ZANOLLI SYNTHESIS 06/40V GAS User manual

SYNTHESIS 06/40V GAS
Tunnel convection oven
Installation, use and maintenance manual
DR. ZANOLLI s.r.l.
Via Casa Quindici, 22
37066 Caselle di Sommacampagna (Verona) Italy
Tel [phone] (r.a.)
Fax [phone]
Web: www.zanolli.it · e-mail: [email protected]

Dr. Zanolli s.r.l.
Via Casa Quindici, 22
37066 Caselle di Sommacampagna VR
Tel. [phone] Fax [phone]
VAT N.IT00213620230
Synthesis 06/40V gas
English manual
cod. SY0640.G.D.UK.12
rev. 0.1 del 09/07/2013

INDEX
3Synthesis 06/40V GAS
INDEX
1.INTRODUCTION.......................................................................................................5
2.HOW TO USE THIS MANUAL...........................................................................6
3.SPECIFICATIONS...................................................................................................8
3.1 PRODUCT IDENTIFICATION............................................................8
3.2 DIRECTIVES COMPLIANCE.............................................................8
3.3 FORESEEN RANGE OF USE ...........................................................8
3.4 TECHNICAL SPECIFICATIONS........................................................9
4.INSTALLATION......................................................................................................11
4.1 CHECKING ON DELIVERY.............................................................11
4.2 CHOOSING A PLACE FOR INSTALLATION..................................11
4.2.1 Location specifications for the installation of gas ovens............12
4.3 MOVING THE UNIT........................................................................12
4.4 POSITIONIG THE UNIT ON ITS BASE...........................................13
4.5 POSITIONING STACKED UNITS....................................................13
4.6 ELECTRICAL CONNECTION..........................................................13
4.7 CONNECTING THE GAS ................................................................14
4.8 EXHAUST PRODUCED BY COMBUSTION ...................................14
4.9 CHECKING BEFORE STARTING WORK.......................................17
5.OPERATION.............................................................................................................18
5.1 CONTROL PANEL ..........................................................................18
5.2 FUNCTIONAL STATES OF THE SYSTEM .....................................19
5.2.1 Main on/off switch.....................................................................19
5.3 SETTINGS.......................................................................................20
5.3.1 Temperature adjustment..........................................................20
5.3.2 Cooking time adjustment................................................................20
5.4 PROGRAMMING.............................................................................21
5.4.1 Setting the current time.............................................................22
5.4.2 Setting the language.................................................................22
5.4.3 Programming of switching on....................................................23
5.5 SWITCHING OFF THE OVEN ........................................................24
5.6 ALARMS..........................................................................................24
5.6.1 “OVER 1” ..................................................................................24
5.6.2 “OVER 2” ..................................................................................24
5.6.3 “OVER” .....................................................................................25
5.6.4 “BELT” ......................................................................................25
5.6.5 “FAN” ........................................................................................25
5.6.6 “PRESS” ...................................................................................25
5.6.7 “FLAME” ...................................................................................26
5.6.8 "BATTERY"...............................................................................26
6.USE................................................................................................................................27
6.1 PREPARATION FOR USE AND BEFORE TURNING.....................27

INDEX
4Synthesis 06/40V GAS
6.1.1 Ignition Control Panel...............................................................27
6.1.2 Settings and start cooking.........................................................27
6.1.3 How to turn off the oven...........................................................28
6.2 GENERAL DIRECTIONS FOR A SATISFACTORY BAKING..........28
7.CLEANING................................................................................................................29
7.1 CLEANING REMOVABLE PARTS..................................................29
7.2 CLEANING OF EXTERNAL PARTS................................................29
7.3 CLEANING THE BAKING CHAMBERS..........................................30
8.MAINTENANCE......................................................................................................31
8.1 ERROR INDICATOR .......................................................................31
8.2 SAFETY THERMOSTAT .................................................................31
8.3 REPLACE BATTERY ......................................................................32
8.4 ADJUSTMENT TO DIFFERENT GAS TYPE...................................33
8.4.1 Replacement of burner injector................................................33
8.4.2 Adjustment of minimum power..................................................34
8.4.3 Application of new label ............................................................34
8.5 WIRING DIAGRAM..........................................................................34
8.6 EXPLODED VIEWS AND LIST OF SPARE PARTS........................36
9.DECOMISSIONING AND DEMOLITION....................................................43
10. DECLARATION OF CONFORMITY.........................................................44

INTRODUCTION
5Synthesis 06/40V GAS
1. INTRODUCTION
The gas conveyor ovens mod. Synthesis 06/40V 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 06/40V gas belong to the family of conveyor ovens. Another important
innovation is that Synthesis 06/40V gas, 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 06/40V 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.

HOW TO USE THIS MANUAL
6Synthesis 06/40V GAS
2. HOW TO USE THIS MANUAL
Paragraphs marked with this symbol give essential directions concerning
security. Installers, user and his employees must read carefully these paragraphs. The
manufacturer is not liable for any damage caused by the ignorance of the directions
given in these paragraphs.
This symbol, located at various places of the oven, serves to alert the user to the
presence of danger "CAUTION: HOT SURFACE.
This symbol, located at various places of the oven, serves to alert the user to the
presence of "dangerous voltage" is not contained within the isolated product to be of
such power as to constitute a risk of fire or electric shock for people.
Paragraphs marked with this symbol give important directions useful to avoid
actions that may damage the appliance. The user will benefit greatly from reading
carefully these paragraphs as well.
We recommend that you keep this manual near the appliance, so that it can be promptly
and easily consulted. If the appliance is transferred to another user this manual must be kept
with it. The appliance cannot be considered complete and safe without its manual.
Please take note of the code and the version reported on the back of the cover sheet, so that
you can easily reorder a copy of this manual, in case of lost of the manual itself.
All the chapters of the manual must be read both by the installers and by the user, both
to accomplish a safe use of the appliance and get the best of it.
Here below you can find some directions, which allow a quicker consultation of the various
chapters.
Chapter 3 states the foreseen range of use of the appliance and gives all technical
specifications that may be useful for choice, installation and use.
Chapter 4 give all necessary directions to install the appliance. They are mainly addressed to
skilled workers, but they should be read in advance by the user as well, to provide the
premises and plants needed to install the appliance.
Chapters 5 e 6 give the final user the necessary instructions for switching on, operation and
the turn off of the oven in safety conditions. contains some useful advices for the use of the
oven.

HOW TO USE THIS MANUAL
7Synthesis 06/40V GAS
Charter 7 gives directions to clean the appliance properly. Careful cleaning is essential to
meet the safety hygiene requirements. Cleaning is also necessary to ensure the safe use of
the appliance and better results from the appliance itself.
Charter 8 gives all information necessary for periodic or extraordinary maintenance, e.g.
repairing or replacing parts of the equipment. In this chapter you can also find a list of spare
parts, to make easier the reordering and the replacement of any damaged part.
Service and maintenance must be performed by skilled personnel only.
Charter 9 gives directions for dismantling the oven.
Charter 10 facsimile declaration of conformity.

SPECIFICATIONS
8Synthesis 06/40V GAS
3. SPECIFICATIONS
3.1 PRODUCT IDENTIFICATION
This manual is valid for conveyor oven mod. Synthesis 06/40V gas.
3.2 DIRECTIVES COMPLIANCE
The gas conveyor oven mod. 06/40V indicates its conformity to the following European
directives:
2006/42/CE machines
2009/142/CE gas appliances
2004/108/CE electromagnetic compatibility
2006/95/CE low voltage
3.3 FORESEEN RANGE OF USE
The gas conveyor oven mod. Synthesis 06/40V is designed to cook pizza, or similar
products. Synthesis 06/40V gas is intended for professional use in the catering industry
(restaurant, pizza shop, etc..) by trained personnel only.
The normal operations are the loading and unloading of products on the conveyor, the
switching on, adjusting, switching off and cleaning of the appliance.

SPECIFICATIONS
9Synthesis 06/40V GAS
3.4 TECHNICAL SPECIFICATIONS
On the following tables you can find all technical specifications of the gas conveyor oven.
Synthesis 06/40V GAS
Unit of
meas.
Weight
115
Kg
Overall dimensions
1030x1300x440
mm
Conveyor width
400
mm
Conveyor length
1070
mm
Chamber length
580
mm
Output per hour
10-8.5 (30-25 pizze/h ø 30 cm)
Kg/h
Electrical power
Single-Phase
Voltage
230
VAC
Frequency
50 o 60
Hz
Current at 230 V 50 Hz
2
A
Total electrical power
450
W
Electrical connection
Bi-polar cable, without plague
Cable length
2
m
Wire section
1.5
mm2
Burner type
Aspirated
Type
II2H3+
Injectors diameter according to gas and pressure
G20 - 20 mbar
1,55
mm
G25 - 25 mbar
1,55
mm
G25 - 20 mbar
1,55
mm
G30 - 28…30 mbar
0,90
mm
G30 - 50 mbar
G31 - 30…37 mbar
G31 - 50 mbar
0,90
mm
Minimum pressure and injector according to gas and pressure
G20 - 20 mbar
3,0
mbar
G25 –25 mbar
4,5
mbar
G25 - 20 mbar
4,5
mbar
G30 - 28…30 mbar
8,0
mbar
G30 - 50 mbar
G31 - 30…37 mbar
G31 - 50 mbar
8,0
mbar
Maximum pressure and injector according to gas and pressure
G20 - 20 mbar
10
mbar
G25 - 25 mbar
15
mbar
G25 - 20 mbar
15
mbar
G30 - 28…30 mbar
27
mbar
G30 - 50 mbar
27
mbar
G31 - 30…37 mbar
27
mbar
G31 - 50 mbar
27
mbar
Gas connection
ISO 7 - (taper pipe thread)
Ø Pipe
1/2”

SPECIFICATIONS
10 Synthesis 06/40V GAS
Synthesis 06/40V GAS
Unit of
meas.
Consumption
Nominal thermal
capacity
9
kW
Consumption G20
0,952
m3/h
Consumption G25
1,108
m3/h
Consumption G30
0,71
Kg/h
Consumption G31
0,699
Kg/h
Reduced thermal
capacity
4,5
kW
Consumption G20
0,476
m3/h
Consumption G25
0,554
m3/h
Consumption G30
0,352
Kg/h
Consumption G31
0,350
Kg/h
Flue connection
Type
A1
Air exchange
31
m3/h
Flame control
Electronic without pilot
Safety time
<5
s
Flame ignition
Hot surface
Baking control
Electronic computerized
Temperature
measuring unit
°C
Maximum possible
temperature
320 °C
°C
Flame power control
Automatic or manual
Errors indicator
By means of display and acoustic alarm
Environment
Temperature
0 - 40
°C
Maximum humidity
95% without condensation
Technical specifications Tab 3-1

INSTALLATION
11 Synthesis 06/40V GAS
4. INSTALLATION
ATTENTION: these installation instructions are for the exclusive use of
personnel qualified for the installation and maintenance of electrical and 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 oven, 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 or
gas systems of the building in which the oven 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
Install the appliance in a dry and easily accessible place both to facilitate its use and to carry
out cleaning and maintenance. The area around the equipment must be kept clear. It is
particularly important to avoid obstructing the cooling outlets located at the sides of the
equipment.
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.

INSTALLATION
12 Synthesis 06/40V GAS
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 paragraph 3.4)
even when the oven itself or other ovens 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 6 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.
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.
In all situations, to avoid unpredictable movement, be aware of the equipment’s
centre of mass.
1

INSTALLATION
13 Synthesis 06/40V GAS
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
NO MORE THAN 3 UNITS SHOULD BE
STACKED ONE ON TOP OF THE OTHER
Once the first oven has been positioned on the base (see previous paragraph), proceed as
follows:
1 - Overlap consecutively the second and third module fit the chimney exhaust fumes and by
matching the exterior side walls of the ovens.
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 Tab. 3-1).
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 cap. 3.4
Tab. 3.1).
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 Table
3-1). Plugs and sockets for industrial use of the type CEE17 are suitable or those which satisfy
European norm EN 60309.
2

INSTALLATION
14 Synthesis 06/40V GAS
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 Table 3-1).
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
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.
The manufacturer does not accept responsibility for damage caused by failure to
observe the abovementioned norms.
For the position of the electrical power connections, see Fig. 5-1.
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 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 Fig. 5-1.
4.8 EXHAUST PRODUCED BY COMBUSTION
This oven produces waste gasses classified as type “A1” (see Tab. 3.1):
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

INSTALLATION
15 Synthesis 06/40V GAS
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.
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 Tab 3.1. 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 short-circuit 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.

INSTALLATION
16 Synthesis 06/40V GAS
A
(mm)
B
(mm)
C
(mm)
D
(mm)
E
(mm)
F
(mm)
I
(mm)
L
(mm)
M
(mm)
N
(mm)
O
(mm)
P
(mm)
Q
(mm)
R
(mm)
06/40V gas
330
720
1160
490
930
1370
51
665
1105
435
875
1315
425
55
G= ENTRY POINT FOR POWER SUPPLY
H= ENTRY POINT FOR GAS
S= COMBUSTION FUMES EXHAUST
Fig. 5-1 Connection for electrical and gas supply, exhaust for a single cooking unit and
a maximum of three cooking units stacked one on top of another.

INSTALLATION
17 Synthesis 06/40V GAS
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.

OPERATION
18 Synthesis 06/40V GAS
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

OPERATION
19 Synthesis 06/40V GAS
5.2 FUNCTIONAL STATES OF THE SYSTEM
5.2.1 Main on/off switch
In the off position there is power in the system but none of the individual functions work as the
main contactor is deactivated.
All the outputs are de-energized except the ones for programming, and all ovens functions are
deactivated.
The display indicates “OFF”, the current time and the day and time the oven will next be
automatically switched on.
where:
A = current hour
B = current minute
C = day, time, minute the oven will be automatically switched on.
The day is written as follows:
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
When the oven is off, the rear illumination on the display is also off.
This turns on when programming is started.
In the ON position the main contactor is activated, the fan turns on and the oven heats up.
The display is illuminated from behind and indicates:
A
B
C

OPERATION
20 Synthesis 06/40V GAS
where:
A = Cooking temperature
B = Cooking time in minutes and seconds
C = Operating condition of burner
(Max =high flame, Min = low flame, --- = flame off).
5.3 SETTINGS
5.3.1 Temperature adjustment
The oven temperature can only be adjusted when the oven is on.
The oven heats up to and then remains at the set temperature until
it is switched off.
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.
See the “Programming” paragraph 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.
5.3.2 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.
Conveyor can be started or stopped at any time using the key .
When the conveyor is still, the cooking time flashes.
When the oven is on, the conveyor can be adjusted manually to reach maximum speed by
pressing the key for 4 seconds. (Fig.2).
Press the same key again to return to the previous setting.
See the “Programming” paragraph to set the cooking time.
A
B
C
1
2