Burford 8830 User manual

BURFORD CORP®
SERVICE MANUAL
FOR YOUR
BURFORD
APPLICATOR
Model 8830 (Station 2)
Model #______________
Serial #______________
Wiring Diagram #______ Issue___
DATE: August 8, 2006
COPYRIGHT ©2004-2006 by BURFORD CORP.
MANUAL PART No. SO47573 ISSUE “B”

ii
DISCLAIMER
The descriptions contained in this Service Manual were in effect at the time
this manual was approved for printing. Our policy is one of continuous
improvement, and we do hereby reserve the right to discontinue models at
any time, or to change specifications, prices, or designs without notice and
without incurring obligations.
Burford Corp. expressly disclaims any liability for damages and/or injuries
caused as a result of negligence or misuse of its product. Such negligence
or misuse includes, but is not limited to the removal of guards, or faulty
wiring due to improper installation.

iii
NOTICE:
As Burford Corp. strives to promote safety in the maintenance and
operation of Burford equipment, we request that the following safety
procedures be followed, along with any additional safety procedures set by
the customer’s in-plant safety officers or local codes.
1. Read operation manual completely before attempting installation or
operation of unit.
2. Incoming electrical power must be properly shielded, routed and
grounded. All safety codes should be followed. Study wiring diagram
before attempting installation.
3. Disconnect power to equipment before removing any guards or
covers. Replace guards and covers before resuming operation of
unit.
4. Loose clothing and long hair should be considered a safety hazard
around mechanical equipment. Ensure that they will not be
entangled in the equipment.
5. Do not by-pass safety switches.
6. Do not attempt repairs while equipment is running.
7. Use only original equipment parts designed to safely operate in the
equipment.
8. Only authorized personnel should be allowed to operate or perform
maintenance on the unit.
9. The equipment should only be used for the purpose for which it was
sold and should not be modified in any way without notifying the
general manager of Burford Corporation in writing of the
modification.

iv
TABLE OF CONTENTS
DISCLAIMER..........................................................................................................................................................................ii
NOTICE: ................................................................................................................................................................................iii
TABLE OF CONTENTS.........................................................................................................................................................iv
1.0 GENERAL INFORMATION .............................................................................................................................. 1-1
1.1 Introduction.............................................................................................................................................................................1-1
1.2 Specifications..........................................................................................................................................................................1-1
2.0 THEORY OF OPERATION...............................................................................................................................2-1
2.1 Operation Sequence...............................................................................................................................................................2-1
2.2 Machine Description................................................................................................................................................................2-1
3.0 INSTALLATION PROCEDURES...................................................................................................................... 3-1
3.1 Determining the best location to mount on existing conveyor..................................................................................................3-1
3.2 Utility Installation.....................................................................................................................................................................3-1
4.0 USING THE OPERATOR CONTROLS............................................................................................................4-1
4.1 Control Panel Description .......................................................................................................................................................4-1
4.2 Main Screen Functions ...........................................................................................................................................................4-2
4.3 Melting Rack Temperature Control..........................................................................................................................................4-3
4.4 Product Tank Temperature Control.........................................................................................................................................4-4
4.5 Control Cabinet.......................................................................................................................................................................4-5
4.5.1 Tank Agitator.................................................................................................................................................................4-6
5.0 OPERATION PROCEDURES..........................................................................................................................5-1
5.1 Initial Start-Up.........................................................................................................................................................................5-1
5.2 Creating a New Recipe...........................................................................................................................................................5-2
5.3 Changing Spray Time & Purging.............................................................................................................................................5-3
5.4 Changing Machine Setpoints ..................................................................................................................................................5-4
5.4.1 Fill Level Setpoints........................................................................................................................................................5-4
5.4.2 Thermocouple Calibration Offset...................................................................................................................................5-5
5.4.3 Pump Setup..................................................................................................................................................................5-5
5.4.4 Melt Rack Alarm Setpoints............................................................................................................................................5-6
5.4.5 Rail Override.................................................................................................................................................................5-6
5.4.6 Mix Tank Alarm Setpoints .............................................................................................................................................5-6
5.4.7 Tank Level Sensor Calibration ......................................................................................................................................5-7
5.4.8 Goto Display Configuration Screen ...............................................................................................................................5-7
5.4.9 Encoder Setup ..............................................................................................................................................................5-7
6.0 SETTINGS AND ADJUSTMENTS ...................................................................................................................6-1
6.1 Nozzle Height..........................................................................................................................................................................6-1
6.2 Actuation and Timing Procedures ...........................................................................................................................................6-2
6.2.1 Product Sensor .............................................................................................................................................................6-2
6.3 Product Flow Rate...................................................................................................................................................................6-3
6.4 Product Tank Level Sensor.....................................................................................................................................................6-4
7.0 PUMP MOTOR DRIVE.....................................................................................................................................7-1
7.1 Pump Motor Drive Settings .....................................................................................................................................................7-2
8.0 MAINTANENCE AND SERVICE PROCEDURES............................................................................................8-1
8.1 Filling the Product Tank Water Jacket.....................................................................................................................................8-1
8.2 Filling the Melting Rack Water Jacket .....................................................................................................................................8-2
8.3 Restoring Product Flow...........................................................................................................................................................8-3
8.4 Changing the Product Filter.....................................................................................................................................................8-4
8.5 Product Pump Seal Maintenance............................................................................................................................................8-5
9.0 START-UP PROCEDURE................................................................................................................................ 9-1
9.1 Start-Up Checklist...................................................................................................................................................................9-2
9.1.1 Mechanical Setup..........................................................................................................................................................9-2
9.1.2 Electric..........................................................................................................................................................................9-2
9.1.3 Pneumatic.....................................................................................................................................................................9-2
9.1.4 Product Lines................................................................................................................................................................9-2
10.0 CLEANING PROCEDURES...........................................................................................................................10-1
10.1 Basic Procedure (after each production run).........................................................................................................................10-1
10.2 Cleaning the Manifold Assembly...........................................................................................................................................10-2
10.3 Cleaning the Product Tank, Agitator and Melting Rack .........................................................................................................10-4
10.4 Cleaning the Product Pump ..................................................................................................................................................10-6
11.0 TROUBLE SHOOTING...................................................................................................................................11-1
11.1 Light Tower Descriptions.......................................................................................................................................................11-1
11.2 Set-Up Values.......................................................................................................................................................................11-2
12.0 RECOMMENDED SPARE PARTS ................................................................................................................12-1
13.0 PREVENTIVE MAINTENANCE...................................................................................................................... 13-1
14.0 PARTS LISTS / ASSEMBLY DRAWINGS .....................................................................................................14-1
14.1 Waukesha Pump Part Identification ......................................................................................................................................14-1
14.2 Waukesha Pump Seal Identification......................................................................................................................................14-4
14.3 Pump System........................................................................................................................................................................14-5
14.4 Tank Detail............................................................................................................................................................................14-6
14.5 Agitator Assembly.................................................................................................................................................................14-7
14.6 Miscellaneous Part Identification...........................................................................................................................................14-8
14.7 Manifold & Nozzle Assembly (2A).......................................................................................................................................14-10
14.8 Manifold & Nozzle Assembly (2C).......................................................................................................................................14-12
14.9 Standard Wiring Diagram....................................................................................................................................................14-14

1-1
1.0 GENERAL INFORMATION
1.1 Introduction
The Burford Model 8830 Applicator utilizes (3) individual spray rail assemblies to
spray a controlled amount of garlic oil, soy oil or butter onto product, without
interruption to the pan flow.
The following pages contain installation, operation and maintenance instructions. To
ensure maximum performance, these instructions should be followed with care.
1.2 Specifications
1. Air – 1 scfm @ 60 psi
2. Electricity – 208/220-50/60-1 phase @ 30 amps

2-1
2.0 THEORY OF OPERATION
2.1 Operation Sequence
Start the conveyor, place a pan on it, and allow it to travel toward the
spray rail assembly. It will encounter the pan sensor. This sensor will
sense the leading edge of the pan and send a signal to the plc to activate
the applicator nozzles to apply the selected liquid as each pan passes.
2.2 Machine Description
Product Pump
Control Panel
Melting Racks
Ethernet Connections

3-1
3.0 INSTALLATION PROCEDURES
3.1 Determining the best location to mount on existing conveyor
1. The portion of the conveyor that is to be used should have at least 30 inches of
free length.
2. The conveyor sides should be free of any interference from bolts, conduit, motors,
shafts, junction boxes, guarding, support members, etc.
3. The underside of the conveyor should also be clear of the interference listed in
number two.
4. The top of the conveyor should be of an open style, (opening between conveyor
chain) so the actuation switch is free to move from side to side, upstream, and
downstream.
5. Pan guides must be used to keep pans straight when traveling through the unit.
6. The conveyor chosen should not allow the pans to stop, turn or back-up during
operation.
7. Area around the unit installation should be clear of any obstruction and unit shall
not be installed in such a way as to create a safety hazard, or block a normal
passageway. Clearance must conform to all local safety codes.
8. Installation site should have ample clearance on operator side for easy access and
normal maintenance. Consideration must be made for positioning the tank
assembly within 10 feet of installation site.
3.2 Utility Installation
A qualified electrician must make all electrical connections. A suitable circuit must be
chosen so the 30 AMP requirement does not overload the total current capacity. A
suitable circuit with all safety requirements must comply with local electrical codes.
Once the unit is mounted to the conveyor and the uprights containing the nozzles are in
place, the tank assembly can be located next to the conveyor. This should be mounted so
the machine operator can have easy access to the controls.

4-1
4.0 USING THE OPERATOR CONTROLS
4.1 Control Panel Description
Other than mechanical set-up and manual nozzle spray, the operator control
panel controls all functions required to operate the applicator. The functions of
the operator control panel are outlined below.
ITEM DESCRIPTION FUNCTION
1 Light Tower Notifies operator of machine status. See Section 11.1
for descriptions.
2 Primary Disconnect Remove electrical power from unit.
3 Main Display
Displays menu screens, error messages and allows
convenient operator interface. Simply touch the screen
at the desired function and follow pop-up screen
instructions.
4 Start/Stop Button Removes electrical power from machine components.
12
3
4

4-2
4.0 USING THE OPERATOR CONTROLS, cont’d.
4.2 Main Screen Functions
Touch desired box or icon to access the desired machine function. Once the
desired function is highlighted by the enlarged lettering a 10 second wait
period is required for the function to initiate.
DESCRIPTION FUNCTION
OFF Turns “OFF” all internal relays and CLEARS the programming registers residing in the
Programmable Logic Controller (PLC).
PREHEAT
Turns “ON” the melting rack and product tank water jacket circulating pumps and
initializes the temperature controls. The agitator is also turned “ON” after a 15 second
delay timer expires; provided the tank lid (section 6.4) is in place. The product pump
and spray nozzle trigger sensor are NOT energized.
CIRCULATE
Melting rack, product tank water jacket, agitator and butter pump are turned “ON”.
Spray nozzle trigger sensor is NOT energized. Product pump will be at low speed for
10 seconds then switch to normal run speed once proper operating pressure is
verified.
RUN Same as “CIRCULATE”, except trigger sensor will activate spray.
LOGIN / LOGOUT LOGIN allows authorized users to enter their user name and password and access the
“MANUAL EDIT MODE”. LOGOUT returns the unit to “AUTO MODE”.
MANUAL EDIT
MODE
This mode is password protected and allows the authorized user to create recipes and
make additional machine setting changes. NOTE: This box is not shown until an
authorized user has completed the “LOGIN” sequence.
Other Functions Touch desired “ICON” to access additional pop-up screens. Follow pop-up screen
instructions. Individual “ICON” settings are accessible while in “MANUAL EDIT
MODE”, which is password protected, see your supervisor.
NOTE: See Section 5 for additional screen information.

4-3
4.0 USING THE OPERATOR CONTROLS, cont’d.
4.3 Melting Rack Temperature Control
Butter must be pre-melted to enter the product tank. A heater is located in the
return side of the each melting rack and heats water as it circulates through the
melting rack. As the butter melts, it falls into the product tank, where the product
is stabilized at the appropriate temperature. The recommended temperature
setting for the temperature controller is 120°Fahrenheit (range: 65°-135°F.). A
lower setting could require excessive time for the butter to enter the product tank.
Once the desired amount of butter is melted into the product tank, melting rack
control should be turned “OFF” to avoid scorching residual butter left on the
melting rack bars and screen.
1. Touch the desired melt rack
“ICON” to access the “SET
TEMP” pop-up screen. Note that
the melting racks are controlled
individually.
2. Touch the “SET TEMP” box to
modify the temperature setting.
This box is ONLY accessible
when in the “MANUAL MODE”.
CAUTION: Melting rack heats quickly but cools down very
slowly. Use care NOT to set temperature too high.

4-4
4.4 Product Tank Temperature Control
The product tank is a double wall design with water being circulated through
the outer jacket. The temperature of this water is controlled as shown below.
The controller will signal the tank heater or chiller to maintain the temperature
setting. The temperature range for this controller is 65°– 135°F. The
controller should be set to maintain the desired product consistency. A hand-
held thermometer will be required to measure actual product temperature.
1. Touch the mix tank temp “ICON”
to access the “SET TEMP” pop-
up screen.
2. Touch the “SET TEMP” box to
modify temperature setting. To
turn the tank chiller and tank
heater “OFF” or “ON”, touch the
respective “ICON” (see arrows).
The “MIX TANK SET TEMP”
popup box is ONLY accessible
when in “MANUAL MODE”.
NOTE: This value is the temperature of the circulating water in the
tank water jacket, NOT the actual product temperature.
CAUTION: Product tank water jacket heats quickly but cools
down very slowly. Use care NOT to set temperature
too high.

4-5
4.5 Control Cabinet
The control cabinet houses the melting rack circulating pump,
product tank chiller, product pump and other electrical components.
Melting rack circulating
pump (P/N 611198)
Product Pump & Motor
(P/N 610906)
Product Tank Chiller
(P/N 611204)
Melting rack water column

4-6
4.5.1 Tank Agitator
The product tank is equipped with an agitator to keep the butter in
constant motion, in order to maintain smooth product consistency.
The agitator also aids in tank clean out by “wiping” the tank walls
with each revolution.
The agitator is only operational when activated via “ICON” located
on the panelview display.
CAUTION: NEVER attempt to use solid butter with the agitator.
Damage to the impeller may result.
NOTE: Agitator will automatically shutdown when access lid is
removed (section 6.4).

5-1
5.0 OPERATION PROCEDURES
5.1 Initial Start-Up
1. Turn on electrical power via the main enclosure
disconnect switch. Verify the red “START/STOP”
button is in the out position to initiate machine
operation. Close the appropriate isolation valve(s)
and check that all hoses are securely connected.
The following screen will be shown on the
operator display.
2. Once unit has completed the set-up sequence,
the “MAIN MENU” screen will be displayed. Verify
the correct recipe is displayed, if not; touch the
“RECIPE SELECT” button and highlight the
desired recipe, then press “enter”. Touch
“PREHEAT” to access this function. Adjust the
melting rack and product tank heater controls to
begin preparing butter for production. Verify the
agitator is free from any obstruction and the
backpressure regulator adjustment screw is
backed out to minimize pressure.
3. After butter has been melted and of desired
consistency inside product tank, open the
appropriate isolation valve(s) and verify butter
has completely filled infeed hose. Touch
“CIRCULATE” and allow the butter to completely
fill the system and circulate for 10 minutes. Verify
spray nozzle operation by touching the “SPRAY
RAIL #1” Icon and use the “PURGE” or “SPRAY”
buttons (see section 5.3 for details). Adjust the
backpressure regulator to give the desired output
quantity.
4. Switch to the “RUN” function once satisfied with
machine operation.
5. Begin production operations.
NOTE: See section 6.1 for identification of spray
rail components.

5-2
5.2 Creating a New Recipe
1. Initially the unit will be in “AUTO” mode as
shown by the following screen. Touch “LOGIN”
and enter the authorized user name and
password.
2. Once the login is successful the “MANUAL
EDIT MODE” box will be shown in the upper
left corner of the screen. To enter the
“MANUAL” mode, touch the “MANUAL EDIT
MODE” box.
3. Once in the “MANUAL” mode the user now
has access to the machine “SETPOINTS”
(lower left corner) and “EDIT RECIPE NAME”
(upper left corner). See section 5.4 for more
information concerning “SETPOINTS”. To
change the recipe name touch the “EDIT
RECIPE NAME” box and follow screen
directions.
4. To exit the “MANUAL” mode touch the
“RETURN TO AUTO MODE” box. Then touch
the “LOGOUT” box to prevent unauthorized
access.
NOTE: See your supervisor or contact Burford
Corporation for an authorized user name
and password.
NOTE: All changes made to the machine “SETPOINTS” will be saved to the
recipe name shown in the upper left corner of the screen.

5-3
5.3 Changing Spray Time & Purging
1. From the “MAIN MENU” screen touch the
“SPRAY RAIL #1” Icon. Note: The spray rail
number may be different depending upon the rail
installed.
2. This pop-up is accessible from either “manual” or
“auto” modes. Touch “PURGE” to activate all
active nozzles for the entire time the “PURGE” is
touched. Touch “SPRAY” to activate all active
nozzles for (1) spray cycle. Touch the “SPRAY
RAIL SPRAY TIMES” box to advance to the
screen shown below. Touch individual nozzle
icons to toggle nozzles valves “ON” or “OFF”.
3. Touch the desired “ROW” to change the spray
time (in milliseconds) for the selected “ROW”.
Select “Delay to Spray” to enter amount of time
(in milliseconds) for all active “ROWS” to be
delayed once the pan sensor has been activated.

5-4
5.4 Changing Machine Setpoints
There are nine screens related to machine set-up. They are accessible only
while in “MANUAL” mode. From the “MAIN” screen touch “SETPOINTS” and
the pop-up screen will be shown. All changes made will only be saved to the
recipe name shown in the upper left corner. See Section 11.2 for table of
start-up values.
5.4.1 Fill Level Setpoints
1. From the “MAIN MENU” screen, touch “FILL
LEVEL SETPOINTS”.
2. The following pop-up screen will appear. “%
STOP FILL LEVEL” sets the tank level (in
percent) which the valve responsible for filling
the tank will close. “% START FILL LEVEL”
sets the tank level (in percent) which the valve
responsible for filling the tank will open.
Range: 0 – 100.
3. Once the desired levels have been entered
touch the “CLOSE” box to return to the
previous screen.

5-5
5.4Changing Machine Setpoints, cont’d.
5.4.2 Thermocouple Calibration Offset
1. From the “MAIN MENU” screen, touch
“THERMOCOUPLE CALIBRATION
OFFSET”.
2. The following pop-up screen will appear.
3. Adjust these offsets to correct differences
between thermocouple output and actual
temperatures. Once the desired offsets have
been entered touch the “CLOSE” box to
return to the previous screen. Range: -999 to
+999.
5.4.3 Pump Setup
1. From the “MAIN MENU” screen, touch
“PUMP SETUP”.
2. The following pop-up screen will appear.
3. Once the desired adjustments have been
entered touch the “CLOSE” box to return to
the previous screen.
ITEM DESCRIPTION
Pump Speed HZ Range: 0 – 75. Determines maximum pump speed.
Low Pressure Run Range: 0 – 25. Determines pressure (psi) that must be reached while the pump is in “low” speed mode. If the pump does not
reach this pressure the unit will shutdown.
High Pressure
Shutoff Range: 0 – 100. Determines pressure (psi) that if reached during “high” speed mode will cause the unit to shutdown.
Upper Scale
Lower Scale
Upper Scaled
Value
Raw Reading
Lower Scaled
Value
Used to calibrate the pressure sensor. Contact Burford
Corporation for additional information.

5-6
5.4 Changing Machine Setpoints, cont’d.
5.4.4 Melt Rack Alarm Setpoints
1. From the “MAIN MENU” screen, touch “MELT
RACK ALARM SETPOINTS”.
2. The following pop-up screen will appear.
3. This setting determines at what temperature
the alarm will sound indicating the maximum
desired temperature for the melt rack(s) have
been reached. Once the desired adjustments
have been entered touch the “CLOSE” box to
return to the previous screen.
5.4.5 Rail Override
1. From the “MAIN MENU” screen, touch “RAIL
OVERRIDE”.
2. The following pop-up screen will appear.
3. When “enabled” the rail number displayed in
the box below “set rail” overrides all other
spray rails. Useful in the event of rail
recognition sensor failure. Once the desired
adjustments have been entered touch the
“CLOSE” box to return to the previous
screen.
5.4.6 Mix Tank Alarm Setpoints
1. From the “MAIN MENU” screen, touch “MIX
TANK ALARM SETPOINTS”.
2. The following pop-up screen will appear.
3. This setting determines at what temperature
the alarm will sound indicating the maximum
(range: 0 – 150) or minimum (range: 0 – 80)
desired temperature for the mix tank has
been reached. Also sets the tank level
(range: 0 – 100) at which the alarm will sound
to prevent the mix tank from being overfilled.
Once the desired adjustments have been
entered touch the “CLOSE” box to return to the previous screen.

5-7
5.4 Changing Machine Setpoints, cont’d.
5.4.7 Tank Level Sensor Calibration
1. From the “MAIN MENU” screen, touch “TANK
LEVEL SENSOR CALIBRATION”.
2. The following pop-up screen will appear.
3. This setting is used to fine-tune the sensitivity
of the level sensor. Contact Burford
Corporation for additional information. Once
the desired adjustments have been entered
touch the “CLOSE” box to return to the
previous screen.
5.4.8 Goto Display Configuration Screen
These settings are preset at the factory. Contact Burford Corporation for
additional information.
5.4.9 Encoder Setup
1. From the “MAIN MENU” screen, touch
“ENCODER SETUP”.
2. The following pop-up screen will appear.
3. This setting is used during initial machine
installation or encoder replacement. Contact
Burford Corporation for additional
information. Once the desired adjustments
have been entered touch the “CLOSE” box to
return to the previous screen.