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

INSTRUCTIONS FOR USE

TUNNEL BAKING OVEN

Type TP

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

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

1.1. Technological data: - Baking time - Baking temperature - Temperature regulation - Adjustment of temperature diagram - Evaporation - Vapour consumption 1.2. Technical data
SINGLE-CUPOLA BAKING OVEN Oven Useful dimensions Surface Width Length type
A B

normally from 15 to 60 min or according to your wish up to 300C by thermostat or automatically manually with valves manual adjustment up to 5 kg/m2/h

Outer dimensions
Length C Width D Height E Vapour consumption Electric connection

TP 1,8x15 2,1x12 2,1x15 2,1x18 2,1x21 2,5x12 2,5x15 2,5x18 2,5x21 3,0x12 3,0x15 3,0x18 3,0x21

m2 27 25,2 31,5 37,8 44,1 30,0 37,5 45,0 52,5 36,0 45,0 54,0 63,0

M 1,8 2,1 2,1 2,1 2,1 2,5 2,5 2,5 2,5 3,0 3,0 3,0 3,0

m 15 12 15 18 21 12 15 18 21 12 15 18 21

mm 17800 14850 17850 20850 23850 14850 17850 20850 23850 14850 17850 20850 23850

mm 2900 3134 3134 3134 3134 3534 3534 3534 3534 4034 4034 4034 4034

mm 3225 3315 3315 3315 3315 3215 3215 3215 3215 3215 3215 3215 3215

kg/m2h

5kg/m2h

kW 8,6 8,6 8,6 10,6 14,6 8,6 8,6 10,6 14,7 10,6 10,6 14,7 14,7

BURNERS FOR NATURAL GAS Z Burner power N. of burners kW 311 389 468 545 370 463 556 648 444 556 667 778

Hu=32,68 MJ m3 Total Working consumption pressure m3 mbar 35,00 43,00 52,00 60,00 41,00 51,00 22 62,00 72,00 49,00 62,00 74,00 86,00

___________________________________________________________________________ TP 2

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

TWO-KUPOLA BAKING OVENS Oven Useful dimensions type TP 2,1x24 2,1x27 2,1x30 2,1x33 2,5x24 2,5x27 2,5x30 2,5x33 3,0x24 3,0x27 3,0x30 3,0x33 3,0x36
Surface Width A Length B

Outer dimensions
Length C Width D Height E Vapour consumption Electric connection

m2 50,4 56,7 63,0 69,3 60,0 67,5 75,0 82,5 72,0 81,0 90,0 99,0 108,0

M 2,1 2,1 2,1 2,1 2,5 2,5 2,5 2,5 3,0 3,0 3,0 3,0 3,0

m 24 27 30 33 24 27 30 33 24 27 30 33 36

mm 26850 29850 32850 35850 26950 29850 32950 35950 26950 29950 32950 35950 38950

mm 3134 3134 3134 3134 3534 3534 3534 3534 4034 4034 4034 4034 4043

Mm 3315 3315 3315 3315 3215 3215 3215 3215 3215 3215 3215 3215 3215

kg/m2h

5kg/m2h

kW 13,4 18,9 18,9 19,7 15,7 17,7 21,2 22,5 17,7 21,2 21,2 22,5 22,5

BURNERS FOR NATURAL GAS Z Hu=32,68 MJ m3 Burner power No. of burners Total kW consumption m3 311 69,00 350 78,00 389 86,00 428 95,00 371 82,00 417 2 92,00 463 102,00 509 119,00 445 98,00 500 110,00 556 123,00 612 135,00 630 141,1

Working pressure mbar

22

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

___________________________________________________________________________ TP 3

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

Drawing No2.3 TP-1K

___________________________________________________________________________ TP 4

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

Drawing No2.3 TP-2K Detail A

___________________________________________________________________________ TP 5

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

2.0. MACHINE DESCRIPTION 2.1. Main component parts The baking oven consists of a baking part (tunnel), combustion unit with a burner, distributing and 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 oven are all installed in the above stated units. All the materials used for the above units of the tunnel baking oven have been chosen carefully, 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 materials enabling 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 c St/20C or 1,6E/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. Application The tunnel baking oven is designed for continuous type of baking all kinds of bread and rolls, which can be baked at temperatures up to 320C. This baking oven is designed above all for larger bakeries in which the working process is completely automated. 2.3. Operating principle The dough is transported on a conveyor belt (wire mesh) through the baking oven made in the shape 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 and lower 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 in slightly movable atmosphere. 3.0. SAFETY MEASURES Baking tunnel oven was designed and constructed by taking into account the technical condition of the oven as well as adequate regulations, but when working with the oven and during maintenance work there are, however, still dangers present. 3.1 General warnings Before 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.

___________________________________________________________________________ TP 6

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

No5.2 TP-1K

___________________________________________________________________________ TP 7

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

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

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

The tunnel baking oven heating should continue gradually with the speed of 50C/h approximately 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 350C (i.e. 100C 150C 200C 250C 300C 350C). During the tunnel baking oven heating, when the temperature in the baking room amounts to 250C approximately, you should perform the burner fine resp. definitive regulation. Finally adjusted burners should operate as follows: A) Oil burner: - soot according to BOXBARACH 1 B) Gas burner: - contents of CO max. 0, 05 % Immediately after the finished fine regulation of the burners you should carry out the checking measuring and draw up the protocol on performed regulation. The temporarily fixed 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, and draw 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 corresponding labels (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 ovens with 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/100C) a switch 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 are equipped with a control lamp which is alight on when the switch is put on. ___________________________________________________________________________ TP 9

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

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

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

Drawing 5.3.1. TP-1K

___________________________________________________________________________ TP 11

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

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

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

19

13

25

SIGNAL LAMPS

8 12 4 11 10 27 29

26

28

___________________________________________________________________________ CONTROL CABINET WITH CLASSIC MANUAL CONTROL N.5.3.1/2 TP 13

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

Drawing No5.3.1/3

30

24

26

25

31

CONTROL DESK WITH PLC SCREEN No. 5.3.1/3

___________________________________________________________________________ TP 14

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

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 inbuilt 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 are located under the oven lining. They can be reached by removing the oven lining by the throttling devices 10 and 11. When the oven is started up, these throttling devices are set into open position (drawn-out arm). When the products are not uniformly baked on the left-right side, 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 throttling devices pos. 10 and 11. Slow opening of the regulation throttling devices is executed gradually with the simultaneous control of products' baking efficiency uniformity. The correction 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, you should clean thoroughly the baking oven inlet (dough pieces, crumbs of bread, litter, etc.) and the 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 and lubricant 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 mesh sliding 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 the extreme 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 oven outlet. 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

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

3. By the help of steel wires (pos. 11, 3 4 mm) you should block the conveyor belt, as shown in the scheme. 4. The inlet roller (pos. 10) should be put into the position P on both sides (L and D). 5. The conveyor belt wire mesh should be undone in point A in such a way that the transverse (pos. 12) is drawn out. Then you should shorten the conveyor belt by removing the required number of segments, and finally to join the conveyor belt together again. In the end you should remove the steel wires (pos. 11). 6. The nuts (pos. 6) placed on screws for lifting the weights should be unwound, so that the weights make the conveyor belt tense. 7. The driving roller and the inlet roller should be moved into the direction marked by the arrow into the position N, so that the weights are lifted into the upper position. 8. You should start the conveyor belt and adjust its running according to the instructions stated in Chapter 4.6. in order to prevent its slipping to the left or to the right.
6.3. Burner operation

The burner adjustment and its putting into operation should be performed by a service worker with an authorization of the burner manufacturer. All further maintenance operations of the burner should be carried out according to the enclosed instructions of the manufacturer. rawing 6.2.2rawing 6.2.3 T

___________________________________________________________________________ TP 16

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

___________________________________________________________________________ TP 17

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

8.0 SPARE PARTS CATALOGUE 8.1. Spare parts ordering In spare parts orders write indicate: - oven type - ident. or oven type number - spare part ident. - number of pieces

___________________________________________________________________________ TP 18

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

1.2. Spare parts listmechanical equipment TP 2,1x12; TP2, 1x15 Pos. 1 2 3 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Iden. 066.226 073.233 073.224 040.660 073.394 214.213 016.230 016.891 017.088 040.699 019.986 213.895 160.930 020.727 066.095 073.217 016.204 016.896 214.203 214.205 214.204 023.164 021.041 021.046 066.217 073.350 073.399 016.478 016.940 060.704 066.225 016.197 016.889 161.443 161.442 215.631 161.110 073.293 073.218 023.112 016.745 Name Intermediate shaft Galls chain Galls chain Plug Ring Bearing housing SNH 513-611N Bearing Bearing H313 Pressure spring Bush Ring Felt seal TSNA 513C Screw M 8x20 Greasing device A 10x1 Drive roller 500 Chain wheel Bearing 222 20EK Bearing H320 Bearing housing Ring 12/189 Felt seal Treenail 22x14x125 Screw M 6x12 Screw M 6x15 Tensioning roller Bearing housing Bearing housing Bearing 1210 Retaining ring 50 x 2 Felt seal 8x6,5x105 Main roller Bearing 1211 Bearing H311 Felt seal 8x6,5-100 Bearing housing Cover Ring Shaft with gear wheel Chain wheel Treenail 14x19x60 Bearing

___________________________________________________________________________ TP 19

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

Pos. 41 42 45 46 47 48 49 50 51 52 53 54 56 59 60 61 62 63 65 66 67 68 69 70 71 73 74 75 76 77 78 79 81 83 84 85 86 89

Iden. 023.008 073.146 040.695 022.046 022.077 022.417 022.712 066.103 073.357 073.389 073.360 022.019 280.479 297.939 292.726 073.387 073.351 073.351 022.781 022.678 020.602 020.576 020.576 020.602 013.382 016.575 060.704 021.128 022.419 022.574 021.181 022.421 066.233 215.940 014.086 020.516 017.205 023.387 014.956 218.809

Name Elastic pin 10x55 Manual shaft with gear wheel Cover Screw M 12x40 Screw M 12x60 Nut M 12 Washer B 12 Balancing shaft Shaft rack Plate Chain wheel C Screw M 12 x 25 Driver Driver Driver Sheave 60 Axle Axle Split pin 5 x 40 Washer Chain with coupling unit Chain Chain Chain Steel wire Bearing 1213 Felt seal Screw M 16 x 60 Nut M 16 Spring washer A 16 Screw M 20 x 200 Nut M 20 Inlet roller Burner Lamp R-04/1-G Thermometer "S" wire mesh Glass Fan motor Bearing

___________________________________________________________________________ TP 20

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

Pos. 90 91 92 95 96 97 98 99

Iden. 016.801 219.710 016.891 023.368 072.152 072.155 072.566 066.320

Name Bearing housing SN513 Belt set Bearing bush Glass Closure Closing hook Cylinder - 710 Centre-fire cartridge

___________________________________________________________________________ TP 21

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

10.0. HOT AIR FLOW SCHEME

___________________________________________________________________________ TP 22