Lincoln - Zephyr - Workshop Manual - 2009 - 2009

PARTS & SERVICE MANUAL Impinger II Express Series International Models MODELS: Please note that the model numbering system changed March 2007. The chart below shows the old model numbering system and its matching new model number system. Please see Model Number Key section on next page for additional information. Old Model Number 1154-000-EA 1154-080-EA 1154-V80-EA 1155-000-EA 1155-080-EA 1155-V80-EA 1164-000-EA 1164-080-EA → → → → → → → → → New Model Number 1154-z00-U-Kxxxx 1154-z00-U-Kxxxx 1157-z00-U-Kxxxx 1155-z00-U-Kxxxx 1155-z00-U-Kxxxx 1158-z00-U-Kxxxx 1164-z00-U-Kxxxx 1164-z00-U-Kxxxx P/N: L371086 REV: 10.21.09 Lincoln Foodservice Products, LLC 1111 North Hadley Road Fort Wayne, Indiana 46804 Telephone: 260.459.8200 Fax: 260.436.0735 Technical Support: 260.459.8200 lincolnfp.com MODEL NUMBER KEY EXAMPLE: 1154-B00-E-K1801 11 54 - B 00 - E - K1801 Panel Setup Code Agency Code (i.e. CE & RoHS combined) Custom Configuration Code (i.e. General Market Version) Language Code Indicates change to base assembly (i.e. Natural Gas, 230V, 1 phase, 50 Hz) Oven Platform Size (i.e. Impinger II) CODE LANGUAGE COUNTRY CODE LANGUAGE COUNTRY 0 English Dom. & Int. Default N Finnish Finland B French France/Luxembourg O Restricted --- C German Germany P Norwegian Norway D Italian Italy Q English Japan E Spanish Spain R Swedish Sweden F English UK/India/Africa/Hungary S English Australia G Spanish Mexico/Latin America T Mandarin China H Portuguese Portugal U Restricted --- I Not Used --- V English Pacific Rim/Korea J Denmark W English Middle East Belgium X Not Used --- L Danish Dutch & French Dutch Netherlands Y Not Used --- M Greek Greece Z Not Used --- K AGENCY CODE TABLE CODE 2 AGENCY N No Agency E CE & RoHS compliance combined U US & Canada compliance only A Advantage style oven to be phased-out B Australia AGA Impinger II – Advantage Digital Express Service Manual - International SEQUENCE OF OPERATIONS IMPINGER II ADVANTAGE DIGITAL EXPRESS SERIES 1154 EXPORT SERIES 1155 EXPORT SERIES 1157 EXPORT SERIES 1158 EXPORT POWER SUPPLY CONTROL BOX AUTO COOL DOWN MAIN FAN CIRCUIT Burner does not go through filter. BURNER CIRCUIT IGNITION CONTROL TEMPERATURE CONTROL CONVEYOR DRIVE NAT. GAS LP GAS NAT. GAS LP GAS 230VAC 230VAC 230VAC 230VAC 50 HZ. 50 HZ. 50/60HZ 50/60HZ 1 PHASE 1 PHASE 1 PHASE 1 PHASE Electrical power to be supplied to the oven by a three conductor service. When the temperature in the control box reaches 120°F ± 3°F (48.9°C ± 1.7°C), the cooling fan thermostat will switch power to the control box cooling fan. The thermostat will interrupt power to the cooling fan when the control box temperature falls to 100°F ± 3°F (37.8°C ± 1.7°C). Power is permanently supplied through a 10 amp oven fuse to the normally open double pole oven fan switch. Closing the oven fan switch supplies line voltage to the main fan motor. Closing the main fan switch also supplies voltage to the cooling fan through the EMI Filter to the primary of the control transformer, the conveyor motor, and the burner system. Closing the oven fan switch supplies line voltage through the normally open air pressure switch (closed by the air pressure from the main fan), through the normally closed oven cavity hi-limit thermostat (opens at 662°F, 350°C), and to the ignition control. The ignition control switches line voltage to the combustion blower motor. The combustion air pressure switch switches from normally closed to normally open upon sensing air pressure in the burner housing. After a pre-purge period of between 30 and 60 seconds, the spark is energized, the main gas valve and the burner pilot light are energized, and ignition should now occur. Closing the oven fan switch supplies line voltage to the primary of the control transformer. Secondary voltage, 24VAC, is supplied to the oven control. The oven control is set to desired temperature. The thermocouple will provide varying millivolts to the oven control. The oven control supplies line voltage to the temperature regulation valve at intermittent intervals to maintain the desired temperature. The display on the oven control will indicate when the temperature regulation valve is energized. NOTE: The display also indicates oven temperature. Closing the oven fan switch supplies line voltage to the conveyor motor and to the primary of the control transformer. Secondary voltage, 24VAC, is supplied to the oven control. Setting the oven control to the desired time outputs voltage, through a reversing switch, to the conveyor motor. NOTE: The conveyor system uses a hall effect sensor and magnet to prove operation of the conveyor motor. If the conveyor motor is not running, “BELT JAM” is indicated on the display. Impinger II – Advantage Digital Express Service Manual - International 3 SEQUENCE OF OPERATIONS IMPINGER II ADVANTAGE DIGITAL EXPRESS SERIES 1164 EXPORT POWER SUPPLY MAIN FAN CIRCUIT HEAT CIRCUIT CONVEYOR CONTROL 4 400/230VAC 50HZ. 3 PHASE Electrical power to be supplied to the oven by a four conductor service. Brown conductor is hot. Black conductor is hot. Black conductor is hot. Green conductor is ground. Power is permanently supplied, through the 10 amp oven fuse, through the normally closed control box hi-limit thermostat (opens at 140°F, 60°C), to the normally open oven fan switch. Power is also supplied to the normally open cooling fan thermostat. Closing the oven fan switch supplies line voltage to the main fan motor, the cooling fans through the EMI Filter to the primary of the control transformer and to the oven control. Closing the oven fan switch supplies line voltage, through the normally open air pressure switch (closed by air pressure from the main fan) to the oven control. Line voltage is also supplied to the primary of the control transformer. Secondary voltage, 24VAC, is supplied to the oven control. The oven control is set to desired temperature. The thermocouple will provide varying millivolts to the oven control. The oven control supplies line voltage to the coil of the contactors at intermittent intervals to maintain the desired temperature. The display on the oven control will indicate when the contactor is energized. NOTE: The display also indicates oven temperature. Closing the oven fan switch supplies line voltage to the conveyor motor and to the primary of the control transformer. Secondary voltage, 24VAC, is supplied to the oven control. Setting the oven control to the desired time outputs voltage, through a reversing switch, to the conveyor motor. NOTE: The conveyor system uses a hall effect sensor and magnet to prove operation of the conveyor motor. If the conveyor motor is not running, “BELT JAM” is indicated on the display. Impinger II – Advantage Digital Express Service Manual - International SCHEMATIC DIAGRAM MODEL SERIES 1154, 1155, 1157, 1158 EXPORT EXPRESS SERIES Impinger II – Advantage Digital Express Service Manual - International 5 SCHEMATIC DIAGRAM MODEL SERIES 1164 EXPORT EXPRESS SERIES 6 Impinger II – Advantage Digital Express Service Manual - International TROUBLESHOOTING GUIDE IMPINGER II ADVANTAGE DIGITAL EXPRESS SERIES 1154 EXPORT SERIES 1155 EXPORT SERIES 1157 EXPORT SERIES 1158 EXPORT NAT. GAS LP GAS NAT. GAS LP GAS 230VAC 230VAC 230VAC 230VAC 50 HZ. 50 HZ. 50/60HZ 50/60HZ 1 PHASE 1 PHASE 1 PHASE 1 PHASE REFER TO PROPER SCHEMATIC FOR IDENTIFIED COMPONENTS SYMPTOM Oven fan will not run POSSIBLE CAUSE Incoming power supply EVALUATION Check breaker, reset if required. Check power plug to be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Fuse, 10 amp Check, replace if necessary. Fuse holder Check, replace if necessary. Switch, main fan With power off, check continuity between switch terminals. Replace as needed. Motor, main fan Check for opens, shorts or grounds. With power off, turn fan blade to check for locked rotor. Capacitor Check for shorts or grounds. WARNING: Capacitor has a stored charge, discharge before testing. No control box cooling Incoming power supply Check breaker, reset if required. Check power plug to be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Switch, main fan With power off, check continuity between switch terminals. Replace as needed. Cooling fan Line voltage should now be at the cooling fan. If voltage is present, check motor for opens, shorts or grounds. With power off, check for locked rotor. No automatic control Incoming power supply Check breaker, reset if required. Check power plug to box cooling be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Cooling fan thermostat Check the cooling fan thermostat (thermostat closes at 120°F and opens at 100°F). With the cooling fan thermostat pre-heated, check for continuity. If thermostat is open, replace cooling fan thermostat. Cooling fan Line voltage should now be at the cooling fan. If voltage is present, check motor for opens, shorts or grounds. With power off, check for locked rotor. Oven will not heat Gas supply Check for adequate gas supply and be sure that the manual gas shut off valve is open. Also check flexible gas line connection. Main fan If not operating, refer to “Oven fan will not run”. Air pressure switch Check air switch terminals for supply voltage to terminals C and NO. If voltage is present on one side only, check for air tube blockage or misalignment. If these are okay, adjust air pressure switch or replace if necessary. Oven cavity hi-limit thermostat Terminals are normally closed, opens at 350°C (660°F). If open, reset and test oven for proper operation. If thermostat will not hold for maximum oven temperature, and oven is not exceeding control setting, check for proper location of capillary bulb in its spring holder. If above checks are okay, replace hi-limit thermostat. Ignition control Check for proper supply voltage to ignition control. Check for proper voltage to the burner blower motor. This can be checked at motor connecting plug terminal Impinger II – Advantage Digital Express Service Manual - International 7 Burner blower motor Air pressure switch (burner blower) Ignition control Igniter/sensor assembly Gas valve Flame will not stay on Flame sensor Power supply Ignition control Low flame is on, but no main flame 8 NOTE: Flame should be on at this time Control transformer 2 and Neutral. If voltage is present, proceed with next step, if not, wait 30 seconds, push reset button and try to restart. If this fails, check wires from burner blower motor to the ignition control. If the above checks okay, replace ignition control. Check for supply voltage to motor. WITH POWER OFF: Turn blower wheel to check for locked rotor. If supply voltage is present at motor connecting plug terminal 2 and Neutral, and motor does not run, replace burner blower motor. Check for proper supply voltage switching from “NC” to “NO” on ignition control. Check for air pressure switch adjustment, air tube blockage or misalignment. If these adjustments fail, replace air pressure switch. A pre-purge time of 30 to 60 seconds occurs after burner blower motor starts. Check for high voltage spark output from the ignition control. If there is no high voltage spark output, check reset button for ignition control. If there is still no high voltage output, replace the ignition control. Check this assembly for visible damage. Replace as needed. If there is no visible damage, check for voltage supply to igniter/sensor assembly. If there is voltage supplied to the igniter/sensor, but there is no spark, replace igniter/sensor assembly. Gas valve should open as the ignition control generates the high voltage spark. Place manometer on the pressure tap fitting (located in the gas piping just prior to the burner manifold) and check for gas pressure. If valve does not open, check reset button on ignition control, and all connections for tightness. If there is still no gas pressure, remove the ignition control from the gas valve. Check the coils of the gas valve for opens or shorts. Readings should be as follows, V1 – 2.9K ohms approx., V2 – 1.3K ohms approx. If these readings are not achieved, replace gas valve. If these readings are achieved, replace ignition control. To check for flame sensor operation, connect a digital multimeter (capable of measuring DC microamps) between the flame sensor wire and the flame sensor connection on the ignition control. Sensor current is to be 0.9 microamps, minimum. If these readings are not achieved, replace igniter/sensor assembly. Also check for any type of damage to flame sensor wire and connections. NOTE: The DC microamp test must be conducted with the oven in low flame (bypass) operation. Set the temperature to the lowest temperature setting. If there is sufficient microamp current, but the flame will not stay lit, check for proper polarity of the power supply. If there is sufficient microamp current, and there is proper polarity of the power supply, but the burner will not stay lit, check the reset button on the ignition control. If the above test is okay, replace the ignition control. Check for supply voltage to the primary of control transformer. If no voltage is present, trace wiring back to oven fan switch. If voltage is present, check for Impinger II – Advantage Digital Express Service Manual - International Conveyor motor Capacitor, conveyor motor Switch, conveyor reversing Oven control Conveyor motor runs, but there is no speed display 24VAC at transformer secondary. If there is primary voltage, but no secondary voltage, replace control transformer. Check for supply voltage to the conveyor motor at wire #6 to neutral. If no voltage is present, trace wiring back to the oven fan switch. If voltage is present, but the motor will not run, check the motor windings for opens or shorts. If any of the above fail, replace the conveyor motor. Check for shorts or grounds. Replace capacitor as needed. WARNING: Capacitor has a stored charge, discharge before testing. Check continuity between switch terminals. Replace switch as needed. If there is voltage supplied to the motor, and the motor, capacitor and reversing switch check good, replace the oven control. NOTE: Display will indicate “BELT JAM” Oven control Conveyor motor Oven control Check for output voltage from oven control to hall effect sensor (sensor is located in the conveyor motor). Measure voltage at the motor connector, red wire and yellow wire. Voltage should be approx. 10VDC. If no voltage is present, trace wiring back to oven control. If there is no voltage output at the oven control, replace oven control. If there is voltage supplied to the hall effect sensor, check for a frequency output from the hall effect sensor. Measure frequency across the yellow and white wires in the motor connector. Frequency reading should be approx. 25-100 Hz. If these readings are not achieved, replace conveyor motor. If the readings are achieved, proceed. If the hall effect sensor readings are correct, but there is no speed indicated on the display, replace the oven control Impinger II – Advantage Digital Express Service Manual - International 9 TROUBLESHOOTING GUIDE IMPINGER II ADVANTAGE DIGITAL EXPRESS SERIES 1164 EXPORT 400/230VAC 50HZ. 3 PHASE REFER TO PROPER SCHEMATIC FOR IDENTIFIED COMPONENTS SYMPTOM Oven fan will not run No control box cooling No automatic control box cooling 10 POSSIBLE CAUSE Incoming power supply EVALUATION Check breaker, reset if required. Check power plug to be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Oven cavity hi-limit Terminals are normally closed, opens at 660°F (350°C). thermostat If open, reset and test oven for proper operation. If thermostat will not hold for maximum oven temperature, and oven is not exceeding control setting, check for proper location of capillary bulb ion its spring holder. If above checks are okay, replace hi-limit thermostat. Fuse, 10 amp Check, replace if necessary. Fuse holder Check, replace if necessary. Switch, main fan With power off, check continuity between switch terminals. Replace as needed. Motor, main fan Check for opens, shorts or grounds. With power off, turn fan blade to check for locked rotor. Capacitor Check for shorts or grounds. WARNING: Capacitor has a stored charge, discharge before testing. Incoming power supply Check breaker, reset if required. Check power plug to be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Oven cavity hi-limit Terminals are normally closed, opens at 660°F (350°C). thermostat If open, reset and test oven for proper operation. If thermostat will not hold for maximum oven temperature, and oven is not exceeding control setting, check for proper location of capillary bulb in its spring holder. If above checks are okay, replace hi-limit thermostat. Fuse, 10 amp Check, replace if necessary. Fuse holder Check, replace if necessary. Switch, main fan With power off, check continuity between switch terminals. Replace as needed. Cooling fan Line voltage should now be at the cooling fan. If voltage is present, check motor for opens, shorts or grounds. With power off, check for locked rotor. Incoming power supply Check breaker, reset if required. Check power plug to be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Oven cavity hi-limit Terminals are normally closed, opens at 660°F (350°C). thermostat If open, reset and test oven for proper operation. If thermostat will not hold for maximum oven temperature, and oven is not exceeding control setting, check for proper location of capillary bulb ion its spring holder. If above checks are okay, replace hi-limit thermostat. Fuse, 10 amp Check, replace if necessary. Fuse holder Check, replace if necessary. Cooling fan thermostat Check the cooling fan thermostat (thermostat closes at 120°F and opens at 100°F). With the cooling fan thermostat pre-heated, check for continuity. If thermostat is open, replace cooling fan thermostat. Cooling fan Line voltage should now be at the cooling fan. If voltage is present, check motor for opens, shorts or grounds. With power off, check for locked rotor. Impinger II – Advantage Digital Express Service Manual - International Oven will not heat Main fan Control transformer If not operating, refer to “Oven fan will not run”. Check for supply voltage to the primary of control transformer. If no voltage is present, trace wiring back to oven fan switch. If voltage is present, check for 24VAC at transformer secondary. If there is primary voltage, but no secondary voltage, replace control transformer. Air pressure switch Check air switch terminals for supply voltage to terminals “NO” and “COM”. If voltage is present on one side only, check for air tube blockage or misalignment. If these are okay, adjust air pressure switch or replace if necessary. Oven control Check for 24VAC supply to oven control. If no voltage is present, trace wiring back to control transformer. Check for supply voltage to oven control. If no voltage is present, trace wiring back to oven fan switch. If voltage is present, check for a read-out on the display. If there is no read-out on the oven display, replace oven display. If there is a read-out on the oven control, set the control to maximum temperature (see Installation operation manual for temperature adjustment). With the control at maximum temperature, check for supply voltage to the mercury contactor. If there is voltage at the contactors, proceed to “Mercury contactor” for next check. If there is no voltage at the mercury contactor, trace wiring back to the oven control. If there is no voltage output at the oven control, check the read-out on the oven control. If the oven control reads “PROBE FAIL” this indicates that the thermocouple has failed or become disconnected from the oven control. Thermocouple Check to see that the thermocouple is securely connected to the oven control. If the thermocouple is connected to the oven control, and the display indicates “PROBE FAIL”, disconnect the thermocouple from the oven control and measure the resistance of the thermocouple. The thermocouple should read approx. 11Ω. If these readings are not achieved, replace the thermocouple. If these readings are correct, proceed. Oven control If the thermocouple checks good, but the oven control indicates that there is a thermocouple failure, replace the oven control. If the oven control indicates a temperature reading but the oven will not heat, proceed. Thermocouple WITH POWER ON AND THERMOCOUPLE ATTACHED TO THE OVEN CONTROL: Measure the DC millivolt output of the thermocouple. Refer to the thermocouple chart (located in the “Removal” section of the manual) for proper millivolt readings. If these readings are not achieved, replace thermocouple. Oven control If the thermocouple checks good, but there is no supply voltage output to the contactor, replace the oven control. If there is supply voltage output to the contactor, proceed. S.S. Relays Check for supply voltage to the contactor coil. If voltage is present and the contactor will not activate, replace the contactor Also check each contactor for high voltage input and output. Heating element(s) Check the Amp draw on each power leg for proper load. Check the specification plate for rating information. If the Amp draw is high or low, check the Impinger II – Advantage Digital Express Service Manual - International 11 Oven heats with switch off Contactor Intermittent heating Thermal/overload of main fan motor Conveyor will not run Display reads “belt jam” Incoming power supply Fuse, 10 amp Fuse holder Switch, main fan Control transformer Conveyor motor Capacitor, conveyor motor Switch, conveyor reversing Oven control Conveyor motor runs, but there is no speed control Oven control Conveyor motor 12 individual elements for opens, shorts and proper resistance. WITH POWER OFF; To check resistance of the elements, remove all leads from the elements and use a digital multimeter. The element resistance should be as follows: 230V – 33 ohm. Replace heating elements as needed. The contactor has probably failed in the closed position. If there is no voltage at the operating coil, but there is high voltage output from the contactor, replace the contactor. The main fan motor is equipped with internal thermal protection and will cease to operate if overheating occurs. As the motor overheats and cools, this will cause the heating system to cycle on and off intermittently. Improper ventilation or lack of preventive maintenance may cause this problem. Also, most of the problem listed under “Oven will not heat” can cause intermittent failure. Check breaker, reset if required. Check power plug to be sure it is firmly in receptacle. Measure incoming power, call power co. if needed. Check, replace if necessary. Check, replace if necessary. With power off, check continuity between switch terminals. Replace as needed. Check for supply voltage to the primary of control transformer. If no voltage is present, trace wiring back to oven fan switch. If voltage is present, check for 24VAC at transformer secondary. If there is primary voltage, but no secondary voltage, replace control transformer. Check for supply voltage to the conveyor motor at wire #10 to neutral. If no voltage is present, trace wiring back to the oven fan switch. If voltage is present, but the motor will not run, check the motor windings for opens or shorts. If any of the above fail, replace the conveyor motor. Check for shorts or grounds. Replace capacitor as needed. WARNING: Capacitor has a stored charge, discharge before testing. Check continuity between switch terminals. Replace switch as needed. If there is voltage supplied to the motor, and the motor, capacitor and reversing switch check good, replace the oven control. Check for output voltage from oven control to hall effect sensor (sensor is located in the conveyor motor). Measure voltage at the motor connector, red wire and yellow wire. Voltage should be approx. 10VDC. If no voltage is present, trace wiring back to oven control. If there is no voltage output at the oven control, replace oven control. If there is voltage supplied to the hall effect sensor, check for a frequency output from the hall effect sensor. Measure frequency across the yellow and white wires in the motor connector. Frequency reading should be approx. 25-100 Hz. If these readings are not achieved, Impinger II – Advantage Digital Express Service Manual - International Oven control replace conveyor motor. If the readings are achieved, proceed. If the hall effect sensor readings are correct, but there is no speed indicated on the display, replace the oven control Impinger II – Advantage Digital Express Service Manual - International 13 REMOVAL, INSTALLATION AND ADJUSTMENTS IMPINGER II ADVANTAGE DIGITAL EXPRESS SERIES CAUTION BEFORE REMOVING OR INSTALLING ANY COMPONENT IN THE IMPINGER OVEN BE SURE TO DISCONNECT ELECTRICAL POWER AND GAS SUPPLY. MAIN FAN – REPLACEMENT A. Shut off power at main breaker. B. Remove motor cover from back of oven. C. Disconnect wiring and mark for reassembly. D. Remove bolts and slide back straight out of the oven. E. Loosen the bolt from fan hub and remove fan from motor shaft. NOTE: Measure distance from fan blade to rear wall assembly before removal to aid in reassembly. F. Reassemble in reverse order and check system operation. MOTOR, MAIN FAN – REPLACEMENT A. Shut off power at main breaker. B. Remove motor cover from back of oven. C. Disconnect wiring and mark for reassembly. D. Remove bolts and slide back straight out of the oven. E. Loosen the bolt from fan hub and remove fan from motor shaft. NOTE: Measure distance from the fan blade to rear wall assembly before removal to aid in reassembly. F. Remove four screws from motor support assembly. G. Remove motor mount clamp and remove motor from oven back. H. Remove motor mount from motor. I. Reassemble in reverse order and check system operation. CAPACITOR – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control box cover and front panel. Discharge capacitor. Remove capacitor. Reassemble in reverse order and check system operation. ON/OFF SWITCH – REPLACEMENT A. Shut off power at main breaker. B. Remove control box cover and front panel. C. Depress spring clips on sides of switch and push out. D. Remove wires from switch and mark for reassembly. E. Reassemble in reverse order and check system operation. NOTE: Make sure switch housing is fully seated in control box housing. 14 Impinger II – Advantage Digital Express Service Manual - International FUSE HOLDER – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control box cover and front panel. Remove wires from fuse holder and mark for reassembly. Remove mounting screws or mounting nut on fuse holder and remove fuse holder. Reassemble in reverse order and check system operation. COOLING FAN, CONTROL BOX – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control panel top and front cover. Remove four mounting screws from fan frame. Disconnect power cord and remove fan. Reassemble in reverse order and check system operation. THERMOSTAT, COOLING FAN, REPLACEMENT A. Shut off power at main breaker. B. Remove control panel top and front cover. C. Remove wires and mark for reassembly. D. Remove two mounting screws and remove thermostat. E. Reassemble in reverse order and check system operation. NOTE: Push reset button on new thermostat. BURNER BLOWER MOTOR – REPLACEMENT A. Shut off power at main breaker. B. Remove control panel top and front cover. C. Unplug motor connector. D. Remove three mounting screws from blower tube at burner housing. E. Remove air shutter assembly from old motor for assembly on new motor. F. Reassemble in reverse order and check system operation. NOTE: Check air shutter at approximately ½ open and adjust to get a blue flame with an occasional tip of yellow under high flame. A view port in the burner assembly should be used to observe flame. HI-LIMIT THERMOSTAT, OVEN CAVITY – REPLACEMENT A. Shut off power at main breaker. B. Remove conveyor and bottom finger assembly. C. Remove capillary bulb from bracket in oven chamber and pull capillary tube through tube into control box. D. Remove all wires and mark for reassembly. E. Remove mounting nut and remove thermostat. F. Reassemble in reverse order and check system operation. Be sure capillary tube is securely in the mount. NOTE: Push reset button on new thermostat. Impinger II – Advantage Digital Express Service Manual - International 15 TRANSFORMER, CONTROL – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control panel top and front cover. Remove all wires from transformer and mark for reassembly. Remove two mounting screws from transformer base and remove transformer. Reassemble in reverse order and check system operation. OVEN CONTROL – REPLACEMENT (2 pcs.) A. B. C. D. E. F. G. Shut off power at main breaker. Remove control box cover and front panel. Remove all wiring connections and mark for reassembly. Remove oven control by pulling control from the mounting pins. Remove control from oven. Before installing new oven control, set voltage jumper (located at the bottom center of the oven control) to the proper voltage (120V/240V) position. Install the four pushbutton extensions (included with the oven control) by pushing the extensions onto the four set buttons on control. Reassemble in reverse order and check system operation. Set the oven control for the proper operating mode. The 1100 series ovens use a single temperature control system. The oven control must be set to the proper operating mode. Set the control as follows: With the oven power switch “off”, depress the “time” and “up” buttons and turn the oven “on”. Control will indicate ”Imp I or Imp II”. Release the buttons, The control will indicate “Temp to store”. Press the “up” or “down” until ”Imp II” appears on the display. Press the “temp” button. The control is now set for single burner operation. THERMOCOUPLE – REPLACEMENT A. B. C. D. Shut off power at main breaker. Remove conveyor and bottom finger assembly. Remove control panel top and front cover. Remove thermocouple from bracket in oven chamber and pull thermocouple through tube into control box. E. Remove two thermocouple wires from temperature control. Note wire color and location for reassembly F. Reassemble in reverse order and check system operation THERMOCOUPLE MEASUREMENT TEMPERATURE (°F) 200° 250° 300° 350° 400° 450° 500° 550° 600° TEMPERATURE (°C) 93° 121° 149° 177° 204° 232° 260° 288° 316° D.C. MILLIVOLTS 2.8 4.0 5.1 6.0 7.1 8.2 9.3 10.4 11.5 BURNER CONTROL – REPLACEMENT (S/N2045408 and Above) A. B. C. D. E. 16 Shut off power at main breaker. Remove control panel top and front cover. Remove wires from control and mark for reassembly. Remove one mounting screw and remove burner control from the gas valve. Reassemble in reverse order and check system operation. Impinger II – Advantage Digital Express Service Manual - International GAS VALVE – REPLACEMENT (S/N 2045408 and Above) A. B. C. D. E. F. G. H. I. J. K. Shut off power at main breaker. Shut off gas supply to the oven and disconnect the flexible gas line to the oven. Remove control panel top and front cover. Remove the manual gas shut off valve. Remove screws from the bulkhead plate on inlet gas pipe and remove inlet gas pipe. Remove wiring from ignition control (mounted on gas valve) mark all wiring for reassembly. Remove pilot tube, Disconnect pipe union in gas line and remove gas valve and piping assembly. Remove piping from gas valve. Reassemble in reverse order and check system operation. Check all gas line fittings for leaks. Adjust the gas manifold pressure on the gas valve. Refer to the specification plate on the oven for proper rating. TEMPERATURE REGULATION VALVE – REPLACEMENT A. B. C. D. E. F. G. Shut off power at main breaker. Shut off gas supply to the oven and disconnect the flexible gas line to oven. Remove control panel top and front cover. Remove bypass tube from burner manifold. Remove wiring from valve and mark for reassembly. Remove four mounting nuts from burner manifold and disconnect pipe union. Remove temperature regulation valve and piping from oven. IGNITER/SENSOR ASSEMBLY – REPLACEMENT A. B. C. D. E. F. G. H. I. Shut off power at main breaker. Shut off gas supply to oven. Remove control panel top and front cover. Remove gas valve assembly.(see “GAS VALVE”) Remove temperature regulation valve. (see “TEMPERATURE REGULATION VALVE”) Disconnect all wires from burner and mark for reassembly. Remove screws from burner tube and remove burner venturi. Remove two mounting screws and remove igniter/sensor assembly from burner venturi. Reassemble in reverse order and check system operation. Check all gas line fittings for leaks. BYPASS ORIFICE – REPLACEMENT A. B. C. D. E. F. G. Shut off power at main breaker. Shut off gas supply to the oven and disconnect the flexible gas line to oven. Remove control panel top and front cover. Disconnect bypass tube from gas valve. Remove bypass orifice from gas valve. Reassemble in reverse order and check system operation. Check all gas line fittings for leaks. MAIN BURNER ORIFICE – REPLACEMENT A. B. C. D. E. F. G. Shut off power at main breaker. Shut off gas supply to the oven and disconnect the flexible gas line to oven. Remove control panel top and front cover. Remove burner manifold. See “TEMPERATURE REGULATION VALVE”. Remove main burner orifice from burner manifold. Reassemble in reverse order and check system operation. Check all gas line fittings for leaks. Impinger II – Advantage Digital Express Service Manual - International 17 REVERSING SWITCH – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control panel top and front cover. Remove wires from reversing switch and mark for reassembly. Remove mounting nut and remove switch. Reassemble in reverse order and check system operation. CONVEYOR DRIVE MOTOR – REPLACEMENT A. B. C. D. E. F. G. Shut off power at main breaker. Remove control panel top and front cover. Disconnect all wiring from motor and mark for reassembly. Remove coupling from motor drive shaft. Remove four screws and remove conveyor motor and mounting bracket. Remove mounting bracket from conveyor motor. Reassemble in reverse order and check system operation. REVERSING CONVEYOR DIRECTION A. Shut off power at oven switch. B. Set conveyor reversing switch in the other position. C. Turn oven “on” and check for proper operation. CAPACITOR, CONVEYOR DRIVE MOTOR – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control panel top and front cover. Discharge capacitor before removing wires. Mark wires for reassembly. Remove mounting screw and remove capacitor. Reassemble in reverse order and check system operation. AIR PRESSURE SWITCH – REPLACEMENT A. B. C. D. E. F. Shut off power at main breaker. Remove control panel top and front cover. Disconnect wiring from air pressure switch and mark for reassembly. Disconnect air tube from air pressure switch. Remove two mounting screws and remove air pressure switch. Reassemble in reverse order and check system operation. Be sure to calibrate new air pressure switch. For proper calibration, see below. G. Turn adjusting screw on air pressure switch fully counter clockwise. H. Turn oven “on”. I. Turn adjusting screw on air pressure switch clockwise until heat shuts off. J. Turn adjusting screw on air pressure switch counter clockwise ¼ turn. K. Reassemble control panel top and front cover. BEARING, CONVEYOR – REPLACEMENT A. Remove conveyor from oven and place on a flat work surface. B. Remove connecting links from conveyor belt. See Installation Operations manual for proper procedure. Remove conveyor belt from conveyor. C. Move drive shaft or idler shaft toward end of conveyor, and shaft with bearing will now slip out of conveyor frame. D. Remove bearing from conveyor shaft. E. Reassemble in reverse order and check system operation. 18 Impinger II – Advantage Digital Express Service Manual - International S.S. RELAYS – REPLACEMENT A. B. C. D. E. Shut off power at main breaker. Remove control panel top and front cover. Disconnect all wires and mark for reassembly. Remove screws from mounting bracket and remove contactor. Reassemble in reverse order and check system operation. HEATING ELEMENT – REPLACEMENT A. B. C. D. E. F. G. H. Shut off power at main breaker. Remove back cover. Disconnect heating element wires and mark for reassembly. Disconnect motor wiring and mark for reassembly. Remove oven back from oven. Remove fan shroud. Heating element may now be unbolted and removed. Check new heating element for proper voltage. Reassemble in reverse order and check for proper operation. Impinger II – Advantage Digital Express Service Manual - International 19 IMPINGER II ADVANTAGE DIGITAL EXPRESS GENERAL VIEW LETTER A* B* C* D* E F G H I J K L M N O P PART NUMBER 370412 370416 369231 369232 369390 370010 369502 369504 370487 369503 370486 370415 370679 371066 369211 DESCRIPTION Cross support Stand side Caster, 4” w/threaded stem Adjustable leg Caster, 4” w/mounting plate Oven door, See “Conveyor / Door” Section Bottom finger housing Bottom finger cover Top finger housing (model ending with –080-A) Top finger housing (model ending with –080-A1) Top finger cover (model ending with –080-A) Top finger cover (model ending with –080-A1) Oven top Conveyor hole cover Baffle Thumb screw Columnating plate, see Installation & Operations manual Columnating plate, see Installation & Operations manual * A new stand was designed and implemented on March 16, 2009. Parts are not compatible between old and new stand styles. See Addendum A in the back of this manual for a parts breakdown and assembly instructions. 20 Impinger II – Advantage Digital Express Service Manual - International GENERAL VIEW Impinger II – Advantage Digital Express Service Manual - International 21 IMPINGER II ADVANTAGE DIGITAL EXPRESS CONTROL BOX 1154, 1155, 1157, 1158 SERIES LETTER A B C D E F G H I J K L M N O P Q R Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown PART NUMBER 357067 369771 390129 370117 370178 9003551 4071234 369192 369378 369507 370241 369125 9004238 370682 370387 9005479 370417 9004480 369856 340034 369579 370364 369432 370408 370417 370409 370673 DESCRIPTION Hi Limit Switch Switch Assembly J-Box Cover Terminal Block, 5 Pole Junction Box 10 Amp Fuse Adapter Assembly Beaded Ferrule Capacitor Fan Motor Thermostat Transformer Terminal Block, 2 Pole RFI Filter Assembly Capacitor 450V EMI Filter See 1154 Conveyor Motor Assembly Section Main Control Board Stand Off Plate Assy. (S/N 0903210000317 & Below)** Stand Off Support (S/N 0903210000318 & Above)** Finger Guard Alarm Ground Lug On/Off Switch Control Facia Control Board Digital Display Air Pressure Switch ** This pertains to all units non-TU units. 22 Impinger II – Advantage Digital Express Service Manual - International IMPINGER II ADVANTAGE DIGITAL EXPRESS CONTROL BOX 1154 SERIES, 1155 SERIES A B C D I K E G J H F L M N O Q P R Impinger II – Advantage Digital Express Service Manual - International 23 IMPINGER II ADVANTAGE DIGITAL EXPRESS BURNER ASSEMBLY, NAT. GAS 1154 SERIES, 1157 SERIES LETTER A B C D E F G H I J K L M N PART NUMBER 369556 370401 370400 369582 370186 369401 369589 370397 369654 369901 369689 370036 370186 369556 DESCRIPTION Nat. Bypass Orifice .061/1.55mm Ignitor Module, Plug-In Valve, VK4115 A 1000 Burner Assembly, Nat. Gas Export Valve, 85294101 Air Shutter Assembly Burner Blower Motor Ignitor, Sensor Assembly Venturi, Nat. Gas Manifold, Burner Plug, Pressure Test Main Orifice, Nat. Solenoid Valve Bypass Orifice, Nat. IMPINGER II ADVANTAGE DIGITAL EXPRESS BURNER ASSEMBLY, LP GAS 1155 SERIES, 1158 SERIES LETTER A B C D E F G H I J K L M N 24 PART NUMBER 369557 370401 370400 4071136 370186 369401 369589 370397 369939 369901 369689 369524 370186 369557 DESCRIPTION LP Bypass Orifice .0374/0.95mm Ignitor Module, Plug-In Valve, VK4115 A 1000 Burner Assembly, LP Export Valve, 85294101 Air Shutter Assembly Burner Blower Motor Ignitor, Sensor Assembly Venturi, LP Gas Manifold, Burner Plug, Pressure Test Main Orifice, LP Solenoid Valve Bypass Orifice, LP Impinger II – Advantage Digital Express Service Manual - International IMPINGER II ADVANTAGE DIGITAL EXPRESS BURNER ASSEMBLY A B C E D F G N M H L K I Impinger II – Advantage Digital Express Service Manual - International J 25 IMPINGER II ADVANTAGE DIGITAL EXPRESS CONVEYOR MOTOR ASSEMBY ALL MODELS 26 LETTER PART NUMBER A B C 370676 370686 370671 DESCRIPTION Conveyor Motor Conveyor Motor Bracket Coupling Impinger II – Advantage Digital Express Service Manual - International IMPINGER II ADVANTAGE DIGITAL EXPRESS CONVEYOR MOTOR ASSEMBY ALL MODELS C B Impinger II – Advantage Digital Express Service Manual - International A 27 IMPINGER II ADVANTAGE DIGITAL EXPRESS CONTROL BOX 1164 SERIES LETTER A B C D E F G H I J K L M N O Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown 28 PART NUMBER 370672 370674 370117 390129 10002030 369192 9005478 370417 369507 370673 369368 370682 370387 369378 370241 340034 370364 369432 370408 370417 370409 370673 DESCRIPTION 50 Amp Solid State Relay Surge Protector Terminal Block, 5 Pole J-Box Cover Line Filter Capacitor See 1164 Conveyor Motor Assembly Section Main Control Board Thermostat Air Switch Hi Limit Thermostat Capacitor EMI Filter Fan Motor Transformer Finger Guard Ground Lug On/Off Switch Control Facia Control Board Digital Display Air Pressure Switch Impinger II – Advantage Digital Express Service Manual - International IMPINGER II ADVANTAGE DIGITAL EXPRESS CONTROL BOX 1164 SERIES A B C I H D G F E J K L M N O Impinger II – Advantage Digital Express Service Manual - International 29 OVEN BACK ASSEMBLY ALL MODELS LETTER A B C D E F G H I J K L M 30 PART NUMBER 369182 369899 369655 370164 369549 369976 369976 369581 369196 369181 369695 369033 369681 369979 369227 369541 DESCRIPTION Fan Fan shroud Stand off Heating Element – 1164 Only Rear Wall - 1164 Rear Wall – 1154, 1155 Rear Wall – 1157, 1158 Motor mount Motor – 1154, 1155, 1164 Motor – 1157, 1158 Bracket, motor Clamp, motor Cover, back Bracket, hi-limit Spring Bracket, thermocouple Impinger II – Advantage Digital Express Service Manual - International OVEN BACK ASSEMBLY ALL MODELS Impinger II – Advantage Digital Express Service Manual - International 31 CONVEYOR / DOOR ALL MODELS LETTER PART NUMBER A B C D E F G H J K ----369223 369223 369666 369226 369516 369514 369515 369978 370509 370678 369513 370413 370016 369501 370414 369927 369925 369926 369929 369165 369194 369394 370155 370157 369471 L M N O P Q R S T U W X Y Not Shown 32 DESCRIPTION ----Crumb pan, right and left Crumb pan, right and left Conveyor frame assembly Pan stop Conveyor bearing Idler shaft Sprocket (includes set screw), Regular Conveyor Set screw Sprocket (includes set screw), Heavy-Duty Conveyor Drive shaft Hinge Door assembly Impinger nameplate Door latch & catch Door assembly with window Window frame, top Glass, access window Window frame, bottom Retainer, window Splice clip, conveyor belt Conveyor belt (complete), Regular Conveyor Conveyor belt (1-Foot section), Regular Conveyor Conveyor Belt (complete), Heavy-Duty Conveyor Conveyor Belt (1-Foot Section), Heavy-Duty Conveyor Roll Pin Impinger II – Advantage Digital Express Service Manual - International CONVEYOR / DOOR Impinger II – Advantage Digital Express Service Manual - International 33 STAINLESS STEEL ACCESS DOOR ALL MODELS (SN 0908210000875 AND ABOVE) LETTER PART NUMBER 369110 371140 371142 370722 371143 371141 370725 371144 370723 A B C D E F G H DESCRIPTION Access Door Assembly Bracket Assembly, Left Dowel, Access Door Screw 8-32 x 3/8 Hx Serr Flng Bracket Assembly, Right Dowel Thread Access Door Frame (top or bottom) Glass A B C H D E G F 34 Impinger II – Advantage Digital Express Service Manual - International ADDENDUM A NEW STYLE OVEN STAND (BEGINNING MARCH 16, 2009) 1. Insert the four Stand Side Bars (G) into the four holes located on each of the Front/Back Assemblies (A). Note: The Stand Side Bar that contains labels should be facing “out” so that the labels can be easily read by the operator. 2. Attach the Stand Side Bars to the Front/Back Assemblies and tighten using the 1 ¾” Hexagon Bolts (B), Washers (E) and Acorn Nuts (D) provided. Two sets each of the bolts, washers and nuts are to be used at each intersection of Stand Side Bars and Front Back Assemblies for a total of 16 sets. 3. Select Caster or Adjustable Leg and screw into nutsert in the bottom corner of each Front/Back Stand Assembly. Tighten Casters securely. 4. Set assembled Stand on casters/legs in an open, clear area and lock casters, as applicable, in preparation for mounting oven on stand. 5. When placing the oven on the stand, align the bolt holes located in the Front/Back Stand Assemblies with the holes located in the bottom of the oven. With holes in alignment, insert the 2 ½” Hexagon Bolts and tighten to secure the oven to Stand (Fig. 2). ! USE EXTREME CARE IN STEP #5 TO INSURE OVEN DOESN’T SLIP OFF STAND BEFORE BOLTS HAVE SECURED OVEN TO STAND. CAUTION: HARDWARE PROVIDED FOR STAND ASSEMBLY LETTER PART # DESCRIPTION A 90000799 Front / Back Stand Assemblies B 000151SP Hexagon Bolt (1 ¾”) C 369231 Caster, 4” D 2133001 Acorn Nut E 000821SP F 369233 G 10004656 H Washer Hexagon Bolt (2 ½” ) Stand Side Bar Adjustable Leg for 1127-1 stand Not Shown 9002533 Not Shown Shelf for 1127-1 stand Hexagon Bolt (1/2”) for double-stack oven configuration G A F E D C B H Impinger II – Advantage Digital Express Service Manual - International 35 36 Lincoln Foodservice Products, LLC 1111 North Hadley Road Fort Wayne, Indiana 46804 Telephone: 260.459.8200 Fax: 260.436.0735 Technical Support: 260.459.8200 lincolnfp.com Impinger II – Advantage Digital Express Service Manual - International