ZANOLLI SYNTHESIS 08/50 V PW GAS Manual For Installation
DR. ZANOLLI s.r.l.
Via Casa Quindici, 22
37066 Caselle di Sommacampagna
(Verona) Italy
Tel +39 045 8581500 (r.a.)
Fax +39 045 8581455
Web: www.zanolli.it • e-mail: zanolli@zanolli.it
cod. SY0
850
PW.
G.D.11
- rev. 0.
3 del
01
/09
/201
5
SYNTHESIS
08/50 V PW GAS
Manuale di installazione, uso e manutenzione
Manual for installation, use and maintenance
Manual de instalación, uso y manutención
Notice d’installation, d’utilisation et d’entretien
INSTALLATIONS-, BEDIENUNGS- UND INSTANDHALTUNGSHANDBUCH
INDEX
1. INTRODUCTION ................................................................................. 5
2. HOW TO USE THIS MANUAL............................................................. 6
3. TECHNICAL SPECIFICATIONS .......................................................... 8
3.1. Identifying the product ............................................................... 8
3.2. Directives compliance ................................................................ 8
3.3. Foreseen range of use ................................................................ 8
3.4. Technical Specifications ............................................................ 8
4. INSTALLATION ................................................................................... 9
4.1. Checking on delivery .................................................................. 9
4.2. Choosing a place for installation ............................................... 9
4.2.1. Location specifications for the installation of gas ovens ....... 10
4.3. Moving the unit ......................................................................... 11
4.4. Positionig the unit on its base ................................................. 11
4.5. Positioning stacked units ......................................................... 11
4.6. Electrical connection ................................................................ 12
4.7. Connecting the gas ................................................................... 13
4.8. Exhaust produced by combustion ........................................... 13
4.9. Checking before starting work ................................................ 15
5. OPERATION ...................................................................................... 16
5.1. Control panel ............................................................................. 16
5.2. Functional states of the system ............................................... 17
5.2.1. Inactive state ....................................................................... 17
5.2.2. State of activity .................................................................... 17
5.3. Settings ..................................................................................... 18
5.3.1. Setting the current time ........................................................ 18
5.3.2. Setting the language ............................................................ 18
5.4. Programming ............................................................................ 19
5.4.1. Cooking programs ............................................................... 19
5.4.2. Cooking time adjustment ..................................................... 20
5.4.3. Temperature adjustment ...................................................... 20
5.4.4. Economy Fuction ................................................................. 21
5.4.5. Programming switching on ................................................... 22
5.5. Switching off the oven ............................................................. 23
5.6. Alarms........................................................................................ 23
5.6.1. “OVER 1” ............................................................................. 23
5.6.2. “OVER 2” ............................................................................. 23
5.6.3. “OVER” ................................................................................ 24
5.6.4. “BELT” ................................................................................. 24
5.6.5. “FAN” ................................................................................... 24
5.6.6. “PRESS” .............................................................................. 24
5.6.7. “FLAME” .............................................................................. 25
5.6.8. “BATTERY” .......................................................................... 25
INDEX
SYNTHESIS GAS 3
INDEX
6. USE ................................................................................................... 26
6.1. Preparation for use and before turning .................................. 26
6.1.1. Ignition Control Panel .......................................................... 26
6.1.2. Settings and start cooking ................................................... 26
6.1.3. How to turn off the oven ...................................................... 27
7. SAFETY WARNINGS ........................................................................ 28
7.1. Prohibited actions and obligations towards the prevention of
accidents ............................................................................................. 28
7.1.1. Warnings for installers ......................................................... 28
7.1.2. Warnings for users .............................................................. 28
7.1.3. Warnings for the maintenance operator .............................. 29
8. CLEANING ........................................................................................ 30
8.1. Cleaning removable parts ........................................................ 30
8.2. Cleaning of external parts ....................................................... 31
8.3. Cleaning the baking chambers ................................................ 31
9. MAINTENANCE ................................................................................ 32
9.1. Error indicator .......................................................................... 32
9.2. Safety thermostat ..................................................................... 32
9.3. Replace battery ......................................................................... 33
9.4. Adjustment to different gas type ................................ ............. 34
9.4.1. Replacement of burner injector ........................................... 34
9.4.2. Adjustment of minimum power ............................................ 35
9.4.3. Application of new label ....................................................... 35
10. DECOMISSIONING AND DEMOLITION .................................... 36
TECHNICAL ENCLOSURES
A. Technical Specifications
B. Connections
C. Wiring diagrams
D. Exploded views
4 SYNTHESIS GAS
1. INTRODUCTION
1. INTRODUCTION
The gas conveyor ovens mod. SYNTHESIS gas have been designed
mainly for the automatic cooking of pizza and similar products. They are
conveyor ovens. Favourable peculiarity of these particular ovens is that it is
possible to make excellent baking, without controlling the same. For this
reason it is possible for un unqualified staff to use the oven.
SYNTHESIS belong to the family of conveyor ovens. Another important
innovation is that SYNTHESIS, thanks to their ventilation system, enable
an excellent and uniform baking. In fact, the flow of hot air surrounds the
product, removing the barrier of colder air that normally insulates it. This
ensures an uniform distribution of the heat in appropriate dosage, in order
to prevent the product from drying out excessively and giving it proper
fragrance.
Finally, SYNTHESIS gas, are useful for those user located in areas
where high electrical powers are not available. These conveyor ovens
allow also a reduction of operation cost.
Thank you for the preference given to us. We can confidently assure you
about your good choice, as our company has been committed to the
production of quality items since decades, without useless restriction in the
choice of the best materials.
To get the best use out of your new oven please read the information
contained in this manual carefully.
SYNTHESIS GAS 5
2. HOW TO USE THIS MANUAL
2. HOW TO USE THIS MANUAL
The paragraphs marked with this symbol contain indications
essential to safety. They must all be read by installers, the end user
and any employees that use the machine. Manufacturer does not
assume any responsibility for damage or injury incurring as a result
of ignoring the safety criteria outlined in these paragraphs.
This symbol applied to various surfaces of the machine,
shows that these can reach very high temperatures and should never
be touched without taking the necessary precautions.
This symbol, applied to various points on the machine,
serves to warn the user of the presence of a non-insulated “high
voltage hazard” inside the machine’s casing there being enough
power to constitute a fire risk or to electrocute a person.
The paragraphs marked with this symbol contain important
information to avoid causing damage to the machine. It is in the users
own interests to read these paragraphs carefully.
It is recommended that this installation, instruction and service
manual be kept in close proximity to the equipment so that it can be easily
and quickly consulted. The manual must accompany the equipment if it is
resold as it cannot be considered complete and safe without it.
Take note of the manual code and version shown on the back cover. In
the event that this copy is lost or destroyed, you can order another using
these
This manual is made up of a number of chapters. They should be
read in their entirety by both installers and service personnel as well as by
the end user to ensure safety of use and to get the best results from this
product.
Some useful indications for the consultation of each chapter are given
below.
Chapter 3 contains the reference standards of the oven and directions
for the proper use of the same.
Chapter 4 contains all the information needed to install the machine.
These are mainly aimed at specialized personnel but should be read by the
end user beforehand so as to predispose the environment where the
machine will be operated for the installation.
6 SYNTHESIS GAS
2. HOW TO USE THIS MANUAL
Chapters 5, 6 and 7 are intended for the user who has to learn how
to use the machine. These serve as a guide to the essential operations of
turning on, using and turning off of the machine under safe conditions.
Chapter 8 gives all the information necessary for the cleaning of the
equipment: all those operations that must be carried out by the user to
guarantee that it continues to function under safe, hygienic and sanitary
conditions and continues to give the best results.
Charter 9 gives all information necessary for periodic or extraordinary
maintenance, e.g. repairing or replacing parts of the equipment.
These maintenance operations must be carried out by
specialized personnel.
Chapter 10 gives directions for dismantling the machine.
The technical annexes contain features related to the specific model of
oven and all values which may be necessary for the selection, installation
and use. This chapter should be used as a point of reference to check that
the way the owner intends to use it is in line with the way the machine has
been designed to operate and ensure that and ensure that information
concerning the precise value of a given measurement or tolerance of the
equipment is available whenever necessary.
This chapter also provides a description of the electrical equipment that
comes with the machine, the exploded of equipment and a list of spare
parts, to facilitate order and replace any damaged parts.
The Manufacturer reserves the right to update the production series
and instruction manuals without the obligation to update the previous
production series and previously issued instruction manuals.
SYNTHESIS GAS 7
3. TECHNICAL SPECIFICATIONS
3. TECHNICAL SPECIFICATIONS
3.1. Identifying the product
This manual refers to conveyor oven SYNTHESIS gas.
3.2. Directives compliance
The oven SYNTHESIS carry the obligatory mark, that guaranteeing
their conforming to the following European directives:
2014/35/CE low current directive;
2014/30/CE electromagnetic compatibility directive;
2006/42/CE machines directive;
2009/142/CE Gas Directive
1935/2004/CE Regulation objects destined for coming into contact with
food products.
3.3. Foreseen range of use
The gas conveyor oven mod. Synthesis is designed to cook pizza, or
similar products. It is intended for professional use in the catering industry
(restaurant, pizza shop, etc..).
The normal operations are the loading and unloading of products on the
conveyor, the switching on, adjusting, switching off and cleaning of the
appliance.
The use to which the product should be put as stated above and the
configurations foreseen for this equipment are the only ones authorized by
the Manufacturer. Do not use these machines in any way other than
that indicated in the instructions provided.
The use intended is only valid for equipment which is in good
structural, mechanical and electrical condition.
3.4. Technical Specifications
For technical specifications refer to the following technical annexes at
the end of this manual:
A. Technical Specifications
B. Connections
C. Wiring diagrams
D. Exploded views
8 SYNTHESIS GAS
4. INSTALLATION
4. INSTALLATION
ATTENTION! These installation instructions are for the
exclusive use of personnel qualified for the installation and
maintenance of electrical or gas equipment conceived for
professional use in the foodservice industry and community catering
operations. An installation carried out by unqualified persons could
cause damage to the machine, to people, animals or property
ATTENTION! Proceed with the installation according to those
norms in force in the country where it is being carried out.
In addition, where it is necessary to carry out modifications or
adaptations to the electrical systems of the building in which the
machine will be installed, whoever carries out such modifications
must certify that the work has been undertaken according to current
“best practices”.
4.1. Checking on delivery
Unless otherwise agreed, the products are carefully packaged in a
robust structure in wood and with a sheet of nylon bubble wrap giving
protection against knocks and humidity during transport. These are
consigned to the freight operator in the best of condition.
We recommend, however, that you to check the packaging on arrival for
any signs of damage. If damage has occurred, have it noted on the receipt
which must be signed by the driver.
Once the equipment has been unpacked, check that it has not suffered
damage. Also check that all the dissembled parts are present.
In the event of damage to the equipment and/or missing parts, bear in
mind that the freight operator can only accept claims within 15 days of
delivery and that the manufacturer cannot be held responsible for damage
incurred to its products during their delivery. We are however, available to
assist you in presenting your claim.
In the event of damage do not try to use the equipment and
consult with professionally qualified personnel.
4.2. Choosing a place for installation
An effective, safe and long lasting functioning of the appliance also
depends on the position in which it is installed. For this reason, it is
advisable to carefully consider where to install the equipment before it is
delivered.
SYNTHESIS GAS 9
4. INSTALLATION
Install the appliance in a dry and easily accessible place both to facilitate
its use and to carry out cleaning and maintenance.
The appliance must be installed at least 20cm from the walls of
the room or from other equipment so that the ventilation outlets
located on the sides of the oven are not obstructed.
Whilst in operation, cooking equipment produces vapor and cooking
smells that compromise the integrity of a healthy working environment.
In the case of gas ovens see paragraph 4.8.
A check must be made to ensure that the temperature and relative
humidity never exceed the maximum and minimum values indicted in the
specifications (see Enclosure A) even when the machine or other
machines in the room are functioning.
Exceeding these values especially the temperature or the maximum
relative humidity can easily and unexpectedly damage electrical equipment
creating hazardous situations.
4.2.1. Location specifications for the installation of gas ovens
It is the installer’s responsibility to check that the gas system
of the room in which the oven will be installed is working properly
and that the ventilation and aeration conduits of this room function as
required for the total nominal heat input.
The Manufacturer cannot answer for damage caused by failure
to observe the norms in force for the installation of gas equipment.
During the installation, care must be taken to avoid obstructing the
cooling vents and the air intakes for combustion air built into the oven.
When dealing with gas equipment, the room in which it will be installed
must be sufficiently ventilated and aerated. To ensure this, the enclosed
area in which it will be housed must have at least two permanent apertures
leading directly through its walls leading to the open air.
As an indication, for every kW of power installed, an air renewal rate of
36 m3/h is recommended.
To get a clear idea of the specifications required for the housing location,
refer to the norms in force in the country where the installation is being
carried out, in particular those prescribed for this type of oven.
10 SYNTHESIS GAS
4. INSTALLATION
4.3. Moving the unit
To offload and transport the unit, use
a pallet truck or a transpallet lifter with
a load capacity at least equal to that of
the unit. Raise the doors at the
entrance and exit of the oven to the
position of maximum aperture. Insert
the forks into the cooking chamber by
way of the tunnel entrance or exit
(Fig.1).
To avoid damage, place protective material between the forks
and the unit.
Make sure that the lifting equipment has a lifting capacity superior to
that of the weight of the load.
All responsibility for the lifting of loads rests with the person doing the
lifting.
In all circumstances, to avoid unpredictable movement, be aware of
the equipment’s centre of mass.
Take care that children do not play with the packaging materials
(e.g., plastic sheeting and Styrofoam): suffocation danger!
4.4. Positionig the unit on its base
Position the oven by sliding it into the
four corners of the basement (Fig.2).
4.5. Positioning stacked
units
FOR THE UNITS THAT CAN
BE STACKED ONE ON TOP OF THE
OTHER SEE ENCLOSURE B.
Once the first oven has been
positioned on the base (see previous paragraph), overlap consecutively the
second and third module fit the chimney exhaust fumes and by matching
the exterior side walls of the ovens.
SYNTHESIS GAS 11
4. INSTALLATION
4.6. Electrical connection
Before making any connection, check that the specifications of the
electrical supply to which the equipment must be connected, correspond to
the specifications of the power supply required by the apparatus itself (see
Enclosure A).
The appliances are supplied with an electric connection with
ground/earth cable for connecting the appliance to the power grid
according to the supply required (see Enclosure A).
In compliance with the safety norms in force. It is obligatory to connect
the ground/earth cable (yellow-green) to an earthing system with the
same dispersion capacity as the appliance itself. The efficiency of this
system must be correctly verified according to the norms in force.
The power cable must terminate with a plug to connect to the electrical
switchgear having a corresponding differential magneto thermal switch.
The equipment is not supplied with a power plug.
The coupling between plug and socket must be such that the earth
conductor is connected first and disconnected last and must have the right
dimensions for the rated current (see Enclosure A). Plugs and sockets for
industrial use of the type CEE17 are suitable or those which satisfy
European norm EN 60309.
The thermal circuit breaker must be calibrated to the total rated current
and the magnetic circuit breaker calibrated to the rated current (In the case
of ovens this is only slightly higher than rated current), while the differential
mechanism must be calibrated to the 30 mA current (see Enclosure A).
The electrical socket must be easily accessible and must not require
further location after the installation of the equipment. The distance
between the equipment and the socket must be sufficient to avoid
stretching the power cable.
For the position of the electrical power connections Enclosure B.
The power cable must never be trapped under the feet or
wheels of the equipment.
If the power cable is damaged it must be substituted by
customer support or by a qualified service engineer so as to avoid
any risk.
12 SYNTHESIS GAS
4. INSTALLATION
The Manufacturer does not accept responsibility for damage
caused by failure to observe the abovementioned norms.
4.7. Connecting the gas
Before making any type of connection, ensure that the type of gas
and pressure of the supply for which the equipment has been calibrated,
(see plate located on the oven, and Appendix A. of this manual),
corresponds to the type and the pressure of the gas that is available. This
is indicated on the initial regulation label applied to the identification plate.
Should these not correspond, refer to paragraph 8.4 to change the
regulation.
Gas appliances have a gas input with a G1/2” conic thread as
indicated in the specifications. The connection to the building’s gas supply
must be made by means of metallic tubing in zinc plated steel or
equipment must be connected to the gas mains supply with an easily
operated mains copper, exposed to view.
The equipment must be connected to the gas mains supply with an
easily operated mains tap.
The connection of the tubing to the equipment must be made with a
three piece metal joint to facilitate disassembly.
The strength of the gas tightness on the threaded joint must be ensured
with materials specifically declared to be suitable by their manufacturer
also for methane and GPL gasses.
For the location of the gas input connections, see Enclosure B.
4.8. Exhaust produced by combustion
This oven produces waste gasses classified as type “A1” (see
Enclosure A): equipment not intended for connection to a chimney or
flue or a device for the evacuation of the combustion residue into the
open air from the room in which the equipment is installed. The
drawing in of combustion air and the expelling of combustion
exhaust takes place in the room where the oven is installed.
To install type “A1” equipment, rooms in which it is housed
must be aerated and ventilated. They must specifically respect the
conditions concerning the flow of air necessary for combustion and
aeration of these spaces and for the disposal of combustion residue.
SYNTHESIS GAS 13
4. INSTALLATION
ATTENTION! Carry out the installation of the oven according to
the standard defined by the norms in force for this type of equipment
in the country in which it is being installed. For more information
refer to these norms.
To find out the nominal heat input of your oven, see Enclosure
A When more than one or more cooking units are stacked one on top
of another, to calculate the nominal heat input simply sum the power
of each single unit.
The area in which the units will be housed must have at least two
permanent apertures leading directly through its walls leading into the open
air:
- one for the intake of combustion air, ventilating the room
- the other for disposing of combustion gasses, aerating the room.
The two apertures must be in such a position so as not to create a shortcircuit in the flow of air: preferably they should be at opposite ends of the
room, they must not be obstructed and must be protected with grilles.
The necessary aeration can be achieved naturally or by way of the
installation of a forced aeration system depending on the norms in force in
the country where the installation is being made for ovens with a type “A1”
exhaust.
Be aware of the total nominal heat input of the ovens housed in
each room in a situation in which more than one unit is being
installed.
The Manufacturer cannot answer for damage caused by
ignoring these abovementioned norms as well as the information in
this manual.
14 SYNTHESIS GAS
4. INSTALLATION
4.9. Checking before starting work
After completing installation of the unit a series of checks must be
carried out, listed as follows:
- check that the various disassembled parts have been assembled.
- Check the power cable.
- Check that the control panel is working.
- Check the integrity of the jointing for gas supply and exhaust tubes.
- Check that the apertures for ventilating the room are adequate.
- Check the nominal capacity of the oven while it is functioning at the exit
point of the solenoid valve.
- If present, check that the ventilation hood is working.
SYNTHESIS GAS 15
5. OPERATION
5. OPERATION
5.1. Control panel
Oven on-off key
Parameter value decrease key
Programme access key
Parameter value increase key
Conveyor start/stop key
Automatic switching on-off key
Reset key
Economy function key
Cooking program setting key.
16 SYNTHESIS GAS
5.2. Functional states of the system
5.2.1. Inactive state
In the inactive state (Fig.1-2) the circuit
board is supplied with current but all the
oven’s functions are disabled, apart from
those for programming.
The display indicates “OFF”, the current
time, the day and time the oven will next be
automatically switched on (if it set, Fig.2).
In the Fig. 1-2 le letters indicate:
A = current hour
B = current minute
C = day, time, minute the oven will be
automatically switched on.
5. OPERATION
5.2.2. State of activity
When the oven is off, the rear illumination
on the display is also off.
This turns on when programming is started.
Press the ON key it is entered in a state of activity: it excites the general
contactor, the fan turns on and enables the heating of the oven. The backlit
display turns on and shows the writing
thereon in Fig.3, where:
A = Cooking temperature (°C)
B = Program set
C = Cooking time (minutes : seconds)
D = Operating condition of burner (Max =
high flame, Min = low flame, --- = flame
off).
E = Economy function active if lit.
SYNTHESIS GAS 17
5. OPERATION
7
5.3. Settings
5.3.1. Setting the current time
The current time can be set by the user both
when the oven is only off.
Press the key for 3 consecutive
seconds to enter the setting mode (Fig.4).
The display indicates (Fig.4), where:
A = current day
B = current month
C = current year
D = current hour
E = current minute.
A cursor indicates the data being modified.
Press the button to decide whether to
change the day, month, year, hour or minutes.
The value can be adjusted using the keys
and (Fig.5) and confirmed press
the key again, then move to the next data
(Fig.6).
After setting day, month, year, hour and
minutes, press the key to program the
current day of the week.
Appears on the display (Fig.7), where:
F = current day of the week.
5.3.2. Setting the language
The display language can be chosen from
a list of available options.
To set the language, enter the clock
programming mode (see chap. 5.4.1) and
confirm the data until appears on the display
(Fig.8).
Adjust and confirm using the same procedure as for setting the clock.
18 SYNTHESIS GAS
5. OPERATION
10
11
By confirming, you leave the programming mode and return to the
previous mode.
5.4. Programming
5.4.1. Cooking programs
It is possible to manage up to 6 different cooking programs. Each can be
set in the following order:
1. Cooking time (minutes : seconds)
2. Temperature setting (°C).
These parameters are normally indicated on the display when the oven
is on.
With the oven turned on it is possible to modify all the programs that can
be set, with the oven turned off it is only possible to modify the last
program that has been used.
Turn on the oven and press the key to
select the programme to modify (Fig.9).
Press the programming access key to
enter the programming mode and move from
one parameter to the next (Fig.10).
A horizontal line flashes below the parameter
being programmed.
The program that is being modified is always
indicated at the top right of the display
To change the value, use the keys to
increase and to decrease (Fig.11).
By keeping the key pressed, you increase the
speed of data change.
If no key is pressed for more than 5 seconds,
the displayed value is memorised and the oven
automatically leaves the programming mode.
During the programming of the
and keys are disabled, the key exits
programming mode.
The order of programming is as follows:
1. Cooking time
2. Temperature
SYNTHESIS GAS 19
5. OPERATION
12
13
5.4.2. Cooking time adjustment
The desired cooking time is set directly by the user, and is directly
connected to the relevant conveyor speed, which is automatically
controlled by the electronic circuit board.
When the oven is switched on, the conveyor is still and the cooking time
flashes on the display.
Press the conveyor start/stop key to
activate the conveyor (Fig.12).
Conveyor can be started or stopped at any
time using the key (Fig.12).
When the conveyor is still, the cooking
time flashes.
See the paragraph 5.4.1. to set the
cooking time.
5.4.3. Temperature adjustment
When the oven is on, the real temperature
of the cooking chamber is indicated; press
the parameter value increase key to
display the set temperature (Fig.13).
See the paragraph 5.4.1. to learn how to
adjust the set temperature..
The intensity of the flame varies
automatically and adjusts according to the operating conditions in the Max,
Min or --- positions indicated on the display.
20 SYNTHESIS GAS
5. OPERATION
14
15
16
5.4.4. Economy Fuction
The Economy function allows the oven, when left idle, to be kept at
a lower temperature than that when it is in use.
This saves energy and consequently money.
Apart from managing the temperature of the oven this can determine
whether the wire mesh conveyer moves or not.
It is recommended to set a
temperature at 50° less than the suitable
cooking temperature.
To access programming of the Economy
function: with the oven on, keep the key
pressed for 5 seconds (Fig.14).
A horizontal line under the parameter in
programming mode will flash on the display
To change the value use the and
(Fig.15).
Keeping the key pressed increases the
speed that the value changes.
To move onto the next value, press the
key.
If no key is pressed within 5 seconds, the
value shown will be memorised.
During the programming, the and
keys are disabled and the key exits
the programming mode
The order of programming is as follows:
1. Eco temperature
2. Mesh in Eco mode ( = enabled; = disabled).
To activate the economy function, press the key, the letters “Eco”
will appear on the display.
SYNTHESIS GAS 21
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