Belshaw DX Installation Manual

OPERATION AND MAINTENANCE MANUAL

MODULAR DECK OVEN

18/06/2013

MANUAL No. Y-DXT UL

FAN (IF FITTED)

Store this document safely and ensure it is available at all times.

Non-availability may affect the service / repair of your machine.

FG257 MODULAR DECK UL 08/07 RAC

Enter

Serial Nos.

here

In the event of an enquiry please quote these serial numbers.

ECOTOUCH CONTROL

DECK 1

DECK 2

DECK 3

DECK 4

DECK 5

•

TO REDUCE RISK OF FIRE OR ELECTRIC SHOCK, DO NOT REMOVE

ONLY.

•

FAILURE TO ADHERE TO THE CLEANING AND MAINTENANCE

WARRANTY OF THIS MACHINE.

•

THE OVEN SHOULD ONLY BE USED FOR BAKING BREAD, PASTRIES AND CAKES

•

SOME SECTIONS OF THIS MANUAL ARE FOR ENGINEERS ONLY AND THE CUSTOMER SHOULD NOT ATTEMPT TO MAKE ALTERATIONS.

•

BEWARE OF HOT SURFACES. DO NOT TOUCH OVEN FRONT OR DOOR WITH BARE SKIN.

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

WARNING LABEL, TO REDUCE RISK OF FIRE

OR ELECTRIC SHOCK

DO NOT REMOVE COVER (OR BACK)

NO USER SERVICEABLE PARTS INSIDE

REPAIR SHOULD BE DONE BY AUTHORISED PERSONNEL ONLY

IMPORTANT NOTES

COVERS (OR BACK SHEETING). NO USER SERVICEABLE PARTS INSIDE. REPAIR SHOULD BE DONE BY AUTHORISED PERSONNEL

INSTRUCTIONS DETAILED IN THIS MANUAL COULD AFFECT THE

- 12.0 Service Infor

Section - 1.0

Introduction

Section - 2.0

Overall Dimensions

Section - 3.0

Specifications

Section - 4.0

Safety

Section - 5.0

Installation

Section - 6.0

Isolation

Section - 7.0

Cleaning

Section - 8.0

Operating Conditions

Section

Operation (and baking advice)

Section

tructions

Section

ing

Section

mation

Replacing light bulbs

Section - 13.0

Spares Information

Section - 15.0

WARNING and INFORMATION LABELS

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

CONTENTS

9.0 Principles Of

10.0 Operating Ins

11.0 Troubleshoot

THIS SECTION IS FOR ENGINEERS ONLY AND THE CUSTOMER

SHOULD NOT ATTEMPT TO MAKE ALTERATIONS.

Section - 14.0 Electrical Information

The electric modular Deck Oven is an easy to use practical, good-looking oven, giving an excellent heat recovery rate and an even bake across a wide range of bread and confectionery products.

store

as give reliable service for

The external and internal contact surfaces are stainless steel.

Each modular deck is fitted with durable reinforced one-piece tiles, and an increase

efficient.

The oven comes with a patented integral steaming system, which reduces energy consumption and the overall size of the oven. The system produces real steam with

steam is also available to reduce the affects of

long loading times.

No drainage is required.

Ecotouch ovens are supplied with

TOUCH

displays for the user-friendly control

been

A voice prompt facility is also available for the basic instructions like “Bake over”.

ECOTOUCH

CONTROLS

The lights are low voltage, sealed from the chamber and easily accessed from outside the oven.

Fitted with a choice of hinged easy to clean double glazed doors (using low energy-

consumption

(0-100% heating available both top and bottom)

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

1.0 INTRODUCTION

• Good looking and totally reliable

Conceived with the no nonsense requirements of both the independent and inbaker in mind, and designed to visually please as well many years. This oven will more than satisfy the most discerning customer.

• Top quality specification

in high-grade insulation and high temperature ceramic sealant, makes the oven

the advantages of spray steam. Pre-

panels. This can show pictures of product types or program numbers that have set by the user. When not being used, the screen can show your company logo.

SCREEN

loss reflective glass for high visibility) or metal doors, means low energy and the high kW rating gives good recovery.

As it is our policy to improve our machines continuously, we reserve the right

to change specifications without prior notice.

H D W

5 HIGH

……………….H

= 84”

(2135mm)

4 HIGH

……………….H

= 79.5”

(2020mm)

3 HIGH

……………….H

= 79.5”

(2020mm)

Ovens available with 1,2,3, 4, and 5 modules

32” deep modules

…... D

= 51 ¾”

(1300mm)

3 Tray wide oven

……. W

= 74 ½”

(1890mm)

2 Tray wide oven

……. W

= 55 ¾”

(1416mm)

1 Tray wide oven

……. W

= 37”

(940mm)

2.0 OVERALL DIMENSIONS

ALL DIMENSIONS ARE APPROXIMATE

FG257 MODULAR DECK UL 08/07 RAC

3.0 SPECIFICATIONS

Dimensions in millimetres

25.4mm = 1”

5 DECK OVEN

DECK PLATE HEIGHTS

4 DECK OVEN

DECK PLATE HEIGHTS

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

3 DECK OVEN

DECK PLATE HEIGHTS

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

ELECTRICAL LOADINGS:

•

SUPPLY REQUIRED PER MODULAR DECK:

3 mp 3 Amp

3 mp

•

SUPPLY REQUIRED FOR CANOPY:

1 Phase (2 wire + ground), 220V. 60Hz Fused at

6Amps

1 Phase (2 wire + ground), 208V. 60Hz Fused at

6Amps

NOISE LEVEL

Less than 80 Db

WEIGHT:

(ALL WEIGHTS ARE APPROXIMATE)

Total oven weight (Including base frame)

–

2 tray wide, 3 deck

1569lbs 2345lbs TBA

(711kg) (1064kg)

Weight per oven chamber module

= 421lbs

(191.5kg) (261kg)

575lbs

TBA

Weight per oven canopy module

(14kg) (17kg)

Weight per fan module

= 62lbs

= TBA

(28kg) (28kg)

Weight of product (max) per deck

(39kg) (60kg)

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

WID

3 TRAY WIDE

Phase (3 wire + ground), 220V. 60Hz 8.85kW, 24Amp

Phase (3 wire + ground), 208V. 60Hz 7.90kW, 22Amp

PROTECTION 30AMPS

Phase (3 wire + ground), 480V. 60Hz 8.78kW, 12.4Amp

PROTECTION 20AMPS

2 TRAY WIDE

5.93kW,18Amp

5.31kW,17Amp

30AMPS

5.86kW,8.2Amp

20AMPS

1 TRAY

3.0kW, 9A

2.7kW, 8.7

4.9kW, 7A

–

3 tray wide, 3 deck

–

1 tray wide, 3 deck

– – – – – – – – – – – –

2 tray wide 3 tray wide 1 tray wide 2 tray wide 3 tray wide 1 tray wide 2 tray wide 3 tray wide 1 tray wide 2 tray wide 3 tray wide 1 tray wide

= = =

TBA 31lbs 38lbs

= 62lbs = TBA = 86lbs = 131lbs

Check all cover panels, and any pipefittings are securely positioned.

Check oven door handles are not damaged.

Do not operate a deck's steaming system with oven door open.

Always use oven gloves when loading the oven.

When products are removed from the oven, ensure:

(a)

Tins are knocked out and stored directly onto tin storage trolley or rack

(b)

Trays are put into a rack and the rack is wheeled to a safe cooling area.

Do not store items on top of the oven.

Do not store items behind the oven.

Beware of hot surfaces. Do not touch oven front or door with bare skin.

All operatives must be fully trained

People undergoing training must be under direct supervision

The oven should only be used for baking bread, pastries and cakes (for other products please contact your oven supplier)

No unauthorized modifications should be made to the oven.

Do not walk on the roof of the oven

DISPOSAL

other

means as the law permits at the time.

The Bakery Manager or the Bakery Supervisor must carry out the above daily safety checks

4.0 SAFETY

All maintenance must be made with the oven disconnected from the

power supply and then only by fully trained authorized persons.



(Do not leave hot tins on the floor or on tables).



Care should be taken when the oven comes to the end of its working life. All parts should be disposed of in the appropriate place, either recycling or

NOTE:

BAKERY STAFF

MUST NOT

UNDER ANY CIRCUMSTANCES REMOVE

PANELS TO ACCESS ANY PART OF THE DECK OVEN.

Panels should only be removed by an Adamatic maintenance engineer

fully trained maintenance contractor) for repairs or maintenance,

oven from power supply.

after isolating

(or other

FG257 MODULAR DECK UL 08/07 RAC

A hard smooth level floor is recommended on which to position the oven and

front of the access panels (right hand side) to allow for servicing.

If not chosen as an oven option, it is recommended that an extraction hood be

an adverse effect on the bakery ceiling and ambient temperature.

•

A chain retainer should be fitted, that is shorter than the power cables, to

the

base, using hole provided in castor fixing corner plates).

•

Installation must be made by a trained authorized engineer and all utilities

and

state building codes.

The oven must be “run in” as stated in the initial start up instructions.

ELECTRICAL CONNECTIONS

SUPPLY REQUIRED PER MODULAR DECK:

3 TRAY WIDE

2 TRAY WIDE

1 TRAY WIDE

3 Phase (3 wire + ground), 220v. 60Hz

8.85kW, 24Amp

5.93kW,18Amp

3.0kW, 9Amp

3 Phase (3 wire + ground), 208v. 60Hz OVERLOAD PROTECTION

7.90kW, 22Amp 30AMPS

5.31kW,17Amp

30AMPS

2.7kW, 8.7Amp

3 Phase (3 wire + ground), 480v. 60Hz

8.78kW, 12.4Amp

5.86kW,8.2Amp

4.9kW, 7Amp

OVERLOAD PROTECTION

20AMPS

SUPPLY REQUIRED FOR CANOPY:

1 Phase (2 wire + ground), 220v. 60Hz Fused at

6Amps

1 Phase (2 wire + ground), 208v. 60Hz Fused at

6Amps

Each modular deck requires its own power supply.

• A wall isolator rated at 30Amps

must

be available in order to completely

5.0 INSTALLATION

GENERAL



access for maintenance should be considered.

The oven is not designed to be ” built in” so sufficient clearance must be left



placed above the oven to disperse excess steam and heat, which could have

isolate the oven.

THIS ISOLATOR MUST BE CLEARLY ACCESSIBLE TO THE OVEN OPERATOR

protect them from strain if the oven is moved. (Fit to the wall or floor and

must be installed by licensed contractors and must conform to all local



•

FG257 MODULAR DECK UL 08/07 RAC

A B C D E F

J K

BASE TO DECK MODULE

BRACKETS

INITIAL START-UP

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

DECK OVEN BUILDING

SEALANT MODULE TO MODULE FIXING MODULES FLUE JOINTS

EVAPORATING/DRIP TRAY

SIDE PANELS and EARTHQUAKE

IMPORTANT OPERATIONS

WATER SYSTEM SETUP

EXHAUST CONNECTIONS

LIFTING POINTS

M10 THREADED LIFTING POINTS, 4 POSITIONS

(ALSO USED AS LOCATORS TO POSITION EACH DECK)

1310mm – 3 TRAY

836mm - - 2 TRAY

858mm

JOINING DECK SECTIONS

FRONT

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

REST MODULE APPROX. 4” FROM FRONT OF BASE

MODULE

BASE

APPLY SILICON ALL THE WAY ACROSS FRONT JOIN AREA.

LIFT MODULE AND LOWER ONTO POSITIONING PINS

THIS WILL COMPRESS THE SEALANT.

SEALANT ACROSS

FRONT

BOLT BASE AND MODULE TOGETHER AT 4 CORNERS

SEAL AND POSITION EACH ADDITIONAL MODULE AS ABOVE.

SEE INSTRUCTIONS FOLLOWING FOR FIXING.

FRONT

WHEN ALL MODULES ARE

FRONT, ATTACH JOINING BRACKETS

TO FLUE JOINTS.

(SELF-TAPPING SCREWS)

FRONT

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

ENSURE ALL FRONT FACES LINE UP THEN

BOLT TOGETHER EACH MODULE.

1 FIXING EACH SIDE AT FRONT.

POSITIONED AND FIXED AT THE

FIT EVAPORATING DRIP TRAY

TO THE BOTTOM SECTION.

(SELF-TAPPING SCREWS)

FRONT

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

FIT SIDE PANELS.

(HOLES ARE SLOTTED) AND THEN TIGHTEN SCREWS.

FIX SCREWS BUT DO NOT TIGHTEN.

MOVE PANELS TO LINE UP FRONT EDGES

SCREWS

CLAMPING DOWN IN EARTHQUAKE ZONES

The base structure should be held in place by bolting down to the floor with suitable fixings, using bracket part number

247-01-00075

Holes for fixings

NOTE

If this method of fixing down is used, enough space should be left surrounding the

oven to allow for maintenance and cleaning, without moving the oven.

in diagonally opposite corners.

Clamp bracket (247-01-00075) over frame and fix to floor in 2 positions

EARTH (GROUND) STRAPS

MUST

BE CONNECTED

BETWEEN EACH SECTION.

REMOVE SCREWS (2 PER BRACKET, NOT SHOWN).

ADJUST BRACKET TO TOUCH TILE AND REFIT SCREWS.

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

POSITION AFTER INSTALLATION

RETAINING BRACKETS IN 2 POSITIONS ON EACH DECK

IMPORTANT OPERATIONS

EARTH STRAP

REAR VIEW OF OVEN

TILE RETAINING BRACKETS

PART NUMBER

M158-25-11200

SUPPLIED

POSITION ON DELIVERY

TURN BRACKET 180 DEGREES.

THIS MUST BE DONE ON EACH DECK.

BRACKET PART No.M257-06-00015

The set up procedure on the next page must be followed to

allow the steaming system to function correctly

All ovens with steam require a ½” NPT hot or cold water supply at a pressure

from

the top of the stand when facing the front of the oven.

Only one water supply is required per oven. A manifold supplies all decks from one connection point.

For proper operation of the steam system it is recommended that the water supply follows the following specifications:

Hardness

0-4 grains per gallon

PH range

7.0 to 8.5

Chloride concentration

0 –30 ppm

Calcium

0 – 4 ppm

Magnesium

0 – 4 ppm

Alkalinity

0 – 20 ppm

Consult your water treatment company for proper water filtration system information.

No drain is required for this oven.

A Dual Check Valve Backflow Prevention Device is supplied fitted to the water inlet manifold.

WATER SUPPLY REQUIREMENTS

THIS EQUIPMENT IS TO BE INSTALLED TO COMPLY WITH THE

APPLICABLE FEDERAL, STATE, OR LOCAL PLUMBING CODES



of 2 - 3 bar (29 – 44 psi). Located approximately 10” from the right and 4”



FG257 MODULAR DECK UL 08/07 RAC

Flush out the main feed pipe to be used, until water runs clear and free from debris.

Connect main feed to oven.

Connect flexible hoses to each deck.

Place a container under the test valve.

Slowly open test valve fully and with the water flowing check the regulator is set to

Never use the oven above this setting

When the pressure has stabilised shut the test valve.

REPEAT

4,5 AND 6 AT THE END OF INSTALLATION.

TO OVENS

REGULATOR

DUAL CHECK VALVE BACKFLOW

PREVENTION DEVICE

STOP TAP

ADJUSTING SCREW

SET TO 0.75 bar

FILTER

TEST VALVE

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

WATER SYSTEM SETUP PROCEDURE

It is imperative that the water delivery to the deck oven is checked for the

steam system to operate correctly

0.75

bar. If not adjust using the screw above the valve.

•

NOTE. DYNAMIC PRESSURE, NOT STATIC, IS BEING MEASURED.

WATER REGULATOR SET UP

LOCATED ON REAR OF OVEN

•

Ideally an exhaust duct should rise 78” (2 metres) above the bakery roof protected from wind and birds by a duct protector.

•

It should be of a suitable material to take the high temperatures and humidity expected.

•

It should be flexible and easily removable at the oven connection point.

This allows the oven to be moved for cleaning when required.

23”

10” Dia.SPIGOT

CONNECTION POINT

9 ½”

13”

10” Dia.SPIGOT

CONNECTION POINT

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

Exhaust Connections (IF CANOPY FITTED)

CANOPY

WITH EXTRACTION FAN FITTED

WITHOUT EXTRACTION FAN FITTED

ROOF

In order for the oven to give good reliable service the deck tiles must be initially

can

be used as required.

Running in procedure

(This will be the temperature inside the cooking chamber)

2. The temperature needs to rise to 110deg C, at no more than 2deg a minute.

DO NOT USE BOTTOM HEAT AT ANY TIME.

3. Take the temperature up to 260deg C, at no more than 1deg in 2 minutes.

THIS WILL TAKE 5 HOURS.

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

INITIAL START UP

THIS PROCEDURE MUST BE ADHERED TO FOR THE OVEN

WARRANTY TO BE VALID.

brought up to temperature as stated below. After this running in period the oven

1. Turn the oven on and note the temperature shown.

A WALL ISOLATOR RATED AT 30AMPS MUST BE

AVAILABLE IN ORDER TO COMPLETELY ISOLATE THE

OVEN.

THIS ISOLATOR MUST BE CLEARLY ACCESSIBLE

AND KNOWN TO THE OVEN OPERATOR

TO STOP THE OVEN IN AN

THE

MAIN WALL ISOLATOR

6.0 ISOLATION

WARNING

THE “POWER OFF” BUTTON ON THE FRONT OF THE OVEN DOES

NOT ISOLATE THE POWER SUPPLY.

EMERGENCY SWITCH OFF AT

FG257 MODULAR DECK UL 08/07 RAC

DAILY CLEANING INSTRUCTIONS

After the oven has been allowed to cool, (this could take several hours),

Use a vacuum cleaner with metal attachments (able to take heat) if available.

Brush down and wipe oven front, back and sides with a damp cloth.

Spot clean with a damp cloth, which has been soaked in a solution of mild

not applied around the area of the electrical panels.

WEEKLY CLEANING INSTRUCTIONS

Complete daily cleaning as above.

Scrub oven wheels with a mild detergent and hot water using nylon cleaning brush (excess water will rust metal).

Ensure the oven roof area is clear of debris and dust build up.

(DO NOT STAND ON THE OVEN ROOF)

ISOLATE OVEN FROM MAINS SUPPLY BEFORE CLEANING.

7.0 CLEANING



sweep any debris out.



detergent, and hot water, paying particular attention to ensure excess water

NOTE: TAKE CARE WATER DOES NOT ENTER CONTROL PANEL

MOUNTING OR ROOF MOUNTED FAN.

ISOLATE OVEN FROM MAINS SUPPLY BEFORE CLEANING.



FG257 MODULAR DECK UL 08/07 RAC

It is recommended that a space of at least 6 feet be left in front of the oven for ease of operation and safety.

Bakery utensils must not be used to operate the control panel buttons.

Products are baked in an insulated heated chamber. The temperature is regulated by

front control panel. Baking heat is radiant

enables

heat to be “balanced” according to product requirement.

STEAM is provided from an integral steam unit, and is introduced into the chamber on demand. This is automatically controlled by the programmed parameters.

Once steamed the oven will not steam until the steam unit

amount of steam selected.

All ovens are fitted with a

steam damper

that evacuates steam humidity into a vent

at the side of the oven.

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

8.0 OPERATING CONDITIONS



9.0 PRINCIPLE OF OPERATION

NOTE

a thermocouple having a read-out on the with top and bottom heat being adjusted by means of separate controls. This

: REFER TO YOUR OWN COMPANY’S RECIPE MANUAL FOR OVEN

TEMPERATURE SETTINGS.

PLEASE ALSO REFER TO THE BAKING ADVICE ON THE NEXT PAGE

has recovered heat, typically 3-8 minutes depending on the

Do not place the products too close together

. If the loaves are close to

may

collapse on cooling.

Place the product evenly within the oven

. Product bunched together will be

paler than those widely spaced.

Product should not be placed too close to the edge of the tile

. As it by the

door.

Door opening should be kept to a minimum

because cold air enters the

be lighter

you

can alter the front top heat to put more heat at the front.

If the loading takes a long time product can form a skin

, which causes an

before injects

steam to increase the humidity.

If whilst baking, the bake is found to be consistently dark or light at the

the front top element can also be adjusted for local fluctuations in

voltage.

Bake settings

1. A good starting point for baking breads in deck ovens is 437F (225C)

Top heat 60-65 bottom heat 40.

2. For cookies etc the heat in the oven can be turned almost off, however it may

still be necessary to place the trays with cookies etc onto upturned trays on the oven sole.

Steam

should be kept to a minimum, for energy efficiency, depending on the

product and finish.

Times between 9 and 12 seconds should be adequate.

4. It is a good idea not to focus on the temperature recovery this can vary from

oven to oven.

FG257 Adamatic ECOTOUCH MODULAR DECK UL 18/06/2013 RAC

Baking Advice

For the best results from deck Ovens

each other after oven spring (expansion), the loaves sides will be soft and

expands towards the front one side of the loaf may enter the cooler air

oven cooling the sidewalls and roof causing the finished product to locally at the front and wasting heat. If loading times are consistently long

imbalance and a less attractive finish. By using the pre-steam function loading this can be minimised. This function turns the elements off and

front

Below are some tips for modifying the bake so you get the product that you require.

•

If your product is

light on top.

Either decrease the bottom heat and extend bake time or increase the top heat.

•

If the product

sides are pale

and the

top dark.

When the products are spaced well apart drop the top heat and extend the bake.

•

If the bake time is too long.

First increase the top heat to speed recovery. If this does not give sufficient savings increase the bake temperature.

•

To thicken the crust

Set the damper to open longer. Different ovens will require different lengths of time.

Is the product baked in the time and to the quality you require?

FG257 MODULAR DECK UL 08/07 RAC

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