installed. Type B gas vent can be used except when bake products are grease laden.