Boyens Backservice Jelly power pack User manual
Instruction manual
Jelly power pack
Hotline:
In case of malfunction please call our Hotline-No:
Tel.: +49 (0) 54 51 / 96 37 38
Fax.: +49 (0) 54 51 / 96 37 35
Before starting operation carefully read
and adhere to this instruction manual
and the safety advice!
Edition: 09.09
Article-No.: 3324
2Contents
Jelly power pack Edition 09.09
1. General hints........................................... 3
2. Basic safety instructions....................... 4
2.1 Obligations and liability............................. 4
2.2 Safety symbols ......................................... 4
2.2.1 General danger symbol ............................ 4
2.2.2 Attention symbol ....................................... 4
2.2.3 Hint symbol............................................... 4
2.3 Intended use............................................. 5
2.4 Improper use ............................................ 5
2.5 Informing safety measures ....................... 5
2.6 Training the personnel.............................. 5
2.7 Safety measures during normal
operation................................................... 5
2.8 Danger by electric energy ........................ 5
2.9 Danger from residual energy.................... 6
2.10 Cleaning, maintenance, repair and remedy
of faults ..................................................... 6
2.11 Modifications............................................. 6
2.12 Cleaning and disposing ............................ 6
3. Description of the implement................ 7
3.1 Implement diagram................................... 7
3.2 Functional description .............................. 8
3.3 Identification of the machine................... 10
3.4 Technical data ........................................ 10
3.5 Technical features .................................. 11
4. Putting into operation .......................... 12
4.1 Operation................................................ 12
4.2 Agent-hose ............................................. 13
4.3 General requirements on the compressed-
air source................................................ 14
4.4 Connecting the implement to an external
compressed air source ........................... 15
4.5 Connect the one-way jelly container BIB 16
4.6 Switching the implement on/off .............. 17
4.7 Setting the processing temperature ....... 18
4.8 Setting the spraying pressure................. 19
4.9 Selecting and exchanging the
agent-nozzle ........................................... 20
4.10 The spraying procedure ......................... 21
4.11 Pauses and operational breaks.............. 22
4.12 Restarting after an operational break ..... 23
5. Cleaning, maintenance and
maintaining ............................................24
5.1 Cleaning - daily after having finished the
operational procedure .............................25
5.2 Cleaning the agent-nozzle ......................26
5.3 Maintenance............................................26
5.3.1 Weekly ....................................................26
5.3.2 Every 14 days .........................................27
5.4 Exchanging the seal kit ...........................27
5.5 Opening and closing the
implement housing..................................28
5.6 Remedy leaking compressed air
connections .............................................29
5.7 Exchanging the agent-hose ....................30
5.8 Exchanging the agent-feed-pump...........31
5.9 Trouble shooting .....................................32
6. Spare part list ........................................34
7. Circuit diagrams....................................38
8. Guarantee ..............................................43
EC Conformity Declaration..................................44
General hints
3
Jelly power pack Edition 09.09
1. General hints
Identification data
Type: Jelly power pack
Model-No.:
Year of construction:
Capacity:
The identification data are of
documentary value and may not be
changed or disguised.
Manufacturer
Name of company: boyens backservice GmbH
Street: Gildestraße 76-80
Town: D-49479 Ibbenbüren
Phone: +49 (0) 54 51 / 96 37-0
Fax: +49 (0) 54 51 / 96 37-16
www.boyensbackservice.de
e-mail: info@boyensbackservice.de
Spare parts ordering and after-sales service
Address as above
Phone: +49 (0) 54 51 / 96 37-38
Fax: +49 (0) 54 51 / 96 37-35
Documentary data
Version: Jelly power pack
Edition: 09.09
Purpose of this document
This instruction manual acquaints the operator of the
implement with:
•the way of function,
•the operation,
•the safety notes and
•the maintenance.
Operator personnel
This implement may only be operated, maintained
and repaired by persons, who are acquainted with
this and who have been informed about any
associated dangers.
Storing the instruction manual
Always keep this instruction manual with the
machine!
The instruction manual must always be at hand!
Transport and take-over
Only transport the implement standing on its transport
rollers or lying on the side opposite the one with the
control panel. Protect the implement against moving
to and fro on the loading area.
The transport and storage temperature must be at
least +2°C and at most +50°C. The maximum
atmospheric humidity during storage may not exceed
90%.
Check the delivery immediately on receipt with the
aid of the shipping documents for:
•completeness and
•possible damage.
In case of damage in transit or loss, immediately
arrange for the damage to be recorded by the
forwarding agent for the purpose of asserting
compensation claims.
User evaluation
Dear reader,
Our operating instructions are updated at regular
intervals. Your improvement suggestions will help us
to continually make these instruction manual more
user friendly. Please send us your improvement
suggestions by fax or e-mail.
Copyright © 2009 by
boyens backservice GmbH
Gildestraße 76-80
D-49479 Ibbenbüren
Germany
All rights are reserved
4Basic safety instructions
Jelly power pack Edition 09.09
2. Basic safety instructions
This instruction manual contains the most important
information for a safety conscious operation of this
implement.
2.1 Obligations and liability
Observe the information contained in the instruction
manual: A basic requirement for a safety conscious
handling and a trouble-free operation of this
implement is the knowledge of the basic safety hints
and safety advice. This instruction manual, especially
the safety hints, must be observed by all persons who
operate the implement. In addition, the rules and
regulations for the prevention of accidents applicable
at the place of application have to be observed.
Dangers when operating the implement:
The implement Jelly powwer pack has been
designed according to the state of the art and
approved safety regulations. Nevertheless dangers
for the health and life of the user or third parties or
impairments to the implement or other material
assets may arise during its use.
The implement may only be used:
•for the intended use
•in a perfect condition as far as safety is
concerned.
Faults which might affect safety must be remedied
immediately.
Guarantee and liability:
In principle, our "General conditions of sale and
delivery" are applicable". These have been available
to the user at the latest since conclusion of the
contract. Warranty and liability claims for personal
injury or damage to property shall be excluded if they
result from one or several of the following reasons:
•use contrary to the intended use of the implement,
•Improper mounting, commissioning, operating and
maintenance of the equipment,
•use of the implement with faulty safety equipment
or improperly fitted or inoperative safety devices
and guards,
•not adhering to the hints in the instruction manual
regarding transport, storage, assembly, putting to
operation, maintenance and setting up the
implement,
•unauthorised structural changes to the equipment,
•inadequate monitoring of implement wearing
parts,
•improper repair work,
•catastrophes caused by alien elements and acts
of god.
2.2 Safety symbols
In the instruction manual the following terms and
signs for dangers are used:
2.2.1 General danger symbol
This symbol indicates a direct danger for life and
health of persons. Not adhering to these hints will
cause severe danger for health up to injuries with
high danger to life.
2.2.2 Attention symbol
This symbol gives important hints for the appropriate
handling of the implement. Not adhering to these
hints may cause faults on the implement itself or in its
environment.
2.2.3 Hint symbol
This symbol offers you hints for operation and
especially useful information. They will help you to
make best use of all functions on your implement.
Basic safety instructions
5
Jelly power pack Edition 09.09
2.3 Intended use
The implement Jelly power pack has exclusively
been designed for the common use as spraying
implement for spraying jelly in bakeries. Spraying of
other agents, apart from air and water to clean the
implement, requires the prior explicit written
permission of Messrs. boyens backservice GmbH.
Any use beyond the one stipulated above shall be
considered use contrary to the intended use. The
manufacturer does not accept any liability for
personal injuries and damage to property resulting
from this. The operator himself carries the full risk for
this.
Intended use also means:
•observing all hints in the instruction manual and
•adhering to the inspection and maintenance work.
2.4 Improper use
Using the implement for other purposes than
stipulated above is prohibited. In case of improper
use, danger for human beings and animals may
result. Such improper using includes, e. g.:
•heating or spraying of, e. g. acids, lyes in
particular salt solution and solvent agents or
•other liquids, especially inflammable ones.
2.5 Informing safety measures
Always keep the instruction manual on the
implement. In addition to these instruction manual
make available and observe the generally and locally
applicable accident prevention and environmental
protection advice. Further more adhere to the general
health- and labour medical regulations and hygienic
precautions.
Keep all safety- and danger hints on the implement
readable and clean and exchange if necessary.
2.6 Training the personnel
Only trained and advised personnel may operate this
implement. The responsibility of the personnel must
be clearly determined for operating, conversion and
maintenance. Semi-skilled personnel may only
operate the implement under supervision of an
expert.
2.7 Safety measures during normal
operation
Only operate the implement with all guards fully
functioning. Check the implement for externally
noticeable damage at least once a day.
Never leave your implement unattended when the
implement is connected to the power supply.
Protect the spray gun during spraying pauses against
unintentional spraying by turning the locking device.
Never pull the implement on the power supply cable
or the agent-hose. Never pull the plug off its plug-
connection by jerks on the cable. Protect the electric
power supply cable and the agent-hose from heat
and sharp edges. Only use a faultless electric power
supply cable and a faultless agent-hose.
Always accurately aim the spraying operation onto
the bakery products. Never aim at people or animals.
Keep children, animals and other persons away from
the operation area of the implement - always ensure
a sufficient clearance.
2.8 Danger by electric energy
Operations on the electric supply may only be
executed by a skilled electrician. Check the electric
equipment of your implement at regular intervals.
Immediately remove loose connections and scorched
cables.
6Basic safety instructions
Jelly power pack Edition 09.09
2.9 Danger from residual energy
Be aware of pneumatic and electric/electronic
residual energies and take corresponding measures
when advising the operator personnel. Detailed hints
will be given once more in the individual chapters of
this instruction manual.
2.10 Cleaning, maintenance, repair and
remedy of faults
Carry out prescribed cleaning, maintenance and
inspection work in due time. Prior to all maintenance,
inspection and repair work
•pull the mains plug out of the socket,
•actuate the spray gun and thus discharge the
residual air pressure in the system,
•when disposing condensate, observe the
prescriptions of the water resources law.
Check the firm seat of screw connections that have
been unscrewed beforehand. On completion of
maintenance work, check the function of all safety
devices.
2.11 Modifications
Never change anything on the implement, do not add
anything to the implement and do not convert the
implement without approval of the manufacturer.
All conversions require the written approval of
Messrs. boyens backservice GmbH.
Immediately exchange faulty implement parts.
Only use original spare- and wearing parts.
When using non original parts it cannot be
guaranteed that they had been designed and
manufactured in such a way that they correspond to
the operational and safety prescriptions.
2.12 Cleaning and disposing
For cleaning only spray air and water. Spraying other
materials requires the prior explicit and written
approval of Messrs boyens backservice GmbH.
Handle and dispose of all agents and material in an
appropriate manner.
To clean the implement, only use:
•a moist sponge or a moist cloth,
•never a high pressure cleaning device.
Description of the implement
7
Jelly power pack Edition 09.09
3. Description of the implement
3.1 Implement diagram
(1) Power supply cable 400 Volt / 50 Hz
(2) Compressed air connection for external
compressed air source. The inlet air pressure of
the external compressed air system may not
exceed 6 bar
(3) Agent-hose
(4) Spray pressure setting
(5) Spray gun
(6) Spray gun retainer
(7) Suction-hose
(8) Implement on/off
(9) Temperature display
(10) Temperature setting device
(11) Front side
(12) Roller frame
8Description of the implement
Jelly power pack Edition 09.09
3.2 Functional description
A pneumatically driven, diaphragm controlled agent-
feed-pump sucks the cold jelly via the suction-
hose
(1) out off the one-
way jelly container (Bag in Box
(BIB)) (2) or the jelly container (3) (special
equipment).
Then the sucked off jelly is delivered via the agent-
feed-pump to the flow-heater. Inside the flow-
heater
the jelly is heated to the set processing temperature.
The processing temperature can be set via UP-
and
DOWN-keys (1 and 2) between 25.0 and 93.0°C.
The temperature display (3) shows the actual
system-
temperature in Degree Celsius. The
im
plement is ready for use when the red
temperature-control light (4) has gone out.
Description of the implement
9
Jelly power pack Edition 09.09
The hot sprayable jelly is delivered via the h
eated
agent-hose (1) to the spray gun (2).
For spraying the product unlock the locking device (3)
against unintended spraying. Hold the spray gun at a
distance of approx. 10 cm above the product to be
sprayed and pull the trigger lever (4).
Depending on t
he size of the surface to be sprayed
use the flat jet- or round jet nozzle.
The jelly layer depends on the pre-
set spraying
pressure.
The spraying pressure can be steplessly set between
0 and 4 bar via the turning knob (1).
The pressure gauge shows the spraying pressure set
in bar.
10 Description of the implement
Jelly power pack Edition 09.09
3.3 Identification of the machine
You will find the type plate (1) on the back of the
implement. The CE-
sign is shown on the operating
panel.
3.4 Technical data
Power Supply: 400 V
Frequency: 50 Hz
Fuse in the feed line: 16 A
Length of power supply cable: 4 m
Heating capacity: 10,000 watt
Maximum permissible operating
pressure (PS): 6 bar
Minimum / maximum permissible
operating temperature (TS): +2°C to +50°C
Maximum humidity: 90%
External compressed air: Compressed air output 90 litres / min – 6 bar
Compressed air connection: Nominal width (NW) 7.2
Pressure relief valve: Set to maximum 6 bar at the factory
Length of the agent-hose: 2.5 m
Measurements:
Length:
Width:
Height:
700 mm
535 mm
1045 mm
Weight: 132 kg
Spraying pressure: stepless setting between 0 and 4 bar
Processing temperature: setting between 25 and 93°C
Transport and storing Operation
Temperature: + 2 to + 50°C + 2 to + 50°C
Humidity: maximum 90% maximum 90%
Description of the implement
11
Jelly power pack Edition 09.09
3.5 Technical features
The implement Jelly power pack:
•with a special flow-heater.
•with energy saving technique -
due to a good heat
insulation the heat is retained for hours in case of
work interruptions.
•with heated agent-hose up to the spray gun.
•with spray gun with heat reflecting casing.
•
with temperature control controlled heat
adjustment.
•
with pneumatically driven, diaphragm controlled
agent-feed-pump.
•with low-maintenance technique.
•with transport rollers.
•in stainless special steel execution.
•in HACCP-conformity execution.
•energy saving.
Within the scope of supply:
(1) Cleaning hose
(2) Flood-nozzle
(3) Adapter
(4) Key to open the front side
(5) Bayonet cap with flat jet nozzle
(6) Bayonet cap with round jet nozzle
12 Putting into operation
Jelly power pack Edition 09.09
4. Putting into operation
The implement is exclusively suited for
operation with alternating current (400 V
/ 50 Hz. Never try to use other sources of
current. Ensure that the voltage of the
implement and your supply voltage are
the same.
Any work on the electric supply may
only be carried out by a skilled
electrician. Check the electric equipment
of your implement at regular intervals.
Immediately remove loose connections
and scorched cables.
-
Check whether the electric circuit is protected by
fuse with 16 Ampere.
- If so,
connect the implement with the aid of the
CEE-power plug to the power supply.
4.1 Operation
Only operate th
e implement with all
guards fully functioning. Check the
implement for externally noticeable
damage at least once a day.
Never leave your implement unattended
while the implement is connected to the
power supply or to an external
compressed-air system.
When operating the implement it is
imperative to observe the instructions
regarding the
•intended use
•training of personnel.
Do not d
rag the implement by using the
power supply cable or the agent-hose.
Protect the spray gun during spraying
pauses against unintentional spraying
by turning the locking device (1).
Putting into operation
13
Jelly power pack Edition 09.09
4.2 Agent-hose
The agent-
hose is a special hose for heating and
consists of the following components:
•Silicone for the fruit acid containing product,
•Silicone textile casing for stability,
•Resistance wires for heating.
Protect the agent-
hose against damage
from sharp-
edged objects. Danger of
injury from discharging hot agent.
In case of damage always exchange the
entire agent-hose.
The agent hose may never be:
•shortened,
•patched or
•manipulated.
Changes on the agent-
hose will cause a
total failure of function.
14 Putting into operation
Jelly power pack Edition 09.09
4.3 General requirements on the
compressed-air source
The implement requires an agent pressure of at least
2.5 bar and at most 6 bar and an air output of 90
litres per
minute. The implement may only be
operated with food safe compressed air.
It is imperative that you use only clean,
dry and food safe compressed air to
operate the implement.
If no filter unit (maintenance unit) to
clean the compressed air and also no
air
dryer is available behind the
compressor, oil and rust particles get
into the compressed air system. This
can lead to fouling of the jelly and to
rusting through of the pressure vessel.
If your present compressed-
air source
does not meet the above
requirements,
we recommend you use our three-
stage
special filter unit.
The three-stage special filter unit consists of:
1. 1 x DV 1000
. Prefilter with filter element and
automatic condensate discharge with float valve
and differential pressure manometer.
2. 1 x DF 1000. Superfine filter
with filter element
and automatic condensate discharge with float
valve and differential pressure manometer. For
higher quality compressed air for pneumatic
control systems.
3. 1 x DA 1000. Activated-carbon filter
with filter
el
ement, stopper and closing plate. For highest
quality compressed air as inhaled air, e.g. in
luxury food processing.
4. 2 x Filter housing threaded joint.
For
connection of filter units.
5. 1 x Assembly kit
. For wall fastening of filter
units.
Putting into operation
15
Jelly power pack Edition 09.09
4.4 Connecting the implement to an
external compressed air source
It is imperative that you comply with the
chapter "General requirements on the
compressed air source", page 14.
During the spraying procedure, the
implement must be permanently
connected with the external compressed
air source as otherwise, spraying will
not be possible.
The bleed valve in the implemen
t
housing cover opens if the maximum
permissible implement pressure of 6 bar
is exceeded.
-
Connect the compressed air supply (1) to an
external compressed air source.
16 Putting into operation
Jelly power pack Edition 09.09
4.5 Connect the one-way jelly
container BIB
To avoid malfunction ensure that the
jelly is cold, liquid, lump free and free
from foreign particles.
-
Remove the screw lid (1) and the ring pull (2) of
the jelly container (3)
- Screw the adapter (4) onto the jelly container (3).
-
Place the jelly containers into the holder (5), so
that the adapter (4) is located below.
- Connect the adapter (4) and the suction-
hose (6)
via the coupling plug (7).
-
For this, simply push the socket (8) from the
suction-hose (6) onto
the plug (9) from the
adapter (4) until the quick-
action locking device
noticeably locks.
To unlock, push down the socket's
push-knob (10) at the suction-hose.
When the coupling plug is separated, a
return valve integrated in the socket (8)
and in the plug (9) prevents on outflow
of jelly.
Putting into operation
17
Jelly power pack Edition 09.09
4.6 Switching the implement on/off
Switching on
- Press the on-/off switch (1).
- It will flash:
•the red temperature-control light (3) and
•the temperature display (3).
The compressor starts running and
provides the factory set spraying
pressure of 2.8 bar. The agent-feed-
pump sucks jelly out off the jelly
container and provides the flow-
heater
and agent-hose with jelly.
The flow-heater and the agent-
hose heat
the jelly up to the prior set processing
temperature. The temperature display (3)
shows the current system temperature.
The implement is ready for operation, if
the red temperature-
control light (2)
goes out.
If the implement is cold, the heating
period will last approx. 5 to 8 minutes.
Ensure that there is always agent in the
flow-heater when
the implement is
switched on. When the jelly container is
empty, no material flows. This would
cause a running dry of the agent-feed-
pump and agent burning inside the flow
-
heater. The running dry damages the
agent-feed-pump.
Switching off
- Press the on-/off switch (1).
After the implement has been switched
off, the temperature display (3) goes out.
18 Putting into operation
Jelly power pack Edition 09.09
4.7 Setting the processing
temperature
-
Choose the desired processing temperature on
the temperature display (1).
- For this press the SET-key (2), hold pres
sed
and simultaneously press the UP- or DOWN-
key (3 or 4).
With the 1st pressure on the UP-
or
DOWN-
key the temperature display
moves
in 0,1°C steps into the desired
direction forward or backward. By
pressing the same key again, the display
continuously moves until the key is
released.
-
After having obtained the desired processing
temperature first release the UP- or DOWN-
key (3
or 4) and only then release the SET-key (2).
A change of the processing temperature
will only become effective if you
•have first pressed the SET-
key (2),
held and simultaneously pressed the
UP- or DOWN-
key (3 or 4) while
selecting the processing temperature.
•have first released the UP- or DOWN-
key (3 or 4) and only then the SET-
key
(2) on reaching the desired
processing temperature.
Putting into operation
19
Jelly power pack Edition 09.09
4.8 Setting the spraying pressure
-
Setting the desired spraying pressure via turning
knob (1).
To set the spraying pressure, slightly
pull out the turning knob (1) and turn it
into the desired direction.
•To increase the spraying pressure -
turn the turning knob clockwise (+).
•To reduce the spraying pressure -
turn the turning knob anti-
clockwise
(-).
-
You can read the spraying pressure set on the set
pointer (2) of the pressure gauge (3).
20 Putting into operation
Jelly power pack Edition 09.09
4.9 Selecting and exchanging the
agent-nozzle
Optionally available: a round jet and a flat jet nozzle.
Principle for choosing the nozzle:
•yellow round jet nozzle (1) fo
r small and round
products.
•red flat jet nozzle (2) for large areas and cake tins.
Exchanging the agent-nozzle
-
Secure the spray gun by means of the locking
device (1) against unintended spraying.
-
Manually slacken the bayonet cap (2) and
remove.
- Remove the agent-
nozzle (3) from the bayonet
cap.
- Insert another agent-nozzle into the bayonet cap.
- Screw the bayonet cap back onto the spray gun.
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