PROOF BOX (All SD,DD, and TD 99 Models)

PROOF BOX (All SD,DD, and TD 99 Models) OWNER'S MANUAL LUCKS FOOD EQUIPMENT COMPANY 21112 72nd Avenue South Kent, Washington 98032-1339 Phone: (253) 872-2180 Toll-Free: (800) 824-0696 FAX: (253) 872-2013 177-201 0102003

IMPORTANT Record the following information pertinent to the specific model being installed. This information will be helpful when calling factory for assistance and/or parts replacement. Model # Serial # Voltage Install Date: Start-up Date: ** The above information can be found on the equipment specifications plate located on the inside back wall of the proof box.. To contact the Lucks Food Equipment Company Service Department, call (800) 824-0696 or Technical Support Hot Line (800) 526-0725.

TABLE OF CONTENTS GENERAL Information to record for your specific piece of equipment How to get Help & Service Table of Contents How to Use This Manual Safety Precautions Inside Cover Inside Cover You are here Pg. 1 Pg. 2 OPERATION Operation Pg. 3 MAINTENANCE Maintenance Pg. 4 The Flush System The Fill System About Humidity Adjusting Water Level THE AUTO FLUSH and FILL SYSTEM Pg. 5 Pg. 5 Pg. 6 Pg. 7 Proofing Tips Proof Box Troubleshooting Guide Warranty Information Returned Merchandise/Parts Policy Warranty APPENDIX Pg. 8 Pg. 9 Pg. 10 Pg. 10 Pg. 11

INTRODUCTION 1 How to Use This Manual This manual contains the instructions to make the operation and maintenance of this Lucks Proof Box as simple and convenient as possible. Some of the instructions require the use of various controls, buttons, switches, etc. When this occurs, all control positions will be indicated as follows: Set the switch to OFF In this example, OFF is not simply a direction, but also a switch setting that is clearly marked on the equipment. The information contained in this manual is essential for your safety. Please take the time to carefully read the entire manual before using this unit. In particular, please pay close attention to the information contained in the following types of boxes: WARNING A WARNING box contains information to protect you from severe injury or death, and/or protect the equipment from severe damage. CAUTION A CAUTION box contains information to protect you from any injury, and/or protect the equipment from any damage. NOTICE A NOTICE box contains information to assist you in the most efficient installation, operation, and maintenance of your equipment.

2 INTRODUCTION cont., Safety Precautions The following information is essential for the safe operation and maintenance of the Lucks Proof Box. These warnings and cautions are stated here for your information, and are repeated whenever applicable throughout the text for your safety and convenience. CAUTION Operating the proof box with excessive humidity for an extended period of time may damage the fan and electrical components and jeopardize the warranty. WARNING The humidity tank is HOT. Be careful not to burn yourself when cleaning it. CAUTION Do not use metal tools, brushes, or chemical cleaners for cleaning the humidity tank. It could damage the plating inside the tank.

OPERATION 3 1. Turn on the POWER, LIGHT, and HUMIDITY CONTROL switches located on the control panel. A light in each switch will come on. The FLUSH system (see page 5) will operate immediately as your proof box starts to heat. 2 1 2. Set the dry heat thermostat (1) to about 85 F. Press the Up arrow (left) to set a higher temperature, the Down arrow (right) to set a lower one. Turn the HUMIDITY CONTROL dial (2) to MED (medium). If more heat or humidity is required, adjust the controls to a higher setting. NOTE: See article ABOUT HUMIDITY on page 6. CAUTION Operating the proof box with excessive humidity for an extended period of time may damage the fan and electrical components and jeopardize the warranty. 3. Note the humidity and temperature settings that are ideal for you. Record the information for future reference. Return to those settings as your proofing baseline. NOTE: See PROOFING TIPS on page 8.

4 MAINTENANCE For best results, the humidity tank should be cleaned weekly (or more often in areas of hard water). The humidity tank is located inside the plenum (1) in the proof box. WARNING The humidity tank is HOT. Be careful not to burn yourself when cleaning it. 1. While the proof box is operating, remove the plenum cover and set it aside. 2. At the control panel, cycle the POWER switch on and off to flush. CAUTION Do not use metal tools, brushes, or chemical cleaners for cleaning the humidity tank. It could damage the plating inside the tank. 2 3. During the flush cycle, briskly scrub the interior of the humidity tank (2) with a nylon scrubber. If the FLUSH cycle stops before you are finished cleaning, cycle the POWER switch on and off again. 4. Verify that the water level in the humidity tank is approximately 1/4 inch. Water level should not exceed 1/2 inch. 1 5. When finished, wipe up any spilled water and put the plenum cover back on. NOTE: For additional information on water level, see the article Adjusting Water Level on page 7.

5 THE AUTO FLUSH and FILL SYSTEM The Auto Flush and Fill System uses water to regularly clean and flush the humidity tank of the proof box to reduce the concentration of contaminants. The humidity tank is periodically flushed with clean water from one end, while contaminated water is drawn out through a venturi system at the other end. These cycles are controlled by a cycle timer, independent of any water level changes. THE FLUSH SYSTEM The flushing portion of the system consists of the cycle timer, solenoid valves, venturi block, and associated piping. When the POWER switch is turned on and at intervals of 60 minutes (or more frequently by adjusting the timer), the cycle timer opens the flush solenoid valve which allows water to flow to the venturi and to the flush line. This creates a wall of water in the humidity tank which sweeps dislodged scale particles into the sump. The suction created by the venturi pulls the contaminated water from the sump and discharges it to the bakery drain system. This reduces cleaning requirements by inhibiting the formation of scale in the tank. When the FLUSH cycle is finished, the fill after flush portion of the system refills the humidity tank. The humidity tank then heats the fresh water and proofing continues. THE FILL SYSTEM The fill system consists of the cycle timer, solenoid valve, and associated piping. The amount of water going into the tank during the 13 second fill time is controlled by a needle valve on the end of the fill/fill after flush tube. This is adjusted to keep the input volume just ahead of what is being used as steam. This keeps the recovery time as short as possible. The level of the water in the humidity tank is controlled by the frequency and quantity of water in a fill cycle. NOTE: For additional information on water level, see article Adjusting Water Level on page 7.

6 ABOUT HUMIDITY Along with temperature, humidity is the key to proper proofing of dough products. While most of us have a pretty good understanding of temperature, humidity is a little more complex, yet understanding it allows us to better understand the quality and consistency of the baked product. Humidity is measured in percent and is technically called Relative Humidity. The percent gives the relative percent of moisture compared to the amount of moisture in the air if it were saturated. When air is saturated, its relative humidity is 100%. The amount of water in saturated air depends drastically on the temperature of the air. For example, one cubic foot of air at 100% humidity at 60 F will have half as much moisture as one cubic foot of air at 100% humidity at 80 F. Therefore, if you heat air at 60 F and 100% humidity to 80 F without adding water, you will be at 50% humidity. For this reason, proofers must add water as they heat up, not just to increase humidity but to maintain it as well. For example, let s take a temperate yet humid day in your bakery at 70 F and 90% humidity. You turn your proofer on and heat it up to 100 F with a set point of 80% humidity. Your proofer must add 1/4 cup of water per cubic foot of air even though the humidity is lower than it started at. Humidity is controlled with a humidistat system similar to the way a thermostat controls temperature. A humidity sensor detects the percent humidity and sends that information to the control board. If it is below your set humidity, then the humidity tank is turned on, if it is above, the humidity tank is turned off. At this point, the comparison between humidity and temperature ends, for humidity is significantly more complex to control. Controlling humidity is complex and less precise than temperature control for several reasons. First is the error associated with humidity measurement. While it is common for thermocouple temperature systems to have errors of 1-2 F, humidity sensor systems rarely are more accurate than +/-5%. Second, and even more important is the dependence of the humidity reading on temperature. Conditions in a proofer are always changing, with both temperatures and humidities going up and down. This leads to humidity working in a +/-5% band at all times with the best controllers and stable conditions. Optimum humidity control at proofing temperatures is between 60%-90%. Proofing at above 90% humidity will usually result in condensation and less precise humidity control. As the unit reaches set humidity points over 90% it will overshoot slightly, if the dry heat call is off, the unit will be cooling, so the humidity will continue to go up as the temperature cools. This will result in humidity readings at or above 100% (yes, humidity readings above 100% are both common and accurate, they show a temporary super saturation of the air due to a source of warm water being available in the air). As the unit cools, and thus the humidity sensor cools, condensation will occur on the sensor, causing poor humidity readings for the next few minutes. The Lucks proofer is designed to minimize this situation by providing constant air flow over the sensor but will still result in a 5-15 minute stretch of time when humidity is not properly controlled due to over saturation of the air. The key point to remember, is that any setting over 90% essentially results in 100% humidity in any type of humidity chamber, such as a proofer. Your Lucks proofer is designed to control these complex processes for you. Proper maintenance and operation will result in the highest quality and consistency in your baked products.

ADJUSTING WATER LEVEL 7 The humidity tank has two different specialized areas with each serving a different function. The deeper of the two areas serves as a sump. Here is where loose scale and particles collect and then are sucked out of the tank when a flush cycle is performed. The sump area is a non-heated part of the humidity tank. The other specialized area is the boil deck. This area is less deep to allow water to boil easily creating the humidity for the proofer. The boil deck is where all water level adjustments are to be performed. Water Level: The water level is the depth of the water at it s shallowest end. Verify that the water level is greater than ¼ inch and no more than ½ inch at all times. Verify that under a full humidity call for at least 30 minutes the water does not drop in level below ¼ inch. Your adjustments must insure that the humidity tank is not allowed to run dry at any time. Adjustment Methods: The water level is determined by three things, water pressure, fill cycle frequency, and the fill line needle valve setting. The greater the water pressure the more water will flow in a given length of time. A more frequent fill cycle will refill the tank with water more often. The fill tube needle valve limits the quantity of water that is allowed to flow into the tank. These three things effect the level of the water in the humidity tank. The water pressure once set during installation should not require further adjustments. All water level adjustments should be made using the frequency of fills and the quantity of water allowed through the fill line needle valve. Note that too frequent filling of the humidity tank causes the water temperature to drop farther than necessary resulting in poor humidity control. It is suggested that all water level adjustments be attempted using the fill tube needle valve before modifying the factory setting for frequency of fills.

8 APPENDIX PROOFING TIPS The best Artisan Bread Bakers in the world do not use proof boxes. They dry proof all of their breads. There is good reason for this. Q.U.A.L.I.T.Y. Therefore, the longer the proof, at close to room temperature (70 F to 75, the better the product. However, since most bakeries today do not have the ultimate conditions required for dry proofing and since time is of the essence, proofing boxes were invented to give us the best possible results in the shortest time available. For best results, we recommend the following: Temperature Range For best results, it is recommended that the temperature range should be set between 85 F and 90 F. Humidity For best results, it is recommended that the humidity should not exceed 85%. Testing the Dough Use your finger to touch the dough. There should be a slight tackiness to the dough. You should be able to pull your finger from the dough without any dough sticking to it. If the dough sticks to your finger, the humidity is set too high. If the dough is not tacky and has a slight crust on it, your humidity is set too low. Setting temperature in a higher range than is recommended will result in a poor crumb structure and a loss of flavor in most bread products. The slower the proof, the better the bread.

APPENDIX 9 PROOF BOX TROUBLESHOOTING GUIDE PROBLEM PROBABLE CAUSE SOLUTION No water in humidity tank. Water level should be at least 1/4 inch, but less than 1/2 inch. 1. Building water supply interrupted. 2. Valve on fill tube assembly closed. 3. Fill valve stuck closed. 4. Flush valve stuck open. 1. Check building water supply. 2. Adjust water flow by opening valve. 3. Call service personnel to locate problem. 4. Call service personnel to locate problem. No humidity (humidity tank not boiling). Not enough humidity (humidity tank boiling). 1. Safety high limit tripped or electrical supply interrupted. 2. Humidity switch off. 1. Dry heat set too high. 2. Proof box door left open too long. 3. RH control needs calibration. 1. Call service personnel. 2. Turn humidity switch on, then power on. 1. Lower dry heat setting. 2. Keep door closed when not in use. 3. Call service personnel. Too much humidity. Not enough dry heat or proof box shuts off completely. 1. Wrong setting for humidity or dry heat. 2. RH control needs calibration. Safety high limit tripped or electrical supply interrupted. 1. Lower humidity setting or raise dry heat setting. 2. Call service personnel. Call service personnel. Uneven proofing. 1. Proof box door left open too long. 2. Plenum door not in place. 3. Worn door gaskets. 1. Keep door closed when not in use. 2. Install plenum door. 3. Call service personnel to replace worn gaskets. GENERAL: 1. Verify that the power is available and on to the unit. 2. Verify that all circuit breakers are on. 3. Verify that the power and humidity switches are on. If you have any questions, call the Lucks Food Equipment Company Service Department at: (800) 824-0696 or (253) 872-2180. Or call the Technical Support Hotline at: (800) 526-0725.

10 WARRANTY INFORMATION Service and maintenance work, other than that covered in this manual, must be performed by Lucks-authorized service people. Unauthorized work on your Lucks Rack Oven will automatically VOID all warranties. To maintain all warranties and certifications, all replacement parts must be original equipment replacement parts. To receive credit for parts replaced under warranty, see the Returned Merchandise/Parts Policy below. All returned parts must be clean and free from grease and dirt. All warranty parts, bills, labor, or travel must be billed to the Lucks Food Equipment Company within 30 days of completion of the work. Failure to follow these procedures will result in delay or possible denial of warranty credit. RETURNED MERCHANDISE/PARTS POLICY Our Returned Merchandise/Parts procedure begins with a phone call or letter to either our Sales or Service Departments for a returned merchandise authorization (RMA) number. When contacting our office (800-824-0696) you should be ready to give the following information: 1. Customer name, address, phone number. 2. Invoice number and date. 3. Model number, serial number, and manufacturer s (mfg.) number. These numbers can be taken from the specification plate located inside the right compartment door. 4. Reason for return, i.e. credit, exchange, warranty or repair. 5. Description of item. 6. Description of problem. After obtaining this information, we will issue you a 5-digit RMA number. This number must be clearly marked on the package you are returning. If it is not, the package will be returned unopened to the sender. Returned merchandise must be: 1. Returned freight prepaid. (Method determined at time of RMA # assignment.) 2. Packaged securely and carefully so that in-transit damage cannot occur. 3. All contents must be returned including operating manuals. 4. Marked RETURN with the RMA number on the lower left hand corner of the package. If the returned merchandise was sent to you due to our mistake then we will pay all freight charges. If the merchandise failed in service and is still covered by warranty, we will attempt to arrange to have repairs done at your facility when possible. For goods returned for reasons other than our mistake or service failure, the minimum restocking charge is 20% of the original invoice amount, or $20.00, whichever is greater. These returns will only be accepted providing the equipment is in new, never-been-used condition and the merchandise is no more than 90 days old. You will be issued a credit memo for your return. There are NO returns on special order items or electronic parts.

LIMITED WARRANTY 11 LUCKS FOOD EQUIPMENT COMPANY warrants Lucks manufactured equipment to be free from defects in material and workmanship under normal use and service, subject to the provisions of this limited warranty. For a period of ninety (90) days from whichever comes first of the following; 1) the date of installation by an authorized Lucks installer, or 2) ninety (90) days after shipment, Lucks will repair or replace, at our option, without charge for parts and/or labor, any part which our examination discloses to be defective. Additionally, for a period of one (1) year from whichever comes first of the following; 1) the date of installation by an authorized Lucks installer, or 2) ninety (90) days after shipment, Lucks will replace without charge for the parts, labor excluded, any part which our examination discloses to be defective. Additionally, for a period of two (2) years from whichever comes first of the following; 1) the date of installation by an authorized Lucks installer, or 2) ninety (90) days after shipment, a) Lucks will replace without charge for the parts, labor excluded, the humidity generator, commonly referred to as the "Auto-Flush" humidity tank, contained within the Lucks proof box product, regardless of model. b) Lucks will repair or replace, at our option, without charge for the parts, labor excluded, the heat exchanger, contained within the Lucks M Series and RoastMasterTM gas rack oven products, regardless of model. Additionally, with a preventive maintenance program in place that tunes the burner bi-annually, the heat exchanger warranty will be extended to 5 years. Additionally, for a period of five (5) years from whichever comes first of the following; 1) the date of installation by an authorized Lucks installer, or 2) ninety (90) days after shipment, Lucks will repair or replace, at our option, without charge for the parts, labor excluded, a) the heating elements contained within the Lucks M Series and RoastMasterTM electric rack oven products, regardless of model; b) the steel framework, which supports the rack lift and rotation assemblies, contained within the Lucks M Series and RoastMasterTM gas and electric rack oven products, regardless of model; c) the steel framework, which supports the tray rotation assemblies, contained within the Lucks gas revolving tray oven products, regardless of style or model; d) the dry heat elements contained within the Lucks proof box products, regardless of style or model; e) the heating elements contained within the Lucks electric donut fryer product, regardless of tank size; or, f) the frying tank on the Lucks gas and electric donut fryer product, regardless of tank size. This warranty is effective only for equipment which is installed in strict accordance with LUCKS FOOD EQUIPMENT COMPANY's Conditions of Installation, and operated and maintained in strict accordance with the Owner's Manual pertaining to the specific equipment item. Any equipment which has been installed, altered or repaired other than by or under the supervision of Lucks' authorized representatives shall not be covered by this warranty. All warranty repairs and labor must be authorized in advance. Parts or equipment on which claims are made shall, upon authorization, be returned for inspection, with transportation charges prepaid by buyer. Replaced parts or equipment will be shipped F.O.B. point of shipment. Since local codes vary extensively, we do not guarantee compliance. Any costs incurred because of delays or modifications required to meet local codes will be at the buyer's expense. THIS WARRANTY IS IN LIEU OF, AND LUCKS FOOD EQUIPMENT COMPANY DISCLAIMS, ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY LAW, COURSE OF DEALING, COURSE OF PERFORMANCE, USAGE OF TRADE OR OTHERWISE, INCLUDING WITHOUT LIMITATION ALL WARRANTIES AS TO CONDITION, USE, OPERATION, DESIGN, QUALITY, CAPACITY, WORKMANSHIP, INSTALLATION, SERVICING, LATENT DEFECTS, COMPLIANCE WITH ANY LAW, ORDINANCE, REGULATION, RULE, CONTRACT OR SPECIFICATION, "MERCHANTABILITY," FITNESS FOR ANY PARTICULAR PURPOSE, AND ALL OTHER QUALITIES AND CHARACTERISTICS WHATSOEVER. THE WARRANTY PROVIDED HEREIN IS THE ONLY WARRANTY MADE BY LUCKS FOOD EQUIPMENT COMPANY, AND LUCKS FOOD EQUIPMENT COMPANY NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF ITS PRODUCTS. LUCKS FOOD EQUIPMENT COMPANY and buyer expressly agree that LUCKS FOOD EQUIPMENT COMPANY's obligation and all remedies are limited exclusively to the repair or replacement of any non-conforming part, at LUCKS FOOD EQUIPMENT COMPANY's option in each respect. IN NO EVENT SHALL LUCKS FOOD EQUIPMENT COMPANY BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES OR EXPENSES INCLUDING WITHOUT LIMITATION, LABOR, TRANSPORTATION, STORAGE, LOSS OF USE, LOSS OF PROFITS OR DAMAGE TO PERSONS OR PROPERTY, EVEN IF LUCKS FOOD EQUIPMENT COMPANY HAS BEEN ADVISED OF THE POSSIBILITY THEREOF. ALL PRODUCTS SOLD TO OR INSTALLED AT LOCATIONS OUTSIDE OF THE UNITED STATES, CANADA OR MEXICO ARE SOLD ON AN "AS IS" BASIS AND ARE NOT COVERED BY THE TERMS OF THIS WARRANTY.