desinewing machine operating instructions · the baader 600 is used for separating soft components...
TRANSCRIPT
6000000802 1206 GB
600
Food Processing Machinery
Desinewing MachineOperating Instructions
600
GB
Nordischer Maschinenbau Rud. Baader GmbH + Co.KGPostfach 1102 D-23501 LübeckGeniner Str. 249 D-23560 LübeckPhone +49 / 451 / 5302-0Telex 26839Internet www.baader.come-mail [email protected]
Fax:Sales +49 / 451 / 5302-492Project Eng. +49 / 451 / 5302-494R & D +49 / 451 / 5302-495Shipping +49 / 451 / 5302-483Purchasing +49 / 451 / 5302-493
Preface
Preface
This operating manual is dedicated to the personnel responsible for the operation and mainte-nance.
Set up, commission and operate the machine only when having perfect knowledge of this operat-ing manual and by strictly observing the instructions given therein.
Nordischer Maschinenbau Rud. Baader GmbH + Co. KG
will not assume any liability for damages due to the nonobservance of the operating manual, insufficiently trained personnel, improper handling of the machine as well as its application in other fields than those specified in the operating manual!
In case of arbitrary modifications by removing or mounting parts or any conversion of the machine without our approval, our conformity declaration (EC directive) will become invalid.
Do not use other than genuine BAADER spare parts!
It is absolutely necessary to observe the legal safety regulations for food processing machinery which are in force in your country!
This operating manual is our intellectual property and may neither be copied, reproduced or made available to third parties without our written approval, nor may it be misused!
GB 1
600Table of Contents
Table of Contents
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Outline drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
7 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
9 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
10 Setting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
11 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
12 Selection of the perforated drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
13 How to treat the squeezing belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
15 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
17 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
18 BAADER 600 with DMM 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
19 Country-related list of cleaning agents and disinfectants . . . . . . . . . . . . . . . . . . . .35
20 HENKEL sales partners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
21 Lubricants and preservatives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
22 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
600
2 GB
Meaning of the pictograms
Meaning of the pictograms
Important note!
In case of non-observance, impairments of the machine or of property assets cannot be ruled out!
Particular attention is required - danger of bodily injury!
Danger to life in way of unprotected electrical systems!
GB 3
600Safety instructions
Safety instructions
Important for machine operators!
Non-specified use as well as improper operation of the machine can result in serious bodily inju-ries and severe material damages. It is absolutely necessary that the operators observe the fol-lowing safety instructions!
• Read the operating instructions prior to starting up the machine!• Unauthorized, untrained personnel must not put the machine into operation and/or carry out
any work at the machine!• Wear tight-fitting working cloth, especially around arms!• Tie long hair together and cover!• Do not wear any finger rings!• Do not reach into running machine!• Do not use the machine to put any article on it!• Do not run the machine unattended!• Switch off the machine, put the main switch to 0-position and secure it:
- in case of failure of the functional sequence- prior to cleaning- prior to maintenance- prior to lubrication
• Warning signs attached to the machine must at any time be legible for the operators! Defective or missing warning signs have to be replaced immediately!
• Have repair work carried out by qualified personnel only strictly observing these operating instructions!
• The safety devices installed by the manufacturer must not be bypassed, modified or removed!• Spraying by means of sprays of any kind whatever in electrical enclosures and control gears is
prohibited; explosion hazard!
600
4 GB
Safety instructions
Safety instructions
Fit all hoods and covers prior to commissioning the machine.Verify the proper functioning of all safety devices!During operation, the machine must stop when …… setting the main switch (1) to 0-position
The machine shall not be commissioned when …
… the intermediate wall (2) is not in operating position!… the storage bin (3) is not in operating position!… the front panel (4) is not in operating position!… the squeezing belt (5) is not fitted!… the perforated drum (6) is not installed!… the scraper (7) is not installed!… a perforated drum with holes of more than 5 mm is installed and the safety
guard provided is not fitted to the machine!
The parking brakes (8) of the castors shall only be released for displacing the machine! After the machine has been displaced, the brakes must be applied again!
In the event of power failure, the main switch of the machine will be set automatically to 0-posi-tion! Once the power is available again, the main switch must be set to position I in order to restart the machine.
5
2
4
7 1
3
6
8
GB 5
600General
1 General
The BAADER 600 is used for separating soft components from solid components according to a press-separation method.
For instance fish filets from skin and bones, meat and poultry from sinews and cartilages, dairy products from their packages, fruits and vegetables from the skin, pips and stones.
1
600
6 GB
Technical data
2 Technical data
Throughput rate* : up to 400 kg/h as a function of the initial product and the size of the holes in the perforated drum
Power consumption : 1.5 kW
Dimensions- width : approx. 1200 mm- depth : approx. 910 mm- height : approx. 1140 mm (max. 1603 mm)
Weight : 220 kg
Operator requirements : 1 person
Noise measurement (evaluation according to DIN 45635) Workplace level (LpA) : 70 dB(A)
* The throughput rate of the machine is contingent upon the raw product to be processed (fish, meat, poultry, fruits or vegetables, packages, etc.), furthermore on the preparation, tempera-ture of the raw product, on the type of feeding, the adjusted pressure of the squeezing belt and on the size of the holes in the perforated drum.
GB 7
600Outline drawing
3 Outline drawing
1 Power connection2 Initial product3 Final product4 Waste
2
878
3
4
4
1
2
4
1170
502
1046
291
1577
422
1144
R480
567
731
602
1550
R592
682
657
3
2
2
600
8 GB
Transport
4 Transport
Lift the machine from the front or back (figure 3, arrows) using a forklift truck or elevating-platformtruck.If none of these industrial trucks is available, then the machine can be lifted from the pallet bymeans of two squared timbers each of approx. 1500 mm in length.
Transport the machine with the necessary care!
Only the load lifting devices provided or equivalent approved ones shall beused!
After the transport, the castors previously removed must be refitted to the machine. Arrange thecastors with the parking brakes (fig. 3, item 1) as shown in figure 3.
The parking brakes of the castors shall only be released for displacing themachine! After the machine has been displaced, the brakes must be appliedagain!
31
GB 9
600Set-up
5 Set-up
The location provided for the machine must be horizontal!The machine must be readily accessible from all sides for ease of operation and maintenance(figure 4).After the machine has been set up, apply the parking brakes of the castors.
The parking brakes of the castors shall only be released for displacing themachine! After the machine has been displaced, the brakes must be appliedagain!
4
800 mm
800 mm
400
mm
800
mm
600
10 GB
Power connection
6 Power connectionThe machine is equipped with a cable of 5 m in length with Euro plug.If national standards require the plug to be changed, then the machine must be connected to the mains according to the circuit diagram taking into account the provisions of the local power sta-tion and the standard EN 60204 as well as VDE 0100 in order to comply with the legal safety reg-ulations.Seal the cable bushes and screw so that they are watertight.
The electric gear of the machine connected to the mains contains hazardous alive, blank parts, and during operation, moving and/or rotating parts if the main switch is put to ”ON” position! Removal of any covering is prohibited! Improper operation or insufficient maintenance can result in serious bodily injuries and severe material dam-ages!
Consequently, the persons who are responsible for the safety of the machine, have to ensure that ...… any work to be carried out on the machine is only entrusted to qualified personnel,… the operating instructions as well as all information required for carrying out works are always
available to this personnel who will be bound to strictly observe the contents of such informa-tion,
… any work on the machine or in its vicinity by unqualified personnel is prohibited.
Spraying by means of sprays of any kind whatever in electrical enclosures and control gears is prohibited; explosion hazard!
Verification of the motor's sense of rotationWhen looking into the drum, the sense of rota-tion of the perforated drum is clockwise (figure 5).
If the mains power is not applied to the machine, the main switch cannot be set to position I but will return automatically into position 0 when released!
5
GB 11
600Safety devices
7 Safety devicesIn order to prevent accidents and personal injuries, it is absolutely necessary to observe the safety reminders at the beginning of this operating manual!It is prohibited to bypass, modify or remove the safety devices installed by the manufacturer!In the event of power failure, the main switch of the machine will be set automatically to position 0. Once the power is available again, the main switch must be set to position I in order to restart the machine!
If a perforated drum with holes of more than 5 mm is installed in the machine, the safety guard provided must be fitted to the machine! It is prohibited to operate the machine without this safety guard when using a perforated drum with this hole size!
600
12 GB
Operation
8 OperationThe machine processes the initial product con-tinuously.The material to be separated is loaded via the bin (fig. 6, item 1).The squeezing belt (fig. 6, item 2) presses the initial product against the perforated drum (fig. 6, item 4) during which process the soft compo-nents are pressed through the holes into the inner drum space. A conveyor screw (fig. 6, item 4) discharges the components pressed through the holes from the perforated drum.The solid components remain on the outer drum shell. They are removed by a scraper (fig. 6, item 5) and discharged via a chute (fig. 6, item 6).The use of another perforated drum may be required as a function of the initial product. Perforated drums with different hole diameters are available (cf. section 12).
When separating meat from sinews, the fibre structure of the meat remains intact, as the initial product is neither chopped nor triturated or ground. The brief passage through the holes results only in a minor warming of the product.
6
4
53
1
2
6
600Commissioning procedure
9 Commissioning procedureIt is absolutely necessary to disassemble and clean the machine prior to commissioning.
9.1 Disassembly
• Set the main switch to position 0 and protect it using a padlock
• Remove the conveyor screw (fig. 7, item 1)• Remove and disassemble the scraper (fig.
7, item 2) including the axle• Relief the belt pressure by means of quick
release- Lift the tensioning lever (fig. 8, item 1)
and lower laterally from the sliding block (fig. 8, item 2)
• Completely reduce the belt tension and remove the lever (fig. 7, item 3)
• Loosen the drum nut (fig. 7, item 4; fig. 9, item 1) and remove it together with the disk (fig. 9, item 2) from the perforated drum
2
14
3
7 12
8
9
1
2
GB 13
600Commissioning procedure
• Fit the extractor (fig. 10, item 1; supplied with the machine) to the perforated drum (fig. 10, item 2) and withdraw the drum with the necessary care
Consider the weight of the perfo-rated drum!
• Loosen and remove the nuts (fig. 12, item 1)• Hinge down the front panel (fig. 12, item 2)
(fig. 11, item 1)• Hinge up the storage bin (fig. 12, item 3) (fig.
11, item 2)• Remove the squeezing belt, pressure device
(fig. 13, item 1) and the rollers (fig. 13, item 2)
• Remove the tensioning roller (fig. 13, item 3)• Adjust the belt tensioning eccentric (fig. 14,
item 1) and the pressure roller (fig. 14, item 2) so in relation to the intermediate wall (fig. 14, item 3) that the latter can be pulled up
• Clean the machine as described in section 15.3.1
Cleaning agents endangering the envi-ronment are to be disposed of accord-ing to the applicable regulations!
2 1
10
2
1
11
11
1
12
3
12
13
2
1
3
14
1
2
3
4
14 GB
600Commissioning procedure
9.2 Assembly• Push the intermediate wall (fig. 14, item 3;
fig. 15, item 1) against the housing and make sure that it is level with the locating flange (fig. 15, item 2) for the perforated drum
• Fit the pressure device (fig. 15, item 3) of the housing side
• Grease the belt tensioning eccentric (fig. 15, item 4) and the axles (fig. 15, item 5) using special BAADER grease GLS 380/N3 and mount the rollers (fig. 15, item 6)
• Fit the tensioning roller (fig. 15, item 7)• Fit the outer pressure device (fig. 15, item 8) • Fit the squeezing belt pressing it under the
drum fastening bolts (fig. 15, item 9)• Swivel the storage bin into operating posi-
tion
• Swivel the front panel into operating position and secure it by means of the nuts
The inner surface of the front panel must be level with the offset of the perfo-rated drum!
• Insert the centring piece (fig. 16; provided with the standard tools) for the perforated drum
• Place the perforated drum with the fitted extractor on the squeezing belt• Push the perforated drum over the centring piece on to the square (fig. 15, item 10)• Remove the extractor from the perforated drum• Remove the centring piece• Fasten the perforated drum by means of the disk (fig. 17, item 1) and the nut (fig. 17, item 2),
during which operation the disk is fixed with the bolt (fig. 15, item 9)
3
7
28
101
2
4655
9
15
16 17
2
1
GB 15
600Commissioning procedure
• Install the conveyor screw (fig. 18, item 1)• Insert the scraper and press it with the adjusting screw (fig. 18, item 2) against the perforated
drum (cf. section 10.1)• Fit the belt tensioning lever (fig. 18, item 3)• Adjust the tension of the squeezing belt (section 10.2.2)• Adjust the belt pressure (section 10.2.1)• Remove the cap from the vent plug (fig. 19, item 1) of the gear motor (fig. 19, item 2)• Verify the proper functioning of all safety devices; cf. safety reminders at the beginning of this
operating manual!• Briefly run the machine and grease in order to remove any penetrated water from the bearings
It is prohibited to bypass, modify or remove the safety devices installed by the manufacturer! The machine shall not be commissioned when …
… the intermediate wall (fig. 18, item 4) is not in operating position!… the storage bin (fig. 18, item 5) is not in operating position!… the front panel (fig. 18, item 6) is not in operating position!… the squeezing belt (fig. 18, item 7) is not fitted!… the perforated drum (fig. 18, item 8) is not installed!… the scraper (fig. 18, item 2) is not installed!… a perforated drum with holes of more than 5 mm is installed and the safety
guard provided is not fitted to the machine!
6
1
23
7
8
4
5
18 19
12
16 GB
600Setting instructions
10 Setting instructions
10.1 Scraper• Turn back the adjusting screw (fig. 20,
item 1) • Push the scraper with the support (fig. 20,
item 2) between front panel (fig. 20, item 3) and intermediate wall (fig. 20, item 4)
• Push the axle (fig. 20, item 5) through the front panel, support and intermediate wall
• Turn the axle to secure it with the pin behind the front panel
• Turn the adjusting screw (fig. 20, item 1) clockwise in order to press the support with the scraper against the perforated drum The perforated drum and the product to be processed determine the pressure exerted by the scraper on the drum
Any too high pressure would result in an unnecessarily high wear of scraper and perforated drum!
• Loosen the nut (behind the intermediate wall, fig. 20, item 6) of the black stop bush (fig. 20, item 6)
• Adjust the stop bush so that the scraper is of a lateral distance of 1 mm each from the interme-diate wall and the front panel
• Retighten the nut
20
2
4
1 3
5
6
GB 17
600Setting instructions
10.2 Squeezing belt
10.2.1 Belt pressure• Lift the tensioning lever (fig. 21, item 1) and
press the pressure roller (fig. 21, item 2) against the perforated drum
The manual force determines the yield!
• Turn the spindle (fig. 21, item 3) with the star handle (fig. 21, item 4) until the sliding block (fig. 21, item 5) is positioned under the ten-sioning lever
By lifting and lowering the tensioning lever by passing the sliding block, a quick pressure relief of the pressure roller is possible.
Before rest periods and prolonged standstills of the machine, the quick pressure relief should be carried out in order to reduce the load on the squeezing belt!
10.2.1.1 Standard values for pressure setting (force applied to the tensioning lever)Fish lowMeat highPoultry mediumDairy products lowFruits, vegetables lowWarm products low
10.2.2 Belt tension• Loosen the clamping lever (fig. 22, item 1)• Turn the tensioning lever (fig. 22, item 2) to
the right thus adjusting the tension of the squeezing belt
• Tighten the clamping lever
Adjust the belt tension only by applying slight manual force! Any too high belt tension would result in an unnecessarily high wear of the squeezing belt and should therefore be avoided!
3
4
1
5
2
21
2
1
22
18 GB
600Setting instructions
10.3 Back-up bearings
The back-up bearings on the eccentric bolts are factory-set to a distance of 0,2 – 0,4 mm from the bearing surface of the perforated drum. If this distance is increasing, the respective back-up bearing has to be readjusted (see fig. 23):• Unscrew the cover (fig. 23, item 1)• Unscrew completely the bearing (fig. 23, item 2) with the eccentric bolt (fig. 23, item 3)• Remove the compensating washers off the pivot or out of the boring (fig. 23, item 4) and screw
down the eccentric bolt again• Measure the clearance between the perforated drum (fig. 23, item 5) and the back-up bearing.
Set the distance of 0,2 mm – 0,4 mm by pinning up compensating washers onto the thread of the eccentric bolt (0,1 mm 24°)
• Screw down the eccentric bolt and inspect the clearance again; if necessary, repeat the proce-dure
Examine the clearance after each grinding of the perforated drum; if necessary, readjust! The compensating washers are included in the accessories.
0,2-
0,4
mm
0,2-0,4 mm
5
21
3
4
1
5
120°
120°
23
Position of the eccentric bolt within this range!
Position of the eccentric bolt within this range!
GB 19
600
20 GB
Operating conditions
11 Operating conditions
11.1 Pre-shreddingThis is required for …
… the perfect infeed of the initial product
… the separation process of the soft and solid components of the ini-tial product
The finer the pre-shredding …… the higher will be the yield… but the final product will be less
pure- examine figure 24 and cf. section 12 –
11.2 Loading the initial product into the machine• As evenly as possible• Feed the finely pre-shred initial product as a flat spread mass• Continuously feed larger pieces one after the other• It is absolutely necessary to avoid dry running!
Accumulations of initial product and/or lump formations prevent the perfect infeed and would overload the machine!
11.3 Temperature of the initial productIt shall be within a range of 0°C and 5°C.
As far as meat is concerned, temperatures above 8°C would result in a deterioration of the initial product!
24
shredding finecoarse
+
-
purity
yield
600Selection of the perforated drum
12 Selection of the perforated drum
12.1 Processing of fish
12.2 Processing of meat
If a perforated drum with holes of more than 5 mm is installed in the machine,the safety guard provided must be fitted to the machine!It is prohibited to operate the machine without this safety guard when using aperforated drum with this hole size!
Hole diameter Initial product Preparations
3 mm TrimmingsBones
5 mm Filets
Whole fish crushing
Hole diameter Initial product Preparations
2 mm Meat quality 1Meat quality 2
Meat grinder with perforated disk 13-20 mm and 2 pre-cutters with knife in between
Separation of bones from large soft pieces
Meat grinder with perforated disk 13 mm and 2 pre-cutters with knife in between
3 mm(standard)
Normal up to extremely sinewy meat (= quality 3 meat) pork, beef and the like as well as remainders
Meat grinder with perforated disk 20-30 mmCutter with 3 bowl revolutions
5 mm Meat quality 2 Meat grinder with coarse adjust-ment (2 pre-cutters with knife in between)
8 mm Meat quality 3 Pieces of the size of a palm
GB 21
600Selection of the perforated drum
12.3 Processing of poultry
If a perforated drum with holes of more than 5 mm is installed in the machine,the safety guard provided must be fitted to the machine!It is prohibited to operate the machine without this safety guard when using aperforated drum with this hole size!
Hole diameter Initial product Preparations
1.3 mm Residual meat from poultry bones
In agreement with the BAADER company
3 mm Turkey drumsticks Trimmings from turkey and chicken meat
Meat grinder with perforated disk 30 mm
5 mm Pieces of the size of a palm, divided into two
Meat grinder with 2 pre-cutters with knife in between
8 mm Pieces of the size of a palm
22 GB
D 23
600How to treat the squeezing belts
13 How to treat the squeezing belts
13.1 Squeezing belt in the machine
13.2 Squeezing belts outside the machine• Store in a cool and dark space
Storage temperature squeezing belt blue: 10 - 15°CStorage temperature squeezing belt white: 5 - 10°C
• Storage periods of more than two years are not to be recommended!
• It is absolutely necessary to avoid dry running!• Never run a new squeezing belt with full pressure!• Pointed and sharp-edged raw material damages the squeezing belt!
When processing poultry, the squeezing belt is exposed to an extreme load by pieces of bones and must be replaced before the surface layer cracks due to incisions!
• Do not tighten the squeezing belt too much; release the tension of the squeezing belt when the machine is in standstill condition!
• Wear of the squeezing belt is contingent upon the product, pretreatment of the product, selection of the perforated drum and of the set pressure!
• Clean with lukewarm water (max. 60°C) only. Do not use any cleaning agents containing chlorine!
600
24 GB
Troubleshooting
14 Troubleshooting
In the event of failure of the sequence of operations, switch off the machine, set the main switch to position 0 and protect it using a padlock!
Symptom Cause Remedy
The initial prod-uct is not fed in
The perforated drum is not clean
Correct the adjustment of the scraper Replace the scraper
The squeezing belt is smeared
Clean the squeezing belt
The squeezing belt is worn Replace the squeezing belt
The drum shell is not cleaned
The scraper is not correctly positioned
Readjust the scraper
The scraper is worn Replace the scraper
The machine is blocked
Foreign matters in the machine
Reduce the pressure of the scraper and pres-sure roller. Remove the conveyor screw, per-forated drum and front panel. Remove the foreign matters.
Belt edges are broken
The front panel is not cor-rectly positioned
Disassemble and clean the machine. Make sure that the perforated drum is correctly positioned between intermediate wall and front panel! The inner surface of the front panel must be level with the offset of the per-forated drum!
The belt is punched through
Bones in the initial product Replace the belt
The life of the squeezing belt is too short
Pressure on the squeezing belt too high
Reduce the pressure on the squeezing belt
Slipping of the pressure roller, high yield losses
The pressure roller is con-taminated
Disassemble and clean the machine (cf. sec-tion 15)
The front panel is not cor-rectly positioned
Make sure that the perforated drum is cor-rectly positioned between intermediate wall and front panel! The inner surface of the front panel must be level with the offset of the per-forated drum!
The squeezing belt is worn Replace the squeezing belt
The squeezing belt is stopped
Too low pressure on the squeezing belt
Increase the pressure on the squeezing belt
Yield losses The hole edges of the on the outer drum surface are no longer sharp
Regrind the outer surface of the drum (ser-vice offered by all BAADER agencies)Replace the perforated drum
600Cleaning
15 CleaningClean the complete machine at regular intervals of 8 operating hours. When using low-pressure cleaning devices, do not direct the jet into bearings.
15.1 Rest periods• Relief the belt pressure by means of quick
release- Lift the tensioning lever (fig. 25, item 1)
and lower laterally from the sliding block (fig. 25, item 2)
• Set the main switch into position 0• Remove product remainders and wash
down the machine from all sides with a pow-erful water jet
15.2 Pre-cleaning
Run the machine with the slowest speed and clean it with a corresponding safety distance from all moving components:
- with drinking water, max. 60°C!- from top to bottom!- with low pressure, max. 30 bar!
Keep the safety distance! Make sure that clothing, hose, cleaning device or the like do not get caught by the moving components of the machine; danger of serious bodily injuries and damages to the machine! Do not run the machine unattended!
After pre-cleaning, stop the machine, set the main switch to position 0 and secure it!
15.3 Main cleaning
The main switch shall be in position 0 and be secured! Observe the safety instructions at the beginning of this operating manual! Wear protective clothing during cleaning and sanitation operations! Observe the specific national regulations for the cleaning agents and disinfectants used!
12
25
GB 25
600Cleaning
15.3.1 Cleaning schedule
The following cleaning schedule does not apply to squeezing belts! For cleaning the squeezing belt, do not use cleaning agents containing chlo-rine, but drinking water max. 60°C!
* In order to avoid white deposits, P3-topax 17 should not be foamed on hot surfaces.
15.4 End of cleaningAfter cleaning, run the machine briefly and grease to remove any water that might have pene-trated the bearings.
Cleaning agents that are ecologically harmful are to be disposed of properly!
15.4.1 Hardened perforated drums
Hardened materials are less resistant to corrosion! We recommend to completely spray removed perforated drums after cleaning and disinfection using BAADER preservatives (cf. section 15.5) wich are recognized as physiologically safe.
Operation Cleaning Agent Device/Method Remarks Main cleaning
2 - 5% P3-topax 17* (Henkel)
foam with low-pres-sure foaming device
from bottom to top, reaction time 15 minutes
For removing calcareous deposits, use 1 time per week cleaning foam 2 - 5 % P3-topax 56 (Henkel) instead of P3-topax 17
from bottom to top, reaction time 15 minutes
drinking water, max. 60°C
rinse with low pres-sure, max. 30
carefully from top to bottom
Check visualSanitation 1% P3-topax 91
(Henkel)low-pressure spray-ing, max. 30 bar
from top to bottom, reaction time abt. 10-15 minutes since contingent upon germe spectrum; refer to product data sheet
rinsing drinking water, abt. 20°C
low pressure, max. 30 bar
rinse again carefully
26 GB
600Cleaning
15.5 Preservation
Prior to any longer standstill, protect the machine using food-approved preservatives!
Recommended preservatives:- Preservation spray BKS; ref. no. 51100201 (400 ml can)- Preservation liquid BKS; ref. no. 51100200 (5 l container)
This preservative is NSF-H1 approved.
Before resuming production, remove the preservative from all areas in contact with the product:- with drinking water, max. 60°C!- from top to bottom!- with low pressure, max. 30 bar!
GB 27
600
28 GB
Maintenance
16 Maintenance
Spraying by means of sprays of any kind whatever in electrical enclosures and control gears is prohibited; explosion hazard! Prior to performing maintenance operations, switch off the machine, set the main switch to position 0 and protect it using a padlock!
16.1 Squeezing beltVerify the squeezing belt at regular intervals for possible damages and wear.
Immediately replace damaged or worn squeezing belts!
16.2 ScraperVerify the scraper at regular intervals for possi-ble damages and wear.If the scraper (fig. 26, item 1) is worn to the extent that the scraping area has a width of 4 mm (figure 26), then it must be replaced!
Broad scraping areas of the scraper require high adjusting forces which would result in premature wear of the outer surface of the perforated drum!
16.3 Perforated drumVerify the perforated drum at regular intervals for possible damages and war.
The hole edges in the outer area of the drum must be sharp. Rounded hole edges would deteriorate the function; the perforated drum must be replaced!
Regrinding of worn perforated drums is offered by all BAADER agencies.Regrinding interval: as a function of the visual inspection, reduction of throughput rate and yield.
16.4 Spur gearsVerify the spur gears (figure 27) every 200 operating hours and/or 6 months for wear.
1
max
. 4m
m
26
27
600Lubrication
17 LubricationPlace the main switch into position 0!
17.1 Grease lubricationThe machine has been lubricated with BAADER Special grease GLS 380/N3.This grease is of the GRAS type, semi-synthetic and highly seawater resistant. It complies with the German Food and Consumer Goods Acts (LMBG § 5, art. 1, clause 1) and is authorized according to USDA H1. We recommend to use this lubricant in the future as well.When using other GRAS lubricants, the troublefree functioning of the machine cannot be guaran-teed anymore because of the considerable differences in quality of the lubricants available on the market!
Do not blend with mineral lubricants! Please note that mineral lubricants do not comply with the provisions of the Food and Consumer Goods Acts and may thus not be used!
Make sure that only clean grease gets to the lubrication points! The complete lubrica-tion system (zerk fitting, mouth of grease gun, hand lever press and the coupling, if required) should be free of any impurities! The maximum lubricant pressure at the mouth of the grease gun should not exceed 150 bar!
Whenever cleaned, the machine is to be lubricated as well to remove any water that might have penetrated the bearings.
GB 29
600Lubrication
17.1.1 Lubrication plan
17.1.2 Gear motorClean roller bearings filled with grease after 3000 operating hours and fill with new grease. Only one third of the cavities between the roller bodies shall be filled with grease!
17.1.3 Spur gears Clean the spur gears (figure 29) including the adjacent spaces every 400 hours and/or 2 years. Subsequently, apply special grease GLS 380/N3 to the spur gears.
Item fig. 28 Lubrication point Lubrication interval Lubricant
1 Grease nipple (centralized lubrication) 8 operating hours
Special grease GLS 380/N3
2 Grease nipple (centralized lubrication) 40 operating hours
3 Supporting bearing Prior to each cleaning as well as when starting production
4 Pressure eccentric 8 operating hours
5 Various axles Apply grease prior to production
13 3
4
5
2
28
29
30 GB
600Lubrication
17.2 Oil lubrication
17.2.1 Gearbox of the gear motorLubricant: mineral gear oil ISO VG 220Required quantity: 0.7 litresChange interval: 3000 operating hours, at least every 2 years
Venting/fillingOil levelOil drain
Lubricant change:• Remove the drain plug and the vent plug• After the old lubricant has been drained,
clean the gearbox using an appropriate flushing oil. Prior to filling in new oil, make sure that all flushing oil residues are removed!
• Turn in the drain plug• Fill in the indicated amount of lubricant
Checking the amount of lubricant: When the gearbox is at rest and the oil level screw removed, the oil must reach the upper edge of the threaded bore
• Turn in the vent plug
30
GB 31
600BAADER 600 with DMM 10
18 BAADER 600 with DMM 10
18.1 GeneralIn conjunction with the DMM 10 machine, the BAADER 600 is best suitable for the recovery of residual meat. The meat adhering to the bone is coarsely removed by the DMM 10 and fed via a piping to the BAADER 600. In the BAADER 600 the sinews and bones are separated from the meat using a perforated drum tuned to the residual meat.
18.2 Set-Up
BAADER 600
3339
31
DMM 10
166
580 mm
902
423
943
878 17
425
6
ø84
636
686
1695 18
7042
60
32 GB
600BAADER 600 with DMM 10
The BAADER 600 and the DMM 10 can be set up in a 90° arrangement (fig. 31) or in a straight line (fig. 32). The spiral hoses are then to be shortened (fig. 33) according to the respective dimensional draw-ing.
Align the machines horizontally and fit the piping in accordance with the respective dimensional draw-ing.
For the spiral hoses, the feeding direction must be observed; it is marked on the hoses.
BAADER 600
5151
32
DMM 10
166
1260 mm
902
943 11
62
423
174
256
ø60
63668
6
915
89
1695 18
70
1396
1680
878
33
GB 33
600BAADER 600 with DMM 10
18.3 Safety devices
It is prohibited to bypass, modify or remove the safety devices installed by the factory!
it is absolutely necessary to observe the safety instructions at the beginning of this operation manual, as well as of the separate operation manual of the DMM 10 machine!
18.4 Start-up procedurePrior to starting up the BAADER 600 and the DMM 10, observe all information contained in the individual operation manuals, e.g. reinstallation of the parts dismantled for cleanup, as well as subsequent cleaning of the machine prior to resuming operation.
18.5 CleanupCleanup is to be performed as described in section 15.
34 GB
D 35
600Country-related list of cleaning agents and disinfectants
19 Country-related list of cleaning agents and disinfectants
CountryProduct
P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91
Brazil Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac
Canada Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac
France P3-topax 12 P3-topax C 80 P3-topax M acide P3-topax M55 P3-sterylmouss P3-triquart
Germany P3-topax 12 P3-clint RI P3-topax 56 P3-zinnfest flüssig P3-topax 99 P3-topax 91
Greece P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91
Italy P3-topax 12 P3-topax 17 P3-topax L54 P3-topax 68 P3-topax SAN P3-topax 91
Japan P3-topax 12 P3-topax 56 P3-topax 68 P3-topax 99 P3-triquart
Namibia Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac
Netherlands P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-triquart
Norway TP 12 TP 17 Tp 56 TP 68 TP 99 Triquart AP
Poland P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91
Russia P3-topax 12 P3-clint RI P3-topax 56 P3-zinnfest flüssig P3-topax 99 P3-topax 91
South Africa Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac
Spain P3-topax 12 P3-topax 17 P3-topax 56 P3-topax 68 P3-topax 99 P3-topax 91
United Kingdom P3-FBC foam P3-rik P3-topax 56 P3-topax 68 P3-triquart
Ukraine P3-topax 12 P3-clint RI P3-topax 56 P3-zinnfest flüssig P3-topax 99 P3-topax 91
USA Quorum Pink II Quorum Pink II Quorum Purple Quorum Amber Quorum Clear Ster-Bac
600
36 D
HENKEL sales partners
20 HENKEL sales partners
Actual data see below:
http://www.ecolab.com
• Click on Global Directory• Select the Continent• Select the Country• Click on Contact
D 37
600Lubricants and preservatives
21 Lubricants and preservativesLu
bric
ants
and
Pre
serv
ativ
es fo
r BA
AD
ER M
achi
nes
Lubr
icat
ing
grea
ses
Oils
Pres
erva
tives
Bea
ring
grea
seFl
uid
grea
seG
reas
e sp
ray
Gea
r oils
Hyd
raul
ic o
ilSp
ray
Flui
d
Des
igna
tion
GLS
380
/N3
GLS
367
/N00
0FL
C 6
5C
LP 6
8C
LP 4
60H
LP 6
8B
KS
BK
S
NLG
I2
000
2-
--
--
ISO
-VG
--
-V
G68
VG
460
VG
68-
-
Col
our
whi
tebr
own
trans
pare
ntye
llow
ish
trans
pare
nttra
nspa
rent
trans
pare
nt-
-
App
rova
l/ cl
assi
ficat
ion
US
DA
/H-1
NS
F-H
1N
SF-
H1
NS
F-H
1N
SF-
H1
NS
F-H
1N
SF-
H1
NS
F-H
1
Avai
labl
e pa
ckag
e si
zes
400
gca
rtrid
ge5
kgbu
cket
400
ml
can
5 l
cani
ster
30 l
cani
ster
5 l
cani
ster
400
ml
can
5 l
cani
ster
Art
icle
cod
e51
5001
0351
5001
5151
1001
8651
1001
4651
2001
2551
1001
4651
1002
0151
1002
00
Avai
labl
e pa
ckag
e si
zes
18 k
g (+
)+
-+
++
--
Art
icle
cod
e51
5001
02+
-+
++
--
Impo
rtant
! Lu
bric
atin
g gr
ease
s an
d oi
ls s
hall
not b
e m
ixed
with
eac
h ot
her,
as th
ere
is a
risk
of c
hem
ical
dec
ompo
sitio
n!
+ ot
her p
acka
ge s
izes
on
requ
est
Not
e:
Gre
ase
or o
il fil
led
gear
boxe
s an
d ge
ar m
otor
s th
e lu
bric
ants
of w
hich
are
not
indi
cate
d in
this
list
mus
t be
lubr
icat
ed in
acc
orda
nce
with
th
e in
form
atio
n in
sec
tion
Lubr
icat
ion!
600
38 D
Notes
22 Notes