XLT XD-9006E User Manual
XD-9006E
GA-AD-KD-SWD-HC
01/29/2014
XLT Gas Oven & AVI Hood
Parts & Service Manual
This appliance is for professional use by qualified personnel. This appliance must be installed by qualified persons in accordance with the regulations in force. This appliance must be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of substances harmful to health in the room in which it is installed. This appliance needs an unobstructed
flow of fresh air for satisfactory operation & must be installed in a suitably ventilated room in accor-
CAUTION
Electronic copies of this manual, Technical Specifications, Installation & Operation Manual, Architectural
Drawings, & a list of International Authorized Distributors are available at: www.xltovens.com
For use with the following XLT Gas Oven Versions:
Australia (AE) D
Korea (K) D
Standard (S) D
World (W) D
dance with current regulations. This appliance should be serviced by qualified personnel at least
every 12 months or sooner if heavy use is expected.
For use with the following AVI Gas Hood Versions:
Standard (S) C
World (W) C
2000887
XLT Ovens
PO Box 9090
Wichita, Kansas 67277
US: 888-443-2751 FAX: 316-943-2769 INTL: 316-943-2751 WEB: www.xltovens.com
2
WARNING & SAFETY INFORMATION
SAFETY DEPENDS ON YOU
Improper installation, adjustment, alteration, service or maintenance can
cause property damage, injury, or death. Read the installation, operating and
maintenance instructions thoroughly before installing, using, or servicing this
DANGER
Post in a prominent location instructions to be followed in the event you smell gas. This infor-
mation can be obtained by consulting your local gas supplier.
DANGER
In the event a gas odor is detected, shut off the gas at the main shutoff valve immediately.
Contact your local Gas Company or supplier.
Do not restrict the flow of combustion and/or ventilation air to the unit. Provide adequate
clearance for operating, cleaning, maintaining the unit & adequate clearance for operating the
gas shutoff valve when the unit is in the installed position.
Keep the area free & clear of combustible material. DO NOT SPRAY AEROSOLS IN THE
VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION.
Ovens are certified for installation on combustible floors.
Electrical schematics are located inside the control box of the oven & and in this manual. Dis-
connect input power to the unit before performing any maintenance.
This unit requires a ventilation hood. The installation must conform to local codes.
This unit may be operated with either natural gas or liquid petroleum fuel as designated on the
nameplate label located on the side of the unit.
This unit must be operated by the same voltage, phase, & frequency of electrical power as des-
ignated on the nameplate label located on the side of the unit.
Minimum clearances must be maintained from combustible & non-combustible construction
materials.
Follow all local codes when installing this unit.
Follow all local codes to electrically ground the unit.
Appliance is not to be cleaned with high pressure water.
XLT ovens are certified for use in stacks of up to three (3) units of XLT products. Integration
of other manufacturer’s products into an oven stack is not recommended, & voids any warran-
ties. XLT Ovens assumes no liability for mixed product applications.
Failure to call XLT Customer Service at 1-888-443-2751 prior to contacting a repair company
voids any & all warranties.
PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE.
equipment.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable liquids or vapors in
the vicinity of this or any other appliance.
XLT Ovens has spent millions of dollars designing and testing our products as well as de-
veloping Installation & Operation Manuals. These manuals are the most complete and easiest to
understand in the industry. However, they are worthless if they are not followed.
We have witnessed store operators and building owners lose many thousands of dollars in
lost revenue due to incorrect installations. We highly recommend you follow all instructions given
in this manual as well as follow best practices in plumbing, electrical, and HVAC building codes.
Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
WARNING & SAFETY INFORMATION
Definitions & Symbols
A safety instruction (message) includes a “Safety Alert Symbol” & a signal word or phrase
such as DANGER, WARNING or CAUTION. Each signal word has the following meaning:
Indicates a potentially hazardous situation that, if not avoided, can result in serious
injury or death.
DANGER
This symbol indicates high voltage. It calls your attention to items or operations
that could be dangerous to you & other persons operating this equipment. Read the
HIGH
VOLTAGE
WARNING
message & follow the instructions carefully.
Indicates a potentially hazardous situation, that if not avoided, can result in cuts or
being crushed. It calls your attention to items or operations that could be dangerous
to you & other persons operating this equipment.
3
CAUTION
NOTE
Tips give a special instruction that can save time or provide other benefits while installing
or using the product. The tip calls attention to an idea that may not be obvious to first-time
TIP
users of the product.
Indicates a potentially hazardous situation, that if not avoided, can result in minor
to moderate injury or serious damage to the product. The situation described in the
CAUTION may, if not avoided, lead to serious results. Important safety measures
are described in CAUTION (as well as WARNING), so be sure to observe them.
Notes indicates an area or subject of special merit, emphasizing either the product’s
capability or common errors in operation or maintenance.
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Warranty – US and Canada
Rev D Approval Date: 10/28/2013
XLT warrants gas ovens manufactured after April 1, 2009 and all electric ovens manufactured
after April 1, 2011 to be free from any defect in material and workmanship under normal use for five
(5) years from the date of original purchase by the end user, and further warrants main fan blades,
conveyor shafts, and conveyor bearings for ten (10) years. XLT further warrants all ovens to be free
from rust for ten (10) years from the date the equipment is originally purchased. XLT warrants AVI
hoods to be free from any defect in material and workmanship under normal use for two (2) years
from the date of original purchase by the end user purchaser. In the event of a part failure, XLT will furnish a replacement part and pay for all labor associated with the replacement of the part. If upon inspection XLT determines that the part is not defective, all incurred cost will be the responsibility of the
end user purchaser. This warranty is extended to the original end user purchaser and is not transferable without prior written consent of XLT. Damages are limited to the original purchase price.
DUTIES OF THE OWNER:
The owner must inspect the equipment and crates at time of receipt. Damage during shipment is
to be immediately reported to the carrier and also to XLT
The equipment must be installed and operated in accordance with the written instructions fur-
nished with the unit
This warranty shall not excuse the owner from properly maintaining the equipment in accordance
with the written instructions furnished with the unit
A copy of the “Initial Start-Up Checklist” must be filled out and returned to XLT when the unit is
initially installed, and/or when the unit is removed and installed in another location
The gas, electric, and HVAC utilities must be connected to the oven and installed by locally licensed
contractors
Failure to contact XLT Ovens prior to contacting a repair company for warranty work voids any and
all warranties
WHAT IS NOT COVERED:
Freight damage
Overtime charges
Any part that becomes defective because of utility services (power surges, high or low voltages,
high or low gas pressure or volume, contaminated fuel, or improper utility connections)
Any part that becomes defective because of moisture and/or other contaminants
Conveyor belts
Filters
Exhaust Fans
Light Bulbs
Normal maintenance or adjustments
This warranty shall not apply if the equipment or any part is damaged as a result of accident, casu-
alty, alteration, misuse, abuse, improper cleaning, improper installation, improper operation, natural disasters, or man-made disasters
CLAIMS HANDLED AS FOLLOWS:
Should any such defect be discovered, XLT must be notified. Upon notification, XLT will arrange for
necessary repairs to be made by an authorized service agent. Denial of services upon the arrival of an
authorized service agent will release XLT of any and all warranty obligations.
7761 W Kellogg Drive 67209-2003 - PO Box 9090 67277-0090 - Wichita, Kansas
Voice (316) 943-2751 - (888) 443-2751 - Fax (316) 943-2769
www.xltovens.com
Warranty – International
Rev D Approval Date: 10/28/2013
XLT warrants gas ovens manufactured after January 1, 2011 and all electric ovens manufactured after April 1, 2011 to be free from any defect in material and workmanship under normal use for
two (2) years from the date of original purchase by the end user. XLT warrants AVI hoods to be free
from any defect in material and workmanship under normal use for one (1) year from the date of original purchase by the end user. In the event of a part failure, XLT will furnish a replacement part to the
Authorized Distributor. The Authorized Distributor will pay for all labor associated with the replacement of the part. This warranty is extended to the original end user purchaser and is not transferable
without prior written consent of the Authorized Distributor. Damages are limited to the original purchase price.
DUTIES OF THE OWNER:
The owner must inspect the equipment and crates at time of receipt. Damage during shipment is
to be immediately reported to the carrier and also to the Authorized Distributor
The equipment must be installed and operated in accordance with the written instructions fur-
nished with the unit
This warranty shall not excuse the owner from properly maintaining the equipment in accordance
with the written instructions furnished with the unit
A copy of the “Initial Start-Up Checklist” must be filled out and returned to the Authorized Distribu-
tor when the unit is initially installed, and/or when the unit is removed and installed in another
location
The gas, electric, and HVAC utilities must be connected to the oven and installed by locally licensed
contractors
Failure to contact the Authorized Distributor prior to contacting a repair company for warranty
work voids any and all warranties
WHAT IS NOT COVERED:
Freight damage
Any part that becomes defective because of utility services (power surges, high or low voltages,
high or low gas pressure or volume, contaminated fuel, or improper utility connections)
Any part that becomes defective because of moisture and/or other contaminants
Conveyor belts
Filters
Exhaust Fans
Light Bulbs
Normal maintenance or adjustments
This warranty shall not apply if the equipment or any part is damaged as a result of accident, casu-
alty, alteration, misuse, abuse, improper cleaning, improper installation, improper operation, natural disasters, or man-made disasters
CLAIMS HANDLED AS FOLLOWS:
Should any such defect be discovered, the Authorized Distributor must be notified. Upon notification,
the Authorized Distributor will arrange for necessary repairs to be made by an authorized service
agent. The Authorized Distributor will notify XLT Ovens of all discovered defects.
7761 W Kellogg Drive 67209-2003 - PO Box 9090 67277-0090 - Wichita, Kansas
Voice (316) 943-2751 - (888) 443-2751 - Fax (316) 943-2769
www.xltovens.com
6
This manual, which contains an illustrated parts breakdown, has been prepared as an aid in
understanding how the unit operates, how to diagnose problems, and order parts for the equipment.
All of the parts, listed in the parts breakdown, are manufactured with the same precision as the
original equipment.
XLT parts and service providers are available worldwide. There are authorized service
providers located in the principle cities of the United States. There are also authorized Distributors
located throughout the world.
The Theory of Operation section describes how the unit operates. An understanding of
normal operation will greatly aid diagnosis and troubleshooting. The Troubleshooting section asks
simple yes or no questions. The next question or statement entirely depends upon the previous answer. It will lead to the solution of a problem in the most efficient way. The illustrated parts section identifies the various sub-assemblies and detailed parts which make up the equipment, as well
as the part number. An explanation of how to order parts is included.
This manual is designed to supplement the Installation & Operation Manual provided with
the unit when new. Please refer to it for descriptions, dimensions, weights, electrical requirements,
maintenance schedules, and certifications.
XLT Ovens wants you to be totally satisfied with every aspect of owning & using your
oven & hood. Your feedback, both positive & negative, is very important to us as it helps us understand how to improve our products & our company. Our goal is to provide you with equipment
that we can be proud to build & you can be proud to own.
To receive technical support for the oven or hood you purchased, XLT has qualified customer service personnel that can provide assistance on any type of XLT oven or hood equipment
problem you may experience. Customer Service is available 24/7/365 at 888-443-2751 or visit
www.xltovens.com.
GENERAL
Repairs of all appliances & ventilation exhaust hoods should only be performed by
a qualified professional who has read & understands these instructions & is familiar
with proper safety precautions. Read this manual thoroughly before installing or
DANGER
servicing this equipment.
Save this Manual
This document is the property of the owner of this equipment.
XLT Ovens reserves the right to make changes in design & specifications, and/or make additions to or improvements to its product without imposing any obligations upon itself to install
them in products previously manufactured.
All Right Hand & Left Hand designations in this manual are from the point of view as if
standing directly in front of the glass sandwich door.
Technical Support US: 888-443-2751 Technical Support INTL: 316-943-2751
TABLE OF CONTENTS
Warning & Safety Information..................................................................................................... 2
Warranty ....................................................................................................................................... 4
General ......................................................................................................................................... 6
Oven Theory of Operation ........................................................................................................... 8
Hood Theory of Operation ......................................................................................................... 14
Oven Troubleshooting ................................................................................................................ 17
Hood Troubleshooting ................................................................................................................ 18
Oven Service Procedures............................................................................................................ 20
Hood Service Procedures ........................................................................................................... 26
Oven Parts .................................................................................................................................. 28
Hood Parts .................................................................................................................................. 53
Oven Schematics ........................................................................................................................ 59
Hood Schematics ........................................................................................................................ 68
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For maintenance procedures, please refer to the XLT Installation & Operation Manual.
Revision History Table
Revision Comments Date
D Updated Warranty, Low flame settings, and Conveyor Control Programming 12/12/2013
E Added Korean Information 01/29/2014
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8
When the Main Switch (S1) is turned on;
1. The Oven Fan Motor (M1) located in the Back Wall will run.
2. The Fan (M3) located on the Control Panel will run.
3. The Temperature Control (TC) will display both the actual and set-point temperatures.
4. The Conveyor Control (CC) will display the belt time.
5. The burner will ignite.
6. The conveyor belt will move.
The first part of the Theory of Operation explains how electrical power is delivered to the
oven and initial sequences when the main operator switch is turned on. The remainder of the Theory of Operation section explains the function of components in alphabetical order. These components are also listed on the schematic.
Line voltage for Standard Ovens is assumed to be 120 VAC, 60 Hz.
Line voltage for World & Australian Ovens is assumed to be 230 VAC, 50 Hz.
Line voltage for Korean Ovens is assumed to be 220 VAC, 60 Hz.
Power originates at the electrical connection on the wall. Line voltage is then carried into
the oven through the power cord to the Terminal Strip (TS). The Neutral line is connected to the
TS, and several jumpers are used to bridge along the TS to make connection points for multiple
neutral lines from all components inside of the control box and Oven Fan Motor (M1). Line 1 is
also connected to the TS. From the other side of the TS, a wire connects to Terminal T11 on the
Cool Down Timer (R1), then continues to the High Limit Switch (S3 World & Australian only),
through the Main Circuit Breaker (CB1), and stops at the Main Switch (S1). Unless the outlet on
the wall has no power, the circuit just described has power at all times.
When S1 is turned on, line voltage will be carried through the switch simultaneously to
four locations via two parallel circuits:
Terminal T6 of the Cool Down Timer (R1)
Terminal T5 of the Temperature Control (TC), via a Circuit Breaker (CB3)
And:
Transformer (XFMR)
Power Supply (PS)
GAS OVEN THEORY OF OPERATION
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GAS OVEN THEORY OF OPERATION
CAP - The Capacitor is physically mounted inside the Control Box but wired to the externally
mounted Oven Fan Motor (M1). The Oven Fan Motor (M1) is a Permanent Split Capacitor (PSC)
motor. PSC means a capacitor motor in which the starting capacitor and the auxiliary winding remain in the circuit for both starting and running. The CAP is a 30.0 uF +/- 6% 370VAC/B 50/60
Hz
CB - Circuit Breakers are used to protect electrical components. The current value is printed on
the front of all breakers. If a CB is tripped, eliminate the cause and press the front to reset.
CC - The Conveyor Control is supplied 24 VDC by the Power Supply (PS) via a Circuit Breaker
(CB6 & CB7, optional) to Terminals 4 & 5. The belt time is displayed, and is user-adjusted by
pressing and holding the up or down arrow button switches. See the Specification Sheet for minimum and maximum belt times. The motor speed is calculated based on the time that is entered.
This time is translated to a RPM on the motor shaft depending on the size of the oven, the diameter
of the sprocket, and the gear ratio of the gearbox. Once the motor is running, hall sensor inputs are
fed back into the driver to determine the speed the motor is currently running at. This input goes
into a PID algorithm to adjust the Pulse Width Modulation (PWM) output to control the speed to
match the target speed that was calculated first. This PWM is adjusting the average voltage that
the motor phases are seeing. As the average voltage goes up, the motor will speed up. As the average voltage drops, the motor speed will also drop. The maximum speed is based on a continuous
18-24V being supplied to the motor. The phasing of the controller is dependent on the hall sensor
signals that are being returned. The controller reads the hall sensor position and from there knows
which phase of the motor receives the 18-24V signal, which phase of the motor is the return and
which phase of the motor is left open. As the motor spins, the hall sensors change, which dictate
which phases are energized.
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FLT 1 - Is an inline filter used in world ovens. The filter is placed in series with the Line voltage
being supplied to the oven. The filter is used to reduce Electromagnetic Interference created by our
equipment and back feeding it into other appliances. EMI filters use capacitors to inhibit direct
current while permitting alternating current. EMI filters also use inductors which redirect high
voltages, and high frequencies by dissipating them to ground.
FS Optical - The Optical Sensor consists of a plastic housing and an flame detector mount with
mirror. The optical sensor utilizes 24VDC which originates at the PS. The positive line is supplied
via the TC1 terminal 1&2 and terminates at the connector for the sensor. The negative line is supplied via the TS #5 and terminates at the connector for the sensor. If the TC1 alarm would activate
and open the circuit, the optical sensor will loose voltage and cause the oven to shut down burner
functionality until alarm is closed. From the connector a brown wire sends a 6.75 μA signal to the
S1 Terminal of the IC. The minimum signal to maintain operation is .7 μA.
When flame is present, the sensor visually looks at the Flicker rate and the UV charactistics of the
flame. If either of these do not appear the sensor will not send current to the IC. The ignition will
continue thru its process until lockout.
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IC - The Ignition Control (IC) is powered by 24 VAC from the Transformer (XFMR). Incoming
power will be interrupted by (S2) centrifugal switch mounted in the M1. When the IC receives
power, it initiates a pre-purge lighting sequence. A red LED will blink once after about 2-3 seconds to give notification that the lighting sequence has started. After about 30 seconds, two events
occur; 1) a high-voltage electrical signal will be sent to the Spark Igniter (SI) from the Spark Terminal, and 2) a 24 VAC signal will be generated across Terminals V1 & V2. The high voltage
jumps across a gap in the SI creating a spark that can be heard, although the IC only produces this
spark for four (4) seconds. One end of the Rectifier Plug is connected to Terminals V1 & V2
through a Circuit Breaker (CB5). The Rectifier Plug rectifies the 24 VAC to 24 VDC. The other
end of the Rectifier Plug is connected to Terminals 1 & 5 of the Main Valve (V1-V2). The V1-V2
valve will open, allowing fuel to flow into the burner. When the two simultaneous events occur,
fuel flow and spark, ignition should occur. When flame is sensed by the FS, a DC signal is sent to
Terminal S1 of the IC. The IC uses this DC current to prove ignition. A minimum of .7 µA is required to maintain operation. If the Burner lights, the LED will not flash. If the Burner fails to
light, the LED will flash three (3) times, repeatedly, and the IC will not attempt to re-light.
M1 – The Main Motor is a Permanent Split Capacitor (PSC), single phase, capacitor run motor and
has an internal centrifugal switch (S2). The motor is dual voltage and reversible. The voltage to
power the motor comes from the Cool Down Timer (R1) terminal T9 via CB2, and the motor will
continue to operate for approximately 30 minutes after the main switch is turned off. There are no
user serviceable parts in the motor, and the bearings are permanently lubricated.
GAS OVEN THEORY OF OPERATION
M2 - The Conveyor Motor (M2) is a brushless 24 VDC gear motor. The motor receives current
from the Conveyor Control (CC) through three (3) wires; 1) A black or “W” phase, 2) a white or
“V” phase, and 3) a red or “U” phase. They carry between 18 to 24 VDC. Each wire is energized
by the Conveyor Control (CC) in sequence to provide power to the individual stator coils which, in
turn, provide motor rotation.
To determine the rotors position and send this position to the controller, three (3) Hall Effect switches are utilized. They read the rotational information from a disc mounted on the rotor
assembly. This information is transmitted to the CC by three (3) wires; 1) an orange “U” phase
pole signal output, 2) a green “V” phase pole signal output, and 3) a green/white “W” phase pole
signal output. These are located in a plug that inserts into the CC. There are two (2) additional
wires in this plug; 1) a purple wire which is supply voltage for the pole sensor, and 2) a gray wire
that is ground.
The CC, using an internal logic circuit, energizes the stator coils to provide proper rotation
and sets the energization (phase) timing to obtain the desired belt speed set on the controller.
The motor drives an integral gear box that reduces the motor output speed to give the correct travel
time to the conveyor belt. The integral gear box is sealed and permanently lubricated with grease.
The ratio is 1/200. This motor contains no serviceable parts.
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GAS OVEN THEORY OF OPERATION
M3 - The Flow Path Pressure Generating (FPPG) fan supplies combustion air for the Burner. It is
wired in parallel with M1 and will continue to operate for 30 minutes after S1 is turned off. A filter is provided to ensure clean air.
PS - The Power Supply rectifies line voltage to 24 VDC, and supplies power to the Conveyor Control (CC) and Flame Sense (FS). A 4 amp fuse is used to provide over current protection, which is
mounted on the PS itself. There are no other fuses used anywhere else.
PU - The Pick-Up is physically mounted within the Conveyor Motor (M2) and utilizes hall effect
technology integral to the M2 to monitor the rotation speed. The hall effect signal is transmitted to
the CC, which converts it into linear travel speed of the conveyor.
R1 - R1 is a 30-minute off delay relay which functions as a cool down timer. Applying power to
T6 activates the relay, which sends a voltage signal out from T9. When power is removed from
T6, voltage continues from T9 for 30 minutes. T9 supplies voltage to the Main Fan Motor (M1)
through a Circuit Breaker (CB2), and also supplies voltage to the FPPG (M3) Fan. M1 and M3 are
the only components that will continue to operate for 30 minutes after S1 is turned off. The off
delay relay is a safety feature to allow the oven to cool down to room temperature, and to eliminate
heat stress on the components of the oven.
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RP – The Rectifier Plug has an integrated full-wave bridge rectifier circuit. It converts 24 VAC
from the Ignition Control (IC) into 22 VDC that is sent to the Multi-Valve (V1-V2).
S1 - This Switch is a SPST normally open switch, mounted on the front of the Control Box. Activating this switch applies voltage to Terminal T6 of the Cool-Down Timer (R1) and to the primary
side of the Transformer (XFMR). When used with the optional AVI Hood System, a remote
switch mounted in the front of the AVI Hood replaces it.
S2 - This Switch is a SPDT centrifugal switch physically mounted inside the Main Motor (M1).
When M1 comes up to full speed, S2 closes and sends a 24 VAC signal to the Ignition Control
(IC) and the Signal Conditioner (SC). It functions as a safety feature to prevent burner operation if
the M1 fails to rotate.
S3 - High Limit Switch (World). This is a bi-metal, NC, SPST switch physically mounted in the
side panel of the Bake Chamber. It’s purpose is to provide fail safe operation. If the temperature
of S3 exceeds 600°F, it opens and interrupts line voltage to all components except the Main Motor
(M1).
SC - The Signal Conditioner is powered by 24 VAC from the Transformer (XFMR) via the Main
Motor Centrifugal Switch (S2) and the Temperature Control (TC) on terminals 1 & 2. Incoming
power will be interrupted by the Main Fan Motor if it stops rotating. The function of the SC is to
convert a 4-20 mA signal from the TC to a 45-250 mA signal and then applies that signal to the
multi valve (V3). This in turn modulates the valve to allow an appropriate amount of fuel to control temperature.
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12
SI - The Spark Igniter consists of a copper-clad metal mounting plate, and an electrode encapsu-
lated in ceramic insulation. The insulated electrodes has a 1/4” male spade welded to it. This spade
connects to the Spark Terminal on the Ignition Control (IC) via a spark wire. The end of this rod is
positioned near the burner tube in such away so as to create a small gap. When the high-voltage
signal from the IC reaches the gap, it is forced to jump the gap resulting in a spark.
T/C - The thermocouple is a type K. It consists of two different conductors that produce a voltage
proportional to a temperature difference between either end of the pair of conductors. The T/C is
connected to Terminals 9 & 10 of the TC. The milli-volt signal is used to display the actual temperature.
TC1/TC2 - The Temperature Control (TC) has line voltage applied to terminal T5, and neutral
voltage applied to terminal T4. There are two displays; one for actual temperature and one for setpoint temperature. Actual temperature is determined by the Thermocouple (T/C), connected to
terminals 9 & 10, with T9 being the negative terminal and T10 being the positive terminal. The
user determines the set-point temperature by pressing and holding the <UP> or <DOWN> arrow
button switches. The TC sends a 4-20 mA (milli-amp) signal to the Signal Conditioner (SC) depending upon the relationship between actual temperature and set-point temperature. An alarm
relay exists between terminals 1 & 2, If the actual temperature achieves temperatures above set
temperature the alarm circuit will open and not allow voltage to be supplied out to the FS. The
Maximum Operating Temperature is set at the factory and cannot be field adjusted.
GAS OVEN THEORY OF OPERATION
V1-V2 & V3- The Multi-Valve assembly has three (3) Gas Valves. The Main Valves (V1-V2)
operate in series, and are wired in series via the Rectifier Plug. The Rectifier Plug rectifies 24
VAC from the Ignition Control (IC) to 22 VDC. V1-V2 are solenoid valves and are open continuously during burner operation, regardless of either actual or set-point temperature values. V3 is a
modulating valve, and is controlled by a variable electrical signal from the Signal Conditioner
(SC). There are two (2) fuel pressure testing ports; one for incoming pressure, and one for both
high-bias and low-bias pressure. The upper port is used for incoming pressure, while the lower
port is used for high- and low-bias pressure. There are two (2) hex adjusting nuts; an 8mm nut for
adjusting high-bias pressure, and a 5mm nut for adjusting low-bias pressure.
XFMR- The Transformer steps down line voltage to 24 VAC. It supplies power to the Signal
Conditioner (SC), Ignition Control (IC), and the Centrifugal Switch (S2). One terminal on the secondary side is connected to chassis ground by a green wire. The XFMR is ON whenever the Main
Switch (S1) is on, and is independent of the Cool Down Timer (R1). Note: The XFMR is
equipped with an integrated circuit breaker for standalone protection.
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14
When any one of, or all of, the Hood Operator Switches (S2, S3, & S4) are turned on;
1. The Exhaust Fan Motor (M1) located on the roof will run.
2. The Variable Frequency Drive (VFD) will display a set value. The values are preset from the
factory and can be referenced in the I&O manual.
3. The ovens associated with the corresponding switches will turn on.
The first part of the Theory of Operation explains how electrical power is delivered to the
hood and initial sequences when the main operator switch is turned on. The remainder of the Theory of Operation section explains the function of components in alphabetical order. These components are also listed on the schematic.
Line voltage for Standard Hoods is assumed to be 208/240 VAC, 60 Hz. (1) Phase
Line voltage for World & Australian Hoods is assumed to be 230 VAC, 50 Hz. (1) Phase
Line voltage for Korean Ovens is assumed to be 220 VAC, 60 Hz.
Power for the hood originates at building’s electrical service panel. A total of two (2) cir-
cuits are required; (1) is a single phase high voltage circuit for VFD/Fan circuit that connects to TS
1 terminals 1 & 2, and (2) is a single phase low voltage circuit for Fire Suppression circuits and
relays that connect to TS 2 terminals 23 & 24. (3, 4, and 5) are single phase low voltage minimum
20A circuits for each oven that connect to terminals 7-8, 9-10, and 11-12 which are located on TS
1.
HOOD THEORY OF OPERATION (STD w/FS)
Switches mounted on the hood control lighting, VFD activation, Make Up Air (MUA) activation
and oven function. When S1 is activated voltage will be carried to the lights turning them on.
When XLT Ovens are installed with an AVI Hood, the Switch Relocation Cord (SRC) effectively
eliminates the Main Switch located on the oven and transfers control to the DPDT switches on the
hood. When S2-S4 switches are activated a contact on the back of the switch will allow a low voltage signal to be sent to the VFD signaling it to turn on to a set frequency, at the same time when
S2 is activated another contact switch will allow line voltage to be carried through the Switch Relocation Cord (SRC) to the oven activating it. Also the S2 switch sends line voltage to R4 to activate a MUA relay coil which switches from Normally Open (NO) to Normally Closed (NC) and
completes the circuit to allow operation of the MUA unit.
The NO switch in the fire alarm system in the building needs to be connected to TS 2 terminals 13
& 14. When the alarm is activated it will supply line voltage to R3 making the relay switch from
NC to NO, disabling all three ovens, shutting down MUA and disabling the lights and cooling fan
at the same time. When line voltage is supplied to the coil of R3 it also is supplied to R2, switching
it from NC to NO activating the VFD to run full speed.
CB - Circuit Breakers are used to protect electrical components. If a CB is tripped, eliminate the
cause and press the front to reset.
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HOOD THEORY OF OPERATION (STD w/FS)
CS - The Current Sensor is a device that detects electrical current in a wire, and then generates a
signal proportional to it. It drives an LED indicator lamp (LT3) to indicate that the fan is drawing
current and operating. A minimum of 1.5 VAC is required.
LT1 & LT2 - These are standard incandescent light bulbs, and should illuminate when the contacts of S1 are closed.
LT3 – This is a green LED indicator that is driven by the CS to indicate that the fan is drawing
current and operating.
M1 – The Exhaust Fan Motor is a 3-phase, direct drive motor. In normal operation, it is powered
by the VFD through R6, and it’s RPM will vary as the frequency from the VFD varies. There are
no user serviceable parts in the motor, and the bearings are permanently lubricated.
M2 & M3 – The Cooling Fan Motor is a 1-phase, direct drive motor. In normal operation, it is
powered through R1. These fans are used to keep the control box for the hood cool. There are no
user serviceable parts in the motor, and the bearings are permanently lubricated.
PLUG 1, 2, & 3 – These are circular electrical plugs on one end of the Switch Relocation Cord
(SRC). The Plugs connect to Receptacles 1, 2, & 3 on the bottom of the Hood Control Box. The
other end of the SRC plugs into the oven wire harness, and eliminates the operator switch supplied
in the oven. Conversely, when the operator switch on the hood is turned off, the corresponding
oven is turned off as well.
R1 – Is a SPDT relay, which is a electrically operated switch. It uses an electromagnet to operate
a switching mechanism. Line voltage is supplied from the VFD and current flows through a coil in
the relay, causing the contacts in the relay to close. This will complete a circuit for the M2 & M3
to activate and turn on.
R2 – Is a SPDT relay, which is a electrically operated switch. It uses an electromagnet to operate
a switching mechanism. No line voltage is supplied from TS2 via R3 until the fire alarm is activated. Once fire alarm is activated voltage is supplied to the coil in the relay, causing the contacts
in the relay to close. This will complete a circuit between terminal 1 and 5 on the VFD activating
the VFD to turn on to full speed.
R3 – Is a SPDT relay, which is a electrically operated switch. It uses an electromagnet to operate
a switching mechanism. No line voltage is supplied from TS2 to R3 until the fire alarm is activated. Once fire alarm is activated voltage is supplied to the coil in the relay, causing the contacts
in the relay to switch from NC to NO. This will interrupt the circuit in the relay supplying voltage
to the lights, the ovens and the cooling fans, the MUA will shut down and the exhaust will run at
full speed.
15
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16
R4, R5, & R6 - These are SPDT relays, which are electrically operated switches. They use an
electromagnet to operate a switching mechanism. When S2, S3, or S4 are activated line voltage is
supplied to the coil of corresponding relay switching it from NC to NO. This completes a circuit
for a damper that could be wired into 17,19, or 21 on TS 2. If only one damper is used install a
jumper between 17,19, and 21 to activate damper no matter which oven is on.
REC 1, 2, & 3– These are electrical receptacles, which supply line voltage for the ovens. Each re-
ceptacle should have a 20A dedicated breaker supplied from the buildings electrical panel. Line
voltage to each receptacle is supplied via TS1 and R3. If fire alarm is activated R3 will disrupt line
voltage being supplied to receptacle shutting the oven off.
REC 4, 5, & 6– These are circular electrical receptacles mounted on the bottom of the Hood Con-
trol Box. The switch relocation cord (SRC) connects into these and to main switch in the corresponding oven. This deactivates the switch on the oven and relocates the operation of it onto the
front of the hood.
S1 - This SPST (NO) switch is located on the front of the hood and controls the lights.
S2, 3, & 4 - These DPST (NO) switches are located on the front of the hood and control the ov-
ens, as well as initiating and sequencing the operation of the VFD and damper circuits.
Line voltage is continuously applied to pin 1 of REC 4, 5, & 6, which is connected by a
wire to a contact in S2, 3, & 4. This is shown on the schematic as the lower RH connection point
of S2, 3, & 4. When the switch contacts are closed, shown on the upper LH connection point on
the schematic, power is applied to pin 2 of the receptacles, as well as terminal B of R1, 2, & 3.
Wires also connect terminal B and pin 4 of the receptacles. In essence, S2, 3, & 4 replace the
switches on the ovens, and also energize the coils of R4, 5, & 6, which closes the relay contacts
and sends a control signal to dampers or Make-up Air System.
The other set of contacts, shown as the upper set on the schematic, connect terminal 24 of
the VFD and terminals 4, 3, & 2 respectively. The VFD generates it’s own 24 VDC signal volt-
age, and the switches serve as inputs to the VFD. The VFD outputs user-selected frequencies depending upon the combination of switches that are closed.
TS 1, 2, &3- These are terminal strips, which serves as a connection point for wires.
VFD - The Variable Frequency Drive (VFD) converts the AC supply voltage to DC and then con-
verts the DC to a suitable three-phase frequency source for M1. Incoming power connects to terminals L1, L2, & L3. M1 connects to terminals T1, T2, & T3 through TS1. The VFD generates
it’s own 24 VDC control voltage on terminal P24. S2, S3, & S4 serve as user-controlled inputs
and connect terminals 1, 2, & 3 to terminal P24. User inputs include a <RUN> and <STOP/
RESET> buttons, as well as <UP> and <DOWN> arrow buttons. A complete manual can be
found at www.xltovens.com.
HOOD THEORY OF OPERATION (STD w/FS)
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OVEN TROUBLESHOOTING
Mechanical Function
If your oven does not function properly, please verify the following conditions:
1. Verify that the power cord to the oven is connected and/or plugged in if equipped with a plug
and receptacle.
2. Check all circuit breakers on the oven control panel to ensure they have not been tripped.
3. Check to see that the circuit breakers in the building electrical service panel have not been
tripped or turned off.
4. Check the Manual gas valve to verify that it is turned on completely. The handle on the valve
should be parallel with the gas piping when the valve is turned on, and the handle will be perpendicular with the gas piping when the valve is turned off. Also remember that anytime the
gas hose has been disconnected it will take time to purge the air from the gas train.
5. Verify that oven is supplied with gas by disengaging and reengaging the quick-disconnect fitting on the gas hose.
6. Check to see that the oven is fully assembled. All of the fingers must be properly installed.
Incorrect or incomplete finger placement can cause a “windy” condition that can cause the
burner not to light.
17
7. Gas line size and pressure must be adequate to support total BTU requirements with all appliances in store turned on. Refer to the “Oven Gas Requirements” section of this manual.
If your oven still does not function properly, XLT has qualified customer service personnel
that can provide assistance on any type of XLT oven problem you may experience. Customer Service is available 24/7/365 at 888-443-2751, or visit www.xltovens.com.
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18
Initial troubleshooting of the hood:
1. Make sure that the RUN lamp and POWER lamp on the VFD are lit.
2. Check to see that the green fan LED on the switch plate is on.
3. Check the actual frequency of the VFD controller. To access the actual frequency, press and
hold the <FUNC> button until the Display Mode shows D001. Release the button, and then
press one (1) more time. This will show actual operating parameters, not programmed parameters.
4. Check to see that the breaker on the hood electrical box is not tripped.
5. Check to see that the breaker in the service panel is not tripped.
6. Make sure the Switch Relocation Cords (SRC) are properly installed to the oven(s).
7. Check to see that the grease filters are clean & installed properly.
8. Check to see if the exhaust fan is rotating in the correct rotation. To verify fan rotation, remove the lid on the exhaust fan. Visually inspect rotation in accordance with label on fan housing.
9. Press and hold the <FUNC> button until the Display Mode shows D002. Fan Motor Amp display, At max HZ Amp display should be less than 2 amps.
The VFD has internal diagnostics, and may show the following ERROR codes:
E01-E04 Inverter output was short circuited
E05 motor overload is detected by electronic thermal function
E07 DC bus voltage exceeds a threshold
E09 DC bus voltage is below a threshold
E14 Ground fault detected between controller output and motor
If any of the above error codes are displayed, then follow these steps to clear them.
1. Check VFD display for error code and record it.
2. Clear error by pressing the <STOP RESET> button.
3. Press the <RUN> button to activate exhaust fan.
4. Normal operation resumes with no error codes.
5. If error codes return press the <STOP RESET> button.
HOOD TROUBLESHOOTING
If the corrective actions listed above do not correct the problem, then XLT has qualified
customer service personnel that can provide assistance on any type of XLT Oven or AVI Hood
problem you may experience. Customer Service is available at 888-443-2751 24/7/365, or visit
www.xltovens.com. The website offers an interactive troubleshooting guide that can further assist
in diagnosing problems.
For repairs or maintenance of the fire suppression system and components, contact the local Ansul dealer or XLT for assistance.
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20
OVEN SERVICE PROCEDURES
Conveyor Control Programming Procedure
Read the entire instruction before programming.
TIP
Configuration Key Functions
< L > = Behind the <L> in XLT is a hidden button. This is used along with the up and down
button to access the programming mode. Use this after each step to advance to the
next parameter when programming.
UP = Increases the setting of the selected parameter.
DOWN = Decrease the setting of the selected parameter.
1. Enter Programming Mode/Program the bake length
Press the <L> button and both <UP> and <DOWN> button simultaneously to enter
programming mode.
0055 will appear on screen, this is already set from factory
Press the <UP> button until the desired belt length is displayed. Belt lengths will read
as follows:
1832 = 0032
1855 = 0055
2440 = 0040
3240 = 0040
3255 = 0055
3270 = 0070
3855 = 0055
3870 = 0070
2. Program the Total Reduction Value - Press the <UP> button until the desired settings is
reached. All ovens = 300.
3. Set Speed Trimming Value - Press the <DOWN> button until the display shows 0000.
4. Set Fast Bake Limit - Press the <UP> button until the display shows 1:30.
5. Set Slow Bake Limit - Press the <UP> button until the display shows 17:00.
6. Set Conveyor Motor Rotation - Press the <UP> OR <DOWN> buttons until the display shows
1 for right-to-left direction, or 2 for left-to-right belt direction.
7. Save and Exit Programming Mode - Press the <L> button two (2) times to save and exit Programming Mode.
After leaving Program Mode, 1:30 run time will appear on the display. Press and hold the <UP> or
<DOWN> buttons until desired run time appears.
Once the conveyor motor rotation is changed the belt direction should be changed also.
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OVEN SERVICE PROCEDURES
Ser1 OFF
P1 5˚C/22˚F
P3 0
P4 315˚C/600˚F
P5 reU
P6 4-20
P9 AL1.P
P10 H.A.
P11 nonE
P16 0
P17 SFtA
P18 norL
P19 norL
P24 reU
P25
OFF
P28 0
P29 0n
P30 0
P34 OFF
P36 tn.30
P37 0
P39 n0FL
P41 P.I.d.
P42 10.0
P43 Fn.SP
P44 0
SP 260°C/500°F
SP2 0
nnn 3111/OFF
AL1 315°C/600°F
HSA1 0.1
Pb 5.0
ti 5.00
td 0.00
1P 30.0
rL 204°C/400°F
rH 310˚C/590°F
Grd1 InF
Grd2 InF
OLH 100.00
toL InF
rnP InF
Table 3
Table 1
Table 2
Temperature Control Programming Procedure
Read the entire instruction before programming.
TIP
Configuration Button Functions
<FUNC> =The new setting of the selected parameter is stored and the
display advances to the next parameter. This is required be
tween each parameter.
UP= Increases the setting of the selected parameter.
DOWN=Decrease the setting of the selected parameter.
1. Open V101 switch for Basic/Advanced Configuration (Figure 1)
Remove instrument from its case
Open switch V101
Verify that jumper J106, is configured as shown
Re-insert the instrument back in its case
2. Basic Configurations
Using the configuration buttons, scroll through parameter codes,
changing them to match (Table 1)
After P17 _._._._. Will appear
Using the configuration buttons scroll to 262 and press <FUNC>
to enter Advanced Configurations
3. Advanced Configuration Procedure
Using the configuration buttons scroll through parameter codes
changing them to match (Table 2)
4. Close V101 switch after Basic/Advanced Configuration (Figure 1)
Remove instrument from its case
Close Switch V101
Re-insert the instrument back in its case
5. Operating Parameters Procedure (Table 3)
On the first pass through change nnn to 3111 to unlock the ad
vanced configuration
Scroll through the parameter codes again and change the nnn to
5 this locks the advanced configuration
Scroll through the parameter codes again and verify nnn in ON
21
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22
OVEN SERVICE PROCEDURES
Multi-Valve Adjustment Procedure
Check Incoming Pressure:
Loosen screw 1 full turn counter clockwise (Figure 1)
Connect Manometer to this test port
Turn main switch to on position and wait for burner to light (up to 30 seconds)
Document incoming pressure on startup checklist. (If new installation)
Turn Main switch to the off position
Disconnect Manometer
Tighten screw clockwise until snug (Figure 2)
Figure 1
Figure 2
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OVEN SERVICE PROCEDURES
Multi-Valve Adjustment Procedure
Check High Bias Pressure:
Loosen screw 1 full turn counter-clockwise (Figure 3)
Connect Manometer to this test port
Turn main switch to on position and wait for burner to light (up to 30 seconds)
23
Figure 3
Using an 8mm socket turn the High Flame Bias screw (Figure 4) until desired setting is
achieved. Use chart on next page (Figure 5) for correct valve settings.
8 mm
Figure 4
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24
W/C mbar kPa W/C mbar kPa
3.5 8.75 0.875 10 25 2.5
0.1 0.25 0.025 0.5 0.25 C
Multi-Valve Adjustment Settings
All Ove n Models
Natural Gas
LP Gas
Low Flame Bias
High Flame Bias
OVEN SERVICE PROCEDURES
Multi-Valve Adjustment Procedure
Figure 5
Check Low Bias Pressure:
Pull one of the two blue wires going into the modulating valve. (This simulates a temperature
drop and allows the oven to run at Low Flame Bias)
If the flame goes out turn the 5mm screw clockwise 1 turn to increase Low Flame
Bias
NOTE
Wait 30 seconds and the oven will re-light.
Using a 5mm socket turn the Low Flame Bias screw (Figure 6) until desired setting is
achieved. Use (Figure 5) for correct valve settings.
5 mm
Figure 6
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