Duke 59-E3P Electric Half-Size Convection Oven Instruction Manual

Duke 59-E3P Electric Half-Size Convection Oven

IMPORTANT SAFETY INSTRUCTIONS

Throughout this manual, you will find the following safety words and symbols that signify important safety risks with regards to operating or maintaining the equipment.

WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION:   Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
CAUTION: Indicates Important Information
Indicates electrical shock hazard which, if not avoided, could result in death or serious injury and/or equipment damage.
Indicates hot surface which, if not avoided, could result in minor or moderate injury.
WARNING: Never steam clean or hose down with water. Electric component will fail due to moisture.

IMPORTANT SAFETY INSTRUCTIONS
In addition to the warnings and cautions in this manual, use the following guidelines for safe operation of the unit.

• Read all instructions before using equipment.
• For your safety, the equipment is furnished with a properly grounded cord connector. Do not attempt to remove or disconnect the grounded connector.
• Install or locate the equipment only for its intended use as described in this manual.
• Do not use corrosive chemicals on this equipment.
• Do not operate this equipment if it has a damaged cord or plug, if it is not working properly, or if it has been damaged or dropped.
• This equipment should be serviced by qualified personnel only. Contact the nearest Duke authorized service facility for adjustment or repair.
• Do not block or cover any openings on the unit.
• Do not immerse cord or plug in water.
• Keep cord away from heated surfaces.
• Do not allow cord to hang over edge of table or counter.

The following warnings and cautions appear throughout this manual and should be carefully observed.

• Turn the unit off, disconnect the power source and allow unit to cool down before performing any service or maintenance on the unit.

• The procedures in this manual may include the use of chemical products. You must read the Material Safety Data Sheets before using any of these products.

• The unit should be grounded according to local electrical codes to prevent the possibility of electrical shock. It requires a grounded receptacle with dedicated electrical lines, protected by fuses or circuit breaker of the proper rating, in accordance with all applicable regulations.

• Disposal of the unit must be in accordance with local environmental codes and/or any other applicable codes.

• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance
  by a person responsible for their safety.

• Do not store gasoline or other flammable liquids in the vicinity of this appliance.

• Improper installation, adjustment, service or maintenance can cause property damage, injury or death. Read all installation, operating and maintenance instructions thoroughly before installing or servicing this appliance.

INSTALLATION INSTRUCTIONS

A. QUALIFIED PERSONNEL
These installation instructions are for the use of qualified installation and service personnel only. Installation or service by other than qualified personnel may result in damage to the oven and/or injury to the operator.
Qualified installation personnel are those individuals, firms, companies or corporations which either in person or through an agent are engaged in and responsible for:

• The installation of electrical wiring from the electric meter, main control box or service outlet to the electrical appliance. Qualified installation personnel must be familiar with all precautions required and have complied with all requirements of state and local authorities having jurisdiction. See: National Electrical code, ANSI/NFPA 70-1990.

B. DELIVERY AND INSPECTION
Duke Manufacturing Co., does everything within its power to insure you receive your oven in good condition. They are strapped down on heavy wooden skids and surrounded by heavy “tri-wall” cartons to prevent shipping damage. They have all been carefully inspected before they were packaged and consigned to the carrier.

Upon Delivery of your Duke oven:

• Look over the shipping container carefully noting any exterior damage on the delivery receipt which must also be signed by the driver/delivery person.
• Un-crate and check for any damage which was not evident on the outside of the shipping container. This is called concealed damage. The carrier must be notified within fifteen (15) days of the delivery of the oven and the carton, skid and all packaging materials must be retained for inspection.

Duke Manufacturing Co. cannot assume liability for loss or damage suffered in transit. The carrier assumes full responsibility for delivery in good order when the shipment was accepted. However, we are prepared to assist you in filing any freight claim.

C. LOCATION OF THE OVEN
Proper planning and placement of the oven will give you the best results in terms of long term user convenience and satisfactory performance. We urge you to give adequate thought in the placement of your oven prior to its arrival.

• The oven should be placed in an area which is free from drafts and accessible for proper operation and servicing.
• The area around the oven must be kept clear of combustible materials. A minimum of one (1) inch from the left or right side, three (3) inches from the rear and eight (8) inches from the floor must be maintained between the oven and any combustible or non-combustible surface.

It is also important not to obstruct the natural flow of ventilation air if the oven is to operate properly. Do not place any objects on top of the oven. This oven should not be installed on a curb base or sealed to the wall. Either condition can prevent proper ventilation of the blower motor. The blower motor has a thermal protection device which will trip because of excessive ambient temperatures at the side of the oven. If the device trips continually, this condition should be corrected immediately to avoid damaging the oven permanently.
Before making any connections to the oven, check the rating plate to be sure the oven specifications concur with the voltage and phase to be supplied to the oven.
The rating plate and serial number data are located behind the motor access cover on the right side panel.

D. ELECTRICAL CONNECTIONS
Each section of the Duke 5/9 Half-Size Convection Ovens is rated at 8.0 kW.
Your oven is supplied for connection to a 208 or 240 volt, 1 phase or 3 phase grounded circuit. The electric motor, indicator lights and control circuits are powered internally and do not have a separate power supply.
Before making any connections to these units, check the rating plate to assure that the voltage and phase rating of the oven is compatible with the electrical supply.
When installing, all ovens must be electrically grounded in accordance with local codes or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70-1990 (in Canada – CSA Std. C22.1).
Wiring diagrams are located on the inside of the motor access panel, on the right side of the oven.

E. VENTILATION
Proper ventilation is very important for the proper function of your oven. A good ventilation system will allow the oven to function properly as well as remove unwanted vapors. Not venting the ovens properly can result in unsatisfactory baking results as well as the possibility of damaging your oven.

F. OVEN ASSEMBLY
Before assembling and installing the oven, please check to make sure that all necessary parts are present. In addition to the oven itself, there will also be legs, feet or casters. (For double sections, retaining clips, and miscellaneous hardware.) Please check the interior of all oven sections for the parts needed to assemble and install your oven(s).

Leg Attachment (in lieu of stand)

• Once the oven has been removed from the carton, lay it on its left side (the side without the controls).
• Hold the leg and align with the matching holes in base and leg flange. Carefully start the 5/16 18 bolts, (avoid cross-threading), by turning clockwise and tighten to the nearest full turn. A total of (12) 15/16-18 × 3/4 bolts, flat washers and lock washers are required to secure all legs.
• Once legs are secured, add two (2) storage shelves between the four (4) legs. Secure these by using the 1/4-20 × 3/4 self-threading screws. After completion, carefully lift the oven to an upright position.

To level the unit, raise or lower the adjustable feet as required.

G. ADJUSTMENTS ASSOCIATED WITH INSTALLATION
Each oven section and all its components parts have been tested thoroughly and inspected before your oven was shipped from the factory. However, it is sometimes necessary to further test or adjust the oven once it has been installed. Such adjustments are the responsibility of the Dealer or Installer. These types of adjustments are not considered defects, rather a normal and routine part of the proper installation of the equipment. These adjustments include but are not limited to:

• Adjustment and re-calibration of the controller
• Adjustment to the doors
• Leveling and tightening of fasteners.
  No installation should be considered complete without proper inspection and, if necessary, any adjustments by qualified service or installation personnel.

SPECIFICATIONS

POWER SUPPLY CONNECTIONS

POPEYE’S OVEN CONTROLS

OPERATION

A. PROGRAM PARAMETERS
This unit comes pre-programmed from the factory with the following parameters for Menu items S1 and S2

Menu Item S1 (Use for Par Baked Biscuits)

Menu Item S2 (Use for Fresh Biscuits)

Shelf position is based on counting from the top rung downward. (See oven drawing, page 9.)
For proper brownness, position each pan of biscuits in the following manner.

Push each pan all the way in until it hits the back wall, then pull it forward (toward you) one (1) inch.

B. PROGRAMMING INSTRUCTIONS
Programming the Oven Control is simple. Anytime a parameter (one of the five cooking times, one of the five load control settings, duty cycle time-base, setpoint, or offset) needs to be changed the procedure is:

• Select the desired menu item by holding down the MENU push button and pressing the UP/DOWN buttons until the menu item is displayed (The Menu items are numbered S1 through S7)
• Press both the number 1 and number 5 start switches at the same time. This action tells the control that something is to be changes; the alarm will sound, and the number one (1) will appear in the display.
• Press one of the following buttons:
  Switch| To Change
  ---|---
  1| Cooking Time
  2| Cooking Temperature (Setpoint)
  3| Duty Cycle On-Time
  4| Duty Cycle Time Base
  5| Offset

Switch 1 Pressed: The display will show the number “2”. Press the switch that is to have its baking time changed. The baking time for the particular switch will be shown in the display. A baking time must be programmed for selections 1, 2, 3 and 4. Use the UP/DOWN buttons to change the baking time to that desired.

NOTE: To change seconds hold in the start switch for one tray, then use the UP/DOWN switches.
Press the “Enter” switch to store the change.
Switch 2 Pressed: The setpoint temperature will be shown in the display.
Use the UP/DOWN switch to set the new setpoint.
Press the “ENTER” switch to store the new setpoint.
Switch 3 Pressed: The display will show the number “2”. Press the switch that is to have its load control changed. The load control “ON TIME” for that particular switch will be shown on the display. An “On Time” must be programmed for selections 1,2, 3 and 4.
Use the UP/DOWN switches to change the load control setting.
Press the “ENTER” switch to store the new load control setting.
Switch 4 Pressed: The Time Base will show in the display.

NOTE: The Time Base should never be changed unless directed to do so by America’s Favorite Chicken Corp.
Use the UP/DOWN switch to change the Time Base.
Press the “ENTER” switch to store the new Time Base.
Switch 5 Pressed: The Offset will show in the display
Use the UP/DOWN switches to change the Offset value.

NOTE: pressing the DOWN switch until the display goes past zero (0) will be negative values, and will be indicated by a lighted COLON.
Press the “ENTER” switch to store the new Offset.

NOTE: The Offset is used as a means to calibrate the probe temperature to agree with the temperature in the center of the oven. The factory setting for Offset is 30.

CONTROLLER RESET
In rare situations, such as a lightening strike near the restaurant, the computer may lose its program, or become “locked up”. If this should happen, press the RESET switch to reset the computer, or turn the power to the oven off and back on. Resetting the computer re-synchronizes its program flow.

C. OPERATION OF THE OVEN
Operation of the computerized Auto Rack Load Controller is quite simple.
Preheat: Close oven door and turn power knob clockwise to “cook” position.
The digital display will illuminate and display a temperature of 212° (The minimum displayed temperature). The amber light will also be lit indicating the oven is heating. When the oven temperature begins to exceed 212°, the actual oven temperatures will be displayed until the temperature set point has been reached and the oven ready light has gone off. At this point, the display shows 10:00 minutes, the cook time for one tray. Always keep oven door closed until biscuits are ready to be loaded onto a rack.

Baking: Open door and quickly load trays(s). (Slide tray all the way to the back wall, then slide forward one inch). Close door and press the switch that corresponds to the number of trays to be loaded (1, 2, 4 or 4)
The pressed switch will illuminate, indicating baking has begun. The time displayed begins counting down. When bake cycle is complete, the switch you originally pressed will flash and the alarm sounds. Press the flashing switch to turn off alarm. Remove the product.

D. COOL DOWN OPERATION
The oven has a cool down feature to expedite cooling of the oven interior so that it can be cleaned.
To initiate the cool down feature, turn the power switch counter clockwise to the off position. Open door and turn the power switch counter clockwise to the cool down positions. The oven fan will only operate, circulating cool air in the oven cavity.
When the oven interior is cooled sufficiently, turn the power switch clockwise to the off position.
Begin the daily cleaning procedures.

CLEANING OF THE OVEN

CAUTION

• Never steam clean or hose down with water. Electric component will fail due to moisture.
• Do not use caustic cleaners, acids, ammonia products or abrasive cleaners or cloths. These can damage the stainless steel and door gaskets.

DAILY

1. Clean the porcelain interior using a degreasing agent. For heavier deposits a commercial oven cleaner can be used.
2. Clean exterior painted surfaces with warm water and a mild detergent. Moisten a cloth and wipe down the oven while it is COLD.
3. Clean Stainless steel on the oven with a good stainless steel cleaner.
4. Make sure that all parts are thoroughly rinsed before returning to use.

WEEKLY
The racks and rack supports can be removed and soaked in a solution of ammonia and water. Make certain that all parts are thoroughly rinsed before returning to use.

MONTHLY

1. Check door handle screws for tightness.

THREE MONTHS

1. Check the door gasket seal on the oven and proofer for leaks. See the section on Door Adjustments and Gasket Maintenance for help.

SIX MONTHS
Before performing control panel maintenance, main distribution panel circuit breaker for oven must be turned off. This maintenance should be preformed by Qualified Maintenance Personnel only. Read and follow the manufacturers instructions, Material Safety Data Sheets (MSDS) and Workplace Hazardous Material Information Systems (WHMIS) before using any type of cleaning chemicals, de greaser, etc.

1. Clean Control Panel Mylar using a mild de greaser and water.
2. Clean Control Compartment Interior – Use commercial electronic component spray (if necessary) to de-grease the control compartment (see Note above).
3. Inspect/Replace any or all wiring which is saturated with oil.
4. Inspect Oven Door-lubricate door plunger assembly and strike plate with food grade high temperature lubricant adjust door as necessary
5. Inspect Element Wire Connections – take amp readings of elements.
6. Inspect Blower Motor – De grease as necessary
7. Inspect Blower Wheel – Clean with ammonia and water solution.
8. Inspect Back-up Thermostat – Check calibration.

MAINTENANCE INSTRUCTIONS

WARNING
These maintenance instructions are for the use of qualified service personnel only. Service by other than qualified personnel may result in damage to the oven and/or injury to the operator.

Qualified service personnel are those individuals, firms, companies or corporations which either in person or through an agent are engaged in and responsible for repair or servicing of commercial food preparation equipment, who are experienced in such work, familiar with all precautions required, and have complied with all requirements of state and local authorities having jurisdiction.
If you should require assistance in the selection of a qualified service agency, please contact Duke Manufacturing Co.’s Service Department at 800-735-3853.

A. ADJUSTMENTS
Quite often malfunctions which are attributed to defects may be repaired by adjusting certain parts rather than replacing them.

B. DOOR ADJUSTMENT
The door switch is located behind the lower front cover, on the right or left side. (Fig.1) The door switch (A) is activated by a cam (B) which is mounted to the door’s hinge pin with a set screw. Position the door so it is nearly closed but not latched. To adjust the cam:

• Loosen the set screw and rotate the cam until you hear the switch click.
• Tighten the set screw in the cam.
• Test the door to make certain the switch will make contact with the doors closed.
• Torque setscrew to 60 in-lbs.
• Replace the compartment cover.

C. LUBRICATION
The door plunger assembly requires periodic lubrication by the operator to ensure smooth, trouble-free operation.
Application of a Food Grade High Temperature Lubricant such as Lubriplate FGL-1 is recommended at least bimonthly. Apply lubricant to the plunger and strike plate sparingly. If necessary, lubricate at more frequent intervals.

D. BACK-UP THERMOSTAT CALIBRATION CHECK:

• Turn the oven on by turning the Power Switch to the ON position.
• Open the doors and place a thermocouple in the center of the middle oven rack. A reliable mercury-type thermometer can be substituted if a pyrometer is not available.
• Turn the power switch to the off position.
• Turn the thermostat dial to 375ºF (177ºC). Allow the oven to preheat ½ hour.
• Note the maximum and minimum temperatures through several cycles.
• If the reading on the pyrometer (or thermometer) is less than 10ºF different from the setting of the thermostat, no adjustment is needed. If this reading is more than 10ºF, proceed with calibration procedure.

To Recalibrate:

• Remove the thermostat knob by loosening the setscrew and pull the knob forward. Take care not to rotate the thermostat stem, which will change the setting.
• With a very small screwdriver, turn the screw located in the bottom of the hollow of the stem clockwise to lower the temperature of counterclockwise to raise the temperature. DO NOT allow the stem of the thermostat to rotate as your turn the screw.

Caution: Maximum turn of screw “A” is 1-1/2 turns – clockwise or counter- clockwiase.
This thermostat is a direct-acting (opens on temperature rise) device.

TROUBLE SHOOTING

EMERGENCY BACK-UP SYSTEM
Your oven is equipped with an emergency back-up system to be used should the computer controller ever malfunction. It is intended only to be used to keep you in operation until a service agent arrives to provide repairs.
Operation: Turn power switch to off position. Push the toggle switch located on the right access panel of the oven to the up position.
Turn power switch clockwise to cook position. The oven will now maintain a temperature of 375° by the back up thermostat. You will need to manually time your bake cycle until the biscuits are baked. No display will be illuminated.
Call your local authorized service agent to render repairs as soon as possible.

Oven Not Heating

1. Oven heating lamp is off.
2. Digital display in the controller is not lit. (Make sure backup thermostat control switch is in the down position.)
3. Check the 24VAC from the transformer. If voltage is present, replace the controller.
4. If no voltage, check the transformer and transformer input voltage. Make certain the correct transformer input voltage taps are used.

Transformer   Primary Voltage

• Orange    240-L1
• Red         208-L1
• White     120-L1
• Black       L2

Transformer Secondary Voltage

• Yellow-blue   12V (pin 4 & pin3)
• Yellow-blue    12V (pin 2 & pin3)
• Yellow-yellow 24V (pin 4 & pin 2)

DIGITAL DISPLAY IN THE CONTROLLER IS LIT, OVEN NOT HEATING

A simple test.

1. Turn the oven off.
2. Disconnect the oven control connector to J1 on the PCB
3. Insert a short insulated jumper wire between pins 1 and 3 in the oven control connector. Make sure the wire is insulated and bare wire cannot touch ground or other metal parts. (CAUTION: Line voltage present.)
4. Turn the oven on.
5. If the oven heats up, turn the oven off, remove the jumper from the oven control connector, and replace the oven control connector. Check the controller’s setpoint. If the setpoint is correct, replace the controller.
6. If the oven does not heat up, the problem is within the oven.
7. Turn the oven off.
8. Remove the jumper wire and replace the connector.
9. Oven Heating Lamp is on. The problem is within the oven.

OVEN TOO HOT (OVEN STAYS ON)

1. Turn the oven off.
2. Disconnect the oven control connector (J1)
3. Turn the oven on.
4. If the oven heats up, the problem is within the oven.
5. If the oven does not heat up, turn the oven off, and replace the oven control connector on J1, then turn the oven back on. Proceed to 6.
6. Press the ENTER switch to read the oven’s temperature.
7. Indicated temperature is obviously less than it should be.
8. The thermocouple cable may be shorted, or,
9. The controller may be defective.
10. Replace the temperature probe.
11. If the temperature now indicates the correct temperature, the problem was the temperature probe.
12. If the temperature still indicates lower than expected, replace the controller.

OVEN NOT RECOVERING WHEN BAKING

1. Check the Duty Cycle ON-TIME setting.
2. Measure the actual ON-TIME and OFF-TIME with a stopwatch or use the second hand of a wristwatch or clock to see if the oven is being controlled properly.
3. If the oven turns on and off at the proper times, the fault is within the oven. Check amp draw to each element. Be certain oven is supplied with proper voltage. (240 volt elements on 208 volt power supply, for instance.)
4. If the oven does not turn on and off at the proper times, replace the controller.

BISCUITS TOO DARK (OVER BAKED)

1. Reduce the duty Cycle ON TIME until the biscuits are the correct brownness.

BISCUITS TOO LIGHT (UNDER BAKED)

1. Increase the Duty Cycle ON-TIME until the biscuits are the correct brownness.

CONTROL FAILURE DIAGNOSTICS
There are two types of failures that will shut down the oven and display numbers that indicate the cause of the trouble:

1. TEMPERATURE PROBE OPENS
   Should the controller’s probe/cable become an open circuit following occur:

   • The oven is turned off
   • The alarm begins beeping
   • The display will show four (4) nines (9999) Press one of the five START switches to turn off the alarm.
     Replace the probe/cable.

2. OVEN STAYS ON TOO LONG
   If the oven stays ON for over fifteen (15) minutes, and this ON condition is caused by the controller receiving an improper temperature signal, the following will occur.

   • The oven is turned off.
   • The alarm begins beeping
   • The display will show four (4) sevens (7777) Press one of the START switches to turn off the alarm.
     Check the probe’s temperature by pressing the ENTER switch. If the indicated temperature is less than the actual oven temperature, the probe cable is probably shorted, causing a second thermocouple at a lower temperature. Replace the thermostat probe/cable.
     If the temperature shown in the display is about the same as that of the oven’s, the problem is probably the Controller. Replace the controller.

MODEL 59-E3P HALF-SIZE ELECTRIC CONVECTION OVEN

REPAIR PARTS LIST

Item #| Part #| Description| Item #| Part #| Description
---|---|---|---|---|---
1| 156333| Mylar| 17| 155113| Support, rack, oven
2| 153142| Knob, control| 18| 155114| Rack, oven
3| 153204| Light, oven ready, 208v/240v| 19| 155404| Handle, door
4| 153200| Holder, fuse| 20| 155451| door, with glass hinged right
5| 153201| Fuse, 10 amp| 155454| door, with glass hinged left
6| 600541| Kit, 3 Position Switch, rotary| 21| 155132| Glass only
7| 600536| Kit, Transformer, Ch/Pop, 208V| 22| 155107| Actuator, door switch
600537| Kit, Transformer, Ch/Pop, 240V| | |
155995| Transformer, 480/240V 2kVA| 23| 148077| Switch, micro, door
8| 600108| Controller| 24| 153056| Bearing, door
9| 155304| Probe| 25| 155007| Gasket, door top
10| 120001| Terminal block| 26| 155006| Gasket, door bottom
11| 600539| Kit, Contactor,

DP-style TO IEC-style

| 27| 155008| Gasket, door side (2)
12| 153036| Motor, 200/240V, 2-speed| 28| 153416| Catch, door
13| 153093| Fan Wheel| 29| 153801| Latch, roller assembly

14

| 155079| Element, outer, 240V, 2.667 kW| 30| 155318| Switch, toggle, back up system
155076| Element, outer, 208V, 2.667 kW| 31| 149403| Thermostat, backup
255256| Element, outer, 230V, 2.667 kW| 32| 153142| Knob, backup thermostat

15

| 155078| Element, center, 240V, 2.667 kW| 33| 153588| Overlay, backup thermostat
155075| Element, center, 208V, 2.667 kW| 34| 600100| Kit, Flue Guard (Optional)
255255| Element, center, 230V, 2.667 kW| 35| 155125| Bracket, Stacking

16

| 155077| Element, inner, 240V, 2.667 kW| 36| 155309*| Harness, Electronic Panel
155074| Element, inner, 208V, 2.667 kW| | |
255254| Element, inner, 230V, 2.667 kW| | |

• Not Shown

Diagrams of parts on following pages
READING THE SERIAL NUMBER

MODEL 59E3P OVEN CONTROLS

INTERIOR OVEN COMPONENTS

MODEL 59-E3P DOOR ASSEMBLY

OVEN BACKUP THERMOSTAT SYSTEM

FLUE GUARD

SECURING
DOUBLE STACKED OVENS

1. On rear of top oven remove two existing screws that are located at the lower right hand corner.
2. On rear of bottom oven remove two existing screws that are located at the upper right hand corner.
3. Install stacking bracket using the existing screws as shown in figure.
4. Repeat steps to install 2nd stacking bracket on left hand side.

Duke Manufacturing Co.
2305 N. Broadway
St. Louis, MO 63102

Phone: 314-231-1130
Toll Free: 1-800-735-3853
Fax: 314-231-5074

www.dukemfg.com

References

• Duke Manufacturing
• Prop65 - Duke Manufacturing

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