Marshall Air FR15BS Service Manual

This document contains the installation and operating instructions for:

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER

MODEL: FR15BS AUTOBROIL™

FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

INSTRUCTIONS TO PURCHASER:

1. THIS MANUAL NEEDS TO BE RETAINED FOR FUTURE REFERENCE.

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

MODEL: FR15BS AUTOBROIL™

TABLE OF CONTENTS

I. MACHINE SETTINGS....................................................................................... ......................………………........ 1

II. MACHINE INSTALLATION ............................................................................... ......................…………….......... 2

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

IV. SCHEDULED MAINTENANCE......................................................................... ......................………………........ 4

V. TROUBLESHOOTING..................................................................................... .......................……………….... 5-7

VI. REPLACEMENT PARTS................................................................................... .....................……………...... 7-10

BROILER LIMITED WARRANTY...................................................................... .......................…………….......... i

BROILER WARRANTY PROCEDURES.......................................................... ...........................……………...... ii

ILLUSTRATIONS

Broiler Overall Dimensions.................................................................................................. Figure 1

Broiler Pans and Covers...................................................................................................... Figure 2

Broiler Components............................................................................................................. Figure 3

Broiler Electrical Components............................................................................................. Figure 4

Axle Scraper......................................................................................................................... Figure 5

Meat Stripper Adjustment.................................................................................................... Figure 6

Electrical Schematic (208V, 60Hz, 10, 39 Amps)............................................................. Drawing No. 118738

Electrical Schematic (220V, 50Hz, 10, 37 Amps)............................................................. Drawing No. 118513

Electrical Schematic (380V, 50Hz, 30, 13 Amps)............................................................. Drawing No. 118508

Electrical Schematic (240V, 50Hz, 10, 34 Amps)............................................................. Drawing No. 118740

Electrical Schematic (415V, 50Hz, 30,12 Amps)............................................................. Drawing No. 118512

Electrical Schematic (220V, 60Hz, 30, 25 Amps)............................................................. Drawing No. 124673

Electrical Schematic (240V, 50Hz, 10, 34 Amps)............................................................. Drawing No. 131685

Electrical Schematic (415V, 50Hz, 30, 12 Amps............................................................... Drawing No. 135837

I. MACHINE SETTINGS

MODEL: FR15BS AUTOBROIL™

SERIAL NUMBER: ___________________________________________________________________ VOLTAGE: _________________________________________________________________________

SPEED SELECTOR SETTING: _________________________________________________________

PASS-THRU TIME: __________________________________________________________________ BROILER HIGH/LOW TEMPERATURE SETTING: __________________________________________

START-UP TECHNICIAN: ____________________________________________________________

START-UP DATE: ___________________________________________________________________

COMMENTS: _______________________________________________________________________

___________________________________________________________________________________

II. MACHINE 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.

APPLIANCE LOCATION

1. Position Autobroil™ to properly align with exhaust hood. Note name plate clearance.

2. The hood/ventilator for the appliance 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" from sides and 6" 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' 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 and the National Electrical Code. A grounding lug is attached inside the control cabinet. Safety precautions dictate this lug be used.

2. On a new electrical service - MAKE CERTAIN THAT VOLTAGE IS WITHIN 10% OF THE UNIT'S RATED

VOLTAGE AND THAT THE NEUTRAL IS IN FACT NEUTRAL. SERIOUS DAMAGE WILL OCCUR BY HAVING VOLTAGE ON THE NEUTRAL. 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 Owner's Manual and also inside the electrical cabinet of the machine.

III. OPERATING INSTRUCTIONS

PRE-OPERATION CHECK

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, set the forward switch "ON" for 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" until the conveyor tightness is eliminated. Twenty -five 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 except for one top element. After the unit is up to temperature, this one element will cycle. For trouble shooting problems, see Section V. CAUTION: NEVER RUN HEAT WITHOUT CONVEYOR ON.

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

BROILER ADJUSTMENT The Autobroil™ requires 20 to 30 minutes to reach stable temperature. After this time lapse, the conveyor

speed can be set to properly cook the product. SETTING TEMPERATURE CONTROLLER FOR PROPER HIGH/LOW OPERATION-WEEKLY

1. Follow the procedure below in order to set temperature control for 700°F (371 °C). After doing this, turn on the broiler.

2. Observe the temperature displayed: push "SET" and release to view the "SET POINT." To change set point push "SET" and, within three seconds, use the arrows to select a new set point. When setting the High/Low for proper operation, make the set point 700°F (371 °C). Press the set button again to make the change permanent. Broiler High/Low control is now set.

3. Place one meat patty on the broiler chain. Based on the appearance of the broiled patty, reset the Digital Speed Control for the desired broiling quality. (Note: This single patty should be cooked to the maximum degree of the Minimum/Maximum doneness tolerance.)

NOTE: THE HIGHER THE NUMERICAL VALUE SET ON THE DIGITAL SPEED CONTROL, THE

FASTER THE CONVEYOR CHAIN WILL RUN.

IV. SCHEDULED MAINTENANCE

DAILY CLEANING PROCEDURES

CAUTION: UNDER NO CIRCUMSTANCES SHOULD OVEN CLEANER EVER BE USED ON THIS APPLIANCE.

1. Scrape axles to remove daily grease buildup.

2. Remove the top heat shield (Figure 2) located above the meat conveyor and clean with wire brush.

3. Remove the meat stripper and wash with hot soapy water.

4. Wire brush the broiler conveyor and wipe with damp cloth.

5. Turn off the conveyor and remove the grease pan, product slide, product slide pan, meat stripper, and conveyor wiper; clean with hot soapy water.

6. Remove the lower reflector, conveyor arm cover, and front deflector; clean with hot soapy water.

7. The tube bundle should be removed and wire brushed. Further cleaning is not necessary; however, make sure carbon deposits are scraped from between the tubes with a tool such as a screwdriver.

8. Additional cleaning should exhibit good housekeeping and entail a general wiping of all exterior surfaces. DO NOT GET WATER ON THE ELECTRICAL CABINET OR THE HEATING ELEMENTS. NEVER HOSE THE MACHINE.

Monthly Cleaning Procedures

1. Remove the broiler conveyor chain from the machine and steam clean or soak in detergent solution. The conveyor is

removed by taking the conveyor apart at the cutlinks. When the conveyor is removed, check all heating elements and replace elements showing extreme corrosion. Check bearings for excessive wear and order replacements where needed. (See Figure 5 for cutlink illustration.) Make certain conveyors are reinstalled going in the correct direction.

PLACING CHAIN ON BACKWARDS WILL CAUSE SEVERE BINDING PROBLEMS.

CAUSTIC FUMES CAUSE ELECTRICAL COMPONENT DAMAGE AND WILL CAUSE MANY OTHER PROBLEMS IF USED TO CLEAN THIS BROILER. SEE FIGURES 2, 3, AND 5 FOR CLEANING.

PREVENTIVE MAINTENANCE

Once Every Three Months

1. Lubricate the roller chain with a few drops of the oil.

2. Inspect all motor brushes and replace if less than 1/4" is left.

3. CAUTION: DISCONNECT POWER BEFORE OPENING PANEL. Retighten the screw lugs on the main power

wires at the main terminal block inside the control box. Check that other electrical connections are still tight.

4. INVENTORY THE SPARE PARTS KIT AND ORDER MISSING PARTS AS NEEDED. KEEP A COMPLETE SET

OF PARTS ON HAND AT ALL TIMES.

V. TROUBLESHOOTING

This section contains a list of imagined problems with your Autobroil™. By locating the problem in this section, you may be able to make a quick repair. ALL ELECTRICAL TROUBLE SHOOTING INVOLVING ACCESS INTO THE MOTORS

OR ELECTRICAL ENCLOSURES MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN.

1. MACHINE HAS POWER BUT ELEMENTS ARE OUT.

POSSIBLE CAUSE

A) Check to make sure broiler on-off switch is in "ON" position and that the right voltage is coming out of

switch (see Electrical Schematic).

B) Check that heat switch is in ON position.

C) Check that power is passing to and through the large mercury relay. D) Check wiring to individual elements.

E) Check fuses to each element.

F) Check elements.

2. CONVEYOR WILL NOT RUN.

POSSIBLE CAUSE:

A) Check rocker switch to make sure power is flowing through switch.

B) Check fuse in control wiring in electrical cabinet. C) Make certain the conveyor is not mechanically jammed. The speed control will allow the motor to stall until

the binding or jamming is removed.

D) Check that set screws are tight in roller chain drive sprockets (Figure 4). E) If everything works up to this point, unplug the motor cord from the speed control and plug it into a spare

speed control. If the motor works, there is a failed speed control board (Figure 4). If it does not work, then the motor has failed.

3. MECHANICAL BINDING

POSSIBLE CAUSE:

A) Check roller chain tension for proper adjustment. Adjust motor if chain is too tight.

B) Inspect conveyor chain closely for bent or warped links that may be hanging up and causing a binding

condition. Also check that the chain links are not climbing out of the sprockets as the conveyor rotates. If they are, then loosen conveyor sprockets and reposition.

C) Make sure the axle assembly is clean and free of grease and food residue to allow smooth movement of

the conveyor.

D) Check the axle assembly to make certain all set screws, bearings, etc. are properly positioned and secure. E) Check that meat stripper is installed and positioned correctly (Figure 6).

F) Disassemble conveyor axle assembly and check condition of teflon bearing for excessive wear.

G) Visually inspect the motor drive chain assembly (Figure 3) for smooth rotation of chain and make certain

there is not binding or worn components.

4. THERE IS NO SPEED CONTROL ON THE CONVEYOR.

POSSIBLE CAUSE:

A) Attach the wires from the board (Figure 4) with no control into a spare circuit board. If there is still no

control, the potentiometer (Figure 4) for that conveyor has failed.

B) If attaching to the spare board makes it work, the circuit board has failed. C) If neither of the above works, then the motor has failed.

5. MEAT DOES NOT COOK COMPLETELY.

POSSIBLE CAUSE:

A) Check to make sure tube bundle is clean.

B) Check to make sure the heat shield is installed (Figure 2). C) Check to make sure all elements are working.

D) Check the speed of the conveyor. E) Check refrigeration. Holding temperature of meat may be lower than 0°F.

F) Check for excessive exhaust by momentarily turning exhaust fan off.

G) Check setting on temperature controller

6. CANNOT MAINTAIN CONSISTENT DEGREE MEAT COOKING.

POSSIBLE CAUSE:

A) Check that tube bundles are being cleaned in accordance with Item 7 in Section IV. B) Check store power supply for large voltage variation. A 5% swing in voltage will require more than a 5%

change in speed to counteract.

C) Meat of different temperatures is being used. (Frozen vs. partially thawed.) D) Check for excessive exhaust by momentarily turning off exhaust fan.

E) Check to make sure the heat shield is installed (Figure 2).

7. MEAT OVERCOOKED ON OUTSIDE AND UNDERCOOKED ON INSIDE.

POSSIBLE CAUSE:

A) Check refrigeration. Holding temperature of meat may be lower than 0°F.

B) Check that tube bundles are being cleaned in accordance with Item 7 in Section IV.

8. MEAT NOT SLIDING INTO HAMBURGER CATCH AREA.

POSSIBLE CAUSE:

A) Meat stripper (Figure 3) needs cleaning. B) Meat stripper needs adjustment (Figure 6).

C) Product slide (Figure 2) not installed properly. D) No teflon sheet installed (Figure 2).

VI. REPLACEMENT PARTS

When ordering parts, make sure to specify the machine model number and serial number as shown by the label attached to the right side cover.

PART# DESCRIPTION QUANTITY PER UNIT LOCATION 101037 Bundle Tube 1 Figure 2

101042 Conveyor Idler W/Meldin Bearing 2 Figure 3 101043 Conveyor Sprocket 2 Figure 3 101044 Conveyor Bearing 2 Figure 3 101363 Axle Scraper 1 Figure 5 104679 Link Cut Conveyor 15" 1 Figure 5 110042 Fan 1 Figure 4 115682 Conveyor Wiper Assembly 1 Figure 3

117228 Control Guard 1 Figure 4 117262 Product Slide Pan 1 Figure 2 117270 Thermocouple Wire Chase 1 Figure 4 117272 Product Slide Assembly with Teflon Sheet 1 Figure 2

+ 19 hidden pages