Diedrich Roasters IR-7 Owner's Manual

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"The Difference is in the Detail"

MANUF ACTURING

DIEDRICH COFFEE ROASTER

OWNER'S MANUAL

For Models IR-7, IR-12 and IR-24

(Standard)

READ THIS MANUAL

For important safety, installation,

operation and maintenance instructions.

Keep this

manual

with the

roaster

at all

times. Locate in a prominent place.

Issued: February 1991

Reissued: August 2008

DIEDRICH MANUFACTURING, INC

P.O. Box 430

Ponderay, Idaho 83852

Telephone: (208) 263-1276

FAX: (208) 265-4584

in any form or by means, electronic, mechanical or otherwise, including photocopy and recording or in connection

with any information storage or retrieval system, without the written permission of Diedrich Manufacturing, Inc.

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Page 1 “The Difference is in the Detail” MANUF ACTURING DIEDRICH COFFEE ROASTER OWNER'S MANUAL For Models IR-7, IR-12 and IR-24 (Standard) READ THIS MANUAL For important safety, installation, operation and maintenance instructions. Keep this manual with the roaster at all times. Locate in a prominent place.
Page 3: Table Of Contents
TABLE OF CONTENTS Page PREFACE IMPORTANT SAFEGUARDS INSTALLATION INSTRUCTIONS Receiving and Unpacking Shipment Leveling Proximity to Walls Gas Installation Electrical Installation Roaster Exhaust Ducting Installation Inspection INITIAL START-UP (for Drum seating) SEASONING THE ROASTING DRUM START-UP (for Roasting) ROASTING (for consumption) SHUT-DOWN (after last roast) ROASTING AND CLEANING LOG CLEANING...
Page 4 TABLE OF CONTENTS - Continued Page 10.0 MAINTENANCE 10.1 Suggested Hand Tools and Lubricants 10.2 Blower Motor 10.3 Agitator Motor 10.4 Drum Motor 10.5 Roasting Drum Drive Chain 10.6 Roasting Drum Drive Chain Adjustment 10.7 Front and Rear Drum Bearings 10.8 Burner &...
Page 5: Preface
Diedrich Coffee Roaster. The information described reflects the features found on current production models. The Diedrich IR-7, IR-12, and IR-24 Coffee Roasters are all identical in construction detail and features offered. They differ only in scale so the descriptions provided in this Manual are generic and if differences exist, they will be specifically mentioned.
Page 6: Important Safeguards
IMPORTANT SAFEGUARDS Proper installation, cleaning and safe operation of the coffee roaster is the owner’s and operator’s responsibility. Read this manual carefully for important operation, maintenance and safety information. This owners manual must be kept with the roaster at all times and be located in a prominent, easily accessible place.
Page 7 Never, under ANY circumstances while operating or servicing the machine, thrust a hand or arm into the roasting drum or any other access port until the roaster is switched “OFF” and disconnected at its electrical source. Keep clear of moving parts such as the drive chain at the rear of the roaster and the agitator arm and brushes in the cooling bin if so equipped.
Page 10 TABLE A - IR Series Basic Specifications Description Unit of Model Model Model Measure IR-7 IR-12 IR-24 Single Roast Range 1-15 1-30 1-52 .453 / 7 .453 / 12 .453 / 24 * Hourly Roast Output 53.9 92.4 184.8 (maximum)
Page 11 Roaster Models - Dimensions Inches / Centimeters IR-7 IR-12 IR-24 A: Chute Height 23.5" / 59.7 24.5" / 62.23cm 26" / 66.04cm B: Bin Height 33.25" / 84.5 36.25" / 92.07cm 39" / 99.06cm C: Overall Height 79" / 201cm 66.5"...
Page 12: Installation Instructions
The floor must meet weight-bearing requirements of local codes for commercial buildings. Roaster gross weight with maximum load of coffee beans: Model IR-7 ……..895 lb / 406 kgs Model IR-12………..990 lb / 450 kgs Model IR-24……..2005 lb / 911.4 kgs Careful leveling of the roaster is critical not only for performance but for alignment of the roasting drum.
Page 13: Proximity To Walls
INSTALLATION INSTRUCTIONS (Continued) LEVELING (continued) For front-to-back leveling, set level lengthwise on top of cooling bin (at 90° from side-to- side leveling). Shim roaster as required to level. Non-combustible shims are required under the roaster. PROXIMITY TO WALLS Due to the extended daily use of the roaster, clearances to combustible or non- combustible walls or counters listed below must be followed to ensure adequate cooling of the roaster and adjacent walls.
Page 14 2.4.1 SAFETY SHUT-OFF VALVE A safety shut-off valve must be installed in the gas supply line close to the roaster and pressure regulator and in a location where it can be reached quickly in an emergency. In an emergency any operator, qualified or not, can turn off the gas flow to the roaster. The safety shut-off valve must be approved by UL in USA, AGA in Australia, CSA in Canada, or CE in the European Union.
Page 15 Note: The WCL measurement on the manometer located on the top of the coffee roaster should read approximately 6” WCL (15 mbars) for Natural Gas and 10” WCL (25 mbars) for Liquid Propane when the burners are on full. 2.4.3 FLEXIBLE CONNECTIONS If the roaster is to be installed with flexible couplings and/or quick-disconnect fittings, the installer must use heavy-duty design-certified commercial flexible connectors of at least ½...
Page 16: Electrical Installation
2.4.5 WARNING LABELS WARNING IF THE INFORMATION IN THIS DIEDRICH ROASTER OWNER’S MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH. 1. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this roaster or any other appliance.
Page 17: Roaster Exhaust Ducting
Power connection for the IR-7, IR-12, and IR-24 manual control roasters is located in the Electrical box mounted on the bottom rear of the roaster. The IR-7 and IR-12 automated roasters are shipped with a power cord on the podium. The power connection for an IR- 24 automated roaster is located in the electrical box located under the bottom shelf inside the podium.
Page 18 Note: Duct diameter may be larger because of individual installation requirements. INSTALLATION INSTRUCTIONS (continued) 2.6.1 The proper design of the exhaust duct system is critical to the performance and safe operation of the roaster. The ducting must be of sufficient diameter to accommodate the cubic feet per minute (CFM) of airflow for a particular model of roaster as indicated in Table A (Technical Specifications) on page 5.
Page 19 The exhaust system must be designed to operate with a static flue pressure between 0.25”wc and – 0.15”wc at the combustion blower exhaust of the roaster while in operation. Restricted air flow caused by a build up of residue presents a severe fire hazard. Consult the separate Ducting Requirements Sheet sent with this operations manual.
Page 20: Installation Inspection
Most Positive Pressure Grease Ducting Vent Systems weigh a considerable amount. Make certain that the duct is properly supported and that component parts are not overloaded and that adequate auxiliary structural members are used. Note: The roaster must not, under any circumstances, support the weight of the exhaust system.
Page 21 Place airflow control handle in "50/50" (mid) position. Set blower and drum switches to “ON” positions. Flame control remains “OFF”. Listen for rubbing sounds. If rubbing is heard, stop operation and contact Diedrich Manufacturing, Inc., for instructions. If no rubbing sound is heard with the drum still rotating, set gas switch to “ON”. Move flame control to obtain a low flame setting, after several seconds you will hear the igniter clicking.
Page 22: Seasoning The Roasting Drum
SEASONING THE ROASTING DRUM Before you roast coffee for customer consumption in a new roaster, the drum should be seasoned to get it impregnated with coffee oil. For this seasoning process use an inexpensive coffee. Do not use a Robusta coffee as it does not emit enough oil for the seasoning process.
Page 23 The new drum requires from 5 to 10 seasoning roasts to become properly oiled. Each seasoning roast requires about 10-15 pounds (4.5 to 6.8 kgs) of coffee, enough to fully cover the drum's lower surfaces. After completion of each seasoning roast, discard the roasted coffee after it cools.
Page 24: Start-Up (For Roasting)
second crack, and oil begins to appear at the tips of the beans. When you begin to notice the first traces of oil, turn the flame control “OFF”. Let the coffee roast in its own liberated heat until the beans are fully oiled and almost black. At this point in the roast, with good lighting, you should still see some brown in the coffee.
Page 25: Roasting For Consumption
be “ON” before the gas system is activated. 5.3 Set gas switch to “ON”. 5.4 Move flame control to “HIGH” (temperature) setting for warm-up. Watch through viewing window for burner ignition. 5.5 After burner ignition, move the airflow control handle from the "50/50" (mid) to "THROUGH COOLING BIN"...
Page 26 hopper. In this area of the roaster the metal becomes very hot and will result in pre- roasting, uneven roasting or even scorching of the beans. Move the hopper gate handle up to release the green beans from the hopper into the drum.
Page 27 ROASTING FOR CONSUMPTION (Continued) (Continued) You should be into the roast six to seven minutes when the coffee reaches this yellow color. If you are at six minutes but far from the yellow color, the coffee requires more heat. If you are at four minutes and the coffee is already turning yellow, you need to reduce the heat.
Page 28 (Continued) After the coffee has been in the cooling bin for a minute or turn off the agitator and spread out the coffee. Remove the coffee from the cooler discharge gate. With the agitator turned off, the air can find a path through the coffee. The air is hindered if the coffee is in motion.
Page 29: Shut-Down (After Last Roast)
SHUT DOWN (after last roast) Set gas switch to “OFF” position. After the roasted beans in the cooling bin have cooled to room temperature, move the air flow control handle to the "THROUGH ROASTING DRUM" (horizontal) position to cool the drum and roasting sections of machine. Roasted and cooled beans are ready for removal from the cooling bin through its chute.
Page 30: Roasting And Cleaning Log
Type of Coffee: The type of coffee is important as naturals (unwashed coffees, i.e. Indonesians) have much more chaff than washed coffees (i.e. Central and South American coffees); and decafs have virtually no chaff on the outside of the bean. Thus, the chaff box and burner tray require much more attention if a fair quantity of Sumatra is roasted, but almost no cleaning if you are roasting decaf.
Page 31 NOTE: THE SERVICING OF THE ROASTER IS EXTREMELY IMPORTANT. THE ROASTING AND CLEANING LOG WILL INDICATE ABOUT WHEN AND HOW OFTEN THE MACHINE NEEDS TO BE SERVICED. DO NOT TAKE THE SIGNIFICANCE OF THE ROASTING AND CLEANING LOG LIGHTLY! This completes the roasting and cleaning log procedure.
Page 32: Cleaning
See Table C...
Page 33: General
General - Keeping your roaster and its exhaust ducting clean, from inside the roaster to its termination outside the building, is of utmost importance. Failure to do so will create a SEVERE FIRE HAZARD. Accumulated chaff and oil residues are extremely flammable. Poor airflows can result in a build-up of flammable gases in the roaster as well as the exhaust ducting.
Page 35: Daily Basis
CLEANING (Continued) Continued from page 29 Decaf coffee has almost no chaff on the exterior of the bean so if a fair quantity of decaf is roasted light, the chaff box will require very little cleaning. Decafs are usually roasted dark and oily, so duct cleaning will require more attention.
Page 36: Drum Chaff Tray
CLEANING (continued) DRUM CHAFF TRAY Clean out broken beans and chaff collected from the roasting drum tray daily. The tray is located directly under the drum and burners. Access is through burner access doors on each side of the roaster, above the control panel. Keep clean by vacuuming or sweeping chaff before it exceeds a depth of ¼”.
Page 37: Blower Impeller
CLEANING BLOWER IMPELLER (Continued) TO CLEAN: A. Open access door at lower right rear of roaster. B. Remove both thumbscrews and remove impeller cover assembly. C. Remove the impeller set screws and pull the impeller from the motor shaft. D. Use putty knife to clean off residue from impeller and housing. Use industrial strength liquid cleaner to scrub aluminum impeller (do not use oven cleaner).
Page 38: Roaster Exhaust Duct
CLEANING (continued) 9.11 ROASTER EXHAUST DUCTING (Continued) Every month, check the ducting from the roaster to the outside of the building for residue build-up. If residue thickness exceeds 1/8” (.3 cm) build-up in the elbows or the exhaust cap on the roof, the ducting must be cleaned. Even if residue build-ups do not exceed 1/8”...
Page 39 CAUTION: ALWAYS DISCONNECT ROASTER AT ELECTRICAL SOURCE (at circuit breaker or safety shut-off switch) BEFORE SERVICING MOTORS OR MOVING COMPONENTS. 10.1 SUGGESTED HAND TOOLS Note: (one each) to be available for cleaning and maintenance: TOOLS REQUIRED: LUBRICANTS REQUIRED: Allen wrench set USDA H1 High Temperature Food Combination wrench set, Grade Grease (AVAILABLE ONLY...
Page 40 10.2 BLOWER MOTORS - See Figure 9 Bearings should be oiled every six months, with sewing machine or light oil. For access, open lower left cover panel. On control panel, set blower switch to “OFF”. Locate the two plugs, one on each end of motor. Apply 2-3 drops oil. Do not over-lubricate. 10.3 AGITATOR MOTORS - See Figure 10 Sealed motor.
Page 44 10.0 MAINTENANCE - (Continued) 10.7 FRONT AND REAR DRUM BEARING – See Figures 1 & 2 Bearings should be lubricated every 20 operating hours, NOT roasting time. Operating time is the time the roaster is turned “ON” until it is turned “OFF”. Use only H1 High Temperature Food Grade Grease.
Page 45 10.0 MAINTENANCE (continued) 10.11 AIR FLOW CONTROL HANDLE - See Figure 7 Lubricate every six months with high temperature grease. 10.12 COOLING BIN - See Figures 10 and 12. Reference: Paragraph 9.8. To remove cooling bin assembly from Roaster frame: A.
Page 50 FIRE CONTROL - READ CAREFULLY AND PRACTICE!!! Roaster Fire Checklist For IR-Series Coffee Roasters ____1. Turn the gas shut-off valve on the gas supply line to the roaster to the “OFF” position. ____2. Turn the Blower Motor ”OFF” on the Roaster’s Control Panel. ____3.
Page 51 5. Cooling Bin Fire/Below Cooling Bin Screen ____ Turn the Blower and “OFF” on Control Panel. _____ Locate water spray bottle or CO2 Fire Extinguisher. _____Ensure Agitator is “ON” at the Control Panel. _____ Discharge water or CO2 liberally over the whole cooling bin surface area while the coffee is agitating.
Page 52 ____ Do not use water in this area Repeat if required. ____ Fire is out of control. Disconnect main power supply and call 911 or Fire Department and evacuate all personnel to a safe area away from fire and smoke. ____ Fire is completely extinguished, then proceed to Step-10.

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Diedrich Roasters IR-7 Owner's Manual

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