Lincoln Electric LOW PROFILE 1600 SERIES, 1600-000-A, 1601-000-A Service Manual

SERVICE MANUAL

(DOMESTIC)

IMPINGER CONVEYOR OVENS

LOW PROFILE 1600 SERIES ADVANTAGE

Lincoln Foodservice Products, LLC

1111 North Hadley Road

Fort Wayne, Indiana 46804

United States of America

Phone : [phone]

U.S. Fax: [phone] • Int’l Fax: [phone]

Technical Service Hot Line

[phone]

www.lincolnfp.com

1600advsvc REV: 1/8/07

TABLE OF CONTENTS

TABLE OF CONTENTS..............................................................................................................................................2

SEQUENCE OF OPERATIONS / 1600-000-A , 1601-000-A.....................................................................................3

TROUBLESHOOTING GUIDE...................................................................................................................................4

SCHEMATIC / 1600-000-A, 1601-000-A..................................................................................................................10

REMOVAL, INSTALLATION & ADJUSTMENTS .....................................................................................................11

PARTS / GENERAL - 1600-000-A ADVANTAGE SERIES......................................................................................18

BLOW UP / GENERAL – 1600-000-A ADVANTAGE SERIES ................................................................................19

PARTS / CONTROL BOX, RIGHT - 1600-000-A, 1601-000-A ................................................................................20

BLOW UP / CONTROL BOX, RIGHT - 1600-000-A, 1601-000-A ...........................................................................21

PARTS / CONTROL BOX, LEFT - 1600-000-A, 1601-000-A...................................................................................22

BLOW UP / CONTROL BOX, LEFT - 1600-000-A, 1601-000-A..............................................................................23

PARTS / OVEN BACK - 1600-000-A - SERIES .......................................................................................................24

BLOW UP / OVEN BACK - 1600-000-A - SERIES ..................................................................................................25

PARTS / CONVEYOR - 1600-000-A - SERIES .......................................................................................................26

BLOW UP / CONVEYOR - 1600-000-A - SERIES...................................................................................................27

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Low Profile – 1600-000-A Advantage Series Service Manual – Domestic

SEQUENCE OF OPERATIONS / 1600-000-A, 1601-000-A

MODEL 1600-000-A / 120 VAC / 60 HZ / NATURAL GAS
MODEL 1601-000-A / 120 VAC / 60 HZ / L.P. GAS

POWER SUPPLY Electrical power to be supplied to the oven by a three conductor cordset. Voltage from

the black conductor to the white conductor to be 120 VAC.

White conductor is Neutral.

Green conductor is Ground.
CONTROL BOX
AUTO COOL DOWN

MAIN FAN CIRCUIT 120 VAC is permanently supplied to the normally open double pole power switch, a

BURNER CIRCUIT Closing the Oven Power Relay supplies 120 VAC to the (2) burner Systems

TEMPERATURE
CONTROL

CONVEYOR DRIVE Closing the on/off switch supplies 120 VAC through the oven power relay to the motor

NOTE: The conveyor control uses a sensor and magnet, mounted on the conveyor motor that

TEMPERATURE
DISPLAY

When the temperature in either one of the Control Boxes reaches 120°F ± 3°F (49°C
± 1.7°C), the Cooling Fan Thermostats will switch power to the Cooling Fans. The
thermostats will interrupt power to the Cooling Fans when the temperature falls to
100°F ± 3°F (37°C ± 1.7°C).

normally open contact of the oven power relay and the normally open cooling fan
thermostats. Closing the power switch supplies 120 VAC, through the 3 A cooling fan
fuse, through both control box hi-limit thermostats to the coil of the oven power relay.
These normally open contacts now close supplying 120 VAC, through the 10A main
fan fuse to the 2 main fan motors and the 2 burner motors. Power is also supplied to
the cooling fans, the heat and conveyor control systems.

NOTE: This oven utilizes (2) complete Burner/Temp. Control systems. The sequence
of operations is the same for each system.120 VAC is supplied, through the
Centrifugal Switch of the Main Fan Motor (this switch closes when the Main Fan
reaches approximately 1600 R.P.M.) through the 10 Amp Fuse, to the Ignition
Control, the Electronic Temperature Control, and the burner transformer. As the
Burner Blower reaches approximately 1600 R.P.M., its internal centrifugal switch will
close, supplying 24 VAC to the ignition control. The Ignition Control operates on both
24 VAC and 120 VAC. When the control is energized by 24 VAC, 120 VAC is
switched to the Hot Surface Igniter for 45 seconds for Hot Surface Igniter warm up.
The igniter glows red, 24 VAC is switched to the gas valve which opens, and ignition
should now occur. If ignition does not occur in 6 seconds, the control will lock out. To
recycle after lockout, turn off the burner switch for 45 seconds and then turn the
switch back on.
When the Centrifugal Switch of the Main Fan Motor closes, power is applied to the
Temperature Control. The1K ohm Temperature Pot is adjusted to desired
temperature. Thermocouple will provide varying millivolts to the Temperature
Controller. The Temperature Controller supplies 120 VAC to the solenoid valve at
intermittent intervals to maintain desired temperature. The heat lamp is energized
with the solenoid valve.

control board. AC volts are converted to DC volts and are supplied to the conveyor
motor at terminals A+ and A-.Adjustments of the speed control potentiometer will
change resistance at terminals P1 and P2 varying the DC voltage to the motor. The
speed of the conveyor motor will increase or decrease as the DC voltage from the
board increases or decreases respectively.

senses the motor speed. Any change in motor load, (±RPM) is detected by the
sensor and the voltage to the motor is adjusted accordingly.
Closing the switch supplies 120 VAC to the primary of the temperature display
transformer. The secondary of this transformer supplies 12 VAC to the temperature
display. The thermocouple supplies D.C. millivolts to the temperature display. The
display converts this millivolt reading to a temperature reading.

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TROUBLESHOOTING GUIDE

GAS OVENS

MODEL 1600-000-A / NATURAL GAS / 120 VAC / 60 HZ / 1 PHASE
MODEL 1601-000-A / L.P. GAS / 120 VAC / 60 HZ / 1 PHASE

NOTE: When checking components on left side of unit, be sure to check for proper connections in power
connector, (marked P. C. on Schematic Diagram.) located inside motor cover.

SYMPTOM POSSIBLE CAUSE EVALUATION

Oven fan will not run

No control box cooling

No automatic control
box cooling

Incoming Power
Supply

Main Fan Switch Check continuity between switch terminals.
Fuse, 10 Amp Check, replace if necessary.
Fuse Holder Check, replace if necessary.
Fuse 3A Check, replace if necessary.
Fuse holder Check, replace if necessary.
Hi Limit Thermostat(s)
Control Box

Oven Power Relay Check for 120 VAC to the relay coil. If voltage is not present,

Main Fan Motor Check for opens, shorts, or grounds. WITH POWER OFF turn

Capacitor Check for shorts or grounds.

Incoming Power Check main circuit breakers, reset if required, call power

Main Fan Switch Check continuity between switch terminals
Fuse 3 amp. Check, replace if necessary.
Fuse Holder Check, replace if necessary.
Hi Limit Thermostat(s)
Control Box

Cooling Fan(s) 120 VAC should now be at the fan motor. If voltage is present,

Incoming Power
Supply
Cooling Fan
Thermostat(s)

Fuse, 3 amp Check, replace if necessary
Fuse Holder Check, replace if necessary
Hi Limit Thermostat(s)
Control Box

Check breakers, reset if required. Check power plug to be sure
it is firmly in receptacle. Measure the incoming power/call
power company if needed.

Check for voltage on both sides of the switch. Terminals are
normally closed. If open, reset and test oven for proper
operation. If thermostat will not hold and control box
temperature is not exceeding 140°F (60°C), replace
thermostat.

trace wiring back to the control box hi-limit. If voltage is
present, check to insure contacts are closing. Check for 120
VAC supplied to terminal #2 of the relay.

fan blade to check for locked rotor.

WARNING: Capacitor has a stored charge, discharge before
testing.

company if needed.

Check for voltage on both sides of the switch. Terminals are
normally closed. If open, reset and test oven for proper
operation. If thermostat will not hold and control box
temperature is not exceeding 140°F (60°C), replace
thermostat.

check motors for shorts or opens. WITH POWER OFF:
Check for locked rotor.
Check circuit breakers, reset if required. Call the power
company if needed.
Check the cooling fan thermostat. (Thermostat closes at
120°F and opens at 100°F). With the cooling fan thermostat
preheated, check for continuity. If switch is open, replace.

Check for voltage on both sides of the switch. Terminals are
normally closed. If open, reset and test oven for proper
operation. If thermostat will not hold and control box
temperature is not exceeding 140°F (60°C), replace
thermostat.

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Low Profile – 1600-000-A Advantage Series Service Manual – Domestic

Cooling Fan(s) 120 VAC should be at the motor. If voltage is present, check

motor for shorts, opens, or grounds. WITH POWER OFF:
check for locked rotor.

Oven will not heat

Gas Supply Check for adequate gas supply and closed manual gas valves.

Also, check flexible gas line connection.

Main Fan If not operating, refer to "Oven fan will not run".

NOTE: These ovens utilize 2 complete burner/temperature control systems. Each system will follow the same
troubleshooting sequence.

Centrifugal Switch of
Main Fan Motor

Check for 120 VAC supplied to the centrifugal switch, if
voltage is not present, trace the wiring back to the oven power
relay. Check for 120 VAC out of the centrifugal switch. If
voltage is supplied to the centrifugal switch, and motor is
running, but there is no voltage out of the centrifugal switch,
replace the fan motor.
(NOTE: See Schematic Diagram of proper wire numbers on

motors.)
Fuse, Burner 10A Check, replace if necessary.
Fuse holder Check, replace if necessary
Burner Blower Motor Check for 120 VAC supply to the burner blower motor, if 120

VAC is present and motor does not turn, replace the motor.
Burner Transformer Check for 120 VAC to primary of the 24 VAC burner

transformer. If voltage is not present, trace wiring back to the

fuse. If voltage is present, check for 24 VAC at the secondary,

if no secondary voltage is present, replace the transformer.
Centrifugal Switch of
Burner Blower Motor

Check for 24 VAC supply to the centrifugal switch of burner

blower motor (see Schematic for proper wire numbers). If no

voltage is present, trace wiring back to the transformer. If

voltage is present, check for 24 VAC at the output of the

centrifugal switch. If there is no output, and the burner blower

motor is running, replace the burner blower motor.
Ignition Control Check for 24 VAC supply to the ignition control at terminals

marked 24V and 24Vgnd. If voltage is not present, trace

wiring back to the centrifugal switch. Check for 120VAC

supply to the ignition control at terminals L1 and L2. If no

voltage is present, trace wiring back to fuse. If the above

checks are okay, proceed. The ignition control should switch

120VAC to the hot surface igniter, across the (2) terminals

marked HIS. If no voltage is present, replace the ignition

control.
Hot Surface Igniter
(Located inside Burner
Assy)

If 120 VAC is present at HSI terminals, visually check to see

that the hot surface igniter is heating (igniter may be viewed

through port glass in end of burner tube). The igniter should

glow bright red. Check all connections to be sure they are

tight. If the igniter does not heat, replace.
Ignition Control After 45 seconds of hot surface igniter pre-heat, the ignition

control will switch 24 VAC to the gas control valves. Check for

24 VAC output from the ignition control, and across terminals

marked "valve" and "valve gnd". If no voltage is present,

replace the ignition control.

NOTE: The ignition control contains a safety lockout circuit. If

a flame is not detected within 6 seconds after the gas control

valve is energized, the ignition control will lockout. To reset,

turn the power switch "off", wait 45 seconds and switch the

system "on" to retry ignition.

Gas Control Valves Check for 24 VAC supplied to the gas control valves. If

voltage is present, the valves should open. Check for gas

pressure at the pressure tap, located in the gas piping just

prior to the burner. If there is no gas pressure, and the voltage

is supplied to valves, check piping for obstructions. If there

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Flame will not stay lit

Low flame is on, but
no main flame

are no obstructions, replace gas control valves.
Hot Surface Igniter The ignition control will keep the gas control valves energized

for 6 seconds. At the end of 6 seconds, the hot surface igniter

must sense a flame, or, the ignition control will go into lockout.

(The ignition control requires a minimum of 0.8 microamps

D.C.) To check the flame sensing operation, connect a digital

multimeter (capable of measuring D.C. micro-amps) between

the "ground" terminal on ignition control and the ground lead.

NOTE: This is a current measurement and the meter must be

connected in series. If these readings are not achieved, check

bypass orifice for obstructions, if bypass orifice is clear,

replace the hot surface igniter.

NOTE: The D.C. micro amp test must be conducted with the

oven in low flame (bypass) operation. Turn the temperature

control to its lowest setting.
Power Supply If there is sufficient micro-amp current, but the flame will not

stay lit, check for proper polarity of the 120 VAC power supply
Ignition Control If there is sufficient micro-amp current, and the 120 VAC

polarity is correct, but the flame will not stay lit, replace the

ignition control.

NOTE: Check for proper ground connection of the ignition

control.
NOTE: Flame should
be lit at this time.
Temperature Control Check for 120 VAC at terminal #7 to neutral on temperature

control. If no voltage, trace voltage back to fuse holder. Turn

the temperature adjustment knob to maximum temperature

position and check for 120 VAC at the load terminal #8 and

neutral. If 120 VAC is present and unit is not heating, refer to

"Temperature Solenoid Valve" for next check. If 120 VAC is

not present, proceed.
Thermocouple Probe WITH POWER ON AND THERMOCOUPLE LEADS

ATTACHED TO THE TEMPERATURE CONTROL BOARD:

Measure the D.C. millivolt output of these leads. Refer to

thermocouple chart on page 17 for proper readings. If these

readings are not achieved, replace the thermocouple.
Temperature Set
Potentiometer

Disconnect the potentiometer leads Disconnect the pot from

the board. Place ohm meter test leads on the blue and green

pot leads. Reading should be 1 K ohms. Place meter leads

across the blue and purple pot leads and rotate knob from high

to low. Repeat on green and purple leads. Check for even

rise and fall of ohms reading to insure that there are no open

or dead spots in the potentiometer. Check each lead to

ground for shorts. Replace pot if it does not meet the above

test
Temperature Solenoid
Valve

If 120 VAC is present on the temperature control board at load

terminal #8 to neutral, check for voltage at temperature

regulation valve. If voltage is present, listen for valve to open

and close. Also check for opens or shorts in the coil. Replace

as necessary.

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Low Profile – 1600-000-A Advantage Series Service Manual – Domestic

Intermittent Heating Thermal/Overload of

Main Fan and Burner
Blower Motors

Conveyor will not run

Voltage Supply Check incoming voltage supply at line 1 to neutral. There

Fan Switch See procedure for checking at beginning of section.
10 Amp Fuse Check and/or replace.
Fuse holder Check and/or replace.
Speed Adjustment
Potentiometer

DC Motor Control
Board

Conveyor Gear Motor If DC voltage is present at A+ and A- and the motor does not

Conveyor Check for any mechanical misalignment. Also, check for worn

The main fan motors and the burner blower motors are

equipped with internal thermal protection and will cease to

operate if overheating occurs. As the motors overheat and

then cool, this will cause the units to cycle on and off

intermittently. Improper ventilation or preventive maintenance

may cause this. Also, most of the problems listed under

"Oven will not heat" can cause intermittent failure.

should be a voltage reading of 120 VAC. If not present, check

breakers.

This is a 0 to 10 K ohm, 1 turn potentiometer. With power off,

remove the black and white pot leads from the motor control

board at terminals P1, P2. Place the meter leads on the black

lead (P2) and on the white lead (P1). Rotating the pot., slowly,

from low to high, the meter readings should show an even

transition from 0 to 10 K ohms ± 5%. There should be no

dead or open spots through out the 1 turn of the pot. Check

both leads to ground. There should be no continuity to

ground. If any of the above checks fail, replace the pot

Check for 120 VAC input to the control board at terminals L1

and L2. If not present, check wiring back to the fuse. If 120

VAC is present at L1 and L2, check both fuses on control

board (8A line and 1A armature), check the VDC output at

terminals A+ and A-. If 120 VAC is present at terminals L1

and L2, and DC voltage is present A+ and A-, but motor does

not run, check gear motor as follows.

run, first check the mini breaker and then the conveyor. Refer

to the next possible cause. Check the leads to the motor for

evidence of any shorts or opens, and each lead to ground.

Check motor brushes. From the top of the motor, rotate motor

shaft to determine if there is a locked rotor or a locked gear

box (use care so magnet and H.S. board are not damaged).

Replace motor as needed.

bearings. A conveyor belt that is over tightened will cause

excessive bearing wear and sometimes, irregular speed.

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Conveyor speed
varying or intermittent

Power Supply Check power supply at the DC control board for the 120 VAC

at board terminals L1 and L2.
Motor Control Board Place the test meter probes on terminals A+ and A-. (With

speed potentiometer set to maximum speed (Approximately 2

min.) The meter reading should be approximately 100 VDC

(±3%), if voltage is not steady within limits, then the board is

probably bad. Always check the speed pot., be sure it is okay

before changing a board. This test is not always 100%

accurate as this test is not performed at operating speeds.

However, this test is the best method currently available.
DC Gearmotor If the DC control board is steady then the problem may be the

motor or gearbox. Check the brushes in the motor for

excessive arching and/or unusual wear. Check the motor and

gearbox from instruction located under "possible cause" listing

"conveyor gear motor."
Magnet Check to insure that the magnet (cemented to shaft of

conveyor drive motor) has not been damaged, or come loose

from motor shaft. Replace as needed.
Hall Effect Sensor Check for any physical damage to hall effect sensor (mounted

on conveyor drive motor.) Check all wiring and connections

for damage. Check all connections for tightness or proper

location. Replace as needed. Connect new hall effect to

system and check for steady operation.

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Low Profile – 1600-000-A Advantage Series Service Manual – Domestic

Temp. display
inoperative

Temp. Display
inaccurate, erratic or
inoperative

Display Transformer Measure the transformer primary for a nominal 120 VAC input,

if voltage is not present, trace wiring back to the oven power

source. Measure the secondary output, which will normally be

12-15 VAC. Voltage across terminals 1 and 3 on the temp.

display should read 12-15 VAC. Terminals 1-2 and 2-3 should

be 1/2 the voltage reading to 1-3. If the above secondary

readings are not achieved, replace transformer.
Temp. Display If proper voltage is present at terminals 1, 2, and 3 on

temperature display, but the display is not lighted, recheck all

connections for tightness. If temperature display is still not

operating, replace the temperature display.
Thermocouple Connect the thermocouple of a pyrometer to the thermocouple

on the temperature control board. (Be sure to maintain proper

polarity of thermocouple leads--see Adjustment Section for

proper procedure.) The pyrometer will indicate oven

temperature. Measure DC millivolts of thermocouple at the

temperature display. See thermocouple chart in adjustment

section for proper readings. Replace thermocouple if proper

readings are not achieved. If readings are correct on the

thermocouple, replace temperature display.

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