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Memak Rota 507, Installation And User Manual

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4

 

I 

memak.com

INSTALLATION AND 

USER MANUAL 

INTRODUCTION 

       6

   Warning Signs Used 

      

7

   Warranty 

       

 

 

8

   Manufacturer Company  

      

9

   Product Information 

      

9

   Product Definition   

      

10

   Product Operating Principle   

      

10

   Manufacturing Site Design  

      

11

   Product Specifications  

      

12

   Product Dimensions   

      

12 

PRODUCT 

COMMISSIONING 

 

      13

   General Rules on Unpacking the Machine 

    

13

   Load Structure 

 

      

 

  

15

   Product Transport  

       

 

 

15

      General Rules for Lifting and Transporting the Machine 

 

   

15

   Rules on Machine Stocking    

     

17

PRODUCT 

INSTALLATION 

 

 

      18

   Fresh Water Installation 

 

     

20

   Waste Water Installation  

 

     

22

   Fuel Connection Installation (Burner)    

    

24

   Electrical Connection Rules 

      

24

   Shaft Installation Connection  

      

27

   Dismounting and Reassembly  

      

29

CONTROL 

PANEL 

USE 

 

      29

   Pre Heating (Preparation)     

     

30

   Cooking  

       

 

30

   Cooling  

       

 

  

30

   Issues to be Considered During Use 

 

    

30

POINTS TO BE CONSIDERED TO ENABLE THE OVEN TO HAVE LONGLASTING SERVICE LIFE   31
PERSONNEL 

PROTECTIVE 

EQUIPMENT 

 

 

     32

   Safety Systems Controlling 

 

      

 

33

   Waste (Residue) Hazards 

      

33

      Burning Hazard    

      

33

      Solutions  

 

      

 

  

33

Summary of Contents for Rota 507

Page 1: ...INSTALLATION AND USER MANUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I1 ...

Page 2: ...2 I memak com 2 I memak com ...

Page 3: ...INSTALLATION AND USER MANUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I3 STELLA COMBINE FIRIN KURULUM VE KULLANIM KILAVUZU I3 ...

Page 4: ... Lifting and Transporting the Machine 15 Rules on Machine Stocking 17 PRODUCT INSTALLATION 18 Fresh Water Installation 20 Waste Water Installation 22 Fuel Connection Installation Burner 24 Electrical Connection Rules 24 Shaft Installation Connection 27 Dismounting and Reassembly 29 CONTROL PANEL USE 29 Pre Heating Preparation 30 Cooking 30 Cooling 30 Issues to be Considered During Use 30 POINTS TO...

Page 5: ...ing Planning 34 Water Installation Cleaning 35 MAINTENANCE AND SETTING 36 Cooking Period and Temperature Setting 36 Steam Injection Setting 36 Routine Maintenance 36 General Rules 36 Regular Maintenance Procedures 37 Lamp Changing 37 Door Seal Changing 38 Door Glass Changing 39 Door Mechanism Lubricating 41 Reducer Shaft Bearing Lubricating 42 Door Lock Mechanism Lubricating 43 Door Ramp Lubricati...

Page 6: ...ust be maintained along the device service life MEMAK MAKİNA shall not be held responsible for the problems arising from unintended use of the oven Installation instructions must be delivered device s subsequent operators Figure All figures given in this manual are exemplary It may show differences according to the current device The company reserves its rights for technical modifications for deve...

Page 7: ...asic safety requirements Center of Weight Indicates the point where the machine should be lifted Hanger Point Indicates where to attach ropes or chains Warning A hazardous situation it may result in severe injury and death Fire Fire hazard High Voltage Attention Death Risk High Temperature Door glass and its vicinity reach high temperatures when the oven is operating Operating Mechanical Parts Do ...

Page 8: ...mpacts during the oven transportation by the customer Losses due to the insufficiency of all network systems supplying the oven Faults that may occur due to user s neglect of the oven No person other than MEMAK MAKİNE s authorized personnel or authorized services should under any circumstances interfere with the repair and modification of the device Due to the failures in electric motors Due to th...

Page 9: ...0 Selçuklu KONYA TURKEY Telephone 90 332 345 36 16 Fax 90 332 345 36 26 Web www memak com E Mail memak memak com Product Information TYPE Bakery Oven with Rotary Trolley SERIAL ROTA MODEL 507 608 609 810 LABEL INFORMATION 1 Manufacturer company information 2 Machine type 3 Machine weight 4 Machine model 5 Production date 6 Serial number 7 CE mark 8 Operating voltage 9 Operating frequency 10 Operat...

Page 10: ... in terms of easily loading and unloading also for bakery oven with rotary trolley Rotary table is driven with a reducer system installed on the top part of the oven ROTA both for the manufacturing of various types of bread and also most efficient cooking of the pastry products has been designed by using all engineering branches It is designed in different sizes and can meet the needs of small med...

Page 11: ...s used to collect waste products and waste water should be made of easy to clean materials and should have sufficient volume 10 Doors and windows opening out of the plant should be isolated to prevent any outsourced contamination 11 Sufficient ventilation should be ensured in the washing rooms 12 Water and water vapor that come into direct contact with the products should be of drinkable quality 1...

Page 12: ...10 ROTA609 Capacity pieces 8 hours 3000 2400 Cooking Area m2 14 4 8 6 Weight kg 2750 2100 Electricity power kw 4 4 Cooking Temperature C 280 300 280 300 Tray Sizes mm 800x1000 600x900 Number of Trays pieces Max 18 Max 18 Product Dimensions Figure1 ...

Page 13: ...uitability of the machine All operations must be carried out in accordance with the directives of a sole authorized person Operators and people under their command must wear protective clothing in compliance with the operation Manufacturer is not liable for accidents damage and machine failures caused by the failure to comply with the rules in this section General Rules on Unpacking the Machine In...

Page 14: ...14 I memak com Figure2 Figure3 ...

Page 15: ...led Ensure there is no hazardous situation Make sure that the vehicle to carry out the machine s lifting and transport procedure of the machine has sufficient lifting capacity Weights are stamped on the packaging and or are available in this manual Check that the hoisting ropes and chain types are approved and that the capacity instructed by the manufacturer is clearly written on the ropes Check w...

Page 16: ...16 I memak com Transport With Crane Figure4 WARNING Take necessary cautions during transport Start with the lifting procedures after ensuring that hangers are fully installed ...

Page 17: ...RE RECEIVING THE PRODUCT DO NOT TAKE OVER PRODUCT WITH DESTROYED PACKAGE DAMAGED CASE AND BEING CRUSHED AND SCRATCHED MOREOVER INFORM THIS SITUATION IMMEDIATELY TO MANUFACTURER BY TAKING PHOTO AND WITH A BRIEF NOTE Rules for Machine Storage Machine must be stored in indoors away from dust moisture and heat Permissible ambient values for storage are as follows Temperature 5 C to 45 C Maximum moistu...

Page 18: ...mi assembled or unassembled machine If the machine shipped as unassembled or semi assembled the assembly operation must be performed by the personnel authorized by the manufacturer 1 If there is no previous layout designed for the ovens oven shall be suitably placed Figure 7 IMPORTANT Distance between the oven and wall should be at least 500 mm half meter Figure7 ...

Page 19: ...L FOR BAKERY OVEN WITH ROTATING TROLLEY I19 2 It should be investigated if multiple ovens are to be installed Figure 8 Figure8 There are five types of installations in rotary ovens as water fuel electricity and shaft installation ...

Page 20: ...hoses Fresh water installation is brought to the proximity of of the oven by the customer It should be tightened with brackets after installing water inlets Operating pressure is 1 3 bars Figure 9 Figure9 Notes Make the connection with a flexible hose to absorb the pressure from the main switch If necessary install a manually controlled valve in order to instantly shut down the system After using ...

Page 21: ...INSTALLATION AND USER MANUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I21 Figure10 ...

Page 22: ...e operation period of the oven If the condensation amount produced is excessive discharge tip should be connected to here by installing an oil pan NOTE Water to be discharged from the machine arrives to pot depot and again transferred to manhole or discharge drain Figure 11 and Figure 12 Figure11 Figure12 NOTE Water to be discharged from the machine arrives to pot depot and again transferred to ma...

Page 23: ...EN WITH ROTATING TROLLEY I23 Figure13 NOTE Since the average temperature of the discharged water is 70 C and over there should be no live contact For that reason the drain shall be directly connected to the place of discharge Figure 14 Figure14 ...

Page 24: ...r Cables used to connect the electrical panel to the power grid must be approved and must be suitable for operating an installed machine Make sure that the power line is switched off before starting the electrical connection Make sure the cables are in a safe place and that there is no risk of accidents Terminals must be properly fixed so that they do not affect each other and do not damage the in...

Page 25: ...ion ROTA810 ELECTRICAL 3 x 80 A FUSE 1 PIECE REQUIRED 3x2 5 ANTIGRON CABLE NEUTRAL EARTH 1 x 6 CABLE SIZE DEPENDS ON THE DISTANCE WHERE THE OVEN IS TO BE INSTALLED OPERATES WITH 3 PHASE 380 V 50 Hz AVERAGE VOLTAGE DRAWN 65 A IT IS NECESSARY TO DRAW INSTALLATION WITH PVC PIPE TO 2 3 m HEIGHT FROM FLOOR WHERE THE OVEN IS TO BE INSTALLED FOR THE FRESH WATER ENTRY WASTE WATER DRAIN NEED TO BE ON THE G...

Page 26: ...N SHOULD BE ON THE FLOOR AND 1 5 m PROXIMITY OF THE OVEN STEAM SHAFT OUTLET IS 13 cm IT SHOULD BE 1 m PROXIMITY TO PLACE WHERE THE OVEN IS TO BE INSTALLED ROTA 609 NATURAL GAS 3 x 10 FUSE 1 PIECE REQUIRED 5 x 1 5 ANTIGRON CABLE REQUIRED CABLE SIZE DEPENDS ON THE DISTANCE WHERE THE OVEN IS TO BE INSTALLED OPERATES WITH 3 PHASE 380 V 50 Hz DRAWS 7 A POWER PER PHASE IT IS NECESSARY TO DRAW INSTALLATI...

Page 27: ...TER ENTRY WASTE WATER DRAIN SHOULD BE ON THE FLOOR AND 1 5 m PROXIMITY OF THE OVEN BURNER S HEAT CAPACITY IS 60 000 kcall 75 Kw BURNER IN ACCORDANCE WITH ITS CAPACITY SHOULD BE 30 cm HIGH ABOVE THE FLOOR WHERE THE OVEN IS TO BE INSTALLED SHAFT OUTPUT SHALL BE 22 cm DIAMETER DOUBLE WALL 1 m PROXIMITY TO THE PLACE WHERE THE OVEN IS TO BE INSTALLED STEAM SHAFT OUTLET IS 13 cm IT SHOULD BE 1 m PROXIMI...

Page 28: ...28 I memak com Figure17 Figure18 ...

Page 29: ...anufacturer or by the personnel authorized by the manufacturer Before moving the burner containing parts of the oven burner area should be allowed to cool until it is equal to the ambient temperature Burner extraction procedure Switch off the fuel inlet and remove with the lever Disconnect the voltage from the electrical panel Disconnect the burner completely Disconnect the pipes from the burner R...

Page 30: ...hed 9 Pull out the trolley after the rotary tray stops Cooking To prolong the life of the materials on the oven the furnace must be cooled at the end of each shift For cooling procedure 1 Open the door 2 Turn on the cooling 3 Turn off the time button and burner button 4 Wait to reduce oven heat about 100 C 5 Leave the door half open when the oven heat reduces 6 Cut the circuit by turning off the p...

Page 31: ...ng the flame height IMPORTANT Long flame height shortens firing chamber s oven firebox service life and causes fuel wastage Flame height shall be set the authorized service personnel when the oven is first commissioned MEMAK MAKİNA is not responsible for any problems that may arise as a result of unauthorized persons tempering the burner setting 7 To ensure a long service life of the door seal the...

Page 32: ...tor and the steam relief valve before taking out the cooked hot products from the oven This allows the steam in the cooking chamber to be evacuated from the oven in just a second If the aspirator is not running the machine is switched off or broken operator should manually open the drain valve and should wait 3 4 minutes for steam discharge and should take the product out thereafter This symbol me...

Page 33: ...against the oven and especially on the door glass While the oven is running steam is discharged from the shaft system and the anti explosion systems at 350 400 C Therefore never touch these parts Special warning signs should be attached to these areas B The operator must wear protective gloves when removing the tray trolley from the oven After the trolley has been removed the part inside the oven ...

Page 34: ...accumulation or smoke evacuation system over time In case of a malfunction in the gas accumulation or smoke evacuation system the burner automatically equipped with the system to stop the operation must be used in an area where the furnace has adequate ventilation conditions to operate properly In any case the oven must comply with local laws and regulations in force in the country of use GENERAL ...

Page 35: ...t of detergent and moisturized cloth EVERY WEEK Clean area out of foodstuff compartment Wipe with a few amount of detergent and cloth then wash with ample amount of water and dry it Clean door glasses Use hot water or any glass cleaner Clean electronic display part Clean button panel with a neutral detergent EVERY MONTH Check the steam function Use anti scale for water installation connections Wat...

Page 36: ...usted This setting gives the bread a glow volume and shell color Steam time can vary according to the user s requirements Steam can be controlled manually from the control panel by pressing the button on the control panel or if necessary Periodical Maintenance Periodic maintenance can be done easily even by someone with little knowledge about the operati on These are general lubrication and cleani...

Page 37: ...aning of oven rotating racks and trays Cooking compartment lighting Lamp Replacing 12V bulbs used for lighting Keeping the lamps off for a period of time protects the lamps as the inside of the oven will reach very high temperature during use Wait for the bulb to cool down before replacing Handle with a cloth or heat absorbing material when in use Figure 2 Figure 3 and Figure 4 Figure2 Figure3 ...

Page 38: ... are removed and the glass opens The lamp is located behind the sheet on the right side Remove the lamp from the socket connections and replace it with a new lamp Door seal replacing Figure5 Seal is removed from its groove by hanging from corner as seen in the figure Figure 5 ...

Page 39: ...INSTALLATION AND USER MANUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I39 Figure6 Seal placed in the groove by pressing as shown in the picture Figure 6 Door Glass Replacing Figure7 Figure8 ...

Page 40: ... 7 Figure 8 and Figure 9 Figure9 Allen screws on the door top shall be dismantled as seen in the picture Figure 10 Figure10 After the screws are removed the glass is removed from the lower hinge Insert the new glass by applying the same procedure backwards ...

Page 41: ... USER MANUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I41 Door Mechanism Lubricating Figure11 Lubricate with oil cups or grease on door bearings as shown in the picture Figure 11 Rotary Table Bearing Lubrication Figure12 ...

Page 42: ...ws and pull out the bearing Lubricate the rotary table bearing as shown in the figure Figure 12 and Figure 13 Reducer Shaft Bearing Lubricating Figure14 Lubricate the bearings from bearings oil cups under the reducer over the oven as shown in the picture Figure 14 ...

Page 43: ...NUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I43 Door Lock Mechanism Lubrication Figure15 Door opened and lever turned as seen in the picture Figure 15 Figure16 Lubricate locking shafts down and up the door with grease Figure 16 ...

Page 44: ...r Ramp Lubricating Figure17 Figure18 Reach the mechanism is the lower part by lifting the top metal sheet of the ramp in front of the door Lubricate the mechanism shown in the picture with grease Figure 17 and Figure 18 ...

Page 45: ...pen Turn steam discharge valve off If the product is not cooked homogenously Cooking temperature and period is not equal Setting proper cooking temperature and period according to the product Size volume and type of the product cooked are not the same No gaps should be left between trays of the products cooked and same type of product should be cooked Water existence in the oven Faulty solenoid va...

Page 46: ...nning regularly Irregular circulation Check the circulation and remove if there is congestion or parts hindering burner operation Oil flow rate can be insufficient Check burner fuel support circuit and contact with the fuel supplier if necessary Settings and arrangements can be insufficient See burner s user s manual If burner is out of order Burner may leak gas See burner user s manual or seek fo...

Page 47: ...INSTALLATION AND USER MANUAL FOR BAKERY OVEN WITH ROTATING TROLLEY I47 ...

Page 48: ...48 I memak com ...

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