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Service Manual

XLT TS Series Conveyorized Oven

XD9011-TS
Rev C - 05/2008
© 2008 BOFI Inc.

BOFI™

P.O. Box 9090

Wichita, KS 67277-0090

Phone: 1-316-943-2751

Fax: 1-316-943-2769

www.xltovens.com

Summary of Contents for XLT TS Series

Page 1: ...Service Manual XLT TS Series Conveyorized Oven XD9011 TS Rev C 05 2008 2008 BOFI Inc BOFI P O Box 9090 Wichita KS 67277 0090 Phone 1 316 943 2751 Fax 1 316 943 2769 www xltovens com ...

Page 2: ...2 XLT TS Series Service Manual ...

Page 3: ...quarter turn bayonet style Use a continuity checker on removed fuses if a visual inspection is indeterminate Fuses are used to protect both the inputs and outputs of each particular device Also check to see if the gas supply is adequate The 3 4 gas hose should be connected to the oven and the shutoff valve fully opened Make sure that the quick disconnect is properly connected A full flow style shu...

Page 4: ...Combustion Blower Trouble Shooting 12 Modulating Valve and Signal Conditioner Trouble Shooting 12 Temperature Control Trouble Shooting 13 Instruction to switch from Fahrenheit to Celsius readout 17 Conveyor Subsystem 18 Conveyor Control Trouble Shooting 19 Dart MD10P Controller Programming Procedure 20 Conveyor Belt 21 Electrical Schematics 35 ...

Page 5: ...l See the electrical schematics There are a few differences between the natural gas model ovens and the propane LP gas models Electrically they are the same The burner orifice modulating valve and combination gas valves are different for the two models The propane models have smaller burner orifices and higher gas pressure ranges See the A4200 burner drawing in the Parts Manual for orifice size in...

Page 6: ...s the electrical components in the control box cool and it must have its filter cleaned frequently Fan Subsystem Trouble Shooting Symptom Possible Case Solution Fan not running No power Check Fuse F1 Check voltage from switch S1 Check voltage from relay R1 Check voltage at motor leads Fan not running Bad capacitor Check capacitor C1 or replace with known good capacitor Fan not running Bad automati...

Page 7: ...1 on the control box if present indicates whether the flame sensor in the burner pilot is hot When the burner control receives power the pilot valve opens and the spark generator operates If the pilot burner lights the burner control senses flame current through the spark wire the spark generator then shuts off and the main valve opens The burner control continues to monitor the pilot flame curren...

Page 8: ...is is when the oven is cold With the oven disconnected from power connect a 1 8 NPT brass hose barb fitting to the combination valve outlet pressure tap port Adjust the manometer scale to zero inches water column and connect the U tube manometer hose to the barb Connect the oven to power and turn on the fan switch and then the burner switch After the oven ignites the manifold pressure reading shou...

Page 9: ... increase the pressure Adjust to 5 7 for natural gas or 8 10 water column for propane Also if available use a micro amp meter to check the current 2 0 micro amps min in the flame sensor circuit The flame inspection window can be used to visually see the pilot light presence and color At minimal pressure the flame will be small or non existent out Too much pressure and the flame will be large and y...

Page 10: ... in the gas train burner casting orifice holder and or flame sensor bracket fasteners can cause flame sense problems Of course the pilot orifice size pilot pressure and air shutter setting also affect proper pilot flame adjustment For direct spark burners if equipped the flame still needs to paint the sense wire but the flame base must also be attached to the end of the burner casting It may be ne...

Page 11: ... are fully open supply hoses and pipes are good pilot orifice is not plugged and air is purged from the system Verify proper gas pressure Make sure electrical connections are good between burner control and pilot valve Check for 24 VAC across PV MV PV terminals on burner control If voltage is OK replace gas control if not replace burner control Main burner not lighting No power Check for 24 VAC ac...

Page 12: ...nt is below 550 F Output light on temperature control should be on if set point is above actual temperature Measure voltage across terminals 1 2 of signal conditioner should be 24 VAC Oven does not come up to set point temperature Faulty signal conditioner Check for voltage going out to modulating valve Voltage across terminals 3 4 should be close to 20 VDC Check wire continuity to top of modulati...

Page 13: ...r persists replace temperature control Error under range or over range Broken thermocouple Check to see that thermocouple is in good condition and is properly connected observe proper polarity Other Errors Internal diagnostic error Upon power up the instrument performs a self check It is possible that reprogramming or calibrating the control will clear the error see the instrument manual for the p...

Page 14: ...14 XLT TS Series Service Manual Figure 4 Temperature Control Figure 5 Burner Control and Signal Conditioner ...

Page 15: ...itching the fan on The display should show COnF press the FUNC key to step through the configuration parameters 3 The following configuration parameters should be entered verified Use the Up Down keys to change the values if necessary Ser1 0FF P7 Ser2 1 P8 Ser3 19 20 P9 AL1 P Ser4 7E P10 H A P11 nonE P1 22 P12 P2 P13 P3 0 P14 P4 600 P15 P5 rEU P16 0 P6 4 20 P17 SFt A 3111 4 The Display should now ...

Page 16: ...following operating parameters The only one that can be changed now is the SP set point SP 500 td 0 00 Snrt 0FF 1P 30 0 SP2 0 rL 0 nnn 0n rH 600 AL1 550 Grd1 Inf HSA1 0 1 Grd2 Inf Pb 5 0 OLH 100 0 ti 5 00 toL Inf rnP Inf 9 To change any of the above operating parameters set nnn to 3111 Safety Lock parameter Be sure to set nnn back to 5 after changing any parameters this turns the Safety Lock back ...

Page 17: ...1 2 3 At step 3 change the value of P1 to 5 and P4 to 300 4 Scroll through the remaining values until COnF is displayed 5 Remove the instrument from its case and return the V101 switch to the closed position Insert the instrument back into the case 6 If the display shows ERROR 400 simultaneously press the Up and Down arrow keys to clear this Your display should now be in Celsius To convert Celsius...

Page 18: ...itch turned off The conveyor gear motor is a brush type 90 VDC variable speed unit that has a pulse generator connected to the gear motor high speed shaft The pulse generator is powered by a 5 VDC supply from the conveyor control and provides a closed loop square wave output of 2 pulses per revolution of the high speed motor shaft back to the conveyor controller This scheme provides a constant con...

Page 19: ...r motor shaft and 3 4 conveyor shaft Check sprockets for worn teeth Display is dim Display intensity parameter is too low Adjust parameter 11 to a higher value range is 0 31 see programming instructions Conveyor runs full speed Loose pickup assembly Check to see if the pickup assembly is properly tightened to the gear motor shaft Conveyor runs full speed Loose pickup wires Check to see if the wiri...

Page 20: ... RPM Push the enter button again Note that the distances below are the length through the bake chamber 32 oven 64 sec 40 oven 79 sec 55 oven 109 sec 70 oven 138 sec 7 Push the up arrow key once the display should read P 31 Push the enter button once push the up arrow to the appropriate value For Dayton gear motors use 2980 and for Baldor use 3094 This is the RPM of the encoder at parameter 30 time...

Page 21: ...he fabric of the conveyor belt itself First things first safety Shut off gas to oven disconnect power and gas lines from oven For your own safety do not attempt this with gas line or electrical line connected Required tools 2 Phillips Screwdriver Needle nose Pliers Approximate time required 45 min 1 hr Remove conveyor flaps on both ends by removing the thumb screws Note which row of holes the scre...

Page 22: ... Remove the six 6 screws located around the control box cover Remove chain guard from side panel of control box by removing two 2 thumb screws tilting the chain guard to clear the lip of the control box cover and pull straight upward ...

Page 23: ...r firmly and lift up until the crumb tray bracket clears the conveyor opening Slide the conveyor 1 2 into the oven to release the tension on the chain Remove the drive chain from the conveyor sprocket and lay it in the tray Remove the cover carefully ...

Page 24: ...s process to ensure all goes smoothly The conveyor drive motor is located in the control box The drive motor is plugged into one of a pair of control wires Disconnect by pulling plastic connectors apart the first set of control wires and reconnect to the second set of control wires to reverse the direction of the motor Split belt units will have two motors and follow the same process for both ...

Page 25: ... removing two 2 screws each at the idler tension shaft blocks Once found disassemble the splice as shown in the following pictures Care must be taken not to over bend the wires while unhooking the links Find the belt splice by manually advancing the fabric ...

Page 26: ...ers grip the free end of the first splice link Pinch the adjacent rows together to relieve tension on the fabric at the splice Twist the end as shown to clear the link The first end of the link has been released To release the edge link rotate the link up as shown ...

Page 27: ...Service Manual 27 Continue to rotate until clear of the lower end hook Pass the hook back around the wire until disengaged Remove and set aside for reinstallation Proceed to the next splice link Grip the end as shown ...

Page 28: ...bric carefully as shown Do not crimp fold or roll tightly Twist the end as shown to clear the link Repeat for all links in the splice row Care should be taken to keep from distorting the splice links during removal Set aside all links for reuse ...

Page 29: ...e rolled turn the fabric end for end in preparation of reinstallation Correct side up Incorrect side up Fabric orientation is critical for the service life of the belt Check to see that the correct side is up by curling the end as shown ...

Page 30: ...ocket following the sprocket until feeding over the conveyor lower guide CAUTION Belt travel should be toward the head of the link Belt travel with the hook of the link constitutes a safety hazard from snagging loose material and dragging it into the conveyor or oven ...

Page 31: ...l 31 Continue feeding the belt through the conveyor as shown As you reach the idler sprockets feed the belt from underneath over the sprockets across the upper conveyor surface and back through the remaining conveyor belt circuit ...

Page 32: ...simply the reverse of the process described earlier during disassembly Once the belt has been spliced check the alignment of the power and idler sprockets for proper engagement as shown Tension the belt and replace the four 4 screws removed earlier from the idler tension shaft blocks Check the conveyor belt for free movement ...

Page 33: ...XLT TS Series Service Manual 33 Set the conveyor back in place Replace the control box cover Reinstall the drive chain ...

Page 34: ...34 XLT TS Series Service Manual Replace the flaps on both sides The conveyor belt direction reversal is complete Reconnect the oven and test for proper function Reinstall the chain guard ...

Page 35: ...XLT TS Series Service Manual 35 Electrical Schematics ...

Page 36: ...36 XLT TS Series Service Manual ...

Page 37: ...XLT TS Series Service Manual 37 ...

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