Belshaw Adamatic Harmony Deck Oven User Manual
MANUAL No. Y-DX-09E
Enter Serial Nos. here
FAN (IF FITTED)
DECK 1
DECK 2
DECK 3
DECK 4
DECK 5
In the event of an enquiry please quote these serial numbers.
Store this document safely and ensure it is available at all times.
Non-availability may affect the service / repair of your machine.
OPERATION AND MAINTENANCE MANUAL
MODULAR DECK OVEN
FG257 MODULAR DECK 02/07 RAC
1
r
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
Failure to adhere to the cleaning and maintenance instructions
detailed in this booklet could affect the warranty of this
machine.
The oven should only be used for baking bread, pastries and cakes
(for other products please contact your oven supplier)
DISPOSAL
Care should be taken when the machine comes to the end of its working
life. All parts should be disposed of in the appropriate place, eithe
recycling or other means as the law permits at the time.
ENGINEERS NOTE
IF THESE NUMBERS APPEAR IN THE TEMPERATURE WINDOW
PLEASE CHECK THE FOLLOWING:
888 – Indicates that the control board is above 80 degrees
Check that the cooling fan entry is not blocked
(oven glove etc)
999 – Indicates a problem with the thermocouple.
Check for connection problems or faulty thermocouple.
MONO FG257 HARMONY MODULAR DECK 01/07 RAC
2
CONTENTS
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 - 9.0 Principles Of Operation
(and baking advice)
Section - 10.0 Operating Instructions
Section - 11.0 Troubleshooting
Section - 12.0 Service Information
Replacing light bulbs
Section - 13.0 Spares Information
THIS SECTION IS FOR ENGINEERS ONLY AND THE CUSTOMER
SHOULD NOT ATTEMPT TO MAKE ALTERATIONS.
Section - 14.0 Electrical Information
Section - 15.0 WARNING and INFORMATION LABELS
FG257 MODULAR DECK 02/07 RAC
3
1.0 INTRODUCTION
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.
x Good looking and totally reliable
Conceived with the no nonsense requirements of both the independent and in-store
baker in mind, and designed to visually please as well as give reliable service for
many years. This oven will more than satisfy the most discerning customer.
x Top quality specification
The external and internal contact surfaces are stainless steel.
Each modular deck is fitted with durable reinforced one-piece tiles, and an increase
in high-grade insulation and high temperature ceramic sealant, makes the oven more
efficient.
The oven comes with a patented integral steaming system, which reduces energy
consumption and the overall size of the oven (no drain required). The system
produces real steam with the advantages of spray steam. Pre-steam is also available
to reduce the affects of long loading times.
No drainage is required.
Supplied with an LED screen. All programmable parameters have separate indicators
for easy programming and extra bake time, if required. An energy saving 7-day timer
is also standard.
The simplified electrical circuits aid reliability with overheat protection (on controllers
and oven) to ensure long life of controllers, all housed in splash-proof electrical
enclosures. The lights are low voltage, sealed from the chamber and easily accessed
from outside the oven.
An “i” button can be used to upgrade firmware without the need of dismantling the
panels.
Fitted with a choice of hinged easy to clean double glazed doors (using low energyloss reflective glass for high visibility) or metal doors, means low energy consumption
and the high kW rating gives good recovery.
(0-100% heating available both top and bottom)
FG257 MODULAR DECK 02/07 RAC
4
2.0 OVERALL DIMENSIONS
ALL DIMENSIONS ARE APPROXIMATE
All ovens……………….H = 80” (2040mm)
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)
MONO FG257 HARMONY MODULAR DECK 01/07 RAC
5
3.0 SPECIFICATIONS
Dimensions in millimetres
25.4mm = 1”
5 DECK OVEN
DECK PLATE HEIGHTS
4 DECK OVEN
DECK PLATE HEIGHTS
3 DECK OVEN
DECK PLATE HEIGHTS
FG257 MODULAR DECK 02/07 RAC
6
FG257 MODULAR DECK 02/07 RAC
FG257 MODULAR DECK 02/07 RAC
7
7
ELECTRICAL LOADINGS:
SUPPLY REQUIRED PER MODULAR DECK: x
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 7.90kW, 22Amp 5.31kW,17Amp 2.7kW, 8.7Amp
OVERLOAD PROTECTION 30AMPS 30AMPS
3 Phase (3 wire + ground), 480V. 60Hz 8.78kW, 12.4Amp 5.86kW,8.2Amp 4.9kW, 7Amp
OVERLOAD PROTECTION 20AMPS 20AMPS
SUPPLY REQUIRED FOR CANOPY: x
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 – 2 tray wide, 3 deck = 1569lbs (711kg)
(Including base frame) – 3 tray wide, 3 deck = 2345lbs (1064kg)
– 1 tray wide, 3 deck = TBA
Weight per oven chamber module – 2 tray wide = 421lbs (191.5kg)
– 3 tray wide = 575lbs (261kg)
– 1 tray wide = TBA
Weight per oven canopy module – 2 tray wide = 31lbs (14kg)
– 3 tray wide = 38lbs (17kg)
– 1 tray wide = TBA
Weight per fan module – 2 tray wide = 62lbs (28kg)
– 3 tray wide = 62lbs (28kg)
– 1 tray wide = TBA
Weight of product (max) per deck – 2 tray wide = 86lbs (39kg)
– 3 tray wide = 131lbs (60kg)
– 1 tray wide = TBA
FG257 MODULAR DECK 02/07 RAC
8
4.0 SAFETY
All maintenance must be made with the oven disconnected from the
power supply and then only by fully trained authorized persons.
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
(Do not leave hot tins on the floor or on tables).
(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
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 other
means as the law permits at the time.
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 (or other
fully trained maintenance contractor) for repairs or maintenance, after isolating
oven from power supply.
The Bakery Manager or the Bakery Supervisor must carry out the above daily safety checks
MONO FG257 HARMONY MODULAR DECK 01/07 RAC
9
5.0 INSTALLATION
GENERAL
A hard smooth level floor is recommended on which to position the oven and
access for maintenance should be considered.
The oven is not designed to be ” built in” so sufficient clearance must be left in
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
placed above the oven to disperse excess steam and heat, which could have
an adverse effect on the bakery ceiling and ambient temperature.
A wall isolator rated at 30Amps must be available in order to completely
x
isolate the oven.
THIS ISOLATOR MUST BE CLEARLY ACCESSIBLE TO THE OVEN OPERATOR
A chain retainer should be fitted, that is shorter than the power cables, to
x
protect them from strain if the oven is moved. (Fit to the wall or floor and the
base, using hole provided in castor fixing corner plates).
x Installation must be made by a trained authorized engineer and all utilities
must be installed by licensed contractors and must conform to all local and
state building codes.
The oven must be “run in” as stated in the initial start up instructions.
ELECTRICAL CONNECTIONS
Each modular deck requires its own power supply.
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 7.90kW, 22Amp 5.31kW,17Amp 2.7kW, 8.7Amp
OVERLOAD PROTECTION 30AMPS 30AMPS
3 Phase (3 wire + ground), 480v. 60Hz 8.78kW, 12.4Amp 5.86kW,8.2Amp 4.9kW, 7Amp
OVERLOAD PROTECTION 20AMPS 20AMPS
SUPPLY REQUIRED FOR CANOPY: x
1 Phase (2 wire + ground), 220v. 60Hz Fused at 6Amps
1 Phase (2 wire + ground), 208v. 60Hz Fused at 6Amps
MONO FG257 HARMONY MODULAR DECK 01/07 RAC
10
IMPORTANT OPERATION
EARTH (GROUND)
STRAPS MUST BE
CONNECTED
BETWEEN EACH
SECTION.
REAR VIEW OF OVEN
PART NUMBER
M158-25-11200
SUPPLIED
FG257 MODULAR DECK 02/07 RAC
11
WATER SUPPLY REQUIREMENTS
The set up procedure on the next page must be followed to
allow the steaming system to function correctly
THIS EQUIPMENT IS TO BE INSTALLED TO COMPLY WITH THE
APPLICABLE FEDERAL, STATE, OR LOCAL PLUMBING CODES
All ovens with steam require a ½” NPT hot or cold water supply at a pressure
of 2 - 3 bar (29 – 44 psi). Located approximately 10” from the right and 4” 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 2-4 grains per gallon
PH range 7.0 to 8.0
Chloride concentration 0 –30 ppm
Consult your water treatment company for proper water filtration system
information.
No drain is required for this oven.
A non-return check-valve is supplied fitted to the water inlet manifold.
MONO FG257 HARMONY MODULAR DECK 01/07 RAC
12
WATER SYSTEM SETUP PROCEDURE
It is imperative that the water delivery to the deck oven is checked for the
steam system to operate correctly
1. Flush out the main feed pipe to be used, until water runs clear and free from debris.
2. Connect main feed to oven.
3. Connect flexible hoses to each deck.
4. Place a container under the test valve.
5. Slowly open test valve fully and with the water flowing check the regulator is set to
0.75 bar. If not adjust using the screw above the valve.
x Never use the oven above this setting
6. When the pressure has stabilised shut the test valve.
REPEAT 4,5 AND 6 AT THE END OF INSTALLATION.
NOTE. DYNAMIC PRESSURE, NOT STATIC, IS BEING MEASURED.
ADJUSTING SCREW
SET TO 0.75 bar
TO OVENS
TEST VALVE
WATER REGULATOR SET UP
LOCATED ON REAR OF OVEN
RESTRICTOR
REGULATOR
FROM SUPPLY
CHECK VALVE
STOP TAP
FILTER
FG257 MODULAR DECK 02/07 RAC
13
Exhaust Connections (IF CANOPY FITTED)
x Ideally an exhaust duct should rise 78” (2 metres) above the bakery roof
protected from wind and birds by a duct protector.
x It should be of a suitable material to take the high temperatures and humidity
expected.
x It should be flexible and easily removable at the oven connection point.
This allows the oven to be moved for cleaning when required.
10” Dia.SPIGOT
CONNECTION POINT
23”
CANOPY
WITH EXTRACTION FAN FITTED
9 ½”
ROOF
13”
10” Dia.SPIGOT
CONNECTION POINT
WITHOUT EXTRACTION FAN FITTED
FG257 MODULAR DECK 02/07 RAC
14
INITIAL START UP
THIS PROCEDURE MUST BE ADHERED TO FOR THE OVEN
WARRANTY TO BE VALID.
In order for the oven to give good reliable service the deck tiles must be initially
brought up to temperature as stated below. After this running in period the oven can
be used as required.
Running in procedure
1. Turn the oven on and note the temperature shown.
(This will be the temperature inside the cooking chamber)
2. The temperature needs to rise to 195deg F over a period of 3 hours.
It must not be allowed to rise by more than 77deg F in an hour or
be allowed to rise above 200deg F.
3. Leave for 3 hours at 195deg F.
4. Take the temperature up to 300deg F for 1 hour.
5. Take the temperature up to 390deg F for 1 hour.
After this procedure the oven can be used as required.
482f
392f
302f
212f
122f
60f
77-104
MAX
77-150
MAX
77-195
MAX
77-195 77-195 77-195
302
77-1392 04 392
302
FG257 MODULAR DECK 02/07 RAC
15
6.0 ISOLATION
WARNING
THE “POWER OFF” BUTTON ON THE FRONT OF THE OVEN DOES NOT
ISOLATE THE POWER SUPPLY.
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
EMERGENCY SWITCH OFF AT THE
MAIN WALL ISOLATOR
MONO FG257 HARMONY MODULAR DECK 01/07 RAC
16
Loading...