zesto CE 2416 Operating instructions

REF #0907-53
OWNER'S , SERVICE & INSTRUCTION
MANUAL
IMPORTANT INSTRUCTIONS FOR
OVEN INSTALLATION, OPERATION AND
MAINTENANCE
1
FOOD EQUIPMENT MANUFACTURING INC.
MANUFACTURIER D'EQUIPEMENT EN ALIMENTATION INC.
6450 HUTCHISON, MONTREAL, QUEBEC, H2V 4C8 TEL[phone] FAX[phone]
e-mail: [email protected] www.zesto.ca
SNEVOROYEVNOCCIRTCELE
8142/6142ECX
LEDOM
DH8103/8103ECX
8104ECX
2363/4263ECX
2384/4284ECX
2306/4206ECX

REF #0907-53
IMPORTANT FOR YOUR SAFETY
Improper installation, adjustment, service or maintenance can cause
property damage, injury or death. Read the installation, operating and
maintenance instructions thoroughly before installing this equipment.
FOR YOUR SAFETY
Do not store or use gasoline or flammable vapors or
liquids in the vicinity of this or any other appliance.
IN THE EVENT OF A POWER FAILURE DO NOT ATTEMPT
TO OPERATE THIS DEVICE. SHUT OFF POWER.
2
CAUTION
Electical disconect breaker should be installed on
each oven section with a minimum 3mm spaced
contact. Disconect the power supply before any
repairs or maintainance work is perfomed on oven.
CAUTION
Risk of electric shock. Do Not Obstruct Access
to this Panelboard. No Storage in this Area
NOTICE
A permanently connected appliance provided with casters
or wheels on all legs of the appliance shall be provided with
a means for securing the appliance to the building structure
to limit the movement of the appliance so that stress is not
transmitted to the electrical supply conduit complying
with either UL 197 or ISBN 0-7629-0856-4

REF #0907-53
3
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REF #0907-53
SAVE THESE INSTRUCTIONS FOR FUTURE USE
GENERAL: Read these instructions and keep them for future reference. Before installing the oven, consult your
local building authority and obtain a building permit if necessary. Do not modify or alter the construction of the oven
or any of its components. Install the oven as described in these instructions. Use only ZESTO components.
Failure to do so will void the Certification approvals and the warranty of this oven.
PURCHASER’S RESPONSIBILITY
1. To see that the electric services for the oven are installed on site in accordance with the manufacturer’s
specifications.
2. To unload, uncrate and install the oven in its proper location in accordance with the Installation Operation
Manual.
3. To see that the electric services are connected properly by a qualified licensed ELECTRICIEN or installer of
your choice. All such connections must be in accordance with applicable Code requirements.
4. Do not attempt to operate the oven until connection of utility service has been fully inspected by an authorized
service technician.
INSTALLATION WARNING:
Input voltage and phasing must
match the units voltage & phasing.
Remove back panel and pass the
service line through the rear of the
unit and connect to the teminal block.
WARNING:ADEQUATE MEANS MUST BE PROVIDED TO LIMIT THE MOVEMENT OF
CASTERED APPLIANCES. A RESTRAINING DEVICE IS REQUIRED FOR ALL TYPES OF
MOVEABLEAPPLIANCES.
WARNING:
*INSTALLATION AND REPAIR SHOULD BE DONE BY A QUALIFIED SERVICE PERSON.
THE APPLIANCE SHOULD BE INSPECTED BEFORE USE AND AT LEAST ANNUALLY
BY A QUALIFIED SERVICE TECHNICIAN. MORE FREQUENT CLEANING MAY BE
REQUIRED DUE TO OVEN GREASE VAPORS, DUST, ETC. IT IS IMPERATIVE THAT
CONTROL COMPARTMENTS, BURNERS AND CIRCULATING AIR PASSAGEWAYS OF
THE OVEN BE KEPT CLEAN.
*DO NOT MODIFY THISAPPLIANCE.
*DO NOT BLOCK THE AIR REGISTERS ON THE OVEN AS THIS WILL CAUSE THE OVEN
TO OVERHEAT.
WARNING: DO NOT USE THIS APPLIANCE IF ITS CONTROL HAS BEEN UNDER WATER.
IMMEDIATELY CALLA QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE
AND TO REPLACE ANY PART OF THE CONTROL SYSTEM WHICH HAS BEEN UNDER
WATER.
VENTILATION:
1. Ventilation hood should extend 6" (15cm) minimum past the oven on the front and back and 6" (15cm)
minimum past each side of the conveyor belt and hung 6’6" (198cm) above the floor surface.
2. Exhaust -Approximately 2000 CFM required for double stacked ovens.
Approximately 1500 CFM required for single oven.
Make-up air should be 65% - 80% of the exhaust air rating.
4

REF #0907-53
RECEIVING:
Immediatly after receiving the oven, check for possible shipping damages. If this oven is found to be
damaged, save the packaging material and contact the carrier within 15 days of delivery. Prior to
installation, verify that the electrical service and type of gas (natural or propane) agree with the
specifications on the oven data plate, located on right front side service panel. Do not use the door
or the handle to lift oven.
LOCATION:
Verify that the doors and access routes into kitchen area are checked for clearance. (When crate is
turned on its side, the oven will pass through a 864mm [34"] door opening). The equipment area
must be kept free and clear of combustibles. Maintain clearances from combustible or
noncombustible construction of at least 76mm (3") from the side and 76mm (3") from the back of the
oven. The installation location must allow adequate clearances for servicing and proper operation.
INSTALLATION CODESAND STANDARDS:
This oven complies with the National Standards of Canada and the United States and is certified by the
Warnock Hersey Inchcape Services and ETL under the standards of UL 197 (ANSI / UL STD.) and National
Sanitation Foundation (NSF). In Canada the installation must conform with local codes or, in the absence of
local codes, with the current CAN/CGAB149 Installation Code.
The oven, when installed, must be electrically grounded in accordance with the local codes or, in the absence
of local codes, with the current Canadian Electrical Code: CSAC22.2 Number 109. In the United States,
installations must conform with local codes, with the current UL197 (ANSI / UL STD.).
The oven, when installed, must be electrically grounded in accordance with local codes or, in the absence of
local codes, with theAmerican National Electrical Code; ANSI/NFPA 70 (latest edition).
A seperate electrical switch box must be provided for each oven. For stacked ovens, each
oven must be considered as a seperate oven.
INSTALLING BASIC OVEN:
1) Tilt oven on back side
2) Place oven on 4 wheel dolly
3) Direct oven to location
4) Remove oven from dolly and place on 2 pieces of 4" (100mm) x 4" (100mm) wood
5) Undo crate
6) Fasten front legs to oven
7) Tilt oven forward resting on front legs
8) Lift oven from rear
9) Once oven is lifted fasten back legs to oven
10) Oven is now ready to be placed in operating location
STACKING OVENS:
Follow same procedure as above to uncrate and then lift and place oven on top of bottom
one.
No fasteners are required, the weight of the oven will keep it in place.
5

REF #0907-53
6
MODELLE CG/CE 3018, 3018HD, 4018
MODELLE CG/CE 3624, 3632, 4824, 4832, 6024, 6032
1) 2) 3)
4) 5)
6)
7) 8) 9) 10)

REF #0907-53
TEMPERATURE CONTROLLER:
NOTE: * DON’T TOUCH THESE ADJUSTMENTS, IT’S ALREADY CALIBRATED
#VD 2001 / 2601 INITIAL POWER-UP: (Part #ZDIVD2001TRIDNA) When power is applied to the
control it will begin operating using the factory set point. The process temperature as measured by
the thermocouple will appear in the digital display and the LOAD (PV) will indicate if the control
output (load) is on.
Key-pad:
- Parameter display / set-point programming.
-Press toRaiseTemperature of Oven.
-Press toLower Temperature of Oven.
WARNING:
To program Controller follow the following steps:(adjustments to be done only by qualified technicien)
1) Press and hold for 5 seconds till appears, then keep pressing togling till
appears. Press till you find 0 100 this unlocks the program.
2) Press till appears press or till you find 0.0.
3) Press till appears press or till you find 2.
4) Press till appears press or till you find 0.
5) Press and hold for 5 seconds till appears, then keep pressing togling till
appears press or till you find (K thermocouple)
6) Press till appears press or till you find Fº or Cº
7) Press till appears press or till you find 0000.
8) Press till appears press or till you find
9) Press till appears press or till you find 0.
10) Press till appears press or
till you find 625Fº or 330Cº.
11) Press till appears press or
till you find 5.0.
12) Press and holding both to exit program.
13) Press and hold for 5 seconds till appears,
then keep pressing togling till
appears. Press or till you find 0 001
this locks the program.
14) Press and holding both to exit program.
#11 Input Power
#12 Output to
selenoid or SSR
#13 110v black
#14 110v white
#6 Thermocouple
negative
#7 Thermocouple
positive
WIRING CONNECTION
7a

REF #0907-53
8
SPEED CONTROL: Model ZRA620
Speed control is made of three different parts: a digital time panel, a reverse switch for belt
direction (for use by serviceman only) and an electronic pcb board.
This control is conected to a tachometer on the back of the gear drive motor which controls
the amount of pulses to regulate the the speed. This is a closed loop system.
TO REGULATE SPEED OF BELT (1 - 20 minutes)
Press for slower rotation of belt (time)
Press for faster rotation of belt (time)
REVERSAL OF ROTATION:
You can reverse the rotation of the belt simply
by removing the back panel on the control side
of oven, locate the tippette switch and push the
switch to the desired rotation (to be done by
serviceman only).
NOTE: IF DIRECTION IS CHANGED BE
SURE THAT BELT LINKS ARE CHANGED,
LINKS SHOULD ALWAYS BE IN PULLING
DIRECTION (see page 12)
CAUTION:
In case of breakage of the
electronic board do not
touch any component; do
not attempt to repair it.
Service and calibration of
the electronic board require
special instruments and must
be performed by the factory only.
Failure to do so would void the
warranty and the replacement
of the defective electronic board.
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8142,6142EC"84)rebmahc"42(1#
8103EC&GC"65)rebmahc"03(2#
8104EC&GC"66)rebmahc"04(4#
2363,4263EC&GC"27)rebmahc"63(3#
2384,4284EC&GC"48)rebmahc"84(5#
2306,4206EC&GC"69)rebmahc"06(6#
DD2304GC"27)rebmahc"04(4#
DD2356GC"69)rebmahc"06(6#

REF #0907-53
9
MAINTENANCE:
Periodically, depending on the amount of use and product you are cooking, the oven belt and
cavity of the oven must be cleaned.
STEP # 1 Remove both exterior crumb trays
daily and wash with soap & water.
STEP # 2 Remove chain cover panel.
STEP # 3 Lift belt and move forward thus
loosening chain from belt shaft
sprocket.
STEP # 4 Now you can remove the belt
by carefully pulling back towards
you.
STEP # 5 Remove bottom crumb tray first, then
bottom air distribution panel and
then the top air distribution panel.
Cavity is now empty.
To clean interior of oven cavity wash with soap and water. If residue is hard
or difficult to clean use a degreaser or abrasive cloth.

REF #0907-53
STEP # 6 It is imperative that the wire netting be kept
clean and free of obstructions as this could
cause the fan to stop which would result in
serious damages to the air circulating motor
inside the oven and would void the warranty
of this product.
CLEAN WEEKLY THIS SHOULD BE DONE BY
PASSING A DAMP CLOTH OVER WIRE NETTING.
ATTENTION
Never use pressure water hose (Jet Spay) to
clean oven to prevent any electrical hazards
REMOVING AND CLEANING WIRE BELT & FRAME:
STEP # 1 Rotate belt until you find chain link
fasteners.
STEP # 2 Undo chain link fasteners.
STEP # 3 Roll belt and clean. Now you may
clean stainless steel frame with soap
and water, if residue is hard you may
use a degreaser or abrasive cloth.
10

REF #0907-53
11
CONVEYOR BELT ASSEMBLING AND DISASSEMBLING INSTRUCTIONS:
Install belt so it always runs in the
direction indicated by this arrow.
Closed end of loop towards direc-
tion of travel.
The arrows in the belt illustrate the
movement of the splicing strand
between steps.
When bending the splicing strand,
try to limit bending to straight por-
tions of the strand rather than in
the "Z" bend area.
Splice one side completely before
starting the other side.
After completely splicing the belt,
it is advisable to go along the
width of the belt straightening the
spliced-in strand.
NOTE: DEPENDING ON WIDTH
OF BELT THERE MIGHT BE
ONE, TWO OR THREE
SPLICING STRANDS.

REF #0907-53
LENAPNOITUBIRTSIDRIAPOT
LEDOM
STIUDNOCFOREBMUN
8142/6142EC2
8103EC2
8104EC2
4263/2363EC2
4284/2384EC3
4206/2306EC4
DD2304EC4
DD2356EC6
LENAPNOITUBIRTSIDRIAMOTTOB
LEDOM
STIUDNOCFOREBMUN
8142/6142EC3
8103EC3
8104EC4
4263/2363EC4
4284/2384EC5
4206/2306EC6
DD2304EC4
DD2356EC6
ADJUSTABLE AIR DISTRIBUTION PANELS:
Ovens have a top adjustable air distribution panel, bottom adjustable air distribution panel and crumb tray.
Top adjustable air distribution panel
Bottom adjustable air distribution panel
Crumb tray
1) Lift and pull out front panel with
access door.
2) Pull out crumb tray.
3) Pull out bottom air distribution
panel.
4) Pull out top air distribution
panel.
Top
Bottom Bottom underside
Top underside
12

REF #0907-53
AIR DISTRIBUTION PANEL ADJUSTMENT:
IMPORTANT NOTICE: All adjustments on conduits must be set to the same opening.
Failing to set the same openings on all conduits will result in uneven cooking and air flow
distribution.
Top Air Distribution panel has two adjustments, one for the quantity of air over product and
the other to control the distribution of air front to back for even cooking.
To increase or decrease quantity of air (heat flow) on top of product:
(1) Loosen bolts on top of conduits.
Pushing top large lever twords
the front of the conduit increases
the quantity of air on top.
Pushing top large lever twords
the back of the conduit decreases
the quantity of air on top.
To shift air in top conduits:
(2) Loosen bolts on top of conduits.
Pushing top small lever twords
the front of the conduit shifts the
air to the front.
Pushing top smal lever twords
the back of the conduit shifts the
air to the back.
Bottom Air Distribution panel has one adjustment
in each conduit to control the distribution of
air from front to back for even cooking.
Loosen bolts on top of conduits.
Pushing top small lever twords the front
of the conduit shifts the air to the front.
Pushing top smal lever twords the back
of the conduit shifts the air to the back.
SEE DIAGRAM PAGE 14
13
Shift air to back
Shift air to front
Shift air to back
Shift air to front
Less top air
More top air

REF #0907-53
14

REF #0907-53
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POT NOITUBIRTSID LENAP
LEDOM S
WOLFRIA SGNITTES TFIHSRIA SGNITTES
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8104/8103
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2363/4263
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2384/4284
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2306/4206
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2384/4284
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2306/4206
ENON)mm5.9("8/3)C(
THERMOCOUPLE FOR TEMPERATURE CONTROLLER:
The themocouple placement is very important as the bulb on the end is what directs the temperature
controller to signal the burner to give more or less heat in the combustion chamber
15
WEIVPOTWEIVTNORF
LEDOM"A"SNOISNEMID"B"SNOISNEMID"C"SNOISNEMID
8142/6142)mm75("4/12)mm081(61/17)mm31("2/1
8103)mm75("4/12)mm542("8/59)mm31("2/1
8104)mm75("4/12)mm372("4/301)mm
31("2/1
4263/2363)mm54("4/31)mm704("61)mm03("61/31
4284/2384)mm54("4/31)mm634("61/371)mm03("61/31
4206/2306)mm5
4("4/31)mm484("61/191)mm03("61/31
“A” Damper to adjust
quantity of air distributed
on top conduits.
“B” Damper to adjust
air flow from front to back
and back to front.
“C” Damper to adjust
air flow from front to back and back to front.
THERMOCOUPLE TEST:With your Ohmmeter test the thermocouple to see if you have continuity. If continuity your
thermocouple should be good. Then test the one wire of your thermocouple against the body of the oven and if you have
continuity the thermocouple is defective. The thermocouple should have +/- 1.1 ohms between terminals.

REF #0907-53
16
ELECTRICAL HEATING SYSTEM:
The system used to heat the oven and transfer the heat to the product to be cooked is by having the return air
of the cavity circulate over hot open element coils. This is controlled by a thermostat set to your desired
temperature.
To remove elements follow the steps below.
STEP # 1: Disconnect from power source.
Remove side panel carefullyby first
removing screws holding temperature
and speed control and then remaining
screws.
STEP # 2: Remove wires, components and
screws holding hinged panel.
LEDOMSLIOCDESOLCYTITNAUQ
8142/6142EC3
8104/8103EC3
2363/4263EC6
2384/4284EC9
2306/4206EC9
DD2304EC21
DD2356EC51
Closed coil type
TECHNICAL SECTION FOR SERVICE

REF #0907-53
STEP # 3: Remove screws & wires from element box and proceed to remove complete box from oven.
STEP # 4: Once removed you can clean with a vacum the interior of heat chamber if necessary.
STEP # 5: With element box removed you can now change elements.
HI-LIMIT CUT-OFF & TIME DELAY:
This unit has a Hi-Limit cut-off
protection and time delay control
card. The Hi-limit cut off and shuts
down the heating elements in the
oven if the interior heat rises above
the permitted level. This control card
also verifies at the beginning of the
cycle that all the components are
properly functioning. Any failure the system shuts down a red light appears
on the front panel and must them be reset. Reset by depressing the reset
button in front panel.
When the oven is shut off the TIME DELAYoption starts allowing the belt
and fans to remain on (without the heat source) for about 10 minutes to
allow the oven components to cool down,
Closed coil type Open back
17
Hi-Limit light.
Reset button.

REF #0907-53
GEAR MOTOR:
18
2416, 2418, 3018 & 4018 3624, 3632, 4824, 4832, 6024, 6032
4032DD & 653DD

REF #0907-53
HEAT CIRCULATING BLOWER MOTOR:
Vibrations and noises generated by the Heat Circulating Blower Motors
1. Make sure the bolts and nuts on the motor bracket are correctly fixed.
2. If everything is in place as indicated and the motor is still noisy, you will have to disassemble the motor to be able to
check the blower cage: if the blower cage is not properly balanced, this could generate vibrations and noises.
Disassembling the motor:
1. Remove the chain guard of the belt.
2. Remove the chain from the gear sprocket.
3. Remove the back panel.
4. Remove the stainless steel panel.
5. Remove the locking nuts holding the blower assembly.
6. Press down on the back of the motor to disengage the bracket from the slot and pull out the blower assembly
towardsyou.
7. Start the motor to verify the blower balance; make sure nothing will come in contact with the blower cage. If the
blower cage is defective, remove it taking care to verify the exact position of the hub on the motor shaft in order to
install correctly the new blower cage.
Note: An improper installation of the new blower cage which could come in contact with the outer casing
would result in the immediate breakage of the blower cage.
Important: When following the procedure in reverse to reassemble the motor, ensure that all the parts are in
place before using the oven.
19
#2
#1 #5
#3 #7 #8
#4
STEP #3
STEP #2
STEP #1
2416, 2418, 3018 & 4018 3624, 3632, 4824, 4832, 6024, 6032
4032DD & 653DD

REF #0907-53
COOLING FAN:
Acooling fan is installed on the left side, at the back of the unit. The function of this fan is to maintain the ambient
temperature surrounding the motors at the proper level as recommended in the standard. It is imperative that the
wire netting be kept clean and free of obstructions as this could cause the fan to stop which would result in serious
damages to the air circulating motor inside the oven and would void the warranty of this product.
20
WARNING
INTAKE FANS AND SLOTS ON REAR PANELS MUST BE CLEANED WEEKLY.
ANY OBSTRUCTIONS WILL CAUSE MOTORS TO SEIZE.
AVERTISSEMENT
LES PRISES D’AIR ET LES OUVERTURES DANS LES PANNEAUX ARRIÈRES DOIVENT ÊTRE
NETTOYÉS ÀTOUTES LES SEMAINES.
TOUT BLOCAGE DE CES OUVERTURES PEUT FAIRE SAISIR LES MOTEURS.