Diedrich Roasters IR-5 User manual

MANUAL IR-5/IR-12 ROASTER
QUICK START GUIDE Keep this guide with the roaster at all times
TECHNICAL SUPPORT HOTLINE
[phone] M-F 7A-3:30P PST
ATTENTION!!
ALL SYSTEMS (Electrical, Gas, and HVAC) MUST BE
CONNECTED, FUNCTIONING AND INSPECTED (if required) PRIOR
TO USING THIS QUICK START GUIDE
You must familiarize with the components of this roaster
before utilizing this Quick Start Guide!!
(refer to Installation & Operation Manual pgs. 14,15, &16
INITIAL START-UP PROCEDURE
1. Ensure Emergency Stop Button is disengaged (out) position (If
pushed in, twist knob to release)
2. Ensure the “Pilot Only/Burners On” switch is in the "PILOT
ONLY” position (3).
3. Verify that the air flow handle in the “COOLING BIN” position.
4. Confirm that the “GAS” knob (4) is turned all theway to the left
(counterclockwise) = Minimum position.
5. A. For Standard roasters:
Activate the switches sequentially as follows:
•Drum (5)
•Blower (6)
•Gas (7)
B. For Universal roasters:
Turn on the switches sequentially as follows:
•Drum (5)
•Gas (7)
Wait for the green air light to illuminate,
•Blower (6) switch.
6. Once the pilot is lit, switch to the "Burners On" (3) position and
use the gas control knob to adjustthe flame intensity (NOTE: IT
MAY TAKE SEVERAL ATTEMPTS AS AIR MAY NEED TO BE
PURGED FROM THE GAS LINE)
7. Move the Gas (7) knob to desired flame settingand watch the
“Bean Temperature Display” (1).
8. Allow the roaster warm to 400°F - 450°F
Check the exhaust and gas connections for leaks.
*PERFORM DRUM SEASONING PROCEDURE on other side prior to
roasting for consumption!!*
COMPONENT DESCRIPTIONS:
1 = BEAN TEMP display: Drum bean temperature
2 = AIR INDICATOR LIGHT:
Standard Model roasters have a red light. It is illuminated when
airflow is diminished causing the gas ignition system to shut
down. (clean all roaster air ducts and impeller housing)
Universal Model roasters have a green light. It will be
illuminated during normal operation. When light goes out, this
indicates abnormal airflow caused by outside air disturbances.
3 = PILOT ONLY / BURNERS ON switch: Toggles
gas system from pilot to main burners
4 = GAS knob: Controls the flame intensity of burners
5 = DRUM switch: Starts drum rotation
6 = BLOWER switch: Starts blower motor
7 = GAS switch: Starts gas ignition system
8 = AGITATOR switch: Starts bean stir in Cooling Bin
9 = RESET switch: When temperature exceeds
485°F, the temperature high limit module will trip.
Once cool, reset used to reignite pilot/burners
10=EMERGENCY STOP button: Stops all functions of
the roaster
11=E-STOP RESET button: Twist the Emergency
Stop button (10) to release and press this button
to reset
“THROUGH COOLING BIN “ “50 / 50 “ “THROUGH ROASTING DRUM”
Things to remember…
•Keep your roaster clean! –the most common issue
occurs when the Impeller Housing and associated
ducting is not scraped down to the metal surface and
vacuumed out. This roaster is equipped with an “Air
Pressure Switch” that will disrupt the gas ignition
system when excessive build-up (1/8” max.) is present.
•Frequent cleaning will also keep the air velocity
more constant, rendering your coffee quality more
consistent.
•Don’t forget to grease the bearings.
SHUT DOWN PROCEDURE
1. Turn the “Gas” switch (7) OFF and set the “Gas” (4) knob to the
“MINIMUM” position
2. Make sure the “Pilot Only/Burners On” (3) toggle switch isin
the “Pilot Only” position.
3. After the temperature reading has dropped to 250ºF(120ºC) or
lower, set the “Blower” (6) and “Drum” (5) switches to “OFF”.
4. Remove the chaff from the lower compartments of theroaster.
5. Open the side doors to remove chaff and for generalcleaning.
6. Inspect for smoldering chaff. If found, extinguish with water (a
small spray bottle is recommended for thispurpose).
7. Using a vacuum, clean the cooled chaff out of theroaster.

MANUAL IR-5/IR-12 ROASTER
QUICK START GUIDE Keep this guide with the roaster at all times
TECHNICAL SUPPORT HOTLINE
[phone] M-F 7A-3:30P PST
ATTENTION!!
ALL SYSTEMS (Electrical, Gas, and HVAC) MUST BE
CONNECTED, FUNCTIONING AND INSPECTED (if required) PRIOR
TO USING THIS QUICK START GUIDE
DRUM SEASONING PROCEDURE
PLEASE READ AND FULLY UNDERSTAND THIS PROCEDURE PRIOR TO
STARTING THE SEASONING PROCESS
The drum of the roaster must be seasoned before roasted coffee is fit
for consumption. Use an inexpensive coffee for the seasoning process.
Do not use a Robusta coffee as it does not emit as much oil for
seasoning the drum. The new drum requires from 8 to 12 seasoning
roasts to become properly oiled. Each seasoning roast requires about
50% of roaster capacity (IR 1 / 2.5 USE FULL BATCH) of coffee,
enough to fully cover the drum's lower surfaces. During seasoning, the
roaster should be operated for 30 –60 minutes with the oily beans
tumbling in the drum at a temperature of 425°F –460°F or until the
beans become dry. After completion of each seasoning roast, discard
the roasted coffee after it cools. It may take additional roasts to achieve
the best flavor from your new roaster. Seasoning the roasting drum will
also give you the opportunity to become familiar with the roaster's
controls and the roasting process.
1. Preheat the roaster to ~ 420ºF.
2. Fill hopper with the pre-described amount of beans.
3. Move the air control lever to the “THROUGH COOLING BIN”
position.
4. Activate the hopper gate handle to load the green beans from the
hopper into the drum to start the roasting/seasoning process
5. Set the gas output to approximately 50%.
The coffee will change in color from green to a pale yellow (4-6
minutes).
6. When the coffee reaches the yellow stage ~280°F, move the air
control handle to the “50/50" (middle) position. This allows for a
more uniform heat.
7. When the coffee approaches ~385°F “1st crack”, reduce fuel % and
let the roast progress in the full roasting stage until the coffee develops
through the second crack (~435°F) and oil begins to appear at the tips
of the beans (try and reach ~460°F slowly).
8. When you begin to notice the first traces of oil, turn the gas control
“OFF.” Note: Due to the exothermic reaction (the chemistry creates its
own heat), the bean temperature can continue to rise on its own with
gas turned off.
9. Let the coffee roast in its own liberated heat until the beans are fully
oiled and almost black. Leave the coffee turning in the drum for 30 –60
minutes or until the beans are dry to help fully coat (season) the drum.
10. Once the beans become less oily, turn on the “AGITATOR” and
move the air lever control to the “THROUGH COOLING BIN”
position and discharge the coffee into the Cooling Bin.
Repeat seasoning cycle if scorching or tipping occurs during normal
roasting.
ROASTING FOR CONSUMPTION
1. Preheat the empty drum until the Bean temp display (1)
reads 415º F or until you reach your desired charge
temperature.
2. Load the green beans into the hopper funnel after the
roaster's empty drum has been preheated.
3. Prior to starting the roasting process, move the airflow control
lever to the "Through Cooling Bin" position.
4. Move the hopper gate lever up to release the greenbeans
from the hopper into the drum.
5. Move the lever down to close the hoppergate.
6. Adjust the flame control to an appropriate heat setting
batch size.
7. When the beans appear yellow in color (~270°F), move the
air flow control lever to the "50/50" (mid)position.
8. When the beans approach “1st crack” (~385°F), move the
air control lever to the “Through RoastingDrum”
position.
9. Reduce gas setting and approach the desired finish
temperature
10. In preparation for discharge of the roasted beans, move the
air flow control lever to the “Through Cooling Bin”
position.
11. Turn on the “Agitator” (8)
12. Switch the flame “Pilot Only” (3)
13. Using the Sample Trier, sample the beans frequently.
14. When the beans reach the desired color /development,
move the Drum Door lever up to discharge the beans into
the Cooling Bin.
15. After the coffee has been in the Cooling Bin for a minute or
so, turn off the “Agitator” (8) and spread out thecoffee.
16. With the Agitator “OFF”, the cool air can find a path through
the beans allowing the coffee to coolfaster.
17. When the beans have cooled to room temperature, position
a container under the cooling binchute.
18. Turn “ON” the “Agitator” (8), and discharge the beans from
the Cooling Bin.
W A R N I N G
Pay close attention to the temperature at this point. DO NOT LET
THE TEMPERATURE RISE ABOVE 480°F!! The roaster is equipped
with a High Temperature Limit System that shuts the gas off at 485°F.
However, the temperature can continue to rise due to the exothermic
reaction of the bean. If the coffee is not removed from the drum
before 500°F, the coffee may ignite. Have a water source or CO2
fire extinguisher nearby.
High Temperature Limit Module Explanation
At 475°F, the main burner shuts off, but the pilot does NOT shut
off (No alarm sounds). At 485°F, the alarm will sound and the
High Temperature limit shuts down the roaster's entire gas
system. (If this happens, wait for temperature to reduce and reset
the roaster)
During this progression look through the drum door view window, you
will start to see chaff, the bean's outer skin, separating from the coffee
bean. Unwashed coffee has considerably more chaff than washed
coffees and decaf coffees have almost no chaff. The bean
development and color can be observed by using the sample trier.
As the coffee reaches the yellow stage, the moisture in the coffee that
was a good conductor of heat early on in the roast, is now turning to
steam. At this stage in the roast, the air flowing through the roasting
drum becomes a more uniform heat medium
As the coffee reaches a temperature of 340°F (171°C) the chemical
changes in the coffee start an exothermic reaction (the chemistry creates
its own heat). This exothermic reaction continues through the remainder
of the roast and therefore the gas % should be reduced during this
period until the end of roast.