Comtec 2200 Operator's Manual

2200

COMTEC INDUSTRIES, LTD.

Pie and Tart Dough Presses

Model 2200

Operator’s Manual

WARNING

Read and understand operator’s

could result in serious injury.

COMTEC INDUSTRIES, LTD.

Model 2200 Operator’s Manual

manual before using this machine.
Failure to follow operating instructions

 Comtec Industries, Ltd.

10210 Werch Drive, Ste 204

Woodridge, IL 60517

Phone [phone] • Fax [phone]

[e-mail]

www.comtecltd.com

www.comtecltd.com r.03JA13

WARNING

Dangerous Voltages

machines power source.

Crushing Force Warning

areas.

CAUTION

Hot Areas

with these areas.

Read Before Operating This Machine

The following symbols are used on the machine and in this manual. Do not operate the
machine until you understand the meaning of these symbols

Potential lethal voltages and currents are present

Disconnect Power Supply

Before Servicing Machine

within the machine. Service should only be done
by qualified personnel after disconnecting the

WARNING

Serious Physical Injury Possible
Keep All Body Parts Away From

Dies While Pressing

HOT!

This warning is used near moving parts of the
machine that move with sufficient force to crush
or damage body parts. Never operate the
machine when any body parts are inside of these

This warning is on areas of the machine that
have a lot of heat associated with it. Serious
burns may result if personnel come in contact

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Heater Block

Travel Plates

Press Activation Handles

Electric Motor

Hydraulic Cylinder

Hydraulic Reservoir

On/Off Switch

Product Description

The Model 2200 is a hydraulic machine that uses custom dies to form dough. Each size
and type of crust requires a separate, custom die. Dies that form bottom crusts are
manufactured to work with a specific pan, chosen by the customer.
To form a crust, a dough portion is placed in the center of the pan to be used. The pan is
then placed in the lower die half. USING TWO HANDS, ONE HAND ON EACH LEVER,
PRESS BOTH LEVERS to bring the lower die half up against the upper stationary heated
die half.

After a short dwell (for example, 2 seconds) the levers are released, bringing the lower die
half down. The formed crust is then removed from the die. ONLY THE OPERATOR OF

THE HANDLES IS TO LOAD THE PAN WITH DOUGH PORTION INTO, AND REMOVE
THE FINISHED CRUST FROM THE PRESS.

with temperature control

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There are no user serviceable hydraulic components on the Model 2200. Any questions
about the hydraulic should be directed to Comtec or Comtec’s authorized representative.

The Model 2200 does not have a dedicated neutral.

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WARNING

SAFETY FIRST

READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO OPERATE THE PRESS.
COMTEC HAS INSPECTED THIS PRESS. OTHER THAN TRANSIT DAMAGE, NO

MODIFICATION IS NECESSARY.

ONLY OPERATOR OF

PRESS HANDLES IS TO LOAD

AND UNLOAD DIE AREA

THE PRESS OPERATOR MUST USE TWO HANDS (ONE ON EACH HANDLE), TO
CYCLE THE PRESS. UNDER NO CIRCUMSTANCES SHOULD A SECO ND PERS ON
BE INVOLVED IN LOADING OR UNLOADING THE DIE AREA OF THE PRESS.

PRECAUTION SHOULD BE TAKEN TO PREVENT A PRESS OPERATOR FROM
CIRCUMVENTING THE DUAL SAFETY HANDLES.

THE PRESS MUST BE DISCONNECTED FROM ELECTRICAL POWER BEFORE ANY
ELECTRICAL SERVICE IS ATTEMPTED. PLEASE NOTE WARNING LABEL ON TOP
COVER OF PRESS.

ELECTRICAL POWER MUST BE TURNED OFF BEFORE ATTEMPTING TO CHANGE A
DIE.

MISINSTALLATION OF A DIE MAY CAUSE MINOR DAMAGE THAT PREVENTS LOW
PRESSURE SAFETY RETRACTION FORCE FROM FULLY RETRACTING THE
HYDRAULIC RAM. DO NOT OPERATE PRESS IN THI S CONDIT ION. CONTACT
FACTORY FOR RECOMMENDATION.

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IMPORTANT
Hydraulic Oil Specifications
BEFORE OPERATING THIS MACHINE, FILL THE

RESERVOIR WITH EITHER:
FIVE (5) GALLONS (18.9 LI TERS) OF MINERAL

BASE “LIGHT” #32 HYDRAULIC OIL, 150 S.S.U.
VISCOSITY (EQUAL TO 10 WT. ENGINE OIL).

USE ONE OF THE NAME BRANDS (ARCO, ENCO,
STANDARD, SHELL, ETC) EQUAL TO CITGO
PACEMAKER #32.

OR
USE FIVE (5) GALLONS (20 QUARTS/18.9 LITERS)

OF S.A.E. 10 WEIGHT, AUTOMOTIVE ENGI N E OIL,
FOR NON-DETERGENT SERVICE.

THE MOTOR STARTER SWITCH (LOCATED ON
THE MACHINE CROWN COVER) SHOULD BE IN
THE “OFF” POSITION BEFORE PLUGGING THE
MACHINE INTO THE APPROPRIATELY RATED
SINGLE PHASE, AC SERVICE OUTLET.
REFERENCE THE MACHINE’S NAME PLATE
INFORMATION FOR THE APPROP RIATE
ELECTRICAL OPERATING VOLTAGE.

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IMPORTANT SANITATION INFORMATION

Compliance with sanitation specifications requires that the bottom of each Comtec crust
forming machine's base be completely sealed to the surface or structure on which it rests.

To guarantee a smooth, airtight seal between the machine and the mounting surface,
perform the following steps:

1. Thoroughly clean and dry the mounting surface and the bottom of the machine's
base.

2. Remove the four glide feet (one at each corner) from the bottom of the machine.
To remove, twist each glide foot counterclockwise (unscrew it).

3. Use only a clear sealant/adhesive that is completely suitable for use in a food
processing environment; i.e. nonflammable, nonhazardous when fully cured, etc.

IMPORTANT: read and understand the product and material
data safety sheets before handling.

4. Position the machine properly.

5. Apply the sealant around the base of the machine as instructed in the product
information. The applied sealant must prevent foreign matter or fluid from
accumulating underneath the machine.

6. Allow the sealant to dry and cure completely.

7. Wash the sealant.

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GENERAL NOTES

You should be familiar with the following information before setting up and operating the
equipment described in this manual.

1. NO ONE OTHER THAN THE OPERATOR SHOULD LOAD AND UNLOAD THE DIE
AREA DURING PRODUCTION. Hundreds of pounds of force is generated in the Comtec
2200 Press during its upward forming motion. Fingers, hands, or arms should never be
placed in the die area while the motor is running. The Press is equipped with a low force
retraction circuit. This limits the downward force of the Press. This downward force is high
enough to cause injury, but not of the permanent nature that would occur from the
hundreds of pounds of upward force. Also, always disconnect the plug before making any
electrical adjustment or alteration. A double lever, requiring two hands to cycle the Press is
provided. Care should be taken not to modify or allow an employee to devise any method
of circumventing this safety feature.

2. PANS AND DIES.
Be certain the upper and lower die halves match and are for the pan to be used. All
Comtec dies are marked with an identifier of the pan for which they were manufactured.
On upper die halves, the pan identifier is marked on the top surface. On lower die halves,
the pan identifier is marked on the inside horizontal surface. Comtec dies are precision
manufactured to match the pan supplied with your order. Generally speaking, pans, other
than those for which the dies were manufactured, may not be substituted. The pressed
crust may look good, but in most instances, the die halves may be damaged and/or the
crust will bake up with problems.

3. DOUGH FORMULA. The Comtec 2200 does not require a special type of dough. In
most cases, your present formula will work satisfactorily, if you bear in mind the following
points:

A. With the Comtec 2200 Press, you should not be rolling or sheeting your dough,
hence toughening it. A "flaking" additive is not necessary or recommended.

B. A pie or pastry flour should be used.
C. You will not need to dust your dough with flour as in a sheeting or rolling operation.

You will not be reworking scrap trimmings. For these two reasons, it is recommended
that you reduce the amount of water used in you formula to be no more than 25% of
the weight of the flour.

D. Comtec recommends using a cake paddle when mixing your dough. Dough hooks
and similar devices can very easily overwork the dough, resulting in pressing
problems.

In operating the Press, keep these things in mind:

1. Don't use dough that is too cold. The best temperature is about 60 degrees. If it is too
cold, it will prevent the dough from flowing.

2. Proper temperature of the upper die: On some of the richer pie crust formulas, you will
find it better to use less heat.

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IMPORTANT DOUGH MIXING INFORMATION

COMTEC equipment forms crust exactly to size. Dough mixing errors may result in deformed
shells.

BE CAREFUL WHEN USING ALL PURPOSE, BREAD FLOUR (H & R FLOUR), INSTEAD OF
PASTRY FLOUR. Bread flour is stronger-it has more gluten. If bread flour is used, the shortening
should be raised to 75% to 80% of the weight of the flour. Do not rest the dough for more than an
hour. Do not store the dough; use all of it in crust production. If stored, the dough gets stronger
and increases the possibility of crust shrinkage.

BEWARE OF EXCESS WATER IN PIE DOUGH. Pie dough formula for rolled and sheeted crust
include extra water to cope with dusting flour and scrap dough recovery. The Comtec crusts
system includes neither scrap dough recovery nor dusting flour, so excess water leads to tougher
dough and shrinkage problems. Water should be no more than 25% of the weight of the flour. A
typical recipe:

24 lb. Pastry Flour
16 lb. Shortening
6 lb Water
1 lb Sugar
½ lb Salt

PIE DOUGH SHOULD BE "SHORT TIME DOUGH"- BEWARE OF OVERMIXING.
COMTEC RECOMMENDS USING ONE OF THE FOLLOWING TWO MIXING METHODS:

METHOD A:

1. Place 1/2 of the flour in the bottom of the mixer bowl. Add all the shortening, broken into a
number of pieces.

2. Use the cake paddle or flat beater at #1 speed setting on a "Hobart" type mixer. Start the mixer.
Mix until shortening and flour are thoroughly blended smooth. Stop the mixer and add the balance
of the flour. Start the mixer and blend until white of new flour can no longer be seen (15 seconds
max). Stop mixer.

3. Add the water, with the balance of the ingredients (sugar, salt, conditioner, etc. in solution)
directly into the middle of the mixer bowl.

4. Start the mixer and count the turns of the socket or orbiter the paddle is inserted into. Twenty
(20) turns. Stop the mixer, feel dough. If slimy, give an additional 3 to 5 turns. Stop the mixer.

5. Rest the dough mixture on a sheet pan at room temperature for at least one half (1/2) hour.
Additional rest time can be done under refrigeration. Dough is ready when a handful can be
gripped and released cleanly without any sticking to hand.

METHOD B

1. All ingredients at room temperature. Place all the flour in the bottom of the mixer bowl. Salt and
sugar can be worked in at this time or added to the water. Add all the shortening, broken into a
number of pieces.

2. Use a cake paddle at the #1 speed on a "Hobart" type mixer. Start the mixer. Mix until
shortening is broken down to "Streusel" size, just before the mix goes from white to gray in color.
Stop the mixer. Add water as described in Method A, follow steps 3, 4, and 5.

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Table of Contents

Read Before Operating This Machine ii
Product Description iii
SAFETY iv
Hydraulic Oil Specifications v
GENERAL NOTES viii
DOUGH MIXING ix

CHAPTERS
INTRODUCTION 1
INITIAL INSTALLATION 2
INSTALLATION OF DIES 4
Tapped Air System 10
TEMPERATURE ADJUSTMENT OF DIE 11
USING THE MODEL 2200 13
SERVICING THE PRESS 15
TROUBLESHOOTING 19
Electrical Schematic 34
Maintenance Schedule 35

MODEL 2200

T

Figure 1 Front View of Machine

INTRODUCTION

he COMTEC Model 2200 Press forms pie, cheesecake, hors d’oeuvres and
other specialty crusts in round and non-round containers. This Press can
form bottom crusts ranging in size from 1-1/2 inches (38 mm) to 12 inches
(300 mm) diameter; top crusts to 11-5/8 inches (295 mm) diameter. The

quality of the crusts formed with this Press exceeds that obtained with sheeted

methods.

The Model 2200 is a hydraulic machine that uses custom dies to form dough. Each size
and type of crust requires a separate, custom die. Dies that form bottom crusts are
manufactured to work with a specific pan, chosen by the customer.

To form a crust, a dough portion is placed in the
center of the pan to be used. The pan is then
placed in the lower die half. USING TWO

HANDS, ONE HAND ON EACH L EVER, PRESS
BOTH LEVERS

against the upper stationary heated die half.

After a short dwell (for example, 2 seconds) the
levers are released, bringing the lower die half
down. The formed crust is then removed from
the die. ONLY THE OPERATOR OF THE

HANDLES IS TO LOAD THE PAN W ITH DO UGH
PORTION INTO, AND REMOVE THE FINISHED
CRUST FROM THE PRESS

to bring the lower die half up

.

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MODEL 2200

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Figure 2 Removing Fill Cap

INITIAL INSTALLATION

he following procedure should be followed when the COMTEC 2200 Press
is initially installed. The Press has been carefully checked, adjusted and preset
at the factory for optimum performance.

NOTE: Do not run the Press without the required amount of hydraulic oil in the
reservoir-tank. Do not adjust hydraulic system. Adjusting the hydraulic system without
first contacting Comtec may seriously compromise the safe operation of the machine.

BEFORE ATTEMPTING ANY MODIFICATION OF THE PRESS OR DIE, CONTACT
THE FACTORY FOR APPROVAL.

1. Uncrate carefully and inspect for any possible damage that may have occurred in
transit. If you notice any damage to the equipment, immediately report this damage to
the carrier.

2. The CE Marked version of the Model 2200 is shipped without a plug. It is the end
user’s responsibility to attach the appropriate grounded plug that conforms to EN
60309-1 and EN 60309-2. The power plug is the Model 2200’s mains disconnect and
must always be accessible.

3. Position the Press so that it is within six (6) feet (2 meters) of an appropriately rated
single phase, AC service outlet. Reference the machine’s name plate information for
the appropriate electrical operating voltage and amperage. Position the Press so that it
is reasonably level. Arrange the area so that the work can be handled smoothly and
efficiently.

4. Fill the reservoir with five (5) gallons, (20 quarts/18.9
liters), of a light mineral base #32 hydraulic oil
(equivalent-CITGO Pacemaker 32), with a viscosity not

to exceed 150 S.S.U. Remove the fill cap at the left side
of the reservoir and add oil. (See Figure 2).

In an extreme emergency, an SAE 10 weight
automotive engine oil FOR NON-DETERGENT
SERVICE may be substituted. While the machine will

operate using 10 weight oil, it may shorten the
operational life of the machine.

5. Plug the power line of the press into an appropriately
rated outlet. Turn on the machine’s power switch which
is located on the top of the machine.

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MODEL 2200

6. USING TWO HANDS, ONE HAND ON EACH LEVER, push both control levers
down. This will move the travel plate to the full UP position. Remove both hands from
the control levers and travel plate will come down to original position.

7. You should hear no noise except the standard operating sounds of the motor and
hydraulic pump.

8. The travel plates should only stop moving at the top and bottom of the machine’s
cycle.

This completes the initial test of the Model 2200.

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MODEL 2200

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INSTALLATION OF DIES

NEVER INSTALL DIES WITH THE MACHINE TURNED ON AND THE MOTOR
RUNNING !

For single-pressing round dies, follow the installation procedure below (Single-Pressing
Round Die Installation). For non-round and multi-pressing dies, follow the installation

procedure on page 6 (Non-round and Multi-Pressing Die Installation).

Single-Pressing Round Die Installation

he following procedures can be used to install all sizes and types of round
single-pressing dies, and tooling, supplied by COMTEC for your Press. We
will assume the Press does not have a set of dies installed at this time.

1. Switch Power Off. Use the power switch at the control panel on top of the
Press.

CAUTION: MAKE SURE THAT THE POWER TO THE PRESS IS OFF BEFORE
ATTEMPTING TO INSTALL A DIE.

2. Examine your dies. Make sure that both hubs are clean. While both hubs should
be clean, be especially certain that the upper die is clean. If the hub of the upper die
is coated with dough or other foreign material, the die may not heat properly (See
Figure 13).

3. Make sure that the circular hub on the heater assembly and all locating holes on
the rectangular travel plate are clean.

4. Fit the tail of the lower die half into its hole in the center of the rectangular travel
plate. (See Figure 3)

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MODEL 2200

Figure 3 Installing Lower Die Half

5. Turn thumb screw on the right side of the travel plate clockwise to lock the
lower die half in position.

6. Insert pocket of upper die half into hub at heater assembly. Using the supplied
hex head wrench, turn wrench to secure die. The hex head wrench fits into the
opening located in the panel on top of Press. The die must be “snug” but not
overly tight to assure good heat conduction. (See Figure 4)

Figure 4 Installing Upper Die Half

7. Switch Power On.

8. USING TWO HANDS, ONE HAND ON EACH LEVER, push both levers

down simultaneously to bring the travel plate up. Check to see if the dies close
fully. When the dies close fully, the damming ring on the upper die half will move
1/8 inch (3 mm) or more. If the dies do not close fully, bring the travel plate down

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MODEL 2200

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Figure 5 Installing Lower Die Half

(release both levers) and carry out the procedures on page 9 (If The Dies Do Not
Close Fully).

If the dies DO close fully, the installation procedure is done.

Non-round and Multi-Pressing Die Installation

he following procedures can be used to install all sizes and types of non­round and multi-pressing dies, and tooling, supplied by COMTEC for your
Press. We will assume the Press does not have a set of dies installed at this
time.

1. Switch Power Off. Use the power switch at the control panel on top of the
Press.

CAUTION: MAKE SURE THAT THE POWER TO THE PRESS IS OFF BEFORE
ATTEMPTING TO INSTALL A DIE.

2. Examine your dies. Make sure that both hubs are clean. While both hubs should
be clean, be especially certain that the upper die is clean. If the hub of the upper die
is coated with dough or other foreign material, the die may not heat properly (See
Figure 13).

3. Make sure that the circular hub on the heater assembly and all locating holes on
the rectangular travel plate are clean.

4. Feed die alignment bolt through the hole in the bottom of the lower die half.

5. Fit tail of lower die half into travel plate. (See Figure 5)

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MODEL 2200

6. DO NOT turn the thumb screw below the lower die half clockwise to lock die
half in position, yet.

7. Insert pocket of upper die half into hub at heater assembly. Using the supplied
hex head wrench, turn wrench to secure die so that it is approximately aligned with
the lower die half. The hex head wrench fits into the opening located in the panel
on top of Press. The die must be “snug” but not overly tight to assure good heat
conduction. (See Figure 6)

Figure 6 Installing Upper Die Half

8. Thread the die alignment bolt into the corresponding hole on upper die half.
Tighten the die alignment bolt until it is completely threaded into the upper die
half.

9. Switch Power On.

10. USING TWO HANDS, ONE HAND ON EACH LEVER, push both levers
down simultaneously to bring the travel plate up. Repeat 3 or 4 times to allow the
die alignment bolt to align the two die halves. If the lower die half binds on the
alignment bolt, release the press handles immediately and check that the alignment
bolt is not bent and that it is completely seated in the upper die half. Check to see if
the dies close fully. If your die is equipped with a damming ring on the upper die
half, the damming ring on the upper die half will move 1/8 inch (3 mm) or more
when the dies close fully. If the dies do not close fully, bring the travel plate down
(release both levers) and carry out the procedures on page 9 (If The Dies Do Not
Close Fully).

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MODEL 2200

11. If the dies DO close fully, turn thumb screw below the lower die half clockwise
to lock the die half in position. This installation procedure is done.

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MODEL 2200

Travel Plate

Flange Plate

If The Dies Do Not Close Fully.

Carry out the following steps:

1. Switch Power Off

2. Measure the distance from the bottom edge of the rectangular travel
plate which supports the bottom die half (also known as a travel plate) to
the top edge of the flange plate directly below the middle of the travel plate
(See Figure 7). The factory sets this distance to 2-3/4 inches (70 mm). The
distance can be safely reduced to 2-1/4 (57 mm) inches if needed.

3. If the measured distance is less than 2-3/4 inches (70 mm), adjust the
cylinder ram. The cylinder ram is located underneath the rectangular travel
plate. Release tension on lock nut at top of cylinder ram under the travel
plate. Take care to place wrenches only on the wrench-flat on top of ram

and hex surface of lock nut. Rotate hydraulic ram clockwise two full turns;

retighten lock nut.

4. Check Closing of Dies. Repeat this procedure if the dies still do not
close properly.

Figure 7 Model 2200 Press

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MODEL 2200

C

Tapped Air System (optional)

omtec’s “Tapped Air” system is meant to ensure that finished crusts release
properly from the forming die. Not all Comtec dies are equipped with a
tapped air system. Please read your order invoice to see if your die is equipped
with tapped air. Dies equipped with a tapped air system will have a threaded

hole marked “AIR” on the top or side of the upper die half.

In order to use your tapped air system, you will need to connect the upper die half to a
compressed air supply. The air supply can be either an installed air system or a portable
air compressor. The portable air compressor can often be acquired at hardware or
home improvement stores. The compressor must be able to provide a minimum of 20
to 30 psi of pressure.

The threaded “AIR” inlet on the upper die half is threaded to a 1/8 NPT (National
Pipe Thread) standard. Because of the wide variety of compressed air systems, Comtec
only provides the 1/8 NPT fitting that connects to the hole in the die. It is the user’s
responsibility to provide any other fitting necessary to connect the upper die half to the
compressed air supply. Most hardware stores carry fittings that are threaded to the
NPT standard.

Thread one end of the brass fitting into the 1/8 NPT hole. If you have an air
compressor, attach a line from an air compressor to the other end. Set the pressure
regulator to 25 PSI (pounds per square inch), and let it run continuously. There is no
need to cycle the pressure. Once the compressed supply is connected and operating,
you should hear a small amount of air escaping from the air outlet on the center
bottom of the upper die half. This is normal.

Now use the die like any other die from Comtec.

Please Note: Depending on your dough formulation, you made discover that your
finished crusts will release correctly without the tapped air. In this case, you can
disconnect the tapped air system.

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MODEL 2200

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TEMPERATURE ADJUSTMENT

OF DIE

he following steps outline a recommended procedure to set the temperature
of the upper die half. The correct temperature will permit the crust to form
properly with a minimum dwell time and release cleanly from the die. A
temperature setting should be established each time a different size crust is

made, the size of the dough portion is changed, or the dough formula is changed.

The temperature settings are established by a trial-and-error method. Once a setting for
a given size crust and type of dough is obtained, it should be recorded for future
reference. The temperature is set with the 0 to 10 graduated knob at the upper right
side of the Press (See Figure 8). We will assume that the dies to be used have been

installed as indicated in the previous section (Installation of Dies).

1. Switch Power On

2. Set The Temperature Control to 4.

3. Allow Time For Die To Reach Temperature Setting. While the die is heating, the

red light at the control panel will light. After approximately three to ten minutes,

the die should reach the preset temperature and the light will turn off.

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MODEL 2200

Figure 8 Setting Temperature Control

Note: As the pastry crusts are being pressed, the red indicator light will intermittently
turn on and off, as additional heat is required to keep the die at the preset temperature.
As the machine is cycled, the temperature light may turn on intermittently, indicating
the die is heating. This is normal. You do not have to wait until the light turns off, once
the initial heating is completed.

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MODEL 2200

F

USING THE MODEL 2200

or best results:

(1) Keep The Temperature Of The Dough At About 60°F (17°C). Cold dough will
form slower than warm dough, thus you will have to run it at a much slower rate. We
recommend a dough temperature of about 60°F (17°C), or above for best results.

(2) Set Correct Temperature At Upper Die Half. The richness and size of the dough
portion should be considered when establishing the setting. A richer formula will
require less heat.

(3) Use The Correct Pan For The Die. Each die is made for a specific pan. When you
use a different pan, the die may be damaged and/or the crust will have problems when
baked.

Operation

The following steps outline a typical procedure to operate the Model 2200. We will
assume that the Press is in an OFF condition.

(1) Switch Power ON. This applies power to the motor of the hydraulic pump and to
the heater of the upper die.

(2) Check Temperature Setting. A different setting should be established for each type
and size of dough portion. Set the temperature as indicated in the Temperature
Adjustment Of Die section of this manual. When the Press is initially turned ON, the red
light at the upper control panel will light, indicating the die is heating. In about three to
ten minutes, the light will turn off, indicating the desired temperature has been reached.

(3) Place Measured Portion Of Dough In Center Of Pie Pan. Make sure that you are
using the correct pan for the die in use. The weight of the dough portion varies with
the type of shortening (hard fat or whipped) and the amount of liquid used in the
recipe. The correct measured portion of dough is a personal choice that can be
determined by placing some dough in a pan and forming a crust. Insert the narrow end
of a ruler into the bottom and side walls of the formed crust, to measure thickness.
Once the correct thickness is obtained, the pan and dough should be weighed and the
weight of the empty pan subtracted from this measurement. The resulting number will

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MODEL 2200

be the correct weight of dough for the pan. If the shortening is changed, either by
percentage or brand, this procedure has to be repeated.

Best results are obtained when a die is “seasoned”. This can be done during the initial
start-up by placing shortening on a paper towel and rubbing the shortening onto the
surface of a warm die. After a number of crusts are formed, the die will retain a coating
of shortening and as with a good “seasoned” frying pan, will release formed crusts
easily. Immediately at the end of a crust forming operation, the upper punch half of the
die can be removed and submerged in water for 10 - 15 minutes. This cools the die and
prevents a build-up of baked-on crust between the ring and the body of the die; and
will help the die retain its seasoned characteristic.

Periodically, the die can be washed in a mild detergent DO NOT USE ALKALI
DETERGENT OR PROCESS THROUGH A PAN WASHER. After washing, the
die should be re-seasoned with shortening.

(4) Bring rectangular travel plate up. Press both levers to bring travel plate up. Hold to
about a count of two (2) seconds; release both levers to bring the travel plate down. If
the die is at the correct temperature and the timing is correct, the crust will release
cleanly from the die.

(5) Remove formed crust.

(6) Repeat steps three (3) through six (6) to form succeeding crusts. As the machine is
cycled, the temperature light may turn on intermittently, indicating the die is heating.
This is normal. You do not have to wait until the light turns off, once the initial heating
is completed.

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MODEL 2200

SERVICING THE PRESS

UNPLUG/DISCONNECT THE PRESS BEFORE PERFORMING ANY
SERVICE

In the upper control panel of the Press are the indicator light junction box, a fuse for
the heaters, and thermostat circuit. To check or replace the fuse, unscrew the three
screws holding the panel to the machine and lift the panel up. This will expose the
terminal strip and the fuse. (See Figure 9)

Figure 9 Upper Control Panel Removed

The heating elements of the machine can be accessed under the cover on the left hand
side of the heater block (See Figure 10 and Figure 11).

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15

MODEL 2200

CAUTION: HEATING ELEMENTS CAN REACH HIGH TEMPERATURES
DURING USE. ALWAYS ALLOW SUFFICIENT TIME FOR HEATING

ELEMENTS TO COOL DOWN BEFORE ATTEMPTING TO SERVICE

THEM.

Figure 10 Removing Heater Cover

Figure 11 Heater Assembly Removed

If authorized by Comtec, the hydraulic system can be serviced by removing the four
screws in the base cover plate on top of the reservoir. The base cover plate with the
motor, and the upper and lower die assemblies can then be removed from the
reservoir. The base cover plate can be turned upside down and placed on two (2) 1” x
2” wood strips for ease of servicing. (See Figure 12)

Figure 12 Base Cover Removed and Inverted

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16

MODEL 2200

SPECIAL NOTE

Keep the center pocket of the upper die half clean. The die is heated through
conduction in this area. If good metal-to-metal contact is not made, the die will not
heat up. (See Figure 13).

Because Comtec dies do not have heaters within them, they may be submerged in
water immediately at the end of production, as you would any aluminum utensil;
however, do not put die in a dishwasher; do not use alkali-detergent to clean the die.
(See Figure 14)

Figure 13 Upper Die Half with Hub/Pocket

Figure 14 Washing Die

The two levers (handles) are used to directly control the operation of the hydraulic
system. This system is enclosed in a drip-resistant enclosure which also serves as the oil
reservoir (tank). Any leaks which might develop in the system are returned to the
reservoir. This provides a clean, sanitary and trouble-free operation.

The electrical temperature control regulates the heat at the upper die. A red indicating
light shows when the upper die is at the desired operating temperature. The Model
2200 does not use a timer. The time of the dwell at the top of the stroke is judged by
the operator. This time can be slightly varied to meet the operating temperature and
the consistency of the dough. With very little experience, you should be able to quickly
obtain the correct dwell. The crust should separate cleanly from the upper die half.

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17

MODEL 2200

The lower die is bearing guided to the upper die along two sturdy columns. These
columns, the guided bearings and the all-welded frame, provide a sturdy assembly with
a minimum amount of deflection. This assembly with the thermostatically controlled
dies assures uniform and accurately formed crusts.

Damage to the machine’s frame will produce incomplete and/or inconsistent crust
formation. Contact Comtec to evaluate your repair options.

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18

19

TROUBLESHOOTING

This section lists the most common performance symptoms associated with the Model
2200 Press. Locate the symptoms that you are experiencing in the list below and read
the suggested troubleshooting sections for possible solutions. If the solutions listed
here do not solve your problem, contact Comtec for more advanced troubleshooting.

SYMPTOMS

SYMPTOM: Pan and dough are sticking to the die
Possible causes

●Incorrect number or placement of flat springs (see 1.1 below)

●Stripper pins are missing (see 1.2 below)

●Using the wrong pan (see 1.3 below)

●Mismatched upper and lower die halves (see 1.13 below)

SYMPTOM: Only the dough (not the pan) is sticking to the die
Possible causes

●Too much water in the dough (see 1.4 below)

●Dough has been over mixed (see 1.5 below)

●Insufficient heat setting (see 2.2 below)

●Heat failure (see 2.1 below)

SYMPTOM: Bottom crust is pressing unevenly or incompletely
Possible causes

●Upper die half is not tight to the machine (see 1.6 below)

●Insufficient dough portion (see 1.12 below)

●Using the wrong pan (bottom crust) (see 1.3 below)

●Excessive buildup in mating surface between machine and upper die half (see

1.8 below)

●Bottom half of the die is not secured with thumb screw (see 1.7 below)

●Excessive build up between lower die half and travel plate (see 1.9 below)

●Lower travel plate is too low (see 3.1 below)

●Travel plate or bearings are worn (see 3.2 below)

●Machine has been dropped and knocked out of alignment (see 3.3 below)

SYMPTOM: Top crust is pressing unevenly or incompletely
Possible causes

●Upper die half is not tight to the machine (see 1.6 below)

●Excessive buildup in mating surface between machine and upper die half (see

1.8 below)

●Excessive build up between lower die half and travel plate (see 1.9 below)

20

●Lower travel plate is too low (see 3.1 below)

●Top crust forming table not completely secured (see 1.10 below)

●Insufficient dough portion (see 1.12 below)

SYMPTOM: Bottom crust and/or Top crust are pressing thick
Possible causes

●Dough portion is to large (see 1.11 below)

●Lower travel plate is too low (see 3.1 below)

●Pressing dough too long (see 1.14 below)

SYMPTOM: Bottom and/or Top crusts are pressing thin
Possible causes

●Insufficient dough portion (see 1.12 below)

●Using the wrong pan (bottom crust) (see 1.3 below)

SYMPTOM: Machine makes unusual noise only when pressing
Possible causes

●High Pressure valve (see 4.8 below)

●Low Pressure valve (see 4.9 below)

SYMPTOM: Machine makes unusual noise all of the time
Possible causes

●Motor cover rubbing (see 5.1 below)

●Loose screw or component (see 6.1 below)

●Incorrect line voltage supplied to the machine (see 5.3 below)

●Failing motor or pump (see 5.2 below)

SYMPTOM: Motor stalls when pressing
Possible causes

●Incorrect line voltage supplied to the machine (see 5.3 below)

●Motor is failing (see 5.4 below)

●Hydraulic settings have been changed from factory standards (see 4.6 below)

SYMPTOM: The dies won’t heat up
Possible causes

●Insufficient heat setting (see 2.2 below)

●Thermal Reset Switch has tripped (Model 2200’s only) (see 2.4 below)

●Blown fuse (see 5.5 below)

●Failed thermostat (see 5.6 below)

●Failed heating element (see 5.7 below)

SYMPTOM: The dies don’t heat up enough
Possible causes

●Insufficient heat setting (see 2.2 below)

●Thermal Reset Switch has tripped (Model 2200’s only) (see 2.4 below)

21

●Failed heating element (see 5.7 below)

SYMPTOM: The dies get too hot
Possible causes

●Heat turned up too high (see 2.3 below)

●Failed thermostat (see 5.6 below)

●Incorrect line voltage (see 5.3 below)

●Incorrect heating element (see 5.8 below)

SYMPTOM: Oil is leaking down the side of the machine base
Possible causes

●Machine has been moved (see 6.2 below)

●Failed oil tank gasket (see 4.1 below)

SYMPTOM: Oil is leaking from the top middle of the machine
Possible causes

●Failing hydraulic cylinder seal (see 4.2 below)

●Failed seal in directional valve (see 4.7 below)

SYMPTOM: Machine pressing surface moves up, but won’t come back down
Possible causes

●Machine columns dry or dirty (see 3.4 below)

●Failed bearing (see 3.5 below)

●Machine has been dropped and knocked out of alignment (see 3.3 below)

SYMPTOM: Machine pressing surface moves up very slowly
Possible causes

●Broken hydraulic line (see 4.3 below)

●Failed pump (see 4.4 below)

●Failed hydraulic valve (see 4.5 below)

SYMPTOM: Dough doesn’t spread evenly
Possible causes

●Incorrect number or placement of flat springs (see 1.1 below)

●Insufficient dough portion (see 1.12 below)

●Mismatched upper and lower die halves (see 1.13 below)

●Wrong pan (see 1.3 below)

●Dough placed too far off center (see 1.15 below)

●Upper die half is not tight to the machine (see 1.6 below)

●Excessive buildup in mating surface between machine and upper die half (see

1.8 below)

●Bottom half of the die is not secured with thumb screw (see 1.7 below)

●Excessive build up between lower die half and travel plate (see 1.9 below)

●Lower travel plate is too low (see 3.1 below)

●Travel plate or bearings are worn (see 3.2 below)

22

●Machine has been dropped and knocked out of alignment (see 3.3 below)

SYMPTOM: Dough shrinks back after pressing
Possible causes

●Dough has been over mixed (see 1.5 below)

●High gluten flour used (see 1.16 below)

●Too much water in dough (see 1.4 below)

● Lower travel plate is too low (see 3.1 below)

SYMPTOM: Dough shoots/oozes out of the die
Possible causes

●Missing stripper pins (see 1.2 below)

●Incorrect number or placement of flat springs (see 1.1 below)

●Wrong pan (see 1.3 below)

●Mismatched upper and lower die halves (see 1.13 below)

●Dough placed too far off center (see 1.15 below)

SYMPTOM: Air pockets form under dough in pan
Possible causes

●Too much water in the dough (see 1.4 below)

●Too much baking powder in the dough (see 1.17 below)

SYMPTOM: Motor gets excessively hot
Possible causes

●Motor fan cover is rubbing (see 5.1 below)

●Wrong line voltage to the machine (see 5.3 below)

●Motor bearing is failing (see 5.4 below)

23

1. Forming Dies & Doug h

Correct 2-spring location. Springs

Correct 3-spring location. Lower 2 springs are stacked, touching

1.1. Incorrect number or placement of flat springs

The upper half of a bottom crust die set has a series of fasteners, pins, and flat springs
that must be properly configured for successful crust production. Occasionally, the flat
springs and the pins need replacement due to normal wear and tear.

A properly functioning bottom crust die set forms dough to the thickness specified in
the original purchase order. For many of our customers, the specified thickness is 1/8
inch across the bottom, 1/8 inch thick on the sidewall, and 1/8 inch thick on the rim.
If ever in doubt, measure the unbaked dough crust thickness with a small ruler.

Typically, Dies Sets will have locations with two or three flat springs. When there are
only 2 flat springs, they should be stacked vertically and positioned so that they reach
across the ring of the die. Where there are 3 springs, the bottom two springs should be
stacked vertically and extend onto the die’s ring. ONLY the top-most spring should
extend over the stripper pin.

the ring and reaching out over the ring. ONLY the upper spring
is covering the pin.

are stacked, touching the ring and
reaching out over the ring.

In either case, the springs should always be attached to the die so that the bend in the
middle of the spring is the highest point on the spring.

24

CORRECT ORENTATION.

INCORRECT ORIENTATION.
Ends of spring are higher than the bend in the

INCORRECT

Flat Spring Orientation

YES

NO

NO

Signs that a die set is not functioning properly:
(1) Dough leaks from in between the two die halves
(2) The pans are severely distorted or even damaged by the die set
(3) The dough does not form a complete, perfect crust
(4) The pans and dough stick excessively to the die.
(5) The stripper pins will pierce the rim of the pan.

Bend in middle of spring is higher than the ends of
the spring.

middle of the spring.

The ends of the flat springs
should be touching the die

Please consult your operator’s manual for a diagram showing correct flat spring
placement and orientation.

25

Stripper Pin

Flat Spring

1.2. Stripper pins are missing

Most Bottom Crust Die Sets have holes around their edge for round-headed stripper
pins. Proper operation and condition of the stripper pins is essential to proper
operation of your Bottom Crust Die Set. Pins should not be bent and should be
spaced symmetrically around the edge of the die. Only the top-most flat spring should
be positioned on top of each stripper pin.

Missing or bent stripper pins will result in pans sticking to the die.

Contact Comtec to order replacement parts.

1.3. Using the wrong pan

Each Comtec Die Set is custom made for a specific pan and to an individual
customer’s specifications. Comtec stamps the pan identifier on the top of each forming
die. This information will either be in the form of pan model number or pan
dimensions.

Your pressing results will be unpredictable and inconsistent if you use a pan other than
the one that the die was made for. Additionally, using the wrong or deformed pan in a
Comtec Die Set can cause other problems like bent stripper pins, uneven crust
thickness and other die malfunctions.

1.4. Too much water in the dough

Comtec presses will work with most dough formulas. However, especially when
transitioning from making crusts by hand to making them by machine, slight

adjustments may be necessary. For example, too much water in a dough recipe can

26

make the dough excessively sticky and cause forming problems. Typically, Comtec
recommends that the weight of water in your dough recipe not exceed 25% of the
weight of the flour in your recipe. Since water weighs approximately 8 pounds per

gallon, that would mean that we suggest no more than 1 gallon of water for every 32
pounds of flour.

1.5. Dough has been over mixed

Typically, the less that dough is worked, the better it will perform in a Comtec press.

Comtec recommends (1) Mix your dough with a cake paddle rather than a dough
hook. The paddle works the dough less than the hook. (2) Only mix your ingredients

until they are blended. Do not over work the dough.

Symptoms of overworked dough include dough that shrinks back after being pressed
and dough that is excessively sticky.

1.6. Upper die half is not tight to the machine

If the upper half of a Comtec die is loose, your pressing results will be unpredictable
and inconsistent. Do not over tighten the die retaining bolt, but you should not be able
to rotate or “wobble” a die with your hands if it has been properly installed on the
machine. Additionally, good die maintenance involves keeping the mating surfaces
between the top of the forming die and the hub that it connects to clean and free of
any build up.

1.7. Bottom half of the die is not secured with thumb screw

For proper die operation, the lower portion of a Bottom Crust Die Set must be

securely fastened to the rectangular Travel Plate that it rests on. The bottom half of a
forming die is attached to the travel plate by the thumb screw that can be found on the
side of the travel plate, just below the lower die half. If the lower die half is not securely
fastened to the travel plate, pressing results will be inconsistent, uneven and
unpredictable.

1.8. Excessive buildup in mating surface between machine and upper die half

Keep the top of the forming die and the hub that it connects to clean and free of any
build up. This buildup can cause the die to press unevenly, and inhibit heat transfer
between the machine and the forming die, causing sticking problems.

1.9. Excessive build up between lower die half and travel plate

The lower die half should sit level and flat against the rectangular travel plate. Any
damage or build up on the die or travel plate can cause uneven, inconsistent and
unpredictable pressing results.

1.10. Top crust forming table not completely secured

It is important for proper top crust formation that all three screws be used to fasten
the top crust forming table to the rectangular travel plate. One of the screws is the
thumb screw on the side of the travel plate. The other two are underneath the travel
plate and attach vertically to the underside of the top crust forming table base. All

27

screws should be tight and you should not be able to rotate or “wobble” top crust
forming table when it is properly installed. If the top crust forming table is incorrectly
installed, your pressing results will be uneven, inconsistent and unpredictable.

1.11. Dough portion is to large

Your Comtec press is designed to form crusts consistently, without scrap dough. To
prevent scrap dough, your Comtec press will attempt to use all of the dough that is

placed in the pan. Consequently, if you put an excessive weight of dough in a pan, the
machine will press a thicker crust. If you put an extraordinarily large amount of dough

in the pan, it may escape out of the side of the die before the die can close.

In general, variation in dough portions will be much more noticeable in smaller
diameter pans.

1.12. Insufficient dough portion

Too little dough in a pan will result in a thinner crust. It will also cause pressing
problems more easily than too much dough. Symptoms of too little dough include
uneven and inconsistent pressings as well as obvious “thin spots” in the crust.

1.13. Mismatched upper and lower die halves

Comtec stamps all of its Bottom Crust Die Sets with identifying numbers. These
numbers can be found on the top surface of the upper half of the die set and inside the
lower half of the die set. All Bottom Crust Die Sets are made as a matched set and
should only be used as a matched set. Use of mismatched upper and lower die halves is

dangerous and SHOULD NEVER BE DONE as it may result in injury to the

operator as well as possible damage to the die halves and the machine.

1.14. Pressing dough too long

Comtec machines are designed to form crusts in a matter of seconds. The machine
will, however continue to press the dough as long as the operating handles are pressed.

If the handles are pressed for an excessive amount of time, dough will begin to leak out

of the die and the pressed crust will have thin spots.

1.15. Dough placed too far off center

Comtec recommends that dough to be pressed be located roughly in the middle of the
pan. If the dough is located at the edge of the pan, it may leak out of the pan before
the die halves can close. This will result in an incomplete or inconsistent crust
formation.

1.16. High gluten flour used

High gluten flours (bread, pizza, and pasta flours) have strong “shrink back”

tendencies. It is especially important to avoid over mixing dough made with these
flours and to avoid excessive amounts of water in these dough recipes.

28

2. Heating System

3. Pressing System

1.17. Too much baking powder in the dough

Excessive baking powder in dough recipes will produce air pockets in the pressed
dough It is especially important to avoid over mixing dough made with baking powder
and to avoid excessive amounts of water in these dough recipes.

2.1. Heat failure

Heat in a Comtec machine helps formed crusts release cleanly and consistently. If part
of the heating system fails, your dough may stick to the die. In an emergency, you can
cover the dough portions with plastic wrap while pressing to prevent sticking.
Common failure components in the heating system are the thermal overload switch
(Model 2200 only), 10A fuse and the thermostat. Less common failure components are
the individual heating elements.

2.2. Insufficient heat setting

When troubleshooting low heat on a machine always verify that the temperature
control knob is set to a high enough number to apply sufficient heat to the die.

2.3. Heat turned up too high

When troubleshooting too much heat on a die, always first try to lower the heat by
setting the temperature control knob to a lower number.

2.4. Thermal Reset Switch has tripped (Model 2200’s only)

Recent Model 2200’s are equipped with a Thermal Overload Reset Switch. This switch

is located on the underside of the machines top cover, near the ON/OFF switch.

Pressing the button on the Overload switch will reset a switch that has “tripped”

3.1. Lower travel plate is too low

The travel plate is the long rectangular plate that connects to the two support columns
on the machine. The starting position of the travel plate on a Model 1100, or the lower
travel plate on a Model 2200, can be adjusted. It is not uncommon for the starting
position of the travel plate to be lowered, when an extraordinarily deep pan is pressed
in the machine. If the travel plate is lowered too much, it can cause incomplete and
inconsistent crust formation.

To check your travel plate height, measure the distance from the bottom edge of the
travel plate to the top edge of the flange plate which is directly below the middle of the

29

travel plate. On a Model 1100, the factory setting for this distance is typically 2-3/4
inches. On a Model 2200, the factory setting for this distance is typically 2-7/8 inches.
On either machine, this distance can be safely reduced to 2-1/4 inches if needed.
Below 2-1/4 inches, pressing results may become inconsistent.

3.2. Travel plate or bearings are worn

Damage or wear to the rectangular travel plate that spans between the two support
columns on the machine will cause incomplete, inconsistent and unpredictable
pressings. As a rule of thumb, you should not be able to “wobble” the travel plate with
your hands. If it does, chances are that the travel plate bearings are worn or that the
machine columns have been damaged.

3.3. Machine has been dropped and knocked out of alignment

If a machine has been dropped, check for obvious signs of damage. Additionally check
that the top and bottom of each support column meets the machine at a right angle;
that there is no gap between the top or bottom of each column and its mating surface
and that the mating surface of the machine is not “coined” with an impression of the
top or bottom of the column. Finally check that both columns line up over their
complete length when viewed from the front of the machine and that they are not
skewed at an angle.

Bent or damaged support columns are one of the most serious types of damage that a
machine can sustain. Comtec must be contacted to determine if the machine can be
salvaged.

Symptoms of bent or damaged support columns include failure of the travel plate to
move or a travel plate that moves up but not down.

3.4. Machine columns dry or dirty

Comtec recommends that the two support columns be lubricated at least once a
month to maintain proper operation. The shafts can be lubricated with the same oil
that is in the machine’s hydraulic reservoir. Dry shafts or shafts with severe nicks or
scratches will produce inconsistent and unpredictable pressing results.

3.5. Failed bearing

Each travel plate uses 2 bearings to move up and down the support columns. If these
bearings are worn or the support columns are damaged or scratched the machine will
press unevenly and inconsistently. In severe cases, failed bearings will cause the travel
plate to move up, but not come back down on its own. Contact Comtec to see if
replacement bearings are available for your machine.

30

4. Hydraulic System

4.1. Failed oil tank gasket.

Every Comtec press is built with a self-adhesive gasket strip between the top of the oil
reservoir and the underside of the machine’s cover. If this gasket strip is damaged or
wears out, oil will “spill” over the side of the machine every time the machine is
moved. This oil will appear to leak down the sides of the machine. A small amount of
oil leaking down the side of the machine should not affect the machine’s performance.
If this leaking continues to occur, however, it can reduce the level of hydraulic oil in
the machine to a point that will affect machine performance.

4.2. Failing hydraulic cylinder seal.

Oil that leaks from the point where the hydraulic piston comes out of the cover of the

machine is a sign that the hydraulic cylinder seals have failed. Failed hydraulic cylinder

seals will affect machine performance and cause uneven and inconsistent crust
formation. Contact Comtec to see if a cylinder seal repair kit is available for your
machine.

4.3. Broken hydraulic line.

If your Comtec Model 1100 or Model 2200 is pressing incorrectly or inconsistently,
there may be a leak in the hydraulic system under the machine cover. Carefully inspect
the hydraulic tubing for cracks or gaps.

4.4. Failed pump.

Poor pressing performance can be caused by a failed hydraulic pump. A failing pump
can sometime be diagnosed by a dark metallic sediment that continues to appear in the
bottom of the hydraulic reservoir. Contact Comtec to see if a replacement pump is
available for your machine.

4.5. Failed hydraulic valve

When the machine’s hydraulic control valve fails, the machine’s travel plate will not
move when both operating handles are activated. This is not a common problem but
can occur on older machines. Contact Comtec to see if a replacement valve is available
for your machine.

4.6. Hydraulic settings have been changed from factory standards

The hydraulic system on Comtec machines is designed and manufactured to not only

be reliable, durable and safe to use. The hydraulic should NEVER be modified or

adjusted by the customer or maintenance personnel without Comtec’s approval.
Adjusting or modifying the hydraulic system unsafe and will cause inconsistent and
unpredictable functioning of the machine.

4.7. Failed seal in directional valve

31

5. Electrical System

Oil that leaks from the point where the hydraulic piston comes out of the cover of the
machine can also be a sign that the directional valve seal has failed. A failed directional
valve seal will affect machine performance and cause uneven and inconsistent crust
formation. Contact Comtec to see if a seal repair kit is available for your machine.

4.8. High Pressure Valve

An improperly functioning High Pressure Valve will cause a loud “screeching” sound

ONLY when the machine is pressing. There is a brief procedure that can be done in
the field to correct this problem.

(1)Locate the High Pressure Valve
(2)Loosen the lock nut at the base of its “T” handle.
(3)Turn the “T” handle 3 full turns counterclockwise, then turn the “T” handle 3 full
turns clockwise.
(4)Retighten the lock nut at the base of the “T” handle.

In many cases this procedure will resolve a “screeching” High Pressure Valve. If the

problem continues, contact Comtec to see if a replacement valve is available for your
machine.

4.9. Low Pressure Valve

An improperly functioning Low Pressure Valve will cause a loud “honking” sound
ONLY when the machine is pressing. This sound has been described as a “goose in
distress”. There is a brief procedure that can be done in the field to correct this
problem.

(1)Locate the Low Pressure Valve
(2)Loosen the lock nut at the base of its adjustment screw.
(3)Turn the adjustment screw 3 full turns counterclockwise, then turn the adjustment
screw 3 full turns clockwise.
(4)Retighten the lock nut at the base of the adjustment screw.

In many cases this procedure will resolve a “honking” Low Pressure Valve. If the
problem continues, contact Comtec to see if a replacement valve is available for your
machine.

5.1. Motor cover rubbing

The top of the electric motor on Comtec presses is a cover for the motor’s cooling fan.
This is not a load bearing surface. If a heavy weight is rested on top of the fan cover,
the inside of the cover will begin rubbing against the cooling fan. This will produce a
sound that is noticeable when ever the machine is turned on. The wear from the fan

32

blades will also be evident on the underside of the fan cover. To correct this problem,
remove and reattach the cover.

NEVER operate the Comtec Model 1100 or Model 2200 without a cover over the

electric motor’s cooling fan.

5.2. Failing motor or pump

A failing motor bearing or hydraulic pump can cause a constant noise whenever the
machine is turned on. Additionally a failed motor bearing will typically cause the
electric motor to become excessively hot. Contact Comtec to see if a replacement
motor or pump is available for your machine.

5.3. Incorrect line voltage supplied to the machine

The operating voltage of each Comtec machine is stamped on the machine’s
nameplate. It is critical to the safe and proper operation of the machine that it is
supplied with the correct operating voltage. If the voltage is too low, the motor may
stall when pressing. If the voltage is too high, the motor or heating elements on the
machine can overheat.

Have qualified personnel measure the voltage at the outlet that the machine is plugged
into.

5.4. Motor is failing

While it is extremely rare, the electric motor on the press can fail, especially when the

machine has been dropped or poorly maintained. Symptoms of a failing motor can be
a motor that overheats, or a motor that stalls whenever the machine presses. Contact
Comtec to see if a replacement motor is available for your machine.

5.5. Blown fuse

The heating system of both the Model 1100 and the Model 2200 is protected by a 10A
fuse. NEVER operate the machine if this fuse has been bypassed or is missing. If the
dies on your machine don’t heat up, the fuse is the simplest item to check.

5.6. Failed thermostat

The temperature of the forming dies is regulated by a thermostat with a numbered dial.
When the thermostat is operating properly, the red “heating” light at the back of the
machine will turn off when the knob is rotated full counterclockwise. The light will also
turn on when the knob is rotated fully clockwise. If you have already checked the fuse,
and the orange light does not operate as stated above, then you should replace the
thermostat. Additionally, if you cannot rotate the knob, you should replace the
thermostat. Contact Comtec to see if a replacement thermostat is available for your
machine.

5.7. Failed heating element

33

6. Miscellaneous

If the fuse and thermostat(s) are functioning correctly, then the heating elements on
the machine may have failed. Contact Comtec to see if replacement heating elements
are available for your machine.

5.8. Incorrect heating element

If your dies are overheating, shut down your machine and allow the die to cool down.
Once the machine has cooled down, remove the cover from the heating elements and
read the markings on the side of the elements. Model 1100’s that are manufactured for
operation in North America are equipped with heating elements that are marked

“120V, 500W”. Model 1100’s that are manufactured for operation in countries with
220 V electrical systems are marked “240V, 500 W”. Elements for a Model 2200 are
marked “240V, 500W”. NEVER operate your Comtec press with the incorrect heating

elements installed.

6.1. Loose screw or component

If all other sources of noise have been ruled out, check over your machine for loose
screws or components. All screws, bolts and other components should be securely
fastened to the machine.

6.2. Machine has been moved

If the machine has been moved, it is possible that some oil may have spilled over the
side of the oil reservoir. See “Failed oil tank gasket” above.

34

Electrical Schematic

35

Comtec Model 2200 Maintenance Schedule

Lubricate Shaft Columns

Each Month

Replace Thermostat

3 years

Replace Oil reservoir gasket

5 years

Replace Heater Elements

7 years

Replace Hydraulic shaft seals

10 years

Replace Hydraulic Oil

Lifetime

T

Maintenance Schedule

he following steps outline a recommended maintenance schedule for your
Model 2200 Pie and Tart Dough Press. Lifespan of listed components is
based on an average yearly duty cycle of the machine. Actual component
lifespans will be effected by excessive machine use and by poor machine

maintenance.