OWNER'S MANUAL - Bakedeco · 2016. 2. 14. · OWNER'S MANUAL Important: Keep in safe, easy-to-find location. AutobroilTM Model 77BG Marshall Air Systems, Inc. 419 Peachtree Drive

OWNER'S MANUAL

Important: Keep in safe, easy-to-find location.

AutobroilTM Model 77BG

Marshall Air Systems, Inc. 419 Peachtree Drive South

Charlotte, North Carolina USA 28217 704-525-6230

704-525-6229 FAX

Sales and Service 1-800-722-3474

OWNER’S MANUAL 77BG AUTOBROIL™

OM77BG RV070512 Copyright© 2012 Marshall Air Systems, Inc. All rights reserved

This document contains the installation and operating instructions for:

MODEL: 77BG AUTOBROIL™

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

AVERTISSEMENT

Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inflammables dans ie voisinage de cet appareil, ni de tout autre appareil.

INSTRUCTIONS TO PURCHASER:

1. ANSI Z83.11 STANDARDS REQUIRE THAT YOU POST IN

A PROMINENT LOCATION THE PROCEDURES TO FOLLOW IN THE EVENT THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED FROM THE LOCAL GAS SUPPLIER.

2. THIS MANUAL NEEDS TO BE RETAINED FOR FUTURE

REFERENCE.

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

AVERTISSEMENT: Une installation, un ajustement, une aleration, un service ou un entretien non conforme aux normes peut casuer des dommages a la propriete, des blessures ou la mort. Lisez attentivement les directives d’installation, d’operation et d’entretien avant de faire I’installation ou I’entretien de cet equipment.





TABLE OF CONTENTS PAGE

I. BROILER SETTINGS (Quick Reference) ........................................................................1

II. BROILER INSTALLATION...............................................................................................2

Pre-Installation...........................................................................................................2 Appliance Location .................................................................................................2-3 Electrical Information .................................................................................................3 Gas Piping to Appliance ............................................................................................3 Restraining Device.....................................................................................................4 Pre-Operation Check ..............................................................................................4-5 Performance Criteria..................................................................................................5

III. OPERATING INSTRUCTIONS ........................................................................................6

Broiler Adjustment-Daily ............................................................................................6 Lighting Instructions For Electronic Ignition System..................................................6 Shut-Off Instructions ..................................................................................................6 Marshall Computer Overview (With 8-Button Control)............................................7-8 Marshall Computer Overview (With 6-Button Control)..........................................9-17 IV. SCHEDULED MAINTENANCE......................................................................................17

Daily Cleaning Procedures .................................................................................17-19 Monthly Cleaning Procedures..................................................................................19 Quarterly Cleaning Procedures and Preventive Maintenance............................19-20 V. TROUBLE SHOOTING .............................................................................................20-24

VI. REPLACEMENT PARTS ..........................................................................................25-27

VII. ILLUSTRATIONS

Broiler Dimensions...................................................................................................30 External Removable Parts .......................................................................................31 Internal Removable Parts ........................................................................................32 Broiler Arm Assembly 77BG....................................................................................33 Drive System 77BG .................................................................................................34 Gas Distribution .......................................................................................................35 Standard Burner Assembly......................................................................................36 Axle Scraper/ 8 Button Control ................................................................................37 Burner Shield Installation/ Thermocouple Location .................................................38 Scheduled Maintenance Parts.................................................................................39

WIRING SCHEMATICS DOMESTIC Wiring Schematic (77BG, 120V, 1Ph, 60 Hz) (With 8-Button Control) ..........#139978 Wiring Schematic (77BG, 120V, 1Ph, 60 Hz) (With 6-Button Control) ..........#144101 INTERNATIONAL Wiring Schematic (77BG, 240V, 1Ph, 50 Hz) ................................................#141642



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I. BROILER SETTINGS SERIAL NUMBER: _____________________________________________________________ TYPE OF GAS: ___________________________________________________________ BROILER TEMPERATURE SETTING: _______________________________________________ GAS PRESSURE: HIGH ___________ LOW __________ BELT PROGRAM TIMES: BUTTON

# 1

2

3

4

5

6

7

8

BELT SPEED

START-UP TECHNICIAN: _________________________________________________________ START-UP DATE: _______________________________________________________________ COMMENTS: _____________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ NOTE: THIS INFORMATION IS TO BE FILLED OUT BY MARSHALL START-UP TECHNICIAN. THIS INFORMATION IS REQUIRED FOR TECHNICAL SUPPORT AT MARSHALL SERVICE CENTERS AND CALL CENTERS.



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II. BROILER INSTALLATION PRE-INSTALLATION 1. After uncrating the Autobroil™ unit, inspect for shipping damage. Contact Marshall Air

Systems, Inc. if there are obvious problems. Set the unit in place and use plastic to protect it from the debris and trash of building construction. DO NOT remove plug from gas inlet pipe. Leave this for the Qualified Service Company. Check that machine has not been dented or damaged by the carrier. Notify your freight carrier immediately to file a concealed damage claim, following the instructions attached to the outside of the shipping crate. Your warranty will not cover freight damage.

2. Installation must be performed by a Qualified Service Company. The term "Qualified Service

Company" means any individual, firm, corporation or company which is either engaged in and is responsible for the installation or replacement of gas piping on the outlet side of the meter, or the service regulator when a meter is not provided, or the connection, installation or repair of gas appliances, who is experienced in such work, familiar with all precautions required, and has complied with all the requirements of the authority having jurisdiction.

3. A remote gas shut-off valve must be provided and interlocked to exhaust system when in

operation. 4. Because this unit is power fan exhausted, it is necessary to provide adequate make up air

equal to the amount removed. In addition to this, any other exhausts, flues, or air removal systems must be taken into consideration. Examples of this are heat removal fans or hot water heater flues.

5. The appliance 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 (3.45 kPa).

6. The appliance must be isolated from the gas supply piping system during any pressure testing

of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.45 kPa). APPLIANCE LOCATION WARNING: IF NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. 1. Position Autobroil™ to properly align with exhaust hood (refer to equipment plan). 2. The hood/ventilator for the appliance should be located in accordance with the National Fire

Protection Association Standard #96, "Removal of Smoke and Grease-Laden Vapors from Commercial Cooking Equipment" and any local applicable requirements.

3. For proper installation, the minimum clearance from combustible construction is .5" from sides

and 18" from food loading end and food delivery end.



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4. Adequate clearance should be maintained to allow easy access to loading and unloading areas of the broiler.

5. For servicing, unit must be moved two feet clear from all construction.

CAUTION: KEEP THE APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

ELECTRICAL INFORMATION 1. The domestic appliance is furnished with a cord and plug. The appliance requires a 120 volt

A.C., 60 HZ, Single Phase, 2 wire w/ground 5 AMP circuit. Appliance must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical code ANSI/NFPA No. 70-latest edition.

2. The international appliance requires 240 volt A.C., 50 HZ, Single Phase and is furnished with

a cord only and no plug. 3. There is a Wiring Diagram located in the Owner's Manual and inside the control cabinet. WARNING: THIS APPLIANCE IS NOT CAPABLE OF BEING SAFELY PLACED INTO OPERATION DURING A POWER FAILURE AND NO ATTEMPT TO OPERATE IT SHOULD BE MADE. GAS PIPING TO APPLIANCE 1. Installation of this appliance must conform with local codes, or in the absence of local codes,

with the National Fuel Gas Code, ANSI Z-223.1-latest edition. 2. In Canada, this appliance is to be installed in accordance with Standard CGA B149.1 or

B149.2 Installation Codes for gas burning appliances and equipment and any local applicable requirements.

3. The appliance is supplied with a 3/4" female pipe thread. The installer must make the pipe

connection to the unit in accordance with the "National Fuel Gas Code,” ANSI Z-223.1-latest edition. The gas line connected to the 3/4" female pipe thread cannot be less than a 3/4" pipe. The gas pressure and gas volume required by this appliance is shown on Page 5. Gas piping from source to broiler must be adequate to satisfy these requirements when all other gas appliances in the restaurant are operating at maximum demand.

4. A flexible AGA approved gas line is available (#500174 36” flex gas line with restraint).

Instructions are: (1) The installation shall be made with a connector that complies with the Standard

for Connectors for Movable Gas Appliances, ANSI Z21.699-latest edition, and Addenda Z21.69a-latest edition, and a quick-disconnect device that complies with the Standard for Quick-Disconnect Devices for Use With Gas Fuel, ANSI Z21.41-latest edition, and Addenda, Z21.41a-latest edition and Z21.41b-latest edition and Z21.41b-latest edition.

(2) Adequate means must be provided to limit the movement of the appliance without

depending on the connector and the quick-disconnect device or its associated piping to limit the appliance movement.



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Optional restraining device is available. (3) The restraining device must always be connected when the appliance is in

operation. Disconnect for movement necessary for service and cleaning. Then reconnect the restraint when the broiler has been returned to its normal position.

(4) The restraining device is a separate line and should be no less than 6 inches

away from the gas connector. It should also be in a parallel position to the floor. Using the adjustable clamps, alter the length of the cable so that the overall length is 3 to 6 inches shorter than the length of the gas connector including the fittings. Attach the wall bracket to an existing wall or other architecturally sound surface. Attach scissor hook to the wall bracket and secure with cotter pin. Finally, attach the spring hook to the gas appliance. Make certain that the overall length of the line is 3 to 6 inches shorter than the gas connector at this point.

5. See Page 2, Item 5 for instructions on gas supply line pressure testing. CAUTION: DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR. PRE-OPERATION CHECK Before lighting and operating your Autobroil™, make a quick check of critical items as follows: 1. Check to see that all parts are in place and that none are damaged. 2. Start conveyor chain by pressing “ON” button of control panel and check for proper operation.

The conveyor chain should run free and not be catching on anything. 3. The speed of the conveyor chain should be checked at various speeds without the chain

stopping.

Overall Length Cotter Pin

Wall Bracket

Scissor Hook

Spring Hook

Clamp



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4. Before first use, and after any special cleaning, it is necessary to "season" the broiler chain. This is done by bringing chain to operating temperature and then (with burner still lit) applying liquid shortening over the full width of the broiler chain while the chain makes 5 or 6 complete revolutions.

5. Check that gas pressure at appliance is correct (see Performance Criteria on Page 5). 6. Check that grease catch pan is in place under unit (See Page 31). PERFORMANCE CRITERIA 1. The manifold pressure for each burner and appliance inlet pressure and gas amount is listed

below:

TYPE OF GAS:

PRESSURE AT THE APPLIANCE

MANIFOLD PRESSURE

Natural

6.0 - 10.0 IWC

Low 3.0 IWC / High 5.5 IWC

(units #2819 and before 5.0 IWC high pressure

Propane

11.0 IWC

Low 5.5 IWC / High 9.0 IWC

Total Gas Amount

63,000 BTUH @ 100 % HIGH FIRE

Manifold pressure is measured by a pressure gauge on the outlet side of the safety gas valve. Once the broiler has been on for at least 20 minutes and reached operating temperature, check the gas pressures. Set the broiler temperature controller to 400°F. The pressure should be at 3.0 IWC (5.5 IWC for propane). With the broiler temperature controller set for 800°F (426°C) the high fire pressure is 5.5 IWC (9.0 IWC for propane). High pressure is adjusted using the regulator in the top of the safety gas valve. Low fire is adjusted using the gas pressure modulator. See Page 35 for gas system layout.

2. The burners in the appliance are a special infrared type. All of the air for combustion must be

injected through the venturis. This makes orifice design and alignment very critical. The orifice design, in combination with the correct natural or propane gas pressure will result in adequate air aspiration and mixing. There are no air shutters. No air adjustment is needed. The proper orifice part numbers are found on page 35.

CAUTION: DO NOT BLOCK THE AREA IN THE IMMEDIATE VICINITY OF VENTURIS OR IN ANY OTHER WAY OBSTRUCT FLOW OF COMBUSTION AIR.

3. The flame rod ignitor is fixed and is not adjustable. 4. All burners will be bright orange when burning properly. If a dull red is observed after 30

minutes of warm-up with a blue flame above the burner face, the orifice is dirty, damaged or misaligned. "Popping," or burning back at the orifice of the burner, is a result of the burner screen being loose or a faulty gasket under the burner screen. LP broilers may exhibit a light "popping" sound when the unit is turned off; this is normal.

NOTE: IF BURNER SCREEN IS TORN OR HAS A HOLE, OR IF A GASKET IS LEAKING, THE

BURNER MUST BE REPAIRED (See Page 36).



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III. OPERATING INSTRUCTIONS BROILER ADJUSTMENT - DAILY LIGHTING INSTRUCTIONS FOR ELECTRONIC IGNITION SYSTEM 1. Make sure filters are in place in the hood. 2. Turn exhaust system on. 3. Depress “ON” button of 8 button control. Doing so starts belts at lowest speed setting and

lights burners. Display of control will read “LO”. 4. The computer control will now automatically modulate the gas pressures to maintain

temperature set point. The temperature set point is 650°F (344°C). 5. When the display of the control reads “REDY,” it is ready for cooking. SHUT-OFF INSTRUCTIONS 1. Allow broiler burners and conveyors to operate for 30 minutes after cooking last product.

2. Depress and hold “OFF” button until “HOT” is displayed on computer. The on/off switch

beside off panel is for emergency shut-off only. Display of control will read “HOT”. 3. Conveyors continue to run for approximately 30 minutes after shut-off. This keeps conveyors

belts from warping and assists in keeping belts clean. The display will then read “OFF” after approximately 30 minutes and once the temperature of the broiler drops below 400°F (204°C).

4. Turn exhaust system off after conveyors stop.



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MARSHALL AIR 8 BUTTON, 2-BELT BROILER COMPUTER OVERVIEW: The Marshall Air 8 Button control consists of an 8-button unit and a Interface Board. The inputs are 1 K-type thermocouple and two tachometers (pick-ups). The outputs are a gas modulation output, a gas on/off output and two belt controllers. The physical system consists of a single gas heated chamber that contains two independently rotating belts. The belt speed is controlled by the product keys (keys 1-4 control left belt, keys 5-8 control right belt). These belts will instantly change speeds when a different key is selected. There is only one “global” heat setting for the chamber. KEYS: 1-4 are left belt keys (orange) 5-8 are right belt keys (violet) Function keys (from left to right)(see Page 37).

On/Off Program NOT USED Enter Temp/Clear Keypad 9 Keypad 0 KEYS ALLOWED IN VARIOUS FUNCTIONS: Refer to Figure 8 for illustration: BUTTON FUNCTION ON/OFF On/Off PROGRAM Enters programming mode ENTER Enter TEMP/CLEAR Displays chamber temperature BUTTONS 1-4 (4) Preset cook times for left belt BUTTONS 5-8 (4) Preset cook times for right belt BUTTON 9 Enters digit 9 in program mode BUTTON 0 Enters digit 0 in program mode MESSAGES: Lo - The chamber temperature is lower than the temperature set point by 100°F (38°C), or the

chamber delay countdown has not reached 10 minutes. The 10 minutes countdown starts when the chamber temperature comes within 50°F (10°C) of temperature set point.

Hi - Chamber temp is high by 50°F (10° C). Redy - Chamber temp is within ready band (±50°F) (10° C) of set point Off - Chamber is off Hot - Chamber is turning off, but 30 minutes has not elapsed. FUNCTIONALITY: Pressing On/Off in the OFF state will cause the controller to turn on LO. Ten minutes after the broiler temperature is within ready band (+ 50°F)(10°C) of set point the broiler is in the REDY state. Pressing and holding On/Off while in the LO or REDY state will cause the broiler to go the HOT state. In the HOT state, the gas to the burners is turned off but the conveyors continue to run. Once the temperature of the broiler falls below 400°F (204°C), the broiler will go to the OFF state and the conveyors stop. When REDY, pressing a button 1 – 8 will change the speed of the belt associated with the programmed time of that key. The chamber temperature will automatically maintain the programmed set point temperature. LIMITS Chamber Temp: 400°F to 800°F (204° C to 427° C) Left belt speeds: :36 to 6:45 Right belt speeds: :36 to 6:45 Hot Temp: 30 minutes after shut-off. Chamber Delay: 10:00



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Codes: See last page of manual if applicable. PROCEDURE TO CHANGE RECIPE COOK TIMES:

1. The display should be “OFF.”

2. Press and hold the button labeled PROGRAM for 2 seconds.

3. The word “CODE” will appear in the display.

4. Enter the number “1724” using the numbers on the recipe buttons as a numeric keypad.

5. Press ENTER.

6. All eight recipe button indicator lights will be illuminated, indicating you need to press one of them to change a recipe speed setting.

7. To change Recipe 1, press recipe button 1.

8. Press ENTER.

9. The letters “SP” (for speed) will appear in the display, then the current conveyor speed

time will be displayed.

10. Press the numbers to enter the speed you want.

11. Press ENTER.

12. Repeat Steps 7 thru 11 to change other recipe buttons.

13. When finished, press the PROGRAM button to return to the “OFF” display. PROCEDURE TO CHANGE BROILER TEMPERATURE SETTING:

1. The display should be “OFF.”

2. Press and hold the button labeled PROGRAM for 2 seconds.

3. The word “CODE” will appear in the display.

4. Enter the number “1234” using the numbers on the recipe buttons as a numeric keypad.

5. Press ENTER. This enters the temperature mode.

6. Enter the desired temperature. There is only one global temperature for all 8 recipe buttons. A typical temperature value is 650 Deg. F.

7. Press ENTER.

8. Press the PROGRAM button to return to the “OFF” display.



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MARSHALL AIR 6-BUTTON CONTROL OVERVIEW (FOR S/N 0302B3059 AND LATER)

ON/OFF KEY

A normal press of this key turns on the control. This causes the unit to start

heating the elements and running the motors at the slowest recipe speed found (overcooked food is safer than undercooked food). This recipe is selected (its

corresponding LED lights up) and the temperature set point is the one defined by this same recipe. At any time in On mode, the user can change the selected recipe.

When just turned On, the unit will scroll PREHEAT on the 1st line until the Soak Time has elapsed. After this time, unit will display either READY, LOW, OR HIGH, depending on the current temperature readings. When On, the unit activates the Heater Kill contactor, which in turn allows the heating elements to get power (through the SSR’s). A 3-second long press of the On/Off key turns off the unit. When the unit is turned Off, the Heater Kill output is deactivated to disable power to heating elements. The 1st line will then blink HOT for the Cool Down period (heaters off, but the motor is still running at the fastest speed supported by the unit). At that point, the unit will then simply display OFF, and all outputs will be disabled. RECIPE KEYS Recipes, there are 6 of them, are defined by a time and a temperature. The time basically sets the conveyor speed. All 6 recipes control the conveyor speed. When the unit is READY, a simple press of the recipe key will activate the selected recipe speed and temperature (LOW and HIGH conditions may or may not be triggered).

When a specific recipe must be changed, keep its button pressed for 3 seconds, until the 1st parameter name scrolls on the 1st line SET COOK TIME. The recipe as well as the Up/Down LED’s will also blink, indicating that they can be used. Pressing either Up or Down the 1st time simply makes the display switch to the parameter’s value (preceded by an arrow, as in ► 4.25, to indicate a changeable value). Subsequent presses will then modify the parameter. If Up or Down are not pressed for 5 seconds, the display resumes scrolling the parameter name.



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Each recipe has 3 programmable parameters. To switch from one to the next, press the recipe key. After the last parameter is programmed, the unit resumes normal operation. - SET COOK TIME, - SET TOP TERMPERATURE, - SET BOTTOM TEMPERATURE.

By default, all recipes are set as follows: Cook time: 5.00 Top temperature: 1325 ºF

Bottom temperature: 1250 ºF VIEW KEY

The View key allows a user to view actual or programmed system parameters. Changes cannot be made just by using this key. In normal operation (On mode), pressing the View key will start scrolling the message TOP TEMPERATURE; also, the View and Up keys blink, indicating they can be used. The 2nd line shows the current conveyor speed. Pressing the Up key causes the 1st line to toggle between the message and the actual temperature value. Pressing the View key a 2nd time will display BOTTOM TEMPERATURE. Again, the Up key toggles between this message and the actual temperature measured. A 3rd and final press of the View key resumes normal operation.

A 3-second long press of the View key allows users to see the current recipe programs without actually being able to change them. After this delay all 6 recipe LED’s blink, allowing the user to select the wanted recipe. Once a recipe is selected, the procedure is the same for all recipes. The 1st parameter shows is COOK TIME. By pressing the Up key, the user can view the parameter value that is currently programmed value (but cannot change it). The user simply waits for 5 seconds before the unit returns to the parameter name. Pressing the Recipe key a 2nd and 3rd time will bring up TOP TEMPERATURE, and BOTTOM TEMPERATURE. Again, using the Up key, the parameter value can be seen. Pressing the recipe key one last time returns the unit to normal operation.

If the unit is operating (i.e. On) when this feature is used, the 2nd line always shows the current conveyor speed. If the unit is Off (or Hot), the conveyor speed is not shown.

CONVEYOR ONLY KEY

The Conveyor Only key is only accessible from the Off state. This key allows the conveyor to be used without any heating. Pressing the key starts the conveyor at its slowest speed.

The word SPEED is displayed on the 1st line. The current speed is displayed on the 2nd line (expressed as a time), the flashing triangle indicating the speed can be changed using the Up and Down keys. Exit this mode by pressing Conveyor Only a 2nd time; however, the speed selection is lost (i.e. the 1st speed used in READY mode is always the slowest recipe speed).



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Note that at all times during the Conveyor Only mode, the motor tachometer feedback loop is disabled. In other words, the controller simply outputs the theoretical RPM derived from the selected speed and the K programmed into the Low-level programming.

There is a “hidden” feature of the Conveyor Only mode that allows easier factory (or field) testing of broilers. When the Conveyor Only mode is active, pressing the View key will show 2 more screens of information.

The first one shows the theoretical motor shaft speed (divided by 100) on the 1st line, and the real tachometer input (divided by 100) on the 2nd line. The theoretical value is simply derived from the requested speed (in terms of time) and the programmed K value. The real value is exactly that, the value coming in from the external tachometer. This screen allows fine-tuning of the various PCM-4 POTENTIOMETERS. The PCM-4 module is included only with broilers having a software revision number of less than 1.04. In an ideal world, the top and bottom lines should read very close to the same value. Since there is no feedback loop in this mode, the values may slightly fluctuate.

The 3rd and final screen of data in the Conveyor Only mode is the real RPM coming in from the tachometer input. By passing the View key a 2nd time, this is displayed on the 1st line (which has enough characters to display the information, as in the previous screen). A third and final press of the View key returns to the standard Conveyor Only screen with SPEED on the 1st line.

RECOVERY KEY

This key is available anytime. When pressed, the controller will list a log of the last 3 recovery times.

A recovery time is the time required for the temperature to go from 200°F to 800°F (temperature limits selectable in Low-level programming). A log exists for each heater (top and bottom). This is useful for service and HACCP purposes.

When the Recovery Key is pressed, the controller will successively display TOP 1, TOP 2, TOP 3, BOT 1, BOT 2, AND BOT 3 ramp times, “1” being the most recent ramp logged. To actually see the logged time, press the Up key. After the last set is seen (BOT 3), the unit resumes normal operation.

FOOD PROBE KEY

This key is useable only when the unit is On (and the Food probe is enabled in the Low-level programming). It is accessible in 2 modes: automatic or manual. In manual mode, it is up to the user to press the Food Probe key to initiate a log, whereas, the automatic mode will remind the user (up to 6 times a day) to take a sample. Even in automatic mode, the user still has the capability to log extra samples manually as he/she wishes.

To do a manual log, the user must first make sure the temperature probe is correctly connected, and then press the Food Probe Key.

Step #1

This step prepares the controller for logging. It determines the equalization time that will be used later on in the process.



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Display: SELECT RECIPE TO LOG is scrolled and recipe LED’s blink. Sound: None. User Action: Select the Recipe corresponding to the sample that will be probed. Step #2 This step starts the logging as such, and gives the user time to set up for the sampling. Display: Shows INSERT PROBE. Actual temperature can be seen when Up key is

pressed. The Up key and Record LED’s blink. Sound: None.

User Action: Insert the Food Probe into the sample according to local sanitary codes and normal restaurant procedures.

Step #3

In this step (basically a continuation of Step #2), the temperature continues being shown to the user. Nothing is being logged yet. The user must wait until a certain temperature is reached (that depends on what is being sampled (chicken, beef, etc.), as well as specific restaurant procedures).

Display: The 1st line displays the temperature currently measured by the Food Probe. The Record key LED also blinks.

Sound: No particular sound. User Action: Keep Food Probe inserted. When temperature reaches a specific point (known to the user), the user presses the Record button.

Step #4

When the Record button was pressed, 2 things happened: the “Start Temperature” was stored, and the equalization timer was started. This timer is low-level programmable on a per recipe basis. The controller now waits for the timer countdown to finish.

Display: The 1st line keeps displaying the temperature currently measured by the Food

Probe. However, there are no keys that function at this point. Sound: A beep every 1 second until 5 seconds before end of timer. During last 5 seconds, beeps accelerate to 2 beeps per second.

User Action: Keep Food Probe inserted. Step #5

In this last step, the actual log is written to memory. The temperature now displayed is logged as the “End temperature.”

Display: Last temperature read when timer reached zero is displayed until Food Probe Key is pressed again. This exits Food Probe.

Sound: None. User Action: Remove probe, and press any key to resume normal operation. Data Logged The following is logged each time a sample is taken (in Step #5):

Date/time stamp (MM/DD/YY if English (degree F), DD/MM/YY if Metric (degree C) as well as HH:MM)

Recipe number (that was selected by user) Top element temperature



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Bottom element temperature Food “Start temperature” (when user pressed Record) Food “End temperature” ( at the end of the equalization time)

NOTE: At the end of Step #5, the user can record another sample of same recipe by pressing Record again instead of Food Probe, which clears display of previous samples. Display then shows probe’s current temperature and Steps 3, 4, and 5 are repeated.

UP AND DOWN KEYS

These keys are used to adjust the various system parameters when required. Time is incremented/decremented at 5-second intervals, and temperature at 5°F (2°C) intervals. These keys have a typematic feature associated with them. Keeping them pressed for more than 2 seconds causes the rate of change to accelerate to 25°F/10°C (temperature), or 20 seconds (time) every 500 msec.

2. DISPLAY

GENERAL In general, all messages are scrolled on the 1st line (about 2 characters per second), and times are displayed on the 2nd. Some keys have a LED, which is used to indicate various situations.

• On/Off LED: full on when broiler is On, otherwise Off. • Up/Down LED’s: blink when Up/Down keys are expected. • Recipe LED’s: on when a recipe is active, blinking when programming or viewing

recipes. • Conveyor Only: blinking when feature is in use. • Recovery: full on when feature is in use. • Food Probe: normally off, blinking when waiting for user to insert probe, and full

on when acquiring temperature. • View: full on when feature is in use. • Conveyor: this is a group of 3 LED’s that simulate a rotating motion (about 2

changes per second). This is active whenever the controller is receiving pulses from all installed tachometers.

• Top and Bottom Heater LED’s: full on when the corresponding heaters are on, otherwise off.

Also, whenever the arrow symbol ( ) is displayed with the data, this means that this is a parameter being changed/adjusted.



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TIME DISPLAY All conveyor speeds are displayed on the 2nd line, and are limited to 9.59. All other times are displayed as MM.SS, or HH:MM (in Low-level programming, this information is on the top line, which has more characters available). For example, 9.59 is 9 minutes and 59 seconds, and 1:10 is 1 hour and 10 minutes.

3. SYSTEM STATES

There are several states of operation as follows: POWER-UP MODE

When a power-up occurs, there is a lamp test, where all LED’s come on for 5 seconds (this includes all LED’s in the two displays). Following the lamp test, the software number and revision are displayed. These are useful for troubleshooting purposes when several versions exist in the field. The first line shows the software number and the second line shows the revision in the format 1.03. Normally, major release versions will be whole numbers (1.00, 2.00, etc.) and if a fraction occurs, these are minor release versions.

Following this, the unit falls automatically into Off mode. OFF STATE In this state, the heaters are disabled. Nothing is displayed, except for OFF on the 1st line.

The motor(s) may be used (and the speed displayed on the 2nd line) if the Conveyor Only function is used. Also the view and recovery keys may be used.

ON STATE

This is the normal cooking state. Before displaying READY, the unit will go through the PREHEAT mode; however, this can be bypassed by pressing the hidden Logo key. The pre-heat mode lasts until the pre-heat Soak Time expires.

In the On mode, 2 extra conditions may exist: LOW and HIGH. Both depend on the current set point, and the current temperature. If the difference between the set point and the current temperature exceeds the programmable thresholds, then either the LOW or HIGH messages are displayed. This warns the user to wait until the READY condition comes back before putting product onto the conveyor. These conditions are likely to occur when a recipe calls for different temperatures.

HOT STATE

This state is active after the unit is turned Off (or if an error occurs that causes the unit to shut-down). This state is basically a cool down step between the On and Off states. The conveyor continues to roll at the fastest speed programmed, but the heaters are off. The display continuously shows HOT until the Cool Down Time has elapsed, at which point the OFF message reappears.

4. FOOD PROBE

AUTOMATIC LOGGING Automatic logging is exactly the same procedure as manual logging, except the controller



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actually reminds the user to do the job. The logging interval is programmable in the low-level programming. Up to 6 times (within a 24-hour period) can be programmed. Each time “slot” can be enabled (by programming a time from 12:00AM to 11:59PM) as well as disabled.

At the appointed time, if the controller is On, a message is scrolled (i.e. SAMPLE FOOD TEMPERATURE) and the buzzer beeps once per second until Food Probe is pressed. At this point the process is the same as the manual one described above.

LOG RETRIEVAL There are basically 3 ways to “see” the logs: Palm™ IR link, RS-485, and manual. Manual log is the simplest, but requires more “paperwork”. The user simply notes (on paper) the time and the temperatures displayed during logging. This is simply using the controller as a precision thermometer. To retrieve the log, press the record button for three seconds, and a message is displayed, RETRIEVE LOG. Press the record button again to return to normal operation. This log can be retrieved while the broiler is running.

When the Palm™ method is used, its software will automatically detect whether the logging option is installed and retrieve it if it is available. This data can then be downloaded to a PC via the normal HotSync® procedure. This data will then be available as a .CSV (comma-separated value) file that can be imported into many Windows® programs (MS Excel® being the most likely).

RS-485 log retrieval is similar to the Palm™ retrieval, except the software is running on a Windows® platform and communications is via the RS-485 link. The end result is the same: a .CSV file is created on the PC.

LOG CAPACITY The serial EEPROM used for storing the log information is 256kB in size. A single log corresponds to approximately 16 bytes of information. Allowing for some overhead in

managing this log, the total log capacity of this memory is about 16 000 logs. At 6 logs per day on a 24/7 basis, this is about 7 years worth of logging. This memory has a 10-year retention capacity when it is not powered.

Downloading the complete log (all of the 256kB) to the Palm™ or PC takes about 5 minutes. Obviously, the smaller the log, the less time it will take to get the information out of the controller.

CLEARING THE LOG

The log can be cleared using the Palm™ handheld, using the RS-485 (with a PC), or using the controller user interface. In the Palm™ or PC software, there will be a command allowing the PDA or PC to tell the controller to clear its log.

To clear the log using the controller keypad, use the following procedure: • Make sure the controller is in Off mode. • Press and hold the Record key (until CLEAR LOG scrolls on the 1st line.) • Use the Up and Down arrows to select YES or NO to confirm operation. • Re-press Record one more time (if YES was selected, the log is cleared at this time.)

The operator will be notified by scrolling CLEAR LOG when the log is 75% full. These words will toggle with OFF and at 100% the words are LOG FULL and the record key will



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not work, but LOG FULL will flash for 2 seconds any time record key is pressed. RECOVERY LOG

The controller always calculates the time it takes the temperatures to go from 200ºF to 800ºF (these limits are Low-level adjustable). This time is stored as M.SS. Only the last 3 recoveries are stored, and when the user requests them, the most recent is displayed 1st. This feature allows restaurant operators to gauge heating efficiency and whether employees follow normal startup procedures.

TIME AND DATE SETUP

When the controller is in Off mode, the system Time and Date can be adjusted by pressing the Off key for 10 seconds. The time is displayed on the 1st line, and the HH are blinking. Using the Up and Down arrows, the hours are changed. Pressing view key moves the “focus” to the MM. Again, Up/Down adjusts this too. By pressing View key again, HH:MM are replaced by DD/MM (or MM/DD, depending on setting of temperature units) (1st line) and YY (2nd line). Again, use the View key to travel from one setting to another, and use the Up/Down keys to modify. The View key will return to HH:MM. Pressing the Off key again stores the new Time and Date, and returns to Off mode.

5. DIAGNOSTICS

This section describes the various diagnostics errors that are available. HEATER TEMPERATURE PROBES

All probes are ungrounded type-K probes. All temperature readings normally associated with a type-K probe are considered valid by the controller. However, if the probes become disconnected or otherwise open, the controller will sound the buzzer and scroll HOT - PROBE ERROR on the 1st line of the display. The defective probe number is displayed on the 2nd line: • 1 is top heater temperature probe • 2 is bottom heater temperature probe

Pressing any key shuts the buzzer off, but will not remove the error message. The only way to remove the error message is to resolve the probe and/or connection problem.

When these heater probe errors occur, there are 2 possible ways to react, depending on the Probe Error parameter:

• If Probe Error Action is set to 0 (default), the unit goes into shutdown via the HOT state. After the Cool Down delay, the error message becomes OFF - PROBE ERROR instead of HOT - PROBE ERROR.

• If Probe Error Action is set to 1, then the unit continues operation, at 100% heater. The operator will most likely then have to adjust the recipe times, but at least the unit can still operate. Due to broiler construction, 100% heater for any amount of time is not a problem as the unit will not “burn” or otherwise ignite.

FOOD PROBE ERROR

In normal operation, if the Food Probe is not connected, it does not trigger any errors (unlike the 2 other probes). However, as soon as the Food Probe key is used, if the controller detects the absence of the probe, it will signal the probe error (beep for a few seconds, display shows FOOD PROBE ERROR). It is important that the user connects the probe before pressing the Food Probe. The controller unit is always remains functional, even though a Food Probe error occurs.



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EXTERNAL DC ERROR The DC I/O connector has a +5VDC supply. This supply is internally protected against over-currents. Should this occur, the unit will internally disconnect the supply and report

HOT - EXTERNAL DC ERROR. The unit goes into shutdown (through HOT mode) and the only way to reset this is to resolve the problem (most likely a short). Since the buzzer is powered through the same +5VDC supply as the DC I/O connectors, the buzzer does not sound when this error occurs.

After the Cool Down delay, the error message becomes OFF - EXTERNAL DC ERROR instead of HOT - EXTERNAL DC ERROR.

IV. SCHEDULED MAINTENANCE If unit is equipped with catalyst, consult the catalyst owner’s manual for scheduled maintenance. DAILY CLEANING PROCEDURES SEE PAGE 39

CAUTION: Do not touch the broiler section immediately after appliance shut-down. The

temperature inside enclosures is in excess of 500°, which eliminates the need to clean any parts inside the enclosures for sanitary purposes. Any grease that may build up on the exterior of the enclosures should be cleaned off with a damp cloth and a minimum amount of detergent. Never use a large amount of water on the enclosure or allow burner faces to get wet as this could cause premature burner or gasket failure.

CAUTION: DISCONNECT THE POWER SUPPLY TO THE APPLIANCE BEFORE CLEANING OR

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

APPLIANCE. IT WILL EAT HOLES IN THE ALUMINUM GAS VALVES AND GAS LINES, CAUSTIC FUMES CAUSE ELECTRICAL COMPONENT DAMAGE, AND WILL CAUSE MANY OTHER PROBLEMS IF USED TO CLEAN THIS BROILER.

CAUTION: KEEP THE APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES. 1. Allow broiler burners and chain to operate for 30 minutes after cooking last product to burn off

excess grease on broiler components. Then turn the unit off and allow to cool. (This applies every time a chain is turned off -- regardless of what time of day chain is shut down -- and regardless of how few products were broiled in the last 30 minutes, last hour, etc.) This will clean some parts of the cooking chamber. Failure to perform this procedure daily will result in poor cooking times.

2. Depress the “ON/OFF” button, wait 30 minutes until the display reads “OFF” and disconnect

electricity. 3. Remove all exterior panels except those that are attached with screws. Be careful not to

touch any hot internal broiler components. 4. Remove the following items and wash with hot soapy water.



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Tunnel Cover Rear Page 31 Tunnel Cover Front Page 31 * Product Pan Bracket Page 31 * Conveyor Cover Page 31 Rear Tunnel Plate Page 31 Meat Stripper Page 32 * Grease Catch Pan Page 31 Grease Tray Page 31

* NOTE: these items may be removed during the 30 minute burn off period. 5. After turning unit off and before conveyors automatically stops, brush the broiler conveyor and, as it cools, wipe with damp cloth. 6. Remove upper burners, lower burners, upper burner shields and lower burner shields. These parts are illustrated on Page 32. Brush surfaces of burner mesh with soft brush. Clean top and lower burner shields with a scraper. DO NOT GET BURNER WET. NOTE: If product being cooked does not produce heavy drippings, such as chicken, this step can be done weekly. WARNING: THE BURNER AND UPPER BURNER SHIELDS ARE MADE FROM INCONEL

METAL MESH. THIS MATERIAL DETERIORATES WITH USE. INSPECT THESE SCREENS DAILY AND REPLACE IF SCREEN IS SEVERELY CORRODED. FAILURE TO DO SO CAN RESULT IN METAL PARTICLES BEING SERVED TO YOUR CUSTOMERS.

7. Using a damp cloth, wipe the inside of each burner venturi. 8. Scrape deposits from the axles with the axle scraping tool, furnished with each machine, as shown below. THIS IS IMPORTANT TO PREVENT GRESE FIRES AT REAR OF THE BROILER.



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Axle Scraper Part Number 100367 The axle scraper provided with the appliance is a handy tool for cleaning the dirt and grime off of the axles. To insert, place end of scraper in between conveyor and turn scraper as shown in the illustration. Scrape the axle back and forth. One end of the scraper is made to scrape a ¾” diameter shaft. The other end of the scraper is made to scrape a 1 1/16” diameter shaft. 9. Remove grease and meat residue from any part of remaining broiler structure where visible. Use a damp cloth with detergent and a putty knife for best results. 10. After cleaning all removable parts as noted, allow to dry and reassemble. MONTHLY CLEANING PROCEDURES 1. Turn off broiler, wait 30 minutes and disconnect electricity. 2. Perform daily cleaning procedures. 3. Clean flame runners using a brush to clear openings. 4. Find cut link and spread conveyor links open with screwdriver or chain pliers (part #500033).

Lift front axle up to make slack in the conveyor belt, unhook conveyor chain and remove to gain access to lower cooking chamber for cleaning side walls.

QUARTERLY CLEANING PROCEDURES 1. Perform daily and monthly cleaning procedures.



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2. If required, remove conveyor and soak in hot soapy water overnight. To remove conveyor, lift front axle up to produce slack in the conveyor and separate conveyor at the cut link. Turning the conveyor “ON” may be required to locate the cut link. If there is not a cut link, open a link with chain pliers (part #500033) to separate conveyor. When replacing the conveyor, make certain the conveyor is installed properly. Make reference to the orientation of the conveyor links and the conveyor direction before reassembly. See illustration on Page 19. PLACING CONVEYOR ON BACKWARD WILL CAUSE SEVERE BINDING PROBLEMS. CLOSE all open links with pliers to match other links.

3. Lubricate the roller (drive) chain with a few drops of any grade motor or machine oil. 4. Remove and inspect all motor brushes and replace if less than a ¼” is left. 5. Do not remove internal gas lines for cleaning. 6. Clean gas orifices:

(1) Orifices are passageways directing gas flow into burners. Uneven gas flow or poor air to gas ratio is caused by dirty or damaged orifices. (2) Orifices are made of brass. Use special care in cleaning – don’t gouge or make gas holes bigger. (3) To reach orifices, remove burners. (4) Use a pipe cleaner dipped in rubbing alcohol to clean orifices. Swab until clean, free of carbon build-up. Do Not use drill bit; this will damage the orifices.

7. Blow out all four (4) burners through the venturi opening with a low pressure air source.

CAUTION: DO NOT DROP BURNERS OR GET WET AS THIS MAY BREAK THE GASKET OR ADD TO PREMATURE BURNER FAILURE.

8. Inventory the spare parts kit and order missing parts as needed. Keep a complete set of parts on hand at all times.

BI-ANNUAL PREVENTIVE MAINTENANCE 1. Perform daily, monthly, and quarterly cleaning procedures. 2. Replace lower burner shields with new ones (see Page 32). ANNUAL PREVENTIVE MAINTENANCE 1. Perform daily, monthly, quarterly and biannual cleaning procedures. 2. Replace upper burner shields (see Page 32). 3. Replace lower burners (see Page 32). 4. Inspect upper burners and replace if necessary. V. TROUBLE SHOOTING This section contains a list of possible problems with the Autobroil unit. ALL ELECTRICAL TROUBLE SHOOTING INVOLVING ACCESS INTO THE MOTORS OR ELECTRICAL ENCLOSURES MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN. All items marked



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with asterisks (*) should be performed by service agency qualified to perform service on gas-fired appliances. 1. PROBLEM: BURNER BACKFIRES. Flashback, blue flame at entrance to burner makes

motor-boating sound like a blowtorch. IMPORTANT: If burner backfires, turn it off. Continued operation will cause damage to the entire burner.

POSSIBLE CAUSE:

A) Burner screen failure (hole) or burner gasket. SOLUTION: Replace burner screen

or gasket.

* B) Check to ensure all screws holding the burner screen in place are snug (see Page 36).

* C) Burner over-fired; manifold pressure too high. SOLUTION: Check and reset gas

control regulator to give rating plate/label value for manifold pressure (shown under Performance Criteria on Page 5). Wait 5 minutes & relight. Flashback will not occur immediately unless a large opening in or around the burner screen is evident. Wait an hour after relighting to check that problem is solved. Page 35 illustrates which regulator sets high and low gas pressures.

2. PROBLEM: FLAMES VISIBLE AT EXHAUST STACK OR IN CHAMBER.

POSSIBLE CAUSE: * A) Low gas pressure. SOLUTION: Check and reset gas control modulator to give

rating plate/label value for manifold pressure (shown under Performance Criteria on Page 5). Page 35 illustrates which valve set high and low pressures.

* INSTRUCTIONS MARKED WITH ASTERISKS SHOULD BE PERFORMED BY

AUTHORIZED SERVICE PERSONNEL. 3. PROBLEM: IGNITER FLAME GOES OUT.

POSSIBLE CAUSE: A) Wires from igniter assembly loose. SOLUTION: Trace wires to where they plug into

gas valve and check connection (see Page 35).

* B) Igniter assembly dirty or bent. SOLUTION: Check for bent pilot gas line and/or dislodge debris. * C) Low gas pressure. SOLUTION: Increase gas pressure to appliance (see Page 35). * D) Igniter orifice clogged. SOLUTION: Dislodge debris or replace orifice. 4. PROBLEM: BURNER WILL NOT LIGHT AT ALL.

POSSIBLE CAUSE: A) Flame Rod igniter not lit. SOLUTION: Turn power switch on then off.



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B) Orifice. SOLUTION: Check that orifice is not plugged. (If it is necessary to change the orifices, new ones must be ordered from the local part distributor.)

C) Check that flame runner is fully lit (see Page 35). SOLUTION: If not, clean flame

runner orifice or remove and clean flame runner.

D) Igniter. SOLUTION: Igniter must light and stay lit in order for burner to light. Check igniter pilot problem list.

* E) Gas Valve Main. SOLUTION: Check that main gas valve is working. 5. PROBLEM: CONVEYOR CHAIN WILL NOT MOVE.

POSSIBLE CAUSE:

A) Check for object caught in conveyor, causing a jam. SOLUTION: Remove object. B) Check to see if motor shaft is moving. SOLUTION: Sprocket needs to be

tightened.

C) Check 1.5 amp fuse on side of the control cabinet. SOLUTION: Turn conveyor switch off, replace fuse, turn conveyor on.

* D) Check fuse. SOLUTION: Replace if blown. * E) Check switch to make sure power is flowing through it. SOLUTION: Replace

switch. * INSTRUCTIONS MARKED WITH ASTERISKS SHOULD BE PERFORMED BY

AUTHORIZED SERVICE PERSONNEL. * F) Connect motor control leads to an operating motor speed control board. (Dual

motor units only) SOLUTION: If motor runs, replace speed circuit board. If motor still does not run, replace motor.

6. PROBLEM: NO CONVEYOR SPEED CONTROL

POSSIBLE CAUSE: * A) Check the pick-up located on the back end of the motor. SOLUTION: Connect the potentially “bad” pick-up to the other motor. If the problem now exists with the other conveyor replace the pick-up. * B) Check the speed circuit board. SOLUTION: Connect the wires from the potentially “bad” speed circuit board to the other speed circuit board. If there is now speed control, replace the “bad” speed circuit board and reconnect all wires appropriately. * C) Measure the resistance (Ohms) of the motor. The Ohms should be between 50-80 Ohms. If the measurement is outside of the range, replace the motor. If the measurement is inside of the range, the motor is good. Check the 8 button control. 7. PROBLEM: REPEATED MECHANICAL BINDING



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POSSIBLE CAUSE: A) Check to see that conveyor chain is not on backward. SOLUTION: See proper conveyor chain installation (see Page 37). B) Inspect chain closely for bent or warped links that may be snagging and causing a binding condition. Also check that the chain links are not climbing out of the sprockets as the conveyor rotates. SOLUTION: Straighten or replace bad links. C) Make sure the axle assembly is clean and free of grease and food residue to allow smooth movement of the conveyor. SOLUTION: Clean axle (see Page 37) D) Check the axle assembly to make certain all set collars, bearings, etc. are properly positioned and secure. (See Page 33 and 34.) E) Disassemble conveyor axle assembly and check condition of bushings and bearings for excessive wear. SOLUTION: Replace if worn or damaged. F) Visually inspect the motor drive chain assembly for smooth rotation of chain. SOLUTION: Make certain there are no binding or worn components. G) Make sure conveyor is not catching on meat stripper. SOLUTION: Reposition `

stripper by adjusting mounting brackets or straighten bent stripper. H) Check that axle adjustment is not too tight. SOLUTION: Loosen so chain is not excessively tight.

• INSTRUCTIONS MARKED WITH ASTERISKS SHOULD BE PERFORMED BY

AUTHORIZED SERVICE PERSONNEL. 8. PROBLEM: PRODUCT WILL NOT FALL CORRECTLY.

POSSIBLE CAUSE: A) Meat stripper is dirty or adjusted too far from conveyor. SOLUTION: Clean meat stripper. Loosen the bolts holding the meat stripper brackets to the sides of the unit. Adjust their position until the top edge of the stripper is within 1/16” of the hot conveyor chain. To properly set the clearance between the meat stripper and the conveyor chain, the broiler must be HOT.

9. TROUBLE SHOOTING GUIDE FOR 6-RECIPE BUTTON CONTROLS

The following Error Messages are associated with the 6-Recipe Button controls: ERROR MESSAGE PROBLEM SOLUTION TACH ERROR or HOT – TACH ERROR or OFF – TACH ERROR Note: On the lower display window, the number 1 or 2 or 12 will be shown 1 indicates a single conveyor problem, or a left conveyor problem on a dual conveyor broiler. 2 indicates a right conveyor problem.



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When a problem occurs, the first message displayed is TACH ERROR, which almost immediately will cause the broiler to shut down and display HOT – TACH ERROR. After the cool down period, the broiler will turn off and display OFF – TACH ERROR

Jammed Conveyor Remove Items Preventing Conveyor From Moving

Failed Fuse Replace Fuse Loose Wire or Connector Check wire connections

Loose Pick-up Tighten Pick-Up Damaged Pick-up Replace Pick-Up Failed Speed Control Circuit Board Replace Circuit Board Failed Motor Replace Motor Failed Speed Module Replace Speed Module HOT – PROBE ERROR or OFF – PROBE ERROR Note: The number on the second line of the control display indicates the thermocouple number. For electric broilers, 1 indicates the top heater thermocouple, and 2 indicates the bottom heater thermocouple. For gas broilers, which have two thermocouples connected in parallel (which acts as one thermocouple to the control), the display will indicate 2 When a problem occurs, the first message displayed is HOT - PROBE ERROR. After the cool down period, the broiler will turn off and display OFF – PROBE ERROR.

Loose Thermocouple Fix wiring connection

Failed Thermocouple Replace Thermocouple Depending on the 6-Recipe Button Control factory setting, some electric broilers will default to 100 percent heater output to allow the broiler to continue to operate until the problem is fixed. In this case, the recipe cook time should be temporarily adjusted to achieve the desired cooked product using the 100 percent heat. A PROBE ERROR message will be displayed until the problem is fixed. HOT – EXTERNAL DC ERROR or OFF – EXTERNAL DC ERROR

Check Wiring and Connectors For Short Repair Wiring Failed Pick-up Replace Pick-up

Failed Speed Control Circuit Board Replace Circuit Board Failed Speed Module Replace Module Failed Gas Module Replace Module Failed 6-Recipe Button Control Replace 6-Recipe Button Control FOOD PROBE ERROR Food Probe Not Connected Plug in Food Probe Failed Food Probe Replace Food Probe CLEAR LOG Log File almost full Clear Food Probe Log

File LOG FULL Log File is full Clear Food Probe Log File



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VI. REPLACEMENT PARTS TABLE

PART NUMBER DESCRIPTION PAGE NUMBER141807 ARM ASBY, 4.5" 33 115405 AXLE, IDLER 33 140547 BAFFLE, REAR HEAT 31 140291 BAFFLE, UPPER BURNER 31 100977 BEARING, 1" SHAFT 34 101357 BEARING, 3/4" SHAFT 34 124578 BEARING ASBY, IDLER 33 500657 BELL REDUCER, 3/4" TO 1/2" 35 118024 BRACKET, BURNER SHIELD 32 139973 BRACKET, PRODUCT PAN (DOMESTIC UNITS) 31 140602 BRACKET, UPPER BURNER SHIELD LEFT 32 140601 BRACKET, UPPER BURNER SHIELD RIGHT 32 503287 BRUSH, MOTOR 34 115367 BURNER ASBY (S/N 2659 AND 2660 ONLY) 32 140610 BURNER ASBY (S/N 2678 AND AFTER) 36 118025 BURNER SHIELD, LOWER 32 140031 BURNER SHIELD, UPPER AE9F,G MODELS (SEE NEXT ITEM) 32 143114 BURNER SHIELD, UPPER (ALL AE9H, AE9G S/N 3162, 3163) 32 503828 CATALYST, 18” X 24” (OPTIONAL) 31 142434 CATALYST KIT, 18” X 24” ADDITION 31 142435 CATALYST EXTENSION 31 135031 CIRCUIT BOARD, MOTOR SPEED CONTROL (DOMESTIC) SCHEMATIC 141643 CIRCUIT BOARD, MOTOR SPEED CONTROL (INTERNATIONAL) SCHEMATIC 143173 CATCH PAN (AE9J, AE9JINTL UNITS) 31 143174 CATCH PAN INSERT (AE9J, AE9JINTL UNITS) 31 500035 CHAIN, ROLLER #35 31.375" LONG 34 140632 CONTROL, 8 BUTTON DOMESTIC °F AE9F 37 141897 CONTROL, 8 BUTTON DOMESTIC °F AE9G 37 141656 CONTROL, 8 BUTTON INTERNATIONAL °C AE9FINTL 37 143175 CONTROL, 8 BUTTON INTERNATIONAL °C AE9JINTL 37 139987 CONVEYOR CUT LINK 7.427" 33 503561 CONVEYOR, 7GA. 7.437" (S/N 2819 AND BEFORE 4.5 FT LONG)

(S/N 2820 AND AFTER 4.3 FT LONG) 33

139970 COVER, BURNER (S/N 2659 AND 2660 ONLY) 32 139679 COVER, CONVEYOR LOADING ARM 31 141804 COVER, FRONT CONVEYOR (S/N 2820 AND AFTER) 31 141806 COVER, LEFT ARM (SCREW DRIVER NEEDED) 32 141085 COVER, RIGHT ARM (SCREW DRIVER NEEDED) 31

733239 COVER, TUNNEL 31 139974 DRIVE TUBE ASBY, 10.125" 34 111987 FITTING, THERMOCOUPLE 38



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PART NUMBER DESCRIPTION PAGE NUMBER116100 FLAME RUNNER ASBY, BOTTOM 35 116101 FLAME RUNNER ASBY, TOP 35 501139 FUSE, 0.5A 35 500061 FUSE, 1.5A 35 500062 FUSE, 5.0A 35 500068 FUSEHOLDER, PANEL MOUNT 35 502261 GAS FLEX-TUBE, 3/8" X 7" 35 500174 GAS LINE, FLEX 36" (NOT SHOWN) 35 500336 GAS LINE, RESTRAINING DEVICE (NOT SHOWN) 36 101978 GASKET, BURNER .125" THK NAT 36 124582 GASKET, BURNER .250" THK LP 36 500070 GAUGE, GAS 35 139994 GUARD, HEAT LOADING ARM COVER (S/N 2819 AND BEFORE) 31 115710 GUIDE, BURNER 32 500083 HALK LINK, #35 ROLLER CHAIN 34 122639 IGNITER, FLAME ROD LP 35 502550 IGNITER, FLAME ROD NAT 35 141637 KIT, CONVERSION NAT TO LP (NOT SHOWN) 35 140807 KIT, GAS TUBING .25” 35 502208 KIT, LP CONVERSION GAS VALVE 35 117199 KIT, MEAT STRIPPER BRACKETS 32 500092 MASTER LINK, #35 ROLLER CHAIN 34 139953 MEAT STRIPPER ASBY 77BG 32 500940 MOTOR, 1/5HP 34 140609 MOUNT, BRACKET 32 139969 MOUNT, BURNER UPPER 32 501348 NUT, HEX 1/4-20 33 501356 NUT, LOCK 1/4-20 33 502532 NUT, LOCKING#10-32 33 500102 ORIFICE, CAP #50 NAT (LOWER BURNERS) 35 500468 ORIFICE, CAP #52 (UPPER BURNERS WITH CATALYST) 35 500104 ORIFICE, CAP #53 NAT (UPPER BURNERS NO CATALYST) 35 500106 ORIFICE, CAP #56 LP (LOWER BURNERS) 35 501016 ORIFICE, CAP #61 LP (UPPER BURNERS) 35 501718 ORIFICE, FLAME RUNNER #70 NAT (UPPER) 35 500979 ORIFICE, FLAME RUNNER #72 NAT (LOWER) 35 500926 ORIFICE, FLAME RUNNER #77 LP 35 502924 ORIFICE, IGNITER LP 35 501710 ORIFICE, PILOT BURNER LP 35 501709 ORIFICE, PILOT BURNER NAT 35 501991 PICK-UP 34 140030 PLATE, REAR TUNNEL 31 500033 PLIERS, CHAIN (NOT SHOWN) 37



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PART NUMBER DESCRIPTION PAGE NUMBERN/A PRODUCT PANS NOT FURNISHED BY MAS 31

501501 SCR: #10-32 X .750" (M) TRS PH S 33 500001 SCR: #6 X .375" (A) S #410 36 501422 SCR: 1/4-20 X .750" (M) HEX P FULL THREAD 33 501423 SCR: 1/4-20 X 1.000" (M) HEX P FULL THREAD 33 502992 SCR: 5/16-18 X .375" (C) SET AL 34 503450 SCR: 5/16-18X .375" (M) SET AL 34 100367 SCRAPER, AXLE 37 106476 SCREEN ASBY, METAL BURNER 36 129746 SET COLLAR ASBY, .505" DIA 33 128489 SET COLLAR ASBY, .755" DIA 33 139988 SHAFT ASBY, IDLER 77BG 33 120083 SHAFT, DRIVE 34 733242 SHELF, SANDWICH 31 139971 SIDE SKIN ASBY 31 115660 SPACER 33 501650 SPROCKET #3512 X .500" 34 129210 SPROCKET ASBY, #3524 X .755" 34 135474 SPROCKET ASBY, #3524 X 1.063 34 124642 SPROCKET ASBY, #5010 X .755" 34 120084 SPROCKET ASBY, #5010 X 1.063" 34 118731 STAND-OFF, BEARING 34 115674 TAB, LOCKING 33 503691 THERMOCOUPLE, TYPE K 38 139963 TRAY, BROILER GREASE (S/N 2659 AND 2660 ONLY) 31 140604 TRAY, BROILER GREASE (S/N 2678 AND AFTER) 31 502868 VALVE, GAS ½” MAIN NAT 35 127359 VALVE, GAS ½” MAIN LP 35 502203 VALVE, GAS ½" MODULATING LP 35 502193 VALVE, GAS ½" MODULATING NAT 35 128322 WASHER, 1.750" X 1.090" 34 501547 WASHER, FLAT 33 501548 WASHER, FLAT 1/4" 33 501555 WASHER, LOCK 1/4" 33

PARTS FOR BROILERS WITH ECM CONTROLS 144112 CONTROL, ECM1-HORIZONTAL SCHEMATIC 503980 MODULE, CONTROL INTERFACE BOARD SCHEMATIC 501864 SWITCH, EMERGENCY STOP SCHEMATIC 500062 FUSE 5A SCHEMATIC 501139 FUSE .5 A SCHEMATIC

CONTROL PANEL QUICK GUIDE AUTOBROIL™

146269 RV061406 Copyright ©2006 Marshall Air Systems, Inc. All Rights Reserved.

Optional – see Owners Manual

Use anytime flashing to change a setting up or down

A 1-second press turns broiler on. A 3-second press turns broiler off.

Displays Time in View Mode

Turns on coveyor without heat

Infrared Port

Press View Button once to view the left conveyor Recipe Setting.

Press the View button followed by the Down Button to view the right conveyor Recipe Setting.

Scrolls Messages and Temperature

Emergency Stop Switch to turn off all power to broiler. Leave this switch on during normal operation and at night.

1 – 3 Left Conveyor Recipes 4 – 6 Right Conveyor Recipes Quick press of any Button activates that recipe. Press and hold 3 seconds to program speed and temperature.

Press Recovery Button followed by Up Button repeatedly to view broiler Heat Up Time today,yesterday and the day before

LEFT BELT

RIGHT BELT

Documents

OWNER'S MANUAL - Bakedeco · 2016. 2. 14. · OWNER'S MANUAL Important: Keep in safe, easy-to-find location. AutobroilTM Model 77BG Marshall Air Systems, Inc. 419 Peachtree Drive