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

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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

/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.

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.

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/5060Hz/3ph/5.3A or 380-415V/50Hz/3ph/ 2.8 - 2.5A circuit required.

Oven fan (1.1kW) operates @ 380-415V 3ph 50 Hz

2.4- 2.2A

Ñ GAS: 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 75,600 75,600

cm W.C. 12.7 - 25.4 30.5 - 35.6

Mj/HR 317 317

kPa 1.25 - 3.50 3.00 - 3.50

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

Ò HOOD VENT:

25.4 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 25.5 m

/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 7 of 60

OV500 SERIES RACK OVEN - GENERAL

F25361 (January 2010) Page 8 of 60

OV500 SERIES RACK OVEN - GENERAL

OV500E1 ELECTRIC 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. Heating Circuit: KW rating in following chart per

supply voltage. Blower Motor: 1 1/2 H.P.

Voltage Full Load AMPS Heaters Rating

208/60/3 100 AMPS 34 KW 208 - 240/60/3 76 - 87 AMPS 26 - 34 KW 440 - 480/60/3 40 - 43 AMPS 29 - 34 KW

Ñ HOOD VENT:

8" DIA connection collar. Customer to supply duct and ventilator fan per state and local codes. 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.

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/5060Hz/3ph/5.3A or 380-415V/50Hz/3ph circuit required.

Oven fan (1.1kW) operates @ 380-415V 3ph 50 Hz

2.4- 2.2A

Voltage Full Load AMPS Heaters Rating

200/50 - 60/3 74 AMPS 24 kW

380 - 415/50/3 46 - 50 AMPS 29 - 34 kW

Ñ 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. 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 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.

/min for safe operation. For fan

/ 2.8 - 2.5A

F25361 (January 2010)Page 9 of 60

OV500 SERIES RACK OVEN - GENERAL

F25361 (January 2010) Page 10 of 60

OV500 SERIES RACK OVEN - GENERAL

OV500E2 ELECTRIC 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:

Rear Drain: 3/4" NPTF Front Drain: 3/8" NPTF

Ð ELECTRICAL:

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

of the following voltage options. Heating Circuit: KW rating in following chart per

supply voltage. Blower Motor: 1 1/2 H.P.

Voltage Full Load AMPS Heaters Rating

208/60/3 146.4 AMPS 51.3 KW 208-240/60/3 111.2 - 127.2 AMPS 38.5 - 51.3KW 440-480/60/3 59.1 - 64.1 AMPS 43 - 51.3 KW

Ñ HOOD VENT:

10"DIA connection collar. Customer to supply duct and ventilator fan per state and local codes. 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. 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.

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.

6. Oven is UL/C-UL classified and CSA (AGA/CGA) approved for 0" clearance on the side and rear walls. Unit required 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 ELECTRICAL:

Single supply connection provided: 200V/5060Hz/3ph/5.3A or 380-415V/50Hz/3ph circuit required.

Oven fan (1.1kW) operates @ 380-415V 3ph 50 Hz

2.4- 2.2A

Voltage Full Load AMPS Heaters Rating

200/50 - 60/3 108 AMPS 36 kW

380 - 415/50/3 68 - 73 AMPS 43 - 51 kW

Ñ HOOD VENT:

25.4 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. 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 25.5 m 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.

/min for safe operation. For fan

/ 2.8 - 2.5A

F25361 (January 2010)Page 11 of 60

OV500 SERIES RACK OVEN - GENERAL

F25361 (January 2010) Page 12 of 60

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

STEAM PANEL

NOTE: Hand tighten only, do not use power tools

when installing panel screws.

1. Remove screws securing steam panel to baking compartment rear wall (through access holes).

4. Reverse the procedure to install.

RACK ROTATOR ASSEMBLY

2. Remove screws securing steam panel to left baking compartment wall.

Removal

1. Remove rack carrier. A. Support rack carrier. B. Loosen set screws. C. Remove snap ring from end of shaft. D. Lower carrier to remove.

2. Remove rotator and lift assembly cover.

3. Remove actuator for rack up and down switches.

4. Disconnect lead wires from rack pointer switches, capacitor, and rotator motor.

3. Remove screws securing steam panel to baking compartment ceiling (left rear corner) Reverse the procedure to install.

F25361 (January 2010)Page 13 of 60

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

5. Lift rack rotator assembly, which will include the rack lift shaft, from rack lift assembly.

NOTE: Removal of actuator housing bolt may be necessary for rack rotator assembly removal.

Disassembly

1. Loosen set screw and remove rack pointer from shaft.

2. Loosen set screws securing the set collar to rotator shaft.

3. Remove the retaining ring from groove in rotator shaft.

NOTE: Remove retaining ring from shaft as you are removing shaft from assembly.

4. Pull rotator shaft from rotator assembly set collar, clutch disk, drive sprocket, thrush washer, flanged bearing and male half of spherical bearing.

lift arm only if replacing.

Assembly

1. Install female half of spherical bearing into the lift arm if removed.

2. Apply high temperature grease to female half of spherical bearing. Spread grease evenly across bearing surface.

3. Install flange bushing into rotator assembly.

4. Install male half of spherical bearing, with taper to mate with female half, onto flanged bushing.

5. Insert rotator shaft into flange bushing from bottom of rotator assembly and install thrust washer.

5. Remove rotator drive chain from sprocket teeth.

6. Remove flange bushing from rotator bracket.

7. Remove female half of spherical bearing from

F25361 (January 2010)

Page 14 of 60

6. Install drive chain around drive sprocket.

7. Continue to push the shaft through the rotator assembly. As you do, install drive sprocket onto shaft (tooth side towards thrush washer) before the shaft is beyond the support bracket.

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

8. Install clutch disk.

9. Install set collar with counter bore edge towards clutch and slide split ring onto shaft.

A. Position set collar so set screw can be

secured onto flat of rack lift shaft.

10. Install retaining ring into groove of rotator shaft.

SERVICE PROCEDURES AND ADJUSTMENTS.

19. Check for proper operation.

ROTATOR MOTOR

Removal

1. Block the rack rotator assembly in a position to access the motor mounting bolts and sprocket set screw.

11. Insert rotator shaft through female half of spherical bearing in lift arm.

12. Apply high temperature grease to drive chain.

13. Lower rotator assembly. Rotator shaft will align with bearings in rotator shaft housing.

NOTE: Anti rotation pin on rotator assembly must mate with anti rotation slot in lift arm.

14. If removed earlier, install actuator housing screw and actuator for rack up and down switches.

15. Install rack pointer onto rotator shaft.

16. Install rack carrier.

17. Adjust RACK POINTER as outlined under SERVICE PROCEDURES AND ADJUSTMENTS.

18. Adjust RACK HEIGHT as outlined under

2. Disconnect the rotator motor lead wires.

3. Remove cooling fan from motor.

4. Loosen rotator motor sprocket set screw.

5. Remove rotator motor mounting screws.

6. Lift rotator motor and sprocket will stay in place. F25361 (January 2010)Page 15 of 60

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

Assembly

1. Install rotator motor shaft through rotator assembly and rotator sprocket.

2. Position sprocket onto rotator motor shaft, collar side towards motor.

3. Install rotator motor mounting screws and align sprocket and rotator drive chain. Ensure rotator drive chain is not in a bind.

4. Secure set screw onto motor shaft.

5. Connect rotator motor lead wires.

NOTE: Shaft rotation viewed from top of oven. Clockwise Rotation: Red wire= #20, Black wire=

#53, White/White wires, recommended.

6. Install cooling fan to motor shaft.

7. Remove block from rotator assembly.

8. Check for proper operation.

4. Align bottom actuator arm pin with access hole in side of rack lift assembly beam.

ACTUATOR

1. Block the rack rotator assembly from moving.

2. Disconnect lead wires to actuator motor.

3. Remove top actuator mounting brackets from rack lift assembly.

5. Block rack lift arm to prevent movement.

6. Remove actuator pin from the assembly and remove actuator from rack lift assembly.

7. Make sure replacement actuator is fully retracted. Turn end of actuator arm CCW 12 complete turns.

NOTE: Measure end of actuator arm to bottom of actuator arm housing, measurement should be approximately 2 1/2".

F25361 (January 2010) Page 16 of 60

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

8. Install lower actuator arm pin through lift pin.

1. If necessary, move the gas line out of the way.

2. Shut off water supply line and remove exterior water supply that is within the boundary of blower cover.

3. Disconnect lead wires at motor junction box.

4. Remove motor junction box.

5. Remove probe cover and any existing probes.

6. Remove blower cover supports.

7. Remove blower cover.

9. Position the rack rotator assembly so the top actuator mounting brackets will align with the rotator assembly.

10. Reconnect lead wires.

11. Put oven into use and check for proper operation.

CONVECTION BLOWER/MOTOR

NOTE: To follow this procedure, there must be 24''

of clearance at the top of the oven. If not, the blower wheel must be accessed thru the heat exchanger compartment.

8. Remove insulation.

9. Remove screws from blower mounting assembly and remove complete blower assembly.

10. Loosen set screws in blower wheel hub.

11. Remove retaining ring from shaft.

12. Remove blower wheel from motor shaft.

A. CHECK ALL JOINTS PRIOR TO THE

GAS VALVE (SOLENOID) BEFORE LIGHTING UNIT.

B. CHECK ALL JOINTS AFTER TO THE

GAS VALVE (SOLENOID) AFTER THE UNIT IS LIT.

13. Remove screws securing motor mounting bracket and remove motor assembly.

F25361 (January 2010)Page 17 of 60

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

14. Remove heat slinger and mounting bracket from motor.

4. Reverse procedure to install.

15. Reverse the procedure to install.

GAS VALVE

A. CHECK ALL JOINTS PRIOR TO THE

GAS VALVE (SOLENOID) BEFORE LIGHTING UNIT.

B. CHECK ALL JOINTS AFTER TO THE

GAS VALVE (SOLENOID) AFTER THE UNIT IS LIT.

1. Open control compartment door to gain access to gas manifold assembly.

2. Disconnect the gas supply union fitting from gas manifold assembly.

NOTE: The burner mounts may have to be loosened to allow the gas valve to rotate.

3. Remove the valve from the burner manifold.

5. Check GAS PRESSURE as outlined under SERVICE PROCEDURES AND ADJUSTMENTS.

6. Operate oven and check for proper operation.

GAS MANIFOLD / ORIFICES

A. CHECK ALL JOINTS PRIOR TO THE

GAS VALVE (SOLENOID) BEFORE LIGHTING UNIT.

B. CHECK ALL JOINTS AFTER TO THE

GAS VALVE (SOLENOID) AFTER THE UNIT IS LIT.

1. Open control compartment door to gain access to gas manifold assembly.

2. Disconnect lead wires to gas valve, ignitor and flame sensor.

3. Loosen the gas supply union fitting from gas manifold assembly.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

4. Remove screws securing burner cover to oven.

5. Remove all screws securing gas manifold to burner rack assembly.

A. CHECK ALL JOINTS PRIOR TO THE

GAS VALVE (SOLENOID) BEFORE LIGHTING UNIT.

B. CHECK ALL JOINTS AFTER TO THE

GAS VALVE (SOLENOID) AFTER THE UNIT IS LIT.

1. Open control compartment door to gain access to burner assembly.

2. Remove screws securing burner cover to oven.

6. Disconnect the gas supply union fitting from gas manifold assembly.

7. Pull gas manifold from burner rack assembly.

8. Remove orifice fitting from gas manifold.

NOTE: Note orifice size for natural or L.P.

9. Reverse the procedure to install.

HEAT EXCHANGER

3. Disconnect gas manifold at the union fitting OV500G1 & OV500G2.

4. Disconnect flame sensor lead wire OV500 G1 & OV500G2.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

5. Remove screw securing hot surface ignitor to burner side rack assembly, and pull ignitor out.

6. Remove screws securing burner rack enclosure from oven.

9. Remove steam and exchanger compartment panels.

10. Remove steam ball assemblies.

11. Access draft inducer box on top of oven and remove. Disconnect deflector baffle from hangers above heat exchanger tubes and remove from top of tubes OV500G1 & OV500G2.

12. Lower leveling post to allow room at flue connection and transition chamber.

OV500G2 OVENS

7. Remove burner firing plates OV500G1 & OV500G2.

8. Remove burner angle rack OV500G1 & OV500G2.

OV500G1 OVENS

13. Remove screws securing heat exchanger tube sections from oven. Early modes only have more than 3 screws.

F25361 (January 2010)

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

IGNITION MODULE

1. Open the control compartment door to gain access to ignition module.

2. Remove control box cover.

3. Disconnect lead wires from the ignition module. Note Wire locations or refer to wiring diagram.

4. Remove screws securing ignition module to oven.

5. Reverse the procedure to install.

14. OV500G1 & OV500G2 oven pull rear of heat exchanger into the oven cavity. As you slide rear of heat exchanger, pull heat exchanger to clear baking compartment to free front of heat exchanger.

15. Replace heat exchanger tubes and flue sections as needed.

NOTE: To aid installation of new flue, remove the four exhaust stack retainers.

CONTROLLER

16. Reverse the procedure to install.

Certain components in this system are subject to damage by electrostatic discharge during field repairs. A field service grounding kit is available to prevent damage. The field service grounding kit must be used anytime the control board is handled.

1. Open the control compartment door to gain access to controller.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

2. Remove controller rear cover.

NOTE: When installing ensure stand off spacers are installed behind controller board.

5. Reverse the procedure to install.

6. Verify controller default settings.

7. Check oven for proper operation.

HIGH LIMIT SWITCH

NOTE: On OV500G1 & OV500G2 oven, access high

limit switch at top of oven in service entrance box. On OV500E1 & OV500E2 oven, access high limit switch at the bottom of the control component box.

1. Open control compartment door and remove component box cover.

3. Disconnect all control harness connections. NOTE: Ovens with Kosher operation will have a

connector for the key lock switch to be disconnected.

4. Remove nuts and washers securing controller to controller panel.

2. Disconnect high limit switch lead wires.

3. Remove screws securing high limit switch to component box or service entrance box.

4. Access high limit probe at top of oven.

5. Remove screws securing probe cover.

6. Remove high limit probe fitting from oven and pull high limit out.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

To install:

1. Install high limit in component box or service entrance box.

2. Connect lead wires to high limit.

3. Route high limit capillary tube to top of oven.

4. Mark 12" from end of probe.

DRAFT INDUCER MOTOR

1. Access draft inducer box from top of oven.

2. Remove vacuum line from fitting on draft inducer housing.

3. Remove screws securing draft inducer exhaust duct & collar to hood.

4. Remove screws securing draft inducer cover to box.

5. Insert male compression fitting onto high limit probe.

6. Install female fitting into center probe location.

7. Insert 12" of high limit probe into oven. Ensure that high limit probe goes through both inner and outer walls of oven.

NOTE: Remove vent lid to aid in feeling for high limit probe protruding down through oven.

8. Install first set of 3 spacers into high limit fitting.

9. Pack seal gasket material around probe into high limit fitting.

10. Insert second set of 3 spacers into high limit fitting.

11. Tighten male compression fitting against second set of spacers to secure high limit probe.

5. Remove screws securing draft inducer motor (flex) conduit clamps from oven.

12. Install probe cover.

13. Check oven for proper operation.

6. Remove screws securing draft inducer box and lift box from oven.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

NOTE: Make note of dimension that draft inducer fan blade is located on motor shaft, for installing fan blade on to new motor.

7. Loosen set screw securing fan blade from draft inducer motor shaft.

12. Check for proper operation.

PRESSURE SWITCHES

1. Open control compartment door to gain access to draft inducer vacuum switch and hood vent pressure switch.

2. Disconnect lead wires from appropriate pressure switch.

3. Remove tube from pressure switch.

4. Remove screws securing pressure switch.

8. Disconnect lead wires from draft inducer motor.

9. Remove screws securing draft induce motor from draft inducer box.

10. Reverse the procedure to install.

11. Verify combustion analyses.

5. Reverse the procedure to install.

OVEN CAVITY VENT MOTOR

1. Remove vent lid.

2. Remove screws securing vent motor cover and mounting assembly from vent box.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

3. Disconnect lead wires from vent motor and vent switch.

4. Loosen vent cam set screw and remove cam from shaft.

NOTE: Mark location of cam on vent motor shaft.

OVEN CAVITY VENT SWITCH

1. Remove screws securing vent motor cover from vent motor box.

2. Disconnect lead wires from vent switch.

3. Remove screws securing vent switch from vent bracket.

4. Reverse procedure to install.

NOTE: When installing, position cam on motor shaft to prevent rubbing.

5. Remove screws securing vent motor from vent motor bracket.

THERMOSTAT (BACK UP

SYSTEM ONLY)

1. Open control compartment door to gain access to backup thermostat.

2. Remove component panel cover.

3. Remove screws securing back up system panel from control box.

4. Disconnect lead wires from backup thermostat.

5. Remove screws securing thermostat from backup system panel.

6. Reverse the procedure to install.

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OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

11. Tighten male compression fitting against second set of spacers to secure backup thermostat bulb.

12. Install probe cover.

6. Access the thermostat bulb at top of the oven.

7. Remove screws securing probe cover from oven.

8. Remove compression fitting and remove thermostat bulb.

To install:

1. Install backup thermostat in component panel.

13. Check oven for proper operation.

TEMPERATURE PROBE

1. Access the probe at top of the oven.

2. Remove screws securing probe cover from oven.

3. Remove compression fitting and remove probe from oven.

2. Connect lead wires to high limit.

3. Route thermostat capillary tube to top of oven.

4. Mark 8 3/4" from end of probe.

5. Insert male compression fitting onto thermostat probe.

6. Install female fitting into bulb location.

7. Insert 8 3/4" of backup thermostat into oven. Ensure that backup thermostat bulb doesn't touch inner walls of oven.

8. Install first set of 3 spacers over capillary tube and allow them to go into the female compression fitting.

9. Pack seal gasket material around capillary tube.

10. Insert second set of 3 spacers over capillary tube and allow them to go into the female compression fitting.

F25361 (January 2010) Page 26 of 60

4. Open the control compartment door to gain

5. Remove cover from controller box.

6. Disconnect temperature probe lead wires from

7. Remove temperature probe from oven. NOTE: Temperature probe should be install

approximately 8 3/4" down from top of probe fitting into oven compartment.

8. Reverse the procedure to install.

access to controller.

controller board.

OV500 SERIES RACK OVEN - REMOVAL AND REPLACEMENT OF PARTS

EPROM REPLACEMENT

1. Open the control compartment door to gain access to controller.

2. Remove the controller box cover.

Static electricity will damage the controller board. Use an anti-static grounding kit when servicing the controller.

3. Remove the prom from the controller.

4. Install the new prom. Verify orientation notch and carefully align pins of prom.

B. The door jamb hinge set screws will need

to be loosened to remove hinge pins and insert in opposite direction (upward).

5. Re-assembly the oven.

6. Perform CONTROLLER DEFAULT SETTINGS as outlined under SERVICE PROCEDURES AND ADJUSTMENTS.

7. Check for proper operation.

DOOR SWING CHANGE

NOTE: If hood installed door can not be lifted to

proper height to clear the hinge pins. Removal of door hinges from door jamb will be required.

1. Open the door at least 90 degrees.

2. Remove door sweep from door assembly.

3. Use a J bar to support door assembly at center bottom to assist in door removal.

A. Remove both door jamb hinges from door

jamb and set door & door hinges aside.

NOTE: Ensure hinge pin set screws engage into notch in pin and tighten set screws.

4. Rotate door such that top of door is at the bottom and install door & door hinges onto door jamb.

5. Remove pan head screws on opposite side of door jamb and install both door jamb hinges with flat head screws while supporting center bottom of door assembly with a J bar.

NOTE: Leave one door jamb hinge loose to aid installation of door assembly.

NOTE: Tighten door jamb hinge if left loose to aid installation of door assembly.

A. Install pan head screws into other side of

door jamb were hinges removed from.

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OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

6. Remove door catches from door jamb.

A. Remove screws on opposite side of door

jamb and install door strike.

B. Install screws onto other side of door jamb

catch was removed from.

C. Install both door catches to opposite door

jamb.

7. Adjust the DOOR as outlined under SERVICE PROCEDURE AND ADJUSTMENTS.

8. Install door sweep onto door assembly at bottom of door.

SERVICE PROCEDURES AND ADJUSTMENTS

CONTROLLER INPUT/OUTPUT

STATUS DIAGNOSTIC

1. Turn oven on.

2. Check controller input/output status indicator LED's on back of controller, for proper input/output operation during various stages of operation.

NOTE: Use oven sequence of operation in conjunction with diagram.

3. Correct any improper input/output operation.

F25361 (January 2010) Page 28 of 60

4. Check oven for proper operation.

7598

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

IGNITION MODULE SELF

DIAGNOSTICS

Ignition module makes three attempts to light burner before proceeding to lock-out mode.

1. Turn oven on and set controller to call for heat.

2. Access the ignition module by removing component panel cover.

3. Check ignition module indicator LED for fault codes as stated in following chart.

NOTE: LED will briefly illuminate during pre-purge.

LED DIAGNOSTIC INDICATOR CODES

LED CODES

LED off No Fault

LED on Control Fault '1' Flash Air Flow Fault '2' Flash Flame No Call For Heat* '3' Flash Ignition Lockout

* Flame continues after controller set temperature is

satisfied. (Gas valve sticks open.)

4. Disconnect power to oven.

5. Correct the fault.

6. Re-apply power.

7. Check ignition module for correct operation.

CONTROLLER TEMPERATURE

CALIBRATION

1. Check setting of controller temperature offset (P4) as outlined under CONTROLLER DEFAULT SETTINGS and record setting.

2. Verify that the probe is functioning properly as outlined under TEMPERATURE PROBE TEST.

3. Place a thermocouple of a temperature tester in the center of right incoming air slot of the bake chamber.

A. Route thermocouple through hinge side of

door to the outside of the oven. Make sure that the lead wire is kept clear of the rack carrier.

4. Turn the oven on.

5. Set the controller temperature to 400EF.

6. Allow the oven temperature to stabilize (minimum 3 cycles).

7. Note temperature reading on temperature tester and controller at the exact time the heat light on the controller goes out.

TEMPERATURE PROBE TEST

1. Access controller board.

2. Disconnect temperature probe lead wires from controller board.

3. Set the multi meter to milli volt scale and connect positive lead (red) to the (white) probe lead wire and negative lead (black) to (red) probe lead wire.

4. Verify the multi meter reading to the temperature conversion chart as follows.

TEMPERATURE CONVERSION CHART

FAHRENHEIT CELSIUS

100 38 -1.8 to 1.2 200 93 1.5 to 4.3 300 149 4.5 to 7.3 400 204 7.5 to 10.6

5. If multi meter reading indicates an open or is outside the millivolt range, replace the temperature probe as outlined under TEMPERATURE PROBE.

MILLIVOLT

RANGE

8. If the temperature difference between the two readings is greater than ±2EF or ±1EC, adjust the temperature offset (P4) as outlined under CONTROLLER DEFAULT SETTINGS.

A. If temperature test shows a temperature

higher than controller, increase offset (P4) the amount of difference.

B. If temperature test shows a temperature

lower than controller, decrease offset (P4) the amount of difference.

C. If temperature difference is greater than

the range of the controller, replace controller (range ±50EF. or ±10EC.).

9. Check for proper operation.

10. Remove temperature tester thermocouple from the oven.

CONTROLLER SETTINGS

CLOCK SETTING

1. Press the Power On/Off keypad to turn the oven on.

2. Press and hold either Auto On/Off Timer Up/Down Arrows for 3 seconds.

3. After the colon stops flashing use the Up/Down Arrows to adjust the clock setting.

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F25361 (January 2010)

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

A. After the desired time is set and the

Up/Down Arrows have not been pressed for 5 seconds, the colon will start to flash indicating the clock has continued running.

PARAMETER SETTINGS

1. Press the Power On/Off keypad to turn the

oven off.

2. Access set-up mode by pressing and holding

Start while pressing Power On/Off for 3

CONTROLLER DEFAULT SETTINGS

Set

Temp

Display

P1 Maximum temperature set point

P2 Preheat temperature

P3 Minimum temperature set point

P4 Temperature offset

P5 Heat OFF offset

P6 Heat difference hysteresis

P7 Maximum steam time (in seconds)

P8 EF or EC

P10 Vent evacuate time (in seconds)

P11 Vent open percentage

P12

P13

P14

P15 Interior light brightness

P16 Clock operation

P17

P18 Setback temperature

0= minutes, 1= hours & minutes

End of bake time auto vent enable

Steam time in seconds or Food

Service Mode Steam Interval

300 to 900= Food Service Mode

Set-Up Item Descriptions

This is the maximum temperature at which the

This is the default temperature set point when

the oven is first turned on (program 0). The

preheat temperature cannot be set higher than

This is the minimum temperature at which the

This value permits an offset or correction

between the temperature probe and the real

This value adjusts the temperature difference

between the set point and stopping the heating

This value adjusts the temperature difference

between the on temperature and off temperature

Time set is the maximum time (in seconds) that

water is supplied during the STEAM TIMER

The oven can be set to display temperature in

Bake time mode

0= disable , 1= enable

End of bake time auto vent

(in minutes)

0= seconds,

Temperature setback time

(in minutes)

The BAKE TIMER cab be set up to display

minutes set/minutes remaining or hours and

minutes. Select 0 for minutes set/minutes

remaining or 1 for hours and minutes.

Time set is the time (in seconds) that the vent is

100% open at the beginning of the venting cycle.

This value is the percentage the bake chamber

vent is open after the vent evacuate time has

This value enables the automatic vent cycle.

This is the number of minutes before the end of

the bake cycle that the vent is open.

Displays steam time in seconds or operation in

Food Service Mode. The number of seconds set

is the steam interval. See FOOD SERVICE

STEAM MODE as outlined in this section.

This value is the brightness of the interior lights.

The higher the number, the brighter the lights.

This selects either 12 hour (AM/PM) or 24 hours real time display. Press the bake time UP button

to switch between the two types of displays.

This selects the elapsed time from the last timed

bake to when the oven will lower the oven set

temperature to the value set in P18.

This selects the oven set temperature that the

oven will change to when the temperature

setback time has been exceeded in P17.

seconds.

3. Press Set Temp Up Arrow to select set-up item shown in set temp display.

4. Use the Bake Timer Arrows to adjust set-up values in the bake timer display.

5. Use the following chart to restore default settings.

oven can be set.

the value in P1.

oven can be set.

baking chamber temperature.

system.

of the heating system.

operation.

Fahrenheit or Celsius.

expired.

Settings Shown In

Bake Timer Display

Set for 525EF (range 50 to 525EF.)

or (10 to 274EC.)

Set for 375EF (range 50 to 525EF.)

or (10 to 274EC.)

Set for 50EF (range 50 to 200EF.)

or (10 to 93EC.)

Default setting 0 (range ± 50)

Default setting -2 (range ± 20)

Default setting 4 (range 0 to 20)

Set for 20 (range 0 to 30 max when

P20 set for 0 = standard) 60 max

when P20 set for 1 = restricted

operator mode)

Set for 0

Set for 90 (range 0 to 180)

Set for 15% (range 5 to 100%)

Set for 0

Set for 1 (range 0 to 99)

Steam time in seconds = 0

Food service Mode (range 300 to

990 seconds)

Set for 90 (range 50 to 100)

Set for A P= 12 hour AM/PM

Set for 24 = 24 hour

Set for 180 (range 10 to 180)

Set for 300EF (range 50 to 300EF.)

or (10 to 149EC.)

F25361 (January 2010) Page 30 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

Lights mode

P19

P20

P21

P22

P23-P24 Unused

P25

0= auto operation

1= continuously ON

Restricted operator mode

0= Standard

1= Restricted Operation Mode

Advanced Energy Saving Mode

0= Standard

1= Advanced Energy Saving

Mode

OV210 Mode

0= Standard

1= OV210 Mode

Communicate Mode

0= Direct Connect

1= NAFEM Protocol

Select 1 for lights on continuously (when oven is on) or select 0 for automatic operation, lights will turn off automatically after 30 minutes of no user

activity (door not opened or closed, no buttons

pushed).

Select 1 for Restricted operator mode. When a

program is selected by the operator the Bake Timer Minutes Set window will display the total bake time of all steps in the program. Standard

operation only displays the minutes in the

selected step. When a program is selected and

the Start button is pressed the operator cannot

make changes to the Bake Time remaining or the Oven Set Temp. If set for steam, steam is

produced in 5 second on - 5 second off intervals

for the time set in P7. The maximum solenoid on

time range that can be set in P7 increases to 60

seconds. Change P7 to 60 when P20 is set for

1. When P20 is changed from 1= Restricted

Operator Mode to 0= Standard Mode P7 must

be changed below 30 (range 0 to 30 max) or

solenoid will energize continuously for up to 60

seconds.

Select 1 for Advance Energy Saving. Forcing the

oven into an Advance Auto On - Auto Off Mode

to conserve energy. Several steps are

necessary to enable this mode. Set the Auto On

Time to 60 minutes before the first bake time.

Set the Auto Off Time. Press the Auto On / Auto

Off button to illuminate the Timer On / Off

indicator. Set P17 & P18 to customer settings.

See Advanced Energy Saving Mode as outlined

in this section.

Select 1 for installation of an HBA control panel

and control door on an OV210. When enabled

the OV210 will emulate all the functions of an

HBA.

Select 1 for NAFEM protocol compliant

communication.

Set for 0

(when P20 is changed P7 setting

must be changed to correspond

with mode selection)

Set for 0

NOTE: If P21 is set to 1 and control is programed for Auto On - Auto Off: oven will not start up in Off Time Mode unless a minimum of 30 minutes is entered into timer within 30 seconds of pressing On/Off keypad. After oven is started up and timer displays 00 for time and no keypads are pressed for the Set Back Time used inP17, the oven will then shut down.

NOTE: Before restarting oven, power switch and gas valve must be OFF for a minimum of 5 minutes.

6. Press On/Off to exit set-up mode.

7. Check for proper operation. BAKERY MODE The Bakery Mode is the default setting. The value for

parameter P14 is 0 and displayed in the Bake Timer display. In Bakery Mode the controller will only initiate one steam cycle, for the set steam time.

FOOD SERVICE STEAM MODE The food service steam mode has been updated to

provide steam at intervals throughout a bake cycle. The length of the steam cycle and the interval between cycles can be set by the operator. Steam Timer Display will display the steam cycle length and the displayed cycle length will not count down while steaming.

1. To enable food service mode: A. Oven controller off. B. Press and hold the Start keypad while

Page 31 of 60

pressing the Power On/Off keypad for 3 seconds.

C. Press the Set Timer Arrows to select

parameter P14.

D. Enable Food Service Steam Mode by

pressing the Bake Timer Up Arrow until display changes to a three digit number.

E. Set desired time (in seconds) between

steam cycles by pressing the Bake Timer Up/Down Arrows. Range 300 to 990 seconds by increments of 10 seconds.

Example:

Parameter P14 set to 300 Steam Time set to 3 Steam cycle will initiate for 3 seconds after every 300

seconds

2. Press the Power On/Off keypad to save

settings and exit Setup Mode.

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OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

OVEN TEMPERATURE SAFETY ALARM

indicator light is illuminated.

NOTE: Standard feature, no parameter setup required.

If the temperature at the oven probe is between 570 to 600°F. (299 to 316EC.) for ten seconds, the controller will do the following:

• Shuts off all oven features.

• Sounds alarm and flashes the Oven Temp display.

• Display SHdn (shutdown) in the Bake Timer display.

NOTE: The oven will remain in Oven Temperature Safety Alarm Mode until the 120Volt supply power is turned off to the oven.

ADVANCED ENERGY SAVING MODE The Advanced Energy Saving Mode is NOT the

default setting. The default value for parameter P21 is 0.

NOTE: When P21 is set to 1, Advanced Energy Saving Mode enabled, the Auto On/Off Time can only be changed in set up mode. To disable the Auto On/Off Time P21 must be set to 0, disabled.

The Advanced Energy Saving Mode automatically starts the oven at the preset time, sets the temperature to (P2) default of 375°F. (191°C.) and the timer is set for 60 minutes and running. When the oven timer is timed out and no buttons are pushed on the controller for 15 minutes (P17), the Set Back Mode will be enabled. The oven will beep twice and the set temperature reduces to (P18) set at 250°F. (121°C.). If oven is in Set Back Mode set the bake temperature and timer for 12 minutes and press start to prepare the oven for baking. When buzzer sounds the oven is ready to load. The oven will shut down automatically at the preset time.

1. To enable the Advanced Energy Saving Mode. A. Oven controller off. B. Press and hold the Start keypad while

pressing the Power On/Off keypad for 3 seconds.

C. Press the Set Timer Arrows to select

parameter P21.

D. Enable Advanced Energy Saving Mode by

pressing the Bake Timer Up Arrow to display 1.

E. Press the Set Timer Arrows to select

parameter P17. Set to 15 using Bake Timer Up/Down Arrows.

F. Press the Set Timer Arrows to select

parameter P18. Set to 250 using Bake Timer Up/Down Arrows.

G. Press Timer On/Off Keypad so that the

H. Consult with Bakery Manager for required

start and end of bake time.

I. Press and hold the Auto On Time keypad

while pressing the Up/Down Arrows to set the Auto On Time 60 minutes prior to the requested start of bake time.

J. Press and hold the Auto Off Time keypad

while pressing the Up/Down Arrows to set the Auto Off Time to the requested end of bake time.

K. Press the Power On/Off keypad to exit

parameter set up mode.

2. Verify proper operation. A. When in Set Back Mode the damper

should not open.

Advanced Energy Saving Mode Operation

1. Auto On Time will start the oven automatically at the set time chosen to a preset set temperature (P2) default 375°F. (191°C.)

A. Oven will not start up unless:

1) Loading door is closed.

2) Hood system is operating gas units only. Typical hood systems are wired to turn on automatically when oven powers on.

B. Controller will set timer for 60 minutes and

start timer.

C. When timer times out showing 0:00 and

buzzer sounds, the oven is ready to use. The operator may then change the desired temperature or time.

2. Set Back Function, P17 & P18. A. Set Back time P17 is set to 15 minutes.

1) Time shows 0:00 and no other keypads are pushed for 15 minutes, controller will automatically set temperature to 250°F. (121°C.), P18. Oven will beep twice.

B. Vent damper should remain closed while in

Set Back Mode.

C. Exit Set Back Mode.

1) Set temperature to required bake temperature.

2) Set timer for 12:00 minutes. Press start.

3) When buzzer sounds oven is ready for use.

3. Auto off Time shuts down the oven automatically at the preset time.

F25361 (January 2010)

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OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

A. If time is remaining on timer counting

down, oven will not shut down.

controller will enter Kosher Active Mode, and have the following operating characteristics:

B. Once timer shows 0:00 the oven will shut

down in 15 minutes, P17.

C. Operator can start oven while in Auto off

Time by pressing the On/Off keypad, set timer to a minimum of 30 minutes and press start keypad.

1) Timer must be set and started within

30 seconds of pushing On/Off keypad.

NOTE: If timer is not started in 30 seconds oven will shut down immediately.

2) Oven will start as described in Auto On sequence.

3) Oven will operate normally until timer shows 0:00 and no keypads are pressed. Oven will shutdown in 15 minutes, P17.

KOSHER OPERATION MODE The Kosher Mode can only be ordered from the

factory and has a key operated manual reset. Kosher Lockout Mode automatically locks out controller (lock-out mode) if Kosher parameters are not maintained.

NOTE: Kosher Reset Keys are shipped with the oven, located inside the controller box, at bottom of box. Keys should be provided to facilities approved authority at oven start-up.

A. The minimum set temperature is 200°F.

(93°C.).

B. If the oven temperature falls below 170°F.

(77°C.). an alarm will sound (fast pulse rate).

NOTE: Alarm will silence if oven temperature recovers back to 170°F. (77°C.).

C. If the oven temperature falls below 150°F.

(150°C.) the alarm will silence and controller will go into Kosher Lock-Out Mode, controller display will read LOC

OUT.

NOTE: In Kosher Lock-Out Mode controller locks out

all controller operations and will need to be reset. Obtain reset key from the facility's approval authority.

3. To reset a Kosher Lock-Out Mode: A. Use the reset key and turn the reset switch

full right to the Reset position then back to the off position.

NOTE: Resetting the switch will put the controller back into the Kosher Enable Mode. Once oven temperature reaches 200°F. (93°C.) controller will enter Kosher Active Mode.

1. To enable Kosher Enable Mode: A. Oven controller off. B. Press and hold the Airflow Delay Arrow

keypad while pressing the Power On/Off keypad for 3 seconds.

NOTE: A flashing 0 in the Bake Timer Display indicates controller is in the Bakery Mode (non Kosher Mode).

C. Press the Bake Timer Up Arrow until

display reads 1 (enabling Kosher Enable Mode).

D. Press the Power On/Off keypad to exit.

2. Once oven temperature reaches 200°F. (93°C.).

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B. Verify the Bake Timer Display reads 1

(flashing). If not, press the Bake Timer Arrows until display reads 1 (flashing).

C. Press the Power On/Off keypad entering

the Kosher Active Mode.

NOTE: The controller will call for heat in the Kosher Active Mode and maintain the minimum Kosher temperature 200°F. (93°C.).

F25361 (January 2010)

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

4. To disable Kosher Operation Mode - Bakery Mode:

1. Attach a manometer to 1/8" NPT inlet pressure tap on gas valve.

A. Oven controller off. B. Press and hold the Airflow Delay Arrow

keypad while pressing the Power On/Off keypad for 3 seconds.

C. Press the Bake Timer Arrows until Bake

Timer Display reads 0.

D. Press the Power On/Off keypad, oven in

Bakery Mode (standard operation).

BURNER ADJUSTMENTS

MANIFOLD PRESSURE ADJUSTMENT

NOTE: Verify the type of gas required is the type of gas supplied.

2. Turn gas supply on to oven and verify that static supply line pressure to oven does not exceed 14" W.C. (1/2 psig, 35.6 cm W.C., 3.5 kPa) for either natural gas or propane. If supply line pressure exceeds 14" W.C. (1/2 psig, 35.6 cm W.C., 3.5 kPa), adjust pressure regulator. If no pressure regulator, customer must supply and install a line pressure regulator. Adjust as needed.

3. Turn gas off at supply valve.

4. Move manometer to 1/8" NPT outlet pressure tap on gas valve.

5. Turn gas on at supply valve.

6. Turn gas valve on and set controller to call for heat.

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OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

7. With a burner flame established and all other gas equipment on the supply line lite, adjust the manifold pressure as indicated in the following charts or as indicated on the oven data plate

NOTE: Accurate gas pressure adjustment can only be made with the burner on.

NOTE: Turn adjustment screw Clockwise

BTU/HR Nat. Gas 180,000 Propane Gas 180,000

W.C. 3.5" W.C. 10.0" W.C.

kCAL/HR 45,400 45,400

cm W.C. 8.89 25.40

Mj/HR 190 190

kPa 0.87 2.49

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

W.C. 3.0" 4.0" 8.0" 10.0"

kCAL/HR 75,600 88,200 75,600 88,200

cm W.C. 7.61 10.15 20.32 25.40

Mj/HR 317 370 317 370

kPa 0.75 1.00 2.00 2.49

to increase the pressure, Counterclockwise to decrease pressure.

OV500G1

MANIFOLD PRESSURE

NATURAL GAS PROPANE GAS

OV500G2

MANIFOLD PRESSURE

NATURAL GAS PROPANE GAS

NOTE: The following diagram represent a typical style of the combination valve.

F25361 (January 2010)Page 35 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

NOTE: The following chart is for reference only. If the manifold pressure must be adjusted to accommodate the altitude you must contact Bakery Product Support for a corrected data plate and orifice part number.

ALTITUDE CORRECTION CHART

OV500G1 OV500G1 OV500G2 OV500G2

Natural Gas Propane Gas Natural Gas Propane Gas

ELEVATION

IN FT.

(sea level)

3000 158,400 2.7 158,400 7.7 300,000 3.0 300,000 8.0

3500 154,800 2.6 154,800 7.3 300,000 3.0 300,000 8.0

4000 151,200 2.4 151,200 7.0 294,000 2.7 294,000 7.4

4500 147,600 2.3 147,600 6.7 287,000 2.6 287,000 7.1

5000 144,000 2.2 144,000 6.4 280,000 2.5 280,000 6.7

5500 140,400 2.1 140,400 6.0 273,000 2.4 273,000 6.4

6000 136,800 2.0 136,800 5.7 266,000 2.2 266,000 6.1

Orifice #53

Orifice Dia. 0.0595

Oven

Rating

BTU/Hr

180,000 3.5 180,000 10.0 300,000 3.0 300,000 8.0

Manifold

Pressure

“ W.C.

Orifice #63

Orifice Dia. 0.037

Oven

Rating

BTU/Hr

Manifold

Pressure

“W.C.

Orifice #49

Orifice Dia. 0.073

Oven

Rating

BTU/Hr

Manifold

Pressure

“W.C.

Orifice #56

Orifice Dia. 0.046

Oven

Rating

BTU/Hr

ORIFICE DIA. MUST CHANGE 6500 FT. ABOVE SEA LEVEL

Orifice #55

Orifice Dia. 0.052

Orifice #66

Orifice Dia. 0.033

Orifice #52

Orifice Dia. 0.0635

Orifice #60

Orifice Dia. 0.04

Manifold

Pressure

“W.C.

6500 133,200 3.2 133,200 8.6 259,000 3.7 259,000 10.1

7000 129,600 3.1 129,600 8.1 252,000 3.5 252,000 9.5

7500 126,000 2.9 126,000 7.7 245,000 3.3 245,000 9.0

8000 122,400 2.7 122,400 7.3 238,000 3.1 238,000 8.5

8500 118,800 2.6 118,800 6.8 231,000 2.9 231,000 8.0

9000 115,200 2.4 115,200 6.4 224,000 2.8 224,000 7.5

9500 111,600 2.3 111,600 6.0 217,000 2.6 217,000 7.1

10,000 108,000 2.1 108,000 5.7 210,000 2.4 210,000 6.6

F25361 (January 2010) Page 36 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

8. If manifold pressure was unattainable, light burner and all other gas equipment on the supply line and check gas supply line flow pressure. If gas supply line flow pressure not attainable find the source of the problem.

OV500G1

GAS SUPPLY LINE FLOW PRESSURE

NATURAL GAS PROPANE GAS

BTU/HR 180,000 180,000

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

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

OV500G2

GAS SUPPLY LINE FLOW PRESSURE

NATURAL GAS 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"

kCAL/HR 75,600 88,200 75,600 88,200

cm W.C. 12.7 - 35.6 15.3 - 35.6 30.5 - 35.6 30.5 - 35.6

Mj/HR 317 370 317 370

kPa 1.25 - 3.50 1.50 - 3.50 2.50 - 3.50 3.00 - 3.50

9. Turn gas valve off and disconnect manometer.

CROSS OVER TUBE ADJUSTMENT

1. Remove GAS MANIFOLD as outlined under REMOVAL AND REPLACEMENT OF PARTS.

2. Remove burner rack enclosure - front panel.

3. Remove screw securing hot surface ignitor to burner side rack assembly, and pull ignitor out.

4. Disconnect flame sensor lead wire.

5. Remove burner side rack and end shot burner assembly.

6. Make sure burners are evenly spaced.

7. Check for .025" spacing in cross over tube.

Page 37 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

FLAME SENSE LOCATION

1. Flame sensor is located at the bottom of the burner assembly.

NOTE: If reading is below 0 microamps reverse meter leads and take another reading.

COMBUSTION ANALYSIS

2. Flame sensor is positioned at the lower edge of the last end shot burner.

3. Flame sensor should be parallel to the face of the burner and horizontal to the lower edge.

FLAME SENSE CURRENT TEST

Flame sense current is rectified through the flame from ground to sensor. A minimum flame sense current is necessary to keep ignition system from lockout.

1. Disconnect flame sensor wire from ignition control module at S2 terminal.

1. Verify the manifold pressure as outlined under BURNER ADJUSTMENTS.

2. Insert combustion analyzer meter 8" into air sampling tube at 300EF. (149°C.) for combustion tests.

DUAL POINT VENTING

2. Connect multi meter black lead to terminal S2 on the ignition control module and red lead to flame sensor lead wire.

NOTE: Flame sense current can also be checked at flame sensor wire connection.

3. Turn oven power on and set controller to call for heat.

4. Meter reading should be a steady 1.0 microamps or higher. If not, troubleshoot flame sense circuit.

F25361 (January 2010) Page 38 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

SINGLE POINT VENTING

3. Set oven temperature to 450EF (230°C.) with a burner flame established, take combustion measurements O

: ( Range 6% to 10%)

and CO readings.

CO: Not to exceed 0.04% (400PPM)

A. If readings can not be obtained, adjust the

draft inducer baffle and retest for combustion.

DRAFT INDUCER TEST

1. Access the component panel area for single point venting and for dual point venting access draft diverter above oven.

2. Single point venting connect incline manometer or equivalent to draft inducer tubing. For dual point venting insert incline manometer tube 6" above draft diverter.

NOTE: If combustion readings still can not be obtained, contact Bakery Support.

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OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

3. There should be a vacuum reading of:

OV500G1

Oven Temp

Cold

400°F.

204.4°C.

Natural Gas

(minimum readings)

-0.46 "W.C.

-11.7 mm W.C.

-0.11 kPa

-0.32 "W.C.

-8.13 mm W.C.

-0.08 kPa

(minimum readings)

OV500G2

Natural Gas Propane Oven Temp

Cold

400°F.

204.4°C.

300k Btu/h

75,600 kCAL/HR

317 Mj/HR

Min. -0.43 "W.C.

-10.9 mm W.C.

-0.11 kPa

Min. -0.31 "W.C.

-7.9 mm W.C.

-0.08 kPa

350k Btu/h

88,200 kCAL/HR

370 Mj/HR

Min. -0.36 "W.C.

-9.1 mm W.C.

-0.09 kPa

Min. -0.23 "W.C.

-5.8 mm W.C.

-0.06 kPa

300k Btu/h

75,600 kCAL/HR

317 Mj/HR

Min. -0.43 "W.C.

-10.9 mm W.C.

-0.11 kPa

Min. -0.31 "W.C.

-7.9 mm W.C.

-0.08 kPa

OV500G1 DUAL POINT VENTING

-0.15" W.C.

Cold / 400°F. / 204.4°C.

4. If minimum reading is not obtained, check the draft inducer motor and fan.

-3.8 mm W.C.

-0.04 kPa

Propane

-0.46 "W.C.

-11.7 mm W.C.

-0.11 kPa

-0.32 "W.C.

-8.13 mm W.C.

-0.08 kPa

350k Btu/h

88,200 kCAL/HR

370 Mj/HR

Min. -0.36 "W.C.

-9.1 mm W.C.

-0.09 kPa

Min. -0.23 "W.C.

-5.8 mm W.C.

-0.06 kPa

HOOD VENT DRAFT

PRESSURE TEST

1. Access the component panel area.

2. Verify operation of roof mounted ventilator. NOTE: Verify plenum or grease filters installed.

A. Remove vacuum line near hood exhaust

pressure switch and connect incline manometer or equivalent.

1) Single & Duel point venting ovens minimum reading should be:

-0.6"W.C., -15.2 mm W.C., or

-0.15kPa.

NOTE: Standard hood reading of -0.3" W.C., -7.6 mm W.C.,or -0.08 kPa is acceptable if air volume is verified as noted in specifications.

B. Disconnect manometer and reconnect

vacuum line onto hood exhaust pressure switch.

NOTE: If vacuum requirements are not met, the customer supplied hood vent stack must be modified to meet the above stated requirements and tested until minimum vacuum is met.

3. If draft diverter is installed (dual point venting), continue.

A. Operate the oven for a minimum of 5

minutes.

B. While burner is lit, check for a back draft at

the draft diverter relief opening (i.e. smoke emitted from a smoldering source).

C. If no back draft indicated (smoke going up

draft diverter relief opening) test is complete.

F25361 (January 2010)

Page 40 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

D. If back draft indicated (smoke not going up

draft diverter relief opening) the oven must not be operated, until proper adjustments have been made (correct flue stack to have adequate up draft through the draft diverter relief opening).

DOOR ADJUSTMENT

Check

1. With the door closed, visually check gap around door jamb and edge of door, gap should be equal on both sides.

2. Loosen mounting screws and adust latches towards door gasket.

NOTE: Adjust both latches the same distance so door assembly will not close in a bind.

NOTE: If the door rubs against the jamb or drags the facility floor when opening, verify oven for levelness. If leveling does not correct the problem then call Bakery Service Support.

NOTE: You may get some movement by adjusting the leveling bolts.

2. Verify door latches properly. A. Insert a piece of paper between door jamb

and door gasket on both sides & top of door.

B. If paper is loose, door latches will need

adjusted.

Adjustments

1. Adjust door hinge inward or outward until door has an air tight seal against door gasket.

3. Repeat the process until desired results are obtained.

DOOR SWITCH ADJUSTMENT

Check

1. With door closed, door switch is operated.

2. When door is unlatched and opened approximately 3 inches at handle side, burner should not light, convection blower will shut off and rack should stop in load/unload position and lower.

3. When closing door, door switch actuator must mate with actuator guide in door jamb. This will push actuator plate inside control compartment and door switch will return to operated position.

NOTE: Door switch LED light (A2) should be illuminated with door closed.

Adjustment

1. Close oven door, door switch actuator should mate with actuator plate inside control compartment and door switch to put door switch in operated position.

F25361 (January 2010)Page 41 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

2. Access door switch in control compartment.

3. With oven door closed, door switch actuator guide should operate actuator plate inside control compartment and door switch.

4. Loosen the door switch screws and move the door switch until door switch is operated.

5. Tighten door switch screws.

5. Tighten screws.

6. Check for proper operation.

RACK POSITION ADJUSTMENT

1. Operate oven so that when door is opened rack will attempt to stop in load/unload position.

2. If rack has not stopped in load/unload position, adjust.

NOTE: Do not allow rotator shaft to move.

A. Access the set screws that secure the rack

carrier.

6. Open oven door.

7. Actuator guide should un-operate the switch before handle side of door is opened more than 3 inches.

8. Check for proper operation.

RACK POSITION SWITCH

ADJUSTMENT

1. Position carrier in product load/unload position.

2. Access the rack position switches at top of oven.

3. Loosen rack position switch screws.

4. Adjust switches up or down so wheel of actuator arm will contact rack pointer in middle of ramp just prior to the load/unload position and will operate switch when flat spot of pointer is contacted.

B. Loosen set screws (4) that secure rack

carrier. C. Move carrier to load/unload position. D. Tighten set screws.

3. Check for proper operation; rack centered in home position with door opening.

RACK HEIGHT ADJUSTMENT

Check

1. With door open and rack carrier centered in door opening, rack should be pushed onto rack carrier without forcing or lifting wheels from oven floor or forcing the rack downward.

2. With door closed and rack carrier raised and turning, the wheels should clear oven floor.

Adjustment (Except "C" Channel Type Rack)

1. Access rack position switches on top of oven.

2. Make sure switch actuator is bent at 90Eand is between rack height switches.

3. Loosen the screws securing lift switch bracket. A. If rack wheels are not touching the floor in

loading/unloading position, lower bracket.

F25361 (January 2010)

B. If rack wheels are touching the floor in

bake position, raise the bracket.

NOTE: Product rack should load onto carrier without resistance and should rotate with the wheels off oven floor.

Page 42 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

NOTE: Do not bend actuator for rack height adjustment.

4. Tighten the lift switches bracket screws.

5. Check for proper operation.

Adjustment for "C" Channel Type Rack NOTE: Locate customer<s shortest and tallest 'C<

type racks. NOTE: Typical upper lift switch mounting location for

'A' type racks use upper set of holes and 'B' & 'C' type racks use lower set of holes.

A. If dimension A is outside of 0.200" to

0.375", access rack position switches on top of oven.

B. Loosen bolts securing upper & lower lift

switch bracket and move bracket up and recheck dimension A.

3. Move shortest rack out of the way.

4. Move tallest rack to rear of rack carrier.

5. Check distance between the top surface of lower section of rack<s 'C< channel and bottom surface of the rack carrier (Dimension B).

1. With door open and rack carrier centered in door opening, push shortest rack up to the front of the rack carrier.

2. Verify distance between the underside of upper section of rack<s 'C< channel and top surface of the rack carrier (Dimension A).

Page 43 of 60

A. If dimension B is less than dimension A,

adjust upper & lower lift switch bracket until dimension A is less than dimension B.

NOTE: If dimension B exceeds 0.400" than adjust upper & lower switch bracket up to have clearance at dimension A.

6. Load rack(s) onto rack carrier, close door, and allow rack carrier to lift and rotate.

NOTE: OV500G2 & OV500E2 oven use 1 double or 2 single racks. If using single racks, use the shortest and tallest together.

F25361 (January 2010)

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

A. Verify that rack(s) wheels (when at the rear

location of the baking compartment) do not drag on the oven floor.

B. If wheels drag, move upper lift switch to the

upper holes in upper & lower lift switch bracket.

2) Install actuator housing cover.

B. Remove motor and gearbox assembly from

actuator.

C. Test with oven at desired operating

temperature for 15 minutes.

D. If wheels drag, then oven floor or racks do

not meet manufactured specifications.

ACTUATOR LUBRICATION

1. Access actuator on top of oven.

2. There are two places to apply high temperature grease.

A. Remove actuator housing cover.

1) Apply high temperature grease in actuator gear box.

1) Apply high temperature grease in top of actuator housing.

2) Install motor and gearbox assembly.

F25361 (January 2010)

3. Check for proper operation.

Page 44 of 60

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

AIR AND ANGLE SHUTTER

ADJUSTMENTS

FACTORY SETTING ON COSTCO OVENS ONLY

Page 45 of 60

FACTORY SETTINGS STANDARD DOUBLE OVENS

F25361 (January 2010)

OV500 SERIES RACK OVEN - SERVICE PROCEDURES AND ADJUSTMENTS

FACTORY SETTINGS ON PANERA BREAD OVENS ONLY

FACTORY SETTINGS ON COSTCO OVENS ONLY

General Information NOTE: Before making any shutter adjustments, refer to the bakery installation basics procedure.

1. Factory settings are used for a starting point on a new oven. Once an oven has been started up and has baked satisfactorily, there is no need to return to factory settings.

2. Illustrations show factory settings for air volume and shutter angles. These settings will be applicable for most situations. If these settings are adjusted, record the settings and place in the control panel area for reference.

F25361 (January 2010)

Page 46 of 60

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

3. The shutters are the short L shaped panels of stainless steel located on the right rear corner panel of the bake chamber. There are 12 shutters per oven, consisting of 24 adjustable air volume settings and 12 adjustable angle settings.

4. Air volume adjustments modifies the heat from top to bottom of rack(s).

5. Shutter angle adjustments direct the heat to side or center of individual pans on a rack.

6. Oven pressure panel feeler gauge Part No. 01-1M5689-1. Do not discard feeler gauges.

Evaluating Product

1. Observe a rack of product. A. Evaluate the rack of product.

1) If the product is the same color from edge to center of trays, but the color varies from top to bottom of the rack, then an air volume adjustment is needed.

2) If individual trays of the product are not the same color from edge to center, then the angles need to be adjusted.

2. Adjust as necessary.

3. If satisfactory results can not be achieved after two or three attempts at adjusting, call Bakery Product Support.

NOTE: Changes in product whether raw, mixed, different mixes, or old mix can affect the bake. Air Volume Adjustment

1. Allow oven to cool.

2. Determine the shutter that needs adjusted.

NOTE: Always start at the dark areas and decrease opening of shutter to prevent air volume depletion.

3. Decrease shutter opening in area where the product is dark and adjust the shutter only 1/32 of an inch at a time.

4. In rare cases it will be applicable to increase shutter openings where the product is light. ONLY if recommended by Bakery Product Support.

5. Validate adjustments by performing a test bake with the same type of product.

Shutter Angle Adjustment

Make corrections with air volume adjustments before making any shutter angle adjustments. Changes to the factory shutter angle settings should only be made to correct specific baking issues that air volume adjustments cannot correct, contact Bakery Product Support for assistance.

ELECTRICAL OPERATION

COMPONENT FUNCTION

Controller ................ Controls oven operation.

Transformers ............. Supplies 24VAC to ignition module, controller door switch, and CR4.

Door Switch .............. Allows control to monitor door position and directs power to rack rotation motor

and rack lift motor.

Draft Inducer

Pressure Switch ........... Senses vacuum created by draft inducer fan. Prevents burner ignition if sufficient

combustion air is not present.

Hood Pressure Switch ...... Senses vacuum in hood vent. Prevents burner ignition if sufficient exhaust

vacuum is not present.

Hi Limit Thermostat ........ Prevents oven temperature from exceeding 608EF. (320EC.) (manual reset).

Gas Valve ................ When energized, allows gas to flow to burners.

Page 47 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

Ignition Control Module ..... Controls and monitors gas heating. Energizes gas valve coil, hot surface ignitor,

draft inducer, and monitors presence of flame.

Hot Surface Ignitor ......... When energized, ignites gas.

Roll Out Switch............ Opens if flame goes beyond confined area of heat exchanger and into control

compartment. At 350EF. (177EC.) opens circuit to ignition module (manual reset).

Flame Sensor ............. Monitors flame at the burner.

Water Solenoid - SV1 ....... When energized, allows water to flow onto oven steam generator.

Cir. Fan Motor - M1 ......... Circulates air around heat exchanger tubes and into oven cavity.

Cir. Fan Motor

Contactor - MR1 ........... Controls power to circulation fan motor.

Rotator Motor - M4 ......... When energized, turns baking rack.

Overload - OL1 ............ Monitors current to circulation motor.

Overload - OL2 ............ Monitors current to rotator and rack lift motors (optional).

Draft Inducer Motor - M3 .... When energized, drives fan to generate draft required for proper burner

operation, and exhausts combustion products into hood vent.

Temperature Sensor ....... Monitors air temperature in the oven cavity and sends signal to control board.

Vent Motor - M2............ When energized operates oven cavity vent.

Vent Position Switch ....... Allows controller to monitor the oven cavity vent (open or closed).

Rack Position Switch #1 .... Allows CR3 (Rack Position Relay) to be energized when door is open and rack

is in load/unload position.

Rack Position Switch #2 .... Signals rack position to control. Switch is operated when the rack is in position

for rack removal. (Centered in door opening).

Rack Lift Relay - CR4 ....... When energized, provides door input to controller, and a path for power to LS1

and LS2.

Rack Position Relay - CR3 . . . When energized, switches power from LS1 to LS2. Has a latching circuit.

Back Up Relay -CR2 ........ If open, closes vent on power up when back up controls are used.

Hood Vent Relay -CR1 ...... CR1 - Powers roof mounted vent motor and allows ignition module to be reset

after a lock-out.

Rack Lift Switch #1- LS1 .... Allows rack to stop in the rased position and rack to turn.

Rack Lift Switch #2- LS2 .... Allows rack to stop in the load/unload position.

Rack Lift Motor - M5 ........ M5 - Raises and lowers rack.

OVEN SEQUENCE OF

OPERATION

Oven Idle Mode

Idle mode exist when the supply voltage is at the oven control and the control power switch has been turned off for a minimum of 20 minutes.

1. Supply voltage to control with clock displayed

(A1 lit).

2. 120V present at the following components.

A. Control board / rack position switch #2 /

vent position switch / F1 of ignition module / CR4 contacts / 24V transformer door

3. If door is closed (A2 lit).

4. If door is open (A2 not lit) and rack in

5. Vent closed (A3 lit).

6. Hood vent output (A5 lit).

7. Interior lights will light if door is opened (A9 lit).

8. Neutral to one side of the following

switch circuit / 24V transformer heating circuit.

load/unload position. A. CR3 energized.

A. CR1 energized and hood mounted fan de-

energized.

components.

F25361 (January 2010)

Page 48 of 60

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

A. 24V transformer heating circuit / 24V

transformer door switch circuit / control board / M3 / CR1 / Lights / MR1 / SV1 / M2 / M4 / M5 / CR3 / CR2 back up control only / circuit breakers.

C. CR4 coil energized.

1) CR3 de-energized.

2) Circuit path to lift motor completed thru CR4 N.O.

9. High limit, roll out switch and overloads OL1and OL2 closed.

Pre - Heat Cycle This condition exist as the operator prepares to

bake.

1. Oven at idle conditions.

2. Door closed (A2 lit).

3. Control power switch turned on. A. Interior lights are illuminated. B. Control energized - display is lit. C. 5 second delay before call for heat.

4. End of 5 second delay. A. CR1 de-energized (A5 not lit). Roof

mounted fan energized.

B. MR1 energized (A6 lit). Circulation motor

energized.

C. 24 VAC transformer energized.

5. Hood pressure switch closes. A. 24 VAC to L1 and R of ignition control. B. 24V to control (A4 lit).

6. Heat output from oven control (A8 lit). A. Refer to burner sequence of operation for

burner details.

7. Oven will cycle at preheat temperature 375EF default (191EC.) until operator changes the conditions.

Bake Cycle

1. Oven at preheat temperature.

2. Operator sets conditions for bake cycle.

NOTE: If steam is part of the bake cycle, bake time must also be entered and the steam cycle will always be first.

3. Door is opened to load rack. A. Control de-energizes outputs to ignition

module and circulation fan motor contactor.

NOTE: If rack carrier is not in load position, the control will position rack carrier in load position if door is ajar.

4. Rack loaded onto carrier and close door. A. DS1 N.C. contacts open (both sets). B. DS1 N.O. contacts close (both sets).

Page 49 of 60

D. Circulation motor energized. E. Refer to burner sequence of operation.

5. Bake cycle started by pushing timer start button.

NOTE: The door can be opened at anytime during the bake cycle. If so, the rack will stop at home position and lower. Circulation motor and burner will not operate. Bake timer paused until door is closed.

A. Out put from control board to lift motor

(A11 lit).

1) Lift motor energized to lift rack.

2) After rack starts to lift LS2 N.O. contacts open and N.C. contacts close.

6. Rack reaches raised position. A. LS1 N.C. contacts open.

1) Lift motor M5 de-energized.

B. LS1 N.O. contacts close.

1) Rotator motor M4 energized.

7. If steam is part of the bake cycle: A. Water solenoid SV1 will be energized (A10

lit) for the required number of seconds.

NOTE: 30 seconds is the maximum number of seconds that the control will energize SV1. The steam time can be set to a maximum of 95 seconds.

B. Circulation motor and burner will not

operate. (A6 and A8 not lit)

8. Steam cycle ends: A. Water solenoid SV1 de-energized . B. Circulation motor and burner operate.

9. Remainder of bake cycle controlled by bake timer.

10. Time expires and buzzer sounds.

11. Stop button pressed to silence buzzer.

NOTE: Rack remains in bake position and rotating until door is opened.

12. Door opened to unload oven. A. Control removes power from heat output

and circulation blower output.

1) Circulation motor and burner will not operate while door is open.

B. DS1 N.C. contacts close (both sets). C. DS1 N.O. contacts open (both sets).

F25361 (January 2010)

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

1) CR4 de-energized.

2) Door input removed from control board (A2 not lit).

3) Circuit to rotator motor continues thru CR4 N.C.

D. Rack continues to rotate until rack pointer

operates rack position switch #1 and #2. (Rack centered in door).

NOTE: In some instances when the door is opened, the rack may be centered in door. CR3 will energize. Rack will stay centered in door and then lower.

E. Rack position switch #2 N.O. contacts

close.

F. Rack position switch #1 N.O. contacts

close. Input signals control board that rack is centered in door for the first time since stop button was pushed and door was opened.CR3 energized thru rack position switch #1 N.O. contacts. Latching circuit keeps CR3 energized if rack would coast past pointer.

1) CR3 N.C. contacts open and rotator motor M4 de-energized.

2) CR3 N.O. contacts close and lift motor is energized thru LS2 N.C. contacts, lowering the rack.

3) As the rack starts to lower LS1 N.O. contacts open and LS1 N.C. contacts close.

13. When rack is completely lowered, LS2 N.C. contacts open and LS2 N.O. contacts close. Lift motor is de-energized.

14. Remove rack.

15. Shut door and oven will continue to maintain set temperature (preheat mode). The rack lift will remain in load/unload position and not rotate.

BURNER SEQUENCE OF

OPERATION

1. Power (24VAC) to ignition module L1 and R (A4 lit).

2. 24VAC output from control (A8 lit) to ignition module terminal W and one side of the draft inducer pressure switch.

A. Draft inducer motor energized from ignition

module terminal F2 (115VAC).

B. Inducer pressure switch closes.

1) Power to terminal PS.

3. Pre-Purge cycle begins (15 seconds).

4. Ignition module energizes hot surface ignitor (24VAC) thru terminal S1 for 4 second heat up time.

5. Gas valve energized thru MV1 two seconds after start of hot surface ignitor cycle.

6. Top burner lights and flame spreads to all burners.

7. Flame sensor rod is engulfed in flame and a current is rectified between the flame and ground thru the sensor. Ignition module requires a steady 1.0 microamp to verify flame presence.

NOTE: Ignition module makes three attempts to achieve ignition. 30 seconds inter-purge between each attempt. If after the three tries for ignition and the burner has not lit, there will be an additional 15 seconds purge time. After which the ignition module will enter a lock-out condition. The ignition module utilizes a 3 blink code of the LED for this problem. The ignition module will have to be reset by removing power from the ignition module. To do this, open the door or cycle the main circuit breaker (110VAC) to the oven.

8. When set temperature is met, control removes heat output to ignition module terminal W (A8 not lit).

F25361 (January 2010)

A. Ignition module is de-energized.

1) Gas valve de-energized.

2) Draft inducer motor M3 de-energized 30 seconds after gas valve deenergized.

B. Inducer pressure switch N.O. contacts

open.

Page 50 of 60

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

COMPONENT LOCATION

OV500G1 & OV500G2 COMPONENT LOCATION

OV500E1 & OV500E2 COMPONENT LOCATION

Page 51 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

WIRING DIAGRAMS

SCHEMATIC - WITH BACKUP CONTROLS

HOBART BAKERY SYSTEMS

DERIVED FROM DRAWING NO. 01-10I663 REV. B

SCHEMATIC - WITHOUT BACKUP CONTROLS

F25361 (January 2010)

Page 52 of 60

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

HOBART BAKERY SYSTEMS

DERIVED FROM DRAWING NO. 01-10I664 REV. B

Page 53 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - ELECTRICAL OPERATION

HEATING CIRCUIT - BURNER

DERIVED FROM DRAWING NO. 01-10I665 REV. B

HOBART BAKERY SYSTEMS

F25361 (January 2010) Page 54 of 60

OV500 SERIES RACK OVEN - TROUBLESHOOTING

OVEN TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSES

Oven completely inoperative. No display on control.

Oven does not operate. Display lit or display flashing and oven cavity lights on.

Oven does not operate. Display shows Shdn (shutdown) in the bake timer display and flashes the Oven Temp display while alarm sounds.

Oven does not operate. Erratic display. 1. E-prom chip malfunction.

Rack does not lift when bake cycle is initiated. 1. Lift motor or OL2 open.

Rack does not turn when bake cycle is operating. 1. Rotator motor malfunction or OL2 open.

1. Facilities main circuit breaker open.

2. Controller inoperative.

3. Controller membrane inoperative.

4. Back-up control switch on. (If applicable)

1. Door open.

2. High limit thermostat open.

3. Hood pressure switch open.

4. Incorrect wiring.

1. Oven in Oven Temperature Safety Alarm Mode. Temperature at the temperature probe between 570EF. to 600EF. (299 to 316EC.) for ten seconds. Remove 120VAC supply power to the oven.

2. Controller malfunction.

2. Door open or door switch malfunction.

3. Controller malfunction.

4. Mechanical bind due to actuator or lift shaft.

5. LS1 inoperative.

2. Door open or door switch malfunction.

3. Controller malfunction.

4. Mechanical bind due to rack or chain.

5. LS1 inoperative.

Page 55 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSES

Rack does not lower when rack stops in load/unload position when door is opened during or at end of bake cycle.

Rack stops in wrong position or doesn't stop after door is opened.

No steam or low volume of steam. 1. Water supply to oven not on.

Excessive moisture in oven. 1. Solenoid valve sticking open.

Recovery time slow after steaming. 1. Excessive water input.

Incorrect heat. 1. Control not calibrated.

Burner does not light. 1. No output from controller.

High or low draft pressure in oven draft inducer. 1. Draft inducer motor or fan malfunction.

Lights do not work. 1. Bulbs burned out.

Uneven baking. 1. Circulation fan loose on motor shaft or damaged.

1. Door switch malfunction.

2. Lift motor or OL2 open.

3. Controller malfunction.

4. Mechanical bind due to actuator or lift shaft.

5. LS2 inoperative.

1. Rack pointer switch out of adjustment.

2. Rack position switches not adjusted or inoperative.

3. CR3 malfunction.

4. CR4 malfunction.

5. Carrier set screws loose.

2. Incoming water pressure too low.

3. Solenoid valve malfunction.

4. Control malfunction.

5. Vent open or vent switch malfunction.

2. Drain clogged or plumbed incorrectly.

3. Malfunctioning water pressure regulator.

4. Excessive water pressure.

2. Program set point incorrect.

3. Hysteresis programed incorrectly.

4. Gas supply pressure improperly adjusted.

5. Cavity vent open.

2. Control in incorrect temperature mode (EF vs.EC).

3. Temperature probe malfunction.

4. Circulation fan motor malfunction.

5. See BURNER TROUBLESHOOTING.

2. Door open or door switch inoperative.

3. See BURNER TROUBLESHOOTING.

2. Draft inducer fan blade not positioned on motor shaft correctly.

3. Damaged draft inducer fan blade.

4. Roof mounted fan too large (high pressure) or too small (low pressure).

2. Control program set to OFF.

3. Incorrect supply voltage.

2. Obstruction in air channels.

3. Circulation motor(s) inoperative.

4. Air and angle shutters not adjusted correctly.

F25361 (January 2010)

Page 56 of 60

OV500 SERIES RACK OVEN - TROUBLESHOOTING

IGNITION MODULE TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSES

Diagnostic LED continuous ON - Ignition control powered, but module does not have outputs at appropriate times.

1. No draft inducer output.

2. No gas valve output.

3. No ignitor output. Diagnostic LED '1' flash - Airflow fault. Module

doesn't have draft inducer pressure switch input.

Diagnostic LED '2' flashes - Flame no call for heat. NOTE: Flame continues after controller set temperature is satisfied. (Gas valve sticks open.)

Diagnostic LED '3' flashes - No flame sense after trial for ignition. (3 attempts)

1. Ignition control module malfunction.

2. Incorrect ignition module.

3. Incorrect wiring.

1. Draft inducer pressure switch inoperative.

2. Draft inducer pressure switch tubing malfunction.

3. Draft inducer fan blade damaged or inoperative.

4. Draft inducer motor malfunction.

5. Incorrect pressure switch wiring.

6. Incorrect wiring.

1. Gas valve malfunction.

1. Flame sensor rod not positioned correctly or malfunction.

2. Insufficient flame current.

3. Ignitor malfunction.

4. Gas valve inoperative or improperly adjusted.

5. Late ignition, check gas manifold pressure.

6. Improper flame propagation (flame produced), check orifice alignment and cross over tube adjustment.

LED DIAGNOSTIC INDICATOR CODES

LED Code

LED off No Fault

LED on Control Fault '1' Flash Air Flow Fault '2' Flash Flame No Call For Heat '3' Flash Ignition Lockout

Page 57 of 60

F25361 (January 2010)

OV500 SERIES RACK OVEN - TROUBLESHOOTING

BURNER TROUBLESHOOTING

F25361 (January 2010) Page 58 of 60

OV500 SERIES RACK OVEN

- NOTES -

F25361 (January 2010)Page 59 of 60

OV500 SERIES RACK OVEN

- NOTES -

F25361 (January 2010) Printed in U.S.A.

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

Specifications and Main Features

Frequently Asked Questions

User Manual