Moffat ROTEL II Manual

Safe Operating Procedures
TRAINING MANUAL
ROTEL II OVEN
4 DECK 2 SPLIT OVEN PICTURED
Current July 2002 Contains 23 pages

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• About this instruction manual
• User liability
• Safety precautions
• Before you start
• Name of parts
• Hazard risk analysis
• Safe operating procedures
• Product guide
• Baking decks
• Operations checklist
• Operations overview
• Daily cleaning
• Operations competency
• Daily cleaning competency
• Risk assessment
• Trouble shooting
• Hand-over checklist
Moffat's policy is one of
continual improvement and
development. We therefore
reserve the right to amend the
information given in this booklet
without prior notice. All sales
will be subject to the company's
conditions of sale.
©MOFFAT 2002
CONTENTS

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This manual contains all the necessary information for the use, cleaning and maintenance of the
machine. The purpose of this booklet is to allow the user to take all measures and set up all the human
and material resources needed for safe and long-lasting use of the machine.
This manual should be available for all staff and maintenance personnel authorised to use the machine.
Do not attempt to use this machine in any other way that is not in compliance with the instructions
supplied.
Firstly
Please read the instruction book carefully and follow the directions given.
Secondly
If you are unsure of any aspect of the instructions or performance of this equipment, contact your dealer
promptly.
About this instruction manual
The bakery must be fitted with an electrical system complying with current electrical regulations, in particular
the earth connection system and electrical control board must be protected against overload currents and short
circuiting. The rated power of the machine is shown on the machine plate. Electrical plant must be properly
installed throughout, maintained and regularly inspected by trained electricians issuing certificates of
compliance for all jobs carried out, guaranteeing compliance with current Australian legislation and Standards.
The electric power supply

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User liability
The manufacturer declines all direct and indirect liability deriving from:
•Use by untrained personnel.
•Non-observance of the instructions contained in this booklet.
•Unauthorised modifications and/or repairs carried out on the oven.
•The use of accessories and parts that are not genuine.
•Exceptional events.
Working Safety
The machine must be used only by personnel suitably trained for the purpose and who have been trained
in the contents of this publication.
To ensure safe work, comply with the following instructions:
•Install the oven in compliance with workplace safe work requirements.
•Install the oven in an area out of reach of the personnel not authorised to operate it and especially out
of the reach of minors.
•Use the oven with great care and never be distracted.
•Do not wear loose fitting clothing or clothing with wide and open sleeves.
•Do not let anyone approach the oven during use.
•Do not remove, cover or modify the identification plates placed on the oven body.
•Work on the products permitted and not on other types.
•Do not place any objects on the oven that are not required for normal working operations.
•Do not use the oven with temporary electrical connections or non-insulated cables.
•Periodically check the state of the power cable and the cable clamp on the oven. If defective replace
immediately by qualified personnel.
•Stop the oven immediately there is defective or abnormal operation, a breakage is
suspected, there are incorrect movements or unusual noises.
•Before cleaning or carrying out maintenance, turn off the oven at the electricity mains.
•Use protective working gloves for cleaning and maintenance.
•For all extraordinary maintenance consult the manufacturer or qualified or authorised personnel.
•Do not aim high-pressure jets of water at the oven.
•When sharp accessories are manipulated, use cut-resistant gloves.
Summary safety notes for owners/operators of this machine
Always operate within the limits of use of the oven.
Always carry out constant and diligent maintenance.
Have the oven used by a single trained person.
Avoid distractions while operating the oven.

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User instructions and precautions
The manufacturer declines all responsibility for any injury to persons or animals or damage to objects
resulting from the failure to observe any of the previous or following information and instructions on the
use or maintenance of the machine:
•Do not use the equipment for any purposes and / or loads different to those stated by the
manufacturer;
•Every day, check the safety devices and general state of the equipment;
•Every day clean the equipment thoroughly;
•Take all the necessary precautions and safety measures when loading, adjusting, changing parts or
carrying out repair or maintenance work on the oven, to make sure that the oven or any parts of it are
not accidentally started up by other persons;
•Do not tamper with the guards and safety devices on the oven;
•Do not remove the guards and safety devices on the oven unless actually necessary for work
purposes and without adopting the measures designed to reduce the risk to the minimum possible, as
described fully and frequently in this manual;
•Put back all the guards and safety devices as soon as the reason for their temporary removal no
longer exists;
•All operators must comply with applicable workplace safety procedures.
Definitions
According to this manual, the following definitions are used:
1. "Danger area" any area inside or near a oven which might be dangerous for a bystander.
2. "Bystander" any person entirely or partly situated in a danger area.
3. "Operator" the person or persons installing, running, adjusting, cleaning, repairing, transporting or
performing maintenance work on an oven.
To ensure maximum safety and optimum
performance from this machine it is essential
that you or any other operator of the machine
read and understand the contents of this
manual before the machine is ever started.
Pay particular attention to the SAFETY
INSTRUCTIONS highlighted by these symbols.
These safety alert symbols mean CAUTION,
WARNING or STOP/DANGER - a personal
safety instruction. Failure to comply with the
instruction may result in personal injury or
death.
WARNING: ELECTRICITY CAN KILL
Test and tag electrical cables to workplace
safety standards.
CAUTION
Serious injury possible
STOP
DANGER
WARNING
Electric shock
Safety precautions

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Before starting, undertake a General Safety check
•Area clean and free from obstructions, e.g. nothing left inside of the oven such as an oven mitten, trays, etc.
•Operator wearing appropriate protective clothing and gloves.
WARNING: Make sure the oven is switched off during cleaning, maintenance.
When using the oven, never place hands near working areas.
Mechanical or electrical repairs must only be done by qualified service technicians.
Only one person may operate the oven at any time. Any bystanders must keep well away
from the oven.
1The side location of door handles on the Top Deck doors are designed to avoid burning hands when
opening.
2Tray stops that lock the rotating racks in the split deck when the doors are open.
Before you start the ROTEL II OVEN
The key safety and hygiene features are:
1Top door has external side handles to avoid
heat rush when door is opened. Stand well
clear on opening.
2Tray stops operate as soon as doors on the split
deck are opened to prevent the rotation of the
racks.
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Names of parts
Flue dampers
Mains power switch
Bottom and centre doors
(open down)
Top doors (open up)
Not on all models
Standard deck
rotating turntables
Split deck rotating
turntables
On/Off switches
4 DECK, 2 SPLIT OVEN PICTURED
Control panels

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Power switch
Light switch
Rotation stop Rotation start
Steam selector
(4 settings)
Timer Start/Reset
Buttons
Heat Balance
Heat Indicator Lights
Split Deck Controls
Standard Deck Controls
Steam on/off
Steam Indicator
Bake Timer
Temperature Control
Names of parts
Not on all models

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Installation Appliance in use
1Note: Oven must be
levelled on installation to
ensure even distribution of
water in steam troughs.
This is critical to ensure that
even heating occurs within
the oven.
See steam troughs below
Hazard Risk Analysis
1Avoid skin contact with all hot
surfaces.
Observe hot surfaces and
warning signs about touching
glass windows.
2When opening oven door, be
careful of steam in baking
chamber.
On some models the top
door has external side
handles to avoid heat rush
when door is opened. Stand
well clear on opening.
6Always switch off oven at
power supply before cleaning
or maintenance.
2Always vent/exhaust oven
fumes via approved canopy
and fan.
4Always handle hot trays and
tins with caution.
Always use sound, clean, dry
oven mitts.
5Ovens should never be used
to dry towels, piping bags,
aprons etc. etc.
7Cleaning - Do not clean the
internal baking chamber of
the oven when it is still hot
3Never ‘steam’oven when
door is open.
Do not open door while
steaming operation is in
progress.
Wait several minutes after
steam is complete before
opening door - if necessary,
observe product through
windows.
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Safe Operating Procedure
1Always work in an organised
and tidy manner on oven.
2Never ignore safety instructions.
Never block or bypass safety
devices.
3 Always replace the lift-out
segment of oven turntable
before starting oven.
1Do not fill any oven with
steam prior to loading in of
product.
2Load oven correctly to avoid
possible damage to oven
drive devices.
3Do not over-steam oven as
this will prolong oven heat
recovery which will have a
detrimental effect on the
products.
4Do not exceed 30ºC
temperature between
different decks of oven.
5Never ‘slam’oven doors
open or closed as may cause
damage to oven or injury to
personnel.
6Always keep turntable
rotating, stop only when
necessary and resume as
soon as possible.
WARNING:
The operator should never
tamper with or make repairs
to this appliance. All
maintenance other than
approved cleaning operations
to be carried out by trained
technicians only.
The oven comes
in a range of chamber
configurations.
The procedure
for operating is as follows:
Oven is either on or off.
To shut down at night set
all temperature controls to
zero and power and lights off.
Moffat recommends turning off
mains power isolator on wall.
4Tray stops should be fully
operational.
5Check that all turntables are
free to turn.
7Do not leave flue dampers
open during entire baking
cycle as it can cause
excessive heat loss (use flue
dampers at specific times for
specific product results).
Before you start Operating the oven
MOFFAT SUGGESTS—Use this form to train staff, copy and laminate for your workplace
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Note: The Product Guide above features general recommendations for times and temperatures, and is
fixed to the fascia of the oven. Variations will occur according to the workplace bakery guidelines.
The Product Guide can also be used to benchmark operating efficiency of the oven. If significant
variations in product quality and bake time occurs, e.g. white bread still underbaked after 35 minutes at
230ºC, or significant variations in baked colour over a full tray in a particular oven compartment, or there
are differences in product time between oven compartments set at the same temperature, firstly re-check
standard work procedure before contacting Moffat Service Agent.
Note: water filter requires
replacement cartridge at
regular intervals subject to
local water conditions.
Moffat Service Agent can
advise on recommended
servicing.
Product Guide for the oven
Routine Maintenance

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Baking decks in the oven
The split decks are those located in the middle of the 4 Deck 2 Split oven
The standard decks are located at the top and bottom of the 4 deck 2 split oven.
Note
Standard decks have top and bottom heat
controls to enable different product baking
at different top and bottom temperatures
(refer to the menu guide for a reference)...
4 DECK 2 SPLIT OVEN PICTURED Split Deck Controls Standard Controls
Control panel for the Top and
bottom decks.

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✓
Turn power on.
Depress rotation button ‘start’.
Set all temperature controls to desired
temperature.
Set all heat balance control gauges on 4 top
heat, 6 bottom heat or ◆setting on split decks.
Note: Temperature Controller must be set
to required temperature for
the desired product.
Standard Operations Checklist
Note: the example below uses times
and temperatures appropriate for a
white 680gm sandwich loaf
At the required temperature - load oven and
set bake timer for desired product time.
OPERATION INSTRUCTIONS
Ensure water is turned on
and flue dampers closed.
Turn lights on.
Note: adjustable steam time option is not
available on all models.
Note: A 20-30 minute pre-heat time is
recommended before loading the oven
at the start of each shift.
Power onLights on
Rotation on
MOFFAT SUGGESTS—Use this form to train staff, copy and laminate for your workplace

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Load proofed products into ovens when
desired temperature has been reached
(‘heat on’light off)
approx. 30 minutes from start up.
Set bake timer for 28/30 mins immediately
after loading oven,
then press bake time ‘start’button.
Set steam time, press then release steam
button immediately after activating ‘bake time’.
Steam is optional for crusty loaves, french sticks, vienna loaves etc.
refer to product recommendations
Baking timer alarm will ring (continuously) after
28/30 mins. Press start/stop button to stop.
Open oven doors. Visually check for baked quality.
Remove bread tins/trays from oven in sequential order (order of loading).
Reload oven with proofed products when desired
temperature is reached and repeat the process.
Carefully remove products from pans.
Close oven door to allow temperature to recover.
Check product quality visually through oven glass mid bake (optional).
Standard Operations Checklist
Note: the example below uses times
and temperatures appropriate for a
white 680gm sandwich loaf
OPERATION
INSTRUCTIONS
START/STOP
STEAM
START/STOP
At end of lapsed bake time,
the timer alarm will continuously ring until reset.
(press, stop/start buttons to stop)
MOFFAT SUGGESTS—Use this form to train staff, copy and laminate for your workplace

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Operations Overview
1 Turn the power on. There is
only 1 power switch on the
oven which activates all baking
chambers.
2 Turn the lights on. There is
only 1 light switch on the oven
which activates all oven
chamber lights.
3 Ensure water is turned on.
Check that the water is
switched on at the mains
connection and at any isolation
valves adjacent to the water
filter or oven inlet.
4 Ensure flue dampers are
closed. Do not leave flue
dampers open during the entire
baking cycle as it can cause
excessive heat loss (use flue
dampers at specific times for
specific product results).
5 Set all temperature controllers
to desired temperature. If
possible set all baking
chambers at the same oven
temperature and heat balance.
Note: There should be no
more than 30ºC temperature
between each deck.
As a guide - sponge cake
190ºC, bun/sweet yeast 205ºC,
vienna sandwich 225-230ºC.
6 Set all heat balance controls
which control both top and
bottom oven heat, ensure an
even and uniform colour and
bakeout of the products.
Note: Temperature controllers
maintain constant temperature
for overall bake.
Heat balance controls maintain
even and uniform bakeout of
products.
7 Load products into ovens -
Load quickly and sequentially
to product variety and/or
workplace specifications.
Keep turntable rotating, stop
only when necessary and
resume as soon as possible.
8 Set bake timer then press start
button. Do this immediately on
each deck as soon as the deck
is loaded.
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Operations Overview
9 Set steam timer. Press, then
release button. Pressing the
steam button on the control
panel produces steam for a
particular oven chamber. The
neon light will illuminate for the
period of time that the water is
being injected.
Steam only at the beginning
of the bake cycle and do not
steam again for the entire
period of the bake.
Note: The steam control is
electronically barred from use
for five minutes after initial
steam to avoid accidental use
and flooding of the oven
generators. Steam on the
baked products in the early
stages of baking helps to
produce a thin, shiny crust on
the outer surface of the
products.
Note: There are four different
steam settings available.
Check the product guide for
recommendations.
(Not available on all models).
10 Check product quality mid
bake (optional).
Visually monitor products in
oven for colour.
11 B aking timer alarm will ring
after preset time. Press
start/stop button to stop.
The timer will then automatically
reset to preset time.
12 Open oven doors and visually
check for product colour.
If products are too light, leave
in oven for additional
appropriate time.
1
Check no product is left in the
oven.
2
Turn temperature and heat
balance to minimum settings.
3
Ensure all timers are off.
4
Close all dampers.
5
Press ‘stop’rotation.
6
Turn lights off.
7
Turn power off.
8
Turn mains power
isolator switch off.
13 Remove bread tins/trays from
the oven.
Note:
Use sound, clean oven mitts.
15 Continue further baking in oven
or use the following sequence
to shut down.
14 Remove bread from pans onto
knockout bench or racks.
STEAM
START/STOP
SHUT DOWN PROCEDURE
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10 Clean glass with dry
stainless steel wool.
WARNING: ENSURE OVEN IS
COOL BEFORE CLEANING.
6The standard turntable has a
removable section to facilitate
cleaning. The oven racks in
the split decks are also
removable for cleaning.
8Use supplied long handled
cleaning broom to brush out
crumbs. Work from top to
bottom.
9Use long handled scraper
supplied to scrape surfaces.
Daily Cleaning Procedure
4Wipe down all external
surfaces with dry cloth.
Weekly use - approved
stainless steel cleaner on
external surfaces.
7Cleaning - Take great care
when cleaning around the
internal oven elements.
3Always wipe over control
panels and switches with lint-
free rag.
2Cleaning oven should only be
carried out with a damp
cloth. Buckets of water or a
hose should not be used.
✓
✗
1Always switch off oven at
power supply before cleaning
or maintenance.
5Cleaning - Do not clean the
internal baking chamber of
the oven when it is still hot
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MOFFAT SUGGESTS—Use this form to train staff, copy and laminate for your workplace

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GUIDE SHEETS
for Staff Training
Pages in the following section of this manual should be copied
and used when training staff to operate the oven.
MOFFAT suggests that competency assessment check lists
be completed signed and a copy kept in the personnel files
for future reference.
SUPERVISORS TO ENSURE
• competency check lists are copied and completed as part of the training of staff
• correct training of staff to the required competency expectations
• sign off the verification section of the competency check list
• place a copy of the completed and signed competency check list in personnel
records as evidence of operator competence

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OPERATIONS COMPETENCY
CHECKLIST
Comments
To gain competency in the use of the Rotel II Oven, the assessor must be satisfied that
the operator has consistently applied the knowledge and skills in all of the above elements.
Element Implement safe work procedures for the Rotel II Oven
MOFFAT SUGGESTS—Use this form to train staff, and place a copy in personnel file.
✓
Assessment Criteria
“Can the operator”
Identify the purpose and use of:
•Equipment guards;
•Warning signs;
•Safety features;
related to this machinery?
Identify:
•Machine related health and safety risks of this equipment?
•Emergency procedures to be used with this equipment?
Operate this equipment correctly in normal and emergency situations?
Identify:
•OH&S reporting procedures related to hazard reporting for this machine?
Assessor’s signature Date / /
Applicant’s signature Date / /
This form should be signed off only when the assessor is satisfied that the
employee/trainee is competent to carry out all of the tasks described above.

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DAILY CLEANING COMPETENCY
CHECKLIST
Element Implement essential hygiene and sanitation procedures for the Rotel II Oven
Comments
To gain competency in the use of the
Rotel II Oven, the assessor must be satisfied that
the operator has consistently applied the knowledge and skills in all of the above elements.
✓
MOFFAT SUGGESTS—Use this form to train staff, and place a copy in personnel file.
Assessment Criteria
“Can the operator”
Maintain sound personal hygiene at all times when working with the Rotel II Oven ?
Use appropriate protective and work clothing while working with the Rotel II Oven ?
Identify:
•Product handling requirements during production process;
•Critical points in the process where contamination can be introduced;
•Why it is important to monitor hygiene and sanitation performance;
•The effect of poorly maintained equipment on the control of contamination and spoilage;
•Company policies and procedures regarding hygiene and sanitation;
•Actual and potential contamination and spoilage hazards;
•Solutions to rectify contamination and spoilage problems?
Use work practices and methods that reduce the risk of product contamination?
Remove contamination where appropriate in accordance with
•Workplace hygiene and sanitation procedures;
•Procedures specific to the
Rotel II Oven ?
Assessor’s signature Date / /
Applicant’s signature Date / /
This form should be signed off only when the assessor is satisfied that the
employee/trainee is competent to carry out all of the tasks described above.