Marshall Air 2424 User Manual

OWNER’S MANUAL

2424, 121224 AUTOBROIL™

THIS MANUAL APPLIES TO BROILERS WITH S/N 3284 FORWARD

MODEL: 2424 121224 AUTOBROIL™

TABLE OF CONTENTS

I. BROILER SETTINGS ..................................................................................................... .......................1

II. EQUIPMENT INSTALLATION ........................................................................................ .......................2

Pre-Installation.......................................................................................................... .......................2

Equipment Location .................................................................................................. .......................2

Electrical Information ................................................................................................ .......................2

III. OPERATING INSTRUCTIONS ....................................................................................... .......................3

Pre-Operation Check ................................................................................................ .......................3

Broiler Adjustment .................................................................................................... .......................3

Toaster Operating Instructions ................................................................................. ................... 3-4

Toaster Shut-Off Instructions.................................................................................... .......................4

Toaster Conveyor Speed.......................................................................................... .......................4

Operation of 6-Button Controller............................................................................... ................. 5-11

IV. SCHEDULED MAINTENANCE....................................................................................... .....................12

Daily Cleaning Procedures ....................................................................................... ............... 12-13

Monthly Cleaning Procedures................................................................................... .....................13

Quarterly Cleaning Procedures and Preventive Maintenance.................................. ............... 13-14

V. TROUBLE SHOOTING ................................................................................................... ............... 14-18

VI. ASSEMBLY & DISASSEMBLY INSTRUCTIONS ........................................................... ............... 18-19

VII. REPLACEMENT PARTS ................................................................................................ ............... 19-21

ILLUSTRATIONS

Overall Dimensions...................................................................................................……….. .......... Figure 1

Exploded View - Removable Parts ........................................................................... ....................... Figure 2

Exploded View - Internal Parts ................................................................................. ....................... Figure 3

Exploded View - Drive System ................................................................................. ....................... Figure 4

Drive System Detail .................................................................................................. ..................... Figure 4A

Control Panel With 6-Button Control......................................................................... ....................... Figure 5

Conveyor Axle Scraper............................................................................................. ....................... Figure 6

Spark Guard Installation…………………………………………………………………. ........................ Figure 7

Broiler Arm Extension 2424 ...................................................................................... ........................ Figure 8

Broiler Arm Extension 121224 .................................................................................. ........................ Figure 9

Broiler Idler Shaft Asby ............................................................................................. ...................... Figure 10

Toaster Platen Asby LH............................................................................................ ...................... Figure 11

Toaster Platen Asby RH ........................................................................................... ...................... Figure 12

Speed Control Circuit Board ..................................................................................... ...................... Figure 13

Fuse Location ........................................................................................................... ..................... Figure 14

Toaster Platen Heat Control ..................................................................................... ..................... Figure 15

Element Locations .................................................................................................... ..................... Figure 16

Wiring Schematic 121224……………………...(208V, 3PH, 60 AMP w/6-Button Control) Drawing #145703

Control Panel Quick Guide……………………………………………………...........................Drawing #145747

OWNER’S MANUAL

2424, 121224 AUTOBROIL™

OWNER’S MANUAL

2424, 121224 AUTOBROIL™

I. BROILER SETTINGS

MODEL NUMBER:____________________________________________________________

SERIAL NUMBER: ____________________________________________________________

ELECTRICAL SUPPLY: _________________________________________________________

SCHEMATIC NUMBER___________________ REV. _________

TOASTER PLATEN TEMPERATURE SETTING (425°F IS FACTORY SETTING)_______________

MENU SETTINGS: TEMPERATURE

RECIPE KEY SPEED TOP BOTTOM 1 ______________ _______ _______ 2 ______________ _______ _______ 3 ______________ _______ _______ 4 ______________ _______ _______ 5 ______________ _______ _______ 6 ______________ _______ _______

START-UP TECHNICIAN: __________________________________________________________

START-UP DATE: ________________________________________________________________

COMMENTS: ____________________________________________________________________

_____________________________________________________________________________

AUTOBROIL™

MODEL: 2424 121224

OWNER’S MANUAL

2424, 121224 AUTOBROIL™

II. EQUIPMENT INSTALLATION

PRE-INSTALLATION

1. After uncrating the Autobroil™ unit, inspect for shipping damage. Check that the controller, switches, and components are intact on the electrical cabinet front. Set the Autobroil™ in place and use the plastic bag to protect it from the debris and trash of building construction. Check that sideskins have not been dented or damaged by the carrier. If damaged, notify your freight carrier immediately to file a concealed damage claim, following the instructions attached to the outside of the shipping crate. Your warranty will not cover freight damage.

2. Because this unit is required to be power fan exhausted, it is necessary to provide adequate make up air equal to the amount of air removed. In addition to this, any other exhausts, flues, or air removal systems must be taken into consideration. Examples of this are heat removal fans or hot water heater flues.

EQUIPMENT LOCATION

1. Position Autobroil™ to properly align with exhaust hood. Check name plate for clearance requirements.

2. The hood/ventilator for the catering equipment should be located in accordance with the National Fire Protection Association Standard #96, "Removal of Smoke and Grease-Laden Vapors from Commercial Cooking Equipment" and any local applicable requirements.

3. For proper installation, the minimum clearance from combustible construction is 6" (152mm) from sides and 6" (152mm) from back.

4. Adequate clearance should be maintained to allow easy access to loading and unloading areas of the machine.

5. For servicing, unit must be moved 2' (610mm) clear from all construction.

ELECTRICAL INFORMATION

1. The Electrical Schematic is inside the electrical cabinet, and a copy is also included at the back of this manual. Make certain the supply voltage and number of supply conductors agrees with the Electrical Schematic. The load-carrying conductors should be sized according to the loads shown on the Electrical Schematic per local codes and the National Electrical Code, ANSI/NFPA 70 -Latest Edition. If the broiler is supplied with a cord, it will be type 4/4 or 6/4 SO 90 DEG C or higher, L1, L2, L3 and ground (See electrical schematic for proper cord size). The cord will be approximately 9 feet long.

2. On a new electrical service - MAKE CERTAIN THAT VOLTAGE IS WITHIN 10% OF THE UNIT'S RATED VOLTAGE. Appliance should be protected by a properly-sized circuit breaker furnished from the

main building circuit panel.

3. There is an Electrical Schematic located in the back of this Owner's Manual and also inside the electrical cabinet of the machine.

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2424, 121224 AUTOBROIL™

III. OPERATING INSTRUCTIONS

PRE-OPERATION CHECK (START-UP)

Before operating your Autobroil™, make a quick check of critical items as follows:

1. Check that no "binding" and resultant conveyor overloading is present. With the electrical

connections complete and with the electrical cabinet door secured shut, turn the broiler "ON" and run

the conveyors. Adjust the speed control for mid-point speed. The conveyor should move forward in smooth unaltered motion. Shut down immediately if there is any evidence of "binding" or other mechanical blockage.

2. Proper conveyor operation is when the amperage draw in the white or black motor lead from the circuit board (Figure 4) to the motor cord measures .15 DC amps or less. To check amperage the

cabinet door will need to be open. THIS PROCEDURE SHOULD ONLY BE PERFORMED BY A QUALIFIED ELECTRICIAN.

3. The Autobroil™ was tested at the factory before shipping so excessive amperage will indicate conveyor binding caused by shipping damage. Remove the roller chain (Figure 4) driving the conveyor in question and move the conveyor by hand. Loosen the sprockets (Figure 4) that drive the various axles and reposition them by 1/32" (1mm) until the conveyor tightness is eliminated. Twentyfive inch pounds of torque is required to drive a properly set up conveyor.

4. After the conveyor checkout is complete, turn on the heat switch. All heater elements should glow red. After the unit is up to temperature, these two elements will cycle. For trouble shooting problems,

see Section V. CAUTION: NEVER RUN HEAT WITHOUT CONVEYOR ON AS THIS CAN WARP THE CHAIN.

5. Before first use, and after any special cleaning, it is necessary to "season" the BROILER

is done by bringing the broiler chain to operating temperature and applying liquid shortening from a saturated cloth over the full width of the broiler chain while the chain makes five or six complete revolutions.

6. Check to see that the three heat reflectors (Figure 3) are in place.

BROILER ADJUSTMENT

The Autobroil™ requires 30 minutes to reach stable temperature. After this time lapse, the conveyor speed can be set to properly cook the product. The control will display “READY” when the broiler reaches cooking temperature.

TOASTER OPERATING INSTRUCTIONS

1. The temperature control is located behind the right side lift-off cover. The control is factory-preset for 425ºF (218ºC).

2. Adjust the bun platen height over the conveyor so the platen touches the bun as it is moved under the platen. To lower platen, turn the knob counter clockwise. To raise platen, turn the knob clockwise. This produces a caramelized surface. If the platen is adjusted too low, the bun will be crushed.

chain. This

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2424, 121224 AUTOBROIL™

TOASTER SHUT-OFF INSTRUCTIONS

1. The toaster section will continue to operate when the main heating (cooking) section of the broiler is on.

DURING A PROLONGED POWER FAILURE, NO ATTEMPT SHOULD BE MADE TO OPERATE THE CATERING EQUIPMENT.

TOASTER CONVEYOR SPEED

1. The toaster conveyor is the lower conveyor on the broiler. This conveyor is linked to the main cooking

chamber broiler and does not have a separate speed control for the toasting section. For broilers without computer controls, he toasting section is controlled by adjusting the toasting section temperature, using the control located behind the right side lift-off cover.

OWNER’S MANUAL

2424, 121224 AUTOBROIL™

OPERATION OF 6-BUTTON CONTROLLER

1. USER INTERFACE

The following is the user interface layout. This control is located on the front of the broiler on the

right side.

The Control Panel illustration above shows a typical control interface layout. Also See Figure 5 for Description of the Buttons. A Control Panel Quick Guide is located at the end of this manual.

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2424, 121224 AUTOBROIL™

TIME AND DATE SETUP (USED ONLY ON BROILERS WITH FOOD PROBE OPTION)

When the controller is in Off mode, the system Time and Date can be adjusted by pressing the Off Key for 10 seconds. The time is displayed on the 1 Down Keys, the hours are changed. Pressing the View Key moves the “focus” to the MM. Use the Up/Down Keys to adjust. By pressing View Key again, HH:MM are replaced by DD/MM (or MM/DD, depending on setting of temperature units) (1 to travel from one setting to another, and use the Up/Down Keys to modify. The View Key will return to HH:MM. Pressing the Off Key again stores the new Time and Date, and returns to Off mode.

ON/OFF KEYS

A normal press of this key turns on the controller. This causes the unit to start heating the elements and running the motors at the slowest recipe speed found (overcooked food is safer than undercooked food). This recipe is automatically selected (its corresponding LED lights up) and the temperature set point is the one defined by this same recipe. At any time in On mode, the user can change the selected recipe. When initially turned On, the unit will scroll PREHEAT on the 1st line until the broiler comes up to temperature. After this time, unit will display either READY, LOW, OR HIGH, depending on the current temperature readings.

A 3-second long press of the On/Off key turns off the unit. When the unit is turned Off, the Heater Kill output is deactivated to disable power to heating elements. The 1st line will then blink HOT for the Cool Down period (heating elements are off, but the conveyor motor is still running at the fastest speed allowed by the unit). At that point, the unit will then simply display OFF, and all outputs will be disabled.

RECIPE KEYS

Recipes are defined by a time and a temperature. The time basically sets the conveyor speed. The top three (3) recipe buttons are for the left conveyor belt and the bottom three (3) buttons are for the right conveyor belt.

When the unit is READY, a simple press of the recipe key will activate the selected recipe speed and temperature (LOW and HIGH conditions may or may not be triggered).

When a specific recipe must be changed, keep its button pressed for 3 seconds, until the 1 parameter name SET COOK TIME scrolls on the 1 LED’s will also blink indicating that they can be used. Pressing either Up or Down the 1st time simply makes the display switch to the parameter’s value (preceded by an arrow, as in ► 4.25, to indicate a changeable value). Subsequent presses will then modify the parameter. If Up or Down is not pressed in 5 seconds, the display resumes scrolling the parameter name.

Each recipe has 3 programmable parameters. To switch from one to the next, press the recipe key. After the last parameter is programmed, the unit resumes normal operation.

- SET COOK TIME,

- SET TOP TERMPERATURE,

- SET BOTTOM TEMPERATURE.

By default, all recipes are set as follows: Cook time: 5.00

line, and the HH is blinking. Using the Up and

line) and YY (2nd line). Use the View Key

line. The recipe as well as the Up/Down

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2424, 121224 AUTOBROIL™

Top temperature: 1325 ºF

Bottom temperature: 1250 ºF

VIEW KEY

The View key allows a user to view actual or programmed system parameters. Changes cannot be made just by using this key.

In normal operation (On mode), pressing the View key will start scrolling the message BOTTOM TEMPERATURE; also, the View and Up keys blink, indicating they can be used. If the broiler has two conveyors, the down key also blinks. The 2nd line shows the current conveyor speed of the illuminated recipe key. Pressing the Up key causes the 1st line to toggle between the message and the actual temperature value. The down key will cycle to the recipe for the second conveyor. A final press of the View key resumes normal operation.

When simply pressing the view key (not holding for 3 seconds), the 2nd line always shows the current conveyor speed. If the unit is Off, or Hot, the conveyor speed is not shown.

A 3-second long press of the View key allows users to see the current recipe programs without actually being able to change them. After this delay all 6 recipe LED’s blink, allowing the user to select the wanted recipe. Once a recipe is selected, the procedure is the same for all recipes. The 1st parameter shows COOK TIME. By pressing the Up key, the user can view the value that is currently programmed (but cannot change it). In 5 seconds the unit returns to the parameter name. Pressing the Recipe key a 2nd time will bring up BOTTOM TEMPERATURE. Again, using the Up key, the value can be seen. In 5 seconds, the unit returns to the parameter name. Pressing the recipe key one last time returns the unit to normal operation.

CONVEYOR ONLY KEY

The Conveyor Only key is only accessible from the Off state. This key allows the conveyor to be used without any heating. Press the Conveyor Only Key, then press the View Key. Press the Up arrow to start the left conveyor moving. Do not run the conveyor faster than 230 on the display. Press the Conveyor Only key to return to Off state. To start the other conveyor moving, press the View button 2 times, then press the Up Arrow to the desired speed. This does not change the programmed speed.

The parameter name SPEED is displayed on the 1 2nd line (expressed as a time). The flashing triangle indicates the speed can be changed using the Up and Down keys. Exit this mode by pressing Conveyor Only a 2 selection is lost (i.e. the 1

speed used in READY mode is always the slowest recipe speed).

The display shows the theoretical motor shaft speed (divided by 100) on the top display, and the real tachometer input (divided by 100) on the 2

line. The current speed is displayed on the

time; however, the speed

line. The theoretical value is simply derived from the requested speed (in terms of time) and the programmed K value. The real value is exactly that, the value coming in from the external tachometer. In an ideal world, the top and bottom lines should read very close to the same value.

The next screen of data in the Conveyor Only mode is the real RPM coming in from the tachometer input. By pressing the View key a 2 enough characters to display the information, as in the previous screen). A third and final press of the View key returns to the standard Conveyor Only screen with SPEED on the 1

time, this is displayed on the 1st line (which has

line.

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2424, 121224 AUTOBROIL™

RECORD/RECOVERY KEY

A recovery time is the time required for the temperature to go from 200°F to 800°F. A log exists for each heater (top and bottom). This is useful for service and HACCP purposes.

Do not press the Recovery Key while in the conveyor only mode. This key is available anytime the broiler is in normal operation. When pressed, the controller will list a log of the last 3 recovery times.

When the Recovery Key is pressed, the controller will successively display TOP 1, TOP2, TOP 3, BOT 1, BOT 2, AND BOT 3 recovery times, “1” being the most recent ramp logged. To actually see the logged time, press the Up key. After the last set is seen (BOT 3), the unit resumes normal operation.

FOOD PROBE KEY – THE FOOD PROBE IS OPTIONAL AND MAY NOT BE INSTALLED ON ALL BROILERS

This key is useable only when the unit is On (and the Food probe is enabled in the Low-level programming). It is accessible in 2 modes: automatic or manual. In manual mode, it is up to the user to press the Food Probe key to initiate a log, whereas, the automatic mode will remind the user (up to 6 times a day) to take a sample. Even in automatic mode, the user still has the capability to log extra samples manually as he/she wishes.

To do a manual log, the user must first make sure the temperature probe is correctly connected, and then press the Food Probe Key.

Step #1

This step prepares the controller for logging.

Display: SELECT RECIPE TO LOG is scrolled and recipe LED blink. Sound: None. User Action: Select the Recipe corresponding to the sample that will be probed.

Step #2

This step starts the logging as such, and gives the user time to set up for the sampling.

Display: Shows INSERT PROBE. Actual temperature can be seen when Up key is

pressed. The Up key and Record LED blink. Sound: None.

User Action: Insert the Food Probe into the sample according to local sanitary codes and normal restaurant procedures.

Step #3

In this step (basically a continuation of Step #2), the temperature continues to be displayed for the user. Nothing is being logged yet. The user must wait until a certain temperature is reached (that depends on what is being sampled (chicken, beef, etc.), as well as specific restaurant procedures).

Display: The 1 Record key LED also blinks.

Sound: No particular sound.

User Action: Keep Food Probe inserted. When temperature reaches a specific point (known to

line displays the temperature currently measured by the Food Probe. The

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2424, 121224 AUTOBROIL™

the user), the user presses the Record button.

Step #4

When the Record button was pressed, 2 things happened: the “Start Temperature” was stored, and the equalization timer was started. The controller now waits for the timer countdown to finish.

Display: The 1 However, there are no keys that function at this point. Sound: A beep every 1 second until 5 seconds before end of timer. During last 5 seconds, beeps accelerate to 2 beeps per second. User Action: Keep Food Probe inserted.

Step #5

In this last step, the actual log is written to memory. The temperature now displayed is logged as the “End temperature.”

Display: Last temperature read when timer reached zero is displayed until Food Probe Key is pressed again. This exits Food Probe. Sound: None. User Action: Remove probe, and press any key to resume normal operation.

Data Logged

The following is logged each time a sample is taken (in Step #5): Date/time stamp (MM/DD/YY if English (degree F), DD/MM/YY if Metric (degree C) as well as HH:MM) Recipe number (that was selected by user) Top element temperature Bottom element temperature Food “Start temperature” (when user pressed Record) Food “End temperature” ( at the end of the equalization time)

NOTE: At the end of Step #5, the user can record another sample of same recipe by pressing Record again instead of Food Probe, which clears display of previous samples. Display then shows probe’s current temperature and Steps 3, 4, and 5 are repeated.

UP AND DOWN KEYS

line continues to display the temperature currently measured by the Food Probe.

These keys are used to adjust the various system parameters when required. Time is incremented/decremented at 5-second intervals, and temperature at 5°F (2°C) intervals. These keys have a typematic feature associated with them. Keeping them pressed for more than 2 seconds causes the rate of change to accelerate to 25°F/10°C (temperature), or 20 seconds (time) every 500 msec.

2. DISPLAY

GENERAL In general, all messages are scrolled on the 1st line (about 2 characters per second), and times are displayed on the 2

Some keys have a LED, which is used to indicate various situations.

• On/Off LED: full on when broiler is On, otherwise Off.

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2424, 121224 AUTOBROIL™

• Up/Down LED’s: blink when Up/Down keys are expected.

• Recipe LED’s: on when a recipe is active, blinking when programming or viewing

recipes.

• Conveyor Only: blinking when feature is in use.

• Recovery: full on when feature is in use.

• Food Probe: off.

• View: full on when feature is in use.

• Conveyor: this is a group of 3 LED’s that simulate a rotating motion (about 2 changes per

second). This is active whenever the controller is receiving pulses from all installed tachometers.

• Top and Bottom Heater LED’s: full on when the corresponding heaters are on, otherwise off.

Also, whenever the arrow symbol (Z) is displayed with the data, this means that this is a parameter being changed/adjusted.

TIME DISPLAY

All conveyor speeds are displayed on the 2nd line, and are limited to 9.59. All other times are displayed as MM.SS, or HH:MM (in Low-level programming, this information is on the top line, which has more characters available). For example, 9.59 is 9 minutes and 59 seconds, and 1:10 is 1 hour and 10 minutes.

3. SYSTEM STATES

There are several states of operation as follows:

POWER-UP STATE

When a power-up occurs, there is a lamp test, where all LED’s come on for 5 seconds (this

includes all LED’s in the two displays). Following the lamp test, the software number and revision

are displayed. These are useful for troubleshooting purposes when several versions exist in the field. The first line shows the software number and the second line shows the revision in the format 1.09. Following this, the unit falls automatically into Off mode.

OFF STATE

In this state, the heaters are disabled. Nothing is displayed, except for OFF on the 1

The conveyor motor(s) may be used (and the speed displayed on the 2 Only function is used. Also the View and Recovery keys may be used in the Off state.

ON STATE

This is the normal cooking state. Before displaying READY, the unit will go through the

PREHEAT mode. The pre-heat mode lasts until the pre-heat time expires.

In the On mode, 2 extra conditions may exist: LOW and HIGH . Both depend on the current set point, and the current temperature. If the difference between the set point and the current temperature exceeds the programmable thresholds, then either the LOW or HIGH messages are displayed. This warns the user to wait until the READY condition comes back before putting product onto the conveyor. These conditions are likely to occur when a recipe calls for different temperatures.

line.

line) if the Conveyor

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2424, 121224 AUTOBROIL™

HOT STATE

This state is active after the unit is turned Off (or if an error occurs that causes the unit to shutdown). This state is basically a cool down step between the On and Off states. The conveyor

continues to roll at the fastest speed programmed, but the heaters are off. The display

continuously shows HOT until the Cool Down Time has elapsed, at which point OFF appears.

4. DIAGNOSTICS

This section describes the various diagnostics errors that are available.

HEATER TEMPERATURE PROBES

All probes are type-K probes. All temperature readings normally associated with a type-K probe are considered valid by the controller. However, if the probes become disconnected or broken, the controller will sound the buzzer display. The defective probe number is displayed on the 2nd line: On the toaster (lower) controller, there are two thermocouples connected:

• 1 is top heater temperature probe

• 2 is bottom heater temperature probe On the broiler (upper) controller, there is only one thermocouple connected. Pressing any key shuts the buzzer off, but will not remove the error message. The only way to remove the error message is to resolve the probe and/or connection problem.

When these heater probe errors occur, there are 2 possible ways to react, depending on the Probe Error parameter:

• If Probe Error Action is set to 0 (default), the unit goes into shutdown via the HOT state. After the Cool Down delay, the error message becomes OFF - PROBE ERROR instead of HOT -

PROBE ERROR.

• If Probe Error Action is set to 1, then the unit continues operation, at full temperature. The

operator will most likely have to adjust the recipe times, but at least the unit can still operate.

EXTERNAL DC ERROR

The DC I/O connector has a +5VDC supply. This supply is internally protected against overcurrents. Should this occur, the unit will internally disconnect the supply and report HOT –

EXTERNAL DC ERROR. The unit goes into shutdown (through HOT mode) and the only way to

reset this is to resolve the problem (most likely a short). Since the buzzer is powered through the

same +5VDC supply as the DC I/O connectors, the buzzer does not sound when this error occurs.

After the Cool Down delay, the error message becomes OFF - EXTERNAL DC ERROR instead of HOT - EXTERNAL DC ERROR.

5. EMERGENCY STOP SWITCH

An emergency stop switch is available on the front of the broiler as shown in Figure 1A. This toggle switch is for immediately stopping the conveyors in case of a conveyor jam or other problem requiring the broiler to shut down.

Do not use this switch for normal shut down at the end of the day. Use it if the conveyor jams or you need to stop the broiler quickly. This switch stops the conveyors and turns off the heating elements and turns off power to the control panels. When you turn the “Emergency Shut Off Switch” back on, the control panels will cycle through an initialization, then display “Off.” From here

you can start as normal.

and scroll HOT - PROBE ERROR on the 1st line of the

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