MAUTING Junior 03 User manual

Operating Instructions
Smoking Chamber
Junior 03
Production Number: 081/11
Year of Production:2011

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
2of 22
Instruction manual
CONTENT:
1. INTRODUCTION......................................................................................................................................... 3
1.1. Usage ................................................................................................................................................... 3
2. GENERAL INSTRUCTIONS....................................................................................................................... 3
2.1. Safety................................................................................................................................................... 3
2.2. Symbol specifications.......................................................................................................................... 3
2.3. Safety regulations –organization measures......................................................................................... 4
2.4. Safety regulations –protective instruments ......................................................................................... 4
2.5. Safety regulations –device operator.................................................................................................... 4
2.6. Safety regulations –work with smoke generator................................................................................. 5
2.7. Safety regulations by maintainanace, cleaning and troubleshooting.................................................... 5
2.8. Warning labels placement.................................................................................................................... 6
2.9. List of safety devices and their role ..................................................................................................... 6
3. TECHNICAL DESCRIPTION...................................................................................................................... 7
3.1. Operation conditions............................................................................................................................ 7
3.2. Technical parameters ........................................................................................................................... 7
3.3. Description........................................................................................................................................... 7
3.4. Material.............................................................................................................................................. 10
3.5. Operator ............................................................................................................................................. 11
4. INSTALLATION OF CHAMBER ............................................................................................................. 14
5. ACCEPTANCE, DELIVERY..................................................................................................................... 15
6. ORDERING ................................................................................................................................................ 15
7. PACKAGING, TRANSPORTATION, STORAGE.................................................................................... 16
8. CLEANING................................................................................................................................................. 16
8.1. Technological process of chamber cleaning ...................................................................................... 16
8.2. Technological process of smoke generator cleaning.......................................................................... 16
9. MAINTAINACE AND TROUBLESHOOTING........................................................................................ 17
9.1. Periodic service and inspection schedule........................................................................................... 17
10. MALFUNCTIONS AND THEIR REPAIRS ......................................................................................... 18
11. SPARE PART LIST ............................................................................................................................... 20
12. GUARANTEE........................................................................................................................................ 20
13. REGULATIONS AND STANDARDS.................................................................................................. 21
14. PICTURES AND APPENDIX:.............................................................................................................. 21
15. REMARKS............................................................................................................................................. 22

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
3of 22
Instruction manual
1. INTRODUCTION
1.1.Usage
Smoking chamber MAUTING Junior is equipment designed for small meat processing
plants and also for restaurants. It makes possible to heat treatment of meat products, e.g.
drying, smoking, cooking and roasting up to 160°C in one cycle without further
manipulation, with manual control of flaps, glowing (smoking) and moistening. It
means that a microprocessor unit according to a chosen program controls technological
process. User can easily create his own programs according to his needs –it means
setting of chamber temperature, core temperature and time of processing. The smoking
chamber is electrically heated. Another way of usage must be consulted with the
manufacturer.
This instruction manual
·is an integral part of the chamber and has to be permanently placed in the
process room
·is designed for a qualified stuff
·contents the most important advices and warnings concerning the putting in
operation and maintenance of the equipment
2. GENERAL INSTRUCTIONS
2.1. Safety
The machine is equipped with accessories not only for operator security but for the
machine protection too. These precautions cannot cover all possible situations.
Therefore it is necessary that operator, earlier than puts the chamber in operation, will
have red through this manual and understood to it. By this way the operator can avoid
mistakes in process. In addition the operator has to be aware of another dangerous that
can appear in relation to environment and materials.
Equipment is possible to use only
·in determined range of usage
·in faultless technically safe condition
·with following instructions in this manual
Defects, that can affect safety, must be taken away immediately.
2.2. Symbol specifications
There are three kinds of safety directions in this instruction manual
·
·This symbol gives you warning that disobedience of this
order can cause from serious bodily harms to death risk

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
·
·This symbol gives you warning that disobedience of this
order could cause life threatening by electrical current
·
·This symbol gives you warning that disobedience of this
order could cause damage or destruction of the equipment or
injuries
2.3. Safety regulations –organization measures
·Do not try to start the machine until you have read all instructions delivered with the
chamber and understood to all features and processes.
·The smoking chamber must not run in a room where some easily combustible matters or
explosives are processed or are on stock.
·Do not modify the chamber in a way, that could endanger its safety.
·Ensure always enough working space and free access to the control unit. Provide
sufficient lighting of the working area.
·Keep clean the space around the machine (continuously remove spilled water and grease
on the floor, be aware of the slipping hazard).
·If you doubt about the manufacturing process, contact the responsible person.
·The equipment can be run only if all safety accessories are fully working.
·Follow all fire precautions.
·It is recommended to not run the machine during a storm.
·Do not work with the equipment under influence of drugs or alcohol.
2.4. Safety regulations –protective instruments
·Operator is obliged to use protective instruments by opening the chamber door of running
machine.
·Do not set the control unit with protective gloves on, it could cause bad choice or another
mistake.
2.5. Safety regulations –device operator
·Check and make sure that the machine is in a good state before the start.
·Remember the positioning of the main power switch.
·Make sure that display shows the required program of product, treated in the chamber.
·Learn the meaning of the individual push buttons on the control panel to avoid running
bad operation.
·Electrical control unit, transformer, engine and connection block are labelled as low
voltage equipment. Do not touch active parts in any case!
·Make sure that all protective shields of the terminal unit are installed before connection

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
to the power supply. In case it is necessary to open the switchboard box or remove the
protective cover, switch off the main breaker.
·Do not switch on the machine if the protective covers are removed. Do not remove
protective shields in any case.
·Check regularly whether protective covers are mounted well and are not damaged. Repair
or exchange the broken cover.
·Check whether electrical cables are not damaged to avoid electric shock.
·Do not spray water to the switchboard box, control unit, electric heat exchanger, electric
motors, electromagnetic valves and cables to avoid electric shock.
·Do not open the switchboard box cover if the main power switch is on.
·In case you do not work with the chamber, switch off the power supply.
·By electricity failure, switch off the main supply
2.6. Safety regulations – work with smoke generator
·Clean the smoke generator regularly.
·Wooden chips in appropriate quantity must be present in the feeding hopper during the
glowing and smoking.
·Use the recommended size of the wooden chips 4 – 12 mm and humidity φ < 20%.
·Do not open the doors during the glowing and smoking.
·Pay attention to the high temperature in the chamber, smoke generator and smoke outlet.
2.7. Safety regulations by maintainanace, cleaning and troubleshooting
·Maintenance has to be provided by a qualified stuff in accordance to the directions of
the responsible person. Worker providing maintenance and allowed repairs has to know
in detail function of the machine, inclusive this manual. Late detection of failure and
incompetent or maintenance in poor quality could cause troubles and economical losses.
·
·Only entitled person with appropriate electro technical qualification may work with
electrical equipment.
·Switch off the main power before any maintenance works. It prevents start the machine
by another person. If it is necessary to have the power on, pay attention to higher safety.
·Check (in a short time after switch-off) by a multi meter or another suitable
measurement device to be sure that no residual voltage is present.
·Check, by exchange of fuse or circuit breaker, whether the new part has the right
nominal value (usage of a part with higher nominal value could damage the equipment)
·Do not start the machine until removed covers are on back to the right position.
·To avoid damage of the smoking chamber and also expiration of guarantee rights, use
only appropriate spare parts and do not neglect periodic maintenance.
·Use safety clothing, protective shield (goggles) and gloves by work.
·Check the results of maintenance by presence of the responsible person.

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
·
Periodic maintenance and adjustment keep your equipment in a good condition.
Periodic interval of maintenance and service are quoted in the schedule.
·Follow the instructions and safety directives subscribed by producer of detergent.
·Use protective instruments subscribed by producer of detergent (safety clothing,
protective shield, goggles and gloves).
·Follow the safety instructions quoted on the labels fixed on the machine. Do not paint
over, dirty, damage or remove these warning labels. In case of damage or illegibility of
any, contact the manufacturer.
2.8. Warning labels placement
This machine is equipped by a safety accessory that protects operator and device. The
main safety equipment consists of main power supply breaker and protective covers.
There are informative and warning labels placed on the machine.
1. Label of Type:
2. Direction of
rotation:
3.
Incoming
pressure of water:
WARNING BY REMOVED COVER:
4.Danger of electric shock: 5.Danger of mechanical
hazard:
6.Accident hazard
2.9. List of safety devices and their role
A) Main supply switch –switches off machine from electricity
B) Breakers of electrical appliances –protect electrical devices from effect of
over current
MAUTING spol. s
r.o.
Type: UKM Junior
Weight: xxx kg
Production No: xxx/xx
Production year: xxxx/xx
Incoming pressure
min. 0,3 MPa

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
4
3
4
1
2
B
A
3. TECHNICAL DESCRIPTION
3.1. Operation conditions
Electrical device is designed to flawless work
under following climatic conditions :
temperature from +5 to +30°C
relative humidity 60% by +30°C
or 90% by +20°C
Electric power of the device is quoted in the
electro technical documentation. The machine is
delivered for the electricity system 400/230V, 50
Hz. Other values have to be declared in the
contract of sale.
Nominal values, dimensions and connection
places are stated in the project drawing.
3.2. Technical parameters
Total electrical power consumption 10,8 kW
Input of heating element in smoke generator 0,7 kW
Input of heating elements in chamber 9 kW
Input of fan 1,1 kW
Dimensions :
width 620 mm
depth 800 mm
height 1780 mm
Total weight (empty chamber) 230 kg
Water connection G 1/4"
Diameter of smoke outlet 100 mm
3.3. Description
Smoking chamber Junior consists of welded housing and other parts that are screwed on it.
Housing of the chamber is created by side panels, rear panel, on it is fixed smoke generator,
floor, ceiling, which part is the fan with a gear, outlet flap, fresh air flap and water
distribution for humidification, and front bars serving for connections and fortifications of
ceiling and floor in the front part of the chamber housing.

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
Another parts of the chamber are:
·Chamber door –serves for closing inward chamber ambient from surroundings. It is
made of mineral wool insulation, hinges, door handle and door seal.
·Smoke generator –serves for production of smoke. It consists of the heating element
which is placed above the ash tray and below the box with wooden chips. The smoke
generator is placed in the bottom part of the chamber. Smoke is created by glowing
wooden chips of hard wood on the red-hot heating element with the controlled access
of air. The wooden chips have to be stored in dry, well ventilated rooms. Injurants of
smoke stem if the temperature of glowing wooden chips is higher than 400oC. Special
scent and taste of smoke meat product are achieved by combination of phenols and
proteins in meat that interact with carboxylic acids contained in smoke. It is necessary
to stock the wooden chips in dry and well-ventilated room.
Picture 1 Description of smking chamber

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
·Tray support –serves for fixation of trays, grids or smoking sticks
·Heating elements –have housing made of high quality stainless steel and are
fixed through the holes in the rear panel
·Side perforated plates –serve to streamline air flow to individual levels of trays
·Soffit –it is inserted inside, underneath the fan to streamline air flow, which is
sucked by the fan
·Switchboard box
There are placed all control, switch and breaker parts. Switchboard box is situated in
the upper part of the chamber, close to the control unit. On the front side of the control
unit is the main power switch, smoking and humidification breaker. By the control
unit keyboard is possible to control the smoking chamber Junior, it means start of
programs, changes in running program steps and manual control of the executor tools
of the machine.
Cables lead to the individual electrical appliances such as motor, heating elements and
sensors from the switchboard box. All ways are made of cable type CYSY except the
terminal lead to the heating elements. There are used cables type CSSS with silicon
insulation.
Regulator is designed for control heat treatment processes. It controls temperature
inside the chamber and also it measures temperature in core (piercing sensor). The
display shows the real values and also the set ones in chamber, core and real time in an
individual step of program.
WOODEN
CHIPS TRAY
ASH TRAY AIR
REGULATION
Picture 2 Smoke generator
ASH TRAY

Smokehouse MAUTING Junior Date:
1.7.2006
Worked out:
Fila Petr
Checked by:
Bielak Antonin Ing.
Approved by:
Bielak Antonin Ing.
Version No: 3 Page:
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Instruction manual
Picture No. 3 Control panel description
.
Chambers type Junior can be equipped with doors made completely of stainless steal
or with a view-through window and inward light. Chamber can be furnished with firm
stands or wheels for easy transposition.
Accessories: -at customer‘s request it is possible to deliver following accessories:
·Trays for roasting (punched plate) made of carbide-nickel stainless steel
·Wire grids
·Smoking sticks
·Smoke outlet for smoke and wet air exhaust, diameter 100 mm
·Trolley for smoking sticks
·Ball valve for water input from distribution water piping
·Glass door
·Wheels
·Showering
3.4. Material
·All parts are made of carbide-nickel stainless steel. Internal insulation is made of
mineral wool in thickness 30 mm except the floor and ceiling, where it is 20 mm.
·Smoke generator, control panel, smoke distribution piping and outlet are also
made of carbide-nickel stainless steel.
Explanation:
1.
Main power switch
6.
Humidification switch
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