Doyon CA6G, CA12G, CAOP6G, CAOP12G Instructions Manual

ÉQUIPEMENT DOYON INC.

1255, rue Principale

Linière, Qc, Canada G0M 1J0

Tel.: [phone]

Canada: 1 [phone]

US: 1 [phone]

FAX: [phone]

Internet: http://www.doyon.qc.ca

e-mail: [e-mail]

CA6G – CA12G – CAOP6G – CAOP12G

Product / Produit:

Serial number / Numéro de série:

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

TABLE OF CONTENTS

SECTION « A » DESCRIPTION PAGE

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

Installation warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

Distances to respect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

Operation / instruction for oven and proofer. . . . . . . . . . . . . . . . . . . . . . . . A7

Operation for proofer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10

Oven maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13

Optional auto steam injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14

Optional watlow control operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A15

SECTION « C » BURNER ADJUSTMENTS

NATURAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1

PROPANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2

SECTION « E » COMPONENT PARTS

Component parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1

SECTION « F » CONTROL PANELS

Control panel 120V/208V/1PH & 120V/240V/1PH (CA12G) . . . . . . . . . F1

Control panel 120V/208V/3PH & 120V/240V/3PH (CA12G) . . . . . . . . . F3

Control panel 120V/208V/1PH & 120V/240V/1PH Watlow (CA12G) . . F5

Control panel 120V/208V/1PH & 120V/240V/1PH (CAOP6G) . . . . . . . F7

Control panel 120V/208V/3PH & 120V/240V/3PH (CAOP6G) . . . . . . . F9

Control panel 120V/208V/1PH & 120V/240V/1PH (CAOP12G) . . . . . . F11

Control panel 120V/208V/3PH & 120V/240V/3PH (CAOP12G) . . . . . . F13

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In case of strong gas odors, shut off the gas input valve

FAMCAGA.DOC 10/08

CAUTION

and contact a specialised gas technician

A1

INTRODUCTION

The manufacturer suggests to read this manual carefully.

This Jet Air gas fired oven is manufactured with first quality material by experienced technicians.
Proper installation and maintenance will guarantee a reliable service for years to come.

A nameplate fixed to the front or right side of the oven specifies the model number, type of
combustible, BTU rating, operating pressures, serial number, voltage and amperage.

Drawings and replacement parts numbers are included in this manual. The electrical diagram is
affixed in the control panel at the back of the oven.

ATTENTION

DOYON is not responsible for damages to the property or the equipment caused
by personnel who is not certified by known organisations. The customer is
responsible for finding qualified technicians in gas, electricity and plumbing for
the installation of the oven.

A2

CONSTRUCTION

You just bought the most advanced gas fired oven in the world, "DOYON" technology at its best.
This gas fired oven is manufactured using the highest quality components and material.

The oven gives a perfect uniform baking with its unique Jet Air convection system. The DOYON
gas fired oven is designed with parts that are easy to find.

SHIPPING

For your safety, this equipment has been verified by qualified technicians and carefully crated before
shipment. The freight company assumes full responsibility concerning the delivery in good condition
of the equipment in accepting to transport it.

IMPORTANT

RECEPTION OF THE MERCHANDISE

Take care to verify that the received equipment is not damaged before signing the delivery receipt. If
a damage or a lost part is noticed, write it clearly on the receipt. If it is noticed after the carrier has
left, contact immediately the freight company in order that they do their inspection.

We do not assume the responsibility for damages or losses that may occur during transportation.

A3

INSTALLATION WARNINGS

The DOYON gas fired ovens are designed to be used with the gas specified on the descriptive
nameplate. Refer to National Fuel Gas Code, ANSI-Z223.1-XX and CAN/CGA-B149-XX. Refer to
last edition year for XX. Copies of these are available at:

American Gas Association, 1515 Wilson Boulevard, Arlington, Virginia, 22209.
Association canadienne du gaz, 55 rue Scarsdale, Don Mills, Ontario, Canada, M3B 2R3.

POWER FAILURE WARNING

WHEN YOU HAVE A POWER FAILURE, SHUT OFF THE OVEN POWER SWITCH TO

PROTECT THE ELECTRONIC COMPONENTS WHEN THE POWER COMES BACK.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS

AND LIQUIDS IN THE VICINITY OF THIS OR ANY APPLIANCE.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR

MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH.

READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

Installation and service must be done by specialised technicians. Contact a certified gas technician,
electrician and plumber for set up.

The oven must be connected to the utility and electrically grounded in conformity to the effective
local regulations. If these are not established, the oven must be connected according to the Canadian
Electrical Code (CSA-C22.1-XX) or National Electrical Code (NFPA 70-XX). Refer to last
edition year for XX. Installation must also allow proper access for service (24 inches each side and
back).

The ovens must be installed with a proper ventilation like:

• under a vent hood

• or an exhaust pipe connected directly to the oven chimney flue using the draft hood provided with

the oven.

A type B gas vent approved for use with gas appliances must be utilized.

Make sure that provision for adequate air supply is provided for the operation of the oven.

Make sure that the adjustments mentioned in the "Installation" section are
correctly done prior to firing the oven or converting to a new gas.

CAUTION

A4

DISTANCES TO RESPECT

A) Back and sides of the oven: 1 inch.

B) Top of the oven: a clearance of 12 inches to the ceiling must exist to permit adequate venting

of the exhaust pipe and hot parts and to give proper access to a technician. The draft hood
must have a clearance of 2 inches minimum all around.

C) Floor: 4 inches minimum.

D) Sides of the oven: do not install other than easily removable equipment for service and

maintenance (not closer than 1 inch).

E) It is recommended to have a certain length of water pipe, electric cable and gas pipe between

oven and wall to help gain access for service.

A5

INSTALLATION

IN GENERAL

Take off the packaging material with care. Take off all the material used for packing and accessories.
Install the draft hood on the chimney of the oven.

Each unit is set up to be used with the type of gas and electrical supply specified on the nameplate
fixed on the oven.

The installation must be conform with the National fuel gas code ANSI Z223.1-XX and CAN/CGA­B149-XX Gas Installation Code and local Codes where applicable. Refer to last edition year for
XX.

The oven's combustion system consists of a very safe gas burner certified in accordance to the
American Gas Association Standard in USA and with the Canadian Gas Association in Canada.

1. To the certified gas technician

The burner installed on DOYON gas fired ovens is set up and adjusted at the plant for a first
class operation. It is nevertheless necessary to verify on site the pressure at the burner input.
The following table indicates the pressures that must be set up to remain conform to the
A.G.A. standards or C.G.A.

GAS TYPE ALTITUDE

(FT)

INPUT

(BTU)
EACH
OVEN

SECTION

REGULATOR

INPUT

PRESSURE

(Water column

inches)

BURNER

INPUT

PRESSURE

(Water column

inches)

BURNER

ORIFICE SIZE

(DMS)

Propane 0-2000 78,500 11,0 8,0 37
Propane 2000-4500 78,500 11,0 8,0 37
Natural 0-2000 78,500 7.0 3,5 20
Natural 2000-4500 78,500 7.0 3,5 20

The burner used is adjusted to be used with the gas indicated on the nameplate. It is
nevertheless possible to convert the burner to another gas by doing the modifications
indicated in the CONVERSION PROCEDURE provided with the oven. These
modifications must be done carefully and completely under the company's instruction
to remain conform to A.G.A. or C.G.A standards. Refer to Doyon Equipment to get
the right

CONVERSION KIT.

A6

The installation must be made with a connector that meets with the standard for connectors movable
gas appliances ANSI Z21.69-XX and a Quick-disconnect device that complies with the standard for
Quick-disconnect devices for use with gas fuel ANSI Z21.41-XX and addenda Z21.41a-XX and
Z21.41b-XX. Refer to last edition year for XX. It must also be installed with restraining device
(chain comes with the oven) to guard against transmission of strain to the gas supply and connectors.
The pipe fittings compound must be certified for gas.

The customer must install a manual shut off valve at the end of the gas supply pipe near the burner
which is approved by the American Gas Association Standard in the United States and with the
Canadian Gas Association in Canada.

Exhaust: A draft hood is provided with the unit and it must be used when the chimney is directly
connected to a gas vent pipe. The exhaust pipe must be certified for use of gases.

Clean the air contained in the gas supply pipe at the installation to insure a successful firing on the
first try. The gas pipe sealing compound tightness must be verified using a solution of water and
soap prior to firing the unit.

WARNING

Make sure not to obstruct the overpressure opening on the gas regulator.

NOTE: If there's any modification done to the system or change of the type of gas used,

make sure that the regulator pressure of the burner is adjusted as recommended in this
manual.

2. To the electrician

Electrical supply installation must be in accordance with the electrical rating on the nameplate.

WARNING

The electrician must make sure that the supply cable does not come in contact
with the oven top which becomes hot.

3. To the plumber

This equipment is to be installed to comply with the applicable federal, state or local plumbing codes.

Connect the steam system (1/4 NPT) to the cold water distribution network.
We highly recommend a water softener to eliminate minerals in the water. We suggest you to use
CUNO # CFS6135 (Doyon part number PLF240).

Do not adjust the needle valves, it has been done at the factory.

WARNING

A7

OPERATION OF THE OVEN

1. Turn the switch to the " ON " position.

• The light inside the oven must light up.

2. Adjust the thermostat at the desired setting (see THERMOSTAT INSTRUCTIONS below).

N.B. The red light must be "ON" (If not, press the breaker on the front).

3. Heat the unit until you reach the baking temperature.

When the desired temperature is reached, the red light goes out and turns green.
If the light is still "ON" and the oven does not produce heat, call for service.

4. Load the oven as fast as possible to avoid letting out too much heat.

5. Set the timer to the desired value and start it. (see "TIMER" adjustment on next page).

NOTE: The timer does not shut the oven off at the end of its cycle. It simply activates the buzzer.

6. Wait until the product is ready. Do not open the doors until the product is done.

VERY IMPORTANT

This oven has an overheat warning alarm to protect the electrical components against overheating. If

the red pilot light (OVERHEAT WARNING) is lit and you hear a buzzer, see troubleshooting.

THERMOSTAT INSTRUCTIONS

To obtain a very good thermal stability, we use a digital temperature controller with thermocouple.
The Omron E5CS thermostat controls the heat of every element at the SP (set point).

The temperature of the oven is always shown on the display of the thermostat and an arrow indicates
if the temperature is over or below the SP. When the green light is lit, it indicates that the temperature
is at the SP ± 1 %.

To adjust the SP (set point) value, you just have to press the key on the left and use the up and down
keys to set the temperature. Press the left key to return to run mode.

A8

INSTRUCTIONS FOR OVEN

BAKING

350oF (Croissants, Sweet doughs, Small rolls)
375oF (Baguette bread, round loaf, 16 oz. bread and more)
375oF (If the oven is filled to its capacity)

Place product in the oven only when the pilot light has gone out.

OPENING AND CLOSING OF THE DOORS

To open the doors: Open one of the doors up to 2" and wait 2 seconds to let the fan reduce its
spinning before opening completely.
To close the doors: Close the first door completely and the second door down to 2" and wait 2
seconds before closing completely and then hold the door closed for 2 seconds.

P.S. Open the doors as little as possible. This will affect the baking.

COOKING TIMER H5CL

Set the baking time required with the small push button on the timer. The green display is the setting
time and the red display is the countdown time (Ex: 25 minutes = set 2500 on green display).

After setting: Push the START / STOP button then, when the time expires, the buzzer will ring.
Push the START / STOP button again to stop the buzzer.
If you want to restart the time in the middle of the countdown, press on the yellow RST button on the
timer.

P.S. The timer is simply a reminder for the approximate duration of the baking time.

STEAM TIMER H5CL

Set the steam injection time required with the small push button on the timer. The green display is the
setting time and the red display is the countdown steam time (Ex: 25 seconds = set 2500 on green
display).

To inject steam in the oven, press and release the START steam timer button (while the fan is
running) to have your setting time steam injection.
If you want to restart the time in the middle of the countdown, press on the START button again or
on the yellow RST button on the timer.

P.S. Do not inject steam more than once each time you bake. Wait at least 10 minutes before re-

timing the steam injection system.

A9

OPERATION OF THE PROOFER

1. Switch "ON".

2. Set the thermostat control at 100o F.

3. Set the humidity control at approximately : 4 or 5 for CAOP6 and CAOP12.

4. If there is too much fog and water drips from the glass doors, adjust humidity control to a lower

number.

5. When the temperature is stabilised, put the products in the proofer.

(Leave them inside until they are ready to bake.)

6. IMPORTANT : When proofing cycle is completed, turn the humidity switch to "OFF" and

let the motor blower and air heat element run for 10-15 minutes to let dry the proofer. Then, turn
the main switch off, and leave the door ajar to prevent moulding.

When the proofer is not in operation, open the doors to let out the humidity and to prevent
mould.

P.S. The doors should not be opened unnecessarily to conserve the heat and humidity in the

proofer.

Every day cleaning of the water pan under the proofer's doors should be exercised.

A10

TROUBLESHOOTING

BEFORE CALLING FOR SERVICE

ANSWERS TO MOST FREQUENT QUESTIONS

Always cut off the main power before replacing any parts. Take care of water and gas
piping system when pulling the oven.

Control parts on the front and proofer
control:

Gas and motor system on the back of the
oven:

Questions Solutions

The oven does not turn on.

The oven does not produce heat.

Remove the side panels of the oven and the
proofer by screwing out the screws.

Pull the oven and screw out of the panels.

Check the breakers on the front panel.
Check the breakers of the building.
Check if the doors are tightly closed.
Check the motor fuses and the overload relays
located in the electrical control panel.

• Make sure: the thermostat is adjusted to a
temperature high enough to turn on the pilot
light.

1. If the oven blowers are not on, check the
overload relays located in the control
compartment. If anyone of these is
disengaged, call for a qualified technician.

2. If the oven blowers are on:

• Check that the manual shut-off valve is open
correctly.

To start it over, simply put the thermostat to the
"OFF" position, wait at least 10 seconds, then
reset it at the desired temperature. The burner
will start up and you can see the flame through
the hole near the gas input. You can repeat this
operation three times. If it does not start up
again, contact our company or a certified gas
technician.

A11

• The burner goes to lock-out because of:

a) Flame failure:

b) The spark is irregular or not present:

c) The air pressure switch does not close its
contact.
Uneven baking.

The burner is equipped with multiple
interlocked safety devices. In the event of a
failure of the flame or any blockage of the
combustion air supply, the burner will "lock
out" in the safety condition.

• Air has not been bled from the gas line

• Porcelain insulators cracked (very little

crack is enough).

• Spark probe grounded.

• It may be disconnected, incorrectly set or

defective or maybe the blower is not
running.

Make sure that the grills do not obstruct the air
flow. Do not use foil on the grills.

Verify the temperature of the oven by using an
oven thermometer and make sure that it is even
with the thermostat setting.

The steam works in the oven but the light
inside the steam button does not lite.
If steam device of the oven does not work
properly.

If the oven is baking too much on the sides, it is
possible that the fan is not cycling properly.
Verify if the motor turns 2.5 minutes in a
direction, stops 30 seconds and starts for 2.5
minutes in the opposite direction.
Replace the inside button bulb light.

The oven must have been heating for at least
half an hour before you use the steam system. If
not, water will appear at the bottom of the oven.

Check if the water supply valve (of the
building) is open.
Check if the water needle valve (of the oven) is
open one eighth of a turn. Just close it and open
it one eighth of a turn maximum.
Check the solenoid valve.
Check the preset steam timer in the back
control box.
Be sure to inject steam while the fan running.
The steam button light should lite during the
steam injection.

A12

If the OVERHEAT WARNING light is on,
and you hear the warning buzzer.

OPTIONAL
Manual fill water pan.
The warning red light in the front control
panel stays on when the water pan is full.

If there is no light in the proofer.

If there is no heat in the proofer.

If there is no humidity in the proofer.

Check if the cooling fan airflow is not
obstructed.
Check the cooling fan if it is running. If not,
call a qualified technician to replace it.
(Electrical components may be damaged if it is
not repaired immediately.)
You have no more water in the principal water
pan.
Check if the water line is not in air lock
condition. Disconnect the water line at the inlet
of the green solenoid valve and clean the
strainer filter.
Also clean the principal water pan and the float
switch.

1.Verify every breaker in front of the proofer.

2.Verify the main proofer switch and the main

proofer contactor.

1.Verify every breaker in front of the proofer.

2.Verify whether the pilot light will function by

raising the thermostat to a higher setting. If yes,
verify element. If not, verify pilot light,
thermostat or contactors.
Verify whether the pilot light works when you
increase the humidity to the position high. If yes,
verify if water comes in the reservoir and check
the water level switch box and the float switch.
Verify if limestone obstructs the waterflow. If the
float switch is working fine, verify the contactor
P1 and the immersion element. If the pilot light
does not lite, verify the pilot light and the infinite
switch.

Do not allow any obstruction to free the airflow of the burner.

Never try to modify the burner controls. This must be done only by a qualified
technician and under the company's instructions.

CAUTION

A13

OVEN MAINTENANCE AND CLEANING

MAINTENANCE OF THE BURNER

• Once a year, you should ask a certified technician to make a tune up.
Make sure everything works properly, verify and clean especially :

1. The gas mixer air inlet.

2. The spark rod and porcelain insulators.

3. The flame detection rod.

4. Verify the burner input pressure.

5. Verify every adjustments.

6. Clean every moving pieces.

MAINTENANCE OF THE OVEN

• Grease the bottom bearing monthly and the top flange bearing yearly, (see the dimension
section).

• Check the tension of the belt yearly.

• It is recommended to use a water filter and to clean or replace it regularly to avoid

accumulation of minerals inside the unit.

• Once a year or as needed, clean the reservoir of the proofer (see parts description for
localization).

Step by step Recommendations

Clean the inside of the oven and the proofer
with water and soap.

Take out the grills (the grills of the oven
could be cleaned with "Easy-Off").
After cleaning the inside of the oven, apply a
silicone base oven protector. It avoids food
from sticking to the metal.

Clean the oven windows with products like
Brasso or equivalents. They are copper
cleaners but good for this use.

Clean the oven exterior with a stainless steel
cleaner.

We recommend and sell:
Dirt Buster III : Action foam cleaner
CHEMCO
Part number : NEB201

We recommend and sell:
316 Silicone base protector and lubricant for
oven
Dow Corning
Part number : EXS400
We recommend and sell:
Wright's: Cream copper cleaner
J.A. Wright & Co.
Part number : EXC300
We recommend and sell:
Stainless steel cleaner
SANY or CURTIS (comestible)
Part number : NES201

A14

AUTOMATIC STEAM OPTION

INTERVALS TIMES SETTING (GREEN)
INJECTION TIMES SETTING (RED)

INTERVALS MULTIPLICATOR SETTING

STEAM INJECTION MULTIPLICATOR SETTING

SCALE ADJUSTMENT

By pushing the GREEN button, the button will light up and the automatic system injection will
start. The injection will be done as per the pre-adjustment time on the automatic steam timer. The
standard steam timer (white light) will light up during the steam injection. Push the RED button
to stop the automatic steam injection and then, the GREEN button will turn off.

Timer adjustments

EXAMPLE : For 5 seconds of steam injection every 10 minutes : Set the interval multiplicator screw
(OFF) at MIN and the GREEN needle at 10. Set the injection multiplicator screw (ON) at SEC and
the RED needle at 5.

EXAMPLE : For 2 seconds of steam injection every 25 seconds : Set the interval multiplicator screw
(OFF) at SEC and the GREEN needle at 25. Set the injection multiplicator screw (ON) at SEC and
the RED needle at 2.

A15

WATLOW CONTROL OPERATION

1. Turn the switch to the " ON " position. (See next paragraph for the factory-preset program on your
watlow control).

• The light inside the oven must light up.

2. Adjust the WATLOW control at the desired setting (see watlow programming procedure next
page).

Digital display must light up, if not, verify the breaker on the front panel.

3. Let the oven heat until the set temperature is reached, the LOAD1 red light on the watlow control
will go off when the temperature is stabilized.

4. Load the oven as fast as possible to avoid letting out too much heat.

5. Wait until the product is ready before opening doors.

FACTORY PRESET BAKING PROGRAM

MENU # 1 PREHEAT 400°F.
MENU # 2 375°F STEAM 15 SEC., COOKING TIMES 22 MINUTES WITH BUZZER.
MENU # 3 350°F STEAM 15 SEC., COOKING TIMES 25 MINUTES WITH BUZZER.
MENU # 4 325°F NO STEAM, COOKING TIMES 25 MINUTES WITH BUZZER.

325°F (Muffins)
350°F (Croissants, Sweet Doughs, Small rolls)

o

F (Baguette bread, round loaf, 16 oz. bread and more)

375
375oF (If the oven is filled to its capacity)

OPENING AND CLOSING OF THE DOORS

To open the doors: Open one of the doors up to 2" and wait 2 seconds to let the fan reduce its
spinning before opening completely.
To close the doors: Close the first door completely and the second door down to 2" and wait 2
seconds before closing completely and then hold the door closed for 2 seconds.

P.S. Open the doors as little as possible. This will affect the baking.

When the power comes back, the oven will start automatically on the menu #1. Then it is
recommended to turn off the oven to avoid that it starts without supervision.

POWER FAILURE