Star Manufacturing UM3255, UM3200 Installation Manual

®
CONVEYOR
OVEN
MODEL
UM3240 UM3255
Operation
Instructions
2M-Z9045 Rev. D 6/26/2007
UM3240
UM3255
1
SAFETY SYMBOL
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.
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
MAINTENANCE AND REPAIRS
Contact your local authorized service agent 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 faster service.
Model No.
Serial No.
Voltage
Purchase Date
Authorized Service Agent
Reference the listing provided with the unit
or
for an updated listing go to:
Website: www.star-mfg.com E-mail Service@star-mfg.com Telephone: (800) 807-9054 Local (314) 781-2777
The Star Service Help Desk
Business 8:00 am to 4:30 p.m. Central Standard Time Hours:
Telephone: (800) 807-9054 Local (314) 781-2777
Fax: (800) 396-2677 Local (314) 781-2714
E-mail Parts@star-mfg.com
Service@star-mfg.com Warranty@star-mfg.com
Website: www.star-mfg.com
Mailing Address: Star Manufacturing International Inc.
10 Sunnen Drive St. Louis, MO 63143 U.S.A
2
2
3
CAUTION
CAUTION
IMPORTANT
POST, IN A PROMINENT LOCATION, THE EMERGENCY TELEPONE NUMBER OF YOU LOCAL GAS SUPPLIER AND INSTRUCTIONS TO BE FOLLOWED IN THE EVENT YOU SMELL GAS.
Instructions to be followed in the event you smell gas shall be obtained by consulting the local gas supplier. If the smell of gas is detected, immediately call the emergency phone number of
your local gas company. There personnel and provisions available to correct the problem.
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 the NATIONAL FUEL GAS CODE "ANSI Z223.1 - LATEST EDITION" AND ALL LOCAL GAS COMPANY RULES AND REGULATIONS.
IN CANADA INSTALLATION SHALL BE IN ACCORDANCE WITH THE CURRENT CAN/ CGA-B149.1 NATURAL GAS INSTALLATION CODE OR CAN/CGA-B149.2 PROPANE INSTALLATION CODE AND LOCAL CODES WHERE APPLICABLE.
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ ALL INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
IMPORTANT
An electrical wiring diagram for the oven is located on the inside cover of the Control Box Top Lid.
NOTICE
THIS APPLIANCE SHALL BE INSTALLED IN CONFORMITY WITH CURRENT REGULATIONS & USED ONLY IN A WELL VENTILATED LOCATION. CONSULT THE
INSTRUCTIONS BEFORE INSTALLING AND USING THE APPLIANCE.
AT, CH, CZ, DK, ES, FI, GB, GR, HU, IE, IT, NO,
PT, SE
GAS I2H I2L I2E I2E+
P
(mBAR)
G20 @ 20 G25 @ 25 G20 @ 20 G20 @ 20/25
Gas/Country Designations
NL LU, DE BE, FR
1
®
UM3240 - UM3255 CONVEYOR OVEN
TABLE OF CONTENTS
page
Important Warnings 1 Specifi cations 3 Oven Components 4 General Information 5 Purchaser’s Responsibilities 5 Important Safety Information 6
INSTALLATION INFORMATION 7 Location 7 Gas Supply Rating & Sizing 7 Access Considerations 7 Electrical Connection 8 IEC/CEE Equipotential Ground 8 Pressure Regulation 9 Pressure Testing 9 Ventilation 10 Smoke Candle Test 10 Base Pad Assembly 11 Oven to Base Assembly 11 Stacking Instructions 12 Conveyor Installation 13 Conveyor Belt Direction 14 Restraint Requirement 15
OPERATING INSTRUCTIONS Safety Operating Instructions 16 Operation 16 Turn Unit On 17 Adjusting Time & Temp 17 Shut Down Procedures 17
DISPLAY INFORMATION Store Level 18 Manger Level 18 Additional Functions 18 Error Codes 18 Bake Time versus Temp 19 Conveyor Speed 19 Time of Delivery 19
MAINTENANCE INSTRUCTIONS
Daily, Monthly, 3 Months, Annually 20-21 Nozzle Finger Assembly / Dissembly 21 Conveyor Belt Tension 22 Conveyor Belt Link Removal 22 Wiring Diagram 23
EXPLODED VIEW & PARTS LIST
Front Panel Assembly 24-25 Rear Panel Assembly 26-27 Conveyor Assembly 28-29 Control Box Assembly 30-31 Control Box Door Assembly 32-33 Manifold & Blower/Burner Assembly 34-35 Warranty 36
2
SPECIFICATIONS
UM3240-NAT, UM3240-LP
Gas Rating/Connection: 120,000 BTU/hr (504 kcal/min)
3/4" NPT female pipe connection (BSP adapter supplied on CE models) Gas Supply Pressure: Natural - 5-6" water column (15-30 mBar) @ rated fl ow Propane - 11-12" water column (27.5-30 mBar) @ rated fl ow
Electrical Supply: Separate 15 Amp 208-240VAC, single phase, 50/60 Hz service per Oven Approximate Weight (Single Oven without base): Shipping - 868 Lbs (393.7 kg)
(Single/Double Base): Shipping - 177.3 Lbs (80.4 kg) (Triple Base): Shipping - 188.3 Lbs (85.4 kg) (Fingers): Shipping - 91.5 Lbs (41.5 kg) (Single Oven with base): Installed - 717 Lbs (325.2 kg) (Double Oven with base): Installed - 1292 Lbs (586 kg) (Triple Oven with base): Installed - 1878 Lbs (851.8 kg)
Dimensions: Width: 80.2" (203.7 cm) - w/control panel door closed
96.2" (244.3 cm) - w/control panel door open Depth: 60.5" (153.7 cm) - Front Door(s) Closed
102.9" (261.4 cm) - Front Door(s) Open Height: 43.1" (109.5 cm) - Single Oven with Stand
61.1" (155.2 cm) - Double Oven with Stand
63.5" (161.4 cm) - Triple Oven with Dolly
Recommended Minimum Clearances:
Rear of Oven to Wall 0" (0 cm) Conveyor Extensions to Wall 6" (0 cm) Allowing 16.25" on the control panel door to open will allow for easier service
UM3255-NAT, UM3255-LP
Gas Rating/Connection: 150,000 BTU/hr (630 kcal/min)
3/4" NPT male pipe connection (BSP adapter supplied on CE models) Gas Supply Pressure: Natural - 5-6" water column (15-30 mBar) @ rated fl ow Propane - 11-12" water column (27.5-30 mBar) @ rated fl ow
Electrical Supply: Separate 15 Amp 208-240VAC, single phase, 50/60 Hz service per Oven Approximate Weight (Single Oven without base): Shipping - 922 Lbs (418.2 kg)
(Single/Double Base): Shipping - 205.3 Lbs (93.1 kg) (Triple Base): Shipping - 216.3 Lbs (98.1 kg) (Fingers): Shipping - 122 Lbs 55.3 kg) (Single Oven with base): Installed - 827 Lbs (375.1 kg) (Double Oven with base): Installed - 1484 Lbs (673.1 kg) (Triple Oven with base): Installed - 2152 Lbs (976.1 kg)
Dimensions: Width: 94.6" (240.3 cm) - w/control panel door closed
110.6" (280.9 cm) - w/control panel door open Depth: 60.5" (153.7 cm) - Front Door(s) Closed
102.9" (261.4 cm) - Front Door(s) Open Height: 43.1" (109.5 cm) - Single Oven with Stand
61.1" (155.2 cm) - Double Oven with Stand
63.5" (161.4 cm) - Triple Oven with Dolly
Recommended Minimum Clearances:
Rear of Oven to Wall 0" (0 cm) Conveyor Extensions to Wall 6" (0 cm) Allowing 16.25" on the control panel door to open will allow for easier service
3
OVEN COMPONENTS
I
A
G
VIEW A
C
B
H
F
J
I
E
H
IL1173
OVEN COMPONETS DESCRIPTION
A: Conveyor Belt: Moves the product through the oven B: Conveyor Assembly: Supports the Conveyor Belt, the
ends fold up for easy removal.
C: Control Panel: Bright Red Display for easy notifi cation
of ovens current operation, and buttons for making quick modifi cations.
D: Air Intake: Located on the end of the control box to pre-
vent the electronic controls from overheating as well as to allow for a more direct air fl ow into the blowers. DO NOT BLOCK these air intakes and wipe them clean on a regular basis.
E: Machinery Compartment Access Door: Allows access
to the oven’s interior Finger components.
F: Access Window: This allows easy access to the cooking chamber, for product to be placed in to give
a shorter or additional cooking time to the product.
G: Heat Shutter: Can be adjusted to various settings, depending on product being placed in the oven, to
prevent heat loss
H: Crumb Tray: Catches crumbs and other material that drops through the conveyor belt. Located at
each end of the conveyor assembly.
I: Conveyor End & Side Stops: Prevents product from falling off of the moving conveyor. J: Fingers: Projects streams of hot air onto the product. K: Circuit Breaker 10Amp: Protects components from over amperage. L: Hi-Limit Reset: Monitors inside cooking temperature and will only trip when unitended temperature is
reached.
M: Nameplate: Has specifi c information regaring this units electrical & gas requirements as well as the
units serial number which is needed for any service that will be required. This number should be written in the inside cover of this manual and kept for future needs
N: Electrical Input: Electrical Supply connection must meet all national and local electrical code
requiremtns.
O: Gas Connection: The installation must confi rm with local codes or in the absence of local codes, with the National Fuel Gas Code, ANSI Z2223.1 latest edition.
K
L
M
N
VIEW A
O
D
4
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.
Before using your new equipment, read and understand all the instructions & labels
associated with the unit prior to putting it into operation. Make sure all people associated with its use understand the units operation & safety before they use the unit.
First and foremost, each crate should be examined before signing the Bill of Lading to report any visible damage by the freight carrier in transit and to account for the proper number of crates. If there is apparent damage, arrangements should be made to fi le a claim against the carrier within 15 days. Interstate Commerce Regulations require that 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 fi le a damage claim. After completing this inspection, fi nish unpacking the oven. Be sure to remove all paper protection and packing material from the unit prior
to lighting.
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 specifi ed in the appliance manufacturer's instructions.
For your protection, we recommend a qualifi ed installing agency install this appliance. They should be familiar with gas installations and your local gas requirements. In any case, your gas company should be called to approve the fi 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.
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 specifi cations and municipal codes.
2. To see that all gas and electric services are connected properly by a qualifi ed installer of your choice. All such connections must be in accordance with applicable code requirements.
3. To arrange for inspection and operation check-out by an authorized service technician. The warranty becomes effective upon verifi cation of proper installation.
5
CAUTION
CAUTION
CAUTION
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 specifi c details on the Warranty and make certain that service connections are made to proper 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.
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ ALL INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
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.
It is required that the oven be placed under a ventilation hood to provide for adequate air supply and ventilation.
CAUTION
CAUTION
CAUTION
WARNING
Minimum clearances must be maintained from all walls and combustible materials. Minimum clearances for this unit should be 0 inches from the rear and 6 inches from both sides. Keep the oven free and clear of all combustible material, for use only on Non-Combustable fl oors.
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.
The oven is to be operated only on the type of gas and electricity shown on the specifi cation plate. The burner will not operate and gas will not fl ow through the burner without electric power.
If the supply cord is damaged, it must be replaced by the manufacture, its service agent or similarly qualifi ed persons in order to avoid a hazard. Star replacement parts are listed in the parts list section of this manual.
6
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.
Qualifi ed installation personnel are individuals, a fi 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.
Qualifi 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.
UTILITY INSTALLATION
LOCATION
The well-planned and proper placement of your oven will result in long-term operator convenience and satisfactory performance.
NOTE: On gas conveyor ovens, routine servicing can 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 fi rst be turned off and disconnected from the oven before 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 suffi cient fl ow of combustion and ventilation air. Follow these guidelines:
1. Place the oven in an area that is free of drafts.
2. Keep the oven area free and clear of all combustibles such as paper, cardboard, fl ammable liquids, and solvents. Oven should only be used on Non-Combustible Floors.
3. Do not place the oven on a curb base or seal to a wall. This will restrict the fl ow of air and prevent proper ventilation to the blower motors. This condition must be corrected to prevent permanent damage to the oven.
4. On all models, tripping of the blower motor's thermal 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.
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 3/4" NPT 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" NPT fl exible quick connect hose and full port gas shut-off valve is recommended as a MINIMUM. The 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.
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.
7
WARNING
CAUTION
WARNING
ELECTRICAL CONNECTION
UTILITY INSTALLATION
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.
ENSURE THAT BOTH THE CIRCUIT BREAKER AND THE POWER (ON/OFF) SWITCH IS IN THE OFF POSITION BEFORE PROCEEDING.
BE CERTIAN THAT ALL PACKING MATERIAL HAS BEEN REMOVED FROM INSIDE THE OVEN'S CHAMBER.
When installed, this appliance must be electrically grounded and its installation must comply with the National Electric Code, ANSI-NFPA 70, latest version, manufacturer's installation instructions, and applicable local municipal building codes. In Canada, all electrical connections are to be in accordance with CSA C22.1 - Canadian Electrical Code Part 1 and/or local codes.
This device is equipped with a 3-prong (grounded) plug for your protection against shock hazard and should be plugged directly into a properly grounded three prong receptacle. DO NOT cut or remove the grounded prong from this plug.
EQUIPOTENTIAL GROUNDING - CE ONLY
On CE units, connect an equipotental ground wire to the ground lug shown in the fi gure below. The equipotential ground connection must meet current IEC/CEE and local code requirements. The ground lug is found on the rear side of the control box, below the equipotential ground symbol.
On certain CE/UK models install the IEC plug using the cord holder provided.
Symbol
Equipotential Ground Lug
Cord Holder
IEC Plug
IL1242
IEC/CEE Equipotential Ground Connection
8
CAUTION
WARNING
UTILITY INSTALLATION
PRESSURE TESTING GAS SUPPLY LINE
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 shut­off 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.
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.
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).
Installation must conform with local codes or, in the absence of local codes, with the National Fuel Gas Code, NFPA54/ANSI Z223.1 - Latest Edition, the Natural Gas Installation Code
CAN/CGA-B149.1 or the Propane Installation Code CAN/CGA-B149.2 as applicable.
PRESSURE READING
TEST NIPPLE
SET-SCREW
GAS PRESSURE
ADJUSTMENT SCREW
IS UNDER CAP
Oven Manifold Regulator, w/Set Screw
IL1191
OVEN MANIFOLD PRESSURE REGULATION
Each oven has been adjusted at the factory to operate with the gas specifi ed on the nameplate.
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 or replaced by another model unless approved by Star Manufacturing. A pressure reading can be taken at the test nipple provided. You must back the set-screw one turn for this test, be certain to re-tighten when you are done. Failure to reset the set­screw to its original position will create a gas leak once the unit is back in operation. The reading should be taken while the oven is heating up & at high fi re. The regulator is located on the bottom of the gas combination valve, just inside the control box. Adjust gas manifold regulator gas pressure by removing the cap and adjusting the regulator adjustment screw to match the pressure listed on the name plate (3.5" Nat, 4.8" Propane). Clockwise to increase, counterclockwise to decrease.
9
VENTILATION
INSTALLATION 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 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. (The effi 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. Air supplied directly from outside the building to the kitchen or oven area, non-tempered, could be used as supply air but the design would have to accommodate potential operational changes.
CAUTION Prevent airfl ow through the cooking
VENTILATION
CAPTURE AREA
VENTILATION
CAPTURE AREA
RIGHT SIDE FRONT SIDE
tunnel. Air must NOT be directed onto the oven's front or rear or to the sides of the cooking area.
The following drawing shows a typical installation and is intended to be a guideline. This is not a rigid specification. Hood dimensions and positioning over the oven will vary with hood manufacturer & local guidelines.
CAUTION
Damage sustained as a direct result of improper ventilation will not be covered by
IL1177
the warranty.
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.
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 so conveyor does not move 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 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 and window closed).
10
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.
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