Mono MODULAR User manual

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OPERATION AND MAINTENANCE MANUAL
MODULAR DECK OVEN
Colour control version
www.monoequip.com
Enter Serial Nos. here
In the event of an enquiry please quote these serial numbers.
DECK 1
DECK 2
DECK 3
DECK 4
DECK 5
FAN (IF FITTED)

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Failure to adhere to the cleaning and maintenance instructions
detailed in this booklet could affect the warranty of this machine.
The oven should only be used for baking bread, pastries and cakes
(for other products please contact your oven supplier)
TO REDUCE RISK OF FIRE OR ELECTRIC SHOCK
DO NOT REMOVE COVERS (OR BACK)
NO USER SERVICEABLE PARTS INSIDE
REPAIR SHOULD BE DONE BY AUTHORISED PERSONNEL ONLY

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CONTENTS
Section - 1.0 Introduction
Section - 2.0 Overall Dimensions
Section - 3.0 Specifications
Section - 4.0 Safety
Section - 5.0 Installation
Section - 6.0 Isolation
Section - 7.0 Cleaning
Section - 8.0 Operating Conditions
Section - 9.0 Principles Of Operation (and baking advice)
Section - 10.0 Operating Instructions
Section - 11.0 Set up and Diagnostics menu
Section - 12.0 Troubleshooting
Section - 13.0 Service Information
Replacing light bulbs
Section - 14.0 Spares Information
Section - 15.0 Electrical Information
Section - 16.0 WARNING and INFORMATION LABELS
THIS SECTION IS FOR ENGINEERS ONLY AND THE CUSTOMER
SHOULD NOT ATTEMPT TO MAKE ALTERATIONS.
THIS SECTION IS FOR ENGINEERS ONLY AND THE CUSTOMER
SHOULD NOT ATTEMPT TO MAKE ALTERATIONS.

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1.0 INTRODUCTION
The electric modular Deck Oven is an easy to use practical, good-looking oven,
giving an excellent heat recovery rate and an even bake across a wide range of
bread and confectionery products.
Good looking and totally reliable
Conceived with the no nonsense requirements of both the independent and in-store
baker in mind, and designed to visually please as well as give reliable service for
many years. This oven will more than satisfy the most discerning customer.
Top quality specification
The external and internal contact surfaces are stainless steel.
Each modular deck is fitted with durable reinforced one-piece tiles, and an increase
in high-grade insulation and high temperature ceramic sealant, makes the oven more
efficient.
The oven comes with a patented integral steaming system, which reduces energy
consumption and the overall size of the oven (no drain required). The system
produces real steam with the advantages of spray steam. Pre-steam is also available
to reduce the affects of long loading times.
No drainage is required.
Supplied with an LCD screen. All programmable parameters have separate
indicators for easy programming and extra bake time, if required.
An energy saving 7-day timer is also standard.
The simplified electrical circuits aid reliability with overheat protection (on controllers
and oven) to ensure long life of controllers, all housed in splash-proof electrical
enclosures.
The lights are low voltage, sealed from the chamber and easily accessed from
outside the oven.
Fitted with a choice of hinged easy to clean glazed doors (using low energy-loss
reflective glass for high visibility) or metal doors, means low energy consumption and
the high kW rating gives good recovery.
(0-100% heating available both top and bottom)
As it is our policy to improve our machines continuously, we reserve the right
to change specifications without prior notice.

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2.0 OVERALL DIMENSIONS
5 DECK oven ………… H = 2135mm
4 DECK oven ………… H = 2020mm
3 DECK oven ………… H = 2020mm
Ovens available with 1,2,3, 4, and 5 modules
812mm deep modules …... D= 1300mm
3 Tray wide oven ……. W = 1890mm
2 Tray wide oven ……. W = 1416mm
1 Tray wide oven ……. W = 940mm
H
D
W
ALL DIMENSIONS ARE APPROXIMATE

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3.0 SPECIFICATIONS
5 DECK OVEN
DECK PLATE HEIGHTS
4 DECK OVEN
DECK PLATE HEIGHTS
3 DECK OVEN
DECK PLATE HEIGHTS

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ELECTRICAL LOADINGS:
SUPPLY REQUIRED PER MODULAR DECK:
3 TRAY WIDE 2 TRAY WIDE 1 TRAY WIDE
3 Phase N + Earth, 400V. 50Hz 9.0kW, 13Amp 6.0kW, 9Amp 3.0kW, 5Amp
NOISE LEVEL:Less than 80 Db
WEIGHT:
(ALL WEIGHTS ARE APPROXIMATE)
Total oven weight –2 tray wide, 3 deck = 1569lbs (711kg)
(Including base frame) –3 tray wide, 3 deck = 2345lbs (1064kg)
–1 tray wide, 3 deck = TBA
Weight per oven chamber module –2 tray wide = 421lbs (191.5kg)
–3 tray wide =575lbs (261kg)
–1 tray wide =TBA
Weight per oven canopy module –2 tray wide = 31lbs (14kg)
–3 tray wide = 38lbs (17kg)
–1 tray wide =TBA
Weight per fan module –2 tray wide = 62lbs (28kg)
–3 tray wide = 62lbs (28kg)
–1 tray wide =TBA
Weight of product (max) per deck –2 tray wide = 86lbs (39kg)
–3 tray wide = 131lbs (60kg)
–1 tray wide =TBA

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4.0 SAFETY
All maintenance must be made with the oven disconnected from the
power supply and then only by fully trained authorized persons.
Check all cover panels, and any pipefittings are securely positioned.
Check oven door handles are not damaged.
Do not operate a deck's steaming system with oven door open.
Always use oven gloves when loading or unloading the oven.
When products are removed from the oven, ensure:
(a) Tins are knocked out and stored directly onto a tin storage trolley or rack
(Do not leave hot tins on the floor or on tables).
(b)Trays are put into a rack and the rack is wheeled to a safe cooling area.
Do not store items on top of the oven.
Do not store items behind the oven.
Beware of hot surfaces. Do not touch oven front or door with bare skin.
All operatives must be fully trained
People undergoing training must be under direct supervision
The oven should only be used for baking bread, pastries and cakes (for other
products please contact your oven supplier)
No unauthorized modifications should be made to the oven.
Do not walk on the roof of the oven
DISPOSAL
Care should be taken when the oven comes to the end of its working life. All
parts should be disposed of in the appropriate place, either recycling or other
means as the law permits at the time.
NOTE: BAKERY STAFF MUST NOT UNDER ANY CIRCUMSTANCES REMOVE
PANELS TO ACCESS ANY PART OF THE DECK OVEN.
Panels should only be removed by a Mono maintenance engineer (or other fully
trained maintenance contractor) for repairs or maintenance, after isolating oven
from power supply.
The Bakery Manager or the Bakery Supervisor must carry out the above daily safety checks

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5.0 INSTALLATION
GENERAL
A hard smooth level floor is recommended on which to position the oven and
access for maintenance should be considered.
The oven is not designed to be ” built in” so sufficient clearance must be left in
front of the access panels (right hand side) to allow for servicing.
If not chosen as an oven option, it is recommended that an extraction hood be
placed above the oven to disperse excess steam and heat, which could have
an adverse effect on the bakery ceiling and ambient temperature.
A wall isolator must be available in order to completely isolate the oven.
THIS ISOLATOR MUST BE CLEARLY ACCESSIBLE TO THE OVEN OPERATOR
A chain retainer should be fitted, that is shorter than the power cables, to
protect them from strain if the oven is moved. (Fit to the wall or floor and the
base, using hole provided in castor fixing corner plates).
Installation must be made by a trained authorized engineer and all utilities
must conform to all local regulations.
The oven must be “run in” as stated in the initial start up instructions.
ELECTRICAL CONNECTIONS
SUPPLY REQUIRED PER MODULAR DECK:
(One main connection point for all deck supplies at top of oven)
3 TRAY WIDE 2 TRAY WIDE 1 TRAY WIDE
3 Phase N + Earth, 400V. 50Hz 9.0kW, 13Amp 6.0kW, 9Amp 3.0kW, 5Amp

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IMPORTANT OPERATION
EARTH (GROUND)
STRAPS MUST BE
CONNECTED
BETWEEN EACH
SECTION.
PART NUMBER
M158-25-11200
SUPPLIED
REAR VIEW OF OVEN

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WATER SUPPLY REQUIREMENTS
The set up procedure on the next page must be followed to
allow the steaming system to function correctly
All ovens with steam require a ¾” BSP hot or cold water supply at a pressure
of 2 - 3 bar (29 –44 psi).
Only one water supply is required per oven. This should comply with local
water regulations.
A manifold supplies all decks from one connection point.
For proper operation of the steam system it is recommended that the water
supply follows the following specifications:
Hardness 0-4 grains per gallon
PH range 7.0 to 8.5
Chloride concentration 0 –20 ppm
Consult Mono for proper water filtration system information.
No drain is required for this oven.
A non-return check-valve is supplied fitted to the water inlet manifold.

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WATER SYSTEM SETUP PROCEDURE
It is imperative that the water delivery to the deck oven is checked for the
steam system to operate correctly
1. Flush out the main feed pipe to be used, until water runs clear and free from debris.
2. Connect main feed to oven.
3. Connect flexible hoses to each deck.
4. Place a container under the test valve.
5. Slowly open test valve fully and with the water flowing check the regulator is set to
0.75 bar. If not adjust using the screw above the valve.
Never use the oven above this setting
6. When the pressure has stabilised shut the test valve.
REPEAT 4,5 AND 6 AT THE END OF INSTALLATION.
NOTE. DYNAMIC PRESSURE, NOT STATIC, IS BEING MEASURED.
STOP TAP
ADJUSTING SCREW
SET TO 0.75 bar
TEST VALVE
FILTER
TO OVENS
WATER REGULATOR SET UP
LOCATED ON REAR OF OVEN
REGULATOR
DUAL CHECK VALVE BACKFLOW
PREVENTION DEVICE

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Exhaust Connections (IF CANOPY FITTED)
Ideally an exhaust duct should rise 2 metres above the bakery roof protected
from wind and birds by a duct protector.
It should be of a suitable material to take the high temperatures and humidity
expected.
It should be flexible and easily removable at the oven connection point.
This allows the oven to be moved for cleaning when required.
255mm Dia.SPIGOT
CONNECTION POINT
WITH EXTRACTION FAN FITTED
WITHOUT EXTRACTION FAN FITTED
CONNECTION POINT
330mm
585mm
240mm
255mm Dia.SPIGOT
ROOF
CANOPY

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INITIAL START UP
THIS PROCEDURE MUST BE ADHERED TO FOR THE OVEN
WARRANTY TO BE VALID.
In order for the oven to give good reliable service the deck tiles must be initially
brought up to temperature as stated below.
After this running in period the oven can be used as required.
Running in procedure
1. Turn the oven on and note the temperature shown.
(This will be the temperature inside the cooking chamber)
2. The temperature needs to rise to 110deg C, at no more than 2deg a minute.
DO NOT USE BOTTOM HEAT AT ANY TIME.
3. Take the temperature up to 260deg C, at no more than 1deg in 2 minutes.
THIS WILL TAKE 5 HOURS.

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6.0 ISOLATION
WARNING
THE “POWER OFF” BUTTON ON THE FRONT OF THE OVEN DOES
NOT ISOLATE THE POWER SUPPLY.
A WALL ISOLATOR MUST BE AVAILABLE IN ORDER
TO COMPLETELY ISOLATE THE OVEN.
THIS ISOLATOR MUST BE CLEARLY ACCESSIBLE
AND KNOWN TO THE OVEN OPERATOR
TO STOP THE OVEN IN AN
EMERGENCY SWITCH OFF AT THE
MAIN WALL ISOLATOR

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7.0 CLEANING
DAILY CLEANING INSTRUCTIONS
ISOLATE OVEN FROM MAINS SUPPLY BEFORE CLEANING.
After the oven has been allowed to cool, (this could take several hours),
sweep any debris out.
Use a vacuum cleaner with metal attachments (able to take heat) if available.
Brush down and wipe oven front, back and sides with a damp cloth.
Spot clean with a damp cloth, which has been soaked in a solution of mild
detergent, and hot water, paying particular attention to ensure excess water is
not applied around the area of the electrical panels.
NOTE: TAKE CARE WATER DOES NOT ENTER CONTROL PANEL
MOUNTING OR ROOF MOUNTED FAN.
WEEKLY CLEANING INSTRUCTIONS
ISOLATE OVEN FROM MAINS SUPPLY BEFORE CLEANING.
Complete daily cleaning as above.
Scrub oven wheels with a mild detergent and hot water using nylon cleaning
brush (excess water will rust metal).
Ensure the oven roof area is clear of debris and dust build up.
(DO NOT STAND ON THE OVEN ROOF)

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8.0 OPERATING CONDITIONS
It is recommended that a space of at least 6 feet be left in front of the oven for
ease of operation and safety.
Bakery utensils must not be used to operate the control panel buttons.
9.0 PRINCIPLE OF OPERATION
NOTE: REFER TO YOUR OWN COMPANY’S RECIPE MANUAL FOR OVEN
TEMPERATURE SETTINGS.
PLEASE ALSO REFER TO THE BAKING ADVICE ON THE NEXT PAGE
Products are baked in an insulated heated chamber.
The temperature is regulated by a thermocouple having an LCD read-out on the
front control panel.
Baking heat is radiant with top and bottom heat being adjusted by means of separate
controls. This enables heat to be “balanced” according to product requirement.
STEAM is provided from an integral steam unit, and is introduced into the chamber
on demand. This is automatically controlled by the programmed parameters.
Once steamed the oven will not steam again until the steam unit has recovered
heat, typically 3-8 minutes depending on the amount of steam selected.
All ovens are fitted with a steam damper that evacuates steam humidity into a vent
at the side of the oven.

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Baking Advice
For the best results from deck Ovens
Loading
1. Do not place the products too close together. If the loaves are close to
each other after oven spring (expansion), the loaves sides will be soft and may
collapse on cooling.
2. Place the product evenly within the oven. Product bunched together will be
paler than those widely spaced.
3. Product should not be placed too close to the edge of the tile. As it
expands towards the front one side of the loaf may enter the cooler air by the
door.
4. Door opening should be kept to a minimum because cold air enters the
oven cooling the sidewalls and roof causing the finished product to be lighter
locally at the front and wasting heat. If loading times are consistently long you
can alter the front top heat to put more heat at the front.
5. If the loading takes a long time product can form a skin, which causes an
imbalance and a less attractive finish. By using the pre-steam function before
loading this can be minimised. This function turns the elements off and injects
steam to increase the humidity.
Bake settings
1. A good starting point for baking breads in Mono deck ovens is 225C (437F)
Top heat 60-65 bottom heat 40.
2. For cookies etc, the heat in the oven can be turned almost off, however it may
still be necessary to place the trays with cookies etc onto upturned trays on
the oven sole.
3. Steam should be kept to a minimum, for energy efficiency, depending on the
product and finish. Times between 9 and 12 seconds should be adequate.
4. It is a good idea not to focus on the temperature recovery this can vary from
oven to oven.