Nuttall flexeserve ZONE 400 User manual

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
FLEXESERVE® | Operation Manual │ Flexeserve Zone® 2 Tier - Countertop | R MAY 2021 | 0002220 Page | 2 of 2
Contents
Introduction 3
Safet S mbols 4
Safet Instructions 5
Specifications 6
Overall Dimensions 7
Installation 8
Positioning 9
Moving 9
Electrical Connection 10-11
Equipment Configuration 12
Power ON/OFF 13
Switching On 14-15
Switching Off 16
Operation 17
Displa and Merchandising 18
Product Probing 18
Dail Cleaning 19
Troubleshooting 20
Spare Parts and Service 21
Disposal of this Equipment 21
Contact Us 22

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Introduction
This manual has been developed as a guide to assist with the continued safe operation of the equipment.
The document covers man aspects of use and maintenance; the relevant level of training and
competence is required from the operators working with the equipment.
The Alan Nuttall Partnership Ltd cannot be held responsible for an accidents or injuries caused b
instructions being carried out incorrectl or b the wa the information is depicted. The manual must be
read and understood before using the equipment.
This manual has been composed with the utmost care. However, as the result of a constant commitment
to development and improvement, it ma be the case that our equipment deviates in detail from what
is described in this manual.
The following instructions are onl intended as guidelines for the installation, operation and maintenance
of the equipment. Furthermore, The Alan Nuttall Partnership Ltd accept no liabilit whatsoever for loss
or injur caused b the failure to strictl adhere to the safet guidelines and instructions in this manual,
whether due to carelessness, lack of the relevant training, qualification or competence, and during
installation, operation, maintenance or repair of the equipment.
This manual should be retained for future use.
© 2021 The Alan Nuttall Partnership Ltd
Do not copy without written permission from The Alan Nuttall Partnership Ltd. All contents of this document remain the intellectual
property of The Alan Nuttall Partnership Ltd.

OPERATION MANUAL
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Safety Symbols
The s mbols defined below, which are relied upon for safet , are used on Flexeserve Zone® and/or
throughout this document.
WARNIN /CAUTION
An appropriate safet instruction should be followed or caution to a potential hazard
exists.
DAN EROUS VOLTA E
To indicate hazards arising from dangerous voltages.
HEAVY
This product is heav and reference should be made to the safet instructions for
provisions of lifting and moving.
HOT SURFACE
To indicate that the marked item can be hot and should not be touched without taking
care.
TROPICAL CLIMATE
To identif the equipment intended to be used in countries having a warm, damp,
equable climate.
INFORMATION
Information provided for trained and skilled operators onl .
MAINTENANCE
Maintenance of the equipment must onl be undertaken b full trained, qualified and
competent engineers.
PROTECTIVE EARTH ( ROUND)
To identif an terminal that is intended for connection to an external conductor for
protection against electric shock in case of a fault, or the terminal of a protective earth
(ground) electrode.
WASTE OF ELECTRICAL AND ELECTRONIC EQUIPMENT
When the end user wishes to discard this product, it must be sent to separate
collection facilities for recover and rec cling.

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Safety Instructions
•This equipment ma onl be used b trained and skilled personnel. An application that does not
conform to the specified use is considered hazardous.
•The equipment must onl be used for its intended purpose; an other application will be
considered improper. Flexeserve Zone® is designed to hot-hold food that has been cooked prior to
displa onl . The equipment is not for cooking.
•These appliances are intended to be used for commercial applications, for example in kitchens or
restaurants, canteens, hospitals and in commercial enterprises such as bakeries, butchers, etc. but
not for continuous mass production of food.
•Heated areas of Flexeserve Zone® exceed 70°C (158°F): onl touch the components used to control
the equipment.
•Food products are to be pre-cooked to the appropriate temperature and displa ed in suitable
containers/packaging.
•Do NOT place an thing heavier than 20kg (44Ibs) on to the displa surface.
•Do NOT cover or block exhaust vents or fan plates.
•This appliance can be used b children aged from 8 ears and above, and persons with reduced
ph sical, sensor or mental capacities, or lack of experience and knowledge if the have been given
supervision or instruction concerning use of the appliance in a safe wa and understand the
hazards involved.
•Children should not be allowed to pla with or near the equipment.
•Before using the equipment:
−Inspect the power cable for damage. If damaged, disconnect and isolate Flexeserve Zone®;
−If the glass displa shelf is cracked, isolate Flexeserve Zone® and remove from service;
−Ensure that there are no foreign or combustible objects other than approved Flexeserve Zone®
accessories or approved food packaging in contact with the heated surfaces;
−Ensure that the glass shelf surface is checked for signs of damage. If an damage is found,
isolate the electrical suppl and report to Flexeserve® Customer Support Department.
•Switch off the appliance:
−When not in use;
−Before carr ing out an maintenance task, such as cleaning;
−Before moving the equipment.
To ensure that the equipment remains in optimum technical condition, maintenance work should be
carried out at least once a ear b an approved Flexeserve® Service Provider.
The end user is full responsible for the fulfilment of locall applicable safet regulations and guidelines
at all times.
An safet s mbols, warnings and/or instructions attached to the equipment are part of the safet
features. The must not be covered or removed, and must be present and legible during the life of the
product. Immediatel replace damaged or illegible s mbols, pictograms, warnings and instructions.

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Specifications
The Flexeserve Zone® range of products detailed within this manual is a series of 2 Tier - Countertop
heated displa s for the presentation of pre-cooked food products in a suitable container or packaging in
commercial outlets.
The Flexeserve Zone® 2 Tier - Countertop models are provided with 2 fixed position heated zones.
Each zone maintains the food products to a fixed temperature of between 65°C (149°F) and 90°C (194°F)
b means of an air circulation heater.
NOTE
Each Flexeserve Zone® will be factor set to maintain a minimum of 85°C (185°F) air temperature in each
zone.
The Flexeserve Zone® range is cord connected and supplied with an appropriate cord set, and for indoor
use onl .
The ambient conditions required to operate the equipment are between 18°C (65°F) to 40°C (104°F), with
a maximum relative humidit of 70%.
Noise Levels
Unit Width Position at Reading Distance from Unit Db (A)
356mm (14”)
Front of unit
1.00 m
62.9
Rear of unit 60.3
556mm (21.8”) Front of unit 62.8
Rear of unit 60.1
975mm (38.3”)
Front of unit 62.9
Rear of unit 61.4

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Overall Dimensions - 2 Tier - Countertop
MODEL TYPE A - Width B - Depth C - Height Weight
400 Square 356mm (14”) 660mm (26”) 884mm (34.8”) 74kg (163.1Ib)
600 Square 556mm (21.8”) 660mm (26”) 884mm (34.8”) 86kg (189.5Ib)
1000 Square 975mm (38.3”) 660mm (26”) 884mm (34.8”) 126kg (277.7Ib)

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Installation
WARNIN
Installation of these units should be carried out b appropriatel qualified and skilled
personnel. Failure to do so ma invalidate the warrant .
The equipment will be delivered to site boxed on a pallet.
Remove all packaging materials from the unit and dispose of correctl , in accordance with local
regulations.
Care must be taken when removing packaging so not to damage or scratch the painted, glass or stainless-
steel surfaces.
Remove all temporar tape.
Prior to the first use, clean with a proprietar food-safe cleaning solution, following the instructions set
out in the cleaning and maintenance section of this manual. Ensure that an excessive amount of water is
NOT used. Do NOT use aggressive detergents.
If there are an signs of damage, contact Flexeserve® Customer Support immediatel . Failure to report
faults, defects or missing items upon deliver ma incur charges.
Ensure that safe manual handling practices are emplo ed at all times. Flexeserve Zone® should be placed
into position using the correct procedures, in line with local and regional safet policies.
The following considerations must be given to the site of installation:
•Avoid placing sources of heat near the appliance.
•Do NOT install the appliance near other equipment that generates high temperatures in order to
avoid damage.
•The equipment should be sited so that it is not affected b draughts from doors or air conditioning
s stems. Temperature fluctuations are likel to occur if the equipment is not sited appropriatel .
This will have an adverse effect on product temperatures and ma increase running costs.
•Ensure that the floor supports the weight of the unit at full capacit .
•Ensure that the unit is installed on a flat, even surface.
•A gap of at least 50mm (2 inches) should be left between the back of the equipment and an
wall/solid surface.
The supporting or surrounding surfaces for the appliance must be:
•Non-combustible;
•Level, flat and even;
•Able to support the appliance’s weight at full load, without undergoing deformation or structural
failure;
•Immovable.

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FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Positioning
WARNIN Installation of these units should be carried out b appropriatel qualified and skilled
personnel. Failure to do so ma result in unsafe operation or personal injur .
WARNIN
Adequate provision should be made for lifting and positioning the unit to avoid risk of
damage or injur . Sufficient personnel should be available to handle each unit without
contravening compan or site health and safet policies.
It is recommended that a minimum of two persons are required for placing the equipment into position.
The equipment must be kept in the vertical orientation at all times.
A gap of at least 50mm (2 inches) should be left between the back of the equipment and an wall/solid
surface.
Once the unit is placed in the desired location, it should be prevented from being moved.
Moving
Before moving the unit, isolate and disconnect the power cord from the wall socket. Stow the electrical
power cord so that it does not become damaged during repositioning.
The units are not suited to pass over ledges or obstacles. Ensure that the feet of the unit can never come
into contact with the power cord (see figure below).
Wall socket Plug

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Electrical Connection
WARNIN
Connection must onl be carried out b suitabl trained, qualified and skilled
engineers, in accordance with all regional and local electrical codes.
Flexeserve Zone® products are designed to be installed with dedicated power cords.
The Flexeserve Zone® units are t picall supplied with an appropriate IEC 60309 appliance “Commando”
st le coupler rated for the appropriate voltage and current of the Flexeserve Zone® unit variant
purchased.
The Flexeserve Zone® units can be supplied without an appliance coupler for attachment as either a
permanentl connected appliance to a dedicated isolator or ma be fitted with a pre-approved regional
plug.
The equipment must be connected to a branch circuit protected grounded suppl in accordance with
local electrical codes.
Each unit must have its own dedicated power suppl .
NOTE For electrical ratings of the unit, refer to the electrical rating sticker located inside the front alance
panel. An example is shown below.
It is highl recommended to provide the equipment with an accessible means of isolation external to the
equipment, i.e. a wall isolator switch.
Electrical rating

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Electrical Ratings
The appliances are electricall rated for 230V 1PH, 50Hz or 60Hz electrical supplies.
MODEL FREQUENCY TOTAL POWER
400 50 Hz 1300 W
60 Hz 1500 W
600 50 Hz 1300 W
60 Hz 1500 W
1000 50 Hz 2700 W
60 Hz 3000 W
WARNIN
For all t pes of installation, ensure that the power cord is in a safe position. Under no
circumstances should an electrical cables or power points be installed directl in contact
with an part of the unit or pose a risk to safet .
If the mains power lead becomes damaged, isolate the equipment removing from service
immediatel until a replacement is fitted b a suitabl trained, qualified and skilled
engineer, in accordance with all regional and local electrical codes.

OPERATION MANUAL
FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Equipment Configuration
CAUTION
Each zone (shelf) must have the pol carbonate risers fitted to ensure safe and correct
operation.
CAUTION
The unit will not operate correctl without the pol carbonate risers in the correct
position.
Slide signage into the ticket strip. Close the valance panel when not in use.
Valance panel /
control box
Zone/shelf
Ticket strip
Double-glazed
end panel
Polycarbonate
riser
Mains lead

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FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Zone power switch
I = On position
O = Off position
Power ON/OFF
Each zone (shelf) is supplied with a power switch to turn individual zones (shelves) on or off, which is
located behind the front valance panel of Flexeserve Zone®.
Set the zone power switch to the ‘I’ position to appl power to each zone (shelf) and set to the ‘O’ position
to power off.
2 Tier - Countertop Control Panel
WARNIN
In an emergenc , switch off the appliance and isolate full from the mains suppl .
Ensure that ou take time to familiarise ourself with this location.

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FLEXESERVE ZONE® 2 TIER - COUNTERTOP
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Zone power switch
I = On position
Controller display
Zone indicator
Switching On
Individual Zones - Heating
WARNIN
In an emergenc , switch off the appliance and isolate full from the mains suppl . Ensure
that ou take time to familiarise ourself with this location.
CAUTION
The surface of the zones will become hot, reaching temperatures above 70°C (158°F).
Each of the model variants are supplied with one set of controls for each zone. The controls are located
behind the valance panel at the base of the equipment.
Ensure that the equipment is empt and clean prior to switching on. Check that the equipment is
connected to a power socket.
Before switching the equipment on, it is the operator’s responsibilit to visuall inspect the equipment
to ensure that there is no damage that ma compromise safet .
Set the zone power switch to the ‘ON’ position and the controller displa will illuminate. The displa will
show the current temperature. The equipment will begin to heat and reach the established temperature
set-point automaticall , generall 85°C 185°F.
Where multiple zones are required, select and set the appropriate zone power switches to the ‘ON’
position separatel .
The zones should be left empt without interference and ma take up to 60 minutes to reach operating
temperature. No products should enter the displa area until it has reached the correct operating
temperature.
WARNIN
Do NOT place unpacked food products directl on to the hot shelves.

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Individual Zones - Ambient
WARNIN
In an emergenc , switch off the appliance and isolate full from the mains suppl .
Ensure that ou take time to familiarise ourself with this location.
CAUTION
When switching from heating mode to ambient mode, the surface of the zones will
remain hot for a period of time. Ensure that the unit has sufficientl cooled before
placing ambient products into the zone (shelf).
Switch on the zone power switch and the controller displa will illuminate. The displa will show the
ambient temperature.
To select the ambient mode
Press the heating enable/disable button and the displa will read ‘OFF’. Visuall , ou will see that the fan
has stopped rotating and there is no air circulating around the zone. The zone is now in ambient mode.
Where multiple ambient zones are required, select and press the appropriate heating enable/disable
button separatel .
No products should enter the displa area until the zone has cooled adequatel to the required ambient
temperature.
To reactivate the heating mode
Press the heating enable/disable button and the displa will read the current operating temperature.
Visuall , ou will see that the fan has started rotating and air is now circulating around the zone. The zone
is now in heating mode.
No products should enter the displa area until the zone has heated to the required temperature.
Controller display Heating enable/disable button
Zone power switch
I = On position
O = Off position

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Zone power switch
O = Off position
Zone indicator
Controller display
Switching Off
Individual Zones
CAUTION
When switched off or disconnected from the power source, the surface of the zones
(shelves) ma still be hot, and ma take up to two hours to cool down.
WARNIN
Cleaning and maintenance should onl be carried out when each of the zones (shelves)
have sufficientl cooled and with the mains suppl isolated.
To switch off the respective zone, set the zone power switch to the ‘O’ position.
When an individual zone is turned off, the controller displa and zone power switch will go blank, and the
zone will be switched off.
To full isolate the unit, disconnect the incoming mains suppl b disconnecting the power cord from the
suppl .

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Operation
Adjusting Temperatures
WARNIN
Onl if the operator has been trained and is skilled in the operation of the equipment
covered in this guide should this information be followed.
Do NOT attempt to cook products on the shelves of the equipment.
Do NOT place cooking vessels on the shelves of the equipment.
Do NOT place an thing heavier than 20kg (44Ibs) on to the displa surface.
The equipment will onl maintain the temperature of products that have initiall been cooked, prior to
displa . Ensure that food is transferred to the displa area immediatel after cooking in appropriate
containers or packaging.
Ensure that temperatures of the displa ed products are checked and recorded on a regular basis, in
accordance with local regulations.
The temperature of each zone (shelf) is displa ed b the appropriate zone controller displa and is for
indication of operating temperature onl . Do NOT use this as a reference to core temperature of foods on
displa ; regular temperature probing of the product is to be performed.
The minimum and maximum set-point values have been pre-set in the factor to prevent the equipment
holding temperatures from being adjusted be ond legal and safet limits. These can onl be adjusted b
a Flexeserve® appointed engineer.
To view the set temperature of each zone, press the ‘SET’ button for half a second, and then release.
To change the temperature of an individual zone, press and hold the ‘SET’ button until ‘°C’ flashes on the
displa . Press the arrow buttons to increase (▲) or decrease (▼) the temperature. Press the ‘SET’ button
again to input the new set point. After the temperature has been set, the displa will revert back to the
operating temperature, which will rise or fall as it reaches the set temperature.
Flexeserve Zone® is manufactured to compl with health and safet regulations, and has been tested and
certified to NSF standards. You must operate the equipment properl using onl calibrated temperature
probes to ensure food is thoroughl cooked to the safe standards according to local regulations.
SET button
Temperature adjustment

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Display and Merchandising
Different products require var ing displa times according to their core temperature. These must be
considered to ensure the best qualit and safe temperature for consumption is achieved. The Alan Nuttall
Partnership Ltd does not accept responsibilit for variances or losses of qualit that occur due to product
differences.
All items placed in Flexeserve Zone® should be in the correct packaging/containers, in line with in-store
procedures and best practice. Remove products in damaged packaging from the equipment and clean as
soon as possible.
Do not obstruct the fan(s) at the rear of each zone as this can cause the built-in safet shut-off to activate
and stop the equipment from working.
Product Probing
INFORMATION
Legal requirements dictate all products displa ed for an extended period within an
heated displa area should be periodicall probed throughout trading to ensure the
core temperature of the product is above the legal holding temperature of the local
authorit . Refer to in-house operations manual for product probing instructions.
It is beneficial to enter the product into the holding unit as hot as possible for that particular food product
to maximise shelf-life at the safe temperature.
The equipment is not designed to increase product temperature; the products graduall fall and regulate
in temperature throughout the displa period to ensure good product qualit . It is critical that the entr
core temperature is as high as possible so the maximum displa time is achieved. The product will fall in
temperature during its displa time regardless of the entr temperature; therefore, a low entr
temperature will reduce displa time.
At the end of recommended displa times, an unsold products should be removed, reduced and
disposed of, in accordance with compan and food safet standards.
The Alan Nuttall Partnership Ltd does not take responsibilit for variances or loss of qualit that ma
occur due to product differences.
Recording Product Temperatures
The core temperature of the products should be periodicall probed and recorded according to local
authorit guidelines.

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Daily Cleaning
CAUTION
Isolate the equipment full before an cleaning is undertaken.
CAUTION
Ensure that the equipment has completel cooled before an cleaning is undertaken.
Onl suitabl trained personnel should carr out cleaning procedures.
Ensure that the power has been isolated.
Ensure that all displa surfaces are allowed to cool to room temperature. Clean the surface
of the shelf with a damp cloth soaked in mild detergent.
Ensure that water is not allowed to pool or sit on the glass surface. Sanitise and dr , as
required.
WARNIN
If the surface glass is cracked or damaged, discontinue use.
Do NOT use excessive amounts of water.
Do NOT clean the equipment with high-pressure cleaners, jets of hot water or high-pressure
steam. All traces of food debris should be removed completel .
Do NOT use abrasive cleaning products as these could damage the finish of the equipment.
It is recommended that non-abrasive cleaning products are used. Do NOT use glass cleaning
products.
The pol carbonate risers and ticket strips can be removed and cleaned b lifting.
Once the front pol carbonate risers are removed, crumbs and debris can be swept forwards and out of
each zone. Glass shelves, inner side wells, lamp diffuser glass and external surfaces can be cleaned using
non-abrasive cleaning products.
WARNIN
Do NOT use aggressive detergents. Ensure that all risers are refitted before use of the
unit.
Polycarbonate risers
and ticket strips
Glass shelf