IF THE PM KIT DOES NOT CONTAIN A DRUM DOOR GASKET PLEASE REFRAIN FROM OPENING THE DRUM DOOR
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Routine Preventative Maintenance Procedures for Bellwether Series 2 Coffee Roasters
Roaster ID: _________________________________
Customer Name: _____________________________
Work Order No.: ______________________________
Technician/Servicer name: ______________________
Start - Date: __________________ Time: _________________
End - Date: ___________________ Time: _________________
Call into Bellwether Support to get Roast volume at the time of service: ______________
Does follow on visit require : [ Yes / No ]
Reason for follow on visit: _______________________________________
Prior to performing the below procedures please ensure you have the following items
|
Used |
BW Part Number |
Description |
Qty |
|
|
447-00003 |
HEPA filter |
1 |
|
|
447-00004 |
Carbon Filter |
1 |
|
|
700-01592 |
Prefilter Media Set |
1 |
|
|
452-00003 |
Drum Door Gasket |
1 |
|
|
452-00028 |
Graphite seal for door slide |
1 |
|
|
452-00038 |
Chaff Can Gasket |
1 |
|
|
451-00035 |
Exhaust Fan |
1 |
The following tools are recommended to perform routine preventative maintenance
|
Tool |
Purpose |
|
|
6mm allen key (long) |
Open rear heat exchanger extrusion |
|
|
#2 Phillips Screwdriver |
Remove body skins, Remove Extrusion Cover |
|
|
Safety Glass Scraper |
Clean drum door glass |
|
|
Sterilite 19849806 |
Waste water catchment |
|
|
Sterilite 16428012 |
Waste water catchment |
|
|
Hot water source |
Flush heat exchanger |
|
|
Shop Vacuum |
Various |
|
|
Foil tape |
Seal HEPA filter |
|
|
Measuring tape or ruler |
Bean Front TC location |
|
|
Roaster soakz |
Cleaning |
|
|
Shop towel |
Cleaning |
|
|
Large adjustable pliers |
Drum door wing nuts |
|
|
Adhesive solvent |
Cleaning adhesive in filter box |
|
|
Spanner Wrench |
For removing Bean Drop Slide |
|
|
Compressed Air |
Blowing out electronics box |
1: Safety procedures and preparations
Prior to performing any work please read and follow these safety procedures:
Always wear PPE; safety glasses, earplugs and closed toe shoes are required.
Power down the roaster using the shut down feature on the Help screen- Turn off the main power switch located in the Maintenance Cubby.
- Unplug the roaster from the power source
- Remove the left body skin
- Locate the pneumatic reservoir (upper right corner), release the pressure by opening the drain valve (anti-clockwise)
- Remove Rear and Right Side Skins
2: Bean Load and Hopper
Start Time : _________ End Time : ________
- Vacuum out the Bean Load cubby and the inside of the Hopper.
- Check the Bean Load Close sensor positions. Tighten any loose straps, adjust Hall sensor positions if required. (LINK)
- Inspect bean load throat and hopper shoe for signs of moisture damage. If found, capture a picture and send to BW Tech with your report.
3: Drum
Start Time : _________ End Time : ________
- Inside Drum
- Open the Drum Door by loosening the three bolts
- Inspect Glass for damage
- Inspect Glass gasket for damage
- Inspect Drum face gasket for damage, replace as necessary.
- Clean Glass with scraper (LINK) DO NOT DAMAGE THERMOCOUPLE
- Measure/Adjust placement of bean front probe (LINK) DO NOT BEND
- Tip is 5/8” out from glass
- Tip is 2 1/4” up from bottom edge of door frame
- Give the Drum Agitator a spin by hand to confirm free movement. If movement feels stiff, report immediately to BW Tech.
- Close the Drum Door by tightening the three bolts slowly in circular pattern. Apply food safe lube as necessary.
- Rear Bearing
- Open the Drive Chain Housing and for signs of moisture/steam leaks. Take a picture for BW Tech.
- Belly Drop
- Check actuators on both sides of the belly slide are free of insulation blockages, kinked tubing or loose connections. (LINK)
- Check the open and close position sensors, tighten straps or adjust position if necessary. (LINK)
- Check the belly drop slide for smooth functioning by pulling the door open/close by hand. If excessive resistance is felt, proceed to clean the slide, if smooth skip to the next section. (LINK)
- Remove the slide door. Clean debris and buildups on the slide or door opening edges. File and sand burrs as necessary. Re-install the door slide. (LINK)
4: Bean Cooler and Bucket Cubby
Start Time : _________ End Time : ________
- Remove and replace the Prefilter media (700-01592)
- Remove and clean the Bean Cooler
- Disconnect the pneumatic lines, power lines and sensor wires
- Remove the bean bucket cubby
- 4 phillips head screws along the vertical sides of the cubby
- Disconnect microswitch for bean bucket
- Pull cubby out from the front of the unit
- Remove the waste water line from the water bottle elbow
- Clean with bottle brush
- Remove the 4 thumb screws to release the bean cooler
- Once the bean cooler is free, rotate it ¼ turn anti-clockwise to pull it forward and away from the roaster
- Vacuum Cooling Tray internals DO NOT DAMAGE THERMOCOUPLE
- Clean perforated plates with a scraper and Roaster Soakz
- Clean the residue from the bean cooler interior with Roaster Soakz and a towel, DO NOT SCRAPE THE INTERIOR OF THE BEAN COOLER
- Vacuum the area below the bean cooler and behind the bean bucket cubby
- Vacuum out Bean Exit Cubby
- Inspect bean detect switch for any buildup and debris, electrical contact integrity or misalignments
- Re assemble and reinstall the bean cooling being sure to reconnect all pneumatics and electronics
- Check Optical/Bean Exit sensors for tightness and correct alignment (LINK)
5: Chaff Can and Waste Water Reservoir
Start Time : _________ End Time : ________
- Remove and clean out chaff can, use Roaster Soakz for a deep clean
- Inspect chaff can gasket for signs of damage
- Remove and empty waste water reservoir
- Inspect bottle cap gasket for signs of damage
- Replace gaskets if outdated or damaged.
- Scrape buildup from the underside of the cyclone (where the chaff can gasket seals against the cyclone).
- Vacuum out chaff and water bottle area
- Check chaff can detect switch for any misalignment. Adjust and tighten if required. Check for electrical contact integrity.
- Check chaff can elevator switch for any misalignment. Adjust and tighten if required. Check for electrical contact integrity.
- Check the water bottle detect switch for any misalignment. Adjust and tighten if required. Check for electrical contact integrity.
6: Exhaust Heat Exchanger and filter box
Start Time : _________ End Time : ________
- Clean Heat Exchanger (LINK)
- Open the heat exchanger by removing the HE Clamp
- Place the sterilite bins below the heat exchanger in a cascading configuration
- Remove the extrusion cover
- Using hot water and roaster soakz rinse the heat exchanger thoroughly (this may take 1 to 3 gallons of water depending on roast count and roast level)
- Pour the water through all portions of the heat exchanger.
- Check and clean buildup from the Elbow fittings and Steam Tube (silicone tube from Blower to Extrusion)
Clean steam tube and fittings
- Remove silicone tube at the heat exchange
- Remove threaded barb located at the bottom of the blower
- Verify all fittings are clear of organic matter
- Replace Exhaust Fan (LINK) NEVER DISCONNECT FAN WHILE ROASTER IS POWERED ON
- Remove fan connector
- Remove cover from extrusion
- Remove cone bracket from old fan
- Clean cone bracket, lid, and internals of Extrusion.
- Place cone bracket on new fan
- Rewire fan into connector on cover
- Filter Replacement (LINK)
- Remove filter protecting panel
- Remove old filter set, cut metal tape and slide out.
- Clean Filter Box with adhesive cleaner so new filters can slide in place.
- Replace filters in new orientation: Carbon first, then HEPA.
- Tape around the HEPA to ensure good seal
- Refit
7: Insulation
Start Time : _________ End Time : ________
- Inspect insulation for signs of smoke and steam.
- If damage is noticed take detailed pictures of insulation
- Take insulation off and inspect union gaskets for leaks
- Check for any loose straps, sagging of the insulation.
- Check for any heat damage or fraying of the insulation.
- Check insulation is not obstructing any movements
8: Electronics
Start Time : _________ End Time : ________
- Check for any loose connections for HDMI, Network, USB, Power adapter at Asrock. Located in electronics panel.
- Check for any loose connections for HDMI, USB and Power adapter at Touchscreen. Located in electronics panel.
- Clean cooling fans located in electronics panel
- Blow out dust with compressed air.
- Vacuum out utility box located on the right hand side of the roaster.
- Vacuum and brush the underside of the VFDs
- Clean fan and screen
9: Inspect all connectors
Start Time : _________ End Time : ________
- Inspect the entire electronics panel for any loose connectors or arching.
- Inspect all components for signs of thermal damage
- Inspect mechanical connections for damaged or loose fasteners
- Inspect pneumatic connectors for leaking
10: Testing
Start Time : _________ End Time : ________
- Plug In and turn on the Roaster.
Pneumatic Assembly
- No leaks, comes up to pressure and holds for at least 5 minutes
- Inspect hoses for swelling/damage
- Pressure Switch cuts out ~100 PS
- Regulator set to 80 PSI
Tech panel Tests (LINK)
- From the help screen access the Tech Panel
- The TDU menu is the home screen on the Tech Panel
- Run each test individually
- Run a Hot Test, no beans are necessary. But beans confirmed must be pressed on the main roasting menu.
- Communications
- Conduct speed test
- Download speed greater than 5Mbps
- Upload speed greater than 5Mbps
- Record Firmware Rev (visible on “comms” page of the tech panel): __________
- Record App Rev (visible on “comms” page of the tech panel): __________
- Run a roast
- Replace skins
- Wipe down roaster panels
- Clean space
11: Customer training for better performance and maintenance of the roaster
- Educate customer to shut down the IPC before powering down the roaster (Graceful Shutdown)
- Thorough pre-filter cleaning at the end of every working day.
- Emptying water bottle and chaff can at every maintenance and clean the chaff can and water bottle area to remove any debris and chaff before replacing the water bottle or chaff can.
- Train the customer to scrape the bottom of the chaff can rather than tapping the bottom. Tapping deforms the chaff can which causes the chaff can to not trigger a switch.
Empty bean bucket after every roast. Remove and clean any debris around the bucket detect switch area. Bucket must be removed for 5 full seconds before the roaster recognizes the bucket is empty.- Educate customer of any new feature/functionality added since last visit
- Educate customers how they can help the CS team for faster resolution of the issues. What information to include while reporting incidence and where to find that information. E.g. versions of the software.
12: Suggested Upgrade List**
- Upgrade water bottle cap
- Record duration: __________
- Upgrade chaff can elevator switch
- Record duration: __________
- Upgrade chaff can detect switch
- Record duration: __________
- Upgrade water bottle detect switch
- Record duration: __________
- Upgrade to optical switch for bean exit Prior to R310
- Record duration: __________
- optical switch arm length alignment and adjustment for bean exit
- Record duration: __________
- Upgrade to teflon door slide for belly drop.
- Record duration: __________
** Upgrades are a one time occurrence.
Additional Notes: