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    Operating instructions and maintenance, spare parts catalogue, electric parts and wiring diagrams

    INSTRUCTIONS FOR USE

    TUNNEL BAKING OVENType TP

    Issue 01; valid until 1 June 2006This document is property of Gostol-Gopan d.o.o..The usage in not agreed purposes is not permitted!

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    1.1. Technological data:- Baking time normally from 15 to 60 min or according to your wish

    - Baking temperature up to 300

    C- Temperature regulation by thermostat or automatically

    - Adjustment of temperature diagram manually with valves- Evaporation manual adjustment- Vapour consumption up to 5 kg/m2/h

    1.2. Technical data

    SINGLE-CUPOLA BAKING OVENOven Useful dimensions Outer dimensionstype Surface Width

    ALengthB

    LengthC

    WidthD

    HeightE

    Vapour consumption

    Electricconnection

    TP m2 M m mm mm mm kg/m2h kW1,8x15 27 1,8 15 17800 2900 3225 8,62,1x12 25,2 2,1 12 14850 3134 3315 8,62,1x15 31,5 2,1 15 17850 3134 3315 8,62,1x18 37,8 2,1 18 20850 3134 3315 10,62,1x21 44,1 2,1 21 23850 3134 3315 14,62,5x12 30,0 2,5 12 14850 3534 3215 5kg/m2h 8,62,5x15 37,5 2,5 15 17850 3534 3215 8,62,5x18 45,0 2,5 18 20850 3534 3215 10,62,5x21 52,5 2,5 21 23850 3534 3215 14,73,0x12 36,0 3,0 12 14850 4034 3215 10,6

    3,0x15 45,0 3,0 15 17850 4034 3215 10,63,0x18 54,0 3,0 18 20850 4034 3215 14,73,0x21 63,0 3,0 21 23850 4034 3215 14,7

    BURNERS FOR NATURAL GAS Z Hu=32,68 MJ m3Burner power kW

    N. of burners Totalconsumptionm3

    Working pressurembar

    311 35,00389 43,00468 52,00545 60,00370 41,00463 1 51,00 22556 62,00648 72,00444 49,00556 62,00667 74,00778 86,00

    ___________________________________________________________________________ TP 2

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    TWO-KUPOLA BAKING OVENSOven Useful dimensions Outer dimensions

    type Surface WidthA

    LengthB

    LengthC

    WidthD

    HeightE

    Vapour consumption

    Electricconnection

    TP m2 M m mm mm Mm kg/m2h kW2,1x24 50,4 2,1 24 26850 3134 3315 13,42,1x27 56,7 2,1 27 29850 3134 3315 18,92,1x30 63,0 2,1 30 32850 3134 3315 18,92,1x33 69,3 2,1 33 35850 3134 3315 19,72,5x24 60,0 2,5 24 26950 3534 3215 5kg/m2h 15,72,5x27 67,5 2,5 27 29850 3534 3215 17,72,5x30 75,0 2,5 30 32950 3534 3215 21,22,5x33 82,5 2,5 33 35950 3534 3215 22,53,0x24 72,0 3,0 24 26950 4034 3215 17,73,0x27 81,0 3,0 27 29950 4034 3215 21,2

    3,0x30 90,0 3,0 30 32950 4034 3215 21,23,0x33 99,0 3,0 33 35950 4034 3215 22,53,0x36 108,0 3,0 36 38950 4043 3215 22,5

    BURNERS FOR NATURAL GAS Z Hu=32,68 MJ m3Burner power kW

    No. of burners Totalconsumptionm3

    Working pressurembar

    311 69,00350 78,00389 86,00428 95,00371 82,00417 2 92,00 22463 102,00509 119,00445 98,00500 110,00556 123,00612 135,00630 141,1

    1.3. Drawing

    1.4. Machine variants and optionsThese instructions refer to all TP ovens. They were written for left of right-sided ovens. Inleft-sided oven there are all controls on the left side, except levers of pos. 16 which are alwayson the right side when leaving the baking tunnel oven open.

    ___________________________________________________________________________ TP 3

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    Operating instructions and maintenance, spare parts catalogue, electric parts and wiring diagrams

    Drawing No2.3 TP-1K

    ___________________________________________________________________________ TP 4

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    Drawing No2.3 TP-2K

    Detail A

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    2.0. MACHINE DESCRIPTION

    2.1. Main component partsThe baking oven consists of a baking part (tunnel), combustion unit with a burner, distributingand return channels with explosion safe flaps and a fan, and of a driving unit with conveyor

    belt. All the key elements necessary for bread baking and regulation of the tunnel baking ovenare all installed in the above stated units.All the materials used for the above units of the tunnel baking oven have been chosencarefully, and thus a long life-period of each single baking oven element is ensured.At the special request of the purchaser it is possible to build in even extra quality materialsenabling bread baking up to the temperature of 350 C (for rye bread).The baking oven construction allows the building-in of a light oil burner (up to 7, 41 cSt/20 C or 1,6 E/20 ), a medium heavy oil burner (up to maximally 37,4 c St/100 or 5E/100 ) or a gas burner. It is also possible to mount combined burners (gas-light oil).

    2.2. ApplicationThe tunnel baking oven is designed for continuous type of baking all kinds of bread and rolls,which can be baked at temperatures up to 320 C. This baking oven is designed above all for larger bakeries in which the working process is completely automated.

    2.3. Operating principleThe dough is transported on a conveyor belt (wire mesh) through the baking oven made in theshape of a tunnel. In this way the dough travels through different heat sections in which the

    baking process is performed. When leaving the tunnel baking oven, the bread is fully baked.The baking room (tunnel) is made in such a way that the hot air travels along the upper andlower sides of the tunnel. By special regulating flaps it is possible to adjust at will the inflow

    of hot air in the lower and upper sides of the baking tunnel. The whole system of heating is based on under pressure assuring in this way a complete security against hot flue gases penetrating into the baking tunnel. The oven has in-built biterm system ensuring baking inslightly movable atmosphere.

    3.0. SAFETY MEASURES

    Baking tunnel oven was designed and constructed by taking into account the technicalcondition of the oven as well as adequate regulations, but when working with the ovenand during maintenance work there are, however, still dangers present.

    3.1 General warningsBefore the application of oven, the staff running, working near, cleaning and maintaining it,must carefully read and understand the instructions for furnace application.

    1.2.

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    Operating instructions and maintenance, spare parts catalogue, electric parts and wiring diagrams

    No5.2 TP-1K

    ___________________________________________________________________________ TP 7

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    Drawing No5.2 TP-2K

    All controls, except handles (pos.16), of the left-sided oven are on the left side of the oven.

    ___________________________________________________________________________ TP 8

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    - The tunnel baking oven heating should continue gradually with the speed of 50 C/happroximately up to the temperature adjusted on the PLC terminal (No5.3.1, pos. 5 3).Temperature on the thermo regulator should be risen step by step up of 350 C(i.e. 100 C 150 C 200 C 250 C 300 C 350 C). During the tunnel bakingoven heating, when the temperature in the baking room amounts to 250 C approximately,you should perform the burner fine resp. definitive regulation.Finally adjusted burners should operate as follows:

    A) Oil burner: - soot according to BOXBARACH 1B) Gas burner: - contents of CO max. 0, 05 %

    - Immediately after the finished fine regulation of the burners you should carry out thechecking measuring and draw up the protocol on performed regulation. The temporarilyfixed valve in the connecting channel (No. 5.3 pos. 14) should be definitively fixed by

    boring a hole and screwing up the screw into the valve axle.- The tunnel baking oven should be gradually cooled down to the temperature of 200 C

    approx., and then let at this temperature to be stunk out.- Switch off the burners on both cupolas, and when the temperature drops under 180 C,

    switch off also both fans, the conveyor belt and illumination in the baking oven.- Switch off the main switch and shut off the fuel supply.- When the tunnel baking oven has been completely cooled down, check up the individual

    units and elements thoroughly, remove all the eventual irregularities, if necessary, anddraw up the minutes on the protocol baking oven test starting.

    5.3.1. Description of the control desk The tunnel baking oven electric control elements are placed on the electric control desk (electric cabinet) (pos. 2). All the switches and keys are equipped with the correspondinglabels (signs).There are the following controls on the electric control desk:- main switch (pos. 1, No5.3.1/1),- 2 (two) keys for the conveyor belt (item 5) switching-on and switching-off;- 2 (two) keys for the fan (pos. 10 and 9) switching-on and switching-off (at two-cupola

    tunnel baking ovens separately for the fan I and the fan II),- switch or key (depending on burner construction and type) for switching the burner

    (pos.11) on and off ; (at two-cupola tunnel baking ovens performed separately for the burner I and the burner II). Some versions of the tunnel baking ovens have got a selection

    switch foreseen for the burner automatics (basic or reserve). The tunnel baking ovenswith combined burners are equipped with a selection switch for a certain type of fuel.At tunnel baking ovens equipped with medium heavy oil burners (up to 37,4 c St/100 C) aswitch for preparation and pre-heating of fuel is foreseen.

    - Key for regulation of the conveyor belt speed (for baking time from 10 to 60 minutes)(pos.7),

    - Switch for switching on the illumination of the baking area (pos. 15, No5.3.1/1),- adjusting thermometer for regulating the temperature of flue gases (pos. 12). There are

    two independent regulation adjusting thermometers one for single recirculation system installed at two-cupola ovens. The switches of the fan, wire mesh conveyor and burner areequipped with a control lamp which is alight on when the switch is put on.

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    - indicating counter of the baking time the scale graduation is presented in minutes (pos.8),

    - alarm bell,- button for the electric control switching on (pos. 3),- pre-heating of the conveyor belt (pos. 27, 29)

    Oven control can be carried out through PLC which lies on the control desk (No 5.2) (pos. 2)On the control cabinet there are the following controls (No5.3.1):- Main switch (pos. 4)- Screen with PLC controls (pos. 5).

    Through PLC terminal the following parameters are set up and switched on:- conveyor belt switching on- fans switching on- burners switching on burners operation control

    - setting up of baking time- setting up of desired baking temperature (pos. 31)- control of automatic draught in the oven- oven operation history (alarms)- statistics of burners operation- alarm switching off (pos. 25)- key for electric control switching on (pos. 24)- control tightening (pos. 26)- stop key (pos. 30)

    ___________________________________________________________________________ TP 10

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    Drawing 5.3.1. TP-1K

    ___________________________________________________________________________ TP 11

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    Drawing 5.3.1/1 TP-2K

    All controls, except handles (pos.16), of the left-sided oven are on the left side of the oven.

    ___________________________________________________________________________ TP 12

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    CONTROL CABINET WITH CLASSIC MANUAL CONTROL N.5.3.1/2

    25

    23

    8

    1319

    7 5 6

    12

    10

    27

    29

    28

    SIGNAL LAMPS

    9 26

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    Drawing No5.3.1/3

    ___________________________________________________________________________ TP 14

    30 24 2526

    CONTROL DESK WITH PLC SCREEN No. 5.3.1/3

    5 31

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    5.3.3 Regulation of baking efficiency uniformity

    If the products on the left or right side of the oven are not uniformly baked, the oven has in- built regulation throttling devices which are located on the left and right side of the oven, i.e.under throttling devices (pos. 10 and 11 No5.3.1).The regulation throttling devices arelocated under the oven lining. They can be reached by removing the oven lining by thethrottling devices 10 and 11. When the oven is started up, these throttling devices are set intoopen position (drawn-out arm). When the products are not uniformly baked on the left-rightside, the regulation throttling devices are slowly opened on the side where products are better

    baked until the baking efficiency is uniform on both sides. The procedure is executed from

    the second baking chamber towards the oven exit on every oven segment which has throttlingdevices pos. 10 and 11. Slow opening of the regulation throttling devices is executedgradually with the simultaneous control of products' baking efficiency uniformity. Thecorrection effect can be seen on the oven not before than 1 - 2 hour(-s).

    6.1. Periodical cleaning At least once a month it is necessary to clean the tunnel baking oven. When doing this, youshould clean thoroughly the baking oven inlet (dough pieces, crumbs of bread, litter, etc.) andthe drive area. For performing these cleaning operations you should first remove the linings of the oven inlet part and drive unit.

    The conveyor belt should be regularly maintained, cleaned and oiled. The oiling intervals andlubricant types are to be found in the tunnel baking oven lubrication scheme.

    Wire mesh lubrication procedure:- The wire mesh should be clean.- The tunnel baking oven should be heated to the working temperature.- The conveyor belt speed should be 15 minutes / cycle approximately.- The wire mesh should be sprayed slightly by the help of a gun. If there is no gun

    available, this operation can be performed by a brush. You should always oil the wire

    mesh at the baking oven inlet. You should not exaggerate with depositing the oil film.- Let the tunnel baking oven operate until oil gets dry, in order to avoid the wire meshsliding at the baking oven full loading.

    You can use common table oil for wire mesh oiling.

    1. By the help of screws (pos. 7) and nuts (pos. 6) you should lift the weights into theextreme upper position. The access to the screws is possible after having removed the rear linings on the left and right sides of the tunnel baking oven, and that is at the baking ovenoutlet.

    2. The driving roller (pos. 1) should be moved into the position P on the left (L) and right

    (D) sides, while the inlet roller (pos. 10) into the position N on both sides (L and D).

    ___________________________________________________________________________ TP 15

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    ___________________________________________________________________________ TP 17

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    8.0 SPARE PARTS CATALOGUE

    8.1. Spare parts orderingIn spare parts orders write indicate:

    - oven type- ident. or oven type number - spare part ident.- number of pieces

    ___________________________________________________________________________ TP 18

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    1.2. Spare parts listmechanical equipmentTP 2,1x12; TP2, 1x15

    Pos. Iden. Name1 066.226 Intermediate shaft

    2 073.233 Galls chain3 073.224 Galls chain5 040.660 Plug6 073.394 Ring8 214.213 Bearing housing SNH 513-611N9 016.230 Bearing

    016.891 Bearing H31310 017.088 Pressure spring11 040.699 Bush12 019.986 Ring13 213.895 Felt seal TSNA 513C14 160.930 Screw M 8x2015 020.727 Greasing device A 10x116 066.095 Drive roller 50017 073.217 Chain wheel18 016.204 Bearing 222 20EK

    016.896 Bearing H32019 214.203 Bearing housing20 214.205 Ring 12/18921 214.204 Felt seal22 023.164 Treenail 22x14x125

    23 021.041 Screw M 6x1224 021.046 Screw M 6x1525 066.217 Tensioning roller 26 073.350 Bearing housing27 073.399 Bearing housing28 016.478 Bearing 121029 016.940 Retaining ring 50 x 230 060.704 Felt seal 8x6,5x10531 066.225 Main roller 32 016.197 Bearing 1211

    016.889 Bearing H311

    33 161.443 Felt seal 8x6,5-10034 161.442 Bearing housing35 215.631 Cover 36 161.110 Ring37 073.293 Shaft with gear wheel38 073.218 Chain wheel39 023.112 Treenail 14x19x6040 016.745 Bearing

    ___________________________________________________________________________ TP 19

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    Pos. Iden. Name41 023.008 Elastic pin 10x5542 073.146 Manual shaft with gear wheel45 040.695 Cover 46 022.046 Screw M 12x4047 022.077 Screw M 12x6048 022.417 Nut M 1249 022.712 Washer B 1250 066.103 Balancing shaft51 073.357 Shaft rack 52 073.389 Plate53 073.360 Chain wheel C54 022.019 Screw M 12 x 2556 280.479 Driver

    297.939 Driver 292.726 Driver

    59 073.387 Sheave 6060 073.351 Axle61 073.351 Axle62 022.781 Split pin 5 x 4063 022.678 Washer 65 020.602 Chain with coupling unit66 020.576 Chain67 020.576 Chain68 020.602 Chain

    69 013.382 Steel wire70 016.575 Bearing 121371 060.704 Felt seal73 021.128 Screw M 16 x 6074 022.419 Nut M 1675 022.574 Spring washer A 1676 021.181 Screw M 20 x 20077 022.421 Nut M 2078 066.233 Inlet roller 79 215.940 Burner 81 014.086 Lamp R-04/1-G

    83 020.516 Thermometer 84 017.205 "S" wire mesh85 023.387 Glass86 014.956 Fan motor 89 218.809 Bearing

    ___________________________________________________________________________ TP 20

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    Pos. Iden. Name90 016.801 Bearing housing SN51391 219.710 Belt set92 016.891 Bearing bush

    95 023.368 Glass96 072.152 Closure97 072.155 Closing hook 98 072.566 Cylinder - 71099 066.320 Centre-fire cartridge

    ___________________________________________________________________________ TP 21

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