Diamond DCM-35 User manual

User Manual for Chocolate Melanger
Model: DCM- 35, 70 and 100
Diamond Custom Machines Corporation
9 Ilene Ct, Unit 9
Hillsborough, NJ 08844
Phone: [phone] Fax: [phone]
Email: [email protected]
Version 4 20190627

User Manual Model: DCM- 35, 70 and 100
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TABLE OF CONTENTS
Parts Diagram 2
Safety Instructions and Precautions 3
Installation procedures 4
Cleaning Instructions 5
Refining Chocolate with Melanger 6
Recipe Notes 7
Troubleshooting and FAQs 8
Technical Specifications 10
Service and Maintenance 10
Warranty Information 11
Pneumatic Pressure System Addendum 13
NOTE: As a result of continuous product improvement, design changes are made from time to
time. Some changes and modifications may not be covered in this manual. If you are unsure
about the safe operation of your Melanger, please contact Diamond Customs Machine
Corporation for assistance.
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Parts Diagram
The images of the parts may not accurately reflect the actual product.
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SAFETY INSTRUCTIONS AND PRECAUTIONS
Generally accepted and recommended safety practices are applicable to appliances purchased from
Diamond Custom Machines. Users are required to read and understand operating instructions, labels
and general safety and warnings prior to using the appliance. Save these instructions for future
reference.
Failure to follow the instructions detailed in this manual may lead to a voided warranty, personal harm,
damage to appliance, fire hazard, or other unsafe and potentially dangerous conditions.
A. General Safety
●Do not use the appliance for any use other than its intended use. Do not use outdoors;
this product is intended for indoor use only. Do not place the appliance near a hot gas or
electric furnace;
●Do not run the appliance longer than the time recommended in the instruction manual;
●Unplug the appliance from the electric outlet when not in use;
●This is a heavy machine. Use proper lifting procedures to avoid personal injury. During
disassembly for maintenance, exercise extra care especially when handling heavy
components such as grinding stone, grinding vessel etc. Handle the pinch point sharp
edges carefully;
●Do not leave the unit unattended while it is in operation. Close supervision is always
necessary when the appliances are used near children, the elderly or disabled.
●Place the appliance on a hard, flat, level stable surface;
●Do not put your hands or any other objects into the vessel during operation. Checking
the contents has to be done only when the unit is turned off and after complete stop of
the operation;
●Do not use any accessory attachments that are not recommended by Diamond Custom
Machines. This may cause personal injuries and/or damage to the unit;
●Do not touch the rotating drum while in operation;
●Loose clothing and long hair must be secured prior to operation;
●Tilt lock bar must be in the locked position before operation of the equipment.
B. Electrical Safety
Use this product with rated voltage AC outlet only. Use a dedicated electrical outlet/circuit for the
unit.
●To protect against electric shock, do not immerse the power cord, power plug or the
machine in water or in any other liquid.
●Close adult supervision is necessary when this appliance is used near children;
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●Always switch off the unit and unplug the wire;
●Do not operate the appliance with a damaged cord or plug;
●If the appliance has malfunctioned or has been damaged in any way. Call Authorized service
technician for examination or repair;
●Disconnect the unit during cleaning or when not in use;
●Check the power cord for any visible damages;
●Do not let power cord touch hot surfaces;
●Do not let the power cord hang loose.
PRECAUTIONS:
●Plug in the Melanger into appropriate motor rated outlet. DO not handle the plug with wet
hands. Ensure that the electrical outlet is properly grounded;
●Ensure the Tilt stop locks are in place and pinned so the Melanger does not accidentally tilt
during operation;
●Do not dry run the Melanger without any ingredients for longer than a couple of minutes;
●Never overload the Melanger. Please take appropriate time while loading the ingredients to
ensure that the stones do not get stuck. In case of overload condition, switch off the
machine immediately, reduce the load and restart the machine;
●Always operate the machine only in the upright vertical position. Do not run the machine
when it is tilted;
●While cleaning the machine after use ensure that water does not enter the motor
compartment;
Installation Procedure:
1. Ensure that the Melanger arrived safely without any damages during transit. Inspect
the grinder for any visual defects. If you see any defects please call 1-888-717-9222
immediately;
2. The unit should be removed from the pallet and the wooden base structures before
use. Use caution while removing the pallet and the wooden base if applicable.
3. Please ensure that the Melanger is placed in a secure well-ventilated area and on a flat
stable surface;
4. Use the caster wheels to move the machine into appropriate place and lower the
footpegs by turning the red knob. Adjust the height of the pegs and use a leveling
gauge to ensure that the machine is level in the front and back;
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5. Be sure the slot in the top bar tensioner is engaged with the flat portion of the vertical
bar of the roller stone holder. Rotate both tension control knobs evenly until they
contact the top bar and begin to apply downward pressure;
6. Adjust the wiper blade such that it does not touch the stone beneath and the stainless
steel drum on the side. On change over to a new batch please ensure that the wipers
are in place and not displaced during operation. The wiper alignment is critical to safe
and effective operation of the machine;
7. Ensure adequate space in front and back of the machine so the Melanger can be tilted
without hitting any objects or walls.
Cleaning Instructions:
When the Melanger arrives it needs to be cleaned. There are a few options to clean the bowl and
stones.
1. Wipe out the bowl and granite stones with a clean cloth. Add a few pounds of roasted chocolate
nibs to the bowl, assemble the unit (as described below) and run for about an hour. Alternately,
you can also run a few cups of vegetable oil for about an hour;
2. The stones and the drum can also be washed with hot soap and water. Let COMPLETELY dry
before using for chocolate;
3. Wipe clean the outside of the drum and the body of the machine;
4. DO NOT dry run the stones. Dry running could result in permanent damage to the stones and
the drum.
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Refining Chocolate with Melanger:
Make sure your Melanger is ABSOLUTELY DRY when you start.
Just a touch of water can ruin the entire batch, seizing and leaving you with thick fudge like mass that
cannot be refined in the Melanger.
1. Plug the unit into appropriate power outlet;
2. Ensure that the Red E-Stop button is pulled out and not depressed;
3. Turn the power On/Off button to on position;
4. Before you start the motor check and see if the FWD, STOP and Hz lights are turned on;
5. Turn the black speed control knob so the display will read approx. 20 Hz. (blinking);
6. Press the run button on the multi-function control panel to turn on the machine;
7. The unit will begin to spin. Immediately begin to slowly add ingredients to the drum. Do not dry
run the machine;
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8.
a. If a Pneumatic Pressure System is installed on the unit please refer to the Addendum on
page 13 and following. If no Pneumatic Pressure System is mounted, please proceed to
8b.
b. To adjust tension turn the end tension control knobs until you start to feel the back
pressure pushing back on the knobs. This is all you will need to refine the chocolate. As
the chocolate is getting refined, the tension will become loose and you will need to
slowly turn the tension knobs until you feel the back pressure and then lock the knobs
with the wingnuts. You will need to keep an eye on the top bar to ensure that it is not
too loose. Active management will get optimal results. You may have to look at the
tension knobs maybe 2 to 3 times a day and adjust the tension accordingly;
Caution: Do not put too much tension to the stones. Too much tension will result in the
plastic parts inside the rollers and the rollers wearing out quickly;
9. Slowly start to add the necessary ingredients to the machine. Slowly increase the speed of the
machine and add the rest of the ingredients as appropriate. Do not run the machine above 40 hz
for the first 48 hours to allow proper break in of the machine;
10. The granite stones could be warmed up using a blow dryer or using a rapid refiner but ensure
that the temperature stays below 150 F / 65 C;
11. After the batch is finished please press the stop button on the controller to stop the rotation of
the drum;
12. Turn off the power to the controller,
13. Release the tilt stop latch on the side and gently tilt the machine to empty the drum. Take care
to slowly tilt to empty the drum.
Recipe Notes:
The sugar you add should be regular white cane sugar. Do not use "powdered" sugar, this contains
cornstarch. If you wish to reduce your refining time a couple hours, a small "whirly blade" coffee grinder
or blender works nicely to "powder" your own sugar. 2 minutes pre-grinding the sugar will save you 2 or
more hours in the Melanger. If you don't wish to bother, that is fine to - the Melanger will handle
crystals of sugar just fine.
You may need to add a little heat to the chocolate during the first 1/2 hour or so if you notice that it
cools too much and starts to thicken. A standard blow dryer (for hair drying) works very well for adding
heat or the rapid refiner can also be used to add heat.
Alternately, you can pre-heat all of your ingredients in a warm oven to about 140 °F/60 °C. This will
allow the Melanger to work more easily.
Other sugars may or may not work due to their moisture content. Brown sugar for instance needs to be
dried before it can be used. Malt powder holds enough moisture to cause your batch of chocolate to
seize. We specifically DO NOT RECOMMEND the following sweeteners and ingredients for refining with
the Melanger:Honey
Agave syrup
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ANY syrup
Liquid milk or cream
Condensed milk
Evaporated milk
Water
Unroasted nuts or cocoa nibs
Fresh or not fully dried fruits
Water or alcohol based extracts (vanilla for instance)
In short ANYTHING that contains water or alcohol.
And if you experiment with alternative unrefined sugars, such as various brown sugars and coconut
sugar, you will probably have to dehydrate them or their water content will be too high and your
chocolate may seize.
The use of any of these (or any other ingredient that contains water - we just cannot name them all) will
most likely cause the chocolate to seize and may damage the equipment. Melangers damaged by the
use of any liquid based ingredient is NOT covered by warranty. Use at your own risk. If you have ANY
concerns about the appropriateness of an ingredient, please feel free to contact us immediately.
Your chocolate should be "flowing" smoothly over and under the rollers like a liquid. If not, something is
not right. Check the Troubleshooting section at the end of this document. It may be as simple as
warming your chocolate a little or adding your ingredients a little slower so they have time to
incorporate.
The Stone Melanger is meant to be run continuously. This does not mean something can't go wrong,
especially when you first get it. In general, we recommend keeping a close eye on it for the first few
hours you use it make sure it is running properly.
We never recommend leaving it running completely unattended.
Once your chocolate has attained the level of refining that you desire (taste it - it is your best tool), turn
off the Melanger and pour your chocolate into chocolate molds for storage or proceed directly to
tempering and finish molding.
Clean the Melanger with hot water, soap and a scrub brush. Make sure you rinse away ALL the soap.
Soap is not desirable in chocolate. All parts must be completely dry before you use it again.
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Troubleshooting and frequently asked questions (FAQ):
Q: The cocoa nibs and sugar are just packing down and the rollers are just running on top.
A: You cannot just dump roasted nibs and sugar together in the Melanger and expect it to make
chocolate. See above for how to add ingredients.
Q: Can the Melanger make liquor out of nibs.
A: Yes it can, but can be a little time consuming.
Q: Can I make nut butters?
A: Yes, absolutely. But the same ‘no water’ rules apply. For instance, a honey sweetened nut butter
will seize.
Q: I added just a tiny amount of honey to my recipe (maybe a teaspoon), but now my chocolate is this
thick fudge like mess.
A: Cannot add ANY water based ingredient or your chocolate will seize.
Q: I mixed up one of your recipes for milk chocolate. It was dry and crumbly. I added it to the Melanger
but it just stuck to everything and clumped up until the motor stopped.
A: The Melanger can do many things and is quite up to the task of refining chocolate, but you cannot just
throw everything in and walk away. In general, if your mixture is crumbly or too thick, you either need to
add more cocoa butter (melted), less sugar or maybe just a little heat to melt the cocoa butter that is
present (cocoa liquor is 50% cocoa butter).
In general, if you refining mixture is not "flowing" then something is wrong and needs to be addressed.
If you have ANY concerns or questions about your Melanger, please feel free to contact us immediately.
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Technical Specification:
Generic Name: DCM Melanger – 35/70/100 lbs
Color: Stainless Steel outer body.
Outer Body: Stainless Steel
Stones and Base: Granite
Power Requirements:: 208-230 VAC,3 phase 50/60 Hz, 20 amps
Plug Type : 208-230 VAC, 20 amps, Turn-lock connector, NEMA L6-20
Overall Dimensions: Approx 24”x 28”x 46” for DCM - 35
Approx 28”x 32”x 48” for DCM - 70
Approx 31”x 33”x 54” for DCM - 100
Weight: Approx 230 lbs for DCM - 35
Approx 400 lbs for DCM - 70
Approx 500 lbs for DCM - 100
Motor: 1 HP, 3 phase motor for DCM - 35
2 HP, 3 phase motor for DCM - 70/100
Cable Length: 10 feet
Maximum Capacity: 35 lbs for DCM - 35
70 lbs for DCM - 70
100 lbs for DCM - 100
Service and Maintenance:
The Gearbox, the motor and the control panel do not require regular service or maintenance. The bowl
and the stones have to be cleaned as per your internal change over operating procedures. Rotate the
roller stones inside out once every month so the stone wear is uniform. The wiper blades should not
touch the bowl. If you need replacement parts, please contact us using the information below.
Repairs:
If your Melanger requires Service, please contact us and we will provide support to get your machine up
and running as quickly as possible.
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Warranty Information:
1-year Limited Warranty
Diamond Custom Machines Corporation (DCM) warrants that for a period of one year from the date of
purchase, this product will be free from defects in material and workmanship. DCM, at its option, will
repair or replace this product or any component of the product found to be defective during the
warranty period. Replacement will be made with a new or remanufactured product or component. If the
product is no longer available, replacement may be made with a similar product of equal or greater
value. This is your exclusive warranty. Do NOT attempt to repair or adjust any electrical or mechanical
functions on this product. Doing so will void this warranty. This warranty is valid for the original
purchaser from the date of initial purchase and is not transferable. Keep the original sales receipt. Proof
of purchase is required to obtain warranty performance. DCM dealers, service centers, or retail stores
selling DCM products do not have the right to alter, modify or any way change the terms and conditions
of this warranty.
This warranty does not cover normal wear of parts or damage resulting from any of the following:
negligent use or misuse of the product, use on improper voltage or current, use contrary to the
operating instructions, disassembly, repair or alteration by anyone other than DCM authorized service
center. Further, the warranty does not cover: Acts of God, such as fire, flood, hurricanes and tornadoes.
What are the limits of DCM’s liability?
DCM shall not be liable for any incidental or consequential damages caused by the breach of any
express, implied or statutory warranty or condition.
Except to the extent prohibited any applicable law, any implied warranty or condition of merchantability
or fitness for a particular purpose is limited in duration to the duration of the above warranty.
DCM disclaims all other warranties, conditions or representation, express, implied, statutory or
otherwise. DCM shall not be liable for any damages of any kind resulting from the purchase, use or
misuse of, or inability to use the product including incidental, special, consequential or similar damages
or loss of profits, or for any breach of contract, fundamental or otherwise, or for any claim brought
against purchaser by any other party.
Some provinces, states or jurisdictions do not allow the exclusion or limitation of incidental or
consequential damages or limitations on how long an implied warranty lasts, so the above limitations or
exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights that vary from province
to province, state to state or jurisdiction to jurisdictions.
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How to obtain warranty Service
If you have any questions regarding this warranty or would like to obtain warranty service, please call
1-888-717-9222.
Contact information:
Diamond Custom Machines Corporation
9 Ilene Ct, Unit 9
Hillsborough, NJ 08844, USA
Direct: 1-888-717-9222
Fax: [phone]
Email: [email protected]
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Addendum for Pneumatic Pressure System:
This addendum is to be used for DCM Melangers that have the Pneumatic Pressure System accessory
installed.
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DCM Melangers with Pneumatic Pressure System have the following additional parts:
●Two Support Spacers between the top bar and the base of the vertical tension control threaded
rod.
●Air Cylinder centered above the top bar to provide tension force.
●Pressure Regulator comprising the tension control valve, pressure gauge, and the air filter.
●Compressed air source must supply clean dry air with a minimum of 80 pounds per square inch
(5.5 bar) and 0.1 cubic feet per minute (2.8 liters per minute).
●Intake Air Tube ( Connected to the factory pressure supply or Air Compressor).
●Regulator air tube is connected to the Air cylinder.
The Support Spacers are located on the threaded rod of the Frame Arms. The top bar is located on the
threaded rods of the frame arms (above the support spacers). Be sure the slot in the top bar tensioner is
engaged with the flat portion of the vertical bar of the roller stone holder. Rotate both tension control
knobs evenly until they lock in place firmly securing the top bar. All tension is controlled by the air
cylinder. The tension control knobs should not be used for tension control in this application. They must
be tightened fully. Connect the air line to your compressed air source. Use the pressure adjustment
knob to adjust the starting air pressure to 10 psi or less as read on the pressure gauge. Use the pressure
adjustment knob and gauge to set the stone tension as required by your process. The pressure must
never be set above 60 psi as this will apply excessive pressure on the stones which will result in
premature wear or other damage that is not covered by the warranty.
The following procedure should be used for disassembling.
1. Remove the air pressure by disconnecting the supply line and the electrical power line.
2. Remove the air line from the air cylinder by pulling back on the quick disconnect sleeve.
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3. Remove the tension control knobs, top bar and spacers. The roller stone assembly may now be
lifted out for cleaning.
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