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1. OPERATION
General Procedure
The smoke is generated by glowing wood-chips on a heated device at temperatures of
700 - 1200 F with a lack of combustion air. The heating is affected by an electrical
heating rod supplying the necessary energy to start the process.
2.
Generator is turned on 20 min before the Natural Smoke Process step begin. To shut
down:
Start Up
Check the generator to be clean of the tar build up and the seals are functional.
Inspect the door gaskets and other potential point of entry for the air.
Check to assure that water and air supply are on and their control valves are
working properly.
Shut Down
If a clean up will follow the shut down, it needs to be performed 30-45 minutes after
the generator is shut down and the element is not hot. Cold water will damage the
heating element.
Turn off master switch. Never turn the generator off using the E-stop button.
Extinguish all material in smoke generator thoroughly, remove sawdust and ash.
3. MECHANICAL ADJUSTMENTS
If too many wood-chips fall over the rim onto the outer surface of the burning
plate, then chute should be lowered in 5 mm increments.
If the wood-chips do not come up to the edge, the chute should be raised in 10
mm increments.
Setting the Partial Vacuum of the System Exerted on the Smoke Generator
The suction acting on the smoke generator is adjusted by way of a dam flap or with a
slide plate in the smoke outlet. These adjustment mechanisms should never be more
than 50 % closed, in order to avoid increased soiling.
The suction on the smoke generator can be judged as ideal when, with the door
(top door) opened by about the width of a hand, a swirl of smoke emerges
approx 5 cm from the housing and is sucked at the edge of the opening back
into the combustion chamber.
Setting:
Open the flap / sliding plate = suction is greater = greater volume of smoke goes into
the system.
Close the flap / sliding plate = suction is less = smaller volume of smoke goes into the
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system.
Fan for Supplying the Smoke Generator with Transport- and Combustion Air
This fan supplies the smoke generator with predefined quantities of air for combustion
(through the distributor below) and transport (entry through the distributor above).
The ratio of air quantities is relevant to safety, and may therefore not be changed!
The total quantity of air that is fed in can be adjusted by changing the gap using a
throttle screw on the ventilator (induction side). Too much air turns the glow-burn
process into combustion, creating smoke that is not suitable for treating foodstuffs.
Adjustment:
Gap greater = more smoke; gap smaller = less smoke
The standard setting is a gap width of 3 mm. Adjustments in 1 mm increments.
Safety information:
Smoke fumes are explosive in certain compounds. Safety features are built into the
smoke generator in order to prevent any possibility of explosiveness. Any alteration to
components or certain assemblies is forbidden and must not be attempted!
4. CLEANING
Instructions for Cleaning
The wood tar created in generating smoke spreads throughout the system and clings
stubbornly to its surfaces.
The cleaning frequency should depend on the amount the system is used and the
number of smoking operations carried out per day (or week). Certain parts of the
smoke generator must be cleaned daily!
The soiling on the smoke generator consists mainly of wood tar deposits and residue
sawdust. The smoke generator is normally cleaned by hand. This means that all
components that come into contact with glow-heated wood-chips must be taken out of
the smoke generator and cleaned externally.
The walls of the housing inside the generator can then also be cleaned with detergents.
The agent used to clean the generator is a smoke resin removal powder (or solution)
dissolved in tap water (ready-mixed solutions or concentrates may need to be diluted
with water or according to the maker's instructions).
The concentration generally used is a 2 - 3% solution. The percentage can be varied
slightly according to the degree of soiling (2 - 5%).
The cleansing agent must be allowed 10 - 15 min to take effect, depending on the
degree of soiling.
Stubborn stains should be worked off with a spatula, is necessary.
The inner components that have been removed can be placed in a bath of detergent for
softening (time approx. 10 - 15 min).
The components may also be sprayed and cleaned while on the ground.
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After the detergent has taken effect, all parts and surfaces must be rinsed thoroughly in
clear water (especially metallic surfaces, burning plate and frame).
The cleaning nozzles installed in the smoke pipe system are connected to the cleaning
device through a distributor and appropriate piping. These areas are reached together
smoke generator when the system is cleaned.
Daily
1) Clean the Generator Temperature sensor
2) Clean the Ignition plate attachments and the chip drop chute
3) Clean the Smoke generator mating surface to the above burner plates
4) Empty ash box and half fill it with water
5) Top up the chip bin and close the lid
6) Make sure the tar separating bucket is filled to overflow with water
Weekly:
1) Clean entire smoke generator. This includes the entire above plus entire
inside cabinet. (The CIP only cleans the smoke duct).
2) Remove and clean the lower pipe bend of the air divider (The pipes now have
different air orifices installed; make sure these are replaced back into the
pipes).
3) Check to make sure the extinguishing equipment is functioning properly
It is essential to ensure that the water supply and the supply of compressed
air to the smoke generator are never cut off!
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1.
2.
3.
IN THE OFF MODE WITH THE DAMPER CLOSED TO THE SMOKE HOUSE.
(VOLATILE GASES ARE FORMING INSIDE THE HEATING PLATE CHAMBEROPENING OF THE FRONT DOOR MAY CAUSE AN EXPLOSION).
4.
5.
6.
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They are manufactures in batched pairs. A distinct letter is assigned for each pair.
They can be placed in any generator, provided they are a properly paired match
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Once this damper is set, no more adjustments need to be made. Occasionally, it will loosen up,
and then you need to make sure it is tightened. inch opening is typical.
Its adjustment will depend on the environmental temperature in order to maintain a temperature
120-130 F in the smoking cabinet compartment
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This air tube must be cleaned every time the generator is cleaned.
There is an orifice inside the tube that must stay intact.
Ratio = combustion air 1 part : top air 20 parts
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Damper control
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Creosote bucket
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If water pressure is shut off to unit, the generator will not turn on.
If power is shut off to the unit, the water will open and spray water in
your chamber.
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7. QUIZ TEST
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