LUCKS FOOD EQUIPMENT COMPANY 21112 72nd Avenue South

Kent, Washington 98032-1339 Phone: (253) 872-2180

Toll-Free: (800) 824-0696 FAX: (253) 872-2013

117-875 0802004

R

Lucks Food Equipment Company, 21112 72nd Ave. S., Kent, WA 98032-1339 (800) 824-0696

IMPORTANT Record the following information pertinent to the specific model being installed. This information will be helpful when calling factory for assistance and/or parts replacement.

Model #________________

Voltage ___________________________

Install Date: _________________________ Start-up Date:_____________________

** The above information can be found on the equipment specification plate located inside the left mullion compartment door.

To contact the Lucks Food Equipment Company Service Department, call (800) 824-0696. or Technical Support Hot Line 800-526-0725

Serial #____________________________

NOTICE

After installation, retain and post this manual in a prominent location for future reference.

WARNING

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Read the operating and maintenance instructions thoroughly before using or servicing this equipment. Contact the Lucks Food Equipment Company or a Lucks-authorized service company for maintenance or repairs.

CAUTION

FOR YOUR SAFETY, do not store or use gasoline or other flammable vapors and liquids in the vicinity of these or any other appliance.

CAUTION

This oven must be mounted on floors of noncombustible construction. No combustible materials, piping, and/or wiring shall be positioned within the floor that supports the oven. No combustible floor finish, such as vinyl or wood, shall be placed under oven. Noncombustible floor construction shall, in all cases, extend not less than 12 inches beyond the equipment on all sides.

A factory technician or factory authorized installation technician must supervise and approve any installation.

Table Of Contents

1 3 4 5 5 6 7 9 10 11 12 17 17 18 20 23 24 25 26

Installation Requirements Crate Contents Assembly Diagram

Assembly Sequence Left/Right Walls & Floor Header Top Caulking Insulation Exterior Panels Roof Mounted Assemblies Wiring Final Location Considerations Hood Installation Door Finish Curved Glass Back Option Insulation Guides

Additional Mechanical Drawings

Assembly

Gas Oven Burner Setup Electric Oven Checkout Airwall Settings Utility Connections

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Oven Setup

M Series Installation Requirements

Clearance Requirements

1. Oven must be mounted on floors of noncombustible construction. (See caution)

2. No clearance is required to combustible materials at the rear and sides of oven.

3. A minimum clearance of 26 inches is required on top of the oven for installation and serviceability.

NOTE: Floor must also be level to 1/4” within 7’

Gas Requirements 1. The supply gas pipe must be a minimum of 1 inch diameter. 2. The gas line pressure required is a minimum static pressure of 7 inches water column (W.C.): and an operating pressure of 4.5 inches W.C. 3. See chart below for gas input requirements on each oven.

Model

M15G-R

M15G-R

M20G-R

M20G-R

M15G-RM

M15G-RM

M20G-RM

M20G-RM

BTU/Hour

175,000

225,000

275,000

325,000

275,000

275,000

325,000

325,000

Reliant-Single Rack

High Performance Option

Reliant-Double Rack

High Performance Option

Roastmaster-Single Rack

High Performance Option

Roastmaster-Double Rack

High Performance Option

NOTICE

Installation of this product must conform to local codes or, in absence of local codes, use the National Electric Code ANSI/NFPA 70-1990, or latest edition, and the National Fuel Gas Code ANSI/NFPA Z223.1-1988, or latest edition. In Canada, use Natural gas Installation Code CAN/CGA-B149-1.

NOTICE

CAUTION This oven must be mounted on floors of noncombustible construction. No combustible materials, piping, and/or wiring shall be positioned within or under the floor that supports the oven. No combustible floor finish, such as vinyl or wood, shall be placed under the oven. Noncombustible floor construction shall, in all cases, extend not less than 12 inches beyond the equipment on all sides.

1

Electrical Requirements

Electrical service: Most gas heated ovens require a 5-wire pull, 3-phase service with neutral and ground for 208/230 VAC. A separate 120 VAC service is required for 460/480 VAC 3-phase ovens. Follow the information listed on the oven specification plate to determine the proper service required for your particular oven. All electrical circuits should be brought within five feet of the oven installation location. NOTE: Do not connect ground and neutral together in the oven. Oven must have true separate ground and neutral service.

M Series Installation Requirements, cont.

NOTE: Electrical load on each oven includes ventilator connect point: 10 amps 120 VAC, 1 phase, 1/3 HP.

Ventilation Requirements

Bakery application: Ovens are manufactured with a built-in Type II hood. Ventilation system supplied by customer. Ventilation fan must provide a minimum of (see chart) CFM at duct collar at 0.4” static pressure with a 10” connection.

Food Service (roasting) application: Ovens are manufactured with a built-in Type I hood. Ventilation system supplied by customer. Ventilation fan must provide a minimum of (see chart) CFM at duct collar at 0.4” static pressure with a 10” connection.

CFM at duct collar Bakery application

M15G-R M20G-R

800 1000

Roasting application M15G-RM M20G-RM

1000 1200

Oven Model

NOTE: Contact factory for optional dual point exhaust (DPE) requirements.

2

Crating Crate – A Left side (1), Right side (3), Back (6), Floor (2), Outside covers (11), Gasket set, Crate – B Door (14), Ceiling (7), Roof (5), Circ fan assembly (9), Rack lift assembly (8), Hood (13), Header (4), Air diverter, Gasket set, Insulation kit, Parts box (parts box contains extra fasteners, oversized self-tapping screws, M15 front drain conversion nipple, and other small parts.) Crate – C Curved glass back wall

Install couplings and extension nipples on both the gas and wa-ter lines at the top of the oven as soon as possible. Doing this later in the oven assembly will be much harder! The nipples and couplings can be found in the parts box.

This would be a good time to verify whether the oven will be drained to the rear or the front and which way the customer would like the door to swing. The oven is shipped for a rear drain (except the Curved Glass Back) and is convertible to a front drain by either moving the drain pipe to the front (on the M20) or installing the longer stainless steel nipple found in the small parts box and removing and plugging the nipple at the rear. The door swing is changeable by moving the hinges, door strike, and door switch activating magnet in the door itself. Pictures and instructions later in the manual.

Oven model numbers ending in ‘RM’ require the use of stainless steel fasteners. Discard any fasteners removed during the instal-lation and replace with fasteners from the supplied Fastener Kit. A tap is supplied with the kit to ease fastener installation.

3 Read This Page!!

Our ovens are constantly improved. The improvements are re-flected in manual updates. Take some time to review this manual for changes in assembly and installation.

4

Floor Panel Gasket The M15 floor panel has a gasket around the edge. The M20 has a gasket around the left and back side of the floor panel. The back right floor panel jog is gasketted with the add-on piece that is taped to the floor panel and slipped into place after the back wall is in place but before the wall is secured to the back.

5

Be sure that the front of the header is flush with the front of both wall modules.

! Install couplings and exten-sion nipples on both the gas and water lines at the top of the oven as soon as possible. Doing this later in the oven assembly will be much harder!! The nipples, cou-plings and pipe dope can be found in the parts box.

6 Connect the header to the left and right mullions.

Attach the header to the right and left wall modules with six self-tapping bolts on each side.

Caulk the end of the header and the top of the light box

Carefully lift the top module above the oven and carry it in through the back opening. Lower the top down onto the two wall sections and front header until fully seated.

Watch out for the floor panel flange!

If this is a prison installation, attach the Prison Alarm Plunger Tube that was taped to the 2X4 Spacer to the under side of the top module. Seal with Red sealant and TEK screw in place.

7 .

Install the top. First, remove the three nuts attached to the studs that will hold the heat exchanger finish flange. Then, use the adjusting screw at the back of the heat exchanger to ad-just the heat exchanger outlet to be 2 1/8 inches from the inside front of the mullion and 1 3/8 inches from the wall plate. (This will center the heat exchanger outlet in the roof penetration.)

Adjustment Screw

Loosely install two self-tappers at each wall-to-back joint and along the floor from inside the oven. With all three walls and floor in place, install the remaining self-tappers.

8 Wedge up the back two corners one inch or more to permit the installation of the back wall.

Set the back panel in place and lower the top module onto the assembled panels. See last page for installation of curved back glass option.

Use the supplied Flex-A-Bit to install TEK screws on the outside of the oven around the roof/wall joint. Start with the TEK screws that pull the roof down and then finish with the screws that go in from the side.

Important!! Before lowering the roof module, inspect the rope gasket position under the roof module.

Wedge a scrap of 1X4 from the crating at the back right edge of the left module (as shown) to back up the Tek screw. When done REMOVE THE 1X4!!!

Use the supplied hose clamp to connect the cooling air duct for the lights to the top module flange.

Once the roof module is secured and before interior panels are attached, take some time to seal the oven cavity.

9

Hose Clamp

Top Module Flange

From inside the oven caulk the seam on the left side of the header.

There are usually air leak sites at the corners of the wall panels and the roof module. Seal all holes (and any other points of light visible from inside the oven) with a liberal amount of high temperature (red) sealant provided.

Seal along the seam at the top of the right mullion overlap of the back wall module as shown

Fasten the heat exchanger seal collar to the ceiling panel

Heat exchanger collar

Install the pre-cut shipped insulation to the back, sides and front over the header. See attached insulation in-stallation instruction sheet and pic-tures of a complete insulation. Intentional void

on the back side

Finished side wall insulation

Don’t forget to stuff insulation in the header!

10

Beware of gaps in the insulation!

Finished back wall insulation

Finished header insulation

Put the exterior panel corner pieces in place.

Then the finish panels, sides and back.

You may need to trim insulation if it makes panel attachment difficult.

Once all the finish panels are in place, drive a TEK screw into each corner overlap flange while compressing the joint together as tightly as possible

11

Secure each panel with TEK screws driven through holes in the panel hanger.

Remove any self-tapping screws that sur-round the circ fan opening on the oven top.

12

Secure the fan assembly to the roof using self-tapping screws. Make sure that the fan assembly is level with the roof.

Drop the circ fan assembly in from roof with the J-box facing front.

Line up the fan venturi from inside the oven so the circ fan does not scrape when spun by hand. Adjust the fan height so the venturi extends into the fan by 1/8″. Check the two set screws in the hub and make sure they are tight.

Do Not use silicone caulk when installing the fan assembly.

Install the front and rear air box spacer. At-tach the front spacer to the header and the rear spacer to the back wall module. M15 front and rear spacers are the same size. The rear spacer on the M20 is larger.

Air box spacer. (M20 front, M15front/rear)

M20 rear air box spacer

M20 rear spacer in place

13

Install the rack lift assembly (with the actuator pointing to the back of the oven) and secure using four 5/16” self tapping bolts.

Install the ceiling panel using just enough self-tapping screws to hold the panel in place.

14

If this is a prison installation, insert the Prison Alarm Plunger through the tube, secure with the locking collar

and adjust the Prison Alarm Switch for best position.

15 Slip the rack shaft with carriage up from the bot-tom, and assemble the rack clutch (see mechani-cal drawing in the appendix.) Adjust the bottom of the rack carriage to be 71 ½ inches from the oven floor. Check the shaft for plumb. Use washers under the rack lift mounting plate to bring the shaft into plumb. Then complete installation of the ceiling panel.

Attach the shaft drive motor and gearbox with the supplied bolts and lock washers. Check that the drive and spur gear mesh loosely. Half the tooth length is enough.

Attach the rack position sensor bracket and adjust the sensor to be about 1/8 inch from the rack position flag.

16

Loose Fit

Final Location Move the oven to its final location and check for level. The oven can be leveled with steel shims included in the parts box. Loosen the bolts holding the floor module to the left, right and rear wall module so the floor can float. Insert the shims as needed under the front and/or back inside corners (nearest the floor panel) of the right and left wall modules but not under the floor panel. Lay a bead of RED SILICONE between the right mullion and the right edge of the floor panel. Once the oven is leveled, retighten the floor panel bolts.

Wiring Feed the wrapped wire bundle up from the mullion into the wir-ing J-box on top of oven.

Feed all wires from the compo-nents on top of oven through sup-plied rubber grommets wiring into the junction box on top of oven. Attach all plugs with matching re-ceptacles.

Route the thermocouples (one from the control panel, one from the limit control, one from the optional auxiliary control system) up through the junction box on the oven top, through a rub-ber grommet, under the t-couple wire cover, and secure with compression fittings in the weld nipples on top right of oven. Do Not over-tighten compression fittings! Finger tight +1/4 turn is enough. Reinstall the t-couple guard.

Insert the t-couple up to the wire insulation

Use a level and straight edge to make sure that the final oven location is level to 1/4 inch over seven feet before moving the oven.

17

Due to equipment options, all plugs may not be used. See Pg. 30 for junction box connector layout.

Remove the diverter plate from the hood assembly.

Lift the hood in place and set back side of hood on top of right and left mul-lions. Anchor the hood to the top of mullions with two 5/16th self-tappers on each side.

(Note: on Type I installations, seal the self-tappers with silicone to be grease tight.)

18 In the crate is a 2X4 measuring 52 inches (for the M20) or 37 inches (M15) with in-struction sheet attached. Use it as a wedge to roll the mullions out at the top and en-sure that they are plumb and parallel to each other before attaching the hood. Measure the distance between the bottom of the mullion and the top at the front surface. After setting the board in place install the 5/16 in. self-tapping bolts in the hood con-necting the bottom of the hood to the top of the right and left walls. Then install the #12 TEK screws in the back of the hood (see the next page.)

While lifting the hood to its’ highest point, install the hood retainer clip at the joint be-tween the hood and the oven panel. Secure with two TEK screws.

Hood Retainer Clip

Put the diverter plate back in (removed in order to install hood) with ¼-20 machine screws. Type I hoods receive grease fil-ters and two inch spacers.

Next install the six main screws that tie the hood to the roof section. Then install the 18 TEK screws around the heat exchanger vent opening and above, and the four screws around the constant vent on the right. Finish with 10 TEK screws along the top back of the hood along the roof module flange.

Caulk the bottom seam of the hood

Note: Retainer clips can be used to join hoods in multi-oven installations

19

Oven Hood

Line up the door at bottom hinge and set one screw hand tight. Install the remaining three screws at top and tighten all four securely. Repeat at the bottom hinge.

Install one 5/16x3/4 flat Philips head screw in the top hinge hand tight.

Install door Place two pieces of 1x4 on floor to set door on, and walk the door in place.

20

When changing the direction of door swing swap sides on the strike plate and cover plates.

Don’t forget to move the hinge pins to the TOP of the hinge so they don’t fall out of the hinges!

Move the door switch actuat-ing magnet to the diagonal corner of the door.

An assortment of hinge shims is available in the small parts box to adjust door hang as needed. Typically at least one shim will be required on the bottom hinge.

21

Once located and leveled use the supplied ¼ by two-inch concrete anchors to secure the oven to the floor.

Adjust the mullion strike plate to close easily and compress the door frame gasket. The strike plate slides in various directions to match the door latch You may use the supplied strike plate shim to provide a better fit.

Install the rebar package. See the illustration in the appendix. Pay special attention to the left/right orientation sequence of the rebar packets. It may be necessary to disconnect water manifold and slide the manifold out to install the packet of rebar.

Use 5/16” self-tappers to reinstall the Perf Sheet and Air Walls. The Perf Wall is not fastened at the bottom edge.

22

Install the door sweep gasket and retainer strip.

Finish Remove any protective vinyl coat-ing from the stainless steel and in-spect the surface for damage and fit.

With a Type I hood, install the grease filters in the hood and hang the grease cup in place.

While the Air-Walls are set at the factory, there is always the chance that they have changed in shipping. Use the setting chart at the back of this manual to verify the air wall settings.

23

Curved glass back option installation Slide the curved glass back into place and attach to the oven in the same manner as a regular back panel. Assemble the curved glass back fascia assembly face down on a protective surface to guard against scratching the finish. Lift the fascia assembly and slip the bottom into the left and right module ends. Use tech screws to secure the fascia to the oven from the top.

24

1

2

3

1. Remove the four indicated screws from the CGB stage panel. Fill each screw hole with red silicone.

2. Use gray silicone to seal the joint from the perf wall on the left to the air wall on the right. Make sure to fill each adjustment slot along the CGB stage panel.

3. Lay a bed of red silicone ½ inch wide and ¼ deep along perimeter of the CGB stage panel.

Sealing the curved glass back option

4. Set the stage panel finish plate into the silicone bed. 5. Attach the stage plate with the screws removed in step #1

and bolts on the floor panel. 6. After the silicone has set, trim silicone flush with finish

panel.

25

M 20 Insulation Package

M 15 Insulation Package

26

Burner Label Color Input LP Orifice Size NG Orifice Size Blue 175 kBTU .173 .234 Green 225 kBTU .199 .281 Yellow 275 kBTU .234 .375 Red 325 kBTU .281 No Orifice Manifold Pressure 4.5 “ wc 4.5” wc

Warning Do not adjust combustion air without a combus-tion analyzer to test the effect of any adjustment.

C. Set Combustion Insert the analyzer probe through the access hole into the heat exchanger exhaust. Test and set burner combustion.

Carbon Monoxide (CO) = Under 50 PPM Excess Oxygen (O2) = 5-5.5% Or Carbon Dioxide = 8.5-9%

WARNING: Injury or death may result if the burner is allowed to operate with exhaust levels of Carbon Monoxide greater than 50 PPM.

Tools Required - Water Column gauge with a range of 0-10 inches W.C. - Combustion analyzer, Carbon Monoxide, Excess Oxygen

and/or Carbon Dioxide sensors - Amp Meter - Hand tools

A. Verify Fuelline Pressure With the burner off, install a barbed fitting in the inlet pressure tap (1) on the combination gas valve. Turn the burner on and note the fuelline pressure. Fuelline pressure under flow must be at least 6 inches W.C. Turn the burner off.

M Series Gas Oven Burner Setup

B. Check Manifold Pressure Reinstall the barbed fitting in the outlet pressure tap (2). Turn the burner on. If necessary, adjust the manifold pressure (3).

Inlet Pressure Tap

Outlet Pressure Tap

Regulator adjust Screw Cap 1

2

3

Alternate Air Shutter

Air Shutter

27

480 V - M15 Contactor 1: 22.8A-20.6A Contactor 2: 28.5A-25.8A 480 V - M20 Contactor 1: 34.2A-31A Contactor 2: 34.2A-31A

208 V - M15 Contactor 1: 30.8A-27.8A Contactor 2: 30.8A-27.8A Contactor 3: 30.8A-27.8A Contactor 4: 23.8A-26.4A 208 V - M20 Contactor 1: 35.8A-39.6A Contactor 2: 35.8A-39.6A Contactor 3: 35.8A-39.6A Contactor 4: 35.8A-39.6A

M Series Electric Oven Checkout

2. Test each leg on each contac-tor and confirm that amperage draws are within limits listed for each applied voltage.

1. Check applied voltages at each leg for +/- 5% of design voltage. {480V(456V-504V), 208V(197V-218V) }

28

Factory settings shown in 16th’s of an inch Spaces provided for customer preferences

29

30

M Series Junction Box Wiring Placement

31

Utility Connections for the M Series Ovens

32