Lucks 115517 Service manual

TECHNICAL SUPPORT HOT LINE
1-800-526-0725
HOURS: 7:30-3:30
21112 72nd Ave. So. Kent, Washington 98032
LUCKS FOOD EQUIPMENT COMPANY
®
TO:
BOB VAN WYCK
Technical Support Manager
Burner Pilot Tube
Replacement
SUBJECT:
FROM:
Service Providers
0102-1
BULLETIN No:
DATE: Feb 1, 2001
MESSAGE:
The purpose of this bulletin is to inform our service providers of a
Burner Pilot Tube Replacement Kit which is available to be used
on all ovens, manufactured after 1997, that are experiencing failure
due to carbon fouling of the ignitor.
See the attached information for diagnoses procedure and
conversion instructions.
Products Affected:
Number of attachments:
Rack Ovens
7 pages

Burner Pilot Tube Replacement
The Reliant R15/R20/R30 rack oven model line uses an Eclipse burner with an ignition
transformer to ignite the burner utilizing an ignitor device similar to an automotive spark
plug. A small number of these ovens are experiencing a problem with carbon fouling of
this ignitor (spark plug).
Included with this bulletin is a field procedure to replace the burner pilot tube with a
smaller diameter tube. This change will lower the BTU of the pilot flame. In lowering the
pilot flame BTU the possibility of carbon fouling of the ignitor is greatly reduced.
Any Lucks Rack oven that has an Eclipse Thermjet burner and is experiencing flame
failure should be diagnosed as follows,
1) Is the flame failure due to a failure to ignite the pilot gas?
2) Does the ignitor (Spark Plug) have carbon on it when inspected?
3) Is the pilot tube currently a 3/8 inch aluminum tube?
If all of the above can be answered YES, after an on-site investigation, then the technician
should order the retro kit (Kit Number 115517) from the Lucks Parts Department and
schedule the field change with the customer.
As a short term fix the ignitor may be cleaned of the carbon with a cloth and re-installed,
allowing the oven to work again. Additionally, if the oven is out of warranty you may
purchase these common parts locally and follow the instructions included with this
bulletin.

Burner Pilot Tube Field Retro Kit Document Number 117950 Page 1 of 6
03/28/01 Lucks Food Equipment Company
Technical Support 800-526-0725 or 800-824-0696
Burner Pilot Tube – Field Retrofit
(Kit Number 115517)
Parts Supplied In Kit:
Description Quantity Lucks Part Number
- Instructions (this document) 1 Ea 117950
- Fitting, Elbow, 3/8 NPT x ¼” comp 2 Ea 207645
- Burner pilot tube ¼” x 8” length 1 Ea 220100
Special Tools Required:
None

Burner Pilot Tube Field Retro Kit Document Number 117950 Page 2 of 6
03/28/01 Lucks Food Equipment Company
Technical Support 800-526-0725 or 800-824-0696
Overview:
The Reliant R15/R20/R30 rack oven model line uses an Eclipse burner with an
ignition transformer to ignite the burner utilizing an ignitor device similar to an
automotive spark plug. A small number of these ovens are experiencing a problem
with carbon fouling of this ignitor (spark plug). It has been determined that the
pilot flame can be too large, resulting in the ignitor being immersed in the pilot
flame, quenching the flame at the ignitor, causing carbon to form on the ignitor.
This field retrofit is to identify and replace the burner pilot tube to reduce the pilot
flame BTU’s. It is important to note that carbon fouling can also be caused by
air/fuel ratio issues and that verification of factory specified air/fuel settings are
required.
Identification:
This retrofit applies to
all Lucks Reliant
R15/R20/R30 ovens
manufactured since
1999 that have an
Eclipse TJ50 or TJ100
burner. See picture
number 1 to the right
for a typical burner
configuration.
Field Modifications Required:
The burner pilot tube and the compression fittings will be replaced. The following
steps will guide you through the process.
A) Shut off the gas and disconnect the power to the oven
1) Flip all the oven’s circuit breaks to the off position.
2) Rotate the manual gas valve to the off position.
Picture 1

Burner Pilot Tube Field Retro Kit Document Number 117950 Page 3 of 6
03/28/01 Lucks Food Equipment Company
Technical Support 800-526-0725 or 800-824-0696
B) Identify and remove the existing burner pilot tube and fittings.
1) Review the detailed picture below. Remove the items identified by the
arrows.
Detail 2
Detail 2Detail 3
Remove 3/8” Alum Tube
Remove 2 each 3/8” NPT x 3/8” Comp fittings
Detail 2

Burner Pilot Tube Field Retro Kit Document Number 117950 Page 4 of 6
03/28/01 Lucks Food Equipment Company
Technical Support 800-526-0725 or 800-824-0696
C) Install the new brass fittings
1) Apply gas service rated thread tape to the 3/8” NPT fittings.
2) Thread these fittings into the black iron pipe tee and into the pilot gas valve. Be sure
these fittings are tight, and aligned so that the compression fittings are facing up (just like
the fittings you removed).
D) Verify length and shape of the new ¼” alum. pilot tube
The new pilot tube is 8 inches long, and should be shaped as shown in detail 3 below. If not
you may use the detail below as a template to shape the tube. Be sure not to kink or crimp the
tube while shaping.
E) Installing the new ¼” alum. pilot tube
1) Install the nut and ferules onto the tubing.
2) Fit the tubing into the fittings. Be sure that the tube ends fit fully into the fittings.
3) Slide the ferules and nuts down the tubing to the fitting, tighten the nuts until fully tight.
F) Functional Testing
1) Remove and clean all the carbon from the ignitor, reinstall the ignitor.
2) Flip on the breakers, be sure the gas supply is still off.
Detail 3

Burner Pilot Tube Field Retro Kit Document Number 117950 Page 5 of 6
03/28/01 Lucks Food Equipment Company
Technical Support 800-526-0725 or 800-824-0696
3) Follow these steps to insure safe operation. Turn on the oven, call for heat. Verify that
these things happen in order.
A) The Honeywell flame controller located in the left mullion has a flashing green
light.
B) The combustion blower starts.
C) After about 10 seconds the pilot gas valve and transformer are powered.
D) 10 seconds later the pilot gas valve and transformer loose power and the
Honeywell’s flame failure buzzer sounds.
4) If all went well with steps A-D above then turn on the manual gas valve, press the reset
button on the Honeywell, and fire the burner.
5) The burner should perform in all ways the same as before. No operational differences
should show up while testing. Careful examination of the pilot flame through the sight
glass will show a flame with the center area dark.
6) Once the burner is firing correctly a verification of the burn performance is
required. Verify the following air/fuel mixture to the procedure on the next page.

Burner Pilot Tube Field Retro Kit Document Number 117950 Page 6 of 6
03/28/01 Lucks Food Equipment Company
Technical Support 800-526-0725 or 800-824-0696
Adjusting the Thermjet TJ50/100 Burner
R(M)15/20/30 Rack Ovens
To adjust the burner on a Lucks Rack Oven you need two special tools.
- Water Column gauge with a range of 0-10 inches W.C.
- Exhaust analyzer, Carbon Monoxide and Oxygen sensors
ADJUST GAS PRESSURE
Install a barbed fitting into the port on the manual gas valve just after the regulator. A tube must connect from the
fitting to the HIGH side of your gauge.
With the oven NOT running you should see a pressure of at least 6 inches W.C. Start the oven and verify that the
pilot and main burners fire on the TJ100 burner. While running, the gas pressure should be 4.5 inches W.C.
The regulator will have a lead seal you must cut to remove the cap and gain access to the adjusting screw. If
adjustments are required, adjust the regulator by turning the screw to get 4.5" W.C. while running. Turning the
screw counter-clockwise decreases the gas pressure.
Note: You may only cut this seal on initial installation without prior approval from the Lucks Company, and you
must notify Lucks technical support within 72 hours that you have done so. At all other times prior approval must be
obtained from the Lucks Company to cut security seals, or the equipment warranty may be voided.
AIR ADJUSTMENT
The air shutter is located inline with the flex tubing coming from the combustion fan. It has a bolt to lock it in place,
raise it to increase air, lower it to decrease air. The air shutter should not be raised any more than 3/8" above its
lowest point.
Look into the sight glass on the burner, you are looking for a blue flame with a large quantity of yellow. NOTE:
Very small adjustments make a large change at this point.
Using the exhaust analyzer place it into the exhaust BELOW the draft hood. It should be in the middle of the tube, at
the hottest spot. Note that you may have to drill a 3/8” hole into the exhaust ventilation. The settings you must get
are...
Carbon Monoxide (Co) = less than 50 PPM ( 0 is expected )
Oxygen (O2) = 6.5 to 7.5 percent O2
With the oven running adjust the air shutter to achieve the desired performance and exhaust results. Adjust the
shutter DOWN to decrease the air, which will INCREASE the flames heat. Watch the oxygen and Carbon Monoxide
results carefully, decrease the air until the Carbon Monoxide level begins to increase, then increase the air slightly
and stop.
If you have any questions, please call the Lucks Technical Support Hot Line at 800-526-0725
WARNING: Injury or death may result if the burner is allowed to operate with exhaust
levels of Carbon Monoxide greater than 50 PPM.