Toastmaster G-24 Operation 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
P5/91

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 DEMON-
STRATED 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 a15" 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
Figure 1-2
2

SECTION 1 -DESCRIPTION
B. Component Function
1. Single and Stacked Ovens
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-
lations the legs must be used on a single oven or
lower oven of stacked oven to validate the
warranty.
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.
Single
Oven
Stacked
Oven
Figure 1-3
3

SECTION 1 -DESCRIPTION
2. Cooking Area
The Toastmaster Model G-24 has a26" (660 mm)
cooking deck (chamber) and comes with a15" (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.
4. Infrared Heating Panels
Patented heating panels are positioned above and
below the conveyor belt of each oven deck (cham-
ber). 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.
6. Conveyor
The conveyor is used to convey the product
through the oven deck (chamber). The conveyor is
made up of aframe 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 will be in the cooking chamber
which is the cooking time. The oven chamber is 18"
(457 mm) wide with a15" (381 mm) wide conveyor
belt.
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 G-
24 by a control cord five feet long. All necessary
parts and instructions are available in the remote
control accessory kit.
Figure 1-4
4

SECTION 1 -DESCRIPTION
NOTICE
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.
Oven Specifications
G-24 Specification Chart
Stainless Steel Conveyor Belt Width 15" (381 mm)
Heating Zone (Chamber) Dimensions 18.5" (470 mm)Wx 26" (660 mm)L x
3.75" (95 mm)H
Conveyor Baking Area 2.70 sq. ft. (0.25sq.m.)
Overall Dimensions -Single unit on legs 45.5"(1156mm)Lx 26" (660 mm)D x
18"(457mm)H
Overall Dimensions -Two stacket units on legs
with stacking bracket
45.5"(1156mm)lx
26" (660 mm)D x
34" (864 mm) H
Net Weight of Single Unit Shipping Weight -
Single Unit
208 Ibs. (94 kgm)
231 Ibs. (105 kgm)
Shipping Dimensions
50" (1270 mm) Lx
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)
Conveyor Drive System
Solid state variable speed control (reversible).
208/240VAC supply voltage converted to
direct current through microprocessor
for motor and speed control.
Cook Time Adjustable from 0.5 to 19.9 minutes
Insulation 2" (51 mm) on all 4 sides.
Heat Source
Infrared heat emitters
2emitters/oven
1emitter above conveyor
1emitter 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
Amp Loading
Voltage Phase kw L1 L2 Wire
Size* Breaker Rating
(Amps)
208 15.4 26 26 640
240 17.1 30 30 640
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
STACKED OVEN
DIMENSION DRAWING
SECTION 1 -DESCRIPTION
7

A. Inspect for Shipping Damage
All shipping containers should be examined for
damage before and during unloading. This equip-
ment was carefully inspected and packaged at the
factory. The freight carrier has assumed responsibil-
ity 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 inspec-
tion.
B. Placement of Oven
Some very important considerations must be made
when choosing the place where the oven is to oper-
ate.
1. This oven is conveyorized and operates continu-
ously. 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 sur-
rounding 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 an-
other 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.
Figure 2-1
10

Figure 2-2
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.
E. Installing Legs
Install the four (4) 4" ad-
justable legs as shown in
Figure 2-3then lift the
oven onto it's legs. On
single oven installation
place the oven in it's per-
manent position and then
skip Step F and go directly
to Step G.
Figure
2
-
3
11

SECTION 2 -INSTALLATION
Figure 2-4
F. Stacking and Mounting
Two Ovens
NOTE: Astacking 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 2-4and use the
screws that were re
moved to secure brackets
on to top of lower oven.
2.Using four people lift the
upper oven on top the lower
oven. Using the four bolts
supplied with brackets
secure bracket to top oven
through the threaded holes
normally used for legs.
Figure 2-5
12

SECTION 2 -INSTALLATION
Figure 2-6
3. Once the ovens are
stacked and secured
check to make sure the
oven(s) are level. Adjust
the legs if necessary.
G. Stacking a single G-24
oven over a Toastmas-
ter CO-19 convection
oven or a Blodgett CTB-
1convection oven.
NOTE: A stacking bracket kit (P/N
ACSBG24C019) must be used
forthis installationorwarranty 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.
Figure
2
-
7
13

SECTION 2 -INSTALLATION
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.
2. Using four people lift
the G-24 and place it on
top of the convection
oven.
14

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 re-
place with a standoff.
These standoffs will keep
the ventilation louvers on
the rear control compart-
ment 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
to escape. The compart-
ment would then overheat
and cause possible dam-
age to electrical compo-
nents.
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 L1 L2 Wire
Size* Breaker Rating (Amps)
208 15.4 26 26 640
240 17.1 30 30 640
*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
Figure 2-9

SECTION 2 -INSTALLATION
Figure 2-10
Heat Curtain
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.
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.
Figure 2-11
Exit Tray
16

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