Toastmaster G-24 Owner's Operating & Installation Manual

OWNER'S OPERATING

& INSTALLATION

MANUAL

G-24

CONVEYOR OVEN

Toastmaster® • 1400 Toastmaster Drive • Elgin, IL 60120 • [phone]

A Middleby Company

Part No. 310-2469

P 5/91

Toastmaster®

OVEN LIMITED WARRANTY

(USA Only)

The seller warrants equipment manufactured by it to be free from defects in material and workmanship
for which it is responsible. The Seller's obligation under this warranty shall be limited to replacing or
repairing at Seller's option, without charge, F.O.B. Seller's factory, any part found to be defective and
any labor and material expense incurred by Seller in repairing or replacing such part, such warranty to
be limited to a period of one (1) year from date of original installation or eighteen (18) months from date
of shipment from Seller's factory, whichever is earlier, provided that terms of payment have been fully
met. All labor shall be performed during regular working hours. Overtime premium will be charged to the
Buyer.

THIS WARRANTY IS NOT VALID UNLESS EQUIPMENT IS INSTALLED, STARTED, AND DEMON­STRATED UNDER THE SUPERVISION OF A FACTORY CERTIFIED INSTALLER.

Normal maintenance functions, including lubrication, thermostat calibration, and replacement of light
bulbs, fuses and indicating lights, are not covered by warranty.

Any repairs or replacements of defective parts shall be performed by Seller's authorized service
personnel. Seller shall not be responsible for any costs incurred if the work is performed by other than
Seller's authorized service personnel.

When returning any part under warranty, the part must be intact and complete, without evidence of
misuse or abuse, freight prepaid.

This warranty is made to the original purchaser/user and is not transferable.
Seller shall not be liable for consequential damages of any kind which occur during the course of

installation of equipment, or which result from the use or misuse by Buyer, its employees or others of the
equipment supplied hereunder, and Buyer's sole and exclusive remedy against Seller for any breach of
the foregoing warranty or otherwise shall before the repair or replacement of the equipment or parts
thereof affected by such breach.

The foregoing warranty shall be valid and binding upon Seller if and only if Buyer loads, operates and
maintains the equipment supplied here under in accordance with the instruction manual provided to
Buyer. Seller does not guarantee the process of manufacture by Buyer or the quality of product to be
produced by the equipment supplied hereunder and Seller shall not be liable for any prospective or lost
profits of Buyer.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED
WARRANTIES WHATSOEVER. SPECIFICALLY THERE ARE NO IMPLIED WARRANTIES OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

The foregoing shall be Seller's sole and exclusive obligation and Buyer's sole and exclusive remedy for
any action, whether in breach of contractor negligence. In no event shall seller be liable for a sum in
excess of the purchase price of the item.

© 1990 Toastmaster

Toastmaster • 1400 Toastmaster Dr. • Elgin, IL 60120-9272 • [phone] • FAX [phone]

i

RETAIN THIS MANUAL FOR FUTURE REFERENCE

This manual provides detailed information for installation and operation of your new Gemini
Series oven. It also contains some information to assist the operator in diagnosing
problems in the event of a malfunction. This manual is an important tool for the operator
and should be kept readily available.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE

VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY

OTHER APPLIANCE

Using any parts other than

genuine Toastmaster factory

manufactured parts relieves the

manufacturer of all liability.

Toastmaster (Manufacturer) reserves the right to

change specifications and product design

without notice. Such revisions do not entitle the

buyer to corresponding changes, improvements,

additions or replacements for previously

purchased equipment.

ii

TABLE OF CONTENTS
SECTION 1
DESCRIPTION 1

A. Component Location 2
B. Component Function 3-4
C. Oven Specifications 5-6
D. Dimension Drawings 7

SECTION 2
INSTALLATION 9

A. Inspect For Shipping Damage 9
B. Placement of Oven 9
C. Unpacking Oven 10
D. Uncrating Oven 11
E. Installing Legs 11
F. Stacking and Mounting Two Ovens 12
G. Stacking a single G-24 oven over a Toastmaster CO-19

convection oven or a Blodgett CTB-1 convection oven 13
H. Conveyor Belt and Temperature Display 14
I. Standoffs 15
J. Electrical Connection 15
K. Heat Curtains 16
L. Exit Tray 16

SECTION 3
OPERATION 17

I. Location and Function of Controls 17-19
II. Programming the G-24 Oven 20

A. Setting the Temperature 20

B. Setting the Cooktime(Conveyor Belt Speed 20

C. Cooking in a CTX Oven 20

1. Infrared Cooking Technology 20

2. Heat Zoning 21

3. General "Rules of Thumb 21

4. Cooking Trials 22

5. Time and Temperature Guide 23-26

6. Loading the Conveyor 27
Production Chart 28

SECTION 4
MAINTENANCE 29

A. Cleaning the Cooling Fan Filter 29
B. Cleaning the Oven Chamber 30
C. Cleaning "Loose" Parts 30
D. Cleaning the Exterior 32
E. Spare Parts Kit 32

SECTION 5
TROUBLESHOOTING 33

Troubleshooting Chart 1 - Oven is Dead 3
Troubleshooting Chart 2 - Conveyor Does Not Run 33
Troubleshooting Chart 3 - Conveyor Runs Full Speed 34
Troubleshooting Chart 4 - Zone Won't Reach Temperature 34

SECTION 6
PARTS LIST 35

Heating Elements and Thermocouple 35
Conveyor, Control Panel and Loose Parts 36-37
Conveyor Motor and Electrical Components 38-39

SECTION 7
ELECTRICAL SCHEMATIC 41

iii

Model G-24 ovens are:

• Electrically heated

• Heated by infrared panels

• Conveyorized

• Electronically controlled

The G-24 conveyor oven is designed for installation on a counter top or worktable that will adequately accommodate
its size and weight.

The oven employs infrared cooking technology. Infrared heat panels are placed one above and one below the
conveyor. These panels form the oven's upper and lower heat zones. A Controller accurately maintains set cooking
temperatures and conveyor speed (cooktime) for consistent and repeatable results. Food is cooked by absorption of
far infrared waves as it is conveyed through the oven chamber.

The oven features an all stainless steel exterior and an aluminized steel oven chamber. The conveyor is a 15" wide
stainless steel chain link belt. Oven operating voltage is dual rated 208/240 VAC, 60 Hz, 1 phase. It is equipped with
factory-installed cord with plug conforming to NEMA Standard 6-50P. The oven also includes a set of four 4" high
NSF approved adjustable legs, heat curtains, crumb trays and exit trays.

1

SECTION 1 - DESCRIPTION

A. Component Location

2

Figure 1-2

B. Component Function

Single

Stacked

3

1. Single and Stacked Ovens

SECTION 1 - DESCRIPTION

lations the legs must be used on a single oven or
lower oven of stacked oven to validate the
warranty.

The Toastmaster Model G-24 oven is available as
either a single oven or two ovens stacked. Each unit
is supplied with four 4" adjustable legs. For all instal-

The stacked oven is made up of two separate units,
one on top the other. A mounting bracket (P/N
ACSBG24) must be installed when stacking two
ovens, if bracket is not used warranty will be
voided.

Oven

Oven

Figure 1-3

4

SECTION 1 - DESCRIPTION

2. Cooking Area
The Toastmaster Model G-24 has a 26" (660 mm)

cooking deck (chamber) and comes with a 15" (381
mm) wide conveyor belt.

3. Controller
The Controller controls both the temperature and

conveyor belt speed (cook time) of the oven. Cook
temperature can be set from 300°F to 950°F (149°C
to 509°C) and cooktime can be set from 0.5
minutes to 19.9 minutes.

6. Conveyor
The conveyor is used to convey the product

through the oven deck (chamber). The conveyor is
made up of a frame and a stainless steel wire belt
which can travel in either direction around the
frame. The conveyor can travel at infinitely variable
speeds and the speed is controlled by the
Controller. The speed of the conveyor determines
how long the product wi ll be in the cooking chamber
which is the cooking time. The oven chamber is 18"
(457 mm) wide with a 15" (381 mm) wide conveyor
belt.

4. Infrared Heating Panels
Patented heating panels are positioned above and

below the conveyor belt of each oven deck (cham­ber). 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.

5. Heat Zones
The heat zones refer to individual areas of heat

control within a cooking deck (chamber). The deck
contains two heat zones (upper and lower). Refer to
Figure 1-4.

7. Accessories
Kit For Stacking Two G-24's

An accessory stacking bracket kit (P/N ACSBG24)
allows you to stack two G-24's one on top of the
other (See Installation Section). This bracket must
be used when stacking a G-24 or the warranty is
voided. Instructions for stacking the ovens are also
available in the stacking bracket kit.

Kit For Stacking a Single G-24 on Top of a
Toast-master CO-19 or a Blodgett CTB-1

An accessory stacking bracket kit (P/N
ACSBG24C019) allows you to a single G-24 on top
of a Toastmaster CO-19 convection oven or a
Blodgett CTB-1 convection oven (See Installation
Section). This bracket must be used when stacking
a G-24 or the warranty is voided. Instructions for
stacking the ovens are also available in the
stacking bracket kit.

Front Facing Controller Kit
Another accessory is a remote control kit which
allows you to remove the control panel from the unit
and place it in a separate box connected to the G­24 by a control cord five feet long. All necessary
parts and instructions are available in the remote
control accessory kit.

Figure 1-4

SECTION 1 - DESCRIPTION

for motor and speed control.

Toastmaster (Manufacturer) reserves the right to change specifications and product design without
notice. Such revisions do not entitle the buyer to corresponding changes, improvements, additions

or replacements for previously purchased equipment.

NOTICE

Oven Specifications

G-24 Specification Chart

Stainless Steel Conveyor Belt Width 15" (381 mm)

18.5" (470 mm)Wx

Heating Zone (Chamber) Dimensions

26" (660 mm)L x

3.75" (95 mm)H

Conveyor Baking Area 2.70 sq. ft. (0.25sq.m.)

45.5"(1156mm)Lx

Overall Dimensions - Single unit on legs

26" (660 mm)D x

18"(457mm)H

45.5"(1156mm)lx

Overall Dimensions - Two stacket units on legs
with stacking bracket

26" (660 mm)D x

34" (864 mm) H

208 Ibs. (94 kgm)

Net Weight of Single Unit Shipping Weight ­Single Unit

231 Ibs. (105 kgm)

50" (1270 mm) Lx

Shipping Dimensions

31 "(787 mm) Dx

22" (559 mm) H

Average Operating kw 2.8 kw
Allowable Temperature Ranges 300°F - 950°F (149°C - 509°C)

Solid state variable speed control (reversible).

208/240VAC supply voltage converted to

Conveyor Drive System

direct current through microprocessor

Cook Time Adjustable from 0.5 to 19.9 minutes
Insulation 2" (51 mm) on all 4 sides.

Infrared heat emitters

Heat Source

2 emitters/oven
1 emitter above conveyor
1 emitter below conveyor

Oven Chamber Steel Welded and reinforced 16 gauge aluminized steel.

Outer Body Steel 18 gauge stainless steel.

5

SECTION 1 - DESCRIPTION

Oven Electrical Specification Chart

Voltage Phase kw

208 1 5.4 26 26 6 40
240 1 7.1 30 30 6 40

Amp Loading

L1 L2

Wire

Size*

Breaker Rating

(Amps)

Provided for reference only. Consult national or local electrical codes.

NOTE: A separate ground wire must be supplied with each oven, conduit may not be used as ground.

6

D. Oven Dimension Drawings

7

STACKED OVEN

DIMENSION DRAWING

SECTION 1 - DESCRIPTION

A. Inspect for Shipping Damage

B. Placement of Oven

All shipping containers 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 15 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.

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

1. This oven is conveyorized and operates continu­ously. It should be placed so it fits into the "flow" of
the operation.

2. 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.

3. Oven should be positioned so hot air from an­other piece of equipment cannot enter oven cooling
fan air intake on top of control compartment.
Serious problems could occur.

NOTE: To validate a new oven(s) warranty a factory certified

Toastmaster installer must supervise Steps C thru K

9

SECTION 2 - INSTALLATION

C. Unpacking Oven

The oven components should be moved as close as
possible to final location before being assembled/
stacked. The oven setting on its bottom, requires
door openings wider than 26" (660 mm).

Tied down to the conveyor belt is a box containing
two (2) exit trays, two (2) heat curtains and four (4)
legs (See Figure 2-1). Check to make sure you
received the correct quantity of parts.

10

Figure 2-1

Figure

2-3

SECTION 2 - INSTALLATION

D. Uncrating

Lay the oven on its front
side then remove the four
(4) 9/16" bolts attaching
crate to bottom of oven.

Figure 2-2

E. Installing Legs

Install the four (4) 4" ad­justable legs as shown in
Figure 2-3 then lift the
oven onto it's legs. On
single oven installation
place the oven in it's per­manent position and then
skip Step F and go directly
to Step G.

11

secure bracket to top oven

SECTION 2 - INSTALLATION

F. Stacking and Mounting

Two Ovens

NOTE: A stacking bracket (Kit #

ACSBG24) is required when
stacking two ovens

1. Move the lower oven
(oven with legs installed)
to it's permanent position.
Remove the four screws,
one located in each corner
of top of lower oven. Place
the brackets as shown in
Figure 2-4 and use the
screws that were re
moved to secure brackets
on to top of lower oven.

Figure 2-4

2. Using four people lift the
upper oven on top the lower
oven. Using the four bolts
supplied with brackets

through the threaded holes
normally used for legs.

12

Figure 2-5

Figure

2-7

SECTION 2 - INSTALLATION

3. Once the ovens are
stacked and secured
check to make sure the
oven(s) are level. Adjust

the legs if necessary.

Figure 2-6

G. Stacking a single G-24

oven over a Toastmas­ter CO-19 convection
oven or a Blodgett CTB­1 convection oven.

NOTE: A stacking bracket kit (P/N

ACSBG24C019) must be used
for this installation or warranty is
voided.

1. Lay the G-24 on its front
side. Then using the four
bolts supplied with the
bracket, secure bracket to
bottom of oven through the
threaded holes normally
used for legs. Opening in
sidewall must be at right
rear of oven.

13

SECTION 2 - INSTALLATION

2. Using four people lift
the G-24 and place it on
top of the convection
oven.

Figure 2-8

H. Conveyor Belt and Temperature Display

The conveyor belt is designed to travel in either direction. Also the
temperature display may be set for either °F or °C.

Your Toastmaster Certified Installer will set both of these functions for
you during the installation. If you require a change in the future call your
local Toastmaster Authorized Service Agency.

SECTION 2 - INSTALLATION

I. Standoffs

If the back side of the
oven will be against a wall
the four (4) standoffs
supplied in the installation
kit must be mounted to
the rear panel of oven. To
install the standoffs
remove one rear panel
screw at a time and re­place with a standoff.

These standoffs will keep
the ventilation louvers on
the rear control compart­ment panel from being
blocked.

Placing the oven directly
against a wall without the
standoffs will block the
vent louvers and will not
allow hot ambient air in
the control compartment

Figure 2-9

to escape. The compart­ment would then overheat
and cause possible dam­age to electrical compo­nents.

J. 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 chart below and electrical
schematic in Section 7 and schematics furnished with the oven.

The G-24 can be wired for 208 or 240VAC. 60HZ, 1 phase power supply. 240V is recommended because of
voltage fluctuations from the local power company. A drop in voltage will also cause the oven's wattage to drop.

Each oven must be on a separate 40 amp breaker. A 50 Amp-250V NEMA 6-50 receptacle is required for each
oven to accept the oven plug. The receptacle is available (optional) through Toastmaster, P/N ACRG24.

Oven Electrical Specification Chart

Amp Loading

Voltage Phase kw

208 1 5.4 26 26 6 40

240 1 7.1 30 30 6 40

L1 L2

Wire

Size*

Breaker

Rating (Amps)

*Provided for reference only. Consult national or local electrical codes.
NOTE: A separate ground wire must be supplied with each oven, conduit may not be used as ground.

15

SECTION 2 - INSTALLATION

K. Heat Curtains

Install one heat curtain at
each end of the oven
chamber by hanging it on
the steel rod as shown in
Figure 2-10.

Figure 2-10

Heat Curtain

L. Exit Tray

Next install the desired
exit tray at the exit end of
the conveyor. Two trays
are supplied with each
oven, one short and one
long.

16

Figure 2-11

Exit Tray

I. Location and Function of Controls

The following information provides a basic description of the oven's controls, their location and the function they
perform. The operator must be familiar with the controls.

Figure 3-1

Control Panel

Style A

17

SECTION 3 - OPERATION

All oven operating controls are on the control panel faceplate. They all relate to the Controller for programming
and for operating the oven.

The letter callouts in Figure 3-1 and 3-2 coincide with the following list which explains the control pad and
provides explanations of various terms and states of the oven.

Explanation of Controls (keyed to Figure 3-1 and 3-2)
A. Display - Liquid crystal display (LCD) provides readout of data being entered and data already entered. LCD

shows set temperature, actual temperature and cooktime. Cooktime is displayed at all times unless a "R
EAD" or "SET" button is pressed.

18

Figure 3-2

Control Panel

Style B

SECTION 3 - OPERATION

B. READ - Pushing the "READ" button will indicate on the display the actual temperature of that element in °F

or °C depending on position of the temperature scale switch on Controller.

NOTE: The position of the temperature scale switch on the Controller is set by the Certified
Toastmaster/CTX Installation the time of oven installation. To change switch position contact your local
Authorized Toastnaster Service Agency.

Display will NOT indicate the temperature until the element is above 300°F.

C. SET - There are two "SET" buttons, one for the upper element and one for the lower element. Pushing the

"SET" button will indicate on the display the set temperature you programmed. When the "SET" button is
used in conjunction with the corresponding knob (See D below), you can change the set temperature by
turning the knob while reading the display.

D. Temperature Adjustment Knob - The control knob is used in conjunction with the "SET" button to adjust

the specific element temperature to your requirements. The numbered scales (A Style Panel Only) around
the knobs are in °F and are for reference only. The maximum set point is 950°F (509°C), the minimum set
point is 300°F (149°C). Operating above or below these temperature limits can cause inconsistent cooking or
damage to oven components.

E. Heating Light - The heating light, when lit, indicates that one or both elements are below set point

temperature. When the oven is first turned ON the light will remain on until both elements are up to set
temperature. Under heavy product load the light may cycle ON and OFF as the elements are energized to
maintain set temperature.

F. Alarm Light-There are two alarm lights on the control panel. These lights will illuminate when a problem exists

in the temperature sensing portion of the control. If either light illuminates, turn the oven switch OFF and
unplug the power cord. Call an Authorized Toastmaster Service Agency for repairs.

G. Cooktime Knob - Used for adjusting the cooktime (conveyor belt speed) for your product. When the knob is

turned the display will automatically show cooktime in minutes and tenths of minutes. For example a reading
of 7.5 would be 7 minutes, 30 seconds. Turning the knob clockwise will increase speed and turning
counterclockwise will decrease belt speed. The cooktime may be set from 0.5 minutes to 19.9 minutes.

H. ON/OFF Switch-Located below the control panel the ON/OFF Switch is your main power shutoff. This switch

is also a circuit breaker which will trip OFF if any short develops in the oven.

WARNING

With the switch in the OFF position there is still High Voltage

inside the control compartment. DO NOT remove the rear

control compartment panel.

I. Cooling Fan (not shown) - The cooling fan's function is to cool the control compartment. A defective fan or

plugged fan filter will cause high control compartment temperatures and cause electrical controls to fail.

19

SECTION 3 - OPERATION

20

II. Programming the G-24

You should now be ready to begin operation. This G-24 conveyorized oven is equipped with a highly efficient heat
transfer system consisting of two infrared emitters or heating elements. These elements are located one above
and one below the conveyor belt. Each is controlled independently. This feature offers much more versatility than
many other ovens. It enables the operator to raise only the bottom temperature to give the product a crisp hearth­baked appearance or to cook a product evenly through a heavy metal pan. Or the operator may choose to raise
only the top element temperature to give a crisp or broiled top to a product.

Since the top and bottom elements are controlled independently, they can be set anywhere in their range. It is
recommended, however, that the top and bottom temperatures be set within 75°F (24°C) of each other. The
elements are very efficient, and a temperature differential greater than 75°F (24°C) will result in the lower
temperature element being heated by the higher temperature one. This, in turn, causes an incorrect reading of
temperatures and will result in an inconsistent product.

A. Setting the Temperature

Control Panel A Control Panel B

1. Turn oven ON

1. Turn oven ON

2. While pressing the upper element "SET"
button turn the corresponding adjustment knob
until the desired set temperature is shown on
the display. The knob is a 3/4 turn knob. The
numbers are an approximate temperature
setting.

3. Repeat Step 2 to set the lower element
temperature using the lower element "SET"
button and corresponding knob.

B. Setting the Cooktime (Conveyor Belt Speed)
NOTE: For Both A & B Style Control Panel

1. Turn Cooktime knob clockwise to increase conveyor belt speed or counterclockwise to decrease conveyor
belt speed. Cooktime will be shown on LCD display in minutes and tenths of minutes. For example a display
reading of 7.5 would be 7 minutes 30 seconds. Each 0.1 equals 6 seconds.
The Cooktime knob is a multi-turn knob so very fine time adjustment is possible.

C. Cooking in a CTX Oven

Before you begin to cook with your new oven you must understand the differences between cooking in it and
cooking in more conventional ovens. You will produce better results if you understand the technology and
follow the "rules".

2. While pressing the upper element "SET"
button turn the corresponding adjustment knob
until the desired set temperature is shown on
display. The knob is a multi-turn knob.

3. Repeat Step 2 to set the lower element
temperature using the lower element "SET"
button and corresponding knob.

1. Infrared Cooking Technology

The technology of infrared cooking used in the CTX series ovens was first introduced by CTX in 1969. Each
deck is fitted with patented infrared emitting heat panels (heating elements). These elements form the top
and bottom surfaces of each oven chamber. The G-24 has two heating elements. One above and one below
the conveyor belt.

SECTION 3 - OPERATION

These elements emit infrared "longwaves" which are absorbed by almost all matter in varying degrees.
Absorption of these waves by an object causes molecular agitation which causes friction which generates
heat. In this instance the object is food and the heat generated is used to cook the food. Infrared waves
penetrate the outer surfaces of the food where they are absorbed by virtually all ingredients plus the
container in which the food is placed. As a result, food cooks from the outside toward the center in very
traditional fashion.

Infrared waves, unlike conventional heat sources, do not heat the air through which they pass, nor do they
create any air currents in the oven chamber to dry out the food product. If there is no food product in the
oven the infrared waves are absorbed by the heating elements located opposite. These unique properties
translate into less food waste, a more moist product and excellent energy efficiency.

2. Heat Zoning
Since the top and bottom elements are controlled independently, they can be set anywhere in their range.

This feature offers much more versatility than many other ovens. It enables the operator to raise only the
bottom temperature to give the product a crisp hearth-baked appearance or to cook a product evenly
through a heavy metal pan. Or the operator may choose to raise only the top element temperature to give a
crisp or broiled top to a product.

It is recommended, however, that the top and bottom temperatures be set within 75°F (24°C) of each other.
The elements are very efficient, and a temperature differential greater than 75°F (24°C) will result in the
lower temperature element being heated by the higher temperature element. This, in turn, causes an
incorrect reading of temperatures and will result in an inconsistent product.

3. General "Rules of Thumb"
Cooking in a CTX infrared conveyor oven is different than cooking in any other type of oven including

microwave ovens. Because of these differences there are some "rules" that must be considered.

a. Continuous "Flow" Operation

CTX ovens perform best in a continuous type of operating environment. They are not well suited to a
batch type operation. Greatest efficiency is attained when as many steps as possible in the operation
are put into a continuous "flow" pattern.

Figure 3-4 Heat Zones/Temperature

Variations

21

SECTION 3 - OPERATION

b. Pans

The type of vessel used to hold the food has a bearing on cooking time and consistency of results.

1. Pans with a dull black finish absorb maximum infrafred heat. Product cooks faster in dull black pans
than in shiny silver ones.

2. Heavier (thicker gauge) pans cook more evenly. They heat slower but hold their heat longer.
Lighter (thinner gauge) pans transfer heat faster but less evenly. They also cool faster.

c. Product

Best results are obtained when product entering the oven is consistent.

1. Food portions entering the oven should all be approximately the same temperature. When food
portions entering the oven vary in temperature, the temperature of those portions coming out of
the oven, though cooked, will also vary.

2. Product size should be the same. If product is 1/2" thick one time and 3/4" thick the next,
cooking results will be different.

3. Product loading density also affects results. If portion size and pan size are the same, two
portions per pan will cook differently than ten portions per pan.

d. Cooking Temperatures
Because infrared waves do not heat the air in the oven chamber the temperature settings and readings

are surface temperatures of the infrared heat panels themselves. For this reason temperature settings
will be higher than those for a conventional oven.

Type of Product Conventional Oven CTX Oven

Bakery Products 300°- 350°F (149-176° C) 450°-550°F (232°-287°C)
Pizza, Casseroles,

Flat Meats, etc.

350° - 450° F (176° –260° C) 600°-750°F (315°-398°C)

Broiled Fish, Steaks etc. 500°- 550°F (260° -287° C) 750°-850°F (398°-454°C)

4. Cooking Trials
The purpose of conducting cooking trials is to determine the exact temperature settings and cooking time(s)

needed to produce best results with your specific product(s). The fastest and easiest way to conduct these
trials is to start with settings already established for product(s) similar to yours. The following table provides
average time and temperature settings for a wide variety of products. We recommend they be used as
beginning set points for your tests.

Testing can be completed easier and faster and with less confusion if you keep accurate records of each test.
To assist you we have included a sample product test form that you can copy.

Choose your first product for test and look it up in the table on the following pages. Now program the oven
with the temperatures and cooktimes shown.

NOTE: If you are starting the oven from "cold" please allow 45 minutes heat up time. The elements cycle
after approximately 15 minutes, however, additional time is needed for the oven chamber(s) to become
stabilized and evenly saturated with heat.

22

SOLUTION

SECTION 3 - OPERATION

Begin your first trial run. Examine the finished product and evaluate it based on the following guidelines.

RESULTS

Outside too dark or burned
Outside too light or not cooked
Inside Overdone or dried out
Inside Underdone or raw

Reduce Temperatures
Increase Temperatures
Shorten Cooking Time
Lengthen Cooking Time

NOTE: Sometimes an increase in temperature may require a corresponding decrease in cooking time. Conversely a decrease in
temperature may require a corresponding increase in cooking time.

After evaluating the results, make the indicated time/temperature setting adjustments and allow about 15
minutes for the oven to stabilize at the new temperature settings. It may be necessary to run several tests
before you obtain the exact results you want. Be sure to document each test in the "Product Test Record"
below so you can ultimately produce a cooking chart for your specific items.

5. Time and Temperature Guide
On the following pages are times and temperatures, remember, these times and temperatures only provide

starting points. You will have to determine the exact times and temperatures for your specific products by
testing your products. Here are some basic guidelines that will help you settle on your set points.

If the product is too dark, lower the temperature or decrease the cook time.
If the product is too light, raise the temperature or increase the cook time.

If the outside of the product is done to your satisfaction but the internal temperature is not hot enough, then
increase the cooktime.

NOTE: Increasing cooktime may require a corresponding decrease in temperature.

23

SECTION

3 - OPERATION

Time and Temperature Guide Continued

Appetizers

Nachos

850/850°F

3.0 Alum.

10" 10oz.

Fresh

454/454°C

Oysters Ro

ckefeller

950/950°F

4.0 Alum.

6-8

Fresh

509/509°C

Potato Skins

850/850°F

3.0 Alum.

10" 10oz.

Fresh

454/454°C

Rumaki

850/850°F

6.0 Alum.

6-8

Fresh

454/454°C

Seafood Kabob

950/950°F

6.0 Alum.

6" 4-6

oz. Fresh

509/509°C

Baked Goods

Bagels

750/750°F

8.0 Wire Mesh

3 oz. Fresh

398/398°C

Bread Sticks

850/850°F

6.0 Alum.

1/2

size 2oz. Fresh

454/454°C

Brown

&

Serve Rolls

700/700°F

4.0 Alum.

1 oz. Thawed

370/370°C

Corn Brea

d 600/600°F

15.0 Alum.

1/2

size 2-1/2

Ibs. Fresh

315/315°C

Dinner Rolls

700/700°F

8.0 Alum.

1/2

size 3

oz. Fresh

370/370°C

Fresh Bread

700/700°F

10.0 Alum.

1/2

Sheet

1 Ib. Fresh

370/370°C

Garlic Bread

900/900°F

2.0 Alum.

1/2

size 1

Ib. Fresh

482/482°C

Muffins

600/600°F

15.0 Dark Alum.

3 oz. Fresh

315/315°C

Popovers

550/550°F

30.0 Dark Alum.

3 oz. Fresh

287/287°C

Soft Pretzels

800/800°F

8.0 Alum.

1/2

size 2

oz. Fresh

426/426°C

Toast

900/900°F

2.0 None

Slice

Fresh

482/482°C

Beef

Beef Ribs (Finish)

950/850°F

8.0 Alum.

1/2

size 8

ribs Precooked

509/454°C

Hamburger

4/1 950/950°F

4.0 Alum.

1/2

size 4

oz. Fresh

509/509°C

Hamburger

4/1 9

50/950°F

6.6 Alum.

1/2

size 4

oz. Frozen

509/509°C

Hamburger

2/1 950/950°F

10.0 Stainless

8 oz. Fresh

509/509°C

Liver

&

Onions

850/850°F

10.0 Alum.

1/2

size 4

oz. Fresh

454/454°C

Meatballs

900/900°F

8.0 Alum.

1/2

size 2oz.

Refrig.

482/482°C

Rib Eye Steak

950/950°F

8.0 Stainless

4x7 10oz.

Fresh

509/509°C

Salisbury Steak

900/900°F

6.0 Alum.

1.2

size 4

oz. Fresh

482/482°C

Strip Steak

950/950°F

8.0 Stainless

4x7 8

oz. Fresh

509/509°C

Strip Steak

950/950°F

10.0 Stainless

4x7 12oz.

Fresh

509/509°C

Tenderloin, Whole

850/850°F

15.0 Alum.

1/2

size 4

Ib. Fresh

454/454°C

Product

Temp

Setting

Top/Bott

Cook

Time

(Min.)

Pan Type

and Size

Amount

(Weight)

or Count)

State

Product

Bacon

900/900°F

6.0 Alum. w/Rack

1 Ib. Refrig.

482/482°C

Biscuits

800/800°F

8.0 Alum.

1/2

size 3

Ib. Fresh

426/426

°C

Egg Patty

750/750°F

4.0 Alum.

5 " 2

eggs

Fresh

398/398°C

Fried Eggs

750/750°F

4.0 Alum.

5 " 2

eggs

Fresh

398/398°C

Puffy Omelet

750/750°F

8.0 Alum. Skillet

9 " 6

oz. Fresh

398/398°C

Quiche

700/700°F

25.0 Dk.

Alum. Pie

24 oz. Fresh

370/370°C

Sausage, Link

900/900°F

6.0 Alum.

1/2

size 1-1/2

oz. Refrig.

482/482°C

Sausage, Patty

900/900°F

4.0 Alum.

1/2

size 1-1/2

oz. Refrig.

482/482°C

Casseroles

Enchiladas

900/900°F

8.0 Oven China

12oz.

Refrig.

482/482°C

Lasagna

850/850°F

12.0 Oven China

12oz.

Refrig.

454/454°C

Macaroni

&

Cheese

700/700°F

25.0 Stainless

12 x 20 5

Ib. Refrig.

370/370°C

Pasta

&

Sauce

850/850°F

8.0 Oven China

12oz.

Refr

ig.

454/457°C

Cookies

Bar Cookies

650/650°F

10.0 Alum.

1/2

size 1

Ib. Fresh

343/343°C

Brownies

700/700°F

15.0 Alum.

1/2

size 3-1/2

Ib. Fresh

370/370°C

Chocolate Chip

650/650°F

7.0 Alum.

1/2

size 3/4

oz. Fresh

343/343°C

Chocolate Chip

650/650°F

8.0 Alum.

1/2

size 1/2

oz. Fresh

343/343°C

Macaroons

650/650°F

15.0 Alum.

1/2

size 1

oz. Fresh

343/343°C

Oatmeal

650/650°F

7.0 Alum.

1/2

size 1-1/2

oz. Fresh

343/343°C

Desse

rts

Baked Apple

700/700°F

25.0 Stainless

12 x 20 12

apples

Fresh

370/370°C

Baked Custard

700/700°F

25.0 Custard Dish in

4 oz. Fresh

1/2

size pan

370/370°C

Cream Puffs

550/550°F

30.0 Alum.

1/2

size 2oz. Fresh

287/287°C

Fruit Pie

550/550°F

30.0 10"

Pie 26

oz. Fresh

287/287°C

Fruit Pie

550/550°F

50.0 10"

Pie 26

oz. Fresh

287/287°C

Layer Cake

650/650°F

15.0 Alum.

1/2

size 3

Ib. Fresh

343/343°C

Meringue Pie

650/650°F

7.0 10"

Pie 26

oz. Fresh

343/343°C

Puff Pastry

650/650°F

15.0 Alum.

1/2

size 4

oz. Thawed

343/343°C

25

Temp.

Setting

Top/Bott

Cook
Time

(Min.)

Pan Type

and Size

Amount

(Weight) or

Count)

SECTION 3 - OPERATION

State

Breakfast Foods

SECTION 3 - OPERATION

Fish

&

Seafood

Temp.

Product

Filet of Sole 950/950°F 6.0 Stainless 4x7 6 oz. Fresh
509/509°C
Lobster Tail 950/950°F 8.0 Stainless 4x7 8 oz. Fresh

509/509°C w/water
Sea Scallops 950/950°F 6.0 Stainless 4x7 8 oz. Fresh
509/509°C
Shrimp Scampi 950/950°F 6.0 Stainless 4x7 8 oz. Fresh
509/509°C
Snow Crab 950/950°F 6.0 Stainless 9x11 8 oz. Fresh
509/509°C
Stuffed Flounder 950/950°F 8.0 Stainless 4x7 8 oz. Fresh
509/509°C
White Fish Fillet 950/950°F 8.0 Strainless 4x7 8 oz. Fresh
509/509°C
Whole Trout 950/950°F 8.0 Stainless 9x11 9 oz. Fresh
509/509°C
Pizza
Deep Dish 750/750°F 10.0 Black Deep Pan Fresh
398/398°C
Calzone 675/675°F 8.0 Pizza Screen or Fresh
357/357°C Black Sheet Pan
Stuffed 650/650°F 20.0 Black Deep Pan Fresh
343/343°C
Thick Crust 775/775°F 6.5 Black Pizza Pan Fresh
412/412°C
Thin Crust 800/800°F 5.5 Pizza Screen Fresh
426/426°C
Thin Crust 650/650°F 9.0 Pizza Screen Frozen
343/343°C
Thin Crust 800/800°F 5.0 Pizza Screen Pre-bake
426/426°C
Pork
Breaded Chop 800/800°F 8.0 Alum. 1/2 size 4 oz. Precooked
426/426°C
Pork Chops 800/800°F 15.0 Alum. 1/2 size 4 oz. Fresh
426/426°C
Pork Ribs (Finish) 950/950°F 8.0 Alum. 1/2 size Slab Precooked
509/509°C
Poultry
Chicken Cordon Bleu 800/800°F 15.0 Alum. 1/2 size 12 pcs. Fresh
426/426°C
Chicken Pieces 800/800°F 18.0 Alum. 1/2 size 12 pcs. Fresh
426/426°C
Half Chicken 800/800°F 20.0 Alum. 1/2 size 1-1/4 Ib. Fresh
426/426°C
Whole Chicken 800/800°F 25.0 Alum. 1/2 size 2-1/2 Ib. Fresh
426/426°C

Setting

Top/Bott

Cook
Time

(Min.)

Pan Type

and Size

Amount

(Weight)

or Count)

State

26

SECTION 3 - OPERATION

6' 8'

6. Loading the Conveyor
Achieving maximum production is dependent on proper utilization of the conveyor belt. Depending on size,

pans can be placed on the conveyor belt in a variety of configurations to best use the space available.
The following illustrations show placement of various size round pans to achieve maximum production rates.

Pans in other sizes or shapes will require different placement. You will have to determine the best placement
configuration for your pans. DO NOT place pans off the edge of the belt or allow them to overhang.

Production output for any pan size can be easily calculated using the following formula:

This formula is based on a succession of single pans being placed on the belt. No consideration is given to
multiple pans across the 18" wide belt nor to staggered loading. The hourly production rate obtained by the
above calculation must be multiplied by a factor equal to the number of pans placed across the belt.

27

SECTION 3 - OPERATION

Cooktime

Round Pans

Sheet Pan

5"* 6"* 7" 8" 9" 10" 11" 12" 13" x 18" 1

min.

288 240 206 180 160 144 131 120

PRODUCTION CHART

G-24

Production Per Hour

2 min. 144 120 103 90 80 72 65 60
3 min. 96 80 68 60 53 43 44 40 27
4 min. 72 60 51 45 40 36 33 30 20
5 min. 58 48 41 36 32 29 26 24 16
6 min. 48 40 34 30 27 24 22 20 13
7 min. 41 34 29 26 23 21 19 17 11
8 min. 36 30 26 22 20 18 16 15 10
9 min. 32 27 23 20 18 16 14.5 13 9
|10 min. 29 24 20 18 16 14 13 12 8
11 min. 26 22 19 16 14.5 13 12 11
12 min. 24 20 17 15 13 12 11 10
13 min. 22 18 16 14 12 22 10 9
14 min. 20 17 15 13 11.5 10 9 8.5
15 min. 19 16 14 12 10.5 9.5 8.5 8
16 min. 18 15 13 11 10 9 8 7.5
17 min. 17 14 12 10.5 9.5 8.5 7.5 7
18 min. 16 13 11 10 9 8 7 6.5
19 min. 15 12.5 10.8 9.5 8.5 7.5 6.5 6.3
20 min. 14 12 10 9 8 7 6 6

* These pans may be placed side by side on the belt, doubling the capacity.
All product to be prepared on the G-24 requires that some product be run through the oven on a trial basis to

determine what times and temperatures are best suited to each specific product.(See
COOKINGTIMESANDTEMPERATURES Chart on page 24. This chart provides reference points for you to start. You
will then have to adjust either the time or the temperature to fit your product.)

28

Frequent cleaning will help your oven operate at peak performance and efficiency. Keep your oven clean! A.
Cleaning the Cooling Fan Filter

The foam filter and the protective grill of the cooling fan should be cleaned weekly. Daily cleaning may be required
if flour has built up on filter. Snap the protective grill off and wipe clean with a cloth. Remove the foam filter and
inspect it. If dusty, shake briskly. If greasy dirt, wash in warm soapy water, rinse, squeeze and set aside to dry
completely. Reinstall filter and grill.

Electrical Components are directly below

the cooling fan. BE SURE filter is dry before

Figure 4-1

CAUTION:

reinstalling.

29

30

SECTION 4 - CLEANING & MAINTENANCE

B. Cleaning the Oven Chamber

Self-Cleaning Mode

The G-24 has a self-cleaning mode. Before starting the cleaning process, set the cooktime control to approxi ­mately 12 minutes. To put the oven in the cleaning mode set both the top and bottom heating element
temperatures to 900°F (482°C). Let the oven run in this mode for approximately one hour. After this hour has
elapsed, return the cooktime and temperature settings to those desired or turn the unit off. After the oven has
cooled, any residue remaining in the chamber can be removed by reaching in and wiping out the chamber. Do not
reach into a hot oven. Severe burns could result.

CAUTION:

Be sure oven is off and cool to the touch and the

conveyor is stopped before attempting to wipe out the

oven chambers.

C. Cleaning "Loose" Parts

NOTE: Commercial oven cleaners can be used to clean stainless steel "loose" parts. The following
items must be removed from the oven to be cleaned manually in the pot sink.

CAUTION:

These procedures should be performed

only when the oven is OFF, cool to the

touch and the conveyor is stopped.

Crumb Trays: Clean daily. Lift the belt and remove the crumb trays from both entrance and exit end of each

conveyor. Empty residue, wash, rinse and dry thoroughly. Re-install.

Figure 4-2

Crumb Trays

SECTION 4 . CLEANING & MAINTENANCE

Exit Trays: Clean daily. Lift out exit tray, empty residue, wash, rinse and dry thoroughly. Re-install.

Figure 4-3
Exit Trays

Heat Curtains: Clean as needed. Unhook the heat curtains from the rods above the entrance and exit end of

each conveyor. Wash, rinse and dry thoroughly. Re-install.

Figure 4-4 Heat

Curtains

31

SECTION 4 - CLEANING & MAINTENANCE

32

D. Cleaning the Exterior

CAUTION:

Disconnect the oven's power supply cord from its receptacle

before you start to clean the oven.

Clean the outside of the unit using a damp cloth or stainless steel cleaner. Do not clean the control panel with an
abrasive cleanser. Use only a damp cloth. Be very careful when cleaning the unit not to allow water to enter the
unit through any of the openings in the control panel box. Liquid in the control panel area could cause damage to
the controls or could cause electrical shorts in the unit which could shock someone. As a reminder, the openings
in the control box area are the opening under the fan filter, the louvers on the side of the control panel area and
the small crack between the control panel and the control panel box.

E. Spare Parts Kit (Kit P/N 790-1262)

Item Part# Description

1 3002751 Conveyor Motor
2 3002755 Brushes for Motor
3 3002918 Main Relay
4 7608516 32V Transformer
5 3004265 Thermocouple
6 97393 Bayonet Adaptor for Thermocouple
7 82910 Solid State Relay
8 3000224 ON/OFF Switch-Circuit Breaker
9 3002686 Cooling Fan
10 3000330 Cooling Fan Guard and Filter
11 3006077 Controller
12 3002695 240V Regulator
12 3002696 208V Regulator

Spare Parts Kit (Kit P/N 790-1262)

Parts List

33

SECTION 5 - TROUBLESHOOTING

34

Figure 6-1 Heating Elements and

Thermocouples

ITEM PART# QUANTITY DESCRIPTION

1 7609642 2 HEATING ELEMENT-HEARTH PLATE
1 7608540 2 HEATING ELEMENT (For early model G-24 w/13"
2 33055 4 PORCELAIN TUBE
3 7609640 2 RACEWAY COVER
4 3004265 4 THERMOCOUPLE

NOTE: Always replace bayonet fitting(P/N97393) when replacing thermocouple.

5 97393 4 BAYONET FITTING w/COMPRESSION FERRULE
6 97394 4 BAYONET ADAPTOR

Section 6 – Parts List

SECTION 6- PARTS LIST

Conveyor, Control Panel and Loose Parts Parts List

ITEM PART# QUANTITY DESCRIPTION

1 7005471 1 EXIT TRAY -18" (457mm)
2 7006683 1 EXIT TRAY-7" (178mm)
3 7005446 2 BRACKET-EXIT TRAY
4 2000227 28 10-32 x1/2"RH SCREW
5 3100335 3 BEARING
6 7608577 1 DRIVE SHAFT - CONVEYOR
7 4111A8849 6 1/4-20 x 3/8" HEX HEAD BOLT
8 F706A8805 6 1/4" FLAT WASHER

9 7005445 2 CRUMB TRAY
10 3101173 3 MASTER LINKS
11 3101172 1 CONVEYOR BELT (1 FOOT)
12 3006077 1 CONTROLLER - SOLID STATE
13 B301A8827 8 6-32 x 1/4" RH SCREW
14 7610025 1 OPTIONAL CONTROL BOX
15 7007106 1 OPTIONAL CONTROL COVER
16 3000330 1 FILTER ASSEMBLY - FAN
17 7006911 2 HEAT CURTAIN
18 7608578 1 IDLER SHAFT
19 7005443 1 OVEN COVER
20 3101908 4 LEG-4" ADJUSTABLE

Stacking Bracket Kit (ACSBG24) includes item numbers 21,22, and 23.
21 7005579 2 STACKING BRACKET
22 A21924 4 3/8" FLAT WASHER

23 220212 4 3/8"-16 X 1/2" HEX HEAD BOLT

37

SECTION 6 PARTS LIST

38

Conveyor Motor and Electrical Components

Parts List

ITEM

1 3002751 1 GEAR MOTOR
2 7005390 1 BEARING MOTOR MOUNT
3 3002755 2 BRUSH MOTOR
4 3002756 2 CAP BRUSH
5 2000168 7 SCREW 8-32 X 2" FLAT HEAD SCREW
6 7005453 1 PLATE MOTOR MOUNT
7 3102494 1 MAGNET - 2 POLE
7 97217 1 MAGNET - CERAMIC - 4 POLE (Old Style)

8 220416 1 Hose Clamp
9 7006773 1 SENSOR BRACKET

10 7609638 1 SENSOR BRACKET
11 2000292 2 SCREW 10-32 x 2-1/2" FLAT HEAD SCREW
12 3002683 1 HEAT SINK
13 220009 2 TEFLON PAD
14 82910 2 SOLID STATE RELAY 45A
15 3430108A 2 VARISTOR
16 1429A8823 4 SCREW 8-32 x 3/8" 8CH SCREW
17 3002686 1 FAN
18 4111A8807 4 LOCK WASHER #8
19 1429A8827 4 HEX NUT#8
20 7608516 1 TRANSFORMER32V
21 3002918 1 RELAY
22 7608591 1 CORD AND PLUG ASSEMBLY
23 3000419 1 STRAIN RELIEF
24 87037 1 GROUND LUG

25 3000224 1 CIRCUIT BREAKER, TOGGLE
*26 3002695 1 REGULATOR, VOLTAGE 240V
*26 3002696 1 REGULATOR, VOLTAGE 208V

PART# QUANTITY DESCRIPTION

(Mount using any metal compatible fast setting epoxy)

• Voltage regulator is NOT required with style "B" controller. See Figure 3-1 & 3-2.

39

MODEL G-24 ELECTRICAL

SCHEMATIC

41