Star Manufacturing UM1854-NATCE, UM 1854 Installation Manual

®
®
®®®
GAS
CONVEYOR OVEN
MODEL
UM1854-NATCE
Operation
Instructions
2M-Z6832 Rev. H 10/20/2010
UM1854
2
These symbols are intended to alert the user to the presence of important operating and maintenance instructions in the manual accompanying the appliance.
RETAIN THIS MANUAL FOR FUTURE REFERENCE
NOTICE
Using any part other than genuine Star factory supplied parts relieves the manufacturer of all liability.
Star reserves the right to change specifi cations and product design without notice. Such revisions do not entitle the buyer to corresponding changes, improvements, additions or replacements for previously purchased equipment.
Due to periodic changes in designs, methods, procedures, policies and regulations, the specifi cations contained in this sheet are subject to change without notice. While Star Manufacturing exercises good faith efforts to provide information that is accurate, we are not responsible for errors or omissions in information provided or conclusions reached as a result of using the specifi cations. By using the information provided, the user assumes all risks in connection with such use.
MAINTENANCE AND REPAIRS
Contact your local dealer for service or required maintenance. Please record the model number, serial number, voltage and purchase date in the area below and have it ready when you call to ensure a faster
service.
SAFETY SYMBOL
Model No.
Serial No.
Voltage
Purchase Date
SPECIFICATIONS UM1854-NATCE
Gas Rating/Connection: 11.72kW (40,000 BTU/hr), 1/2" BSP female pipe connection Country: AT, DK, FI, IE, HU, PT NL LU, DE BE, FR ES, SE, GB, IT, CH, CR Gas Category: I2H I2L I2E 12E+ Pressure (mBar): G20@20 G25@25 G20@20 G20@20/25
Electrical Supply: 220-240v, single phase, 1.2A (max), 50Hz Approximate Weight (Single Oven with Cart): Installed - 280 Lbs (127.27 kg), Shipping - 350 Lbs (159.09 kg)
Dimensions: Width: 60.6" (153.9 cm) Depth: 39.9" (99.82 cm) - Front Door(s) Closed
51.3" (130.3 cm) - Front Door(s) Open Height: 43.3" (110.0 cm) - Single Oven with Stand
60.6" (153.9 cm) - Double Oven with Stand
62.8" (159.5 cm) - Triple Oven with Dolly Recommended Minimum Clearances:
Rear of Oven to Wall 0" (0 cm)
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GENERAL INFORMATION
This equipment is designed and sold for commercial use only by personnel trained and experienced in its operation and is not sold for consumer use in and around the home nor for use directly by the general public in food service locations.
First and foremost, each crate should be examined before signing the Bill of Lading to report any visible damage by the trucker in transit and to account for the proper number of crates. If there is apparent damage,
arrangements should be made to le a claim against the
carrier the claim must be initiated by the consignee. Proper and secure storage facilities should be arranged for the oven(s) if necessary to protect it from outdoor or damp conditions at all times before installation.
-IMPORTANT-
When you have all the crates unloaded, open the crates and remove all plastic covers. Inspect at once for concealed damage. If anything appears to be damaged, contact the appropriate persons immediately
to le a damage claim. After completing this inspection, nish unpacking the oven. Be sure to remove all paper
protection and packing material from the unit prior to lighting.
CAUTION
. Interstate Commerce Regulations require that
NOTICE
This appliance must be installed with a stand and casters designed by Star Manufacturing as part of a complete installation. The installation must also include a connector complying with either ANSI Z21.69 or CAN/ CGA-6.16 and a quick-disconnect device complying with either ANSI Z21.41 or CAN1-6.9. It must also be installed with restraining means to guard against
transmission of strain to the connector as specied in
the appliance manufacturer's instructions.
For your protection, we recommend a qualied
installing agency install this appliance in accordance with the rules in force within the country of destination. They should be familiar with gas installations and your local gas requirements. In any case, your gas
company should be called to approve the nal
installation.
This appliance, its pressure regulator, and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSIG. This appliance and its pressure regulator must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than 1/2 PSIG.
FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
The installation of the Appliance must conform to "ANSI Z223.1 - LATEST EDITION" AND ALL LOCAL GAS COMPANY RULES AND REGULATIONS.
IN CANADA INSTALLATION SHALL BE IN ACCORDANCE WITH THE CURRENT CAN/CGA­B149.1 NATURAL GAS INSTALLATION CODE OR CAN/CGA-B149.2 PROPANE INSTALLATION CODE AND LOCAL CODES WHERE APPLICABLE.
PURCHASER'S RESPONSIBILITY
It is the responsibility of the purchaser:
1. To see that the gas and electric services for the oven are installed on site in accordance
with the manufacturer's specications.
2. To unload, uncrate, and install the oven in its proper location and in accordance with this installation operation manual.
3. To see that all gas and electric services are
connected properly by a qualied installer
of your choice. All such connections must be in accordance with applicable code requirements.
4. To arrange for inspection and operation check­out by an authorized service technician. The
warranty becomes effective upon verication
of proper installation.
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IMPORTANT SAFETY INFORMATION
Do not attempt to operate the oven until connection of utility service has been fully inspected by an authorized service technician or a Star Service Representative. This service is required by Star in order to assist the purchaser in proper start-up of the oven on site. Please
note the specic details on the Warranty and make
certain utility services.
The warranty shall not apply if the oven is started up and operated prior to the utilities and oven being inspected and check-out made by an authorized service technician or a Star Service Representative.
that service connections are made to proper
CAUTION
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ ALL INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
CAUTION
Post in a prominent location the emergency telephone number of your local gas supplier and instructions to be followed in the event you smell gas. If the smell of gas is detected, immediately call the emergency phone number of your local gas company. They will have personnel and provisions available to correct
the problem.
CAUTION
It is required that the oven be placed under a ventilation hood to provide for adequate air supply
and ventilation.
CAUTION
Adequate clearance for air openings to the combustion control chamber on the right side of the oven is required. Do not obstruct the ventilation holes in the control panels as these provide the combustion air for the burner and
cooling air for the controls.
CAUTION
The oven is to be operated only on the type of gas
and electricity shown on the specication plate. The burner will not operate and gas will not ow through
the burner without electric power.
INSTALLATION INFORMATION
THE INSTALLATION INSTRUCTIONS CONTAINED HEREIN ARE FOR THE USE OF QUALIFIED INSTALLATION AND SERVICE PERSONNEL ONLY. INSTALLATION OR SERVICE BY OTHER THAN QUALIFIED PERSONNEL MAY RESULT IN DAMAGE TO THE OVEN AND/OR INJURY TO THE OPERATOR.
Qualied installation personnel are individuals, a rm,
a corporation, or a company which either in person or through a representative are engaged in and responsible for:
1. The installation or replacement of gas piping and the connection, installation, repair, or servicing of equipment.
2.
The installation of electrical wiring from the electric meter, main control box, or service outlet to the
electric appliance.
Qualied installation personnel must be experienced in
such
work, familiar with all precautions required, and
have complied with all requirements of state or local authorities having jurisdiction.
CAUTION
Minimum clearances must be maintained from all walls and combustible materials. Minimum clearances for this unit should be 0 inches from the rear (rear bumpers provided must be in place) and 6 inches from both sides. Keep the oven free and clear of all combustible material.
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LOCATION
The well-planned and proper placement of your oven will result in long-term operator convenience and satisfactory performance.
NOTE: usually be accomplished within the limited movement provided by the gas hose restraint. If the oven needs
to be moved further from the wall, the gas must rst
be removing the restraint. Reconnect the restraint after
the oven has been returned to its regular position. It is essential that an adequate air supply to the oven
be maintained to provide a sufcient ow of combustion
and
1. Place the oven in an area that is free of drafts.
2. Keep the oven area free and clear of all combustibles
3.
4. On all models, tripping of the blower motor's thermal
On gas conveyor ovens, routine servicing can
turned off and disconnected from the oven before
ventilation air. Follow these guidelines:
such as paper, cardboard, ammable liquids, and
solvents. Do not place the oven on a curb base or seal to a
wall. This will restrict the ow of air and prevent
p
roper ventilation to the blower motors. This condition must be corrected to prevent permanent damage to the oven.
overload device indicates an excessive ambient temperature at the back of the oven. This condition must be corrected to avoid permanent damage to the oven.
CAUTION
VENTILATION
A VENT IS REQUIRED: Local codes prevail. These are the "authority having jurisdiction" as stated by the National Fire Protection Association, Inc. in NFPA 96-Latest Edition. For further ventilation information
see below. A ventilation hood is required to remove heat and
cooking odors. For gas ovens, a ventilation hood is also required to remove the products of combustion. The hood and HVAC installation must meet local codes to gain approval by the authority having jurisdiction. Requirements may vary throughout the country depending on the location by city, county, and state. Obtain information from the authority having jurisdiction to determine the requirements for your installation. Obtain information and review copies of codes or documents that will be used to inspect and approve your installation. Your ventilation hood supplier and HVAC contractor should be contacted to provide guidance. A properly engineered and installed ventilation hood and HVAC system will expedite approval and reduce oven maintenance costs. Proper ventilation is the
responsibility of the oven's owner. The ventilation hood must operate in harmony with the
building HVAC system. It typically requires between
750 and 2500 CFM exhaust. (The efciency of various
hood
designs makes it necessary to specify such a wide range of ventilator CFM.) Make-up air must be supplied by either a hood design or the HVAC system to avoid a negative pressure condition. This will vary
with hoods from various manufacturers.
Failure to properly vent the oven can be hazardous to the health of the operator and may result in operational problems, unsatisfactory baking, and possible damage to the equipment.
Damage sustained as a direct result of improper ventilation will not be covered by the warranty.
CAUTION
Prevent airow through the cooking tunnel. Air
must NOT be directed onto the oven's front or rear or to the sides of the cooking area.
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The following drawing shows a typical installation and is intended to be a guideline. This is not a rigid
specication. Hood dimensions and positioning over
the oven will vary with hood manufacturer.
SMOKE CANDLE TEST
In order to verify the proper function of your ventilation system, a smoke candle test should be done. If testing a multiple oven system, this test should be done on the bottom oven. The conveyor coupling should be disconnected and the oven temperature must be set and operating at a minimum of 480°F (249°C).
Test Procedure:
1. Wear heat-resistant gloves to prevent burns.
2. Put the smoke candle in an 8"x8"x2" cake pan.
3. Insert candle through conveyor tunnel or oven door.
(Use Star Smoke Candle 2W-Z5668.)
4. Light the fuse of the smoke candle and immediately center the pan in the oven cavity on the conveyor belt (keeping the oven door closed).
5. Observe the smoke pattern coming out of all oven openings and the collection of this smoke by the ventilation system.
6. All smoke from the oven must be captured by the ventilation system.
GAS SUPPLY RATING AND SIZING
Calculations for pipe sizing must take into account the maximum usage rate of all other appliances in the kitchen or one or more of the appliances will suffer from inadequate or dangerous performance. The 1/2" BSP connection for the oven is generously sized for use in the control box of the oven. However, unless the oven installation is within 10 feet of the main building gas supply, the supply must be larger. For each oven,
a 3/4" exible quick connect hose and full port gas
shut-of main pipe supplying each oven branch may need to be larger depending on the number of appliances serviced, the number of elbows in the piping, and the pressure. This should be sized and installed by a professional familiar with any local codes that may also affect the installation.
f valve is recommended as a MINIMUM. The
ACCESS CONSIDERATIONS
Locating the gas valve(s), quick connect hose(s) and electrical outlet(s) at the control box end of the oven will allow easier access for any service visits. This improved access should make any necessary service quicker resulting in less kitchen disruption. It will also allow easier disconnection of electricity, gas, and restraints for cleaning around and behind the oven.
ELECTRICAL CONNECTION
Before making any electrical connections to this unit, check that the power supply is adequate for the voltage, amperage, and phase requirements stated on the rating plate. A wiring diagram is included herewith.
When installed, this appliance must be electrically grounded and its installation must comply with IEC codes, manufacturer's installation instructions, and applicable local municipal building codes.
PRESSURE REGULATION AND TESTING
Each oven is supplied with a regulator to maintain the proper gas pressure. The regulator is essential to the proper operation of the oven and should not be removed. A pressure reading can be taken at the 9mm test port on the rear of the combination valve. The reading should be taken while the oven is heating up. The regulator is located on the bottom of the gas combination valve, just inside the control box. There is no need to install an additional regulator where the oven connects to the gas supply unless the supply exceeds the maximum.
NOTE: The supplied regulator is evaluated for a maximum gas supply pressure of 14" water column (34.5 mBar). The recommended maximum gas supply pressure is 12" water column (29.9 mBar).
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Installation must conform with local codes or, in the absence of local codes, with NFPA54/ANSI Z223.1
- Latest Edition.
CAUTION
During pressure testing note the following:
1. The oven and its individual manual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.45 kPa). Turn OFF main gas shut-off valve or main gas supply line.
2. The oven must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.45 kPa).
3. If incoming pressure is over 14" water column, a separate regulator for the oven must be installed before the gas supply to the oven. It must regulate pressure to 11" water column (27.1 mBar) maximum.
Stacked Oven Install Preparation:
1. Remove door, conveyor, and nger assemblies.
2. Unbolt unit from shipping crate (4 bolts).
3. Turn unit on front as shown.
4. Remove top of lower oven (4 screws total, 2 each front and rear) and bolt to stacked oven base using 5/8 - 11 bolts (4 each, included).
5. Place top oven on lower unit and re-attach with screws for top of lower oven.
6. Use restraint on lowest oven to prevent any high loads that could tip the oven stack.
WARNING: To prevent damage to the control valve regulator during the initial turn-on of gas, it is very important to open the manual shut-off valve very slowly. After the initial gas turn-on, the manual shut-off valve must remain open except during pressure testing as outlined in the above steps or when necessary during
service maintenance. STACKING INSTRUCTIONS
The following instructions should be followed when stacking more than one unit.
Single Oven (or Bottom) Cart Install:
1. Remove door, conveyor, and nger assemblies.
2. Unbolt unit from shipping crate (4 bolts).
3. Turn unit on front as shown.
4. Slide legs into stand shelf and thread legs into bottom of oven.
5. Install casters into bottom of legs. Place casters with brakes to the front.
6. Position shelf as desired and fasten to legs.
7. CAREFULLY lift oven upright.
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RESTRAINT REQUIREMENT
HOLLOW WALL STUD OR MASONRY WALL
A
B
C
CAUTION
1. The installation shall be made with a gas connector that complies with local codes for connectors for movable gas appliances and a quick-disconnect device that complies with local codes for such devices in use with gas fuel.
2. The installation of the restraint must limit the movement of the oven(s) without depending on the connector, the quick disconnect device, or associated piping to limit the oven movement.
3. If the restraint must be disconnected during maintenance or cleaning, it must be reconnected after the oven has been returned to its originally installed position.
OPERATING INSTRUCTIONS
DO NOT ATTEMPT TO OPERATE THE OVEN until connection of utility service and installation has been fully inspected (start-up check-out) by an authorized service technician or your dealer/distributor in order to assure the oven is properly installed and in working order. The warranty becomes effective upon
verication of proper installation.
DO NOT WORK AROUND THE CONVEYOR BELT WITH LONG HAIR, LOOSE CLOTHING, OR DANGLING JEWELRY. GETTING CAUGHT IN THE BELT COULD RESULT IN DISMEMBERMENT OR FATAL INJURY.
Unless specied otherwise, conveyor travel is factory
set for left to right operation when facing the front of the oven. If a direction change is required, refer to "DISPLAY INFORMATION," section 3 for instructions on how to program the controller for a direction change. In addition, the conveyor belt must be changed to travel
in the new direction.
SAFETY OPERATING INSTRUCTIONS
The information contained in this section is provided
for the use of qualied operating personnel. Qualied
operating read the information contained in this manual, are familiar with the functions of the oven and/or have had previous experience with the operation of the equipment described. Adherence to the procedures recommended herein will assure the achievement of optimum performance and long, trouble-free service.
personnel are those who have carefully
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3) Press the up button ( ) to increase or the down button ( ) to decrease
TIME or TEMPERATURE. Hold button down for faster display changes.
4) After five seconds, the new numbers will be saved and the oven will display
new settings.
4) Après cinq secondes, les nouveaux nombres seront sauvés et le four montrera de nouveaux arrangements.
3) Tenez "vers le haut" bouton ( ) pour augmenter ou "vers le bas" boutonnez ( )
pour diminution de le TEMPS ou TEMPÉRATURE. Maintenez le bouton pour
des changements plus rapides.
1) Press the up and down buttons ( ) at the same time, hold for four
seconds until TIME display is blank.
2) Press the enter button ( ) to switch between TIME and TEMPERATURE.
Adjusting TIME and TEMPERATURE:
If burner does not light in one minute push the power switch to the "OFF" position and wait five minutes.
After five minutes, retry.
Push power switch "ON."
To Start:
2) Appuyez sur le bouton de "entrée" ( ) pour commuter entre le TEMPS et la
TEMPÉRATURE.
1) Tenez "vers le haut" et "vers le bas" boutonne ( ) en même temps. Tenez
les boutons pendant quatre secondes
jusqu'à ce que l'affichage de la
TEMPS soit blanc.
Après cinq minutes, nouvelle tentative.
Si le brûleur n'allume pas en une minute, poussée le commutateur de puissance dans
la position de "ARRÊTE" et attend 5 minutes.
Poussez le commutateur de puissance à "MARCHE."
OFF / ARRÊTE
Ajustement du TEMPS et de la
TEMPÉRATURE:
Pour Commencer:
ON / MARCHE
SWITCH CUTOUT
IL1050
Please take time to read the following safety operating instructions. They are the key to the successful operation of your Ultra-Max Conveyor
Oven.
SAFETY TIPS
For your safety, read before operating.
If you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switches.
3. Use an exterior phone to call your gas supplier immediately.
4. If you cannot reach your gas supplier, call the re
department.
In the event of a power failure:
1. Turn all switches off.
2. DO NOT attempt to operate the oven until the power is restored.
NOTE: In the event of a shut-down of any kind, allow
a ve (5) minute shut-off period before attempting
to
restart the oven.
General Safety Tips:
To adjust the time and temperature:
1. Press the DOWN and UP arrows ( ) at the same time. Hold for four seconds until the TIME display goes blank.
2. Press the ENTER button (
) to switch between
TIME and TEMPERATURE.
3. Press the UP arrow ( DOWN arrow (
) to decrease the TIME or
) to increase or the
TEMPERATURE. Hold either button down for faster display changes.
4. After ve seconds, the new numbers will be saved
and the oven will display the new settings.
To turn the oven off:
1. Push the power switch to "OFF." The oven is equipped with a cool-down feature for motor shaft and bearing protection. This enables the blower motor(s) to run regardless of the controller status. The blower(s) continue to run until the oven cools
to a safe temperature.
1. DO NOT use tools to turn off the gas control. If the gas cannot be turned off manually do not try
to repair it. Call a qualied service technician.
2. If the oven needs to be moved for any reason, the gas must be turned off and disconnected from the unit before moving the restraint cable. Reconnect the restraint after the oven has been returned to its original location.
3. DO NOT remove the control box cover unless theoven is unplugged.
OPERATION
To turn the oven on:
1. Push the power switch to "ON."
2. If the burner does not light in one minute, push the
power switch to the "OFF" position and wait ve
minutes.
3. After ve minutes, retry.
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DISPLAY INFORMATION
When operating the oven, there are three levels of access:
1. Store Level - General employees would know these functions and how to change them. While the oven is running, enter this mode by holding the DOWN
and UP arrows ( seconds. The TIME display goes blank and the TEMP setpoint is displayed. Adjust with the DOWN
or UP arrows. The ENTER button ( between TIME and TEMP. The parameter that can be adjusted is displayed, the other is blank. When TIME and TEMP are adjusted as needed, wait
ve seconds and SAVE is displayed. The values
are accepted and the controller begins controlling to these new values. The conveyor continues to operate at the same speed until a new value is accepted. The temperature control output should
be OFF during changes.
2. Manager Level - This is a lock so that TIME and TEMP cannot be changed even at the Store Level. While the oven is running, enter this mode by holding the DOWN and UP arrows simultaneously for 4 seconds. The TIME display goes blank and the TEMP setpoint is displayed. Release the UP arrow and continue to hold the DOWN arrow for an additional 4 seconds. The TEMP display shows LOC as the TIME display shows nO, which indicates that the TIME/TEMP parameters can be changed
) simultaneously for four
) toggles
after reaching the STORE level. yES indicates
that the parameters cannot be changed even after entering the STORE level. The LOC setting can
be toggled using the ENTER button (
).
ADDITIONAL FUNCTIONS
The conveyor belt direction and the temperature display can be changed on the conveyor oven
by a qualied technician. To change the belt
direction, the technician must reverse the motor direction and rotate the conveyor belt for proper oven function. A technician can also change the temperature display from Fahrenheit to Celsius. These changes can be made by the technician during the start-up/check-out or at a later date.
ERROR CODES
Error codes will display as ashing text messages for
diagnostic purposes. Any temperature or thermocouple error should turn the temperature output OFF and leave the conveyor running at the same speed. The belt error should turn the temperature output OFF. The speed error should display when the motor is unable to settle at the chosen speed. This might occur if a fast speed is chosen that the motor is unable to spin fast enough to achieve. The speed signal output will remain the
same but the display will ash the error message.
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BAKE TIME VERSUS TEMPERATURE
BAKE vs. DELIVERY TIME
Time to Delivery changes with product
but
Bake Time remains constant
at a steady conveyor speed.
28 (BAKE)
36 (DELIVERY)
44 (DELIVERY)
6:00 (BAKE)
7:43 (DELIVERY)
9:26 (DELIVERY)
1. Bake time is actually conveyor speed and is dened
as the time the product is actually in the oven. This is measured by noting the time when the leading edge of the product enters the oven and the time the leading edge of the product leaves the oven. This is adjusted by using the conveyor speed controller.
2. Bake temperature is adjusted by changing the setpoint of the temperature controller to the desired bake temperature. When the oven reaches the desired temperature, the red dot in the lower right corner of the temperature display will turn off and on as the controller maintains the temperature.
3. When establishing a bake time and temperature for a given product, the general rule shall be as the bake time increases the bake temperature decreases and the reverse is also true; increase temperature, decrease time. However, there are limits to the above rule. Going to extremes will result in a burnt exterior and raw interior or it will result in a very light color but over-baked product.
4. Once a good bake has been established, the ne
adjustments should be made by holding either the bake time or bake temperature constant, then varying the other.
CONVEYOR SPEED
Bake Time (Conveyor Speed) - As stated previously,
bake time (conveyor speed) is dened as the amount
of time elapsed between the time the leading edge of the product enters the oven and the leading edge of the product exits the oven. Bake time is controlled by adjusting the digital speed controller. The setting on the control panel indicates the actual bake time.
Bake time will be the same for any size product.
TIME OF DELIVERY
The time of delivery is the amount of elapsed time between the period when the leading edge of the product enters the oven and the trailing edge of the product is fully discharged and is ready to be delivered
to the customer.
Time of delivery changes if the product size changes.
Tip: Train yourself not to pull the product out of the oven when the leading edge comes out. Always wait until the entire product is out - the product needs this time to fully bake.
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