Boyens Backservice Jelly User manual

Jelly Shop Sprayer
Instruction manual
Jelly Shop Sprayer
Hotline:
In case of malfunction please call our Hotline-No.:
Phone: [phone] / 96 37 38
Fax: [phone] / 96 37 35
Before starting operation carefully read
and adhere to this instruction manual
and the safety advice!
Edition: 05.07
Article-No.: 2895

2Contents
Jelly Shop Sprayer Edition 05.07
1. General hints........................................... 3
2. Basic safety advice ................................ 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 common
operation................................................... 5
2.8 Danger by electric energy ........................... 5
2.9 Danger from residual energy.................... 5
2.10 Cleaning, maintenance, repair and
remedy of faults ........................................ 6
2.11 Constructional change of the machine..... 6
2.12 Cleaning the machine and disposal ......... 6
3. Description of the implement................ 7
3.1 Implement diagram................................... 7
3.2 Functional description .............................. 8
3.3 Identification of the machine..................... 9
3.4 Technical data .......................................... 9
3.5 Technical features .................................. 10
4. Putting into operation .......................... 11
4.1 Operation................................................ 11
4.2 The agent hose....................................... 12
4.3 Connect the one-way jelly container BIB 13
4.4 Switching the implement on/off .............. 14
4.5 Choosing the agent nozzle and
exchange ................................................ 15
4.6 The spraying procedure ......................... 16
4.7 Pauses and operational breaks.............. 17
4.8 Restarting after an operational break..... 18
5. Cleaning, maintenance and
maintaining ........................................... 19
5.1 Cleaning - daily after having finished the
operational procedure ............................ 20
5.2 Cleaning the agent nozzle ..................... 21
5.3 Cleaning the agent filter ......................... 21
5.4 Maintenance........................................... 22
5.4.1 Weekly ................................................... 22
5.4.2 Every 14 days ........................................ 23
5.5 Exchanging Teflon-sealing..................... 23
5.6 Checking the nozzle needle................... 24
5.7 Opening the implement housing ............ 25
5.8 Remedy leaking compressed air
connections ............................................ 26
5.9 Activate the safety switch....................... 26
5.10 Exchanging the silencer......................... 27
5.11 Exchanging the agent-hose ................... 28
5.12 Exchanging the pressure switch ............ 29
5.13 Exchanging the agent feed pump .......... 29
5.14 Trouble shooting .................................... 30
6. Spare part list ....................................... 32
6.1 Spare part list spray gun ........................ 32
6.2 Spare parts............................................. 33
7. Circuit diagrams................................... 37
8. Guarantee ............................................. 38
EC Conformity Declaration................................. 39

General hints 3
Jelly Shop Sprayer Edition 05.07
1. General hints
Identification data
Type: Jelly Shop Sprayer
Model-No.:
Year of construction:
Performance:

The identification data are o
f
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: [phone] / 96 37-0
Fax: [phone] / 96 37-16
www.boyensbackservice.de
e-mail: [email protected]
Spare parts ordering and after-sales service
Address as above
Phone: [phone] / 96 37-38
Fax: [phone] / 96 37-35
Documentary data
Documentary number of the instruction manual:
Version: Jelly Shop Sprayer
Edition: 05.07
Purpose of this document
This instruction manual acquaints the operator of a
Jelly Shop Sprayer 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 Jelly Shop Sprayer standing
upright. 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 operating instructions more
user friendly. Please send us your improvement
suggestions by fax.
Copyright © 2007 by
boyens backservice GmbH
Gildestraße 76-80
D-49479 Ibbenbüren
Germany
All rights are reserved

4Basic safety advice
Jelly Shop Sprayer Edition 05.07
2. Basic safety advice
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 Jelly Shop Sprayer has been designed
according to the state of art and the 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,
 incorrect assembly, putting into operation,
operation and maintenance of the implement,
 use of the implement with faulty safety equipment
or improperly fitted or inoperative safety devices
and guards,
 non-adherence to the information in the instruction
manual with regard to transport, storage,
assembly, putting into operation, operation,
maintenance and setting up the implement,
 arbitrary structural changes to the implement,
 inadequate monitoring of implement wearing
parts,
 inadequately executed repair work,
 unforeseen calamities caused by the influence of
foreign objects and force majeure.
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 advice 5
Jelly Shop Sprayer Edition 05.07
2.3 Intended use
The Jelly Shop Sprayer is exclusively intended for
the brief employment as spraying implement for
spraying jelly in baker's shops. 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 the information 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 and solvent
agents or
 other liquids, especially inflammable ones.
2.5 Informing safety measures
Always keep the instruction manual on the
implement. In addition 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 common
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.
During the spraying interruptions protect the spray
gun.
Never pull the implement on the power supply cable
or the material supply hose. Never pull the plug by
jerks on the cable off its plug-connection. Protect the
electric power supply cable and the agent hose from
heat and sharp edges. Only use a faultless electric
power supply cable.
Only spray aiming at the product, never aiming at
human beings 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.
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.

6Basic safety advice
Jelly Shop Sprayer Edition 05.07
2.10 Cleaning, maintenance, repair and
remedy of faults
Carry out the prescribed cleaning-, maintenance and
monitoring work right in time. Prior to all
maintenance-, monitoring- and repair work
 pull the electric net work plug off the socket.
 actuate the spray gun, and thus deflate the
residual air pressure in the system.
 when disposing condensate, observe the
prescriptions of the water resources law.
Check prior slackened bolted connections for firm
seating. After having finished maintenance work,
check the guards for function.
2.11 Constructional change of the
machine
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 the machine and
disposal
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 Shop Sprayer Edition 05.07
3. Description of the implement
3.1 Implement diagram
Spray gun
Agent-hose
Temperature-
control light
Power supply cable
Implement on/off
Jelly storage tank

8Description of the implement
Jelly Shop Sprayer Edition 05.07
3.2 Functional description
A
pneumatically driven, diaphragm controlled agent
feed pump sucks the cold jelly via the suction lance
(1) with its agent filter (2) out off the one-way jell
y
container (Bag in Box (BIB)) (3). The agent filte
r
protects the system against impermissible
contamination.
Then the sucked off jelly is delivered via the agent
feed pump to the dry running heater. Inside the dry
running heater the jelly is heated to the set
processing temperature.
By the factory the processing temperature has been
set to 87°C.
The Jelly Shop Sprayer is ready for operation when
the red temperature-control light (4) goes out.
The hot sprayable jelly is delivered via the heated
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 the size of the surface to be sprayed
use the flat jet- or round jet nozzle.
1
2
4
3
2
1
3
4

Description of the implement 9
Jelly Shop Sprayer Edition 05.07
3.3 Identification of the machine
You will find the type plate (1) and the CE-sign on the
back side of the implement.
3.4 Technical data
Power Supply: 230 V
Frequency: 50 Hz
Fuse in the feed line: 16 A
Length of power supply cable: 3 m
Heating capacity: 1,200 watt
Length of the agent hose: 1.2 m
Measurements:
Length:
Width:
Height:
370 mm
300 mm
350 mm
Weight: 20 kg
Spraying pressure: set to 2,8 bar and cannot be changed
Processing temperature: set to 87 °C and cannot be changed
Transport and storing Operation
Temperature + 2 to + 50°C + 2 to + 50°C
Humidity maximum 90% maximum 90%
1

10 Description of the implement
Jelly Shop Sprayer Edition 05.07
3.5 Technical features
The Jelly Shop Sprayer
 with diaphragm controlled compressor.
 with a special dry running heater.
 with energy saving technique - due to a good heat
insulation the heat is retained for hours in case o
f
work interruptions.
 with heated agent-hose up to the spray gun.
 spray gun with heat reflecting casing.
 with analog controlled heat adjustment.
 with pneumatically driven, diaphragm controlled
agent feed pump.
 with maintenance-free technique.
 in stainless special steel execution.
 with HACCP-conformity execution.
 energy saving.

Putting into operation 11
Jelly Shop Sprayer Edition 05.07
4. Putting into operation

The Jelly Shop Sprayer is exclusively
suited for the operation with alternating
current (230 V / 50 Hz). Never try to use
other sources of current. Ensure that the
voltage of the Jelly Shop Sprayers 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 Jelly Shop Sprayer with the aid
of the power plug to the power supply.
4.1 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.
When operating the implement it is
imperative to observe the instructions
regarding the
 intended use
 training of personnel.
Do not drag the Jelly Shop Sprayer 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).
1

12 Putting into operation
Jelly Shop Sprayer Edition 05.07
4.2 The 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
by sharp-edged parts. Danger of injury
from penetrating jelly.
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.

Putting into operation 13
Jelly Shop Sprayer Edition 05.07
4.3 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) o
f
the jelly container (3)
- Introduce the suction lance (1) into the jelly
container carefully.
- Screw the suction lance (1) onto the jelly
container by means of the screw fastening (2).

Always keep the agent filter and the
suction lance clean and free from
chokes. A choked agent filter or a
choked suction lance prevent the free
agent flow. This would cause a running
dry of the agent delivery pump and
agent burning inside the flow heater.
The running dry damages the agent
delivery pump.

Damage on the agent delivery pump will
not be accepted as claims unde
r
guarantee if they result from sucking
foreign particles.
1
2
3
1
2

14 Putting into operation
Jelly Shop Sprayer Edition 05.07
4.4 Switching the implement on/off
Switching on
- Press the green main switch.
- It will flash:
 the green control light (2) and
 the red temperature-control light (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 heate
r
and agent hose with jelly.
The flow heater and the agent hose heat
the jelly up to the prior set processing
temperature.
The Jelly Shop Sprayer is ready for use
when the red temperature-control light
(3) has gone out.

If the implement is cold, the heating
period will last approx. 5 to 8 minutes.
Switching off
- Press the green main switch.

After the implement has been switched
off, the green control light (2) goes out.
1
3
2

Putting into operation 15
Jelly Shop Sprayer Edition 05.07
4.5 Choosing the agent nozzle and
exchange
Optionally available: a round jet and a flat jet agen
t
nozzle.
Principle for choosing the nozzle:
 yellow round jet agent nozzle (1) for small and round
products.
 red flat jet agent nozzle (2) for large areas and cake
tins.
Exchanging the agent nozzle
-
A
ctivate the spray gun locking (1) agains
t
unintended spraying (the illustrated spray gun is
not locked as this spray gun is not connected).
- Slacken the collar nut (2) by hand and remove.
- Remove the agent nozzle (3) from the collar nut.
- Insert another agent nozzle into the collar nut.
- Bolt the collar nut onto the spray gun again and
tighten by hand.
- Replace the spray gun into its container.
12
1
3 2

16 Putting into operation
Jelly Shop Sprayer Edition 05.07
4.6 The spraying procedure
Always accurately aim the spraying
operation onto the bakery products.
Never aim at people or animals.
The spraying procedure differs between
 rotary spraying and
 flat- or wide spraying.
Rotary spraying:
- For rotary spraying guide the spray gun in circula
r
movements over the bakery products.
Flat spraying:
- For flat spraying guide the spray gun in left and
right hand swivelling movements above the
bakery products.
Spraying the product:
- During the spraying pauses protect the spray gun
against unintended spraying by turning the locking
device (1).
- Hold the spray gun at a distance of approx. 10 cm
directly above the bakery products.
- Pull the trigger (2) of the spray gun and apply the
jelly onto the bakery products.
Interrupting the spraying procedure:
- Release the trigger (2). The agent immediatel
y
stops discharging from the spray gun.

If you interrupt the spraying procedure it
may happen that the liquid jelly already
jellies inside the spraying nozzle. Before
spraying new products you should hold
the spray gun into a bin/bucket and
actuate briefly.
1
2

Putting into operation 17
Jelly Shop Sprayer Edition 05.07
4.7 Pauses and operational breaks

Switch off the implement if the
operational break will be more than 1/4
hour.

After switching off, the dry running
heater provides a residual heat for some
hours. Thus, after having been started
again, the Jelly Shop Sprayer only needs
a few minutes to obtain the pre-set
processing temperature.

Before longer operational interruptions
(more than 3 hours) spray the system
empty,
 in order to save the system from
material-burns.
 because the jelly will have lost its
ability to jelly after more than 2 - 4
hours of stale.

Immediately switch off the implement
when the system has been emptied.
Material-burns inside the material
channel would be the result when the
system goes on heating without
material.

Damage due to hoses which have not
been flushed (emptied by spraying) will
not be accepted as claims unde
r
guarantee.
- Switch off the implement if the operational break
will be more than 1/4 hour.
- Before switching off the implement, ensure that it
is empty if the intended operational break will last
longer than 3 hours.
Spraying the system empty
- Slacken screw joint (1) and pull the suction lance
(2) out off the jelly container.
- Go on spraying your pastry until only an air / jell
y
mixture will emerge the spray gun.
- Secure the spray gun (3) by means of the locking
device (4) against unintended spraying.
- Place the spray gun into the retainer (5).
- Switch off the implement.
- Introduce the suction lance (2) into the jelly
container again carefully.
- Screw the suction lance (2) onto the jelly
container by means of the screw fastening (1).
3 4
5
2
1

18 Putting into operation
Jelly Shop Sprayer Edition 05.07
4.8 Restarting after an operational
break
- Switch on the implement. It will flash:
 the green control light (1) and
 the red temperature-control light (2).

When the red temperature-control light
(2) has gone out the implement is ready
for operation again.
The operational break lasted longer than 3 hours:
- Take the spray gun out of the retainer.
- Protect the spray gun against unintended spraying
by turning the locking device.
- Spray approx. 300 ml jelly into a bin/bucket before
you start to spray your products.

We recommend this procedure because
the jelly will lose its ability to jelly after 2
- 4 hours of stale.
The system had been sprayed empty before the
operational break:
- Take the spray gun out of the retainer.
- Protect the spray gun against unintended spraying
by turning the locking device.
-
A
fter the agent feed pump has delivered the jelly
up to the agent nozzle of the spray gun, you may
start to spray your products.
The system had not been sprayed empty before
the operational break:
- Take the spray gun out of the retainer.
- Protect the spray gun against unintended spraying
by turning the locking device.
- Now you may start to spray your products.
The operational break lasted less than 3 hours:
- Take the spray gun out of the retainer.
- Protect the spray gun against unintended spraying
by turning the locking device.
- Hold the spray gun into a bin/bucket and actuate
the trigger of the spray gun briefly.
- Now you may start to spray your products.

It the operational breaks will last longe
r
than 3 hours, this procedure is only
permitted in exceptional cases. If the
system will not be sprayed empty afte
r
such a long operational break, material
burns inside the system may be the
result.
1
2

Cleaning, maintenance and maintaining 19
Jelly Shop Sprayer Edition 05.07
5. Cleaning, maintenance and
maintaining

Carry out prescribed cleaning and
maintenance work in due time. Prior to
all cleaning and maintenance 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 wate
r
resources law.
Check the firm seat of screw
connections that have been unscrewed
beforehand. On completion o
f
maintenance work, check the function o
f
all safety devices.

To clean the implement, only use
 clear water.
 clear water with a maximum wate
r
temperature of 50°C.
 a moist sponge or a moist cloth.
 never a high pressure cleaning
device.
Clean the agent hose at regula
r
intervals.

In case of leaks in the compressed ai
r
system, slightly tighten screw
connections on the spray gun and othe
r
compressed air system components.
These bolted connections may work
loose:
 because the system is constantly
moving due to the compressed ai
r
and the agent to be sprayed.
 because of improper handling, e.g. i
f
the spray gun is dropped.

Every operator may check compressed
air connections and repair leaky
compressed air connections.
Repair work on the electric supply may
only be executed by a skilled electrician.

20 Cleaning, maintenance and maintaining
Jelly Shop Sprayer Edition 05.07
5.1 Cleaning - daily after having
finished the operational
procedure
- Slacken screw joint (1) and pull the suction lance
(2) out off the jelly container. Refer to chapte
r
"Pauses and operational breaks", page 17.
- Close the jelly container and keep cool.
- Spray empty the jelly storage tank until only a
jelly-air mixture will come out of the spray gun.

Stop spraying the system empty as soon
as only a jelly-air mixture will come out
of the spray gun.
Ensure that the system does not heat
without agent/water. Agent burns inside
the agent channel might be the result.
- Dip the suction lance with the agent filter into a
bucket with water.
- Actuate the spray gun and spray the water-jelly
mixture into a bin/bucket.

Flush the system until only clean wate
r
will discharge from the spray gun.
- Pull the suction lance off the bucket with water.
- Spray empty the system until only a water-ai
r
mixture will come out of the spray gun.
- As soon as just a water-air mixture comes out o
f
the spray gun, immediately switch off the
implement.
- Actuate the spray gun and thus discharge the
residual air pressure out off the system.
- Lock the spray gun against unintended spraying.
- Pull off the electric network plug.
- Check the agent filter for pollution.
- In case of pollution, unscrew the agent filter and
clean.
- Check the suction lance for pollution.
- Cleaning the suction lance (1), if necessary.
- Cleaning with a moist cloth
 the implement.
 the agent-hose.
 the spray gun.