MOBILE BAKERY HIGH PERFORMANCE 2500 KG PER DAY
E-mail: heli-spare@ukr.net
pp-alex@mail.ru
Ukraine, Kiev
Saksaganskogo str. 133
tel. +380503838538
M O B I L E F I E L D B A K E R Y
DESCRIPTION:
At present, we can
supply you with Automotive baking block "AHB-2, 5"(АХБ-2,5) unit
is mounted in a semitrailer, and is designed for baking bread in the field, as
the parking lot, and when moving (on the go). Consists of a trailer truck
ZIL-137-terrain (Formula 10x10) and the back of the semitrailer. Bumper truck mounted crane. Tyre pressure is adjusted depending on the
road surface while running. Bakery AHB-2, 5, has no analogues in the world.
Since the machine was designed for the army, it is equipped with a light
masking agents, autonomous operation of bakery ovens on diesel fuel and firewood,
a all-wheel drive 10x10,
and reliability in all weather conditions from -50 to +50.Bakery «AHB-2, 5»(АХБ-2,5) can provide bread 5880 people a day at a rate of 425gramm per person (normal Ukrainian Army). With this amount of bread, bakery service only 3 people: 1) The driver-mechanic, 2) Baker, 3) baker's assistant. Supply of food in bakery enough for three hours of continuous operation.
Field bakery AHB-2, 5, has the ability to work both independently and connect to external sources.
CONSISTS OF
1) Baking Oven
2) Power plant
3) Set for receiving, storage, sifting flour
4) Dispenser for flour
5) Grinder feed screw
6) Dough preparatory unit
7) Dough device
8) Rack for dough fermentation
CONTENTS
Page
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CONTENTS
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2
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INTRODUCTION
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4
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1.
INTENDED USE
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4
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2.
ENGINEERING DATA
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5
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3. units and components OF THE ARTICLE
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7
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4. ARRANGEMENT AND OPERATION OF
THE ARTICLE
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7
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4.1. General arrangement.
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7
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4.2. Tractor-trailer unit body
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7
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4.3. Flour feeding system
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9
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4.4. Doughing plant
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22
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4.5. Rack
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26
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4.6. Fuel feeding arrangement
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26
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4.7. Salt dissolver
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27
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4.8. Water supply system
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28
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4.9. Air feeding system
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30
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4.10. Bakery travelling oven
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31
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4.11. Electrical equipment
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31
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4.12. Preparation of components
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34
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4.13. The order of operations at doughing
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34
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4.14. Loading, baking and discharge
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35
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4.15. Bread making technique
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36
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HPK-63L Bakery Travelling Oven
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39
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1.
INTRODUCTION
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39
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2.
INTENDED USE
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40
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3. SPECIFICATIONS
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41
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4. UNITS AND
COMPONENTS OF THE ARTICLE
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43
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5. ARRANGEMENT AND
OPERATION OF OVEN AND ITS CONSTITUENT PARTS
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44
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6. CONTROL AND
MEASURING DEVICES
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48
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7. ARRANGEMENT AND
MOUNTING
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49
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8. SAFETY
PRECAUTIONS
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50
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9. PREPARATION FOR
OPERATION
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52
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10. OPERATING
PROCEDURE AND TECHNOLOGICAL PROCESS DESCRIPTION
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54
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11. INSPECTION OF
TECHNICAL CONDITION
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57
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12. TYPICAL FAULTS
AND REPAIR
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59
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13. MAINTENANCE (Procedures and Regulations) AT OVEN OPERATION, lubrication
arrangement or lubrication chart
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63
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14. RULES FOR
STORAGE, PRESERVATION AND DEPRESERVATION
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68
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15. TRANSPORTATION
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70
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16. MARKING AND
SEALING
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71
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17. CONTAINERS AND
PACKAGING
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72
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APPENDICES:
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1. Dimensional Drawing.
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73
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2. Kinematic Scheme.
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74
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3. Scheme of Flue Gas Movement.
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75
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4. Lubrication Chart.
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79
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5. Lubrication Diagram.
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78
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6. Oven Depreservation Chart.
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79
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7. Scheme of Oven Flexibility in Railway Clearance.
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80
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INTRODUCTION
The present technical
description and operating instructions are intended for study of the arrangement
of and operating rules for the AHB 2.5 marching bakery plants.
First sections refer to the technical description, they contain
the background information about the intended use, arrangement and operating principle
of the baking unit and the separate assembly units.
The baking unit operating
instructions are set out in the following sections. It contains the fundamentals on the safety, operation and maintenance regulations, equipment operation and
maintenance instructions, as well as other data necessary for the product
operation.
1. INTENDED USE
The baking unit of the AHB 2.5 marching
bakery plant is intended for execution of the full cycle of operations in
production of the panned
loaf in field conditions, being located on the site (at
parking) and during driving (on the move) without interruption in the technological process.
2. ENGINEERING DATA
2.1. At 16 loading, baking and discharge cycles a
day, the output (design one) of:
а) bread from rye or the rye-wheat flour,
weighed out in 1.7 kg portions, kg 2500;
b) bread from the wheaten wholemeal flour,
weighed out in 1.6 kg portions, kg 2500;
c) bread from the 2 Grade wheaten
(dark wheat) flour,
weighed out in 1.4 kg portions, kg 2500;
d) bread from the 1 Grade wheaten (straight white)
flour,
weighed out in 1.2 kg portions, kg 2500.
2.2. The store of raw materials,
fuel and finished product, which is arranged in one baking unit:
а) rye wholemeal flour, kg 220;
or wheaten graded flour, kg 300;
b) drinking cold water, litres 400;
c) edible salt, kg 50;
d) salt solution, litres 26;
e) vegetable oil, litres 10;
f) hot water, litres 56;
g) ready bread, pieces 90;
h) petrol, litres 32;
i) fuel for the injector, litres 40.
2.3. The total capacity of the
installed electric motors, kilowatt 9.19;
2.4. Kind of current and voltage
of
the electrical equipment, V, three-phase
alternating current 220.
2.5. The power supply variants for
the electrical equipment of the unit:
а) in parked condition from the industrial network 220/380 V
(380 V through the transformer):
from the petrol-electric set AB-8T-230M.
b) on the move: from the petrol-electric set AB-8T-230M.
2.6. Mass of the baking unit
consisting of the tractor-trailer unit, van body and equipment mounted in it,
kg 17,425
including the mass of the mounted
equipment, kg 4,455
2.7. Time of the autonomous
operation of the baking unit without restocking of raw materials, fuel etc.,
hours 3
2.8. Number of production
workers, men 3
2.9. Outline dimensions, mm
length 14,820
width 2,500
height 3,585.
Figure 1. General Appearance
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3. units and
components OF THE ARTICLE
3.1. AHB-2.5 baking unit contains:
b) portable process equipment:
Ø PHZ-14 grinder feed screw portable;
Ø the kit of sleeves and hoses for pumps;
c) portable electrical equipment:
Ø PHZ 01.230 transformer portable;
Ø PHZ 01.140 control panel portable;
Ø the kit of cables, electric conductors and devices for
connecting and earthing of the electrical equipment;
d) spare tools and accessories
kit for the baking unit;
4. ARRANGEMENT AND OPERATION OF THE ARTICLE
4.1. General arrangement.
All equipment of the baking
unit, except for the portable one, is arranged in K-137B2 body mounted on the
chassis of ZIL-137-137B tractor-trailer unit.
The general appearance of the
baking unit is shown in Figure 1, and the equipment arrangement inside the body
- in Figure 2.
4.2. Tractor-trailer unit body
4.2.1. The tractor-trailer unit
consists of ZIL-4E-137 truck-tractor and ZIL-137B bolster-type semitrailer.
4.2.2. The van body shell of the
frameless panel construction is mounted on the metal welded base and fixed by
means of special devices on the tractor-trailer unit chassis.
The body part, which is located
over the bolster-type device of the tractor-trailer unit, is separated from the
other part by the partition with the door. While in service, access to the body
is carried out through the side door. For the equipment installation, as well
as for maintenance operation while in service, the body is furnished with the
rear double swing door. The aperture is made in the front body wall with the demountable
cover for mounting and demounting of the petrol-electric set.
4.2.3. For illumination of the
body, there are glazed windows on its side walls and roof chamfers. The
night-time illumination is created by ceiling plafonds with 12 volt voltage lamps
powered either from the accumulator battery installed in the special container
outside of the body, or from the operating main of 220 volt through the
reducing transformer installed inside the body. The illumination lamps are
installed for creation of local illumination on some equipment, besides, there
is one portable lamp.
4.2.4. Ventilating in the body could
be natural through the ventipanes, and during parking - through the door, and artificial
- by means of 4 electric ventilators, two of which are located in the ceiling
part of the body, one of which is in the floor near the petrol-electric set,
and one of which is in the front end wall.
Figure 2. Equipment arrangement inside the van body
1 - A1-PHZ-23 air blower; 2 - A1-PHZ-1 installation for flour
reception, storages and screening; 3 - board of automatic protection; 4 - baking
oven HPK-
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4.2.5. The body has no special
heating devices, the necessary temperature conditions are created by operation
of the bakery oven and operation of forced-air and exhaust ventilators.
4.2.6. The body is linked with
the driver's cab by the two-way sonic signalling.
4.2.7. The following equipment
is arranged outside of the body:
under the floor - luggage containers,
the container with the accumulator battery, supporting brackets for mounting of
the big chimney, grinder feed screw, the connecting pipe for connection of the
water-supply line of the baking unit to the water service source, the connecting
pipe for connection of the air sleeve of the portable grinder feed screw, the
pan for drain waters;
Ø on the back panel - the spare wheel, rear dovetail;
Ø on the front panel – the tanks for petrol; the tank
with fuel for the injector and with the pump for manual fuel injecting; air filters
of the air blower; the input box for connection of the electrical equipment of
the baking unit to the supply network and for connection of the portable
grinder feed screw;
Ø on the right panel near the door - the side dovetail.
4.3. Flour feeding system
4.3.1. The flour feeding system (Figure
З) provides a mechanized or manual flour charging into the baking unit body,
creation of its current reserve for securing continuous work, screening it,
cleaning from tramp iron and batching it in certain portions into the dough
mixing drums for dough kneading.
4.3.2. The flour feeding system
includes:
а) installation for flour reception,
storage and feeding, consisting of the flour storage bin 1, receiving hopper 4,
screener 5 and drive gear 6;
b) grinder feed screw stationary 3;
c) grinder feed screw portable 2;
d) flour batcher 9;
e) feeding products pipeline 7;
f) return products pipeline 10.
4.3.3. The flour storage bin
represents a welded capacity, inside which are arranged: the access hatch who
could be used as a manhole hatch for maintenance of the installation, the
filter, device for breaking down of hang-ups. For input into the bin, the
products pipeline has the special dressing in the front and rear walls. The bin
is connected with the screener by the connecting pipe with the cut-off plate,
which serves for the flour feeding control.
The filter serves for separating
the compressed air from the flour and exhausting it into the atmosphere. It consists
of two (upper and lower) concentric combs, between which the fabric is tightened.
The lower comb is connected with the shaking mechanism for periodic cleaning of
the filter fabric from the flour dust.
4.3.4. The flour screener is a hexagonal
reel installed on the same shaft with the feeding worm. The reel is placed in
the body shell, which has: the cover with sealing and two locks, which is opened
on joints, the connecting pipe for feeding into the receiving bin with the
fold-out blocking and the connecting pipe with the cloth sack for
1-
flour storage bin
A1-PHZ-1 01.000;
2-
grinder feed screw
portable A1-PHZ-14;
3-
grinder feed screw
A1-PHZ-2;
4-
bin receiving
A1-PHZ-1 02 000;
5-
body shell of the
screener A1-PHZ-1 03000;
6-
drive gear
A1-PHZ-1 04000
7-
feeding products
pipeline;
8-
connecting pipe
pellucid A1-PHZ-25 000.10;
9-
flour batcher
A1-PHZ-25;
10- return products pipeline;
Inscriptions At bottom: Flour Discharge
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Inscriptions: from the top downward:
Connector A
Connector B
At bottom: Flour Loading
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Figure 3. Schematic diagram of flour feeding
Note: The arrow designates
air supply from the air main.
collection of screened out admixtures.
4.3.5. The installation drive
gear consists of: the flange electric motor, reducer and shaft, which is a
shaft simultaneously of the feed screw and reel.
The drive gear reducer is a single-stage,
worm one. One end of the worm screw is connected with the motor shaft by means
of the elastic coupling, and a hand crank is fixed on the second end for
barring of the shaft manually. For the purpose of maintenance safety, the hand
crank is closed by the fold-out housing.
4.3.6. The receiving bin serves
for intermediate arrangement of the sifted flour at the further feeding it
through the grinder feed screw into the batcher, as well as for loading of the
flour manually from sacks for feeding through the grinder feed screw into the
flour storage bin. The receiving bin consists of the housing, cover with the sealing
and lock opened on joints, and the lattice preventing penetration of coarse
impurities into the grinder feed screw.
4.3.7.
Specifications of the installation for flour reception, storage and feeding:
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а) capacity of the
receiving hopper, m3
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0.18;
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b) capacity of the
flour storage bin, m3
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0.6;
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c) number of the feeding worm revolutions, rev/min
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36;
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d) diameter of the
feed screw, mm
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120;
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e) screener productivity,
kg/hour
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900;
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f) electric motor
- type
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АОL 22-4;
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- power, kilowatt
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0.4;
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g) mass, kg
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244.
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4.3.8. The grinder feed screw is
intended for the flour reception and subsequent feeding by the pneumatic
conveying method into the storage bin or into the flour batcher. It consists of
the flour feeding chamber, aeration chamber and drive gear.
The flour feeding chamber
represents the pipe with the bin connected with the discharge opening of the
receiving hopper. One pipe mouth is fastened to the aeration chamber by means
of a flange, and another serves as an output of the feed screw shank located inside
this pipe.
The aeration chamber consists of
the body, which is connected by means of a flange with the bottom, the rotary
valve with pull-rod and hand lever, and the aerating partition. The hatch for cleaning,
the cock for the condensate discharge are mounted on the chamber, and the
back-pressure valve is hingedly suspended on the flour input,
which prevents penetration of the compressed air
through the grinder feed screw into the van body.
The aerating partition is
installed between flanges of the body and bottom, and the rotary valve is
installed in the upper part of the body, the control pull-rod of which is placed
inside the body. The compressed air is fed to the chamber bottom, and the upper
part of the body has two outputs for mixture of the flour with the compressed
air. One output is connected by the products pipeline with the flour storage
bin, and second one - with the flour batcher. Feeding direction change is conducted
by turning the hand lever of the valve control pull-rod. If the flour discharge
is required from the storage bin, then the connecting pipe of branch pipe of flour
feeding into the batcher is closed in the upper part, and discharge is made
through the rubber-fabric sleeve disengaged from the connector B.
The feeder drive gear consists of
the electric motor and double-grooved V-belt transmission from the motor shaft
to the feed screw.
4.3.9. Specifications of the
grinder feed screw:
а) productivity, tonnes/hour 0.9
b) diameter of the feed screw, mm 60
c) number of the feed screw revolutions, rev/minute 565
d) diameter of the products pipelines, mm 38
e) electric motor
type АОL 2-21-4
power, kilowatt 1.1
f) mass, kg 64.
4.З.10. The portable grinder
feed screw allows making a mechanized loading of the flour into the baking unit
system from the tent of subsidiary assignment, where the flour is stored, or
from the body of a motor vehicle delivering the flour, at a distance about 3-4 metres .
The portable grinder feed screw
consists of the bin, feed screw, aeration chamber, two demountable
rubber-fabric sleeves, support frame with two carrying handles. A canopy closes
the bin from above.
The feeder is driven with the
individual electric motor, having the power of 1.1 kilowatts, through two
V-type belts. For tightening of the belts, a part of the frame, on which the
electric motor is installed, is made as a slider part.
Control of operation of the
portable grinder feed screw is realized by means of a packet-type switch installed
on the control panel;
The control panel has two
plugholes, one of which is connected to the portable bushing cable, and the
second one – to the electric motor cable. The bushing cable is connected by the
second end to the terminal box located outside – on the front wall of the body.
Lighting up of the signalling lamp indicates energising of the control panel.
Presence of the second plughole allows connecting portable electro-driven tools
to the control panel of the portable grinder feed screw (during unhooking the electric
motor cable) during conducting operations out of the van body shell.
The flour is loaded from sacks into
the bin and, having passed through the lattice in the central portion of the
bin, enters the feed screw. The feed screw feeds the flour into the aeration
chamber. The compressed air is delivered into the bottom part of the chamber by
means of the demountable rubber-fabric sleeve with the length of 5 metres , from the air
network of the baking unit (connector A). The mixture of the flour and compressed
air is delivered by means of the same sleeve from the upper part into the flour
storage bin (connector B).
4.3.11. Specifications of the
portable grinder feed screw:
а) productivity, tonnes/hour 1.6;
b) diameter of the feed screw, mm 60;
c) number of the feed screw revolutions, rev/minute 910;
d) diameter of the products pipelines, mm 38;
e) electric motor
type: AOL2-21-4;
power, kilowatt 1.1;
f) outline dimensions, mm
length 1090;
width 825;
height 790;
g) mass, kg 70.
4.3.12. The portioning
volumetric batcher for the flour (see general schematics of the batcher below)
is intended for batching the flour for mixing the starter cultures, sponge
dough and dough.
The batcher design provides
sequential execution of the following operations:
а) receiving and batching the flour to the specified volume;
b) automatic cut-off of feeding into the batcher and switching of its
delivery to the return mainline in the flour storage bin;
c) cutting off of electric motors of the batcher and grinder feed screw;
d) switching of the air supply under the aerating bottom and output of
the measured flour batch.
4.3.13. The basic part of the
batcher is a volumetric glass formed by the cylindrical body 8, to which on
flanges are connected from above: the cover 7 and charging section 9 with input
and output connecting pipes, and from below - the cover 10 (see the batcher
itemised schematics on the batcher itself) with aerating and discharging
devices.
The upstream end of the charging
section is sequentially connected with the pellucid connecting pipe 1 of the products
pipeline and the changeover cock 2. The connecting pipe of the bottom discharge
is connected with the pressure-pneumatic chute 17 for delivery of the flour
batch into the next dough dish.
There is the round hatch 3 with
the hinged hermetical cover in the wall of the batcher body – in the front part
on the midpoint of its height, which serves for visual inspection,
reconditioning and periodic prophylactic cleaning of the batcher chamber.
The hatch cover is locked by the
limit switch VK-6 included into the control circuit of the electric motor of
the air blower, thereby eliminating the possibility of opening the hatch in the
presence of pressure inside the batcher, as well as preventing start-up of the
air blower at the open hatch.
Near the hatch, to the left of
it, along all the height of the batcher body, there is the pellucid viewing
window 4 with the scale 5 and two sliders for setting the reference mark of the
set batch values.
The box with the automobile
lamps is mounted on the cover 7 for illumination of the chamber aimed at
convenience of observation of the course of batching and discharging process.
Also, the lever device is
mounted on the cover for winding and fixing with the latch 25 of the batch cut-off
device 32 located in the channel of the charging section.
The pushing electromagnet 26 is
mounted near the latch 25, conducting its shut down upon receipt of the signal from
the limit switch of the of the batch cut-off transmitter.
The thrust block 34 is hingedly
connected with the free end of the lever 27. This thrust block is effected by
the lever of the changeover cock 2 at its switching.
The batcher drive gear is
mounted in the centre of the batcher cover. It consists of the worm reducer 11
with the flange electric motor 12 that actuates the drive shaft 13 with the
impeller 20 and bottom cleanout device 22.
The reducer consists of the cast
body with the cover, with the flange electric motor mounted to the cast body,
which shaft is connected through the bushing with the rolling pin imbedded with its second end in
the spherical ball-bearing and leaning by the face on
the footstep bearing with the ball and stop screw. The worm screw is freely
mounted on the rolling pin. There is a slot on the worm screw face, which
engages the protuberance of the bushing. The worm screw has the possibility of a
longitudinal travel. The worm screw has an undercut on the opposite end with
two bearing ribs, between which mounted on the reducer cover.
The double-arm lever (24 see
itemised schematics on the batcher itself) is rigidly fixed on the external end
of the lever shaft, with one shoulder of which the tension spring 30 is connected
(see itemised schematics on the batcher itself). And the second shoulder has a
protuberance, which can impact the pusher of the microswitch 35 (VKZ) at
turning of the lever.
For filling and discharge of oil,
the oil pressure pipe 29 is provided, being connected to the reducer body at the
bottom level and mounted towards the batcher maintenance side. The T-connector
with the fill plug and drain plugs is screwed on the pipe end, which ensures
filling of the body with oil to a necessary level.
The upper end of the drive shaft
13 (see itemised schematics on the batcher itself) passes through the reducer
along the vertical axis. The worm wheel hub is dressed on the shaft. The hub is
connected with the shaft by means of the cam clutch.
During batching, the worm
reducer rotates the drive shaft clockwise (looking from above). At shifting the
impeller to a set level on the scale, the electric motor can be reversed. At the
cleanout of the bottom, the shaft rotates anti-clockwise.
The central portion of the shaft
represents the screw having acme thread almost along all its length corresponding
to the height of the cylindrical part of the body of the batcher 4.
The threaded part of the shaft
has keyways on four generatrixes along all the length of the latter.
The shaft enters by its lower
end - cylindrical fluting - into the vertical bearing in the body of the outlet
valve 16.
The operating impeller of the
batcher is located on the threaded shaft section. The impeller has three
horizontal radial operating blades.
The impeller level indicator 15
is fastened to the impeller hub by means of the plate. Two rubber cleaning
devices are fastened on its ends for cleaning the glass with a scale from the
flour.
The lower edge of the indicator
lays in a plane of the lower blade edges, and installation of the impeller on
the required scale mark is defined by the edge.
The hub of the impeller is cut
lengthways and is sitting on the threaded part of the shaft by means of the
split screw nut having the acme thread corresponding to the shaft thread. Both
halves of the impeller are fastened together with two tightening screws 21 with
springs.
For transfer to the impeller of
the torsion torque, the cross tongue, which is mobile in the radial direction,
is placed in one of the hub halves, moving along the prismatic guides of the body
and forming an integral unit with the hub.
The joint tongue is linked with
the hinged arm 14, which at rotation of the shaft, depending on a position of
the locking guide bar 19, can either pass by the guide bar, or rest against it.
At resting against the guide bar, the lever is folded at the joint and draws
out the joint tongue from the shaft slot. In this position at rotation of the
shaft, the impeller freely moves on the shaft thread upwards or downwards,
depending on the direction of its rotation. Turning of the guide bar is made by
the handle 18. At turning of the guide bar, the handle 18 is sliding at first
in the horizontal section of the slot, and then, as needed, can be shifted
either in the upper, or in the lower section of the T-junction. At that, either
the upper, or the lower limit switch (VK-2 or VK-7) is turned on, ensuring reversing
of the batcher, and consequently, the impeller movement accordingly upwards or
downwards. Upon reaching by the lower edge of the impeller indicator of the pre-set
scale mark indicated on the pellucid window glass, the handle 18 is released,
and it returns to the initial position under the influence of the spring. After
that, the lever is straightened, the joint tongue again enters into the shaft
key, and the impeller is connected with the shaft. The electric motor of the
batcher is simultaneously disconnected.
If at shift of the impeller along
the chamber height, the joint tongue of the lever has not entered into the shaft
key and has not fixed the impeller on the shaft, then by short-duration
turnings on of the electric motor, pressing on the button 43, one should either
achieve fixing of the impeller on the shaft, or open the access hatch and
manually tighten the impeller till entering of the joint tongue of the lever into
the shaft key.
The batcher hanger unit is
fastened to the cover on the fixed members. Under the upper cover of the
batcher, the charging section 9 (see itemised schematics on the batcher itself)
is arranged with the arc-wise channel of the right-angled lateral section for
input of the sifted flour in the mixture with the compressed air. The flour
moves by the pneumatic system from the grinder feed screw A1-PHZ-2.
The channel is laid on the
circular arc of the inner section wall and goes outside tangentially by the
connecting pipe, which is connected to the return mainline of the products
pipeline leading to the bin A1-PHZ-1.
Immediately behind the upstream
end, the channel has the section with the side window opened inwards the
chamber. This window is closed by the rotary cut-off device 32 (See itemised
schematics on the batcher itself) opened inwards the channel, and at that, the air-flour
flow switch movement into the chamber. In this position, the cut-off device fits
tight the walls of the channel along its perimeter, thereby protecting from the
flour penetrating and depositing in the channel behind the valve.
A hole is cut in the upper
(horizontal) channel wall in front of the outlet fitting, which is closed by
fold-out rubber valve 36. The valve is opened under pressure of the used
conveying air going from the batcher chamber into the return pipeline, and is closed
at blowing-down, when the batching is completed, and the valve of the cut-off device
is closed.
The changeover cock represents
the double plug valve with the cylindrical plug and serves for opening and
closing of the input channel for feeding of the pure compressed air under the
aerating bottom and the pressure-pneumatic chute at discharge of the batcher.
In order to avoid negative
aftereffects from incomplete turn of the cock plug (clogging of the products
pipeline, etc.), automatic interlocking of the batcher and the grinder feed
screw is provided, which is realized by means of the limit switch closing the
control circuit only at a correct position of the plug.
The outlet valve 16 is located
in the central part of the aerating bottom of the batcher and serves for
opening and closing of the discharge outlet. The valve is guided in the
discharge outlet with four ribs and sealed along the seat edge by the conical
rubber ring.
The central valve part contains
the sealings, lower bearing of the shaft and valve sleeve 38 with the
spring-controlled footstep bearing 39, the spring of which ensures initial
tightness of the valve fit against the seat.
Prior to mounting, the valve
sleeve 38 is topped up with oil, so that at stroke of valve, the oil is partially
displaced upward up by the lowering footstep bearing 39 and moved into the
oilway for lubrication of the lower end of the shaft.
Oil excesses are inadmissible,
as they could be displaced outside on the valve surface and get into the flour
and on the surface of the bottom made of cloth.
The valve stroke is made by turn
of the hand lever 23. The eccentric 40 is mounted on the same shaft with the
hand lever. At turn of the shaft, the eccentric rests against valve sleeve bottom
38 and lifts the valve.
For removal of the flour residues
from the batcher walls and bottom after discharge, the special mechanism is
provided with two brushes 22, which are fixed by means of the driver pin on the
bushing with cams. The bushing is loosely fitted on the shaft 13. The spider 42
with cams is rigidly fixed above the cam bushing on the shaft 13. At stroke of
valve 16, the bushings are meshed by cams, and brushes are rotating together
with the shaft. Start-up of the shaft is carried out by pushing the button 43 and
holding it in the depressed position during the entire cleaning process.
The lower cover of the batcher
with the aerating bottom consists of the base - the conical bottom with
external and internal flanges.
The ring is clamped between the
external (big) flange and the lower flange of the cylindrical body of the
batcher, to which the edge of the conical aerating fabric bottom is fastened. The
internal edge has the collar dressed on the exhaust neck and fixed on it by the
hose clamp with the thick rubber gasket.
In an assembled form, the bottom
made of cloth (of a fabric of a high aerodynamic resistance) should be strongly
tightened. For best support of the bottom form, 8 rods are sewed in into it
along cone generatrixes.
The rotary neck is mounted to the
lower flange of the bottom. The pneumatic chute 17 is suspended on the rotary
neck by means of two hooks.
For fixing of the pneumatic chute
in operating and folded-back positions, the spring clamper is provided.
Besides, the output end of the pneumatic
chute can rise, turning about the horizontal axis, which passes across the
connecting pipe.
4.3.14. Interacting of
mechanisms of the batcher at its operation occurs as follows (in the process of
carrying out production operations).
The cock plug is installed by rotation
of the hand lever 33 of the changeover cock 2 by the angle 90° (to yourself) into
the position of the batcher loading (an arrow on the axis of the cock plug is directed
along the products pipeline axis). At that, the channel “products
pipeline-batcher” is opened. The cock plug closes normally open contacts of the
limit switch VK-1 blocking start-up of the batcher.
By pressing ”Start-up” button (KN2),
the air blower is turned on, by pressing KN4 button – the screener is turned on.
The toggle switch of illumination is turned on. By pressing KN5 button, the
batcher and grinder feed screw are turned on. Flour feeding and batcher loading
are beginning.
In the course of the batcher loading,
the conveying air from the batcher is removed into the return mainline through
the valve 37.
When the flour level approaches
directly to the impeller, the blades are raking up, compacting and levelling the
flour. The flour is filling wedge-shaped cavities under the blades and is wedged
between the blades and compacted surface of the flour.
The torsion torque on the shaft
of the worm sprocket reducer is increasing sharply, and reactive force, which
is acting along the worm screw, displaces it with stretching the balance spring
30.
The second lever end effects the
microswitch 35, which engages the pushing electric magnet 26 of the cut-off
device lever, and the pushing electric magnet rotates the latch 25. The latch
releases the lever 27, and the spring 36 rotates the lever, and the cut-off
device together with it into the closure position. Air-flour mixture is
directed towards the internal by-pass canal of the charging section and further
through the return products pipeline to the flour storage bin А1-PHZ-1.
After that, the blow-down of the
products pipeline is conducted with the air from the air blower continuing to
act. One can notice termination of the blow-down, observing the flour movement
in the pellucid connecting pipe 1.
After the cut-off and termination
of the blow-down, the hand lever of the changeover cock rotates by 90°. At
that, the air supply into the batcher will stop, and the channel will be opened
for air supply under the aerating bottom.
The hand lever pushes the end of
the lever 34 with its opposite end with a roller and places it on the latch 25 –
the cut-off device 32 will open access to the batcher for conducting of the
following loading cycle.
The cock for air supply into the
pneumatic chute is opened.
Pull to the full extent a hand
lever of the eccentric 23 for opening the valve. The flour starts to discharge
that should be observed through the window of the body.
After termination of the flour discharge
by gravity, push the button 43 without releasing it. After completion of cleaning
the bottom by brushes (22) and removal of the flour residues, release the
button and close fully the discharge valve.
Shake two-three times the pneumatic
chute for removal of the flour residues and take aside its discharging end.
Upon termination of operation,
the air blower (by Kn1 button) and illumination are turned off, the air supply cock
on the main branch line is closed.
4.3.15. Specifications of the
flour batcher
а) maximum batch:
by volume, litres 80
b) minimum batch:
by volume, litres 20
c) inaccuracy of batching, % up to ± 2.5
d) electric motor
type AOL-12-4
power, kilowatt 0.08
e) mass, kg 108.
4.3.16. Products pipelines are
made of duralumin tubes with the inner diameter of 38 mm . As a matter of cleaning
convenience, the entire products pipeline is assembled from separate pipe
segments, which are connected together by couplings. Aimed at flour movement
observability, a section of the products pipeline before the batcher is made of
the pellucid organic glass 8.
4.4. Doughing plant
Figure 5. Doughing Plant (side-view)
1 Dough mixing drum
2 Carcase with the bin.
3 Dough dividing head
4 Conveyor
5 Stabilisation mechanism
7 STOP Button - dividing
head
|
4.4.1. The doughing plant is intended for mixing and fermentation of the
starter culture (sponge dough) and dough, batching of the starter culture and
dough dividing into equal mass lumps.
4.4.2. The plant consists of the rotor five-drum conveyor 1, receiving
hopper 2, dough dividing device 3, mechanism of stabilisation of the drum dough
trough 4, mounting pedestal with the roll drive 5 of drums and separately
installed conveyor rotation drive 6.
4.4.3. The dough trough conveyor represents a rotor welded from tubes,
which is rotating in the vertical plane. The horizontal shafts of five kneading
and fermenting dough troughs of drums are mounted in the bearings placed at
ends of the rotor spokes in cantilever fashion. The conveyor is rotating on bearings
round the central shaft. The drive gear of the conveyor consists of the frame, electric
motor, V-belt transmission, reducer and sprocket meshed with the pin-wheel
installed along the rotor perimeter. Turning on of the drive gear of the rotor is
reversible, i.e. it can rotate both in a clockwise direction, and counter-clockwise.
4.4.4. The dough dish-drum consists of the welded body of the spherical
form with hermetically closed detachable cover. Leakproofness is attained at
the expense of the rubber gasket and three locking devices located at an angle of
120° against each other and with heads tightened with a special wrench. There is
a valve on the cover for exhaust of gaseous products of fermentation. In the
dough dish, two blades are fixed by means of locking bolts. At lateral sides,
along the transverse axis, the drum has welded flanges with wrist pins and with
holes for fixing of the drum in a certain position. The drum is installed by
wrist pins on the fork and can rotate manually about the axis, which is passing
through points of support. Fixing of the drum in the necessary position is carried
out by means of the spring-controlled arrester of the turn, a dowel of which enters
into holes on the drum flange.
Figure 5. Doughing Plant (back view)
6 - conveyor drive
8 - lever for stopping dividing head drum
rotation
9 - dividing head rotor
10 - dividing head engaging
mechanism
|
Each drum, except for the manual rotation about the transverse axis, can
mechanically be rotated round the longitudinal axis at the expense of rotation
of the fork, which has been connected with the fulcrum pin.
4.4.5. The roll drive of drums consists of the electric motor, worm
reducer and chain drive (the schematic diagram A1-PHZ-4 ).
The rotation is transmitted from the worm reducer through the chain
drive to the sprocket of the unit, which is loosely fitted on the central shaft
of the plant
and consists of two sprockets and the gear half-coupling.
The second sprocket of the unit is connected through four intermediate sprockets
by the chain drive with the sprockets installed on fulcrum pins of drums. One
of the intermediate sprockets has a device for regulating the chain tension.
The power-driven sprockets are
installed on fulcrum pins of drums on the bronze bushings. Torque transfer to
the shaft is carried out at the expense of joint of the cam half-couplings, one
of which is connected with the sprocket, and second one is fixed on the fulcrum
pin of the drum. Turning on of the coupling is made by spring-controlled pull-rods
with a bayonet fastening.
At switched-off state, the cam
half-coupling by its slot falls on the protuberance of the suspension arm of
the stabilisation ring and fixes the drum fork in the horizontal position - irrespective
of rotation or non-rotation of the conveyor.
4.4.6. The dividing device
consists of the receiving hopper, dividing head and drive gear.
The bin is made of the sheet
steel and represents a capacity of the prismatic form with the angled side
walls, located in the central space between the drums. The central shaft of the
doughing plant passes through the tube, which has been welded to the end walls,
and the feed screw is located in the bottom part of the bin. The dough dividing
head with the mechanism of the drive gear is mounted on the front side of the
end wall.
The dough dividing head
represents the hollow drum, in which the through-the-thickness tube is welded in
the direction perpendicular to the rotor shaft. The freely movable piston is
mounted in the tube on the feather key. The piston consists of two parts, which
are connected with the shaft. By rotating the shaft with the special key, it is
possible to draw together or apart parts of the piston, thereby changing a
volume occupied by the piston in the tube. The free space of the tube is filled
with the dough and defines its weighing out. The range of a possible adjustment
at the expense of rotating the shaft is restricted, therefore, there is a
replaceable piston and three shafts in the set supplied. The rotor together
with the piston is mounted in the cylindrical body of the dividing head, which
has the hole for input and output of a twine of dough.
Turning on of the dough dividing
device into operation is conducted by the lever located in front of maintenance
of the doughing plant, at the lower and left part of the dough dividing head.
In an extreme left position of the lever, the dough dividing device is turned
off from operation, in the extreme right position it is turned on.
The pinion gear is mounted on the
central shaft on the joint tongue. It is meshed with the pinion gear installed
on the shaft of the drive gear of the feed screw. The feed screw with the shaft
are connected by means of the shank with the wrist pin. That allows pulling out
or installing it with a little effort. On the front end of the central shaft,
the pinion gear of the dividing head drive gear is mounted. It is meshed with
the pinion gear of the single revolution clutch, and the latter is meshed with
the pinion gear of the rotor of the dividing head.
Turning on of the single
revolution clutch is carried out automatically by means of a system of levers
and spring-controlled rotary joint tongue only after filling with dough of the pre-set
volume of the cylinder, and shut down is carried out during the moment, when
the rotor is installed into a position of the pumping beginning.
4.4.7.
Specifications of
the doughing plant
а) productivity, tonnes/day (by dough)
at production of rye or
rye-wheat bread 2.84;
at production of 1st
Grade wheat white bread 2.84;
b) number of kneading drums, pieces 5;
c) capacity of the kneading drum, litres 140;
d) capacity of the bin for dough, litres
120;
e) productivity of the dividing head, lumps/minute 15;
f) limits for weighing of dough lumps:
at production of the rye dough,
kg 1
to 2;
at production of the wheat
dough, kg 0.8 to 1.5;
g) number of the kneading drum revolutions, rev/minute 12.0;
h) number of the feed screw revolutions, rev/minute 56.3;
i) time of full turn of the conveyor, seconds 26.5;
j) electric motor of the rotary drive for the drums and dividing head
type AOL2-21-4;
power, kilowatts 1.1;
k) electric motor of the rotary drive
of the conveyor
type A0L2-11-4;
power, kilowatt 0.6;
l) duration of mixing, minutes up to 10;
m) mass, kg 1115.
4.5. Rack
4.5.1. The rack is intended for
installation of baking tins with the dough for proofing before oven loading,
and for intermediate arrangement of one bread made lot. There are four drawers
for arrangement of the stock and instruments of first necessity in the bottom
part of the rack, as well as the section for installation and mounting of the
scales with the set of weights.
The compartment for proofing is located
in the left upper part of the rack and represents the guides welded on the
framework for installation of the baking tins. Each pair of sections of the bread
tins is fastened in the slot with one spring-controlled rotary clamper.
The compartment for bread stacking
is located below and to the right of the proofing compartment.
Rear and side walls of the rack are
made of veneer, and the front one is closed by blinds. For prevention of
penetration of cold air into the rack, the left vertical and upper edges of the
rack have the rubber valves.
4.5.2. Specifications of the
rack
a) capacity of the dough proofing compartment, pieces of baking tins 90;
b) capacity of the bread arrangement compartment, pieces of round
loaves 90;
c) mass, kg 178.
4.6. Fuel feeding arrangement
4.6.1. The fuel feeding
arrangement is intended for storage of the current store of a wet (diesel) fuel
and feeding it to the injector of the bakery oven.
4.6.2. The fuel feeding
arrangement consists of the fuel tank mounted on the outside of the front end
wall of the body shell, the pump, which is mounted at the same location, for
manual injecting of the fuel with the suction hose and discharge hose, and the system
of fuel lines with the shut-off cock. The geometrical capacity of the tank is 60 litres , process
capacity (with the diesel fuel) is 40 litres .
The fuel tank in the upper part
has two adapters closed by blind plugs – the left one with a filter for
possibility of fuel filling through the funnel at failure of the manual pump,
and the right one with the fuel level indicator of a float type. There is the
adapter with the T-connector in the bottom part. The fuel line is connected to the
side branch pipe of the T-connector, and the fuel drain from the tank is
carried out through the lower branch pipe, which is closed by the blind plug.
For fuel injecting, the suction
hose is lowered into the fuel tank, the cover is removed from the adapter with
the float gauge, and observation of a level is made according to a height of
the float gauge stock rise.
4.7. Salt dissolver
4.7.1. The salt dissolver is intended
for preparation of the saturated salt solution necessary at the dough kneading.
A saturated solution of the cooking
salt is obtained at the ratio of salt and water 1:3. Proceeding from this ratio,
the solution dosing from the salt dissolver is made.
4.7.2. The salt dissolver
represents a tank of the right-angled cross-section of the welded construction
from sheet noncorrosive steel. The tank has the pyramidal bottom ending with the
bleed holder latched with the conical rubber plug, which is fitted to the body of
the bleed holder by the spring.
Lifting of the plug is carried
out manually with the pull-rod, which goes out through the upper cover, which
closes the tank top part. Firmness of the cover fit to the upper flange of the
tank is attained by means of clamps.
The air inlet pipe is mounted on
the cover, and it reaches the tank bottom. The pipe mouth has 6 branch pipes
uniformly arranged on the tank bottom; these branch pipes have at the side,
which faces the bottom, a series of small holes for the air outlet into the small
tank.
In the cover of the tank there
is the hatch through whom filling of the tank with water is ma and salt is load.
There is a hatch is the small tank cover, through which the small tank is
filled with water and salt. The hatch is closed by the cover, which is furnished
with the special connecting pipe for tapping the air delivered into the small tank
through the tube of the air main.
The demountable cylindrical
filter is inserted in the front wall of the tank, in the right bottom part of it,
consisting of the filter bowl with holes and covered with the filtrating fabric.
The external face wall-flange of the filter bowl is furnished with the drain
connecting pipe, on which the rubber tube is dressed, serving for draining of
the salt solution into the capacity (measuring vessel) put under it.
Stopping of the solution draining
process is conducted by constricting of the rubber tube by the provided screw
clip.
Discharge of the mud, which has
been accumulated at the tank bottom, is conducted through the lower down-flow
spout (in the tank bottom) locked with the conic rubber plug. This tube is also
used at washing the tank.
4.7.3. Specifications of the
salt dissolver
а) geometrical capacity of the small tank, litres 30;
b) quantity of the brew solution, kg 33.5;
(water volume - 25 litres , salt mass - 8.5 kg )
c) salt dissolution time, minutes 8 – 10.
4.8. Water supply system
4.8.1. The water supply system is
intended for water delivery into the body shell of the baking unit, for
arrangement of the current water reserve, for preparation of water of the required
temperature, for batching of water at its delivery for preparation of the
sponge dough or dough into the dough mixing drums, for distribution of water
for economic needs.
4.8.2. The water supply system consist
of: the portable installation of the BKF-4 manual pump, the centrifugal pump
(VSN-1M or other brand), the tank for cold water, the tank for hot water of the
bakery oven HPK-63L, the water mixer, the water gauge, water mains.
4.8.3. Feeding of water into the
cold water tank is conducted from a water tank truck or any other capacity with
water. Pumping-in of water is conducted by the centrifugal or manual pump. The
manual pump is installed outside of the van body. Connection of sleeves is made
to the connector laid outside through the angled wall of the body part, which
is located over the bolster-type device of the tractor-trailer unit (connector
A).
At pumping-in of water by the
centrifugal pump, the connector A is fastened to the suction hose, having the length
of 15 m
with the filter on the end. At pumping-in of water by BKF-4 pump, its suction
hose, having the length of 8 m
with the filter on the end, is put down into a capacity with water, and the delivery
sleeve, having the length of 4-5
m , is connected to the connector A. In this case, water
delivery is conducted by the bypass mainline.
For prevention of the inverse
leak of water on the water delivery mainline, the check valve is installed into
the tank for cold water. Water delivery is regulated by the cock. For water discharge
from the centrifugal pump at operation interruptions in the winter time, the
drain cock is installed on it.
4.8.4. The water tank represents
a welded right-angled capacity covered with a heat-insulation layer of microporous
rubber, cover with calico from above and painted. The tank is installed on the
supporting brackets fixed at the upper part of the HPK-63L bakery oven.
The tank is furnished with two
hatches with sight glasses.
The cross ridge partition is
installed inside the tank for softening of hydraulic shocks during driving of
the baking unit. There are tapped holes in the tank for mounting of the
downspout and tubes of the water pipeline.
4.8.5. The hot water tank is a
constructive element of the HPK-63L bakery oven. Water heating in the tank is carried
out with the hot flue gases passing through the smoke duct located in the tank.
For water level control, the
tank is furnished with two pet cocks. For steam removal, the steam pipe line,
which goes through the roof of the van body outside, is fastened on the tank
cover. The tank is furnished with the tapped holes for mounting of the inlet,
outlet, drain and overflow tubes.
4.8.6. The water mixer is intended
for proportional feed of hot and cold water into the water gauge. It represents
a three-way cock with the dual valve actuated with the hand lever with the
eccentric. At installation of the hand lever in extreme left position, the hot
water is delivered, in the extreme right position – the cold water is delivered;
other positions produce the mixture of hot and cold water in different ratios
for obtaining of water of the pre-set temperature.
4.8.7. The water gauge is intended
for portioned batching of water in the course of the doughing.
The water gauge represents the
capacity equipped with the level indicator of the measured batch, temperature
indicator, as well as a device for the batcher installation into the vertical
position.
The water gauge is intended for
operation only during parking. For water dosing, it is necessary to install the
batcher into the vertical position by means of the screw, hinged hanger and niveling
plummet.
The front wall of the batcher has
the scale, by which a value of the required batch is pre-set by means of the
screw. At rotation of the screw, the nut with an arrow-indicator is moving
along the screw – together with the end of the flexible down-flow tube fastened
to the nut. The second end of the tube is connected with the bleed holder in the
front wall of the batcher.
A water level and, consequently,
a volume of water in the batcher, is determined by a value of rise of the nut
along the screw. The signal of obtaining the required volume is beginning of
the water outflow from the bleed holder.
Monitoring of water temperature
in the batcher is carried out by means of the kerosene temperature indicator
with the limit of readings 0 to 100°С.
4.8.8. Specifications of the
water supply system
а) volume of the cold water tank, litres 65-400;
b) working volume of the hot water tank, litres 56.1;
c) volume of the water gauge, litres 35;
d) batching limits of the batcher, litres 4 – 35;
e) scale graduation value of the batcher, litres 1.
4.9. Air feeding system
4.9.1. The air feeding system is
intended for provision with the compressed air of the flour transportation,
breaking down of hang-ups in bins, preparation of the salt solution, creation
of air draft at the moment of lighting up the oven injector, as well as improvement
of the flour output from the batcher and through the pneumatic chute.
4.9.2. The air feeding system
consists of the air blower with air filters and with the electric drive, air
mains with fitments, vacuum gauge.
4.9.3. The air blower of the
automobile engine is used as an air blower. The air blower is installed on the same
frame with the electric motor and connected with it with three V-type belts.
Intake lines of the air blower go outside through the front face panel of the body
part, which is located over the bolster-type device of the tractor-trailer unit,
two air automobile filters, which are closed by the housing, are mounted on the
intake lines. The spring pressure-relief valve, which is adjusted on pressure
of 0.5 atmospheres, is installed on the delivery tube. The vacuum gauge for
pressure control in the mainline is installed at the air main, which goes out of
the body part, which is located over the bolster-type device of the
tractor-trailer unit, into the van body.
4.9.4. Specifications of air
feeding system
a) productivity of the air blower, m3/minute 1.5;
b) operating pressure, atmospheres up to 0.5;
c) electric motor
type A0L2-32-4;
power, kilowatt 3.0;
d) number of the rotor revolutions of the air blower, rev/minute 1140.
4.10. Bakery travelling oven
4.10.1. The HPK-63L bakery
travelling oven is intended for bread making and preparation of hot water for
technological needs. The furnace design is analogous to the design of the HPK-50 M2 bakery travelling oven,
but, taking into account the specificity of use, there are following
differences:
Ø the charge-discharge window is located on the left
side of the oven;
Ø removal of steams of baking losses from the baking
chamber is directed not into the chimney, but outside through the vapour removal
tube - through the van body ceiling panel;
Ø the chimney is manufactured in two variants: one (big)
for operation during parking, another (small) for operation on the move;
Ø the hot water tank has the heat insulation;
Ø clampers for mounting the bread tins are installed on the
swinging trays;
Ø the electric motor with the reducer are fixed on the
floor of the van body;
Ø the cover of the water-heating tank contains the
exhaust steam pipe going outside through the van body ceiling panel;
Ø heat insulation of the oven shell is enhanced.
Specifications of the bakery
oven
Number of the baking tins placed
on one swinging tray, pieces 10
Number of the baking tins placed
in the oven, pieces 90
Fuel consumption rate (kerosene,
diesel fuel), kg/ton of bread 64.
4.11. Electrical equipment
4.11.1. The electrical equipment
of the baking unit is intended for support of the power supply, control, operation
signalling equipment, baking unit equipment, as well as for illumination.
4.11.2. The electrical equipment
of the baking unit can be powered with the electric power from the
petrol-electric set installed in the body part, which is located over the
bolster-type device of the tractor-trailer unit, as well as from the external
power supplies.
4.11.З. The electrical equipment of the baking unit includes:
a) The control panel, hermetic,
hinged with the front door, is intended for arrangement in it of the control
apparatus, protection and signalling equipment.
b) The transformer bushing cable
(A1-PHZ 01.200) is intended for connection of the reducing transformer to the
terminal box of the baking unit (through the bushing cable A1-PHZ 01.180).
c) The grounding electrode (EO-55.08.000)
and the ground wire (EO-55.09.020) serve for earthing of the bakery plant at
operation during parking.
d) 12 V portable electric lamps are
intended for illumination in the van body of the bakery plant and in the subsidiary
rooms.
e) The kit of the electrical
equipment of the baking unit includes also the electrical equipment of separate
machines and plants, as well as connecting leads, cables, dividing boxes.
4.11.4. Wiring scheme of the
baking unit
Wiring scheme of the baking unit
is developed for power supply from the alternate current main having the
voltage of 220 V, frequency of 50 Hz.
Figure 6. Wiring schematic diagram
Designation in the Figure in Russian
|
Item
|
АВ
|
Power automatic
breaker
|
АБ
|
|
А1
|
20A thermal
protection automatic breaker
|
А2
|
10A thermal
protection automatic breaker
|
В1
|
General
illumination switch
|
В2, В3
|
Background lighting switch
|
В4
|
Rectifier unit
switch
|
ВВ
|
60A-380V input
plug input
|
ВШ
|
Earthing rod plug
|
ВС
|
Selenium rectifier
|
ВК
|
Silicon rectifier
|
ГШ
|
Earthing rod inlet
|
D1-D4
|
Background lighting
|
ЛН1
|
“Network On” neon
glow lamp
|
ЛН2
|
“Automatic Breaker
On” neon glow lamp
|
ЛС1, ЛС2
|
Blackout dome lamp
|
В5
|
Light transformer
switch
|
П2
|
Lights switch
|
П3, П4
|
Blackout switch
|
Л1-Л12
|
Lighting dome lamp
|
Р1
|
12V socket
|
РИ
|
Pulse relay
|
РП
|
Interposing relay
|
РТА
|
Traction automatic
breaker relay
|
К1
|
“Protection
Automatic Breaker Check” button
|
К2, К3
|
“Signal to Driver”
button
|
А
|
20-0-
|
ТР1, ТР2
|
220/12 V
transformer
|
ШР
|
Plug connector
assembly
|
4.12. Preparation of components.
Preparation of components consists
in preparation of water of the required temperature, preparation of a salt
solution and in yeast dilution.
Water of the required temperature
is prepared in the water gauge by filling it in different ratios with the hot
and cold water by means of a mixer.
The salt solution is prepared in
the salt dissolver by loading salt in it, adding of water and accelerated
dissolution of salt by means of the compressed air.
Yeasts manually dissolve in the warm
water in a pail.
4.13. The order of operations at
doughing
4.13.1. Put the dough dish for components
batching under the airslide conveyor of the flour batcher and install it with the
cover upwards. Remove the cover and install it into the cartridge for covers.
4.13.2. At barm-making, measure the
required batch according to the scale of the water gauge and feed it into the
dough dish by means of the hose.
At doughing, measure and load into
the dough dish the necessary quantity of the starter culture from the dough
dish, in which it has been prepared.
4.13.3. Measure according to the
scale of the flour batcher the required batch and feed it into the dough dish
through the airslide conveyor.
4.13.4. At doughing, take from
the salt dissolver the necessary solution quantity into the salt solution bucket
and infuse it into the dough dish.
4.13.5. At barm-making, fill in the
diluted yeasts into the dough dish.
4.13.6. Close the dough dish with
the cover, draw it aside from the airslide conveyor, install it in the horizontal
position and switch on rotation for mixing.
Mixing duration is 7-10 minutes.
4.13.7. After the mixing
completion, install the dough dish with the cover directed upwards and leave it
for fermentation.
4.13.8. During the fermentation,
turn the drum every 25-30 minutes into the horizontal position and switch on
rotation (onto knock-back) for the purpose of removal of the carbon dioxide and
decrease of volume. Duration of the knock-back is 1-2 minutes.
4.13.9. After the fermentation
completion, transfer the dough dish into the upper position by rotation of the
conveyor, open the roof, by tipping discharge the innage into the bin.
4.13.10. Pile the prepared bread
tins on the floor near the doughing plant. The baking tins, which are subject
to filling with dough, are installed on the little table near the dividing
head.
4.13.11. Proceed to the scaling
dough process. Make check-weighing of first lumps of dough.
4.13.12. Install the baking tins
filled with the dough on the rack of the proofing and fix with clampers. Close the
rack blinds.
Duration of the proofing is determined
according to the technological process.
4.14. Loading, baking and
discharge
4.14.1. Install the baking tins
with dough in the bakery oven. Make the loading carefully, so that no subsidence
of dough could occur, and as fast as possible, so that not to chill the baking
chamber. Begin the loading at the left side at manual rotation of the oven
conveyor. Mark in any way the first swinging tray loaded by the baking tins.
At baking the rye bread, in
20-25 minutes after the loading, open the steam exhaust valve for removal of
excessive steam from the baking chamber, because the cracks can originate in
excessively moistened chamber on the surface of the top crust. At baking the
wheat bread, the steam exhaust valve is not opened.
4.14.2. Make rapidly removal of the
baking tins with the baked bread out from the oven. Moisten the top crust
immediately with water by means of the wiper or brush. Begin removal of the bread
from the right side, beginning from the first series, which was loaded into the
oven.
4.14.3. For knockout of bread out
from the baking tins, use the special demountable little table to be installed for
the period of bread knockout out from the baking tins on the oven.
4.14.4. Lay the bread, which has
been knocked out from the baking tins, into the rack compartment intended for the
bread.
4.14.5. Pile the emptied baking
tins on the special flooring made of the metal sheet – for protection of the van
body floor from damage.
4.14.6. Prepare the baking tins
for the further operation.
4.15. Bread making technique
4.15.1. Bread making is conducted
by the two-phase dough process method. The dough from the rye and rye-wheat
wholemeal flour is prepared on the starter culture, and the dough from the
wheaten flour of all Grades - on the sponge dough.
During the production cycle, the
starter culture brewed according to the corresponding formula, after the fermentation
time specified by the process conditions, is divided by means of the dividing
head (or manually) into three equal parts. One part is used for preparation of
the new starter culture in one drum, and two parts – for dough preparation in
two drums.
At such mode of dough process
starter cultures will constantly occupy three dough dishes, and dough - two
dough dishes.
At doughing based on the wheaten
flour, at first, the sponge dough for the total volume of the drum is prepared.
After fermentation, the sponge dough is divided into two equal parts, which are
consumed for dough preparation in two drums.
Exemplary formulas and process
conditions of barm-making, sponge dough and dough making from the rye flour,
wheaten wholemeal flour and from the wheaten flour of the second Grade are specified
in Tables 6 and 7.
The formulas account for the
doughing from the flour with moisture of 14.5% and obtaining of the bread according
to the characteristics specified in Table 5.
Table 5
Grade of Bread
|
Mass of Round Loaf, kg
|
Moisture of Bread, %
|
Output of Bread, %
|
1.7
|
51
|
155
|
|
Wheaten wholemeal
|
1.6
|
48
|
149
|
Wheaten of 2nd Grade
|
1.4
|
46
|
137
|
Wheaten of 1st Grade
|
1.2
|
45
|
134
|
Table 6
Exemplary formula and process conditions for
barm-making and doughing from the rye wholemeal flour
in the baking unit of AHB-2.5 marching bakery plant
(production cycle)
Raw Materials and Process Conditions
|
Bulk Starter
|
Dough
|
Bulk starter in kg
|
33
|
33
|
Flour in kg
|
38
|
30
|
Water in litres
|
28
|
25
|
Salt in kg
|
-
|
0.75
|
Total in kg
|
99
|
88.75
|
Including:
|
||
Flour in kg
|
57
|
49
|
Water in litres
|
42
|
39
|
Moisture in %
|
50.8
|
52.0
|
Quantity of the
previous phase %
|
33.33
|
37.2
|
Initial
temperature in °С
|
27-28
|
28-30
|
Duration of
fermentation in hours and minutes
|
315
- 400
|
110
- 120
|
Final acidity
number
|
14 - 15
|
10 - 11
|
Table 7
Exemplary formula and process conditions for sponge
dough and dough making from the dark wheat (2nd Grade) flour in the
baking unit of AHB-2.5 marching bakery plant
Raw Materials and Process Conditions
|
Sponge Dough
|
Dough
|
Flour in kg
|
44
|
23
|
Water in litres
|
34
|
10
|
Dry yeast or
compressed yeast in kg
|
0.35
|
-
|
Salt in kg
|
-
|
0.6
|
Sponge dough
|
-
|
39.175
|
Total in kg
|
78.35
|
72.775
|
Including:
|
||
Flour in kg
|
44
|
45
|
Water in litres
|
34
|
27
|
Moisture in %
|
51.57
|
46.15
|
Initial
temperature in °С
|
28 – 29
|
29 – 30
|
Duration of
fermentation in hours and minutes
|
315
– 330
|
115
- 120
|
Final acidity
number
|
4 – 4.5
|
3.5 – 4
|
HPK-63L
Bakery Travelling Oven
1. INTRODUCTION
The operating instructions are
intended for study of HPK-63L Bakery Travelling Oven (hereinafter referred to
as the "oven").
The present manual specifies
device description and operating principle of the oven, its constituent parts,
as well as the other data required for the maximum use of the oven engineering
capabilities.
2. INTENDED USE
HPK-63L bakery travelling oven
is intended for baking of panned loaf from rye flour and wheaten flour in field
conditions both during parking, and on the march (on the move). The oven is
mounted in the van body, therefore, bread making can be conducted in any
weather conditions in different seasons and days.
Working capacity of the oven,
as well as of its constituent parts, remains unchanged at air temperature in
the van body ranging from +5 to +45 °С and relative humidity up to 90% (at the
temperature of +25°С).
The oven-surrounding medium
should be explosion-proof, should not contain dust or aggressive gases, or
vapour in concentrations, which harmfully affect operation of the oven and its
constituent parts, as well as the serving staff.
3. SPECIFICATIONS
3.1. The oven capacity at
baking the rye bread or rye-wheat bread, weighed out as 1.7 kg/piece at 16
cycles (bakings) per day,
kg/day -
2500
3.2. Quantity of the conveyor
swinging trays, pieces - 9
3.3. Quantity of the baking
tins installed on one swinging tray, pieces -
10
З.4. Total number of the
baking tins placed on 9 swinging trays, pieces -
90
3.5. Volumetric capability of
the hot-water boiler, litres -
65
3.6. Electric motor of the
4АH80V8UЗ conveyor drive (AOL2-11-4)
- power 0.55
kilowatts
-
rotational speed 11.5 s-1 (675 rev/min)
-
voltage 220/380
Volts.
3.7. The worm reducer
24-80-80-51-1-2 with the gear ratio -
80,
the oil volume, which is
filled into the reducer gear box (at one time), litres - 2
- first oil change - upon 120 hours of the reducer
gear box operation
- subsequent oil changes - every 400-450 hours.
3.8. The conveyor rotation
speed - 0.003 s-1 (0.2
rev/min)
3.9. AF-65M automatic injector
with the electric motor (AOL21-4)
- electric motor power - 0.27-10 kilowatts
- rotational speed - 24 s-1 (1440
rev/min)
- voltage -
220/380 Volt.
3.10. All electric motors are
prepared for connection to the 220 Volt main, the current is three-phase
alternating current, and the current frequency is 50 Hz.
3.11. The fuel consumption
rate per 1 ton of bread, depending on a Grade of baked bread,
а) liquid (diesel, kerosene), kg -
64-77
(per hour - depending on a
injector sprayer number, kg/hour - 8-12
b) solid (fire-wood with the moisture content of 21-33%), m3 - 0.5-0.6
3.12. The temperature of the medium inside the baking
chamber at bread baking (depending on a Grade and weighed out portion), °С 200... 250
3.13. The time necessary for
heating up the baking chamber to the temperature of 250°С at the ambient air
temperature of + 18°С, minutes:
а) at operation on the liquid fuel 40-50
b) at operation on fire-woods -
60-90
3.14. Leading dimensions of
the oven, mm:
а) length -
3030
b) width -
1650
c) height (without the chimney) - 1635
d) height with the chimney - 2330
3.15. Mass, kg:
а) oven -
1406
4. UNITS AND COMPONENTS OF THE ARTICLE
4.1. List of the basic
constituent parts of HPK-63L oven.
No.
|
Designation
|
Name
|
Quantity
|
Remarks
|
а) mounted parts
|
||||
1.
|
HPK-63L 01.00.00
|
Baking chamber
|
1
|
|
2.
|
HPK-63L 02.00.00
|
Conveyor with the drive
|
1
|
|
3.
|
HPK-63L 02.02.00
|
Swinging trays of the conveyor
|
9
|
|
4.
|
HPK-63L 03.00.00
|
Fire box
|
1
|
|
5.
|
HPK-63L 04.00.00
|
Boiler for water heating
|
1
|
|
b) demountable parts
|
||||
6.
|
HPK-63L 02.06.00
|
Conveyor drive
|
1
|
|
7.
|
HPK-50М2 02.02.00
|
Chain guard
|
1
|
|
8.
|
HPK-63L 05.00.00
|
Steam exhaust pipe
|
1
|
|
9.
|
HPK-6ЗL 06.00.00
|
Marching chimney
|
1
|
|
10.
|
HPK-63L 07.00.00
|
Stationary chimney
|
1
|
|
11.
|
HPK-63L 09.00.00
|
АF-65М injector (with the control panel)
|
1
|
|
12.
|
HPK-63L 09.03.00
|
Pipe duct
|
1
|
|
13.
|
HPK-63L 09.05.00
|
Thermostatic controller unit
|
1
|
|
14.
|
HPK-50M2 09.03.00
|
Filter supporting bracket (assembled with the
filter)
|
1
|
|
15.
|
Roller chain
|
67
|
chain links
|
|
с) accessories
|
||||
16.
|
HPK-50M2 00.00.01
|
Fire rake
|
1
|
In the oven firebox
|
17.
|
HPK-6ЗL 03.04.00
|
Ash pit
|
1
|
In the container #2
|
d) kit of spare parts
|
||||
18.
|
HPK-6ЗL
|
Spare parts, tools and accessories
|
1
|
Inventory equipment sheet is attached
|
5. ARRANGEMENT AND OPERATION OF OVEN AND ITS
CONSTITUENT PARTS
5.1. HPK-6ZL is attributed to a type of bakery ovens
of continuous operation with a travelling conveyor and with channel heating of
the baking chamber with hot gases, which pass from the firebox sequentially
through the conic flue tube, vertical gas flue of the hot-water boiler and
horizontal gas flue of the baking chamber, and exhausted through the chimney.
During passing, hot gases make convective heat exchange, by which the necessary
temperature for bread making is attained inside the baking chamber.
5.2. The oven consists of the mounted and demountable
main component parts listed in section “UNITS AND COMPONENTS OF THE
ARTICLE".
5.3. The baking chamber is intended for immediate
bread making in the baking tins installed on the swinging trays, which are
suspended on the conveyor tubes. The conveyor with swinging trays and gas flue
are located in the baking chamber.
The baking chamber has a form of the regular cylinder
with a horizontal axle and consists of the carcase and demountable end walls.
The baking chamber carcase is a welded construction
made of angular steel, closed by sheet steel from outside and inside. At that,
the internal sheeting is welded to the carcase, and the external one, with a
view of repair simplification, is made of single detachable plates and fastened
to the carcase with bolts and screw nuts.
The end walls of the baking chamber from inside and
outside are also closed by the sheet steel and connected to the carcase with
bolts and screw nuts.
With a view of decreasing heat losses, inter-wall
space of the baking chamber and face walls is filled with kaolin wool. The gas
flue is provided in the baking chamber, in the upper part, for additional
heating of the chamber and removal of gases into the chimney. The butterfly
damper is installed for regulating the oven draft at maintenance. By means of
the hand lever, the damper can be installed at different angles of inclination,
augmenting or diminishing the quantity of removed gases.
A device for removing vapour of baking losses is
mounted in the upper central portion of the baking chamber.
There is the loading/unloading window of a rectangular
form closed by the door on the left side of the chamber. The door is furnished
with the hand lever
fixed in an oven marching position by the special spring mechanism.
Supporting brackets with guides are welded to the
carcase face corners of the baking chamber, as well as the bearing rods, on
which the support rollers and lower limit stops and special supports are
mounted, by means of which the baking chamber is fastened to four boot ends.
5.4. The steam discharge tube is intended for steam
removal from the baking chamber outside. The steam discharge tube consists of
the connecting pipe, special demountable cap and butterfly damper.
5.5. The chimney is intended for removal of waste
gases from the oven firebox and regulation of draft at fuel burning. There are
two tubes: one is short (730
mm long), which is installed on the oven on the move,
and the long one (2700 mm
long), which is installed at bread making during parking. The tubes are
fastened to the connecting pipe with the special axles.
The conveyor drive mechanism is intended for the
conveyor rotation both manually, and from the electric drive. The drive
mechanism consists of the pig-iron body with the special bearings, drive shaft
with the sprocket wheel rigidly fitted on it (for meshing with the conveyor) on
one end, and the second hollow end of the shaft has the rod with a handle and
special joint tongue, the hub with a power-driven hand lever and restrainer,
the sprocket wheel (for transmission of rotation from the electric drive). In
the home position, the drive mechanism is prepared for operation from the
electric drive (the home position is considered such a position, in which the
hand lever is in the upper position and locked, the rod is in the normal
position).
At rotation manually, the lever handle is put into the
horizontal position, and handles of the restrainer and rod are pulled to the
full extent from the primal position. At that, the joint tongue of the rod goes
into the slot of the hub of the hand lever and is fixed in this position, the sprocket
wheel, which is connected by the chain with the electric drive, is released
from the joint tongue and can run idle (even if the electric drive is powered
up), without transmission of rotation to the conveyor.
The rod of the drive mechanism has three fixed
positions:
the normal (initial) position - the joint tongue of
the rod is inside the slot of the sprocket wheel (rotation from the electric
drive); the medium (not operating) position - the joint tongue of the rod is
simultaneously in slots of the sprocket wheel and hub (in this position the
safety clutch is checked for actuation); and the extreme position, in which the
rod is pulled out to the full extent - the joint tongue of the rod is meshed
with the hub of the hand lever (manual rotation).
5.6. The combustion chamber consists of the carcase
(central gas flue), pig-iron walls, cylinder, fire bar.
The carcase of the combustion chamber of a welded
construction consists of the cylindrical housing (firebox) and the conic flue
tube. The wide end of the central gas flue is not fixed and can move along the
axle at thermal expansion. The combustion chamber with the pig-iron firebox is
located in the central gas flue. The firebox consists of the cylinder, rear and
front walls. The rear pig-iron wall and cylinder are freely inserted into the
firebox housing and fixed by the front wall, which is fastened by studs with
brass screw nuts to the flange of the housing and to the face wall of the
baking chamber. The fire bar is mounted in the pig-iron cylinder, forming the
fire and ash pit chambers. There are the fire-box and ash pit doors on the
front pig-iron wall. The same wall has mounted swinging arm for installation of
AF-65M automatic injector.
The upper part of the front wall has a hole with the
butterfly valve for feed control of the air delivered into space between the
firebox housing and pig-iron cylinder.
5.7. The cold air, which is delivered into the
inter-wall space, flows around the cylinder, thereby preventing it from
premature burn-out, and delivered through holes in the cylinder into the
firebox.
For even distribution of heat in the baking chamber,
the shield is mounted on the central gas flue (opposite to the door of the
baking chamber).
The special pig-iron cone, which protects the central
gas flue from burn-out, is put inside a conic part of the central gas flue.
The expanded end of the central gas flue is connected
through the seal with the vertical gas flue, which is passing through the
hot-water boiler and connected with the upper gas flue.
There is a special heat-isolating housing outside - on
the front wall of the firebox.
5.8. The hot-water boiler is intended for water
heating up. The water heating up occurs at the expense of the heat received
from removed gases. The boiler of a welded construction, which is made of sheet
noncorrosive steel, consists of the body and vertical gas flue. The vertical
gas flue borders by its lower expanded end with the end of the central gas
flue, its upper narrow end goes into in the horizontal gas flue of the baking
chamber. From above and from below of the hot-water boiler, there are special
access holes for cleaning from ashes and smut of the central and upper gas
flues.
In order to avoid full emptying of the boiler during
the oven operation, water
is delivered from the boiler through the vertical pipe with the filter.
In such a way, it is impossible to drain all water through the cock, thereby
protecting the boiler from its burn-out.
The hot-water boiler, the upper and lower gas flues of
the boiler are closed by the special safety housings.
5.9. AF-65M automatic injector is intended for liquid
fuel burning inside the oven firebox. The liquid fuel (kerosene, diesel fuel)
is delivered by gravity through the filter into the injector, where under the
pressure of 700-900 kPa (7-9 kg/cm2), which is created with the pump
in the injector, delivered through the sprayer into the firebox in the form of
ultimate particles, where it is burnt down. AF-65M injector is mounted on the
special supporting bracket allowing folding out the injector aside at operation
on a solid fuel. At mounted injector, the fire-box door is in the open
position.
The injector supporting bracket axle has the limit
switch, which disconnects the injector from the main at its turning
(folding-back).
6. CONTROL AND MEASURING DEVICES
6.1. For
measurement of temperature inside the baking chamber, the glass liquid
expansion thermometer, U 8.5.240.201 GOST 2823-73, is applied with the
measurement limits 0 to + 350°С.
The temperature
indicator is inside the metal body.
6.2. T32-06
thermostatic controller is applied for automatic temperature control in the
baking chamber in the range +200 to +250°С.
The thermostatic
controller is efficient at the ambient air temperature from +5 to +55°С and
relative humidity of 95%; the dead zone is from 2 to 25°С, basic inaccuracy is +
25%, capillary length is 1.5 m .
The thermal phial
of the device is inserted into the baking chamber through the hole in the end
wall and is fixed by a special adapter, and the device itself is placed in the
special box fastened by means of two bolts on the end wall of the oven - to the
right side of the temperature indicator.
The operating
principle of the device is based on dependence of a pressure of the filler
placed in a hermetically closed thermal system, vs. the baking chamber
temperature.
Forced cutting off
and transfer of the device into the automatic mode is carried out by means of
the lever with “Switch on” inscription.
Before beginning
of the oven operation, the limb on the thermostatic controller set opposite to
scale mark "250" (the temperature of +250°С should be in the baking
chamber) and the lever should be put into ”Switch on” position. Adjustment of
setting of the thermostatic controller of the given range should be conducted
by comparing readings of the temperature indicator and thermostatic controller.
At cutting off by the thermostatic controller of the injector before reaching
of the pre-set temperature, it is necessary either to diminish plunging of the
thermal phial, or to turn the compensator clockwise. At temperature increase
inside the baking chamber over the pre-set one, it is necessary to turn the
compensator counter-clockwise. In the time in the oven use, it is necessary to
watch readings of the temperature indicator and thermostatic controller,
comparing them.
6.3. For check of
a fuel pressure in the fuel pump of AF-65M injector, which should be 700-900
kPa (7-9 kg/cm2), the pressure gauge MT-4, type 1, GOST 8625-77, is
applied.
The one-arrow
pressure gauge in the round body (with the diameter of 60 mm ), with the flat dial
and circular motion of the arrow in relation to the scale. The upper
measurement limit is 1600 kPa (16 kg/cm2).
7. ARRANGEMENT AND MOUNTING
7.1. The oven is
mounted in the van body of AHB-2.5 automobile baking unit and fastened to the
floor with bolts М12. During lifting and moving of the oven during mounting, it
is necessary to use the special cramps located on the end walls. Lifting of the
oven behind the water-heating boiler is strictly forbidden.
7.2. A plate with
the electric drive is also fastened to the floor near the oven (at the left).
At that, it is necessary to preserve parallel alignment of shafts of the drive
mechanism and reducer.
The driving
sprocket and driven sprocket should be situated in the same plane.
8. SAFETY PRECAUTIONS
8.1. The oven
maintenance can be conducted by persons, who are well aware of the oven and
assembly unit arrangement and method of operation specified in the present
instruction and instructions on complete set articles, who have passed
instructing in User Safety Rules for Operating Electrical Equipment.
8.2. The oven
should be safely grounded. For this purpose, there is a special nut bolt on the
electric drive. The place of earth wire connection is designated by the sign
"earth". Earth mounting of the oven is conducted at operation during
parking.
8.3. It is
forbidden to raise the temperature in the oven baking chamber above + 300°С and
to lubricate the rotating parts in the baking chamber.
8.4. The rotating
muff, chain gear and safety clutch should be closed by demountable guards.
Remove these guards for regulation of the safety clutch and lubricant only at
switched off voltage (cutting off).
8.5. The electric
circuit diagram of the injector should be bonded on the control panel cover of
the AF-65M injector.
8.6. The clearance
between starting electrodes the AF-65M injector should be 5 mm .
8.7. At transfer
of the switch on the injector control panel into "Manual" position,
KN button should be necessarily pressed simultaneously with it.
Delay in turning
on of the button results in that unignited fuel is delivered into the firebox
that could cause ejection of the flame from the firebox.
8.8. At detection
of fuel leakage flow in the system, the further injector operation is forbidden
till elimination of the leakage flow. For the period of cleaning and
replacement of the sprayer (orifice plug), the fuel should not be delivered
into the injector.
8.9. It is
necessary to clean regularly a hole in the plug of the oil gauge of the
reducer.
8.10. It is
necessary to keep serviceability of the filter in the hot-water boiler in order
to keep always the required water level at open discharge cock in the boiler.
8.11. During
sanitary processing of the oven, it is required to avoid penetration of
moisture on the electrical equipment.
8.12. For the
purpose of noise abatement and vibration decrease of working electric motors of
the drive and injector, safe mounting of these units and secure bolt tightening
and screw nuts should be ensured.
8.13. It is
forbidden:
a) to use the injector at an
out-of-order closing valve or without the valve - in order to avoid the fuel
penetration into the firebox from the pump and sprayer;
b) to direct the torch of the flame
outside the firebox;.
c) to open the window in the injector
and touch high-voltage cables in the time of the injector operation;
d) to use means with a smaller
electric power for obtaining a spark at faults of the transformer;
e) to keep the fuel and inflammable
fluids near to the injector;
f) to use petrol as a fuel;
g) to fill in the heated firebox with
water.
9. PREPARATION FOR OPERATION
9.1. Timely and
thorough preparation for operation is prerequisite for the successful and
uninterrupted operation of the oven and its component parts.
Preparation for
operation begins from inspection of completeness, de-preservation and careful
visual inspection of all units of the oven, mounting, correct arrangement and
connections thereof.
9.2. Check
security of attachment of the guides and correct arrangement of the swinging
trays of the conveyor. The swinging trays should hang vertically, without
distortions and offset, pins of the swinging trays should be between the guides
at rotation of the conveyor.
Ensure free
rotation of the conveyor, having turned the conveyor manually not less than 9
times. At rotation of the conveyor manually, the switch handle (lower one)
should be pulled to the full extent in order to switch from the electric drive
to manual rotation. Having convinced in good operation of the drive and
conveyor, switch the handle to the electric drive.
9.3. Check
integrity of glass of the temperature indicator.
9.4. Check rotation
direction of the electric motors of the reducer and injector. At non-conformity
of rotation to the directions specified by arrows, it is necessary to swap two
wires of phases of the power supply cable on the power board.
9.5. Check
operation of the safety clutch on the reducer. For this purpose, transfer the
switching handle into the middle position and, by turning the hand lever of the
drive mechanism with the force equal to about 45 kg , check actuation of the
safety clutch. At that, the chain guard should be removed, one of
half-couplings (with three bolts) should be locked. Make adjustment of the
safety clutch by tensioning three springs, having tightened up the
corresponding screw nuts.
9.6. Check an oil
level in the reducer. For this purpose, the reducer cover contains the special
screw nut with the pin, on which there are marks of the upper and lower oil
levels. If necessary, add winter transmission oil of GOST 610-72 standard.
9.7. Install the
chimney (short or long one), having fixed it with the special locking bars.
Check opening of the damper of the chimney and steam outlet pipe, as well as of
the baking chamber door.
9.8. Before
turning on AF-65M injector, verify serviceability of the fuel system, presence
of the dissector fastened on the fire bar,
impermeability of sleeve
connections, absence of damages in the control panel and inlet wires, check a
clearance between electrodes: it should be not more than 5 mm . Push the button and
check presence of a spark on the starting electrodes. It is necessary to take
into account that the injector should not work for a long time without fuel
(1-2 minutes), as the pump lubricant is absent that could lead to its damage.
9.9. Remove air
from the fuel pump. For this purpose, unscrew the screw nut by means of the
wrench and turn out the plug of the reducing valve a little. When air bubbles
disappear and the liquid fuel appears, seal with the plug.
9.10. In the
manual control mode, verify correctness of the injector operation. After 10
minutes of operation in the manual control mode, switch operation of the
injector to the automatic control mode. For this purpose, transfer the packet
switch into "automatic" position, the injector is started, ignition
of fuel will occur automatically if the injector has all its component units
serviceable. Combustion rate is observed through the viewing window. Colour of
the flame should be yellow-white, without fly ash.
9.11. Heat up the
oven to the temperature of 250°С, having set the thermostatic controller limb
on "250" before that.
9.12. At operation
of the oven on solid types of fuel (fire-wood, peat), move the injector
downwards so that the fire-box door be freely closed.
10. OPERATING PROCEDURE AND TECHNOLOGICAL PROCESS
DESCRIPTION
10.1. The oven is
served by the one baker, who is engaged in loading and removal of the baking
tins with bread, and monitoring a temperature condition of the baking chamber.
10.2. At bread
making, it is necessary to maintain certain conditions, remove uniformly the
vapours of the baking losses at baking of the rye bread (in twenty minutes, in
the process of vapour accumulation – to open the steam removal tube damper and
keep it open for 3-5 minutes).
10.3. The conveyor
rotation could be carried out both from manual rotation, and from the electric
drive. At manual conveyor rotation, it is necessary to disengage (to pull till
release of the restrainer and then rotate by 90°) the restrainer handle (upper
one), and disengage the rod handle (lower one) from meshing with the sprocket
wheel, i.e. to pull the handle maximally (till coincidence of marks on hubs of
the power-driven hand lever and sprocket wheel).
At rotation of the
hand lever of the drive by 360°, one of nine swinging trays is placed so that
its base for baking tins installation is facing the bottom part of the baking
chamber window (moving from below upwards), at that, the conveyor carcase is
turning about its axis by 40°, i.e. will make 1/9 part of the revolution.
At the conveyor
rotation from the electric drive, the drive mechanism should be in the home
position: the restrainer and rod handles - in the normal fixed position, the
hand lever of the drive mechanism should be in the upper position at that.
LOADING
AND DISCHARGE OF BAKING TINS WITH BREAD SHOULD BE CONDUCTED ONLY AT MANUAL
ROTATION AND ONLY IN FIXED CONVEYOR POSITIONS.
10.4. Using the
method of simultaneous loading and discharge, all nine swinging trays of the
conveyor are loaded with the baking tins with dough in one step. After that,
the loaded conveyor in every 7-8 minutes is rotated manually by one swinging
tray during all baking time. Upon baking time ending and bread readiness, the
baking tins are discharged from the oven. At that, every swinging tray, which is
released from the baking tins with the ready bread, is loaded with the baking
tins with dough. After bread removal and new loading of the whole conveyor, the
baking process is repeated.
10.5. At all listed bread baking
procedures, it is required that each swinging tray with the loaded baking tins
with dough should make uniformly
a full circle throughout all the baking
time and, in such a way, should be exposed to action of the temperatures that
are created in the baking chamber in its various areas.
10.6. Start loading
the baking tins with dough from the right side of the swinging tray, put the
baking tins on the swinging tray carefully – otherwise, the baking tins may
fall from the swinging tray and jam the conveyor. Make discharge of the baking
tins from the oven in the reverse order.
10.7. Baking chamber
door should be kept open only during bread loading and discharge. At that, the
temperature in the baking chamber must not drop below 220°C . The temperature fall
below the specified value may lead to defective bread.
10.8. The conveyor
rotation should be smooth, without jerks. If difficulties arise at conveyor
rotation, examine immediately the baking chamber and determine the cause.
The most common
cause of this problem is falling down of the baking tins resulted from
negligent installation of the baking tins or sharp turn of the conveyor (jerk).
In this case, rotate carefully the conveyor in the reverse direction, remove
the baking tin fallen or incorrectly placed on the swinging tray.
At jam of the baking
tins and impossibility to rotate the conveyor in the reverse direction, rotate
it carefully in the current direction, as a result, fallen out baking tin
section is moving under the conveyor. After removal of two-three swinging
trays, the fallen out baking tin section is pulled out from the oven.
10.9. Oven operation
on the liquid fuel, which is carried out by AF-65N injector, can be performed
in the automatic and manual modes.
In the automatic
mode, after starting the injector, automatic ignition of the atomized fuel is
made by an electric spark of high voltage.
Switching on of the
ignition device after formation of a flame tongue and re-ignition of
accidentally extinguished flame tongue occurs also automatically. In a case of
extinction of the flame tongue, the ignition mechanism is switched on at the
ignition electrodes located in front of the orifice, the high voltage current
is supplied from the transformer, and spark discharge occurs, thereby igniting
the atomized fuel.
At restoring the
fuel inflow, the combustion process is resumed. If a normal combustion process
is not restored, the injector switches off upon expiration of 20 seconds. In
this case, the injector turning off is accompanied with alarm signal (red light
is on). The injector starting
can be made only after fault elimination.
The injector operation in the automatic mode is controlled by the thermostatic
controller T32-06, which is mounted under the mercury thermometer and connected
with the injector control unit. Upon reaching the desired temperature in the
baking chamber, the injector automatically shuts off. The injector ignition
occurs again at lowering the temperature in the baking chamber by 20-25°C .
The amount of fuel
combusted is adjusted by setting of the respective sprayers. The injector kit
includes sprayers No.8 - 2 pieces (one of which is mounted on the injector) and
No. 10 - 1 piece. At the automation system faults, temporary operation of the
injector can be allowed under supervision of the servicing staff. To do this, put
the packet switch into "Manual" position and immediately press
"Manual ignition" button. Press the button repeatedly until the fuel
lights up. The injector is switched off by the packet switch. The temperature
in the baking chamber in this case is controlled by the mercury thermometer.
WARNING! At burning the liquid fuel, the pig iron dissector is
fixed in the combustion chamber at the fire bar.
At fault of AF-65M
injector, operating the oven can be carried out on a solid fuel. In this case,
the injector is folded down, releasing firebox doors, the dissector is removed.
10.10. After
operation, it is necessary to put the oven and its components into the initial
position:
a) disconnect the electric motors of the
injector and conveyor electric drive;
b) stop the fuel supply to the injector;
c) make a thorough inspection of all oven
subassemblies, connections, hoses, wiring - in order to start the subsequent
work without delay.
10.10. At operation
of the oven during winter, after a long interruption in the operation, it is
necessary to bring the oven into the operating condition according to the
requirements of paragraphs 9.1 - 9.12 of the present technical description.
11. INSPECTION OF TECHNICAL CONDITION
List of basic inspections of the technical
condition of the oven.
No.
|
Inspection Subjects and Instruments, Devices and Equipment. Inspection
Technique.
|
Technical Requirements.
|
1.
|
The operating temperature in the baking
chamber is checked by means of the mercury thermometer. (Visually).
|
The temperature should be up to + 250º
C.
|
2.
|
The constant level of water and
cleanliness of the filter screen in the hot-water boiler are visually
checked.
|
The hot-water boiler should be
constantly filled by water.
|
3.
|
Intensity of the combustion process is
observed visually through inspection window in the front wall of the firebox.
|
The flame colour should be yellow-white.
|
4.
|
Formation of fly ash resulted from
imperfect combustion is observed according to the smoke exhausted from the
chimney.
|
The smoke out from the chimney should be
hardly noticeable.
|
5.
|
The fuel pressure is checked with the
pressure gauge on the injector.
|
The pressure should be 700 to 900 kPa (7
to 9 kgf/cm2).
|
6.
|
Serviceability of the closing valve is
checked visually after stopping of the electric motor.
|
The fuel delivery from the sprayer into
the firebox should stop.
|
7.
|
Correct hand lever rotation of the drive
mechanism of the conveyor is checked (manually).
|
Should rotate smoothly without jam.
|
8.
|
Correct arrangement of the swinging
trays in relation to the tubes and guides is visually checked.
|
The swinging trays should hang
vertically. Hangers of the swinging trays should be located between washers
(protecting against longitudinal displacement). The swinging tray pins should
be located over (under) shelves of the guides, not touching them.
|
9.
|
Working capacity of the electric motors
of the injector and reducer is checked (visually).
|
At turning on of the corresponding
buttons, the electric motors should work.
|
No.
|
Inspection Subjects and Instruments, Devices and Equipment. Inspection
Technique.
|
Technical Requirements.
|
10.
|
Security of attachment and
serviceability status of all assembly units is checked by the external
examination.
|
Screw nuts and bolts should be tightened
normally, assembly units should be fastened.
|
11.
|
An oil level in the reducer is checked
with token oil indicator
|
There should be a constant oil level
marked by graduation lines on the indicator.
|
12.
|
A state of the starting electrodes and
clearance between them is checked by means of a calliper.
|
The electrodes should be clean, and the
gap between them should be
|
12. TYPICAL FAULTS AND REPAIR
12.1. The list of the most frequently
encountered or possible faults.
No.
|
Name of Faults, External Manifes-tations
and Additional Signs
|
Probable Cause
|
Method of Elimination
|
Re-marks
|
1.
|
The oven conveyor does not rotate or
rotates hardly
|
1. One of the guides is disconnected or
bent and the swinging trays of the conveyor touch it.
2. There is no gap between the conveyor
rings and restrictors (upper or lower ones)
3. Several support rollers do not rotate
or rotate hardly, the conveyor slips by the rings on the rollers.
|
Determine,
which guide is weakened, let the oven to cool, remove the swinging tray.
A
repairman lays down on the following swinging tray and gently moves towards
the damage (rotate the conveyor manually) and puts the guide in place. If
this method cannot solve the problem, one must remove the combustion chamber
frame and rectify the fault.
It is
necessary to pull out the combustion chamber, install gaps not less than
Pull
out the combustion chamber. Remove a support roller, eliminate fault or
substitute by the new one.
Replace
the central gas flue with the firebox.
|
No.
|
Name of Faults, External Manifestations
and Additional Signs
|
Probable Cause
|
Method of Elimination
|
Re-marks
|
4. Jamming in bearings of the drive
shaft.
5. Safety clutch nuts are loose.
|
Pull
out the central gas flue, unscrew the drive, having removed before the hand
lever and driven sprocket outside of the baking chamber, to eliminate faults.
Assemble back the drive and the central gas flue.
Tighten
screw nuts and adjust the safety clutch.
|
|||
2.
|
Thermometer does not give readings.
|
Broken thermometer
|
Replace
the thermometer
|
|
3.
|
A bad draft in the chimney.
|
1. The damper of the gas flue is
insufficiently open.
2. Gas flues are choked with ashes.
|
Open
completely the damper.
Clear
gas flues.
|
|
4.
|
A hole appeared on the inner or outer
casing of the baking chamber or gas flues
|
From corrosion affect.
|
Apply
patches, weld or rivet them at the place of the hole.
|
|
5.
|
The hand drive is not switched to the
electric drive or vice versa.
|
Squeezed joint tongue or the joint
tongue has come out of the nest.
|
Disassemble
the drive mechanism, eliminate the fault and assemble it back.
|
|
6.
|
Oil dribbles in the reduction gear box
glands or in junctions of covers
|
1. Worn out glands or loosened gland
nut.
2. Loosened tightening of bolts.
|
Tighten
the nut and, if necessary, replace glands.
Tighten
the bolts.
|
No.
|
Name of Faults, External Manifestations
and Additional Signs
|
Probable Cause
|
Method of Elimination
|
Re-marks
|
3. Contaminated drainage holes in the
oil-level gage plug.
|
Clean
the holes.
|
|||
7.
|
The liquid fuel dribbles in the fuel
system sleeves.
|
Loosened mounting of hose clamps.
|
Tighten
sleeves and clench the hose clamps.
|
|
8.
|
Faulty fire bar, cylinder or fire bar
walls - back and front ones.
|
Burned under high temperature influence.
|
Substitute
with the new ones.
|
|
9.
|
Unusual noise and knocking appeared in
the reduction gear box,
bearing units became heated up.
|
1. Incorrect alignment of the shafts of
the reduction gear box and electric motor.
2. Increase or decrease of the bearing
clearance.
|
Perform
proper alignment of the shafts.
Adjust
the bearing clearance.
|
|
NOTE: Faults, which are possible at operating
AF-65M injector and temperature controller, are described in the attached
instructions on these articles.
|
||||
12.2. For repair or
substitution of assembly units or parts, it is necessary to develop such. The
development rules are common for all varieties of the assembly units. As
exemplified by the combustion chamber and support rollers dismantling, one can
develop a standard technique for dismantling a required assembly unit.
а) At substitution
of the fire bar, cylinder, rear or front walls, pig-iron cone, it is necessary
to remove the injector assembled with the supporting bracket, having unscrewed
for this purpose three screw nuts M12 and two crimped locks, unscrew ten screw nuts
M12, remove the front wall of the firebox, pull out the fire bar, cylinder,
rear wall of the firebox, pull out the combustion chamber carcase, unscrew (or
cut down) three bolts М8 of the pig-iron cone mounting, pull out the cone.
Substitute the faulty parts, perform assembling under the procedure reverse to
disassembling.
b) At substitution of the
support rollers, except the operations set forth above, it is necessary to make
the following: to release two hose clamps of the mounting of the water tanks
located on the rear end wall of the oven, to remove the injector control panel,
temperature indicator, thermostatic controller and filter, to remove the chain
guard, chain and the hand lever of the hand drive, to remove the flange of the
drive mechanism with the sprocket wheel, to remove the oven end wall, having
unscrewed 36 bolts with screw nuts, to remove fastening with a cotter pin and
remove swinging trays of the conveyor, to unscrew and remove the conveyor
restrictors (upper ones), to unscrew the drive mechanism, to pull out the
conveyor from the baking chamber, to unscrew and remove the support rollers, to
substitute them, to mount into their place. The further assemblage is conducted
in reverse order.
12.3. There is an individual
kit of transported repair parts for each oven, which is packaged in containers
No. 2 and No. 1 used for the oven repair.
12.4. After repair or
substitution of assembly units and assembling thereof, the oven operation
inspection is conducted according to the requirements of paragraphs 9.2 - 9.11.
12.5. In case of an accident
with the oven, it is necessary to turn off all electric motors and power supply
cable, clarify a reason and eliminate faults.
13. MAINTENANCE (Procedures
and Regulations) AT OVEN OPERATION, lubrication arrangement or lubrication chart
13.1. Maintenance is
carried out in order to maintain the oven in constant serviceable condition. It
comprises performance of works, which provide:
- Ongoing technical
readiness;
- Safety of use;
- Maximizing the
time between overhauls and depreciation periods;
- Early detection
and elimination of the causes of deterioration and malfunction of components,
parts and appliances;
- Minimum fuel
consumption.
13.2. The planned
preventive maintenance system should be available, which is based on obligatory
carrying out a certain amount of work both in the oven operation process, and
during its storage and transportation.
13.3. A complex of
the maintenance works includes:
- Cleaning and
washing of the oven;
- Check a status of
the oven mechanisms and devices and eliminate identified faults;
- Mounting and
adjustment works;
- Washing, cleaning
and refilling the fuel system;
- Control of the
proper connections to electric networks;
- Lubrication works;
- Verification of
completeness;
- Verification of
the documentation correctness and its keeping.
During the oven
maintenance, cleaning and washing, lubricating, control-and-verification and
mounting works are performed on a mandatory basis, and filling, adjustment and
troubleshooting works are performed as necessary. All deficiencies identified
during the oven operation are eliminated during all types of maintenance.
13.4. The following
maintenance types are established:
- Walk-around
inspection (WAI);
- Daily maintenance
(DM);
- Maintenance No. 1
(M-1);
- Maintenance No. 2
(M-2);
- Seasonal maintenance (SM).
13.5. Walk-around
inspection (WAI) is carried out before starting the work and during the work.
a) Before starting
the work, one should:
- Check the
reliability of fastening removable equipment guards, injector, boiler and other
equipment;
- Clean the outer
surface of the oven from pollution;
- Conduct a visual
inspection of the oven;
- Check the fuel and
water presence in the water-heating boiler;
- Check correctness of
installation of the flame spreader, starting electrodes, cleanliness of the
inspection manhole and injector photo cells.
- Check connection of the
protective earthing;
- Inspect fuel lines and
ensure absence of fuel afterdribble;
- Remove air from the fuel
system;
- Check smoothness of the
conveyor rotation, direction of rotation of the electric motor of the oven
conveyor drive and operation of the safety clutch;
- Check operation and
direction of rotation of the electric motor of the injector, fuel pump, ensure
the closing valve serviceability, absence of a graze contact of the ventilator
impeller, correctness of fuel pulverisation and serviceability of the injector
automatic system;
- Eliminate the revealed
faults.
b) During the
walk-around inspection during operation, it is required to:
- Monitor the
temperature in the baking chamber;
- Monitor operation
of the electric drive of the oven conveyor, absence of oil afterdribble in the
reduction gearbox glands;
- Monitor the presence of baking loss vapours in the baking chamber and periodically release
them by means of the damper;
- Check presence of the fuel
in the fuel tank;
- Monitor through a viewing window of the injector a gap value and correctness of
arrangement of the starting electrodes;
- Watch serviceability of the
closing valve of the fuel pump of the injector, operation of the electric motor
and automatic system of the injector;
- Regulate the fuel burning
quality with the choke valve;
- Check
operation of the thermostatic controller by comparing the pre-set
temperature on the
thermostatic controller with readings of the mercury temperature indicator;
- Monitor presence of water in
the hot-water boiler, absence of water afterdribble in joints and cocks of the
water supply system;
- Eliminate the revealed
faults.
13.6. Daily maintenance (DM)
is conducted in the end of the working day (shift), at that, it is required to:
- Clear the oven from
pollution and bread residues, clear the firebox from ashes and smut;
- Check security of attachment
of the oven component parts, tighten loosened joints;
- Check operation of the
damper for removal the baking loss vapour;
- Check mounting of the
swinging trays and guides;
- Check chain tension of the
conveyor drive of the oven and its guard mounting;
- Check an oil level in the
reduction gearbox of the conveyor drive of the oven;
- Lubricate the chain gear of
the oven;
- Clear the starting
electrodes of the injector and check correctness of their installation;
- Wipe the window of the
inspection manhole and photo cells in the photoresistor unit of the injector;
- Check mounting of the
ignition transformer and high-voltage cables;
- Inspect fuel lines and
eliminate the fuel afterdribble;
- Check presence of fuel in
the fuel tank and refuel as necessary;
- Check serviceability of the
closing valve of the injector fuel pump;
- Eliminate the revealed
faults.
Labour intensity of daily
maintenance in man-hours - 1.0.
13.7. Maintenance No.1 (M-1)
is performed every 90-100 hours of the oven operation. At this maintenance, it
is necessary to conduct all operations specified for daily maintenance, and
besides, it is necessary to:
- Clean the mounting baseline
from pollution;
- Clean the oven from
pollution, wipe greasy surfaces
with the a brass rag moistened in kerosene or diesel
fuel;
- Clean from ashes and smut
the central, vertical and upper gas flues and chimney;
- Check tension of springs of
the safety clutch;
- Clean the fuel filter and
injector spray nozzle;
- Check the pressure created
by the fuel pump of the injector in the spray nozzle; substitute the pump
gasket at pressure lower than 700 kPa (7 kg/cm2);
- Strip contacts of contactors
of the relay and switches;
- Check and adjust operation
of the automatic system and thermostatic controller of the injector;
- Clear of a scale deposit and
wash out the hot-water boiler;
- Check a state of joints of
parts and their mounting, state of protective guards, locks, doors; tighten all
bolts and screw nuts;
- Eliminate revealed faults;
- Make a record in the service
log on the performed operations. The labour intensity of M-1 in man-hours - 4.0.
13.8. Maintenance No. 2 (M-2)
is conducted every 270-300 hours of the oven operation. At this maintenance, it
is necessary to conduct all operations specified for maintenance No. 1, and
besides, it is necessary to:
- Check a gap between the
conveyor rings and restrictors;
- disassemble and clear of
corrosion the inner surfaces of bearings of the conveyor support rollers and
drive mechanism;
- Wash out with kerosene or
diesel fuel the reduction gearbox of the conveyor drive and substitute the oil;
- Check mounting of sheets of
the outside skin of the baking chamber;
- Check operation of chimney
dampers and steam discharge pipe;
- Check mounting of the
chimney in marching position;
- Check a state of locks,
doors of the baking chamber, guards of the drive and muff coupling;
- Check operation of the
photoresistor unit of the injector;
- Check the fuel pulverisation
quality, position and gap between the injector starting electrodes;
- Check operation of the
switch of injector operating modes;
- Make partial painting of the
oven;
- Make a record in the service
log on the preformed operations. The M-2 labour intensity in man-hours is 8.0.
13.9. Seasonal maintenance is
performed two times a year at preparation of the oven for the summer and winter
operation periods. At preparation of the oven for operation during the summer
period, it is necessary to perform the scope of works in maintenance No. 2 and,
besides:
- Wash out the fuel filter;
- Check an insulation
resistance of electric motors windings and, if necessary, dry them;
- Wash out the reduction
gearbox casing and substitute the lubricant.
At preparation of the oven for
operation during the winter period, it is necessary to perform the scope of
works in maintenance No. 2 and, besides:
- Wash out the fuel filter;
- Check an insulation
resistance of electric motors windings;
- Wash out the reduction
gearbox casing and substitute the lubricant;
- If necessary, make painting
of the oven.
13.10. Lubrication of the oven
rotating parts should be performed according to the lubrication chart and
lubrication diagram (Appendices 7, 8).
14. RULES FOR STORAGE,
PRESERVATION AND DEPRESERVATION
14.1. The oven could be put
both on short-duration, and on long-term storage.
For the short-duration storage
(up to 3 months), the oven is usually put in the field conditions in
interruptions between certain operation periods.
At that, it are necessary to
perform the following operations:
- to release the water-heating
boiler from water and air dry it;
- to remove the chimney
(stationary) and put the short one (marching);
- to clean out the injector
from smut.
14.2. Before putting the oven
for long-term storage, it is necessary to conduct its preservation. For this
purpose, it is required to:
а) Remove the injector together with the supporting bracket, control
panel and thermostatic controller, clean it out from smut and dust;
b) Remove the front firebox wall, pull out the deflector, fire bar,
cylinder and rear wall, clean out from ashes, smut and calx, cover with black
MS-17 enamel;
c) Pull out the combustion chamber carcase, detach the pig-iron cone,
clean out from smut, cover the cone with black MS-17 enamel, the rest parts –
with drying oil natural GOST 7931-76;
d) Clean out the vertical and upper gas flues, inner surface of the
baking chamber, conveyor with the swinging trays and all parts in the baking
chamber, and cover with drying oil;
e) Lubricate through oilcans the support rollers and drive mechanism
with USsA graphite grease;
f) Clean out the hot-water boiler from a scale deposit, wipe dry and
lubricate with the spindle oil AU GOST 1642-75;
g) Replace oil in the reduction gearbox (fill in winter transmission
axle oil GOST 610-72), having previously washed out it with the diesel fuel;
h) Remove, wash out the chain and filter in the diesel fuel.
14.3. Assemble the oven. Cover
all non-painted parts, joint and open threaded connections with PVK
corrosion-preventing oil. Cover frayed areas of the paint and varnish coating
with HV-518 khaki enamel.
14.4. Сheck the spare parts
and, if necessary, paint or lubricate them with PVK lubricant, place them back.
14.5.
Oven depreservation is performed according to the oven depreservation chart
(Appendix 9).
15. TRANSPORTATION
15.1.
Ovens can be transported by rail, water and combined transport.
Prior to
transporting ovens by any kind of transport, it is necessary to make a thorough
inspection of all oven parts, check reliability of fastening of detachable
parts.
15.2.
Oven dimensions conform to the loading outline dimensions of rolling stock of
the USSR and conform to the railcar envelope 02-T (appendix).
15.3. Loading of
ovens onto the flat wagons is performed by lifting them with a crane by means
of their special brackets. Slinging and lifting ovens by means of their other
parts is not permitted.
15.4. Ovens in
quantity of 4 pieces are mounted on a flat wagon in such a way that they do not
touch each other. To prevent movement of the ovens along the flat wagon, each
oven is fixed by four guys. Guys (two-thread wire with the diameter of 6 mm GOST 3282-74) are
attached with one end to the oven end walls, with the second end – to the flat
wagon rack-mountable brackets.
16. MARKING AND SEALING
16.1. The product
information plate is manufactured in accordance with the requirements of state
standards GOST 12969-67 and GOST 12971-67 and should be attached to the oven
body. The plate of rectangular shape. 16.2. The plate should specify:
a) trademark, name
of the manufacturer;
b) make of the
product;
c) the serial
number;
d) year and month of
manufacture;
e) technical
specification No.
16.3. The water
heating boiler housing, as well as the cover of the inventory box are
stencilled with black enamel with indication of the oven designation and
number, Quality Department acceptance stamp of the factory-manufacturer on the
left side in the figure of "circle" and of the customer
representative – on the right side in the figure of "diamond".
16.4. The operating
manual is attached at the rear end wall of the oven.
16.5. Directions of
the drive chain rotation, coupling, injector electric motor are indicated by
arrows.
16.6. The earth sign
is indicated at the electric drive plate in accordance with GOST 21130-75.
16.7. Marking of
shipping containers should be carried out by stencilling in accordance with
GOST 14192-77.
16.8. A box with the
injector.
17. CONTAINERS AND PACKAGING
17.1. The
oven is shipped without packaging.
17.2. Box for
spare inventory reusable injector (box No. 1).
17.3. Boxes
of spare parts (cylinder wall furnace fire bar, cones) No. 2 and No. 3 are
manufactured in accordance with GOST 2991-76 type U1.
17.4. When
packing items such as rollers, pins, sprockets, metal products must be wrapped
in waterproof paper GOST 8828-75 and stacked in a box GOST 2991-76 Type 1,
which is placed inside the box No. 2.
17.5. All
items packed in boxes should be securely packed with stringers.
APPENDICES:
1. Dimensional drawing.
2. Kinematic scheme
3. Scheme of flue gas movement.
4. Lubrication chart.
5. Lubrication diagram.
6. Oven depreservation chart.
7. Scheme of oven flexibility in railway clearance.
Dimensional
Drawing Appendix
1
Layout
of Foundation Bolts
|
||
Kinematic
Scheme Appendix
2
Inscriptions: об/мин = revolutions per minute;
4АХ80В8У3 = 4AH80V8U3
Редуктор = Reductor Gear Box
|
Scheme
of Flue Gas Movement Appendix
3
Lubrication Chart Appendix
4
Item Name and No. (in Lubrication Diagram)
|
Lubricating Material Name and Standard No.
|
Number of Lubrication Points
|
Lubricating Material Application Technique
|
Interval Between Inspections and Relubrica-tion
|
Notes
|
||
At Tempera-ture up to Minus 40 ºC
|
At Tempera-ture up to Plus 50 ºC
|
For Long-Term Storage
|
|||||
1. Driving sprocket (mounting
seat)
|
Lubricant LVK GOST 19537-74.
|
1
|
Lubricant is applied through a
lubricating can with a lubricating- filling gun
|
Every 24 hours
|
|||
2. Driving sprocket (mounting
seat)
|
The same
|
1
|
The same
|
The same
|
|||
3. Driving chain
|
- “ -
|
1
|
Lubricant is applied on to the
chain surface
|
- “ -
|
|||
4. Bearings of electric motors
of injector, drive
|
Lubricant US GOST 1033-73
|
5
|
Lubricant is applied manually
at assembling
|
Every 4000 hours
|
|||
5. Reduction gear box
|
Transmission “winter” oil GOST 610-72
|
1
|
The oil is filled through a
hole in the reduction gear box cover
|
Topping-up to the proper level
every 24 hours, first change – in 120 hours, next ones – in 72 hours of
operation.
|
Oil level is controlled by a
level gauge
|
||
Lubrication Chart Appendix
4
Item Name and No. (in Lubrication Diagram)
|
Lubricating Material Name and Standard No.
|
Number of Lubrication Points
|
Lubricating Material Application Technique
|
Interval Between Inspections and Relubrica-tion
|
Notes
|
||
At Tempera-ture up to Minus 40 ºC
|
At Tempera-ture up to Plus 50 ºC
|
For Long-Term Storage
|
|||||
6. Bearings of the support
rollers and drive mechanism
|
Graphite lubricant USsA GOST 3333-55
|
5
|
Lubricant is applied through a
lubricating can with a lubricating- filling gun
|
Lubricant is applied only
during the oven storage.
|
Do not lubricate during
operation!
|
||
NOTES:
1. Prior to lubrication, wipe
lubricating cans and lubricated areas.
2. After lubrication, wipe the
lubricant appeared on the outer surface of all parts in order to prevent dust
sticking to it.
|
|||||||
Lubrication Diagram Appendix
5
1 Driving Sprocket
2 Driven Sprocket
3 Driving Chain
4 Bearings of Electric Motors of Injector and Drive
5 Reduction Gear Box
6 Bearings of Support Rollers and Drive Mechanism
(the lubricant is applied only during the oven storage)
|
Scheme of Oven Depreservation Appendix 6
Name of Depreservation Areas
|
Operation for Preservation Coating Removal
|
Remarks
|
1. The inner part of the
baking chamber, conveyor with swinging trays, rollers, drive mechanism.
|
Oven heating up to the
temperature of 300°С.
|
The baking chamber door should be open.
|
2. Inner surfaces of the
water-heating boiler.
|
||
3. Threaded connections and
parts of the spare parts, tools and accessories.
|
Washing in petrol, careful
wiping with clean brass rag.
|
Scheme of Oven Flexibility in Railway Clearance Appendix 7
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