Diedrich Coffee Roaster Maintenance Cleaning …...cleaning and maintenance program produce better...

Diedrich Manufacturing, Inc. p. +1.208.263.1276 | U.S. Toll Free. 1.877.263.1276 | f. +1.208.265.4584

www.diedrichroasters.com | e. [email protected]

Diedrich Manufacturing, Inc. “Engineering Responsibly

…Environmentally Conscious“

Made in the U.S.A.

Diedrich Coffee Roaster

Maintenance

&

Cleaning Handout

Diedrich Manufacturing, Inc.

p. +1.208.263.1276 | U.S. Toll Free. 1.877.263.1276 | f. +1.208.265.4584 www.diedrichroasters.com | e. [email protected]

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Preface

As we all know, the coffee roasting industry is a very

dynamic and exciting industry to be a part of. We all strive to

give our customers that perfect cup of coffee that keeps them

coming back time after time. To name just a few sensory

delights, it’s the aroma, texture, color, and taste that set you

apart from your competitors, right? But to insure your roasts

are perfect batch after batch, a regular cleaning and

maintenance program is an absolute must. Generally speaking,

Coffee Roasting Establishments that follow an established

cleaning and maintenance program produce better cupping

(tasting) coffees.

Roasting coffee, especially very dark roasts, produces an oily

reside. This oily residue accumulates over time on the internal

components of the roaster and in the vent ducting. As the

residue accumulates (becomes thicker and thicker) good airflow

is impeded. Restricted airflow will affect the consistency of your

roast profiles and will have an adverse effect on your coffee

quality. Also, any residue or chaff buildup increases the probability of a roaster or ducting fire.

That’s because the oily residues and chaff are fuel sources and as in the natural world the more fuel

there is, then the hotter and longer the fire will burn, unless quickly extinguished. Consequently, this

increases the potential for damage to your roaster, ducting, or even your facility.

With over 2500 Roasters installed worldwide Diedrich receives on average two or three reports

annually of Roaster fires. We can unequivocally state (in our opinion) after reviewing the pictures

that the majority of these fires are caused by inadequate cleaning.

Now! You can understand why we cannot stress enough the importance of keeping your roaster

clean and well maintained. A little prevention goes along way in ensuring your Roaster is

continually ready to meet a rigorous production schedule and produce optimum tasting coffees.



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TABLE of CONTENTS

IMPORTANT SAFEGUARDS ................................................................................................. 4

CLEANING & MAINTENANCE SCHEDULE ..................................................................... 5

CRITICAL CLEANING POINTS ............................................................................................ 7

Chaff Collection Compartment............................................................................................. 8

Impeller Compartment ........................................................................................................... 9

Roaster Impeller Removal Instructions ......................................................................... 10

Cooling Bin ............................................................................................................................. 16

Cooling Bin ............................................................................................................................. 17

Infrared Burner Compartment ............................................................................................ 18

Rear Duct ................................................................................................................................. 19

Exhaust Ducting ..................................................................................................................... 20

Vacuum Tube ......................................................................................................................... 21

MAINTENANCE PROCEDURES ......................................................................................... 22

Lubricate the front and back Drum Bearings. .................................................................. 22

Lubricate Air Flow Control Handle. .................................................................................. 24

Lubricate Drum Drive Chain. ............................................................................................. 25

Check Drive Chain for proper tension .............................................................................. 26

IR-24 models Lubricate Chain Tension mechanism. ...................................................... 27



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IMPORTANT SAFEGUARDS

1. Proper installation, cleaning and safe operation of the coffee roaster and ancillary

equipment is the owner and operator’s responsibility.

2. Prior to cleaning or servicing unplug the coffee roaster. If hard conduit is utilized,

then ensure the circuit breaker in the electrical control box is switched to the off

position. Test prior to cleaning or servicing.

3. Ensure the coffee roaster is cool to the touch prior to cleaning or servicing.

4. Wear protective gloves and eye ware when scrapping residue off internal walls and

components.

5. Use extreme caution when utilizing scrappers or other devices to clean internal

walls and components, a slip of a tool may cause bodily injury.

6. Do not use a water hose or any type of sprayer other than a normal cleaning bottle

for the purposes of cleaning.

7. Ensure you have assistance when lifting the cooling bin off of the roaster during

servicing.

8. Follow all the instructions in this handout.



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CLEANING & MAINTENANCE SCHEDULE

Diedrich Roaster Cleaning & Maintenance Schedule Daily Date √ when complete Signature

Vacuum all chaff from the Chaff Collection

Compartment

Vacuum any chaff and/or bean debris from the

Infrared Burner Compartment

Vacuum any residual chaff from Impeller Compartment

Clean the perforated holes of the Cooling Bin Screen by

using a small bottle of compressed air.

Vacuum all debris under the perforated Cooling Bin

Screen

Weekly or every 40 hours of roasting

Check the vacuum tube for IR Standard Series Roasters

or the vacuum port on IR Universal Series Roasters for

evidence of residue blockage. Clean all residues from

the tube or port.

Wipe down all exterior surfaces of the Roasting System.

Open the Blower Motor Compartment Door and check

for any debris, clean accordingly.

Inspect perforated Cooling Bin Screen for clogging.

Clean as necessary with a screen roller, wire brush or by

utilizing a sharp point to clean out the perforated holes.

Check residue build-up in the Impeller Compartment.

If accumulation is greater than 1/8th inch (3mm), then

scrape/clean all effected interior surfaces and clean the

impeller with a liquid cleaner and brush.

Check the residue build-up in the Chaff Collection

Compartment. If accumulation is greater than 1/8th

inch (3mm), then scrape/clean all affected interior

surfaces.

Check the residue build-up in the Roaster's Rear Duct.

If accumulation is greater than 1/8th (3mm), then clean

accordingly.



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Weekly or every 40 hours of roasting (cont) Date √ when complete Signature

Check the residue build-up at the Roaster's exhaust

outlet & intermediate ducting. If the accumulation is

greater than 1/8th inch (3mm), then clean thoroughly

Check the clean out port on the exhaust ducting. It the

residue accumulations is greater than 1/8th inch (3mm),

then ensure a professional chimney sweep cleans all the

exhaust ducting.

Lubricate front and back roasting drum bearings

Semi Annually (Every 6 months)

Lubricate air flow control handle

Lubricate drum drive chain

Check drum drive chain for proper tension

On IR-24 models lubricate chain tension mechanism

Do a cursory check of all bolts and screws and ensure

they are tight.

Annually

Ensure a professional chimney sweep cleans the exhaust

ducting at least once a year regardless if the residue

buildup is minimal.



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CRITICAL CLEANING POINTS

1. Chaff Collection Compartment

2. Impeller Compartment

3. Cooling Bin

4. Infrared Burner Compartment

5. Rear Duct

6. Exhaust Ducting

7. Vacuum Tube



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CRITICAL CLEANING POINT #1. Chaff Collection Compartment

The Chaff collection compartment’s function is to collect the chaff, the parchment that

separates from the coffee during the roasting process.. Therefore, this area fills up fairly

rapidly and requires constant emptying. Residue will slowly accumulate on the metal

surfaces within the compartment.

Under the

Cooling Bin

Screen

Notes: Chaff Collection Compartment is specifically designed to remove the chaff from the exhaust

stream. Remove the chaff at a minimum every 4 hours of roasting or at the end of the day whichever

comes first. Warning! Make sure the chaff is cool and contains no hot embers before vacuuming.

Chaff is a

fuel source.

Chaff

Collection

Compartment



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CRITICAL CLEANING POINT #2. Impeller Compartment

The impeller compartment is a major collection point for residue build-up. The residue

collects on the all the metal surfaces in this compartment, including the impeller itself.

Please follow the instructions below for removing the impeller protective shroud and the

impeller. Once the shroud and impeller are removed, then thoroughly clean all residue

coated metal surfaces and reassemble. Follow the checklist below for removing the

impeller.

Impeller

Compartment



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Roaster Impeller Removal Instructions

Purpose: To remove the impeller for cleaning, exchanging for a new one, or to replace

the impeller motor.

Tools/Materials required: Set of Allen Wrenches.

Parts required: Not applicable unless impeller is damaged, if damaged replace with

new impeller.

Instructions:

1. Unscrew the two (2) Wing Bolts securing the Impeller Shroud. See Illustration #1

2. Once the Wing Bolts are unscrewed simultaneously push down on the Impeller Shroud

with your left hand and pull the bottom right edge as your facing the impeller towards

the back of the Roaster.

This procedure should dislodge the Impeller Shroud from the mounting brackets. Lay

the Shroud off to the side. See Illustration #2

3. Clean thoroughly the top of the two Set Screws with a scribe or very pointed object.

This will allow the Allen Wrench to penetrate the Set Screw top fully, this will assist in

alleviating any possibility of stripping (wearing out) the Allen Wrench end or the Set

Screw top. See Illustration #3

4. Insert the Allen Wrench into the top of the Set Screw and turn counter-clockwise until

the Set Screw is loose. Repeat this procedure on the second Set Screw. See Illustration

#4

5. Grab the Impeller firmly with both hands and pull towards you.

6. If the Impeller will not release from the shaft try the following:

a. Remove the ducting at the back of the roaster and insert a long flat head screwdriver

with the tip behind the back of the impeller. Now, attempt to pry one side of the

impeller utilizing the screw driver. Turn the Impeller ½ turn and repeat this procedure.

Now, repeat step 5.



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b. If the Impeller is still lodged on the shaft you will have to use a gear puller to remove

the Impeller.

7. Thoroughly clean the Impeller while it is removed from the Roaster with a typical

household cleaner.

8. Apply anti-seize to the motor shaft.

9. Reinstall the old or a new Impeller whichever is applicable back on the motor shaft;

ensure it is in the exact same location on the motor shaft.

10. Tighten the Set Screw that resides on the flat portion of the shaft first. This Set Screw

should be as tight as possible.

11. Tighten the Set Screw that resides on the round portion of the shaft second. Do not over

tighten this one.

12. Reinstall the Impeller Shroud and tighten the two Wing Nuts.

13. Spin the Impeller to ensure it does not interfere with the Shroud. If it does a slight

impeller adjustment will be required.

Checklist complete.



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ILLUSTRATION #1

Unscrew these two wing nuts



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ILLUSTRATION #2

1. Push the shroud down

2. Push the bottom right side towards the bottom right arrow.

Note: This should free the shroud, now set it aside.



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ILLUSTRATION #3

Clean out set screw holes so you can

firmly insert the Allen wrench

Clean out set screw holes so you

can firmly insert the Allen

wrench



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ILLUSTRATION #4

Insert Allen wrench, then

turn counter clockwise to

loosen. Perform this same

procedure on 2nd

Set Screw.

An example of a very dirty

impeller compartment.



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CRITICAL CLEANING POINT #3. Cooling Bin

The Cooling Bin’s function is to cool the fresh roasted beans before transporting to

storage, blending, or packaging. Good air-flow through the cooling bin is critical for

rapidly cooling the beans, thus arresting any further roast development.

Looking inside

the cooling bin

Clean perforated holes enhance good airflow and decreases roasted bean cooling times.



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CRITICAL CLEANING POINT #3. Cooling Bin

An extremely clogged

cooling bin screen

Note: A dirty cooling bin screen will also affect air controllability through the roasting

drum.



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CRITICAL CLEANING POINT #4.

Infrared Burner Compartment

The infrared burner compartment is another area that residual debris collects mainly

small amounts of chaff and micro pieces of coffee beans in various states of roast.

Warning! Ensure all debris is cool before vacuuming.

Vacuum any chaff or other debris

from the floor of the burner

compartment.



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Rear Duct

The rear duct is the 3”, 4”, or 5” pipe located at the back of the roaster that connects the

drum area at the top of the roaster with the impeller area at the bottom of the roaster.

The vacuum that is created from the spinning impeller pulls air through the drum and

the duct. This duct experiences major residue buildup.

Rear duct

Remove this bolt and the one on the other side and take the elbow

from the straight section and clean the inside of the pipes with a putty

knife, wire brush, or use the special cleaning tool Diedrich

manufactures for this task.

While the duct is removed, ensure this

opening is completely cleaned.



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Exhaust Ducting

The vent ducting is an integrated part of the Roasting System. A dirty vent ducting

will also effect the performance of your roaster and your cupping results. In addition a

dirty vent ducting creates the possibility of a ducting fire which could cause collateral

damage to your building.

Exhaust ducting. Have a certified chimney

sweep perform this cleaning.

Clean out port. A good point to check

for ducting residue build-up.



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Vacuum Tube

The vacuum tube is an aluminum tube that is connected to the vacuum sensor in the

gas train area of the Roaster. The vacuum tubes’ termination point is in the top of the

impeller compartment. The vacuum tube’s purpose is to measure pressure within the

impeller compartment. Therefore, if it is clogged with oily residue the roaster will fail

to ignite. This is a built in safety feature.

Use a small pointed object, like a

paperclip, etc. to clean out any debris

that may have accumulated in the

impeller tube opening.



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MAINTENANCE PROCEDURES Diedrich Coffee Roasters are specifically designed to require minimal maintenance and

if the above cleaning instructions are rigorously followed, then the maintenance of your

Roaster will be a breeze. We highly recommend that you reference the maintenance

instructions in your operations manual or Diedrich’s Tech Support Instruction Sheets

for more detailed information. Failure to lubricate the bearings will cause their

premature failure.

Lubricate the front and back Drum Bearings.

Use only H1 High Temperature Food Grade Grease. Hardware store or automotive

types of grease can be toxic and are not to be used in the proximity of food products.

Roaster must be at roasting temperatures (without beans in drum). Lubrication is best

done upon finishing the day's roasting while the roaster is still hot. To lubricate the

front bearing attach grease gun to bearing fitting. Bring operating temperature to

approximately 450ºF (232ºC). With drum rotating, use grease gun to inject 2-3 pumps of

grease into the bearing fitting.

WARNING: Keep fingers, hair and loose clothing clear of moving chain and sprockets.

Remove electrical power and lock it out.

Before lubricating the rear bearing STOP THE DRUM FROM ROTATING. Insert the

grease gun onto fitting. Again inject 2-3 pumps of grease into the bearing fitting.

Remove grease gun and wipe off excess grease. Restart Drum motor and allow it to run

several minutes.



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Note: Repeat this same process on the back drum bearing at the rear of the roaster.

Front

bearing

Attach the end of the grease

gun hose to the Zirk fitting

and pump two to three times.



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Lubricate Air Flow Control Handle.

Open the impeller motor compartment and immediately to the right is the air flow

position mechanism that is connected to air flow control handle on the outside of the

roaster. This mechanism pivots as the airflow control handle is moved from Cooling

Bin Position, 50/50 Position, and Roast Air Position.

Lubricate the pivot mechanism. Put

a little of the food grade grease used

on the front/back bearings on your

finger and generously apply here.



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Lubricate Drum Drive Chain.

Remove electrical power and lock it out.

Oil every six months with SAE20 non-detergent or sewing machine oil. For access,

remove the rear upper and lower cover panels. Do not over-lubricate

WARNING - KEEP FINGERS, HAIR AND LOOSE CLOTHING CLEAR OF MOVING

CHAIN AND SPROCKETS.

Drum Drive

Chain.

Apply 4 to 5 drops of SAE 20 or sewing

machine oil at various intervals around

the circumference of the chain.

Warning! Ensure power is off at main control panel before oiling or

servicing Drum Drive Chain.



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Check Drive Chain for proper tension

With the drum motor turned “OFF” and roaster disconnected at electrical source, the

chain can be adjusted. Loosen the drum motor mounting bolts and firmly push down

on the motor until its weight draws the slack out of the chain. Use wrench to tighten the

mounting bolts securely to prevent a loose engagement of chain and motor sprocket.

When tightening bolts, be sure motor remains in a level, horizontal position.

With a new machine the drum drive chain may need to be adjusted several times to

compensate for the initial stretching of the chain. After completing the first 40-hour

Squeezing the chain together, both

sides of the chain should flex in

approximately ½ inch (13mm).

If the chain is too tight or loose, then

slightly loosen the four nuts attaching the

drum motor to the mounting plate and

move the drum motor up or down to

adjust accordingly. Retighten the nuts

Drum motor and

sprocket.



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cleaning check the tension of the chain and adjust accordingly. The first three 40 hour

cleaning cycles should include checking the tension of the drum drive chain.

IR-24 models Lubricate Chain Tension mechanism.

Note: On IR-24 models pull down on the chain tension mechanism (see next page) to take the tension

of the chain while doing the squeeze test.

Drive chain tension mechanism.

Connect grease gun to Zirk fitting

and pump two to three times.

Diedrich Coffee Roaster Maintenance Cleaning …...cleaning and maintenance program produce better...

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