Comtec 2200 Operator's Manual

Pie and tart dough presses

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2200

COMTEC INDUSTRIES, LTD.

Pie and Tart Dough Presses

Model 2200

Operator' s Manual

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Page 1 2200 COMTEC INDUSTRIES, LTD. Pie and Tart Dough Presses Model 2200 Operator’ s Manual...
Page 2 C O M T E C I N D U S T R I E S , L T D . Model 2200 Operator’s Manual WARNING Read and understand operator’s manual before using this machine. Failure to follow operating instructions could result in serious injury.
Page 3: Read Before Operating This Machine
Read Before Operating This Machine The following symbols are used on the machine and in this manual. Do not operate the machine until you understand the meaning of these symbols WARNING Dangerous Voltages Potential lethal voltages and currents are present Disconnect Power Supply within the machine.
Page 4: Product Description
Product Description The Model 2200 is a hydraulic machine that uses custom dies to form dough. Each size and type of crust requires a separate, custom die. Dies that form bottom crusts are manufactured to work with a specific pan, chosen by the customer.
Page 5 SAFETY FIRST READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO OPERATE THE PRESS. COMTEC HAS INSPECTED THIS PRESS. OTHER THAN TRANSIT DAMAGE, NO MODIFICATION IS NECESSARY. WARNING ONLY OPERATOR OF PRESS HANDLES IS TO LOAD AND UNLOAD DIE AREA THE PRESS OPERATOR MUST USE TWO HANDS (ONE ON EACH HANDLE), TO CYCLE THE PRESS.
Page 6: Hydraulic Oil Specifications
IMPORTANT Hydraulic Oil Specifications BEFORE OPERATING THIS MACHINE, FILL THE RESERVOIR WITH EITHER: FIVE (5) GALLONS (18.9 LITERS) OF MINERAL BASE “LIGHT” #32 HYDRAULIC OIL, 150 S.S.U. VISCOSITY (EQUAL TO 10 WT. ENGINE OIL). USE ONE OF THE NAME BRANDS (ARCO, ENCO, STANDARD, SHELL, ETC) EQUAL TO CITGO PACEMAKER #32.
Page 7 IMPORTANT SANITATION INFORMATION Compliance with sanitation specifications requires that the bottom of each Comtec crust forming machine's base be completely sealed to the surface or structure on which it rests. To guarantee a smooth, airtight seal between the machine and the mounting surface, perform the following steps: 1.
Page 8 www.comtecltd.com For Kasco service use only.
Page 9: General Notes
3. DOUGH FORMULA. The Comtec 2200 does not require a special type of dough. In most cases, your present formula will work satisfactorily, if you bear in mind the following points: A.
Page 10 BEWARE OF EXCESS WATER IN PIE DOUGH. Pie dough formula for rolled and sheeted crust include extra water to cope with dusting flour and scrap dough recovery. The Comtec crusts system includes neither scrap dough recovery nor dusting flour, so excess water leads to tougher dough and shrinkage problems.
Page 11: Table Of Contents
Hydraulic Oil Specifications GENERAL NOTES viii DOUGH MIXING C H A P T E R S INTRODUCTION INITIAL INSTALLATION INSTALLATION OF DIES Tapped Air System TEMPERATURE ADJUSTMENT OF DIE USING THE MODEL 2200 SERVICING THE PRESS TROUBLESHOOTING Electrical Schematic Maintenance Schedule...
Page 12: Introduction
Press exceeds that obtained with sheeted methods. The Model 2200 is a hydraulic machine that uses custom dies to form dough. Each size and type of crust requires a separate, custom die. Dies that form bottom crusts are manufactured to work with a specific pan, chosen by the customer.
Page 13: Initial Installation
If you notice any damage to the equipment, immediately report this damage to the carrier. 2. The CE Marked version of the Model 2200 is shipped without a plug. It is the end user’s responsibility to attach the appropriate grounded plug that conforms to EN 60309-1 and EN 60309-2.
Page 14 7. You should hear no noise except the standard operating sounds of the motor and hydraulic pump. 8. The travel plates should only stop moving at the top and bottom of the machine’s cycle. This completes the initial test of the Model 2200. www.comtecltd.com For Kasco Corp use only.
Page 15: Installation Of Dies
COMTEC for your Press. We will assume the Press does not have a set of dies installed at this time.
Page 16 M O D E L 2 2 0 0 Figure 3 Installing Lower Die Half 5. Turn thumb screw on the right side of the travel plate clockwise to lock the lower die half in position. 6. Insert pocket of upper die half into hub at heater assembly. Using the supplied hex head wrench, turn wrench to secure die.
Page 17 COMTEC for your Press. We will assume the Press does not have a set of dies installed at this time.
Page 18 M O D E L 2 2 0 0 6. DO NOT turn the thumb screw below the lower die half clockwise to lock die half in position, yet. 7. Insert pocket of upper die half into hub at heater assembly. Using the supplied hex head wrench, turn wrench to secure die so that it is approximately aligned with the lower die half.
Page 19 M O D E L 2 2 0 0 11. If the dies DO close fully, turn thumb screw below the lower die half clockwise to lock the die half in position. This installation procedure is done. www.comtecltd.com For Kasco Corp use only.
Page 20 Rotate hydraulic ram clockwise two full turns; retighten lock nut. 4. Check Closing of Dies. Repeat this procedure if the dies still do not close properly. Travel Plate Flange Plate Figure 7 Model 2200 Press www.comtecltd.com For Kasco Corp use only.
Page 21: Tapped Air System
“Tapped Air” system is meant to ensure that finished crusts release properly from the forming die. Not all Comtec dies are equipped with a tapped air system. Please read your order invoice to see if your die is equipped with tapped air.
Page 22: Temperature Adjustment Of Die
M O D E L 2 2 0 0 TEMPERATURE ADJUSTMENT OF DIE he following steps outline a recommended procedure to set the temperature of the upper die half. The correct temperature will permit the crust to form properly with a minimum dwell time and release cleanly from the die. A temperature setting should be established each time a different size crust is made, the size of the dough portion is changed, or the dough formula is changed.
Page 23 M O D E L 2 2 0 0 Figure 8 Setting Temperature Control Note: As the pastry crusts are being pressed, the red indicator light will intermittently turn on and off, as additional heat is required to keep the die at the preset temperature. As the machine is cycled, the temperature light may turn on intermittently, indicating the die is heating.
Page 24: Using The Model 2200
Operation The following steps outline a typical procedure to operate the Model 2200. We will assume that the Press is in an OFF condition. (1) Switch Power ON. This applies power to the motor of the hydraulic pump and to the heater of the upper die.
Page 25 M O D E L 2 2 0 0 be the correct weight of dough for the pan. If the shortening is changed, either by percentage or brand, this procedure has to be repeated. Best results are obtained when a die is “seasoned”. This can be done during the initial start-up by placing shortening on a paper towel and rubbing the shortening onto the surface of a warm die.
Page 26: Servicing The Press
M O D E L 2 2 0 0 SERVICING THE PRESS UNPLUG/DISCONNECT THE PRESS BEFORE PERFORMING ANY SERVICE In the upper control panel of the Press are the indicator light junction box, a fuse for the heaters, and thermostat circuit. To check or replace the fuse, unscrew the three screws holding the panel to the machine and lift the panel up.
Page 27 Figure 10 Removing Heater Cover Figure 11 Heater Assembly Removed If authorized by Comtec, the hydraulic system can be serviced by removing the four screws in the base cover plate on top of the reservoir. The base cover plate with the motor, and the upper and lower die assemblies can then be removed from the reservoir.
Page 28 The Model 2200 does not use a timer. The time of the dwell at the top of the stroke is judged by the operator. This time can be slightly varied to meet the operating temperature and the consistency of the dough.
Page 29 This assembly with the thermostatically controlled dies assures uniform and accurately formed crusts. Damage to the machine’s frame will produce incomplete and/or inconsistent crust formation. Contact Comtec to evaluate your repair options. www.comtecltd.com For Kasco Corp use only.
Page 30: Troubleshooting
TROUBLESHOOTING This section lists the most common performance symptoms associated with the Model 2200 Press. Locate the symptoms that you are experiencing in the list below and read the suggested troubleshooting sections for possible solutions. If the solutions listed here do not solve your problem, contact Comtec for more advanced troubleshooting.
Page 31 SYMPTOM: The dies won’t heat up Possible causes ●Insufficient heat setting (see 2.2 below) ●Thermal Reset Switch has tripped (Model 2200’s only) (see 2.4 below) ●Blown fuse (see 5.5 below) ●Failed thermostat (see 5.6 below) ●Failed heating element (see 5.7 below) SYMPTOM: The dies don’t heat up enough...
Page 32 ●Failed heating element (see 5.7 below) SYMPTOM: The dies get too hot Possible causes ●Heat turned up too high (see 2.3 below) ●Failed thermostat (see 5.6 below) ●Incorrect line voltage (see 5.3 below) ●Incorrect heating element (see 5.8 below) SYMPTOM: Oil is leaking down the side of the machine base Possible causes ●Machine has been moved (see 6.2 below) ●Failed oil tank gasket (see 4.1 below)
Page 33 ●Machine has been dropped and knocked out of alignment (see 3.3 below) SYMPTOM: Dough shrinks back after pressing Possible causes ●Dough has been over mixed (see 1.5 below) ●High gluten flour used (see 1.16 below) ●Too much water in dough (see 1.4 below) ●...
Page 34 1. Forming Dies & Dough 1.1. Incorrect number or placement of flat springs The upper half of a bottom crust die set has a series of fasteners, pins, and flat springs that must be properly configured for successful crust production. Occasionally, the flat springs and the pins need replacement due to normal wear and tear.
Page 35 Signs that a die set is not functioning properly: (1) Dough leaks from in between the two die halves (2) The pans are severely distorted or even damaged by the die set (3) The dough does not form a complete, perfect crust (4) The pans and dough stick excessively to the die.
Page 36 Flat Spring 1.3. Using the wrong pan Each Comtec Die Set is custom made for a specific pan and to an individual customer’s specifications. Comtec stamps the pan identifier on the top of each forming die. This information will either be in the form of pan model number or pan dimensions.
Page 37 1.5. Dough has been over mixed Typically, the less that dough is worked, the better it will perform in a Comtec press. Comtec recommends (1) Mix your dough with a cake paddle rather than a dough hook. The paddle works the dough less than the hook. (2) Only mix your ingredients until they are blended.
Page 38 Your Comtec press is designed to form crusts consistently, without scrap dough. To prevent scrap dough, your Comtec press will attempt to use all of the dough that is placed in the pan. Consequently, if you put an excessive weight of dough in a pan, the machine will press a thicker crust.
Page 39 The starting position of the travel plate on a Model 1100, or the lower travel plate on a Model 2200, can be adjusted. It is not uncommon for the starting position of the travel plate to be lowered, when an extraordinarily deep pan is pressed in the machine.
Page 40 In severe cases, failed bearings will cause the travel plate to move up, but not come back down on its own. Contact Comtec to see if replacement bearings are available for your machine.
Page 41 4. Hydraulic System 4.1. Failed oil tank gasket. Every Comtec press is built with a self-adhesive gasket strip between the top of the oil reservoir and the underside of the machine’s cover. If this gasket strip is damaged or wears out, oil will “spill” over the side of the machine every time the machine is moved.
Page 42 5.1. Motor cover rubbing The top of the electric motor on Comtec presses is a cover for the motor’s cooling fan. This is not a load bearing surface. If a heavy weight is rested on top of the fan cover, the inside of the cover will begin rubbing against the cooling fan.
Page 43 Comtec to see if a replacement motor is available for your machine. 5.5. Blown fuse The heating system of both the Model 1100 and the Model 2200 is protected by a 10A fuse. NEVER operate the machine if this fuse has been bypassed or is missing. If the dies on your machine don’t heat up, the fuse is the simplest item to check.
Page 44 North America are equipped with heating elements that are marked “120V, 500W”. Model 1100’s that are manufactured for operation in countries with 220 V electrical systems are marked “240V, 500 W”. Elements for a Model 2200 are marked “240V, 500W”. NEVER operate your Comtec press with the incorrect heating elements installed.
Page 45: Electrical Schematic
Electrical Schematic...
Page 46: Maintenance Schedule
Maintenance Schedule he following steps outline a recommended maintenance schedule for your Model 2200 Pie and Tart Dough Press. Lifespan of listed components is based on an average yearly duty cycle of the machine. Actual component lifespans will be effected by excessive machine use and by poor machine maintenance.