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Maintenance

Operating Instructions - Dedy Chocolate Enrobing Machine 220 mm and 320 mm

7. Maintenance

7.1. Safety information relating to maintenance

Servicing and maintenance work on the system may only be carried out by
specialists with the required quali

cations and training. The power supply must

be disconnected and measures taken to prevent accidental restart.
The skilled experts at Dedy are also available for major maintenance and repair
work.

DANGER!

Risk of explosion when using benzine
Benzine is highly in

ammable, susceptible to static charge and is

conducive to the formation of explosive mixtures of vapour and air.
Do not use benzine to clean the machine.

7.2. Servicing and maintenance

The Dedy chocolate enrobing machine requires virtually no maintenance.
Any necessary servicing work must be carried out by duly quali

ed persons

in accordance with the German health and safety ordinance (BetrSichV). The
manufacturer recommends the service intervals speci

ed in the maintenance

schedule.

•

Always set the main switch to “OFF” before servicing work.

•

Make certain that there is no energy stored in the machine which can lead to
inadvertent movements.

•

Carry out the servicing work in accordance with the maintenance schedule.

•

If safety devices have been removed (hood):
Re

t the safety devices and have them checked by a professional before put-

ting the machine into operation to ensure that they are working correctly.

•

Put the machine back into operation (section 5.4).

7.3. Servicing and maintenance schedule

Interval

Maintenance work

Personnel

Before initial use

Check the mesh conveyor
for freedom of movement

Operator

After every rinse cycle

Spray the mesh conveyor
with the food grade
lubricant supplied with the
machine

Operator

Spray the chains behind
the cover with the food
grade lubricant supplied
with the machine

Operator

Every 2 years

Check the bath lining for
leaks (visual check)

Operator

Every 4 years

Check the machine elec-
trics in accordance with
German accident preven-
tion regulation BGV A3

Quali

ed staff deployed by

owner

Содержание 220

Страница 1: ...Operating Instructions Dedy enrobing machine 220 mm 320 and ...

Страница 2: ...11 Environmental protection 9 3 Build and function 10 3 1 Scope of delivery 10 3 2 Optional accessories 10 3 3 Build and function of the Dedy chocolate enrobing machine 10 4 Transport and storage 13 4 1 Safety information for transport and storage 13 4 2 Machine transport 13 4 3 Machine storage 13 4 4 Coating storage 13 5 Assembly and initial use 14 5 1 Safety information for assembly and initial ...

Страница 3: ...ing and disposal 35 9 1 Safety information relating to dismantling 35 9 2 Dismantling 35 9 3 Disposal 35 10 Technical data 36 10 1 Dedy chocolate enrobing machine specifications 36 10 2 Dimensions 36 10 3 Replacement parts 38 10 4 List of replacement parts for Dedy enrobing machines 38 11 Appendix 42 11 1 Declaration of conformity 42 11 2 Information on the processing of chocolate 43 11 3 Document...

Страница 4: ...signal words at the beginning of the safety notice express the level of risk DANGER This combination of symbol and signal word indicates a situation that constitutes an imminent danger of death or serious injury if it is not avoided WARNING This combination of symbol and signal word indicates a situation that constitutes a possible danger of death or serious injury if it is not avoided CAUTION Thi...

Страница 5: ...construction of the machine Machinery Directive 2006 42 EC Amendment 91 368 EEC Second Amendment 93 44 EEC The following standards trade association regulations BGV trade association rules BGR trade association information BGI and further rules were consulted for the machine risk assessment DIN EN ISO 12100 1 2 DIN prEN ISO 12100 DIN EN ISO 14121 1 DIN EN 349 DIN EN 614 1 DIN EN 894 1 DIN EN 953 D...

Страница 6: ...the machine The manufacturer shall not accept liability for damage resulting from improper modifications to the machine 2 3 Risks from electric energy Note the voltage and current ratings when installing the machine see technical specifications Work on the electric drive or control unit may only be carried out by qualified electricians Always unplug the mains plug before starting maintenance work ...

Страница 7: ...kills The personnel who work on the machine must be duly authorised and be capable of the following carrying out the jobs safely and independently or carrying out the work after prior instruction under the supervision of an au thorised person 2 7 Safety devices The machine is fitted with various safety devices and thus meets the require ments laid down in the relevant directives and standards The ...

Страница 8: ...the enrobing machine Fig 2 Type plate example Sign warning of dangerous high voltages at the relevant danger points Fig 3 Danger high voltage Sign warning of hot surfaces at the relevant danger points Fig 4 Danger hot surface Sign warning of entanglement hazard at the relevant danger points Fig 5 Danger risk of entanglement Damaged or detached warning and information signs must be replaced promptl...

Страница 9: ...antee the operational reliability of the machine Before carrying out repairs and servicing work take measures to prevent unau thorised accidental or unexpected starting of the machine and to prevent the onset of hazardous movements as a result of stored energy 2 11 Environmental protection When carrying out servicing and repair work always observe the applicable environmental protection regulation...

Страница 10: ...er truffle tables Vibrating tables Special mesh conveyors for gingerbread Delivery table with dedicated drive unit and photo eye 1 5 m Heating cabinets Cooling tunnel 3 3 Build and function of the Dedy chocolate enrobing machine Build The mobile Dedy chocolate enrobing machine is made entirely of stainless steel It can be supplied in various belt widths The standard capacity of approx 20 kg or 30 ...

Страница 11: ...ove and replace Fig 6 8 6 3 4 11 10 9 5 2 1 2 5 6 7 8 9 10 12 13 11 Diagram of chocolate enrobing machine 1 Base frame with castors 2 Feeding conveyor 3 Mesh conveyor 4 Immersion bath 5 Chocolate wheel 6 Chocolate spout 7 Curtain box 8 Fan 9 Hood heating unit 2 10 Heated chocolate baths in base cabinet 11 Evener cylinder 12 Rubber belt for evener cylinder 13 Hood ...

Страница 12: ... chocolate wheel carries the coating e g chocolate from the chocolate bath over the chocolate spout into the curtain box and coats the products from above If the bridge is used the chocolate is routed via the bridge into a bath fitted in the mesh conveyor so that the products are not coated with chocolate from above If the products are also to be coated on the base and or on the sides they are the...

Страница 13: ... 185 kg including base cabinet The machine is assembled at the place of installation 4 3 Machine storage The machine must be stored under the following conditions Temperature 15 to 60 C Relative humidity max 80 4 4 Coating storage The room temperature should not be above 22 C The optimum room temper ature for working with the chocolate is between 20 C and 22 C The air humidity should not be above ...

Страница 14: ...ied out by qualified electricians ATTENTION Operate the machine only within the specified temperature range 0 C 60 C 5 2 Assembly The machine is delivered in several packing units Screw the four castors under the enrobing machine and set the machine up right Fit the rear panel on the machine and secure in place with the VDE keys pro vided Adjust the castors to set the correct working surface heigh...

Страница 15: ...r cable into a 230 V earthed Schuko socket All the switches must be set to 0 or Off Plug in the heating unit connector at the mesh conveyor discharge Set the main switch to ON Press the RESET button above the EMERGENCY OFF button Check the EMERGENCY OFF button The machine can only be switched on when the EMERGENCY OFF button is unlocked The machine is now ready for operation ...

Страница 16: ...h hot surfaces Do not touch hot surfaces CAUTION Risk of entanglement Do not reach into the machine between its moving parts while the machine is running ATTENTION Risk of damage to the machine Always check that the mesh conveyor is running freely before starting the machine Staff are to be selected by the managers and trained in the safe use of the machine Staff training Do not remove guards and ...

Страница 17: ...ller Hood heating unit 4 Switch Chocolate wheel off on 5 Potentiometer Chocolate wheel speed 6 Switch Mesh conveyor off on 7 Potentiometer Mesh conveyor speed 8 Switch Fan off on 9 Potentiometer Fan speed continuously variable 10 Switch Evener cylinder E cylinder left 0 off right 11 Potentiometer Evener cylinder E cylinder speed 12 Main switch 13 Reset button to acknowledge faults 14 EMERGENCY OFF...

Страница 18: ...oupling is free Insert the VDE key provided Fig 10 into the casing and turn it If the key can be turned easily the mesh conveyor is moving freely Take the key out again push the mesh conveyor in and tighten the two knurled screws Fig 8 Undo knurled screws on mesh conveyor Fig 9 Pull out mesh conveyor and check coupling Fig 10 Insert special key and check mesh conveyor is moving freely Connect the ...

Страница 19: ...setting the Standby Operation switch Fig 7 No 2 to Standby and set the left hand control standby 1 to a temperature setting of approx 45 C The heating and fan will now operate until the temperature setting is reached Preheat the chocolate baths in the base cabinet where applicable by press ing the button Fig 11 No 1 and set the control 3 to the required tem perature e g 45 C The heating cycle in t...

Страница 20: ...ector Fig 7 No 16 Remove the rubber belt from the evener cylinder Fig 6 No 12 Take out the mesh conveyor Fill the machine with warm chocolate 45 50 C Make sure that the drain valve is closed during this process Fig 20 Fit the mesh conveyor fix it in place with the knurled screws and connect the heating unit connector Temper the chocolate see separate instructions Close the hood Fig 12 Fig 12 1 1 C...

Страница 21: ...ings Do this by adding approx 1 to 5 solid pieces of chocolate at room temperature This will cause the warm chocolate to cool more quickly and with pre crystal lised chocolate the end result will be a reproduction of the desired crystalline form Again these are only guidelines The ideal mixture will depend on the room temperature and the quality of the chocolate The machine now mixes the solid cho...

Страница 22: ...r switch Fig 7 No 6 to the ON position Start the chocolate wheel by setting the Chocolate wheel switch 4 to ON Select a low speed on the Chocolate wheel potentiometer 5 and increase it slowly in order to prevent the chocolate from spilling over the curtain box bridge The chocolate will now flow into the open curtain box bridge and the products will be coated with chocolate and the chocolate will b...

Страница 23: ...n order to close any pockets which may form in the chocolate coating especially on the edges or tips or when handling very large products Set the Fan switch Fig 7 No 8 to the ON position Use the Fan potentiometer 9 to regulate the fan output and therefore the thickness of the chocolate coating on the product Fig 14 1 2 Curtain box with front baffle plate open Use the shaker Fig 15 No 1 to smooth o...

Страница 24: ... off the bottom The exact setting of the evener cylinder always depends on the product Set the speed on the Evener cylinder potentiometer 11 Base and edge coating Place the perforated sheet for the base coating under the mesh conveyor Fig 16 No 1 Fig 16 1 1 Inserting the perforated sheet Place the bridge with the overflow to the chocolate wheel on the mesh conveyor under the chocolate spout Fig 13...

Страница 25: ...e Evener cylinder switch Fig 7 No 10 to the LEFT or RIGHT position We recommend the RIGHT position in the direction of travel of the mesh conveyor The cylinder should be a little lower than the mesh conveyor and also a little lower than the discharge belt otherwise the chocolate coating will be completely wiped off the bottom The exact setting of the evener cylinder always depends on the product S...

Страница 26: ... hold the paper down in order to prevent it from slipping back 3 Fig 19 Move the weight 4 Fig 19 shortly before the coated products have reached the evener cylinder Cut the paper holding the coated products into lengths of 50 to 60 cm and pull the strips of paper with the coated products onto the lift off plate The flow of paper can be quickly stopped by engaging the catch 5 Fig 19 The offload bel...

Страница 27: ... dull patches can appear on the surface of the chocolate and the desired sheen is not achieved However the moulds must never be hotter than the chocolate Temper the chocolate see separate instructions Start the chocolate wheel by setting the Chocolate wheel switch Fig 7 No 4 to ON Select a low speed setting on the Chocolate wheel potentiometer 5 Hold the moulds under the chocolate spout Fig 20 Fil...

Страница 28: ...he Fan potentiometer 9 selecting the maximum setting in order to blow the chocolate off the mesh conveyor into the bath Open the base gate Fig 17 in the mesh conveyor Remove the chocolate spout Fig 6 No 6 Switch off the fan Fig 7 No 8 and mesh conveyor 6 Remove the curtain box Fig 13 No 1 or bridge 2 Place a bowl under the outlet valve Fig 21 open the valve and allow the chocolate to drain Any cho...

Страница 29: ...e washed in situ with hot water ATTENTION Risk of damage to the machine Do not forget to remove the heating unit at the mesh conveyor discharge Fig 23 No 1 before washing the mesh conveyor Fig 23 1 Heating unit by the mesh conveyor Resetting the machine After a power cut or disconnection from the mains power supply set all the switches to 0 with the exception of the main switch and the EMERGENCY O...

Страница 30: ...ect it from the mains and take measures to prevent restart Finishing the coating work without draining the chocolate Switch the chocolate wheel off by setting the Chocolate wheel switch Fig 7 No 4 to OFF Give the mesh conveyor a preliminary clean several minutes of shaking and blowing Open the base gate Fig 17 in the mesh conveyor Set the Mesh conveyor switch Fig 7 No 6 to the OFF position Give th...

Страница 31: ...ufacturer recommends the service intervals specified in the maintenance schedule Always set the main switch to OFF before servicing work Make certain that there is no energy stored in the machine which can lead to inadvertent movements Carry out the servicing work in accordance with the maintenance schedule If safety devices have been removed hood Refit the safety devices and have them checked by ...

Страница 32: ...rgent Then wipe it down with a soft cloth Note We recommend cleaning the machine when it is warm In this case you will only need warm water You can also wash all the stainless steel parts curtain box bridge spout and mesh conveyor in a suitable dishwasher Always verify the following after cleaning and before use the machine bath is completely dry the drain valve is closed the mesh conveyor is dry ...

Страница 33: ...31 The table below is a general guide to the most frequent malfunctions and how to remedy them Malfunction Cause Remedy Machine cannot be switched on EMERGENCY OFF switch has been pressed Turn the EMERGENCY OFF knob pull the knob on older models until the switch jumps to its initial position and a yellow ring is visible One or more controls on the control panel are switched on Set all the controls...

Страница 34: ...ber belt Motor defective Replace motor Control unit defective Replace control unit Base cabinet is not heating up is overheating Heating unit defective Replace heating unit Thermostat defective Replace thermostat Temperature sensor defective Replace temperature sensor Thermostat is reporting a fault Temperature sensor defective Replace temperature sensor No chocolate bath Base gate is not closed C...

Страница 35: ...machine must be dismantled and disposed of in compliance with environmental regulations Remove all coating residues from the machine Disconnect all mains supply connections before dismantling the enrobing machine Remove all the attachments first e g curtain box or bridge mesh conveyor and chocolate wheel The machine can then be completely dismantled 9 3 Disposal If no arrangements have been made f...

Страница 36: ... in the baths 90 2 x 30 in the baths Belt speed continuously variable m min 0 5 to 4 Weight kg 145 5 Weight with chocolate baths kg 185 Maximum noise emission Standby In operation dB A dB A 60 5 75 6 Connection data Electrical connection V Hz 230 50 60 Mains L1 N PE Maximum current consumption A 16 Electric power consumption Electric power consumption with chocolate baths kW kW 2 0 2 5 Operating c...

Страница 37: ...Technical data 37 Operating Instructions Dedy Chocolate Enrobing Machine 220 mm and 320 mm Fig 24 250 900 1000 1380 1280 660 1050 A B Dedy chocolate enrobing machine dimensions ...

Страница 38: ...Nirosta stainless steel 4301 4 Adjusting rod Nirosta stainless steel 4301 1 Self locking cap nuts M5 stainless steel Nirosta DIN986 AZ 1 Rail Nirosta stainless steel 4301 1 Pipe elbow 90 ø 38 Nirosta stainless steel 1 Fan hose food safe AIRDUC PUR VA 351 MHF ø 38 approx 40 cm 1 Clamping lever s w GN 300 63M8 sw Heating unit assembly 1 Heating cross joint complete 230 V 750 W 1 Pipe elbow 3 S 98 WS...

Страница 39: ...eter 23 96 mm length 54 mm bore size 12 mm with notch without set screw 320 gear rings Number of teeth 14 width 48 mm outer diameter 27 96 mm bore size 12 mm Tooth depth 2 0 mm tip notched type in acc with DIN 6885 with M6 set screw tooth form 60 degrees 2 2 m Wire conveyor 220 mm Nirosta stainless steel 2 2 m Wire conveyor 320 mm Nirosta stainless steel 1 Wire conveyor coupling complete 2 Chain w...

Страница 40: ... with hub Nirosta stainless steel 1 Adapter sleeve Nirosta stainless steel 1 Feather key form A width 6 length 28 Nirosta stainless steel for the gear shaft 1 Feather key with indent Evener cylinder assembly 1 Oriental motor with control 41K25RA CWE 1 Control unit ES02 1 E cylinder 3 mm 220 mm 345 mm 320 mm 445 mm with drive gear 2 E cylinder drive belt 88x3 5 NBR 70 1 POM drive gear motor shaft 1...

Страница 41: ...for E cylinder 5 Selector switch 1 Main switch 1 EMERGENCY OFF switch 1 Reset switch 1 Red LED 1 Fan 1 Connector complete for heating 1 Schuko plug socket right side 1 Power cable 1 m discharge path assembly for 220 model Drive roll Ø 20 27 x 255 mm rubberised food grade beige cambered Discharge belt 1989 x 220 Nirosta stainless steel sheet Pipe 25 x 25 Feet M50 10 100 Gear wheel module 1 5 40 tee...

Страница 42: ...breite Baujahr 2019 Zum Überziehen von Produkten mit Schokolade Hersteller Dedy GmbH Frankenstraße 152 45134 Essen Tel 0201 471031 Fax 0201 440123 E Mail info dedy de Internet www dedy de Angewandte Normen DIN EN ISO 12100 1 und 2 DIN prEN ISO 12100 DIN EN ISO 14121 1 DIN EN 349 DIN EN 614 1 DIN EN 894 1 DIN EN 953 DIN EN 982 DIN EN 1037 DIN EN ISO 1127 1 DIN EN ISO 11688 DIN EN ISO 11690 DIN EN I...

Страница 43: ... several structures with different melting points Therefore the chocolate needs to be melted first at a temperature of approx 45 C guaranteeing that all the fat structures are liquefied and that there are no more crystals The following temperatures are a guide when melting the chocolate in this first instance Dark chocolate approx 45 to max 50 C Milk chocolate approx 42 to max 45 C White chocolate...

Страница 44: ...ioned if possible and offer the facility to cool the coating with a light jet of air Correctly tempered chocolate starts to solidify after two minutes Check this by taking a sample of chocolate with a plastic scraper wait 2 minutes and see whether the chocolate starts to set and whether it has an even consistency Under the cooling conditions prescribed above it will be completely set after 5 7 min...

Страница 45: ...0 mm 11 3 Documentation for outsourced products We have included plenty of useful information from our suppliers in your documentation pack in order to give you as much information as possible about your Dedy machine You will find this information at the back of the Dedy documents ...

Страница 46: ...46 Operating Instructions Dedy Chocolate Enrobing Machine 220 mm and 320 mm ...

Страница 47: ...47 Operating Instructions Dedy Chocolate Enrobing Machine 220 mm and 320 mm ...

Страница 48: ...Last revised 10 2015 Dedy GmbH Confectionery machines Chocolate enrobing machines www dedy de Frankenstr 152 D 45134 Essen Tel 49 0 201 47 10 31 Fax 49 0 201 44 01 23 email info dedy de ...

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