USER MANUAL BSC01 BSC02 BSC01 BCS02 BSC05 BSC05 BSC10 BSC10 BSC15 BSC15
COFFEE ROASTING MACHINE 1572 SOKAK No:31, 35170 KONAK/İZMİR/TURKEY TEL/FAX: +90 (232) 486 98 36 www.bescaroasters.com
INTRODUCTION Welcome to the BESCA Roasters community! Coffee Society is a very dynamic and fast moving sector and we are aware that everybody in the community is trying to serve best cup of coffee for his clients. On the road to this target, BESCA roasters are designed with the highest quality equipments in order to achieve the flexibility of having different coffee roasting profiles with different types of coffee beans, so that you may serve the exact taste that every individual client needs. Hot air circulation speed, drum speed and gas adjustment is standard for every BESCA roaster model. Also, all the equipments that are used in production is worldwide brands so that in case of a replacement, spare parts have easy access in every spot in the world. Wide range of capacity that we supply to our customers from 1kg batch to 240kg batch, enables us to fulfill the requirements every coffee supplier from small coffee shops to big coffee roastery facilities. There is always an appropriate BESCA Roasters model for your optimum investment. The aim of this manual is to guide the users about the installment, usage and periodical maintenance for the machine that is supplied. Moreover, our technical department is always ready for your questions. It is strongly recommended to follow the steps that are explained in this manual. These instructions will provide a longer life for your machine, better roasting results and avoid any unexpected failure and accidents. As BESCA Roasters team, we are very glad to be a part of your business development steps. Have a nice roastery! ii
INDEX 1. SAFETY WARNINGS 1.1 General Safety Page 1 2. GENERAL VIEW & TECHNICAL SPECIFICATIONS 2.1 General View Page 2-3 2.2 Technical Specifications Page 3 3. INSTALLATION 3.1 Electrical Installation Page 4 3.2 Gas Installation Page 4 3.3 Mechanical Parts Installation Page 4 3.3 Chaff Collector Installation Page 4 3.4 General Key Issues During Installation Page 4 4. OPERATING THE MACHINE 4.1 Control Panel Layout Page 5 4.2 Operating Page 6, 7 5. PRECAUTIONS 5.1 Transportation Precautions Page 8 5.2 Electrical Precautions Page 8 5.3 Gas System Precautions Page 8 5.4 General Precautions Page 9 6. DRUM GAP CALIBRATION AND ADJUSTMENT Page 9, 10 7. ROASTING GUIDE TABLE Page 10, 11 8. MAINTENANCE AND CLEANING Page 11 8.1 Periodical Maintenance Follow Up Table Page 11 9. TROUBLESHOOTING Page 12, 13 10. COMPUTER CONNECTION (ARTISAN) Page 14 iii
1. SAFETY WARNING This article contains precautions and instructions in order to avoid any possible injury and material loss. 1.1 General Safety Warnings turns. This machine is designed based on international safety regulations. This machine should be operated by authorized staff. Cleaning and maintenance should be done by authorized staff. If there is a damage on the machine and electrical components, do not operate the machine and get in touch with the supplier. Power supply must be appropriate according to the information given on the machine label Do not supply electric with an extension cable. In order to prevent any breakage on the electrical cables, avoid sharp corners and sharp Do not touch electrical components with wet hands. Use the machine with the maximum capacity given. Any overload may cause constant damage. Do not open the coffee exit flap during process. Use the indicated handles, do not use any other part in order to handle the machine Load the machine through the loading tank as indicated in the instructions The machine must work on a flat place and alignment must be adjusted. Do not disassemble the machine During maintenance, use the original spare parts that may be supplied by the producer. Do not operate the machine in an environment that consist of explosive and flammable substances. Place the appropriate fuse in front of the machine. Never leave the machine while working. 1
2. GENERAL VIEW AND TECHNICAL SPECIFICATIONS Figure 1 Side View 2.1 General View 1- Gas Inlet 2- Cooling Exhaust Pipe 3- Cooling Fan Motor 4- Cooling Mixer Motor 5- Cooling Container Cleaning Access 6- Cooling Mixer Unloading Exit 7- Cooling Mixer 8- Front Drum Bearing 9- Air Flow Temperature Gauge 10- Exhause Fan 11- Drum Motor 12- Drawer 2
13- Drum Sight Glass 14- Drum Position Regulator 15- Sampler 16- Drum Unloading Exit 17- Drum Unloading Exit cover lever 18- Drum 19- Hopper Lever 20- Hopper 21- Fire Sight Glass 2.2. Technical Specifications Figure 2 Front View BCS - 01 BCS - 02 BCS 05 BCS - 10 BCS - 15 Capacity/Bench 1 kg 2 kg 5 kg 10 kg 15 kg Capacity Per Hour 6 11 25 50 75 Fuel Types Natural Gas/Propane Natural Gas/Propane Natural Gas/Propane Natural Gas/Propane Natural Gas/Propane Burner Capacity 15 000 kcal/h 15 000 kcal/h 22 000 kcal/h 40 000 kcal/h 44 000 kcal/h Voltage 110/220/380 110/220/380 110/220/380 110/220/380 110/220/380 Frequency 50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz 50-60 Hz Drum Motor 0.18 0.25 0.37 0.55 0.75 Cooling Mixer Motor 0.12 0.12 0.25 0.37 0.37 Roasting Fan Motor 0.18 0.18 0.37 0.55 0.55 Cooling Fan Motor 0.18 0.18 0.37 0.55 0.55 Roasting Time 10-13 min 10-13 min 10-14 min 10-14 min 10-14 min 3
3. INSTALLATION Before installation and start, please be sure that you have read the whole manual. Installation and first start must be done by trained personnel. 3.1 Electrical Installation All electrical installation must be done by trained technical personnel. Please be sure that the needed supply of the machine matches with your supply. There are different kinds of supply in different countries (100/110/208/220/380 V, 50/60 Hz, monophase/threephase). Check your machine s electrical specifications and install electrical supply accordingly. 3.2 Gas Installation All gas supply installation must be done by trained technical personnel. Please be sure that the regulator that is used is appropriate for your country gas supply settings. The nozzles on the burner are plugin nozzles for LPG. If it is not a suitable nozzle, please replace the nozzles with the appropriate nozzles. Propane nozzles come as an addition. Gas pressure must be 21 mbar minimum. 3.3 Mechanical Parts Installation All Besca Roasters are 100% tested before shipment. Some parts are disassembled before loading. These parts must be assembled at your site before start-up. 3.3.1 Chaff Collector Installation Connect Chaff Collector to exhaust fan pipe directly or if needed use proper pipe to connect Chaff Collector to exhaust pipe. 3.4. General Key İssues During Installation İf you plan to change your fuel supply, please get in touch with our technical department beforehand. Chimney exit must be well protected, so that it does not let rain, snow, or any other substance in. It is strongly recommended that the chimney exit is protected with a regular filter. All exhaust air connections must be well isolated. Chimney pipe diameters must not be smaller than the machine s exhaust outlet diameter. İn order to have a proper exhaust, chimney height must be arranged accordingly. Otherwise, additional exhaust fan may be needed for the chimney. Please be sure that, any obstacle around the machine is located minimum 50 cm far from the machine. There should not be sharp turns close to machine exhausts. If 2 exhausts will be connected to one chimney, the connection should not to be 90. 4
4. OPERATING THE MACHINE 4.1. Control Panel Figure3 Control Panel View 22- Roasting Fan Speed Control 23- Drum Rotation Speed Control 24- Bean Temperature 25- Exhaust Temperature 26- Exhaust Fan and Drum Motor ON/OFF 27- Cooling Fan ON/OFF 28- Cooling Mixer ON/OFF 29- Flame Control 30- Burner ON/OFF 31- Burner On Indicator 32- Burner Malfunction Alarm Reset Important Note: Please keep the track of all off your roasting experience (Roasting period, roasting temperature, roasting type, coffee type, etc.). These tracks will help you to have a better understanding of the dynamics of roasting and will help you have better results in the future. 5
4.2. OPERATING Starting the machine: Turn on the main switch. (Fig.1-17) From position 0 to 1. Turn on the Drum motor and Exhaust Fan by pushing the green button. (Fig.3-34) Turn on the pilot switch (Fig.3-31) to that the burner starts. İf burner does not start, reset button (Fig.3-33) light will be on. This may happen in the first start due to lack of gas in the burner. Reset the pilot by pressing the reset button (Fig.3-33). Try it for couple of times if the burner does not start. Adjust the target temperature on temperature adjustment and control panel (Fig.3-30) according to the roasting profile that you need. 4 degrees below the target temperature, reminder alarm will start. (it can be changed in temperature adjustment and control panel) When the target temperature had been achieved, load the green beans inside the drum by pushing the Hopper Lever (Fig.1-26) down. Do not exceed the green bean roasting capacity of your machine given in technical specifications. After loading, the temperature will quickly fall down and after a while it will be stabilized and will start to rise again. You can check the process through the sight glass (Fig.1-19) or by taking samples with the sampler (Fig.1-22) during roasting. When your roasting has been completed, push the Drum unloading exit cover lever (Fig.1-23) up and drum unloading exit (Fig.1-24) will be opened. Start the cooling mixer before the unloading, by pressing the Cooling Mixer ON button (green) (fig.3-36) Start the cooling fan by pressing the Cooling Fan ON button (green) (fig.3-35) and cool your coffee around 5 minutes. Repeat the same process for the next batch Stopping The Machine: Turn off the pilot switch (Fig.3-31) so that burner fades off. Do not turn off drum motor and exhaust fan until the temperature decreases down to 50 C, otherwise drum may be damaged. When temperature decreases below 50 C, turn off the drum motor and exhaust fan by pushing the red button (Fig.3-34) Turn off the main switch (Fig.1-17) Clean the dust in chaff collector. 6
STARTING THE MACHINE: 1- Turn on the main switch. 2- Turn on Exhaust Fan & Drum 3- Turn on Burner Switch 4- Turn on Cooling Mixer and Cooling Fan 10 seconds before the unloading 5- Heat the drum up to the desired temperature level STARTING THE MACHINE: 6- Open the hopper and load the green coffee beans 7- Check your process regularly through the sight glass and sampler, in order to achieve the required color. 8- After the required color has been reached, open the drum gate, and unload the roasted coffee to the cooling tray. 9- You can get your cooled coffee through the cooling mixer unloading exit 7
5. PRECAUTIONS 5.1. Transportation Precautions In order to avoid any damage, please follow the instructions on the package. Please avoid any impact during transportation. After unpacking, please check the general view of the machine. If there is a sign of impact or damage, please do not start the machine. After unpacking, the machine must operate on a smooth, plane surface. Machine must be located so that it does not fall down after a normal impact. Avoid operating in humid environment. Even packed, please avoid and humid storage area. 5.2. Electrical Precautions For the machine to work safely and efficiently, electrical installment must be new and well-kept. Please check the working voltage of the machine and supply the proper feed. Drum must rotate clockwise direction. Please check the direction of rotation before first start. The machine must be grounded. Feeder cable must be: (2*2,5 mm for 220V / 3*2,5 mm for 380V.) In case of a fire due to electrical failure, use dry chemical fire extinguishers. In case of a failure in electrical system, first shut of the main system and then turn off and unplug the machine. Contact with the maintenance department. It is strongly recommended to install: - Phase leakage relay - Phase protection relay - Phase squence control relay Before the electrical feeding of the machine. The machine must be grounded before running 5.3. Gas System Precautions Installation of gas feeding must be done by trained personnel. Do not check leakage by fire. Gas system maintenance must be done every year. If your system is working with natural gas, please do not forget that the natural gas has no smell. If you change burner nozzles, be sure that they are screwed tightly. In case of a leakage: o Open the doors and windows in order to refresh the ambient air. o Turn off all flames around. o Avoid using electrical switches, electrical instruments, and telephones o Turn off the gas from the main supply and from the machine inlet valve o Immediately call the related authorized department in your city and inform. o If the gas leakage flow is high, leave the room immediately. 8
5.4. General Precautions Before start, always fill the hopper with coffee. After the operation, always turn off the gas supply. Before first start, please make the chimney installation. Since the machine needs Oxygen to operate, please recirculate the air in the room periodically. During maintenance and cleaning, make sure that electrical supply is off. In case of a failure, please get in touch with our service department. Don t use machine without chimney connection Avoid bends with 90 degrees when installing all outlet pipes. It is recommended that the exit pipes have a 90 degree bend if at least 3 meters later. 6. DRUM GAP CALIBRATION AND ADJUSTMENT Gap between the drum and the front cover is very important. İf it is too wide, beans may drop and if it is too narrow, the drum scrapes on the front cover. Due to the operation on high temperature, the gap calibration of your machine may go wrong and calibration may be needed. Figure 4: Drum Gap Calibrator Calibration of the gap may be done through the drum position regulator (Fig.4) located in front side of the machine. 33 Locking ring hole 34 Bearing housing hole 35 Bearing housing cover 36 Bearing housing cover 9
Adjustment must be done while the machine is hot and empty. Minimum needed temperature for the adjustment is recommended roasting temperature. A wrench for calibration is supplied with your machine. Use this wrench in order to loosen the drum position regulator locking ring. (fig4-37) After losing the ring, adjust drum position regulator main body according to the gap that you need to have. Rotation to clockwise direction increases the gap, counterclockwise decreases the gap. (fig4-38) Recommended gap value is 1 mm. After the adjustment of the gap, tighten the locking ring using the wrench. 7. ROASTING GUIDE TABLE ROASTING DEGREE Light Roast Light Cinnamon Cinnamon New England Medium Roast American (light) City(medium) und Plus Dark Roast Full City Viennese French İtalian ROASTING TIME 10-12 min. 12-15 min. 15-18 min TEMPERATURE ( C) CHARACTERISTIC <196 C Very light brown coffee = 196 C >196 C first crack 210 C 219 C 225 C 230 C 240 C 245 C A very light roast level which is immediately at first crack. The origin flavors of the bean are retained. Coffee begins to darken the light brown. Medium light brown, developed during first crack. Acidity is slightly muted Medium brown, common for most specialty coffee. Good for tasting origin character. Medium dark brown with occasional oil sheen, roast character is prominent Moderate dark brown with light surface oil, more bittersweet, caramel flavor, acidity muted Dark brown, shiny with oil, burnt undertones, acidity diminished Nearly black and shiny, burnt tones become more distinct, acidity nearly eliminated 10
For a satisfactory roasting please keep in mind: Roasting period may vary due to: o Humidity percentage of the coffee o Type of coffee that you are roasting o Ambient temperature o Aroma and color level that is required to be achieved First roasting of the day may be longer than expected because of the low ambient temperature and average initial temperature of the machine Additional: Roasting is a process and during roasting moisture inside the coffee is vaporized. Moreover, outer shell of the coffee is ripped off. So final weight of the roasted coffee is expected to be lower than the green coffee. During roasting, coffee beans start to expand. So final volume of the roasted coffee will be higher than the green coffee. So, keep in mind that the container that you are using for the green coffee, may not be enough for the roasted coffee storage. You can adjust drum speed and roasting fan speed for various roasting profiles 8. MAINTENANCE AND CLEANING It is recommended to make the machine's general care once a year. For annual maintenance, you can contact the authorized service. It is recommended to have a maintenance every year. You may get in touch with our technical department for yearly maintenance. While cleaning the outer cover of the machine, be sure that the machine is off. During maintenance and cleaning, turn off the gas and electric supplies. While cleaning, you may use a fabric and small amount of alcohol. Do not use any chemical that may be harmful for human health (gasoline, fuel oil, etc.). Do not wash the machine with water, use wet fabrics and after that dry the machine well. If machine parts are replaced with spare parts that are not produced by our company, warranty is not valid. Drum gap calibration may be needed from time to time. Recommended drum gap is 1 mm (For Drum gap calibration see section 6) 8.1. Periodical Maintenance Follow Up Table ACTION Chaff collector cleaning Cooling tray cleaning Exhaust Fan cleaning Chimney cleaning Exhaust Fan pipe and inner parts Sight glass cleaning Temperature gauge cleaning Drum gap control and calibration Drum bearings lubrication Burner Nozzle check Gas system check PERIOD Once in every 5 cycles Once in every 500h Once in every 500h Once in every 500h Once in every 500h Once in every 500h Once in every 500h Once in a month Once in 4 months Once in a month Once in a month 11
9. TROUBLESHOOTING PROBLEM POSSIBLE REASON SOLUTION Noise in the Drum Wrong adjustment of the drum position Adjust the drum position Not enough lubricant in bearings Lubricate bearings Green Bean is coming out of the Wrong adjustment of the drum Drum exit position Adjust the drum position Turn on the system and roast 2 Not enough roasting more minutes. Various colors in roasted coffee Different types of coffee in the Roast the different type of batch coffee in different batches. Hopper clap may be open Close the hopper clap Low Voltage Supply proper voltage Roasting period is long Wrong adjustment of exhaust pipe clap Adjust exhaust fan clap Exhaust pipe and fan is dirty Clean the exhaust pipe and fan Chimney pipes are dirty Clean the chimney pipes Mixer is not rotating Mixer arm may be loose Tighten the mixer arm Lack of Electric supply, machine Beans in the machine are still is on alarm position Reset the alarm and restart green Malfunction in electrical components Check electrical components Drum Motor is not working Drum motor is on alarm Check the voltage, contactors, and thermal relays. If contactors or thermal relays are off, turn on. If the problem continues, call our technical department. Exhaust Fan is not working Exhaust Fan motor is on alarm Check the voltage, contactors, and thermal relays. If contactors or thermal relays are off, turn on. If the problem continues, call our technical department. Mixer motor is not working Burning traces on the door of chaff collector Exhaust Fan motor is on alarm Chaff collector and chimneys are dirty Check the voltage, contactors, and thermal relays. If contactors or thermal relays are off, turn on. If the problem continues, call our technical department. Clean the chaff collector at least once in 5 cycles. 12
PROBLEM POSSIBLE REASON SOLUTION Cooling period is too long Flame Pilot is not working Burner starts but fades away after a while Burner is ignited hardly Cooling tray is dirty Cooling fan is dirty Cooling fan pipes are dirty Gas pressure may be low Burner not working Burner not working Burner nozzle may be dirty Pilot cable may be damaged Gas filter may be stucked Machine plugged not correctly (for 220V) Gas pressure may be low Grounding may be not enough İgnitor may be oxidized Pilot connections and cables may be damaged Burner nozzle may be dirty Gas filter may be stucked There may be more than one regulator in the system Capacity of the regulator may not be enough Gas pressure may be low Drum exit may be open Hopper clap may be open Wrong adjustment of exhaust pipe clap Clean the cooling tray Clean the cooling fan Clean the cooling fan pipes Gas pressure must be 30 Bars. Check the pressure and regulator. Check the electrical system Reset the pilot and try again Clean the nozzle and consider putting a filter in the system Check the pilot cables Replace the gas filter and try again Unplug and rotate the plug Gas pressure must be 30 Bars. Check the pressure and regulator. Check the grounding Clean the ignitor Check the pilot connections and cables Clean the nozzle and consider putting a filter in the system Replace the gas filter and try again There must be only one regulator connected into the system Check the regulator and use a proper regulator Gas pressure must be 30 Bars. Check the pressure and regulator. Close the drum exit Close the hopper clap Adjust exhaust fan clap 13
10. COMPUTER CONNECTION Artisan has a set-up batch for BESCA ROASTERS. You may use it. In case of a trouble, get in contact with the supplies. 14