CTX DZ33I Operators Manual

DZ33I, English

OWNER’S OPERATING

& INSTALLATION

MANUAL

CTX GEMINI SERIES OVENS

DZ33I

CTX ®  1400 Toastmaster Drive Elgin, IL. 60120  847-741-3300

A Middleby Company www.middleby.com

Part No. 69982

7/1/13

Model No._________________Serial No.__________________________Installation Date________

CTX®

NO QUIBBLE LIMITED WARRANTY

(U.S.A ONLY)

MIDDLEBY MARSHALL HEREINAFTER REFERRED TO AS THE SELLER, WARRANTS EQUIPMENT MANUFACTURED BY IT TO BE FREE FROM DEFECTS IN MATERIAL AND

WORKMANSHIP FOR WHICH IT IS RESPONSIBLE. THE SELLER’S OBLIGATRION UNDER THIS WARRANTY SHALL BE LIIIMITED TO REPLACING OR REPAIRING AT SELLER’S OPTION,

WITHOUT CHARGE, ANY PART FOUND TO BE DEFECTIVE AND ANY LABOR AND MATERIAL EXPENSE INCURRED BY SELLER IN REPAIRING OR REPLACING SUCH PART, SUCH WARRANTY SHALL BE LIMITED TO THE ORIGINAL PURCHASER ONLY AND SHALL BE EFFECTIVE FOR A PERIOD OF ONE YEAR FROM DATE OF ORIGINAL INSTALLATION, OR 18 MONTHS FROM DATE OF SHIPMENT, WHICHEVER IS EARLIER; PROVIDED THAT TERMS OF PAYMENT HAVE BEEN FULLY MET.

This warranty is valid only if the equipment is installed, started and demonstrated under the supervision of a factory certified installer.

Normal maintenance functions, including lubrication, cleaning or customer abuse are not covered by this no quibble warranty.

Seller shall be responsible only for repairs or replacements of defective parts performed by Seller’s

authorized service personnel. Authorized service agencies are located in principal cities throughout the contiguous United States, Alaska and Hawaii. This warranty is valid in the 50 United States and is void elsewhere unless the product is purchased through Middleby International with warranty included.

The foregoing warranty is exclusive and in lieu of all other warranties, expressed or implied. There are no implied warranties of merchantability or of fitness of a particular purpose.

The foregoing warranty shall be Seller’s sole and exclusive obligation and Buyer’s sole and exclusive

remedy for any action including breach of contract or negligence. In no event shall Seller be liable for a sum in excess of the purchase price of the item. Seller shall not be liable for any prospective or lost profits of Buyer.

CTX®  1400 Toastmaster Drive  Elgin, IL 60120  USA (847) 741-3300

FOR YOUR SAFETY

WARNING

maintenance instructions thoroughly before installing

NOTICE: This Operating and Installation Manual should be given to the user. The operator of the oven should be familiar with the functions and operation of the oven.

This manual must be kept in a prominent, easily reachable location near the oven. It is suggested to obtain a service contract with a manufactures certified service agent.

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS AND LIQUIDS IN THE

VICINTIY OF THIS OR ANY OTHER APPLIANCE

NOTICE

CONTACT YOUR LOCAL SERVICE COMPANY TO PERFORM MAINTENANCE AND REPAIRS.

Improper installation, adjustment, alteration,

service or maintenance can cause property damage,

injury or death. Read the installation, operating and

or servicing this equipment.

A SERVICE AGENT DIRECTORY IS SUPPLIED IN YOUR

INSTALLATION KIT.

NOTICE

Using any parts other than genuine

CTX factory

manufactured parts relieves the manufacturer

of all warranty and liability.

NOTICE

CTX (Manufacturer) reserves the right to

change specifications at any time.

WARNING

The equipment warranty is not valid unless the oven is installed, started and demonstrated under the

supervision of a factory certified installer.

TABLE OF CONTENTS

SECTION 1- DESCRIPTION ........................................................................ 5

A. Component Location………………………………………………..........6

B. Component Function……………………………………………………...7 C. Oven Specifications……………………………………………………….8 D. Dimension Drawings…………………………………………………..9-11

SECTION 2- INSTALLATION………………………………………………….12

A. Inspect For Shipping Damage………………………………………….12 B. Placement of Oven………………………………………………………12 C. Items for Stacking Oven………………………………………………...12 D. Base Section Assembly……………………………………………..13-14 E. Mounting Single Oven Onto Base Assembly……………………..14-15 F. Stacking and Mounting Two Ovens………………………………..15-16

G. Stacking and Mounting Three Ovens……………………………........16

H. Stacking and Mounting Four Ovens…………………………………...16 I. Electrical Connection……………………………………………………16 J. “Loose” Parts……………………………………………………………..16

SECTION 3- OPERATION……………………………………………………..17

A. Location of Controls……………………………………………………..17 B. MenuSelect™ Control Operation and Programming…………….18-29 C. Cooking in a CTX Oven……………………………………………..30-31 D. Time and Temperature Guide.……………………………………..31-36

SECTION 4- CLEANINING.........................................................................37

A. Cleaning the Cooling Fan Filter………………………………………...37 B. Oven Cleaning Operation…………………………………...………37-38 C. Cleaning “Loose” Parts………………………………………………….38 D. Cleaning the Exterior………………………………………………...….39

SECTION 5- MAINTENANCE & TROUBLESHOOTING…………….….....39

A. Chart 1- Error Messages…………...…………………………………...39 B. Chart 2- Troubleshooting………………………………………………..40

SECTION 6- PARTS LISTS………………………………………………..41-42 Oven Open Rear View………………………………………………………42

Oven Elements Exposed View……………………………………………..43 Oven Front Closed View…………………………………………………….44 Oven Front Open View………………………………………………………45 Single Belt Conveyor………………………………………………………...46 Split Belt Conveyor…………………………………………………………..47

SECTION 7- ELECTRICAL SCHEMATICS……………………………...…..48

A. Model DZ33I, 208/230V, 3Ph Schematic……………………………..48 B. Model DZ33I, 380/415V, 3Ph Schematic…………...………………...49 C. Model DZ33I, 230V, CE, 3Ph Schematic……………………………..50 D. Model DZ33I, 380V, CE, 3Ph Schematic……………………………..51

This manual must be kept for future reference

Note:

Wiring diagrams are contained in the manual and

are also located in the oven.

SECTION 1 - DESCRIPTION

CTX Series oven is:

• Electrically powered • Conveyorized

• Zone heated by infrared panels • Electronically controlled

CTX Oven Model:

• DZ33I – 31” (787 mm) long cooking chamber with a MenuSelect™ control. NOTE: “DZ” designation on ovens stands for: “DZ” = Duel Zone Temperature Control.

DZ33I

Figure 1

A. Component Location

Oven Data Plate

Figure 1-2

B. Component Function

1. Oven Controller

The controller controls all functions of the oven. The cooking temperatures can be set from 200F to 900F (93C to 509C). Cooking times (conveyor speed) can be set from 1:00 minute to 60:00 minutes on the DZ33I.

Controller features a self-cleaning mode, a programmable automatic ON/OFF timing mode, and an energy conserving standby mode. Also included is a service mode designed to assist the service technician.

The Menu Select control contains 10 menu keys which can be preset to control both oven temperature and cook time. The operator must then press only the menu key for the desired product being cooked.

2. Infrared Heating Panels Heating panels are positioned above and below the conveyor belt in the oven chamber

(figure 1-3). When energized these panels emit infrared long waves. These waves do not heat the air through which they pass. Instead the waves are absorbed by the outer surface of the product transported through the oven on the conveyor belt. Using this application, food is placed on the conveyor and the unique properties of the infrared waves cause it to cook from the outside to the center in traditional fashion.

Figure 1-3

DZ33I Heat Zones

3. Conveyor

The conveyor is used to convey the product through the oven deck (chamber). The conveyor is made up of 1to 2 stainless steel wire belts which can travel in either direction around the frame. The conveyor is controlled by the controller and can travel at speeds from 1:00 to 60:00 minutes. The speed of the conveyor determines how long the product will be in the cooking chamber which is the cooking time.

CAUTION: All DZ ovens are Voltage Specific. Check the oven data plate for the voltage. Applying the wrong voltage can immediately damage the oven. Refer to the Installation Section of this manual for complete instructions before installing an oven.

C. Oven Specifications

Model

Volts

Phase

Connected

AVG

Operating

Connected Load (Amps)

Required

Breaker

(Amps)

DZ33I

208

50/60

8.95

3.1

45.7

DZ33I

208

50/60

9.5

3.1

30.3

19.8

DZ33I

240

50/60

10.0

3.1

41.7

DZ33I

240

50/60

10.0

3.1

27.6

18.1

Model

Volts

Phase

Connected

AVG

Operating

Connected Load (Amps)

Required

Breaker

(Amps)

DZ33I

(CE Listed)

230

50/60

9.2

3.1

18.9

32.6 - 40

DZ33I

(CE Listed)

380

50/60

8.4

3.1

18.9

9.2

8.9

Figure 1-1 Dimensions DZ33I

Single Oven on Base and Casters

Overall Height 39.44” (1001.8mm) Overall Depth 39.03” (991.4mm) Overall Length 59.00” (1499mm)

Double Oven on Base and Casters

Overall Height 55.32” (1328.9mm) Overall Depth 39.03” (991.4mm) Overall Length 59.00” (1499mm)

Triple Oven on Base and Casters

Overall Height 65.17” (1655.3mm) Overall Depth 39.03” (991.4mm) Overall Length 59.00” (1499mm)

Quad Oven on Base and Casters

Overall Height 72.02” (1829.3mm) Overall Depth 39.03” (991.4mm) Overall Height 59.00” (1499mm)

Oven Chamber Dimensions

Overall Height 5.5” (140mm) Overall Width 22.25” (565mm) Overall Length (Heating Zone) 31.22” (793mm) Conveyor Baking Area 3.88sq. ft. (0.36sq. m.) Stainless Steel Single Conveyor Belt Width 18” (457mm) Stainless Steel Duel Conveyor Belt Width (2) 8.00” (203mm) Net Weight of Single Unit 362 lbs. (164.2 kg) Temperature Range 1500F-9000F (66.50C-4820C)

Oven Electrical Specification Chart

NOTE: A separate ground wire must be supplied with each oven; conduit may not be used as a ground. NOTE: Supply wire must be rated minimum 900C (1940F).

Domestic Amp Loading Charts

DZ33I Domestic

DZ33I International

Minimum Clearance

Rear

0”

Left

4”

Right

4”

We reserve the right to change specifications and product

or replacements for previously purchased equipment.

D. Dimension Drawings

1. Dimension drawing of Single DZ33I Oven on Base.

design without notice. Such revisions do not entitle the buyer to corresponding changes. Improvements, additions

Note: All figures in parentheses are in millimeters.

2. Dimension drawing of two stacked DZ33I ovens on base.

Minimum Clearance

Rear

0”

Left

4”

Right

4”

Minimum Clearance

Rear

0”

Left

4”

Right

4”

Note: All figures in parentheses are in millimeters.

3. Dimension drawing of three stacked DZ33I ovens on base.

Note: All figures in parentheses are in millimeters.

Minimum Clearance

Rear

0”

Left

4”

Right

4”

4. Dimension drawing of a Quad stacked DZ33I ovens on base.

Note: All figures in parentheses are in millimeters.

Side View Front View

Quantity

Description

4”x4”x4’ (10.2cm x 10.2cm x 61cm) board

4”x4”x2’ (10.2cm x 10.2cm x 122cm)

board (stacking ovens only)

1-1/2”x7’ (3.8cm x 213cm) rigid pipe Schedule 40

Custom M5 Lift (Vermette)

A. Inspect for shipping Damage

All shipping container should be examined for damage before and during unloading. This equipment was carefully inspected and packaged at the factory. The freight carrier has assumed responsibility for its safe transit and delivery. If equipment is received in damaged

condition, either apparent or concealed, a claim must be made with the delivering carrier.

1. Apparent Damage or Loss- If damage or loss is apparent it must be noted on the freight bill or express receipt at the time of delivery, and it must be signed by the

carrier’s agent (driver). If this is not

done, the carrier may refuse the claim. The carrier will supply the necessary claim forms.

2. Concealed Damage or Loss- If damage or loss is not apparent until after equipment is uncrated, a request for inspection of concealed damage must be made with carrier within 10 days. The carrier will make an inspection and will supply necessary claim forms. Be certain to retain all contents plus external and internal packaging/crating materials for inspection.

B. Placement of Oven

Some very important considerations must be made when choosing the place where the oven is to operate.

3. This Oven is conveyorized and operates continuously. It should be placed so it fits into the “flow” of the operation.

4. Drafts entering the oven chambers can cause inconsistent cooking results. Check the area surrounding the oven and eliminate sources of drafts such as open windows or doors and fans or other appliances that cause air circulation.

SECTION 2 – Installation

5. Oven should be positioned so hot air from and other piece of equipment cannot enter oven cooling fan air intake on oven front. Serious problems could occur.

NOTE: To validate a new oven(s) warranty a certified CTX installer must supervise Steps C through H of installation.

C. Items for Stacking Oven

The following items are required for stacking ovens:

Item

Qty,

Part Number

Description

67880

INSUL, BASE PART A

67881

INSUL, BASE PART C

67882

INSUL, BASE PART B

PARTS LISTED ABOVE ARE FROM 69978 KIT, DZ33I INSULATION

67884

WLDMT. BASE DZ33

67614

PANEL, TOP

66948

ASSY. LEG, CASTER

59156

SCR, SL TRUSS HD SS 10-32X1-1/2”

21422-0001

WASHER, LOCK SPLIT 3/8” ZP

21416-0001

WASHER, FLAT SS 3/8”

2000531

SCR, CAP HX HD 3/8”-16X1” NP

D. Base Section Assembly

1. Locate the carton containing the oven base. Remove and inventory the contents. Refer to the correct parts lists below and also to Figure 2-1.

Figure 2-1

Single Oven Stand Parts

Qty,

Part Number

Description

67880

INSUL, BASE PART A

67881

INSUL, BASE PART C

67882

INSUL, BASE PART B

PARTS LISTED ABOVE ARE FROM 69978 KIT, DZ33I INSULATION

67884

WLDMT. BASE DZ33

67614

PANEL, TOP

66948

ASSY. LEG, CASTER

59156

SCR, SL TRUSS HD SS 10-32X1-1/2”

21422-0001

WASHER, LOCK SPLIT 3/8” ZP

21416-0001

WASHER, FLAT SS 3/8”

2000531

SCR, CAP HX HD 3/8”-16X1” NP

Item

Qty,

Part Number

Description

67880

INSUL, BASE PART A

67881

INSUL, BASE PART C

67882

INSUL, BASE PART B

PARTS LISTED ABOVE ARE FROM 69978 KIT, DZ33I INSULATION

67884

WLDMT. BASE DZ33

67614

PANEL, TOP

66947

ASSY. LEG, CASTER

59156

SCR, SL TRUSS HD SS 10-32X1-1/2”

21422-0001

WASHER, LOCK SPLIT 3/8” ZP

21416-0001

WASHER, FLAT SS 3/8”

2000531

SCR, CAP HX HD 3/8”-16X1” NP

Item

Qty,

Part Number

Description

67880

INSUL, BASE PART A

67881

INSUL, BASE PART C

67882

INSUL, BASE PART B

PARTS LISTED ABOVE ARE FROM 69978 KIT, DZ33I INSULATION

67884

WLDMT. BASE DZ33

67614

PANEL, TOP

58930

CASTER

Double Oven Stand Parts

Triple Oven Stand Parts

Quad Oven Stand Parts

2. Lay Wldmt. Base (Item 4, Figure 2-1) upside down on the floor and remove the protective film from base. Attach the four Assy. Leg, Caster (Item 5) using 16

SCR, Cap HX HD 3/8”-16X1” NP (Item

10), 16 Washer, Flat SS 3/8” (Item 9), and 16 Washer, Lock Split 3/8” ZP (Item

8). For Quad screw casters directly into basepad.

3. Turn the base assembly upright and set aside. Also set aside 4 SCR, SL Truss HD SS 10-32X1-1/2” (Item 7), and

E. Mounting Single Oven onto Base

Panel, Top (Item 5). The base will be used to stack oven on, and the top secures to the top of the oven top oven.

Assembly

1. Cut the bands holding the protective shipping carton to the skid. Carefully remove the bands and lift the carton up off the oven.

2. Cut the bands holding the oven to the skid.

IMPORTANT: Lift the oven with the

4”X4”X10’ (10.2cmX10.2cmX122cm)

running through the oven only. DO NOT lift the oven by the conveyor. Damage

WILL result.

IMPORTANT: Lift the oven with the

4”X4”X10’ (10.2cmX10.2cmX122cm)

running through the oven only. DO NOT lift the oven by the conveyor. Damage WILL result.

3. Slide the two 4”X4”X10’ (10.2cm X

10.2cm X 304.8cm) pieces of wood through the oven cavity. The wood pieces should be sticking out of the oven equally on both sides. One of the pieces of wood should be placed to the rear of the oven and the other in the front of the oven. See figure 2-2.

4. Position the two Vermette lifts on either

ends of the oven under the 10’

(304.8cm) pieces of wood, making sure the legs with wheels are up as close as possible to the skid. Place the two

4”X4”X4’ (10.2cm X 10.2cm X 122cm)

pieces of wood across the two Vermette

forks, at least 6” (182.88cm) in from the

end of the forks, and centered with the

10’ (304.8cm) pieces of wood running

through the oven cavity. See figure 2-2.

5. With the 4’ (122cm) pieces positioned under the 10’ (304.8cm) begin to lift the oven with the two Vermette lifts. (keeping the oven level at all times).

6. When the oven is completely free from the skid, slide it out from under the oven. (dispose of the skid in accordance with local regulations).

7. Lift the oven high enough to position the stand under. Roll the stand under the oven (do not roll the oven and lifts over the stand) and lower onto the stand.

The bottom of the oven will wrap around

the stand.

(careful not to get hands or fingers

between oven and stand).

Figure 2-2

F. Stacking and Mounting Two Ovens

1. Cut the bands holding the protective shipping carton to the skid. Carefully remove the bands and lift the carton up off the oven.

2. Cut the bands holding the oven to the skid.

3. Slide the two 4”X4”X10’ (10.2cm X

4. Position the two Vermette lifts on either

ends of the oven under the 10’

(304.8cm) pieces of wood, making sure the legs with wheels are up as close as possible to the skid. Place the two 4”X4”X4’ (10.2cm X 10.2cm X 122cm) pieces of wood across the two Vermette

lift forks, at least 6” (182.88cm) in from

the end of the forks, and centered with

the 10’ (304.8cm) pieces of wood

running through the oven cavity.

(figure 2-2)

5. With the 4’ (122cm) pieces positioned

IMPORTANT: Lift the oven with the

4”X4”X10’ (10.2cmX10.2cmX122cm)

running through the oven cavity only. DO NOT lift the oven by the conveyor. Damage WILL result.

IMPORTANT: Lift the oven with the

4”X4”X10’ (10.2cmX10.2cmX122cm) running through the oven cavity only.

DO NOT lift the oven by the conveyor. Damage WILL result.

under the 10’ (304.8cm) begin to lift the

oven with the two Vermette lifts (keeping the oven level at all times).

6. When the oven is completely free from the skid, slide it out from under the oven. (dispose of the skid in accordance with local regulations).

7. Elevate the upper oven high enough to position the lower oven underneath.

8. Roll the stand with the lower oven under the upper oven (do not roll the oven and lifts over the lower oven) and lower onto the lower oven. The bottom of the oven will wrap around the top of the lower oven.

(careful not to get hands or fingers

between ovens).

G. Stacking and Mounting Three Ovens

1. Follow the previous procedures in step F.

(careful not to get hands or fingers

between ovens).

H. Stacking and Mounting Four Ovens

1. Follow the previous procedures in step F.

(careful not to get hands or fingers

between ovens).

I. Electrical Connection All wiring and electrical connections required

for the oven(s) must be performed by a certified electrician. Each oven must be wired according to the electrical specification for the oven rating. See charts in Section 1, electrical schematic in Section 7 and schematics furnished with the oven. A separate ground wire must be supplied with each oven. Conduit may

not be used as ground. Consult national or local electrical codes for wire gauge and circuit breaker ratings.

CAUTION: All DZ Series Ovens are manufactured for voltage specific operation.

IMPORTANT: ALWAYS carefully check the data

plate voltage rating to be sure which voltage to apply when installing a DZ Series oven. Applying the wrong voltage can immediately damage oven.

If local codes allow, we recommend that flexible conduit be used for final connection as the oven assembly is on casters and the use of flexible conduit will allow movement for cleaning.

J. Loose Parts

The aluminum crumb trays (PN 67932) (2 per oven) are shipped mounted in place. They are removable for cleaning and are considered loose parts. They should be checked prior to startup to be sure they are properly in place. The stainless steel draft curtain and exit shelves are packed in a separate carton inside oven.

NOTE: Make sure protective plastic film is removed from draft curtains before installation.

1. Draft Curtains, stainless steel (PN

322904) (2 per oven). These mount above the conveyor at the ends of the cooking chamber. They serve to reduce drafts through the oven chamber and to reduce heat loss to the environment. To install, locate the thin rod above each entrance/exit of the oven. Hang one draft curtain over each rod. They are in their lowest position when hanging vertical. To raise the curtains to their highest position, swing them outward until they are horizontal and then push in toward oven chamber.

NOTE: Make sure protective plastic film is removed from exit shelves before installation.

2. Exit Shelves, stainless steel (PN

69776) (2 per oven). These shelves mount in cantilever fashion at the exit and entrance end of the conveyor and provide a landing zone for cooked product. Depending on the operation they may or may not be needed or used. To install, place the slotted end of the shelf over the crossbar at the end of the conveyor extension frame.

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